SEN00291-04 Shop Manual 12V140E -3 SERIES ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. Copyright 2007 Komatsu Printed in U.S.A. Komatsu America Corp. July 2007
Transcript
SEN00291-04
Shop Manual
12V140E-3 SERIES
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu Printed in U.S.A.
Komatsu America Corp. July 2007
12V140E-3 Series 1
SEN00294-04
ENGINE1SHOP MANUAL
12V140E-3 Series
00 Index and foreword 1Index
Composition of shop manual................................................................................................................ 2Table of contents .................................................................................................................................. 3
SEN00294-04 00 Index and foreword
2 12V140E-3 Series
Composition of shop manual 1The 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:QQQQ: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:� Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:� File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00291-04
00 Index and foreword SEN00292-04Index SEN00294-04 qForeword and general information SEN00296-02 q
01 Specification SEN00301-02Specification and technical data SEN00303-02 q
10 Structure, function and maintenance standard SEN00304-02Structure, function and maintenance standard, Part 1 SEN00307-02 qStructure, function and maintenance standard, Part 2 SEN00309-02 q
20 Standard value table SEN00310-03Standard service value table SEN00311-03 q
30 Testing and adjusting SEN00312-00Testing and adjusting SEN00313-00
40 Troubleshooting SEN00314-00General information on troubleshooting SEN00315-00Troubleshooting of mechanical system (S-mode) SEN00316-00Troubleshooting of electrical system (E-mode), Part 1 SEN00317-00Troubleshooting of electrical system (E-mode), Part 2 SEN00318-00
50 Disassembly and assembly SEN00319-00General information on disassembly and assembly SEN00320-00Disassembly and assembly, Part 1 SEN00321-00Disassembly and assembly, Part 2 SEN00322-00Disassembly and assembly, Part 3 SEN00876-00
00 Index and foreword SEN00294-04
12V140E-3 Series 3
Table of contents 100 Index and foreword
Index SEN00294-04Composition of shop manual ................................................................................................... 2Table of contents ..................................................................................................................... 3
Foreword and general information SEN00296-02Safety notice............................................................................................................................ 2How to read the shop manual.................................................................................................. 7Explanation of terms for maintenance standard ...................................................................... 9Handling of electric equipment and hydraulic component ....................................................... 11Handling of connectors newly used for engines ...................................................................... 20How to read electric wire code ................................................................................................ 23Precautions when carrying out operation ................................................................................ 26Method of disassembling and connecting push-pull type coupler ........................................... 29Standard tightening torque table.............................................................................................. 32Conversion table...................................................................................................................... 36
01 SpecificationSpecification and technical data SEN00303-02
10 Structure, function and maintenance standardStructure, function and maintenance standard, Part 1 SEN00307-02
Air intake and exhaust system .................................................................................................... 3Air intake and exhaust unit ...................................................................................................... 3Air cleaner ............................................................................................................................... 4Turbocharger ........................................................................................................................... 6Aftercooler ............................................................................................................................... 11Muffler...................................................................................................................................... 12
Engine unit .................................................................................................................................. 14Cylinder head .......................................................................................................................... 14Cylinder block .......................................................................................................................... 18Cylinder liner............................................................................................................................ 22Main moving parts ................................................................................................................... 24Crankshaft ............................................................................................................................... 26Camshaft ................................................................................................................................. 28Cam follower, push rod............................................................................................................ 29Piston, piston ring, and piston pin............................................................................................ 30Connecting rod ........................................................................................................................ 32Flywheel and flywheel housing................................................................................................ 34Vibration damper ..................................................................................................................... 35Timing gear.............................................................................................................................. 36Valve system ........................................................................................................................... 38Valve and valve guide.............................................................................................................. 40Rocker arm and shaft .............................................................................................................. 42Crosshead and guide .............................................................................................................. 43
Structure, function and maintenance standard, Part 2 SEN00309-02Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4
20 Standard value tableStandard service value table SEN00311-03
Standard service value table ....................................................................................................... 2Standard service value table for testing, adjusting, and troubleshooting................................. 2Running-in standard and performance test standard .............................................................. 7
30 Testing and adjustingTesting and adjusting SEN00313-00
Testing and adjusting................................................................................................................... 3Testing and adjusting tools list ................................................................................................. 3Testing air boost pressure........................................................................................................ 5Testing exhaust temperature ................................................................................................... 6Adjusting valve clearance ........................................................................................................ 7Testing compression pressure ................................................................................................. 9Testing blow-by pressure ......................................................................................................... 11Measuring blow-by pressure.................................................................................................... 12Testing oil pressure.................................................................................................................. 13Handling fuel system parts ...................................................................................................... 14Releasing residual pressure in fuel system ............................................................................. 14Testing fuel pressure................................................................................................................ 15Reduced cylinder mode operation ........................................................................................... 16No-injection cranking ............................................................................................................... 16Testing leakage-from pressure limiter and return rate from injector ........................................ 17Bleeding air from fuel circuit (for D475A-5).............................................................................. 20Bleeding air from fuel circuit (for PC2000)............................................................................... 23Testing fuel system for leakage ............................................................................................... 25Adjusting speed sensor ........................................................................................................... 26Testing and adjusting alternator belt tension ........................................................................... 26Handling controller high-voltage circuit .................................................................................... 27
40 TroubleshootingGeneral information on troubleshooting SEN00315-00
General information on troubleshooting ...................................................................................... 2Points to remember when troubleshooting .............................................................................. 2
00 Index and foreword SEN00294-04
12V140E-3 Series 5
Error codes and failure codes list ............................................................................................ 3Troubleshooting of mechanical system (S-mode) SEN00316-00
Troubleshooting of mechanical system (S-mode) ....................................................................... 3Method of using troubleshooting charts................................................................................... 3S-1 Starting performance is poor............................................................................................. 6S-2 Engine does not start ........................................................................................................ 7S-3 Engine does not pick up smoothly .................................................................................... 10S-4 Engine stops during operations ........................................................................................ 11S-5 Engine does not rotate smoothly ...................................................................................... 12S-6 Engine lacks output (or lacks power) ................................................................................ 13S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16S-9 Oil becomes contaminated quickly ................................................................................... 17S-10 Fuel consumption is excessive ....................................................................................... 18S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 19S-12 Oil pressure drops........................................................................................................... 20S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21S-14 Coolant temperature becomes too high (overheating).................................................... 22S-15 Abnormal noise is made ................................................................................................. 23S-16 Vibration is excessive ..................................................................................................... 24
Troubleshooting of electrical system (E-mode), Part 1 SEN00317-00Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 4
Information in troubleshooting table ........................................................................................ 4E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank)............................................... 6E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank) .............................................. 8E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank) ....................... 10E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)....................... 11E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only)......................... 12E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only).......................... 14E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only) ......................................... 16E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) .......................................... 18E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)...................................... 20E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) .................................... 22E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) ............................ 24E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ............................. 26E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) ....................... 28E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only) ........................ 30E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) ......................................... 31E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)......................................... 31E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)............................. 32E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ............................. 34E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ..................... 36E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) ...................... 38E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ........................................ 40E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)........................................ 42E-23 Code [234/CA234] Eng. Overspeed (LH bank only) ....................................................... 44E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank) ................................... 46E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) .................................. 48E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank) ......................................... 50E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ........................................ 52E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank).......................................... 54E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) ......................................... 54E-30 Code [271/CA271] PCV1 Short Error (LH bank)............................................................. 56E-31 Code [271/CB271] PCV1 Short Error (RH bank) ............................................................ 58E-32 Code [272/CA272] PCV1 Open Error (LH bank) ............................................................ 60E-33 Code [272/CB272] PCV1 Open Error (RH bank)............................................................ 61
Troubleshooting of electrical system (E-mode), Part 2 SEN00318-00Troubleshooting of electrical system (E-mode), Part 2................................................................ 3
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank).............................................. 3E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) ............................................. 3E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank).......................................... 4E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) ......................................... 6E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) .......................................... 8E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank).......................................... 8E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) ................................................... 9E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) .................................................. 10E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) .................................. 11E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank).................................. 11E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank).................................................... 12E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank) ................................................... 16E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank) ........................................... 20E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank)........................................... 22E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) .......................... 24E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only) ........................... 26E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank) ...................... 27E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank)...................... 27E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) ........................................ 28E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank)........................................ 28E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) ................................. 30E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank)................................. 32E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) ...................... 34E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ..................... 36E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank)............................................. 37E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) ............................................ 37E-82 Code [1257/CA1257] Harness Key error (LH bank)........................................................ 38E-83 Code [1257/CB1257] Harness Key error (RH bank) ....................................................... 39E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank)............ 40E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank)............ 42E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank).......... 44E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank).......... 46E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank).......... 48
00 Index and foreword SEN00294-04
12V140E-3 Series 7
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ........... 50E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ................................ 52E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)..................... 54E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only)...................... 56E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) .......................................... 57E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank).......................................... 57E-95 Code [� �*1/�] Eng. Overheat (LH bank only) ................................................................ 58E-96 Code [� �*2/�] Eng. Oil Press. Low Speed Derate (LH bank only) ................................. 58E-97 Code [� �*3/�] Press. Low Torque Derate (LH bank only) .............................................. 59
50 Disassembly and assemblyGeneral information on disassembly and assembly SEN00320-00
General information on disassembly and assembly.................................................................... 2How to read this manual.......................................................................................................... 2Coating materials list ............................................................................................................... 3Special tools list ....................................................................................................................... 6
Disassembly and assembly, Part 1 SEN00321-00Disassembly and assembly, Part 1 ............................................................................................. 2
General disassembly of engine ............................................................................................... 2
Disassembly and assembly, Part 2 SEN00322-00Disassembly and assembly, Part 2 ............................................................................................. 2
General assembly of engine.................................................................................................... 2
Disassembly and assembly, Part 3 SEN00876-00Disassembly and assembly, Part 3 ............................................................................................. 2
Removal and installation fuel supply pump unit ...................................................................... 2Replacement of oil seal of engine mounted on machine......................................................... 4
00 Index and foreword 1Foreword and general informationSafety notice ................................................................................................................................................... 2How to read the shop manual ......................................................................................................................... 7Explanation of terms for maintenance standard ............................................................................................. 9Handling of electric equipment and hydraulic component .............................................................................11Handling of connectors newly used for engines ........................................................................................... 20How to read electric wire code...................................................................................................................... 23Precautions when carrying out operation...................................................................................................... 26Method of disassembling and connecting push-pull type coupler................................................................. 29Standard tightening torque table ................................................................................................................... 32Conversion table ........................................................................................................................................... 36
SEN00296-02 00 Index and foreword
2 12V140E-3 Series
(Rev. 2007/03)Safety notice 1Important safety noticeProper service and repair are extremely important for safe machine operation. The service and repairtechniques recommended by Komatsu and described in this manual are both effective and safe.Some of these techniques require the use of tools specially designed by Komatsu for the specificpurpose.To prevent injury to workers, the symbol kkkk is used to mark safety precautions in this manual. Thecautions accompanying these symbols should always be followed carefully. If any dangerous situa-tion arises or may possibly arise, first consider safety, and take the necessary actions to deal withthe situation.
1. General precautionsk Mistakes in operation are extremely
dangerous. Read the Operation andMaintenance Manual carefully beforeoperating the machine.
1) Before carrying out any greasing orrepairs, read all the safety plates stuck tothe machine. For the locations of thesafety plates and detailed explanation ofprecautions, see the Operation and Main-tenance Manual.
2) Decide a place in the repair workshop tokeep tools and removed parts. Alwayskeep the tools and parts in their correctplaces. Always keep the work area cleanand make sure that there is no dirt, water,or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke whileworking.
3) When carrying out any operation, alwayswear safety shoes and helmet. Do notwear loose work clothes, or clothes withbuttons missing.q Always wear safety glasses when hit-
ting 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 oper-ating procedure before starting. Alwaysinform your fellow workers before startingany step of the operation. Before startingwork, hang UNDER REPAIR warningsigns in the operator's compartment.
5) Only qualified workers must carry out workand operation which require license orqualification.
6) Keep all tools in good condition, learn thecorrect way to use them, and use theproper ones of them. Before starting work,thoroughly check the tools, machine, fork-lift, service car, etc.
7) If welding repairs are needed, alwayshave a trained and experienced weldercarry out the work. When carrying outweld ing work, always wear weldinggloves, apron, shielding goggles, cap andother clothes suited for welding work.
8) Before starting work, warm up your bodythoroughly to start work under good condi-tion.
2. Preparations for work1) Before adding oil or making any repairs,
park the machine on hard and levelground, and apply the parking brake andblock the wheels or tracks to prevent themachine from moving.
2) Before starting work, lower the workequipment (blade, ripper, bucket, etc.) tothe ground. If this is not possible, insertthe lock pin or use blocks to prevent thework equipment from falling. In addition,be sure to lock all the control levers andhang warning signs on them.
Safety points1 Good arrangement2 Correct work clothes3 Following work standard4 Making and checking signs
5 Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work
7 Wearing protective goggles(for cleaning or grinding work)
8 Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation
10 Precautions against work which you are not used to or you are used to too much
00 Index and foreword SEN00296-02
12V140E-3 Series 3
3) When disassembling or assembling, sup-port the machine with blocks, jacks, orstands before starting work.
4) Remove all mud and oil from the steps orother places used to get on and off themachine. Always use the handrails, lad-ders or steps when getting on or off themach ine. Never jump on or o ff themachine. If it is impossible to use thehandrails, ladders or steps, use a stand toprovide safe footing.
3. Precautions during work1) Before disconnecting or removing compo-
nents of the oil, water, or air circuits, firstrelease the pressure completely from thecircuit. When removing the oil filler cap, adrain plug, or an oil pressure pickup plug,loosen it slowly to prevent the oil fromspurting out.
2) The coolant and oil in the circuits are hotwhen the engine is stopped, so be carefulnot to get scalded. Wait for the oil andcoolant to cool before carrying out anywork on the oil or water circuits.
3) Before starting work, stop the engine.When working on or around a rotatingpart, in particular, stop the engine. Whenchecking the machine without stoppingthe engine (measuring oi l pressure,revolving speed, temperature, etc.), takeextreme care not to get rolled or caught inrotating parts or moving parts.
4) Before starting work, remove the leadsfrom the battery. Always remove the leadfrom the negative (�) terminal first.
5) When raising a heavy component (heavierthan 25 kg), use a hoist or crane. Beforestarting work, check that the slings (wireropes, chains, and hooks) are free fromdamage. Always use slings which haveample capacity and install them to properplaces. Operate the hoist or crane slowlyto prevent the component from hitting anyother part. Do not work with any part stillraised by the hoist or crane.
6) When removing a cover which is underinternal pressure or under pressure from aspring, always leave 2 bolts in diagonalpositions. Loosen those bolts graduallyand alternately to release the pressure,and then remove the cover.
7) When removing components, be carefulnot to break or damage the electrical wir-ing. Damaged wiring may cause electricalfires.
8) When removing piping, stop the fuel or oilfrom spilling out. If any fuel or oil dripsonto the floor, wipe it up immediately. Fuelor oil on the floor can cause you to slipand can even start fires.
9) As a general rule, do not use gasoline towash parts. Do not use it to clean electri-cal parts, in particular.
10) Be sure to assemble all parts again in theiroriginal places. Replace any damagedparts and parts which must not be reusedwith new parts. When installing hoses andwires, be sure that they will not be dam-aged by contact with other parts when themachine is operated.
11) When installing high pressure hoses,make sure that they are not twisted. Dam-aged tubes a re dangerous , so beextremely careful when installing tubes forhigh pressure circuits. In addition, checkthat connect ing parts are cor rect lyinstalled.
12) When assembling or installing parts,always tighten them to the specifiedtorques. When installing protective partssuch as guards, or parts which vibrate vio-lently or rotate at high speed, be particu-lar ly carefu l to check that they areinstalled correctly.
13) When aligning 2 holes, never insert yourfingers or hand. Be careful not to get yourfingers caught in a hole.
14) When measuring hydraulic pressure,check that the measuring tools are cor-rectly assembled.
15) Take care when removing or installing thetracks of track-type machines. Whenremoving the track, the track separatessuddenly, so never let anyone stand ateither end of the track.
16) If the engine is operated for a long time ina place which is not ventilated well, youmay suffer from gas poisoning. Accord-ingly, open the windows and doors to ven-tilate well.
SEN00296-02 00 Index and foreword
4 12V140E-3 Series
4. Precautions for sling work and makingsigns1) Only one appointed worker must make
signs and co-workers must communicatewith each other frequently. The appointedsign maker must make specified signsclearly at a place where he is seen wellfrom the operator's seat and where he cansee the working condition easily. The signmaker must always stand in front of theload and guide the operator safely.q Do not stand under the load.q Do not step on the load.
2) Check the slings before starting slingwork.
3) Keep putting on gloves during sling work.(Put on leather gloves, if available.)
4) Measure the weight of the load by the eyeand check its center of gravity.
5) Use proper sling according to the weightof the load and method of slinging. If toothick wire ropes are used to sling a lightload, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.If it is slung so, it may rotate and may slipout of the rope. Install 2 or more wireropes symmetrically.k Slinging with 1 rope may cause
turning of the load during hoisting,untwisting of the rope, or slippingof the rope from its original wind-ing position on the load, which canresult in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.Do not sling a heavy load with ropes form-ing a wide hanging angle from the hook.When hoisting a load with 2 or moreropes, the force subjected to each ropewill increase with the hanging angle. Thetable below shows the variation of allow-able load in kN {kg} when hoisting is madewith 2 ropes, each of which is allowed tosling up to 9.8 kN {1,000 kg} vertically, atvarious hanging angles. When the 2 ropessling a load vertically, up to 19.6 kN {2,000kg} of total weight can be suspended.This weight is reduced to 9.8 kN {1,000kg} when the 2 ropes make a hangingangle of 120°. If the 2 ropes sling a 19.6kN {2,000 kg} load at a lifting angle of150°, each of them is subjected to a forceas large as 39.2 kN {4,000 kg}.
8) When installing wire ropes to an angularload, apply pads to protect the wire ropes.If the load is slippery, apply proper mate-rial to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wireropes, chains, etc. to them with shackles,etc.
10) Apply wire ropes to the middle portion ofthe hook.q Slinging near the tip of the hook may
cause the rope to slip off the hookduring hoisting. The hook has themaximum strength at the middle por-tion.
11) Do not use twisted or kinked wire ropes.12) When lifting up a load, observe the follow-
ing.q Wind in the crane slowly until wire
ropes are stretched. When settlingthe wire ropes with the hand, do notgrasp them but press them fromabove. If you grasp them, your fingersmay be caught.
q After the wire ropes are stretched,stop the crane and check the condi-tion of the slung load, wire ropes, andpads.
00 Index and foreword SEN00296-02
12V140E-3 Series 5
q If the load is unstable or the wire ropeor chains are twisted, lower the loadand lift it up again.
q Do not lift up the load slantingly.13) When lifting down a load, observe the fol-
lowing.q When lifting down a load, stop it tem-
porarily at 30 cm above the floor, andthen lower it slowly.
q Check that the load is stable, andthen remove the sling.
q Remove kinks and dirt from the wireropes and chains used for the slingwork, and put them in the specifiedplace.
5. Precautions for using mobile cranea Read the Operation and Maintenance
Manual of the crane carefully in advanceand operate the crane safely.
6. Precautions for using overhead hoist cranek When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disas-sembly and assembly, the weight of apart heavier than 25 kg is indicatedafter the mark of 4444.
1) Before starting work, inspect the wireropes, brake, clutch, controller, rails, overwind stop device, electric shock preven-tion earth leakage breaker, crane collisionprevention device, and power applicationwarning lamp, and check safety.
2) Observe the signs for sling work.3) Operate the hoist at a safe place.4) Check the direction indicator plates (east,
west, south, and north) and the directionsof the control buttons without fail.
5) Do not sling a load slantingly. Do not movethe crane while the slung load is swinging.
6) Do not raise or lower a load while thecrane is moving longitudinally or laterally.
7) Do not drag a sling.8) When lifting up a load, stop it just after it
leaves the ground and check safety, andthen lift it up.
9) Consider the travel route in advance andlift up a load to a safe height.
10) Place the control switch on a positionwhere it will not be an obstacle to workand passage.
11) After operating the hoist, do not swing thecontrol switch.
12) Remember the position of the main switchso that you can turn off the power immedi-ately in an emergency.
13) If the hoist stops because of a power fail-ure, turn the power switch OFF. Whenturning on a switch which was turned OFFby the electric shock prevention earthleakage breaker, check that the devicesrelated to that switch are not in operationstate.
14) If you find an obstacle around the hoist,stop the operation.
15) After finishing the work, stop the hoist atthe specified position and raise the hookto at least 2 m above the floor. Do notleave the sling installed to the hook.
7. Selecting wire ropes1) Select adequate ropes depending on the
weight of parts to be hoisted, referring tothe table below.
a The allowable load is one-sixth of thebreaking strength of the rope used(Safety coefficient: 6).
Wire ropes(Standard �Z� twist ropes without galvanizing)
8. Precautions for disconnecting and con-necting hoses and tubes in air conditionercircuit1) Disconnection
k Collect the air conditioner refriger-ant (R134a) from the air condi-tioner circuit in advance.
a Ask professional traders for collectingand filling operation of refrigerant(R134a).
a Never release the refrigerant (R134a)to the atmosphere.
k If the refrigerant gas (R134a) getsin your eyes, you may lose yoursight. Accordingly, when collect-ing or filling it, you must be quali-fied for handling the refrigerantand put on protective goggles.
2) Connection1] When installing the air conditioner cir-
cuit hoses and tubes, take care thatdirt, dust, water, etc. will not enterthem.
2] When connecting the air conditionerhoses and tubes, check that O-rings(1) are fitted to their joints.
3] Check that each O-ring is not dam-aged or deteriorated.
4] When connecting the refrigerant pip-ing, apply compressor oil for refriger-ant (R134a) (DENSO: ND-OIL8,ZEXEL: ZXL100PG (equivalent toPAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint ofhoses and tubes)
a For tightening torque, see the precautions forinstallation in each section of "Disassemblyand assembly".
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12V140E-3 Series 7
How to read the shop manual 1
1. Composition of shop manualThis 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 forewordThis section explains the shop manuals list, table of contents, safety, and basic information.
01. SpecificationThis section explains the specifications of the machine.
10. Structure, function and maintenance standardThis 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. Itserves not only to give an understanding of the structure, but also serves as reference material fortroubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-assembly and service.
20. Standard value tableThis 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 intesting and adjusting and to judge parts in troubleshooting.
30. Testing and adjustingThis section explains measuring instruments and measuring methods for testing and adjusting, andmethod of adjusting each part. The standard values and judgement criteria for testing and adjustingare explained in Testing and adjusting.
40. TroubleshootingThis section explains how to find out failed parts and how to repair them. The troubleshooting isdivided by failure modes. The �S mode� of the troubleshooting related to the engine may be alsoexplained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assemblyThis section explains the special tools and procedures for removing, installing, disassembling, andassembling each component, as well as precautions for them. In addition, tightening torque andquantity and weight of coating material, oil, grease, and coolant necessary for the work are alsoexplained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distributionAny additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the mostup-to-date information before you start any work.
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If oneof them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.q Shop manuals are divided into the �Chassis volume� and �Engine volume�. For the engine unit, see the
engine volume of the engine model mounted on the machine.
SEN00296-02 00 Index and foreword
8 12V140E-3 Series
3. Filing methodFile by the brochures in the correct order of the form number printed in the shop manual compositiontable.
qqqq Revised edition markWhen a manual is revised, the ones and tens digits of the form number of each brochure isincreased by 1. (Example: 00, 01, 02 �)
qqqq RevisionsRevised brochures are shown in the shop manual composition table.
4. SymbolsImportant safety and quality portions are marked with the following symbols so that the shop manual willbe used practically.
5. UnitsIn this shop manual, the units are indicated with International System of units (SI). For reference, con-ventionally used Gravitational System of units is indicated in parentheses { }.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
a Caution Special technical precautions or other precautions for preserving stan-dards are necessary when performing work.
4 Weight Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3 Tightening torque
Places that require special attention for tightening torque during assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5 Oil, coolant Places where oil, etc. must be added, and capacity.
6 Drain Places where oil, etc. must be drained, and quantity to be drained.
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12V140E-3 Series 9
Explanation of terms for maintenance standard 1The maintenance standard values necessary for judgment of products and parts are described by the follow-ing terms.
1. Standard size and toleranceq To be accurate, the finishing size of parts
is a little different from one to another.q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-able difference from that size is indicated.
q The above size set temporarily is calledthe �standard size� and the range of differ-ence from the standard size is called the�tolerance�.
q The tolerance with the symbols of + or � isindicated on the right side of the standardsize.
a The tolerance may be indicated in the textand a table as [standard size (upper limitof tolerance/lower limit of tolerance)].Example) 120 (�0.022/�0.126)
q Usually, the size of a hole and the size ofthe shaft to be fitted to that hole are indi-cated by the same standard size and dif-ferent tolerances of the hole and shaft.The tightness of fit is decided by the toler-ance.
q Indication of size of rotating shaft and holeand relationship drawing of them
Example: Standard size Tolerance
120 �0.022�0.126
Example:
Standard sizeTolerance
Shaft Hole
60 �0.030�0.076
+0.046+0
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10 12V140E-3 Series
2. Standard clearance and standard valueq The clearance made when new parts are
assembled is called the �standard clear-ance�, which is indicated by the rangefrom the minimum clearance to the maxi-mum clearance.
q When some parts are repaired, the clear-ance is generally adjusted to the standardclearance.
q A value of performance and function ofnew products or equivalent is called the�standard value�, which is indicated by arange or a target value.
q When some parts are repaired, the valueof performance/function is set to the stan-dard value.
3. Standard interferenceq When the diameter of a hole of a part
shown in the given standard size and tol-erance table is smaller than that of themating shaft, the difference between thosediameters is called the �interference�.
q The range (A � B) from the difference (A)between the minimum size of the shaftand the maximum size of the hole to thedifference (B) between the maximum sizeof the shaft and the minimum size of thehole is the �standard interference�.
q After repairing or replacing some parts,measure the size of their hole and shaftand check that the interference is in thestandard range.
4. Repair limit and allowable valueq The size of a part changes because of
wear and deformation while it is used. Thelimit of changed size is called the �repairlimit�.
q If a part is worn to the repair limit must bereplaced or repaired.
q The performance and function of a prod-uct lowers while it is used. A value belowwhich the product can be used withoutcausing a problem is called the �allowablevalue�.
q If a product is worn to the allowable value,it must be checked or repaired. Since thepermissible value is estimated from vari-ous tests or experiences in most cases,however, it must be judged after consider-ing the operating condition and customer'srequirement.
5. Clearance limitq Parts can be used until the clearance
between them is increased to a certainlimit. The limit at which those parts cannotbe used is called the �clearance limit�.
q If the clearance between the partsexceeds the clearance limit, they must bereplaced or repaired.
6. Interference limitq The allowable maximum interference
between the hole of a part and the shaft ofanother part to be assembled is called the�interference limit�.
q The interference limit shows the repairlimit of the part of smaller tolerance.
q If the interference between the partsexceeds the interference limit, they mustbe replaced or repaired.
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12V140E-3 Series 11
Handling of electric equipment and hydraulic component 1To maintain the performance of the machine over a long period, and to prevent failures or other troublesbefore they occur, correct �operation�, �maintenance and inspection�, �troubleshooting�, and �repairs� mustbe carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed atimproving 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 electricequipment1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connectingone component to another component, con-nectors used for connecting and disconnectingone wire from another wire, and protectors ortubes used for protecting the wiring.Compared with other electrical components fit-ted in boxes or cases, wiring harnesses aremore likely to be affected by the direct effectsof rain, water, heat, or vibration. Furthermore,during inspection and repair operations, theyare frequently removed and installed again, sothey are likely to suffer deformation or damage.For this reason, it is necessary to be extremelycareful when handling wiring harnesses.
2. Main failures occurring in wiring harness1) Defective contact of connectors (defec-
tive contact between male and female)Problems with defective contact are likelyto occur because the male connector isnot properly inserted into the female con-nector, or because one or both of the con-nectors is deformed or the position is notcorrectly aligned, or because there is cor-rosion or oxidization of the contact sur-faces. The corroded or oxidized contactsurfaces may become shiny again (andcontact may become normal) by connect-ing and disconnecting the connector about10 times.
2) Defective crimping or soldering of connec-torsThe pins of the male and female connec-tors are in contact at the crimped terminalor soldered portion, but if there is exces-sive force brought to bear on the wiring,the plating at the joint will peel and causeimproper connection or breakage.
SEN00296-02 00 Index and foreword
12 12V140E-3 Series
3) Disconnections in wiringIf the wiring is held and the connectors arepulled apart, or components are lifted witha crane with the wiring still connected, or aheavy object hits the wiring, the crimpingof the connector may separate, or the sol-dering may be damaged, or the wiringmay be broken.
4) High-pressure water entering connectorThe connector is designed to make it diffi-cult for water to enter (drip-proof struc-ture), but if high-pressure water is sprayeddirectly on the connector, water may enterthe connector, depending on the directionof the water jet. Accordingly, take care notto splash water over the connector. Theconnector is designed to prevent waterfrom entering, but at the same time, ifwater does enter, it is difficult for it to bedrained. Therefore, if water should get intothe connector, the pins will be short-cir-cuited by the water, so if any water gets in,immediately dry the connector or takeother appropriate action before passingelectricity through it.
5) Oil or dirt stuck to connectorIf oil or grease are stuck to the connectorand an oil film is formed on the mating sur-face between the male and female pins,the oil will not let the electricity pass, sothere will be defective contact. If there isoil or grease stuck to the connector, wipe itoff with a dry cloth or blow it dry with com-pressed air and spray it with a contactrestorer.a When wiping the mating portion of the
connector, be careful not to useexcessive force or deform the pins.
a If there is oil or water in the com-pressed air, the contacts will becomeeven dirtier, so remove the oil andwater from the compressed air com-pletely before cleaning with com-pressed air.
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12V140E-3 Series 13
3. Removing, installing, and drying connec-tors and wiring harnesses1) Disconnecting connectors
1] Hold the connectors when discon-necting.When disconnecting the connectors,hold the connectors. For connectorsheld by a screw, loosen the screwfully, then hold the male and femaleconnectors in each hand and pullapart. For connectors which have alock stopper, press down the stopperwith your thumb and pull the connec-tors apart.a Never pull with one hand.
2] When removing from clipsq Both of the connector and clip have
stoppers, which are engaged witheach other when the connector isinstalled.
q When removing a connector from aclip, pull the connector in a paralleldirection to the clip for removing stop-pers.a If the connector is twisted up and
down or to the left or right, thehousing may break.
3] Action to take after removing connec-torsAfter removing any connector, cover itwith a vinyl bag to prevent any dust,dirt, oil, or water from getting in theconnector portion.a If the machine is left disassem-
bled for a long time, it is particu-larly easy for improper contact tooccur, so always cover the con-nector.
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14 12V140E-3 Series
2) Connecting connectors1] Check the connector visually.
Check that there is no oil, dirt, orwater stuck to the connector pins(mating portion).Check that there is no deformation,defective contact, corrosion, or dam-age to the connector pins.Check that there is no damage orbreakage to the outside of the con-nector.a If there is any oil, water, or dirt
stuck to the connector, wipe it offwith a dry cloth. If any water hasgot inside the connector, warmthe inside of the wiring with adryer, but be careful not to makeit too hot as this will cause shortcircuits.
a If there is any damage or break-age, replace the connector.
2] Fix the connector securely.Align the position of the connectorcorrectly, and then insert it securely.For connectors with the lock stopper,push in the connector until the stop-per clicks into position.
3] Correct any protrusion of the boot andany misalignment of the wiring har-ness.For connectors fitted with boots, cor-rect any protrusion of the boot. Inaddition, if the wiring harness is mis-aligned, or the clamp is out of posi-tion, adjust it to its correct position.a If the connector cannot be cor-
rected easily, remove the clampand adjust the position.
q If the connector clamp has beenremoved, be sure to return it toits original position. Check alsothat there are no loose clamps.
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12V140E-3 Series 15
3) Heavy duty wire connector (DT 8-pole, 12-pole)Disconnection (Left of figure)
While pressing both sides of locks (a)and (b), pull out female connector (2).
Connection (Right of figure)1] Push in female connector (2) horizon-
tally until the lock clicks.Arrow: 1)
2] Since locks (a) and (b) may not be setcompletely, push in female connector(2) while moving it up and down untilthe locks are set normally.Arrow: 1), 2), 3)a Right of figure: Lock (a) is pulled
down (not set completely) andlock (b) is set completely.
(1): Male connector(2): Female connector(a), (b): Locks
q Disconnection q Connection (Example ofincomplete setting of (a))
SEN00296-02 00 Index and foreword
16 12V140E-3 Series
4) Drying wiring harnessIf there is any oil or dirt on the wiring har-ness, wipe it off with a dry cloth. Avoidwashing it in water or using steam. If theconnector must be washed in water, donot use high-pressure water or steamdirectly on the wiring harness. If watergets directly on the connector, do as fol-lows.1] Disconnect the connector and wipe
off the water with a dry cloth.a If the connector is blown dry with
compressed air, there is the riskthat oil in the air may causedefective contact, so remove alloi l and water from the com-pressed air before blowing withair.
2] Dry the inside of the connector with adryer.If water gets inside the connector, usea dryer to dry the connector.a Hot air from the dryer can be
used, but regulate the time thatthe hot air is used in order not tomake the connector or relatedparts too hot, as this will causedeformation or damage to theconnector.
3] Carry out a continuity test on the con-nector.After drying, leave the wiring harnessdisconnected and carry out a continu-ity test to check for any short circuitsbetween pins caused by water.a After completely drying the con-
nector, b low i t wi th contactrestorer and reassemble.
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12V140E-3 Series 17
4. Handling controller1) The controller contains a microcomputer
and electronic control circuits. These con-trol all of the electronic circuits on themachine, so be extremely careful whenhandling the controller.
2) Do not place objects on top of the control-ler.
3) Cover the control connectors with tape ora vinyl bag. Never touch the connectorcontacts with your hand.
4) During rainy weather, do not leave thecontroller in a place where it is exposed torain.
5) Do not place the controller on oil, water, orsoil, or in any hot place, even for a shorttime. (Place it on a suitable dry stand).
6) Precautions when carrying out arc weldingWhen carrying out arc welding on thebody, disconnect all wiring harness con-nectors connected to the controller. Fit anarc welding ground close to the weldingpoint.
5. Points to remember when troubleshootingelectric circuits1) Always turn the power OFF before discon-
necting or connecting connectors.2) Before carrying out troubleshooting, check
that all the related connectors are properlyinserted.a Disconnect and connect the related
connectors several times to check.3) Always connect any disconnected con-
nectors before going on to the next step.a If the power is turned ON with the
connectors still disconnected, unnec-essary abnormality displays will begenerated.
4) When carrying out troubleshooting of cir-cuits (measuring the voltage, resistance,continuity, or current), move the relatedwiring and connectors several times andcheck that there is no change in the read-ing of the tester.a If there is any change, there is proba-
bly defective contact in that circuit.
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18 12V140E-3 Series
Points to remember when handling hydraulic equipmentWith the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assemblinghydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.Avoid adding hydraulic oil, replacing filters, orrepairing the machine in rain or high winds, orplaces where there is a lot of dust.
2. Disassembly and maintenance work in thefieldIf disassembly or maintenance work is carriedout on hydraulic equipment in the field, there isdanger of dust entering the equipment. It isalso difficult to check the performance afterrepairs, so it is desirable to use unit exchange.Disassembly and maintenance of hydraulicequipment should be carried out in a speciallyprepared dustproof workshop, and the perfor-mance should be checked with special testequipment.
3. Sealing openingsAfter any piping or equipment is removed, theopenings should be sealed with caps, tapes, orvinyl bags to prevent any dirt or dust fromentering. If the opening is left open or isblocked with a rag, there is danger of dirtentering or of the surrounding area beingmade dirty by leaking oil so never do this. Donot simply drain oil out onto the ground, butcollect it and ask the customer to dispose of it,or take it back with you for disposal.
4. Do not let any dirt or dust get in duringrefilling operationsBe careful not to let any dirt or dust get in whenrefilling with hydraulic oil. Always keep the oilfiller and the area around it clean, and also useclean pumps and oil containers. If an oil clean-ing device is used, it is possible to filter out thedirt that has collected during storage, so this isan even more effective method.
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12V140E-3 Series 19
5. Change hydraulic oil when the temperatureis highWhen hydraulic oil or other oil is warm, it flowseasily. In addition, the sludge can also bedrained out easily from the circuit together withthe oil, so it is best to change the oil when it isstill warm. When changing the oil, as much aspossible of the old hydraulic oil must bedrained out. (Drain the oil from the hydraulictank; also drain the oil from the filter and fromthe drain plug in the circuit.) If any old oil is left,the contaminants and sludge in it will mix withthe new oil and will shorten the life of thehydraulic oil.
6. Flushing operationsAfter disassembling and assembling the equip-ment, or changing the oil, use flushing oil toremove the contaminants, sludge, and old oilfrom the hydraulic circuit. Normally, flushing iscarried out twice: primary flushing is carriedout with flushing oil, and secondary flushing iscarried out with the specified hydraulic oil.
7. Cleaning operationsAfter repairing the hydraulic equipment (pump,control valve, etc.) or when running themachine, carry out oil cleaning to remove thesludge or contaminants in the hydraulic oil cir-cuit. The oil cleaning equipment is used toremove the ultra fine (about 3 m) particles thatthe filter built in the hydraulic equipment can-not remove, so it is an extremely effectivedevice.
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20 12V140E-3 Series
Handling of connectors newly used for engines 1a Mainly, following engines are object for follow-
ing connectors.q 107E-1q 114E-3q 125E-5q 140E-5q 170E-5q 12V140E-3
Disconnect connector (1) according to the fol-lowing procedure.1) Slide lock (L1) to the right.2) While pressing lock (L2), pull out connec-
tor (1) toward you.a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out towardyou, if part A does not float. In thiscase, float part A with a small screw-driver while press lock (L2), and thenpull out connector (1) toward you.
2. Pull lock type (PACKARD-2)q 107 � 170, 12V140 engine
q Various temperature sensorsExample)
Intake air temperature sensor inintake manifold: TIMFuel temperature sensor: TFUELOil temperature sensor: TOILCoolant temperature sensor: TWTR,etc.
Disconnect the connector by pulling lock(B) (on the wiring harness side) of connec-tor (2) outward.
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12V140E-3 Series 21
3. Push lock typeq 107, 114 engines
Example)Fuel pressure sensor in common rail(BOSCH-03)
Disconnect connector (3) according to the fol-lowing procedure.1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107 engine
a If the lock is on the underside, useflat-head screwdriver [1] since youcannot insert your fingers.
2) While pressing up lock (C) of the connec-tor with flat-head screwdriver [1], pull outconnector (3) in the direction of the arrow.
3) While pressing lock (D), pull out connector(4) in the direction of the arrow.
SEN00296-02 00 Index and foreword
22 12V140E-3 Series
q 125 � 170, 12V140 engine4) While pressing lock (E) of the connector,
pullout connector (5) in the direction of thearrow.
Example)Fuel pressure in common rail: PFUEL etc.(AMP-3)
Example)Injection pressure control valve of fuelsupply pump: PCV (SUMITOMO-2)
Example)Speed sensor of fuel supply pump: G (SUMITOMO-3)a Pull the connector straight up.
4. Turn-housing type (Round green connector)q 140 engine
Example)Intake air pressure sensor in intake mani-fold (CANNON-04): PIM etc.
1) Disconnect connector (6) according to thefollowing procedure.1] Turn housing (H1) in the direction of
the arrow.a When connector is unlocked,
housing (H1) becomes heavy toturn.
2] Pull out housing (H1) in the directionof the arrow.
a Housing (H1) is left on the wiring har-ness side.
2) Connect the connector according to thefollowing procedure.1] Insert the connector to the end, while
setting its groove.2] Turn housing (H1) in the direction of
the arrow until it �clicks�.
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12V140E-3 Series 23
How to read electric wire code 1a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-bols. The electric wire code is helpful in understanding the electric circuit diagram.
1. Type, symbol, and materialAV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV inthickness and outside diameter of AEX and different from AV and AVS in material of the cover.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-nal No. of 0.85Indicates color of wire by color code.Color codes are shown in Table 3.
Indicates size of wire by nominal No.Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.Type, symbol, and material of wire are shown in Table 1.(Since AV and AVS are classified by size (nominal No.), they are not indi-cated.)
Remarks: In a color code consisting of 2 colors, the first color is the color of the background andthe second color is the color of the marking.Example: �GW� means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 3)Color Code Color of wire Color Code Color of wire
B Black LgW Light green & WhiteBr Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & RedBrR Brown & Red LW Blue & WhiteBrW Brown & White LY Blue & YellowBrY Brown & Yellow O OrangeCh Charcoal P PinkDg Dark green R Red G Green RB Red & Black
GB Green & Black RG Red & GreenGL Green & Blue RL Red & BlueGr Gray RW Red & WhiteGR Green & Red RY Red & YellowGW Green & White Sb Sky BlueGY Green & Yellow Y YellowL Blue YB Yellow & Black
LB Blue & Black YG Yellow &GreenLg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & RedLgR Light green & Red YW Yellow & White
(Table 4)Type of wire AVS or AV AEX
Type ofcircuit
Charge R WG � � � � R �
Ground B � � � � � B �
Start R � � � � � R �
Light RW RB RY RG RL � D �
Instrument Y YR YB YG YL YW Y GrSignal G GW GR GY GB GL G Br
Others
L LW LR LY LB � L �
Br BrW BrR BrY BrB � � �
Lg LgR LgY LgB LgW � � �
O � � � � � � �
Gr � � � � � � �
P � � � � � � �
Sb � � � � � � �
Dg � � � � � � �
Ch � � � � � � �
SEN00296-02 00 Index and foreword
26 12V140E-3 Series
Precautions when carrying out operation 1[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the generalprecautions given below when carrying out the operation.]
1. Precautions when carrying out removal workq If the coolant contains antifreeze, dispose of it correctly.q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.q When draining oil, prepare a container of adequate size to catch the oil.q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.q Check the number and thickness of the shims, and keep in a safe place.q When raising components, be sure to use lifting equipment of ample strength.q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.1) Face seal type hoses and tubes
2) Split flange type hoses and tubes
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal number Plug (nut end) Sleeve nut (elbow end)
2. Precautions when carrying out installation workq Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.q Bend the cotter pins and lock plates securely.q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 � 3 drops of adhesive.q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.q Clean all parts, and correct any damage, dents, burrs, or rust.q Coat rotating parts and sliding parts with engine oil.q When press fitting parts, coat the surface with anti-friction compound (LM-P).q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and otherhydraulic equipment removed for repair, always bleed the air as follows:1) Start the engine and run at low idle.2) Operate the work equipment control lever to operate the hydraulic cylinder 4 � 5 times, stopping the
cylinder 100 mm from the end of its stroke.3) Next, operate the hydraulic cylinder 3 � 4 times to the end of its stroke.4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.Run the engine to circulate the coolant through the system. Then check the coolant levelagain.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-fied level. Run the engine to circulate the oil through the system. Then check the oil levelagain.
q If the piping or hydraulic equipment have been removed, always bleed the air from the systemafter reassembling the parts.a For details, see Testing and adjusting, �Bleeding air�.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipmentparts.
2) Checking cylinder head and manifolds for loosenessCheck the cylinder head and intake and exhaust manifold for looseness.If any part is loosened, retighten it.q For the tightening torque, see �Disassembly and assembly�.
3) Checking engine piping for damage and loosenessIntake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for airsuction and exhaust gas leakage.If any part is loosened or damaged, retighten or repair it.
Cooling systemCheck the piping for damage, the mounting bolts and nuts for looseness, and the joints forcoolant leakage.If any part is loosened or damaged, retighten or repair it.
Fuel systemCheck the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuelleakage.If any part is loosened or damaged, retighten or repair it.
SEN00296-02 00 Index and foreword
28 12V140E-3 Series
4) Checking muffler and exhaust pipe for damage and looseness1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.If any bolt or nut is loosened, retighten it.
5) Checking muffler functionCheck the muffler for abnormal sound and sound different from that of a new muffler.If any abnormal sound is heard, repair the muffler, referring to �Troubleshooting� and �Disassemblyand assembly�.
00 Index and foreword SEN00296-02
12V140E-3 Series 29
Method of disassembling and connecting push-pull type coupler 1k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection1) 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) againstadapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pullit out. (Fig. 3)a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligningthem with each other. (Fig. 4)a Do not hold rubber cap portion (4).
2) After inserting the hose in the matingadapter perfectly, pull it back to check itsconnecting condition. (Fig. 5)a When the hose is pulled back, the
rubber cap portion moves toward thehose about 3.5 mm. This does notindicate abnormality, however.
SEN00296-02 00 Index and foreword
30 12V140E-3 Series
Type 2
1. Disconnection1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)contacts contact surface (a) of the hexag-onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turnlever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)and 2), pull out whole body (7) to discon-nect it. (Fig. 8)
2. Connectionq Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)contacts contact surface (a) of the hexag-onal portion at the male end. (Fig. 9)
00 Index and foreword SEN00296-02
12V140E-3 Series 31
Type 3
1. Disconnection1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)contacts contact surface (b) of the hexag-onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),push cover (10) straight until it contactscontact surface (b) of the hexagonal por-tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)and 2), pull out whole body (9) to discon-nect it. (Fig. 12)
2. Connectionq Hold the tightening portion and push body
(9) straight until the sliding prevention ringcontacts contact surface (b) of the hexag-onal portion at the male end. (Fig. 13)
SEN00296-02 00 Index and foreword
32 12V140E-3 Series
Standard tightening torque table 11. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When usingtorque wrench)
a The following table corresponds to the bolts in Fig. A.
a The following table corresponds to the bolts in Fig. B.
2. Table of tightening torques for split flange boltsa Unless there are special instructions, tighten split flange bolts to the torque below.
3. Table of tightening torques for O-ring boss piping jointsa Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
4. Table of tightening torques for O-ring boss plugsa Unless there are special instructions, tighten O-ring boss plugs to the torque below.
5. Table of tightening torques for hoses (taper seal type and face seal type)a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.a Apply the following torque when the threads are coated (wet) with engine oil.
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
Conversion table 1Method of using the conversion tableThe conversion table in this section is provided to enable simple conversion of figures. For details of themethod of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-heit temperatures and read the corresponding Centigrade temperature in the column at the left.When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-grade values, and read the corresponding Fahrenheit temperature on the right.
q The 12V140E-3 engine is a high-performanceand high-efficiency engine which provides lowfuel consumption, low noise, and improvedexhaust gas color, and improved accelerationperformance, and it cleared the strict exhaustgas regulation (USA: EPA regulations for2006). Accordingly, this newly developedengine is suitable as a power source ofconstruc t ion machinery, and industr ia lmachinery used for various purposes.
q It is the successor of conventional 12V140-1engine which introduces various kinds of newtechnologies while adhering fundamentally tothe configuration of V12-cylinder, water-cooled, direct injection, and 4-stroke dieselengine.
1) High-pressure fuel injection system controlledelectronicallyThe conventional one is a jerk in-line fuelinjection pump-based engine mechanicallycontrolled by a governor, while in all series ofthe new one, an electronic control system- andhigh-pressure injection system-based commonrail injection system is adopted. This systemprovides high pressure fuel of 118 MPa {1,200kg/cm2} level from the low-speed range to thehigh-speed range. In addition, it can controlthe form of injection most properly by theelectronic control system according to thespeed and load. As a result, clean exhaustgas, c lean exhaust gas color, low fue lconsumption, and low noise are attainedsimultaneously.
2) It adopts a re-entrant piston combustionchamber wh ich has been used s inceintroduction into the 6D140E-2 engine and alsouses a quality cast iron piston with less thermalexpansion and shaker cooling gallery. As aresult, clean exhaust gas, clean exhaust gascolor, and low fuel consumption are attainedsimultaneously, and also high durability andhigh reliability are also obtained.
3) It also provides a higher compression ratiothan the conven t iona l one to improvecombustion efficiency and reduce the whiteexhaust smoke when starting the engine incold climate areas. In addition, by using theabove-mentioned high-pressure fuel injectionsystem controlled electronically and setting theinjection characteristics most properly toimprove the startability and reduce the whiteexhaust smoke when the temperature is low.
4) It is equipped with an improved turbochargerKOMATSU KTR110 of which high reliabilityand high performance have been proven in the12V140-1 engine. The following improvements
are added: mounting of a recirculation port forsurging control at the compressor side and adesign to improve efficiency of the turbine. Asa result, high performance is attained in a widerange from the low-speed range to the high-speed range, and high performance and lowfuel consumption are also obtained.
5) The piston cooling nozzle of 12V140-1 isreviewed in regard to oil flow. As a result,durabi l i ty of the piston is improved andtemperature of the rear surface of the piston isreduced to prevent deterioration of the pistondue to exposure of lubricating oil on thesurface to high temperature. Since the high-pressure fuel injection system controllede lec t ron ica l l y i s employed , l ess -soo tcombustion is attained and the draininginterval of the oil is lengthened.
6) The high-pressure pump to create highpressure in the common rail injection system isone-third of the conventional in-l ine fuelinjection pump, and in addition, it is connectedcompact to the timing gear case as a flangemount rather than a saddle mount. As a result,sound radiation is reduced to provide lownoise.
7) Capacity of the lubrication pump is increasedby 10% over the conventional engine tocontribute to the reliability and durability.
8) The air cleaner is changed from theconventional end surface seal type to radialseal type to prevent the entry of dust due todeformation into the clean side. In addition, theair cleaner clogging sensor for 5 clogging levelindication is provided to inform users of aprecise cleaning time.
9) A high performance and high efficiencycombination filter is adopted as an oil filter, anda filter system to collect small dirts as well aslarge dirts is adopted for all specifications.
10) The fuel filter system includes a high efficiencymain filter and prefilter as standard features toallow use of low-grade fuel in the market(corresponding to NAS13 level). In addition,the delivery of the priming pump used toreplace the filters is increased for higherserviceability.
11) In addition, since the engine controller ismounted on the engine and equipped with theautomatic high-altitude compensation function,it can be operated at high altitude withoutreplacing the controller. As a result, theserviceability is improved.
SEN00303-02 01 Specification
4 12V140E-3 Series
Specifications 1
Engine name SAA12V140E-3
Machine model D475A-5E0
Number of cylinders � Bore × StrokeTotal displacementFiring order
mml {cc}
�
12 � 140 x 16530.5 {30,480}
R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4
Dim
ensi
ons Overall length mm 1,772
Overall width mm 1,532.5
Overall height (excluding exhaust pipe) mm 2,171.5
Structure, function and maintenance standard, Part 1Air intake and exhaust system ........................................................................................................................ 3
Air intake and exhaust unit ................................................................................................................... 3Air cleaner............................................................................................................................................. 4Turbocharger ........................................................................................................................................ 6Aftercooler ...........................................................................................................................................11Muffler ................................................................................................................................................. 12
SEN00307-02 10 Structure, function and maintenance standard
2 12V140E-3 Series
Crankshaft........................................................................................................................................... 26Camshaft............................................................................................................................................. 28Cam follower, push rod ....................................................................................................................... 29Piston, piston ring, and piston pin ....................................................................................................... 30Connecting rod.................................................................................................................................... 32Flywheel and flywheel housing ........................................................................................................... 34Vibration damper................................................................................................................................. 35Timing gear ......................................................................................................................................... 36Valve system....................................................................................................................................... 38Valve and valve guide ......................................................................................................................... 40Rocker arm and shaft.......................................................................................................................... 42Crosshead and guide.......................................................................................................................... 43
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 3
Air intake and exhaust system 1Air intake and exhaust unit 1(Left side view of engine)
a The illustration shows the engine for D475A-5E0.
A: Air intake (From air cleaner)B: Air intake (To air-cooled aftercooler)C: Air intake (From air-cooled aftercooler)D: Exhaust gas
1. Electrical intake air heater2. Air intake manifold3. Muffler4. Turbocharger
SEN00307-02 10 Structure, function and maintenance standard
4 12V140E-3 Series
Air cleaner 1ERB type[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
a The shape is subject to machine models.
A: Air inletB: To turbocharger (Intake air)C: To muffler (Dust)
1. Pre-cleaner2. Air cleaner casing3. Outer element4. Inner element
Engine Machine model Type Method of discharging dust from pre-cleaner
Number of elements
SAA12V140E-3
D475A-5E0 PC2000-8WA800-3E0, WA900-3E0
Komaclone, multi-cyclone(ERB type)
Automatic discharge(Exhaust ejector)
1 Inner element,1 Outer element
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 5
FRG type[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
a The shape is subject to machine models.
1. Inlet2. Outlet3. Guide vane4. Primary element5. Safety element
6. Evacuator valve7. Dust pan8. Guide plate (Sleeve)9. Body10. Element
Structureq The size of the body is reduced from the con-
ventional type without changing the diameterof the element.
q Since the inlet is set in the tangential direction,air is given sufficient centrifugal force by thesimple spiral guide vane, not by the guideplate.
Operationq Air containing dust is sucked in vertically
through inlet (1) and the dust is separated bythe centrifugal effect of guide vane (3).
q More than 99.9% of the dust is removed by pri-mary element (4) and clean air is sucked in theengine 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) andenter evacuator valve (6) and then are dis-charged out automatically.
Engine Machine model Type Evacuator valve Number of elements
SAA12V140E-3 HD785-7 FRG (Radial seal type) Automatic discharge 1 Inner element,1 Outer element
SEN00307-02 10 Structure, function and maintenance standard
6 12V140E-3 Series
Turbocharger 1Water-cooled typeType: KTR110L
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 7
A: Intake air inletB: Intake air outletC: Exhaust gas inletD: Exhaust gas outletE: Oil inletF: Oil outletG: Coolant
1. Blower housing2. V-band3. Diffuser plate4. Center housing5. Shroud6. Turbine housing7. Blower impeller8. Seal ring9. Thrust metal10. Journal bearing11. Seal ring12. Turbine impeller
6 Tightening torque for head cover mounting bolt 32.4 {3.3} 29.4 � 34.3 {3.0 � 3.5}
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 17
SEN00307-02 10 Structure, function and maintenance standard
18 12V140E-3 Series
Cylinder block 1
1. Cylinder block2. Cylinder liner3. Clevis seal4. O-ring5. O-ring6. Main bearing metal cap bolt7. Main bearing metal cap8. Main bearing metal9. Piston cooling nozzle10. Thrust bearing metal
10 Structure, function and maintenance standard SEN00307-02
12V140E-3 Series 19
Specifications
Cylinder blockCrankshaft: 7 bearingsCamshaft: High cam type, 7 bearingsMain bearing cap bolt: Plastic-region tightening
Piston coolingWith piston cooling nozzle
Cylinder linerWet typeMachining on inside: Plateau honing and
Structure, function and maintenance standard, Part 2Lubrication system .......................................................................................................................................... 4
SEN00309-02 10 Structure, function and maintenance standard
14 12V140E-3 Series
Outline of CRI system 1Outlineq The CRI system checks the condition of the
engine (engine speed, accelerator angle, cool-ant temperature, etc.) with sensors.
q The microcomputer of the CRI system controlsthe fuel injection rate, fuel injection timing, fuelinjection pressure, etc. totally to operate theengine under the best condition.
q The CRI system has a diagnosis function andan alarm function, with which the computer ofthe system checks the main component partsand notifies the operator of detected failures.
q In addition, the CRI system has a failsafe func-tion which stops the engine when a certain partfails and a backup function which continuesthe operation by changing the control methodin such a case.
Configurationq The CRI system is divided by the function into
the fuel system and control system.
1. Fuel system
q The fuel system distributes the high-pressurefuel generated by the fuel supply pump to thecylinders through the common rail.
q The solenoid valve in the injector opens andcloses the nozzle needle valve to start and fin-ish fuel injection.
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 15
2. Control system
q To the ECU (engine control unit), the signalsare sent from the sensors installed to themachine. Based on the signals, the ECU cal-culates and controls the energizing timing andenergizing period of the injector to injectaproper quantity of fuel in proper timing.
q The control system is roughly divided by theelectric parts into the sensors, computer, andactuators.
SEN00309-02 10 Structure, function and maintenance standard
16 12V140E-3 Series
Structure and operation of CRI system
q The CRI system consists of fuel supply pump,common rail, injector, ECU which controlsthese 3 units, and sensors.
q The fuel supply pump generates fuel pressurein the common rail. The fuel pressure is con-trolled by the fuel discharge rate of the supplypump.
q The fuel discharge rate is controlled by turningon and off the PCV (Fuel injection pressurecontrol valve) of the fuel supply pump accord-ing to the electric signals from the ECU.
q The common rail receives the pressurized fuelfrom the fuel supply pump and distributes it tothe cylinders.
q The fuel pressure is sensed by the commonrail fuel pressure sensor installed to the com-mon rail.
q A feedback control is applied so that the actualfuel pressure will match to the command pres-sure set according to the engine speed and theload on the engine.
q The fuel pressure in the common rail is appliedto the nozzle side of the injector and to thecontrol chamber through the fuel injection pipeof each cylinder.
q The injector controls the fuel injection rate andfuel injection timing by turning ON and OFF theTWV (2-way solenoid valve).
q If the TWV is turned ON (energized), the fuelcircuit is changed so that the high-pressurefuel in the control chamber will flow through theorifice. As a result, the needle valve is raisedto start fuel injection by the nozzle crackingpressure of the high-pressure fuel on the noz-zle side.
q If the TWV is turned OFF (de-energized), thefuel circuit is changed so that the high-pres-sure fuel will flow to the control chamberthrough the orifice. As a result, the needlevalve lowers to finish fuel injection.
q Accordingly, the fuel injection timing and fuelinjection rate are controlled respectively by thetiming to turn on the TWV and the length of theturn-on time of the TWV.
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 17
Structure and operation of component parts 11. Fuel supply pump
1. 3-thread type cam2. Overflow valve3. Drive gear4. No. 1 high-pressure pump5. PCV (Fuel injection pressure control valve)
6. No. 2 high-pressure pump7. Priming pump8. Feed pump9. Gear for G speed sensor
Outlineq The fuel supply pump consists of priming
pump (7), feed pump (8), and high-pressurepumps (4) and (6).
q The function of the fuel supply pump is to gen-erate common rail fuel pressure by controllingthe fuel discharge rate.
Structureq High-pressure pumps (4) and (6) have the
pressure feed systems similar to those of theconventional in-line fuel injection pump and thePCVs (Fuel injection pressure control valves)for each cylinder to control the fuel delivery.
q By employing the 3-head cam, the necessarynumber of the cylinders of high-pressurepumps (4) and (6) is reduced to 1/3 of theengine cylinders.
q Since the number of the times of feeding fuelto the common rail is the same as the numberof the times of fuel injection, the common railfuel pressure is smooth and stable.
q The fuel fed by high-pressure pumps (4) and(6) to the common rail is divided as follows.
q No. 1 high-pressure pump (on the drive gearside) (4) compensates for drop in the commonrail fuel pressure caused by fuel injection intothe No. 1, 3, and 5 cylinders.
q No. 2 high-pressure pump (on the feed pumpside) (6) compensates for drop in the commonrail fuel pressure caused by fuel injection intothe No. 2, 4, and 6 cylinders.
SEN00309-02 10 Structure, function and maintenance standard
18 12V140E-3 Series
Operation
q (A): The PCV is open when the plunger is inlowering stroke, through which low-pres-sure fuel is sucked in the plunger chamber.
q (B): While the PCV is not energized and is openafter the plunger starts the rising stroke, thesucked fuel is returned through the PCVwithout being pressurized.
q (C): If the PCV is energized and closed in thetiming for the necessary delivery, the returnpassage is closed and the pressure in theplunger chamber rises. Accordingly, thefuel is fed through the delivery valve (checkvalve) to the common rail. That is, thequantity of the fuel corresponding to theplunger lift after the PCV is closed is deliv-ery. The delivery is changed and the com-mon rail fuel pressure is controlled bychanging the opening timing of the PCV.(pre-stroke of plunger)
q (D): After the cam passes the maximum liftpoint, the plunger starts the lowering strokeand the pressure in it lowers. At this time,the delivery valve closes to stop feeding thefuel. Since the PCV is de-energized, itopens and the low-pressure fuel is suckedin the plunger chamber, or the state of (A)starts again.
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 19
1) PCV (Fuel injection pressure control valve)
q The PCV adjusts the fuel delivery from the fuelsupply pump to adjust the common rail fuelpressure. It means that the delivery from thefuel supply pump to the common rail is decidedby the timing of energizing the PCV.
2) Feed pump
q The feed pump built in the fuel supply pumpassembly draws the fuel from the fuel tank andsends it through the fuel filter to the high-pres-sure pump chamber.
q The outer and inner rotors of the feed pumpare rotated by the camshaft.
q The fuel is sucked in on the suction side anddischarged on the delivery side according tothe increase and decrease of the spacesbetween the outer and inner rotors.
SEN00309-02 10 Structure, function and maintenance standard
20 12V140E-3 Series
2. Common rail
Structureq Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injec-tors of the cylinders.
q Common rail (4) is equipped with common railfuel pressure sensor (2), flow dampers (1), andpressure limiter (3).
q The fuel injection pipes are connected to flowdampers (1) to send the high-pressure fuel tothe injectors.
q The piping of the pressure limiter (3) isreturned to the fuel tank.
1) Flow damper
Functionq The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel tothe injectors with stable pressure.
q If excessive fuel flows out, the flow dampersblock the fuel passage to prevent abnormaloutflow of the fuel.
q If the fuel flows out abnormally, high pressureis applied to the piston, which moves to theright until it reaches the seat to stop the fuel.
2) Pressure limiterq If abnormally high pressure is generated, the
pressure limiter opens to release that pres-sure.
q If the common rail fuel pressure reaches about140 MPa {1,430 kg/cm2}, the pressure limiteroperates (Opens).
q If the common rail fuel pressure lowers to 30MPa {310 kg/cm2}, the pressure limiter resetsitself (close) to maintain the pressure.
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 21
3) Common rail fuel pressure sensorq The common rail fuel pressure sensor is
installed to the common rail to sense the fuelpressure.
q This sensor is a semiconductor pressure sen-sor, which utilizes the phenomenon that theelectric resistance of silicon changes accordingto the pressure applied to it.
SEN00309-02 10 Structure, function and maintenance standard
22 12V140E-3 Series
3. Injector
Outlineq The function of the injector is to inject the high
pressure fuel from the common rail into eachcombustion chamber of the engine in the opti-mum timing, by the optimum quantity, at theoptimum injection rate, and under the optimumspray condition.
q The TWV (2-way solenoid valve) controls thestart and finish of fuel injection by controllingthe pressure in the control chamber.
q The orifice limits the opening speed of the noz-zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-ated by the pressure in the control chamber tothe needle valve of the nozzle.
q The nozzle sprays the fuel.
10 Structure, function and maintenance standard SEN00309-02
q The injector consists of the nozzle section, ori-fice to control the fuel injection rate, hydraulicpiston section, and 2-way solenoid valve sec-tion.
SEN00309-02 10 Structure, function and maintenance standard
24 12V140E-3 Series
A: No fuel injectionB: Start of fuel injection
C: Finish of fuel injectionD: From common rail
1. Nozzle2. Control piston3. Orifice (in)4. Orifice (out)
5. Valve body6. Solenoid7. Spring8. Pressure control chamber
Operation
1) No fuel injection (A)q While solenoid (6) is not energized, valve body
(5) is pressed down by spring (7).q Since the high-pressure fuel is applied from
the common rail to pressure control chamber(8), nozzle (1) is closed and the fuel is notinjected.
2) Start of fuel injection (B)q If solenoid (6) is energized, valve body (5) is
raised by electromagnetic power to open thefuel passage.
q Since the fuel in pressure control chamber (8)flows out through orifices (3) and (4), nozzle(1) rises and the fuel injection pump starts.
q The fuel injection rate is increased gradually bythe function of orifices (3) and (4).
q Continuing energization to solenoid (6) pro-vides the maximum fuel injection rate.
3) Finish of fuel injection (C)q If solenoid (6) is de-energized, valve body (5)
is lowered by spring (7) and the fuel passage isclosed.
q Since the high-pressure fuel in the commonrail is applied to pressure control chamber (8)suddenly at this time, nozzle (1) is closedquickly and fuel injection is finished sharply.
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 25
Electric circuit diagram
k Since high voltage (65V) is applied to thewiring harnesses connected to the ECU,COMMON1 and COMMON2 of ECU, andTWV#1 � #6 of the injector, take care not toget an electric shock.
SEN00309-02 10 Structure, function and maintenance standard
26 12V140E-3 Series
4. Various sensors and relays
1) Fuel temperature sensorq The fuel temperature sensor senses the fuel
temperature and sends it to the engine control-ler. The sensor unit is a thermistor the resis-tance of which changes according to thetemperature.
q The engine controller applies voltage to thethermistor and senses the temperature by thevoltage divided by the resistance in the com-puter and the resistance of the thermistor.
2) NE speed sensor (Crank angle sensor)q If the signal hole made on the flywheel passes
the sensor, the magnetic line of force changes.q If the magnetic line of force changes, the out-
put of the hall element sensor changes linearlyand it is converted into pulse of 0 - 5 V by thewave form shaping circuit in the sensor, andthen output.
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 27
3) Atmospheric pressure sensorq This sensor is used to correct altitude.
A: Pressure inletB: Mounting screw: M5
Tightening torque: 4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
q The following graph shows the output charac-teristics of the atmospheric pressure sensor.
4) Common rail pressure sensor
5) Oil pressure sensor
SEN00309-02 10 Structure, function and maintenance standard
q Similarly to the NE speed sensor, this sensorutilizes the pulses of 0 � 5 V generated by thechange of the magnetic line of force crossingthe sensor unit.
q The disc gear installed to the central part of thecamshaft of the high-pressure pump has teeth(cut parts) around it at intervals of 120°.
q In addition to the above teeth, one more toothis installed. Accordingly, 7 pulses are gener-ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-ognized by the combination of the NE speedsensor pulse and Bkup speed sensor pulse.
7) Charge pressure sensorq This sensor is used to sense the charge pres-
sure (boost pressure).
A: Mounting screw: M6Tightening torque:
5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor2. O-ring
q The following graph shows the output charac-teristics of the charge pressure sensor.
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 29
8) Charge temperature sensorq The charge temperature sensor senses the
intake air temperature (boost temperature) andsends it to the engine controller.
q The sensor unit is a thermistor the resistanceof which changes according to the tempera-ture. The engine controller applies voltage tothe thermistor and senses the temperature bythe voltage divided by the resistance in thecomputer and the resistance of the thermistor.
9) Coolant temperature sensorq The coolant temperature sensor senses the
coolant temperature and sends it to the enginecontroller.
q The sensor unit is a thermistor the resistanceof which changes according to the tempera-ture. The engine controller applies voltage tothe thermistor and senses the temperature bythe voltage divided by the resistance in thecomputer and the resistance of the thermistor.
SEN00309-02 10 Structure, function and maintenance standard
30 12V140E-3 Series
Various controls
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 31
q The CRI system controls the fuel injection rateand fuel injection timing more properly than themechanical governor or timer of the conven-tional fuel injection pump.
q For the control of the system, calculations nec-essary to the ECU are performed from the sig-nals sent from the sensors installed to theengine and machine.
q The energizing timing and energizing period ofthe injector are so controlled that the optimumquantity of fuel will be injected in the optimumtiming.
1. Fuel injection rate control functionq The fuel injection rate control function is
employed instead of the function of the con-ventional governor. It controls the fuel injectionaccording to the signals of engine speed andaccelerator angle so that the fuel injection ratewill be most proper.
2. Fuel injection timing control functionq The fuel injection timing control function is
employed instead of the function of the con-ventional timer. It controls the fuel injection tim-ing most properly from the engine speed andfuel injection rate.
3. Fuel injection pressure control function(Common rail fuel pressure controlfunction)
q The fuel injection control function (common railfuel pressure control function) controls the fueldischarge rate of the fuel supply pump by mea-suring the fuel pressure by the common railfuel pressure sensor and feeding it back toECU.
q This function performs pressure feedback con-trol so that the fuel injection pressure will bethe same as the optimum value (commandvalue) set according to the engine speed andfuel injection rate.
SEN00309-02 10 Structure, function and maintenance standard
32 12V140E-3 Series
Fuel piping 1Left bank
a The shape is subject to machine models.a The illustration shows the engine for D475A-5E0.
SpecificationsType of heater: Electrical intake air heaterRated voltage: 22 V (DC)Load current: 175 A
10 Structure, function and maintenance standard SEN00309-02
12V140E-3 Series 55
Engine controller 1
FeaturesMounting of engine controller on engineq 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 controllerq Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is
employed.
SEN00309-02 10 Structure, function and maintenance standard
20 Standard value table 1Standard service value tableStandard service value table........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2Running-in standard and performance test standard ........................................................................... 7
2 12V140E-3 Series
SEN00311-03 20 Standard value table
Standard service value table 1Standard service value table for testing, adjusting, and troubleshooting1
Engine SAA12V140E-3
Machine model D475A-5E0
Cat
egor
y
Item Measurement conditions Unit Standard value for new machine
Service limit value
Per
form
ance Speed
Max. speed at no load rpm 2,150 (+25/-50) 2,150 (+25/-50)
Min. speed at no load rpm 660 ± 40 660 ± 40
Necessary speed for starting
At 0°C (without starting aid) rpm Min. 110 �
At �20°C (with starting aid) rpm Min. 100 �
Air
inta
ke a
nd e
xhau
st s
yste
m
Air intake resistance Whole speed range kPa
{mmH2O}Max. 3.73{Max. 380}
7.47{762}
Air boost pressure At rated output kPa
{mmHg}Min. 126.66{Min. 950} �
Exhaust pressure At rated output kPa
{mmHg} � �
Exhaust temperature Whole speed range (20°C ) °C Max. 680 750
Exhaust gas color
At sudden acceleration (Low to High) Bosch index Max. 4.5 5.5
At rated output Bosch index Max. 1.0 2.0
At high idle Bosch index Max. 1.0 2.0
Valve clearanceIntake valve mm 0.35 ± 0.02 0.35 ± 0.02
At rated outputEngine coolant temperature: Min. 70°C
kPa{mmH2O}
Max. 2.94{Max. 300}
5.88{600}
Lubr
icat
ion
syst
em
Oil pressure
At rated output Engine oil temperature: Min. 80°C
SAE0W30E0SSAE5W40E0SSAE10W30DHSAE15W40DHSAE30DH
MPa{kg/cm2}
0.29 � 0.44{3.0 � 4.5}
0.2{2.0}
At low idleEngine oil temperature: Min. 80°C
MPa{kg/cm2}
Min. 0.08{Min. 0.8}
0.04{0.4}
Oil temperature Whole speed range (Oil in oil pan) °C 90 � 110 120
Oil consumption Ratio to fuel consumption at continuous rated output % 0.15 0.3
Coo
ling
syst
em Function of radiator pres-sure valve
Cracking pressure (Differential pressure)kPa
{kg/cm2}� �
Fan speed At rated speed rpm 1,005 1,005
� Alternator belt tension Deflection under finger pressure of 59 N {6 kg} mm 20 20
12V140E-3 Series 7
20 Standard value table SEN00311-03
Running-in standard and performance test standard 1Running-in standard
a This table shows the values when the fan is not installed.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
a This table shows the standard values obtained by using the JIS correction coefficients.a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.a Use ASTM No.1 or No. 2 diesel fuel as fuel.a Use SAE15W-40 as lubricating oil.a Aftercooler outlet temperature must not exceed 50°C.
a This table shows the values when the fan is not installed.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
a This table shows the standard values obtained by using the JIS correction coefficients.a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.a Use ASTM No.1 or No. 2 diesel fuel as fuel.a Use SAE15W-40 as lubricating oil.a Aftercooler outlet temperature must not exceed 50°C.
a This table shows the values when the fan is not installed.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
a This table shows the standard values obtained by using the JIS correction coefficients.a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.a Use ASTM No.1 or No. 2 diesel fuel as fuel.a Use SAE15W-40 as lubricating oil.a Aftercooler outlet temperature must not exceed 50°C.
a This table shows the values when the fan is not installed.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
a This table shows the standard values obtained by using the JIS correction coefficients.a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.a Use ASTM No.1 or No. 2 diesel fuel as fuel.a Use SAE15W-40 as lubricating oil.a Aftercooler outlet temperature must not exceed 50°C.
a This table shows the values when the fan is not installed.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
a This table shows the standard values obtained by using the JIS correction coefficients.a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.a Use ASTM No.1 or No. 2 diesel fuel as fuel.a Use SAE15W-40 as lubricating oil.a Aftercooler outlet temperature must not exceed 50°C.
3 Commercially available Hose 1 Inside diameter: Approx. 11 mm
4 Commercially available Hose 1 Inside diameter: Approx. 17 mm
5 Commercially available Measuring cylinder 1
6 Commercially available Stopwatch 1
7 07376-70315 Plug 1 Size: 03
Controller � sensor � Actuator diagnosis J
799-601-4130 T-adapter 1 For Ne sensor799-601-4330 Socket 1 For G (Bkup) sensor799-601-4240 Socket 1 For atmospheric pressure sensor799-601-4250 Socket 1 For boost pressure sensor799-601-9420 T-adapter 1 For common rail pressure sensor799-601-4150 T-adapter 1 For oil pressure sensor
4 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
Controller � sensor � Actuator diagnosis J
795-799-5540 Socket 1 For boost temperature sensorFor intake air sensor
795-799-5530 Socket 1For coolant temperature sensorFor fuel temperature sensorOil temperature sensor
799-601-9430 Socket 1 For supply pump PCV799-601-9020 T-adapter 1 For injector799-601-4260 T-adapter 1 For controller (4 - pole)799-601-4211 T-adapter 1 For controller (50 - pole)799-601-4220 T-adapter 1 For controller (60 - pole)799-601-4350 T-box 1 For 60 - pole type799-601-9320 T-box 1 For 24 - pole type799-601-9310 Plate 1
Testing/Adjusting item Sym-bol Part No. Part name Q
'ty Remarks
12V140E-3 Series 5
30 Testing and adjusting SEN00313-00
Testing air boost pressure 1a Testing tools for air boost pressure
k Be careful not to touch any hot part whenremoving or installing the testing tools.
a The test point is subject to machine models.
1. Remove air boost pressure pickup plug ((L1)on left bank or (R1) on right bank) from the bot-tom of the air intake connector.
2. Install nipple [1] of boost gauge kit A and con-nect it to gauge [2].a Example of (L1) on the left bank
3. Run the engine at the rated output and test theair boost pressure.a When testing with the engine mounted on
the machine, tes t on the condi t iondescribed in the shop manual for themachine.
4. After finishing testing, remove the testing toolsand return the removed parts.
Symbol Part No. Part name
A799-201-2202 Boost gauge kit
790-401-2220 Hose
6 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
Testing exhaust temperature 1a Testing tool for exhaust temperature
k Remove and install the testing tools afterthe exhaust manifold temperature has low-ered.
a The test point is subject to machine models.
1. Remove an exhaust temperature pickup plug(1) of the subject section for measuring fromthe top of the exhaust manifold.a Subject section for measuring includes
front left, rear left, front right and rear right(4 points in total).
2. Install sensor [1] of digital thermometer B andconnect it to thermometer [2].a Installation example to the rear right-hand
side (RR)
a For engines mounted with the exhausttemperature sensor, connect temperaturegauge [2] to the sensor on machine.
3. Run the engine and test the exhaust tempera-ture in the whole speed range.a When testing with the engine mounted on
the machine, test on the condi t iondescribed in the shop manual for themachine.
4. After finishing testing, remove the testing toolsand return the removed parts.
Symbol Part No. Part name
B 799-101-1502 Digital thermometer
12V140E-3 Series 7
30 Testing and adjusting SEN00313-00
Adjusting valve clearance 1a Adjusting tool for valve clearance
Valve clearance adjusting method1. Remove cylinder head cover.
2. Rotate the crankshaft forward and matchstamped line of R1.6 TOP on vibration damper(1) to pointer (2), by setting RH No. 1 cylinderto the compression top dead center whilewatching the movement of the intake valve ofRH No. 6 cylinder.a Crank the engine using the barring tool (B)
mounted to the front right-hand side of theflywheel housing.
a At near the compression top dead centerof the RH No. 1 cylinder, the intake valveof RH No. 6 cylinder moves.(opens).
3. Loosen locknut (6) of RH No. 1 cylinder adjustscrew (5). Insert a clearance gauge C of speci-fied clearance between the crosshead (4) androcker arm (3) and adjust the adjustmentscrew to the degree that the clearance gaugecan be moved lightly.a Valve clearance
Air Intake valve: 0.35 mm, Exhaust valve:0.57 mm
4. Tighten locknut (6) to secure adjustmentscrew.3 Locknut tightening torque:
52.9 � 64.7 Nm {5.4 � 6.6 kgm}a After tightening the locknut, check the
valve clearance again.
5. Hereafter crank the engine similar way in thefiring order. Match the stamped line of thedamper to the pointer and adjust the valveclearance of each cylinder.a Firing order
6. After finishing adjustment, return the removedparts.3 Cylinder head cover mounting bolt:
14.7 � 34.3 Nm {1.5 � 3.5 kgm}
12V140E-3 Series 9
30 Testing and adjusting SEN00313-00
Testing compression pressure 1a Testing tools for compression pressure
k When measuring the compression pres-sure, take care not to burn yourself on theexhaust manifold, muffler, etc. or getcaught in a rotating part.
a Measure the compression pressure after theengine is warmed up.(Engine oil temperature: 40 � 60°C).
1. Remove cylinder head cover (1) of the cylinderto be tested for compression pressure.
2. Bring the cylinder to be tested to the compres-sion top dead center and remove rocker armassembly (2).a See �Adjusting valve clearance�.
3. Disconnect fuel high-pressure tube (3) andinjector wiring harness and remove injector (4).a Disconnect the terminal of the injector wir-
ing harness on the injector side and thebracket on the rocker housing side andremove the in jec tor wir ing harness(Loosen the 2 terminal nuts alternately)from the injector.
a Pass injector under the fuel path projectedsideways and pull up the injector throughwire (Do not pry the injector top up).
4. Install adapter D2 to the mounting hole on theinjector and compression gauge D1.a Fit the gasket to the injector end without
faila Fix the adapter with the injector holder.3 Holder mounting bolt:
58.8 � 73.5 Nm {6.0 � 7.5 kgm}a Apply a little amount of engine oil to the
connecting parts of the adapter and gaugeso that air will not leak easily.
5. Install rocker arm assembly (2) and adjust thevalve clearance.3 Rocker arm assembly mounting bolt:
a Install the injector wiring harness accord-ing to the following procedure
1) Install the injector wiring harness to thecylinder head and fix the connector sidewith the plate.Install O-ring (16).
2) Install cap (17) with clip on the injectorside of wiring harness.Press wiring harness (18) between theinjector top and cap to the injector mainbody without slack.
3) Tighten nut (19) on the injector side.3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
4) Tighten the clamp and spacer with thebolt.
5) Install rocker arm assembly.3 Rocker arm assembly mounting bolt:
93 � 103 Nm {9.5 � 10.5 kgm}a Adjust the valve clearance. For details,
see �Adjusting valve clearance�.6) Install head cover.3 Cylinder head cover mounting bolt:
29.4 � 34.3 Nm {3.0 � 3.5 kgm}
12V140E-3 Series 11
30 Testing and adjusting SEN00313-00
Testing blow-by pressure 1a Testing tool for blow-by pressure
a The test point is subject to machine models.a Measure blow-by pressure after the engine is
warmed up.(Engine coolant temperature: Min. 70°C)
a Breather is provided to each RH and LHbanks. Test the breather on either one of thebanks.
1. Install adaptor [2] and nozzle [3] to the tip ofeach breather hose on the RH and LH.
2. Connect tube [4] and gauge [1] to either one ofthe nozzles.Close the tube connecting mate ofother nozzle with a piece of short cut tube, etc.
3. Run the engine at the rated output and test theblow-by pressure.a When testing with the engine mounted on
the machine, test on the cond i t iondescribed in the shop manual for themachine.
4. After finishing testing, remove the testing toolsand return the removed parts.
Symbol Part No. Part name Q'ty
E
1 799-201-1590 Gauge 1
2 799-201-1450 Adapter 2
3 799-201-1511 Nozzle 2
4 799-201-1571 Tube 1
12 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
Measuring blow-by pressure 1Measuring method of blow-by pressurek When measuring blow-by pressure, care
should be taken not to burn yourself on theexhaust manifold or muffler or caught in arotating part.
a Measure blow-by pressure after the engine iswarmed up.(Engine coolant temperature: Min. 70°C)
a Breather is provided to each RH and LHbanks. Test the breather on either one of thebanks.
1. Install adaptor and tool main body of blow-bychecker to the tip of breather tube on one ofthe banks.
2. Install adaptor, tool main body of blow-bychecker, hose and gauge to the tip of breathertube on one of the banks.
3. Run the engine at rated output and read thepressure indicated on the gauge.a In the case of actual vehicle, run the
engine to full stroke and read the pressureindicated on the gauge.
a If rated output or full-stroke operation is notpossible, measure the blow-by in high-idlingoperation.In this case, approx. 80% of blow-by pressureof the rated output can be obtained.
a Since blow-by pressure varies sharply depend-ing on engine condition, if measured value isjudged abnormal, investigate phenomenaassociated with defective blow-by such aslarge oil consumption, abnormal exhaust color,oil degradation and earlier contamination, etc.
a When measuring on the LH bank, close thehose on RH bank.
12V140E-3 Series 13
30 Testing and adjusting SEN00313-00
Testing oil pressure 1a Testing tools for oil pressure
a The test point is subject to machine models.
1. Remove oil temperature sensor (1) on the LHside of the cylinder block.Keep the removed oil temperature sensor andthe wiring harness connector connected.toeach other.a Don't remove the oil pressure sensor from
the block because the engine controllerdetects abnormal low pressure error of theoil pressure sensor.
2. Install nipples [1] and [2] of hydraulic tester F1and connect them to hydraulic tester F2.a Since the screw size of the sensor mount
is 14 x P1.5, nipple (799-101-5230) maybe used.
3. Run the engine at the rated output and low idleand test the oil pressure.a When testing with the engine mounted on
the machine, test on the cond i t iondescribed in the shop manual for themachine.
4. After finishing testing, remove the testing toolsand return the removed parts.
Symbol Part No. Part name
F1
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
14 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
Handling fuel system parts 1a Precautions for testing and maintaining fuel
systemThe common rail fuel injection system (CRI)consists of more precise parts than the con-ventional fuel injection pump and nozzle. If for-eign matter enters this system, it can cause atrouble.When testing and maintaining the fuel system,take care more than the past. If dust, etc.sticks to any part, wash that part thoroughlywith clean fuel.
a Precautions for replacement of fuel filter car-tridgeThe fuel filter cartridge used must be a genuineKomatsu part.The fuel injection pump and nozzle of the com-mon rail type fuel injection system (CRI) areconsisted of more precision parts than thoseused for the current pumps and nozzles. Thissystem, therefore, employs a special filter withhighly efficient filtering performance to preventmixing of foreign substances. Thus, substitut-ing it with a non-genuine filter could causetroubles in the fuel system. It is strictly prohib-ited to use such part.
Releasing residual pressure in fuel system 1a Pressure is generated in the low-pressure cir-
cuit and high-pressure circuit of the fuel sys-tem while the engine is running.Low-pressure circuit: Feed pump � Fuel filter � Supply pumpHigh-pressure circuit: Supply pump � Common rail � Injector
a The pressure in both low-pressure circuit andhigh-pressure circuit lowers to a safety levelautomatically 30 seconds after the engine isstopped.
a Before the fuel circuit is tested and its parts areremoved, the residual pressure in the fuel cir-cuit must be released completely. Accordingly,observe the following.
k Before testing the fuel system or removingits parts, wait at least 30 seconds after stop-ping the engine until the residual pressurein the fuel circuit is released. (Do not startthe work just after stopping the enginesince there is residual pressure.)
12V140E-3 Series 15
30 Testing and adjusting SEN00313-00
Testing fuel pressure 1a Testing tools for fuel pressure
a Test only the fuel pressure in the low-pressurecircuit from the feed pump through the enginecontroller cooler and fuel filter to the supplypump.
k Since the pressure in the high-pressure cir-cuit from the supply pump through thecommon rail to the injector is very high, itcannot be measured.
a The position of the oil filler varies depending onthe applicable machine.
1. Remove air bleeder plug (1) on the top of fuelfilter.
2. Install adapter [G2] and connect to gauge [G4].
3. Run the engine at high idle and measure thefuel pressure.a If the fuel pressure is in the following
range, it is normal.
4. Since the fuel circuits on the LH and RH banksafter the priming pump are independent, testeach circuit.
5. After finishing testing, remove the testing toolsand return the removed parts.
Symbol Part No. Part name
G
1799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester
2 (Setting) Adapter
3799-101-5220 Nipple
07002-11023 O-ring
4 799-401-2320 Gauge
Engine speed Fuel pressure
High idle0.15 � 0.3 MPa{1.5 � 3 kg/cm2}
16 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
Reduced cylinder mode operation 1a Reduced cylinder mode operation means to
run the engine with the fuel injectors of 1 ormore cylinders disabled electrically to reducethe number of effective cylinders. The pur-poses and effects of this operation are as fol-lows.
1. This operation is used to find out a cylinderwhich does not output power normally (or,combustion in it is abnormal).
2. When a cylinder is selected for the reducedcylinder mode operation, if the engine speedand output do not change from the normaloperation (all-cylinder operation), that cylinderhas 1 or more defects. The possible defectsare as follows.q Leakage through cylinder head gasketq Defective injectionq Defective piston, piston ring, or cylinder
linerq Defective valve mechanism
(Moving valve system)q Defect in electrical system
3. Since the common rail fuel injection systemcontrols the injector of each cylinder electroni-cally, the operator can perform the reduced cyl-inder mode operation easily with switches tofind out a defective cylinder.a Perform the reduced cylinder mode opera-
tion with the engine mounted on themachine or connected to INSITE (benchtest tool).Before performing, see Testing method inthe shop manual for the machine orINSITE (bench test tool).
No-injection cranking 1a No-injection cranking means to crank the
engine with the starting motor while all theinjections are stopped electrically. The pur-pose and effect of this operation are as follows.
q When a machine or engine has been stored fora long time, implementing the no-injectioncranking before starting the engine lubricatesthe engine parts and thus prevents its seizure.
a Perform the no-injection operation with theengine mounted on the machine or connectedto INSITE (bench test tool).Before performing, see Testing method in theshop manual for the machine or INSITE(bench test tool).
12V140E-3 Series 17
30 Testing and adjusting SEN00313-00
Testing leakage-from pressure limiter and return rate from injector 1Type of engine having intake manifold equipped with return block
a If the engine is of a type that returns the fuelspilling from the injector from the return blockinstalled to the front of intake manifold, checkthe engine according to the following (the fig-ure showing the LH bank for PC2000).
a Testing tools for pressure limiter leakage andinjector return rate
a Prepare an oil pan of about 20 l to receive thefuel flowing out during the test.
1. Preparatory work (case of the LH bank)1) Remove tube (4) between common rail (3)
and supply pump (5).2) Insert spacer H1 on supply pump (5) side
and tighten the removed joint bolt again.Symbol Part No. Part name
H
1 6151-51-8490 Spacer
2 6141-71-1710 Joint
3 Commercially available
Inside diameter of the hose: Approx. 11 mm
4 Commercially available
Inside diameter of the hose: Approx. 17 mm
5 Commercially available Measuring cylinder
6 Commercially available Stopwatch
7 07376-70315 Plug
18 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
a Connect the return pipe to the fueltank again, too.
a Be sure to provide a gasket to bothends of the spacer.
3) Insert joint H2 on common rail (3) side andtighten the removed joint bolt again.a Be sure to fit the gaskets to both ends
of the joint.4) Connect test hose H3 to the end of joint
H2.a Bind the connecting part of the test
hose with a wire, etc. to prevent itfrom coming off.
a The above is the preparation work fortesting the leakage from the pressurelimiter.
2. Testing leakage from pressure limiter1) Lay test hose H3 so that it will not slacken
and put its end in the oil pan.2) Connect INSITE (bench test tool) to the
engine and set it so that it can check theengine speed.
3) Start the engine and keep its speed to1,600 rpm with no load.
4) After the engine speed is stabilized, testthe leakage in 1 minute with measuringcylinder H5.a You may test for 20 seconds and
judge by multiplying the result by 3.a If the leakage from the pressure lim-
iter is in the following range, it is nor-mal.
5) After finishing testing, stop the engine.
Engine speed(rpm)
Leakage(cc/min)
1,600 Max. 10
12V140E-3 Series 19
30 Testing and adjusting SEN00313-00
3. Testing return rate from injectora Keep the hose on the pressure limiter side
connected and keep its end in the oil panwhile testing the return rate from the injec-tor.
1) Disconnect return hose (2) of return block(1) and connect test hose H4.a Apply plug H7 to the return hose side
to stop oil, and fix it to the fuel tank.a Bind the connecting part of the test
hose with a wire, etc. to prevent itfrom coming off.
2) Lay test hose H4 so that it will not slackenand put its end in the oil pan.
3) Connect INSITE (bench test tool) to theengine and set it so that it can check theengine speed.
4) Run the engine at the rated output.5) After the engine speed is stabilized, test
the return rate in 1 minute with measuringcylinder H5.a You may test for 20 seconds and
judge by multiplying the result by 3.a If the supply pump is not supplying
fuel, the engine speed may not rise.In this case, record the engine speed,too, during the test.
a If the return rate (spill) from the injec-tor is in the following range, it is nor-mal.
6) After finishing testing, stop the engine.
4. Work after finishing testingAfter finishing all testing, remove the testingtools and return the removed parts.
5. Check the RH bank following the identical pro-cedure.
Rated output speed(rpm)
Limit of return rate (spill)(cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
20 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
Bleeding air from fuel circuit (for D475A-5) 1
a If fuel is used up or if a fuel circuit part isremoved and installed, bleed air from the fuelcircuit according to the following procedure.
a The locations of the fuel circuit parts are sub-ject to machine models (The figure showingthe LH bank for D475A-5).
1. Remove fuel pre-filter (6) and fill it with fuel.a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter (6), andthen add fuel through part (b) (holesaround the central hole).
a After filling the fuel pre-filter (6) with fuel,remove the cap from part (a).
a If clean fuel is not available, do notremove the filter but fill it with the fuel byoperating priming pump (3).
a Don't fill fuel directly after removing mainfilter (1).
2. Install fuel pre-filter (6) to the pre-filter head.a Apply engine oil thinly over the packing on
the fuel pre-filter side.
12V140E-3 Series 21
30 Testing and adjusting SEN00313-00
a After the packing of the fuel pre-filtertouches the sealing face of the filter head,tighten the fuel filter 1/2 � 3/4 turns.
3. Loosen air bleed plugs (2) and (4) of the fuelmain filter and operate priming pump (3).a Operate the priming pump until the fuel
flows out of the hole of plug (2). Whenbubbles stop coming out, tighten plug (2).
3 Air bleeding plug:2.0 � 3.9 Nm {0.2 � 0.4 kgm}
4. Continue priming pump operation until fuelflows out of the hole of plug (4). When bubblesstop coming out, tighten plug (4).3 Air bleeding plug:
2.0 � 3.9 Nm {0.2 � 0.4 kgm}
5. Loosen air bleeder (5) of the fuel supply pumpand operate priming pump (3) 90 � 100 times.a Operate the priming pump until the fuel
flows out of the air bleeder and tighten theair bleeder. Then, operate the primingpump several times more until it becomesheavy.
3 Air bleeder: 4.9 � 6.9 Nm {0.5 � 0.7 kgm}
22 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
6. Move over to the RH side of the engine.Loosen the air bleeder (8) of the fuel supplypump and operate priming pump (7).a Operate the priming pump until the fuel
flows out of the air bleeder and the fuel ischecked. Further operate the primingpump until it becomes heavy.
3 Air bleeder: 4.9 � 6.9 Nm {0.5 � 0.7 kgm}
7. Crank the engine with the starting motor tostart engine.a The air in the high-pressure circuit is bled
automatically if the engine is cranked.a If the engine does not start, there may be
still air in the low-pressure circuit. In thiscase, repeat the above procedure fromstep 3.
12V140E-3 Series 23
30 Testing and adjusting SEN00313-00
Bleeding air from fuel circuit (for PC2000) 1
a If fuel is used up or if a fuel circuit part isremoved and installed, bleed air from the fuelcircuit according to the following procedure.
a The locations of the fuel circuit parts are sub-ject to machine models (The figure showingthe LH bank for PC2000).
1. Remove fuel pre-filter and fill it with fuel.a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter, and thenadd fuel through part (b) (holes around thecentral hole).
a After filling the fuel pre-filter with fuel,remove the cap from part (a).
a If clean fuel is not available, do notremove the filter but fill it with the fuel byoperating priming pump (3).
a Don't fill fuel directly after removing mainfilter (1).
2. Install fuel pre-filter to the filter head.a Apply engine oil thinly over the packing on
the fuel pre-filter side.
24 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
a After the packing of the fuel pre-filtertouches the sealing face of the filter head,tighten the fuel filter 1/2 � 3/4 turns.
3. Loosen air bleed plug (2) (plug on the outletside) of the fuel main filter and operate primingpump (3).a Operate the priming pump until the fuel
flows out of the plug hole and tighten theplug after checking the fuel.
3 Air bleeding plug:2.0 � 3.9 Nm {0.2 � 0.4 kgm}
4. Loosen air bleeder (5) of the fuel supply pumpand operate priming pump (3) 90 - 100 times.a Operate the priming pump until the fuel
flows out of the air bleeder and tighten theair bleeder. Then, operate the primingpump several times more until it becomesheavy.
3 Air bleeder: 4.9 � 6.9 Nm {0.5 � 0.7 kgm}
5. Bleed the air from the RH bank to the aboveprocedure.
6. Start the engine with the starting motor.a The air in the high-pressure circuit is bled
automatically if the engine is cranked.a If the engine does not start, there may be
still air in the low-pressure circuit. In thiscase, repeat the above procedure fromstep 3.
12V140E-3 Series 25
30 Testing and adjusting SEN00313-00
Testing fuel system for leakage 1k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuelleaks while the engine is running, it is dan-gerous since it can catch fire.After testing the fuel system or removingits parts, test it for fuel leakage accordingto the following procedure.
a Clean and degrease the engine and the partsaround it in advance so that you can test it eas-ily for fuel leakage.
1. Spray color checker (developer) over the fuelsupply pump, common rail, fuel injector, andjoints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm andstop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuelleakage.a Check mainly around the high-pressure
circuit parts coated with the color checkerfor fuel leakage.
a If any fuel leakage is detected, repair itand inspect again from step 1.
4. Run the engine at low idle.
5. Inspect the fuel piping and devices for fuelleakage.a Check mainly around the high-pressure
circuit parts coated with the color checkerfor fuel leakage.
a If any fuel leakage is detected, repair itand inspect again from step 1.
6. Run the engine at high idle.
7. Inspect the fuel piping and devices for fuelleakage.a Check mainly around the high-pressure
circuit parts coated with the color checkerfor fuel leakage.
a If any fuel leakage is detected, repair itand inspect again from step 1.
8. Run the engine at high idle and load it.a When checking while the components to
be checked are mounted on the machine,stall the torque converter or relieve thehydraulic pump.
9. Inspect the fuel piping and devices for fuelleakage.a Check mainly around the high-pressure
circuit parts coated with the color checkerfor fuel leakage.
a If any fuel leakage is detected, repair itand inspect again from step 1.
a If no fuel leakage is detected, check iscompleted.
26 12V140E-3 Series
SEN00313-00 30 Testing and adjusting
Adjusting speed sensor 1a The G (Bkup) speed sensor and Ne speed
sensor for the common rail fuel injection sys-tem cannot be adjusted.
a Adjust speed sensor (1), which detects the sig-nal of the flywheel ring gear to use it for theelectronic system on the machine side, accord-ing to the following procedure.
1. Remove speed sensor (1) and check that its tipis free from steel chips and flaws, and theninstall it again temporarily.2 Threads: Gasket sealant (LG-6)
2. Screw in sensor (1) until its tip touches thetooth tip of flywheel ring gear (2).
3. Return sensor (1) by 3/4 � 1 turn.a Clearance (a) of 1.1 � 1.5 mm will be
Testing and adjusting alternator belt tension 1TestingPress the intermediate point of the belt betweenalternator pulley and drive pulley with a finger andmeasure deflection (a) of the belt.a Pressing force: Approx. 59 Nm {Approx. 6 kg}a Deflection (a): approx. 20 mm (1 piece)
Adjustinga If the deflection is out of the standard range,
adjust it according to the following procedure.
1. Loosen nut (B) and bolt (2) alternately.
2. Adjust belt tension using nut (A).
3. Tighten bolt (2) to have adjust bolt (1) andplate (3) made orthogonal to each other.
4. Tighten nut (B) to fix plate (3).a After adjusting, test the belt tension again.
12V140E-3 Series 27
30 Testing and adjusting SEN00313-00
Handling controller high-voltage circuit 11. When disconnecting or connecting a connector
between engine controller and engine, be sureto turn the starting switch OFF.
2. Don't start the engine with T-adapter insertedor connected to a connector between theengine controller and the engine for diagnosis.a You may turn the starting switch to the
OFF or ON position but must not turn it tothe START position.
40 TroubleshootingGeneral information on troubleshootingGeneral information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting ........................................................................................... 2Error codes and failure codes list ......................................................................................................... 3
2 12V140E-3 Series
SEN00315-00 40 Troubleshooting
General information on troubleshootingPoints to remember when troubleshootingk When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.k When disconnecting wiring, always disconnect the negative (�) terminal of the battery first.k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and theprevent reoccurrence of the failure.When carrying out troubleshooting, and important point is of course tounderstand the structure and function. However, a short cut to effective troubleshooting is to ask the operatorvarious questions to form some idea of possible causes of the failure that would produce the reported symp-toms.
1. When carrying out troubleshooting, do nothurry to disassemble the components.If components are disassembled immediatelyafter any failure occurs:q Parts that have no connection with the fail-
ure or other unnecessary parts will be dis-assembled.
q It will become impossible to find the causeof the failure.
It will also cause a waste of manhours, parts,or oil or grease, and at the same time, will alsolose the confidence of the user or operator.For this reason, when carrying out trouble-shooting, it is necessary to carry out thoroughprior investigation and to carry out trouble-shooting in accordance with the fixed proce-dure.
2. Points to ask user or operator1) Have any other problems occurred apart
from the problem that has been reported?2) Was there anything strange about the
machine before the failure occurred?3) Did the failure occur suddenly, or were
there problems with the machine conditionbefore this?
4) Under what conditions did the failureoccur?
5) Had any repairs been carried out beforethe failure? When were these repairs car-ried out?
6) Has the same kind of failure occurredbefore?
3. Check before troubleshooting1) Check for symptoms of any abnormality in
the machine and engine.2) Be sure to check the CHECKS BEFORE
STARTING items.
3) Check other inspection items, if neces-sary.
4) Some other maintenance items can bechecked externally, so check any item thatis considered to be necessary.
5) Check the controller for display of an error.
4. Confirming failureConfirm the extent of the failure yourself, andjudge whether to handle it as a real failure oras a problem with the method of operation, etc.a When operating the machine or engine to
reenact the troubleshooting symptoms, donot carry out any investigation or mea-surement that may make the problemworse.
5. TroubleshootingUse the results of the investigation and inspec-tion in Items 2 � 4 to narrow down the causesof failure, then use the troubleshooting matrixto 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 informa-
tion.
6. Measures to remove root cause of failureEven if the failure is repaired, if the root causeof the failure is not repaired, the same failurewill occur again. To prevent this, always inves-tigate why the problem occurred. Then,remove the root cause.
12V140E-3 Series 3
40 Troubleshooting SEN00315-00
Error codes and failure codes list
*1 � *3: Machine monitor in KES 6 digit display
INSITEerror code
Machine failurecode Failure phenomenon
111 CA111 ECM Critical Internal Failure (LH bank)
111 CB111 ECM Critical Internal Failure (RH bank)
115 CA115 Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)
115 CB115 Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)
122 CA122 Charge Air Press. Sensor High Error (LH bank only)
123 CA123 Charge Air Press. Sensor Low Error (LH bank only)
131 CA131 Throttle Sensor High Error (LH bank only)
132 CA132 Throttle Sensor Low Error (LH bank only)
135 CA135 Oil Press. Sensor High Error (LH bank only)
141 CA141 Oil Press. Sensor Low Error (LH bank only)
144 CA144 Coolant Temp. Sensor High Error (LH bank only)
145 CA145 Coolant Temp. Sensor Low Error (LH bank only)
153 CA153 Charge Air Temp. Sensor High Error (LH bank only)
154 CA154 Charge Air Temp. Sensor Low Error (LH bank only)
187 CA187 Sensor Sup. 2 Volt. Low Error (LH bank)
187 CB187 Sensor Sup. 2 Volt. Low Error (RH bank)
212 CA212 Eng. Oil Temp.Sensor High Error (LH bank only)
213 CA213 Eng. Oil Temp.Sensor Low Error (LH bank only)
221 CA221 Ambient Air Press. Sensor High Error (LH bank only)
222 CA222 Ambient Air Press. Sensor Low Error (LH bank only)
227 CA227 Sensor Sup. 2 Volt. High Error (LH bank)
227 CB227 Sensor Sup. 2 Volt. High Error (RH bank)
234 CA234 Eng. Over (LH bank only)
238 CA238 Ne Speed Sensor Sup. Volt. Error (LH bank)
238 CB238 Ne Speed Sensor Sup. Volt. Error (RH bank)
263 CA263 Fuel Temp. Sensor High Error (LH bank)
263 CB263 Fuel Temp. Sensor High Error (RH bank)
265 CA265 Fuel Temp. Sensor Low Error (LH bank only)
a INSITE error code:An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition ofthe failure is confirmed with the INSITE.
a Machine failure code:An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of thefailure is confirmed with the machine monitor, etc. on the machine side.
40 Troubleshooting 1Troubleshooting of mechanical system(S-mode)Troubleshooting of mechanical system (S-mode)........................................................................................... 3
Method of using troubleshooting charts ................................................................................................ 3S-1 Starting performance is poor .......................................................................................................... 6S-2 Engine does not start ..................................................................................................................... 7S-3 Engine does not pick up smoothly ............................................................................................... 10S-4 Engine stops during operations.....................................................................................................11S-5 Engine does not rotate smoothly.................................................................................................. 12S-6 Engine lacks output (or lacks power) ........................................................................................... 13S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 15S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................................ 16S-9 Oil becomes contaminated quickly............................................................................................... 17S-10 Fuel consumption is excessive .................................................................................................. 18S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ......................................... 19S-12 Oil pressure drops...................................................................................................................... 20
2 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel)....................................................................................... 21S-14 Coolant temperature becomes too high (overheating) ............................................................... 22S-15 Abnormal noise is made............................................................................................................. 23S-16 Vibration is excessive................................................................................................................. 24
12V140E-3 Series 3
40 Troubleshooting SEN00316-00
Troubleshooting of mechanical system (S-mode) 1Method of using troubleshooting charts 1The troubleshooting chart consists of the �ques-tions�, �check items�, �causes�, and �troubleshoot-ing� blocks.The questions and check items are used to pinpointhigh probability causes by simple inspection orfrom phenomena without using troubleshootingtools.Next, troubleshooting tools or direct inspection areapplied to check the narrowed causes in order fromthe most probable one to make final confirmationaccording to the troubleshooting procedure.[Questions]:
Items to be drawn from the user or operator.They correspond to A and B in the chart on theright.The items in A are basic ones.The items in B can be drawn from the user oroperator, depending on their level.
[Check items]:Simple check items used by the serviceman tonarrow down the causes.They corresponds to C in the chart on the right.
[Causes]:Items to be narrowed from the questions andcheck items.The serviceman narrows down the probablecauses from A, B, and C.
[Troubleshooting]:Items to finally verify whether the narroweddown causes are undoubtedly the real causesusing the troubleshooting tools and directinspections.
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 itemsQ: Causes related to questions and check itemsw: 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 andthe causes cannot be narrowed, however, you may apply them.)
4 12V140E-3 Series
SEN00316-00 40 Troubleshooting
<Example of troubleshooting> Exhaust smoke is blackLet us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symp-toms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power waslost gradually], and [Air cleaner clogging caution lamp is flashing].
12V140E-3 Series 5
40 Troubleshooting SEN00316-00
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-tionship with five causes.Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
6 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-1 Starting performance is poor1
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode
General causes for poor starting performance areq Defective electrical systemq Insufficient supply of fuelq Insufficient intake of airq Improper selection of fuel (particularly during winter)q Coolant in exhaust pipea The common rail fuel injection system (CRI) recognizes
the fuel injection timing electrically. Accordingly, even ifthe starting operation is carried out, the engine may notstart until the crankshaft revolves 2 turns at maximum.This phenomenon does not indicate a trouble, however.
Causes
Clo
gged
air
clea
ner e
lem
ent
Def
ectiv
e co
ntac
t of v
alve
and
val
ve s
eat
Wor
n pi
ston
ring
and
cyl
inde
rC
logg
ed a
ir br
eath
er h
ole
of fu
el ta
nk c
apLe
akin
g or
clo
gged
fuel
pip
ing,
ent
ry o
f air
Clo
gged
fuel
filte
r ele
men
tC
logg
ed fe
ed p
ump
gauz
e fil
ter
Stuc
k or
sei
zed
supp
ly p
ump
plun
ger
Def
ectiv
e in
ject
orD
efec
tive
inta
ke a
ir he
ater
sys
tem
D
efec
tive
alte
rnat
or (r
egul
ator
sec
tion)
Def
ectiv
e al
tern
ator
(gen
erat
or s
ectio
n)D
efec
tive
or d
eter
iora
ted
batte
ry
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E E
Starting perfor-mance
Became worse gradually Q w w Q QEngine starts easily when warm w
Non-specified fuel is being used Q Q Q QReplacement of filters not carried out according to Operation and Maintenance Manual w w w Q Q
Engine oil replenished more frequently wWhen engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator is red (if indicator is installed) wAir breather hole of fuel tank cap is clogged wFuel is leaking from fuel piping wWhen priming pump is operated, it makes no reaction or it is heavy E w Q QStarting motor cranks engine slowly w
Che
ck it
ems
While engine is cranked with start-ing motor,
Fuel does not flow out if air bleeding plug of fuel filter is removed w w
If spill hose from injector is disconnected, little fuel spills Q w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q wThere is hunting from engine (rotation is irregular) Q Q QBlow-by gas is excessive w
Trou
bles
hoot
ing
Inspect air cleaner directly qWhen compression pressure is measured, it is found to be low q qWhen air is bled from fuel system, air comes out qInspect fuel filter and strainer directly qInspect feed pump gauze filter directly qCarry out troubleshooting according to �No-pressure feed by supply pump (*1)� in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 � 30 V between alternator terminal B and terminal E with engine at low idle?
Yes qNone q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Remedy
Cle
anC
orre
ctR
epla
ceC
lean
Cor
rect
Cle
anC
lean
Rep
lace
Rep
lace
Rep
lace
Rep
lace
Rep
lace
Rep
lace
12V140E-3 Series 7
40 Troubleshooting SEN00316-00
S-2 Engine does not start 1a) Engine does not turnGeneral causes why engine does not turnq Engine seized inside
o See "S-4 Engine stops during operations".q Water hammer caused by coolant which entered cylinderq Defective electrical systemq Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side
Causes
Bro
ken
flyw
heel
ring
gea
rD
efec
tive
or d
eter
iora
ted
batte
ryD
efec
tive
conn
ectio
n of
bat
tery
term
inal
Def
ectiv
e ba
ttery
rela
yD
efec
tive
star
ting
switc
hD
efec
tive
star
ting
mot
or (s
afet
y re
lay
sect
ion)
Def
ectiv
e st
artin
g m
otor
(mot
or s
ectio
n)
Def
ectiv
e st
eerin
g ci
rcui
t wiri
ng
Que
stio
ns
Confirm recent repair historyDegree of machine opera-tion Operated for long period E E
Condition of horn when starting switch is turned ON
Horn does not sound Q Q
Horn volume is low w
Battery electrolyte is low wBattery terminal is loose wWhen starting switch is turned ON, there is no operating sound from battery relay Q w
Che
ck it
ems When starting switch is turned to START, starting pinion does not move out Q Q
When starting switch is turned to START, starting pinion moves out, but
Speed of rotation is low wMakes grating noise w wSoon disengages wMakes rattling noise and does not turn Q Q
Trou
bles
hoot
ing
Inspect flywheel ring gear directly q
Car
ry o
ut tr
oubl
esho
otin
g on
inst
alle
d m
achi
ne
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Turn starting switch OFF, connect cord, turn the switch ON and carry out troubleshooting
There is not voltage (20 - 30 V) between battery relay terminal B and terminal E q
When terminal B and terminal C of starting switch are connected, engine starts q
When terminal B and terminal C at safety relay outlet are connected, engine starts q
When terminal B and terminal C at safety relay outlet are connected, engine does not start q
Remedy
Rep
lace
Rep
lace
Cor
rect
Rep
lace
Rep
lace
Rep
lace
Rep
lace
�
8 12V140E-3 Series
SEN00316-00 40 Troubleshooting
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode*2: Code [271/CA271], [271/CB271] and code [272/CA272], [272/CB272] in E-mode*3: Code [273/CA273], [273/CB273] and code [274/CA274], [274/CB274] in E-mode
b) Engine turns but no exhaust smoke comes outGeneral causes why engine turns but no exhaust smokecomes outq Fuel is not being suppliedq Supply of fuel is extremely smallq Improper selection of fuel (particularly in winter)
Causes
Use
of i
mpr
oper
fuel
Insu
ffici
ent f
uel i
n ta
nkC
logg
ed a
ir br
eath
er h
ole
of fu
el ta
nk c
apLe
akin
g, c
logg
ing
and
entry
of a
ir to
fuel
pip
ing
Clo
gged
fuel
filte
r ele
men
tC
logg
ed fe
ed p
ump
gauz
e fil
ter
Sei
zed,
abn
orm
ally
wor
n fe
ed p
ump
Bro
ken
supp
ly p
ump
shaf
t spl
ine
Stuc
k or
sei
zed
supp
ly p
ump
plun
ger
Def
ectiv
e su
pply
pum
p P
CV
Wro
ng c
onne
ctio
n of
sup
ply
pum
p P
CV
Def
ectiv
e op
erat
ion
of o
verfl
ow v
alve
(Doe
s no
t clo
se)
Def
ectiv
e op
erat
ion
of fl
ow d
ampe
rD
efec
tive
inje
ctor
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E ENon-specified fuel is being used wReplacement of filters not carried out according to Operation and Maintenance Manual w w E E Q
When fuel tank is inspected, it is found to be empty wAir breather hole of fuel tank cap is clogged Q wRust and water are found when fuel tank is drained Q Q Q Q Q
Che
ck it
ems
When fuel filter is removed, there is no fuel in it w Q wFuel is leaking from fuel piping wWhen priming pump is operated, it makes no reaction or it is heavy w Q QWhile engine is cranked with starting motor,
If air bleeding plug of fuel filter is removed, fuel does not flow out Q Q Q w Q
If spill hose from injector is disconnected, little fuel spills Q w w w w Q
Trou
bles
hoot
ing
When air is bled from fuel system, air comes out qInspect fuel filter directly qInspect feed pump gauze filter directly qInspect feed pump directly qCarry out troubleshooting according to �No-pressure feed by supply pump error (*1)� in E-mode q q q
Carry out troubleshooting according to �Abnormality in PCV1 (*2) or Abnormality in PCV2 (*3)� in E-mode q
Inspect overflow valve directly qEngine can be started in reduced cylinder mode q q
Remedy
Rep
lace
Add
Cor
rect
Cor
rect
Rep
lace
Cle
anR
epla
ceR
epla
ceR
epla
ceR
epla
ceC
orre
ctR
epla
ceR
epla
ceR
epla
ce
12V140E-3 Series 9
40 Troubleshooting SEN00316-00
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode
c) Exhaust smoke comes out but engine does not start (fuel is being injected)General causes why exhaust smoke comes out but enginedoes not startq Lack of rotating force due to defective electrical systemq Insufficient supply of fuelq Insufficient intake of airq Improper selection of fuel
Causes
Clo
gged
air
clea
ner e
lem
ent
Wor
n dy
nam
ic v
alve
sys
tem
(Val
ve, r
ocke
r lev
er, e
tc.)
Wor
n pi
ston
ring
and
/or c
ylin
der l
iner
Use
of i
mpr
oper
fuel
Clo
gged
air
brea
ther
hol
e of
fuel
tank
cap
Leak
ing,
clo
ggin
g of
fuel
sys
tem
, and
ent
ry o
f air
Clo
gged
fuel
filte
r and
/or s
train
erC
logg
ed fe
ed p
ump
gauz
e fil
ter
Stuc
k an
d/or
sei
zed
supp
ly p
ump
plun
ger
Clo
gged
inje
ctor
and
/or d
efec
tive
spra
yD
efec
tive
or d
eter
iora
ted
batte
ryD
efec
tive
cool
ant t
empe
ratu
re s
enso
r and
/or w
iring
har
ness
Def
ectiv
e in
take
air
heat
er s
yste
m
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E E
Suddenly failed to start w w QNon-specified fuel is being used Q Q Q QReplacement of filters not carried out according to Operation and Maintenance Manual w w w
Engine oil replenished more frequently wWhen engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed) w
Dust indicator is red (if indicator is installed) wAir breather hole of fuel tank cap is clogged QRust and water are found when fuel tank is drained w wWhen fuel filter is removed, there is no fuel in it wFuel is leaking from fuel piping wWhen priming pump is operated, it makes no reaction or it is heavy w Q QStarting motor cranks engine slowly w
Che
ck it
ems When engine is cranked, abnormal sound is generated around cylinder head w
While engine is cranked with start-ing motor,
Fuel does not flow out if air bleeding plug of fuel filter is removed Q Q w w
If spill hose from injector is disconnected, little fuel spills Q Q wWhen exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w
Trou
bles
hoot
ing
Inspect air cleaner directly qInspect dynamic valve system directly qWhen compression pressure is measured, it is found to be low qWhen air is bled from fuel system, air comes out qInspect fuel filter, strainer directly qInspect feed pump gauze filter directly qCarry out troubleshooting according to �No-pressure feed by supply pump error (*1)� in E-mode q
When injector unit is tested, spray condition is bad qWhen specific gravity of electrolyte and voltage of battery are measured, they are low qCoolant temperature gauge does not indicate normally (if coolant temperature gauge is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Remedy
Cle
anR
epla
ceR
epla
ceR
epla
ceC
lean
Cor
rect
Cle
anC
lean
Rep
lace
Cle
anR
epla
ceR
epla
ceR
epla
ce
10 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-3 Engine does not pick up smoothly 1
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode
General causes why engine does not pick up smoothlyq Insufficient intake of airq Insufficient supply of fuelq Defective spray condition of fuelq Improper selection of fuelq Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electri-cal system)
Causes
Clo
gged
air
clea
ner e
lem
ent
Def
ectiv
e co
ntac
t of v
alve
and
val
ve s
eat
Impr
oper
val
ve c
lear
ance
Sei
zed
turb
ocha
rger
or i
nter
fere
nce
of tu
rboc
harg
erW
orn
pist
on ri
ng a
nd/o
r cyl
inde
r lin
erC
logg
ed a
ir br
eath
er h
ole
of fu
el ta
nk c
apLe
akin
g, c
logg
ing
of o
r ent
ry o
f air
to fu
el p
ipin
gC
logg
ed fu
el fi
lter a
nd/o
r stra
iner
Clo
gged
feed
pum
p ga
uze
filte
rSt
uck
or s
eize
d su
pply
pum
p pl
unge
rD
efec
tive
oper
atio
n of
flow
dam
per (
Max
imum
leak
age
from
inje
ctor
)C
logg
ed in
ject
or a
nd/o
r def
ectiv
e sp
ray
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E E E
Engine pick-up suddenly became worse w Q Q QNon-specified fuel is being used w w w wReplacement of filters not carried out according to Operation and Maintenance Manual w w wEngine oil replenished more frequently wDust indicator is red (if indicator is installed) wAir breather hole of fuel tank cap is clogged wRust and water are found when fuel tank is drained w wFuel is leaking from fuel piping wWhen priming pump is operated, it makes no reaction or it is heavy w Q Q
Che
ck it
ems
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Q w
Color of exhaust gas is
Blue under light load wBlack w Q w w
When engine is cranked, abnormal sound is generated around cylinder head wWhen engine is cranked, interference sound is emitted from around turbocharger wHigh idle speed under no load is normal, but speed suddenly drops when load is applied Q w wThere is hunting from engine (rotation is irregular) Q Q w QBlow-by gas is excessive w
Trou
bles
hoot
ing
Inspect air cleaner directly qWhen compression pressure is measured, it is found to be low q qInspect valve clearance directly qWhen turbocharger is rotated by hand, it is found to be heavy qWhen air is bled from fuel system, air comes out qInspect fuel filter and strainer directly qInspect feed pump gauze filter directlyCarry out troubleshooting according to �No-pressure feed by supply pump error (*1)� in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders q q
Remedy
Cle
anR
epla
ceA
djus
ting
Rep
lace
Rep
lace
Cle
anC
orre
ctC
lean
Cle
anR
epla
ceR
epla
ceC
orre
ct
12V140E-3 Series 11
40 Troubleshooting SEN00316-00
S-4 Engine stops during operations 1
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode
General causes why engine stops during operationsq Seized parts inside engineq Insufficient supply of fuelq There is overheatingq Problem in drive devices on applicable machine side
o Troubleshoot the applicable machine side
Causes
Bro
ken
dyna
mic
val
ve s
yste
m (v
alve
, roc
ker a
rm, e
tc.)
Bro
ken
or s
eize
d pi
ston
and
/or c
onne
ctin
g ro
dB
roke
n or
sei
zed
cran
ksha
ft be
arin
gB
roke
n or
sei
zed
gear
trai
nIn
suffi
cien
t fue
l in
tank
Clo
gged
air
brea
ther
hol
e of
fuel
tank
cap
Leak
ing
and/
or c
logg
ed fu
el p
ipin
gC
logg
ed fu
el fi
lter a
nd/o
r stra
iner
Clo
gged
feed
pum
p ga
uze
filte
rBr
oken
or s
eize
d fe
ed p
ump
Bro
ken
supp
ly p
ump
shaf
t spl
ine
Stuc
k or
sei
zed
supp
ly p
ump
plun
ger
Bro
ken
auxi
liary
equ
ipm
ent (
pum
p, c
ompr
esso
r, et
c.)
Pro
blem
in d
rive
devi
ces
on in
stal
led
mac
hine
sid
e
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E
Condition when engine stopped
Abnormal noise was heard and engine stopped sud-denly w w w w Q w Q w w
Engine overheated and stopped w Q QEngine stopped slowly w Q QEngine stopped after hunting w Q Q Q Q
Non-specified fuel is being used Q Q Q QReplacement of filters not carried out according to Operation and Maintenance Manual w w
Fuel level monitor indicates low level (if monitor is installed) wWhen fuel tank is inspected, it is found to be empty wAir breather hole of fuel tank cap is clogged wFuel is leaking from fuel piping w
Che
ck it
ems
When priming pump is operated, it makes no reaction or it is heavy w Q QRust and water are found when fuel tank is drained w wMetal particles are found when oil pan is drained w w Q Q
When engine is cranked by hand
Does not turn at all w wTurns in opposite direction wMoves by amount of gear backlash w wSupply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w
Trou
bles
hoot
ing
Inspect dynamic valve system directly q
Car
ry o
ut tr
oubl
esho
otin
g on
inst
alle
d m
achi
ne
Inspect piston and connecting rod directly qInspect crankshaft bearing directly qInspect gear train directly qInspect fuel filter and strainer directly qInspect feed pump gauze filter directly qInspect feed pump directly qCarry out troubleshooting according to �No-pressure feed by supply pump error (*1)� in E-mode q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed q
Remedy
Rep
lace
Rep
lace
Rep
lace
Rep
lace
Add
Cle
anC
orre
ctC
lean
Cle
anR
epla
ceR
epla
ceR
epla
ceR
epla
ce
�
12 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-5 Engine does not rotate smoothly 1
*1: Code [689/CA689] and [689/CB689] in E-mode*2: Code [778/CA778] and [778/CB778] in E-mode
1
General causes why engine does not rotate smoothlyq Air in fuel systemq Defective speed sensor (Error at degree that it is not indicated)
Causes
Low
set
ting
of lo
w id
le s
peed
Insu
ffici
ent f
uel i
n ta
nkC
logg
ed a
ir br
eath
er h
ole
of fu
el ta
nk c
apLe
akin
g or
clo
ggin
g or
ent
ry o
f air
to fu
el p
ipin
gC
logg
ed fe
ed p
ump
gauz
e fil
ter
Clo
gged
fuel
filte
r or s
train
erD
efec
tive
oper
atio
n of
flow
dam
per (
Max
imum
leak
age
from
inje
ctor
)C
logg
ed in
ject
or a
nd/o
r def
ectiv
e sp
ray
(dirt
in in
ject
or)
Def
ectiv
e N
e sp
eed
sens
or a
nd/o
r wiri
ng h
arne
ssD
efec
tive
G (B
kup)
spe
ed s
enso
r or w
iring
har
ness
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E
Condition of hunting
Occurs at a certain speed range Q Q QOccurs at low idle w Q Q Q Q Q Q QOccurs even when speed is raised Q Q QOccurs on slopes w Q Q
Replacement of filters not carried out according to Operation and Maintenance Manual w wWhen fuel tank is inspected, it is found to be empty w
Che
ck it
ems Air breather hole of fuel tank cap is clogged w
Rust and water are found when fuel tank is drained Q QFuel is leaking from fuel piping wWhen priming pump is operated, it makes no reaction or it is heavy w Q Q
Trou
bles
hoot
ing
When air is bled from fuel system, air comes out qInspect feed pump gauze filter directly qInspect fuel filter and strainer directly qWhen a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders q q
Carry out troubleshooting according to �Abnormality in engine Ne speed sensor (*1)� in E-mode q
Carry out troubleshooting according to �Abnormality in engine Bkup speed sensor (*2)� in E-mode q
Remedy
Cor
rect
Add
Cle
anR
epla
ceR
epla
ceR
epla
ceR
epla
ceC
orre
ctC
orre
ctC
orre
ct
12V140E-3 Series 13
40 Troubleshooting SEN00316-00
S-6 Engine lacks output (or lacks power) 1General causes why engine lacks outputq Insufficient intake of airq Insufficient supply of fuelq Defective spray condition of fuelq Improper selection of fuelq Overheat
o See "S-14 Coolant temperature becomes toohigh (Overheating)"
q Controller is controlling in derate mode(limiting injection rate (output) because of anerror in electrical system)
Causes
Clo
gged
air
clea
ner e
lem
ent
Air l
eaka
ge fr
om a
ir in
take
pip
ing
Seiz
ed tu
rboc
harg
er o
r int
erfe
renc
e of
turb
ocha
rger
Def
ectiv
e co
ntac
t of v
alve
and
val
ve s
eat
Impr
oper
val
ve c
lear
ance
Wor
n pi
ston
ring
and
/or c
ylin
der l
iner
Clo
gged
air
brea
ther
hol
e of
fuel
tank
cap
Leak
ing
or c
logg
ed fu
el p
ipin
g
Clo
gged
fuel
filte
r and
/or s
train
er
Clo
gged
feed
pum
p ga
uze
filter
Stuc
k or
sei
zed
supp
ly p
ump
plun
ger
Clo
gged
inje
ctor
or d
efec
tive
spra
y (d
irt in
inje
ctor
)
Def
ectiv
e dr
ive
of in
ject
or (s
igna
l and
/or s
olen
oid)
Def
ectiv
e in
stal
latio
n of
boo
st p
ress
ure
sens
or (a
ir le
akag
e)
Def
ectiv
e bo
ost p
ress
ure
sens
or a
nd/o
r wiri
ng h
arne
ss
Def
ectiv
e fu
el te
mpe
ratu
re s
enso
r and
/or w
iring
har
ness
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E E E
Power was lostSuddenly Q Q Q QGradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q QReplacement of filters not carried out according to Operation and Mainte-nance Manual w Q
Engine oil replenished more frequently Q Q QDust indicator is red (if indicator is installed) wAir breather hole of fuel tank cap is clogged wFuel is leaking from fuel piping wOutput becomes insufficient after short stop of operation w
Che
ck it
ems
Color of exhaust gas
Black w wBlue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w
When engine is cranked, interference sound is emitted from around turbocharger wWhen engine is cranked, abnormal sound is generated around cylinder head wHigh idle speed is too high QHigh idle speed under no load is normal, but speed suddenly drops when load is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w QThere is hunting from engine (rotation is irregular) Q Q Q QBlow-by gas is excessive w w
Trou
bles
hoot
ing
Inspect air cleaner directly qInspect air intake piping directly qWhen boost pressure is measured, it is found to be low q q qWhen compression pressure is measured, it is found to be low q qInspect valve clearance directly qInspect fuel filter and strainer directly qInspect feed pump gauze filter directly qCarry out troubleshooting according to �No-pressure feed by supply pump error (*1)� in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders q q
Inspect boost pressure sensor mount directly qCarry out troubleshooting according to �Abnormality in charge pressure sensor (*2)� in E-mode q
Carry out troubleshooting according to �Abnormality in fuel temperature sensor (*3)� in E-mode q
Remedy
Cle
anC
orre
ctR
epla
ceR
epla
ceA
djus
ting
Rep
lace
Cle
anC
orre
ctR
epla
ceC
lean
Rep
lace
Rep
lace
Rep
lace
Cor
rect
Rep
lace
Rep
lace
14 12V140E-3 Series
SEN00316-00 40 Troubleshooting
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode*2: Code [122/CA122] and code[123/CA123] in E-mode.*3: Code [263/CA263], [263/CB263] and code [265/CA265], [265/CB265] in E-mode
12V140E-3 Series 15
40 Troubleshooting SEN00316-00
S-7 Exhaust smoke is black (incomplete combustion) 1
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode*2: Code [144/CA144] and code[145/CA145] in E-mode
General causes why exhaust smoke is blackq Insufficient intake of airq Excessive injection of fuelq Defective spray condition of fuelq Improper selection of fuelq Overheat
o See "S-14 Coolant temperature becomes too high(Overheating)"
q Controller is controlling in derate mode(limiting injection rate (output) because of an error inelectrical system)
Causes
Clo
gged
air
clea
ner e
lem
ent
Sei
zed
turb
ocha
rger
or i
nter
fere
nce
of tu
rboc
harg
erD
efec
tive
cont
act o
f val
ve a
nd v
alve
sea
tIm
prop
er v
alve
cle
aran
ceLe
akag
e of
air
betw
een
turb
ocha
rger
and
cyl
inde
r hea
dC
rush
ed o
r clo
gged
muf
fler
Wor
n pi
ston
ring
and
/or c
ylin
der l
iner
Stuc
k or
sei
zed
supp
ly p
ump
plun
ger
Clo
gged
or s
eize
d in
ject
orA
bnor
mal
ly w
orn
inje
ctor
Clo
gged
fuel
spi
ll pi
ping
(on
cylin
der h
ead
side
)Im
prop
er in
ject
ion
timin
gIm
prop
er fu
el in
ject
ion
pres
sure
Def
ectiv
e co
olan
t tem
pera
ture
sen
sor o
r wiri
ng h
arne
ss
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E E
Color of exhaust gas
Suddenly became black w Q Q QGradually became black w Q QBlue under light load w
Non-specified fuel is being used Q QOil replenished more frequently w
Power was lostSuddenly w Q Q QGradually Q Q Q Q
Dust indicator is red (if indicator is installed) wMuffler is crushed wAir leaks between turbocharger and cylinder head, and clamp is loosened w
Che
ck it
ems
Engine is operated in low-temperature mode at normal temperature Q Q QWhen exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Q w
When engine is cranked, interference sound is emitted from around turbocharger wWhen engine is cranked, abnormal sound is generated around cylinder head wTorque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w QEngine does not pick up smoothly and combustion is irregular Q Q Q Q Q wBlow-by gas is excessive wIf spill hose from injector is disconnected, abnormally much fuel spills w
Trou
bles
hoot
ing
Inspect air cleaner directly qWhen turbocharger is rotated by hand, it is fount to be heavy qWhen compression pressure is measured, it is found to be low q qInspect valve clearance directly qWhen muffler is removed, exhaust sound improves qCarry out troubleshooting according to �No-pressure feed by supply pump error (*1)� in E-mode q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinder q
Inspect fuel spill piping (on cylinder head side) directly q qCarry out troubleshooting according to �Abnormality in coolant temperature sen-sor error (*2)� in E-mode
Remedy
Cle
anR
epla
ceR
epla
ceA
djus
ting
Cor
rect
Rep
lace
Rep
lace
Rep
lace
Rep
lace
Rep
lace
Cor
rect
Adj
ustin
gA
djus
ting
Rep
lace
16 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1General causes why oil consumption is excessiveq Abnormal combustion of oilq Long-time operation of engine at low idle or high idle
(Do not run engine continuously at idle without load formore than 20 minutes)
q External leakage of oilq Wear of parts in lubrication system
Causes
Dus
t suc
ked
in fr
om in
take
sys
tem
Wor
n or
dam
aged
val
ve (s
tem
, gui
de, s
eal)
Turb
ocha
rger
1
Clo
gged
bre
athe
r or b
reat
her h
ose
Bro
ken
pist
on ri
ngW
orn
pist
on ri
ng a
nd/o
r cyl
inde
r lin
erW
orn
or d
amag
ed re
ar o
il se
alB
roke
n oi
l coo
ler
Oil
leak
age
from
oil
cool
erO
il le
akag
e fro
m o
il fil
ter
Oil
leak
age
from
oil
pipi
ngO
il le
akag
e fro
m o
il dr
ain
plug
Oil
leak
age
from
oil
pan,
cyl
inde
r hea
d, e
tc.
Wor
n se
al a
t tur
boch
arge
r end
Wor
n se
al a
t blo
wer
end
Que
stio
ns
Confirm recent repair historyDegree of machine oper-ation Operated for long period E E E E
Oil consumption suddenly increased w QOil replenished more frequently w QOil becomes contaminated quickly Q Q wOutside of engine is contaminated with oil w w w w wThere are loose piping clamps in intake system w
Che
ck it
ems
Inside of turbocharger intake outlet pipe is contaminated with oil wInside of turbocharger exhaust outlet pipe is contaminated with oil Q wThere is oil in coolant wOil level in clutch chamber or damper chamber on the installed machine side is increasing w
Exhaust smoke is blue under light load w w
Amount of blow-by gasExcessive Q Q w wNone w
Trou
bles
hoot
ing
When intake manifold is removed, dust is found inside qWhen intake manifold is removed, inside is found contaminated abnormally qExcessive play of turbocharger shaft q qCheck breather and breather hose directly qWhen compression pressure is measured, it is found to be low q qInspect rear oil seal directly qPressure-tightness test of oil cooler shows there is leakage q qThere is external leakage of oil from engine q q q q
Remedy
Cor
rect
Cor
rect
Rep
lace
Rep
lace
Cle
anR
epla
ceR
epla
ceC
orre
ctR
epla
ceR
epla
ceC
orre
ctC
orre
ctC
orre
ctC
orre
ct
12V140E-3 Series 17
40 Troubleshooting SEN00316-00
S-9 Oil becomes contaminated quickly 1General causes why oil becomes contaminatedq Entry of exhaust gas into oil due to internal wearq Clogging of lubrication passageq Use of improper fuelq Use of improper oilq Operation under excessive load
Causes
Def
ectiv
e se
al a
t tur
boch
arge
r tur
bine
end
Wor
n va
lve
and/
or v
alve
gui
deW
orn
pist
on ri
ng a
nd/o
r cyl
inde
r lin
erC
logg
ed b
reat
her a
nd/o
r bre
athe
r hos
eC
logg
ed o
il co
oler
Clo
gged
oil
filte
rD
efec
tive
oil f
ilter
saf
ety
valv
eC
logg
ed tu
rboc
harg
er lu
bric
atio
n dr
ain
tube
Exh
aust
sm
oke
is b
ad
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E ENon-specified fuel is being used QEngine oil replenished more frequently wEven when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is installed) w Q
Metal particles are found when oil filter is drained Q Q wInside of exhaust pipe is contaminated with oil wEngine oil temperature rises quickly w
Che
ck it
ems
Color of exhaust gas Blue under light load wBlack w
Amount of blow-by gasExcessive Q Q w QNone w
Trou
bles
hoot
ing
Excessive play of turbocharger shaft q
See
S-7
When compression pressure is measured, it is found to be low q qInspect breather and breather hose directly qInspect oil cooler directly qInspect oil filter directly qSpring of oil filter safety valve is hitched or broken qInspect turbocharger lubrication drain tube directly q
Remedy
Rep
lace
Rep
lace
Rep
lace
Cle
anC
lean
Rep
lace
Rep
lace
Cle
an �
18 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-10 Fuel consumption is excessive 1
*1: Code [559/CA559], [559/CB559] and code [2249/CA2249], [2249/CB2249] in E-mode*2: Code [144/CA144] and code[145/CA145] in E-mode
General causes why fuel consumption is excessiveq Leakage of fuelq Defective condition of fuel injection (fuel pressure, injection timing)q Excessive injection of fuel
Causes
Fuel
leak
age
insi
de h
ead
cove
rFu
el le
akag
e fro
m fu
el fi
lter,
pipi
ng, e
tc.
Def
ectiv
e fe
ed p
ump
oil s
eal
Def
ectiv
e su
pply
pum
p pl
unge
rD
efec
tive
com
mon
rail
fuel
pre
ssur
eD
efec
tive
spra
y by
inje
ctor
Def
ectiv
e op
erat
ion
of in
ject
orIm
prop
er in
ject
ion
timin
gD
efec
tive
cool
ant t
empe
ratu
re s
enso
r or w
iring
har
ness
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E
Condition of fuel consumption
More than other machines of same model Q Q Q QGradually increased Q QSuddenly increased Q Q
There is external leakage of fuel from engine wCombustion is irregular wEngine oil level rises and oil smells of diesel fuel w w
Che
ck it
ems
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-ders is low w
Low idle speed is high QTorque converter stall speed or hydraulic pump relief speed is high Q
Color of exhaust gas
Black Q Q Q QWhite Q
Trou
bles
hoot
ing
Remove and inspect head cover directly qInspect feed pump oil seal directly qCarry out troubleshooting according to �No-pressure feed by supply pump error (*1)� in E-mode qWhen a cylinder is cut out for reduced cylinder mode operation, engine speed does not change change on some cylinders q
If spill hose from injector is disconnected and measured, much fuel spills qCarry out troubleshooting according to �Abnormality in coolant temperature sensor (*2)� in E-mode qConfirm with INSITE or with monitoring function on installed machine side q q
Remedy
Cor
rect
Cor
rect
Rep
lace
Rep
lace
Cor
rect
Rep
lace
Rep
lace
Cor
rect
Cor
rect
12V140E-3 Series 19
40 Troubleshooting SEN00316-00
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1General causes why oil is mixed in coolantq Internal leakage in lubrication systemq Internal leakage in cooling system
Causes
Bro
ken
cylin
der h
ead
and/
or h
ead
gask
etC
rack
s in
side
cyl
inde
r blo
ckD
amag
ed c
ylin
der l
iner
O-r
ing
and/
or h
ole
caus
ed b
y pi
tting
Insu
ffici
ent p
rotru
sion
of c
ylin
der l
iner
Bro
ken
oil c
oole
r cor
e an
d/or
O-r
ing
Bro
ken
hydr
aulic
oil
cool
er o
r pow
er tr
ain
oil c
oole
r on
inst
alle
d m
achi
ne s
ide
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E
Oil levelSuddenly increased Q Q Q
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
Che
ck it
ems There are excessive air bubbles in radiator, coolant spurts back w w
Hydraulic oil or power train oil on installed machine side is milky w
When hydraulic oil or power train oil is drained, water is found w
Trou
bles
hoot
ing
Pressure-tightness test of cylinder head shows there is leakage q
Car
ry o
ut tr
oubl
esho
otin
g on
inst
alle
d m
achi
neInspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remedy
Rep
lace
Rep
lace
Rep
lace
Rep
lace
Rep
lace
�
20 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-12 Oil pressure drops 1
*1: Code [135/CA135] and code[141/CA141] in E-mode
General causes why oil pressure dropsq Leakage, clogging, and/or wear of lubrication systemq Defective oil pressure controlq Improper selection of fuel (improper viscosity)q Deterioration of oil due to overheating
Causes
Wor
n jo
urna
l of b
earin
gLa
ck o
f oil
in o
il pa
nC
oola
nt a
nd fu
el m
ixin
g in
oil
Clo
gged
stra
iner
in o
il pa
nC
logg
ed a
nd/o
r bro
ken
pipe
in o
il pa
nD
efec
tive
oil p
ump
Def
ectiv
e oi
l pum
p re
lief v
alve
Clo
gged
oil
filte
rLe
akin
g, c
rush
ed, c
logg
ed h
ydra
ulic
pip
ing
Def
ectiv
e oi
l pre
ssur
e se
nsor
and
/or d
efec
tive
wiri
ng h
arne
ssD
efec
tive
oil l
evel
sen
sor a
nd/o
r wiri
ng h
arne
ss
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q wNon-specified oil is being used Q QReplacement of filters not carried according to Operation and Maintenance Manual w
Oil pressuremonitor (if installed)
Indicates pressure drop at low idling time w QIndicates pressure drop at low and high idling times Q w w w QIndicates pressure drop on slopes wIndicates pressure drop occasionally w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w wOil level in oil pan is low w
Che
ck it
ems External hydraulic piping is leaking or crushed w
Oil is milky or smells of diesel oil wMetal particles are found when oil pan is drained wMetal particles are found when oil filter is drained w Q
Trou
bles
hoot
ing
Metal particles are found in oil filter q
See
S-1
3
Inspect oil pan strainer and pipe directly q qOil pump rotation is heavy, there is play in oil pump qValve and spring of oil pump relief valve are fatigued and damaged qInspect oil filter directly qCarry out troubleshooting according to �Abnormality in oil pressure sensor (*1)� in E-mode qIf oil level sensor is replaced, oil level monitor indicates normally q
Remedy
Cle
anA
dd�
Cle
anC
lean
Rep
lace
Adj
ustin
gC
lean
Cor
rect
Rep
lace
Rep
lace
12V140E-3 Series 21
40 Troubleshooting SEN00316-00
S-13 Oil level rises (Entry of coolant or fuel) 1
General causes why oil level risesq Coolant in oil (milky)q Fuel in oil (smells diluted diesel fuel)a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-
ant".
Causes
Bro
ken
cylin
der h
ead
and/
or h
ead
gask
etFu
el le
akag
e in
side
hea
d co
ver
Cra
cks
insi
de c
ylin
der b
lock
Dam
aged
cyl
inde
r lin
er O
-rin
g an
d/or
hol
e ca
used
by
pitti
ngW
orn
or d
amag
ed re
ar o
il se
alB
roke
n oi
l coo
ler c
ore
and/
or O
-rin
gC
logg
ed w
ater
pum
p dr
ain
hole
(bre
athe
r hol
e) a
nd/o
r def
ectiv
e se
alD
efec
tive
ther
mos
tat s
eat
Def
ects
in s
uppl
y pu
mp
Def
ectiv
e se
al o
f aux
iliary
equ
ipm
ent (
pum
p, c
ompr
esso
r)
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E E
Fuel consumption increasing w wCoolant replenished more frequently Q wThere is oil mixed in coolant Q Q Q wOil smells of diesel fuel w wOil is milky Q wWhen engine is started, drops of water come from muffler Q
Che
ck it
ems
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, or coolant spurts back w Q
Exhaust smoke is white Q QWater pump drain hole (breather hole) is clogged wWhen water pump drain hole (breather hole) is cleaned, coolant comes out wOil level in clutch or damper chamber of installed machine is low wOil level in hydraulic tank of installed machine is low w
Trou
bles
hoot
ing
When compression pressure is measured, it is found to be low qRemove and inspect head cover directly qInspect cylinder block and/or liner directly q qInspect rear oil seal directly qPressure-tightness test of oil cooler shows there is leakage qRemove and inspect water pump directly qRemove and inspect thermostat cover directly qRemove and inspect supply pump directly qInspect seal of auxiliary equipment directly q
Remedy
Rep
lace
Cor
rect
Rep
lace
Rep
lace
Cor
rect
Rep
lace
Rep
lace
Cor
rect
Rep
lace
Rep
lace
22 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating) 1General causes why coolant temperature becomes too highq Lack of cooling air (deformation, and/or damages of fan)q Drop in heat dissipation efficiencyq Problem in coolant circulation systemq Rise in oil temperature in power train on applicable
machine side o Trouble shoot on the applicable machine side
Causes
Bro
ken
cylin
der h
ead
and/
or h
ead
gask
etD
amag
ed c
ylin
der l
iner
O-r
ing
and/
or h
ole
caus
ed b
y pi
tting
Clo
gged
or b
roke
n oi
l coo
ler
Lack
of c
oola
ntB
roke
n w
ater
pum
pD
efec
tive
oper
atio
n of
ther
mos
tat
Clo
gged
or c
rush
ed ra
diat
or fi
nsC
logg
ed ra
diat
or c
ore
Def
ectiv
e ra
diat
or c
ap (p
ress
ure
valv
e)S
lippi
ng fa
n be
lt an
d/or
wor
n fa
n pu
lley
Def
ectiv
e co
olan
t tem
pera
ture
gau
ge
Ris
e in
pow
er tr
ain
oil t
empe
ratu
re o
n ap
plic
able
mac
hine
sid
e
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E E
Condition forSudden overheated Q w QPersistent overheating Q w w Q
Coolant tempera-ture gauge (if installed)
Rises quickly Q w
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) wEngine oil level has risen and oil is milky w QFan belt tension is low w
Che
ck it
ems
Milky oil is floating on coolant wThere are excessive air bubbles in radiator and coolant spurts back wWhen light bulb is held behind radiator core, no light passes through wRadiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps wCoolant flows out from radiator overflow hose wFan belt whines under sudden acceleration wPower train oil temperature gauge enters red range faster than engine coolant tem-perature gauge (if oil temperature gauge and coolant temperature gauge are installed) on the installed machine side
w
Trou
bles
hoot
ing
When compression pressure is measured, it is found to be low q
Car
ry o
ut tr
oubl
esho
otin
gon
inst
alle
d m
achi
ne
Inspect cylinder liner directly qInspect oil cooler directly qTemperature difference between upper and lower tanks of radiator is large qWhen operation of thermostat is tested, it does not open at cracking temperature qTemperature difference between upper and lower tanks of radiator is slight qInspect radiator core directly qWhen operation of radiator cap is carried out, its cracking pressure is low qInspect fan belt and pulley directly qWhen coolant temperature is measured, it is found to be normal q
Remedy
Rep
lace
Rep
lace
Rep
lace
Add
Rep
lace
Rep
lace
Cor
rect
Cor
rect
Rep
lace
Cor
rect
Rep
lace
�
12V140E-3 Series 23
40 Troubleshooting SEN00316-00
S-15 Abnormal noise is made 1General causes why abnormal noise is emittedq Abnormality due to defective partsq Abnormal combustionq Air leakage from air intake systema Judge if the noise is an internal noise or an external noise
before starting troubleshooting.a While the engine is not sufficiently warmed up, it is operated
in the low-temperature mode. Accordingly, the engine soundrises slightly higher. This is no abnormality, however.
a When the engine is accelerated, the engine sound risesslightly for approx. 3 seconds maximum. This is no abnor-mality, however.
Causes
Leak
age
of a
ir be
twee
n tu
rboc
harg
er a
nd c
ylin
der h
ead
Inte
rfere
nce
or s
eizu
re o
f tur
boch
arge
rB
roke
n dy
nam
ic v
alve
sys
tem
(val
ve a
nd/o
r roc
ker l
ever
)D
efec
tive
insi
de o
f muf
fler (
divi
ding
boa
rd o
ut o
f pos
ition
)Im
prop
er v
alve
cle
aran
ceE
xces
sive
wea
r of p
isto
n rin
g an
d/or
cyl
inde
r lin
erIm
prop
er g
ear t
rain
bac
klas
hR
emov
ed o
r sei
zed
gear
trai
n bu
shin
gD
efor
med
coo
ling
fan
and/
or lo
osen
ess
or in
terfe
renc
e of
fan
belt
Clo
gged
or s
eize
d in
ject
orD
irt c
augh
t in
inje
ctor
Impr
oper
fuel
inje
ctio
n tim
ing
(abn
orm
ality
in c
oola
nt te
mpe
ratu
re s
enso
r)
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E
Condition of abnormal noise
Gradually increased Q QSuddenly increased Q Q Q
Non-specified fuel is being used QOil replenished more frequently wMetal particles are found when oil filter is drained w wAir leaks between turbocharger and cylinder head w
Che
ck it
ems
When engine is cranked, interference sound is emitted from around turbocharger wWhen engine is cranked, abnormal sound is generated around EGR gas pipingWhen engine is cranked, abnormal sound is generated around cylinder head w wWhen engine is cranked, beat noise is emitted around muffler wWhen exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low w Q
Color of exhaust gas
Blue under light load wBlack Q w Q
Engine does not pick up smoothly and combustion is irregular wAbnormal noise is loud when engine is accelerated Q Q Q QBlow-by gas is excessive w
Trou
bles
hoot
ing
When turbocharger is rotated by hand, it is fount to be heavy qInspect dynamic valve system directly qWhen muffler is removed, abnormal noise disappears qInspect valve clearance directly qWhen compression pressure is measured, it is found to be low qInspect gear train directly q qInspect fan and fan belt directly qWhen a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders q q
Abnormal noise is heard only when engine is started qConfirm with INSITE or with monitoring function on installed machine side q
Remedy
Rep
lace
Rep
lace
Cor
rect
Rep
lace
Rep
lace
Rep
lace
Rep
lace
Rep
lace
Cor
rect
Rep
lace
Cor
rect
Cor
rect
24 12V140E-3 Series
SEN00316-00 40 Troubleshooting
S-16 Vibration is excessive 1General causes why vibration occursq Defective parts (abnormal wear, breakage, etc.)q Misalignment between installed machineq Abnormal combustiona If abnormal noise vibration occur, carry out troubleshooting for "S-15
Abnormal noise is emitted", too.
Causes
Stuc
k dy
nam
ic v
alve
sys
tem
(val
ve, r
ocke
r lev
er, e
tc.)
Wor
n m
ain
bear
ing
and/
or c
onne
ctin
g ro
d be
arin
gIm
prop
er g
ear t
rain
bac
klas
hW
orn
cam
shaf
t bus
hing
Impr
oper
inje
ctio
n tim
ing
Loos
e en
gine
mou
ntin
g bo
lts a
nd/o
r bro
ken
cush
ions
Mis
alig
nmen
t bet
wee
n en
gine
and
dev
ices
on
inst
alle
d m
achi
ne s
ide
Wor
n fro
nt s
uppo
rt sp
igot
join
t por
tion
Bro
ken
outp
ut s
haft
and/
or p
arts
in d
ampe
r on
inst
alle
d m
achi
ne s
ide
Que
stio
ns
Confirm recent repair historyDegree of machine operation Operated for long period E E E E
Condition of vibra-tion
Suddenly increased Q QGradually increased Q Q Q
Non-specified oil is being used Q QMetal particles are found when oil filter is drained w wMetal particles are found when oil pan is drained w w
Che
ck it
ems Oil pressure is low at low idle Q Q
Vibration occurs at mid-range speed Q QVibration follows engine speed Q Q Q Q QExhaust smoke is black w Q
Trou
bles
hoot
ing
Inspect dynamic valve system directly qInspect main bearing and connecting rod bearing directly qInspect gear train directly qInspect camshaft bushing directly qConfirm with INSITE or with monitoring function on installed machine side qInspect engine mounting bolts and cushions directly qWhen alignment is checked, radial runout or facial runout is detected qInspect front support spigot joint portion directly qInspect output shaft or inside of damper directly q
40 Troubleshooting 1Troubleshooting of electrical system(E-mode), Part 1Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 4
Information in troubleshooting table ..................................................................................................... 4E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) ........................................................... 6E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)........................................................... 8E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank).................................. 10E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) ..................................11E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) ................................... 12E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) .................................... 14E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only).................................................... 16E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) .................................................... 18E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) ................................................ 20E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) ............................................... 22E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) ....................................... 24E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ....................................... 26
2 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) .................................. 28E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)................................... 30E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) .................................................... 31E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ................................................... 31E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ....................................... 32E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ........................................ 34E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ................................ 36E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) ................................. 38E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ................................................... 40E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)................................................... 42E-23 Code [234/CA234] Eng. Overspeed (LH bank only).................................................................. 44E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank).............................................. 46E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ............................................. 48E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank).................................................... 50E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ................................................... 52E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)..................................................... 54E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) .................................................... 54E-30 Code [271/CA271] PCV1 Short Error (LH bank) ....................................................................... 56E-31 Code [271/CB271] PCV1 Short Error (RH bank)....................................................................... 58E-32 Code [272/CA272] PCV1 Open Error (LH bank) ....................................................................... 60E-33 Code [272/CB272] PCV1 Open Error (RH bank)....................................................................... 61E-34 Code [273/CA273] PCV2 Short Error (LH bank) ....................................................................... 62E-35 Code [273/CB273] PCV2 Short Error (RH bank)....................................................................... 64E-36 Code [274/CA274] PCV2 Open Error (LH bank) ....................................................................... 66E-37 Code [274/CB274] PCV2 Open Error (RH bank)....................................................................... 67E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) ........................... 68E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) ........................... 70E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) ........................... 72E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) ........................... 74E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) ........................... 76E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) ........................... 78E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ................................................ 80E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank)................................................ 80E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ............................................................... 82E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)............................................................... 84E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) .................................................... 86E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ................................................... 86E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ................................................... 88E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)................................................... 90E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) .......................................................... 92E-53 Code [441/CB441] Battery Voltage Low Error (RH bank).......................................................... 92E-54 Code [442/CA442] Battery Voltage High Error (LH bank).......................................................... 93E-55 Code [442/CB442] Battery Voltage High Error (RH bank) ......................................................... 93
4 12V140E-3 Series
SEN00317-00 40 Troubleshooting
Troubleshooting of electrical system (E-mode), Part 1 1Information in troubleshooting table 1a 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 codeTrouble Problem that appears on engineDisplay on
INSITEDisplay on
applicable machineContents of
trouble Contents of trouble detected by engine controller
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)
Relatedinformation Information related to detected trouble or troubleshooting
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1
Possible causes of trouble (Given numbers are refer-ence numbers, which do not indicate priority)
<Contents of description>� Standard value in normal state to judge possible causes� Remarks on judgment
<Troubles in wiring harness>� Disconnection
Connector is connected imperfectly or wiring harness is broken.
� Ground faultWiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit.
� Hot shortWiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit.
� Short circuitIndependent wiring harnesses are in contact with each other abnormally.
2
3
<Precautions for troubleshooting>(1) Method of indicating connector No. and handling of T-
adapterInsert or connect T-adapter as explained below for trouble-shooting, unless otherwise specified.� If connector No. has no marks of �male� and �female�,
disconnect connector and insert T-adapters in both male side and female side.
� If connector No. has marks of �male� and �female�, dis-connect connector and connect T-adapter to only male side or female side.
(2) Entry order of pin Nos. and handling of tester leadsConnect positive (+) lead and negative (-) lead of tester as explained below for troubleshooting, unless otherwise specified.� Connect positive (+) lead to pin No. or wiring harness
entered on front side.� Connect negative (-) lead to pin No. or wiring harness
entered on rear side.
4
12V140E-3 Series 5
40 Troubleshooting SEN00317-00
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.� Connector No.: Indicates (Model � Number of pins) and (Color).� �Connector No. and pin No.� from each branching/merging point: Shows the ends of
branch or source of merging within the parts of the same wiring harness.� Arrow(io): Roughly shows the location on the machine.
Contents of trouble � Abnormality occurred in controller.
Action of controller � None in particular.
Problem that appears
on machine� Engine continues operation normally, but it may stop during operation or may not be able to start.
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective fuseCheck fuse or circuit breaker on machine side directly for defect. (If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.)
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between PW L (female) (3), (4) � battery (+)
Resis-tance Max. 1 z
Wiring harness between PW L (female) (1), (2) � chassis ground
Resis-tance Max. 1 z
3
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between PW L(female) (3), (4) � battery (+)
Resis-tance Min. 1 Mz
4 Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
PW L Voltage
Between (3), (4) � (1), (2) 20 � 30 V
12V140E-3 Series 7
40 Troubleshooting SEN00317-00
Circuit diagram related to controller power supply
Contents of trouble � Abnormality occurred in controller.
Action of controller � None in particular.
Problem that appears on
machine� Engine continues operation normally, but it may stop during operation or may not be able to start.
Related infor-mation � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective fuse
Check fuse or circuit breaker on machine side directly for possible defect.(If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.)
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between PW R (female) (3), (4) � battery (+)
Resis-tance Max. 1 z
Wiring harness between PW R (female) (1), (2) � chassis ground
Resis-tance Max. 1 z
3
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between PW R (female) (3), (4) � battery (+) and chassis ground
Resis-tance Min. 1 Mz
4 Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
PW R Voltage
Between (3), (4) � (1), (2) 20 � 30 V
12V140E-3 Series 9
40 Troubleshooting SEN00317-00
Circuit diagram related to controller power supply
10 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error(LH bank) 1
Error code Failure codeTrouble Abnormality in engine Ne and G (Bkup) speed sensor (LH bank)
115 CA115Contents of
trouble � Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously.
Action of controller � Engine stop
Phenomenon that appears on
machine
� Engine cannot be started (engine has been stopped).� Engine stops (if engine has been running).
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective Ne speed sensor system Carry out troubleshooting for code [689/CA689].
2 Defective G (Bkup) speed sensor system Carry out troubleshooting for code [778/CA778].
3 Defective mount of Ne speed sensor
Check mount of Ne speed sensor directly for defect (defective installation of sensor, internal defect of flywheel, etc.)
4 Defective mount of G (Bkup) speed sensor
Check mount of G (Bkup) speed sensor directly for defect (defec-tive installation of sensor, internal defect of supply pump, etc.)
5 Defective connection of sen-sor (Wrong connection)
Check Ne speed sensor and G (Bkup) speed sensor directly for defective connection (wrong connection).
6 Defective engine controllerIf causes 1 � 5 are not detected, engine controller may be defec-tive. (Since trouble is in system, troubleshooting cannot be carried out.)
12V140E-3 Series 11
40 Troubleshooting SEN00317-00
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error(RH bank) 1
Error code Failure codeTrouble Abnormality in engine Ne and G (Bkup) speed sensor (RH bank)
115 CB115Contents of
trouble � Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously.
Action of controller � Engine stop
Phenomenon that appears on
machine
� Engine cannot be started (if engine has been stopped).� Engine stops (if engine has been running).
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective Ne speed sensor system Carry out troubleshooting for code [689/CA689].
2 Defective G(Bkup) speed sensor system Carry out troubleshooting for code [778/CA778].
3 Defective mount of Ne speed sensor
Check mount of Ne speed sensor directly for defect (defective installation of sensor, internal defect of flywheel, etc.)
4 Defective mount of G (Bkup) speed sensor
Check mount of G (Bkup) speed sensor directly for defect (defec-tive installation of sensor, internal defect of supply pump, etc.)
5 Defective connection (Wrong connection)
Check Ne speed sensor and G (Bkup) speed sensor directly for defective connection (wrong connection).
6 Defective engine controllerIf causes 1 � 5 are not detected, engine controller may be defec-tive. (Since trouble is in system, troubleshooting cannot be carried out.)
12 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) 1
Error code Failure codeTrouble Sensor detection of abnormally high charge pressure
(LH bank only)122 CA122Contents of
trouble � Charge pressure sensor circuit detects abnormally high pressure.
Action of controller � Sets charge pressure to fixed value (400 kPa) and continues operation.
Phenomenon that appears on
machine� Acceleration performance of engine drops.
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [187/CA187] or [227/CA227] is indicated, carry out trouble-shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ONor start engine and carry out troubleshooting.
PIM Voltage
Between (1) � (2) Power supply 4.75 � 5.25 V
Pressure sensor voltage is measured with wiring harness con-nected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Action of controller � Sets charge pressure to fixed value (400 kPa) and continues operation.
Phenomenon that appears on
machine� Acceleration performance of engine drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for E-5 Code [122/CA122].
16 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only) 1Throttle sensor of decelerator pedal type (Case of D475-5)
Error code Failure codeTrouble Throttle sensor detection of abnormally high level (LH bank only)
131 CA131Contents of
trouble � Throttle sensor circuit detection of abnormally high level.
Action of controller
� Sets throttle angle with signal other than throttle sensor signal and continues operation.(depending on each model)
Phenomenon that appears on
machine� Depends on machine model.
Related infor-mation � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [2185/CA2185] or [2186/CA2186] is indicated, carry out troubleshooting for it first.
2
Defective deceleration sen-sor(Internal trouble)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
DEC (male) Resistance
Between (A) � (C) 4.0 � 6.0 kz
Between (B) � (A) 0.25 � 5.0 kz
Between (B) � (C) 0.25 � 5.0 kz
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between OEM L (female) (22) � DEC (female) (A)
Resis-tance Max. 1 z
Wiring harness between OEM L (female) (9) � DEC (female) (B)
Resis-tance Max. 1 z
Wiring harness between OEM L (female) (23) � DEC (female) (C)
Resis-tance Max. 1 z
4
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between OEM L(female) (22) � DEC (female) (A) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between OEM L(female) (9) � DEC (female) (B) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between OEM L(female) (23) � DEC (female) (C) and chassis ground
Resis-tance Min. 1 Mz
5 Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
OEM L Voltage
Between (22) � (23) Power supply 4.75 � 5.25 V
Between (9) � (23) Signal 0.5 � 4.5 V
12V140E-3 Series 17
40 Troubleshooting SEN00317-00
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475�5)
18 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) 1Throttle sensor of decelerator pedal type (Case of D475-5)
Error code Failure codeTrouble Throttle sensor detection of abnormally low level (LH bank only)
132 CA132Contents of
trouble � Signal voltage in throttle sensor circuit is abnormally low.
Action of controller
� Sets throttle angle with signal other than throttle sensor signal and continues operation.(depending on each model)
Phenomenon that appears on
machine� Varies by installed machine
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for E-7 Code [131/CA131].
20 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) 1Error code Failure code
Trouble Oil pressure sensor detection of abnormally high pressure (LH bank only)135 CA135
Contents of trouble � Signal voltage in oil pressure sensor circuit is abnormally high.
Action of controller � Set oil pressure to default value (250 kPa) and continue operation.
Phenomenon that appears on
machine
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [187/CA187] or [227/CA227] is indicated, carry out trouble-shooting for it first.
2 Defective oil pressure sensor(Internal trouble)
a Prepare with starting switch OFF, then turn starting switch ONor start engine and carry out troubleshooting.
POIL Voltage
Between (1) � (2) Power supply 4.75 � 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and con-troller, too, for another cause of trouble, and then judge.
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Error code Failure codeTrouble Power supply 2 sensor detection of abnormally low voltage
(LH bank)187 CA187Contents of
trouble � Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
Action of controller
� 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
machine� Output drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for E-21 Code [227/CA227].
Error code Failure codeTrouble Power supply 2 sensor detection of abnormally low voltage
(RH bank)187 CB187Contents of
trouble � Signal voltage in sensor power supply 2(5 V) circuit is abnormally low.
Action of controller � Operate G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon that appears on
machine� Output drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for E-22 Code [227/CB227].
32 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) 1
Error code Failure codeTrouble Engine oil temperature sensor detection of abnormally high tem-
perature (LH bank only)212 CA212Contents of
trouble � Signal voltage in engine oil temperature sensor circuit is abnormally high.
Action of controller � Sets oil pressure to default value (100 °C) and continues operation.
Phenomenon that appears on
machine
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1Defective oil temperature sensor(Internal trouble)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
TOIL (male) Oil temperature Resistance
Between (A) � (B) 0 � 100 °C 0.5 � 36 kz
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
PAMB Voltage
Between (1) � (2) Power supply 4.75 � 5.25 V
Between (3) � (2) Signal 0.5 � 4.5 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and con-troller, too, for another cause of trouble, and then judge.
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
trouble � Signal voltage in atmospheric pressure sensor circuit is abnormally low.
Action of controller � Sets atmospheric pressure to default value (52.44 kPa) and continues operation.
Phenomenon that appears on
machine� Output drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for E-19 Code [221/CA221].
40 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) 1Error code Failure code
Trouble Power supply 2 sensor detection of abnormally high voltage (LH bank)227 CA227
Contents of trouble � Signal voltage in sensor power supply 2(5 V) circuit is abnormally high.
Action of controller
� 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
machine� Output drops.
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
2 Defective sensor (Internal trouble)
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
Disconnect devices at right in order. If error code disap-pears subsequently, that device has a defect in it.
Atmospheric pressure sensor PAMB connector
Oil pressure sensor POIL connector
Charge pressure sensor PIM connector
G (Bkup) sensor G connector
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Contents of trouble � Engine speed is above operating range.
Action of controller � Limits fuel injection rate until engine speed lowers to operating range.
Phenomenon that appears on
machine� Engine speed fluctuates.
Relatedinformation
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
3 Defective engine controllerIf causes 1 � 2 are not detected, engine controller may be defec-tive. (Since trouble is in system, troubleshooting cannot be carried out.)
46 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank) 1Error code Failure code
Trouble Ne Speed Sensor Sup. Volt. Error (LH bank)238 CA238
Contents of trouble � Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
Action of controller � Controls Ne speed sensor with signals of G (Bkup) speed sensor.
Phenomenon that appears on
machine
� Running engine stops (when G (Bkup) speed sensor is also abnormal).� Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective Ne speed sensor(Internal trouble)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Disconnect devices at right in order. If error code disap-pears subsequently, that device has a defect in it.
Ne speed sensor NE connector
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1)
Resis-tance Max. 1 z
Wiring harness between LH J1 (female) (48) � Ne (female) (2)
Resis-tance Max. 1 z
3
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (48) � Ne (female) (2) and chassis ground
Resis-tance Min. 1 Mz
4
Short circuit in wiring har-ness(With another wiring har-ness)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and LH J1 (female) (48) � Ne (female) (2)
Resis-tance Min. 1 Mz
5 Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
LH J1 Voltage
Between (16) � (48) 4.75 � 5.25 V
12V140E-3 Series 47
40 Troubleshooting SEN00317-00
Circuit diagram related to Ne speed sensor power supply
48 12V140E-3 Series
SEN00317-00 40 Troubleshooting
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) 1Error code Failure code
Trouble Ne Speed Sensor Sup. Volt. Error (RH bank)238 CB238
Contents of trouble � Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
Action of controller � Controls Ne speed sensor with signals of G (Bkup) speed sensor.
Phenomenon that appears on
machine
� Running engine stops (when G (Bkup) speed sensor is also abnormal).� Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
Relatedinformation � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective Ne speed sensor(Internal trouble)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Disconnect devices at right in order. If error code disap-pears subsequently, that device has a defect in it.
Ne speed sensor NE connector
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1)
Resis-tance Max. 1 z
Wiring harness between RH J1 (female) (48) � Ne (female) (2)
Resis-tance Max. 1 z
3
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between RH J1 (female) (48) � Ne (female) (2) and chassis ground
Resis-tance Min. 1 Mz
4
Short circuit in wiring har-ness(With another wiring har-ness)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and RH J1 (female) (48) � Ne (female) (2)
Resis-tance Min. 1 Mz
5 Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
LH J1 (16) � RH J1 (48)Voltage
4.75 � 5.25 V
12V140E-3 Series 49
40 Troubleshooting SEN00317-00
Circuit diagram related to Ne speed sensor power supply
Contents of trouble � Abnormality occurred in injector drive circuit.
Action of controller � Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on
machine� Output drops.
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective related system If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it.
2 Defective fuse
Check fuse or circuit breaker on installed machine side directly for possible defect.(If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.)
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between PW L (female) (3), (4) � battery (+)
Resis-tance Max. 1 z
Wiring harness between PW L (female) (1), (2) � chassis ground
Resis-tance Max. 1 z
4
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between PW L (female) (3), (4) � battery (+) and chassis ground
Resis-tance Min. 1 Mz
5 Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
PW L Voltage
Between (3), (4) � (1), (2) 20 � 30 V
12V140E-3 Series 83
40 Troubleshooting SEN00317-00
Circuit diagram related to controller power supply
Contents of trouble � Abnormality occurred in injector drive circuit.
Action of controller � Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on
machine� Output drops.
Relatedinformation � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective related system If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it.
2 Defective fuse
Check fuse or circuit breaker on installed machine side directly for possible defect.(If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.)
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between PW R (female) (3), (4) � battery (+)
Resis-tance Max. 1 z
Wiring harness between PW R (female) (1), (2) � chassis ground
Resis-tance Max. 1 z
4
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between PW R (female) (3), (4) � battery (+) and chassis ground
Resis-tance Min. 1 Mz
5 Defective engine controller
a Prepare with starting switch OFF, then turn starting switch ONand carry out troubleshooting.
PW R Voltage
Between (3), (4) � (1), (2) 20 � 30 V
12V140E-3 Series 85
40 Troubleshooting SEN00317-00
Circuit diagram related to controller power supply
40 Troubleshooting 1Troubleshooting of electrical system (E-mode), Part 2Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
Trouble Common rail pressure sensor detected abnormally high pressure (LH bank)451 CA451
Contents of trouble � Signal voltage in common rail pressure sensor circuit is abnormally high.
Action of controller � Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on
machine� Output drops.
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [187/CA187] or [227/CA227] is indicated, carry out trouble-shooting for it first.
2Defective common rail pres-sure sensor(Internal trouble)
a Prepare with starting switch OFF, then turn starting switch ONor start engine and carry out troubleshooting.
LH PFUEL Voltage
Between (1) � (3) Power supply 4.75 � 5.25 V
Between (2) � (3) Signal 0.25 � 4.6 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and con-troller, too, for another cause of trouble, and then judge.
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Trouble Common rail pressure sensor detected abnormally high pressure (RH bank)451 CB451
Contents of trouble � Signal voltage in common rail pressure sensor circuit is abnormally high.
Action of controller � Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on
machine� Output drops.
Relatedinformation � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [187/CB187] or [227/CB227] is indicated, carry out trouble-shooting for it first.
2Defective common rail pres-sure sensor(Internal trouble)
a Prepare with starting switch OFF, then turn starting switch ONor start engine and carry out troubleshooting.
RH PFUEL Voltage
Between (1) � (3) Power supply 4.75 � 5.25 V
Between (2) � (3) Signal 0.25 � 4.6 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and con-troller, too, for another cause of trouble, and then judge.
3
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
trouble � Supply pump does not feed fuel (level 1).
Action of controller � Limits common rail pressure.
Phenomenon that appears on
machine� Output drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
2 Use of improper fuel Improper fuel may be used. Check fuel used directly .
3 Defective low-pressure cir-cuit device
a For contents of troubleshooting, see Note 1. For checking offuel low-pressure circuit, see Testing and adjusting, Testing fuelpressure.
Pressure in fuel low-pressure circuit
Max. 0.15 MPa{Max. 1.5 kg/cm2}
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
5 Defective supply pump PCV electrical system
Supply pump PCV may have electric trouble. Carry out trouble-shooting for following codes [271/CA271] (E-30), [272/CA272] (E-32), [273/CA273] (E-34), [274/CA274] (E-36).
6 Defective common rail pres-sure sensor
Common rail pressure sensor may be defective. Check wiring har-ness for damage.
7 Defective pressure limiter
a For testing of leakage from pressure limiter, see Testing andadjusting, Testing leakage from pressure limiter and return ratefrom injector.
Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm)
8 Defective injector
a For testing of return (spill) limit from injector, see Testing andadjusting, Testing leakage from pressure limiter and return ratefrom injector.
Speed at rated operation Return (Spill) limit from injector
1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 � 8 are not detected, supply pump may be defective.
12V140E-3 Series 13
40 Troubleshooting SEN00318-00
Note 1: When low-pressure circuit is defective, check the following:1) Fuel level2) Clogged fuel tank breather3) Stuck or worn feed pump, clogged filter4) Leaked or clogged low-pressure fuel pipe5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)6) Clogged fuel filter7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)q Overflow valve (1): Spring is seen through both holes.q Bypass valve (2): Spring is seen through hole on nut side.q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.1) Gauze filter: Disassemble and check. If clogged, clean.2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
14 12V140E-3 Series
SEN00318-00 40 Troubleshooting
Check sheet for no-pressure feed
Model Work No.
Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG
1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
4
Check of monitoring information
Code Displayed item Checking condition UnitStandard value
*1 � *11:When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testingmethod).When inspecting with the monitoring function of the machine, use the codes specified for each machinemodel.
Equivalent to rating <By models>:When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. Whenthe engine is installed to the machine, however, the operation load equivalent to the rating depends onthe machine model.
C. Check of fuel circuit pressure Checking condition UnitStandard value
(Reference value)
Measured value Good NG
6 Fuel low-pressure circuit pres-sure High idle MPa
{kg/cm2}Min. 0.15 {Min. 1.5}
D. Check of strainers and filters Good NG
7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and return rate Checking condition Unit
Standard value (Reference
value)
Measured value Good NG
11 Leakage through pressure limiter No load, 1,600 rpm cc/min Max. 10
12 Return rate from injector
Equivalent to rating<By models> 1,600 rpm cc/min 960
Speed:
Return rate:
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
trouble � Supply pump does not feed fuel (level 1).
Action of controller � Limits common rail pressure.
Phenomenon that appears on
machine� Output drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
2 Use of improper fuel Improper fuel may be used. Check fuel used directly .
3 Defective low-pressure cir-cuit device
a For contents of troubleshooting, see Note 1. For checking offuel low-pressure circuit, see Testing and adjusting, Testing fuelpressure.
Pressure in fuel low-pressure circuit
Max. 0.15 MPa{Max. 1.5 kg/cm2}
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
5 Defective supply pump PCV electrical system
Supply pump PCV may have electric trouble. Carry out trouble-shooting for following codes [271/CB271] (E-31), [272/CB272] (E-33), [273/CB273] (E-35), [274/CB274] (E-37).
6 Defective common rail pres-sure sensor
Common rail pressure sensor may be defective. Check wiring har-ness for damage.
7 Defective pressure limiter
a For testing of leakage from pressure limiter, see Testing andadjusting, Testing leakage from pressure limiter and return ratefrom injector.
Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm)
8 Defective injector
a For testing of return (spill) limit from injector, see Testing andadjusting, Testing leakage from pressure limiter and return ratefrom injector.
Speed at rated operation Return (Spill) limit from injector
1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 � 8 are not detected, supply pump may be defective.
12V140E-3 Series 17
40 Troubleshooting SEN00318-00
Note 1: When low-pressure circuit is defective, check the following:1) Fuel level2) Clogged fuel tank breather3) Stuck or worn feed pump, clogged filter4) Leaked or clogged low-pressure fuel pipe5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)6) Clogged fuel filter7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)q Overflow valve (1): Spring is seen through both holes.q Bypass valve (2): Spring is seen through hole on nut side.q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.1) Gauze filter: Disassemble and check. If clogged, clean.2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
18 12V140E-3 Series
SEN00318-00 40 Troubleshooting
Check sheet for no-pressure feed
Model Work No.
Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG
1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
4
Check of monitoring information
Code Displayed item Checking condition UnitStandard value
*1 � *11:When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testingmethod).When inspecting with the monitoring function of the machine, use the codes specified for each machinemodel.
Equivalent to rating <By models>:When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. Whenthe engine is installed to the machine, however, the operation load equivalent to the rating depends onthe machine model.
C. Check of fuel circuit pressure Checking condition UnitStandard value
(Reference value)
Measured value Good NG
6 Fuel low-pressure circuit pres-sure High idle MPa
{kg/cm2}Min. 0.15 {Min. 1.5}
D. Check of strainers and filters Good NG
7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and return rate Checking condition Unit
Standard value (Reference
value)
Measured value Good NG
11 Leakage through pressure limiter No load, 1,600 rpm cc/min Max. 10
12 Return rate from injector
Equivalent to rating<By models> 1,600 rpm cc/min 960
Speed:
Return rate:
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
Trouble Engine Ne Speed Sensor detected abnormality (LH bank)689 CA689
Contents of trouble � Abnormality occurred in engine Ne speed sensor circuit.
Action of controller � Controls Ne speed sensor with signals of G (Bkup) speed sensor.
Phenomenon that appears on
machine
� Running engine stops (when G (Bkup) speed sensor is also abnormal).� Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [238/CA238] is indicated, carry out troubleshooting for it first.
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1)
Resis-tance Max. 1 z
Wiring harness between LH J1 (female) (48) � Ne (female) (2)
Resis-tance Max. 1 z
Wiring harness between LH J1 (female) (27) � Ne (female) (3)
Resis-tance Max. 1 z
3
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (48) � Ne (female) (2) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (27) � Ne (female) (3) and chassis ground
Resis-tance Min. 1 Mz
4
Short circuit in wiring har-ness(With another wiring har-ness)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and LH J1 (female) (48) � Ne (female) (2)
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and LH J1 (female) (48) � Ne (female) (2)
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (48) � Ne (female) (2) and LH J1 (female) (27) � Ne (female) (3)
Resis-tance Min. 1 Mz
5Defective mount of sensor or defective rotation sensing part
Check Ne speed sensor directly for defective mount (defective clearance) or check rotation sensing part (flywheel) directly for defect.
6 Defective engine Ne speed sensor
If causes 1 � 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7 Defective engine controllerIf causes 1 � 5 are not detected, engine controller may be defec-tive. (Since trouble is in system, troubleshooting cannot be carried out.)
Trouble Engine Ne Speed Sensor detected abnormality (RH bank)689 CB689
Contents of trouble � Abnormality occurred in engine Ne speed sensor circuit.
Action of controller � Controls Ne speed sensor with signals of G (Bkup) speed sensor.
Phenomenon that appears on
machine
� Running engine stops (when G (Bkup) speed sensor is also abnormal).� Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [238/CB238] is indicated, carry out troubleshooting for it first.
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1)
Resis-tance Max. 1 z
Wiring harness between RH J1 (female) (48) � Ne (female) (2)
Resis-tance Max. 1 z
Wiring harness between RH J1 (female) (27) � Ne (female) (3)
Resis-tance Max. 1 z
3
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between RH J1 (female) (48) � Ne (female) (2) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between RH J1 (female) (27) � Ne (female) (3) and chassis ground
Resis-tance Min. 1 Mz
4
Short circuit in wiring har-ness(With another wiring har-ness)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and RH J1 (female) (48) � Ne (female) (2)
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (16) � Ne (female) (1) and RH J1(female) (27) � Ne (female) (3)
Resis-tance Min. 1 Mz
Wiring harness between RH J1 (female) (48) � Ne (female) (2) and RH J1 (female) (27) � Ne (female) (3)
Resis-tance Min. 1 Mz
5Defective mount of sensor or defective rotation sensing part
Check Ne speed sensor directly for defective mount (defective clearance) or check rotation sensing part (flywheel) directly for defect.
6 Defective engine Ne speed sensor
If causes 1 � 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
7 Defective engine controllerIf causes 1 � 5 are not detected, engine controller may be defec-tive. (Since trouble is in system, troubleshooting cannot be carried out.)
12V140E-3 Series 23
40 Troubleshooting SEN00318-00
Circuit diagram related to engine Ne speed sensor
24 12V140E-3 Series
SEN00318-00 40 Troubleshooting
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) 1
Error code Failure codeTrouble Intake air temperature sensor detected abnormally high tempera-
ture (LH bank)691 CA691Contents of
trouble � Intake air temperature sensor circuit detected abnormally high temperature.
Action of controller � Fixes intake air temperature at (25 °C) and continues operation.
Phenomenon that appears on
machine
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
Trouble Engine G (Bkup) speed sensor abnormal (LH bank)778 CA778
Contents of trouble � Abnormality occurred in engine G (Bkup) speed sensor circuit.
Action of controller � Controls with signals of Ne speed sensor.
Phenomenon that appears on
machine
� Running engine stops (when Ne speed sensor is also abnormal).� Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [187/CA187] or [227/CA227] is indicated, carry out trouble-shooting for it first.
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (37) � LH G (female) (1)
Resis-tance Max. 1 z
Wiring harness between LH J1 (female) (47) � LH G (female) (2)
Resis-tance Max. 1 z
Wiring harness between LH J1 (female) (26) � LH G (female) (3)
Resis-tance Max. 1 z
3
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (37) � LH G (female) (1) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (47) � LH G (female) (2) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (26) � LH G (female) (3) and chassis ground
Resis-tance Min. 1 Mz
4
Short circuit in wiring har-ness(With another wiring har-ness)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between LH J1 (female) (37) � LH G (female) (1) and LH J1 (female) (47) � LH G (female) (2)
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (37) � LH G (female) (1) and LH J1 (female) (26) � LH G (female) (3)
Resis-tance Min. 1 Mz
Wiring harness between LH J1 (female) (47) � LH G (female) (2) and LH J1(female) (26) � LH G (female) (3)
Resis-tance Min. 1 Mz
5Defective mount of sensor or defective rotation sensing part
Check G (Bkup) speed sensor directly for defective mount (defec-tive clearance) or check rotation sensing part (in supply pump) directly for defect.
6 Defective G (Bkup) speed sensor system
If causes 1 � 5 are not detected, engine G (Bkup) speed sensor may be defective. (Since trouble is in system, troubleshooting can-not be carried out.)
7 Defective engine controllerIf causes 1 � 5 are not detected, engine controller may be defec-tive. (Since trouble is in system, troubleshooting cannot be carried out.)
12V140E-3 Series 31
40 Troubleshooting SEN00318-00
Circuit diagram related to engine G (Bkup) speed sensor system
Trouble Engine G (Bkup) speed sensor abnormal (RH bank)778 CB778
Contents of trouble � Abnormality occurred in engine G (Bkup) speed sensor circuit.
Action of controller � Controls with signals of Ne speed sensor.
Phenomenon that appears on
machine
� Running engine stops (when Ne speed sensor is also abnormal).� Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Defective sensor power sup-ply system
If code [187/CB187] or [227/CB227] is indicated, carry out trouble-shooting for it first.
2
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between RH J1 (female) (37) � RH G (female) (1)
Resis-tance Max. 1 z
Wiring harness between RH J1 (female) (47) � RH G (female) (2)
Resis-tance Max. 1 z
Wiring harness between RH J1 (female) (26) � RH G (female) (3)
Resis-tance Max. 1 z
3
Ground fault in wiring har-ness(Short circuit with GND cir-cuit)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between RH J1 (female) (37) � RH G (female) (1) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between RH J1 (female) (47) � RH G (female) (2) and chassis ground
Resis-tance Min. 1 Mz
Wiring harness between RH J1 (female) (26) � RH G (female) (3) and chassis ground
Resis-tance Min. 1 Mz
4
Short circuit in wiring har-ness(With another wiring har-ness)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Wiring harness between RH J1 (female) (37) � R G (female) (1) and RH J1 (female) (47) � RH G (female) (2)
Resis-tance Min. 1 Mz
Wiring harness between RH J1 (female) (37) � R G (female) (1) and RH J1 (female) (26) � RH G (female) (3)
Resis-tance Min. 1 Mz
Wiring harness between RH J1 (female) (47) � R G (female) (2) and RH J1 (female) (26) � RH G (female) (3)
Resis-tance Min. 1 Mz
5Defective mount of sensor or defective rotation sensing part
Check G (Bkup) speed sensor directly for defective mount (defec-tive clearance) or check rotation sensing part (in supply pump) directly for defect.
6 Defective G (Bkup) speed sensor system
If causes 1 � 5 are not detected, engine G (Bkup) speed sensor may be defective. (Since trouble is in system, troubleshooting can-not be carried out.)
7 Defective engine controllerIf causes 1 � 5 are not detected, engine controller may be defec-tive. (Since trouble is in system, troubleshooting cannot be carried out.)
12V140E-3 Series 33
40 Troubleshooting SEN00318-00
Circuit diagram related to engine G (Bkup) speed sensor system
34 12V140E-3 Series
SEN00318-00 40 Troubleshooting
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) 1
Error code Failure codeTrouble Inter multi-controller communication error (LH bank)
781 CA781Contents of
trouble � Communication error occurred between engine controllers (LH bank)
Action of controller � None in particular.
Phenomenon that appears on
machine
� Single-bank operation� Engine cannot be started with the key ON
Related information � Different machine models may have different connector Nos.
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1
Disconnection in wiring har-ness(Disconnection in wiring or defective contact in connec-tor)
a Prepare with starting switch OFF, then carry out troubleshoot-ing without turning starting switch ON.
Error code Failure codeTrouble Engine overheat (LH bank only)
� �*1 �Contents of
trouble � Engine coolant temperature is above operating range.
Action of controller � Limits output and continues operation.
Phenomenon that appears on
machine� Output drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Carry out troubleshooting on machine side
This defective phenomenon is indicated only on the installed machine when it was detected.Accordingly, contents of troubleshooting differ by the machine model. See Shop manual for machine.
Error code Failure codeTrouble Engine oil pressure low and speed derate (LH bank only)
� �*2 �Contents of
trouble � Engine oil pressure is below operating range.
Action of controller � Limits output and continues operation (Limits fuel injection rate and engine speed).
Phenomenon that appears on
machine� Output drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Carry out troubleshooting on machine side
This defective phenomenon is indicated only on the installed machine when it was detected.Accordingly, contents of troubleshooting differ by the machine model. See Shop manual for machine.
Trouble Engine oil pressure low and torque derate (LH bank only)� �*3 �
Contents of trouble � Engine oil pressure is below operating range.
Action of controller � Limits output and continues operation (Limits fuel injection rate and engine speed).
Phenomenon that appears on
machine� Output drops.
Related information
Possible causes and standard
value in normal state
Causes Standard value in normal state/Remarks on troubleshooting
1 Carry out troubleshooting on machine side
This defective phenomenon is indicated only on the installed machine when it was detected.Accordingly, contents of troubleshooting differ by the machine model. See Shop manual for machine.
50 Disassembly and assemblyGeneral information on disassembly andassemblyGeneral information on disassembly and assembly ....................................................................................... 2
How to read this manual ....................................................................................................................... 2Coating materials list ............................................................................................................................ 3Special tools list .................................................................................................................................... 6
2 12V140E-3 Series
SEN00320-00 50 Disassembly and assembly
General information on disassembly and assemblyHow to read this manual 1Disassemblyq In Disassembly section, the work procedures,
precautions and know-how for carrying outthose procedures, and quantity of the oil andcoolant drained are described.
q The meanings of the symbols used in Disas-sembly section are as follows.
k Precautions related to safety in executionof work
a : Know-how or precautions for work6 : Quantity of oil or coolant drained4 : Weight of part or component
Assemblyq In Assembly section, the work procedures, pre-
cautions and know-how for carrying out thoseprocedures, and quantity of the oil and coolantadded are described.
q The meanings of the symbols used in Assem-bly section are as follows.
k : Precautions related to safety in executionof work
a : Know-how or precautions for work2 : Type of coating material3 : Tightening torque5 : Quantity of oil or coolant to be added4 : Weight of part or component
12V140E-3 Series 3
50 Disassembly and assembly SEN00320-00
Coating materials list 1a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.a For coating materials not listed below, use the equivalent of products shown in this list.
Cate-gory
Komatsu code Part No. Q'ty Container Main features and applications
Adh
esiv
e
LT-1A 790-129-9030 150 g Tube � Used to prevent falling off of rubber gaskets, rubber cushions, and cork plugs.
LT-1B 790-129-9050 20 g(2 pcs.)
Polyethylene container
� Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
LT-2 09940-00030 50 g Polyethylene container
� Features: Resistant to heat and chemicals.� Used to fix and seal bolts and plugs.
LT-3
790-129-9060Set of adhesive and hardener
Adhesive:1 kg
Hardener:500 g
Can � Used to stick and seal metal, glass, and plastics.
LT-4 790-129-9040 250 g Polyethylene container � Used to seal plugs for drilled holes.
HoltzMH 705 790-129-9120 75 g Tube � Heat-resistant sealant used to repair engines.
Three Bond1735 790-129-9140 50 g Polyethylene
container
� Quick-setting adhesive.� Setting time: Within 5 sec. to 3 min.� Used mainly to stick metals, rubbers, plastics, and
woods.
Aron-alpha201 790-129-9130 2 g Polyethylene
container
� Quick-setting adhesive.� Quick-hardening type. (max. strength is obtained after
30 minutes of application)� Used mainly to stick rubbers, plastics, and metals.
Loctite648-50 79A-129-9110 50 cc Polyethylene
container� Features: Resistant to heat and chemicals.� Used for fitted portions of high temperatures.
Gas
ket s
eala
nt
LG-1 790-129-9010 200 g Tube � Used to stick or seal gaskets and packings of power train case, etc.
LG-5 790-129-9080 1 kg Polyethylene container
� Used to seal various threaded portions, pipe joints, and flanges.
� Used to seal tapered plugs, elbows, and nipples of hydraulic pipes.
LG-6 790-129-9020 200 g Tube
� Features: Silicon-based heat and cold-resistant seal-ant.
� Used to seal flanged surfaces and threaded portions.� Used to seal oil pan, final drive case, etc.
LG-7 790-129-9070 1 kg Tube� Features: Silicon-based quick-hardening sealant.� Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
Three Bond1211 790-129-9090 100 g Tube � Gasket sealant used to repair engine.
Three Bond1207B 419-15-18131 100 g Tube
� Features: Silicon-based, heat-resistant, vibration-resistant and impact-resistant sealant.
� Used to seal transfer case, etc.
4 12V140E-3 Series
SEN00320-00 50 Disassembly and assembly
Cate-gory
Komatsucode Part No. Q'ty Container Main features and applications
Mol
ybde
num
dis
ulfid
elu
bric
ant
LM-G 09940-00051 60 g Can � Used to lubricate sliding portions. (to prevent squeaking)
LM-P 09940-00040 200 g Tube
� Used to prevent scuffing and seizure of press-fit-ted portions, shrink-fitted portions, and threaded portions.
Various Various � Used for bearings used at normal temperature under light load in contact with water or steam.
Molybdenum disulfide grease LM-G (G2-M)
SYG2-400MSYG2-400M-ASYGA-16CNM
400 gx10400 gx20
16 kg
Bellows-type container
Can� Used for parts under heavy load.
Hyper White Grease G2-T, G0-T (*)*: For cold dis-trict
SYG2-400T-ASYG2-16CNTSYG0-400T-A(*)SYG0-16CNT(*)
400 g16 kg
Bellows-type container
Can
� Seizure resistance and heat resistance higher than molybdenum disulfide grease.
� Not conspicuous on machine since color is white.
Biogrease G2-B, G2-BT (*)*: For use at high tempera-ture and under high load
SYG2-400BSYGA-16CNBSYG2-400BT(*)SYGA-16CNBT(*)
400 g16 kg
Bellows-type container
Can
� Since this grease is decomposed by natural bac-teria in short period, it has less effects on micro-organisms, animals, and plants.
Prim
er
SUNSTAR PAINT PRIMER 580 SUPER
417-926-3910
20 ml Glass container
Adh
esiv
e fo
r cab
gla
ss
� Used as primer for cab side.(Using limit: 4 months after date of manufac-ture)
SUNSTAR GLASS PRIMER 580 SUPER
20 ml Glass container
� Used as primer for glass side.(Using limit: 4 months after date of manufac-ture)
SUNSTAR PAINT PRIMER 435-95
22M-54-27230 20 ml Glass container
� Used as primer for painted surface on cab side.(Using limit: 4 months after date of manufac-ture)
SUNSTAR GLASS PRIMER 435-41
22M-54-27240 150 ml Can
� Used as primer for black ceramic-coated surface on glass side and for hard polycar-bonate-coated surface.(Using limit: 4 months after date of manufac-ture)
SUNSTAR SASH PRIMER GP-402
22M-54-27250 20 ml Glass container
� Used as primer for sash. (Almite) (Using limit: 4 months after date of manufac-ture)
12V140E-3 Series 5
50 Disassembly and assembly SEN00320-00
Adh
esiv
e
SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
417-926-3910 320 mlPolyethyl-ene con-
tainer
Adh
esiv
e fo
r cab
gla
ss
� "S" is used for high-temperature season (April � October) and "W" for low-tempera-ture season (November � April) as adhesive for glass.(Using limit: 4 months after date of manufac-ture)
Sika Japan, Sikaflex 256HV 20Y-54-39850 310 ml
Polyethyl-ene con-
tainer
� Used as adhesive for glass.(Using limit: 6 months after date of manufac-ture)
SUNSTAR PENGUINE SUPER 560
22M-54-27210 320 mlEcocart (Special
container)
� Used as adhesive for glass.(Using limit: 6 months after date of manufac-ture)
Cau
lkin
g m
ater
ial
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920 320 mlPolyethyl-ene con-
tainer
� Used to seal joints of glass parts.(Using limit: 4 months after date of manufac-ture)
SEKISUI SILI-CONE SEAL-ANT
20Y-54-55130 333 mlPolyethyl-ene con-
tainer
� Used to seal front window.(Using limit: 6 months after date of manufac-ture)
GE TOSHIBA SILICONES TOSSEAL 381
22M-54-27220 333 ml Cartridge
� Used to seal joint of glasses.Translucent white seal.(Using limit: 12 months after date of manu-facture)
Cate-gory
Komatsucode Part No. Q'ty Container Main features and applications
6 12V140E-3 Series
SEN00320-00 50 Disassembly and assembly
Special tools list 1a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured).a Necessity : t . . . . . . Cannot be substituted, should always be installed (used)
: q . . . . . . Extremely useful if available, can be substituted with commercially available parta New/Remodel
: N . . . . . . Tools newly developed for this model and given new part Nos.: R . . . . . . Tools remodeled from tools already available for other models and given upgraded
part Nos.: Blank. . . Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools(See Sketches of special tools)
Work item Sym-bol Part No. Part name
Nec
essi
tyQ
'tyN
ew/R
emod
elS
ketc
hes
Remarks
Disassembly and assembly of engine assembly
A
790-501-4000 Engine repair stand t 1
790-901-1800 Bracket assembly t 1
790-901-1810 Bracket t 1
790-901-1820 Bracket t 1
790-901-1830 Bracket t 1
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
Disassembly and assembly of cylinder head
B
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 C 795-100-1191 Piston ring tool t 1
Measurement of cylinder liner projection D 795-502-1121 Holder t 1
Removal of cylinder liner E 795-236-1000 Liner puller t 1
Installation of cylinder liner F 795-230-5472 Liner driver t 1
Angle tightening of bolt G 795-331-1110 Wrench t 1
Installation of piston H 795-236-1500 Piston holder t 1
Installation of front oil seal J 795-602-2200 Installer t 1
Installation of rear oil seal K 795-602-2300 Installer t 1
12V140E-3 Series 7
50 Disassembly and assembly SEN00320-00
Press fitting of valve stem seal L 795-130-1720 Push tool t 1
Adjusting valve clearance M Commercially
available Thickness gauge q 1 IN: 0.35 mm, EX: 0.57 mm
Removal of rear oil seal N 795-931-1100 Seal puller q 1
50 Disassembly and assemblyDisassembly and assembly, Part 1Disassembly and assembly, Part 1 ................................................................................................................. 2
General disassembly of engine ............................................................................................................ 2
SEN00321-00 50 Disassembly and assembly
2 12V140E-3 Series
Disassembly and assembly, Part 1 1General disassembly of engine 1a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.Take care.
a When a part is provided on both sides of thebank, one side alone is shown as an example.Except where otherwise specified, contents ofthe work shall be the same on both sides of thebank.
1. Preparation workBefore disassembling the engine, check itsparts for cracking, damage, etc. and clean theentire engine carefully for accurate inspectionof its parts and quick disassembly and assem-bly.a Before cleaning the engine, carefully seal
or remove the openings, electric parts,and wiring connectors so that water willnot enter them.
2. Installation to engine repair stand1) Install the engine assembly (1) to tool A.
4 Engine assembly: Approx. 3,800 kg
2) Drain the engine coolant and engine oil.a Quantity of the engine oil depends on
the applicable machines.6 Engine oil: Approx. 130 l
3. Engine wiring harnessDisconnect the connector and terminal andthen remove engine harness (1) from theengine assembly.
4. Starting motor assemblyRemove engine harness (1) and then removestarting motor assemblies (2) and (3).a Remove the assembly at the top first
being followed by that at the bottom.
5. Alternator1) Remove auxiliary equipment belt (1).2) Remove alternator (2).
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 3
6. Fuel filter and filter head assembly, andpriming pump1) Remove fuel tubes (1) and (2).2) Remove fuel filter and filter head assem-
bly (3).3) Remove priming pump (4).
7. Engine controller and controller cooler1) Remove engine controller (1).2) Remove fuel hoses (2) and (3).3) Remove controller cooler (4).
8. Air inlet pipe1) Remove the clamp and then remove air
2) Insert a small L-bar [1] under the fuel con-nector and pry out fuel injector (2) slowly.a Do not grip the solenoid valve at the
top of the injector to pull off the injec-tor.
30. CrossheadRemove crosshead (1).
31. Cylinder head assembly1) Remove the water tube.2) Lift off cylinder head assembly (1).
4 Cylinder head assembly: 25 kg
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 9
a When removing the cylinder headassembly without removing the fuelinjector, be sure to prevent its interfer-ence with the floor surface since theinjector tip protrudes through the bot-tom of the cylinder head.
3) Remove the cylinder head gasket.4) Disassemble the cylinder head assembly
according to the following procedure.1] Using tool B, compress the valve
spring to remove cotter (2).2] Remove upper seat (3), outer spring
(4), and inner spring (5).
3] Remove lower seat (6).4] Raise the cylinder head and remove
valve (7).
32. Oil pan1) Support the front and rear side of oil pan
(1) with block [1].2) Remove all oil pan mounting bolts.3) Separate the gasket sealant.4) Lift the engine and then remove oil pan
(1).4 Oil pan: 90 kg
33. Suction pie and under plate1) Fix under plate (1) temporarily using sev-
eral oil pan mounting bolts.2) Remove stay (2) and then remove suction
pipe (3).
SEN00321-00 50 Disassembly and assembly
10 12V140E-3 Series
3) Support under plate (1) using jack [1].4) Remove the bolts used for temporary fix-
ing and then lower the jack carefully toremove under plate (1).4 Under plate: 25 kg
a Be sure to remove the piston cooling noz-zle before removing the piston connectingrod assembly.
a When removing the nozzle, turn it 90° sothat it may not hit the piston.
58. Piston and connecting rod assembly1) Prior to the removal, measure the side
clearance of the connecting rod using dialgauge [1] in order to use it as a roughstandard in the assembly.a Check the stamped No. of the con-
necting rod cap.q Make sure that the cap No. and
cylinder No. are the same.q The No. must be stamped on the
cam side.a If the cylinder No. is not stamped,
write it using an electric pen priorto the removal (it is not accept-able to stamp the number).
2) Rotate the crankshaft in order to drive thepiston to be removed to the bottom deadcenter.
3) Loosen connecting rod bolt (1) by 5 to 6turns.
SEN00321-00 50 Disassembly and assembly
16 12V140E-3 Series
4) Hit the connecting rod head lightly using aplastic hammer to loosen the connectingrod cap and connecting rod.
5) Scrub the carbon off the top wall of theliner using fine sandpaper.
6) Turn the crankshaft until the piston comesto the top dead center and then removethe connecting rod cap (2).
7) Push in and piston and connecting rodassembly using pushing bar [1] from theoil pan side and then remove the assem-bly while supporting piston (3) from thecylinder head side.a Take care not to damage the inside of
the cylinder with a corner of the con-necting rod.
8) Remove other piston and connecting rodassemblies according to the above proce-dure.a Keep the sliding portion and bearing
of the piston in a safe place to protectthem from damage.
a Assemble the connecting rod and captemporarily and keep them along withthe connecting rod bearing on a cylin-der to cylinder basis.
9) Disassemble the piston and connectingrod assembly according to the followingprocedure.1] Remove snap ring (4)2] Support connecting rod (5) with hand
and then remove piston pin (6) to dis-connect piston (7) from the connect-ing rod.a When the piston pin is firmly
fixed and unremovable, heat it(roughly 5 minutes at 100°C)using an industrial dryer.
3] Remove the snap ring on the otherside.
4] Using tool C, remove piston ring (8).5] Remove oil ring expander (9)
a Keep the piston, connecting rod,connecting rod bearing, pistonring, and piston pin on a cylinderto cylinder basis.
50 Disassembly and assembly SEN00321-00
12V140E-3 Series 17
59. Crankshaft1) Before removing crankshaft, measure the
end play of the crankshaft using dialgauge [1] in order to use it as a roughstandard in the assembly.
2) Remove mounting bolts (2) of main cap(1).
3) Insert the bolts in the bolt hole of the maincap (1) and remove the cap, while shakingit.
a Lower thrust bearing (3) is assembledto No. 7 main cap. Record its assem-bly position after removal.
4) Lift off crankshaft (4).a Use care in lifting the crankshaft so
that it may not hit and get damagefrom the cylinder block.
50 Disassembly and assemblyDisassembly and assembly, Part 2Disassembly and assembly, Part 2 ................................................................................................................. 2
General assembly of engine ................................................................................................................. 2
2 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
Disassembly and assembly, Part 2General assembly of enginea The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.Take care.
a When a part is provided on both sides of thebanks, one side alone will be shown as anexample. Except where otherwise noted, thesame work procedure shall be employed forthe both banks.
a Clean each part carefully, and check it forbruise, flaw, cavity, etc. Make sure each oil orcoolant path is through.
Tightening bolts by plastic-region turning anglemethoda Bolts tightened by plastic-region turning angle
methodq Cylinder head mounting boltq Main cap mounting boltq Connecting rod cap mounting bolt
a If the plastic-region turning angle method isapplied, the tightened bolts have permanentstrain. Accordingly, the allowable number ofusing times of each bolt is limited. Observe thefollowing precautions.q Check each mounting bolt head for punch
marks. If there were punch marks morethan the specified numbers, replace thebolt.
1. Cylinder block1) Lift the cylinder block and then set it on
tool A.4 Cylinder block: 850 kg
2) Before inserting the cylinder liners, pre-pare the cylinder block according to thefollowing procedure.1] Remove the rust and scales from
faces A and B with sandpaper, etc.unti l the machined surfaces areexposed.
2] Polish parts B, R and r with sandpa-per of about No. 200 unt i l theybecome smooth.If part R is sharpened or burrs arepresent there, finish it with a scraperor sandpaper.F in ish th is sur face par t icu lar lysmoothly so that it will not damagethe O-ring.
3] If face R is so pitted that it cannot berepaired, replace the cylinder block.
4] If faces A and parts R and r are pit-ted, finish them smoothly.
5] Check the counterbored part andremove burrs. If chips or dust is onface C, the liner does not fit and cool-ant may leak and the projection of theliner may become improper conse-quently.a If the counterbored part is droop-
ing, corroded, or pitted, repair it.
2. Cylinder linera 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 rough-ened because of rusting or pitting. If thoseparts are roughened, replace the cylinderliner.
2) Install clevis seal (1), O-rings (2) and (3) tothe 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 itagainst the seal groove all round sothat it will not be twisted.
a When installing O-rings (2) and (3),refer to the following.q O-ring (2): Blackq O-ring (3): Orange
2 Clevis seal and O-ring:Rubber lubricant (RF-1)
a RF-1: DAIDO CHEMICAL INDUSTRYCO., LTD.If RF-1 is not available, apply cleanengine oil (EO30).
a Since the clevis seal and O-ring areswollen and deteriorated by oil, applya small amount of oil to them thinlywith a brush just before fitting them.
12V140E-3 Series 3
50 Disassembly and assembly SEN00322-00
3) After fitting the liner O-ring, check it fortwist. If it is twisted, correct it with asmooth rod (about 10 mm in diameter).
4) Install the cylinder liner according to thefollowing procedure.1] Using cloth, wipe dirt and oil com-
pletely off the contact faces betweenthe counterbored part of the cylinderblock and liner flange.
2] Apply silicon-based gasket sealant tothe counterbored mating parts a ofthe cylinder block and cylinder liner.2 Cylinder block:
Gasket sealant (LG-6)
q Gasket sealant application diam-eter: ø0.8 � 1.6 mm
a When applying the gasket seal-ant, make sure overlapping bbetween the coating at start andthe end complies with the follow-ing dimension.
q Gasket sealant overlappingdimension b: 6 ± 6 mm
a After applying the gasket sealant,finish the cylinder liner installa-tion within 50 minutes.
q When the bottom contact face ofthe counterbored liner flange ismodified and shim (2) is used.
4 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
1] Coat the bottom side of shim(2) with a small amount ofgasket sealant LG-6 andthen assemble the shim.
2] Then apply gasket sealantLG-6 according to the sameprocedure as that employedwhen the shim is not used.
5) Immediately before press-fitting of theliner, apply a small amount of engine oil tothe liner O-ring, crevice seal and contactface of the cylinder block.2 Clevis seal, O-ring and cylinder
block: Engine oil (EO30)a Apply the engine oil, using hands,
uniformly on the entire contact face ofthe cylinder block.
6) Direct stamping "T" on the top face of theliner toward the engine front side and theninsert cylinder liner (1) to the cylinderblock while taking care so that the O-ringmay not be damaged.
7) Push in cylinder liner keeping weight onboth hands.a If the liner does not enter the cylinder
block smoothly when pushed withweight on both hands, stop the worksince the O-ring is potentially dam-aged. In this case, check the cylinderblock for burrs.
9) To prevent the gasket sealant from pro-jecting through the clearance between theblock and liner after the cylinder head istightened, tighten the cylinder head tem-porar i ly wi th the used head gasketinserted.a At this time, observe the following
10) Remove the cylinder head and wipe offthe gasket sealant projected from thecounterbored part.a Be sure to perform steps 9) and 10)
above since the projected gasketsealant can deform the grommet ofthe head gasket.
11) After press-fitting the cylinder liner, mea-sure its projection using tool D.a Before measuring projection of the
liner, tighten it with plate [1] so that itmay not be lifted by the O-ring.
q Measuring position:4 positions at a, b, c and d.
12V140E-3 Series 5
50 Disassembly and assembly SEN00322-00
3 Plate mounting bolt:686 � 980 Nm {7 � 10 kgm}
a Standard cylinder projection:0.07 � 0.15 mm
a If the projection is out of the standard,correct it according to the mainte-nance standard.
a If the gasket sealant is projected fromthe fitting parts of the cylinder blockand cylinder liner up to the top of thecylinder block, wipe it off.
3. Crankshaft1) Fit upper main bearing (6) to the cylinder
block, matching the projection of theformer to the notch of the latter.
a Upper bearing: With oil hole Aa No. 4 bearing is wider than others.
Thus, care must be taken to preventan assembly error.
a Bearing with aNo. 4 bearing: 52 mmBearings other than No. 4: 48 mm
a Before fitting the bearing, make surethat its back side is free from foreignmatter.
2 Bearing inner surface:Engine oil (EO30)
a Don't apply the engine oil to the bear-ing backside.
2) Drive in the roll pin in such that its projec-tion from the block end face may become2.7 � 3.4 mm and then install upper thrustbearing (5).a Install the thrust bearing with the
3) Before assembling crankshaft, confirm thefollowing items.q Presence/absence of abnormality in
the front and rear threaded portions.(Make sure the bolt can be smoothlyscrewed in with hand.)
q Presence/absence of scratches ordents on the pin and main journal.
q Presence/absence of dusts in the oilhole.
4) Lift crankshaft (4) and then install it on thecylinder block.a When installing the crankshaft, take
care not to hit its sliding surfacesagainst the cylinder block.
4 Crank shaft: 210 kg2 Cylinder block journal:
Engine oil (EO30)
6 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
5) Install the projection of lower bearing (7)locating it to the notch of main cap (1) andinstall.a Before fitting the bearing, make sure
that its back side is free from foreignmatter.
2 Inside of bearing:Engine oil (EO30)
a Don't apply the engine oil to the bear-ing backside.
a Lower bearing: Without oil holea No. 4 bearing is wider than others. Thus, care
must be used to prevent an assembly error.a Bearing with a
No. 4 bearing: 52 mmBearings other than No. 4: 48 mm
6) Drive the roll pin of cap No. 7 so that it willbe projected by 2.7 � 3.4 mm from the capend and then install lower thrust bearings(3) to both sides.a Install the thrust bearing with the
7) Apply the engine oil to the surface of thejournal of the crankshaft. Then install themain cap after making sure that the No.being stamped on respective main caps(1) is matching the cylinder block No.2 Crankshaft journal:
Engine oil (EO30)a When installing the main cap, direct
its cast part number side toward thefront of the engine.
8) Apply engine oil to the threaded portion ofthe main cap mounting bolt and washerand then drive in the bolts alternately untilthe main cap is completely fitted.2 Main cap mounting bolt:
Engine oil (EO30)
9) Tighten main cap mounting bolts (2)according to the following procedure.a Tighten the bolts from the center one
to the outer ones in order.
12V140E-3 Series 7
50 Disassembly and assembly SEN00322-00
2 Threaded portion of mounting boltand washer: Engine oil (EO30)
3 Main cap mounting bolt1st time: 284 ± 15 Nm {29 ± 1.5 kgm}2nd time: 569 ± 10 Nm {58 ± 1.0 kgm}3rd time: Using tool G, retighten the
bolt by 90° (+30°/0°).
a When tool G is not used, applymarking b to the main cap andbolt with paint, and then retightenthe bolt by 90° (+30°/0°).
10) Make punch mark c on the mounting bolthead.a When a new bolt is used, do not
make a punch mark on its head.
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 mma If the end play is out of the standard,
correct it. For details, see "Structure,function and maintenance standard".
4. Piston and connecting rod assembly1) Assemble the piston and connecting rod
according to the following procedure.1] Fit in oil ring expander (9) to the oil
ring groove.2] Using tool C, assemble the oil ring,
second ring and top ring, in this order.
a Assemble respective piston ringsas shown in the figure.
a When assembling the respectiverings to the piston, direct theirstamped side upward.
a Take the expander out of the oilring and fit it to the piston firstand then assemble the oil ring. Atthis time, make sure that theexpander is fitted to the ringgroove perfectly.
a Make sure that the coil butt jointof the expander is situated in aposition 180° to the oil ring abut-ment joint.
8 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
3] Install snap ring (10) to one side ofpiston (7).
4] Set the piston (7) and connecting rod(5). Mate the cast letters "EX i F" onthe piston against the chamfered holeside in the big end of the connectingrod and then assemble them.
5] Apply engine oil to the piston pin bossand inner surface of the connectingrod bushing and then insert piston pin(6) while directing the connecting rodupward.2 Piston pin: Engine oil (EO30)
6] Install snap ring (4) on the oppositeside.a Turn the snap ring to make sure
that the left and right side snaprings are completely fitted in thering groove.
a Also make sure that the connect-ing rod moves lightly.
7] Install the projection of connectingrod upper bearing (11) locating it tothe notch of the connecting rod.a Before fitting the bearing, make
sure that its back side is freefrom foreign matter.
a Don't apply the oil to the bearingbackside.
a Make sure that the connectingrod small end bushing are largeend bearing hole are aligned withthe connecting rod oil hole.
a Before assembling the connect-ing rod, check the connecting rodoil hole for settled dusts.
2 Connecting rod bearing innersurface: Engine oil (EO30)
8] Install the projection of connectingrod lower bearing (12) locating it tothe notch of the connecting rod cap.a Before fitting the bearing, make
sure that its back side is freefrom foreign matter. Don't applythe engine oil to the backside.
12V140E-3 Series 9
50 Disassembly and assembly SEN00322-00
2) Apply the engine oil to the cylinder liner.a Apply the engine oil uniformly on the
entire circumference with hands.2 Cylinder liner: Engine oil (EO30)
3) Turn the crankshaft to drive the pin journalof the target cylinder of insertion to the topdead center position.
4) After confirming No. of the piston and con-necting rod assembly, insert the assemblyto the cylinder block directing it in thedirection shown in the figure.a Set the direction of the cylinder block
in such that the cylinder may facesideways. This process is needed toprevent sudden insertion of the pistonand connecting rod assembly to thecylinder.
a On each bank, install notch A for thepiston cooling nozzle and chamferedside B of the connecting rod. In thiscase, their positional relation withfront direction F of the engine must beas shown in the figure.
5) Align the abutment joint of respective pis-ton rings as well as the piston to the posi-tion shown in the figure.
a Make sure that the coil butt joint of the oil ringis situated in a position 180° to the abutmentjoint
2 Piston ring, piston and crank journal:Engine oil (EO30)
6) Using tool H, compress the piston ring andthen push in the piston head with awooden bar and the like.
10 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
7) Using the connecting rod puller [1] shownin the figure, pull the connecting rod until itis closely contacted against the pin jour-nal.a Make sure the connecting rod bearing
is not displaced.a The connecting rod puller [1] is made
by welding bar b to unnecessary con-necting rod bolt a.
a Total length of connecting rod puller l:Approx. 500 mm.
2 Crank pin journal:Engine oil (EO30)
8) Turn the crankshaft 180° while pulling theconnecting rod.
9) Install connecting rod lower bearing (12)to connecting rod cap (2).2 Connecting rod lower bearing:
Engine oil (EO30)10) Install connecting rod cap (2) aligning it to
the dowel pin on the connecting.a Check the cylinder No.
a When assembling a new connectingrod, record its cylinder No. on theconnecting rod cap using a electricpen (stamping is not acceptable). It isstrictly prohibited to change the com-bination of the connecting rod andcap through this operation.
11) Apply the engine oil to the threaded por-tion and washer of the connecting rod.2 Connecting rod bolt and washer
Engine oil (EO30)
12) Tighten connecting rod bolts (1) alter-nately until the connecting rod cap isclosely contacted.
12V140E-3 Series 11
50 Disassembly and assembly SEN00322-00
13) Turn the crankshaft 180° and insert thepiston and connecting rod assembly onone bank according to the steps 1) � 12).
14) Tighten the mounting bolts in the orderindicated in the figure according to the fol-lowing procedure.3 Connecting rod bolt:
a When tool G is not used, apply marking b tothe connecting rod, connecting rod cap andbolt with paint and then retighten the bolt by90° (+30°/0°).15) After tightening the bolt, make a punch
mark c on its head.a When a new bolt is used, do not
make a punch mark on its head.
a After assembling the connecting rod,make sure that the crankshaft rotatesnormally.
16) Measure the side clearance of the con-necting rod with dial gauge [1].q Standard side clearance:
0.3 � 0.454 mma When the side clearance is out of the
standard, remove the connecting rodcap and check the connecting rod forassembly errors, presence of burrs orpinching of foreign substances.
a Install idler gears (large) (2) and (3) insuch that their counter marks as wellas that of respective gears may cometo the positions shown in the figure.
4) Install plate (1) and then tighten themounting bolt.a Install the plate setting its "OUT"
15. Check of timing gear for backlash and endplay1) Attach gear (1) to the compressor and
then install them temporarily. (When theengine is equipped with the compressor)
2) Install water pump assembly (2) tempo-rarily.
3) Measure the backlash and end play ofeach gear with the dial gauge.a Symbols in the figure correspond to
"Position" field in the following table.
16 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
1] Backlash of each gear
2] End play of each gear
16. Gear case coverLift and install gear case cover (1).4 Gear case cover: 75 kg
a When cover (2) was removed, apply thegasket sealant in the position shown in thefigure before installing it again.
2 Cover: Gasket sealant (LG-7)q Application diameter: ø2.0 mm
17. Front oil sealFollowing remedial actions are neededdepending on presence and absence wear onthe contact face of the oil seal on the crank-shaft.1) When a new crankshaft is used or when
wear is not recognized on the contact sur-face of oil seal.q Either of the dimensions listed in the
following table shall apply to oil sealpress-fitting depth a depending onfront cover size b and presence/absence of bolt hole in the cover endface.
(mm)
Position Measuring points Standardvalue
A�A Right idler gear (small) and right sub idler gear
0.130 � 0.390(0.125 � 0.363)
B1�B1 Right sub idler gear and right supply pump gear
0.051 � 0.469(0.125 � 0.363)
B2�B2 Left sub idler gear and left supply pump gear
0.051 � 0.469(0.125 � 0.363)
C�C Left sub idler gear and left cam gear
0.129 � 0.391(0.125 � 0.363)
D�D Right idler gear (small) and right cam gear
0.129 � 0.391(0.125 � 0.363)
E�E Right idler gear (large) and water pump drive gear 0.052 � 0.481
F�F Right idler gear (large) and oil pump gear 0.137 � 0.421
G�G Left supply pump gear and compressor gear
0.106 � 0.381(0.138 � 0.354)
H�H Right cam gear and acces-sory drive gear
0.085 � 0.492(0.138 � 0.354)
L�L Crank gear and left idler gear (large) 0.141 � 0.425
R�R Crank gear and right idler gear (large) 0.141 � 0.425
Note): The standard value enclosed in ( ) indicates the backlash between spur gears
(mm)Position Gear name Standard value
1 Idler gear (large) end play 0.07 � 0.182 Idler gear (small) end play 0.07 � 0.183 Supply pump gear end play 0.07 � 0.204 Oil pump gear end play 0.03 � 0.088
5 Accessory drive gear end play 0.1 � 0.4
6 Crank gear end play 0.14 � 0.327 Cam gear end play 0.10 � 0.25
12V140E-3 Series 17
50 Disassembly and assembly SEN00322-00
2) When wear is recognized on the oil sealcontact face of crankshaft (2) and oil sealinstallation position is movable.q Move the oil seal (1) installation posi-
tion backward up to a location wherethe lip of the new oil seal (1) won't bein touch with the wear groove on thecrankshaft (2).
3) When the actions up to step 2) abovehave been conducted on crankshaft (2).q Attach sleeve (3) to crankshaft (2)
and then install an oversized oil seal.
4) Install sleeve (3) according to the followingprocedure.1] Scrub rusts off the press-fitted portion
of the sleeve (60 mm range from thetip) on crankshaft (2).
2] Apply entire inner surface of thesleeve with gasket sealant.
2 Inner surface of sleeve:Gasket sealant (LG-7)
3] Install sleeve (3) in parallel withcrankshaft (2) while hitting sleeve (3)end face lightly in circumferentialdirection using a plastic hammer.a Since sleeve (3) is symmetric in
its shape, no mounting directionis specified.
Dimen-sion b
Bolt hole 6-12 x 1.75
Oil sealpress-fitting
depth a109 mm Absent 13 � 14 mm114 mm Present 18 � 19 mm
18 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
4] Using tool J, press-fit sleeve (3) to thespecified position.a Be sure to tighten the bolts
evenly.a After press-fitting the sleeve,
clean the projected gasket seal-ant completely (adhesion of suchgasket sealant to the seal lip cancause leakage of oil).
5) Using tool J, install front oil seal (1).a Tighten the mounting bolts evenly.a Before assembling the oil seal, clean
periphery of the crankshaft and applyall circumferences with the engine oil.
2 Crankshaft: Engine oil (EO30)a Apply all circumferences of the oil
seal lip with the engine oil.2 Oil seal lip: Engine oil (EO30)2 Metal ring face in oil seal periphery:
Gasket sealant (LG-4)a Use care in above operation so
that the seal l ip may not beapplied with the oil.
a When rubber is used in the peripheryof the oil seal, use rubber lubricatingliquid (RF-1) or soap water for theapplying.
a Select one of the following 3 oil seal(1) press-fitting depths depending onthe condition of the crankshaft (2).
1] When a new crankshaft (2) is used orwhen wear is not recognized on thecontact surface of oil seal.q Prior to installation, insert a 1.8 �
2.8 mm spacer [1] between tool Jand oil seal (1).
2] When installing oil seal (1) after modi-fying its originally intended installationposition.q Install oil seal (1) as is using tool
J.
3] When sleeve (3) is provided forcrankshaft (2).q Install the sleeve using a washer
[2] between tool J and crankshaft(2).
12V140E-3 Series 19
50 Disassembly and assembly SEN00322-00
18. Front supportInstall front support (1).a Prior to the installation, fill the oil hole with
grease.a Volume of grease filled: 20 cc2 Front support: Grease (G2-LI)
19. Damper and crank pulley assembly1) When the damper and crank pulley are
separated, assemble them again by tight-ening the mounting bolts in the order indi-cated in the figure.2 Damper mounting bolt and washer:
Engine oil (EO30)3 Damper mounting bolt:
98 � 122 Nm {10 � 12.5 kgm}
2) Lift and install damper and crank pulleyassembly (1).a Install the assembly aligning it to the
dowel pin of the crankshaft.4 Damper and crank pulley assem-
bly: 75 kg
a Tighten the mounting bolts in 3 stepsaccording to the order indicated in thefigure.
2 Damper and crank pulley pumpassemb ly moun t ing bo l t andwasher: Engine oil (EO30)
3 Damper and crank pulley assemblymounting bolt1st time:
73.5 ± 19.6 Nm {7.5 ± 2 kgm}2nd time:
245 ± 19.6 Nm {25 ± 2 kgm}3rd time:
744.8 ± 19.6 Nm {76 ± 2 kgm}
20 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
20. Flywheel housing1) Lift and install flywheel housing (4).
4 Flywheel housing: 230 kg
a Tighten the mounting bolts in 3 stepsaccording to the order indicated in thefigure.
2) After the installation, cut off the gasketprojecting from the oil pan mounting sur-face to make height of the gasket andmounting surface even.
3) Install burring tool (1) and Ne speed sen-sor (2).
21. Rear oil sealFollowing remedial actions are needed whenwear is recognized on the contact face of theoil seal on the crankshaft.1) When a new crankshaft is used or when
wear is not recognized on the contact sur-face of oil seal (1).q Install the rear oil seal in such that the
dimension from the flywheel housingend face may conform to the standarddimension indicated in the figure.
12V140E-3 Series 21
50 Disassembly and assembly SEN00322-00
2) When wear is recognized on the oil sealcontact face of crankshaft (2) and oil seal(1) installation position is movable.q Move the oil seal installation position
backward up to the location shown inthe figure where the lip of a new oilseal won't be in touch with the weargroove on the crankshaft.
3) When the actions up to step 2) abovehave been conducted on a crankshaft.q Attach sleeve (3) to crankshaft (2)
and then install an oversized oil seal(1) in the position indicated in the fig-ure.
4) Install sleeve (3) according to the followingprocedure.1] Scrub rusts off the press-fitted portion
of the sleeve (60 mm range from thetip) on crankshaft (2).
2] Coat entire inner surface of sleeve (3)with gasket sealant.2 Inner surface of sleeve:
Gasket sealant (LG-7)
3] Install sleeve (3) in parallel withcrankshaft (2) while hitting sleeve (3)end face lightly in circumferentialdirection using a plastic hammer.a Since sleeve (3) is symmetric in
its shape, no mounting directionis specified.
4] Using tool K, press-fit sleeve (3) up tothe position indicated in the figure.a Be sure to tighten the bolts
evenly.a After press-fitting the sleeve,
clean the projected gasket seal-ant completely (adhesion of suchgasket sealant to the seal lip cancause leakage of oil).
22 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
5) Using tool K, install rear oil seal (1).a Tighten the mounting bolts evenly.a Before assembling the oil seal, clean
periphery of the crankshaft and applyall circumferences with the engine oil.
2 Crankshaft: Engine oil (EO30)a Apply all circumferences of the oil
seal lip with the engine oil.2 Oil seal lip: Engine oil (EO30)2 Metal ring face in oil seal periphery:
Gasket sealant (LG-4)a Use care in above operation so
that the seal l ip may not beapplied with the oil.
a When rubber is used in the peripheryof the oil seal (1), use rubber lubricat-ing liquid (RF-1) or soap water for theapplying.
a Select one of the following 3 oil sealpress-fitting depths depending on thecondition of the crankshaft (2).
1] When a new crankshaft is used orwhen wear is not recognized on thecontact surface of oil seal.q Use 2 washers [1] between tool
K and crankshaft.
2] When installing the oil seal after mod-ifying its originally intended installa-tion position.q Don't use a washer [1] between
tool K and crankshaft.
3] When sleeve (3) is provided for thecrankshaft.q Use 2 washers [1] between tool
K and crankshaft (2).
12V140E-3 Series 23
50 Disassembly and assembly SEN00322-00
22. Flywheel assembly1) Lift and install flywheel assembly (1).
a Install the assembly aligning it to thedowel pin of the crankshaft.
4 Flywheel assembly: 130 kg
a When tightening the mounting bolt, fixthe space flywheel and flywheelhousing using plate [1] in order to pre-vent the crankshaft from turning.
a Tighten the mounting bolts in the fol-lowing order.
2) After installing the flywheel, inspect itsfacial runout and radial runout using dialgauge [2].Standard facial runout: Max. 0.25 mmStandard radial runout: Max. 0.25 mm
3) Install engine speed sensor (3).a Tighten the locknut until the sensor tip
is contacted against the ring geartooth tip of the flywheel. Return thesensor 3/4 - 1 turn from above posi-tion and then tighten the locknut.
34. Cylinder head assembly1) Assemble the cylinder head assembly
according to the following procedure.1] Install valve (7).2] Install lower seat (6).
3] Using tool L, install stem seal (8).a Drive in tool L until its lower end
a is contacted against lower seat(6).
4] Install inner spring (5), outer spring(4) and upper seat (3).
12V140E-3 Series 27
50 Disassembly and assembly SEN00322-00
5] Using tool B, compress the valvespring to install cotter (2).a After the installation, hit the valve
stem lightly with the plastic ham-mer to make sure the cotter isinstalled stably.
2) Install the cylinder head gasket.3) Lift and install cylinder head assembly (1).
4 Cylinder head assembly: 30 kg
4) Tighten the mounting bolts according tothe following procedure.1] Tighten mounting bolts (No. 1 � 7)
temporarily.2] Tighten the mounting bolts (No. 1 � 6)
in 3 steps according to the order indi-cated in the figure.a When a bolt with 5 punch marks,
which indicates the tighteningfrequency up to today, in its headis found, replace it with a newone.
2 Cylinder head assembly mount-ing bolt: Molybdenum disul-fide lubricant (LM-P)
3 Cylinder head assembly mountingbolt (No. 1 � 6)1st time:
137 � 157 Nm {14 � 16 kgm}2nd time:
284 � 294 Nm {29 � 30 kgm}3rd time: 90 (+30/0)°
a When tool G is not used in tight-ening of the 3rd time, check therotating angle after applyingmarking b to the cylinder headand bolt head using paint.
3] Tighten the mounting bolt (No. 7) withthe following torque.2 Cylinder head assembly mount-
ing bolt:Molybdenum disulfide lubri-cant (LM-P)
3 Cylinder head assembly mount-ing bolt (No. 7):
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}4] After the tightening, stamping punch
mark a to the head of mounting bolts(No. 1 � 6).
28 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
5) Install the water tube.3 Water tube joint bolt:
9.8 � 12.7 Nm {1.0 � 1.3 kgm}
35. Fuel injectora Check that the inside of the injector sleeve
is free from dirt.1) Install O-rings (4) and (5) and gasket (6) to
the fuel injector.2 O-ring: Engine oil (EO30)
2) Insert fuel injector (2) to the cylinder headalong with holder (3).
3) Install spherical washer (7) and thentighten holder mounting bolt (1) tempo-rarily.2 Special washer: Engine oil (EO30)
4) Tighten sleeve nut (5) of the high-pressurepipe temporarily.a Also tighten the sleeve nut on the
common rail side temporarily to pro-ceed with the positioning.
a See "High-pressure pipe" for precau-tions on this operation.
temporarily in above operation as is.This nut is to be tightened with thespecified torque in the next step.
36. High-pressure pipe (between common rail -fuel injector)k Install the high-pressure pipe and
clamp paying attention to the followingpoints.q It is strictly prohibited to reuse a high-
pressure pipe by modifying its bendor using the pipe in an unintendedlocation.
q The clamp used must be a legitimateone. And it must be installed in thespecified position with the specifiedtorque.
q After installing the high-pressure pipeand clamp, make sure that 10 mmminimum clearance is providedbetween the high-pressure pipe andadjacent harness. If the clearance isless than 10 mm, adjust the harnessposition to secure the space.
k Before installing the high-pressurepipe, check it for the following defects.If there is any of these defects, it cancause fuel leakage. Accordingly,replace the high-pressure pipe.
12V140E-3 Series 29
50 Disassembly and assembly SEN00322-00
q Check the taper seal of the connect-ing part (Part a: Part of 2 mm from theend) for visible lengthwise slit b anddent c.
q Check part d (end of the taper seal:Par t at 2 mm from the end) forstepped-type wear (fatigue) whichyour nail can feel.
1) After installing fuel injector (5) and com-mon rail (6) temporarily to high-pressurepipe (4), tighten the sleeve nut with thespecified torque.a Control the torque by using a spanner
type torque wrench (commerciallyavailable) for the tightening.
a Tighten the clamp of the air intakemanifold after installing the manifold.
30 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
9) Install the rubber cover to the sleeve nuton the high-pressure pipe.a Direct the slit downward when install-
ing the rubber cover.q Injector side (8): Bottomq Common rail side (9): Cylinder
block side
a When installing the high-pressure pipe withoutremoving the fuel injector (for example, whenreplacing only the high-pressure pipe with newone), follow the procedure below.q Tighten sleeve nut (10) by 2 turns with the
hand into the threads of the fuel injectorand then tighten it with the spanner.
a If sleeve nut (10) does not catch thethreads, it will help to turn the spannerwhile pressing sleeve nut (8) end with asmall rod, etc. toward the injector.
37. Crosshead1) Install crosshead (1).
2 Crosshead sliding portion:Engine oil (EO30)
2) Adjust the crosshead according to the fol-lowing procedure.1] Loosen locknut (2) and then loosen
adjustment screw (3) to a positionwhere it does not valve stem (4).
2] Maintain the contact with valve stem(5) on the push rod side by pressingthe contact face against the rockerarm using a finger.
3] Tighten adjustment screw (3) to con-firm the position where adjustmentscrew (3) is contacted against valvestem (4).
4] Drive in adjustment screw (3) furtherby 20° from the contacting positionagainst valve stem (4).
5] Tighten locknut (2) while suppressingmove of adjustment screw (3).
3 Locknut: 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}
38. Injector harness1) Push connector (3) out of the cylinder
head and then install injector harness (4)in the cylinder head.
a After tighten the injector terminalmounting nut, push the harnessagainst the injector body to eliminatesagging.
39. Push rodInstall push rod (1).a Make sure that the push rod end is
securely fitted to the cam follower socket.2 Both ends of push rod:
Engine oil (EO30)
40. Rocker arm assembly1) Assemble the rocker arm assembly
according to the following procedure.1] Install adjustment screw (2) on rocker
arms (4) and (6), and then install locknut (1).a Screw in adjustment screw (2)
until its spherical part touchesrocker arms (4) and (6).
2) Install exhaust rocker arm (4), spacer (5)and air intake rocker arm (6) to rocker armshaft (7).2 Rocker arm shaft:
Engine oil (EO30)
3) Install rocker arm assembly (3).a Make sure that the ball of adjustment
screw (2) is securely fitted to the pushrod socket.
a When tightening the mounting bolt,make sure adjustment screw (2) isnot pushing the push rod.
2 Rocker arm: Engine oil (EO30)3 Rocker arm assembly mounting
bolt:93 � 103 Nm {9.5 � 10.5 kgm}
a Tighten locknut (1) after adjustment ofthe valve clearance is completed.
32 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
41. Adjusting valve clearance1) Rotate the crankshaft forward and drive
right No.1 cylinder to the compression topdead center, while watching move of theintake valve on right No. 6 cylinder. Thenlocate the stamped line of R1.6 TOP ofvibration damper (1) to pointer (2).a Crank the engine using the burring
tool (B) being provided in the frontright side of the flywheel housing.
a The intake valve of right No. 6 cylin-der will start moving as right No. 1 cyl-inder is driven to vicini ty of thecompression top dead center. (Open)
a Figure shows the cylinder No. andtheir firing order (circled numbersindicate the firing order).
2) Loosen locknut (6) of adjustment screw(5) of the right No. 1 cylinder and theninsert clearance gauge M , which isadjusted to the specif ied thickness,between crosshead (4) and rocker arm(3). Then using the adjustment screw,adjust the clearance to a degree thatallows only slight move of the gauge.a Standard valve clearance:
52.9 � 64.7 Nm {5.4 � 6.6 kgm}a After tightening the locknut, check the
valve clearance again.4) Repeat the same procedure for other
engines, too, in the order of firing. Namely,crank the engine and then locate thestamped of the damper to the pointer toadjust the valve clearance of respectivecylinders.a Firing order
52. High-pressure pipe clampInstall brackets (1) and (2) to the exhaust man-ifold and then tighten high-pressure pipe clampbolt (3).3 High pressure pipe clamp bolt:
54. Supply pump assembly and high-pressurepipe (between supply pump - common rail)k Install the high-pressure pipe and
clamp paying attention to the followingpoints.q It is strictly prohibited to reuse a high-
pressure pipe by modifying its bendor using the pipe in an unintendedlocation.
q The clamp used must be a legitimateone. And it must be installed in thespecified position with the specifiedtorque.
q After installing the high-pressure pipeand clamp, make sure that 10 mmminimum clearance is providedbetween the high-pressure pipe andadjacent harness. If the clearance isless than 10 mm, adjust the harnessposition to secure the space.
1) Install supply pump assembly (1) tempo-rarily.a Align and insert the unequal spline
portion of the supply pump side tounequal spline portion A of the supplypump drive case side.
a When it is difficult to insert the supplypump , turn the crankshaft to changeposition of unequal spline portion A.
12V140E-3 Series 37
50 Disassembly and assembly SEN00322-00
a Tighten mounting bolt (2) with thespecified torque after tightening thesleeve nut of the high-pressure pipe(between supply pump and commonrail).
2) After installing high-pressure pipes (4) and(5) to supply pump (1) and common rail(3) temporarily, tighten the sleeve nut withthe specified torque.a Control the torque by using a spanner
type torque wrench (commerciallyavailable part) for the tightening.
61. Starting motor assemblyInstall staring motor assemblies (3) and (2) andthen connect wiring harness (1) to them.a Install the top assembly first being fol-
lowed by the bottom one.3 Starting motor B terminal nut:
19.6 � 25.5 Nm {2 � 2.6 kgm}
62. Engine wiring harnessInstall engine wiring harness (1) on the engineassembly and then connect the connector andterminal.
63. Checking for fuel leakagea When removal and installation of fuel sup-
ply pump (1), common rail (2), or high-pressure pipes (3) and (4) were con-ducted, check fuel leakage according tothe following procedure after assemblingthe engine.
a Here, high-pressure pipes (3) and (4)denote every fuel pipe (the figure showsan example).
a Clean and degrease the engine and theparts around it in advance so that you cantest it easily for fuel leakage.
1) Spray color checker (developer) over thefuel supply pump, common rail, fuel injec-tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpmand stop it after its speed is stabilized.
3) Check the fuel piping and devices for fuelleakage.a Check mainly around the high-pres-
sure circuit parts coated with the colorchecker for fuel leakage.
a If any fuel leakage is detected, repairit and check again from step 1).
4) Run the engine at low idle.
40 12V140E-3 Series
SEN00322-00 50 Disassembly and assembly
5) Check the fuel piping and devices for fuelleakage.a Check mainly around the high-pres-
sure circuit parts coated with the colorchecker for fuel leakage.
a If any fuel leakage is detected, repairit and check again from step 1).
6) Run the engine at high idle.7) Check the fuel piping and devices for fuel
leakage.a Check mainly around the high-pres-
sure circuit parts coated with the colorchecker for fuel leakage.
a If any fuel leakage is detected, repairit and check again from step 1).
8) Run the engine at high idle and load it.a When checking while the components
to be checked are mounted on themachine, stall the torque converter orrelieve the hydraulic pump.
9) Check the fuel piping and devices for fuelleakage.a Check mainly around the high-pres-
sure circuit parts coated with the colorchecker for fuel leakage.
a If any fuel leakage is detected, repairit and check again from step 1).
a If no fuel leakage is detected, checkis completed.
50 Disassembly and assemblyDisassembly and assembly, Part 3Disassembly and assembly, Part 3 ................................................................................................................. 2
Removal and installation fuel supply pump unit.................................................................................... 2Replacement of oil seal of engine mounted on machine ...................................................................... 4
2 12V140E-3 Series
SEN00876-00 50 Disassembly and assembly
Disassembly and assembly, Part 3 1Removal and installation fuel supply pump unit 1a Figure shows an example of the left side bank.
Except where otherwise noted, the same workprocedure shall be employed for the bothbanks.
Removal1. Remove the connectors (in 3 places).2. Remove fuel return hose (3) between common
rail (1) and supply pump (2). [*1]a A fuel return pipe is provided on the right
side bank. Since it does not allow removalhalfway, the whole set of the pipe must beremoved.
3. Remove fuel tube (5) between priming pump(4) and supply pump (2). [*2]
4. Remove fuel tube and hose assembly (7)between supply pump (2) and controller cooler(6).
5. Remove 2 high-pressure pipes (8) betweensupply pump (2) and common rail (1). [*3]
6. Remove oil tube (9) between supply pump (2)and the cylinder block. [*4]
7. Disconnect fuel tube (10) between the fuel fil-ter and supply pump (2) from the supply pumpside. [*5]
2) After installing high-pressure pipes (8) onsupply pump (2) and common rail (1) tem-porarily, tighten the sleeve nut with thespecified torque.a Use a spanner type torque wrench
(commercially available part) shouldbe used for the tightening to ensureobservance of the specified torque.
3) Install the clamp of the high-pressure pipeaccording to the following procedure.1] Manually tighten and install tempo-
rarily the stay and top and bottomclamps of the high-pressure pipe.
2] Tighten the top and bottom clampspermanently.a Before tightening the stay perma-
nently, deflect the rubber fist.a Take care in the tightening so
that excessive force may not beapplied to the supply pump sideinstall position.
3 Top and bottom clamp bolt:9.8 ± 1 Nm {1 ± 0.1 kgm}
3] Tighten respective stays permanently.4) Install the rubber cover to the sleeve nut
on the high-pressure pipe.a Direct the slit downward when install-
ing the rubber cover.q Supply pump side: Bottom sideq Common rail side:
Faced inward (Opposed)
[*4]3 Oil tube (9) joint bolt:
9.8 � 12.7 Nm {1.0 � 1.3 kgm}
[*5]3 Fuel tube (10) joint bolt:
24.5 � 34.3 Nm {2.5 -� 3.5 kgm}
[*6]3 Supply pump mounting bolt (Pump bottom
side): 19.6 � 29.4 Nm {2.0 � 3.0 kgm}
4 12V140E-3 Series
SEN00876-00 50 Disassembly and assembly
Replacement of oil seal of engine mounted on machine 1
1. Rear oil seala For the work up to removal of the flywheel,
see the shop manual for the applicablemachine.
Removal of standard sealHitch the end of tool N to the metal ring of seal (1)and pull out the seal with impacts of slide hammer[1].a Before pulling out the seal, drive in it a little to
separate it from the housing for the ease ofremoval.
a Do not use a drill, etc. since chips may enterthe engine.
Removal of sleeved seal1) Hitch the end of tool N to the metal ring of
seal (1) and pull out the seal with impactsof slide hammer [1].a Before pulling out the seal, drive in it
a little to separate it from housing (2)for the ease of removal.
2) Cut and remove sleeve (3) with a chiseland a hammer.a When cutting the sleeve, take care
extremely not to damage crankshaft(4).
a Remove all the chips.a The left one in the following figure is
the standard seal and the right one isthe sleeved seal.
Installationa Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace itwith the "Standard seal "or " Sleeved seal".
a If the shaft is worn to the degree of luster (Ifwear which you feel with your finger is lessthan 10 m) and does not have any flaw,install the standard seal.In other cases, installthe sleeved seal.
a The left one in the following figure is the stan-dard seal and the right one is the sleeved seal.
12V140E-3 Series 5
50 Disassembly and assembly SEN00876-00
InstallationFollowing remedial actions are needed when wearis recognized on the contact face of the oil seal onthe crankshaft.1) When a new crankshaft is used or when wear
is not recognized on the contact surface of oilseal.
q Install the rear oil seal in such that the dimen-sion from the flywheel housing end face mayconform to the standard dimension indicated inthe figure.
2) When wear is recognized on the oil seal con-tact face of crankshaft (2) and oil seal (1)installation position is movable.
q Move the oil seal installation position backwardup to the location shown in the figure wherethe lip of a new oil seal won't be in touch withthe wear groove on the crankshaft.
3) When the actions up to step 2) above havebeen conducted on a crankshaft.
q Attach sleeve (3) to crankshaft (2) and theninstall an oversized oil seal (1) in the positionindicated in the figure.
4) Install sleeve (3) according to the following pro-cedure.1] Scrub rusts off the press-fitted portion of
the sleeve (60 mm range from the tip) oncrankshaft (2).
2] Apply entire inner surface of sleeve (3)with gasket sealant.
2 Inner surface of sleeve:Gasket sealant (LG-7)
3] Install sleeve (3) in parallel with crankshaft(2) while hitting sleeve (3) end face lightlyin circumferential direction using a plastichammer.
a Since sleeve (3) is symmetric in its shape,no mounting direction is specified.
6 12V140E-3 Series
SEN00876-00 50 Disassembly and assembly
4] Using tool K, press-fit sleeve (3) up to theposition indicated in the figure.
a Be sure to tighten the bolts evenly.a After press-fitting the sleeve, clean the
projected gasket sealant completely(adhesion of such gasket sealant to theseal lip can cause leakage of oil).
5) Using tool K, install rear oil seal (1).a Tighten the mounting bolts evenly.a Before assembling the oil seal, clean periphery
of the crankshaft and apply all circumferenceswith the engine oil.
2 Crankshaft: Engine oil (EO30)a Apply all circumferences of the oil seal lip with
the engine oil.2 Oil seal lip: Engine oil (EO30)2 Metal ring face in oil seal periphery:
Gasket sealant (LG-4)a Take care in above operation so that the
seal lip may not be applied with the oil.a When rubber is used in the periphery of the oil
seal, use rubber lubricating liquid (RF-1) orsoap water for the applying.
a Select one of the following 3 oil seal press-fit-ting depths depending on the condition of thecrankshaft.1] When a new crankshaft is used or when
wear is not recognized on the contact sur-face of oil seal.
q Use 2 washers [1] between tool K andcrankshaft.
2] When installing oil seal after modifying itsoriginally intended installation position.
q Don't use a washer [1] between tool K andcrankshaft.
3] When sleeve (3) is provided for the crank-shaft.
q Use 2 washers [1] between tool K andcrankshaft (2).
12V140E-3 Series 7
50 Disassembly and assembly SEN00876-00
2. Front oil seal
Removala For the work up to removal of the damper, see
the shop manual for the applicable machine.1) Remove front oil seal (1).
InstallationInstall front seal (1) according to the following pro-cedure.Following remedial actions are needed dependingon presence and absence wear on the contact faceof the oil seal on the crankshaft.
1) When a new crankshaft is used or whenwear is not recognized on the contact sur-face of oil seal.q Either of the dimensions listed in the
following table shall apply to oil sealpress-fitting depth a depending onfront cover size b and presence/absence of bolt hole in the cover endface.
2) When wear is recognized on the oil sealcontact face of crankshaft (2) and oil sealinstallation position is movable.q Move the oil seal (1) installation posi-
tion backward up to a location wherethe lip of the new oil seal (1) won't bein touch with the wear groove on thecrankshaft (2).
3) When the actions up to step 2) abovehave been conducted on crankshaft (2).q Attach sleeve (3) to crankshaft (2)
and then install an oversized oil seal.
Dimen-sion b
Bolt hole 6-12 x 1.75
Oil sealpress-fitting
depth a109 mm Absent 13 � 14 mm114 mm Present 18 � 19 mm
8 12V140E-3 Series
SEN00876-00 50 Disassembly and assembly
4) Install sleeve (3) according to the followingprocedure.1] Scrub rusts off the press-fitted portion
of the sleeve (60 mm range from thetip) on crankshaft (2).
2] Apply entire inner surface of thesleeve with gasket sealant.2 Inner surface of sleeve:
Gasket sealant (LG-7)
3] Install sleeve (3) in parallel withcrankshaft (2) while hitting sleeve (3)end face lightly in circumferentialdirection using a plastic hammer.a Since sleeve (3) is symmetric in
its shape, no mounting directionis specified.
4] Using tool J, press-fit sleeve (3) to thespecified position.a Be sure to tighten the bolts
evenly.a After press-fitting the sleeve,
clean the projected gasket seal-ant completely (adhesion of suchgasket sealant to the seal lip cancause leakage of oil).
5) Using tool J, install front oil seal (1).a Tighten the mounting bolts evenly.a Before assembling the oil seal, clean
periphery of the crankshaft and applyall circumferences with the engine oil.
2 Crankshaft: Engine oil (EO30)a Apply all circumferences of the oil
seal lip with the engine oil.2 Oil seal lip: Engine oil (EO30)2 Metal ring face in oil seal periphery:
Gasket sealant (LG-4)a Take care in above operation so
that the seal l ip may not beapplied with the oil.
a When rubber is used in the peripheryof the oil seal, use rubber lubricatingliquid (RF-1) or soap water for theapplying.
a Select one of the following 3 oil seal(1) press-fitting depths depending onthe condition of the crankshaft (2).
1] When a new crankshaft (2) is used orwhen wear is not recognized on thecontact surface of oil seal.q Prior to installation, insert a 1.8 �
2.8 mm spacer [1] between tool Jand oil seal (1).
12V140E-3 Series 9
50 Disassembly and assembly SEN00876-00
2] When installing oil seal (1) after modi-fying its originally intended installationposition.q Install oil seal (1) as is using tool
J.
3] When sleeve (3) is provided forcrankshaft (2).q Install the sleeve using a washer
