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Shop Manual
12V140E-3
ENGINE
SERIES
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu Printed in U.S.A. Komatsu America Corp. July 2007
SEN00294-04
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00294-04
Note 3: To file this shop manual in the special binder for management, handle it as follows: Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title Shop Manual, contents binder, binder label and tabs 00 Index and foreword Index Foreword and general information 01 Specification Specification and technical data 10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 Structure, function and maintenance standard, Part 2 20 Standard value table Standard service value table 30 Testing and adjusting Testing and adjusting 40 Troubleshooting General information on troubleshooting Troubleshooting of mechanical system (S-mode) Troubleshooting of electrical system (E-mode), Part 1 Troubleshooting of electrical system (E-mode), Part 2 50 Disassembly and assembly General information on disassembly and assembly Disassembly and assembly, Part 1 Disassembly and assembly, Part 2 Disassembly and assembly, Part 3 Form Number SEN00291-04 SEN00292-04 SEN00294-04 q SEN00296-02 q SEN00301-02 SEN00303-02 q SEN00304-02 SEN00307-02 q SEN00309-02 q SEN00310-03 SEN00311-03 q SEN00312-00 SEN00313-00 SEN00314-00 SEN00315-00 SEN00316-00 SEN00317-00 SEN00318-00 SEN00319-00 SEN00320-00 SEN00321-00 SEN00322-00 SEN00876-00
12V140E-3 Series
SEN00294-04
Table of contents
00 Index and foreword Index SEN00294-04 Composition of shop manual ................................................................................................... 2 Table of contents ..................................................................................................................... 3 Foreword and general information SEN00296-02 Safety notice............................................................................................................................ 2 How to read the shop manual.................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code ................................................................................................ 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table.............................................................................................. 32 Conversion table...................................................................................................................... 36 01 Specification Specification and technical data SEN00303-02 Outline ..................................................................................................................................... 2 Specifications........................................................................................................................... 4 General view............................................................................................................................ 10 Weight table............................................................................................................................. 19 Engine performance curves..................................................................................................... 20 10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 SEN00307-02 Air intake and exhaust system .................................................................................................... 3 Air intake and exhaust unit ...................................................................................................... 3 Air cleaner ............................................................................................................................... 4 Turbocharger ........................................................................................................................... 6 Aftercooler ............................................................................................................................... 11 Muffler...................................................................................................................................... 12 Engine unit .................................................................................................................................. 14 Cylinder head .......................................................................................................................... 14 Cylinder block .......................................................................................................................... 18 Cylinder liner............................................................................................................................ 22 Main moving parts ................................................................................................................... 24 Crankshaft ............................................................................................................................... 26 Camshaft ................................................................................................................................. 28 Cam follower, push rod............................................................................................................ 29 Piston, piston ring, and piston pin............................................................................................ 30 Connecting rod ........................................................................................................................ 32 Flywheel and flywheel housing................................................................................................ 34 Vibration damper ..................................................................................................................... 35 Timing gear.............................................................................................................................. 36 Valve system ........................................................................................................................... 38 Valve and valve guide.............................................................................................................. 40 Rocker arm and shaft .............................................................................................................. 42 Crosshead and guide .............................................................................................................. 43 Structure, function and maintenance standard, Part 2 SEN00309-02 Lubrication system ...................................................................................................................... 4 Lubrication system diagram..................................................................................................... 4
12V140E-3 Series
SEN00294-04
Oil pump .................................................................................................................................. Oil cooler.................................................................................................................................. Oil filter..................................................................................................................................... Main relief valve....................................................................................................................... Oil cooler bypass valve and regulator valve ............................................................................ Fuel system ................................................................................................................................. CRI system diagram ................................................................................................................ Outline of CRI system.............................................................................................................. Fuel piping ............................................................................................................................... Fuel filter .................................................................................................................................. Priming pump........................................................................................................................... Cooling system............................................................................................................................ Cooling system diagram .......................................................................................................... Water pump ............................................................................................................................. Thermostat............................................................................................................................... Corrosion resistor .................................................................................................................... Cooling fan drive...................................................................................................................... Electrical equipment .................................................................................................................... Alternator ................................................................................................................................. Starting motor .......................................................................................................................... Starting aid............................................................................................................................... Engine controller......................................................................................................................
6 7 8 9 10 12 12 14 32 37 39 40 40 42 44 45 47 50 50 52 54 55
20 Standard value table Standard service value table SEN00311-03 Standard service value table ....................................................................................................... 2 Standard service value table for testing, adjusting, and troubleshooting ................................. 2 Running-in standard and performance test standard .............................................................. 7 30 Testing and adjusting Testing and adjusting SEN00313-00 Testing and adjusting................................................................................................................... 3 Testing and adjusting tools list ................................................................................................. 3 Testing air boost pressure........................................................................................................ 5 Testing exhaust temperature ................................................................................................... 6 Adjusting valve clearance ........................................................................................................ 7 Testing compression pressure ................................................................................................. 9 Testing blow-by pressure ......................................................................................................... 11 Measuring blow-by pressure.................................................................................................... 12 Testing oil pressure.................................................................................................................. 13 Handling fuel system parts ...................................................................................................... 14 Releasing residual pressure in fuel system ............................................................................. 14 Testing fuel pressure................................................................................................................ 15 Reduced cylinder mode operation ........................................................................................... 16 No-injection cranking ............................................................................................................... 16 Testing leakage-from pressure limiter and return rate from injector ........................................ 17 Bleeding air from fuel circuit (for D475A-5).............................................................................. 20 Bleeding air from fuel circuit (for PC2000)............................................................................... 23 Testing fuel system for leakage ............................................................................................... 25 Adjusting speed sensor ........................................................................................................... 26 Testing and adjusting alternator belt tension ........................................................................... 26 Handling controller high-voltage circuit.................................................................................... 27 40 Troubleshooting General information on troubleshooting SEN00315-00 General information on troubleshooting ...................................................................................... 2 Points to remember when troubleshooting .............................................................................. 2
12V140E-3 Series
SEN00294-04
Error codes and failure codes list ............................................................................................ 3 Troubleshooting of mechanical system (S-mode) SEN00316-00 Troubleshooting of mechanical system (S-mode) ....................................................................... 3 Method of using troubleshooting charts................................................................................... 3 S-1 Starting performance is poor ............................................................................................. 6 S-2 Engine does not start ........................................................................................................ 7 S-3 Engine does not pick up smoothly .................................................................................... 10 S-4 Engine stops during operations ........................................................................................ 11 S-5 Engine does not rotate smoothly ...................................................................................... 12 S-6 Engine lacks output (or lacks power) ................................................................................ 13 S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16 S-9 Oil becomes contaminated quickly ................................................................................... 17 S-10 Fuel consumption is excessive ....................................................................................... 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 19 S-12 Oil pressure drops........................................................................................................... 20 S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21 S-14 Coolant temperature becomes too high (overheating).................................................... 22 S-15 Abnormal noise is made ................................................................................................. 23 S-16 Vibration is excessive ..................................................................................................... 24 Troubleshooting of electrical system (E-mode), Part 1 SEN00317-00 Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 4 Information in troubleshooting table ........................................................................................ 4 E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank)............................................... 6 E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank) .............................................. 8 E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank) ....................... 10 E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)....................... 11 E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only)......................... 12 E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only).......................... 14 E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only) ......................................... 16 E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) .......................................... 18 E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)...................................... 20 E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) .................................... 22 E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) ............................ 24 E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ............................. 26 E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) ....................... 28 E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only) ........................ 30 E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) ......................................... 31 E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)......................................... 31 E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)............................. 32 E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ............................. 34 E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ..................... 36 E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) ...................... 38 E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ........................................ 40 E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)........................................ 42 E-23 Code [234/CA234] Eng. Overspeed (LH bank only) ....................................................... 44 E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank) ................................... 46 E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) .................................. 48 E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank) ......................................... 50 E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ........................................ 52 E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank) .......................................... 54 E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) ......................................... 54 E-30 Code [271/CA271] PCV1 Short Error (LH bank)............................................................. 56 E-31 Code [271/CB271] PCV1 Short Error (RH bank) ............................................................ 58 E-32 Code [272/CA272] PCV1 Open Error (LH bank) ............................................................ 60 E-33 Code [272/CB272] PCV1 Open Error (RH bank)............................................................ 61
12V140E-3 Series
SEN00294-04
E-34 Code [273/CA273] PCV2 Short Error (LH bank)............................................................. E-35 Code [273/CB273] PCV2 Short Error (RH bank) ............................................................ E-36 Code [274/CA274] PCV2 Open Error (LH bank)............................................................. E-37 Code [274/CB274] PCV2 Open Error (RH bank) ............................................................ E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank)................. E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank)................. E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank)................. E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank)................. E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank)................. E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank)................. E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ...................................... E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) ..................................... E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank)..................................................... E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank) .................................................... E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) ......................................... E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank)......................................... E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank)......................................... E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank) ........................................ E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) ................................................ E-53 Code [441/CB441] Battery Voltage Low Error (RH bank) ............................................... E-54 Code [442/CA442] Battery Voltage High Error (LH bank) ............................................... E-55 Code [442/CB442] Battery Voltage High Error (RH bank) ..............................................
62 64 66 67 68 70 72 74 76 78 80 80 82 84 86 86 88 90 92 92 93 93
Troubleshooting of electrical system (E-mode), Part 2 SEN00318-00 Troubleshooting of electrical system (E-mode), Part 2................................................................ 3 E-56 Code [449/CA449] Rail Press. Very High Error (LH bank).............................................. 3 E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) ............................................. 3 E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank).......................................... 4 E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) ......................................... 6 E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) .......................................... 8 E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank).......................................... 8 E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) ................................................... 9 E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) .................................................. 10 E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) .................................. 11 E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank).................................. 11 E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank).................................................... 12 E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank) ................................................... 16 E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank) ........................................... 20 E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank)........................................... 22 E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) .......................... 24 E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only) ........................... 26 E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank) ...................... 27 E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank)...................... 27 E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) ........................................ 28 E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank)........................................ 28 E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) ................................. 30 E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank)................................. 32 E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank) ...................... 34 E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ..................... 36 E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank)............................................. 37 E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) ............................................ 37 E-82 Code [1257/CA1257] Harness Key error (LH bank)........................................................ 38 E-83 Code [1257/CB1257] Harness Key error (RH bank) ....................................................... 39 E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank)............ 40 E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank)............ 42 E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank).......... 44 E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) .......... 46 E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank).......... 48
12V140E-3 Series
SEN00294-04
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ........... E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ................................ E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)..................... E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only)...................... E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) .......................................... E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) .......................................... E-95 Code [ *1/] Eng. Overheat (LH bank only) ................................................................ E-96 Code [ *2/] Eng. Oil Press. Low Speed Derate (LH bank only) ................................. E-97 Code [ *3/] Press. Low Torque Derate (LH bank only) ..............................................
50 52 54 56 57 57 58 58 59
50 Disassembly and assembly General information on disassembly and assembly SEN00320-00 General information on disassembly and assembly.................................................................... 2 How to read this manual.......................................................................................................... 2 Coating materials list ............................................................................................................... 3 Special tools list ....................................................................................................................... 6 Disassembly and assembly, Part 1 SEN00321-00 Disassembly and assembly, Part 1 ............................................................................................. 2 General disassembly of engine ............................................................................................... 2 Disassembly and assembly, Part 2 SEN00322-00 Disassembly and assembly, Part 2 ............................................................................................. 2 General assembly of engine.................................................................................................... 2 Disassembly and assembly, Part 3 SEN00876-00 Disassembly and assembly, Part 3 ............................................................................................. 2 Removal and installation fuel supply pump unit ...................................................................... 2 Replacement of oil seal of engine mounted on machine......................................................... 4
12V140E-3 Series
SEN00294-04
12V140E-3 Series
SEN00296-02
ENGINE
1SHOP MANUAL
12V140E-3 Series
Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
12V140E-3 Series
SEN00296-02
Safety notice
(Rev. 2007/03)
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition.
8)
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Precautions against work which you are not used to or you are used to too much
2.
Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
12V140E-3 Series
SEN00296-02
3) 4)
When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
8)
9) 10)
3.
Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative () terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.
11)
12)
16)
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
12V140E-3 Series
SEN00296-02
4.
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
12V140E-3 Series
SEN00296-02
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
q
13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
5.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
6.
Wire ropes (Standard Z twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
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8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles. 2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
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Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The S mode of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
1.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
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3.
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table.
q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 ) Revisions Revised brochures are shown in the shop manual composition table.
4.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol k a 4 3 2 5 6 Item Safety Caution Weight Tightening torque Coat Oil, coolant Drain Remarks Special safety precautions are necessary when performing work. Special technical precautions or other precautions for preserving standards are necessary when performing work. Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
5.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the standard size and the range of difference from the standard size is called the tolerance. q The tolerance with the symbols of + or is indicated on the right side of the standard size.
q
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (0.022/0.126) Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
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2.
Standard clearance and standard value The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the standard value, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
q
5.
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the clearance limit. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
q
6.
3.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the interference. q The range (A B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the standard interference. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. Repair limit and allowable value The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the repair limit. q If a part is worn to the repair limit must be replaced or repaired. q The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the allowable value. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
q
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
q
4.
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To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and Handling hydraulic equipment (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
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3)
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
5)
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3.
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2]
q
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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2)
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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3)
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
Disconnection
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4)
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
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4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
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Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1. Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment. Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
2.
3.
4.
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5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
6.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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1.
Pull lock type (PACKARD-2) 107 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
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3.
Push lock type q 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow.
q
114 engine
107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04) While pressing lock (D), pull out connector (4) in the direction of the arrow.
3)
107 engine
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
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4)
125 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc. Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
1)
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it clicks.
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
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The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Symbol AV Conductor Insulator Conductor Insulator Conductor Insulator Material Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Using temperature range (C) Example of use General wiring (Nominal No. 5 and above) 30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely 50 to +110 cold district, wiring at high-temperature place
AVS
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2.
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 CovAV Standard 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
50
60
85
100
108/0.80 127/0.80 169/0.80 217/0.80 54.29 9.8 13.0 13.0 63.84 10.4 13.6 13.6 84.96 12.0 16.0 16.0 109.1 13.6 17.6 17.6
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3.
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: GW means that the background is Green and marking is White. 4. Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch WG
AEX R B R D Y G L
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
YW GL
Gr Br
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[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1.
q q q q q q q q q q
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2) Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234 Sleeve nut (elbow end) 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500
3)
If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34
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2.
q q q q q q q q q q q q q
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, Bleeding air. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see Disassembly and assembly. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
a 3.
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4)
5)
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly and assembly.
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Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 1. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
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Type 2 1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
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Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
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Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a The following table corresponds to the bolts in Fig. A. Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Tightening torque Nm kgm 11.8 14.7 1.2 1.5 27 34 2.8 3.5 59 74 6.0 7.5 98 123 10.0 12.5 153 190 15.5 19.5 235 285 23.5 29.5 320 400 33.0 41.0 455 565 46.5 58.0 610 765 62.5 78.0 785 980 80.0 100.0 1,150 1,440 118 147 1,520 1,910 155 195 1,960 2,450 200 250 2,450 3,040 250 310 2,890 3,630 295 370
The following table corresponds to the bolts in Fig. B. Width across flats mm 10 13 14 27 Tightening torque Nm 5.9 9.8 13.7 23.5 34.3 46.1 74.5 90.2
a Fig. B
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2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Width across flats mm 14 17 22 Tightening torque Nm kgm 59 74 6.0 7.5 98 123 10.0 12.5 235 285 23.5 29.5
3.
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below. Thread diameter mm 14 20 24 33 42 Tightening torque Nm {kgm} Range Target 35 63 { 3.5 6.5} 44 { 4.5} 84 132 { 8.5 13.5} 103 {10.5} Varies depending on type of connec- 128 186 {13.0 19.0} 157 {16.0} tor. 363 480 {37.0 49.0} 422 {43.0} 746 1,010 {76.0 103} 883 {90.0} Width across flats mm
4.
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52 Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52 Width across flats mm 14 17 19 22 24 27 30 32 32 36 Tightening torque Nm {kgm} Range Target 5.88 8.82 {0.6 0.9} 7.35 {0.75} 9.81 12.74 {1.0 1.3} 11.27 {1.15} 14.7 19.6 {1.5 2.0} 17.64 {1.8} 19.6 24.5 {2.0 2.5} 22.54 {2.3} 24.5 34.3 {2.5 3.5} 29.4 {3.0} 34.3 44.1 {3.5 4.5} 39.2 {4.0} 44.1 53.9 {4.5 5.5} 49.0 {5.0} 58.8 78.4 {6.0 8.0} 68.6 {7.0} 93.1 122.5 { 9.5 12.5} 107.8 {11.0} 107.8 147.0 {11.0 15.0} 127.4 {13.0} 127.4 176.4 {13.0 18.0} 151.9 {15.5} 181.3 240.1 {18.5 24.5} 210.7 {21.5} 274.4 367.5 {28.0 37.5} 323.4 {33.0}
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5.
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Thread size (mm) 14 18 22 24 30 33 36 42 Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2
Range 34 54 { 3.5 5.5} 34 63 { 3.5 6.5} 54 93 { 5.5 9.5} 59 98 { 6.0 10.0} 84 132 { 8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
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. Thread size mm 6 8 10 12 14 Nm 10 2 24 4 43 6 77 12 Tightening torque Bolts and nuts kgm 1.02 0.20 2.45 0.41 4.38 0.61 7.85 1.22
7.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14 Tightening torque Nm 82 10 2 12 2 24 4 36 5 kgm 0.81 0.20 1.02 0.20 1.22 0.20 2.45 0.41 3.67 0.51
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8.
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1 Tightening torque Nm 31 82 12 2 15 2 24 4 36 5 60 9 kgm 0.31 0.10 0.81 0.20 1.22 0.20 1.53 0.20 2.45 0.41 3.67 0.51 6.12 0.92
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Conversion table
Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 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.
2.
Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
(B) 5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898
0 10 20 30 40 (A) 50 60 70 80 90
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Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929 2.244 2.638 3.032 3.425 3.819 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898
0 10 20 30 40 50 60 70 80 90
Kilogram to pound 0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42 1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62 2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83 3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03 4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24 5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44 1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03 123.46 145.51 167.55 189.60 211.64 125.66 147.71 169.76 191.80 213.85 127.87 149.91 171.96 194.01 216.05 130.07 152.12 174.17 196.21 218.26
0 10 20 30 40 50 60 70 80 90
Liters to U.S. Gallons 0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095 13.209 15.850 18.492 21.134 23.775 13.473 16.115 18.756 21.398 24.040 13.737 16.379 19.020 21.662 24.304 3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568 4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832 1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944 14.529 17.171 19.813 22.455 25.096 14.795 17.435 20.077 22.719 25.361 15.058 17.700 20.341 22.983 25.625 15.322 17.964 20.605 23.247 25.889 15.586 18.228 20.870 23.511 26.153
0 10 20 30 40 50 60 70 80 90
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Liters to U.K. Gallons 0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797 1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017 2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237 3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457 4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677 5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117 12.528 14.738 16.938 19.137 21.337 12.758 14.958 17.158 19.357 21.557 12.978 15.178 17.378 19.577 21.777
0 10 20 30 40 50 60 70 80 90
kgm to ft.lb 0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4 412.3 484.6 556.9 629.3 701.6 419.5 491.8 564.2 636.5 708.8 426.8 499.1 571.4 643.7 716.1
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7 1084.9 1157.3 1129.6 1301.9 1374.3 1092.2 1164.5 1236.8 1309.2 1381.5 1099.4 1171.7 1244.1 1316.4 1388.7 1106.6 1179.0 1251.3 1323.6 1396.0 1113.9 1186.2 1258.5 1330.9 1403.2 1121.1 1193.4 1265.8 1338.1 1410.4 1128.3 1200.7 1273.0 1345.3 1417.7 1135.6 1207.9 1280.1 1352.6 1424.9 1142.8 1215.1 1287.5 1359.8 1432.1 1150.0 1222.4 1294.7 1367.0 1439.4
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kg/cm2 to lb/in2 0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414 1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428 2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442 3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456 4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470 5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485 6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499 1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 953.0 1,095 1,237 1,380 1,522 1,664 1,806 1,949 2,091 2,233 2,375 2,518 2,660 2,802 2,944 3,086 3,229 3,371 3,513 825.0 967.2 1,109 1,252 1,394 1,536 1,678 1,821 1,963 2,105 2,247 2,389 2,532 2,674 2,816 2,958 3,101 3,243 3,385 3,527 839.2 981.4 1,124 1,266 1,408 1,550 1,693 1,835 1,977 2,119 2,262 2,404 2,546 2,688 2,830 2,973 3,115 3,257 3,399 3,542
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
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Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1C = 33.8F F 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
C 40.4 37.2 34.4 31.7 28.9 28.3 27.8 27.2 26.7 26.1 25.6 25.0 24.4 23.9 23.3 22.8 22.2 21.7 21.1 20.6 20.0 19.4 18.9 18.3 17.8 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 40 35 30 25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10
F 40.0 31.0 22.0 13.0 4.0 2.2 0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
C 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4
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12V140E-3 Series
SEN00303-02
ENGINE
1SHOP MANUAL
12V140E-3 Series
01 Specification
Specification and technical data
Outline.................................................................................................................................................. 2 Specifications ....................................................................................................................................... 4 General view ...................................................................................................................................... 10 Weight table ....................................................................................................................................... 19 Engine performance curves ............................................................................................................... 20
12V140E-3 Series
SEN00303-02
01 Specification
Outline
1. Applicable machine
Engine Engine serial No.
Machine model D475A-5E0 Bulldozer Dump truck Hydraulic excavator Wheel loader HD785-7 PC2000-8 WA800-3E0, WA900-3E0
SAA12V140E-3
12V140E-3 Series
01 Specification
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2. Outline of engine
q
The 12V140E-3 engine is a high-performance and high-efficiency engine which provides low fuel consumption, low noise, and improved exhaust gas color, and improved acceleration performance, and it cleared the strict exhaust gas regulation (USA: EPA regulations for 2006). Accordingly, this newly developed engine is suitable as a power source of c o n s t r u c t i o n m a c h i n e r y, a n d i n d u s t r i a l machinery used for various purposes. It is the successor of conventional 12V140-1 engine which introduces various kinds of new technologies while adhering fundamentally to the configuration of V12-cylinder, watercooled, direct injection, and 4-stroke diesel engine. High-pressure fuel injection system controlled electronically The conventional one is a jerk in-line fuel injection pump-based engine mechanically controlled by a governor, while in all series of the new one, an electronic control system- and high-pressure injection system-based common rail injection system is adopted. This system provides high pressure fuel of 118 MPa {1,200 kg/cm2} level from the low-speed range to the high-speed range. In addition, it can control the form of injection most properly by the electronic control system according to the speed and load. As a result, clean exhaust g a s , c l e a n e x h a u s t g a s c o l o r, l o w f u e l consumption, and low noise are attained simultaneously. It adopts a re-entrant piston combustion chamber which has been used since introduction into the 6D140E-2 engine and also uses a quality cast iron piston with less thermal expansion and shaker cooling gallery. As a result, clean exhaust gas, clean exhaust gas color, and low fuel consumption are attained simultaneously, and also high durability and high reliability are also obtained. It also provides a higher compression ratio than the conventional one to improve combustion efficiency and reduce the white exhaust smoke when starting the engine in cold climate areas. In addition, by using the above-mentioned high-pressure fuel injection system controlled electronically and setting the injection characteristics most properly to improve the startability and reduce the white exhaust smoke when the temperature is low. It is equipped with an improved turbocharger KOMATSU KTR110 of which high reliability and high performance have been proven in the 12V140-1 engine. The following improvements
are added: mounting of a recirculation port for surging control at the compressor side and a design to improve efficiency of the turbine. As a result, high performance is attained in a wide range from the low-speed range to the highspeed range, and high performance and low fuel consumption are also obtained. 5) The piston cooling nozzle of 12V140-1 is reviewed in regard to oil flow. As a result, durability of the piston is improved and temperature of the rear surface of the piston is reduced to prevent deterioration of the piston due to exposure of lubricating oil on the surface to high temperature. Since the highpressure fuel injection system controlled electronically is employed, less-soot combustion is attained and the draining interval of the oil is lengthened. The high-pressure pump to create high pressure in the common rail injection system is one-third of the conventional in-line fuel injection pump, and in addition, it is connected compact to the timing gear case as a flange mount rather than a saddle mount. As a result, sound radiation is reduced to provide low noise. Capacity of the lubrication pump is increased by 10% over the conventional engine to contribute to the reliability and durability. The air cleaner is changed from the conventional end surface seal type to radial seal type to prevent the entry of dust due to deformation into the clean side. In addition, the air cleaner clogging sensor for 5 clogging level indication is provided to inform users of a precise cleaning time. A high performance and high efficiency combination filter is adopted as an oil filter, and a filter system to collect small dirts as well as large dirts is adopted for all specifications.
1)
6)
7)
8)
2)
9)
3)
10) The fuel filter system includes a high efficiency main filter and prefilter as standard features to allow use of low-grade fuel in the market (corresponding to NAS13 level). In addition, the delivery of the priming pump used to replace the filters is increased for higher serviceability. 11) In addition, since the engine controller is mounted on the engine and equipped with the automatic high-altitude compensation function, it can be operated at high altitude without replacing the controller. As a result, the serviceability is improved.
4)
12V140E-3 Series
SEN00303-02
01 Specification
Specifications
Engine name Machine model Number of cylinders Bore Stroke Total displacement Firing order Dimensions Overall length Overall width Overall height (excluding exhaust pipe) Overall height (including exhaust pipe) Rated output Max. torque No-load max. speed (High idle speed) No-load min. speed (Low idle speed) Fuel consumption ratio at rated output Dry weight Fuel supply pump Governor Quantity of lubricating oil (Refill capacity) Quantity of coolant Alternator Starting motor Battery Turbocharger Air compressor Others
1
SAA12V140E-3 D475A-5E0 mm l {cc} mm mm mm mm kW{HP}/rpm Nm{kgm}/rpm rpm rpm g/kWh {g/HPh} kg l l 12 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4 1,772 1,532.5 2,171.5 671 {899}/2,000 (Gross) 3,825 {390}/1,400 (Gross) 2,150 50 620 + 80/0 210 {156.7} 3,600 DENSO ECD-U2 Electronic control type 138 (130) 86 (For only engine) 24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4 KOMATSU KTR110L x 2 With air-cooled aftercooler
Performance
12V140E-3 Series
01 Specification
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Engine name Machine model Number of cylinders Bore Stroke Total displacement Firing order Dimensions Overall length Overall width Overall height (excluding exhaust pipe) Overall height (including exhaust pipe) Rated output Max. torque No-load max. speed (High idle speed) No-load min. speed (Low idle speed) Fuel consumption ratio at rated output Dry weight Fuel supply pump Governor Quantity of lubricating oil (Refill capacity) Quantity of coolant Alternator Starting motor Battery Turbocharger Air compressor Others mm l {cc} mm mm mm mm kW{HP}/rpm Nm{kgm}/rpm rpm rpm g/kWh {g/HPh} kg l l
SAA12V140E-3 HD785-7 12 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4 2,046.5 1,479.7 1,745.3 895 {1,200}/1,900 (Gross) 5,076 {518}/1,350 (Gross) 2,250 25 650 20 207 {154} 3,600 DENSO ECD-U2 Electronic control type 138 (130) 86 (For only engine) 24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4 KOMATSU KTR110L x 2 With air-cooled aftercooler
Performance
12V140E-3 Series
SEN00303-02
01 Specification
Engine name Machine model Number of cylinders Bore Stroke Total displacement Firing order Dimensions Overall length Overall width Overall height (excluding exhaust pipe) Overall height (including exhaust pipe) Rated output Max. torque No-load max. speed (High idle speed) No-load min. speed (Low idle speed) Fuel consumption ratio at rated output Dry weight Fuel supply pump Governor Quantity of lubricating oil (Refill capacity) Quantity of coolant Alternator Starting motor Battery Turbocharger Air compressor Others mm l {cc} mm mm mm mm kW{HP}/rpm Nm{kgm}/rpm rpm rpm g/kWh {g/HPh} kg l l
SAA12V140E-3 PC2000-8 12 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4 1,807.7 1,588.8 1,734.3 728 {976}/1,800 (Gross) 4,488 {458}/1,350 (Gross) 1,980 25 825 25 207 {154} 3,600 DENSO ECD-U2 Electronic control type 138 (130) 86 (For only engine) 24V, 90A 24V, 11kW x 2 12V, 170Ah x 4 KOMATSU KTR110L x 2 With air-cooled aftercooler
Performance
12V140E-3 Series
01 Specification
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Engine name Machine model Number of cylinders Bore Stroke Total displacement Firing order Dimensions Overall length Overall width Overall height (excluding exhaust pipe) Overall height (including exhaust pipe) Rated output Max. torque No-load max. speed (High idle speed) No-load min. speed (Low idle speed) Fuel consumption ratio at rated output Dry weight Fuel supply pump Governor Quantity of lubricating oil (Refill capacity) Quantity of coolant Alternator Starting motor Battery Turbocharger Air compressor Others mm l {cc} mm mm mm mm kW{HP}/rpm Nm{kgm}/rpm rpm rpm g/kWh {g/HPh} kg l l
SAA12V140E-3 WA800-3E0 12 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4 2,123 1,463.5 1,940 636 {853}/2,000 (Gross) 3,802 {388}/1,400 (Gross) 2,200 (+10/-20) 680 + 50/0 215 {160} 3,600 DENSO ECD-U2 Electronic control type 138 (130) 86 (For only engine) 24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4 KOMATSU KTR110L x 2 With air-cooled aftercooler
Performance
12V140E-3 Series
SEN00303-02
01 Specification
Engine name Machine model Number of cylinders Bore Stroke Total displacement Firing order Dimensions Overall length Overall width Overall height (excluding exhaust pipe) Overall height (including exhaust pipe) Rated output Max. torque No-load max. speed (High idle speed) No-load min. speed (Low idle speed) Fuel consumption ratio at rated output Dry weight Fuel supply pump Governor Quantity of lubricating oil (Refill capacity) Quantity of coolant Alternator Starting motor Battery Turbocharger Air compressor Others mm l {cc} mm mm mm mm kW{HP}/rpm Nm{kgm}/rpm rpm rpm g/kWh {g/HPh} kg l l
SAA12V140E-3 WA900-3E0 12 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4 2,123 1,463.5 1,940 672 {900}/2,050 (Gross) 4,159 {424}/1,300 (Gross) 2,200 + 10/0 680 + 50/0 215 {160} 3,600 DENSO ECD-U2 Electronic control type 138 (130) 86 (For only engine) 24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4 KOMATSU KTR110L x 2 With air-cooled aftercooler
Performance
12V140E-3 Series
01 Specification
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12V140E-3 Series
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01 Specification
General view
a 1. 2.
The shape is subject to machine models. Center of crankshaft Rear face of flywheel housing
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01 Specification
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a 1. 2.
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01 Specification
a 1. 2.
The shape is subject to machine models. Center of crankshaft Rear face of flywheel housing
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01 Specification
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a 1. 2.
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01 Specification
a 1. 2.
The shape is subject to machine models. Center of crankshaft Rear face of flywheel housing
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01 Specification
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a 1. 2.
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01 Specification
a 1. 2.
The shape is subject to machine models. Center of crankshaft Rear face of flywheel housing
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01 Specification
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a 1. 2.
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01 Specification
Dimensions table
Unit: mm Engine Machine model D475A-5E0 SAA12V140E-3 HD785-7 PC2000-8 WA800-3E0, WA900-3E0 Dimensions of each part A 287 230 353 230 B 1,582 1,585.8 1,574.8 1,585.8 C 1,772 2,046.5 1,807.7 2,123 D 2,171.5 1,745.3 1,734.3 1,940 E 726 715 726 715.2 F 507 210 600 210 G 507 210 600 210
These dimensions are given for reference when the engine is set on a test bench.
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01 Specification
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Weight table
1
Unit: kg
No. 1 2 3 4 5 Turbocharger
Item
Main parts KOMATSU KTR110L (Water-cooled) Cylinder head, valve, rocker arm, valve spring Cylinder block, bearing cap, cylinder liner
SAA12V140E-3 25 x 2 22.5 x 12 810 72 52 D475A-5E0 HD785-7 WA800-3E0, WA900-3E0 PC2000-8 D475A-5E0 HD785-7 88.4 89.2 127.6 72.5 88.7
Cylinder head assembly Cylinder block assembly Gear case Gear case
Oil pan
Integral-type
Flywheel assembly
8 9 10 11 12 13 14 15
Flywheel housing assembly Crankshaft assembly Camshaft assembly Piston and connecting rod assembly Oil pump Fuel supply pump Water pump Alternator 24V, 90A 24V, 7.5kW 24V, 11kW Crankshaft, crank gear Camshaft, cam gear thrust plate Piston, piston ring, piston pin, connecting rod
16
Starting motor
18 x 2
17
Aftercooler assembly
12V140E-3 Series
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01 Specification
1
Machine model Page 21 22 23 24 25
D475A-5E0
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01 Specification
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01 Specification
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01 Specification
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01 Specification
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01 Specification
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01 Specification
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12V140E-3 Series
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ENGINE
1SHOP MANUAL
12V140E-3 Series
Air intake and exhaust system ........................................................................................................................ 3 Air intake and exhaust unit ................................................................................................................... 3 Air cleaner............................................................................................................................................. 4 Turbocharger ........................................................................................................................................ 6 Aftercooler ...........................................................................................................................................11 Muffler ................................................................................................................................................. 12 Engine unit .................................................................................................................................................... 14 Cylinder head...................................................................................................................................... 14 Cylinder block ..................................................................................................................................... 18 Cylinder liner....................................................................................................................................... 22 Main moving parts............................................................................................................................... 24
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Crankshaft........................................................................................................................................... 26 Camshaft............................................................................................................................................. 28 Cam follower, push rod ....................................................................................................................... 29 Piston, piston ring, and piston pin ....................................................................................................... 30 Connecting rod.................................................................................................................................... 32 Flywheel and flywheel housing ........................................................................................................... 34 Vibration damper................................................................................................................................. 35 Timing gear ......................................................................................................................................... 36 Valve system ....................................................................................................................................... 38 Valve and valve guide ......................................................................................................................... 40 Rocker arm and shaft.......................................................................................................................... 42 Crosshead and guide.......................................................................................................................... 43
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1
1
a A: B: C: D:
The illustration shows the engine for D475A-5E0. Air intake (From air cleaner) Air intake (To air-cooled aftercooler) Air intake (From air-cooled aftercooler) Exhaust gas 1. 2. 3. 4. Electrical intake air heater Air intake manifold Muffler Turbocharger
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Air cleaner
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
a A: B: C: 1. 2. 3. 4.
The shape is subject to machine models. Air inlet To turbocharger (Intake air) To muffler (Dust) Pre-cleaner Air cleaner casing Outer element Inner element
Engine
Machine model
12V140E-3 Series
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FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
a 1. 2. 3. 4. 5.
The shape is subject to machine models. Inlet Outlet Guide vane Primary element Safety element
Engine Machine model Type FRG (Radial seal type)
6. 7. 8. 9. 10.
SAA12V140E-3 HD785-7
Structure q The size of the body is reduced from the conventional type without changing the diameter of the element. q Since the inlet is set in the tangential direction, air is given sufficient centrifugal force by the simple spiral guide vane, not by the guide plate.
Operation q Air containing dust is sucked in vertically through inlet (1) and the dust is separated by the centrifugal effect of guide vane (3). q More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the engine through safety element (5) and outlet (2). q The dust and water separated by guide vane (3) swirl along the inside wall of body (9) and enter evacuator valve (6) and then are discharged out automatically.
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Turbocharger
Water-cooled type
Type: KTR110L
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Intake air inlet Intake air outlet Exhaust gas inlet Exhaust gas outlet Oil inlet Oil outlet Coolant Blower housing V-band Diffuser plate Center housing Shroud Turbine housing Blower impeller Seal ring Thrust metal Journal bearing Seal ring Turbine impeller
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Model: KTR110L
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Unit: mm No. 1 2 3 Check item End play (Play in axial direction) Radial play (Play in radial direction) Clearance between blower housing and impeller Standard 0.08 0.13 0.43 0.68 Criteria Repair limit 0.18 0.84 Remedy Replace thrust parts Replace bearing parts Replace bearing parts
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Turbocharger mounting
a a A: B: 1. 2.
The illustration shows the engine for D475A-5E0. The shape is subject to machine models. Intake air inlet Intake air (Between turbocharger and air-cooled aftercooler) Exhaust manifold Turbocharger
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Aftercooler
Air-cooled type
a a A: B: 1. 2. 3. 4. 5.
The shape is subject to machine models. The illustration shows the engine for D475A-5E0. Air inlet (From turbocharger) Air outlet (To air intake manifold) Upper tank Core Lower tank Fin Tube
12V140E-3 Series
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Muffler
a a A: 1. 2.
The shape is subject to machine models. The illustration shows the engine for D475A-5E0. Exhaust gas outlet Turbocharger Muffler
12
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Engine unit
Cylinder head
1
1
a A: B: 1. 2. 3. 4. 5.
The shape is subject to machine models. Air intake Exhaust gas Spill pipe Air bleeding pipe Cylinder head Head cover Head cover bolt C: D: 6. 7. 8. 9. 10. To fuel tank To radiator Cylinder head bolt Injector connector Injector assembly Injector holder mounting bolt Injector holder retainer
14
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Specifications Cylinder head Direct injection type 4-valve type Split-type 1 cylinder, 1 cylinder head Centralized cooling system for valve bridge and injector Cylinder head bolt: Plastic-region tightening Valve seat Valve seat inserts are press fitted to both intake and exhaust valves Rocker cover O-ring seal Injector Installation: Dry type (without sleeve)
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Unit: mm No. 1 2 Check item Strain of cylinder head mounting face Projection of nozzle Tightening torque for cylinder head mounting bolt (Apply molybdenum disulfied or engine oil to threaded part) Tightening torque for injector holder mounting bolt Tightening torque for fuel injection pipe Tightening torque for head cover mounting bolt Tolerance 0 0.06 Engine SAA12V140E-3 Bolt No. [1] [6] [7] Procedure 1st phase 2nd phase 3rd phase Target (Nm {kgm}) 66.7 {6.8} 37.3 {3.8} 32.4 {3.3} 147 {15} Criteria Repair limit 0.09 Standard 2.3 2.9 Target (Nm{kgm}) Range (Nm{kgm}) Remedy Repair by grinding or replace Replace nozzle or gasket
Tighten in order 137 157 {14 16} shown above. If 216 {22} 284 294 {29 30} there are 5 punch marks, replace Retighten by 90 90(+30/0) the bolt. 68.6 {7} 58.8 73.5 {6 7.5} Range (Nm {kgm}) 58.8 73.5 {6 7.5} 34.3 40.2 {3.5 4.1} 29.4 34.3 {3.0 3.5} Retighten
4 5 6
Do not use a cylinder head mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.
16
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Cylinder block
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Cylinder block Cylinder liner Clevis seal O-ring O-ring Main bearing metal cap bolt Main bearing metal cap Main bearing metal Piston cooling nozzle Thrust bearing metal
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Specifications Cylinder block Crankshaft: 7 bearings Camshaft: High cam type, 7 bearings Main bearing cap bolt: Plastic-region tightening Piston cooling With piston cooling nozzle Cylinder liner Wet type Machining on inside: Plateau honing and Tufftride
Liner ring Upper: Clevis seal (Ethylene-propylene rubber) Middle: O-ring (Ethylene-propylene rubber) Lower: O-ring (Silicon rubber)
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Unit: mm No. 1 Check item Strain of cylinder head mounting face Inside diameter of main bearing metal mounting hole Surface roughness of main bearing metal mounting hole Roundness of mounting hole Thickness of main bearing metal No.4 only Other than No.4 4.5 4.5 Standard size 148 148 Standard size 69 Standard size 65 Procedure 1st time 2nd time 3rd time Tolerance +0.040 +0.025 Target (Nm {kgm}) 284 {29} 569 {58} Retighten by 90 65.7 {6.7} Repair limit: 0.14 Tolerance +0.175 +0.130 +0.145 +0.100 Tolerance 0 0.09 Standard size 157 10S or less Repair limit: 0.005 0.050 0.060 0.065 0.075 Repair limit 148.23 148.20 Tolerance +0.025 +0.025 Repair limit 65.15 Range (Nm {kgm}) 270 299{27.5 30.5} 559 579{57.0 59.0} 90(+30/0) 58.8 73.6 {6 7.5} Reassemble Retighten Correct or replace block Replace cam bushing Criteria Repair limit 0.135 Tolerance +0.025 0.010 Remedy Repair by grinding or replace Replace or correct main bearing metal cap Correct
Inside diameter of main bearing metal No.4 only (When tightening bolt with specified Other torque) than No.4 Inside diameter of cam bushing mounting hole Inside diameter of cam bushing Tightening torque for main bearing cap (Apply engine oil to threaded portion and washer) Tightening torque for oil pan mounting bolt
Level difference between under surfaces of cylinder block and front cover
Do not use a main cap mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.
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Cylinder liner
Unit: mm No. 1 Check item Projection of cylinder liner Rank Inside diameter of cylinder liner Roundness of cylinder liner Cylindricality of cylinder liner Outside diameter of cylinder liner (Counterbore portion) 3 Clearance between cylinder liner and block (counterbore portion) Outside diameter of cylinder liner (Lower portion of counterbore) Interference of cylinder liner and block (Lower portion of counterbore) Outside diameter of cylinder liner (at O-ring) 5 Clearance between cylinder liner and block (O-ring portion) S L Criteria Repair limit: 0.07 0.15 Tolerance Repair limit +0.020 140 140.12 +0.020 +0.040 140 140.14 +0.021 Repair limit: 0.02 Repair limit: 0.02 Standard size Tolerance 0.10 170.2 0.10 Standard clearance: 0 0.163 Standard size 161.2 Standard interference 0.02 0.12 Standard size 158 Tolerance +0.090 +0.050 Interference limit 0.02 or above Tolerance 0.024 0.049 Standard size Remedy Replace cylinder liner or cylinder block
Replace cylinder liner or block Replace cylinder liner Replace or correct cylinder liner or block Replace cylinder liner Replace cylinder liner or block
22
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a 1. 2. 3. 4. 5. 6. 7. 8. 9.
The shape is subject to machine models. Piston (FCD piston) Piston pin Connecting rod bushing Top ring Second ring Oil ring Connecting rod cap bolt Connecting rod (Front of engine: for L bank, rear: for R bank) Connecting rod cap 10. 11. 12. 13. Connecting rod bearing metal Crank gear (Number of teeth: 45) Crankshaft Vibration damper
24
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Specifications Crankshaft Closed die forging Journal, filet: Induction hardening Piston Special thin ductile cast iron FCD piston Re-entrant piston Connecting rod Closed die forging With lubricating oil hole Cap bolt is screw type, installed by plastic-region tightening.
Piston rings
: Double-side keystone, inner cut, ba rr e l f ac e, har d ch ro mi umplated Second ring (2) : Double-side keystone, inner cut, taper face, hard chromium-plated Oil ring (3) : M-shaped steel, with coil expander, nitrided surface
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Crankshaft
26
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Unit: mm No. 1 Check item Standard value End play 0.140 0.315 Rank S.T.D. Outside diameter of main journal 2 Roundness of main journal Journal Clearance of main journal No.4 only Other than No.4 Surface roughness of main journal 0.25 U.S. 0.50 U.S. 0.75 U.S. 1.00 U.S. Standard size 148 147.75 147.50 147.25 147.00 Repair limit: 0.010 Standard clearance 0.130 0.195 0.100 0.165 Clearance limit 0.25 0.22 Use undersize journal or replace main metal Correct surface roughness of crankshaft journal 0.020 0.020 Tolerance Criteria Repair limit 0.50 Repair limit 147.98 147.73 147.48 147.23 146.98 Use undersize journal or replace Remedy Replace thrust bearing metal or use oversize metal
0.8S (Surface roughness of R portion: 3.2S) Rank S.T.D. Standard size 100 99.75 89.50 99.25 99.00 Repair limit: 0.010 Standard clearance 0.046 0.116 Clearance limit 0.17 0.020 0.020 Tolerance Repair limit 89.88 89.63 89.38 89.13 88.88
Outside diameter of crank pin journal 3 Roundness of pin journal Clearance of crank pin journal Surface roughness of crankpin journal
0.8S (Surface roughness of R portion: 3.2S) Standard Repair limit 0.09 0.05
Bend of crankshaft
Coaxiality of all main journals: 0.09 or less Coaxiality of adjacent main journals: 0.05 or less Procedure
Replace
Target (Nm {kgm}) Range (Nm {kgm}) 74 {7.5} 245 {25} 745 {76} 54 93 {5.5 9.5} 226 265 {23 27} 725 765 {74 78} Retighten
Tightening torque for adapter mounting bolt Tightening torque for damper mounting bolt
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Camshaft
Unit: mm No. 1 Check item End play Outside diameter of camshaft journal Clearance of camshaft journal 3 4 Bend of camshaft Height of cam Standard 0.1 0.25 Standard size 65 Standard clearance 0.016 0.096 Cam Intake Exhaust Standard size 55.48 55.75 Tolerance 0.1 0.1 Criteria Repair limit 0.36 Tolerance 0.016 0.036 Clearance limit 0.15 Repair limit 55.08 55.35 Replace Remedy Replace thrust plate
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Unit: mm No. Check item Outside diameter of cam follower shaft Inside diameter of cam follower shaft hole 2 Outside diameter of cam roller Inside diameter of cam roller Outside diameter of cam roller pin Diameter of push rod ball end Diameter of push rod socket end Bend of push rod Standard size 22 22 31.7 12.7 12.63 Standard size 12.7 13.4 Criteria Tolerance 0.021 0.034 +0.021 +0.021 +0.05 +0.02 +0.038 +0.013 0.006 Repair limit 21.92 22.07 31.50 12.78 12.56 Tolerance 0.20 0.20 0.20 0.20 Replace Remedy
4 5 6
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Unit: mm No. Check item Rank 1 Outside diameter of piston S L No. 2 Thickness of piston ring 3 4 2 Width of piston ring groove 3 4 No. 2 4 Clearance between piston ring and piston ring groove 2 3 4 2 Standard size 140 140 Measuring point No.1 ring No.2 ring Oil ring No.1 ring No.2 ring Oil ring Criteria Tolerance 0.120 0.135 0.105 0.120 Standard size 2.9 2.41 4 Repair limit 139.830 139.845 Tolerance 0.015 0.035 0.010 0.035 0.010 0.030 Replace piston Remedy
Measuring point Standard clearance Clearance limit No.1 ring No.2 ring Oil ring No.1 ring Check with group wear gauge 0.035 0.060 0.42 0.57 (Tension: 16.5 23.5 N {1.68 2.40 kg}) 0.14 2.0 Replace piston or piston ring
0.65 0.80 No.2 ring (Tension: (Identification 16.2 24.2 N 2RN white mark) {1.65 2.47 kg}) Oil ring Standard size 52 52 0.30 0.50 (Tension: 70.1 94.6 N {7.15 9.65 kg}) Tolerance 0.006 0.006 +0.045 +0.035 Clearance limit 0.10
1.5
1.0
Outside diameter of piston pin 5 Inside diameter of piston pin hole Clearance between piston pin and piston
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Connecting rod
32
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Unit: mm No. Check item Inside diameter of connecting rod small end bushing 1 Clearance between connecting rod small end bushing and piston pin Inside diameter of connecting rod small end bushing mounting hole Inside diameter of connecting rod large end bearing metal (Crankpin journal) Standard size 52 Standard clearance 0.030 0.055 Standard size 57.4 Standard size 100 Tolerance +0.096 +0.046 Criteria Tolerance +0.049 +0.030 Repair limit 52.09 Clearance limit 0.11 Tolerance +0.030 +0.030 Repair limit 100.15 Remedy Replace bushing (Refilled part is semi-finished part) Replace bushing or piston pin Replace connecting rod (Correction not allowed) Replace bearing metal
Inside diameter of connecting +0.026 106 Replace connectrod large end hole 0.004 ing rod (Correction (Without bearing metal, X, Y, Tighten connecting rod cap with specified torque and measure not allowed) and Z directions) Thickness of connecting rod bearing metal Parallelism and twist of connecting rod Tightening torque for connecting rod cap mounting bolts (Apply engine oil to seat surface of nut of threaded portion of bolts) Inside diameter of connecting rod large end Roughness Swell 3.0 Item 0.025 0.035 Standard 0 0.10 0 0.25 340 Target (Nm {kgm}) 74 {7.5} Retighten 90 3.2S 0.004 (In overall width) Repair limit 0.15 0.30 Range (Nm {kgm}) 69 78 {7 8} 90(+30/0) Replace Tighten in order shown in figure Replace connecting rod Replace bearing metal
Parallelism (a) Twist (b) Dimensions (c) Procedure 1st time 2nd time
Do not use a connecting rod cap mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.
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Unit: mm No. 1 2 3 4 Check item Facial runout of flywheel housing Radial runout of flywheel housing Facial runout of flywheel Radial runout of flywheel Tightening torque for flywheel housing mounting bolt (Apply engine oil to threaded portion) Procedure 1st time 2nd time 1st time 2nd time 3rd time Criteria Repair limit: 0.25 Repair limit: 0.25 Repair limit: 0.30 Repair limit: 0.13 Target (Nm {kgm}) 343 {35} 412 {42} 98 {10} 294 {30} 539 {55} Range (Nm {kgm}) 294 392 {30 40} 392 432 {40 44} 78 118 {8 12} 275 314 {28 32} 520 559 {53 57} Tighten in order shown in above figure Reassemble Remedy
Tightening torque for flywheel mounting bolt (Apply engine oil to threaded portion)
34
12V140E-3 Series
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Vibration damper
a 1. 2. 3. 4. 5. 6.
The shape is subject to machine models. Vibration damper Pin (between adapter and vibration damper) Adapter Pin (between adapter and crankshaft) Bolt (between adapter and crankshaft) Bolt (between adapter and vibration damper)
12V140E-3 Series
35
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Timing gear
36
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Unit: mm No. Check item Position a b c d Backlash of each gear e f g h j k Clearance between main idler gear bushing and shaft (Both right and left banks) Clearance between sub idler gear bushing and shaft End play of main idler gear Criteria Measuring point Crank gear and right main idler gear (Large) Right main idler gear (Small) and right sub idler gear Right sub idler gear and right cam gear Right cam gear and accessory drive gear Right main idler gear (Small) and right fuel injection pump gear Right main idler gear (Large) and water pump driver gear Right main idler gear (Large) and oil pump gear Crank gear and left main idler gear (Large) Left main idler gear (Small) and left cam gear Left main idler gear (Small) and left fuel injection pump gear Tolerance Shaft 0.016 0.029 0.016 0.029 Standard 0.09 0.26 4 5 6 7 End play of sub idler gear End play of fuel injection pump drive gear End play of oil pump drive gear End play of accessory drive gear 0.07 0.18 0.07 0.20 0.03 0.088 0.1 0.4 Hole +0.034 +0.009 +0.055 +0.055 Standard 0.141 0.425 0.130 0.390 0.129 0.391 0.085 0.492 0.051 0.469 0.6 0.052 0.481 0.137 0.421 0.141 0.425 0.129 0.391 0.051 0.469 Standard clearance 0.025 0.063 0.016 0.084 Repair limit 0.4 0.4 0.4 0.4 0.4 Replace thrust bearing Clearance limit 0.20 0.20 Replace bushing Replace Repair limit Remedy
Standard size 56 56
2 3
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Valve system
38
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1. 2. 3. 4. 5. 6. 7. 8.
Cam gear Thrust plate Camshaft Cam follower Cam roller Rocker arm shaft Cam follower shaft Rocker arm adjustment screw 9. Locknut 10. Push rod 11. Rocker arm
12. Crosshead adjustment screw 13. Locknut 14. Crosshead 15. Valve guide 16. Exhaust valve 17. Valve spring (Outer) 18. Valve spring (Inner) 19. Spring seat 20. Valve retainer 21. Intake valve 22. Cam roller pin
Valve timing
Specifications Camshaft Drawn steel bar (Machining) Journal and cam sections: Induction hardening
12V140E-3 Series
39
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40
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Unit: mm No. 1 Check item Valve Sinking distance of valve Intake Exhaust Valve 2 Thickness of valve lip Intake Exhaust Valve 3 Valve seat angle Intake Exhaust Outside diameter of valve stem Intake Exhaust Before head is press fitted Inside diameter of valve guide 0 0 2.4 2.15 Standard size 30 45 10 10 10 Standard size 4 After head is press fitted Criteria Standard size Tolerance 0.10 0.10 Standard size Repair limit 0.70 0.70 Repair limit 1.9 1.75 Tolerance 15' 15' 0.045 0.060 0.074 0.089 +0.019 +0.001 Tolerance Press Not press Replace valve guide fitted fitted portion portion +0.008 0.009 Clearance between valve guide and stem Bend of valve stem 5 Driving height of valve guide Valve Intake Exhaust Standard 22.0 Spring Free length of valve spring Outer Inner Spring 6 Installed load of valve spring Outer Inner Perpendicularity of valve spring Installed length 51.0 46.0 Standard size 81.7 72.0 Standard clearance 0.034 0.071 0.063 0.100 +0.011 0.009 Replace valve or valve guide Replace valve Correct Correct or replace valve or valve seat Replace valve Remedy Replace valve or valve seat
Replace valve
10
Standard installed Allowable installed Replace valve load (N {kg}) load (N {kg}) spring 424.3 21.6 377.3 {43.3 2.2} 215.6 10.8 {22.0 1.1} {38.5} 192.1 {19.6}
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Unit: mm No. Check item Outside diameter of rocker arm shaft 1 Inside diameter of rocker arm bushing Clearance between rocker arm shaft and rocker arm 2 Valve clearance (When cold) Tightening torque for locknut of rocker arm adjustment screw Standard size 32.0 32.0 Standard clearance 0.0285 0.0935 Valve Intake Exhaust Target (Nm {kgm}) 58.8 {6} Standard 0.35 0.57 Criteria Tolerance 0.0065 +0.087 +0.035 Clearance limit 0.13 Tolerance 0.02 0.02 Range (Nm {kgm}) 52.9 64.7 {5.4 6.6} Tighten Adjust Remedy Replace rocker arm shaft Replace rocker arm Replace rocker arm shaft or rocker arm
42
12V140E-3 Series
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Unit: mm No. 1 Check item Depth of crosshead stem receiver Inside diameter of crosshead Outside diameter of crosshead guide Projection of crosshead guide Standard size 6.2 11.04 11 49.0 Criteria Tolerance +0.3 +0.3 0.02 +0.011 +0.011 0.25 Repair limit 6.61 11.17 10.95 Correct Replace Remedy
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43
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ENGINE
1SHOP MANUAL
12V140E-3 Series
Lubrication system .......................................................................................................................................... 4 Lubrication system diagram .................................................................................................................. 4 Oil pump ............................................................................................................................................... 6 Oil cooler............................................................................................................................................... 7 Oil filter.................................................................................................................................................. 8 Main relief valve.................................................................................................................................... 9 Oil cooler bypass valve and regulator valve ....................................................................................... 10 Fuel system................................................................................................................................................... 12 CRI system diagram ........................................................................................................................... 12 Outline of CRI system ......................................................................................................................... 14 Fuel piping .......................................................................................................................................... 32
12V140E-3 Series
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Fuel filter ............................................................................................................................................. 37 Priming pump...................................................................................................................................... 39 Cooling system.............................................................................................................................................. 40 Cooling system diagram ..................................................................................................................... 40 Water pump ........................................................................................................................................ 42 Thermostat .......................................................................................................................................... 44 Corrosion resistor................................................................................................................................ 45 Cooling fan drive ................................................................................................................................. 47 Electrical equipment...................................................................................................................................... 50 Alternator ............................................................................................................................................ 50 Starting motor...................................................................................................................................... 52 Starting aid .......................................................................................................................................... 54 Engine controller ................................................................................................................................. 55
12V140E-3 Series
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Lubrication system
Lubrication system diagram
1
1
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W: Coolant 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Oil pan Strainer Oil pump (Triple gear pump) Main relief valve Oil cooler Regulator valve Oil cooler bypass valve Oil filter Oil filter safety valve Main gallery Crankshaft Camshaft Rocker arm Cam follower Intake valve and exhaust valve Piston Piston cooling nozzle Timing gear Turbocharger Fuel supply pump
12V140E-3 Series
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Oil pump
A: B: 1. 2. 3. 4. 5.
From oil pan To oil cooler Pump body Pump drive gear (Number of teeth: 27) Drive gear Driven gear Pump cover
Specifications Oil pump Type: Gear pump Revolving speed: Engine speed x 1.67
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Oil cooler
A: Oil inlet and outlet port (Flow is reversed depending on front and rear oil cooler) B: Oil inlet and outlet port (Flow is reversed depending on front and rear oil cooler) C: Coolant 1. 2. Oil cooler cover Cooler element
Specifications Oil cooler Heat dissipation surface area: 0.986 m2 Element: 12 stages
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Oil filter
A: B: 1. 2. 3.
Oil inlet port Oil outlet port Safety valve Filter head Cartridge
Specifications Oil filter Filtration area: 1.62 m2(0.42 m2 x 4) Rated flow: 330l/min Safety valve Cracking pressure: 196 20 kPa {2.0 0.2 kg/cm2}
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1. 2. 3.
Specifications Main relief valve Cracking pressure: 1,196 49 kPa {12.2 0.5 kg/cm2}
Unit: mm
No.
Check item
Criteria Tolerance Standard size Outside diam- Inside diameeter of valve ter of body 33 Free length 75.8 0.040 0.060 Installed length 59.8 0.016 0.016 Standard clearance 0.040 0.076
Remedy
Installed load Allowable load (N {kg}) (N {kg}) Replace spring 621 {63.4} 353 {36} Correct or replace spring
12V140E-3 Series
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A: B: C: D: 1. 2. 3. 4. 5.
From main gallery From oil cooler To oil pan To oil filter Oil cooler bypass valve Bypass valve spring Regulator valve Regulator valve spring Valve body
Specifications Oil cooler bypass valve Cracking pressure (differential pressure): 392 20 kPa {4.0 0.2 kg/cm2} Regulator valve Cracking pressure: 402 49 kPa {4.1 0.5 kg/cm2}
10
12V140E-3 Series
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Unit: mm No. Check item Criteria Tolerance Standard size Outside diam- Inside diameeter of valve ter of body 22 Free length 111.5 3 Cracking pressure of regulator valve 0.020 0.041 Installed length 75 +0.033 +0.033 Standard clearance 0.020 0.074 Remedy
Installed load Allowable load (N {kg}) (N {kg}) Replace spring 136.0 {13.87} 239 {24.4} Correct or replace spring
Standard: 402 49 kPa {4.1 0.5 kg/cm2} Tolerance Standard size Outside diam- Inside diameeter of valve ter of body 28 Free length 125.8 0.020 0.053 Installed length 89.8 +0.033 +0.033 Installed load (N {kg}) 186 {19} Standard clearance 0.020 0.086 Allowable load
Oil cooler bypass valve spring Cracking pressure of oil cooler bypass valve
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11
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Fuel system
CRI system diagram
1
1
12
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NE speed sensor Engine controller Injector Fuel tank Pre-fuel filter Main fuel filter Overflow valve Fuel supply pump assembly PCV High-pressure pump Feed pump Relief valve G speed sensor Common rail Flow damper Pressure limiter High-pressure injection pipe Priming pump (Main)
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1
1. Fuel system
The fuel system distributes the high-pressure fuel generated by the fuel supply pump to the cylinders through the common rail. The solenoid valve in the injector opens and closes the nozzle needle valve to start and finish fuel injection.
14
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2. Control system
To the ECU (engine control unit), the signals are sent from the sensors installed to the machine. Based on the signals, the ECU calculates and controls the energizing timing and energizing period of the injector to injecta proper quantity of fuel in proper timing. The control system is roughly divided by the electric parts into the sensors, computer, and actuators.
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The CRI system consists of fuel supply pump, common rail, injector, ECU which controls these 3 units, and sensors. The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump. The fuel discharge rate is controlled by turning on and off the PCV (Fuel injection pressure control valve) of the fuel supply pump according to the electric signals from the ECU. The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders. The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail. A feedback control is applied so that the actual fuel pressure will match to the command pressure set according to the engine speed and the load on the engine. The fuel pressure in the common rail is applied to the nozzle side of the injector and to the control chamber through the fuel injection pipe of each cylinder. The injector controls the fuel injection rate and fuel injection timing by turning ON and OFF the TWV (2-way solenoid valve).
If the TWV is turned ON (energized), the fuel circuit is changed so that the high-pressure fuel in the control chamber will flow through the orifice. As a result, the needle valve is raised to start fuel injection by the nozzle cracking pressure of the high-pressure fuel on the nozzle side. If the TWV is turned OFF (de-energized), the fuel circuit is changed so that the high-pressure fuel will flow to the control chamber through the orifice. As a result, the needle valve lowers to finish fuel injection. Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn on the TWV and the length of the turn-on time of the TWV.
16
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1. 2. 3. 4. 5.
3-thread type cam Overflow valve Drive gear No. 1 high-pressure pump PCV (Fuel injection pressure control valve)
6. 7. 8. 9.
No. 2 high-pressure pump Priming pump Feed pump Gear for G speed sensor Since the number of the times of feeding fuel to the common rail is the same as the number of the times of fuel injection, the common rail fuel pressure is smooth and stable. The fuel fed by high-pressure pumps (4) and (6) to the common rail is divided as follows. No. 1 high-pressure pump (on the drive gear side) (4) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 1, 3, and 5 cylinders. No. 2 high-pressure pump (on the feed pump side) (6) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 2, 4, and 6 cylinders.
Outline q The fuel supply pump consists of priming pump (7), feed pump (8), and high-pressure pumps (4) and (6). q The function of the fuel supply pump is to generate common rail fuel pressure by controlling the fuel discharge rate. Structure High-pressure pumps (4) and (6) have the pressure feed systems similar to those of the conventional in-line fuel injection pump and the PCVs (Fuel injection pressure control valves) for each cylinder to control the fuel delivery. q By employing the 3-head cam, the necessary number of the cylinders of high-pressure pumps (4) and (6) is reduced to 1/3 of the engine cylinders.
q
q q
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Operation
(A): The PCV is open when the plunger is in lowering stroke, through which low-pressure fuel is sucked in the plunger chamber. (B): While the PCV is not energized and is open after the plunger starts the rising stroke, the sucked fuel is returned through the PCV without being pressurized. (C): If the PCV is energized and closed in the timing for the necessary delivery, the return passage is closed and the pressure in the plunger chamber rises. Accordingly, the fuel is fed through the delivery valve (check valve) to the common rail. That is, the quantity of the fuel corresponding to the plunger lift after the PCV is closed is delivery. The delivery is changed and the common rail fuel pressure is controlled by changing the opening timing of the PCV. (pre-stroke of plunger) (D): After the cam passes the maximum lift point, the plunger starts the lowering stroke and the pressure in it lowers. At this time, the delivery valve closes to stop feeding the fuel. Since the PCV is de-energized, it opens and the low-pressure fuel is sucked in the plunger chamber, or the state of (A) starts again.
18
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2) Feed pump
q q
The PCV adjusts the fuel delivery from the fuel supply pump to adjust the common rail fuel pressure. It means that the delivery from the fuel supply pump to the common rail is decided by the timing of energizing the PCV.
q q
The feed pump built in the fuel supply pump assembly draws the fuel from the fuel tank and sends it through the fuel filter to the high-pressure pump chamber. The outer and inner rotors of the feed pump are rotated by the camshaft. The fuel is sucked in on the suction side and discharged on the delivery side according to the increase and decrease of the spaces between the outer and inner rotors.
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2. Common rail
Structure q Common rail (4) distributes the high-pressure fuel from the high-pressure pump to the injectors of the cylinders. q Common rail (4) is equipped with common rail fuel pressure sensor (2), flow dampers (1), and pressure limiter (3). q The fuel injection pipes are connected to flow dampers (1) to send the high-pressure fuel to the injectors. q The piping of the pressure limiter (3) is returned to the fuel tank.
1)
Flow damper
Function The flow dampers damp the pressure pulses in the high pressure piping and supply the fuel to the injectors with stable pressure. q If excessive fuel flows out, the flow dampers block the fuel passage to prevent abnormal outflow of the fuel. q If the fuel flows out abnormally, high pressure is applied to the piston, which moves to the right until it reaches the seat to stop the fuel.
q
2)
q
Pressure limiter If abnormally high pressure is generated, the pressure limiter opens to release that pressure. If the common rail fuel pressure reaches about 140 MPa {1,430 kg/cm2}, the pressure limiter operates (Opens). If the common rail fuel pressure lowers to 30 MPa {310 kg/cm2}, the pressure limiter resets itself (close) to maintain the pressure.
20
12V140E-3 Series
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3)
q
Common rail fuel pressure sensor The common rail fuel pressure sensor is installed to the common rail to sense the fuel pressure. This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the electric resistance of silicon changes according to the pressure applied to it.
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3. Injector
Outline q The function of the injector is to inject the high pressure fuel from the common rail into each combustion chamber of the engine in the optimum timing, by the optimum quantity, at the optimum injection rate, and under the optimum spray condition. q The TWV (2-way solenoid valve) controls the start and finish of fuel injection by controlling the pressure in the control chamber. q The orifice limits the opening speed of the nozzle and controls the fuel injection rate. q The hydraulic piston transmits the force generated by the pressure in the control chamber to the needle valve of the nozzle. q The nozzle sprays the fuel.
22
12V140E-3 Series
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Structure
1. 2. 3. 4. 5. 6.
q
Inlet connector Terminal Upper body Solenoid Valve body Orifice (out) The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic piston section, and 2-way solenoid valve section.
Orifice (in) Pressure control chamber Command piston Spring Pressure pin Nozzle assembly
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A: B: 1. 2. 3. 4.
No fuel injection Start of fuel injection Nozzle Control piston Orifice (in) Orifice (out)
C: D: 5. 6. 7. 8.
Finish of fuel injection From common rail Valve body Solenoid Spring Pressure control chamber
Operation 1)
q q
No fuel injection (A) While solenoid (6) is not energized, valve body (5) is pressed down by spring (7). Since the high-pressure fuel is applied from the common rail to pressure control chamber (8), nozzle (1) is closed and the fuel is not injected. Start of fuel injection (B) If solenoid (6) is energized, valve body (5) is raised by electromagnetic power to open the fuel passage. Since the fuel in pressure control chamber (8) flows out through orifices (3) and (4), nozzle (1) rises and the fuel injection pump starts. The fuel injection rate is increased gradually by the function of orifices (3) and (4). Continuing energization to solenoid (6) provides the maximum fuel injection rate.
3)
q
Finish of fuel injection (C) If solenoid (6) is de-energized, valve body (5) is lowered by spring (7) and the fuel passage is closed. Since the high-pressure fuel in the common rail is applied to pressure control chamber (8) suddenly at this time, nozzle (1) is closed quickly and fuel injection is finished sharply.
2)
q
q q
24
12V140E-3 Series
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Since high voltage (65V) is applied to the wiring harnesses connected to the ECU, COMMON1 and COMMON2 of ECU, and TWV#1 #6 of the injector, take care not to get an electric shock.
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Fuel temperature sensor The fuel temperature sensor senses the fuel temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
2)
q q
NE speed sensor (Crank angle sensor) If the signal hole made on the flywheel passes the sensor, the magnetic line of force changes. If the magnetic line of force changes, the output of the hall element sensor changes linearly and it is converted into pulse of 0 - 5 V by the wave form shaping circuit in the sensor, and then output.
26
12V140E-3 Series
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3)
q
4) 5)
A: B:
Pressure inlet Mounting screw: M5 Tightening torque: 4.5 0.5 Nm {0.46 0.05 kgm} The following graph shows the output characteristics of the atmospheric pressure sensor.
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6)
q
Bkup speed sensor (G sensor) (Cylinder No. sensor) Similarly to the NE speed sensor, this sensor utilizes the pulses of 0 5 V generated by the change of the magnetic line of force crossing the sensor unit. The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts) around it at intervals of 120. In addition to the above teeth, one more tooth is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine. The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and Bkup speed sensor pulse.
7)
q
Charge pressure sensor This sensor is used to sense the charge pressure (boost pressure).
A:
Mounting screw: M6 Tightening torque: 5.5 0.5 Nm {0.56 0.05 kgm} Sensor O-ring The following graph shows the output characteristics of the charge pressure sensor.
1. 2.
q
28
12V140E-3 Series
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8)
q
Charge temperature sensor The charge temperature sensor senses the intake air temperature (boost temperature) and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
9)
q
Coolant temperature sensor The coolant temperature sensor senses the coolant temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.
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Various controls
30
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The CRI system controls the fuel injection rate and fuel injection timing more properly than the mechanical governor or timer of the conventional fuel injection pump. For the control of the system, calculations necessary to the ECU are performed from the signals sent from the sensors installed to the engine and machine. The energizing timing and energizing period of the injector are so controlled that the optimum quantity of fuel will be injected in the optimum timing.
The fuel injection rate control function is employed instead of the function of the conventional governor. It controls the fuel injection according to the signals of engine speed and accelerator angle so that the fuel injection rate will be most proper.
The fuel injection timing control function is employed instead of the function of the conventional timer. It controls the fuel injection timing most properly from the engine speed and fuel injection rate.
3. Fuel injection pressure control function (Common rail fuel pressure control function)
q
The fuel injection control function (common rail fuel pressure control function) controls the fuel discharge rate of the fuel supply pump by measuring the fuel pressure by the common rail fuel pressure sensor and feeding it back to ECU. This function performs pressure feedback control so that the fuel injection pressure will be the same as the optimum value (command value) set according to the engine speed and fuel injection rate.
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Fuel piping
Left bank
a a 1. 2. 3. 4. 5. 6.
The shape is subject to machine models. The illustration shows the engine for D475A-5E0. Main fuel filter Pre-fuel filter Priming pump (Main) Fuel pipe (From pre-fuel filter) Fuel pipe (To feed pump) Drain pipe
32
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The shape is subject to machine models. PCV Fuel injection pipe (No.1 cylinder) Fuel injection pipe (No.2 cylinder) Fuel injection pipe (No.3 cylinder) Fuel injection pipe (No.4 cylinder) Fuel injection pipe (No.5 cylinder) 13. 14. 15. 16. 17. 18. Fuel injection pipe (No.6 cylinder) Common rail Fuel return pipe Feed pump Oil pump (For pump lubricating oil) High-pressure pump
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Right bank
a a 1. 2. 3.
The shape is subject to machine models. The illustration shows the engine for D475A-5E0. Fuel pipe (To feed pump) Fuel pipe (From pre-fuel filter) Priming pump (Main)
34
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4. 5. 6. 7. 8. 9.
Fuel injection pipe (No.6 cylinder) Fuel injection pipe (No.5 cylinder) Fuel injection pipe (No.4 cylinder) Fuel injection pipe (No.3 cylinder) Fuel injection pipe (No.2 cylinder) Fuel injection pipe (No.1 cylinder)
PCV High-pressure pump Feed pump Oil pump (For pump lubricating oil) Fuel return pipe Common rail
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35
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36
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Fuel filter
a A: B: 1. 2. 3.
The shape is subject to machine models. Fuel inlet Fuel outlet Air bleeding plug Filter head Cartridge
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37
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Pre-fuel filter
a A: B: 1. 2. 3.
The shape is subject to machine models. Fuel inlet Fuel outlet Air bleeding plug Filter head Cartridge
38
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Priming pump
1. 2. 3. 4. 5. 6. 7. 8.
Spring Cover Shaft Bushing Diaphragm Diaphragm cover Body Check valve
Valve stopper Packing Check valve body Lever pin E-ring Washer Bolt Lever
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Cooling system
Cooling system diagram
1
1
40
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A: 1. 2.
Lubricating oil
Radiator Cooling fan 2A. Hydraulic fan motor 3. Water pump 4. Oil cooler (For engine) 5. Corrosion resistor 6. Thermostat housing 7. Oil cooler (For power train) 8. Oil cooler bypass circuit (For power train) 9. Air bleeding 10. Turbocharger
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41
SEN00309-02
Water pump
A: B: C: 1. 2. 3. 4. 5. 6. 7. 8.
From thermostat (Coolant) From radiator (Coolant inlet) To oil cooler (Coolant outlet) Pump shaft Water seal Pump body Water pump drive gear (Number of teeth: 25) Ball bearing Oil seal Impeller Pump cover
Specifications Water pump Type: Centrifugal, gear-driven Revolving speed: Engine speed x 1.80
42
12V140E-3 Series
SEN00309-02
a A. B: C: 1. 2. 3.
The shape is subject to machine models. To radiator inlet (Coolant) From power train cooler (Coolant) To power train oil cooler (Coolant) Oil cooler Thermostat housing Water pump
12V140E-3 Series
43
SEN00309-02
Thermostat
A: B: C: 1. 2. 3.
To radiator To water pump (When bypassing) To thermostat Thermostat housing Thermostat Cylinder block
Specifications Valve cracking temperature: 76.5 2C Temperature at full opening: 90C Lift at full opening: Min. 10 mm Q'ty: 3
Unit: mm No. Check item Lift of thermostat at full opening 2 Opening/Closing of thermostat Criteria Min. 10 mm (Before checking, leave it in water tank of 90C for 4 5 minutes) Move valve in fully open condition (in water tank of 90C) to water tank of 71C and keep it for 4 -5 minutes. Valve must fully close. Replace Remedy
44
12V140E-3 Series
SEN00309-02
Corrosion resistor
A: B: 1. 2. 3. 4.
Coolant inlet Coolant outlet Head Element case (Cartridge) Inhibitor (Solid anti-corrosion agent) Valve
Specifications Corrosion resistor Filtration area: 0.373 m2x 2 Quantity of anti-corrosion agent: 1,000 g x 2
12V140E-3 Series
45
SEN00309-02
a 1. 2. 3. 4.
The shape is subject to machine models. Tube (To radiator) Tube (From thermostat housing) Corrosion resistor head Corrosion resistor cartridge
46
12V140E-3 Series
SEN00309-02
a 1. 2. 3. 4. 5. 6. 7.
The shape is subject to machine models. Crankshaft pulley Fan belt Tension pulley Adjustment bolt Tension pulley bracket Fan pulley Fan
12V140E-3 Series
47
SEN00309-02
a 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
The shape is subject to machine models. Tension shaft Spring Roller bearing Tension bracket Spacer Tension pulley (outside diameter: 154 mm) Ball bearing Oil seal Grease fitting Grease fitting
48
12V140E-3 Series
SEN00309-02
(For D475A-5E0, PC2000-8) The cooling fan is hydraulic motor-driven. For more information, refer to the shop manual for the machine body.
12V140E-3 Series
49
SEN00309-02
Electrical equipment
Alternator
Alternator with built-in regulator (Open type, 90A)
1
1
a 1. 2. 3. 4. 5.
The shape is subject to machine models. Alternator Alternator pulley Terminal B Terminal R Terminal E 6. Internal connection diagram 6A. Field coil 6B. Initial excitation resistor 6C. Regulator
Engine
Machine model
Type
Weight (kg)
D475A-5E0 HD785-7 Open type (brushless) manuSAA12V140E-3 PC2000-8 factured by NIKKO DENKI WA800-3E0, WA900-3E0
19
50
12V140E-3 Series
SEN00309-02
Alternator mounting
a a: 1. 2. 3. 4. 5.
The shape is subject to machine models. Outside diameter of accessory pulley: 167 mm Adjustment bolt Alternator pulley Alternator Alternator drive belt Accessory pulley
12V140E-3 Series
51
SEN00309-02
Starting motor
For 7.5 kW
a E: R: S: 1. 2. 3. 4. 5.
The shape is subject to machine models. To chassis ground To alternator terminal R To starting switch terminal C Pinion gear Starting motor assembly Magnetic switch Terminal B Terminal C 6. 7. Safety relay External connection diagram (2-pole connector type) 7A. Safety relay section 7B. Starting motor section
Engine
Machine model
Type
Specifications
D475A-5E0 Water-resistant, oil-resistant SAA12V140E-3 HD785-7 type manufactured by NIKKO 24V, 7.5 kW WA800-3E0, WA900-3E0 DENKI
52
12V140E-3 Series
SEN00309-02
For 11 kW
a E: R: S: 1. 2. 3. 4. 5. 6.
The shape is subject to machine models. To chassis ground To alternator terminal R To starting switch terminal C Pinion gear Starting motor assembly Magnetic switch Terminal B Terminal C Safety relay 7. External connection diagram (2-pole connector type) 7A. Safety relay section 7B. Starting motor section Jump start prohibition label Jump start prevention cover
8. 9.
Engine SAA12V140E-3
Specifications 24V, 11 kW
Weight (kg) 18
Type of connector DT
12V140E-3 Series
53
SEN00309-02
Starting aid
Electric heater
a 1. 2. 3. 4.
The shape is subject to machine models. Body Heater coil Terminal Connection diagram Specifications Type of heater: Electrical intake air heater Rated voltage: 22 V (DC) Load current: 175 A
54
12V140E-3 Series
SEN00309-02
Engine controller
Features Mounting of engine controller on engine q Since the engine controller is mounted on the engine, the operator can service it easily in the field. q Vibrations are damped by the vibration-proof rubber. Unified specifications of engine controller Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is employed.
12V140E-3 Series
55
SEN00309-02
56
12V140E-3 Series
SEN00311-03
ENGINE
1SHOP MANUAL
12V140E-3 Series
Standard service value table ........................................................................................................................... 2 Standard service value table for testing, adjusting, and troubleshooting ............................................. 2 Running-in standard and performance test standard ........................................................................... 7
12V140E-3 Series
SEN00311-03
Performance
Speed Necessary speed for starting Air intake resistance Air boost pressure Exhaust pressure Exhaust temperature
2,150 (+25/-50) 2,150 (+25/-50) 660 40 Min. 110 Min. 100 Max. 3.73 {Max. 380} Min. 126.66 {Min. 950} Max. 680 Max. 4.5 Max. 1.0 Max. 1.0 0.35 0.02 0.57 0.02 Min. 4.1 {Min. 42} Max. 2.94 {Max. 300} 0.29 0.44 {3.0 4.5} Min. 0.08 {Min. 0.8} 90 110 0.15 Hydraulically driven on machine side 20 660 40 7.47 {762} 750 5.5 2.0 2.0 0.35 0.02 0.57 0.02 2.8 {29} 5.88 {600} 0.2 {2.0} 0.04 {0.4} 120 0.3 Hydraulically driven on machine side 20
Lubrication system
Body
Oil temperature Whole speed range (Oil in oil pan) Oil consumption Function of radiator pressure valve Fan speed Alternator belt tension Ratio to fuel consumption at continuous rated output Cracking pressure (Differential pressure)
Cooling system
12V140E-3 Series
SEN00311-03
Engine Machine model Category Item Measurement conditions Max. speed at no load Min. speed at no load At 0C (without starting aid) At 20C (with starting aid) Whole speed range At rated output At rated output Whole speed range (20C ) At sudden acceleration (Low to High) Exhaust gas color At rated output At high idle Valve clearance Compression pressure Blow-by pressure Intake valve Exhaust valve Engine oil temperature: 40 60C Engine speed: 200 250 rpm At rated output Engine coolant temperature: Min. 70C At rated output Engine oil temperature: Min. 80C Oil pressure At low idle Engine oil temperature: Min. 80C SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH Unit rpm rpm rpm rpm kPa {mmH2O} kPa {mmHg} kPa {mmHg} C Bosch index Bosch index Bosch index mm mm MPa {kg/cm2} kPa {mmH2O} MPa {kg/cm2} MPa {kg/cm2} C % kPa {kg/cm2} rpm mm
SAA12V140E-3 HD785-7 Standard value for new machine 2,250 25 650 20 Min. 110 Min. 100 Max. 3.73 {Max. 380} Min. 165.40 {Min. 1,250} Max. 700 Max. 4.5 Max. 1.0 Max. 1.0 0.35 0.02 0.57 0.02 Min. 4.1 {Min. 42} Max. 2.94 {Max. 300} 0.29 0.44 {3.0 4.5} Min. 0.08 {Min. 0.8} 90 110 0.15 Service limit value 2,250 25 650 20 7.47 {762} 750 5.5 2.0 2.0 0.35 0.02 0.57 0.02 2.8 {29} 5.88 {600} 0.2 {2.0} 0.04 {0.4} 120 0.3
Speed Necessary speed for starting Air intake resistance Air boost pressure Exhaust pressure Exhaust temperature
Oil temperature Whole speed range (Oil in oil pan) Oil consumption Function of radiator pressure valve Fan speed Alternator belt tension Ratio to fuel consumption at continuous rated output Cracking pressure (Differential pressure)
Cooling system
860 20
860 20
12V140E-3 Series
SEN00311-03
Engine Machine model Category Item Measurement conditions Max. speed at no load Min. speed at no load At 0C (without starting aid) At 20C (with starting aid) Whole speed range At rated output At rated output Whole speed range (20C ) At sudden acceleration (Low to High) Exhaust gas color At rated output At high idle Valve clearance Compression pressure Blow-by pressure Intake valve Exhaust valve Engine oil temperature: 40 60C Engine speed: 200 250 rpm At rated output Engine coolant temperature: Min. 70C At rated output Engine oil temperature: Min. 80C Oil pressure At low idle Engine oil temperature: Min. 80C SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH Unit rpm rpm rpm rpm kPa {mmH2O} kPa {mmHg} kPa {mmHg} C Bosch index Bosch index Bosch index mm mm MPa {kg/cm2} kPa {mmH2O} MPa {kg/cm2} MPa {kg/cm2} C % kPa {kg/cm2} rpm mm
SAA12V140E-3 PC2000-8 Standard value for new machine 1,980 25 825 25 Min. 110 Min. 100 Max. 3.73 {Max. 380} Min. 125.70 {Min. 950} Max. 700 Max. 4.5 Max. 1.0 Max. 1.0 0.35 0.02 0.57 0.02 Min. 4.1 {Min. 42} Max. 2.94 {Max. 300} 0.29 0.44 {3.0 4.5} Min. 0.08 {Min. 0.8} 90 110 0.15 Hydraulically driven on machine side 20 Service limit value 1,980 25 825 25 7.47 {762} 750 5.5 2.0 2.0 0.35 0.02 0.57 0.02 2.8 {29} 5.88 {600} 0.2 {2.0} 0.06 {0.6} 120 0.3 Hydraulically driven on machine side 20
Speed Necessary speed for starting Air intake resistance Air boost pressure Exhaust pressure Exhaust temperature
Oil temperature Whole speed range (Oil in oil pan) Oil consumption Function of radiator pressure valve Fan speed Alternator belt tension Ratio to fuel consumption at continuous rated output Cracking pressure (Differential pressure)
Cooling system
12V140E-3 Series
SEN00311-03
Engine Machine model Category Item Measurement conditions Max. speed at no load Min. speed at no load At 0C (without starting aid) At 20C (with starting aid) Whole speed range At rated output At rated output Whole speed range (20C ) At sudden acceleration (Low to High) Exhaust gas color At rated output At high idle Valve clearance Compression pressure Blow-by pressure Intake valve Exhaust valve Engine oil temperature: 40 60C Engine speed: 200 250 rpm At rated output Engine coolant temperature: Min. 70C At rated output Engine oil temperature: Min. 80C Oil pressure At low idle Engine oil temperature: Min. 80C SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH Unit rpm rpm rpm rpm kPa {mmH2O} kPa {mmHg} kPa {mmHg} C Bosch index Bosch index Bosch index mm mm MPa {kg/cm2} kPa {mmH2O} MPa {kg/cm2} MPa {kg/cm2} C % kPa {kg/cm2} rpm mm
SAA12V140E-3 WA800-3E0 Standard value for new machine Service limit value
Performance
Speed Necessary speed for starting Air intake resistance Air boost pressure Exhaust pressure Exhaust temperature
2,200 (+10/-20) 2,200 (+10/-20) 680 (+50/0) Min. 110 Min. 100 Max. 3.73 {Max. 380} Min. 125.70 {Min. 950} Max. 680 Max. 4.5 Max. 1.0 Max. 1.0 0.35 0.02 0.57 0.02 Min. 4.1 {Min. 42} Max. 2.94 {Max. 300} 0.29 0.44 {3.0 4.5} Min. 0.08 {Min. 0.8} 90 110 0.15 680 (+50/0) 7.47 {762} 750 5.5 2.0 2.0 0.35 0.02 0.57 0.02 2.8 {29} 5.88 {600} 0.2 {2.0} 0.04 {0.4} 120 0.3
Lubrication system
Body
Oil temperature Whole speed range (Oil in oil pan) Oil consumption Function of radiator pressure valve Fan speed Alternator belt tension Ratio to fuel consumption at continuous rated output Cracking pressure (Differential pressure)
Cooling system
980 20
980 20
12V140E-3 Series
SEN00311-03
Engine Machine model Category Item Measurement conditions Max. speed at no load Min. speed at no load At 0C (without starting aid) At 20C (with starting aid) Whole speed range At rated output At rated output Whole speed range (20C ) At sudden acceleration (Low to High) Exhaust gas color At rated output At high idle Valve clearance Compression pressure Blow-by pressure Intake valve Exhaust valve Engine oil temperature: 40 60C Engine speed: 200 250 rpm At rated output Engine coolant temperature: Min. 70C At rated output Engine oil temperature: Min. 80C Oil pressure At low idle Engine oil temperature: Min. 80C SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH Unit rpm rpm rpm rpm kPa {mmH2O} kPa {mmHg} kPa {mmHg} C Bosch index Bosch index Bosch index mm mm MPa {kg/cm2} kPa {mmH2O} MPa {kg/cm2} MPa {kg/cm2} C % kPa {kg/cm2} rpm mm
SAA12V140E-3 WA900-3E0 Standard value for new machine Service limit value
Performance
Speed Necessary speed for starting Air intake resistance Air boost pressure Exhaust pressure Exhaust temperature
2,200 (+10/-20) 2,200 (+10/-20) 680 (+50/0) Min. 110 Min. 100 Max. 3.73 {Max. 380} Min. 132.30 {Min. 1,000} Max. 700 Max. 4.5 Max. 1.0 Max. 1.0 0.35 0.02 0.57 0.02 Min. 4.1 {Min. 42} Max. 2.94 {Max. 300} 0.29 0.44 {3.0 4.5} Min. 0.08 {Min. 0.8} 90 110 0.15 680 (+50/0) 7.47 {762} 750 5.5 2.0 2.0 0.35 0.02 0.57 0.02 2.8 {29} 5.88 {600} 0.2 {2.0} 0.04 {0.4} 120 0.3
Lubrication system
Body
Oil temperature Whole speed range (Oil in oil pan) Oil consumption Function of radiator pressure valve Fan speed Alternator belt tension Ratio to fuel consumption at continuous rated output Cracking pressure (Differential pressure)
Cooling system
1,005 20
1,005 20
12V140E-3 Series
SEN00311-03
a a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
671 kW/2,000 rpm 3,825 Nm/1,400 rpm 2,150(+25/-50)rpm {899 HP/2,000 rpm} {390 kgm/1,400 rpm} 2,000 5 4,341 4,596 {443 469} 651 691 {873 926} Min. 19.5 70 90 90 110 0.34 0.49 {3.0 4.5} Max. 650 1,300 1,500 5,174 5,498 {528 561} 3,704 3,940 {378 402} 70 90 90 110 Max. 680 70 90 90 110
a a a a a a a
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil. Aftercooler outlet temperature must not exceed 50C.
12V140E-3 Series
SEN00311-03
Running-in standard
Engine Machine model Item Running time Speed Dynamometer load Output min. rpm N {kg} kW {HP} 1 5 650 0 {0} 0 {0} 2 15 1,000 784 {80} 59 {79} 3 5 1,250 1,568 {160} 147 {197} SAA12V140E-3 HD785-7 Procedure 4 5 1,550 3,136 {320} 365 {489} 5 20 1,800 4,704 {480} 635 {852} 6 10 1,900 6,272 {640} 894 {1,200}
a a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
895 kW/1,900 rpm 5,076 Nm/1,350 rpm {1,200 HP/1,900 rpm} {518 kgm/1,350 rpm} 1,900 5 6,086 6,468 {621 660} 868 922 {1,160 1,240} Min. 15.2 70 90 90 110 0.34 0.49 {3.0 4.5} Max. 650 1,300 1,400 6,870 7,311 {701 746} 4,920 5,233 {502 534} 70 90 90 110 Max. 700
a a a a a a a
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil. Aftercooler outlet temperature must not exceed 50C.
12V140E-3 Series
SEN00311-03
Running-in standard
Engine Machine model Item Running time Speed Dynamometer load Output min. rpm N {kg} kW {HP} 1 5 825 0 {0} 0 {0} 2 15 1,000 676 {69} 51 {68} 3 5 1,250 1,352 {138} 127 {171} SAA12V140E-3 PC2000-8 Procedure 4 5 1,550 2,695 {275} 313 {420} 5 20 1,800 4,074 {413} 546 {733} 6 10 1,800 5,390 {550} 728 {976}
a a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
728 kW/1,800 rpm 4,488 Nm/1,350 rpm {976 HP/1,800 rpm} {458 kgm/1,350 rpm} 1,800 5 4,341 4,596 {534 567} 706 750 {947 1,010} Min. 18.6 70 90 90 110 0.34 0.49 {3.0 4.5} Max. 650 1,300 1,400 6,076 6,380 {620 659} 4,351 4,626 {444 472} 70 90 90 110 Max. 700
a a a a a a a
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil. Aftercooler outlet temperature must not exceed 50C.
12V140E-3 Series
SEN00311-03
Running-in standard
Engine Machine model Item Running time Speed Dynamometer load Output min. rpm N {kg} kW {HP} 1 5 680 0 {0} 0 {0} 2 15 1,000 529 {54} 40 {53} 3 5 1,250 1,058 {108} 99 {133} SAA12V140E-3 WA800-3E0 Procedure 4 5 1,550 2,107 {215} 245 {328} 5 20 1,800 3,156 {322} 427 {572} 6 10 2,000 4,214 {430} 633 {848}
a a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
636 kW/2,000 rpm 3,802 Nm/1,400 rpm {853 HP/2,000 rpm} {388 kgm/1,400 rpm} 2,000 5 4,116 4,371 {420 446} 617 655 {827 879} Min. 20.5 70 90 90 110 0.34 0.49 {3.0 4.5} Max. 650 1,350 1,450 5,155 5,468 {526 558} 3,685 3,920 {376 400} 70 90 90 110 Max. 680
a a a a a a a
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil. Aftercooler outlet temperature must not exceed 50C.
10
12V140E-3 Series
SEN00311-03
Running-in standard
Engine Machine model Item Running time Speed Dynamometer load Output min. rpm N {kg} kW {HP} 1 5 680 0 {0} 0 {0} 2 15 1,000 549 {56} 41 {55} 3 5 1,250 1,088 {111} 102 {137} SAA12V140E-3 WA900-3E0 Procedure 4 5 1,550 2,185 {223} 254 {341} 5 20 1,800 3,273 {334} 442 {593} 6 10 2,050 4,361 {445} 671 {899}
a a
This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
672 kW/2,050 rpm 4,159 Nm/1,300 rpm 2,200(+10/-20)rpm {900 HP/2,050 rpm} {424 kgm/1,300 rpm} 2,050 5 4,234 4,488 {432 458} 652 691 {874 927} Min. 19.5 70 90 90 110 0.34 0.49 {3.0 4.5} Max. 650 1,250 1,350 5,625 5,978 {574 610} 4,028 4,283 {411 437} 70 90 90 110 Max. 700 70 90 90 110
a a a a a a a
This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil. Aftercooler outlet temperature must not exceed 50C.
12V140E-3 Series
11
SEN00311-03
12
12V140E-3 Series
SEN00313-00
ENGINE
1SHOP MANUAL 2 3
12V140E-3 Series
Testing and adjusting ...................................................................................................................................... 3 Testing and adjusting tools list ............................................................................................................. 3 Testing air boost pressure .................................................................................................................... 5 Testing exhaust temperature................................................................................................................ 6 Adjusting valve clearance .................................................................................................................... 7 Testing compression pressure ............................................................................................................. 9 Testing blow-by pressure ....................................................................................................................11 Measuring blow-by pressure .............................................................................................................. 12 Testing oil pressure ............................................................................................................................ 13 Handling fuel system parts ................................................................................................................. 14 Releasing residual pressure in fuel system........................................................................................ 14 Testing fuel pressure .......................................................................................................................... 15 Reduced cylinder mode operation ..................................................................................................... 16 No-injection cranking.......................................................................................................................... 16 Testing leakage-from pressure limiter and return rate from injector................................................... 17 Bleeding air from fuel circuit (for D475A-5) ........................................................................................ 20
12V140E-3 Series
SEN00313-00
Bleeding air from fuel circuit (for PC2000) ......................................................................................... 23 Testing fuel system for leakage .......................................................................................................... 25 Adjusting speed sensor ...................................................................................................................... 26 Testing and adjusting alternator belt tension ...................................................................................... 26 Handling controller high-voltage circuit .............................................................................................. 27
12V140E-3 Series
SEN00313-00
1
1
Q'ty Part name Remarks
1 -101 200 kPa {-760 1,500 mmHg} 1 1 - 99.9 1,299C 1 Intake: 0.35 mm Exhaust: 0.57 mm
1 0 6.9 MPa {0 70 kg/cm2} 1 For 140E-3, 5 1 1 0 10 kPa {0 1,000 mmH2O} 2 2 1 1 Pressure gauge: 2.5, 6, 40, 60 MPa {25.5, 61.2, 408, 612 kg/cm2}
1 Pressure gauge: 60 MPa {612 kg/cm2} 1 Pressure gauge: 1 MPa {10 kg/cm2} Pressure gauge: 2.5, 6, 40, 60 MPa 1 {25.5, 61.2, 408, 612 kg/cm2} 1 Pressure gauge: 60 MPa {612 kg/cm2} 1 8 x 1.25 (male) PT1/8 (female) 1 Size: 10 x 1.25 mm 1 1 Pressure gauge: 1 MPa {10 kg/cm2} 1 14 1 10 1 Inside diameter: Approx. 11 mm 1 Inside diameter: Approx. 17 mm 1 1 1 Size: 03 1 For Ne sensor 1 For G (Bkup) sensor 1 For atmospheric pressure sensor 1 For boost pressure sensor 1 For common rail pressure sensor 1 For oil pressure sensor
07376-70315 Plug 799-601-4130 T-adapter 799-601-4330 Socket 799-601-4240 Socket 799-601-4250 Socket 799-601-9420 T-adapter 799-601-4150 T-adapter
12V140E-3 Series
SEN00313-00
Testing/Adjusting item
Symbol
Q'ty
Part name
Remarks
For boost temperature sensor For intake air sensor For coolant temperature sensor 1 For fuel temperature sensor Oil temperature sensor 1 For supply pump PCV 1 1 For injector 1 For controller (4 - pole) 1 For controller (50 - pole) 1 For controller (60 - pole) 1 For 60 - pole type 1 For 24 - pole type 1
799-601-9020 T-adapter 799-601-4260 T-adapter 799-601-4211 T-adapter 799-601-4220 T-adapter 799-601-4350 T-box 799-601-9320 T-box 799-601-9310 Plate
12V140E-3 Series
SEN00313-00
a 1.
Be careful not to touch any hot part when removing or installing the testing tools. The test point is subject to machine models. Remove air boost pressure pickup plug ((L1) on left bank or (R1) on right bank) from the bottom of the air intake connector. 4. After finishing testing, remove the testing tools and return the removed parts.
2.
Install nipple [1] of boost gauge kit A and connect it to gauge [2]. a Example of (L1) on the left bank
3.
Run the engine at the rated output and test the air boost pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
12V140E-3 Series
SEN00313-00
3.
Symbol
Run the engine and test the exhaust temperature in the whole speed range. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
a 1.
Remove and install the testing tools after the exhaust manifold temperature has lowered. The test point is subject to machine models. Remove an exhaust temperature pickup plug (1) of the subject section for measuring from the top of the exhaust manifold. a Subject section for measuring includes front left, rear left, front right and rear right (4 points in total).
4.
After finishing testing, remove the testing tools and return the removed parts.
2.
Install sensor [1] of digital thermometer B and connect it to thermometer [2]. a Installation example to the rear right-hand side (RR)
For engines mounted with the exhaust temperature sensor, connect temperature gauge [2] to the sensor on machine.
12V140E-3 Series
SEN00313-00
5.
Hereafter crank the engine similar way in the firing order. Match the stamped line of the damper to the pointer and adjust the valve clearance of each cylinder. a Firing order R1 L1 R5 L5 R3 L3 R6 L6 R2 L2 R4 L4
Valve clearance adjusting method 1. 2. Remove cylinder head cover. Rotate the crankshaft forward and match stamped line of R1.6 TOP on vibration damper (1) to pointer (2), by setting RH No. 1 cylinder to the compression top dead center while watching the movement of the intake valve of RH No. 6 cylinder. a Crank the engine using the barring tool (B) mounted to the front right-hand side of the flywheel housing. a At near the compression top dead center of the RH No. 1 cylinder, the intake valve of RH No. 6 cylinder moves.(opens).
3.
Loosen locknut (6) of RH No. 1 cylinder adjust screw (5). Insert a clearance gauge C of specified clearance between the crosshead (4) and rocker arm (3) and adjust the adjustment screw to the degree that the clearance gauge can be moved lightly. a Valve clearance Air Intake valve: 0.35 mm, Exhaust valve: 0.57 mm Tighten locknut (6) to secure adjustment screw. 3 Locknut tightening torque: 52.9 64.7 Nm {5.4 6.6 kgm} a After tightening the locknut, check the valve clearance again.
4.
12V140E-3 Series
SEN00313-00
6.
After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 14.7 34.3 Nm {1.5 3.5 kgm}
12V140E-3 Series
SEN00313-00
Symbol
When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 60C). Remove cylinder head cover (1) of the cylinder to be tested for compression pressure.
4.
1.
Install adapter D2 to the mounting hole on the injector and compression gauge D1. a Fit the gasket to the injector end without fail a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 73.5 Nm {6.0 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily. Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm assembly mounting bolt: 93 103 Nm {9.5 10.5 kgm} a See Adjusting valve clearance.
5.
2.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a See Adjusting valve clearance. Disconnect fuel high-pressure tube (3) and injector wiring harness and remove injector (4). a Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and r e mo v e t he i n j ec to r w i r i ng h a r n es s (Loosen the 2 terminal nuts alternately) from the injector. a Pass injector under the fuel path projected sideways and pull up the injector through wire (Do not pry the injector top up).
3.
6.
Connect the INSITE (bench test tool) to the engine and set the engine in the no-injection cranking mode. k If the engine is not set in the no-injection cranking mode, it will start and will be dangerous. Accordingly, be sure to set the engine in this mode.
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7.
Rotate the engine with the starting motor and measure the compression pressure. a Read the pressure gauge pointer when it is stabilized. After finishing testing, remove the testing tools and return the removed parts. a Install the injector and fuel high-pressure tube according to the following procedure. 1) Push in injector (11) with the hand to assemble holder (12) temporarily. 2) Tighten bolt (13) and washer (14) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily. 4) Tighten bolt (13) permanently. 3 Bolt: 58.8 73.5 Nm {6.0 7.5 kgm} 5) Tighten sleeve nut (15) permanently. 3 Sleeve nut: 39.2 49.0 Nm {4 5 kgm}
8.
Tighten the clamp and spacer with the bolt. 5) Install rocker arm assembly. 3 Rocker arm assembly mounting bolt: 93 103 Nm {9.5 10.5 kgm} a Adjust the valve clearance. For details, see Adjusting valve clearance. 6) Install head cover. 3 Cylinder head cover mounting bolt: 29.4 34.3 Nm {3.0 3.5 kgm}
4)
Install the injector wiring harness according to the following procedure 1) Install the injector wiring harness to the cylinder head and fix the connector side with the plate.Install O-ring (16). 2) Install cap (17) with clip on the injector side of wiring harness. Press wiring harness (18) between the injector top and cap to the injector main body without slack. 3) Tighten nut (19) on the injector side. 3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
10
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1
Q'ty 1 2 2 1
3.
Run the engine at the rated output and test the blow-by pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
a a a
The test point is subject to machine models. Measure blow-by pressure after the engine is warmed up. (Engine coolant temperature: Min. 70C) Breather is provided to each RH and LH banks. Test the breather on either one of the banks. Install adaptor [2] and nozzle [3] to the tip of each breather hose on the RH and LH. Connect tube [4] and gauge [1] to either one of the nozzles.Close the tube connecting mate of other nozzle with a piece of short cut tube, etc. 4. After finishing testing, remove the testing tools and return the removed parts.
1.
2.
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Measuring method of blow-by pressure k When measuring blow-by pressure, care should be taken not to burn yourself on the exhaust manifold or muffler or caught in a rotating part. a Measure blow-by pressure after the engine is warmed up. (Engine coolant temperature: Min. 70C) a Breather is provided to each RH and LH banks. Test the breather on either one of the banks. 1. Install adaptor and tool main body of blow-by checker to the tip of breather tube on one of the banks. 2. Install adaptor, tool main body of blow-by checker, hose and gauge to the tip of breather tube on one of the banks. 3. Run the engine at rated output and read the pressure indicated on the gauge. a In the case of actual vehicle, run the engine to full stroke and read the pressure indicated on the gauge. a If rated output or full-stroke operation is not possible, measure the blow-by in high-idling operation. In this case, approx. 80% of blow-by pressure of the rated output can be obtained. Since blow-by pressure varies sharply depending on engine condition, if measured value is judged abnormal, investigate phenomena associated with defective blow-by such as large oil consumption, abnormal exhaust color, oil degradation and earlier contamination, etc. When measuring on the LH bank, close the hose on RH bank.
12
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3.
Run the engine at the rated output and low idle and test the oil pressure. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.
a 1.
The test point is subject to machine models. Remove oil temperature sensor (1) on the LH side of the cylinder block. Keep the removed oil temperature sensor and the wiring harness connector connected.to each other. a Don't remove the oil pressure sensor from the block because the engine controller detects abnormal low pressure error of the oil pressure sensor. 4. After finishing testing, remove the testing tools and return the removed parts.
2.
Install nipples [1] and [2] of hydraulic tester F1 and connect them to hydraulic tester F2. a Since the screw size of the sensor mount is 14 x P1.5, nipple (799-101-5230) may be used.
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Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacement of fuel filter cartridge The fuel filter cartridge used must be a genuine Komatsu part. The fuel injection pump and nozzle of the common rail type fuel injection system (CRI) are consisted of more precision parts than those used for the current pumps and nozzles. This system, therefore, employs a special filter with highly efficient filtering performance to prevent mixing of foreign substances. Thus, substituting it with a non-genuine filter could cause troubles in the fuel system. It is strictly prohibited to use such part.
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump Fuel filter Supply pump High-pressure circuit: Supply pump Common rail Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
14
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3.
Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal.
Engine speed High idle Fuel pressure 0.15 0.3 MPa {1.5 3 kg/cm2}
Test only the fuel pressure in the low-pressure circuit from the feed pump through the engine controller cooler and fuel filter to the supply pump. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured. The position of the oil filler varies depending on the applicable machine. Remove air bleeder plug (1) on the top of fuel filter. 4. Since the fuel circuits on the LH and RH banks after the priming pump are independent, test each circuit. After finishing testing, remove the testing tools and return the removed parts.
1.
5.
2.
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No-injection cranking
a
1.
2.
3.
Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. q Leakage through cylinder head gasket q Defective injection q Defective piston, piston ring, or cylinder liner q Defective valve mechanism (Moving valve system) q Defect in electrical system Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a Perform the reduced cylinder mode operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see Testing method in the shop manual for the machine or INSITE (bench test tool).
No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. When a machine or engine has been stored for a long time, implementing the no-injection cranking before starting the engine lubricates the engine parts and thus prevents its seizure. Perform the no-injection operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see Testing method in the shop manual for the machine or INSITE (bench test tool).
16
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If the engine is of a type that returns the fuel spilling from the injector from the return block installed to the front of intake manifold, check the engine according to the following (the figure showing the LH bank for PC2000). Testing tools for pressure limiter leakage and injector return rate
Part No. 6151-51-8490 6141-71-1710 Commercially available Commercially available Commercially available Commercially available 07376-70315 Spacer Joint Inside diameter of the hose: Approx. 11 mm Inside diameter of the hose: Approx. 17 mm Measuring cylinder Stopwatch Plug Part name 1 2 3
Prepare an oil pan of about 20 l to receive the fuel flowing out during the test. 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.
1.
Symbol
4 5 6 7
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a a
Connect the return pipe to the fuel tank again, too. Be sure to provide a gasket to both ends of the spacer.
2.
Testing leakage from pressure limiter 1) Lay test hose H3 so that it will not slacken and put its end in the oil pan. 2) Connect INSITE (bench test tool) to the engine and set it so that it can check the engine speed. 3) Start the engine and keep its speed to 1,600 rpm with no load. 4) After the engine speed is stabilized, test the leakage in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed (rpm) 1,600 Leakage (cc/min) Max. 10
3)
4)
Insert joint H2 on common rail (3) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Connect test hose H3 to the end of joint H2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. a The above is the preparation work for testing the leakage from the pressure limiter.
5)
18
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3.
Testing return rate from injector a Keep the hose on the pressure limiter side connected and keep its end in the oil pan while testing the return rate from the injector. 1) Disconnect return hose (2) of return block (1) and connect test hose H4. a Apply plug H7 to the return hose side to stop oil, and fix it to the fuel tank. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. 2) Lay test hose H4 so that it will not slacken and put its end in the oil pan. 6) 4. After finishing testing, stop the engine.
Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts. Check the RH bank following the identical procedure.
5.
3)
4) 5)
Connect INSITE (bench test tool) to the engine and set it so that it can check the engine speed. Run the engine at the rated output. After the engine speed is stabilized, test the return rate in 1 minute with measuring cylinder H5. a You may test for 20 seconds and judge by multiplying the result by 3. a If the supply pump is not supplying fuel, the engine speed may not rise. In this case, record the engine speed, too, during the test. a If the return rate (spill) from the injector is in the following range, it is normal.
Rated output speed Limit of return rate (spill) (rpm) (cc/min) 1,600 1,700 1,800 1,900 2,000 960 1,020 1,080 1,140 1,200
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19
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a a
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. The locations of the fuel circuit parts are subject to machine models (The figure showing the LH bank for D475A-5). Remove fuel pre-filter (6) and fill it with fuel. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. a Check that the cap is fitted to part (a) (central hole) of the fuel pre-filter (6), and then add fuel through part (b) (holes around the central hole). a After filling the fuel pre-filter (6) with fuel, remove the cap from part (a). a If clean fuel is not available, do not remove the filter but fill it with the fuel by operating priming pump (3).
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.
20
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After the packing of the fuel pre-filter touches the sealing face of the filter head, tighten the fuel filter 1/2 3/4 turns.
3.
Loosen air bleed plugs (2) and (4) of the fuel main filter and operate priming pump (3). a Operate the priming pump until the fuel flows out of the hole of plug (2). When bubbles stop coming out, tighten plug (2). 3 Air bleeding plug: 2.0 3.9 Nm {0.2 0.4 kgm} Continue priming pump operation until fuel flows out of the hole of plug (4). When bubbles stop coming out, tighten plug (4). 3 Air bleeding plug: 2.0 3.9 Nm {0.2 0.4 kgm} Loosen air bleeder (5) of the fuel supply pump and operate priming pump (3) 90 100 times. a Operate the priming pump until the fuel flows out of the air bleeder and tighten the air bleeder. Then, operate the priming pump several times more until it becomes heavy. 3 Air bleeder: 4.9 6.9 Nm {0.5 0.7 kgm}
4.
5.
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21
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6.
Move over to the RH side of the engine. Loosen the air bleeder (8) of the fuel supply pump and operate priming pump (7). a Operate the priming pump until the fuel flows out of the air bleeder and the fuel is checked. Further operate the priming pump until it becomes heavy. 3 Air bleeder: 4.9 6.9 Nm {0.5 0.7 kgm} Crank the engine with the starting motor to start engine. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 3.
7.
22
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a a
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. The locations of the fuel circuit parts are subject to machine models (The figure showing the LH bank for PC2000). Remove fuel pre-filter and fill it with fuel. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. a Check that the cap is fitted to part (a) (central hole) of the fuel pre-filter, and then add fuel through part (b) (holes around the central hole). a After filling the fuel pre-filter with fuel, remove the cap from part (a). a If clean fuel is not available, do not remove the filter but fill it with the fuel by operating priming pump (3).
1.
2.
Install fuel pre-filter to the filter head. a Apply engine oil thinly over the packing on the fuel pre-filter side.
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23
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After the packing of the fuel pre-filter touches the sealing face of the filter head, tighten the fuel filter 1/2 3/4 turns.
3.
Loosen air bleed plug (2) (plug on the outlet side) of the fuel main filter and operate priming pump (3). a Operate the priming pump until the fuel flows out of the plug hole and tighten the plug after checking the fuel. 3 Air bleeding plug: 2.0 3.9 Nm {0.2 0.4 kgm} Loosen air bleeder (5) of the fuel supply pump and operate priming pump (3) 90 - 100 times. a Operate the priming pump until the fuel flows out of the air bleeder and tighten the air bleeder. Then, operate the priming pump several times more until it becomes heavy. 3 Air bleeder: 4.9 6.9 Nm {0.5 0.7 kgm} Bleed the air from the RH bank to the above procedure. Start the engine with the starting motor. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 3.
4.
5.
6.
24
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9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. Run the engine at low idle. Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. Run the engine at high idle. Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. Run the engine at high idle and load it. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the hydraulic pump.
Inspect the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. a If no fuel leakage is detected, check is completed.
1.
2.
3.
4. 5.
6. 7.
8.
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The G (Bkup) speed sensor and Ne speed sensor for the common rail fuel injection system cannot be adjusted. Adjust speed sensor (1), which detects the signal of the flywheel ring gear to use it for the electronic system on the machine side, according to the following procedure.
1.
Remove speed sensor (1) and check that its tip is free from steel chips and flaws, and then install it again temporarily. 2 Threads: Gasket sealant (LG-6) Screw in sensor (1) until its tip touches the tooth tip of flywheel ring gear (2). Return sensor (1) by 3/4 1 turn. a Clearance (a) of 1.1 1.5 mm will be made between the sensor tip and gear tooth tip. While fixing sensor (1), tighten nut (3). 3 Nut: 49 68.6 Nm {5 7 kgm}
Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1. 2. 3. Loosen nut (B) and bolt (2) alternately. Adjust belt tension using nut (A). Tighten bolt (2) to have adjust bolt (1) and plate (3) made orthogonal to each other. Tighten nut (B) to fix plate (3). a After adjusting, test the belt tension again.
2.
3.
4.
4.
26
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2.
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ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2 Points to remember when troubleshooting ........................................................................................... 2 Error codes and failure codes list ......................................................................................................... 3
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40 Troubleshooting
When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so be sure to wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative () terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and the prevent reoccurrence of the failure.When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for symptoms of any abnormality in the machine and engine. 2) Be sure to check the CHECKS BEFORE STARTING items. 3) 4) 5) 4. Check other inspection items, if necessary. Some other maintenance items can be checked externally, so check any item that is considered to be necessary. Check the controller for display of an error.
Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine or engine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of failure, then use the troubleshooting matrix to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
5.
2.
6.
3.
12V140E-3 Series
40 Troubleshooting
SEN00315-00
12V140E-3 Series
SEN00315-00
40 Troubleshooting
*1 *3: Machine monitor in KES 6 digit display INSITE error code 332 342 342 351 351 352 352 386 386 441 441 442 442 449 449 451 451 452 452 553 553 554 554 559 559 689 689 691 692 731 731 757 757 778 778 781 781 1117 1117 1257 1257 1548 1549 1551 Machine failure code CA332 CA342 CB342 CA351 CB351 CA352 CB352 CA386 CB386 CA441 CB441 CA442 CB442 CA449 CB449 CA451 CB451 CA452 CB452 CA553 CB553 CA554 CB554 CA559 CB559 CA689 CB689 CA691 CA692 CA731 CB731 CA757 CB757 CA778 CB778 CA781 CB781 CA1117 CB1117 CA1257 CB1257 CB1548 CB1549 CB1551 Failure phenomenon Injector #4 (LA/B #4) System Open/Short Error (LH bank) Caribration Code Incompatibility (LH bank) Caribration Code Incompatibility (RH bank) Inj. Drive Circuit Error (LH bank) Inj. Drive Circuit Error (RH bank) Sensor Sup. 1 Volt. Low Error (LH bank) Sensor Sup. 1 Volt. Low Error (RH bank) Sensor Sup. 1 Volt. High Error (LH bank) Sensor Sup. 1 Volt. High Error (RH bank) Battery Voltage Low Error (LH bank) Battery Voltage Low Error (RH bank) Battery Voltage High Error (LH bank) Battery Voltage High Error (RH bank) Rail Press. Very High Error (LH bank) Rail Press. Very High Error (RH bank) Rail Press. Sensor High Error (LH bank) Rail Press. Sensor High Error (RH bank) Rail Press. Sensor Low Error (LH bank) Rail Press. Sensor Low Error (RH bank) Rail Press. High Error 1 (LH bank) Rail Press. High Error 1 (RH bank) Rail Press. Sensor In Range Error (LH bank) Rail Press. Sensor In Range Error (RH bank) Rail Press. Low Error 1 (LH bank) Rail Press. Low Error 1 (RH bank) Eng. Ne Speed Sensor Error (LH bank) Eng. Ne Speed Sensor Error (RH bank) Intake Air Temp Sensor High Error (LH bank only) Intake Air Temp Sensor Low Error (LH bank only) Eng. G (Bkup) Speed Sensor Phase Error (LH bank) Eng. G (Bkup) Speed Sensor Phase Error (RH bank) All Continuous Data Lost Error (LH bank) All Continuous Data Lost Error (RH bank) Eng. G (Bkup) Speed Sensor Error (LH bank) Eng. G (Bkup) Speed Sensor Error (RH bank) Inter Multi-controller Communication Error (LH bank) Inter Multi-controller Communication Error (RH bank) Persistent Data Lost Error (LH bank) Persistent Data Lost Error (RH bank) Harness Key error (LH bank) Harness Key error (RH bank) Injector #7 (R/B #1) System Open/Short Error (RH bank) Injector #8 (R/B #2) System Open/Short Error (RH bank) Injector #10 (R/B #4) System Open/Short Error (RH bank)
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40 Troubleshooting
SEN00315-00
*1 *3: Machine monitor in KES 6 digit display INSITE error code 1552 1553 1622 1633 2185 2186 2249 2249 --*1 --*2 --*3 Machine failure code CB1552 CB1553 CB1622 CA1633 CA2185 CA2186 CA2249 CB2249 Failure phenomenon Injector #11 (R/B #5) System Open/Short Error (RH bank) Injector #12 (R/B #6) System Open/Short Error (RH bank) Injector #9 (R/B #3) System Open/Short Error (RH bank) KOMNET Data Time Error (LH bank) Throttle Sens. Sup. Volt. High Error (LH bank only) Throttle Sens. Sup. Volt. Low Error (LH bank only) Rail Press. Very Low Error (LH bank) Rail Press. Very Low Error (RH bank) Eng. Overheat (LH bank only) Eng. Oil Press. Low Speed Derate (LH bank only) Eng. Oil Press. Low Torque Derate (LH bank only)
a a
INSITE error code: An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of the failure is confirmed with the INSITE. Machine failure code: An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the failure is confirmed with the machine monitor, etc. on the machine side.
12V140E-3 Series
SEN00315-00
40 Troubleshooting
12V140E-3 Series
SEN00316-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
Troubleshooting of mechanical system (S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 3 Method of using troubleshooting charts ................................................................................................ 3 S-1 Starting performance is poor .......................................................................................................... 6 S-2 Engine does not start ..................................................................................................................... 7 S-3 Engine does not pick up smoothly ............................................................................................... 10 S-4 Engine stops during operations.....................................................................................................11 S-5 Engine does not rotate smoothly.................................................................................................. 12 S-6 Engine lacks output (or lacks power) ........................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 15 S-8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................ 16 S-9 Oil becomes contaminated quickly............................................................................................... 17 S-10 Fuel consumption is excessive .................................................................................................. 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ......................................... 19 S-12 Oil pressure drops ...................................................................................................................... 20
12V140E-3 Series
SEN00316-00
40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel)....................................................................................... 21 S-14 Coolant temperature becomes too high (overheating) ............................................................... 22 S-15 Abnormal noise is made............................................................................................................. 23 S-16 Vibration is excessive ................................................................................................................. 24
12V140E-3 Series
40 Troubleshooting
SEN00316-00
1
1
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w. E: Causes to be referred to for questions and check items Q: Causes related to questions and check items w: Causes highly probable among ones marked with Q a When narrowing the "auses", apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)
12V140E-3 Series
SEN00316-00
40 Troubleshooting
<Example of troubleshooting> Exhaust smoke is black Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].
12V140E-3 Series
40 Troubleshooting
SEN00316-00
If we look for the linkage of these three phenomena to possible causes, we find that they have causal relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
12V140E-3 Series
SEN00316-00
40 Troubleshooting
Confirm recent repair history Degree of Operated for long period machine operation Became worse gradually Starting performance Engine starts easily when warm Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed) During operation, charge level monitor indicates abnormal charge (if monitor is installed) Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly Fuel does not flow out if air bleeding plug of fuel filter is While engine is removed cranked with startIf spill hose from injector is disconnected, ing motor, little fuel spills When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive
E Q w w
E E Q Q w Q Q Q Q
Questions
w w
w w Q Q w w w
w w w E w Q Q w w w Q w w Q Q Q Q Q w Q Q Q w
Check items
Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to No-pressure feed by supply pump (*1) in Emode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 30 V between alternator terminal B and terminal E with Yes engine at low idle? None When specific gravity of electrolyte and voltage of battery are measured, they are low Replace Correct Clean Clean Remedy
q q q q q q q q q
Replace Replace Replace Replace Replace Replace Correct Clean Clean
Troubleshooting
12V140E-3 Series
Defective injector
General causes for poor starting performance are q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel (particularly during winter) q Coolant in exhaust pipe a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.
Causes
40 Troubleshooting
SEN00316-00
1
Causes
Confirm recent repair history Degree of machine opera- Operated for long period tion Condition of horn when Horn does not sound starting switch is turned Horn volume is low ON Battery electrolyte is low Battery terminal is loose When starting switch is turned ON, there is no operating sound from battery relay When starting switch is turned to START, starting pinion does not move out Speed of rotation is low When starting switch is Makes grating noise turned to START, starting Soon disengages pinion moves out, but Makes rattling noise and does not turn Inspect flywheel ring gear directly When specific gravity of electrolyte and voltage of battery are measured, they are low
Questions
E E Q w w w Q Q w w Q w Q w w Q
Carry out troubleshooting on installed machine
Check items
q q q q q q
Replace Replace Replace Replace Replace Replace Correct
Troubleshooting
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 When terminal B and terminal C of starting switch are connected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine does not start Remedy
12V140E-3 Series
a) Engine does not turn General causes why engine does not turn q Engine seized inside o See "S-4 Engine stops during operations". q Water hammer caused by coolant which entered cylinder q Defective electrical system q Problem in drive devices on applicable machine side o Troubleshoot the applicable machine side
SEN00316-00
40 Troubleshooting
b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)
Causes
Confirm recent repair history Degree of Operated for long period E E machine operation Exhaust smoke suddenly stopped coming out (when starting again) Non-specified fuel is being used w Replacement of filters not carried out according to Operation and Maintenance w Manual When fuel tank is inspected, it is found to be empty w Air breather hole of fuel tank cap is clogged Q w Rust and water are found when fuel tank is drained Q When fuel filter is removed, there is no fuel in it w Q w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q If air bleeding plug of fuel filter is removed, fuel does not flow While engine is Q Q Q out cranked with starting motor, If spill hose from injector is disconnected, little fuel spills Q When air is bled from fuel system, air comes out Inspect fuel filter directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting according to No-pressure feed by supply pump error (*1) in E-mode Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality in PCV2 (*3) in E-mode Inspect overflow valve directly Engine can be started in reduced cylinder mode Replace Correct Remedy
Questions
E w Q w w w w E E E E Q
Q Q
Q Q
Check items
Q w Q w w w w Q
q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Correct Correct Clean Add
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
12V140E-3 Series
Defective injector
40 Troubleshooting
SEN00316-00
c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel
Causes
Confirm recent repair history Degree of machine Operated for long period E E E E operation Suddenly failed to start w w Q Non-specified fuel is being used Q Q Q Q Replacement of filters not carried out according to Operation and Maintenance w w w Manual Engine oil replenished more frequently w When engine is preheated or when temperature is low, preheating monitor does not w indicate normally (if monitor is installed) Dust indicator is red (if indicator is installed) w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w w When fuel filter is removed, there is no fuel in it w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q Q Starting motor cranks engine slowly w When engine is cranked, abnormal sound is generated around cylinder head w Fuel does not flow out if air bleeding plug of fuel filter is While engine is Q Q w w removed cranked with starting motor, If spill hose from injector is disconnected, little fuel spills Q Q w When exhaust manifold is touched immediately after starting engine, temperature of w some cylinders is low Inspect air cleaner directly q Inspect dynamic valve system directly q When compression pressure is measured, it is found to be low q When air is bled from fuel system, air comes out Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to No-pressure feed by supply pump error (*1) in E-mode When injector unit is tested, spray condition is bad When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed) When starting switch is turned to HEAT, intake air heater mount does not become warm Replace Replace Replace Clean Remedy Clean
Check items
Questions
q q q q q q q q
Replace Replace Replace Replace Correct Clean Clean Clean
Troubleshooting
12V140E-3 Series
SEN00316-00
40 Troubleshooting
1
Causes
General causes why engine does not pick up smoothly q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
Defective contact of valve and valve seat
Confirm recent repair history Degree of machine operation Operated for long period Engine pick-up suddenly became worse Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Blue under light load Color of exhaust gas is Black When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, interference sound is emitted from around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive
Questions
E E w w
E Q Q
E E w w w w w Q w
w w w w w w w Q Q Q w w Q w w Q Q w w w Q w Q w w w
Check items
Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q Inspect valve clearance directly q When turbocharger is rotated by hand, it is found to be heavy q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to No-pressure feed by supply pump error (*1) in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Adjusting Replace Replace Replace Clean Clean Remedy
Troubleshooting
q q q q q
Replace Correct Correct Clean Clean
10
12V140E-3 Series
40 Troubleshooting
SEN00316-00
1
Causes Problem in drive devices on installed machine side
General causes why engine stops during operations q Seized parts inside engine q Insufficient supply of fuel q There is overheating q Problem in drive devices on applicable machine side o Troubleshoot the applicable machine side
Confirm recent repair history Degree of machine operation Questions Operated for long period Abnormal noise was heard and engine stopped sudw w w w denly Condition when engine Engine overheated and stopped stopped Engine stopped slowly Engine stopped after hunting Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Fuel level monitor indicates low level (if monitor is installed) When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Rust and water are found when fuel tank is drained Check items Metal particles are found when oil pan is drained Does not turn at all When engine is cranked by hand Turns in opposite direction Moves by amount of gear backlash Supply pump shaft does not turn Engine turns, but stops when load is applied to machine Inspect dynamic valve system directly Inspect piston and connecting rod directly Inspect crankshaft bearing directly Inspect gear train directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting according to No-pressure feed by supply pump error (*1) in E-mode Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Remedy
EE Q w Q w w Q w w Q Q Q Q Q Q Q Q Q w w w w w w w Q Q w w Q Q
w Q
w w w w w w
w w w
q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Replace Correct Clean Clean Clean Carry out troubleshooting on installed machine
Troubleshooting
Add
12V140E-3 Series
11
SEN00316-00
40 Troubleshooting
1
Causes
General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)
Check items
Confirm recent repair history Degree of machine Operated for long period operation Occurs at a certain speed range Occurs at low idle Condition of hunting Occurs even when speed is raised Occurs on slopes Replacement of filters not carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When air is bled from fuel system, air comes out Inspect feed pump gauze filter directly Inspect fuel filter and strainer directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Carry out troubleshooting according to Abnormality in engine Ne speed sensor (*1) in Emode Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*2) in Emode
E E Q w Q Q Q Q Q Q Q Q Q w Q w w w w Q Q w w Q Q q q q q q q q
Replace Replace Replace Replace Correct Correct Correct Clean
Questions
Troubleshooting
*1: Code [689/CA689] and [689/CB689] in E-mode *2: Code [778/CA778] and [778/CB778] in E-mode
Add
Remedy
12
12V140E-3 Series
Q Q Q Q
40 Troubleshooting
SEN00316-00
1
Causes
Defective fuel temperature sensor and/or wiring harness Defective boost pressure sensor and/or wiring harness
E Q Q w
E Q
E Q
E E Q Q Q Q Q Q Q Q Q Q
Questions
Suddenly Power was lost Gradually Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Color of exhaust Black gas Blue under light load When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head
Q Q Q w w w w w w w w w w Q w w Q w w q q q q q q q q q q q q q q q
Adjusting Replace Replace Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct Clean Clean Clean
Check items
High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Inspect air cleaner directly Inspect air intake piping directly When boost pressure is measured, it is found to be low When compression pressure is measured, it is found to be low Inspect valve clearance directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting according to No-pressure feed by supply pump error (*1) in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Inspect boost pressure sensor mount directly Carry out troubleshooting according to Abnormality in charge pressure sensor (*2) in E-mode Carry out troubleshooting according to Abnormality in fuel temperature sensor (*3) in E-mode Remedy
Q Q Q Q Q Q w
w Q
Troubleshooting
General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q 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 in electrical system)
12V140E-3 Series
13
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
14
12V140E-3 Series
40 Troubleshooting
SEN00316-00
1
Causes Defective coolant temperature sensor or wiring harness
Confirm recent repair history Degree of machine operation Operated for long period Suddenly became black Color of exhaust Gradually became black gas Blue under light load Non-specified fuel is being used Oil replenished more frequently Suddenly Power was lost Gradually Dust indicator is red (if indicator is installed) Muffler is crushed Air leaks between turbocharger and cylinder head, and clamp is loosened Engine is operated in low-temperature mode at normal temperature When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular Blow-by gas is excessive If spill hose from injector is disconnected, abnormally much fuel spills
E w w
E Q
E Q Q Q Q
Questions
w Q Q w w Q w Q Q w w Q Q Q Q w w w Q Q Q Q w Q Q Q w w Q Q w Q Q Q Q
Check items
Inspect air cleaner directly q When turbocharger is rotated by hand, it is fount to be heavy q When compression pressure is measured, it is found to be low q Inspect valve clearance directly q When muffler is removed, exhaust sound improves Carry out troubleshooting according to No-pressure feed by supply pump error (*1) in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinder Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting according to Abnormality in coolant temperature sensor error (*2) in E-mode Adjusting Replace Replace Correct Clean Remedy
q q q q q q q
Troubleshooting
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
General causes why exhaust smoke is black q Insufficient intake of air q Excessive injection of fuel q Defective spray condition of fuel q Improper selection of fuel q 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 in electrical system)
*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 12V140E-3 Series
15
Replace
Correct
SEN00316-00
40 Troubleshooting
Confirm recent repair history Degree of machine operOperated for long period ation Oil consumption suddenly increased Oil replenished more frequently Oil becomes contaminated quickly Outside of engine is contaminated with oil There are loose piping clamps in intake system Inside of turbocharger intake outlet pipe is contaminated with oil Inside of turbocharger exhaust outlet pipe is contaminated with oil There is oil in coolant Oil level in clutch chamber or damper chamber on the installed machine side is increasing Exhaust smoke is blue under light load Excessive Amount of blow-by gas None When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found contaminated abnormally Excessive play of turbocharger shaft Check breather and breather hose directly When compression pressure is measured, it is found to be low Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage There is external leakage of oil from engine Remedy
Questions
E E E w
E w Q Q w Q Q w w w w w
w w Q w w w Q Q w q q q q q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Correct Correct Correct Correct Correct Correct Correct Clean
Check items
w w w w
16
Troubleshooting
12V140E-3 Series
40 Troubleshooting
SEN00316-00
1
Causes
General causes why oil becomes contaminated q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load
Check items
Confirm recent repair history Degree of machine operation Operated for long period E E E Non-specified fuel is being used Q Engine oil replenished more frequently w Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is w Q installed) Metal particles are found when oil filter is drained Q Q w Inside of exhaust pipe is contaminated with oil w Engine oil temperature rises quickly w w Blue under light load Color of exhaust gas Black w Excessive Q Q w Q Amount of blow-by gas None w Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Inspect breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly Remedy
Questions
q q q q q q q
Replace Replace Replace Replace Replace Clean Clean Clean See S-7
Troubleshooting
12V140E-3 Series
17
SEN00316-00
40 Troubleshooting
1
Defective coolant temperature sensor or wiring harness
Confirm recent repair history Degree of Operated for long period machine operation More than other machines of same model Condition of fuel Gradually increased consumption Suddenly increased There is external leakage of fuel from engine Combustion is irregular Engine oil level rises and oil smells of diesel fuel When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Low idle speed is high Torque converter stall speed or hydraulic pump relief speed is high Color of exhaust Black gas White
Questions
E E Q Q Q Q w
E Q Q Q Q
w w w w Q Q Q Q Q Q Q
Check items
Remove and inspect head cover directly q Inspect feed pump oil seal directly Carry out troubleshooting according to No-pressure feed by supply pump error (*1) in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change change on some cylinders If spill hose from injector is disconnected and measured, much fuel spills Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in E-mode Confirm with INSITE or with monitoring function on installed machine side Correct Correct Remedy
Troubleshooting
q q q q q q
Replace Replace Replace Replace Correct
Correct
q
Correct
*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
18
12V140E-3 Series
40 Troubleshooting
SEN00316-00
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Broken hydraulic oil cooler or power train oil cooler on installed machine side
General causes why oil is mixed in coolant q Internal leakage in lubrication system q Internal leakage in cooling system
Causes
Confirm recent repair history Questions Degree of machine operation Oil level Operated for long period Suddenly increased Gradually increased
E Q Q Q Q Q Q w w
E Q Q w w w Q
Hard water is being used as coolant Oil level has risen and oil is milky Check items There are excessive air bubbles in radiator, coolant spurts back Hydraulic oil or power train oil on installed machine side is milky When hydraulic oil or power train oil is drained, water is found
Inspect cylinder block and liner directly Inspect cylinder liner directly Pressure-tightness test of oil cooler shows there is leakage Replace
q q q q
Replace Replace Replace Remedy Replace
12V140E-3 Series
19
SEN00316-00
40 Troubleshooting
1
Causes Defective oil pressure sensor and/or defective wiring harness
General causes why oil pressure drops q Leakage, clogging, and/or wear of lubrication system q Defective oil pressure control q Improper selection of fuel (improper viscosity) q Deterioration of oil due to overheating
Check items
Confirm recent repair history Degree of machine operation Operated for long period Oil pressure monitor indicates low oil pressure (if monitor is installed) Non-specified oil is being used Replacement of filters not carried according to Operation and Maintenance Manual Indicates pressure drop at low idling time Oil pressure Indicates pressure drop at low and high idling times monitor Indicates pressure drop on slopes (if installed) Indicates pressure drop occasionally Oil level monitor indicates oil level drop (if monitor is installed) Oil level in oil pan is low External hydraulic piping is leaking or crushed Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained Metal particles are found when oil filter is drained
Questions
E Q w Q w w w
Q w Q w Q w w w Q w Q Q w w w
w w
Metal particles are found in oil filter q Inspect oil pan strainer and pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of oil pump relief valve are fatigued and damaged Inspect oil filter directly Carry out troubleshooting according to Abnormality in oil pressure sensor (*1) in E-mode If oil level sensor is replaced, oil level monitor indicates normally Clean Remedy
Troubleshooting
q q
See S-13
q q q q q
Adjusting Replace Replace Replace Correct Clean Clean Clean
20
Add
12V140E-3 Series
40 Troubleshooting
SEN00316-00
1
Causes
Confirm recent repair history Degree of Operated for long period machine operation Fuel consumption increasing Coolant replenished more frequently There is oil mixed in coolant Oil smells of diesel fuel Oil is milky When engine is started, drops of water come from muffler When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, or coolant spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, coolant comes out Oil level in clutch or damper chamber of installed machine is low Oil level in hydraulic tank of installed machine is low When compression pressure is measured, it is found to be low Remove and inspect head cover directly Inspect cylinder block and/or liner directly Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove and inspect water pump directly Remove and inspect thermostat cover directly Remove and inspect supply pump directly Inspect seal of auxiliary equipment directly Remedy
Questions
E E w Q Q w Q Q w Q Q
E w w
Q Q
w w w
Check items
Q w w w w
q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct
Troubleshooting
12V140E-3 Series
21
General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant".
SEN00316-00
40 Troubleshooting
1
Rise in power train oil temperature on applicable machine side
General causes why coolant temperature becomes too high q Lack of cooling air (deformation, and/or damages of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system q Rise in oil temperature in power train on applicable machine side o Trouble shoot on the applicable machine side
Broken cylinder head and/or head gasket
Causes
Confirm recent repair history Degree of Operated for long period machine operation Sudden overheated Condition for Persistent overheating Coolant tempera- Rises quickly ture gauge Does not go down from red range (if installed) Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Engine oil level has risen and oil is milky Fan belt tension is low Milky oil is floating on coolant There are excessive air bubbles in radiator and coolant spurts back When light bulb is held behind radiator core, no light passes through Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps Coolant flows out from radiator overflow hose Fan belt whines under sudden acceleration Power train oil temperature gauge enters red range faster than engine coolant temperature gauge (if oil temperature gauge and coolant temperature gauge are installed) on the installed machine side When compression pressure is measured, it is found to be low Inspect cylinder liner directly Inspect oil cooler directly Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is tested, it does not open at cracking temperature Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low Inspect fan belt and pulley directly When coolant temperature is measured, it is found to be normal Remedy
Questions
E E Q w Q w w Q
E E Q w w w Q Q w
w w w w w w w w w w
Check items
q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct Add Carry out troubleshooting on installed machine
22
Troubleshooting
12V140E-3 Series
Lack of coolant
40 Troubleshooting
SEN00316-00
1
Improper fuel injection timing (abnormality in coolant temperature sensor)
Confirm recent repair history Degree of Operated for long period machine operation Gradually increased Condition of abnormal noise Suddenly increased Non-specified fuel is being used Oil replenished more frequently Metal particles are found when oil filter is drained Air leaks between turbocharger and cylinder head When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around EGR gas piping When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, beat noise is emitted around muffler When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust Blue under light load gas Black Engine does not pick up smoothly and combustion is irregular Abnormal noise is loud when engine is accelerated Blow-by gas is excessive When turbocharger is rotated by hand, it is fount to be heavy Inspect dynamic valve system directly When muffler is removed, abnormal noise disappears Inspect valve clearance directly When compression pressure is measured, it is found to be low Inspect gear train directly Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Abnormal noise is heard only when engine is started Confirm with INSITE or with monitoring function on installed machine side
Questions
E Q Q Q w w w w w w w Q w Q w Q Q w q q q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct Correct
Q Q Q w
Check items
w Q Q
Troubleshooting
Remedy
12V140E-3 Series
23
SEN00316-00
40 Troubleshooting
1
Causes Broken output shaft and/or parts in damper on installed machine side
General causes why vibration occurs q Defective parts (abnormal wear, breakage, etc.) q Misalignment between installed machine q Abnormal combustion a If abnormal noise vibration occur, carry out troubleshooting for "S-15 Abnormal noise is emitted", too.
Check items
Confirm recent repair history Degree of machine operation Operated for long period Condition of vibra- Suddenly increased tion Gradually increased Non-specified oil is being used Metal particles are found when oil filter is drained Metal particles are found when oil pan is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Inspect dynamic valve system directly Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Confirm with INSITE or with monitoring function on installed machine side Inspect engine mounting bolts and cushions directly When alignment is checked, radial runout or facial runout is detected Inspect front support spigot joint portion directly Inspect output shaft or inside of damper directly Remedy
Questions
E Q Q Q w w Q Q w q q q
E Q Q w w Q
E Q
E Q
Q Q Q Q Q Q Q
Troubleshooting
q q q q q q
Adjusting Adjusting Replace Replace Replace Replace Replace Replace
24
12V140E-3 Series
SEN00316-00
40 Troubleshooting
26
12V140E-3 Series
SEN00317-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
Troubleshooting of electrical system (E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 4 Information in troubleshooting table ..................................................................................................... 4 E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) ........................................................... 6 E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)........................................................... 8 E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank).................................. 10 E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) ..................................11 E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) ................................... 12 E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) .................................... 14 E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only).................................................... 16 E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) .................................................... 18 E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) ................................................ 20 E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only) ............................................... 22 E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only) ....................................... 24 E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ....................................... 26
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) .................................. 28 E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)................................... 30 E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank) .................................................... 31 E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ................................................... 31 E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ....................................... 32 E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only) ........................................ 34 E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) ................................ 36 E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) ................................. 38 E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank) ................................................... 40 E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)................................................... 42 E-23 Code [234/CA234] Eng. Overspeed (LH bank only).................................................................. 44 E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank).............................................. 46 E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank) ............................................. 48 E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank).................................................... 50 E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank) ................................................... 52 E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)..................................................... 54 E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank) .................................................... 54 E-30 Code [271/CA271] PCV1 Short Error (LH bank) ....................................................................... 56 E-31 Code [271/CB271] PCV1 Short Error (RH bank)....................................................................... 58 E-32 Code [272/CA272] PCV1 Open Error (LH bank) ....................................................................... 60 E-33 Code [272/CB272] PCV1 Open Error (RH bank)....................................................................... 61 E-34 Code [273/CA273] PCV2 Short Error (LH bank) ....................................................................... 62 E-35 Code [273/CB273] PCV2 Short Error (RH bank)....................................................................... 64 E-36 Code [274/CA274] PCV2 Open Error (LH bank) ....................................................................... 66 E-37 Code [274/CB274] PCV2 Open Error (RH bank)....................................................................... 67 E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) ........................... 68 E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) ........................... 70 E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) ........................... 72 E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) ........................... 74 E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) ........................... 76 E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) ........................... 78 E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ................................................ 80 E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank) ................................................ 80 E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ............................................................... 82 E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)............................................................... 84 E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank) .................................................... 86 E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ................................................... 86 E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ................................................... 88 E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)................................................... 90 E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) .......................................................... 92 E-53 Code [441/CB441] Battery Voltage Low Error (RH bank).......................................................... 92 E-54 Code [442/CA442] Battery Voltage High Error (LH bank).......................................................... 93 E-55 Code [442/CB442] Battery Voltage High Error (RH bank) ......................................................... 93
12V140E-3 Series
SEN00317-00
40 Troubleshooting
1
1
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Error code Display on INSITE Contents of trouble Action of controller Problem that appears on machine Related information Failure code Display on applicable machine Trouble Problem that appears on engine
Contents of trouble detected by engine controller Action taken by engine controller to protect system or devices when engine controller detects trouble Phenomenon that appears on engine as trouble as result of action taken by engine controller (shown above) Information related to detected trouble or troubleshooting
Causes
Standard value in normal state/Remarks on troubleshooting <Contents of description> Standard value in normal state to judge possible causes Remarks on judgment
Possible causes of trouble (Given numbers are reference numbers, which do not <Precautions for troubleshooting> (1) Method of indicating connector No. and handling of Tindicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified. 3 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, disconnect connector and connect T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (-) lead of tester as explained below for troubleshooting, unless otherwise 4 specified. Connect positive (+) lead to pin No. or wiring harness entered on front side. Connect negative (-) lead to pin No. or wiring harness entered on rear side.
<Troubles in wiring harness> Disconnection Connector is connected imperfectly or wiring harness is broken. Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. Hot short Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit. Short circuit Independent wiring harnesses are in contact with each other abnormally.
12V140E-3 Series
40 Troubleshooting
SEN00317-00
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(i o): Roughly shows the location on the machine.
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Abnormality occurred in controller. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start. Different machine models may have different connector Nos.
Standard value in normal state/Remarks on troubleshooting Check fuse or circuit breaker on machine side directly for defect. (If fuse is burnt or circuit breaker is turned OFF, circuit probably has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between PW L (female) (3), Resis2 (Disconnection in wiring or Max. 1 z (4) battery (+) tance defective contact in connecWiring harness between PW L (female) (1), Resistor) Max. 1 z (2) chassis ground tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between PW L(female) (3), (4) battery (+) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PW L Between (3), (4) (1), (2) Voltage 20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Abnormality occurred in controller. None in particular. Engine continues operation normally, but it may stop during operation or may not be able to start. Different machine models may have different connector Nos.
Standard value in normal state/Remarks on troubleshooting 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.)
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between PW R (female) (3), Resis2 (Disconnection in wiring or Max. 1 z (4) battery (+) tance defective contact in connecWiring harness between PW R (female) (1), Resistor) Max. 1 z (2) chassis ground tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between PW R (female) (3), (4) battery (+) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PW R Between (3), (4) (1), (2) Voltage 20 30 V
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)
Error code 115 Contents of trouble Action of controller Failure code CA115 Trouble Abnormality in engine Ne and G (Bkup) speed sensor (LH bank)
Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously. Engine stop
Phenomenon Engine cannot be started (engine has been stopped). that appears on Engine stops (if engine has been running). machine Related information Causes 1 2 Possible causes and standard value in normal state 3 4 5 Defective Ne speed sensor system Defective G (Bkup) speed sensor system Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for code [689/CA689]. Carry out troubleshooting for code [778/CA778].
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective sensor installation of sensor, internal defect of flywheel, etc.) Defective mount of G (Bkup) Check mount of G (Bkup) speed sensor directly for defect (defecspeed sensor tive installation of sensor, internal defect of supply pump, etc.) Defective connection of sen- Check Ne speed sensor and G (Bkup) speed sensor directly for sor (Wrong connection) defective connection (wrong connection). If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
10
12V140E-3 Series
40 Troubleshooting
SEN00317-00
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)
Error code 115 Contents of trouble Action of controller Failure code CB115 Trouble Abnormality in engine Ne and G (Bkup) speed sensor (RH bank)
Abnormality occurred in Ne speed sensor circuit and G (Bkup) speed sensor circuit simultaneously. Engine stop
Phenomenon Engine cannot be started (if engine has been stopped). that appears on Engine stops (if engine has been running). machine Related information Causes 1 2 Possible causes and standard value in normal state 3 4 5 Defective Ne speed sensor system Defective G(Bkup) speed sensor system Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for code [689/CA689]. Carry out troubleshooting for code [778/CA778].
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective sensor installation of sensor, internal defect of flywheel, etc.) Defective mount of G (Bkup) Check mount of G (Bkup) speed sensor directly for defect (defecspeed sensor tive installation of sensor, internal defect of supply pump, etc.) Defective connection (Wrong connection) Check Ne speed sensor and G (Bkup) speed sensor directly for defective connection (wrong connection). If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
12V140E-3 Series
11
SEN00317-00
40 Troubleshooting
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) 1
Error code 122 Contents of trouble Action of controller Failure code CA122 Trouble Sensor detection of abnormally high charge pressure (LH bank only)
Charge pressure sensor circuit detects abnormally high pressure. Sets charge pressure to fixed value (400 kPa) and continues operation.
Phenomenon that appears on Acceleration performance of engine drops. machine Related information Different machine models may have different connector Nos.
Causes 1
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
Pressure sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Ground fault in wiring harness 4 (Short circuit with GND circuit)
Wiring harness between LH J1 (female) (37) PIM (female) (1) Wiring harness between LH J1 (female) (47) PIM (female) (3) Wiring harness between LH J1 (female) (44) PIM (female) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) PIM (female) (1) and chassis ground Wiring harness between LH J1 (female) (47) PIM (female) (3) and chassis ground Wiring harness between LH J1 (female) (44) PIM (female) (2) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) PIM (female) (1) and LH J1 (female) (47) PIM (female) (3) Wiring harness between LH J1 (female) (37) PIM (female) (1) and LH J1 (female) (44) PIM (female) (2) Wiring harness between LH J1 (female) (47) PIM (female) (3) and LH J1 (female) (44) PIM (female) (2) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
12
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. LH J1 Between (37) (47) Power supply Voltage 4.75 5.25 V
12V140E-3 Series
13
SEN00317-00
40 Troubleshooting
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) 1
Error code 123 Contents of trouble Action of controller Failure code CA123 Trouble Sensor detection of abnormally low charge pressure (LH bank only)
Abnormally low pressure detected in charge pressure sensor circuit. Sets charge pressure to fixed value (400 kPa) and continues operation.
Phenomenon that appears on Acceleration performance of engine drops. 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-5 Code [122/CA122].
14
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only)
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code 131 Contents of trouble Action of controller Failure code CA131 Trouble Throttle sensor detection of abnormally high level (LH bank only)
Throttle sensor circuit detection of abnormally high level. Sets throttle angle with signal other than throttle sensor signal and continues operation. (depending on each model)
Phenomenon that appears on Depends on machine model. machine Related information Different machine models may have different connector Nos.
Causes 1
Defective sensor power sup- If code [2185/CA2185] or [2186/CA2186] is indicated, carry out ply system troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. DEC (male) Between (A) (C) Between (B) (A) Between (B) (C) Resistance 4.0 6.0 kz 0.25 5.0 kz 0.25 5.0 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between OEM L (female) (22) DEC (female) (A) Wiring harness between OEM L (female) (9) DEC (female) (B) Wiring harness between OEM L (female) (23) DEC (female) (C) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between OEM L(female) (22) DEC (female) (A) and chassis ground Wiring harness between OEM L(female) (9) DEC (female) (B) and chassis ground Wiring harness between OEM L(female) (23) DEC (female) (C) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller OEM L Between (22) (23) Between (9) (23) Power supply Signal Voltage 4.75 5.25 V 0.5 4.5 V
16
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Circuit diagram related to deceleration pedal type throttle sensor (Case of D4755)
12V140E-3 Series
17
SEN00317-00
40 Troubleshooting
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only)
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code 132 Contents of trouble Action of controller Failure code CA132 Trouble Throttle sensor detection of abnormally low level (LH bank only)
Signal voltage in throttle sensor circuit is abnormally low. Sets throttle angle with signal other than throttle sensor signal and continues operation. (depending on each model)
Phenomenon that appears on Varies by installed machine 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].
18
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)
Error code 135 Contents of trouble Action of controller Phenomenon that appears on machine Related information Different machine models may have different connector Nos. Failure code CA135 Trouble Oil pressure sensor detection of abnormally high pressure (LH bank only)
Signal voltage in oil pressure sensor circuit is abnormally high. Set oil pressure to default value (250 kPa) and continue operation.
Causes 1
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between LH J1 (female) (37) POIL (female) (1) Wiring harness between LH J1 (female) (47) POIL (female) (2) Wiring harness between LH J1 (female) (13) POIL (female) (3) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) POIL (female) (1) and chassis ground Wiring harness between LH J1 (female) (47) POIL (female) (2) and chassis ground Wiring harness between LH J1 (female) (13) POIL (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) POIL (female) (1) and LH J1 (female) (47) POIL (female) (2) Wiring harness between LH J1 (female) (37) POIL (female) (1) and LH J1 (female) (13) POIL (female) (3) Wiring harness between LH J1 (female) (47) POIL (female) (2) and LH J1 (female) (13) POIL (female) (3) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
20
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. LH J1 Between (37) (47) Power supply Voltage 4.75 5.25 V
12V140E-3 Series
21
SEN00317-00
40 Troubleshooting
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only)
Error code 141 Contents of trouble Action of controller Phenomenon that appears on 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-9 Code [135/CA135]. Failure code CA141 Trouble Oil pressure sensor detection of abnormally low pressure (LH bank only)
Signal voltage in oil pressure sensor circuit is abnormally low. Sets oil pressure to default value (250 kPa) and continues operation.
22
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)
Error code 144 Contents of trouble Action of controller Phenomenon that appears on machine Related information Different machine models may have different connector Nos. Failure code CA144 Trouble
Coolant temperature sensor detection of abnormally high temperature (LH bank only)
Signal voltage in coolant temperature sensor circuit is abnormally high. Fixes coolant temperature at (90 C) and continues operation.
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWTR (male) Between (A) (B) Coolant temperature 10 100 C Resistance 0.6 20 kz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (15) Resis2 (Disconnection in wiring or Max. 1 z TWTR (female) (A) tance defective contact in connecWiring harness between LH J1 (female) (38) Resistor) Max. 1 z TWTR (female) (B) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (15) TWTR (female) (A) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female) Between (15) (38) Coolant temperature 10 100 C Resistance 0.6 20 kz
24
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
25
SEN00317-00
40 Troubleshooting
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)1
Error code 145 Contents of trouble Action of controller Phenomenon that appears on 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-11 Code [144/CA144]. Failure code CA145 Trouble Coolant temperature sensor detection of abnormally low temperature (LH bank only)
Signal voltage in coolant temperature sensor circuit is abnormally low. Fixes coolant temperature at (90 C) and continues operation.
26
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only) 1
Error code 153 Contents of trouble Action of controller Phenomenon that appears on machine Related information Different machine models may have different connector Nos. Failure code CA153 Trouble Charge temperature sensor detection of abnormally high temperature (LH bank only)
Signal voltage in charge temperature sensor circuit is abnormally high. Fixes charge temperature (intake air temperature) at (70 C) and continues operation.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (23) Resis2 (Disconnection in wiring or Max. 1 z TIM (female) (A) tance defective contact in connecWiring harness between LH J1 (female) (47) Resistor) Max. 1 z TIM (female) (B) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (23) TIM (female) (A) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (23) (47) Intake air temperature 10 100 C Resistance 0.5 20 kz
28
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
29
SEN00317-00
40 Troubleshooting
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only) 1
Error code 154 Contents of trouble Action of controller Phenomenon that appears on 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-13 Code [153/CA153]. Failure code CA154 Trouble Charge temperature sensor detection of abnormally low charge temperature (LH bank only)
Signal voltage in charge temperature sensor circuit is abnormally low. Fixes charge temperature (intake air temperature) at (70 C) and continues operation.
30
12V140E-3 Series
40 Troubleshooting
SEN00317-00
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)
Error code 187 Contents of trouble Action of controller Failure code CA187 Trouble Power supply 2 sensor detection of abnormally low voltage (LH bank)
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low. Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation. Sets oil pressure sensor to default value (250 kPa) and continues operation. Fixes charge pressure sensor value (400 kPa) and continues operation. Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon that appears on Output drops. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-21 Code [227/CA227].
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)
Error code 187 Contents of trouble Action of controller Failure code CB187 Trouble Power supply 2 sensor detection of abnormally low voltage (RH bank)
Signal voltage in sensor power supply 2(5 V) circuit is abnormally low. Operate G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon that appears on Output drops. 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-22 Code [227/CB227].
12V140E-3 Series
31
SEN00317-00
40 Troubleshooting
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)
Error code 212 Contents of trouble Action of controller Phenomenon that appears on machine Related information Different machine models may have different connector Nos. Failure code CA212 Trouble Engine oil temperature sensor detection of abnormally high temperature (LH bank only)
Signal voltage in engine oil temperature sensor circuit is abnormally high. Sets oil pressure to default value (100 C) and continues operation.
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TOIL (male) Between (A) (B) Oil temperature 0 100 C Resistance 0.5 36 kz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (17) Resis2 (Disconnection in wiring or Max. 1 z TOIL (female) (A) tance defective contact in connecWiring harness between LH J1 (female) (47) Resistor) Max. 1 z TOIL (female) (B) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (17) TOIL (female) (A) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (17) (47) Oil temperature 0 100 C Resistance 0.5 36 kz
32
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
33
SEN00317-00
40 Troubleshooting
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only)
Error code 213 Contents of trouble Action of controller Phenomenon that appears on machine Related information Possible causes and standard value in normal state Different machine models may have different connector Nos. Failure code CA213 Trouble
Engine oil temperature sensor detection of abnormally low temperature (LH bank only)
Signal voltage in engine oil temperature sensor circuit is abnormally low. Sets oil temperature to default value (100 C) and continues operation.
Causes
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-17 Code [212/CA212].
34
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only) 1
Error code 221 Contents of trouble Action of controller Failure code CA221 Trouble Atmospheric pressure sensor detection of abnormally high pressure (LH bank only)
Signal voltage in atmospheric pressure sensor circuit is abnormally high. Sets atmospheric pressure to default value (52.44 kPa) and continues operation.
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Causes 1
Defective sensor power sup- If code [352/CA352] or [386/CA386] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
PAMB Between (1) (2) Between (3) (2) Power supply Signal
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between LH J1 (female) (37) PAMB (female) (1) Wiring harness between LH J1 (female) (38) PAMB (female) (3) Wiring harness between LH J1 (female) (3) PAMB (female) (2) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between LH J1 (female) (37) PAMB (female) (1) and chassis ground Wiring harness between LH J1 (female) (38) PAMB (female) (3) and chassis ground Wiring harness between LH J1 (female) (3) PAMB (female) (2) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) PAMB (female) (1) and LH J1 (female) (38) PAMB (female) (3) Wiring harness between LH J1 (female) (37) PAMB (female) (1) and LH J1 (female) (3) PAMB (female) (2) Wiring harness between LH J1 (female) (38) PAMB (female) (3) and LH J1 (female) (3) PAMB (female) (2) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
36
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
12V140E-3 Series
37
SEN00317-00
40 Troubleshooting
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only) 1
Error code 222 Contents of trouble Action of controller Failure code CA222 Trouble Atmospheric pressure sensor detection of abnormally low pressure (LH bank only)
Signal voltage in atmospheric pressure sensor circuit is abnormally low. Sets atmospheric pressure to default value (52.44 kPa) and continues operation.
Phenomenon that appears on Output drops. 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-19 Code [221/CA221].
38
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank)
Error code 227 Contents of trouble Action of controller Failure code CA227 Trouble Power supply 2 sensor detection of abnormally high voltage (LH bank)
Signal voltage in sensor power supply 2(5 V) circuit is abnormally high. Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation. Sets oil pressure sensor to default value (250 kPa) and continues operation. Fixes charge pressure sensor value (400 kPa) and continues operation. Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Disconnect devices at right in order. If error code disappears subsequently, that device has a defect in it.
Atmospheric pressure sensor Oil pressure sensor Charge pressure sensor G (Bkup) sensor
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (37) Resis3 (Disconnection in wiring or Max. 1 z respective sensors (female) tance defective contact in connecWiring harness between LH J1 (female) (47) Resistor) Max. 1 z respective sensors (female) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between LH J1 (female) (37) respective sensors (female) and chassis ground Wiring harness between LH J1 (female) (47) respective sensors (female) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) respective sensors (female) and LH J1 (female) (47) respective sensors (female) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LH J1 Between (37) (47) Voltage 4.75 5.25 V
40
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
41
SEN00317-00
40 Troubleshooting
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)
Error code 227 Contents of trouble Action of controller Failure code CB227 Trouble Power supply 2 sensor detection of abnormally high voltage (RH bank)
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high. Operates G(Bkup) sensor with signals of Ne speed sensor.
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Disconnect devices at right in order. If error code disappears subsequently, that device has a defect in it.
G (Bkup)speed sensor
G connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis3 (Disconnection in wiring or Max. 1 z (37) respective sensors (female) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (47) respective sensors (female) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between RH J1 (female) (37) respective sensors (female) and chassis ground Wiring harness between RH J1 (female) (47) respective sensors (female) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (37) respective sensors (female) and RH J1 (female) (47) respective sensors (female) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RH J1 Between (37) (47) Voltage 4.75 5.25 V
42
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
43
SEN00317-00
40 Troubleshooting
Engine speed is above operating range. Limits fuel injection rate until engine speed lowers to operating range.
Phenomenon that appears on Engine speed fluctuates. machine Related information Causes Possible causes and standard value in normal state 1 Defective related system 2 Improper way of use 3 Defective engine controller Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Way of use may be improper. Teach proper way of use to operator. If causes 1 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
44
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)
Error code 238 Contents of trouble Action of controller Failure code CA238 Trouble Ne Speed Sensor Sup. Volt. Error (LH bank)
Abnormality occurred in Ne speed sensor power supply (5 V) circuit. Controls Ne speed sensor with signals of G (Bkup) speed sensor.
Phenomenon Running engine stops (when G (Bkup) speed sensor is also abnormal). that appears on Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal). machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnect devices at right in order. If error code disappears subsequently, that device has a defect in it.
Ne speed sensor
NE connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (16) Resis2 (Disconnection in wiring or Max. 1 z Ne (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (48) Resistor) Max. 1 z Ne (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (16) Ne (female) (1) and chassis ground Wiring harness between LH J1 (female) (48) Ne (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (16) Ne (female) (1) and LH J1 (female) (48) Ne (female) (2) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LH J1 Between (16) (48) Voltage 4.75 5.25 V
46
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
47
SEN00317-00
40 Troubleshooting
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank)
Error code 238 Contents of trouble Action of controller Failure code CB238 Trouble Ne Speed Sensor Sup. Volt. Error (RH bank)
Abnormality occurred in Ne speed sensor power supply (5 V) circuit. Controls Ne speed sensor with signals of G (Bkup) speed sensor.
Phenomenon Running engine stops (when G (Bkup) speed sensor is also abnormal). that appears on Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal). machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnect devices at right in order. If error code disappears subsequently, that device has a defect in it.
Ne speed sensor
NE connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (16) Resis2 (Disconnection in wiring or Max. 1 z Ne (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (48) Ne (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (16) Ne (female) (1) and chassis ground Wiring harness between RH J1 (female) (48) Ne (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (16) Ne (female) (1) and RH J1 (female) (48) Ne (female) (2) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LH J1 (16) RH J1 (48) Voltage 4.75 5.25 V
48
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
49
SEN00317-00
40 Troubleshooting
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)
Error code 263 Contents of trouble Action of controller Phenomenon that appears on machine Related information Different machine models may have different connector Nos. Failure code CA263 Trouble
Fuel temperature sensor detection of abnormally high temperature (LH bank only)
Signal voltage in fuel temperature sensor circuit is abnormally high. Fixes fuel temperature at (95 C) and continues operation.
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH TFUEL (male) Between (A) (B) Fuel temperature 10 100 C Resistance 0.6 20 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (30) LH TFUEL (female) (A) Wiring harness between LH J1 (female) (47) LH TFUEL (female) (B) Resistance Resistance Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (30) LH TFUEL (female) (A) and chassis ground Resistance Max. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH J1 (female) Between (30) (47) Fuel temperature 10 100 C Resistance 0.6 20 kz
50
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
51
SEN00317-00
40 Troubleshooting
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank)
Error code 263 Contents of trouble Action of controller Phenomenon that appears on machine Related information Different machine models may have different connector Nos. Failure code CB263 Trouble
Fuel temperature sensor detection of abnormally high temperature (RH bank only)
Signal voltage in fuel temperature sensor circuit is abnormally high. Fixes fuel temperature at (95 C) and continues operation.
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH TFUEL (male) Between (A) (B) Fuel temperature 10 100 C Resistance 0.6 20 kz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (30) RH TFUEL (female) (A) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (47) RH TFUEL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (30) RH TFUEL (female) (A) and chassis ground Resistance Max. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH J1 (female) Between (30) (47) Fuel temperature 10 100 C Resistance 0.6 20 kz
52
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
53
SEN00317-00
40 Troubleshooting
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)
Error code 265 Contents of trouble Action of controller Phenomenon that appears on 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-26 Code [263/CA263]. Failure code CA265 Trouble
Signal voltage in fuel temperature sensor circuit is abnormally low. Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal state. Sets oil temperature to default value (95 C) and continues operation.
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)
Error code 265 Contents of trouble Action of controller Phenomenon that appears on 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-27 Code [263/CB263]. Failure code CB265 Trouble
Signal voltage in fuel temperature sensor circuit is abnormally low. Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal state. Fixes fuel temperature at (95 C) and continues operation.
54
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH PCV1 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (4) LH PCV1 (female) (1) and chassis ground Wiring harness between LH J1 (female)(5) LH PCV1 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Hot short in wiring harness (Contact with 24 V) Wiring harness between LH J1 (female) (4) LH PCV1 (female) (1) and chassis ground Wiring harness between LH J1 (female) (5) LH PCV1 (female) (2) and chassis ground Voltage Voltage Max. 1 V Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (4) (5) Between (4), (5) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
56
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
57
SEN00317-00
40 Troubleshooting
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH PCV1 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (4) RH PCV1 (female) (1) and chassis ground Wiring harness between RH J1 (female) (5) RH PCV1 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Hot short in wiring harness (Contact with 24 V) Wiring harness between RH J1 (female) (4) RH PCV1 (female) (1) and chassis ground Wiring harness between RH J1 (female) (5) RH PCV1 (female) (2) and chassis ground Voltage Voltage Max. 1 V Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller RH J1 (female) Between (4) (5) Between (4), (5) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
58
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
59
SEN00317-00
40 Troubleshooting
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH PCV1 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (4) Resis2 (Disconnection in wiring or Max. 1 z LH PCV1 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (5) Resistor) Max. 1 z LH PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller LH J1 (female) Between (4) (5) Between (4), (5) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
60
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH PCV1 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) (4) Resis2 (Disconnection in wiring or Max. 1 z RH PCV1 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) (5) Resistor) Max. 1 z RH PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller RH J1(female) Between (4) (5) Between (4), (5) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
12V140E-3 Series
61
SEN00317-00
40 Troubleshooting
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH PCV2 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (9) LH PCV2 (female) (1) and chassis ground Wiring harness between LH J1 (female) (10) LH PCV2 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Hot short in wiring harness (Contact with 24 V) Wiring harness between LH J1 (female) (9) LH PCV2 (female) (1) and chassis ground Wiring harness between LH J1 (female) (10) LH PCV2 (female) (2) and chassis ground Voltage Voltage Max. 1 V Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (9) (10) Between (9), (10) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
62
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
63
SEN00317-00
40 Troubleshooting
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH PCV2 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (9) RH PCV2 (female) (1) and chassis ground Wiring harness between RH J1(female) (10) RH PCV2 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Hot short in wiring harness (Contact with 24 V) Wiring harness between RH J1 (female) (9) RH PCV2 (female) (1) and chassis ground Wiring harness between RH J1 (female) (10) RH PCV2 (female) (2) and chassis ground Voltage Voltage Max. 1 V Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller RH J1 (female) Between (9) (10) Between (9), (10) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
64
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
65
SEN00317-00
40 Troubleshooting
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LH PCV2 (male) Between (1) (2) Resistance 2.3 5.3 z
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (9) Resis2 (Disconnection in wiring or Max. 1 z LH PCV2 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (10) Resistor) Max. 1 z LH PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller LH J1 (female) Between (9) (10) Between (9), (10) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
66
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RH PCV2 (male) Between (1) (2) Resistance 2.3 5.3 z
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) (9) Resis2 (Disconnection in wiring or Max. 1 z RH PCV2 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (10) RH PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller RH J1 (female) Between (9) (10) Between (9), (10) chassis ground Resistance 2.3 5.3 z Min. 1 Mz
12V140E-3 Series
67
SEN00317-00
40 Troubleshooting
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) 1
Error code 322 Contents of trouble Action of controller Failure code CA322 Trouble Disconnection or short circuit in injector #1 (L/B #1) system (LH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH CN1 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (45) Resis2 (Disconnection in wiring or Max. 1 z LH CN1 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (53) Resistor) Max. 1 z LH CN1 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (45) LH CN1 (female) (1) and chassis ground Wiring harness between LH J1 (female) (53) LH CN1 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (45) (53) Between (45), (53) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
68
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
69
SEN00317-00
40 Troubleshooting
E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank) 1
Error code 323 Contents of trouble Action of controller Failure code CA323 Trouble Disconnection or short circuit in injector #5 (L/B #5) system (LH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH CN5 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (46) Resis2 (Disconnection in wiring or Max. 1 z LH CN5 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (60) Resistor) Max. 1 z LH CN5 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (46) LH CN5 (female) (1) and chassis ground Wiring harness between LH J1 (female) (60) LH CN5 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (46) (60) Between (46), (60) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
70
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
71
SEN00317-00
40 Troubleshooting
E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank) 1
Error code 324 Contents of trouble Action of controller Failure code CA324 Trouble Disconnection or short circuit in injector #3 (L/B #3) system (LH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH CN3 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (55) Resis2 (Disconnection in wiring or Max. 1 z LH CN3 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (52) Resistor) Max. 1 z LH CN3 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (55) LH CN3 (female) (1) and chassis ground Wiring harness between LH J1 (female) (52) LH CN3 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (55) (52) Between (55), (52) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
72
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
73
SEN00317-00
40 Troubleshooting
E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank) 1
Error code 325 Contents of trouble Action of controller Failure code CA325 Trouble Disconnection or short circuit in injector #6 (L/B #6) system (LH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH CN6 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (57) Resis2 (Disconnection in wiring or Max. 1 z LH CN6 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (59) Resistor) Max. 1 z LH CN6 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (57) LH CN6 (female) (1) and chassis ground Wiring harness between LH J1 (female) (59) LH CN6 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (57) (59) Between (57), (59) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
74
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
75
SEN00317-00
40 Troubleshooting
E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank) 1
Error code 331 Contents of trouble Action of controller Failure code CA331 Trouble Disconnection or short circuit in injector #2 (L/B #2) system (LH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH CN2 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (54) Resis2 (Disconnection in wiring or Max. 1 z LH CN2 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (51) Resistor) Max. 1 z LH CN2 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (54) LH CN2 (female) (1) and chassis ground Wiring harness between LH J1 (female) (51) LH CN2 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (54) (51) Between (54), (51) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
76
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
77
SEN00317-00
40 Troubleshooting
E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank) 1
Error code 332 Contents of trouble Action of controller Failure code CA332 Trouble Disconnection or short circuit in injector #4 (L/B #4) system (LH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
LH CN4 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (56) Resis2 (Disconnection in wiring or Max. 1 z LH CN4 (female) (1) tance defective contact in connecWiring harness between LH J1 (female) (58) Resistor) Max. 1 z LH CN4 (female) (2) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (56) LH CN4 (female) (1) and chassis ground Wiring harness between LH J1 (female) (58) LH CN4 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller LH J1 (female) Between (56) (58) Between (56), (58) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
78
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
79
SEN00317-00
40 Troubleshooting
Phenomenon that appears on Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].
Phenomenon that appears on Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].
80
12V140E-3 Series
SEN00317-00
40 Troubleshooting
Abnormality occurred in injector drive circuit. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Standard value in normal state/Remarks on troubleshooting If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it. 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.)
2 Defective fuse
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between PW L (female) (3), Resis3 (Disconnection in wiring or Max. 1 z (4) battery (+) tance defective contact in connecWiring harness between PW L (female) (1), Resistor) Max. 1 z (2) chassis ground tance Ground fault in wiring harness 4 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between PW L (female) (3), (4) battery (+) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PW L Between (3), (4) (1), (2) Voltage 20 30 V
82
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
83
SEN00317-00
40 Troubleshooting
Abnormality occurred in injector drive circuit. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Standard value in normal state/Remarks on troubleshooting If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it. 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.)
2 Defective fuse
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between PW R (female) (3), Resis3 (Disconnection in wiring or Max. 1 z (4) battery (+) tance defective contact in connecWiring harness between PW R (female) (1), Resistor) Max. 1 z (2) chassis ground tance Ground fault in wiring harness 4 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between PW R (female) (3), (4) battery (+) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PW R Between (3), (4) (1), (2) Voltage 20 30 V
84
12V140E-3 Series
40 Troubleshooting
SEN00317-00
12V140E-3 Series
85
SEN00317-00
40 Troubleshooting
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)
Error code 352 Contents of trouble Action of controller Failure code CA352 Trouble Power supply 1 sensor detection of abnormally low voltage (LH bank)
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low. Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Phenomenon that appears on Output drops. 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-50 Code [386/CA386].
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank)
Error code 352 Contents of trouble Action of controller Failure code CB352 Trouble Power supply 1 sensor detection of abnormally low voltage (RH bank)
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low. Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Phenomenon that appears on Output drops. 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-51 Code [386/CB386].
86
12V140E-3 Series
SEN00317-00
40 Troubleshooting
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank)
Error code 386 Contents of trouble Action of controller Failure code CA386 Trouble Power supply 1 sensor detection of abnormally high voltage (LH bank)
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Disconnect devices at right in order. If error code disappears subsequently, that device has a defect in it.
LH PFUEL connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between LH J1 (female) (33) LH PFUEL (female) (1) Wiring harness between LH J1 (female) (25) LH PFUEL (female) (2) Wiring harness between LH J1 (female) (47) LH PFUEL (female) (3) Possible causes and standard value in normal state Ground fault in wiring harness 4 (Short circuit with GND circuit) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (33) LH PFUEL (female) (1) and chassis ground Wiring harness between LH J1 (female) (25) LH PFUEL (female) (2) and chassis ground Wiring harness between LH J1 (female) (47) LH PFUEL (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (33) LH PFUEL (female) (1) and LH J1 (female) (25) LH PFUEL (female) (2) Wiring harness between LH J1 (female) (33) LH PFUEL (female) (1) and LH J1 (female) (47) LH PFUEL (female) (3) Wiring harness between LH J1 (female) (25) LH PFUEL (female) (2) and LH J1 (female) (47) LH PFUEL (female) (3) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
88
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. LH J1 Between (33) (47) Voltage 4.75 5.25 V
12V140E-3 Series
89
SEN00317-00
40 Troubleshooting
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)
Error code 386 Contents of trouble Action of controller Failure code CB386 Trouble Power supply 1 sensor detection of abnormally high voltage (RH bank)
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Disconnect devices at right in order. If error code disappears subsequently, that device has a defect in it.
RH PFUEL connector
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between RH J1 (female) (33) RH PFUEL (female) (1) Wiring harness between RH J1 (female) (25) RH PFUEL (female) (2) Wiring harness between RH J1 (female) (47) RH PFUEL (female) (3) Possible causes and standard value in normal state Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (33) RH PFUEL (female) (1) and chassis ground Wiring harness between RH J1 (female) (25) RH PFUEL (female) (2) and chassis ground Wiring harness between RH J1 (female) (47) RH PFUEL (female) (2) and chassis ground Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (33) RH PFUEL (female) (1) and RH J1 (female) (25) RH PFUEL (female) (2) Wiring harness between wiring RH J1 (female) (33) RH PFUEL (female) (1) and RH J1 (female) (47) RH PFUEL (female) (3) Wiring harness between RH J1 (female) (25) RH PFUEL (female) (2) and RH J1 (female) (47) RH PFUEL (female) (3) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
90
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RH J1 Between (33) (47) Voltage 4.75 5.25 V
12V140E-3 Series
91
SEN00317-00
40 Troubleshooting
Phenomenon that appears on Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].
Phenomenon that appears on Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].
92
12V140E-3 Series
40 Troubleshooting
SEN00317-00
Phenomenon that appears on Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].
Phenomenon that appears on Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related nformation Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].
12V140E-3 Series
93
SEN00317-00
40 Troubleshooting
94
12V140E-3 Series
SEN00318-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting
Troubleshooting of electrical system (E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3 E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) .......................................................... 3 E-57 Code [449/CB449] Rail Press. Very High Error (RH bank).......................................................... 3 E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) ...................................................... 4 E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) ..................................................... 6 E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank)....................................................... 8 E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) ...................................................... 8 E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) ............................................................... 9 E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) ............................................................. 10 E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank)..............................................11 E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) .............................................11 E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) .............................................................. 12 E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank).............................................................. 16 E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank)...................................................... 20
12V140E-3 Series
SEN00318-00
40 Troubleshooting
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank) ..................................................... 22 E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only) ..................................... 24 E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only) ...................................... 26 E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank)................................. 27 E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) ................................ 27 E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank)................................................... 28 E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) .................................................. 28 E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) ............................................ 30 E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) ........................................... 32 E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank)................................. 34 E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank) ................................ 36 E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) ....................................................... 37 E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank)....................................................... 37 E-82 Code [1257/CA1257] Harness Key error (LH bank) .................................................................. 38 E-83 Code [1257/CB1257] Harness Key error (RH bank).................................................................. 39 E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ...................... 40 E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank) ...................... 42 E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) .................... 44 E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank) .................... 46 E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank) .................... 48 E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) ...................... 50 E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) ........................................... 52 E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)................................ 54 E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) ................................ 56 E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) ..................................................... 57 E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank)..................................................... 57 E-95 Code [ *1/] Eng. Overheat (LH bank only) ........................................................................... 58 E-96 Code [ *2/] Eng. Oil Press. Low Speed Derate (LH bank only)............................................ 58 E-97 Code [ *3/] Press. Low Torque Derate (LH bank only)......................................................... 59
12V140E-3 Series
40 Troubleshooting
SEN00318-00
1
1
Common rail pressure sensor circuit detected abnormally high pressure (level 2). Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-66 Code [559/CA559].
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank)
Error code 449 Contents of trouble Action of controller Failure code CB449 Trouble Common rail pressure abnormally high Error 2 (RH bank)
Common rail pressure sensor circuit detected abnormally high pressure (level 2). Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-67 Code [559/CB559].
12V140E-3 Series
SEN00318-00
40 Troubleshooting
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank)
Error code 451 Contents of trouble Action of controller Failure code CA451 Trouble Common rail pressure sensor detected abnormally high pressure (LH bank)
Signal voltage in common rail pressure sensor circuit is abnormally high. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Causes 1
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
LH PFUEL Between (1) (3) Between (2) (3) Power supply Signal
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between LH J1 (female) (33) LH PFUEL (female) (1) Wiring harness between LH J1 (female) (25) LH PFUEL (female) (2) Wiring harness between LH J1 (female) (47) LH PFUEL (female) (3) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (33) LH PFUEL (female) (1) and chassis ground Wiring harness between LH J1 (female) (25) LH PFUEL (female) (2) and chassis ground Wiring harness between LH J1 (female) (47) LH PFUEL (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (33) LH PFUEL (female) (1) and LH J1 (female) (25) LH PFUEL (female) (2) Wiring harness between LH J1 (female) (33) LH PFUEL (female) (1) and LH J1 (female) (47) LH PFUEL (female) (3) Wiring harness between LH J1 (female) (25) LH PFUEL (female) (2) and LH J1 (female) (47) LH PFUEL (female) (3) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller LH J1 Between (33) (47) Between (25) (47) Voltage 4.75 5.25 V 0.25 4.6 V
12V140E-3 Series
SEN00318-00
40 Troubleshooting
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank)
Error code 451 Contents of trouble Action of controller Failure code CB451 Trouble Common rail pressure sensor detected abnormally high pressure (RH bank)
Signal voltage in common rail pressure sensor circuit is abnormally high. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Different machine models may have different connector Nos.
Causes 1
Defective sensor power sup- If code [187/CB187] or [227/CB227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.
RH PFUEL Between (1) (3) Between (2) (3) Power supply Signal
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Wiring harness between RH J1 (female) (33) RH PFUEL (female) (1) Wiring harness between RH J1 (female) (25) RH PFUEL (female) (2) Wiring harness between RH J1 (female) (47) RH PFUEL (female) (3) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (33) RH PFUEL (female) (1) and chassis ground Wiring harness between RH J1 (female) (25) RH PFUEL (female) (2) and chassis ground Wiring harness between RH J1 (female) (47) RH PFUEL (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) (33) RH PFUEL (female) (1) and RH J1 (female) (25) RH PFUEL (female) (2) Wiring harness between RH J1 (female) (33) RH PFUEL (female) (1) and RH J1 (female) (47) RH PFUEL (female) (3) Wiring harness between RH J1 (female) (25) RH PFUEL (female) (2) and RH J1 (female) (47) RH PFUEL (female) (3) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller RH J1 Between (33) (47) Between (25) (47) Voltage 4.75 5.25 V 0.25 4.6 V
12V140E-3 Series
SEN00318-00
40 Troubleshooting
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank)
Error code 452 Contents of trouble Action of controller Failure code CA452 Trouble Common rail pressure sensor detected abnormally low pressure (LH bank)
Signal voltage in common rail pressure sensor circuit is abnormally low. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-58 Code [451/CA451].
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank)
Error code 452 Contents of trouble Action of controller Failure code CA452 Trouble Common rail pressure sensor detected abnormally low pressure (RH bank)
Signal voltage in common rail pressure sensor circuit is abnormally low. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-59 Code [451/CB451].
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Common rail pressure sensor circuit detected abnormally high pressure (level 1). None in particular.
Phenomenon that appears on Output drops. machine Related information Causes 1 Defective related system 2 Use of improper fuel Possible causes and standard value in normal state 3 Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Check fuel used directly. (High viscosity)
Defective electrical system of Common rail pressure sensor may have electric trouble. common rail pressure sensor Carry out troubleshooting for code [451/CA451] (E-58).
Defective mechanical system 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly. sor 5 Defective overflow valve 6 Clogging of overflow piping 7 Defective pressure limiter Check overflow valve directly for broken spring, worn seat, and stuck ball. Check overflow piping directly for clogging. Check pressure limiter directly for mechanical defect.
12V140E-3 Series
SEN00318-00
40 Troubleshooting
Common rail pressure sensor circuit detected abnormally high pressure (level 1). None in particular.
Phenomenon that appears on Output drops. machine Related information Causes 1 Defective related system 2 Use of improper fuel Possible causes and standard value in normal state 3 Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Check fuel used directly. (High viscosity)
Defective electrical system of Common rail pressure sensor may have electric trouble. common rail pressure sensor Carry out troubleshooting for code [451/CB451] (E-59).
Defective mechanical system 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly. sor 5 Defective overflow valve 6 Clogging of overflow piping 7 Defective pressure limiter Check overflow valve directly for broken spring, worn seat, and stuck ball. Check overflow piping directly for clogging. Check pressure limiter directly for mechanical defect.
10
12V140E-3 Series
40 Troubleshooting
SEN00318-00
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank)
Error code 554 Contents of trouble Action of controller Failure code CA554 Trouble Common rail pressure sensor detection of in range abnormality (LH bank)
In range error occurred in common rail pressure sensor circuit. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-58 Code [451/CA451].
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank)
Error code 554 Contents of trouble Action of controller Failure code CB554 Trouble Common rail pressure sensor detected In range abnormality (RH bank)
In range error occurred in common rail pressure sensor circuit. Limits output and continues operation (Limits common rail pressure).
Phenomenon that appears on Output drops. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-59 Code [451/CB451].
12V140E-3 Series
11
SEN00318-00
40 Troubleshooting
Supply pump does not feed fuel (level 1). Limits common rail pressure.
Phenomenon that appears on Output drops. machine Related information Causes 1 Defective related system 2 Use of improper fuel Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Improper fuel may be used. Check fuel used directly . a For contents of troubleshooting, see Note 1. For checking of fuel low-pressure circuit, see Testing and adjusting, Testing fuel pressure. Pressure in fuel low-pressure circuit Max. 0.15 MPa {Max. 1.5 kg/cm2}
Supply pump PCV may have electric trouble. Carry out troubleDefective supply pump PCV shooting for following codes [271/CA271] (E-30), [272/CA272] (Eelectrical system 32), [273/CA273] (E-34), [274/CA274] (E-36). Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor ness for damage. a For testing of leakage from pressure limiter, see Testing and adjusting, Testing leakage from pressure limiter and return rate from injector. Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm) a For testing of return (spill) limit from injector, see Testing and adjusting, Testing leakage from pressure limiter and return rate from injector. Speed at rated operation Return (Spill) limit from injector 960 cc/min 1,020 cc/min 1,080 cc/min 1,140 cc/min 1,200 cc/min 1,600 rpm 1,700 rpm 1,800 rpm 1,900 rpm 2,000 rpm
8 Defective injector
<How to use check sheet> Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for nopressure feed.
12
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Note 1: When low-pressure circuit is defective, check the following: 1) 2) 3) 4) 5) 6) 7) Fuel level Clogged fuel tank breather Stuck or worn feed pump, clogged filter Leaked or clogged low-pressure fuel pipe Bypass valve malfunction, defective assembly of other parts (See Fig.1.) Clogged fuel filter Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q q q
Overflow valve (1): Spring is seen through both holes. Bypass valve (2): Spring is seen through hole on nut side. 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) 2) 3) Gauze filter: Disassemble and check. If clogged, clean. Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
12V140E-3 Series
13
SEN00318-00
40 Troubleshooting
A. Visual check
1 2 Fuel leakage to outside Clogging of fuel tank breather
Good NG
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of error/failure code Check of monitoring information Code Displayed item Checking condition Low idle *1 Engine speed High idle Equivalent to rating <By models> *2 *3 4 *4 *5 Throttle opening Fuel injection command Common rail pressure command Low idle High idle Equivalent to rating <By models> Equivalent to rating <By models> Unit rpm rpm rpm % % mm3 MPa MPa CA CA CA kPa Standard value (Reference value) <By models> <By models> <By models> 0 100 / / / /
Good NG
Common rail fuel pressure Equivalent to rating <By models> Low idle Fuel injection timing comHigh idle mand Equivalent to rating <By models> Boost pressure Engine coolant temperature (High) Engine coolant temperature (Low) Fuel temperature Equivalent to rating <By models> Low idle Low idle Low idle
Standard value (Reference value)
*6
*7 *8 *9 *10
C C C
Check of reduced cylinder mode operation (Engine speed) Func tion Reduced cylinder No. 1 cylinder 5 *11 No. 2 cylinder No. 3 cylinder No. 4 cylinder No. 5 cylinder No. 6 cylinder Checking condition Low idle Low idle Low idle Low idle Low idle Low idle Unit rpm rpm rpm rpm rpm rpm Measured Good NG value
14
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Checking condition
High idle
Good NG
Checking condition
11 Leakage through pressure limiter No load, 1,600 rpm Equivalent to rating <By models> 1,600 rpm Equivalent to rating <By models> 1,700 rpm 12 Return rate from injector Equivalent to rating <By models> 1,800 rpm Equivalent to rating <By models> 1,900 rpm Equivalent to rating <By models> 2,000 rpm
*1 *11: When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing method). When inspecting with the monitoring function of the machine, use the codes specified for each machine model. Equivalent to rating <By models>: When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When the engine is installed to the machine, however, the operation load equivalent to the rating depends on the machine model.
12V140E-3 Series
15
SEN00318-00
40 Troubleshooting
Supply pump does not feed fuel (level 1). Limits common rail pressure.
Phenomenon that appears on Output drops. machine Related information Causes 1 Defective related system 2 Use of improper fuel Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. Improper fuel may be used. Check fuel used directly . a For contents of troubleshooting, see Note 1. For checking of fuel low-pressure circuit, see Testing and adjusting, Testing fuel pressure. Pressure in fuel low-pressure circuit Max. 0.15 MPa {Max. 1.5 kg/cm2}
Supply pump PCV may have electric trouble. Carry out troubleDefective supply pump PCV shooting for following codes [271/CB271] (E-31), [272/CB272] (Eelectrical system 33), [273/CB273] (E-35), [274/CB274] (E-37). Defective common rail pres- Common rail pressure sensor may be defective. Check wiring harsure sensor ness for damage. a For testing of leakage from pressure limiter, see Testing and adjusting, Testing leakage from pressure limiter and return rate from injector. Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm) a For testing of return (spill) limit from injector, see Testing and adjusting, Testing leakage from pressure limiter and return rate from injector. Speed at rated operation Return (Spill) limit from injector 960 cc/min 1,020 cc/min 1,080 cc/min 1,140 cc/min 1,200 cc/min 1,600 rpm 1,700 rpm 1,800 rpm 1,900 rpm 2,000 rpm
8 Defective injector
<How to use check sheet> Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for nopressure feed.
16
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Note 1: When low-pressure circuit is defective, check the following: 1) 2) 3) 4) 5) 6) 7) Fuel level Clogged fuel tank breather Stuck or worn feed pump, clogged filter Leaked or clogged low-pressure fuel pipe Bypass valve malfunction, defective assembly of other parts (See Fig.1.) Clogged fuel filter Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q q q
Overflow valve (1): Spring is seen through both holes. Bypass valve (2): Spring is seen through hole on nut side. 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) 2) 3) Gauze filter: Disassemble and check. If clogged, clean. Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too. Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
12V140E-3 Series
17
SEN00318-00
40 Troubleshooting
A. Visual check
1 2 Fuel leakage to outside Clogging of fuel tank breather
Good NG
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of error/failure code Check of monitoring information Code Displayed item Checking condition Low idle *1 Engine speed High idle Equivalent to rating <By models> *2 *3 4 *4 *5 Throttle opening Fuel injection command Common rail pressure command Low idle High idle Equivalent to rating <By models> Equivalent to rating <By models> Unit rpm rpm rpm % % mm3 MPa MPa CA CA CA kPa Standard value (Reference value) <By models> <By models> <By models> 0 100 / / / /
Good NG
Common rail fuel pressure Equivalent to rating <By models> Low idle Fuel injection timing comHigh idle mand Equivalent to rating <By models> Boost pressure Engine coolant temperature (High) Engine coolant temperature (Low) Fuel temperature Equivalent to rating <By models> Low idle Low idle Low idle
Standard value (Reference value)
*6
*7 *8 *9 *10
C C C
Check of reduced cylinder mode operation (Engine speed) Func tion Reduced cylinder No. 1 cylinder 5 *11 No. 2 cylinder No. 3 cylinder No. 4 cylinder No. 5 cylinder No. 6 cylinder Checking condition Low idle Low idle Low idle Low idle Low idle Low idle Unit rpm rpm rpm rpm rpm rpm Measured Good NG value
18
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Checking condition
High idle
Good NG
Checking condition
11 Leakage through pressure limiter No load, 1,600 rpm Equivalent to rating <By models> 1,600 rpm Equivalent to rating <By models> 1,700 rpm 12 Return rate from injector Equivalent to rating <By models> 1,800 rpm Equivalent to rating <By models> 1,900 rpm Equivalent to rating <By models> 2,000 rpm
*1 *11: When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing method). When inspecting with the monitoring function of the machine, use the codes specified for each machine model. Equivalent to rating <By models>: When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When the engine is installed to the machine, however, the operation load equivalent to the rating depends on the machine model.
12V140E-3 Series
19
SEN00318-00
40 Troubleshooting
Abnormality occurred in engine Ne speed sensor circuit. Controls Ne speed sensor with signals of G (Bkup) speed sensor.
Phenomenon Running engine stops (when G (Bkup) speed sensor is also abnormal). that appears on Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal). machine Related information Different machine models may have different connector Nos.
Causes 1
Defective sensor power sup- If code [238/CA238] is indicated, carry out troubleshooting for it ply system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (16) Ne (female) (1) Wiring harness between LH J1 (female) (48) Ne (female) (2) Wiring harness between LH J1 (female) (27) Ne (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state Wiring harness between LH J1 (female) (16) Ne (female) (1) and chassis ground Wiring harness between LH J1 (female) (48) Ne (female) (2) and chassis ground Wiring harness between LH J1 (female) (27) Ne (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (16) Ne (female) (1) and LH J1 (female) (48) Ne (female) (2) Wiring harness between LH J1 (female) (16) Ne (female) (1) and LH J1 (female) (48) Ne (female) (2) Wiring harness between LH J1 (female) (48) Ne (female) (2) and LH J1 (female) (27) Ne (female) (3) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for part defect. 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.) If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
20
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
21
SEN00318-00
40 Troubleshooting
Abnormality occurred in engine Ne speed sensor circuit. Controls Ne speed sensor with signals of G (Bkup) speed sensor.
Phenomenon Running engine stops (when G (Bkup) speed sensor is also abnormal). that appears on Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal). machine Related information Different machine models may have different connector Nos.
Causes 1
Defective sensor power sup- If code [238/CB238] is indicated, carry out troubleshooting for it ply system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (16) Ne (female) (1) Wiring harness between RH J1 (female) (48) Ne (female) (2) Wiring harness between RH J1 (female) (27) Ne (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state Wiring harness between LH J1 (female) (16) Ne (female) (1) and chassis ground Wiring harness between RH J1 (female) (48) Ne (female) (2) and chassis ground Wiring harness between RH J1 (female) (27) Ne (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (16) Ne (female) (1) and RH J1 (female) (48) Ne (female) (2) Wiring harness between LH J1 (female) (16) Ne (female) (1) and RH J1(female) (27) Ne (female) (3) Wiring harness between RH J1 (female) (48) Ne (female) (2) and RH J1 (female) (27) Ne (female) (3) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective 5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for part defect. 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.) If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
22
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
23
SEN00318-00
40 Troubleshooting
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only)
Error code 691 Contents of trouble Action of controller Phenomenon that appears on machine Related information Causes Standard value in normal state/Remarks on troubleshooting Failure code CA691 Trouble Intake air temperature sensor detected abnormally high temperature (LH bank)
Intake air temperature sensor circuit detected abnormally high temperature. Fixes intake air temperature at (25 C) and continues operation.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective charge tempera1 ture sensor (Internal trouble) TAM1 Between (A) (B) Between (A) chassis ground Intake air temperature 10 100 C All range Resistance 0.5 20 kz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (43) Resis2 (Disconnection in wiring or Max. 1 z TAM1 (female) (A) tance defective contact in connecWiring harness between LH J1 (female) (47) Resistor) Max. 1 z TAM1 (female) (B) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (43) TAM1 (female) (A) and chassis ground Resistance Max. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller TAM1 (male) Between (43) (47) Intake air temperature 10 100 C Resistance 0.5 20 kz
24
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
25
SEN00318-00
40 Troubleshooting
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only)
Error code 692 Contents of trouble Action of controller Phenomenon that appears on 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-70 Code [691/CA691]. Failure code CA692 Trouble Intake air temperature sensor detected abnormally low temperature (LH bank only)
Intake air temperature sensor circuit detected abnormally low temperature. Fixes intake air temperature at (25 C) and continues operation.
26
12V140E-3 Series
40 Troubleshooting
SEN00318-00
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank) 1
Error code 731 Contents of trouble Action of controller Failure code CA731 Trouble Engine G (Bkup) speed sensor abnormal phase (LH bank)
Engine G (Bkup) sensor circuit detected abnormality in phase. Controls with signals of engine Ne speed sensor.
Phenomenon Running engine stops (when Ne speed sensor is also abnormal). that appears on Stopped engine cannot be started (when Ne speed sensor is also abnormal). machine Related information Causes 1 2 Defective engine Ne speed sensor system Defective G (Bkup) speed sensor system Standard value in normal state/Remarks on troubleshooting Engine Ne speed sensor may be defective. Carry out troubleshooting for [689/CA689] (E-68). Common rail pressure sensor may have electric trouble. Carry out troubleshooting for code [778/CA778] (E-76).
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) 1
Error code 731 Contents of trouble Action of controller Failure code CB731 Trouble Engine G (Bkup) speed sensor abnormal phase (RH bank)
Engine G (Bkup) sensor circuit detected abnormality in phase. Controls with signals of engine Ne speed sensor.
Phenomenon Running engine stops (when Ne speed sensor is also abnormal). that appears on Stopped engine cannot be started (when Ne speed sensor is also abnormal). machine Related information Causes Defective engine Ne speed 1 sensor system 2 Defective G (Bkup) speed sensor system Standard value in normal state/Remarks on troubleshooting Engine Ne speed sensor may be defective. Carry out troubleshooting for [689/CB689] (E-69). Common rail pressure sensor may have electric trouble. Carry out troubleshooting for code [778/CB778] (E-77).
12V140E-3 Series
27
SEN00318-00
40 Troubleshooting
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank)
Error code 757 Contents of trouble Action of controller Failure code CA757 Trouble All Engine Controller Data Lost Error (LH bank)
Phenomenon that appears on Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-1 Code [111/CA111].
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank)
Error code 757 Contents of trouble Action of c ontroller Failure code CB757 Trouble All Engine Controller Data Lost Error (RH bank)
Phenomenon that appears on Engine continues operation normally, but it may stop during operation or may not be able to start. machine Related information Possible causes and standard value in normal state Causes Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-2 Code [111/CB111].
28
12V140E-3 Series
SEN00318-00
40 Troubleshooting
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) 1
Error code 778 Contents of trouble Action of controller Failure code CA778 Trouble Engine G (Bkup) speed sensor abnormal (LH bank)
Abnormality occurred in engine G (Bkup) speed sensor circuit. Controls with signals of Ne speed sensor.
Phenomenon Running engine stops (when Ne speed sensor is also abnormal). that appears on Stopped engine cannot be started (when Ne speed sensor is also abnormal). machine Related information Different machine models may have different connector Nos.
Causes 1
Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out troubleply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between LH J1 (female) (37) LH G (female) (1) Wiring harness between LH J1 (female) (47) LH G (female) (2) Wiring harness between LH J1 (female) (26) LH G (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Possible causes and standard value in normal state Wiring harness between LH J1 (female) (37) LH G (female) (1) and chassis ground Wiring harness between LH J1 (female) (47) LH G (female) (2) and chassis ground Wiring harness between LH J1 (female) (26) LH G (female) (3) and chassis ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (37) LH G (female) (1) and LH J1 (female) (47) LH G (female) (2) Wiring harness between LH J1 (female) (37) LH G (female) (1) and LH J1 (female) (26) LH G (female) (3) Wiring harness between LH J1 (female) (47) LH G (female) (2) and LH J1 (female) (26) LH G (female) (3) Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec5 defective rotation sensing tive clearance) or check rotation sensing part (in supply pump) part directly for defect. 6 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 cannot be carried out.) If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
30
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
31
SEN00318-00
40 Troubleshooting
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) 1
Error code 778 Contents of trouble Action of controller Phenomenon that appears on machine Related information Failure code CB778 Trouble Engine G (Bkup) speed sensor abnormal (RH bank)
Abnormality occurred in engine G (Bkup) speed sensor circuit. Controls with signals of Ne speed sensor. Running engine stops (when Ne speed sensor is also abnormal). Stopped engine cannot be started (when Ne speed sensor is also abnormal). Different machine models may have different connector Nos. Causes Standard value in normal state/Remarks on troubleshooting Defective sensor power sup- If code [187/CB187] or [227/CB227] is indicated, carry out trouble1 ply system shooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring har- Wiring harness between RH J1 (female) ResisMax. 1 z ness (37) RH G (female) (1) tance 2 (Disconnection in wiring or Wiring harness between RH J1 (female) Resisdefective contact in connecMax. 1 z (47) RH G (female) (2) tance tor) Wiring harness between RH J1 (female) ResisMax. 1 z (26) RH G (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) Resis(37) RH G (female) (1) and chassis Min. 1 Mz tance Ground fault in wiring harground ness 3 Wiring harness between RH J1 (female) (Short circuit with GND cirResis(47) RH G (female) (2) and chassis Min. 1 Mz cuit) tance ground Wiring harness between RH J1 (female) Resis(26) RH G (female) (3) and chassis Min. 1 Mz tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between RH J1 (female) Resis(37) R G (female) (1) and RH J1 Min. 1 Mz tance Short circuit in wiring har(female) (47) RH G (female) (2) ness 4 Wiring harness between RH J1 (female) (With another wiring harResis(37) R G (female) (1) and RH J1 Min. 1 Mz ness) tance (female) (26) RH G (female) (3) Wiring harness between RH J1 (female) Resis(47) R G (female) (2) and RH J1 Min. 1 Mz tance (female) (26) RH G (female) (3) Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec5 defective rotation sensing tive clearance) or check rotation sensing part (in supply pump) part directly for defect. If causes 1 5 are not detected, engine G (Bkup) speed sensor Defective G (Bkup) speed 6 may be defective. (Since trouble is in system, troubleshooting cansensor system not be carried out.) If causes 1 5 are not detected, engine controller may be defec7 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried out.)
32
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
33
SEN00318-00
40 Troubleshooting
Communication error occurred between engine controllers (LH bank) None in particular.
Phenomenon Single-bank operation that appears on Engine cannot be started with the key ON machine Related information Different machine models may have different connector Nos.
Causes
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between LH J1 (female) (8) Resis1 (Disconnection in wiring or Max. 1 z RH J1 (female) (8) tance defective contact in connecWiring harness between LH J1 (female) (6) Resistor) Max. 1 z RH J1 (female) (6) tance Possible causes and standard value in normal state Ground fault in wiring harness 2 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LH J1 (female) (8) RH J1 (female) (8) and chassis ground Wiring harness between LH J1 (female) (6) RH J1 (female) (6) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller LH J1 (female) Between (8) (6) Between (8), (6) chassis ground Resistance 108 132 z Min. 1 Mz
34
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
35
SEN00318-00
40 Troubleshooting
Communication error occurred between engine controllers (LH bank) None in particular.
Phenomenon Single-bank operation that appears on Engine cannot be started with the key ON machine Related information Possible causes and standard value in normal state Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-78 Code [781/CA781].
36
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
37
SEN00318-00
40 Troubleshooting
Collation of identification harness between respective bank controllers fail (LH bank) Stops operation
Phenomenon that appears on Engine cannot be started with the key ON machine Related information Different machine models may have different connector Nos.
Causes
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ness 1 (Disconnection in wiring or Resisdefective contact in connec- Wiring harness between OEM L (female) (7) Max. 1 z OEM L (female) (34) tance tor) Possible causes and standard value in normal state Ground fault in wiring harness 2 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness OEM L (female) (8) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller Between wiring harness OEM L (female) (7) and chassis ground Between wiring harness OEM L (female) (8) and chassis ground Resistance Resistance Max. 1 z Min. 1 Mz
38
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Collation of identification harness between respective bank controllers fail (RH bank) Stops operation
Phenomenon that appears on Engine cannot be started with the key ON machine Related information Different machine models may have different connector Nos.
Causes
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wrong connection of harness 1 Connector connection error Between OEM R (female) (7) OEM R ResisMin. 1 Mz (female) (34) terminals tance Possible causes and standard value in normal state Ground fault in wiring harness 2 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness OEM R (female) (8) and chassis ground Resistance Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller Between wiring harness OEM R (female) (7) and chassis ground Between wiring harness OEM R (female) (8) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
12V140E-3 Series
39
SEN00318-00
40 Troubleshooting
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) 1
Error code 1548 Contents of trouble Action of controller Failure code CB1548 Trouble Disconnection or short circuit in injector #7 (R/B #1) system (RH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH CN1 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (45) RH CN1 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (53) RH CN1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Wiring harness between RH J1 (female) (45) RH CN1 (female) (1) and chassis ground Wiring harness between RH J1 (female) (53) RH CN1 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller RH J1 (female) Between (45) (53) Between (45), (53) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
40
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
41
SEN00318-00
40 Troubleshooting
E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank) 1
Error code 1549 Contents of trouble Action of controller Failure code CB1549 Trouble Disconnection or short circuit in injector #8 (R/B #2) system (RH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH CN2 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (54) RH CN2 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (51) RH CN2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Wiring harness between RH J1 (female) (54) RH CN2 (female) (1) and chassis ground Wiring harness between RH J1 (female) (51) RH CN2 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller RH J1 (female) Between (54) (51) Between (54), (51) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
42
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
43
SEN00318-00
40 Troubleshooting
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank)
Error code 1551 Contents of trouble Action of controller Failure code CB1551 Trouble Disconnection or short circuit in injector #10 (R/B #4) system (RH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH CN4 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (56) RH CN4 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (58) RH CN4 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Wiring harness between RH J1 (female) (56) RH CN4 (female) (1) and chassis ground Wiring harness between RH J1 (female) (58) RH CN4 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller RH J1 (female) Between (56) (58) Between (56), (58) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
44
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
45
SEN00318-00
40 Troubleshooting
E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank)
Error code 1552 Contents of trouble Action of controller Failure code CB1552 Trouble Disconnection or short circuit in injector #11 (R/B #5) system (RH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH CN5 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (46) RH CN5 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (60) RH CN5 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Wiring harness between RH J1 (female) (46) RH CN5 (female) (1) and chassis ground Wiring harness between RH J1 (female) (60) RH CN5 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller RH J1 (female) Between (46) (60) Between (46), (60) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
46
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
47
SEN00318-00
40 Troubleshooting
E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank)
Error code 1553 Contents of trouble Action of controller Failure code CB1553 Trouble Disconnection or short circuit in injector #12 (R/B #6) system (RH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH CN6 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (57) RH CN6 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (59) RH CN6 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Wiring harness between RH J1 (female) (57) RH CN6 (female) (1) and chassis ground Wiring harness between RH J1 (female) (59) RH CN6 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller RH J1 (female) Between (57) (59) Between (57), (59) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
48
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
49
SEN00318-00
40 Troubleshooting
E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank) 1
Error code 1622 Contents of trouble Action of controller Failure code CB1622 Trouble Disconnection or short circuit in injector #9 (R/B #3) system (RH bank)
Phenomenon Output drops. that appears on Idle speed is unstable. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
RH CN3 (male) Between (1) (2) Between (1), (2) chassis ground
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between RH J1 (female) Resis2 (Disconnection in wiring or Max. 1 z (55) RH CN3 (female) (1) tance defective contact in connecWiring harness between RH J1 (female) Resistor) Max. 1 z (52) RH CN3 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit) Wiring harness between RH J1 (female) (55) RH CN3 (female) (1) and chassis ground Wiring harness between RH J1 (female) (52) RH CN3 (female) (2) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller RH J1 (female) Between (55) (52) Between (55), (52) chassis ground Resistance 0.4 1.1 z Min. 1 Mz
50
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
51
SEN00318-00
40 Troubleshooting
Abnormality occurred in circuit of KOMNET communication with machine (LH bank). Normal control (communication function disabled)
Phenomenon that appears on Different problems occur on different machine models. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between OEM L (female) (46) OEM R (female) (46) Wiring harness between OEM L (female) (47) OEM R (female) (47) Wiring harness between OEM L (female) (46) OEM L (female) (47)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 2 (Short circuit with GND circuit) Wiring harness between OEM L (female) (46) OEM R (female) (46) and chassis ground Wiring harness between OEM L (female) (47) OEM R (female) (47) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller Wiring harness between OEM L (female) (46) OEM L (female) (47) Wiring harness between OEM R (female) (46) OEM R (female) (47) Resistance Resistance 108 132z 108 132 z
52
12V140E-3 Series
40 Troubleshooting
SEN00318-00
12V140E-3 Series
53
SEN00318-00
40 Troubleshooting
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only) 1
Throttle sensor of decelerator pedal type (Case of D475-5)
Error code 2185 Contents of trouble Action of controller Failure code CA2185 Trouble Throttle sensor detection of abnormally high supply voltage (LH bank only)
High voltage abnormality occurred to throttle sensor power supply (5 V) circuit. Sets throttle angle with signal other than throttle sensor signal and continues operation. (depending on each model)
Phenomenon that appears on Depends on machine model. machine Related information Different machine models may have different connector Nos.
Causes
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Disconnect devices at right in order. If error code disappears subsequently, that device has a defect in it.
Decelerator sensor
DEC connector
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON. ness Wiring harness between OEM L (female) Resis2 (Disconnection in wiring or Max. 1 z (22) DEC (female) (A) tance defective contact in connecWiring harness between OEM L (female) Resistor) Max. 1 z (23) DEC (female) (C) tance Ground fault in wiring harness 3 (Short circuit with GND circuit) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (22) DEC (female) (A) and chassis ground Wiring harness between OEM L (female) (23) DEC (female) (C) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (22) DEC (female) (A) and OEM L (female) (23) DEC (female) (C) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. OEM L Between (22) (23) Voltage 4.75 5.25 V
54
12V140E-3 Series
40 Troubleshooting
SEN00318-00
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475-5)
12V140E-3 Series
55
SEN00318-00
40 Troubleshooting
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) 1
Error code 2186 Contents of trouble Action of controller Failure code CA2186 Trouble Throttle sensor detected abnormally low supply voltage (LH bank only)
Low-voltage abnormality occurred to throttle sensor power supply (5V) circuit. Sets throttle angle with signal other than throttle sensor signal and continues operation. (depending on each model)
Phenomenon that appears on Depends on machine model. 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-91 Code [2185/CA2185].
56
12V140E-3 Series
40 Troubleshooting
SEN00318-00
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank)
Error code 2249 Contents of trouble Action of controller Failure code CA2249 Trouble Supply pump no-pressure feed error 2 (LH bank)
Supply pump does not feed fuel (level 2). Limits common rail pressure.
Phenomenon that appears on Output drops. 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-66 Code [559/CA559].
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank)
Error code 2249 Contents of trouble Failure code CB2249 Trouble Supply pump no-pressure feed error 2 (RH bank)
Action of ontrol Limits common rail pressure. ler Phenomenon that appears on Output drops. 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-67 Code [559/CB559].
12V140E-3 Series
57
SEN00318-00
40 Troubleshooting
Engine coolant temperature is above operating range. Limits output and continues operation.
Phenomenon that appears on Output drops. machine Related information Causes Standard value in normal state/Remarks on troubleshooting
This defective phenomenon is indicated only on the installed Carry out troubleshooting on machine when it was detected. 1 machine side Accordingly, contents of troubleshooting differ by the machine model. See Shop manual for machine.
E-96 Code [ *2/] Eng. Oil Press. Low Speed Derate (LH bank only) 1
Error code *2 Contents of trouble Action of controller Failure code Trouble Engine oil pressure low and speed derate (LH bank only)
Engine oil pressure is below operating range. Limits output and continues operation (Limits fuel injection rate and engine speed).
Phenomenon that appears on Output drops. machine Related information Causes Standard value in normal state/Remarks on troubleshooting
This defective phenomenon is indicated only on the installed Carry out troubleshooting on machine when it was detected. 1 machine side Accordingly, contents of troubleshooting differ by the machine model. See Shop manual for machine.
58
12V140E-3 Series
40 Troubleshooting
SEN00318-00
E-97 Code [ *3/] Press. Low Torque Derate (LH bank only)
Error code *3 Contents of trouble Action of controller Failure code Trouble Engine oil pressure low and torque derate (LH bank only)
Engine oil pressure is below operating range. Limits output and continues operation (Limits fuel injection rate and engine speed).
Phenomenon that appears on Output drops. machine Related information Causes Standard value in normal state/Remarks on troubleshooting
This defective phenomenon is indicated only on the installed Carry out troubleshooting on machine when it was detected. 1 machine side Accordingly, contents of troubleshooting differ by the machine model. See Shop manual for machine.
12V140E-3 Series
59
SEN00318-00
40 Troubleshooting
60
12V140E-3 Series
SEN00320-00
ENGINE
1SHOP MANUAL
12V140E-3 Series
12V140E-3 Series
SEN00320-00
Assembly q In Assembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. q The meanings of the symbols used in Assembly section are as follows. k : Precautions related to safety in execution of work a : Know-how or precautions for work 2 : Type of coating material 3 : Tightening torque
4 5
12V140E-3 Series
SEN00320-00
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Komatsu code LT-1A Part No. 790-129-9030 Q'ty 150 g Container Tube Main features and applications Used to prevent falling off of rubber gaskets, rubber cushions, and cork plugs. Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
Category
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene Features: Resistant to heat and chemicals. container Used to fix and seal bolts and plugs. Can Used to stick and seal metal, glass, and plastics.
LT-3 Adhesive
790-129-9060 Adhesive: Set of 1 kg adhesive and Hardener: hardener 500 g 790-129-9040 790-129-9120 250 g 75 g
Polyethylene Used to seal plugs for drilled holes. container Tube Heat-resistant sealant used to repair engines.
50 g
Quick-setting adhesive. Polyethylene Setting time: Within 5 sec. to 3 min. container Used mainly to stick metals, rubbers, plastics, and woods. Quick-setting adhesive. Polyethylene Quick-hardening type. (max. strength is obtained after container 30 minutes of application) Used mainly to stick rubbers, plastics, and metals. Polyethylene Features: Resistant to heat and chemicals. container Used for fitted portions of high temperatures. Tube Used to stick or seal gaskets and packings of power train case, etc.
2g
79A-129-9110 790-129-9010
50 cc 200 g
LG-5
790-129-9080
1 kg
Used to seal various threaded portions, pipe joints, Polyethylene and flanges. container Used to seal tapered plugs, elbows, and nipples of hydraulic pipes. Tube Features: Silicon-based heat and cold-resistant sealant. Used to seal flanged surfaces and threaded portions. Used to seal oil pan, final drive case, etc. Features: Silicon-based quick-hardening sealant. Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. Gasket sealant used to repair engine. Features: Silicon-based, heat-resistant, vibrationresistant and impact-resistant sealant. Used to seal transfer case, etc.
Gasket sealant
LG-6
790-129-9020
200 g
LG-7
790-129-9070
1 kg 100 g 100 g
12V140E-3 Series
SEN00320-00
Q'ty 60 g
Container Can
Main features and applications Used to lubricate sliding portions. (to prevent squeaking) Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. Used to lubricate linkages, bearings, etc.
LM-P
09940-00040
200 g
Tube
G2-LI
Various
Various
G2-CA
Various
Used for bearings used at normal temperature under light load in contact with water or steam.
Grease
Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM Hyper White Grease G2-T, G0-T (*) *: For cold district Biogrease G2B, G2-BT (*) *: For use at high temperature and under high load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER 417-926-3910 SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
400 gx10 Bellows-type 400 gx20 container Used for parts under heavy load. 16 kg Can Bellows-type Seizure resistance and heat resistance higher container than molybdenum disulfide grease. Can Not conspicuous on machine since color is white.
400 g 16 kg
400 g 16 kg
Bellows-type Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants. Used as primer for cab side. (Using limit: 4 months after date of manufacture) Used as primer for glass side. (Using limit: 4 months after date of manufacture) Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture) Used as primer for sash. (Almite) (Using limit: 4 months after date of manufacture)
20 ml
20 ml
Primer
SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402
22M-54-27230
20 ml
Glass container
22M-54-27240
150 ml
Can
22M-54-27250
20 ml
Glass container
12V140E-3 Series
SEN00320-00
Category
Komatsu code SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W" Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381
Part No.
Q'ty
Container
Main features and applications "S" is used for high-temperature season (April October) and "W" for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months after date of manufacture) Adhesive for cab glass Used as adhesive for glass. (Using limit: 6 months after date of manufacture) Used as adhesive for glass. (Using limit: 6 months after date of manufacture) Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture) Used to seal front window. (Using limit: 6 months after date of manufacture) Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
417-926-3910
320 ml
Polyethylene container Polyethylene container Ecocart (Special container) Polyethylene container Polyethylene container Cartridge
Adhesive
20Y-54-39850
310 ml
22M-54-27210
320 ml
417-926-3920
320 ml
Caulking material
20Y-54-55130
333 ml
22M-54-27220
333 ml
12V140E-3 Series
SEN00320-00
Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured). Necessity : t . . . . . . Cannot be substituted, should always be installed (used) : q . . . . . . Extremely useful if available, can be substituted with commercially available part New/Remodel : N . . . . . . Tools newly developed for this model and given new part Nos. : R . . . . . . Tools remodeled from tools already available for other models and given upgraded part Nos. : Blank. . . Tools already available for other models, usable without any modification Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See Sketches of special tools)
New/Remodel Sketches
Work item
Symbol
Necessity
Q'ty
Part No.
Part name
Remarks
790-501-4000 790-901-1800 790-901-1810 790-901-1820 790-901-1830 Disassembly and assembly of engine assembly A 790-901-1840 790-901-1510 02100-01038 01252-11050 01643-31645 01643-31032 01602-21648 795-102-2102 795-102-2110 795-102-2120 Disassembly and assembly of cylinder head B 795-102-4210 01016-50830 01580-10806 01144-31270 01580-11210 Removal and installation of piston ring Measurement of cylinder liner projection Removal of cylinder liner Installation of cylinder liner Angle tightening of bolt Installation of piston Installation of front oil seal Installation of rear oil seal C D E F G H J K 795-100-1191 795-502-1121 795-236-1000 795-230-5472 795-331-1110 795-236-1500 795-602-2200 795-602-2300
Engine repair stand Bracket assembly Bracket Bracket Bracket Bracket Plate Bolt Bolt Washer Washer Washer Spring pusher Handle Bracket Bracket Bolt Nut Stud Nut Piston ring tool Holder Liner puller Liner driver Wrench Piston holder Installer Installer
t 1 t 1 t 1 t 1 t 1 t 1 t 4 t 36 t 16 t 12 t 16 t 24 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
12V140E-3 Series
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Work item
Symbol
New/Remodel Sketches
Necessity
Q'ty
Part No.
Part name
Remarks
Press fitting of valve stem seal Adjusting valve clearance Removal of rear oil seal
L M N
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ENGINE
1SHOP MANUAL
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1.
4.
Starting motor assembly Remove engine harness (1) and then remove starting motor assemblies (2) and (3). a Remove the assembly at the top first being followed by that at the bottom.
2.
5.
2)
Drain the engine coolant and engine oil. a Quantity of the engine oil depends on the applicable machines. 6 Engine oil: Approx. 130 l
3.
Engine wiring harness Disconnect the connector and terminal and then remove engine harness (1) from the engine assembly.
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6.
Fuel filter and filter head assembly, and priming pump 1) Remove fuel tubes (1) and (2). 2) Remove fuel filter and filter head assembly (3). 3) Remove priming pump (4).
9.
7.
Engine controller and controller cooler 1) Remove engine controller (1). 2) Remove fuel hoses (2) and (3). 3) Remove controller cooler (4).
8.
Air inlet pipe 1) Remove the clamp and then remove air inlet pipe (1). 2) Remove bracket (2). 3) Remove bracket (3). a Remove bracket (3) on the right side bank alone. 11. High-pressure pipe (between supply pump common rail) 1) Apply a marking to the installation positions of clamps (1) (3) using paint. 2) Remove bracket (4). 3) Remove clamps (1) (3). 4) Remove high-pressure pipes (5) and (6).
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12. High-pressure pipe (between common rail fuel injector) 1) Remove bracket (1).
3) 4) 5)
Remove bracket. Remove all clamps (2) and (3). Remove 6 high-pressure pipes (4).
2)
Apply a marking to every installation positions of clamps (2) and (3) using paint.
2) 3)
Lift air intake manifold (2) temporarily and then remove the mounting bolts. Lift off air intake manifold assembly (2). 4 Air intake manifold assembly: 45 kg
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16. Exhaust manifold assembly 1) Remove instation plates (1), muffler bracket (2), water pipes (3) and bracket (4).
2) 3)
Lift exhaust manifold assembly (5) temporarily and then remove the mounting bolts. Lift off exhaust manifold assembly (5). 4 Exhaust manifold assembly: 25 kg
15. Turbocharger assembly 1) Remove 2 water pipes and 2 oil pipes. a When the air-cooled turbocharger is used, the oil pipes alone are provided. 2) Lift turbocharger assembly (1) temporarily and then remove the mounting bolts. 3) Lift off turbocharger assembly (1). 4 Turbocharger assembly: 35 kg
17. Common rail 1) Remove fuel tube (1). 2) Remove common rail (2). 3) Remove bracket (3).
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18. Supply pump assembly 1) Remove oil tube (1) 2) Remove supply pump assembly mounting bolt (2). 3) Remove supply pump assembly (3).
3)
4)
19. Corrosion resister and filter head assembly Remove corrosion resister and filter head assembly (1).
21. Oil cooler (rear side) 1) Remove oil manifold (1). 2) Remove oil cooler (2) a Remove the oil cooler (front side) after removing the supply pump drive case. 20. Water pump assembly 1) Remove block (1) 2) Remove water connector (2).
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22. Plate and block Remove plates (1) and (2) and block (3).
25. Head cover Remove head cover (1). a Repeat the same procedure on every cylinder up to removal of the cylinder head assembly.
23. Fuel tube 1) Remove fuel tube (1). 26. Rocker arm assembly 1) Loosen locknuts (1) and then loosen adjustment screws (2) fully. a Make sure that the valve tension is not applied to the rocker arm and thus it is free to move. 2) Remove rocker arm assembly (3). a Record the parts installation positions using a tag to avoid confusion in the later assembly.
24. Oil level gauge and oil filler tube 1) Remove bracket (1) and then remove oil filler tube (2). 2) Loosen the sleeve nut at the base and then remove oil level gauge (3). 3) Remove bracket (4).
3)
Remove air intake rocker arm (4), spacer (5) and exhaust rocker arm (6) from rocker shaft (7).
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2)
Insert a small L-bar [1] under the fuel connector and pry out fuel injector (2) slowly. a Do not grip the solenoid valve at the top of the injector to pull off the injector.
28. Injector harness 1) Remove injector terminal mounting nut (1) and clamp mounting bolt (2). 2) Push connector (3) into the cylinder head and remove injector harness (4).
31. Cylinder head assembly 1) Remove the water tube. 2) Lift off cylinder head assembly (1). 4 Cylinder head assembly: 25 kg
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When removing the cylinder head assembly without removing the fuel injector, be sure to prevent its interference with the floor surface since the injector tip protrudes through the bottom of the cylinder head.
3) 4)
Remove the cylinder head gasket. 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).
32. Oil pan 1) Support the front and rear side of oil pan (1) with block [1]. 2) Remove all oil pan mounting bolts. 3) Separate the gasket sealant. 4) Lift the engine and then remove oil pan (1). 4 Oil pan: 90 kg
3] 4]
Remove lower seat (6). Raise the cylinder head and remove valve (7).
33. Suction pie and under plate 1) Fix under plate (1) temporarily using several oil pan mounting bolts. 2) Remove stay (2) and then remove suction pipe (3).
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3) 4)
Support under plate (1) using jack [1]. Remove the bolts used for temporary fixing and then lower the jack carefully to remove under plate (1). 4 Under plate: 25 kg
36. Breather Remove breather (1), blowby pipe (2) and plate (3). a Remove the plate on the left bank alone.
37. Thermostat case 1) Remove water outlets (1). 2) Remove thermostat case (2).
2)
3)
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2] 3] 4]
Remove shaft (5), thrust plate (6) and gear (7) as a unit. Remove gear (7) from shaft (5). Pull off oil seal (9) and bushing (10) from housing (8).
39. Thermostat housing 1) Remove coolant temperature sensor (1). 2) Remove thermostat housing (2).
41. Flywheel assembly 1) Lift and secure flywheel assembly (1). 2) Remove the mounting bolt. 3) Separate the bolt from the crankshaft using forcing screw [1]. 4) Lift off flywheel assembly (1). 4 Flywheel assembly: 130 kg
40. Accessory drive 1) Remove pulley (1). 2) Remove accessory drive (2).
3)
Disassemble the accessory drive according to the following procedure. 1] Pull off hub (3) and then remove thrust plate (4).
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42. Flywheel housing 1) Remove burring tool (1) and Ne speed sensor (2).
43. Rear oil seal Remove rear oil seal (1) from the flywheel housing.
2)
44. Damper and crank pulley assembly 1) Lift damper and crank pulley assembly (1) temporarily and then remove the mounting bolts. 2) Lift off damper and crank pulley assembly (1). 4 Damper and crank pulley assembly: 75 kg
3) 4)
Lift flywheel housing (4) temporarily and then remove the mounting bolt. Lift off the flywheel housing (4). 4 Flywheel housing: 230 kg
45. Front support Remove front support (1) using puller [1].
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46. Gear case cover Lift off gear case cover (1). 4 Gear case cover:75 kg
47. Front oil seal Remove front oil seal (1) from the gear case cover.
49. Supply pump gear 1) Remove the mounting nut. 2) Remove supply pump gear (1) using puller [1]. a After removing the supply pump gear, remove the key from the shaft and maintain so that it may not be lost.
48. Idler gear (Large) 1) Remove plate (1). 2) Remove idler gears (large) (2) and (3).
50. Idler gear (Small) 1) Remove plate (1). 2) Remove idler gear (small) (2).
3)
Remove thrust plate (4) from the shaft. a A indicates the oil channel.
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2) 52. Supply pump drive case 1) Remove oil tube (1) a Remove the oil tube on the left bank alone. 2) Remove supply pump drive case (2).
3)
Disassemble the cam follower assembly according to the following procedure. 1] Remove snap rings (4) 2] Remove cam followers (5) from shaft (6). 3] Remove snap rings (7) from shaft (6).
53. Oil cooler (Front side) Remove oil cooler (front side) (1)
54. Cam follower assembly 1) Remove plate (1) and cam follower cover (2).
55. Camshaft assembly 1) Turn cam gear (1) to remove mounting bolt (2) through lightening hole.
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Be sure to remove the piston cooling nozzle before removing the piston connecting rod assembly. When removing the nozzle, turn it 90 so that it may not hit the piston.
2)
Pull off cam shaft assembly (3) along with the cam gear. a Turn the cam shaft carefully when removing it so that the bushing may not be damaged.
58. Piston and connecting rod assembly 1) Prior to the removal, measure the side clearance of the connecting rod using dial gauge [1] in order to use it as a rough standard in the assembly. a Check the stamped No. of the connecting rod cap. q Make sure that the cap No. and cylinder No. are the same. q The No. must be stamped on the cam side. a If the cylinder No. is not stamped, write it using an electric pen prior to the removal (it is not acceptable to stamp the number).
56. Timing gear case 1) Lift timing gear case (1) temporarily and then remove the mounting bolt. 2) Lift off timing gear case (1). 4 Gear case cover: 55 kg
2)
3)
Rotate the crankshaft in order to drive the piston to be removed to the bottom dead center. Loosen connecting rod bolt (1) by 5 to 6 turns.
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4)
5) 6)
Hit the connecting rod head lightly using a plastic hammer to loosen the connecting rod cap and connecting rod. Scrub the carbon off the top wall of the liner using fine sandpaper. Turn the crankshaft until the piston comes to the top dead center and then remove the connecting rod cap (2).
9)
Disassemble the piston and connecting rod assembly according to the following procedure. 1] Remove snap ring (4) 2] Support connecting rod (5) with hand and then remove piston pin (6) to disconnect piston (7) from the connecting rod. a When the piston pin is firmly fixed and unremovable, heat it (roughly 5 minutes at 100C) using an industrial dryer. 3] Remove the snap ring on the other side.
7)
8)
Push in and piston and connecting rod assembly using pushing bar [1] from the oil pan side and then remove the assembly while supporting piston (3) from the cylinder head side. a Take care not to damage the inside of the cylinder with a corner of the connecting rod. Remove other piston and connecting rod assemblies according to the above procedure. a Keep the sliding portion and bearing of the piston in a safe place to protect them from damage. a Assemble the connecting rod and cap temporarily and keep them along with the connecting rod bearing on a cylinder to cylinder basis.
4] 5]
Using tool C, remove piston ring (8). Remove oil ring expander (9) a Keep the piston, connecting rod, connecting rod bearing, piston ring, and piston pin on a cylinder to cylinder basis.
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59. Crankshaft 1) Before removing crankshaft, measure the end play of the crankshaft using dial gauge [1] in order to use it as a rough standard in the assembly.
4)
Lift off crankshaft (4). a Use care in lifting the crankshaft so that it may not hit and get damage from the cylinder block. 4 Crankshaft: 210 kg
2) 3)
Remove mounting bolts (2) of main cap (1). Insert the bolts in the bolt hole of the main cap (1) and remove the cap, while shaking it.
5) 6)
Remove upper thrust bearing (5) from No.7 journal. Remove upper bearing (6). a Apply marking to the assembly positions of the main cap, main bearing and thrust bearing using paint or tags and then keep them on a cap to cap basis.
Lower thrust bearing (3) is assembled to No. 7 main cap. Record its assembly position after removal.
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60. Cylinder liner 1) Before removing cylinder liner (1), measure its projection using tool D and dial gauge [1]. a Before measuring projection of the liner, tighten the liner with plate [2] so that it may not be lifted by the O-ring. 3 Plate mounting bolt: 69 98 Nm {7 10 kgm}
61. Cylinder block Lift off the cylinder block from tool A. 4 Cylinder block: 850 kg
2)
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1SHOP MANUAL
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Tightening bolts by plastic-region turning angle method a Bolts tightened by plastic-region turning angle method q Cylinder head mounting bolt q Main cap mounting bolt q Connecting rod cap mounting bolt a If the plastic-region turning angle method is applied, the tightened bolts have permanent strain. Accordingly, the allowable number of using times of each bolt is limited. Observe the following precautions. q Check each mounting bolt head for punch marks. If there were punch marks more than the specified numbers, replace the bolt. 1. Cylinder block 1) Lift the cylinder block and then set it on tool A. 4 Cylinder block: 850 kg 2) Before inserting the cylinder liners, prepare the cylinder block according to the following procedure. 1] Remove the rust and scales from faces A and B with sandpaper, etc. until the machined surfaces are exposed. 2] Polish parts B, R and r with sandpap e r o f a b o u t No . 2 0 0 un t i l t h e y become smooth. If part R is sharpened or burrs are present there, finish it with a scraper or sandpaper. F i n i s h t h i s s u r f a c e pa r t i c u l a r l y smoothly so that it will not damage the O-ring. 3] If face R is so pitted that it cannot be repaired, replace the cylinder block. 4] If faces A and parts R and r are pitted, finish them smoothly.
2.
Cylinder liner a Replace the O-ring and clevis seal with new ones. 1) Check that the cylinder liner O-ring groove and periphery of the liner are not roughened because of rusting or pitting. If those parts are roughened, replace the cylinder liner. 2) Install clevis seal (1), O-rings (2) and (3) to the cylinder liner. a Check that there is not a burr, dust, etc. in the groove of the liner. a Fit the clevis seal with the chamfered side down. When fitting it, press it against the seal groove all round so that it will not be twisted. a When installing O-rings (2) and (3), refer to the following. q O-ring (2): Black q O-ring (3): Orange 2 Clevis seal and O-ring: Rubber lubricant (RF-1) a RF-1: DAIDO CHEMICAL INDUSTRY CO., LTD. If RF-1 is not available, apply clean engine oil (EO30). a Since the clevis seal and O-ring are swollen and deteriorated by oil, apply a small amount of oil to them thinly with a brush just before fitting them.
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3)
After fitting the liner O-ring, check it for twist. If it is twisted, correct it with a smooth rod (about 10 mm in diameter).
When applying the gasket sealant, make sure overlapping b between the coating at start and the end complies with the following dimension. Gasket sealant overlapping dimension b: 6 6 mm
4)
Install the cylinder liner according to the following procedure. 1] Using cloth, wipe dirt and oil completely off the contact faces between the counterbored part of the cylinder block and liner flange. 2] Apply silicon-based gasket sealant to the counterbored mating parts a of the cylinder block and cylinder liner. 2 Cylinder block: Gasket sealant (LG-6)
After applying the gasket sealant, finish the cylinder liner installation within 50 minutes. When the bottom contact face of the counterbored liner flange is modified and shim (2) is used.
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1]
2]
Coat the bottom side of shim (2) with a small amount of gasket sealant LG-6 and then assemble the shim. Then apply gasket sealant LG-6 according to the same procedure as that employed when the shim is not used.
8)
9)
5)
Immediately before press-fitting of the liner, apply a small amount of engine oil to the liner O-ring, crevice seal and contact face of the cylinder block. 2 Clevis seal, O-ring and cylinder block: Engine oil (EO30) a Apply the engine oil, using hands, uniformly on the entire contact face of the cylinder block.
To prevent the gasket sealant from projecting through the clearance between the block and liner after the cylinder head is tightened, tighten the cylinder head tempo r a r i l y wi t h th e u s e d h ea d g a s k e t inserted. a At this time, observe the following tightening torque and tightening order. 3 Temporary tightening torque: 137 157 Nm {14 16 kgm} a Installation of No. 7 bolt is not necessary.
6)
7)
Direct stamping "T" on the top face of the liner toward the engine front side and then insert cylinder liner (1) to the cylinder block while taking care so that the O-ring may not be damaged. Push in cylinder liner keeping weight on both hands. a If the liner does not enter the cylinder block smoothly when pushed with weight on both hands, stop the work since the O-ring is potentially damaged. In this case, check the cylinder block for burrs.
10) Remove the cylinder head and wipe off the gasket sealant projected from the counterbored part. a Be sure to perform steps 9) and 10) above since the projected gasket sealant can deform the grommet of the head gasket. 11) After press-fitting the cylinder liner, measure its projection using tool D. a Before measuring projection of the liner, tighten it with plate [1] so that it may not be lifted by the O-ring. q Measuring position: 4 positions at a, b, c and d.
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a a a
Plate mounting bolt: 686 980 Nm {7 10 kgm} Standard cylinder projection: 0.07 0.15 mm If the projection is out of the standard, correct it according to the maintenance standard. If the gasket sealant is projected from the fitting parts of the cylinder block and cylinder liner up to the top of the cylinder block, wipe it off.
2)
3) 3. Crankshaft 1) Fit upper main bearing (6) to the cylinder block, matching the projection of the former to the notch of the latter.
Drive in the roll pin in such that its projection from the block end face may become 2.7 3.4 mm and then install upper thrust bearing (5). a Install the thrust bearing with the grooved surface on the crankshaft side. 2 Thrust bearing sliding surface: Engine oil (EO30) Before assembling crankshaft, confirm the following items. q Presence/absence of abnormality in the front and rear threaded portions. (Make sure the bolt can be smoothly screwed in with hand.) q Presence/absence of scratches or dents on the pin and main journal. q Presence/absence of dusts in the oil hole.
a a
Upper bearing: With oil hole A No. 4 bearing is wider than others. Thus, care must be taken to prevent an assembly error. a Bearing with a No. 4 bearing: 52 mm Bearings other than No. 4: 48 mm a Before fitting the bearing, make sure that its back side is free from foreign matter. 2 Bearing inner surface: Engine oil (EO30) a Don't apply the engine oil to the bearing backside. 12V140E-3 Series
4)
Lift crankshaft (4) and then install it on the cylinder block. a When installing the crankshaft, take care not to hit its sliding surfaces against the cylinder block. 4 Crank shaft: 210 kg 2 Cylinder block journal: Engine oil (EO30)
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5)
Install the projection of lower bearing (7) locating it to the notch of main cap (1) and install. a Before fitting the bearing, make sure that its back side is free from foreign matter. 2 Inside of bearing: Engine oil (EO30) a Don't apply the engine oil to the bearing backside.
6)
7)
8)
a a a
Lower bearing: Without oil hole No. 4 bearing is wider than others. Thus, care must be used to prevent an assembly error. Bearing with a No. 4 bearing: 52 mm Bearings other than No. 4: 48 mm
Drive the roll pin of cap No. 7 so that it will be projected by 2.7 3.4 mm from the cap end and then install lower thrust bearings (3) to both sides. a Install the thrust bearing with the grooved surface on the crankshaft side. 2 Thrust bearing sliding surface: Engine oil (EO30) Apply the engine oil to the surface of the journal of the crankshaft. Then install the main cap after making sure that the No. being stamped on respective main caps (1) is matching the cylinder block No. 2 Crankshaft journal: Engine oil (EO30) a When installing the main cap, direct its cast part number side toward the front of the engine. Apply engine oil to the threaded portion of the main cap mounting bolt and washer and then drive in the bolts alternately until the main cap is completely fitted. 2 Main cap mounting bolt: Engine oil (EO30)
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
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Threaded portion of mounting bolt and washer: Engine oil (EO30) 3 Main cap mounting bolt 1st time: 284 15 Nm {29 1.5 kgm} 2nd time: 569 10 Nm {58 1.0 kgm} 3rd time: Using tool G, retighten the bolt by 90 (+30/0).
4.
When tool G is not used, apply marking b to the main cap and bolt with paint, and then retighten the bolt by 90 (+30/0). 10) Make punch mark c on the mounting bolt head. a When a new bolt is used, do not make a punch mark on its head.
Piston and connecting rod assembly 1) Assemble the piston and connecting rod 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 a a 11) Check that the crankshaft turns smoothly. a Standard crankshaft starting torque: Max. 147 Nm {15 kgm} 12) Measure the end play of the crankshaft with dial gauge [1]. a End play standard value: 0.140 0.320 mm a If the end play is out of the standard, correct it. For details, see "Structure, function and maintenance standard".
Assemble respective piston rings as shown in the figure. When assembling the respective rings to the piston, direct their stamped side upward. Take the expander out of the oil ring and fit it to the piston first and then assemble the oil ring. At this time, make sure that the expander is fitted to the ring groove perfectly. Make sure that the coil butt joint of the expander is situated in a position 180 to the oil ring abutment joint.
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3]
7]
4]
5]
6]
Set the piston (7) and connecting rod (5). Mate the cast letters "EX i F" on the piston against the chamfered hole side in the big end of the connecting rod and then assemble them. Apply engine oil to the piston pin boss and inner surface of the connecting rod bushing and then insert piston pin (6) while directing the connecting rod upward. 2 Piston pin: Engine oil (EO30) Install snap ring (4) on the opposite side. a Turn the snap ring to make sure that the left and right side snap rings are completely fitted in the ring groove. a Also make sure that the connecting rod moves lightly.
Install the projection of connecting rod upper bearing (11) locating it to the notch of the connecting rod. a Before fitting the bearing, make sure that its back side is free from foreign matter. a Don't apply the oil to the bearing backside. a Make sure that the connecting rod small end bushing are large end bearing hole are aligned with the connecting rod oil hole. a Before assembling the connecting rod, check the connecting rod oil hole for settled dusts. 2 Connecting rod bearing inner surface: Engine oil (EO30)
8]
Install the projection of connecting rod lower bearing (12) locating it to the notch of the connecting rod cap. a Before fitting the bearing, make sure that its back side is free from foreign matter. Don't apply the engine oil to the backside.
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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)
5)
Align the abutment joint of respective piston rings as well as the piston to the position shown in the figure.
3)
4)
Turn the crankshaft to drive the pin journal of the target cylinder of insertion to the top dead center position. After confirming No. of the piston and connecting rod assembly, insert the assembly to the cylinder block directing it in the direction shown in the figure. a Set the direction of the cylinder block in such that the cylinder may face sideways. This process is needed to prevent sudden insertion of the piston and connecting rod assembly to the cylinder. a On each bank, install notch A for the piston cooling nozzle and chamfered side B of the connecting rod. In this case, their positional relation with front direction F of the engine must be as shown in the figure.
Make sure that the coil butt joint of the oil ring is situated in a position 180 to the abutment joint 2 Piston ring, piston and crank journal: Engine oil (EO30) 6) Using tool H, compress the piston ring and then push in the piston head with a wooden bar and the like.
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7)
Using the connecting rod puller [1] shown in the figure, pull the connecting rod until it is closely contacted against the pin journal. a Make sure the connecting rod bearing is not displaced. a The connecting rod puller [1] is made by welding bar b to unnecessary connecting rod bolt a. a Total length of connecting rod puller l: Approx. 500 mm. 2 Crank pin journal: Engine oil (EO30)
When assembling a new connecting rod, record its cylinder No. on the connecting rod cap using a electric pen (stamping is not acceptable). It is strictly prohibited to change the combination of the connecting rod and cap through this operation.
11) Apply the engine oil to the threaded portion and washer of the connecting rod. 2 Connecting rod bolt and washer Engine oil (EO30)
8)
Turn the crankshaft 180 while pulling the connecting rod. 9) Install connecting rod lower bearing (12) to connecting rod cap (2). 2 Connecting rod lower bearing: Engine oil (EO30) 10) Install connecting rod cap (2) aligning it to the dowel pin on the connecting. a Check the cylinder No.
12) Tighten connecting rod bolts (1) alternately until the connecting rod cap is closely contacted.
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When tool G is not used, apply marking b to the connecting rod, connecting rod cap and bolt with paint and then retighten the bolt by 90 (+30/0). 15) After tightening the bolt, make a punch mark c on its head. a When a new bolt is used, do not make a punch mark on its head.
13) Turn the crankshaft 180 and insert the piston and connecting rod assembly on one bank according to the steps 1) 12). 14) Tighten the mounting bolts in the order indicated in the figure according to the following procedure. 3 Connecting rod bolt: 1st time: 69 78 Nm {7 8 kgm} 2nd time: 69 78 Nm {7 8 kgm} (again) 3rd time: Using tool G, retighten the bolt by 90 (+30/0).
After assembling the connecting rod, make sure that the crankshaft rotates normally. 16) Measure the side clearance of the connecting rod with dial gauge [1]. q Standard side clearance: 0.3 0.454 mm a When the side clearance is out of the standard, remove the connecting rod cap and check the connecting rod for assembly errors, presence of burrs or pinching of foreign substances.
5.
Piston cooling nozzle 1) Install piston cooling nozzle (1). a After completely inserting the spigot joint portion to the block side mounting hole, tighten the mounting bolt. 3 Piston cooling nozzle mounting bolt: 54 20 Nm {5.5 2.0 kgm} a Prior to the installation, check the nozzle for damages or internal clogging .
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Make sure prior to the installation that the notch for preventing interference of the piston cooling nozzle is provided on the piston skirt portion.
7.
Camshaft assembly 1) Insert the camshaft assembly (3) to the cylinder block along with the cam gear. a Install it carefully turning the cam shaft so that the cam bushing may not be damaged. a Use care when inserting the cam shaft so that your fingers may not be pinched. 2 Camshaft: Engine oil (EO30)
2)
Turn the crankshaft slowly to make sure that interference is not observed between piston cooling nozzle (1) and piston (2) or connecting rod (3).
2)
Turn the cam gear (1) and tighten mounting bolt (2) through the lightening hole a Replace the current mounting bolt with a new one. 3 Cam shaft mounting bolt: 88 34 Nm {9.0 3.5 kgm}
6.
Timing gear case Lift and install timing gear case (1). a Prior to the installation, fix several portions on the gasket temporarily using the gasket sealant so that it may not be displaced. 4 Gear case cover: 55 kg
8.
Cam follower assembly 1) Assemble the cam follower according to the following procedure. 1] Install snap ring (7) to shaft (6). 2] Install cam follower (5) to shaft (6). 2 Cam follower bushing inner surface: Engine oil (EO30) 3] Install snap rings (4).
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2)
Install cam follower assembly (3). 3 Cam follower assembly mounting bolt: 44.1 58.8 Nm {4.5 6.0 kgm}
10. Supply pump drive case 1) Install supply pump drive case (2). 2) Install oil tube (1). a Install the oil tube on the left bank alone. 3 Oil tube joint bolt: 7.9 12.7 Nm {0.8 1.3 kgm}
3)
Install cam follower cover (2) and then tighten it along with plate (1) using the mounting bolt. a The plate between No. 3 and No. 4 cylinders is longer than those used in other sections. 3 Cam follower cover mounting bolt: 34.3 44.1 Nm {3.5 4.5 kgm}
11. Oil pump assembly Install oil pump assembly (1). 3 Oil pump mounting bolt: 54 20 Nm {5.5 2.0 kgm}
9.
Oil cooler (front side) Install oil cooler (front side) (1)
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12. Idler gear (small) 1) Install idler gear (small) (2). a When installing the idler gear, align the counter mark "D" to that of the cam gear (3) for the right bank. 2 Idler gear bushing inner surface: Engine oil (EO30) 2) Install plate (1) and then tighten the mounting bolt. 2 Plate sliding surface: Engine oil (EO30) 3 Idler gear (small) mounting bolt: 98.0 122.5 Nm {10.0 12.5 kgm} 14. Idler gear (large) 1) Set No. 1 cylinder on the right bank to the top dead center position. a It is referenced as the standard position when adjusting respective gears. 2) Install thrust plate (4) to the shaft. a Install the plate in such that oil groove A may be set on the idler gear side. 2 Thrust plate: Engine oil (EO30)
3)
Install idler gears (large) (2) and (3). 2 Idler gear bushing inner surface: Engine oil (EO30)
2)
Install supply pump gear (1). a After installing all timing gears, tighten mounting nut (3) while fixing the crankshaft. a Or tighten the nut while retaining the lightening hole with a general purpose retention tool and fixing the supply pump gear. 3 Supply pump gear mounting nut: 176 196 Nm {18 20 kgm}
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2) a Install idler gears (large) (2) and (3) in such that their counter marks as well as that of respective gears may come to the positions shown in the figure.
3)
4)
Install plate (1) and then tighten the mounting bolt. a Install the plate setting its "OUT" marking on the outside. 2 Plate sliding surface: Engine oil (EO30) 3 Idler gear (large) mounting bolt: 98.0 122.5 Nm {10.0 12.5 kgm}
Measure the backlash and end play of each gear with the dial gauge. a Symbols in the figure correspond to "Position" field in the following table.
15. Check of timing gear for backlash and end play 1) Attach gear (1) to the compressor and then install them temporarily. (When the engine is equipped with the compressor)
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1]
Position AA B1B1 B2B2 CC DD EE FF GG HH LL RR Note):
(mm) Standard Measuring points value Right idler gear (small) and 0.130 0.390 right sub idler gear (0.125 0.363) Right sub idler gear and right 0.051 0.469 supply pump gear (0.125 0.363) Left sub idler gear and left 0.051 0.469 supply pump gear (0.125 0.363) Left sub idler gear and left 0.129 0.391 cam gear (0.125 0.363) Right idler gear (small) and 0.129 0.391 right cam gear (0.125 0.363) Right idler gear (large) and 0.052 0.481 water pump drive gear Right idler gear (large) and 0.137 0.421 oil pump gear Left supply pump gear and 0.106 0.381 compressor gear (0.138 0.354) Right cam gear and acces0.085 0.492 sory drive gear (0.138 0.354) Crank gear and left idler gear 0.141 0.425 (large) Crank gear and right idler 0.141 0.425 gear (large) The standard value enclosed in ( ) indicates the backlash between spur gears
When cover (2) was removed, apply the gasket sealant in the position shown in the figure before installing it again. 2 Cover: Gasket sealant (LG-7) q Application diameter: 2.0 mm
2]
Position 1 2 3 4 5 6 7
Gear name Idler gear (large) end play Idler gear (small) end play Supply pump gear end play Oil pump gear end play Accessory drive gear end play Crank gear end play Cam gear end play
16. Gear case cover Lift and install gear case cover (1). 4 Gear case cover: 75 kg
17. Front oil seal Following remedial actions are needed depending on presence and absence wear on the contact face of the oil seal on the crankshaft. 1) When a new crankshaft is used or when wear is not recognized on the contact surface of oil seal. q Either of the dimensions listed in the following table shall apply to oil seal press-fitting depth a depending on front cover size b and presence/ absence of bolt hole in the cover end face.
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3)
When the actions up to step 2) above have 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 following procedure. 1] Scrub rusts off the press-fitted portion of the sleeve (60 mm range from the tip) on crankshaft (2). 2] Apply entire inner surface of the sleeve with gasket sealant. 2 Inner surface of sleeve: Gasket sealant (LG-7)
2)
When wear is recognized on the oil seal contact face of crankshaft (2) and oil seal installation position is movable. q Move the oil seal (1) installation position backward up to a location where the lip of the new oil seal (1) won't be in touch with the wear groove on the crankshaft (2).
3]
Install sleeve (3) in parallel with crankshaft (2) while hitting sleeve (3) end face lightly in circumferential direction using a plastic hammer. a Since sleeve (3) is symmetric in its shape, no mounting direction is specified.
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1]
When rubber is used in the periphery of the oil seal, use rubber lubricating liquid (RF-1) or soap water for the applying. Select one of the following 3 oil seal (1) press-fitting depths depending on the condition of the crankshaft (2). When a new crankshaft (2) is used or when wear is not recognized on the contact surface of oil seal. q Prior to installation, insert a 1.8 2.8 mm spacer [1] between tool J and oil seal (1).
4]
Using tool J, press-fit sleeve (3) to the specified position. a Be sure to tighten the bolts evenly. a After press-fitting the sleeve, clean the projected gasket sealant completely (adhesion of such gasket sealant to the seal lip can cause leakage of oil).
2]
When installing oil seal (1) after modifying its originally intended installation position. q Install oil seal (1) as is using tool J.
5)
Using tool J, install front oil seal (1). a Tighten the mounting bolts evenly. a Before assembling the oil seal, clean periphery of the crankshaft and apply all circumferences with the engine oil. 2 Crankshaft: Engine oil (EO30) a Apply all circumferences of the oil seal lip with the engine oil. 2 Oil seal lip: Engine oil (EO30) 2 Metal ring face in oil seal periphery: Gasket sealant (LG-4) a Use care in above operation so tha t the s eal li p m ay not be applied with the oil.
3]
When sleeve (3) is provided for crankshaft (2). q Install the sleeve using a washer [2] between tool J and crankshaft (2).
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18. Front support Install front support (1). a Prior to the installation, fill the oil hole with grease. a Volume of grease filled: 20 cc 2 Front support: Grease (G2-LI)
2)
Lift and install damper and crank pulley assembly (1). a Install the assembly aligning it to the dowel pin of the crankshaft. 4 Damper and crank pulley assembly: 75 kg
19. Damper and crank pulley assembly 1) When the damper and crank pulley are separated, assemble them again by tightening the mounting bolts in the order indicated in the figure. 2 Damper mounting bolt and washer: Engine oil (EO30) 3 Damper mounting bolt: 98 122 Nm {10 12.5 kgm}
Tighten the mounting bolts in 3 steps according to the order indicated in the figure. 2 Damper and crank pulley pump assembly mounting bolt and washer: Engine oil (EO30) 3 Damper and crank pulley assembly mounting bolt 1st time: 73.5 19.6 Nm {7.5 2 kgm} 2nd time: 245 19.6 Nm {25 2 kgm} 3rd time: 744.8 19.6 Nm {76 2 kgm}
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20. Flywheel housing 1) Lift and install flywheel housing (4). 4 Flywheel housing: 230 kg
2)
3)
After the installation, cut off the gasket projecting from the oil pan mounting surface to make height of the gasket and mounting surface even. Install burring tool (1) and Ne speed sensor (2).
Tighten the mounting bolts in 3 steps according to the order indicated in the figure. 2 Flywheel housing mounting bolt: Engine oil (EO30) 3 Flywheel housing mounting bolt: 1st time: 343 49 Nm {35 5 kgm} 2nd time: Loosen it fully 3rd time: 411.6 19.6 Nm {42 2 kgm}
21. Rear oil seal Following remedial actions are needed when wear is recognized on the contact face of the oil seal on the crankshaft. 1) When a new crankshaft is used or when wear is not recognized on the contact surface of oil seal (1). q Install the rear oil seal in such that the dimension from the flywheel housing end face may conform to the standard dimension indicated in the figure.
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2)
When wear is recognized on the oil seal contact 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 in the figure where the lip of a new oil seal won't be in touch with the wear groove on the crankshaft.
3]
Install sleeve (3) in parallel with crankshaft (2) while hitting sleeve (3) end face lightly in circumferential direction using a plastic hammer. a Since sleeve (3) is symmetric in its shape, no mounting direction is specified.
3)
When the actions up to step 2) above have been conducted on a crankshaft. q Attach sleeve (3) to crankshaft (2) and then install an oversized oil seal (1) in the position indicated in the figure.
4]
4)
Install sleeve (3) according to the following procedure. 1] Scrub rusts off the press-fitted portion of the sleeve (60 mm range from the tip) on crankshaft (2). 2] Coat entire inner surface of sleeve (3) with gasket sealant. 2 Inner surface of sleeve: Gasket sealant (LG-7)
Using tool K, press-fit sleeve (3) up to the position indicated in the figure. a Be sure to tighten the bolts evenly. a After press-fitting the sleeve, clean the projected gasket sealant completely (adhesion of such gasket sealant to the seal lip can cause leakage of oil).
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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 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 tha t the s eal li p m ay not be applied with the oil. a When rubber is used in the periphery of the oil seal (1), use rubber lubricating liquid (RF-1) or soap water for the applying. a Select one of the following 3 oil seal press-fitting depths depending on the condition of the crankshaft (2). 1] When a new crankshaft is used or when wear is not recognized on the contact surface of oil seal. q Use 2 washers [1] between tool K and crankshaft.
2]
When installing the oil seal after modifying its originally intended installation position. q Don't use a washer [1] between tool K and crankshaft.
3]
When sleeve (3) is provided for the crankshaft. q Use 2 washers [1] between tool K and crankshaft (2).
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22. Flywheel assembly 1) Lift and install flywheel assembly (1). a Install the assembly aligning it to the dowel pin of the crankshaft. 4 Flywheel assembly: 130 kg
2)
After installing the flywheel, inspect its facial runout and radial runout using dial gauge [2]. Standard facial runout: Max. 0.25 mm Standard radial runout: Max. 0.25 mm
When tightening the mounting bolt, fix the space flywheel and flywheel housing using plate [1] in order to prevent the crankshaft from turning.
3)
Tighten the mounting bolts in the following order. 2 Flywheel assembly mounting bolt: Engine oil (EO30) 3 Flywheel mounting bolt 1st time: 98 19.6 Nm {10 2 kgm} 2nd time: 294 19.6 Nm {30 2 kgm} 3rd time: 539 19.6 Nm {55 2 kgm}
Install engine speed sensor (3). a Tighten the locknut until the sensor tip is contacted against the ring gear tooth tip of the flywheel. Return the sensor 3/4 - 1 turn from above position and then tighten the locknut. 3 Engine speed sensor locknut: 49 68.6 Nm {5 7 kgm}
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23. Accessory drive assembly 1) Assemble the accessory drive. 1] Pull off bushing (10) and oil seal (9) to housing (8). a Press-fit the bushing 2 mm deeper from the end face. 2 Bushing inner surface: Engine oil (EO30) a Press-fit the oil seal 1.5 mm deeper from the end face. 2 Seal lip: Grease (G2-LI) a Fill 50 80% of the lip open space with the grease. 2] Press-fit gear to (7) to shaft (5). 3] Assemble thrust plate (6) to the shaft and gear assembly and then insert the housing from the rear side. 4] Assemble thrust plate (4) to the shaft and then press-fit hub (3). a Use care in above operation so that the seal lip may not be damaged.
24. Thermostat housing 1) Install thermostat housing (2). 2) Install water temperature sensor (1).
2) 3)
2) 3)
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29. Relief valve 1) Remove engine assembly (1) from tool A and then support it using block [1]. a Make sure the engine is supported stably. 2) Install relief valve (1).
27. Breather Install breather (1), blow-by pipe (2) and plate (3). 3 Breather mounting bolt: 24.5 29.4 Nm {2.5 3.0 kgm} a Install plate (3) to the left side bank alone. 30. Suction pie and under plate 1) Using jack [1], install under plate (1) and then fix it temporarily using the oil pan mounting bolt. 4 Under plate: 25 kg
2)
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2)
34. Cylinder head assembly 1) Assemble the cylinder head assembly according to the following procedure. 1] Install valve (7). 2] Install lower seat (6).
32. Oil level gauge and oil filler tube 1) Install bracket (4). 2) Install oil level gauge (3) and then tighten the sleeve nut at the base. 3) Install oil filler tube (2). 4) Install bracket (1).
3]
Using tool L, install stem seal (8). a Drive in tool L until its lower end a is contacted against lower seat (6).
33. Common rail 1) Install bracket (3). 2) Install common rail (2). a Install the common rail at this point since positioning of the high-pressure pipe is needed when installing the fuel injector. 3 Common rail mounting bolt: 59 74 Nm {4 5 kgm}
4]
Install inner spring (5), outer spring (4) and upper seat (3).
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5]
Using tool B, compress the valve spring to install cotter (2). a After the installation, hit the valve stem lightly with the plastic hammer to make sure the cotter is installed stably.
Cylinder head assembly mounting bolt (No. 1 6) 1st time: 137 157 Nm {14 16 kgm} 2nd time: 284 294 Nm {29 30 kgm} 3rd time: 90 (+30/0)
2) 3)
Install the cylinder head gasket. Lift and install cylinder head assembly (1). 4 Cylinder head assembly: 30 kg
When tool G is not used in tightening of the 3rd time, check the rotating angle after applying marking b to the cylinder head and bolt head using paint.
4)
Tighten the mounting bolts according to the following procedure. 1] Tighten mounting bolts (No. 1 7) temporarily. 2] Tighten the mounting bolts (No. 1 6) in 3 steps according to the order indicated in the figure. a When a bolt with 5 punch marks, which indicates the tightening frequency up to today, in its head is found, replace it with a new one. 2 Cylinder head assembly mounting bolt: Molybdenum disulfide lubricant (LM-P)
3]
4]
Tighten the mounting bolt (No. 7) with the following torque. 2 Cylinder head assembly mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Cylinder head assembly mounting bolt (No. 7): 66.2 7.4 Nm {6.75 0.75 kgm} After the tightening, stamping punch mark a to the head of mounting bolts (No. 1 6).
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3)
4)
5)
5)
Install the water tube. Water tube joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm}
Install spherical washer (7) and then tighten holder mounting bolt (1) temporarily. 2 Special washer: Engine oil (EO30) Tighten sleeve nut (5) of the high-pressure pipe temporarily. a Also tighten the sleeve nut on the common rail side temporarily to proceed with the positioning. a See "High-pressure pipe" for precautions on this operation. Tighten holder mounting bolt (1) with the specified torque. 3 Holder mounting bolt: 58.8 73.5 Nm {6 7.5 kgm} a Leave sleeve nut (5) being tightened temporarily in above operation as is. This nut is to be tightened with the specified torque in the next step.
35. Fuel injector a Check that the inside of the injector sleeve is free from dirt. 1) Install O-rings (4) and (5) and gasket (6) to the fuel injector. 2 O-ring: Engine oil (EO30)
2)
Insert fuel injector (2) to the cylinder head along with holder (3).
36. High-pressure pipe (between common rail fuel injector) k Install the high-pressure pipe and clamp paying attention to the following points. q It is strictly prohibited to reuse a highpressure pipe by modifying its bend or using the pipe in an unintended location. q The clamp used must be a legitimate one. And it must be installed in the specified position with the specified torque. q After installing the high-pressure pipe and clamp, make sure that 10 mm m i n im u m c le a r a nc e i s p r ov i d e d between the high-pressure pipe and adjacent harness. If the clearance is less than 10 mm, adjust the harness position to secure the space. k Before installing the high-pressure pipe, check it for the following defects. If there is any of these defects, it can cause fuel leakage. Accordingly, replace the high-pressure pipe.
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Check the taper seal of the connecting part (Part a: Part of 2 mm from the end) for visible lengthwise slit b and dent c. Check part d (end of the taper seal: Part at 2 mm from the end) for stepped-type wear (fatigue) which your nail can feel.
2) 3)
1)
After installing fuel injector (5) and common rail (6) temporarily to high-pressure pipe (4), tighten the sleeve nut with the specified torque. a Control the torque by using a spanner type torque wrench (commercially available) for the tightening. 3 High-pressure pipe sleeve nut (injector side): 39.2 49 Nm {4 - 5 kgm} 3 High-pressure pipe sleeve nut (common rail side): 39.2 - 49 Nm {4 5 kgm} a After the tightening, make sure the Oring is not projecting from the sleeve nut.
4) 5) 6)
7)
8)
Manually tighten and install temporarily the stay and top and bottom clamps of high-pressure pipe clamp (7). Tighten the top and bottom clamps permanently. a Before tightening the stay permanently, deflect the rubber fist. 3 Top and bottom clamp bolt: 9.8 1 Nm {1 0.1 kgm} Tighten the stay permanently. Manually tighten and install temporarily the stay and top and bottom clamps of the high-pressure pipe. Install the high-pressure pipe clamp and gate type frame temporarily. a First tighten the high-pressure pipe clamp permanently, and then tighten the gate type frame permanently to the common rail mounting bolt. 3 Gate type frame mounting bolt: 9.8 1 Nm {1 0.1 kgm} Tighten the high-pressure pipe clamp permanently. 3 High pressure pipe clamp bolt: 9.8 1 Nm {1 0.1 kgm} Tighten the clamp stay permanently. a Tighten the clamp of the air intake manifold after installing the manifold.
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9)
Install the rubber cover to the sleeve nut on the high-pressure pipe. a Direct the slit downward when installing the rubber cover. q Injector side (8): Bottom q Common rail side (9): Cylinder block side
2)
When installing the high-pressure pipe without removing the fuel injector (for example, when replacing only the high-pressure pipe with new one), follow the procedure below. q Tighten sleeve nut (10) by 2 turns with the hand into the threads of the fuel injector and then tighten it with the spanner. a If sleeve nut (10) does not catch the threads, it will help to turn the spanner while pressing sleeve nut (8) end with a small rod, etc. toward the injector.
Adjust the crosshead according to the following procedure. 1] Loosen locknut (2) and then loosen adjustment screw (3) to a position where it does not valve stem (4). 2] Maintain the contact with valve stem (5) on the push rod side by pressing the contact face against the rocker arm using a finger. 3] Tighten adjustment screw (3) to confirm the position where adjustment screw (3) is contacted against valve stem (4). 4] Drive in adjustment screw (3) further by 20 from the contacting position against valve stem (4). 5] Tighten locknut (2) while suppressing move of adjustment screw (3). 3 Locknut: 58.8 5.9 Nm {6.0 0.6 kgm}
37. Crosshead 1) Install crosshead (1). 2 Crosshead sliding portion: Engine oil (EO30)
38. Injector harness 1) Push connector (3) out of the cylinder head and then install injector harness (4) in the cylinder head. 2) Tighten injector terminal mounting nut (1) and clamp mounting bolt (2).
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Alternately tighten injector terminal mounting nuts (1). 3 Injector terminal mounting nut: 2 0.2 Nm {0.2 0.02 kgm} a After tighten the injector terminal mounting nut, push the harnes s against the injector body to eliminate sagging.
2)
Install exhaust rocker arm (4), spacer (5) and air intake rocker arm (6) to rocker arm shaft (7). 2 Rocker arm shaft: Engine oil (EO30)
39. Push rod Install push rod (1). a Make sure that the push rod end is securely fitted to the cam follower socket. 2 Both ends of push rod: Engine oil (EO30)
3)
40. Rocker arm assembly 1) Assemble the rocker arm assembly according to the following procedure. 1] Install adjustment screw (2) on rocker arms (4) and (6), and then install lock nut (1). a Screw in adjustment screw (2) until its spherical part touches rocker arms (4) and (6).
Install rocker arm assembly (3). a Make sure that the ball of adjustment screw (2) is securely fitted to the push rod socket. a When tightening the mounting bolt, make sure adjustment screw (2) is not pushing the push rod. 2 Rocker arm: Engine oil (EO30) 3 Rocker arm assembly mounting bolt: 93 103 Nm {9.5 10.5 kgm} a Tighten locknut (1) after adjustment of the valve clearance is completed.
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3)
4)
Tighten locknut (6) to secure adjustment screw (5). 3 Locknut tightening torque: 52.9 64.7 Nm {5.4 6.6 kgm} a After tightening the locknut, check the valve clearance again. Repeat the same procedure for other engines, too, in the order of firing. Namely, crank the engine and then locate the stamped of the damper to the pointer to adjust the valve clearance of respective cylinders. a Firing order R1 - L1 - R5 - L5 - R3 - L3 - R6 - L6 R2 - L2 - R4 - L4
41. Adjusting valve clearance 1) Rotate the crankshaft forward and drive right No.1 cylinder to the compression top dead center, while watching move of the intake valve on right No. 6 cylinder. Then locate the stamped line of R1.6 TOP of vibration damper (1) to pointer (2). a Crank the engine using the burring tool (B) being provided in the front right side of the flywheel housing. a The intake valve of right No. 6 cylinder will start moving as right No. 1 cyli nder i s dri ve n to vi ci nity of the compression top dead center. (Open) a Figure shows the cylinder No. and their firing order (circled numbers indicate the firing order).
2)
Loosen locknut (6) of adjustment screw (5) of the right No. 1 cylinder and then in se r t cl ea ra nc e ga ug e M , wh ic h i s adjusted to the specified thickness, between crosshead (4) and rocker arm (3). Then using the adjustment screw, adjust the clearance to a degree that allows only slight move of the gauge. a Standard valve clearance: q Intake valve: 0.35 0.02 mm q Exhaust valve: 0.57 0.02 mm 12V140E-3 Series
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42. Head cover Install head cover (1). 3 Head cover mounting bolt: 14.7 34.3 Nm {1.5 3.5 kgm}
45. Oil cooler (rear side) 1) Install oil cooler (2). 2) Install oil manifold (1).
43. Fuel tube Install fuel tube (1). 3 Fuel tube joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm}
46. Water pump assembly 1) Install housing (5) to water pump (4).
2) 44. Plate and block Install block (3) and plates (2) and (1).
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3) 4)
Tighten the mounting bolts in the following order. a Tighten it once and then tighten again with the same torque. 2 Exhaust manifold assembly mounting bolt: Molybdenum disulfide lubricant (LM-P) 3 Exhaust manifold assembly mounting bolt: 44.1 53.9 Nm {4.5 5.5 kgm}
47. Corrosion resister and filter head assembly Install corrosion resister and filter head assembly (1).
3)
Install bracket (4), water pipe (3), muffler bracket (2) and insulating plate (1).
48. Exhaust manifold assembly 1) Install the gasket. a Install the gasket directing its "OUT" marking to the exhaust manifold side. 2) Lift and install exhaust manifold assembly (5). 4 Exhaust manifold assembly: 25 kg
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49. Turbocharger assembly 1) Lift and install turbocharger assembly (1). a Tighten the turbocharger assembly mounting bolt after temporarily tightening and positioning of respective connections. 4 Turbocharger assembly: 35 kg 2 Turbocharger assembly mounting bolt and nut: Molybdenum disulfide lubricant (LM-P) 3 Turbocharger assembly mounting bolt: 44.1 53.9 Nm {4.5 5.5 kgm}
51. Air intake manifold assembly 1) Install the gasket. a Install the gasket setting its "UP" marking upward and also directing this side to the intake manifold. 2) Lift and install air intake manifold assembly (2). 4 Intake manifold assembly: 45 kg
2)
Install water pipes (2) and (3) and oil pipes (4) and (5). a As for the air-cooled turbocharger, install the oil pipes alone. 3 Water connector (Block side): 78.5 103 Nm {8 10.5 kgm} 3 Water pipe flare nut (Water connector side): 24.5 59 Nm {2.5 6 kgm} 3 Water pipe joint bolt (Turbocharger side): 24.5 34.3 Nm {2.5 3.5 kgm} 3 Water connector (Turbocharger side): 29.4 39.2 Nm {3 4 kgm} 3 Water pipe flare nut (Water connector side): 29.4 39.2 Nm {3 4 kgm}
Tighten the mounting bolts in the following order. 3 Intake manifold assembly mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
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3)
53. Spill tube Install spill tube (1). 3 Spill tube joint bolt Cylinder head side: 9.8 12.7 Nm {1.0 1.3 kgm} Intake manifold side: 19.6 29.4 Nm {2.0 3.0 kgm}
52. High-pressure pipe clamp Install brackets (1) and (2) to the exhaust manifold and then tighten high-pressure pipe clamp bolt (3). 3 High pressure pipe clamp bolt: 9.8 1 Nm {1 0.1 kgm} 54. Supply pump assembly and high-pressure pipe (between supply pump - common rail) k Install the high-pressure pipe and clamp paying attention to the following points. q It is strictly prohibited to reuse a highpressure pipe by modifying its bend or using the pipe in an unintended location. q The clamp used must be a legitimate one. And it must be installed in the specified position with the specified torque. q After installing the high-pressure pipe and clamp, make sure that 10 mm m i n im u m c le a r a nc e i s p r ov i d e d between the high-pressure pipe and adjacent harness. If the clearance is less than 10 mm, adjust the harness position to secure the space. 1) Install supply pump assembly (1) temporarily. a Align and insert the unequal spline portion of the supply pump side to unequal spline portion A of the supply pump drive case side. a When it is difficult to insert the supply pump , turn the crankshaft to change position of unequal spline portion A.
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Tighten mounting bolt (2) with the specified torque after tightening the sleeve nut of the high-pressure pipe (between supply pump and common rail). 2 Supply pump assembly mounting bolt: Adhesive (LT-2)
6)
7)
2)
3) 4)
5)
After installing high-pressure pipes (4) and (5) to supply pump (1) and common rail (3) temporarily, tighten the sleeve nut with the specified torque. a Control the torque by using a spanner type torque wrench (commercially available part) for the tightening. 3 High-pressure pipe sleeve nut (supply pump side): 39.2 49 Nm {4 5 kgm} 3 High-pressure pipe sleeve nut (common rail side): 39.2 58.8 Nm {4 6 kgm} Tighten supply pump assembly mounting bolt (2). Tighten the mounting bolt across the supply pump assembly bottom face and bracket. 3 Supply pump mounting bolt (Bottom side): 19.6 29.4 Nm {2.0 3.0 kgm} Install oil tube (6). 3 Oil tube joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm}
Install high-pressure pipe clamp (7) according to the following procedure. 1] Manually tighten and install temporarily the stay and top and bottom clamps of the high-pressure pipe clamp. 2] Tighten the top and bottom clamps permanently. a Before tightening the stay permanently, deflect the rubber fist. a Use care in the tightening so that ex c e ss i v e fo r ce ma y n ot b e applied to the supply pump side install position. 3 Top and bottom clamp bolt: 9.8 1 Nm {1 0.1 kgm} 3] Tighten respective stays permanently. Install the rubber cover to the sleeve nut on the high-pressure pipe. a Direct the slit downward when installing the rubber cover. q Supply pump side (8): Bottom q Common rail side (9): Facing inward (Opposed)
55. Fuel pipe 1) Install priming pump (4). a If the air bleeding plug is removed, tighten the pump with the following torque.
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3
2)
Air bleeding plug: 24.5 34.3 Nm {2.5 3.5 kgm} Install fuel pipes (1) (3). 3 Fuel pipe joint bolt (Common rail side): 17.7 22.6 Nm {1.8 2.3 kgm} 3 Fuel pipe joint bolt (Supply pump side): 14.8 19.6 Nm {1.5 2.0 kgm}
58. Engine controller and controller cooler 1) Install controller cooler (4). 2) Install fuel hoses (2) and (3). 3) Install engine controller (1). 3 Engine controller mounting bolt: 23.5 Nm {2.4 kgm}
57. Air inlet pipe 1) Install bracket (3). a Install bracket (3) to the right side bank alone. 2) Install bracket (2). 3) Install air inlet pipe (1) and then fix it with the clamp. 3 Clamping nut: 29.4 44.1 Nm {3.0 4.5 kgm} 4 Air inlet pipe: 35 kg
59. Fuel filter and filter head assembly 1) Install fuel filter and filter head assembly (3). 2) Install fuel tubes (1) and (2). 3 Fuel tube joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
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60. Alternator 1) Install alternator (2). 2) Install auxiliary equipment belt (1). 3) Adjust tension of the auxiliary equipment belt. a Adjust its deflection to 20 mm when the pushing force of 58.8 Nm {6 kgm} is applied to the belt center through a finger. 3 Adjuster lock bolt: 53.9 122.6 Nm {5.5 12.5 kgm}
63. Checking for fuel leakage a When removal and installation of fuel supply pump (1), common rail (2), or highpressure pipes (3) and (4) were conducted, check fuel leakage according to the following procedure after assembling the engine. a Here, high-pressure pipes (3) and (4) denote every fuel pipe (the figure shows an example). 61. Starting motor assembly Install staring motor assemblies (3) and (2) and then connect wiring harness (1) to them. a Install the top assembly first being followed by the bottom one. 3 Starting motor B terminal nut: 19.6 25.5 Nm {2 2.6 kgm}
1)
2) 62. Engine wiring harness Install engine wiring harness (1) on the engine assembly and then connect the connector and terminal. 3)
4)
Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1). Run the engine at low idle.
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5)
6) 7)
8)
9)
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1). Run the engine at high idle. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1). Run the engine at high idle and load it. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the hydraulic pump. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1). a If no fuel leakage is detected, check is completed.
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ENGINE
1SHOP MANUAL
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Figure shows an example of the left side bank. Except where otherwise noted, the same work procedure shall be employed for the both banks.
Removal 1. 2. Remove the connectors (in 3 places). Remove fuel return hose (3) between common rail (1) and supply pump (2). [*1] a A fuel return pipe is provided on the right side bank. Since it does not allow removal halfway, the whole set of the pipe must be removed.
6. 7.
Remove oil tube (9) between supply pump (2) and the cylinder block. [*4] Disconnect fuel tube (10) between the fuel filter and supply pump (2) from the supply pump side. [*5]
3. 4.
Remove fuel tube (5) between priming pump (4) and supply pump (2). [*2] Remove fuel tube and hose assembly (7) between supply pump (2) and controller cooler (6).
8.
5.
Remove 2 high-pressure pipes (8) between supply pump (2) and common rail (1). [*3]
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9.
Remove 4 mounting bolts (12) and then remove supply pump assembly (2). [*7]
2)
3) Fuel return hose (3) joint bolt (Common rail side): 17.7 22.6 Nm {1.8 2.3 kgm} Fuel tube (5) joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
[*2]
[*3] [*7] Install the supply pump and high-pressure pipe by finalizing their position the following procedure. 1) Install supply pump assembly (2) temporarily. a Align the unequal spline portion of the supply pump side to unequal spline portion A of the supply pump drive case side and then insert the supply pump.. a When it is difficult to insert the supply pump , turn the crankshaft to change position of unequal spline portion A.
4)
Tighten mounting bolt (12) with the specified torque after tightening the sleeve nut of the high-pressure pipe (between supply pump and common rail). 2 Supply pump assembly mounting bolt: Adhesive (LT-2) After installing high-pressure pipes (8) on supply pump (2) and common rail (1) temporarily, tighten the sleeve nut with the specified torque. a Use a spanner type torque wrench (commercially available part) should be used for the tightening to ensure observance of the specified torque. 3 High-pressure pipe sleeve nut (Supply pump side): 39.2 49 Nm {4 5 kgm} 3 High-pressure pipe sleeve nut (Common rail side): 39.2 58.8 Nm {4 6 kgm} Install the clamp of the high-pressure pipe according to the following procedure. 1] Manually tighten and install temporarily the stay and top and bottom clamps of the high-pressure pipe. 2] Tighten the top and bottom clamps permanently. a Before tightening the stay permanently, deflect the rubber fist. a Take care in the tightening so that excessive force may not be applied to the supply pump side install position. 3 Top and bottom clamp bolt: 9.8 1 Nm {1 0.1 kgm} 3] Tighten respective stays permanently. Install the rubber cover to the sleeve nut on the high-pressure pipe. a Direct the slit downward when installing the rubber cover. q Supply pump side: Bottom side q Common rail side: Faced inward (Opposed) Oil tube (9) joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm} Fuel tube (10) joint bolt: 24.5 34.3 Nm {2.5 - 3.5 kgm} Supply pump mounting bolt (Pump bottom side): 19.6 29.4 Nm {2.0 3.0 kgm}
[*4]
[*5]
[*6]
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Removal of standard seal Hitch the end of tool N to the metal ring of seal (1) and pull out the seal with impacts of slide hammer [1]. a Before pulling out the seal, drive in it a little to separate it from the housing for the ease of removal. a Do not use a drill, etc. since chips may enter the engine.
Removal of sleeved seal 1) Hitch the end of tool N to the metal ring of seal (1) and pull out the seal with impacts of slide hammer [1]. a Before pulling out the seal, drive in it a little to separate it from housing (2) for the ease of removal. 2) Cut and remove sleeve (3) with a chisel and a hammer. a When cutting the sleeve, take care extremely not to damage crankshaft (4). a Remove all the chips. a The left one in the following figure is the standard seal and the right one is the sleeved seal.
Installation a Check the Teflon seal (Laydown lip seal) by checking the wear of the shaft and replace it with the "Standard seal "or " Sleeved seal". a If the shaft is worn to the degree of luster (If wear which you feel with your finger is less than 10 m) and does not have any flaw, install the standard seal.In other cases, install the sleeved seal. a The left one in the following figure is the standard seal and the right one is the sleeved seal.
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Installation Following remedial actions are needed when wear is recognized on the contact face of the oil seal on the crankshaft. 1) When a new crankshaft is used or when wear is not recognized on the contact surface of oil seal. q Install the rear oil seal in such that the dimension from the flywheel housing end face may conform to the standard dimension indicated in the figure.
4)
Install sleeve (3) according to the following procedure. 1] Scrub rusts off the press-fitted portion of the sleeve (60 mm range from the tip) on crankshaft (2). 2] Apply entire inner surface of sleeve (3) with gasket sealant. 2 Inner surface of sleeve: Gasket sealant (LG-7)
2)
When wear is recognized on the oil seal contact face of crankshaft (2) and oil seal (1) installation position is movable. Move the oil seal installation position backward up to the location shown in the figure where the lip of a new oil seal won't be in touch with the wear groove on the crankshaft.
3]
Install sleeve (3) in parallel with crankshaft (2) while hitting sleeve (3) end face lightly in circumferential direction using a plastic hammer. Since sleeve (3) is symmetric in its shape, no mounting direction is specified.
3)
q
When the actions up to step 2) above have been conducted on a crankshaft. Attach sleeve (3) to crankshaft (2) and then install an oversized oil seal (1) in the position indicated in the figure.
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4] a a
Using tool K, press-fit sleeve (3) up to the position indicated in the figure. Be sure to tighten the bolts evenly. After press-fitting the sleeve, clean the projected gasket sealant completely (adhesion of such gasket sealant to the seal lip can cause leakage of oil).
2]
q
When installing oil seal after modifying its originally intended installation position. Don't use a washer [1] between tool K and crankshaft.
5) a a
Using tool K, install rear oil seal (1). Tighten the mounting bolts evenly. Before assembling the oil seal, clean periphery of the crankshaft and apply all circumferences with the engine oil. 2 Crankshaft: Engine oil (EO30) a Apply all circumferences of the oil seal lip with the engine oil. 2 Oil seal lip: Engine oil (EO30) 2 Metal ring face in oil seal periphery: 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) or soap water for the applying. a Select one of the following 3 oil seal press-fitting depths depending on the condition of the crankshaft. 1] When a new crankshaft is used or when wear is not recognized on the contact surface of oil seal. q Use 2 washers [1] between tool K and crankshaft.
3]
q
When sleeve (3) is provided for the crankshaft. Use 2 washers [1] between tool K and crankshaft (2).
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2.
Removal a For the work up to removal of the damper, see the shop manual for the applicable machine. 1) Remove front oil seal (1).
2)
Installation Install front seal (1) according to the following procedure. Following remedial actions are needed depending on presence and absence wear on the contact face of the oil seal on the crankshaft. 1) When a new crankshaft is used or when wear is not recognized on the contact surface of oil seal. q Either of the dimensions listed in the following table shall apply to oil seal press-fitting depth a depending on front cover size b and presence/ absence of bolt hole in the cover end face.
Dimension b 109 mm 114 mm Bolt hole 6-12 x 1.75 Absent Present Oil seal press-fitting depth a 13 14 mm 18 19 mm
When wear is recognized on the oil seal contact face of crankshaft (2) and oil seal installation position is movable. q Move the oil seal (1) installation position backward up to a location where the lip of the new oil seal (1) won't be in touch with the wear groove on the crankshaft (2).
3)
When the actions up to step 2) above have been conducted on crankshaft (2). q Attach sleeve (3) to crankshaft (2) and then install an oversized oil seal.
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4)
Install sleeve (3) according to the following procedure. 1] Scrub rusts off the press-fitted portion of the sleeve (60 mm range from the tip) on crankshaft (2). 2] Apply entire inner surface of the sleeve with gasket sealant. 2 Inner surface of sleeve: Gasket sealant (LG-7)
5)
3]
Install sleeve (3) in parallel with crankshaft (2) while hitting sleeve (3) end face lightly in circumferential direction using a plastic hammer. a Since sleeve (3) is symmetric in its shape, no mounting direction is specified.
Using tool J, install front oil seal (1). a Tighten the mounting bolts evenly. a Before assembling the oil seal, clean periphery of the crankshaft and apply all circumferences with the engine oil. 2 Crankshaft: Engine oil (EO30) a Apply all circumferences of the oil seal lip with the engine oil. 2 Oil seal lip: Engine oil (EO30) 2 Metal ring face in oil seal periphery: Gasket sealant (LG-4) a Take care in above operation so that the se al lip ma y not b e applied with the oil. a When rubber is used in the periphery of the oil seal, use rubber lubricating liquid (RF-1) or soap water for the applying. a Select one of the following 3 oil seal (1) press-fitting depths depending on the condition of the crankshaft (2). 1] When a new crankshaft (2) is used or when wear is not recognized on the contact surface of oil seal. q Prior to installation, insert a 1.8 2.8 mm spacer [1] between tool J and oil seal (1).
4]
Using tool J, press-fit sleeve (3) to the specified position. a Be sure to tighten the bolts evenly. a After press-fitting the sleeve, clean the projected gasket sealant completely (adhesion of such gasket sealant to the seal lip can cause leakage of oil).
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2]
When installing oil seal (1) after modifying its originally intended installation position. q Install oil seal (1) as is using tool J.
3]
When sleeve (3) is provided for crankshaft (2). q Install the sleeve using a washer [2] between tool J and crankshaft (2).
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