Komatsu Engine 12V140E-3 series workshop service manual

Description Komatsu Engine 12V140E-3 series workshop service manual

Komatsu Engine 12V140E-3 series pdf workshop service & repair manual

Specifications, maintenance, testing, technical documentation, troubleshooting, diagrams, circuits, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Composition of shop manual
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Outline
Specifications
General view
Weight table
Engine performance curves

Structure, function and maintenance standard
Air intake and exhaust unit
Air cleaner
Turbocharger
Aftercooler
Muffler
Cylinder head
Cylinder block
Cylinder liner
Main moving parts
Crankshaft
Camshaft
Cam follower and push rod
Piston, piston ring, and piston pin
Connecting rod
Flywheel and flywheel housing
Vibration damper
Timing gear
Valve system
Valve and valve guide
Rocker arm and shaft
Crosshead and guide
Lubrication system
Lubrication system diagram
Oil pump
Oil cooler
Oil filter
Main relief valve
Oil cooler bypass valve and regulator valve
Fuel system
CRI system diagram
CRI system diagram (Poor fuel spec.)
Outline of CRI system
Fuel piping
Fuel piping (Poor fuel spec.)
Fuel filter
Water separator
Priming pump
Electric priming pump
Cooling system
Cooling system diagram
Water pump
Thermostat
Corrosion resistor
Cooling fan drive
Electrical equipment
Alternator
Starting motor
Starting aid
Engine controller
Engine controller cooler

Standard value table
Standard service value table
Standard service value table for testing, adjusting, and troubleshooting
Running-in standard and performance test standard

Testing and adjusting
Testing and adjusting tools list
Testing air boost pressure
Testing exhaust temperature
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing oil pressure
Handling fuel system parts
Releasing residual pressure in fuel system
Testing fuel pressure
Reduced cylinder mode operation
No-injection cranking
Testing leakage-from pressure limiter and return rate from injector
Bleeding air from fuel circuit
Testing fuel system for leakage
Adjusting speed sensor
Testing and adjusting alternator belt tension
Handling controller high-voltage circuit

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Error codes and failure codes list
Information in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting of mechanical system (S-mode)
Method of using troubleshooting charts
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

Troubleshooting of electrical system (E-mode), Part 1
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank)
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank)
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank)
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only)
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only)
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only)
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only)
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only)
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only)
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only)
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only)
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only)
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank)
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)
E-23 Code [234/CA234] Eng. Overspeed (LH bank only)
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank)
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank)
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)
E-30 Code [271/CA271] PCV1 Short Error (LH bank)
E-31 Code [271/CB271] PCV1 Short Error (RH bank)
E-32 Code [272/CA272] PCV1 Open Error (LH bank)
E-33 Code [272/CB272] PCV1 Open Error (RH bank)
E-34 Code [273/CA273] PCV2 Short Error (LH bank)
E-35 Code [273/CB273] PCV2 Short Error (RH bank)
E-36 Code [274/CA274] PCV2 Open Error (LH bank)
E-37 Code [274/CB274] PCV2 Open Error (RH bank)
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank)
E-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)

Troubleshooting of electrical system (E-mode), Part 2
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank)
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank)
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank)
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank)
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank)
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank)
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank)
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank)
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank)
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank)
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank)
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank)
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank)
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank)
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only)
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only)
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank)
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank)
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank)
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank)
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank)
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank)
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank)
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank)
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank)
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank)
E-82 Code [1257/CA1257] Harness Key error (LH bank)
E-83 Code [1257/CB1257] Harness Key error (RH bank)
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank)
E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank)
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank)
E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank)
E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank)
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)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Disassembly and assembly, Part 1
General disassembly of engine
Disassembly and assembly, Part 2
General assembly of engine
Disassembly and assembly, Part 3
Removal and installation fuel supply pump unit
Removal and installation oil seal unit

Repair and replacement of parts
Information related to repair and replacement
Flowchart
Special tool table
Parts related to cylinder head
Part names related to cylinder head
Testing and inspection of cylinder head
Pressure test of cylinder head
Replacement of valve guide
Replacement of valve seat insert
Replacement of crosshead guide
Repair of cylinder head mounting face by grinding
Repair of valve by grinding

Parts related to cylinder block
Part names related to cylinder block
Testing and inspection of cylinder block
Part names related to crankshaft
Testing and inspection of crankshaft
Part names related to connecting rod
Testing and inspection of connecting rod
Replacement of flywheel ring gear
Replacement of crankshaft gear
Replacement of camshaft gear
Replacement of main bearing metal cap
Replacement of connecting rod small end bushing
Replacement of cam bushing
Repair of cylinder block top by grinding
Repair of counterbore by grinding
Check and identification after repair by grinding
Gasket sealant application procedure
Repair standard for cylinder liner O-ring
Repair of crankshaft by grinding
Improvement of surface roughness of crankshaft journal