Komatsu 12V140E-3 Series Engine Service Manual
602 pages · Publication SEN00291-14
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- Models
- 12V140E-3 Series
- Manual type
- Service Manual
- Pages
- 602
- Publication
- SEN00291-14
- Condition
- Brand new
What's inside
From the manual's own table of contents: 8 sections, 238 entries. See sample pages (PDF, 532 KB)
Index and foreword11 topics
- Composition of shop manual
- 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
Specification5 topics
- Outline
- Specifications
- General view
- Weight table
- Engine performance curves
Structure, function and maintenance standard50 topics
- 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 table3 topics
- Standard service value table
- Standard service value table for testing, adjusting, and troubleshooting
- Running-in standard and performance test standard
Testing and adjusting20 topics
- 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 (for D475A-5)
- Bleeding air from fuel circuit (for PC2000)
- Bleeding air from fuel circuit (Poor fuel spec.)
- Testing fuel system for leakage
- Adjusting speed sensor
- Testing and adjusting alternator belt tension
- Handling controller high-voltage circuit
Troubleshooting103 topics
- 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
- 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
- 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-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)
- 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-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-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-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-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 assembly9 topics
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Disassembly and assembly, Part 1
- General disassembly of engine
- General assembly of engine
- Removal and installation fuel supply pump unit
- Removal and installation oil seal unit
Repair and replacement of parts29 topics
- Flowchart
- Special tool table
- 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
- 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
Inside this manual
Real pages from this service manual (602 pages). Open the sample pages (PDF, 532 KB)
- Specifications, page 72: 01 Specification
- Troubleshooting, page 243: Information in troubleshooting table
- Diagram, page 405: Circuit diagram related to common rail pressure sensor
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 602 pages
Quantity one is the manual described above.
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Other editions and similar models
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