Komatsu 12V140E-3 Series Engine Service Repair Shop Manual - SEN00291-04

This complete service repair workshop manual PDF download for the 12V140E-3 Series Komatsu Engine has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

SAA12V140E-3

D475A-5E0
HD785-7
PC2000-8
WA800-3E0
WA900-3E0


TABLE OF CONTENTS :

00 INDEX AND FOREWORD
01 SPECIFICATION
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 STANDARD VALUE TABLE
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN00291-04
Total Pages : 468


This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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00 INDEX AND FOREWORD
INDEX
COMPOSITION OF SHOP MANUAL
TABLE OF CONTENTS
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 OF 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

01 SPECIFICATION
SPECIFICATION AND TECHNICAL DATA
OUTLINE
SPECIFICATIONS
GENERAL VIEW
WEIGHT TABLE
ENGINE PERFORMANCE CURVES

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, PART 1
AIR INTAKE AND EXHAUST SYSTEM
AIR INTAKE AND EXHAUST UNIT
AIR CLEANER
TURBOCHARGER
AFTERCOOLER
MUFFLER
ENGINE UNIT
CYLINDER HEAD
CYLINDER BLOCK
CYLINDER LINER
MAIN MOVING PARTS
CRANKSHAFT
CAMSHAFT
CAM FOLLOWER, 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
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, PART2
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
OUTLINE OF CRI SYSTEM
FUEL PIPING
FUEL FILTER
PRIMING PUMP
COOLING SYSTEM
COOLING SYTEM DIAGRAM
WATER PUMP
THERMOSTAT
CORROSION RESISTOR
COOLING FAN DRIVE
ELECTRICAL EQUIPMENT
ALTERNATOR
STARTING MOTOR
STARTING AID
ENGINE CONTROLLER

20 STANDARD VALUE TABLE
STANDARD SERVICE VALUE TABLE
STANDARD SERVICE VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD

30 TESTING AND ADJUSTING
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
MEASURING 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 RETURE RATE FROM INJECTOR
BLEEDING AIR FROM FUEL CIRCUIT (FOR D475A-5)
BLEEDING AIR FROM FUEL CIRCUIT (FOR PC2000)
TESTING FUEL SYSTEM FOR LEAKAGE
ADJUSTING SPEED SENSOR
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT

40 TROUBLESHOOTING
GENERAL INFORMATION ON TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
ERROR CODES AND FAILURE CODES LIST
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 DOSE 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
INFORMATION IF TROUBLESHOOTING TABLE
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 SENSORS ERROR (LH BANK)
E-4 CODE [115/CB115] ENG. NE AND G (BKUP) SPEED SENSORS 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] SENSOE SUP.2 VOLT. LOW ERROR (LH BANK)
E-16 CODE [187/CB187] SENSOE 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] SENSOE SUP.2 VOLT. HIGH ERROR (LH BANK)
E-22 CODE [227/CB227] SENSOE 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 (BH 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] CALIBRATION CODE INCOMPATIBILITY (LH BANK)
E-45 CODE [342/CB342] CALIBRATION 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 [1662/CB1662] 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 DISASSEMBLY AND ASSEMBLY
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
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
REPLACEMENT OF OIL SEAL OF ENGINE MOUNTED ON MACHINE

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