Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu 12V140E-3 Series Diesel Engine Shop Manual – PDF DOWNLOAD
Original price was: $42.95.$29.95Current price is: $29.95.
Komatsu 12V140E-3 Series Diesel Engine Shop Manual
Book Code: SEN00291-14
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu 12V140E-3 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 12V140E-3 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 12V140E-3 Series Engine
Book Code: SEN00291-14
Language: English
Pages: 601
File Format: Portable Document Format (PDF)
KOMATSU 12V140E-3 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 12V140E-3 Series Diesel Engine Shop Manual
How to read the shop manual:
1. 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):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu 12V140E-3 Series Diesel Engine Shop Manual
COVER ..................................................................................... 1 00 Index and foreword...................................................................... 0 Index.................................................................................. 2 Composition of shop manual......................................................... 3 Table of contents.................................................................. 4 Foreword and general information....................................................... 12 Safety notice...................................................................... 13 How to read the shop manual........................................................ 18 Explanation of terms for maintenance standard...................................... 20 Handling of electric equipment and hydraulic component............................. 22 Handling of connectors newly used for engines...................................... 31 How to read electric wire code..................................................... 34 Precautions when carrying out operation............................................ 37 Method of disassembling and connecting push-pull type coupler...................... 40 Standard tightening torque table................................................... 43 Conversion table................................................................... 47 01 Specification........................................................................... 0 Specification and technical data....................................................... 54 Outline............................................................................ 55 Specifications..................................................................... 57 General view....................................................................... 63 Weight table....................................................................... 72 Engine performance curves.......................................................... 73 10 Structure, function and maintenance standard............................................ 0 Structure, function and maintenance standard, Part 1................................... 80 Air intake and exhaust unit........................................................ 82 Air cleaner........................................................................ 83 Turbocharger....................................................................... 85 Aftercooler........................................................................ 90 Muffler............................................................................ 91 Cylinder head...................................................................... 93 Cylinder block..................................................................... 97 Cylinder liner.....................................................................101 Main moving parts..................................................................103 Crankshaft.........................................................................105 Camshaft...........................................................................107 Cam follower and push rod..........................................................108 Piston, piston ring, and piston pin................................................109 Connecting rod.....................................................................111 Flywheel and flywheel housing......................................................113 Vibration damper...................................................................114 Timing gear........................................................................115 Valve system.......................................................................117 Valve and valve guide..............................................................119 Rocker arm and shaft...............................................................121 Crosshead and guide................................................................122 Structure, function and maintenance standard, Part 2...................................124 Lubrication system.................................................................127 Lubrication system diagram.....................................................127 Oil pump.......................................................................129 Oil cooler.....................................................................130 Oil filter.....................................................................131 Main relief valve..............................................................132 Oil cooler bypass valve and regulator valve....................................133 Fuel system........................................................................135 CRI system diagram.............................................................135 CRI system diagram (Poor fuel spec.)...........................................137 Outline of CRI system..........................................................139 Fuel piping....................................................................157 Fuel piping (Poor fuel spec.)..................................................162 Fuel filter....................................................................167 Water separator................................................................169 Priming pump...................................................................170 Electric priming pump..........................................................171 Cooling system.....................................................................173 Cooling system diagram.........................................................173 Water pump.....................................................................175 Thermostat.....................................................................177 Corrosion resistor.............................................................178 Cooling fan drive..............................................................180 Electrical equipment...............................................................183 Alternator.....................................................................183 Starting motor.................................................................185 Starting aid...................................................................187 Engine controller..............................................................190 Engine controller cooler.......................................................191 20 Standard value table.................................................................... 0 Standard service value table...........................................................194 Standard service value table.......................................................195 Standard service value table for testing, adjusting, and troubleshooting.......195 Running-in standard and performance test standard..............................200 30 Testing and adjusting................................................................... 0 Testing and adjusting..................................................................206 Testing and adjusting tools list...................................................208 Testing air boost pressure.........................................................210 Testing exhaust temperature........................................................211 Adjusting valve clearance..........................................................212 Testing compression pressure.......................................................214 Testing blow-by pressure...........................................................216 Testing oil pressure...............................................................217 Handling fuel system parts.........................................................218 Releasing residual pressure in fuel system.........................................218 Testing fuel pressure..............................................................219 Reduced cylinder mode operation....................................................220 No-injection cranking..............................................................220 Testing leakage-from pressure limiter and return rate from injector................221 Bleeding air from fuel circuit (for D475A-5).......................................224 Bleeding air from fuel circuit (for PC2000)........................................227 Bleeding air from fuel circuit (Poor fuel spec.)...................................229 Testing fuel system for leakage....................................................231 Adjusting speed sensor.............................................................232 Testing and adjusting alternator belt tension......................................232 Handling controller high-voltage circuit...........................................233 40 Troubleshooting......................................................................... 0 General Information on troubleshooting.................................................236 Points to remember when troubleshooting............................................237 Error codes and failure codes list.................................................238 Information in troubleshooting table...............................................242 Connection table for connector pin numbers.........................................244 T- branch box and T- branch adapter table..........................................280 Troubleshooting of mechanical system (S-mode)..........................................284 Method of using troubleshooting charts.............................................286 S-1 Starting performance is poor...................................................289 S-2 Engine does not start..........................................................290 S-3 Engine does not pick up smoothly...............................................293 S-4 Engine stops during operations.................................................294 S-5 Engine does not rotate smoothly................................................295 S-6 Engine lacks output (or lacks power)...........................................296 S-7 Exhaust smoke is black (incomplete combustion).................................298 S-8 Oil consumption is excessive (or exhaust smoke is blue)........................299 S-9 Oil becomes contaminated quickly...............................................300 S-10 Fuel consumption is excessive.................................................301 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).........302 S-12 Oil pressure drops............................................................303 S-13 Oil level rises (Entry of coolant or fuel)....................................304 S-14 Coolant temperature becomes too high (overheating)............................305 S-15 Abnormal noise is made........................................................306 S-16 Vibration is excessive........................................................307 Troubleshooting of electrical system (E-mode), Part 1..................................310 E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank).......................313 E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank).......................315 E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank).............317 E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank).............318 E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only)............319 E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only).............321 E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only).....................323 E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only)......................324 E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only)...................325 E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only)...................327 E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)...............329 E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)................331 E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only)............333 E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only).............335 E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)......................336 E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)......................336 E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)...............337 E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only)................339 E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only)..........341 E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only)...........343 E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank).....................345 E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank).....................347 E-23 Code [234/CA234] Eng. Overspeed (LH bank only)................................349 E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)...................351 E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank)...................353 E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank).......................355 E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank).......................357 E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)........................359 E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)........................359 E-30 Code [271/CA271] PCV1 Short Error (LH bank)...................................361 E-31 Code [271/CB271] PCV1 Short Error (RH bank)...................................363 E-32 Code [272/CA272] PCV1 Open Error (LH bank)....................................365 E-33 Code [272/CB272] PCV1 Open Error (RH bank)....................................366 E-34 Code [273/CA273] PCV2 Short Error (LH bank)...................................367 E-35 Code [273/CB273] PCV2 Short Error (RH bank)...................................369 E-36 Code [274/CA274] PCV2 Open Error (LH bank)....................................371 E-37 Code [274/CB274] PCV2 Open Error (RH bank)....................................372 E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank).......373 E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error (LH bank).......375 E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error (LH bank).......377 E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error (LH bank).......379 E-42 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error (LH bank).......381 E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH bank).......383 E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank)...................385 E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank)...................385 E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank)...........................387 E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)...........................389 E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)......................391 E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank)......................391 E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank).....................393 E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank).....................395 E-52 Code [441/CA441] Battery Voltage Low Error (LH bank)..........................397 E-53 Code [441/CB441] Battery Voltage Low Error (RH bank)..........................397 E-54 Code [442/CA442] Battery Voltage High Error (LH bank).........................398 E-55 Code [442/CB442] Battery Voltage High Error (RH bank).........................398 Troubleshooting of electrical system (E-mode), Part 2..................................400 E-56 Code [449/CA449] Rail Press. Very High Error (LH bank)........................402 E-57 Code [449/CB449] Rail Press. Very High Error (RH bank)........................402 E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank)......................403 E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank)......................405 E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank).......................407 E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank).......................407 E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank)...........................408 E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank)...........................409 E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank)..................410 E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank)..................410 E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank)............................411 E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank)............................415 E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank).........................419 E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank).........................421 E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only).............423 E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only)..............425 E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank).............426 E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank).............426 E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank).....................427 E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank).....................427 E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank)...................429 E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank)...................431 E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank).........433 E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank).........435 E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank).......................436 E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank).......................436 E-82 Code [1257/CA1257] Harness Key error (LH bank)................................437 E-83 Code [1257/CB1257] Harness Key error (RH bank)................................438 E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank).....439 E-85 Code [1549/CB1549] Injector #8 (R/B #2) System Open/Short Error (RH bank).....441 E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank)....443 E-87 Code [1552/CB1552] Injector #11 (R/B #5) System Open/Short Error (RH bank)....445 E-88 Code [1553/CB1553] Injector #12 (R/B #6) System Open/Short Error (RH bank)....447 E-89 Code [1622/CB1622] Injector #9 (R/B #3) System Open/Short Error (RH bank).....449 E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank)....................451 E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)........453 E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only).........455 E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank).......................456 E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank).......................456 E-95 Code [- -*1/-] Eng. Overheat (LH bank only)...................................457 E-96 Code [- -*2/-] Eng. Oil Press. Low Speed Derate (LH bank only)................457 E-97 Code [- -*3/-] Press. Low Torque Derate (LH bank only)........................458 50 Disassembly and assembly................................................................ 0 General information on disassembly and assembly........................................460 How to read this manual............................................................461 Coating materials list.............................................................463 Special tool list..................................................................466 Sketches of special tools..........................................................468 Disassembly and assembly, Part 1.......................................................472 Disassembly and assembly, Part 1...................................................473 General disassembly of engine..................................................473 Disassembly and assembly, Part 2.......................................................492 General assembly of engine.........................................................493 Disassembly and assembly, Part 3.......................................................532 Removal and installation fuel supply pump unit.....................................533 Removal and installation oil seal unit.............................................536 90 Repair and replacement of parts......................................................... 0 Information related to repair and replacement..........................................544 Flowchart .........................................................................545 Special tool table.................................................................547 Parts related to cylinder head.........................................................550 Part names related to cylinder head................................................551 Testing and inspection of cylinder head............................................552 Pressure test of cylinder head.....................................................554 Replacement of valve guide.........................................................554 Replacement of valve seat insert...................................................555 Replacement of crosshead guide.....................................................562 Repair of cylinder head mounting face by grinding..................................563 Repair of valve by grinding........................................................564 Parts related to cylinder block........................................................566 Part names related to cylinder block...............................................568 Testing and inspection of cylinder block...........................................569 Part names related to crankshaft...................................................572 Testing and inspection of crankshaft...............................................573 Part names related to connecting rod...............................................574 Testing and inspection of connecting rod...........................................575 Replacement of flywheel ring gear..................................................576 Replacement of crankshaft gear.....................................................577 Replacement of camshaft gear.......................................................578 Replacement of main bearing metal cap..............................................579 Replacement of connecting rod small end bushing....................................581 Replacement of cam bushing.........................................................582 Repair of cylinder block top by grinding...........................................584 Repair of counterbore by grinding..................................................585 Check and identification after repair by grinding..................................587 Gasket sealant application procedure...............................................588 Repair standard for cylinder liner O-ring..........................................590 Repair of crankshaft by grinding...................................................591 Improvement of surface roughness of crankshaft journal.............................597
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
