E-10 Code (141/CA141) Oil Press. Sensor Low Error (LH Bank Only)

SEN00317-03 40 Troubleshooting
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only)
Error code Failure code Oil pressure sensor detection of abnormally low pressure
Trouble
(LH bank only)
141 CA141
Contents of
q Signal voltage in oil pressure sensor circuit is abnormally low.
trouble
Action of
controller q Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
Phenomenon
that appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting
and standard
value in normal Carry out troubleshooting for E-9 Code [135/CA135].
state
18 12V140E-3 Series
40 Troubleshooting SEN00317-03
12V140E-3 Series 19
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)
Error code Failure code Coolant temperature sensor detection of abnormally high tempera-
Trouble
ture (LH bank only)
144 CA144
Contents of
q Signal voltage in coolant temperature sensor circuit is abnormally high.
trouble
Action of
q Fixes coolant temperature at (90 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
q Different machine models may have different connector Nos.
information
Causes Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective coolant tempera- without turning starting switch ON.
1 ture sensor TWTR (male) Coolant temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100 °C 0.6 – 20 k
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between LH J1 (female) Resis-
2 (Disconnection in wiring or (15) – TWTR (female) (A) Max. 1 
Possible causes tance
and standard defective contact in connec-
Wiring harness between LH J1 (female) (38) Resis-
value in normal tor) Max. 1 
– TWTR (female) (B) tance
state
Ground fault in wiring har-
without turning starting switch ON.
ness
3 Wiring harness between LH J1 (female)
(Short circuit with GND cir- Resis-
(15) – TWTR (female) (A) and chassis Min. 1 M
cuit) tance
ground
4 Defective engine controller LH J1 (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100 °C 0.6 – 20 k
20 12V140E-3 Series
Circuit diagram related to coolant temperature sensor
12V140E-3 Series 21
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only)
Error code Failure code Coolant temperature sensor detection of abnormally low tempera-
Trouble
ture (LH bank only)
145 CA145
Contents of
q Signal voltage in coolant temperature sensor circuit is abnormally low.
trouble
Action of
q Fixes coolant temperature at (90 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
and standard
state
22 12V140E-3 Series
12V140E-3 Series 23
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank
only)
Error code Failure code Charge temperature sensor detection of abnormally high tempera-
Trouble
ture (LH bank only)
153 CA153
Contents of
q Signal voltage in charge temperature sensor circuit is abnormally high.
trouble
Action of
q Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective charge tempera- Intake air tempera-
TIM (male) Resistance
1 ture sensor ture
(Internal trouble) Between (A) – (B) 10 – 100 °C 0.5 – 20 k
Between (A) – chas-
All range Min. 1 M
sis ground
Possible causes ness Wiring harness between LH J1 (female) Resis-
and standard 2 (Disconnection in wiring or (23) – TIM (female) (A) Max. 1 
tance
value in normal defective contact in connec-
state Wiring harness between LH J1 (female) (47) Resis-
tor) Max. 1 
– TIM (female) (B) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
3
(Short circuit with GND cir- Wiring harness between LH J1 (female) (23) Resis-
Min. 1 M
cuit) – TIM (female) (A) and chassis ground tance
4 Defective engine controller Intake air tempera-
LH J1 (female) Resistance
ture
Between (23) – (47) 10 – 100 °C 0.5 – 20 k
24 12V140E-3 Series
Circuit diagram related to charge temperature sensor
12V140E-3 Series 25
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank
only)
Error code Failure code Charge temperature sensor detection of abnormally low charge
Trouble
temperature (LH bank only)
154 CA154
Contents of
q Signal voltage in charge temperature sensor circuit is abnormally low.
trouble
Action of
q Fixes charge temperature (intake air temperature) at (70 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
and standard
state
26 12V140E-3 Series
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)
Error code Failure code Power supply 2 sensor detection of abnormally low voltage
Trouble
(LH bank)
187 CA187
Contents of
q Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
q Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues opera-
tion.
Action of
controller q Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
q Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
q Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
that appears on q Output drops.
machine
Related
information
and standard
state
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank)
Error code Failure code Power supply 2 sensor detection of abnormally low voltage
Trouble
(RH bank)
187 CB187
Contents of
q Signal voltage in sensor power supply 2(5 V) circuit is abnormally low.
trouble
Action of
q Operate G (Bkup) sensor with signals of Ne speed sensor.
controller
Phenomenon
machine
Related
information
and standard
value in normal Carry out troubleshooting for E-22 Code [227/CB227].
state
12V140E-3 Series 27
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only)
Error code Failure code Engine oil temperature sensor detection of abnormally high tem-
Trouble
perature (LH bank only)
212 CA212
Contents of
q Signal voltage in engine oil temperature sensor circuit is abnormally high.
trouble
Action of
q Sets oil pressure to default value (100 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective oil temperature without turning starting switch ON.
1 sensor TOIL (male) Oil temperature Resistance
(Internal trouble)
Between (A) – (B) 0 – 100 °C 0.5 – 36 k
ness Wiring harness between LH J1 (female) (17) Resis-
Possible causes 2 (Disconnection in wiring or – TOIL (female) (A) Max. 1 
tance
value in normal Wiring harness between LH J1 (female) (47) Resis-
tor) Max. 1 
state – TOIL (female) (B) tance
3
Min. 1 M
cuit) – TOIL (female) (A) and chassis ground tance
4 Defective engine controller LH J1 Oil temperature Resistance
(17) – (47) 0 – 100 °C 0.5 – 36 k
28 12V140E-3 Series
Circuit diagram related to engine oil temperature sensor
12V140E-3 Series 29
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only)
Error code Failure code Engine oil temperature sensor detection of abnormally low temper-
Trouble
ature (LH bank only)
213 CA213
Contents of
q Signal voltage in engine oil temperature sensor circuit is abnormally low.
trouble
Action of
q Sets oil temperature to default value (100 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information
and standard
state
30 12V140E-3 Series
12V140E-3 Series 31
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank
only)
Error code Failure code Atmospheric pressure sensor detection of abnormally high pres-
Trouble
sure (LH bank only)
221 CA221
Contents of
q Signal voltage in atmospheric pressure sensor circuit is abnormally high.
trouble
Action of
controller q Sets atmospheric pressure to default value (52.44 kPa {0.5 kg/cm2}) and continues operation.
Phenomenon
machine
Related
information

Defective sensor power sup- If code [352/CA352] or [386/CA386] is indicated, carry out trouble-
1
ply system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
PAMB Voltage
Defective atmospheric pres- Between (1) – (2) Power supply 4.75 – 5.25 V
2 sure sensor
(Internal trouble) Between (3) – (2) Signal 0.5 – 4.5 V
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Ground fault in wiring har- Min. 1 M
– PAMB (female) (1) and chassis ground tance
ness
3
Possible causes (Short circuit with GND cir- Wiring harness between LH J1 (female) (38) Resis-
Min. 1 M
and standard cuit) – PAMB (female) (3) and chassis ground tance
value in normal Wiring harness between LH J1 (female) (3) Resis-
Min. 1 M
state – PAMB (female) (2) and chassis ground tance
Wiring harness between LH J1 (female) (37)
Resis-
– PAMB (female) (1) and LH J1 (female) Min. 1 M
Short circuit in wiring har- tance
(38) – PAMB (female) (3)
ness
4 Wiring harness between LH J1 (female) (37)
(With another wiring har- Resis-
– PAMB (female) (1) and LH J1 (female) (3) Min. 1 M
ness) tance
– PAMB (female) (2)
Resis-
– PAMB (female) (3) and LH J1 (female) (3) Min. 1 M
tance
– PAMB (female) (2)
or start engine and carry out troubleshooting.
LH J1 Voltage
5 Defective engine controller
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.5 – 4.5 V
32 12V140E-3 Series
Circuit diagram related to atmospheric pressure sensor
12V140E-3 Series 33
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank
only)
Error code Failure code Atmospheric pressure sensor detection of abnormally low pressure
Trouble
(LH bank only)
222 CA222
Contents of
q Signal voltage in atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
controller q Sets atmospheric pressure to default value (52.44 kPa {0.5 kg/cm2}) and continues operation.
Phenomenon
machine
Related
information
and standard
state
34 12V140E-3 Series
12V140E-3 Series 35
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank)
Error code Failure code Power supply 2 sensor detection of abnormally high voltage
Trouble
(LH bank)
227 CA227
Contents of
q Signal voltage in sensor power supply 2(5 V) circuit is abnormally high.
trouble
q Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues opera-
tion.
Action of
controller q Sets oil pressure sensor to default value (250 kPa {2.5 kg/cm2}) and continues operation.
q Fixes charge pressure sensor value (400 kPa {4.1 kg/cm2}) and continues operation.
q Operates G (Bkup) sensor with signals of Ne speed sensor.
Phenomenon
machine
Related
information
1 Defective related system If another failure code is indicated, carry out troubleshooting for it.

Atmospheric pres-
Disconnect devices PAMB connector
sure sensor
Defective sensor (Internal at right in order. If
2 Oil pressure sensor POIL connector
trouble) error code disap-
pears subsequently, Charge pressure
PIM connector
that device has a sensor
defect in it. G (Bkup) sensor G connector
3 (Disconnection in wiring or – respective sensors (female) Max. 1 
tance
defective contact in connec-
Possible causes Wiring harness between LH J1 (female) (47) Resis-
and standard
tor) Max. 1 
– respective sensors (female) tance
value in normal
state
Ground fault in wiring har- Wiring harness between LH J1 (female) (37)
Resis-
ness – respective sensors (female) and chassis Min. 1 M
4 tance
(Short circuit with GND cir- ground
cuit) Wiring harness between LH J1 (female) (47)
Resis-
– respective sensors (female) and chassis Min. 1 M
tance
ground
Short circuit in wiring har- without turning starting switch ON.
ness Wiring harness between LH J1 (female)
5
(With another wiring har- (37) – respective sensors (female) and LH Resis-
Min. 1 M
ness) J1 (female) (47) – respective sensors tance
(female)
6 Defective engine controller LH J1 Voltage
Between (37) – (47) 4.75 – 5.25 V
36 12V140E-3 Series
Circuit diagram related to sensor power supply 2 (5 V)
12V140E-3 Series 37
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank)
Error code Failure code Power supply 2 sensor detection of abnormally high voltage
Trouble
(RH bank)
227 CB227
Contents of
q Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
Action of
q Operates G(Bkup) sensor with signals of Ne speed sensor.
controller
Phenomenon
machine
Related
information

Disconnect devices
Defective sensor (Internal at right in order. If
2
trouble) error code disap- G (Bkup)speed sen-
G connector
pears subsequently, sor
that device has a
defect in it.
Possible causes
Ground fault in wiring har- Wiring harness between RH J1 (female)
and standard Resis-
ness (37) – respective sensors (female) and Min. 1 M
value in normal 3 tance
(Short circuit with GND cir- chassis ground
state
cuit) Wiring harness between RH J1 (female)
Resis-
(47) – respective sensors (female) and Min. 1 M
tance
chassis ground
Short circuit in wiring har- without turning starting switch ON.
ness Wiring harness between RH J1 (female)
4
(With another wiring har- (37) – respective sensors (female) and RH Resis-
Min. 1 M
ness) J1 (female) (47) – respective sensors tance
(female)
5 Defective engine controller RH J1 Voltage
Between (37) – (47) 4.75 – 5.25 V
38 12V140E-3 Series
12V140E-3 Series 39
E-23 Code [234/CA234] Eng. Overspeed (LH bank only)

Error code Failure code
Trouble Engine overspeed (LH bank only)
234 CA234
Contents of
q Engine speed is above operating range.
trouble
Action of
q Limits fuel injection rate until engine speed lowers to operating range.
controller
Phenomenon
that appears on q Engine speed fluctuates.
machine
Related
information
Possible causes
and standard
value in normal 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
state
If causes 1 – 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40 12V140E-3 Series
12V140E-3 Series 41
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)
Trouble Ne Speed Sensor Sup. Volt. Error (LH bank)
238 CA238
Contents of
q Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
q Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
Phenomenon
q Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
q Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
1
(Internal trouble) error code disap-
Ne speed sensor NE connector
pears subsequently,
that device has a
defect in it.
2 (Disconnection in wiring or – Ne (female) (1) Max. 1 
tance
Possible causes tor) Max. 1 
– Ne (female) (2) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
3 Min. 1 M
(Short circuit with GND cir- – Ne (female) (1) and chassis ground tance
cuit) Wiring harness between LH J1 (female) (48) Resis-
Min. 1 M
– Ne (female) (2) and chassis ground tance
Short circuit in wiring har-
ness
– Ne (female) (1) and LH J1 (female) (48) – Min. 1 M
ness) tance
Ne (female) (2)
Between (16) – (48) 4.75 – 5.25 V
42 12V140E-3 Series
Circuit diagram related to Ne speed sensor power supply
12V140E-3 Series 43
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank)
Trouble Ne Speed Sensor Sup. Volt. Error (RH bank)
238 CB238
Contents of
q Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
q Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
Phenomenon
q Running engine stops (when G (Bkup) speed sensor is also abnormal).
that appears on
q Stopped engine cannot be started (when G (Bkup) speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
1
Ne speed sensor NE connector
pears subsequently,
that device has a
defect in it.
2 (Disconnection in wiring or (16) – Ne (female) (1) Max. 1 
tance
Wiring harness between RH J1 (female) Resis-
(48) – Ne (female) (2) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
3 Min. 1 M
(Short circuit with GND cir- – Ne (female) (1) and chassis ground tance
cuit) Wiring harness between RH J1 (female) Resis-
Min. 1 M
(48) – Ne (female) (2) and chassis ground tance
Short circuit in wiring har-
ness
4 Wiring harness between LH J1 (female)
(16) – Ne (female) (1) and RH J1 (female) Min. 1 M
ness) tance
(48) – Ne (female) (2)
5 Defective engine controller Voltage
LH J1 (16) – RH J1 (48)
4.75 – 5.25 V
44 12V140E-3 Series
Circuit diagram related to Ne speed sensor power supply
12V140E-3 Series 45
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)
Error code Failure code Fuel temperature sensor detection of abnormally high temperature
Trouble
(LH bank only)
263 CA263
Contents of
q Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
q Fixes fuel temperature at (95 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective fuel temperature without turning starting switch ON.
1 sensor LH TFUEL (male) Fuel temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100 °C 0.6 – 20 k
Disconnection in wiring har-
2 Max. 1 
Possible causes (Disconnection or defective (30) – LH TFUEL (female) (A) tance
and standard contact in connector) Wiring harness between LH J1 (female) (47) Resis-
value in normal Max. 1 
– LH TFUEL (female) (B) tance
state
ness Resis- Max.
3 – LH TFUEL (female) (A) and chassis
(Short circuit with GND cir- tance 1 M
ground
cuit)
LH J1 (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100 °C 0.6 – 20 k
46 12V140E-3 Series
Circuit diagram related to fuel temperature sensor
12V140E-3 Series 47
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank)
Error code Failure code Fuel temperature sensor detection of abnormally high temperature
Trouble
(RH bank only)
263 CB263
Contents of
q Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective fuel temperature without turning starting switch ON.
1 sensor RH TFUEL (male) Fuel temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100 °C 0.6 – 20 k
ness Wiring harness between RH J1 (female) Resis-
2 (Disconnection in wiring or (30) – RH TFUEL (female) (A) Max. 1 
Possible causes tance
value in normal tor) Max. 1 
(47) – RH TFUEL (female) (B) tance
state
Wiring harness between RH J1 (female)
ness Resis- Max.
3 (30) – RH TFUEL (female) (A) and chassis
(Short circuit with GND cir- tance 1 M
ground
cuit)
RH J1 (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100 °C 0.6 – 20 k
48 12V140E-3 Series
Circuit diagram related to fuel temperature sensor
12V140E-3 Series 49
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank)
Error code Failure code Fuel temperature sensor detection of abnormally low temperature
Trouble
(LH bank)
265 CA265
Contents of
q Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
q Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
Action of
state.
controller
q Sets oil temperature to default value (95 °C) and continues operation.
Phenomenon
that appears on
machine
Related
information
and standard
state
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)
Error code Failure code Fuel temperature sensor detection of abnormally low temperature
Trouble
(RH bank)
265 CB265
Contents of
q Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
q Substitutes with coolant temperature sensor. If coolant temperature sensor is also in abnormal
Action of
state.
controller
Phenomenon
that appears on
machine
Related
information
and standard
state
50 12V140E-3 Series
12V140E-3 Series 51
E-30 Code [271/CA271] PCV1 Short Error (LH bank)

Trouble PCV1 Short circuit Error (LH bank)
271 CA271
Contents of
q There is short circuit in PCV1 circuit of supply pump.
trouble
Action of
q None in particular.
controller
Phenomenon
that appears on
machine
Related
information

Defective supply pump LH PCV1 (male) Resistance
1 PCV1
(Internal trouble) Between (1) – (2) 2.3–5.3 
Between (1), (2) – chassis
Min. 1 M
ground
2 Min. 1 M
(Short circuit with GND cir- – LH PCV1 (female) (1) and chassis ground tance
Possible causes cuit) Wiring harness between LH J1 (female)(5) – Resis-
and standard Min. 1 M
LH PCV1 (female) (2) and chassis ground tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness Wiring harness between LH J1 (female) (4)
3 Voltage Max. 1 V
(Contact with 24 V) – LH PCV1 (female) (1) and chassis ground
Voltage Max. 1 V
– LH PCV1 (female) (2) and chassis ground
Between (4) – (5) 2.3 – 5.3 
Min. 1 M
ground
52 12V140E-3 Series
Circuit diagram related to supply pump PCV1
12V140E-3 Series 53
E-31 Code [271/CB271] PCV1 Short Error (RH bank)

Trouble PCV1 Short circuit Error (RH bank)
271 CB271
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective supply pump RH PCV1 (male) Resistance
1 PCV1
(Internal trouble) Between (1) – (2) 2.3–5.3 
Min. 1 M
ground
ness Wiring harness between RH J1 (female) (4) Resis-
2 Min. 1 M
(Short circuit with GND cir- – RH PCV1 (female) (1) and chassis ground tance
Possible causes cuit) Wiring harness between RH J1 (female) (5) Resis-
– RH PCV1 (female) (2) and chassis ground tance
value in normal
Hot short in wiring harness Wiring harness between RH J1 (female) (4)
3 Voltage Max. 1 V
(Contact with 24 V) – RH PCV1 (female) (1) and chassis ground
Wiring harness between RH J1 (female) (5)
Voltage Max. 1 V
– RH PCV1 (female) (2) and chassis ground
RH J1 (female) Resistance
Between (4) – (5) 2.3 – 5.3 
Min. 1 M
ground
54 12V140E-3 Series
12V140E-3 Series 55
E-32 Code [272/CA272] PCV1 Open Error (LH bank)

Trouble PCV1 Disconnection Error (LH bank)
272 CA272
Contents of
q There is disconnection in PCV1 circuit of supply pump.
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

1 PCV1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 
Min. 1 M
ground
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between LH J1 (female) (4) Resis-
value in normal 2 (Disconnection in wiring or – LH PCV1 (female) (1) Max. 1 
tance
state defective contact in connec-
tor) Max. 1 
– LH PCV1 (female) (2) tance
Between (4) – (5) 2.3 – 5.3 
Min. 1 M
ground
56 12V140E-3 Series
E-33 Code [272/CB272] PCV1 Open Error (RH bank)

Trouble PCV1 Disconnection Error (RH bank)
272 CB272
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

1 PCV1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 
Min. 1 M
ground
and standard ness Wiring harness between RH J1 (female) (4) Resis-
value in normal 2 (Disconnection in wiring or – RH PCV1 (female) (1) Max. 1 
tance
Wiring harness between RH J1 (female) (5) Resis-
tor) Max. 1 
– RH PCV1 (female) (2) tance
RH J1(female) Resistance
Between (4) – (5) 2.3 – 5.3 
Min. 1 M
ground
12V140E-3 Series 57
E-34 Code [273/CA273] PCV2 Short Error (LH bank)

Trouble PCV2 Short circuit Error (LH bank)
273 CA273
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

1 PCV2
(Internal trouble) Between (1) – (2) 2.3 – 5.3 
Min. 1 M
ground
2 Min. 1 M
(Short circuit with GND cir- – LH PCV2 (female) (1) and chassis ground tance
Possible causes cuit) Wiring harness between LH J1 (female) (10) Resis-
– LH PCV2 (female) (2) and chassis ground tance
value in normal
Hot short in wiring harness Wiring harness between LH J1 (female) (9)
3 Voltage Max. 1 V
(Contact with 24 V) – LH PCV2 (female) (1) and chassis ground
Voltage Max. 1 V
– LH PCV2 (female) (2) and chassis ground
Between (9) – (10) 2.3 – 5.3 
Min. 1 M
ground
58 12V140E-3 Series
12V140E-3 Series 59
E-35 Code [273/CB273] PCV2 Short Error (RH bank)

Trouble PCV2 Short circuit Error (RH bank)
273 CB273
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

1 PCV2
Min. 1 M
ground
ness Wiring harness between RH J1 (female) (9) Resis-
2 Min. 1 M
(Short circuit with GND cir- – RH PCV2 (female) (1) and chassis ground tance
Possible causes cuit) Wiring harness between RH J1(female) (10) Resis-
– RH PCV2 (female) (2) and chassis ground tance
value in normal
state
Wiring harness between RH J1 (female) (9)
Hot short in wiring harness Voltage Max. 1 V
3 – RH PCV2 (female) (1) and chassis ground
(Contact with 24 V)
(10) – RH PCV2 (female) (2) and chassis Voltage Max. 1 V
ground
Between (9) – (10) 2.3 – 5.3 
Min. 1 M
ground
60 12V140E-3 Series
12V140E-3 Series 61
E-36 Code [274/CA274] PCV2 Open Error (LH bank)

Trouble PCV2 Disconnection Error (LH bank)
274 CA274
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective supply pump without turning starting switch ON.
1 PCV2 LH PCV2 (male) Resistance
(Internal disconnection)
Between (1) – (2) 2.3 – 5.3 
Possible causes ness Wiring harness between LH J1 (female) (9) Resis-
and standard 2 (Disconnection in wiring or – LH PCV2 (female) (1) Max. 1 
tance
tor) Max. 1 
– LH PCV2 (female) (2) tance
Between (9) – (10) 2.3 – 5.3 
Min. 1 M
ground
62 12V140E-3 Series
E-37 Code [274/CB274] PCV2 Open Error (RH bank)

Trouble PCV2 Disconnection Error (RH bank)
274 CB274
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

Defective supply pump without turning starting switch ON.
1 PCV2 RH PCV2 (male) Resistance
(Internal disconnection)
Between (1) – (2) 2.3 – 5.3 
Possible causes ness Wiring harness between RH J1 (female) (9) Resis-
and standard 2 (Disconnection in wiring or – RH PCV2 (female) (1) Max. 1 
tance
state Wiring harness between RH J1 (female) Resis-
tor) Max. 1 
(10) – RH PCV2 (female) (2) tance
Between (9) – (10) 2.3 – 5.3 
Min. 1 M
ground
12V140E-3 Series 63
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH
bank)
Error code Failure code Disconnection or short circuit in injector #1 (L/B #1) system (LH
Trouble
bank)
322 CA322
Contents of
q There is disconnection or short circuit in injector in injector #1 circuit.
trouble
Action of
controller
Phenomenon
q Output drops.
that appears on
q Idle speed is unstable.
machine
Related
information

Defective injector #1 LH CN1 (male) Resistance
1
Min. 1 M
ground
2 (Disconnection in wiring or – LH CN1 (female) (1) Max. 1 
tance
Wiring harness between LH J1 (female) Resis-
tor) Max. 1 
Possible causes (53) – LH CN1 (female) (2) tance
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Ground fault in wiring har-
ness Min. 1 M
3 – LH CN1 (female) (1) and chassis ground tance
(Short circuit with GND cir-
cuit) Wiring harness between LH J1 (female)
Resis-
(53) – LH CN1 (female) (2) and chassis Min. 1 M
tance
ground
Defective another cylinder Prepare with starting switch OFF, then carry out troubleshooting
4
injector or wiring harness without turning starting switch ON.
Between (45) – (53) 0.4 – 1.1 
Min. 1 M
ground
64 12V140E-3 Series
Circuit diagram related to injector #1
12V140E-3 Series 65
E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error

(LH bank)
Error code Failure code Disconnection or short circuit in injector #5 (L/B #5) system
Trouble
(LH bank)
323 CA323
Contents of
q There is disconnection or short circuit in injector #5 circuit.
trouble
Action of
controller
Phenomenon
q Output drops.
that appears on
machine
Related
information

1
Min. 1 M
ground
tance
– LH CN5 (female) (2) tance
and standard
value in normal
3 Min. 1 M
(Short circuit with GND cir- – LH CN5 (female) (1) and chassis ground tance
Min. 1 M
– LH CN5 (female) (2) and chassis ground tance
Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry
4
injector or wiring harness out troubleshooting for them, too.
Between (46) – (60) 0.4 – 1.1 
Min. 1 M
ground
66 12V140E-3 Series
12V140E-3 Series 67

(LH bank)
Error code Failure code Disconnection or short circuit in injector #3 (L/B #3) system
Trouble
(LH bank)
324 CA324
Contents of
trouble
Action of
controller
Phenomenon
q Output drops.
that appears on
machine
Related
information

1
Min. 1 M
ground
tance
tor) Max. 1 
Possible causes – LH CN3 (female) (2) tance
ness Min. 1 M
3 – LH CN3 (female) (1) and chassis ground tance
(Short circuit with GND cir-
Resis-
tance
ground
4
Between (55) – (52) 0.4 – 1.1 
Min. 1 M
ground
68 12V140E-3 Series
12V140E-3 Series 69

(LH bank)
Trouble
bank)
325 CA325
Contents of
trouble
Action of
controller
Phenomenon
q Output drops.
that appears on
machine
Related
information

1
Min. 1 M
ground
2 (Disconnection in wiring or (57) – LH CN6 (female) (1) Max. 1 
tance
tor) Max. 1 
Possible causes – LH CN6 (female) (2) tance
state Ground fault in wiring har- Wiring harness between LH J1 (female)
Resis-
ness (57) – LH CN6 (female) (1) and chassis Min. 1 M
3 tance
Resis-
tance
ground
4
Between (57) – (59) 0.4 – 1.1 
Min. 1 M
ground
70 12V140E-3 Series
12V140E-3 Series 71

(LH bank)
Trouble
bank)
331 CA331
Contents of
trouble
Action of
controller
Phenomenon
q Output drops.
that appears on
machine
Related
information

1
Min. 1 M
ground
tance
Possible causes defective contact in connec-
and standard Wiring harness between LH J1 (female) Resis-
tor) Max. 1 
value in normal (51) – LH CN2 (female) (2) tance
state a Prepare with starting switch OFF, then carry out troubleshooting
3 Min. 1 M
Min. 1 M
4
Between (54) – (51) 0.4 – 1.1 
Min. 1 M
ground
72 12V140E-3 Series
12V140E-3 Series 73
E-43 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error (LH
bank)
Error code Failure code Disconnection or short circuit in injector #4 (L/B #4) system(LH
Trouble
bank)
332 CA332
Contents of
trouble
Action of
controller
Phenomenon
q Output drops.
that appears on
machine
Related
information

1
Min. 1 M
ground
2 (Disconnection in wiring or (56) – LH CN4 (female) (1) Max. 1 
tance
– LH CN4 (female) (2) tance
and standard
value in normal
3 Min. 1 M
Min. 1 M
4
Between (56) – (58) 0.4 – 1.1 
Min. 1 M
ground
74 12V140E-3 Series
12V140E-3 Series 75
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank)

Trouble Engine Controller data matching failure (LH bank)
342 CA342
Contents of
q Matching error occurred in engine controller data.
trouble
Action of
controller
Phenomenon
that appears on q Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information
and standard
state
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank)

Trouble Engine Controller data matching failure (RH bank)
342 CB342
Contents of
q Matching error occurred in engine controller data.
trouble
Action of
controller
Phenomenon
machine
Related
information
and standard
state
76 12V140E-3 Series
12V140E-3 Series 77
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank)

Trouble Injector drive circuit error (LH bank)
351 CA351
Contents of
q Abnormality occurred in injector drive circuit.
trouble
Action of
q Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
machine
Related
information
If another failure code (code of abnormality in injector system) is

1 Defective related system
indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on installed machine side directly for

possible defect.
2 Defective fuse
(If fuse is burnt or circuit breaker is turned OFF, circuit probably has
ground fault.)

and standard ness Wiring harness between PW L (female) (3), Resis-
value in normal 3 (Disconnection in wiring or (4) – battery (+) Max. 1 
tance
Wiring harness between PW L (female) (1), Resis-
tor) Max. 1 
(2) – chassis ground tance
4
(Short circuit with GND cir- Wiring harness between PW L (female) (3), Resis-
Min. 1 M
cuit) (4) – battery (+) and chassis ground tance
5 Defective engine controller PW L Voltage
Between (3), (4) – (1), (2) 20 – 30 V
78 12V140E-3 Series
Circuit diagram related to controller power supply
12V140E-3 Series 79
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)

Trouble Injector drive circuit error (RH bank)
351 CB351
Contents of
q Abnormality occurred in injector drive circuit.
trouble
Action of
controller
Phenomenon
machine
Related
information
If another failure code (code of abnormality in injector system) is

1 Defective related system
indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on installed machine side directly for

possible defect.
2 Defective fuse
(If fuse is burnt or circuit breaker is turned OFF, circuit probably has
ground fault.)

and standard ness Wiring harness between PW R (female) (3), Resis-
value in normal 3 (Disconnection in wiring or (4) – battery (+) Max. 1 
tance
Wiring harness between PW R (female) (1), Resis-
tor) Max. 1 
(2) – chassis ground tance
4
(Short circuit with GND cir- Wiring harness between PW R (female) (3), Resis-
Min. 1 M
cuit) (4) – battery (+) and chassis ground tance
5 Defective engine controller PW R Voltage
Between (3), (4) – (1), (2) 20 – 30 V
80 12V140E-3 Series
Circuit diagram related to controller power supply
12V140E-3 Series 81
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)
Error code Failure code Power supply 1 sensor detection of abnormally low voltage (LH
Trouble
bank)
352 CA352
Contents of
trouble
Action of q Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues opera-
controller tion.
Phenomenon
machine
Related
information
and standard
state
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank)
Error code Failure code Power supply 1 sensor detection of abnormally low voltage (RH
Trouble
bank)
352 CB352
Contents of
trouble
Action of q Sets atmospheric pressure sensor to default value (52.44 kPa {0.5 kg/cm2}) and continues opera-
controller tion.
Phenomenon
machine
Related
information
and standard
state
82 12V140E-3 Series
12V140E-3 Series 83
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank)
Error code Failure code Power supply 1 sensor detection of abnormally high voltage (LH
Trouble
bank)
386 CA386
Contents of
q Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of
controller
Phenomenon
machine
Related
information

Disconnect devices at
Defective sensor (Internal
2 right in order. If error
trouble) LH common rail
code disappears sub- LH PFUEL connector
pressure sensor
sequently, that device
has a defect in it.
Disconnection in wiring har- Wiring harness between LH J1 (female) (33) Resis-
Max. 1 
ness – LH PFUEL (female) (1) tance
3 (Disconnection in wiring or
defective contact in connec- Max. 1 
– LH PFUEL (female) (2) tance
tor)
Max. 1 
Possible causes
Ground fault in wiring har- Min. 1 M
– LH PFUEL (female) (1) and chassis ground tance
ness
4
Min. 1 M
cuit) – LH PFUEL (female) (2) and chassis ground tance
Min. 1 M
– LH PFUEL (female) (3) and chassis ground tance
Resis-
– LH PFUEL (female) (1) and LH J1 (female) Min. 1 M
(25) – LH PFUEL (female) (2)
ness
ness) tance
Resis-
tance
Between (33) – (47) 4.75 – 5.25V
84 12V140E-3 Series
12V140E-3 Series 85
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)
Error code Failure code Power supply 1 sensor detection of abnormally high voltage (RH
Trouble
bank)
386 CB386
Contents of trouble q Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
Action of
controller
Phenomenon that
appears on q Output drops.
machine
Related information q Different machine models may have different connector Nos.

Defective related sys-
1 If another failure code is indicated, carry out troubleshooting for it.
tem
a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Disconnect devices at
Defective sensor(Inter-
2 right in order. If error
nal trouble) RH common rail RH PFUEL
code disappears sub-
pressure sensor connector
sequently, that device
has a defect in it.
Disconnection in wir- Wiring harness between RH J1 (female) (33) – Resis-
Max. 1 
ing harness RH PFUEL (female) (1) tance
3 (Disconnection in wir-
Wiring harness between RH J1 (female) (25) – Resis-
ing or defective contact Max. 1 
RH PFUEL (female) (2) tance
in connector)
Max. 1 
RH PFUEL (female) (3) tance
Possible causes
and standard value
in normal state Wiring harness between RH J1 (female) (33) – Resis-
Ground fault in wiring Min. 1 M
RH PFUEL (female) (1) and chassis ground tance
harness
4
(Short circuit with GND Wiring harness between RH J1 (female) (25) – Resis-
Min. 1 M
circuit) RH PFUEL (female) (2) and chassis ground tance
Min. 1 M
RH PFUEL (female) (2) and chassis ground tance
Wiring harness between RH J1 (female) (33) –
Resis-
RH PFUEL (female) (1) and RH J1 (female) Min. 1 M
Short circuit in wiring tance
(25) – RH PFUEL (female) (2)
harness
5 Wiring harness between wiring RH J1 (female)
(With another wiring Resis-
(33) – RH PFUEL (female) (1) and RH J1 Min. 1 M
harness) tance
(female) (47) – RH PFUEL (female) (3)
Wiring harness between RH J1 (female) (25) –
Resis-
RH PFUEL (female) (2) and RH J1 (female) Min. 1 M
tance
(47) – RH PFUEL (female) (3)
a Prepare with starting switch OFF, then turn starting switch ON and
Defective engine con- carry out troubleshooting.
6
troller RH J1 Voltage
Between (33) – (47) 4.75 – 5.25V
86 12V140E-3 Series
12V140E-3 Series 87
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank)

Trouble Supply voltage abnormally low (LH bank)
441 CA441
Contents of
q Abnormally low supply voltage in circuit.
trouble
Action of
controller
Phenomenon
machine
Related
information
and standard
state
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank)

Trouble Supply voltage abnormally low (RH bank)
441 CB441
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information
and standard
state
88 12V140E-3 Series
E-54 Code [442/CA442] Battery Voltage High Error (LH bank)

Trouble Supply voltage abnormally high (LH bank)
442 CA442
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information
and standard
state
E-55 Code [442/CB442] Battery Voltage High Error (RH bank)

Trouble Supply voltage abnormally high (RH bank)
442 CB442
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information
and standard
state
12V140E-3 Series 89
KOMATSU 12V140E-3 Series engine
Form Number : SEN00317-03
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
90
SEN00318-03
ENGINE 1SHOP MANUAL
12V140E-3 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 2
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
12V140E-3 Series 1
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-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) ............................... 44
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
2 12V140E-3 Series
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) 1
Trouble Common rail pressure abnormally high Error 2 (LH bank)
449 CA449
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Phenomenon
that appears on • Output drops.
machine
Related
information

and standard
state
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank) 1
Trouble Common rail pressure abnormally high Error 2 (RH bank)
449 CB449
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
12V140E-3 Series 3
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally high pressure
Trouble
451 CA451 (LH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Phenomenon
machine
Related
• Different machine models may have different connector Nos.
information

1
LH PFUEL Voltage
Defective common rail pres-
Between (1) – (3) Power supply 4.75 – 5.25 V
2 sure sensor
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Possible causes Disconnection in wiring har- Wiring harness between LH J1 (female) (33) Resis-
and standard ness Max. 1 z
value in normal 3 (Disconnection in wiring or
state defective contact in connec- Wiring harness between LH J1 (female) (25) Resis-
Max. 1 z
tor) – LH PFUEL (female) (2) tance
Max. 1 z
Resis-
– LH PFUEL (female) (1) and chassis Min. 1 Mz
Ground fault in wiring har- tance
ground
ness
cuit) – LH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
Resis-
– LH PFUEL (female) (3) and chassis Min. 1 Mz
tance
ground
4 12V140E-3 Series

Resis-
– LH PFUEL (female) (1) and LH J1 Min. 1 Mz
(female) (25) – LH PFUEL (female) (2)
ness
Possible causes – LH PFUEL (female) (1) and LH J1 Min. 1 Mz
ness) tance
and standard (female) (47) – LH PFUEL (female) (3)
value in normal
state Resis-
– LH PFUEL (female) (2) and LH J1 Min. 1 Mz
tance
(female) (47) – LH PFUEL (female) (3)
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
12V140E-3 Series 5
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally high pressure
Trouble
451 CB451 (RH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Phenomenon
machine
Related
information

Defective sensor power sup- If code [352/CB352] or [386/CB386] is indicated, carry out trouble-
1
RH PFUEL Voltage
Defective common rail pres-
Between (1) – (3) Power supply 4.75 – 5.25 V
2 sure sensor
Possible causes Disconnection in wiring har- Wiring harness between RH J1 (female) Resis-
and standard ness Max. 1 z
(33) – RH PFUEL (female) (1) tance
value in normal 3 (Disconnection in wiring or
state defective contact in connec- Wiring harness between RH J1 (female) Resis-
Max. 1 z
tor) (25) – RH PFUEL (female) (2) tance
Max. 1 z
(47) – RH PFUEL (female) (3) tance
Resis-
(33) – RH PFUEL (female) (1) and chassis Min. 1 Mz
ground
ness
4 Wiring harness between RH J1 (female)
cuit) (25) – RH PFUEL (female) (2) and chassis Min. 1 Mz
tance
ground
Resis-
(47) – RH PFUEL (female) (3) and chassis Min. 1 Mz
tance
ground
6 12V140E-3 Series

Resis-
(33) – RH PFUEL (female) (1) and RH J1 Min. 1 Mz
ness
Possible causes (33) – RH PFUEL (female) (1) and RH J1 Min. 1 Mz
ness) tance
and standard (female) (47) – RH PFUEL (female) (3)
value in normal
state Resis-
(25) – RH PFUEL (female) (2) and RH J1 Min. 1 Mz
tance
6 Defective engine controller RH J1 Voltage
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
12V140E-3 Series 7
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally low pressure
Trouble
452 CA452 (LH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected abnormally low pressure
Trouble
452 CA452 (RH bank)
Contents of
• Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
8 12V140E-3 Series
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank) 1

Trouble Common rail pressure abnormally high Error 1 (LH bank)
553 CA553
Contents of
trouble
Action of
• None in particular.
controller
Phenomenon
machine
Related
information

Check fuel used directly.
2 Use of improper fuel
(High viscosity)
Defective electrical system of Common rail pressure sensor may have electric trouble.
Possible causes 3
common rail pressure sensor Carry out troubleshooting for code [451/CA451] (E-58).
and standard
value in normal Defective mechanical system
state 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
12V140E-3 Series 9
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank) 1

Trouble Common rail pressure abnormally high Error 1 (RH bank)
553 CB553
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

Check fuel used directly.
2 Use of improper fuel
(High viscosity)
Defective electrical system of Common rail pressure sensor may have electric trouble.
Possible causes 3
common rail pressure sensor Carry out troubleshooting for code [451/CB451] (E-59).
and standard
value in normal Defective mechanical system
state 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
10 12V140E-3 Series
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank) 1
Error code Failure code Common rail pressure sensor detection of in range abnormality
Trouble
554 CA554 (LH bank)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) 1
Error code Failure code Common rail pressure sensor detected In range abnormality
Trouble
554 CB554 (RH bank)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
12V140E-3 Series 11
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) 1

Trouble Supply pump no-pressure feed error 1 (LH bank)
559 CA559
Contents of
• Supply pump does not feed fuel (level 1).
trouble
Action of
• Limits common rail pressure.
controller
Phenomenon
machine
Related
information

2 Use of improper fuel Improper fuel may be used. Check fuel used directly.
Loosening of fuel pipe and Fuel pipe may be loosened or fuel may be leaked. Check fuel pipe
3
leaked fuel directly.
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
Clogging of fuel tank air Fuel tank air breather may be clogged. Clean air breather and
5
breather check the hose directly.
Supply pump PCV may have electric trouble. Carry out trouble-
Defective supply pump PCV
6 shooting for following codes [271/CA271] (E-30), [272/CA272] (E-
electrical system
32), [273/CA273] (E-34), [274/CA274] (E-36).
a For contents of troubleshooting, see Note 1. For checking of
fuel low-pressure circuit, see Testing and adjusting, Testing fuel
Defective low-pressure cir- pressure.
7
Possible causes cuit device
and standard Pressure in fuel low-pressure Max. 0.15 – 0.29 MPa
value in normal circuit {Max. 1.5 – 3.0 kg/cm2}
state 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
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
a For testing of leakage from pressure limiter, see Testing and
9 Defective pressure limiter from injector.
Leakage from pressure limiter Max. 10 cc/min (at rated output)
10 Defective supply pump If causes 1 – 9 are not detected, supply pump may be defective.
12 12V140E-3 Series
Note 1: When low-pressure circuit is defective, check the following:

q Fuel level
q Clogged fuel tank breather
q Water separator/Prefilter filled with water
q Clogged fuel filter
q Clogged screen in water separator
q Stuck or worn feed pump, clogged filter
q Leaked or clogged low-pressure fuel pipe
q Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
q 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 Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q 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.
q Fuel filter: Replace (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it.
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
12V140E-3 Series 13
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor

Good NG
(Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Measured
Code Displayed item Checking condition Unit (Reference Good NG
value
value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating <By models> mm3 — — —
4
Common rail pressure
*4 Equivalent to rating <By models> MPa
command
*5 Common rail fuel pressure Equivalent to rating <By models> MPa
Low idle CA — — —
Fuel injection timing com-
*6 High idle CA — — —
mand
Equivalent to rating <By models> CA — — —
*7 Boost pressure Equivalent to rating <By models> kPa — — —
Engine coolant tempera-
*8 Low idle °C — — —
ture
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Func Measured
Reduced cylinder Checking condition Unit (Reference Good NG
tion value
value)
No. 1 cylinder Low idle rpm — — —
5 No. 2 cylinder Low idle rpm — — —
*10
14 12V140E-3 Series
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
Fuel low-pressure circuit pres- MPa Min. 0.15
6 High idle
sure {kg/cm2} {Min. 1.5}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
Standard value
E. Check of leakage and return Measured
Checking condition Unit (Reference Good NG
rate value)
value
11 Leakage through pressure limiter No load, at rated output cc/min Max. 10

Equivalent to rating
cc/min 960
<By models> 1,600 rpm
cc/min 1,020
<By models> 1,700 rpm Speed:
12 Return rate from injector cc/min 1,080
Return
cc/min 1,140 rate:
cc/min 1,200
*1 – *10:
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
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank) 1

Trouble Supply pump no-pressure feed error 1 (RH bank)
559 CB559
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

2 Use of improper fuel Improper fuel may be used. Check fuel used directly.
Loosening of fuel pipe and Fuel pipe may be loosened or fuel may be leaked. Check fuel pipe
3
leaked fuel directly.
4 Clogging of filter/strainer a For contents of troubleshooting, see Note 2.
Clogging of fuel tank air Fuel tank air breather may be clogged. Clean air breather and
5
breather check the hose directly.
Supply pump PCV may have electric trouble. Carry out trouble-
Defective supply pump PCV
6 shooting for following codes [271/CB271] (E-31), [272/CB272] (E-
electrical system
33), [273/CB273] (E-35), [274/CB274] (E-37).
a For contents of troubleshooting, see Note 1. For checking of
fuel low-pressure circuit, see Testing and adjusting, Testing fuel
Defective low-pressure cir- pressure.
7
Possible causes cuit device
and standard Pressure in fuel low-pressure Max. 0.15 – 0.29 MPa
value in normal circuit {Max. 1.5 – 3.0 kg/cm2}
state a For testing of return (spill) limit from injector, see Testing and
from injector.
Speed at rated operation Return (Spill) limit from injector
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
a For testing of leakage from pressure limiter, see Testing and
9 Defective pressure limiter from injector.
Leakage from pressure limiter Max. 10 cc/min (at rated output)
10 Defective supply pump If causes 1 – 9 are not detected, supply pump may be defective.
16 12V140E-3 Series
Note 1: When low-pressure circuit is defective, check the following:

q Fuel level
q Clogged fuel tank breather
q Water separator/Prefilter filled with water
q Clogged fuel filter
q Clogged screen in water separator
q Stuck or worn feed pump, clogged filter
q Leaked or clogged low-pressure fuel pipe
q Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
q 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 Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q 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.
q Fuel filter: Replace (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it.
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
12V140E-3 Series 17
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor

Good NG
(Fault history function, monitoring function, and reduced cylinder mode function)
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Measured
Code Displayed item Checking condition Unit (Reference Good NG
value
value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating <By models> mm3 — — —
4
Common rail pressure
*4 Equivalent to rating <By models> MPa
command
*5 Common rail fuel pressure Equivalent to rating <By models> MPa
Low idle CA — — —
Fuel injection timing com-
*6 High idle CA — — —
mand
Equivalent to rating <By models> CA — — —
*7 Boost pressure Equivalent to rating <By models> kPa — — —
Engine coolant tempera-
*8 Low idle °C — — —
ture
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Func Measured
Reduced cylinder Checking condition Unit (Reference Good NG
tion value
value)
5 No. 2 cylinder Low idle rpm — — —
*10
18 12V140E-3 Series
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
Fuel low-pressure circuit pres- MPa Min. 0.15
6 High idle
sure {kg/cm2} {Min. 1.5}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
Standard value
E. Check of leakage and return Measured
Checking condition Unit (Reference Good NG
rate value)
value
11 Leakage through pressure limiter No load, at rated output cc/min Max. 10

cc/min 960
cc/min 1,020
<By models> 1,700 rpm Speed:
12 Return rate from injector cc/min 1,080
Return
cc/min 1,140 rate:
cc/min 1,200
*1 – *10:
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
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank) 1

Trouble Engine Ne Speed Sensor detected abnormality (LH bank)
689 CA689
Contents of
• Abnormality occurred in engine Ne speed sensor circuit.
trouble
Action of
• Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
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

Defective sensor power sup- If code [238/CA238] is indicated, carry out troubleshooting for it
1
ply system first.
ness Max. 1 z
defective contact in connec- Wiring harness between LH J1 (female) (48) Resis-
Max. 1 z
tor) – Ne (female) (2) tance
Max. 1 z
Ground fault in wiring har- Wiring harness between LH J1 (female) (16) Resis-
Min. 1 Mz
ness – Ne (female) (1) and chassis ground tance
3
cuit) Min. 1 Mz
– Ne (female) (2) and chassis ground tance
Min. 1 Mz
and standard – Ne (female) (3) and chassis ground tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Resis-
– Ne (female) (1) and LH J1 (female) (48) – Min. 1 Mz
Ne (female) (2)
ness
ness) – Ne (female) (1) and LH J1 (female) (48) – Min. 1 Mz
tance
Ne (female) (2)
Resis-
– Ne (female) (2) and LH J1 (female) (27) – Min. 1 Mz
tance
Ne (female) (3)
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.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
out.)
20 12V140E-3 Series
Circuit diagram related to engine Ne speed sensor
12V140E-3 Series 21
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank) 1

Trouble Engine Ne Speed Sensor detected abnormality (RH bank)
689 CB689
Contents of
• Abnormality occurred in engine Ne speed sensor circuit.
trouble
Action of
• Controls Ne speed sensor with signals of G (Bkup) speed sensor.
controller
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

Defective sensor power sup- If code [238/CB238] is indicated, carry out troubleshooting for it
1
ply system first.
ness Max. 1 z
defective contact in connec- Wiring harness between RH J1 (female) Resis-
Max. 1 z
tor) (48) – Ne (female) (2) tance
Max. 1 z
(27) – Ne (female) (3) tance
Min. 1 Mz
ness – Ne (female) (1) and chassis ground tance
3
(Short circuit with GND cir- Wiring harness between RH J1 (female) Resis-
cuit) Min. 1 Mz
(48) – Ne (female) (2) and chassis ground tance
Possible causes Wiring harness between RH J1 (female) Resis-
Min. 1 Mz
and standard (27) – Ne (female) (3) and chassis ground tance
Resis-
– Ne (female) (1) and RH J1 (female) (48) – Min. 1 Mz
Ne (female) (2)
ness
ness) – Ne (female) (1) and RH J1(female) (27) – Min. 1 Mz
tance
Ne (female) (3)
Resis-
(48) – Ne (female) (2) and RH J1 (female) Min. 1 Mz
tance
(27) – Ne (female) (3)
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.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
out.)
22 12V140E-3 Series
Circuit diagram related to engine Ne speed sensor
12V140E-3 Series 23
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank
only) 1
Error code Failure code Intake air temperature sensor detected abnormally high tempera-
Trouble
691 CA691 ture (LH bank)
Contents of
• Intake air temperature sensor circuit detected abnormally high temperature.
trouble
Action of
• Fixes intake air temperature at (25 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

Defective charge tempera- Intake air
TAM1 Resistance
1 ture sensor temperature
(Internal trouble) Between (A) – (B) 10 – 100 °C 0.5 – 20 kz
Between (A) –
All range Min. 1 Mz
chassis ground
Disconnection in wiring har- ing without turning starting switch ON.
Possible causes ness
and standard 2 (Disconnection in wiring or Max. 1 z
– TAM1 (female) (A) tance
state tor) Wiring harness between LH J1 (female) (47) Resis-
Max. 1 z
– TAM1 (female) (B) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
3
cuit) Max. 1 Mz
– TAM1 (female) (A) and chassis ground tance
4 Defective engine controller Intake air
TAM1 (male) Resistance
temperature
Between (43) – (47) 10 – 100 °C 0.5 – 20 kz
24 12V140E-3 Series
Circuit diagram related to intake air temperature sensor
12V140E-3 Series 25
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank
only) 1
Error code Failure code Intake air temperature sensor detected abnormally low tempera-
Trouble
692 CA692 ture (LH bank only)
Contents of
• Intake air temperature sensor circuit detected abnormally low temperature.
trouble
Action of
• Fixes intake air temperature at (25 °C) and continues operation.
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
26 12V140E-3 Series
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH
bank) 1
Trouble Engine G (Bkup) speed sensor abnormal phase (LH bank)
731 CA731
Contents of
• Engine G (Bkup) sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
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

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective.
and standard 1
sensor system Carry out troubleshooting for [689/CA689] (E-68).
value in normal
state Defective G (Bkup) speed Common rail pressure sensor may have electric trouble.
2
sensor system Carry out troubleshooting for code [778/CA778] (E-76).
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH
bank) 1
Trouble Engine G (Bkup) speed sensor abnormal phase (RH bank)
731 CB731
Contents of
• Engine G (Bkup) sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Phenomenon
that appears on
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective.
and standard 1
sensor system Carry out troubleshooting for [689/CB689] (E-69).
value in normal
state Defective G (Bkup) speed Common rail pressure sensor may have electric trouble.
2
sensor system Carry out troubleshooting for code [778/CB778] (E-77).
12V140E-3 Series 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank) 1
Trouble All Engine Controller Data Lost Error (LH bank)
757 CA757
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Phenomenon
that appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) 1
Trouble All Engine Controller Data Lost Error (RH bank)
757 CB757
Contents of
trouble
Action of c
ontroller
Phenomenon
that appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
28 12V140E-3 Series
12V140E-3 Series 29
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank) 1
Trouble Engine G (Bkup) speed sensor abnormal (LH bank)
778 CA778
Contents of
• Abnormality occurred in engine G (Bkup) speed sensor circuit.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Phenomenon
that appears on
machine
Related
information

1
ness Max. 1 z
– LH G (female) (1) tance
defective contact in connec- Wiring harness between LH J1 (female) (47) Resis-
Max. 1 z
tor) – LH G (female) (2) tance
Max. 1 z
– LH G (female) (3) tance
Min. 1 Mz
ness – LH G (female) (1) and chassis ground tance
3
cuit) Min. 1 Mz
– LH G (female) (2) and chassis ground tance
Min. 1 Mz
and standard – LH G (female) (3) and chassis ground tance
Resis-
– LH G (female) (1) and LH J1 Min. 1 Mz
(female) (47) – LH G (female) (2)
ness
ness) – LH G (female) (1) and LH J1 Min. 1 Mz
tance
Resis-
– LH G (female) (2) and LH J1 Min. 1 Mz
tance
Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec-
5 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 can-
sensor system
not be carried out.)
out.)
30 12V140E-3 Series
Circuit diagram related to engine G (Bkup) speed sensor system
12V140E-3 Series 31
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) 1
Trouble Engine G (Bkup) speed sensor abnormal (RH bank)
778 CB778
Contents of
• Abnormality occurred in engine G (Bkup) speed sensor circuit.
trouble
Action of
• Controls with signals of Ne speed sensor.
controller
Phenomenon
that appears on
machine
Related
information

Defective sensor power sup- If code [187/CB187] or [227/CB227] is indicated, carry out trouble-
1
Disconnection in wiring har- Wiring harness between RH J1 (female) Resis-
ness Max. 1 z
(37) – RH G (female) (1) tance
defective contact in connec- Max. 1 z
tor)
Max. 1 z
Resis-
(37) – RH G (female) (1) and chassis Min. 1 Mz
ground
ness
cuit) (47) – RH G (female) (2) and chassis Min. 1 Mz
tance
ground
Possible causes Wiring harness between RH J1 (female)
and standard Resis-
(26) – RH G (female) (3) and chassis Min. 1 Mz
value in normal tance
ground
state a Prepare with starting switch OFF, then carry out troubleshoot-
Resis-
(37) – R G (female) (1) and RH J1 Min. 1 Mz
(female) (47) – RH G (female) (2)
ness
ness) (37) – R G (female) (1) and RH J1 Min. 1 Mz
tance
Resis-
(47) – R G (female) (2) and RH J1 Min. 1 Mz
tance
Defective mount of sensor or Check G (Bkup) speed sensor directly for defective mount (defec-
5 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 can-
sensor system
not be carried out.)
out.)
32 12V140E-3 Series
Circuit diagram related to engine G (Bkup) speed sensor system
12V140E-3 Series 33
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH

bank) 1
Trouble Inter multi-controller communication error (LH bank)
781 CA781
Contents of
• Communication error occurred between engine controllers (LH bank)
trouble
Action of
controller
Phenomenon
• Single-bank operation
that appears on
• Engine cannot be started with the key ON
machine
Related
information

ness
1 (Disconnection in wiring or Max. 1 z
– RH J1 (female) (8) tance
tor) Wiring harness between LH J1 (female) (6) Resis-
Max. 1 z
– RH J1 (female) (6) tance
Possible causes ing without turning starting switch ON.
and standard
value in normal 2 Min. 1 Mz
(Short circuit with GND cir- – RH J1 (female) (8) and chassis ground tance
state
Min. 1 Mz
– RH J1 (female) (6) and chassis ground tance
Between (8) – (6) 54 – 66 z
Min. 1 Mz
ground
34 12V140E-3 Series
Circuit diagram related to inter multi-controller communication
12V140E-3 Series 35
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH

bank) 1
Trouble Inter multi-controller communication error (RH bank)
781 CB781
Contents of
• Communication error occurred between engine controllers (LH bank)
trouble
Action of
controller
Phenomenon
• Single-bank operation
that appears on
• Engine cannot be started with the key ON
machine
Related
information

and standard
state
36 12V140E-3 Series
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) 1

Trouble Engine Controller Data Lost Error (LH bank)
1117 CA1117
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank) 1

Trouble Engine Controller Data Lost Error (RH bank)
1117 CB1117
Contents of
trouble
Action of
controller
Phenomenon
that appears on
machine
Related
information

and standard
state
12V140E-3 Series 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) 1

Trouble Multi-controller identification harness key error (LH bank)
1257 CA1257
Contents of
• Collation of identification harness between respective bank controllers fail (LH bank)
trouble
Action of
• Stops operation
controller
Phenomenon
that appears on • Engine cannot be started with the key ON
machine
Related
information

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
defective contact in connec- Wiring harness between OEM L (female) (7) Resis-
Max. 1 z
tor) – OEM L (female) (34) tance
Possible causes Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness ing without turning starting switch ON.
2
value in normal (Short circuit with GND cir- Between wiring harness OEM L (female) (8) Resis-
cuit) Min. 1 Mz
state and chassis ground tance
Between wiring harness OEM L (7) and Resis-
3 Defective engine controller Max. 1 z
chassis ground tance
Between wiring harness OEM L (8) and Resis-
Min. 1 Mz
Circuit diagram related to multi-controller identification harness key
38 12V140E-3 Series
E-83 Code [1257/CB1257] Harness Key error (RH bank) 1

Trouble Multi-controller identification harness key error (RH bank)
1257 CB1257
Contents of
• Collation of identification harness between respective bank controllers fail (RH bank)
trouble
Action of
• Stops operation
controller
Phenomenon
that appears on • Engine cannot be started with the key ON
machine
Related
information

Wrong connection of harness ing without turning starting switch ON.
1
Connector connection error Between OEM R (female) (7) – OEM R Resis-
Min. 1 Mz
(female) (34) terminals tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes ing without turning starting switch ON.
ness
and standard 2
(Short circuit with GND cir- Between wiring harness OEM R (female) (8) Resis-
value in normal Min. 1 Mz
cuit) and chassis ground tance
state
Between wiring harness OEM R (7) and Resis-
3 Defective engine controller Min. 1 Mz
Between wiring harness OEM R (8) and Resis-
Min. 1 Mz
Circuit diagram related to multi-controller identification harness key
12V140E-3 Series 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error

(RH bank) 1
Error code Failure code Disconnection or short circuit in injector #7 (R/B #1) system
Trouble
1548 CB1548 (RH bank)
Contents of
• There is disconnection or short circuit in injector #7 circuit.
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
• Idle speed is unstable.
machine
Related
information

Defective injector #7 RH CN1 (male) Resistance
1
(Internal trouble) Between (1) – (2) 0.4 – 1.1 z
Min. 1 Mz
ground
ness
(45) – RH CN1 (female) (1) tance
tor) Wiring harness between RH J1 (female) Resis-
Possible causes Max. 1 z
and standard
Resis-
ness (45) – RH CN1 (female) (1) and chassis Min. 1 Mz
3 tance
Resis-
(53) – RH CN1 (female) (2) and chassis Min. 1 Mz
tance
ground
Between (45) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
40 12V140E-3 Series
Circuit diagram related to injector #7 (R/B #1) system
12V140E-3 Series 41

(RH bank) 1
Trouble
1549 CB1549 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (54) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
42 12V140E-3 Series
12V140E-3 Series 43
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short

Error (RH bank) 1
Trouble
1551 CB1551 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (56) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
44 12V140E-3 Series
12V140E-3 Series 45

Error (RH bank) 1
Trouble
1552 CB1552 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (46) – (60) 0.4 – 1.1 z
Min. 1 Mz
ground
46 12V140E-3 Series
12V140E-3 Series 47

Error (RH bank) 1
Trouble
1553 CB1553 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (57) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
48 12V140E-3 Series
12V140E-3 Series 49

(RH bank) 1
Trouble
1622 CB1622 (RH bank)
Contents of
trouble
Action of
controller
Phenomenon
• Output drops.
that appears on
machine
Related
information

1
Min. 1 Mz
ground
ness
and standard
Resis-
3 tance
Resis-
tance
ground
Between (55) – (52) 0.4 – 1.1 z
Min. 1 Mz
ground
50 12V140E-3 Series
12V140E-3 Series 51
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) 1

Trouble KOMNET error (LH bank)
1633 CA1633
Contents of
• Abnormality occurred in circuit of KOMNET communication with machine (LH bank).
trouble
Action of
• Normal control (communication function disabled)
controller
Phenomenon
that appears on • Different problems occur on different machine models.
machine
Related
information

Disconnection in wiring har- Wiring harness between OEM L (female) Resis-
ness Max. 1 z
(46) – OEM R (female) (46) tance
defective contact in connec- Wiring harness between OEM L (female) Resis-
Max. 1 z
tor) (47) – OEM R (female) (47) tance
Wiring harness between OEM L (female) Resis- 108 –
(46) – OEM L (female) (47) tance 132 z
Possible causes
and standard
value in normal Ground fault in wiring har- Wiring harness between OEM L (female)
Resis-
state ness (46) – OEM R (female) (46) and chassis Min. 1 Mz
2 tance
cuit) Wiring harness between OEM L (female)
Resis-
(47) – OEM R (female) (47) and chassis Min. 1 Mz
tance
ground
Wiring harness between OEM L (female) Resis- 108 –
(46) – OEM L (female) (47) tance 132z
Wiring harness between OEM R (female) Resis- 108 –
(46) – OEM R (female) (47) tance 132 z
52 12V140E-3 Series
KOMNET-related circuit diagram
12V140E-3 Series 53
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 Failure code Throttle sensor detection of abnormally high supply voltage
Trouble
2185 CA2185 (LH bank only)
Contents of
• High voltage abnormality occurred to throttle sensor power supply (5 V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Depends on machine model.
machine
Related
information

Defective deceleration sen- Disconnect devices

1 sor at right in order. If
Decelerator sensor DEC connector
pears subsequently,
that device has a
defect in it.
ness
Wiring harness between OEM L (female) Resis-
(22) – DEC (female) (A) tance
tor) Wiring harness between OEM L (female) Resis-
(23) – DEC (female) (C) tance
and standard
state Ground fault in wiring har- ing without turning starting switch ON.
ness Wiring harness between OEM L (female) Resis-
3 Min. 1 Mz
(Short circuit with GND cir- (22) – DEC (female) (A) and chassis ground tance
cuit) Wiring harness between OEM L (female) Resis-
Min. 1 Mz
(23) – DEC (female) (C) and chassis ground tance
Short circuit in wiring har- ing without turning starting switch ON.
ness
4 Wiring harness between OEM L (female)
ness) (22) – DEC (female) (A) and OEM L Min. 1 Mz
tance
(female) (23) – DEC (female) (C)
OEM L Voltage
Between (22) – (23) 4.75 – 5.25 V
54 12V140E-3 Series
Circuit diagram related to deceleration pedal type throttle sensor (Case of D475-5)
12V140E-3 Series 55
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank
only) 1
Error code Failure code Throttle sensor detected abnormally low supply voltage
Trouble
2186 CA2186 (LH bank only)
Contents of
• Low-voltage abnormality occurred to throttle sensor power supply (5V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation.
controller (depending on each model)
Phenomenon
that appears on • Depends on machine model.
machine
Related
information

and standard
state
56 12V140E-3 Series
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank) 1
Trouble Supply pump no-pressure feed error 2 (LH bank)
2249 CA2249
Contents of
trouble
Action of
controller
Phenomenon
machine
Related
information

and standard
state
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) 1
Trouble Supply pump no-pressure feed error 2 (RH bank)
2249 CB2249
Contents of
trouble
Action of ontrol-
ler
Phenomenon
machine
Related
information

and standard
state
12V140E-3 Series 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only) 1

Trouble Engine overheat (LH bank only)
– –*1 –
Contents of
• Engine coolant temperature is above operating range.
trouble
Action of
• Limits output and continues operation.
controller
Phenomenon
machine
Related
information

Possible causes
and standard This defective phenomenon is indicated only on the installed
value in normal Carry out troubleshooting on machine when it was detected.
1
state 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
Trouble Engine oil pressure low and speed derate (LH bank only)
– –*2 –
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Phenomenon
machine
Related
information

Possible causes
1
58 12V140E-3 Series
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only) 1
Trouble Engine oil pressure low and torque derate (LH bank only)
– –*3 –
Contents of
• Engine oil pressure is below operating range.
trouble
Action of
• Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Phenomenon
machine
Related
information

Possible causes
1
12V140E-3 Series 59

Form No. SEN00318-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (02)
60 12V140E-3 Series
SEN00320-03
ENGINE 1SHOP MANUAL
12V140E-3 Series
50 Disassembly and assembly

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools ................................................................................................................................ 9
12V140E-3 Series 1
SEN00320-03 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In "Removal" section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1,•••X1 etc. and their parts the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is described are described as [1], [2] ••• etc. and their part
in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in "Removal" section
tuted and should always be used are explained and listed below.
k
q : Special tools that will be useful if avail-
: Precautions related to work safety
able and are substitutable with tools
available on the market a: Guidance or precautions for the work
2) Distinction of new and existing special tools [*1] : This mark shows that instructions or precau-
N: Tools newly developed for this tions for parts installation work are given in
model. They have a new part num- "Installation" section.
ber respectively.
R: Tools made available by redesign- 6 : Amount of oil or coolant to be drained
ing the existing tools which were 4 : Weight of part or component
developed for other models. Each
of them has a new part number
assigned by setting forward the Installation
part number of the existing tool. q Unless otherwise instructed, installation of parts
Blank: Tools already available for other is to be done in the reverse order to removal.
models. They can be used without q Instructions and precautions for parts installa-
any modification. tion is shown with the mark ([*1], [*2]...) which
3) Circle mark Q in sketch column: corresponds to the mark in "Removal" section.
q The sketch of the special tool is pre- q Common tools that are necessary for installa-
sented in the section of "Sketches of tion are described as [1], [2] ••• etc. and their
special tools". part numbers, part names and quantities are not
q Part No. of special tools starting with described.
79*T-***-****: q Marks shown in the "Installation" section stand
means that they are not available for the following.
k
from Komatsu Ltd. (i.e. tools to be
made locally).
a: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 12V140E-3 Series
50 Disassembly and assembly SEN00320-03
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In "Disassembly" section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1,•••X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] ••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in "Disas-
and should always be used. sembly" section are as follows.
k
q : Special tools that will be useful if avail-
able and are substitutable with tools
available on the market. a: Guidance or precautions for the work
2) Distinction of new and existing special tools 6: Amount of oil or coolant drained
N : Tools newly developed for this
model. They have a new part
number respectively. Assembly
R : Tools made available by redesign- q In "Assembly" section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assem-
part number of the existing tool. bly are described as [1], [2] ••• etc. and their
Blank : Tools already available for other part numbers, part names and quantities are
models. They can be used without not described.
any modification. q The meanings of the symbols used in "Assem-
3) Circle mark Q in sketch column: bly" section are as follows.
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of "Sketches of
special tools". a: Guidance or precautions for the work
2
q Part No. of special tools starting with : Type of coating material
79*T-***-****:
means that they are not available 3 : Tightening torque
5
from Komatsu Ltd. (i.e. tools to be : Amount of oil or coolant to be replenished
made locally).
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
12V140E-3 Series 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
Gasket sealant
• Used to seal oil pan, final drive case, etc.

• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
• Used for rough surfaces such as the circle
LG-9 gear top seal which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped, water resistance of the clearance at
1206D the welded area, etc.
• Can be coated with paint.
4 12V140E-3 Series
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
SYG2-400T-A • Seizure resistance, heat resistance and water

Hyper White
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
12V140E-3 Series 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 12V140E-3 Series
Special tool list 1

(Rev. 2009.01)
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity : t . . . . . . Special tools that cannot be substituted and should always be used
: q . . . . . . Special tools that will be useful if available and are substitutable with tools avail-
able on the market
a New/Remodel: N. . . . . . Tools newly developed for this model. They have a new part number respec-
tively.
: R. . . . . . Tools made available by redesigning the existing tools which were developed for
other models. Each of them has a new part number assigned by setting forward
the part number of the existing tool.
: Blank . . Tools already available for other models. They can be used without any modifi-
cation.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketch-
es of special tools")
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
790-501-4000 Engine repair stand t 1

790-901-1800 Bracket assembly t 1
790-901-1810 Bracket t 1
790-901-1820 Bracket t 1
790-901-1830 Bracket t 1
Disassembly and 790-901-1840 Bracket t 1
assembly of engine A
assembly 790-901-1510 Plate t 4
02100-01038 Bolt t 36
01252-11050 Bolt t 16
01643-31645 Washer t 12
01643-31032 Washer t 16
01602-21648 Washer t 24
795-102-2102 Spring pusher t 1
795-102-2110 Handle t 1
795-102-2120 Bracket t 1
Disassembly and 795-102-4210 Bracket t 1
assembly of cylinder B
head 01016-50830 Bolt t 1
01580-10806 Nut t 1
01144-31270 Stud t 1
01580-11210 Nut t 1
Removal and
C 795-100-1191 Piston ring tool t 1
installation of piston ring
Measurement of
D 795-502-1121 Holder t 1
cylinder liner projection
Removal of cylinder liner E 795-236-1000 Liner puller t 1
Installation of cylinder
F 795-230-5472 Liner driver t 1
liner
Angle tightening of bolt G 795-331-1110 Wrench t 1
Installation of piston H 795-236-1500 Piston holder t 1
12V140E-3 Series 7
New/Remodel
Necessity
Sketches
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
795T-621-1430 Plate t 1 Q
795T-621-1441 Push tool t 1 Q
Installation of front oil
J 01050-32280 • Bolt t 3
seal
01582-02218 • Nut t 3
01640-22232 • Washer t 3
795T-621-1531 Push tool t 1 Q
01050-32050 Bolt t 5
Installation of rear oil 01640-02032 Washer t 5
K
seal 795T-621-1540 Push tool t 1 Q For PC2000-8
01050-32060 Bolt t 5 For PC2000-8
01640-02032 Washer t 5 For PC2000-8
Press fitting of valve
L 795-130-1720 Push tool t 1
stem seal
Adjusting valve Commercially
M Thickness gauge q 1 IN: 0.35 mm, EX: 0.57 mm
clearance available
Removal of front and
N 795-931-1100 Seal puller q 1
rear oil seal
8 12V140E-3 Series
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
J Plate
J Push tool
12V140E-3 Series 9
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
K Push tool
K Push tool (For PC2000-8)
10 12V140E-3 Series
12V140E-3 Series 11

Form No. SEN00320-03
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11
12 12V140E-3 Series
SEN00321-01
ENGINE 1SHOP MANUAL
12V140E-3 Series
50 Disassembly and assembly

Disassembly and assembly, Part 1
Disassembly and assembly, Part 1 ................................................................................................................. 2
General disassembly of engine ............................................................................................................ 2
12V140E-3 Series 1
Disassembly and assembly, Part 1 1

General disassembly of engine 1
a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
Take care.
a When a part is provided on both sides of the
bank, one side alone is shown as an example.
Except where otherwise specified, contents of
the work shall be the same on both sides of the
bank.
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean the
entire engine carefully for accurate inspection
of its parts and quick disassembly and assem- 4. Starting motor assembly
bly. Remove engine harness (1) and then remove
a Before cleaning the engine, carefully seal starting motor assemblies (2) and (3).
or remove the openings, electric parts, a Remove the assembly at the top first
and wiring connectors so that water will being followed by that at the bottom.
not enter them.
2. Installation to engine repair stand

1) Install the engine assembly (1) to tool A.
4 Engine assembly:
Approx. 3,800 kg
5. Alternator
1) Remove auxiliary equipment belt (1).
2) Remove alternator (2).
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.
2 12V140E-3 Series
6. Fuel filter and filter head assembly, and

priming pump
1) Remove fuel tubes (1) and (2).
2) Remove fuel filter and filter head assem-
bly (3).
3) Remove priming pump (4).
9. Air intake connector

1) Remove air intake connector (1).
7. Engine controller and controller cooler

1) Remove engine controller (1).
2) Remove fuel hoses (2) and (3).
3) Remove controller cooler (4).
10. Spill tube

Remove spill tube (1).
8. Air inlet pipe

1) Remove the clamp and then remove air
inlet pipe (1).
2) Remove bracket (2).
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 posi-
tions of clamps (1) – (3) using paint.
3) Remove clamps (1) – (3).
4) Remove high-pressure pipes (5) and (6).
12V140E-3 Series 3
12. High-pressure pipe (between common rail 3) Remove bracket.

– fuel injector) 4) Remove all clamps (2) and (3).
1) Remove bracket (1). 5) Remove 6 high-pressure pipes (4).
2) Apply a marking to every installation posi- 13. Air intake manifold assembly
tions of clamps (2) and (3) using paint. 1) Remove support (1).
2) Lift air intake manifold (2) temporarily and

then remove the mounting bolts.
3) Lift off air intake manifold assembly (2).
4 Air intake manifold assembly:
45 kg
4 12V140E-3 Series
16. Exhaust manifold assembly

1) Remove instation plates (1), muffler
bracket (2), water pipes (3) and bracket
(4).
14. Exhaust connector

Remove exhaust connectors (1) and (2).
2) Lift exhaust manifold assembly (5) tempo-

rarily and then remove the mounting bolts.
3) 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 pro-
vided.
2) Lift turbocharger assembly (1) temporarily
and then remove the mounting bolts. 17. Common rail
3) Lift off turbocharger assembly (1). 1) Remove fuel tube (1).
4 Turbocharger assembly: 35 kg 2) Remove common rail (2).
12V140E-3 Series 5

E-10 Code (141/CA141) Oil Press. Sensor Low Error (LH Bank Only)

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E-10 Code (141/CA141) Oil Press. Sensor Low Error (LH Bank Only)

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E-10 Code (141/CA141) Oil Press. Sensor Low Error (LH Bank Only)

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SEN00317-03 40 Troubleshooting

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to coolant temperature sensor

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to charge temperature sensor

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to engine oil temperature sensor

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to atmospheric pressure sensor

Causes Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON

Circuit diagram related to sensor power supply 2 (5 V)

Causes Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON

Circuit diagram related to sensor power supply 2 (5 V)

E-23 Code [234/CA234] Eng. Overspeed (LH bank only)

Causes Standard value in normal state/Remarks on troubleshooting

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to Ne speed sensor power supply

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to Ne speed sensor power supply

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to fuel temperature sensor

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to fuel temperature sensor

E-30 Code [271/CA271] PCV1 Short Error (LH bank)

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to supply pump PCV1

E-31 Code [271/CB271] PCV1 Short Error (RH bank)

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to supply pump PCV1

E-32 Code [272/CA272] PCV1 Open Error (LH bank)

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to supply pump PCV1

E-33 Code [272/CB272] PCV1 Open Error (RH bank)

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to supply pump PCV1

E-34 Code [273/CA273] PCV2 Short Error (LH bank)

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to supply pump PCV2

E-35 Code [273/CB273] PCV2 Short Error (RH bank)

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to supply pump PCV2

E-36 Code [274/CA274] PCV2 Open Error (LH bank)

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to supply pump PCV2

E-37 Code [274/CB274] PCV2 Open Error (RH bank)

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to supply pump PCV2

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to injector #1

E-39 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to injector #5

E-40 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error

Causes Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to injector #3

E-41 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error

Causes Standard value in normal state/Remarks on troubleshooting