Engine 12V140E-3 Series: 10 Structure, Function and Maintenance Standard

SEN00309-04
ENGINE 1SHOP MANUAL
12V140E-3 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram.................................................................................................................. 4
Oil pump ............................................................................................................................................... 6
Oil cooler............................................................................................................................................... 7
Oil filter.................................................................................................................................................. 8
Main relief valve.................................................................................................................................... 9
Oil cooler bypass valve and regulator valve ....................................................................................... 10
Fuel system................................................................................................................................................... 12
CRI system diagram ........................................................................................................................... 12
CRI system diagram (Poor fuel spec.)................................................................................................ 14
Outline of CRI system......................................................................................................................... 16
12V140E-3 Series 1
SEN00309-04 10 Structure, function and maintenance standard
Fuel piping .......................................................................................................................................... 34

Fuel piping (Poor fuel spec.) ............................................................................................................... 39
Fuel filter ............................................................................................................................................. 44
Water separator .................................................................................................................................. 46
Priming pump...................................................................................................................................... 47
Electric priming pump ......................................................................................................................... 48
Cooling system.............................................................................................................................................. 50
Cooling system diagram ..................................................................................................................... 50
Water pump ........................................................................................................................................ 52
Thermostat.......................................................................................................................................... 54
Corrosion resistor................................................................................................................................ 55
Cooling fan drive ................................................................................................................................. 57
Electrical equipment...................................................................................................................................... 60
Alternator ............................................................................................................................................ 60
Starting motor...................................................................................................................................... 62
Starting aid .......................................................................................................................................... 64
Engine controller ................................................................................................................................. 67
Engine controller cooler ...................................................................................................................... 68
2 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-04
12V140E-3 Series 3
Lubrication system 1
Lubrication system diagram 1
a The shape is subject to machine models.
4 12V140E-3 Series
W: Coolant
1. Oil pan
2. Strainer
3. Oil pump (Triple gear pump)
4. Main relief valve
5. Oil cooler
6. Regulator valve
7. Oil cooler bypass valve
8. Oil filter
9. Oil filter safety valve
10. Main gallery
11. Crankshaft
12. Camshaft
13. Rocker arm
14. Cam follower
15. Intake valve and exhaust valve
16. Piston
17. Piston cooling nozzle
18. Timing gear
19. Turbocharger
20. Fuel supply pump
*1 When install optional parts. Since pre-lubrication

pump is to be installed in the machine, so for the
detail see the Shop Manual for the Machine.
12V140E-3 Series 5
Oil pump 1
A: From oil pan Specifications

B: To oil cooler Oil pump
Type: Gear pump
1. Pump body Revolving speed: Engine speed x 1.67
2. Pump drive gear (Number of teeth: 27)
3. Drive gear
4. Driven gear
5. Pump cover
6 12V140E-3 Series
Oil cooler 1
A: Oil inlet and outlet port (Flow is reversed Specifications

depending on front and rear oil cooler) Oil cooler
B: Oil inlet and outlet port (Flow is reversed Heat dissipation surface area: 0.986 m2
depending on front and rear oil cooler) Element: 12 stages
C: Coolant
1. Oil cooler cover

2. Cooler element
12V140E-3 Series 7
Oil filter 1
A: Oil inlet port Specifications

B: Oil outlet port Oil filter
Filtration area: 1.62 m2(0.42 m2 x 4)
1. Safety valve Rated flow: 480l/min
2. Filter head
3. Cartridge Safety valve
Cracking pressure: 196 ± 20 kPa {2.0 ± 0.2 kg/
cm2}
8 12V140E-3 Series
Main relief valve 1
1. Valve spring Specifications

2. Main relief valve Main relief valve
3. Valve body Cracking pressure:
1,245 ± 69 kPa {12.7 ± 0.7 kg/cm2}
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard
Standard size Outside diam- Inside diame-
Clearance between main relief clearance Replace valve or
4 eter of valve ter of body
valve and body body
–0.040 +0.016
33 0.040 – 0.076
–0.060 +0.016
Installed Installed load Allowable load
Free length
length (N {kg}) (N {kg})
5 Main relief valve spring Replace spring
75.8 59.8 621 {63.4} 353 {36}
Cracking pressure of main relief Correct or

6 Standard: 1,245 ± 69 kPa {12.7 ± 0.7 kg/cm2}
valve replace spring
12V140E-3 Series 9
Oil cooler bypass valve and regulator valve 1
A: From main gallery Specifications

B: From oil cooler
C: To oil pan Oil cooler bypass valve
D: To oil filter Cracking pressure (differential pressure):
392 ± 20 kPa {4.0 ± 0.2 kg/cm2}
1. Oil cooler bypass valve
2. Bypass valve spring Regulator valve
3. Regulator valve Cracking pressure: 402 ± 49 kPa {4.1 ± 0.5 kg/
4. Regulator valve spring cm2}
5. Valve body
10 12V140E-3 Series
Unit: mm
Tolerance
Standard
Clearance between regulator clearance Replace valve or
valve and body body
–0.020 +0.033
22 0.020 – 0.074
–0.041 +0.033
Installed Installed load Allowable load
Free length
length (N {kg}) (N {kg})
2 Regulator valve spring Replace spring
111.5 75 136.0 {13.87} 239 {24.4}
Cracking pressure of regulator Correct or

3 Standard: 402 ± 49 kPa {4.1 ± 0.5 kg/cm2}
valve replace spring
Tolerance
Standard
Clearance between oil cooler clearance Replace valve or
bypass valve and body body
–0.020 +0.033
28 0.020 – 0.086
–0.053 +0.033
Installed Installed load Allowable
Free length
5 Oil cooler bypass valve spring length (N {kg}) load Replace spring
125.8 89.8 186 {19} —
Cracking pressure of oil cooler Correct or
6 Standard: 392 ± 20 kPa {4.0 ± 0.2 kg/cm2}
bypass valve replace spring
12V140E-3 Series 11
Fuel system 1
CRI system diagram 1
a CRI is an abbreviation for common rail injection.
12 12V140E-3 Series
1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel tank
5. Pre-fuel filter
6. Main fuel filter
7. Overflow valve
8. Fuel supply pump assembly
9. PCV
10. High-pressure pump
11. Feed pump
12. Relief valve
13. G speed sensor
14. Common rail
15. Flow damper
16. Pressure limiter
17. High-pressure injection pipe
18. Priming pump (Main)
12V140E-3 Series 13
CRI system diagram (Poor fuel spec.) 1
a CRI is an abbreviation for common rail injection.
14 12V140E-3 Series
1. NE speed sensor
3. Injector
4. Fuel tank
5. Pre-fuel filter
6. Main fuel filter
7. Overflow valve
8. Fuel supply pump assembly
9. PCV
10. High-pressure pump
11. Feed pump
12. Relief valve
13. G speed sensor
14. Common rail
15. Flow damper
16. Pressure limiter
17. High-pressure injection pipe
18. Electrical priming pump (Main)
19. Water separator
12V140E-3 Series 15
Outline of CRI system 1

Outline 1. Fuel system
q The CRI system checks the condition of the
engine (engine speed, accelerator angle, cool-
ant temperature, etc.) with sensors.
q The microcomputer of the CRI system controls
the fuel injection rate, fuel injection timing, fuel
injection pressure, etc. totally to operate the
engine under the best condition.
q The CRI system has a diagnosis function and
an alarm function, with which the computer of
the system checks the main component parts
and notifies the operator of detected failures.
q In addition, the CRI system has a failsafe func-
tion which stops the engine when a certain part
fails and a backup function which continues
the operation by changing the control method
in such a case.
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
q The fuel system distributes the high-pressure

fuel generated by the fuel supply pump to the
cylinders through the common rail.
q The solenoid valve in the injector opens and
closes the nozzle needle valve to start and fin-
ish fuel injection.
16 12V140E-3 Series
2. Control system
q To the ECU (engine control unit), the signals

are sent from the sensors installed to the
machine. Based on the signals, the ECU cal-
culates and controls the energizing timing and
energizing period of the injector to injecta
proper quantity of fuel in proper timing.
q The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
12V140E-3 Series 17
Structure and operation of CRI system
q The CRI system consists of fuel supply pump, q If the TWV is turned ON (energized), the fuel
common rail, injector, ECU which controls circuit is changed so that the high-pressure
these 3 units, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The fuel discharge rate is controlled by turning q If the TWV is turned OFF (de-energized), the
on and off the PCV (Fuel injection pressure fuel circuit is changed so that the high-pres-
control valve) of the fuel supply pump accord- sure fuel will flow to the control chamber
ing to the electric signals from the ECU. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers to finish fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning ON and OFF the
TWV (2-way solenoid valve).
18 12V140E-3 Series
Structure and operation of component parts 1

1. Fuel supply pump
1. 3-thread type cam 6. No. 2 high-pressure pump

2. Overflow valve 7. Priming pump
3. Drive gear 8. Feed pump
4. No. 1 high-pressure pump 9. Gear for G speed sensor
5. PCV (Fuel injection pressure control valve)
Outline q Since the number of the times of feeding fuel

q The fuel supply pump consists of priming to the common rail is the same as the number
pump (7), feed pump (8), and high-pressure of the times of fuel injection, the common rail
pumps (4) and (6). fuel pressure is smooth and stable.
q The function of the fuel supply pump is to gen- q The fuel fed by high-pressure pumps (4) and
erate common rail fuel pressure by controlling (6) to the common rail is divided as follows.
the fuel discharge rate. q No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
Structure rail fuel pressure caused by fuel injection into
q High-pressure pumps (4) and (6) have the the No. 1, 3, and 5 cylinders.
pressure feed systems similar to those of the q No. 2 high-pressure pump (on the feed pump
conventional in-line fuel injection pump and the side) (6) compensates for drop in the common
PCVs (Fuel injection pressure control valves) rail fuel pressure caused by fuel injection into
for each cylinder to control the fuel delivery. the No. 2, 4, and 6 cylinders.
q By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.
12V140E-3 Series 19
Operation
q (A): The PCV is open when the plunger is in

lowering stroke, through which low-pres-
sure fuel is sucked in the plunger chamber.
q (B): While the PCV is not energized and is open
after the plunger starts the rising stroke, the
sucked fuel is returned through the PCV
without being pressurized.
q (C): If the PCV is energized and closed in the
timing for the necessary delivery, the return
passage is closed and the pressure in the
plunger chamber rises. Accordingly, the
fuel is fed through the delivery valve (check
valve) to the common rail. That is, the
quantity of the fuel corresponding to the
plunger lift after the PCV is closed is deliv-
ery. The delivery is changed and the com-
mon rail fuel pressure is controlled by
changing the opening timing of the PCV.
(pre-stroke of plunger)
q (D): After the cam passes the maximum lift
point, the plunger starts the lowering stroke
and the pressure in it lowers. At this time,
the delivery valve closes to stop feeding the
fuel. Since the PCV is de-energized, it
opens and the low-pressure fuel is sucked
in the plunger chamber, or the state of (A)
starts again.
20 12V140E-3 Series
1) PCV (Fuel injection pressure control 2) Feed pump

valve)
q The feed pump built in the fuel supply pump

q The PCV adjusts the fuel delivery from the fuel assembly draws the fuel from the fuel tank and
supply pump to adjust the common rail fuel sends it through the fuel filter to the high-pres-
pressure. It means that the delivery from the sure pump chamber.
fuel supply pump to the common rail is decided q The outer and inner rotors of the feed pump
by the timing of energizing the PCV. are rotated by the camshaft.
q The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.
12V140E-3 Series 21
2. Common rail
Structure
q Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injec-
tors of the cylinders.
q Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q The piping of the pressure limiter (3) is
returned to the fuel tank.
1) Flow damper
Function
q The flow dampers damp the pressure pulses in 2) Pressure limiter
the high pressure piping and supply the fuel to q If abnormally high pressure is generated, the
the injectors with stable pressure. pressure limiter opens to release that pres-
q If excessive fuel flows out, the flow dampers sure.
block the fuel passage to prevent abnormal q If the common rail fuel pressure reaches about
outflow of the fuel. 140 MPa {1,430 kg/cm2}, the pressure limiter
q If the fuel flows out abnormally, high pressure operates (Opens).
is applied to the piston, which moves to the q If the common rail fuel pressure lowers to 30
right until it reaches the seat to stop the fuel. MPa {310 kg/cm2}, the pressure limiter resets
itself (close) to maintain the pressure.
22 12V140E-3 Series
3) Common rail fuel pressure sensor

q The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
q This sensor is a semiconductor pressure sen-
sor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to the pressure applied to it.
12V140E-3 Series 23
3. Injector
Outline
q The function of the injector is to inject the high
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
24 12V140E-3 Series
Structure
1. Inlet connector 7. Orifice (in)

2. Terminal 8. Pressure control chamber
3. Upper body 9. Command piston
4. Solenoid 10. Spring
5. Valve body 11. Pressure pin
6. Orifice (out) 12. Nozzle assembly
q The injector consists of the nozzle section, ori-

fice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve sec-
tion.
12V140E-3 Series 25
A: No fuel injection C: Finish of fuel injection

B: Start of fuel injection D: From common rail
1. Nozzle 5. Valve body

2. Control piston 6. Solenoid
3. Orifice (in) 7. Spring
4. Orifice (out) 8. Pressure control chamber
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q Since the high-pressure fuel in the common
(8), nozzle (1) is closed and the fuel is not rail is applied to pressure control chamber (8)
injected. suddenly at this time, nozzle (1) is closed
quickly and fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
raised by electromagnetic power to open the
fuel passage.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and the fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q Continuing energization to solenoid (6) pro-
vides the maximum fuel injection rate.
26 12V140E-3 Series
Electric circuit diagram
k Since high voltage (65V) is applied to the

wiring harnesses connected to the ECU,
COMMON1 and COMMON2 of ECU, and
TWV#1 – #6 of the injector, take care not to
get an electric shock.
12V140E-3 Series 27
4. Various sensors and relays
1) Fuel temperature sensor 2) NE speed sensor (Crank angle sensor)

q The fuel temperature sensor senses the fuel q If the signal hole made on the flywheel passes
temperature and sends it to the engine control- the sensor, the magnetic line of force changes.
ler. The sensor unit is a thermistor the resis- q If the magnetic line of force changes, the out-
tance of which changes according to the put of the hall element sensor changes linearly
temperature. and it is converted into pulse of 0 - 5 V by the
q The engine controller applies voltage to the wave form shaping circuit in the sensor, and
thermistor and senses the temperature by the then output.
voltage divided by the resistance in the com-
puter and the resistance of the thermistor.
28 12V140E-3 Series
3) Atmospheric pressure sensor 4) Common rail pressure sensor

q This sensor is used to correct altitude.
5) Oil pressure sensor
A: Pressure inlet
B: Mounting screw: M5
Tightening torque:
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
q The following graph shows the output charac-
teristics of the atmospheric pressure sensor.
12V140E-3 Series 29
6) Bkup speed sensor (G sensor) 7) Charge pressure sensor

(Cylinder No. sensor) q This sensor is used to sense the charge pres-
q Similarly to the NE speed sensor, this sensor sure (boost pressure).
utilizes the pulses of 0 – 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120°.
q In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
A: Mounting screw: M6
Tightening torque:
5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring
q The following graph shows the output charac-

teristics of the charge pressure sensor.
30 12V140E-3 Series
8) Charge temperature sensor 9) Coolant temperature sensor

q The charge temperature sensor senses the q The coolant temperature sensor senses the
intake air temperature (boost temperature) and coolant temperature and sends it to the engine
sends it to the engine controller. controller.
q The sensor unit is a thermistor the resistance q The sensor unit is a thermistor the resistance
of which changes according to the tempera- of which changes according to the tempera-
ture. The engine controller applies voltage to ture. The engine controller applies voltage to
the thermistor and senses the temperature by the thermistor and senses the temperature by
the voltage divided by the resistance in the the voltage divided by the resistance in the
computer and the resistance of the thermistor. computer and the resistance of the thermistor.
12V140E-3 Series 31
Various controls
32 12V140E-3 Series
q The CRI system controls the fuel injection rate

and fuel injection timing more properly than the
mechanical governor or timer of the conven-
tional fuel injection pump.
q For the control of the system, calculations nec-
essary to the ECU are performed from the sig-
nals sent from the sensors installed to the
engine and machine.
q The energizing timing and energizing period of
the injector are so controlled that the optimum
quantity of fuel will be injected in the optimum
timing.
1. Fuel injection rate control function

q The fuel injection rate control function is
employed instead of the function of the con-
ventional governor. It controls the fuel injection
according to the signals of engine speed and
accelerator angle so that the fuel injection rate
will be most proper.
2. Fuel injection timing control function

q The fuel injection timing control function is
employed instead of the function of the con-
ventional timer. It controls the fuel injection tim-
ing most properly from the engine speed and
fuel injection rate.
3. Fuel injection pressure control function

(Common rail fuel pressure control
function)
q The fuel injection control function (common rail
fuel pressure control function) controls the fuel
discharge rate of the fuel supply pump by mea-
suring the fuel pressure by the common rail
fuel pressure sensor and feeding it back to
ECU.
q This function performs pressure feedback con-
trol so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.
12V140E-3 Series 33
Fuel piping 1
Left bank

a The illustration shows the engine for D475A-5E0.
1. Main fuel filter

2. Pre-fuel filter
4. Fuel pipe (From pre-fuel filter)
5. Fuel pipe (To feed pump)
6. Drain pipe
34 12V140E-3 Series
7. PCV 13. Fuel injection pipe (No.6 cylinder)

8. Fuel injection pipe (No.1 cylinder) 14. Common rail
9. Fuel injection pipe (No.2 cylinder) 15. Fuel return pipe
10. Fuel injection pipe (No.3 cylinder) 16. Feed pump
11. Fuel injection pipe (No.4 cylinder) 17. Oil pump (For pump lubricating oil)
12. Fuel injection pipe (No.5 cylinder) 18. High-pressure pump
12V140E-3 Series 35
Right bank

a The illustration shows the engine for D475A-5E0.

36 12V140E-3 Series
4. Fuel injection pipe (No.6 cylinder) 10. PCV

12V140E-3 Series 37
Front view of engine
Rear view of engine
38 12V140E-3 Series
Fuel piping (Poor fuel spec.) 1

Left bank
1. Main fuel filter

2. Electrical pre-fuel filter
3. Priming pump
6. Drain pipe
12V140E-3 Series 39
7. PCV 13. Fuel injection pipe (No.6 cylinder)

40 12V140E-3 Series
Right bank

12V140E-3 Series 41
4. Fuel injection pipe (No.6 cylinder) 10. PCV

42 12V140E-3 Series
Front view of engine
Rear view of engine
12V140E-3 Series 43
Fuel filter 1
A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug

2. Filter head
3. Cartridge
Specifications
Filtration area: 1.0 m2
44 12V140E-3 Series
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug

2. Filter head
3. Cartridge
Specifications
Filtration area: 2.12 m2
12V140E-3 Series 45
Water separator 1
A: Fuel inlet
B: Fuel outlet
1. Head
2. Screen
3. Gasket
4. Ring
5. Case
6. Drain cup
46 12V140E-3 Series
Priming pump 1
1. Spring 9. Valve stopper

2. Cover 10. Packing
3. Shaft 11. Check valve body
4. Bushing 12. Lever pin
5. Diaphragm 13. E-ring
6. Diaphragm cover 14. Washer
7. Body 15. Bolt
8. Check valve 16. Lever
12V140E-3 Series 47
Electric priming pump 1
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
48 12V140E-3 Series
12V140E-3 Series 49
Cooling system 1
Cooling system diagram 1
50 12V140E-3 Series
A: Lubricating oil
1. Radiator
2. Cooling fan
2A. Hydraulic fan motor
3. Water pump
4. Oil cooler (For engine)
5. Corrosion resistor
6. Thermostat housing
7. Oil cooler (For power train)
8. Oil cooler bypass circuit (For power train)
9. Air bleeding
10. Turbocharger
12V140E-3 Series 51
Water pump 1
A: From thermostat (Coolant)

B: From radiator (Coolant inlet)
C: To oil cooler (Coolant outlet)
1. Pump shaft
2. Water seal
3. Pump body
4. Water pump drive gear (Number of teeth: 25)
5. Ball bearing
6. Oil seal
7. Impeller
8. Pump cover
Specifications
Water pump
Type: Centrifugal, gear-driven
Revolving speed: Engine speed x 1.80
52 12V140E-3 Series
Water pump mounting
A. To radiator inlet (Coolant)

B: From power train cooler (Coolant)
C: To power train oil cooler (Coolant)
1. Oil cooler
3. Water pump
12V140E-3 Series 53
Thermostat 1
A: To radiator
B: To water pump (When bypassing)
C: To thermostat
2. Thermostat
3. Cylinder block
Specifications
Valve cracking temperature: 76.5 ± 2?
Temperature at full opening: 90?
Lift at full opening: Min. 10 mm
Q'ty: 3
Unit: mm
Lift of thermostat at full Min. 10 mm (Before checking, leave it in water tank of 90? for 4
opening – 5 minutes)
2 Move valve in fully open condition (in water tank of 90?) to water Replace
Opening/Closing of
tank of 71? and keep it for 4 -–5 minutes.
thermostat
Valve must fully close.
54 12V140E-3 Series
Corrosion resistor 1
A: Coolant inlet Specifications

B: Coolant outlet Corrosion resistor
Filtration area: 0.373 m2x 2
1. Head Quantity of anti-corrosion agent: 1,000 g x 2
2. Element case (Cartridge)
3. Inhibitor (Solid anti-corrosion agent)
4. Valve
12V140E-3 Series 55
Corrosion resistor mounting
1. Tube (To radiator)

2. Tube (From thermostat housing)
3. Corrosion resistor head
4. Corrosion resistor cartridge
56 12V140E-3 Series
Cooling fan drive 1

Mounting (Adjustment bolt type)
SAA12V140E-3 (HD785-7)

a For HD785-7cold area arrangement models, type of grease for fan pulley and fan belt material are dif-
ferent. See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40ºC specification
models for the detail.
1. Crankshaft pulley
2. Fan belt
3. Tension pulley
4. Adjustment bolt
5. Tension pulley bracket
6. Fan pulley
7. Fan
Outside diameter of pulley

Unit: mm
Direction of wind
Engine Machine model Crankshaft pulley Tension pulley Fan pulley
from fan
HD785-7 182 154 398 Suck
SAA12V140E-3
WA800-3E0, WA900-3E0 182 154 367 Blow out
12V140E-3 Series 57
Tension pulley
SAA12V140E-3 (HD785-7, WA800-3E0, WA900-3E0)

a For HD785-7 cold area arrangement models, type of grease is different.
See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40ºC specification models
for the detail.
1. Tension shaft
2. Spring
3. Roller bearing
4. Tension bracket
5. Spacer
6. Tension pulley (outside diameter: 154 mm)
7. Ball bearing
8. Oil seal
9. Grease fitting
10. Grease fitting
58 12V140E-3 Series
(For D475A-5E0, PC2000-8)
The cooling fan is hydraulic motor-driven. For more information, refer to the shop
manual for the machine body.
12V140E-3 Series 59
Electrical equipment 1
Alternator 1
Alternator with built-in regulator (Open type, 90A)
1. Alternator 6. Internal connection diagram

2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal R 6C. Regulator
5. Terminal E
Pulley
Specifica- Outside Weight
Engine Machine model Type Number
tions diameter (kg)
of stages
(mm)
D475A-5E0
HD785-7 Open type (brushless) manu-
SAA12V140E-3 24V, 90A 2 95 19
PC2000-8 factured by NIKKO DENKI
WA800-3E0, WA900-3E0
60 12V140E-3 Series
Alternator mounting

a For HD785-7 cold area arrangement models, material of alternator drive belt is different.
See the Shop Manual or Operation and Maintenance Manual for HD785-7 -40ºC specification models for
the detail.
a: Outside diameter of accessory pulley: 167 mm
1. Adjustment bolt
2. Alternator pulley
3. Alternator
4. Alternator drive belt
5. Accessory pulley
12V140E-3 Series 61
Starting motor 1
For 7.5 kW
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
1. Pinion gear 6. Safety relay

2. Starting motor assembly 7. External connection diagram
3. Magnetic switch (2-pole connector type)
4. Terminal B 7A. Safety relay section
5. Terminal C 7B. Starting motor section
Number
Specifica- Weight Type of
Engine Machine model Type of pinion
tions (kg) connector
teeth
D475A-5E0 Water-resistant, oil-resistant
SAA12V140E-3 HD785-7 type manufactured by NIKKO 24V, 7.5 kW 11 18 DT
WA800-3E0, WA900-3E0 DENKI
62 12V140E-3 Series
For 11 kW
E: To chassis ground
R: To alternator terminal R
S: To starting switch terminal C
1. Pinion gear 7. External connection diagram

2. Starting motor assembly (2-pole connector type)
3. Magnetic switch 7A. Safety relay section
4. Terminal B 7B. Starting motor section
5. Terminal C 8. Jump start prohibition label
6. Safety relay 9. Jump start prevention cover
Number
Specifica- Weight Type of
Engine Machine model Type of pinion
tions (kg) connector
teeth
Water-resistant, oil-resistant type
SAA12V140E-3 PC2000-8 24V, 11 kW 11 18 DT
manufactured by NIKKO DENKI
12V140E-3 Series 63
Starting aid 1
Electric heater
1. Body Specifications
2. Heater coil Type of heater: Electrical intake air heater
3. Terminal Rated voltage: 22 V (DC)
4. Connection diagram Load current: 175 A
64 12V140E-3 Series
oil pan heater, coolant heater (Option)
1. oil pan heater

2. coolant heater
12V140E-3 Series 65
oil pan heater
Specifications
Rated voltage: 230 V (AC)
Capacity : 600 W
Coolant heater
Specifications
Rated voltage: 230 V (AC)
Capacity : 1.5 kW
66 12V140E-3 Series
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the engine, the operator can service it easily in the field.
q Vibrations are damped by the vibration-proof rubber.
Unified specifications of engine controller

q Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is
employed.
12V140E-3 Series 67
Engine controller cooler 1

HD785-7, PC2000-8
A: Fuel IN (From feed pump of fuel supply pump)

B: Fuel OUT (Main fuel filter)
2. Engine controller cooler
Outline
q The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
q The fuel is not circuited in some applicable
machines.
68 12V140E-3 Series
12V140E-3 Series 69

Engine 12V140E-3 Series: 10 Structure, Function and Maintenance Standard

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Engine 12V140E-3 Series: 10 Structure, Function and Maintenance Standard

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SEN00309-04

ENGINE 1SHOP MANUAL

10 Structure, function and

Fuel piping .......................................................................................................................................... 34

a The shape is subject to machine models.

*1 When install optional parts. Since pre-lubrication

A: From oil pan Specifications

A: Oil inlet and outlet port (Flow is reversed Specifications

1. Oil cooler cover

A: Oil inlet port Specifications

Main relief valve 1

1. Valve spring Specifications

Cracking pressure of main relief Correct or

Oil cooler bypass valve and regulator valve 1

A: From main gallery Specifications

Cracking pressure of regulator Correct or

a CRI is an abbreviation for common rail injection.

CRI system diagram (Poor fuel spec.) 1

a CRI is an abbreviation for common rail injection.

Outline of CRI system 1

q The fuel system distributes the high-pressure

q To the ECU (engine control unit), the signals

Structure and operation of CRI system

Structure and operation of component parts 1

1. 3-thread type cam 6. No. 2 high-pressure pump

Outline q Since the number of the times of feeding fuel

q (A): The PCV is open when the plunger is in

1) PCV (Fuel injection pressure control 2) Feed pump

q The feed pump built in the fuel supply pump

3) Common rail fuel pressure sensor

1. Inlet connector 7. Orifice (in)

q The injector consists of the nozzle section, ori-

A: No fuel injection C: Finish of fuel injection

1. Nozzle 5. Valve body

Electric circuit diagram

k Since high voltage (65V) is applied to the

4. Various sensors and relays

1) Fuel temperature sensor 2) NE speed sensor (Crank angle sensor)

3) Atmospheric pressure sensor 4) Common rail pressure sensor

6) Bkup speed sensor (G sensor) 7) Charge pressure sensor

q The following graph shows the output charac-

8) Charge temperature sensor 9) Coolant temperature sensor

q The CRI system controls the fuel injection rate

1. Fuel injection rate control function

2. Fuel injection timing control function

3. Fuel injection pressure control function

a The shape is subject to machine models.

1. Main fuel filter

a The shape is subject to machine models.

7. PCV 13. Fuel injection pipe (No.6 cylinder)

a The shape is subject to machine models.

1. Fuel pipe (To feed pump)

4. Fuel injection pipe (No.6 cylinder) 10. PCV

Front view of engine

Rear view of engine

Fuel piping (Poor fuel spec.) 1

a The shape is subject to machine models.

1. Main fuel filter

a The shape is subject to machine models.

7. PCV 13. Fuel injection pipe (No.6 cylinder)

a The shape is subject to machine models.

1. Fuel pipe (To feed pump)

4. Fuel injection pipe (No.6 cylinder) 10. PCV