Engine Saa12v140e-3 Hpcr Sen00291-00d 46475b

SEN00291-00

ENGINE

SEN00294-00

ENGINE 1SHOP MANUAL

12V140E-3 Series

00 Index and foreword

1

Index Organization list of the shop manual.................................................................................................... 2 Table of contents .................................................................................................................................. 3

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Organization list of the shop manual

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The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN00291-00

00 Index and foreword Index Foreword and general information

SEN00292-00 SEN00294-00 SEN00296-00

01 Specification Specification and technical data

SEN00301-00 SEN00303-00

10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 Structure, function and maintenance standard, Part 2

SEN00304-00 SEN00307-00 SEN00309-00

20 Standard value table Standard service value table

SEN00310-00 SEN00311-00

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Table of contents

1

00 Index and foreword Index SEN00294-00 Organization list of the shop manual ....................................................................................... 2 Table of contents ..................................................................................................................... 3 Foreword and general information SEN00296-00 Safety notice............................................................................................................................ 2 How to read the shop manual.................................................................................................. 6 Explanation of for maintenance standard ...................................................................... 8 Handling electric equipment and hydraulic component ........................................................... 10 How to read electric wire code ................................................................................................ 18 Method of disassembling and connecting push-pull type coupler ........................................... 21 Standard tightening torque table.............................................................................................. 24 Conversion table...................................................................................................................... 28 01 Specification Specification and technical data SEN00303-00 Outline ..................................................................................................................................... 2 Specifications........................................................................................................................... 4 General view............................................................................................................................ 5 Weight table............................................................................................................................. 8 Engine performance curves..................................................................................................... 10 10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 SEN00307-00 Air intake and exhaust system .................................................................................................... 3 Air intake and exhaust unit ...................................................................................................... 3 Air cleaner ............................................................................................................................... 4 Turbocharger ........................................................................................................................... 6 Aftercooler ............................................................................................................................... 11 Muffler...................................................................................................................................... 12 Engine unit .................................................................................................................................. 14 Cylinder head .......................................................................................................................... 14 Cylinder block .......................................................................................................................... 18 Cylinder liner............................................................................................................................ 22 Main moving parts ................................................................................................................... 24 Crankshaft ............................................................................................................................... 26 Camshaft ................................................................................................................................. 28 Cam follower, push rod............................................................................................................ 29 Piston, piston ring, and piston pin............................................................................................ 30 Connecting rod ........................................................................................................................ 32 Flywheel and flywheel housing................................................................................................ 34 Vibration damper ..................................................................................................................... 35 Timing gear.............................................................................................................................. 36 Valve system ........................................................................................................................... 38 Valve and valve guide.............................................................................................................. 40 Rocker arm and shaft .............................................................................................................. 42 Crosshead and guide .............................................................................................................. 43 Structure, function and maintenance standard, Part 2 SEN00309-00 Lubrication system ...................................................................................................................... 4 Lubrication system diagram..................................................................................................... 4 Oil pump .................................................................................................................................. 6 Oil cooler ................................................................................................................................. 7

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Oil filter..................................................................................................................................... Main relief valve....................................................................................................................... Oil cooler by valve and regulator valve ............................................................................ Fuel system ................................................................................................................................. CRI system diagram ................................................................................................................ Outline of CRI system.............................................................................................................. Fuel piping ............................................................................................................................... Fuel filter .................................................................................................................................. Priming pump........................................................................................................................... Cooling system............................................................................................................................ Cooling system diagram .......................................................................................................... Water pump ............................................................................................................................. Thermostat............................................................................................................................... Corrosion resistor .................................................................................................................... Cooling fan drive...................................................................................................................... Electrical equipment .................................................................................................................... Alternator ................................................................................................................................. Starting motor .......................................................................................................................... Starting aid............................................................................................................................... Engine controller......................................................................................................................

8 9 10 12 12 14 32 37 39 40 40 42 44 45 47 48 48 50 51 52

20 Standard value table Standard service value table SEN00311-00 Standard service value table ....................................................................................................... 2 Standard service value table for testing, adjusting, and troubleshooting ................................. 2 Running-in standard and performance test standard .............................................................. 3

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KOMATSU 12V140E-3 Series engine Form No. SEN00294-00

© 2005 KOMATSU All Rights Reserved Printed in Japan 11-05 (02)

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ENGINE 1SHOP MANUAL

12V140E-3 Series


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Foreword and general information Foreword and general information .................................................................................................................. 2 Safety notice ........................................................................................................................................ 2 How to read the shop manual .............................................................................................................. 6 Explanation of for maintenance standard................................................................................... 8 Handling electric equipment and hydraulic component...................................................................... 10 How to read electric wire code ........................................................................................................... 18 Method of disassembling and connecting push-pull type coupler...................................................... 21 Standard tightening torque table ........................................................................................................ 24 Conversion table ................................................................................................................................ 28

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Foreword and general information Safety notice

(Rev. 2005/11)

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Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.

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General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

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If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w eld in g wo rk , alw ay s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs Prohibition of operation and handling by 5 unlicensed workers 6 Safety check before starting work Wearing protective goggles 7 (for cleaning or grinding work) Wearing shielding goggles and protectors 8 (for welding work) 9 Good physical condition and preparation Precautions against work which you are 10 not used to or you are used to too much

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Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

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When disassembling or assembling, the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.

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When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r l y c a r e fu l t o c he c k t h a t t h ey ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

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Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.


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When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

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13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

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Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and age. 11) After operating the hoist, do not swing the control switch. 12) the position of the main switch so that you can turn off the power immediately in an emergency.

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Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

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The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

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How to read the shop manual q q q

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Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.

Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.

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Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

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Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q

Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)

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Revisions Revised brochures are shown in the shop manual composition table.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol

Item

k

Safety

a

Caution

4

Weight

3

Tightening torque

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Coat

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Oil, coolant

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Drain

Remarks Special safety precautions are necessary when performing work. Special technical precautions or other precautions for preserving standards are necessary when performing work. Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

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Explanation of for maintenance standard

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The maintenance standard values necessary for judgment of products and parts are described by the following . 1.

Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q

Example: Standard size 120

Tolerance –0.022 –0.126

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The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)

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Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

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Example: Standard size 60

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Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

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Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.

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Standard interference When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference between these sizes is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. q

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Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

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Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

Repair limit and allowable value The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit must be replaced or repaired. q The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the “allowable value”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement. q

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Handling electric equipment and hydraulic component


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To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).

Points to when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.

Main failures occurring in wiring harness 1) Defective of connectors (defective between male and female) Problems with defective are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the surfaces.

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Defective crimping or soldering of connectors The pins of the male and female connectors are in at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the t will peel and cause improper connection or breakage.

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Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

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High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before ing electricity through it.

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Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity , so there will be defective . If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the s will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q

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When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.

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When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.

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Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper to occur, so always cover the connector.

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Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective , corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

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Connecting DT connectors Since the DT 8-pin and 12-pin heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. 1. 2. q q

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Male connector Female connector Normal locking state (Horizontal): a, b, d Incomplete locking state (Diagonal): c

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4)

14


Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective , so remove all oil and wa te r fr om the compressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

12V140E-3 Series


4.

Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector s with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.

5.

Points to when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective in that circuit.

12V140E-3 Series

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Points to when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.

1.

Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.

2.

Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.

3.

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.

4.

Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

16

12V140E-3 Series


5.

Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

6.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7.

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

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17

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How to read electric wire code a

1

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type

Symbol

Low-voltage wire for automobile

AV

Thin-cover low-voltage wire for automobile

AVS

Heat-resistant low-voltAEX age wire for automobile

18

Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

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2.

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Dimensions

(Table 2) Nominal No.

0.5f

(0.5)

0.75f

(0.85)

1.25f

(1.25)

2f

2

3f

3

5

Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) AVS CovAV er D AEX

d (approx.) Standard Standard Standard

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

1.0 2.0 – 2.0

1.2 2.2 – 2.2

1.5 2.5 – 2.7

1.9 2.9 – 3.0

50

1.9 2.9 – 3.1

2.3 3.5 – –

60

2.4 3.6 – 3.8

85

3.0 – 4.6 4.6

8

15

20

30

40

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“f” of nominal No. denotes flexible”.

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3.


Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.

4.

Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit

Others

20

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

WG

–

–

–

–

–

–

–

–

–

–

R B R D Y G L

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

–

–

–

–

–

–

–

– – –

YW GL

– – – –

Gr Br –

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Method of disassembling and connecting push-pull type coupler k k

1

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1 1.

Disconnection 1) Hold adapter (1) and push hose t (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose t (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.

2.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

12V140E-3 Series

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Type 2 1.

Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) s surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)

2.

Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) s surface (a) of the hexagonal portion at the male end. (Fig. 9)

22

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Type 3 1.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) s surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it s surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)

2.

Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring s surface (b) of the hexagonal portion at the male end. (Fig. 13)

12V140E-3 Series

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Standard tightening torque table 1.

Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a

The following table corresponds to the bolts in Fig. A.

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6 – 7.5 98 – 123 10 – 12.5 153 – 190 15.5 – 19.5 235 – 285 23.5 – 29.5 320 – 400 33 – 41 455 – 565 46.5 – 58 610 – 765 62.5 – 78 785 – 980 80 – 100 1,150 – 1,440 118 – 147 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12

24

1

Width across flats mm 10 13 14 27

Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

a Fig. B

12V140E-3 Series


2.

Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

3.

Width across flats mm 14 17 22

Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5

Table of tightening torques for O-ring boss piping ts a Unless there are special instructions, tighten O-ring boss piping ts to the torque below.

Nominal No. 02 03,04 05,06 10,12 14

4.

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Thread diameter mm 14 20 24 33 42

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

12V140E-3 Series

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

25

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5.


Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}

Nominal No. of hose

Width across flats

02

19 22 24 27 32 36 41 46 55

03 04 05 06 (10) (12) (14)

6.

Range

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Thread size (mm) – 14 – 18 22 24 30 33 36 42

Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below.

mm 6 8 10 12 14

Tightening torque Bolt Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 –

BANJO bolt kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 –

Nm 8± 2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

Table of tightening torques for 102, 107 and 114 engine series (Eye ts) a Unless there are special instructions, tighten the metric eye ts of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14

26

Target

34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Thread size

7.

Taper seal

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

12V140E-3 Series


8.

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Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1

12V140E-3 Series

Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

27

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Conversion table

1

Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.

Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.

2.

Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

(A)

28

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

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Millimeters to inches

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

12V140E-3 Series

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

29

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Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

30

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

12V140E-3 Series


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kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

12V140E-3 Series

31

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Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C –40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

°F –40.0 –31.0 –22.0 –13.0 –4.0

°C –11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

°F 51.8 53.6 55.4 57.2 59.0

°C 7.8 8.3 8.9 9.4 10.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

32

1°C = 33.8°F °F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0

46 47 48 49 50

°F 114.8 116.6 118.4 120.2 122.0

°C 27.2 27.8 28.3 28.9 29.4

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

12V140E-3 Series


12V140E-3 Series

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33

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34

12V140E-3 Series

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ENGINE 1SHOP MANUAL

12V140E-3 Series

01 Specification

1

Specification and technical data Outline .................................................................................................................................................. 2 Specifications........................................................................................................................................ 4 General view......................................................................................................................................... 5 Weight table .......................................................................................................................................... 8 Engine performance curves ................................................................................................................ 10

12V140E-3 Series

1

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01 Specification

Outline

1

1. Applicable machine Engine SAA12V140E-3

2

Engine serial No.

Machine model D475A-5

Bulldozer

12V140E-3 Series

01 Specification

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2. Outline of engine q

The 12V140E-3 engine is a high-performance and high-efficiency engine which provides low fuel consumption, low noise, and improved exhaust gas color, and improved acceleration performance, and it cleared the strict exhaust gas regulation (USA: EPA regulations for 2006). Accordingly, this newly developed engine is suitable as a power source of c o n s t r u c t i o n m a c h i n e r y, a n d i n d u s t r i a l machinery used for various purposes.

q

It is the successor of conventional 12V140-1 engine which introduces various kinds of new technologies while adhering fundamentally to the configuration of V12-cylinder, watercooled, direct injection, and 4-stroke diesel engine.

1)

High-pressure fuel injection system controlled electronically The conventional one is a jerk in-line fuel injection pump-based engine mechanically controlled by a governor, while in all series of the new one, an electronic control system- and high-pressure injection system-based common rail injection system is adopted. This system provides high pressure fuel of 118 MPa {1,200 kg/cm2} level from the low-speed range to the high-speed range. In addition, it can control the form of injection most properly by the electronic control system according to the speed and load. As a result, clean exhaust g a s , c l e a n e x h a u s t g a s c o l o r, l o w f u e l consumption, and low noise are attained simultaneously.

2)

3)

4)

It adopts a re-entrant piston combustion chamber which has been used since introduction into the 6D140E-2 engine and also uses a quality cast iron piston with less thermal expansion and shaker cooling gallery. As a result, clean exhaust gas, clean exhaust gas color, and low fuel consumption are attained simultaneously, and also high durability and high reliability are also obtained. It also provides a higher compression ratio than the conventional one to improve combustion efficiency and reduce the white exhaust smoke when starting the engine in cold climate areas. In addition, by using the above-mentioned high-pressure fuel injection system controlled electronically and setting the injection characteristics most properly to improve the startability and reduce the white exhaust smoke when the temperature is low. It is equipped with an improved turbocharger KOMATSU KTR110 of which high reliability and high performance have been proven in the 12V140-1 engine. The following improvements

12V140E-3 Series

are added: mounting of a recirculation port for surging control at the compressor side and a design to improve efficiency of the turbine. As a result, high performance is attained in a wide range from the low-speed range to the highspeed range, and high performance and low fuel consumption are also obtained. 5)

The piston cooling nozzle of 12V140-1 is reviewed in regard to oil flow. As a result, durability of the piston is improved and temperature of the rear surface of the piston is reduced to prevent deterioration of the piston due to exposure of lubricating oil on the surface to high temperature. Since the highpressure fuel injection system controlled electronically is employed, less-soot combustion is attained and the draining interval of the oil is lengthened.

6)

The high-pressure pump to create high pressure in the common rail injection system is one-third of the conventional in-line fuel injection pump, and in addition, it is connected compact to the timing gear case as a flange mount rather than a saddle mount. As a result, sound radiation is reduced to provide low noise.

7)

Capacity of the lubrication pump is increased by 10% over the conventional engine to contribute to the reliability and durability.

8)

The air cleaner is changed from the conventional end surface seal type to radial seal type to prevent the entry of dust due to deformation into the clean side. In addition, the air cleaner clogging sensor for 5 clogging level indication is provided to inform s of a precise cleaning time.

9)

A high performance and high efficiency combination filter is adopted as an oil filter, and a filter system to collect small dirts as well as large dirts is adopted for all specifications.

10) The fuel filter system includes a high efficiency main filter and prefilter as standard features to allow use of low-grade fuel in the market (corresponding to NAS13 level). In addition, the delivery of the priming pump used to replace the filters is increased for higher serviceability. 11) In addition, since the engine controller is mounted on the engine and equipped with the automatic high-altitude compensation function, it can be operated at high altitude without replacing the controller. As a result, the serviceability is improved.

3

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01 Specification

Specifications

1 Engine name

SAA12V140E-3

Machine model

D475A-5 mm l {cc} —

12 – 140 x 165 30.5 {30,480} R1-L1-R5-L5-R3-L3-R6-L6-R2-L2-R4-L4

Overall length

mm

1,772

Overall width

mm

1,532.5

Overall height (excluding exhaust pipe)

mm

2,171.5

Overall height (including exhaust pipe)

mm

—

Rated output

kW{HP}/rpm

671 {899}/2,000 (Gross)

Max. torque

Nm{kgm}/rpm

3,825 {390}/1,400 (Gross)

No-load max. speed (High idle speed)

rpm

2,150 ± 50

No-load min. speed (Low idle speed)

rpm

620 + 80/0

g/kW·h {g/HP·h}

210 {156.7}

Dry weight

kg

3,600

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

l

134 (128)

Quantity of coolant

l

210

Alternator Starting motor Battery

— — —

24V, 90A 24V, 7.5kW x 2 12V, 170Ah x 4

Turbocharger Air compressor Others

— — —

KOMATSU KTR110L x 2 — With air-cooled aftercooler

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

4

12V140E-3 Series

01 Specification

General view

SEN00303-00

1

SAA12V140E-3 (Left side view of engine) Machine model: D475A-5

a

The shape is subject to machine models.

1. 2.

Center of crankshaft Rear face of flywheel housing

12V140E-3 Series

5

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01 Specification

SAA12V140E-3 (Front view of engine) Machine model: D475A-5

a


1. 2.

Center of crankshaft Center of cylinder liner

6

12V140E-3 Series

01 Specification

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Dimensions table Unit: mm Engine SAA12V140E-3

a

Machine model D475A-5

Dimensions of each part A

B

C

D

E

F

G

287

1,582

1,772

2,171.5

726

507

507

These dimensions are given for reference when the engine is set on a test bench.

12V140E-3 Series

7

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01 Specification

Weight table

1 Unit: kg

No.

8

Item

Main parts

SAA12V140E-3

1

Turbocharger

KOMATSU KTR110L (Water-cooled)

25 x 2

2

Cylinder head assembly

Cylinder head, valve, rocker arm, valve spring

3

Cylinder block assembly

Cylinder block, bearing cap, cylinder liner

4

Gear case

72

5

Gear case

52

22.5 x 12 810

6

Oil pan

Integral-type

88.4

7

Flywheel assembly

Flywheel, ring gear

127.6

8

Flywheel housing assembly

9

Crankshaft assembly

Crankshaft, crank gear

10

Camshaft assembly

Camshaft, cam gear thrust plate

11

Piston and connecting rod assembly

Piston, piston ring, piston pin, connecting rod

133.5 210 L

20

R

20 10.5 x 12

12

Oil pump

9

13

Fuel supply pump

13

14

Water pump

22

15

Alternator

24V,90A

16

Starting motor

24V,7.5kW

17

Aftercooler assembly

12 18 x 2 35 x 2

12V140E-3 Series

01 Specification

12V140E-3 Series

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9

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01 Specification

Engine performance curves Engine SAA12V140E-3

10

Engine serial No.

1 Machine model

D475A-5

Page 11

12V140E-3 Series

01 Specification

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SAA12V140E-3 (Machine model: D475A-5) Rated output: 671 kW {899 HP}/2,000 rpm (Gross) Max. torque: 3,825 Nm {390 kgm}/1,400 rpm (Gross)

12V140E-3 Series

11

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01 Specification



12

12V140E-3 Series

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ENGINE 1SHOP MANUAL

12V140E-3 Series

10 Structure, function and maintenance standard

1

Structure, function and maintenance standard, Part 1 Air intake and exhaust system ........................................................................................................................ 3 Air intake and exhaust unit ................................................................................................................... 3 Air cleaner............................................................................................................................................. 4 Turbocharger ........................................................................................................................................ 6 Aftercooler ...........................................................................................................................................11 Muffler ................................................................................................................................................. 12 Engine unit .................................................................................................................................................... 14 Cylinder head...................................................................................................................................... 14 Cylinder block ..................................................................................................................................... 18 Cylinder liner....................................................................................................................................... 22 Main moving parts............................................................................................................................... 24

12V140E-3 Series

1

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Crankshaft........................................................................................................................................... 26 Camshaft............................................................................................................................................. 28 Cam follower, push rod ....................................................................................................................... 29 Piston, piston ring, and piston pin ....................................................................................................... 30 Connecting rod.................................................................................................................................... 32 Flywheel and flywheel housing ........................................................................................................... 34 Vibration damper................................................................................................................................. 35 Timing gear ......................................................................................................................................... 36 Valve system ....................................................................................................................................... 38 Valve and valve guide ......................................................................................................................... 40 Rocker arm and shaft.......................................................................................................................... 42 Crosshead and guide.......................................................................................................................... 43

2

12V140E-3 Series


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Air intake and exhaust system

1

Air intake and exhaust unit

1

(Left side view of engine)

a

The illustration shows the engine for D575A-5.

A: B: C: D:

Air intake (From air cleaner) Air intake (To air-cooled aftercooler) Air intake (From air-cooled aftercooler) Exhaust gas

12V140E-3 Series

1. 2. 3. 4.

Electrical intake air heater Air intake manifold Muffler Turbocharger

3

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Air cleaner

1

ERB type [Air cleaner of automatic exhaust gas discharge type (Radial seal type)]

a


A: B: C:

Air inlet To turbocharger (Intake air) To muffler (Dust)

1. 2. 3. 4.

Pre-cleaner Air cleaner casing Outer element Inner element

Engine

Machine model

Type

Method of discharging dust from pre-cleaner

Number of elements

SAA12V140E-3

D475A-5

Komaclone, multi-cyclone (ERB type)

Automatic discharge (Exhaust ejector)

Inner cylinder: 1, outer cylinder: 1

4

12V140E-3 Series


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5

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Turbocharger


1

Water-cooled type Type: KTR110L

6

12V140E-3 Series


A: B: C: D: E: F: G:

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Intake air inlet Intake air outlet Exhaust gas inlet Exhaust gas outlet Oil inlet Oil outlet Coolant

1. 2. 3. 4.

Blower housing V-band Diff plate Center housing (Water-cooled center housing: Standard for D475A-5, and optional for other machine models) 5. Shroud 6. Turbine housing 7. Blower impeller 8. Seal ring 9. Metal 10. Journal bearing 11. Seal ring 12. Turbine impeller Specifications Model: Overall length: Overall width: Overall height: Weight:

KOMATSU KTR110L (Water-cooled) 308 mm 305 mm 287 mm 25 kg

12V140E-3 Series

7

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Model: KTR110L

a

8

The illustration shows the water-cooled turbocharger.

12V140E-3 Series


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Unit: mm No.

Check item

1

End play (Play in axial direction)

2

Radial play (Play in radial direction)

3

Clearance between blower housing and impeller

12V140E-3 Series

Criteria

Remedy

Standard

Repair limit

0.08 – 0.13

0.18

0.43 – 0.68

0.84

Clearance limit (Min.): 0.14

Replace thrust parts Replace bearing parts Replace bearing parts

9

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Turbocharger mounting

a a

The illustration shows the engine for D475A-5. The shape is subject to machine models.

A: B:

Intake air inlet Intake air (Between turbocharger and air-cooled aftercooler)

1. 2.

Exhaust manifold Turbocharger

10

12V140E-3 Series


Aftercooler

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1

Air-cooled type

a


A: B:

Air inlet (From turbocharger) Air outlet (To air intake manifold)

1. 2. 3. 4. 5.

Upper tank Core Lower tank Fin Tube

12V140E-3 Series

11

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Muffler

a


A:

Exhaust gas outlet

1. 2.

Turbocharger Muffler

12


1

12V140E-3 Series


12V140E-3 Series

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13

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Engine unit

1

Cylinder head

1

a


A: B:

Air intake Exhaust gas

C: D:

To fuel tank To radiator

1. 2. 3. 4. 5.

Spill pipe Air bleeding pipe Cylinder head Head cover Head cover bolt

6. 7. 8. 9. 10.

Cylinder head bolt Injector connector Injector assembly Injector holder mounting bolt Injector holder retainer

14

12V140E-3 Series


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Specifications Cylinder head Direct injection type 4-valve type Split-type 1 cylinder, 1 cylinder head Centralized cooling system for valve bridge and injector Cylinder head bolt: Plastic-region tightening Valve seat Valve seat inserts are press fitted to both intake and exhaust valves Rocker cover O-ring seal Injector Installation: Dry type (without sleeve)

12V140E-3 Series

15

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a


Tighten the cylinder head mounting bolt in order of [1] to [7].

Unit: mm No.

Check item

1

Strain of cylinder head mounting face

2

Projection of nozzle

3

Tightening torque for cylinder head mounting bolt (Apply molybdenum disulfied or engine oil to threaded part)

4

Tightening torque for injector holder mounting bolt

5 6

a

16

Criteria

Remedy

Tolerance

Repair limit

0 – 0.06

0.09

Engine

Standard

SAA12V140E-3

2.3 – 2.9

Bolt No.

Procedure 1st phase

[1] – [6]

2nd phase 3rd phase

[7]

—

Repair by grinding or replace Replace nozzle or gasket

Target (Nm{kgm}) Range (Nm{kgm})

Tighten in order 137 – 157 {14 – 16} shown above. If 216 {22} 284 – 294 {29 – 30} there are 5 punch marks, replace Retighten by 90° 90(+30/0)° the bolt. 68.6 {7} 58.8 – 73.5 {6 – 7.5} 147 {15}

Target (Nm {kgm})

Range (Nm {kgm})

66.7 {6.8}

58.8 – 73.5 {6 – 7.5}

Tightening torque for fuel injection pipe

37.3 {3.8}

34.3 – 40.2 {3.5 – 4.1}

Tightening torque for head cover mounting bolt

32.4 {3.3}

29.4 – 34.3 {3.0 – 3.5}

Retighten

Do not use a cylinder head mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.

12V140E-3 Series


12V140E-3 Series

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17

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Cylinder block

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

18


1

Cylinder block Cylinder liner Clevis seal O-ring O-ring Main bearing metal cap bolt Main bearing metal cap Main bearing metal Piston cooling nozzle Thrust bearing metal

12V140E-3 Series


Specifications Cylinder block Crankshaft: 7 bearings Camshaft: High cam type, 7 bearings Main bearing cap bolt: Plastic-region tightening

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Liner ring Upper: Clevis seal (Ethylene-propylene rubber) Middle: O-ring (Ethylene-propylene rubber) Lower: O-ring (Silicon rubber)

Piston cooling With piston cooling nozzle Cylinder liner Wet type Machining on inside: Plateau honing Tufftride

12V140E-3 Series

19

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20


12V140E-3 Series


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Unit: mm No.

Check item

1

Strain of cylinder head mounting face Inside diameter of main bearing metal mounting hole

2

0 – 0.09

0.135

Standard size

Tolerance

157

+0.025 –0.010

Roundness of mounting hole

Repair limit: 0.005 4.5

–0.050 –0.060

Other than No.4

4.5

–0.065 –0.075

Inside diameter of main bearing metal No.4 only (When tightening bolt with specified Other torque) than No.4

5

Inside diameter of cam bushing

6

Tightening torque for main bearing cap (Apply engine oil to threaded portion and washer) Tightening torque for oil pan mounting bolt

Level difference between — under surfaces of cylinder block and front cover

Standard size

Tolerance

Repair limit

148

+0.175 +0.130

148.23

148

+0.145 +0.100

148.20

Standard size

Tolerance

69

+0.025 +0.025

Standard size

Tolerance

Repair limit

65

+0.040 +0.025

65.15

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st time

284 {29}

270 – 299{27.5 – 30.5}

2nd time

569 {58}

559 – 579{57.0 – 59.0}

3rd time

Retighten by 90°

90(+30/0)°

—

65.7 {6.7}

58.8 – 73.6 {6 – 7.5}

Repair limit: 0.14

Repair by grinding or replace Replace or correct main bearing metal cap Correct

No.4 only

4

a

Repair limit

10S or less

Inside diameter of cam bushing mounting hole

—

Remedy

Tolerance

Surface roughness of main bearing metal mounting hole

Thickness of main bearing metal

3

Criteria

Replace bearing metal

Correct or replace block Replace cam bushing

Retighten

Reassemble

Do not use a main cap mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.

12V140E-3 Series

21

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Cylinder liner

1

Unit: mm No. 1

Check item

Criteria

Projection of cylinder liner

Inside diameter of cylinder liner 2

Repair limit: 0.07 – 0.15 Rank

Standard size

S

140

L

140

Roundness of inside of cylinder liner Cylindricality of inside of cylinder liner Outside diameter of cylinder liner (Counterbore portion)

4

Repair limit 140.12 140.14 Replace cylinder liner (Refilling is allowed only for L)

Repair limit: 0.02 Standard size 170.2

Tolerance –0.10 –0.10

Standard clearance: 0 – 0.163

Outside diameter of cylinder liner (Lower portion of counterbore)

Standard size

Interference of cylinder liner and block (Lower portion of counterbore)

Standard interference

Tolerance +0.090 +0.050 Interference limit

0.02 – 0.12

0.02 or above

Standard size

Tolerance –0.024 –0.049

Outside diameter of cylinder liner (at O-ring) 5 Clearance between cylinder liner and block (O-ring portion)

22

Tolerance +0.020 +0.020 +0.040 +0.021

Repair limit: 0.02

3 Clearance between cylinder liner and block (counterbore portion)

Remedy Replace cylinder liner or cylinder block

161.2

158

Standard clearance: 0.024 – 0.094

Replace cylinder liner or block Replace cylinder liner Replace or correct cylinder liner or block Replace cylinder liner Replace cylinder liner or block

12V140E-3 Series


12V140E-3 Series

SEN00307-00

23

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Main moving parts

a


1. 2. 3. 4. 5. 6. 7. 8.

Piston (FCD piston) Piston pin Connecting rod bushing Top ring Second ring Oil ring Connecting rod cap bolt Connecting rod (Front of engine: for L bank, rear: for R bank) Connecting rod cap

9.

24

1

10. 11. 12. 13.

Connecting rod bearing metal Crank gear (Number of teeth: 45) Crankshaft Vibration damper

12V140E-3 Series


Specifications

SEN00307-00

Piston rings

Crankshaft Closed die forging Journal, filet: Induction hardening Piston Special thin ductile cast iron FCD piston Re-entrant piston Connecting rod Closed die forging With lubricating oil hole Cap bolt is screw type, installed by plastic-region tightening.

12V140E-3 Series

Top ring (1)

: Double-side keystone, inner cut, ba rr e l f ac e, har d ch ro mi umplated Second ring (2) : Double-side keystone, inner cut, taper face, hard chromium-plated Oil ring (3) : M-shaped steel, with coil expander, nitrided surface

25

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Crankshaft

26


1

12V140E-3 Series


SEN00307-00

Unit: mm No. 1

Check item End play

Outside diameter of main journal 2

Criteria Standard value

Repair limit

0.140 – 0.315

0.50

Rank

Standard size

S.T.D.

148

0.25 U.S.

147.75

0.50 U.S.

147.50

0.75 U.S.

147.25

147.23

1.00 U.S.

147.00

146.98

Roundness of main journal Clearance of main journal

Surface roughness of main journal

3

Surface roughness of crankpin journal

4

Bend of crankshaft

6

Tightening torque for adapter mounting bolt

Tightening torque for damper mounting bolt

12V140E-3 Series

147.98 147.73 –0.020 –0.020

147.48

Use undersize journal or replace

Repair limit: 0.010 Clearance limit

No.4 only

0.130 – 0.195

0.25

Other than No.4

0.100 – 0.165

0.22

0.8S (Surface roughness of R portion: 3.2S) Standard size

S.T.D.

100

0.25 U.S.

99.75

Tolerance

Use undersize journal or replace main metal Correct surface roughness of crankshaft journal

Repair limit 89.88 89.63

–0.020 –0.020

0.50 U.S.

89.50

0.75 U.S.

99.25

89.13

1.00 U.S.

99.00

89.38 88.88

Use undersize journal or replace

Repair limit: 0.010 Standard clearance

Clearance limit

0.046 – 0.116

0.17

Replace connecting rod bearing metal

0.8S (Surface roughness of R portion: 3.2S) Standard

Repair limit

Coaxiality of all main journals: 0.09 or less

0.09

Coaxiality of adjacent main journals: 0.05 or less

0.05

Procedure 5

Replace thrust bearing metal or use oversize metal

Repair limit

Standard clearance

Roundness of pin journal Clearance of crank pin journal

Tolerance

Journal

Rank

Outside diameter of crank pin journal

Remedy

Replace

Target (Nm {kgm}) Range (Nm {kgm})

1st time

74 {7.5}

54 – 93 {5.5 – 9.5}

2nd time

245 {25}

226 – 265 {23 – 27}

3rd time

745 {76}

725 – 765 {74 – 78}

Retighten

108 ± 10 Nm {11 ± 1.0 kgm}

27

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Camshaft

1

Unit: mm No. 1

Check item

Criteria Standard

Repair limit

0.1 – 0.25

0.36

Standard size

Tolerance

65

–0.016 –0.036

Standard clearance

Clearance limit

0.016 – 0.096

0.15

End play Outside diameter of camshaft journal

2 Clearance of camshaft journal 3

Bend of camshaft

4

Height of cam

28

Remedy Replace thrust plate

Replace

Replace cam bushing

Repair limit: 0.04 (Overall swing of indicator) Cam

Standard size

Tolerance

Repair limit

Air intake

55.48

± 0.1

55.08

Exhaust

55.75

± 0.1

55.35

Replace

12V140E-3 Series


SEN00307-00

Cam follower, push rod

1

Unit: mm No.

1

Check item

3

Remedy

Standard size

Tolerance

Repair limit

22

–0.021 –0.034

21.92

22

+0.021 +0.021

22.07

Outside diameter of cam roller

31.7

+0.05 +0.02

31.50

Inside diameter of cam roller

12.7

+0.038 +0.013

12.78

Outside diameter of cam roller pin

12.63

± 0.006

12.56

Outside diameter of cam follower shaft Inside diameter of cam follower shaft hole

2

Criteria

4

Diameter of push rod ball end

5

Diameter of push rod socket end

6

Bend of push rod

12V140E-3 Series

Standard size

Tolerance

12.7

–0.20 –0.20

13.4

–0.20 –0.20

Replace

Repair limit: 0.3 (Overall swing of indicator)

29

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Piston, piston ring, and piston pin

30


1

12V140E-3 Series


SEN00307-00

Unit: mm No.

1

Check item

Outside diameter of piston

Thickness of piston ring

Width of piston ring groove

Criteria Rank

Standard size

Tolerance

Repair limit

S

140

–0.120 –0.135

139.830

L

140

–0.105 –0.120

139.845

No.

Measuring point

Standard size

Tolerance

2

No.1 ring

2.9

–0.015 –0.035

3

No.2 ring

2.41

–0.010 –0.035

4

Oil ring

4

–0.010 –0.030

2

No.1 ring

3

No.2 ring

4 No. 2 – 4 Clearance between piston ring and piston ring groove

Outside diameter of piston pin 5

Inside diameter of piston pin hole Clearance between piston pin and piston

12V140E-3 Series

Oil ring

Replace piston

Replace piston ring

Check with group wear gauge Replace piston +0.040 +0.025

4

Measuring point Standard clearance Clearance limit

2

No.1 ring

3

No.2 ring

4

Oil ring

0.035 – 0.060

0.14

No.1 ring

0.42 – 0.57 (Tension: 16.5 – 23.5 N {1.68 – 2.40 kg})

2.0

3

0.65 – 0.80 No.2 ring (Tension: (Identification 16.2 – 24.2 N 2RN white mark) {1.65 – 2.47 kg})

1.5

4

0.30 – 0.50 (Tension: 70.1 – 94.6 N {7.15 – 9.65 kg})

1.0

2

Closed gap of piston ring

Remedy

Oil ring

Check with group wear gauge

Standard size

Tolerance

52

–0.006 –0.006

52

+0.045 +0.035

Standard clearance

Clearance limit

0.035 – 0.051

0.10

Replace piston or piston ring

Replace piston ring or cylinder liner

Replace piston pin Replace piston Replace piston or piston pin

31

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Connecting rod

32


1

12V140E-3 Series


SEN00307-00

Unit: mm No.

Check item

Criteria

Inside diameter of connecting rod small end bushing

Remedy

Standard size

Tolerance

Repair limit

52

+0.049 +0.030

52.09

1

Replace bushing (Refilled part is semi-finished part)

Clearance between connecting rod small end bushing and piston pin

Standard clearance

Clearance limit

0.030 – 0.055

0.11

Standard size

Tolerance

2

Inside diameter of connecting rod small end bushing mounting hole

57.4

+0.030 +0.030

3

Inside diameter of connecting rod large end bearing metal (Crankpin journal)

4

Inside diameter of connecting +0.026 106 — Replace connectrod large end hole –0.004 ing rod (Correction (Without bearing metal, X, Y, not allowed) • Tighten connecting rod cap with specified torque and measure and Z directions)

5

Thickness of connecting rod bearing metal

6

Parallelism and twist of connecting rod

7

Tightening torque for connecting rod cap mounting bolts (Apply engine oil to seat surface of nut of threaded portion of bolts)

8

a

Inside diameter of connecting rod large end

Standard size

Tolerance

Repair limit

100

+0.096 +0.046

100.15

3.0

–0.025 –0.035

—

Item

Standard

Repair limit

Parallelism (a)

0 – 0.10

0.15

Twist (b)

0 – 0.25

0.30

Dimensions (c)

340

—

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st time

74 {7.5}

69 – 78 {7 – 8}

2nd time

Retighten 90°

90(+30/0)°

Roughness

3.2S

Swell

0.004 (In overall width)

Replace bushing or piston pin Replace connecting rod (Correction not allowed) Replace bearing metal

Replace bearing metal

Replace connecting rod

Tighten in order shown in figure

Replace

Do not use a connecting rod cap mounting bolt more than 5 times. Each time the bolt is used, make a punch mark on its head.

12V140E-3 Series

33

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Flywheel and flywheel housing

1

Unit: mm No.

Check item

Criteria

1

Facial runout of flywheel housing

Repair limit: 0.25

2

Radial runout of flywheel housing

Repair limit: 0.25

3

Facial runout of flywheel

Repair limit: 0.30

4

Radial runout of flywheel

Repair limit: 0.13

5

Tightening torque for flywheel housing mounting bolt (Apply engine oil to threaded portion)

6

34

Tightening torque for flywheel mounting bolt (Apply engine oil to threaded portion)

Remedy

Reassemble

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st time

343 {35}

294 – 392 {30 – 40}

2nd time

412 {42}

392 – 432 {40 – 44}

1st time

98 {10}

78 – 118 {8 – 12}

2nd time

294 {30}

275 – 314 {28 – 32}

3rd time

539 {55}

520 – 559 {53 – 57}

Tighten in order shown in above figure

12V140E-3 Series


Vibration damper

a


1. 2. 3. 4. 5. 6.

Vibration damper Pin (between adapter and vibration damper) Adapter Pin (between adapter and crankshaft) Bolt (between adapter and crankshaft) Bolt (between adapter and vibration damper)

12V140E-3 Series

SEN00307-00

1

35

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Timing gear

36


1

12V140E-3 Series


SEN00307-00

Unit: mm No.

Check item

Criteria Position

— Backlash of each gear

1

Clearance between main idler gear bushing and shaft (Both right and left banks)

2

Clearance between sub idler gear bushing and shaft

3

End play of main idler gear

Measuring point

Remedy Standard

a

Crank gear and right main idler gear (Large)

0.141 – 0.425

b

Right main idler gear (small) and right sub idler gear

0.130 – 0.390

c

Right sub idler gear and right cam gear

0.129 – 0.391

d

Right cam gear and accessory drive gear

0.085 – 0.492

e

Right main idler gear (small) and right fuel injection pump gear

0.051 – 0.469

f

Right main idler gear (small) and water pump driver gear

0.052 – 0.481

g

Right main idler gear (small) and oil pump gear

0.137 – 0.421

h

Crank gear and left main idler gear (Large)

0.141 – 0.425

j

Left main idler gear (small) and left cam gear

0.129 – 0.391

k

Left main idler gear (small) and left fuel injection pump gear

0.051 – 0.469

Tolerance

Standard size

Replace 0.6

Standard clearance

Clearance limit

+0.034 +0.009

0.025 – 0.063

0.20

+0.055 +0.055

0.016 – 0.084

0.20

Shaft

Hole

56

–0.016 –0.029

56

–0.016 –0.029 Standard

Repair limit

0.09 – 0.26

0.4

4

End play of sub idler gear

0.07 – 0.18

0.4

5

End play of fuel injection pump drive gear

0.07 – 0.20

0.4

6

End play of oil pump drive gear

0.03 – 0.088

0.4

7

End play of accessory drive gear

0.1 – 0.4

0.4

a

Repair limit

Replace bushing

Replace thrust bearing


12V140E-3 Series

37

SEN00307-00

Valve system

38


1

12V140E-3 Series


1. 2. 3. 4. 5. 6. 7. 8.

Cam gear Thrust plate Camshaft Cam follower Cam roller Rocker arm shaft Cam follower shaft Rocker arm adjustment screw 9. Locknut 10. Push rod 11. Rocker arm

12. Crosshead adjustment screw 13. Locknut 14. Crosshead 15. Valve guide 16. Exhaust valve 17. Valve spring (Outer) 18. Valve spring (Inner) 19. Spring seat 20. Valve retainer 21. Air intake valve 22. Cam roller pin

SEN00307-00

Valve timing

Specifications Camshaft Drawn steel bar (Machining) Journal and cam sections: Induction hardening

12V140E-3 Series

39

SEN00307-00

Valve and valve guide

40


1

12V140E-3 Series


SEN00307-00

Unit: mm No. 1

2

3

Check item Sinking distance of valve

Thickness of valve lip

Valve seat angle

Outside diameter of valve stem

4

Inside diameter of valve guide

Criteria

Remedy

Valve

Standard size

Tolerance

Repair limit

Air intake

0

± 0.10

0.70

Exhaust

0

± 0.10

0.70

Valve

Standard size

Repair limit

Air intake

2.4

1.9

2.15

1.75

Valve

Standard size

Tolerance

Air intake

30°

± 15'

Exhaust

45°

± 15'

Air intake

10

–0.045 –0.060

Exhaust

10

–0.074 –0.089

Before head is press fitted

10

+0.019 +0.001

Standard size

Tolerance

10

Bend of valve stem 5

Valve

Standard clearance

Clearance limit

0.034 – 0.071

0.22

Exhaust

0.063 – 0.100

0.24

Repair limit: 0.02 (Total runout of indicator, per 100) Standard

Tolerance

22.0

± 0.2

Spring

Standard size

Repair limit

Outer

81.7

—

72.0

—

Free length of valve spring

Inner Spring

Installed length

Outer

51.0

6 Installed load of valve spring

Inner Perpendicularity of valve spring

12V140E-3 Series

46.0

Replace valve

+0.011 –0.009

Air intake

Driving height of valve guide

Correct or replace valve or valve seat

Press Not press Replace valve guide fitted fitted portion portion +0.008 –0.009

Clearance between valve guide and stem

Replace valve

Exhaust

After head is press fitted

Replace valve or valve seat

Replace valve or valve guide Replace valve Correct

Standard installed Allowable installed Replace valve load (N {kg}) load (N {kg}) spring 424.3 ± 21.6 377.3 {43.3 ± 2.2}

{38.5}

215.6 ± 10.8 {22.0 ± 1.1}

192.1 {19.6}

Repair limit: 2° (Both ends)

41

SEN00307-00


Rocker arm and shaft

1

Unit: mm No.

Check item Outside diameter of rocker arm shaft

1

3

42

Valve clearance (When cold) Tightening torque for locknut of rocker arm adjustment screw

Remedy

Standard size

Tolerance

32.0

± 0.0065

32.0

+0.087 +0.035

Standard clearance

Clearance limit

0.0285 – 0.0935

0.13

Inside diameter of rocker arm bushing Clearance between rocker arm shaft and rocker arm

2

Criteria

Valve

Standard

Tolerance

Air intake

0.35

± 0.02

Exhaust

0.57

± 0.02

Target (Nm {kgm})

Range (Nm {kgm})

58.8 {6}

52.9 – 64.7 {5.4 – 6.6}

Replace rocker arm shaft Replace rocker arm Replace rocker arm shaft or rocker arm

Adjust

Tighten

12V140E-3 Series


SEN00307-00

Crosshead and guide

1

Unit: mm No. 1

2

3

Check item Depth of crosshead stem receiver Inside diameter of crosshead Outside diameter of crosshead guide Projection of crosshead guide

12V140E-3 Series

Criteria

Remedy

Standard size

Tolerance

Repair limit

6.2

+0.3 +0.3

6.61

11.04

± 0.02

11.17

11

+0.011 +0.011

10.95

49.0

± 0.25

—

Replace

Correct

43

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44

12V140E-3 Series

SEN00309-00

ENGINE 1SHOP MANUAL

12V140E-3 Series


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 by valve and regulator valve ....................................................................................... 10 Fuel system................................................................................................................................................... 12 CRI system diagram ........................................................................................................................... 12 Outline of CRI system ......................................................................................................................... 14 Fuel piping .......................................................................................................................................... 32

12V140E-3 Series

1

SEN00309-00


Fuel filter ............................................................................................................................................. 37 Priming pump...................................................................................................................................... 39 Cooling system.............................................................................................................................................. 40 Cooling system diagram ..................................................................................................................... 40 Water pump ........................................................................................................................................ 42 Thermostat .......................................................................................................................................... 44 Corrosion resistor................................................................................................................................ 45 Cooling fan drive ................................................................................................................................. 47 Electrical equipment...................................................................................................................................... 48 Alternator ............................................................................................................................................ 48 Starting motor...................................................................................................................................... 50 Starting aid .......................................................................................................................................... 51 Engine controller ................................................................................................................................. 52

2

12V140E-3 Series


12V140E-3 Series

SEN00309-00

3

SEN00309-00


Lubrication system

1

Lubrication system diagram

1

a

4


12V140E-3 Series


SEN00309-00

W: Coolant 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Oil pan Strainer Oil pump (Triple gear pump) Main relief valve Oil cooler Regulator valve Oil cooler by valve Oil filter Oil filter safety valve Main gallery Crankshaft Camshaft Rocker arm Cam follower Air intake valve and exhaust valve Piston Piston cooling nozzle Timing gear Turbocharger Fuel supply pump

12V140E-3 Series

5

SEN00309-00


Oil pump

1

A: B:

From oil pan To oil cooler

1. 2. 3. 4. 5.

Pump body Pump drive gear (Number of teeth: 27) Drive gear Driven gear Pump cover

6

Specifications Oil pump Type: Gear pump Revolving speed: Engine speed x 1.67

12V140E-3 Series


SEN00309-00

Oil cooler

A: Oil inlet and outlet port (Flow is reversed depending on front and rear oil cooler) B: Oil inlet and outlet port (Flow is reversed depending on front and rear oil cooler) C: Coolant 1. 2.

1

Specifications Oil cooler Heat dissipation surface area: 0.986 m2 Element: 12 stages

Oil cooler cover Cooler element

12V140E-3 Series

7

SEN00309-00


Oil filter

A: B:

Oil inlet port Oil outlet port

1. 2. 3.

Safety valve Filter head Cartridge

8

1

Specifications Oil filter Filtration area: 1.62 m2(0.42 m2 x 4) Rated flow: 330l/min Safety valve Cracking pressure: 196 ± 20 kPa {2.0 ± 0.2 kg/cm2}

12V140E-3 Series


SEN00309-00

Main relief valve

1. 2. 3.

1

Specifications Main relief valve Cracking pressure: 1,196 ± 49 kPa {12.2 ± 0.5 kg/cm2}

Valve spring Main relief valve Valve body

Unit: mm No.

4

5

6

Check item

Clearance between main relief valve and body

Main relief valve spring

Cracking pressure of main relief valve

12V140E-3 Series

Criteria

Remedy

Tolerance Standard size Outside diam- Inside diameeter of valve ter of body

Standard clearance

33

–0.040 –0.060

0.040 – 0.076

Free length

Installed length

75.8

59.8

–0.016 –0.016

Replace valve or body

Installed load Allowable load (N {kg}) (N {kg}) Replace spring 621 {63.4}

353 {36}

Standard: 1,196 ± 49 kPa {12.2 ± 0.5 kg/cm2}

Correct or replace spring

9

SEN00309-00


Oil cooler by valve and regulator valve

A: B: C: D:

From main gallery From oil cooler To oil pan To oil filter

1. 2. 3. 4. 5.

Oil cooler by valve By valve spring Regulator valve Regulator valve spring Valve body

10

1

Specifications Oil cooler by valve Cracking pressure (differential pressure): 392 ± 20 kPa {4.0 ± 0.2 kg/cm2} Regulator valve Cracking pressure: 402 ± 49 kPa {4.1 ± 0.5 kg/cm2}

12V140E-3 Series


SEN00309-00

Unit: mm No.

1

2

3

4

5

6

Check item

Clearance between regulator valve and body

Regulator valve spring

Criteria Tolerance Standard size Outside diam- Inside diameeter of valve ter of body

Standard clearance

22

–0.020 –0.041

0.020 – 0.074

Free length

Installed length

111.5

75

Cracking pressure of regulator valve

Clearance between oil cooler by valve and body

Oil cooler by valve spring Cracking pressure of oil cooler by valve

12V140E-3 Series

Remedy

+0.033 +0.033


Installed load Allowable load (N {kg}) (N {kg}) Replace spring 136.0 {13.87}

239 {24.4} Correct or replace spring

Standard: 402 ± 49 kPa {4.1 ± 0.5 kg/cm2} Tolerance Standard size Outside diam- Inside diameeter of valve ter of body

Standard clearance

28

–0.020 –0.053

+0.033 +0.033

0.020 – 0.086

Free length

Installed length

Installed load (N {kg})

Allowable load

125.8

89.8

186 {19}

—

Standard: 392 ± 20 kPa {4.0 ± 0.2 kg/cm2}


Replace spring Correct or replace spring

11

SEN00309-00


Fuel system

1

CRI system diagram

1

a

12

CRI is an abbreviation for common rail injection.

12V140E-3 Series


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

SEN00309-00

NE speed sensor Engine controller Injector Fuel tank Pre-fuel filter Main fuel filter Overflow valve Fuel supply pump assembly PCV High-pressure pump Feed pump Relief valve G speed sensor Common rail Flow damper Pressure limiter High-pressure injection pipe Priming pump (Main)

12V140E-3 Series

13

SEN00309-00


Outline of CRI system Outline q The CRI system checks the condition of the engine (engine speed, accelerator angle, coolant 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 function which stops the engine when a certain parts fail and a backup function which continues the operation by changing the control method in such a case.

1 1. Fuel system

Configuration The CRI system is divided by the function into the fuel system and control system.

q

q

q

14

The fuel system distributes the high-pressure fuel generated by the fuel supply pump to the cylinders through the common rail. The solenoid valve in the injector opens and closes the nozzle needle valve to start and finish fuel injection.

12V140E-3 Series


SEN00309-00

2. Control system

q

q

To the ECU (engine control unit), the signals are sent from the sensors installed to the machine. Based on the signals, the ECU calculates and controls the energizing timing and energizing period of the injector to inject proper quantity of fuel in proper timing. The control system is roughly divided by the electric parts into the sensors, computer, and actuators.

12V140E-3 Series

15

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Structure and operation of CRI system

q

q

q

q

q

q

q

q

16

The CRI system consists of fuel supply pump, common rail, injector, ECU which controls these 3 units, and sensors. The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump. The fuel discharge rate is controlled by turning on and off the PCV (pressure rate control valve) of the fuel supply pump according to the electric signals from the ECU. The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders. The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail. A control is applied so that the actual fuel pressure will match to the command pressure set according to the engine speed and the load on the engine. 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. The injector controls the fuel injection rate and fuel injection timing by turning ON and OFF the TWV (2-way solenoid valve).

q

q

q

If the TWV is turned ON (energized), the fuel circuit is changed so that the high-pressure fuel in the control chamber will flow through the orifice. As a result, the needle valve is raised to start fuel injection by the nozzle cracking pressure of the high-pressure fuel on the nozzle side. If the TWV is turned OFF (de-energized), the fuel circuit is changed so that the high-pressure fuel will flow to the control chamber through the orifice. As a result, the needle valve lowers to finish fuel injection. Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn on the TWV and the length of the turn-on time of the TWV.

12V140E-3 Series


SEN00309-00

Structure and operation of component parts

1

1. Fuel supply pump

1. 2. 3. 4. 5.

3-thread type cam Overflow valve Drive gear No. 1 high-pressure pump PCV (Discharge rate control valve)

Outline q The fuel supply pump consists of priming pump (7), feed pump (8), and high-pressure pumps (4) and (6). q The function of the fuel supply pump is to generate common rail fuel pressure by controlling the fuel discharge rate. Structure High-pressure pumps (4) and (6) have the pressure feed systems similar to those of the conventional in-line fuel injection pump and the PCVs (pressure control valves) for each cylinder to control the fuel delivery. 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. q

12V140E-3 Series

6. 7. 8. 9.

No. 2 high-pressure pump Priming pump Feed pump Gear for G speed sensor

q

Since the number of the times of feeding fuel to the common rail is the same as the number of the times of fuel injection, the common rail fuel pressure is smooth and stable. The fuel fed by high-pressure pumps (4) and (6) to the common rail is divided as follows. No. 1 high-pressure pump (on the drive gear side) (4) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 1, 3, and 5 cylinders. No. 2 high-pressure pump (on the feed pump side) (6) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 2, 4, and 6 cylinders.

q q

q

17

SEN00309-00


Operation

q

q

q

q

(A): The PCV is open when the plunger is in lowering stroke, through which low-pressure fuel is sucked in the plunger chamber. (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. (C): If the PCV is energized and closed in the timing for the necessary delivery, the return age 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 delivery. The delivery is changed and the common rail fuel pressure is controlled by changing the opening timing of the PCV. (D): After the cam es 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.

18

12V140E-3 Series


1) PCV (Pressure control valve)

q

The PCV adjusts the fuel delivery from the fuel supply pump to adjust the common rail fuel pressure. It means that the delivery from the fuel supply pump to the common rail is decided by the timing of energizing the PCV.

SEN00309-00

2) Feed pump

q

q q

12V140E-3 Series

The feed pump built in the fuel supply pump assembly draws the fuel from the fuel tank and sends it through the fuel filter to the high-pressure pump chamber. The outer and inner rotors of the feed pump are rotated by the camshaft. 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.

19

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2. Common rail Structure q Common rail (4) distributes the high-pressure fuel from the high-pressure pump to the injectors 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 The flow dampers damp the pressure pulses in the high pressure piping and supply the fuel to the injectors with stable pressure. q If excessive fuel flows out, the flow dampers block the fuel age to prevent abnormal outflow of the fuel. q If the fuel flows out abnormally, high pressure is applied to the piston, which moves to the right until it reaches the seat to stop the fuel. q

20

2) q

q

q

Pressure limiter If abnormally high pressure is generated, the pressure limiter opens to release that pressure. If the common rail fuel pressure reaches about 140 MPa {1,430 kg/cm2}, the pressure limiter operates (Opens). If the common rail fuel pressure lowers to 30 MPa {310 kg/cm2}, the pressure limiter resets itself (close) to maintain the pressure.

12V140E-3 Series


3) q

q

SEN00309-00

Common rail fuel pressure sensor The common rail fuel pressure sensor is installed to the common rail to sense the fuel pressure. This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the electric resistance of silicon changes according to pressure applied to it.

12V140E-3 Series

21

SEN00309-00


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 optimum 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 nozzle and controls the fuel injection rate. q The hydraulic piston transmits the force generated by the pressure in the control chamber to the needle valve of the nozzle. q The nozzle sprays the fuel.

22

12V140E-3 Series


SEN00309-00

Structure

1. 2. 3. 4. 5. 6.

Inlet connector Terminal Upper body Solenoid Valve body Orifice (out)

q

The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic piston section, and 2-way solenoid valve section.

12V140E-3 Series

7. 8. 9. 10. 11. 12.

Orifice (in) Pressure control chamber Command piston Spring Pressure pin Nozzle assembly

23

SEN00309-00


A: B:

No fuel injection Start of fuel injection

C: D:

Finish of fuel injection From common rail

1. 2. 3. 4.

Nozzle Control piston Orifice (in) Orifice (out)

5. 6. 7. 8.

Valve body Solenoid Spring Pressure control chamber

3)

Finish of fuel injection (C) If solenoid (6) is de-energized, valve body (5) is lowered by spring (7) and the fuel age is closed. Since the high-pressure fuel in the common rail is applied to pressure control chamber (8) suddenly at this time, nozzle (1) is closed quickly and fuel injection is finished sharply.

Operation 1) q q

2) q

q

q q

24

No fuel injection (A) While solenoid (6) is not energized, valve body (5) is pressed down by spring (7). Since the high-pressure fuel is applied from the common rail to pressure control chamber (8), nozzle (1) is closed and the fuel is not injected.

q

q

Start of fuel injection (B) If solenoid (6) is energized, valve body (5) is raised by electromagnetic power to open the fuel age. Since the fuel in pressure control chamber (8) flows out through orifices (3) and (4), nozzle (1) rises and the fuel injection pump starts. The fuel injection rate is increased gradually by the function of orifices (3) and (4). Continuing energization to solenoid (6) provides the maximum fuel injection rate.

12V140E-3 Series


SEN00309-00

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

25

SEN00309-00


4. Various sensors and relays 1) q

q

26

Fuel temperature sensor The fuel temperature sensor senses the fuel temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

2) q q

NE speed sensor (Crank angle sensor) If the signal hole made on the flywheel es the sensor, the magnetic line of force changes. If the magnetic line of force changes, the output of the hall element sensor changes linearly and it is converted into pulse of 0 - 5 V by the wave form shaping circuit in the sensor, and then output.

12V140E-3 Series


3) q

A: B:

q

Atmospheric pressure sensor This sensor is used to correct altitude.

SEN00309-00

4)

Common rail pressure sensor

5)

Oil pressure sensor

Pressure inlet Mounting screw: M5 Tightening torque: 4.5 ± 0.5 Nm {0.46 ± 0.05 kgm} The following graph shows the output characteristics of the atmospheric pressure sensor.

12V140E-3 Series

27

SEN00309-00

6) q

q

q

q

28

Bkup speed sensor (G sensor) (Cylinder No. sensor) Similarly to the NE speed sensor, this sensor utilizes the pulses of 0 – 5 V generated by the change of the magnetic line of force crossing the sensor unit. 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°. In addition to the above teeth, one more tooth is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine. The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and Bkup speed sensor pulse.


7) q

Charge pressure sensor This sensor is used to sense the charge pressure (boost pressure).

A:

Mounting screw: M6 Tightening torque: 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}

1. 2.

Sensor O-ring

q

The following graph shows the output characteristics of the charge pressure sensor.

12V140E-3 Series


8) q

q

Charge temperature sensor The charge temperature sensor senses the intake air temperature (boost temperature) and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

12V140E-3 Series

SEN00309-00

9) q

q

Coolant temperature sensor The coolant temperature sensor senses the coolant temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine controller applies voltage to the thermistor and senses the temperature by the voltage divided by the resistance in the computer and the resistance of the thermistor.

29

SEN00309-00


Various controls

30

12V140E-3 Series


q

q

q

SEN00309-00

The CRI system controls the fuel injection rate and fuel injection timing more properly than the mechanical governor or timer of the conventional fuel injection pump. For the control of the system, calculations necessary to the ECU are performed from the signals sent from the sensors installed to the engine and machine. 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 conventional 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 conventional timer. It controls the fuel injection timing most properly from the engine speed and fuel injection rate.

3. Fuel injection pressure control function (Common rail fuel pressure control function) q

q

The fuel injection control function (common rail fuel pressure control function) controls the fuel discharge rate of the fuel supply pump by measuring the fuel pressure by the common rail fuel pressure sensor and feeding it back to ECU. This function performs pressure control 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

31

SEN00309-00

Fuel piping


1

Left bank

a


1. 2. 3. 4. 5. 6.

Main fuel filter Pre-fuel filter Priming pump (Main) Fuel pipe (From pre-fuel filter) Fuel pipe (To feed pump) Drain pipe

32

12V140E-3 Series


a


7. 8. 9. 10. 11. 12.

PCV Fuel injection pipe (No.1 cylinder) Fuel injection pipe (No.2 cylinder) Fuel injection pipe (No.3 cylinder) Fuel injection pipe (No.4 cylinder) Fuel injection pipe (No.5 cylinder)

12V140E-3 Series

SEN00309-00

13. 14. 15. 16. 17. 18.

Fuel injection pipe (No.6 cylinder) Common rail Fuel return pipe Feed pump Oil pump (For pump lubricating oil) High-pressure pump

33

SEN00309-00


Right bank

a


1. 2. 3.

Fuel pipe (To feed pump) Fuel pipe (From pre-fuel filter) Priming pump (Main)

34

12V140E-3 Series


4. 5. 6. 7. 8. 9.

Fuel injection pipe (No.6 cylinder) Fuel injection pipe (No.5 cylinder) Fuel injection pipe (No.4 cylinder) Fuel injection pipe (No.3 cylinder) Fuel injection pipe (No.2 cylinder) Fuel injection pipe (No.1 cylinder)

12V140E-3 Series

SEN00309-00

10. 11. 12. 13. 14. 15.

PCV High-pressure pump Feed pump Oil pump (For pump lubricating oil) Fuel return pipe Common rail

35

SEN00309-00


Front side

Rear side

36

12V140E-3 Series


Fuel filter

a


A: B:

Fuel inlet Fuel outlet

1. 2. 3.

Air bleeding plug Filter head Cartridge

SEN00309-00

1

Specifications Filtration area: 1.0 m2

12V140E-3 Series

37

SEN00309-00


Pre-fuel filter

a


A: B:

Fuel inlet Fuel outlet

1. 2. 3.

Air bleeding plug Filter head Cartridge

Specifications Filtration area: 2.12 m2

38

12V140E-3 Series


SEN00309-00

Priming pump

1. 2. 3. 4. 5. 6. 7. 8.

Spring Cover Shaft Bushing Diaphragm Diaphragm cover Body Check valve

12V140E-3 Series

1

9. 10. 11. 12. 13. 14. 15. 16.

Valve stopper Packing Check valve body Lever pin E-ring Washer Bolt Lever

39

SEN00309-00


Cooling system

1

Cooling system diagram

1

40

12V140E-3 Series


A:

SEN00309-00

Lubricating oil

1. 2.

Radiator 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 by circuit (For power train) 9. Air bleeding 10. Turbocharger

12V140E-3 Series

41

SEN00309-00

Water pump

A: B: C:

From thermostat (Coolant) From radiator (Coolant inlet) To oil cooler (Coolant outlet)

1. 2. 3. 4. 5. 6. 7. 8.

Pump shaft Water seal Pump body Water pump drive gear (Number of teeth: 25) Ball bearing Oil seal Impeller Pump cover


1

Specifications Water pump Type: Centrifugal, gear-driven Revolving speed: Engine speed x 1.80

42

12V140E-3 Series


SEN00309-00

Water pump mounting

a


A. B: C:

To radiator inlet (Coolant) From power train cooler (Coolant) To power train oil cooler (Coolant)

1. 2. 3.

Oil cooler Thermostat housing Water pump

12V140E-3 Series

43

SEN00309-00


Thermostat

1

A: B: C:

To radiator To water pump (When bying) To thermostat

1. 2. 3.

Thermostat housing Thermostat Cylinder block

Specifications Valve cracking temperature: 76.5 ± 2°C Temperature at full opening: 90°C Lift at full opening: Min. 10 mm Q'ty: 3 Unit: mm No.

2

44

Check item

Criteria

Remedy

Lift of thermostat at full opening

Min. 10 mm (Before checking, leave it in water tank of 90°C for 4 – 5 minutes)

Opening/Closing of thermostat

Move valve in fully open condition (in water tank of 90°C) to water tank of 71°C and keep it for 4 -–5 minutes. Valve must fully close.

Replace

12V140E-3 Series


SEN00309-00

Corrosion resistor

A: B:

Coolant inlet Coolant outlet

1. 2. 3. 4.

Head Element case (Cartridge) Inhibitor (Solid anti-corrosion agent) Valve

12V140E-3 Series

1

Specifications Corrosion resistor Filtration area: 0.373 m2x 2 Quantity of anti-corrosion agent: 1,000 g x 2

45

SEN00309-00


Corrosion resistor mounting

a


1. 2. 3. 4.

Tube (To radiator) Tube (From thermostat housing) Corrosion resistor head Corrosion resistor cartridge

46

12V140E-3 Series


SEN00309-00

Cooling fan drive

1

The cooling fan is hydraulic motor-driven. For more information, refer to the shop manual for the machine body.

12V140E-3 Series

47

SEN00309-00


Electrical equipment

1

Alternator

1

Alternator with built-in regulator (Open type, 90A)

a


1. 2. 3. 4. 5.

Alternator Alternator pulley Terminal B Terminal R Terminal E

6.

Internal connection diagram 6A. Field coil 6B. Initial excitation resistor 6C. Regulator

Pulley Engine

SAA12V140E-3

48

Machine model

D475A-5

Type

Open type (brushless) manufactured by NIKKO DENKI

Specifications

24V, 90A

Number of stages

Outside diameter (mm)

Weight (kg)

2

95

19

12V140E-3 Series


SEN00309-00

Alternator mounting

a


a:

Outside diameter of accessory pulley: 167 mm

1. 2. 3. 4. 5.

Adjustment bolt Alternator pulley Alternator Alternator drive belt Accessory pulley

12V140E-3 Series

49

SEN00309-00


Starting motor

1

For 7.5 kW

E: R: S:

To ground R terminal of alternator C terminal of starting motor switch

1. 2. 3. 4. 5.

Pinion gear Starting motor assembly Magnetic switch Terminal B Terminal C

Engine

Machine model

SAA12V140E-3

D475A-5

50

6. 7.

Safety relay External connection diagram (2-pole connector type) 7A. Safety relay section 7B. Starting motor section

Type Water-resistant, oil-resistant type manufactured by NIKKO DENKI

Specifications

Number of pinion teeth

Weight (kg)

Type of connector

24V, 7.5 kW

11

18

DT

12V140E-3 Series


SEN00309-00

Starting aid

1

Electric heater

a


1. 2. 3. 4.

Body Heater coil Terminal Connection diagram

12V140E-3 Series

Specifications Type of heater: Electrical intake air heater Rated voltage: 22 V (DC) Load current: 175 A

51

SEN00309-00


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 Engine controller CM850 developed by the cooperation between KOMATSU and CUMMINS is employed.

q

52

12V140E-3 Series


12V140E-3 Series

SEN00309-00

53

SEN00309-00




54

12V140E-3 Series

SEN00311-00

ENGINE 1SHOP MANUAL

12V140E-3 Series

20 Standard value table

1

Standard service value table Standard service value table ........................................................................................................................... 2 Standard service value table for testing, adjusting, and troubleshooting ............................................. 2 Running-in standard and performance test standard ........................................................................... 3

12V140E-3 Series

1

SEN00311-00


Standard service value table

1

Air intake and exhaust system

Performance

Category

Standard service value table for testing, adjusting, and troubleshooting1

Necessary speed for starting

Body Lubrication system Cooling system

2

Machine model

D475A-5 Standard value for new machine

Service limit value

Max. speed at no load

rpm

2,150 ± 25

2,150 ± 25

Min. speed at no load

rpm

600 ± 40

600 ± 40

At 0°C (without starting aid)

rpm

Min. 110

—

At –20°C (with starting aid)

rpm

Min. 100

—

Measurement conditions

Air intake resistance

Whole speed range

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.47 {762}

Air boost pressure

At rated output

kPa {mmHg}

Min. 132.30 {Min. 1,000}

—

Exhaust pressure

At rated output

kPa {mmHg}

—

—

Exhaust temperature

Whole speed range (20°C )

°C

Max. 680

750

At sudden acceleration (Low to High)

Bosch index

Max. 4.5

5.5

At rated output

Bosch index

Max. 1.0

2.0

At high idle

Bosch index

Max. 1.0

2.0

Intake valve

mm

0.35 ± 0.02

0.35 ± 0.02

Exhaust gas color

Valve clearance

—

SAA12V140E-3

Unit

Item

Speed

Engine

Exhaust valve

mm

0.57 ± 0.02

0.57 ± 0.02

Min. 4.1 {Min. 42}

2.0 {20}

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 200 – 250 rpm

MPa {kg/cm2}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 2.94 {Max. 300}

5.88 {600}

MPa {kg/cm2}

0.29 – 0.44 {3.0 – 4.5}

0.2 {2.0}

MPa {kg/cm2}

Min. 0.08 {Min. 0.8}

0.07 {0.7}

°C

80 – 110

120

%

0.5

1.0

kPa {kg/cm2}

—

—

At rated output Engine oil temperature: Min. 80°C Oil pressure

At low idle Engine oil temperature: Min. 80°C

SAE0W30E0S SAE5W40E0S SAE10W30DH SAE15W40DH SAE30DH

Oil temperature Whole speed range (Oil in oil pan) Oil consumption

Ratio to fuel consumption at continuous rated output

Function of radiator pressure valve

Cracking pressure (Differential pressure)

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 59 N {6 kg}

mm

Approx. 20

Approx. 20

12V140E-3 Series


SEN00311-00

Running-in standard and performance test standard

1

Running-in standard Engine

SAA12V140E-3

Machine model

D475A-5 Procedure

Item

1

2

3

4

5

6

Running time

min.

5

15

5

5

20

10

Speed

rpm

660

1,000

1,250

1,550

1,800

2,000

Dynamometer load

N{kg}

0{0}

568{58}

1,127{115}

2,254{230}

3,381{345}

4,508{460}

Output

kW{HP}

0{0}

43{57}

106{142}

263{352}

457{612}

677{907}

a a

This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA12V140E-3

Machine model

D475A-5

Test item

Rated output

Max. torque

Max. speed at no load

Min. speed at no load

2,150 ± 25 rpm

660 ± 40 rpm

Specification value (Gross value)

—

Speed

rpm

2,000 ± 5

1,300 – 1,500

—

—

Dynamometer load

N {kg}

4,341 – 4,596 {443 – 469}

5,174 – 5,498 {528 – 561}

—

—

Output (Gross value)

kW {HP}

651 – 691 {873 – 926}

—

—

—

Torque (Gross value)

Nm {kgm}

—

3,704 – 3,940 {378 – 402}

—

—

Fuel consumption

sec/300cc

Min. 19.5

—

—

—

Coolant temperature

°C

70 – 90

70 – 90

70 – 90

70 – 90

Lubricating oil temperature

°C

90 – 110

90 – 110

90 – 110

90 – 110

Lubricating oil pressure

kPa {kg/cm2}

0.34 – 0.49 {3.0 – 4.5}

—

—

Min. 0.08 {Min. 0.8}

Exhaust temperature

°C

Max. 620

Max. 680

—

—

a a a a a a

671 kW/2,000 rpm 3,822 Nm/1,400 rpm {899 HP/2,000 rpm} {390 kgm/1,400 rpm}

This table shows the standard values obtained by using the JIS correction coefficients. Since the output and torque in this table are the standard values when the fan is not installed, they are different from the specification values. This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. Use ASTM No.1 or No. 2 diesel fuel as fuel. Use SAE15W-40 as lubricating oil.

12V140E-3 Series

3

SEN00311-00




4

12V140E-3 Series

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