Engine Saa12v140e-3 Hpcr Sen00291-00d

SEN00291-00

ENGINE

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SEN00294-00

ENGINE 1SHOP MANUAL

12V140E-3 Series

00 Index and foreword

1

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







































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Organization list of the shop manual

1

The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this this manual in accordance with this list list and utilize accordingly. accordingly. The marks shown to the right of Form No. denote the following: : New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle itit as follows:  Place a divider on the top of each section in the file after after matching the Tub No. with No. 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

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

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Oil filter.............................................................................. filter..................................................................................................................................... ....................................................... Main relief valve...................................................................................................... valve ....................................................................................................................... ................. Oil cooler bypass valve and regulator valve ............................................................................ Fuel system ............................................................................................. ................................................................................................................................. .................................... CRI system diagram ............................................................................................... ................................................................................................................ ................. Outline of CRI system....................................................................................... system .............................................................................................................. ....................... Fuel piping .................................................................................... ............................................................................................................................... ........................................... Fuel filter ....................................................................................... .................................................................................................................................. ........................................... Priming pump.................................................................... pump........................................................................................................................... ....................................................... Cooling system..................................................................................................... system.... ........................................................................................................................ ....................... Cooling system diagram .......................................................................................................... Water pump .................................................................................. ............................................................................................................................. ........................................... Thermostat............................................................................................................................... Thermostat.............................................. ................................................................................. Corrosion resistor ................................................................................ .................................................................................................................... .................................... Cooling fan drive..................................................................................................... drive ...................................................................................................................... ................. Electrical equipment ......................................................................... .................................................................................................................... ........................................... Alternator ................................................................................................... ................................................................................................................................. .............................. Starting motor ............................................................................... .......................................................................................................................... ........................................... Starting aid........................................................................................... aid ............................................................................................................................... .................................... Engine controller..................................................................................................... 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 Standard service value table table ...... ............ ............. ............. ............ ............. ............. ............ ............. ............. ............ ............. ............. ............ ............. .............. ......... 2 Standard Standard service service value value table table for testing testing,, adjusting, adjusting, and and troubleshooti troubleshooting ng...... ............ ............ ............. .............. ......... 2 Running-in standard and performance test standard .............................................................. 3










































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ENGINE 1SHOP MANUAL

12V140E-3 Series

00 Index and foreword Foreword and general information

1







































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Foreword and general information Safety notice

(Rev. 2005/11)

1

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 prevent injury injury to workers, the symbol is used to mark mark safety safety precautions precautions in this this manual. manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may p ossibly arise, first consider safety, safety, and take the necessary actions to deal with the situation. 1.

Gene eneral ral p pre rec cauti aution ons s k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Befo Before re car carry ryin ing g out out any any greas greasin ing g 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 Decide a place place in tthe he repair repair worksh workshop op tto o 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. f loor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When When carry carrying ing out any ope operati ration, on, always always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitq ting parts with a hammer. Always wear safety glasses when q grinding parts with a grinder, etc.

7)

8)

If weldi welding ng repa repair irs s are need needed ed,, alwa always ys have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before Before startin starting g work work,, warm warm up your your body body thoroughly to start work under good condition.

Safety points 1 Good Good arra arrang ngem emen entt 2 Co Corr rrec ectt wor work k clo cloth thes es 3 Foll Follow owing ing wo work rk stan standar dard d 4 Ma Maki king ng and and chec checki king ng sign signs s Prohibition of operation and handling by 5 unlicensed workers 6 Safety Safety check check befo before re starti starting ng work work Wearing protective goggles 7 (for cleaning or grinding work) Wearing shielding goggles and protectors 8 (for welding work) 9 Good physic physical al condit condition ion and and prep prepara aration tion Precautions against work which you are 10 not used to or you are used to too much








































3)

4)

3.

When When disas disassemb semblin ling g or or assem assemblin bling, g, supsupport the machine with blocks, jacks, or stands before starting work. Remo Re move ve all all mud mud and and oil oil from from the step steps s or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Prec Precau auti tion ons s duri during ng work work 1) Before Before disconn disconnect ecting ing or removin removing g comp compoonents 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 coolan coolantt and and oil oil in the circui circuits ts are are hot 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 Before starti starting ng work, work, stop stop the the eng engine. ine. 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) Befo Before re start starting ing work work,, remov remove e the lea leads ds from the battery. Always remove the lead from the negative (–) terminal first. 5) When When raisi raising ng a heavy heavy compon component ent (heavie (heavierr 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

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8)

9)

10)

11)

12)

13)

14)

15)

16)

When removin removing g pipin piping, g, stop stop the the fuel fuel or oil 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 gene genera rall rule rule,, do n not ot use use gaso gasoli line ne to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble assemble all parts parts again again in their 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 contact with other parts when the machine is operated. When installing installing high pressure pressure hoses, 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 that connecting parts are correctly installed. When assembl assembling ing or installing installing parts, 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 particularly careful to check that they are installed correctly. correctly. When aligning aligning 2 holes, holes, never never insert insert your your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring measuring hydraul hydraulic ic pressur pressure, e, check that the measuring tools are correctly assembled. Take care when when removing removing or installi installing ng 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 en engine gine is is operated operated for a long time in a place which is not ventilated well, you









































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4.

Preca Precaut ution ions s for for sling sling work work and and mak making ing signs 1) Only Only one one app appoi ointe nted d work worker er mus mustt make 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. Do not stand under the load. q Do not step on the load. q 2) Ch Chec eck k the sli slings ngs befo before re star starti ting ng slin sling g work. 3) Keep Keep putti putting ng on gloves gloves during during sling sling work. work. (Put on leather gloves, if available.) 4) Me Meas asur ure e the we weigh ightt of the the loa load d by the the eye eye and check its center of gravity. 5) Use Use proper proper sli sling ng acco accord rdin ing g to the the weight 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 not slin sling g a lload oad with with 1 wire wire rope rope alon alone. e. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. 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


8)

When instal installin ling g wire wire rope ropes s to an ang angula ularr 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 specif specified ied eyebolt eyebolts s and and fix wire wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes ropes to the middle middle portion portion of the hook. Slinging near the tip of the hook may q cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.








































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

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13) If the hoist hoist stops stops because because of a power failfailure, 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 find an obstac obstacle le around around the hoist, hoist, stop the operation. 15) After finishing finishing the work, stop the 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.

q

5.

6.

Preca Precaut ution ions s for for usi using ng mobi mobile le cra crane ne a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Preca Precaut ution ions s for using using over overhe head ad hois hoistt crane 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 . 1) Before Before start starting ing work, work, inspec inspectt the the wire wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application

7.

Selec electi ting ng wire wire rope ropes s 1) Sele Select ct adeq adequa uate te rope ropes s depen dependi ding ng on on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN t on 10 12 14 16 18 20

8.8 12.7 17.3 22.6 28.6 35.3

0 .9 1. 3 1. 7 2. 3 2. 9 3. 6







































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How to read the shop manual q

q q

1.


1

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult co nsult KOMATSU 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.

Comp Compos osit itio ion n of of sho shop p man manua uall 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. 00. Index Index and and fore forewo word rd This section explains the shop manuals list, table of contents, safety, and basic information. 01. 01. Spec Specif ifica icati tion on This section explains the specifications of the machine. 10. Structure, Structure, function function and maintenance maintenance standard 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. Standa Standard rd value value table 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.








































3.

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

4.

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

Item

k

Safet Safety y

a

Caution

4 3 2 5 6

Weight Tightening torque Coat Co at Oil, Oil, coolant coolant Drai Drain n

Remarks Specia peciall safe safety ty pre preca caut utio ions ns are are nec neces essar sary y when when per perfo form rmin ing g work. work. Special technical precautions or other precautions for preserving standards are necessary when performing work. Weight of parts of component 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. Plac Places es to be coat coated ed with with a adh dhes esiv ives es,, etc etc.. dur durin ing g ass assem embl bly y. Places Places wher where e oil, etc. etc. must must be added, added, and capac capacity ity.. Plac Places es wh where ere oil, oil, etc. etc. mu must st be drai drained ned,, and and quant quantit ity y to to be be drai drained ned..







































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Explanation of terms for maintenance standard

1

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

Standa andard rd siz size e and and tole tolera ranc nce e To be accurate, the finishing size of parts q is a little different from one to another. To specify a finishing size of a part, a temq porary standard size is set and an allowable difference from that size is indicated. The above size set temporarily is called q the “standard size” and the range of difference from the standard size is called the “tolerance”. The tolerance with the symbols of + or – is q indicated on the right side of the standard size. Example: Standard size 120

Tolerance –0.022 –0.126

a

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)

q

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 dif-










































2.

3.

Stan Standar dard d cleara clearance nce and and stand standard ard val value ue The clearance made when new parts are q assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. When some parts are repaired, the clearq ance is generally adjusted to the standard clearance. A value of performance and function of q new products or equivalent is called the “standard value“, which is indicated by a range or a target value. When some parts are repaired, the value q of performance/function is set to the standard value. Stan Standa dard rd inte interf rfer eren ence ce When the size of a hole is smaller s maller than the q size of a shaft because of the standard size and tolerance, the difference between

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5.

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

6.

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







































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Handling electric equipment and hydraulic component


1

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 fo r 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 remember when handling electric equipment 1. Ha Handl ndlin ing g wirin wiring g harnes harnesse ses s and con connec nector tors s 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,








































3)

Disc Discon onne nect ctio ions ns in in wiri wiring ng 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.

4)

High-p High-press ressure ure wat water er ent enterin ering g connec connector tor 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

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3.

Removing Remov ing,, insta install llin ing, g, and and drying drying conn connec ec-tors and wiring harnesses 1) Disc Discon onne nect ctin ing g conn connec ecto tors rs 1] Hold Hold the the conn connec ecto tors rs whe when n dis disco connnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, 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

When When remo removi ving ng from from clip clips s Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.









































2)

Connec Conn ecti ting ng conn connec ecto tors rs 1] Ch Chec eck k the the con conne nect ctor or visu visual ally ly.. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, 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.

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4)

Dryi Drying ng wiri wiring ng harn harnes ess s 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, connector, do as follows. 1] Disc Discon onnec nectt the the connec connecto torr and and wip wipe e off the water with a dry cloth.









































4.

Handli Hand ling ng cont contro roll lle er 1) The control controller ler contai contains ns a micr microco ocompu mputer ter 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 place obje object cts s on top of the the control control-ler. 3) Cover Cover the contro controll conne connector ctors s with with tap tape e or or a vinyl bag. Never touch the connector contacts with your hand.

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Points to remember 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 care careful ful of of the the operat operating ing env envir ironm onmen ent. t. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.








































5.

Chang Change e hydra hydraul ulic ic oil oil when when the tem tempe perat rature ure 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,

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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.










































2

Di

i

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3.

Col

de table able









































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Method of disassembling and connecting push-pull type coupler

1







































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Type 2









































Type 3

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Model: KTR110L

10 Structure, function and maintenance standard








































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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

Criteria

Remedy

Standard

Repair limit

0.08 – 0.13

0 .1 8

0.43 – 0.68

0 .8 4

Clearance limit (Min.): 0.14

Replace thrust parts Replace bearing parts Replace bearing parts







































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Turbocharger mounting

a

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

A: B:

Intak ntake e air air inle inlett Intake Intake air air (Betwee (Between n turboch turbocharger arger and air-cooled air-cooled aftercooler) aftercooler)

1. 2.

Exhau haust man manifold Turbocharger

a








































Aftercooler Air-cooled type

a

The shape is subject to machine models.

A: B:

Air Air inl inlet et (Fr (From om turboc turbocha harg rger er)) Air outlet outlet (T (To air air intak intake e manif manifold old))

1. 2. 3. 4. 5.

Upper tank Core Lower tank Fin Tube

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Muffler

a


A:

Exha xhaust ust gas gas out outlet let

1. 2.

Turbocharger Muffler


1










































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Engine unit

1

Cylinder head

1








































Specifications Cylinder head Direct injection type 4-valve type Split-type 1 cylinder, 1 cylinder head Centralized cooling system for valve bridge and injector

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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

Criteria

Remedy

Tolerance

Repair limit

0 – 0.06

0.09

Engine

Standard

SAA12V140E-3

2.3 – 2.9

Bolt No. [1] – [6]

Procedure

Target (Nm{kgm})

1st phase

147 {15}

2nd phase 3rd ph phase

Range (Nm{kgm})

Repair by grinding or replace Replace nozzle or gasket

Tighten in order 137 – 157 {14 – 16} shown above. If 216 {22} 284 – 294 {29 – 30} there are 5 punch marks, replace Retighten by by 90 90° 90(+30/0)°








































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Cylinder block


1








































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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

Remedy

Tolerance

Repair limit

0 – 0.09

0.135

Standard size

Tolerance

157

+0.025 –0.010

Surface roughness of main bearing metal mounting hole

10S or less

Roundness of mounting hole

Repair limit: 0.005

Thickness of main bearing metal

3

Criteria

4.5

–0.050 –0.060

Other than No.4

4.5

–0.065 –0.075

4

Inside diameter of cam bushing mounting hole

5

Inside diameter of cam bushing Tightening torque for main

Replace or correct main bearing metal cap Correct

No.4 only

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

Repair by grinding or replace

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})

Replace bearing metal

Correct or replace block Replace cam bushing







































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Cylinder liner

1

Unit: mm No.

Check item

Criteria

Remedy Replace cylinder liner










































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Main moving parts parts


1








































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Crankshaft


1








































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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

Surface roughness of main journal

Tolerance

Replace thrust bearing metal or use oversize metal

Repair limit 147.98 147.73

– 0.020 –0.020

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

Remedy

147.48

Use undersize journal or replace

Repair limit: 0.010 Journal

Standard clearance

Clearance limit

No.4 only

0.130 – 0.195

0 .2 5

Other than No.4

0.100 – 0.165

0 . 22

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

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









































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Camshaft

1








































Cam follower, push rod

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Piston, piston ring, and piston pin


1








































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Unit: mm No.

1

Check item

Outside diameter of piston

Criteria

Remedy

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

Replace piston







































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Connecting rod


1










































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Flywheel and flywheel housing


1








































Vibration damper

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Timing gear


1








































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A: B:

No fue fuell inj injec ecti tion on Start tart of of fuel fuel inj injec ecti tion on

C: Fini Finish sh of fuel fuel injec injectio tion n D: From From comm common on rai rail

1. 2. 3. 4.

Nozzle Contro ntroll pisto ston Orifice (in) Orifice ((o out)

5. 6. 7. 8.

Valve body Solenoid Spring Pres Pressu sure re cont contro roll cha chamb mber er

3)

Fini Finish sh of of fuel fuel inj injec ecti tion on (C) (C) If solenoid (6) is de-energized, valve body (5) is lowered by spring (7) and the fuel passage 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. sharply.

Operation 1) q

q

2) q

q

No fue fuell in inject jectio ion n (A) (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. Start art of fue fuell inje inject ctio ion n (B) (B) If solenoid (6) is energized, valve body (5) is raised by electromagnetic power to open the fuel passage. 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

q

q








































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.

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4. Vario arious us sen senso sors rs a and nd rela relays ys 1) q

q

Fuel Fuel temp temper erat atur ure e sen senso sorr 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 th e thermistor.

2) q

q

NE spe speed ed sen senso sorr (Cra (Crank nk angl angle e sens sensor) or) If the signal hole made on the flywheel passes 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.








































3) q

A: B:

q

Atmos Atmosphe pheric ric press pressure ure sens sensor or This sensor is used to correct altitude.

Pressure in inlet let Moun Mo untting ing scr screw ew:: M5 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.

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4)

Comm Common on rai raill pres pressu sure re sen senso sorr

5)

Oil Oil pre pres ssure sure sens sensor or







































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6) q

q

q

q

Bkup Bk up spe speed ed sen senso sorr (G sens sensor or)) (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

Char Charge ge pres pressu sure re sens sensor or This sensor is used to sense the charge pressure (boost pressure).

A:

Mount ountin ing g scr scre ew: 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.










































8) q

q

Char Charge ge tem tempe pera ratu ture re sen senso sorr 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.

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9) q

q

Cool Coolan antt tempe tempera ratu ture re sen senso sorr 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.







































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Various controls









































q

q

q

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 Fuel injec injectio tion n rate rate cont control rol functi function on 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 Fuel injec injectio tion n timin timing g contro controll funct function ion 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 pu mp by measuring the fuel pressure by the common rail fuel pressure sensor and feeding it back to ECU. This function performs pressure feedback 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.

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Fuel piping Left bank


1








































a


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Right bank









































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Front side

Rear side









































Fuel filter

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Pre-fuel filter











































Priming pump

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Cooling system

1

Cooling system diagram

1








































A: 1. 2.

Lubr Lubric icat atin ing g oil oil

Radiator Cooling fan 2A. Hydrau Hydraulic lic fan motor motor 3. Water p pu um p 4. Oil Oil cool cooler er (For (For engi engine ne)) 5. Co Corrrosi rosion on resi resist stor or 6. Ther Thermo most stat at hous housiing 7. Oil Oil cool cooler er (Fo (Forr powe powerr trai train) n) 8. Oil cooler cooler bypass bypass circui circuitt (For (For pow power er train) train) 9. Air bleeding 10. 10. Turb Turboc ochar harge gerr

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Water pump


1








































Water pump mounting

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Thermostat


1








































Corrosion resistor

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Corrosion resistor mounting









































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

1







































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Electrical equipment

1

Alternator

1

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










































Alternator mounting

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Starting motor


1








































Starting aid

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Engine controller


1








































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Engine Saa12v140e-3 Hpcr Sen00291-00d

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