SHOP MANUAL SEN00322-00 ENGINE 12V140E-3 Series 50 Disassembly and assembly Disassembly and assembly, Part 2 Disassembly and assembly, Part 2 General assembly of engine... 12V140E-3 Series KomaATsU zy‘SEN00322-00 Disassembly and assembly, Part 2 General assembly of engine The shapes, quantity, locations, etc. of the parts depend on each applicable machine. Take care. When a part is provided on both sides of the banks, one side alone will be shown as an example. Except where otherwise noted, the same work procedure shall be employed for the both banks. % Clean each part carefully, and check it for bruise, flaw, cavity, etc. Make sure each oil or coolant path is through. Tightening bolts by plastic- method % Bolts tightened by plastic-region turning angle method * Cylinder head mounting bolt ‘© Main cap mounting bolt * Connecting rod cap mounting bolt If the plastic-region turning angle method is applied, the tightened bolts have permanent strain. Accordingly, the allowable number of Using times of each bolt is limited. Observe the following precautions. © Check each mounting bolt head for punch marks. If there were punch marks more than the specified numbers, replace the bolt gion turning angle 1, Cylinder block 1) Lift the cylinder block and then set it on tool A. 5 Cylinder block: 850 kg 2) Before inserting the cylinder liners, pre- pare the cylinder block according to the following procedure. 1] Remove the rust and scales from faces A and B with sandpaper, etc. until the machined surfaces are exposed. 2] Polish parts B, R and r with sandpa- per of about No. 200 until they become smooth. If part R is sharpened or burrs are present there, finish it with a scraper or sandpaper. Finish this surface particularly ‘smoothly so that it will not damage the O-ring. 3] If face R is so pitted that it cannot be repaired, replace the cylinder block. 4] If faces A and parts R and r are pit- ted, finish them smoothly. 5] Check the counterbored part and remove burrs. If chips or dust is on face C, the liner does not fit and cool- ant may leak and the projection of the liner may become improper conse- quently. If the counterbored part is droop- ing, corroded, or pitted, repair i. 91508312 2. Cylinder liner Replace the O-ring and clevis seal with new ones. 1) Check that the cylinder liner O-ring groove and periphery of the liner are not rough- ened because of rusting or pitting. If those parts are roughened, replace the cylinder liner. 2) Install clevis seal (1), O-rings (2) and (3) to the cylinder liner. Check that there is not a burr, dust, etc. in the groove of the liner. * Fit the clevis seal with the chamfered side down. When fitting it, press it against the seal groove all round so that it will not be twisted. 4 When installing O-rings (2) and (3), refer to the following. © Oring (2): Black © _ Oxting (3): Orange <2 Clevis seal and O-ring: Rubber lubricant (RF-1) % RF-1: DAIDO CHEMICAL INDUSTRY CO.,LTD. If RF-1 is not available, apply clean engine oil (E030). Since the clevis seal and O-ring are swollen and deteriorated by oil, apply a small amount of oil to them thinly with a brush just before fitting them. 12V140E-3 Series50 Disassembly and assembly ‘SEN00322-00 94503798 ‘Gasket sealant application diam- eter: 20.8 - 1.6 mm 9us05313 coweo0sso 3) After fitting the liner O-ring, check it for twist. If it is twisted, correct it with a ‘smooth rod (about 10 mm in diameter), ceE00201 4) Install the cylinder liner according to the following procedure. 4] Using cloth, wipe dirt and oil com- pletely off the contact faces between the counterbored part of the cylinder block and liner flange. 2] Apply silicon-based gasket sealant to the counterbored mating parts a of the cylinder block and cylinder liner. X= Cylinder block: Gasket sealant (LG-6) 12V140E-3 Series ausosais When applying the gasket seal- ant, make sure overlapping b between the coating at start and the end complies with the follow- ing dimension. Gasket sealant overlapping dimension b: 6 + 6 mm 91805560 After applying the gasket sealant, finish the cylinder liner installa- tion within 50 minutes. ‘© When the bottom contact face of the counterbored liner flange is modified and shim (2) is used.SEN00322-00 11 Coat the bottom side of shim (2) with a small amount of gasket sealant LG-6 and then assemble the shim. 2] Then apply gasket sealant LG-6 according to the same procedure as that employed when the shim is not used. 50 Disassembly and assembly 8) Using tool F, press-fit cylinder liner (1) to the cylinder block. 9808317 94805915 5) Immediately before press-fiting of the liner, apply a small amount of engine oil to. the liner O-ring, crevice seal and contact face of the cylinder block ‘ADs Clevis seal, O-ring and cylinder block: Engine oil (E030) * Apply the engine oil, using hands, uniformly on the entire contact face of the oylinder block 9) To prevent the gasket sealant from pro- jecting through the clearance between the block and liner after the cylinder head is tightened, tighten the cylinder head tem- porarily with the used head gasket inserted, At this time, observe the following tightening torque and tightening order. & Temporary tightening torque: 137 — 157 Nm {14-16 kgm} + Installation of No. 7 bolt is not neces- sary. DaDoao4a \S rs 6) Direct stamping "T" on the top face of the liner toward the engine front side and then insert cylinder liner (1) to the cylinder block while taking care so that the O-ring may not be damaged 7) Push in cylinder liner keeping weight on both hands. Ifthe liner does not enter the cylinder block smoothly when pushed with weight on both hands, stop the work since the O-ring is potentially dam- aged. In this case, check the cylinder block for burrs 10) Remove the cylinder head and wipe off the gasket sealant projected from the counterbored part 4 Be sure to perform steps 9) and 10) above since the projected gasket sealant can deform the grommet of the head gasket. 11) After press-fiting the cylinder liner, mea- Sure its projection using tool D. * Before measuring projection of the liner, tighten it with plate [1] so that it may not be lifted by the O-ring © Measuring posi 4 positions at a, b, ¢ and d. 12V140E-3 Ser50 Disassembly and assembly SEN00322-00 ==> Plate mounting bott: 686 — 980 Nm {7 ~ 10 kgm} Standard cylinder projection: 0.07 - 0.15 mm 4 Ifthe projection is out of the standard, correct it according to the mainte- nance standard. Ifthe gasket sealant is projected from the fitting parts of the cylinder block and cylinder liner up to the top of the oylinder block, wipe it off. ausosai6 3. Crankshaft 1) Fit upper main bearing (6) to the cylinder block, matching the projection of the former to the notch of the latter. eus0sa19 93505320, 2) Drive in the roll pin in such that its projec- tion from the block end face may become 2.7 - 3.4 mm and then install upper thrust bearing (6). % Install the thrust bearing with the grooved surface on the crankshaft side. <2 Thrust bearing sliding surface: Engine oil (E030) 3) Before assembling crankshaft, confirm the following items, * Presence/absence of abnormality in the front and rear threaded portions. (Make sure the bolt can be smoothly screwed in with hand.) © Presence/absence of scratches or dents on the pin and main journal. ‘* Presence/absence of dusts in the oil hole. Upper bearing: With oil hole A No. 4 bearing is wider than others. Thus, care must be taken to prevent an assembly error. Bearing with a No. 4 bearing: 52 mm Bearings other than No. 4: 48 mm % Before fitting the bearing, make sure that its back side is free from foreign matter. X& Bearing inner surface: Engine oil (E030) Don't apply the engine oil to the bear- ing backside. 12V140E-3 Series. susosazt 4) Lift crankshaft (4) and then install it on the cylinder block When installing the crankshaft, take care not to hit its sliding surfaces against the cylinder block 5 Crank shaft: 210 kg ZX Cylinder block journal: Engine oll (E030)‘$EN00322-00 50 Disassembly and assembly eusosaz2 91505496 5) Install the projection of lower bearing (7) locating it to the notch of main cap (1) and install Before fitting the bearing, make sure that its back side is free from foreign matter. AD Inside of bearing: Engine oil (E030) Don't apply the engine oil to the bear- ing backside. 24805323 Lower bearing: Without oil hole No. 4 bearing is wider than others. Thus, care must be used to prevent an assembly error. Bearing with a No. 4 bearing: 52 mm Bearings other than No. 4: 48 mm 6) Drive the roll pin of cap No. 7 so that it will be projected by 2.7 ~ 3.4 mm from the cap end and then install lower thrust bearings (8) to both sides. % Install the thrust bearing with the grooved surface on the crankshaft <2 Thrust bearing sliding surface: Engine oil (E030) 7) Apply the engine oil to the surface of the journal of the crankshaft. Then install the main cap after making sure that the No. being stamped on respective main caps (1) is matching the cylinder block No. De Crankshaft journal: Engine oil (E030) %* When installing the main cap, direct its cast part number side toward the front of the engine, 8) Apply engine oil to the threaded portion of the main cap mounting bolt and washer and then drive in the bolts alternately until the main cap is completely fitted. <= Main cap mounting bolt: Engine (E030) aus05497 9) Tighten main cap mounting bolts (2) according to the following procedure. 4 Tighten the bolts from the center one to the outer ones in order. 12V140E-3 Series50 Disassembly and assembly ‘SEN00322-00 Take the expander out of the oil ring and fit it to the piston first and then assemble the oil ring. At oueooa7e 11) Check that the crankshaft turns smoothly. this time, make sure that the 4 Standard crankshaft starting torque: expander is fitted to the ring Max. 147 Nm {15 kgm} groove perfectly 12) Measure the end play of the crankshaft + Make sure that the coil butt joint with dial gauge [1]. of the expander is situated in a 4 End play standard value: position 180° to the oil ring abut- 0.140 — 0.320 mm ment joint. + Ifthe end play is out of the standard, correct it. For details, see "Structure, function and maintenance standard!” 12V140E-3 Series 7‘SEN00322-00 50 Disassembly and assembly 9u805503 3] Install snap ring (10) to one side of piston (7). 91508502 4) 5] 6) Set the piston (7) and connecting rod (6). Mate the cast letters "EX < F" on the piston against the chamfered hole side in the big end of the connecting rod and then assemble them. Apply engine oil to the piston pin boss and inner surface of the connecting rod bushing and then insert piston pin (6) while directing the connecting rod upward. Piston pin: Engine oil (E030) Install snap ring (4) on the opposite side. 4 Tum the snap ring to make sure that the left and right side snap rings are completely fitted in the ring groove. Also make sure that the connect- ing rod moves lightly 7 8) Install the projection of connecting rod upper bearing (11) locating it to the notch of the connecting rod * Before fitting the bearing, make sure that its back side is free from foreign matter. + Don't apply the oil to the bearing backside. * Make sure that the connecting rod small end bushing are large end bearing hole are aligned with the connecting rod oil hole. Before assembling the connect- ing rod, check the connecting rod oil hole for settled dusts. 2s Connecting rod bearing inner ausosso4 Install the projection of connecting rod lower bearing (12) locating it to the notch of the connecting rod cap. * Before fitting the bearing, make sure that its back side is free from foreign matter. Don't apply the engine oil to the backside. 12V140E-3 Series50 Disassembly and assembly SEN00322-00 91508505 ror on cra] nae A A B 8 93805507 2) Apply the engine oil to the cylinder liner. * Apply the engine oil uniformly on the entire circumference with hands. AX Cylinder liner: Engine oil (E030) 194808506 5) Align the abutment joint of respective pis- ton rings as well as the piston to the pos- tion shown in the figure. lent bank 13 459 2nd ou, Front 3508508 3) Turn the crankshaft to drive the pin journal of the target cylinder of insertion to the top dead center position. 4) After confirming No. of the piston and con- necting rod assembly, insert the assembly to the cylinder block directing it in the direction shown in the figure. Set the direction of the cylinder block in such that the cylinder may face sideways. This process is needed to prevent sudden insertion of the piston and connecting rod assembly to the oylinder. On each bank, install notch A for the piston cooling nozzle and chamfered side B of the connecting rod. In this case, their positional relation with front direction F of the engine must be as shown in the figure. 12V140E-3 Series Lett bank Of ‘and 45° 307 30" a TP Front 94808500 + Make sure that the coil butt joint of the oil ring is situated in a position 180° to the abutment joint <= Piston ring, piston and crank journal: Engine oil (£030) 6) Using tool H, compress the piston ring and then push in the piston head with a ‘wooden bar and the like.‘SEN00322-00 50 Disassembly and assembly 91808810 disossi2 7) Using the connecting rod puller [1] shown in the figure, pull the connecting rod until it is closely contacted against the pin jour- nal Make sure the connecting rod bearing is not displaced. The connecting rod puller [1] is made by welding bar b to unnecessary con- necting rod bolt a + Total length of connecting rod puller £: ‘Approx. 500 mm. <2» Crank pin journal: Engine oil (E030) 94808811 % When assembling a new connecting rod, record its cylinder No. on the connecting rod cap using a electric en (stamping is not acceptable). It is strictly prohibited to change the com- bination of the connecting rod and cap through this operation. Ws crt. Wo 9808513, 11) Apply the engine oil to the threaded por- tion and washer of the connecting rod. <@ Connecting rod bolt and washer Engine oil (E030) 8) Turn the crankshaft 180° while pulling the ‘connecting rod. 9) Install connecting rod lower bearing (12) to connecting rod cap (2). = Connecting rad lower bearing: Engine oil (E030) 10) Install connecting rod cap (2) aligning it to the dowel pin on the connecting, + Check the cylinder No. 10 12) Tighten connecting rod bolts (1) alter- nately until the connecting rod cap is closely contacted. 12V140E-3 Series.50 Disassembly and assembly ‘SEN00322-00 13) Tum the crankshaft 180° and insert the piston and connecting rod assembly on ‘one bank according to the steps 1) ~ 12). 14) Tighten the mounting bolts in the order indicated in the figure according to the fol- lowing procedure. = Connecting rod bott: ‘jsttime: 69-78 Nm {7-8 kgm} 2nd time: 69 - 78 Nm {7 — 8 kgm} (again) 3rd time: Using tool G, retighten the bolt by 90" (+30°/0°) 94808517, 94305516 * When tool G is not used, apply marking b to the connecting rod, connecting rod cap and bolt with paint and then retighten the bolt by 90° (+30°/0"). 15) After tightening the bolt, make a punch mark ¢ on its head, % When a new bolt is used, do not make a punch mark on its head og oye00379 After assembling the connecting rod, make sure that the crankshaft rotates normally. 16) Measure the side clearance of the con- necting rod with dial gauge [1] © Standard side clearance: 0.3- 0.454 mm * When the side clearance is out of the standard, remove the connecting rod cap and check the connecting rod for assembly errors, presence of burrs or inching of foreign substances. ausossi6 ton cooling nozzle 41) Install piston cooling nozzle (1). After completely inserting the spigot jeint portion to the block side mount- ing hole, tighten the mounting bolt. 12V140E-3 Series Piston cooling nozzle mounting bolt: 54 #20 Nm {5.5 + 2.0 kgm} %* Prior to the installation, check the nozzle for damages or internal clog- ging 1‘SEN00322-00 50 Disassembly and assembly Make sure prior to the installation that the notch for preventing interference of the piston cooling nozzle is pro- vided on the piston skirt portion, ausossia 2) Tum the crankshaft slowly to make sure that interference is not observed between piston cooling nozzle (1) and piston (2) or connecting rod (3). 91805520 6. Timing gear case Lift and install timing gear case (1). * Prior to the installation, fix several portions ‘on the gasket temporarily using the gasket sealant so that it may not be displaced (5 Gear case cover: 55 kg [AJS04070} 12 7. Camshaft assembly 1) Insert the camshaft assembly (3) to the cylinder block along with the cam gear. + Install it carefully tuming the cam shaft so that the cam bushing may not be damaged. + Use care when inserting the cam shaft so that your fingers may not be pinched. <= Camshaft: Engine oil (E030) 2) Tum the cam gear (1) and tighten mount- ing bolt (2) through the lightening hole * Replace the current mounting bolt with a new one. = Cam shaft mounting bolt: 88 + 34 Nm {9.0 + 3.5 kgm} Cam follower assembly 1) Assemble the cam follower according to the following procedure. 41] _ Install snap ring (7) to shaft (6). 2] Install cam follower (5) to shaft (6). <= Cam follower bushing inner surface: Engine oil (E030) 3] Install snap rings (4).50 Disassembly and assembly ‘SEN00322-00 ‘Avso4067 2) Install cam follower assembly (3). = Cam follower assembly mounting bolt: 44.1 ~ 58.8 Nm {4.5 ~ 6.0 kgm) 3) Install cam follower cover (2) and then tighten it along with plate (1) using the mounting bolt. The plate between No. 3 and No. 4 cylinders is longer than those used in other sections. = Cam follower cover mounting bot 34,3 — 44.1 Nm {3.5 ~4.5 kgm} 9. Oil cooler (front side) Install oil cooler (front side) (1) 12V140E-3 Series AJS04064 40. Supply pump drive case 1) Install supply pump drive case (2). 2) Install oil tube (1). % Install the oil tube on the left bank alone. < Oil tube joint bolt: 7.9 — 12.7 Nm {0.8 - 1.3 kgm} 3 Se 11. Oil pump assembly Install oll pump assembly (1). 2 Oil pump mounting bolt: 54 +20 Nm {5.5 + 2.0 kgm} 1 oe aco 13SEN00322-00 50 Disassembly and assembly 12. Idler gear (small) 1) Install idler gear (small) (2) When installing the idler gear, align the counter mark "D" to that of the cam gear (3) for the right bank. <> Idler gear bushing inner surface: Engine oil (E030) 2) Install plate (1) and then tighten the mounting bott AD Plate sliding surface: Engine oil (E030) 2 Idler gear (small) mounting bolt: .0 = 122.5 Nm {10.0 ~ 12.5 kgm} 14, Idler gear (large) 1) Set No. 1 cylinder on the right bank to the top dead center position. Its referenced as the standard posi- tion when adjusting respective gears. 2) Install thrust plate (4) to the shaft. 4 Install the plate in such that oil groove Armay be set on the idler gear side. Engine oil (E030) 13. Supply pump gear 1) _ Install key (2) to the shaft. 3) _ Install idler gears (large) (2) and (3). ‘ Oil seal lip: Engine oil (E030) ‘<2 Metal ring face in oil seal periphery: Gasket sealant (LG-4) 4 Use care in above operation so that the seal lip may not be applied with the oil. 18 + When rubber is used in the periphery of the oil seal, use rubber lubricating liquid (RF-1) or soap water for the applying. Select one of the following 3 oil seal (1) press-fitting depths depending on the condition of the crankshaft (2). 4] When a new crankshaft (2) is used or when wear is not recognized on the contact surface of oil seal. ‘* Prior to installation, insert a 1.8 — 2.8 mm spacer [1] between tool J and oil seal (1). 8-1 90m 16. 2mm J a Lon mi / XX ul ' 2 41505533 2] When installing oil seal (1) after modi fying its originally intended installation Position, ‘* Install oil seal (1) as is using tool J ays0553¢ 3] When sleeve (3) is provided for crankshaft (2). ‘¢ Install the sleeve using a washer [2] between tool J and crankshaft @). 12V140E-3 Series50 Disassembly and assembly SEN00322-00 J Dr, Le j (ah (| L 3 ! 2 94805535 | O, ® OD sos 18. Front support Install front support (1). 4 Prior to the installation, fll the oll hole with grease. Volume of grease filed: 20 co Damper and crank pulley assembly mounting bott ‘st time: 73.5 # 19.6 Nm {7.5 +2 kgm} 2nd time: 245 £ 19.6 Nm (25 £2 kgm} 3rd time: 744.8 + 19.6 Nm {76 + 2 kgm} 19SEN00322-00 50 Disassembly and assembly 9805636 94805538 20. Flywheel housing 1) _Lift.and install whee! housing (4). (5 Flywheel housing: 230 kg 4 Tighten the mounting bolts in 3 steps according to the order indicated in the figure. Flywheel mounting bolt 1st time: 98 + 19.6 Nm {10 2 kgm} 2nd time: 294 + 19.6 Nm {30 +2 kgm} rd time: ‘539. 19.6 Nm {55 2 kgm} 12V140E-3 Series 1505640 2) After installing the flywheel, inspect its facial runout and radial runout using dial gauge (2. ‘Standard facial runout: Max. 0.25 mm. ‘Standard radial runout: Max. 0.25 mm Install engine speed sensor (3). Tighten the locknut until the sensor tip is contacted against the ring gear tooth tip of the flywheel. Return the sensor 3/4 - 1 turn from above po: tion and then tighten the locknut. © Engine speed sensor locknut: 49 — 68.6 Nm {57 kgm} 23‘SEN00322-00 50 Disassembly and assembly 23. Accessory drive assembly 1) Assemble the accessory drive. 1] Pull off bushing (10) and oil seal (9) to housing (8). % Press-fit the bushing 2 mm deeper from the end face. = Bushing inner surface: Engine oil (E030) * Press-fit the oil seal 1.5 mm deeper from the end face. Seal lip: Grease (G2-LI) Fill 50 — 80% of the lip open ‘space with the grease. 2] Press-ft gear to (7) to shaft (5), 3] Assemble thrust plate (6) to the shaft and gear assembly and then insert the housing from the rear side. 4] Assemble thrust plate (4) to the shaft and then press-fit hub (3). Use care in above operation so that the seal lip may not be dam- | Locknut tightening torque: 52.9 ~ 64.7 Nm {5.4 - 6.6 kgm} + After tightening the locknut, check the valve clearance again 4) Repeat the same procedure for other engines, too, in the order of firing. Namely, crank the engine and then locate the stamped of the damper to the pointer to adjust the valve clearance of respective cylinders, Firing order R1-L1-R5-L5-R3-L3-R6-L6- R2-12-R4-L4 S ae avnooa72 ‘avet0s42 ApS | ausoss62 12V140E-3 Series50 Disassembly and assembly ‘SEN00322-00 Tec00281 42. Head cover Install head cover (1), 5 Head cover mounting bolt: 14.7 — 34.3 Nm {1.5 - 3.5 kgm} f om 43, Fuel tube Install fuel tube (1). 5 Fuel tube joint bolt: 9.8 - 12.7 Nm {1.0 - 1.3 kgm} as0s206 44, Plate and block Install block (3) and plates (2) and (1) 12V140E-3 Series 45. Oil cooler (rear side) 1) Install oil cooler (2). 2) _ Install oil manifold (1). 46. Water pump assembly 1) Install housing (5) to water pump (4). Vy 2) Install water pump assembly (3). ‘83803604 33‘SEN00322-00 5803603, 50 Disassembly and assembly 3) Install water connector (2). 4) Install block (1). 1803692 47. Corrosion resister and filter head assembly Install corrosion resister and filter head assem- AS09601 48, Exhaust manifold assembly 1) Install the gasket. Install the gasket directing its "OUT" marking to the exhaust manifold side. 2) _Lift and install exhaust manifold assembly } = Exhaust manifold assembly: 25 kg 4 Tighten the mounting bolts in the fol- lowing order. 4 Tighten it once and then tighten again with the same torque. <~ Exhaust manifold assembly mount- ing bolt: Molybdenum disulfide lubricant (LM-P) = Exhaust manifold assembly mount ing bott 44.1 — 53.9 Nm {4.5 - 5.5 kgm} TH M2 113 1663282 aus05556 3) Install bracket (4), water pipe (3), muffler bracket (2) and insulating plate (1). 12V140E-3 Series50 Disassembly and assembly ‘SEN00322-00 49, Turbocharger assembly 1) Lift and install turbocharger assembly (1). % Tighten the turbocharger assembly mounting bolt after temporarily tight- ening and positioning of respective connections. 55 Turbocharger assembly: 35 kg Turbocharger assembly mounting bolt and nut: Molybdenum disulfide lubricant (LM-P) © Turbocharger assembly mounting bolt: 44.4 ~ 53.9 Nm (4.5 — 2) Install water pipes (2) and (3) and oil pipes (4) and (6). As for the air-cooled turbocharger, install the oil pipes alone. <> Water connector (Block side): 78.5 - 103 Nm {8 ~ 10.5 kgm} = Water pipe flare nut (Water connec- tor side): 24.5 — 59 Nm {25-6 kgm} © Water pipe joint bolt (Turbocharger side): 24.5 - 34.3 Nm {2.5 ~ 3.5 kgm} = Water connector (Turbocharger side): 29.4 — 39.2 Nm {3 - 4 kgm} = Water pipe flare nut (Water connec- tor side): 29.4 — 39.2 Nm {3-4 kgm) 50. Exhaust connector Install exhaust connectors (1) and (2). 51. Air intake manifold assembly 1) _ Install the gasket. * Install the gasket setting its "UP" marking upward and also directing this side to the intake manifold 2) Lift and install air intake manifold assem- bly (2). Intake manifold assembly: 45 kg > Tighten the mounting bolts in the fol- lowing order. = Intake manifold assembly mounting bolt: 58.8 - 73.5 Nm {6 ~ 7.5 kgm} ~ 94805557 ii os $7 TP RR we 915805556 12V140E-3 Series 35SEN00322-00 50 Disassembly and assembly 3) _Install support (1). 53. Spill tube Install spill tube (1), © Spill tube joint bolt Cylinder head side: 9.8 — 12.7 Nm {1.0 ~ 1.3 kgm} Intake manifold side: 19.6 — 29.4 Nm {2.0 - 3.0 kgm) 52. High-pressure pipe clamp Install brackets (1) and (2) to the exhaust man- ifold and then tighten high-pressure pipe clamp bott (3). <= High pressure pipe clamp bolt: 9.821 Nm {1 £0.14 kgm} 54. Supply pump assembly and high-pressure pipe (between supply pump - common rail) @ Install the high-pressure pipe and clamp paying attention to the following points. tis strictly prohibited to reuse a high- pressure pipe by modifying its bend or using the pipe in an unintended location. © The clamp used must be a legitimate one. And it must be installed in the specified position with the specified torque. ‘* After installing the high-pressure pipe and clamp, make sure that 10 mm minimum clearance is provided between the high-pressure pipe and adjacent hamess. If the clearance is less than 10 mm, adjust the hamess position to secure the space. 1) Install supply pump assembly (1) tempo- rary % Align and insert the unequal spline Portion of the supply pump side to unequal spline portion A of the supply pump drive case side. + When itis difficult to insert the supply pump , turn the crankshaft to change position of unequal spline portion A. 36 12V140E-3 Series‘50 Disassembly and assembly % Tighten mounting bolt (2) with the specified torque after tightening the sleeve nut of the high-pressure pipe (between supply pump and common rail), = Supply pump assembly mounting 2) After installing high-pressure pipes (4) and (5) to supply pump (1) and common rail (3) temporarily tighten the sleeve nut with the specified torque. + Control the torque by using a spanner type torque wrench (commercially available part) for the tightening. High-pressure pipe sleeve nut (supply pump side): 39.2 - 49 Nm {4-5 kgm} = High-pressure pipe sleeve nut (common rail side): 39.2 - 58.8 Nm {4-6 kgm) 3) Tighten supply pump assembly mounting bott (2) 4) Tighten the mounting bolt across the sup- ply pump assembly bottom face and bracket. <= Supply pump mounting bolt (Bot- tom side): 19.6 - 29.4 Nm {2.0 - 3.0 kgm} 5) Install oil tube (6). 7 = Oil tube joint bott: 9.8 12.7 Nm {1.0 ~ 1.3 kgm} 12V140E-3 Series ‘SEN00322-00 6) Install high-pressure pipe clamp (7) ‘according to the following procedure. 1] Manually tighten and install tempo- rarily the stay and top and bottom clamps of the high-pressure pipe clamp. 2] Tighten the top and bottom clamps permanently % Before tightening the stay perma- rently, deflect the rubber fist. 4 Use care in the tightening so that excessive force may not be applied to the supply pump side install position © Top and bottom clamp bott: 9.8 + 1.Nm {1 £0.1 kgm} 3] Tighten respective stays permanently 7) Install the rubber cover to the sleeve nut on the high-pressure pipe + Direct the slit downward when install- ing the rubber cover. ‘Supply pump side (8): Bottom ‘© Common rail side (9): Facing 55. Fuel pipe 1) Install priming pump (4). * if the air bleeding plug is removed, tighten the pump with the following torque. 37‘SEN00322-00 50 Disassembly and assembly = Air bleeding plug: 24.5 ~ 34.3 Nm {2.5 ~ 3.5 kgm) 2) Install fuel pipes (1) - (3) Fuel pipe joint bolt (Common rail side): 417.7 ~ 22.6 Nm {1.8 - 2.3 kgm} = Fuel pipe joint bolt (Supply pump side): 56. Air intake connector Install air intake connector (1). 4) Install bracket (3). * Install bracket (3) to the right bank alone. 2) Install bracket (2). 3) Install air inlet pipe (1) and then fix it with the clamp, = Clamping nut: 29.4 ~ 44.1 Nm {3.0 ~ 4.5 kgm} 5 Air inlet pipe: 35 kg 38 58. Engine controller and controller cooler 1) 2) 3) Install controller cooler (4), Install fuel hoses (2) and (3). Install engine controller (1). = Engine controller mounting bolt: 23.5 Nm {2.4 kgm} rh 7 59. Fuel filter and filter head assembly Install fuel fiter and filter head assembly @). Install fuel tubes (1) and (2) = Fuel tube joint bolt: 24.5 - 34.3 Nm {2.5 — 3.5 kgm} 1) 2) 12V140E-3 Series50 Disassembly and assembly $EN00322-00 60. Alternator 1) Install alternator (2). 2) Install auxiliary equipment bett (1) 3) Adjust tension of the auxiliary equipment belt Adjust its deflection to 20 mm when the pushing force of 58.8 Nm {6 kgm} is applied to the belt center through a finger. = Adjuster lock bolt: kgm} 63. Checking for fuel leakage + When removal and installation of fuel sup- ply pump (1), common rail (2), or high- pressure pipes (3) and (4) were con- ducted, check fuel leakage according to the following procedure after assembling the engine. * Here, high-pressure pipes (3) and (4) denote every fuel pipe (the figure shows an example). 61. Starting motor assembly Install staring motor assemblies (3) and (2) and then connect wiring hamess (1) to them, + Install the top assembly first being fol lowed by the bottom one. = Starting motor B terminal nut: 19.6 ~ 25.5 Nm {2— % Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage. 1) Spray color checker (developer) over the fuel supply pump, common rail, fuel injec- tor, and joints of the high-pressure piping. 2) Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized 62. Engine wiring harness 3) Check the fuel piping and devices for fuel Install engine wiring hamess (1) on the engine leakage. assembly and then connect the connector and %* Check mainly around the high-pres- terminal, sure circuit parts coated with the color checker for fuel leakage. If any fuel leakage is detected, repair it and check again from step 1). 4) Run the engine at low idle. 12V140E-3 Series 39‘SEN00322-00 50 Disassembly and assembly 5) Check the fuel piping and devices for fuel leakage. % Check mainly around the high-pres- sure circuit parts coated with the color checker for fuel leakage % Ifany fuel leakage is detected, repair it and check again from step 1) 6) Run the engine at high idle. 7) Check the fuel piping and devices for fuel leakage. Check mainly around the high-pres- sure circuit parts coated with the color checker for fuel leakage. + Ifany fuel leakage is detected, repair itand check again from step 1). 8) Run the engine at high idle and load it When checking while the compenents to be checked are mounted on the machine, stall the torque corverter or relieve the hydraulic pump. 9) Check the fuel piping and devices for fuel leakage. %* Check mainly around the high-pres- sure circuit parts coated with the color checker for fuel leakage. If any fuel leakage is detected, repair ittand check again from step 1) If no fuel leakage is detected, check is completed 40 12V140E-3 Series50 Disassembly and assembly SEN00322-00 12V140-3 Series 4SEN00322-00 50 Disassembly and assembly KOMATSU 12V140E-3 Series engine Form No. SEN00322-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 03-06 (02) 42 HOMATSU 12V140E-3 Series