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

SEN00307-05
12V140E-3 Series
SEN00307-04
ENGINE
Shop Manual
12V140E-3 Series
Machine model Serial number

12V140E-3 SERIES ENGINE...
10 Structure,function and
maintenance standard
Structure, function and maintenance
standard, Part 1
Air intake and exhaust unit.......................................................................................................................... 3

Air cleaner................................................................................................................................................... 4
Turbocharger............................................................................................................................................... 6
Aftercooler................................................................................................................................................... 11
Muffler ......................................................................................................................................................... 12
Cylinder head.............................................................................................................................................. 14
Cylinder block ............................................................................................................................................. 18
Cylinder liner ............................................................................................................................................... 22
12V140E-3 Series 1
SEN00307-05 10 Structure,function and maintenance standard
Main moving parts ....................................................................................................................................... 24

Crankshaft................................................................................................................................................... 26
Camshaft..................................................................................................................................................... 28
Cam follower and 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
10 Structure,function and maintenance standard SEN00307-05
Air intake and exhaust unit
(Left side view of engine)
a The illustration shows the engine for D475A-5E0.
A: Air intake (From air cleaner) 1. Electrical intake air heater

B: Air intake (To air-cooled aftercooler) 2. Air intake manifold
C: Air intake (From air-cooled aftercooler) 3. Muffler
D: Exhaust gas 4. Turbocharger
12V140E-3 Series 3
Air cleaner
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
a The shape is subject to machine models.
A: Air inlet
B: To turbocharger (Intake air)
C: To muffler (Dust)
1. Pre-cleaner
2. Air cleaner casing
3. Outer element
4. Inner element
Method of discharging Number of

Engine Machine model Type
dust from pre-cleaner elements
D475A-5E0
PC2000-8 Komaclone, multi-cyclone Automatic discharge 1 Inner element,
SAA12V140E-3
WA800-3E0, (ERB type) (Exhaust ejector) 1 Outer element
WA900-3E0
4 12V140E-3 Series
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
1. Inlet 6. Evacuator valve

2. Outlet 7. Dust pan
3. Guide vane 8. Guide plate (Sleeve)
4. Primary element 9. Body
5. Safety element 10. Element
Number of
Engine Machine model Type Evacuator valve
elements
1 Inner element,
SAA12V140E-3 HD785-7 FRG (Radial seal type) Automatic discharge
1 Outer element
Structure Operation
q The size of the body is reduced from the conven- q Air containing dust is sucked in vertically through
tional type without changing the diameter of the inlet (1) and the dust is separated by the centrif-
element. ugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the sim- mary element (4) and clean air is sucked in the
ple spiral guide vane, not by the guide plate. engine through safety element (5) and outlet (2).
q The dust and water separated by guide vane (3)
swirl along the inside wall of body (9) and enter
evacuator valve (6) and then are discharged out
automatically.
12V140E-3 Series 5
Turbocharger
Water-cooled type
Type: KTR110L
6 12V140E-3 Series
A: Intake air inlet

B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
G: Coolant
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Thrust metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model: KOMATSU KTR110L (Water-cooled)
Overall length: 308 mm
Overall width: 305 mm
Overall height: 287 mm
Weight: 25 kg
12V140E-3 Series 7
Model: KTR110L
a The illustration shows the water-cooled turbocharger.
8 12V140E-3 Series
Unit: mm
No. Check item Criteria Remedy

Standard Repair limit
1 End play (Play in axial direction) Replace thrust parts
0.08 – 0.13 0.18
Replace
2 Radial play (Play in radial direction) 0.43 – 0.68 0.84
bearing parts
Clearance between blower hous- Replace
3 Clearance limit (Min.): 0.14
ing and impeller bearing parts
12V140E-3 Series 9
Turbocharger mounting

A: Intake air inlet

B: Intake air (Between turbocharger and air-cooled aftercooler)
1. Exhaust manifold
2. Turbocharger
10 12V140E-3 Series
Aftercooler
Air-cooled type

A. Air inlet (From turbocharger)

B. Air outlet (To air intake manifold)
1. Upper tank
2. Core
3. Lower tank
4. Fin
5. Tube
12V140E-3 Series 11
Muffler

A: Exhaust gas outlet
1. Turbocharger
2. Muffler
12 12V140E-3 Series
12V140E-3 Series 13
Cylinder head
A. Air intake C. To fuel tank

B. Exhaust gas D. To radiator
1. Spill pipe 6. Cylinder head bolt

2. Air bleeding pipe 7. Injector connector
3. Cylinder head 8. Injector assembly
4. Head cover 9. Injector holder mounting bolt
5. Head cover bolt 10. Injector holder retainer
14 12V140E-3 Series
Specifications
Cylinder head
Direct injection type
4-valve type
Split-type 1 cylinder, 1 cylinder head
Centralized cooling system for valve bridge and in-
jector
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
a Tighten the cylinder head mounting bolt in order of [1] to [7].
Unit: mm

Tolerance Repair limit
Strain of cylinder head mounting Repair by grinding
1
face 0 – 0.06 0.09 or replace
Engine Standard
Replace nozzle or
2 Projection of nozzle
SAA12V140E-3 2.3 – 2.9 gasket
Bolt No. Procedure Target (Nm{kgm}) Range (Nm{kgm})
1st phase 147 {15} 137 – 157 {14 – 16}

Tighten in order
Tightening torque for cylinder head
shown above. If
mounting bolt (Apply molybdenum [1] – [6] 2nd phase 289 {29.5} 284 – 294 {29 – 30}
3 there are 5 punch
disulfied or engine oil to threaded
marks, replace the
part) 3rd phase Retighten by 90° 90(+30/0)°
bolt.
[7] — 68.6 {7} 58.8 – 73.5 {6 – 7.5}
Target (Nm {kgm}) Range (Nm {kgm})

Tightening torque for injector holder
4
mounting bolt 66.7 {6.8} 58.8 – 73.5 {6 – 7.5}
Tightening torque for fuel injection Retighten
5 44.1 {4.5} 39.2 – 49.0 {4 – 5}
pipe
Tightening torque for head cover
6 32.4 {3.3} 29.4 – 34.3 {3.0 – 3.5}
mounting bolt
a 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.
16 12V140E-3 Series
12V140E-3 Series 17
Cylinder block
1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. O-ring
5. O-ring
6. Main bearing metal cap bolt
7. Main bearing metal cap
8. Main bearing metal
9. Piston cooling nozzle
10. Thrust bearing metal
18 12V140E-3 Series
Specifications Liner ring

Upper: Clevis seal (Ethylene-propylene rubber)
Cylinder block Middle: O-ring (Ethylene-propylene rubber)
Crankshaft: 7 bearings Lower: O-ring (Silicon rubber)
Camshaft: High cam type, 7 bearings
Main bearing cap bolt: Plastic-region tightening
Piston cooling
With piston cooling nozzle
Cylinder liner
Wet type
Machining on inside: Plateau honing andTufftride
12V140E-3 Series 19
20 12V140E-3 Series
Unit: mm

Tolerance Repair limit
Strain of cylinder head mounting Repair by grinding
1
face 0 – 0.09 0.135 or replace
Standard size Tolerance Replace or correct

Inside diameter of main bearing
+0.025 main bearing metal
metal mounting hole 157
0 cap
Surface roughness of main bearing
10S or less
metal mounting hole
Correct
2
Roundness of mounting hole Repair limit: 0.005
–0.050
No.4 only 4.5
Thickness of main bear- –0.060
ing metal Other than –0.065
No.4
4.5
–0.075
Replace bearing
Standard size Tolerance Repair limit
Inside diameter of main metal
+0.175
bearing metal No.4 only 148 148.23
3 +0.130
(When tightening bolt
with specified torque) Other than +0.145
No.4
148 148.20
+0.100
Standard size Tolerance
Inside diameter of cam bushing Correct or replace
4 +0.030
mounting hole 69 block
0
Replace cam bush-
5 Inside diameter of cam bushing +0.060
65 65.15 ing
0.025
Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque for main bearing 1st time 284 {29} 270 – 299 {27.5 – 30.5}
cap
6
(Apply engine oil to threaded por- 2nd time 569 {58} 559 – 579 {57.0 – 59.0}
Retighten
tion and washer)
3rd time Retighten by 90° 90 (+30/0)°
Tightening torque for oil pan mount-
— — 65.7 {6.7} 58.8 – 73.6 {6 – 7.5}
ing bolt
Level difference between under
— surfaces of cylinder block and front Repair limit: 0.14 Reassemble
cover
a Do not use a main cap mounting bolt more than 5 times.
12V140E-3 Series 21
Cylinder liner
Unit: mm

Replace cylinder
1 Projection of cylinder liner Repair limit: 0.07 – 0.15
liner or cylinder
Rank Standard size Tolerance Repair limit
+0.020
S 140 140.12
Inside diameter of cylinder liner 0
+0.040
L 140 140.14
2 +0.021 Replace cylinder
liner
Roundness of cylinder liner Repair limit: 0.02
(Refilling is allowed
only for rank L.)
Cylindricality of cylinder liner Repair limit: 0.02

Outside diameter of cylinder liner
0
(Counterbore portion) 170.2
3 –0.10
Clearance between cylinder liner
Replace cylinder
and block Standard clearance: 0 – 0.163
liner or block
(counterbore portion)
Outside diameter of cylinder liner Replace cylinder
+0.090
(Lower portion of counterbore) 161.2 liner
+0.050
4
Interference of cylinder liner and Standard interference Interference limit Replace or correct
block cylinder liner or
0.02 – 0.12 0.02 or above
(Lower portion of counterbore) block
Outside diameter of cylinder liner Replace cylinder
–0.053
(at O-ring) 158 liner
5 –0.103
Clearance between cylinder liner
Replace cylinder
and block Standard clearance: 0.093 – 0.143
liner or block
(O-ring portion)
22 12V140E-3 Series
12V140E-3 Series 23
Main moving parts
1. Piston (FCD piston) 10. Connecting rod bearing metal

2. Piston pin 11. Crank gear (Number of teeth: 45)
3. Connecting rod bushing 12. Crankshaft
4. Top ring 13. Vibration damper
5. Second ring
6. Oil ring
7. Connecting rod cap bolt
8. Connecting rod
(Front of engine: for L bank, rear: for R bank)
9. Connecting rod cap
24 12V140E-3 Series
Specifications 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 Top ring (1) : Double-side keystone, inner cut,
tightening. barrel face, hard chromium-plated
Second ring (2): Double-side keystone, inner cut, ta-
per face, hard chromium-plated
Oil ring (3) : M-shaped steel, with coil expand-
er, nitrided surface
12V140E-3 Series 25
Crankshaft
26 12V140E-3 Series
Unit: mm

Standard value Repair limit Replace thrust
1 End play bearing metal or
0.140 – 0.32 0.50
use oversize metal
S.T.D. 148 147.97
0.25 US 147.75 147.72

Outside diameter of main journal 0
0.50 US 147.50 147.47 Use undersize jour-
–0.030
nal or replace
0.75 US 147.25 147.22
1.00 US 147.00 146.97

2
Roundness of main journal Repair limit: 0.010
Journal Standard clearance Clearance limit

Use undersize jour-
No.4 only 0.130 – 0.205 0.25
Clearance of main journal nal or replace main
metal
Other than No.4 0.100 – 0.175 0.22
Correct surface
Surface roughness of main journal 0.8S (Surface roughness of R portion: 3.2S) roughness of crank-
shaft journal
S.T.D. 100 99.87
0.25 US 99.75 99.62

Outside diameter of main journal 0 Use undersize jour-
0.50 US 89.50 99.37
–0.030 nal or replace
0.75 US 99.25 99.12
3
1.00 US 99.00 98.87
Roundness of main journal Repair limit: 0.010

Standard clearance Clearance limit
Clearance of main journal Replace connect-
0.046 – 0.126 0.17
ing rod bearing
metal
Surface roughness of main journal 0.8S (Surface roughness of R portion: 3.2S)

Coaxiality of all main journals:
0.15
4 Bend of crankshaft 0.15 or less Replace
Coaxiality of adjacent main journals:
0.07
0.07 or less
1st time 74 {7.5} 54 – 93 {5.5 – 9.5}

Tightening torque for adapter
5
mounting bolt 2nd time 245 {25} 226 – 265 {23 – 27}
Retighten
3rd time 745 {76} 725 – 765 {74 – 78}
Tightening torque for damper

6 108 ± 10 Nm {11 ± 1.0 kgm}
mounting bolt
a US: Undersize
12V140E-3 Series 27
Camshaft
Unit: mm

1 End play Replace thrust plate
0.1 – 0.25 0.36

Outside diameter of camshaft jour-
–0.016 Replace
nal 65
–0.036
2
Replace cam bush-
Clearance of camshaft journal
0.016 – 0.096 0.15 ing
3 Bend of camshaft Repair limit: 0.04 (Overall swing of indicator)
Cam Standard size Tolerance Repair limit

Replace
Intake 55.48 ± 0.1 55.08
4 Height of cam
Exhaust 55.75 ± 0.1 55.35
28 12V140E-3 Series
Cam follower and push rod
Unit: mm
Outside diameter of cam follower
–0.021
shaft 22 21.92
1 –0.034
Inside diameter of cam follower +0.021
22 22.07
shaft hole 0
+0.05
2 Outside diameter of cam roller 31.7 31.50
+0.02
+0.038
Inside diameter of cam roller 12.7 12.78
+0.013
3 Replace
Outside diameter of cam roller pin 12.63 ± 0.006 12.56

4 Diameter of push rod ball end 0
12.7
–0.20
0
5 Diameter of push rod socket end 13.4
–0.20
6 Bend of push rod Repair limit: 0.3 (Overall swing of indicator)
12V140E-3 Series 29
Piston, piston ring, and piston pin
30 12V140E-3 Series
Unit: mm

Replace pis-
–0.120
S 140 139.830 ton(Refilling is
1 Outside diameter of piston –0.135
allowed only for
–0.105 rank S.)
L 140 139.845
–0.120
No. Measuring point Standard size Tolerance
–0.015
2 No.1 ring 2.9
–0.035
Thickness of piston ring –0.010 Replace piston ring
3 No.2 ring 2.41
–0.035
–0.010
4 Oil ring 4
–0.030
2 No.1 ring Judge using groove wear gauge (*1)
3 No.2 ring Judge using groove wear gauge (*2)
Width of piston ring groove Replace piston
+0.030
4 Oil ring 4
+0.010
No. Measuring point Standard clearance Clearance limit
2 No.1 ring
Clearance between piston ring and Check with groove wear gauge Replace piston or
2 – 4 piston ring groove piston ring
3 No.2 ring
4 Oil ring 0.020 – 0.060 0.14

0.42 – 0.57
(Tension:
2 No.1 ring 2.0
16.5 – 23.5 N
{1.68 – 2.40 kg})
1.15 – 1.30
No.2 ring
(Tension: Replace piston ring
Closed gap of piston ring 3 (Identification 2RN 1.5
16.2 – 24.2 N or cylinder liner
white mark)
{1.65 – 2.47 kg})
0.30 – 0.50
(Tension:
4 Oil ring 1.0
84.4 – 112 N
{8.61 – 11.39 kg})
Outside diameter of piston pin 0 Replace piston pin
52
–0.006
+0.045
Lateral:
+0.035
5 Inside diameter of piston pin hole 52 Replace piston
+0.055
Vertical:
+0.035
Clearance between piston pin and Replace piston or
Lateral:0.035 – 0.051
piston 0.10 piston pin
Vertical:0.035 – 0.061
a *1: Part No. (Groove wear gauge) 795-901-1150
a *2: Part No. (Groove wear gauge) 795-901-1130
12V140E-3 Series 31
Connecting rod
32 12V140E-3 Series
Unit: mm
Standard size Tolerance Repair limit Replace bushing
Inside diameter of connecting rod
+0.049 (Refilled part is
small end bushing 52 52.09
+0.030 semi-finished part)
1
Clearance between connecting rod Replace bushing or
small end bushing and piston pin 0.030 – 0.055 0.11 piston pin
Standard size Tolerance Replace connect-

Inside diameter of connecting rod ing rod
2 +0.030
small end bushing mounting hole 57.4 (Correction not
0
allowed)
Inside diameter of connecting rod Standard size Tolerance Repair limit
Replace bearing
3 large end bearing metal +0.096
100 100.15 metal
(Crankpin journal) +0.046
Inside diameter of connecting rod +0.026 Replace connect-
106 —
large end hole –0.004 ing rod
4
(Without bearing metal, X, Y, and Z (Correction not
q Tighten connecting rod cap with specified torque and measure
directions) allowed)
Thickness of connecting rod bear- –0.025 Replace bearing
5 3.0 —
ing metal –0.035 metal
Item Standard Repair limit
Parallelism (a) 0 – 0.10 0.15

Parallelism and twist of connecting Replace connect-
6
rod Twist (b) 0 – 0.25 0.30 ing rod
Dimensions (c) 340 —

Tightening torque for connecting
69 – 78
rod cap mounting bolts 1st time 74 {7.5} Tighten in order
7 {7 – 8}
(Apply engine oil to seat surface of shown in figure
nut of threaded portion of bolts) 2nd time Retighten 90° 90(+30/0)°
Roughness 3.2S
Inside diameter of con-
8 Replace
necting rod large end
Swell 0.004 (In overall width)
a Do not use a connecting rod cap mounting bolt more than 5 times.
12V140E-3 Series 33
Flywheel and flywheel housing
Unit: mm
1 Facial runout of flywheel housing Repair limit: 0.25
2 Radial runout of flywheel housing Repair limit: 0.25

Reassemble
3 Facial runout of flywheel Repair limit: 0.30
4 Radial runout of flywheel Repair limit: 0.13

Tightening torque for flywheel
housing mounting 1st time 343 {35} 294 – 392 {30 – 40}
5
(Apply engine oil to threaded por-
tion) 2nd time 412 {42} 392 – 432 {40 – 44}
Tighten in order
shown in above fig-
1st time 98 {10} 78 – 118 {8 – 12}
Tightening torque for flywheel ure
mounting bolt
6 2nd time 294 {30} 275 – 314 {28 – 32}
(Apply engine oil to threaded por-
tion)
3rd time 539 {55} 520 – 559 {53 – 57}
34 12V140E-3 Series
Vibration damper
1. Vibration damper
2. Pin (between adapter and vibration damper)
3. Adapter
4. Pin (between adapter and crankshaft)
5. Bolt (between adapter and crankshaft)
6. Bolt (between adapter and vibration damper)
12V140E-3 Series 35
Timing gear
36 12V140E-3 Series
Unit: mm
Posi-
Measuring point Standard Repair limit
tion
Crank gear and right main idler
a 0.141 – 0.425
gear (Large)
Right main idler gear (Small) and
b 0.130 – 0.390
right sub idler gear
Right sub idler gear and right
c 0.129 – 0.391
cam gear
Right cam gear and accessory
d 0.085 – 0.492
drive gear
Right main idler gear (Small) and
— Backlash of each gear e
right fuel injection pump gear
0.051 – 0.469 Replace
0.6
Right main idler gear (Large) and
f 0.052 – 0.481
water pump driver gear
Right main idler gear (Large) and
g 0.137 – 0.421
oil pump gear
Crank gear and left main idler
h 0.141 – 0.425
gear (Large)
Left main idler gear (Small) and
j 0.129 – 0.391
left cam gear
Left main idler gear (Small) and
k 0.051 – 0.469
left fuel injection pump gear
Tolerance Standard Clearance
Clearance between main idler gear Standard size
Shaft Hole clearance limit
1 bushing and shaft
(Both right and left banks) –0.016 +0.034 Replace bushing
56 0.025 – 0.063 0.20
–0.029 +0.009
Clearance between sub idler gear –0.016 +0.055
2 56 0.016 – 0.084 0.20
bushing and shaft –0.029 0
3 End play of main idler gear
0.09 – 0.26 0.4
4 End play of sub idler gear 0.07 – 0.18 0.4

Replace thrust
End play of fuel injection pump
5 0.07 – 0.20 0.4 bearing
drive gear
6 End play of oil pump drive gear 0.03 – 0.094 0.4
7 End play of accessory drive gear 0.1 – 0.4 0.4
12V140E-3 Series 37
Valve system
38 12V140E-3 Series
1. Cam gear Valve timing

2. Thrust plate
3. Camshaft
4. Cam follower
5. Cam roller
6. Rocker arm shaft
7. Cam follower shaft
8. 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. Intake valve
22. Cam roller pin
Specifications
Camshaft
Drawn steel bar (Machining)
Journal and cam sections: Induction hardening
12V140E-3 Series 39
Valve and valve guide
40 12V140E-3 Series
Unit: mm

Valve Standard size Tolerance Repair limit
Intake 0 ± 0.10 0.70 Replace valve or

1 Sinking distance of valve
valve seat
Exhaust 0 ± 0.10 0.70
Valve Standard size Repair limit
Intake 2.4 1.9

2 Thickness of valve lip Replace valve
Exhaust 2.15 1.75
Valve Standard size Tolerance
Intake 30° ± 15' Correct or replace

3 Valve seat angle
valve or valve seat
Exhaust 45° ± 15'
–0.045
Intake 10
–0.060
Outside diameter of valve stem Replace valve
–0.074
Exhaust 10
–0.089
Before head is press +0.019
10
fitted +0.001
Not press Replace valve
Inside diameter of valve guide Press fit-
After head is press fit- fitted por- guide
ted portion
4 ted 10 tion
+0.008 +0.011
–0.009 –0.009
Valve Standard clearance Clearance limit
Clearance between valve guide Intake 0.034 – 0.071 0.22 Replace valve or
and stem valve guide
Exhaust 0.063 – 0.100 0.24
Bend of valve stem Repair limit: 0.02 (Total runout of indicator, per 100) Replace valve
Standard Tolerance
5 Driving height of valve guide Correct
22.0 ± 0.2
Spring Standard size Repair limit
Outer 81.7 —
Free length of valve spring
Inner 72.0 —
Installed Standard installed Allowable installed
Spring Replace valve
6 length load (N {kg}) load (N {kg})
spring
424.3 ± 21.6 377.3
Installed load of valve spring Outer 51.0
{43.3 ± 2.2} {38.5}
215.6 ± 10.8 192.1
Inner 46.0
{22.0 ± 1.1} {19.6}
Perpendicularity of valve spring Repair limit: 2° (Both ends)
12V140E-3 Series 41
Rocker arm and shaft
Unit: mm

Outside diameter of rocker arm Replace rocker arm
shaft 32.0 ± 0.0065 shaft
1 Inside diameter of rocker arm bush- 32.0

+0.088
Replace rocker arm
ing +0.028
Clearance between rocker arm Standard clearance Clearance limit Replace rocker arm
shaft and rocker arm 0.0215 – 0.0945 0.13 shaft or rocker arm
Valve Standard Tolerance
Intake 0.35 ± 0.02

2 Valve clearance (When cold) Adjust
Exhaust 0.57 ± 0.02
Target (Nm {kgm}) Range (Nm {kgm})

Tightening torque for locknut of
3 Tighten
rocker arm adjustment screw 58.8 {6} 52.9 – 64.7 {5.4 – 6.6}
42 12V140E-3 Series
Crosshead and guide
Unit: mm
1 Depth of crosshead stem receiver +0.3
6.2 6.61
0
Replace
Inside diameter of crosshead 11.04 ± 0.02 11.17
2
Outside diameter of crosshead +0.011
11 10.95
guide 0
3 Projection of crosshead guide 49.0 ± 0.25 — Correct
12V140E-3 Series 43

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

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

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SEN00307-05

Machine model Serial number

Air intake and exhaust unit.......................................................................................................................... 3

Main moving parts ....................................................................................................................................... 24

Air intake and exhaust unit

(Left side view of engine)

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

A: Air intake (From air cleaner) 1. Electrical intake air heater

a The shape is subject to machine models.

Method of discharging Number of

a The shape is subject to machine models.

1. Inlet 6. Evacuator valve

A: Intake air inlet

a The illustration shows the water-cooled turbocharger.

No. Check item Criteria Remedy

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

A: Intake air inlet

a The shape is subject to machine models.

A. Air inlet (From turbocharger)

a The shape is subject to machine models.

A: Exhaust gas outlet

a The shape is subject to machine models.

A. Air intake C. To fuel tank

1. Spill pipe 6. Cylinder head bolt

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

No. Check item Criteria Remedy

Bolt No. Procedure Target (Nm{kgm}) Range (Nm{kgm})

1st phase 147 {15} 137 – 157 {14 – 16}

[7] — 68.6 {7} 58.8 – 73.5 {6 – 7.5}

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

a Do not use a cylinder head mounting bolt more than 5 times.

Specifications Liner ring

No. Check item Criteria Remedy

Standard size Tolerance Replace or correct

No. Check item Criteria Remedy

Standard size Tolerance

Main moving parts

a The shape is subject to machine models.

1. Piston (FCD piston) 10. Connecting rod bearing metal

Specifications Piston rings

No. Check item Criteria Remedy

S.T.D. 148 147.97

0.25 US 147.75 147.72

1.00 US 147.00 146.97

Journal Standard clearance Clearance limit

Rank Standard size Tolerance Repair limit

S.T.D. 100 99.87

0.25 US 99.75 99.62

Roundness of main journal Repair limit: 0.010

Standard Repair limit

1st time 74 {7.5} 54 – 93 {5.5 – 9.5}

Tightening torque for damper

No. Check item Criteria Remedy

Standard size Tolerance

3 Bend of camshaft Repair limit: 0.04 (Overall swing of indicator)

Cam Standard size Tolerance Repair limit

Cam follower and push rod

Standard size Tolerance

6 Bend of push rod Repair limit: 0.3 (Overall swing of indicator)

Piston, piston ring, and piston pin

No. Check item Criteria Remedy

4 Oil ring 0.020 – 0.060 0.14