SEN05156-01 90 Repair and replacement of parts

KOMATSU 12V140E-3 Series engine

Form No. SEN05156-01

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 12-10

16 12V140E-3 Series
 SEN05157-00

ENGINE 1SHOP MANUAL

2
3

12V140E-3 Series

90 Repair and replacement of

parts 1
Parts related to cylinder block
Part names related to cylinder block............................................................................................................... 3
Testing and inspection of cylinder block.......................................................................................................... 4
Part names related to crankshaft .................................................................................................................... 7
Testing and inspection of crankshaft............................................................................................................... 8
Part names related to connecting rod ............................................................................................................. 9
Testing and inspection of connecting rod...................................................................................................... 10
Replacement of flywheel ring gear.................................................................................................................11
Replacement of crankshaft gear ................................................................................................................... 12
Replacement of camshaft gear ..................................................................................................................... 13
Replacement of main bearing metal cap ...................................................................................................... 14
Replacement of connecting rod small end bushing ...................................................................................... 16
Replacement of cam bushing ....................................................................................................................... 17
Repair of cylinder block top by grinding ........................................................................................................ 19

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Repair of counterbore by grinding................................................................................................................. 20

Check and identification after repair by grinding ........................................................................................... 22
Gasket sealant application procedure........................................................................................................... 23
Repair standard for cylinder liner O-ring ....................................................................................................... 25
Repair of crankshaft by grinding ................................................................................................................... 26
Improvement of surface roughness of crankshaft journal ............................................................................. 32

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Part names related to cylinder block 1

1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing metal cap bolt
6. Main bearing metal cap
(No. 1, 2, 3, 5 and 6 are same)
7. Camshaft bushing

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Testing and inspection of cylinder block 1

Unit: mm
Inspection item Criteria Remedy
Presence of crack (External dye check)
Crack
Cylinder head bolt hole etc. Replace cylinder
a See Fig. A block
Repair of contact of packing
Water leakage caused by corrosion
a See Fig. B
Standard value
Outside Standard
Standard size Bore of Replace cylinder
Clearance to cylinder liner diameter of clearance
cylinder block liner or cylinder block
cylinder liner
158.00 – 157.897 – 0.073 –
158.00
158.04 157.927 0.143
Inside diameter
Inside diameter of camshaft Replace camshaft
Standard size Standard value Repair limit
bushing bushing
65 65.00 – 65.06 65.10
Replace cylinder
a See Fig. C
Projection of cylinder liner liner or repair cylin-
Allowable range: 0.07 – 0.15
der block
a See Fig. D
Presence of corrosion
Depth and bottom corrosion Repair by cutting
counterbore Standard size Standard value and add shim
11 11.00 – 11.05
Tolerance Repair limit
Distortion and wear of cylinder All cylinder block
Max. 0.09 0.135 Repair by cutting
head mounting face top of 1 cylinder
Max. 0.05 0.100
Main bearing mounting hole a See Fig. E
diameter Standard size Standard value Repair limit
• Tighten main bearing metal
156.990 –
cap bolt to specified torque 157 —
157.025
• Measure in rage of 10° on
upper and lower sides of General concentricity Max. 0.020
main bearing metal cap Replace cylinder
Concentricity of adjacent holes Max. 0.013
block
a See Fig. F
Fit of main bearing metal cap Standard fit
Journal Allowable clearance
and cylinder block (Interference)
(Interference) No. 1 – 6 0.083 – 0.144 —
No. 7 0.038 – 0.099 —
a See Fig. G
Cylinder liner
Standard size Standard value Repair limit
Replace cylinder
170.10 – liner
Upper section 170.2 —
170.20
Inside diameter of counterbore 161.25 –
Lower section 161.2 —
and outside diameter of 161.29
cylinder liner flange
Cylinder block
Standard size Standard value Repair limit
170.200 – Repair cylinder block
Upper section 170.2 — and sleeve
170.263
161.170 –
Lower section 161.2 —
161.230

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Illustrations related to testing and inspection table

Fig. A Fig. D

a: Packing portion f: Depth of counterbore

Fig. B Fig. E

b: Clearance g: Inside diameter

Fig. C Fig. F

c: Cylinder liner h: Fit

d: Cylinder block
e: Projection

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Fig. G Method of checking main bearing metal inside

diameter with alignment bar

q When checking the main bearing metal inside

diameter with tool J (alignment bar), follow the
procedure below.
Unit: mm
Specified dimension
–0.014
Diameter 157 –0.039

Roundness 0.005
Straightness 0.010
Length Min. 1,300
i: Upper section
j: Lower section

1. Set the cylinder block on the stand with the

main bearing metal cap side up.

2. Apply engine oil to the inside of the main bear-

ing metal hole of the cylinder block.
a Leave the main bearing metal cap
removed.

3. Set tool J (alignment bar) to the main bearing

metal hole of the cylinder block.

4. Install the main bearing metal cap and tighten

it to the following torque.

5. Check that tool J (alignment bar) moves

smoothly.

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Part names related to crankshaft 1

1. Crankshaft
2. Main bearing metal (upper) (All other than No.
4 are the same)
3. Main bearing metal (lower) (All other than No.
4 are the same)
4. Thrust metal (All of upper x 1 and lower x 2 are
the same)

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Testing and inspection of crankshaft 1

Unit: mm
Inspection item Criteria Remedy
Crack Check for crack by magnaflux inspection Replace camshaft
If damaged slightly,
• Flaw repair with oilstone
Presence of damage in journal • Seizure or by lapping. If
Damage • Discoloration seized, replace
crankshaft

Damage of tap holes at front and rear ends Repair or replace

crankshaft
Clogging of oil hole Presence of clogged oil hole Repair
Standard value Repair limit Replace thrust metal
End play of crankshaft or replace with over-
0.140 – 0.320 0.50 size parts
Size Standard size Tolerance Repair limit
Standard 4.000 3.79
0.25 OS 4.125 3.92 Replace thrust metal
Thrust metal thickness –0.07 or replace with over-
0.50 OS 4.250 4.04 size crankshaft
–0.12
0.75 OS 4.375 4.17
1.00 OS 4.500 4.29
Size Standard size Tolerance Repair limit
Standard 100.00 99.88
Outside diameter of crankpin 0.25 OS 99.75 99.63
journal 0.50 OS 99.50 –0.030 99.38 Replace with under-
–0.030 size parts or replace
0.75 OS 99.25 99.13 crankshaft
1.00 OS 99.00 98.88
Standard Repair limit
Roundness of crankpin journal
0 – 0.010 0.010
Replace with under-
size parts or replace
Clearance in crankpin journal 0.046 – 0.116 0.260 connecting rod bear-
ing metal
Size Standard size Tolerance Repair limit
Standard 148.00 147.97
Outside diameter of crank 0.25 OS 147.75 147.72
–0.030
main journal 0.50 OS 147.50 –0.030 147.47 Replace with under-
size parts or replace
0.75 OS 147.25 147.22 crankshaft
1.00 OS 147.00 146.97
Roundness of crank main Standard Repair limit
journal 0 – 0.010 0.010
No. 4 only 0.130 – 0.195 0.250 Replace with under-
Clearance in crank main size parts or replace
journal Other than 0.100 – 0.165 0.220
No. 4 main bearing metal
Standard Repair limit
Concentricity of all
Bend of crankshaft main journals Max. 0.15 0.15 Replace camshaft
(Total indicator reading)
Concentricity of
adjacent journals Max. 0.07 0.07

a OS: Oversize

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Part names related to connecting rod 1

1. Connecting rod bolt

2. Washer
3. Cap
4. Dowel pin
5. Bearing metal (lower)
6. Bearing metal (upper)
7. Rod
8. Small end bushing

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Testing and inspection of connecting rod 1

Unit: mm
Inspection item Criteria Remedy
Crack Check for crack by dye check or magnaflux inspection
a See Fig. H Replace connecting
Parallelism and twist of small Presence of bend (after small end bushing is installed)
and large end holes of rod
Parallelism: 0.10
connecting rod Twist: 0.25
Standard Tolerance Standard Allowable Replace small end
Clearance between connecting size Shaft Hole clearance clearance bushing
rod small end bushing and pis- Surface roughness
ton pin –0.006 +0.049 0.030 – of inside of small end
52 –0.006 +0.030 0.055 0.11
bushing: Max. 3.2S
Standard Tolerance
• Large end hole diameter size
• Without bearing metal.
• Inside surface roughness of large +0.026
106 –0.004
end hole: Max. 3.2 S
• Clearance to crankshaft bearing Standard Allowable Replace bearing
Connecting rod large end hole (with bearing metal) clearance clearance metal or connecting
diameter rod
• Wave of large end hole: Max. 0.004 0.046 –
(All width) 0.26
0.126
Even if dimensions of each part are within allowable limits, if any
clearance exceeds allowable clearance, replace parts (bearing
metal etc.)
Size Standard size Tolerance Repair limit
Standard 3.000 2.91
0.125 US 3.125 3.04 Replace bearing
Bearing metal thickness –0.025
0.250 US 3.250 3.16 metal
–0.035
0.375 US 3.375 3.29
0.500 US 3.500 3.40
Replace bearing
Flaw on inside of or seizure of Presence of flaw and seizure metal and connecting
bearing metal rod
Standard size Tolerance
Distance between large and Replace connecting
end small end holes 305 –0.05 rod
–0.05
a See Fig. J Replace connecting
• Presence of lateral grinding mark rod
Streak and bruise on H-portion • Presence of lateral streak If there is bruise,
of connecting rod replace connecting
rod regardless of
size of bruise
Presence of fretting on mating face If fretting is felt with
Fretting on cap mating face • Mating face roughness: Max. 6.3 S nail, replace con-
• Fitted area of mating face: Min. 70% necting rod
Scuffing on cap bolt seat surface Repair with oilstone
Scuffing on bolt seat surface Scuffing on bolt seat surface Replace bolt
Scuffing on washer surface Replace washer
• Presence of deformation of dowel pin Replace connecting
Deformation of dowel pin rod
• Presence of deformation of dowel pin hole

Damage of bolt • Presence of crack and damage on threaded portion of bolt Replace bolt
• Presence of bend of bolt
a US: Undersize
a If all the items of this criteria (particularly the wave of the large end hole) cannot be measured after the
connecting rod is rebuilt, do not rebuild since the accuracy of the connecting rod large end hole after
rebuilding cannot be confirmed.
a When reusability is judged, if there are honing marks left on the inside of the connecting rod large end
hole, it is not required to measure the surface roughness of the inside and wave of the large end hole.
a Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on it.

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Fig. H Replacement of flywheel ring gear1

k Take care not to throw down the flywheel
and get hurt by mistake.

Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder and break the gear to remove
with a chisel.

k Take care in handling the grinder and

chisel.

Press fitting of gear

a: Measured value 1. Check the gear mounting face. If there is a
flaw, repair with an oilstone.
Fig. J
2. Heat the gear at the specified shrink fit temper-
ature for a certain time.
a Gear shrink fit temperature: Max. 200 °C
Heating time: Min. 50 min

3. Press fit the gear with the chamfered side

directed toward the flywheel until its side is fit-
ted with the flywheel.

b: Inspection range
c: Streaks
d: Lengthwise direction

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Replacement of crankshaft gear 1 4. Using the drive tool, press fit the gear with the
timing mark out until its side is fitted with the
a Crankshaft gear replacement tools crankshaft flange.
Symbol Part No. Part name a Press fit the gear quickly before it cools
down.
1 790-101-2800 Bearing puller
K
2 790-101-2300 Push puller

Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder, assemble tools K1 and K2, and
rotate the nut to pull out the gear.
a If the gear cannot be pulled out by the above
method, make a notch at the tooth bottom of
the gear with a grinder, heat the gear with a
gas burner, and drive out the gear with a cop-
per rod etc.
a Take care not to damage the crankshaft.

Press fitting of gear

1. Check the gear mounting face, key way, flange
surface, etc. If there is a flaw, repair with an oil-
stone.

2. Drive a new key into the key way of the crank-

shaft.

3. Heat the gear at the specified shrink fit temper-

ature for a certain time.
a Gear shrink fit temperature: 200 °C
Heating time: Min. 30 min

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Replacement of camshaft gear 1

k When setting the camshaft assembly on the
press stand, take care not to catch your fin-
gers between the press stand and the gear.

Removal of gear
Set the camshaft assembly on the press stand and
press the camshaft to pull out the gear.

Press fitting of gear

1. Check the gear mounting face, key way, flange
surface, etc. If there is a flaw, repair with an oil-
stone.

2. Drive a new key into the key way of the cam-

shaft.

3. Install the thrust plate.

4. Heat the gear at the specified shrink fit temper-

ature for a certain time.
a Gear shrink fit temperature: 220 – 240 °C
Heating time: Min. 30 min

5. Using the drive tool, press fit the gear with the
timing mark out until its side is fitted with the
camshaft flange.
a Press fit the gear quickly before it cools
down.

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Replacement of main bearing
metal cap
a When replacing the main bearing metal cap,
work on the semi-finished cap according to the
following procedure and install it.
Repair parts
Part No. Part name
6215-99-4160 No. 1, 2, 3, 5, 6 main bearing metal cap
6215-99-4170 No. 4 main bearing metal cap
6215-99-4180 No. 7 main bearing metal cap
Inside machining of main bearing metal cap
1. Remove the cylinder liner.
2. Install the replacement main bearing metal cap
to the cylinder block and tighten it to the speci-
fied torque.
a Match the notches of the cylinder block
and main bearing metal cap to each other.
2 Main bearing metal cap mounting bolt:
Apply engine oil to threaded portion and
seat.
a Tighten with the angle tightening wrench
at the 3rd time.
3 Main bearing metal cap mounting bolt:
4. Apply dial gauges to the inside of the 2 main
bearing metal caps at the longest pitch among
1 the caps to be used to center the arbor of the
boring machine.
5. While checking the inside diameter of main
bearing metal cap (1), cut little by little.
a Cut to the degree that the boring bar tool
almost touches the inside of cylinder block
(2).
a Inside diameter of main bearing metal cap
q Machining dimension
Tolerance: 157 +0.025/0 mm
q After machining, remove the main bearing
metal cap, assemble it again, and check
its inside diameter.
Tolerance: 157 +0.025/–0.010 mm
(Range to upper and lower 10° from mat-
ing face of main bearing metal cap)
a Finished surface roughness: Max. 10 S
a Do not cut the inside surface of the cylin-
der block.

Unit: Nm {kgm}
Step Target Range

1st time 284 {29} 270 – 299

{27.5 – 30.5}

2nd time 569 {58} 559 – 579

{57.0 – 59.0}
3rd time 90° tightening 90° +30°
+00

3. Set the cylinder block mounting jig on the table

of the horizontal boring machine and install the
cylinder block by fitting its cylinder liner mount-
ing hole to the datum line of the jig.

a The cylinder block in the illustration has 6

cylinders.

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Side machining of main bearing metal cap

(Machine only No. 7 main bearing metal cap)
1. Insert cast iron bushing (3) and pass arbor (4)
through it.

2. Install facing tool (5) to the arbor.

3. Cut main bearing metal cap (1) to the degree

that facing tool almost touches the cylinder
block surface.

4. Cut the opposite side similarly.

a Thrust metal mounting surface roughness:
Max. 12.5 S
a Do not cut the cylinder block.
a Tolerance of main bearing metal cap
width: 51 0/–0.030 mm

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Replacement of connecting rod Press fitting of bushing

small end bushing 1 1. Set the connecting rod to block (3) of tool L.

a Connecting rod small end bushing replace- 2. Install the bushing to push tool (1), set push
ment tool tool (4), and fix them with nut (2).
Symbol Part No. Part name a Match the oil holes of the bushing and
connecting rod to each other.
L 795-240-6401 Push tool (KIT)
3. Drive push tool (1) with the press to press fit
Pulling out of bushing the bushing.
1. Set the connecting rod to block (3) of tool L. a Since the bushing is semi-finished, its
inside diameter is small and the piston pin
2. Using push tool (1) and nut, drive out the bus- does not go through it.
ing with the press. After press fitting the bushing, machine its
a After removing the bushing, remove sharp inside with a reamer or a honing machine
edges and burrs from and clean the bush- according to the maintenance standard.
ing mounting hole. a After machining, remove all the chips from
the oil hole and oil groove.
a The inside surface roughness of the
machined bushing must be maximum of
3.2 S.

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Replacement of cam bushing 1 3. Pulling out of No. 3, No. 4 and No. 5 bushings
1) Assemble bar (1), push tool (2), collar (3)
a Cam bushing replacement tools and guide (4) .
Symbol Part No. Part name 2) While hitting bar (1), drive out the bushing
from the cylinder block.
M 795-213-1200 Push tool (KIT)

a Before replacing the cam bushing, remove the

plug at the rear of the cylinder block.

Removal
1. Pulling out of No. 1 and No. 7 bushings
1) Assemble push tool (2), collar (3) and bar
(1) of tool M.
2) While hitting bar (1), drive out the bushing
from the cylinder block.

4. After removing the bushing, remove burrs and

foreign matter from and clean the bushing
mounting hole.

2. Pulling out of No. 2 and No. 6 bushings

1) Assemble bar (1), push tool (2), collar (3)
and guide (4) .
2) While hitting bar (1), drive out the bushing
from the cylinder block.

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Installation
a Cam bushing installation drawing
a Press fit the cam bushing, while checking its
direction so that its mating part will be on the
upper side of its center after installed.
1. Press fitting of No. 3, No. 4 and No. 5 bushings
1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d b u s h i n g a r e
matched to each other.
2. Press fitting of No. 2 and No. 6 bushings
1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d b u s h i n g a r e
matched to each other.
18
90 Repair and replacement of parts
3. Press fitting of No. 1 and No. 7 bushings
1) Install bar (1), push tool (2) and collar (3)
to the bushing.
2) Press fit the bushing until the oil holes of
t h e c y l i n d e r b l o c k a nd b u s h i n g ar e
matched to each other.
4. Measurement after bushing is press fitted
1) Using dial inside gauge (a), measure the
inside diameter of the bushing.
2) Measure the clearance between the bush-
ing and shaft. If it is out of the allowable
range or the shaft does not go through
smoothly, repair the inside of the bushing
with a reamer.
a After repairing the inside of the bush-
ing with a reamer, remove all the
chips from the oil hole and oil groove.
a Inside diameter of cam bushing:
ø65 +0.06/0 mm
a Clearance to camshaft journal:
0.016 – 0.096 mm
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Repair of cylinder block top by Grinding of top

grinding 1 q Measure the wear quantity and distortion of the
cylinder block top. If the measured value is
Repair by grinding larger than the allowable limit, repair the cylin-
If there is distortion or corrosion on the cylinder der block top by grinding within the allowable
block top, remove it by grinding. limit of cylinder block height (H).
a If the cylinder liner contact surface of counter-
Unit: mm
bore portion (b) is blackened and grained (par-
Standard Repair limit
ticularly in the forward and backward directions size
of the cylinder block) more than a half of the
Flatness of cylinder block Max. 0.05 0.10
contact surface or the cylinder block top needs top (per cylinder)
to be ground, repair the counterbore portion.
a Rough criteria for repairing cylinder block top Cylinder block height (H) 471.5 ± 0.04 471.06
by grinding Cylinder block top surface Max. 12.5S
q The cylinder block top is worn and corroded in roughness
the shape of the trace of the head gasket.
q Quantity (a) of the above wear is 0.15 mm or
more.

a When repairing with grinding stone (Refer-

ence)
Grinding speed: 1,650 – 1,950 m/min
Table speed: 15 – 30 m/min
Grinding depth by 1 grinding: 0.025 mm
Cross feed for 1 grinding: 1 – 2 mm
Grinding stone: A461 V
Grinding fluid: Water soluble grinding fluid

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Repair of counterbore by grinding 1 q Machine only the hatched part of counterbore

portion depth (e).
a Counterbore grinding tool q Set the machining margin of counterbore por-
Symbol Part No. Part name tion depth (e) so that cylinder liner projection (f)
will be within the standard value.
1 79A-513-1710 Basic machine
q If counterbore portion depth (e) exceeds the
2 79A-513-1780 Guide plate standard dimension and the counterbore por-
3 79A-513-1820 Cutter plate tion needs to be ground within the allowable
4 79A-513-1860 Cutter limit, set the machining margin so that 1 shim
shown below will be used for 1 cylinder.
5 79A-513-1940 Cutter set gauge
q Remove burrs and sharp edges from the
6 79A-513-1950 Micrometer tapered portion etc.
7 79A-513-1960 Driver plate q (g) is a line parallel with the cylinder center.
8 79A-513-2090 Driver shaft
9 79A-513-2110 Driver handle
10 79A-513-2120 Service package
N
11 79A-513-2130 Case
12 79A-513-2140 Basic machine
13 79A-513-2160 Cutter plate
14 79A-513-2230 Cutter
15 79A-513-2240 Remover pin
16 79A-513-2250 Case
17 79A-513-2260 Service package
18 79A-513-2270 Compound
19 79A-513-2280 Primer
20 79A-513-2320 Bushing

q After repairing the top of cylinder block (a) by

grinding, measure the counterbore portion
depth and repair the counterbore by grinding
within the allowable limit of counterbore depth
(e) if necessary.
a Rough criteria for repairing counterbore portion
by grinding
q A dimension is out of the standard dimension.
q The cylinder liner contact surface (a) of the
counterbore portion is blackened and grained
(particularly in the forward and backward direc-
tions) more than a half of the whole area.
q If counterbore portion depth (e) after the repair
is 11.05 – 12.525 mm, adjust cylinder liner pro-
jection (f) to 0.07 – 0.15 mm with shims.
Unit: mm
Standard Repair limit
size
Counterbore portion depth (e) 11 +0.05
+0
12.525

Cylinder liner projection (f) — 0.07 – 0.15

Counterbore surface rough- Max. 12.5S

ness
Grinding shape See figure below

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Shims for adjusting counterbore depth (reference) q When grinding the counterbore portion, use
Unit: mm tool N.

Part No. T t Weight Remarks

(kg)
6210-29-2260 1.50 0.025 0.023

6210-29-2250 0.80 0.025 0.012

6210-29-2240 0.50 0.025 0.008

6210-29-2230 0.26 0.025 0.004

6210-29-2220 0.20 0.020 0.003

6210-29-2210 0.16 0.016 0.002

a Outside diameter (i) and inside diameter (j) of

shim (1)
q i: 169 ± 0.15 mm
q j: 161.3 + 0.030/0 mm

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Check and identification after

repair by grinding 1
q After repairing by grinding, check the flat por-
tions around the water and oil holes on the cyl-
inder block top for flaw.
q Remove all burrs and sharp edges.
q After grinding the top, if cylinder block height
(H) is larger than the standard dimension and
within allowable limit (471.06 – 471.45 mm), be
sure to use the oversize head gasket.
Unit: mm
Head gasket Part No. Plate thickness

Standard 6210-17-1814 2.0

Oversize 6210-19-1814 2.4

a The 2 letters of "OS" are stamped on the plate

for identification.
q After repairing, stamp the contents of repair on
the cylinder block top (rear of the left bank) (a).
Stamp method is shown in the following table.
Oversize head Shim Stamp
gasket
— — Unnecessary
Spare parts used

Q — OS

— Q SH

Q Q WS

(Stamp letter size shall be 5 – 10 mm)

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Gasket sealant application

procedure 1
q When press fitting the cylinder liner again after
pulling it out, apply gasket sealant (LG-6) to
the cylinder block top deck (cylinder liner
flange contact surface of the cylinder block)
according to the following procedure.
a When using shim for the deck, apply the gas-
ket sealant similarly.

1. Wipe off dirt, oil etc. from cylinder block top (c)
and the cylinder liner flange contact surface
with cloths.

2. Apply LG-6 to gasket sealant application area

(a).
q String diameter: 2 – 3 mm
q Overlap length of starting and ending
points (b): 6 ± 6 mm
a When using shim for the deck
q Thinly apply LG-6 to the underside (e) of
shim (1) and fit the shim to the cylinder
block deck.
q Then, apply LG-6 as when no shim is
used.

3. Press fit cylinder liner to the cylinder block. 4.
At this time, apply a little amount of rubber
lubricant (RF-1) to cylinder block contact sur-
face (d) of the O-ring and seal of the cylinder
liner.
a Apply the engine oil just before press fit-
Set the cylinder liner to the cylinder block,
install the used head gasket, and tighten the
cylinder head temporarily.
At this time, tighten the bolts in the following
order.
3 Tightening torque:

ting the cylinder liner. 147 ± 10 Nm {15 ± 1 kgm}

a RF-1: Product of DAIDO CHEMICAL
INDUSTRY CO., LTD.
If RF-1 cannot be obtained, apply clean
engine oil SAE No. 30.
a Since the clevis seal and O-ring are
swelled and deteriorated with oil, apply a
little amount of oil with a brush just before
installing.

12V140E-3 Series 23
SEN05157-00 90 Repair and replacement of parts

5. Loosen the cylinder head mounting bolts,

remove the cylinder head, and wipe off the
excessive gasket sealant projected from the
counterbore portion.
a If the gasket sealant sticks to grommet (1)
of the head gasket, it deforms the grom-
met into a heart shape and can cause
coolant leakage into water hole (2).
Accordingly, wipe off the gasket sealant
thoroughly.
a When installing the cylinder head after
performing step "4.5", use a new head
gasket.

24 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00

Repair standard for cylinder liner

O-ring 1
After repairing the bushing at the cylinder liner O-
ring portion of the cylinder block, finish to the fol-
lowing dimensions.
a Concentricity of (6) to standard (A): Max. 0.05
mm
Unit: mm
No. Finish dimension

1 ø167

2 ø161.45 ± 0.25

3 ø160.67 ± 0.064

4 176 ± 0.25

5 184.94 ± 0.18

6 ø158 +0.040
+0

7 ø159.03 (Gauge diameter)

12V140E-3 Series 25
SEN05157-00 90 Repair and replacement of parts

Repair of crankshaft by grinding 1 q Finish the oil holes of the main journal and pin
journal to the dimensions shown below.
q When the crankshaft is worn, seized or dam-
aged slightly and needs to be repaired, grind it Main journal portion
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
q If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high tech-
nologies)
q Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.

Finish dimensions of fillet portion

Unit: mm
Finish Surface
dimension roughness
R1 4 +0.4
+0
3.2S
Pin journal portion
(a)
r1 6 —

R2 3.5 –0
–0.5 3.2S
Main journal (b)
r2 6 —

26 12V140E-3 Series
90 Repair and replacement of parts
Pin journal portion
q The outside surface roughness of the pin jour-
nal and main journal must be maximum of 0.8
S.
Equipment necessary for grinding
q Magnaflux inspection machine
q Shore hardness tester
q Etching kit
q Crankshaft grinding machine
q Crankshaft grinding polishing machine
q Surface roughness gauge
q Fillet R gauge
12V140E-3 Series
SEN05157-00
Inspection before repair by grinding
Visual check
Check for crack, damage, discoloration by seizure,
wear, etc. and judge if the crankshaft can be
repaired by grinding.
Hardness check of journal surface
Standard value: 63 – 69 Hs
If the hardness is below the allowable limit, discard
the crankshaft.
Check during and after repair by grinding
Check of fillet R portion
q Check that each fillet R portion is connected to
the journal shoulder smoothly.
q Using the fillet R gauges, check that the R
dimension is between the minimum value
gauge and maximum value gauge.
q (a) is the contact point of minimum value
gauge.
q (b) is the contact point of maximum value
gauge.
Unit: mm
Fillet R Min. radius Max. radius
Pin journal 4.0 4.4
Main journal 3.0 3.5
Check for seizure mark by etching
q After repairing by grinding, check that there is
no grinding seizure mark by etching inspection.
q If any seizure mark is detected, grind about
0.02 mm again to the next undersize dimen-
sion.
q After checking, neutralize and clean the
checked surface and apply rust preventive oil.
Magnaflux inspection
q Before using the repaired crankshaft, check it
by magnaflux inspection to ensure that it has
no crack.
q Extremely closely check journal fillet portion (c)
which is in each dangerous area of the crank-
shaft shown in the figure.
q After the magnaflux inspection, be sure to
demagnetize the crankshaft.
27
SEN05157-00 90 Repair and replacement of parts

Measurement of bend (Measurement of alignment) Undersize dimensions of main journal

q Measure the bend of the ground crankshaft
Unit: mm
and ensure that it is within the standard value.
q Measure the bend (alignment) at the following Size Standard size Tolerance
4 places. Standard 148.00
Tolerance of overall length alignment:
0.25 US 147.75
Max. 0.15 mm
Tolerance of adjacent alignment: 147.50 –0
0.50 US –0.030
Max. 0.07 mm 147.25
0.75 US
Tolerance of front end alignment:
Max. 0.03 mm 1.00 US 147.00
Tolerance of rear end alignment:
a US: Undersize
Max. 0.03 mm
q Roundness, cylindricality (TIR) and surface
roughness of main journal
Tolerance: Max. 0.010 mm
Allowable limit: 0.010 mm
Surface roughness: Max. 0.8 µm

Grinding of main journal

a Grind all the main journals to the same under-
size.
a When grinding, leave the polish finishing mar-
gin of 0.007 – 0.008 mm.
a Stamp undersize dimension (a) on the ground
crankshaft as shown in the figure to prevent
installation of bearing metals of a different size.
q M: Main journal
q P: Crankpin journal
Grinding of thrust surface
a It is not always required to grind the thrust sur-
faces of front (b) and rear (c) to the same
undersize dimension.
a Stamp the undersize dimension on the ground
crankshaft as shown in the figure to prevent
installation of a wrong thrust metal.
a If thrust surface (a) was repaired by grinding,
ensure that the end play of the crankshaft is
within the allowable range.
(See Disassembly and assembly, "General
assembly")

28 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00

Oversize dimensions of thrust surface

Unit: mm
Rear thrust surface
Standard 0.125 OS 0.25 OS 0.375 OS 0.50 OS
+0.050 +0.050 +0.050 +0.050 +0.050
Standard size 59.000 +0 59.125 +0 59.250 +0 59.375 +0 59.500 +0
Standard
Repair limit 59.060 59.185 59.310 59.435 59.560
+0.050 +0.050 +0.050 +0.050 +0.050
Standard size 59.125 +0 59.250 +0 59.375 +0 59.500 +0 59.625 +0
0.125 OS
Front thrust surface

Repair limit 59.185 59.310 59.435 59.560 59.685

+0.050 +0.050 +0.050 +0.050 +0.050
Standard size 59.250 +0 59.375 +0 59.500 +0 59.625 +0 59.750 +0
0.25 OS
Repair limit 59.310 59.435 59.560 59.685 59.810
+0.050 +0.050 +0.050 +0.050 +0.050
Standard size 59.375 +0 59.500 +0 59.625 +0 59.750 +0 59.875 +0
0.375 OS
Repair limit 59.435 59.560 59.685 59.810 59.935
+0.050 +0.050 +0.050 +0.050 +0.050
Standard size 59.500 +0 59.625 +0 59.750 +0 59.875 +0 60.000 +0
0.50 OS
Repair limit 59.560 59.685 59.810 59.935 60.060

a OS: Oversize
q Squareness of thrust surface (TIR)
Tolerance: 0.02 mm
Allowable limit: 0.02 mm
a TIR is an abbreviation for Total Indicator Read-
ing, which is the difference between the maxi-
m u m a nd m i n i m u m r e a d i n gs i n r u n ou t .
measurement.

Grinding of pin journal

a Grind all the pin journals to the same under-
size.
a When grinding, leave the polish finishing mar-
gin of 0.007 – 0.008 mm.
a Stamp undersize dimension (a) on the ground
crankshaft as shown in the figure to prevent
installation of bearing metals of a different size.

Undersize dimensions of pin journal

Unit: mm
Size Standard size Tolerance
Standard 100.000 q M: Main journal
0.25 US 99.750 q P: Crankpin journal
99.500 –0
0.50 US –0.030
0.75 US 99.250

1.00 US 99.000

a US: Undersize
q Roundness, cylindricality (TIR) and surface
roughness of pin journal
Tolerance: Max. 0.010 mm
Allowable limit: 0.010 mm
Surface roughness: Max. 0.8 µm

12V140E-3 Series 29
SEN05157-00
Grinding of sides of main journal and pin jour-
nal
q When repairing the worn surfaces of the main
journal and pin journal, limit the grinding quan-
tity to the minimum.
q Width of crankshaft main journal
#1 standard: 57 +0.1/0 mm
#2, 3, 5, 6 standard: 55 +0.1/0 mm
#4 standard: 59 +0.1/0 mm
#7 standard: 59 +0.05/0 mm
q Width of crankshaft pin journal
Standard: 92 +0.054/0 mm
Dressing of grinding stone
q Dress the grinding stone for each journal.
q Adjust the grinding stone edge to the arc of the
fillet with the grinding stone modifying device.
q Test and correct the grinding stone edge by
grinding a piece of wood on trial, while check-
ing with ball gauges.
Prevention of grinding seizure
q Apply the plunge grinding method.
q Use all the width of the grinding stone.
q Avoid grinding the boss surface as much as
possible.
q Apply cooling oil sufficiently.
q Set the standard peripheral speed of the grind-
ing stone to 2,000 m/min when the crankshaft
rotation speed is 40 rpm.
Finishing of surface
See "Improvement of surface roughness of crank-
shaft journal".
q Surface roughness standard (Pin journal and
main journal)
Journal surface: Max. 0.8S
Thrust surface: Max. 1.6S
End taper portions, boss portions and fillet por-
tions of pin and main journals: Max. 3.2S
q Polish finishing margin: 0.007 – 0.008 mm
30
90 Repair and replacement of parts
Work after repair by grinding
q Ensure again that each dimension is as speci-
fied.
q Clean each part thoroughly and apply rust-pre-
ventive oil.
q When storing the crankshaft for a long period,
support it on 3 points or keep it erected with a
sling.
Balancing (Reference)
Avoid performing repair that may affect the crank-
shaft balancing, as much as possible.
q Allowable limit of unbalance:
0.0098 Nm {100 g•cm}
q Limits for reading balance accurately
Bend of crankshaft: 0.07 mm (TIR)
Rotation speed of crankshaft: Max. 325 rpm
q Correct the balance by drilling holes in or grind
the counterweight, if necessary.
Drilling direction: Radial direction
Hole diameter: Max. 15 mm
Hole depth: Max. 50 mm
Number of holes: Max. 6/counterweight
Center of hole:
Match to the center of the counterweight.
(Deviation: Max. 0.5 mm)
Distance between holes:
Thickness must be at least 5 mm.
a TIR is an abbreviation for Total Indicator Read-
ing, which is the difference between the maxi-
m u m an d m i n i m u m r e a d i ng s i n r u no u t .
measurement.
12V140E-3 Series
90 Repair and replacement of parts SEN05157-00

Measuring procedure for bend and outside Measuring points of journal

diameter of journal portion Pin journal: 5 places in directions X and Y
1. Support both end centers of the crankshaft Main journal: 3 places in directions X and Y
with a lathe.
Apply the dial gauge probe to the central jour-
nal (No. 4) perpendicularly from side so that
deflection caused by the own weight of the
crankshaft will not affect the measurement and
then set the gauge to 0 at the top.
Rotate the crankshaft 1 turn and read the mini-
mum and maximum values.
a If a lathe is not available, support the No.
1 and No. 7 journals on V-blocks.

2. Measure the outside diameters of the main

journal and pin journal with a micrometer or an
air micrometer.

12V140E-3 Series 31
SEN05157-00
Improvement of surface
roughness of crankshaft journal 1
q If the surface roughness of the journal portions
of the crankshaft is out of the standard or the
journal surface has a flaw, bruise or rust which
can be removed, improve the surface rough-
ness.
1. Cleaning and blowing air
Before starting grinding, brush the oil holes
and blow air into them.
2. Improvement of surface roughness of journal
portions
When improving with special polishing ma-
chine
q Use the special polishing machine shown
below.
1. Set the rotation speed of the polishing machine
to 40 – 50 rpm.
Improve the surface roughness by making
round polishing with sandpaper (belt type)
between both ends of each journal.
a Use sandpaper (belt type) of #320.
a Move the sandpaper smoothly without
stopping at a place.
a Do not use honing oil.
2. Replace the sandpaper with one of #500.
Apply honing oil to the journal surface. Make
round polishing with the sandpaper between
both ends of the journal, while operating han-
dle (1) to move the sandpaper by the play.
a Move the sandpaper smoothly without
stopping at a place.
32
90 Repair and replacement of parts
3. Check the surface roughness with the stan-
dard piece.
a Measure the surface roughness of the
journal by comparing it with the standard
piece.
Surface roughness standard (Pin journal
and main journal)
Journal surface: Max. 0.8S
Round part: Max. 3.2S
4. If the surface roughness does not satisfy the
standard, make round polishing with the sand-
paper (#500) again between both ends.
a After improving the surface roughness, be
sure to brush the oil holes and blow air
into them.
a Ensure that the there is no flaw or bruise
on the journal portion and the round part
of each fillet.
If there is any flaw or bruise, polish again
from step 1.
If the special polishing machine is not available,
use the following clamp jig for polishing to
improve the surface roughness.
1. Using the crankshaft grinding machine, rotate
the crankshaft to polish.
q Sandpaper: #800
q Grinding oil:
Honing oil (Diesel fuel oil may be used)
q Rotation speed of crankshaft: 40 rpm
12V140E-3 Series
90 Repair and replacement of parts SEN05157-00

2. While moving the polishing jig in the axial

direction by the play of the journal width
(approx. 5 mm), polish the journal.
a Finish polishing each journal in about 6
minutes. Each time honing of 1 journal is
finished, replace the sandpaper with new
one.
a When honing the pin journal, set it to the
center of rotation.

Assembly and using procedure of clamp jig for

polishing
1. Assemble the clamp jigs for the pin journal and
main journal as shown in the following figure.

3. Insert 2 pieces of upper and lower sandpapers

2. Cut off sandpaper (#800) (a, b) to the shapes (a) or (b) in slit (e) and fix the ends with tape
shown below. (f).
q (a) is for the pin journal and its size is as
follows; 4 Fold slit portion (d) of the sandpaper along the
L: 200 mm, W:108 mm round part of the clamp.
q (b) is for the main journal and its size is as
follows. 5. Hold the journal with the clamp and fix the
L: 170 mm, W: 70 mm lever ends with rubber tube (g) etc.
a Make slits (c) 20 mm long on both sides of
the sandpaper at intervals of 10 mm and
cut off one part at each end (d).

12V140E-3 Series 33
SEN05157-00 90 Repair and replacement of parts

Clamp jig for polishing

a Make the polishing jig according to the following drawings.

Clamp jig for polishing (for pin journal)

Plate 1 (Use 2 pieces for 1 jig)

Lever 2 (Use 2 pieces for 1 jig)

34 12V140E-3 Series
90 Repair and replacement of parts SEN05157-00

Clamp jig for polishing (for main journal)

Plate 1 (Use 2 pieces for 1 jig)

Lever 2 (Use 2 pieces for 1 jig)

12V140E-3 Series 35
SEN05157-00 90 Repair and replacement of parts

KOMATSU 12V140E-3 Series engine

Form No. SEN05157-00

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (02)

36 12V140E-3 Series