SHOP MANUAL ‘SENO0321-00 ENGINE 12V140E-3 Series 50 Disassembly and assembly Disassembly and assembly, Part 1 Disassembly and assembly, Part 4 General disassembly of engine 12V140E-3 Series KOMATSU 4‘$EN00321-00 50 Disassembly and assembly Disassembly and assembly, Part 1 General disassembly 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 bank, one side alone is shown as an example. Except where otherwise specified, contents of the work shall be the same on both sides of the bank. 1. Preparation work Before disassembling the engine, check its, parts for cracking, damage, etc. and clean the entire engine carefully for accurate inspection of its parts and quick disassembly and assem- bly. % Before cleaning the engine, carefully seal or remove the openings, electric parts, and wiring connectors so that water will not enter them. Installation to engine repair stand 1) Install the engine assembly (1) to tool A. Engine assembly: ‘Approx. 3,800 kg ausos20s 2) Drain the engine coolant and engine oil * Quantity of the engine oil depends on the applicable machines. vel Engine oil: Approx. 130 ¢ 3. Engine wiring harness Disconnect the connector and terminal and then remove engine harness (1) from the engine assembly. Starting motor assembly Remove engine harness (1) and then remove starting motor assemblies (2) and (3). % Remove the assembly at the top first being followed by that atthe bottom, 5. Alternator 1) Remove auxiliary equipment belt (1). 2) Remove alternator (2). 12V140E-3 Series50 Disassembly and assembly ‘SEN00321-00 6. Fuel filter and filter head assembly, and priming pump 1) Remove fuel tubes (1) and (2). 2) Remove fuel fitter and filter head assem- bly (3). 3) Remove priming pump (4). wale a ON feedN hi 5 y 9. Air intake connector 1) Remove air intake connector (1), 7. Engine controller and controller cooler 1) Remove engine controller (1. 2) Remove fuel hoses (2) and (3). 3) Remove controller cooler (4) 10. Spill tube Remove spill tube (1). 8. Air inlet pipe 1) Remove the clamp and then remove air inlet pipe (1).. 2) Remove bracket (2) 3) Remove bracket (3) Remove bracket (3) on the right side bank alone. 11. High-pressure pipe (between supply pump = common rail) 1) Apply a marking to the installation post- tions of clamps (1) ~ (3) using paint 2) Remove bracket (4). | 3) Remove clamps (1) - (3). 4) Remove high-pressure pipes (5) and (6). 12V140E-3 Series 3‘$EN00321-00 50 Disassembly and assembly 12. High-pressure pipe (between common rail 3) Remove bracket — fuel injector) 4) Remove all clamps (2) and (3). 1) Remove bracket (1) 5) Remove 6 high-pressure pipes (4). 2) Apply a marking to every installation posi- 43. ‘Air intake manifold assembly tions of clamps (2) and (3) using paint. 1) Remove support (1). 2) Lif air intake manifold (2) temporarily and then remove the mounting bolts. 3) Liftoff air intake manifold assembly (2). 5 Air intake manifold assembly: 45 kg 4 12V140E-3 Series50 Disassembly and assembly SEN00321-00 14, Exhaust connector Remove exhaust connectors (1) and (2). 15, Turbocharger assembly 1) Remove 2 water pipes and 2 oil pipes. When the air-cooled turbocharger is used, the oil pipes alone are pro- vided 2) Lift turbocharger assembly (1) temporarily and then remove the mounting bolts, 3) Liftoff turbocharger assembly (1). Turbocharger assembly: 35 kg 12V140E-3 Series 16. Exhaust manifold assembly 1) Remove instation plates (1), muffler bracket (2), water pipes (3) and bracket 2) _Lift exhaust manifold assembly (5) ternpo- rarily and then remove the mounting bolts. 3) _Lift off exhaust manifold assembly (5). 5 Exhaust manifold assembly: 25 kg 47. Common rail 1) Remove fuel tube (1). 2) Remove common rail (2). 3) Remove bracket (3).SEN00321-00 50 Disassembly and assembly 18. Supply pump assembly 3) Remove water pump assembly (3). 1) Remove oil tube (1) 2) Remove supply pump assembly mount- ing bott (2) 3) Remove supply pump assembly (3). 43309698 Ass03604 19. Corrosion resister and filter head assembly Remove corrosion resister and filter head assembly (1). aa 4 ; 24. Oil cooler (rear side) 1) Remove oll manifold (1), 2) Remove oil cooler (2) a * Remove the oil cooler (front side) after removing the supply pump drive case, 20. Water pump assembly 1) Remove block (1) 2) Remove water connector (2) 12V140E-3 Series50 Disassembly and assembly ‘SENO0321-00 22. Plate and block 25. Head cover Remove plates (1) and (2) and block (3). Remove head cover (1) - * Repeat the same procedure on every cyl- inder up to removal of the cylinder head assembly, 7 55 23, Fuel tube 1) Remove fuel tube (1) 26. Rocker arm assembly 1) Loosen locknuts (1) and then loosen adjustment screws (2) fully. Make sure that the valve tension is not applied to the rocker arm and thus itis free to move. 2) Remove rocker arm assembly (3). + Record the parts installation positions using a tag to avoid confusion in the ’ later assembly. 94805206 24. i level gauge and oil filler tube 1) Remove bracket (1) and then remove oil filer tube (2). 2) Loosen the sleeve nut at the base and then remove oil level gauge (3). 3) Remove bracket (4). 3) Remove air intake rocker arm (4), spacer (6) and exhaust rocker arm (6) from rocker shaft (7). 12V140E-3 Series 7‘SEN00321-00 | / wn bly 4 6 7 pusos700 27. Push rod 2) Insert a small L-bar [1] under the fuel con- Remove push rod (1). ector and pry out fuel injector (2) slowly. Do not grip the solenoid valve at the top of the injector to pull off the injec- tor. C1, 28. Injector harness 41) Remove injector terminal mounting nut (1) land clamp mounting bolt (2). 2) Push connector (3) into the cylinder head 30. Crosshead and remove injector harness (4). Remove crosshead (1). 29. Fuel injector 31. Cylinder head assembly 1) Remove holder mounting bolt (1) 1) Remove the water tube. 2) Liftoff cylinder head assembly (1). 5 Cylinder head assembly: 25 kg 8 12V140E-3 Series50 Disassembly and assembly ‘SEN00321-00 %* When removing the cylinder head assembly without removing the fuel injector, be sure to prevent its interfer- ence with the floor surface since the injector tip protrudes through the bot- tom of the cylinder head. 3) Remove the cylinder head gasket. 4) Disassemble the cylinder head assembly according to the following procedure. 1] Using tool B, compress the valve spring to remove cotter (2) 2] Remove upper seat (3), outer spring (4), and inner spring (5). susossse 3] Remove lower seat (6) 4] Raise the cylinder head and remove valve (7) 12V140E-3 Series AS04101 32. Oil pan 1) Support the front and rear side of oil pan (1) with block [1]. 2) Remove all oll pan mounting botts. 3) Separate the gasket sealant, 4) Lift the engine and then remove oil pan “ ‘2 cpa: 20 kg 1S 33. Suction pie and under plate 1) _ Fix under plate (1) temporarily using sev- eral oil pan mounting bolts, 2) Remove stay (2) and then remove suctionSEN00321-00 50 Disassembly and assembly 3) Support under plate (1) using jack [1] 36. Breather 4) Remove the bolts used for temporary fix: Remove breather (1), blowby pipe (2) and ing and then lower the jack carefully to plate (3). remove under plate (1). % Remove the plate on the left bank alone, Under plate: 25 kg 37. Thermostat case 34, Relief valve 1) Remove water outlets (1). 1) Remove relief valve (1), 2) Remove thermostat case (2). Ass03710 2) Install the engine again to tool A. 3) Remove thermostat (3) from thermostat case (2). 35. Alternator bracket Remove alternator bracket (1) 3 \ AJs04045, 1050 Disassembly and assembly ‘SEN00321-00 38, Front engine hanger Remove front engine hanger (1). 39, Thermostat housing 1) Remove coolant temperature sensor (1). 2) Remove thermostat housing (2) 40. Accessory drive 1) Remove pulley (1). 2) Remove accessory drive (2). 3) Disassemble the accessory drive accord- ing to the following procedure. 1] Pull off hub (3) and then remove thrust plate (4). 12V140E-3 Series 2] Remove shaft (6), thrust plate (6) and gear (7) as a unit. 3] Remove gear (7) from shaft (5) 4] Pull off oll seal (9) and bushing (10) from housing (8). 4 94305297 41. Flywheel assembly 1) Liftand secure flywheel assembly (1) 2) Remove the mounting bol. 3) Separate the bolt from the crankshaft Using forcing screw [1]. 4) Liftoff flywheel assembly (1). (> Flywheel assembly: 130 kg 11‘SEN00321-00 issembly and assembly 42. Flywheel housing 1) Remove burring tool (1) and Ne speed sensor (2). 43, Rear oil seal Remove rear oil seal (1) from the flywheel housing. 2) Remove engine speed sensor (3). 3) Lift flywheel housing (4) temporarily and then remove the mounting bolt. 4) Lift off the flywhee! housing (4). Flywheel housing: 230 kg \ ‘4so40s2 12 44, Damper and crank pulley assembly 1) Lift damper and crank pulley assembly (1) temporarily and then remove the mounting bolts 2)__Lift off damper and crank pulley assembly (1), (5 Damper and crank pulley assem- 45. Front support Remove front support (1) using puller [1]. SS 12V140E-3 Series50 Disassembly and assembly ‘SEN00321-00 48. Gear case cover Lift off gear case cover (1). 5 Gear case cover:75 kg 49. Supply pump gear Aesotos 1) Remove the mounting nut. 2) Remove supply pump gear (1) using puller 47. Front oil seal i. Remove front oil seal (1) from the gear case Alter removing the supply pump gear, cover remove the key from the shaft and maintain so that it may not be lost. 3804060] 48. Idler gear (Large) 1) Remove plate (1). 50. Idler gear (Small) 2) Remove idler gears (large) (2) and (3). 1) Remove plate (1). 2) Remove idler gear (small) (2) 2 ia 3) Remove thrust plate (4) from the shaft. + Aindicates the oil channel. 12V140E-3 Series 13‘SEN00321-00 51. Oil pump assembly Remove oil pump assembly (1). f.s504062] 52. Supply pump drive case 4) Remove oil tube (1) Remove the oil tube on the left bank alone, 2) Remove supply pump drive case (2). & ge 53. Oil cooler (Front side) Remove oil cooler (front side) (1) 54, Cam follower assembly 1) Remove plate (1) and cam follower cover (2). 14 50 Disassembly and assembly 3) Disassemble the cam follower assembly according to the following procedure. 1] Remove snap rings (4) 2] Remove cam followers (5) from shaft (6). 3] Remove snap rings (7) from shaft (6). 55. Camshaft assembly 1) Tum cam gear (1) to remove mounting bolt (2) through lightening hole. 12V140E-3 Series50 Disassembly and assembly ‘SEN00321-00 4 Be sure to remove the piston cooling noz~ le before removing the piston connecting rod assembly When removing the nozzle, tum it 90° so that it may not hit the piston. 2) Pull off cam shaft assembly (3) along with the cam gear. Turn the cam shaft carefully when removing it so that the bushing may not be damaged. sys05208 58. Piston and connecting rod assembly 1) Prior to the removal, measure the side clearance of the connecting rod using dial gauge [1] in order to use it as a rough standard in the assembly. + Check the stamped No. of the con- necting rod cap. ¢ Make sure that the cap No. and cylinder No. are the same. ¢ The No. must be stamped on the cam side. 4 Ifthe cylinder No. is not stamped, write it using an electric pen prior to the removal (it is not accept- able to stamp the number). 56. Timing gear case 1) Lift timing gear case (1) temporarily and then remove the mounting bolt 2) _Lift off timing gear case (1) (5 Gear case cover: 55 kg ausosees 2) Rotate the crankshaft in order to drive the piston to be removed to the bottom dead center. Te cor07O1 3) Loosen connecting rod bolt (1) by 5 to 6 turns. 57. Piston cooling nozzle Remove piston cooling nozzle (1). 12V140E-3 Series 15‘SEN00321-00 50 Disassembly and assembly 94308300 "2505202 4) Hit the connecting rod head lightly using a plastic hammer to loosen the connecting rod cap and connecting rod. 5) Scrub the carbon off the top wall of the liner using fine sandpaper. 6) Turn the crankshaft until the piston comes to the top dead center and then remove the connecting rod cap (2). 7) Push in and piston and connecting rod assembly using pushing bar [1] from the oil pan side and then remove the assem- bly while supporting piston (3) from the cylinder head side. Take care not to damage the inside of the cylinder with a comer of the con- necting rod. 8) Remove other piston and connecting rod assemblies according to the above proce- dure. % Keep the sliding portion and bearing of the piston in a safe place to protect them from damage. + Assemble the connecting rod and cap temporarily and keep them along with the connecting rod bearing on a cylin- der to cylinder basis. 9) Disassemble the piston and connecting rod assembly according to the following procedure, 1] Remove snap ring (4) 2] Support connecting rod (5) with hand and then remove piston pin (6) to dis- connect piston (7) from the connect- ing rod. When the piston pin is firmly fixed and unremovable, heat it (roughly 5 minutes at 100°C) using an industrial dryer. 3] Remove the snap ring on the other side. 93808303 4] _ Using tool C, remove piston ring (8). 5] Remove oil ring expander (9) % Keep the piston, connecting rod, connecting rod bearing, piston ring, and piston pin on a cylinder to cylinder basis. 12V140E-3 Series‘50 Disassembly and assembly SENO00321-00 9308306 94805307 59. Crankshaft 1) Before removing crankshaft, measure the end play of the crankshaft using dial gauge [1] in order to use it as a rough standard in the assembly. 4) Liftoff crankshaft (4), * Use care in lifting the crankshaft so that it may not hit and get damage from the cylinder block. 5 Crankshaft: 210 kg 91908305 93805308 2) Remove mounting bolts (2) of main cap (1). 3) _ Insert the bolts in the bolt hole of the main cap (1) and remove the cap, while shaking aus0s206 * Lower thrust bearing (3) is assembled to No. 7 main cap. Record its assem- bly position after removal. 12V140E-3 Series 5) Remove upper thrust bearing (5) from No.7 journal. 6) Remove upper bearing (6). Apply marking to the assembly posi- tions of the main cap, main bearing and thrust bearing using paint or tags and then keep them on a cap to cap basis. aus0sa08 17‘SEN00321-00 50 Disassembly and assembly 60. Cylinder liner 1) Before removing cylinder liner (1), mea- sure its projection using tool D and dial gauge [1]. % Before measuring projection of the liner, tighten the liner with plate [2] so that it may not be lifted by the O-ring &> Plate mounting bolt ‘69-98 Nm {7 - 10 kgm} 84805310 2) Using tool E, remove cylinder liner (1). nM iso 18 61. Cylinder block Liftoff the cylinder block from tool A. 5 Cylinder block: 850 kg 12V140E-3 Series50 Disassembly and assembly ‘SEN00321-00 12V140E-3 Series 19SEN00321-00 50 Disassembly and assembly KOMATSU 12V140E-3 Series engine Form No. SENO0321-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 03-06 (02) 20 HOMATSU 12V140E-3 Series