SEN00322-04 50 Disassembly and Assembly

SEN00322-04 50 Disassembly and assembly
50. Exhaust connector 3) Install support (1).

Install exhaust connectors (1) and (2).
52. High-pressure pipe clamp

51. Air intake manifold assembly Install brackets (1) and (2) to the exhaust man-
1) Install the gasket. ifold and then tighten high-pressure pipe clamp
a Install the gasket setting its "UP" bolt (3).
marking upward and also directing 3 High pressure pipe clamp bolt:
this side to the intake manifold. 9.8 ± 1 Nm {1 ± 0.1 kgm}
2) Lift and install air intake manifold assem-
bly (2).
4 Intake manifold assembly: 45 kg
a Tighten the mounting bolts in the fol-

lowing order.
3 Intake manifold assembly mounting
bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
34 12V140E-3 Series
50 Disassembly and assembly SEN00322-04
53. Spill tube

Install spill tube (1).
3 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}
a Tighten mounting bolt (2) with the

specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
54. Supply pump assembly and high-pressure
pipe (between supply pump - common rail)
k Install the high-pressure pipe and
clamp paying attention to the following
points.
q It is strictly prohibited to reuse a high-
pressure pipe by modifying its bend
or using the pipe in an unintended
location.
q The clamp used must be a legitimate
one. And it must be installed in the
specified position with the specified
torque.
q After installing the high-pressure pipe
and clamp, make sure that 10 mm
m i n im u m c l e a r a n c e i s p r o v i d e d 2) After installing high-pressure pipes (4) and
(5) to supply pump (1) and common rail
between the high-pressure pipe and
(3) temporarily, tighten the sleeve nut with
adjacent harness. If the clearance is the specified torque.
less than 10 mm, adjust the harness a Control the torque by using a spanner
position to secure the space. type torque wrench (commercially
1) Install supply pump assembly (1) tempo- available part) for the tightening.
rarily. 3 High-pressure pipe sleeve nut
a Align and insert the unequal spline (supply pump side):
portion of the supply pump side to 39.2 – 49 Nm {4 – 5 kgm}
3 High-pressure pipe sleeve nut
unequal spline portion A of the supply
pump drive case side. (common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
a When it is difficult to insert the supply
3) Tighten supply pump assembly mounting
pump , turn the crankshaft to change
bolt (2).
position of unequal spline portion A.
4) Tighten the mounting bolt across the sup-
ply pump assembly bottom face and
bracket.
3 Supply pump mounting bolt (Bot-
tom side):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
5) Install oil tube (6).
3 Oil tube joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
12V140E-3 Series 35
55. Fuel pipe

1) Install priming pump (4).
a If the air bleeding plug is removed,
tighten the pump with the following
torque.
3 Air bleeding plug:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2) Install fuel pipes (1) – (3).
3 Fuel pipe joint bolt (Common rail
side):
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
3 Fuel pipe joint bolt (Supply pump
side):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
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.
a Before tightening the stay perma-
nently, deflect the rubber fist.
a Use care in the tightening so that
excessive force may not be
applied to the supply pump side
install position.
3 Top and bottom clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm} 56. Air intake connector
3] Tighten respective stays permanently. Install air intake connector (1).
7) Install the rubber cover to the sleeve nut
on the high-pressure pipe.
a Direct the slit downward when install-
ing the rubber cover.
q Supply pump side (8): Bottom
q Common rail side (9): Facing
inward (Opposed)
36 12V140E-3 Series
57. Air inlet pipe 59. Fuel filter and filter head assembly
1) Install bracket (3). 1) Install fuel filter and filter head assembly
a Install bracket (3) to the right side (3).
bank alone. 2) Install fuel tubes (1) and (2).
2) Install bracket (2). 3 Fuel tube joint bolt:
3) Install air inlet pipe (1) and then fix it with 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
the clamp.
3 Clamping nut:
29.4 – 44.1 Nm {3.0 – 4.5 kgm}
4 Air inlet pipe: 35 kg
60. Alternator
1) Install alternator (2).
2) Install auxiliary equipment belt (1).
3) Adjust tension of the auxiliary equipment
belt.
58. Engine controller and controller cooler a Adjust its deflection to 20 mm when
1) Install controller cooler (4). the pushing force of 58.8 Nm {6 kgm}
2) Install fuel hoses (2) and (3). is applied to the belt center through a
3) Install engine controller (1). finger.
3 Engine controller mounting bolt: 3 Adjuster lock bolt:
23.5 Nm {2.4 kgm} 53.9 – 122.6 Nm {5.5 – 12.5 kgm}
12V140E-3 Series 37
61. Starting motor assembly

Install staring motor assemblies (3) and (2) and
then connect wiring harness (1) to them.
a Install the top assembly first being fol-
lowed by the bottom one.
3 Starting motor B terminal nut:
19.6 – 25.5 Nm {2 – 2.6 kgm}
a 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
62. Engine wiring harness and stop it after its speed is stabilized.
Install engine wiring harness (1) on the engine 3) Check the fuel piping and devices for fuel
assembly and then connect the connector and leakage.
terminal. a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 1).
4) Run the engine at low idle.
5) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
6) Run the engine at high idle.
leakage.
63. Checking for fuel leakage a Check mainly around the high-pres-
a When removal and installation of fuel sup- sure circuit parts coated with the color
ply pump (1), common rail (2), or high- checker for fuel leakage.
pressure pipes (3) and (4) were con- a If any fuel leakage is detected, repair
ducted, check fuel leakage according to it and check again from step 1).
the following procedure after assembling 8) Run the engine at high idle and load it.
the engine. a When checking while the components
a Here, high-pressure pipes (3) and (4) to be checked are mounted on the
denote every fuel pipe (the figure shows machine, stall the torque converter or
an example). relieve the hydraulic pump.
leakage.
a Check mainly around the high-pres-
38 12V140E-3 Series

a If no fuel leakage is detected, check
is completed.
12V140E-3 Series 39
KOMATSU 12V140E-3 Series engine

Form No. SEN00322-04
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 12-11
40 12V140E-3 Series
SEN00876-03
ENGINE 1SHOP MANUAL
12V140E-3 Series
50 Disassembly and assembly

Disassembly and assembly, Part 3
Removal and installation fuel supply pump unit .............................................................................................. 2
Removal and installation oil seal unit .............................................................................................................. 5
12V140E-3 Series 1
Removal and installation fuel

supply pump unit 1
a Figure shows an example of the left side bank.
Except where otherwise noted, the same work
procedure shall be employed for the both
banks.
Removal
1. Remove the connectors (in 3 places).
2. Remove fuel return hose (3) between common
rail (1) and supply pump (2). [*1]
a A fuel return pipe is provided on the right
side bank. Since it does not allow removal
halfway, the whole set of the pipe must be 6. Remove oil tube (9) between supply pump (2)
removed. and the cylinder block. [*4]
7. Disconnect fuel tube (10) between the fuel fil-
ter and supply pump (2) from the supply pump
side. [*5]
3. Remove fuel tube (5) between priming pump

(4) and supply pump (2). [*2]
4. Remove fuel tube and hose assembly (7)
between supply pump (2) and controller cooler 8. Remove supply pump mounting bracket (11).
(6). [*6]
5. Remove 2 high-pressure pipes (8) between

supply pump (2) and common rail (1). [*3]
2 12V140E-3 Series
9. Remove 4 mounting bolts (12) and then Installation

remove supply pump assembly (2). [*7] q Carry out installation in the reverse order to
removal.
[*1]
3 Fuel return hose (3) joint bolt (Common rail
side): 17.7 – 22.6 Nm {1.8 – 2.3 kgm}
[*2]
3 Fuel tube (5) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*3], [*7]
Install the supply pump and high-pressure pipe by
finalizing their position the following procedure.
1) Install supply pump assembly (2) tempo-
10. Remove nut (12), coupling (13) and key (14) rarily.
from supply pump assembly (2). [*8] a Align the unequal spline portion of the
supply pump side to unequal spline
portion A of the supply pump drive
case side and then insert the supply
pump..
a When it is difficult to insert the supply
pump , turn the crankshaft to change
position of unequal spline portion A.
a Tighten mounting bolt (12) with the

specified torque after tightening the
sleeve nut of the high-pressure pipe
(between supply pump and common
rail).
2 Supply pump assembly mounting
bolt: Adhesive (LT-2)
12V140E-3 Series 3
2) After installing high-pressure pipes (8) on

supply pump (2) and common rail (1) tem-
porarily, tighten the sleeve nut with the
specified torque.
a Use a spanner type torque wrench
(commercially available part) should
be used for the tightening to ensure
observance of the specified torque.
(Supply pump side):
39.2 – 49 Nm {4 – 5 kgm}
(Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
3) Install the clamp of the high-pressure pipe
1] Manually tighten and install tempo-
rarily the stay and top and bottom
clamps of the high-pressure pipe.
2] Tighten the top and bottom clamps
permanently.
a Before tightening the stay perma-
nently, deflect the rubber fist.
a Take care in the tightening so
that excessive force may not be
applied to the supply pump side
install position.
3 Top and bottom clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
3] Tighten respective stays permanently.
4) Install the rubber cover to the sleeve nut
on the high-pressure pipe.
a Direct the slit downward when install-
ing the rubber cover.
q Supply pump side: Bottom side
q Common rail side:
Faced inward (Opposed)
[*4]
3 Oil tube (9) joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*5]
3 Fuel tube (10) joint bolt:
24.5 – 34.3 Nm {2.5 -– 3.5 kgm}
[*6]
3 Supply pump mounting bolt (Pump bottom
side): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*8]
3 Nut (12):
176 – 196 Nm {18 – 20 kgm}
4 12V140E-3 Series
Removal and installation oil seal a CS: Crankshaft

unit 1
Rear oil seal
a For the work up to removal of the flywheel, see
the shop manual for the applicable machine.
1. Remove rear seal (3).
a Take care in the removal not to damage

the seal installation position on the fly-
wheel housing and the seal contact face
on the crankshaft.
a Before removing, slightly drive the seal in
once to free it from fixation.
1) Replace the tip of tool N with the hook
type one.
2) Hitch the hook to the hoop of rear
seal (3).
3) Remove rear seal with impact of slide
hammer (SH).
q Tool N
12V140E-3 Series 5
Installation
1. Clean, degrease and then dry the contact sur-
face between the flywheel housing and rear
seal.
2. Using a clean cloth, remove foreign matter

deposited on the crankshaft flange.
a Clean foreign matter deposited on the seal
lip surface (surface around the crankshaft)
and then degrease and dry the surface.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.
3. When installing rear oil seal (3), do not apply

oil or grease to the shaft and seal lip. Wipe off
the oil from the shaft.
1) The surface having the parts number (PN)
marking must face to the outside of
engine.
2) Using the K (push tool), press oil seal (3)

in the flywheel housing until it becomes
the dimension (a) or (b) as shown in the
figure.
a Oil seal press fit dimensions
(a): 5 mm (from flywheel housing
end surface)
q Carry out the following work in the shop

manual of the applicable machine.
6 12V140E-3 Series
Removal (PC2000-8) Installation

a For the work up to removal of the flywheel, see a Check the Teflon seal (Laydown lip seal) by
the shop manual for the applicable machine. checking the wear of the shaft and replace it
with the “Standard seal”.
1. Remove rear seal (2).
a Take care in the removal not to damage
the seal installation position on the fly-
wheel housing and the seal contact face
on the crankshaft.
a Before removing, slightly drive the seal in
once to free it from fixation.
a When rear seal (2) is fixed too hard to the
flywheel housing (FWH), carry out the fol-
lowing procedure.
1) Replace the tip of tool N with the drill
type one.
2) Drill through a hole of approx. 3 mm
dia. on rear seal (2).
3) Insert the top end of tool N into the a Clean, degrease and then dry the contact
drilled hole, and remove the rear seal surface between the flywheel housing and
by the impact of slide hammer (SH). rear seal.
(Apply the slide hammer evenly not to a Clean foreign matter deposited on the seal
tilt the rear seal.) lip surface (surface around the crankshaft)
a Remove the metal powders completely. and then degrease and dry the surface.
a Take care not to damage crankshaft (4). a Check the crankshaft end face corner and
q Tool A3
12V140E-3 Series 7
1. Installation procedure of standard seal 4) Apply rear seal (2) on the end of crank-
a Do not apply any grease, oil and others to shaft (4).
the seal lip surface (a). a Install the rear seal in the correct
a Never remove inside plastic cylinder (3) of direction.
the standard spare seal before installing 5) Manually push the metal ring of rear seal
the seal. (2) evenly, and insert in its position.
6) Using the tool K, further press and insert
rear seal (2) evenly.
1) Set the large inside diameter side (b) of

plastic inside cylinder (3) to the end of
crankshaft (4). 7) Using the tool K, press rear seal (2) by
a Extremely take care not to mistake tightening bolts equally.
the direction of the plastic inside cylin- a Press rear seal (2) until tool K
der. reaches crankshaft (4).
q Press fit method of oil seal (from
flywheel housing end surface)
(a): 13.5 mm
q Press fit method of oil seal (from
crankshaft end surface)
(b): 25.7 mm
a After having pressed the rear seal,
remove the red sealant form outer
edge.
2) Hold the metal ring of rear oil seal (1) with

both hands and push it in firmly.
3) After pushing in the rear oil seal, remove
plastic inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
q Carry out the following work in the shop man-

ual of the applicable machine.
8 12V140E-3 Series
Front oil seal Installation

1. Clean, degrease and then dry the contact sur-
Removal face between the front cover and front seal.
a For the work up to removal of the damper, see
the shop manual for the applicable machine. 2. Using a clean cloth, remove foreign matter
1. Remove front oil seal (1) according to the fol- deposited on the crankshaft flange.
lowing procedures. a Clean foreign matter deposited on the seal
lip surface (surface around the crankshaft)
and then degrease and dry the surface.
a Check the crankshaft end face corner and
3. When installing front oil seal (2), do not apply

oil or grease to the shaft and seal lip. Wipe off
the oil from the shaft.
2 Inner circumference of front oil seal:
Gasket sealant (LG-7 or equivalent)
1) The surface having the parts number (PN)
marking must face to the outside of
engine.
1) Replace the tip of tool N with the hook
type one.
2) Hitch the hook to the hoop of front seal
(2).
3) Remove front seal with impact of slide
hammer (SH).
q Tool A3
2) Tighten nuts [1] using the tool J (plate),

and press oil seal (8) to the crank shaft
end surface.
a CS: Crankshaft
12V140E-3 Series 9
3) Tighten nuts [1] using the tool J (push

tool), press oil seal (8) in the front case
until it becomes the dimension (a) as
shown in the figure.
a Oil seal press fit dimensions
(a): 17 mm (from crank shaft end sur-
face)
(b): 25.1 mm (from front cover end
surface)
q Carry out the following work in the shop man-

ual of the applicable machine.
12V140E-3 Series 10
12V140E-3 Series 11

© 2011 KOMATSU
All Rights Reserved
12 12V140E-3 Series
SEN05155-00
ENGINE 1SHOP MANUAL

2
3
12V140E-3 Series
90 Repair and replacement of

parts 1
Information related to repair and
replacement
Flowchart ........................................................................................................................................................ 2
Special tool table............................................................................................................................................. 4
12V140E-3 Series 1
SEN05155-00 90 Repair and replacement of parts
Flowchart 1
Repair of cylinder block top and counterbore by grinding
a For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
a If the judgment of No. 9 is NO, examine A. If the result is NO again, examine B.
2 12V140E-3 Series
90 Repair and replacement of parts SEN05155-00
12V140E-3 Series 3
Special tool table 1

Sym-
Replacement/Repair item Part No. Part name Q'ty Remarks
bol
A 795-611-1300 Coolant tester 1 KIT
Pressure test of cylinder head
B 79A-471-1050 Pump assembly 1
1 795-100-1522 Push tool 1
Replacement of valve guide C
2 795-411-1310 Push tool 1
D 795-100-4801 Seat puller 1 For valve seat insert
1 790-101-5001 Push tool kit 1 KIT
E 2 790-101-5081 Plate 1 For intake valve
3 790-101-5071 Plate 1 For exhaust valve
795-100-3005 Seat cutter 1 KIT
795-100-3100 Body assembly 1
795-100-3200 Micrometer 1
1
795-100-3300 Gauge 1
Replacement of valve seat
795-100-3401 Tool head 1
insert
795-100-3601 Head support 1
F 2 795-100-3710 Cutter 1 For oversize machining
3 795-100-3720 Cutter 1 For 30°
4 795-100-3730 Cutter 1 For 45°
795-100-4211 Pilot 1 ø10.000 mm
795-100-4221 Pilot 1 ø10.010 mm
5
795-100-4231 Pilot 1 ø10.020 mm
795-100-4241 Pilot 1 ø10.030 mm
Replacement of crosshead 1 795-140-6410 Guide puller 1

G
guide 2 795-130-1310 Guide driver 1
Commercially
Repair of valve by grinding H Valve refacer 1
available
Check of main bearing mount- Commercially
J Alignment bar 1
ing hole inside diameter available
Replacement of crankshaft 1 790-101-2800 Bearing puller 1

K
gear 2 790-101-2300 Push puller 1
L 795-240-6401 Push tool 1 KIT
1 795-240-6411 Push tool 1
Replacement of connecting
2 795-240-6420 Push tool 1
rod small end bushing L
3 795-240-6431 Block 1
4 795-240-6440 Nut 1
M 795-213-1200 Push tool 1 KIT
1 795-213-1250 Bar 1
2 795-213-1210 Push tool 1
Replacement of cam bushing
M 3 795-213-1240 Collar 1
4 795-213-1230 Guide 1
5 792-103-0400 Grip 1
4 12V140E-3 Series
Sym-
Replacement/Repair item Part No. Part name Q'ty Remarks
bol
1 79A-513-1710 Basic machine 1
2 79A-513-1780 Guide plate 1
3 79A-513-1820 Cutter plate 1
4 79A-513-1860 Cutter 1
5 79A-513-1940 Cutter set gauge 1
6 79A-513-1950 Micrometer 1
7 79A-513-1960 Driver plate 1
8 79A-513-2090 Driver shaft 1
9 79A-513-2110 Driver handle 1
10 79A-513-2120 Service package 1
Repair of counterbore portion N
11 79A-513-2130 Case 1
12 79A-513-2140 Basic machine 1
13 79A-513-2160 Cutter plate 1
14 79A-513-2230 Cutter 1
15 79A-513-2240 Remover pin 1
16 79A-513-2250 Case 1
17 79A-513-2260 Service package 1
18 79A-513-2270 Compound 1 LOCTITE
19 79A-513-2280 Primer 1 LOCTITE
20 79A-513-2320 Bushing 12
12V140E-3 Series 5

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (02)
6 12V140E-3 Series
SEN05156-01
ENGINE 1SHOP MANUAL

2
3
12V140E-3 Series

parts 1
Parts related to cylinder head
Part names related to cylinder head ............................................................................................................... 2
Testing and inspection of cylinder head .......................................................................................................... 3
Pressure test of cylinder head ........................................................................................................................ 5
Replacement of valve guide............................................................................................................................ 5
Replacement of valve seat insert.................................................................................................................... 6
Replacement of crosshead guide ................................................................................................................. 13
Repair of cylinder head mounting face by grinding ....................................................................................... 14
Repair of valve by grinding ........................................................................................................................... 15
12V140E-3 Series 1
Part names related to cylinder head 1
1. Cylinder head
2. Crosshead guide
3. Valve guide
4. Valve seat insert (intake side)
5. Valve (intake valve)
6. Valve (exhaust valve)
7. Valve seat insert (exhaust side)
2 12V140E-3 Series
Testing and inspection of cylinder head 1

Unit: mm
Inspection item Criteria Remedy
• Presence of crack (External dye check)
• Presence of water leakage during air pressure test (0.29 – Repair by welding or
Water leakage from and crack
0.34 MPa {3.0 – 3.5 kg/cm2}, 30 sec) replace cylinder
of cylinder head
• Water pressure test (0.34 – 0.39 MPa {3.5 – 4.0 kg/cm2}, 10 head
min)
Tolerance Repair limit Repair by grinding or
Distortion of cylinder head top
replace cylinder
and bottom 0 – 0.06 0.09 head
Replace copper gas-
a See Fig. A
Projection of injector nozzle ket, injector or cylin-
Allowable range of projection (a): 2.3 – 2.9
der head
• Presence of dent on valve seat insert contact surface Repair valve seat
Damage of valve contact sur-
• Check of valve seat insert contact surface insert contact sur-
face of valve seat insert or
• Airtightness test face or replace valve
looseness of valve seat insert
• Hit cylinder head lightly to check for looseness seat insert
a See Fig. B
Valve sinking quantity (both Sink (b) Replace valve or
intake and exhaust valves) Standard value Repair limit valve seat insert
0 ± 0.1 0.7
a See Fig. C
Valve head thickness (d)
Valve Standard value Repair limit
Intake 2.4 1.9
Valve head thickness
Exhaust 2.15 1.6
Valve seat contact surface angle (c)
Intake valve: 30° Replace valve
Exhaust valve: 45°
• Deformation of head into dish shape
• Presence of crack or dent on seat contact surface of valve
• Airtightness test
Abnormality in valve
• Play when new cotter pin is inserted in cotter groove
• Uneven wear or bend of valve stem
• Presence of dent at valve stem end Repair valve stem
Valve Standard size Standard value Repair limit
Outside diameter of valve stem Intake 10 9.940 – 9.955 — Replace valve
Exhaust 10 9.911 – 9.926 —
Valve Standard size Standard value Repair limit
Inside diameter of valve guide Intake 10 9.989 – 10.011 —
Exhaust 10 9.989 – 10.011 — Replace valve guide
a See Fig. D
Projection of valve guide
Allowable range of projection (e): 22 ± 0.2
Outside diameter of cross- Standard size Standard value Repair limit Replace crosshead
head guide 11 11.000 – 11.011 10.95 guide
a See Fig. E Repair crosshead
Projection of crosshead guide
Allowable range of projection (f): 49 ± 0.25 guide
12V140E-3 Series 3
Illustrations related to testing and inspection table
Fig. A Fig. D
a: Projection e: Projection
1. Injector
2. Copper gasket Fig. E
3. Cylinder head
Fig. B
f: Projection
1. Crosshead guide
2. Cylinder head
b: Sink
Fig. C
c: Valve seat contact surface angle

d: Valve head thickness
4 12V140E-3 Series
Pressure test of cylinder head 1 Replacement of valve guide 1

a Pressure test tools a Valve guide replacement tools
Symbol Part No. Part name Symbol Part No. Part name
A 790-553-1601 Coolant tester 1 795-100-1522 Push tool
C
B 79A-471-1050 Pump assembly 2 795-411-1310 Push tool
Pulling out of valve guide

q Using tool C1, pull out the valve guide.
q If the cylinder head parts were repaired, per-

form the test according to the following proce-
dure.
Press fitting of valve guide
1. Machine the valve guide hole of the cylinder
Water pressure test head to the dimension below.
1. Combine tools A and B and connect the hose q Inside diameter: 17(+0.011/0) mm
to the cylinder head.
2. Press fit the valve guide until the tool C2 end
2. Apply water pressure (0.34 – 0.39 MPa {3.5 – touches the cylinder head.
4.0 kg/cm2}) for about 10 minutes and check
around the cylinder head for leakage. 3. Check that the projection of the valve guide is
within the standard value.
a Warm the whole cylinder head and then per- a Projection tolerance of valve guide:
form the test with hot water at 80 – 95 °C. 22 ± 0.2 mm
k Pay fully attention to handling the cylinder
head and water whose temperature are
high, and take care not to get burnt.
Air pressure test

1. Connect the air compressor hose to the cylin-
der head.
2. Put the cylinder head in a water tub, apply air

pressure (0.29 – 0.34 MPa {3.0 – 3.5 kg/cm2}
for about 30 seconds, and check for air leak-
age.
a If any crack is detected in the cylinder head by

the above tests, replace the cylinder head.
12V140E-3 Series 5
Replacement of valve seat insert 1

a Valve seat insert replacement tools
Symbol Part No. Part name
D 795-100-4801 Seat puller
1 790-101-5001 Push tool kit
E 2 790-101-5081 Plate
3 790-101-5071 Plate
1 795-100-3005 Seat cutter
2 795-100-3710 Cutter
F 3 795-100-3720 Cutter
4 795-100-3730 Cutter
5 795-100-4211 Pilot
Pulling out of valve seat insert
k Keep the air pressure at 0.5 – 0.6 MPa {5 – 6

kg/cm2} during the work.
k When replacing the grinding stone, stop
the air.
k Before starting the grinding work, perform
a trial operation of the grinder for 1 minute
and ensure that the grinder is normal.
a After replacing the grinding stone, perform
a trial operation for 3 minutes.
k Ensure that the grinding stone is free from
damage and install it to the grinder shaft
with no play.
k When using the grinder, put on safety
glasses.
When pulling out with seat puller of tool D

1. Install grinding stone (4) to grinder (1).
2. While matching the groove of sleeve (2), insert

the grinder in holder (3).
(Adjust the grinder position with set screw (5).)
3. Adjust the position of grinder (1) so that the

center of grinding stone (4) will be at the center
of valve seat insert (a) and then tighten set
screw (5) to fix grinder (1).
4. Rotate grinding stone (4) and move it slowly

until it touches valve seat insert (a).
5. While lightly pressing grinding stone (4)

against the inside surface of valve seat insert
(a), make a groove about 1 mm deep all
around the inside surface of valve seat insert
(a).
6 12V140E-3 Series
6. Push in 3 claws (10) of puller head (9) of tool D When pulling out valve seat insert (a) by weld-
with the hand and put them in valve seat insert ing a bar to it
(a). 1. Weld bar (b) (Length: 0.1 – 0.5 mm shorter
than valve seat inside diameter, Diameter:
7. Tighten screw (12) to press 3 claws (10) Approx. 10 mm) to the inside of valve seat
against the inside groove of valve seat insert insert (a).
(a). a Take care that welding spatters will not
a If screw (12) is tightened too strongly, the stick to the head.
insert will be broken and become difficult
to pull out. Accordingly, stop tightening 2. After the temperature of the welded parts has
when 3 claws (10) reach the groove fully. decreased to around the ambient temperature,
insert an unnecessary valve (c) in the reverse
8. Put bridge (8) in the outside of puller head (9), direction and hit its head with a small hammer
place plates (11) and (7) on the bridge, and to pull out valve seat insert (a).
tighten nut (6) to pull out valve seat insert (a). a If a large impact is given, the welded parts
may come off. Take care.
12V140E-3 Series 7
Press fitting of valve seat insert
When press fitting hole for valve seat insert (a)

is not repaired by cutting
1. Using tools E1 and E2 or tools E1 and E3,
press fit standard valve seat insert (a) with
press (d).
a Do not press fit with a hammer.
a Press fitting force of valve seat insert (a)
Intake side:
Approx. 14.7 kN {Approx. 1.5 ton}
Exhaust side:
Approx. 14.7 kN {Approx. 1.5 ton}
2. Measure sinking quantity (f) of valve seat

insert (a) from cylinder head bottom (e).
a Sinking quantity (f) of valve seat insert (a)
Intake side: 2.2 mm
Exhaust side: 2.4 mm
8 12V140E-3 Series
12V140E-3 Series 9
Oversize machining of valve seat insert

mounting hole
q Using tool F1 and attached cutter F2, increase
the valve seat insert mounting hole to the next
oversize.
a Limit the increase of the mounting hole diame-

ter to 1.0 mm. If the hole diameter needs to be
increased more than 1.0 mm, replace the cylin-
der head.
Machining dimensions of valve seat insert and mounting hole

Intake valve side
Unit: mm
Valve seat insert Valve seat insert mounting hole
Valve seat insert size
d1 c1 d2 d3 c2
Standard +0.111 –0 +0.019 58.00 ± 0.2 –0
55.0 +0.086 8.8 –0.1 55.0 +0 11 –0.1
0.25 OS +0.111 –0 +0.019 58.25 ± 0.2 –0

55.25 +0.086 8.8 –0.1 55.25 +0 11 –0.1
0.50 OS +0.111 –0 +0.019 58.50 ± 0.2 –0

55.5 +0.086 8.92 –0.1 55.5 +0 11.12 –0.1
0.75 OS +0.111 –0 +0.019 58.75 ± 0.2 –0

55.75 +0.086 9.05 –0.1 55.75 +0 11.25 –0.1
1.00 OS +0.111 –0 +0.019 59.00 ± 0.2 –0

56.0 +0.086 9.18 –0.1 56.0 +0 11.38 –0.1
a OS: Oversize
Exhaust valve side

Unit: mm
Valve seat insert Valve seat insert mounting hole
Valve seat insert size
d1 c1 d2 d3 c2
Standard +0.080 –0 +0.019 55.00 ± 0.2 –0
52.0 +0.070 8.6 –0.1 52.0 +0 11 –0.1
0.25 OS +0.080 –0 +0.019 55.25 ± 0.2 –0

52.25 +0.070 8.6 –0.1 52.25 +0 11 –0.1
0.50 OS +0.080 –0 +0.019 55.50 ± 0.2 –0

52.5 +0.070 8.72 –0.1 52.5 +0 11.12 –0.1
0.75 OS +0.080 –0 +0.019 55.75 ± 0.2 –0

52.75 +0.070 8.85 –0.1 52.75 +0 11.25 –0.1
1.00 OS +0.080 –0 +0.019 56.00 ± 0.2 –0

53.0 +0.070 8.98 –0.1 53.0 +0 11.38 –0.1
a OS: Oversize
10 12V140E-3 Series
Valve seat insert Finish machining of valve contact sur-

face of valve seat insert
1. Using tool F1 and attached cutters F3 and F4,
machine the valve contact surface of the valve
seat insert to the following dimensions.
a Select tool F5 which will be inserted in the
valve guide with no clearance.
Valve seat insert mounting hole
g: Cylinder head bottom
a Inside finished surface roughness: Max. 12.5 S

a Mounting hole bottom surface roughness:
Max. 12.5 S
a Concentricity of valve guide hole and valve EV: Exhaust valve
seat insert hole: Max. 0.07 mm (TIR) IV: Intake valve
a Squareness of valve guide hole to valve seat h: Finish machining width
insert hole bottom: Max. 0.03 mm (TIR)
a TIR is an abbreviation for Total Indicator Read-
ing, which is the difference between the maxi-
mum and minimum readings in runout.
measurement.
12V140E-3 Series 11
2. Fit the contact surface of the valve seat insert Final inspection
to the valve by using compound. q Thinly apply red lead to the valve seat insert
1) Thinly apply rough compound mixed with contact surface of a new valve and insert that
oil to the seat surface of a valve and insert valve in the valve guide.
that valve in the valve guide. q Lightly press the valve against the valve seat
2) Install the fitting rod to the valve head and insert and rotate it 10°.
lightly hit valve against the valve seat q Check the valve seat insert contact surface of
while rotating it with both hands to fit the it the valve and ensure that the contact is even
to the valve seat. and is not broken.
3) After the valve and valve seat are fitted q Or , make marks (m) (about 20 places) on the
and their surfaces become smooth, wipe valve seat insert contact surface of a new
off the compound. valve with a pencil and insert that valve in the
4) Apply fine compound and fit the valve and valve guide.
valve seat again similarly to the above q Lightly press the valve against the valve seat
until they are fitted to each other without insert and rotate it 10°.
breakage. q Ensure that all the pencil marks (m) have been
erased evenly.
When master valve is used
EV: Exhaust valve

IV: Intake valve
j: Cylinder head bottom
k: Contact width against valve
a Concentricity of contact surfaces of valve

guide and valve seat insert: Max. 0.07 mm
(TIR)
m u m an d m i n i m u m r e a d i n g s i n r u n o u t .
measurement.
12 12V140E-3 Series
Replacement of crosshead guide1 Press fitting of crosshead guide

q Using tool G2, insert crosshead guide (a) in
a Crosshead guide replacement tools cylinder head (b) and press fit it with a copper
Symbol Part No. Part name or plastic hammer until the projection is within
the tolerance.
1 795-140-6410 Guide puller
G a Projection tolerance of crosshead guide:
2 795-130-1310 Guide driver 49 ± 0.25 mm
a Diameter of cylinder head crosshead guide hoe:
Pulling out of crosshead guide ø11 –0.027/–0.054 mm
q Using tool G1, pull out crosshead guide (a)
from cylinder head (b).
1. Hold crosshead guide (a) with collet (4) of the
puller.
2. Tighten collet (4) with bolt (1) to lock sleeve

(2).
3. Rotate nut (3) and pull out the crosshead

guide.
4. Remove burrs and fins from and clean the

crosshead guide mounting portion.
12V140E-3 Series 13
Repair of cylinder head mounting

face by grinding 1
Grinding
1. Remove the valve seat insert.
q For the removal procedure, see "Replace-
ment of valve seat insert".
2. Remove the distortion and corrosion of the cyl-

inder head by grinding within the tolerance of
cylinder head height (a).
q Stamp "R" on the left side of the cylinder
head.
a Standard cylinder head height (a):

140 ± 0.05 mm
a Limit after grinding: 139.65 mm
a Grinding depth by 1 grinding: 0.10 – 0.15 mm
a Ground surface roughness: Max. 8S
a Flatness (Distortion): Max. 0.05 mm
a Grinding depth limit: 0.3 mm
a Difference in head height (a) for 1 unit:
Max. 0.15 mm
3. Press fit the valve seat insert of the next over-

size.
q For the press fitting procedure, see
"Replacement of valve seat insert".
Check after repair by grinding

q Measure the sinking quantity of the valve and
projection of the injector and ensure that they
are within the standard values and then adjust
if necessary.
a Valve sinking quantity Standard: 0 ± 0.1 mm
14 12V140E-3 Series
Repair of valve by grinding 1 a Apply dial gauge (1) to the facial runout mea-
suring point of seat contact surface (c) of the
a Valve grinding tool valve and rotate the valve to measure its facial
Symbol Part No. Part name runout while pressing it toward left (d).
Intake valve: Max. 0.045 mm (TIR)
Commercially
H Valve refacer Exhaust valve: Max. 0.030 mm (TIR)
available
Grinding of seat contact surface of mum and minimum readings in runout.
valve measurement.
q Using tool H, grind the seat contact surface of
the valve.
e: Block
a Seat contact surface angle of valve (a) a Check the contact of the seat contact surface
Intake valve: 30° ± 0°15' of the valve by either of the following methods.
Exhaust valve: 45° ± 0°15' q Thinly apply red lead to the seat contact sur-
face of the ground valve and insert that valve
in the valve guide.
Check after grinding q Lightly press the valve against the valve seat
q Measure the valve head thickness, sinking insert and rotate it 10°.
quantity of the valve, and contact of the seat q Check the valve seat insert contact surface of
contact surface of the valve, and ensure that the valve and ensure that the contact is even
they are within the standard values. and is not broken.
a Allowable limit of valve head thickness (b) q Make marks (f) (about 20 places) on the seat
Intake valve: contact surface of the ground valve with a pen-
Min. 1.9 mm (Standard size: 2.4 mm) cil and insert that valve in the valve guide.
Exhaust valve: q Lightly press the valve against the valve seat
Min. 1.6 mm (Standard size: 2.15 mm) insert and rotate it 10°.
a Valve sinking quantity Standard: 0 ± 0.1 mm q Ensure that all the pencil marks (f) have been
Allowable limit: 0.7 mm erased evenly.
12V140E-3 Series 15

© 2010 KOMATSU
All Rights Reserved
16 12V140E-3 Series
SEN05157-00
ENGINE 1SHOP MANUAL

2
3
12V140E-3 Series

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
12V140E-3 Series 1
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
2 12V140E-3 Series
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
12V140E-3 Series 3
Testing and inspection of cylinder block 1

Unit: mm
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
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
170.200 – Repair cylinder block
Upper section 170.2 — and sleeve
170.263
161.170 –
Lower section 161.2 —
161.230
4 12V140E-3 Series
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
12V140E-3 Series 5
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.
6 12V140E-3 Series
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)
12V140E-3 Series 7
Testing and inspection of crankshaft 1

Unit: mm
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
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
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
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
8 12V140E-3 Series
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
12V140E-3 Series 9
Testing and inspection of connecting rod 1

Unit: mm
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.)
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.
10 12V140E-3 Series
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
12V140E-3 Series 11
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.

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.

a Gear shrink fit temperature: 200 °C
12 12V140E-3 Series
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.

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.

a Gear shrink fit temperature: 220 – 240 °C
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.
12V140E-3 Series 13
Replacement of main bearing 4. Apply dial gauges to the inside of the 2 main
bearing metal caps at the longest pitch among
metal cap 1 the caps to be used to center the arbor of the
a When replacing the main bearing metal cap, boring machine.
work on the semi-finished cap according to the
following procedure and install it. 5. While checking the inside diameter of main
bearing metal cap (1), cut little by little.
Repair parts a Cut to the degree that the boring bar tool
almost touches the inside of cylinder block
Part No. Part name
(2).
6215-99-4160 No. 1, 2, 3, 5, 6 main bearing metal cap a Inside diameter of main bearing metal cap
6215-99-4170 No. 4 main bearing metal cap q Machining dimension
6215-99-4180 No. 7 main bearing metal cap Tolerance: 157 +0.025/0 mm
q After machining, remove the main bearing
Inside machining of main bearing metal cap metal cap, assemble it again, and check
1. Remove the cylinder liner. its inside diameter.
Tolerance: 157 +0.025/–0.010 mm
2. Install the replacement main bearing metal cap (Range to upper and lower 10° from mat-
to the cylinder block and tighten it to the speci- ing face of main bearing metal cap)
fied torque. a Finished surface roughness: Max. 10 S
a Match the notches of the cylinder block a Do not cut the inside surface of the cylin-
and main bearing metal cap to each other. der block.
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:
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.
14 12V140E-3 Series
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
12V140E-3 Series 15
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.
16 12V140E-3 Series
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
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
12V140E-3 Series 17
Installation 3. Press fitting of No. 1 and No. 7 bushings

a Cam bushing installation drawing 1) Install bar (1), push tool (2) and collar (3)
a Press fit the cam bushing, while checking its to the bushing.
direction so that its mating part will be on the 2) Press fit the bushing until the oil holes of
upper side of its center after installed. 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.
1. Press fitting of No. 3, No. 4 and No. 5 bushings

1) Install bar (1), push tool (2), collar (3) and 4. Measurement after bushing is press fitted
guide (4) to the bushing. 1) Using dial inside gauge (a), measure the
2) Press fit the bushing until the oil holes of inside diameter of the bushing.
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) Measure the clearance between the bush-

ing and shaft. If it is out of the allowable
2. Press fitting of No. 2 and No. 6 bushings range or the shaft does not go through
1) Install bar (1), push tool (2), collar (3) and smoothly, repair the inside of the bushing
guide (4) to the bushing. with a reamer.
2) Press fit the bushing until the oil holes of a After repairing the inside of the bush-
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 ing with a reamer, remove all the
matched to each other. 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
18 12V140E-3 Series
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-
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
12V140E-3 Series 19
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
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
20 12V140E-3 Series
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
12V140E-3 Series 21
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)
22 12V140E-3 Series
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)
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. Set the cylinder liner to the cylinder block,
At this time, apply a little amount of rubber install the used head gasket, and tighten the
lubricant (RF-1) to cylinder block contact sur- cylinder head temporarily.
face (d) of the O-ring and seal of the cylinder At this time, tighten the bolts in the following
liner. order.
a Apply the engine oil just before press fit- 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
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
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
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
Pin journal portion 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 The outside surface roughness of the pin jour- q After repairing by grinding, check that there is
nal and main journal must be maximum of 0.8 no grinding seizure mark by etching inspection.
S. q If any seizure mark is detected, grind about
0.02 mm again to the next undersize dimen-
Equipment necessary for grinding sion.
q After checking, neutralize and clean the
q Magnaflux inspection machine checked surface and apply rust preventive oil.
q Shore hardness tester
q Etching kit Magnaflux inspection
q Crankshaft grinding machine q Before using the repaired crankshaft, check it
q Crankshaft grinding polishing machine by magnaflux inspection to ensure that it has
q Surface roughness gauge no crack.
q Fillet R gauge 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.
12V140E-3 Series 27
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. q M: Main journal
a Stamp undersize dimension (a) on the ground q P: Crankpin journal
crankshaft as shown in the figure to prevent
installation of bearing metals of a different size. 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
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
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
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
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
Surface roughness: Max. 0.8 µm
12V140E-3 Series 29
Grinding of sides of main journal and pin jour- Work after repair by grinding
nal q Ensure again that each dimension is as speci-
q When repairing the worn surfaces of the main fied.
journal and pin journal, limit the grinding quan- q Clean each part thoroughly and apply rust-pre-
tity to the minimum. ventive oil.
q Width of crankshaft main journal q When storing the crankshaft for a long period,
#1 standard: 57 +0.1/0 mm support it on 3 points or keep it erected with a
#2, 3, 5, 6 standard: 55 +0.1/0 mm sling.
#4 standard: 59 +0.1/0 mm
#7 standard: 59 +0.05/0 mm Balancing (Reference)
q Width of crankshaft pin journal Avoid performing repair that may affect the crank-
Standard: 92 +0.054/0 mm 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)
Dressing of grinding stone
Distance between holes:
q Dress the grinding stone for each journal. Thickness must be at least 5 mm.
q Adjust the grinding stone edge to the arc of the a TIR is an abbreviation for Total Indicator Read-
fillet with the grinding stone modifying device. ing, which is the difference between the maxi-
q Test and correct the grinding stone edge by 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 .
grinding a piece of wood on trial, while check- measurement.
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 12V140E-3 Series
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

SEN00322-04 50 Disassembly and Assembly

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SEN00322-04 50 Disassembly and Assembly

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SEN00322-04 50 Disassembly and assembly

50. Exhaust connector 3) Install support (1).

52. High-pressure pipe clamp

a Tighten the mounting bolts in the fol-

53. Spill tube

a Tighten mounting bolt (2) with the

55. Fuel pipe

6) Install high-pressure pipe clamp (7)

61. Starting motor assembly

a Clean and degrease the engine and the

a If any fuel leakage is detected, repair

KOMATSU 12V140E-3 Series engine

ENGINE 1SHOP MANUAL

50 Disassembly and assembly

Removal and installation fuel

3. Remove fuel tube (5) between priming pump

5. Remove 2 high-pressure pipes (8) between

9. Remove 4 mounting bolts (12) and then Installation

a Tighten mounting bolt (12) with the

2) After installing high-pressure pipes (8) on

Removal and installation oil seal a CS: Crankshaft

1. Remove rear seal (3).

a Take care in the removal not to damage

2. Using a clean cloth, remove foreign matter

3. When installing rear oil seal (3), do not apply

2) Using the K (push tool), press oil seal (3)

q Carry out the following work in the shop

Removal (PC2000-8) Installation

1) Set the large inside diameter side (b) of

2) Hold the metal ring of rear oil seal (1) with

q Carry out the following work in the shop man-

Front oil seal Installation

3. When installing front oil seal (2), do not apply

2) Tighten nuts [1] using the tool J (plate),

3) Tighten nuts [1] using the tool J (push

q Carry out the following work in the shop man-

KOMATSU 12V140E-3 Series engine

ENGINE 1SHOP MANUAL

90 Repair and replacement of

Special tool table 1

Replacement of crosshead 1 795-140-6410 Guide puller 1

Replacement of crankshaft 1 790-101-2800 Bearing puller 1

KOMATSU 12V140E-3 Series engine

ENGINE 1SHOP MANUAL

90 Repair and replacement of

Part names related to cylinder head 1

Testing and inspection of cylinder head 1

Illustrations related to testing and inspection table

c: Valve seat contact surface angle

Pressure test of cylinder head 1 Replacement of valve guide 1

Pulling out of valve guide

q If the cylinder head parts were repaired, per-

Air pressure test

2. Put the cylinder head in a water tub, apply air

a If any crack is detected in the cylinder head by

Replacement of valve seat insert 1

Pulling out of valve seat insert

k Keep the air pressure at 0.5 – 0.6 MPa {5 – 6

When pulling out with seat puller of tool D