Komatsu 12 v140e 3 series engine service repair manual

ENGINE
SEN00291-05
12V140E-3 SERIES

12V140E-3 Series 1
SEN00294-05
ENGINE 1SHOP MANUAL
12V140E-3 Series
00 Index and foreword 1
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 3

SEN00294-05 00 Index and foreword
2 12V140E-3 Series
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
QQQQ: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00291-05
00 Index and foreword SEN00292-05
Index SEN00294-05 q
Foreword and general information SEN00296-02
01 Specification SEN00301-02
Specification and technical data SEN00303-02
10 Structure, function and maintenance standard SEN00304-02
Structure, function and maintenance standard, Part 1 SEN00307-02
20 Standard value table SEN00310-03
Standard service value table SEN00311-03
30 Testing and adjusting SEN00312-01
Testing and adjusting SEN00313-01 q
40 Troubleshooting SEN00314-01
General information on troubleshooting SEN00315-00
Troubleshooting of mechanical system (S-mode) SEN00316-00
Troubleshooting of electrical system (E-mode), Part 1 SEN00317-01 q
Troubleshooting of electrical system (E-mode), Part 2 SEN00318-01 q
50 Disassembly and assembly SEN00319-01
General information on disassembly and assembly SEN00320-01 q
Disassembly and assembly, Part 1 SEN00321-00
Disassembly and assembly, Part 2 SEN00322-01 q
Disassembly and assembly, Part 3 SEN00876-01 q

12V140E-3 Series 3
Table of contents 1
00 Index and foreword
Index SEN00294-05
Composition of shop manual................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00296-02
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00303-02
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 4
General view............................................................................................................................ 10
Weight table............................................................................................................................. 19
Engine performance curves..................................................................................................... 20
10 Structure, function and maintenance standard
Air intake and exhaust system .................................................................................................... 3
Air intake and exhaust unit ...................................................................................................... 3
Air cleaner ............................................................................................................................... 4
Turbocharger ........................................................................................................................... 6
Aftercooler ............................................................................................................................... 11
Muffler...................................................................................................................................... 12
Engine unit .................................................................................................................................. 14
Cylinder head .......................................................................................................................... 14
Cylinder block.......................................................................................................................... 18
Cylinder liner............................................................................................................................ 22
Main moving parts ................................................................................................................... 24
Crankshaft ............................................................................................................................... 26
Camshaft ................................................................................................................................. 28
Cam follower, push rod............................................................................................................ 29
Piston, piston ring, and piston pin............................................................................................ 30
Connecting rod ........................................................................................................................ 32
Flywheel and flywheel housing................................................................................................ 34
Vibration damper ..................................................................................................................... 35
Timing gear.............................................................................................................................. 36
Valve system ........................................................................................................................... 38
Valve and valve guide.............................................................................................................. 40
Rocker arm and shaft .............................................................................................................. 42
Crosshead and guide .............................................................................................................. 43
Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4

4 12V140E-3 Series
Oil pump .................................................................................................................................. 6
Oil cooler.................................................................................................................................. 7
Oil filter..................................................................................................................................... 8
Main relief valve....................................................................................................................... 9
Oil cooler bypass valve and regulator valve ............................................................................ 10
Fuel system................................................................................................................................. 12
CRI system diagram ................................................................................................................ 12
Outline of CRI system.............................................................................................................. 14
Fuel piping ............................................................................................................................... 32
Fuel filter.................................................................................................................................. 37
Priming pump........................................................................................................................... 39
Cooling system............................................................................................................................ 40
Cooling system diagram .......................................................................................................... 40
Water pump ............................................................................................................................. 42
Thermostat............................................................................................................................... 44
Corrosion resistor .................................................................................................................... 45
Cooling fan drive...................................................................................................................... 47
Electrical equipment.................................................................................................................... 50
Alternator ................................................................................................................................. 50
Starting motor .......................................................................................................................... 52
Starting aid............................................................................................................................... 54
Engine controller...................................................................................................................... 55
20 Standard value table
Standard service value table SEN00311-03
Standard service value table ....................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting................................. 2
Running-in standard and performance test standard .............................................................. 7
30 Testing and adjusting
Testing and adjusting SEN00313-01
Testing and adjusting tools list..................................................................................................... 3
Testing air boost pressure ........................................................................................................... 5
Testing exhaust temperature....................................................................................................... 6
Adjusting valve clearance............................................................................................................ 7
Testing compression pressure..................................................................................................... 9
Testing blow-by pressure............................................................................................................. 11
Measuring blow-by pressure ....................................................................................................... 12
Testing oil pressure ..................................................................................................................... 13
Handling fuel system parts .......................................................................................................... 14
Releasing residual pressure in fuel system................................................................................. 14
Testing fuel pressure ................................................................................................................... 15
Reduced cylinder mode operation............................................................................................... 16
No-injection cranking................................................................................................................... 16
Testing leakage-from pressure limiter and return rate from injector............................................ 17
Bleeding air from fuel circuit (for D475A-5) ................................................................................. 20
Bleeding air from fuel circuit (for PC2000) .................................................................................. 23
Testing fuel system for leakage................................................................................................... 25
Adjusting speed sensor............................................................................................................... 26
Testing and adjusting alternator belt tension............................................................................... 26
Handling controller high-voltage circuit ....................................................................................... 27
40 Troubleshooting
General information on troubleshooting SEN00315-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Error codes and failure codes list ............................................................................................ 3

12V140E-3 Series 5
Troubleshooting of mechanical system (S-mode) SEN00316-00
Troubleshooting of mechanical system (S-mode)....................................................................... 3
Method of using troubleshooting charts................................................................................... 3
S-1 Starting performance is poor............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operations ........................................................................................ 11
S-5 Engine does not rotate smoothly ...................................................................................... 12
S-6 Engine lacks output (or lacks power)................................................................................ 13
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16
S-9 Oil becomes contaminated quickly ................................................................................... 17
S-10 Fuel consumption is excessive ....................................................................................... 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 19
S-12 Oil pressure drops........................................................................................................... 20
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21
S-14 Coolant temperature becomes too high (overheating).................................................... 22
S-15 Abnormal noise is made ................................................................................................. 23
S-16 Vibration is excessive ..................................................................................................... 24
Troubleshooting of electrical system (E-mode), Part 1 SEN00317-01
Information in troubleshooting table ............................................................................................ 4
E-1 Code [111/CA111] ECM Critical Internal Failure (LH bank) .................................................. 6
E-2 Code [111/CB111] ECM Critical Internal Failure (RH bank).................................................. 8
E-3 Code [115/CA115] Eng. Ne and G (Bkup) Speed Sensor Error (LH bank)........................... 10
E-4 Code [115/CB115] Eng. Ne and G (Bkup) Speed Sensor Error (RH bank) .......................... 11
E-5 Code [122/CA122] Charge Air Press. Sensor High Error (LH bank only) ............................ 12
E-6 Code [123/CA123] Charge Air Press. Sensor Low Error (LH bank only) ............................. 14
E-7 Code [131/CA131] Throttle Sensor High Error (LH bank only)............................................. 16
E-8 Code [132/CA132] Throttle Sensor Low Error (LH bank only) ............................................. 18
E-9 Code [135/CA135] Oil Press. Sensor High Error (LH bank only) ......................................... 20
E-10 Code [141/CA141] Oil Press. Sensor Low Error (LH bank only)........................................ 22
E-11 Code [144/CA144] Coolant Temp. Sensor High Error (LH bank only)................................ 24
E-12 Code [145/CA145] Coolant Temp. Sensor Low Error (LH bank only) ................................ 26
E-13 Code [153/CA153] Charge Air Temp. Sensor High Error (LH bank only)........................... 28
E-14 Code [154/CA154] Charge Air Temp. Sensor Low Error (LH bank only)............................ 30
E-15 Code [187/CA187] Sensor Sup. 2 Volt. Low Error (LH bank)............................................. 31
E-16 Code [187/CB187] Sensor Sup. 2 Volt. Low Error (RH bank) ............................................ 31
E-17 Code [212/CA212] Eng. Oil Temp.Sensor High Error (LH bank only) ................................ 32
E-18 Code [213/CA213] Eng. Oil Temp.Sensor Low Error (LH bank only)................................. 34
E-19 Code [221/CA221] Ambient Air Press. Sensor High Error (LH bank only)......................... 36
E-20 Code [222/CA222] Ambient Air Press. Sensor Low Error (LH bank only).......................... 38
E-21 Code [227/CA227] Sensor Sup. 2 Volt. High Error (LH bank)............................................ 40
E-22 Code [227/CB227] Sensor Sup. 2 Volt. High Error (RH bank) ........................................... 42
E-23 Code [234/CA234] Eng. Overspeed (LH bank only)........................................................... 44
E-24 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error (LH bank)....................................... 46
E-25 Code [238/CB238] Ne Speed Sensor Sup. Volt. Error (RH bank)...................................... 48
E-26 Code [263/CA263] Fuel Temp. Sensor High Error (LH bank)............................................. 50
E-27 Code [263/CB263] Fuel Temp. Sensor High Error (RH bank)............................................ 52
E-28 Code [265/CA265] Fuel Temp. Sensor Low Error (LH bank) ............................................. 54
E-29 Code [265/CB265] Fuel Temp. Sensor Low Error (RH bank)............................................. 54
E-30 Code [271/CA271] PCV1 Short Error (LH bank) ................................................................ 56
E-31 Code [271/CB271] PCV1 Short Error (RH bank)................................................................ 58
E-32 Code [272/CA272] PCV1 Open Error (LH bank)................................................................ 60
E-33 Code [272/CB272] PCV1 Open Error (RH bank) ............................................................... 61
E-34 Code [273/CA273] PCV2 Short Error (LH bank) ................................................................ 62
E-35 Code [273/CB273] PCV2 Short Error (RH bank)................................................................ 64
E-36 Code [274/CA274] PCV2 Open Error (LH bank)................................................................ 66

6 12V140E-3 Series
E-37 Code [274/CB274] PCV2 Open Error (RH bank)................................................................ 67
E-38 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error (LH bank) .................... 68
E-44 Code [342/CA342] Caribration Code Incompatibility (LH bank) ......................................... 80
E-45 Code [342/CB342] Caribration Code Incompatibility (RH bank)......................................... 80
E-46 Code [351/CA351] INJ. Drive Circuit Error (LH bank) ........................................................ 82
E-47 Code [351/CB351] INJ. Drive Circuit Error (RH bank)........................................................ 84
E-48 Code [352/CA352] Sensor Sup. 1 Volt. Low Error (LH bank)............................................. 86
E-49 Code [352/CB352] Sensor Sup. 1 Volt. Low Error (RH bank) ............................................ 86
E-50 Code [386/CA386] Sensor Sup. 1 Volt. High Error (LH bank) ............................................ 88
E-51 Code [386/CB386] Sensor Sup. 1 Volt. High Error (RH bank)............................................ 90
E-52 Code [441/CA441] Battery Voltage Low Error (LH bank) ................................................... 92
E-53 Code [441/CB441] Battery Voltage Low Error (RH bank)................................................... 92
E-54 Code [442/CA442] Battery Voltage High Error (LH bank)................................................... 93
E-55 Code [442/CB442] Battery Voltage High Error (RH bank).................................................. 93
Troubleshooting of electrical system (E-mode), Part 2 SEN00318-01
E-56 Code [449/CA449] Rail Press. Very High Error (LH bank) ................................................. 3
E-57 Code [449/CB449] Rail Press. Very High Error (RH bank)................................................. 3
E-58 Code [451/CA451] Rail Press. Sensor High Error (LH bank) ............................................. 4
E-59 Code [451/CB451] Rail Press. Sensor High Error (RH bank)............................................. 6
E-60 Code [452/CA452] Rail Press. Sensor Low Error (LH bank).............................................. 8
E-61 Code [452/CB452] Rail Press. Sensor Low Error (RH bank) ............................................. 8
E-62 Code [553/CA553] Rail Press. High Error 1 (LH bank)....................................................... 9
E-63 Code [553/CB553] Rail Press. High Error 1 (RH bank)...................................................... 10
E-64 Code [554/CA554] Rail Press. Sensor In Range Error (LH bank)...................................... 11
E-65 Code [554/CB554] Rail Press. Sensor In Range Error (RH bank) ..................................... 11
E-66 Code [559/CA559] Rail Press. Low Error 1 (LH bank) ....................................................... 12
E-67 Code [559/CB559] Rail Press. Low Error 1 (RH bank)....................................................... 16
E-68 Code [689/CA689] Eng. Ne Speed Sensor Error (LH bank)............................................... 20
E-69 Code [689/CB689] Eng. Ne Speed Sensor Error (RH bank) .............................................. 22
E-70 Code [691/CA691] Intake Air Temp Sensor High Error (LH bank only).............................. 24
E-71 Code [692/CA692] Intake Air Temp Sensor Low Error (LH bank only)............................... 26
E-72 Code [731/CA731] Eng. G (Bkup) Speed Sensor Phase Error (LH bank).......................... 27
E-73 Code [731/CB731] Eng. G (Bkup) Speed Sensor Phase Error (RH bank) ......................... 27
E-74 Code [757/CA757] All Continuous Data Lost Error (LH bank)............................................ 28
E-75 Code [757/CB757] All Continuous Data Lost Error (RH bank) ........................................... 28
E-76 Code [778/CA778] Eng. G (Bkup) Speed Sensor Error (LH bank)..................................... 30
E-77 Code [778/CB778] Eng. G (Bkup) Speed Sensor Error (RH bank) .................................... 32
E-78 Code [781/CA781] Inter Multi-controller Communication Error (LH bank).......................... 34
E-79 Code [781/CB781] Inter Multi-controller Communication Error (RH bank)......................... 36
E-80 Code [1117/CA1117] Persistent Data Lost Error (LH bank) ................................................ 37
E-81 Code [1117/CB1117] Persistent Data Lost Error (RH bank)................................................ 37
E-82 Code [1257/CA1257] Harness Key error (LH bank) ........................................................... 38
E-83 Code [1257/CB1257] Harness Key error (RH bank)........................................................... 39
E-84 Code [1548/CB1548] Injector #7 (R/B #1) System Open/Short Error (RH bank) ............... 40
E-86 Code [1551/CB1551] Injector #10 (R/B #4) System Open/Short Error (RH bank) ............. 44
E-90 Code [1633/CA1633] KOMNET Datalink Timeout Error (LH bank) .................................... 52
E-91 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error (LH bank only)......................... 54
E-92 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error (LH bank only) ......................... 56

12V140E-3 Series 7
E-93 Code [2249/CA2249] Rail Press. Very Low Error (LH bank).............................................. 57
E-94 Code [2249/CB2249] Rail Press. Very Low Error (RH bank) ............................................. 57
E-95 Code [– –*1/–] Eng. Overheat (LH bank only).................................................................... 58
E-96 Code [– –*2/–] Eng. Oil Press. Low Speed Derate (LH bank only)..................................... 58
E-97 Code [– –*3/–] Press. Low Torque Derate (LH bank only).................................................. 59
50 Disassembly and assembly
General information on disassembly and assembly SEN00320-01
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 3
Special tools list........................................................................................................................... 6
Disassembly and assembly, Part 1 ............................................................................................. 2
General disassembly of engine ............................................................................................... 2
General assembly of engine ....................................................................................................... 2
Removal and installation fuel supply pump unit .......................................................................... 2
Removal and installation oil seal unit .......................................................................................... 4

SEN00321-00 50 Disassembly and assembly
2 12V140E-3 Series
Disassembly and assembly, Part 1 1
General disassembly of engine 1
a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
Take care.
a 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.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
2. Installation to engine repair stand
1) Install the engine assembly (1) to tool A.
4 Engine assembly:
Approx. 3,800 kg
2) Drain the engine coolant and engine oil.
a Quantity of the engine oil depends on
the applicable machines.
6 Engine oil: Approx. 130 l
3. Engine wiring harness
Disconnect the connector and terminal and
then remove engine harness (1) from the
engine assembly.
4. Starting motor assembly
Remove engine harness (1) and then remove
starting motor assemblies (2) and (3).
a Remove the assembly at the top first
being followed by that at the bottom.
5. Alternator
1) Remove auxiliary equipment belt (1).
2) Remove alternator (2).

12V140E-3 Series 3
6. Fuel filter and filter head assembly, and
priming pump
1) Remove fuel tubes (1) and (2).
2) Remove fuel filter and filter head assem-
bly (3).
3) Remove priming pump (4).
7. Engine controller and controller cooler
1) Remove engine controller (1).
2) Remove fuel hoses (2) and (3).
3) Remove controller cooler (4).
8. Air inlet pipe
1) Remove the clamp and then remove air
inlet pipe (1).
2) Remove bracket (2).
a Remove bracket (3) on the right side
bank alone.
9. Air intake connector
1) Remove air intake connector (1).
10. Spill tube
Remove spill tube (1).
11. High-pressure pipe (between supply pump
– common rail)
1) Apply a marking to the installation posi-
tions of clamps (1) – (3) using paint.
3) Remove clamps (1) – (3).
4) Remove high-pressure pipes (5) and (6).

4 12V140E-3 Series
12. High-pressure pipe (between common rail
– fuel injector)
2) Apply a marking to every installation posi-
tions of clamps (2) and (3) using paint.
3) Remove bracket.
4) Remove all clamps (2) and (3).
5) Remove 6 high-pressure pipes (4).
13. Air intake manifold assembly
1) Remove support (1).
2) Lift air intake manifold (2) temporarily and
then remove the mounting bolts.
3) Lift off air intake manifold assembly (2).
4 Air intake manifold assembly:
45 kg

12V140E-3 Series 5
14. Exhaust connector
Remove exhaust connectors (1) and (2).
15. Turbocharger assembly
1) Remove 2 water pipes and 2 oil pipes.
a 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) Lift off turbocharger assembly (1).
4 Turbocharger assembly: 35 kg
16. Exhaust manifold assembly
1) Remove instation plates (1), muffler
bracket (2), water pipes (3) and bracket
(4).
2) Lift exhaust manifold assembly (5) tempo-
rarily and then remove the mounting bolts.
3) Lift off exhaust manifold assembly (5).
4 Exhaust manifold assembly: 25 kg
17. Common rail
1) Remove fuel tube (1).
2) Remove common rail (2).

6 12V140E-3 Series
18. Supply pump assembly
1) Remove oil tube (1)
2) Remove supply pump assembly mount-
ing bolt (2).
3) Remove supply pump assembly (3).
19. Corrosion resister and filter head assembly
Remove corrosion resister and filter head
assembly (1).
20. Water pump assembly
1) Remove block (1)
2) Remove water connector (2).
3) Remove water pump assembly (3).
4) Remove housing (5) from water pump (4).
21. Oil cooler (rear side)
1) Remove oil manifold (1).
2) Remove oil cooler (2)
a Remove the oil cooler (front side)
after removing the supply pump drive
case.

12V140E-3 Series 7
22. Plate and block
Remove plates (1) and (2) and block (3).
23. Fuel tube
1) Remove fuel tube (1).
24. Oil level gauge and oil filler tube
1) Remove bracket (1) and then remove oil
filler tube (2).
2) Loosen the sleeve nut at the base and
then remove oil level gauge (3).
25. Head cover
Remove head cover (1).
a Repeat the same procedure on every cyl-
inder up to removal of the cylinder head
assembly.
26. Rocker arm assembly
1) Loosen locknuts (1) and then loosen
adjustment screws (2) fully.
a Make sure that the valve tension is
not applied to the rocker arm and thus
it is free to move.
2) Remove rocker arm assembly (3).
a Record the parts installation positions
using a tag to avoid confusion in the
later assembly.
3) Remove air intake rocker arm (4), spacer
(5) and exhaust rocker arm (6) from rocker
shaft (7).

8 12V140E-3 Series
27. Push rod
Remove push rod (1).
28. Injector harness
1) Remove injector terminal mounting nut (1)
and clamp mounting bolt (2).
2) Push connector (3) into the cylinder head
and remove injector harness (4).
29. Fuel injector
1) Remove holder mounting bolt (1).
2) Insert a small L-bar [1] under the fuel con-
nector and pry out fuel injector (2) slowly.
a Do not grip the solenoid valve at the
top of the injector to pull off the injec-
tor.
30. Crosshead
Remove crosshead (1).
31. Cylinder head assembly
1) Remove the water tube.
2) Lift off cylinder head assembly (1).
4 Cylinder head assembly: 25 kg

12V140E-3 Series 9
a 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).
3] Remove lower seat (6).
4] Raise the cylinder head and remove
valve (7).
32. Oil pan
1) Support the front and rear side of oil pan
(1) with block [1].
2) Remove all oil pan mounting bolts.
3) Separate the gasket sealant.
4) Lift the engine and then remove oil pan
(1).
4 Oil pan: 90 kg
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
pipe (3).

10 12V140E-3 Series
3) Support under plate (1) using jack [1].
4) Remove the bolts used for temporary fix-
ing and then lower the jack carefully to
remove under plate (1).
4 Under plate: 25 kg
34. Relief valve
1) Remove relief valve (1).
2) Install the engine again to tool A.
35. Alternator bracket
Remove alternator bracket (1).
36. Breather
Remove breather (1), blowby pipe (2) and
plate (3).
a Remove the plate on the left bank alone.
37. Thermostat case
1) Remove water outlets (1).
2) Remove thermostat case (2).
3) Remove thermostat (3) from thermostat
case (2).

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12V140E-3 Series 11
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).
2] Remove shaft (5), thrust plate (6) and
gear (7) as a unit.
3] Remove gear (7) from shaft (5).
4] Pull off oil seal (9) and bushing (10)
from housing (8).
41. Flywheel assembly
1) Lift and secure flywheel assembly (1).
2) Remove the mounting bolt.
3) Separate the bolt from the crankshaft
using forcing screw [1].
4) Lift off flywheel assembly (1).
4 Flywheel assembly: 130 kg

12 12V140E-3 Series
42. Flywheel housing
1) Remove burring tool (1) and Ne speed
sensor (2).
2) Remove engine speed sensor (3).
3) Lift flywheel housing (4) temporarily and
then remove the mounting bolt.
4) Lift off the flywheel housing (4).
4 Flywheel housing: 230 kg
43. Rear oil seal
Remove rear oil seal (1) from the flywheel
housing.
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).
4 Damper and crank pulley assem-
bly: 75 kg
45. Front support
Remove front support (1) using puller [1].

12V140E-3 Series 13
46. Gear case cover
Lift off gear case cover (1).
4 Gear case cover:75 kg
47. Front oil seal
Remove front oil seal (1) from the gear case
cover.
48. Idler gear (Large)
1) Remove plate (1).
2) Remove idler gears (large) (2) and (3).
3) Remove thrust plate (4) from the shaft.
a A indicates the oil channel.
49. Supply pump gear
1) Remove the mounting nut.
2) Remove supply pump gear (1) using puller
[1].
a After removing the supply pump gear,
remove the key from the shaft and
maintain so that it may not be lost.
50. Idler gear (Small)
1) Remove plate (1).
2) Remove idler gear (small) (2).

Komatsu 12 v140e 3 series engine service repair manual

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Komatsu 12 v140e 3 series engine service repair manual