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KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-01 – PDF DOWNLOAD
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Description
KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-01 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-01 – PDF DOWNLOAD
Language : English
Pages : 304
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-01 – PDF DOWNLOAD
COVER................................................................................... 1 00 INDEX AND FOREWORD.................................................................. 3 INDEX.............................................................................. 4 ABBREVIATION LIST.................................................................. 6 FOREWORD, SAFETY, BASIC INFORMATION................................................ 12 HOW TO READ THE ENGINE SHOP MANUAL............................................. 12 SAFETY NOTICE FOR OPERATION.................................................... 14 PRECAUTIONS TO PREVENT FIRE.................................................... 22 ACTIONS IF FIRE OCCURS......................................................... 24 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS................................... 25 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS.................................. 26 PRECAUTIONS FOR DEF............................................................ 27 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING............................. 27 PRECAUTIONS FOR ADDING..................................................... 27 PRECAUTIONS FOR STORING.................................................... 27 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE.................................... 27 THE OTHER PRECAUTIONS...................................................... 27 STORE AdBlue/DEF............................................................... 28 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT................................... 29 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS........................ 32 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT.................................. 39 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT................................. 41 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT............................... 42 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER.................................. 43 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...... 43 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...... 44 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...... 45 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS..................... 47 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...................... 51 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR.............. 52 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............ 54 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............ 55 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE....... 57 HOW TO READ ELECTRICAL WIRE CODE............................................... 58 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................. 62 STANDARD TIGHTENING TORQUE TABLE............................................... 65 CONVERSION TABLE............................................................... 72 01 SPECIFICATIONS...................................................................... 77 CONTENTS........................................................................... 78 ABBREVIATION LIST.................................................................. 79 SPECIFICATIONS..................................................................... 85 OUTLINE OF EXHAUST GAS REGULATION.............................................. 85 SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION.................... 86 IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION.................... 87 LIST OF APPLICABLE MACHINES: 12V140E-7......................................... 88 SPECIFICATIONS................................................................. 89 SPECIFICATIONS: SAA12V140E-7 (PC2000-11)................................... 89 SPECIFICATIONS: SAA12V140E-7 (WA900-8)..................................... 90 ENGINE GENERAL VIEW............................................................ 91 ENGINE GENERAL VIEW: SAA12V140E-7 (PC2000-11).............................. 91 ENGINE GENERAL VIEW: SAA12V140E-7 (WA900-8)................................ 95 WEIGHT TABLE................................................................... 99 WEIGHT TABLE: 12V140E-7.................................................... 99 ENGINE PERFORMANCE CURVE.......................................................100 ENGINE PERFORMANCE CURVE: SAA12V140E-7 (PC2000-11).........................100 ENGINE PERFORMANCE CURVE: SAA12V140E-7 (WA900-8)...........................101 10 STRUCTURE AND FUNCTION..............................................................103 CONTENTS...........................................................................104 ABBREVIATION LIST..................................................................106 ENGINE SYSTEM......................................................................112 LAYOUT OF ENGINE COMPONENTS....................................................112 LAYOUT DRAWING OF ENGINE COMPONENTS........................................112 INTAKE AND EXHAUST SYSTEM PARTS................................................114 LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM................................114 INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM..................................116 FUNCTION OF INTAKE AND EXHAUST SYSTEM......................................117 AIR CLEANER................................................................118 ENGINE MAIN BODY PARTS.........................................................119 CYLINDER HEAD..............................................................119 CYLINDER BLOCK.............................................................122 MAIN MOVING PARTS..........................................................125 VIBRATION DAMPER...........................................................128 TIMING GEAR................................................................129 FRONT COVER................................................................130 VALVE SYSTEM...............................................................131 FLYWHEEL AND FLYWHEEL HOUSING..............................................135 TURBOCHARGER SYSTEM............................................................136 CIRCUIT DIAGRAM OF VGT SYSTEM..............................................136 FUNCTION OF VGT SYSTEM.....................................................137 VGT........................................................................139 EGR SYSTEM.................................................................143 EGR VALVE..................................................................147 EGR COOLER.................................................................148 MIXING CONNECTOR...........................................................150 KCCV SYSTEM................................................................152 KCCV.......................................................................157 KDPF.......................................................................159 LUBRICATION SYSTEM.............................................................163 LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS.................................163 LUBRICATION SYSTEM CIRCUIT DIAGRAM.........................................164 ENGINE OIL PUMP............................................................165 ENGINE BOOST OIL PUMP......................................................167 ENGINE OIL FILTER..........................................................169 ENGINE OIL COOLER..........................................................170 ENGINE OIL PAN.............................................................172 FUEL SYSTEM....................................................................173 LAYOUT DRAWING OF FUEL SYSTEM PARTS........................................173 FUEL SYSTEM CIRCUIT DIAGRAM................................................174 FUNCTION OF FUEL SYSTEM....................................................175 OPERATION OF FUEL SYSTEM...................................................175 CRI SYSTEM.................................................................175 SUPPLY PUMP................................................................180 COMMON RAIL................................................................183 INJECTOR...................................................................186 FUEL DOSING SYSTEM.........................................................189 FUEL PREFILTER.............................................................192 FUEL MAIN FILTER...........................................................193 COOLING SYSTEM.................................................................194 LAYOUT DRAWING OF COOLING SYSTEM PARTS.....................................194 COOLING SYSTEM CIRCUIT DIAGRAM.............................................195 WATER PUMP.................................................................196 THERMOSTAT.................................................................197 ELECTRICAL SYSTEM..................................................................199 COMPONENT PARTS OF ELECTRICAL SYSTEM...........................................199 ALTERNATOR.................................................................199 ALTERNATOR MOUNTING........................................................203 STARTING MOTOR.............................................................204 ENGINE CONTROLLER..........................................................206 FUEL FEED PUMP.............................................................221 FUEL FEED PUMP SWITCH......................................................222 SENSOR.........................................................................223 STRUCTURE OF AMBIENT PRESSURE SENSOR.......................................223 FUNCTION OF AMBIENT PRESSURE SENSOR........................................223 STRUCTURE OF ENGINE OIL PRESSURE SENSOR....................................224 FUNCTION OF ENGINE OIL PRESSURE SENSOR.....................................224 STRUCTURE OF CHARGE PRESSURE SENSOR........................................225 FUNCTION OF CHARGE PRESSURE SENSOR.........................................225 STRUCTURE OF CHARGE TEMPERATURE SENSOR.....................................226 FUNCTION OF CHARGE TEMPERATURE SENSOR......................................226 STRUCTURE OF COOLANT TEMPERATURE SENSOR....................................227 FUNCTION OF COOLANT TEMPERATURE SENSOR.....................................227 STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR..................................228 FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR...................................228 STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR..................................229 FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR...................................229 STRUCTURE OF COMMON RAIL PRESSURE SENSOR...................................230 FUNCTION OF COMMON RAIL PRESSURE SENSOR....................................230 STRUCTURE OF EGR VALVE LIFT SENSOR.........................................231 FUNCTION OF EGR VALVE LIFT SENSOR..........................................231 STRUCTURE OF VGT SPEED SENSOR..............................................232 FUNCTION OF VGT SPEED SENSOR...............................................232 STRUCTURE OF VGT POSITION SENSOR...........................................233 FUNCTION OF VGT POSITION SENSOR............................................233 STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR..........................234 FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR...........................234 STRUCTURE OF DOSING FUEL PRESSURE SENSOR...................................235 FUNCTION OF DOSING FUEL PRESSURE SENSOR....................................235 STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR.........236 FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR..........236 STRUCTURE OF CRANKCASE PRESSURE SENSOR.....................................237 FUNCTION OF CRANKCASE PRESSURE SENSOR......................................237 STRUCTURE OF ENGINE OIL LEVEL SENSOR.......................................238 FUNCTION OF ENGINE OIL LEVEL SENSOR........................................238 STRUCTURE OF AIR CLEANER CLOGGING SENSOR...................................239 FUNCTION OF AIR CLEANER CLOGGING SENSOR....................................239 20 STANDARD VALUE TABLE................................................................241 CONTENTS...........................................................................242 ABBREVIATION LIST..................................................................243 STANDARD VALUE TABLE FOR ENGINE....................................................249 STANDARD VALUE TABLE FOR ENGINE: SAA12V140E-7 (PC2000-11)......................249 STANDARD VALUE TABLE FOR ENGINE: SAA12V140E-7 (WA900-8)........................251 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD..................................253 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA12V140E-7 (PC2000-11)....253 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA12V140E-7 (WA900-8)......255 60 MAINTENANCE STANDARD................................................................257 CONTENTS...........................................................................258 ABBREVIATION LIST..................................................................259 ENGINE SYSTEM......................................................................265 INTAKE AND EXHAUST SYSTEM PARTS................................................265 MAINTENANCE STANDARD OF VGT................................................265 ENGINE MAIN BODY PARTS.........................................................266 MAINTENANCE STANDARD OF CYLINDER HEAD......................................266 MAINTENANCE STANDARD OF CYLINDER BLOCK.....................................268 MAINTENANCE STANDARD OF CYLINDER LINER.....................................270 MAINTENANCE STANDARD OF CRANKSHAFT.........................................272 MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD..........................274 MAINTENANCE STANDARD OF PISTON.............................................276 MAINTENANCE STANDARD OF CONROD.............................................278 MAINTENANCE STANDARD OF VIBRATION DAMPER...................................280 MAINTENANCE STANDARD OF TIMING GEAR........................................282 MAINTENANCE STANDARD OF CAMSHAFT...........................................284 MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE..............................285 MAINTENANCE STANDARD OF ROCKER ARM.........................................287 MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE................................288 MAINTENANCE STANDARD OF FLYWHEEL...........................................289 LUBRICATION SYSTEM.............................................................291 MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP....................291 MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP..............294 MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER..................295 MAINTENANCE STANDARD OF OIL COOLER BYPASS VALVE AND REGULATOR VALVE........296 COOLING SYSTEM.................................................................297 MAINTENANCE STANDARD OF WATER PUMP.........................................297 MAINTENANCE STANDARD OF THERMOSTAT.........................................298 INDEX...................................................................................299
DESCRIPTION:
KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-01 – PDF DOWNLOAD
HOW TO READ THE ENGINE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
S.S 18/12/24
