Komatsu 12V140-1 Series Diesel Engine Shop Manual – PDF DOWNLOAD

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Komatsu 12V140-1 Series Diesel Engine Shop Manual

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Komatsu 12V140-1 Series Diesel Engine Shop Manual

Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 12V140-1 Series Diesel Engine
Book Code: SEBM028318
Language: English
Pages: 471
File Format: Portable Document Format (PDF)

KOMATSU 12V140-1 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu 12V140-1 Series Diesel Engine Shop Manual

FOREWORD:
GENERAL:

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu 12V140-1 Series Diesel Engine Shop Manual

COVER......................................................................................................................................  1
CONTENTS...................................................................................................................................  2
01 GENERAL................................................................................................................................. 27
	APPLICABLE MACHINE..................................................................................................................... 28
	SPECIFICATIONS......................................................................................................................... 29
	GENERAL ASSEMBLY DRAWING............................................................................................................... 38
	ENGINE PERFORMANCE CURVE............................................................................................................... 51
	WEIGHT TABLE........................................................................................................................... 64
11 STRUCTURE AND FUNCTION.................................................................................................................. 66
	GENERAL STRUCTRE....................................................................................................................... 67
	INTAKE AND EXHAUST SYSTEM.............................................................................................................. 69
		AIR CLEANER........................................................................................................................ 71
		TURBOCHARGER....................................................................................................................... 72
		AFTER-COOLER....................................................................................................................... 74
	ENGINE BODY............................................................................................................................ 75
		CYLINDER HEAD...................................................................................................................... 75
		CYLINDER BLOCK..................................................................................................................... 79
		MAIN REVOLVING SYSTEM.............................................................................................................. 81
		TIMING GEAR........................................................................................................................ 83
		VALVE SYSTEM....................................................................................................................... 87
		FLYWHEEL AND FLYWHEEL HOUSING...................................................................................................... 91
	LUBRICATION SYSTEM..................................................................................................................... 92
		LUBRICATION SYSTEM CHART........................................................................................................... 92
		OIL PUMP........................................................................................................................... 94
		MAIN RELIEF........................................................................................................................ 95
		OIL COOLER BY-PASS VALVE, REGULATOR VALVE.......................................................................................... 96
		OIL FILTER......................................................................................................................... 98
		OIL COOLER.........................................................................................................................102
	FUEL SYSTEM ...........................................................................................................................103
		FUEL SYSTEM CHART..................................................................................................................103
		FUEL INJECTION PUMP................................................................................................................106
		FUEL INJECTION NOZZLE..............................................................................................................120
		FUEL FILTER........................................................................................................................121
		ENGINE STOP MOTOR..................................................................................................................123
	COOLING SYSTEM.........................................................................................................................128
		COLING SYSTEM SHART................................................................................................................128
		WATER PUMP.........................................................................................................................129
		COOLING FAN........................................................................................................................130
		THERMOSTAT.........................................................................................................................136
		CORROSION RESISTOR.................................................................................................................137
	ACCESSORY..............................................................................................................................138
		AIR COMPRESSOR.....................................................................................................................138
		EXHAUST BRAKE......................................................................................................................140
	ELECTRICAL SYSTEM......................................................................................................................141
		ALTERNATOR.........................................................................................................................141
		STARTING MOTOR.....................................................................................................................144
		ELECTRICAL INTAKE AIR HEATER.......................................................................................................145
		OIL PAN HEATER.....................................................................................................................146
		COOLING WATER HEATER...............................................................................................................147
12 TESTING AND ADJUSTING...................................................................................................................148
	ENGINE BODY............................................................................................................................149
		ADJUSTING VALVE CLEARANCE..........................................................................................................149
		MEASURING COMPRESSION PRESSURE.....................................................................................................150
		MEASURING BLOW-BY..................................................................................................................151
	FUEL SYSTEM............................................................................................................................152
		TESTING AND ADJUSTMENT OF FUEL INJECTION TIMAING...................................................................................152
			(WITH ZEXEL MECHANICAL GOVERNOR)...............................................................................................152
			(WITH ZEXEL ELECTRONICAL GOVERNOR).............................................................................................155
		TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING (WITH KOMATSU ELECTRONICAL GOVERNOR)...............................................158
		ADJUSTING INJECTION PUMP GOVERNOR LINK.............................................................................................161
			(WITH MECHANICAL GOVERNOR).....................................................................................................161
			(WITH ZECEL ELECTRONICAL GOVERNOR).............................................................................................163
		PROCEFURE FOR ADJUSTING ENGINE STOP MOTOR CABLE (APPLICABLE FOR MODELSUSING ENGINE STOP MOTOR).....................................165
		METHOD FOR INSTALLING (ADJUSTMENT) OF ENGINE SPEED SENSOR..........................................................................166
		ADJUSTING FUEL INJECTION PRESSURE..................................................................................................167
		FUEL INJECTION PUMP CALIBRATION DATA...............................................................................................168
		ADJUSTMENT OF ELECTRONICAL GOVERNOR MADE BY KOMATSU................................................................................192
		HANDLING OF THROTTLE BOX...........................................................................................................209
		HANDLING OF XEP CHECKER............................................................................................................219
	COOLING SYSTEM.........................................................................................................................224
		CHECKING AND ADJUSTING V-BELT TENSION..............................................................................................224
	PERFORMANCE TEST.......................................................................................................................226
		RUNNING IN STANDARD................................................................................................................226
		PERFORMANCE TEST CRITERIA..........................................................................................................230
		TESING AND ADJUSTING TOOL LIST.....................................................................................................240
		TESTING AND ADJUSTING DATA.........................................................................................................241
	TROUBLESHOOTING........................................................................................................................252
		POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................254
		METHOD OF USING TROUBLESHOOTING CHART..............................................................................................255
		S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) (WITH ELECTRONICAL GOVERNOR).........................................259
		S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) (WITH MECHANICAL GOVERNOR)...........................................260
		S-2 EGINE DOES NOT START...........................................................................................................261
			① ENGINE DOES NOT TURN.........................................................................................................261
			② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (WITH ELECTRONICAL GOVERNOR) .........................262
			② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (WITH MECHANICAL GOVERNOR)............................263
			③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) ....................................................264
		S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...........................................................................265
		S-4 ENGINE STOPS DURING OPERATIONS (WITH MECHANICAL GOVERNOR)......................................................................267
		S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) (WITH ELECTRONICAL GOVERNOR)..........................................................268
		S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) (WITH MECHANICAL GOVERNOR)...........................................................269
		S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH ELECTRONICAL GOVERNOR)....................................................................270
		S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH MECHANICAL GOVERNOR)......................................................................271
		S-7 EXHAUST GAS IS  BLACK (INCOMPLETE COMBUSTION) (WITH ELECTRONICAL GOVERNOR).....................................................272
		S-7 EXHAUST GAS IS  BLACK (INCOMPLETE COMBUSTION) (WITH MECHANICAL GOVERNOR).......................................................273
		S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)..........................................................................274
		S-9 OIL BECOMES CONTAMINATED QUICKLY...............................................................................................275
		S-10 FUEL CONSUMPTION IS EXCESSIVE (WITH ELECTRONICAL GOVERNOR) ...................................................................276
		S-10 FUEL CONSUMPTION IS EXCESSIVE (WITH MECHANICAL GOVERNOR)......................................................................277
		S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.......................................................278
		S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................................................279
		S-13 OIL LEVEL RISES...............................................................................................................280
		S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..............................................................................281
		S-15 ABNORMAL NOISE IS MADE........................................................................................................282
		S-16 VIBRATION IS EXCESSIVE........................................................................................................283
		S-17 DIAGNOSIS OF ELECTRONICAL GOVERNOR BY DIAGNOSIS DISPLAY (ELECTRONICAL GOVERNOR MADE BY ZEXEL).................................284
			1. CONTROLLER SYSTEM ABNORMALITY...............................................................................................287
			2. GOVERNOR SERVO SYSTEM ABNORMALITY...........................................................................................287
			3. RACK SENSOR SYSTEM ABORMALITY...............................................................................................289
			4. OVERRUN ABNORMALITY.........................................................................................................291
			5. 1ST SPEED SENSOR ABNORMALITY................................................................................................292
			6. 2ND SPEED SENSOR ABNORMALITY................................................................................................292
			7. LOW IDLING SPEED CONTROL DIAL ABNORMALITY...................................................................................293
			8. DROOP CONTROL DIAL ABNORMALITY..............................................................................................294
			9. DIAGNOSIS LAMP FAILS TO MAKE INDICATION.....................................................................................295
			10. NORMAIL INDICATION.........................................................................................................296
			11. MEMORY CLEAR CANNOT BE ACHIEVED BY PRESSING THE MEMORY CLEAR SWITCH (WHEN FAILURE INDICATION IS MADE BY DIAGNOSIS LAMP)....301
13 DISASSEMBLY AND ASSEMBLY................................................................................................................302
	GENERAL DISASSEMBLY....................................................................................................................303
		1. WASHING.........................................................................................................................304
		2. SETTING ENGINE STAND............................................................................................................304
		3. ENGINE COOLING WATER AND ENGINE OIL.............................................................................................305
		4. FILTER..........................................................................................................................305
		5. MUFFLER ASSERMBLY...............................................................................................................305
		6. FAN.............................................................................................................................305
		7. FAN BELT........................................................................................................................306
		8. FAN PULLEY ASSEMBLY.............................................................................................................306
		9. LNTAKE CONNECTOR................................................................................................................306
		10. EXHAUST BRAKE ASSEMBLY.........................................................................................................306
		11. TURBOCHARGER ASSEMBLY..........................................................................................................307
		12. INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY..........................................................................................307
		13. EXHAUST MANIFOLD ASSEMBLY......................................................................................................308
		14. FUEL INJECTION PIPE,SPIL TUBE..................................................................................................308
		15. FUEL INJECTION PUMP ASSEMBLY...................................................................................................309
		16. WATER PUMP ASSEBLY.............................................................................................................310
		17. BREATHER.......................................................................................................................310
		18. AIR COMPRESSOR.................................................................................................................310
		19. OIL COOLER ASSEMBLY............................................................................................................311
		20. OIL FILLER, OIL LEVEL GAUGE....................................................................................................311
		21. HEAD COVER.....................................................................................................................312
		22. NOZZZLE HOLDER, CONNECTION.....................................................................................................312
		23. ROCKER ARM.....................................................................................................................313
		24. PUSH ROD.......................................................................................................................313
		25. CROSSHEAD......................................................................................................................313
		26. ROCKER ARM HOUSING.............................................................................................................313
		27. CYLINDER HEAR ASSEMBLY.........................................................................................................313
		28. CAM FOLLOWER ASSEMBLY..........................................................................................................314
		29. THERMOSTAT HOUSING.............................................................................................................314
		30. ASSESSORY DRIVE ASSEMBLY.......................................................................................................315
		31. DAMPER, CRANKSHAFT PULLEY ASSEMBLY.............................................................................................315
		32. OIL PAN........................................................................................................................316
		33. MAN RELIEF VALVE, SUCTION TUBE.................................................................................................316
		34. FRONT SUPPOR...................................................................................................................316
		35. FLYWHEEL.......................................................................................................................316
		36. FLYWHEEL HOUSING, REAR SEAL....................................................................................................317
		37. GEAR CASE COVER, FRONT SEAL....................................................................................................317
		38. IDLER GEAR (LARGE).............................................................................................................317
		39. INJECTION PUMP DRIVE GEAR......................................................................................................317
		40. INJECTION PUMP DRIVE CASE ASSEMLY..............................................................................................318
		41. OIL PUMP ASSEMBLY..............................................................................................................318
		42. IDLER GEAR (SMALL).............................................................................................................318
		43. CAMSHAFT ASSEMBLY..............................................................................................................319
		44. TIMING GEAR CASE...............................................................................................................319
		45. PISTON COOLING NOZZLE..........................................................................................................319
		46. PISTON AND CONNECTING ROD ASSEMBLY.............................................................................................319
		47. CRANKSHAFT.....................................................................................................................321
		48. CYLINDER LINER.................................................................................................................322
	WASHING................................................................................................................................323
		WASHING CYLINDER BLOCK.............................................................................................................324
		WASHING CRANKSHFT..................................................................................................................326
		WASHING CONNECTING ROD.............................................................................................................326
	MEASURING AND INSPECTING PARTS.........................................................................................................327
		MEASURING PARTS....................................................................................................................328
			MEASURING CURVATURE OF CRANKSHAFT..............................................................................................328
			MEASURING OUTSIDE DIAMETER OF JOURNAL..........................................................................................328
			MEASURING OUT-OF-ROUNDNESS OF JOURNAL..........................................................................................328
			MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL.....................................................................329
			MEASURING DEPTH OF CYLINDER LINER COUNTERBORE..................................................................................330
			MEASURING MAIN BERING BORE.....................................................................................................330
			MEASURING CUVATURE OF CAMSHAFT.................................................................................................331
			MEASURING OUTSIDE DIAMETER OF JOURNAL..........................................................................................331
			MEASURING HELGHT OF CAM........................................................................................................331
			MEASURING PISTON RING GROOVE...................................................................................................332
			MEASURING OUTSIDE DIAMETER OF PISTON...........................................................................................332
			MEASURING LENGTH OF CONNECTING ROD.............................................................................................333
			MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD.......................................................................333
			MEASUING INSIDE DIAMENTER AT BIG END OF CONNECTING ROD.........................................................................333
			MEASURING SURVATURE, TWISTING OF CONNECTING ROD................................................................................334
			STANDARD PRESSURE FOR PARTS PRESSURE TESTING...................................................................................335
	GENERAL ASSEMBLY.......................................................................................................................336
		1. CYLINDER LINER..................................................................................................................339
		2. CRANKSHAFT......................................................................................................................342
		3. PISTON, CONNECTING ROD ASSEMBLY.................................................................................................345
		4. PISTON COOLING NOZZLE...........................................................................................................351
		5. GEAR CASE ......................................................................................................................352
		6. CAMSHAFT ASSEMBLY...............................................................................................................352
		7. IDLER GEAR (SMALL)..............................................................................................................352
		8. OIL PUMP ASSEMBLY...............................................................................................................353
		9. INJECTION PUMP DRIVE CASE.......................................................................................................353
		10. INJECION PUMP DRIVE GEAR.......................................................................................................354
		11. IDIER GEAR (LARGE) (RIGHT BANK)................................................................................................354
		12. IDIER GGEAR (LARGE) (LEFT BANK)................................................................................................355
		13. MEASURING BACKLASH OF GEAR.....................................................................................................355
		14. GEAR CASE COVER................................................................................................................357
		15. FRONT OIL SEAL, SLEEVE.........................................................................................................357
		16. FLYWHEEL HOUSING...............................................................................................................360
		17. REAR OIL SEAL, SLEEVE..........................................................................................................360
		18. FLYWHEEL.......................................................................................................................363
		19. FRONT SUPPORT..................................................................................................................364
		20. MAIN RELIEF VALVE, SUCTION PIPE................................................................................................365
		21. OIL PAN .......................................................................................................................365
		22. DAMPER, CRANKSHAFT PULLEY ASSEMBLY.............................................................................................365
		23. ACCESSORY DRIVE ASSEMBLY.......................................................................................................366
		24. THERMOSTAT HOUSING.............................................................................................................367
		25. CAM FOLLOWER ASSEMBLY..........................................................................................................367
		26. CYLINDER HEAD ASSEMBLY.........................................................................................................367
		27. ROCKER ARM HOUSING.............................................................................................................370
		28. CROSSHEAD......................................................................................................................370
		29. PUSH ROD.......................................................................................................................370
		30. ROCKER ARM.....................................................................................................................370
		31. NOZZLE HOLDER, CONNECTION......................................................................................................372
		32. ADJUSTING VALVE CLEARANCE......................................................................................................372
		33. HEAD COVER, TURBOCHARGER LUBRICATION TUBE......................................................................................373
		34. OIL LEVEL GAUGE,OIL FILLER.....................................................................................................373
		35. OIL COOLER ASSEMBLY............................................................................................................373
		36. AIR COMPRESSOR.................................................................................................................373
		37. BREATHER.......................................................................................................................374
		38. WATER PUMP ASSEMBLY............................................................................................................375
		39. FUEL INJECTION PUMP ASSEMBLY...................................................................................................375
		40. FUEL INJECTION PIPES, SPILL TUBE...............................................................................................377
		41. EXHAUST MANIFOLD ASSEMBLY......................................................................................................377
		42. INTAKE MANIFOLD, AFTER-COOLER ASSEMBLY.........................................................................................378
		43. TURBOCHARGER ASSEMBLY..........................................................................................................379
		44. EXHAUST BRAKE ASSEMBLY.........................................................................................................379
		45. INTAKE CONNECTOR...............................................................................................................380
		46. FAN PULLEY ASSEMBLY............................................................................................................380
		47. FAN BELT.......................................................................................................................380
		48. FAN............................................................................................................................380
		49. MUFFLER ASSEMBLY...............................................................................................................381
		50. FILTER.........................................................................................................................381
		51. SETTING ON ENGINE STAND........................................................................................................381
		52. ALTERNATOR ASSEMBLY............................................................................................................381
		53. STARTING MOTOR ASSEMBLY........................................................................................................382
14 MAINTENANCE STANDIRD....................................................................................................................383
	INTAKE AND EXHAUST SYSTEM..............................................................................................................384
		TRBOCHARGER........................................................................................................................384
	ENGINE BODY............................................................................................................................386
		CYLINDER HEAD......................................................................................................................386
		VALVE, VALVE SPRING AND VALVE GUIDE ...............................................................................................387
		ROCKER ARM AND SHAFT...............................................................................................................389
		CROSSHEAD AND GUIDE................................................................................................................390
		CYLINDER BLOCK.....................................................................................................................391
		CYLINDER LINER.....................................................................................................................393
		CRANKSHAFT.........................................................................................................................394
		CAMSHAFT...........................................................................................................................396
		CAM FOLLOWER AND PUSH ROD..........................................................................................................397
		TIMING GEAR........................................................................................................................398
		PISTON, PISTON RING AND PISTON PIN.................................................................................................400
		CONNECTING ROD.....................................................................................................................402
		FLYWHEEL AND FLYWHEEL HOUSING......................................................................................................404
	LUBRICATION SYSTEM.....................................................................................................................405
		OIL PUMP ..........................................................................................................................405
		MAIN RELIEF VALVE..................................................................................................................409
		OIL COOLER BY-PASS VALVE, REGULATOR VALVE..........................................................................................410
	COOLING SYSTEM.........................................................................................................................412
		WATER PUMP.........................................................................................................................412
		THRMOSTAT..........................................................................................................................413
15 REPAIR AND REPLACEMENT OF PARTS.........................................................................................................414
	TABLE OF SPECIAL TOOLS.................................................................................................................415
	TESTING ANF INSPECTING CYINDER HEAD....................................................................................................417
	GRINDING CYLINDER HEAD MOUNTING FACE...................................................................................................420
	REPLACING VALVE SEAT...................................................................................................................421
	PRESSURE TEST OF CYLONDER HEAD.........................................................................................................426
	REPLACING VALVE GUIDE..................................................................................................................427
	REPLACING CROSSHEAD GUIDE..............................................................................................................428
	GRINDING VALVE.........................................................................................................................429
	TESTING AND INSPECTING CYLINDER BLOCK..................................................................................................430
	CORRECTING CYLINDRE BLOCK TOP SURFACE, COUNTERBORE.....................................................................................434
	REPLACING MAIN BEARING CAP.............................................................................................................442
	REPLACING CAM BUSHING..................................................................................................................444
	TESTING AND INSPECTING CRANKSHAFT......................................................................................................446
	CORRECTING SURFACE ROUGHESS OF CRANKSHAFT JOURNAL PORTION..............................................................................448
	GRINDING CRANKSHAFT....................................................................................................................453
	CORRECTING FRONT SEAL CONTACT SURFCE...................................................................................................462
	CORRECTING REAR SEAL CONTACT SURFACE...................................................................................................464
	TESTING AND INSPECTING CONNECTING ROD..................................................................................................466
	REPLACING CONNECTING ROD SMALL END BUSHING.............................................................................................468
	REPLACING CRANKSHAFT GEAR..............................................................................................................469
	REPLACING CAMSHAFT GEAR................................................................................................................470
	REPLACING FLYWHEEL RING GEAR...........................................................................................................471

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