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KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-11 – PDF DOWNLOAD
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Description
KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-11 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-11 – PDF DOWNLOAD
Language : English
Pages : 1090
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-11 – 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 Procedures If Fire Occurs............................................................................................................................... 24 Precautions for Disposing of Waste Materials............................................................................................................ 25 Engine Technology to Conform Exhaust Gas Emission....................................................................................................... 26 Precautions When You Handle Hydraulic Equipment......................................................................................................... 27 Precautions When You Disconnect and Connect Pipings..................................................................................................... 30 Precautions When You Handle Electrical Equipment........................................................................................................ 37 Precautions When You Handle Fuel System Equipment....................................................................................................... 39 Precautions When You Handle Intake System Equipment..................................................................................................... 40 Disconnect and Connect Push-Pull Type Coupler........................................................................................................... 41 How to Disconnect and Connect Type 1 Push-Pull Type Coupler......................................................................................... 41 How to Disconnect and Connect Type 2 Push-Pull Type Coupler......................................................................................... 42 How to Disconnect and Connect Type 3 Push-Pull Type Coupler......................................................................................... 43 Precautions for Disconnection and Connection of Connectors.............................................................................................. 45 How to Disconnect and Connect Deutsch Connector......................................................................................................... 49 How to Disconnect and Connect Slide Lock Type Connector................................................................................................. 50 How to Disconnect and Connect Connector with Lock to Pull............................................................................................... 52 How to Disconnect and Connect Connector with Lock to Push............................................................................................... 53 How to Disconnect and Connect Connector with Housing to Rotate.......................................................................................... 55 How to Read the Codes for Electric Cable................................................................................................................ 56 Explanation of Terms for Maintenance Standard........................................................................................................... 60 Standard Tightening Torque Table........................................................................................................................ 63 Conversion Table........................................................................................................................................ 70 01 Specifications............................................................................................................................................... 75 Table of Contents........................................................................................................................................... 76 Abbreviation List........................................................................................................................................... 77 Specifications.............................................................................................................................................. 83 Outline of Exhaust Gas Regulation....................................................................................................................... 83 System Diagram of Engine Complied with Tier 4 and EU Stage V Regulation............................................................................. 84 Improvement of Engine Complied with Tier 4 and EU Stage V Regulation Against Tier2 Regulation....................................................... 85 System Diagram of Engine Other Than Engine Complied with Tier 4 and EU Stage V Regulation........................................................... 86 List of Applicable Machines: 12V140E-7.................................................................................................................. 87 Specifications.......................................................................................................................................... 88 Specifications: SAA12V140E-7 (D475A-8, D475A-8E0, D475AI-8, D475AI-8E0)............................................................................. 88 Specifications: SAA12V140E-7 (D475A-8R, D475AI-8R).................................................................................................. 89 Specifications: SAA12V140E-7 (HD785-8, HD785-8E0)................................................................................................... 90 Specifications: SAA12V140E-7 (PC2000-11, PC2000-11E0)............................................................................................... 91 Specifications: SAA12V140E-7 (PC2000-11R)........................................................................................................... 92 Specifications: SAA12V140E-7 (WA800-8, WA800-8E0)................................................................................................... 93 Specifications: SAA12V140E-7 (WA900-8, WA900-8E0)................................................................................................... 94 Specifications: SAA12V140E-7 (WA900-8R)............................................................................................................. 95 Engine General View..................................................................................................................................... 96 Engine General View: SAA12V140E-7 (D475A-8, D475A-8E0, D475AI-8, D475AI-8E0)........................................................................ 96 Engine General View: SAA12V140E-7 (D475A-8R, D475AI-8R)............................................................................................. 100 Engine General View: SAA12V140E-7 (HD785-8, HD785-8E0).............................................................................................. 104 Engine General View: SAA12V140E-7 (PC2000-11, PC2000-11E0).......................................................................................... 108 Engine General View: SAA12V140E-7 (PC2000-11R)...................................................................................................... 112 Engine General View: SAA12V140E-7 (WA800-8, WA800-8E0, WA900-8, WA900-8E0).......................................................................... 116 Engine General View: SAA12V140E-7 (WA900-8R)........................................................................................................ 120 Weight Table............................................................................................................................................ 124 Weight Table: 12V140E-7............................................................................................................................. 124 Engine Performance Curve................................................................................................................................ 129 Engine Performance Curve: SAA12V140E-7 (D475A-8, D475A-8E0, D475A-8R, D475AI-8, D475AI-8E0, D475AI-8R).............................................. 129 Engine Performance Curve: SAA12V140E-7 (HD785-8, HD785-8E0)......................................................................................... 130 Engine Performance Curve: SAA12V140E-7 (PC2000-11, PC2000-11E0, PC2000-11R)......................................................................... 131 Engine Performance Curve: SAA12V140E-7 (WA800-8, WA800-8E0)......................................................................................... 132 Engine Performance Curve: SAA12V140E-7 (WA900-8, WA900-8E0, WA900-8R)............................................................................... 133 10 Structure and Function....................................................................................................................................... 135 Table of Contents........................................................................................................................................... 136 Abbreviation List........................................................................................................................................... 139 Engine System............................................................................................................................................... 145 Layout of Engine Components............................................................................................................................. 145 Layout Drawing of Engine Components................................................................................................................. 145 Intake and Exhaust System Parts......................................................................................................................... 147 Layout Drawing of Air Intake and Exhaust System (For Engines Complied with Tier 4 and EU Stage V Regulation)........................................ 147 Circuit Diagram of Air Intake and Exhaust System (For Engines Complied with Tier 4 and EU Stage V Regulation)....................................... 149 Function of Intake and Exhaust System (For Engines Complied with Tier 4 and EU Stage V Regulation).................................................. 150 Layout Drawing of Air Intake and Exhaust System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)..................... 151 Circuit Diagram of Air Intake and Exhaust System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation).................... 153 Function of Intake and Exhaust System (For Engines Does Not Comply with Tier 4 and EU Stage V Regulation)........................................... 154 Air Cleaner (For Engines Complied with Tier 4 and EU Stage V Regulation)............................................................................ 155 Air Cleaner (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)......................................................... 156 Engine Main Body Parts.................................................................................................................................. 157 Cylinder Head....................................................................................................................................... 157 Cylinder Block...................................................................................................................................... 160 Main Drive Parts.................................................................................................................................... 163 Vibration Damper.................................................................................................................................... 166 Timing Gear......................................................................................................................................... 167 Front Cover......................................................................................................................................... 168 Valve System........................................................................................................................................ 169 Flywheel and Flywheel Housing....................................................................................................................... 173 Turbocharger System..................................................................................................................................... 174 Circuit Diagram of Turbocharger System (For Engines Complied with Tier 4 and EU Stage V Regulation)................................................. 174 Function of Turbocharger System (For Engines Complied with Tier 4 and EU Stage V Regulation)........................................................ 175 Circuit Diagram of Turbocharger System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation).............................. 177 Function of Turbocharger System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)..................................... 178 VGT (For Engines Complied with Tier 4 and EU Stage V Regulation).................................................................................... 180 Turbocharger (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)........................................................ 184 EGR System (For Engines Complied with Tier 4 and EU Stage V Regulation)............................................................................. 186 EGR Valve (For Engines Complied with Tier 4 and EU Stage V Regulation).............................................................................. 190 EGR Cooler (For Engines Complied with Tier 4 and EU Stage V Regulation)............................................................................. 192 Mixing Connector (For Engines Complied with Tier 4 and EU Stage V Regulation)....................................................................... 193 KCCV System (For Engines Complied with Tier 4 and EU Stage V Regulation)............................................................................ 195 KCCV................................................................................................................................................ 200 KDPF (For Engines Complied with Tier 4 and EU Stage V Regulation)................................................................................... 203 Muffler (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)............................................................. 207 Lubrication System...................................................................................................................................... 208 Layout Drawing of Component Parts of Lubrication System (For Engines Complied with Tier 4 and EU Stage V)........................................... 208 Circuit Diagram of Lubrication System (For Engines Complied with Tier 4 and EU Stage V Regulation).................................................. 209 Layout Drawing of Component Parts of Lubrication System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)............. 210 Circuit Diagram of Lubrication System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)............................... 211 Engine Oil Pump..................................................................................................................................... 212 Engine Boost Oil Pump (For Engines Complied with Tier 4 and EU Stage V Regulation).................................................................. 214 Engine Oil Filter................................................................................................................................... 216 Engine Oil Cooler................................................................................................................................... 217 Engine Oil Pan...................................................................................................................................... 219 Fuel System............................................................................................................................................. 220 Layout Drawing of Component Parts of Fuel System (For Engines Complied with Tier 4 and EU Stage V Regulation)....................................... 220 Circuit Diagram of Fuel System (For Engines Complied with Tier 4 and EU Stage V Regulation)......................................................... 222 Function of Fuel System (For Engines Complied with Tier 4 and EU Stage V Regulation)................................................................ 223 Operation of Fuel System (For Engines Complied with Tier 4 and EU Stage V Regulation)............................................................... 223 Layout Drawing of Component Parts of Fuel System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation).................... 224 Circuit Diagram of Fuel System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)...................................... 225 Function of Fuel System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)............................................. 226 Operation of Fuel System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)............................................ 226 CRI System.......................................................................................................................................... 226 Supply Pump......................................................................................................................................... 232 Common Rail......................................................................................................................................... 235 Injector............................................................................................................................................ 238 Fuel Dosing System (For Engines Complied with Tier 4 and EU Stage V Regulation)..................................................................... 241 Fuel Prefilter...................................................................................................................................... 244 Fuel Main Filter.................................................................................................................................... 246 Cooling System.......................................................................................................................................... 247 Layout Drawing of Component Parts of Cooling System (For Engines Complied with Tier 4 and EU Stage V Regulation).................................... 247 Circuit Diagram of Cooling System (For Engines Complied with Tier 4 and EU Stage V Regulation)...................................................... 248 Layout Drawing of Component Parts of Cooling System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V)............................ 249 Circuit Diagram of Cooling System (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)................................... 250 Coolant Filter (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)...................................................... 251 Water Pump.......................................................................................................................................... 252 Thermostat Case..................................................................................................................................... 253 Thermostat.......................................................................................................................................... 256 Electrical System........................................................................................................................................... 258 Component Parts of Electrical System.................................................................................................................... 258 Alternator.......................................................................................................................................... 258 Alternator Mounting................................................................................................................................. 262 Starting Motor...................................................................................................................................... 264 Engine Controller (For Engines Complied with Tier 4 and EU Stage V Regulation)...................................................................... 266 Engine Controller (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)................................................... 281 Fuel Feed Pump (For Engines Complied with Tier 4 and EU Stage V Regulation)......................................................................... 296 Electric Fuel Primer Pump (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)........................................... 297 Electric Fuel Primer Pump........................................................................................................................... 297 Fuel Feed Pump Switch............................................................................................................................... 298 Electric Fuel Primer Pump Switch.................................................................................................................... 298 Sensor.................................................................................................................................................. 301 Structure of Ambient Pressure Sensor................................................................................................................ 301 Function of Ambient Pressure Sensor................................................................................................................. 301 Structure of Engine Oil Pressure Sensor............................................................................................................. 302 Function of Engine Oil Pressure Sensor.............................................................................................................. 302 Structure of Charge Pressure Sensor................................................................................................................. 303 Function of Charge Pressure Sensor.................................................................................................................. 303 Structure of Charge Temperature Sensor.............................................................................................................. 304 Function of Charge Temperature Sensor............................................................................................................... 304 Structure of Coolant Temperature Sensor............................................................................................................. 305 Function of Coolant Temperature Sensor.............................................................................................................. 305 Structure of NE (Crankshaft) Speed Sensor........................................................................................................... 306 Function of NE (Crankshaft) Speed Sensor............................................................................................................ 306 Structure of Bkup (Camshaft) Speed Sensor........................................................................................................... 307 Function of Bkup (Camshaft) Speed Sensor............................................................................................................ 307 Structure of Common Rail Pressure Sensor............................................................................................................ 308 Function of Common Rail Pressure Sensor............................................................................................................. 308 Structure of EGR Valve Lift Sensor (For Engines Complied with Tier 4 and EU Stage V Regulation)..................................................... 309 Function of EGR Valve Lift Sensor................................................................................................................... 309 Structure of VGT Speed Sensor (For Engines Complied with Tier 4 and EU Stage V Regulation).......................................................... 310 Function of VGT Speed Sensor........................................................................................................................ 310 Structure of VGT Position Sensor (For Engines Complied with Tier 4 and EU Stage V Regulation)....................................................... 311 Function of VGT Position Sensor..................................................................................................................... 311 Structure of Mass Air Flow and Temperature Sensor (For Engines Complied with Tier 4 and EU Stage V Regulation)...................................... 312 Function of Mass Air Flow and Temperature Sensor.................................................................................................... 312 Structure of Doser Fuel Pressure Sensor (For Engines Complied with Tier 4 and EU Stage V Regulation)................................................ 313 Function of Dosing Fuel Pressure Sensor............................................................................................................. 313 Structure of KDPF Differential Pressure and Outlet Pressure Sensor (For Engines Complied with Tier 4 and EU Stage V Regulation)..................... 314 Function of KDPF Differential Pressure and Outlet Pressure Sensor................................................................................... 314 Structure of Crankcase Pressure Sensor.............................................................................................................. 315 Function of Crankcase Pressure Sensor............................................................................................................... 315 Structure of Engine Oil Level Sensor................................................................................................................ 316 Function of Engine Oil Level Sensor................................................................................................................. 316 Structure of Air Cleaner Clogging Sensor............................................................................................................ 317 Function of Air Cleaner Clogging Sensor............................................................................................................. 317 20 Standard Value Table......................................................................................................................................... 319 Table of Contents........................................................................................................................................... 320 Abbreviation List........................................................................................................................................... 321 Standard Value Table for Engine............................................................................................................................. 327 Standard Value Table for Engine: SAA12V140E-7 (D475A-8, D475A-8E0, D475AI-8, D475AI-8E0)................................................................ 327 Standard Value Table for Engine: SAA12V140E-7 (D475A-8R, D475AI-8R)..................................................................................... 329 Standard Value Table for Engine: SAA12V140E-7 (HD785-8, HD785-8E0)...................................................................................... 331 Standard Value Table for Engine: SAA12V140E-7 (PC2000-11, PC2000-11E0).................................................................................. 333 Standard Value Table for Engine: SAA12V140E-7 (PC2000-11R).............................................................................................. 335 Standard Value Table for Engine: SAA12V140E-7 (WA800-8, WA800-8E0, WA900-8, WA900-8E0).................................................................. 337 Standard Value Table for Engine: SAA12V140E-7 (WA900-8R)................................................................................................ 339 Machine Posture and Procedures to Measure Performance................................................................................................... 341 Running-in Standard and Performance Test Standard........................................................................................................... 342 Running-in Standard and Performance Test Standard: SAA12V140E-7 (D475A-8, D475A-8E0, D475AI-8, D475AI-8E0).............................................. 342 Running-in Standard and Performance Test Standard: SAA12V140E-7 (D475A-8R, D475AI-8R)................................................................... 344 Running-in Standard and Performance Test Standard: SAA12V140E-7 (HD785-8, HD785-8E0).................................................................... 346 Running-in Standard and Performance Test Standard: SAA12V140E-7 (PC2000-11, PC2000-11E0)................................................................ 348 Running-in Standard and Performance Test Standard: SAA12V140E-7 (PC2000-11R)............................................................................ 350 Running-in Standard and Performance Test Standard: SAA12V140E-7 (WA800-8, WA800-8E0).................................................................... 352 Running-in Standard and Performance Test Standard: SAA12V140E-7 (WA900-8, WA900-8E0).................................................................... 354 Running-in Standard and Performance Test Standard: SAA12V140E-7 (WA900-8R).............................................................................. 356 50 Disassembly and Assembly..................................................................................................................................... 359 Table of Contents........................................................................................................................................... 360 Precautions Before Work..................................................................................................................................... 363 Abbreviation List........................................................................................................................................... 364 Related Information on Disassembly and Assembly............................................................................................................. 370 How to Read This Manual................................................................................................................................. 370 Coating Materials List.................................................................................................................................. 371 Special Tool List....................................................................................................................................... 376 Sketches of Special Tools............................................................................................................................... 379 Engine System............................................................................................................................................... 381 How to Disassemble Engine Generally..................................................................................................................... 381 How to Remove Fuel Main Filter and Oil Filter....................................................................................................... 389 How to Remove Alternator Wiring Harness............................................................................................................. 391 How to Remove Engine Wiring Harness Clamp and Band (Left Bank)...................................................................................... 394 How to Remove Engine Wiring Harness (Left Bank) and Wiring Harness Bracket (Left Bank).............................................................. 399 How to Remove Engine Wiring Harness Clamp and Band (Right Bank)..................................................................................... 405 How to Remove Engine Wiring Harness (Right Bank) and Wiring Harness Bracket (Right Bank)............................................................ 410 How to Remove Alternator............................................................................................................................ 416 How to Remove Heat Insulation Cover................................................................................................................. 421 How to Remove Boost Tube............................................................................................................................ 425 How to Remove EGR Cooler Air Vent Tube (Left Bank) and VGT Air Vent Tube (Left Bank)................................................................ 428 How to Remove EGR Cooler Air Vent Tube (Right Bank) and VGT Air Vent Tube (Right Bank).............................................................. 431 How to Remove Engine Oil Filter Head, Tube, and Hose................................................................................................ 434 How to Remove Cooling Plate Hose (Left Bank)........................................................................................................ 437 How to Remove Cooling Plate Hose (Right Bank)....................................................................................................... 439 How to Remove Fuel Main Filter Head and Tube........................................................................................................ 441 How to Remove Exhaust Temperature Sensor............................................................................................................ 446 How to Remove KCCV (Left Bank)...................................................................................................................... 449 How to Remove KCCV (Right Bank)..................................................................................................................... 455 How to Remove Engine Controller (Left Bank)......................................................................................................... 461 How to Remove Engine Controller (Right Bank)........................................................................................................ 464 How to Remove Oil Filler Tube, Oil Level Gauge, and Oil Level Sensor................................................................................ 467 How to Remove Water Pump Bypass Tube................................................................................................................ 471 How to Remove Fuel Doser Wiring Harness (Left Bank) and VGT Wiring Harness (Left Bank).............................................................. 475 How to Remove Fuel Doser Wiring Harness (Right Bank) and VGT Wiring Harness (Right Bank)............................................................ 478 How to Remove VGT Hydraulic Pressure Tube (Left Bank) and EGR Valve Hydraulic Pressure Tube (Left Bank)............................................. 481 How to Remove VGT Hydraulic Pressure Tube (Right Bank) and EGR Valve Hydraulic Pressure Tube (Right Bank)........................................... 486 How to Remove EGR Cooler (Left Bank) and EGR Valve (Left Bank)...................................................................................... 491 How to Remove EGR Cooler (Right Bank) and EGR Valve (Right Bank).................................................................................... 502 How to Remove Fuel Feed Pump (Left Bank) and Fuel Doser Solenoid Valve (Left Bank).................................................................. 513 How to Remove Fuel Feed Pump (Right Bank) and Fuel Doser Solenoid Valve (Right Bank)................................................................ 521 How to Remove Blower Connector...................................................................................................................... 528 How to Remove Fuel Doser (Left Bank), Fuel Doser Water Tube (Left Bank), and Exhaust Connector (Left Bank).......................................... 530 How to Remove Fuel Doser (Right Bank), Fuel Doser Water Tube (Right Bank), and Exhaust Connector (Right Bank)....................................... 534 How to Remove Air Intake Connector (Left Bank) and Mixing Connector (Left Bank)..................................................................... 538 How to Remove Air Intake Connector (Right Bank) and Mixing Connector (Right Bank)................................................................... 541 How to Remove Fuel High-Pressure Piping Clamps (Left Bank), Fuel Injection Piping Clamps (Left Bank), and Injector Wiring Harness (Left Bank)....... 544 How to Remove Fuel High-Pressure Piping Clamps (Right Bank), Fuel Injection Piping Clamps (Right Bank), and Injector Wiring Harness (Right Bank).... 548 How to Remove Air Intake Manifold................................................................................................................... 552 How to Remove Breather.............................................................................................................................. 557 How to Remove VGT (Left Bank) and VGT Water Tube (Left Bank)........................................................................................ 561 How to Remove VGT (Right Bank) and VGT Water Tube (Right Bank)...................................................................................... 566 How to Remove Alternator Drive and Engine Boost Oil Pump............................................................................................ 571 How to Remove Cylinder Head Cover, Rocker Arm Housing, and Injector Wiring Harness.................................................................. 574 How to Remove VGT Oil Tube (Left Bank), Fuel High-Pressure Pipe (Left Bank), and Fuel Injection Pipe (Left Bank).................................... 578 How to Remove VGT Oil Tube (Right Bank), Fuel High-Pressure Pipe (Right Bank), and Fuel Injection Pipe (Right Bank)................................. 583 How to Remove Supply Pump (Left Bank), Common Rail (Left Bank), and KCCV Oil Drain Check Valve (Left Bank).......................................... 588 How to Remove Supply Pump (Right Bank) and Common Rail (Right Bank)................................................................................. 593 How to Remove KCCV Oil Drain Check Valve (Right Bank) and Regulator Valve........................................................................... 596 How to Remove Injector and Cam Follower............................................................................................................. 599 How to Remove Cylinder Head Air Vent Tube........................................................................................................... 604 How to Remove Exhaust Manifold...................................................................................................................... 607 How to Remove Cylinder Head......................................................................................................................... 610 How to Remove Crank Pulley, and Vibration Damper.................................................................................................... 614 How to Remove Starting Motor........................................................................................................................ 617 How to Remove Barring Device and NE (Crankshaft) Speed Sensor....................................................................................... 619 How to Remove Flywheel and Water Manifold Cover..................................................................................................... 621 How to Remove Engine Oil Pan and Relief Valve....................................................................................................... 624 How to Remove Front Cover........................................................................................................................... 628 How to Remove Flywheel Housing...................................................................................................................... 631 How to Remove Timing Gear, Oil Pump, Gear Case, and Water Pump...................................................................................... 634 How to Remove Engine Oil Cooler..................................................................................................................... 641 How to Remove Front Hanger and Thermostat Housing................................................................................................... 644 How to Remove Rear Hanger and EGR Water Divider Connector........................................................................................... 647 How to Remove Piston and Connecting Rod............................................................................................................. 649 How to Remove Crankshaft............................................................................................................................ 653 How to Remove Cylinder Liner........................................................................................................................ 656 How to Assemble Engine Generally........................................................................................................................ 659 How to Install Cylinder Liner....................................................................................................................... 667 How to Install Crankshaft........................................................................................................................... 672 How to Install Piston and Connecting Rod............................................................................................................ 676 How to Install Rear Hanger and EGR Water Divider Connector.......................................................................................... 685 How to Install Front Hanger and Thermostat Housing.................................................................................................. 687 How to Install Engine Oil Cooler.................................................................................................................... 690 How to Install Timing Gear, Oil Pump, Gear Case, and Water Pump..................................................................................... 694 How to Install Flywheel Housing..................................................................................................................... 706 How to Install Front Cover.......................................................................................................................... 710 How to Install Engine Oil Pan and Relief Valve...................................................................................................... 713 How to Install Flywheel and Water Manifold Cover.................................................................................................... 718 How to Install Barring Device and NE (Crankshaft) Speed Sensor...................................................................................... 723 How to Install Starting Motor....................................................................................................................... 725 How to Install Crank Pulley and Vibration Damper.................................................................................................... 728 How to Install Cylinder Head........................................................................................................................ 732 How to Install Exhaust Manifold..................................................................................................................... 737 How to Install Cylinder Head Air Vent Tube.......................................................................................................... 741 How to Install Injector and Cam Follower............................................................................................................ 744 How to Install KCCV Oil Drain Check Valve (Right Bank) and Regulator Valve.......................................................................... 750 How to Install Supply Pump (Right Bank) and Common Rail (Right Bank)................................................................................ 754 How to Install Supply Pump (Left Bank), Common Rail (Left Bank), and KCCV Oil Drain Check Valve (Left Bank)......................................... 758 How to Install VGT Oil Tube (Right Bank), Fuel High-Pressure Pipe (Right Bank), and Fuel Injection Pipe (Right Bank)................................ 765 How to Install VGT Oil Tube (Left Bank), Fuel High-Pressure Pipe (Left Bank), and Fuel Injection Pipe (Left Bank)................................... 773 How to Install Cylinder Head Cover, Rocker Arm Housing, and Injector Wiring Harness................................................................. 781 How to Install Alternator Drive and Engine Boost Oil Pump........................................................................................... 787 How to Install VGT (Right Bank) and VGT Water Tube (Right Bank)..................................................................................... 790 How to Install VGT (Left Bank) and VGT Water Tube (Left Bank)....................................................................................... 797 How to Install Breather............................................................................................................................. 804 How to Install Air Intake Manifold.................................................................................................................. 808 How to Install Fuel High-Pressure Piping Clamps (Right Bank), Fuel Injector Clamps (Right Bank), and Injector Wiring Harness (Right Bank)........... 814 How to Install Fuel High-Pressure Piping Clamps (Left Bank), Fuel Injector Clamps (Left Bank), and Injector Wiring Harness (Left Bank).............. 820 How to Install Air Intake Connector (Right Bank) and Mixing Connector (Right Bank).................................................................. 826 How to Install Air Intake Connector (Left Bank) and Mixing Connector (Left Bank).................................................................... 829 How to Install Fuel Doser (Right Bank), Fuel Doser Water Tube (Right Bank), and Exhaust Connector (Right Bank)...................................... 832 How to Install Fuel Doser (Left Bank), Fuel Doser Water Tube (Left Bank), and Exhaust Connector (Left Bank)......................................... 840 How to Install Blower Connector..................................................................................................................... 848 How to Install Fuel Feed Pump (Right Bank) and Fuel Doser Solenoid Valve (Right Bank)............................................................... 851 How to Install Fuel Feed Pump (Left Bank) and Fuel Doser Solenoid Valve (Left Bank)................................................................. 862 How to Install EGR Cooler (Right Bank) and EGR Valve (Right Bank)................................................................................... 876 How to Install EGR Cooler (Left Bank) and EGR Valve (Left Bank)..................................................................................... 892 How to Install VGT Hydraulic Pressure Tube (Right Bank) and EGR Valve Hydraulic Pressure Tube (Right Bank).......................................... 908 How to Install VGT Hydraulic Pressure Tube (Left Bank) and EGR Valve Hydraulic Pressure Tube (Left Bank)............................................ 915 How to Install Fuel Doser Wiring Harness (Right Bank) and VGT Wiring Harness (Right Bank)........................................................... 923 How to Install Fuel Doser Wiring Harness (Left Bank) and VGT Wiring Harness (Left Bank)............................................................. 927 How to Install Water Pump Bypass Tube............................................................................................................... 931 How to Install Oil Filler Tube, Oil Level Gauge, and Oil Level Sensor............................................................................... 937 How to Install Engine Controller (Right Bank)....................................................................................................... 941 How to Install Engine Controller (Left Bank)........................................................................................................ 944 How to Install KCCV (Right Bank).................................................................................................................... 947 How to Install KCCV (Left Bank)..................................................................................................................... 954 How to Install Exhaust Temperature Sensor........................................................................................................... 962 How to Install Fuel Main Filter Head and Tube....................................................................................................... 967 How to Install Cooling Plate Hose (Right Bank)...................................................................................................... 975 How to Install Cooling Plate Hose (Left Bank)....................................................................................................... 978 How to Install Engine Oil Filter Head, Tube, and Hose............................................................................................... 981 How to Install EGR Cooler Air Vent Tube (Right Bank) and VGT Air Vent Tube (Right Bank)............................................................. 985 How to Install EGR Cooler Air Vent Tube (Left Bank) and VGT Air Vent Tube (Left Bank)............................................................... 989 How to Install Boost Tube........................................................................................................................... 992 How to Install Heat Insulation Cover................................................................................................................ 995 How to Install Alternator........................................................................................................................... 999 How to Install Engine Wiring Harness (Left Bank) and Wiring Harness Bracket (Left Bank).............................................................1007 How to Install Engine Wiring Harness Clamp and Band (Right Bank)....................................................................................1013 How to Install Engine Wiring Harness (Left Bank) and Wiring Harness Bracket (Left Bank).............................................................1018 How to Install Engine Wiring Harness Clamp and Band (Left Bank).....................................................................................1025 How to Install Alternator Wiring Harness............................................................................................................1030 How to Install Fuel Main Filter and Oil Filter......................................................................................................1035 60 Maintenance Standard.........................................................................................................................................1037 Table of Contents...........................................................................................................................................1038 Abbreviation List...........................................................................................................................................1039 Engine System...............................................................................................................................................1045 Intake and Exhaust System Parts.........................................................................................................................1045 Maintenance Standard for VGT (For Engines Complied with Tier 4 and EU Stage V Regulation)...........................................................1045 Maintenance Standard for Turbocharger (For Engines Other Than Engines Complied with Tier 4 and EU Stage V Regulation)...............................1046 Engine Main Body Parts..................................................................................................................................1048 Maintenance Standard for Cylinder Head..............................................................................................................1048 Maintenance Standard for Cylinder Block.............................................................................................................1050 Maintenance Standard for Cylinder Liner.............................................................................................................1052 Maintenance Standard for Crankshaft.................................................................................................................1054 Maintenance Standard for Cam Follower and Push Rod..................................................................................................1056 Maintenance Standard for Piston.....................................................................................................................1058 Maintenance Standard for Connecting Rod.............................................................................................................1060 Maintenance Standard for Vibration Damper...........................................................................................................1062 Maintenance Standard for Timing Gear................................................................................................................1064 Maintenance Standard for Camshaft...................................................................................................................1066 Maintenance Standard for Valve and Valve Guide......................................................................................................1067 Maintenance Standard for Rocker Arm.................................................................................................................1070 Maintenance Standard for Crosshead and Guide........................................................................................................1071 Maintenance Standard for Flywheel...................................................................................................................1072 Lubrication System......................................................................................................................................1074 Maintenance Standard for Relief Valve of Engine Oil Pump............................................................................................1074 Maintenance Standard for Relief Valve of Engine Boost Oil Pump (For Engines Complied with Tier 4 and EU Stage V Regulation).........................1076 Maintenance Standard for Safety Valve of Engine Oil Filter..........................................................................................1077 Maintenance Standard for Oil Cooler Bypass Valve and Regulator Valve................................................................................1078 Cooling System..........................................................................................................................................1079 Maintenance Standard for Water Pump.................................................................................................................1079 Maintenance Standard for Thermostat.................................................................................................................1080 Index............................................................................................................................................................1081
DESCRIPTION:
KOMATSU 12V140E-7 SERIES ENGINE SHOP MANUAL SEN06656-11 – 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.
S.S 24/12/24
