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KOMATSU SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM002603
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Description
KOMATSU SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL
KOMATSU SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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. - TESTING, ADJUSTING AND TROUBLESHOOTING
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” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL
COVER........................................................................................... 1 CONTENTS........................................................................................ 2 01 GENERAL..................................................................................... 25 SPECIFICATIONS.............................................................................. 26 GENERAL ASSEMBLY DRAWING.................................................................... 27 VIEW FROM LEFT SIDE..................................................................... 27 VIEW FROM RIGHT SIDE.................................................................... 28 VIEW FROM FRONT......................................................................... 29 VIEW FROM REAR.......................................................................... 30 VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS)................................................ 31 VIEW FROM TOP........................................................................... 32 ENGINE PERFORMANCE CURVE.................................................................... 33 WA800-2LC............................................................................... 33 WA900-1LC............................................................................... 34 330M.................................................................................... 35 11 STRUCTURE AND FUNCTION....................................................................... 37 GENERAL STRUCTURE........................................................................... 39 INTAKE AND EXHAUST SYSTEM................................................................... 41 INTAKE SYSTEM........................................................................... 41 EXHAUST SYSTEM.......................................................................... 42 TURBOCHARGER............................................................................ 43 AFTERCOOLER............................................................................. 44 ENGINE BODY................................................................................. 45 CYLINDER HEAD........................................................................... 45 SPECIFICATIONS...................................................................... 46 VALVE SEAT.......................................................................... 46 ROCKER ARM HOUSING COVER............................................................ 46 FUEL INJECTION NOZZLE............................................................... 46 CYLINDER BLOCK.......................................................................... 47 SPECIFICATIONS...................................................................... 48 PISTON COOLING...................................................................... 48 CYLINDER LINER...................................................................... 48 LINER SEAL.......................................................................... 48 MAIN REVOLVING SYSTEM................................................................... 49 CRANKSHAFT.......................................................................... 50 PISTON.............................................................................. 50 CONNECTING ROD...................................................................... 50 TIMING GEAR............................................................................. 51 FRONT SEAL.......................................................................... 52 VALVE SYSTEM............................................................................ 53 VALVE TIMING........................................................................ 54 CAMSHAFT............................................................................ 54 FLYWHEEL AND FLYWHEEL HOUSING........................................................... 55 REAR SEAL........................................................................... 55 LUBRICATING OIL SYSTEM...................................................................... 56 PISTON COOLING, CONNECTING ROD, OVERHEAD................................................ 57 FRONT GEAR TRAIN........................................................................ 58 TURBOCHARGER............................................................................ 59 FULL FLOW LUBRICATING OIL FILTERS....................................................... 60 LUBRICATING OIL PUMP.................................................................... 61 SPECIFICATIONS...................................................................... 61 MAIN RELIEF VALVE....................................................................... 62 SPECIFICATIONS...................................................................... 62 OIL COOLER BYPASS VALVE................................................................. 63 SPECIFICATIONS...................................................................... 63 REGULATOR VALVE..................................................................... 63 LUBRICATING OIL FILTER.................................................................. 64 SPECIFICATIONS...................................................................... 64 SAFETY VALVE........................................................................ 64 LUBRICATING OIL BYPASS FILTER........................................................... 65 SPECIFICATIONS...................................................................... 65 LUBRICATING OIL COOLER.................................................................. 66 SPECIFICATIONS...................................................................... 66 FUEL SYSTEM................................................................................. 67 FLOW DIAGRAM............................................................................ 67 FUEL INJECTION PUMP..................................................................... 68 SPECIFICATIONS...................................................................... 68 RIGHT BANK PIPING....................................................................... 69 LEFT BANK PIPING........................................................................ 70 FUEL INJECTION NOZZLE................................................................... 71 SPECIFICATIONS...................................................................... 71 FUEL FILTER............................................................................. 72 SPECIFICATIONS...................................................................... 72 COOLING SYSTEM.............................................................................. 73 THERMOSTAT HOUSING FLOW................................................................. 74 COOLING FAN BELT........................................................................ 75 WATER PUMP.............................................................................. 76 SPECIFICATIONS...................................................................... 76 COOLING FAN............................................................................. 77 CORROSION RESISTOR...................................................................... 78 SPECIFICATIONS...................................................................... 78 ACCESSORY................................................................................... 79 AIR COMPRESSOR.......................................................................... 79 SPECIFICATIONS...................................................................... 80 UNLOADER VALVE...................................................................... 80 ELECTRICAL SYSTEM........................................................................... 81 ALTERNATOR MOUNTING..................................................................... 81 ALTERNATOR WITH REGULATOR............................................................... 82 STARTING MOTOR.......................................................................... 83 ELECTRICAL INTAKE AIR HEATER............................................................ 84 SPECIFICATIONS...................................................................... 84 12 TESTING, ADJUSTING AND TROUBLESHOOTING...................................................... 85 ADJUSTING VALVE CLEARANCE................................................................... 87 MEASURING COMPRESSION PRESSURE.............................................................. 88 FUEL SYSTEM................................................................................. 89 FUEL PUMP REMOVAL....................................................................... 89 FUEL PUMP INSTALLATION AND TIMING....................................................... 91 CHECKING INJECTION TIMING................................................................... 96 USING PROXIMITY SENSOR.................................................................. 96 USING FUEL PUMP LOCK PIN................................................................ 99 SENSOR INSTALLATION.........................................................................102 SPEED SENSOR............................................................................102 TIMING SENSOR (WITH FLYWHEEL TIMING HOLES)..............................................102 2ND DESIGN (FLYWHEEL TIMING LUGS).......................................................103 FUEL OVERFLOW VALVE PRESSURE................................................................104 ADJUSTING FUEL INJECTION PRESSURE...........................................................105 PERFORMANCE TEST............................................................................106 ENGINE TESTING..........................................................................106 IN SERVICE RUN......................................................................106 ENGINE DYNAMOMETER RUN-IN...........................................................106 PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN............................................106 INSITE SERVICE TOOL.................................................................106 FUEL FLOW MEASUREMEnT...................................................................107 INSTALLATION........................................................................107 MEASUREMENT OF FUEL CONSUMPTION RATIO...............................................107 SPECIFICATIONS......................................................................108 DYNAMOMETER WORKSHEET...................................................................109 ENGINE DYNAMOMETER TESTING..................................................................110 SETUP...................................................................................110 COOLANT PLUMBING........................................................................110 GENERAL ENGINE TEST PROCEDURES..........................................................110 ENGINE THROTTLE CONTROL.................................................................111 TESTING PROCEDURE.......................................................................112 ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER.......................................112 FUEL INLET RESTRICTION..............................................................112 FUEL DRAIN LINE RESTRICTION.........................................................113 INTAKE MANIFOLD PRESSURE............................................................113 INTAKE AIR RESTRICTION..............................................................113 EXHAUST RESTRICTION.................................................................113 ENGINE BLOWBY.......................................................................114 LUBRICATING OIL PRESSURE............................................................116 COOLANT PRESSURE....................................................................116 LUBRICATING OIL TEMPERATURE.........................................................116 AIR COMPRESSOR......................................................................117 STARTING MOTOR......................................................................117 ENGINE RUN-IN INSTRUCTIONS..............................................................118 TEST LOAD...........................................................................118 TESTING AND ADJUSTING TOOL LIST.............................................................121 COOLING SYSTEM..............................................................................123 CHECKING FAN BELT TENSION...............................................................123 330M................................................................................123 WA800/WA900.........................................................................123 ALTERNATOR BELT.............................................................................123 CHECKING BELT TENSION...................................................................123 ADJUSTING BELT TENSION..................................................................124 DRIVE BELT TENSION......................................................................124 13 DISASSEMBLY AND ASSEMBLY....................................................................125 DISASSEMBLY.................................................................................127 SPECIAL TOOLS...........................................................................127 WASHING.................................................................................127 SETTING ENGINE STAND....................................................................127 GENERAL DISASSEMBLY.....................................................................127 ENGINE COOLING WATER AND ENGINE OIL.................................................127 MUFFLES ASSEMBLY....................................................................128 FAN.................................................................................128 AIR COMPRESSOR ASSEMBLY.............................................................136 FUEL PUMP DRIVE ASSEMBLY............................................................137 WATER PUMP ASSEMBLY.................................................................139 BREATHER............................................................................139 OIL COOLER ASSEMBLY.................................................................140 ROCKER LEVER COVER..................................................................140 ROCKER LEVER........................................................................141 CYLINDER HEAD ASSEMBLY..............................................................142 CAM FOLLOWER ASSEMBLY...............................................................142 THERMOSTAT HOUSING..................................................................143 ACCESSORY DRIVE ASSEMBLY............................................................143 DAMPER, CRANKSHAFT PULLEY ASSEMBLY..................................................144 OIL PAN.............................................................................144 MAIN RELIEF VALVE, SUCTION TUBE.....................................................144 FRONT SUPPORT.......................................................................144 SENSORS.............................................................................144 FLYWHEEL............................................................................145 GEAR CASE...........................................................................145 CYLINDER BLOCK......................................................................147 WASHING.....................................................................................151 WASHING CYLINDER BLOCK..................................................................151 WASHING CRANKSHAFT......................................................................153 WASHING CONNECTING ROD..................................................................153 MEASURING PARTS.............................................................................154 MEASURING CURVATURE OF CRANKSHAFT.......................................................154 MEASURING OUTSIDE DIAMETER OF JOURNAL...................................................154 MEASURING OUT-OF-ROUNDNESS OF JOURNAL...................................................154 MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL..............................155 DIAMETER OF JOURNAL.....................................................................155 MEASURING DEPTH OF CYLINDER LINER COUNTERBORE...........................................155 MEASURING MAIN BEARING BORE.............................................................156 MEASURING CURVATURE OF CAMSHAFT.........................................................156 MEASURING OUTSIDE DIAMETER OF JOURNAL...................................................156 MEASURING HEIGHT OF CAM.................................................................157 MEASURING PISTON RING GROOVE............................................................157 SPECIAL TOOLS.......................................................................157 MEASURING PISTON RING END GAP...........................................................157 MEASURING OUTSIDE DIAMETER OF PISTON....................................................158 MEASURING LENGHT OF CONNECTING ROD......................................................158 MEASURING INSIDE DIAMTER AT SMALL END OF CONNECTING ROD.................................159 MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD..................................159 MEASURING CURVATURE, TWISTING OF CONNECTING ROD.........................................159 STANDARD PRESSURE FOR PARTS PRESSURE TESTING............................................160 ASSEMBLY....................................................................................161 TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD..................................161 SPECIAL TOOLS...........................................................................162 PREPARATORY WORK........................................................................162 GENERAL ASSEMBLY........................................................................163 CYLINDER BLOCK......................................................................163 GEAR CASE...........................................................................175 FLYWHEEL............................................................................181 SENSOR..............................................................................185 FRONT SUPPORT.......................................................................186 MAIN RELIEF VALVE, SUCTION PIPE.....................................................186 OIL PAN.............................................................................186 DAMPER, CRANKSHAFT PULLEY ASSEMBLY..................................................186 ACCESSORY DRIVE ASSEMBLY............................................................187 THERMOSTAT HOUSING..................................................................188 CAM FOLLOWER ASSEMBLY...............................................................188 CYLINDER HEAD ASSEMBLY..............................................................188 ROCKER LEVER........................................................................191 ROCKER LEVER COVER..................................................................192 OIL COOLER ASSEMBLY.................................................................193 BREATHER............................................................................195 WATER PUMP ASSEMBLY.................................................................195 FUEL PUMP DRIVE.....................................................................196 AIR COMPRESSOR ASSEMBLY.............................................................198 FUEL INJECTION PUMP.................................................................199 EXHAUST MANIFOLD ASSEMBLY...........................................................199 INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY...............................................200 TURBOCHARGER ASSEMBLY...............................................................205 INTAKE CONNECTOR....................................................................206 FAN.................................................................................206 GENERAL ASSEMBLY....................................................................207 14 MAINTENANCE STANDARD........................................................................209 INTAKE AND EXHAUST SYSTEM...................................................................210 TURBOCHARGER............................................................................210 ENGINE BODY.................................................................................211 CYLINDER HEAD...........................................................................211 VALVE, VALVE SPRING AND VALVE GUIDE.....................................................212 ROCKER ARM AND SHAFT....................................................................214 CROSSHEAD AND GUIDE.....................................................................215 CYLINDER BLOCK..........................................................................216 CYLINDER LINER..........................................................................218 CRANKSHAFT..............................................................................219 CAMSHAFT................................................................................221 CAM FOLLOWER AND PUSH ROD...............................................................222 TIMING GEAR.............................................................................223 PISTON, PISTON RING AND PISTON PIN......................................................225 CONNECTING ROD..........................................................................227 FLYWHEEL AND FLYWHEEL HOUSING...........................................................229 LUBRICATION SYSTEM..........................................................................230 OIL PUMP................................................................................230 MAIN RELIEF VALVE.......................................................................232 OIL COOLER BY-PASS VALVE, REGULATOR VALVE...............................................233 COOLING SYSTEM..............................................................................234 WATER PUMP..............................................................................234 THERMOSTAT..............................................................................235 15 REPAIR AND REPLACEMENT OF PARTS..............................................................237 TABLE OF SPECIAL TOOLS......................................................................238 CYLINDER HEAD...............................................................................239 CYLINDER AND MOUNTING FACE..............................................................242 REPLACING VALVE SEAT....................................................................243 PRESSURE TEST OF CYLINDER HEAD..........................................................247 REPLACING VALVE GUIDE...................................................................248 REPLACING CROSSHEAD GUIDE...............................................................248 GRINDING VALVE..........................................................................249 CYLINDER BLOCK..............................................................................250 METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE USING ALIGNMENT BAR....253 CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE......................................254 REPLACING MAIN BEARING CAP..............................................................261 REPLACING CAM BUSHING...................................................................263 CRANKSHAFT..................................................................................265 CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION..............................267 GRINDING CRANKSHAFT.....................................................................271 CORRECTING FRONT SEAL CONTACT SURFACE...................................................278 CORRECTING REAR SEAL CONTACT SURFACE....................................................280 CONNECTING ROD..............................................................................282 REPLACING CONNECTING ROD SMALL END BUSHING..............................................284 REPLACING CRANKSHAFT GEAR...............................................................285 REPLACING CAMSHAFT GEAR.................................................................286 REPLACING FLYWHEEL RING GEAR............................................................286
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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Xander Lance –
First time I’ve used this service and everything was as expected – product, price, and delivery. Thanks!!