Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE Shop Manual PDF

Description

Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE Shop Manual CEBM002603 – PDF DOWNLOAD

FILE DETAILS:

Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE Shop Manual CEBM002603 – PDF DOWNLOAD

Language : English
Pages : 286
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE Shop Manual CEBM002603 – PDF DOWNLOAD

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

DESCRIPTION:

Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES DIESEL ENGINE Shop Manual CEBM002603 – PDF DOWNLOAD

G.B  21/12/24