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KOMATSU SA6D140-H-1 DIESEL ENGINE SERVICE MANUAL – PDF DOWNLOAD
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Description
KOMATSU SA6D140-H-1 DIESEL ENGINE SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU SA6D140-H-1 DIESEL ENGINE SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 290
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU SA6D140-H-1 DIESEL ENGINE SERVICE MANUAL – PDF DOWNLOAD
COVER........................................................................................ 1 CONTENTS..................................................................................... 2 01 GENERAL................................................................................... 23 APPLICABLE MACHINE....................................................................... 24 SPECIFICATIONS........................................................................... 25 GENERAL ASSEMBLY DRAWING................................................................. 26 WEIGHT TABLE............................................................................. 31 ENGINE PERFORMANCE CURVE................................................................. 32 11 STRUCTURE AND FUNCTION.................................................................... 33 GENERAL STRUCTURE........................................................................ 34 GENERAL STRUCTURE.................................................................... 34 INTAKE AND EXHAUST SYSTEM................................................................ 36 INTAKE AND EXHAUST SYSTEM............................................................ 36 AIR CLEANER (IF EQUIPPED)............................................................ 42 TURBOCHARGER......................................................................... 43 ENGINE BODY.............................................................................. 45 CYLINDER HEAD........................................................................ 45 CYLINDER BLOCK....................................................................... 49 MAIN CIRCULATION SYSTEM.............................................................. 54 PISTON AND CONNECTING ROD............................................................ 57 MAIN CIRCULATION SYSTEM.............................................................. 62 TIMING GEAR.......................................................................... 64 VALVE MECHANISM...................................................................... 66 FLYWHEEL, FLYWHEEL HOUSING........................................................... 70 LUBRICATION SYSTEM....................................................................... 72 LUBRICATION SYSTEM................................................................... 72 LUBRICATION SYSTEM CHART............................................................. 75 OIL PUMP............................................................................. 76 REGULATOR VALVE, PISTON COOLING VALVE................................................ 77 OIL FILTER (FULL-FLOW OIL FILTER).................................................... 78 BYPASS FILTER ....................................................................... 80 OIL COOLER........................................................................... 81 FUEL SYSTEM.............................................................................. 83 FUEL SYSTEM.......................................................................... 83 FUEL SYSTEM CHART.................................................................... 84 FUEL INJECTION PUMP.................................................................. 85 ELECTRONIC GOVERNOR (RED-|||)........................................................ 91 STRUCTURAL DRAWING................................................................... 94 CONTROLLER I/O PORT.................................................................. 95 CONTROL OF ELECTRONIC GOVERNOR....................................................... 96 CONTROL BOX..........................................................................101 FEED PUMP............................................................................102 PRIMING PUMP.........................................................................104 FUEL INJECTION NOZZLE................................................................105 FUEL FILTER..........................................................................107 COOLING SYSTEM...........................................................................109 COOLING SYSTEM.......................................................................109 COOLING SYSTEM CHART.................................................................111 WATER PUMP...........................................................................112 THERMOSTAT...........................................................................114 STARTING MOTOR.......................................................................116 12 TESTING AND ADJUSTING.....................................................................118 TESTING AND ADJUSTING....................................................................119 MOUNTING (ADJUSTING) METHOD OF ENGINE SPEED SENSOR...................................119 INTAKE AND EXHAUST SYSTEM................................................................120 SUCTION RESISTANCE...................................................................120 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).......................................121 ADJUSTING VALVE CLEARANCE............................................................122 MEASURING EXHAUST GAS COLOR..........................................................123 ENGINE BODY..............................................................................124 MEASURING COMPRESSION PRESSURE.......................................................124 MEASURING BLOW-BY PRESSURE...........................................................125 LUBRICATION SYSTEM.......................................................................126 MEASURING OIL PRESSURE...............................................................126 FUEL SYSTEM..............................................................................127 TESTING AND ADJUSTING FULE INJECTION TIMING..........................................127 ADJUSTING FUEL INJECTION PRESSURE....................................................129 ADJUSTING FUEL INJECTION PUMP........................................................130 FUEL INJECTION VOLUME STANDARD (WITH ELECTRONIC GOVERNOR)............................131 ADJUSTING GOVERNOR...................................................................132 ADJUSTING OUTPUT.....................................................................133 COOLING SYSTEM...........................................................................135 CHECKING COOLING SYSTEM (RADIATOR) FOR COOLANT LEAKAGE...............................135 METHOD OF MEASURING CORROSION PREVENTIVE CONTENT IN COOLANT..........................136 PERFORMANCE TEST.........................................................................137 RUN-IN STANDARD......................................................................137 PERFORMANCE TEST STANDARDS...........................................................138 TROUBLESHOOTING..........................................................................140 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................142 METHOD OF USING TROUBLESHOOTING CHARTS...............................................143 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)........................147 S-2 ENGING DOES NOT START............................................................148 (1) ENGINE DOES NOT TURN.........................................................148 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)......149 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)....150 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)..............................151 S-4 ENGINE STOPS DURING OPERATIONS...................................................152 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................153 S-6 ENGINE LACKS OUTPUT (NO POWER)...................................................154 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...................................155 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)..........................156 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................157 S-10 FUEL CONSUMPTION IS EXCESSIVE...................................................158 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.........159 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)......................160 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)............................................161 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................162 S-15 ABNORMAL NOISE IS MADE..........................................................163 S-16 VIBRATION IS EXCESSIVE..........................................................164 S-17 DIAGNOSIS USING ELECTRONIC GOVERNOR DIAGNOSIS SYSTEM DISPLAY....................165 TESTING AND ADJUSTING DATA...............................................................184 13 DISASSEMBLY AND ASSEMBLY..................................................................185 GENERAL DISASSEMBLY......................................................................186 1. STARTING MOTOR....................................................................186 2. TURBOCHARGER DRAIN TUBE...........................................................186 3. SETTING ENGINE IN ENGINE OVERHAUL STAND...........................................187 4. CONNECTOR.........................................................................187 5. DIPSTICK GUIDE, AIR COMPRESSOR....................................................187 6. FUEL HOSE.........................................................................187 7. TURBOCHARGER......................................................................187 8. EXHAUST MANIFOLD..................................................................188 9. AFTER-COOLER ASSEMBLY.............................................................188 10. FUEL INJECTION TUBE..............................................................188 11. FUEL INJECTION PUMP ASSEMBLY.....................................................188 12. TUBE, BRACKET, PTO CASE..........................................................189 13. FUEL FILTER......................................................................189 14. OIL FILTER.......................................................................189 15. BRACKET, COVER...................................................................189 16. OIL PAN..........................................................................189 17. SUCTION PIPE, UNDER FRAME........................................................190 18. FLYWHEEL.........................................................................190 19. FLYWHEEL HOUSING.................................................................190 20. AIR VENT TUBE, SPILL PIPE, ROCKER ARM HOUSING COVER..............................190 21. NOZZLE HOLDER, INLET CONNECTOR...................................................191 22. ROCKER ARM.......................................................................191 23. PUSH ROD.........................................................................191 24. CROSSHEAD........................................................................191 25. ROCKET ARM HOUSING...............................................................191 26. CYLINDER HEAD ASSEMBLY...........................................................192 27. VIBRATION DAMPER・CRANKSHAFT PULLEY ASSEMBLY......................................192 28. FRONT SUPPORT....................................................................192 29. THERMOSTAT HOUSING...............................................................193 30. WATER PUMP ASSEMBLY..............................................................193 31. OIL COOLER ASSEMBLY..............................................................193 32. CAM FOLLOWER.....................................................................193 33. GEAR CASE COVER..................................................................194 34. INJECTION PUMP DRIVE GEAR........................................................194 35. CAMSHAFT.........................................................................194 36. OIL PUMP ASSEMBLY, OIL PUMP IDLER GEAR...........................................194 37. MAIN IDLER GEAR, INJECTION PUMP DRIVE SHAFT......................................194 38. PISTON COOLING NOZZLE............................................................195 39. PISTON AND CONNECTING ROD ASSEMBLY...............................................195 40. CRANKSHAFT.......................................................................196 41. CYLINDER LINER...................................................................198 GENERAL ASSEMBLY.........................................................................199 GENERAL ASSEMBLY.....................................................................200 TIGHTENING BOLTS BY THE PLASTIC RANGE TURNING ANGLE METHOD.......................200 SPECIAL TOOLS....................................................................201 PREPARATORY WORK.................................................................201 1. CYLINDER LINER................................................................202 2. CRANKSHAFT....................................................................204 3. PISTON AND CONNECTING ROD ASSEMBLY............................................206 4. PISTON COOLING NOZZLE.........................................................209 5. MAIN IDLER GEAR, FUEL INJECTION PUMP DRIVE SHAFT..............................209 6. SUB IDLER GEAR, OIL PUMP ASSEMBLY.............................................209 7. CAMSHAFT......................................................................210 8. FUEL INJECTION PUMP DRIVE GEAR................................................210 9. GEAR CASE COVER...............................................................211 10. CAM FOLLOWER.................................................................212 11. OIL COOLER ASSEMBLY..........................................................212 12. WATER PUMP ASSEMBLY..........................................................212 13. THERMOSTAT HOUSING...........................................................213 14. FRONT SUPPORT................................................................213 15. VIBRATION DAMPER, CRANKSHAFT PULLEY ASSEMBLY.................................213 16. CYLINDER HEAD ASSEMBLY.......................................................213 17. CROSSHEAD....................................................................215 18. ROCKER ARM HOUSING...........................................................215 19. PUSH ROD.....................................................................215 20. ROCKER ARM...................................................................215 21. ADJUSTING VALVE CLEARANCE....................................................216 22. NOZZLE HOLDER, INLET CONNECTOR...............................................217 23. ROCKER ARM HOUSING COVER, SPILL PIPE, AIR VENT TUBE..........................217 24. FLYWHEEL HOUSING.............................................................218 25. FLYWHEEL.....................................................................219 OIL PAN PLATE AND SUCTION PIPE...................................................220 26. SUCTION PIPE.................................................................220 27. OIL PAN......................................................................220 28. BRACKET, COVER ..............................................................221 29. OIL FILTER ASSEMBLY..........................................................221 30. FUEL FILTER ASSEMBLY.........................................................221 31. PTO CASE TUBE, BRACKET.......................................................221 32. FUEL INJECTION PUMP ASSEMBLY.................................................221 33. FUEL INJECTION TUBE..........................................................223 34. AFTER-COOLER ASSEMBLY........................................................223 35. EXHAUST MANIFOLD.............................................................223 36. TURBOCHARGER.................................................................223 37. FUEL HOSE....................................................................223 38. DIPSTICK GUIDE, AIR COMPRESSOR...............................................223 39. CONNECTOR....................................................................224 40. RESETTING ENGINE IN ENGINE STAND.............................................224 41. TURBOCHARGER DRAIN TUBE......................................................224 42. STARTING MOTOR...............................................................224 REFILLING WITH OIL...............................................................225 DISASSEMBLY OF TURBOCHARGE:KTR110................................................226 ASSEMBLY OF TURBOCHARGER:KTR110..................................................230 14 MAINTENANCE STANDARD......................................................................234 INTAKE AND EXHAUST SYSTEM................................................................235 TURBOCHARGER.........................................................................235 ENGINE BODY..............................................................................237 CYLINDER HEAD........................................................................237 VALVE, VALVE GUIDE...................................................................238 ROCKER ARM AND SHAFT ................................................................240 CROSSHEAD AND GUIDE..................................................................241 CYLINDER BLOCK.......................................................................242 CYLINDER LINER.......................................................................243 CRANKSHAFT...........................................................................244 CAMSHAFT.............................................................................245 CAM FOLLOWER AND PUSH ROD............................................................246 TIMING GEAR..........................................................................247 PISTON...............................................................................249 CONNECTING ROD.......................................................................251 FLYWHEEL AND FLYWHEEL HOUSING........................................................252 LUBRICATION SYSTEM.......................................................................253 OIL PUMP.............................................................................253 REGULATOR VALVE, PISTON COOLING VALVE AND SAFETY VALVE...............................255 OIL COOLER...........................................................................256 COOLING SYSTEM...........................................................................257 WATER PUMP...........................................................................257 THERMOSTAT...........................................................................258 15 REPAIR AND REPLACEMENT OF PARTS...........................................................259 CYLINDER HEAD............................................................................260 GRINDING CYLINDER HEAD MOUNTING FACE.................................................260 REPLACING VALVE SEAT INSERT..........................................................261 REPLACING CROSSHEAD GUIDE............................................................266 REPLACING VALVE GUIDE................................................................267 GRINDING VALVE.......................................................................268 PRESSURE TEST........................................................................269 CYLINDER BLOCK...........................................................................270 REPLACING CAM BUSHING ...............................................................270 REPLACING CRANKSHAFT GEAR............................................................272 REPLACING CAM GEAR...................................................................273 REPLACING FLYWHEEL RING GEAR.........................................................274 REPLACING CONNECTING ROD SMALL END BUSHING...........................................275 RECLAMATION AND REPLACEMENT..............................................................276 CYLINDER BLOCK.......................................................................277 REPAIRING CRACK OF CYLINDER BLOCK................................................277 REPAIRING CYLINDER BLOCK TOP BY GRINDING.........................................278 REPAIRING SLEEVE OF CYLINDER BLOCK WATER HOLE....................................278 REPAIRING COUNTERBORE OF CYLINDER BLOCK..........................................278 REPAIRING WATER LEAKAGE THROUGH PANEL PLUG.......................................278 REPLACING MAIN BEARING CAP.......................................................279 REPAIRING CRANKSHAFT BY GRINDING.................................................282
S.S 12/12/24
