Komatsu SA6D140-H-1 Diesel Engine Shop Manual SEBM036200 – PDF DOWNLOAD

Description

Komatsu SA6D140-H-1 Diesel Engine Shop Manual SEBM036200 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu SA6D140-H-1 Diesel Engine Shop Manual SEBM036200 – PDF DOWNLOAD

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 Shop Manual SEBM036200 – 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

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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