Komatsu SA12V140Z-1 Series Diesel Engine Service Repair Shop Manual - CEBM002602

This Service Repair Workshop Manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the SA12V140Z-1 Series Komatsu Diesel Engine 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.


APPLICABLE MODELS :

Engine model : SA12V140Z-1
Applicable machine : WA800-2LE, WA900-1LC, 330M


TABLE OF CONTENTS :

01 GENERAL
11 STRUCTURE AND FUNCTION
12 TESTING, ADJUSTING AND TROUBLESHOOTING
13 DISASSEMBLY AND ASSEMBLY
14 MAINTENANCE STANDARD
15 REPAIR AND REPLACEMENT OF PARTS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM002602
Total Pages : 280


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.

Completly bookmarked and complete searcheble so you can easily find what you are looking for. This is the same Repair Service manual your local dealer will use when doing a repair. These are real files not scans. Complete Manuals in PDF format

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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COVER PAGE
CONTENTS
01 GENERAL
SPECIFICATIONS
GENERAL ASSEMBLY DRAWING
VIEW FROM LEFT SIDE
VIEW FROM RIGHT SIDE
VIEW FROM FRONT
VIEW FROM REAR
VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS)
VIEW FROM TOP
ENGINE PERFORMANCE CURVE
WA800-2LC
WA900-1LC
330M
11 STRUCTURE AND FUNCTION
GENERAL STRUCTURE
INTAKE AND EXHAUST SYSTEM
INTAKE SYSTEM
EXHAUST SYSTEM
TURBOCHARGER
AFTERCOOLER
ENGINE BODY
CYLINDER HEAD
SPECIFICATIONS
VALVE SEAT
ROCKER ARM HOUSING COVER
FUEL INJECTION NOZZLE
CYLINDER BLOCK
SPECIFICATIONS
PISTON COOLING
CYLINDER LINER
LINER SEAL
MAIN REVOLVING SYSTEM
CRANKSHAFT
PISTON
CONNECTING ROD
TIMING GEAR
FRONT SEAL
VALVE SYSTEM
VALVE TIMING
CAMSHAFT
FLYWHEEL AND FLYWHEEL HOUSING
REAR SEAL
LUBRICATING OIL SYSTEM
PISTON COOLING, CONNECTING ROD, OVERHEAD
FRONT GEAR TRAIN
TURBOCHARGER
FULL FLOW LUBRICATING OIL FILTERS
LUBRICATING OIL PUMP
SPECIFICATIONS
MAIN RELIEF VALVE
SPECIFICATIONS
OIL COOLER BYPASS VALVE
SPECIFICATIONS
REGULATOR VALVE
LUBRICATING OIL FILTER
SPECIFICATIONS
SAFETY VALVE
LUBRICATING OIL BYPASS FILTER
SPECIFICATIONS
LUBRICATING OIL COOLER
SPECIFICATIONS
FUEL SYSTEM
FLOW DIAGRAM
FUEL INJECTION PUMP
SPECIFICATIONS
RIGHT BANK PIPING
LEFT BANK PIPING
FUEL INJECTION NOZZLE
SPECIFICATIONS
FUEL FILTER
SPECIFICATIONS
COOLING SYSTEM
THERMOSTAT HOUSING FLOW
COOLING FAN BELT
WATER PUMP
SPECIFICATIONS
COOLING FAN
CORROSION RESISTOR
SPECIFICATIONS
ACCESSORY
AIR COMPRESSOR
SPECIFICATIONS
UNLOADER VALVE
ELECTRICAL SYSTEM
ALTERNATOR MOUNTING
ALTERNATOR WITH REGULATOR
STARTING MOTOR
ELECTRICAL INTAKE AIR HEATER
SPECIFICATIONS
12 TESTING, ADJUSTING AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
FUEL SYSTEM
FUEL PUMP REMOVAL
FUEL PUMP INSTALLATION AND TIMING
CHECKING INJECTION TIMING
USING PROXIMITY SENSOR
USING FUEL PUMP LOCK PIN
SENSOR INSTALLATION
SPEED SENSOR
TIMING SENSOR (WITH FLYWHEEL TIMING HOLES)
2ND DESIGN (FLYWHEEL TIMING LUGS)
FUEL OVERFLOW VALVE PRESSURE
ADJUSTING FUEL INJECTION PRESSURE
PERFORMANCE TEST
ENGINE TESTING
IN SERVICE RUN
ENGINE DYNAMOMETER RUN-IN
PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN
INSITE SERVICE TOOL
FUEL FLOW MEASUREMEnT
INSTALLATION
MEASUREMENT OF FUEL CONSUMPTION RATIO
SPECIFICATIONS
DYNAMOMETER WORKSHEET
ENGINE DYNAMOMETER TESTING
SETUP
COOLANT PLUMBING
GENERAL ENGINE TEST PROCEDURES
ENGINE THROTTLE CONTROL
TESTING PROCEDURE
ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER
FUEL INLET RESTRICTION
FUEL DRAIN LINE RESTRICTION
INTAKE MANIFOLD PRESSURE
INTAKE AIR RESTRICTION
EXHAUST RESTRICTION
ENGINE BLOWBY
LUBRICATING OIL PRESSURE
COOLANT PRESSURE
LUBRICATING OIL TEMPERATURE
AIR COMPRESSOR
STARTING MOTOR
ENGINE RUN-IN INSTRUCTIONS
TEST LOAD
TESTING AND ADJUSTING TOOL LIST
COOLING SYSTEM
CHECKING FAN BELT TENSION
330M
WA800/WA900
ALTERNATOR BELT
CHECKING BELT TENSION
ADJUSTING BELT TENSION
DRIVE BELT TENSION
13 DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
SPECIAL TOOLS
WASHING
SETTING ENGINE STAND
GENERAL DISASSEMBLY
ENGINE COOLING WATER AND ENGINE OIL
MUFFLES ASSEMBLY
FAN
INTAKE CONNECTOR
TURBOCHARGER ASSEMBLY
INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY
EXHAUST MANIFOLD ASSEMBLY
FUEL INJECTOR
AIR COMPRESSOR ASSEMBLY
FUEL PUMP DRIVE ASSEMBLY
WATER PUMP ASSEMBLY
BREATHER
OIL COOLER ASSEMBLY
ROCKER LEVER COVER
ROCKER LEVER
CYLINDER HEAD ASSEMBLY
CAM FOLLOWER ASSEMBLY
THERMOSTAT HOUSING
ACCESSORY DRIVE ASSEMBLY
DAMPER, CRANKSHAFT PULLEY ASSEMBLY
OIL PAN
MAIN RELIEF VALVE, SUCTION TUBE
FRONT SUPPORT
SENSORS
FLYWHEEL
GEAR CASE
CYLINDER BLOCK
WASHING
WASHING CYLINDER BLOCK
WASHING CRANKSHAFT
WASHING CONNECTING ROD
MEASURING PARTS
MEASURING CURVATURE OF CRANKSHAFT
MEASURING OUTSIDE DIAMETER OF JOURNAL
MEASURING OUT-OF-ROUNDNESS OF JOURNAL
MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL
DIAMETER OF JOURNAL
MEASURING DEPTH OF CYLINDER LINER COUNTERBORE
MEASURING MAIN BEARING BORE
MEASURING CURVATURE OF CAMSHAFT
MEASURING OUTSIDE DIAMETER OF JOURNAL
MEASURING HEIGHT OF CAM
MEASURING PISTON RING GROOVE
SPECIAL TOOLS
MEASURING PISTON RING END GAP
MEASURING OUTSIDE DIAMETER OF PISTON
MEASURING LENGHT OF CONNECTING ROD
MEASURING INSIDE DIAMTER AT SMALL END OF CONNECTING ROD
MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD
MEASURING CURVATURE, TWISTING OF CONNECTING ROD
STANDARD PRESSURE FOR PARTS PRESSURE TESTING
ASSEMBLY
TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD
SPECIAL TOOLS
PREPARATORY WORK
GENERAL ASSEMBLY
CYLINDER BLOCK
GEAR CASE
FLYWHEEL
SENSOR
FRONT SUPPORT
MAIN RELIEF VALVE, SUCTION PIPE
OIL PAN
DAMPER, CRANKSHAFT PULLEY ASSEMBLY
ACCESSORY DRIVE ASSEMBLY
THERMOSTAT HOUSING
CAM FOLLOWER ASSEMBLY
CYLINDER HEAD ASSEMBLY
ROCKER LEVER
ROCKER LEVER COVER
OIL COOLER ASSEMBLY
BREATHER
WATER PUMP ASSEMBLY
FUEL PUMP DRIVE
AIR COMPRESSOR ASSEMBLY
FUEL INJECTION PUMP
EXHAUST MANIFOLD ASSEMBLY
INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY
TURBOCHARGER ASSEMBLY
INTAKE CONNECTOR
FAN
GENERAL ASSEMBLY
14 MAINTENANCE STANDARD
INTAKE AND EXHAUST SYSTEM
TURBOCHARGER
ENGINE BODY
CYLINDER HEAD
VALVE, VALVE SPRING AND VALVE GUIDE
ROCKER ARM AND SHAFT
CROSSHEAD AND GUIDE
CYLINDER BLOCK
CYLINDER LINER
CRANKSHAFT
CAMSHAFT
CAM FOLLOWER AND PUSH ROD
TIMING GEAR
PISTON, PISTON RING AND PISTON PIN
CONNECTING ROD
FLYWHEEL AND FLYWHEEL HOUSING
LUBRICATION SYSTEM
OIL PUMP
MAIN RELIEF VALVE
OIL COOLER BY-PASS VALVE, REGULATOR VALVE
COOLING SYSTEM
WATER PUMP
THERMOSTAT
15 REPAIR AND REPLACEMENT OF PARTS
TABLE OF SPECIAL TOOLS
CYLINDER HEAD
CYLINDER AND MOUNTING FACE
REPLACING VALVE SEAT
REPLACING CROSSHEAD GUIDE
GRINDING VALVE
CYLINDER BLOCK
METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE USING ALIGNMENT BAR
CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE
REPLACING CAM BUSHING
CRANKSHAFT
CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION
GRINDING CRANKSHAFT
CORRECTING FRONT SEAL CONTACT SURFACE
CORRECTING REAR SEAL CONTACT SURFACE
CONNECTING ROD
REPLACING CONNECTING ROD SMALL END BUSHING
REPLACING CRANKSHAFT GEAR
REPLACING CAMSHAFT GEAR
REPLACING FLYWHEEL RING GEAR

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