Komatsu 12V140-1 Series Diesel Engine Shop Manual - SEBM028316

Komatsu 12V140-1 Series Diesel Engine Shop Manual - SEBM028316

This Komatsu 12V140-1 Series Diesel Engine Shop Manual PDF Download 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


APPLICABLE MODELS :

SA12V140-1
D475A-2, D475A-3, D475A-5
WA800-2, WA800-3, WA900-1, WA900-3
HD785-3, HD785-5, HD985-3
INGERSOLL RAND
EPSA12V140
EG750B-1L
Generator
DCA800SPK
DCA-800SSK
J12V140E-G1-1
J12V140E-G1-1

SDA12V140E-1
D475A-3

SAA12V140-1
Generator
SAA 12V140-P920
SAA12V140-P920
SAA 12V140-P1030
SAA12V140-P1150


TABLE OF CONTENTS :

01 GENERAL
-APPLICABLE MACHINE
-SPECIFICATIONS
-GENERAL ASSEMBLY DRAWING
-ENGINE PERFORMANCE CURVE
-WEIGHT TABLE
11 STRUCTURE AND FUNCTION
-GENERAL STRUCTRE
-INTAKE AND EXHAUST SYSTEM
--AIR CLEANER
--TURBOCHARGER
--AFTER-COOLER
-ENGINE BODY
--CYLINDER HEAD
--CYLINDER BLOCK
--MAIN REVOLVING SYSTEM
--TIMING GEAR
--VALVE SYSTEM
--FLYWHEEL AND FLYWHEEL HOUSING
-LUBRICATION SYSTEM
--LUBRICATION SYSTEM CHART
--OIL PUMP
--MAIN RELIEF
--OIL COOLER BY-PASS VALVE, REGULATOR VALVE
--OIL FILTER
--OIL COOLER
-FUEL SYSTEM
--FUEL SYSTEM CHART
--FUEL INJECTION PUMP
--FUEL INJECTION NOZZLE
--FUEL FILTER
--ENGINE STOP MOTOR
-COOLING SYSTEM
--COLING SYSTEM SHART
--WATER PUMP
--COOLING FAN
--THERMOSTAT
--CORROSION RESISTOR
-ACCESSORY
--AIR COMPRESSOR
--EXHAUST BRAKE
-ELECTRICAL SYSTEM
--ALTERNATOR
--STARTING MOTOR
--ELECTRICAL INTAKE AIR HEATER
--OIL PAN HEATER
--COOLING WATER HEATER
12 TESTING AND ADJUSTING
-ENGINE BODY
--ADJUSTING VALVE CLEARANCE
--MEASURING COMPRESSION PRESSURE
--MEASURING BLOW-BY
-FUEL SYSTEM
--TESTING AND ADJUSTMENT OF FUEL INJECTION TIMAING
---(WITH ZEXEL MECHANICAL GOVERNOR)
---(WITH ZEXEL ELECTRONICAL GOVERNOR)
--TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING (WITH KOMATSU ELECTRONICAL GOVERNOR)
--ADJUSTING INJECTION PUMP GOVERNOR LINK
---(WITH MECHANICAL GOVERNOR)
---(WITH ZECEL ELECTRONICAL GOVERNOR)
--PROCEFURE FOR ADJUSTING ENGINE STOP MOTOR CABLE (APPLICABLE FOR MODELSUSING ENGINE STOP MOTOR)
--METHOD FOR INSTALLING (ADJUSTMENT) OF ENGINE SPEED SENSOR
--ADJUSTING FUEL INJECTION PRESSURE
--ADJUSTMENT OF ELECTRONICAL GOVERNOR MADE BY KOMATSU
--HANDLING OF THROTTLE BOX
--HANDLING OF XEP CHECKER
-COOLING SYSTEM
--CHECKING AND ADJUSTING V-BELT TENSION
-PERFORMANCE TEST
--RUNNING IN STANDARD
--PERFORMANCE TEST CRITERIA
--TESING AND ADJUSTING TOOL LIST
--TESTING AND ADJUSTING DATA
-TROUBLESHOOTING
--POINTS TO REMEMBER WHEN TROUBLESHOOTING
--METHOD OF USING TROUBLESHOOTING CHART
--S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) (WITH ELECTRONICAL GOVERNOR)
--S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) (WITH MECHANICAL GOVERNOR)
--S-2 EGINE DOES NOT START
---① ENGINE DOES NOT TURN
---② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (WITH ELECTRONICAL GOVERNOR)
---② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (WITH MECHANICAL GOVERNOR)
---③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
--S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
--S-4 ENGINE STOPS DURING OPERATIONS (WITH MECHANICAL GOVERNOR)
--S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) (WITH ELECTRONICAL GOVERNOR)
--S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) (WITH MECHANICAL GOVERNOR)
--S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH ELECTRONICAL GOVERNOR)
--S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH MECHANICAL GOVERNOR)
--S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) (WITH ELECTRONICAL GOVERNOR)
--S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) (WITH MECHANICAL GOVERNOR)
--S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
--S-9 OIL BECOMES CONTAMINATED QUICKLY
--S-10 FUEL CONSUMPTION IS EXCESSIVE (WITH ELECTRONICAL GOVERNOR)
--S-10 FUEL CONSUMPTION IS EXCESSIVE (WITH MECHANICAL GOVERNOR)
--S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
--S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
--S-13 OIL LEVEL RISES
--S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
--S-15 ABNORMAL NOISE IS MADE
--S-16 VIBRATION IS EXCESSIVE
--S-17 DIAGNOSIS OF ELECTRONICAL GOVERNOR BY DIAGNOSIS DISPLAY (ELECTRONICAL GOVERNOR MADE BY ZEXEL)
---1. CONTROLLER SYSTEM ABNORMALITY
---2. GOVERNOR SERVO SYSTEM ABNORMALITY
---3. RACK SENSOR SYSTEM ABORMALITY
---4. OVERRUN ABNORMALITY
---5. 1ST SPEED SENSOR ABNORMALITY
---6. 2ND SPEED SENSOR ABNORMALITY
---7. LOW IDLING SPEED CONTROL DIAL ABNORMALITY
---8. DROOP CONTROL DIAL ABNORMALITY
---9. DIAGNOSIS LAMP FAILS TO MAKE INDICATION
---10. NORMAIL INDICATION
---11. MEMORY CLEAR CANNOT BE ACHIEVED BY PRESSING THE MEMORY CLEAR SWITCH (WHEN FAILURE INDICATION IS MADE BY DIAGNOSIS LAMP)
13 DISASSEMBLY AND ASSEMBLY
-GENERAL DISASSEMBLY
--1. WASHING
--2. SETTING ENGINE STAND
--3. ENGINE COOLING WATER AND ENGINE OIL
--4. FILTER
--5. MUFFLER ASSERMBLY
--6. FAN
--7. FAN BELT
--8. FAN PULLEY ASSEMBLY
--9. LNTAKE CONNECTOR
--10. EXHAUST BRAKE ASSEMBLY
--11. TURBOCHARGER ASSEMBLY
--12. INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY
--13. EXHAUST MANIFOLD ASSEMBLY
--14. FUEL INJECTION PIPE,SPIL TUBE
--15. FUEL INJECTION PUMP ASSEMBLY
--16. WATER PUMP ASSEBLY
--17. BREATHER
--18. AIR COMPRESSOR
--19. OIL COOLER ASSEMBLY
--20. OIL FILLER, OIL LEVEL GAUGE
--21. HEAD COVER
--22. NOZZZLE HOLDER, CONNECTION
--23. ROCKER ARM
--24. PUSH ROD
--25. CROSSHEAD
--26. ROCKER ARM HOUSING
--27. CYLINDER HEAR ASSEMBLY
--28. CAM FOLLOWER ASSEMBLY
--29. THERMOSTAT HOUSING
--30. ASSESSORY DRIVE ASSEMBLY
--31. DAMPER, CRANKSHAFT PULLEY ASSEMBLY
--32. OIL PAN
--33. MAN RELIEF VALVE, SUCTION TUBE
--34. FRONT SUPPOR
--35. FLYWHEEL
--36. FLYWHEEL HOUSING, REAR SEAL
--37. GEAR CASE COVER, FRONT SEAL
--38. IDLER GEAR (LARGE)
--39. INJECTION PUMP DRIVE GEAR
--40. INJECTION PUMP DRIVE CASE ASSEMLY
--41. OIL PUMP ASSEMBLY
--42. IDLER GEAR (SMALL)
--43. CAMSHAFT ASSEMBLY
--44. TIMING GEAR CASE
--45. PISTON COOLING NOZZLE
--46. PISTON AND CONNECTING ROD ASSEMBLY
--47. CRANKSHAFT
--48. CYLINDER LINER
-WASHING
--WASHING CYLINDER BLOCK
--WASHING CRANKSHFT
--WASHING CONNECTING ROD
-MEASURING AND INSPECTING PARTS
--MEASURING PARTS
---MEASURING CURVATURE OF CRANKSHAFT
---MEASURING OUTSIDE DIAMETER FO JOURNAL
---MEASURING OUT-OF-ROUNDNESS OF JOURNAL
---MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL
---MEASURING DEPTH OF CYLINDER LINER COUNTERBORE
---MEASURING MAIN BERING BORE
---MEASURING CUVATURE OF CAMSHAFT
---MEASURING OUTSIDE DIAMETER OF JOURNAL
---MEASURING HELGHT OF CAM
---MEASURING PISTON RING GROOVE
---MEASURING OUTSIDE DIAMETER OF PISTON
---MEASURING LENGTH OF CONNECTING ROD
---MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD
---MEASUING INSIDE DIAMENTER AT BIG END OF CONNECTING ROD
---MEASURING SURVATURE, TWISTING OF CONNECTING ROD
---STANDARD PRESSURE FOR PARTS PRESSURE TESTING
-GENERAL ASSEMBLY
--1. CYLINDER LINER
--2. CRANKSHAFT
--3. PISTON, CONNECTING ROD ASSEMBLY
--4. PISTON COOLING NOZZLE
--5. GEAR CASE
--6. CAMSHAFT ASSEMBLY
--7. IDLER GEAR (SMALL)
--8. OIL PUMP ASSEMBLY
--9. INJECTION PUMP DRIVE CASE
--10. INJECION PUMP DRIVE GEAR
--11. IDIER GEAR (LARGE) (RIGHT BANK)
--12. IDIER GGEAR (LARGE) (LEFT BANK)
--13. MEASURING BACKLASH OF GEAR
--14. GEAR CASE COVER
--15. FRONT OIL SEAL, SLEEVE
--16. FLYWHEEL HOUSING
--17. REAR OIL SEAL, SLEEVE
--18. FLYWHEEL
--19. FRONT SUPPORT
--20. MAIN RELIEF VALVE, SUCTION PIPE
--21. OIL PAN
--22. DAMPER, CRANKSHAFT PULLEY ASSEMBLY
--23. ACCESSORY DRIVE ASSEMBLY
--24. THERMOSTAT HOUSING
--25. CAM FOLLOWER ASSEMBLY
--26. CYLINDER HEAD ASSEMBLY
--27. ROCKER ARM HOUSING
--28. CROSSHEAD
--29. PUSH ROD
--30. ROCKER ARM
--31. NOZZLE HOLDER, CONNECTION
--32. ADJUSTING VALVE CLEARANCE
--33. HEAD COVER, TURBOCHARGER LUBRICATION TUBE
--34. OIL LEVEL GAUGE,OIL FILLER
--35. OIL COOLER ASSEMBLY
--36. AIR COMPRESSOR
--37. BREATHER
--38. WATER PUMP ASSEMBLY
--39. FUEL INJECTION PUMP ASSEMBLY
--40. FUEL INJECTION PIPES, SPILL TUBE
--41. EXHAUST MANIFOLD ASSEMBLY
--42. INTAKE MANIFOLD, AFTER-COOLER ASSEMBLY
--43. TURBOCHARGER ASSEMBLY
--44. EXHAUST BRAKE ASSEMBLY
--45. INTAKE CONNECTOR
--46. FAN PULLEY ASSEMBLY
--47. FAN BELT
--48. FAN
--49. MUFFLER ASSEMBLY
--50. FILTER
--51. SETTING ON ENGINE STAND
--52. ALTERNATOR ASSEMBLY
--53. STARTING MOTOR ASSEMBLY
14 MAINTENANCE STANDARD
-INTAKE AND EXHAUST SYSTEM
--TRBOCHARGER
-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
--THRMOSTAT
15 REPAIR AND REPLACEMENT OF PARTS
-TABLE OF SPECIAL TOOLS
-TESTING ANF INSPECTING CYINDER HEAD
-GRINDING CYLINDER HEAD MOUNTING FACE
-REPLACING VALVE SEAT
-PRESSURE TEST OF CYLONDER HEAD
-REPLACING VALVE GUIDE
-REPLACING CROSSHEAD GUIDE
-GRINDING VALVE
-TESTING AND INSPECTING CYLINDER BLOCK
-CORRECTING CYLINDRE BLOCK TOP SURFACE, COUNTERBORE
-REPLACING MAIN BEARING CAP
-REPLACING CAM BUSHING
-TESTING AND INSPECTING CRANKSHAFT
-CORRECTING SURFACE ROUGHESS OF CRANKSHAFT JOURNAL PORTION
-GRINDING CRANKSHAFT
-CORRECTING FRONT SEAL CONTACT SURFCE
-CORRECTING REAR SEAL CONTACT SURFACE
-TESTING AND INSPECTING CONNECTING ROD
-REPLACING CONNECTING ROD SMALL END BUSHING
-REPLACING CRANKSHAFT GEAR
-REPLACING CAMSHAFT GEAR
-REPLACING FLYWHEEL RING GEAR


File Format : PDF
Language : English
Total Pages : 469
Bookmarked : Yes
Part Number : SEBM028316
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