Komatsu SA12V140Z-1, SAA12V140ZE-2 Series Diesel Engine Shop Manual CEBM002603

Komatsu SA12V140Z-1, SAA12V140ZE-2 Series Diesel Engine Shop Manual CEBM002603 - Image 2

Komatsu SA12V140Z-1, SAA12V140ZE-2 Series Diesel Engine Shop Manual CEBM002603 - Image 3

Komatsu SA12V140Z-1, SAA12V140ZE-2 Series Diesel Engine Shop Manual CEBM002603

$50.00

Type Of Manual: Shop Manual
Manual ID: CEBM002603
Format: PDF
Size: 6.0MB
Number of Pages: 286

Category: Komatsu Shop Manual PDF

Description
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Description

Model List:
- SA12V140Z-1 Series Diesel Engine
- SAA12V140ZE-2 Series Diesel Engine

1. COVER
2. CONTENTS
3. GENERAL
3.1. SPECIFICATIONS
3.2. GENERAL ASSEMBLY DRAWING
3.2.1. VIEW FROM LEFT SIDE
3.2.2. VIEW FROM RIGHT SIDE
3.2.3. VIEW FROM FRONT
3.2.4. VIEW FROM REAR
3.2.5. VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS)
3.2.6. VIEW FROM TOP
3.3. ENGINE PERFORMANCE CURVE
3.3.1. WA8002LC
3.3.2. WA9001LC
4. STRUCTURE AND FUNCTION
4.1. GENERAL STRUCTURE
4.2. INTAKE AND EXHAUST SYSTEM
4.2.0.1. ROCKER ARM HOUSING COVER
4.2.0.2. FUEL INJECTION NOZZLE
4.2.1. MAIN REVOLVING SYSTEM
4.2.2. FLYWHEEL AND FLYWHEEL HOUSING
4.2.2.1. REAR SEAL
4.3. LUBRICATING OIL SYSTEM
4.3.1. PISTON COOLING, CONNECTING ROD, OVERHEAD
4.3.2. FRONT GEAR TRAIN
4.3.3. TURBOCHARGER
4.3.4. FULL FLOW LUBRICATING OIL FILTERS
4.3.5. LUBRICATING OIL PUMP
4.3.5.1. SPECIFICATIONS
4.3.6. MAIN RELIEF VALVE
4.3.6.1. SPECIFICATIONS
4.3.7. OIL COOLER BYPASS VALVE
4.3.7.1. SPECIFICATIONS
4.3.7.2. REGULATOR VALVE
4.3.8. LUBRICATING OIL FILTER
4.3.8.1. SPECIFICATIONS
4.3.8.2. SAFETY VALVE
4.3.9. LUBRICATING OIL BYPASS FILTER
4.3.9.1. SPECIFICATIONS
4.3.10. LUBRICATING OIL COOLER
4.3.10.1. SPECIFICATIONS
4.4. FUEL SYSTEM
4.4.1. FLOW DIAGRAM
4.4.2. FUEL INJECTION PUMP
4.4.2.1. SPECIFICATIONS
4.4.3. RIGHT BANK PIPING
4.4.4. LEFT BANK PIPING
4.4.5. FUEL INJECTION NOZZLE
4.4.5.1. SPECIFICATIONS
4.4.6. FUEL FILTER
4.4.6.1. SPECIFICATIONS
4.5. COOLING SYSTEM
4.5.1. THERMOSTAT HOUSING FLOW
4.5.2. COOLING FAN BELT
4.5.3. WATER PUMP
4.5.3.1. SPECIFICATIONS
4.5.4. COOLING FAN
4.5.5. CORROSION RESISTOR
4.6. ELECTRICAL SYSTEM
4.6.1. ALTERNATOR MOUNTING
4.6.2. ALTERNATOR WITH REGULATOR
4.6.3. STARTING MOTOR
4.6.4. ELECTRICAL INTAKE AIR HEATER
4.6.4.1. SPECIFICATIONS
5. TESTING, ADJUSTING AND TROUBLESHOOTING
5.1. ADJUSTING VALVE CLEARANCE
5.2. MEASURING COMPRESSION PRESSURE
5.3. FUEL SYSTEM
5.3.1. FUEL PUMP REMOVAL
5.3.2. FUEL PUMP INSTALLATION AND TIMING
5.4. CHECKING INJECTION TIMING
5.4.1. USING PROXIMITY SENSOR
5.4.2. USING FUEL PUMP LOCK PIN
5.5. SENSOR INSTALLATION
5.5.1. SPEED SENSOR
5.5.2. TIMING SENSOR (WITH FLYWHEEL TIMING HOLES)
5.5.3. D DESIGN (FLYWHEEL TIMING LUGS)
5.6. FUEL OVERFLOW VALVE PRESSURE
5.7. ADJUSTING FUEL INJECTION PRESSURE
5.8. PERFORMANCE TEST
5.8.1. ENGINE TESTING
5.8.1.1. IN SERVICE RUN
5.8.1.2. ENGINE DYNAMOMETER RUNIN
5.8.1.3. PORTABLE DYNAMOMETER OR LOAD BANK RUNIN
5.8.1.4. INSITE SERVICE TOOL
5.8.2. FUEL FLOW MEASUREMEnT
5.8.2.1. INSTALLATION
5.8.2.2. MEASUREMENT OF FUEL CONSUMPTION RATIO
5.8.2.3. SPECIFICATIONS
5.8.3. DYNAMOMETER WORKSHEET
5.9. ENGINE DYNAMOMETER TESTING
5.9.1. SETUP
5.9.2. COOLANT PLUMBING
5.9.3. GENERAL ENGINE TEST PROCEDURES
5.9.4. ENGINE THROTTLE CONTROL
5.9.5. TESTING PROCEDURE
5.9.5.1. ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER
5.9.5.2. FUEL INLET RESTRICTION
5.9.5.3. FUEL DRAIN LINE RESTRICTION
5.9.5.4. INTAKE MANIFOLD PRESSURE
5.9.5.5. INTAKE AIR RESTRICTION
5.9.5.6. EXHAUST RESTRICTION
5.9.5.7. ENGINE BLOWBY
5.9.5.8. LUBRICATING OIL PRESSURE
5.9.5.9. COOLANT PRESSURE
5.9.5.10. LUBRICATING OIL TEMPERATURE
5.9.5.11. AIR COMPRESSOR
5.9.5.12. STARTING MOTOR
5.9.6. ENGINE RUNIN INSTRUCTIONS
5.9.6.1. TEST LOAD
5.10. TESTING AND ADJUSTING TOOL LIST
5.11. COOLING SYSTEM
5.11.1. CHECKING FAN BELT TENSION
5.11.1.2. WA800/WA900
5.12. ALTERNATOR BELT
5.12.1. CHECKING BELT TENSION
5.12.2. ADJUSTING BELT TENSION
5.12.3. DRIVE BELT TENSION
6. DISASSEMBLY AND ASSEMBLY
6.1. DISASSEMBLY
6.1.1. SPECIAL TOOLS
6.1.2. WASHING
6.1.3. SETTING ENGINE STAND
6.1.4. GENERAL DISASSEMBLY
6.1.4.1. ENGINE COOLING WATER AND ENGINE OIL
6.1.4.2. MUFFLES ASSEMBLY
6.1.4.4. AIR COMPRESSOR ASSEMBLY
6.1.4.5. FUEL PUMP DRIVE ASSEMBLY
6.1.4.6. WATER PUMP ASSEMBLY
6.1.4.7. BREATHER
6.1.4.8. OIL COOLER ASSEMBLY
6.1.4.9. ROCKER LEVER COVER
6.1.4.10. ROCKER LEVER
6.1.4.11. CYLINDER HEAD ASSEMBLY
6.1.4.12. CAM FOLLOWER ASSEMBLY
6.1.4.13. THERMOSTAT HOUSING
6.1.4.14. ACCESSORY DRIVE ASSEMBLY
6.1.4.15. DAMPER, CRANKSHAFT PULLEY ASSEMBLY
6.1.4.16. OIL PAN
6.1.4.17. MAIN RELIEF VALVE, SUCTION TUBE
6.1.5. WASHING CYLINDER BLOCK
6.1.6. WASHING CRANKSHAFT
6.1.7. WASHING CONNECTING ROD
6.2. MEASURING PARTS
6.2.1. MEASURING CURVATURE OF CRANKSHAFT
6.2.2. MEASURING OUTSIDE DIAMETER OF JOURNAL
6.2.3. MEASURING OUTOFROUNDNESS OF JOURNAL
6.2.4. MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL
6.2.5. DIAMETER OF JOURNAL
6.2.6. MEASURING DEPTH OF CYLINDER LINER COUNTERBORE
6.2.7. MEASURING MAIN BEARING BORE
6.2.8. MEASURING CURVATURE OF CAMSHAFT
6.2.9. MEASURING OUTSIDE DIAMETER OF JOURNAL
6.2.10. MEASURING HEIGHT OF CAM
6.2.11. MEASURING PISTON RING GROOVE
6.2.11.1. SPECIAL TOOLS
6.2.12. MEASURING PISTON RING END GAP
6.2.13. MEASURING OUTSIDE DIAMETER OF PISTON
6.2.14. MEASURING LENGHT OF CONNECTING ROD
6.2.15. MEASURING INSIDE DIAMTER AT SMALL END OF CONNECTING ROD
6.2.16. MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD
6.2.17. MEASURING CURVATURE, TWISTING OF CONNECTING ROD
6.2.18. STANDARD PRESSURE FOR PARTS PRESSURE TESTING
6.3. ASSEMBLY
6.3.1. TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD
6.3.2. SPECIAL TOOLS
6.3.3. PREPARATORY WORK
6.3.4. GENERAL ASSEMBLY
6.3.4.1. MAIN RELIEF VALVE, SUCTION PIPE
6.3.4.2. OIL PAN
6.3.4.3. DAMPER, CRANKSHAFT PULLEY ASSEMBLY
6.3.4.4. ACCESSORY DRIVE ASSEMBLY
6.3.4.5. THERMOSTAT HOUSING
6.3.4.6. CAM FOLLOWER ASSEMBLY
6.3.4.7. CYLINDER HEAD ASSEMBLY
6.3.4.8. ROCKER LEVER
6.3.4.9. ROCKER LEVER COVER
6.3.4.10. OIL COOLER ASSEMBLY
6.3.4.11. BREATHER
6.3.4.12. WATER PUMP ASSEMBLY
6.3.4.13. FUEL PUMP DRIVE
6.3.4.14. AIR COMPRESSOR ASSEMBLY
6.3.4.15. FUEL INJECTION PUMP
6.3.4.16. EXHAUST MANIFOLD ASSEMBLY
6.3.4.17. INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY
6.3.4.18. TURBOCHARGER ASSEMBLY
6.3.4.19. INTAKE CONNECTOR
6.3.4.21. GENERAL ASSEMBLY
7. MAINTENANCE STANDARD
7.1. INTAKE AND EXHAUST SYSTEM
7.1.1. TURBOCHARGER
7.2. ENGINE BODY
7.2.1. CYLINDER HEAD
7.2.2. VALVE, VALVE SPRING AND VALVE GUIDE
7.2.3. ROCKER ARM AND SHAFT
7.2.4. CROSSHEAD AND GUIDE
7.2.5. CYLINDER BLOCK
7.2.6. CYLINDER LINER
7.2.7. CRANKSHAFT
7.2.8. CAMSHAFT
7.2.9. CAM FOLLOWER AND PUSH ROD
7.2.10. TIMING GEAR
7.2.11. PISTON, PISTON RING AND PISTON PIN
7.2.12. CONNECTING ROD
7.2.13. FLYWHEEL AND FLYWHEEL HOUSING
7.3. LUBRICATION SYSTEM
7.3.1. OIL PUMP
7.3.2. MAIN RELIEF VALVE
7.3.3. OIL COOLER BYPASS VALVE, REGULATOR VALVE
7.4. COOLING SYSTEM
7.4.1. WATER PUMP
7.4.2. THERMOSTAT
8. REPAIR AND REPLACEMENT OF PARTS
8.1. TABLE OF SPECIAL TOOLS
8.2. CYLINDER HEAD
8.2.1. CYLINDER AND MOUNTING FACE
8.2.2. REPLACING VALVE SEAT
8.2.3. PRESSURE TEST OF CYLINDER HEAD
8.2.4. REPLACING VALVE GUIDE
8.2.5. REPLACING CROSSHEAD GUIDE
8.2.6. GRINDING VALVE
8.3. CYLINDER BLOCK
8.3.1. METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE USING ALIGNMENT BAR
8.3.2. CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE
8.3.3. REPLACING MAIN BEARING CAP
8.3.4. REPLACING CAM BUSHING
8.4. CRANKSHAFT
8.4.1. CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION
8.4.2. GRINDING CRANKSHAFT
8.4.3. CORRECTING FRONT SEAL CONTACT SURFACE
8.4.4. CORRECTING REAR SEAL CONTACT SURFACE
8.5. CONNECTING ROD
8.5.1. REPLACING CONNECTING ROD SMALL END BUSHING
8.5.2. REPLACING CRANKSHAFT GEAR
8.5.3. REPLACING CAMSHAFT GEAR
8.5.4. REPLACING FLYWHEEL RING GEAR