Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES Diesel Engine Shop Manual CEBM002603 – PDF DOWNLOAD

Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES Diesel Engine Shop Manual CEBM002603 – PDF DOWNLOAD

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Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES Diesel Engine Shop Manual CEBM002603 – PDF DOWNLOAD

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Pages : 286
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Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES Diesel Engine Shop Manual CEBM002603 – PDF DOWNLOAD

The Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES Diesel Engine Shop Manual CEBM002603 is a comprehensive guidebook that provides detailed technical information and instructions on how to operate, maintain, and repair the Komatsu SA12V140Z-1 and SAA12V140ZE-2 series diesel engines. These engines are commonly used in heavy construction and mining equipment, as well as power generation applications.

• The manual is organized into several sections, each providing detailed information on specific topics. These sections include specifications, structure and function, testing and adjusting, disassembly and assembly, maintenance, and troubleshooting.
• The specifications section of the manual provides detailed information on the engine’s physical and operational characteristics, including its dimensions, weight, performance, and power output. It also provides information on the engine’s cooling system, fuel system, and lubrication system.
• The structure and function section of the manual provides an overview of the engine’s internal components and their functions. This section includes detailed diagrams and descriptions of the engine’s various components, such as the cylinder block, cylinder head, crankshaft, pistons, and valves.
• The testing and adjusting section of the manual provides instructions on how to test and adjust the engine’s various components to ensure they are functioning correctly. This section includes detailed procedures for testing and adjusting the engine’s fuel injection system, valve clearances, and oil pressure.
• The disassembly and assembly section of the manual provides step-by-step instructions on how to disassemble and reassemble the engine’s various components. This section includes detailed diagrams and photographs to guide the user through the process.
• The maintenance section of the manual provides information on routine maintenance tasks that should be performed to keep the engine in good working condition. This section includes instructions on how to perform tasks such as changing the engine oil and replacing the air filter.
• The troubleshooting section of the manual provides guidance on how to diagnose and resolve common issues that may arise with the engine. This section includes a list of common symptoms and their likely causes, as well as step-by-step instructions for troubleshooting and resolving each issue.
• Overall, the Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES Diesel Engine Shop Manual CEBM002603 is an essential resource for anyone who operates, maintains, or repairs these powerful diesel engines. With its detailed technical information and comprehensive instructions, this manual is an invaluable tool for ensuring the efficient and reliable operation of Komatsu SA12V140Z-1 and SAA12V140ZE-2 series engines in heavy equipment applications.

TABLE OF CONTENTS:

Komatsu SA12V140Z-1 SERIES SAA12V140ZE-2 SERIES Diesel Engine Shop Manual CEBM002603 – PDF DOWNLOAD

COVER………………………………………………………………………………. 1
CONTENTS……………………………………………………………………………. 2
01 GENERAL…………………………………………………………………………. 25
SPECIFICATIONS…………………………………………………………………… 26
GENERAL ASSEMBLY DRAWING………………………………………………………….. 27
VIEW FROM LEFT SIDE…………………………………………………………… 27
VIEW FROM RIGHT SIDE………………………………………………………….. 28
VIEW FROM FRONT………………………………………………………………. 29
VIEW FROM REAR……………………………………………………………….. 30
VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS)………………………………………… 31
VIEW FROM TOP………………………………………………………………… 32
ENGINE PERFORMANCE CURVE………………………………………………………….. 33
WA800-2LC……………………………………………………………………. 33
WA900-1LC……………………………………………………………………. 34
330M………………………………………………………………………… 35
11 STRUCTURE AND FUNCTION…………………………………………………………….. 37
GENERAL STRUCTURE………………………………………………………………… 39
INTAKE AND EXHAUST SYSTEM…………………………………………………………. 41
INTAKE SYSTEM………………………………………………………………… 41
EXHAUST SYSTEM……………………………………………………………….. 42
TURBOCHARGER…………………………………………………………………. 43
AFTERCOOLER………………………………………………………………….. 44
ENGINE BODY……………………………………………………………………… 45
CYLINDER HEAD………………………………………………………………… 45
SPECIFICATIONS……………………………………………………………. 46
VALVE SEAT……………………………………………………………….. 46
ROCKER ARM HOUSING COVER…………………………………………………… 46
FUEL INJECTION NOZZLE……………………………………………………… 46
CYLINDER BLOCK……………………………………………………………….. 47
SPECIFICATIONS……………………………………………………………. 48
PISTON COOLING……………………………………………………………. 48
CYLINDER LINER……………………………………………………………. 48
LINER SEAL……………………………………………………………….. 48
MAIN REVOLVING SYSTEM…………………………………………………………. 49
CRANKSHAFT……………………………………………………………….. 50
PISTON…………………………………………………………………… 50
CONNECTING ROD……………………………………………………………. 50
TIMING GEAR………………………………………………………………….. 51
FRONT SEAL……………………………………………………………….. 52
VALVE SYSTEM…………………………………………………………………. 53
VALVE TIMING……………………………………………………………… 54
CAMSHAFT…………………………………………………………………. 54
FLYWHEEL AND FLYWHEEL HOUSING………………………………………………….. 55
REAR SEAL………………………………………………………………… 55
LUBRICATING OIL SYSTEM……………………………………………………………. 56
PISTON COOLING, CONNECTING ROD, OVERHEAD………………………………………… 57
FRONT GEAR TRAIN……………………………………………………………… 58
TURBOCHARGER…………………………………………………………………. 59
FULL FLOW LUBRICATING OIL FILTERS………………………………………………. 60
LUBRICATING OIL PUMP………………………………………………………….. 61
SPECIFICATIONS……………………………………………………………. 61
MAIN RELIEF VALVE…………………………………………………………….. 62
SPECIFICATIONS……………………………………………………………. 62
OIL COOLER BYPASS VALVE……………………………………………………….. 63
SPECIFICATIONS……………………………………………………………. 63
REGULATOR VALVE…………………………………………………………… 63
LUBRICATING OIL FILTER………………………………………………………… 64
SPECIFICATIONS……………………………………………………………. 64
SAFETY VALVE……………………………………………………………… 64
LUBRICATING OIL BYPASS FILTER………………………………………………….. 65
SPECIFICATIONS……………………………………………………………. 65
LUBRICATING OIL COOLER………………………………………………………… 66
SPECIFICATIONS……………………………………………………………. 66
FUEL SYSTEM……………………………………………………………………… 67
FLOW DIAGRAM…………………………………………………………………. 67
FUEL INJECTION PUMP…………………………………………………………… 68
SPECIFICATIONS……………………………………………………………. 68
RIGHT BANK PIPING…………………………………………………………….. 69
LEFT BANK PIPING……………………………………………………………… 70
FUEL INJECTION NOZZLE…………………………………………………………. 71
SPECIFICATIONS……………………………………………………………. 71
FUEL FILTER………………………………………………………………….. 72
SPECIFICATIONS……………………………………………………………. 72
COOLING SYSTEM…………………………………………………………………… 73
THERMOSTAT HOUSING FLOW……………………………………………………….. 74
COOLING FAN BELT……………………………………………………………… 75
WATER PUMP…………………………………………………………………… 76
SPECIFICATIONS……………………………………………………………. 76
COOLING FAN………………………………………………………………….. 77
CORROSION RESISTOR……………………………………………………………. 78
SPECIFICATIONS……………………………………………………………. 78
ACCESSORY……………………………………………………………………….. 79
AIR COMPRESSOR……………………………………………………………….. 79
SPECIFICATIONS……………………………………………………………. 80
UNLOADER VALVE……………………………………………………………. 80
ELECTRICAL SYSTEM………………………………………………………………… 81
ALTERNATOR MOUNTING…………………………………………………………… 81
ALTERNATOR WITH REGULATOR……………………………………………………… 82
STARTING MOTOR……………………………………………………………….. 83
ELECTRICAL INTAKE AIR HEATER…………………………………………………… 84
SPECIFICATIONS……………………………………………………………. 84
12 TESTING, ADJUSTING AND TROUBLESHOOTING……………………………………………… 85
ADJUSTING VALVE CLEARANCE…………………………………………………………. 87
MEASURING COMPRESSION PRESSURE…………………………………………………….. 88
FUEL SYSTEM……………………………………………………………………… 89
FUEL PUMP REMOVAL…………………………………………………………….. 89
FUEL PUMP INSTALLATION AND TIMING………………………………………………. 91
CHECKING INJECTION TIMING…………………………………………………………. 96
USING PROXIMITY SENSOR………………………………………………………… 96
USING FUEL PUMP LOCK PIN………………………………………………………. 99
SENSOR INSTALLATION……………………………………………………………….102
SPEED SENSOR………………………………………………………………….102
TIMING SENSOR (WITH FLYWHEEL TIMING HOLES)……………………………………….102
2ND DESIGN (FLYWHEEL TIMING LUGS)……………………………………………….103
FUEL OVERFLOW VALVE PRESSURE……………………………………………………….104
ADJUSTING FUEL INJECTION PRESSURE…………………………………………………..105
PERFORMANCE TEST………………………………………………………………….106
ENGINE TESTING………………………………………………………………..106
IN SERVICE RUN…………………………………………………………….106
ENGINE DYNAMOMETER RUN-IN…………………………………………………..106
PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN……………………………………..106
INSITE SERVICE TOOL………………………………………………………..106
FUEL FLOW MEASUREMEnT………………………………………………………….107
INSTALLATION………………………………………………………………107
MEASUREMENT OF FUEL CONSUMPTION RATIO………………………………………..107
SPECIFICATIONS…………………………………………………………….108
DYNAMOMETER WORKSHEET………………………………………………………….109
ENGINE DYNAMOMETER TESTING…………………………………………………………110
SETUP………………………………………………………………………..110
COOLANT PLUMBING………………………………………………………………110
GENERAL ENGINE TEST PROCEDURES………………………………………………….110
ENGINE THROTTLE CONTROL………………………………………………………..111
TESTING PROCEDURE……………………………………………………………..112
ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER…………………………………112
FUEL INLET RESTRICTION……………………………………………………..112
FUEL DRAIN LINE RESTRICTION…………………………………………………113
INTAKE MANIFOLD PRESSURE……………………………………………………113
INTAKE AIR RESTRICTION……………………………………………………..113
EXHAUST RESTRICTION………………………………………………………..113
ENGINE BLOWBY……………………………………………………………..114
LUBRICATING OIL PRESSURE……………………………………………………116
COOLANT PRESSURE…………………………………………………………..116
LUBRICATING OIL TEMPERATURE…………………………………………………116
AIR COMPRESSOR…………………………………………………………….117
STARTING MOTOR…………………………………………………………….117
ENGINE RUN-IN INSTRUCTIONS……………………………………………………..118
TEST LOAD…………………………………………………………………118
TESTING AND ADJUSTING TOOL LIST…………………………………………………….121
COOLING SYSTEM……………………………………………………………………123
CHECKING FAN BELT TENSION………………………………………………………123
330M……………………………………………………………………..123
WA800/WA900……………………………………………………………….123
ALTERNATOR BELT…………………………………………………………………..123
CHECKING BELT TENSION………………………………………………………….123
ADJUSTING BELT TENSION…………………………………………………………124
DRIVE BELT TENSION…………………………………………………………….124
13 DISASSEMBLY AND ASSEMBLY…………………………………………………………..125
DISASSEMBLY………………………………………………………………………127
SPECIAL TOOLS…………………………………………………………………127
WASHING………………………………………………………………………127
SETTING ENGINE STAND…………………………………………………………..127
GENERAL DISASSEMBLY……………………………………………………………127
ENGINE COOLING WATER AND ENGINE OIL………………………………………….127
MUFFLES ASSEMBLY…………………………………………………………..128
FAN………………………………………………………………………128
AIR COMPRESSOR ASSEMBLY…………………………………………………….136
FUEL PUMP DRIVE ASSEMBLY……………………………………………………137
WATER PUMP ASSEMBLY………………………………………………………..139
BREATHER………………………………………………………………….139
OIL COOLER ASSEMBLY………………………………………………………..140
ROCKER LEVER COVER…………………………………………………………140
ROCKER LEVER………………………………………………………………141
CYLINDER HEAD ASSEMBLY……………………………………………………..142
CAM FOLLOWER ASSEMBLY………………………………………………………142
THERMOSTAT HOUSING…………………………………………………………143
ACCESSORY DRIVE ASSEMBLY……………………………………………………143
DAMPER, CRANKSHAFT PULLEY ASSEMBLY…………………………………………..144
OIL PAN…………………………………………………………………..144
MAIN RELIEF VALVE, SUCTION TUBE……………………………………………..144
FRONT SUPPORT……………………………………………………………..144
SENSORS…………………………………………………………………..144
FLYWHEEL………………………………………………………………….145
GEAR CASE…………………………………………………………………145
CYLINDER BLOCK…………………………………………………………….147
WASHING………………………………………………………………………….151
WASHING CYLINDER BLOCK…………………………………………………………151
WASHING CRANKSHAFT…………………………………………………………….153
WASHING CONNECTING ROD…………………………………………………………153
MEASURING PARTS…………………………………………………………………..154
MEASURING CURVATURE OF CRANKSHAFT……………………………………………….154
MEASURING OUTSIDE DIAMETER OF JOURNAL……………………………………………154
MEASURING OUT-OF-ROUNDNESS OF JOURNAL……………………………………………154
MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL…………………………155
DIAMETER OF JOURNAL……………………………………………………………155
MEASURING DEPTH OF CYLINDER LINER COUNTERBORE…………………………………….155
MEASURING MAIN BEARING BORE…………………………………………………….156
MEASURING CURVATURE OF CAMSHAFT…………………………………………………156
MEASURING OUTSIDE DIAMETER OF JOURNAL……………………………………………156
MEASURING HEIGHT OF CAM………………………………………………………..157
MEASURING PISTON RING GROOVE……………………………………………………157
SPECIAL TOOLS……………………………………………………………..157
MEASURING PISTON RING END GAP…………………………………………………..157
MEASURING OUTSIDE DIAMETER OF PISTON…………………………………………….158
MEASURING LENGHT OF CONNECTING ROD………………………………………………158
MEASURING INSIDE DIAMTER AT SMALL END OF CONNECTING ROD……………………………159
MEASURING INSIDE DIAMETER AT BIG END OF CONNECTING ROD…………………………….159
MEASURING CURVATURE, TWISTING OF CONNECTING ROD…………………………………..159
STANDARD PRESSURE FOR PARTS PRESSURE TESTING……………………………………..160
ASSEMBLY…………………………………………………………………………161
TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD…………………………….161
SPECIAL TOOLS…………………………………………………………………162
PREPARATORY WORK………………………………………………………………162
GENERAL ASSEMBLY………………………………………………………………163
CYLINDER BLOCK…………………………………………………………….163
GEAR CASE…………………………………………………………………175
FLYWHEEL………………………………………………………………….181
SENSOR……………………………………………………………………185
FRONT SUPPORT……………………………………………………………..186
MAIN RELIEF VALVE, SUCTION PIPE……………………………………………..186
OIL PAN…………………………………………………………………..186
DAMPER, CRANKSHAFT PULLEY ASSEMBLY…………………………………………..186
ACCESSORY DRIVE ASSEMBLY……………………………………………………187
THERMOSTAT HOUSING…………………………………………………………188
CAM FOLLOWER ASSEMBLY………………………………………………………188
CYLINDER HEAD ASSEMBLY……………………………………………………..188
ROCKER LEVER………………………………………………………………191
ROCKER LEVER COVER…………………………………………………………192
OIL COOLER ASSEMBLY………………………………………………………..193
BREATHER………………………………………………………………….195
WATER PUMP ASSEMBLY………………………………………………………..195
FUEL PUMP DRIVE……………………………………………………………196
AIR COMPRESSOR ASSEMBLY…………………………………………………….198
FUEL INJECTION PUMP………………………………………………………..199
EXHAUST MANIFOLD ASSEMBLY…………………………………………………..199
INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY………………………………………..200
TURBOCHARGER ASSEMBLY………………………………………………………205
INTAKE CONNECTOR…………………………………………………………..206
FAN………………………………………………………………………206
GENERAL ASSEMBLY…………………………………………………………..207
14 MAINTENANCE STANDARD………………………………………………………………209
INTAKE AND EXHAUST SYSTEM………………………………………………………….210
TURBOCHARGER………………………………………………………………….210
ENGINE BODY………………………………………………………………………211
CYLINDER HEAD…………………………………………………………………211
VALVE, VALVE SPRING AND VALVE GUIDE……………………………………………..212
ROCKER ARM AND SHAFT…………………………………………………………..214
CROSSHEAD AND GUIDE……………………………………………………………215
CYLINDER BLOCK………………………………………………………………..216
CYLINDER LINER………………………………………………………………..218
CRANKSHAFT……………………………………………………………………219
CAMSHAFT……………………………………………………………………..221
CAM FOLLOWER AND PUSH ROD………………………………………………………222
TIMING GEAR…………………………………………………………………..223
PISTON, PISTON RING AND PISTON PIN………………………………………………225
CONNECTING ROD………………………………………………………………..227
FLYWHEEL AND FLYWHEEL HOUSING…………………………………………………..229
LUBRICATION SYSTEM………………………………………………………………..230
OIL PUMP……………………………………………………………………..230
MAIN RELIEF VALVE……………………………………………………………..232
OIL COOLER BY-PASS VALVE, REGULATOR VALVE………………………………………..233
COOLING SYSTEM……………………………………………………………………234
WATER PUMP……………………………………………………………………234
THERMOSTAT……………………………………………………………………235
15 REPAIR AND REPLACEMENT OF PARTS……………………………………………………..237
TABLE OF SPECIAL TOOLS…………………………………………………………….238
CYLINDER HEAD…………………………………………………………………….239
CYLINDER AND MOUNTING FACE……………………………………………………..242
REPLACING VALVE SEAT…………………………………………………………..243
PRESSURE TEST OF CYLINDER HEAD………………………………………………….247
REPLACING VALVE GUIDE………………………………………………………….248
REPLACING CROSSHEAD GUIDE………………………………………………………248
GRINDING VALVE………………………………………………………………..249
CYLINDER BLOCK……………………………………………………………………250
METHOD OF CHECKING INSIDE DIAMETER OF MAIN BEARING MOUNTING HOLE USING ALIGNMENT BAR….253
CORRECTING CYLINDER BLOCK TOP SURFACE, COUNTERBORE………………………………..254
REPLACING MAIN BEARING CAP……………………………………………………..261
REPLACING CAM BUSHING………………………………………………………….263
CRANKSHAFT……………………………………………………………………….265
CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION…………………………267
GRINDING CRANKSHAFT……………………………………………………………271
CORRECTING FRONT SEAL CONTACT SURFACE……………………………………………278
CORRECTING REAR SEAL CONTACT SURFACE…………………………………………….280
CONNECTING ROD……………………………………………………………………282
REPLACING CONNECTING ROD SMALL END BUSHING……………………………………….284
REPLACING CRANKSHAFT GEAR………………………………………………………285
REPLACING CAMSHAFT GEAR………………………………………………………..286
REPLACING FLYWHEEL RING GEAR……………………………………………………286