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

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

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

Language : English
Pages : 290
Downloadable : Yes
File Type : PDF
Size: 19.6 MB

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

The Komatsu SA6D140-H-1 Series Diesel Engine Shop Manual SEBM036200 is a comprehensive guide for the maintenance, repair, and overhaul of the SA6D140-H-1 series engine. This engine is used in a variety of Komatsu equipment, including excavators, bulldozers, and other heavy equipment.

• The manual is organized into several sections, each covering a different aspect of the engine. The first section provides an overview of the engine, including its specifications, performance data, and features. This section also includes a table of contents, a list of illustrations, and a list of symbols and abbreviations used throughout the manual.
• The second section covers engine inspection and measurement procedures. This section provides step-by-step instructions for checking and measuring various components of the engine, including the cylinder block, cylinder head, and crankshaft. The manual includes detailed illustrations to help the reader understand the procedures.
• The third section covers engine disassembly and assembly procedures. This section provides instructions for removing and installing various components of the engine, including the cylinder head, pistons, and crankshaft. The manual also includes torque specifications for each component.
• The fourth section covers engine testing and adjusting procedures. This section provides instructions for testing and adjusting various components of the engine, including the fuel injection system, the turbocharger, and the valve clearance. The manual includes detailed illustrations to help the reader understand the procedures.
• The fifth section covers engine maintenance procedures, including routine maintenance and inspections. This section provides instructions for maintaining the engine to ensure its continued performance and longevity.
• The sixth section covers engine troubleshooting and diagnosis procedures. This section provides instructions for diagnosing and troubleshooting various engine problems, including starting problems, low power output, and excessive smoke. The manual includes a troubleshooting chart and detailed illustrations to help the reader diagnose and fix the problem.
• Overall, the Komatsu SA6D140-H-1 Series Diesel Engine Shop Manual SEBM036200 is an essential tool for anyone working on or maintaining this engine. The manual is available in print or digital formats, making it a convenient and accessible resource for mechanics and technicians. It is designed to be user-friendly and easy to understand, with clear instructions and detailed illustrations. With this manual, you can ensure that your Komatsu equipment is operating at its best and avoid costly repairs and downtime.

TABLE OF CONTENTS:

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

COVER…………………………………………………………………………….. 1
CONTENTS………………………………………………………………………….. 2
01 GENERAL………………………………………………………………………… 26
GENERAL VIEW…………………………………………………………………… 27
SPECIFICATIONS…………………………………………………………………. 29
GENERAL ASSEMBLY DRAWING………………………………………………………… 45
WEIGHT TABLE…………………………………………………………………… 57
ENGINE PERFORMANCE CURVE………………………………………………………… 58
11 STRUCTURE AND FUNCTION…………………………………………………………… 90
GENERAL STRUCTURE………………………………………………………………. 91
INTAKE AND EXHAUST SYSTEM……………………………………………………….. 93
TURBOCHARGER………………………………………………………………..100
AFTER-COOLER………………………………………………………………..104
ENGINE BODY…………………………………………………………………….105
CYLINDER HEAD……………………………………………………………….105
VALVE SYSTEM………………………………………………………………..107
CYLINDER BLOCK………………………………………………………………109
MAIN CIRCULATION PART………………………………………………………..111
TIMING GEAR…………………………………………………………………114
FLYWHEEL AND FLYWHEEL HOUSING…………………………………………………116
LUBRICATION SYSTEM………………………………………………………………117
LUBRICATION SYSTEM CHART……………………………………………………..117
OIL PUMP……………………………………………………………………118
OIL FILTER AND SAFETY VALVE…………………………………………………..119
OIL COOLER………………………………………………………………….120
OIL PUMP RELIEF VALVE………………………………………………………..122
OIL COOLER BY-PASS VALVE……………………………………………………..122
PISTON COOLING VALVE…………………………………………………………123
MECHANICAL PUMP……………………………………………………………..124
FUEL SYSTEM…………………………………………………………………….125
FUEL SYSTEM CHART……………………………………………………………125
FUEL INJECTION PUMP………………………………………………………….126
FUEL INJECTION NOZZLE………………………………………………………..130
FUEL INJECTION PUMP DRIVE…………………………………………………….131
FUEL FILTER…………………………………………………………………133
FUEL CUT SOLENOID……………………………………………………………134
ENGINE STOP MOTOR……………………………………………………………136
STARTING AID………………………………………………………………..141
OUTLINE OF ELECTRONICAL GOVERNOR SYSTEM (WITH ELECTRONICAL GOVERNOR MADE BY ZEXEL)….142
COOLING SYSTEM………………………………………………………………….148
COOLING SYSTEM CHART…………………………………………………………148
WATER PUMP………………………………………………………………….149
FAN DRIVE AND TENSION PULLEY………………………………………………….150
CORROSION RESISTOR…………………………………………………………..155
THERMOSTAT………………………………………………………………….156
ACCESSORY………………………………………………………………………157
AIR COMPRESSOR MOUNTING………………………………………………………157
AIR COMPRESSOR………………………………………………………………160
ELECTRICAL SYSTEM……………………………………………………………….161
ALTERNATOR………………………………………………………………….161
STARTING MOTOR………………………………………………………………165
WIRING DIAGRAM………………………………………………………………170
12 TESTING AND ADJUSTING…………………………………………………………….172
ENGINE BODY…………………………………………………………………….178
ADJUSTING VALVE CLEARANCE…………………………………………………….178
MEASURING COMPRESSION PRESSURE………………………………………………..179
FUEL SYSTEM…………………………………………………………………….180
TESTING AND ADJUSTING FUEL INJECTION TIMING…………………………………….180
ADJUSTING FUEL CUT SOLENOID…………………………………………………..182
PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE…………………………………186
ADJUSTING FUEL INJECTION PRESSURE(VALVE CRACKING PRESSURE)……………………….188
METHOD FOR INSTALLING (ADJUSTMENT) OF ENGINE SPEED SENSOR………………………..189
CALIBRATION DATA…………………………………………………………….191
COOLING SYSTEM………………………………………………………………….255
FNA BELT TENSION…………………………………………………………….255
REPLACING FAN BELT AND ADJUSTING AUTO TENSIONER…………………………………256
PERFORMANCE TEST………………………………………………………………..257
RUN-IN STANDARD……………………………………………………………..257
PERFORMANCE TEST CRITERIA…………………………………………………….267
TESTING AND ADJUSTING TOOL LIST……………………………………………….292
TESTING AND ADJUSTING DATE……………………………………………………293
FAN BELT TENSION…………………………………………………………….313
TROUBLESHOOTING…………………………………………………………………315
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………..316
METHOD OF USING TROUBLESHOOTING CHART………………………………………….317
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…………………….321
S-2 ENGINE DOES NOT START…………………………………………………….322
(1) ENGINE DOES NOT TURN………………………………………………….322
(2) ENGINE TURNS BUT NO EXHAUST COMES OUT (FUEL IS NOT BEING INJECTED)…………323
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)……324
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR)…………………………325
S-4 ENGINE STOPS DURING OPERATIONS…………………………………………….326
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…………………………………..327
S-6 ENGINE LACKS OUTPUT (NO POWER)…………………………………………….328
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)………………………………..329
S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)………………………330
S-9 OIL BECOMES CONTAMINATED QUICKLY…………………………………………..331
S-10 FUEL CONSUMPTION IS EXCESSIVE…………………………………………….332
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVER GOES DOWN……….333
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)………………………….334
S-13 OIL LEVEL RISES…………………………………………………………335
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)……………………………336
S-15 ABNORMAL NOISE IS MADE…………………………………………………..337
S-16 VIBRATION IS EXCESSIVE…………………………………………………..338
13 DISASSEMBLY AND ASSEMBLY………………………………………………………….356
DISASSEMBLY…………………………………………………………………….357
WASHING…………………………………………………………………….374
WASHING CYLINDER BLOCK……………………………………………………….374
WASHING CRANKSHAFT…………………………………………………………..375
MEASURING PARTS……………………………………………………………..376
ASSEMBLY……………………………………………………………………….382
14 MAINTENANCE STANDARD……………………………………………………………..416
INTAKE AND EXHAUST SYSTEM………………………………………………………..417
TURBOCHARGER………………………………………………………………..417
ENGINE BODY…………………………………………………………………….422
CYLINDER HEAD……………………………………………………………….422
VALVES AND VALVE GUIDE……………………………………………………….423
CROSSHEAD AND CROSSHEAD GUIDE…………………………………………………424
PUSH ROD AND CAM FOLLOWER…………………………………………………….425
CYLINDER BLOCK………………………………………………………………426
CYLINDER LINER………………………………………………………………428
CRANKSHAFT………………………………………………………………….429
CAMSHAFT……………………………………………………………………430
TIMING GEAR…………………………………………………………………431
PISTON, PISTON RING AND PISTON PIN…………………………………………….433
CONNECTING ROD………………………………………………………………435
LUBRICATION SYSTEM………………………………………………………………436
OIL PUMP……………………………………………………………………436
OIL PUMP RELIEF VALVE, PISTON COOLING VALVE AND OIL COOLER BY-PASS VALVE…………..437
COOLING SYSTEM………………………………………………………………….438
WATER PUMP………………………………………………………………….438
ACCESSORY………………………………………………………………………439
AIR COMPRESSOR………………………………………………………………439
15 REPAIR AND REPLACEMENT OF PARTS……………………………………………………441
TABLE OF SPECIAL TOOLS…………………………………………………………..442
CYLINDER HEAD…………………………………………………………………..443
TESTING AND INSPECTING…………………………………………………………..444
REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING………………………………..446
REPLACING VALVE SEAT INSERTS……………………………………………………..447
REPLACING NOZZLE HOLDER SLEEVE……………………………………………………453
REPLACING VALVE GUIDE……………………………………………………………457
REPLACING CROSS HEAD GUIDE……………………………………………………….458
GRINDING THE VALVE………………………………………………………………459
CYLINDER BLOCK………………………………………………………………….460
TESTING AND INSPECTING…………………………………………………………..461
GRINDING THE TOP SURFACE OF CYLINDER BLOCK…………………………………………463
REPLACING MAIN METAL CAP…………………………………………………………469
REPLACING CAM BUSHING……………………………………………………………471
CRANKSHAFT……………………………………………………………………..473
REPAIRING THE CRANKSHAFT…………………………………………………………480
CONNECTING ROD………………………………………………………………….485
REPLACING CRANKSHAFT GEAR………………………………………………………..487
REPLACING CAMSHAFT GEAR………………………………………………………….488
REPLACING FLYWHEEL RING GEAR……………………………………………………..489