This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the Komatsu 12V140-1 Series 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 :
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
SAA12V140-P920
SAA12V140-P920
SAA12V140-P1030
SAA12V140-P1150
TABLE OF CONTENTS :
01 GENERAL
11 STRUCTURE AND FUNCTION
12 TESTING AND ADJUSTING
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 : SEBM028316
Total Pages : 469
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.
This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, maintenance manual, operating manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.
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Komatsu 12V140-1 Series Diesel Engine Factory Service Manual PDF Download
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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
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