Komatsu 12V140-1 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 12V140-1 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 12V140-1 Series Diesel Engine
Book Code: SEBM028318
Language: English
Pages: 471
File Format: Portable Document Format (PDF)
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DESCRIPTION:
Komatsu 12V140-1 Series Diesel Engine Shop Manual
FOREWORD:
GENERAL:
- This shop manual 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.
- 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.
TABLE OF CONTENTS:
Komatsu 12V140-1 Series Diesel Engine Shop Manual
COVER...................................................................................................................................... 1 CONTENTS................................................................................................................................... 2 01 GENERAL................................................................................................................................. 27 APPLICABLE MACHINE..................................................................................................................... 28 SPECIFICATIONS......................................................................................................................... 29 GENERAL ASSEMBLY DRAWING............................................................................................................... 38 ENGINE PERFORMANCE CURVE............................................................................................................... 51 WEIGHT TABLE........................................................................................................................... 64 11 STRUCTURE AND FUNCTION.................................................................................................................. 66 GENERAL STRUCTRE....................................................................................................................... 67 INTAKE AND EXHAUST SYSTEM.............................................................................................................. 69 AIR CLEANER........................................................................................................................ 71 TURBOCHARGER....................................................................................................................... 72 AFTER-COOLER....................................................................................................................... 74 ENGINE BODY............................................................................................................................ 75 CYLINDER HEAD...................................................................................................................... 75 CYLINDER BLOCK..................................................................................................................... 79 MAIN REVOLVING SYSTEM.............................................................................................................. 81 TIMING GEAR........................................................................................................................ 83 VALVE SYSTEM....................................................................................................................... 87 FLYWHEEL AND FLYWHEEL HOUSING...................................................................................................... 91 LUBRICATION SYSTEM..................................................................................................................... 92 LUBRICATION SYSTEM CHART........................................................................................................... 92 OIL PUMP........................................................................................................................... 94 MAIN RELIEF........................................................................................................................ 95 OIL COOLER BY-PASS VALVE, REGULATOR VALVE.......................................................................................... 96 OIL FILTER......................................................................................................................... 98 OIL COOLER.........................................................................................................................102 FUEL SYSTEM ...........................................................................................................................103 FUEL SYSTEM CHART..................................................................................................................103 FUEL INJECTION PUMP................................................................................................................106 FUEL INJECTION NOZZLE..............................................................................................................120 FUEL FILTER........................................................................................................................121 ENGINE STOP MOTOR..................................................................................................................123 COOLING SYSTEM.........................................................................................................................128 COLING SYSTEM SHART................................................................................................................128 WATER PUMP.........................................................................................................................129 COOLING FAN........................................................................................................................130 THERMOSTAT.........................................................................................................................136 CORROSION RESISTOR.................................................................................................................137 ACCESSORY..............................................................................................................................138 AIR COMPRESSOR.....................................................................................................................138 EXHAUST BRAKE......................................................................................................................140 ELECTRICAL SYSTEM......................................................................................................................141 ALTERNATOR.........................................................................................................................141 STARTING MOTOR.....................................................................................................................144 ELECTRICAL INTAKE AIR HEATER.......................................................................................................145 OIL PAN HEATER.....................................................................................................................146 COOLING WATER HEATER...............................................................................................................147 12 TESTING AND ADJUSTING...................................................................................................................148 ENGINE BODY............................................................................................................................149 ADJUSTING VALVE CLEARANCE..........................................................................................................149 MEASURING COMPRESSION PRESSURE.....................................................................................................150 MEASURING BLOW-BY..................................................................................................................151 FUEL SYSTEM............................................................................................................................152 TESTING AND ADJUSTMENT OF FUEL INJECTION TIMAING...................................................................................152 (WITH ZEXEL MECHANICAL GOVERNOR)...............................................................................................152 (WITH ZEXEL ELECTRONICAL GOVERNOR).............................................................................................155 TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING (WITH KOMATSU ELECTRONICAL GOVERNOR)...............................................158 ADJUSTING INJECTION PUMP GOVERNOR LINK.............................................................................................161 (WITH MECHANICAL GOVERNOR).....................................................................................................161 (WITH ZECEL ELECTRONICAL GOVERNOR).............................................................................................163 PROCEFURE FOR ADJUSTING ENGINE STOP MOTOR CABLE (APPLICABLE FOR MODELSUSING ENGINE STOP MOTOR).....................................165 METHOD FOR INSTALLING (ADJUSTMENT) OF ENGINE SPEED SENSOR..........................................................................166 ADJUSTING FUEL INJECTION PRESSURE..................................................................................................167 FUEL INJECTION PUMP CALIBRATION DATA...............................................................................................168 ADJUSTMENT OF ELECTRONICAL GOVERNOR MADE BY KOMATSU................................................................................192 HANDLING OF THROTTLE BOX...........................................................................................................209 HANDLING OF XEP CHECKER............................................................................................................219 COOLING SYSTEM.........................................................................................................................224 CHECKING AND ADJUSTING V-BELT TENSION..............................................................................................224 PERFORMANCE TEST.......................................................................................................................226 RUNNING IN STANDARD................................................................................................................226 PERFORMANCE TEST CRITERIA..........................................................................................................230 TESING AND ADJUSTING TOOL LIST.....................................................................................................240 TESTING AND ADJUSTING DATA.........................................................................................................241 TROUBLESHOOTING........................................................................................................................252 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................254 METHOD OF USING TROUBLESHOOTING CHART..............................................................................................255 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) (WITH ELECTRONICAL GOVERNOR).........................................259 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) (WITH MECHANICAL GOVERNOR)...........................................260 S-2 EGINE DOES NOT START...........................................................................................................261 ① ENGINE DOES NOT TURN.........................................................................................................261 ② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (WITH ELECTRONICAL GOVERNOR) .........................262 ② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) (WITH MECHANICAL GOVERNOR)............................263 ③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) ....................................................264 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...........................................................................265 S-4 ENGINE STOPS DURING OPERATIONS (WITH MECHANICAL GOVERNOR)......................................................................267 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) (WITH ELECTRONICAL GOVERNOR)..........................................................268 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) (WITH MECHANICAL GOVERNOR)...........................................................269 S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH ELECTRONICAL GOVERNOR)....................................................................270 S-6 ENGINE LACKS OUTPUT (NO POWER) (WITH MECHANICAL GOVERNOR)......................................................................271 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) (WITH ELECTRONICAL GOVERNOR).....................................................272 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) (WITH MECHANICAL GOVERNOR).......................................................273 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)..........................................................................274 S-9 OIL BECOMES CONTAMINATED QUICKLY...............................................................................................275 S-10 FUEL CONSUMPTION IS EXCESSIVE (WITH ELECTRONICAL GOVERNOR) ...................................................................276 S-10 FUEL CONSUMPTION IS EXCESSIVE (WITH MECHANICAL GOVERNOR)......................................................................277 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.......................................................278 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................................................279 S-13 OIL LEVEL RISES...............................................................................................................280 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..............................................................................281 S-15 ABNORMAL NOISE IS MADE........................................................................................................282 S-16 VIBRATION IS EXCESSIVE........................................................................................................283 S-17 DIAGNOSIS OF ELECTRONICAL GOVERNOR BY DIAGNOSIS DISPLAY (ELECTRONICAL GOVERNOR MADE BY ZEXEL).................................284 1. CONTROLLER SYSTEM ABNORMALITY...............................................................................................287 2. GOVERNOR SERVO SYSTEM ABNORMALITY...........................................................................................287 3. RACK SENSOR SYSTEM ABORMALITY...............................................................................................289 4. OVERRUN ABNORMALITY.........................................................................................................291 5. 1ST SPEED SENSOR ABNORMALITY................................................................................................292 6. 2ND SPEED SENSOR ABNORMALITY................................................................................................292 7. LOW IDLING SPEED CONTROL DIAL ABNORMALITY...................................................................................293 8. DROOP CONTROL DIAL ABNORMALITY..............................................................................................294 9. DIAGNOSIS LAMP FAILS TO MAKE INDICATION.....................................................................................295 10. NORMAIL INDICATION.........................................................................................................296 11. MEMORY CLEAR CANNOT BE ACHIEVED BY PRESSING THE MEMORY CLEAR SWITCH (WHEN FAILURE INDICATION IS MADE BY DIAGNOSIS LAMP)....301 13 DISASSEMBLY AND ASSEMBLY................................................................................................................302 GENERAL DISASSEMBLY....................................................................................................................303 1. WASHING.........................................................................................................................304 2. SETTING ENGINE STAND............................................................................................................304 3. ENGINE COOLING WATER AND ENGINE OIL.............................................................................................305 4. FILTER..........................................................................................................................305 5. MUFFLER ASSERMBLY...............................................................................................................305 6. FAN.............................................................................................................................305 7. FAN BELT........................................................................................................................306 8. FAN PULLEY ASSEMBLY.............................................................................................................306 9. LNTAKE CONNECTOR................................................................................................................306 10. EXHAUST BRAKE ASSEMBLY.........................................................................................................306 11. TURBOCHARGER ASSEMBLY..........................................................................................................307 12. INTAKE MANIFOLD, AFTERCOOLER ASSEMBLY..........................................................................................307 13. EXHAUST MANIFOLD ASSEMBLY......................................................................................................308 14. FUEL INJECTION PIPE,SPIL TUBE..................................................................................................308 15. FUEL INJECTION PUMP ASSEMBLY...................................................................................................309 16. WATER PUMP ASSEBLY.............................................................................................................310 17. BREATHER.......................................................................................................................310 18. AIR COMPRESSOR.................................................................................................................310 19. OIL COOLER ASSEMBLY............................................................................................................311 20. OIL FILLER, OIL LEVEL GAUGE....................................................................................................311 21. HEAD COVER.....................................................................................................................312 22. NOZZZLE HOLDER, CONNECTION.....................................................................................................312 23. ROCKER ARM.....................................................................................................................313 24. PUSH ROD.......................................................................................................................313 25. CROSSHEAD......................................................................................................................313 26. ROCKER ARM HOUSING.............................................................................................................313 27. CYLINDER HEAR ASSEMBLY.........................................................................................................313 28. CAM FOLLOWER ASSEMBLY..........................................................................................................314 29. THERMOSTAT HOUSING.............................................................................................................314 30. ASSESSORY DRIVE ASSEMBLY.......................................................................................................315 31. DAMPER, CRANKSHAFT PULLEY ASSEMBLY.............................................................................................315 32. OIL PAN........................................................................................................................316 33. MAN RELIEF VALVE, SUCTION TUBE.................................................................................................316 34. FRONT SUPPOR...................................................................................................................316 35. FLYWHEEL.......................................................................................................................316 36. FLYWHEEL HOUSING, REAR SEAL....................................................................................................317 37. GEAR CASE COVER, FRONT SEAL....................................................................................................317 38. IDLER GEAR (LARGE).............................................................................................................317 39. INJECTION PUMP DRIVE GEAR......................................................................................................317 40. INJECTION PUMP DRIVE CASE ASSEMLY..............................................................................................318 41. OIL PUMP ASSEMBLY..............................................................................................................318 42. IDLER GEAR (SMALL).............................................................................................................318 43. CAMSHAFT ASSEMBLY..............................................................................................................319 44. TIMING GEAR CASE...............................................................................................................319 45. PISTON COOLING NOZZLE..........................................................................................................319 46. PISTON AND CONNECTING ROD ASSEMBLY.............................................................................................319 47. CRANKSHAFT.....................................................................................................................321 48. CYLINDER LINER.................................................................................................................322 WASHING................................................................................................................................323 WASHING CYLINDER BLOCK.............................................................................................................324 WASHING CRANKSHFT..................................................................................................................326 WASHING CONNECTING ROD.............................................................................................................326 MEASURING AND INSPECTING PARTS.........................................................................................................327 MEASURING PARTS....................................................................................................................328 MEASURING CURVATURE OF CRANKSHAFT..............................................................................................328 MEASURING OUTSIDE DIAMETER OF JOURNAL..........................................................................................328 MEASURING OUT-OF-ROUNDNESS OF JOURNAL..........................................................................................328 MEASURING SURFACE ROUGHNESS OF OUTSIDE DIAMETER OF JOURNAL.....................................................................329 MEASURING DEPTH OF CYLINDER LINER COUNTERBORE..................................................................................330 MEASURING MAIN BERING BORE.....................................................................................................330 MEASURING CUVATURE OF CAMSHAFT.................................................................................................331 MEASURING OUTSIDE DIAMETER OF JOURNAL..........................................................................................331 MEASURING HELGHT OF CAM........................................................................................................331 MEASURING PISTON RING GROOVE...................................................................................................332 MEASURING OUTSIDE DIAMETER OF PISTON...........................................................................................332 MEASURING LENGTH OF CONNECTING ROD.............................................................................................333 MEASURING INSIDE DIAMETER AT SMALL END OF CONNECTING ROD.......................................................................333 MEASUING INSIDE DIAMENTER AT BIG END OF CONNECTING ROD.........................................................................333 MEASURING SURVATURE, TWISTING OF CONNECTING ROD................................................................................334 STANDARD PRESSURE FOR PARTS PRESSURE TESTING...................................................................................335 GENERAL ASSEMBLY.......................................................................................................................336 1. CYLINDER LINER..................................................................................................................339 2. CRANKSHAFT......................................................................................................................342 3. PISTON, CONNECTING ROD ASSEMBLY.................................................................................................345 4. PISTON COOLING NOZZLE...........................................................................................................351 5. GEAR CASE ......................................................................................................................352 6. CAMSHAFT ASSEMBLY...............................................................................................................352 7. IDLER GEAR (SMALL)..............................................................................................................352 8. OIL PUMP ASSEMBLY...............................................................................................................353 9. INJECTION PUMP DRIVE CASE.......................................................................................................353 10. INJECION PUMP DRIVE GEAR.......................................................................................................354 11. IDIER GEAR (LARGE) (RIGHT BANK)................................................................................................354 12. IDIER GGEAR (LARGE) (LEFT BANK)................................................................................................355 13. MEASURING BACKLASH OF GEAR.....................................................................................................355 14. GEAR CASE COVER................................................................................................................357 15. FRONT OIL SEAL, SLEEVE.........................................................................................................357 16. FLYWHEEL HOUSING...............................................................................................................360 17. REAR OIL SEAL, SLEEVE..........................................................................................................360 18. FLYWHEEL.......................................................................................................................363 19. FRONT SUPPORT..................................................................................................................364 20. MAIN RELIEF VALVE, SUCTION PIPE................................................................................................365 21. OIL PAN .......................................................................................................................365 22. DAMPER, CRANKSHAFT PULLEY ASSEMBLY.............................................................................................365 23. ACCESSORY DRIVE ASSEMBLY.......................................................................................................366 24. THERMOSTAT HOUSING.............................................................................................................367 25. CAM FOLLOWER ASSEMBLY..........................................................................................................367 26. CYLINDER HEAD ASSEMBLY.........................................................................................................367 27. ROCKER ARM HOUSING.............................................................................................................370 28. CROSSHEAD......................................................................................................................370 29. PUSH ROD.......................................................................................................................370 30. ROCKER ARM.....................................................................................................................370 31. NOZZLE HOLDER, CONNECTION......................................................................................................372 32. ADJUSTING VALVE CLEARANCE......................................................................................................372 33. HEAD COVER, TURBOCHARGER LUBRICATION TUBE......................................................................................373 34. OIL LEVEL GAUGE,OIL FILLER.....................................................................................................373 35. OIL COOLER ASSEMBLY............................................................................................................373 36. AIR COMPRESSOR.................................................................................................................373 37. BREATHER.......................................................................................................................374 38. WATER PUMP ASSEMBLY............................................................................................................375 39. FUEL INJECTION PUMP ASSEMBLY...................................................................................................375 40. FUEL INJECTION PIPES, SPILL TUBE...............................................................................................377 41. EXHAUST MANIFOLD ASSEMBLY......................................................................................................377 42. INTAKE MANIFOLD, AFTER-COOLER ASSEMBLY.........................................................................................378 43. TURBOCHARGER ASSEMBLY..........................................................................................................379 44. EXHAUST BRAKE ASSEMBLY.........................................................................................................379 45. INTAKE CONNECTOR...............................................................................................................380 46. FAN PULLEY ASSEMBLY............................................................................................................380 47. FAN BELT.......................................................................................................................380 48. FAN............................................................................................................................380 49. MUFFLER ASSEMBLY...............................................................................................................381 50. FILTER.........................................................................................................................381 51. SETTING ON ENGINE STAND........................................................................................................381 52. ALTERNATOR ASSEMBLY............................................................................................................381 53. STARTING MOTOR ASSEMBLY........................................................................................................382 14 MAINTENANCE STANDIRD....................................................................................................................383 INTAKE AND EXHAUST SYSTEM..............................................................................................................384 TRBOCHARGER........................................................................................................................384 ENGINE BODY............................................................................................................................386 CYLINDER HEAD......................................................................................................................386 VALVE, VALVE SPRING AND VALVE GUIDE ...............................................................................................387 ROCKER ARM AND SHAFT...............................................................................................................389 CROSSHEAD AND GUIDE................................................................................................................390 CYLINDER BLOCK.....................................................................................................................391 CYLINDER LINER.....................................................................................................................393 CRANKSHAFT.........................................................................................................................394 CAMSHAFT...........................................................................................................................396 CAM FOLLOWER AND PUSH ROD..........................................................................................................397 TIMING GEAR........................................................................................................................398 PISTON, PISTON RING AND PISTON PIN.................................................................................................400 CONNECTING ROD.....................................................................................................................402 FLYWHEEL AND FLYWHEEL HOUSING......................................................................................................404 LUBRICATION SYSTEM.....................................................................................................................405 OIL PUMP ..........................................................................................................................405 MAIN RELIEF VALVE..................................................................................................................409 OIL COOLER BY-PASS VALVE, REGULATOR VALVE..........................................................................................410 COOLING SYSTEM.........................................................................................................................412 WATER PUMP.........................................................................................................................412 THRMOSTAT..........................................................................................................................413 15 REPAIR AND REPLACEMENT OF PARTS.........................................................................................................414 TABLE OF SPECIAL TOOLS.................................................................................................................415 TESTING ANF INSPECTING CYINDER HEAD....................................................................................................417 GRINDING CYLINDER HEAD MOUNTING FACE...................................................................................................420 REPLACING VALVE SEAT...................................................................................................................421 PRESSURE TEST OF CYLONDER HEAD.........................................................................................................426 REPLACING VALVE GUIDE..................................................................................................................427 REPLACING CROSSHEAD GUIDE..............................................................................................................428 GRINDING VALVE.........................................................................................................................429 TESTING AND INSPECTING CYLINDER BLOCK..................................................................................................430 CORRECTING CYLINDRE BLOCK TOP SURFACE, COUNTERBORE.....................................................................................434 REPLACING MAIN BEARING CAP.............................................................................................................442 REPLACING CAM BUSHING..................................................................................................................444 TESTING AND INSPECTING CRANKSHAFT......................................................................................................446 CORRECTING SURFACE ROUGHESS OF CRANKSHAFT JOURNAL PORTION..............................................................................448 GRINDING CRANKSHAFT....................................................................................................................453 CORRECTING FRONT SEAL CONTACT SURFCE...................................................................................................462 CORRECTING REAR SEAL CONTACT SURFACE...................................................................................................464 TESTING AND INSPECTING CONNECTING ROD..................................................................................................466 REPLACING CONNECTING ROD SMALL END BUSHING.............................................................................................468 REPLACING CRANKSHAFT GEAR..............................................................................................................469 REPLACING CAMSHAFT GEAR................................................................................................................470 REPLACING FLYWHEEL RING GEAR...........................................................................................................471
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