PDF Shop Manual Komatsu SA6D140-1 Diesel Engine - 3 MB
This shop manual is the complete and authoritative guide for overhauling and repairing the robust Komatsu SA6D140-1 diesel engine.
It provides professional engine technicians with all the necessary specifications, critical tolerances, and detailed step-by-step procedures for both disassembly and assembly.
This is the definitive resource for performing a professional engine rebuild that meets precise factory standards.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
SEBM036200
1
DIESEL ENGINE
Β© 2004 1
All Rights Reserved 00-1
Printed in Japan 04-04(01)
--- Page 3 ---
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
β’ Used as lubricant for sliding portion
LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum β’ Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
β’ Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI β’ General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA β’ Used for normal temperature, light
SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum β’ Used for heavy load portion
SYG2-400M 400 g Γ 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g Γ 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
β’ Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can β’ Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B β’ Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR β’ Used as primer for cab side
Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR β’ Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
β’ "S" is used for high-tempera-
SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene β’ Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR β’ Used to seal joints of glass
Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material β’ Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
--- Page 4 ---
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1Β°C = 33.8Β°F
Β°C Β°F Β°C Β°F Β°C Β°F Β°C Β°F
β40.4 β40 β40.0 β11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
β37.2 β35 β31.0 β11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
β34.4 β30 β22.0 β10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
β31.7 β25 β13.0 β10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
β28.9 β20 β4.0 β9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
β28.3 β19 β2.2 β8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
β27.8 β18 β0.4 β8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
β27.2 β17 1.4 β7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
β26.7 β16 3.2 β7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
β26.1 β15 5.0 β6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
β25.6 β14 6.8 β6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
β25.0 β13 8.6 β5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
β24.4 β12 10.4 β5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
β23.9 β11 12.2 β4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
β23.3 β10 14.0 β3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
β22.8 β9 15.8 β3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
β22.2 β8 17.6 β2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
β21.7 β7 19.4 β2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
β21.1 β6 21.2 β1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
β20.6 β5 23.0 β1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
β20.0 β4 24.8 β0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
β19.4 β3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
β18.9 β2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
β18.3 β1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
β17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
β17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
β16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
β16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
β15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
β15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
β14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
β13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
β13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
β12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
β12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
--- Page 5 ---
GENERAL WEIGHT TABLE
WEIGHT TABLE
Unit: kg
No. Item Components SA6D140-H-1
1 Turbocharger Komatsu KTR110G 21
Cylinder head, valve, rocker arm,
2 Cylinder head assembly valve spring 18.3
Cylinder block, bearing cap,
3 Cylinder block assembly cylinder liner 340
4 Front cover 115
5 Oil pan 27
6 Oil pan case 85
7 Flywheel assembly Flywheel, ring gear 35.5
8 Flywheel housing 52
9 Crankshaft assembly Crankshaft, crankshaft gear 132
10 Camshaft assembly Camshaft, camshaft gear, thrust plate 19
Piston and connecting Piston, piston ring, piston pin,
11 rod assembly connecting rod 10.5 Γ 6
12 Oil pump 5.5
13 Fuel injection pump 29
14 Water pump 17
15 Alternator β
16 Starting motor 24V, 7.5 kW 18
17 Air compressor 11
18 Aftercooler assembly 43
SA6D140-H-1 01-9
--- Page 6 ---
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
RIGHT SIDE VIEW
SA6D140-H-1 11-9
--- Page 7 ---
STRUCTURE AND FUNCTION ENGINE BODY
4. FUNCTION AND MATERIAL OF
THRUST BEARING
Thurust bearing
β’ The crankshaft takes out the engine power
through the flywheel on its end and receives
load in the axial direction (thrust load) caused
by operations of the clutch, etc.
β’ Accordingly, thrust bearings are installed to
both sides of 1 main bearing of the crank-
shaft.
SA6D140-H-1 11-19
--- Page 8 ---
STRUCTURE AND FUNCTION ENGINE BODY
5. CONNECTING ROD 2) Connecting rod bushing
β’ The connecting rod bushing is used under the
severest condition in the engine. It has high
fatigue strength against high surface pressure,
fitting performance, and wear resistance.
β’ The connecting rod bushing is made of phos-
phor bronze which is an alloy of copper (Cu),
tin (Sn), and phosphorus (P) and which re-
sists high load and has high wear resistance
among the bearing materials.
3) Connecting rod bearing
β’ The connecting rod bearing is used under
almost the same condition as the crankshaft
main bearing, and the necessary conditions
for those bearings are the same.
ο¬ See the section of the crankshaft bearing.
4) Connecting rod bolt
β’ The connecting rod bolt is used to tighten
1. Connecting rod bushing the connecting rod cap to connect the con-
2. Connecting rod necting rod and crankshaft. It receives a ten-
3. Connecting rod bearing sile load caused by tightening and the high
4. Dowel pin tensile loads repeated by the inertia force of
5. Connecting rod cap the piston and connecting rod.
6. Connecting rod bolt ο¬ The connecting rod bolt is the most impor-
tant bolt in the engine, as well as the cylin-
1) Function of connecting rod der head bolt and main cap bolt, for the above
β’ The piston receives the energy of the com- reason. Its stem and thread must be checked
bustion pressure. The connecting rod receives carefully for a flaw and damage. It is tight-
that energy as reciprocation through the pis- ened by plastic-region angle tightening
ton pin and transfers it as rotation to the crank- method.
shaft.
β’ The connecting rod receives impulsive com-
pression and buckling loads caused by com-
bustion pressure. Since the engine rotates at
high speed, the connecting rod also repeat-
edly receives tensile loads and bending loads
caused by the inertia force of the piston and
it. Accordingly, the connecting rod is so de-
signed that it will stand those loads easily.
β’ For the above reason, the connecting rod is
made of special steel having high strength,
high fatigue strength in particular, by closed
die forging.
ο¬ The connecting rod receives strong and com-
plicated alternating loads. Accordingly, if it
has a flaw (a lateral flaw in particular) or a
bruise, stress is concentrated on that flaw or
a bruise and can cause breakage. Do not
make a flaw or a bruise on it.
SA6D140-H-1 11-29
--- Page 9 ---
STRUCTURE AND FUNCTION ENGINE BODY
STRUCTURE AND FUNCTION
1. FLYWHEEL
β’ The flywheel is bolted to the crankshaft and
used to transfer the engine power to the chas-
sis and other parts.
β’ Since the engine power is obtained only dur-
ing the combustion stroke, the evolutional
force is uneven.
The flywheel has large inertia force to ab-
sorb the unevenness of the evolutional force
and transfers the power smoothly.
2. RING GEAR
β’ The ring gear is installed to the end rim of
the flywheel by shrink fit. When the engine
is started, the pinion gear of the starting
motor is engaged with the ring gear to crank
the engine.
3. FLYWHEEL HOUSING
β’ The flywheel housing is installed to the rear
of the cylinder block to isolate the inside of
the engine and protect the flywheel which is
a rotating part.
4. REAR SEAL
β’ The rear seal is installed to the flywheel hous-
ing to seal the sliding part of the crankshaft.
SA6D140-H-1 11-39
--- Page 10 ---
STRUCTURE AND FUNCTION LUBRICATION SYSTEM
SA6D140-H-1 11-49
--- Page 11 ---
STRUCTURE AND FUNCTION FUEL SYSTEM
ELECTRONIC GOVERNOR (RED-III)
GOVERNOR UNIT
1. Housing
2. Actuator
3. Control rod
4. Connector
5. Copper plate
6. Cover
7. Eyebolt
β’ The electronic governor roughly consists of β’ The actual fuel injection rate is calculated in
the housing and actuator cover. the control unit and controlled properly by
the above series of operations, depending
β’ The actuator consists of the linear DC motor, on the operating condition of the machine.
link, and control rod position sensor, and is
operated by the signals from the control unit. β’ The linear DC motor consists of the magnet
section to supply a magnetic field, ball sec-
β’ The linear DC motor moves the coil assem- tion to lead the magnetic field, and coil as-
bly vertically according to the signal from sembly which moves up and down.
the control unit and stops it so that the con-
trol rod will be at the target position. (This is β’ The principle of operation of the DC motor is
performed according to the calculation in the based on the Flemingβs left-hand rule.
control unit.)
β’ If a current flows in the coil in the direction
β’ The movement is further transferred through of A, the magnetic force acts in the direction
the link to the connector to move the control C. If the current flows in the direction B, the
rod to the right and left and adjust the fuel magnetic force acts in the direction of D.
injection rate. Accordingly, the coil assembly can be moved
up and down and the control rod can be
β’ That is, if the coil assembly moves up, the stopped at any position by controlling the
fuel injection rate is increased. If the former direction and level of the current flowing in
moves down, the latter is decreased. the coil according the feedback from the po-
sition sensor.
β’ The copper plate at the connector end is a
control rod position sensor. It senses the
position of the control rod and feed it back to
the linear DC motor.
11-60 SA6D140-H-1
--- Page 12 ---
STRUCTURE AND FUNCTION FUEL SYSTEM
CONTROL BOX
β’ How to check diagnosis lamps (Green and red)
A while after the power is turned ON, β0.0β is displayed, if the system is normal. If nothing is
displayed at first, the controller may be defective or the power may not be supplied.
β’ How to check notch lamp (Yellow)
The notch lamp lights up when the signal (24 V) is input to the notch input line. While the engine
is stopped, input the notch signal to see if the lamp lights up. (For the relationship between the
notch and input line, see the notch signal specification.)
If the lamp does not light up, the bulb may be broken or the notch signal may not be input.
11-70 SA6D140-H-1
--- Page 13 ---
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM CHART
To radiator
To heating circuit
From radiator
1. Thermostat
2. After cooler Β· air bleed
3. Cylinderhead Β· air bleed
4. Water-cooled exhaust manifold
5. Aftercooler
6. Oil cooler
7. Water pump
A. Oil inlet port, outlet port
11-80 SA6D140-H-1
--- Page 14 ---
TESTING AND ADJUSTING INTAKE AND EXHAUST SYSTEM
MEASURING INTAKE AIR PRESSURE
(BOOST PRESSURE)
ο£Ώ When removing or installing the plug and
pressure gauge, stop the engine. Intake After-
manifold cooler 1
ο¬ When measuring the intake air pressure,
remove all the sand and dirt from the
nipple and plug.
1) Remove plug (1).
2) Install the engine pressure measuring
tool.
3) Start the engine and measure the intake
air pressure βwhen the engine stallsβ.
12-4 SA6D140-H-1
--- Page 15 ---
TESTING AND ADJUSTING FUEL SYSTEM
FUEL INJECTION VOLUME STANDARD
(WITH ELECTRONIC GOVERNOR)
Rack sensor Fuel injection volume (mm3/st) Maximum
Fuel injection Rack Pump
Applicable output variance
Engine pump Position speed Service Manufacturer
machine voltage between
Part No. (mm) (rpm) standard Standard
Vist (V) cylinder
Maintenance (13.8) 1.24 1,000 375Β±5 290 Β±3
6934-71-1113
disel motor car (6.8) Approx.2.6 315 19Β±1.5 20 Β±15
SA6D140-H-1
12-14 SA6D140-H-1
--- Page 17 ---
TESTING AND ADJUSTING TROUBLESHOOTING
ο£Ώ When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit
safety pins, block the wheels, and apply the parking brake.
ο£Ώ When carrying out operations with two or more workers, always use signals, and do not allow any
unauthorized person near the machine.
ο£Ώ When checking the water level, if the radiator cap is removed when the engine is hot, boiling water
will spurt out and may cause burns, so always wait for the engine to cool down before checking
the water level.
ο£Ώ Be extremely careful not to touch any hot parts.
ο£Ώ Be extremely careful not to get caught in the fan or any other rotating parts.
ο£Ώ When removing the plugs or caps from places under hydraulic pressure, water pressure, or air
pressure, release the internal pressure first. Fit the measuring tools securely before carrying out
any testing, adjusting, or troubleshooting.
ο¬ When using the standard values table for judgement in testing, adjusting, or troubleshooting, it is
necessary to be careful of the following points.
1. The standard values for the new machines in the standard values table are values given as
reference from the standards for new machines and machines shipped from the factory. They
should be used as values for estimating wear during operation or as target values when carrying
out repairs.
2. The failure judgement standard values in the standard values table are values using estimated
values based on the results of various tests and standard values for machines shipped from the
factory. Use these values for reference together with the repair and operation history of the
machine when judging failures.
3. Do not use this standard values table as a standard for judging claims.
12-26 SA6D140-H-1
--- Page 18 ---
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)
Causes
ο¬ Check that the monitor panel does not display any
ap
abnormality in the governor control system.
ray
seat
nk c
e sp
General causes why engine does not pick up smoothly
lve
el ta
β’ Insufficient intake of air
ctiv
e
d va
enc
er
in fu
r
β’ Insufficient supply of fuel
defe
e
r lin
rfer
e an
ung
ent
er
ng
β’ Improper condition of fuel injection
er
rain
ole
pipi
e
inde
e
lem
zle,
rain
p pl
valv
ranc
, int
β’ Improper fuel used
er h
p st
noz
er e