Komatsu Engine Saa12v140ze 2 Workshop Manuals
Komatsu Engine Saa12v140ze 2 Workshop Manuals
SA12V140Z-1 SERIES
SAA12V140ZE-2 SERIES
DIESEL ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
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FOREWORD
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FOREWORD
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FOREWORD SAFETY
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation. Some
of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cau-
tions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may
possibly arise, first consider safety, and take the necessary actions to deal with the situation.
Mistakes in operation are extremely dangerous. Read 7. Before adding oil or making repairs, park the
the OPERATION & MAINTENANCE MANUAL carefully machine on hard, level ground, and block the
BEFORE operating the machine. wheels or tracks to prevent the machine from mov-
ing.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are 8. Before starting work, lower blade, ripper, bucket or
fixed to the machine. any other work equipment to the ground. If this is
not possible, insert the safety pin or use blocks to
2. When carrying out any operation, always wear prevent the work equipment from falling. In addi-
safety shoes and helmet. Do not wear loose work tion, be sure to lock all the control levers and hang
clothes, or clothes with buttons missing. warning signs on them.
• Always wear safety glasses when hitting parts with
a hammer. 9. When disassembling or assembling, support the
• Always wear safety glasses when grinding parts machine with blocks, jacks or stands before start-
with a grinder, etc. ing work.
3. If welding repairs are needed, always have a 10. Remove all mud and oil from the steps or other
trained, experienced welder carry out the work. places used to get on and off the machine. Always
When carrying out welding work, always wear use the handrails, ladders or steps when getting on
welding gloves, apron, glasses, cap and other or off the machine. Never jump on or off the
clothes suited for welding work. machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe foot-
4. When carrying out any operation with two or more ing.
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on the 11. When removing the oil filler cap, drain plug or
controls in the operator's compartment. hydraulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out. Before
5. Keep all tools in good condition and learn the cor- disconnecting or removing components of the oil,
rect way to use them. water or air circuits, first remove the pressure com-
pletely from the circuit.
6. Decide a place in the repair workshop to keep tools
and removed parts. Always keep the tools and 12. The water and oil in the circuits are hot when the
parts in their correct places. Always keep the work engine is stopped, so be careful not to get burned.
area clean and make sure that there is no dirt or oil Wait for the oil and water to cool before carrying
on the floor. Smoke only in the areas provided for out any work on the oil or water circuits.
smoking. Never smoke while working.
13. Before starting work, remove the leads from the
battery. ALWAYS remove the lead from the nega-
tive (-) terminal first.
00-3 1
FOREWORD SAFETY
14. When raising heavy components, use a hoist or 24. Take care when removing or installing the tracks of
crane. Check that the wire rope, chains and hooks track-type machines. When removing the track, the
are free from damage. Always use lifting equip- track separates suddenly, so never let anyone
ment which has ample capacity. Install the lifting stand at either end of the track.
equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the compo-
nent from hitting any other part. Do not work with
any part still raised by the hoist or crane.
00-4 1
FOREWORD GENERAL
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu-
rate 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 work-
shop. For ease of understanding, the manual is divided into the following sections. These sections are further
divided into each main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and
fuel, coolant and lubricant specification charts.
This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
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” to “Causes” are also
included in this section.
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.
00-5 1
FOREWORD HOW TO READ THE SHOP MANUAL
00-6 1
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS dent can result. Hooks have maximum strength at the
middle portion.
HOISTING
00-7 1
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials prescribed in the shop manuals are listed below.
test
Category Code Part No. Quantity Container Main applications, features
• Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions and cork plugs from coming
out
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene • Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
• Features: Resistance to heat, chemi-
Polyethylene cals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhe- • Used as adhesive or sealant for metal,
LT-3 Hardening Can
sive and hard- glass or plastic.
agent:
Adhesives
ening agent)
500 g
Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive.
Three
Polyethylene • Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container • Used mainly for adhesion of metals,
1735
rubbers, plastics and woods.
• Quick hardening type adhesive.
Aron- • Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 • Used mainly for adhesion of rubbers,
plastics and metals.
• Features: Resistance to heat, chemi-
Loctite Polyethylene cals
79A-129-9110 50 cc
648-50 container • Used at joint portions subject to high
temperature.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Features: Resistance to heat
Gasket • Used as sealant for flange surfaces and
sealant bolts at high temperature locations;
used to prevent seizure.
LG-3 790-129-9070 1 kg Can
• Used as sealant for heat resistant gas-
ket for at high temperature locations
such as engine pre-combustion cham-
ber, exhaust pipe.
00-8 1
FOREWORD COATING MATERIALS
400 g (10
SYG2-400M Belows type • Used for places with heavy load.
per case)
00-9 1
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
00-10 1
FOREWORD STANDARD TIGHTENING TORQUE
00-11 1
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of Cross sec- Applicable circuit
number (mm) rating (A)
strands strand (mm) tion (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Red & Yellow & Green &
Color — Blue & Red
Black Yellow Black Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Black & Red & Yel- Yellow & Green & Blue & Yel-
Color —
Blue Red low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-12 1
FOREWORD CONVERSION TABLES
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method
of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(a) Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from
1.
(b) Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from
2.
(c) Take the point where the two lines cross as 3. This point 3 gives the value when converting from millime-
ters to inches. Therefore, 55 millimeters = 2.165 inches.
2
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-13 1
FOREWORD CONVERSION TABLES
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
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FOREWORD CONVERSION TABLES
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-15 1
Komatsu Engine Saa12v140ze 2 Workshop Manuals
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FOREWORD CONVERSION TABLES
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
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