166275075 Komatsu Engine Serie SA12V140Z 1 PDF

00-1 2

ShopManual

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or dis-closed except in accordance with written authorization from Komatsu America International Company.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to makechanges or add improvements at any time without incurring any obligation to install such changes on products soldpreviously.

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.

Copyright 2000 KomatsuDataKom Publishing Corporation

SA12V140Z-1 SERIES

DIESEL ENGINE

August 2000

CEBM002602

FOREWORD CONTENTS

00-2 1

CONTENTS

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . .11-1

12 TESTING, ADJUSTING AND TROUBLESHOOTING. . . . . . . 12-1

13 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 13-1

14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

15 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . 15-1

pubinfok.fm 10/12/99

PRODUCT PUBLICATIONS INFORMATIONVarious product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals.

Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages.

The Publications listed below are available for this particular machine(s).

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

PARTS BOOK - MICROFICHE:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

OPERATION AND MAINTENANCE MANUAL:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

SHOP MANUALChassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific ApplicationEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002602

SAFETY MANUAL

Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS).

If the PIPS system is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page.

PURCHASE ORDER NO.

ORDER DATE

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORMAND RETURN TO DataKom Publishing Corporation

440 North Fairway DriveVernon Hills, IL 60061-8112 U.S.A.Attn: Service PublicationsFax No. (847) 970-4186Tel No. (847) 970-5887

COMPANY NAME

ATTN.

STREET ADDRESS

CITY, STATE, ZIP CODE

COUNTRY

SHIP TO

TYPE or PRINTONLY

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

IMPORTANT -TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINESERIAL NUMBER MUST BE SHOWN.

QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER PARTS BOOK

M-Microfiche

PUBLICATIONDESCRIPTION

KDC91E 072199 CURRENT PRICES WILL BE CHARGED

FOREWORD

00-2-1 2

The affected pages are indicated by using the followingmarks. It is requested that necessary actions be taken tothese pages according to the table below.

Mark Indication Action

New page to be added Add

Page to be replaced Replace

( ) Page to be deleted Discard

Mark Page Rev

00-1 2

00-2 1

00-2-1 2

00-2-2 2

00-2-3 2

00-2-4 2

00-3 1

00-4 1

00-5 1

00-6 1

00-7 1

00-8 1

00-9 1

00-10 1

00-11 1

00-12 1

00-13 1

00-14 1

00-15 1

00-16 1

00-17 1

00-18 1

01-1

01-2

01-3

01-4

01-5

01-6

01-7

01-8

01-9

01-10

01-11

01-12

11-1

11-2

11-3

11-4

11-5

11-6

11-7

11-8

11-9

11-10

11-11

11-12

11-13

11-14

11-15

11-16

11-17

11-18

11-19

11-20

11-21

11-22

Mark Page Rev

11-23

11-24

11-25

11-26

11-27

11-28

11-29

11-30

11-31

11-32

11-33

11-34

11-35

11-36

11-37

11-38

11-39

11-40

11-41

11-42

11-43

11-44

11-45

11-46

11-47

11-48

12-1 1

12-2 1

Mark Page Rev

12-3 1

12-4 1

12-5 1

12-6 1

12-7 1

12-8 1

12-9 1

12-10 1

12-11 1

12-12 1

12-13 1

12-14 1

12-15 1

12-16 1

12-17 1

12-18 1

12-19 1

12-20 1

12-21 1

12-22 1

12-23 1

12-24 1

12-25 1

12-26 1

12-27 1

12-28 1

12-29 1

12-30 1

12-31 1

Mark Page Rev

FOREWORD

00-2-2 2

12-32 1

12-33 1

12-34 1

12-35 1

12-36 1

12-37 1

12-38 1

12-39 1

12-40 1

13-1 1

13-2 1

13-3 1

13-4 1

13-5 1

13-6 1

13-7 1

13-8 1

13-9 1

13-10 1

13-11 1

13-12 1

13-13 1

13-14 1

13-15 1

13-16 1

13-17 1

13-18 1

13-19 1

13-20 1

13-21 1

13-22 1

13-23 1

Mark Page Rev

13-24 1

13-25 1

13-26 1

13-27 1

13-28 1

13-29 1

13-30 1

13-31 1

13-32 1

13-33 1

13-34 1

13-35 1

13-36 1

13-37 1

13-38 1

13-39 1

13-40 1

13-41 1

13-42 1

13-43 1

13-44 1

13-45 1

13-46 1

13-47 1

13-48 1

13-49 1

13-50 1

13-51 1

13-52 1

13-53 1

13-54 1

13-55 1

13-56 1

Mark Page Rev

13-57 1

13-58 1

13-59 1

13-60 1

13-61 1

13-62 1

13-63 1

13-64 1

13-65 1

13-66 1

13-67 1

13-68 1

13-69 1

13-70 1

13-71 1

13-72 1

13-73 1

13-74 1

13-75 1

13-76 1

14-1

14-2

14-3

14-4

14-5

14-6

14-7

14-8

14-9

14-10

14-11

14-12

Mark Page Rev

14-13

14-14

14-15

14-16

14-17

14-18

14-19

14-20

14-21

14-22

14-23

14-24

14-25

14-26

14-27

14-28

15-1 2

15-2 2

15-3 2

15-4 2

15-5 2

15-6 2

15-7 2

15-8 2

15-9 2

15-10 2

15-11 2

15-12 2

15-13 2

15-14 2

15-15 2

15-16 2

Mark Page Rev

FOREWORD

00-2-3 2

15-17 2

15-18 2

15-19 2

15-20 2

15-21 2

15-22 2

15-23 2

15-24 2

15-25 2

15-26 2

15-27 2

15-28 2

15-29 2

15-30 2

15-31 2

15-32 2

15-33 2

15-34 2

15-35 2

15-36 2

15-37 2

15-38 2

15-39 2

15-40 2

15-41 2

15-42 2

15-43 2

15-44 2

15-45 2

15-46 2

15-47 2

15-48 2

15-49 2

Mark Page Rev

15-50 2

Mark Page Rev Mark Page Rev Mark Page Rev

FOREWORD

00-2-4 2

Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev

FOREWORD SAFETY

SAFETYSAFETY NOTICE

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous. Readthe OPERATION & MAINTENANCE MANUAL carefullyBEFORE operating the machine.

1. Before carrying out any greasing or repairs, readall the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, always wearsafety shoes and helmet. Do not wear loose workclothes, or clothes with buttons missing.

Always wear safety glasses when hitting parts witha hammer.

Always wear safety glasses when grinding partswith a grinder, etc.

3. If welding repairs are needed, always have atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, glasses, cap and otherclothes suited for welding work.

4. When carrying out any operation with two or moreworkers, always agree on the operating procedurebefore starting. Always inform your fellow workersbefore starting any step of the operation. Beforestarting work, hang UNDER REPAIR signs on thecontrols in the operator's compartment.

5. Keep all tools in good condition and learn the cor-rect way to use them.

6. Decide a place in the repair workshop to keep toolsand removed parts. Always keep the tools andparts in their correct places. Always keep the workarea clean and make sure that there is no dirt or oilon the floor. Smoke only in the areas provided forsmoking. Never smoke while working.

PREPARATIONS FOR WORK

7. Before adding oil or making repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine from mov-ing.

8. Before starting work, lower blade, ripper, bucket orany other work equipment to the ground. If this isnot possible, insert the safety pin or use blocks toprevent the work equipment from falling. In addi-tion, be sure to lock all the control levers and hangwarning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands before start-ing work.

10. Remove all mud and oil from the steps or otherplaces used to get on and off the machine. Alwaysuse the handrails, ladders or steps when getting onor off the machine. Never jump on or off themachine. If it is impossible to use the handrails,ladders or steps, use a stand to provide safe foot-ing.

PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosen themslowly to prevent the oil from spurting out. Beforedisconnecting or removing components of the oil,water or air circuits, first remove the pressure com-pletely from the circuit.

12. The water and oil in the circuits are hot when theengine is stopped, so be careful not to get burned.Wait for the oil and water to cool before carryingout any work on the oil or water circuits.

13. Before starting work, remove the leads from thebattery. ALWAYS remove the lead from the nega-tive (-) terminal first.

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repairtechniques recommended and described in this manual are both effective and safe methods of operation. Someof 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 maypossibly arise, first consider safety, and take the necessary actions to deal with the situation.00-3 1

FOREWORD SAFETY

14. When raising heavy components, use a hoist orcrane. Check that the wire rope, chains and hooksare free from damage. Always use lifting equip-ment which has ample capacity. Install the liftingequipment at the correct places. Use a hoist orcrane and operate slowly to prevent the compo-nent from hitting any other part. Do not work withany part still raised by the hoist or crane.

15. When removing covers which are under internalpressure or under pressure from a spring, alwaysleave two bolts in position on opposite sides.Slowly release the pressure, then slowly loosen thebolts to remove.

16. When removing components, be careful not tobreak or damage the wiring, Damaged wiring maycause electrical fires.

17. When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips on to the floor,wipe it up immediately. Fuel or oil on the floor cancause you to slip, or can even start fires.

18. As a general rule, do not use gasoline to washparts. In particular, use only the minimum of gaso-line when washing electrical parts.

19. Be sure to assemble all parts again in their originalplaces. Replace any damaged part with new parts.

When installing hoses and wires, be sure that theywill not be damaged by contact with other partswhen the machine is being operated.

20. When installing high pressure hoses, make surethat they are not twisted. Damaged tubes are dan-gerous, so be extremely careful when installingtubes for high pressure circuits. Also check thatconnecting parts are correctly installed.

21. When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be particu-larly careful to check that they are installed cor-rectly.

22. When aligning two holes, never insert your fingersor hand. Be careful not to get your fingers caught ina hole.

23. When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24. Take care when removing or installing the tracks oftrack-type machines. When removing the track, thetrack separates suddenly, so never let anyonestand at either end of the track.00-4 1

FOREWORD GENERAL

GENERALThis 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 furtherdivided into each main group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, andfuel, coolant and lubricant specification charts.

STRUCTURE AND FUNCTION

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.

TESTING, ADJUSTING AND TROUBLESHOOTING

This section explains checks to be made before and after performing repairs, as well as adjustments to bemade at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are alsoincluded in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assemblingeach 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 advancenotice. Contact your distributor for the latest information.00-5 1

FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUALVOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machinemodel

Engine volume: Issued for each engine series

Electrical volume: Each issued as one to coverall models

Attachment volume: Each issued as one to coverall models

These various volumes are designed to avoid duplica-tion of information. Therefore to deal with all repairs forany model, it is necessary that chassis, engine, electri-cal and attachment be available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will besent to your distributors. Get the most up-to-date infor-mation before you start any work.

FILING METHOD

1. See the page number on the bottom of the page.File the pages in correct order.

2. Following examples show how to read the pagenumber:Example:

10 - 3

Item number (10. Structure and Function)

Consecutive page number for each item

3. Additional pages: Additional pages are indicated bya hyphen (-) and numbered after the page number.File as in the example.Example:

10-410-4-1

Added pages10-4-210-5

REVISED EDITION MARK

When a manual is revised, an edition mark (123) isrecorded on the bottom outside corner of the pages.

REVISIONS

Revised pages are shown at the LIST OF REVISEDPAGES between the title page and SAFETY page.

SYMBOLS

So that the shop manual can be of ample practical use,important places for safety and quality are marked withthe following symbols.

Symbol Item Remarks

SafetySpecial safety precautions are necessary when perform-ing the work.

Caution

Special technical precau-tions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.

Tightening torque

Places that require special attention for tightening torque during assembly.

Coat Places to be coated with adhesives and lubricants etc.

Oil, waterPlaces where oil, water or fuel must be added, and the capacity.

DrainPlaces where oil or water must be drained, and quantity to be drained.00-6 1

FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONSHOISTING

If a part cannot be smoothly removed from themachine by hoisting, the following checks shouldbe made:

1. Check for removal of all bolts fastening the part tothe relative parts.

2. Check for existence of another part causing inter-face with the part to be removed.

WIRE ROPES1. Use adequate ropes depending on the weight of

parts to be hoisted, referring to the table below:

The allowable load value is estimated to be 1/6 or1/7 of the breaking strength of the rope used.

2. Sling wire ropes from the middle portion of thehook.

Slinging near the edge of the hook may cause the ropeto slip off the hook during hoisting, and a serious acci-

dent can result. Hooks have maximum strength at themiddle portion.

3. Do not sling a heavy load with one rope alone, butsling with two or more ropes symmetrically woundon to the load.

Slinging with one rope may cause turning ofthe load during hoisting, untwisting of the rope,or slipping of the rope from its original windingposition on the load, which can result in a dan-gerous accident.

4. Do not sling a heavy load with ropes forming awide hanging angle from the hook. When hoisting aload with two or more ropes, the force subjected toeach rope will increase with the hanging angles.The table below shows the variation of allowableload (kg) when hoisting is made with two ropes,each of which is allowed to sling up to 1000 kg ver-tically, at various hanging angles. When two ropessling a load vertically, up to 2000 kg of total weightcan be suspended. This weight becomes 1000 kgwhen two ropes make a 120 hanging angle. Onthe other hand, two ropes are subject to an exces-sive force as large as 4000 kg if they sling a 2000kg load at a lifting angle of 150.

Heavy parts (25 kg or more) must be liftedwith a hoist etc. In the DISASSEMBLY ANDASSEMBLY section, every part weighing 25kg or more is indicated clearly with the symbol

Wire ropes(Standard Z or S twist ropes without galvanizing)

Rope diameter Allowable loadmm kN tons

10 9.8 1.0

11.2 13.7 1.4

12.5 15.7 1.6

14 21.6 2.2

16 27.5 2.8

18 35.3 3.6

20 43.1 4.4

22.4 54.9 5.6

30 98.1 10.0

40 176.5 18.0

50 274.6 28.0

60 392.2 40.000-7 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

Adhe

sive

s

LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets, rubber

cushions and cork plugs from comingout

LT-1B 790-129-9050 20 g(2 pes.)Polyethylene

container

Used in places requiring an immediatelyeffective, strong adhesive.

Used for plastics (except polyethylene,polypropylene, tetrafluoroethylene, andvinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylene container

Features: Resistance to heat, chemi-cals

Used for anti-loosening and sealantpurposes for bolts and plugs.

LT-3

790-129-9060(Set of adhe-sive and hard-ening agent)

Adhesive:1 kg

Hardening agent:500 g

Can Used as adhesive or sealant for metal,glass or plastic.

LT-4 790-129-9040 250 g Polyethylene container Used as sealant for machined holes.

HoltzMH 705 790-126-9120 75 g Tube

Used as heat-resisting sealant forrepairing engine.

Three bond 1735

179-129-9140 2 g Polyethylene container

Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha201

790-129-9130 50 g Polyethylene container

Quick hardening type adhesive. Quick cure type (max. strength after 30

minutes). Used mainly for adhesion of rubbers,

plastics and metals.

Loctite 648-50 79A-129-9110 50 cc

Polyethylene container

Features: Resistance to heat, chemi-cals

Used at joint portions subject to hightemperature.

Gasket sealant

LG-1 790-129-9010 200 g Tube Used as adhesive or sealant for gas-

kets and packing of power train case,etc.

LG-3 790-129-9070 1 kg Can

Features: Resistance to heat Used as sealant for flange surfaces and

bolts at high temperature locations;used to prevent seizure.

Used as sealant for heat resistant gas-ket for at high temperature locationssuch as engine pre-combustion cham-ber, exhaust pipe.00-8 1

FOREWORD COATING MATERIALS

Gasket sealant

LG-4 790-129-9020 200 g Tube

Features: Resistance to water, oil Used as sealant for flange surface,

thread. Also possible to use as sealant for

flanges with large clearance. Used as sealant for mating surfaces of

final drive case, transmission case.

LG-5 790-129-9080 1 kg Polyethylene container

Used as sealant for various threads,pipe joints, flanges.

Used as sealant for tapered plugs,elbows, nipples of hydraulic piping.

LG-6 09940-00011 250 g Tube

Features: Silicon based, resistant toheat, cold.

Used as sealant for flange surface,thread.

Used as sealant for oil pan, final drivecase, etc.

LG-7 09920-00150 150 g Tube

Features: Silicon based, quick harden-ing type.

Used as sealant for flywheel housing,intake manifold, oil pan, thermostathousing, etc.

Three bond 1211

790-129-9090 100 g Tube Used as heat-resisting sealant forrepairing engines.

Mo

lybde

num

disu

lphi

delu

brica

nt

LM-G 09940-00051 60 g Can Used as lubricant for sliding parts (toprevent squeaking).

LM-P 09940-00040 200 g Tube

Used to prevent seizure or scuffing ofthe thread when press fitting or shrinkfitting.

Used as lubricant for linkage, bearings,etc.

Grease

G2-LI

SYG2-400LISYG2-350LI

SYG2-400LI-ASYG2-160LI

SYGA160CNLI

Various Various General purpose type

G2-CA

SYG2-400CASYG2-350CA

SYG2-400CA-ASYG2-160CA

SYG2-160CNCA

Various Various Used for normal temperature, light load

bearing at places in contact with wateror steam.

Mo

lybde

nu

mdi

sulp

hide

lu

brica

nt

SYG2-400M 400 g (10 per case) Belows type Used for places with heavy load.

Category Code Part No. Quantity Container Main applications, features00-9 1

FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUESTANDARD TIGHTENING TORQUE OF BOLTS AND NUTSThe following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of DIS-ASSEMBLY AND ASSEMBLY.

Thread diameter of bolt Width across flats

mm mm Nm kgm6 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

Thread diameter of bolt Width across flats

mm mm Nm kgm6 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 0.800-10 1

FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF HOSE NUTSUse these torques for hose nuts.

TIGHTENING TORQUE OF SPLIT FLANGE BOLTSUse these torques for split flange bolts.

TIGHTENING TORQUE FOR FLARED NUTSUse these torques for flared part of nut.

Nominal No.Thread diameter Width across flat Tightening torque

mm mm Nm kgm02 14 19 24.5 4.9 2.5 0.5

03 18 24 49 19.6 5 2

04 22 27 78.5 19.6 8 2

05 24 32 137.3 29.4 14 3

06 30 36 176.5 29.4 18 3

10 33 41 196.1 49 20 5

12 36 46 245.2 49 25 5

14 42 55 294.2 49 30 5

Thread diameter Width across flat Tightening torquemm mm Nm kgm10 14 65.7 6.8 6.7 0.7

12 17 112 9.8 11.5 1

16 22 279 29 28.5 3

Thread diameter Width across flat Tightening torquemm mm Nm kgm14 19 24.5 4.9 2.5 0.5

18 24 49 19.6 5 2

22 27 78.5 19.6 8 2

24 32 137.3 29.4 14 3

30 36 176.5 29.4 18 3

33 41 196.1 49 20 5

36 46 245.2 49 25 5

42 55 294.2 49 30 500-11 1

FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire codetable will help you understand WIRING DIAGRAMS.Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

CLASSIFICATION BY COLOR AND CODE

Nominal number

Copper wireCable O.D.

(mm)Current

rating (A) Applicable circuitNumber of strands

Dia. Of strand (mm)

Cross sec-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 Starting60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

PriorityCircuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1

Prim

ary Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxi

liary

Code WR BW RW YR GW LW

Color White & Red Black & White

Red & White

Yellow & Red

Green & White

Blue & White

3Code WB BY RB YB GR LR

Color White & Black Black & Yellow

Red & Black

Yellow & Black

Green & Red Blue & Red

4Code WL BR RY YG GY LY

Color White & Blue Black &

RedRed & Yel-

lowYellow & Green

Green & Yellow

Blue & Yel-low

5Code WG RG YL GB LB

Color White & Green Red & Green

Yellow & Blue

Green & Black

Blue & Black

6Code RL YW GL

Color Red & Blue Yellow & WhiteGreen &

Blue 00-12 1

FOREWORD CONVERSION TABLES

CONVERSION TABLESMETHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of the methodof 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 from1.

(b) Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from2.

(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. Convert 550 mm into inches.(a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to

convert it to 55 mm.(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(c) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one

place to the right) to return to the original value. This gives 550 mm = 21.65 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

150 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 3.89800-13 1


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

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

Kilogram to Pound 1 kg = 2.2046 lb0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

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

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.2600-14 1


Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019

20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661

30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303

40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

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

Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179

20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579

40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

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 21.77700-15 1


kgm to ft. lb. 1 kgm = 7.233 ft. lb.0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4

20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1

40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

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 1439.400-16 1


kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2

20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5

30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2

60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266

90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693

120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835

130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977

140 1991 2005 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 354200-17 1


TemperatureFahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centi-grade temperature reading or vise versa is to enter the accompanying table in the center or boldface column offigures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired toconvert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tempera-tures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convertfrom Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and readthe corresponding Fahrenheit temperature on the right.C F C F C F C F

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.000-18 1

pubinfok.fm 10/12/99

PRODUCT PUBLICATIONS INFORMATIONVarious product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals.

Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages.

The Publications listed below are available for this particular machine(s).

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

PARTS BOOK - MICROFICHE:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

OPERATION AND MAINTENANCE MANUAL:Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific Application

SHOP MANUALChassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Specific ApplicationEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002601

SAFETY MANUAL

Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS).

If the PIPS system is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page.

PURCHASE ORDER NO.

ORDER DATE

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORMAND RETURN TO

01-1

01 GENERAL

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-2GENERAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-3

VIEW FROM LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-3VIEW FROM RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-4VIEW FROM FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-5VIEW FROM REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-6VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-7VIEW FROM TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-8

ENGINE PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-9WA800-2LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-9WA900-1LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-10330M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-11

GENERAL SPECIFICATIONS

01-2

SPECIFICATIONSEngine model SA12V140Z-1

Applicable machine WA800-2LE WA900-1LC 330M

Number of cylinder 12

Bore x Stroke mm 140 x 165

Total piston displacement cc 30,480

Firing order R1 LI R5 L5 R3 L3 R6 L6 R2 L2 R4 L4

Dimensions

Overall length

Overall width

Overall height(excluding exhaust pipe)

mm

mm

mm

1887.7

1320.1

1658

1887.7

1320.1

1658

1887.7

1320.1

1658

Performance

Flywheel horsepower

Gross horsepower

Maximum torque, gross

Maximum torque, net

High idling speedLow idling speed

Minimum fuel consumption at fullpower

kW(HP)/rpm

kW(HP)/rpm

Nm(lb/ft)/rpm

Nm(lb/ft)/rpm

rpmrpm

g/kWh(lb/HPh)

588(789)/2,000

621(833)/2,000

3806(2807)/1,400

3279(2750)/1,400

2,25050

650

194 (.319)

636(853)/2,000

669(897)/2,000

4100(3024)/1,300

4034(2975)/1,300

2,25050

650

193 (.317)

753(1010)/2,000

783(1050)/2,000

4628(3414)/1,400

4560(3363)/1,400

2,35050

650

193 (.317)

Dry weight kg 3,271 3,271 3,271

Fuel injection pump BOSCH RP 39

Governor BOSCH RE 33

Lubricating oil amount (total system)(minimum required)

l(US Gal)

148(39.1)132(34.9)

148(39.1)132(34.9)

148(39.1)132(34.9)

Coolant amount (engine only)(total system)

l(US Gal)

85(22.4)310(81.9)

85(22.4)310(81.9)

85(22.4)228(60.2)

Alternator 24 V, 75 A 24 V, 75 A 24 V, 75 A

Starting motor 24 V, 11kW 50 MT x 1

24 V, 11kW, 50 MT x 1

24 V, 11kW, 50 MT x 1

Battery 12V 200 Ah x 412 V 200 Ah x 412 V 200 Ah x 4

Turbocharger H x 60 x 2 H x 60 x 2 H x 60 x 2

Air compressor Holset TC676Holset TC676Holset TC676

50+

0

50+

0

50+

0

GENERAL GENERAL ASSEMBLY DRAWING

01-3

GENERAL ASSEMBLY DRAWINGVIEW FROM LEFT SIDE


01-4

VIEW FROM RIGHT SIDE


01-5

VIEW FROM FRONT


01-6

VIEW FROM REAR


01-7

VIEW FROM LEFT SIDE (CUSTOM CONNECTIONS)


01-8

VIEW FROM TOP

GENERAL ENGINE PERFORMANCE CURVE

01-9

ENGINE PERFORMANCE CURVEWA800-2LC

Curves above represent gross engine performance capabilities obtained and corrected in accordance with SAEJ1995 conditions of 100 kPa (29.61 in. Hg) barometric pressure [91 m (300 ft.) altitude], 25C (77F) inlet air tem-perature, and 1kPa (0.30 in. Hg) water vapor pressure with No. 2 diesel fuel. The engine may be operated withoutchanging the fuel setting up to 3048 m (10,000 ft.) altitude. For sustained operation at high altitudes, the fuel rate ofthe engine will be adjusted to limit performance by 4% per 305 m (1,000 ft.) above 3048 m (10,000 ft.) altitude and2% per 11C above 38C (1% per 10F above 100F).


01-10

WA900-1LC



01-11

330M


11-1

11 STRUCTURE AND FUNCTION

GENERAL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3INTAKE AND EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5

INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8

ENGINE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10Valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10Rocker arm housing cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10Fuel injection nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12Piston cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12Liner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12

MAIN REVOLVING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-14Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-14Connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-14

TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15Front seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-16

VALVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-17Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-18Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-18

FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-19Rear seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-19

LUBRICATING OIL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-20Piston cooling, connecting rod, overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-21Front gear train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-22Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-23

FULL FLOW LUBRICATING OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-24LUBRICATING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-25

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-25MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-26

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-26OIL COOLER BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-27

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-27Regulator valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-27

LUBRICATING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-28Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-28Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-28

LUBRICATING OIL BYPASS FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-29Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-29

LUBRICATING OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-30Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-30

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-31

11-2

STRUCTURE AND FUNCTION TABLE OF CONTENTS

FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-31FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-32

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-32RIGHT BANK PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-33LEFT BANK PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-34FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-35

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-35FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-36

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-36COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-37

THERMOSTAT HOUSING FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-38COOLING FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-39WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-40

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-40COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-41CORROSION RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-42

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-42ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-43

AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-43Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-44Unloader valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-44

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-45ALTERNATOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-45ALTERNATOR WITH REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-46STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-47ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-48

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-48

STRUCTURE AND FUNCTION GENERAL STRUCTURE

11-3

GENERAL STRUCTURE

1. Front cover2. Cylinder block3. Cylinder liner4. Rocker lever housing5. Cylinder head cover6. Exhaust valve7. Intake valve8. Piston

9. Turbocharger10.Cam follower11.Camshaft12.Flywheel13.Flywheel housing14.Main bearing cap15.Crankshaft16.Oil pan

17.Connecting rod18.Connecting rod cap19.Oil strainer20.Lubricating oil pump21.Crankshaft gear22.Vibration damper23.Crankshaft pulley

STRUCTURE AND FUNCTION GENERAL STRUCTURE

11-4

24.Cylinder head25.Intake manifold26.Electrical intake air heater27.Lubricating oil cooler28.Intake connector pipe29.Rocker lever

30.Aftercooler31.Nozzle holder32.Push rod33.Piston cooling nozzle

STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

11-5

INTAKE AND EXHAUST SYSTEMINTAKE SYSTEM

1. Intake manifold (Right bank)2. Electrical intake air heater 3. Aftercooler cover (Right bank)4. Aftercooler cover (Left bank)5. Intake manifold (Left bank)A. Air intake


11-6

EXHAUST SYSTEM

1. Exhaust manifold (Left bank)2. Exhaust manifold (Right bank)3. Turbocharger (Right bank)4. Turbocharger (Left bank)


11-7

TURBOCHARGER

1. V band clamp2. Turbine Housing3. Turbocharger heat shield4. Drive screw5. Lock nut6. Split ring seal7. Split ring seal8. Dataplate9. Regular hexagon nut10.Thrust collar11.Oil slinger12.Oil seal plate13.V band clamp14.Oil baffle

15.Shaft and wheel16.Turbo thrust bearing17.Turbo compressor impeller18.Compressor housing19.Turbo bearing housing20.Roll pin21.Retaining pin22.Retaining ring23.Turbocharger bearing24.Retaining ring25.O-ring seal26.Oil control sleeve


11-8

AFTERCOOLER

1. Aftercooler cover2. Aftercooler core3. Intake manifold

H The diagram above shows the right bank.

A. Intake air inlet (from turbocharger)B. Intake air outlet (to cylinder head)C. Water inlet (to cylinder head)D. Water outlet (to thermostat)

STRUCTURE AND FUNCTION ENGINE BODY

11-9

ENGINE BODYCYLINDER HEAD

1. Fuel spill tube2. Air vent tube3. Rocker lever housing4. Cylinder head5. Head cover6. Nozzle holder retainer

7. Fuel injection nozzle holder assembly

8. Head cover mounting bolt9. Cylinder head mounting bolt10.Fuel inlet connector

B. Intake C. Exhaustd. To fuel tanke. To radiator


11-10

Specifications Direct fuel injection type 4-valve Divided type (One cylinder head for one cylinder) Injection nozzle and fuel inlet connector assembled

in rocker arm housing and cylinder head Cylinder head bolt: Tighten bolts by the plastic

range turning angle method

Valve seat Press fitted insert for intake and exhaust

Rocker arm housing cover Floating type seal

Fuel injection nozzle Mount: Dry type (without sleeve)


11-11

CYLINDER BLOCK

1. Cylinder block2. Cylinder liner3. Crevice seal4. Liner seal5. Liner seal6. Main bearing cap bolt

7. Main bearing cap8. Main bearing9. Piston cooling nozzle10.Thrust bearing


11-12

Specifications Crankshaft: 7 bearings Camshaft: 7 bearings Main bearing cap bolt: Tightening bolts by the

plastic range turning angle method.Piston cooling With piston cooling nozzle

Cylinder liner Wet type Treatment: Plateau honing finish

Tuffride treatedLiner seal TOP:Crevice seal (Ethylene propylene

rubber) MIDDLE: O-ring (Ethylene propylene

rubber) BOTTOM: O-ring (Silicon rubber)


11-13

MAIN REVOLVING SYSTEM

1. Piston2. Piston pin3. Connecting rod bushing4. Top ring5. Second ring6. Oil ring7. Crankshaft pulley8. Vibration damper

9. Crankshaft10.Crankshaft gear (No. of teeth: 45)11.Connecting rod bearing12.Connecting rod cap13.Connecting rod14.Connection rod cap bolt


11-14

Crankshaft Stamp forging Journal and filet portion:

Induction hardening

Piston Ductile cast iron (FCD)

Connecting rod Stamp forging:

With lubrication hole

Top ring Second ring Oil ring

Both faces key-stone.Barrel face.Hard chrome plating.

Keystone inner cut.Tapered face.Hard chrome plating.

M-shape steel ring.Hard chrome plating with coil expander.


11-15

TIMING GEAR

H Circled numbers indicate spur gear. Other gears are helical.

1. Accessory drive gear (No. of teeth: 22)2. R-Sub-idler gear (No. of teeth: 50)3. R-Idler gear (large) (No. of teeth: 75)4. R-Camshaft gear (No. of teeth: 60)5. Idler gear (small) (No. of teeth: 45)6. L-Camshaft gear (No. of teeth: 60)7. L-Idler gear (large) (No. of teeth: 75)8. L-Sub-idler gear (No. of teeth: 50)9. L-Fuel injection pump drive gear (No. of teeth: 60)

10.Air compressor drive gear (No. of teeth: 30)11.Crankshaft gear (No. of teeth: 45)12.Oil pump drive gear (No. of teeth: 27)13.Water pump drive gear (No. of teeth: 25)14.R-Fuel injection pump drive gear (No. of teeth: 60)15.Front seal

R, L, A, B, B1, B2, C, D: Match marks for timing gears


11-16

Front seal Single lip with dust seal


11-17

VALVE SYSTEM


11-18

1. Camshaft gear (No. of teeth: 48)

2. Thrust plate3. Camshaft4. Cam follower5. Cam roller6. Rocker arm shaft7. Cam follower shaft8. Rocker arm adjust-

ment screw9. Lock nut10.Push rod11.Rocker arm12.Crosshead adjust-

ment screw

13.Locknut14.Crosshead15.Valve guide16.Exhaust valve17.Valve spring (outer)18.Valve spring (inner)19.Valve spring seat

(lower)20.Valve spring seat

(upper)21.Intake valve22.Cam roller pin

Valve timing

Camshaft Drawn steel bar Journal and cam portion: Induction hardening


11-19

FLYWHEEL AND FLYWHEEL HOUSING

1. Ring gear (No. of teeth: 142)2. Flywheel3. Flywheel housing4. Crankshaft rear sealA. Timing sensor pickup portB. RPM sensor port

Rear seal Dry type: Single lip oil seal Wet type: Double lip oil seal

STRUCTURE AND FUNCTION LUBRICATING OIL SYSTEM

11-20

LUBRICATING OIL SYSTEM

1. Full flow filter head2. Full flow filter(s)3. Lubricating oil pump4. High pressure regulator5. Suction tube6. Lubricating oil cooler7. Low pressure and lubricating oil cooler bypass reg-

ulator8. Signal line9. Cold oil flow10.Hot oil flow

11.Bypass filters12.Oil cooler bypass valve13.Bypass valve spring14.Regulator valve15.Regulator valve spring16.Valve bodyA. From main gallery (signal line)B. From oil coolerC. To oil panD. To oil filter


11-21

Piston cooling, connecting rod, overhead1. Crankshaft oil drillings2. Main oil drilling3. Connecting rod wrist pin oil supply4. Upper rocker lever oil supply5. Piston cooling oil drilling6. Cam follower oil drilling7. Piston cooling nozzle


11-22

Front gear train1. Right bank (large) idler gear2. Right bank (small) idler gear3. Piston cooling oil supply drillings4. Left bank (large) idler gear


11-23

Turbocharger1. Piston cooling oil supply drilling2. Turbocharger oil supply3. Turbocharger oil drain


11-24

FULL FLOW LUBRICATING OIL FILTERS

1. Oil supply2. Oil drain3. Full flow filters


11-25

LUBRICATING OIL PUMP

1. Pump body2. Pump drive (No. of teeth: 27)3. Drive gear4. Driven gear5. Pump cover

a. Suction (From oil pan)b. Discharge (To oil cooler)

Specifications Type: Gear pump Pump speed: Engine speed x 1.67


11-26

MAIN RELIEF VALVE

1. Valve spring2. Main relief valve3. Valve body

Specifications Cracking pressure:

8.5 0.5 kg/cm2

121 7 psi


11-27

OIL COOLER BYPASS VALVE1. Oil cooler bypass valve2. Bypass valve spring3. Regulator valve4. Regulator valve spring5. Valve bodyA. From main galleryB. From oil coolerC. To oil panD. To oil filter

Specifications Cracking pressure

(differential pressure)

2.3 0.2 kg/cm2 3.3 2.5 psi

Regulator valve Cracking pressure:

4.1 0.5 kg/cm2

58 7.1 psi


11-28

LUBRICATING OIL FILTER

1. Filter head2. Filter connector3. Cover4. Cartridge

A. Oil inlet portB. Oil outlet port

Specifications Filtering area:

3.6 m2 38.75 sq.ft.

Safety valve Cracking pressure:

2.0 0.2 kg/cm2

28.44 2.8 psi


11-29

LUBRICATING OIL BYPASS FILTER

1. Filter head2. Cartridge

A. Oil inlet portB. Oil outlet port

Specifications Filtering area: 2.8 m2 [30.1 sq. ft.]


11-30

LUBRICATING OIL COOLER

1. Oil cooler cover2. Cooler element: 12 cores

a. Oil inlet or outletb. Oil inlet or outletc. Cooling water

Specifications Effective area:

0.986 m2 10.61 sq. ft.

STRUCTURE AND FUNCTION FUEL SYSTEM

11-31

FUEL SYSTEMFLOW DIAGRAM

1. Fuel tank2. Prefilter3. Fuel connection block4. Fuel lift pump5. Fuel filter6. EHAB

7. Fuel injection pump8. Fuel injection nozzle9. Electronic governorA. Fuel supply (From tank)B. Fuel overflow valveC. Fuel gallery outlet

D. Fuel gallery inletE. Fuel out to lift pumpF. Fuel in from fuel filterG. Fuel drain (to tank)


11-32

FUEL INJECTION PUMP

Specifications Maker:BOSCH Type:RP39


11-33

RIGHT BANK PIPING

1. Fuel injection pipe (No. 6 cylinder)2. Fuel injection pipe (No. 5 cylinder)3. Fuel injection pipe (No. 4 cylinder)4. Fuel injection pipe (No. 3 cylinder)5. Fuel spill tube6. Fuel injection pipe (No. 2 cylinder)7. Fuel injection pipe (No. 1 cylinder)8. Pump drive gear (No. of teeth: 60)9. Pump drive shaft

10.Housing11.Coupling12.Air bleed plug13.Oil outlet pipe14.Fuel injection pump15.Adapter16.Feed pump17.Emergency stop valve


11-34

LEFT BANK PIPING

1. Fuel injection pipe (No. 1 cylinder)2. Fuel injection pipe (No. 2 cylinder)3. Fuel injection pipe (No. 3 cylinder)4. Fuel spill tube5. Fuel injection pipe (No. 4 cylinder)6. Fuel injection pipe (No. 5 cylinder)7. Fuel injection pipe (No. 6 cylinder)8. Emergency stop valve9. Air bleed plug10.Oil inlet pipe

11.Feed pump12.Fuel injection pump13.Oil outlet pipe14.Hand priming pump15.Coupling16.Pump drive shaft17.Housing18.Pump drive gear (No. of teeth: 60)


11-35

FUEL INJECTION NOZZLE

1. Inlet connector2. Nozzle holder3. Adjusting shim4. Spring5. Spring seat6. Spacer7. Nozzle8. Retaining cap9. Needle10.#1 RB and #1 LB injector with needle lift sensor

a. Fuel inlet (From injection pump)b. Injection (To cylinder)c. Fuel return (To fuel tank)

Specifications Type: Multi-hole type Adjusting injection pressure: Shim adjusting type


11-36

FUEL FILTER

1. Filter head2. Cartridge

a. Fuel inlet (From transfer pump)b. Fuel outlet (To injection pump)

H Additional ports are marked indicating flow direc-tion.

Specifications Filtration area: 2.0 m2 (1.0 x 2 pcs)

STRUCTURE AND FUNCTION COOLING SYSTEM

11-37

COOLING SYSTEM

1. Aftercooler2. Water outlet3. Aftercooler water inlet4. Water pump impeller5. Bypass flow6. Water outlet to block7. Water inlet

8. Bypass flow9. Water filters10.Cylinder liner coolant cavity11.Cylinder head coolant passage12.Oil coolers13.Vent line flow


11-38

THERMOSTAT HOUSING FLOW

1. Thermostat2. Water outlet3. Coolant from block4. Closed thermostat flow5. Open thermostat flow


11-39

COOLING FAN BELT

1. Fan hub2. Air crossover3. Coolant temperature sensor4. Oil pan5. Fan idler tensioner6. Water filters7. Engine barring location8. Full flow oil filters


11-40

WATER PUMP

1. Pump shaft2. Water seal3. Pump body4. Water pump drive gear (No. of teeth: 25)5. Ball bearing6. Oil seal7. Impeller8. Pump cover

a. From thermostatb. From radiator (water inlet)c. To oil cooler (water outlet)

Specifications Type: Centrifugal gear drive Pump speed: Engine speed x 1.80


11-41

COOLING FAN

1. Fan 2. Fan pulley3. Fan belt (poly V-belt)4. Crank pulley5. Tension pulley6. Idler pulley

A. Wind direction

Pulley outside diameter (mm)

Fan pulley Crank pulleyTension pulley

405 203 150


11-42

CORROSION RESISTOR

1. Head 2. Cartridge3. Element (Chemicals)4. Valve

a. Water inletb. Water outlet

Specifications Filtration area:0.373 m2 x 2

4.01 sq. ft. x 2

STRUCTURE AND FUNCTION ACCESSORY

11-43

ACCESSORYAIR COMPRESSOR

1. Cylinder head2. Unloader valve3. Piston4. Piston ring5. Piston pin6. Cylinder7. Connecting rod8. Crankcase9. Crankshaft10.Bushing11.Cover12.Thrust bearings13.Unloading assembly

a. Air inletb. Air outletc. Unload pressure (from air governor)d. Oil inlete. Water inlet or outletf. Water inlet or outletg. Oil outlet

STRUCTURE AND FUNCTION ACCESSORY

11-44

Specifications Type: Water cooled, two cylinder Unloader valve method: intake valve, open type Cylinder O.D. x stroke: 92.08 x 50.8 mm Discharge volume: 1352 cc/rev Weight: 33.5 kg

Unloader valve Governor controlled Max 125 psi

STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

11-45

ELECTRICAL SYSTEMALTERNATOR MOUNTING

1. Alternator2. Adjustment molt3. Alternator drive pulley4. Alternator bracket

a. Alternator pulleyb. Alternator drive pulley


11-46

ALTERNATOR WITH REGULATOR

1. Alternator2. Alternator pulley


11-47

STARTING MOTOR

DELCO 50MT 24V1. Solenoid2. Pinion gear3. Starting motor


11-48

ELECTRICAL INTAKE AIR HEATER

1. Heater body2. Heater coil3. Terminal

Specifications Rated voltage: 11V Rated current: 86A

12 TESTING, ADJUSTING ANDTROUBLESHOOTING

ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5FUEL PUMP INSTALLATION AND TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

CHECKING INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12USING PROXIMITY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12USING FUEL PUMP LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18TIMING SENSOR (WITH FLYWHEEL TIMING HOLES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-182ND DESIGN (FLYWHEEL TIMING LUGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19

FUEL OVERFLOW VALVE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20ADJUSTING FUEL INJECTION PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

ENGINE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22IN SERVICE RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22ENGINE DYNAMOMETER RUN-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22PORTABLE DYNAMOMETER OR LOAD BANK RUN-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22INSITE SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22

FUEL FLOW MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23MEASUREMENT OF FUEL CONSUMPTION RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24

DYNAMOMETER WORKSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25ENGINE DYNAMOMETER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26COOLANT PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26GENERAL ENGINE TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26ENGINE THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 12-28FUEL INLET RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28FUEL DRAIN LINE RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29INTAKE MANIFOLD PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29INTAKE AIR RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29EXHAUST RESTRICTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29ENGINE BLOWBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30LUBRICATING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32COOLANT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3212-1 1

LUBRICATING OIL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33STARTING MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33

ENGINE RUN-IN INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34TEST LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

TESTING AND ADJUSTING TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-37COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39

CHECKING FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39

12-2

TESTING AND ADJUSTING TABLE OF CONTENTS330M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39WA800/WA900. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39

ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39CHECKING BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-39ADJUSTING BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-401

TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

12ADJUSTING VALVE CLEARANCE Adjust clearance between crosshead and rocker arm.Adjusting method of valve clearance1. Remove the rocker arm housing cover

2. Rotate the crankshaft in a clockwise direction. While watch-ing the movement of the intake valve of the R6 cylinder,bring the R1 cylinder into the top dead center position of thecompression stroke and align the R1.6 TOP line on thevibration damper (1) with the pointer (2).

Hold with a wrench in position B in the diagram on the right,then crank the engine in the direction of the arrow.

When the R1 cylinder comes near the top dead center ofthe compression stroke, the R6 intake valve will start tomove (open)

3. Loosen locknut (6) of adjustment screw (5) of R1 cylinder,insert the feeler gauge A corresponding to the specifiedclearance between crosshead (4) and rocker arm (3), andadjust the clearance with the adjustment screw until thethickness gauge can slide lightly.

Valve clearance (When engine is cold)Intake valve: 0.43 mmExhaust valve: 0.80 mm

4. Tighten locknut in this position, secure adjustment screw.

Locknut: 58.8 5.9 Nm (43.4 4.4 lbf-ft)

5. Follow the same procedure to align the line with the pointerand adjust the valve clearance of each cylinder according tothe firing order.

Firing order:R1 L1 R5 L5 R3 L3 R6 L6 R2 L2 R4 L4

The lines and marks shown in the diagram are on the out-side circumference of the damper.12-3 1

TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

12MEASURING COMPRESSION PRESSUREMethod of measuring compression pressure

Avoid touching the exhaust manifold or muffler when measuring compression. Be careful of rotating parts.Do NOT wear loose fitting or torn clothing. Remove ALL jewelry when working.

Warm up the engine before measuring the compression pressure. (Oil temperature 40 - 60 C)

1. Adjust valve clearance.

For details, see ADJUSTING VALVE CLEARANCE on page 12-32. Power to EHAB must be OFF.

3. Remove the nozzle holder assembly from the cylinder to be measured.

4. Install adapter A1 in the mount of the nozzle holder of thecylinder to be measured, then secure with retainer (2).

Mounting bolt: 66.2 7.4 Nm (48.8 5.5 ft-lb)

5. Connect compression gauge A to the adapter.

6. Crank the engine with the starting motor and measure thecompression pressure.

Measure the compression pressure at the point where thegauge indicator remains steady.

If the adapter mount is coated with a small amount of oil, itwill prevent leakage.

For details of the standard values for compression pressure,see Standard value table.12-4 1

TESTING AND ADJUSTING FUEL SYSTEM

12FUEL SYSTEMFUEL PUMP REMOVAL Rotate the crankshaft to the engine timing specification

before removing the right bank fuel pump.

1. Install a protective cover to prevent any dirt or dust from get-ting into the discharge port of the injection pump or the inletport of the nozzle connector. Clean the debris from aroundthe inline fuel injection pump.

2. Remove electrical connections (1) and fuel lines (2).Remove all of the oil lines (3).

Right bank and left bank pumps are removed and installedat the right bank timing location.

If the fuel pump is to be reused, remove the timing lock pinand install in the locked position, as shown, to preserve thepump timing.

3. Remove the four capscrews (1), washers and nuts holdingthe pump to the drive housing.

4. Remove the injection pump bracket mounting bolts (2).

The right bank fuel pump bracket has six mounting bolts.The left bank fuel pump bracket has three mounting bolts.12-5 1


125. Move pump away from housing. Disengage the pump drive-shaft gear from the spline coupling. Remove the pump fromthe drive housing.

6. If pump is to be recalibrated, remove spline drive gear frompump. Use spline coupling with bar attached to preventpump rotation while removing large nut. Use flange gearpuller to remove gear.

Remove locking pin to prevent damage.

7. Remove capscrews from mounting support and removesupport.

8. Install drive spline after repair. Remove locking pin.

Spine retaining nut:407 Nm (300 ft-lb)

9. Install locking pin and cap.

Locking pin and cap:27 Nm (20 ft-lb)12-6 1


12FUEL PUMP INSTALLATION AND TIMING

1. Rotate the engine clockwise until the crankshaft damperpointer aligns with the specified engine timing, which is pro-vided on the engine dataplate before TDC for the right bankNo. 1 cylinder on the compression stroke.

Right bank and left bank pumps are installed at the rightbank setting location.

2. Remove the No. 1 cylinder rocker cover and verify that theNo. 1 cylinder is at TDC, right bank.

3. Remove the fuel injection pump timing pin cap and verifythat the pump is locked.

4. Install the timing pin, plug, and sealing washer.

Timing pin plug:30 Nm (22 ft-lb)

5. Install the mounting bracket onto the fuel pump. Do NOTtighten the capscrews.

6. Install the spline coupling onto the pump drive shaft gear(1).

7. Install new o-rings.12-7 1


12IIf the pump does not align, do NOT force the pump anddrive into alignment. Forcing will result in fuel pumpdamage.

8. Engage the spine coupling and install the pump drive shaftgear into the drive housing. Install the flange mounting cap-screws (1) and the fuel pump mounting capscrews (2).

The injection pump assembly MUST be at an angle to theengine block.

If the pump does not align, remove fuel pump and the coverplate on the front gear cover to gain access to the fuel pumpdrive gear.

9. Loosen (2 to 3 turns) the large nut securing the two-piecedrive gear to the drive shaft. Using the barring tool to holdthe engine in position, remove the two opposing capscrewssecuring the fuel pump drive gear to the hub.

10. Fabricate two jackscrews (M12x1.5) using bolts, Part No.01011-31265. Remove 25mm of thread from the end ofeach capscrew to form a 6mm diameter. The remaining 25mm of thread will be used to install the jackscrews.

11. Install the two jackscrews.

12. Tighten the jackscrews through the gear and hub until mak-ing contact with the thrust plate.

13. Tighten each capscrew with 1/4 turn until the two-piece gearassembly pops off the drive shaft taper.

14. Remove the jackscrews.12-8 1


1215. Engage the spline coupling and install the pump drive shaftgear into the drive housing. Install the flange mounting cap-screw (1) and the fuel pump mounting screw (2).

The injection pump assembly MUST be at an angle to theengine block.

16. Tighten the two pumps to bracket capscrews (1).

17. Tighten the four flange mounting capscrews (2).

18. Tighten the fuel pump mounting capscrews (3).

All capscrews:65 Nm (48 ft-lb)

19. Install large nut securing gear to shaft

Gear nut: 24 Nm (17 ft-lb)

20. Remove fuel pump locking pin.

If locking pin is difficult to remove, install metric capscrewinto end of pin to aid in removal.12-9 1


1221. Tighten large nut securing gear to shaft.

Large nut: 109 Nm (80 ft-lb)

22. Install and tighten two attaching bolts in gear.

Mounting bolt:14 Nm (84 ft-lb)

23. Rotate the engine

166275075 Komatsu Engine Serie SA12V140Z 1 PDF

Documents

technical service publications

service tool

service publicationsfax

turbocharger service

special publications

correct publications

maintenance manuals

parts books