SEBM028317

DIESEL ENGINE

© 2007 1 00-1
All Rights Reserved (17)
Printed in Japan 07-07 (01)
 CONTENTS

No. of page

01 GENERAL ..................................................................... 01-001

11 STRUCTURE AND FUNCTION ................................... 11-001

12 TESTING AND ADJUSTING ....................................... 12-001

13 DISASSEMBLY AND ASSEMBLY .............................. 13-001

14 MAINTENANCE STANDARD ......................................

621501
14-001

15 REPAIR AND REPLACEMENT OF PARTS ................. 15-001

00-2
y
SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.

To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10. Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20. When installing high pressure hoses, make sure
12. The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21. When assembling or installing parts, always use
13. Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14. When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22. When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23. When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24. Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15. When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.

00-4
FOREWORD GENERAL

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under -
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com -
ponent, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.

00-5
GENERAL APPLICABLE MACHINE

APPLICABLE MACHINE
a Serial No. shows for engine serial No.

Engine Serial No. Applicable machine

D475A-2, D475A-3, D475A-5 Bulldozer

WA800-2, WA800-3, WA900-1, WA900-3 Wheel loader

HD785-3, HD785-5, HD985-3 Dump truck

INGERSOLL RAND Crawler drill

EPSA12V140

EG750B-1 L
SA12V1 40-1
Generator Generator (50Hz)
Generator
Generator (IMS in South Africa)
DCA800SPK DENYO Generator

DCA-800SSK Ma Generator

L 0 gL Z 9
J12V140E-G 1-1 Generator (4 Pole)

J12V140E-G1-1 Generator (6 pole)

SDA12V140E-1 D475A-3 Bulldozer

Generator Generator (50Hz)

SAA12V140-P920 Generator (50Hz)

SAA12V140-P920 Generator (60Hz)

SAA12V140-P1O30 Generator (50Hz)

SAA12V140-P1150 Generator (50Hz)

SAA12V140-1

01-001-1
(15)
GENERAL SPECIFICATIONS

SPECIFICATIONS
Engine model SA12V140-1

Applicable machine D475A-2 t WA800-2 WA800-3

Number of cylinder — Bore x Stroke mm 12 - 140 x 65

Total piston displacement é (cc} 30.5 (30,480)

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

Overall length mm 1,715 2,000 2,000

Overall width mm 1,515 1,450 1,450

Dimensions

Overall height mm 1,475 2,000 2,000

(excluding exhaust pipe)

Overall height mm 1,592

(including exhaust pipe)

Flywheel horsepower kW (HP}/rpm 574 {770}/2,000 588 {789)/2,000 603 (808)/2,000

(Net) (Net) (Net)
Performance

Maximum torque Nm Tkgm)/rpm 3,350 (342}/1,400 3,730 (380}/1,400 3,730 {380)/1,400

(Net) (Net) (Net)

621501
High idling speed rpm 2,100 — 2,200 2,200 — 2,300 2,200 — 2,300
650 - 700 (on the machine)
Low idling speed rpm 600 — 680 600 — 650 680 - 730 (engine only)
g/kW•h 201 (150} (Net) 197 (147} (Net) 208 {155} (Net)
Minimum fuel consumption ratio (g/HP•h)
Dry weight kg 3,300 3,200 3,170

Fuel injection pump BOSCH PE-P type BOSCH PE-P(PS7S) type

BOSCH RSUV centrifugal,
Governor BOSCH RSUV centrif ugal, all speed type all speed type

Lubricating oil amount 103 98 120

(refill capacity) (95) (90) 1108)

Coolant amount 215 301 (engine only: 85)

Alternator 24 V, 35 A 24 V, 75 A 24 V, 75 A
(With cab andair
conditioner: SOA)
Starting motor 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2

Bakery 12 V 170 Ah x 4 12 V 200 Ah x 4 12 V 170 Ah x 4

KOMATSU KOMATSU KOMATSU
Turbocharger KTR110 tvpe x 2 KTR110 type x 2 KTR110 type x 2
ZEXEL reciprocation,
Air compressor — single cylinder —
type x 2

Others With aftercooler With aftercooler With aftercooler

01t002
 GENERAL SPECIFICATIONS

SA12V140-1

HD785-3 (option)
WA9O0-1 WA900-3 HD785-3 (With KOMATSU electronic governor)
12 — 140 x 165

305(30,480)

R 1 — L1— R5 — LS — R3 — L3 - R6 — L6 — R2 - L2 — R4 — L4

2,000 2,036 2,036 2,036

1,450 1,252 1,252 1,252

2,000 2,000 1,525

1,874
(With retarder: option)
High power mode t Economy mode
627/2,000 (Net) 636/2,000 (Net) 783/2,100 (Net) 753/2,100 {Net) 647/1,700 (Nett
(840/2,000) (Net) (853/2,000) (Nett 11,010/2,100) (Netl (1,010/2, 100) (Netl 1880/1,700) (Net)

3,730/1,400 (Net) 4,090/1,300 Net› 4,170/1,500 (Net) 4,170/1,500 (Net) 3,820/1,250 (Net)
(380/1,400) (Net) (417/1,300) (Net) {425/1,500) (Net) ' {425/1,500) (Net) (390/1,250) (Net)

2,200 — 2,300 2,300 - 2,350 2.400 — 2,500 2,400 — 2,500 2,050 - 2,150
t0g tZ9

650 — 700 680 — 730 650 — 700 620 - 720 645 - 695
194 (Net) 208 {Netl 205 (Net) 205 (Net) 205 (Net)
(145) (Net) (155) (Net) (153) {Net) (153) (Nett (153) (Net)
3,200 3,520 3,100 ' 3.100

BOSCH PE-P (PS7S) type BOSCH PE-P type KOMATSU KFE6S135 type
BOSCH RFD min. max.
BOSCH RSUV centrifugal, all speed type KOMATSU electronic control type
speed control type
82 96 85 88
T64) \87) (66) (59)

317 (engine only: 85) 230 230

24 V, 50 A 24 V, 75 A 24 V, 50 A 24 V, 75 A

24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2

12 V 170 Ah x 4 12 V 170 Ah x 4 12 V 200 Ah x 4 12 V 200 Ah x 4

KOMATSU KOMATSU KOMATSU

KTR 110 type x 2 , KTR 110 type x 2 KTR110 type x 2 KOMATSU KTR 110 type x 2

ZEXEL reciprocation, ! ZEXEL reciprocation, single cylinder

single cylinder | type x 2
type x 2
With aftercooler,
With aftercooler With aftercooler {option) retarder With aftercooler, (option) retarder

01-003
s›
GENERAL SPECIFICATIONS

Engine model SA12V140-1

Applicable machine HD785-5 HD785-5 (option)

(With KOMATSU electronic governor)

Number of cylinder — Bore x Stroke mm 12 — 140 x 165

Total piston displacement / (cc) 30.5 (30,480)

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

Overall length mm 2,036

Dimensions

Overall width mm 1,252

Overall height mm
(excluding exhaust pipe)

Overall height mm 1,514

(including exhaust pipe) 1,874 (with retarder: option)
High power mode Economy mode
Flywheel horsepower kW/rpm 783/2,000 (Gross) 793/2,000 tGrossl 699/1,900 (Gross)
(HP/rpm) (1,050/2,000) (Gross) (1,060/2,000) (Gross) (937/1,900) (Gross)
753/2,000 (Net) 753/2,000 (Net)
(1,010/2,000) (Net) (1,010/2,000) (Net)
Performance

Nm/rpm 4,170/1,400 (Gross) 4,170/1,400 ‹Gross) 4,050/1,300 (Gross)

621501
Maximum torque
(kgm/rpm) (425/1,400) (Gross) 1425/1,400) (Gross) (413/1,300) (Gross)
4,120/1,400 (Net) 4,130/1,400 (Net)
(421/1,400) (Net) (421/1,400} (Net)

High idling speed rpm 2,300 - 2,400 2,300 — 2,400 2,300

Low idling speed rpm 620 — 720 620 — 720 620 — 720

g/kW•h 197 (Gross) 194 TG ross) 194 {Gross)

Minimum fuel consumption ratio (g/HP•h) (145) (Gross) (145) (Gross) (145} (Gross)

Dry weight kg 3,100 3,100 3,100

Fuel injection pump BOSCH PE-P (PS7S) type KOMATSU KFE6S135 type

Governor BOSCH RFD min. max. Electronic control type

speed control type
Lubricating oil amount 132 132
(refill capacity) (1201 (120T

Coolant amount (Engine only: 90) (Engine: 90a

Alternator 24 V, 75 A 24 V, 75 A

Starting motor 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2

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

KOMATSU
Turbocharger KTR110 type x 2 KOMATSU KTR110 type x 2
ZEXEL reciprocation,
Airconnpressor single cylinder type x 2 ZEXEL reciprocation, single cylinder type x 2
With aftercooler,
Others (option) retarder With aftercooler, (option) retarder

01-%4
 GENERAL SPECIFICATIONS

SA12V14O-1

HD985-3 J12V140E-G1-1 J12V14OE-G1-1

(With KOMATSU electronic governor) (4 pole generator) (6 pole generator)

12 — 140 x 165

30.5 (30,480)

R1 — L1— RS — L5 — R3 — L3 — R6 — L6 — R2 — L2 — R4 — L4

2,036 2,284 2,284

1,252 1,333 1,333

1,655 1,655

1,874
(With retarder: option)
High power mode Economy mode
753 (1,010}/2,100 647 (880)/1,700 549 (757}/1,500 382 (527}/1,100
(Net) (Net) (50 Hz) (50 Hz)

615 (848)/1,800 451 (622}/1,200

T60 Hz) T60 Hz)
4,170 (425}/1,500 3,820 (390)/1,250
# 0fS Z9

(Net) (Net)

Max. 1,575 (50 Hz) Max. 1,550 (50 Hz)

2,400 — 2,500 2,050 — 2,150 Max. 1,890 (60 Hz) Max. 1,260 (60 Hz)

620 — 720 645 — 695 700- 900 700-900

(At rated flywheel horsepower) (At rated flywheel horsepower)
205 {153) (Net) 205 (153) (Net)
211 {157) (50 Hz) 211 (157} T50 Hz)
215 {160) (60 Hz) 215 (160} (60 Hz)
3,100 3,200 3,200

KOMATSU KFE6S135 type BOSCH PE-P (PS7S) type BOSCH PE-P (PS7S) type

KOMATSU electronic control type ZEXEL electronic ZEXEL electronic

control type control type
93 159 159
(77) (155) (155)

230 85 (Engine only) 85 (Engine only)

24 V, 50 A 24V, 35 A 24 V, 35 A
(opt) (optl
24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2

12 V 170 Ah x 4 12 V 200 Ah x 4 12 V 200 Ah x 4

KOMATSU KTR110 type x 2 KOMATSU KOMATSU

KTR110 type x 2 KTR110 type x 2
ZEXEL reciprocation, single cylinder type x 2

With aftercooler, (option) retarder With aftercooler With aftercooler

01-00J
GENERAL SPECIFICATIONS

Engine model SA12V140-1

DCA800SPK
Applicable machine (DENYO • generator) Generator INGERSOLL RAND
(With ZEXEL (50 Hz only) crawler drill
electronic governor)
Number of cylinder — Bore x Stroke mm 12 — 140 x 165

Total piston displacement 9 (cc) 30.5 {30,480T

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

Overall length mm 1,996 2,936 1,755

mm 1,342 1,924 1,513

Dimensions

Overall width

Overall height mm 1,590 1,616 1,552

(excluding exhaust pipe)

Overall height mm
(including exhaust pipe)

Flywheel horsepower kW (HP}/rpm 613 (822}/1,500 613 (822}/1,500 709 T950}/1,800

(50 Hz) (50 Hz) (Net)
(Net) (Net)
736 (987}/1,800
(60 Hz)
(Net)
Performance

Maximum torque — 3,980 {406}/1,400

(Net)

621501
High idling speed rpm 1,563 — 1,573 (50 Hz) Max. 1,560 1,950 — 2,050

1,876 — 1,886 (60 Hz)

Low idling speed rpm 750 — 850 700 — 900 1,150 — 1,250

Minimum fuel consumption ratio g/kW•h (At rated flywheel (At rated flywheel
{g/HP•h} horsepoer) horsepower)
211 (157} (Net, 50 Hz) 211 {157} (Net, 50 Hz) 205 {153} (Net)
215 (160} (Net, 60 Hz) _

Dry weight kg 3,300 3,100 3,100

Fuel injection pump BOSCH PE-P (PS7S) type BOSCH PE-P (PS7S) type BOSCH PE-P type

Governor ZEXEL electronic ZEXEL electronic BOSCH RSUV centri-

control type control type fugal, all speed type
Lubricating oil amount 103 88 102
(refill capacity) (95) (80) (92)

Coolant amount 215 85 (Engine only) 85 (Engine only)

Alternator 24 V, 35 A 24 V, 25 A —
(With cab andair
conditioner: SOA)
Starting motor 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2

Battery 12 V 170 Ah x 4 12 V 220 Ah x 2 12 V 240 Ah x 4

KOMATSU KOMATSU KOMATSU
Turbocharger KTR110 type x 2 KTR110 type x 2 KTR110 type x 2
Air compressor

Others With aftercooler With aftercooler With aftercooler

01-005-1
i
GENERAL SPECIFICATIONS

SA12V140-1
Generator
DCA-800SSK
EG750B-1L EPSA12V140 IMS
‹Mo generator)
(in South Africa)
12 — 140 x 165

30.5 {30,480)

R1 — L1— R5 — L5 — R3 — L3 — R6 — L6 — R2 — L2 — R4 — L4

2,936 2,267 2,936 1,996

1,924 1,329 1,924 1,334

1,616 2,027 1,916 1,528

613 f822)/1,500 581 (779)/1,800 630 {844) /1,500 812 (1,088) /1,800
(Net) (Net) (50 Hz) (60 Hz)
(Net) (Net)
762 (1,022} /1,800
(60 Hz)
(Net)

Max. 1,560 2,000 + 50 1,563 — 1,573 (50 Hz) Max. 1,890

1,876 — 1,886 (60 Hz)

700 — 900 850 — 900 700 — 900 700 — 900

IAt rated flywheel (At rated flywheel (At rated flywheel

horsepower) horsepower) horsepower)
210 (157} (Net) 208 {155) (Net) 210 {157} (Net) 215 (160) (Net)

3,100 3,100 2,950 3,100

BOSCH PE-P type BOSCH PE-P type BOSCH PE-P (PS7S) BOSCH PE-P (PS7S)
BOSCH RSUV centri- BOSCH RSUV centri- BOSCH RSUV centri- Electronic governor
fugal, all speed type fugal, all speed type fugal, all speed type (ZEXEL)
88 88 88 151
(80) (80) (79) (148)

58 (Engine only) 168 85 (Engine only) 85 (Engine onIy)

24 V, 25 A 24 V, 25 A 24 V, 25 A 24 V, 35 A

24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2

12 V 220 Ah x 2 12 V 220 Ah x 2 12 V 200 Ah x 4 12 V 200 Ah x 4

KOMATSU KOMATSU KOMATSU KOMATSU
KTR110 type x 2 KTR110 type x 2 KTR110 type x 2 KTR110 type x 2

With aftercooler With aftercooler With aftercooler With aftercooler

01-005-2
(15)
GENERAL SPECIFICATIONS

Engine model SAA12V140-1

Applicable machine Generator

(50 Hz only)

Number of cylinder — Bore x Stroke mm 12 — 140 x 165

Total piston displacement 30.5 T30,480}

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

Overall length mm 2,187

Overall width mm 1,600

Dimensions

Overall height mm 1,697

(excluding exhaust pipe)

Overall height mm
(including exhaust pipe)

Rated flywheel
Flywheel horsepower kW {HP)/rpm horsepower
773 (1,050)/1,500
(Net)
Maximum flywheel
horsepower
851 {1,160)/1,500
(Net)
Performance

Maximum torque Nm {Agm}/rpm —

621501
High idling speed rpm (At rated flywheel horse
power) Max. 1,570
(At max. flywheel horse-
power) Max. 1,580

Low idling speed rpm 800 — 850

Minimum fuel consumption ratio g/kW•h (At rated flywheel

(g/HP•h} horsepower)
211 (155) (Net)

Dry weight kg 3,170

Fuel injection pump BOSCH PE-P type

Governor BOSCH RSUV centri-

fugal, all speed type
Lubricating oil amount 157
(refill capacity) (40)

Coolant amount 170

Alternator 24 V, 25 A

Starting motor 24 V, 7.5 kW x 2

Battery 12 V 200 Ah x 4
KOMATSU
Turbocharger KTR110 type x 2
Air compressor
With air cooled
Others aftercooler

01-005-3
›
 GENERAL SPECIFICATIONS

SAA12V140-1

SAA12V140-P920 SAA12V140-P920 SAA12V140-P1030 SAA12V140-P1150

(50 Hzl (60 Hzl (50 Hz) (50 Hzl

12 - 140 x 165

30.5 (30,480)
R1 - L1— RS — LS — R3 — L3 — R6 — L6 - R2 — L2 - R4 — L4

2,283 2,283 2,283 2,283

1,701 1,701 1,701 1,701

1,748 1,748 1,748 1,785

689/1,500 861/1,800 774/1,500 861/1,500

T924/1,5O0T (1,154/1,800) (1,037/1,500) {1,154/1,500)

758/1.500 947/1,800 8501,500 947/1,500

(1,016/1,500) (1,269/1,800) (1,140/1,500) (1.269/1,500)
621501

Max. 1.568 Max. 1,882 Max. 1,568 Max. 1,568

Max. 1,575 Max. 1,890 Max. 1,575 Max. 1,575

800 — 850 800 — 850 800 — 850 800 - 850

(At rated flywheel (At rated flywheel (At rated flywheel tAt rated flywheel
horsepowerl horsepower) horsepower) horsepower)
208 (155) 208 (155} 210 (157) 208 (155}

3,170 3,170 3,170 3,170

BOSCH PE-P type BOSCH PE-P type BOSCH PE-P type BOSCH PE-P type
BOSCH RSUV centri- BOSCH RSUV centri- BOSCH RSUV centri- BOSCH RSUV centri-
fugal, all speed type fugal, all speed type fugal, all speed type fugal, all speed type
157 157 157 157
(141) (141) ( 141) (141)

170 170 170 170

24 V, 25 A 24 V, 25 A 24 V, 25 A 24 V, 25 A

24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2

12 V 200 Ah x 2 12 V 200 Ah x 2 12 V 200 Ah x 2 12 V 200 Ah x 2

KTR110 x 2 KTR110 x 2 KTR110 x 2 KTR110 x 2

01-00J-4
GENERAL SPECIFICATIONS

Engine model SDA12V140E-1

D475A-3 D475A-5
Applicable machine with KOMATSU with KOMATSU
electric governor / electric governor /
Number of cylinder — Bore x Stroke mm 12 — 140 x 165

Total piston displacement 30.5 T30,480)

Firing order R1 — L1— R5 — LS — R3 — L3 — R6 — L6 — R2 — L2 — R4 — L4

Overall length mm 1,970 1,715

Dimensions

Overall width mm 1,535 1,525

Overall height mm 2,178 1,453

(excluding exhaust pipe)

Overall height mm
(including exhaust pipe)

Flywheel horsepower kW (HP)/rpm 619 {830)/2,000 670 T899)/2,000

(Net) (Gross)
Performance

Maximum torque Nm (kgm)/rpm 3,697 (377}/1,400 3,825 (390)/1,400

(Net) (Gross)

621501
High idling speed rpm 2,150+50 2,150+50

Low idling speed rpm 620 +80

0 620 + 080

Minimum fuel consumption ratio g/kW•h 201 {150) (Net) 213 (159} (Gross)
(g/HP•h)

Dry weight kg 3,540 3,540

Fuel injection pump KOMATSU KFE6S135

Governor Electronic control type

Lubricating oil amount 142 32
(refill capacity) (134) (120)
82 (Engine on ly)
Coolant amount 8.4 (Dual circuit aftercooler)
Alternator 24 V, 75 A 24 V, 90 A —

Starting motor 24 V, 7.5 kW x 2 24 V, 7.5 kW x 2

Battery 12 V 170 Ah x 4 —
KOMATSU KOMATSU
Turbocharger KTR110 type x 2 KTR110 type x 2
Air compressor
With dual circuit With dual circuit
Others aftercooler aftercooler

01-005-5
(15)
DISASSEMBLY

Special tools

No. Part No. Part Name O‘ty

A 795-102-2102 Spring pusher 1

B 795-100-1191 Piston ring tool 1

C 795-236-1000 Liner puller 1

D 795-502-1121 Holder 1

E 795-507-1110 Remover 1

1. Washing
Before disassembling the engine, check all parts for
any cracks or damage, then clean the whole engine
carefully with steam so that the disassembly work

›
can be carried out swiftly.
1) Before washing, remove starting motor assembly
(1), alternator assembly (2), and electric wiring.
2) Cover all the openings of the engine with tape.
3) Using a washing machine, clean engine.
4 Wash with particular care all mating surfaces
where mud tands to collect.

6215F0052

2. Setting engine stand

• Prepare a stable engine stand that will prevent the
engine from falling over, then set the engine assem-
bly on the stand and secure it in position.

e Engine assembly: Approx. 3,200 kg

(The weight differs according to the machine
mounting the engine.)

6215F0053

13-003
3. Engine cooling water and engine oil
Drain engine cooling water and engine oil.

Engine oil: Approx. 90 9

(The amount of oil difiers according to the ma-

cine model.)

4. Filter
• Engine equipped with filters
1) Using filter wrench, remove corrosion resistor (1),
oil filter (2), and fuel filter (3).
2) Remove bypass filter.

t 0 g t59
5. Puffier assembly
• Engine equipped with muffler
1) Disconnect komaclone tube t4), then remove
muffler assembly (5) and muffler bracket.

6215F0054

6. Fan
1) Using nylon sling, sling fan, then remove mounting
bolts.
2) Remove fan (1).

Fan: 75 kg

(The weight differs according to the machine

model.)

6215F0055

13-004
7. Fan belt
1) Insert bar (length: approx. 50 cm [19.685 in])
in hole ($ 18 mm [0.7087 inj) of tension pulley
bracket, then pull it forward to loosen spring
tension, and remove fan belt.

Insert the bar securely and make sure that it

does not come out.

2) Remove tension pulley assembly (1) together

with bracket.

6215F0056

8. Fan pulley assembly

1) Using nylon sling, sling fan pulley assembly, and
remove mounting bolts.
2) Remove fan pulley assembly (21.

Fan pulley assembly: 85 kg

6215F0057

9. Intake connector
Remove intake sonnector (1).

6215F0058

10. Exhaust brake assembly

1) Disconnect clamp (2) of exhaust connector (1).
2) Remove exhaust brake assembly (4) together
with bracket (3).

6215F0059

13-005
11. Turbocharger assembly
1) Disconnect turbocharger oil supply tube (1) and
drain tube (2).
2) Remove turbocharger assembly (3).
4 Remove the turbocharger oil supply tube
and the drain tube after removing the intake
manifold.

6215F0060

12. Intake manifold, aftercooler assembly

Left bank
1) Disconnect tubes (1) and (2) for air compressor.
2) Remove tubes (3) and (4) for aftercooler.
3) Remove heater relay wiring (5).

621501
6215F0061

4) Remove boost compensator tube (6).

5) Remove clamp (7) of fuel injection tube.

6215F0062

Right bank
1) Remove tubes (8) and (9) for aftercooler.
2) Remove wiring (101 of electrical intake air hea-
ter.

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13-006
 31 Sling intake manifold and aftercooler assembly
(11), and remove mounting bolts.
a To prevent the electrical intake air heater
from falling off, install a guide bar in the
mounting bolt hole of the intake manifold
below.
4) Remove intake manifold and aftersooler assem-
bly.

intake manifold, aftercooler assembly:

50 kg

6215F0064

Remove the aftercooler core as follows.

i) Remove connector (12).
ii) Remove cover (13).
iii) Remove aftercooler core (14).

6215F00G5

13. Exhaust manifold assembly

Remove exhaust manifold assembly (1).

Exhaust manifold assembly: 30 kg

6215F0066

14. Fuel injection pipe. spill tube

1) Remove cover of injection pump drive shaft.
2) Remove fuel injection pipe (1).
3) Remove spill tube (2).
a Install a protective cover to prevent any dirt
or dust from getting into the discharge port
of the injection pump or the inlet port of the
nozzle connector.

6215F0067

13-007
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15. Fuel injection pump assembly
1) Remove governor rod (1).
2) Disconnect fuel hoses (2) and (3).
3) Remove oil supply tubes (4) and (5).

6215F0068

4) Remove 4 bolts (6), then loosen coupling bolt

(7), and remove injection pump assembly (8).
For the right bank injection pump assembly,
disconnect the coupling, loosen 4 mounting
bolts holding the injection pump bracket,
pull out the injection pump and bracket at
an angle as one unit, then remove the
mounting bolts.
a Use tape to prevent the coupling key from
being lost.

t 0 g t89
Fuel injection pump assembly: 38 kg
6215F0069

5) Disconnect fuel hoses (9) and (10).

6) Remove bracket (11).
7) Remove clamp, then remove tubes (12) and (13).

— • 12
0 0

13
Ib
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13-008
16. Water pump assembly
1) Disconnect 2 U-clamps and master joint (1), then
remove bypass tube (2).
2) Remove bypass tube (3).
3) Remove tube (4).

6215F0074 6215F0075

4) Remove tubes (5), (6), and (7) as a set.

5) Remove tube (8).
6) Remove bolts, then remove water pump assem-
bly (9).
a The water pump is held by two mounting
bolts at the front and two mounting bolts at
the rear.

6215F0076

17. Breather Leh bank

1) Remove alternator bracket (1).
< The alternator bracket is on the right bank
only.
2) Remove clamp, then remove tube (2).
3) Remove breather (3).

6215F0078

18. Air compressor

• Engine installed with air compressor.
1) Remove tubes (1), (2), (3), (4), and (5).
2) Remove unloader valve (6).

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13-009
 3) Remove front compressor (7).
With spline shaft
4) Remove rear compressor (8).
a With gear

6215F0080

19. Oil cooler assembly

1) Remove front oil cooler assembly (1).
2) Remove manifolds (2) and (31.
3) Remove rear oil cooler assembly (4).

621501
6215F0081

20. Oil filter, oil level gauge

1) Remove bracket, then oil filler (1).
2) Remove oil level gauge guide (2).
Loosen the nut at the root of the level
guide, then remove the guide.

6215F0082

13-010