Factory Shop Troubleshooting Repair Manual For Komatsu Engine. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 975
Number: CEBM000601 (may 1997)
Bookmarks: Yes
Model
Komatsu Engine
S6D114E-1
SA6D114E-1
SAA6D114E-1
Contents
1. SHOP MANUAL SGD114E-1, SAID114E-l, SAAGD114E-1 SERIES ENGINE.
-INTRODUCTION
General Cleaning Instructions
General Repair Instructions
General Safety Instructions
Generic Symbols
Glossary of Terms
How To Use This Manual
Illustrations
-ENGINE AND COMPONENT IDENTIFICATION
Engine Diagrams
Engine Identification
General Engine Specifications
-ENGINE DISASSEMBLY AND ASSEMBLY
Engine – Assembly
Engine – Disassembly
Engine Disassembly and Assembly – Service Tools
General Information
-CYLINDER BLOCK
Camshaft Bore Expansion Plug – Installation
Camshaft Bushing Bore – Cleaning
Camshaft Bushing – Installation
Camshaft Bushing – Removal
Camshaft – Cleaning and Inspection for Reuse
Camshaft Gear – Replacement
Connecting Rod Bearings – Cleaning and Inspection for Reuse
Connecting Rod Bushing – Replacement
Connecting Rods – Bend and Twist Inspection
Connecting Rods – Cleaning and Inspection for Reuse
Crankshaft – Cleaning and Inspection for Reuse
Crankshaft Gear – Replacement
Cylinder Block – Cleaning in a Hot Tank
Cylinder Block – Cleaning with Solvent
Cylinder Block – Disassembly
Cylinder Block – Exploded View
Cylinder Block – General Information
Cylinder Block – Inspection For Reuse
Cylinder Block – Service Tools
Cylinder Head Capscrews – Cleaning and Inspection for Reuse
Cylinder Liners – Cleaning and Inspection for Reuse
Dowel Pins (Cylinder Head) – Removal
Engine Dataplate – Replacement
Engine Lifting Brackets – Cleaning and Inspection for Reuse
Expansion Plug – Installation
Gear Cover – Cleaning and Inspection for Reuse
Gear Housing – Cleaning and Inspection for Reuse
Main Bearing Caps and Capscrews – Cleaning and Inspection for Reuse
Main Bearings – Cleaning and Inspection for Reuse
Pistons – Cleaning and Inspection for Reuse
Rear Cover – Cleaning and Inspection
Vibration Damper – Cleaning and Checking for Reuse
-CYLINDER HEAD
Cylinder Head Capscrew – Cleaning and Inspection for Reuse
Cylinder Head – Cleaning and Inspection for Reuse
Cylinder Head – Exploded View
Cylinder Head – General Information
Cylinder Head – Pressure Testing
Cylinder Head – Rebuild
Cylinder Head – Service Tools
Cylinder Head – Vacuum Testing Valve Seating
Cylinder Head – Valve Guide Replacement
Cylinder Head – Valve Seat Insert Replacement
Free Length – Measurement
-ROCKER LEVERS
Crankcase Breather Tube – Cleaning and Inspection for Reuse
Rocker Assembly Oil Manifold – Cleaning and Inspection for Reuse
Rocker Lever Assembly – Cleaning and Inspection
Rocker Lever Assembly – Exploded View
Rocker Lever Assembly – General Information
Valve Cover – Cleaning and Inspection for Reuse
-VALVE TAPPETS AND PUSH RODS
Push Rods – Cleaning and Inspection for Reuse
Valve Tappet Cleaning and Inspection for Reuse
Valve Tappets and Push Rods – Exploded View
Valve Tappets and Push Rods – General Information
-FUEL SYSTEMS
Direct Link Shutdown Lever – Replacement
Fuel Injection Pump Gaskets and Seals – Replacement
Fuel System – General Information
Fuel Transfer Pump – Exploded View
Fuel Transfer Pump – Rebuild
RSV Governor Fuel Shutoff Solenoid – Orientation and Adjustment
RQVK Governor Fuel Shutoff Solenoid – Adjustment
Shutdown Lever or Spring – Replacement
-INJECTORS AND FUEL LINES
Fuel Drain Manifold – Inspection
Fuel Lines, High Pressure – Cleaning and Inspection for Reuse
Fuel Lines, Low Pressure – Cleaning and Inspection for Reuse
Injector – Chatter Testing
Injector – Spray Testing
Injectors and Fuel Lines – Exploded View
Injectors and Fuel Lines – Exploded View
Injectors and Fuel Lines – Exploded View
Injectors and Fuel Lines – General Information
Injectors and Fuel Lines – Service Tools
Injectors – Cleaning and Inspection for Reuse
-LUBRICATING OIL SYSTEM
Lubricating Oil Dipstick – Calibration
Lubricating Oil Pan – Cleaning and Inspection for Reuse
Lubricating Oil Pump – Cleaning and Inspection for Reuse
Lubricating Oil System – Exploded View
Lubricating Oil System – General Information
Lubricating Oil System – Service Tools
Lubricating Oil Temperature Thermostat – Cleaning and Inspection
Oil Cooler Cover – Disassembly and Assembly
Oil Cooler Element – Cleaning and Inspection for Reuse
Oil Filter Bypass Valve – Replacement
Oil Pressure Regulating Valve – Cleaning and Inspection
-COOLING SYSTEM
Belt Tensioner Inspection
Coolant Filter Shutoff Valve – Cleaning and Inspection for Reuse
Cooling System Components – Exploded View
Cooling System – General Information
Cooling System – Service Tools
Fan – Cleaning and Inspection for Reuse
Fan Flub – Cleaning and Inspection for Reuse
Fan Flub – Rebuild
Thermostat Housing – Cleaning and Inspection for Reuse
Thermostat – Inspection
Water Outlet Connection – Cleaning and Inspection for Reuse
Water Pump Assembly – Cleaning and Inspection for Reuse
-DRIVE UNITS
Accessory Drive Adapter – Cleaning and Inspection for Reuse
Accessory Drive Adapter – Exploded View
Accessory Drive Adapter – Rebuild
Accessory Drive – General Information
Drive Units – Service Tools
-AIR INTAKE SYSTEM
Aftercooler Assembly – Cleaning and Inspection for Reuse
Aftercooler Assembly – Rebuild
Air Crossover Tube – Cleaning and Inspection for Reuse
Air Intake System – Exploded View
Air Intake System – General Information
Air Intake System – Service Tools
Air Transfer Pipe – Cleaning and Inspection for Reuse
Charge Air Cooler (CAC) – Cleaning and Inspection for Reuse
Charge Air Cooler (CAC) – Pressure Testing
Intake Manifold Cover – Cleaning and Inspection for Reuse
Turbocharger – Cleaning and Inspection for Reuse
-EXHAUST SYSTEM
Exhaust Manifold – Cleaning and Inspection for Reuse
Exhaust Manifold – Exploded View
Exhaust Manifold Outlet Connection – Cleaning and Inspection for Reuse
Exhaust Manifold Turbocharger Mounting Stud – Replacement
Exhaust System – General Information
-ENGINE TESTING
Blowby Measurement
Engine Dynamometer Test – Engine Run-In
Engine Dynamometer Test – Installation of the Engine
Engine Dynamometer Test – Performance Checking
Engine Painting
Engine Run-In Procedure – “In-Chassis”
Engine Run-In – General Procedures
Engine Storage – Long Term
Engine Storage – Short Term
Engine Testing – Component Identification and Diagrams
Engine Testing – General Information
Engine Testing – General Specifications
Engine Testing – Service Tools
Fuel Injection Pump – Idle Speed Adjustment
General Engine Test Procedure – In Chassis
-MOUNTING ADAPTATIONS
Engine Support Bracket, Front – Cleaning and Inspection for Reuse
Flexplate Assembly – Cleaning and Inspection for Reuse
Flywheel – Cleaning and Inspection for Reuse
Flywheel Housing – Assembly (Wet Clutch Application)
Flywheel Housing – Cleaning and Inspection for Reuse
Flywheel Rina Gear – Replacement
Mounting Adaptations – Exploded View
Mounting Adaptations – General Information
Mounting Adaptations – Service Tools
-SPECIFICATIONS AND TORQUE VALUES
Air Compressor Inspection Specifications
Air Compressor Torque Values
Capscrew Markings and Torque Values
Component Specifications and Torque Values
Cooling System Specifications
Drive Belt Tension
Electrical System Specifications
Electrical System Torque Values
Engine Components – General Information
Engine Testing – Test Specifications
Exhaust System Specifications
Exhaust System Torque Values
Fuel Systems – Rebuild Specifications
Lubricating Oil System Specifications
Lubricating Oil System Torque Values
Mounting Adaptations – Torque Values
Mounting Adaptations Specifications
Newton-Meter to Foot-Pound Conversion Chart
Pipe Plug Torque Values
Rocker Lever Assembly – Rebuild Specifications
Tap-Drill – U.S. Customary & Metric
Valve Tappet – Rebuild Specifications
Weight and Measures – Conversion Factors
2. TROUBLESHOOTING AND REPAIR MANUAL S6D114E-1, SA6D114E-1, SAA6D114E-1 SERIES ENGINE.
-INTRODUCTION
About the Manual
General Cleaning Instructions
General Repair Instructions
General Safety Instructions
Generic Symbols
Glossary of Terms
How To Use This Manual
Illustrations
-ENGINE AND COMPONENT IDENTIFICATION
Engine Identification
General Engine Specifications
Engine Diagrams
-TROUBLESHOOTING LOGIC
Troubleshooting
Troubleshooting Symptoms Charts
-COOLING SYSTEM
Belt Tensioner – Replacement
Cooling System – Diagnosing Malfunctions
Cooling System – Flow Diagrams
Cooling System – General Information
Cooling System – Maintenance
Cooling System – Service Tools
Cooling System – Specifications
Drive Belt – Replacement
Fan Hub – Replacement
Fan Pulley – Replacement
Thermostat – Replacement
Water Pump – Replacement
-LUBRICATING OIL SYSTEM
Internal Engine Damage – Checking
Lubricating Oil Cooler Element and Gasket – Replacement
Lubricating Oil Dipstick – Calibration
Lubricating Oil Dipstick Tube – Replacement
Lubricating Oil Filter – Changing
Lubricating Oil Leaks (External) – Checking
Lubricating Oil Level – Checking
Lubricating Oil Pan – Draining
Lubricating Oil Pan – Filling
Lubricating Oil Pan, Suction Tube and Gasket – Replacement
Lubricating Oil Pressure Regulator, Valve and Spring – Replacement
Lubricating Oil Pump – Replacement
Lubricating Oil System – Diagnosing Malfunctions
Lubricating Oil System – Flow Diagram
Lubricating Oil System – General Information
Lubricating Oil System – Service Tools
Lubricating Oil System – Specifications
Lubricating Oil Temperature Thermostat – Replacement
-AIR COMBUSTION SYSTEM REPAIR
Aftercooler and Gasket – Replacement
Air Crossover Tube – Replacement
Air System Flow – Diagrams
Charge Air Cooler
Charge Air Cooler (CAC) – Troubleshooting
Combustion Air System – Diagnosing Malfunctions
Combustion Air System Flow – General Information
Combustion Air System – Service Tools
Exhaust Manifold and Gaskets – Replacement
Intake Air and Exhaust System Specifications
Intake Manifold Cover and Gasket – Replacement
Turbocharger Boost Pressure Specifications
Turbocharger – Replacement
Turbocharger Wastegate Actuator – Calibration
Turbocharger Wastegate Actuator – Functional Checking
Turbocharger Wastegate Actuator – Replacement
Turbocharger Wastegate Actuator – Visual Inspection
-COMPRESSED AIR SYSTEM REPAIR
Air Compressor Carbon Buildup – Checking
Air Compressor Gasket Leaks – Checking
Air Compressor – Replacement
Air Governor and Compressor Unloader Valve – Checking
Air Governor – Checking
Compressed Air System Flow Diagrams
Compressed Air System General Information
Compressed Air System Specifications
-FUEL SYSTEM
AFC Tube – Replacement
Fuel Drain Manifold – Replacement
Fuel Filter Flead Adapter – Replacement
Fuel Injection Pump – Replacement
Fuel Return Overflow Valve – Replacement
Fuel Shutoff Solenoid – Replacement
Fuel System Components and Flow
Fuel System Diagnosing – Malfunctions
Fuel System – Service Tools
Fuel System Specifications
Fuel Transfer Pump – Replacement/Rebuild
High Pressure Fuel Lines – Replacement
Idle Speed – Adjustment
Injector – Replacement
Inline Fuel Injection Pump Spill-Port Timing
Low Pressure Fuel Line – Replacement
-ELECTRICAL SYSTEM
Alternator – Replacement
Coolant Temperature Sensor – Replacement
Electrical System Description and Operation
Electrical System – Diagnosing Malfunctions
Electrical System – Service Tools
Electrical System – Specifications
Engine Block and Coolant Heater (750 and 500 Wats) – Replacement
Lubricating Oil Pan Heater – Replacement
Lubricating Oil Pressure Switch – Replacement
Starting Motor – Replacement
-BASE ENGINE COMPONENTS
Base Engine Components – General Information
Base Engine Components – Service Tools
Camshaft – Replacement
Camshaft Gear – Replacement
Connecting Rod Bearings – Replacement
Connecting Rods – Replacement
Crankcase Breather Tube – Replacement
Crankshaft Gear – Replacement
Cup Plug – Replacement
Cylinder Head – Pressure Test
Cylinder Head – Replacement
Cylinder Liners – Replacement
Engine Compression – Checking
Engine Dataplate – Replacement
Flywheel – Replacement
Flywheel Housing – Replacement
Flywheel Ring Gear – Replacement
Gear Cover – Replacement
Gear Housing – Replacement
Main and Thrust Bearings – Replacement
Pipe Plug – Replacement
Pistons and Rings – Replacement
Push Rod – Replacement
Rocker Lever – Replacement
Rocker Lever Diagnosing – Malfunctions
Seal, Front Crankshaft – Replacement
Seal, Rear Crankshaft – Replacement
Timing Pin Assembly – Installation
Valve Cover – Replacement
Valve Lash – Adjustment
Valve Tappet – Replacement
Vibration Damper – Replacement
Wear Sleeve, Front Crankshaft – Replacement
Wear Sleeve, Rear Crankshaft Seal – Replacement
-ENGINE TESTING
Blowby Measurement
Engine Run-in Procedure
Engine Testing – General Information
Engine Testing – General Specifications
Engine Testing – Service Tools
General Engine Test Procedures
-ENGINE REMOVAL AND INSTALLATION
Engine – Installation
Engine Mount – Inspection
Engine Removal and Installation – General Information
Engine – Removal
-ENGINE COMPONENT SPECIFICATIONS
Capscrew Markings and Torque Values
Component Specifications and Torque Values
Drive Belt Tension
Newton-Meter to Foot-Pound Conversion Chart
Pipe Plug Torque Values
Specification – General Information
Weight and Measures – Conversion Factors
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