Factory Shop Troubleshooting Repair Manual For Komatsu Diesel 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: 978
Number: SEBM020400 (march 2000)
Bookmarks: Yes
Model
Komatsu Diesel Engine
114 Series
S6D114E-1
SA6D114E-1
SAA6D114E-1
Contents
1. SHOP MANUAL S6D114E-1, SA6D114E-1, SAA6D114E-1 SERIES ENGINE.
-INTRODUCTION
How To Use This Manual
Generic Symbols
Illustrations
General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Glossary Of Terms
-ENGINE AND COMPONENT IDENTIFICATION
Engine Identification
General Engine Specifications
Engine Diagrams
-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 – Preparation for Cleaning
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-Service Tools
Cylinder Head-Exploded View
Cylinder Head-General Information
Cylinder Head-Cleaning And Inspection For Reuse
Cylinder Head-Rebuild
Cylinder Head-Valve Guide Replacement
Cylinder Head-Valve Seat Insert Replacement
Cylinder Head-Pressure Testing
Cylinder Head-Vacuum Testing Valve Seating
Cylinder Head Capscrew-Cleaning And Inspection
Free Length-Measurement
-ROCKER LEVERS
Rocker Lever Assembly-Exploded View
Rocker Lever Assembly-General Information
Rocker Lever Assembly-Cleaning And Inspection
Rocker Assembly Oil Manifold-Cleaning And Inspection For Reuse
Valve Cover-Cleaning And Inspection For Reuse
Crankcase Breather Tube-Cleaning And Inspection For Reuse
-VALVE TAPPETS AND PUSH RODS
Valve Tappets And Push Rods-Exploded View
Valve Tappets And Push Rods-General Information
Valve Tappet Cleaning And Inspection For Reuse
Push Rods-Cleaning And Inspection For Reuse
-FUEL SYSTEMS
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
Direct Link Shutdown Lever-Replacement
Fuel Injection Pump Gaskets And Seals-Replacement
-INJECTORS AND FUEL LINES
Injectors And Fuel Lines-Service Tools
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-Cleaning And Inspection For Reuse
Injector-Spray Testing
Injector-Chatter Testing
Fuel Lines, High Pressure-Cleaning And Inspection For Reuse
Fuel Drain Manifold-Inspection
Fuel Lines, Low Pressure-Cleaning And Inspection For Reuse
-LUBRICATING OIL SYSTEM
Lubricating Oil System-Service Tools
Lubricating Oil System-General Information
Lubricating Oil System-Exploded View
Lubricating Oil Pan-Cleaning And Inspection For Reuse
Oil Cooler Element-Cleaning And Inspection For Reuse
Oil Pressure Regulating Valve-Cleaning And Inspection
Oil Filter Bypass Valve-Replacement
Oil Cooler Cover-Disassembly And Assembly
Lubricating Oil Temperature Thermostat-Cleaning And Inspection
Lubricating Oil Dipstick-Calibration
Lubricating Oil Pump-Cleaning And Inspection For Reuse
-COOLING SYSTEM
Cooling System-Service Tools
Cooling System Components-Exploded View
Cooling System-General Information
Water Pump Assembly-Cleaning And Inspection For Reuse
Thermostat Housing-Cleaning And Inspection For Reuse
Thermostat-Inspection
Water Outlet Connection-Cleaning And Inspection For Reuse
Fan Hub-Cleaning And Inspection For Reuse
Fan Hub-Rebuild
Belt Tensioner Inspection
Coolant Filter Shutoff Valve-Cleaning And Inspection For Reuse
Fan-Cleaning And Inspection For Reuse
-DRIVE UNITS
Drive Units-Service Tools
Accessory Drive Adapter-Exploded View
Accessory Drive-General Information
Accessory Drive Adapter-Cleaning And Inspection For Reuse
Accessory Drive Adapter-Rebuild
-AIR INTAKE SYSTEM
Air Intake System-Service Tools
Air Intake System-Exploded View
Air Intake System-General Information
Turbocharger-Cleaning And Inspection For Reuse
Intake Manifold Cover-Cleaning And Inspection For Reuse
Aftercooler Assembly-Cleaning And Inspection For Reuse
Aftercooler Assembly-Rebuild
Air Transfer Pipe-Cleaning And Inspection For Reuse
Air Crossover Tube-Cleaning And Inspection For Reuse
Charge Air Cooler(CAC)-Cleaning And Inspection For Reuse
Charge Air Cooler(CAC)-Pressure Testing
-EXHAUST SYSTEM
Exhaust Manifold-Exploded View
Exhaust System-General Information
Exhaust Manifold-Cleaning And Inspection For Reuse
Exhaust Manifold Turbocharger Mounting Stud-Replacement
Exhaust Manifold Outlet Connection-Cleaning And Inspection For Reuse
-ENGINE TESTING
Engine Testing-Service Tools
Engine Testing-Component Identification And Diagrams
Engine Testing-General Information
Engine Testing-General Specifications
Blow By Measurement
Engine Run-In-General Procedures
Engine Dynamometer Test-Installation Of The Engine
Engine Dynamometer Test-Engine Run-In
Engine Dynamometer Test-Performance Checking
General Engine Test Procedure-In Chassis
Engine Run-In Procedure-“In-Chassis”
Fuel Injection Pump-Idle Speed Adjustment
Engine Painting
Engine Storage-Shortterm
Engine Storage-Long Term
-MOUNTING ADAPTATIONS
Mounting Adaptations-Service Tools
Mounting Adaptations-Exploded View
Mounting Adaptations-General Information
Flywheel-Cleaning And Inspection For Reuse
Flexplate Assembly-Cleaning And Inspection For Reuse
Flywheel Ring Gear-Replacement
Flywheel Housing-Cleaning And Inspection For Reuse
Flywheel Housing-Assembly(Wet Clutch Application)
Engine Support Bracket, Front-Cleaning And Inspection For Reuse
-SPECIFICATIONS AND TORQUE VALUES
Engine Components-General Information
Component Specifications And Torque Values
Rocker Lever Assembly-Rebuild Specifications
Valve Tappet-Rebuild Specifications
Fuel Systems-Rebuild Specifications
Lubricating Oil System Specifications
Lubricating Oil System Torque Values
Cooling System Specifications
Exhaust System Specifications
Exhaust System Torque Values
Air Compressor Inspection Specifications
Air Compressor Torque Values
Electrical System Specifications
Electrical System Torque Values
Engine Testing-Test Specifications
Mounting Adaptations Specifications
Mounting Adaptations-Torque Values
Drive Belt Tension
Weight And Measures-Conversion Factors
Newton-Meter To Foot-Pound Conversion Chart
Capscrew Markings And Torque Values
Pipe Plug Torque Values
Tap-Drill Chart-US Customary & Metric
2. TROUBLESHOOTING AND REPAIR MANUAL S6D114E-1, SA6D114?-1,SAA6D114E-1 SERIES ENGINE
-INTRODUCTION
How To Use This Manual
Generic Symbols
Illustrations
General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Glossary Of Terms
-ENGINE AND COMPONENT IDENTIFICATION
Engine Identification
General Engine Specifications
Engine Diagrams
-TROUBLESHOOTING LOGIC
Troubleshooting
Troubleshooting Symptoms Charts
-COOLING SYSTEM
Cooling System-General Information
Cooling System-Flow Diagrams
Cooling System-Specifications
Cooling System-Service Tools
Cooling System-Maintenance
Cooling System-Diagnosing Malfunctions
Drive Belt-Replacement
Belt Tensioner-Replacement
Fan Pulley-Replacement
Fan Hub-Replacement
Water Pump-Replacement
Thermostat-Replacement
-LUBRICATING OIL SYSTEM
Lubricating Oil System-Service Tools
Lubricating Oil System-General Information
Lubricating Oil System-Specifications
Lubricating Oil System-Flow Diagram
Lubricating Oil Leaks(External)-Checking
Internal Engine Damage-Checking
Lubricating Oil System-Diagnosing Malfunctions
Lubricating Oil Pan-Draining
Lubricating Oil Pan-Filling
Lubricating Oil Level-Checking
Lubricating Oil Filter-Changing
Lubricating Oil Dipstick-Calibration
Lubricating Oil Dipstick Tube-Replacement
Lubricating Oil Pressure Regulator, Valve And Spring-Replacement
Lubricating Oil Cooler Element And Gasket-Replacement
Lubricating Oil Temperature Thermostat-Replacement
Lubricating Oil Pan, Suction Tube And Gasket-Replacement
Lubricating Oil Pump-Replacement
-COMBUSTION AIR SYSTEM
Combustion Air System Flow-General Information
Air System Flow-Diagrams
Intake Air And Exhaust System Specifications
Turbocharger Boost Pressure Specifications
Combustion Air System-Service Tools
Combustion Air System-Diagnosing Malfunctions
Turbocharger Wastegate Actuator-Visual Inspection
Turbocharger Wastegate Actuator-Functional Checking
Turbocharger Wastegate Actuator-Replacement
Turbocharger Wastegate Actuator-Calibration
Charge Air Cooler(CAC)-Troubleshooting
Charge Air Cooler
Air Crossover Tube-Replacement
Intake Manifold Cover And Gasket-Replacement
Aftercooler And Gasket-Replacement
Turbocharger-Replacement
Exhaust Manifold And Gaskets-Replacement
-COMPRESSED AIR SYSTEM
Compressed Air System General Information
Compressed Air System Specifications
Compressed Air System Flow Diagrams
Air Compressor Carbon Buildup-Checking
Air Compressor Gasket Leaks-Checking
Air Governor And Compressor Unloader Valve-Checking
Air Governor-Checking
Air Compressor-Replacement
-FUEL SYSTEM
Compressed Air System General Information
Compressed Air System Specifications
Compressed Air System Flow Diagrams
Air Compressor Carbon Buildup-Checking
Air Compressor Gasket Leaks-Checking
Air Governor And Compressor Unloader Valve-Checking
Air Governor-Checking
Air Compressor-Replacement
-ELECTRICAL SYSTEM
Fuel System Components And Flow
Fuel System Specifications
Fuel System -Service Tools
Fuel System Diagnosing-Malfunctions
Low Pressure Fuel Line-Replacement
Fuel Filter Head Adapter-Replacement
Fuel Transfer Pump-Replacement/Rebuild
High Pressure Fuel Lines-Replacement
Fuel Drain Manifold-Replacement
Injector-Replacement
Fuel Shutoff Solenoid-Replacement
Fuel Return Overflow Valve-Replacement
AFC Tube-Replacement
Fuel Injection Pump-Replacement
Idlespeed-Adjustment
Inline Fuel Injection Pump Spill-Port Timing
-BASE ENGINE COMPONENTS
Electrical System Description And Operation
Electrical System-Specifications
Electrical System-Service Tools
Electrical System-Diagnosing Malfunctions
Starting Motor-Replacement
Alternator-Replacement
Coolant Temperature Sensor-Replacement
Engine Block And Coolant Heater(750 And 500 Wats)-Replacement
Lubricating Oil Pan Heater-Replacement
Lubricating Oil Pressure Switch Replacement
-ENGINE TESTING
Base Engine Components-Service Tools
Base Engine Components-General Information
Engine Compression-Checking
Valve Cover-Replacement
Crankcase Breather Tube-Replacement
Rocker Lever Diagnosing-Malfunctions
Rocker Lever-Replacement
Valve Lash-Adjustment
Timing Pin Assembly-Installation
Push Rod-Replacement
Cylinder Head-Replacement
Cylinder Head-Pressure Test
Main And Thrust Bearings-Replacement
Connecting Rod Bearings-Replacement
Piston And Rings-Replacement
Connecting Rods-Replacement
Cylinder Liners-Replacement
Vibration Damper-Replacement
Gear Cover-Replacement
Seal, Front Crankshaft-Replacement
Wear Sleeve, Front Crankshaft-Replacement
Gear Housing-Replacement
Engine Dataplate-Replacement
Camshaft-Replacement
Camshaft Gear-Replacement
Valve Tappet-Replacement
Crankshaft Gear-Replacement
Flywheel-Replacement
Flywheel Ring Gear-Replacement
Flywheel Housing-Replacement
Seal, Rear Crankshaft-Replacement
Wear Sleeve, Rear Crankshaft Seal-Replacement
Pipe Plug-Replacement
Cup Plug-Replacement
-ENGINE REMOVAL AND INSTALLATION
Engine Testing-General Information
Engine Testing-General Specifications
Blow By Measurement
Engine Testing-Service Tools
General Engine Test Procedures
Engine Run-In Procedure
-ENGINE COMPONENT SPECIFICATIONS
Engine Removal And Installation-General Information
Engine-Removal
Engine Mount-Inspection
Engine-Installation
-ENGINE COMPONENT SPECIFICATIONS
Specification-General Information
Component Specifications And Torque Values
Drive Belt Tension
Weight And Measures-Conversion Factors
Newton-Meter to Foot-Pound Conversion Chart
Capscrew Markings And Torque Values
Pipe Plug Torque Values
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