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1991 KOMATSU DRESSER KDC 614 SERIES ENGINE TROUBLESHOOTING AND SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- 1991 KOMATSU DRESSER KDC 614 SERIES ENGINE TROUBLESHOOTING AND SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBMGI 4TRl
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Description
1991 KOMATSU DRESSER KDC 614 SERIES ENGINE TROUBLESHOOTING AND SERVICE REPAIR MANUAL
1991 KOMATSU DRESSER KDC 614 SERIES ENGINE TROUBLESHOOTING AND SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
1991 KOMATSU DRESSER KDC 614 SERIES ENGINE TROUBLESHOOTING AND SERVICE REPAIR MANUAL
This manual provides instructions for troubleshooting and repairing the 614 Series Engine in the chassis. Component and assembly rebuild procedures are provided in the 614 Series Engine Shop Manual. Refer to Page i-2 in the Introduction for instructions on how to use this manual. The manual is’ organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover machine or equipment problems. Consult the appropriate machine chassis shop manual for repair procedures. A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be ordered through your distributor using the form in Section L. The repair procedures used in this manual are recommended by Komatsu Dresser Company. Some service procedures require the use of special service tools. Use the correct tools as described. The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Komatsu Dresser Co. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact your KDC Distributor. The latest technology and the highest quality components are used to manufacture KDC engines. When replacement parts are needed, we recommend using only genuine KDC exchange parts.
TABLE OF CONTENTS:
1991 KOMATSU DRESSER KDC 614 SERIES ENGINE TROUBLESHOOTING AND SERVICE REPAIR MANUAL
MAIN MENU..................................................................................... 0 Table of Contents............................................................................. 5 Section i - Introduction ..................................................................... 7 About the Manual ......................................................................... 8 General Cleaning Instructions ............................................................ 13 Solvent and Acid Cleaning............................................................. 13 Steam Cleaning........................................................................ 13 General Repair Instructions .............................................................. 12 General Safety Instructions .............................................................. 11 Generic Symbols .......................................................................... 9 Glossary of Terms ........................................................................ 14 How To Use This Manual ................................................................... 8 Group Contents........................................................................ 8 Index................................................................................. 8 Metric Information,................................................................... 8 Table of Contents..................................................................... 8 Illustrations ............................................................................ 10 Section E - Engine and Component Identification .............................................. 17 Engine Diagrams .......................................................................... 22 Engine Identification .................................................................... 18 Engine Dataplate ..................................................................... 18 Fuel Injection Pump Dataplate......................................................... 19 General Engine Specifications ............................................................ 20 Cooling System........................................................................ 21 Fuel System........................................................................... 21 General Engine Data................................................................... 20 Intake Air and Exhaust System......................................................... 21 Lubrication System.................................................................... 20 Section T - Troubleshooting Logic ............................................................ 25 Section T - Troubleshooting .............................................................. 26 Procedures and Techniques............................................................. 26 Troubleshooting Symptoms Charts .......................................................... 26 Air Compressor Air Pressure Rises Slowly ............................................. 29 Air Compressor Operates with Excessive Noise ......................................... 27 Air Compressor Pumping Excessive Lubricating Oil into Air System ..................... 28 Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) .... 30 Air Compressor Will Not Pump Air Pressure ............................................ 31 Air Compressor Will Not Stop Pumping Air ............................................. 32 Alternator Not Charging or Insufficient Charging ..................................... 33 Compression Knock .................................................................... 34 Coolant Contaminated ................................................................. 35 Coolant Loss ......................................................................... 36 Coolant Temperature Above Normal - Gradual Overheat .................................. 38 Coolant Temperature Above Normal - Sudden Overheat ................................... 41 Coolant Temperature Below Normal ..................................................... 42 Engine Crankcase Gases (Blowby) - Excessive ......................................... 43 Engine Cranks, But Will Not Start - No Smoke from Exhaust ............................ 44 Engine Difficult to Start or Will Not Start - Exhaust Smoke Present .................. 45 Engine Idle Rough, Warm Engine ....................................................... 47 Engine Misfiring ..................................................................... 48 Engine Noise Excessive................................................................ 53 Engine Power Output Low .............................................................. 49 Engine Starts But Will Not Keep Running............................................... 54 Engine Surges at Idle ................................................................ 55 Engine Vibration Excessive ........................................................... 56 Engine Will Not Crank or Cranks Slowly ............................................... 57 Engine Will Not Reach Rated When Loaded .............................................. 58 Engine Will Not Shut Off ............................................................. 59 Exhaust Black Smoke Excessive Under Load ............................................. 60 Exhaust White Smoke Excessive (Warm Engine) ......................................... 62 Fuel Consumption Excessive ........................................................... 63 Fuel or Oil Leaking from Exhaust Manifold ............................................ 64 Lubricating Oil Consumption Excessive ................................................ 66 Lubricating Oil Contaminated ......................................................... 65 Lubricating Oil Pressure High......................................................... 70 Lubricating Oil Pressure Low ......................................................... 68 Section 1 - Cooling System ................................................................... 71 Belt Tensioner - Replacement ............................................................ 97 Installation.......................................................................... 98 Removal............................................................................... 97 Removal and Installation.............................................................. 98 Cooling System - Diagnosing Malfunctions ................................................ 83 Belt Tension.......................................................................... 88 Coolant Hose - Inspection............................................................. 89 Coolant Pressure - Measurement........................................................ 91 Cooling System - Test for Combustion Gases............................................ 84 Fuel Pump Overfueled.................................................................. 96 Radiator Cap - Pressure Test.......................................................... 84 Radiator, Fan and Shutters............................................................ 91 Temperature Gauge Operation........................................................... 96 Thermostat Leakage and Opening Temperature - Testing "In-Chassis"..................... 94 Thermostat Opening Temperature - Testing "Thermostat Removed"......................... 95 Thermostat Operation and Testing...................................................... 93 Vehicle Overloaded.................................................................... 97 Water Pump - Inspection............................................................... 89 Water Pump Seal Weep Hole - Inspection................................................ 89 Cooling System - Flow Diagrams ........................................................... 73 Cooling System - General Information ..................................................... 72 Cooling System - Maintenance.............................................................. 77 Additive Concentration - Checking..................................................... 77 Antifreeze............................................................................ 77 Antifreeze Concentration - Checking................................................... 77 Cooling System - Cleaning............................................................. 78 Cooling System - Draining............................................................. 77 Filling and Venting................................................................... 82 Cooling System - Service Tools ........................................................... 76 Cooling System - Specifications .......................................................... 75 Drive Belt - Replacement ................................................................. 97 Fan Hub - Replacement .................................................................... 98 Removal and Installation.............................................................. 99 Fan Pulley - Replacement ................................................................. 98 Thermostat - Replacement .................................................................102 Cleaning .............................................................................103 Installation .........................................................................103 Removal...............................................................................102 Water Pump - Replacement ................................................................ 99 Cleaning .............................................................................100 Installation .........................................................................100 Removal............................................................................... 99 Section 2 - Lubricating Oil System............................................................107 Internal Engine Damage - Checking .......................................................117 Lubricating Oil Analysis .............................................................117 Lubricating Oil Filter Inspection ....................................................117 Lubricating Oil Cooler Element and Gasket - Replacement .................................134 Cleaning and Inspection ..............................................................135 Installation .........................................................................136 Removal ..............................................................................134 Lubricating Oil Dipstick - Calibration ...................................................131 Lubricating Oil Dipstick Tube - Replacement .............................................132 Installation .........................................................................132 Removal ..............................................................................132 Lubricating Oil Filter - Changing ........................................................130 Lubricating Oil Leaks (External) - Checking .............................................116 Lubricating Oil Level - Checking .........................................................129 Lubricating Oil Pan - Draining............................................................128 Lubricating Oil Pan - Filling.............................................................128 Lubricating Oil Pan, Suction Tube and Gasket - Replacement ..............................139 Cleaning .............................................................................139 Oil Pan - Installation ...............................................................140 Oil Pan - Removal ....................................................................139 Suction Tube - Replacement ...........................................................140 Lubricating Oil Pressure Regulator, Valve and Spring - Replacement .......................133 Cleaning and Inspection ..............................................................133 Removal ..............................................................................133 Installation .........................................................................134 Lubricating Oil Pump - Replacement ......................................................141 Cleaning and Inspection ..............................................................142 Installation .........................................................................145 Removal ..............................................................................142 Lubricating Oil System - Diagnosing Malfunctions.........................................118 Aftercooler ..........................................................................122 Bearings and Oil Pump ................................................................121 Coolant Diluted Oil ..................................................................121 Cracked Cylinder Block ...............................................................124 Cracked Cylinder Head ................................................................123 Cracked Cylinder Liner................................................................124 Cylinder Head Expansion Plugs ........................................................123 Cylinder Head Gasket .................................................................123 Cylinder Liner Seals ................................................................123 Fuel Diluted Oil .....................................................................124 Fuel Leaking by Piston Rings .........................................................125 Fuel Transfer Pump ...................................................................125 High Oil Pressure ....................................................................118 Injection Pump .......................................................................126 Low Oil Pressure .....................................................................118 Oil Cooler ...........................................................................122 Oil Dilution .........................................................................121 Oil Filter ...........................................................................119 Oil Leaks ............................................................................126 Oil Level ............................................................................118 Oil Pressure Gauge - Checking ........................................................119 Oil Pressure Regulating Valve ........................................................118 Oil Suction Tube .....................................................................121 Oil Temperature Gauge - Checking .....................................................120 Oil Temperature Thermostat ...........................................................120 Lubricating Oil System - Flow Diagram ....................................................112 Lubricating Oil System - General Information .............................................110 Lubricating Oil System - Service Tools ...................................................109 Lubricating Oil System - Specifications ..................................................111 Lubricating Oil Temperature Thermostat - Replacement ....................................137 Inspection ...........................................................................138 Installation..........................................................................139 Removal ..............................................................................137 Section 3 - Combustion Air System.............................................................149 Aftercooler and Gasket - Replacement .....................................................160 Cleaning .............................................................................161 Installation .........................................................................161 Removal ..............................................................................161 Air Crossover Tube - Replacement .........................................................159 Removal and Installation .............................................................159 Combustion Air System - Diagnosing Malfunctions .........................................153 Clean Air ............................................................................153 Damage From Non-filtered Air .........................................................154 Intake Air Restriction - Checking ....................................................153 Malfunctioning Turbocharger ..........................................................156 Oil Consumption and Leaks ............................................................156 Rotor Assembly Clearance - Measurement ...............................................158 Turbocharged Engines Air Leaks, Pressure Side .......................................154 Turbocharged Engines - Exhaust Leaks .................................................155 Turbocharger Boost Pressure - Measurement ............................................155 Turbocharger Noise ...................................................................157 Combustion Air System Flow - General Information .........................................150 Combustion Air System - Service Tools ....................................................152 Exhaust Manifold and Gaskets - Replacement ..............................................166 Cleaning and Inspection ..............................................................166 Installation..........................................................................167 Removal ..............................................................................166 Intake Air and Exhaust System Specifications .............................................151 Intake Manifold Cover and Gasket - Replacement...........................................159 Cleaning..............................................................................160 Installation..........................................................................160 Removal...............................................................................159 Turbocharger Boost Pressure Specifications ...............................................151 Turbocharger - Replacement................................................................162 Cleaning and Inspection...............................................................163 Installation..........................................................................164 Removal...............................................................................162 Section 4 - Compressed Air System.............................................................169 Air Compressor Carbon Buildup - Checking ................................................173 Air Compressor Gasket Leaks - Checking ..................................................175 Air Compressor - Replacement .............................................................178 Inspection ...........................................................................180 Installation .........................................................................180 Removal...............................................................................179 Air Governor and Compressor Valve - Checking.............................................175 Air Governor - Checking ..................................................................176 Compressed Air System Flow Diagrams ......................................................172 Compressed Air System General Information ...............................................170 Compressed Air System Specifications .....................................................171 Section 5 - Fuel System.......................................................................183 AFC Tube - Replacement ...................................................................208 Installation .........................................................................208 Removal ..............................................................................208 Fuel Drain Manifold - Replacement .......................................................204 Removal and Installation .............................................................204 Fuel Filter Head Adapter - Replacement ..................................................201 Removal and Installation .............................................................201 Fuel Injection Pump - Replacement.........................................................208 Installation .........................................................................210 Removal ..............................................................................208 Fuel Shutoff Solenoid - Replacement ......................................................206 RQVK Governor Fuel Shutoff Solenoid - Removal and Installation ......................207 RSV Governor Fuel Shutoff Solenoid - Installation ...................................207 RSV Governor Fuel Shutoff Solenoid - Removal .........................................206 Fuel System Components and Flow ..........................................................184 Fuel System Diagnosing - Malfunctions ....................................................187 Air Fuel Control (AFC) Malfunctions ..................................................194 Air in the Fuel System ...............................................................191 Electrical Shut Down Devices .........................................................196 Fuel Control Lever Travel and Adjustment .............................................195 Fuel Drain Manifold ..................................................................200 Fuel Injection Pump ..................................................................194 Fuel Injection Pump Idle Adjustment Screws ...........................................195 Fuel Injection Pump Timing ...........................................................197 Fuel Transfer Pump ...................................................................187 Fuel Water Separator/Filter Unit .....................................................193 Governor Malfunctions ................................................................194 High Pressure Fuel Lines..............................................................198 Injectors ............................................................................199 Manual Shut Down Levers ..............................................................195 Fuel System - Service Tools ..............................................................186 Fuel System Specifications ...............................................................185 Fuel Transfer Pump - Replacement .........................................................202 Cleaning .............................................................................202 Installation .........................................................................202 Removal ..............................................................................202 High Pressure Fuel Lines - Replacement ..................................................203 Installation .........................................................................203 Removal ..............................................................................203 Idle Speed - Adjustment ..................................................................214 Bosch RQVK Governor...................................................................215 Bosch RSV Governor ...................................................................214 Injector - Replacement....................................................................204 Cleaning and Inspection ..............................................................205 Installation .........................................................................205 Removal ..............................................................................204 Low Pressure Fuel Line - Replacement ....................................................201 Removal and Installation .............................................................201 Section 6 - Electrical System.................................................................217 Alternator - Replacement..................................................................235 Installation..........................................................................236 Removal...............................................................................235 Coolant Temperature Sensor - Replacement..................................................236 Installation .........................................................................237 Removal ..............................................................................237 Electrical System Description and Operation ..............................................218 Bosch K1 Model Alternator (Wiring Diagram) ...........................................221 Cranking Motor and Electrical Circuits ...............................................218 Delco Remy Model 15S1 116 Alternator Wiring Diagram ..................................221 Delco Remy Model 37MT Starting Motor .................................................219 Delco Remy Model 42MT Starting Motor .................................................219 Nippendenso Model F2 Basic Cranking Current Flow .....................................220 Nippendenso Model F2 Starting Motor ..................................................220 Electrical System - Diagnosing Malfunctions..............................................223 Alternator ...........................................................................230 Batteries - Checking .................................................................223 Coolant or Pan Heaters - Checking ....................................................234 Engine Cranking Speed Too Slow .......................................................229 Oil Pressure Switch and Temperature Sensor - Checking ...............................233 Starting Circuit - Checking ..........................................................224 Starting Motor Solenoid and Starting Motor Checking .................................227 Electrical System - Service Tools ........................................................222 Engine Block and Coolant Heater (750 and 500 Wats) - Replacement ........................237 Installation .........................................................................238 Removal ..............................................................................238 Lubricating Oil Pan Heater - Replacement .................................................238 Installation .........................................................................239 Removal ..............................................................................239 Lubricating Oil Pressure Switch - Replacement ...........................................239 Installation .........................................................................239 Removal ..............................................................................239 Starting Motor - Replacement .............................................................234 Removal and Installation .............................................................235 Section 7 - Base Engine Components............................................................241 Base Engine Components - General Information ............................................248 Base Engine Components - Service Tools ...................................................244 Camshaft Gear - Replacement...............................................................379 Cleaning and Inspection ..............................................................379 Installation .........................................................................381 Removal ..............................................................................379 Camshaft - Replacement ...................................................................367 Cleaning and Inspection ..............................................................372 Installation..........................................................................376 Removal ..............................................................................369 Connecting Rod Bearings - Replacement ....................................................298 Cleaning and Inspection ..............................................................300 Installation .........................................................................303 Removal ..............................................................................299 Connecting Rods - Replacement ...........................................................322 Cleaning and Inspection ..............................................................324 Installation .........................................................................326 Removal ..............................................................................323 Crankcase Breather Tube - Replacement ...................................................252 Cleaning and Inspection ..............................................................252 Installation .........................................................................253 Removal ..............................................................................252 Crankshaft Gear - Replacement ............................................................391 Cleaning and Inspection ..............................................................394 Installation .........................................................................395 Removal...............................................................................392 Cup Plug - Replacement ...................................................................423 Cleaning and Inspection ..............................................................424 Installation .........................................................................424 Removal ..............................................................................423 Cylinder Head Pressure Test ..............................................................286 Cylinder Head - Replacement ..............................................................269 Cylinder Block/Head Deck Cleaning and Inspection .....................................273 Cylinder Head - Cleaning and Inspection ..............................................276 Installation .........................................................................281 Removal...............................................................................272 Cylinder Liners - Replacement ............................................................328 Cleaning and Inspection ..............................................................332 Installation .........................................................................335 Removal ..............................................................................328 Engine Compression - Checking ............................................................248 Compression Gauge and Adapter .......................................................248 Cylinder Head Gasket Sealing .........................................................249 Intake and Exhaust Valve Sealing .....................................................249 Piston Ring Sealing ..................................................................249 Engine Dataplate - Replacement ...........................................................366 Installation .........................................................................366 Removal ..............................................................................366 Flywheel Housing - Replacement ..........................................................405 Cleaning and Inspection ..............................................................407 Concentricity - Checking .............................................................409 Installation (Dry Clutch Application) ................................................408 Installation (Wet Clutch Application) ................................................411 Removal ..............................................................................405 Flywheel - Replacement ..................................................................398 Cleaning and Inspection ..............................................................399 Flywheel Bore Runout Measurement .....................................................402 Flywheel Face Runout Measurement .....................................................403 Installation .........................................................................400 Removal ..............................................................................398 Flywheel Ring Gear - Replacement .........................................................405 Installation .........................................................................405 Removal ..............................................................................405 Gear Cover - Replacement .................................................................347 Cleaning and Inspection ..............................................................348 Installation..........................................................................349 Removal...............................................................................347 Gear Housing - Replacement ...............................................................356 Cleaning and Inspection ..............................................................358 Installation .........................................................................360 Removal...............................................................................357 Main and Thrust Bearings - Replacement ..................................................287 Cleaning and Inspection...............................................................291 General Information ..................................................................287 Installation..........................................................................293 Removal ..............................................................................289 Pipe Plug - Replacement ..................................................................422 Cleaning and Inspection ..............................................................422 Installation .........................................................................423 Removal ..............................................................................422 Pistons and Rings - Replacement...........................................................305 Cleaning and Inspection ..............................................................310 Installation .........................................................................315 Piston - General Information..........................................................305 Removal ..............................................................................307 Push Rod - Replacement ...................................................................266 Cleaning and Inspection ..............................................................267 Installation .........................................................................268 Removal...............................................................................266 Rocker Lever Diagnosing - Malfunctions ...................................................253 Rocker Lever - Replacement................................................................254 Cleaning and Inspection...............................................................256 Disassembly...........................................................................255 Installation..........................................................................258 Removal...............................................................................254 Seal, Front Crankshaft - Replacement .....................................................351 General Information ..................................................................351 Removal and Installation .............................................................352 Seal, Rear Crankshaft - Replacement .....................................................413 Cleaning and Inspection ..............................................................414 Installation .........................................................................415 Removal ..............................................................................413 Timing Pin Assembly - Installation .......................................................262 Valve Cover - Replacement ................................................................250 Cleaning and Inspection ..............................................................251 Installation .........................................................................251 Removal ..............................................................................250 Valve Lash - Adjustment ..................................................................259 Valve Arrangement ....................................................................261 Valve Tappet - Replacement ...............................................................382 Cleaning and Inspection ..............................................................386 Installation .........................................................................387 Removal...............................................................................383 Vibration Damper - Replacement ...........................................................342 General Information ..................................................................342 Installation .........................................................................346 Removal ..............................................................................345 Rubber Element Vibration Damper - Inspection (In-Chassis).............................342 Viscous Vibration Damper - Inspection ................................................344 Wear Sleeve, Front Crankshaft - Replacement ..............................................352 Cleaning and Inspection ..............................................................353 Installation .........................................................................353 Removal ..............................................................................352 Wear Sleeve, Rear Crankshaft Seal - Replacement .........................................416 Cleaning and Inspection ..............................................................418 Installation .........................................................................419 Removal ..............................................................................416 Section 8 - Engine Testing....................................................................427 Blowby Measurement .......................................................................430 Engine Run-In Procedure ..................................................................435 Engine Testing - General Information .....................................................428 Engine Testing - General Specifications ..................................................429 Engine Testing - Service Tools ...........................................................431 General Engine Test Procedures............................................................432 General Information ..................................................................432 Section 9 - Engine Removal and Installation...................................................437 Section V - Engine Component Specifications...................................................439 Capscrew Markings and Torque Values ......................................................470 Capscrew Markings and Torque Values - Metric .........................................471 Capscrew Markings and Torque Values - U.S. Customary .................................471 Component Specifications and Torque Values ..............................................441 Base Engine Component Specifications .................................................452 Base Engine Torque Values ............................................................463 Combustion Air System Specifications .................................................445 Combustion Air System Torque Values ..................................................445 Compressed Air System Torque Values ..................................................446 Cooling System Specifications.........................................................441 Cooling System Torque Values .........................................................441 Electrical System Specifications .....................................................451 Electrical System Torque Values ......................................................451 Fuel System Specifications ...........................................................447 Fuel System Torque Values ............................................................448 Lubricating Oil System Specifications ................................................442 Lubricating Oil System Torque Values .................................................443 Drive Belt Tension .......................................................................466 Newton-Meter to Foot-Pound Conversion Chart ..............................................469 Pipe Plug Torque Values ..................................................................472 Specifications - General Information .....................................................440 Tap-Drill - U.S. > Customary & Metric ....................................................473 Weight and Measures - Conversion Factors .................................................468 Section L - Service Literature................................................................475 Index.........................................................................................478
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
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