Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

Description

Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

Language : English
Pages :978
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

• Foreword
• This manual contains complete rebuild specifications and information for the 60114E-1 Series
  engines.
• The repair procedures in this manual are based on the engine being installed on an approved engine
  stand. Some rebuild procedures require the use of special service tools. Make sure the correct
  tools are used as described in the procedures.
• When a specific brand name, number, or special tool is referenced in this manual, an
  equivalent product can be used in place of the recommended item.
• 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 the
  front of this book.
• The specifications and rebuild information in this manual is based on the information in
  effect at the time of printing. Komatsu America International Company 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 Komatsu Distributor.
• The latest technology and the highest quality components are used to manufacture Komatsu engines.When replacement parts are needed, we recommend using only genuine Komatsu exchange parts.

TABLE OF CONTENTS:

Komatsu 114 Series Diesel Engine Shop Manual SEBM020400 – PDF DOWNLOAD

COVER 1
PRODUCT PUBLICATIONS INFORMATION 3
FOREWORD 5
ENGINE-EXPLODED VIEW BY GROUPS 6
TABLE OF CONTENTS 7
INTRODUCTION 8
ABOUT THE MANUAL 9
HOW TO USE THIS MANUAL 10
TABLE OF CONTENTS 10
GROUP CONTENTS 10
INDEX 10
METRIC INFORMATION 10
GENERIC SYMBOLS 11
ILLUSTRATIONS 12
GENERAL SAFETY INSTRUCTIONS 13
GENERAL REPAIR INSTRUCTIONS 14
GENERAL CLEANING INSTRUCTIONS 15
SOLVENT AND ACID CLEANING 15
STEAM CLEANING 15
GLASS OR PLASTIC BEAD CLEANING 15
GLOSSARY OF TERMS 16
ENGINE AND COMPONENT IDENTIFICATION 18
ENGINE IDENTIFICATION 19
ENGINE DATAPLATES 19
FUEL INJECTION PUMP DATAPLATE 20
GENERAL ENGINE SPECIFICATIONS 21
GENERAL ENGINE DATA 21
LUBRICATION SYSTEM 21
COOLING SYSTEM 22
INTAKE AIR AND EXHAUST SYSTEM 22
FUEL SYSTEM 22
ENGINE DIAGRAMS 23
ENGINE DISASSEMBLY AND ASSEMBLY-GROUP 00 26
ENGINE DISASSEMBLY AND ASSEMBLY-SERVICE TOOLS 29
GENERAL INFORMATION 33
DISASSEMBLY 33
ASSEMBLY 33
ENGINE LIFTING EQUIPMENT AND BRACKETS 34
ENGINE-PREPARATION FOR STEAM CLEANING 34
ENGINE-STEAM CLEANING 34
LUBRICATING OIL-DRAINING 35
COOLANT-DRAINING 35
COOLANT FILTER-REMOVAL 35
LUBRICATING OIL FILTER-REMOVAL 35
FUEL FILTER-REMOVAL 36
FUEL FILTER HEAD-REMOVAL 36
FUEL LINES,LOW PRESSURE-REMOVAL 36
FUEL TRANSFER PUMP-REMOVAL 36
FUEL LINES,HIGH PRESSURE-REMOVAL 37
FUEL INJECTION PUMP SUPPLY LINE-REMOVAL 37
AFC TUBE-REMOVAL 37
TACHOMETER DRIVE-REMOVAL 38
FUEL INJECTION PUMP-REMOVAL 38
AIR COMPRESSOR-REMOVAL 39
FUEL PUMP SOLENOID-REMOVAL 40
ENGINE-INSTALLATION ONTO ENGINE REBUILD STAND 40
TURBOCHARGER EXHAUST OUTLET CONNECTION-REMOVAL 41
WASTEGATE ACTUATOR HOSE-REMOVAL 41
CRANKCASE BREATHER TUBE-REMOVAL 41
AIR CROSSOVER TUBE-REMOVAL 42
INTAKE MANIFOLD COVER-REMOVAL 42
AFTERCOOLER-REMOVAL 42
FUEL DRAIN MANIFOLD-REMOVAL 43
INJECTOR-REMOVAL 43
VALVE COVER-REMOVAL 43
ROCKER LEVER ASSEMBLY-REMOVAL 44
PUSH ROD-REMOVAL 44
TURBOCHARGER OIL SUPPLY HOSE-REMOVAL 45
TURBOCHARGER OIL DRAIN TUBE-REMOVAL 45
TURBOCHARGER-REMOVAL 45
EXHAUST MANIFOLD-REMOVAL 45
DRIVE BELT-REMOVAL 46
BELT TENSIONER-REMOVAL 46
BELT TENSIONER BRACKET-REMOVAL 46
ALTERNATOR BRACE-REMOVAL 46
ALTERNATOR-REMOVAL 47
ALTERNATOR MOUNTING BRACKET-REMOVAL 47
COOLANT OUTLET CONNECTION-REMOVAL 47
THERMOSTAT AND HOUSING-REMOVAL 47
COOLANT VENT TUBE-REMOVAL 48
COOLANT VENT PETCOCK-REMOVAL 48
COOLANT VENT TUBE FITTING-REMOVAL 48
CYLINDER HEAD-REMOVAL 48
LUBRICATING OIL COOLER-REMOVAL 49
COOLANT INLET CONNECTION-REMOVAL 49
FAN HUB ASSEMBLY-REMOVAL 49
WATER PUMP-REMOVAL 50
VIBRATION DAMPER-REMOVAL 50
GEAR COVER-REMOVAL 51
SEAL,FRONT CRANKSHAFT-REMOVAL 51
STARTING MOTOR-REMOVAL 51
COOLANT HEATER-REMOVAL 51
FLYWHEEL-REMOVAL 52
FLYWHEEL HOUSING-REMOVAL 52
LUBRICATING OIL PAN-REMOVAL 52
LUBRICATING OIL SUCTION TUBE-REMOVAL 52
SEAL,REAR CRANKSHAFT-REMOVAL 53
CAMSHAFT-REMOVAL 53
VALVE TAPPET-REMOVAL 54
LUBRICATING OIL PUMP GEAR BACKLASH-MEASUREMENT 55
LUBRICATING OIL PUMP-REMOVAL 56
ENGINE SUPPORT,FRONT-REMOVAL 56
GEAR HOUSING-REMOVAL 56
CYLINDER LINER CARBON DEPOSITS-REMOVAL 57
PISTON ASSEMBLY-REMOVAL 58
PISTON PIN-REMOVAL 59
PISTON RING-REMOVAL 60
MAIN BEARING CAP-REMOVAL 60
MAIN BEARING(LOWER)-REMOVAL 61
CRANKSHAFT-REMOVAL 61
MAIN BEARING(UPPER)-REMOVAL 61
PISTON COOLING NOZZLE-REMOVAL 61
CYLINDER LINER PROTRUSION-CHECKING 62
CYLINDER LINER-REMOVAL 62
EXPANSION PLUG-REPLACEMENT 63
EXPANSION PLUG-REMOVAL 64
CYLINDER BLOCK-REMOVAL FROM ENGINE REBUILD STAND 64
ENGINE-ASSEMBLY 64
CYLINDER LINER-INSTALLATION 65
VALVE TAPPET-INSTALLATION 69
PISTON COOLING NOZZLE-INSTALLATION 70
MAIN BEARING(UPPER)-INSTALLATION 71
CRANKSHAFT-INSTALLATION 72
MAIN BEARING(LOWER)-INSTALLATION 73
MAIN BEARING CAP-INSTALLATION 73
SEAL,REAR CRANKSHAFT-INSTALLATION 77
WEAR SLEEVE,REAR CRANKSHAFT SEAL-INSTALLATION 78
CONNECTING ROD BOLT-INSTALLATION 81
PISTON PIN-INSTALLATION 81
PISTON RING END GAP-MEASUREMENT 82
PISTON RING-INSTALLATION 83
PISTON ASSEMBLY-INSTALLATION 85
GEAR HOUSING-INSTALLATION 89
LUBRICATING OIL PUMP-INSTALLATION 91
CAMSHAFT-INSTALLATION 92
WATER PUMP-INSTALLATION 94
LUBRICATING OIL SUCTION TUBE-INSTALLATION 95
LUBRICATING OIL PAN-INSTALLATION 95
TIMING PIN ASSEMBLY-INSTALLATION 96
FLYWHEEL HOUSING-INSTALLATION 99
FLYWHEEL-INSTALLATION104
FLYWHEEL BORE RUNOUT MEASUREMENT106
FLYWHEEL FACE RUNOUT MEASUREMENT108
STARTING MOTOR-INSTALLATION109
COOLANT HEATER-INSTALLATION109
LUBRICATING OIL COOLER-INSTALLATION111
LUBRICATING OIL FILTER-INSTALLATION112
CYLINDER HEAD-INSTALLATION112
PUSH ROD-INSTALLATION116
ROCKER LEVER AND SHAFT-ASSEMBLY116
ROCKER LEVER ASSEMBLY-INSTALLATION118
VALVE CLEARANCE-ADJUSTMENT119
VALVE ARRANGEMENT120
VALVE COVER-INSTALLATION121
INJECTOR-INSTALLATION122
FUEL DRAIN MANIFOLD-INSTALLATION123
ENGINE LIFTING BRACKET-INSTALLATION123
INTAKE MANIFOLD COVER-INSTALATION123
AFTERCOOLER-INSTALLATION124
EXHAUST MANIFOLD-INSTALLATION124
TURBOCHARGER-INSTALLATION125
TURBOCHARGER OIL DRAIN TUBE-INSTALLATION126
TURBOCHARGER OIL SUPPLY HOSE-INSTALLATION128
TURBOCHARGER EXHAUST OUTLET CONNECTION-INNSTALLATION129
AIR CROSSOVER TUBE-INSTALLATION129
THERMOSTAT AND HOUSING-INSTALLATION129
COOLANT OUTLET CONNECTION-INSTALLATION130
COOLANT FILTER-INSTALLATION130
COOLANT VENT FITTING-INSTALLATION130
COOLANT VENT PETCOCK-INSTALLATION130
COOLANT VENT TUBE-INSTALLATION131
COOLANT INLET CONNECTION-INSTALLATION131
ALTERNATOR MOUNTING BRACKET-INSTALLATION131
ALTERNATOR-INSTALLATION131
ALTERNATOR BRACE-INSTALLATION132
BELT TENSIONER BRACKET-INSTALLATION133
BELT TENSIONER-INSTALLATION133
FAN HUB ASSEMBLY-INSTALLATION134
FUEL INJECTION PUMP-INSTALLATION134
FUEL INJECTION PUMP SUPPLY LINE-INSTALLATION138
FUEL FILTER HEAD-INSTALLATION139
FUEL FILTER-INSTALLATION139
FUEL LINES,HIGH PRESSURE-INSTALLATION140
AFC TUBE-INSTALLATION140
SEAL,FRONT CRANKSHAFT-INSTALLATION141
GEAR COVER-INSTALLATION144
TACHOMETER DRIVE-INSTALLATION145
VIBRATION DAMPER-INSTALLATION145
DRIVE BELT-INSTALLATION146
ENGINE SUPPORT,FRONT-INSTALLATION146
FUEL TRANSFER PUMP-INSTALLATION146
FUEL LINES,LOW PRESSURE-INSTALLATION147
FUEL PUMP SOLENOLD-INSTALLATION147
AIR COMPRESSOR-INSTALLATION147
ENGINE ACCESSORIES-INSTALLATION149
CYLINDER BLOCK-GROUP 01150
CYLINDER BLOCK-SERVICE TOOLS152
CYLINDER BLOCK-EXPLODED VIEW155
CYLINDER BLOCK-GENERAL INFORMATION157
CAMSHAFT157
CRANKSHAFT157
CYLINDER BLOCK157
CYLINDER LINER157
OIL SEALS157
PISTONS157
VIBRATION DAMPER157
CONNECTING RODS157
CYLINDER BLOCK-PREPARATION FOR CLEANING158
CYLINDER BLOCK-DISASSEMBLY158
DOWEL PINS(CYLINDER HEAD)-REMOVAL159
CYLINDER BLOCK-CLEANING WITH SOLVENT160
CYLINDER BLOCK-CLEANING IN A HOT TANK163
CYLINDER BLOCK-INSPECTION FOR REUSE164
EXPANSION PLUG-INSTALLATION167
PIPE PLUG-INSTALLATION168
CAMSHAFT BORE EXPANSION PLUG INSTALLATION169
CAMSHAFT BUSHING-REMOVAL170
CAMSHAFT BUSHING BORE-CLEANING171
CAMSHAFT BUSHING-INSTALLATION171
CYLINDER LINERS-CLEANING AND INSPECTION FOR REUSE172
CYLINDER LINERS-CLEANING172
CYLINDER LINERS-INSPECTION173
PISTONS-CLEANING AND INSPECTION FOR REUSE175
PISTON RINGS-REMOVAL175
PISTONS-CLEANING175
PISTON-INSPECTION176
CRANKSHAFT-CLEANING AND INSPECTION FOR REUSE178
CRANKSHAFT-CLEANING178
CRANKSHAFT-INSPECTION179
CRANKSHAFT GEAR-REPLACEMENT182
GENERAL INFORMATION182
CRANKSHAFT GEAR-REMOVAL182
CRANKSHAFT GEAR-INSPECTION183
CRANKSHAFT GEAR-INSTALLATION184
MAIN BEARINGS-CLEANING AND INSPECTION FOR REUSE185
GENERAL INFORMATION185
MAIN BEARINGS-CLEANING186
MAIN BEARINGS-INSPECTION186
THRUST BEARINGS-INSPECTION187
MAIN BEARING CAPS AND CAPSCREWS-CLEANING AND INSPECTION FOR REUSE187
CLEANING187
INSPECTION188
CONNECTING ROD BEARINGS-CLEANING AND INSPECTION FOR REUSE188
CONNECTING ROD BEARINGS-CLEANING188
CONNECTING ROD BEARINGS-INSPECTION188
CONNECTING RODS-CLEANING AND INSPECTION FOR REUSE189
CONNECTING RODS-CLEANING189
CONNECTING RODS-INSPECTION190
CONNECTING RODS-BEND AND TWIST INSPECTION192
FIXTURE CALIBRATION192
CONNECTING ROD ALIGNMENT-INSPECTION193
CONNECTING ROD TWIST-INSPECTION193
CONNECTING ROD BUSHING-REPLACEMENT194
REMOVAL194
INSTALLATION196
MACHINING198
INSPECTION198
CAMSHAFT-CLEANING AND INSPECTION FOR REUSE199
CAMSHAFT-CLEANING199
CAMSHAFT-INSPECTION199
CAMSHAFT GEAR-INSPECTION202
CAMSHAFT GEAR-REPLACEMENT203
CAMSHAFT GEAR-REMOVAL203
CAMSHAFT GEAR-CLEANING203
CAMSHAFT GEAR-INSPECTION203
CAMSHAFT GEAR-INSTALLATION205
GEAR HOUSING-CLEANING AND INSPECTION FOR REUSE206
GEAR HOUSING-CLEANING206
GEAR HOUSING-INSPECTION206
ENGINE DATAPLATE-REPLACEMENT208
ENGINE DATAPLATE-REMOVAL208
ENGINE DATAPLATE-INSTALLATION208
GEAR COVER-CLEANING AND INSPECTION FOR REUSE209
GEAR COVER-CLEANING209
GEAR COVER-INSPECTION209
VIBRATION DAMPER-CLEANING AND CHECKING FOR REUSE210
GENERAL INFORMATION210
RUBBER VIBRATION DAMPER-CLEANING210
RUBBER ELEMENT VIBRATION DAMPER-INSPECTION210
VISCOUS VIBRATION DAMPER-CLEANING211
VISCOUS VIBRATION DAMPER-INSPECTION211
REAR COVER-CLEANING AND INSPECTION212
CLEANING212
INSPECTION213
CYLINDER HEAD CAPSCREWS-CLEANING AND INSPECTION FOR REUSE213
CLEANING213
INSPECTION214
FREE LENGTH-MEASUREMENT215
ENGINE LIFTING BRACKETS-CLEANING AND INSPECTION FOR REUSE215
CYLINDER HEAD-GROUP 02216
CYLINDER HEAD-SERVICE TOOLS217
CYLINDER HEAD-EXPLODED VIEW221
CYLINDER HEAD-GENERAL INFORMATION223
CYLINDER HEAD-CLEANING AND INSPECTION FOR REUSE224
HANDLING224
CLEANING224
INSPECTION225
CYLINDER HEAD-REBUILD226
DISASSEMBLY226
CLEANING227
INSPECTION228
VALVE GUIDE-INSPECTION232
VALVE SEAT INSERT-INSPECTION233
VALVE SPRING-INSPECTION234
VALVE STEM SEAL-INSPECTION235
VALVE-INSPECTION236
VALVE-GRINDING237
VALVE SEAT INSERT-GRINDING238
ASSEMBLY242
CYLINDER HEAD-VALVE GUIDE REPLACEMENT244
DISASSEMBLY244
INSPECTION245
ASSEMBLY245
CYLINDER HEAD-VALVE SEAT INSERT REPLACEMENT247
REMOVAL247
INSPECTION249
INSTALLATION249
CYLINDER HEAD-PRESSURE TESTING250
CYLINDER HEAD-VACUUM TESTING VALVE SEATING252
CYLINDER HEAD CAPSCREW-CLEANING AND INSPECTION253
CLEANING254
INSPECTION254
FREE LENGTH-MEASUREMENT255
ROCKER LEVERS-GROUP 03256
ROCKER LEVER ASSEMBLY-EXPLODED VIEW257
ROCKER LEVER ASSEMBLY-GENERAL INFORMATION258
ROCKER LEVER ASSEMBLY-CLEANING AND INSPECTION259
DISASSEMBLY259
CLEANING260
INSPECTION260
ASSEMBLY261
ROCKER ASSEMBLY OIL MANIFOLD-CLEANING AND INSPECTION FOR REUSE262
CLEANING262
INSPECTION262
VALVE COVER-CLEANING AND INSPECTION FOR REUSE263
CLEANING263
INSPECTION263
CRANKCASE BREATHER TUBE-CLEANING AND INSPECTION FOR REUSE263
CLEANING AND INSPECTION263
VALVE TAPPETS AND PUSH RODS-GROUP 04264
VALVE TAPPETS AND PUSH RODS-EXPLODED VIEW265
VALVE TAPPETS AND PUSH RODS-GENERAL INFORMATION266
VALVE TAPPET CLEANING AND INSPECTION FOR REUSE266
CLEANING266
INSPECTION266
PUSH RODS-CLEANING AND INSPECTION FOR REUSE267
CLEANING267
INSPECTION267
FUEL SYSTEMS-GROUP 05269
FUEL SYSTEM-GENERAL INFORMATION270
FUEL INJECTION PUMP270
FUEL INJECTION PUMP-DATA TAG LOCATION270
FUEL INJECTION PUMP-DATA TAG INFORMATION270
GOVERNOR-DATA TAG INFORMATION 271
DERIVATIVE FUEL INJECTION PUMP-DATA TAG INFORMATION271
FUEL SHUTOFF SOLENOID-WIRING REQUIREMENTS271
FUEL TRANSFER PUMP-EXPLODED VIEW272
FUEL TRANSFER PUMP-REBUILD273
CLEANING273
ASSEMBLY273
RSV GOVERNOR FUEL SHUTOFF SOLENOID-ORIENTATION AND ADJUSTMENT274
FUEL SHUTOFF SOLENOID-ORIENTATION274
FUEL SHUTOFF SOLENOID-ADJUSTMENT276
RQVK GOVERNOR FUEL SHUTOFF SOLENOID-ADJUSTMENT277
SHUTDOWN LEVER OR SPRING-REPLACEMENT278
DIRECT LINK SHUTDOWN LEVER-REPLACEMENT279
FUEL INJECTION PUMP GASKETS AND SEALS-REPLACEMENT280
INJECTORS AND FUEL LINES-GROUP 06281
INJECTORS AND FUEL LINES-SERVICE TOOLS282
INJECTORS AND FUEL LINES-EXPLODED VIEW283
INJECTORS AND FUEL LINES-EXPLODED VIEW285
INJECTORS AND FUEL LINES-EXPLODED VIEW286
INJECTORS AND FUEL LINES-GENERAL INFORMATION287
INJECTORS-CLEANING AND INSPECTION FOR REUSE288
GENERAL INFORMATION288
INJECTOR-DISASSEMBLY288
INJECTOR-CLEANING AND INSPECTION290
INJECTOR-ASSEMBLY292
INJECTOR-SPRAY TESTING293
INJECTOR-CHATTER TESTING294
FUEL LINES,HIGH PRESSURE-CLEANING AND INSPECTION FOR REUSE294
GENERAL INFORMATION294
FUEL LINES-CLEANING AND INSPECTION295
FUEL DRAIN MANIFOLD-INSPECTION296
FUEL LINES,LOW PRESSURE-CLEANING AND INSPECTION FOR REUSE296
LUBRICATING OIL SYSTEM-GROUP 07298
LUBRICATING OIL SYSTEM-SERVICE TOOLS299
LUBRICATING OIL SYSTEM-GENERAL INFORMATION300
LUBRICATING OIL COOLER AND FILTER HEAD300
OIL PRESSURE REGULATOR300
OIL FILTER HEAD300
OIL TEMPERATURE THERMOSTAT300
LUBRICATING OIL PUMP300
DIPSTICK300
OIL PAN300
LUBRICATING OIL SYSTEM-EXPLODED VIEW301
LUBRICATING OIL PAN-CLEANING AND INSPECTION FOR REUSE302
CLEANING302
INSPECTION302
OIL COOLER ELEMENT-CLEANING AND INSPECTION FOR REUSE303
CLEANING303
INSPECTION303
PRESSURE TEST303
OIL PRESSURE REGULATING VALVE-CLEANING AND INSPECTION304
DISASSEMBLY304
CLEANING305
INSPECTION305
ASSEMBLY305
OIL FILTER BYPASS VALVE-REPLACEMENT306
OIL COOLER COVER-DISASSEMBLY AND ASSEMBLY307
DISASSEMBLY307
CLEANING307
ASSEMBLY308
LUBRICATING OIL TEMPERATURE THERMOSTAT-CLEANING AND INSPECTION309
CLEANING309
INSPECTION309
LUBRICATING OIL DIPSTICK-CALIBRATION310
LUBRICATING OIL PUMP-CLEANING AND INSPECTION FOR REUSE311
DISASSEMBLY311
CLEANING312
INSPECTION312
COOLING SYSTEM-GROUP 08315
COOLING SYSTEM-SERVICE TOOLS316
COOLING SYSTEM COMPONENTS-EXPLODED VIEW317
COOLING SYSTEM-GENERAL INFORMATION318
WATER PUMP318
THERMOSTATS318
PRESSURE CAPS318
FAN HUB318
BELT TENSIONER318
COOLING FANS318
WATER PUMP ASSEMBLY-CLEANING AND INSPECTION FOR REUSE320
CLEANING320
INSPECTION320
THERMOSTAT HOUSING-CLEANING AND INSPECTION FOR REUSE321
CLEANING321
INSPECTION321
THERMOSTAT-INSPECTION321
WATER OUTLET CONNECTION-CLEANING AND INSPECTION FOR REUSE322
FAN HUB-CLEANING AND INSPECTION FOR REUSE322
CLEANING322
INSPECTION323
FAN HUB-REBUILD323
DISASSEMBLY323
ASSEMBLY324
BELT TENSIONER INSPECTION325
COOLANT FILTER SHUTOFF VALVE-CLEANING AND INSPECTION FOR REUSE325
DISASSEMBLY325
CLEANING326
ASSEMBLY326
FAN-CLEANING AND INSPECTION FOR REUSE327
DRIVE UNITS-GROUP 09328
DRIVE UNITS-SERVICE TOOLS329
ACCESSORY DRIVE ADAPTER-EXPLODED VIEW330
ACCESSORY DRIVE-GENERAL INFORMATION331
ACCESSORY DRIVE ADAPTER331
ACCESSORY DRIVE ADAPTER-CLEANING AND INSPECTION FOR REUSE332
CLEANING332
INSPECTION332
ACCESSORY DRIVE ADAPTER-REBUILD332
DISASSEMBLY332
ASSEMBLY333
AIR INTAKE SYSTEM-GROUP 10335
AIR INTAKE SYSTEM-SERVICE TOOLS336
AIR INTAKE SYSTEM-EXPLODED VIEW337
AIR INTAKE SYSTEM-GENERAL INFORMATION339
TURBOCHARGER-CLEANING AND INSPECTION FOR REUSE340
INSPECTION340
INTAKE MANIFOLD COVER-CLEANING AND INSPECTION FOR REUSE344
INSPECTION344
AFTERCOOLER ASSEMBLY-CLEANING AND INSPECTION FOR REUSE344
INSPECTION345
AFTERCOOLER ASSEMBLY-REBUILD345
AIR TRANSFER PIPE-CLEANING AND INSPECTION FOR REUSE346
CLEANING346
INSPECTION346
AIR CROSSOVER TUBE-CLEANING AND INSPECTION FOR REUSE346
CLEANING346
INSPECTION346
CHARGE AIR COOLER(CAC)-CLEANING AND INSPECTION FOR REUSE347
CLEANING347
INSPECTION347
CHARGE AIR COOLER(CAC)-PRESSURE TESTING348
EXHAUST SYSTEM-GROUP 11350
EXHAUST MANIFOLD-EXPLODED VIEW351
EXHAUST SYSTEM-GENERAL INFORMATION352
EXHAUST MANIFOLD352
EXHAUST MANIFOLD-CLEANING AND INSPECTION FOR REUSE353
CLEANING353
INSPECTION353
EXHAUST MANIFOLD TURBOCHARGER MOUNTING STUD-REPLACEMENT354
REMOVAL354
INSPECTION354
INSTALLATION354
EXHAUST MANIFOLD OUTLET CONNECTION-CLEANING AND INSPECTION FOR REUSE355
CLEANING355
INSPECTION355
AIR EQUIPMENT-GROUP 12356
ELECTRICAL EQUIPMENT-GROUP 13357
ENGINE TESTING-GROUP 14358
ENGINE TESTING-SERVICE TOOLS359
ENGINE TESTING-COMPONENT IDENTIFICATION AND DIAGRAMS360
ENGINE TESTING-GENERAL INFORMATION362
IN-CHASSIS RUN-IN362
ENGINE DYNAMOMETER RUN-IN362
ENGINE TESTING-GENERAL SPECIFICATIONS363
BLOWBY MEASUREMENT364
ENGINE RUN-IN-GENERAL PROCEDURES365
ENGINE DYNAMOMETER TEST-INSTALLATION OF THE ENGINE366
ENGINE DYNAMOMETER TEST-ENGINE RUN-IN374
ENGINE DYNAMOMETER TEST-PERFORMANCE CHECKING378
GENERAL ENGINE TEST PROCEDURE-IN CHASSIS380
ENGINE RUN-IN PROCEDURE-“IN-CHASSIS”385
FUEL INJECTION PUMP-IDLE SPEED ADJUSTMENT386
RSV GOVERNOR386
RQV AND RQVK GOVERNOR387
ENGINE PAINTING387
ENGINE STORAGE-SHORT TERM388
ENGINE REMOVAL FROM SHORT TERM STORAGE390
ENGINE STORAGE-LONG TERM390
ENGINE REMOVAL FROM TERM STORAGE393
INSTRUMENTS AND CONTROLS-GROUP 15397
MOUNTING ADAPTATIONS-GROUP 16398
MOUNTING ADAPTATIONS-SERVICE TOOLS399
MOUNTING ADAPTATIONS-EXPLODED VIEW400
MOUNTING ADAPTATIONS-GENERAL INFORMATION401
FLYWHEEL HOUSING401
FLYWHEEL AND RING GEAR401
FLYWHEEL-CLEANING AND INSPECTION FOR REUSE402
CLEANING402
INSPECTION402
FLEXPLATE ASSEMBLY-CLEANING AND INSPECTION FOR REUSE403
FLYWHEEL RING GEAR-REPLACEMENT403
REMOVAL403
INSTALLATION403
FLYWHEEL HOUSING-CLEANING AND INSPECTION FOR REUSE404
CLEANING404
INSPECTION404
FLYWHEEL HOUSING-ASSEMBLY(WET CLUTCH APPLICATION)405
ENGINE SUPPORT BRACKET,FRONT-CLEANING AND INSPECTION FOR REUSE406
CLEANING406
INSPECTION406
SPECIFICATIONS AND TORQUE VALUES-GROUP 18407
ENGINE COMPONENTS-GENERAL INFORMATION408
COMPONENT SPECIFICATIONS AND TORQUE VALUES409
ENGINE ASSEMBLY-SPECIFICATIONS409
ENGINE ASSEMBLY-TORQUE VALUES411
CYLINDER BLOCK-REBUILD SPECIFICATIONS421
CYLINDER BLOCK-TORQUE VALUES427
CYLINDER HEAD-REBUILD SPECIFICATIONS428
ROCKER LEVER ASSEMBLY-REBUILD SPECIFICATIONS432
VALVE TAPPET-REBUILD SPECIFICATIONS432
FUEL SYSTEMS-REBUILD SPECIFICATIONS432
FUEL SYSTEM SPECIFICATIONS432
FUEL SHUTOFF SOLENOID ADJUSTMENT434
FUEL SYSTEM TORQUE VALUES434
FUEL INJECTION PUMP SEALING WASHER434
LUBRICATING OIL SYSTEM SPECIFICATIONS437
LUBRICATING OIL SYSTEM TORQUE VALUES438
COOLING SYSTEM SPECIFICATIONS440
COOLING SYSTEM TORQUE VALUES441
AIR INTAKE SYSTEM SPECIFICATIONS442
AIR INTAKE SYSTEM TORQUE VALUES442
EXHAUST SYSTEM SPECIFICATIONS444
EXHAUST SYSTEM TORQUE VALUES444
AIR COMPRESSOR INSPECTION SPECIFICATIONS444
AIR COMPRESSOR TORQUE VALUES444
ELECTRICAL SYSTEM SPECIFICATIONS445
ELECTRICAL SYSTEM TORQUE VALUES445
ENGINE TESTING-TEST SPECIFICATIONS446
MOUNTING ADAPTATIONS SPECIFICATIONS446
FLYWHEEL HOUSING(WET APPLICATION)446
FLYWHEEL RING GEAR INSTALLATION447
MOUNTING ADAPTATIONS-TORQUE VALUES447
DRIVE BELT TENSION448
WEIGHT AND MEASURES-CONVERSION FACTORS450
NEWTON-METER TO FOOT-POUND CONVERSION CHART451
CAPSCREW MARKINGS AND TORQUE VALUES452
CAPSCREW MARKINGS AND TORQUE VALUES-METRIC453
CAPSCREW MARKINGS AND TORQUE VALUES-US CUSTOMARY453
PIPE PLUG TORQUE VALUES454
TAP-DRILL CHART-US CUSTOMARY & METRIC455
INDEX456
COVER460
CONTENTS461
PRODUCT PUBLICATIONS INFORMATION462
TROUBLESHOOTING AND REPAIR MANUAL464
FOREWORD465
TABLE OF CONTENTS466
INTRODUCTION467
ABOUT THE MANUAL468
HOW TO USE THIS MANUAL468
TABLE OF CONTENTS468
INDEX468
METRIC INFORMATION468
GENERIC SYMBOLS469
ILLUSTRATIONS470
GENERAL SAFETY INSTRUCTIONS471
GENERAL REPAIR INSTRUCTIONS472
GENERAL CLEANING INSTRUCTIONS473
SOLVENT AND ACID CLEANING473
STEAM CLEANING473
GLASS OR PLASTIC BEAD CLEANING473
GLOSSARY OF TERMS475
ENGINE AND COMPONENT IDENTIFICATION477
ENGINE IDENTIFICATION478
ENGINE DATAPLATES478
FUEL INJECTION PUMP DATAPLATE479
GENERAL ENGINE SPECIFICATIONS480
GENERAL ENGINE DATA480
LUBRICATION SYSTEM480
COOLING SYSTEM481
INTAKE AIR AND EXHAUST SYSTEM481
FUEL SYSTEM481
ELECTRICAL SYSTEM482
BATTERIES(SPECIFIC GRAVITY)482
ENGINE DIAGRAMS483
TROUBLESHOOTING LOGIC486
SECTION T-TROUBLESHOOTING487
PROCEDURES AND TECHNIQUES487
TROUBLESHOOTING SYMPTOMS CHARTS487
AIR COMPRESSOR OPERATES WITH EXCESSIVE NOISE488
AIR COMPRESSOR PUMPING EXCESSIVE LUBRICATING OIL INTO AIR SYSTEM489
AIR COMPRESSOR AIR PRESSURE RISES SLOWLY490
AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE(NOT PUMPING CONTINUOUSLY)491
AIR COMPRESSOR WILL NOT PUMP AIR PRESSURE492
AIR COMPRESSOR WILL NOT STOP PUMPING AIR493
ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING494
COMPRESSION KNOCK495
COOLANT CONTAMINATED496
COOLANT LOSS497
COOLANT TEMPERATURE ABOVE NORMAL-GRADUAL OVERHEAT499
COOLANT TEMPERATURE ABOVE NORMAL-SUDDEN OVERHEAT502
COOLANT TEMPERATURE BELOW NORMAL504
ENGINE CRANKCASE GASES(BLOWBY)-EXCESSIVE505
ENGINE CRANKS,BUT WILL NOT START-NO SMOKE FROM EXHAUST506
ENGINE DIFFICULT TO START OR WILL NOT START-EXHAUST SMOKE PRESENT509
ENGINE IDLE ROUGH,WARM ENGINE511
ENGINE MISFIRING513
ENGINE POWER OUTPUT LOW515
ENGINE NOISE EXCESSIVE519
ENGINE STARTS BUT WILL NOT KEEP RUNNING520
ENGINE SURGES AT IDLE521
ENGINE VIBRATION EXCESSIVE522
ENGINE WILL NOT CRANK OR CRANKS SLOWLY523
ENGINE WILL NOT REACH RATED SPEED WHEN LOADED524
ENGINE WILL NOT SHUT OFF526
EXHAUST BLACK SMOKE EXCESSIVE UNDER LOAD527
EXHAUST WHITE SMOKE EXCESSIVE(WARM ENGINE)529
FUEL CONSUMPTION EXCESSIVE530
FUEL OR OIL LEAKING FROM EXHAUST MANIFOLD531
LUBRICATING OIL CONTAMINATED532
LUBRICATING OIL CONSUMPTION EXCESSIVE533
LUBRICATING OIL PRESSURE LOW535
LUBRICATING OIL PRESSURE HIGH537
ENGINE NOISE DIAGNOSTIC PROCEDURES-GENERAL INFORMATION538
MAIN BEARING NOISE(REFER TO ENGINE NOISE EXCESSIVE-MAIN BEARING SYSTEM CHART)538
CONNECTING ROD BEARING NOISE(REFER TO ENGINE NOISE EXCESSIVE-CONNECTING ROD SYMPTOM CHART)538
PISTON NOISE(REFER TO ENGINE NOISE EXCESSIVE-PISTON SYMPTOM CHART)538
FUEL CONSUMPTION-GENERAL INFORMATION538
FUEL CONSUMPTION-INDUSTRIAL CUSTOMER COMPLAINT FORM539
OIL CONSUMPTION540
COOLING SYSTEM542
COOLING SYSTEM-GENERAL INFORMATION543
COOLING SYSTEM-FLOW DIAGRAMS544
COOLING SYSTEM-SPECIFICATIONS546
COOLING SYSTEM-SERVICE TOOLS547
COOLING SYSTEM-MAINTENANCE548
ANTIFREEZE548
ANTIFREEZE CONCENTRATION-CHECKING548
COOLING SYSTEM-DRAINING548
ADDITIVE CONCENTRATION-CHECKING548
COOLING SYSTEM-CLEANING549
FILLING AND VENTING553
COOLING SYSTEM-DIAGNOSING MALFUNCTIONS554
RADIATOR CAP-PRESSURE TEST555
COOLING SYSTEM-TEST FOR COMBUSTION GASES555
BELT TENSION559
COOLANT HOSE-INSPECTION560
WATER PUMP-INSPECTION560
WATER PUMP SEAL WEEP HOLE-INSPECTION560
COOLANT PRESSURE-MEASUREMENT562
RADIATOR,FAN AND SHUTTERS562
THERMOSTAT OPERATION AND TESTING564
THERMOSTAT LEAKAGE AND OPENING TEMPERATURE-TESTING”IN-CHASSIS”565
THERMOSTAT OPENING TEMPERATURE-TESTING”THERMOSTAT REMOVED”566
TEMPERATURE GAUGE OPERATION567
FUEL PUMP OVERFUELED567
VEHICLE OVERLOADED568
DRIVE BELT-REPLACEMENT568
BELT TENSIONER-REPLACEMENT568
REMOVAL568
INSTALLATION569
FAN PULLEY-REPLACEMENT569
REMOVAL AND INSTALLATION569
FAN HUB-REPLACEMENT569
REMOVAL AND INSTALLATION570
WATER PUMP-REPLACEMENT570
REMOVAL570
CLEANING571
INSTALLATION571
THERMOSTAT-REPLACEMENT573
REMOVAL573
CLEANING574
INSTALLATION574
LUBRICATING OIL SYSTEM577
LUBRICATING OIL SYSTEM-SERVICE TOOLS579
LUBRICATING OIL SYSTEM-GENERAL INFORMATION580
LUBRICATING OIL SYSTEM-SPECIFICATIONS581
LUBRICATING OIL SYSTEM-FLOW DIAGRAM582
LUBRICATING OIL LEAKS(EXTERNAL)-CHECKING586
INTERNAL ENGINE DAMAGE-CHECKING587
LUBRICATING OIL ANALYSIS587
LUBRICATING OIL FILTER INSPECTION587
LUBRICATING OIL SYSTEM-DIAGNOSING MALFUNTIONS588
HIGH OIL PRESSURE588
OIL PRESSURE REGULATION VALVE588
LOW OIL PRESSURE588
OIL LEVEL588
OIL FILTER589
OIL PRESSURE GAUGE-CHECKING589
OIL TEMPERATURE GAUGE-CHECKING590
OIL TEMPERATURE THERMOSTAT590
OIL SUCTION TUBE591
BEARINGS AND OIL PUMP591
OIL DILUTION591
COOLANT DILUTED OIL591
OIL COOLER592
AFTERCOOLER592
CYLINDER HEAD EXPANSION PLUGS593
CYLINDER LINER SEALS593
CYLINDER HEAD GASKET593
CRACKED CYLINDER HEAD593
CRACKED CYLINDER LINER594
CRACKED CYLINDER BLOCK594
FUEL DILUTED OIL594
FUEL TRANSFER PUMP595
FUEL LEAKING BY PISTON RINGS595
INJECTION PUMP596
OIL LEAKS596
LUBRICATING OIL PAN-DRAINING598
LUBRICATING OIL PAN-FILLING598
LUBRICATING OIL LEVEL-CHECKING599
LUBRICATING OIL FILTER-CHANGING600
LUBRICATING OIL DIPSTICK-CALIBRATION601
LUBRICATING OIL DIPSTICK TUBE-REPLACEMENT602
REMOVAL602
INSTALLATION602
LUBRICATING OIL PRESSURE REGULATOR,VALVE AND SPRING-REPLACEMENT603
REMOVAL603
CLEANING AND INSPECTION603
INSTALLATION604
LUBRICATING OIL COOLER ELEMENT AND GASKET-REPLACEMENT604
REMOVAL604
CLEANING AND INSPECTION605
INSTALLATION606
LUBRICATING OIL TEMPERATURE THERMOSTAT-REPLACEMENT607
REMOVAL607
INSPECTION608
INSTALLATION609
LUBRICATING OIL PAN,SUCTION TUBE AND GASKET-REPLACEMENT609
OIL PAN -REMOVAL609
CLEANING609
SUCTION TUBE-REPLACEMENT610
OIL PAN -INSTALLATION610
LUBRICATING OIL PUMP-REPLACEMENT612
REMOVAL613
CLEANING AND INSPECTION613
INSTALLATION616
COMBUSTION AIR SYSTEM620
COMBUSTION AIR SYSTEM FLOW-GENERAL INFORMATION622
AIR SYSTEM FLOW-DIAGRAMS623
INTAKE AIR AND EXHAUST SYSTEM SPECIFICATIONS624
TURBOCHARGER BOOST PRESSURE SPECIFICATIONS624
COMBUSTION AIR SYSTEM-SERVICE TOOLS625
COMBUSTION AIR SYSTEM-DIAGNOSING MALFUNCTIONS626
CLEAN AIR626
INTAKE AIR RESTRICTION-CHECKING626
DAMAGE FROM NON-FILTERED AIR627
TURBOCHARGED ENGINES-AIR LEAKS,PRESSURE SIDE627
TURBOCHARGED ENGINES-EXHAUST LEAKS628
TURBOCHARGED BOOST PRESSURE-MEASUREMENT628
MALFUNCTIONING TURBOCHARGER629
OIL CONSUMPTION AND LEAKS629
TURBOCHARGER NOISE630
ROTOR ASSEMBLY CLEARANCE-MEASUREMENT631
TURBOCHARGER WASTEGATE ACTUATOR-VISUAL INSPECTION632
TURBOCHARGER WASTEGATE ACTUATOR-FUNCTIONAL CHECKING633
TURBOCHARGER WASTEGATE ACTUATOR-REPLACEMENT634
AIR REGULATOR WITH PRESSURE GAUGE634
TURBOCHARGER WASTEGATE ACTUATOR-CALIBRATION636
EXHAUST RESTRICTION-MEASUREMENT637
CHARGE AIR COOLER(CAC)-TROUBLESHOOTING637
PRESSURE DROP-CHECKING637
CHECKING-AIR LEAK639
CHARGE AIR COOLER640
CLEANING AND INSPECTION640
AIR CROSSOVER TUBE-REPLACEMENT641
REMOVAL AND INSTALLATION641
INTAKE MANIFOLD COVER AND GASKET-REPLACEMENT642
REMOVAL642
CLEANING643
INSTALLATION643
AFTERCOOLER AND GASKET-REPLACEMENT643
REMOVAL644
CLEANING644
INSTALLATION644
TURBOCHARGER-REPLACEMENT645
REMOVAL645
CLEANING AND INSPECTION646
INSTALLATION647
EXHAUST MANIFOLD AND GASKETS-REPLACEMENT649
REMOVAL649
CLEANING AND INSPECTION650
INSTALLATION650
COMPRESSED AIR SYSTEM652
COMPRESSED AIR SYSTEM GENERAL INFORMATION653
COMPRESSED AIR SYSTEM SPECIFICATIONS654
COMPRESSED AIR SYSTEM FLOW DIAGRAMS655
AIR COMPRESSOR CARBON BUILDUP-CHECKING656
AIR COMPRESSOR GASKET LEAKS-CHECKING658
AIR GOVERNOR AND COMPRESSOR UNLOADER VALVE-CHECKING658
AIR GOVERNOR-CHECKING659
AIR COMPRESSOR-REPLACEMENT661
REMOVAL662
INSPECTION663
INSTALLATION663
FUEL SYSTEM666
FUEL SYSTEM COMPONENTS AND FLOW668
FUEL SYSTEM SPECIFICATIONS669
FUEL SYSTEM -SERVICE TOOLS670
FUEL SYSTEM DIAGNOSING-MALFUNCTIONS672
FUEL TRANSFER PUMP672
AIR IN THE FUEL SYSTEM676
FUEL WATER SEPARATOR/FILTER UNIT678
FUEL INJECTION PUMP679
GOVERNOR MALFUNCTIONS679
AIR FUEL CONTROL(AFC)MALFUNCTIONS679
FUEL CONTROL LEVER TRAVEL AND ADJUSTMENT680
FUEL INJECTION PUMP IDLE ADJUSTMENT SCREWS680
MANUAL SHUT DOWN LEVERS680
ELECTRICAL SHUT DOWN DEVICES681
FUEL INJECTION PUMP TIMING682
HIGH PRESSURE PUMP TIMING683
INJECTORS684
FUEL DRAIN MANIFOLD685
LOW PRESSURE FUEL LINE-REPLACEMENT686
REMOVAL AND INSTALLATION686
FUEL FILTER HEAD ADAPTER-REPLACEMENT686
REMOVAL AND INSTALLATION686
FUEL TRANSFER PUMP-REPLACEMENT/REBUILD687
REMOVAL687
REBUILD687
CLEANING688
ASSEMBLY688
CLEANING MOUNTING SURFACE689
INSTALLATION689
HIGH PRESSURE FUEL LINES-REPLACEMENT689
REMOVAL689
INSTALLATION690
FUEL DRAIN MANIFOLD-REPLACEMENT691
REMOVAL AND INSTALLATION691
INJECTOR-REPLACEMENT691
REMOVAL691
CLEANING AND INSPECTION691
INSTALLATION692
FUEL SHUTOFF SOLENOID-REPLACEMENT693
RSV GOVERNOR FUEL SHUTOFF SOLENOID-REMOVAL693
RSV GOVERNOR FUEL SHUTOFF SOLENOID-INSTALLATION694
DIRECT LINK SOLENOID,CYLINDER BLOCK MOUNTED694
RQVK GOVERNOR FUEL SHUTOFF SOLENOID-REMOVAL AND INSTALLATION694
FUEL RETURN OVERFLOW VALVE-REPLACEMENT695
AFC TUBE-REPLACEMENT696
REMOVAL696
INSTALLATION696
FUEL INJECTION PUMP-REPLACEMENT696
REMOVAL697
INSTALLATION698
IDLE SPEED-ADJUSTMENT703
BOSCH RSV GOVERNOR703
BOSCH RQVK GOVERNOR704
INLINE FUEL INJECTION PUMP SPILL-PORT TIMING704
GOVERNOR LEVER POSITIONING706
ELECTRICAL SYSTEM711
ELECTRICAL SYSTEM DESCRIPTION AND OPERATION712
CRANKING MOTOR AND ELECTRICAL CIRCUITS712
DELCO REMY MODEL 37MT/41MT STARTING MOTOR713
DELCO REMY MODEL 42MT STARTING MOTOR713
NIPPENDENSO MODEL F2 STARTING MOTOR714
NIPPENDENSO MODEL F2 BASIC CRANKING CURRENT FLOW714
DELCO REMY MODEL 15SI 116 ALTERNATOR(WIRING DIAGRAM)715
BOSCH K1 MODEL ALTERNATOR(WIRING DIAGRAM)715
NIPPONDENSO F4 STARTING MOTOR716
DELCO 42MT STARTING MOTOR716
ELECTRICAL SYSTEM-SPECIFICATIONS717
MINIMUM RECOMMENDED BATTERY CAPACITY717
MAXIMUM ALLOWABLE RESISTANCE OF STARTING CIRCUIT717
WIRING SIZE RECOMMENDATIONS FOR STARTER SOLENOID AND FUEL SOLENOID CIRCUIT718
ELECTRICAL SYSTEM-SERVICE TOOLS719
ELECTRICAL SYSTEM-DIAGNOSING MALFUNCTIONS720
BATTERIES-CHECKING720
STARTING CIRCUIT-CHECKING721
STARTING MOTOR SOLENOID AND STARTING MOTOR CHECKING724
ENGINE CRANKING SPEED TOO SLOW726
ALTERNATOR727
OIL PRESSURE SWITCH AND TEMPERATURE SENSOR-CHECKING730
COOLANT OR PAN HEATERS-CHECKING731
STARTING MOTOR-REPLACEMENT731
REMOVAL AND INSTALLATION732
ALTERNATOR-REPLACEMENT732
REMOVAL732
INSTALLATION733
COOLANT TEMPERATURE SENSOR-REPLACEMENT733
REMOVAL734
INSTALLATION734
ENGINE BLOCK AND COOLANT HEATER(750 AND 500 WATS)-REPLACEMENT734
REMOVAL735
INSTALLATION735
LUBRICATING OIL PAN HEATER-REPLACEMENT735
REMOVAL736
INSTALLATION736
LUBRICATING OIL PRESSURE SWITCH REPLACEMENT736
REMOVAL736
INSTALLATION736
BASE ENGINE COMPONENTS737
BASE ENGINE COMPONENTS-SERVICE TOOLS740
BASE ENGINE COMPONENTS-GENERAL INFORMATION745
ENGINE COMPRESSION-CHECKING745
COMPRESSION GUAGE AND ADAPTER745
PISTON RING SEALING746
INTAKE AND EXHAUST VALVE SEALING746
CYLINDER HEAD GASKET SEALING746
VALVE COVER-REPLACEMENT747
REMOVAL747
CLEANING AND INSPECTION748
INSTALLATION748
CRANKCASE BREATHER TUBE-REPLACEMENT749
REMOVAL749
CLEANING AND INSPECTION749
INSTALLATION750
ROCKER LEVER DIAGNOSING-MALFUNCTIONS750
VALVE LASH SPECIFICATIONS750
ROCKER LEVER-REPLACEMENT751
REMOVAL751
DISASSEMBLY752
CLEANING AND INSPECTION753
ASSEMBLY754
INSTALLATION755
VALVE LASH-ADJUSTMENT756
VALVE ARRANGEMENT758
TIMING PIN ASSEMBLY-INSTALLATION759
PUSH ROD-REPLACEMENT763
REMOVAL763
CLEANING AND INSPECTION764
INSTALLATION765
CYLINDER HEAD-REPLACEMENT766
GENERAL INFORMATION766
DIAGNOSING MALFUNCTIONS766
REMOVAL769
CYLINDER BLOCK/HEAD DECK-CLEANING AND INSPECTION770
CYLINDER HEAD-CLEANING AND INSPECTION773
INSTALLATION778
CYLINDER HEAD-PRESSURE TEST783
MAIN AND THRUST BEARINGS-REPLACEMENT784
GENERAL INFORMATION784
DIAGNOSING MALFUNCTIONS785
REMOVAL786
CLEANING AND INSPECTION788
INSTALLATION790
CONNECTING ROD BEARINGS-REPLACEMENT795
DIAGNOSING MALFUNCTIONS795
REMOVAL796
CLEANING AND INSPECTION797
INSTALLATION800
PISTON AND RINGS-REPLACEMENT802
PISTON-GENERAL INFORMATION802
PISTON AND RINGS-DIAGNOSING MALFUNCTIONS802
REMOVAL804
CLEANING AND INSPECTION807
INSTALLATION812
CONNECTING RODS-REPLACEMENT819
GENERAL INFORMATION819
REMOVAL820
CLEANING AND INSPECTION821
INSTALLATION823
CYLINDER LINERS-REPLACEMENT825
GENERAL INFORMATION825
REMOVAL825
CLEANING AND INSPECTION829
INSTALLATION832
VIBRATION DAMPER-REPLACEMENT839
GENERAL INFORMATION839
RUBBER ELEMENT VIBRATION DAMPER-INSPECTION(IN-CHASSIS)839
VISCOUS VIBRATION DAMPER-INSPECTION841
REMOVAL842
INSTALLATION843
GEAR COVER-REPLACEMENT844
REMOVAL844
CLEANING AND INSPECTION845
INSTALATION846
SEAL,FRONT CRANKSHAFT-REPLACEMENT848
GENERAL INFORMATION848
REMOVAL AND INSTALLATION849
WEAR SLEEVE,FRONT CRANKSHAFT-REPLACEMENT849
REMOVAL849
CLEANING AND INSPECTION850
INSTALLATION850
GEAR HOUSING-REPLACEMENT853
GENERAL INFORMATION853
REMOVAL854
CLEANING AND INSPECTION855
INSTALLATION857
ENGINE DATAPLATE-REPLACEMENT862
REMOVAL863
INSTALLATION863
CAMSHAFT-REPLACEMENT864
GENERAL INFORMATION864
REMOVAL866
CLEANING AND INSPECTION869
INSTALLATION873
CAMSHAFT GEAR-REPLACEMENT876
REMOVAL876
CLEANING AND INSPECTION876
INSTALLATION878
VALVE TAPPET-REPLACEMENT879
GENERAL INFORMATION879
REMOVAL880
CLEANING AND INSPECTION883
INSTALLATION884
CRANKSHAFT GEAR-REPLACEMENT888
GENERAL INFORMATION888
REMOVAL889
CLEANING AND INSPECTION891
INSTALLATION892
FLYWHEEL-REPLACEMENT895
REMOVAL895
CLEANING AND INSPECTION896
INSTALLATION897
FLYWHEEL BORE RUNOUT MEASUREMENT899
FLYWHEEL FACE RUNOUT MEASUREMENT900
FLYWHEEL RING GEAR-REPLACEMENT902
REMOVAL902
INSTALLATION902
FLYWHEEL HOUSING-REPLACEMENT902
REMOVAL902
CLEANING AND INSPECTION904
INSTALLATION(DRY CLUTCH APPLICATION)905
CONCENTRICITY-CHECKING906
INSTALLATION(WET CLUTCH APPLICATION)908
SEAL,REAR CRANKSHAFT-REPLACEMENT910
REMOVAL910
CLEANING AND INSPECTION911
INSTALLATION912
WEAR SLEEVE,REAR CRANKSHAFT SEAL-REPLACEMENT913
REMOVAL913
CLEANING AND INSPECTION915
INSTALLATION916
PIPE PLUG-REPLACEMENT919
REMOVAL919
CLEANING AND INSPECTION919
INSTALLATION920
CUP PLUG-REPLACEMENT920
REMOVAL920
CLEANING AND INSPECTION921
INSTALLATION921
ENGINE TESTING923
ENGINE TESTING-GENERAL INFORMATION924
ENGINE TESTING-GENERAL SPECIFICATIONS925
BLOWBY MEASUREMENT926
ENGINE TESTING-SERVICE TOOLS927
GENERAL ENGINE TEST PROCEDURES928
ENGINE RUN-IN PROCEDURE930
ENGINE REMOVAL AND INSTALLATION932
ENGINE REMOVAL AND INSTALLATION-GENERAL INFORMATION933
ENGINE-REMOVAL933
ENGINE MOUNT-INSPECTION936
ENGINE-INSTALLATION936
THROTTLE CONTROL LEVER CONNECTION937
ENGINE COMPONENT SPECIFICATIONS941
SPECIFICATION-GENERAL INFORMATION942
COMPONENT SPECIFICATIONS AND TORQUE VALUES943
COOLING SYSTEM SPECIFICATIONS943
COOLING SYSTEM TORQUE VALUES943
LUBRICATING OIL SYSTEM SPECIFICATIONS944
LUBRICATING OIL SYSTEM TORQUE VALUES945
COMBUSTION AIR SYSTEM SPECIFICATIONS947
COMBUSTION AIR SYSTEM TORQUE VALUES947
COMPRESSED AIR SYSTEM TORQUE VALUES948
FUEL SYSTEM SPECIFICATIONS949
FUEL SHUTOFF SOLENOID ADJUSTMENT949
FUEL SYSTEM TORQUE VALUES950
ELECTRICAL SYSTEM SPECIFICATIONS953
ELECTRICAL SYSTEM TORQUE VALUES953
BASE ENGINE COMPONENT SPECIFICATIONS954
BASE ENGINE TORQUE VALUES965
DRIVE BELT TENSION967
WEIGHT AND MEASURES-CONVERSION FACTORS969
NEWTON-METER TO FOOT-POUND CONVERSION CHART970
CAPSCREW MARKINGS AND TORQUE VALUES971
CAPSCREW MARKINGS AND TORQUE VALUES-METRIC972
CAPSCREW MARKINGS AND TORQUE VALUES-US CUSTOMARY973
PIPE PLUG TORQUE VALUES974
INDEX975

IMAGES PREVIEW OF THE MANUAL:

S.M 13/12/24