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KOMATSU 6D140-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM008612) KOMATSU 6D140 2 – PDF DOWNLOAD
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- KOMATSU 6D140-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM008612
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Description
KOMATSU 6D140-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM008612) KOMATSU 6D140 2
KOMATSU 6D140-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM008612) KOMATSU 6D140 2 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 6D140-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM008612) KOMATSU 6D140 2
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - Testing and adjusting
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - Disassembly and assembly
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - Maintenance standard
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”. - Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU 6D140-2 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM008612) KOMATSU 6D140 2
COVER................................................................................. 1 CONTENTS.............................................................................. 2 01 GENERAL............................................................................ 27 APPLICABLE MACHINE................................................................ 28 SPECIFICATIONS.................................................................... 29 GENERAL ASSEMBLY DRAWING.......................................................... 38 WEIGHT TABLE...................................................................... 52 ENGINE PERFORMANCE CURVE.......................................................... 55 11 STRUCTURE AND FUNCTION............................................................. 67 INTAKE AND EXHAUST SYSTEM......................................................... 68 INTAKE AND EXHAUST SYSTEM..................................................... 68 AIR CLEANER................................................................... 81 TURBOCHARGER.................................................................. 84 AFTERCOOLER................................................................... 86 ENGINE BODY....................................................................... 89 CYLINDER HEAD................................................................. 89 CYLINDER BLOCK................................................................ 91 MAIN CIRCULATION SYSTEM....................................................... 93 VIBRATION DAMPER.............................................................. 95 TIMING GEAR................................................................... 96 VALVE SYSTEM.................................................................. 98 FLYWHEEL AND FLYWHEEL HOUSING.................................................100 LUBRICATION SYSTEM................................................................101 LUBRICATION SYSTEM CHART......................................................101 OIL PUMP......................................................................103 REGULATOR VALVE AND PISTON COOLING VALVE......................................104 OIL FILTER....................................................................105 OIL COOLER....................................................................109 FUEL SYSTEM.......................................................................110 FUEL SYSTEM CHART.............................................................110 FUEL INJECTION PUMP...........................................................112 FEED PUMP.....................................................................120 FUEL INJECTION NOZZLE.........................................................121 FUEL FILTER...................................................................122 ENGINE STOP MOTOR.............................................................123 COOLING SYSTEM....................................................................128 COOLING SYSTEM CHART..........................................................128 WATER PUMP....................................................................131 THERMOSTAT....................................................................137 CORROSION RESISTOR............................................................138 CORROSION RESISTOR MOUNTING...................................................139 COOLING FAN DRIVE.............................................................140 ACCESSORY.........................................................................148 AIR COMPRESSOR................................................................148 EXHAUST BRAKE.................................................................151 ELECTRICAL SYSTEM.................................................................155 ALTERNATOR....................................................................155 STARTING MOTOR................................................................161 ELECTRICAL INTAKE AIR HEATER..................................................166 FRONT PTO MOUNTING............................................................167 FRONT PTO ASSEMBLY............................................................168 FRONT PTO DRIVE GEAR ASSEMBLY.................................................169 12 TESTING AND ADJUSTING..............................................................170 MOUNTING (ADJUSTING) METHOD OF ENGINE SPEED SENSOR................................171 ENGINE BODY.......................................................................172 ADJUSTING VALVE CLEARANCE.....................................................172 MEASURING COMPRESSION PRESSURE................................................173 FUEL SYSTEM.......................................................................174 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................174 ADJUSTING FUEL INJECTION PRESSURE.............................................175 PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE...............................176 COOLING SYSTEM....................................................................178 CHECKING AND ADJUSTING FAN BELT TENSION.......................................178 FUEL INJECTION PUMP CALIBRATION DATA..............................................179 PERFORMANCE TEST..................................................................195 RUN-IN STANDARD...............................................................195 PERFORMANCE TEST CRITERIA.....................................................200 TROUBLESHOOTING...................................................................208 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................210 METHOD OF USING TROUBLESHOOTING CHARTS........................................211 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)..................215 S-2 ENGING DOES NOT START.....................................................216 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).......................219 S-4 ENGINE STOPS DURING OPERATIONS............................................220 S-5 ENGINE DOES NO ROTATE SMOOTHLY(HUNTING)...................................221 S-6 ENGINE LACKS OUTPUT(NO POWER).............................................222 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION).............................223 S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)....................224 S-9 OIL BECOMES CONTAMINATED QUICKLY..........................................225 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................226 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN....227 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)................228 S-13 OIL LEVEL RISES(WATER,FUEL IN OIL).......................................229 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)..........................230 S-15 ABNORMAL NOISE IS MADE...................................................231 S-16 VIBRATION IS EXCESSIVE...................................................232 TESTING AND ADJUSTING TOOL LIST...............................................233 TESTING AND ADJUSTING DATA....................................................234 13 DISASSEMBLY AND ASSEMBLY...........................................................242 GENERAL DISASSEMBLY...............................................................242 AIR CLEANER･MUFFLER...........................................................243 STARTING MOTOR................................................................243 TURBOCHARGER DRAIN TUBE.......................................................244 SETTING ENGINE IN ENGINE OVERHAUL STAND ......................................244 CORROSION RESISTOR, AIR COMPRESSOR SUCTION TUBE...............................244 BRACKET.......................................................................244 CONNECTOR.....................................................................245 TENSION PULLEY ASSEMBLY.......................................................245 FAN PULLEY ASSEMBLY...........................................................245 ALTERNATOR ASSEMBLY･PULLEY....................................................245 DIPSTICK GUIDE,AIR COMPRESSOR.................................................246 FUEL HOSE.....................................................................246 TURBOCHARGER..................................................................246 EXHAUST MAINIFOLD ............................................................246 AFTER-COOLER ASSEMBLY (INTAKE MANIFOLD ASSEBLY)...............................246 FUEL INJECTOR TUBE............................................................246 FUEL INJECTION PUMP ASSEMBLY..................................................247 TUBE, BRACKET, PTO CASE.......................................................247 FUEL FILTER･FUEL FILTER BRACKET...............................................247 OIL FILTER･OIL REGULATOR......................................................247 OIL PAN.......................................................................248 SUCTION PIPE, UNDER FRAME.....................................................248 FLYWHEEL......................................................................248 REAR SEAL.....................................................................248 FLYWHEEL HOUSING..............................................................249 AIR VENT TUBE, SPILL PIPE, ROCKER ARM HOUSING COVER...........................249 NOZZLE HOLDER, INLET CONNECTOR................................................250 ROCKER ARM....................................................................250 PUSH ROD .....................................................................251 CROSSHEAD.....................................................................251 ROCKER ARM HOUSING ...........................................................251 CYLINDER HEAD ASSEMBLY........................................................251 VIBRATION DAMPER･CRANKSHAFT PULLEY ASSEMBLY...................................252 FRONT SUPPORT.................................................................252 THERMOSTAT HOUSING............................................................252 WATER PUMP ASSEMBLY...........................................................252 OIL COOLER ASSEMBLY...........................................................252 CAM FOLLOWER..................................................................253 GEAR CASE COVER...............................................................253 INJECTION PUMP DRIVE GEAR.....................................................253 CAMSHAFT......................................................................253 OIL PUMP ASSEMBLY, OIL PUMP IDLER GEAR........................................254 MAIN IDLER GEAR,INJECTION PUMP DRIVE SHAFT....................................254 PISTON COOLING NOZZLE.........................................................254 PISTON AND CONNECTING ROD ASSEMBLY............................................254 CRANKSHAFT....................................................................256 CYLINDER LINER................................................................257 GENERAL ASSEMBLY..................................................................258 TIGHTENING BOLTS BY THE PLASTIC RANGE TURNING ANGLE METHOD....................259 DRAWING OF SPECIAL TOOL.......................................................260 PREPARATORY WORK..............................................................261 CYLINDER LINER................................................................262 CRANKSHAFT....................................................................264 PISTON AND CONNECTING ROD ASSEMBLY............................................267 PISTON COOLING NOZZLE.........................................................269 MAIN IDLER GEAR, FUEL INJECTION PUMP DRIVE SHAFT..............................270 OIL PUMP IDLER GEAR, OIL PUMP ASSEMBLY........................................271 CAMSHAFT......................................................................271 FUEL INJECTION PUMP DRIVE GEAR................................................271 FUEL INJECTION PUMP DRIVE SHAFT OIL SEAL......................................272 GEAR CASE COVER...............................................................273 BREATHER......................................................................273 FRONT SEAL....................................................................274 CAM FOLLOWER..................................................................275 OIL COOLER ASSEMBLY...........................................................275 WATER PUMP ASSEMBLY...........................................................276 THWERMOSTAT HOUSING ..........................................................276 FRONT SUPPORT.................................................................276 VIBRATION DAMPER, CRANKSHAFT PULLEY ASSEMBLY..................................276 CYLINDER HEAD ASSEMBLY........................................................277 CROSSHEAD.....................................................................279 ROCKER ARM HOUSING............................................................279 PUSH ROD .....................................................................279 ROCKER ARM....................................................................280 ADJUSTING VALVE CLEARANCE.....................................................280 NOZZLER HOLDER, INLET CONNECTOR...............................................281 ROCKER ARM HOUSING COVER, SPILL PIPE, AIR VENT TUBE...........................282 FLYWHEEL HOUSING..............................................................282 REAR SEAL.....................................................................283 FLYWHEEL......................................................................286 SUCTION PIPE..................................................................287 OIL PAN ......................................................................287 OIL FILTER ASSEMBLY, OIL REGULATOR............................................287 FUEL FILTER ASSEMBLY･FUEL FILTER BRACKET......................................287 PTO CASE TUBE, BRACKET........................................................288 FUEL INJECTION PUMP ASSEMBLY..................................................288 ADJUSTING FUEL INJECTION PUMP.................................................289 FUEL INJECTION TUBE...........................................................291 AFTER-COOLER ASSEMBLY (INTAKE MANIFOID ASSEMBLY)..............................291 EXHAUST MAINIFOID.............................................................291 TURBOCHARGER..................................................................292 FUEL HOSE.....................................................................292 DIPSTICK GUIDE, AIR COMPRESSOR................................................292 ALTERNATOR ASSEMBLY, PULLEY...................................................292 FAN PULLEY ASSEMBLY...........................................................293 TENSION PULLY ASSEMBLY........................................................293 INTAKE CONNECTOR..............................................................293 MUFFLER BRAKET, AIR CLEANER BRAKET............................................293 CORROSION RESISTOR............................................................294 RESETTING ENGINE IN ENGINE STAND..............................................294 TURBOCHARGER DRAIN TUBE.......................................................294 STARTING MOTOR................................................................294 AIR CLEANER, MUFFLER..........................................................295 REFILLING WITH OIL............................................................295 14 MAINTENANCE STANDARD...............................................................296 INTAKE AND EXHAUST SYSTEM.........................................................297 TURBOCHARGER..................................................................297 ENGINE BODY.......................................................................301 CYLINDER HEAD.................................................................301 VALVE, VALVE GUIDE............................................................303 ROCKER ARM AND SHAFT .........................................................305 CROSSHEAD AND GUIDE...........................................................306 CYLINDER BLOCK................................................................307 CYLINDER LINER................................................................308 CRANKSHAFT....................................................................309 CAMSHAFT......................................................................310 CAM FOLLOWER AND PUSH ROD.....................................................311 TIMING GEAR...................................................................312 PISTON........................................................................314 CONNECTING ROD................................................................316 FLYWHEEL AND FLYWHEEL HOUSING.................................................317 LUBRICATION SYSTEM................................................................318 OIL PUMP .....................................................................318 REGULATOR VALVE, PISTON COOLING VALVE AND SAFETY VALVE........................320 OIL COOLER....................................................................321 COOLING SYSTEM....................................................................322 WATER PUMP....................................................................322 THERMOSTAT....................................................................325 15 REPAIR AND REPLACEMENT OF PARTS....................................................326 TABLE OF SPECIAL TOOLS............................................................327 CYLINDER HEAD.....................................................................328 GRINDING OF FITTING FACE OF CYLINDER HEAD.....................................328 REPLACING VALVE SEAT INSERT...................................................329 PRESSURE TEST.................................................................334 REPLACING VALVE GUIDE.........................................................335 REPLACING CROSSHEAD GUIDE.....................................................336 GRINDING VALVE................................................................337 CYLINDER BLOCK....................................................................338 REPLACING CAM BUSHING ........................................................338 REPLACING CRANKSHAFT GEAR.....................................................341 REPLACING CAM GEAR............................................................342 REPLACING FLYWHEEL RING GEAR..................................................343 REPLACING CONNECTING ROD SMALL END BUSHING....................................344 CYLINDER BLOCK PARTS.............................................................345 TESTING AND INSPECTING CYLINDER BLOCK.............................................346 CORRECTING CYLINDER BLOCK TOP SURFACE,COUNTERBORE.................................349 REPLACING MAIN BEARING CAP........................................................357
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