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KOMATSU 6D140-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM008613 – PDF
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Description
KOMATSU 6D140-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM008613 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 6D140-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM008613 – PDF DOWNLOAD
Language : English
Pages : 376
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 6D140-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM008613 – PDF DOWNLOAD
Cover................................................................................... 1 Contents................................................................................ 2 01 General.............................................................................. 27 Applicable machine.................................................................. 28 Specifications...................................................................... 30 General assembly drawing............................................................ 38 Weight table........................................................................ 54 Engine performance curve............................................................ 57 11 Structure and function............................................................... 69 Intake and exhaust system........................................................... 70 Intake and exhaust system....................................................... 70 Air cleaner..................................................................... 83 Turbocharger.................................................................... 86 Aftercooler..................................................................... 88 Engine body......................................................................... 92 Cylinder head................................................................... 92 Cylinder block.................................................................. 94 Main circulation system......................................................... 96 Vibration damper................................................................ 98 Timing gear.....................................................................100 Valve system....................................................................102 Flywheel and flywheel housing...................................................104 Lubrication system..................................................................106 Lubrication system chart........................................................106 Oil pump........................................................................108 Regulator valve and piston cooling valve........................................109 Oil filter......................................................................110 Oil cooler......................................................................114 Fuel system.........................................................................116 Fuel system chart...............................................................116 Fuel injection pump.............................................................118 Feed pump.......................................................................126 Fuel injection nozzle...........................................................127 Fuel filter.....................................................................128 Engine stop motor...............................................................129 Cooling system......................................................................134 Cooling system chart............................................................134 Water pump......................................................................138 Thermostat......................................................................144 Corrosion resistor..............................................................145 Corrosion resistor mounting.....................................................146 Cooling fan drive...............................................................147 Accessory...........................................................................156 Air compressor..................................................................156 Exhaust brake...................................................................161 Electrical system...................................................................165 Alternator......................................................................165 Starting motor..................................................................172 Electrical intake air heater....................................................177 Front PTO mounting..............................................................178 Front PTO assembly..............................................................179 Front PTO drive gear assembly...................................................180 12 Testing and adjusting................................................................181 Mounting (adjusting) methodof engine speed sensor...................................182 Engine body.........................................................................183 Adjusting valve clearance.......................................................183 Measuring compressionpressure...................................................184 Fuel system.........................................................................185 Testing and adjusting fuelinjection timing......................................185 Adjusting fuel injectionpressure................................................186 Procedure for adjustingengine stop motor cable..................................187 Cooling system......................................................................189 Checking and adjusting fan belt tension.........................................189 Fuel injection pump calibration data................................................190 Performance test....................................................................206 Run-in standard.................................................................206 Performance test criteria.......................................................212 Troubleshooting.....................................................................221 Points to remember when troubleshooting.........................................223 Method of using troubleshooting charts..........................................224 S-1 Starting performance is poor (starting always takes time)...................228 S-2 Engine does not start.......................................................229 S-3 Engine does not pick up smoothly (follow-up is poor)........................232 S-4 Engine stops during operations..............................................233 S-5 Engine does not rotate smoothly (hunting)...................................234 S-6 Engine lacks output (no power)..............................................235 S-7 Exhaust smoke is black (incomplete combustion)..............................236 S-8 Oil consumption is excessive (or exhaust smoke is blue).....................237 S-9 Oil becomes contaminated quickly............................................238 S-10 Fuel consumption is excessive..............................................239 S-11 Oil is in cooling water, or water spurts back, or water level goes down....240 S-12 Oil pressure caution lamp lights up (drop in oil pressure).................241 S-13 Oil level rises (water, fuel in oil).......................................242 S-14 Water temperature becomes too high (overheating)...........................243 S-15 Abnormal noise is made.....................................................244 S-16 Vibration is excessive.....................................................245 Testing and adjusting tool list.................................................247 Testing and adjusting dataa.....................................................248 13 DISASSEMBLY AND ASSEMBLY.............................................................257 GENERAL DISASSEMBLY.................................................................257 Air cleaner･muffler.............................................................258 Starting motor..................................................................258 Turbocharger drain tube.........................................................259 Setting engine in engine overhaul stand.........................................259 Corrosion resistor, air compressor suction tube.................................259 Bracket.........................................................................259 Connector.......................................................................260 Tension pulley assembly.........................................................260 Fan pulley assembly.............................................................260 Alternator assembly･pulley......................................................260 Dipstick guide, air compressor..................................................261 Fuel hose.......................................................................261 Turbocharger....................................................................261 Exhaust manifold................................................................261 After-cooler assembly (Intake manifold assembly)................................261 Fuel injection tube.............................................................261 Fuel injection pump assembly....................................................262 Tube, bracket, PTO case.........................................................262 Fuel filter･fuel filter bracket.................................................262 Oil filter･oil regulator........................................................262 Oil pan.........................................................................263 Suction pipe, under frame.......................................................263 Flywheel........................................................................263 Rear seal.......................................................................263 Flywheel housing................................................................264 Air vent tube, spill pipe, rocker arm housing cover.............................264 Nozzle holder, inlet connector..................................................265 Rocker arm......................................................................265 Push rod........................................................................266 Crosshead.......................................................................266 Rocker arm housing..............................................................266 Cylinder head assembly..........................................................266 Vibration damper･crankshaft pulley assembly.....................................267 Front support...................................................................267 Thermostat housing..............................................................267 Water pump assembly.............................................................267 Oil cooler assembly.............................................................267 Cam follower....................................................................268 Gear case cover.................................................................268 Injection pump drive gear.......................................................268 Camshaft........................................................................268 Oil pump assembly, oil pump idler gear..........................................269 Main idler gear, injection pump drive shaft.....................................269 Piston cooling nozzle...........................................................269 Piston and connecting rod assembly..............................................269 Crankshaft......................................................................271 Cylinder liner..................................................................272 GENERAL ASSEMBLY....................................................................273 Tightening bolts by the plastic range turning angle method......................274 Drawing of special tool.........................................................275 Preparatory work................................................................276 Cylinder liner..................................................................277 Crankshaft......................................................................279 Piston and connecting rod assembly..............................................282 Piston cooling nozzle...........................................................284 Main idler gear, fuel injection pump drive shaft................................285 Oil pump idler gear, oil pump assembly..........................................286 Camshaft........................................................................286 Fuel injection pump drive gear..................................................286 Fuel injection pump drive shaft oil seal........................................287 Gear case cover.................................................................288 Breather........................................................................288 Front seal......................................................................289 Cam follower....................................................................290 Oil cooler assembly.............................................................290 Water pump assembly.............................................................291 Thermostat housing..............................................................291 Front support...................................................................291 Vibration damper, crankshaft pulley assembly....................................291 Cylinder head assembly..........................................................292 Crosshead.......................................................................294 Rocker arm housing..............................................................294 Push rod........................................................................294 Rocker arm......................................................................295 Adjusting valve clearance.......................................................295 Nozzle holder, inlet connector..................................................296 Rocker arm housing cover, spill pipe, air vent tube.............................297 Flywheel housing................................................................297 Rear seal.......................................................................298 Flywheel........................................................................301 Suction pipe....................................................................302 Oil pan.........................................................................302 Oil filter assembly, oil regulator..............................................302 Fuel filter assembly･fuel filter bracket........................................302 PTO case tube, bracket..........................................................303 Fuel injection pump assembly....................................................303 Adjusting fuel injection pump...................................................304 Fuel injection tube.............................................................306 After-cooler assembly (Intake manifold assembly)................................306 Exhaust manifold................................................................306 Turbocharger....................................................................307 Fuel hose.......................................................................307 Dipstick guide, air compressor..................................................307 Alternator assembly, pulley.....................................................307 Fan pulley assembly.............................................................308 Tension pulley assembly.........................................................308 Intake connector................................................................308 Muffler bracket, air cleaner bracket............................................308 Corrosion resistor..............................................................309 Resetting engine in engine stand................................................309 Turbocharger drain tube.........................................................309 Starting motor..................................................................309 Air cleaner, muffler............................................................310 Refilling with oil..............................................................310 14 Maintenance standard.................................................................311 Intake and exhaust system...........................................................312 Turbocharger....................................................................312 Engine body.........................................................................316 Cylinder head...................................................................316 Valve, valve guide..............................................................318 Rocker arm and shaft............................................................320 Crosshead and guide.............................................................321 Cylinder block..................................................................322 Cylinder liner..................................................................323 Crankshaft......................................................................324 Camshaft........................................................................325 Cam follower and push rod.......................................................326 Timing gear.....................................................................328 Piston..........................................................................330 Connecting rod..................................................................332 Flywheel and flywheel housing...................................................333 Lubrication system..................................................................334 Oil pump........................................................................334 Regulator valve, piston cooling valve and safety valve..........................336 Oil cooler......................................................................337 Cooling system......................................................................338 Water pump......................................................................338 Thermostat......................................................................341 15 Repair and replacement of parts......................................................343 Table of special tools..............................................................344 Cylinder head.......................................................................345 Grinding of fitting face ofcylinder head........................................345 Replacing valve seat insert.....................................................346 Pressure test...................................................................351 Replacing valve guide...........................................................352 Replacing crosshead guide.......................................................353 Grinding valve..................................................................354 Cylinder block......................................................................355 Replacing cam bushing...........................................................355 Replacing crankshaft gear.......................................................358 Replacing cam gear..............................................................359 Replacing flywheel ring gear....................................................360 Replacing connecting rodsmall end bushing.......................................361 Cylinder block parts............................................................362 Testing and inspecting cylinder block...........................................363 Correcting cylinder block top surface, counterbore..............................366 Replacing main bearing cap......................................................374
DESCRIPTION:
KOMATSU 6D140-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM008613 – PDF DOWNLOAD
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
S.S 18/12/24
