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KOMATSU 76E-6 SERIES ENGINE SHOP MANUAL SEN05334-02 – PDF DOWNLOAD
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Description
KOMATSU 76E-6 SERIES ENGINE SHOP MANUAL SEN05334-02 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 76E-6 SERIES ENGINE SHOP MANUAL SEN05334-02 – PDF DOWNLOAD
Language : English
Pages : 278
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 76E-6 SERIES ENGINE SHOP MANUAL SEN05334-02 – PDF DOWNLOAD
Cover.................................................................... 1 00 Index and foreword.................................................... 3 100 Index............................................................ 3 Composition of shop manual....................................... 4 Table of contents................................................ 5 200 Foreword and general information................................. 11 Introduction..................................................... 12 Applicable machine model and serial number....................... 13 Safety Statements................................................ 14 Safety Precautions............................................... 15 01 Specification......................................................... 33 100 Specification and technical data................................. 33 Component Identification......................................... 35 Location of Labels............................................... 36 Function of Major Engine Components.............................. 37 Function of Cooling System Components............................ 39 Diesel Fuel...................................................... 40 Diesel Fuel Specifications................................... 40 Filling the Fuel Tank........................................ 41 Priming the Fuel System...................................... 43 Engine Oil....................................................... 44 Engine Oil Specifications.................................... 44 Service Categories........................................... 44 Engine Oil Viscosity......................................... 45 Checking Engine Oil.......................................... 45 Adding Engine Oil............................................ 45 Engine Oil Capacity (Typical)................................ 46 Engine Coolant................................................... 46 Engine Coolant Specifications................................ 47 Filling Radiator with Engine Coolant......................... 48 Engine Coolant Capacity (Typical)............................ 48 Specifications................................................... 49 Description of Model Number.................................. 49 Engine Speed Specifications.................................. 49 Engine General Specifications................................ 50 Principal Engine Specifications.................................. 51 Engine Service Information....................................... 52 Tightening Torques for Standard Bolts and Nuts................... 53 Abbreviations and Symbols........................................ 55 Abbreviations................................................ 55 Symbols...................................................... 55 Unit Conversions................................................. 56 Unit Prefixes................................................ 56 Units of Length.............................................. 56 Units of Volume.............................................. 56 Units of Mass................................................ 56 Units of Force............................................... 56 Units of Torque.............................................. 56 Units of Pressure............................................ 56 Units of Power............................................... 56 Units of Temperature......................................... 56 30 Testing and adjusting................................................. 59 101 Testing and adjusting, Part 1.................................... 59 Introduction..................................................... 60 Precautions...................................................... 72 The Importance of Periodic Maintenance....................... 72 Performing Periodic Maintenance.............................. 72 Komatsu Replacement Parts.................................... 73 Periodic Maintenance Schedule.................................... 73 Periodic Maintenance Procedures.................................. 75 After Initial 50 Hours of Operation.......................... 75 Every 50 Hours of Operation.................................. 78 Every 250 Hours of Operation................................. 81 Every 500 Hours of Operation................................. 86 Every 1000 Hours of Operation................................ 89 Every 1500 Hours of Operation................................ 91 Every 2000 Hours of Operation................................ 93 102 Testing and adjusting, Part 2.................................... 95 Before You Begin Servicing....................................... 97 Introduction..................................................... 99 Cylinder Head Specifications..................................... 99 Adjustment Specifications.................................... 99 Cylinder Head................................................ 99 Intake / Exhaust Valve and Guide.............................100 Push Rod.....................................................100 Valve Spring.................................................100 Rocker Arm and Shaft.........................................100 Camshaft and Timing Gear Train Specifications....................101 Camshaft.....................................................101 Idler Gear Shaft and Bushing.................................101 Timing Gear Backlash.........................................101 Crankshaft and Pistons Specifications............................102 Crankshaft...................................................102 Crankshaft Reconditioning....................................102 Thrust Bearing...............................................102 Piston.......................................................103 Piston Ring..................................................103 Connecting Rod...............................................104 Tappet.......................................................104 Cylinder Block Specifications....................................105 Cylinder Block...............................................105 Special Torque Chart.............................................105 Torque for Bolts and Nuts....................................105 Special Service Tools............................................106 Measuring Instruments............................................108 Cylinder Head....................................................110 Cylinder Head Components.....................................110 Disassembly of Cylinder Head.................................111 Cleaning of Cylinder Head Components.........................115 Inspection of Cylinder Head Components.......................115 Reassembly of Cylinder Head..................................119 Measuring and Adjusting Valve Clearance......................123 Cylinder Block...................................................126 Crankshaft and Camshaft Components...........................126 Disassembly of Cylinder Block Components.....................127 Disassembly of Camshaft and Timing Components................128 Disassembly of Crankshaft and Piston Components..............132 Inspection of Crankshaft and Camshaft Components.............136 Reconditioning the Crankshaft................................141 Honing and Boring............................................142 Reassembly of Crankshaft and Piston Components...............143 Reassembly of Camshaft and Timing Components.................149 103 Testing and adjusting, Part 3....................................153 Before You Begin Servicing.......................................155 Introduction.....................................................157 Fuel Injection Pump..........................................157 Stop Solenoid................................................158 Fuel System Specifications.......................................159 Special Torque Chart.........................................159 Test and Adjustment Specifications...........................159 Special Service Tools............................................160 Measuring Instruments............................................160 Fuel System Diagram..............................................161 Fuel System Components...........................................162 Fuel Injection Lines.............................................163 Removal of High-Pressure Fuel Injection Lines................163 Installation of High-Pressure Fuel Injection Lines...........163 Removal of Fuel Return Line..................................164 Installation of Fuel Return Line.............................164 Fuel Injection Pump..............................................165 Removal of Fuel Injection Pump...............................165 Installation of Fuel Injection Pump..........................168 Checking and Adjusting Fuel Injection Timing.....................171 Checking Fuel Injection Timing...............................171 Adjusting Fuel Injection Timing..............................174 Fuel Injectors...................................................175 Removal of Fuel Injectors....................................175 Testing of Fuel Injectors....................................175 Disassembly and Inspection of Fuel Injectors.................178 Adjusting Fuel Injector Pressure.............................179 Reassembly of Fuel Injectors.................................180 Installation of the Fuel Injectors...........................180 104 Testing and adjusting, Part 4....................................183 Before You Begin Servicing.......................................184 Introduction.....................................................186 Cooling System Diagram...........................................186 Engine Coolant Pump Components...................................187 Engine Coolant System Check......................................188 Engine Coolant Pump..............................................189 Disassembly of Engine Coolant Pump...........................189 Cleaning and Inspection......................................190 Reassembly of Engine Coolant Pump............................191 105 Testing and adjusting, Part 5....................................195 Before You Begin Servicing.......................................196 Introduction.....................................................198 Oil Pump Service Information.....................................198 Engine Oil Pressure..........................................198 Outer Rotor Outside Clearance................................198 Outer Rotor Side Clearance...................................198 Outer Rotor to Inner Rotor Tip Clearance.....................198 Inner Rotor and Gear Boss Clearance..........................198 Lubrication System Diagram.......................................199 Checking Engine Oil Pressure.....................................200 Trochoid Oil Pump................................................201 Oil Pump Components..........................................201 Disassembly of Oil Pump......................................201 Cleaning and Inspection......................................202 Reassembly of Oil Pump.......................................204 106 Testing and adjusting, Part 6....................................207 Before You Begin Servicing.......................................208 Introduction.....................................................210 Starter Motor Information........................................210 Starter Motor Specifications.....................................211 Starter Motor Troubleshooting....................................212 Starter Motor Components.........................................213 Starter Motor....................................................214 Removal of Starter Motor.....................................214 Disassembly of Starter Motor.................................214 Cleaning and Inspection......................................217 Reassembly of Starter Motor..................................221 Check Pinion Projection Length...............................223 No-Load Test.................................................224 Installation of Starter Motor................................225 107 Testing and adjusting, Part 7....................................227 Before You Begin Servicing.......................................229 Introduction.....................................................232 Standard and Optional Alternator Information.....................232 Alternator Specifications........................................232 Alternator Troubleshooting.......................................233 Alternator Components............................................234 Alternator Wiring Diagram........................................235 Alternator Standard Output.......................................236 Alternator.......................................................237 Removal of Alternator........................................237 Disassembly of Alternator....................................238 Reassembly of Alternator.....................................240 Installation of Alternator...................................242 Dynamo Component Location........................................243 Dynamo Wiring Diagram............................................244 Operation of Dynamo..............................................244 Dynamo Standard Output...........................................245 Testing of Dynamo................................................246 Testing Stator Coil Continuity...............................246 Testing Stator Coil Short-to-Ground..........................246 Testing Dynamo Regulated Output..............................246 Dynamo...........................................................247 Removal of Dynamo............................................247 Disassembly of Dynamo........................................247 Reassembly of Dynamo.........................................248 Installation of Dynamo.......................................249 108 Testing and adjusting, Part 8....................................251 Electric Wiring Precautions......................................252 Electric Wire Resistance.........................................253 Battery Cable Resistance.........................................254 Electrical Wire Sizes - Voltage Drop.............................255 Conversion of AWG to European Standards..........................256 40 Troubleshooting.......................................................259 100 Troubleshooting of mechanical system.............................259 Special Service Tools............................................261 Troubleshooting By Measuring Compression Pressure................262 Compression Pressure Measurement Method......................262 Standard Compression Pressure................................263 Engine Speed and Compression Pressure (Use for Reference)....263 Measured Value and Troubleshooting...........................263 Quick Reference Table For Troubleshooting........................264 Troubleshooting Charts.......................................265 Electric Wiring..................................................275
DESCRIPTION:
KOMATSU 76E-6 SERIES ENGINE SHOP MANUAL SEN05334-02 – PDF DOWNLOAD
- This manual describes the maintenance procedure for 76E-6 Series engines (swirl chamber type).
- The contents of this manual shall be used as materials for correct, quick and safe maintenance of the above engines.
- Since this manual explains the maintenance procedure for the standard engine, the specifications and component parts shown below are partly different from those of the engine mounted on each work equipment (generator, pump, compressor, etc.)
- This shop manual consists of volumes.
- Some volumes titled “Testing and adjusting” [Testing and adjusting, Part 1 – Part 8] contain descriptions related to disassembly and assembly.
- For the contents of description, see the general contents or the contents of each volume.
S.S 22/12/24
