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KOMATSU COMPONENT OF ENGINE SHOP MANUAL SEBDCOMP009 – PDF DOWNLOAD
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Description
KOMATSU COMPONENT OF ENGINE SHOP MANUAL SEBDCOMP009 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU COMPONENT OF ENGINE SHOP MANUAL SEBDCOMP009 – PDF DOWNLOAD
Language : English
Pages : 648
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU COMPONENT OF ENGINE SHOP MANUAL SEBDCOMP009 – PDF DOWNLOAD
MAIN MENU...................................................................... 0 COVER.......................................................................... 1 CONTENTS....................................................................... 2 SAFETY......................................................................... 3 FOREWORD....................................................................... 5 GENERAL.................................................................... 5 HOW TO READ THE SHOP MANUAL................................................ 6 HOISTING INSTRUCTIONS...................................................... 7 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................. 8 COATING MATERIALS.......................................................... 10 STANDARD TIGHTENING TORQUE................................................. 12 ELECTRIC WIRE CODE......................................................... 15 CONVERSION TABLE........................................................... 16 UNITS...................................................................... 22 TURBOCHARGER................................................................... 23 CONTENTS................................................................... 24 00 INTRODUCTION............................................................ 26 01 GENERAL................................................................. 27 TURBOCHARGER MODEL NO.................................................. 28 SPECIFICATIONS......................................................... 28 11 STRUCTURE AND FUNCTION.................................................. 29 GENERAL STRUCTURE...................................................... 30 STRUCTURE AND FUNCTION................................................. 32 13 DISASSEMBLY AND ASSEMBLY................................................ 35 GENERAL................................................................ 37 DISASSEMBLY........................................................ 37 ASSEMBLY........................................................... 42 14 MAINTENANCE STANDARD AND INSPECTION OF PARTS............................ 46 MAINTENANCE STANDARD................................................... 47 KTR100............................................................. 47 KTR110............................................................. 48 KTR130............................................................. 49 KTR150............................................................. 50 INSPECTION OF PARTS.................................................... 51 AIR COMPRESSOR................................................................. 55 CONTENTS................................................................... 56 01 GENERAL................................................................. 58 SPECIFICATIONS......................................................... 59 11 STRUCTURE AND FUNCTION.................................................. 65 GENERAL STRUCTURE...................................................... 66 CROSS-SECTIONAL DRAWING OF THE CYLINDER HEAD........................... 70 STRUCTURE.............................................................. 72 FUNCTION............................................................... 74 OPERATION OF UNLOADER VALVE............................................ 75 12 TESTING AND ADJUSTING................................................... 77 PERFORMANCE TEST....................................................... 78 13 DISASSEMBLY AND ASSEMBLY................................................ 79 TIGHTENING TORQUE...................................................... 80 DISASSEMBLY AND ASSEMBLY............................................... 79 6206-91-1100 (S)6D95L-1 SERIES..................................... 84 6136-81-3112 S6D105-1 SERIES....................................... 84 6138-81-3111 S(A)6D110-1 SERIES.................................... 84 6151-81-3110 (SA)6D125-1 SERIES.................................... 84 6136-81-3120 S6D105-1,S6D110-1 SERIES.............................. 88 6151-81-3140 S6D125-1 SERIES....................................... 88 6210-81-3111 S6D140-1 SERIES....................................... 88 6210-81-3121 S6D140-1, SA6D140-1 SERIES............................ 88 6162-83-6700 S6D170-1.............................................. 88 6162-83-6600 S6D170-1 SERIES....................................... 92 6162-83-6800 S6D170-1 SERIES....................................... 92 6215-81-3101 SA12V140-1 SERIES..................................... 92 6215-81-3201 SA12V140-1 SERIES..................................... 92 6165-91-1001 SA8V170-1, SA12V170-1 SERIES.......................... 96 6165-91-1004 SA8V170-1, SA12V170-1 SERIES.......................... 96 6165-91-1005 SA8V170-1, SA12V170-1 SERIES.......................... 96 14 MAINTENANCE STANDARD AND INSPECTION OF PARTS............................100 MAINTENANCE STANDARD...................................................101 6206-91-110 SERIES.................................................101 6136-81-3112 SERIES................................................101 6138-81-3111 SERIES................................................101 6136-81-3120 SERIES................................................102 6151-81-3110 SERIES................................................102 6151-81-3140 SERIES................................................103 6210-81-3111 SERIES................................................103 6210-81-3121 SERIES................................................103 6162-83-6600 SERIES................................................103 6162-83-6700 SERIES................................................103 6162-83-6800 SERIES................................................103 6215-81-3101 SERIES................................................103 6215-81-3201.......................................................103 6165-91-1001 SERIES................................................104 6165-91-1004 SERIES................................................104 6165-91-1005 SERIES................................................104 INSPECTION OF PARTS....................................................105 PERIODIC INSPECTION....................................................108 FUEL INJECTION PUMP............................................................109 FUEL INJECTION PUMP PE(S)-A TYPE...........................................109 CONTENTS...............................................................110 01 GENERAL.............................................................111 FUEL INJECTION SYSTEM OUTLINE......................................112 PRINCIPAL SPECIFICATIONS...........................................113 11 STRUCTURE...........................................................114 CONSTRUCTION AND OPERATION.........................................115 PLUNGER HELIXES................................................117 INJECTION QUANTITY CHARACTERISTICS.............................117 PLUNGER ROTATING MECHANISM.....................................118 TWO-STEP HELIX PLUNGER.........................................118 DELIVERY VALVE ASSEMBLY........................................119 DELIVERY VALVE (FOR VARIABLE RETRACTION PISTION)...............119 DUMPING VALVE EQUIPPED DELIVERY VALVE HOLDER...................120 CAMSHAFT.......................................................121 TAPPET ASSEMBLY................................................121 SUPPLY PUMP....................................................121 12 TESTING AND ADJUSTING...............................................123 SPECIAL TOOLS......................................................124 SERVICE TOOLS FOR ADJUSTMENT...................................124 ADJUSTMENT.........................................................129 PREPARATION....................................................129 SETTING CONTROL RACK "0" POSITION..............................130 INJECTION TIMING ADJUSTMENT....................................131 INJECTION QUANTITY ADJUSTMENT..................................136 SUPPLY PUMP TEST...............................................137 INJECTION TIMING ALIGNING MARK.................................139 PRECAUTIONS........................................................143 FUEL OIL.......................................................143 FUEL FILTER....................................................143 BLEEDING THE FUEL SYSTEM.......................................143 LUBRICATION....................................................144 LUBRICATION PROCEDURE..........................................145 13 DISASSEMBLY AND ASSEMBLY............................................146 SPECIAL TOOLS......................................................147 SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY...................147 EXPLODED VIEW OF PE-A PUMP.........................................156 EXPLODED VIEW OF THE SUPPLY PUMPS..................................157 DISASSEMBLY........................................................158 PREPARATION....................................................158 INJECTION PUMP DISASSEMBLY.....................................158 SUPPLY PUMP DISASSEMBLY........................................169 INSPECTION.........................................................172 GASKETS AND O-RINGS............................................172 PLUNGER........................................................172 DELIVERY VALVE.................................................173 CONTROL RACK AND CONTROL SLEEVE................................173 TAPPET.........................................................174 CAMSHAFT AND BEARINGS..........................................174 SUPPLY PUMP PARTS..............................................175 REASSEMBLY.........................................................176 14 MAINTENANCE STANDARD................................................182 TIGHTENING TORQUE..................................................183 15 OTHERS..............................................................186 TROUBLESHOOTING ...................................................187 EXPLANATION OF PART NUMBERS........................................191 FUEL INJECTION PUMP PE(S)-P TYPE...........................................194 CONTENTS...............................................................195 01 GENERAL.............................................................196 FUEL INJECTION SYSTEM OUTLINE......................................197 PRINCIPAL SPECIFICATIONS...........................................198 INJECTION QUANTITY CHARACTERISTICS.................................198 11 STRUCTURE AND FUNCTION..............................................199 CONTRUCTION AND OPERATION..........................................200 CONSTRUCTION...................................................200 OPERATION......................................................203 INJECTION PUMP MAIN COMPONENTS................................206 12 TESTING AND ADJUSTING...............................................211 SERVICE TOOLS FOR ADJUSTMENT.......................................212 ADJUSTMENT.........................................................216 PREPARATION....................................................216 INJECTION TIMING ADJUSTMENT....................................218 INJECTION QUANTITY ADJUSTMENT..................................222 ALIGNING MARK..................................................224 KD TYPE SUPPLY PUMP ADJUSTMENT.................................225 PRECAUTIONS........................................................227 FUEL OIL.......................................................227 FUEL FILTER....................................................227 BLEEDING THE FUEL SYSTEM.......................................227 LUBRICATION....................................................228 LUBRICATION PROCEDURE..........................................228 TROUBLESHOOTING....................................................229 13 DISASSEMBLY AND ASSEMBLY............................................234 SPECIAL TOOLS......................................................235 SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY...................235 EXPLODED VIEW OF THE PE-P PUMP AND SUPPLY PUMP.....................243 DISASSEMBLY........................................................244 PREPARATION....................................................244 INJECTION PUMP DIASSEMBLY......................................244 SUPPLY PUMP DISASSEMBLY........................................258 INSPECTION.........................................................262 PE-P TYPE PUMP DISASSEMBLY.....................................262 KD-TYPE SUPPLY PUMP INSPECTION.................................266 REASSEMBLY.........................................................267 PLUNGER BLOCK ASSEMBLY.........................................267 INJECTION PUMP.................................................269 14 MAINTENANCE STANDARD................................................277 TIGHTENING TORQUES.................................................278 15 OTHERS..............................................................280 EXPLANATION OF PART NUMBERS........................................281 INJECTION PUMP PROPER NUMBER...................................281 BOSCH TYPE NUMBER..............................................281 FUEL INJECTION PUMP KFE TYPE...............................................283 CONTENTS...............................................................284 01 GENERAL.............................................................286 SPECIFICATIONS.....................................................287 GENERAL VIEW.......................................................289 11 STRUCTURE AND FUNCTION..............................................293 STRUCTURE..........................................................294 OPERATION..........................................................315 12 TESTING AND ADJUSTING...............................................320 SPECIAL TOOLS OF ADJUSTING.........................................321 PREPARATION........................................................322 PRESTROKE AJUSTMENT................................................324 ADJUSTMENT OF FUEL INJECTION VOLUME................................327 GOVERNOR PERFORMANCE CHECK.........................................330 PRESTROKE OIL PRESSURE CHECK.......................................331 FIGURE OF SPECIAL TOOLS............................................332 13 DISASSEMBLY AND ASSEMBLY............................................335 SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY.........................336 DISASSEMBLY........................................................338 ASSEMBLY...........................................................344 FIGURE OF SPECIAL TOOLS............................................351 14 MAINTENANCE STANDARD................................................358 ADJUSTING FUEL INJECTION PUMP......................................359 PREPARATION WORK...............................................359 TESTING FUEL INJUCTION TIMING..................................360 MEASURING FUEL INJECTION RATE..................................362 CALIBRATION DATA...............................................363 ADJUSTING ELECTRONIC GOVERNOR......................................365 ADJUSTING RACK SENSOR..........................................366 CHECK OF GOVERNOR PERFORMANCE..................................367 CHECK OF PRE-STROKE OIL PRESSURE...............................368 15 REPAIRS AND REPLACEMENT OF PARTS....................................369 PARTS INSPECTION...................................................370 JUDGEMENT STANDARD FOR REUSE.......................................373 FUEL INJECTION PUMP GOVERNOR...................................................376 FUEL INJECTION PUMP GOVERNOR - RSV.........................................376 CONTENTS...............................................................377 01 GENERAL.............................................................378 FEATURES...........................................................379 11 STRUCTURE AND FUNCTION..............................................380 CONSTRUCTION.......................................................381 OPERATION..........................................................383 GOVERNOR SPRING OPERATION......................................383 PERFORMANCE LINE DRAWINGS OF THE GOVERNOR......................384 CONTROL OF ENGINE STARTINGS....................................385 IDLING CONTROL.................................................386 MAXIMUM SPEED CONTROL..........................................387 TORQUE CONTROL DEVICE..........................................388 NO-LOAD MAXIMUM SPEED OPERATION................................391 CONDITION AT STOPPING..........................................392 TORQUE SPRING OPERATION........................................394 BOOST COMPRESSOR OPERATION.....................................397 12 TESTING AND ADJUSTION...............................................399 SPECIAL TOOLS......................................................400 SERVICE TOOLS FOR ADJUSTMENT...................................400 ADJUSTMENT.........................................................405 PREPARATION ...................................................405 FULL-LOAD ADJUSTMENT (TEMPORARY)...............................408 TORQUE CONTROL SPRING ADJUSTMENT (WHEN INSTALLED)..............409 IDLING ADJUSTMENT..............................................411 MAXIMUM-SPEED ADJUSTMENT.......................................412 SPEED DROP ADJUSTMENT..........................................413 FULL-LOAD ADJUSTMENT...........................................416 CONTROL LEVER ANGLE MEASUREMENT................................417 TORQUE SPRING ADJUSTMENT (WHEN INSTALLED)......................418 BOOST COMPENSATOR ADJUSTMENT (WHEN INSTALLED)..................420 PRECAUTIONS........................................................424 STOPPERS.......................................................424 LUBRICATION....................................................424 13 DISASSEMBLY AND ASSEMBLY............................................426 SPECIAL TOOLS......................................................427 SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY...................427 EXPLODED VIEW OF THE RSV GOVERNOR..................................432 DISASSEMBLY........................................................433 PREPARATION....................................................433 GOVERNOR ASSEMBLY..............................................433 GOVERNOR COVER ASSEMBLY........................................441 INSPECTION.........................................................446 FLYWEIGHT......................................................446 TENSION LEVER..................................................447 SWIVEL LEVER...................................................447 GUIDE LEVER....................................................448 SPRING.........................................................448 REASSEMBLY.........................................................449 GUIDE LEVER AND SLEEVE REASSEMBLY..............................449 REASSEMBLY OF GOVERNOR COVER INNER COMPONENTS..................450 IMPELLER.......................................................450 MOUNTING THE FLYWEIGHT.........................................451 14 MAINTENANCE STANDARD................................................452 TIGHTENING TORQUE..................................................453 15 OTHERS..............................................................454 EXPLANATION OF PART NUMBERS........................................455 FUEL INJECTION PUMP GOVERNOR - RSUV(D)-Z...................................457 CONTENTS...............................................................458 01 GENERAL.............................................................459 FEATURES...........................................................460 12 TESTING AND ADJUSTING...............................................461 SPECIAL TOOLS......................................................462 ADJUSTMENT.........................................................466 PREPARATION....................................................466 FULL LOAD ADJUSTMENT...........................................468 TORQUE CONTROL SPRING ADJUSTMENT (WHEN INSTALLED)..............470 IDLING SUB-SPRING ADJUSTMENT...................................471 PUMP SPEED ADJUSTMENT AT THE START OF MAXIMUM SPEED CONTROL....472 SPEED DROP ADJUSTMENT..........................................473 SETTING THE MAXIMUM SPEED STOPPER CREW.........................475 BOOST COMPENSATOR ADJUSTMENT (WHEN INSTALLED)..................476 MINIMUM SPEED STOPPER SCREW ADJUSTMENT.........................480 FULL LOAD ADJUSTING SCREW ADJUSTMENT...........................480 FULL LOAD ADJUSTING SCREW PLUG INSTALLATION....................480 STOP LEVER ADJUSTMENT..........................................480 CHECKING THE SPEE CONTROL LEVER AND STOP LEVER ANGLES..........481 CONTROL RACK LIMITER ADJUSTMENT................................481 RSUVD GOVERNOR ADJUSTMENT......................................484 PRECAUTIONS........................................................494 STOPPERS ......................................................494 LUBRICATIONS...................................................494 13 DISASSEMBLY AND ASSEMBLY............................................495 SPECIAL TOOLS......................................................496 EXPLODED VIEW OF THE RSUV GOVERNOR.................................497 DISASSEMBLY........................................................499 INSPECTION.........................................................518 REASSEMBLY.........................................................522 14 MAINTENANCE STANDARD................................................526 TIGHTENING TORQUES.................................................527 FUEL SUPPLY PUMP (COMMON RAIL TYPE)............................................528 CONTENTS...................................................................529 13 DISASSEMBLY AND ASSEMBLY................................................531 SPECIAL TOOL LIST......................................................532 CONSUMABLE PARTS LIST..................................................533 SKETCHES OF SPECIAL TOOLS..............................................534 DISASSEMBLY OF FUEL SUPPLY PUMP........................................535 ASSEMBLY OF FUEL SUPPLY PUMP...........................................544 TIGHTENING TORQUE TABLE............................................555 14 PERFORMANCE TEST........................................................557 SPECIAL TOOLS LIST.....................................................558 SKETCHES OF SPECIAL TOOLS..............................................559 PERFORMANCE TEST ON FUEL SUPPLY PUMP...................................560 1. PREPARATION.....................................................560 2. BENCH SETTING...................................................561 3. ELECTRICAL WIRING...............................................565 4. PERFORMANCE TEST................................................567 WATER PUMP.....................................................................569 CONTENTS...................................................................570 01 GENERAL.................................................................571 INTRODUCTION...........................................................572 COOLING SYSTEM.........................................................573 SPECIFICATIONS.........................................................574 11 STRUCTURE AND FUNCTION..................................................575 GENERAL STRUCTURE......................................................576 STRUCTURE AND FUNCTION.................................................579 13 DISASSEMBLY AND ASSEMBLY................................................580 STANDARD VALUES AND TIGHTENING TORQUE TABLE............................581 95, 105, 108, AND 110 SERIES GENERAL DISASSEMBLY.......................583 GENERAL DISASSEMBLY...............................................583 GENERAL DISASSEMBLY...............................................587 125,12V140 SERIES......................................................591 GENERAL DISASSEMBLY...............................................591 GENERAL ASSEMBLY..................................................594 6D140..................................................................597 GENERAL DISASSEMBLY...............................................597 GENERAL ASSEMBLY..................................................600 155 SERIES.............................................................604 GENERAL DISASSEMBLY...............................................604 GENERAL ASSEMBLY..................................................607 170 SERIES.............................................................611 GENERAL DISASSEMBLY...............................................611 GENERAL DISASSEMBLY...............................................614 14 MAINTENANCE STANNDARD AND INSPECTION....................................617 MAINTENANCE STANDARD...................................................618 95 SERIES..........................................................618 105 SERIES.........................................................619 110 SERIES.........................................................621 125 SERIES.........................................................623 140 SERIES.........................................................624 155 SERIES.........................................................626 170 SERIES.........................................................627 PARTS INSPECTION AND EVALUATION CRITERIA...............................629 REUSE CRITERIA.........................................................630 FUEL PUMP......................................................................632 CONTENTS...................................................................633 01 GENERAL.................................................................634 FOREWORD...............................................................635 CONTENTS OF REPAIRS AND MATRIX FOR REQUIRED PARTS KIT..................636 SPECIFICATIONS.........................................................637 PUMP CONFIGURATION.....................................................638 13 DISASSEMBLY AND ASSEMBLY................................................639 DISASSEMBLY OF FUEL PUMP ASSEMBLY......................................640 ASSEMBLY OF FUEL PUMP ASSEMBLY.........................................643
DESCRIPTION:
KOMATSU COMPONENT OF ENGINE SHOP MANUAL SEBDCOMP009 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding oi 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 alter performing repairs, as we] as adjustments to be made at completion of the checks and Repair. 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 at 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.
S.S 29/12/24
