Komatsu S6D114E-1, SA6D114E-1, SAA6D114E-1 Diesel Engine Workshop Repair Service Manual – PDF DOWNLOAD

Description

Komatsu S6D114E-1, SA6D114E-1, SAA6D114E-1 Diesel Engine Workshop Repair Service Manual

FILE DETAILS:

Komatsu S6D114E-1, SA6D114E-1, SAA6D114E-1 Diesel Engine Workshop Repair Service Manual 

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBD000601
Total Pages : 975

DESCRIPTION:

Komatsu S6D114E-1, SA6D114E-1, SAA6D114E-1 Diesel Engine Workshop Repair Service Manual 

FOREWORD:

• This manual contains complete rebuild specifications and information for the 6D114E-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 S6D114E-1, SA6D114E-1, SAA6D114E-1 Diesel Engine Workshop Repair Service Manual 

MAIN MENU....................................................................................................  0
CONTENTS.....................................................................................................  2
SHOP MANUAL..................................................................................................  5
	Table of Contents........................................................................................  8
	Introduction.............................................................................................  9
		About the Manual..................................................................................... 10
		General Cleaning Instructions........................................................................ 16
			Solvent and Acid Cleaning........................................................................ 16
			Steam Cleaning................................................................................... 16
		General Repair Instructions.......................................................................... 15
		General Safety Instructions.......................................................................... 14
		Generic Symbols...................................................................................... 12
		Glossary of Terms.................................................................................... 17
		How To Use This Manual............................................................................... 11
			Group Contents................................................................................... 11
			Index............................................................................................ 11
			Metric Information............................................................................... 11
			Table of Contents................................................................................ 11
		Illustrations........................................................................................ 13
	Engine and Component Identification...................................................................... 19
		Engine Diagrams...................................................................................... 24
		Engine Identification................................................................................ 20
			Engine Dataplates................................................................................ 20
			Fuel Injection Pump Dataplate.................................................................... 21
		General Engine Specifications........................................................................ 22
			Cooling System................................................................................... 23
			Fuel System...................................................................................... 23
			General Engine Data.............................................................................. 22
			Intake Air and Exhaust System.................................................................... 23
			Lubrication System............................................................................... 22
	Engine Disassembly and Assembly - Group 00............................................................... 27
		Engine - Assembly.................................................................................... 65
			AFC Tube - Installation..........................................................................141
			Aftercooler - Installation.......................................................................125
			Air Compressor - Installation....................................................................148
			Air Crossover Tube - Installation................................................................130
			Alternator Brace - Installation..................................................................133
			Alternator - Installation........................................................................132
			Alternator Mounting Bracket - Installation.......................................................132
			Belt Tensioner Bracket - Installation............................................................134
			Belt Tensioner - Installation....................................................................134
			Camshaft - Installation.......................................................................... 93
			Connecting Rod Bolt - Installation............................................................... 82
			Coolant Filter - Installation....................................................................131
			Coolant Heater - Installation....................................................................110
			Coolant Inlet Connection - Installation..........................................................132
			Coolant Outlet Connection - Installation.........................................................131
			Coolant Vent Fitting - Installation..............................................................131
			Coolant Vent Petcock - Installation..............................................................131
			Coolant Vent Tube - Installation.................................................................132
			Crankcase Breather Tube - Installation...........................................................123
			Crankshaft - Installation........................................................................ 73
			Cylinder Block - Installation onto Engine Rebuild Stand.......................................... 65
			Cylinder Head Installation.......................................................................113
			Cylinder Liner - Installation.................................................................... 66
			Drive Belt - Installation........................................................................147
			Engine Lifting Bracket - Installation............................................................124
			Engine - Removal from the Rebuild Stand..........................................................134
			Engine Support, Front - Installation.............................................................147
			Exhaust Manifold - Installation..................................................................125
			Fan Hub Assembly - Installation..................................................................135
			Flywheel Bore Runout Measurement.................................................................107
			Flywheel Face Runout Measurement.................................................................109
			Flywheel Housing - Installation..................................................................100
			Flywheel - Installation..........................................................................105
			Fuel Drain Manifold - Installation...............................................................124
			Fuel Filter Head - Installation..................................................................140
			Fuel Filter - Installation.......................................................................140
			Fuel Injection Pump - Installation...............................................................135
			Fuel Injection Pump Supply Line - Installation...................................................139
			Fuel Lines, High Pressure - Installation.........................................................141
			Fuel Lines, Low Pressure - Installation..........................................................148
			Fuel Pump Solenoid - Installation................................................................148
			Fuel Transfer Pump - Installation................................................................147
			Gear Cover - Installation........................................................................145
			Gear Housing - Installation...................................................................... 90
			Injector - Installation..........................................................................123
			Intake Manifold Cover - Installation.............................................................124
			Lubricating Oil Cooler - Installation............................................................112
			Lubricating Oil Filter - Installation............................................................113
			Lubricating Oil Pan - Installation............................................................... 96
			Lubricating Oil Pump - Installation.............................................................. 92
			Lubricating Oil Suction Tube - Installation...................................................... 96
			Main Bearing (Lower) - Installation.............................................................. 74
			Main Bearing (Upper) - Installation.............................................................. 72
			Main Bearing Cap - Installation.................................................................. 74
			Piston Assembly - Installation................................................................... 86
			Piston Cooling Nozzle - Installation............................................................. 71
			Piston Pin - Installation........................................................................ 82
			Piston Ring End Gap - Measurement................................................................ 83
			Piston Ring - Installation....................................................................... 84
			Push Rod - Installation..........................................................................117
			Rocker Lever and Shaft - Assembly................................................................117
			Rocker Lever Assembly - Installation.............................................................119
			Seal, Front Crankshaft - Installation............................................................142
			Seal, Rear Crankshaft - Installation............................................................. 78
			Starting Motor - Installation....................................................................110
			Tachometer Drive - Installation..................................................................146
			Thermostat and Housing - Installation............................................................130
			Timing Pin Assembly - Installation............................................................... 97
			Turbocharger Exhaust Outlet Connection - Installation............................................130
			Turbocharger - Installation......................................................................126
			Turbocharger Oil Drain Tube - Installation.......................................................127
			Turbocharger Oil Supply Hose - Installation......................................................129
			Valve Arrangement................................................................................121
			Valve Clearance - Adjustment.....................................................................120
			Valve Cover - Installation.......................................................................122
			Valve Tappet - Installation...................................................................... 70
			Vibration Damper - Installation..................................................................146
			Water Pump - Installation........................................................................ 95
			Wear Sleeve, Rear Crankshaft Seal - Installation................................................. 79
			Engine Accessories - Installation................................................................150
		Engine - Disassembly................................................................................. 35
			AFC Tube - Removal............................................................................... 38
			Aftercooler - Removal............................................................................ 43
			Air Compressor - Removal......................................................................... 40
			Air Crossover Tube - Removal..................................................................... 43
			Alternator Brace - Removal....................................................................... 47
			Alternator Mounting Bracket - Removal............................................................ 48
			Alternator - Removal............................................................................. 48
			Belt Tensioner Bracket - Removal................................................................. 47
			Belt Tensioner - Removal......................................................................... 47
			Camshaft - Removal............................................................................... 54
			Coolant - Draining............................................................................... 36
			Coolant Filter - Removal......................................................................... 36
			Coolant Heater - Removal......................................................................... 52
			Coolant Inlet Connection - Removal............................................................... 50
			Coolant Outlet Connection - Removal.............................................................. 48
			Coolant Vent Petcock - Removal................................................................... 49
			Coolant Vent Tube Fitting - Removal.............................................................. 49
			Coolant Vent Tube - Removal...................................................................... 49
			Crankcase Breather Tube - Removal................................................................ 42
			Crankshaft - Removal............................................................................. 62
			Cylinder Head - Removal.......................................................................... 49
			Cylinder Liner Carbon Deposits - Removal......................................................... 58
			Cylinder Liner Protrusion - Checking............................................................. 63
			Cylinder Liner - Removal......................................................................... 63
			Drive Belt - Removal............................................................................. 47
			Engine - Installation onto Engine Rebuild Stand.................................................. 41
			Engine Lifting Equipment and Brackets............................................................ 35
			Engine - Preparation for Steam Cleaning.......................................................... 35
			Engine - Steam Cleaning.......................................................................... 35
			Engine Support, Front - Removal.................................................................. 57
			Exhaust Manifold - Removal....................................................................... 46
			Expansion Plug - Removal......................................................................... 65
			Expansion Plug - Replacement..................................................................... 64
			Fan Hub Assembly - Removal....................................................................... 50
			Flywheel Housing - Removal....................................................................... 53
			Flywheel - Removal............................................................................... 53
			Fuel Drain Manifold - Removal.................................................................... 44
			Fuel Filter Head - Removal....................................................................... 37
			Fuel Filter - Removal............................................................................ 37
			Fuel Injection Pump - Removal.................................................................... 39
			Fuel Injection Pump Supply Line - Removal........................................................ 38
			Fuel Lines, High Pressure - Removal.............................................................. 38
			Fuel Lines, Low Pressure - Removal............................................................... 37
			Fuel Pump Solenoid - Removal..................................................................... 41
			Fuel Transfer Pump - Removal..................................................................... 37
			Gear Cover - Removal............................................................................. 52
			Gear Housing - Removal........................................................................... 57
			Injector - Removal............................................................................... 44
			Intake Manifold Cover - Removal.................................................................. 43
			Lubricating Oil Cooler - Removal................................................................. 50
			Lubricating Oil - Draining....................................................................... 36
			Lubricating Oil Filter - Removal................................................................. 36
			Lubricating Oil Pan - Removal.................................................................... 53
			Lubricating Oil Pump Gear Backlash - Measurement................................................. 56
			Lubricating Oil Pump - Removal................................................................... 57
			Lubricating Oil Suction Tube - Removal........................................................... 53
			Main Bearing (Lower) - Removal................................................................... 62
			Main Bearing (Upper) - Removal................................................................... 62
			Main Bearing Cap - Removal....................................................................... 61
			Piston Assembly - Removal........................................................................ 59
			Piston Cooling Nozzle - Removal.................................................................. 62
			Piston Pin - Removal............................................................................. 60
			Piston Ring - Removal............................................................................ 61
			Push Rod - Removal............................................................................... 45
			Rocker Lever Assembly - Removal.................................................................. 45
			Seal, Front Crankshaft - Removal................................................................. 52
			Seal, Rear Crankshaft - Removal.................................................................. 54
			Starting Motor - Removal......................................................................... 52
			Tachometer Drive - Removal....................................................................... 39
			Thermostat and Housing - Removal................................................................. 48
			Turbocharger Exhaust Outlet Connection - Removal................................................. 42
			Turbocharger Oil Drain Tube - Removal............................................................ 46
			Turbocharger Oil Supply Hose - Removal........................................................... 46
			Turbocharger - Removal........................................................................... 46
			Valve Cover - Removal............................................................................ 44
			Valve Tappet - Removal........................................................................... 55
			Vibration Damper - Removal....................................................................... 51
			Wastegate Actuator Hose - Removal................................................................ 42
			Water Pump - Removal............................................................................. 51
			Cylinder Block - Removal from Engine Rebuild Stand............................................... 65
		Engine Disassembly and Assembly - Service Tools...................................................... 30
		General Information.................................................................................. 34
			Disassembly...................................................................................... 34
			Assembly......................................................................................... 34
	Cylinder Block - Group 01................................................................................151
		Camshaft Bore Expansion Plug - Installation..........................................................170
		Camshaft Bushing Bore - Cleaning.....................................................................172
		Camshaft Bushing - Installation......................................................................172
		Camshaft Bushing - Removal...........................................................................171
		Camshaft - Cleaning and Inspection for Reuse.........................................................200
			Camshaft - Cleaning..............................................................................200
			Camshaft Gear - Inspection.......................................................................203
			Camshaft - Inspection............................................................................200
		Camshaft Gear - Replacement..........................................................................204
			Camshaft Gear - Cleaning.........................................................................204
			Camshaft Gear - Inspection.......................................................................204
			Camshaft Gear - Installation.....................................................................206
			Camshaft Gear - Removal..........................................................................204
		Connecting Rod Bearings - Cleaning and Inspection for Reuse..........................................189
			Connecting Rod Bearings - Cleaning...............................................................189
			Connecting Rod Bearings - Inspection.............................................................189
		Connecting Rod Bushing - Replacement.................................................................195
			Inspection.......................................................................................199
			Installation.....................................................................................197
			Machining........................................................................................199
			Removal..........................................................................................195
		Connecting Rods - Bend and Twist Inspection..........................................................193
			Connecting Rod Alignment - Inspection............................................................194
			Connecting Rod Twist - Inspection................................................................194
			Fixture Calibration..............................................................................193
		Connecting Rods - Cleaning and Inspection for Reuse..................................................190
			Connecting Rods - Cleaning.......................................................................190
			Connecting Rods - Inspection.....................................................................191
		Crankshaft - Cleaning and Inspection for Reuse.......................................................179
			Crankshaft - Cleaning............................................................................179
			Crankshaft - Inspection..........................................................................180
		Crankshaft Gear - Replacement........................................................................183
			Crankshaft Gear - Inspection.....................................................................184
			Crankshaft Gear - Installation...................................................................185
			Crankshaft Gear - Removal........................................................................183
			General Information..............................................................................183
		Cylinder Block - Cleaning in a Hot Tank..............................................................164
		Cylinder Block - Cleaning with Solvent...............................................................161
		Cylinder Block - Disassembly.........................................................................159
		Cylinder Block - Exploded View.......................................................................156
		Cylinder Block - General Information.................................................................158
			Camshaft.........................................................................................158
			Connecting Rods..................................................................................158
			Crankshaft.......................................................................................158
			Cylinder Block...................................................................................158
			Cylinder Liner...................................................................................158
			Oil Seals........................................................................................158
			Pistons..........................................................................................158
			Vibration Damper.................................................................................158
		Cylinder Block - Inspection For Reuse................................................................165
		Cylinder Block - Preparation for Cleaning............................................................159
		Cylinder Block - Service Tools.......................................................................153
		Cylinder Head Capscrews - Cleaning and Inspection for Reuse..........................................214
			Cleaning.........................................................................................214
			Free Length - Measurement........................................................................216
			Inspection.......................................................................................215
		Cylinder Liners - Cleaning and Inspection for Reuse..................................................173
			Cylinder Liners - Cleaning.......................................................................173
			Cylinder Liners - Inspection.....................................................................174
		Dowel Pins (Cylinder Head) - Removal.................................................................160
		Engine Dataplate - Replacement.......................................................................209
			Engine Dataplate - Installation..................................................................209
			Engine Dataplate - Removal.......................................................................209
		Engine Lifting Brackets - Cleaning and Inspection for Reuse..........................................216
		Expansion Plug - Installation........................................................................168
			Pipe Plug - Installation.........................................................................169
		Gear Cover - Cleaning and Inspection for Reuse.......................................................210
			Gear Cover - Cleaning............................................................................210
			Gear Cover - Inspection..........................................................................210
		Gear Housing - Cleaning and Inspection for Reuse.....................................................207
			Gear Housing - Cleaning..........................................................................207
			Gear Housing - Inspection........................................................................207
		Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse..................................188
			Cleaning.........................................................................................188
			Inspection.......................................................................................189
		Main Bearings - Cleaning and Inspection for Reuse....................................................186
			General Information..............................................................................186
			Main Bearings - Cleaning.........................................................................187
			Main Bearings - Inspection.......................................................................187
			Thrust Bearings - Inspection.....................................................................188
		Pistons - Cleaning and Inspection for Reuse..........................................................176
			Piston Rings - Removal...........................................................................176
			Pistons - Cleaning...............................................................................176
			Pistons - Inspection.............................................................................177
		Rear Cover - Cleaning and Inspection.................................................................213
			Cleaning.........................................................................................213
			Inspection.......................................................................................214
		Vibration Damper - Cleaning and Checking for Reuse...................................................211
			General Information..............................................................................211
			Rubber Element Vibration Damper - Inspection.....................................................211
			Rubber Vibration Damper - Cleaning...............................................................211
			Viscous Vibration Damper - Cleaning..............................................................212
			Viscous Vibration Damper - Inspection............................................................212
	Cylinder Head - Group 02.................................................................................217
		Cylinder Head Capscrew - Cleaning and Inspection for Reuse...........................................254
			Cleaning.........................................................................................255
			Inspection.......................................................................................255
		Cylinder Head - Cleaning and Inspection for Reuse....................................................225
			Cleaning.........................................................................................225
			Handling.........................................................................................225
			Inspection.......................................................................................226
		Cylinder Head - Exploded View........................................................................222
		Cylinder Head - General Information..................................................................224
		Cylinder Head - Pressure Testing.....................................................................251
		Cylinder Head - Rebuild..............................................................................227
			Assembly.........................................................................................243
			Cleaning.........................................................................................228
			Disassembly......................................................................................227
			Inspection.......................................................................................229
			Valve - Grinding.................................................................................238
			Valve Guide - Inspection.........................................................................233
			Valve - Inspection...............................................................................237
			Valve Seat Insert - Grinding.....................................................................239
			Valve Seat Insert - Inspection...................................................................234
			Valve Spring - Inspection........................................................................235
			Valve Stem Seal - Inspection.....................................................................236
		Cylinder Head - Service Tools........................................................................218
		Cylinder Head - Vacuum Testing Valve Seating.........................................................253
		Cylinder Head - Valve Guide Replacement..............................................................245
			Assembly.........................................................................................246
			Disassembly......................................................................................245
			Inspection.......................................................................................246
		Cylinder Head - Valve Seat Insert Replacement........................................................248
			Inspection.......................................................................................250
			Installation.....................................................................................250
			Removal..........................................................................................248
		Free Length - Measurement............................................................................256
	Rocker Levers - Group 03.................................................................................257
		Crankcase Breather Tube - Cleaning and Inspection for Reuse..........................................264
			Cleaning and Inspection..........................................................................264
		Rocker Assembly Oil Manifold - Cleaning and Inspection for Reuse.....................................263
			Cleaning.........................................................................................263
			Inspection.......................................................................................263
		Rocker Lever Assembly - Cleaning and Inspection......................................................260
			Assembly.........................................................................................262
			Cleaning.........................................................................................261
			Disassembly......................................................................................260
			Inspection.......................................................................................261
		Rocker Lever Assembly - Exploded View................................................................258
		Rocker Lever Assembly - General Information..........................................................259
		Valve Cover - Cleaning and Inspection for Reuse......................................................264
			Cleaning.........................................................................................264
			Inspection.......................................................................................264
	Valve Tappets and Push Rods - Group 04...................................................................265
		Push Rods - Cleaning and Inspection for Reuse........................................................268
			Cleaning.........................................................................................268
			Inspection.......................................................................................268
		Valve Tappet Cleaning and Inspection for Reuse.......................................................267
			Cleaning.........................................................................................267
			Inspection.......................................................................................267
		Valve Tappets and Push Rods - Exploded View..........................................................266
		Valve Tappets and Push Rods - General Information....................................................267
	Fuel Systems - Group 05..................................................................................270
		Direct Link Shutdown Lever - Replacement.............................................................280
		Fuel Injection Pump Gaskets and Seals - Replacement..................................................281
		Fuel System - General Information....................................................................271
			Fuel Injection Pump..............................................................................271
			Fuel Injection Pump - Data Tag Location..........................................................271
			Fuel Injection Pump - Data Tag Information.......................................................271
			Governor - Data Tag Information..................................................................272
			Derivative Fuel Injection Pump - Data Tag Information............................................272
			Fuel Shutoff Solenoid - Wiring Requirements......................................................272
		Fuel Transfer Pump - Exploded View...................................................................273
		Fuel Transfer Pump - Rebuild.........................................................................274
			Assembly.........................................................................................274
			Cleaning.........................................................................................274
		RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment......................................275
			Fuel Shutoff Solenoid - Orientation..............................................................275
			Fuel Shutoff Solenoid - Adjustment...............................................................277
		RQVK Governor Fuel Shutoff Solenoid - Adjustment.....................................................278
		Shutdown Lever or Spring - Replacement...............................................................279
	Injectors and Fuel Lines - Group 06......................................................................282
		Fuel Drain Manifold - Inspection.....................................................................297
		Fuel Lines, High Pressure - Cleaning and Inspection for Reuse........................................295
			General Information..............................................................................295
			Fuel Lines - Cleaning and Inspection.............................................................296
		Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse.........................................297
		Injector - Chatter Testing...........................................................................295
		Injector - Spray Testing.............................................................................294
		Injectors and Fuel Lines - Exploded View.............................................................284
		Injectors and Fuel Lines - Exploded View.............................................................286
		Injectors and Fuel Lines - Exploded View.............................................................287
		Injectors and Fuel Lines - General Information.......................................................288
		Injectors and Fuel Lines - Service Tools.............................................................283
		Injectors - Cleaning and Inspection for Reuse........................................................289
			General Information..............................................................................289
			Injector - Assembly..............................................................................293
			Injector - Cleaning and Inspection...............................................................291
			Injector - Disassembly...........................................................................289
	Lubricating Oil System - Group 07........................................................................299
		Lubricating Oil Dipstick - Calibration...............................................................311
		Lubricating Oil Pan - Cleaning and Inspection for Reuse..............................................303
			Cleaning.........................................................................................303
			Inspection.......................................................................................303
		Lubricating Oil Pump - Cleaning and Inspection for Reuse.............................................312
			Cleaning.........................................................................................313
			Disassembly......................................................................................312
			Inspection.......................................................................................313
		Lubricating Oil System - Exploded View...............................................................302
		Lubricating Oil System - General Information.........................................................301
			Dipstick.........................................................................................301
			Lubricating Oil Cooler and Filter Head...........................................................301
			Lubricating Oil Pump.............................................................................301
			Oil Filter Head..................................................................................301
			Oil Pan..........................................................................................301
			Oil Pressure Regulator...........................................................................301
			Oil Temperature Thermostat.......................................................................301
		Lubricating Oil System - Service Tools...............................................................300
		Lubricating Oil Temperature Thermostat - Cleaning and Inspection.....................................310
			Cleaning.........................................................................................310
			Inspection.......................................................................................310
		Oil Cooler Cover - Disassembly and Assembly..........................................................308
			Assembly.........................................................................................309
			Cleaning.........................................................................................308
			Disassembly......................................................................................308
		Oil Cooler Element - Cleaning and Inspection for Reuse...............................................304
			Cleaning.........................................................................................304
			Inspection.......................................................................................304
			Pressure Test....................................................................................304
		Oil Filter Bypass Valve - Replacement................................................................307
		Oil Pressure Regulating Valve - Cleaning and Inspection..............................................305
			Assembly.........................................................................................306
			Cleaning.........................................................................................306
			Disassembly......................................................................................305
			Inspection.......................................................................................306
	Cooling System - Group 08................................................................................316
		Belt Tensioner Inspection............................................................................326
		Coolant Filter Shutoff Valve - Cleaning and Inspection for Reuse.....................................326
			Assembly.........................................................................................327
			Cleaning.........................................................................................327
			Disassembly......................................................................................326
		Cooling System Components - Exploded View............................................................318
		Cooling System - General Information.................................................................319
			Belt Tensioner...................................................................................319
			Cooling Fans.....................................................................................319
			Fan Hub..........................................................................................319
			Pressure Caps....................................................................................319
			Thermostats......................................................................................319
			Water Pump.......................................................................................319
		Cooling System - Service Tools.......................................................................317
		Fan - Cleaning and Inspection for Reuse..............................................................328
		Fan Hub - Cleaning and Inspection for Reuse..........................................................323
			Cleaning.........................................................................................323
			Inspection.......................................................................................324
		Fan Hub - Rebuild....................................................................................324
			Assembly.........................................................................................325
			Disassembly......................................................................................324
		Thermostat Housing - Cleaning and Inspection for Reuse...............................................322
			Cleaning.........................................................................................322
			Inspection.......................................................................................322
		Thermostat - Inspection..............................................................................322
		Water Outlet Connection - Cleaning and Inspection for Reuse..........................................323
		Water Pump Assembly - Cleaning and Inspection for Reuse..............................................321
			Cleaning.........................................................................................321
			Inspection.......................................................................................321
	Drive Units - Group 09...................................................................................329
		Accessory Drive Adapter - Cleaning and Inspection for Reuse..........................................333
			Cleaning.........................................................................................333
			Inspection.......................................................................................333
		Accessory Drive Adapter - Exploded View..............................................................331
		Accessory Drive Adapter - Rebuild....................................................................333
			Assembly.........................................................................................334
			Disassembly......................................................................................333
		Accessory Drive - General Information................................................................332
			Accessory Drive Adapter..........................................................................332
		Drive Units - Service Tools..........................................................................330
	Air Intake System - Group 10.............................................................................336
		Aftercooler Assembly - Cleaning and Inspection for Reuse.............................................345
			Inspection.......................................................................................346
		Aftercooler Assembly - Rebuild ......................................................................346
		Air Crossover Tube - Cleaning and Inspection for Reuse...............................................347
			Cleaning.........................................................................................347
			Inspection.......................................................................................347
		Air Intake System - Exploded View....................................................................338
		Air Intake System - General Information..............................................................340
			Inspection.......................................................................................341
		Air Intake System - Service Tools....................................................................337
		Air Transfer Pipe - Cleaning and Inspection for Reuse................................................347
			Cleaning.........................................................................................347
			Inspection.......................................................................................347
		Charge Air Cooler (CAC) - Cleaning and Inspection for Reuse..........................................348
			Cleaning.........................................................................................348
			Inspection.......................................................................................348
		Charge Air Cooler (CAC) - Pressure Testing...........................................................349
		Intake Manifold Cover - Cleaning and Inspection for Reuse............................................345
			Inspection.......................................................................................345
		Turbocharger - Cleaning and Inspection for Reuse.....................................................341
			Inspection.......................................................................................341
	Exhaust System - Group 11................................................................................351
		Exhaust Manifold - Cleaning and Inspection for Reuse.................................................354
			Cleaning.........................................................................................354
			Inspection.......................................................................................354
		Exhaust Manifold - Exploded View.....................................................................352
		Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse...............................356
			Cleaning.........................................................................................356
			Inspection.......................................................................................356
		Exhaust Manifold Turbocharger Mounting Stud - Replacement............................................355
			Inspection.......................................................................................355
			Installation.....................................................................................355
			Removal..........................................................................................355
		Exhaust System - General Information.................................................................353
			Exhaust Manifold.................................................................................353
	Air Equipment - Group 12.................................................................................357
	Electrical Equipment - Group 13..........................................................................358
	Engine Testing - Group 14................................................................................359
		Blowby Measurement...................................................................................365
		Engine Dynamometer Test - Engine Run-In..............................................................375
		Engine Dynamometer Test - Installation of the Engine.................................................367
		Engine Dynamometer Test - Performance Checking.......................................................379
		Engine Painting......................................................................................388
		Engine Run-In Procedure - "In-Chassis”...............................................................386
		Engine Run-In - General Procedures...................................................................366
		Engine Storage - Long Term...........................................................................391
			Engine Removal from Long Term Storage............................................................394
		Engine Storage - Short Term..........................................................................389
			Engine Removal From Short Term Storage...........................................................391
		Engine Testing - Component Identification and Diagrams...............................................361
		Engine Testing - General Information.................................................................363
			Engine Dynamometer Run-in........................................................................363
			In-Chassis Run-In................................................................................363
		Engine Testing - General Specifications..............................................................364
		Engine Testing - Service Tools.......................................................................360
		Fuel Injection Pump - Idle Speed Adjustment..........................................................387
			RSV Governor.....................................................................................387
			RQV and RQVK Governor............................................................................388
		General Engine Test Procedure - In Chassis...........................................................381
	Instruments and Controls - Group 15......................................................................398
	Mounting Adaptations - Group 16..........................................................................399
		Engine Support Bracket, Front - Cleaning and Inspection for Reuse....................................407
			Cleaning.........................................................................................407
			Inspection.......................................................................................407
		Flexplate Assembly - Cleaning and Inspection for Reuse...............................................404
		Flywheel - Cleaning and Inspection for Reuse.........................................................403
			Cleaning.........................................................................................403
			Inspection.......................................................................................403
		Flywheel Housing - Assembly (Wet Clutch Application).................................................406
		Flywheel Housing - Cleaning and Inspection for Reuse.................................................405
			Cleaning.........................................................................................405
			Inspection.......................................................................................405
		Flywheel Ring Gear - Replacement.....................................................................404
			Installation.....................................................................................404
			Removal..........................................................................................404
		Mounting Adaptations - Exploded View.................................................................401
		Mounting Adaptations - General Information...........................................................402
			Flywheel and Ring Gear...........................................................................402
			Flywheel Housing.................................................................................402
		Mounting Adaptations - Service Tools.................................................................400
	Specifications and Torque Values - Group 18..............................................................408
		Air Compressor Inspection Specifications.............................................................445
		Air Compressor Torque Values.........................................................................445
		Capscrew Markings and Torque Values..................................................................453
			Capscrew Markings and Torque Values - Metric.....................................................454
			Capscrew Markings and Torque Values - U.S. Customary.............................................454
		Component Specifications and Torque Values...........................................................410
			Cylinder Block - Rebuild Specifications..........................................................422
			Cylinder Block - Torque Values...................................................................428
			Cylinder Head - Rebuild Specifications...........................................................429
			Engine Assembly - Specifications.................................................................410
			Engine Assembly - Torque Values..................................................................412
		Cooling System Specifications........................................................................441
			Air Intake System Specifications.................................................................443
			Air Intake System Torque Values..................................................................443
			Cooling System Torque Values.....................................................................442
		Drive Belt Tension...................................................................................449
		Electrical System Specifications.....................................................................446
		Electrical System Torque Values......................................................................446
		Engine Components - General Information..............................................................409
		Engine Testing - Test Specifications.................................................................447
		Exhaust System Specifications........................................................................445
		Exhaust System Torque Values.........................................................................445
		Fuel Systems - Rebuild Specifications................................................................433
			Fuel Injection Pump Sealing Washer...............................................................435
			Fuel Shutoff Solenoid Adjustment.................................................................435
			Fuel System Specifications.......................................................................433
			Fuel System Torque Values........................................................................435
		Lubricating Oil System Specifications................................................................438
		Lubricating Oil System Torque Values.................................................................439
		Mounting Adaptations - Torque Values.................................................................448
		Mounting Adaptations Specifications..................................................................447
			Flywheel Housing (Wet Application)...............................................................447
			Flywheel Ring Gear Installation..................................................................448
		Newton-Meter to Foot-Pound Conversion Chart..........................................................452
		Pipe Plug Torque Values..............................................................................455
		Rocker Lever Assembly - Rebuild Specifications.......................................................433
		Tap-Drill - U.S. Customary & Metric..................................................................456
		Valve Tappet - Rebuild Specifications................................................................433
		Weight and Measures - Conversion Factors.............................................................451
	Index....................................................................................................457
TROUBLESHOOTING AND REPAIR MANUAL............................................................................461
	Table of Contents........................................................................................463
	Introduction.............................................................................................464
		About the Manual.....................................................................................465
		General Cleaning Instructions........................................................................470
			Solvent and Acid Cleaning........................................................................470
			Steam Cleaning...................................................................................470
		General Repair Instructions..........................................................................469
		General Safety Instructions..........................................................................468
		Generic Symbols......................................................................................466
		Glossary of Terms....................................................................................472
		How To Use This Manual...............................................................................465
			Index............................................................................................465
			Metric Information...............................................................................465
			Table of Contents................................................................................465
		Illustrations........................................................................................467
	Engine and Component Identification......................................................................474
		Engine Identification................................................................................475
			Engine Dataplates................................................................................475
			Fuel Injection Pump Dataplate....................................................................476
		General Engine Specifications........................................................................477
			General Engine Data..............................................................................477
			Lubrication System...............................................................................477
			Cooling System...................................................................................478
			Intake Air and Exhaust System....................................................................478
			Fuel System......................................................................................478
			Electrical System................................................................................479
			Batteries (Specific Gravity).....................................................................479
		Engine Diagrams......................................................................................480
	Troubleshooting Logic....................................................................................483
		Section T - Troubleshooting..........................................................................484
			Procedures and Techniques........................................................................484
		Troubleshooting Symptoms Charts......................................................................484
			Air Compressor Operates with Excessive Noise.....................................................485
			Air Compressor Pumping Excessive Lubricating Oil into Air System.................................486
			Air Compressor Air Pressure Rises Slowly.........................................................487
			Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)................488
			Air Compressor Will Not Pump Air Pressure........................................................489
			Air Compressor Will Not Stop Pumping Air.........................................................490
			Alternator Not Charging or Insufficient Charging.................................................491
			Compression Knock................................................................................492
			Coolant Contaminated.............................................................................493
			Coolant Loss.....................................................................................494
			Coolant Temperature Above Normal - Gradual Overheat..............................................496
			Coolant Temperature Above Normal - Sudden Overheat...............................................499
			Coolant Temperature Below Normal.................................................................501
			Engine Crankcase Gases (Blowby) - Excessive......................................................502
			Engine Cranks, But Will Not Start - No Smoke from Exhaust........................................503
			Engine Difficult to Start or Will Not Start - Exhaust Smoke Present..............................505
			Engine Idle Rough, Warm Engine...................................................................507
			Engine Misfiring.................................................................................509
			Engine Power Output Low..........................................................................511
			Engine Noise Excessive...........................................................................515
			Engine Starts But Will Not Keep Running..........................................................516
			Engine Surges at Idle............................................................................517
			Engine Vibration Excessive.......................................................................518
			Engine Will Not Crank or Cranks Slowly...........................................................519
			Engine Will Not Reach Rated Speed When Loaded....................................................520
			Engine Will Not Shut Off.........................................................................522
			Exhaust Black Smoke Excessive Under Load.........................................................523
			Exhaust White Smoke Excessive (Warm Engine)......................................................525
			Fuel Consumption Excessive.......................................................................526
			Fuel or Oil Leaking from Exhaust Manifold........................................................527
			Lubricating Oil Contaminated.....................................................................528
			Lubricating Oil Consumption Excessive............................................................529
			Lubricating Oil Pressure Low.....................................................................531
			Lubricating Oil Pressure High....................................................................533
			Engine Noise Diagnostic Procedures - General Information.........................................534
			Main Bearing Noise (Refer to Engine Noise Excessive - Main bearing System Chart).................534
			Connecting Rod Bearing Noise (Refer to Engine Noise Excessive - Connecting Rod Symptom Chart)....534
			Piston Noise (Refer to Engine Noise Excessive - Piston Symptom Chart)............................534
			Fuel Consumption - General Information...........................................................534
			Fuel Consumption - Industrial Customer Complaint Form............................................535
			Oil Consumption..................................................................................536
	Cooling System...........................................................................................538
		Belt Tensioner - Replacement.........................................................................564
			Installation.....................................................................................565
			Removal..........................................................................................564
			Removal and Installation.........................................................................565
		Cooling System - Diagnosing Malfunctions.............................................................550
			Belt Tension.....................................................................................555
			Coolant Hose - Inspection........................................................................556
			Coolant Pressure - Measurement...................................................................558
			Cooling System - Test for Combustion Gases.......................................................551
			Fuel Pump Overfueled.............................................................................563
			Radiator Cap - Pressure Test.....................................................................551
			Radiator, Fan and Shutters.......................................................................558
			Temperature Gauge Operation......................................................................563
			Thermostat Leakage and Opening Temperature - Testing "In-Chassis"................................561
			Thermostat Opening Temperature - Testing "Thermostat Removed"....................................562
			Thermostat Operation and Testing.................................................................560
			Vehicle Overloaded...............................................................................564
			Water Pump - Inspection..........................................................................556
			Water Pump Seal Weep Hole - Inspection...........................................................556
		Cooling System - Flow Diagrams.......................................................................540
		Cooling System - General Information.................................................................539
		Cooling System - Maintenance.........................................................................544
			Additive Concentration - Checking................................................................544
			Antifreeze.......................................................................................544
			Antifreeze Concentration - Checking..............................................................544
			Cooling System - Cleaning........................................................................545
			Cooling System - Draining........................................................................544
			Filling and Venting..............................................................................549
		Cooling System - Service Tools.......................................................................543
		Cooling System - Specifications......................................................................542
		Drive Belt - Replacement.............................................................................564
		Fan Hub - Replacement................................................................................565
			Removal and Installation.........................................................................566
		Fan Pulley - Replacement.............................................................................565
			Removal and Installation.........................................................................565
		Thermostat - Replacement.............................................................................569
			Cleaning.........................................................................................570
			Installation.....................................................................................570
			Removal..........................................................................................569
		Water Pump - Replacement.............................................................................566
			Cleaning.........................................................................................567
			Installation.....................................................................................567
			Removal..........................................................................................566
	Lubricating Oil System...................................................................................573
		Internal Engine Damage - Checking....................................................................583
			Lubricating Oil Analysis.........................................................................583
			Lubricating Oil Filter Inspection................................................................583
		Lubricating Oil Cooler Element and Gasket - Replacement..............................................600
			Cleaning and Inspection..........................................................................601
			Installation.....................................................................................602
			Removal..........................................................................................600
		Lubricating Oil Dipstick - Calibration...............................................................597
		Lubricating Oil Dipstick Tube - Replacement..........................................................598
			Installation.....................................................................................598
			Removal..........................................................................................598
		Lubricating Oil Filter - Changing....................................................................596
		Lubricating Oil Leaks (External) - Checking..........................................................582
		Lubricating Oil Level - Checking.....................................................................595
		Lubricating Oil Pan - Draining.......................................................................594
		Lubricating Oil Pan - Filling........................................................................594
		Lubricating Oil Pan, Suction Tube and Gasket - Replacement...........................................605
			Cleaning.........................................................................................605
			Oil Pan - Installation...........................................................................606
			Oil Pan - Removal................................................................................605
			Suction Tube - Replacement.......................................................................606
		Lubricating Oil Pressure Regulator, Valve and Spring - Replacement...................................599
			Cleaning and Inspection..........................................................................599
			Removal..........................................................................................599
			Installation.....................................................................................600
		Lubricating Oil Pump - Replacement...................................................................608
			Cleaning and Inspection..........................................................................609
			Installation.....................................................................................612
			Removal..........................................................................................609
		Lubricating Oil System - Diagnosing Malfunctions.....................................................584
			Aftercooler......................................................................................588
			Bearings and Oil Pump............................................................................587
			Coolant Diluted Oil..............................................................................587
			Cracked Cylinder Block...........................................................................590
			Cracked Cylinder Head............................................................................589
			Cracked Cylinder Liner...........................................................................590
			Cylinder Head Expansion Plugs....................................................................589
			Cylinder Head Gasket.............................................................................589
			Cylinder Liner Seals.............................................................................589
			Fuel Diluted Oil.................................................................................590
			Fuel Leaking by Piston Rings.....................................................................591
			Fuel Transfer Pump...............................................................................591
			High Oil Pressure................................................................................584
			Injection Pump...................................................................................592
			Low Oil Pressure.................................................................................584
			Oil Cooler.......................................................................................588
			Oil Dilution.....................................................................................587
			Oil Filter.......................................................................................585
			Oil Leaks........................................................................................592
			Oil Level........................................................................................584
			Oil Pressure Gauge - Checking....................................................................585
			Oil Pressure Regulating Valve....................................................................584
			Oil Suction Tube.................................................................................587
			Oil Temperature Gauge - Checking.................................................................586
			Oil Temperature Thermostat.......................................................................586
		Lubricating Oil System - Flow Diagram................................................................578
		Lubricating Oil System - General Information.........................................................576
		Lubricating Oil System - Service Tools...............................................................575
		Lubricating Oil System - Specifications..............................................................577
		Lubricating Oil Temperature Thermostat - Replacement.................................................603
			Inspection.......................................................................................604
			Installation.....................................................................................605
			Removal..........................................................................................603
	Air Combustion System Repair.............................................................................616
		Aftercooler and Gasket - Replacement.................................................................639
			Removal..........................................................................................640
			Cleaning.........................................................................................640
			Installation.....................................................................................640
		Air Crossover Tube - Replacement.....................................................................637
			Removal and installation.........................................................................637
		Air System Flow - Diagrams...........................................................................619
		Charge Air Cooler....................................................................................636
			Cleaning and inspection..........................................................................636
		Charge Air Cooler (CAC) - Troubleshooting............................................................633
			Pressure Drop - Checking.........................................................................633
			Checking - Air Leak..............................................................................635
		Combustion Air System - Diagnosing Malfunctions......................................................622
			Clean Air........................................................................................622
			Intake Air Restriction - Checking................................................................622
			Damage From Non-filtered Air.....................................................................623
			Turbocharged Engines - Air Leaks, Pressure Side..................................................623
			Turbocharged Engines - Exhaust Leaks.............................................................624
			Turbocharger Boost Pressure - Measurement........................................................624
			Malfunctioning Turbocharger......................................................................625
			Oil Consumption and Leaks........................................................................625
			Turbocharger Noise...............................................................................626
			Rotor Assembly Clearance - Measurement...........................................................627
		Combustion Air System Flow - General Information.....................................................618
		Combustion Air System - Service Tools................................................................621
		Exhaust Manifold and Gaskets - Replacement...........................................................645
			Removal..........................................................................................645
			Cleaning and Inspection..........................................................................646
			Installation.....................................................................................646
		Intake Air and Exhaust System Specifications.........................................................620
		Intake Manifold Cover and Gasket - Replacement.......................................................638
			Removal..........................................................................................638
			Cleaning.........................................................................................639
			Installation.....................................................................................639
		Turbocharger Boost Pressure Specifications...........................................................620
		Turbocharger - Replacement...........................................................................641
			Removal..........................................................................................641
			Cleaning and Inspection..........................................................................642
			Installation.....................................................................................643
		Turbocharger Wastegate Actuator - Calibration........................................................632
			Exhaust Restriction - Measurement................................................................633
		Turbocharger Wastegate Actuator - Functional Checking................................................629
		Turbocharger Wastegate Actuator - Replacement........................................................630
			Air regulator with pressure gauge................................................................630
		Turbocharger Wastegate Actuator - Visual Inspection..................................................628
	Compressed Air System Repair.............................................................................648
		Air Compressor Carbon Buildup - Checking.............................................................652
		Air Compressor Gasket Leaks - Checking...............................................................654
		Air Compressor - Replacement.........................................................................657
			Inspection.......................................................................................659
			Installation.....................................................................................659
			Removal..........................................................................................658
		Air Governor and Compressor Unloader Valve - Checking................................................654
		Air Governor - Checking..............................................................................655
		Compressed Air System Flow Diagrams..................................................................651
		Compressed Air System General Information............................................................649
		Compressed Air System Specifications.................................................................650
	Fuel System..............................................................................................662
		AFC Tube - Replacement...............................................................................692
			Removal..........................................................................................692
			Installation.....................................................................................692
		Fuel Drain Manifold - Replacement....................................................................687
			Removal and Installation.........................................................................687
		Fuel Filter Head Adapter - Replacement...............................................................682
			Removal and Installation.........................................................................682
		Fuel Injection Pump - Replacement....................................................................692
			Removal..........................................................................................693
			Installation.....................................................................................694
		Fuel Return Overflow Valve - Replacement.............................................................691
		Fuel Shutoff Solenoid - Replacement..................................................................689
			RSV Governor Fuel Shutoff Solenoid - Removal.....................................................689
			RSV Governor Fuel Shutoff Solenoid - Installation................................................690
			Direct Link Solenoid, Cylinder Block Mounted.....................................................690
			RQVK Governor Fuel Shutoff Solenoid - Removal and Installation...................................690
		Fuel System Components and Flow......................................................................664
		Fuel System Diagnosing - Malfunctions................................................................668
			Fuel Transfer Pump...............................................................................668
			Air in the Fuel System...........................................................................672
			Fuel Water Separator/Filter Unit.................................................................674
			Fuel Injection Pump..............................................................................675
			Governor Malfunctions............................................................................675
			Air Fuel Control (AFC) Malfunctions..............................................................675
			Fuel Control Lever Travel and Adjustment.........................................................676
			Fuel Injection Pump Idle Adjustment Screws.......................................................676
			Manual Shut Down Levers..........................................................................676
			Electrical Shut Down Devices.....................................................................677
			Fuel Injection Pump Timing.......................................................................678
			High Pressure Fuel Lines.........................................................................679
			Injectors........................................................................................680
			Fuel Drain Manifold..............................................................................681
		Fuel System - Service Tools..........................................................................666
		Fuel System Specifications...........................................................................665
		Fuel Transfer Pump - Replacement/Rebuild.............................................................683
			Removal..........................................................................................683
			Rebuild..........................................................................................683
			Cleaning.........................................................................................684
			Assembly.........................................................................................684
			Cleaning Mounting Surface........................................................................685
			Installation.....................................................................................685
		High Pressure Fuel Lines - Replacement...............................................................685
			Removal..........................................................................................685
			Installation.....................................................................................686
		Idle Speed - Adjustment..............................................................................699
			Bosch RSV Governor...............................................................................699
			Bosch RQVK Governor..............................................................................700
		Injector - Replacement...............................................................................687
			Removal..........................................................................................687
			Cleaning and Inspection..........................................................................687
			Installation.....................................................................................688
		Inline Fuel Injection Pump Spill-Port Timing.........................................................700
			Governor Lever Positioning.......................................................................702
		Low Pressure Fuel Line - Replacement.................................................................682
			Removal and Installation.........................................................................682
	Electrical System........................................................................................707
		Alternator - Replacement.............................................................................728
			Installation.....................................................................................729
			Removal..........................................................................................728
		Coolant Temperature Sensor - Replacement.............................................................729
			Installation.....................................................................................730
			Removal..........................................................................................730
		Electrical System Description and Operation..........................................................708
			Bosch Kl Model Alternator (Wiring Diagram).......................................................711
			Cranking Motor and Electrical Circuits...........................................................708
			Delco 42MT Starting Motor........................................................................712
			Delco Remy Model 15SI 116 Alternator (Wiring Diagram)............................................711
			Delco Remy Model 37MT/41MT Starting Motor........................................................709
			Delco Remy Model 42MT Starting Motor.............................................................709
			Nippondenso F4 Starting Motor....................................................................712
			Nippendenso Model F2 Starting Motor..............................................................710
			Nippendenso Model F2 Basic Cranking Current Flow.................................................710
		Electrical System - Diagnosing Malfunctions..........................................................716
			Alternator.......................................................................................723
			Batteries - Checking.............................................................................716
			Coolant or Pan Heaters - Checking................................................................727
			Engine Cranking Speed Too Slow...................................................................722
			Oil Pressure Switch and Temperature Sensor - Checking............................................726
			Starting Circuit - Checking......................................................................717
			Starting Motor Solenoid and Starting Motor.......................................................720
		Electrical System - Service Tools....................................................................715
		Electrical System - Specifications...................................................................713
			Maximum Allowable Resistance of Starting Circuit.................................................713
			Minimum Recommended Battery Capacity.............................................................713
			Wiring Size Recommendations for Starter Solenoid and Fuel Solenoid Circuit.......................714
		Engine Block and Coolant Heater (750 and 500 Wats) - Replacement.....................................730
			Installation.....................................................................................731
			Removal..........................................................................................731
		Lubricating Oil Pan Heater - Replacement.............................................................731
			Installation.....................................................................................732
			Removal..........................................................................................732
		Lubricating Oil Pressure Switch - Replacement........................................................732
			Installation.....................................................................................732
			Removal..........................................................................................732
		Starting Motor - Replacement.........................................................................727
			Removal and Installation.........................................................................728
	Base Engine Components...................................................................................733
		Base Engine Components - General Information.........................................................741
		Base Engine Components - Service Tools...............................................................736
		Camshaft - Replacement...............................................................................860
			General Information..............................................................................860
			Removal..........................................................................................862
			Cleaning and Inspection..........................................................................865
			Installation.....................................................................................869
		Camshaft Gear - Replacement..........................................................................872
			Removal..........................................................................................872
			Cleaning and Inspection..........................................................................872
			Installation.....................................................................................874
		Connecting Rod Bearings - Replacement................................................................791
			Diagnosing Malfunctions..........................................................................791
			Removal..........................................................................................792
			Cleaning and Inspection..........................................................................793
			Installation.....................................................................................796
		Connecting Rods - Replacement........................................................................815
			General Information..............................................................................815
			Removal..........................................................................................816
			Cleaning and Inspection..........................................................................817
			Installation.....................................................................................819
		Crankcase Breather Tube - Replacement................................................................745
			Removal..........................................................................................745
			Cleaning and Inspection..........................................................................745
			Installation.....................................................................................746
		Crankshaft Gear - Replacement........................................................................884
			General Information..............................................................................884
			Removal..........................................................................................885
			Cleaning and Inspection..........................................................................887
			Installation.....................................................................................888
		Cup Plug - Replacement...............................................................................916
			Removal..........................................................................................916
			Cleaning and Inspection..........................................................................917
			Installation.....................................................................................917
		Cylinder Head - Pressure Test........................................................................779
		Cylinder Head - Replacement..........................................................................762
			General Information..............................................................................762
			Diagnosing Malfunctions..........................................................................762
			Removal..........................................................................................765
			Cylinder Block/Head Deck Cleaning and Inspection.................................................766
			Cylinder Head - Cleaning and Inspection..........................................................769
			Installation.....................................................................................774
		Cylinder Liners - Replacement........................................................................821
			General Information..............................................................................821
			Removal..........................................................................................821
			Cleaning and Inspection..........................................................................825
			Installation.....................................................................................828
		Engine Compression - Checking........................................................................741
			Compression Gauge and Adapter....................................................................741
			Piston Ring Sealing..............................................................................742
			Intake and Exhaust Valve Sealing.................................................................742
			Cylinder Head Gasket Sealing.....................................................................742
		Engine Dataplate - Replacement.......................................................................858
			Removal..........................................................................................859
			Installation.....................................................................................859
		Flywheel - Replacement...............................................................................891
			Removal..........................................................................................891
			Cleaning and Inspection..........................................................................892
			Installation.....................................................................................893
			Flywheel Bore Runout Measurement.................................................................895
			Flywheel Face Runout Measurement.................................................................896
		Flywheel Housing - Replacement.......................................................................898
			Removal..........................................................................................898
			Cleaning and Inspection..........................................................................900
			Installation (Dry Clutch Application)............................................................901
			Concentricity - Checking.........................................................................902
			Installation (Wet Clutch Application)............................................................904
		Flywheel Ring Gear - Replacement.....................................................................898
			Removal..........................................................................................898
			Installation.....................................................................................898
		Gear Cover - Replacement.............................................................................840
			Removal..........................................................................................840
			Cleaning and Inspection..........................................................................841
			Installation.....................................................................................842
		Gear Housing - Replacement...........................................................................849
			General Information..............................................................................849
			Removal..........................................................................................850
			Cleaning and Inspection..........................................................................851
			Installation.....................................................................................853
		Main and Thrust Bearings - Replacement...............................................................780
			General Information..............................................................................780
			Diagnosing Malfunctions..........................................................................781
			Removal..........................................................................................782
			Cleaning and Inspection..........................................................................784
			Installation.....................................................................................786
		Pipe Plug - Replacement..............................................................................915
			Removal..........................................................................................915
			Cleaning and Inspection..........................................................................915
			Installation.....................................................................................916
		Pistons and Rings - Replacement......................................................................798
			Piston - General Information.....................................................................798
			Piston and Rings - Diagnosing Malfunctions.......................................................798
			Removal..........................................................................................800
			Cleaning and Inspection..........................................................................803
			Installation.....................................................................................808
		Push Rod - Replacement...............................................................................759
			Removal..........................................................................................759
			Cleaning and Inspection..........................................................................760
			Installation.....................................................................................761
		Rocker Lever - Replacement...........................................................................747
			Removal..........................................................................................747
			Disassembly......................................................................................748
			Cleaning and Inspection..........................................................................749
			Assembly.........................................................................................750
			Installation.....................................................................................751
		Rocker Lever Diagnosing - Malfunctions...............................................................746
			Valve Lash Specifications........................................................................746
		Seal, Front Crankshaft - Replacement.................................................................844
			General Information..............................................................................844
			Removal and Installation.........................................................................845
		Seal, Rear Crankshaft - Replacement..................................................................906
			Removal..........................................................................................906
			Cleaning and Inspection..........................................................................907
			Installation.....................................................................................908
		Timing Pin Assembly - Installation...................................................................755
		Valve Cover - Replacement............................................................................743
			Removal..........................................................................................743
			Cleaning and Inspection..........................................................................744
			Installation.....................................................................................744
		Valve Lash - Adjustment..............................................................................752
			Valve Arrangement................................................................................754
		Valve Tappet - Replacement...........................................................................875
			General Information..............................................................................875
			Removal..........................................................................................876
			Cleaning and Inspection..........................................................................879
			Installation.....................................................................................880
		Vibration Damper - Replacement.......................................................................835
			General Information..............................................................................835
			Rubber Element Vibration Damper - Inspection (In-Chassis)........................................835
			Viscous Vibration Damper - Inspection............................................................837
			Removal..........................................................................................838
			Installation.....................................................................................839
		Wear Sleeve, Front Crankshaft - Replacement..........................................................845
			Removal..........................................................................................845
			Cleaning and Inspection..........................................................................846
			Installation.....................................................................................846
		Wear Sleeve, Rear Crankshaft Seal - Replacement......................................................909
			Removal..........................................................................................909
			Cleaning and Inspection..........................................................................911
			Installation.....................................................................................912
	Engine Testing...........................................................................................919
		Blowby Measurement...................................................................................922
		Engine Run-in Procedure..............................................................................926
		Engine Testing - General Information.................................................................920
		Engine Testing - General Specifications..............................................................921
		Engine Testing - Service Tools.......................................................................923
		General Engine Test Procedures.......................................................................924
	Engine Removal and Installation..........................................................................928
		Engine - Installation................................................................................932
			Throttle Control Lever Connection................................................................933
		Engine Mount - Inspection............................................................................932
		Engine Removal and Installation - General Information................................................929
		Engine - Removal.....................................................................................929
	Engine Component Specifications..........................................................................937
		Capscrew Markings and Torque Values..................................................................967
			Capscrew Markings and Torque Values - Metric.....................................................968
			Capscrew Markings and Torque Values - U.S. Customary.............................................969
		Component Specifications and Torque Values...........................................................939
			Base Engine Component Specifications.............................................................950
			Base Engine Torque Values........................................................................961
			Combustion Air System Specifications.............................................................943
			Combustion Air System Torque Values..............................................................943
			Compressed Air System Torque Values..............................................................944
			Cooling System Specifications....................................................................939
			Cooling System Torque Values.....................................................................939
			Electrical System Specifications.................................................................949
			Electrical System Torque Values..................................................................949
			Fuel Shutoff solenoid Adjustment.................................................................945
			Fuel System Specifications.......................................................................945
			Fuel System Torque Values........................................................................946
			Lubricating Oil System Specifications............................................................940
			Lubricating Oil System Torque Values.............................................................941
		Drive Belt Tension...................................................................................963
		Newton-Meter to Foot-Pound Conversion Chart..........................................................966
		Pipe Plug Torque Values..............................................................................970
		Specification - General Information..................................................................938
		Weight and Measures - Conversion Factors.............................................................965
	Index....................................................................................................971

KOMATSU S6D114E-1, SA6D114E-1, SAA6D114E-1 DIESEL ENGINE WORKSHOP REPAIR SERVICE MANUAL – PDF DOWNLOAD:

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