Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

Description

Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

About the Manual:

• This 6D114E-1 Series Shop Manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding
  and assembly of components of the 6D114E-1 Series engines. The manual is divided into sections. Section 00 outlines
  the disassembly and assembly of the engine while the other section detail specific components.
• The procedures in this manual were developed for a shop environment with engine disassembly and assembly being
  performed on a rollover stand. A Group System has been used to subdivide the instructions by major components and
  systems. Refer to the Table of Contents (page i-l) for the various groups. The information is presented in very basic terms to make sure the instructions are easily understood. Wrench sizes and shop tooling are identified in the procedure when needed.

Each group contains the following in sequence:

An Alphabetical Table of Contents (Index).
Exploded view(s) of all the components -in the group.
General Information Section(s) containing the basic service, maintenance, and design information necessary to assist
in the rebuild of the engine or a component.
Procedural instructions for the disassembly, inspection, repair, and assembly that can be required to rebuild an
engine. Additional repairs that are not essential during every rebuild, but can be necessary, are included. These
repairs depend on the length of time an engine has been in service and the condition of the parts.

TABLE OF CONTENTS:

Komatsu S6D114E-1 SA6D114E-1 SAA6D114E-1 Series Engine Shop Manual CEBM000601 – PDF DOWNLOAD

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

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