Komatsu KDC 410 & KDC 610 & KDC 614 Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu KDC410, KDC610, KDC 614 Series, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu KDC 410 & KDC 610 & KDC 614 Series Engine workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,802 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM610SH0 - KDC 410 & KDC 610 Series Engine (1991 Series) Shop Manual.pdf
CEBM610TR0 - KDC 410 & KDC 610 Series Engine (1991 Series) Troubleshooting & Repair Manual.pdf
CEBM614SH0 - KDC 614 Series Engine (1991 Series) Shop Manual.pdf
CEBM614TR1 - KDC 614 Series Engine (1991 Series) Troubleshooting & Repair Manual.pdf
MAIN SECTIONS
Main Menu...0
Table of Contents...5
Section i - 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
Table of Contents...11
Group Contents...11
Index...11
Metric Information...11
Illustrations...13
Section E - Engine and Component Identification...19
Engine Diagrams...24
Engine Identification...20
Engine Dataplate...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...138
Aftercooler - Installation...123
Air Compressor - Installation...145
Air Crossover Tube - Installation...127
Alternator Brace - Installation...130
Alternator - Installation...129
Alternator Mounting Bracket - Installation...129
Belt Tensioner Bracket - Installation...131
Belt Tensioner - Installation...131
Camshaft - Installation...91
Connecting Rod Bolt - Installation...80
Coolant Filter - Installation...128
Coolant Heater - Installation...108
Coolant Inlet Connection - Installation...129
Coolant Outlet Connection - Installation...128
Coolant Vent Fitting - Installation...128
Coolant Vent Petcock - Installation...128
Coolant Vent Tube - Installation...129
Crankcase Breather Tube - Installation...121
Crankshaft - Installation...73
Cylinder Block - Installation onto Engine Rebuild Stand...65
Cylinder Head - Installation...111
Cylinder Liner - Installation...66
Drive Belt - Installation...144
Engine Lifting Bracket - Installation...122
Engine - Removal from the Rebuild Stand...131
Engine Support, Front - Installation...144
Exhaust Manifold - Installation...123
Fan Hub Assembly - Installation...132
Flywheel Bore Runout Measurement...105
Flywheel Face Runout Measurement...107
Flywheel Housing - Installation...98
Flywheel - Installation...103
Fuel Drain Manifold - Installation...122
Fuel Filter Head - Installation...137
Fuel Filter - Installation...137
Fuel Injection Pump - Installation...132
Fuel Injection Pump Supply Line - Installation...136
Fuel Lines, High Pressure - Installation...138
Fuel Lines, Low Pressure - Installation...145
Fuel Pump Solenoid - Installation...145
Fuel Transfer Pump - Installation...144
Gear Cover - Installation...142
Gear Housing - Installation...88
Injector - Installation...121
Intake Manifold Cover - Installation...122
Lubricating Oil Cooler - Installation...110
Lubricating Oil Filter - Installation...111
Lubricating Oil Pan - Installation...94
Lubricating Oil Pump - Installation...90
Lubricating Oil Suction Tube - Installation...94
Main Bearing (Lower) - Installation...73
Main Bearing (Upper) - Installation...72
Main Bearing Cap - Installation...73
Piston Assembly - Installation...84
Piston Cooling Nozzle - Installation...71
Piston Pin - Installation...80
Piston Ring End Gap - Measurement...81
Piston Ring - Installation...82
Push Rod - Installation...115
Rocker Lever and Shaft - Assembly...115
Rocker Lever Assembly - Installation...117
Seal, Front Crankshaft - Installation...139
Seal, Rear Crankshaft - Installation...77
Starting Motor - Installation...108
Tachometer Drive - Installation...143
Thermostat and Housing - Installation...127
Timing Pin Assembly - Installation...95
Turbocharger Exhaust Outlet Connection Installation...127
Turbocharger - Installation...124
Turbocharger Oil Drain Tube - Installation...125
Turbocharger Oil Supply Hose - Installation...126
Valve Arrangement...119
Valve Clearance - Adjustment...118
Valve Cover - Installation...120
Valve Tappet - Installation...70
Vibration Damper - Installation...143
Water Pump - Installation...93
Engine Accessories - Installation...147
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 Tube - Removal...49
Coolant Vent Petcock - Removal...49
Coolant Vent Tube Fitting - 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...149
Camshaft Bore Expansion Plug - Installation...168
Camshaft Bushing Bore - Cleaning...170
Camshaft Bushing - Installation...170
Camshaft Bushing - Removal...169
Camshaft - Cleaning and Inspection for Reuse...197
Camshaft - Cleaning...197
Camshaft Gear - Inspection...200
Camshaft - Inspection...197
Camshaft Gear - Replacement...201
Camshaft Gear - Cleaning...201
Camshaft Gear - Inspection...201
Camshaft Gear - Installation...203
Camshaft Gear - Removal...201
Connecting Rod Bearings - Cleaning and Inspection for Reuse ...186
Connecting Rod Bearings - Cleaning ...186
Connecting Rod Bearings - Inspection ...186
Connecting Rod Bushing - Replacement ...192
Inspection ...196
Installation ...194
Machining ...196
Removal...192
Connecting Rods - Bend and Twist Inspection...190
Connecting Rod Alignment - Inspection ...191
Connecting Rod Twist - Inspection ...191
Fixture Calibration ...190
Connecting Rods - Cleaning and Inspection for Reuse ...187
Connecting Rods - Cleaning ...187
Connecting Rods - Inspection ...188
Crankshaft - Cleaning and Inspection for Reuse...176
Crankshaft - Cleaning...176
Crankshaft - Inspection...177
Crankshaft Gear - Replacement...180
Crankshaft Gear - Inspection ...181
Crankshaft Gear - Installation ...182
Crankshaft Gear - Removal ...180
General Information ...180
Cylinder Block - Cleaning in a Hot Tank...162
Cylinder Block - Cleaning with Solvent...159
Cylinder Block - Disassembly...157
Cylinder Block - Exploded View...154
Cylinder Block - General Information...156
Camshaft...156
Connecting Rods...156
Crankshaft...156
Cylinder Block...156
Cylinder Liner...156
Oil Seals...156
Pistons...156
Vibration Damper...156
Cylinder Block - Inspection For Reuse...163
Cylinder Block - Preparation for Cleaning...157
Cylinder Block - Service Tools...151
Cylinder Head Capscrews - Cleaning and Inspection for Reuse ...211
Cleaning...211
Free Length - Measurement...213
Inspection...212
Cylinder Liners - Cleaning and Inspection for Reuse...171
Cylinder Liners - Cleaning...171
Cylinder Liners - Inspection...172
Dowel Pins (Cylinder Head) - Removal...158
Engine Dataplate - Replacement ...206
Engine Dataplate - Installation...206
Engine Dataplate - Removal...206
Engine Lifting Brackets - Cleaning and Inspection for Reuse...213
Expansion Plug - Installation...166
Pipe Plug - Installation...167
Gear Cover - Cleaning and Inspection for Reuse...207
Gear Cover - Cleaning...207
Gear Cover - Inspection...207
Gear Housing - Cleaning and Inspection for Reuse...204
Gear Housing - Cleaning...204
Gear Housing - Inspection...204
Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse ...185
Cleaning ...185
Inspection ...186
Main Bearings - Cleaning and Inspection for Reuse...183
General Information ...183
Main Bearings - Cleaning ...184
Main Bearings - Inspection ...184
Thrust Bearings - Inspection ...185
Pistons - Cleaning and Inspection for Reuse...174
Piston Rings - Removal...174
Pistons - Cleaning...174
Pistons - Inspection...175
Rear Cover - Cleaning and Inspection...210
Cleaning...210
Inspection...211
Vibration Damper - Cleaning and Checking for Reuse...208
General Information...208
Rubber Element Vibration Damper - Inspection...208
Rubber Vibration Damper - Cleaning...208
Viscous Vibration Damper - Cleaning...209
Viscous Vibration Damper - Inspection...209
Cylinder Head - Group 02...215
Cylinder Head Capscrew - Cleaning and Inspection...251
Cleaning...251
Inspection...252
Cylinder Head - Cleaning and Inspection for Reuse ...223
Cleaning...223
Handling...223
Inspection...224
Cylinder Head - Exploded View...220
Cylinder Head - General Information...222
Cylinder Head - Pressure Testing...248
Cylinder Head - Rebuild...225
Assembly...240
Cleaning...226
Disassembly...225
Inspection...227
Valve - Grinding...235
Valve Guide - Inspection...231
Valve - Inspection...234
Valve Seat Insert - Grinding...236
Valve Seat Insert - Inspection...232
Valve Spring - Inspection...233
Valve Stem Seal - Inspection...233
Cylinder Head - Service Tools...216
Cylinder Head - Vacuum Testing Valve Seating...250
Cylinder Head - Valve Guide Replacement...242
Assembly...243
Disassembly...242
Inspection...243
Cylinder Head - Valve Seat Insert Replacement...245
Inspection...247
Installation...247
Removal...245
Free Length - Measurement...253
Rocker Levers - Group 03...255
Crankcase Breather Tube - Cleaning and Inspection for Reuse...262
Cleaning and Inspection...262
Rocker Assembly Oil Manifold - Cleaning . and Inspection for Reuse...261
Cleaning...261
Inspection...261
Rocker Lever Assembly - Cleaning and Inspection...258
Assembly...260
Cleaning...259
Disassembly...258
Inspection...259
Rocker Lever Assembly - Exploded View...256
Rocker Lever Assembly - General Information...257
Valve Cover - Cleaning and Inspection for Reuse...262
Cleaning...262
Inspection...262
Valve Tappets and Push Rods - Group 04...263
Push Rods - Reuse Cleaning and Inspection for...266
Cleaning...266
Inspection...266
Valve Tappet Cleaning and Inspection for Reuse...265
Cleaning...265
Inspection...265
Valve Tappets and Push Rods - Exploded View...264
Valve Tappets and Push Rods - General Information...265
Fuel Systems - Group 05...269
Fuel Injection Pump Gaskets and Seals - Replacement...279
Fuel System - General Information...270
Derivative Fuel Injection Pump - Data Tag Information...271
Fuel Injection Pump...270
Fuel Injection Pump - Data Tag Information...270
Fuel Injection Pump - Data Tag Location...270
Fuel Shutoff Solenoid - Wiring Requirements...271
Governor - Data Tag Information...271
Fuel Transfer Pump - Exploded View...272
Fuel Transfer Pump - Rebuild ...273
Cleaning...273
Assembly...273
RQVK Governor Fuel Shutoff Solenoid - Adjustment...277
RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment...274
Fuel Shutoff Solenoid - Adjustment...276
Fuel Shutoff Solenoid - Orientation...274
Shutdown Lever or Spring - Replacement...278
Injectors and Fuel Lines - Group 06...281
Fuel Drain Manifold - Inspection...296
Fuel Lines, High Pressure - Cleaning and Inspection for Reuse...294
Fuel Lines - Cleaning and Inspection...295
General Information...294
Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse...296
Injector - Chatter Testing...294
Injector - Spray Testing...293
Injectors and Fuel Lines - Exploded View...283
Injectors and Fuel Lines - Exploded View...285
Injectors and Fuel Lines - Exploded View...286
Injectors and Fuel Lines - General Information...287
Injectors and Fuel Lines - Service Tools...282
Injectors - Cleaning and Inspection for Reuse...288
General Information...288
Injector - Assembly...292
Injector - Cleaning and Inspection...290
Injector - Disassembly...288
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...317
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...319
Cooling System - General Information...320
Belt Tensioner...320
Cooling Fans...320
Fan Hub...320
Pressure Caps...320
Thermostats...320
Water Pump...320
Cooling System - Service Tools...318
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 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...337
Aftercooler Assembly - Cleaning and Inspection for Reuse...343
Inspection...344
Aftercooler Assembly - Rebuild...344
Air Crossover Tube - Cleaning and Inspection for Reuse...345
Cleaning...345
Inspection...345
Air Intake System - Exploded View...339
Air Intake System - General Information...340
Air Intake System - Service Tools...338
Air Transfer Pipe - Cleaning and Inspection for Reuse...345
Cleaning...345
Inspection...345
Intake Manifold Cover - Cleaning and Inspection for Reuse...343
Inspection...343
Turbocharger - Cleaning and Inspection for Reuse...341
Inspection...341
Exhaust System - Group 11...347
Exhaust Manifold - Cleaning and Inspection for Reuse...350
Cleaning...350
Inspection...350
Exhaust Manifold - Exploded View...348
Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse...352
Cleaning...352
Inspection...352
Exhaust Manifold Turbocharger Mounting Stud - Replacement...351
Inspection...351
Installation...351
Removal...351
Exhaust System - General Information...349
Exhaust Manifold...349
Air Equipment - Group 12...353
Electrical Equipment - Group 13...355
Engine Testing - Group 14...357
Blowby Measurement...363
Engine Dynamometer Test - Engine Run-In...373
Engine Dynamometer Test - Installation of the Engine...365
Engine Dynamometer Test - Performance Checking...377
Engine Painting ...382
Engine Run-In Procedure - "In-Chassis"...380
Engine Run-In - General Procedures...364
Engine Storage - Long Term...385
Engine Removal from Long Term Storage...388
Engine Storage - Short Term...383
Engine Removal From Short Term Storage...385
Engine Testing - Component Identification and Diagrams...359
Engine Testing - General Information...361
Engine Dynamometer Run-in...361
In-Chassis Run-In...361
Engine Testing - General Specifications...362
Engine Testing - Service Tools...358
Fuel Injection Pump - Idle Speed Adjustment...381
RSV Governor...381
RQV and RQVK Governor...382
General Engine Test Procedure - In Chassis...379
Instruments and Controls - Group 15...393
Mounting Adaptations - Group 16...395
Engine Support Bracket, Front - Cleaning and Inspection for Reuse...403
Cleaning...403
Inspection...403
Flexplate Assembly - Cleaning and Inspection for Reuse...400
Flywheel - Cleaning and Inspection for Reuse...399
Cleaning...399
Inspection...399
Flywheel Housing - Assembly (Wet Clutch Application)...402
Flywheel Housing - Cleaning and Inspection for Reuse...401
Cleaning...401
Inspection...401
Flywheel Ring Gear - Replacement...400
Installation...400
Removal...400
Mounting Adaptations - Exploded View...397
Mounting Adaptations - General Information...398
Flywheel and Ring Gear...398
Flywheel Housing...398
Mounting Adaptations - Service Tools...396
Section V - Specifications and Torque Values - Group 18...405
Air Compressor Inspection Specifications...441
Air Compressor Torque Values...441
Capscrew Markings and Torque Values...449
Capscrew Markings and Torque Values - Metric...450
Capscrew Markings and Torque Values - U.S. Customary...450
Component Specifications and Torque Values...407
Cylinder Block - Rebuild Specifications...419
Cylinder Block - Torque Values...425
Cylinder Head - Rebuild Specifications...426
Engine Assembly - Specifications...407
Engine Assembly - Torque Values...409
Cooling System Specifications...437
Air Intake System Specifications...439
Air Intake System Torque Values...439
Cooling System Torque Values...438
Drive Belt Tension...445
Electrical System Specifications...442
Electrical System Torque Values...442
Engine Components - General Information...406
Engine Testing - Test Specifications...443
Exhaust System Specifications...441
Exhaust System Torque Values...441
Fuel Systems - Rebuild Specifications...429
Fuel Injection Pump Sealing Washer...431
Fuel Shutoff Solenoid Adjustment...431
Fuel System Specifications...429
Fuel System Torque Values...431
Lubricating Oil System Specifications...434
Lubricating Oil System Torque Values...435
Mounting Adaptations Specifications...443
Flywheel Housing (Wet Application)...443
Flywheel Ring Gear Installation...444
Mounting Adaptations - Torque Values...444
Newton-Meter to Foot-Pound Conversion Chart...448
Pipe Plug Torque Values...451
Rocker Lever Assembly - Rebuild Specifications...429
Tap-Drill - U.S. Customary & Metric...452
Valve Tappet - Rebuild Specifications...429
Weight and Measures - Conversion Factors...447
Section L - Service Literature...453
Index...457
