Komatsu 76E-6 Series Engine Shop Manual SEN05334-01 – PDF DOWNLOAD

Komatsu 76E-6 Series Engine Shop Manual SEN05334-01 – PDF DOWNLOAD

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Komatsu 76E-6 Series Engine Shop Manual SEN05334-01 – PDF DOWNLOAD

Language : English
Pages : 278
Downloadable : Yes
File Type : PDF
Size: 13.4 MB

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Komatsu 76E-6 Series Engine Shop Manual SEN05334-01 – PDF DOWNLOAD

Introduction:
This manual describes the maintenance procedure for 76E-6 Series engines (swirl chamber type).
The contents of this manual shall be used as materials for correct, quick and safe maintenance of the above
engines.
Since this manual explains the maintenance procedure for the standard engine, the specifications and component
parts shown below are partly different from those of the engine mounted on each work equipment
(generator, pump, compressor, etc.)
This shop manual consists of volumes.
Some volumes titled “Testing and adjusting” [Testing and adjusting, Part 1 – Part 8] contain descriptions
related to disassembly and assembly.
For the contents of description, see the general contents or the contents of each volume.

TABLE OF CONTENTS:

Komatsu 76E-6 Series Engine Shop Manual SEN05334-01 – PDF DOWNLOAD

Cover………………………………………………………….. 1
00 Index and foreword……………………………………………. 0
100 Index…………………………………………………… 3
Composition of shop manual………………………………… 4
Table of contents………………………………………… 5
200 Foreword and general information…………………………… 11
Introduction…………………………………………….. 12
Applicable machine model and serial number………………….. 13
Safety Statements………………………………………… 14
Safety Precautions……………………………………….. 15
01 Specification………………………………………………… 33
100 Specification and technical data…………………………… 33
Component Identification………………………………….. 35
Location of Labels……………………………………….. 36
Function of Major Engine Components………………………… 37
Function of Cooling System Components………………………. 39
Diesel Fuel……………………………………………… 40
Diesel Fuel Specifications…………………………….. 40
Filling the Fuel Tank…………………………………. 41
Priming the Fuel System……………………………….. 43
Engine Oil………………………………………………. 44
Engine Oil Specifications……………………………… 44
Service Categories……………………………………. 44
Engine Oil Viscosity………………………………….. 45
Checking Engine Oil…………………………………… 45
Adding Engine Oil…………………………………….. 45
Engine Oil Capacity (Typical)………………………….. 46
Engine Coolant…………………………………………… 46
Engine Coolant Specifications………………………….. 47
Filling Radiator with Engine Coolant……………………. 48
Engine Coolant Capacity (Typical)………………………. 48
Specifications…………………………………………… 49
Description of Model Number……………………………. 49
Engine Speed Specifications……………………………. 49
Engine General Specifications………………………….. 50
Principal Engine Specifications……………………………. 51
Engine Service Information………………………………… 52
Tightening Torques for Standard Bolts and Nuts………………. 53
Abbreviations and Symbols…………………………………. 55
Abbreviations………………………………………… 55
Symbols……………………………………………… 55
Unit Conversions…………………………………………. 56
Unit Prefixes………………………………………… 56
Units of Length………………………………………. 56
Units of Volume………………………………………. 56
Units of Mass………………………………………… 56
Units of Force……………………………………….. 56
Units of Torque………………………………………. 56
Units of Pressure…………………………………….. 56
Units of Power……………………………………….. 56
Units of Temperature………………………………….. 56
30 Testing and adjusting…………………………………………. 59
101 Testing and adjusting, Part 1……………………………… 59
Introduction…………………………………………….. 60
Precautions……………………………………………… 72
The Importance of Periodic Maintenance………………….. 72
Performing Periodic Maintenance………………………… 72
Komatsu Replacement Parts……………………………… 73
Periodic Maintenance Schedule……………………………… 73
Periodic Maintenance Procedures……………………………. 75
After Initial 50 Hours of Operation…………………….. 75
Every 50 Hours of Operation……………………………. 78
Every 250 Hours of Operation…………………………… 81
Every 500 Hours of Operation…………………………… 86
Every 1000 Hours of Operation………………………….. 89
Every 1500 Hours of Operation………………………….. 91
Every 2000 Hours of Operation………………………….. 93
102 Testing and adjusting, Part 2……………………………… 95
Before You Begin Servicing………………………………… 97
Introduction…………………………………………….. 99
Cylinder Head Specifications………………………………. 99
Adjustment Specifications……………………………… 99
Cylinder Head………………………………………… 99
Intake / Exhaust Valve and Guide………………………..100
Push Rod……………………………………………..100
Valve Spring………………………………………….100
Rocker Arm and Shaft…………………………………..100
Camshaft and Timing Gear Train Specifications………………..101
Camshaft……………………………………………..101
Idler Gear Shaft and Bushing……………………………101
Timing Gear Backlash…………………………………..101
Crankshaft and Pistons Specifications……………………….102
Crankshaft……………………………………………102
Crankshaft Reconditioning………………………………102
Thrust Bearing………………………………………..102
Piston……………………………………………….103
Piston Ring…………………………………………..103
Connecting Rod………………………………………..104
Tappet……………………………………………….104
Cylinder Block Specifications………………………………105
Cylinder Block………………………………………..105
Special Torque Chart………………………………………105
Torque for Bolts and Nuts………………………………105
Special Service Tools……………………………………..106
Measuring Instruments……………………………………..108
Cylinder Head…………………………………………….110
Cylinder Head Components……………………………….110
Disassembly of Cylinder Head……………………………111
Cleaning of Cylinder Head Components…………………….115
Inspection of Cylinder Head Components…………………..115
Reassembly of Cylinder Head…………………………….119
Measuring and Adjusting Valve Clearance………………….123
Cylinder Block……………………………………………126
Crankshaft and Camshaft Components………………………126
Disassembly of Cylinder Block Components…………………127
Disassembly of Camshaft and Timing Components…………….128
Disassembly of Crankshaft and Piston Components…………..132
Inspection of Crankshaft and Camshaft Components………….136
Reconditioning the Crankshaft…………………………..141
Honing and Boring……………………………………..142
Reassembly of Crankshaft and Piston Components……………143
Reassembly of Camshaft and Timing Components……………..149
103 Testing and adjusting, Part 3………………………………153
Before You Begin Servicing…………………………………155
Introduction……………………………………………..157
Fuel Injection Pump……………………………………157
Stop Solenoid…………………………………………158
Fuel System Specifications…………………………………159
Special Torque Chart…………………………………..159
Test and Adjustment Specifications………………………159
Special Service Tools……………………………………..160
Measuring Instruments……………………………………..160
Fuel System Diagram……………………………………….161
Fuel System Components…………………………………….162
Fuel Injection Lines………………………………………163
Removal of High-Pressure Fuel Injection Lines…………….163
Installation of High-Pressure Fuel Injection Lines………..163
Removal of Fuel Return Line…………………………….164
Installation of Fuel Return Line………………………..164
Fuel Injection Pump……………………………………….165
Removal of Fuel Injection Pump………………………….165
Installation of Fuel Injection Pump……………………..168
Checking and Adjusting Fuel Injection Timing…………………171
Checking Fuel Injection Timing………………………….171
Adjusting Fuel Injection Timing…………………………174
Fuel Injectors……………………………………………175
Removal of Fuel Injectors………………………………175
Testing of Fuel Injectors………………………………175
Disassembly and Inspection of Fuel Injectors……………..178
Adjusting Fuel Injector Pressure………………………..179
Reassembly of Fuel Injectors……………………………180
Installation of the Fuel Injectors………………………180
104 Testing and adjusting, Part 4………………………………183
Before You Begin Servicing…………………………………184
Introduction……………………………………………..186
Cooling System Diagram…………………………………….186
Engine Coolant Pump Components……………………………..187
Engine Coolant System Check………………………………..188
Engine Coolant Pump……………………………………….189
Disassembly of Engine Coolant Pump………………………189
Cleaning and Inspection………………………………..190
Reassembly of Engine Coolant Pump……………………….191
105 Testing and adjusting, Part 5………………………………195
Before You Begin Servicing…………………………………196
Introduction……………………………………………..198
Oil Pump Service Information……………………………….198
Engine Oil Pressure……………………………………198
Outer Rotor Outside Clearance…………………………..198
Outer Rotor Side Clearance……………………………..198
Outer Rotor to Inner Rotor Tip Clearance…………………198
Inner Rotor and Gear Boss Clearance……………………..198
Lubrication System Diagram…………………………………199
Checking Engine Oil Pressure……………………………….200
Trochoid Oil Pump…………………………………………201
Oil Pump Components……………………………………201
Disassembly of Oil Pump………………………………..201
Cleaning and Inspection………………………………..202
Reassembly of Oil Pump…………………………………204
106 Testing and adjusting, Part 6………………………………207
Before You Begin Servicing…………………………………208
Introduction……………………………………………..210
Starter Motor Information………………………………….210
Starter Motor Specifications……………………………….211
Starter Motor Troubleshooting………………………………212
Starter Motor Components…………………………………..213
Starter Motor…………………………………………….214
Removal of Starter Motor……………………………….214
Disassembly of Starter Motor……………………………214
Cleaning and Inspection………………………………..217
Reassembly of Starter Motor…………………………….221
Check Pinion Projection Length………………………….223
No-Load Test………………………………………….224
Installation of Starter Motor…………………………..225
107 Testing and adjusting, Part 7………………………………227
Before You Begin Servicing…………………………………229
Introduction……………………………………………..232
Standard and Optional Alternator Information…………………232
Alternator Specifications………………………………….232
Alternator Troubleshooting…………………………………233
Alternator Components……………………………………..234
Alternator Wiring Diagram………………………………….235
Alternator Standard Output…………………………………236
Alternator……………………………………………….237
Removal of Alternator………………………………….237
Disassembly of Alternator………………………………238
Reassembly of Alternator……………………………….240
Installation of Alternator……………………………..242
Dynamo Component Location………………………………….243
Dynamo Wiring Diagram……………………………………..244
Operation of Dynamo……………………………………….244
Dynamo Standard Output…………………………………….245
Testing of Dynamo…………………………………………246
Testing Stator Coil Continuity………………………….246
Testing Stator Coil Short-to-Ground……………………..246
Testing Dynamo Regulated Output…………………………246
Dynamo…………………………………………………..247
Removal of Dynamo……………………………………..247
Disassembly of Dynamo………………………………….247
Reassembly of Dynamo…………………………………..248
Installation of Dynamo…………………………………249
108 Testing and adjusting, Part 8………………………………251
Electric Wiring Precautions………………………………..252
Electric Wire Resistance…………………………………..253
Battery Cable Resistance…………………………………..254
Electrical Wire Sizes – Voltage Drop………………………..255
Conversion of AWG to European Standards……………………..256
40 Troubleshooting……………………………………………….259
100 Troubleshooting of mechanical system………………………..259
Special Service Tools……………………………………..261
Troubleshooting By Measuring Compression Pressure…………….262
Compression Pressure Measurement Method………………….262
Standard Compression Pressure…………………………..263
Engine Speed and Compression Pressure (Use for Reference)….263
Measured Value and Troubleshooting………………………263
Quick Reference Table For Troubleshooting……………………264
Troubleshooting Charts…………………………………265
Electric Wiring…………………………………………..275