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Komatsu EG Series II Diesel Engine Shop Manual SEBM0690LA00 PDF
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Komatsu EG Series II Diesel Engine Shop Manual SEBM0690LA00 PDF

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Komatsu EG Series II Diesel Engine Shop Manual SEBM0690LA00 – PDF DOWNLOAD

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Description

Komatsu EG Series II Diesel Engine Shop Manual SEBM0690LA00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu EG Series II Diesel Engine Shop Manual SEBM0690LA00 – PDF DOWNLOAD 

Language : English
Pages : 634
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu EG Series II Diesel Engine Shop Manual SEBM0690LA00 – PDF DOWNLOAD 

COVER 1
CONTENTS 2
01 GENERAL 32
GENERAL VIEW 33
GENERAL SPECIFICATIONS 45
ENGINE GENERAL VIEW 49
ENGINE SPECIFICATIONS 53
DIMENSIONS 55
WEIGHT TABLE 58
HANDING ON SEPARATION SHIPPING 61
JIGS FOR SEPARATION SHIPPING 62
02 STRUCTURE AND FUNCTION 65
GENERAL 66
PRINCIPLES OF ELECTRIC POWER GENERATION 68
CONTROL OF THE GENERATOR 71
SELF-EXCITED GENERATOR, BRUSHLESS GENERATOR 72
GENERATOR 76
SYNCHRONOUS GENERATORS 77
GENERATOR 78
PARALLEL RUNNING 95
EMERGENCY SYSTEM 99
GENERATOR WIRING DIAGRAM 110
ENGINE WIRING DIAGRAM 131
03 CHECK 141
INSPECTION OF GENERATOR SET 142
GENERATOR AND GENERATOR PANEL 145
EMERGENCY EQUIPMENT 154
ADJUSTING THE AVR (AUTOMATIC VOLTAGE REGULATOR) 156
STANDARD VALUES FOR TESTING AND ADJUSTING 157
TESTING AND ADJUSTING TOOL LIST 161
04 TROUBLE SHOOTING 163
SECTION 1 PROBLEMS AND CAUSES 164
PROBLEM 1 ALL OF THREE NO-LOAD LINE VOLTAGE MEASUREMENTS ARE TOO LOW 165
PROBLEM 2 ONLY ONE OR TWO NO-LOAD LINE-VOLTAGE MEASUREMENTS ARE TOO LOW 165
PROBLEM 3 ALL OF THREE NO-LOAD LINE-VOLTAGE MEASUREMENTS ARE NEAR TO ZERO 166
PROBLEM 4 ONLY ONE OR TWO NO-LOAD LINE-VOLTAGE MEASUREMENTS ARE NEAR TO ZERO 166
PROBLEM 5 ALL OF THREE NO-LOAD LINE-VOLTAGE MEASUREMENTS ARE TOO HIGH 167
PROBLEM 6 ALL OF THREE LOAD LINE-VOLTAGE MEASUREMENTS ARE TOO LOW (NO-LOAD LINE-VOLTAGE MEASUREMENTS ARE NORMAL ) 167
PROBLEM 7 ONLY ONE OR TWO LOAD LINE-VOLTAGE MEASUREMENTS ARE TOO LOW (NO-LOAD LINE-VOLTAGE MEASUREMENTS ARE NORMAL ) 167
SECTION 2 DIAGNOSIS COMPONENT PARTS 168
DIAGNOSIS 1 AVR 169
DIAGNOSIS 2 SILICON RECTIFIER ASSEMBLY (SI2) 170
DIAGNOSIS 3 THYRISTORS (S1 TO S3) 170
DIAGNOSIS 4 REACTOR (RT) 171
DIAGNOSIS 5 WIRING 172
DIAGNOSIS 6 VARIABLE RESISTOR ADJUST RHEOSTAT 172
DIAGNOSIS 7 VOLTMETER (V) 172
DIAGNOSIS 8 GENERATOR 173
DIAGNOSIS 9 VOLTAGE CHANGE-OVER BOARD 177
DIAGNOSIS 10 CURRENT TRANSFORMER FOR CONTROL (CT1) 180
DIAGNOSIS 11 DISAPPEARANCE OF RESIDUAL MAGNETISM 181
METHODS FOR TROUBLE SHOOTING 182
TROUBLE SHOOTING OF EMERGENCY SYSTEM 184
05 DISASSEMBLY AND ASSEMBLY 193
EG150-3 194
ENGINE 194
STARTING MOTOR ASS’Y 195
DISMOUNTING AND MOUNTING 195
ALTERNATOR ASS’Y 196
DISMOUNTING AND MOUNTING 196
WATER PUMP ASS’Y 197
DISMOUNTING AND MOUNTING 197
TURBOCHARGER ASS’Y 198
DISMOUNTING AND MOUNTING 198
FUEL INJECTION PUMP ASS’Y 199
DISMOUNTING 199
MOUNTING 200
ENGINE OIL COOLER ASS’Y 201
DISMOUNTING AND MOUNTING 201
NOZZLE HOLDER ASS’Y 202
DISMOUNTING AND MOUNTING 202
AFTER COOLER CORE ASS’Y 203
DISMOUNTING 203
MOUNTING 206
CYLINDER HEAD ASS’Y 209
DISMOUNTING 209
MOUNTING 216
ENGINE ASS’Y 224
DISMOUNTING 224
MOUNTING 228
GENERATOR 232
GENERATOR CONTROL BOX AND FRAME 233
DISMOUNTING 233
MOUNTING 239
RADIATOR 245
DISMOUNTING 245
MOUNTING 247
GENERATOR CONTROL BOX 249
DISMOUNTING 249
MOUNTING 252
GENERATOR 255
DISMOUNTING 255
MOUNTING 257
EG175-2 259
ENGINE 260
STARTING MOTOR 260
DISMOUNTING AND MOUNTING 260
ALTERNATOR 261
DISMOUNTING AND MOUNTING 261
WATER PUMP 262
DISMOUNTING 262
MOUNTING 263
OIL COOLER 264
DISMOUNTING AND MOUNTING 264
PT PUMP 265
DISMOUNTING 265
MOUNTING 267
GOVERNOR 269
DISMOUNTING AND MOUNTING 269
OIL PUMP 270
DISMOUNTING AND MOUNTING 270
TURBOCHARGER 271
DISMOUNTING AND MOUNTING 271
INJECTOR 272
DISMOUNTING 272
MOUNTING 273
CYLINDER HEAD 274
DISMOUNTING 274
MOUNTING 281
RADIATOR 291
DISMOUNTING 291
MOUNTING 295
ENGINE 299
DISMOUNTING 299
MOUNTING 305
GENERATOR 311
GENERATOR CONTROL BOX 312
DISMOUNTING 312
MOUNTING 315
GENERATOR CONTROL BOX AND FRAME 318
DISMOUNTING 318
MOUNTING 323
GENERATOR 328
DISMOUNTING 328
MOUNTING 329
EG200-1 330
STARTING MOTOR 331
DISMOUNTING 331
MOUNTING 332
DYNAMO 333
DISMOUNTING 333
MOUNTING 334
WATER PUMP 335
DISMOUNTING 335
MOUNTING 337
PT PUMP 339
DISMOUNTING 339
MOUNTING 340
OIL PUMP 341
DISMOUNTING 341
MOUNTING 343
OIL COOLER 345
DISMOUNTING 345
MOUNTING 346
TURBOCHARGER 347
DISMOUNTING 347
MOUNTING 349
GOVERNOR 351
DISMOUNTING 351
MOUNTING 353
INJECTOR 355
DISMOUNTING 355
MOUNTING 357
CYLINDER HEAD 359
DISMOUNTING 359
MOUNTING 366
ENGINE 374
DISMOUNTING 374
MOUNTING 383
FUEL TANK 393
DISMOUNTING 393
MOUNTING 396
GENERATOR CONTROL BOX 399
DISMOUNTING 399
MOUNTING 402
GENERATOR CONTROL BOX AND FRAME 405
DISMOUNTING 405
MOUNTING 411
GENERATOR 417
DISMOUNTING 417
MOUNTING 419
EG200-3 421
ENGINE 421
STARTING MOTOR ASSEMBLY 422
DISMOUNTING AND MOUNTING 422
ALTERNATOR ASSEMBLY 423
DISMOUNTING AND MOUNTING 423
WATER PUMP ASSEMBLY 424
DISMOUNTING AND MOUNTING 424
ENGINE OIL COOLER ASSEMBLY 425
DISMOUNTING AND MOUNTING 425
FUEL INJECTION PUMP ASSEMBLY 426
DISMOUNTING 426
MOUNTING 428
TURBOCHARGER ASSEMBLY 430
DISMOUNTING AND MOUNTING 430
NOZZLE HOLDER ASSEMBLY 431
DISMOUNTING AND MOUNTING 431
CYLINDER HEAD ASSEMBLY 432
DISMOUNTING 432
MOUNTING 439
HOOD AND FRAME ASSEMBLY 448
DISMOUNTING AND MOUNTING 448
RADIATOR ASSEMBLY 449
DISMOUNTING AND MOUNTING 449
GENERATOR 450
ENGINE AND GENERATOR ASSEMBLY 451
DISMOUNTING 451
MOUNTING 453
GENERATOR ASSEMBLY 455
DISMOUNTING AND MOUNTING 455
GENERATOR CONTROL BOX ASSEMBLY 456
DISMOUNTING AND MOUNTING 456
PANEL BOX ASSEMBLY 457
DISMOUNTING AND MOUNTING 457
EG300-1 458
STARTING MOTOR 459
DISMOUNTING 459
MOUNTING 460
ALTERNATOR 461
DISMOUNTING 461
MOUNTING 462
WATER PUMP 463
DISMOUNTING 463
MOUNTING 465
FUEL INJECTION PUMP 467
DISMOUNTING 467
MOUNTING 469
OIL COOLER 471
DISMOUNTING 471
MOUNTING 473
TURBOCHARGER 475
DISMOUNTING 475
MOUNTING 477
CYLINDER HEAD 479
DISMOUNTING 479
MOUNTING 487
ENGINE 497
DISMOUNTING 497
MOUNTING 502
RADIATOR 507
DISMOUNTING 507
MOUNTING 510
FUEL TANK 513
DISMOUNTING 513
MOUNTING 516
GENERATOR CONTROL BOX 519
DISMOUNTING 519
MOUNTING 522
GENERATOR CONTROL BOX AND FRAME 525
DISMOUNTING 525
MOUNTING 530
GENERATOR 535
DISMOUNTING 535
MOUNTING 537
EG300-2 539
ENGINE 540
STARTING MOTOR ASSEMBLY 540
DISMOUNTING AND MOUNTING 540
ALTERNATOR ASSEMBLY 541
DISMOUNTING AND MOUNTING 541
WATER PUMP ASSEMBLY 542
DISMOUNTING AND MOUNTING 542
FUEL INJECTION PUMP ASSEMBLY 543
DISMOUNTING AND MOUNTING 543
OIL COOLER ASSEMBLY 544
DISMOUNTING 544
MOUNTING 545
TURBOCHARGER ASSEMBLY 546
DISMOUNTING 546
MOUNTING 547
CYLINDER AND ASSEMBLY 548
DISMOUNTING 548
MOUNTING 557
ENGINE ASSEMBLY 567
DISMOUNTING 567
MOUNTING 573
GENERATOR 579
RADIATOR ASSEMBLY 580
DISMOUNTING 580
MOUNTING 581
GENERATOR CONTROL BOX ASSEMBLY 582
DISMOUNTING 582
MOUNTING 584
GENERATOR CONTROL BOX AND FRAME ASSEMBLY 586
DISMOUNTING 586
MOUNTING 591
GENERATOR ASSEMBLY 596
DISMOUNTING 596
MOUNTING 598
EG450 550-1 600
STARTING MOTOR ASSEMBLY 601
DISMOUNTING AND MOUNTING 601
ALTERNATOR ASSEMBLY 602
DISMOUNTING AND MOUNTING 602
WATER PUMP ASSEMBLY 603
DISMOUNTING AND MOUNTING 603
TURBOCHARGER ASSEMBLY 604
DISMOUNTING AND MOUNTING 604
FUEL INJECTION PUMP ASSEMBLY 605
DISMOUNTING AND MOUNTING 605
ENGINE OIL COOLER ASSEMBLY 606
DISMOUNTING AND MOUNTING 606
NOZZLE HOLDER ASSEMBLY 607
DISMOUNTING AND MOUNTING 607
AFTERCOOLER CORE ASSEMBLY 608
DISMOUNTING AND MOUNTING 608
CYLINDER HEAD ASSEMBLY 610
DISMOUNTING 610
MOUNTING 615
RADIATOR ASSEMBLY 622
DISMOUNTING AND MOUNTING 622
ENGINE ASSEMBLY 623
DISMOUNTING 623
MOUNTING 627
GENERATOR, CONTROL BOX ASSEMBLY 631
DISMOUNTING 631
MOUNTING 633

DESCRIPTION:

Komatsu EG Series II Diesel Engine Shop Manual SEBM0690LA00 – PDF DOWNLOAD 

MACHINE MODELS       SERIAL No.
EG150-1                          1001-2000
EG150-2                          2001-3000
EG150(S)-3                     3001 and up
EG175-1                         1001-2000
EG175(S)-2                   2001 and up
EG200-1                        1001-2000
EG200(S)-2                  2001-3000
EG200-3                       3001 and up
EG300-1                      1001-2000
EG300-2                        2001 and up
EG450-1 1001 and up
EG550-1 1001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK :

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

S.V 28/12/24 

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