Komatsu KDC410 and KDC610 Diesel Engines (USA) set of Service Manuals (CEBD610)

Illustrated factory set of Service Manuals for Komatsu Diesel Engines Models KDC410 and KDC610.

This manuals will assist you in diagnosing, repairing, adjusting, troubleshooting, assembling, and disassembling for your diesel engine.
You can use a Windows, Mac, or Android device to view this manuals. You only need to have a PDF reader installed.

Covered Models (USA):
   KDC410
   KDC610

The manual comprises 2 documents, including the Workshop Manual, and Diagnostic and Repair Manual

1. Workshop Manual (CEBD610SH0)
Format: PDF, 404 pages
Language: English
Table of Contents:
   Introduction
      About the Manual
      General Cleaning Instructions
      General Repair Instructions
      General Safety Instructions
      Generic Symbols
      Glossary of Terms
      How To Use This Manual
      Illustrations
   Engine and Component Identification
      Engine Diagram
      Engine Identification
      Injection Pump Dataplate
   Engine Disassembly and Assembly
      Accessories - Installation
      Accessories - Removal
      Alternator - Installation
      Alternator - Removal
      Balancer - Installation
      Balancer - Removal
      Belt Tensioner - Installation
      Belt Tensioner - Removal
      Camshaft - Installation
      Camshaft - Removal
      Crankshaft End Play - Measuring
      Crankshaft - Installation
      Crankshaft - Removal
      Cylinder Block - Prepare for Assembly
      Cylinder Block - Removing From the Rollover Stand
      Cylinder Head - Installation
      Cylinder Head - Removal
      Cylinder Head - Tightening
      Dipstick - Removal
      Drive Belt - Installation
      Drive Belt - Removal
      Engine Assembly
      Engine Disassembly
      Engine Disassembly and Assembly
      Engine Disassembly and Assembly - Service Tools
      Engine Disassembly Check List
      Engine Weight
      Exhaust Manifold - Installation
      Exhaust Manifold - Removal
      Fan Hub - Installation
      Fan Hub - Removal
      Fan Pulley - Removal
      Flywheel Housing - Installation
      Flywheel Housing - Removal
      Flywheel - Installation
      Flywheel - Removal
      Front Cover - Installation
      Front Cover - Removal
      Fuel Filter Head - Installation
      Fuel Filter Head - Removal
      Fuel Filter - Removal
      Fuel Lines - Installation
      Fuel Lines - Removal
      Fuel Transfer Pump - Installation
      Fuel Transfer Pump - Removal
      Gear Housing - Installation
      Gear Housing - Removal
      Injection Pump - Installation
      Injection Pump - Removal (Rotary Type Pumps)
      Injector Nozzles - Installation
      Injector Nozzles - Removal
      Lifting Bracket Removal - Rear
      Lube Pump - Installation
      Lube Pump - Removal
      Manifold Cover - Installation
      Manifold Cover - Removal
      Oil Cooler - Installation
      Oil Cooler - Removal
      Oil - Draining
      Oil Filter - Installation
      Oil Pan - Installation
      Oil Pan - Removal
      Piston and Rod Assemblies - Installation
      Piston and Rod Assemblies - Removal
      Push Rods - Installation
      Push Rods - Removal
      Rear Seal Housing - Removal
      Rear Seal - Installation
      Rocker Levers - Installation
      Rocker Levers - Removal
      Rollover Stand - Engine Mounting
      Rollover Stand - Engine Removal
      Side Oil Fill - Installation
      Side Oil Fill - Removal
      Starter - Installation
      Starter - Removal
      Steam Cleaning The Engine
      Suction Tube - Installation
      Suction Tube - Removal
      Tappet Cover - Installation
      Tappet Cover - Removal
      Thermostat - Installation
      Thermostat - Removal
      Timing Pin Housing - Removal
      Timing Pin - Installation
      Turbocharger Drain Tube - Removal
      Turbocharger - Installation
      Turbocharger - Removal
      Valve Clearance - Adjustment
      Valve Covers - Installation
      Valve Covers - Removal
      Valve Tappets - Installation
      Valve Tappets - Removal
      Vibration Damper/Crankshaft Pulley - Removal
      Vibration Damper - Installation
      Water Inlet Connection - Installation
      Water Inlet Connection - Removal
      Water Pump - Installation
      Water Pump - Removal
   Cylinder Block - Group 1
      Balancer - Assembly
      Balancer - Disassembly
      Camshaft and Gear - Inspection
      Camshaft Bushing - Installation
      Camshaft - Cleaning
      Camshaft Expansion Plug - Installation
      Camshaft Gear - Replacement
      Connecting Rod - Inspection
      Crankshaft - Cleaning
      Crankshaft Gear - Replacement
      Crankshaft - Inspection
      Cylinder Block - Cleaning
      Cylinder Block - De-Glazing
      Cylinder Block - Disassembly
      Cylinder Block - Exploded View
      Cylinder Block - General Information
      Cylinder Block Group Inspection Checklist
      Cylinder Block - Inspection
      Cylinder Block - Precheck Before Disassembly
      Cylinder Block - Service Tools
      Cylinder Block - Storing
      Data Plate - Replacement
      Dipstick Tube - Replacement
      Expansion and Pipe Plug - Installation
      Fuel Pump Stud - Replacement
      Gear Housing and Timing Pin Assembly - Inspection
      Gear Housing - Disassembly
      Piston and Connecting Rod - Assembly
      Piston and Connecting Rod - Disassembly
      Piston Inspection
      Piston, Pin and Connecting Rod - Cleaning
      Piston Pin - Inspection
      Piston Ring Gap - Checking
      Piston Rings - Installation
      Rod Bearing Clearance - Checking
      Vibration Damper - Cleaning and Inspection
   Cylinder Head - Group 2
      Cup Plug Replacement
      Cylinder Head - Assembly
      Cylinder Head - Cleaning
      Cylinder Head Combustion Face Inspection
      Cylinder Head Cracks - Reuse Guidelines
      Cylinder Head - Disassembly
      Cylinder Head - Precheck Before Disassembly
      Cylinder Head - Service Tools
      Exploded View
      General Information
      Valve Guide Inspection
      Valve - Inspection
      Valve Seat Inspection
      Valve Seats - Grinding
      Valve Spring Inspection
      Valves - Grinding
   Rocker Levers - Group 3
      Rocker Lever Assembly - Exploded View
      Rocker Lever Assembly - General Information
      Rocker Lever - Inspection
      Rocker Lever Pedestals - Inspection
      Rocker Levers and Pedestals - Cleaning
      Rocker Levers - Assembly
      Rocker Levers - Disassembly
   Tappets and Push - Group 04
      Push Rods - Inspection
      Tappets and Push Rods - Exploded View
      Tappets and Push Rods - General Information
      Valve Tappets - Inspection
   Fuel System - Group 05
      Exploded View - Fuel System
      Injection Pump - General Information
      Injection Pump - Identification
      Injection Pump Repairs - Bosch VE
      Injection Pump Repairs - Lucas CAV DPA
      Injection Pump - Service Tools
      Injection Pump Timing - Bosch VE
   Injectors - Group 06
      Exploded View - Fuel System
      Fuel Lines - Clean and Inspect
      Fuel Transfer Pump - Cleaning and Inspecting
      Fuel Transfer Pump - General Information
      Fuel Transfer Pump - Piston Style Rebuild
      General Information - Injectors
      Injector - Assembly
      Injector - Clean and Inspect
      Injector - Disassembly
      Injector Pump - Service Tools
      Injector - Testing
   Lubrication Oil System - Group 7
      Filter Bypass Valve - Replace
      General Information - Lubrication System
      Lubricating Oil Cooler - Exploded View
      Lubricating Oil Pump - Exploded View
      Lubrication Oil Pump - General Information
      Oil Cooler - Cleaning
      Oil Cooler - Inspection
      Oil Pan and Suction Tube - Cleaning and Inspection
      Oil Pan and Suction Tube - Exploded View
      Oil Pan and Suction Tube - General Information
      Oil Pump - Inspection
      Pressure Regulator Valve - Assembly
      Pressure Regulator Valve - Disassembly
      Pressure Regulator Valve - Inspection
   Cooling System - Group 8
      Belt Tensioner and Fan Hub - Exploded View
      Belt Tensioner and Fan Hub - General Information
      Belt Tensioner - Inspection
      Fan Hub Assembly
      Fan Hub - Disassembly
      Fan Hub - Inspection
      Thermostat Housing Assembly - Exploded View
      Thermostat Housing Assembly - General Information
      Thermostat - Inspection
      Water Pump - Exploded View
      Water Pump

2. Diagnostic and Repair Manual (CEBD610TR0)
Format: PDF, 452 pages
Language: English
Table of Contents:
   Introduction
      About the Manual
      General Cleaning Instructions
      General Repair Instructions
      General Safety Instructions
      Generic Symbols
      Glossary of Terms
      How to Use the Manual
      Illustrations
   Engine and Component Identification
      Engine Diagram
      Engine Identification
      Injection Pump Dataplate
   Troubleshooting
      T - Troubleshooting
      Troubleshooting Symptoms Charts
   Cooling System
      Belt Tensioner - Replacement
      Coolant
      Coolant System Components and Flow
      Coolant System Malfunctions
      Cooling System Specifications
      Cup Plugs - Replacement
      Drive Belt - Replacement
      Fan Hub - Replacement
      Fan Pulley - Replacement
      Thermostat - Replacement
      Water Pump - Replacement
   Lubricating Oil System
      Cup Plugs - Replacement
      Diagnosing Lubricating System Malfunctions
      Flow Diagrams - Lubricating System
      General Information - Lubrication System
      High Oil Pressure
      Low Oil Pressure
      Lubrication for the Power Components
      Lubrication for the Turbocharger
      Oil Cooler Element and/or Gasket - Replacement
      Oil Leaks
      Oil Pan, Suction Tube and/or Gaskets - Replacement
      Oil Pressure Regulating Valve
      Oil Pressure Regulator Valve/ Spring - Replacement
      Oil Pump - Replacement
      Specifications - Lubricating Oil System
   Combustion Air System
      Aftercooler and Gasket
      Air Crossover Tube
      Air System Flow - Diagrams
      Combustion Air System Flow - General Information
      Combustion Air System - Service Tools
      Diagnosing Air System Malfunctions
      Exhaust Manifold and Gaskets
      Intake Air and Exhaust System Specifications
      Intake Manifold Cover and Gasket
      Turbocharger
      Turbocharger Boost Pressure Specifications
      Turbocharger - Testing
   Compressed Air System
      Air Compressor - Removal
      Air Governor and Compressor Unloader Valve - Check
      Air Governor - Check
      Carbon Buildup, Air Compressor - Check
      Compressed Air System - General Information
      Compressed Air System - Service Tools
      Flow Diagrams - Compressed Air System
      Gasket Leaks, Air Compressor, Check
      Specifications - Compressor Air System
      Unloader and Cylinder Head Disassembly
   Fuel Systems
      Air Fuel Control Tube Replacement - Bosch VE Pump
      Air In The Fuel System
      Back Leakage Valve and Sealing Washer (Lucas CAV DPA) - Replacement
      Delivery Valve Holder and Sealing Washer (Bosch VE) - Replacement
      External Pump Leaks - Repair
      Fuel Drain Manifold
      Fuel Drain Manifold Replacement
      Fuel Filter - Replacement
      Fuel Shut Off Valve Replacement - Bosch VE
      Fuel System Components and Flow
      Fuel System Identification
      Fuel System - Service Tools
      Fuel System Specifications
      Fuel Transfer (Lift) Pump Diagnosing Malfunctions
      Fuel Transfer (Lift) Pump - Testing
      Fuel Water Separator/Filter Unit
      General Information - Fuel Systems
      High Pressure Fuel Lines
      High Pressure Line Replacement
      Idle Speed Adjustment
      Injection Pump Replacement (Bosch VE and Lucas CAV DPA)
      Injection Pump Supply Line Replacement
      Injection Pump Timing
      Injection Pump - Troubleshooting
      Injector - Replacement
      Injectors
      Low Pressure Fuel Line Replacement
      Pump Timing Check - (Lucas CAV DPA)
      Timing Check - (Bosch VE Pump)
      Transfer (Lift) Pump Replacement
      Venting the Fuel Systems
   Electrical System
      Alternator - Checking
      Alternator - Replacement
      Battery Checking
      Battery Terminal Connections - Checking
      Block Water Heater Replacement
      Coolant or Pan Heater - Check
      Electrical System - Service Tools
      Engine Electrical System Replacement Procedures
      Flow Diagrams - Electrical System
      General Information - Electrical System
      Oil Pan Heater Replacement
      Oil Pressure Switch and Temperature Sensor - Checking
      Oil Pressure Switch - Replacement
      Starting Circuit - Checking
      Starting Motor - Replacement
      Temperature Sensor - Replacement
   Base Engine Components System
      Base Engine Components - General Information
      Base Engine Components - Replacement Procedures
      Base Engine Components Specifications
      Camshaft and Tappet - Replacement
      Camshaft Gear - Replacement
      Connecting Rod Bearing - Replacement
      Connecting Rods - Replacement
      Crankshaft Gear - Replacement
      Cup Plug Replacement
      Cylinder Bore Deglaze
      Cylinder Head - Replacement
      Diagnosing Base Engine Component Malfunctions
      Exhaust Manifold - Replacement
      Flywheel Housing - Replacement
      Flywheel/Ring Gear - Replacement
      Front Seal - Replacement
      Gear Cover - Replacement
      Gear Housing or Gasket - Replacement
      Main Bearing - Replacement
      Operation and Description Cylinder Head and Valve Train
      Pipe Plug - Replacement
      Piston and Rings - Replacement
      Rear Seal - Replacement
      Timing Pin Assembly - Replacement
      Turbocharger - Replacement
      Valves - Adjustment
      Vibration Damper/Crank Pulley - Replacement
   Engine Testing
      Blowby Conversion Chart (5.613 mm [0.221 in] Orifice)
      Engine Run-In Procedure
      Engine Testing - Engine Side Views
      Engine Testing - General Information
      Engine Testing - Service Tools
      General Engine Test Procedures
   Engine Removal and Installation
   Engine Component Specifications
      Capscrew Markings and Torque Values
      Component Specifications and Torque Values
      Drive Belt Tension
      Newton-Meter to Foot-Pound Conversion Chart
      Pipe Plug Torque Values
      Tap-Drill - U.S. Customary and Metric
      Weight and Measures - Conversion F actors
   Service Literature
   Index