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1991 KOMATSU DRESSER KDC 410 AND 610 SERIES ENGINE TROUBLESHOOTING AND REPAIR MANUAL – PDF DOWNLOAD
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- 1991 KOMATSU DRESSER KDC 410 AND 610 SERIES ENGINE TROUBLESHOOTING AND REPAIR MANUAL
- Publication Number:CEBM610TR0
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Description
1991 KOMATSU DRESSER KDC 410 AND 610 SERIES ENGINE TROUBLESHOOTING AND REPAIR MANUAL
1991 KOMATSU DRESSER KDC 410 AND 610 SERIES ENGINE TROUBLESHOOTING AND REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
1991 KOMATSU DRESSER KDC 410 AND 610 SERIES ENGINE TROUBLESHOOTING AND REPAIR MANUAL
This manual provides instructions for troubleshooting and repairing the 410 and 610 Series Engine in the chassis. Component and assembly rebuild procedures are provided in the 410 and 610 Series Engine Shop Manual. Refer to Page i-2 in the Introduction for instructions on how to use this manual. The procedures given in this manual are applicable for the 410 and 610 Series engines introduced in 1991. The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover machine or equipment problems. Consult the appropriate chassis shop manual for repair procedures. A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be ordered through your distributor using the form in Section L. The repair procedures used in this manual are recommended by Komatsu Dresser Company. Some service procedures require the use of special service tools. Use the correct tools as described. The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Komatsu Dresser Compnay reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact your KDC Distributor. The latest technology and the highest quality components are used to manufacture KDC engines. When replacement parts are needed, we recommend using only genuine KDC exchange parts.
TABLE OF CONTENTS:
1991 KOMATSU DRESSER KDC 410 AND 610 SERIES ENGINE TROUBLESHOOTING AND REPAIR MANUAL
MAIN MENU........................................................................... 0 Table of Contents................................................................... 5 Section i - Introduction............................................................ 7 About the Manual ............................................................... 8 General Cleaning Instructions .................................................. 13 Solvent and Acid Cleaning .................................................. 13 Steam Cleaning ............................................................. 13 General Repair Instructions..................................................... 12 General Safety Instructions .................................................... 11 Generic Symbols ................................................................ 9 Glossary of Terms .............................................................. 14 How to Use the Manual .......................................................... 8 Illustrations .................................................................. 10 Section E - Engine and Component Identification..................................... 17 Engine Diagram ................................................................. 22 Engine Identification .......................................................... 18 Engine Dataplate ........................................................... 18 Injection Pump Dataplate ....................................................... 19 Cooling System ............................................................. 21 Fuel System ................................................................ 21 General Engine Data......................................................... 20 Intake Air and Exhaust System .............................................. 21 Lubrication System ......................................................... 20 Lucas CAV DPA dataplate location. .......................................... 19 Robert Bosch VE dataplate location. ........................................ 19 Section T - Troubleshooting......................................................... 25 Section T - Troubleshooting .................................................... 26 Procedures and Techniques .................................................. 26 Troubleshooting Symptoms Charts ................................................ 26 Alternator Not Charging or Insufficient Charging............................ 68 Compression Knocks ......................................................... 61 Coolant Contaminated ....................................................... 58 Coolant Loss ............................................................... 51 Coolant Temperature Above Normal - Gradual Overheat......................... 45 Coolant Temperature Above Normal - Sudden Overheat ......................... 48 Coolant Temperature Below Normal............................................ 50 Engine Cranks But Will Not Start - No Smoke From Exhaust.................... 28 Engine Hard to Start Or Will Not Start - Smoke From Exhaust ................ 30 Engine Idle Rough (Irregularly Firing Or Engine Shaking).................... 34 Engine Noise Excessive ..................................................... 67 Engine Power Output Low .................................................... 40 Engine RPM Will Not Reach Rated Speed ...................................... 37 Engine Runs Rough or Misfiring ............................................. 35 Engine Starts But Will Not Keep Running .................................... 32 Engine Surging (Speed Change) .............................................. 33 Engine Vibration Excessive.................................................. 65 Engine Will Not Crank Or Cranks Slowly ..................................... 27 Engine Will Not Shut Off.................................................... 64 Exhaust Black Smoke Excessive .............................................. 43 Exhaust White Smoke Excessive .............................................. 44 Fuel Consumption Excessive ................................................. 62 Fuel Or Oil Leaking From Exhaust Manifold .................................. 60 Lubricating Oil Consumption Excessive ..................................... 57 Lubricating Oil Contaminated ............................................... 59 Lubricating Oil Pressure High .............................................. 55 Lubricating Oil Pressure Low ............................................... 53 Section 1 - Cooling System.......................................................... 69 Belt Tensioner - Replacement ................................................... 80 Coolant ....................................................................... 82 Draining ................................................................... 82 Filling..................................................................... 83 Coolant System Components and Flow ............................................. 70 Coolant System Malfunctions .................................................... 72 Diagnosis .................................................................. 72 Gauges, Ovetfueling and Loading ............................................ 79 Pressure Caps............................................................... 74 Radiator, Fans and Shutters ................................................ 76 Thermostat ................................................................. 78 Water (Coolant) Pump ....................................................... 75 Cooling System Specifications .................................................. 71 Cup Plugs - Replacement......................................................... 86 Drive Belt - Replacement ....................................................... 80 Fan Hub - Replacement .......................................................... 81 Fan Pulley - Replacement ....................................................... 81 Thermostat - Replacement ....................................................... 85 Water Pump - Replacement ....................................................... 83 Section 2 - Lubricating Oil System.................................................. 89 Cup Plugs - Replacement.........................................................119 Diagnosing Lubricating System Malfunctions..................................... 96 General Information......................................................... 96 Flow Diagrams - Lubricating System ............................................. 91 Lubricating Oil Pump ....................................................... 91 Oil Coolers ................................................................ 92 Oil Filter Bypass Valve .................................................... 92 Oil Filters ................................................................ 92 Pressure Regulating Valve .................................................. 91 General Information - Lubrication System........................................ 90 High Oil Pressure .............................................................. 96 Low Oil Pressure ............................................................... 96 Bearings and Oil Pump ...................................................... 98 Coolant Diluted Oil ........................................................ 99 Fuel Diluted Oil............................................................100 Incorrect Oil Pump ......................................................... 98 Oil Dilution ............................................................... 98 Oil Filter ................................................................. 97 Oil Gauge .................................................................. 97 Oil Level .................................................................. 97 Oil Suction Tube............................................................ 98 Lubrication for the Power Components ........................................... 94 Lubrication for the Turbocharger ............................................... 93 Oil Cooler Element and/or Gasket - Replacement ................................106 Oil Leaks ......................................................................103 Oil Pan, Suction Tube and/or Gaskets - Replacement.............................109 Oil Pressure Regulating Valve................................................... 96 Oil Pressure Regulator Valve/ Spring - Replacement ............................105 Assembly ...................................................................106 Cleaning and Inspection ....................................................105 Disassembly ................................................................105 Oil Pump - Replacement .........................................................112 Clean and Inspect ..........................................................113 Gear Cover - Installation ..................................................117 Oil Pump - Installation ....................................................116 Oil Pump - Removal .........................................................113 Specifications - Lubricating Oil System ........................................ 95 Section 3 - Combustion Air System ..................................................121 Aftercooler and Gasket .........................................................133 Air Crossover Tube..............................................................132 Replacement ................................................................132 Air System Flow - Diagrams .....................................................123 Combustion Air System Flow - General Information ...............................122 Combustion Air System - Service Tools ..........................................125 Diagnosing Air System Malfunctions .............................................126 Clean Air ..................................................................126 Damage From Non-filtered Air ...............................................127 Intake Air Restriction - Checking...........................................126 Malfunctioning Turbocharger ................................................129 Oil Consumption and Leaks ..................................................129 Turbocharged Engines - Air Leaks, Pressure Side ...........................127 Turbocharged Engines - Exhaust Leaks .......................................128 Turbocharger Boost Pressure - Measurement .................................128 Turbocharger Noise .........................................................130 Exhaust Manifold and Gaskets ...................................................139 Replacement ................................................................139 Intake Air and Exhaust System Specifications ...................................124 Intake Manifold Cover and Gasket ...............................................132 Replacement ................................................................132 Turbocharger....................................................................135 Replacement.................................................................135 Turbocharger Boost Pressure Specifications .....................................124 Turbocharger - Testing..........................................................131 Rotor Assembly Clearance - Measurement .....................................131 Section 4 - Compressed Air System...................................................141 Air Compressor - Removal .......................................................160 Inspection .................................................................161 Installation ...............................................................162 Air Governor and Compressor Unloader Valve - Check ............................156 Air Governor - Check ...........................................................158 Carbon Buildup, Air Compressor - Check .........................................146 Compressed Air System - General Information ...................................142 Compressed Air System - Service Tools ..........................................145 Flow Diagrams - Compressed Air System ..........................................143 Gasket Leaks, Air Compressor, Check ............................................156 Specifications - Compressor Air System .........................................144 Unloader and Cylinder Head Disassembly .........................................147 Assembly ...................................................................153 Cleaning ...................................................................149 Cleaning ...................................................................149 Section 5 - Fuel Systems ...........................................................165 Air Fuel Control Tube Replacement - Bosch VE Pump .............................192 Air In The Fuel System .........................................................172 Back Leakage Valve and Sealing Washer (Lucas CAV DPA) - Replacement ...........195 Delivery Valve Holder and Sealing Washer (Bosch VE) - Replacement .............194 External Pump Leaks - Repair ...................................................197 Fuel Drain Manifold.............................................................181 Fuel Drain Manifold Replacement ................................................191 Fuel Filter - Replacement ......................................................184 Fuel Shut Off Valve Replacement - Bosch VE ....................................192 Fuel System Components and Flow ................................................167 Fuel System Identification .....................................................168 Fuel System - Service Tools ....................................................169 Fuel System Specifications .....................................................168 Fuel Transfer (Lift) Pump Diagnosing Malfunctions..............................170 Fuel Transfer (Lift) Pump - Testing ............................................170 Test 1: Output Pressure Test ...............................................170 Test 2: Flow Volume Test....................................................171 Fuel Water Separator/Filter Unit ...............................................173 General Information - Fuel Systems .............................................167 Fuel System Components and Flow - Distributor Type Fuel Injection Pump ....167 High Pressure Fuel Lines........................................................179 High Pressure Line Replacement .................................................189 Idle Speed Adjustment ..........................................................210 Injection Pump Replacement (Bosch VE and Lucas CAV DPA) .......................197 Installing the Pump.........................................................200 Removing the Pump ..........................................................198 Injection Pump Supply Line Replacement..........................................186 Injection Pump Timing ..........................................................205 Injection Pump - Troubleshooting ...............................................174 Advance Timing Mechanism ...................................................176 Delivery Valves (Back Leakage Valves On Lucas CAV Pumps) ..................178 Electrical Shut Off Valves .................................................177 Fuel Control Lever Travel and Adjustment....................................175 Governor Malfunctions.......................................................174 Lucas CAV DPA/DPS Pump Adjustment Screws....................................175 Manual Shut Down Levers.....................................................176 Robert Bosch VE Pump Adjustment Screws......................................175 Injector - Replacement .........................................................211 Injectors ......................................................................180 Low Pressure Fuel Line Replacement ............................................185 Pump Timing Check - (Lucas CAV DPA) ...........................................210 Timing Check - (Bosch VE Pump) .................................................208 Transfer (Lift) Pump Replacement ...............................................188 Venting the Fuel Systems........................................................182 High Pressure Lines - Venting ..............................................183 Injection Pumps - Venting ..................................................183 Low Pressure Lines and Fuel Filter - Venting ...............................182 Section 6 - Electrical System.......................................................215 Alternator - Checking ..........................................................228 Abnormal Charging System Operation..........................................230 Abnormal Indicator Lamp Operation...........................................228 Alternator - Replacement........................................................233 Battery Checking ...............................................................221 Battery Terminal Connections - Checking .......................................222 Block Water Heater Replacement .................................................236 Coolant or Pan Heater - Check ..................................................232 Electrical System - Service Tools ..............................................220 Engine Electrical System Replacement Procedures ...............................232 Flow Diagrams - Electrical System ..............................................217 Basic Wiring Circuit (with auxillary magnetic switch) ......................218 Delco Remy Model 27MT/28MT Starting Motor ..................................217 Nippondenso “R” type starter ...............................................218 Typical Bosch K1 charging system circuit....................................219 Typical Delco 1551 charging system circuit..................................219 General Information - Electrical System ........................................216 Oil Pan Heater Replacement .....................................................238 Oil Pressure Switch and Temperature Sensor - Checking .........................231 Oil Pressure Switch - Check.................................................231 Temperature Sensor - Check..................................................231 Oil Pressure Switch - Replacement .............................................234 Starting Circuit - Checking ....................................................222 Engine Cranking Speed Too Slow .............................................227 Magnetic Switch - Checking..................................................222 Starting Motor Solenoid and Starting Motor - Checking .....................225 Starting Motor Switch - Checking ...........................................223 Starting Motor - Replacement ...................................................232 Temperature Sensor - Replacement................................................235 Section 7 - Base Engine Components System ..........................................241 Base Engine Components - General Information ...................................244 Definition..................................................................244 Base Engine Components - Replacement Procedures ...............................269 Push Rod - Installation.....................................................274 Push Rods - Cleaning .......................................................274 Push Rods - Inspection .....................................................274 Removal ....................................................................269 Rocker Lever Assembly - Installation........................................275 Rocker Levers and Push Rods - Replacement ..................................269 Rocker Levers - Assembly....................................................272 Rocker Levers - Cleaning ...................................................271 Rocker Levers - Disassembly.................................................270 Rocker Levers - Inspection .................................................271 Base Engine Components Specifications ..........................................264 Camshaft ...................................................................265 Connecting Rod .............................................................267 Crankshaft .................................................................267 Cylinder Block .............................................................268 Cylinder Bore ..............................................................269 Gear Train .................................................................265 Pistons ....................................................................266 Tappets ....................................................................266 Valve Train ................................................................264 Camshaft and Tappet - Replacement ..............................................349 Camshaft and Gear - Inspection..............................................353 Camshaft Bore - Inspection .................................................358 Camshaft Bushing - Replacement .............................................358 Camshaft Installation.......................................................362 Camshaft Removal............................................................349 Edge Deterioration (Breakdown) Criteria.....................................355 Pitting Reuse Criteria .....................................................354 Tappet Installation ........................................................359 Tappet Removal..............................................................350 Tappets - Inspection .......................................................352 Camshaft Gear - Replacement ....................................................364 Cleaning and Inspection ....................................................365 Installing the Gear.........................................................366 Removal.....................................................................364 Connecting Rod Bearing - Replacement ..........................................321 Cleaning and Inspection.....................................................323 Installation................................................................324 Removal.....................................................................321 Connecting Rods - Replacement ..................................................317 Cleaning and Inspection.....................................................318 Installation................................................................320 Removal ....................................................................317 Crankshaft Gear - Replacement ..................................................380 Cup Plug Replacement............................................................391 Cleaning ...................................................................392 Installation ...............................................................392 Removal ....................................................................391 Cylinder Bore Deglaze ..........................................................332 Assembly....................................................................337 Cleaning....................................................................336 Deglazing ..................................................................333 Disassembly.................................................................332 Inspection .................................................................333 Cylinder Head - Replacement ....................................................285 Cylinder Head - Assembly....................................................295 Cylinder Head - Cleaning....................................................290 Cylinder Head Cracks - Reuse Guidelines.....................................294 Cylinder Head Deck Inspection ..............................................293 Cylinder Head - Disassembly.................................................289 Cylinder Head - Installation................................................296 Cylinder Head - Precheck Before Disassembly.................................288 Removal ....................................................................285 Valve Guide Inspection......................................................293 Valve - Inspection..........................................................292 Valve Seat Inspection.......................................................294 Valve Spring Inspection ....................................................295 Diagnosing Base Engine Component Malfunctions .................................252 Air and Fuel Systems - Check ...............................................253 Compression Check...........................................................254 Crankshaft and Main Bearings ...............................................262 Cylinder Block .............................................................263 Flywheel Housing and Flywheel ..............................................263 Front Gear Housing and Gear Train ..........................................257 Injector Protrusion ........................................................256 Piston and Rod Assembly.....................................................259 Rocker Lever, Valve Stem, Push Rod, Tappet, and Camshaft ..................258 Valve Adjustment - Check ...................................................253 Valve Seal - Wear ..........................................................256 Valve Train and Head Assembly ..............................................252 Exhaust Manifold - Replacement .................................................283 Cleaning....................................................................284 Installation................................................................284 Removal ....................................................................283 Flywheel Housing - Replacement .................................................382 Cleaning and Inspection ....................................................383 Flywheel Housing Bore Alignment - Check.....................................385 Flywheel Housing Face Alignment - Check ...................................387 Installation (Dry Clutch Application) ......................................384 Installation (Wet Clutch Application) ......................................388 Removal ....................................................................382 Flywheel/Ring Gear - Replacement ...............................................380 Flywheel - Installation ....................................................381 Ring Gear - Replacement.....................................................380 Front Seal - Replacement .......................................................340 Cleaning and Inspection ....................................................341 Installation................................................................341 Removal.....................................................................340 Gear Cover - Replacement .......................................................345 Cleaning and Inspection.....................................................346 Installation ...............................................................347 Removal ....................................................................345 Gear Housing or Gasket - Replacement ..........................................369 Cleaning and Inspection ....................................................370 Installation ...............................................................371 Pan Gasket - Repair ........................................................370 Relocating the Timing Pin ..................................................375 Removal ....................................................................369 Main Bearing - Replacement .....................................................327 Main Bearing Preliminary Inspection ........................................327 Main Bearing Replacement ...................................................328 Operation and Description Cylinder Head and Valve Train .......................245 Camshaft, Tappets and Push Rods ............................................246 Crankshaft and Main Bearings ...............................................250 Cylinder Block..............................................................250 Cylinder Head and Valve Train...............................................245 Flywheel Housing and Flywheel ..............................................247 Front Crankshaft Seal ......................................................246 Front Gear Housing and Gear Train ..........................................246 Oil Pan ....................................................................252 Piston and Rod Assemblies ..................................................248 Rear Crankshaft Seal .......................................................252 Pipe Plug - Replacement ........................................................390 Cleaning and Inspection ....................................................390 Installation................................................................391 Removal.....................................................................390 Piston and Rings - Replacement .................................................303 Oil Pan Sealing Surfaces - Sealants ........................................316 Piston and Connecting Rod - Assembly........................................309 Piston and Connecting Rod - Disassembly ...................................306 Piston and Rod Assemblies - Installation ...................................313 Piston and Rod Assemblies - Removal.........................................304 Piston Inspection...........................................................308 Piston, Pin and Connecting Rod - Cleaning...................................307 Piston Pin - Inspection.....................................................309 Piston Ring Gap - Checking..................................................311 Piston Rings - Installation.................................................311 Rear Seal - Replacement ........................................................343 Timing Pin Assembly - Replacement ..............................................368 Turbocharger - Replacement .....................................................279 Installation ...............................................................281 Removal ....................................................................279 Valves - Adjustment ............................................................276 Four Cylinder Engine Adjustment.............................................277 Six-Cylinder Engine Adjustment..............................................278 Vibration Damper/Crank Pulley - Replacement ...................................338 Inspection .................................................................339 Installation ...............................................................339 Removal.....................................................................338 Section 8 - Engine Testing .........................................................395 Blowby Conversion Chart (5.613 mm [0.221 in] Orifice)...........................401 Engine Run-In Procedure.........................................................405 Engine Testing - Engine Side Views ............................................398 Engine Testing - General Information ...........................................400 General* Engine Test Specifications ........................................400 Engine Testing - Service Tools .................................................396 General Engine Test Procedures..................................................402 General Information.........................................................402 Section 9 - Engine Removal and Installation.........................................407 Section V - Engine Component Specifications.........................................409 Capscrew Markings and Torque Values ............................................439 Capscrew Markings and Torque Values - Metric................................440 Capscrew Markings and Torque Values - U.S. Customary........................440 Component Specifications and Torque Values ....................................410 Base Engine Specifications .................................................422 Base Engine Torque Values ..................................................431 Combustion Air System Specifications .......................................413 Combustion Air System Torque Values ........................................414 Compressed Air System Torque Values ........................................416 Cooling System Specifications ..............................................410 Cooling System Torque Values ...............................................410 Electrical System Specifications ...........................................420 Electrical System Torque Values ............................................420 Fuel System Specifications .................................................416 Fuel System Torque Values ..................................................418 Lubricating Oil System Specifications ......................................411 Lubricating Oil System Torque Values .......................................412 Drive Belt Tension .............................................................435 Newton-Meter to Foot-Pound Conversion Chart ....................................438 Pipe Plug Torque Values ........................................................441 Tap-Drill - U.S. Customary & Metric ............................................442 Weight and Measures - Conversion F actors ......................................437 Section L - Service Literature .....................................................443 Index...............................................................................447
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