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Komatsu Dresser 410 and 610 Series Engine 1991 Model Service Repair Workshop Manual – PDF DOWNLOAD
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Komatsu Dresser 410 and 610 Series Engine 1991 Model Service Repair Workshop Manual
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Description
Komatsu Dresser 410 and 610 Series Engine 1991 Model Service Repair Workshop Manual
FILE DETAILS:
Komatsu Dresser 410 and 610 Series Engine 1991 Model Service Repair Workshop Manual
Brands: Komatsu Dresser
Manuals Type: Shop Manual
Machine Model: 410, 610
Language: English
Pages: 404
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu Dresser 410 and 610 Series Engine 1991 Model Service Repair Workshop Manual
FOREWORD:
- This manual contains complete rebuild specifications and information for the 410 and 610 Series engines. The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild procedures require the use of special service tools.
- Make sure the correct tools are used as described in the procedures. When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item.
- A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be ordered through your distributor using the forms in the end of this section, DR-91 for U.S. use, DR-20 for Canadian use and DR-128 for Foreign use.
- The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Komatsu Dresser Co. 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:
Komatsu Dresser 410 and 610 Series Engine 1991 Model Service Repair Workshop Manual
MAIN MENU........................................................... 0 Table of Contents................................................... 3 Section i - Introduction............................................ 5 About the Manual ............................................... 6 General Cleaning Instructions .................................. 12 Solvent and Acid Cleaning................................... 12 Steam Cleaning.............................................. 12 General Repair Instructions .................................... 11 General Safety Instructions ................................... 10 Generic Symbols ................................................ 8 Glossary of Terms .............................................. 13 How To Use This Manual ......................................... 7 Group Contents.............................................. 7 Index....................................................... 7 Metric Information.......................................... 7 Table of Contents........................................... 7 Illustrations .................................................. 9 Section E - Engine and Component Identification..................... 15 Engine Diagram ................................................. 20 Engine Identification .......................................... 16 Engine Dataplate ........................................... 16 Injection Pump Dataplate ....................................... 17 Cooling System.............................................. 19 Fuel System................................................. 19 General Engine Data......................................... 18 Intake Air and Exhaust System............................... 19 Lubrication System.......................................... 18 Lucas CAV DPA dataplate location............................ 17 Robert Bosch VE dataplate location.......................... 17 Section 0 - Engine Disassembly and Assembly......................... 23 Accessories - Installation ..................................... 97 Accessories - Removal........................................... 44 Alternator - Installation.......................................119 Alternator - Removal ........................................... 33 Balancer - Installation ........................................ 77 Balancer - Removal ............................................. 53 Locking the Balancer........................................ 54 Measuring Backlash.......................................... 53 Measuring the End Play...................................... 54 Removing the Balancer....................................... 55 Belt Tensioner - Installation .................................118 Belt Tensioner - Removal........................................ 32 Camshaft - Installation ........................................ 72 Camshaft End Play - Measuring............................... 74 Camshaft Gear Backlash - Measuring.......................... 74 Camshaft - Removal ............................................. 49 Measuring Gear Lash......................................... 49 Crankshaft End Play - Measuring ................................ 83 Crankshaft - Installation ...................................... 61 Crankshaft - Removal ........................................... 58 Cylinder Block - Prepare for Assembly ......................... 60 Cylinder Block - Removing From the Rollover Stand .............. 60 Cylinder Head - Installation ...................................102 Cylinder Head - Removal ........................................ 42 Cylinder Head - Tightening......................................104 Dipstick - Removal.............................................. 39 Drive Belt - Installation ......................................120 Drive Belt - Removal ........................................... 31 Engine Assembly ................................................ 60 Engine Disassembly ............................................. 30 Engine Disassembly and Assembly ................................ 26 Assembly.................................................... 26 Disassembly................................................. 26 General Information......................................... 26 Engine Disassembly and Assembly - Service Tools ................ 27 Engine Disassembly Check List .................................. 29 Engine Weight .................................................. 30 Exhaust Manifold - Installation ................................113 Exhaust Manifold - Removal ..................................... 36 Fan Hub - Installation .........................................118 Fan Hub - Removal............................................... 33 Fan Pulley - Removal ........................................... 32 Flywheel Housing - Installation ................................ 98 Flywheel Housing - Removal ..................................... 44 Flywheel - Installation ........................................ 98 Flywheel - Removal ............................................. 44 Front Cover - Installation .....................................100 Front Cover - Removal .......................................... 43 Fuel Filter Head - Installation.................................112 Fuel Filter Head - Removal ..................................... 36 Fuel Filter - Removal .......................................... 36 Fuel Lines - Installation ......................................110 Fuel Drain Manifold - Installation..........................111 High Pressure Fuel Lines - Installation.....................111 Injection Pump Supply Line - Installation...................110 Injection Pump Vent Line - Installation.....................111 Fuel Lines - Removal ........................................... 37 Fuel Drain Manifold - Removal............................... 38 High Pressure Fuel Line - Removal........................... 37 Low Pressure Fuel Lines - Removal........................... 38 Fuel Transfer Pump - Installation .............................. 86 Fuel Transfer Pump - Removal.................................... 47 Gear Housing - Installation .................................... 69 Gear Housing - Removal ......................................... 53 Injection Pump - Installation ................................. 87 Injection Pumps - Unlocking................................. 90 Locked Timed Injection Pump - installation.................. 89 Unlocked Bosch VE Injection Pump Installation............... 93 Unlocked CAV Injection Pump - Installation.................. 92 Injection Pump - Removal (Rotary Type Pumps) .................. 44 Drive Gear - Removal........................................ 46 Gear Lash - Check........................................... 45 Locking the Pump............................................ 45 Injector Nozzles - Installation ................................108 Injector Nozzles - Removal...................................... 40 Lifting Bracket Removal - Rear ................................. 31 Lube Pump - Installation ....................................... 70 Lube Pump - Removal ............................................ 51 Measuring Backlash.......................................... 51 Manifold Cover - Installation ..................................110 Manifold Cover - Removal ....................................... 39 Aftercooler - Removal....................................... 40 Oil Cooler - Installation ...................................... 85 Oil Cooler - Removal ........................................... 48 Oil - Draining ................................................. 31 Oil Filter - Installation ......................................121 Oil Pan - Installation ......................................... 85 Oil Pan Sealing Surfaces - Sealants......................... 85 Oil Pan - Removal .............................................. 48 Piston and Rod Assemblies - Installation ....................... 65 Piston and Rod Assemblies - Removal ........................... 55 Push Rods - Installation........................................102 Push Rods - Removal ............................................ 42 Rear Seal Housing - Removal .................................... 49 Rear Seal - Installation........................................ 83 Rocker Levers - Installation ...................................103 Rocker Levers - Removal ........................................ 41 Rollover Stand - Engine Mounting ............................... 30 Rollover Stand - Engine Removal ................................121 Side Oil Fill - Installation ................................... 86 Side Oil Fill - Removal ........................................ 47 Starter - Installation .........................................121 Starter - Removal .............................................. 30 Steam Cleaning The Engine ...................................... 30 Suction Tube - Installation .................................... 84 Suction Tube - Removal ......................................... 49 Tappet Cover - Installation .................................... 86 Tappet Cover - Removal.......................................... 47 Thermostat - Installation ......................................117 Thermostat - Removal ........................................... 34 Timing Pin Housing - Removal ................................... 52 Timing Pin - Installation....................................... 74 Turbocharger Drain Tube - Removal ............................. 59 Turbocharger - Installation ....................................114 Turbocharger - Removal ......................................... 34 Valve Clearance - Adjustment ...................................106 Valve Covers - Installation ....................................109 Valve Covers - Removal.......................................... 40 Valve Tappets - Installation ................................... 60 Valve Tappets - Removal ........................................ 51 Vibration Damper/Crankshaft Pulley - Removal................... 32 Vibration Damper - Installation ................................118 Water Inlet Connection - Installation ..........................119 Water Inlet Connection - Removal ............................... 48 Water Pump - Installation ..................................... 99 Water Pump - Removal ........................................... 43 Section 1 - Cylinder Block - Group 1................................123 Balancer - Assembly ............................................171 Balancer - Disassembly..........................................169 Camshaft and Gear - Inspection .................................151 Camshaft Lobe Edge Deterioration (Breakdown)Criteria .......153 Camshaft Lobe Pitting Reuse Criteria .......................152 Camshaft Bushing - Installation ................................145 Camshaft - Cleaning ............................................151 Camshaft Expansion Plug - Installation .........................144 Camshaft Gear - Replacement ....................................156 Camshaft Gear - Installation (Heated Gear Method) .........156 Camshaft Gear - Installation (With Special Tool 3823589)....158 Camshaft Gear - Removal ....................................156 Connecting Rod - Inspection ....................................164 Crankshaft - Cleaning...........................................147 Crankshaft Gear - Replacement...................................149 Crankshaft - Inspection ........................................148 Cylinder Block - Cleaning.......................................134 Cylinder Block - De-Glazing.....................................139 Cylinder Block - Disassembly....................................132 Cylinder Block - Exploded View..................................126 Cylinder Block - General Information............................129 Camshaft....................................................129 Crankshaft..................................................129 Cylinder Block..............................................129 Oil Seals...................................................129 Pistons.....................................................129 Vibration Damper............................................129 Cylinder Block Group Inspection Checklist.......................131 Cylinder Block - Inspection.....................................137 Cylinder Block - Precheck Before Disassembly....................132 Cylinder Block - Service Tools..................................130 Cylinder Block - Storing........................................147 Data Plate - Replacement........................................179 Dipstick Tube - Replacement.....................................146 Expansion and Pipe Plug - Installation .........................142 Fuel Pump Stud - Replacement ...................................179 Gear Housing and Timing Pin Assembly - Inspection .............178 Gear Housing - Disassembly .....................................178 Piston and Connecting Rod - Assembly ...........................165 Piston and Connecting Rod - Disassembly .......................161 Piston Inspection ..............................................163 Piston, Pin and Connecting Rod - Cleaning .....................162 Piston Pin - Inspection.........................................164 Piston Ring Gap - Checking .....................................167 Piston Rings - Installation ....................................167 Rod Bearing Clearance - Checking ...............................165 Vibration Damper - Cleaning and Inspection ....................161 Section 2 - Cylinder Head - Group 2.................................181 Cup Plug Replacement ...........................................193 Cylinder Head - Assembly........................................201 Cylinder Head - Cleaning .......................................187 Cylinder Head Combustion Face Inspection ......................191 Cylinder Head Cracks - Reuse Guidelines ........................192 Cylinder Head - Disassembly....................................186 Cylinder Head - Precheck Before Disassembly ..................186 Cylinder Head - Service Tools ..................................182 Exploded View ..................................................184 General Information ............................................185 Valve Guide Inspection .........................................191 Valve - Inspection .............................................189 Valve Seat Inspection ..........................................191 Valve Seats - Grinding .........................................196 Calculating the Grinding Depth .............................196 Measuring the Valve Depth ..................................196 Valve Spring Inspection.........................................192 Valves - Grinding ..............................................195 Section 3 - Rocker Levers - Group 3.................................203 Rocker Lever Assembly - Exploded View ..........................204 Rocker Lever Assembly - General Information ....................206 Rocker Lever - Inspection ......................................208 Rocker Lever Pedestals - Inspection ............................209 Rocker Levers and Pedestals - Cleaning ........................208 Rocker Levers - Assembly .......................................209 Rocker Levers - Disassembly ...................................207 Section 4 - Tappets and Push - Group 04.............................211 Push Rods - Inspection..........................................214 Tappets and Push Rods - Exploded View ..........................212 Tappets and Push Rods - General Information ...................213 Valve Tappets - Inspection .....................................214 Section 5 - Fuel System - Group 05..................................217 Exploded View - Fuel System ....................................220 Injection Pump - General Information ...........................221 Injection Pump - Identification ................................221 Injection Pump Repairs - Bosch VE ..............................221 Delivery Valve Holder/Sealing Washer - Replacement..........222 Fuel Inlet Adapter/Seal - Replacement.......................226 Overflow Adapter/Sealing Ring - Replacement.................225 Shaft Seal - Replacement ...................................221 Shutdown Lever/Spring - Replacement.........................224 Shutdown Solenoid - Replacement ............................223 Injection Pump Repairs - Lucas CAV DPA ........................231 Automatic Timing Advance - Disassembly .....................239 Back Leakage Valve - Replacement/Inspection.................232 Bleed Screws/Sealing Washers - Replacement..................234 Control Lever - Replacement ................................237 Fuel Inlet Fitting/Sealing Washer - Replacement.............236 Locking Screw/O-Ring - Replacement .........................231 Shutdown Lever/Spring - Replacement ........................238 Shutdown Solenoid - Replacement ............................233 Timing Advance - Assembly ..................................241 Timing Advance Components - Inspection .....................241 Vent Fitting/Sealing Washer - Inspection/Replacement........235 Injection Pump - Service Tools .................................218 Injection Pump Timing - Bosch VE................................227 Section 6 - Injectors - Group 06....................................247 Exploded View - Fuel System ....................................249 Fuel Lines - Clean and Inspect .................................262 Fuel Drain Manifold ........................................263 High Pressure Fuel Lines ...................................262 Low Pressure Fuel Lines ....................................264 Fuel Transfer Pump - Cleaning and Inspecting ..................259 Fuel Transfer Pump - General Information .......................251 Fuel Transfer Pump - Identification ........................251 Fuel Transfer Pump - Piston Style Rebuild .....................260 Assembly ...................................................261 Cleaning ...................................................261 General Information - Injectors ................................250 Injector - Assembly ............................................256 Injector - Clean and Inspect ...................................254 Injector - Disassembly .........................................253 Injector Pump - Service Tools ..................................248 Injector - Testing .............................................258 Chatter Test................................................259 Section 7 - Lubrication Oil System - Group 7........................267 Filter Bypass Valve - Replace ..................................274 General Information - Lubrication System .......................272 Oil Cooler Core ............................................272 Lubricating Oil Cooler - Exploded View .........................271 Lubricating Oil Pump - Exploded View ...........................276 Lubrication Oil Pump - General Information .....................277 Oil Cooler - Cleaning ..........................................274 Oil Cooler - Inspection ........................................275 Oil Pan and Suction Tube - Cleaning and Inspection ............270 Oil Pan and Suction Tube - Exploded View .......................268 Oil Pan and Suction Tube - General Information .................269 Oil Pump - Inspection ..........................................278 Pressure Regulator Valve - Assembly ............................274 Pressure Regulator Valve - Disassembly .........................273 Pressure Regulator Valve - Inspection .........................273 Section 8 - Cooling System - Group 8................................281 Belt Tensioner and Fan Hub - Exploded View ....................285 Belt Tensioner and Fan Hub - General Information ...............286 Belt Tensioner .............................................286 Belt Tensioner - Inspection ....................................290 Fan Hub Assembly ...............................................288 Fan Hub - Disassembly ..........................................287 Fan Hub - Inspection............................................287 Thermostat Housing Assembly - Exploded View ....................291 Thermostat Housing Assembly - General Information ..............292 Thermostat - Inspection ........................................292 Water Pump - Exploded View ....................................282 Water Pump - General Information ...............................283 Water Pump - Inspection .......................................284 Section 9 - Drive Units - Group 9...................................293 Accessory Drive Adapter - Exploded View ........................294 Accessory Drive Adaptor - Assembly .............................297 Accessory Drive Adaptor - Disassembly ..........................296 Accessory Drive - Cleaning .....................................296 Accessory Drive - Inspection ...................................296 Drive Units - General Information ..............................295 Accessory Drive Adapter.....................................295 Section 10 - Air Intake System - Group 10...........................299 Aftercooler - Inspection .......................................304 Air Intake System - Exploded View ..............................300 Air Intake System - General Information ........................302 Turbocharger - Cleaning and Inspection for Reuse ...............303 Inspection .................................................303 Section 11 - Exhaust System - Group 11..............................305 Exhaust Manifold - Exploded View ...............................306 Exhaust Manifold Inspection.....................................308 General Information ............................................307 Exhaust Manifold ...........................................307 Turbocharger Mounting Stud Replacement.........................308 Section 12 - Air Equipment - Group 12...............................309 Section 13 - Electrical Equipment - Group 13........................311 Section 14 - Engine Testing - Group 14..............................313 Blowby Measurement .............................................319 Blowby Conversion Chart (5.613 mm [0.221 in] Orifice) ......319 Engine Dynamometer Test - Engine Run-In .......................326 Engine Dynamometer Test - Installation of the Engine ..........320 Engine Dynamometer Test - Performance Checking .................330 Engine - Painting ..............................................334 Engine Run-In Procedure “In Chassis” ..........................333 Engine Storage - Long Term......................................338 Removing the Engine from Long-Term Storage .................340 Engine Storage - Short Term.....................................335 Removing the Engine from Short-Term Storage ................337 Engine Testing - Engine Side Views .............................316 Engine Testing - General Information ...........................318 General Engine Test Specifications .........................318 Engine Testing - Service Tools .................................314 Section 16 Mounting Adaptions - Group 16............................345 Flywheel and Ring Gear Inspection ............................347 Flywheel Housing Assembly ......................................348 Flywheel Housing Inspection ....................................348 Front Support - Cleaning and Inspection.........................350 General Information ............................................346 Flywheel and Ring Gear .....................................346 Flywheel Housing ...........................................346 Front Support ..............................................346 Ring Gear Replacement ..........................................347 Wet Clutch Application .........................................349 Section V - Engine Component Specifications - Group 18..............351 Capscrew Markings and Torque Values ............................390 Component Specifications and Torque Values .....................356 Air Intake System ..............................................382 Combustion Air System ......................................381 Compressed Air System Torque Values ........................382 Cylinder Block - Rebuild Specifications ....................366 Cylinder Block - Torque Values .............................372 Cylinder Head - Rebuild Specifications .....................373 Cylinder Head - Torque Values ..............................375 Electrical System ..........................................383 Engine Assembly - Capscrew Torque Values ...................360 Engine Assembly - Specifications............................356 Engine Testing - Test Specifications .......................384 Fan Hub - Specifications ...................................380 Fuel System ................................................376 Lubricating Oil System - Specifications ....................378 Rocker Levers and Pedestals ................................375 Tappet and Push Rods .......................................376 Thermostat, Coolant Operating Temperature ..................380 Drive Belt Tension .............................................385 Engine Component Torque Values .................................353 Newton-Meter to Foot-Pound Conversion Chart ....................388 Capscrew Markings and Torque Values - U.S. Customary .......389 Pipe Plug Torque Values ........................................391 Specifications - General Information ...........................352 Tap-Drill - U.S. Customary & Metric ............................392 Weight and Measures - Conversion Factors .......................387 Section L - Service Literature......................................393 Index...............................................................399
KOMATSU DRESSER 410 AND 610 SERIES ENGINE 1991 MODEL SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:
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