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Komatsu Perkins 1000 Series Diesel Engine Shop Manual – PDF DOWNLOAD
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Komatsu Perkins 1000 Series Diesel Engine Shop Manual
Book Code: SEBE1006600
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Description
Komatsu Perkins 1000 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu Perkins 1000 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 1000 Series
Book Code: SEBE1006600
Language: English
Pages: 170
File Format: Portable Document Format (PDF)
KOMATSU PERKINS 1000 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Perkins 1000 Series Diesel Engine Shop Manual
INTRODUCTION:
- This workshop manual has been designed to provide assistance in the service and overhaul of Perkins Phaser and 1000 Series engines. Most of the general infomlation which is included in the relevant User’s Handbook (sections 1 to 9) has not been repeated in this workshop manual and the two publications should be used together.
- Special tools have been made available and a list of these is given in section 25. Reference to the relevant special tools is also made at the beginning of each operation. Read and remember the “Safety precautions”. They are given for your protection and must be used at all times.
- A hazard symbol in the text indicates that there is a danger of personal injury if certain operations are . not done correctly. Where the information applies only to certain engine types, this is indicated in the text. The details of some operations will be different according to the type of fuel injection pump which is fitted. The pump type can be found by reference to the manufacturer’s identification plate on the pump but, generally, the type of pump fitted is as shown below.
TABLE OF CONTENTS:
Komatsu Perkins 1000 Series Diesel Engine Shop Manual
MAIN MENU.................................................................................. 0 Contents................................................................................... 2 General Information........................................................................ 3 Introduction........................................................................... 4 Engine identification.................................................................. 5 Safety precautions..................................................................... 6 Asbestos joints........................................................................ 7 Specifications............................................................................. 8 Weight table........................................................................... 9 Recommended torque tensions............................................................ 10 Cylinder head assembly............................................................. 11 Piston and connecting rod assemblies............................................... 11 Crankshaft assembly................................................................ 11 Timing case and drive assembly..................................................... 11 Aspiration system.................................................................. 11 Lubrication system................................................................. 11 Fuel system........................................................................ 11 Cooling system..................................................................... 11 Flywheel and housing............................................................... 12 Electrical equipment............................................................... 12 Auxiliary equipment................................................................ 12 Data and dimensions.................................................................... 13 Introduction....................................................................... 14 Cylinder head assembly............................................................. 14 Pistons and connecting rods........................................................ 17 Crankshaft assembly................................................................ 19 Timing case and drive assembly..................................................... 23 Cylinder block assembly............................................................ 24 Aspiration system.................................................................. 24 Lubrication system................................................................. 25 Fuel system........................................................................ 26 Cooling system..................................................................... 28 Flywheel and housing............................................................... 28 Electrical equipment............................................................... 29 Auxiliary equipment................................................................ 30 Service Operations......................................................................... 31 Cylinder head assembly................................................................. 31 General description................................................................ 32 Rocker cover....................................................................... 33 12A-01 To remove and to fit ................................................... 33 Rocker assembly.................................................................... 34 12A-02 To remove and to fit ................................................... 34 12A-03 To dismantle and to assemble ........................................... 34 12A-04 To inspect and to correct .............................................. 34 Valve tip clearances............................................................... 35 12A-05 To check and to adjust ................................................. 35 Valve springs...................................................................... 36 12A-06 To change the valve springs (with cylinder head fitted) ................ 36 Cylinder head assembly............................................................. 37 12A-07 To remove and to fit ................................................... 37 Valves and valve springs........................................................... 40 12A-08 To remove and to fit ................................................... 40 12A-09 To inspect and to correct .............................................. 41 Valve guides....................................................................... 42 12A-10 To inspect ............................................................. 42 12A-11 To remove and to fit ................................................... 42 Cylinder head...................................................................... 43 12A-12 To inspect and to correct .............................................. 43 12A-13 To correct a valve seat with a valve seat cutter ....................... 43 12A-14 To fit valve seat inserts .............................................. 44 Piston and connecting rod assemblies................................................... 45 General description................................................................ 46 Big end bearing.................................................................... 47 13A-01 To remove and to fit ................................................... 47 13A-02 To inspect ............................................................. 47 Piston and connecting rod assembly................................................. 48 13A-03 To remove and to fit ................................................... 48 Piston rings....................................................................... 50 13A-04 To remove and to fit ................................................... 50 Piston and connecting rod assembly................................................. 51 13A-05 To dismantle and to assemble ........................................... 51 Piston and rings................................................................... 52 13A-06 To inspect ............................................................. 52 Connecting rod..................................................................... 52 13A-07 To inspect ............................................................. 52 Small end bush..................................................................... 53 13A-08 To remove and to fit ................................................... 53 Piston cooling jets................................................................ 53 13A-09 To remove and to fit ................................................... 53 13A-10 To check the jet alignment ............................................. 53 Crankshaft assembly.................................................................... 54 General description................................................................ 55 Crankshaft pulley.................................................................. 56 14A-01A To remove and to fit - engine types AA, AB, AC and AD ................. 56 14A-01B To remove and to fit - engine types YA, YB, YC and YD ................. 56 Rear oil seal assembly............................................................. 57 14A-02 To remove and to fit ................................................... 57 14A-03 To renew the rear oil seal ............................................. 57 Thrust washers..................................................................... 58 14A-04 To check crankshaft end-float .......................................... 58 14A-05 To remove and to fit ................................................... 58 Main bearing....................................................................... 59 14A-06 To remove and to fit (with the crankshaft in position) ................. 59 Crankshaft......................................................................... 60 14A-08 To remove and to fit ................................................... 60 14A-09 To inspect ............................................................. 61 Balancer unit...................................................................... 62 14A-10 To remove and to fit ................................................... 62 14A-11 To dismantle and to assemble ........................................... 63 14A-12 To inspect ............................................................. 65 14A-13 To remove and to fit the needle roller bearings for the drive shaft .... 66 14A-14 To remove and to fit the bushes for the balance weights ................ 66 Timing case and drive assembly ........................................................ 67 General description................................................................ 68 Timing case cover.................................................................. 69 15A-01 To remove and to fit ................................................... 69 Front oil seal..................................................................... 70 15A-02 To remove and to fit ................................................... 70 Idler gear and hub................................................................. 71 15A-03 To remove and to fit ................................................... 71 Fuel pump gear..................................................................... 72 To remove and to fit 15A-04.................................................... 72 Camshaft gear...................................................................... 73 15A-05 To remove and to fit ................................................... 73 Crankshaft gear ................................................................... 74 15A-06 To remove and to fit ................................................... 74 Timing case........................................................................ 75 15A-07 To remove and to fit.................................................... 75 Camshaft and tappets............................................................... 76 15A-08 To remove and to fit ................................................... 76 Cylinder block assembly................................................................ 78 General description................................................................ 79 Cylinder block..................................................................... 80 16A-01 To dismantle and to assemble ........................................... 80 16A-02 To inspect ............................................................. 80 Cylinder liner..................................................................... 81 16A-03 To inspect ............................................................. 81 16A-04 To remove glaze from the bore .......................................... 81 16A-05 To remove and to fit ................................................... 82 Engine timing.......................................................................... 84 Engines fitted with Bosch fuel injection pumps..................................... 85 General description ........................................................... 86 17A-01 To set number 1 piston to TDC on the compression stroke ............ 87 17A-02 To check the valve timing .......................................... 88 17A-03 To check the timing of the fuel injection pump ..................... 89 17A-04 To check the timing mark of the fuel injection pump ................ 90 17A-05 To check the engine timing mark .................................... 91 Engines fitted with CAV fuel injection pumps....................................... 92 General description............................................................ 93 17B-01 To set number 1 piston to TDC on the compression stroke ............ 94 17B-02 To check the valve timing .......................................... 95 17B-03 To check the timing of the fuel injection pump ..................... 95 17B-04 To check the timing mark of the fuel injection pump ................ 96 17B-05 To check the engine timing mark .................................... 97 Aspiration system...................................................................... 98 General description................................................................ 99 Turbocharger.......................................................................100 18A-01 To remove and to fit ...................................................100 To clean the impeller and the compressor casing................................101 Lubrication system.....................................................................102 General description................................................................103 Filter canister....................................................................104 19A-01 To renew ...............................................................104 Filter head........................................................................104 19A-02 To remove and to fit ...................................................104 Sump...............................................................................105 19A-03 To remove and to fit ...................................................105 Oil strainer and suction pipe......................................................105 19A-04 To remove and to fit ...................................................105 19A-05 To inspect and to correct ..............................................105 Lubricating oil pump...............................................................106 19A-06 To remove and to fit ...................................................106 19A-07 To inspect .............................................................107 Relief valve.......................................................................108 19A-08 To remove and to fit ...................................................108 19A-09 To dismantle and to assemble ...........................................108 19A-10 To inspect .............................................................108 Fuel system............................................................................109 General description................................................................110 Fuel filter........................................................................111 20A-01 To remove and to fit ...................................................111 Atomisers..........................................................................111 Atomiser fault.................................................................111 20A-02 To remove and to fit ...................................................111 Fuel lift pump.....................................................................112 20A-03 To remove and to fit ...................................................112 20A-04 To dismantle and to assemble ...........................................112 20A-05 To test ................................................................113 Fuel injection pump................................................................114 20A-06A To remove and to fit - Bosch pump .....................................114 20A-06B To remove and to fit - CAV pump .......................................115 20A-07A To adjust - Bosch pump ................................................115 20A-07B To adjust - CAV pump ..................................................115 Fuel System........................................................................116 20A-08A To eliminate air from the fuel system - Bosch pump ....................116 20A-08B To eliminate air from the fuel system - CAV pump ......................117 Cooling system.........................................................................118 General description................................................................119 Thermostats........................................................................120 21A-01 To remove and to fit ...................................................120 To test........................................................................120 Water pump.........................................................................121 21A-02 To remove and to fit ...................................................121 21A-03 To dismantle and to assemble ...........................................121 Fan................................................................................123 21A-04 To remove and to fit ...................................................123 Fan drive..........................................................................123 21A-05 To remove and to fit ...................................................123 21A-06 To dismantle and to assemble ...........................................123 Lubricating oil cooler.............................................................124 21A-07A To remove and to fit - engine types AB and AD .........................124 21A-07B To remove and to fit - engine types YA, YB, YC and YD .................124 21A-08A To dismantle and to assemble - engine types AB and AD .................125 21A-08B To dismantle and to assemble - engine types YA, YB, YC and YD .........125 Cooler by-pass valve...............................................................126 21A-09 To remove and to fit ...................................................126 Flywheel and flywheel housing..........................................................127 General description................................................................128 Flywheel...........................................................................129 22A-01 To remove and to fit ...................................................129 Ring gear..........................................................................129 22A-02 To remove and to fit ...................................................129 Flywheel housing...................................................................130 22A-03 To remove and to fit ...................................................130 Electrical equipment...................................................................131 Alternators .......................................................................132 General description ...........................................................133 Precautions....................................................................133 Drive belts....................................................................134 23A-01 To check ...........................................................134 23A-02 To adjust tension ..................................................134 23A-03 To remove and to fit ...............................................134 Alternator.....................................................................135 23A-04 To remove and to fit ...............................................135 To maintain................................................................135 Fault diagnosis................................................................136 Starter motors ....................................................................137 General description............................................................138 Starter motor..................................................................139 23B-01 To remove and to fit ...............................................139 23B-02 To maintain the brush gear and the commutator ......................139 23B-03 To test on the engine ..............................................139 Starting aid ......................................................................140 General description............................................................141 Starting aid...................................................................141 23C-01 To remove and to fit ...............................................141 Auxiliary equipment....................................................................142 Clayton Dewandre compressor........................................................143 General description............................................................144 Compressor.....................................................................145 24A-01 To remove and to fit compressor and drive housing ..................145 Compressor drive...............................................................145 24A-02 To remove and to fit ...............................................145 24A-03 To dismantle and to assemble .......................................146 Power steering pump ...............................................................147 Power steering pump............................................................148 24B-01 To remove and to fit ...............................................148 Exhauster .........................................................................149 Exhauster......................................................................150 24C-01 To remove and to fit ...............................................150 List of special tools .................................................................151 List of special tools..............................................................152 Fault Finding Guide for Diesel Engines ................................................157 INTRODUCTION.......................................................................158 STARTING PROBLEMS..................................................................159 LOW CRANKING SPEED.............................................................160 COLD ENGINE WILL NOT START.....................................................160 ENGINE IS DIFFICULT TO START...................................................161 ENGINE STARTS AND STOPS........................................................161 ENGINE WILL NOT START HOT OR COLD..............................................162 ENGINE MISFIRES....................................................................162 LACK OF POWER......................................................................163 EXCESSIVE FUEL CONSUMPTION.........................................................163 BLACK EXHAUST......................................................................164 ENGINE KNOCKING....................................................................164 BLUE/WHITE EXHAUST.................................................................165 EXCESSIVE LUBRICATING OIL CONSUMPTION..............................................165 POOR COMPRESSION...................................................................166 OVERHEATING........................................................................166 EXCESSIVE CRANKCASE PRESSURE.......................................................167 ERRATIC RUNNING....................................................................167 VIBRATION..........................................................................168 LOW OIL PRESSURE...................................................................168 HIGH OIL PRESSURE..................................................................169
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