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Repair Manual for Komatsu Perkins 1000 Series Engine SEBE1006600
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Komatsu Perkins 1000 Series Diesel Engine Shop Manual SEBE1006600 – PDF DOWNLOAD
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Description
Komatsu Perkins 1000 Series Diesel Engine Shop Manual SEBE1006600 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Perkins 1000 Series Diesel Engine Shop Manual SEBE1006600 – PDF DOWNLOAD
Language : English
Pages : 170
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu Perkins 1000 Series Diesel Engine Shop Manual SEBE1006600 – PDF DOWNLOAD
MAIN MENU.................................................................................. 1 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
S.S 17/12/24
