Cummins Service Diesel Engine 410 & 610 Series Manual Workshop Service Repair Manual

Shop Manual 410 and 610 Series Engine 1991 Model KDC 410 Series Engine KDC 610 Series Engine

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 Introduction ......................... Engine Identification ................... Engine Disassembly and Assembly - Group 00 . . Cylinder Block - Group 01 ............... Cylinder Head - Group 02 ............... Rocker Levers - Group 03 ............... Cam Followers - Group 04 ............... Fuel System - Group 05 ................. Injectors and Fuel Lines - Group 06 ......... Lubricating Oil System - Group 07 . . Cooling System - Group 08 . . . . . . . Drive Units - Group 09 . . . . . . . . Air Intake System - Group 10 . . . . . . Exhaust System - Group 11 . . . . . . . Air Equipment - Group 12 . . . . . . . Electrical Equipment - Group 13 . . . . Engine Testing - Group 14 . . . . . . . Instruments and Controls - Group 15 . Mounting Adaptations - Group 16 . . Specifications - Group 18 . . . . . . . Service Literature . . . . . . . . . . . . . . . . . . . . . . . ............ ............ ............ ............ ............ ............ ............ ............ ............ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page . . . . . 1 . . . . . E . . . . 0 . . . . . 1 . . . . . 2 . . . . . 3 . . . . . 4 . . . . . 5 . . . . 6 ........... 7 ........... 8 ........... 9 .......... 10 .......... 11 .......... 12 .......... 13 .......... 14 .......... 15 .......... 16 .......... 18 ........... L Index . . . . . . . . . . . . . . . . . . . . . . . . . . . .._....................................... X

Group 22 - System Exploded Diagram GROUP 10 1 i GROUP 02 ? $ROUP 06

Section i - Introduction 410 and 610 Series Shop Manual Page i-l Section i - Introduction About the Manual . . . . General Cleaning Instructions Solvent and Acid Cleaning . . Steam Cleaning . . . . . . . . . General Repair Instructions . . . . . . . . General Safety Instructions . Generic Symbols . . . . . . . . . Glossary of Terms . . . . . . How To Use This Manual . . . Group Contents . . . . . . . . . . Index . . . . . . . . . . . . . . . . . Metric Information, . . . . . . . Table of Contents . . . . . Illustrations . . . . . . . . . . . . . . . . . . . Section Contents Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-2 i-8 i-8 i-8 i-7 i-6 i-4 i-9 i-3 i-3 i-3 i-3 i-3 i-5

About the Manual Section i - Introduction Page i-2 410 and 610 Series Shop Manual About the Manual This manual contains information for 1991 engines. starting with ESN 44566920. For information on prior built engines refer to the 410 and 610 Shop Manual, Form No. 1128 178 Hl. The procedures in this manual were developed for a shop environment with engine disassembly and assembly being performed on a rollover stand. A Group System has been used to subdivide the instructions by major components and systems. Refer to the Table of Contents (page i-l) for the various groups. The information is presented in very basic terms to make sure the instructions are easily understood. Wrench sizes and shop tooling are identified in the procedure when needed. Each group contains the following in sequence: l An Alphabetical Table of Contents (Index). l Exploded view(s) of all the components in the group. l General Information Section(s) containing the basic service, maintenance, and design information necessary to assist in the rebuild of the engine or a component. l Procedural instructions for the disassembly, inspection, repair, and assembly that can be required to rebuild an engine. Additional repairs that are not essential during every rebuild, but can be necessary, are included. These repairs depend on the length of time an engine has been in service and the condition of the parts.

Section i - Introduction 410 and 610 Series Shop Manual How To Use This Manual Page i-3 How To Use This Manual Table of Contents The Table of Contents in the front of the manual contains a quick page reference for each group number. Group Contents Each group contains the following information: l A group index page at the beginning of each group to quickly aid in locating the information desired. l General information to aid in rebuilding the component and an explanation of design change differences. l Step-by-step rebuild instructions for disassembly, cleaning, inspection, and assembly of the component. l Symbols which represent the action outlined in the instructions. The definitions of the symbols, appear on pages i-5 through i-8. Index An alphabetical index is in the back of the manual to aid in locating specific information. Metric Information, Both metric and U.S. customary values are used in this manual. The metric value is listed first, followed by the U.S. customary in brackets. An example is 60” C [140” F].

About the Manual Page i-4 Generic Symbols Section i - Introduction 410 and 610 Series Shop Manual The following group of symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below. WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUTION - Minor personal injury can result or a part, an assembly or the engine can be damaged if the caution instructions are not followed, Indicates a REMOVAL or DISASSEMBLY step. Indicates an INSTALLATION or ASSEMBLY step, INSPECTION is required, CLEAN the part or assembly. PERFORM a mechanical or time MEASUREMENT. LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque, PERFORM an electrical MEASUREMENT. Refer to another location in this manual or another publication for additional information, The component weighs 23 kg [50 lb] or more, To avoid personal injury, use a hoist or get assistance to lift the component.

Section i - Introduction 410 and 610 Series Shop Manual Illustrations The illustrations used in the “Repair Sections” of this manual are intended to give an example of a problem, and to show what to look for and where the problem can be found. Some of the illustrations are “generic” and might not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required, and an acceptable or not acceptable condition. The illustrations are intended to show repair or replacement procedures. The illustration can differ from your application, but the procedure given will be the same. Certain procedures may not apply to all applications (e.g. engine balancer). Disregard any procedures that are not applicable. Illustration Page i-5 [Rev. A]

General Safety Instructions Page i-6 Section i - lntrodcution 410 and 610 Series Shop Manual General Safety Instructions Important Safety Notice A WARNING A Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist. Always wear protective glasses and protective shoes when working. Do not wear loose-fitting or torn clothing. Remove all jewelry when working. Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a I’ Do Not Operate,, tag in the operator’s compartment or on the controls. Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler cap and relieve the pressure from the cooling system. Do not work on any thing that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work. Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure, Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon) lines in a well ventilated area. To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN. To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes and compartments. Always use tools that are in good condition, Make sure you understand how to use them before performing any service work. Use ONLY genuine KDC replacement parts. Always use the same fastener part number (or equivalent) when replacing fasteners, Do not use a fastener, of lessor quality if replacements are necessary.

Cummins Service Diesel Engine 410 & 610 Series Manual Workshop Service Repair Manual

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