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詳細描述

項目   零配件號碼         新件號   描述  

    1   KRP3026    6   KRP3026    活塞裝備         

    1   KRP3020    6   KRP3026    活塞裝備      01/01/2007

    6   KRP3021    6   KRP3021    活塞環(huán)裝備

    項目   零配件號碼         新件號   描述  

    2      1      活塞         

    3   CH11503    1   CH11503    軸頭銷       

    4   CH11508    1   CH11508    CIRCLIP          

    5   CH11508    1   CH11508    CIRCLIP   

    項目   零配件號碼         新件號   描述  

    2      1      活塞         

    3   CH11503    1   CH11503    軸頭銷       

    4   CH11992    1   CH11992    CIRCLIP          

    4   CH11508    1   CH11508    CIRCLIP          

    5   CH11992    1   CH11992    CIRCLIP          

    5   CH11508    1   CH11508    CIRCLIP   

    項目   零配件號碼         新件號   描述  

       CH11352    1   CH11352    密封墊       

           1      TIMINGGEAR 蓋       

       CH11976    14  CH10946              

    1   CH11848    1   CH11848    正時齒輪箱蓋        

    1   CH11848    1   CH11848    正時齒輪箱蓋               

    項目   零配件號碼         新件號   描述  

    2      1      TIMINGGEAR 蓋       

    3   CH11352    1   CH11352    密封墊       

    4   CH10946    14  CH10946    螺旋         

    4   CH11976    14  CH10946   

    項目   零配件號碼         新件號   描述  

    1   CH11667    1   CH11667    正時齒輪箱       

    1   CH11615    1   CH11667    正時齒輪箱       

    2   CH10829    1   CH10829    密封墊 - 正時齒輪箱        

    3   CH10953    10  CH10953    圖釘         

    4   CH10815    8   CH10815    螺拴         

    5   CH10255    8   CH10255    墊圈         

    5   CH10541    8   CH10255    墊圈         

    6   CH10791    9   CH10791    螺拴         

    6   CH11476    9   CH10791    螺拴         

    7   CH10832    1   CH10832    支撐托架         

    8   CH11895    2   CH11895    螺拴         

    8   CH10537    2   CH11895    螺拴         

    9   CH10615    2   CH10615    墊圈  

    項目   零配件號碼         新件號   描述  

    1   CH12895    1   CH12895    引擎控制組件ECM        

    1   CH11930    1   CH12895    引擎控制組件ECM        

    1   CH12104    1   CH12895    引擎控制組件ECM        

    2   CH10578    4   CH10578    圖釘         

    3   CH10272    8   CH10272             

    4   CH10108    4   CH10108    間隔器       

    5   CH10279    8   CH10279    墊圈         

    6   CH10576    1   CH10576    架        

    7   CH10577    1   CH10577    架        

    8   CH11932    2   CH11932    托架         

    9   CH11931    2   CH11931    不C 螺拴        

    10  CH11933    2   CH11933    普通墊圈         

    11  CH10277    2   CH10277    墊圈             

    項目   零配件號碼         新件號   描述  

    1   KRP1721    1   KRP1721    提升泵       

    1   KRP1679    1   KRP1721    提升泵       

    4   CH10582    2   CH10582    螺拴             

    項目   零配件號碼         新件號   描述  

    1   CH12071    6   CH12071    噴油器       

    1   CH12341    6   CH12071    噴油器       

    (1) CH12071    6   CH12071    噴油器           

    6   CH10790    6   CH10790    搖臂座       

    7   CH10791    6   CH10791    螺拴         

    8   CH10792    6   CH10792    間隔器              

    項目   零配件號碼         新件號   描述  

    2   KRP1643    1   KRP1643    密封墊裝備              

    項目   零配件號碼         新件號   描述  

       CH10970    1   CH10970    支撐托架         

    1   CH10974    1   CH10974    噴油器馬具       

    2   CH10195    6   CH10195    帽        

    3   CH10977    1   CH10977    架設(shè)托架         

    4   CH10938    3   CH10938    螺拴         

    5   CH10099    3   CH10099    墊圈         

    6   CH10827    5   CH10827    纜拉桿       

    7   T400187    12  T400187    螺拴         

    7   CH10566    12  CH10566    螺拴          

    8   T400186    2   T400186    螺拴         

    8   CH10160    2   CH10160    螺拴         

    9   CH10303    2   CH10303    墊圈      

    項目   零配件號碼         新件號   描述  

    1   CH12371    1   CH12371    飛輪殼       

    1   CH11584    1   CH12371    飛輪殼       

    2   CH11304    1   CH11304    密封墊 -后油封          

    3   CH12062    1   CH12062    密封墊       

    3   CH11583    1   CH12062    密封墊       

    4   CH12063    1   CH12063    密封墊       

    4   CH11582    1   CH12063    密封墊       

    5   CH10539    1   CH10539    堵塞蓋       

    6   CH10540    1   CH10540    密封墊       

    7   CH10538    1   CH10538    螺拴         

    8   CH10255    2   CH10255    墊圈         

    8   CH10541    2   CH10255    墊圈         

    9   CH11895    1   CH11895    螺拴         

    9   CH10537    1   CH11895    螺拴         

    10  CH10262    2   CH10262    栓塞         

    11  CH11587    9   CH11587    螺拴         

    12  CH10099    9   CH10099    墊圈         

    13  CH10939    1   CH10939    排泄栓塞         

    14  CH10940    1   CH10940    密封墊       

    15  CH11585    8   CH11585    螺拴         

    16  CH10255    8   CH10255    墊圈         

    16  CH10541    8   CH10255    墊圈         

    17  CH11586    7   CH11586    螺拴         

    18  CH10255    7   CH10255    墊圈         

    18  CH10541    7   CH10255    墊圈         

    19  CH11588    1   CH11588    栓塞         

    20  CH10220    1   CH10220    栓塞  

2800 Series

How to check the tappet clearances


4



Special tools

Descript ion

Engine turning tool

Tappet clearances


Part number

CH11148


Inlet

Exhaust


0,38 +/- 0,08 mm (0.015 +/- 0.003 in)

0,76 +/- 0,08 mm (0.030 +/- 0.003 in)


1

 

2

 
The tappet clearance is measured between the rocker levers  and the top of the valve bridge pieces. The

operation must be done with the engine cold and stopped. Refer also to "How to check/adjust the electronic

unit injectors" on page 42.

1  Remove the rocker cover.

2  Remove the top bolt (A1) from the cover (A2) on the flywheel housing and slacken the other cover bolt to

allow the cover to open. The top bolt (A1) is the timing bolt.

Caution: If a customer-fitted speed sensor is fitted to the flywheel housing, it must be remov ed before the

engine turning tool c an be inserted.

3  Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing bolt.

Note: There are two locations for the timing bolt, one at each side of the flywheel housing. Use the location

which is the most convenient.

4  Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind the cover

rotation (anti-clockwise when viewed on the flywheel) until the timing bolt engages with the threaded hole in

the flywheel. The piston of number 1 cylinder is now at TDC (top dead centre).

Caution: If the flywheel is turned past the threaded hole, the flywheel must be turned in the opposite direction

for approximately 45 degrees and then back in the normal direction of rotation until the timing bolt engages

with the threaded hole. This is to eliminate backlash.



User’s Handbook, TPD1516E, Issue 1


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This document has been printed from SPI². Not for Resale


4


2800 Series


5  Check the inlet and exhaust valves of the number 1 cylinder. If they are fully closed the piston is on its

compression stroke and the rocker levers can be moved by hand. If the rocker levers can not be moved

because the valves are slightly open, the piston is on its exhaust stroke. If it is on its exhaust stroke, withdraw

the timing bolt and turn the flywheel a further 360 degrees in the normal direction of rotation so that the number

1 cylinder is set to TDC on its compression stroke, then insert again the timing bolt.

6 Before each set of tappet clearances is adjusted, ensure that the roller of the rocker lever is fully against the

camshaft lobe.

7 Use a set of feeler gauges, inserted at the position shown (B3) between the valve bridge piece and the rocker

lever button, to check the tappet clearances for the inlet valves (C1) on cylinders 1, 2 and 4. Adjust the

clearances if necessary. Check the tappet clearance for the exhaust valves (C2) on cylinders 1, 3 and 5, and

adjust the clearances if neces sary.

Notes:

Move each valve bridge piece before the feeler gauge is inserted to reduce the effect of the oil film.

During the procedure, ensure that the feeler gauge is fully inserted

8  After each unit has been adjusted, tighten the lock nut (B2) of the adjustment screw (B1) to a torque of

30 ± 4 Nm (22 ± 3 lbf ft) 3 ± 0,4 kgf m.

9  Withdraw the timing bolt and rotate the flywheel by 360 degrees so that the number 6 piston is at TDC on

its compression strok e. Insert again the timing bolt into the threaded hole.


Continued



40


User’s Handbook, TPD1516E, Issue 1


This document has been printed from SPI². Not for Resale


2800 Series

10  Check the tappet clearances for the inlet valves (C1) on cylinders 3, 5 and 6. Adjust the clearances if


4


necessary. Check the tappet clearances for the exhaust valves (C2) on cylinders 2, 4 and 6, and adjust the

clearances  if necessary.

11  After each unit has been adjusted, tighten the lock nut of the adjustment screw to a torque of 30 ± 4 Nm

(22 ± 3 lbf ft) 3 ± 0,4 kgf m.

12  Check again the tappet clearances for all six cylinders.

13  Fit the rock er cover. Remove the engine turning tool and the timing bolt and fit the cov er to the flywheel

housing.

14  Fit the plug to the timing bolt location.



User’s Handbook, TPD1516E, Issue 1


41


This document has been printed from SPI². Not for Resale


4

How to check/adjust the electronic unit injectors


2800 Series


Spec ial tools

De scription

Part number

Fuel injector setting gauge

CH11149


This operation should be performed at the same time as the operation to c heck the valve tappet clearances.

Warning! The electrical circuit for the fuel injector units operates on 110 volts. Do NOT work on the fuel injector

units unless the power supply to the ECM has been disconnected.

1  With the rocker covers removed, set the number 1 piston to TDC (top dead centre) on its compression

stroke. Check/adjus t the height dimensions for the fuel injectors of cylinders 3, 5 and 6.

2 Use the fuel injector setting gauge, CH11149, to obtain the correct height for the fuel injector. The dimension

to be measured is from the top of the unit injector (A1) to the machined ledge on the fuel injector body (A2).

This dimension should be 78,0 ± 0,2 mm (3.07 ± 0.01 in). Slacken the lock nut and use the adjustment screw

of the rock er lever to obtain the correct dimension. Tighten the lock nut to a torque of

55 ± 10 Nm (41 ± 7 lbf ft) 5,6 ± 1 kgf m.

3  Remove the timing bolt from the flywheel housing and rotate the flywheel by 360 degrees in the normal

direction of engine rotation until the timing bolt can be inserted into the threaded hole. This will put the number

1 piston at TDC in its  exhaust stroke.

4  Check/adjust the height dimensions for the fuel injectors of cylinders 1, 2 and 4 as given in step 2.

5  When all adjustments have been made, remove the timing bolt, fit the cover to the flywheel housing, fit the

plug to the timing bolt position and fit the rocker cov ers.



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User’s Handbook, TPD1516E, Issue 1


This document has been printed from SPI². Not for Resale


2800 Series

Engine protection devices


4


The engine is fitted with an electronic management unit which monitors all c ritical engine temperatures and

pressures and will stop the engine if a critical fault occurs .

If any of the sensors fail, the diagnostic s indicator will be activated and your Perkins dealer should be contacted

so that the fault can be identified by use of the Perkins Electronic Service Tool (EST).

Visual inspection

Chec k visually the condition of all gauges, sensors and wiring. Look for wiring and components that are loose,

broken, or damaged. Damaged wiring or components should be repaired or renewed immediately.



User’s Handbook, TPD1516E, Issue 1


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This document has been printed from SPI². Not for Resale


4

How to renew the thermostats of the coolant system


2800 Series


Renew the coolant thermostats at the periods given in the service schedule. This is recommended preventive

maintenance practice.

Warnings!

Do not remove the coolant filler cap while the engine is still hot and the system is under pressure because

dangerous hot coolant can be discharged.

Discard used coolant in a safe place and in accordance with local regulations.

Cautions:

Failure to replace the thermostats at the periods given in the service schedule c ould cause severe engine

damage.

The engine must be operated with the thermostats installed. If a thermostat is fitted incorrectly  the engine

may overheat.

1  Drain the coolant until the level is below the thermostat housing (A1).

Caution: Certain sensors fitted to the engine have a short lead which is part of the sensor unit. For this type

of sensor ensure that the wiring harness  is disconnected from the end of the lead. Do not attempt to remove

the lead from the s ensor unit.

2  Disconnec t the cable (A3) from the coolant temperature sensor.

3  Release the hose clips (A2) and disconnect the pipe and hose clip from the top of the unit.

4  Slacken the five setscrews of the thermostat housing; then remove fully the three setscrews (A4) which

retain the thermostat housing on the cy linder head.

5  Lift carefully the assembly to separate it from the coolant bobbin (A5) at its base.



44


User’s Handbook, TPD1516E, Issue 1


This document has been printed from SPI². Not for Resale


2800 Series


4


6  Remove the two short setscrews which remain, separate the two halves of the assembly and remove the

thermostats.

7  Clean thoroughly both parts of the assembly and check  the condition of the lip-type seals. Renew the seals

if they are worn or damaged.

8  Fit the new thermostats. Ensure that the new thermostats are fitted correc tly. Fit a new ‘O’ ring type seal to

the groove in the thermos tat housing (B1), assemble the two halves of the unit and retain with the two short

setsc rews.

9  Ensure that the mating face on the cylinder head is clean.

10  Fit new seals to the coolant bobbin (B5) whic h fits into the base of the unit and lubricate the seals with a

small amount of rubber lubricant.

11  Fit a new ‘O’ ring type seal to the groove in the mating face of the housing and fit the assembly over the

coolant bobbin.

12  Fit the three setscrews (B4) which retain the thermostat housing on the cylinder head.

13  Gradually and evenly tighten the five setscrews to a torque of 38 Nm (28.0 lbf ft) 3,8 kgf m.

14  Connect the hose to the top of the housing and tighten the hose clip (B2).

15  Connect the cable (B3) to the coolant temperature sensor.

16  Fill the coolant system, s ee "How to fill the coolant system" on page 38.


B



User’s Handbook, TPD1516E, Issue 1


45


This document has been printed from SPI². Not for Resale


4

How to clean and to calibrate the engine speed/timing sensors


2800 Series


1 Disconnect the wiring harness from the sensor and remove the two speed-timing s ensors  from the left side

of the engine at the back of the gear case.

2  Check the c ondition of the plas tic end of the sensors for wear and/or contaminants.

3  Clean the metal shavings and other debris from the face of the sensors.

4  Fit the s ensors to the correct locations and connect the wiring harness.

Note: If a new ECM unit has been fitted, or the engine gear train has been renewed or dismantled and

assembled, the engine speed/timing s ensors  must be calibrated. Refer to engine timing calibration in the

Diagnostic Manual.



46


User’s Handbook, TPD1516E, Issue 1


This document has been printed from SPI². Not for Resale


2800 Series

How to inspect the turbochargers


4


At the periods given in the s ervice schedule, with the engine switched off and cool, disconnect and remove the

pipes from between the air filter and the turbochargers. Turn, rapidly, the rotor assembly of each turbocharger,

check for freedom of movement and for sounds of interference. If necessary, contact your Perkins

dealer/distributor.

Caution: Failure of the turbocharger bearings can cause large amounts of oil to enter the air inlet and exhaust

systems. Loss of engine lubricant can cause serious engine damage.

Minor leakage of a turbocharger housing under extended low load operation should not cause problems unless

turbocharger bearing failure has occurred.

Caution: When a turbocharger bearing failure is accompanied by a significant loss in engine performance

(exhaust smoke or engine speed up at no load), do not continue to operate the engine until the turbocharger

has been repaired or renewed.

Deposits must not be removed from the turbine wheels nor the compressor wheels or the balance of the

assembly will be adversely affected.

Chec k the oil supply and drain pipes for oil leaks.

Chec k for air leakage when the engine is run.

To remove and to fit a turbocharger

Refer the Workshop Manual for details of how to remove and to fit the turbocharger.

How to inspect the battery charging alternator

Inspect the battery charging alternator, for loose connections. Ins pect the ammeter (if fitted) during engine

operation to ensure correct battery performance and/or correct performance of the electrical system. Clean the

outside of the alternator and ens ure that the ventilation holes are c lear.

The alternator must be checked and corrected, if necessary, by a person who has  had the correct training, at

the periods given in the servic e schedule.



User’s Handbook, TPD1516E, Issue 1


47


This document has been printed from SPI². Not for Resale


4

How to inspect the starter motor


2800 Series


Check the electrical connections of the starter motor assembly and clean them. Check the starter motor for

correc t operation.

The starter motor must be checked and corrected, if necessary, by a person who has had the correct training,

at the periods given in the service schedule.

How to inspect the coolant pump

Inspect the coolant pump for leaks. If leakage is observed, renew the coolant pump seal or the coolant pump

assembly. Refer to the Workshop Manual for the dismantle and ass embly procedures.

Refer to the Workshop Manual or consult your Perkins dealer/distributor if any repair or replacement is  needed.

Notes:

A small amount of leakage of coolant across the surface of the face seal in the water pump is normal. Its

purpose is to provide lubrication for the seal.

There is a hole in the water pump body to allow coolant to drain. Small amounts of coolant might be seen

to leak intermittently from the drain hole during the engine operation cycle.

Signs of a small leakage through the drain hole are not an indication that the pump is faulty. Coolant stains

or intermittent drops of coolant from the hole, indicate normal operation of the pump.



48


User’s Handbook, TPD1516E, Issue 1


This document has been printed from SPI². Not for Resale


2800 Series

How to eliminate air from the fuel system

This procedure is used normally when the engine runs out of fuel.


4


1 Loosen the union of the fuel return pipe (A1). Unlock and operate the hand priming pump (A2) until fuel, free

from air, flows from the union; this procedure will require many strokes of the pump. Use a cloth or a container

to collect the excess fuel.

2  Tighten the union (A1). Operate the hand priming pump until a strong pressure is felt on the pump. Push the

priming pump plunger inward. Tighten the plunger by hand and continue immediately with the next stage.

3  Start the engine.

Caution: Do not operate the engine c ontinuously for more than 30 seconds. Allow the starter motor to cool for

two minutes before the engine is operated again.

4  If the engine will not start, allow the starter motor to cool for 2 minutes. Repeat steps 1 and 2 to start the

engine. Continue to eliminate air from the fuel system if:

The engine starts, but runs unevenly.

The engine starts, but continues to misfire or smoke.

5  Run the engine with no load until it runs  smoothly.



User’s Handbook, TPD1516E, Issue 1


49


This document has been printed from SPI². Not for Resale


 

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