SA6D170E-1

Shop Manual

SEBE6161

Al 4

SERIES 6D1704DIESEL ENGINES

This material is proprietary to Komatsu America international Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We resew8 the right to make changes or add Improvements at any time without Incurring any obligation to Install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for infomwtion on the latest revision.

December 1997

Coovriaht 1997 Komatsu America International Comoanv

00-l03

No. of page

01

GENERAL ........................................................................................................ 01-001

11

STRUCTURE AND FUNCTION

....................................................... I 1-001

12

TESTING AND ADJUSTING

............................................................. 12-001

13

DISASSEMBLY

AND ASSEMBLY ................................................. 13-001

14

MAINTENANCE

STANDARD ........................................................... 14-0012 z

15

REPAIR AND REPLACEMENT

OF PARTS .............................. 15-001

'

00-2 0

The affected pages are indicated bythe use ofthe following marks. Itis requested that necessary actions be taken to these pages according to the table below.

0( )

Pageto be replaced Pageto be deleted

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Pages having no marks are those previously revised or made aditions.

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00-2-3 @

SAFETY

SAFETY

NOTICE

SAFETYSAFETY NOTICE

IMPORTANT SAFETY NOTICEProper service and repair is extremely important for safe machine operation. The

service and repair techniques are both effective designed To prevent manual. by Komatsu

recommended

by Komatsu

and described

in this manual

and safe. Some of these techniques for the specific the purpose.

require the use of tools specially

injury to workers,

symbol A

is used to mark safety precautions should always be followed arise, first consider

in this care-

The cautions

accompanying situation

these symbols

fully. If any dangerous take the necessary

arises or may possibly

safety, and

actions to deal with the situation.

GENERAL Mistakes carefully

PRECAUTIONS in operation are extremely and dangerous. Manual

6. Decide

a place

in the repair

workshop correct

to keep

keep tools and removed the tools Always Smoke Read the Operation Maintenance the machine. or repairs,

parts. Always

and parts in their

places.

keep the work area clean and make only in the areas provided for smok-

BEFORE operating

sure that there is no dirt or oil on the floor. ing. Never smoke while working.

1. Before carrying which 2. When

out any greasing

read all the precautions

given on the decals

are fixed to the machine. carrying out any operation, always PREPARATIONS 7. Before FOR WORK oil or making or tracks any repairs, and the

wear safety shoes and helmet. loose work clothes, missing. . Always . Always wear wear

Do not wear adding park the machine on hard, level ground, to prevent

or clothes with buttons hitting grind-

safety glasses when safety glasses etc. when

block the wheels machine 8. Before ground. equipment

parts with a hammer. ing parts with a grinder, 3. If welding trained, ways ing

from moving. starting If this work, lower blade, ripper, to the the

bucket or any other work equipment is not possible, out the work, alhand

repairs are needed, experienced carrying welding welder gloves,

always have a carry

insert

safety pin or use blocks to prevent the work from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, blocks, jacks support or stands

work. When wear

out welding

apron,

shield, cap and other clothes suited for weld-

work.carrying out any operation always before starting. with two Always inagree on the operbefore starting any work,

4. When

the

machine

with

or more workers, ating procedure

before starting work. 10. Remove all mud and oil from use the handrails, the steps or ladders or

form your fellow workers step of the operation. hang UNDER in the operators

other places used to get on and off the machine. Always steps when Never jump impossible getting on or off the machine. If it is or ladders

Before starting

REPAIR signs on the controls compartment. and learn

on or off the machine. to use the handrails,

5. Keep all tools in good condition the correct way to use them.

steps, use a stand to provide

safe footing.

00-3

SAFETY

SAFETY

NOTICE

PRECAUTIONS 11 When or

DURING

WORK

19. Be sure to assemble original places. Replace any damaged . When installing

all parts again

in their

removing

the oil filler cap, drain plug pressure measuring plugs, to prevent the oil from compofirst the from

parts with new parts. be sure is beby contact

hydraulic out.

hoses and wires,

loosen them spurting Before remove circuit. 12. The when Wait water

slowly

that they will not be damaged ing operated. 20. When sure installing that they high pressure are

with other parts when the machine or removing completely or air circuits,

disconnecting the pressure

nents of the oil, water

hoses,

make careparts

not twisted.

Damaged

tubes are dangerous, and oil in the circuits is stopped, are hot ful when circuits. installing Also, the engine so be careful to cool before

so be extremely connecting

tubes for high pressure

check that installed.

not to get burned. for the oil and water out any work carrying circuits. 13. Before starting work, remove the leads from the battery. the negative Always remove first. use a hoist the lead from (-) terminal on the oil or water

are correctly 21 When

assembling

or installing tightening

parts, always torques. When

use the specified installing or parts which high speed,

protective vibrate

parts such as guards, violently correctly. or rotate at to check careful

be particularly

that they are installed 22. When fingers fingers 23. When which has aligning caught

14. When raising heavy components, or crane.

two holes, never insert your Be careful not to get your in a hole. hydraulic pressure, check assem-

or hand.

Check that the wire rope, chains and hooks are free from damage. Always ample Install places. slowly use lifting equipment capacity. the lifting Use to prevent equipment or crane at the correct and operate from with hitany a hoist

measuring

that the measuring

tool is correctly

bled before taking any measurements. 24. Take care when When removing removing the track, or installing the track the sepa-

the component

tracks of track-type rates suddenly,

machines. stand at

ting any other

part. Do not work

part still raised by the hoist or crane. 15. When ternal spring, removing pressure always covers which or under leave two are under infrom a in position the pres-

so never let anyone

either end of the track.

pressure bolts release

on opposite

sides. Slowly

sure, then slowly loosen the bolts to remove. 16. When wiring 17 When removing components, be careful not Damaged fires.

to break

or damage

the wiring.

may cause electrical removing piping,

stop the fuel or oil Fuel or oil

from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor even start fires. 18. As a general mum parts. rule, do not use gasoline when washing to can cause you to slip, or can

wash parts. In particular, of gasoline

use only the minielectrical

00-4

FOREWORD

GENERAL

FOREWORDGENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing the contents him the correct way to perform of this manual and use it to full

repairs and make judgements. effect at every opportunity.

Make sure you understand

This shop manual service workshop. chapters are further

mainly

contains

the necessary

technical

information is divided

for operations

performed chapters;

in a these

For ease of understanding, divided

the manual

into the following

into the each main group of components.

STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give for troubleshooting. an understanding of the structure, but also serves as reference material

TESTING AND ADJUSTINGThis section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion charts correlating of the checks and repairs. to Causes are also included in this section.

Troubleshooting

Problems

DISASSEMBLYThis section assembling

AND ASSEMBLYexplains the order to be followed when removing, installing, disassembling or each component, as well as precautions to be taken for these operations.

MAINTENANCEThis section

STANDARDgives the judgement standards when inspecting disassembled parts.

NOTICEThe time with specifications and the without latest date. contained any advance in this notice. shop Use manual the are subject to change given in the at any book specifications

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUALVOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Engine volume: Issued for every machine model Issued for each engine series Each issued as one volume to cover all models REVISED When pages. EDITION MARK is revised, an edition bottom mark of the

a manual

(@@@....I

is recorded

on the

Electrical volume: Attachments volume:

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

1

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. FILING METHOD See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number. Example 1 (Chassis volume): 10 -3

Symbol

item

Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when work. performing the

A*

Safety

TTItem number ~~~~~~~b.,. each item. Example 12 - 5TT -F

Caution

(IO. Structure number for

2 (Engine volume):

elkg

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where

Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.

Tghteninc torque Coat

Oil, water Additional cated pages: Additional pages are indiafter the Drain by a hyphen (-) and number

oil, water or fuel must be added, and the capacity. Places wheremust oil or water be drained, and quan-

page number. Example: IO-4

File as in the example.

tity to be drained.

Added IO-5

12-203 12-203-I pages -C12_203_2 12-204

00-6

FOREWORD

HOISTING

INSTRUCTIONS

HOISTINGHOISTING

INSTRUCTIONS

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASg every part weighing 25 kg or more indicated clearly with the symbol & is

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

.

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made:I) Check

for removal

of all bolts fastening parts. part causthe part to be reof another

100%

88%

79%

71%

41%SAD00479

the part to the relative 2) Check for existence ing interference moved. with

WIRE ROPES 1) Use adequate ropes depending on the to weight of parts to be hoisted, referring

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause a turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN (1000 kg1 vertically, at various hanging angles. When two ropes sling a load vertically, to 19.6 kN (2000 kg} of total weight suspended. (1000 hanging This weight two becomes make kg1 when angle. ropes up can be 9.8 kN a 120 force

the table below: Wire ropes (Standard Z or S twist ropes without galvanizing) Rope diameter mm 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60 *

r

Allowa kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

e load tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

On the other

hand, two

ropes are subjected

to an excessive

as large as 39.2 kN (4000 of 150.

kg1 if they sling

a 19.6 kN (2000 kg1 load at a lifting angle 0 a Dibid

88

E,

16.7 0(1400) Q (1000) % 600)

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. portion

2) Sling wire ropes from the middle of the hook.

30 Lifting

60 anrle

90 (dearee)

120

150SAD00480

00-7

FOREWORD

COATING

MATERIALS

COATING*

MATERIALSused for

The recommended coating materials such as adhesives, gasket sealants and greases disassembly and assembly are listed below. Sr For coating materials not listed below, use the equivalent of products shown in this list.

Category

omatsu code

Part No.

Q' W150 g

Container

I

Main

applications,

features

LT-IA

790-129-9030

ITubeTrl

Used to prevent rubber gaskets, rubber ~ ~~ ~~ cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs. Used as adhesive and plastic. or sealant for metal, glass

LT-IB

790-129-9050

20 g

(2 pes.)

Polyethylene container

l

LT-2

09940-00030

50 g


l

LT-3

790-129-9060 (Set of adhesive and hardening agent) 790-129-9040

Adhesive: 1 kg iardening agent: 500 g Polyethylene container TubeI I

l

Can

Adhesives LT-4 Holtz MH 705 250 g . Used as sealant for machined holes.

790-126-9120

.

75 g

Used as heat-resisting ing engine. Quick Cure Used bers,

sealant

for repair-

Three bond 1735

790-129-9140

50 g


. . .

hardening type adhesive time: within 5 sec. to 3 min. mainly for adhesion of metals, plastics and woods.

rub-

IAron-alpha201 790-129-9130 29

l

II


Il l

I

Quick hardenina tvoe adhesive Quick cure typejmax. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.

Loctite 648-50

79A-129-9110

LG-1

790-129-9010

Gasket sealant

LG-3

790-129-9070

I1 kg

200 g

Used as adhesive or sealant for gaskets and packing of power train case, etc. Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations, used to prevent seizure. Used as sealant for heat resistance gasket for high temperature locations such as engine precombustion chamber, exhaust pipe, etc.

00-8

FOREWORD

COATING

MATERIALS

Category

Komatsu code

Part No.

Q'W

Containerl

Main

applications,

features

. LG-4 790-129-9020 200 g Tubel

l

Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc. Silicon based, quick hardening

l

LG-5

790-129-9080

1 kg


l

l

Gasket sealant

LG-6

09940-00011

250 g

Tube

l

l

* Features: LG-7 09920-00150 150 g Tube

type - Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

Three bond 1211 LM-G

. 790-129-9090 100 g Tube

Used as heat-resisting engine.

sealant

for repairing

l

Molybdenum disulphide lubricant

09940-00051

60 g

Can .

Used as lubricant for sliding portion (to prevent from squeaking). Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc. General purpose type

LM-P

09940-00040

200 g

Tube .

G2-LI

SYG2-400LI SYG2-350LI SYG2-4OOLl-A SYGS-16OLI

l

Various

Various

SYGA-1 6OCNLIl

Grease

SYG2-4OOCA SYG2-350CA GP-CASYGS-4OOCA-A SYG2-160CA Various Various

Used for normal temperature, light load bearing at places in contact with water or steam.

SYGA-IEOCNCAMolybdenum disulphide lubricant 400 g (IO per case)

l

Used for places with

heavy

load

SYG2-400M

Belows

type

00-9

FOREWORD

STANDARD

TIGHTENING

TORQUE

STANDARDSTANDARD

TIGHTENINGTORQUES

TORQUEOF BOLTS AND NUTS use torque wrench).

TIGHTENING

Use these torques Thread diameter of boltI

for metric

bolts and nuts. (Always

Width across fiatsI

mm6 8 IO 12 14

mm10 13 17 19 22

Nm 13.2+ 1.4 31+3 6657 113*10 177f19 279+30 382?39 549f59 745f83 927*103

kqm 1.35kO.15 3.2kO.3 6.7f0.7 11.5+1 18f2 28.5f3 39f4 56f6 76f8.5 94.5f 10.5 135f15 175f20 225f25 280f30 335f35

27 30 33 36 39

41 46 50 55 60 I

1320+140 1720+190 2210+240 2750+290 3290*340

Thread diameter of bolt mm6 8 10 12

Width across flats mm10 13 14 27 Nm 7.85f 1.95 18.6f4.9 40.2f5.9 82.35k7.85 kgm 0.8f0.2 1.9f0.5 4.1f0.6 8.450.8

TIGHTENING

TORQUE

OF HOSE NUTS for hose nuts. Thread diameter mm14 18 22 24 30 33 36 42

Use these torques Nominal02 03 04 05 06 10 12 14

No.

Width

across flat mm19 24 27 32 36 41 46 55

Tightening Nm24.5f 4.9 49k19.6 78.5k19.6 137.3k29.4 176.5f29.4 196.1*49 245.2f49 294.2+49

torque kgm2.5rt0.5 5f2 8+2 14&3 18*3 20+5 2525 30*5

TIGHTENING

TORQUE

OF SPLIT FLANGE for split flange Width

BOLTS

Use these torques Thread diameter mmIO 12 16

bolts. Tightening torque

across flat mm14 17 22

I

I

Nm 65.7* 6.8 112k9.8 279*29

I

kgm6.7f0.7 11.5+1 28.5f3

00-10

FOREWORD

STANDARD

TIGHTENING

TORQUE

TIGHTENING

TORQUE

OF O-RING

BOSS CONNECTOR

Use these torques Nominal02 03.04 05,06 IO,12 14

for O-ring boss connector Thread diameter mm14 20 24 33 42

No.

I

Width

across flat mm

I

Tightening Nm34.3* 4.9

I

torque kgm3.5kO.5 9.5fl 14.5&Z 4356 89.5*13.5

Varies depending on type of connector.

93.1f9.8142.1f19.6 421.4f58.8 877.1f 132.3

TIGHTENING

TORQUE

OF O-RING for O-ring Thread

BOSS CONNECTOR

Use these torques

boss connector diameter Width across flat mm14 17 19 22 24 27 30 32 32 36 -

Nominal08 10 12 14 16 18 20 24 30 33 36 42 52

No.

Tighteni Nm7.35+ 1.47 11.27f 1.47 17.64f 1.96 22.54k 1.96 29.4& 4.9 39.2+ 4.9 49f 4.9 68.6+ 9.8 107.8f14.7 127.4f19.6 151.9k24.5 210.7f29.4 323.4f 44.1

I torque

mm8 10 12 14 16 18 20 24 30 33 36 42 52

kgm0.75+0.15 1.15~0.15 I.85 0.2 2.3f0.2 3kO.5 4kO.5 5f0.5 7&l Ilk 1.5 13+2 15.5k2.5 21.5+3 33* 4.5

TIGHTENING

TORQUES

OF FLARE NUT for O-ring Width boss connector TighteningNm 24.5f 4.9 49+ 19.6 78.5? 19.6 137.3k29.4 176.5ir29.4 196.1f49 245.2+49 294.2f49

Use these torques Thread diameter mm14 18 22 24 30 33 36 42

SAD00483

across flat mm19 24 27 32 36 41 46 55

torquebm 2.5+ 0.5 5+2 8k2 1423 18k3 2Ok5 25f5 30+5

00-l 1

FOREWORD

STANDARD

TIGHTENING

TORQUE

TIGHTENING

TORQUE

FOR 102 ENGINE

SERIIES

(BOLT AND

NUTS) Engine. torque kgm1.02 2.45 4.38 7.85 f 0.20 f 0.41 If: 0.61 f 1.22

Use these torques Thread

for bolts and nuts (unit: mm) of Cummins

diameter mm 68 10 12

Tightening Nm10 24 43 77 f2 f 4 6 z!z rk 12

TIGHTENING

TORQUE

FOR 102 ENGINE

SERIIES

(EYE JOINTS) Engine. Tightening Nm8k2 lOf2 12 +2 24 f 4 36 + 5


for eye joints (unit: mm) of Cummins

diameter mm6 8 10 12 14

torque kgm0.81 1.02 1.22 2.45 3.67 f + + f + 0.20 0.20 0.20 0.41 0.51

TIGHTENING

TORQUE

FOR 102 ENGINE for tapered screws

SERIIES

(TAPERED

SCREWS) Engine. torque kgm0.31 0.81 1.22 1.53 2.45 3.67 6.12 * f k f f f f 0.10 0.20 0.20 0.41 0.41 0.51 0.92


(unit: inch) of Cummins

diameter inchII16 l/8 l/4 318 l/2 314 1

Tightening Nm351 8+2 12f2 1552 24 + 4 36 k 5 60 k 9

00-12

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION

BY THICKNESSCopper wire

Number of strands 0.85 2 5 15 40 60100

Dia. yfmst$ndsCross section (mm*) 0.32 0.32 0.88 2.09

Currerrtrating Cali:rzD. 2.4 3.1 12 20 37 59 135~~~ I I

Applicable

circuit

11 26

Starting,

lighting, signal etc. signal etc. and signal (Glow plug)

I Lighting,Charging Starting Starting Starting Starting

I

65 84 85

I

0.32 0.45 0.80

I

5.23 13.36 42.73

I

4.6

I

127 217

I

0.80 0.80

1

63.84 109.1

1

13.6 17.6

178 230

CLASSIFICATION\ Priority1

BY COLOR AND CODE

Circuits1 Starting Pri- Code man/ Color Code W White WR White & Red WB B Black B Black BW Black & White BY Lighting Instrument Signal Other

IR Red RW Y Yellow YR

I ! GGreen GW

IL Blue LW

2 Color Code 3 Black & YellowI Red & Black Yellow & Black Green & Red BR Black & Red ICode 5 IColorlWhite Code 6 Color WG RY I YG I GY I Blue & Red LY Xed & White Yellow & Red Green & White Blue & White RB YB GR LR

led & Yellow Yellow & Green Green & Yellow Blue & Yellow RG

386/2,100 (Gross) ~518/2,100~ (Gross1 2,108/1,400 I215/1,4001 (Gross: (Gross1

534i2.100 {715/2,100} 2.971/1.400 {303/l ,400)

8 :E b t lz

Maximum High idling Low idling Minimum

2,330 - 2,400 1,075 - 1,125 fuel consumption ratio

2,400-2,500 1.850-1.950

*2 l 3

2,330 - 2,400 900 - 950 211 I1571

2 z z

920 - 970 211 {I571

gkWh {g/HPhl kg

211 {I571

Dry weight

2,600 (With;;;kee;haust

2,750 JVith exhaust brake

2,670

Fuel pump Governor

3osch PE-ZWx typr Bosch RSUV-D zentrifugal, minimun naximum-speed type

Komatsu Electronic

KFE control

Bosch PE-ZWx type Bosch RSUV centrifJgal, all-speed type

Lubricating

oil amount

(refill capacity)

Q

(Xi,174 174

Coolant amount

Q

24V, 50A

24V, 50A

24V. 50A

Starting

motor

24V. 7.5kW x 2

24V,llkWx2

24V, 7.5kW x 2

Battery

12V 200Ah x 4

12V 200Ah x 2

12V 200Ah x 2

Turbocharger

Water cooled Gallet TV77 x 2 Zexel single cylinder reciprocated type With after cooler *I: l2: l3: High altitude spec. en Power mode Economy mode ne No. 15963 a up to 15966

Gallet TV77 x 2 Zexel single cylinder reciprocated type With after cooler, exhaust brake

Gallet TV77 x 2 Zexel single cylinder reciprocated type With after cooler

Air compressor

Others

01-004-6

GENERAL

SPECIFICATIONS

SA6D170-A-1

EM680A

EG680A-1 6M170B-1

EM680A-A

OEM for generator

OEM for Marine engine

OEM for generator (Prime use)

6-170x170 23,150 l-5-3-6-2-4

2,880 (With marine 1,285 (With marine 1,757 (With marine

gear)

2,841 With marine gear) 1,137 With marine 1,831 With marine

2,796 With marine 1,150 With marine 1,781 With marine

gear]

2,603

-

2,603

gear)

gear)

gear)

1,048

1,048

gear)

gear)

gear]

1,756 -

1,756 -

-

-

-

55212,000 (740/2,000}

*4 *4

552/2,000 I740/2,000} 2,893/l ,400 I295/1,4001 2,100 - 2,200 550 - 600 211 {I571 (At rated output) 2,750 (Withog;;Tarine

629/2,000 {842/2,0001 3,295/1,400 {336/1,4001 2,100 - 2,200 550 - 600 217 (157) (At rated output) 3,250 (Withw;;arine

2,501/1,400 {255/l ,400) 2 & z 2,100 - 2,200 550 - 600 217 {162)

473/1,500 (50 Hz) [633/1,500} (50 Hz) 546/1,800 (60 Hz) f732/1,800} (60 Hz) Max. 1,560 (50 Hz) Max. 1,872 (60 Hz) 950 - 1,000 211 (157) (50 Hz) 217 I1621 (60 Hz)

55212,000 {740/2,000} 2,100 - 2,200 550 - 600 211 1157)

419/1,500 I561/1,5001 467/1,800 {625/l ,800) -

(50 Hz) (50 Hz) (60 Hz) (60 Hz)

Max. 1,568 (50 Hz) Max. 1,881 (60 Hz) 700 - 900 211 1157) (50 Hz) 217 1162) (60 Hz)

2,750 (Withw;r;;arine

2,720

2,500

2,720

Bosch PE-ZWx Bosch RSUV centrifugal,

type all speed type

100

(90)

120 (108)

120 (108)

67 (60) 119 (107) opt

119 (107) 122 (110) *5

118

85

85

(Engine

only 43)

24V, 30A

24V, 25A

24V, 30A

24V, 13A 24V, 25A (opt) 24V, 11 kW

24V, 13A 24V, 25A (opt) 24V. 7.5kW

24V, 13A 24V, 25A (opt) 24V, IlkW

24V, 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

Komatsu

KTRI 10

Komatsu

KTRI 10

Komatsu -

KTRI 10

Komatsu

KTRI 10

Komatsu

KTRllO

Komatsu -

KTRIIO

With after cooler *4: *5:

With after cooler

With after cooler

With after cooler

With after cooler

With after cooler

Without marine gear With bypass filter

01-004-7 0

GENERAL

SPECIFICATIONS

SA6D170-A-1

Applicable

machine

DEM for generator (Stanby use)

H D465-3 (Single turbocharger)

HD465-3 (Single turbocharger)

Number

of cylinders-Bore

x Stroke

mm cc

6-170x170 23,150 l-5-3-6-2-4

Total piston displacement Firing order

Overall

length

mm

2,603

1,861

1,861

.P t i

t?

Ovrali width Overall height (Excluding exhaust Overall height (Including exhaust

mm

1,048

1,060

1,060

6

pipe)

mm

1,750 -

1,626 -

1,623 -

pipe)

mm

Flywheel Maximum

horsepower torque

kW/rpm {HP/rpm} {kgr%Pml rPm

581/1,500 (50 Hz) {779/1,5001 (50 Hz) 672/1,800 (60 Hz) {900/1,800} (60 Hz) Max. 1,575 (50 Hz) Max. 1,890 (60 Hz) 700 - 900

515/2,100 (Net) {690/2,1001 (Net) 2,824/1,400 {288/1,4001 (Net) (Net)

524/2,100 (Net) {702/2,1001 (Net) 2,824/1,400 {288/1,4001 (Net) (Net) 8 z z

High idling Low idling Minimum fuel consumption ratio

2,250 - 2,350 850 - 900 219 (163)

2,250 - 2,350 850 - 900 221 (163)

g/kWh {g/I-W kg

211 11571 (50 Hz) 217 {1621(60 Hz)

Dry weight

2,720

2,470

2,470

Fuel pump Governor

3osch PE-ZWx

typf

Bosch PE-ZWx type Bosch RSUV centrifugal, minimum maximum-speed type

3osch RSUV centrif, ugal, all speed type

Lubricating

oil amount

(refill capacity)

e

67 (60) 119 (107) opt

Coolant amount

e

(Engine

107 only 43)

170

170

Alternator

24V, 13A 24V, 25A (Opt) motor 24V, 11 kW

24V, 50A

24V, 50A

Starting

24V, 7.5kW x 2

24V, 7.5kW x 2

Battery

12V 200Ah

x 2

12V 170Ah x 4

12V 170Ah x 4

Turbocharger

Komatsu

KTRI IO

Komatsu

KTRllO

Komatsu

KTRI 10

Air compressor

Cummins single cylinder reciprocated type With after cooler With after cooler

Cummins single cylinder reciprocated type With after cooler

Others

01-004-8 0

GENERAL

SPECIFICATIONS

SA6D170-A-1

H D465-3 (For ORAPA MINE)

Pc1ooosP-1 (For LAYTON)

6-170x170 23,150 l-5-3-6-2-4

1,861

2,373

1,060

1,909

1,626

1,080 -

-

485/2,000 (Net) {650/2,0001 (Net) 2,800/l ,300 (Net) (285/1,300} (Net) z 2,250 - 2,350 840 - 860 216 I1611 (Net)

434/1,750 {582/1,750} 2,730/1,300 1279/1,3001

(Net) (Net) (Net) (Net)

1,900 - 2,000 650 - 700 211 (Net) 11571 (Net)

ioz

2,480

2,555

BOSCH PE-ZWx wpe BOSCH RFD minimun maximum-speed control type

IOSCH PE-P(PS7S1 type BOSCH RSUV centrifugal, all speed type

170

160

24V, 50A

24V, 50A

24V, 7.5kW x 2

24V, 7.5kW x 2

12V 200Ah

x 2

12V 200Ah

x 2

GARRET TV77 typex2 CUMMINS single cylinder reciprocated type With aftercooler

KOMATSU KTRllOtype EXEL reciprocation jingle cylinder type With aftercooler

01-004-9 63

GENERAL

SPECIFICATIONS

Engine model D375A-1 IEngine Serial No. up to 11045)

SA6D170-B-1 D375A-1 (Engine Serial No. 11046 and up) D375A-1 (Engine Serial No. 13551 and up)

Applicable

machine

Number

of cylinders

- Bore x Stroke

mm cc

6-170x170 23,150 l-5-3-6-2-4

Total piston displacement Firing order

tOverall length mm 2,017 2,017 2,017

Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust

mm

1,139

1,139

1,139

pipe)

mm

1,746 -

1,746 -

1,746 -

pipe)

mm

Flywheel Maximum

horsepower torque

kW/rpm IHP/rpm) tkgr%?pmI rpm rpm

379/1,800 {508/1,8001 2,609/l ,300 {266/l ,300) 1,950 - 2,050 600 - 700 215 {I601

379/l ,800 {508/1,800} 2,609/l ,300 {266/l ,300) 1,950 - 2,050 600 - 700 215 {160}

392/l ,800 {525/1,8001 2,618/1,300 {267/l ,300) 1,960 - 2,040 580 - 680 215 {ISO} 8 z z

High idling Low idling Minimum fuel consumption ratio

g/kWh {g/HPh)

Dry weight

kg

2,660

2,660

2,660

Fuel pump Governor

losch PES-PDx typ 3osch RSUV centrif Jgal, all-speed type

Bosch PE(PS7S) 3osch RSUV centrifugal,

type all-speed type

Lubricating

oil amount

(refill capacity)

Q

Coolant

amount

Q

165

165

165

Alternator

24V, 30A

24V, 35A (1104612802) 24V, 50A (12806 -) 24V, 7.5kW x 2

24V, 50A

Starting

motor

24V, 7.5kW x 2

24V, 7.5kW x 2

Battery

12V 170Ah x 2

12V 170Ah x2

12V 170Ah x 2

Turbocharger

Komatsu -

KTRllO

Komatsu -

KTRIIO

Komatsu -

KTRI 10

Air compressor

Others

With after cooler

With after cooler

With after cooler

01-004-10 0

GENERAL

SPECIFICATIONS

SA6D170-B-1 EG500-1, EG500B-1 EG500BS-1 OEM for generator EG500-1, EG500B-1 EG500BS-1 OEM for generator

Pc1000-1

HD465-3 (Single turbocharger)

EG450-1

EG480-1 EG480B-1

6-170x170 23,150 l-5-3-6-2-4

2,373

2,373

2,577

2,603

2,603

2,603

1,909

1,909

1,048

1,048

1,048

1,048

1,080

1,080 -

1,809

1,746 -

1,746 -

1,746 -

2,275

405/1,700 {542/1,7001 2,550/1,300 I260/1,3001 2 1,800 - 1,900 650 - 700 211 {157}

451/2,100 {604/2,1001 2,481/1,400 {253/1,400} 1,800 - 1,900 650 - 700 224 {I 67)

354/1,500 (50 Hz) (481/1,5001 (50 Hz) 400/l ,800 (60 Hz) [544/1,8001 (60 Hz) 1,800 - 1,890 950 - 1,000 217 I1621

37211,500 (50 Hz) l498/1,500~ (50 Hz) 416/l ,800 (60 Hz) (557/1,8001 (60 Hz) Max. Max. 1,560 (50 Hz) 1,872 (60 Hz) 750 - 850 217 {162} (At rated output)

383/1,500 (50 Hz) {513/1,5001 (50 Hz) 427/1,800 (60 Hz) {572/1,8001 (60 Hz) Max. Max. 1,572 (50 Hz) 1,890 (60 Hz) 750 - 850 217 1162) (At rated output)

383/1,500 (50 Hz) {513/1,500) (50 Hz) 427/l ,800 (60 Hz) {572/1,8001 (60 Hz) Max. Max. 1,568 (50 Hz) 1,881 (60 Hz) 700 - 900 217 I1621 (At rated output)

(Dz

2,555

2,555

2,650

2,650

2,750

2,720

BOSCH PE-P(PS7S) type BOSCH RSUV centrif ugal, ail-speed type

BOSCH PE-ZWx type BOSCH RSUV-D :entrifugal, minimum naximum-speed type

BOSCH PES-PD type 30SCH RSUV centrif ugal, all-speed type

BOSCH BOSCH PE-ZWx type

PE-P(PS-7% type

BOSCH RSUV centrifugal, all-speed type

lOSCH RSUVcentrifugal, all-speed type (with cocel spring) 119 (107)

(z,

119 (107)

119 (107)

160

160

(Engin%ly

43)

(Enginiinly

43)

(Engine8tnly

43)

24V, 50A

24V, 50A

24V, 50A

24V, 13A

24V, 13A

24V. 25A

24V, 7.5kW

x 2

24V, 7.5kW

x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

KOMATSU

KTRI 10

&Io! m

4

F6164159

15-010 0


OF PARTS

REPLACING

VALVE SEAT INSERTS

4.

Calking circumference of insert Calk the circumference of the exhaust valve seat insert as follows. * It is unnecessary to talk the insert for the intake valve. Differences between exhaustNew

*

valve insertsOld

1I OO- 500mm

Part No.

6162-13-1321 (2 per valve)Part No. and size stamped on outside circumference

6162-13-1320 (2 per valve)No stamp (Note: The oversize insert is stamped.)

Difference Need for calking after press

No

Yes

fitting Calking above. is not needed for any insert not listed

head

1) Set with the bottom surface of the cylinder 8head facing up, and place on wooden blocks. * Leave enough space so that the valve guide does not contact the ground. Insert calking tools A4 and A5 into the valve guide. Hold calking tools A4 and A5 down with one hand, and hit around the whole circumference 15 times with the hammer to talk. * Check that there are no cracks in the talk portion and that the calking is uniform around the whole circumference.

z z

2)3)

6162F816A

F6164160A

150110

REPAIR

AND

REPLACEMENT

OF PARTS

REPLACING

VALVE

SEAT

INSERTS

5.

Finishing

the seat surface with valve seat cutter intake Exhaust surface: side: 3.69 side: 3.79 and guide mm mm mm insert: side: 30 in the figure. surface: side: 45O

1) Finish the seat surface A2 as shown + * Angie Width of seat

of seat fininshing Intake Exhaust

+

Connectricity

of valve 0.07

(T.I R) max.Unit: mm

2) Fit the seat surface a rough compound the and When valve turn the guide it with rubbing and

using the compound. of the valve thinly oil insert forms a pair with to rub the above with with it in that3o 459+0.05$57.4 * 0.05

Coat the seat surface that

mixed with

valve, then fit a rubbing both against the valve seat.

bar to the valve head, hands lightly

removes the

roughness, process no break to in

Intake

side

Exhaust

side

wipe off the compound. compound contact. 6. Final check * Standard sinking width repeat give a good contact

Then coat with a fine

surface

6162F507A

8

distance of contact Intake Exhaust

of valve 0.9 surface

(new): against mm ?c 0.2Bottom surface of cylinder head

Lo

Unit:

mm

z z

to 1.5 mmBottom surface of cylmder head

-Sr Standarad valve:

side: 2.5 side: 2.8

* 0.2

l

Coat the seat surface with guide, surface, contact red lead (minium), push lightely and rotate surface, without

of the new valve thinly insert it in the valve insertIntake side Exhaust side

against

the valve

1 O. Check the valve insert that the contact any breaks.

and confirm

is uniform or Make of the

F6164100

l

marks with a pencil on the seal surface new valve as shown in the diagram,

insert it in the valve guide, push lightly against the valve insert surface, that the pencil around marks uniformly and rotate 1 O. Check have been erased circumference.Pencil ,(about marks 20

places)

the whole

F6164101

15-012 0


OF PARTS

REPLACING

VALVE SEAT INSERTS

Air pressure testing method When carrying out an airtightness test with a vacuum tester, test as follows 1) Wipe off all the dirt, dust, and oil from the valve and valve seat surface with a cloth. 2) Assemble the valve, valve spring, retainer, and cotter, tap the tip of the valve stem with a plastic hammer 2 or 3 times directly from above to bring it into tight contact with the seat surface. 3) Fit a vacuum cup that matches the size of the valve in tight contact with the head surface. When doing this, to improve the airtightness of the vacuum cup, coat grease on the O-ring fitted to the vaccum cup, and fit it in tight contact with the flat surface of the head. (Be careful not to get any grease on the seat surface.) 4) Set the vacuum gauge, and check that the pressure drops less than 10 mmHg in 3 seconds. If it drops more than 10 mmHg in 3 seconds, check for any dirt on the seat surface, or rub the surface to correct it.l

15013 0


OF PARTS

REPLACING

NOZZLE HOLDER SLEEVE

REPLACING NOZZLE HOLDER SLEEVE1. Cutting a hole at bottom of sleeve . Insert 12 mm diameter drill 0 in the hole at the bottom of the sleeve to make the hole.

2.

Removing the sleeve 1) Insert-push bar Bl inside the sleeve. 2) Using sleeve extraction tap 0, cut tap to about 25 mm depth from top face of sleeve. Add oil while cutting. + Sleeve extraction tap: M32, P q 2.0 3) Insert push bar 82 from the bottom of the head and tap with the hammer to remove the sleeve. 4) Remove the sleeve materials from the tap portion of portion a of the cylinder head. 5) Remove O-ring (2). Press-fitting the sleeve I) Install O-ring (2) to the cylinder head. 2) Insert sleeve (I) in the cylinder head, then insert sleeve driver B3 and lightly tap it until the sleeve contacts the seat surface. * Before installing the sleeve, clean the sleeve and seat. * Apply adhesive to the seat around the sleeve. & Seat: LT-2

F6164102

3.

F6164103A

8z z

-----______

ea

-

%

F6164104

F6164105A

15-014 0


OF PARTS

REPLACING


4.

Calking the sleeve seat face 1) Fitthe sleeve seat with sleeve holder B5. w Tightening torque for sleeve holder: 2 kgm. B4

/

2) Install punch bushing Cl and insert sleeve3) driver B4. Place support @ under the cylinder head to allow the bolt of the sleeve holder to move out. Hit the sleeve driver with a hammer to talk the seat surface. Lightly hit with a hammer several times. * Remove the sleeve holder and punch bushing. hole of sleeve6162F511A

4)

5)

5.

Roll-fit the bottom

.

Using sleeve rolling tool C2, roll-fit bottom hole @ of sleeve (1). * Adjust the roll-fitting height with bearing collar @ so that the shaft of the rolling tool will protrude a little from the bottom hole. * Install the rolling tool to a radial drilling machine or upright drilling machine to roll-fitwith its own weight. + Rotating speed: 200 to 300 rpm

6.

Roll-fitting

the taper section of sleeve

.

Using sleeve expander C3, roll-fit the taper section of the sleeve. Set the roll-fitting amount with stopper @ of the expander. Install the expander to a radial drilling machine or upright drilling machine to roll-fitwith its own weight. Rotating speed: 200 to 300 rpm

6162F512A

6162F513A

15015 0


OF PARTS

REPLACING


7.

Spot-facing the inside seat of the sleeve I) Using guide bushing C5 as the guide, spotface the seat with sleeve cutter C4. + Cut the seat little by little while checking the protrusion of the nozzle with the holder for measuring it and a dial gauge so that the protrusion of the nozzle will be within the specification. * Rotating speed: 500 to 600 rpm * Protrusion of nozzle: 4.9 to 5.7 mm 2) Remove all the metal chips and dust from the machined surface. Checking the leakage from the seat . Confirm that fluid does not leak through the sleeve seat in the air pressure test. (There must be no leakage for 30 seconds at an air pressure of 3.0 - 3.5 kg/cm2.) + When carrying out the air pressure test, install a used nozzle holder.

8.

6162F514A

15016 0


OF PARTS

REPLACING


Water pressure testing method . If the area around the head has been corrected, test as follows. 1. Water Dressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Assemble tool E and tool F, and connect a hose to frange (I). 3) Apply water pressure (3.5 - 4.0 kg/cm2) for approx. 10 minutes, and check for any leakage from around the head. sr It is preferable to warm the whole cylinder head and carry out the test with hot water (82 - 93C).

2.

Air pressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Connect the pump hose to flange (I). 3) Place the head in a water bath, apply air pressure (3.0 - 3.5 kg/cm? for approx. 30 seconds, and check for any air leakage in the water. sr If the above test shows that there are cracks around the nozzle holder and plugs, replace the cylinder head.

F6164106A

2 Z Z

15017 0


OF PARTS

REPLACING

VALVE GUIDE

REPLACING VALVE GUIDE1. Removing the valve guide . Remove the valve guide with valve guide remover Gl.

6162F811A

2.

Press-fitting the valve guide 1) Press-fit the valve guide until the tip of valve guide driver G2 contacts the cylinder head. 2) Confirm that the protrusion of the valve guide is within specification. Ir Protrusion of valve guide: 23.7:::; mm * Inside diameter of valve guide hole in cylinder head: 19+~~021 mm

15018 0


OF PARTS

REPLACING

CROSS HEAD GUIDE

REPLACING1. Removingl

CROSS HEAD GUIDE

,

the cross head guide

Using cross head guide puller H, pull out thje cross head guide. 1) As shown in the figure, hold the cross head to lock sleeve guide with collet @of the puller.

2) Tighten the collet with bolt 0 0. 3) Rotate guide. 4) Remove nut @and

pull out the cross head

burrs, fins, etc. from the mounting it.

place of the cross head guide and clean

615F019A

2.

Press-fittingl

the cross head guide head with a copper its protrusion is

Insert the cross head guide in the cylinder head, then hit it into the cylinder bar or plastic + Protrusion hammer within specification of cross head guide Tolerance: + Inside diameter 54 -0.3 mm until

of crosshead guide hole: ,5 + 0.018 mm 0

15019 0

REPAIR

AND

REPLACEMENT

OF PARTS

GRINDING

THE

VALVE

GRINDING1. Grindingl

THE VALVE

the seat surface I. of valve seat: Intake valve: Exhaust 30

Grind the seat surface with valve refacer * Angle

valve: 45O

2.

Checkingl

after grinding that the thickness of the valve head, of the valve, and the contact surface of valve head of valve head

Confirm protrusion *

of the valve seat are within specification. ThicknessF6164107A

Ir Thickness

Repair limit Intake valve: Min. 2.9 mm (Standard Exhaust (Standard * Sinking of valve size 3.4 mm) size 3.5 mm) 0.9 1.5 mmF6164108

valve: Min. 3.1 mm

Standard:

8

Repair limit: 2.1 mm

z z

*

Check the contact of the valve with the seat surfacel

using one of the following

methods. insert it in the

F6164109

Coat the seat surface of the ground valve thinly with red lead (minium), the valve guide, valve insert surface, push lightly against any breaks. on the seat inPencil (about marks 20

and confirm that the

contact is uniform without Make surface push marks with insert

l

a pencil

of the ground valve as shown lightly against the loo. valve

the diagram, surface, around

it in the valve guide, insert Check that the

places)

and rotate the whole

pencil marks have been erased uniformly circumference.F6164101

15-020 0


OF PARTS

CYLINDER

BLOCK

CYLINDER BLOCK

HLE00055

1. 2. 3. 4. 5. 6. 7.

Cylinder liner Crevice seal O-ring Cylinder block Main bearing cap Main bearing cap bolt Camshaft bushing

15-0210

REPAIR

AND

REPLACEMENT

OF PARTS

TESTING

AND

INSPECTING

TESTING(1) Cylinder

AND INSPECTINGblock Unit: mm Judgement Check for cracks (external Cylinder standards Remedy

inspection A. Cracks

item

l

color check) etc.

Replace

head bolts hole portion,

6. Correction of con tact at packing portion Check for water leakage caused by corrosion

Replace

IC. Clearance liner from

F6164111

~~~Clearance from liner

ji190.34 190.40 190.19 190.29

zi%z!0.05 0.21 Replace cylinder liner or block

F616411:

D. Inside diameter of camshaft bushing

l

Inside diameter Standard 72 size Standard 72.00 bearing Standard 0.24 value value 72.07 Repair limit 72.10 Replace bushing

l

Clearance

from camshaft Standard 0.08 -

clearance 0.18

E. Protrusion

of line

Permissible

range: 0.07

-

0.15 Replace cylinder liner or correct cylinder block

I

\

F6164113

F. Depth of counter. bore and corrosion of bottom surface

Depth of counterbore

Standard 14

size

Standard 14.00 -

value 14.05

Repair by machining, add shim

~6164114

l

Check for corrosion Repair limit 0.15 0.10 Repair by machining

G. Distortion, wear of cylinder head mounting surfac

Tolerance Overall top surface of block: Max. 0.09 Max. 0.05

For one cylinder:

15022 0

REPAIR

AND

REPLACEMENT

OF PARTS

TESTING

AND

INSPECTING

Unit: mm inspection item Judgement standards Remedy

H. inside diameter of main bearing mounting holel

Standard 148 Ran$bf

size

Standard 147.992 -

value 147.025 171.025

Repair -

limit

Tighten main bearing cap bolt and guide bolt at specifier torque

@

170.992

Replace I. Fitting of cap and cylinder z z z block

J. Inside diameter of counterbore, outside diameter of cylinder liner flange

Replace cylinder

liner

F6164117

Bottom

1 194.59

/ ~~$&I

-

Cylinder block Top

Standard size

Standard value

Repair limit

1 206.0194.5

1 ;;,.,194.48 194.54

I;,,,194.46 194.57

Correct cylinder sleeve

block

Bottom

15023 0

REPAIR

AND

REPLACEMENT

OF PARTS

GRINDING

THE TOP

SURFACE

OF CYLINDER

BLOCK

GRINDINGGrinding

THE TOP SURFACE

OF CYLINDER

BLOCK

Grind off the strained and corroded portions of the cylinder block within the allowable height (H) of the cylinder block. Ir Use the followinga as a guide to decide when to grind to the top surface. If the top surface of the cylinder block is worn or corroded in the shape of the head gasket, and the amount of wear is more than 0.10 mm, grind the top surface. * If there are blackened portions on the cylinder liner contact surface of the counterbore (particularly in the front-to-rear direction), or there is speckled wear, and these portions extend over more than half of the contact width of the deck, and if grinding has been carried out on the top surface, correct the counterbore.

.c $

z

Wear

ofcounterbore

portion

% 3 _I I, \

1.

Grinding

top surfaceF6164118

1) Measure the wear and strain of the top surface of the cylinder block, and if it is over the repair limit, grind the top surface. + Flatness of cylinder block (for one cylinder): Standard dimension: 0.05 mm Repair limit: 0.10 mm * Height of cylinder block (H): Standard dimension: 509.835 - 510.065 mm Repair limit: 509.5 mm + Roughness of top surface of cylinder block: Max. 12.5s

If grinding * * It * * Speed Speed

with

a grindstone

(for reference) to 1,950 m/min. mm

of grindstone: of table: depth/time:

1,650

15 to 30 m/min. 0.025 A461V Water-soluble ing lubricant grind1 to2mm

+ Grinding

Cross feed/time: Grindstone: Grinding lubricant:

HLE00058

15024 0


OF PARTS

GRINDING

THE TOP SURFACE

OF CYLINDER

BLOCK

2.

Grinding couterboreAfter block, are grinding measure the top surface of the cylinder If or if there linerCylinder liner 12.5s / / Cylinder block v L (Liner Drotrusion)

Unit:mm

the depth of the counterbore. the standard portions dimension, on the cylinder

-

it is not within blackened surface contact wear,

of the counterbore direction), portions width extend

(particularly

in the front-to-rear and these half of the contact counterbore correcting, 14.05 mm. * Counterbore depth* if the 15.525

or there is speckled over more than

of the deck, correct the the repair limit. After depth with is within shims and 0.15I

within

counterbore mm, combine

adjust so that the liner protrusion

is 0.07

I

depth L: dimension limit: 15.46 liner I: 0.15 12.5s with detail mmUnit:mm

Standard Repair

14 + io5 mm

mm

F6164120

* Protrusion+ * Roughness Machined

of cylinder

Standard shape:

value: 0.07

of counterbore: diagram

Max.

In accordance

for portion

acylinder

For the decide value. When

extra

amount

for counterbore amount that will

depth

L,

a machining

bring the

protrusion

of the cylindr liner within within the repair

the standard limit in cases

grinding

where the counterbore depth L exceeds the standard dimension, set the machining amount so that one shim can be used for each cylinder as shown in the table below.Detail a F6164121

[Reference]

Adjustment

shims for counterbore Weight (kg)

depthIlnit. mm

Unit: mm

.Part No. 6162-29-2260 6162-29-2250 6162-29-2240 6162-29-2230 6162-29-2220 6162-29-2210

T

t 1 0.025

Remarks

1

1.50

1 0.004 1 0.0021 0.001 0.001 0.001 0.001

11 1 \

1 0.80 1 0.50 0.26 0.20 0.16

1 0.025 1 0.0250.025 0.020 0.016

Shim

T*t

F6164122

15-025 0


OF PARTS

GRINDING

THE TOP SURFACE

OF CYLINDER

BLOCK

3.

Checking and distinguishing after grinding and correctingAfter grinding in the cylinder Remove height always * and correcting, check for scratches and oil holes on the flat surface around the water

block top surface. if the cylinder dimension, 509.8 block but mm),

all burrs completely.

After grinding the top surface,

H exceedsthe repair

the

standard

is within

limit (569.5

use an oversize

head gasket. 6162-19-1811

Oversize Thickness

head gasket part number: of plate: 2.4 mm (Standard: 2.0 mm) are stamped of the of thePosition Ds,r I.

Ir To distinguish, on the plate. After correcting, block

the letters stamp the

OS

top surface content

cylinder correction

according

to the

as shown

in the table below.

Table of letters to stampOversize head gasket Shim Stamp

18,(Size of letters: 5 10 mm) HLE00067

15026 0

REPAIR

AND

REPLACEMENT

OF PARTS

GRINDING

THE

TOP

SURFACE

OF CYLINDER

BLOCK

4.

Procedure gasket When fitting 6 +

for coating out the

bottom cylinder contact

of linei liner

lip with

sealant pulling it again, and press under LGcoat the surface

the counterbore

liner lip with gasket sealant part. available

as follows. Use the same procedure when usingThe following is equivalent Three commercially to LG-6. SS-6OF6162F759

a shim for the corresponding

sealant

l l

Bond: TBI 215

Nihon Hermetic:

1) Use a cloth to wipe off all the dirt and oil from the contact surface block counterbore.Meting portion

of the liner lip and cylinder marked in the diagram line with

Top surface

of block

Of liner

2) Coat the position LG-6.l

Make sealant

the

diameter 3 mm.

of the

of gasket

$2 -

l

Make the overlapping and ending the mm as shown

portion for beginning of sealant 6 f 6Position to coat with gasket sealant

coating

in the diagram.

F6164124

*

Whenl

using shims coating with the LG-6, bottom instll of the it to the shim deck way-1

,

Overlap

amount

6 + 6 mm

After thinly Next,

portion of the block.l

coat with

LG-6

in the same

as when

not using shims.

dG-6 / (@2 -

F6164125

3 mm)

3) Press fit the liner in the cylinder When doing RF-I. is equivalent is not surface to the this, coat the lubricant

block.

1rubber

seal with

+ RF-l

commercially coat the block oil

available

Daido Kagaku

Kogyo DS-50. and seal with of engine press fitting

+ If RF-1contaet (SAE30) the liner.

available, of the O-ring amount

an extremely

small

immediately

before

F6164126

15-027 0


OF PARTS

GRINDING

THE TOP SURFACE

OF CYLINDER

BLOCK

4)

Coat the liner O-ring, clevis seal, and cylinder block contact surface with a small amount of engine oil (SAE #30) immediately before press fitting the liner. * Coat the contact surface of the cylinder block uniformly around the whole circumference by hand.

\+a

6162F761

5)

Insert liner (I) into the cylinder care not to damage the O-ring.

block, taking

6)

Use your weight and push the liner in with both hands. Ir If the liner does not go in smoothly when you apply your weight, there is danger that the O-ring may be damaged, so check the cylinder block for burrs or flashes.

7)

Using liner driver I, press fit cylinder liner (1) into the cylinder block. * Using the following procedure, squeeze out the gasket sealant coated on the counterbore. i) Tighten the cylinder head temporarily with a used head gasket. w Mounting bolt: 26 * 1 kgm

ii)

Ir

Remove the cylinder head, and wipe off the gasket sealant that has been squeezed out from between the cylinder liner and cylinder block. If gasket sealant sticks to the grommet in the head gasket, the grommet will be deformed, and this will cause leakage of water, so remove all the gasket sealant.

I

6162F764

15-028 0


OF PARTS

GRINDING

THE TOP SURFACE OF CYLINDER

BLOCK

8)

Loosen the cylinder head mounting bolts, remove the head, then wipe off the excess gasket sealant that has come out from the cylinder bore. a The gasket sealant that comes out may cause deformation of the head gasket grommet, so always carry out steps 4) and 5) without fail.

If the grommet is deformed into a heart shaDe. it blocks the water hole

/

and may cause the coolant.

leakage

of

/ /Grommet

R

\ \Water hole

F616417.7

15029 0


OF PARTS

REPLACING

MAIN METAL CAP

REPLACING MAIN METAL CAP * When replacing the main metal cap, machinethe semi-finished part according to the following procedure. No. 1,2,3,4,5 and 7 Main cap 6162-29-1210 No. 6 Main cap 6162-29-l 250 ( 1 1. Machining the bore of main metal cap 1) Remove the cylinder liner 2) Install the replacement metal cap to the cylinder block and tighten it to specification. w * Mounting boltfor main metal cap: and seat with engine oil

Coat the thread SAE30

Unit: kgm Procedure 1 st step 2st step 3st step 4st step 5st step 6st step Target 56 113 0 38 75 113 51 -61 5) 107-118 Loosen completely 33-43 70-80 107-118 on the cylinder block Cut the inside of metal cap (I) little by little while checkinn its inside diameter. Cut until the cutting tool contacts the inside wall of cylinder block (2). Inside diameter of main cap: i) Machining dimension Tolerance: ii) 148+to25 mm Inside diameter of cap when main cap is tightened to specified torque after machining. Tolerance: 148$::%: mm Range

2 z &

*

Align the notches and cap.

3)

4)

Set the jig for mounting the cylinder block to the table of a horizontal boring machine. Install the cylinder block by mounting its hole for the liner to the datum plug of the jig. Center the arbor of the boring machine by applying a dial gauge to the inside wall of the two metal caps which have the largest pitch in the metal caps to b e used again.

(IO range above and below cap matching surface) Surface roughness: 12.5s max. Never cut the inside wall of the cylinder block.

HLE00060

15030 0


OF PARTS

REPLACING

MAIN METAL CAP

2.

Correcting the width of the main metal cap (Modifvinn No. 6 main cap onlv) 1) lnskrtcast iron bushing @and pass arbor @I through. 2) Install facing tool @to the arbor. 3) Cut cap (I), until the cutting tool contacts the cylinder block. 4) Cut the opposite side in the same way. * Never cut the cylinder block.6 I27F230

* +

Roughness Width

of surface facing thrust metal: 12.5 max. of main cap Tolerance:

Max.R0.5 1

HKE00068

15031 0


OF PARTS

REPLACING

CAM BUSHING

REPLACING CAM BUSHING* Before replacing the cam bushing, remove plug from the rear of the cylinder block. Removing No. 1 and No. 7 bushings the

1. .

As shown in the figure, assemble push tool @ and collar @ in push tool set Jl, and grip J2, then pull bushing (2) out of cylinder block (I) by hitting the grip.6162F518A

2. .

Removing

No. 2 and No. 6 bushings

Assemble push bar 0, push tool 0, guide 0, and collar @ in push tool set Jl, then pull bushing (2) out of cylinder block (1) while hitting the bar.

2

1

c6162F519

3. .

Removing

No. 3, No. 4, and No. 5 bushings

Assemble push bar 0, push tool 0, guide 0, and collar 8 in push tool set Jl, then pull bushing (2) out of cylinder block while hitting the bar.

2 1

6162F520

4. .

Press-fitting

No. 3, No. 4, and No. 5 bushings

Assemble tool set Jl and bushing (2), then fit the bushing until the end face of push tool @I contacts cylinder block (I). Ir Align the oil hole on the bushing. (This must be cared whenever fitting the bushings.)

1

6162F521

15-032 0


OF PARTS

REPLACING

CAM BUSHING

5. .

Press-fitting


Assemble tool set Jl and bushing (2), then fit the bushing until the end face of push tool @I contacts the cylinder block. * Align the oil hole on the bushing.

6162F522

6. .

Press-fitting


Assemble tool set Jl, grip J2, and bushing (2), then fit the bushing until the end face of push tool @I contacts the cylinder block. Ir Align the oil hole on the bushing. Press-fit the plug to the rear of the cylinder block.6162F523A

*


OF PARTS

CRANKSHAFT

CRANKSHAFT

HLE00062

1.

Crankshaft

Unit: mm Inspection A. Cranks 6. Damage Check for damage to the journal portion 1 Damage C. Clogging of oil hole Scratches seizure discoloration item Judgement Use a magnetic standards to check for cracks Replace If the damage is slight, correct with an oilstone or correct by lapping. Replace if there is seizure Correct Correct Remedy

flaw detector

to cap hole at front and rear end of oil hole

Check for clogging

15-034 0


OF PARTS

CRANKSHAFT

Unit: Inspection item Judgement Standard value 0.14 - 0.320 standards Repair 0.69 limit

mm

I

1Repair 3.79 3.92 limit

Remedy

D. End play of crankshaft

Replace thrust bearing or correct with oversize

E. Thickness bearing

of thrust

Size STD 0.25 US 0.50 us 0.75 us 1 .oo us

Standard 4.0 4.125 4.25 4.375 4.5 Standard 108.00 107.75 107.50 107.25 107.00

size

Tolerance

-0.07 -0.12

4.04 4.17 4.29

_ Replace thrust bearing or correct crankshaft . with oversize

F. Outside diameter crankshaft pin journal

of

Size STD 0.25 US 0.50 us 0.75 us 1.00 us

size

Tolerance

Repair

limit

107.91 107.66 -:.022 107.41 107.16 106.91 Correct with undersize or replace

G. Out-of-roundness crankshaft pin

of

I. Outside diameter main journal

of

L. Curvature of crankshaft (total runout of indicator)

Standard Total coaxiality main journal of Max. 0.09 Max. 0.05

Repair 0.09 0.05

limit Replace

Coaxiality of neighboring journals

15-035 0


OF PARTS

CRANKSHAFT

Correcting surface journal portionIf the does roughness not fulfill

roughness

of crankshaft

of the the

crankshaft

journal the

portion surface

standard,

correct

roughness. 1. Cleaning Before 2. with air. Correcting 1) When machine Use a special the diagram polishing on the right. speed for the work use No. 320 dry polishing paper at 40 (belt up and machine as shown in surface correcting roughness with of journal special portion polishing and blowing polishing, brush with air and blow

the oil holes

i)

Set the rotating 50 rpm, type). honing journal. Perform

(do not use once width for each

oil), and move the paper

and down the whole journal ii) Next, replace journal right the handle by the movement. journal.

with No. 500 paper, coat the with honing oil, and move to the left and to move of the and doMove handle to left and right, and move once up and down width of journal F6164131 z z

surface

of the machine amount Use this

of play to give fine movement smoothly width

once up and down the whole Move the paper not stop at any point. iii) Check the surface not within roughness,

and if it is with

the standard,

polish again once of the journal

up and down the width No. 500 paper.

F6164132

15-036 0


OF PARTS

CRANKSHAFT

2) When(When

using a work clamp jig for polishing a special clamp polishing jig such grinding No. 800 oil: Honing 40 rpm time for Move one the journal clamp is the oil machine as shown machine is not in the under

available) Use a work diagram on the right. polising conditions.

Use a crankshaft the following Paper: Machining The polishing Work speed: approx. amount width down replace When

6 minutes. (approx.

of play of the clamp 5 mm), the journal in the axial

and journal up and direction.

and move

After completing honing

the honing of one journal, the pin journal, it is safer

the paper with new paper.

to carry out the work with the pin journal at the rotation center.F6164133

3) Assembly use

of work

clamp

jig and

method

of

i) Jig for pin journal Assemble diagram component separate on the parts, pages.

and jig for main journal jig as shown For details the in the of the on right. see

the clamp

drawings

F6164134

15-037 0

REPAIR

AND

REPLACEMENT

OF PARTS

CRANKSHAFT

ii) Cut out a piece of No. 800 paper with the shape shown in the diagram on the right.Make cuts of 20 mm length\ at approx. 10 mm intervals

Dimensions

of paper for pin journal 230 mm

IIIIIIIIIII

i E 9

iii) Take 2 pieces of paper prepared in Step ii), insert the top and bottom pieces in the slit of the clamp jig. then fix in position with tape. iv) Fit the journal in the clamp, and fix the ends of the lever with a rubber tube.Cut out slit 2 portions

I I I I I I I I I n_,Dimensions of paper for main journal

F6164135

3.

Measuring

surface

roughness

Standard for surface roughness Journal surface, thrust surface: Max. 0.8 S Using a surface roughness measuring tool, check that the roughness is within the standard. If no measuring tool is available, rub No. 1500 paper extremely lightely in the axial direction, and use a 30-times magnifying glass to inspect the pattern on the paper. If the horizontal lines can be seen to be connected it is within the standard value. If the lines cannot be seen to be connected, the roughness of the journal surface is excessive, so polish it again.4. Cleaning after correcting surface roughness

8

z z

After correcting the surface roughness, always brush the oil hole and blow with air.5. Check that there portion are no scratches and fillet or dents at

the journal

R portion.

Fix in position Bend to fit round

with tape w inside plate

.Rubber

shape

F6164136

15038 0


OF PARTS

CRANKSHAFT

Clamp jig parts drawing

(for pin journal)

@I Plate (2 are used for each jig)Unit: mm I= 5 69 k 0.1 -i (10) 74

A

F==iA

LLI31.5

I=H--

--t-F

/STKM 13A

I

Section A-AF6164137A

@

Handle (2 are used for each jig)

Umt: mm132 450

F6164138A

15039 0


OF PARTS

CRANKSHAFT

Clamp jig parts drawing 0

(for main journal)

Plate (2 are used for each jig)Unit: mm

t A 27.5

1 A

/6.5 6.5 STKMI 3A

Section A-Ag=x Section

A-A

F6164139A

@I Handle (2 are used for each jig)Unit: mm

F6164140A


OF PARTS

REPAIRING

THE CRANKSHAFT

REPAIRING THE CRANKSHAFT.If the crankshaft is worn or slightly seized or damaged, cut it to any one of the following thicknesses. Undersize dimensions: 0.25, 0.50,0.75, 1.00 mm If the crankshaft is bent or worn unevenly, replace it instead of repairing it. (A lot of skill is required to repair it.) Carefully finish section R of the fillet of the crankshaft, section r on the shoulder, and section R facing the hole. . Dimension Roughness of outside surface of pin journal, main journal: Max. 0.8s Tolls and jigs required for cutting 1) Magnetic flaw detector 2) Shore hardness tester 3) Etching kit 4) Crankshaft cutting machine 5) Crankshaft grinding machine 6) Roughness gauge 7) Ball gauge for measuring radii of fillets Min. 795-500-1140 Max. 795-500-I 150 Check before cutting 1) Visual check Check for cracks, damage, seizure, discoI: oration, wear, etc. to see if it can be repaired. 2) Hardness test of journal Hardness of journal (Shore hardness) Allowable range: 60 - 67 Hs Limit: 60 Hs If the hardness is below the limit, dispose of the crankshaft. 3) Torsion test

.

l

\ / IFof filletR

r

i

.

Dimension

\ c/rR: 6.5_g.s mm, Surface roughness r: 6.4 mm, Surface roughnessR6127F231

1.6s 12.5s

Stroke

of oil hole on journal

Main journal

Pin journal

6127F233

Throw

of eccentric:

85-t,,,

mm

15041 0


OF PARTS

REPAIRING

THE CRANKSHAFT

2.

Check during and after cutting 1) Checking the round sections of fillets i) Confirm that the round sections of fillets are smoothly connected to the shoulders of journals. ii) Using ball gauges for measuring the radii of the fillets, confirm that each radii of the fillets, confirm that each radii is between the minimum and maximum limits. 3.

4) Measuring the bend (Alignment) l Measure the bend of the repaired crankshaft. l Measure the bend (alignment) at the following four places. i) Overall length alignment: 0.09 mm max. 0.05 mm max. ii) Adjoining alignment: 10.04 mm max. iii) Forward end alignment: iv) Rear end alignment: 0.03 mm max.

&tact

kkpoint

Cutting the main journals Cut all the main journals to the same undersize. When cutting the main journals, count in the finishing allowance for grinding 0.007 to 0.008 mm. Undersized of main journal Unit: mm Size Basic dimension 140.000 139.750 139.500 139.250 139.000 -00.025 8 Z Z Allowable error

Contact point

6127F234

Minimum radius of fillet: 6.00 mm Maximum radius of fillet: 6.50 mm 2) Checking the seized surfaces by etching After cutting the journals, confirm that no parts were seized in the cutting procedure by the etching test. l If any seized part is found, cut the journal another 0.02 mm to apply the next undersize. l After etching the journals, neutralize and wash the checked surface, then apply oil.

l

S.T.D 0.25 US 0.50 us 0.75 us 1 .oo us

3) Magnetic flaw detecting l Before using the repaired crankshaft, confirm that there are no cracks on it by magnetic flaw detection. l Check the fillets of journals which are put in the critical area of each web of the crankshaft especially carefully. l After inspecting with a magneticflawdetector, always demagnetize the crankshaft.

Out of roudness and cylindricality of main journals (T.1.R). surface roughness. Allowable error: 0.010 mm max. Limit: 0.015 mm Surface roughness: 0.8s

Critical area of web of crankshaft

I 6127F235

15042 0


OF PARTS

REPAIRING

THE CRANKSHAFT

4.

Grinding the thrust bearing surface Jc It is not always required to grind the front and rear thrust bearing surfaces to the same undersize. * If the thrust bearing surfaces have been ground, confirm that the end play of the crankshaft is within the allowable range (For details, see DISASSEMBLY AND ASSEMBLY). . Undersizes of thrust bearing surfaces

5.

Grinding pin journals * Grind all the pin journals to the same undersize. * When grinding, count in finishing allowance for grinding 0.007 to 0.008 mm. . Undersizes of pin journalUnit: Size S.T.D 3asic dimension 108.00 107.75 107.50 107.25 107.00 0 -0.022

mm

Ulowable error

Unit: Rear thrust S.T.D bearing

mm 0.25 US 0.50 us 0.75 us 1 .oo us

surface

10.25 0.S +0.050 64.25 o 64.310 64.50+;.05 64.560

Basicdimension Limit Basic dimension Limit

64+:.05064.060 64.25+;050 64.310

.

Out of roundness and cylindricality of pin journal (T.I.R), surface roughness Allowable error: 0.010 mm max. Limit: 0.015 mm Surface roughness: 0.8s

6..

Squareness (T.1.R)

of thrust bearing Limit: 0.04 mm

surface .

.

Correcting the width of the main journal and pin journal by grinding When correcting the worn surfaces of the main journals and pin journals, limit the grinding thickness to the minimum. Width of crank pin journal If cutting one side only: Standard: 72+i.074 mm Limit: 72.32 mm Width of main journal: 64+g.05 mm Standard: Limit: 64.30 mm Squareness of thrust bearing surface (T.1.R) Limit: 0.04 mmThickness of friction surface -L Journal

i

Friction surface 1 6 I27F236

15-043 0


OF PARTS

REPAIRING

THE CRANKSHAFT

7. . .

Correcting the grindstone Dress the grindstone each time one journal is ground. Grindstone dresser Tip angle: 75? I0 Radius of edge: 0.38 * 0.25 mm At the edge of the dresser, a diamond for industrial use must be embedded.

l

IO. Treatment after grinding Confirm that each dimension is within specification. . Carefully wash each section and apply oil to it. . When storing the crankshaft for a long time, support it at three points or hang it vertically. 11. Balancing (for reference) (Do not perform any repair which will have an adverse effect on the balance of the crank shaft.) . Limit of unbalance: 110 g.cm . Limits for reading the balance correctly Bend of crankshaft: 0.09 mm (T.1.R) Speed of crankshaft: 325 rpm max. . Balance the crankshaft with the crank gear installed or install a weight equivalent to the weight of the gear fixing key to the keyway. . To balance the crankshaft, make a hole on the counter weight with a drill or cut it. Limit of amount of counterweight to be removed: 56 g 6 max. Number of holes: 19 mm or 23 mm Diameter of hole: 50 mm max. Depth of hole: Distance between hole and side face: 3 mm min. Distance among holes: 5 mm min.

Adjust the machine for correcting the grindstone, and correct the edge of the grindstone to the radius of the fillet. When checking and correcting the grindstone edge, grind a wood bar for trial and use ball gauges. Preventing seizure caused by grinding 1) Use the plunge grinding method. 2) Use the overall width of the grindstone. Do not grind the bosses if possible. 3) Apply sufficient cooling oil. 4) Set the circumferential speed of the grindstone to 2,000 m/min when the speed of crankshaft is 50 rpm. 9. . Surface finishing Standard surface roughness 0.8s Journal: 1.6s max. Thrust bearing, fillet: 1-2s Tapered end: Bosses of pin and main journal: 3.2s max. Finishing allowance for grinding: 0.007 to 0.008 mm

8 z z

15-044 0


OF PARTS

REPAIRING

THE CRANKSHAFT

12. Procedure for measuring curvature of crankshaft and outside diameter of journal Method of measurement 1) When measuring the curvature, use No. 1 and No. 7 journals as the datum point, put the dial gauge in contact with the journal and set the dial to 0 at the peak. Then rotate one turn and read the minimum and maximum values.

Example of measuring curvature

F6164144

2)

Measure the outside diameter of the main journal in the XY direction (No. 1 - 2) at 2 places, and the outside diameter of the pin journal in the XY direction (No. 1 - 2) at 2 places with a micrometer or air micrometer.

Locations for measurement

12345

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OF PARTS

CONNECTING

ROD

CONNECTING

ROD1. 2. 3. 4. 5. 6. Bolt Washer Cap Dowel pin Connecting Bushing

rod

F6164151

Unit: mm Inspection A. Cracks B. Curvature, twisting Check for curvature or &visingF6164152A

item

Judgement

standards flaw detector

Remedy

Check for cracks with a color check or magnetic

,,,I:::~

:,

I DReplace

C. Clearance between connecting rod bushing and piston pin

Replace bushing, roughness of inside surface of bushing: Max. 2.4s Inside diameter of hole at big end Without bearing Standard 115 size

8 Z G,

D. Inside diameter of hole at big end of connecting rod

1

Tolerance

+0.026 0 Roughness of inside surface of hole at big end: Max. 6.35 Clearance from crankshaft bearing (with bearing) Standard clearance

I

Replace

1I

Clearance 0.20

limit

0.058 - 0.132

Even if each part is within the repair limit, if it is above the clearance limit, replace the part (bearing, etc.) E. Thickness bearing of S.T.D U.S 0.125 0.250 0.375 0.500 F. Scratches on inside surface of bearing, seizure G. Distance between holes at big end and small end Standard 3.500 3.625 3.725 3.875 4.000 -0.029 -0.042 size Tolerance Repair limit 3.41 3.54 3.66 3.79 3.90 Replace, replace connecting rod also size

Check for scratches or seizure

Standard 305

1 I

Tolerance Replace -:.05

15046 0


OF PARTS

CONNECTING

ROD

Unit: mm Inspection item Judgement standards Remedy

I

H. Scratches at I shape portion of connecting rod (dents)

Check for scratches direction in area A

in horizontal

Check for grinder grain in horizontal direction in area A dents, regardless of size Replace if fingernail catches in fretting

F6164153 I

I. Fretting of mating surface of cap

Check for fretting

of mating

surface surface: Max. 6.3 S

Roughness Contact

of mating

of mating

surface:

Min. 70%

J. Scuffing of bolt seat surface

Scuffing

of cap bolt seat surface

II

Correct with oilstone Replace Replace washer Replace bolt

Scuffing

of bolt seat surface

Scuffing

of washer

surface of dowel of dowel pin pin hole

IIto bolt thread

T

2W

K. Deformation dowel pin L. Damage

of

Check for deformation Check for deformation

G to bolt Check for cracks, damage Check for curvature of bolt Replace bolt

+

*

If it is impossible to measure all the items in this judgment standard (in particular, the localized wear of big internal circumference) after machining and rebuilding the connecting rod, do not carry out any rebuilding. The reason for this is that it is impossible to confirm the precision after machining and rebuilding the hole at the connecting rod big end. When deciding on whether to reuse or discard the connecting rod, if honing grain can be observed on hole surface at big end, measurement of big end hole surface roughness and wave is unnecessary.

15-047 0


OF PARTS

REPLACING

CRANKSHAFT

GEAR

REPLACING CRANKSHAFT1. . Removal of gear Make a scratch in the surface at the root of the teeth with a nrinder, then assemble tools Kl and K2 and turn nut @ to remove the gear. * If the gear cannot be removed in this way, make a scratch in the surface at the root of the teeth with a grinder, then heat the gear with a gas burner and knock the gear out with a copper rod. t Be careful not to damage the crankshaft. Press fitting gear 1) Check the gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock a new key into the key groove of the shaft. 3) Heat the gear for the specified time at the specified shrink-fitting temperature. * Gear shrink-fitting temperature: 200C Heating time: Min. 30 minutes 4) Put the timing mark of the gear on the outside, then use a hitting tool to press fit until the side face of the gear is in close contact with the crankshaft flange. * Knock in quickly before the gear becomes cool.

K2 /

6162F813A

2.

15048 0


OF PARTS

REPLACING

CAMSHAFT

GEAR

REPLACING CAMSHAFT1.

GEAR

Removal of gear Set the camshaft assembly on the press stand, then push the camshaft to remove the gear When setting the camshaft assembly on the press stand, be careful not to get your fingers caught between the press stand and the gear. Press fitting gear 1) Checkthe gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock a new key into the key groove of the shaft. 3) Assemble the thrust plate. 4) Heat the gear for the specified time at the specified shrink-fitting temperature. * Gear shrink-fitting temperature: 200C Heating time: Min. 30 minutes 5) Put the timing mark of the gear on the outside, then use a hitting tool to press fit until the side face of the gear is in close contact with the camshaft flange. Knock in quickly before the gear becomes * cool.

a

2.

15049 0


OF PARTS

REPLACING

FLYWHEEL RING GEAR

REPLACING FLYWHEEL RING GEARg Be careful not to let the flywheel you. fall

Documents

SA6D170E-1