SEBE6161 Shop Manual Al 4 SERIES 6D1704 DIESEL ENGINES This material is proprietary to Komatsu America international
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SEBE6161
Shop Manual
Al 4
SERIES 6D1704 DIESEL 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-l 03
No. of page
01
GENERAL ........................................................................................................ 01-001
11
STRUCTURE AND FUNCTION
12
TESTING AND ADJUSTING
13
DISASSEMBLY
AND ASSEMBLY ................................................. 13-001
14
MAINTENANCE
STANDARD’ ........................................................... 14-001
....................................................... I 1-001
............................................................. 12-001
2 z
15
00-2 0
REPAIR AND REPLACEMENT
OF PARTS .............................. 15-001
'
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00-2-3 @
SAFETY
SAFETY
NOTICE
SAFETY SAFETY
NOTICE
IMPORTANT SAFETY NOTICE Proper
service
and
repair
is extremely
service and repair techniques are both effective designed
manual.
for the specific
injury to workers,
The cautions
by Komatsu
take the necessary
situation
machine
operation.
and described
in this manual
require the use of tools specially
is used to mark safety precautions
these symbols
should
arises or may possibly
always
arise, first consider
in operation
carefully
6. Decide
are extremely and
Manual
the machine.
out any greasing
read all the precautions which
dangerous.
Maintenance
BEFORE operating
1. Before carrying
a place
in the repair
Always
and parts in their
correct
to keep
places.
keep the work area clean and make
sure that there is no dirt or oil on the floor.
or repairs,
given on the decals
carrying
out any operation,
wear safety shoes and helmet.
Smoke
only in the areas provided
for smok-
ing. Never smoke while working.
loose work clothes,
always
. Always
or clothes with buttons
wear
safety glasses when
trained,
7. Before
adding
hitting
oil or making
wear
safety
glasses
repairs are needed, experienced
when
welder
or tracks
blade,
ripper,
bucket or any other work equipment
starting
work,
out welding gloves,
out the work,
apron,
al-
hand
shield, cap and other clothes suited for weld-
work.
to the
If this
equipment
is not possible,
from falling.
ating procedure
before
step of the operation.
agree on the operstarting.
form your fellow workers
with two Always
in-
before starting any
Before starting
work,
REPAIR signs on the controls
in the operator’s
compartment.
5. Keep all tools in good condition the correct way to use them.
In addition,
the
be sure
ing signs on them.
the
machine
with
or assembling, blocks,
jacks
support or stands
before starting work. 10. Remove
all mud and oil from
the steps or
other places used to get on and off the machine. Always steps when Never
and learn
insert
to lock all the control levers and hang warn-
9. When disassembling out any operation always
lower
safety pin or use blocks to prevent the work
carrying
or more workers,
the
from moving.
carry
welding
carrying
to prevent
and
ground.
ways
hang UNDER
8. Before
repairs,
always have a
work. When wear
grind-
etc.
any
on hard, level ground,
block the wheels machine
ing parts with a grinder, 3. If welding
FOR WORK
park the machine
parts with a hammer. . Always
PREPARATIONS
Do not wear
missing.
4. When
the tools
workshop
parts. Always
are fixed to the machine.
2. When
ing
care-
safety, and
keep tools and removed Mistakes
in this
be followed
actions to deal with the situation.
PRECAUTIONS
Read the Operation
The
purpose.
symbol A
the
accompanying
fully. If any dangerous
GENERAL
recommended
for safe
and safe. Some of these techniques
by Komatsu
To prevent
important
jump
impossible
use the handrails,
getting
ladders
or
on or off the machine.
on or off the machine. to use the handrails,
steps, use a stand to provide
If it is
ladders
or
safe footing.
00-3
SAFETY
SAFETY
PRECAUTIONS
DURING
19. Be sure to assemble
WORK
original 11 When or
removing
hydraulic
pressure
loosen them spurting Before
the oil filler cap, drain plug
slowly
measuring
to prevent
disconnecting
or removing
the pressure
when
or air circuits, completely
from
first the
and
oil in the circuits
the engine
is stopped,
20. When sure
installing that
high pressure
they
are hot
ful when
are
circuits.
so be careful
out any work
to cool
before
21 When
on the oil or water
Also,
13. Before starting work, remove the leads from Always
remove
(-) terminal
the lead from
first. use a hoist
or parts which
22. When
aligning
fingers
caught
ample
capacity.
Install
the lifting Use
23. When
equipment
which
has
a hoist
ting any other
or crane
and operate
the component
part. Do not work
15. When
removing
covers which
ternal
pressure
or under
always
leave two
hit-
with
any
wiring 17 When
bolts
from
a
in position
release
components,
or damage
the pres-
removing
be careful not
the wiring.
may cause electrical piping,
Damaged
fires.
stop the fuel or oil
from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor
Fuel or oil
can cause you to slip, or can
even start fires. 18. As a general
rule, do not use gasoline
to
wash parts. In particular,
use only the mini-
mum
washing
parts.
00-4
or rotate at
careful
to check
correctly.
Be careful
measuring
hydraulic
that the measuring
not to get your
pressure,
tool is correctly
of gasoline
when
electrical
removing
tracks of track-type When
removing
rates suddenly,
are under in-
pressure
sides. Slowly
removing
to break
violently
in a hole.
24. Take care when
from
sure, then slowly loosen the bolts to remove. 16. When
When
check assem-
at the correct
part still raised by the hoist or crane.
on opposite
parts, always torques.
bled before taking any measurements. equipment
to prevent
spring,
parts
two holes, never insert your
Check that the wire rope, chains and hooks lifting
care-
parts such as guards,
vibrate
or hand.
use
or installing
be particularly
fingers
are free from damage.
Damaged
connecting
tightening
protective
high speed,
make
so be extremely
check that
or crane.
Always
is be-
hoses,
not twisted.
that they are installed
14. When raising heavy components,
places.
by contact
installed.
assembling
installing
the negative
be sure
tubes for high pressure
use the specified
circuits.
the battery.
installing
are correctly
for the oil and water
carrying
slowly
parts with new parts.
hoses and wires,
tubes are dangerous,
not to get burned. Wait
installing
ing operated.
compo-
circuit. water
in their
with other parts when the machine
nents of the oil, water
12. The
Replace any damaged
that they will not be damaged
the oil from
out.
remove
all parts again
places.
. When
plugs,
NOTICE
or installing
the
machines.
the track,
the track
so never let anyone
either end of the track.
sepa-
stand at
FOREWORD
GENERAL
FOREWORD GENERAL This
shop
serviceman
manual
has been
an accurate
prepared
as an aid to improve
understanding
repairs and make judgements.
the
quality
of the product and by showing
Make sure you understand
of repairs
by giving
the
him the correct way to perform
the contents
of this manual
and use it to full
effect at every opportunity.
This shop manual
mainly
service workshop.
For ease of understanding,
chapters
are further
contains
divided
the necessary
technical
the manual
information is divided
for operations
performed
into the following
chapters;
in a these
into the each main group of components.
STRUCTURE AND FUNCTION This section
explains
an understanding
the structure
of the structure,
and function
of each component.
but also serves as reference
It serves not only to give
material
for troubleshooting.
TESTING AND ADJUSTING This
section
adjustments
explains
Troubleshooting
DISASSEMBLY This section assembling
checks
charts correlating
This section
before
and
after
performing
repairs,
as well
as
of the checks and repairs.
“Problems”
to “Causes” are also included
in this section.
AND ASSEMBLY explains
the order
each component,
MAINTENANCE
to be made
to be made at completion
to be followed
when
as well as precautions
removing,
installing,
disassembling
or
to be taken for these operations.
STANDARD gives the judgement
standards
when
inspecting
disassembled
parts.
NOTICE The
specifications
time
and
with
the
contained
without latest
any
advance
in this notice.
shop Use
manual the
are subject
specifications
to change given
in the
at any book
date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL VOLUMES
REVISED
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When
Chassis volume: Engine volume:
pages.
Issued for every machine model Issued for each engine series
Electrical volume: Attachments volume:
1
Each issued as one volume to cover all models
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
Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
EDITION
a manual
(@@@....I
MARK is revised,
is recorded
an edition
on the
bottom
mark of the
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
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):
Symbol
item
A
Safety
10 -3
TT Item number ~~~~~~~b.,.
*
(IO. Structure number
el kg
2 (Engine volume):
-F
Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.
Special technical precautions or other precautions for preserving standards are necesperforming
the
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tghteninc torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
12 - 5 TT
Special safety precautions are necessary when performing the work.
sary when work.
for
each item. Example
Caution
Remarks
oil, water or fuel must be added, and the capacity.
Places where
Oil, water Additional cated
pages:
by a hyphen
page number. Example:
Added
00-6
pages are indi-
(-) and number
after the
File as in the example.
IO-4
IO-5
Additional
Places where Drain
must
oil or water be drained, and quan-
tity to be drained.
12-203 12-203-I pages -C12_203_2 12-204
HOISTING
FOREWORD
HOISTING
INSTRUCTIONS
INSTRUCTIONS
HOISTING 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.
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
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
the part to the relative 2) Check for existence ing
interference
part caus-
the part to be re-
moved.
WIRE ROPES 1) Use
adequate
weight
ropes
79%
88%
71%
41% SAD00479
of another
with
100%
parts.
depending
of parts to be hoisted,
on the
referring
to
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.
the table below: 4)
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter mm
Allowa
e load
kN
tons
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
suspended.
18
35.3
3.6
(1000
20
43.1
4.4
10
*
r
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.
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle of the hook.
portion
When two ropes sling a load vertically, to 19.6 kN (2000 kg} of total weight This weight
kg1 when
hanging
angle.
two
becomes
ropes
9.8 kN
make
On the other
ropes are subjected
a 120”
hand, two
to an excessive
as large as 39.2 kN (4000
up
can be
force
kg1 if they sling
a 19.6 kN (2000 kg1 load at a lifting angle of 150”.
0 a
D
E,
88
16.7 0
ibid
(1400)
Q (1000)
% 600)
30 Lifting
60 anrle
90 (dearee)
120
150 SAD00480
00-7
COATING
FOREWORD
COATING
MATERIALS
MATERIALS
*
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
LT-IA
Part No.
Q'W
790-129-9030
150 g
Container
Main
I
l
LT-IB
790-129-9050
(2 pes.)
50 g
Polyethylene container
20 g
l
LT-2
09940-00030
790-129-9060 (Set of adhesive and hardening agent)
Adhesive:
LT-4
790-129-9040
250 g
Holtz MH 705
790-126-9120
75 g
LT-3
l
l
1 kg iardening
features
Used to prevent rubber gaskets, rubber ~ ~~ ~~ cushions, and cock plug from coming out.
ITubeTr-
Polyethylene container
applications,
used for
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
Can
agent: 500 g
Adhesives Polyethylene container
790-129-9140
50 g
Used as sealant
.
Used as heat-resisting ing engine.
. . .
Quick Cure Used bers,
Tube I
Three bond 1735
.
201
790-129-9130
29
Polyethylene container
I
Polyethylene container
I
Loctite 648-50
LG-1
Gasket sealant
00-8
LG-3
sealant
holes.
for repair-
I
I Aron-alpha
for machined
l
I l
l
I
hardening type adhesive time: within 5 sec. to 3 min. mainly for adhesion of metals, plastics and woods.
rub-
Quick hardenina tvoe adhesive Quick cure typejmax. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
79A-129-9110
790-129-9010
790-129-9070
200 g
Used as adhesive or sealant for gaskets and packing of power train case, etc.
1 kg
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
I
pipe, etc.
COATING
FOREWORD
Category
Komatsu code
Part No.
Q'W
Container
Main
. 790-129-9020
200 g
l
Tube
l
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
l
LG-5
790-129-9080
1 kg
Polyethylene container
l
Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc.
l
Gasket sealant
LG-6
09940-00011
250 g
Tube
l
l
* Features: LG-7
09920-00150
150 g
features
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.
l
LG-4
applications,
MATERIALS
Silicon
based,
quick
hardening
type - Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing,
Tube
etc. .
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
l
Molybdenum disulphide lubricant
.
G2-LI
SYG2-400LI SYG2-350LI SYG2-4OOLl-A SYGS-16OLI
Various
Used as heat-resisting engine.
sealant
for repairing
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.
l
General
purpose
type
Various
SYGA-1 6OCNLI l
SYG2-4OOCA SYG2-350CA
Grease
GP-CA
SYGS-4OOCA-A SYG2-160CA
Used for normal temperature, light load bearing at places in contact with water or steam.
Various
Various
SYGA-IEOCNCA Molybdenum disulphide lubricant
SYG2-400M
400 g (IO per
l
Belows
Used for places with
heavy
load
type
case)
00-9
FOREWORD
STANDARD
STANDARD STANDARD
TIGHTENING
TIGHTENING
Use these torques
TORQUE
TORQUE
TORQUES
for metric
TIGHTENING
OF BOLTS AND NUTS
bolts and nuts. (Always
use torque
wrench).
Width across fiats
Thread diameter of bolt I
I
mm
mm
Nm
kqm
6 8 IO 12 14
10 13 17 19 22
13.2+ 1.4 31+3 6657 113*10 177f19
1.35kO.15 3.2kO.3 6.7f0.7 11.5+1 18f2
279+30 382?39 549f59 745f83 927*103
28.5f3 39f4 56f6 76f8.5 94.5f 10.5
27 30 33 36 39
41 46 50 55 60
1320+140 1720+190 2210+240 2750+290 3290*340
135f15 175f20 225f25 280f30 335f35
I
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
7.85f 1.95 18.6f4.9 40.2f5.9 82.35k7.85
0.8f0.2 1.9f0.5 4.1f0.6 8.450.8
TIGHTENING
TORQUE
Use these torques Nominal
OF HOSE NUTS for hose nuts. Thread
No.
02 03 04 05 06 10 12 14
TIGHTENING
TORQUE
Use these torques Thread
diameter mm
00-10
Width
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
for split flange
IO 12
14 17
16
22
torque
Nm
kgm
24.5f 4.9 49k19.6 78.5k19.6 137.3k29.4 176.5f29.4 196.1*49 245.2f49 294.2+49
2.5rt0.5 5f2 8+2 14&3 18*3 20+5 2525 30*5
BOLTS
bolts.
across flat mm
Tightening
across flat mm
OF SPLIT FLANGE
Width
I
diameter mm
Tightening
I
Nm 65.7* 6.8 112k9.8 279*29
I
torque
kgm 6.7f0.7 11.5+1 28.5f3
FOREWORD
STANDARD
TIGHTENING
TORQUE
Use these torques Nominal
OF O-RING
Thread
No.
02 03.04 05,06 IO,12 14
BOSS CONNECTOR
diameter 14 20 24 33 42
TORQUE
Use these torques
Nominal
No.
Thread
TORQUES
Width
across flat mm
Tightening
I
I
torque
Nm
kgm
34.3* 4.9
3.5kO.5 9.5fl 14.5&Z 4356 89.5*13.5
93.1f9.8 142.1f19.6 421.4f58.8 877.1f 132.3
BOSS CONNECTOR
boss connector diameter
Width
Tighteni
across flat
I torque
mm
mm
Nm
kgm
8 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 -
7.35+ 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
0.75+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
36 -
OF FLARE NUT
Use these torques
for O-ring
Thread
Width
diameter
I
Varies depending on type of connector.
OF O-RING for O-ring
08 10 12 14 16 18 20 24 30 33 36 42 52
TIGHTENING
TORQUE
for O-ring boss connector
mm
TIGHTENING
TIGHTENING
SAD00483
boss connector
across flat
Tightening
torque
mm
mm
Nm
14
19
24.5f 4.9
18 22
24 27
49+ 19.6 78.5? 19.6
5+2 8k2
24 30
32 36
137.3k29.4 176.5ir29.4
1423 18k3
33 36 42
41 46 55
196.1f49 245.2+49 294.2f49
2Ok5 25f5 30+5
bm 2.5+ 0.5
00-l 1
FOREWORD
TIGHTENING
STANDARD
TORQUE
Use these torques Thread
FOR 102 ENGINE
SERIIES
diameter
Tightening
10 24 43 77
8 10 12
TORQUE
Thread
FOR 102 ENGINE
SERIIES
Tightening
Thread
00-12
torque kgm 0.81 1.02 1.22 2.45 3.67
8k2 lOf2 12 +2 24 f 4 36 + 5
8 10 12 14
FOR 102 ENGINE for tapered
screws
SERIIES
f 0.20 f 0.41 If: 0.61 f 1.22
Engine.
Nm
6
Use these torques
kgm 1.02 2.45 4.38 7.85
(EYE JOINTS)
diameter
TORQUE
torque
f2 f 4 6 z!z rk 12
for eye joints (unit: mm) of Cummins
mm
TIGHTENING
Engine.
Nm
6
Use these torques
NUTS)
for bolts and nuts (unit: mm) of Cummins
mm
TIGHTENING
(BOLT AND
TIGHTENING
(TAPERED
diameter
Engine.
Tightening Nm
II16 l/8 l/4 318 l/2 314 1
351 8+2 12f2 1552 24 + 4 36 k 5 60 k 9
0.20 0.20 0.20 0.41 0.51
SCREWS)
(unit: inch) of Cummins
inch
f + + f +
torque kgm 0.31 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
TORQUE
ELECTRIC WIRE CODE
FOREWORD
ELECTRIC WIRE CODE In 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 THICKNESS Copper wire
Number of strands
Applicable
Cali:rzD.
circuit
0.85
11
0.32
0.88
2.4
12
I
2
26
0.32
2.09
3.1
20
I Lighting,
signal etc.
4.6
37
Charging
and signal
59
Starting
(Glow plug)
5
65
I
I
0.32
5.23
I
15
84
0.45
13.36
40
85
0.80
42.73
60
127
I
100
\
I
217
CLASSIFICATION
1
0.80
63.84
0.80
I
1
109.1
Starting,
135~~~ I
Starting
13.6
178
Starting
17.6
230
Starting
lighting, signal etc.
BY COLOR AND CODE
Circuits1
Priority 1
Currerrtrating
Dia. yfmst$ndsCross section (mm*)
Starting
Lighting
Instrument
I
Other
Signal
I
I G
L
Yellow
Green
Blue
YR
GW
LW
Pri- Code man/ Color
W
B
B
R
Y
White
Black
Black
Red
Code
WR
-
BW
RW
Color
White & Red
-
Black & White
Code
WB
-
BY
!
2 Xed & White Yellow & Red Green & White Blue & White RB
YB
LR
GR
3 Black & YellowI Red & Black Yellow & Black Green & Red BR Black & Red ICode
I
-
I
-
& Green1
-
1
-
-
-
-
-
-
-
WG
5 IColorlWhite Code 6 Color
RY
I
YG
I
GY
Blue & Red I
LY
led & Yellow Yellow & Green Green & Yellow Blue & Yellow YL
RG
fuel consumption
ratio
gkWh {g/HPhl kg
Dry weight
2,600 (With;;;kee;haust
Fuel pump
3osch PE-ZWx typr
Governor
Bosch RSUV-D zentrifugal, minimun naximum-speed type
Lubricating
oil amount
(refill capacity)
Komatsu Electronic
*2 l3
2,330 - 2,400
KFE
Bosch PE-ZWx type
control
Bosch RSUV centrifJgal, all-speed type
(Xi,
Q
Q
Coolant amount
2,400-2,500 1.850-1.950
174
24V, 50A
174
24V, 50A
24V. 50A
24V. 7.5kW x 2
24V,llkWx2
24V, 7.5kW x 2
12V 200Ah x 4
12V 200Ah x 2
12V 200Ah x 2
Water cooled Gallet TV77 x 2
Gallet TV77 x 2
Gallet TV77 x 2
Air compressor
Zexel single cylinder reciprocated type
Zexel single cylinder reciprocated type
Zexel single cylinder reciprocated type
Others
With after cooler
With after cooler, exhaust brake
With after cooler
Starting
motor
Battery
Turbocharger
01-004-6
*I: l2: l3:
High altitude spec. en Power mode Economy mode
ne No. 15963 a
up to 15966
2 z z
SPECIFICATIONS
GENERAL
SA6D170-A-1
EG680A-1 6M170B-1
EM680A
EM680A-A
OEM for Marine engine
OEM for generator (Prime use)
2,603
-
2,603
1,048
-
1,048
1,756
-
1,756
-
-
-
OEM for generator
6-170x170 23,150 l-5-3-6-2-4
2,880 (With marine
gear)
2,841 With marine gear)
2,796 With marine
gear]
1,285 (With marine
gear)
1,137 With marine
gear)
1,150 With marine
gear)
1,757 (With marine
gear)
1,831 With marine
gear)
1,781 With marine
gear]
-
-
552/2,000 I740/2,000}
629/2,000 {842/2,0001
2,501/1,400 {255/l ,400)
2,893/l ,400 I295/1,4001
3,295/1,400 {336/1,4001
2
2,100 - 2,200
2,100 - 2,200
2,100 - 2,200
Max. 1,560 (50 Hz) Max. 1,872 (60 Hz)
2,100 - 2,200
Max. 1,568 (50 Hz) Max. 1,881 (60 Hz)
& z
550 - 600
550 - 600
550 - 600
950 - 1,000
550 - 600
700 - 900
217 {162)
211 {I571 (At rated output)
217 (157) (At rated output)
211 (157) (50 Hz) 217 I1621 (60 Hz)
211 1157)
211 1157) (50 Hz) 217 1162) (60 Hz)
2,750 (Withog;;Tarine
3,250 (Withw;;arine
2,720
2,500
2,720
-
55212,000 (740/2,000}
*4 *4
2,750 (Withw;r;;arine
473/1,500 (50 Hz) [633/1,500} (50 Hz) 546/1,800 (60 Hz) f732/1,800} (60 Hz) -
Bosch PE-ZWx Bosch RSUV centrifugal,
100
-
120 (108)
118
85
85
24V, 30A
24V, 25A
24V, 30A
24V, 13A 24V, 25A (opt)
24V, 13A 24V, 25A (opt)
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, 11 kW
24V. 7.5kW
12V 200Ah x 2
12V 200Ah x 2
12V 200Ah x 2
12V 200Ah x 2
12V 200Ah x 2
Komatsu
KTRI 10
Komatsu
-
-
-
With after cooler
With after cooler
With after cooler
Without marine gear With bypass filter
67 (60) 119 (107) opt
119 (107) 122 (110) *5
(Engine
KTRI 10
(50 Hz) (50 Hz) (60 Hz) (60 Hz)
all speed type
120 (108)
KTRI 10
419/1,500 I561/1,5001 467/1,800 {625/l ,800) -
type
(90)
Komatsu
*4: *5:
55212,000 {740/2,000}
Komatsu
KTRI 10
Komatsu
KTRllO
only 43)
24V, 13A 24V, 25A (opt) 24V, IlkW
12V 200Ah x 2
Komatsu
KTRIIO
-
With after cooler
With after cooler
With after cooler
01-004-7 0
SPECIFICATIONS
GENERAL
SA6D170-A-1
Applicable
Number
of cylinders-Bore
DEM for generator (Stanby use)
machine
x Stroke
Total piston displacement
mm
6-170x170
cc
23,150
Firing order
length
.P t
Ovrali width
i
Overall height (Excluding exhaust
6
Overall height (Including exhaust
Flywheel
pipe)
pipe)
mm
2,603
1,861
1,861
mm
1,048
1,060
1,060
mm
1,750
1,626
1,623
mm
-
-
-
515/2,100 (Net) {690/2,1001 (Net)
524/2,100 (Net) {702/2,1001 (Net)
2,824/1,400 {288/1,4001
2,824/1,400 {288/1,4001
kW/rpm {HP/rpm}
horsepower
Maximum
torque
{kgr%Pml
fuel consumption
ratio
Dry weight
700 - 900
850 - 900
850 - 900
g/kWh {g/I-W
211 11571 (50 Hz) 217 {1621(60 Hz)
219 (163)
221 (163)
kg
2,720
2,470
2,470
3osch PE-ZWx
Governor
3osch RSUV centrif, ugal, all speed type
Coolant amount
Alternator
Starting
motor
Battery
Turbocharger
(refill capacity)
e
e
01-004-8 0
Bosch PE-ZWx type
typf
Bosch RSUV centrifugal, minimum maximum-speed type
67 (60) 119 (107) opt
107 only 43)
170
170
24V, 13A 24V, 25A (Opt)
24V, 50A
24V, 50A
24V, 11 kW
24V, 7.5kW x 2
24V, 7.5kW x 2
12V 170Ah x 4
12V 170Ah x 4
(Engine
12V 200Ah
Komatsu
x 2
KTRI IO
Air compressor
Others
(Net) (Net)
2,250 - 2,350
Fuel pump
oil amount
(Net) (Net)
2,250 - 2,350
Low idling Minimum
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)
rPm
High idling
Lubricating
HD465-3 (Single turbocharger)
l-5-3-6-2-4
Overall
t?
H D465-3 (Single turbocharger)
With after cooler
Komatsu
KTRllO
Komatsu
KTRI 10
Cummins single cylinder reciprocated type
Cummins single cylinder reciprocated type
With after cooler
With after cooler
8 z z
SPECIFICATIONS
GENERAL
SA6D170-A-1
H D465-3 (For ORAPA MINE)
Pc1ooosP-1 (For LAYTON)
6-170x170 23,150 l-5-3-6-2-4
z
io z
1,861
2,373
1,060
1,909
1,626
1,080
-
-
485/2,000 (Net) {650/2,0001 (Net)
434/1,750 {582/1,750}
(Net) (Net)
2,800/l ,300 (Net) (285/1,300} (Net)
2,730/1,300 1279/1,3001
(Net) (Net)
2,250 - 2,350
1,900 - 2,000
840 - 860
650 - 700
216 I1611 (Net)
211 (Net) 11571 (Net)
2,480
2,555
BOSCH PE-ZWx wpe
IOSCH PE-P(PS7S1 type
BOSCH RFD minimun maximum-speed control 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
12V 200Ah
x 2
GARRET TV77 typex2 CUMMINS single cylinder reciprocated type With
aftercooler
x 2
KOMATSU KTRllOtype EXEL reciprocation jingle cylinder type With
aftercooler
01-004-9 63
SPECIFICATIONS
GENERAL
Engine model
Applicable
Number
of cylinders
SA6D170-B-1 D375A-1 IEngine Serial No. up to 11045)
machine
- Bore x Stroke
Total piston displacement
D375A-1 (Engine Serial No. 11046 and up)
mm
6-170x170
cc
23,150
Firing order
D375A-1 (Engine Serial No. 13551 and up)
l-5-3-6-2-4
t Overall
length
mm
2,017
2,017
2,017
mm
1,139
1,139
1,139
mm
1,746
1,746
1,746
mm
-
-
-
kW/rpm IHP/rpm)
379/1,800 {508/1,8001
379/l ,800 {508/1,800}
392/l ,800 {525/1,8001
tkgr%?pmI
2,609/l ,300 {266/l ,300)
2,609/l ,300 {266/l ,300)
2,618/1,300 {267/l ,300)
High idling
rpm
1,950 - 2,050
1,950 - 2,050
1,960 - 2,040
Low idling
rpm
600 - 700
600 - 700
580 - 680
g/kWh {g/HPh)
215 {I601
215 {160}
215 {ISO}
2,660
2,660
2,660
Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust
Flywheel
pipe)
horsepower
Maximum
Minimum
pipe)
torque
fuel consumption
ratio
kg
Dry weight
Fuel pump
losch PES-PDx typ
Governor
3osch RSUV centrif Jgal, all-speed type
Lubricating
Coolant
oil amount
amount
Alternator
Starting
motor
Battery
Turbocharger
Air compressor
Others
01-004-10 0
(refill capacity)
Bosch PE(PS7S) 3osch RSUV centrifugal,
z z
type all-speed
type
Q
Q
165
165
165
24V, 30A
24V, 35A (1104612802) 24V, 50A (12806-)
24V, 50A
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, 7.5kW x 2
12V 170Ah x 2
12V 170Ah x2
12V 170Ah x 2
Komatsu
KTRllO
Komatsu
KTRIIO
Komatsu
8
KTRI 10
-
-
-
With after cooler
With after cooler
With after cooler
SPECIFICATIONS
GENERAL
SA6D170-B-1
HD465-3 (Single turbocharger)
Pc1000-1
EG450-1
EG480-1 EG480B-1
EG500-1, EG500B-1 EG500BS-1 OEM for generator
EG500-1, EG500B-1 EG500BS-1 OEM for generator
6-170x170 23,150 l-5-3-6-2-4
2
(D z
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
451/2,100 {604/2,1001
2,550/1,300 I260/1,3001
2,481/1,400 {253/1,400}
354/1,500 (50 Hz) (481/1,5001 (50 Hz) 400/l ,800 (60 Hz) [544/1,8001 (60 Hz) -
37211,500 (50 Hz) l498/1,500~ (50 Hz) 416/l ,800 (60 Hz) (557/1,8001 (60 Hz) -
383/1,500 (50 Hz) {513/1,5001 (50 Hz) 427/1,800 (60 Hz) {572/1,8001 (60 Hz) -
383/1,500 (50 Hz) {513/1,500) (50 Hz) 427/l ,800 (60 Hz) {572/1,8001 (60 Hz) -
Max. Max.
Max. Max.
Max. Max.
1,560 (50 Hz) 1,872 (60 Hz)
1,572 (50 Hz) 1,890 (60 Hz)
1,568 (50 Hz) 1,881 (60 Hz)
1,800 - 1,900
1,800 - 1,900
1,800 - 1,890
650 - 700
650 - 700
950 - 1,000
750 - 850
750 - 850
700 - 900
217 1162) (At rated output)
217 I1621 (At rated output)
2,750
2,720
211 {157}
224 {I 67)
217 I1621
217 {162} (At rated output)
2,555
2,555
2,650
2,650
BOSCH PE-P(PS7S) type
BOSCH PE-ZWx type
BOSCH PES-PD type
BOSCH RSUV centrif ugal, ail-speed type
BOSCH RSUV-D :entrifugal, minimum naximum-speed type
BOSCH BOSCH
PE-ZWx
119 (107)
160
24V, 50A
24V, 50A
119 (107)
119 (107)
(Engin%ly
43)
PE-P(PS-7% type
lOSCH RSUVcentrifugal, all-speed type (with cocel spring)
BOSCH RSUV centrifugal, all-speed type
30SCH RSUV centrif ugal, all-speed type
(z,
160
type
(Enginiinly
43)
(Engine8tnly
43)
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
12V 200Ah
12V 200Ah
12V 200Ah
KOMATSU
KTRI 10
& I
o! m
F6164159
8 z z
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
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
exhaust
valve inserts
New
Old
6162-13-1321 (2 per valve)
6162-13-1320 (2 per valve)
VALVE SEAT INSERTS
1 I OO- 500mm
Part No.
Part No. and size stamped on outside circumference
Difference Need for calking after press
No
No stamp (Note: The oversize insert is stamped.)
Yes
fitting Calking above.
is not needed
head
for any insert not listed
1) Set with the bottom surface of the cylinder 8
z z
2) 3)
head 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.
6162F816A
F6164160A
15011 0
REPAIR
5.
AND
REPLACEMENT
Finishing
OF PARTS
A2 as shown Angie
of seat
Width
surface:
intake
of seat fininshing
side:
Connectricity
side: 3.69
of valve
Coat the seat surface guide
mm
and
mm
insert:
(T.I R) max. Unit:
using the compound.
a rough compound valve
mm
side: 3.79
guide
0.07 2) Fit the seat surface
30°
side: 45O
surface:
Exhaust
the
INSERTS
with valve seat cutter
Intake +
SEAT
in the figure. Exhaust
*
VALVE
the seat surface
1) Finish the seat surface +
REPLACING
of the valve thinly
mixed with
that
forms
with
oil insert
that
bar to the valve head,
and
hands
against When
it with
both
to rub
mm
* 0.05
it in
a pair with
valve, then fit a rubbing turn
$57.4
459+0.05
3o”
lightly
the valve seat. the
rubbing
removes
wipe off the compound. compound
and
repeat
give a good contact
the
roughness,
Intake
Exhaust
side
side
Then coat with a fine the
surface
above
process
to
with
no break
in
6162F507A
contact. 6.
Final check *
8
Standard
sinking
distance
of valve 0.9
-Sr Standarad
width
of contact
valve:
Intake
l
Coat the seat surface with
push
surface,
and rotate
contact
surface,
is uniform
l
lightely
surface
insert
against
mm
?c 0.2
it in the valve
the valve
insert
1 O”. Check the valve insert
Intake
side
Exhaust
side
that the contact
any breaks.
F6164100
or Make of the
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
uniformly
and rotate 1 O”. Check
pencil
marks
have
around
the whole
been
erased
Pencil ,(about
marks 20
places)
circumference.
F6164101
15-012 0
z z
Bottom surface of cylmder head
Bottom surface of cylinder head
against
* 0.2
side: 2.8
and confirm
without
Lo
mm
of the new valve thinly
red lead (minium),
guide,
Unit:
to 1.5 mm
side: 2.5
Exhaust
(new):
REPAIR AND REPLACEMENT
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
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
NOZZLE HOLDER SLEEVE
REPLACING NOZZLE HOLDER SLEEVE 1.
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).
3.
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
F6164103A
e
-
a
F6164104
F6164105A
15-014 0
z z
-----______
%
8
REPAIR AND REPLACEMENT
4.
OF PARTS
REPLACING
NOZZLE HOLDER SLEEVE
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 sleeve 3)
4)
5)
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.
5.
Roll-fit the bottom
hole of sleeve
.
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
.
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
6162F511A
the taper section of sleeve
6162F512A
6162F513A
15015 0
REPAIR AND REPLACEMENT
OF PARTS
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.
8.
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.
15016 0
REPLACING
NOZZLE HOLDER SLEEVE
6162F514A
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
NOZZLE HOLDER SLEEVE
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
2.
2 Z Z
It is preferable to warm the whole cylinder head and carry out the test with hot water (82 - 93°C).
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
F6164106A
If the above test shows that there are cracks around the nozzle holder and plugs, replace the cylinder head.
15017 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
VALVE GUIDE
REPLACING VALVE GUIDE 1.
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
REPAIR AND REPLACEMENT
REPLACING 1.
Removing l
OF PARTS
REPLACING
CROSS HEAD GUIDE
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,
guide with collet @of
hold the cross head
the puller.
2) Tighten the collet with bolt 0 0. 3) Rotate
nut @and
to lock sleeve
pull out the cross head
guide. 4) Remove
burrs, fins, etc. from the mounting
place of the cross head guide and clean
it.
615F019A
2.
Press-fitting l
the cross head guide
Insert the cross head guide in the cylinder head, then hit it into the cylinder bar or plastic
hammer
head with a copper
until
its protrusion
is
within specification +
Protrusion
of cross head guide Tolerance:
+
Inside diameter
54
’ -0.3
mm
of crosshead guide hole: ,5 + 0.018 mm 0
15019 0
REPAIR
AND
REPLACEMENT
GRINDING 1.
Grinding l
OF PARTS
VALVE
the seat surface
Angle
of valve seat: Intake valve: Exhaust
Checking l
THE
THE VALVE
Grind the seat surface with valve refacer *
2.
GRINDING
I.
30°
valve: 45O
after grinding
Confirm
that the thickness
protrusion
of the valve head,
of the valve, and the contact surface
of the valve seat are within specification. *
Thickness
of valve head
Ir Thickness
F6164107A
of valve head
Repair limit Intake valve: Min. 2.9 mm (Standard Exhaust
size 3.4 mm)
valve: Min. 3.1 mm (Standard
*
Sinking
of valve
size 3.5 mm)
Standard:
0.9 -
F6164108
8
1.5 mm
z z
Repair limit: 2.1 mm
*
Check the contact of the valve with the seat surface l
using one of the following
Coat the seat surface of the ground valve thinly with red lead (minium), the valve guide,
Make
marks
any breaks.
a pencil
on the
seat
of the ground valve as shown
the diagram, push
with
the
and confirm that the
contact is uniform without
surface
insert it in
push lightly against
valve insert surface,
l
F6164109
methods.
lightly
surface,
insert
against
and rotate
in
it in the valve guide, the loo.
valve
Pencil
marks
(about
20
places)
insert
Check that the
pencil marks have been erased uniformly around
15-020 0
the whole
circumference.
F6164101
REPAIR AND REPLACEMENT
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
15-021 0
REPAIR
AND
TESTING (1)
Cylinder
REPLACEMENT
OF PARTS
TESTING
AND
INSPECTING
AND INSPECTING block Unit: mm
inspection
Judgement
item
A. Cracks
Check for cracks (external
l
Cylinder
Remedy
standards
color check)
head bolts hole portion,
Replace
etc.
6. Correction of con tact at packing portion Check for water leakage caused by corrosion
I C. Clearance liner
Replace
F6164111
from
~~~
zi%z!
ji
Clearance from liner
190.34
-
190.40
190.19
-
190.29
0.05
-
0.21 Replace cylinder liner or block
F616411:
D. Inside diameter of camshaft bushing
l
Inside diameter Standard
size
72 l
Clearance
from camshaft Standard 0.08
E. Protrusion
Standard
value
Repair limit
72.00
72.07
72.10 Replace bushing
bearing Standard
clearance -
-
0.18
of line
value
0.24
Permissible
range: 0.07
-
0.15 Replace cylinder liner or correct cylinder block
I
F. Depth of counter. bore and corrosion of bottom surface
G. Distortion, wear of cylinder head mounting surfac
’ \
F6164113
Depth of counterbore
Standard 14
~6164114
l
Overall
Standard
value
14.00
14.05
-
Repair by machining, add shim
Check for corrosion Repair limit
Tolerance top surface
For one cylinder:
15022 0
size
of block: Max. 0.09
0.15
Max. 0.05
0.10
Repair by machining
REPAIR
AND
REPLACEMENT
OF PARTS
TESTING
AND
INSPECTING
Unit: mm inspection
H. inside diameter of main bearing mounting hole l
Judgement
item
Tighten main bearing cap bolt and guide bolt at specifier torque
Standard 148 Ran$bf
Standard
size
@
standards
value
Remedy
Repair
147.992
-
147.025
-
170.992
-
171.025
-
limit
Replace I. Fitting of cap and cylinder
block
z z z
J. Inside diameter of counterbore, outside diameter of cylinder liner flange
Replace cylinder
F6164117
Bottom
1 194.59
Cylinder block
Standard size
Top
Bottom
1 206.0 194.5
/ ‘“~~$&I
Standard value
1 ‘““;;“,., 194.48 194.54
liner
-
Repair limit
I’““;“,‘,,
Correct cylinder sleeve
block
194.46 194.57
15023 0
REPAIR
AND
REPLACEMENT
GRINDING
GRINDING
OF PARTS
THE TOP SURFACE
THE TOP
OF CYLINDER
SURFACE
OF CYLINDER
BLOCK
BLOCK’
Grinding
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 surface
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.
F6164118
+ 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
with
a grindstone
*
Speed
of grindstone:
*
Speed
of table:
+ Grinding It
depth/time:
Cross feed/time:
(for reference)
1,650
to 1,950 m/min.
15 to 30 m/min. 0.025
mm
1 to2mm
*
Grindstone:
A461V
*
Grinding
Water-soluble
lubricant:
grind-
ing lubricant
HLE00058
15024 0
REPAIR AND REPLACEMENT
2.
OF PARTS
GRINDING
THE TOP SURFACE
OF CYLINDER
Unit:mm
Grinding couterbore After
grinding
the
block,
measure
the depth of the counterbore.
it is not within are
contact
top surface
the standard
blackened
direction),
and these
portions
half of the contact counterbore correcting, 14.05
-
on
the
width
depth* if the
15.525
(Liner Drotrusion)
cylinder
-
If
or if there
cylinder
of the counterbore
in the front-to-rear wear,
of the
dimension,
portions
surface
liner Cylinder liner
(particularly
extend
/
over more than
the repair limit. After
counterbore
depth
mm, combine
with
Cylinder block
is within shims
is 0.07
-
and 0.15 I
mm. Counterbore
Repair
dimension limit:
Roughness
*
Machined
14 + io5
15.46
of cylinder
Standard +
I
depth L:
Standard
* Protrusion
v
/
of the deck, correct the
within
L 12.5s
or there is speckled
adjust so that the liner protrusion
*
BLOCK
F6164120
mm
liner I:
value: 0.07
of counterbore: shape:
mm
-
0.15
Max.
In accordance diagram
mm Unit:mm
12.5s with
for portion
detail
a cylinder
For the
extra
decide
amount
a machining
protrusion
for counterbore amount
that
will
of the cylindr liner within
depth
L,
bring the
the standard
value. When
grinding
within
the
repair
limit
in cases
where the counterbore depth L exceeds the standard dimension, set the machining amount Detail a
so that one shim can be used for each cylinder as shown
[Reference]
F6164121
in the table below.
Adjustment
shims for counterbore
Unit: mm
depth Ilnit. mm
.Part No. 6162-29-2260
T
1
1.50
t
Weight (kg)
1 0.025
1 0.004
Remarks
1
6162-29-2250
1 0.80
1 0.025
1 0.002
1
6162-29-2240
1 0.50
1 0.025
1 0.001
1
0.26
0.025
0.001
6162-29-2220
0.20
0.020
0.001
6162-29-2210
0.16
0.016
0.001
6162-29-2230
\
Shim
T*t
F6164122
15-025 0
REPAIR AND REPLACEMENT
3.
GRINDING
OF PARTS
THE TOP SURFACE
OF CYLINDER
BLOCK
Checking and distinguishing after grinding and correcting After grinding
and correcting,
on the flat surface in the cylinder Remove
all burrs completely.
H exceeds
is within always *
and oil holes
block top surface.
After grinding the top surface, height
check for scratches
around the water
the
the repair
limit (569.5
use an oversize
Oversize
if the cylinder
standard
block
dimension, -
509.8
but mm),
head gasket.
head gasket part number: 6162-19-1811
Thickness
of plate: 2.4 mm (Standard:
Ir To distinguish,
2.0 mm)
the letters
“OS”
are stamped
stamp
top surface
on the plate. After
correcting,
cylinder correction
block
according
as shown
the
to the
content
of the
Position Ds,r I.
of the
in the table below.
Table of letters to stamp Oversize head gasket
Shim
Stamp
18, (Size of letters: 5 -
10 mm) HLE00067
15026 0
REPAIR
4.
AND
REPLACEMENT
Procedure gasket
for coating
bottom
When
pulling it again,
out the
of linei
cylinder
coat the
the counterbore
liner
contact
THE
TOP
SURFACE
OF CYLINDER
BLOCK
lip with
and press
surface
under
liner lip with gasket sealant
LG-
as follows. Use the same procedure when using
a shim for the corresponding +
GRINDING
sealant
fitting 6
OF PARTS
The following
part.
commercially
is equivalent
available
sealant
to LG-6.
l
Three
l
Nihon Hermetic:
Bond: TBI 215 SS-6OF 6162F759
1) Use a cloth to wipe off all the dirt and oil from the contact surface
Top surface
of the liner lip and cylinder
of block
block counterbore. Meting
2) Coat the position
marked
in the diagram
Of liner
portion
with
LG-6. l
Make
the
sealant l
diameter
$2 -
of the
Make the overlapping and ending
line
of gasket
3 mm. the
mm as shown
portion for beginning
coating
of sealant
6 f
Position to coat with gasket sealant
6
in the diagram.
F6164124
*
When l
using shims
After
coating
thinly
with
,
the
bottom
LG-6,
of the
shim
it to the
deck
in the same
way
instll
portion of the block. l
Next,
coat with
as when
LG-6
not using shims.
Overlap
amount
6 + 6 mm
-1
d
F6164125
G-6
(@2 -
3 mm)
/
3) Press fit the liner in the cylinder When
doing
this,
coat the
lubricant
RF-I.
+ RF-l
is equivalent
available
+ If RF-1 contaet
to
Daido Kagaku is not surface
an extremely (SAE30)
the
available,
small
1 rubber
commercially
Kogyo DS-50. coat
of the O-ring
immediately
block.
seal with
amount before
the
block
and seal with of engine press
oil
fitting
the liner. F6164126
15-027 0
REPAIR AND REPLACEMENT
4)
OF PARTS
GRINDING
THE TOP SURFACE
OF CYLINDER
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
5)
Insert liner (I) into the cylinder care not to damage the O-ring.
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
ii)
Ir
Mounting
6162F761
block, taking
bolt: 26 * 1 kgm
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
15-028 0
BLOCK
6162F764
REPAIR AND REPLACEMENT
8)
OF PARTS
GRINDING
THE TOP SURFACE OF CYLINDER
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
BLOCK
If the grommet is deformed into a heart shaDe. it blocks the water hole and may cause the coolant.
/
The gasket sealant that comes out may cause deformation of the head gasket grommet, so always carry out steps 4) and 5) without fail.
/ / Grommet
R
leakage
of
\ \ Water
hole
F616417.7
15029 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
MAIN METAL CAP
REPLACING MAIN METAL CAP * When replacing the main metal cap, machine the 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
Coat the thread SAE30
boltfor main metal cap: and seat with engine
oil
Unit: kgm Procedure
Target
Range
1 st step
56
51 -61
2st step
113
3st step
0
4st step
38
33-43
5st step
75
70-80
6st step
113
5)
*
3)
4)
107-118 Loosen completely
Tolerance:
107-118
Align the notches and cap.
on the cylinder
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 ii)
block
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.
148+to25 mm
Inside diameter of cap when main cap is tightened to specified torque after machining. Tolerance:
148$::%:
mm
(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
2 z &
REPAIR AND REPLACEMENT
2.
REPLACING
OF PARTS
MAIN METAL CAP
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
of surface facing thrust metal: 12.5 max. of main cap Tolerance:
+
Width
Max.R0.5 1
HKE00068
15031 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
CAM BUSHING
REPLACING CAM BUSHING *
Before replacing the cam bushing, remove plug from the rear of the cylinder block.
the
1.
Removing
.
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.
No. 1 and No. 7 bushings
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
c 6162F519
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
REPAIR AND REPLACEMENT
OF PARTS
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.
REPLACING
CAM BUSHING
No. 2 and No. 6 bushings
6162F522
6.
Press-fitting
No. 1 and No. 7 bushings
.
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
REPAIR AND REPLACEMENT
OF PARTS
CRANKSHAFT
CRANKSHAFT
HLE00062
1.
Crankshaft
Unit: mm Inspection
item
A. Cranks
Judgement Use a magnetic
standards
flaw detector
to check for cracks
6. Damage Check for damage to the journal portion 1 Damage C. Clogging
15-034 0
of oil hole
Scratches seizure discoloration
to cap hole at front and rear end
Check for clogging
of oil hole
Remedy Replace If the damage is slight, correct with an oilstone or correct by lapping. Replace if there is seizure Correct Correct
REPAIR AND REPLACEMENT
OF PARTS
CRANKSHAFT
Unit: Inspection
item
D. End play of crankshaft
E. Thickness bearing
Size
of
G. Out-of-roundness crankshaft pin
of
I. Outside diameter main journal
of
L. Curvature of crankshaft (total runout of indicator)
Standard
1
standards Repair
Standard value 0.14 - 0.320
of thrust
F. Outside diameter crankshaft pin journal
Judgement
I
limit
Tolerance
Repair
limit
3.79 3.92
STD 0.25 US
4.0 4.125
0.50 us
4.25
0.75 us
4.375
4.17
1 .oo us
4.5
4.29
Size
Standard
size
Tolerance
_ Replace thrust bearing or correct crankshaft . with oversize
4.04
-0.07 -0.12
Repair
limit
STD
108.00
107.91
0.25 US
107.75
107.66
0.50 us
107.50
0.75 us
107.25
107.16
1.00 us
107.00
106.91
-:.022
Standard Total coaxiality main journal
of
Coaxiality of neighboring journals
Remedy
Replace thrust bearing or correct with oversize
0.69
size
mm
107.41
Repair
Max. 0.09
0.09
Max. 0.05
0.05
Correct with undersize or replace
limit Replace
15-035 0
REPAIR AND REPLACEMENT
Correcting surface journal portion If the does
roughness not
roughness
of the
fulfill
OF PARTS
the
of crankshaft
crankshaft
standard,
CRANKSHAFT
journal
correct
portion
the
surface
roughness. 1.
Cleaning Before
and blowing polishing,
with
brush
air
the oil holes
and blow
with air. 2.
Correcting
surface
1) When
roughness
correcting
with
of journal special
portion
polishing
machine Use a special the diagram
i)
polishing
Set the rotating -
50
rpm,
type).
as shown
speed for the work
and
Perform
honing
machine
in
on the right. use No. 320 dry polishing
paper
at 40 (belt
(do not use
oil), and move the paper
and down the whole journal
once
up
width for each
journal. ii)
Next, replace journal
the handle right
with No. 500 paper, coat the
surface by the
movement.
with
honing
of the machine amount Use this
oil, and move to the left and
of play to give fine movement
once up and down the whole journal.
Move the paper
to move
width
smoothly
of the
not stop at any point. iii) Check the surface not within
roughness,
the standard,
up and down the width
F6164131
and do
and if it is
polish again once of the journal
z Move handle to left and right, and move once up and down width of journal
with
No. 500 paper.
F6164132
15-036 0
z
REPAIR AND REPLACEMENT
2) When
OF PARTS
CRANKSHAFT
using a work clamp jig for polishing
(When
a special
polishing
machine
is not
jig such
as shown
in the
machine
under
available) Use a work diagram
clamp
on the right.
Use a crankshaft the following
grinding
polising
Paper:
No. 800
Machining
oil: Honing
Work speed: The
time
6 minutes.
amount
oil
40 rpm
polishing
approx.
conditions.
for
one
Move
the
of play of the clamp
width
(approx.
5 mm),
down
the journal
After completing replace When
journal clamp
is the
and journal
and move
in the axial
up and
direction.
the honing of one journal,
the paper with new paper. honing
the
pin journal,
it is safer
to carry out the work with the pin journal at the rotation
3) Assembly
center.
of work
F6164133
clamp
jig and
method
of
use i) Jig for pin journal Assemble diagram
on the
component separate
and jig for main journal
the clamp parts,
jig as shown
in the
For details
of the
right. see
the
drawings
on
pages.
F6164134
15-037 0
REPAIR
AND
REPLACEMENT
CRANKSHAFT
OF PARTS
ii) Cut out a piece of No. 800 paper with the shape shown in the diagram on the right.
Dimensions
230 Make cuts of 20 mm length\ at approx. 10 mm intervals
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.
of paper for pin journal
I I I I I I I I I n_, Cut out slit 2 portions 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
8
z z
roughness
After correcting the surface roughness, always brush the oil hole and blow with air. 5.
Check
that
the journal
there portion
are no scratches and fillet
or dents
at
R portion.
Fix in position Bend to fit round
.Rubber
with tape w
shape
inside
plate
F6164136
15038 0
REPAIR AND REPLACEMENT
Clamp jig parts drawing
CRANKSHAFT
OF PARTS
(for pin journal)
@I Plate (2 are used for each jig) Unit: mm 69 k 0.1
I=
74
(10)
-i 5
A
F==i A
LLI 31.5
I =H--
/
--t-F”
I
STKM 13A
Section A-A F6164137A
@
Handle (2 are used for each jig)
Umt:mm -
450
132
F6164138A
15039 0
REPAIR AND REPLACEMENT
Clamp jig parts drawing 0
OF PARTS
CRANKSHAFT
(for main journal)
Plate (2 are used for each jig) Unit:
mm
1 A
t A -
27.5
/ 6.5
6.5
STKMI
3A
Section A-A g=x Section
A-A
F6164139A
@I Handle (2 are used for each jig) Unit:
mm
F6164140A
REPAIR AND REPLACEMENT
OF PARTS
REPAIRING
THE CRANKSHAFT
REPAIRING THE CRANKSHAFT .
.
l
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.
\c
\ /IF.
Dimension
R
of fillet
/r
r’
i
R: 6.5_g.s mm, Surface roughness r: 6.4 mm, Surface roughness
-
R
-
1.6s 12.5s
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
6127F231
.
Dimension
Main journal
Stroke
of oil hole on journal
Pin journal
6127F233
Throw
of eccentric:
85-t,,,
mm
15041 0
REPAIR AND REPLACEMENT
2.
OF PARTS
REPAIRING
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.
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.
kk
&tact
point
Contact point
6127F234
THE CRANKSHAFT
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
Minimum radius of fillet: 6.00 mm Maximum radius of fillet: 6.50 mm Size 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
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.
Critical area of web of crankshaft
I 6127F235
15042 0
Basic dimension
S.T.D
140.000
0.25 US
139.750
0.50 us
139.500
0.75 us
139.250
1 .oo us
139.000
Allowable error
-00.025
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
8 Z Z
REPAIR AND REPLACEMENT
4.
REPAIRING
OF PARTS
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).
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
Undersizes
3asic dimension
Rear thrust
bearing
Basic dimension Limit Basic dimension
surface
64+:.050
0.25 0.S +0.050 64.25 o
64.060
64.310
64.25+;‘050
64.50+;.05’
64.310
64.560
.
6.
Squareness (T.1.R)
Ulowable error
of thrust bearing
S.T.D
108.00
0.25 US
107.75
0.50 us
107.50
0.75 us
107.25
1 .oo us
107.00
mm
1 S.T.D
.
mm
of thrust bearing surfaces Unit:
Limit
of pin journal Unit:
Size
.
THE CRANKSHAFT
surface .
Limit: 0.04 mm
.
0 -0.022
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
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 mm Thickness of friction surface -L Journal
i
Friction surface 1 6 I27F236
15-043 0
REPAIR AND REPLACEMENT
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.
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
15-044 0
REPAIRING
OF PARTS
THE CRANKSHAFT
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.
l
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.
8 z z
REPAIR AND REPLACEMENT
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
15-045 0
REPAIR AND REPLACEMENT
CONNECTING
OF PARTS
CONNECTING
ROD
ROD 1. 2. 3. 4. 5. 6.
Bolt Washer Cap Dowel pin Connecting Bushing
rod
F6164151
Unit: mm Inspection
item
A. Cracks
Judgement
standards
Remedy
Check for cracks with a color check or magnetic
B. Curvature, twisting
,,,I:::~
flaw detector
I D
:,
Replace
Check for curvature or &vising F6164152A
C. Clearance between connecting rod bushing and piston pin
D. Inside diameter of hole at big end of connecting rod
Replace bushing, roughness of inside surface of bushing: Max. 2.4s Inside diameter of hole at big end Without bearing Standard
1
size
Tolerance
I
+0.026 0 Roughness of inside surface of hole at big end: Max. 6.35 Clearance from crankshaft bearing (with bearing) 115
Standard
clearance
0.058 - 0.132
1 I
Clearance
Replace
limit
0.20
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
F. Scratches on inside surface of bearing, seizure G. Distance between holes at big end and small end
15046 0
Standard
size
Tolerance
Repair limit
S.T.D
3.500
U.S 0.125
3.625
3.41
0.250
3.725
0.375
3.875
3.79
0.500
4.000
3.90
3.54 -0.029 -0.042
3.66
Check for scratches or seizure
Standard
Replace, replace connecting rod also size
1
Tolerance Replace
305
I
-:.05
8 Z G,
REPAIR AND REPLACEMENT
CONNECTING
OF PARTS
ROD
Unit: mm Inspection
item
Judgement
H. Scratches at I shape portion of connecting rod (dents)
standards
Check for scratches direction in area A
I
Remedy
in horizontal
Check for grinder grain in horizontal direction in area A
F6164153 I
I. Fretting of mating surface of cap
Check for fretting
Roughness Contact
J. Scuffing of bolt seat surface
2
K. Deformation dowel pin
T
W
of
of mating
surface
of mating
of mating
surface:
surface:
Scuffing
of cap bolt seat surface
Scuffing
of bolt seat surface
Scuffing
of washer
Replace if fingernail catches in fretting
Max. 6.3 S
Min. 70%
I I
I
surface
Check for deformation
of dowel
pin
Check for deformation
of dowel
pin hole
dents, regardless of size
Correct with oilstone Replace
bolt
Replace washer Replace
I
G L. Damage
to bolt
Check for cracks, damage Check for curvature
+
*
of bolt
to bolt thread
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
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
CRANKSHAFT
GEAR
REPLACING ‘CRANKSHAFT 1. .
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.
K2 /
6162F813A
2.
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: 200°C 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.
15048 0
REPAIR AND REPLACEMENT
REPLACING CAMSHAFT 1.
a
2.
REPLACING
OF PARTS
CAMSHAFT
GEAR
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: 200°C 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.
15049 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING FLYWHEEL RING GEAR Be careful not to let the flywheel you.
g
fall and injure
1. .
Removal of gear Make a scratch in the surface at the root of the gear teeth with a grinder, then split with a chisel to remove.
a
Be careful when handling the grinder and chisel.
2.
Press fitting gear 1) Check the gear mounting surface, and if there are any scratches, correct them with an oilstone. 3 Heat the gear for the specified time at the specified shrink-fitting temperature. sr Gear shrink-fitting temperature: Max. 200°C Heating time: Min. 50 minutes 3) Set the chamfered face of the gear facing the flywheel, and press fit until the side face of the gear is in close contact with the flywheel.
15-050 0
REPLACING
FLYWHEEL RING GEAR
Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186
PROPOSAL
1
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR 2
NAME OF COMPANY:
:
PHONE NO:
: S
DEPARTMENT:
E R
NAME:
MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:
PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE: