Page 2 CONTENTS No. of page GENERAL ........................... 01-1 STRUCTURE AND FUNCTION ................ 11-1 TESTING AND ADJUSTING ................12-1 DISASSEMBLY AND ASSEMBLY ..............13-1 MAINTENANCE STANDARD ................14-1 REPAIR AND REPLACEMENT OF PARTS ........15-1 00-2 170-3 SERIES...
Page 3 12-4 (10) 12-112 12-230 01-10 (10) 11-24 12-5 (10) 12-112-1 12-231 01-11 (10) 11-25 12-5-1 (10) 12-112-2 12-232 01-12 (10) 11-26 12-6 12-113 12-233 01-13 (10) 11-27 12-6-1 12-114 12-234 01-14 (10) 11-28 12-7 12-114-1 12-235 00-2-1 170-3 SERIES (12)
Page 4 13-7 14-3 15-26 12-321 13-8 14-3-1 (10) 15-27 12-322 13-9 14-3-2 (10) 15-28 12-323 13-10 14-3-3 (10) 15-29 12-324 13-11 14-3-4 (10) 15-30 12-325 13-12 14-4 15-31 12-326 13-13 14-5 (10) 15-32 12-327 13-14 14-6 15-33 00-2-2 170-3 SERIES (12)
Page 5 Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 6 SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi- nal places. 11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts. hydraulic pressure measuring plugs, loosen •...
Page 7 FOREWORD GENERAL FOREWORD GENERAL This 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 him the correct way to perform repairs and make judge- ments.
Page 8 DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be Symbol Item Remarks sent to KOMATSU distributors. Get the most up-to- date information before you start any work. Special safety precautions Safety are necessary when per- forming the work.
Page 9 FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted 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 max- with a hoist, etc.
Page 10 FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release Type 1 the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
Page 11 FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER Type 2 Type 3 1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre- vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of the hexagonal portion at the male end.
Page 12 ! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. ! For coating materials not listed below, use the equivalent of products shown in this list. Category Komatsu code Part No. Q’ty Container Main applications, features •...
Page 13 FOREWORD COATING MATERIALS Category Komatsu code Part No. Q’ty Container Main applications, features • Used as lubricant for sliding portion (to LM-G 09940-00051 60 g prevent from squeaking). Molybdenum • Used to prevent seizure or scuffling of the disulphide thread when press fitting or shrink fitting.
Page 14 FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter Width across...
Page 15 FOREWORD STANDARD TIGHTENING TORQUE TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter Width across flat Tightening torque 59 –...
Page 16 FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter Tightening torque 10 ± 2 1.02 ± 0.20 24 ± 4 2.45 ±...
Page 17 FOREWORD ELECTRIC WIRE CODE 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 Current...
Page 18 FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE •...
Page 19 FOREWORD CONVERSION TABLE Millimeters to Inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
Page 20 FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1l = 0.2642 U.S. Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
Page 21 FOREWORD CONVERSION TABLE kgm to ft. lb 1 kgm = 7.233 ft. lb 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 108.5 115.7 123.0 130.2 137.4 72.3 79.6 86.8 94.0 101.3 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2...
Page 22 FOREWORD CONVERSION TABLE kg/cm to lb/in 1kg/cm = 14.2233 lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
Page 23 FOREWORD CONVERSION TABLE Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen- tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col- umn of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
Page 24 FOREWORD UNITS UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm kPa {mmH kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}...
Page 25 01 GENERAL Applicable machine ........... 01- 2 Specifications ............ 01- 4 Overall drawing ..........01-5-3 Weight table ............01-16 Engine performance curve ........ 01-17 01-1 170-3 SERIES (11)
Page 26 Applicable machine SA6D170E-3 D375A-5 Bulldozer PC1250-7 Hydraulic excavator WA600-3 Wheel loader WA700-3 Wheel loader SAA6D170E-3 WD600-3 Wheel dozer HD465-7 Dump truck HD605-7 Dump truck Generator Generator DCA-800SSK2 SAA6D170E2-3 Generator (DENYO GENERATOR) SAA6D170E-P910 EGS950-6 Generator SAA6D170E-P970 EGS1050-7 Generator 01-2 170-3 SERIES (11)
Page 28 Minimum fuel consumption ratio g/kWh{g/HPh} 224 {167} 221 {165} Dry weight 2,740 2,900 Fuel pump Trochoid gear pump (KOMATSU HPI system) Governor Electronic control type Lubricating oil amount (refill capacity) 67 (56) 64 (60) Coolant amount (Engine side: 47) (Engine side: 47)
Page 29 212 {157} 222 {163} 218 {160} 211 {155} 3,100 2,900 2,870 2,740 Trochoid gear pump (KOMATSU HPI system) Electronic control type 67 (56) 64 (60) 67 (56) 67 (56) (Engine side: 47) (Engine side: 47) (Engine side: 47) (Engine side: 47)
Page 30 203 {151} (50Hz) 198 {148} (60Hz) 212 {158} (60Hz) Dry weight 2,565 2,597 Fuel pump Trochoid gear pump (KOMATSU HPI system) Governor Electronic control type Lubricating oil amount (refill capacity) 196 (190) 140 (135) Coolant amount (Engine side: 47) (Engine side: 47) Alternator —...
Page 31 800 ± 100 (Rated output) (Rated output) 203 {151} (50Hz) 203 {151} (50Hz) 2,565 2,565 Trochoid gear pump (KOMATSU HPI system) Electronic control type 141 (135) 141 (135) (Engine side: 47) (Engine side: 47) 24V, 35A 24V, 35A 24V, 7.5kW 24V, 7.5kW...
Page 32 GENERAL OVERALL DRAWING OVERALL DRAWING a The actual engine may be different SA6D170E-3 VIEW FROM LEFT SIDE (D375A-5) because of modifications. a. Center of crankshaft b. Rear face of flywheel housing 01-5-3 170-3 SERIES (11)
Page 33 GENERAL OVERALL DRAWING SA6D170E-3 VIEW FROM RIGHT SIDE (D375A-5) a The actual engine may be different because of modifications. 01-5-4 170-3 SERIES (11)
Page 34 GENERAL OVERALL DRAWING SA6D170E-3 VIEW FROM FRONT (D375A-5) a The actual engine may be different because of modifications. a. Center of crankshaft c. Center of cylinder liner 01-5-5 170-3 SERIES (11)
Page 35 GENERAL OVERALL DRAWING SA6D170E-3 VIEW FROM REAR (D375A-5) a The actual engine may be different because of modifications. a. Center of crankshaft c. Center of cylinder liner 01-5-6 170-3 SERIES (11)
Page 37 GENERAL OVERALL DRAWING a The actual engine may be different SAA6D170E-3 VIEW FROM LEFT SIDE (WA600-3) because of modifications. a. Center of crankshaft b. Rear face of flywheel housing 01-6 170-3 SERIES...
Page 38 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM RIGHT SIDE (WA600-3) a The actual engine may be different because of modifications. a. Center of crankshaft b. Rear face of flywheel housing 01-7 170-3 SERIES (10)
Page 39 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM FRONT (WA600-3) a The actual engine may be different because of modifications. a. Center of crankshaft b. Center of cylinder liner 01-8 170-3 SERIES (10)
Page 40 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM REAR (WA600-3) a The actual engine may be different because of modifications. a. Center of crankshaft b. Center of cylinder liner 01-9 170-3 SERIES (10)
Page 41 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM TOP (WA600-3) a The actual engine may be different because of modifications. a. Center of cylinder liner 01-10 170-3 SERIES (10)
Page 42 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM LEFT SIDE (GENERATOR) a The actual engine may be different because of modifications. a. Center of crankshaft b. Rear face of flywheel housing 01-11 170-3 SERIES (10)
Page 43 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM RIGHT SIDE (GENERATOR) a The actual engine may be different because of modifications. a. Center of crankshaft b. Rear face of flywheel housing 01-12 170-3 SERIES (10)
Page 44 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM FRONT (GENERATOR) a The actual engine may be different because of modifications. a. Center of crankshaft b. Center of cylinder liner 01-13 170-3 SERIES (10)
Page 45 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM REAR (GENERATOR) a The actual engine may be different because of modifications. a. Center of crankshaft b. Center of cylinder liner 01-14 170-3 SERIES (10)
Page 46 GENERAL OVERALL DRAWING SAA6D170E-3 VIEW FROM TOP (GENERATOR) a The actual engine may be different because of modifications. a. Center of cylinder liner 01-15 170-3 SERIES (10)
Page 47 GENERAL OVERALL DRAWING SAA6D170E2-3 VIEW FROM LEFT SIDE (DCA-800SSK2, DENYO GENERATOR) a The actual engine may be different because of modifications. a. Center of crankshaft b. Rear face of flywheel housing 01-15-1 170-3 SERIES (10)
Page 48 GENERAL OVERALL DRAWING SAA6D170E2-3 VIEW FROM RIGHT SIDE (DCA-800SSK2, DENYO GENERATOR) a The actual engine may be different because of modifications. a. Center of crankshaft b. Rear face of flywheel housing 01-15-2 170-3 SERIES (10)
Page 49 GENERAL OVERALL DRAWING SAA6D170E2-3 VIEW FROM FRONT (DCA-800SSK2, DENYO GENERATOR) a The actual engine may be different because of modifications. a. Center of crankshaft b. Center of cylinder liner 01-15-3 170-3 SERIES (10)
Page 50 GENERAL OVERALL DRAWING SAA6D170E2-3 VIEW FROM REAR (DCA-800SSK2, DENYO GENERATOR) a The actual engine may be different because of modifications. a. Center of crankshaft b. Center of cylinder liner 01-15-4 170-3 SERIES (10)
Page 51 GENERAL OVERALL DRAWING SAA6D170E2-3 VIEW FROM TOP (DCA-800SSK2, DENYO GENERATOR) a The actual engine may be different because of modifications. a. Center of cylinder liner 01-15-5 170-3 SERIES (10)
Page 52 Water pump — 11 (60A) 11 (60A) Alternetor — 8 (35A) 12.5 (75A) 12.5 (75A) Starting motor — 18 x 2 18 x 2 18 x 2 After cooler — — Air compressor — — — 01-16 170-3 SERIES (10)
Page 53 GENERAL ENGINE PERFORMANCE CURVE ENGINE PERFORMANCE CURVE Engine Engine serial No. Applicable machine Page SA6D170E-3 D375A-5 01-18 WA600-3 01-19 WA700-3 01-19-1 WD600-3 01-20 SAA6D170E-3 PC1250-7 01-21 HD465-7 01-22 HD605-7 01-17 170-3 SERIES...
Page 54 GENERAL ENGINE PERFORMANCE CURVE SA6D170E-3 (D375A-5) Flywheel horsepower: 391 kW {524 HP} /1,800 rpm (Net) Maximum torque : 2,650 Nm {270 kgm} /1,300 rpm (Net) 01-18 170-3 SERIES...
Page 55 GENERAL ENGINE PERFORMANCE CURVE SAA6D170E-3 (WA600-3) Flywheel horsepower: 337 kW {452 HP} /2,000 rpm (Net) Maximum torque : 2,120 Nm {216 kgm} /1,400 rpm (Net) 01-19 170-3 SERIES...
Page 56 GENERAL ENGINE PERFORMANCE CURVE SAA6D170E-3 (WA700-3) Flywheel horsepower: 478 kW {641 HP} /2,000 rpm (Net) Maximum torque : 2,806 Nm {286 kgm} /1,400 rpm (Net) 01-19-1 170-3 SERIES...
Page 58 GENERAL ENGINE PERFORMANCE CURVE SAA6D170E-3 (WD600-3) Flywheel horsepower: 370 kW {497 HP} /2,000 rpm (Net) Maximum torque : 2,391 Nm {244 kgm} /1,400 rpm (Net) 01-20 170-3 SERIES...
Page 59 GENERAL ENGINE PERFORMANCE CURVE SAA6D170E-3 (PC1250-7) Flywheel horsepower: 485 kW {651 HP} /1,800 rpm (Net) Maximum torque : 2,913 Nm {297 kgm} /1,300 rpm (Net) 01-21 170-3 SERIES...
Page 60 GENERAL ENGINE PERFORMANCE CURVE SAA6D170E-3 (HD465-7, HD605-7) Flywheel horsepower: 533 kW {715 HP} /2,000 rpm (Net) Maximum torque : 3,207 Nm {327 kgm} /1,400 rpm (Net) 01-22 170-3 SERIES...
Page 62 The dust and moisture that is separated by the guide vane (3) rotates around the inside wall of body, and goes inside vacuator valve (6), where it is discharged automatically to the outside. 11-2 170-3 SERIES (11)
Page 63 The shape is subject to machine models. 1. Inner element 2. Outer element 3. Check valve 4. Tube (34 pcs.) 5. Precleaner 6. Body of air cleaner A. Air inlet B. To turbocharger (sucked air) C. To muffler (dust) 11-3 170-3 SERIES...
Page 64 The shape is subject to machine models. 1. Inner 2. Outer 3. Check vane 4. Primary element 5. Safety element 6. Evacuator valve 7. Dust pan 8. Guide plate (Sleeve) 9. Body 10. Element 11-3-1 170-3 SERIES (11)
Page 65 KTR110L (oil cooled type) 1. Blower housing A. Air intake SPECIFICATIONS 2. Center housing B. Air output Type: Komatsu KTR110L 3. Thrust nozzle C. Exhaust (inlet port) (oil cooled type) 4. Turbine housing D. Exhaust (outlet port) Overall length: 308 mm 5.
Page 68 B. Intake outlet Overall height: 346 mm 5. Shroud C. Exhaust inlet Weight: 51 kg 6. Turbine housing D. Exhaust outlet 7. Turbine impeller E. Oil inlet 8. Seal ring F. Oil outlet 9. Metal 10. Thrust metal 11-6-1 170-3 SERIES (10)
Page 69 B. Intake outlet Overall height: 302 mm 6. Turbine housing C. Exhaust inlet Weight: 51 kg 7. Turbine impeller D. Exhaust outlet 8. Seal ring E. Oil inlet 9. Metal F. Oil outlet 10. Thrust metal 11-6-2 170-3 SERIES (10)
Page 70 SAA6D170E-3 (WA600-3) a The shape is subject to machine models. a The illustration shows the engine for WA600-3. A. Intake air port 1. Tank (Turbocharger o i Intake manifold) 2. Side support 3. Tube 4. Fin 11-7 170-3 SERIES...
Page 71 The specifications are subject to change according to modification etc. SAA6D170E-3 (Generator) a The shape is subject to machine models. a. Intake air port 1. Tank (Turbocharger o i Intake manifold) 2. Side support 3. Tube 4. Fin 11-8 170-3 SERIES...
Page 83 • Special alloy steel forging, 7 bearings Plunger rise Plunger lower- • Journal surface, cam surface: Induction hardening Camshaft part completion ing start angle angle ° ° 6240-41-1210 BTDC53 BTDC109 Valve timing (HD465-7, generator) Valve timing (D375A-5, WA600-3, WA700-3, WD600-3, PC1250-7) 11-21 170-3 SERIES...
Page 84 10. Crankshaft 16. Oil pressure gauge 4. Regulator valve 11. Camshaft 17. Turbocharger 5. Oil cooler 12. Rocker arm 6. Thermo valve 13. Piston cooling nozzle W. Cooling water 7. Oil filter 14. Timing gear (rear side) 11-22 170-3 SERIES...
Page 107 The actual engine may be different because of modifications. 1. Tension shaft 6. Tension pulley (outside diameter: 150 mm) 2. Spring 7. Ball bearing 8. Oil seal 3. Roller bearing 4. Tension bracket 9. Grease nipple 5. Spacer 11-47 170-3 SERIES...
Page 108 3. Tension pulley Crankshaft Tension Model of wind pulley pulley pulley 4. Adjustment bolt from fan 5. Tension pulley bracket WA600-3 6. Fan pulley Blows out WD600-3 7. Fan WA700-3 Blows out a. Direction of wind HD465-7 Suck HD605-7 11-48 170-3 SERIES...
Page 109 1. Tension shaft 7. Ball bearing 2. Spring 8. Oil seal 3. Roller bearing 9. Grease nipple 4. Tension bracket 10. Grease nipple 5. Spacer 11. Adjustment bolt 6. Tension pulley (outside diameter: 150 mm) 11-49 170-3 SERIES...
Page 110 The actual engine may be different because of modifications. 1. Drive pulley (pulley outside diameter: 200 mm) 2. Alternator pulley (pulley outside diameter: 85 mm) 3. Alternator 4. Alternator mounting bolt 5. Adjustment bolt 6. Locknut 7. V-belt 11-50 170-3 SERIES...
Page 111 1. Drive pulley (pulley outside diameter: 182 mm) 2. Alternator pulley (pulley outside diameter: 85 mm) 3. Alternator 4. Alternator mounting bolt 5. Adjustment bolt 6. Locknut 7. V-belt 11-51 170-3 SERIES...
Page 112 2. Alternator pulley 6B. Primary energized resistance 3. Terminal B 6C. Regulator 4. Terminal R 5. Terminal E Pulley diameter Weight Engine Machine model Type Specification (mm) (kg) D375A-5 SA6D170E-3 Sawafuji Denki, open type 24V, 60A (If equipped) 11-52 170-3 SERIES...
Page 113 4. Terminal E 5. Terminal R Pulley diameter Weight Engine Machine model Type Specification (mm) (kg) D375A-5 SA6D170E-3 Sawafuji Denki, open type 24V, 75A 12.5 (If equipped) WA600-3 SAA6D170E-3 WA700-3 Sawafuji Denki, open type 24V, 75A 12.5 WD600-3 11-53 170-3 SERIES...
Page 114 5. Terminal E Weight Machine Pulley diameter Engine Type Specification model (mm) (kg) Nikko Denki PC1250-7 24V, 50A Open type (brushless) Nikko Denki SAA6D170E-3 HD465-7 24V, 50A Open type (brushless) Nikko Denki HD605-7 24V, 50A Open type (brushless) 11-53-1 170-3 SERIES...
Page 116 (kg) teeth type ing type 27V, Nikko Denki SA6D170E-3 D375A-5 (water-proof, oil-proof type) 7.5kW WA600-3 Nikko Denki 27V, WA700-3 (water-proof, oil-proof type) 7.5kW SAA6D170E-3 WD600-3 Nikko Denki 27V, HD465-7 (water-proof, oil-proof type) 7.5kW HD605-7 11-54 170-3 SERIES...
Page 120 The actual engine may be different because of modifications. SPECIFICATIONS 1. Heater assembly 2. Body Heater type: Coil heater 3. Terrminal Rated voltage: 22V (DC) Rated current: 36 A Capacity: 0.8 kW (0.4 kW x 2) 11-57 170-3 SERIES...
Page 121 ELECTRICAL HEATER (SAA6D170E-3) a The actual engine may be different because of modifications. SPECIFICATIONS 1. Terminal 2. Body Heater type: Electrical intake air heater 3. Heater coil Rated voltage: 22V (DC) 4. Connection diagram Rated current: 111 A 11-58 170-3 SERIES...
Page 122 Testing and adjusting alternator belt tension ..... 12-20 Precautions when operating engine as an individual part ............12-21 Arrangement of control devices and electric circuit diagram for HPI ............12-22 Run-in standard ............12-25 Performance test standards ........12-26 Troubleshooting............12-101 12-1 170-3 SERIES...
Page 123 98 N {10 kg} a This STANDARD VALUE TABLE does not give the standard values for adjusting the engine output. a Do not use the values in this table to change the adjusting the ECVA or injector. 12-2 170-3 SERIES (10)
Page 124 Max. 0.4 — — — — 70{0.7} — 1,150±35 1,150±35 1,070±35 1,070±35 960±30 960±30 Semi auto-ten- Semi auto-ten- — — sion sion 10 – 15 10 – 15 10 – 15 10 – 15 — — 12-3 170-3 SERIES (10)
Page 125 98 N {10 kg} a This STANDARD VALUE TABLE does not give the standard values for adjusting the engine output. a Do not use the values in this table to change the adjusting the ECVA or injector. 12-3-1 170-3 SERIES (11)
Page 126 Max. 1.5 Max. 0.4 — — 70 {0.7} — 70 {0.7} — 1,080±35 1,080±35 1,150±35 1,150±35 960±30 960±30 Semi auto-ten- — sion 10 – 15 10 – 15 10 – 15 10 – 15 — — 12-3-2 170-3 SERIES (11)
Page 127 98 N {10 kg} a This STANDARD VALUE TABLE does not give the standard values for adjusting the engine output. a Do not use the values in this table to change the adjusting the ECVA or injector. 12-3-3 170-3 SERIES (11)
Page 128 Intake manifold 25°C 3k – 5kz temperature IMTS Between (A) – (B) 50°C 1k – 2kz sensor (For generator) 80°C 6,200 – 7,500z 100°C 3,500 – 4,500z Between (A), (B) — Min. 1 Mz – ground 12-4 170-3 SERIES (10)
Page 129 Fuel pressure Voltage Between (A) – (B) — 4.75 – 5.25 V Fuel pump PMPR 0 kPa pressure sensor 0.5 ± 0.04 V {0 kg/cm Between (C) – (B) 2,582 kPa 4.5 ± 0.06 V {26.33 kg/cm 12-5 170-3 SERIES (10)
Page 130 If the condition is within the range shown in the table below, 1) Turn starting switch it is normal. OFF. 2) Disconnect connec- Resistance Timing rail tor. TIMG actuator 7 – 9 Ω Between (A) – (C) Between (A), (C) – ground Min. 1 MΩ 12-5-1 170-3 SERIES (10)
Page 131 Coolant freezing 799-202-9001 Specific gravity: 1,100 – 1,300 temperature Pressure valve function Radiator cap tester 799-202-9001 0 – 0.2 MPa{0 – 2 kg/cm Leakage from cooling system Quality of coolant Water tester 799-202-7002 PH, nitrous acid ion density 12-6 170-3 SERIES...
Page 132 Fuel rail pressure sensor 3824774) Timing rail pressure sensor 795-799-5470 Fuel pump actuator Cable (cummins No. Fuel rail actuator 3824775) Timing rail actuator Engine oil pressure sensor 795-799-5480 Boost pressure sensor Cable (cummins No. Fuel pump pressure sensor 3824776) 12-6-1 170-3 SERIES...
Page 133 4. After completing the measurement, remove the measurement equipment and set to the original condition. 12-7 170-3 SERIES...
Page 134 Unit:°C points. Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 Measured value Compensated value Average value 12-8 170-3 SERIES...
Page 135 (2), and adjust the valve clearance with adjustment screw (3). Insert the feeler gauge and turn the adjust- ment screw until the clearance is a sliding fit. Valve clearance Intake valve: 0.32 mm Exhaust valve: 0.62 mm 12-9 170-3 SERIES...
Page 136 1st time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm} 2nd time : Loosen fully 3rd time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm} 4th time : Loosen fully 5th time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm} 12-10 170-3 SERIES...
Page 137 Install each adapter assembly with the hole for taking out the injector on the opposite side of the holder. Hold the adapter in position with an injector holder. Mounting bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 12-11 170-3 SERIES...
Page 138 ING AND ADJUSTING INJECTOR LIFT. machine. Cylinder head cover mounting bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} 3. After completing the measurement, remove the measuring equipment and set to the original con- dition. 12-12 170-3 SERIES...
Page 139 Precautions when replacing fuel filter cartridge Always use a genuine Komatsu part for the fuel 2. Install the nipple and hose of pressure test kit filter cartridge.
Page 140 {11.60 ± 1.41} {Max. –203} condition 1.25 ± 0.14 MPa 1,000 2.42 ± 0.21 {12.70 ± 1.41} 1.34 ± 0.14 MPa 1,100 2.59 ± 0.21 {13.70 ± 1.41} 1.46 ± 0.14 MPa 1,200 2.76 ± 0.21 {14.90 ± 1.41} 12-14 170-3 SERIES...
Page 141 (C) and (B)): Engine Signal Fuel pump outlet port speed voltage pressure (reference) (rpm) (MPa{kg/cm 0.83±0.14 1.78±0.21 {8.45±1.41} 0.93±0.1 1.94±0.21 {9.50±1.41} 1.03±0.14 2.10±0.21 {10.53±1.41} 1.14±0.14 2.26±0.21 {11.60±1.41} 1.25±0.14 1,000 2.42±0.21 {12.70±1.41} 1.34±0.14 1,100 2.59±0.21 {13.70±1.41} 1.46±0.14 1,200 2.76±0.21 {14.90±1.41} 12-15 170-3 SERIES...
Page 142 Fill the fuel filter with fuel. Do this only after the fuel filter has been replaced. If the fuel filter has not been replaced, there is danger of dirt or dust getting in, so do not remove the fuel filter. 12-16 170-3 SERIES...
Page 147 When installing the engine to the machine, replace the oil seal with the double-lip type shown in the diagram below. Seal Part No.: 6240-21-4250 Install the engine, taking care not to damage For details, see DISASSEMBLY AND ASSEM- BLY. 12-21 170-3 SERIES...
Page 148 ARRANGEMENT OF CONTROL DEVICES AND TESTING AND ADJUSTING ELECTRIC CIRCUIT DIAGRAM FOR HPI ARRANGEMENT OF CONTROL DEVICES AND ELECTRIC CIRCUIT DIAGRAM FOR HPI Arrangement of control devices (for troubleshooting) 12-22 170-3 SERIES...
Page 149 11. Fuel pump pressure sensor (PMPR) 12. Fuel rail pressure sensor (RPR) 13. Timing rail pressure sensor (TPR) Actuator 14. Fuel pump actuator (FLTP) 15. Fuel shut-off valve (FSO+, FSO–) 16. Fuel rail actuator (RAIL) 17. Timing rail actuator (TIMG) 12-23 170-3 SERIES (11)
Page 150 ARRANGEMENT OF CONTROL DEVICES AND TESTING AND ADJUSTING ELECTRIC CIRCUIT DIAGRAM FOR HPI Electric circuit diagram (For troubles shooting) 12-24 170-3 SERIES...
Page 151 {130} {260} {488} {781} Operating time Engine speed 1,000 1,200 1,200 1,500 1,800 DCA-800SSK2 SAA6D170E2-3 (DENYO Dynamometer 1,396 2,791 4,187 5,570 GENERATOR) load {kg} {713} {142} {285} {427} {568} Output {HP} {126} {253} {505} {758} {1,009} 12-25 170-3 SERIES (10)
Page 152 The table shows the standard values with an air cleaner installed, muffler installed, alternator under no load, and air compressor open (when installed). a The dynamometer load shows the value for an arm length of 716 mm. 12-26 170-3 SERIES...
Page 153 — {3.5 – 5.5} Min. 118 — — — 70 – 90 80 – 110 — {Min. 1.2} a Use JIS No. 2 diesel oil as the fuel. a Use SAE15W-40 or SAE30 as the lubricating oil. 12-27 170-3 SERIES...
Page 154 The table shows the standard values with an air cleaner installed, muffler installed, alternator under no load, and air compressor open (when installed). a The dynamometer load shows the value for an arm length of 716 mm. 12-27-1 170-3 SERIES (11)
Page 155 90 – 110 Min. 118 — — — — 70 – 90 90 – 110 {Min. 1.2} — a Use JIS No. 2 diesel oil as the fuel. a Use SAE15W-40 or SAE30 as the lubricating oil. 12-27-2 170-3 SERIES (11)
Page 157 Oil pressure caution lamp lights up (drop in oil pressure)..............12-119 S-13 Oil level rises ..........................12-120 S-14 Water temperature becomes too high (overheating) ..............12-121 S-15 Abnormal noise is made ......................... 12-122 S-16 Vibration is excessive ........................12-123 12-101 170-3 SERIES...
Page 158 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause. 12-102 170-3 SERIES...
Page 159 Use the in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. 12-103 170-3 SERIES...
Page 160 When temperature of injector of each cylinder is measured, there are some cylinders that are low Abnormality in timing rail pressure sensor system is indicated ( 1) Inspect sensor directly (Output voltage) Inspect actuator directly (Resistance and filter for clogging) Remedy 12-104 170-3 SERIES...
Page 161 [Worn piston ring, cylinder liner]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal. 12-105 170-3 SERIES...
Page 162 When starting switch is turned to HEAT, heater mount does not become warm Is voltage 26 - 30V between alternator terminal B and terminal E with engine at low idling? Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Remedy 12-106 170-3 SERIES...
Page 163 In this case, inspect the other devices for the cause.) [514][E-73]: Abnormality in fuel rail actuator [112] [E-83]: Abnormality in timing rail actuator [318][E-93]: Abnormality in fuel pump actuator 12-106-1 170-3 SERIES...
Page 164 When terminal B and terminal C of safety relay are connected, engine starts When terminal of safety switch and terminal B of starting motor are connected, engine starts Remedy 1. Carry out troubleshooting of machine 12-107 170-3 SERIES (10)
Page 165 When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector pins Inspect timing rail actuator screen directly Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Remedy 12-108 170-3 SERIES (10)
Page 166 In this Causes case, inspect the other devices for the cause.) [514][E-73]: Abnormality in fuel rail actuator [112] [E-83]: Abnormality in timing rail actuator [318][E-93]: Abnormality in fuel pump actuator 12-108-1 170-3 SERIES (10)
Page 167 When specific gravity of electrolyte and voltage of battery are measured, one of them is low When starting switch is at HEAT, heater mount does not become warm Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Inspect fuel rail actuator directly Remedy 12-108-2 170-3 SERIES (10)
Page 168 In this case, inspect the other devices for the cause.) [514][E-73]: Abnormality in fuel rail actuator [112] [E-83]: Abnormality in timing rail actuator [318][E-93]: Abnormality in fuel pump actuator 12-109 170-3 SERIES (10)
Page 169 When temperature of injector of each cylinder is measured, there are some cylinders that are low When intake air pressure (boost pressure) is measured, it is found to be normal Inspect actuator directly (Resistance and filter for clogging) Inspect sensor directly (Output voltage and resistance) Inspect for air leakage Remedy 12-110 170-3 SERIES...
Page 170 In this case, inspect the other devices for the cause.) [514][E-73]: Abnormality in fuel rail actuator [112] [E-83]: Abnormality in timing rail actuator [318][E-93]: Abnormality in fuel pump actuator 12-110-1 170-3 SERIES...
Page 171 When temperature of injector of each cylinder is measured, there are some cylinders that are low Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Remedy 12-110-2 170-3 SERIES...
Page 172 In this case, inspect the other devices for the cause.) [514][E-73]: Abnormality in fuel rail actuator [112] [E-83]: Abnormality in timing rail actuator [318][E-93]: Abnormality in fuel pump actuator 12-111 170-3 SERIES...
Page 173 When flow of spill fuel is checked visually, it is found to be low Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Inspect fuel rail actuator screen directly Inspect timing rail actuator screen directly Remedy 12-112 170-3 SERIES...
Page 174 "EA mode" or "EB mode". (If it is not displayed, it is not probably the cause of the trou- ble. In this case, inspect the other devices for the cause.) [318][E-93]: Abnormality in fuel pump actuator 12-112-1 170-3 SERIES...
Page 175 When temperature of injector of each cylinder is measured, there are some cylinders that are low Inspect sensor directly (Output voltage and resistance) Inspect actuator directly (Resistance and filter for clogging) Check part No. of controller calibration data Remedy 12-112-2 170-3 SERIES...
Page 176 In this case, inspect the other devices for the cause.) [514][E-73]: Abnormality in fuel rail actuator [112] [E-83]: Abnormality in timing rail actuator [318][E-93]: Abnormality in fuel pump actuator 12-113 170-3 SERIES...
Page 177 When temperature of injector of each cylinder is measured, there are some cylinders that are low Abnormality in timing rail pressure sensor system is indicated ( 2) Inspect sensor directly (Output voltage) Inspect actuator directly (Resistance and filter for clogging) Remedy 12-114 170-3 SERIES...
Page 178 [112] [E-83]: Abnormality in timing rail actuator 2.If an error code of the timing rail pressure sensor system is displayed, carry out the troubleshooting in "EA mode" or "EB mode". 12-114-1 170-3 SERIES...
Page 181 When flow of return fuel is checked visually, it is found to be low Inspect sensor directly (Output voltage) 1. If an error code of the fuel rail pressure sensor system or timing rail pressure sensor system is displayed, carry out the troubleshooting in "EA mode" or "EB mode". Remedy 12-117 170-3 SERIES...
Page 182 When hydraulic oil, transmission oil on machine side is drained, water is found Carry out pressure-tightness test of cylinder head Inspect cylinder block, liner directly Inspect cylinder liner directly Carry out pressure-tightness test of oil cooler Inspect water pump directly Remedy 12-118 170-3 SERIES...
Page 344 Install oil ring (111) to piston (112). a Connect both ends of the expander and fit in the groove inside the ring. a Align the position of the end gaps as shown in the diagram. 13-27 170-3 SERIES (10)
Page 377 TURBOCHARGER MAINTENANCE STANDARD TURBOCHARGER KTR110L 14-2 170-3 SERIES...
Page 378 2.35 –002 Thickness –0.08 of seal ring Ring 1.85 –0.10 Blower –0.03 1 Ring 2.05 –0.04 Groove –0.11 2 Ring 4.05 –0.12 Replace parts Clearance between blower housing Clearance limit: (Min.) 0.20 related to and impeller bearing 14-3 170-3 SERIES...
Page 379 TURBOCHARGER MAINTENANCE STANDARD S500 14-3-1 170-3 SERIES (10)
Page 380 –002 Thickness –0.08 of seal ring Ring 1.85 –0.10 Blower –0.03 1 Ring 2.05 –0.04 Groove –0.11 2 Ring 4.05 –0.12 Replace parts Clearance between blower housing Clearance limit: (Min.) 0.20 related to and impeller bearing 14-3-2 170-3 SERIES (10)
Page 381 TURBOCHARGER MAINTENANCE STANDARD HOLSET 14-3-3 170-3 SERIES (10)
Page 382 Check item Criteria Remedy Standard size Repair limit Replace End play related to (play in axial direction) 0.025 – 0.152 – thrust Replace Radial play 0.254 – 0.787 – related to (play in radial direction) bearing 14-3-4 170-3 SERIES (10)
Page 384 Inside diameter of valve –0.001 12.10 guide –0.019 Protrusion of valve guide ±0.5 – Permissible load Free length Installed length Installed load N{kg} N{kg} Valve spring 99.6 87.4 647±65{66.0±6.6} 553{56.4} Perpendicularity of valve Repair limit: 2° spring 14-5 170-3 SERIES (10)
Page 385 0.011 – 0.072 – Standard size Tolerance Protrusion of crosshead guide ±0.25 Replace Intake valve Exhaust valve Valve clearance (at cold) 0.32 0.62 Tightening torque of cross- 59 ± 6 Nm {6.0 ± 0.6 kgm} Tighten head lock nut 14-6 170-3 SERIES...
Page 399 Clearance of idler gear in axial thrust direction 0.04 – 0.18 bearing Position Measurement place Standard Repair limit Crankshaft gear and idler gear 0.155 – 0.412 – Backlash of each gear (large) Replace Crankshaft gear and idler gear 0.145 – 0.380 (medium) 14-23 170-3 SERIES...
Page 400 Gap in piston ring at end gap 2nd ring 0.70 – 0.85 Oil ring 0.50 – 0.70 Standard clearance Clearance limit Inside diameter of piston pin +0.044 hole +0.034 –0.020 Outside diameter of piston pin –0.026 14-24 170-3 SERIES (12)
Page 407 CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION ....15-31 REPAIRING CRANKSHAFT ........15-36 TESTING AND INSPECTING OF CONNECTING ROD ......... 15-44 REPLACING CRANKSHAFT GEAR ....... 15-46 REPLACING CAMSHAFT GEAR ......15-47 REPLACING FLYWHEEL RING GEAR ....15-48 15-1 170-3 SERIES...
Page 408 Replacing valve guide 795-611-1620 Valve guide driver Replacing crosshead guide 795-611-1700 Crosshead guide pulle Commercially Grinding valve Valve refacer available 795-621-1600 Push tool set Replacing cam bushing 792-103-0400 Grip 790-101-2800 Bearing puller Replacing crankshaft gear 790-101-2300 Push puller 15-2 170-3 SERIES...
Page 409 REPAIR AND REPLACEMENT OF PARTS TESTING AND INSPECTING CYLINDER HEAD TESTING AND INSPECTING CYLINDER HEAD 1. Valve guide 2. Closshead guide 3. Fuel injection nozzle sleeve 4. O-ring 5. Cylinder head 6. O-ring 7. Pushrod tube 8. Valve seat insert 15-3 170-3 SERIES...
Page 410 0.21(protrusion) and exhaust) • Thickness of valve head Standard value Repair limit Intake valve 3.2 Exhaust valve 3.3 • Angle of seat surface "a" ° Intake valve: G. Thickness of valve Replace ° Exhaust valve: 45 head 15-4 170-3 SERIES...
Page 411 Permissible range: 42.5 – 43.5 Replace (after press fitted to head) Standard size Standard value Repair limit L. Outside diameter of crosshead guide 13.028 – 13.039 13.00 a: Cylinder head Permissible range: 85.75 – 86.25 M. Protrution of crosshed Replace guide 15-5 170-3 SERIES...
Page 412 • Check the sinking of the valves and protrution of the injector are within the standard values a Standard sinking of valves: (sinking) 0.39 – (protrution) 0.21 mm a Allowable protrusion of injector: 3.7 – 4.3 mm 15-6 170-3 SERIES...
Page 413 When using the grinder, wear safety gog- gles. Install grindstone [5] to grinder [1]. ii) Install the sleeve and grinder after align- ing the groove of sleeve [3] with holder [2]. a Adjust the position of the grinder with set screw [4]. 15-7 170-3 SERIES...
Page 414 Therefore, stop tightening the screw when the claws compretely contact the groove. iii) Place bridge [9] over the puller head, then place plates [10] and [11] on the bridge. tighten nut [12] to pull out the insert. 15-8 170-3 SERIES...
Page 415 Mounting hole bottom roughness:Max. 12.5S a Concentricity of inside diameter of valve guide and inside diameter of insert hole: 0.07 mm (T.l.R) max. a Rectangularity of inside diameter of valve guide and bottom of insert hole: Max. 0.03 mm (T.l.R) 15-9 170-3 SERIES...
Page 416 When the rubbing removes the rough- ness, wipe off the compound. Then coat with a fine compound and repeat the above process to give a good contact surface with no break in contact. 15-10 170-3 SERIES...
Page 417 1.3 kPa {10 mmHg} in 3 seconds. If it drops more than 1.3 kPa {10 mmHg} in 3 seconds, check for any dirt on the seat sur- face, or rub the surface to correct it. 15-11 170-3 SERIES...
Page 418 2) Place the head in a water bath, apply air – – pressure 343 392 kPa {3.0 3.5 kg/cm for approx. 30 seconds, and check for any air leakage in the water. a If the above test shows that there are cracks, replace the cylinder head. 15-12 170-3 SERIES...
Page 419 G2 contacts the cylinder head. 2) Confirm that the protrusion of the valve guide is within specification. a Protrusion of valve guide: 43 ± 0.5 mm a Inside diameter of valve guide hole in cylin- + 0.021 der head: 15-13 170-3 SERIES...
Page 420 Protrusion of cross head guide Toletance: ± 0.25 a Inside diameter of crosshead guide hole: + 0.008 - 0.010 15-14 170-3 SERIES...
Page 421 ° surface, and rotate 10 . Check that the pencil marks have been erased uniformly around the whole circumference. 15-15 170-3 SERIES...
Page 422 REPAIR AND REPLACEMENT OF PARTS TESTING AND INSPECTING CYLINDER BLOCK TESTING AND INSPECTING CYLINDER BLOCK 1. Cylinder liner 2. Crevice seal 3. O-ring 4. Cylinder block 5. Main bearing cap 6. Main bearing cap bolt 7. Camshaft bushing 15-16 170-3 SERIES...
Page 423 Permissible range: 0.07 – 0.15 cylinder block a: Cylinder block b: Cylinder liner F. Depth of counter-bore Repair by Standard size Standard value and corro-sion of bot- machining, add 14.00 – 14.05 tom surface shim • Check for corrosion 15-17 170-3 SERIES...
Page 424 J. Inside diameter of 194.615 counterbore, outside diameter of cylinder liner flange Cylinder block Cylinder Standerd Standerd Repair block size valve limit Replace cylinder block 205.93 – 205.92 – 206.0 205.99 206.02 194.48 – 194.46 – Bottom 194.5 194.54 194.57 15-18 170-3 SERIES...
Page 425 Speed of grindstkone: 1,650 – 1,950 m/min. a Speed of table: 15 – 30 m/min. a Grinding depth/time: 0.025 mm a Cross feed/time: 1 – 2 mm a Grindstone: A461V a Grinding lubricant: Water-soluble grind-ing lubricant 15-19 170-3 SERIES...
Page 426 0.50 0.025 0.001 6162-29-2230 0.26 0.025 0.001 6162-29-2220 0.20 0.020 0.001 6162-29-2210 0.16 0.016 0.001 a Inside diameter j and outside diameter I of shims (1) ± • I: 205.5 0.15 mm + 0.030 • j: 194.6 15-20 170-3 SERIES...
Page 427 The arrow in the figure indicates the flywheel side of the cylinder block. Talbe of letters to stamp Oversize Shim Stamp head gaske – – Not needed – – – (Size of letters: 5 10mm) 15-21 170-3 SERIES...
Page 428 (SAE30) immediately before press fitting the liner. 15-22 170-3 SERIES...
Page 429 Using the following procedure, squeeze out the gasket sealant coated on the counter- bore. Tighten the cylinder head temporarily with a used head gasket. 3 Mounting bolt: 255 ± 10 Nm {26 ± 1 kgm} • Tighten order of head bolt (3) 15-23 170-3 SERIES...
Page 430 (2). To prevent this, wipe off the gasket sealant. a Be sure to perform i) and ii). 15-24 170-3 SERIES...
Page 431 Cut until the cutting tool contacts the inside wall of cylinder block (2). a Inside diameter of main cap: + 0.025 Tolerance: 148 a Surface roughness: Max. 12.5S a Never cut the inside wall of the cylinder block. 15-25 170-3 SERIES...
Page 432 175 ± 2 mm • Depth c of thrust bearing mounting part: 2.5 ± 0.2 mm • Radius R of thrust bearing mounting part: Max. 0.5 mm • Outside width d of main cap : 61 ± 0.5 mm 15-26 170-3 SERIES...
Page 433 Insert the bushing with the 1-cut end in front (See the following page). a Match the oil hole of the bushing (Take this precaution for the following press-fitting work, too). 15-27 170-3 SERIES...
Page 434 If the inside of the bushing has been cor- rected with a reamer, remove the all chips from the oil holes and oil grooves. a Inside diameter of cam bushing: + 0.101 + 0.017 a Clearance of camshaft journal: 0.059 – 0.173 mm 15-28 170-3 SERIES...
Page 435 Seizure nal portion rect by lapping. B. Damage Discoloration Replace if there is seizure Damage to cap hole at front and rear end Correct C. Clogging of oil hole Check for clogging of oil hole Correct 15-29 170-3 SERIES...
Page 436 K. Clearance of main Replace main 0.076 – 0.152 0.20 bearing journal Standard Repair limit L. Curvature of Total coaxiality of crankshaft Max. 0.150 0.150 main journal Replace (total runout of Coaxiality of neigh- indicator) Max. 0.070 0.070 boring journals 15-30 170-3 SERIES...
Page 437 Move the paper smoothly and do not stop at any point. iii) Check the surface roughness, and if it is not within the standard, polish again once up and down the width of the journol with No. 500 paper. 15-31 170-3 SERIES...
Page 438 3) Assembly of work clamp jig and method of Cramping jig for pin journal and main jou- nal is assembled as shown in the dia- gram on the right. For details of the component parts, see the drawings on sepatate pages. 15-32 170-3 SERIES...
Page 439 4. Cleaning after correcting surface roughness After correcting the surface roughness, always brush the oil hole and blow with air. 5. Check that there are no scratches or dents at the journal portion and fillet R portion. 15-33 170-3 SERIES...
Page 440 REPAIR AND REPLACEMENT OF PARTS JOURNAL PORTION Clamp jig parts drawing (for pin journal) 1) Plate (2 are used for each jig) (a : Width of slit) Unit: mm 2) Handle (2 are used for each jig) Unit: mm 15-34 170-3 SERIES...
Page 441 REPAIR AND REPLACEMENT OF PARTS JOURNAL PORTION Clamp jig parts drawing (for main journal) 1) Plate (2 are used for each jig) (a : Width of slit) Unit: mm 2) Handle (2 are used for each jig) Unit: mm 15-35 170-3 SERIES...
Page 442 Radius R of 2 round parts: 1 2 mm 2) Oil hole of pin journal (See figure at right) Pin journal portion Finish part d with sandpaper. ii) Check part e particularly, since it tends to have a quenching crack. 15-36 170-3 SERIES...
Page 443 (Difference between 1st cylinder and last cyl- inder): 0.94 mm Dispersion of throw a of each cylinder: Max. 0.20 If any of the above item of a is out of the per- missible range, discard the crankshaft. • Dimension b is the stroke. 15-37 170-3 SERIES...
Page 444 Tolerance of front end: 0.04 mm iv) Tolerance of rear end: 0.03 mm 3. Grinding main journals a Grind all the main journals to the same undersize. a When grinding, leave the polishing allow- – ance of 0.007 0.008 mm. 15-38 170-3 SERIES...
Page 445 Rear thrust bearing surface S.T.D 0.25 O.S Basic + 0.050 + 0.050 64.25 dimension S.T.D Limit 64.060 64.310 Basic + 0.050 + 0.050 dimension 64.25 64.50 0.25 Limit 64.310 64.560 • Squareness of thrust bearing surface (T.I.R) Limit: 0.04 mm 15-39 170-3 SERIES...
Page 446 Width of crank pin journal If cutting one side only: + 0.074 Standard: Repair limit: 72.32 mm Width of main journal (For No. 6 only): + 0.05 Standard: Repair limit: 64.30 mm Squareness of thrust bearing surface (T.I.R) Limit: 0.04 mm 15-40 170-3 SERIES...
Page 447 Confirm that each dimension is within specifica- tion. • Carefully wash each section and apply oil to it. • When storing the crankshaft for a long time, sup- port it at three points or hang it vertically. 15-41 170-3 SERIES...
Page 448 Drill holes direction: Radial direction Number of holes: Max. 6 Diameter of hole: 19 mm or 23 mm Depth of hole: Max. 50 mm Distance between hole and side face: Min. 3 mm Distance among holes: Min. 5 mm 15-42 170-3 SERIES...
Page 449 – 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. 15-43 170-3 SERIES...
Page 450 (bearing, etc.) Item Standard size Tolerance Repair limit S.T.D 3.500 3.41 U.S 0.25 3.625 3.54 E. Thickness of bearing -0.029 U.S 0.50 3.725 3.66 -0.042 U.S 0.75 3.875 3.79 U.S 1.00 4.000 3.91 15-44 170-3 SERIES...
Page 451 Replace washer K. Deformation of dowel Check for deformation of dowel pin Replace Check for deformation of dowel pin hole Check for cracks, damage to bolt thread L. Damage to bolt Replace bolt Check for curvature of bolt 15-45 170-3 SERIES...
Page 452 Knock in quickly before the gear becomes cool. a There is not a timing mark on the front gear. 15-46 170-3 SERIES...
Page 453 5) Put the timing mark of the gear on the out- side, then use a hitting tool to press fit until the side face of the gear is in close contact with the camshaft flange. a Knock in quickly before the gear becomes cool. 15-47 170-3 SERIES...
Page 454 Gear shrink-fitting temperature: Max. 200 ° Heating time: Min. 20 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. 15-48 170-3 SERIES...

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