Beruflich Dokumente
Kultur Dokumente
SHOP MANUAL
6BG1, 6BG1T ENGINE
SERIAL No.
5001 and up
2001 and up
2301 and up
1001 and up
BE
00-1
CONTENTS
No. of page
TROUBLESHOOTING .........................................................................8-1
SPECIAL TOOLS.................................................................................9-1
10
00-1
SAFETY
FOREWORD
FOREWORD
This workshop manual is designed to use for the repair and adjusting procedures on Model 6BG1 and 6BG1T
industrial engines.
This manual provides service men with a guide on maintaining the best conditions of the engines.
Komatsu Forklift Co. LTD reserves the right to make changes concerning numerical values due to the design
change at any time without prior notice.
00-2
SAFETY
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the 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.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any dangerous
situation arises or may possibly arise, first consider safety, and take the necessary actions to
deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which
are fixed to the machine.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting
parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
00-3
SAFETY
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be
lifted with a hoist, etc. In the Disassembly
and Assembly section, every part weighing
25 kg or more is indicated clearly with the
symbol
4
00-4
GENERAL INFORMATION
1 GENERAL INFORMATION
Page
General precautions for repairing engine ...................................................................................................... 1- 2
How to read repair manual ............................................................................................................................ 1- 4
Sketch drawing .............................................................................................................................................. 1- 6
Main specifications ......................................................................................................................................... 1-11
Tightening torque specifications .................................................................................................................... 1-12
Angular tightening method ............................................................................................................................. 1-14
Tightening torque of main parts .................................................................................................................... 1-15
Parts which need packings ............................................................................................................................ 1-21
Inspection and maintenance .......................................................................................................................... 1-22
Recommended lubricants .............................................................................................................................. 1-26
1-1
GENERAL INFORMATION
1-2
GENERAL INFORMATION
10. Arrange the valves, bearings, pistons, piston rings, connecting rods, bearing caps, etc. by putting "numbered
tags" to them according to the "cylinder Nos." (The cylinders are number 1, 2, 3, and 4 from the crank
pulley side.)
11. When installing the rotary parts and sliding parts, apply "engine oil" or "grease" to them.
12. Observe the "tightening torque" of the bolts and nuts.
13. After completing inspection and maintenance, perform the "final inspection" to make sure that the work has
been performed correctly.
1-3
GENERAL INFORMATION
1-4
GENERAL INFORMATION
5. The following is the symbols identifying the type of the inspection maintenance operation.
6. Definition of terms
"Nominal size" ....... A standard value for manufacture.
"Standard" .............. A standard value for maintenance (inspection, adjustment, assembly, and installation).
"Limit" ........ A maximum value or a minimum value which an inspected part must not exceed or fall below.
If the inspected part exceeds the maximum value or falls below the minimum value, it must be
replaced or repaired.
7. Explanation of abbreviations
"IN" ...................... Intake (Intake air)
"EX" .................... Exhaust (Exhaust gas)
"STD" .................. Standard
"O/S" ................... Oversize
"" ...................... Diameter
1-5
GENERAL INFORMATION
SKETCH DRAWING
Model BB-6BG1T
1-6
GENERAL INFORMATION
1-7
GENERAL INFORMATION
Model A-6BG1
1-8
GENERAL INFORMATION
1-9
GENERAL INFORMATION
MAIN SPECIFICATIONS
Engine name
Item
Unit
Type
BB-6BG1T
(with turbocharger)
AA-6BG1
Direct injection
mm
6 105 x 125
6.494
Compression ratio
18.0
kg
484
458
19
47
57
15
mm
mm
8
Clockwise when seen from fan side
Rotation direction
Governor
Cooling method
*
mm
Made of plastics
12.0
Excluding water
in radiator
Forced lubrication
Lubrication method
Quantity of lubricating oil (in oil pan)
Max. 13 Min. 10
Generator output
24V, 40A
24V, 25A
Cartridge type
Oil filter
Cartridge type
Fuel oil
Diesel fuel
Oil cooler
Recommended battery capacity
24V, 4.5kW
Fuel filter
Lubricating oil
Prepared by
manufacturer
Element type
Turbocharger
Dry weight
153624
Firing order
Cooling fan
Remarks
Installed
Prepared by
manufacturer
(Note) Items marked with *: Depend on the machine equipped with the engine.
1-11
GENERAL INFORMATION
Nominal
thread size
(Diameter x Pitch)
M6 X 1.0
M8 X 1.25
M10 X 1.25
*M10 X 1.5
M12 X 1.25
*M12 X 1.75
M14 X 1.5
*M14 X 2.0
M16 X 1.5
*M16 X 2.0
M18 X 1.5
*M18 X 2.5
M20 X 1.5
*M20 X 2.5
M22 X 1.5
*M22 X 2.5
M24 X 2.0
*M24 X 3.0
Use the bolts marked with * for "female screws" of soft materials such as "cast iron".
1-12
GENERAL INFORMATION
Nominal
thread size
(Diameter x Pitch)
M6 X 1.0
M8 X 1.25
M10 X 1.25
*M10 X 1.5
M12 X 1.25
*M12 X 1.75
M14 X 1.5
*M14 X 2.0
M16 X 1.5
*M16 X 2.0
Use the bolts marked with * for "female screws" of soft materials such as "cast iron".
1-13
GENERAL INFORMATION
1-14
GENERAL INFORMATION
1-15
GENERAL INFORMATION
Cylinder body, oil pan, and oil pump
(Nm {kgfm})
1-16
GENERAL INFORMATION
Crankshaft, piston, flywheel, and flywheel housing
(Nm {kgfm})
1-17
GENERAL INFORMATION
Camshaft and timing gear parts
(Nm {kgfm})
1-18
GENERAL INFORMATION
Water pump, fan, generator, starting motor, etc
(Nm {kgfm})
1-19
GENERAL INFORMATION
Injection pipe and turbocharger
(Nm {kgfm})
1-20
GENERAL INFORMATION
1-21
GENERAL INFORMATION
Cylinder No.
Valve arrangement
IN
EX
IN
1-22
3
EX
IN
4
EX
IN
5
EX
IN
6
EX
IN
EX
Q
q
GENERAL INFORMATION
Fuel injection timing (1)
Match the "T.D.C mark" (top dead center mark) of
the crank pulley to the "pointer".
6BG1T
8 or 10
6BG1
1-23
GENERAL INFORMATION
Adjusting the injection timing
In the case of the flange mount type, loosen the
mounting nuts (4 pieces) of the injection pump
housing and pump bracket with the special tool and
change the installed angle of the injection pump to
adjust the injection timing. The injection timing
adjusted when the engine was assembled is indicated
by the stamped "match marks" at the joint of the
injection pump housing and bracket.
Special tool: Injection pump wrench
9-8511-3703-0
Standard
Limit
3.0 {31}
2.5 {26}
1-24
GENERAL INFORMATION
Injection nozzle
Check the condition and pressure of injection, and
then adjust them if necessary.
(MPa {kgf/cm2})
Fuel injection pressure
18.1 {185}
Fan belt
(mm)
Belt deflection
Approx. 7 10
1-25
GENERAL INFORMATION
RECOMMENDED LUBRICANTS
ENGINE TYPE AND GRADE
Enging type
With turbocharger
CD Grade
Without turbocharger
CC or CD Grade
SAE 10W
(Ambient
30C
Temperature) (22F)
15C
(0F)
SAE 30
0C
(32F)
15C
(60F)
25C
(80F)
30C
(90F)
(Multi- grade)
SAE 10W-30
Start-up, operability, oil consumption, the wear of sliding portions and seizure of the engine may be affected
by engine oil viscosity. Select the proper oil according to the temperature referring to the above table.
1-26
ENGINE ASSEMBLY
2 ENGINE ASSEMBLY
Page
General view of engine .................................................................................................................................. 2- 2
Disassembly ................................................................................................................................................... 2- 3
Main component parts ............................................................................................................................. 2- 3
Disassembly procedure (1) ..................................................................................................................... 2- 4
Disassembly procedure (2) ..................................................................................................................... 2- 5
Disassembly procedure (3) ..................................................................................................................... 2- 6
Engine oil and coolant ............................................................................................................................. 2- 7
Exterior parts ........................................................................................................................................... 2- 7
Rocker arm shaft assembly .................................................................................................................... 2-11
Cylinder head assembly .......................................................................................................................... 2-11
Cylinder body parts ................................................................................................................................. 2-13
Timing train parts, camshaft, and tappet ................................................................................................ 2-15
Piston and connecting rod assembly ...................................................................................................... 2-18
Crankshaft assembly ............................................................................................................................... 2-19
Inspection and replacement .......................................................................................................................... 2-20
Cylinder body ........................................................................................................................................... 2-20
Cylinder head .......................................................................................................................................... 2-22
Valve, valve guide, valve guide insert ..................................................................................................... 2-23
Rocker arm shaft assembly parts ........................................................................................................... 2-25
Camshaft, tappet, idle gear, and shaft ................................................................................................... 2-26
Piston, piston pin, piston ring .................................................................................................................. 2-30
Connecting rod, connecting rod bearing ................................................................................................. 2-32
Crankshaft, crankshaft bearing ............................................................................................................... 2-34
Reassembly ................................................................................................................................................... 2-37
Cylinder head assembly .......................................................................................................................... 2-37
Rocker arm shaft assembly .................................................................................................................... 2-39
Piston and connecting rod assembly ...................................................................................................... 2-40
Component parts ..................................................................................................................................... 2-42
Crank shaft assembly .............................................................................................................................. 2-43
Cylinder body parts ................................................................................................................................. 2-44
Piston and connecting rod ...................................................................................................................... 2-46
Timing gear, tappet, and oil pump .......................................................................................................... 2-47
Rear oil seal, housing, oil pan, and oil cooler ........................................................................................ 2-49
Fuel injection pump and gear case cover .............................................................................................. 2-50
Relationship between flywheel, crank pulley, and cylinder head ........................................................... 2-51
Exterior parts ........................................................................................................................................... 2-53
2-1
ENGINE ASSEMBLY
2-2
ENGINE ASSEMBLY
DISASSEMBLY
MAIN COMPONENT PARTS
2-3
ENGINE ASSEMBLY
2-4
ENGINE ASSEMBLY
2-5
ENGINE ASSEMBLY
2-6
ENGINE ASSEMBLY
Coolant
Loosen the drain valve of the cylinder body and drain
the coolant remaining in the engine.
Note: If water leaks through the water pump, collect
first 0.1 L (100 cc) of it for inspection.
EXTERIOR PARTS
Cooling fan
Remove the cooling fan.
Take care not to break or damage the removed fan.
Intake duct
Remove the duct between the turbocharger and
intake manifold.
Note: Take care that foreign matter will not enter
the turbocharger and intake manifold.
2-7
ENGINE ASSEMBLY
Lubrication piping
Remove the lubricating oil pipe of the injection pump,
oil pipe of the oil filter, and oil feed pipe of the
turbocharger (Remove the return pipe later).
Note: Cover the oil feed opening of the turbocharger
with an adhesive tape to prevent foreign matter
from entering the turbocharger. When
reassembling, remove the tape and clean.
Turbocharger
1. Remove the turbocharger and return oil pipe
together.
2. Remove the return pipe from the turbocharger.
Note: Take care that foreign matter will not enter
the intake opening, exhaust opening, and
return oil port of the turbocharger.
Generator
Remove the adjustment plate of the generator, and
then remove the generator and fan belt.
Starting motor
Remove the starting motor mounting nuts, and then
remove the starting motor and ground cable from the
flywheel housing.
Glow plug
Remove the glow plug connector, and then remove
the glow plug from the cylinder head.
2-8
ENGINE ASSEMBLY
Oil filter
Loosen each cartridge, and then remove the oil filter
assembly. (Replace the cartridges.)
Note: Take care that foreign matter and dirt will not
enter the oil filter fitting parts of the cylinder
body.
Oil cooler
Remove the oil cooler from the cylinder body by
lightly hitting around it with a wooden hammer, etc.
2-9
ENGINE ASSEMBLY
Water pump and fan pulley
Loosen the bypass hose band and remove the pump
mounting bolts and water pump.
2-10
ENGINE ASSEMBLY
2-11
ENGINE ASSEMBLY
Valve
Valve and valve spring
Special tool: Valve spring replacer
1-85235-006-0
Compress the valve spring and remove the split collar,
spring seat, valve spring, and valve.
2-12
ENGINE ASSEMBLY
Oil pan
Remove the mounting bolts and oil pan.
Oil pump and oil pipe
Remove the oil pump and oil pipe together from the
cylinder body.
At this time, remove the drive gear shaft coupling,
too.
2-13
ENGINE ASSEMBLY
Flywheel
1. Lock the crankshaft and remove the mounting
bolts.
2. Remove the flywheel, hitting it lightly with a plastic
hammer.
Note: Do not damage the ring gear.
Timing gear case cover
1. Loosen the bolts (7 pieces) of the timing gear
case cover and remove the injection pump. Then,
remove the other bolts and gear case cover.
Note: Remove the rear bracket of the injection pump
in advance.
2. Install the claw nut of the crank pulley temporarily
to rotate the crankshaft.
2-14
ENGINE ASSEMBLY
Backlash of gears
Before removing each gear, measure its backlash.
(mm)
Standard
Limit
0.10 0.17
0.3
2-15
ENGINE ASSEMBLY
Clearance of idle gear in axial direction
(mm)
Standard
Limit
0.128 0.185
0.2
Limit
0.15 0.33
0.4
Camshaft assembly
Remove the thrust plate mounting bolts through the
hole of the cam gear and pull out the camshaft slowly.
Gear case
Remove the timing gear case from the cylinder body.
Rear oil seal
Remove the flywheel housing.
Using the special tool, remove the oil seal.
Special tool: Rear oil seal remover
5-8840-2360-0
2-16
ENGINE ASSEMBLY
Flywheel housing
Remove the flywheel housing from the cylinder body.
Camshaft bearing
Remove the flywheel and the flywheel housing, and
pull out the plate plug, and then remove the bearings
successively from the rear of the cylinder body using
a puller.
Special tool: Bearing puller
9-8523-1818-0
2-17
ENGINE ASSEMBLY
Piston ring
Use a replacer to remove the piston ring.
Special tool: Piston ring replacer
1-8522-1025-0
Piston pin
Remove the snap ring. Put a holding-up rod to the
piston pin and tap it out with a hammer.
2-18
ENGINE ASSEMBLY
CRANKSHAFT ASSEMBLY
Crankshaft gear
Use a puller to remove the crankshaft gear.
Special tools: Puller; Crankshaft gear
9-8521-0141-0
2-19
ENGINE ASSEMBLY
CYLINDER BODY
Cylinder body
Inspect the cylinder body for wear, breakage, water
leakage, etc.
Water leakage: Water pressure test 490kpa {5 kg/cm2}
(for 3 min.)
2. Inspect the cylinder body for damage with defect
detector material, etc.
Limit
0.05 or less
0.2
Repair procedure
Grinding with surface
grinder
Limit
Repair procedure
105.0
105.2
Replacement
2-20
ENGINE ASSEMBLY
Setting of grade part Nos. of pistons, cylinder
liners, and liner sets
Part Nos. are set for each grade of the spare pistons,
cylinder liners, and liner sets supplied in and after
August 1997. Accordingly, when repairing these
parts, observe the following points.
1. Repair standard
Judge the repair standard of these parts by the
repair standard values in this repair manual as
before.
2. Grade part Nos. (Replacement of new and
current part Nos.)
3. How to order parts
Select a proper grade of each part in the new
and current part Nos. table and place an order
by the corresponding new part No.
Selecting the liner
The combinations of the liners and cylinder bores
are as follows. The interference between each liner
and cylinder must be 0.001 - 0.0019 mm.
(mm)
Liner inside Cylinder body
diameter
bore
105
Liner
Liner outside
grade No. diameter
107.001 107.010
107.001 107.010
107.011 107.020
107.011 107.020
107.021 107.030
107.021 107.030
2-21
ENGINE ASSEMBLY
Installing cylinder liner
Carefully wipe away oil from the cylinder liner and
body and install the liner with special tools.
Use the bench press to apply initial pressure of 500
kg for press-fitting the liner and apply final pressure
of 2500 kg for press-fitting and fully seating the liner.
Special tools: Setting tool; Cylinder liner
5 85221 018 0
CYLINDER HEAD
Cylinder head
Remove carbon residues which are sticking on the
bottom face of the head carfully not to damage the
valve seat face and inspect wear, damage and the
like.
Water leakage: Water pressure test 490 kpa {5 kg/
cm2} (for 3 min)
Perform a magnetic particle inspection and a red
check, as necessary.
(mm)
Standard
Limit
0.05
or less
0.20
Repair procedure
Grinding with surface
grinder
2-22
ENGINE ASSEMBLY
Standard
Limit
0.39 0.068
0.20
0.064 0.096
0.25
Depression
(B)
Contact
width (A)
Intake
Standard
Limit
1.0
2.5
Exhaust
Intake
1.5
2.0
Repair
procedure
Correct
or replace
the valve
and insert
Exhaust
2-23
ENGINE ASSEMBLY
Valve stem diameter
Correct slightly stepped wear with an oil stone.
(mm)
Standard
Limit
Repair Procedure
9.00
8.88
Replacement
Intake
Exhaust
Valve thickness
(mm)
Standard
Limit
Repair Procedure
1.5
1.0
Replacement
Intake
Exhaust
Standard
Limit
Repair
procedure
Blue
142 {14.5}
127 {13.0}
Replacement
Standard
Limit
Repair
procedure
Pink
142 {14.5}
127 {13.0}
Replacement
(mm)
Distinction
Standard
Limit
Repair
procedure
Blue
60.6
58.0
Replacement
(mm)
Distinction
Standard
Limit
Repair
procedure
Pink
55.0
53.0
Replacement
2-24
(mm)
Standard
Limit
Repair procedure
1.9 or less
2.7
Replacement
ENGINE ASSEMBLY
Limit
Repair procedure
19.00
18.85
Replacement
Limit
Repair procedure
0.01 0.05
0.2
Replacement
Limit
Repair procedure
0.2 or less
0.3
Replacement
2-25
ENGINE ASSEMBLY
Push rod bend
If the both ends of a push rod are worn or damaged
remarkably, replace that push rod.
(mm)
Limit
0.3
Limit
0.050 0.114
0.2
2-26
ENGINE ASSEMBLY
Camshaft runout
Inspect the camshaft for bend.
Measure the runout and divide it by 2 (to obtain the
bend).
(mm)
Limit
Repair procedure
0.12
Replacement
Limit
Repair procedure
7.71
7.21
Replacement
(mm)
Standard
Limit
55.94 55.97
55.6
(mm)
0.05
(mm)
Standard
Limit
0.03 0.09
0.15
2-27
ENGINE ASSEMBLY
Replacing the camshaft bearing
1. Removal procedure
(1) Remove the sealing cup of the cylinder body.
(2) Using the camshaft bearing puller, remove
the bearing.
Special tool: Camshaft bearing puller
9-8523-1818-0
2. Installation procedure
(1) Match the oil hole of the bearing to that of
the cylinder body.
(2) Using the bearing replacer, install the bearing.
Special tool: Camshaft bearing installer
9-8523-1818-0
2-28
Nominal size
Limit
Repair procedure
28
27.92
Replacement
ENGINE ASSEMBLY
Clearance between tappet and cylinder body
Using a bore gauge, measure the inside diameter of
the tappet inserting hole of the cylinder body and
calculate the difference between it and outside
diameter of the tappet.
(mm)
Standard
Limit
Repair procedure
0.020 0.054
0.1
Replacement
(mm)
Nominal size
Limit
Repair procedure
45
44.9
Replacement
Limit
Repair procedure
0.025 0.085
0.2
Replacement
2-29
ENGINE ASSEMBLY
105.021 105.060
104.945 104.984
0.051 0.085
AX
CX
104.959
104.975
104.974
104.990
2-30
Cylinder inside
diameter grade
Piston grade
Combination
AX
AX
OK
CX
CX
OK
AX
CX
NG
CX
AX
NG
ENGINE ASSEMBLY
Piston pin wear
Piston pin outside diameter
(mm)
Nominal size
Limit
Repair procedure
35
34.95
Replacement
(mm)
0.010 0.018
Limit
Repair procedure
1.5
Replacement
0.30 0.50
Standard
Limit
Repair procedure
Replacement
2-31
ENGINE ASSEMBLY
Piston ring tension
(N {kgf})
Standard
20.4
1st pressure ring {2.08
14.1
2nd pressure ring {1.44
14.1
3rd pressure ring {1.46
36.3
Oil ring
{3.7
30.6
3.12}
21.2
2.16}
21.2
2.16}
55.9
5.7}
Replacement
Standard
Limit
0.05 or less
0.2
0.05 or less
0.2
Repair procedure
Repair or
replacement
2-32
Standard
Limit
Repair procedure
0.012 0.025
0.05
Replacement
ENGINE ASSEMBLY
Replacing the bushing
Use a proper rod and a bench press.
Inside diameter finish after press fitting the bushing.
(mm)
Standard
Bearing tension
Check if the tension of the bearing is sufficient. The
back face must be fit closely.
Limit
Repair procedure
0.030 0.073
0.1
Replacement
Limit
Repair procedure
0.17 0.30
0.35
Replacement
2-33
ENGINE ASSEMBLY
2-34
(mm)
ENGINE ASSEMBLY
Journal, pin outside diameter
(mm)
Portion
Nominal size
Standard
Journal
80
79.919 79.939
No. 4 journal is
79.905 79.925
Pin
64
63.924 63.944
Limit: 0.05
Runout of crankshaft
Apply a dial gauge to No. 4 journal, turn the shaft
slowly, and read the gauge.
(mm)
Standard
Limit
Repair procedure
0.05 or less
0.4
Replacement
Limit
Repair procedure
0.025 0.084
No. 4 journal is
0.039 0.098.
0.11
Bearing
replacement
2-35
ENGINE ASSEMBLY
Removing the crankshaft gear
Using the puller, remove the crankshaft gear.
Special tool: crankshaft gear, puller
9-8521-0141-0
2-36
ENGINE ASSEMBLY
REASSEMBLY
CYLINDER HEAD ASSEMBLY
Valve seal
When press fitting the valve seal, apply engine oil to
the periphery of the valve guide.
Special tool: Valve seal setting tool
1-85221-005-0
Note: Press fit the seal securely until it reaches the
cylinder head top. When press fitting the seal,
take care not to damage its lip. After press
fitting, check that the spring has not come off.
2-37
ENGINE ASSEMBLY
Valve
Valve spring
Lubricate valve stems with engine oil when inserting
the valve.
Install the valve spring with the shorter pitch side
(painted side) down.
Intake manifold
Tightening torque: 2.1 3.1 kg.m
{20.6 30.4 N.m}
Exhaust manifold
Tightening torque: 2.6 3.2 kg.m
{25.5 31.4 N.m}
Install the gasket with the TOP mark facing up to
the engine and to you.
2-38
ENGINE ASSEMBLY
Bracket (Front)
Warm the bracket in hot water.
Coat the O-ring with oil and fit it to the bracket.
Install the bracket to the rocker arm shaft with the Oring side ahead.
2-39
ENGINE ASSEMBLY
Piston pin
Insert the piston pin manually without heating the
piston.
2-40
ENGINE ASSEMBLY
Install the expander ring
Engage the abutting faces of the expander ring closely
and insert into the groove of the piston.
Piston ring
Install the top ring with its marking facing up. Install
the second ring with its undercut facing down. The
oil ring has no facing mark. Then, lubricate the
periphery of the rings with oil and rotate the rings.
Check that the piston rings rotate smoothly without
any catching.
1-8522-1025-0
2-41
ENGINE ASSEMBLY
COMPONENT PARTS
2-42
ENGINE ASSEMBLY
Crankshaft gear
Install the crankshaft gear to the crankshaft with the
chamfered side of the key facing the front. Use the
setting tool to install the crankshaft gear with the
gear timing set mark facing outside.
Special tools: Crankshaft gear setting tool
9-8522-0033-0
2-43
ENGINE ASSEMBLY
16 25 {1.6 2.6}
Crankshaft bearings
Since the lower bearing (on the bearing cap side)
does not have an oil groove or an oil hole, take care
not to mistake it for the upper bearing.
Note: If the lower and upper bearings are installed
reversely, the crankshaft bearing will be seized.
Take care.
Thrust bearings
Apply sufficient amount of engine oil to the inside of
the crankshaft bearing and place the crankshaft
slowly. Apply oil to both sides of the thrust bearings
and push them into both sides of No. 4 journal with
the hand, setting the oil groove sides out (on the
crankshaft side).
2-44
ENGINE ASSEMBLY
16 25 {1.6 2.6}
2-45
ENGINE ASSEMBLY
39 {4.0} o 60 90
2-46
ENGINE ASSEMBLY
21 30 {2.1 3.1}
Idle gear
1. Apply engine oil to the inside of the idle gear.
2. Match mark "A" of the idle gear to that of the
crankshaft gear and install the idle gear to the
idle gear shaft.
3. Install the idle gear with the chamfered side of
the thrust collar out.
(N.m {kgf.m})
Tightening torque
44 64 {4.5 6.5}
Camshaft assembly
1. Apply engine oil to the camshaft journals and
install the camshaft to the cylinder body.
Note: Install the camshaft carefully so that its lift will
not damage the camshaft bearing.
2-47
ENGINE ASSEMBLY
2. When installing the camshaft, match mark "B" of
the idle gear to that of the crankshaft gear.
3. Check that the camshaft is installed perfectly
and tighten the thrust plate.
(N.m {kgf.m})
Tightening torque
21 30 {2.1 3.1}
Tappet
Coat each tappet with engine oil and install it to the
cylinder body.
2-48
42 62 {4.3 6.3}
21 30 {2.1 3.1}
ENGINE ASSEMBLY
21 30 {2.1 3.1}
Oil pan
Install the oil pan and gasket together to the cylinder
body and tighten the bolts alternately and evenly.
(N.m {kgf.m})
Tightening torque
21 30 {2.1 3.1}
Note: Wipe off oil and grease from the gasket fitting
surface of the cylinder body, and then install
the gasket to the correct position of the cylinder
body.
Oil cooler
Apply gasket sealant to the packing and stick it to
the body case and tighten the bolts in the numerical
order shown in the figure.
(N.m {kgf.m})
Tightening torque
14 24 {1.4 2.4}
2-49
ENGINE ASSEMBLY
Oil relief valve
Apply engine oil to the threads of the oil relief valve
and tighten it, check that the gasket is not shifted.
(N.m {kgf.m})
Tightening torque
21 30 {2.1 3.1}
21 30 {2.1 3.1}
2-50
21 30 {2.1 3.1}
ENGINE ASSEMBLY
Crank pulley
(N.m {kgf.m})
Tightening torque
Cylinder head
Clean the underside of the cylinder head and place it
slowly on the gasket.
Apply "molybdenum disulfide" to the seat and threads
of the head bolts and tighten them spirally, starting
with the central one, as shown in the figure.
Use the 6 shorter bolts on the nozzle side.
Do not use the head bolts more than 2 times.
Tightening torque of head bolt
(N.m {kgf.m})
Tightening
Loosen
69 {7.0} o
o 88 {9.0} o 90 120
torque
all bolts
2-51
ENGINE ASSEMBLY
Push rod
Insert each push rod and hit it lightly with a plastic
hammer to bring the tappet in contact with the cam
surface of the camshaft.
25 35 {2.6 3.6}
2-52
21 30 {2.1 3.1}
ENGINE ASSEMBLY
EXTERIOR PARTS
2-53
ENGINE ASSEMBLY
Nozzle holder
(N.m {kgf.m})
Tightening torque
17 21 {1.7 2.1}
Glow plug
Connector
(N.m {kgf.m})
Tightening torque (Glow plug)
20 25 {2.0 2.5}
Fuel piping
1. Install the injection pipe and secure it with the
clip.
(N.m {kgf.m})
Tightening torque
29 {3.0}
20 25 {2.0 2.5}
10 15 {1.0 1.5}
2-54
ENGINE ASSEMBLY
Turbocharger
Fit the gasket with the folded side up and install the
turbocharger.
At this time apply seizure prevention compound to
the mounting nuts.
Since heat-resistant nuts are used, do not replace
them with other ones.
(N.m {kgf.m})
Tightening torque
52 {5.3}
25 {2.6}
21 {2.1}
Return pipe
37 {3.8}
21 {2.1}
Water pump
(N.m {kgf.m})
Tightening torque
42 62 {4.3 6.3}
Fan pulley
Fan belt
Fan
2-55
ENGINE ASSEMBLY
Generator
For adjustment of the fan belt tension, see the section
of the fan belt (page 1-25).
Starting motor
(N.m {kgf.m})
Tightening torque
75 91 {7.6 9.3}
2-56
LUBRICATING SYSTEM
3 LUBRICATING SYSTEM
Page
Lubricating oil circulation system diagram ...................................................................................................... 3-2
Oil pump .......................................................................................................................................................... 3-3
Disassembly .............................................................................................................................................. 3-3
Inspecting .................................................................................................................................................. 3-4
Assembly ................................................................................................................................................... 3-6
Oil relief valve .................................................................................................................................................. 3-8
Removing and installing the oil relief valve .............................................................................................. 3-8
Inspecting .................................................................................................................................................. 3-8
3-1
LUBRICATING SYSTEM
3-2
LUBRICATING SYSTEM
OIL PUMP
DISASSEMBLY
Disassembly procedure
1. Oil pump body
2. Drive shaft and gear
3. Driven gear
4. Split pin and spring seat
5. Relief valve spring
6. Relief valve
7. Oil pump cover
3-3
LUBRICATING SYSTEM
INSPECTING
Clearance between gear and inside wall
Using a feeler gauge, measure the clearance between
the gear and cover inside wall.
If the clearance between the gear and cover inside
wall exceeds the limit, replace the gear or cover
assembly.
Clearance between gear and cover inside wall
(mm)
Standard
Limit
0.075 0.150
0.2
Limit
0.040 0.094
0.15
Limit
16
15.9
3-4
Standard
Limit
0.032 0.070
0.15
LUBRICATING SYSTEM
Clearance between driven gear shaft and gear
1. Using a micrometer, measure the outside
diameter of the drive gear shaft.
Outside diameter of driven gear shaft
(mm)
Standard
Limit
15.956 15.974
15.9
Limit
0.045 0.078
0.15
3-5
LUBRICATING SYSTEM
ASSEMBLY
Assembly procedure
1. Oil pump cover
2. Relief valve
3. Relief valve spring
4. Split in and spring seat
5. Driven gear
6. Drive shaft and gear
7. Oil pump body
3-6
LUBRICATING SYSTEM
Driven gear
Drive shaft and gear
1. Apply engine oil to the driven gear and shaft.
2. Apply engine oil to the drive shaft and gear and
install them to the pump body.
3. Install the pump cover to the pump body and
secure them with the bolts.
(N.m {kgf.m})
Tightening torque
10 16 {1.0 1.6}
3-7
LUBRICATING SYSTEM
21 30 {2.1 3.1}
INSPECTING
Relief valve and spring
Press the relief valve with a screwdriver, etc. to check
for fixing. If it is fixed, replace it.
Breathe into the relief valve to check for air leakage.
If air leaks through the relief valve, replace the relief
valve.
3-8
COOLING SYSTEM
4 COOLING SYSTEM
Page
Cooling water circulating system ..................................................................................................................... 4-2
Water pump ..................................................................................................................................................... 4-3
Component parts ....................................................................................................................................... 4-3
Disassembly .............................................................................................................................................. 4-4
Assembly ................................................................................................................................................... 4-6
Inspecting .................................................................................................................................................. 4-8
Thermostat ....................................................................................................................................................... 4-9
Inspecting and replacing ........................................................................................................................... 4-9
4-1
COOLING SYSTEM
4-2
COOLING SYSTEM
WATER PUMP
COMPONENT PARTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Cover
Packing
Screw
Seal unit
Impeller
Shaft
Ball bearing: Rear
Ball bearing: Front
Snap ring (Clip)
10.
11.
12.
13.
14.
15.
16.
Snap ring
Fan center
Spacer
Dust cover
Spacer (Washer)
Seal: Secondary (Oil seal)
Pump body
4-3
COOLING SYSTEM
DISASSEMBLY
Rear cover
Remove the rear cover and packing.
Fan center
Remove the fan center.
Snap ring
Remove the dust cover and the snap ring on the fan
center side.
Impeller
Using the special tool (remover), pull out the impeller.
Special tool: Water pump impeller remover
9-8521-0097-0
Note: Never pull out the impeller by giving impacts
with a hammer, etc.
4-4
COOLING SYSTEM
Shaft and bearing
Using a press, push out the shaft and bearing
together from the impeller side.
4-5
COOLING SYSTEM
ASSEMBLY
Note: Since the fan center and impeller are press fitted to the shaft, they are loosened if they are
removed and installed repeatedly.
Accordingly, if they have been removed 2 times or their press fitting load is less than 5.9 kN
{600 kgf}, replace the water pump assembly.
Oil seal
Apply bearing grease (NIHON KOYU, HILEX NO. 3
GREASE) to the lip of the oil seal. Then, using a
press, install the oil seal to the pump body.
Note: Do not reuse the oil seal. Install the new oil
seal by using the jig.
Rear bearing
Install the washer to the shaft, and then press fit the
rear bearing to the shaft with the seal side toward
the impeller.
Note: Hold the inner race or both inner race and
outer race of the bearing.
Shaft
Press fit the shaft to the pump body.
At this time, press the outer race of the bearing with
the special tool (setting tool).
Special tool: Water pump bearing setting tool
9-8522-1140-0
Press fit the shaft until the bearing reaches the pump
body. Before press fitting, fill the space between the
inner race and outer race of the bearing with bearing
grease (NIHON KOYU, HILEX NO. 3 GREASE).
Note: The bearing may be reused only when it has
little play and rotates smoothly.
4-6
COOLING SYSTEM
Spacer
Install the spacer to the shaft and supply sufficient
bearing grease to the spaces between the bearing
and body and shaft.
(g)
Quantity of grease
Approx. 28
Front bearing
Press fit the front bearing.
Direct the seal side toward the center. Hold both of
the shaft and pump body so that the shaft will not go
through down and the bearing will not be broken and
press fit the bearing until it reaches the spacer.
Use the jig to push the inner race and outer race
simultaneously.
Dust cover
Install the slip ring and dust cover.
Fan center
Press fit the fan center. Hold only the shaft so that it
will not go through and the bearing will not be broken
and press fit the fan center until it reaches the dust
cover.
Seal unit
Install the seal unit to the pump body.
Note: Fix the pump body and press fit the seal unit
with the jig. Do not reuse the seal unit.
4-7
COOLING SYSTEM
Floating seat (Seal unit)
Press fit the floating seal side of the seal unit to the
impeller.
Note: Limit leaning of the floating seal to 0.1 mm.
Impeller
While press fitting the impeller, adjust the clearance
between it and the pump body to the standard range.
At this time, put a liner to the shaft on the fan center
side so that the snap ring will not be broken.
Clearance between impeller and body
(mm)
Standard
0.3 1.0
Cover
Install the packing and cover with the screws.
INSPECTING
Turn the pump with the hand and check that it rotates
smoothly.
4-8
COOLING SYSTEM
THERMOSTAT
INSPECTING AND REPLACING
82 2 C
Valve lift
4-9
FUEL SYSTEM
5 FUEL SYSTEM
Page
Fuel circulation system diagram ...................................................................................................................... 5-2
Nozzle holder assembly ................................................................................................................................... 5-3
Nozzle assembly .............................................................................................................................................. 5-3
5-1
FUEL SYSTEM
5-2
FUEL SYSTEM
NOZZLE ASSEMBLY
Inspection and replacement
Put the removed nozzle into clean light oil and
separate the needle valve from the nozzle body to
clean them. Check to see if the valve moves lightly
through the needle body. If the valve does not move
smoothly, remedy or replace the defective part.
Adjustment
Refer to INSPECTION AND MAINTENANCE for
the injection pressure adjustments and spray
conditions.
(Page 1 - 25)
5-3
AIR COMPRESSOR
6 AIR COMPRESSOR
Page
Outline .............................................................................................................................................................. 6-2
Sectional view ............................................................................................................................................ 6-2
Disassembly ..................................................................................................................................................... 6-3
Inspecting and repairing .................................................................................................................................. 6-4
Assembly .......................................................................................................................................................... 6-6
6-1
AIR COMPRESSOR
OUTLINE
SECTIONAL VIEW
Main specifications
Piston ring
Delivery
Bore x Stroke
Max. speed
Revolution ratio (to crankshaft)
Weight
6-2
mm
rpm
kg
3-piece unit
0.155 L/rev {155 cc/rev.}
70 X 40
1,650
0.5
7.0
AIR COMPRESSOR
DISASSEMBLY
Disassembly procedure
1. Cylinder head and gasket
e2. Cylinder body
3. Piston
4. Bearing cover
5. Bearing
6. Connecting rod
7. Crankshaft
Important work
2. Cylinder body
1) Remove the cylinder mounting bolts.
2) Lightly hitting the cylinder, remove it from the
crankcase.
6-3
AIR COMPRESSOR
Limit
0 0.03
0.2
Limit
0.10 0.30
1.0
Limit
0.025 0.050
0.15
6-4
(mm)
Standard
Limit
0.10 0.30
1.0
AIR COMPRESSOR
Piston pin and connecting rod
1. Measure the clearance between the piston pin
and piston pin hole.
Clearance between piston pin and piston pin hole
(mm)
Standard
Limit
0.002 0.023
0.04
Limit
0.002 0.026
0.1
Limit
0.02 0.06
0.15
6-5
AIR COMPRESSOR
ASSEMBLY
Disassembly procedure
e1. Crankshaft and bearing
e2. Connecting rod
3. Bearing
e4. Bearing cover
6-6
5. Piston
e6. Cylinder body
e7. Cylinder head and gasket
AIR COMPRESSOR
Important work
1. Crankshaft, bearing, and spacer
Using a copper hammer, install the bearing and
spacer to the crankshaft.
2. Connecting rod
(1) Apply engine oil to the bearing.
(2) Install the connecting rod and bearing cap.
(3) Tighten the connecting rod bearing cap bolts
to the specified torque.
Bearing cap bolt
(N.m {kgf.m})
Tightening torque
23 26 {2.3 2.7}
4. Bearing cover
Install the bearing cover to the crankcase and
tighten the mounting bolts to the specified torque.
Bearing cover mounting bolt
(N.m {kgf.m})
Tightening torque
5.9 {0.6}
6-7
AIR COMPRESSOR
5. Piston rings
(1) Using the piston ring replacer, install the
piston rings.
(2) Direct the abutment joints of the piston rings
as shown in the figure.
Front mark
No. 1 compression ring
No. 2 compression ring
Oil ring with expander (Upper)
Oil ring with expander (Upper)
Oil ring (Upper) rail
(3) Apply engine oil to the surfaces.
7. Cylinder body
(1) Apply engine oil to the O-ring and install it to
the cylinder body.
Take care not to twist the O-ring.
(2) Install the cylinder body to the crankcase
and tighten the mounting bolts to the specified
torque.
Cylinder body bolt
(N.m {kgf.m})
Tightening torque
27 31 {2.8 3.2}
8. Cylinder head
(1) Install cylinder head
and tighten the
mounting bolts to the specified torque.
(2) Tighten unloader valve
to the specified
torque.
Tightening torque of mounting bolt and valve
(N.m {kgf.m})
6-8
27 31 {2.8 3.2}
Unloader valve
44 54 {4.5 5.5}
FLYWHEEL P.T.O.
7 FLYWHEEL, P.T.O.
Page
Component parts ............................................................................................................................................. 7-2
Disassembly ..................................................................................................................................................... 7-3
Inspection and measurement .......................................................................................................................... 7-6
Assembly .......................................................................................................................................................... 7-9
7-1
FLYWHEEL P.T.O.
COMPONENT PARTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
7-2
Bearing case
Packing
Oil seal
P.T.O. gear
P.T.O. shaft
Bearing
Nut
Lock washer
P.T.O. flange
Packing
Oil thrower
Washer
Nut
Split pin
Spacer
Shim
Idle gear
Bearing
Outer spacer
Inner spacer
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Cover
Packing
Spindle
Bolt
Nut
Lock washer
Bolt
Spring washer
Plain washer
Bolt
Spring washer
Plain washer
Clip; Oil pipe
Bolt
Nut
Spring washer
Spacer
FLYWHEEL P.T.O.
DISASSEMBLY
The following disassembly and assembly drawings show Model DH100 engine. The shapes of some parts of
other models are different from those in these drawings.
Removing the P.T.O. gear assembly
1. Remove the P.T.O. gear assembly from the
flywheel housing.
Remove the oil pipe for lubrication of the P.T.O.
gear in advance.
7-3
FLYWHEEL P.T.O.
Disassembling the P.T.O. gear assembly
1. Removing the flange mounting nut
Grip the P.T.O. fixing nut in a vise and remove
the split pin and flange mounting nut. Then,
remove the flange, bearing (outer), bearing case,
etc.
7-4
FLYWHEEL P.T.O.
4) Insert a proper rod in the 17 hole from
which the bolt was removed and move it up,
down, to the right, and to the left to remove
the spindle.
At this time, the tapered roller bearing (outer)
is removed, too.
7-5
FLYWHEEL P.T.O.
Assembly standard
Limit
0.10
0.2
7-6
FLYWHEEL P.T.O.
3. Select one from 23 spacers prepared at intervals
of 0.07 mm so that t1 - t2 will be 0 - 0.07 mm.
Bearing spacer
(mm)
Part No.
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
38226
022
023
024
025
026
027
028
029
030
031
032
033
034
035
036
037
038
039
040
041
042
043
044
Thickness
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
9.28
9.21
9.14
9.07
9.00
8.93
8.86
8.79
8.72
8.65
8.58
8.51
8.44
8.37
8.30
8.23
8.16
8.09
8.02
7.95
7.88
7.81
7.74
7-7
FLYWHEEL P.T.O.
Selecting P.T.O. gear bearing shim
Similarly to "Selecting the idle gear bearing spacer"
explained above, select the P.T.O. gear bearing shim.
Select 3 shims, however, so that t2 - t2 will be 0.01
- 0.07 mm.
Bearing shims
(mm)
Part No.
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
7-8
41229
41229
41229
41229
41229
41229
41229
41229
41229
41229
41229
38226
38226
38226
38226
38226
38226
38226
324
325
326
327
328
329
330
331
332
333
334
045
046
047
048
049
050
051
Thickness
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3.50
3.51
3.52
3.53
3.54
3.55
3.56
3.57
3.58
3.59
3.60
17.95
18.20
18.45
18.70
18.95
19.20
19.45
FLYWHEEL P.T.O.
ASSEMBLY
Assembling the P.T.O. gear
1. Install the P.T.O. gear and lock washer to the
P.T.O. shaft and tighten the nut.
(N.m {kgf.m})
Tightening torque
294 {30.0}
7-9
FLYWHEEL P.T.O.
Installing the flywheel to the P.T.O.
1. Assembling the crankshaft gear
1) Match the dowel pin at the rear end of the
crankshaft to the dowel pin hole of the
crankshaft gear and drive the crankshaft gear
with a copper hammer.
7-10
FLYWHEEL P.T.O.
3. Installing the P.T.O. gear
Install the P.T.O. gear assembly assembled in
the previous section to the flywheel.
4. Installing the flywheel
Apply engine oil to the flywheel and install it.
(N.m {kgf.m})
Tightening torque
7-11
TROUBLESHOOTING
8 TROUBLESHOOTING
Page
Engine fails to start ........................................................................................................................................ 8- 2
Engine fails to run smoothly .......................................................................................................................... 8- 3
Engine lacks power ....................................................................................................................................... 8- 4
Engine knocks ............................................................................................................................................... 8- 6
Smoky exhaust .............................................................................................................................................. 8- 7
Excessive oil consumption ............................................................................................................................ 8- 8
Excessive fuel consumption .......................................................................................................................... 8- 9
Low oil pressure ............................................................................................................................................ 8-10
Run-down battery ........................................................................................................................................... 8-11
Engine does not start .................................................................................................................................... 8-12
8-1
TROUBLESHOOTING
8-2
TROUBLESHOOTING
8-3
TROUBLESHOOTING
8-4
TROUBLESHOOTING
8-5
TROUBLESHOOTING
ENGINE KNOCKS
8-6
TROUBLESHOOTING
SMOKY EXHAUST
8-7
TROUBLESHOOTING
8-8
TROUBLESHOOTING
8-9
TROUBLESHOOTING
8-10
TROUBLESHOOTING
RUN-DOWN BATTERY
8-11
TROUBLESHOOTING
Crankshaft revolves
OK
Check battery charge level
and check battery terminals
for disconnection and
corrosion
OK
Same as *1
Charge or replace battery
Repair battery terminals
OK
Viscosity is improper
(Replace engine oil)
OK
OK
OK
8-12
OK
OK
SPECIAL TOOLS
9 SPECIAL TOOLS
Page
Special tool list ................................................................................................................................................. 9-2
9-1
SPECIAL TOOLS
Outside view
Part No.
Part name
Page
9 8511 3703 0
1-24
5 85317 001 0
1-24
2-12
1 85235 006 0
Removing and installing split collar
2-38
9 8521 0122 0
2-13
Removing tapered bushing of crank pulley
Camshaft bearing puller and installer
2-17
2-28
2-44
2-18
2-41
2-19
2-36
9 8523 1818 0
1 8522 1025 0
9 8521 0141 0
9 8523 1169 0
5 8523 1004 0
Angle
Removing
cylinder
liner
2-22
5 8522 1018 0
2-22
Installing cylinder liner
Valve guide replacer
11
1 85220 001 0
2-23
Removing and installing valve guide
9-2
SPECIAL TOOLS
No.
Outside view
Part No.
Part name
Page
9 8522 0034 0
2-26
Installing oil seal to timing gear case cover
Valve seal setting tool
12
1 85221 005 0
2-37
Installing valve seal
Crankshaft gear setting tool
13
9 8522 0033 0
2-43
Installing camshaft bearing
Piston setting tool
14
9 8522 1173 0
2-46
Installing piston to cylinder liner
15
5 8840 2360 0
2-17
16
5 8840 9025 0
2-49
9-3
10-1
GENERAL
1. This standard table is applicable to KOMATSU FORKLIFT diesel engine model 6BG1 and 6BG1T.
2. Repair Service Standard includes the Checking Item, Nominal Size, Assembly Standard, Limit, and Repair
Method.
1) Nominal Size specifies the values to be referred to in manufacturing of new engines.
2) Assembly Standard specifies the target values that apply to reconditioned engines and may somewhat
differ from those values of newly assembled engines.
3) Limit specifies the values beyond which any worn parts should not be used continually, but repaired or
replaced.
4) Repair Method gives the points of repair work.
5) Unless otherwise specified, all dimensions are in mm.
3. Definition
1) Wear means a difference between the size of non-worn part (or nominal size if no part remains
without wear) and the size of most worn down part.
2) Uneven wear means a difference between a maximum wear and a minimum wear.
4. When reconditioning an engine as a whole is entrusted to you, first check the engine by bench test or
another suitable means to asscertain which part needs repairing, and proceed to an overhaul of the
restricted, minimum necessary portion of the engine. When reconditioning a part of the engine is requested,
carry out repair work of that part according to this repair service standard.
10-2
Part name
Cylinder block
Engine
10-4
Proper time
for
engine overhaul
Group
0.05 or less
490 {5}
KPa
{kgf/cm2}
0.2
105.2
200 %
100 %
105
140 %
2.5 {26}
Limit
100 %
0.03 0.10
3.0 {31}
mm
mm
mm
L/h
Oil consumption,
L/h
MPa
{kg/cm2}
Fuel consumption,
Unit
Checking item
Adequate projection is
indispensable
Repair method
Difference in projection
between adjacent liners shall
not exceed 0.03. (0.0012)
0.001 0.019
(Reference)
Interface of liner to cylinder:
Remarks
Engine
Part name
Cylinder head
Piston
Group
69 (7.0)
O
(Loosen all)
O
88 (9.0)
O
90 120
Wear of pin
mm
mm
mm
Nm
Cylinder head bolt tightening
torque,
(angular method) {kgfm}
35
490 {5}
KPa
{kgf/cm2}
0.05 or less
0.005 0.018
Clearance at major
axis 0.047 0.085
34.95
0.05
0.4
Replace piston.
Correct.
mm
0.2
0.05 or less
mm
2.0
1.5
mm
Remarks
Repair method
Limit
2.5
1.0
Unit
mm
Checking item
10-5
Part name
Piston rings
Group
10-6
N {kgf}
mm
0.05 0.09
0.03 0.07
Oil ring
0.07 0.11
2nd pressure
ring
3rd pressure
ring
0.15
0.15
0.15
31 {3.2}
36.3 55.9
{3.7 5.7}
1st pressure
ring
Oil ring
4.9 {0.5}
14.1 21.2
{1.44 2.16}
14.1 21.2
{1.44 2.16}
2nd pressure
ring
3rd pressure
ring
4.9 {0.5}
20.4 30.6
{2.08 3.12}
1st pressure
ring
N
{kgf}
9.8 {1.0}
0.30 0.50
Oil ring
1.5
0.60 0.75
mm
Limit
3rd pressure
ring
Clearance between
piston ring groove
and ring
Tension
0.60 0.75
No. 2
compression
Unit
No. 1
compression
Checking item
Remarks
Replace.
Replace.
Repair method
Part name
Connecting rod
Group
192
Repair method
39 o 60 90
{4.0}
mm
Nm
{kgfm}
20 or less
mm
0.05 or less
0.05 or less
mm
0.17 0.30
mm
0.2
0.2
0.35
0.05
Repair or replace.
Repair or replace.
Repair or replace.
0.012 0.025
0.030 0.073
mm
Replace bearing.
0.1
Limit
1.5
mm
Unit
Checking item
4.9kN {500kgf}
Projection: 0.043 0.068
Remarks
10-7
Part name
Crankshaft
Group
10-8
mm
mm
Crankshaft runout
Nm
{kgfm}
g-cm
Crankshaft balance
Ring gear
mm
64
mm
Wear of pins
Journal bearings
80
mm
Wear of journals
80
64
mm
0.4
0.05 or less
226 245
{23.0 25.0}
36 or less
0.4
0.11
0.05
Limit
0.15 0.33
No.4
0.039 0.098
Other than # 4
0.025 0.084
63.924 63.944
79.919 79.939
* No.4 journal
79.905 79.925
Unit
Checking item
(Reference value)
At both ends.
If turbocharger is installed, do
not polish.
Remarks
Replace.
Replace bearing.
Replace.
Repair method
Valve-train mechanism
Part name
Camshaft
Timing gear
Group
mm
mm
Wear of journal
mm
mm
mm
mm
mm
mm
mm
mm
Unit
Checking item
45
56
0.128 0.185
0.025 0.085
0.021 or less
0.021 or less
0.10 0.17
0.050 0.114
0.2
44.9
0.2
0.3
0.2
7.21
55.6
55.94 55.97
7.71
0.15
0.05
Limit
0.03 0.09
Replace gear.
If damaged excessively,
replace camshaft.
Replace camshaft.
Replace camshaft.
Replace bearing.
Repair method
Remarks
10-9
10-10
Part name
mm
mm
mm
mm
mm
mm
mm
mm
Valve margin
Squareness
Free height
Blue
Pink
mm
mm
Tension
N {kgf}
(When installed and compressed)
Unit
Checking item
Valve spring
Valves
Group
8.5
14.1
1.5
1.9 or less
2.7
58.0
53.0
55.0
60.6
127 {13.0}
8.8
1.0
0.25
0.20
8.88
8.88
Limit
142 {14.5}
0.024
0.064 0.096
0.039 0.068
Replace valve.
Replace valve.
Repair method
Reference value
Remarks
Valve-train mechanism
Valve-train mechanism
Intake system
Part name
Valve
Tappet
Air creaner
Group
mm
28
mm
mm
27.92
0.1
0.3
(Reference)
Length of push rod: 301 mm
Remarks
Replace tappet.
Replace tappet.
Replace.
Replace.
18.85
mm
19
0.2
Adjust.
Repair method
mm
0.01 0.05
Limit
0.4
mm
Unit
Checking item
10-11
Lubricating system
Oil
pressure
Part name
mm
mm
mm
Oil pump
KPa
{kgf/cm2}
mm
Oil gallery
L/min
Delivery flow,
(1650 rpm, SAE #30, delivery pressure
392 KPa {4 kg/cm2}, oil temp 50C)
mm
KPa
{kgf/cm2}
Unit
Checking item
Oil filter
10-12
Oil cooler
Group
16
196 {2.0}
785 {8}
441 {4.5}
0.045 0.078
0.032 0.070
0.040 0.094
53.3
0.075 0.150
15.9
0.15
0.15
0.15
0.2
Limit
Replace.
Replace shaft.
Replace bushing.
Repair method
Replacement interval of
cartridge: 500 hours
Reference value
Remarks
Part name
Water pump
Group
mm
mm
mm
mm
mm
L/min
mm
Unit
Deflection of
fan belt
Delivery flow,
(3720 rpm, normal water temp, total lift
13.5 mm)
Checking item
#6204 V
0.14 or less
A temperature at which
thermostat lift is 10 mm or
more.
Adjust.
Repair method
0.2
Limit
0.07 0.11
95
82 2
Approx. 7 10
0.3 1.0
300
0.008 0.01
If malfunctioning, replace
thermostat.
(Reference)
10 kg/belt (22 lb) [98 N]
Remarks
10-13
Cooling system
Fuel system
Part name
Piping, ets.
Injection pump
10-14
Air tightness,
[Air pressure: 196 kPa {2.0 kgf/cm2}]
Sucking capacity:
Hand pumping speed 60 100 st./min;
head 1 m; pipe ID 8 mm x length 2 m
cc
405 or more
Sucking to be
completed by
within 25 times
of pumping.
Limit
Repair method
300
or less
Repair or replace.
120 times
or more Repair or replace.
Replace.
Unit
Repair or replace.
Checking item
Delivery valve
Group
Cartridge type
Remarks
Part name
Injection pump
Group
Limit
Repair method
Remarks
Adjustment condition
Standard
Lever
Rack
Lever
14
89 1.5
9 1.3
150 5
1,075
450
100
10.3
7.5
Rack limit
Remarks
Fixing method
Variance
(%)
Pump speed
(rpm)
Rack position
(mm)
40 5
Fuel temperature
Adjustment point
mm
Test fuel
6 x 2.0 x 600
157 {1.6}
MPa {kgf/cm2}
17.2 {175}
MPa {kgf/cm2}
Pipe
Outside diameter x Inside diameter x Length
105780 8140
115603 3280
Unit
105780 0000
Nozzle No.
Turning direction
Adjustment item
The following are examples of adjustment values of the injection rate. For the adjustment values of each injection pump, see the data supplied by ZEXEL.
Checking item
10-15
Fuel equipment
Part name
Injection pump
Group
10-16
Nominal size Assembly standard
Checking item
Limit
Remarks
Max. 13
Max. 16
Max. 20
1350
1230
Notch limit
1450
Target notch: 9
Remarks
Repair method
Fuel equipment
Fuel equipment
Electrical system
Part name
Injection nozzle
Charge
indicator
Wiring
AC generator
Limit
Repair method
0.06 or less
0.1
Loose bearing
50
Replace bearing.
Replace rotor.
Correct.
Bent shaft
If abnormality is found at
ordinary engine speeds,
correct electrical system.
mm
Replace.
Unit
If fuel leaks through seat,
repair or replace.
Checking item
Rotor
Performance
Group
Remarks
10-17
Preheating
system
Starting motor
Electrical system
Part name
10-18
Battery
Group
mm
mm
mm
mm
min-1
Hear side
(Armature)
Front side
(Armature)
Pinion shaft
(Shaft)
No-load
characteristics
(Max. 24 V,
100 A)
mm
Outer
diameter
Depth of
undercut
Cloudy electrolyte
Battery terminal
mm
Unit
Resistance of
series coil
Resistance of
shaft coil
Performance
Ball bearing
Commulator
Magnetic switch
Brush length
Loose fitting
Checking item
16
3,500
Replace if disconnection or
short-circuit is found.
6905D
Correct.
Replace armature.
Replace.
16 (Outside
diameter of
bearing)
0.2
Repair method
Correct.
6001D
0.5 0.8
36.5
10
Limit
28 (Outside
diameter of
bearing)
37
18
Remarks
Part name
Battery
Group
Electrical equipment
Completion inspection
290 590
{3 6}
85 or more
110 or less
KPa
{kgf/cm2}
KPa
{kgf/cm2}
%
Output inspection
3.0 {31}
MPa
{kgf/cm2}
Unit
Electrolyte level
Terminal voltage
Checking item
Repair method
200
{2.0}
Adjust.
Correct.
Limit
Remarks
10-19
6BG1T-BE2
6BG1T-BE2
SHOP MANUAL
6BG1, 6BG1T ENGINE
SERIAL No.
5001 and up
2001 and up
2301 and up
1001 and up
BE
00-1