Komatsu GD610 Series Install guide

SEBMG6150109
© 2011 7
All Rights Reserved
Printed in Japan 08-11(01) 00-1
o
GD663A-2 1001 and up
For GD663A-2, see pages prepared for GD623A-1 except two descriptions below.
1) Front axle (page 41-9) 1. Steering cylinder has both types of single cylinder and dual cylinder.
2) For rear mount ripper, see page 74-9.
~IBI@JF
KOMA1sU
GD610,
GD620
SERIES
GD660,
GD670
SERIES
MACHINE SERIAL No. COMPONENT MACHINE SERIAL No. COMPONENT
MODEL
TYPE
MODEL
TYPE
GD621A-1 10001
and
up
A GD621
R-1
10001 and
up
K
GD622A-1 20001
and
up
B GD623R-1 30001 and up L
GD623A-1 30001
and
up
C GD611R-1 10001 and up
M
GD625A-1 50001
and
up
D GD613R-1 30001 and up N
GD672A-1 20001 and
up
E GD615A-1 50001 and up p
GD611A-1 10001
and
up
F GD625A-1C 60001 and up
a
GD613A-1 30001
and
up
G GD625A-1A 60001 and
up}
See
table
of
GD661A-1 10001
and
up
H applicable
GD625A-1 B 65001 and up components.
GD663A-1 30001
andup
J
•
This
shop
manual
may
contain
attachments
and
optional
equipment
that
are
not
available
in
your
area. Please
consult
your
local
Komatsu
distributor
for
those
items
you
may
require.
Materials
and
specifications
are
subject
to
change
without
notice.
• GD621A, 611A, 661A,
621R,
623R, 611R,
613R-1
mount
the S6D105-1 engine;
•
GD622A, 623A, 625A, 672A, 613A, 663A, 625A-1C, 625A-1A
mount
the 6D125-1 engine;
GD615A-1
mount
the S6D110-1 engine.
For details
of
the engines,
see
the
105
Series Shop Manual, 110 Series Shop Manual
and 6D125 Series Shop Manual.

CONTENTS
No. of page
10 ENGINE
12 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 -1
22 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
23 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
24 MAINTENANCE STANDA RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
40 STEERING SYSTEM
41 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 -1
42 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1
43 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-1
44 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44- 1
50 BRAKE SYSTEM
51 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 -1
52 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-1
53 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-1
54 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-1
60 HYDRAULIC SYSTEM
61 STRUCTUREANDFUNCTION .................................................... 61-1
62 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-1
63 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-1
64 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-1
70 WORK EQUIPMENT
71 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 -1
72 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-1
73 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-1
74 MAINTENANCE STANDA
RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-1
80 ELECTRIC AND ELECTRONIC SYSTEM
81 STRUCTURE AND FUNCTION .................................................... 81-1
82 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-1
90 OTHERS ................................................... .. ................... 90-1
AIR
CONDITIONER.................................................................. 90-2
00-2
®
GD610, 620
GD660, 670
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GD660, 670
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82-61
®
82-101
82-62
®
82-102
82-63
®
82-103
82-64
®
82-104
82-65
®
82-66
®
90- 1
82-67
® 90- 2
82-68
®
90- 3
82-69
®
90- 4
82-70 ®
90- 5
82-71
®
82-72
®
82-73
®
82-74
®
82-75
CID
82-76
®
82-77
®
82-78
®
82-79
®
82-80
®
82-81 ®
82-82
,3)
Time
of
revision
®
®
®
®
®
®
®
®
®
®
®
®
®
@
®
@
@
@
@
@
@
®
®
®
®
®
®
Mark
Page
Time
of
revision
GD610, 620
GD660, 670
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SAFETY
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
SAFETY NOTICE
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.
To prevent
injury
to
workers,
the
symbol
A
is used
to
mark
safety precautions in
this
manual. The cautions accompanying these symbols should always be
followed
care-
fully.
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 grind-
ing 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, al-
ways
wear
welding
gloves,
apron,
hand
shield, cap and other clothes suited
for
weld-
ing work.
4.
When carrying
out
any operation
with
two
or
more workers, always agree on the oper-
ating procedure before starting. Always in-
form
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.
6.
Decide a place in the repair
workshop
to
keep
tools
and removed parts.
Always
keep
the
tools
and parts in
their
correct places.
Always
keep the
work
area clean and make
sure
that
there is no
dirt
or
oil on
the
floor.
Smoke
only
in the areas provided
for
smok-
ing. Never smoke
while
working.
PREPARATIONS FOR WORK
7.
Before adding oil
or
making any repairs,
park the machine on hard, level
ground,
and
block the wheels
or
tracks
to
prevent
the
machine
from
moving.
8.
Before starting work,
lower
blade, ripper,
bucket
or
any other
work
equipment
to
the
ground.
If
this is
not
possible, insert the
safety pin
or
use blocks
to
prevent
the
work
equipment
from
falling. In addition, be sure
to
lock all the control levers and hang
warn-
ing signs on them.
9.
When disassembling
or
assembling,
support
the machine
with
blocks, jacks
or
stands
before starting work.
10. Remove all
mud
and oil
from
the steps
or
other places used
to
get
on and
off
the
ma-
chine.
Always
use
the
handrails, ladders
or
steps
when
getting on
or
off
the machine.
Never
jump
on
or
off
the machine. If
it
is
impossible
to
use
the
handrails, ladders
or
steps, use a stand
to
provide safe
footing.
00-3
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SAFETY
PRECAUTIONS DURING WORK
11.
When
removing
the oil
filler
cap, drain plug
or
hydraulic
pressure
measuring
plugs,
loosen
them
slowly
to
prevent the oil
from
spurting
out.
Before disconnecting
or
removing
compo-
nents
of
the
oil,
water
or
air
circuits,
first
remove
the
pressure
completely
from
the
circuit.
12. The
water
and oil in the circuits are
hot
when
the engine is stopped, so be careful
not
to
get
burned.
Wait
for
the oil and
water
to
cool before
carrying
out
any
work
on
the
oil
or
water
circuits.
13. Before starting work, remove the leads
from
the
battery.
Always
remove
the
lead
from
the
negative
(-)
terminal
first.
14.
When
raising heavy components, use a
hoist
or
crane.
Check
that
the
wire
rope, chains and hooks
are free
from
damage.
Always
use
lifting
equipment
which
has
ample
capacity.
Install the
lifting
equipment
at
the
correct
places. Use a
hoist
or
crane and operate
slowly
to
prevent
the
component
from
hit-
ting
any
other
part. Do
not
work
with
any
part
still raised
by
the
hoist
or
crane.
15.
When
removing
covers
which
are
under
in-
ternal pressure
or
under
pressure
from
a
spring, always leave
two
bolts in
position
on opposite sides.
Slowly
release
the
pres-
sure, then
slowly
loosen the bolts
to
remove.
16.
When
removing
components, be careful
not
to
break
or
damage the
wiring.
Damaged
wiring
may
cause electrical fires.
17.
When
removing
piping,
stop
the
fuel
or
oil
from
spilling
out.
If
any
fuel
or
oil drips
onto
the
floor,
wipe
it
up
immediately. Fuel
or
oil
on
the
floor
can cause
you
to
slip,
or
can
even start fires.
18. As a general rule,
do
not
use gasoline
to
wash
parts. In particular, use
only
the
mini-
mum
of
gasoline
when
washing
electrical
parts.
00-4
SAFETY NOTICE
19.
Be
sure
to
assemble all parts again in
their
original places.
Replace any damaged parts
with
new
parts.
• When installing hoses and wires, be sure
that
they
will
not
be damaged
by
contact
with
other
parts when the machine is be-
ing operated.
20. When installing high pressure hoses, make
sure
that
they
are
not
twisted. Damaged
tubes are dangerous, so be extremely care-
ful
when
installing tubes
for
high pressure
circuits. Also, check
that
connecting parts
are correctly installed.
21. When assembling
or
installing parts, always
use
the
specified
tightening
torques. When
installing protective parts such
as
guards,
or
parts
which
vibrate
violently
or
rotate at
high speed, be particularly careful
to
check
that
they
are installed correctly.
22.
When aligning
two
holes, never insert
your
fingers
or
hand.
Be
careful
not
to
get
your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that
the measuring
tool
is correctly assem-
bled before taking any measurements.
24. Take care
when
removing
or
installing the
tracks
of
track-type machines.
When
removing
the
track,
the
track sepa-
rates suddenly, so never let anyone stand at
either end
of
the track.
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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 judgements. Make sure
you
understand the contents
of
this
manual and use
it
to
full
effect at every
opportunity.
This shop manual
mainly
contains
the
necessary technical
information
for
operations
performed
in a
service workshop. For ease
of
understanding,
the
manual is divided
into
the
following
chapters; these
chapters are
further
divided
into
the
each
main
group
of
components.
STRUCTURE AND FUNCTION
This section explains
the
structure and
function
of
each component. It serves
not
only
to
give
an
understanding
of
the structure,
but
also serves
as
reference material
for
troubleshooting.
TESTING AND ADJUSTING
This section explains checks
to
be made before and after
performing
repairs,
as
well
as
adjustments
to
be made at
completion
of
the
checks and repairs.
Troubleshooting charts correlating "Problems"
to
"Causes" are also included in
this
section.
DISASSEMBLV AND ASSEMBLV
This section explains the
order
to
be
followed
when
removing,
installing, disassembling
or
assembling each component,
as
well
as
precautions
to
be taken
for
these operations.
MAINTENANCE STANDARD
This section gives the
judgement
standards
when
inspecting disassembled parts.
NOTICE
The
specifications
contained
in
this
shop
manual
are
subject
to
change
at
any
time
and
without
any
advance
notice.
Use
the
specifications
given
in
the
book
with
the
latest
date.
00-5
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FOREWORD
HOW TO
READ
THE
SHOP MANUAL
VOLUMES
Shop
manuals are issued
as
a
guide
to
carrying
out
repairs. They are divided
as
follows:
Chassis volume:
Issued
for
every machine model
Engine volume:
Issued
for
each engine series
Electrical volume:
lEach issued
as
one
Attachments volume:
volume
to
cover all
models
These various
volumes
are designed
to
avoid
duplicating
the
same
information.
Therefore,
to
deal
with
all repairs
for
any
model
,
it
is neces-
sary
that
chassis, engine, electrical and attach-
ment
volumes
be available.
DISTRIBUTION AND UPDATING
Any
additions, amendments
or
other
changes
will
be sent
to
KOMATSU distributors. Get the
most
up-to-date information before
you
start any
work.
FILING METHOD
1. See
the
page
number
on the
bottom
of
the
page. File
the
pages in correct order.
2.
Following
examples
show
how
to
read the
page number.
Example 1 (Chassis volume):
10
-3
4=
Item
number
(10. Structure
and Function)
Consecutive page
number
for
each item.
Example 2 (Engine volume):
12 -5
t
Unit
number
(1.
Engine)
Item
number
(2.
Testing and
Adjusting)
Consecutive page
number
for
each item.
3.
Additional
pages:
Additional
pages are indi-
cated
by
a hyphen (-) and
number
after
the
page
number.
File as in
the
example.
Example:
10-4 12-203
10-4-1
_j-
r--12-203-1
10-4-2 Added pages
-L
12-203-2
10-5 12-204
00-6
HOW TO
READ
THE
SHOP MANUAL
REVISED EDITION MARK
When a
manual
is revised, an
edition
mark
(G)(g)@
....)
is recorded on the
bottom
of
the
pages.
REVISIONS
Revised pages are
shown
in the LIST
OF
RE-
VISED PAGES
next
to
the
CONTENTS page.
SYMBOLS
So
that
the shop manual can be
of
ample prac-
tical use,
important
safety and
quality
portions
are marked
with
the
following
symbols.
Symbol Item
Remarks
•
Special safety precautions are
Safety necessary when
performing
the work.
Special technical precautions
*
or
other
precautions
for
pre-
Caution serving standards are neces-
sary
when
performing
the
work.
Weight
of
parts
of
systems.
~
Caution necessary when se-
Weight
lecting hoisting wire,
or
when
working posture
is
important,
etc.
~
Tightening Places
that
require special at-
tention
for
the
tightening
torque torque
during
assembly.
~
Coat Places
to
be coated
with
ad-
hesives and lubricants, etc.
6w
Places where oil, water
or
fuel
Oil,
water
must
be added, and the ca-
pacity.
•
Places
where
oil
or
water
' • '
Drain
must
be drained, and quan-
tity
to
be drained.
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FOREWORD
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25
kg
or
more)
must
be
lifted
with
a hoist, etc. In the DISAS-
SEMBLY
AND
ASSEMBLV
section,
every
part
weighing
25
kg
or
more
is
indicated clearly
with
the
symbol
~
•
If
a part cannot be
smoothly
removed
from
the machine
by
hoisting, the
following
checks
should be made:
1)
Check
for
removal
of
all bolts fastening
the part
to
the
relative parts.
2)
Check
for
existence
of
another part caus-
ing interference
with
the part
to
be re-
moved.
WIRE
ROPES
1)
Use adequate ropes
depending
on
the
weight
of
parts
to
be hoisted, referring
to
the table below:
Wire
ropes
(Standard "Z"
or
"S"
twist
ropes
without
galvanizing)
Rope diameter
Allowable
load
mm
kN
tons
10
9.8 1.0
11.2 13.7 1.4
12.5 15.7 1.6
14
21.6 2.2
16
27.5 2.8
18
35.3 3.6
20
43.1
4.4
22.4 54.9 5.6
30
98.1
10.0
40
176.5 18.0
50
274.6 28.0
60
392.2 40.0
*
The allowable load value is estimated
to
be one-sixth
or
one-seventh
of
the break-
ing strength
of
the rope used.
2)
Sling
wire
ropes
from
the
middle
portion
of
the hook.
HOISTING INSTRUCTIONS
Slinging
near
the
edge
of
the
hook
may
cause
the
rope
to
slip
off
the
hook
during
hoisting, and a serious accident can re-
sult. Hooks have
maximum
strength at
the
middle
portion.
100% 88% 79% 71%
41%
SAD00479
3)
Do
not
sling a heavy load
with
one rope
alone,
but
sling
with
two
or
more
ropes
symmetrically
wound
onto
the load.
A
Slinging
with
one rope
may
cause
turning
of
the
load
during
hoisting,
untwisting
of
the rope,
or
slipping
of
the
rope
from
its
original
winding
position on the load,
which
can re-
sult
in a dangerous accident.
4)
Do
not
sling a heavy load
with
ropes
form-
ing a
wide
hanging
angle
from
the
hook.
When
hoisting a load
with
two
or
more
ropes, the force subjected
to
each rope
will
increase
with
the hanging angles. The
table
below
shows the variation
of
allow-
able load
kN
{kg}
when
hoisting is made
with
two
ropes, each
of
which
is
allowed
to
sling up
to
9.8
kN
{1000 kg} vertically,
at various hanging angles.
When
two
ropes sling a load vertically, up
to
19.6
kN
{2000 kg}
of
total
weight
can be
suspended. This
weight
becomes 9.8
kN
{1000 kg}
when
two
ropes make a 120°
hanging angle. On
the
other
hand,
two
ropes are subjected
to
an excessive force
as
large
as
39.2
kN
{4000 kg}
if
they
sling
a 19.6
kN
{2000 kg} load at a
lifting
angle
of
:50°.
B
A /\
¢.
~
19.6
□
□
6._
(Kg)
~
(2000)
18.6
16
7
LJ
>,
19.6
(l
9oo)
U
700)
13.7
c::]
-~
(2000)
(1400)
"'
0
9.8
]
(1000)
~
4.9
(500)
30
60
90
120
150
Lifting
angle (degree)
SAD00480
00-7

FOREWORD
COATING MATERIALS
COATING MATERIALS
*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
.Used
to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cock plug
from coming out.
.Used in places requiring an
immediately
20 g Polyethylene effective, strong adhesive. Used
for plas-
LT-18
790-129-9050 tics (except polyethylene, polyprophylene,
(2 pes.) container tetrafluoroethlene and
vinyl chloride), rub-
ber, metal and non-metal.
.Features: Resistance
to heat and chemi-
LT-2
09940-00030
50 g Polyethylene cals
container . Used
for anti-loosening and sealant pur-
pose
for bolts and plugs.
790-129-9060 Adhesive: .Used
as adhesive or sealant for metal, glass
(Set
of adhe- 1
kg
and plastic.
LT-3
sive and Hardening
Can
hardening agent:
agent) 500 g
Adhesives
LT-4
790-129-9040 250 g Polyethylene • Used
as sealant for machined holes.
container
Holtz .Used as heat-resisting sealant
for repair-
MH 705 790-126-9120 75 g Tube ing engine.
.Quick hardening type adhesive
Three
bond
50 g Polyethylene • Cure time:
within 5 sec. to 3 min.
1735 790-129-9140 container .Used
mainly for adhesion of metals, rub-
bers, plastics and
woods.
.Quick hardening
type adhesive
Polyethylene . Quick cure type (max. strength after
30 min-
Aron-alpha 790-129-9130 2 g utes)
201
container . Used
mainly for adhesion of rubbers, plas-
tics and metals.
Loctite . Features: Resistance
to heat, chemicals
79A-129-9110 50 cc Polyethylene • Used at
joint portions subject to high tern-
648-50 container peratures.
.Used
as adhesive or sealant for gaskets
LG-1
790-129-9010 200 g Tube and packing
of power train case, etc.
. Features: Resistance
to heat
.Used
as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant
LG-3 790-129-9070 1
kg
Can
to prevent seizure.
. Used
as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8

FOREWORD
COATING MATERIALS
Category Komatsu code Part No.
O'ty
Container Main applications, features
.
Features: Resistance
to
water, oil
.
Used
as
sealant
for
flange surface, thread.
LG-4
790-129-9020
200 g Tube • Also possible
to
use
as
sealant
for
flanges
with
large clearance.
.
Used
as
sealant
for
mating
surfaces
of
fi-
nal
drive
case, transmission case.
.
Used
as
sealant
for
various threads, pipe
LG-5
790-129-9080
1
kg
Polyethylene joints, flanges.
container
.
Used
as
sealant
for
tapered plugs, elbows,
nipples
of
hydraulic piping.
.
Features: Silicon based, resistance
to
heat,
Gasket cold
sealant LG-6 09940-00011 250 g Tube
.
Used
as
sealant
for
flange surface, tread.
. Used
as
sealant
for
oil pan, final drive case,
etc.
.
Features: Silicon based, quick hardening
type
LG-7
09920-00150 150 g Tube
.
Used
as
sealant
for
flywheel housing, in-
take manifold, oil an,
thermostat
housing,
etc.
Three bond
.
Used
as
heat-resisting sealant
for
repairing
1211
790-129-9090
100
g Tube engine.
. Used
as
lubricant
for
sliding portion (to pre-
Molybde- LM-G
09940-00051
60
g
Can
vent
from
squeaking).
num
disulphide
.
Used
to
prevent seizure
or
scuffling
of
the
lubricant LM-P
09940-00040
200 g Tube thread when press fitting
or
shrink fitting.
.
Used
as
lubricant
for
linkage, bearings, etc.
SYG2-400LI
• General purpose
type
SYG2-350LI
G2-LI
SYG2-400LI-A
Various Various
SYG2-160LI
SYGA-160CNLI .
Used
for
normal temperature,
light
load
Grease
SYG2-400CA
bearing at places in contact
with
water
or
SYG2-350CA
steam.
G2-CA SYG2-400CA-A
Various Various
SYG2-160CA
SYGA-160CNCA
Molybdenum
400
g
.
Used
for
places
with
heavy load
disulphide
SYG2-400M
(10 per Belows type
lubricant case)
00-9

FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS
Use these torques
for
metric bolts and nuts. (Always use
torque
wrench).
Thread diameter
Width
of
bolt
across flats
mm mm
6
10
8
13
10
17
12
19
14
22
16
24
18
27
20 30
22
32
24 36
27
41
30
46
33
50
36
55
39 60
Thread diameter
Width
of
bolt
across flats
mm mm
6
10
8 13
10 14
12
27
TIGHTENING TORQUE
OF
HOSE NUTS
Use these torques
for
hose nuts.
®
Ci)
@
Cl)
8
CDL00372
Nm kgm
13.2±1.4 1.35±0.15
31
±3
3.2±
0.3
66±7
6.7±0.7
113±
10
11.5± 1
177
±
19
18±2
279±30
28.5±3
382±39
39±4
549±
59
56±6
745±83
76±
8.5
927±
103
94.5±
10.5
1320±140
135±
15
1720±190
175±
20
2210±240
225±25
2750±290
280±30
3290±340
335±35
~'"'""
Nm kgm
7.85±
1.95
0.8±0.2
18.6±4.9
1.9±0.5
40.2±5.9
4.1
± 0.6
82.35±7.85
8.4±
0.8
Nominal
No. Thread diameter
Width
across
flat
Tightening torque
mm
02
14
03
18
04
22
05 24
06
30
10
33
12
36
14
42
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques
for
split
flange bolts.
Thread diameter
Width
across
flat
mm mm
10
14
12
17
16 22
00-10
mm
Nm kgm
19
24.5±4.9 2.5±0.5
24
49±
19.6
5±2
27
78.5± 19.6
8±2
32
137.3±29.4
14±3
36 176.5±29.4
18±3
41
196.1±
49
20±5
46 245.2±
49
25±5
55 294.2±
49
30±5
Tightening
torque
Nm
kgm
65.7±6.8
6.7±0.7
112±
9.8 11.5±1
279±
29
28.5±3

FOREWORD
TIGHTENING TORQUE
OF
O-RING BOSS CONNECTOR
Use these torques
for
0-ring
boss connector
Nominal No. Thread diameter
Width
across
flat
mm mm
02 14
03,04
20
Varies depending on
05,06
24
type
of
connector.
10, 12 33
14 42
TIGHTENING TORQUE
OF
O-RING BOSS CONNECTOR
Use these torques
for
0-ring
boss connector
Nominal No. Thread diameter
Width
across
flat
mm
mm
08 8 14
10 10
17
12
12 19
14 14 22
16 16 24
18 18 27
20 20 30
24 24 32
30 30 32
33 33
-
36 36
36
42
42
-
52
52
-
TIGHTENING TORQUES
OF
FLARE
NUT
Use these torques
for
0-ring
boss connector
Thread diameter Width across
flat
mm mm
Nm
14 19
24.5±
4.9
18 24
49±
19.6
22
27
78.5±
19.6
24 32
137.3±29.4
30
36
176.5±29.4
33
41
196.1±49
36 46 245.2± 49
42
55 294.2± 49
STANDARD TIGHTENING TORQUE
Tightening
torque
Nm
kgm
34.3±4.9
3.5±0.5
93.1
±9.8
9.5±
1
142.1 ± 19.6
14.5±2
421.4±58.8
43±6
877.1 ± 132.3
89.5±
13.5
Tightening
torque
Nm
kgm
7.35±
1.47
0.75±0.15
11.27± 1.47
1.15±0.15
17.64± 1.96
1.8±0.2
22.54± 1.96
2.3±
0.2
29.4±
4.9
3±0.5
39.2±
4.9
4±0.5
49±
4.9
5±0.5
68.6±9.8
7±1
107.8± 14.7
11±
1.5
127.4± 19.6
13±
2
151.9±24.5
15.5±2.5
210.7±29.4 21.5± 3
323.4±
44.1
33±
4.5
SAD00483
Tightening
torque
kgm
2.5±0.5
5±2
8±2
14±3
18±3
20±5
25±5
30±5
00-11

FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)
Use these
torques
for
metric
bolts
and
nuts
of
102 Series Engine.
Thread
diameter
mm
6
8
10
12
Nm
10 ± 2
24 ± 4
43 ±
6
77
± 12
Tightening
torque
TIGHTENING TORQUE
FOR
102 SERIES ENGINE
(EVE
JOINTS)
Use these
torques
for
metric
eye
joints
of
102 Series Engine.
Thread
diameter
mm
6
8
10
12
14
Nm
8±2
10 ±
2
12 ± 2
24 ± 4
36
±
5
Tightening
torque
TIGHTENING TORQUE
FOR
102 SERIES ENGINE (TAPERED SCREWS)
Use these
torques
for
inches tapered screws
of
102 Series Engine.
00-12
Thread
diameter
inches
1 / 16
1 / 8
1 / 4
3/8
1 / 2
3/4
1
Nm
3
±
1
8±2
12 ±
2
15 ±
2
24 ± 4
36
±
5
60 ± 9
Tightening
torque
kgm
1.02 ± 0.20
2.45 ± 0.41
4.38 ± 0.61
7.85 ± 1.22
kgm
0.81 ± 0.20
i
.02 ± 0.20
1.22 ± 0.20
2.45 ± 0.41
3.67 ± 0.51
kgm
0.31 ± 0.10
0.81 ± 0.20
1.22 ± 0.20
1.53 ± 0.41
2.45 ± 0.41
3.67 ± 0.51
6.12 ± 0.92

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
Nominal Cable 0.D. Current rating
number
Number of
Dia. of strandsCross section
(mm)
(A)
Applicable circuit
strands
(mm)
(mm
2)
0.85
11
0.32 0.88 2.4
12
Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20
Lighting, signal etc.
5 65 0.32 5.23 4.6 37
Charging and signal
15
84
0.45 13.36 7.0 59
Starting (Glow plug)
40
85
0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230
Starting
CLASSIFICATION BY COLOR AND CODE
~
Prior- C Charging
Ground Starting
Lighting
Instrument
Signal
Other
ity
f
Pri-
Code w B B R y G L
1
mary
Color
White
Black Black Red Yellow Green Blue
Code
WR
-
BW
RW YR GW LW
2
Color
White & Red -Black & White Red & White Yellow & Red
Green & White Blue &
White
-Code
WB
- BY
RB YB GR LR
3
Color
White & Black -
Black & Yellow
Red & Black Yellow & Black Green & Red Blue & Red
-
Auxi-
Code
WL
-
BR
RY VG GY LY
4
liary
Color
White & Blue Black & Red Red &
Yellow Yellow & Green Green & Yellow Blue & Yellow
-
-Code
WG
--
RG YL
GB
LB
5
Color
White & Green
--Red & Green Yellow & Blue Green & Black Blue & Black
-Code ---
RL YW GL -
6
Color
---Red & Blue Yellow &
White
Green & Blue -
00-13

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
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as@, then draw a horizontal
line
from@.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from@.
(3) Take the point where the two lines cross as ©- This point © gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm =21.65 inches.
@
Millimeters to inches 1
mm =0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197! 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 j 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984! 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378! 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772\ 1.811 1.850 1.890 1.929
© i
50 1.969 2.008 2.047 2.087 2.126 12.1651 2.205 2.244 2.283 2.323
............... ............. ............. .............. . ............. . .............
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-14

FOREWORD
CONVERSION TABLE
Millimeters
to
Inches
1
mm
=
0.03937
in
~
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30
1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1
kg
=
2.2046 lb
~
0
1
2
3
4
5 6 7
8
9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10
22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30
66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-15

FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1
f. =0.2642 U.S. Gal
~
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80
21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon
1f. =0.21997 U.K. Gal
~
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80
17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-16