610 Alternative Repair Manual

CEBMGI OAR0
KDC 410 AND 610 SERIES

ENGINE ALTERNATIVE
REPAIR MANUAL
1991 SERIES
KOMRU
Alternative Repair Manual
KOMAfbU 410 and 610 Series Engine
KDC 410 Series Engine KDC 610 Series Engine

Foreword
This alternative repair manual contains specifications and instructions for repairing damaged or worn components in the
410 and 610 Series engines. The repair procedures are based on the engine being repaired with approved machining and
grinding equipment. Some procedures require the use of specials service tools. Make sure the correct tools and
equipment are used as described in the procedures.
When a specific brand name, number or special tool is referenced in this manual, an equivalent product can be used in
place of the recommended item.
A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be
ordered through your distributor using the form in Section L.
The specifications and rebuild in this manual is based on the information in effect at the time of printing. Komatsu Dresser
Company reserves the right to make any changes at any time without obligation. If differences are found between your
engine and the information in this manual, contact your KDC Distributor.
The latest technology and the highest quality components are used to manufacture KDC engines. When replacement parts
are needed, we recommend using only genuine KDC exchange parts.
Table of Contents
Page
Introduction . . , . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
General Repair Instructions ....................................... 0
Cylinder Block Group ............................................ 1
Cylinder Head Group ............................................ 2
Service Literature .............................................. L
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Section i - Introduction
410 and 610 Series Page i-l
Section i - Introduction
Section Contents
Page
Aboutthe Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine Identification ......................................................... ;

Engine Dataplate ...........................................................
General Safety Instructions ..................................................... ;

Important Safety Notice ......................................................
Symbols .................................................................. 6
About the Manual Section i - Introduction
Page i-2 410 and 610 Series
About the Manual

The procedures in this manual were developed for a shop environment. A Group System has been used to subdivide the
instructions by major components and systems. Refer to the Table of Contents for the various groups. Wrench sizes and
shop tooling are identified in the procedure when needed.
The initial publication provides some general repair information, cylinder block repair and cylinder head repair. Subsequent
versions of the manual will include alternative repairs for additional components as they are developed.
The contents of this manual are based on information in effect at the time of publication approval and are subject to
change without notice.
Section i - Introduction Engine Identification
410 and 610 Series Page i-3
Engine Identification
Engine Dataplate
The engine dataplate shows specific information about your
engine. The engine serial number provides information for
ordering parts and service needs.
NOTE: The engine dataplate must not be changed unless
approved by KDC.
KimatsuDresser
I
ENGINE SERIAL NO.
LISERTWILLE. ILLINOIS. SO048 .S.A

TIMINQ TDC KDC P/N
0 VALVE LASH COLD EXH. RATED HP AT RPH

Warning Injury May Result And
Warranty II Volded If Fuel Rale
RPM Or Altitudes Exceed Plubllshed FIRING ORDER FUEL RATE AT RATED HP t&/STROKE
Maxlmum Values For This Model And
Application.
E.C.S. KDC MODEL
MADE IN U.S.A.
E2BWOOOi
Engine Dataplate
The KDC model designation represents the basic design and

configuration of your engine.
Example Engine Model Name:
6 10TA
(1) (2) (3) (1) Number of cylinders
(2) Displacement per cylinder/l00 in cc
(3) Type of aspiration:
T = Turbocharged
A = Aftercooled
General Safety Instructions Section i - Introduction
Page i-4 410 and 610 Series
General Safety Instructions

Important Safety Notice
Read and understand all safety precautions and warnings before performing repairs.
A This symbol appears in the manual when a potential safety hazard exists that can cause personal injury. These
hazards are not always apparent to a trained mechanic.
It is not possible for Komatsu Dresser Company to anticipate every possible circumstance that can involve a
potential hazard.
A Komatsu Dresser Company does not recommend or authorize any modifications or repairs to engines
components except those detailed in Komastu Dresser Company SERVICE INFORMATION.
or
In particular, unauthorized repair to safety-related components can cause personal injury. Components classified
as safety-related include the following:
Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter
Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing Turbocharger Oil Drain Tubes Turbocharger Oil Supply Tubes
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included in
the procedures when they apply.
A Make sure the work area surrounding the product Is safe. Be aware of hazardous conditions that can exist.
A Always wear protective glasses and protective shoes when working.
A Do not wear loose-fitting or torn clothing. Remove all jewelry such as rings, watches, etc., when working,
A
Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air
starting motor If equipped to prevent accidental engine starting. Put a Do Not Operate tag in the operators
compartment or on the controls.
Section i - Introduction General Safety Instructions
410 and 610 Series Page i-5
General Safety Instructions

Important Safety Notice
A Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
A If an engine has been operating and the coolant Is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
A Do not work on anything that Is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related Items are
A removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that
utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal
injury.
.
To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon)
A lines in a well ventilated area.
To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or
A more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Make
sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not
be side-loaded.
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact
A with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case
of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY
CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
A manufacturers instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines,
A tubes, and compartments.
Always use tools that are in good condition. Make sure you understand how to use them before performing
A any service work. Use ONLY genuine KDC replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
A lessor quality if replacements are necessary.
Symbols Section i - Introduction
Page i-6 614 Series
Symbols
The following group of symbols have been used in this manual to help communicate the intent of the instructions.
When one of the symbols appears, it conveys the meaning defined below.
A
WARNING - Serious personal injury or extensive property damage can result if the warning instructions
are not followed.
A CAUTION - Minor personal injury can result or a part, an assembly or the engine can be damaged if
the caution instructions are not followed,
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step,
043 INSPECTION is required,
qB CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque,
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information,
The component weighs 23 kg 150 lb] or more, To avoid personal injury, use a hoist or get assistance
to lift the component.
Section 0 - General Repair Instructions
401 and 610 Series Page O-l
Section 0 - General Repair Instructions

Section Contents
Page
Follow All Safety Instructions Noted in the Procedures ................................. 2
Follow the Cleaning Instructions Specified in the Procedures ............................. 2
General Information .......................................................... 2
Inspection.. ............................................................... 2
Perform the Inspections Specified in the Procedures ................................... 2
Repair Guidelines ........................................................... 2
Repair Procedure.. .......................................................... 5
Repairing Threads With Coiled Thread Inserts ....................................... 3
Repairing Worn Pipe Plug Holes With Oversize Copper Plated Plugs ....................... 6
Sealing Small Casting Holes Or Pockets With Taper Threaded Plugs ....................... 4
Using Metal Fillers For Temporary Repairs .......................................... 6
When Should An Alternative Repair Be Performed? .................................... 2

General Information Section 0 - General Repair Instructions
Page O-2 410 and 610 Series
General Information
Repair Guidelines
The 410 and 610 Series engine incorporates the latest diesel technology, yet it is designed to be repaired using existing
repair practices performed to quality standards.
Service support for the 410 and 610 Series engine includes worldwide availability of new replacement parts.
When Should An Alternative Repair Be Performed?

The following procedures do provide an alternative to replacement of major engine components. Local machine shop
expertise is the first criterion. Beyond the technical requirements, availability, price and equipment down time are the
considerations that will influence the decision.
Inspection
The procedures assume the component was inspected and the discrepancy noted during repair or overhaul. Only those
inspection requirements directly related to the alternative repair procedure are provided in this manual. Complete
inspection criteria is available in the Shop Manual, Form No. CEBMGlOSHO, which can be ordered or purchased from a
local KDC Distributor.
Follow All Safety Instructions Noted in the Procedures

Follow the manufacturers recommendations for cleaning solvents and other substances used during the repair of the
engine. Also, be sure to use good safety practices with tools and equipment.
Follow the Cleaning Instructions Specified in the Procedures

After completing the repair, make sure all machining debris is removed and that the part is thoroughly cleaned.
Perform the Inspections Specified in the Procedures

After the repair, perform the required inspection to make sure the part meets the technical requirements for continued
use in an engine.
Section 0 - General Repair instructions Repairing Threads With Coiled Thread Inserts
410 and 610 Series Page O-3
Repairing Threads With Coiled Thread Inserts

The 410 and 610 Series engine uses metric capscrews.
Metric Capscrew Nomenclature.
M8 x1.25 - 25
Length in Millimeters
-LT Distance Between Thread in Millimeters
-L Major Thread Diameter in Millimeters

A coiled insert is a precision-formed thread-repair liner made of coiled stainless steel wire. These coils, in their free state,
are designed to be larger in diameter than the tapped hole. After installation, the insert expands to the outer wall of the
tapped hole. This expansion holds the insert in place.
Standard inserts are made of stainless steel wire; however, other materials are available to meet special installation
requirements.
This method of thread repair requires only four steps: drilling, tapping, installation, and breaking off and removing the tang.
Also, in thin wall material sections, these inserts restore failed or mutilated threads to their original size. An additional
advantage to these inserts is that they provide freedom from wear even after repeated use.
For special installations, call or write the following manufacturers:
For Perma-Thread For Heli-Coil For Coil Thread
Microdot Inserts Heli-Coil Products Tridair Industries

1025 N. Armanda St. Shelter Rock Lane 3000 West Lomita Blvd.
Anaheim, CA 92806 Danbruy, CT 06810 Torrance, CA 90505
(714) 870-6650 (203) 743-7651 (213) 530-2220
Sealing Small Casting Holes Or Pockets With Taper Threaded Plugs Section 0 - General Repair Instructions
Sealing Small Casting Holes Or Pockets With Taper Threaded Plugs

The repair procedure will provide guidelines for using taper threaded plugs to repair minor defects such as pin
holes, blow holes, and sand, slag or dirt pockets which cause leaks in castings. These defects can be repaired
if:
1. They allow oil or water to leak to the outside of the engine.
2. The defect is in a non-stress area or other areas of the casting which are not machined.
Although taper threaded plugs are also used to repair cracks, this repair procedure will not give guidelines for repairing
cracked castings.
Locations which are not to be repaired using this method are as follows:
1. Oil passage bosses.
2. Sections of the casting where a drilled hole or an installed taper threaded plug would interfere with the operation
of the engine or any of its components.
3. Casting wall sections between water and oil passages.
4. Cylinder head capscrew bosses.
Castings can be repaired by using a taper threaded plug if:
1. The defect is removed by the tap drill.
2. The maximum size plug needed is 27.53 mm [1.084 inch] or less.
3. The minimum wall thickness in the defective area is not less than 3.97 mm [5/32 inch].
Section 0 - General Repair Instructions Repair Procedure
Repair Procedure
For each taper threaded plug size there is a special tap drill size and tap size. Make sure that you use the correct tap
drill size and tap size according to the taper threaded plug size.
lronite KDC
Part Diaieter ThrYead Drill lronite Tap
No. Small End Length Size Tap No. Part No.
Inch mm Inch mm
210200 .200 5.08 15/16 3.8 11/64 530200 555228
210235 .235 5.97 15/16 23.8 13164 530235 555229
210237 .327 8.32 1 7/16 36.5 5116 530237 555230
210420 .420 10.67 1 25.4 25164 530420 555231
210421 .420 10.67 1 7/16 36.5 25164 530420 555232
210490 .490 12.45 1 25.4 15/32 530490 555234
210491 .490 12.45 1 7/16 36.5 15132 530590 555234
210590 590 14.99 1 25.4 23132 530780 555236
260780 .780 19.81 1 25.4 23132 530780 555236
261080 1.084 27.53 1 25.4 1.00 531080 555237
A: Standard Pipe Plug

B: Taper Threaded Plug
1. Use a hand held disc grinder or wire brush to remove paint or rust from around the defective area.
Caution: If this repair procedure is done while the engine Is still In chassis, do not allow shavings to enter the engine.
2. Drill the hole with the correct tap drill size for the plug that will be used. Make sure that the size of the drill bit is
large enough to remove the defective area, but do not use a drill bit size larger than is necessary. After the hole
has been drilled, remove all of the shavings.
3. Visually examine the drilled hole. If you see any defects in the wall of the drilled hole, then drill the hole for the next
largest plug. Repeat this step until no defects can be found in the wall of the hole, but remember: Do not exceed
a maximum hole diameter of 1.000 Inch [25.4 mm].
NOTE: The wall thickness of the casting in the defective area must not be less than 3.97 mm [5/32 inch].
Repair Procedure Section 0 - General Repair Instructions
4. Use the correct size tape to cut threads in the hole. A minimum of four full threads is necessary in order for the
plug to seal. Remove all shavings.
APPLY Loctitem 601, ST-1272-12 LoctiteTM Compound, or an equivalent sealer to the threads of the plug.
Install and then tighten the plug.
Use a hacksaw to cut the plug off. Leave at least 0.794 mm [l/32 inch] of the plug above the surface.
Use a small ball peen hammer to spread out the protruding _.part of the plug. The plug must be spread out enough
to seal the top threads of the plug with the top threads of the hole.
9. Allow the LoctiteTM sealant to harden for at least thirty minutes.
10. Use a hand held grinder or file to grind the plug flush with the casting surface.
NOTE: If a water or oil passage wall has been repaired, then the plug must be tested with 345 kPa [50 psi] air pressure.
With the pressure applied to the passage, put a soap and water solution on the plug and look for air bubbles. If bubbles
appear, then the leak has not been repaired. Start with Step 2 of this procedure and install the next oversize taper
threaded plug.
11. If needed, paint the repaired area with a matching color.
Repairing Worn Pipe Plug Holes With Oversize Copper Plated Plugs
Worn pipe plug holes can be repaired by:
0 Cleaning threaded area with Trichlorocthylene Ill or equivalent.
0 Chasing the threads with the correct size pipe tap.
l Installing a copper plated (oversize) pipe plug coated with pipe plug sealant 3375066.
Copper Plated Tool

Pipe Plugs Part Number
Plug, Pipe (l/8-27) 3014981
Plug, Pipe (l/4-18) 30 14982
Plug, Pipe (3/8-18) 3014983
Plug, Pipe (l/2-14) 3014984
Plug, Pipe (3/4-14) 30 14985
Plug, Pipe (l-l 1.5) 3014986
Using Metal Fillers For Temporary Repairs

This procedure will give information on metal filler compounds and guidelines for their use in temporary repairs. Repairs
made by using metal fillers must not take the place of more permanent repairs or part replacement.
Metal fillers can be used to temporarily limit seepage, to correct surface imperfections or to replace a missing section.
A Warning: Repair of safety related components must not be attempted. See page i-4.
Different metal based metal fillers are available such

. .as_ferrous, brass,
_. and aluminum. Make sure you use a metal filler
which is correct for the material that is being repaired. Also, this filler must be able to withstand the same temperatures,
stresses, and pressures as the material being repaired.
Some filler compounds are multipurpose, and have the ability to bond dissimilar metals, others do not. The manufacturers
recommendations must be followed for best results.
Section 0 - General Repair Instructions Using Metal Fillers For Temporary Repairs
Listed below are some of the known suppliers of metal filler compounds. These products are available through industrial
or automotive supply stores and are sold in conveniently packaged quantities. Corporate headquarters of each company
are provided for reference.
1. Devcon Corporation
30 Endicott Street
Danvers, Massachusetts 01923
Phone: (508) 777-l 100
Telex: 94-04-57
2. American Velodur Metal, Inc.

P.C. Box 156
Scituate, Massachusetts 02066
Phone: (617) 545-9100
Telex: 94-0249
3. J.B. Weld Co.

P.C. Box 483
Sulphur Springs, Texas 75482
Phone: (903) 885-7696
4. Achim Schultz
Diamont Kitle
Schulz GMBH & Co.
(Rheydt) P.O. Box 70
D4050 Monchengladbach 2
Federal Republic of Germany
Telex: 852353-DIAM-D
5. Alvin Products, Inc.

P.O. Box 942
Worchester, Massachusetts 01613-0942
Phone: (508) 754-8604
6. Fel-Pro, Inc.
Chemical Products Division
7450 N. McCormick Boulevard
Box 1205
Skokie, Illinois 60076
Phone: (708) 674-7700
Section 1 - Cylinder Block Group
410 and 610 Series Page l-1
Section 1 - Cylinder Block Group

Section Contents
Page
Connecting Rod - Repair ........................................ ....... . . . . 13

Connecting Rod Alignment - Inspection .............................. ....... . . . . 19
Connecting Rod - Bend and Twist Inspection .......................... ....... . . . . 18
Connecting Rod Bushing Machining ................................ ....... . . . . 17
Connecting Rod Twist .......................................... ....... . . . . 20
Pin Bore Bushing - Installing ..................................... ....... . . . . 15
Pin Bore Bushing - Removing .................................... ....... . . . . 13
Crankshaft Main Journal Regrind Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crankshaft Repair Procedures ..................... . . . . . . . . . . . . . . . ....... . . . . 10

Crankshaft Grinding General ..................... ....... . . . . 10
Repair Tools ................................ . . . . . . . . . . . . . . . ....... . . . . 10
Cylinder Block Repair Procedures .................. . . . . . . . . . . . . . . ....... . . . . .

Cam Bore(s) ................................ . . . . . . . . . . . . . . ....... . . . . .
Combustion Deck ............................ . . . . . ....... . . . . .
Cylinder Bore(s) ............................. . . . . . ....... . . . . .
Cylinder Bore(s) Repair - General .................. . . . . . . . . . . . . . . ....... . . . . .
Repair Sleeve Installation ........................ . . . . . ....... . . . . .
Repair Tools ................................ . . . . . . . . . . . . . . ....... . . . . .
Main Bearing Cap - Repair ....................................... . . . . . . . 8
Thrust Journal/Thrust Surface Width Regrinding ........................ 10

Crankshaft Rod Journal Regrind Specifications ......................... 12
Regrind of Crankshaft Main Journal Radius ........................... 11
Regrind of Crankshaft Rod Journal Radius ............................ 12
Cylinder Block Repair Procedures Section 1 - Cylinder Block Group
Page 1-2 410 and 610 Series
Cylinder Block Repair Procedures

Repair Tools
Camshaft Bore Boring Bar
Camshaft Bushing Driver
Cylinder Boring Bar
Cylinder Block and Head Surface Grinder
Cylinder Hone Set
NOTE: The repairs can be performed with standard gasoline automotive tooling at local automotive engine repair shops.
Combustion Deck
RI Straight Edge and Feeler Gauge

Use a straight edge and feeler gauge to measure the overall
flatness of the block. The overall flatness, end to end and side
@ to side, must not exceed .075 mm [0.003 in].
Visually inspect the combustion deck for any localized dips or

0
@ii!9imperfections. If present, the block deck must be reground.
The combustion deck can be refaced twice. The first reface

should be 0.25 mm [.OlOO in]. If additional refacing is required,
an additional 0.25 mm [.0098 in] can be removed. Total
allowed refacing is 0.50 mm [.0197 in].
A= 0.25 mm [.0098 in] First reface
0.25 mm [.0098 in] Second additional reface
0.50 mm [.0197 in] Total allowed
B= 323.00 mm + 0.10 Standard

[12.7165 in 2 .0039]
322.75 mm -c 0.10 First reface
[12.7066 in + .0039]
322.50 mm + 0.10 Second reface
[12.6968 in + .0039]
Surface finish requirements = 1.5 - 3.2 micrometers [60 - 126
microinch].
Section 1 - Cylinder Block Group Cylinder Block Repair Procedures
The upper right corner of the rear face of the block must be
stamped with an X when the block is refaced to 0.25 mm
[.0098 in]. A second X must be stamped beside the first
when the block is refaced to 50 mm I.0197 in].
Consult the parts catalog for the proper head gaskets which e
must be used with refaced blocks to ensure proper piston to
valve clearance.
Cam Bore(s)
The front cam bushing bore can be rebored to 57.734 ? 0.018 mm [2.273 in + .0007] oversize. Do not bore the
intermediate or rear journal to the front journal oversize dimensions. Intermediate and rear journals may be rebored
to 57.240 + 0.018 mm [2.253 ? .0007] oversize. A surface finish of 2.3 micrometers [92 microinch] must be maintained.
Not more than 20 percent of area of any one bore may be up to 3.2 micrometers [126 microinch].
NOTE: Journals can be repaired individually. It is not necessary to over bore undamaged journals in order to repair
individually damaged journals.
Install all cam bushings flush or below the front journal

surface. The oil hole must align to allow a 3.2 mm [.125 in]
rod to pass through freely.
The standard front bushing cannot be used to repair

intermediate or rear journals. Consult the parts manual for $$@B
correct oversize cam bushing part numbers.
Cylinder Bore(s) Repair - General

Cylinder bore(s) can be repaired by two methods.
Method 1. Over boring and use of oversize pistons and rings.
Method 2. Borina and installina a repair sleeve to return the bore to standard dimensionsOversize piston and rings
are available in two-sizes:.50 mm [.0197 in] and 1.00 mm [.0393 in].lf more than 1.00 mm [.0393 in] over
bore is needed, a repair sleeve(s) is required. It is permissible to install sleeves into individual cylinders as
required. Repair sleeves can be replaced by using a boring bar to bore out the old sleeve. Do not cut the
cylinder bore beyond the oversize limit.
Cylinder Bore(s)
Block cylinder bores may be rebored twice before use of a
repair sleeve is required. The first rebore is 0.50 mm [.0197 in]
oversize. The second rebore is 1.00 mm [.0393 in] oversize.
Boring Diameter Dimensions
A = 102.469 mm [4.0342] 1st rebore
102.969 mm [4.0539] 2nd rebore
Honing Diameter Dimensions
B = 102.020 * .020 mm Standard bore
14.0165 + .0008 in]
102.520 + .020 mm 1st rebore
[4.0362 * .0008 in]
103.020 t- .020 mm 2nd rebore
[4.0559 & .0008 in]
After boring, use a honing stone to break the edge of the bore
to Dimension C.
C = Approximately 1.25 mm
[.049 in] X 15 Degrees
A correctly honed surface will have a cross-hatched

appearance with the lines at 15 to 25 degree angles with the
top of the cylinder block.
Top of Block Rough hone: use 80 grit honing stones.
Finish hone: use 280 grit honing stones.
A 1.2 maximum micrometer [48 microinch] surface finish must
be obtained.
After finish honing is complete:

Immediately clean the cylinder bores with a strong solution of
laundry detergent and hot water.
After rinsing, blow the block dry.
cksbreh
410 and 610 Series Page 1-5
Check the bore cleanliness by wiping with a white, lint

lightly oiled cloth. If grit residue is still present, re-clean.
If the block is not to be used right away, coat with a rust

preventative solvent.
ck9bdwn
Repair Sleeve Installation

Repair Sleeve Part No. 3904166.
r-- t-4
If more than a 1.00 mm [.03937 in] diameter oversize bore is
required, the block must be rebored and a repair sleeve
installed, The sleeve bore must be refinished after installation
to a 102.020 + .020 mm 14.0165 t .0008 in] diameter. A
standard diameter piston and a service piston ring set must
be used.
Block Rebore For Repair Sleeve
A= 104.515 + .015 mm [4.1148 + .0006 in]
104.500 - .OOOmm [4.1142 - .OOOOin]
B= 6.35 mm [.250 in]
After boring thoroughly, clean the bore of all metal chips,
debris and oil before installing the repair sleeves.
Freeze the repair sleeve(s) for a minimum of one hour at a

temperature at or below -12C [ + 1OOF]. Remove the sleeves
one at a time and install in the block using the following
procedure.
-12 deg. C
[+lO deg. F]
Page l-6 410 and 610 Series
Apply a coat of Loctite TM 620 to the bore one at a time as the

sleeve is installed.
@@A Using protectiye gloves, push the frozen sleeve into the bore
4~ as far as possible by hand.
Part No. 3823230

sin g a sleeve driver, press or drive the sleeve in until it
contacts the step in the bottom of the bore.
Set up a boring bar and machine to the following dimensions.
A = 101.956 mm [4.014 in]
B = Minimum - flush with block

Maximum - .050 mm [.0019 in] protrusion
After remove the boring bar, use a honing stone to break the edge of the repair sleeve(s) to Dimension C.
C = Approximately 1.25 mm I.049 in] X 15 Degrees

Main Bearing Cap - Repair Section 1 - Cylinder Block Group
A correctly honed surface will have a cross-hatched

appearance with the lines at 15 to 25 degree angles with the
top of the cylinder block.
Top of Block Rough hone: use 80 grit honing stones.
Finish hone: use 280 grit honing stones.
Finish hone dimension:
102.020 2 .020 mm [4.0165 2 .0008 in]
A 1.2 maximum micrometer I48 microinch] surface finish must
be obtained.
After finish honing is complete:

Immediately clean the cylinder bores with a strong solution of
laundry detergent and hot water.
After rinsing, blow the block dry.
ck9breh
Check the bore cleanliness by wiping with a white, lint free,

lightly oiled cloth. If grit residue is still present, re-clean.
If the block is not to be used right away, coat with a rust
preventative solvent.
ck9bdwn
Main Bearing Cap - Repair

Caution: The removal of excessive material from the block
saddle surface will result in improper gear backlash.
The original main bearing cap can be repaired by machining
the parting surface, or replacement semi-machined caps are
available.
Do not machine more than 0.25 mm [O.OlO in] from the cap
and 0.05 mm [0.002 in] from the block saddle.
Section 1 - Cylinder Block Group Main Bearing Cap - Repair
0
NOTE: When machining the parting surface of a cap, it is
very important that the surfaces are machined parallel to @ 6 A// B
each other and perpendicular to the sides of the cap. After
machining, the cap must fit squarely on the parting surface
of the cylinder block.
0a!3
To check for squareness, apply a light coat of bluing
compound to the cylinder block parting surface.
Install the main bearing cap.
Torque Value: Step One: 50 Nom [ 37 ft-lb]
Step Two: 119 Nom [ 88 ft-lb]
Step Three: 176 Nom [129 ft-lb]
Remove the retaining capscrews and the main bearing cap.

A bluing transfer of less than 80 percent is not acceptable.
0a!3
Remove the bluing from the parting surfaces and the main
bearing bore.
Main Bearing Bore Repair - Specifications
Measurement mm Inch
Main Bearing Bore I.D. 87.982 MIN 3.4639
88.018 MAX 3.4652
I.D. Enlargement-Per Cut 0.76 MAX 0.030
I.D. Enlargement-Final Cut 0.25 MAX 0.010
Surface Finish 3.2 /LM MIN 125 p in
Main Bearing Capscrew Torque:
Torque Value: Step One - 50 Nom [37 ft-lb]

Step Two - 119 Nom 188 ft-lb]
Step Three - 176 Nom [129 ft-lb]
Crankshaft Repair Procedures Section 1 - Cylinder Block Group
Crankshaft Repair Procedures

Repair Tools
Crankshaft Regrinding Lathe
Crankshaft Grinding General

Crankshaft main and rod journals may be reground in increments of 0.25 mm [0.0098 in] up to four times for a total of
1.00 mm [0.0394 in]. The only exception is the main journal thrust width surface which must be reground in two
increments 0.50 mm [0.0197 in] and 1.00 mm [0.0394 in]. The thrust surface is located on the number four main bearing
on the four cylinder and on the number six main bearing on the six cylinder engines. When the thrust surface requires
regrinding, the main journal must be reground to the same undersize.
Two procedures, a preferred and an option, will be given for regrinding all of the crankshaft journals except when
the thrust width surface requires regrinding. Then the preferred procedure is the only accepted procedure (refer
to page l-13).
Crankshaft Main Journal Regrind Specifications

Standard main journal size: 82.000 + .013 mm [3.2677 + .0005 in]
Worn Limit: 82.962 mm [3.2662 in]
All Main Journal
Available Undersize Regrind To

0.25 mm [.0098 in] 82.750 + .013 mm [3.2579 f .0005 in]
0.50 mm [.0197 in] 82.500 + .013 mm t3.2480 t .0005 in]
0.75 mm [.0295 in] 82.250 + .013 mm [3.2381 + .0005 in]
1.00 mm [.0394 in] 82.000 + .013 mm [3.2283 + .0005 in]
All main journals to be parallel to the front and rear mains within 0.03 mm [O.OOl in]
Out of roundness - 0.005 mm [0.0002 in] maximum
Taper - 0.005 mm [0.0002 in] maximum
All main journals to be ground in the opposite direction of engine rotation (clockwise as viewed from the front of
crankshaft). Polish the journals in the same direction of rotation.
Thrust Journal/Thrust Surface Width Regrinding

Thrust journals can be reground in the same increments and using the same specifications as all other main journals. The
main journals radius may be reground using either the preferred or the optional procedure providing the thrust surface
width is not being reground. Then the preferred procedure must be used. Refer to page 1-12. When the thrust surface
width requires regrinding, the main journal must be reground to the same undersize.
Available Undersize Regrind To:

Thrust Journal/Thrust Surface A= Diameter B = Width
0.50 mm 82.500 + .013 mm 38.00 + .025 mm
[.0197 in] [3.248 f .0005 in] [1.4961 2 .OOl in]
1.00 mm 82.00 2 .013 mm 38.500 2 .025 mm
[.0394 in] [3.228 + .0005 in] [1.5158 2 .OOl in]
Section 1 - Cylinder Block Group Thrust Journal/Thrust Surface Width Regrinding
410 and 610 Series Page l-l 1
The thrust surface (C) is to be ground on center within 0.10

mm I.004 in] and must be perpendicular to the front and / II
rear mains within .0015 mm [.OOOOSin] per radial inch on the
thrust area. The surface finish requirement is 0.4 micrometer
[16 microinch].
Refer to page l-13 for radius regrind and surface finish.
Regrind of Crankshaft Main Journal Radius

Preferred Procedure - All Main Journals
Smoothly blend a 4.20 + .020 mm [.1654 f .0008 in] radius
to the reground diameters.
Surface Finish:
A= 0.8 micrometer [32 microminch] for a minimum of 45
degrees into the fillet beyond the journal surface.
B= 1.6 micrometers 164 microinch] for the remainder of
the fillet.
c= 0.4 micrometers [16 microinch] (journal surface).
D= Original dimension.
E= New undercut dimension.
Optional Procedure - Not To Be Used When Thrust

Surface Width is Reground
Smoothly blend a 1.25 + .020 mm [0.0492 + .0008 in]
radius to the reground diameters.
Surface Finish:
A= 0.8 micrometers [32 microinch] for a minimum of 45
B= 1.6 micrometer [64 microinch] for the remainder of
the fillet.
c= Original dimension.
D= New undercut dimension.
E= 0.4 micrometers [16 microinch] (journal surface).
Width of regrind for undercut radius.

F= 34.500 + .025 mm [1.358 + .OOl in]
Thrust Journal/Thrust Surface Width Regrinding Section 1 - Cylinder Block Group
Crankshaft Rod Journal Regrind Specifications
Standard rod journal size: 69.000 + .013 mm [2.7165 ? .0005 in]
Worn Limit: 68.962 mm [2.7150 in]
Available Undersize Regrind To:
0.25 mm [.0098 in] 68.750 + 0.013 mm 12.7067 ? .0005 in]
0.50 mm [.0197 in] 68.500 + 0.013 mm [2.6969 + .0005 in]
0.75 mm [.0295 in] 68.250 f 0.013 mm 12.6870 + .0005 in]
1.00 mm [.0394 in] 68.000 + 0.013 mm [2.6772 f .0005 in]
All rod journals to be parallel to front and rear main journals within . . . . . . . . . . . . . . . . . . . . 0.03 mm [O.OOl in]
Out of roundness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 mm [0.0002 in] maximum
Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 mm [0.0002 in] maximum
Journals to be ground in the opposite direction of rotation (clockwise as viewed from the front of the crankshaft).
Polish the journals in the same direction of rotation.
Regrind of Crankshaft Rod Journal Radius

Preferred Procedure
Smoothly blend a 4.00 f 0.20 mm [1.575 + .0008 in] radius to
the reground diameters and side faces.
Surface Finish:
A= 0.8 micrometers [32 microinch] for a minimum of 45
B= 1.6 micrometers [64 microinch] for the remainder of the
fillet.
c= Journal surface 0.4 micrometer [16 microinch].
D= New undercut dimension.
E= Original dimension.
Optional Procedure
Smoothly blend a 1.25 + .020 mm [.0492 2 .00008 in] radius
to the reground journal and side faces.
Surface finish:
A= 0.4 micrometer [16 microinch] (journal surface)
B= 0.4 micrometer [32 microinch] for a minimum of 45
c= 1.6 micrometer [64 microinch] for the remainder of the
fillet.
D= Original dimension.
E= New undercut dimension
Section 1 - Cylinder Block Group Connecting Rod - Repair
Width of regrind for undercut radius.

F= 34.790 if: .025 mm [1.369 + .OOl in]
Connecting Rod - Repair

Pin Bore Bushing - Removing
Part No. 3823902, connecting rod pin bore bushing removal
and installation tool contains the following:
Ref. Part
No. No. Description QtY
1 3823903 Anvil 1
2 3823904 Cup 1
3 3823905 Mandrel 1
I
4 3823906 Stop Ring (Thick) 1
5 3823907 Removal/Installation Ring (Thin) 1
6 Hairpin Cotter 1
7 3377676 Instructions 1
Place the pin bore end of the connecting rod on the @A

mandrel.
@
Connecting Rod - Repair Section 1 - Cylinder Block Group
410 and 610 Series
Page 1-14
ace the thin wall removal/installation ring on the mandrel on

of the connecting rod. Match up the angle surfaces.
Install the cup on the mandrel and secure with the hairpin
cotter.
Install the mandrel in the anvil. Place the rod so that the angle
on the rod matches with angle on the anvil. The rod will be in
the horizontal position.
Press the bushing out by applying force on top of the cup.

Press the bushing through the bore.
Remove the hairpin cotter. Remove the cup and slide the rod
from the mandrel.
Measure the connecting rod bushing bore with the bushing

removed.
NOTE: If the connecting rod bushing bore is not within
specifications, replace the connecting rod.
Diameter
mm in
42.987 MIN 1.6924
43.013 MAX 1.6934
Pin Bore Bushing - Installing

Before installing the bushing, submerge the bushing
connecting rod pin end in clean 15W-40 engine oil.
and
%
0
Place the bushing on the mandrel.
Websha
Place the removal/installation ring inside the stop ring.

Match the angles, place the angle side down and align the
notch of the removal/installation ring to the pin in the stop ring
and slide on the mandrel.
Cx9bshb
Install the cap and secure with the hairpin cotter.
cx9bshc
Insert the mandrel and components into the chamfered side of

the rod.
Align the angles of the bushing, connecting rod, and stop rings.
NOTE: All rods do not have a double chamfer. A chamfer may
be added to aid in the bushings installation, but should not
result in an unsupported bushing area.
Align the oil hole in the bushing and rod (use the groove in the
mandrel) and push the mandrel and components into the pin
bore of the rod until contact is made. This contact helps
maintain the alignment of the oil holes.
Place the rod and mandrel assembly on the anvil (position

so that the angle on the rod matches the angle on the anvil).
The rod is in the horizontal position.
Press the bushing into the rod by applying force on the top
of the cup using either an arbor or hydraulic press. Push
through in a continuous motion until the stop ring makes
contact with the rod.
Check the alignment of oil holes. A 3 mm [l/8 in] diameter

rod must move freely through the rod and the bushing oil
holes (A).
Check for clearance between the connecting rod bushing B
and the connecting rod.
Use a 25 mm [O.OOl in] feeler gauge to make sure the
bushing has seated properly. The 25 mm [O.OOl] feeler
gauge must not enter between the bushing and the rod (B).
A
Connecting Rod Bushing Machining

It will be necessary to finish the inside diameter (ID) of the new rod bushing. It is recommended that you use KDC rod
boring machine, Part No. 3823601 (Sunnen PM-3009 or KDC old style boring machine, Part No. 3375144 (Tobin Arpe
rod boring machine) or the equivalent to machine the bushing.
When properly adjusted, a Sunnen PM-300@, or equivalent, connecting rod boring machine will be able to control the
crankshaft-to-pin bore center-to-center tolerance as well as bend-and-twist tolerance.
This type of boring machine must be used when making alternate repairs to the 410 and 610 Series connecting rods.
Do not use a floating-rod type honing machine.
Bushing Finished Dimensions.
Inside Diameter (Pre 1994)

mm in
40.053 MIN 1.571
40.067 MAX 1.577
Inside Diameter (1994 only)

mm in
40.019 MIN 1.5755
40.033 MAX 1.5761
Pin-to-Bushing Clearance.
Clearance
mm in
0.050 MIN 0.002
0.077 MAX 0.003
Connecting Rod - Bend and Twist Inspection

Calibrate the checking fixture.
0
Use the Part No. ST561, Connecting Rod Checking Fixture, and
ai!9 the
the
Part No. 3823285, Connecting Rod Mandrel Set, to inspect
bend and twist of the rods. Calibrate the checking fixture
with a new rod that has been measured for correct
center-to-center length.
cxztoaa
Center-to-Center Length
mm in
191.975 MIN 7.558
192.025 MAX 7.560
Install the connecting rod into the fixture.

Move the dial holder to position the contact points of the
indicators on the mandrel in the piston pin bore.
Tighten the bracket to hold the indicators in position. Set the
dial indicators to zero, 0.
Remove the connecting rod from the fixture.

Turn the rod 180 degrees horizontally
the fixture again.
and install the rod into 6%
Q
0a3
Check the dial indicators for zero, O, position again.
If the dial indicators show any change from zero, O, adjust
the dials to half the indicated reading.
The fixture is now calibrated to allow the connecting rod to
be installed into the fixture in either direction and the dials
will indicate an equal deflection on either side of zero, 0.
Connecting Rod Bend

mm in
0.150 MAX 0.006
Connecting Rod Alignment - Inspection

Install the mandrel and arbor into the connecting rod to be @
inspected. @
Install the connecting rod into the fixture.

Connecting Rod Twist

Apply slight pressure against the rod to hold it against the
fixture. Pass a feeler gauge behind the pin on both sides of the
mandrel.
Connecting Rod Twist

mm in
0.150 MAX 0.006
cx800nd
Section 2 - Cylinder Head Repair Procedures
Section 2 - Cylinder Head Repair Procedures

Section Contents
Page
Assembly of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Combustion Deck inspection and Refacing ......................................... 2
Exhaust Valve Insert Pocket Machining ............................................ 9
Grinding the Valve Seats ...................................................... 5
Grinding the Valves ......................................................... 12

Check Valve Spring Tension .................................................. 13
Installing Service Valve ....................................................... 8
Repair Tools ............................................................... 2
Replacing Service Seats ...................................................... 11
Salvage Procedure to Use Part No. 1240677Hl and 1249678Hl Service Valve Guides ............ 4
Salvage Procedure to Use Part No. 1240763Hl Service Valve Guides ....................... 3
Valve Guides - Inspection and Installation .......................................... 3
Valve Seats - General ......................................................... 4

Calculating the Grinding Depth .................................................. 5
Repair Tools Section 2 - Cylinder Head Repair Procedures
Repair Tools
Valve Refacer
Valve Seat Grinder
Valve Guide Installation Tool
Combustion Deck Inspection and

Refacing
Inspect the head surface for nicks, erosion, etc.
Check for head distortion as illustrated.
Limit:
Variation: .OlO mm [.0004 in] in any given 50.8 mm [2.0 in]
diameter area. The overall end to end or side to side variation
limit is:
0.20 mm IO.008 in] - 4 cylinder
0.30 mm [0.012 in] - 6 cylinder
The combustion deck may be refaced in whatever increments necessary to clean up surface and maintain surface finish
and flatness tolerancing, as long as combined total of stock removal on all clean ups does not exceed 1.00 mm [.0393
inch]. Each amount of stock removed must be steel stamped just above edge of combustion deck on lower right hand
corner of rear face.
A = 1.00 mm [.03937 in] total
B = 94.00 it 0.25 mm [3.7008 + .OOlO in] Minimum (reference only)
C = Surface finish 1.5 to 3.2 micrometers [60 to 128 microinches]
D = Identification area for stamping amounts of stock removed.

Section 2 - Cylinder Head Repair Procedures Valve Guides - Inspection and Installation
Valve Guides - Inspection and Installation

Inspect the valve guides for scuffing or scoring.
Measure the valve guide bore.
Limit:
Diameter: 8.039 mm [.316 inch]
If the valve guide bores are found to be worn during inspection, the cylinder head must be machined for service valve
guides. The valve guides must be finish reamed after installation into the head.
If, after the inspection, it is determined that service valve guides and valve inserts are required, install the service valve
guides first.
Valve Guide Part No.
1240677Hl - Intake (Thick wall)
1240678Hl - Exhaust (Thick wall)
1240763Hl - Intake and Exhaust (Thin wall)
Salvage Procedure to Use Part No.

1240763Hl Service Valve Guides
Machine the cylinder head parent metal valve guide bores to
Dimension A.
A = 11.125 + 0.013 mm [.4380 -t .0005 in] diameter.
To be centered with valve seats within 0.35 mm [.01378 in]
diameter and to be square with the combustion face within
0.10 mm [.004 in] at 50.0 mm [1.9685 in] radius.
Install the valve guides as illustrated.

@A
A= Lubricate with oil and press the guides flush to the @
bottom of the bosses.
B= 12.00 f 0.75 mm [.4724 + .0295 in] (reference)
c= Trim off flush to top of guide bosses if necessary.
D= 8.029 + 0.010 mm [.3161 f .0004 in]
NOTE: Final bore after assembly is to be centered with the
valve seats within 0.35 mm [0.0138 in] diameter and square
with the combustion face within 0.10 mm [0.004 in] at 50.0
mm 12.0 in] radius.
Service Valve Guides Section 2 - Cylinder Head Repair Procedures
Salvage Procedure to Use Part No.

1240677Hl and 1249678Hl Service Valve
Guides
Machine the cylinder head parent metal valve guide bores to
Dimension A.
A = 14.000 & 0.013 mm [0.5512 + .0005 in] diameter.
To be centered with valve seats within 0.35 mm [.01378 in]
diameter and to be square with the combustion face within 0.10
mm [.0004 in] at 50.0 mm [1.9685 in] radius.
Install the valve guides as illustrated.

Lubricate with oil and press the guides to dimension A
protrusion above the cylinder head.
Finish ream the bores to dimension B.
A = 12.25 + 0.50 mm [0.4823 + 0.020 in]
B = 8.029 +- 0.010 mm IO.3161 + 0.0004 in]
Valve Seats - General
0a3 The cylinder head has integral valve seats. The seats can be
reground once only. Seats that have been previously reground
must be replaced with service seats.
Seats that have been previously reground should be marked
with one X.
0
Two Xs should be stamped on the head to indicate service
43 seats have been installed.
Service seats can be reground once only. Refer to Grinding the
Seats in this section.
Section 2 - Cylinder Head Repair Procedures Grinding the Valve Seats
Calculating the Grinding Depth

Install the valves in their designated location and measure
valve depth.
The valve depth is the distance from the valve face to the
head deck.
Record the depth of each valve as (A).
Grinding the Valve Seats

Grind the valve seats to remove scores, scratches and burns.
Seat Angle:
Intake: 30 Degrees
Exhaust: 45 Degrees
Grinding the Valve Seats Section 2 - Cylinder Head Repair Procedures
@ lnst?ll the valves in their respective bores and measure depth

4~ again.
Record the depth of each valve as (B).

Calculate grinding depth (GD) as follows:
GD - (B) - (A)
Limit:
GD: .254 mm [.OlO inch]
Service valve seats are available for over the limit seats.
Identify reground valve seats.

Section 2 - Cylinder Head Repair Procedures Grinding the Valve Seats
Install the valves in their designated locations and measure @@A

the depth.
4!ii
Check valve depth (C).

Limit:
Depth: 0.99 mm to 1.52 mm [.039 to .060 inch]
Replace the valve if the depth is over the limit.
Apply a light coat of valve lapping compound to each valve

and lap each valve to its companion seat.
Remove the valves and clean lapping compound from the

valves and seats.
Installing Service Valve Seat(s) Section 2 - Cylinder Head Repair Procedures
Measure the valve seat width indicated by the lapped surface.

Valve Seat Width Limit:
Minimum 1: 1.5 mm [.060 inch]
Maximum 2: 2.0 mm [.080 inch]
If required, grind area (A) with a 60 degree stone and (B) with
a 15 degree stone to center the seat on the valve face.
Maintain the valve seat width limits.
Installing Service Valve Seat(s)

Inspect the valve guide bores per the valve guide section of this manual. If it is necessary to install valve guides, install
the valve guides before installing the service seats.
Intake valve insert pocket machining. (Valve Insert Part No. 1240779Hl)
A = 8.029 2 0.010 mm [.3161 t .0004 in]
C = 10.40 2 0.10 mm [.4094 + .004 in]
D = 47.00 2 0.013 mm Il.8504 + .0005 in] diameter
E = 0.40 mm [.0157 in] radius maximum
F = 3.2 micrometers [128 microinch] surface finish
Section 2 - Cylinder Head Repair Procedures Exhaust Valve Insert Pocket Machining
Exhaust Valve Insert Pocket Machining

(Valve Insert Part No. 1240668Hl)
A = 8.029 + 0.010 mm [.3161 ? .0004 in] diameter
C = 10.20 f: 0.10 mm j.4015 + .004 in]
D = 43.650 f 0.013 mm [1.7185 f .0005 in] diameter
E = 0.40 mm I.0157 in] radius maximum
F = 3.2 micrometers I-128 microinch] surface finish
Comb D-
Face
Staking Tool 3823031

Press service seats into machined pockets. Refer to the parts Ezl
catalog for current part numbers of service seats.
Stake the valve seats into the pockets.
Grind the valve seats lightly to ensure proper seat angle.

Exhaust Valve insert Pocket Machining Section 2 - Cylinder Head Repair Procedures
Seat Angle:
intake: 30 Degrees
Exhaust: 45 Degrees
@@A Install the valves in their designated location and measure the
aw depth.
Check valve depth (C).

Limit:
Depth: 0.99 mm to 1.52 mm [.039 to .060 inch]
Apply a light coat of valve lapping compound to each valve

and lap each valve to its companion seat.
Section 2 - Cylinder Head Repair Procedures Replacing Service Seats
Remove the valves and clean the lapping compound from

the valves and seats. 0
C%
Measure the valve seat width indicated by the lapped

surface.
Valve Seat Width Limit:
If required, grind area (A) with a 60 degree stone and (B)

with a 15 degree stone to center the seat on the valve face.
Maintain the valve seat width limits.
Replacing Service Seats

To replace service seat inserts: Machine the seat insert out of the head in the same manner, and holding the same
tolerances, as if machining out the integral seat. Follow the same installation procedures as installing service seats when
installing new seats.
Grinding the Valves Section 2 - Cylinder Head Repair Procedures
Grinding the Valves

Inspect for abnormal wear on the heads and stems.
Measure the valve stem diameter.
Limit:
Diameter Minimum: 7.935 mm [.312 inch]
kn9vata
Reface all reused valves. Check/replace bent valves.
Seat Angle:
Intake: 30 Degrees
Exhaust: 45 Degrees
Measure rim thickness.

Limit:
Minimum (T): -79 mm 1.031 inch]
Section 2 - Cylinder Head Repair Procedures Grinding the Valves
Check the valve stem tip for flatness.
If required, resurface tip.
inspect the valve springs.

Measure the valve spring.
Limits:
Approx. Free Length (L): 55.63 mm [2.190 in]
Maximum Inclination: 1.0 mm I.039 in]
Check Valve Spring Tension

A minimum load of 289.32 N. [6!5.0 - 72.2 lb] is required to
compress the spring to a height of 49.25 mm [1.94 inches].
Assembly of the Cylinder Head Section 2 - Cylinder Head Repair Procedures
Assembly of the Cylinder Head

NOTE: Clean all cylinder head components before assembling.
Install the valve stem seals.
The intake and exhaust seals are the same.
Lubricate the stems with SAE 9OW engine oil before installing
the valves.
Compress the valve spring after assembling the spring and

retainer.
Install new valve collets and release the spring tension.

Section 2 - Cylinder Head Repair Procedures Assembly of the Cylinder Head
0a3
After assembly, tap the valve stems to verify the collets are
seated.
Service Literature
410 and 610 Series Page L-l
Section L - Service Literature

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO - Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
SHIP TO l
ATTN.
STREET ADDRESS
TYPE or PRINT
ONLY l
CITY, STATE, ZIP CODE
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS zaTe; PUBLICATION

QTY. PUBLICATION FORM NUMBER MODEL NUMBER SERIAL NUMBER
DESCRIPTION
$ M-Microfiche
KDC91 D 081696 CURRENT PRICES WILL BE CHARGED

Index
Page X-l
AbouttheManual ................................... 2
Assembly of the Cylinder Head ........................ 14
Combustion Deck inspection and Refacing ............... 2
Connecting Rod- Repair ............................. 13
Connecting Rod Alignment - Inspection ................. 19
Connecting Rod - Bend and Twist Inspection ............. 18
Connecting Rod Bushing Machining ................... 17
Connecting Rod Twist .............................. 20
Pin Bore Bushing - Installing ......................... 15
Pin Bore Bushing - Removing ........................ 13
Crankshaft Main Journal Regrind Specifications ........... 10
Crankshaft Repair Procedures ......................... 10
Crankshaft Grinding General ......................... 10
RepairTools ..................................... 10
Cylinder Block Repair Procedures ...................... 2
Cam Bore(s) ..................................... 3
Combustion Deck ................................. 2
Cylinder Sore(s) ................................... 4
Cylinder Bore(s) Repair - General ...................... 4
Repair Sleeve Installation ............................ 5
Repair Tools ..................................... 2
Engine Identification.. ............................... 3
Engine Dataplate .................................. 3
Exhaust Valve Insert Pocket Machining .................. 9
Follow All Safety Instructions Noted in the Procedures ...... 2
Follow the Cleaning Instructions Specified in the Procedures . 2
General Information ................................. 2
General Safety Instructions ........................... 4
Important Safety Notice ............................. 5
Grinding the Valve Seats ............................. 5
Grinding the Valves ................................. 12
Check Valve Spring Tension ......................... 13
Inspection ......................................... 2
Installing Service Valve ............................... 8
Main Bearing Cap - Repair ............................ 8
Perform the Inspections Specified in the Procedures ....... 2
Repair Guidelines ................................... 2
Repair Procedure ................................... 5
Repair Tools ....................................... 2
Repairing Threads with Coiled Thread Inserts. ............ 3
Repairing Worn Pipe Plug Holes With Oversize Copper Plated
Plugs ............................................. 6
Replacing Service Seats .............................. 11
Salvage Procedure to Use Part No. 1240677Hl and 1249678Hl
Service Valve Guides ................................ 4
Salvage Procedure to Use Part No. 1240763Hl Service Valve
Guides ........................................... 3
Sealing Small Casting Holes Or Pockets With Taper Threaded
Plugs ............................................. 4
Symbols .......................................... 6
Thrust Journal/Thrust Surface Width Regrinding .......... 10
Crankshaft Rod Journal Regrind Specifications ........... 12
Regrind of Crankshaft Main Journal Radius .. ............. 11
Regrind of Crankshaft Rod Journal Radius ............... 12
Using Metal Fillers For Temporary Repairs ............... 6
Valve Guides - Inspection and Installation ................ 3
Valve Seats - General ................................ 4
Calculating the Grinding Depth ....................... 5
When Should An Alternative Repair Be Performed? ......... 2
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610 Alternative Repair Manual

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610 Alternative Repair Manual

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CEBMGI OAR0

KDC 410 AND 610 SERIES

KDC 410 Series Engine KDC 610 Series Engine

General Repair Instructions ....................................... 0

Cylinder Block Group ............................................ 1

Cylinder Head Group ............................................ 2

Service Literature .............................................. L

Engine Identification ......................................................... ;

General Safety Instructions ..................................................... ;

About the Manual

LISERTWILLE. ILLINOIS. SO048 .S.A

0 VALVE LASH COLD EXH. RATED HP AT RPH

The KDC model designation represents the basic design and

General Safety Instructions

A Always wear protective glasses and protective shoes when working.

General Safety Instructions

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step,

043 INSPECTION is required,

qB CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque,

PERFORM an electrical MEASUREMENT.

Section 0 - General Repair Instructions

Follow All Safety Instructions Noted in the Procedures ................................. 2

Follow the Cleaning Instructions Specified in the Procedures ............................. 2

General Information .......................................................... 2

Perform the Inspections Specified in the Procedures ................................... 2

Repair Guidelines ........................................................... 2

Repair Procedure.. .......................................................... 5

Repairing Threads With Coiled Thread Inserts ....................................... 3

Using Metal Fillers For Temporary Repairs .......................................... 6

When Should An Alternative Repair Be Performed? .................................... 2

When Should An Alternative Repair Be Performed?

Follow All Safety Instructions Noted in the Procedures

Follow the Cleaning Instructions Specified in the Procedures

Perform the Inspections Specified in the Procedures

Repairing Threads With Coiled Thread Inserts

Metric Capscrew Nomenclature.

-LT Distance Between Thread in Millimeters

-L Major Thread Diameter in Millimeters

For special installations, call or write the following manufacturers:

For Perma-Thread For Heli-Coil For Coil Thread

Microdot Inserts Heli-Coil Products Tridair Industries

Sealing Small Casting Holes Or Pockets With Taper Threaded Plugs

1. They allow oil or water to leak to the outside of the engine.

1. Oil passage bosses.

3. Casting wall sections between water and oil passages.

4. Cylinder head capscrew bosses.

Castings can be repaired by using a taper threaded plug if:

1. The defect is removed by the tap drill.

2. The maximum size plug needed is 27.53 mm [1.084 inch] or less.

A: Standard Pipe Plug

Install and then tighten the plug.

9. Allow the LoctiteTM sealant to harden for at least thirty minutes.

11. If needed, paint the repaired area with a matching color.

0 Cleaning threaded area with Trichlorocthylene Ill or equivalent.

0 Chasing the threads with the correct size pipe tap.

Copper Plated Tool

Using Metal Fillers For Temporary Repairs

Different metal based metal fillers are available such

2. American Velodur Metal, Inc.