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Shop Manual

SEBE6161

Al 4

SERIES 6D1704
DIESEL ENGINES

This material is proprietary to Komatsu America international Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We resew8 the right to make changes or add Improvements at any time without Incurring any obligation to Install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for infomwtion on the latest revision.

December 1997

Coovriaht 1997 Komatsu America International Comoanv

00-l
03

No. of page

01

GENERAL ........................................................................................................ 01-001

11

STRUCTURE AND FUNCTION

....................................................... I 1-001

12

TESTING AND ADJUSTING

............................................................. 12-001

13

DISASSEMBLY

AND ASSEMBLY ................................................. 13-001

14

MAINTENANCE

STANDARD ........................................................... 14-001


2 z

15

REPAIR AND REPLACEMENT

OF PARTS .............................. 15-001

'

00-2 0

The affected pages are indicated bythe use ofthe following marks. Itis requested that necessary actions be taken to these pages according to the table below.

0
( )

Pageto be replaced Pageto be deleted

Replace Discard

Pages having no marks are those previously revised or made aditions.

LIST OF REVISED PAGES


Mark Page Revisior number Mark Page Revisior number Mark Page Revisior number Mark Page Revisior number Mark Page Revision number

00-l 00-2 00-2-I 00-2-2 00-2-3 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 01-001 01-002 01-003 01-004 01-004-1 01-004-2 01-004-4 01-004-5 01-004-6 01-004-7 01-004-8 01-004-9 01-004-10 0 01-004-11 @ 01-004-12 @ 01-004-13 0 01-004-14 @ 01-004-15 @I

01-005 01-006 01-007 01-008 01-009 01-010 01-010-1 01-010-2 01-010-3 01-010-4 01-010-5 01-010-6

01-028 01-029 0 11-001 II-002 II-003 II-004 II-005 11-005-1 II-006 11-006-I 11-006-2 11-006-3 II-007 II-008 11-008-I 11-008-2 II-009 11-010 11-011 II-012 II-013 II-014 II-015

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11-031-1 11-031-2 II-032 II-033 11-033-I II-034 11-034-I 11-034-2 11-034-3 11-034-4 11-034-5 11-034-6 11-034-7 II-035 11-035-I 11-035-2 11-035-3 11-035-4 11-035-5 11-035-6 II-036 II-037

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12-022 0 12-023 @ 12-023-I @ 12-023-2 @ 12-023-3 0 12-023-4 @ 12-023-5 @I 12-024 @ 12-024-I @ 12-024-2 @ 12-024-3 @ 12-024-4 @ 12-024-5 @ 12-024-6 @ 12-024-7 @ 12-024-8 @ 12-024-g 0 12-025 0 12-026 0 12-027 @ 12-028 0 12-028-I @ 12-028-2 @ 12-029 0 12-030 @ 12-030-I @ 12-030-2 @ 12-030-3 @ 12-030-4 @ 12-030-5 @ 12-030-6 @ 12-030-7 @ 12-030-8 @ 12-030-9 0 12-030-10 @ 12-030-11 @I 12-030-12 @ 12-030-13 @ 12-030-14 @ 12-030-15 @ 12-031 @ 12-032 0 12-033 0 12-034 0 12-035 @ 12-035-I @ 12-035-2 @ 12-035-3 @ 12-035-4 @ 12-035-5 @ 12-035-6 @I 12-035-7 @ 12-036 0 12-037 0

12-037-I @ 12-037-2 @ 12-037-3 @ 12-037-4 @ 12-037-5 @ 12-037-6 @ 12-038 0 12-039 0 12-039-I 0 12-039-2 @ 12-040 @ 12-041 0 12-041-I @ 12-041-2 @ 12-041-3 @ 12-041-4 @ 12-041-5 @ 12-041-6 @ 12-041-7 @ 12-041-8 @ 12-041-9 @ 12-041-10 @ 12-042 @ 12-043 @ 12-044 0 12-044-I 0 12-044-2 @J 12-045 0 12-046 0 12-047 0 12-047-I @ 12-047-2 @ 12-047-3 @ 12-047-4 @ 12-048 @ 12-049 8 12-049-I 0 12-049-2 0 12-049-3 0 12-049-4 0 12-049-5 0 12-049-6 @ 12-050 @ 12-051 0 12-053 @ 12-055 @ 12-056 @ 12-057 8 12-058 8 12-059 8 12-060 @ 12-061 @ 12-062 @ 12-063 @

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12-064 12-065 12-066 12-067 12-068 12-069 12-070 12-071 12-072 12-073 12-074 12-075 12-076 12-077 12-078 12-079 12-080 12-081 12-082 12-083 12-084 12-085 12-086 12-087 12-088 12-089 12-090 12-091 12-092 12-093 12-094 13-001 13-002 13-003 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 13-013 13-014 13-015 13-016 13-017 13-018 13-019 13-020 13-021 13-022 0 0 0 0 0 0 0 0 0 0 0 @I 0 0 0 0 0 0 0 0 0 0 0

13-023 13-024 13-025 13-026 13-027 13-028 13-029 13-030 13-031 13-032 13-033 13-034 13-035 13-036 13-037 13-038 13-039 13-040 13-041 13-042 13-043 13-044 13-045 13-046 13-047 13-048 13-049 13-050 13-051 13-052 13-053 13-054 13-055 13-056 13-057 13-058 13-059 13-060 14-001 14-002 14-003 14-003-I 14-003-2 14-004 14-005 14-006 14-007 14-008 14-009 14-010 14-011 14-012 14-013

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14-013-I 14-013-2 14-014 14-015 14-016 14-017 14-018 14-020 14-021 15-001 15-002 15-004 15-005 15-006 15-007 15-008 15-009 15-010 15-011 15-012 15-013 15-014 15-015 15-016 15-017 15-018 1.5-019 15-020 15-021 15-022 15-023 15-024 15-025 15-026 15-027 15-028 15-029 15-030 15-031 15-032 15-033 15-034 15-035 15-036 15-037 15-038 15-039 15-040 15-041 15-042 15-043 15-044 15-045

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15-046 15-047 15-048 15-049 15-050

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00-2-3 @

SAFETY

SAFETY

NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT SAFETY NOTICE


Proper service and repair is extremely important for safe machine operation. The

service and repair techniques are both effective designed To prevent manual. by Komatsu

recommended

by Komatsu

and described

in this manual

and safe. Some of these techniques for the specific the purpose.

require the use of tools specially

injury to workers,

symbol A

is used to mark safety precautions should always be followed arise, first consider

in this care-

The cautions

accompanying situation

these symbols

fully. If any dangerous take the necessary

arises or may possibly

safety, and

actions to deal with the situation.

GENERAL Mistakes carefully

PRECAUTIONS in operation are extremely and dangerous. Manual

6. Decide

a place

in the repair

workshop correct

to keep

keep tools and removed the tools Always Smoke Read the Operation Maintenance the machine. or repairs,

parts. Always

and parts in their

places.

keep the work area clean and make only in the areas provided for smok-

BEFORE operating

sure that there is no dirt or oil on the floor. ing. Never smoke while working.

1. Before carrying which 2. When

out any greasing

read all the precautions

given on the decals

are fixed to the machine. carrying out any operation, always PREPARATIONS 7. Before FOR WORK oil or making or tracks any repairs, and the

wear safety shoes and helmet. loose work clothes, missing. . Always . Always wear wear

Do not wear adding park the machine on hard, level ground, to prevent

or clothes with buttons hitting grind-

safety glasses when safety glasses etc. when

block the wheels machine 8. Before ground. equipment

parts with a hammer. ing parts with a grinder, 3. If welding trained, ways ing

from moving. starting If this work, lower blade, ripper, to the the

bucket or any other work equipment is not possible, out the work, alhand

repairs are needed, experienced carrying welding welder gloves,

always have a carry

insert

safety pin or use blocks to prevent the work from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, blocks, jacks support or stands

work. When wear

out welding

apron,

shield, cap and other clothes suited for weld-

work.
carrying out any operation always before starting. with two Always inagree on the operbefore starting any work,

4. When

the

machine

with

or more workers, ating procedure

before starting work. 10. Remove all mud and oil from use the handrails, the steps or ladders or

form your fellow workers step of the operation. hang UNDER in the operators

other places used to get on and off the machine. Always steps when Never jump impossible getting on or off the machine. If it is or ladders

Before starting

REPAIR signs on the controls compartment. and learn

on or off the machine. to use the handrails,

5. Keep all tools in good condition the correct way to use them.

steps, use a stand to provide

safe footing.

00-3

SAFETY

SAFETY

NOTICE

PRECAUTIONS 11 When or

DURING

WORK

19. Be sure to assemble original places. Replace any damaged . When installing

all parts again

in their

removing

the oil filler cap, drain plug pressure measuring plugs, to prevent the oil from compofirst the from

parts with new parts. be sure is beby contact

hydraulic out.

hoses and wires,

loosen them spurting Before remove circuit. 12. The when Wait water

slowly

that they will not be damaged ing operated. 20. When sure installing that they high pressure are

with other parts when the machine or removing completely or air circuits,

disconnecting the pressure

nents of the oil, water

hoses,

make careparts

not twisted.

Damaged

tubes are dangerous, and oil in the circuits is stopped, are hot ful when circuits. installing Also, the engine so be careful to cool before

so be extremely connecting

tubes for high pressure

check that installed.

not to get burned. for the oil and water out any work carrying circuits. 13. Before starting work, remove the leads from the battery. the negative Always remove first. use a hoist the lead from (-) terminal on the oil or water

are correctly 21 When

assembling

or installing tightening

parts, always torques. When

use the specified installing or parts which high speed,

protective vibrate

parts such as guards, violently correctly. or rotate at to check careful

be particularly

that they are installed 22. When fingers fingers 23. When which has aligning caught

14. When raising heavy components, or crane.

two holes, never insert your Be careful not to get your in a hole. hydraulic pressure, check assem-

or hand.

Check that the wire rope, chains and hooks are free from damage. Always ample Install places. slowly use lifting equipment capacity. the lifting Use to prevent equipment or crane at the correct and operate from with hitany a hoist

measuring

that the measuring

tool is correctly

bled before taking any measurements. 24. Take care when When removing removing the track, or installing the track the sepa-

the component

tracks of track-type rates suddenly,

machines. stand at

ting any other

part. Do not work

part still raised by the hoist or crane. 15. When ternal spring, removing pressure always covers which or under leave two are under infrom a in position the pres-

so never let anyone

either end of the track.

pressure bolts release

on opposite

sides. Slowly

sure, then slowly loosen the bolts to remove. 16. When wiring 17 When removing components, be careful not Damaged fires.

to break

or damage

the wiring.

may cause electrical removing piping,

stop the fuel or oil Fuel or oil

from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor even start fires. 18. As a general mum parts. rule, do not use gasoline when washing to can cause you to slip, or can

wash parts. In particular, of gasoline

use only the minielectrical

00-4

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 the contents him the correct way to perform of this manual and use it to full

repairs and make judgements. effect at every opportunity.

Make sure you understand

This shop manual service workshop. chapters are further

mainly

contains

the necessary

technical

information is divided

for operations

performed chapters;

in a these

For ease of understanding, divided

the manual

into the following

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 for troubleshooting. an understanding of the structure, but also serves as reference material

TESTING AND ADJUSTING


This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion charts correlating of the checks and repairs. to Causes are also included in this section.

Troubleshooting

Problems

DISASSEMBLY
This section assembling

AND ASSEMBLY
explains the order to be followed when removing, installing, disassembling or each component, as well as precautions to be taken for these operations.

MAINTENANCE
This section

STANDARD
gives the judgement standards when inspecting disassembled parts.

NOTICE
The time with specifications and the without latest date. contained any advance in this notice. shop Use manual the are subject to change given in the at any book specifications

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

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: Engine volume: Issued for every machine model Issued for each engine series Each issued as one volume to cover all models REVISED When pages. EDITION MARK is revised, an edition bottom mark of the

a manual

(@@@....I

is recorded

on the

Electrical volume: Attachments volume:

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

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 See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number. Example 1 (Chassis volume): 10 -3

Symbol

item

Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when work. performing the

A
*

Safety

TT
Item number ~~~~~~~b.,. each item. Example 12 - 5
TT -F

Caution

(IO. Structure number for

2 (Engine volume):

el
kg

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where

Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.

Tghteninc torque Coat

Oil, water Additional cated pages: Additional pages are indiafter the Drain by a hyphen (-) and number

oil, water or fuel must be added, and the capacity. Places where
must oil or water be drained, and quan-

page number. Example: IO-4

File as in the example.

tity to be drained.

Added IO-5

12-203 12-203-I pages -C12_203_2 12-204

00-6

FOREWORD

HOISTING

INSTRUCTIONS

HOISTING
HOISTING

INSTRUCTIONS

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASg every part weighing 25 kg or more indicated clearly with the symbol & is

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made:
I) Check

for removal

of all bolts fastening parts. part causthe part to be reof another

100%

88%

79%

71%

41%
SAD00479

the part to the relative 2) Check for existence ing interference moved. with

WIRE ROPES 1) Use adequate ropes depending on the to weight of parts to be hoisted, referring

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause a turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN (1000 kg1 vertically, at various hanging angles. When two ropes sling a load vertically, to 19.6 kN (2000 kg} of total weight suspended. (1000 hanging This weight two becomes make kg1 when angle. ropes up can be 9.8 kN a 120 force

the table below: Wire ropes (Standard Z or S twist ropes without galvanizing) Rope diameter mm 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60 *

Allowa kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

e load tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

On the other

hand, two

ropes are subjected

to an excessive

as large as 39.2 kN (4000 of 150.

kg1 if they sling

a 19.6 kN (2000 kg1 load at a lifting angle 0 a D


ibid

88

E,

16.7 0
(1400) Q (1000) % 600)

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. portion

2) Sling wire ropes from the middle of the hook.

30 Lifting

60 anrle

90 (dearee)

120

150
SAD00480

00-7

FOREWORD

COATING

MATERIALS

COATING
*

MATERIALS
used for

The recommended coating materials such as adhesives, gasket sealants and greases disassembly and assembly are listed below. Sr For coating materials not listed below, use the equivalent of products shown in this list.

Category

omatsu code

Part No.

Q' W
150 g

Container

Main

applications,

features

LT-IA

790-129-9030

ITubeTrl

Used to prevent rubber gaskets, rubber ~ ~~ ~~ cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs. Used as adhesive and plastic. or sealant for metal, glass

LT-IB

790-129-9050

20 g

(2 pes.)

Polyethylene container

LT-2

09940-00030

50 g

Polyethylene container

LT-3

790-129-9060 (Set of adhesive and hardening agent) 790-129-9040

Adhesive: 1 kg iardening agent: 500 g Polyethylene container Tube


I I

Can

Adhesives LT-4 Holtz MH 705 250 g . Used as sealant for machined holes.

790-126-9120

75 g

Used as heat-resisting ing engine. Quick Cure Used bers,

sealant

for repair-

Three bond 1735

790-129-9140

50 g

Polyethylene container

. . .

hardening type adhesive time: within 5 sec. to 3 min. mainly for adhesion of metals, plastics and woods.

rub-

I
Aron-alpha
201 790-129-9130 29

I
I

Polyethylene container

I
l l

Quick hardenina tvoe adhesive Quick cure typejmax. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.

Loctite 648-50

79A-129-9110

LG-1

790-129-9010

Gasket sealant

LG-3

790-129-9070

I
1 kg

200 g

Used as adhesive or sealant for gaskets and packing of power train case, etc. Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations, used to prevent seizure. Used as sealant for heat resistance gasket for high temperature locations such as engine precombustion chamber, exhaust pipe, etc.

00-8

FOREWORD

COATING

MATERIALS

Category

Komatsu code

Part No.

Q'W

Container
l

Main

applications,

features

. LG-4 790-129-9020 200 g Tube


l

Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc. Silicon based, quick hardening

LG-5

790-129-9080

1 kg

Polyethylene container

Gasket sealant

LG-6

09940-00011

250 g

Tube

* Features: LG-7 09920-00150 150 g Tube

type - Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

Three bond 1211 LM-G

. 790-129-9090 100 g Tube

Used as heat-resisting engine.

sealant

for repairing

Molybdenum disulphide lubricant

09940-00051

60 g

Can .

Used as lubricant for sliding portion (to prevent from squeaking). Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc. General purpose type

LM-P

09940-00040

200 g

Tube .

G2-LI

SYG2-400LI SYG2-350LI SYG2-4OOLl-A SYGS-16OLI

Various

Various

SYGA-1 6OCNLI
l

Grease

SYG2-4OOCA SYG2-350CA GP-CA


SYGS-4OOCA-A SYG2-160CA Various Various

Used for normal temperature, light load bearing at places in contact with water or steam.

SYGA-IEOCNCA
Molybdenum disulphide lubricant 400 g (IO per case)

Used for places with

heavy

load

SYG2-400M

Belows

type

00-9

FOREWORD

STANDARD

TIGHTENING

TORQUE

STANDARD
STANDARD

TIGHTENING
TORQUES

TORQUE
OF BOLTS AND NUTS use torque wrench).

TIGHTENING

Use these torques Thread diameter of bolt


I

for metric

bolts and nuts. (Always

Width across fiats


I

mm
6 8 IO 12 14

mm
10 13 17 19 22

Nm 13.2+ 1.4 31+3 6657 113*10 177f19 279+30 382?39 549f59 745f83 927*103

kqm 1.35kO.15 3.2kO.3 6.7f0.7 11.5+1 18f2 28.5f3 39f4 56f6 76f8.5 94.5f 10.5 135f15 175f20 225f25 280f30 335f35

27 30 33 36 39

41 46 50 55 60 I

1320+140 1720+190 2210+240 2750+290 3290*340

Thread diameter of bolt mm


6 8 10 12

Width across flats mm


10 13 14 27 Nm 7.85f 1.95 18.6f4.9 40.2f5.9 82.35k7.85 kgm 0.8f0.2 1.9f0.5 4.1f0.6 8.450.8

TIGHTENING

TORQUE

OF HOSE NUTS for hose nuts. Thread diameter mm


14 18 22 24 30 33 36 42

Use these torques Nominal


02 03 04 05 06 10 12 14

No.

Width

across flat mm
19 24 27 32 36 41 46 55

Tightening Nm
24.5f 4.9 49k19.6 78.5k19.6 137.3k29.4 176.5f29.4 196.1*49 245.2f49 294.2+49

torque kgm
2.5rt0.5 5f2 8+2 14&3 18*3 20+5 2525 30*5

TIGHTENING

TORQUE

OF SPLIT FLANGE for split flange Width

BOLTS

Use these torques Thread diameter mm


IO 12 16

bolts. Tightening torque

across flat mm
14 17 22

Nm 65.7* 6.8 112k9.8 279*29

kgm
6.7f0.7 11.5+1 28.5f3

00-10

FOREWORD

STANDARD

TIGHTENING

TORQUE

TIGHTENING

TORQUE

OF O-RING

BOSS CONNECTOR

Use these torques Nominal


02 03.04 05,06 IO,12 14

for O-ring boss connector Thread diameter mm


14 20 24 33 42

No.

Width

across flat mm

Tightening Nm
34.3* 4.9

torque kgm
3.5kO.5 9.5fl 14.5&Z 4356 89.5*13.5

Varies depending on type of connector.

93.1f9.8
142.1f19.6 421.4f58.8 877.1f 132.3

TIGHTENING

TORQUE

OF O-RING for O-ring Thread

BOSS CONNECTOR

Use these torques

boss connector diameter Width across flat mm


14 17 19 22 24 27 30 32 32 36 -

Nominal
08 10 12 14 16 18 20 24 30 33 36 42 52

No.

Tighteni Nm
7.35+ 1.47 11.27f 1.47 17.64f 1.96 22.54k 1.96 29.4& 4.9 39.2+ 4.9 49f 4.9 68.6+ 9.8 107.8f14.7 127.4f19.6 151.9k24.5 210.7f29.4 323.4f 44.1

I torque

mm
8 10 12 14 16 18 20 24 30 33 36 42 52

kgm
0.75+0.15 1.15~0.15 I.85 0.2 2.3f0.2 3kO.5 4kO.5 5f0.5 7&l Ilk 1.5 13+2 15.5k2.5 21.5+3 33* 4.5

TIGHTENING

TORQUES

OF FLARE NUT for O-ring Width boss connector Tightening


Nm 24.5f 4.9 49+ 19.6 78.5? 19.6 137.3k29.4 176.5ir29.4 196.1f49 245.2+49 294.2f49

Use these torques Thread diameter mm


14 18 22 24 30 33 36 42

SAD00483

across flat mm
19 24 27 32 36 41 46 55

torque
bm 2.5+ 0.5 5+2 8k2 1423 18k3 2Ok5 25f5 30+5

00-l 1

FOREWORD

STANDARD

TIGHTENING

TORQUE

TIGHTENING

TORQUE

FOR 102 ENGINE

SERIIES

(BOLT AND

NUTS) Engine. torque kgm


1.02 2.45 4.38 7.85 f 0.20 f 0.41 If: 0.61 f 1.22

Use these torques Thread

for bolts and nuts (unit: mm) of Cummins

diameter mm 6
8 10 12

Tightening Nm
10 24 43 77 f2 f 4 6 z!z rk 12

TIGHTENING

TORQUE

FOR 102 ENGINE

SERIIES

(EYE JOINTS) Engine. Tightening Nm


8k2 lOf2 12 +2 24 f 4 36 + 5

Use these torques Thread

for eye joints (unit: mm) of Cummins

diameter mm
6 8 10 12 14

torque kgm
0.81 1.02 1.22 2.45 3.67 f + + f + 0.20 0.20 0.20 0.41 0.51

TIGHTENING

TORQUE

FOR 102 ENGINE for tapered screws

SERIIES

(TAPERED

SCREWS) Engine. torque kgm


0.31 0.81 1.22 1.53 2.45 3.67 6.12 * f k f f f f 0.10 0.20 0.20 0.41 0.41 0.51 0.92

Use these torques Thread

(unit: inch) of Cummins

diameter inch
II16 l/8 l/4 318 l/2 314 1

Tightening Nm
351 8+2 12f2 1552 24 + 4 36 k 5 60 k 9

00-12

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

Number of strands 0.85 2 5 15 40 60


100

Dia. yfmst$ndsCross section (mm*) 0.32 0.32 0.88 2.09

Currerrtrating Cali:rzD. 2.4 3.1 12 20 37 59 135~~~ I I

Applicable

circuit

11 26

Starting,

lighting, signal etc. signal etc. and signal (Glow plug)

I Lighting,
Charging Starting Starting Starting Starting

65 84 85

0.32 0.45 0.80

5.23 13.36 42.73

4.6

127 217

0.80 0.80

63.84 109.1

13.6 17.6

178 230

CLASSIFICATION
\ Priority
1

BY COLOR AND CODE

Circuits1 Starting Pri- Code man/ Color Code W White WR White & Red WB B Black B Black BW Black & White BY Lighting Instrument Signal Other

I
R Red RW Y Yellow YR

I ! G
Green GW

I
L Blue LW

2 Color Code 3 Black & YellowI Red & Black Yellow & Black Green & Red BR Black & Red ICode 5 IColorlWhite Code 6 Color WG RY I YG I GY I Blue & Red LY Xed & White Yellow & Red Green & White Blue & White RB YB GR LR

led & Yellow Yellow & Green Green & Yellow Blue & Yellow RG <ed & Green bellow RL YL & Bluebreen GB LB

I
1

& Green1

& Black1Blue & Black

WJ

GL

Red & Blue ly ellow &White Green & Blue

00-13

FOREWORD

CONVERSION

TABLE

CONVERSION
METHOD The details OF USING

TABLE
THE CONVERSION Table in this section TABLE is provided to enable simple conversion of figures. For Table, see the example given below.

Conversion

of the method

of using the Conversion

EXAMPLE . 1. Method Convert of using the Conversion 55 mm into inches. Table to convert from millimeters to 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 down from @. (3) Take the point where from millimeters 2. the two lines cross as 0. Therefore, This point @ gives the value when converting to inches. 55 mm = 2.165 inches. 5 in the row across the top, take this as @, then draw a perpendicular line

Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal 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. point one place

Millimeters

to inches 0 0 IO 20 30 40 0 0.394 0.787 1.181 1.575 1 0.039 0.433 0.827 1.220 1.614 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5; 0.197 i 0.591 i 0.984: 1.378: 1.772; 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937

in

8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858

9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898

0 i ....... . . .. . .. .. . . . . . . . . .. . . . . .. .. . . . .50.. .. . . .. . .1.969 . .. . . .2.008. .. . . ..2.047. .. . .. . 2.087. .. . . ..2.126 . . . . 12.1651 .. . @_.. 2.520 2.559 2.441 2.480 2.362 2.402 60 2.913 2.835 2.874 2.953 2.756 2.795 70 3.307 3.228 3.268 3.346 3.150 3.189 80 3.701 3.740 3.543 3.622 3.661 90 3.583

00-l 4

FOREWORD

CONVERSION

TABLE

Millimeters

to Inches
7 mm = 0.03937 in

0 10 20 30

0 0.394 0.787 1.181

0.039 0.433 0.827 1.220

0.079 0.472 0.866 1.260

0.118 0.512 0.906 1.299

0.157 0.551 0.945 1.339

0.197 0.591 0.984 1.378

0.236 0.630 1.024 1.417

0.276 0.669 1.063 1.457

0.315 0.709 1.102 1.496

0.354 0.748 1.142 1.536

Kilogram

to Pound

1 kg = 2.2046

lb

2.20 24.25 46.30 68.34 90.39

4.41 26.46 48.50 70.55 92.59

6.61 28.66 50.71 72.75 94.80

8.82 30.86 51.91 74.96 97.00

11.02 33.07 55.12 77.16 99.21

13.23 35.27 57.32 79.37 101.41

15.43 37.48 59.53 81.57 103.62

17.64 39.68 61.73 83.78 105.82

19.84 41.89 63.93 85.98 108.03

10 20 30 40

22.05 44.09 66.14 88.18

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

00-l5

FOREWORD

CONVERSIONTABLE

Literto U.S. Gallon


1C = 0.2642 U.S. Gal

0 IO 20 30 40

0 2.642 5.283 7.925 10.567

0.264 2.906 5.548 8.189 10.831

0.528 3.170 5.812 8.454 11.095

0.793 3.434 6.076 8.718 11.359

1.057 3.698 6.340 8.982 11.624

1.321 3.963 6.604 9.246 11.888

1.585 4.227 6.869 9.510 12.152

1.849 4.491 7.133 9.774 12.416

2.113 4.755 7.397 10.039 12.680

2.378 5.019 7.661 10.303 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

Literto U.K. Gallon

IC = 0.21997 U.K. Gal 1 2 3 4 5 6 7 8 9

0 IO 20 30 40

0 2.200 4.399 6.599

0.220 2.420 4.619 6.819

0.440 2.640 4.839 7.039

0.660 2.860 5.059 7.259

0.880 3.080 5.279 7.479

1.100 3.300 5.499 7.969

1.320 3.520 5.719 7.919

1.540 3.740 5.939 8.139

1.760 3.950 6.159 8.359

1.980 4.179 6.379 8.579

8.799 1 9.019 ( 9.239 1 9.459 / 9.679 1 9.899 1 10.119 1 10.339 1 10.559 1 10.778

50 60 70 80 90

10.998 13.198

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098

12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

14.298
16.498 18.697 20.897

15.398
17.598 19.797

00-l 6

FOREWORD

CONVERSIONTABLE

kgm to ft. lb

1 kqm = 7.233 ft. lb

0 IO 20 30 40

0 72.3 144.7 217.0 289.3

7.2 79.6 151.9 224.2 296.6

14.5 86.8 159.1 231.5 303.8

21.7 94.0 166.4 238.7 311.0

28.9 101.3 173.6 245.9 318.3

36.2 108.5 180.8 253.2 325.5

43.4 115.7 188.1 260.4 332.7

50.6 123.0 195.3 267.6 340.0

57.9 130.2 202.5 274.9 347.2

65.1 137.4 209.8 282.1 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 795.6 868.0 940.3 1012.6

730.5 802.9 875.2 947.5 1019.9

737.8 810.1 882.4 954.8 1027.1

745.0 817.3 889.7 962.0 1034.3

752.2 824.6 896.9 969.2 1041.5

759.5 831.8 904.1 976.5 1048.8

766.7 839.0 911.4 983.7 1056.0

773.9 846.3 918.6 990.9 1063.2

781.2 853.5 925.8 998.2 1070.5

788.4 860.7 933.1 1005.4 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

00-17

FOREWORD

CONVERSIONTABLE

kg/cm*

to lb/in
1 kg/cm2 = 14.2233 lb/in2

0 10 20 30 40

0 142.2 284.5 426.7 568.9

14.2 156.5 298.7 440.9 583.2

28.4 170.7 312.9 455.1 597.4

42.7 184.9 327.1 469.4 611.6

56.9 199.1 341.4 483.6 625.8

71.1 213.4 355.6 497.8 640.1

85.3 227.6 369.8 512.0 654.3

99.6 241.8 384.0 526.3 668.5

113.8 256.0 398.3 540.5 682.7

128.0 270.2 412.5 554.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1138 1280

725.4 867.6 1010 1152 1294

739.6 881.8 1024 1166 1309

753.8 896.1 1038 1181 1323

768.1 910.3 1053 1195 1337

782.3 924.5 1067 1209 1351

796.5 938.7 1081 1223 1365

810.7 953.0 1095 1237 1380

825.0 967.2 1109. 1252 1394

839.2 981.4 1124 1266 1408

100 110 120 130 140

1422 1565 1707 1849 1991

1437 1579 1721 1863 2005

1451 1593 1735 1877 2020

1465 1607 1749 1892 2034

1479 1621 1764 1906 2048

1493 1636 1778 1920 2062

1508 1650 1792 1934 2077

1522 1664 1806 1949 2091

1536 1678 1821 1963 2105

1550 1693 1835 1977 2119

150 160 170 180 190

2134 2276 2418 2560 2702

2148 2290 2432 2574 2717

2162 2304 2446 2589 2731

2176 2318 2460 2603 2745

2190 2333 2475 2617 2759

2205 2347 2489 2631 2773

2219 2361 2503 2646 2788

2233 2375 2518 2660 2802

2247 2389 2532 2674 2816

2262 2404 2546 2688 2830

200 210 220 230 240

2845 2987 3129 3271 3414

2859 3001 3143 3286 3428

2873 3015 3158 3300 3442

2887 3030 3172 3314 3456

2901 3044 3186 3328 3470

2916 3058 3200 3343 3485

2930 3072 3214 3357 3499

2944 3086 3229 3371 3513

2958 3101 3243 3385 3527

2973 3115 3257 3399 3542

00-18

FOREWORD

CONVERSION

TABLE

Temperature
Fahrenheit-Centigrade Conversion

; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperain either Fahrenheit or Centigrade degrees.

ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1C = 33.8F

C
-40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -6 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

F
-40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0

C
-11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

F
51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0

C
7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

F
114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0

C
27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 146 145 150 155 160 165 170 175

F
117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0

00-l9

ENGINE
01 GENERAL

General view . . . . . . .. ......... Specifications ........................... General assembly drawing ................ Weight table ............................ Engine performance curve ................

01-002 01-004 01-005

01-01 1 01-012

170-1 SERIES

01-001

GENERAL

GENERAL VIEW

GENERAL

VIEW

S6D170-1 for PC650-1

1. 2. 3.

Corrosion resistor Crankcase breather intake manifold Fuel injection pump Fuel filter Oil filler Oil filter Vibration damper

4. 5. 6. 7. 8.

9. 10. 11. 12. 13.

Turbocharger Oil cooler Starting motor Alternator Water pump

6162POOZ

01-002

170-1 SERIES

GENERAL

GENERAL VIEW

SA6D170-A-1

for EG550-1

1. 2. 3. 4. 5. 6.

After-cooler Fuel filter Oil filter Fuel injection pump Oil filler Oil level gauge

7. 8. 9. 10.

Turbocharger Corrosion resister Alternator Starting motor

170-1 SERIES

01-003

GENERAL

SPECIFICATIONS

SPECIFICATIONS
Engine model S6D170-1

Applicable

machine

D275A-2

PC650-1

Pc1500-1 (Twin engine)

Number

of cylinders

- Bore x Stroke

mm cc

6-170x170 23,150 l-5-3-6-2-4

Total piston displacement Firing order

Overall

length

mm

1,860

2,029

2,029 1,009

Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust

mm

1,155

1,009

pipe)

mm

2,070 -

1,875

1,875 -

pipe)

mm

Flywheel Maximum

horsepower torque

302/l ,800 (404/l ,800I 2,079/1,300 {212/l ,300) 1,960 - 2,040 600 - 660

302/1,600 {404/1,600} 2,030/1,200 {207/l ,200) 1,700 - 1,800 650 - 700 224 {I671

302/l ,600 {404/l ,600) 2,030/1,200 {207/1,200~ 1,700 - 1,800 650 - 700 224 I1671

High idling Low idling Minimum fuel consumption ratio

219 {163}

Dry weight

2,620

2,375

2,375

Fuel pump Governor

Bosch PE-PDx type Bosch RSUV centrifugal, all speed type

Lubricating

oil amount

(refill capacity)

Coolant amount

Alternator

24V, 50A

24V, 13A

24V, 13A

Starting

motor

24V. 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

Battery

12V 170Ah x 2
I

12V 200Ah x 2
I

12V200Ahx2x2

I
Turbocharger Komatsu KTRI IO Komatsu KTR130 Air compressor Cummins single cylinder reciprocated type -

I
Komatsu KTR130 Cummins single cylinder reciprocated type -

Others

01-004 0

GENERAL

SPECIFICATIONS

S6D170-1 WA600-1 (Extreme cold weather)

WA600-1

WD600-1 (Cold weather)

WD600-1

6-170x 23,150 l-5-3-6-2-4

170

2,024

2,340

2,340

2,350

1,068

1,068

1,120

1,120

1,921 -

1,909 -

1,921 -

1,921 -

305/2,000 {409/2,000) 1,961/1,400 {200/1,400}

(Net) (Net) (Net) (Net)

305/2,000 (Net) {409/2,0001 (Net) 1,961/1,400 {200/1,400~ (Net) (Net)

334/2,000 #48/2,000) 2,089/1,400 I213/1,400}

(Net) (Net) (Net) (Net)

334/2,000 (Net) {448/2,0001 (Net) 2,089/1,400 {213/1,4001 (Net) (Net)

2,200 - 2,300 650 - 700 212 1158) (Net)

2,200 - 2,300 650 - 700 212 {I581 (Net)

2,300 - 2,400 650 - 700 212 11581 (Net)

2,300 - 2,400 650 - 700 212 {I581 (Net)

2,750

2,750

2,750

2,750

BOSCH PE-PDx type BOSCH RSUV centrifugal, all speed typf

BOSCH

PE-P type

lOSCH RSUV centrifugal, all speed type

DENS0 NE (EP-11) type DENS0 RSUV-D centrifugal, all speed type

135

135

135

139

24V, 50A

24V, 50A

24V, 50A

24V, 50A

24V, 7.5kW x 2

24V, IlkWx2

24V. 7.5kW x 2

24V, 7.5kW x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

KOMATSU KTRllOtype ZEXEL reciprocation, single cylinder type

KOMATSU KTRI IO type ZEXEL reciprocation single cylinder type

KOMATSU KTRllO type EXEL reciprocation, jingle cylinder type -

KOMATSU KTRIIO type EXEL reciprocation, single cylinder type -

01-004-l 03

GENERAL

SPECIFICATIONS

Engine

model

S6D170-1

Applicable

machine

OEM ;;;ig,ee;erator

OEM for generator (Standby)

OEM for generator (Power up)

Number

of cylinders-Bore displacement

x Stroke

mm cc

6-170x170 23,150 l-5-3-6-2-4

Total piston Firing order

Overall

length

mm

2,306

2,306

2,306

Ovrall

width

mm

1,048

1,048

1,048

Overall height (Excluding exhaust Overall height (Including exhaust

pipe)

mm

1,631 -

1,631 -

1,631 -

pipe)

mm

Flywheel Maximum High idling Low idling Minimum

horsepower torque

kW/rpm +lP/rpm) IkgG?pmI

324/l ,500 (50 Hz) {434/1,500} (50 Hz) 371/1,800 (60 Hz) {497/l ,800) (60 Hz) Max. Max. 1,560 (50 Hz) 1,872 (60 Hz) 700 - 900 219 I1631

355/1,500 (50 Hz) {476/1,5001 (50 Hz) 408/1,800 (60 Hz) 1547/1,800) (60 Hz) Max. Max. 1,775 (50 Hz) 1,890 (60 Hz) 700 - 900 217 {162)

345/1,500 :462/1,500} 403/1,800 [539/1,800}

(50 Hz) (50 Hz) (60 Hz) (60 Hz) 8 z z

Max. 1,560 (50 Hz) Max. 1,872 (60 Hz) 700 - 900 224 I1671

vm
fuel consumption ratio

Dry weight

kg

2,600

2,600

2,600

Fuel pump Governor

Bosch

PE-ZWx

type

Bosch PE-PDx type Bosch RSUV centrifJgal, all speed type

Bosch RSUV centrifugal, minimum maximum-speed

type

Lubricating

oil amount

(refill

capacity)

e
e
(Engine

107 (96)

107 (96)

107 (96)

Coolant

amount

only 43)

(Engine

only

43)

(Engine

only

43)

Alternator

24V, 13A

24V, 13A

24V, 13A

Starting

motor

24V, 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

Battery

12V 200Ah

x 2

12V 200Ah

x 2.

12V 200Ah

x 2

Turbocharger

Komatsu

KTRI 10

Komatsu

KTRI 10

Komatsu -

KTRI 10

Air compressor

Others

01-004-2 0

GENERAL

SPECIFICATIONS

Engine model

Applicable

machine

T
mm cc mm mm mm

SA6D170-A-1 WA700-1 n$$~$~t~$ne

HD465-3 (Twin turbcharger)

HD465-5 (Twin turbcharger)

Number

of cylinders - Bore x Stroke

6-170x170 23,150 l-5-3-6-2-4

Total piston displacement Firing order

Overall

length

1,877

1,989

2,391

Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust

1,060

1,106

1,080

pipe)

1,692

1,678

2,017

pipe)

Flywheel Maximum

horsepower torque

kW/rpm IHP/rpm) Ikgi?prnl vm

524/2,100 (Net) {702/2,1001 (Net) 2,820/1,400 {288/1,4001 (Net) (Net)

534/2,100 {715/2,100)

(Net) (Net)

478/2,000 {641/2,0001 2,810/1,400 {287/1,4001 2,240 - 2,300 700 - 750 208 {I 551

2,970/1,400(Net) {303/1,4001 (Net) 2,300 - 2,400 850 - 900 211 {157)

High idling Low idling Minimum fuel consumption ratio

2,300 - 2,400 630 - 680 221 (165)

vm
{g/HPh) kg
g/kWh

Dry weight

2,480

2,750 JZlithexhaust brake

2,900

Fuel pump Governor

BOSCH PE-ZWx type BOSCH RFD minimum maximum-speed control type

BOSCH PE-ZWx type BOSCH RSUV centrifugal, all speed type

I
Lubricating oil amount (refill capacity)

e
e
170 174

Coolant amount

Alternator

24V, 50A

24V, 13A

24V, 13A

Starting

motor

24V, 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

Battery

12V170Ahx2

12V 200Ah x 2

12V 200Ah x 2

Turbocharger

GARRET TV77 typex2 CUMMINS single cylinder reciprocated type With aftercooler

GARRET TV77 typex2 ZEXEL single cylinder reciprocated type With aftercooler, exhaust brake

GARRET TV77 type x 2 ZEXEL single cylinder reciprocated type With aftercooler

Air compressor

Others

01-004-4 63

GENERAL

SPECIFICATIONS

SAGDI 70-A-1 EG600-l,EG600B-1 EG600BS-1 OEM for generctor EG600BS-1 OEM for generctor (Engine No. 15503 and up)

EG550-1

EG580-1 EG580B-1

EG580B-IL

EPSAGD170-A-1

6-170x170 23,150 l-5-3-6-2-4

2,015 1,048

2,603

2,603

2,603

2,601

2,603

1103

1,103

1,103

1,120

1,103

2,015

1,746

1,746

1,746

2,332

1,746

431/1,500 (50 Hz) I578/1,5001 (50 Hz) 473/1,800 (60 Hz) {634/1,8001 (60 Hz)

456/1,500 (50 Hz) :611/1,500~ (50 Hz) 503/1,800 (60 Hz) :673/1,8001 (60 Hz)

470/1,500 (50 Hz) f630/1,5001 (50 Hz) 514/1,800 (60 Hz) 1688/1,800} (60 Hz) Max. 1,560 (50 Hz) Max. 1,872 (60 Hz) 700 - 900 217 I1621 (At rated output)

470/1,500 (50 Hz) 630/1,5001 (50 Hz) 514/1,800 (60 Hz) 688/1,8001 (60 Hz)

472/1,500 (50 Hz) ;633/1,5001 (50 Hz)

440/l ,800 {590/l ,800) 2,648/1,300 {270/1,300} 1,950 - 2,050 750 - 850 231 1172) (At rated output)

Vlax. 1,560 (50 Hz) 700 - 900 217 {162} (At rated output)

1,700 - 1,800 650 - 700 230 {I711 (50 Hz) 236 1176) (60 Hz)

Max. 1,560 (50 Hz) Max. 1,872 (60 Hz) 700 - 900 217 1162) (At rated output)

Wax. 1,560 (50 Hz) Vlax. 1,881 (60 Hz) 700 - 900 217 1162) (At rated output)

2,650

2,770

2,770

2,750

2,850

2,770

Bosch PE-ZWx type Bosch RSUV centrifugal, all speed type

Bosch PE-P (PS7S) type 3osch RSUV centrif. ugal, all speed type

osch PE-ZWx type, voodward PSG hyaulic type governor

119 (107)

;.::..,

139

(Engin&ly

43)

24V, 13A

24V, 13A

24V, 13A

I
24V, 7.5kW x 2 24V, IlkWx2

24V, 13A 24V, 25A (opt) 24V, 7.5kW x 2

24V, 50A

24V, 13A 24V, 25A (opt) 24V. 7.5kW x 2

24V, 7.5kW x 2

24V, llkWx2

12V 170Ah x 2

12V 200Ah

x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

Komatsu -

KTR150

Komatsu -

KTRI 50

Komatsu -

KTR150

Komatsu -

KTR150

Komatsu

KTR150

Komatsu

KTR150

With after cooler

With after cooler

With after cooler

With after cooler

With after cooler

With after cooler

01-004-5 0

GENERAL

SPECIFICATIONS

Engine model

SA6D170-A-1 HD465-5 (With electronic governor) HD465-5 (Mechanical governor)

Applicable

machine

HD465-5 *I (Twin turbcharger)

Number

of cylinders

- Bore x Stroke

mm cc

6-170x 23,150 l-5-3-6-2-4

170

Total piston displacement Firing order

Overall

length

mm

1,989

1,989

1,989

Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust

mm

1,106

1,106

1,106

pipe)

mm

1,678 -

1,678

1,678 -

pipe)

mm

534/2,100 (Net) l 2 015/2,100) Net) l 2 Iu 3 43W.750 ( et) l (587/1,1501 (Net) *3

Flywheel

horsepower torque

kW/rpm {HP/rpmI
tkgr$pm>

386/2,100 (Gross) ~518/2,100~ (Gross1 2,108/1,400 I215/1,4001 (Gross: (Gross1

534i2.100 {715/2,100} 2.971/1.400 {303/l ,400)

8 :
E b t lz

Maximum High idling Low idling Minimum

2,330 - 2,400 1,075 - 1,125 fuel consumption ratio

2,400-2,500 1.850-1.950

*2 l 3

2,330 - 2,400 900 - 950 211 I1571

2 z z

920 - 970 211 {I571

gkWh {g/HPhl kg

211 {I571

Dry weight

2,600 (With;;;kee;haust

2,750 JVith exhaust brake

2,670

Fuel pump Governor

3osch PE-ZWx typr Bosch RSUV-D zentrifugal, minimun naximum-speed type

Komatsu Electronic

KFE control

Bosch PE-ZWx type Bosch RSUV centrifJgal, all-speed type

Lubricating

oil amount

(refill capacity)

(Xi,
174 174

Coolant amount

24V, 50A

24V, 50A

24V. 50A

Starting

motor

24V. 7.5kW x 2

24V,llkWx2

24V, 7.5kW x 2

Battery

12V 200Ah x 4

12V 200Ah x 2

12V 200Ah x 2

Turbocharger

Water cooled Gallet TV77 x 2 Zexel single cylinder reciprocated type With after cooler *I: l2: l3: High altitude spec. en Power mode Economy mode ne No. 15963 a up to 15966

Gallet TV77 x 2 Zexel single cylinder reciprocated type With after cooler, exhaust brake

Gallet TV77 x 2 Zexel single cylinder reciprocated type With after cooler

Air compressor

Others

01-004-6

GENERAL

SPECIFICATIONS

SA6D170-A-1

EM680A

EG680A-1 6M170B-1

EM680A-A

OEM for generator

OEM for Marine engine

OEM for generator (Prime use)

6-170x170 23,150 l-5-3-6-2-4

2,880 (With marine 1,285 (With marine 1,757 (With marine

gear)

2,841 With marine gear) 1,137 With marine 1,831 With marine

2,796 With marine 1,150 With marine 1,781 With marine

gear]

2,603

2,603

gear)

gear)

gear)

1,048

1,048

gear)

gear)

gear]

1,756 -

1,756 -

55212,000 (740/2,000}

*4 *4

552/2,000 I740/2,000} 2,893/l ,400 I295/1,4001 2,100 - 2,200 550 - 600 211 {I571 (At rated output) 2,750 (Withog;;Tarine

629/2,000 {842/2,0001 3,295/1,400 {336/1,4001 2,100 - 2,200 550 - 600 217 (157) (At rated output) 3,250 (Withw;;arine

2,501/1,400 {255/l ,400) 2 & z 2,100 - 2,200 550 - 600 217 {162)

473/1,500 (50 Hz) [633/1,500} (50 Hz) 546/1,800 (60 Hz) f732/1,800} (60 Hz) Max. 1,560 (50 Hz) Max. 1,872 (60 Hz) 950 - 1,000 211 (157) (50 Hz) 217 I1621 (60 Hz)

55212,000 {740/2,000} 2,100 - 2,200 550 - 600 211 1157)

419/1,500 I561/1,5001 467/1,800 {625/l ,800) -

(50 Hz) (50 Hz) (60 Hz) (60 Hz)

Max. 1,568 (50 Hz) Max. 1,881 (60 Hz) 700 - 900 211 1157) (50 Hz) 217 1162) (60 Hz)

2,750 (Withw;r;;arine

2,720

2,500

2,720

Bosch PE-ZWx Bosch RSUV centrifugal,

type all speed type

100

(90)

120 (108)

120 (108)

67 (60) 119 (107) opt

119 (107) 122 (110) *5

118

85

85

(Engine

only 43)

24V, 30A

24V, 25A

24V, 30A

24V, 13A 24V, 25A (opt) 24V, 11 kW

24V, 13A 24V, 25A (opt) 24V. 7.5kW

24V, 13A 24V, 25A (opt) 24V, IlkW

24V, 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

12V 200Ah x 2

Komatsu

KTRI 10

Komatsu

KTRI 10

Komatsu -

KTRI 10

Komatsu

KTRI 10

Komatsu

KTRllO

Komatsu -

KTRIIO

With after cooler *4: *5:

With after cooler

With after cooler

With after cooler

With after cooler

With after cooler

Without marine gear With bypass filter

01-004-7 0

GENERAL

SPECIFICATIONS

SA6D170-A-1

Applicable

machine

DEM for generator (Stanby use)

H D465-3 (Single turbocharger)

HD465-3 (Single turbocharger)

Number

of cylinders-Bore

x Stroke

mm cc

6-170x170 23,150 l-5-3-6-2-4

Total piston displacement Firing order

Overall

length

mm

2,603

1,861

1,861

.P t i

t?

Ovrali width Overall height (Excluding exhaust Overall height (Including exhaust

mm

1,048

1,060

1,060

pipe)

mm

1,750 -

1,626 -

1,623 -

pipe)

mm

Flywheel Maximum

horsepower torque

kW/rpm {HP/rpm} {kgr%Pml rPm

581/1,500 (50 Hz) {779/1,5001 (50 Hz) 672/1,800 (60 Hz) {900/1,800} (60 Hz) Max. 1,575 (50 Hz) Max. 1,890 (60 Hz) 700 - 900

515/2,100 (Net) {690/2,1001 (Net) 2,824/1,400 {288/1,4001 (Net) (Net)

524/2,100 (Net) {702/2,1001 (Net) 2,824/1,400 {288/1,4001 (Net) (Net) 8 z z

High idling Low idling Minimum fuel consumption ratio

2,250 - 2,350 850 - 900 219 (163)

2,250 - 2,350 850 - 900 221 (163)

g/kWh {g/I-W kg

211 11571 (50 Hz) 217 {1621(60 Hz)

Dry weight

2,720

2,470

2,470

Fuel pump Governor

3osch PE-ZWx

typf

Bosch PE-ZWx type Bosch RSUV centrifugal, minimum maximum-speed type

3osch RSUV centrif, ugal, all speed type

Lubricating

oil amount

(refill capacity)

67 (60) 119 (107) opt

Coolant amount

(Engine

107 only 43)

170

170

Alternator

24V, 13A 24V, 25A (Opt) motor 24V, 11 kW

24V, 50A

24V, 50A

Starting

24V, 7.5kW x 2

24V, 7.5kW x 2

Battery

12V 200Ah

x 2

12V 170Ah x 4

12V 170Ah x 4

Turbocharger

Komatsu

KTRI IO

Komatsu

KTRllO

Komatsu

KTRI 10

Air compressor

Cummins single cylinder reciprocated type With after cooler With after cooler

Cummins single cylinder reciprocated type With after cooler

Others

01-004-8 0

GENERAL

SPECIFICATIONS

SA6D170-A-1

H D465-3 (For ORAPA MINE)

Pc1ooosP-1 (For LAYTON)

6-170x170 23,150 l-5-3-6-2-4

1,861

2,373

1,060

1,909

1,626

1,080 -

485/2,000 (Net) {650/2,0001 (Net) 2,800/l ,300 (Net) (285/1,300} (Net) z 2,250 - 2,350 840 - 860 216 I1611 (Net)

434/1,750 {582/1,750} 2,730/1,300 1279/1,3001

(Net) (Net) (Net) (Net)

1,900 - 2,000 650 - 700 211 (Net) 11571 (Net)

io
z

2,480

2,555

BOSCH PE-ZWx wpe BOSCH RFD minimun maximum-speed control type

IOSCH PE-P(PS7S1 type BOSCH RSUV centrifugal, all speed type

170

160

24V, 50A

24V, 50A

24V, 7.5kW x 2

24V, 7.5kW x 2

12V 200Ah

x 2

12V 200Ah

x 2

GARRET TV77 typex2 CUMMINS single cylinder reciprocated type With aftercooler

KOMATSU KTRllOtype EXEL reciprocation jingle cylinder type With aftercooler

01-004-9 63

GENERAL

SPECIFICATIONS

Engine model D375A-1 IEngine Serial No. up to 11045)

SA6D170-B-1 D375A-1 (Engine Serial No. 11046 and up) D375A-1 (Engine Serial No. 13551 and up)

Applicable

machine

Number

of cylinders

- Bore x Stroke

mm cc

6-170x170 23,150 l-5-3-6-2-4

Total piston displacement Firing order

t
Overall length mm 2,017 2,017 2,017

Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust

mm

1,139

1,139

1,139

pipe)

mm

1,746 -

1,746 -

1,746 -

pipe)

mm

Flywheel Maximum

horsepower torque

kW/rpm IHP/rpm) tkgr%?pmI rpm rpm

379/1,800 {508/1,8001 2,609/l ,300 {266/l ,300) 1,950 - 2,050 600 - 700 215 {I601

379/l ,800 {508/1,800} 2,609/l ,300 {266/l ,300) 1,950 - 2,050 600 - 700 215 {160}

392/l ,800 {525/1,8001 2,618/1,300 {267/l ,300) 1,960 - 2,040 580 - 680 215 {ISO} 8 z z

High idling Low idling Minimum fuel consumption ratio

g/kWh {g/HPh)

Dry weight

kg

2,660

2,660

2,660

Fuel pump Governor

losch PES-PDx typ 3osch RSUV centrif Jgal, all-speed type

Bosch PE(PS7S) 3osch RSUV centrifugal,

type all-speed type

Lubricating

oil amount

(refill capacity)

Coolant

amount

165

165

165

Alternator

24V, 30A

24V, 35A (1104612802) 24V, 50A (12806 -) 24V, 7.5kW x 2

24V, 50A

Starting

motor

24V, 7.5kW x 2

24V, 7.5kW x 2

Battery

12V 170Ah x 2

12V 170Ah x2

12V 170Ah x 2

Turbocharger

Komatsu -

KTRllO

Komatsu -

KTRIIO

Komatsu -

KTRI 10

Air compressor

Others

With after cooler

With after cooler

With after cooler

01-004-10 0

GENERAL

SPECIFICATIONS

SA6D170-B-1 EG500-1, EG500B-1 EG500BS-1 OEM for generator EG500-1, EG500B-1 EG500BS-1 OEM for generator

Pc1000-1

HD465-3 (Single turbocharger)

EG450-1

EG480-1 EG480B-1

6-170x170 23,150 l-5-3-6-2-4

2,373

2,373

2,577

2,603

2,603

2,603

1,909

1,909

1,048

1,048

1,048

1,048

1,080

1,080 -

1,809

1,746 -

1,746 -

1,746 -

2,275

405/1,700 {542/1,7001 2,550/1,300 I260/1,3001 2 1,800 - 1,900 650 - 700 211 {157}

451/2,100 {604/2,1001 2,481/1,400 {253/1,400} 1,800 - 1,900 650 - 700 224 {I 67)

354/1,500 (50 Hz) (481/1,5001 (50 Hz) 400/l ,800 (60 Hz) [544/1,8001 (60 Hz) 1,800 - 1,890 950 - 1,000 217 I1621

37211,500 (50 Hz) l498/1,500~ (50 Hz) 416/l ,800 (60 Hz) (557/1,8001 (60 Hz) Max. Max. 1,560 (50 Hz) 1,872 (60 Hz) 750 - 850 217 {162} (At rated output)

383/1,500 (50 Hz) {513/1,5001 (50 Hz) 427/1,800 (60 Hz) {572/1,8001 (60 Hz) Max. Max. 1,572 (50 Hz) 1,890 (60 Hz) 750 - 850 217 1162) (At rated output)

383/1,500 (50 Hz) {513/1,500) (50 Hz) 427/l ,800 (60 Hz) {572/1,8001 (60 Hz) Max. Max. 1,568 (50 Hz) 1,881 (60 Hz) 700 - 900 217 I1621 (At rated output)

(D
z

2,555

2,555

2,650

2,650

2,750

2,720

BOSCH PE-P(PS7S) type BOSCH RSUV centrif ugal, ail-speed type

BOSCH PE-ZWx type BOSCH RSUV-D :entrifugal, minimum naximum-speed type

BOSCH PES-PD type 30SCH RSUV centrif ugal, all-speed type

BOSCH BOSCH PE-ZWx type

PE-P(PS-7% type

BOSCH RSUV centrifugal, all-speed type

lOSCH RSUVcentrifugal, all-speed type (with cocel spring) 119 (107)

(z,

119 (107)

119 (107)

160

160

(Engin%ly

43)

(Enginiinly

43)

(Engine8tnly

43)

24V, 50A

24V, 50A

24V, 50A

24V, 13A

24V, 13A

24V. 25A

24V, 7.5kW

x 2

24V, 7.5kW

x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

24V, 7.5kW x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

KOMATSU

KTRI 10

<OMATSU

KTRI 10

<OMATSU -

KTRllr

<OMATSU -

KTRI IO

KOMATSU -

KTRllO

KOMATSU

KTRI 10

ZEXEL single cylinder reciprocated type With aftercooler

ZEXEL single cylinder reciprocated type With aftercooler With

With aftercooler

aftercooler

With

aftercooler

With

aftercooler

01-004-11 a3

GENERAL

SPECIFICATIONS

Engine model

Applicable

machine

Number

of cylinders

- Bore x Stroke

mm cc

6-170x170 23,150 l-5-3-6-2-4

Total piston displacement Firing order

Overall

length

mm

2,603

2,601

2,603

Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust

mm

1,100

1,120 -

1,048

pipe)

mm

1,746 -

1,746 -

pipe)

mm

2,332

Flywheel Maximum

horsepower torque

kW/rpm WP/rpml Ikg:?pmpm) rDm

364/l ,500 ~488/1,500~ Max. 1,560

397f1.800 {540/1,800} 2,461/l ,300 {251/1,300} 1,950 - 2,050 750 - 850 231 {I721 (At rated output)

367/1,500 (50 Hz) {492/1,5001(50 Hz) 416/1,800 (60 Hz) {557/1,800} (60 Hz)

High idling Low idling Minimum fuel consumption ratio

Max. 1,560 (50 Hz) Max. 1,862 (60 Hz) 700 - 800 223 {I 661 (At rated output)

8 z z

rpm g/kWh
{g/HPM

700 - 900 220 I1641 (At rated output)

Dry weight

2,650

2,850

2,650

Fuel pump Governor

Bosch PE-PDx type Bosch RSUV centrifugal, all-speed type

Bosch PE-P(PS7S) type 3osch RSUV centrif Jgal, all-speed type

losch PES-PDx type 3osch RSUV centrifugal, all-speed type

Lubricating

oil amount

(refill capacity)

119 (107)

Coolant amount

(Engine

120 only 43)

139

(Engine8Znly

43)

Alternator

24V, 13A

24V, 25A

24V. 13A

Starting

motor

24V, IlkWx2

24V, 11 kW

24V, 7.5kW x 2

Battery

12V 200Ah x 4

12V 200Ah x 2

12V 200Ah x 2

Turbocharger

Komatsu -

KTR130

Komatsu -

KTR130

Komatsu

KTR130

Air compressor

With after cooler

Others

With after cooler

With after cooler

01-004-12 0

GENERAL

SPECIFICATIONS

SA6D170-B-1

OEM for generator

OEM for generator

OEM for generator (Stand by use)

OEM for generator (Prime use)

OEM for 6-Pole generator

6-170x 23,150 l-5-3-6-2-4

170

2,603

2603

2,603

2,603

2,323

1,048

1,048

1,048

1,048

1,080

1,746

1,746

1,746

1,746

1,611 -

406/1,500 (50 Hz) {543/1,5001 (50 Hz) 457/1,800 (60 Hz) {612/1,800} (60 Hz)

379/1,500 (50 Hz) {508/1,500~ (50 Hz) 446/1,800 (60 Hz) {598/1,8001 (60 Hz) Max. Max. 1,560 (50 Hz) 1,872 (60 Hz) 700 - 900 217 {I621

417/1,500 (50 Hz) :559/1,5001 (50 Hz) 492/1,800 (60 Hz) :660/1,800~ (60 Hz) Vlax. 1,568 (50 Hz) Vlax. 1,881 (60 Hz) 700 - 900 217 1162)

37811,500 (50 Hz) {506/1,5001(50 Hz) 403/1,800 (60 Hz) {539/1,800> (60 Hz) Max. Max. 1,568 (50 Hz) 1,881 (60 Hz) 700 - 900 224 {I 671

275/1,000 (50 Hz) :369/1,0001 (50 Hz) 345/1,200 (60 Hz) [462/1,2001 (60 Hz)

8
z z

Max. Max.

1,572 (50 Hz) 1,890 (60 Hz) 700 - 800

Max. 1,045 (50 Hz) Max. 1,254 (60 Hz) 750 - 850 217 {I601 217 {I621 (50 Hz) (60 Hz)

223 {I 66) (At rated output)

2,650

2,650

2,650

2,650

2,700

Bosch Bosch

PE-PDx type all-speed type

Bosch PE-P(PS7S) type Bosch RSUV centrifJgal, all-speed type

RSUV centrifugal,

119 (107)

67 (60) 119 (107) opt

67 (60) 119 (107) opt

122 (110)

(Engin%ly

43)

(Engine

only 43)

(Engine

only 43)

(Engine

only 43)

(Engine

107 only 43)

24V, 13A

24V, 13A 24V, 25A (opt) 24V, 7.5kW x 2

24V, 13A 24V, 25A (Opt) 24V, 7.5kW x 2

24V, 13A 24V, 25A (Opt) 24V, 7.5kW x 2

24V, 11 kW

24V. 7.5kW x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

12V 200Ah

x 2

Komatsu -

KTR130

Komatsu -

KTR130

Komatsu -

KTR130

Komatsu

KTR130

Komatsu

KTR130

With after cooler With

after cooler

With

after cooler

With after cooler

With

after cooler

01-004-13 0

GENERAL

SPECIFICATIONS

Engine

model

SA6D170-AE-1

Applicable

machine

WA600-1 (EC regulation)

DENY0 generator DCAGOOSSK

Number

of cylinders

- Bore x Stroke

mm cc

6-170x170 23.2 {23,150} l-5-3-6-2-4

Total piston Firing order

displacement

Overall

length

mm

2,024

2,603

Ovrall

width

mm

1,136

1,062

Overall height (Excluding exhaust Overall height (Including exhaust

pipe)

mm

2,242 -

1,736

pipe)

Flywheel Maximum High idling Low idling Minimum

horsepower torque

kW/rpm {HP/rpm) ckgr!$pmpm)

305/2,000 (Net) {409/2,0001 (Net) 1,960/1,400 (Net1 {200/l ,400) (Net) 2,200 - 2,300

170/l ,500 j30/1,500} j13/1,800 j88/1,800) Max. Max.

(Net, 50Hz) (Net, 50Hz (Net, 60Hz) (Net, 60Hz

1,570 (50 Hz) 1,880 (60 Hz) 700 - 900

rpm
fuel consumption ratio

650 - 700 212 (Net) {1581 (Net)

g/kWh Ig/HPh)

At rated flywheel horsepower !ll {157} (Net, 50Hzl !I8 11631 (Net, 60Hzl 2,770

Dry weight

2,900

Fuel pump Governor

30SCH PE-PDx tyr #OSCH RSUV centri ugal, all speed type

3OSCH PE-ZWx type ZEXEL electronic control type

Lubricating

oil amount

(refill capacity)

119 (107)

Coolant

amount

135

(Engine

only

: 43)

Alternator

24V, 50A

24V, 25A

Starting

motor

24V, 7.5kW x 2

24V, 11 kW

Battery

12V 200Ah

x 2

12V 200Ah

x 2

Turbocharger

KOMATSU KTRllOtype :EXEL reciprocatio single cylinder typ Aftercooler

KOMATSU KTR150 type

Air compressor

Aftercooler

Others

01-004-14 03

GENERAL

SPECIFICATIONS

SAAGD170-1

Generator (50 Hz only)

6-170x170 23.15 I23,1501 l-5-3-6-2-4

2,635

1,048

1,770

597/1,500 (Net) I800/1,500} (Net)

8
z z

Max.

1,570

700 - 900 At rated flywheel horsepower 205 (Net) Cl531 (Net) 2,650

BOSCH PE-ZWy type GAC electronic governor

147 (135)

(EngineZnly

: 43)

24V, 13A

24V, 11 kW

12V 200Ah

x 2

KOMATSU KTRISO type

Air cooled aftercooler

01-004-15 63

/
GENERAL GENERAL ASSEMBLY DRAWING

GENERAL
S6D170-1 .
LEFT

ASSEMBLY

DRAWING

(for PC650-1)
SIDE VIEW

r
Wind c3

z ./ i
Zrankshaft center

lb/3 9

1851.9 20289

6162FOOl

170-1 SERIES

01-005

GENERAL

GENERAL

ASSEMBLY

DRAWING

RIGHT SIDE VIEW

16114

Exhaust 0

Crankshaft

Iii i i it

6162FOOZ

01-006

170-1 SERIES

GENERAL

GENERAL

ASSEMBLY

DRAWING

FRONT SIDE VIEW

1001.5

Crankshaft

6162FOO3

170-1

SERIES

01-007

GENERAL

GENERAL

ASSEMBLY

DRAWING

REAR SIDE VIEW

Crankshaft center

Thread dia. 12 mm, pitch 1.75 mm. thread depth 21 mm, 16 points

Thread dia. 10 mm, pitch 1.5 mm, thread depth 13 mm, 24 points

330.2
6 162FOO4

01-008

170-l

SERIES

GENERAL

GENERAL

ASSEMBLY

DRAWING

SAGD170-A-1 .

(for EG550-I)

LEFT SiDE VIEW

I II I lt=i
uun 0 ILo 01

c. center

0 n

IIIII
0 0 0 0

2006.4

170-1 SERIES

0 l-009

GENERAL

GENERAL

ASSEMBLY

DRAWING

RIGHT SIDE VIEW

\ 1663.9

d ?

01-010

170-1 SERIES

GENERAL

GENERAL

ASSEMBLY

DRAWING

FRONT SIDE VIEW

170-1 SERIES

01-010-1

GENERAL

GENERAL

ASSEMBLY

DRAWING

REAR

SIDE

VIEW

41.4

243.4

01-01 o-2 0

170-1 SERIES

GENERAL

GENERAL

ASSEMBLY

DRAWING

SA6D170-B-1 0

(for D375A-1)

LEFT SIDE VIEW

Crankshaft center

/ -

6162FOO9

170-1 SERIES

01-01 o-3 0

GENERAL

GENERAL

ASSEMBLY

DRAWING

RIGHT SIDE VIEW

r-n

b-4 -

6162FOlO I

01-010-4 0

170-1 SERIES

GENERAL

GENERAL

ASSEMBLY

DRAWING

FRONT SIDE VIEW

6162FOll

170-l

SERIES

O -%-5

GENERAL

GENERAL

ASSEMBLY

DRAWING

REAR SIDE

VIEW

Crankshaft

center

6162FO12

01-01 O-6 0

170-1 SERIES

GENERAL

WEIGHT

TABLE

WEIGHT TABLE
Unit: kg

No.
I

Item
I

Component
I

S6D170-1 31 -

SA6D170-A-1
I

SA6D170-B-l 20 31 37

TV77 1 Turbocharger KTRI 10 KTR 130 KTR 150 2 Cylinder head assembly Cylinder spring head, valve and valve

17x2 31 35 37

37

I
675 675

I
675

Cylinder

block assembly

1
4 5 6

Cylinder block Main bearing cap Cylinder liner

Gear case cover

48

48

48

Xming

gear case

30

30

30

Oil pan

45

45

45

Flywheel

assembly

Flywheel Ring gear

71:{ ;~~$tzl 51: WA600-1 95

48: HD465-3 122: EG550-1 95

43: D375A-1 122: EG450-1 92: D375A-1 117: EG450-1

8
8 Flywheel housing

Crankshaft

assembly

Crankshaft Crank gear Camshaft, plate cam gear and thrust


I

270

270

270

10
I

Camshaft

assembly

31
I

31

31

11

Piston and connecting assembly

rod

Piston, piston ring, piston pin and connecting rod

21

21

21

I
21 21

I
21

12

Oil pump

13

Fuel injection

pump

30: { ;$;;;;:J 31: WA600-1 20

48

31

14

Water pump

20

20

15

Alternator

15: { p$~50& 12: WA600-1 motor 18

15

IO

16

Starting

18

18

17

Air compressor

15

15

18

After cooler

65

43.5

01-011
0

GENERAL

ENGINE

PERFORMANCE

CURVE

ENGINE
S6D170-1
Flywheel Maximum Minimum

PERFORMANCE
PC1500-1)
410 HP/l,600 207 kgm/1,200 ratio: rpm rpm

CURVE

(for PC650-1,
horsepower: torque:

fuel consumption

165 g/HP.h

150 125 100 E ;

I\I

t75F

450

400

350 EI
I

5 P ,
0

300

250

400

600

800

1000

1200

1400

1600

1800

2000

Engine speed (rpm)

01-012 0

170-1 SERIES

GENERAL

ENGINE

PERFORMANCE

CURVE

S6D170-1
Flywheel

(for D275A-2)
horsepower: 405HP/1,800 rpm

200 Maximum torque: 212 kgm/l,300 + 0 rpm . Minimum fuel consumption ratio: 16lg/HP.h

,150 -125 -100 -75 E m Y J P z

- 50
- 25 -0

400

600

800

1000

1200

1400

1600

1800

2ooO

Engine speed (rpm)

170-1 SERIES

01-012-l @

GENERAL

ENGINE PERFORMANCE CURVE

S6D170-1 (for WDSOO-11 SA6D170-AE-1 (for WA600-1


Flywheel horsepower Maximumtorque

EC regulation)
HPV2,OOO rpm

: 305 kWM09
: 1,960 Nm

1200 kgml/l,400 rpm

s
200

9
-2.000

150 -1.500

2 U L :

100 -1,000

50 0

-500 -0

0.
I

3 Y

co
a

450 300

450

400

; 3 0 :
co
L

350

250

300 200 250 150

200 I

x -

LL

150

100

150

100 50 50

100

50 n _

..
600

600

1,000 1,200 1.400 1,600 1.800 2.000 2.200 2,400 Engine speed (rpm) SWEOI184

01-013 @

GENERAL

ENGINE PERFORMANCE CURVE

S6D170-1
Flywheel

(for WDSOO-1)
horsepower torque

: 334 kW (448 HP}/2,000 rpm


: 2,089 Nm {213 kgmV1,400 rpm

Maximum

z
/
250

-: !500

200

2000 a 2 1500 z 0 c

150

100

1000

&
500.

3
1

, cnn I! I
500

350
450 0

400

300

350 250 3 a G 200 250 250I

300 \ / I 200 15C


L

Inn

\I

150 IOC 100 5c 50

150

100

50

(I-

::

800

1000

1200 Ens

1400 ine

1600 speed

1800 (rpmi

2000

2200

2400
SWEOIOZI

01-014 0

GENERAL

ENGINE PERFORMANCE CURVE

S6D170-1
Flywheel

(for EPS6D170-1)
horsepower

: 385 kW {516 HP} 1,800 rpm

E
550-

3 1

2
550

400-

500350450-

500

450

400-

300-

400

350250c ; S 250300200-

350

300

250

200-

150-

200

150IOOIOO5050-

150

100

50

o-

o-

Engine

speed

(rpm)

SWE01022

01-014-l 0

GENERAL

ENGINE PERFORMANCE CURVE

S6D170-1
Flywheel

(OEM for generator)


horsepower use

Prime

: 324 kW I434 HP} 1,500 rpm (50 Hz) 371 kW 1497 HP} 1,800 rpm (60 Hz)

Stand

by use

: 355 kW (476 HP} 1,500 rpm (50 Hz)


408 kW {547 HP} 1,800 rpm (60 Hz)

a
1

3 _b

2
600 355kW1476Hd (Standbul II I 50Hz I

408kW&07H@ 60Hz

itandbrl /

600

450

550

400

550

/I

500 350 450

500

400

300

I 60Hz

371 kW(497HP) (Prime) 350 250 300 200 z z 200 150 250 250 :

I
50Hz

I
(Prime)

324kWt434Hd

150 100 100 50 50

1100

1200

1300

1400

1500

1600

1700

1800

1900 SWE01023

En9

i ne

speed

(rpm)

01-014-2 0

GENERAL

ENGINE PERFORMANCE CURVE

SA6D170-A-1
Flywheel Maximum

(PClOOOSP-1 for LAYTON)


horsepower torque

: 434 kW {582 HP}/l,750 rpm : 2,731 Nm I278.5 kgm}/1,300 rpm

3
400 300 200 4000 c 3000 -2000

Yj
m

z +-

100 0

-1000 -0

a r

3
2.

600550500-

450

600 550 500

400

350 450400; a g 300200 250200150100 IOO50 0 150 250 200 150 350300 450 400

250

50 50 0 0 ::

BOO

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900
SWE01024

Ens i ne

speed

(rpm)

01-014-3 G9

GENERAL

ENGINE PERFORMANCE CURVE

SAGD170-A-1

(for HD465-3

with single turbocharger)


HP}/2,100 rpm rpm

Flywheel horsepower Maximumtorque

: 524 kWi613

: 2,824 Nm (288 kgmI/1,400

s
400

E
4000

3000

2000

100

1000

a
I:

B
Y

:
80(

800

600

700

500

70(

600 400 < : 400 300 500

60(

50(

40(

300 200 200 100 100

30(

20(

lO(

800

1000

1200

1400

1600 speed

1600 (rpm)

2000

2200

2400
SWE01025

Engine

01-014-4 0

GENERAL

ENGINE PERFORMANCE CURVE

SAGD170-A-1
Flywheel Maximum

(for HD465-3

with single turbocharger

and twin turbocharger)

horsepower torque

: 524 kW (702 HP} 2,100 rpm : 2,824 Nm I288


kgm1 1,400 rpm

s
-400

s
-4000 -3000 ; u L

-300

-200

-2000

-100

-1000

-0

-0

L1
1

3 2 600

2
800

800

700 500 600

700--

600 400

z
z

500

500

400

300

400

300 200 200 100 100

300

200

100

800

1000

1200

1400

1600

1800

2000

2200

2400 SWE01026

Ens i ne

speed

(rpm)

01-015 0

GENERAL

ENGINE PERFORMANCE

CURVE

S6D170-AFlywheel Maximum Minimum

1 (For HD465-5)
horsepower: torque: 715 307 HP/2,100 kgm/l,400 ratio: rpm rpm

fuel consumption

150 g/HP.h

200

P 2 J P I-"

100

800 output /

\ \

l/l

II
0 800 1000 1200 1400 1600 1800 2000 2200 Engine speed (rpm)

2400

II

6162F817

O-F

170-1 SERIES

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-A-1
Flywheel Maximum

(for HD465-3
horsepower torque

high altitude

spec.)

: 386 kW I518 HP) 2,100 rpm : 2,108 Nm 1215 kgm1 1,400 rpm

s
300

5
3000

200

2000 a, 2 0 If

100

1000

&
600-

Y 3

400500-

2 a G

400-

300-

300zoo200100loo100 200 I

o-

o-

500

1000

1500

2000

2500 SWE01027

Engine

speed

(rpm)

01-016-l 0

GENaERAL

ENGINE PERFORMANCE,CURVE

S6D170-1

(For WA700-1) 641 HP/2,000 286.5 kgm/l,400 rpm rpm

Flywheel horsepower: Maximum torque:

Minimum fuel consumption ratio: 153 g/HP.h

250

600-

,C
170-1 SERIES

600

800

1000

1200

1400

1600

1800

2000

2200

Engine speed (rpm) F6161A012

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-A-1

(for EG550-1)

Flywheel horsepower: 578 HP/l ,500 rpm (50 Hz) 634 HP/l,800 rpm (60 Hz)

800

600 c I s P 'j 0 500

400

2
300 190 4 2 .g s '"a

180 200 170

100

Enginespeed x 100 (rpm)

1560

1870

o-:8

170-l

SERIES

GENERAL

ENGINE PERFORMANCE

CURVE

SA6D170-A-1
Flywheel

(EG5808-1)
horsepower: 611 673 HP/l,500 HP/l,800 rpm (50 rpm (60 Hz) Hz)

Fuel consumption

ratio:

160 g/HP.h

(Rated output)

800

600.

500

/ 611 HP (50HZ) I I I \

I I I I I

400

300

I I I
I ,

I I
I

200

I
I

-190
180

200 1 100 --wFue


CO.nsOmptiOn

I
ratio

I I
I I

-170
160 - 150 1700 1800 1900 2000

1000

1100

1200

1300

1400

1500

I 1600

Engine speed @pm) F6161A013

170-1 SERIES

01-ii19

GENERAL

ENGINE PERFORMANCE

CURVE

SA6D170-A-1

(EG5808-1

L) 633 HP/l,500 rpm (50 Hz)

Flywheel horsepower:

Fuel consumption ratio: 160 g/HP.h (Rated output)

800

500

E. 400 c 'j 6 s 300

i
II \I I 200 , I lOO------/ ,' I .-I I I

220 --210 '200 --190 180 s-170 160 --150 1700

1000

1100

1200

1300

1400

1500

1600

1800

F6161A020

O-iJ 9-1

170-1 SERIES

GENERAL

ENGINE PERFORMANCE

CURVE

SA6D170-A-1
Flywheel

(EG600BS-1)
horsepower: 630 688 HP/l,500 HP/l,800 rpm (50 rpm (60 Hz) Hz)

Fuel consumption

ratio:

160 g/HP.h

(Rated output)

800

600

500

c
I

s a s

400

220 210

z p
\ = .P 5 s E 2 E 5 I=

300

!OO 190

200

180 170

100

160 150

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

Engine speed (rpm) F6161A014

O -Z20

170-1 SERIES

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-A-1
Flywheel Maximum

(for EM680A)
horsepower torque

: 552 kW 1740 HP) 2,000 rpm : 2,501 Nm I255 kgm) 1,400 rpm

s
400

s
-4000 -3000 g m L

Torque

300

200

-2000

If

100 -1000

i 0

a
1

3
24

600-

600-

700500600: 500400-

: 400300-

300200200IOOIOO-

o-

o-

J-2) 1 .
600

II
600
1000 1200 1400 1600 1800 2000 2200 SWEOlOZtl

En9 i ne

speed

(rpm)

Ol -020- 1 0

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-A-1
Flywheel Maximum

(for EM680A-1,6M170B-1,
horsepower torque

OEM for marine

engine)

: 552 kW (740 HP} 2,000 rpm


: 2,893 Nm I295 kgm) 1,400 rpm

s
-400

e
-4000 -3000 ; Is L

-300

-200

-2000

If

.lOO

-1000

-0

-0

0
2

3 2.

8OC

600

700

600

z 0'

500

400

300

200

100

..
800

1000

1200

1400

1600

1800

2000

2200

2400 SWE01029

En9 ine

speed

(rpm)

01-020-2 0

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-A-1
Flywheel Maximum

(for EM680A-A)
horsepower torque : 629 kW I842 HP} 2,000 rpm : 3,295 Nm I336 kgm} 1,400 rpm

9
400

s
-4000 -3000

300

200

-2000

100

-1000

-0

3
24

700900l300- 6007005006004005 : 400300500-

300200200looIOO-

100 A
o-

o-

?!
.\

600

800

1000

1200

1400

1600

1800

2000

2200

2400 SWE01030

En9 i ne

speed

(rpm)

01-020-3 0

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-A-1
Flywheel

(for EPSAGD170-A-l)
horsepower

: 508 kW (680 HP1 2,000 rpm

&
800-

Y 3

600-

700500; : 500600400-

400-

300-

300200200tooloo-

o-

o-

800

1000

1200

1400

1600

1800

2000

2200

2400 SWEOtO31

En9 ine

speed

(rpm)

01-020-4 0

GENERAL

ENGINE

PERFORMANCE

CURVE

SAGD170-B-1
Flywheel Maximum Minimum

(for D375A-1)
508 HP/l ,800 rpm 266 kgm/l,300 ratio: rpm

horsepower: torque:

fuel consumption

158 g/HP.h

280

260 T 2 S 220 : I-

240

200

800

1000

1200 Engine

1400 speed (rpm)

1600

1800

c
I50

170-1 SERIES

01-021 0

GENERAL

ENGINE PERFORMANCE

CURVE

SAGD170-B-1
Flywheel Maximum Minimum

(D375A-2)
horsepower: torque: 525 HP/l ,800 rpm rpm

267 kgm/l,300 ratio:

fuel consumption

158 g/HP.h

Torque

z 150 210 $ \ = .P ;;j ; 0 .E z C 8 Z I?

-200 -190

lOO-

180 -170

50

Fuel consumption ratio I

160 - 150

600

800

1000

1200

1400

1600

1800

2000

2200

Engine speed @pm) F6161A015

01-:22

170-1

SERIES

GENERAL

ENGINE PERFORMANCE

CURVE

SAGD170-B-1
Flywheel Maximum Minimum

(PCIOOO-1)
horsepower: torque: 542 260 HP/l ,700 rpm rpm

kgm/l,300 ratio:

fuel consumption

155 g/HP.h

250

1100

1200

1300

1400

1500 (rpm)

1600

1700

1800

1900

Engine

speed

F6161A016

170-1 SERIES

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-B-1
Flywheel Maximum

(for PClOOO-1 high altitude


horsepower torque

spec.)

: 341 kW {457 HP} 2,000 rpm : 2,157 Nm (220 kgm) 1,300 rpm

,
400

5
-4000

300 200

-3000 -2000

; D i

100 0

1000 t 0

Ene

i ne

speed

(rpm)

SWE01032

01-023-l 0

GENERAL

ENGINE PERFORMANCE

CURVE

SAGD170-B-1

(for HD465-3

with

single turbocharger) rpm rpm

Flywheel horsepower: Maximum torque:

613 HP/2,100 253 kgm/l,400

Minimum fuel consumption ratio: 165 g/HP.h

250

200

50

7oc

600

500

z I 5 a 5 0

400 z 3oc 200 Igo 20( 180 170 1OC \ \ 150 C 1000 1200 Fuel consumption ratio 160 : , z ; .o z E z 8 2

1400

1600

1800

2000

2200

2300

2400

Engine

speed (rpm) F6161A017

O -:24

170-1 SERIES

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-B-1
Flywheel

(for EG450-1)
481 HP/l,500 rpm (50 Hz)

horsepower:

544 HP/l ,800 rpm (60 Hz)

I HP/l

DO rpi -

600 0 HP, /

h
500 z I 2 n ; 0 400

k/

lP/l ,E

1 rpm

I
I
I

I
I I I

300

1 i-I
I I I

I t
I

I
I I I

200

100

12

13

14

15

Engine speed x 100 (rpm)

:I
I I
I I L

CO

,mpti

I I

I I I

I + I

I I

16

17

16

19

170-1 SERIES

O -$25

GENERAL

ENGINE PERFORMANCE

CURVE

SAGD170-B-1

(EG480B-1) 488 HP/l,500 549 HP/l,800 rpm (50 Hz) rpm (60 Hz)

Flywheel horsepower:

Fuel consumption ratio: 162 g / HP.h (Rated output)

220 210 200 190 180 170 160 150 E $ \ _a .P ;;; h : .E 7 6 0 5 I?

Engine speed (rpm) F6161AO18

01-026 0

170-1 SERIES

GENERAL

ENGINE PERFORMANCE

CURVE

SAGD170-B-1
Flywheel

(EG5OOBS-1)
horsepower: 513 572 HP/l ,500 rpm (50 rpm (60 Hz) Hz)

HP/l,800

Fuel consumption

ratio:

160 g/HP.h

(Rated output)

I
600

550

,I
I

I
500 111

.I

I
I
I

I I I

I
350 Y 300

I I I I
I

I I

250

I I

200

I i

I I

150

! I

I I
1

210 200 190 180

z : p .i .$ 2 2 i : IL

100
50

I I I
/ d* I

I I
/

/I

I
I

170 160 50

I
1700 1800

1000

1100

1200

1300

1400

1500

I 1600

2000

Engine speed(rpm) F6161A019

170-1 SERIES

O -:27

GENERAL

ENGINE PERFORMANCE CURVE

SA6D170-B-1
Flywheel

(OEM for generator)


horsepower

Prime use

: 367 kW 1492 HP] 1,500 rpm (50 Hz)


416 kW (557 HP} 1,800 rpm (60 Hz)

Stand by use : 406 kW (543 HP) 1,500 rpm (50 Hz) 457 kW 1612 HP) 1,800 rpm (60 Hz)

a
I

3
Y

450.

650
450.

600

550

400

500I350 45c l-

4oc l-

300

350I250 300l3 a g 200 250l-

350 367kWI492Hd 50Hz 300(Prime)

250

O- 15( 201
D151
lot 101 D51 51 O-

200

.-_
150

100

50

O-

OLLI

1100 1200 1300 1400 1500 1600 1700' 1800 1900 SWE01033

Engine

speed

(rpm)

01-028 0

GENERAL

ENGINE

PERFORMANCE

CURVE

SA6D170-B-1

(for EPS6D170-B-1)

Flywheel horsepower :445 kW{597 HP)1,800rpm

CL 1

3
Y

500650650 450-

600-

600

550-

400-

500350450-

400-

300-

400

3503 P
0

250-

350 / 300 /

';' 300200250-

250 I 150- 200 / I

zoo-

150looloo5050-

150

100

o-

o-

600

600

1000

1200

1400

1600

1600

2000

2200
SWE01034

Engine

sPeed(rPm)

01-029 0

II

ENGINE
STRUCTURE AND FUNCTION
GENERAL STRUCTURE.. ............................ 1 I-002

INTAKE AND EXHAUST SYSTEM Intake and exhaus system ..................... 1 I-004 1 I-007 Turbocharger .......................................... 1 I-009 After-cooler.. ........................................... ENGINE BODY 11-010 Cylinder head ......................................... II-012 Valve system ........................................... 1 I-014 Cylinder block ......................................... 1 I-016 Main circulation part .............................. 1 I-018 Timing gear.. ........................................... Flywheel and flywheel housing ............ 1 I-020 LUBRICATION SYSTEM 1 I-021 Lubrication system chart ....................... II-022 Oil pump ................................................. Oil filter and safety valve.. ..................... 1 I-023 1 I-024 Oil cooler ................................................ 1 I-025 Oil pump relief valve.. ............................ 1 I-025 Oil cooler by-pass valve ........................ 1 I-026 Piston cooling valve ............................... Mechanical pump.. ................................. 1 I-027 FUEL SYSTEM 1 I-028 Fuel system chart.. ................................. 1 I-030 Fuel injection pump ............................... 1 I-032 Fuel injection nozzle ............................... Fuel injection pump drive ...................... 1 I-033 1 I-034 Fuel filter.. ............................................... 11-034-I Fuel cut solenoid ................................. 1 I-034-3 Engine stop motor .............................. 1 I-035 Starting aid ............................................. Outline of electronical governor system (with electronical governor made 11-035-I by ZEXEL) ..........................................

COOLING SYSTEM
Cooling system chart.. ........................... Water pump.. .......................................... Fan drive and tension pulley.. ............... Corrosioon resistor ................................ Thermostar ............................................. 1 I-036 1 I-037 1 I-038 1 I-040 1 I-041 1 I-042 1 I-043 1 I-044 1 I-045 1 I-047

ACCESSORY
Air compressor mounting ..................... Air compressor. ...................................... ELECTRICAL SYSTEM Alternator ................................................ Starting motor ........................................ Wiring diagram ......................................

11-001

43

STRUCTURE

AND

FUNCTION

GENERAL

STRUCTURE

GENERAL
S6D170-1

STRUCTURE

6162FlOl

1.

Crank pulley Thermostat Cylinder head Fuel injection nozzle Rocker arm housing cover Piston pin Intake valve Exhaust valve

9. 10.

Camshaft Rocker arm shaft

17. 18. 19. 20. 21. 22. 23. damper 24.

Front seal Oil pump Connecting rod cap Oil pan Main bearing cap Crankshaft Ring gear Flywheel

2. 3. 4. 5. 6. 7. 8.

11. Push rod 12. 13. 14. 15. 16. Tappet Rocker arm housing Cylinder block Rear seal Vibration

1 l-002

170-1

SERIES

STRUCTURE

AND

FUNCTION

GENERAL

STRUCTURE

25. 26. 27. 28. 29. 30.

Cylinder liner Piston Oil cooler Fuel injection pump Piston cooling nozzle Connecting rod 6162F102

170-1 SERIES

11-003

STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

INTAKE
S6D170-1

AND

EXHAUST

SYSTEM

for PC650-1

Intake system

1. 2. 3. 4. 5.

Air cleaner Turbocharger Intake manifold Exhaust manifold Muffler

A.
6162F106

Intake inlet Exhaust

B.

Exhaust system

6162F107

11-004 0

170-l SERIES

STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

S6D170-1

for PC1500-1

Intake system

1. 2. 3. 4. 5.

Air cleaner Turbocharger Intake manifold Exhaust manifold Muffler

Exhaust system
A. 6. Intake inlet Exhaust

170-l SERIES

1 l-005

STRUCTURE

AND

FUNCTION INTAKE ANQ EXHAUST SYSTEM

S6D170-1 for WA600-1 Intake system

Exhaust system

F6161A002

F6161A003

1 J-005 1

170-l SERIES

STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

SA6D170-A-1

for EG550-1 Intake system

F
/--(-Exhaust system

1. 2. 3. 4. 5.

Air cleaner Turbocharger Intake manifold Exhaust manifold Muffler

A. 6.

Intake inlet Exhaust

1 I-006 0

170-l SERIES

STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

SAGDI 70-A-1 for H D465-3


Intake system

2. 3. 4.

Turbocharger intake manifold Exhaust manifold

A. B.

Intake inlet Exhaust

Exhaust system

170-1 SERIES

l l -0060

STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

SAGD170-B-1 for EG450-1 Intake system

1. 2. 3. 4. 5.

Air cleaner Turbocharger Intake manifold Exhaust manifold Muffler

Exhaust system
A. B. Intake inlet Exhaust

1 l-006-2 0

170-1 SERIES

STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

SAGD170-B-1

for D375A-1 Intake system

1 . Air cleaner 2. 3. 4. 5. Turbocharger Intake manifold Exhaust manifold Muffler

Exhaust system

A. 6.

Intake inlet Exhaust

170-1 SERIES

11-006-3 0

STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

TURBOCHARGER .Q
KTRllO

1. 2. 3. 4.

Blower housing Blower impeller Clamp Center housing

a.

Oil inlet (from oil filter)

TURBOCHARGER
Type: Overall length: Overall width: Overall height: Weight: Maximum Maximum Maximum Direction Lubrication Komatsu KTRI 290 mm 305 mm 267 mm 19 kg allowable rotation: charging: 46 kg/min. allowable temperature of rotation method: (inlet): 75OC max. Right with (view from blower side): Forced lubrication engine oil 94,000 rpm 10

b. Oil outlet (to oil pan) c. Air inlet d. Air outlet e. f. Exhaust inlet Exhaust outlet

5. Journal bearing 6. shield 7. Turbine impeller 8. 9. 10. 11. Flinger Thrust bearing Turbin shaft Turbine housing

170-1 SERIES

1 l-007 0

STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM

KTR130

6162F108

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Blower housing Blower impeller Clamp Center housing Journal bearing Clamp Shield Turbine impeller Turbine housing Flinger

11. 12. 13.

Insert Thrust bearing Turbine shaft

Specifications * Type: *Weight:

of turbocharger

Komatsu KTR130 31 kg 70,000 rpm 750C max. Right charging: of rotation method: 32 kg/min. (inlet,C): (view from blower side): Forced lubrication engine oil with

* Length x width x height: 366 x 358 x 323 mm


- Continuous rotation:

a.
b. c. d. e. f.

Oil inlet (from oil filter) Oil outlet (to oil pan) Air inlet

* Maximum
l

Appropriate Lubrication

temperature

- Direction
l

Air outlet Exhaust inlet Exhaust outlet

:O*

170-l SERIES

STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

KTRl50 5 6

F6166009

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Blower housing Blower impeller Clamp Center housing Journal bearing Turbine impeller Turbine housing Flinger Thrust bearing Turbine shaft

a. b. c. d. e. f.

Oil inlet (from oil filter) Oil outlet (to oil pan) Air inlet Air outlet Exhaust inlet Exhaust outlet

Specifications
l

of turbocharger

Type: Weight: Maximum Maximum Maximum Direction

Komatsu KTR 150 350 x 289 x 358 mm 65,000 rpm 75OC max. Right
with

* * * *
*
l

Length x width x height: 38 kg

allowable rotation: charging: of rotation method:

78 kg/min. (inlet): (view from blower side): Forced lubrication engine oil

allowable temperature

Lubrication

170-l

SERIES

1 T8-

STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

TV77

615OF106-1

1. Lock nut 2. Blower housing 3. Blower impeller 4. Thrust collar 5. Back plate 6. Thrust bearing 7. Seal ring 8. Center housing 9. Retaining ring

12. Turbine housing 13. Piston ring impeller Overall length ~_______ ~7 Overall width Overall height Weight Continuous speed F Oil outlet Max. air supply Compression ratio Applicable Direction exhaust temp. of rotation 0.43 kglsec 7

Type

GARRETT

CO. TV7705

14. Turbine A B C D E Air inlet

.275mm I I
284 mm 264 mm 17 kg 90,000 rpm

Air outlet Gas inlet Gas outlet Oil inlet

10. Journal bearing 11. Shroud

3.4 Max. 700C Clockwise (see from

I the blower side)

1 l-008-2 0

SERIES

170-l

STRUCTURE

AND

FUNCTION

INTAKE

AND

EXHAUST

SYSTEM

AFTER-COOLER

l!!!zll El I
0 0

00 oo

~~[T~_fL!,:0 0 0 0

;:

O O 0 O O -Oo0 0 O oo0 0

1. 2.

Cover After-cooler body

A: 6:

From water pump To water manifold

170-1

SERIES

1 l-009

STRUCTURE

AND

FUNCTION

ENGINE

BODY

ENGINE BODY
CYLINDER HEAD

_
a-.

A4

B4

6162F109

1. 2. 3. 4. 5. 6. 7.

Water manifold Cylinder head Rocker arm housing Rocker arm housing cover Valve guide Nozzle holder sleeve Tube

a. b. c. d.

Coolant

(to thermostat)

Fuel (return) Oil (from main gallery) Tap for water temperature gauge sensor

1l-010 0

170-1

SERIES

STRUCTURE

AND

FUNCTION

ENGINE

BODY

Section A - A

Section B - B
6162FllO

Cylinder

head type, injection nozzle, 4-valve type

. Direct-injection
l

Separate type (1 -head for 1 -cylinder)

Valve seat . Press fitted into cylinder head of intake valve and exhaust valves.

170-1 SERIES

11-011

STRUCTURE AND FUNCTION

ENGINE BODY 1

VALVE SYSTEM

1. 2. 3. 4. 5. 6. 7.

Intake valve Exhaust valve Rocker arm Collar Camshaft gear (No. of teeth: 48) Camshaft Adjustment screw

8. 9. 10. 11. 12. 13. 14.

Lock nut Upper spring seat Valve spring (outer) Valve spring (inner) Lower spring seat Push rod Cam roller

15. 16. 17. 18. 19. 20. a.

Cam follower pin Cam follower Cam follower;haft Adjustment screw Lock nut Cross head Oil (from oil pump)

11-012

170-1 SERIES

STRUCTURE

AND

FUNCTION

ENGINE

BODY

13

14 15 16 17

intake side of No. 1 cylinder

Exhaust side of No. 1 cylinder

6162F112

6162F113

Valve timing

TDC (Top Dead Center)

Camshaft
l

Special cast/forged alloy, 7 bearings

- Cam face and journal face: High frequency hardening

close

BDC (Bottom Dead Center) 6162F114

170-1 SERIES

11-013 0

STRUCTURE

AND

FUNCTION

ENGINE

BODY

CYLINDER

BLOCK

\ 8

9
6162F115

1. 2. 3. 4. 5. 6. 7.

Front cover Cylinder block Cylinder linw Crevice seal O-ring (nitrile rubber: O-ring (silicone rubber: Front seal black) red)

8. 9. 10. 11. 12. 13. 14.

Main bearing Thrust bearing Cam bushing Piston cooling nozzle Main bearing cap Main bearing cap bolt Oil level gauge

11-014

170-1 SERIES

STRUCTURE

AND

FUNCTION

ENGINE

BODY

10

14

6162F116

Cylinder

block Seven bearings Seven bearings

- Crankshaft: - Camshaft: Cylinder liner

- Wet type liner, tufftride

treatment

on bore surface

* Crevice seal, two O-rings

170-1 SERIES

1 J-015

STRUCTURE AND FUNCTION

ENGINE BODY

MAIN

CIRCULATION

PART

6162F117

1. 2. 3. 4. 5. 6. 7. 8.

Piston pin Connecting rod Connecting rod bushing Piston Top ring 2nd ring Oil ring Crankshaft (Outside pulley 200 mm)

9. 10. 11. 12. 13. 14. 15. 16.

Vibration

damper 36)

Crankshaft
* Special cast/forged

Crank gear (No. of teeth: Connecting rod bearing Crankshaft Thrust bearing Main bearing Connecting rod cap Connecting rod bolt

alloy, seven

bearings
- Journal face:

High frequency

hardening

diameter:

11-016 0

170-1 SERIES

STRUCTURE

AND

FUNCTION

ENGINE

BODY

ALUMINUM

PISTON TYPE

Main bearing and connecting rod bearing * 34ayer Kelmet * Upper main bearing: Piston * Lo-Ex aluminum alloy Niresist is cast on top ring. * Thermal flow solid type (S6Dl70-1) with oil groove

. Groove of top ring:

15

- Thermal flow shaker type


(SAGD170-A-1) (SAGD170-B-1)

-16

- Forced cooling with piston cooling


Connecting rod

- Forged alloy steei

6162F118

Piston T

Piston ring
Engine Top ring 2nd ring Oil ring

P-face keystone barrel face

2-face keystone inner cut taper face

Bevel cutter with coil expander

S6D170-1 SAGD170-A-I SAGD170-B-1 Hard chrome plating Hard chrome plating Hard chrome plating

6162Fllg

170-1 SERIES

STRUCTURE

AND FUNCTION

ENGINE BODY

FCD PISTON

TYPE

Main bearing, connecting bearing


l l

rod

34ayer Kelmet Upper main bearing: with oil groove

Piston (FCD piston type)


l

0 l

Ductile special iron casting with thin structure Thermal flow shaker type Forced lubricating oil cooling by piston cooling

--

Al6
+

2
Piston
Shaker type

6162Fll8

Piston ring
Engine Top ring 2nd ring Oil ring

2-face keystone eccentric barrel face SAGDl70-A-1 (HD465-5) (WA700: 14594 and up) Hard chrome plating

2-face keystone inner cut taper face

Bevel cutter with coil expander

Hard chrome plating

Hard chrome plating

6162F819

11-017-l CD

STRUCTURE

AND

FUNCTION

ENGINE

BODY

TIMING GEAR

i
1. Idler gear (No. of teeth: 2. 3. 4. Cam gear (No. of teeth: 571 48) 24) 6. 7. 8. 9. 10. 5. Idler gear (No. of teeth: 45) Idler gear (No. of teeth: 30) 36) 33)

6162FlZO

Crankshaft gear (No. of teeth:

Compressor driving gear (No. of teeth: Injection pump driving gear (No. of teeth: 48)

Oil pump driving gear (No. of teeth: Idler gear (No. of teeth: 41)

Water pump driving gear (No. of teeth

20)

11-018

170-1 SERIES

STRUCTURE AND FUNCTION

ENGINE BODY

l-l

Section B - 6

SectionC-C

Section D - D (with timer)

Section d - D (without SectionA-A

timer)

6162F121

170-1

SERIES

11-019

STRUCTURE

AND

FUNCTION

ENGINE

BODY

FLYWHEEL

AND

FLYWHEEL

HOUSING

6162F122

1. 2. 3. 4. 5.

Ring gear Flywheel Rear seal Flywheel housing Drain plug

Tightening order of flywheel mounting bolt.

Ring gear No. of teeth


118

Applicable machine PC650, PClOOO, PC1 500, HD465-5 D275A-2, D355A. D375A. WA600. WD600, WA700, HD465-3, EG550

138

1 l-020 0

STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

LUBRICATION
LUBRICATION

SYSTEM
CHART

SYSTEM

Oil pan Oil level sensor Oil pump Main relief valve Piston cooling valve Oil cooler $lcyler 8. Oil filter 9. Safety valve 10. 11. Main gallery Crankshaft by-pass

12. Camshaft 13. Rot ker arm 14. Piston cooling nozzle 15. Timing gear 16. Fuel injection pump 17. Turbocharger 18. Mechanical pump 19. a. 6162F123A w. Oil pressure gauge To intake manifold Coolant

170-1 SERIES

1 l-021 0

STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

OIL PUMP

6162F124

1. 2. 3. 4. 5. 6. 7. 8. 9.

Oil pump driving gear (No. of teeth: Oil pump body Bushing Drive shaft Bushing Pump cover Driven shaft Driven gear (No. of teeth: Bushing 12)

33)

Oil pump

* Gear pump type * Oil pump speed: Engine speed x 1.091

1 l-022

170-1

SERIES

STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

OIL FILTER AND

SAFETY

VALVE

6actionA-A
6162F125

1. 2. 3. 4. 5. 6. 7. a. b.

Safety valve cap Oil pressure sensor Filter bracket Filter element Cartridge Filter case Safety valve Valve spring From oil pump To engine each component >

Oil filter - Filteration area: 0.82 m2 x 2

Safety valve - Cracking pressure (difference pressure): 2.0 + 0.2 kg/cm2

170-1 SERIES

1 l-023

STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

OIL COOLER
S6D170-1 SAGD170-B-1

i-B

Section A - A

Section B - B

6162F126

1. Cooler cover 2. 3. a. b. c. Cooler element Drain cock Coolant (from water pump) Oil (from oil pump) Oil (to engine each component)

Oil cooler * Heat exchanged: * Heat-transmitting Min. 45000 area: Kcel/hr.

2.94 m2

* Oil flow capacity: 180 Urnin. * Water flow capacity: 890 Q/min.

11-024 0

170-1 SERIES

STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

SAGD170-A-1

Section A - A

Section B - B

1. 2. 3. a. b. c.

Cooler cover Cooler element Drain cock Coolant (from water pump) Oil (from oil pump) Oil (to engine each component)

Oil cooler

Heat exchanged: Heat-transmitting Oil flow capacity:

Min. 55000 area: 4.146 180 Q/min.

Kcal/hr. m2

Water flow capacity:

890 Qlmin.

170-1 SERIES

11-024-l 0

STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

OIL PUMP

RELIEF VALVE
1. Plug Valve spring Valve body Relief valve Ball type valve (Main relief valve) 6. a. b. c. Main relief valve spring From oil pump To oil pan From main gallery

Main relief valve

- Cracking pressure (difference


8 f 1 kg/cm2 Oil-line
-0

pressure):

check valve 3.3 f 0.3 kg/cm2

- Cracking pressure:

6162F127

OIL COOLER

BY-PASS

VALVE

1. 2. 3. 4. a. b.

cap Valve spring Valve body By-pass valve From oil pump To oil filter

Oil cooler by-pass valve * Cracking pressure: 4.5 + 0.5 kg/cm2

6162F128

170-1 SERIES

1 l-025 0

STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

PISTON

COOLING

VALVE

1.

cap Valve spring Oil filter adapter Piston cooling valve From oil pump To piston cooling nozzle To cylinder block

2. 3. 4. a. b. c.

Piston cooling valve * Cracking pressure: 1.3 2.: kg/cm

b
6162F129

11-026

170-1 SERIES

STRUCTURE

AND

FUNCTION

LUBRICATION

SYSTEM

MECHANICAL

PUMP

1. 2. 3. 4.

Spring Plunger Plunger Plunger Pump body Worm Oil inlet (from main gallery) Oil outlet (to intake manifold)

-f
B

-f
B

5. 6. a.

% C 5 \ / b.

Section A - A

Section B - B

Section C - C

View 2

6162F130

Mechanical pump * Capacity: 10 + 1 cc/h x 2 - The oil is sent from the main gallery into the pump,
and sent out from the two outlets of the pump to the two intake manifolds through the oil tubes. sprayed in the intake manifolds The oil is by the intake air onto

* The mechanical pump is a worm pump used to increase


the wear resistance of the intake valve seat.

*The pump is driven by the slit shaft connected to the


camshaft.

the seats of the valves to reduce the wear of the seats.

170-1

SERIES

11-027

FUEL SYSTEM

STRUCTURE

AND

FUNCTION

FUEL SYSTEM
FUEL SYSTEM CHART

6162F131

1. 2. 3. 4. 5.

Fuel tank Fuel filter Fuel injection pump Feed pump Fuel injection nozzle

1 l-028

170-l

SERIES

STRUCTURE

AND

FUNCTION

FUEL SYSTEM

FUEL INJECTION
S6D170-1, SAGD170-B-1

PUMP

6162F132

1. 2. 3. 4. 5. 6. 7. 8. 9.

Injection pump driving gear (No. of teeth: Injection pump drive shaft Service meter output Fuel injection pump Feed pump Governor Relay Solenoid Fuel filter

48)

a. b. c. d. e. f.

Fuel (from fuel tank) Fuel (to fuel filter) Fuel (from fuel filter) Fuel (to nozzle holder) Oil (from main gallery) Oil (to oil pan)

11-030 0

170-1 SERIES

STRUCTURE

AND

FUNCTION

FUEL

SYSTEM

6162F133

Fuel injection pump * Maker: Diesel Kiki PES-PD type RSUV, centrifugal type, all-speed type method: Forced lubrication oil with engine

- Type:
* Governor:

* Lubrication

170-1 SERIES

11-031 0

STRUCTURE AND FUNCTION

FUEL SYSTEM

SAGD170-A-1

1. 2. 3. 4. 5. 6. 7. 8. 9.

injection pump driving gear (No. of teeth: injection pump drive shaft Service meter output Fuel injection pump Feed pump Governor Relay Solenoid Fuel filter

48)

a. b. c. d. e. f.

Fuel (from fuel tank) Fuel (to fuel filter) Fuel (from injection pump) Fuel (to nozzle holder) Oil (from main gallery) Oil (to oil pan)

11-031-l Cc

170-1 SERIES

STRUCTURE

AND

FUNCTION

FUEL SYSTEM

Fuel injection pump

* Maker: - Type:

Diesel Kiki PE-ZWX type RSUV, centrifugal type, ail-speed type Forced lubrication with engine oil method:

* Governor: - Lubrication

170-l SERIES

11-031-2 0

STRUCTURE

AND

FUNCTION

FUEL

SYSTEM

FUEL INJECTION

NOZZLE

1. 2. 3.

Nozzle holder Nozzle spring Nozzle Retaining cap Adjustment shim Fuel inlet Fuel return (To fuel tank)

b
4. 5. a. b.

FL
IIll Ill II I IllI
II 1 I ill I 6162F134A

IllI

Fuel injection nozzle - Maker: Diesel Kiki - Type: Bosch DLL-S type, multiple hole type

1 l-032 @

170-1

SERIES

STRUCTURE

AND

FUNCTION

FUEL SYSTEM

FUEL INJECTION
For PES-PD type injection

PUMP
pump

DRIVE

7
5 6

Section

A--A

4
6162F135

1. 2. 3. 4. 5. 6. 7. 8.

Fuel injection pump drive shaft Nut Tachometer drive gear (No. of teeth: 14)

Tachometer drive

- Tachometer drive shaft speed = Engine speed x l/2

Drive housing Pinion gear housing Tachometer drive shaft 14)

Pihion gear (No. of teeth: Bushing

170-1 SERIES

11-033 @

MAINTENANCE

STANDARD

FUEL SYSTEM

For PE-ZWX

tYpe injection

pump

Section A-A

Detail P
6162F135-1

1. 2. 3. 4. 5. 6. 7. 8.

Fuel injection pump drive shaft Nut Tachometer drive gear (No. of teeth: 14)

Tachometer * Tachometer

drive drive shaft speed = Engine speed x l/2

Drive housing Pinion gear housing Tachometer drive shaft 14)

Pihion gear (No. of teeth: Bushing

11-033-l @

170-1 SERIES

STRUCTURE

AND

FUNCTION

FUEL SYSTEM

FUEL FILTER

6162F136

1. 2. 3. 4. a. b.

Air bleeding plug Filter bracket

Fuel filter
l

Filtration area: 0.4 m2 x 2

Filter element Cartridge Filter case From feed pump TO fuel injection pump

11-034 0

STRUCTURE

AND

FUNCTION

FUEL SYSTEM

FUEL CUT SOLENOID


B contact (electricity flows in ordinary operations) method

F621201037

*
l

Maker: Type:

NIKKO Sealed DC24ti

DENKI

* Rated voltage: * Operating current: * Stroke: * Weight:


Inner wiring

Maximum: Continuity: 12 f 0.1 mm 2.7 kg

35A max. 0.5A max.

Cl

Pull-in coil Holding coil

1. Shaft 2. Case 3. Piston

5. Stop lever 6. Return spring 7. Solenoid 8. Fuel control lever

C2:

FUNCTION
* Starting engine When the starting key is turned energized. Solenoid injection shaft pump (1) is electrically attracted, pulling it in the stop lever (5) and fixing on, the solenoid is

4. Coil

RUN position. . Stopping engine When the starting key is turned de-energized. Injection pump stop lever (5) is returned to STOP position (non-injection * During operation, the position) by return spring (6). amount of fuel injection is off, the solenoid is

controlled *

by fuel control lever (8). the fuel solenoid, adjust clearance A AND ADJUSTING.
6162F151

When installing

referring to TESTING

170-l SERIES

11-034-l 0.

STRUCTURE

AND

FUNCTION

FUEL SYSTEM

A contact (electricity flows when stopped) method EG580B-1 L

-Y

02F082-K

Z View

Y View
F6161A021

Pull-in coil -$($Ejl

Pull-in coil l$o

1. Case

2. Coil 3. Return spring 4. Plunger


6134F166A

Holding coil Holding coil After pull-in Before pull-in Inner wiring

FUNCTION
When stopping the engine, the solenoid is energized, the solenoid plunger is electrically attracted, and the stop lever of the injection pump is moved by a rod to the stop (non-injection) position. As a result, the fuel is cut off and the engine is brought to a stop. Accordingly, this solenoid is used only when the engine is being stopped; it is in free condition during ordinary operations.

FUEL SOLENOID l Maker:

l l

Type: Operating current Pull-in coil: Holding coil:

NIPPON DENS0 Made by synchro start (EG5808-1 L) Sealed 20A max. 37A (EG580B-1 L) 5A max. 0.4A (EG580B-1 L) 27 mm 25 mm (EG580B-1 L)

Stroke:

1-?z4-2

170-l SERIES

STRUCTURE

AND

FUNCTION

FUEL

SYSTEM

ENGINE

STOP MOTOR

Shape of cable tip 7(non-threaded stopper type)-

.--r--y-\ :_ A_:.,/

35 Stroke

Shape of cable tip (threaded stopper type)

Stroke

Made by AMP Co., Econoseal connector, 2. Not used (filler plug added) / J. Not used (filler plug added) B(AV 0.85LR)

. Not used (filler plug added) 5. p, (AV 0.85LW)

8. E(AV 0.858)

1. Motor assembly 2. Cover 3. Cable assembly 4. Cable clamp 5. Coil spring 6. Cable 7. Screw 8. Breather 9. Bracket assembly 10. Cover assembly

Engine stop motor * * Maker: Rated voltage: Stroke: Weight: Jidosha Denki Kogyo Co., Ltd. DC24V 15 kg min. 35:::40 1.2 kg_ mm

* Operating force:

170-l

SERIES

1 l-034-3 0

STRUCTURE AND FUNCTION

FUEL SYSTEM

STRUCTURAL

DRAWING

(1)

1. Gear cover assembly

2. Slider assembly 3. Armature shaft 4. Contactor assembly 5. Roller 6. Worm wheel assembly 7. Motor assembly 8. Gear case assembly

-o34-4

170-l SERIES

STRUCTURE

AND

FUNCTION

FUEL

SYSTEM

STRUCTURAL

DRAWING

(2)

1. Gear cover assembly 2. Motor assembly 3. Cable clamp 4. Cable assembly 5. Gear case assembly

170-l SERIES

1 l-034-5 0

STRUCTURE

AND

FUNCTION

FUEL

SYSTEM

DESCRIPTION
1. Stop condition

OF OPERATION
(O or 390)

AND

CIRCUITS

Battery 4+-i

The

above

drawing

shows the stopped

condition The slider

assembly is stopped at the auto-stop position on the P, side.

when a closed circuit has been formed. 2.

When switch is turned (when starting the motor) attery

b-i

When the switch is moved to the P, side (starting switch ON), an electric current flows from the plus side contactor plate through the P2 auto-stop terminal and switch and into the armature shaft assem3. Turning condition (90 in the drawing)

bly, thereby starting the motor. starts to move in the direction

The slider assembly of the arrow at the

same time as the roller starts to move.

Battery

I7b
Electric current continues to pass through the armature turn. shaft assembly and the motor continues to Because of the rotation of the rol,ler, the tion of the arrow.

Id7
slider assembly also continues to move in the direc-

-ki?4-6

170-l SERIES

STRUCTURE

AND

FUNCTION

FUEL

SYSTEM

4.

When stopped (180)

A closed circuit terminal 5.

is formed

when the P, auto-stop contactor plate,

and the motor comes to a sudden stop. assembly also stops.

The slider

rides on the minus-side

When switch is turned (when starting the motor) Batterv

When the switch is moved to the PI side (starting switch OFF), contactor and switch 6. an electric current flows from the plus the PI auto-stop terminal and into the armature (270 shaft assembly, plate through

thereby

starting

the motor.

The slider assembly of the arrow at the

starts to move in the direction

same time as the roller starts to move.

Turning condition

in the drawing)

Electric current continues to pass through the armature turn. shaft assembly and the motor continues to The slider assembly also continues to move in

the direction

of the arrow. 1.

Then the circuit returns

to stop condition

170-l

SERIES

11-34-7 0

STRUCTURE

AND

FUNCTION

FUEL SYSTEM

STARTING

AID

Auto priming system (APS)

6162F137 1. 2. 3. 4. 5. Glow plug Clamp Wiring harness cover Nozzle 6. 7. 8. 9. Hose Bracket Hose Valve a. b. c. d. a. To heater switch To APS controller To APS controller To heater switch From fuel filter (Fuel1

170-1 SERIES

1 l-035

OUTLINE OF ELECTRONICAL
electronical governor

GOVERNOR made by ZEXEL)

SYSTEM

(with

OVERALL CONFIGURATION

! Injection

pump

1 /

=-I
stop output ) L Low idle control dial f

Electronical

governor

controller i Fuse -

50160Hz changeover

6 z

Start signal

Battery

SAE00126

The electronical governor system is composed of fuel injection pump governor unit (actuator driven), electronical governor controller, controller mounting panel, switches, dials, sensors and others. The electronical governor controller has a built-in microcomputer and it runs the engine by driving the governor actuator under the running conditions specified by contents of control set in the microcomputer, external switches, dials, etc.

11-035-l @

CONTENTS
VO.

OF ELECTRONIC
Item

GOVERNOR

CONTROL
Contents

Selection

of droop/isochronous

Droop control (Revolution changes according to the load) or isochronous control (Revolution is kept at the rated speed, regardless of the load) is selected with switch input. Low-idling speed or rated speed is selected with switch input. knob dur-

2 3

Selection Adjustment

of Li/rated

speed

of Li speed

Engine speed is changed with the rpm adjustment control ing low idling. Lower limit : 700 rpm Upper limit : 900 rpm, Rated speed is adjusted Adjustment range with outside control f 50 rpm, adjustment knob. Judgment knob during

Adjustment of frequency (In isochronous control mode) Selection (In droop of droop (adjustment) control mode)

: Approx.

: 15 msec
high idling

Regulation is changed with droop from about 3% to 5%.

Adjustment Hi speed (In droop control mode)

Engine speed is adjusted with speed control switches (Speed raising switch and speed lowering switch) during high idling. Speed adjustment range : Approx. i_i}lOOrpm Judgment: 50msec Adjusting speed : Approx. 5rpm/sec, Initial set engine speed (set when power is reset) is shown in separate table. Engine (50/60Hz) speed is kept constant with during switch low idling, input. temperature to outside. easily. rises regardless of load.

7 8 9

Li isochronous Selection

control

of frequency

50Hz or 60Hz is selected

Emergency stop function (Error signal output) Injection start rate control function for

Engine is stopped when oil pressure lowers, water or he engine overruns, and error signal is output Fuel injection rate is control so that engine

10

will start

11

Overrun-preventive

function

If engine speed exceeds set value, fuel is turned is output to outside. Set value : (1) 2070rpm (by software) (2) 2300rpm (by hardware)

off and stop signal

12

Diagnosis

function

If electronic governor system has trouble, set measures and error signal is output to outside. (See next item.) function limiting speed Error signal to outside is reset. (See next item.) full rack position

are taken

13 14

Memory Sharp

clearing acceleration

When engine is accelerated sharply, prevent production of black smoke. Rack is moved to reduce at low temperature. sliding

is limited

to

15

Pre-operating

function

of rack

resistance

before

engine

is started

16

Overspeed testing (Used only during

function test)

While Li/Hi selector switch is set to Hi position, overspeed operation can be executed with external input. Engine speed is adjusted with speed control switch in droop control mode and with control knob in isochronous control mode.

11-035-2 @

CONTROLLER

SEE00127

1. Case 2. Connector 3. Mounting

bolt

Function . The controller produces signals for controlling the fuel injection pump for the engine with signals received from sensors and switches which are installed on the panel and externally located. The controller possesses a self-diagnostic function, and abnormalities are displayed on the LED.

11-035-3 @

Electronical

governor

main

unit

1. 2. 3. 4. 5. 6. 7.

Housing Actuator Control rod Connector Copper plate Cover Lubrication outlet

eyebolt

615OFl76

The electronical governor is roughly cornposed of housing, actuator and cover. The actuator is composed of linear DC motor, link and control rod position sensor. It operates in accordance with signals from the control unit. The linear DC motor causes the coil assembly to make up/down motions in accordance with signals from the control unit and causes the coil assembly to become still so that the control rod reaches the target position. (It is because arithmetic processing is executed in the control unit.) The motion of the linear DC motor is further transmitted to the connector through the link, and the fuel injection rate is increased/ decreased when the control rod moves rightward/leftward. That is, the injection rate increases when the coil assembly moves upward, and the injection rate decreases when the coil assembly moves downward. The copper plate at the connector end is the control rod position sensor. It senses the control rod position and feeds it back to the linear DC motor.

The actual injection rate is controlled by these series of motions. That is, the injection rate is controlled at the optimum level that corresponds to the machine running conditions as a result of arithmetic processing executed in the control unit. The linear DC motor is composed of magnet unit that supplies magnetic field, pole unit that leads the magnetic field and coil assembly that makes up and down motions. The operating principle of the DC motor is based on Flemings left-hand rule, as it is related to the force applied to current leads in a magnetic field. When the current fed to the coil is of direction A, the magnetic force is applied in direction C. When the current fed to the coil is of direction B, the magnetic force is applied in direction D. When the direction and magnitude of the current fed to the coil are controlled, therefore, the coil assembly can be moved up/down, and it is possible to cause the control rod to be still at an arbitrary position by the feedback from the position sensor.

11-035-4 @

1)

Actuator
Copper plate Control position rod sensor Copper I plate

Connector

Connect0

rod

inear

DC motor
615OF176

615OFl77

2) Linear DC motor

, Coil assembly

Cover

Magnet

Pole

615OFl79

(Upper

side sectional

view)

11-035-5 @

3) Control . Structural

rod position view

sensor

Operation

diagram

JwInductance
615OFl81

Large

6150Fl82

1. 2. 3. 4. 5. 6.

Copper plate (fixed) coil Compensator E-core Copper plate (movable) Sensing coil Copper plate

This position sensor is located at the center of the governor top for sensing if the control rod is actually located at the correct position with respect to the target position instructed from the control unit. This position sensor is composed of E-core shown above and sensing coils and copper plates of two sets. One of copper plates is installed to the end of the control rod, and another copper plate is fixed to the E-core. This position sensor senses changes in the coil inductance (may be considered as impedance changes) as changes in the counter electromotive force generated in the coil. When a copper plate is placed in a position to intersect the magnetic field generated by the coil as shown above, the magnetic field beyond the copper plate is canceled.

That is, the counter electromotive force generated in the coil changes when the position .of the copper plate changes. Another coil and copper plate are provided for compensation. They compensate for impedance changes such as temperature changes. The sensing accuracy is increased by absorbing the abnormality caused by the influence of temperature, etc. through sensing of the control rod position by the ratio (ratio of counter electromotive force) of impedances of two sensing coils.

11-035-6 @

STRUCTURE

AND FUNCTION

COOLING

SYSTEM

COOLING
COOLING

SYSTEM
CHART

SYSTEM

6162F136

1. 2. 3. 4. 5. 6.

Water pump Oil cooler Corrosion resistor Cylinder liner Cylinder block Thermostat switch

7. 8. 9. 10. A. B.

Water manifold Thermostat Radiator Fan From oil pump (oil) To engine each component (oil)

11-036

170-1

SERIES

STRUCTURE

AND

FUNCTION

COOLING

SYSTEM

WATER PUMP

6162F139

1. 2. 3. 4. 5. 6. 7.

Pump body Impeller Floating seal Water seal Pump shaft (rear) Pump shaft (front) Inlet housing

A. B.

From radiator To oil cooler

Water pump

* Water pump speed =


Engine speed x 1.8

* Flow capacity:

1050 !Z/min. (3,600 rpm)

170-1 SERIES

11-037

STRUCTURE AND FUNCTION

COOLING SYSTEM

FAN DRIVE
l

AND

TENSION
D375A-1.2,

PULLEY
PClOOO-1, HD465-3)

FAN DRIVE

(For D275A-2,

6162F140

1. 2. 3. 4. 5. 6. 7.

Tension spring Tension shaft Tension pulley Fan pulley Fan belt Crankshaft pulley Fan

Outside diameter for Pulley Applicable machine D275A-2 D375A- 1 D375A-2 PClDDD-1 HD465-3 Fan Pulley Crankshaft Pulley 200 200 200 200 184

Unit Tension Pulley 150 150 150 150 150

: mm

328 342 328 347 308

1 l-038 0

STRUCTURE

AND FUNCTION

COOLING SYSTEM

TENSION

PULLEY

(For D275A-2)

X / \ \

5
Section

fi
A-A

View 1. Tension pulley shaft 2. Roller bearing

3. Tension pulley bracket 4. Tension pulley (Outside diameter: 150 mm)

5. Oil seal 6. Ball Bearing

7. Spacer 8. Stopper

11-038-l 0

STRUCTURE

AND

FUNCTION

COOLING

SYSTEM

TENSION

PULLEY

(For D375A-1

2, PClOOO-1)

/I

7
6162F141

Section A - A

1. 2. 3. 4. 5. 6. 7. 8.

Tension pulley shaft Roller bearing Tension pulley bracket Tension pulley (Outside diameter: Oil seal Ball bearing Spacer Stopper 150 mm)

1 l-039 0

STRUCTURE

AND

FUNCTION

COOLING

SYSTEM

FAN DRIVE AND TENSION PULLEY


l

FAN

DRIVE

(For WA600,

WD600,

WA700,

HD465-5)

\
I

\_____P---

1. 2. 3. 4. 5. 6. 7. a.

Tension spring Tension shaft

Fan pulley diameter

) Tension pulley (Outside diameter: Fan pulley Fan belt Crankshaft pulley (Outside diameter: Fan Direction of wind 200 mm) 379 293 WA700 WA600 (A.C spec.), EG480B-1 150 mm)

11-039-l 0

STRUCTURE

AND FUNCTION

COOLING

SYSTEM

TENSION

PULLEY

5 I

7
A-A

SLE00255

1. 2. 3. 4. 5. 6. 7. 8.

Tension Seal Inner Roller Tension Spacer

pulley

shaft

race bearing pulley (Outside diameter: 150 mm)

Ball bearing Oil seal

1 l-039-2 0

STRUCTURE

AND

FUNCTION

COOLING

SYSTEM

CORROSION

RESISTOR

t-/

b
Section X - X (Detail valve)

6162F142

1. 2. 3.

Head Element case Cartridge Solid drug i (included 1,000 g) Coolant inlet Coolant outlet

Corrosion resistor

- Filteration area: 0.13 m*

a. b.

11-040

STRUCTURE

AND

FUNCTION

COOLING

SYSTEM

THERMOSTAT

1. Seal 2. Thermostat Valve Body Piston Sensor Sleeve Wax From engine each component To water pump To radiator

3.
4. 5. 6. 7. 8. a.

b. c.

b
OPERATION

6162F143

-._
At cold (close) At warm (full open)

Function
Opening temperature: 76.5 f 2C - Full opening temperature: 9OC
l

6162F144

* Valve lift: Minimum 10 mm

170-l

SERIES

11-041

STRUCTURE

AND FUNCTION

ACCESSORY

PC1 000-l

(Diesel Kiki Air compressor) Without air delivery relief valve

-.iSection A-A

-_q

ir 9
1
?;

View 2

6162F655

1. 2. 3. 4. a. b. c. d.

Flange Coupling Air compressor Air governor From intake To thermostat manifold housing (air) (cooling tiater)

Intake manifold Air

To air tank (air) From oil cooler (cooling water)

Air circuit diagram

6162F146

170-l

SERIES

-Oi2-

STRUCTURE

AND FUNCTION

ACCESSORY

HD465-5,

WA600-1,

WA700-1

(Diesel Kiki Air compressor) Without air delivery relief valve

A-A View 2

Air delivery relief valve

6162F620

1. 2. 3. a. b. c. d.

Flange Coupling Air compressor From intake To thermostat manifold housing (air) (cooling water)

Intake manifold 1

To air tank (air) From oil cooler (cooling water)

6162F821

-G2-2

170-1 SERIES

STRUCTURE

AND

FUNCTION

ACCESSORY

AIR COMPRESSOR

6162F147

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Inlet valve seat

11. 12. 13. 14. 15. 16. 17.

Thrust washer Crankshaft Drive gear (No. of teeth Oil ring 2nd ring Top ring Cylinder head

Air compressor

Unloader valve body


Unloader valve spring Unloader valve cap Head cap Inlet valve Inlet valve spring Piston Crank case Connecting rod

24)

* Maker: Cummins * Rated speed: 1,600 rpm


(at engine rated speed)

* Discharge capacity:
l

245 Illmin.

(at rated speed) No. of cylinder - Bore x Stroke: 1 - 92.1 x 44.5

a. b.

Air inlet Air outlet

170-1

SERIES

11-043 0

STRUCTURE AND FUNCTION

ELECTRICAL SYSTEM

ELECTRICAL
ALTERNATOR

SYSTEM

Inner connecting diagram 6162F148 1. Alternator assembly

Engine

Applicable machine model PC650-1 PC1 500-l

Type

Specifications

Pulley outside diameter (mm) 95

Weight

S6D170-1

Delco-Remy,

2581-450,

Open type

24V, 50A

15 kg

ALTERNATOR

BUILT-IN

REGULATOR

1. 2.

Alternator Regulator

Wiring diagram F6166049 Pulley outside diameter (mm)

Engine

Applicable machine model D275A-2 WA600-1 WD600-1 WA700-1

Type

Specification

Weight

SAGD170-1

Sawafuji, Open type

24V. 75A Sawafuji. Open type 24V. 50A 95

SAGD170.A-1

HD465-3 HD465-5 D375A-1 (-12802)

Nikko Denki, Open type

24V. 35A

SA6D170-B-1

D375A-1 (12803 and up) D375A-2 PClOOO-1

Sawafuji, Open type

24V. 50A

n-044-1 0

STRUCTURE

AND

FUNCTION

ELECTRICAL

SYSTEM

ALTERNATOR

WITH

REGULATOR

Alternator R -----JJRl-----

Regulator

B.E.F.R:

Terminal Wiring diagram 6114F151

Engine

Applicable machine model

Tvw

Specifications

Pulley outside diameter (mm) 95

Weight

EG550-1 SAGD170-A-1 EG5808-1 L

Nikko Denki, Open type

24V. 50A

15kg

Nikko Denki, Closed type

24V. 13A

95

7.6 kg

SAGDI 70-B-1

EG450-1

Nikko Denki, Open type

24V. 13A

95

7.8 kg

-ii4-2

STRUCTURE

AND FUNCTION

ELECTRICAL

SYSTEM

ALTERNATOR

BUILT-IN

REGULATOR

B.E.R: Terminal

EWiring diagram Pulley outside diameter (mm) 95 F6161 A022 Applicable machine model Type Specifications Weight Nikko Denki, Open type 24V. 25A 6.5 kg

Engine

SAGDI 70-A-1

EPSAGD170-A-1

SAGDl70-B-1

EPSAGDI 70-B-l

Nikko Denki, Open type

24V. 25A

95

6.5 kg

11-044-3 0

STRUCTURE

AND

FUNCTION

ELECTRICAL

SYSTEM

STARTING

MOTOR

6162F149

1. 2. 3. 4.

Pinion gear Starting motor assembly Magnetic switch Safety relay

B, C, E, R, S: Terminal

Engine

Applicable machine model :;;;l$2 PC1500-1 WA600-1

Type

Specifications

No. of pinion teeth

Weight

S6D170-1

Nikko Denki, Sealed type

24V. 7.5KW

11

18 kg

SAGDl70-A-1

Nikko Denki, Sealed type

24V, 7.5KW

11

18 kg

SAGD170-B-1

Nikko Denki, Sealed type

24V. 7.5KW I

11 I

18 kg

STRUCTURE

AND FUNCTION

ELECTRICAL

SYSTEM

EG580B-IL, EPSAGD170-A-1, EPSAGD170-B-1 EG480B-1 (For CIS -45C spec.)

F6161 A023

1. 2. 3. 4.

Pinion gear Starting Magnetic motor assembly switch

B, C, E, Fi, S: Terminal

Safety relay

Engine

Applicable machine model

Type

SA6D170-A-1

SA6D170-B-l EG480B-1 (-45C spec.) SAWAFUge Denki, Water tight, oil resistant type

11-046 0

Specificatons

Pulley outside diameter

Weight

24V, IIKW

19.5 kg

STRUCTURE

AND FUNCTION

ELECTRICAL

SYSTEM

F6161 A023

Pinion gear Starting Magnetic motor assembly switch

B, C, E, I?, S: Terminal

Safety relay

Engine

Applicable machine model WA600-1 (-50C spec.)

Type
SAWAFUge Denki, Water tight, oil resistant type

Specificatons

Pulley outside diameter

Weight

S6D170-1

24V, IIKW

11

19.5 kg

11-046-l 0

STRUCTURE

AND

FUNCTION

ELECTRICAL

SYSTEM

WIRING

DIAGRAM
(for EG550-1)

SA6D170-A-1

170-1 SERIES

11-047 0

STRUCTURE

AND FUNCTION

ELECTRICAL

SYSTEM

EG580B-1

Engine stop solenoid

unit Water temperature unit nJ7-

m-@-Zergency

stop

9
I
Fuse (30A)

Charge ammeter

Alternator

motor

OFF PREHEAT

O,,,
START

Starting switch

F6161 A024

1 l-048 0

170-1 SERIES

12 TESTING

ENGINE
AND ADJUSTING

ENGINE BODY Adjusting valve clearance . . .._........__._.... 12-003 Measuring compression pressure ._.._.._12-004 FUEL SYSTEM Testing and adjusting fuel injection timing . .. . . . .. . . . .. . . . . . . . . . . . .. . . . . .. . . . . 12-005 Adjusting fuel cut solenoid . .. . .. . . . . . .. . .. . .. 12-007 Procedure for adjusting engine stop motor cable .. . . . . . . .. . .. . . . . . . . . . . . .. . . . .. . . . 12-009 Adjusting fuel injection pressure .. .. .. . . . . 12-011 Method of installing (adjustment) of engine speed sensor . . . . . . . . .. .. . .. . . . .. 12-01 l-l Calibration data . . . . . . . .. . . .. . . . . . .. . . . .. . . . .. . . . . .. . . 12-013 COOLING SYSTEM Fan belt tension . . .. . . . .. . . .. . . .. . . . . . . . . .. . . . .. . .. . .. 12-031 Replacing fan belt and adjust auto tensioner _....__.._..___._.._..................12-032 PERFORMANCE TEST Run-in standard ._._....._..___....___..__..._...._.._ 12-033 Performance test criteria .. . . . . . . . . .. . .. .. . . . . . . 12-036 Testing and adjusting tool list . .. . . . .. . . . . .. . 12-043 Testing and adjusting date .. .. .. . . . . .. .. . .. . . . 12-044 Fan belt tension . .. . . .. . .. . . . .. .. . . . . . . . . .. . ... . . .. . . . 12-052 TROUBLESHOOTING .. . . . . . . . . .. .. . .. . . . . . . .. . . . .. . . . 12-053

12-001 43

A
A

When

carrying

out

testing

and

adjusting, the parking with two

or troubleshooting, brake. workers,

stop

the

machine

on level

ground,

fit safety

pins, block the wheels, When thorized carrying person checking out and out

and apply

operations

or more

always

use signals,

and

do not allow

any

unau-

near the machine. the may water cause level, burns, if the radiator cap for is removed the engine when the engine down is hot, before boiling water the will water

When spurt level.

so always

wait

to cool

checking

A A
*A!

Be extremely Be extremely

careful careful the

not to touch

any hot parts. in the fan or any other from Fit the places under rotating parts. pressure, before water carrying pressure, out any or air testing, pressure, adjust-

not to get caught plugs pressure or caps first.

Wh en removing release the

hydraulic tools

internal

measuring

securely

ing, or troubleshooting. When using the standard of the following values during judgement of various for new values points. in the standard shipped values values from when values table are values They should using given as reference from the and machines or as target values the factory. table be used as values estimated failures. values for estibased on table for judgement in testing, adjusting, or troubleshooting, it is necessary to

be careful standards mating The failure the results erence

The standard wear

for the new machines machines operation standard

carrying value

out repairs. are values from the factory. Use these values for ref-

in the standard history

tests and standard values

for machines for judging

shipped claims.

together

with the repair

and operation

of the machine

when judging

Do not use this standard

table as a standard

12-002 0

TESTING

AND

ADJUSTING

FUEL

SYSTEM

ADJUSTING

ENGINE

STOP

MOTOR

Procedure for adjusting engine stop motor

1. 2.

Temporarily

assemble nut and bolt (1). then with actuated, adjust nut and bolt (1) end is 1 f 0.5 mm,

stop motor actuated, assemble ball joint (2). With stop motor and ball joint and stopper 3. Switch (2) so that clearance of stop lever (3) bolt (4) at STOP

then assemble fully. the stop motor on and off ten times, and If necescheck the condition 4. of the adjustment.

sary, adjust ball joint (2). Check that the engine stops.

[Precautions] 1) When the stop motor is actuated, and stopper the stop lever (3) bolt (4) and (5) should not hit.

2) Check that there is no clearance between the stop lever (3) and the stopper bolt (5) at the RUN end when the stop motor (If there is OFF. If there is any clearof the return spring power may ance, adjust the hole position is any clearance,

the output

drop.)

569FlOl

170-l

SERIES

12-002- 1 0

TESTING

AND

ADJUSTING

FUEL SYSTEM

ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE)


ADJUSTING FUEL (VALVE CRACKING
1. 2.

INJECTION PRESSURE PRESSURE)

Remove retaining cap (1). Remove spring (4). nozzle (2). spring seat (3), and nozzle

3.

Adjust *

the

injection

pressure (valve cracking presper 0.1 mm shim

sure) by adjusting shim thickness (5). Injection thickness: m 4. After pressure adjusted Approx. 15 kg/cm2

Retaining cap: 9 + 1 kgm adjusting the thickness of shims, check the

fuel injection pressure using nozzle tester.

6162F202

12-002-2 0

170-1 SERIES

TESTING

AND

ADJUSTING

FUEL SYSTEM

DATA

FOR
Engine

INJECTION
model

PRESSURE

ADJUSTMENT
contour

SHIMS
Shim thickness (Range) Shim thickness (Interval)

Shim

I
a = 4.5 mm

S6D170-1 SAGDI 70-A-1 SAGDl70-B-1

0.50 b=11.5mm

- 1.54

mm

0.02

mm

Part No.

Thickness

(mm)

Part No.

Thickness 1.06 1.08 1.10 1.12 1.14 1.16 1.18 1.20 1.22 1.24 1.26 1.28 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.44 1.46 1.48 1.50 1.52 1.54

(mm)

DK150523-5000 DK150523-5100 DK150523-5200 DK150523-5300 DK150523-5400 DK150523-5500 DKI 50523-5600

0.50 0.52 0.54 0.56 0.58 0.60 0.62 0.64 0.66 0.68 0.70 0.72 0.74 0.76 0.18 0.80 0.82 0.84 0.86 0.88 0.90 0.92 0.94 0.96 0.98 1 .oo 1.02 1.04

DK150523-7800 DK150523-7900 DK150523-8000 DK150523-8100 DKl50523-8200 DK150523-8300 DKl50523-8400 DK150523-8500 DKl50523-8600 DKl50523-8700 DK150523-8800 DK150523-8900 DKl50523-9000 DK150523-9100 DK150523-9200 DK150523-9300 DK150523-9400 DK150523-9500 DK150523-9600 DKl50523-9700 DK150523-9800 DKl50523-9900 DK150530-0000 DKI 50530-0100

DK150523-5700 DK150523-5800 DKl50523-5900 DK150523-6000 DK150523-6100 DKl50523-6200 DKl50523-6300 DK150523-6400 DK150523-6500 DKI 50523-6600

DKl50523-6700 DK150523-6800 DK150523-6900 DK150523-7000 DKl50523-7100 DK150523-7200 DK150523-7300 DK150523-7400 DK150523-7500 DK150523-7600 DK150523-7700

DK150530-0200

c 170-1 SERIES

12-002-3 0

TESTING

AND

ADJUSTING

FUEL SYSTEM

CALIBRATION
Machine Model Engine Model Pump Assembly Number

DATA
Applicable Engine Serial Number Page

PC650-1 S6D170-1 PC 1500-I 6 162-73-l 170

10025

and

up

12-003 10126 and


up

EG450-1

SAGDI 70-B-l

6162-73-1251

10095

and

up

12-004

6 162-73-l EG550-1 SAGDI 70-A-1 6162-73-l

330

10001

10052

12-004-

331

10053

and

up

12-004-2

12-002-4 0

170-1 SERIES

ENGINE
ADJUSTING
Method 1. 2. of adjusting Remove

BODY
VALVE
valve clearance in the normal direction to set and head cover. top dead center, check the

CLEARANCE

the cyliner

Rotate the crankshaft No.1 cylinder align pointer damper * When center,

at compression rotating,

(3) with the 1.6 TOP mark on vibration movement top dead (is open).

(2). When

of the intake valve of No.6 cylinder. No.1 cylinder the No.6 is near compression intake valve moves

3. 4.

Adjust Next,

the clearance rotate and

of the valves chart. one the 0. turn

marked in the

0 in the normal of the


Cylinder No. 1 0 2

valve arrangement direction remaining

crankshaft adjust

Valve

arrangement 3 0 0 0 0 0 4 0 0 5 0 0 6 0

valve

clearance

valves marked

8 = Exhaust valve Intakevalve 0

2 E; z

To adjust between turn + the

the valve clearance screw crosshead adjustment clearance

loosen feeler the

locknut gauge

(8) A

of adjustment

(7), insert screw until

(6) and rocker

arm (5), and clearance

is a sliding fit. Valve (cold, warm)


Unit: mm

5.

Tighten

the

locknut

to hold the adjustment

screw

in position. m * Locknut: 6.9 + 1 kgm to turn the the crankshaft and to the 120 exhaust firing

It is also possible each valves order.


l

time

and

adjust cylinder

intake

of each

according

Firing order:

1-5-3-6-2-4 the locknut, check the clearance

After tightening again.

6162F658

12-003 @

MEASURING
Method of measuring When careful muffler, engine

COMPRESSION
compression pressure pressure, manifold parts.

PRESSURE

measuring

the compression the exhaust in rotating

be or

not to touch

or to get caught warmed

-k Measure

the compression

pressure

with the

up (oil temperature: 40 60C)

I.

Adjust For

valve clearance. details, see 12 ADJUSTING VALVE

CLEARANCE. 2. Remove + the nozzle holder assembly of the cylinder

to be measured. Be careful not to let any dirt or dust get in.

3.

Install

adapter

Al

in the mount of the nozzle holder and tighten

assembly

of the cylinder to be measured, torque. 2.75 + 0.25 kgm

to the specified m Torque:

4. 5.

Connect Place

compressor control

gauge A to the adapter. lever in the NO INJECTION with the starting motor pressure. in the

the fuel

position.

Crank the engine

and measure

the compression

A
Ir If the

If the fuel control NO INJECTION out. adapter mount

lever is not placed

position,

the fuel will spurt

is coated value AND

with

a small comFOR

amount * pression TESTING,

of oil, it will reduce the leakage. of the standard for the pressure, see TABLE OF VALUES

For details

ADJUSTING,

TROUBLE-

SHOOTING. m Torque: 2.25 + 0.25 kgm

2-:04

FUEL SYSTEM
TESTING
the fuel injection
l

AND
timing

ADJUSTlNG
of the injection assembling without assembling or replaced valve method, these parts pump.

FUEL INJECTION

TMING

There are the following Aligning Delivery When replace valve starting * Set the center, match

methods

of testing and adjusting the injection the injection always before

mark when engine

pump to the original


l

repair

valve method when using the delivery gasket parts.

pump that has been repaired * the copper with new

and O-ring

of the delivery

Prepare

the operation. No.1 cylinder at the compression VALVE top dead then test and adjust. see ADJUSTING CLEARANCE

For details,

Testing (flange

and type) the

adjusting

by

aligning

match

mark

1. 2.

Turn

crankshaft TOP.

back slowly

approx.

45O from

No.1

cylinder to align 3. 2 z z w Check and *

Rotate the crankshaft pointer that crankshaft line damper b at the

in the normal timing

direction line on end

( with the injection


(1).

line a at the fuel drive

injection end adjust

pump

housing

are aligned. at the oblong

If the lines are not aligned hole of the flange. Bolt nut: 6.75 + 0.75

kgm

Testing (laminated

and

adjusting type)

by

aligning

match

mark

coupling the same type.

1. 2.

Follow Check *

procedure lines

as for Steps

1 and 2

for the flange that

the

on the coupling adjust

and bearing at the oblong

cover of the fuel injetion hole of the coupling. w Bolt nut:

pump are aligned.

If the lines are not aligned

injection pump type Bosch PE-P, PE-PD Bosch PE-ZWx *Bosch PE-ZWy

Width across fiats of nut for coupling oblong hole 19 I

Tightening rorque for bolt of oblong hole kgm 9.0 kO.5

I
I
653
21

7.75 + 0.25

I
682

16.Ok

1.0

* 6162-73-l pump only.

and 6162-73-l

are the

injection
Oblong hole 6162F663

12-005 0

Testing methd *

fuel

injection

timing

by

delivery gasket

valve and Othe

Prepare ring operation.

new

parts for the copper delivery valve before

of the

starting

1.

Disconnect cylinder.

fuel

injection

pipe

(1)

of

the

No.1

2.

Remove

delivery

valve

holder

(2). take out delivery install delivery valve

valve (3) and spring holder (2) again. 3. Place * the fuel

(4), then

control pumps position.

lever with

at the

FULL

position.

For injection OPERATION

a stop lever set to the

4.

Turn the crankshaft center.

back 40 -

50

from top dead

5.

Operate slowly where

the feed in the the fuel

pump

and rotate direction. from

the crankshaft the point valve delivery

normal

Check

stops flowing

holder (2). 6.
197F402

Check

that

the pulley

fuel

injection

timing

line

on at

crankshaft j, + BEYOND BEFORE

(5) and pointer timing timing

(6) are aligned

the point where

the fuel stops flowing. line: Timing RETARDED line: Timing ADVANCED injection at the timing laminated is

injection injection shows adjust the

If the test incorrect, portion coupling. 7. Remove valve +

that at the

the fuel oblong hole

hole of the flange

or at

oblong

delivery

valve holder (2), assemble (4) then install wash

delivery valve

(3) an spring assembling replace

delivery

holder (2) again. When careful Sr Always again, with fuel and be and O-ring of not to let any dir dust stick to any part. the copper gasket valve with new parts. 11.5 & 0.5 kgm

the delivery w

Delivery Note:

valve holder: 14.0

+ 1 .O kgm for the EPl 1 injec-

tion pump on the WD600. 8. Connect w fuel injection Sleeve pipe (1).

nut: 2.2 + 0.2 kgm

12-006

TESTING

AND ADJUSTING

ADJUSTING

FUEL CUT SOLENOID

ADJUSTING
l

FUEL CUT SOLENOID


/3 2
Detail P

Continuous

type (continuous when operating) 3

6162~201

7. Solenoid 2. Stopper 4. Rod 3. Stop lever

valve (FULL stopper pin)

This fugure (-45C). differ from method

is for PC650-1,

PC1500-I

and EG480B-1 of stop lever may upon the machine the adjusting

The linkage

and the shape is mounted,

that given here depending


the same.

in which the engine

however

5. Return spring 6. Rod

is fundamentally

8
& z

Adjusting method 1.
2. Stop the engine Adjust Then, stroke of 12 mm. adjust rod (4) so that there injection is clearance pump stopper and loosen the nuts of rod (4). has a maximum 3) For EG550-1 Adjust rod (7) so that the there is length C of 31 to 32 mm.

rod (4), so that the solenoid

A of
(2)

0.4 + 0.1 mm between position 3. Adjust with hand.

and stop lever (3), while pulling the rod to the RUN the length of the return spring as follows. PC1500-1, EG450-I and EG480B-1 spec.) rod (6) so that there is length B of 138 to

1)

For PC650-1, (-45C Adjust

141 mm.

2)

For WA600-1 No need adjusting. (The return pump.) spring is installed in the injection

F6161A004

Turn on the engine solenoid

starting

key and confirm

that

has a stroke of 12 mm and there is clearon and off the key several times, re-

ance A of 0.4 * 0.1 mm. After turning clearance Tighten A. up the nuts of the rod. confirm the amount of the stroke of the solenoid and

12-007 0

SAGDI 70-A-1 SAGDI 70-B-1


1. Connect rod. When returned lever the doing

(EG580B. (EG480B.

EGGOOBS) EG500BS)
pump with the stop lever the pump the is

the solenoid this,

and injection so that so that 1.5 or

adjust 1 end,

to a position FULL bolt

1.5 mm from

the stop stop

pin at the STOP

and

is returned 70-B-1

to a position (SAGD170-A-1)

2.0 mm from limit position

(SAGDI

) when the solenoid shaft is pushed

in fully by hand.

2.

Pass electricity the solenoid OFF 2 smooth, movement.

through

the solenoid

and check that ON/ is not the is no change improve

moves smoothly. condition. the

Turn the power

3 times adjust

and check that there linkage to

in the operating

If the movement

---

--

6162F620

3.

After

checking

that the operation through the solenoid

is smooth,

start then

the engine, the engine

check that output

is as specified,

Stoip pin at FULL end

pass electricity

and check that 10 seconds.)

stops. (It must stop within

Problems

caused by improper

adjustment

of solenoid.
Stop pin at STOP end Clearance 1.5-2.0mm

-When electricity is passing, clearance between stop bolt and lever is 0.

* Solenoid coil burns out (when solenoid is half pulled). - Injection pump governor breaks or causes scuffing (Excessive force is brought to bear on lever).

6162F621

. When free, clearance between stop lever and bolt at FULL side is too large (defective linkage)

- Amount of fuel injected drops, so engine output


drODs.

12-008 0

SA6D170-A-1
1. Connect rod. When returned lever doing

(EG5808-1
the solenoid this,

L)
pump with the stop lever pump the is

and injection so that so that

adjust end,

to a position FULL

1 to 1.5 mm from and the 1.0 to 2.0 when

the stop stop mm from

pin at the the STOP

is returned

to a position in fully by hand.

bolt (SAGD170-A-1)

the solenoid

shaft is pushed

2.

Pass electricity the solenoid OFF 2 smooth, movement.

through

the solenoid

and check that ON/ is not the is no change improve

moves smoothly. condition. the

Turn the power

3 times adjust

and check that there linkage to

in the operating

If the movement

3.

After

checking

that the operation through the solenoid

is smooth,

start then

the engine, the engine

check that output

is as specified,

pass electricity

and check that 10 seconds.)

stops. (It must stop within

Problems

caused by improper

adjustment

of solenoid.

* When
and

electricity is passing, clearance between stop bolt lever is 0.

- Solenoid

coil

burns

out

(when solenoid * Injection pump breaks or causes (Excessive force to bear on lever).

is half pulled). governor scuffing is brought

- When

stop bolt - Amount of fuel drops, so engine drops. F6161 A025 injected output

free, clearance between stop lever and bolt at FULL side is too large (defective linkage)

12-008-l 0

SA6D170-A-1 SAGD170-B-1
1. After that adjust pulling

(EPSAGD170-A-1) (EPSAGD170-B-l)
rod (1) to solenoid works while of rod to become stop-lever side by hand so

stop-lever the length

solenoid

operates, (3) of

1 .O to 1.5 mm

clearance

between pump.

(2) and stopper

fuel injection

2.

Pass electricity the solenoid OFF 2 smooth, movement.

through

the solenoid

and check that ON/ is not the is no change improve

moves smoothly. condition. the

Turn the power

3 times adjust

and check that there linkage to

in the operating

If the movement

3.

After

checking

that the operation through the solenoid

is smooth,

start then

the engine, the engine

check that output

is as specified,

pass electricity

and check that 10 seconds.)

stops. (It must stop within

Problems

caused

by improper

adjustment

of solenoid.

When electricity is passing, clearance between stop bolt and lever is 0.

* Solenoid coil burns out (when solenoid is half pulled). - Injection pump governor breaks or causes scuffing (Excessive force is brought to bear on lever).

2
Detail P

F6161 A026

12-008-2 co

PROCEDURE
SAGD170-A-I
1.
Temporarily engine pump. stop

FOR ADJUSTING
l

ENGINE

STOP MOTOR

CABLE

(HD465-3
install motor

HD465-5)
to the cable it to the of the

a ball joint to connect

injection

2.

Pull the ENGINE

injection STOP

pump (NO

stop lever

by hand to the position, and

INJECTION) (1).

temporarily secure * *

intall ball joint (2) to the stop lever, then stop motor is delivered stop). position when to the operating position with the cable

the cable to bracket

The engine

pulled (engine it is free

Stop lever (3) is at the operating (it is pulled spring). clearance when the by a built-in

3.

Adjust injection 0.5 installed amount

so that 1.5 mm can

A between
engine out stop

the

fuel is is the

pump stop lever and the STOP (when the engine be carried is stopped).

stopper motor

Adjustment

by adjusting in. the

that the ball joint is screwed adjusting the clearance from

4.

After tighten

stoppers,

all nuts and bolts. the engine starting switch check ON/OFF that several

z
z z

5.

Turn

times to check that the engine smoothly. between * * Limit Check In particular,

stop motor operates clearance

A
569FlOl

stop lever (3) and STOP the engine are built switches visually into

stopper the

(4) is 0.5 stop

1.5 mm when

is stopped. engine

motor at both ends of the cable stroke. that there is slack in the engine is running built and fully to the operating into the of the stop motor cable when position. * Problems engine The action caused the engine

that the stop lever returns fuel injection

of the spring

pump keeps it at the oting position. by defective adjustment

stop motor cable


* Engine does not stop.

* Clearance
is

between stop lever and STOP stopper too large when engine stop motor cable is pulled.

* Clearance between stop lever and OPERATION stopper is too large when cable is free.

* Engine output drops because of drop in amount of fuel injected.

l l

Stroke of engine Stroke of fuel

stop motor: 35 mm injection pump stop lever: 25 mm

12-009 @

S6D170-1 1.

(WA600-1,
install motor

WA700-1)
a ball joint to connect to the cable it to the of the

Temporarily engine pump. stop

injection

2.

Pull the STOP install stop

injection

pump

stop lever to the position, and

ENGINE

(NO lever

INJECTION) in contact install

temporarily (4), and (1) with 5

ball joint (2) to the stop lever. Then keep the with STOP stopper the cable to bracket

temporarily locknut (6). Ir The engine *

stop motor is delivered stop).

with the cable position when 4

pulled (engine it is free

Stop lever (3) is at the operating (it is pulled spring). turn cable locknut by a built-in

out the operating

position

3.

In this condition, (1) 2 turns more against is pushed *

(6) of bracket

(in the direction securely against

to push the stop lever the stopper. is absorbed by the inside the motor.

STOP stopper (4)) so that the stop lever for two turns

The movement loose spring

mechanism

4. 5.

Tighten Turn

all nuts and bolts. engine smoothly, switches that there starting then are switch ON/OFF several
6162F642

the

times to check that the engine operate again. * * Limit Check engine
l l

stop motor and cable points stop stop the

check the following built into the engine between

motor at both ends of the cable stroke. is no clearance lever (3) and stoppers starting switch Stroke of engine (4) and (5), both when is ON and when

it is OFF.

stop motor: 35 mm pump stop lever: 30 mm

Stroke of fuel injection

12-010 0

ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE)


1.
2. Remove retaining Remove spring (4). 3. Adjust the injection pressure (valve (5). per 0.1 mm shim cracking presnozzle cap (1). (2), spring seat (3), and nozzle

sure) by adjusting shim thickness * Injection pressure adjusted thickness: w 4. After Approx. cap:

15 kg/cm2 9 +_ 1 kgm of shims, check the

Retaining adjusting

the

thickness

fuel injection

pressure using nozzle tester.

6162F202

METHOD FOR INSTALLING SPEED SENSOR


0

(ADJUSTMENT)

OF ENGINE

Speed sensor mounting hole Observe the instructions given below at the time of installing of the engine speed sensor (after it was dismounted). Turn the crankshaft in the normal direction and match the position of speed pickup pin (I), which is driven into the external periphery of the flywheel. -f This pin comes to the-position of the speed sensor mounting hole when the Ll cylinder is located at the top position. (There are six pins.) Turn in speed sensor (2) in this position. After it made contact with pin (1) in the flywheel and then back it off by two turns. * Clearance a at this time: 2mm Tighten lock nut (3). m Lock nut: 49.0 + 4.9 Nm (5 f 0.5 kgm) * Assure that smooth cranking is made on termination of adjustment.
SEE00060

1.

SEE00059

2.

3.

12-011-l 03

DATA

FOR
Engine

INJECTION
model

PRESSURE
Shim

ADJUSTMENT
contour

SHIMS
Shim thickness (Range) Shim thickness (Interval)

S6D170-1 SAGDI SAGDI 70-A-1 70-B-l

a =

4.5 mm 0.50 - 1.54 mm 0.02 mm

b=11.5mm

Part No.

Thickness

(mm)

Part No.

Thickness 1.06 1.08 1.10 1.12 1 .I4 1.16 1.18 1.20 1.22 1.24 1.26 1.28 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.44 1.46 1.48 1.50 1.52 1.54

(mm)

DKI DKI DKI DKI

50523-5000 50523-5100 50523-5200 50523-5300

0.50 0.52 0.54 0.56 0.58 0.60 0.62 0.64 0.66 0.68 0.70 0.72 0.74 0.76 0.78 0.80 0.82 0.84 0.86 0.88 0.90 0.92 0.94 0.96 0.98 1 .oo 1.02 1 .04

DKI 50523-7800 DK150523-7900 DKl50523-8000 DKI 50523-8100 DK150523-8200 DK150523-8300 DKI 50523-8400

DK150523-5400 DKI DKI DKI DKI 50523-5500 50523-5600 50523-5700 50523-5800

DKl50523-8500 DKl50523-8600 DKI DKI 50523-8700 50523-8800

DK150523-5900 DKI 50523-6000

DKl50523-6100 DKI DKI DKI 50523-6200 50523-6300 50523-6400

DKl50523-8900 DKl50523-9000 DK150523-9100 DKI 50523-9200

DK150523-6500 DKI 50523-6600

DK150523-9300 DKl50523-9400 DKl50523-9500 DKI DKI 50523-9600 50523-9700

DKI 50523-6700 DKI 50523-6800

DK150523-6900 DKI 50523-7000

DK150523-9800 DK150523-9900 DKI 50530-0000 DKI 50530-0100

DK150523-7100 DKI DKI DKI DKI 50523-7200 50523-7300 50523-7400 50523-7500

DK150530-0200

DK150523-7600 DKl50523-7700

TESTING

AND ADJUSTING

CALIBRATION

DATA

CALIBRATION

DATA

I I
SA6D170-A-1

6162-73-1331
6162-73-1332 6162-73-1333 6162-73-1334 6162-73-1341 6162-73-1342

( EG550-1

1 12-022 I 12-022
12-022 12-022 12-024-2 12-024-2

1 EG550-1
EG550-1 EG550-1 EM680A

I I

6162-73-1343 6162-73-1350

I
I

1 EM680A
l

EM680A

I 12-024-T
(Extremecoldweather)

EG550-1

I 12-021

12-013 0

TESTING

AND ADJUSTING

CALIBRATION

DATA

Engine model

Pump

assembly

No.

Engine serialNo.

Applicable machine EG550-1 EG550-1 EG550-1 EG550-1 HD465-3 (Extreme cold weather) (Extreme cold weather) (Extreme cold weather) (Extreme cold weather)

Page 12-022 12-022 12-022 12-022 12-024-3

6162-73-1351 6162-73-1352 6162-73-1353 6162-73-1354 6162-73-1372

I I I

6162-73-1410 6162-73-1480 6162-73-1481 6162-73-1482 6162-73-1510 6162-73-1531

I I

l l

1 WA700-1
HD465-3 HD465-3 HD465-3 HD465-5 OEMforBRO

I 12-02T 1 12-023
1 12-023 12-023-I 12-023-2 12-024-4 1~12Z,

I
SAGD170-A-1

6162-73-1550 6162-73-1571 6162-73-1572 6162-73-1612 6162-73-1640 6162-73-1670 6162-73-1682 6162-73-1751 6162-73-1752 6162-73-1753 6162-73-2350

I I 1

1 HD465-5 1 WA700-1 1 WA700-1


EPSAGD170-A-1 OEMfor EM680A-1 EM680A-A EG550-1,EG580B-1,EG580B-1-L EG550-l,EG580B-1, EG550-l,EG580B-1, OEM for stand EG580B-1-L EG580B-1-L marine

1 12-023-3 / 12-023-3
12-0246 12-024-7 12-024-8 12-024-9 12-023-4 12-023-4 12-023-4 8 z &

by generator

6162-73-2370 6162-73-2410 6162-73-2411 6162-73-1560

1 PCIOOOSP-1

(for Layton)

1 12-023-5
12-024 12-024 12-016-I
I

EPSAGD170-A-1 EPSAGD170-A-1 WA600-1


I

SA6D170-AE-1

6162-73-1583 6162-74-1310 6162-73-1151 6162-73-1250 6162-73-1251 6162-73-1252 6162-73-1253

I
I

(EC reguration)

I DENYOgenerator DCAGOOSSK 1 12-030-11


10332-11045 D375A-1 EG450-1, EG480-1, EG500BS-1 EG450-l,EG480-l,EG500BS-1 EG450-l,EG480-1, EG450-l,EG480-1, EG500BS-1 EG500BS-1 12-025 12-026 12-027 12-027 12-027 12-027 12-027

SA6D170-B-1

6162-73-1254

1 EG450-1, EG480-1, EG500BS-1


EG450-1 (Extreme cold weather) (Extreme cold weather) (Extremecoldweather) (Extremecoldweather)

6162-73-1430

EG480-1 EG450-1

6162-73-1431

EG500BS-1 EG450-1

12-027

6162-73-1432

(Extreme cold weather) (Extremecoldweather)

EG500BS-1

12-027

12-013-l @

TESTINGANDADJUSTING

CALIBRATION

DATA

Applicable machine

6162-73-2121 6162-73-2130 SA6D170-B-1 6162-73-2131 6162-73-2132 6162-73-2133 6162-73-2141 6162-73-2142 6162-73-2173 6162-73-2174 6162-73-2175 6162-73-2180 6162-73-2181 6162-73-2340 6162-73-2341 6162-73-2380 6162-73-2381 6162-73-2420 6162-73-2421 SAA6D170-1 6162-74-1750 13551-15523 15524and up

HD500-3, HD465-3C Pc1000-1 Pc1000-1 Pc1000-1 Pc1000-1 D375A-2 D375A-2 (Extreme cold weather) (Extreme cold weather)

12-029 12-030 12-030 12-030 12-030 12-028-I 12-028-2 12-030-8 12-030-12

OEMforgenerator OEMforgenerator (Prime use) EG500-1,EG500B-1,EG500BS-1 OEMforgenerator OEMforgenerator (Standby use) OEM for generator

12-030-13 12-030-14 12-030-8 12-030-15 12-030-I 12-030-I

OEMfor6-polegenerator EPSAGD170-B-1 EPSAGD170-B-1 OEMforgenerator(50 Hz)

12-030-10

12-013-2 @

Machine Model

Engine Model S6D170-1

Injection Pump Type PEGZW

Pump Manufacturer DIESEL KlKl

Pump Assembly
6162-73-l

Number
170 (106692-4030)...2

E%b

Injection

Timing
Unit Basis Counterclockwise from drive end l-5-3-6-2-4 60 mm mm3 2.4 90 5930to6030 23.5 to 24.5 Allowance viewed

Rotating direction Injection order Injection interval Plunger pre-stroke Delivery valve retraction volume

Specification

for engine
HP/rpm kgm/rpm rpm rpm

with

fan (reference only)


41 O/l 800 215/l 200

Rated horsepower:

Maximum High idling: Low idling:

torque:

1,700 to 1800 600 to 700

Calibration
r Conditions

Standard
Unit Manufacturer standard (with nearly the same actual machine parts) (105015-5210) (105041-7020) mm 8~2.4~1400 ASTM D975 No. 2 diesel fuel or equivalent C kg/cm2 kg/cm2 43 to 47 255 1.6 Injection volume (cc/l OOst) for manufacturer standard Rack yrooion Calibration basic point Pump speed (rpm) 800 335 Maximum variance between cylinder 21.18 20.51 * * * * Injection volume(cc/ for service standard st) Maximum variance between cylinder Service standard (with calibration test parts)

Nozzle part no. Nozzle holder part no. In ectron pope (d/D x I/D x length) Test oil Oil temperature Nozzle opening pressure Transfer pump pressure ipecifications

( (

I 1

Basis

Allowance Each cyl. 28.9 to 29.9 * * * * 4.6 to 5.6

Basis

Allowance Each cyl.

11.4 5.8

29.4 5.1

Rack positions

B B to E are the reference volume when C adjusting the injection volume. D Marks * are average volumes. E

Ziovernor performance

Pump speed (rpm) Numbers in parentheses are pump manufacturer part numbers.

Pump Assembly
6162-73-1171

Number

(106692-4034) part No.

Applicable Model

Machine Serial No.

Applicable Model S6D170-1 S6D170-1

Engine Serial No.

( ): Manufactures

PC650-1 PC1500

Injection
Rotating Injection Injection Plunger

Timing
direction order interval pre-stroke (mm) Counterclockwise viewed from drive end l-5-3-6-2-4 60 (5930 to 6030)
2.4 (23.5 to 24.5)

Engine Specification
Rated horsepower Maximum High idling Low idling Pump tester capacity for Service standard (kw(HP)/rpm) 306(410)/1,800 2108(215)/1,200 1,700 to 1,800 600 to 700 Motor: 7.5 KW

torque (Nm(kgm)/rpm) (rpm) (rpm)

Delivery valve retraction volume (mm/st)

90

Calibration

Standard

Service standard indicates data

using calibration test parts.


Manufacture standard is data test parts.

Rack positions

B to E are rhe reference volume


when adjusting rhe injection volume.

Govern&

perfomance

Governor

springset

325 335

775+25

BIJo:;:

Pump speed Wpm)

6162FZO3B

1Z-01 4-1 0

Pump Assembly Number


6162-73-1580 6162-73-I (1066924352) 590 (I 066924410) part No. Pump Manufacturer
I

I
KIKI

Applicable Model WA600-1 WA600- 1 c

Machine Serial No. 10001 and up 10001 and up

Applicable Model S6D170-1

Engine Serial No. 10490 and up

( ): Manufacturers
Injection Pump Type 1
1

PES-6PD

1 DIESEL

I
I

I I

I I

I I

I
I

Injection Timing
Rotating direction Counterclockwise viewed from drive end

Engine specification
Rated horsepower Maximum High idling Low idling r torque HP/rpm kgm/rpm rpm rpm 41512000 200/l 400 2200 to 2300

I I I

650 to 700 I Motor 7.5 KW

Delivery valve wtmctinn vnhlmo mm3/st

Pump tester capacity for Service standard

Calibration Standard
Conditions Service standard
Nozzle part no. Nozzle holder part no. Injection ipe (C/D x l/g x length) Test oil Oil temperature OC 175 1.6 mm

Manufacturer

standard

- Service

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

(I 05780-0050) (I 05780-2090)
8 x 3 x 600 ASTM D975

(105015-5210) (I 05041-7020)
8~2.4~1400 No. 2 diesel fuel or equivalent 43 to 47 300 1.6

Nozzle opening pressure kg/cm* Transfer pump pressure kg/cm*

Injection

volume Rack point

Rack position
(mm)

Pump speed
(rpm)

Service standard

(cc/ 100 st)


Maximum

Manufacturer Basis
24 7

standard (cc/ 100 st


Maximum

Basis

Allowance
Each cyl.

)$!$$E
cylinder

Allowance
Each cyl.

variance between
cylinder

Rack positions B to E are the reference volume when adjusting the injection volume. Marks l are average volumes.

Basic point B C D E

11.4
A %r?o

Ooo 350

28.05 3.93

27.55 *3.43 * * *

to 28.55 to 4.43

kO.393

4.7 * * * *

Governor performance

(350

- 1000

rpm)

I 3

II

II

II P;:;,25 +10

3 t.25 iJ.7 750;;;Jo

Pump speed (rpm)

FORM

NO.

SEBH4567

12-015 0

6162-73-1580(106692-4357)6162-73-1590 (1066924412) 6162-73-1581(106692-4740)6162-73-1591 (1066924413) 6162-73-1582(106692-4741)6162-73-1592 (106692-9010)

Injection

Pump Assembly

Number

Applicable Model

Machine Serial No.

Applicable Model S6D170-1 S6D170

Engine Serial No.

( ): Injection Pump Manufactures

part No.

Injection

Pump Specification

Engine Specification

Plunger prestroke (mm) Delivery valve retraction volume (mmh)

2.35 - 2.45 90

Low idling

speed

(rpm)

650 - 700 Motor: 7.5 kW

Pump tester capacity for Service standard

Calibration

Standard

1 1 : lnjenction

pump manufactures

part number

Service standard indicates data using calibration test pa ITS. Manufacture standard is data test parts.

curve (350 - 1,000 rpm)

/ 0 350 \ 700 /\1125+25

i,

450'-25 (580) (g75)'201000~;~

Pump speed (rpm)

12-016 0

TESTING

AND

ADJUSTING

CALIBRATION

DATA

Injection
6162-73-1583

Pump Assembly
(106692-9231) (I 06692-9002) Pump

Number

6162-73-1560 ( ): Injection Injection Pump Type PES-PDX

Applicable

Machine

Applicable

Engine

Manufactures Injection Pump Manufactuer ZEXEL

part No.

Injection
Rotating Injection Injection Plunger

Pump Specification
direction order interval prestroke (mm)
Counterclockwise drive end viewed from

Engine Specification
Flywheel horsepower

(Without

fan)
32112,000 {430/2,000} 2,010/1,400 {205/1,400)

(kWiHPYrpm) Maximum High idling Low idling torque (Nm{kgmI/rpmi speed speed Irpm) (rpm)

l-5-3-6-2-4 59 30 - 60 30 2.35 - 2.45 90

2,200 - 2,300 700 - 750 Motor: 7.5 kW

Delivery valve retraction volume (mmst)

Pump tester capacity for Service standard

test parts.

Rack positions B to E are the refernce volume when adjusting the

Injection

volume

injection

volume

Governor perfomance curve

; = z .z

12. 4 Il. 9 10.3

1.3

:: a ;
= 6.8 6.0

0 350 Pump speed (rpm) 1035f5 TWE00606

12-016-l @

Injection

6162-73-2150 (106682-4540) 6162-73-2151 (106682-4790) 6162-73-2160(106682-4670) ( ):Injection Pump Manufactures

Pump Assembly

Number

Applicable Model

Machine Serial No.

Applicable Model

Engine

Serial

No.

part No.

Injection Pumo Tvoe

I I

Injection Pump Manufactuer ZEXEL

I
Enaine Soecification
Flywheel horsepower (kW{HPYrpm) Maximum 1 High idling Low idling torque (NmIkgmYrpm) speed speed (rpm) (rpm) I 302/l ,800 (404/l ,800) 2,079/1,300 I212/1,3001 I

Injection
Rotating Injection 1 Injection

Pump Specification
direction order interval
(mm) Counterclockwise viewed from

drive end 1-5-3-6-2-4 59 30 - 60 30

1,960 -2,040 600 - 660 Motor: 7.5 kW

1 Plunger prestroke Delivery valve

3.15 - 3.25 120

I retraction volume (mmistj I


Calibration Standard

Pump tester capacity for Service standard

) : lnjenction

pump

manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Governor

perfomance

curve (325 - 900 rpm)

12-016-2 0

Pump Assembly Number


6162-73-2231 (191000-3930)

Applicable Model WA600-1

Machine Serial No.

Applicable Model S6D170-1

Engine Serial No.

( ): Manufacturers part No.

Injection Timing
Rotating direction 1 Injection order
Counterclockwise viewed from drive end

Engine specification
Rated horsepower HP/rpm 41512,000

I-5-3-6-2-4

Plunger pre-stroke F%ZX,V!,V~

mm

3.2 120 Pump tester capacity for Service standard Motor 7.5 KW

,mO mm3/st

Calibration Standard
Conditions
standard indicates data using calibration test parts. . Manufacture standard is data for factory test.

Service standard
Nozzle part no. Nozzle holder part no. Injection ipe

Manufacturer

standard

* Service

(093400-1800) (093100-0951) mm 6x2.2x650 ASTM


OC

(O/D x l/g x length) Test oil


Oil temperature

D975 No. 2 diesel fuel or equivalent


40 to 45

Nozzle opening pressure kg/cm

250 2.0 Service standard (cc/ 100 st) Manufacturer standard (cc/ st

Transfer pump pressure kg/cm* Injection volume Rack point

Rack position (mm)

Pump speed b-pm)

Basis 23 o

Allowance Each cyl. 22.5 to 23.5 * 26.6 to 27.6 * * * 4.8 to 5.2

- Rack positions
6 to E are the reference volume when
adjusting the injection volume. - Marks * are aver-

Maximum pig!, Basis cylinder Max. 1.0 Max. 1 .O Max. 1.0

Allowance Each cyl. * * * *

Maximurr variance between cylinder

Basic

point

12.3 13.4 L6.71

1000 700 340

B C D E

27.1 5.0

age volumes.

Governor performance

( 340 - 1000 rpm)

300

1025+10 Pump speed (rpm)

SEBH4634

12-017 0

Injection
6162-73-2241 6162-73-2242 6162-73-2243

Pump Assembly
(191000-4260) (191000-4262) (191000-4263)

Number

Applicable Model

Machine Serial No.

Applicable Model S6D170-1

Engine Serial No.

( ): Injection Pump Manufactures

part No.

WD600-1

Injection
Rotating

Pump Specification
direction Counterclockwise viewed from drive end

Engine Specification
Flywheel horsepower (kW{HPI/rom) 339/2,000 I454/2,000}

Calibration Conditions

Standard

) : lnienction

oump manufactures

Dart number

Service standard
Nozzle & Nozzle holder part No. Nozzle part No.
Nozzle holder part No. (093400-1800) (093100-0951)

Manufacturer standard

Service standard indicates data using calibration


test parts.

Manufacture standard is data


for factory test parts.

Injection pipe
(Outside dia.x Inside dia.x Length lest oil

) (mm)
1C)

6 X 2.2 X 650 ASTM D975 No.2 diesel 40-45 24.5 I2501 196 (2.01 fuel or equivalent

Oil temperature Nozzle opening Transfer pressure

(MPa{kg/cm}) (kPaIkg/cm)) Pump speed

pump pressure Rack position

njection volume
Rack point

Service standard (cc/l,000 st)


Injection volume Max.imum g,G$E
cylinder

Manufacturer standard (cc/1,000 st)


Injection volume Maximum ~~~~~~
cylinder

Rack positions
B to E are the refernce volume A(Basic point) when adjusting the B injection volume. , Marks * are C average volumes. D E

(mm)
12.8 13.6 6.7

(mm)
1,000 700 300

245 - 255 27.8 - 28.8 48-52

Max. 2.5 Max. 2.8 Max. 0.5

Governor

perfomance

curve (300 - 1,000 rpm)

12-018 0

Injection

Pump Assembly
(191000-4620) (191000-4222)

Number

6162-73-2251 6162-73-2252

Applicable Model

Machine Serial No.

Applicable Model S6D170-1

Engine Serial No.

( ): Injection Pump Manufactures

part No.

WD600-1

Injection
Rotating Injection Injection

Pump Specification
direction order interval Counterclockwise viewed from drive end l-5-3-6-2-4 59 30 - 60 30 3.15 - 3.25 120

Engine Specification
339/2,000 I454/2,0001

2,089/1,400I213/1,400~ 2,200 - 2,300 Low idling speed (rpm) 650 - 700 Motor: 7.5 kW

1
I

Plunger prestroke (mm) Delivery valve retraction volume (mm/stj

Pump tester capacity for Service standard

Calibration

Standard

) : lnjenction

pump manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data

Pump speed (rpm)

Pump Assembly
6162-73-2260

Number
(191000-4630)

Applicable Model

Machine Serial No.

Applicable Model S6D170-1

Engine Serial No.

( ): Manufacturers

part No.

WA600-IC

Injection

Timing
Counterclockwise viewed from drive end

Engine specification
Rated horsepower Maximum High idling torque HP/rpm kgm/rpm rpm rpm 4 15/2,000 200/I 2,200 ,400 to 2,300

Rotating direction Injection order Injection interval Plunger pre-stroke !%e+?%!~,m~ mm mm3/st

l-5-3-6-2-4 60 f 30

Low idling 3.2 120

650 to 700

I
Pump tester capacity for Service standard Motor 7.5KW I

Calibration
Conditions

Standard
Service standard
Nozzle part no. Nozzle holder part no. Injection Test oil ipe mm

Manufacturer

standard

standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

*Service

(093400-I

800)

(093100-0951) 6 x 2.2 x 650 ASTM


OC

(O/D x l/g x length)

D975 No. 2 diesel fuel or equivalent 40 to 45

Oil temperature

Nozzle opening pressure kg/cm Transfer pump pressure kg/cm Injection volume Rack point Rack position (mm) Pump speed (rpm)

250 2.0 Service standard (CC/ 100 St)

Manufacturer standard (cc/


Allowance Each cyl. * * * *

st

Basis

Allowance Each cyl. 22.5 to 23.5 *26.6 * * * to 27.6

- Rack positions
B to E are the reference volume when adjusting the injecBasic

Maximum rer!$$E Basis cylinder Max. 1.0 Max. 1.0 Max. 1 .O

Maximum variance between cylinder

point
B C D E

12.3 13.4
Le.71

1000 700 340

23.0 27.1 5.0

- Marks

tion volume.
l

are average volumes.

4.8 to 5.2

Governor performance

( 340 - 1000

rpm)

300

1025210 Pump speed (rpm)

SEBH4635X

Injection

Pump Assembly
(106692-4980)

Number

6162-73-1192

Applicable Model

Machine *Serial No.

Applicable Model S6D170-1

Engine Serial No.

( ): Injection Pump Manufactures

part No.

D155 (BEML)

lniection
Rotating Injection 1 Injection

Puma, Soecification
direction order interval 1 Counterclockwise viewed from drive end l-5-3-6-2-4 59 30 - 60 30
2.35 - 2.45 90

Enoine Soecification
Flywheel horsepower

(Without

fan)
247/2,000 {331/2,000}

(kWWWrpm)

Maximum torque (NmIkgmYrpm)

1,442/1,400

{147/1,400~

I 1High idling
Low

speed speed

(rpm) (rpm)

2,150 -2,250
600 - 700 Motor: 7.5 kW

Plunger prestroke (mm)


Delivery valve retraction volume (mm3M

idling

Pump tester capacity for Service standard

Calibration
(Conditions

Standard

) : lnjenction

pump manufactures

part number

. Service standard
indicates data using calibration test parts.

. Manufacture standard is data for factory test parts.

Injection volume . Rack positions


B to E are the refernce volume when adjusting thl injection volume. Marks * are average volumes.

Governor 18:

perfomance

curve

Rack

limit : IO.

O+~.'mm

325
Pump

750+20 (9;
speed (rpm) TWE00607

12-020-l 0

Injection Pump Assembly Number


6162-73-1163 (106692-4970)

Applicable Model

Machine Serial No.

Applicable Model S6D170-1

Engine Serial No.

( 1:Injection Pump Manufactures

part No.

D355 (BEML)

injection Pump Specification


Rotating Injection Injection direction order interval
Counterclockwise drive end viewed from

Engine Specification (Without fan)

l-5-3-6-2-4 59 30 - 60 30 2.35 - 2.45

Plunger prestroke (mm)


Delivery valve retraction volume (mm%)

Calibration Standard

\ . Inic,nrtinn

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Governor perfomancecurve

Boost compensatorperformance curve

mpensator

stroke

0 410f20 Pump speed 720f50 (rpm) 900:::

Boost

Pressure

(kPaImmHs1)

TWE00606

12-020-2 0

Injection

Pump Assembly

Number

6162-73-1212 (106692-4110) 6162-73-1214(106692-4113) 6162-73-1213 (106692-4111)6162-73-1215(106692-4990)

Applicable Model OEM for generator

Machine Serial No.

Applicable Model S6D170-1

Engine Serial No.

( ): Injection

Pump

Manufactures

part No.

Injection
Rotating

Pump Specification
direction Counterclockwise viewed from drive end

Engine Specification

(Without

fan)
329 I441~/1,500 (50 Hz) 380 I509M1,800 (60 Hz)

Flywheel horsepower (kW{HPl/rpm) Maximum torque (NmIkgmMrpm)

~,~i
Calibration Conditions
Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Standard

1 ) : lnienction

DumD manufactures

Dart number

Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes.

C D E

Governor perfomance curve

18+;l,,,,,,l,,,Tk

limit :l4. 8:0"mm

le sub 'ring set: 3-t,smm

400 /
Min. 500

75OtlO

\ Max. 945 900b0


TWE00610

Pump speed (rpm)

12-020-3 0

Injection

Pump Assembly
(106692-4372)

Number

6162-73-1721 ( 1: Injection ki

Applicable Model

Machine Serial No.

Applicable Model S6D170-1

Engine

Serial No.

Pump Manufactures

part

No.

EPS6D170-1

Injection
Rotating Injection Injection

Pump Specification
direction order interval
Counterclockwise

Engine Specification
viewed from

(Without

fan)

drive end l-5-3-6-2-4 59 30 - 60 30 2.35 - 2.45 90 Low idling


for Service

Plunger prestroke (mm) Delivery valve retraction volume (mmsr)

speed
standard

(rpm)

600 - 1,000 Motor: 7.5 kW

Pump tester capacity

Calibration Conditions

Standard

) : lnienction

oumo manufactures

Dart number

I
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (Outside dia.x Inside dia.x Length ) (mm) Test oil Oil temperature (0

Service standard
(105780-8130)

Manufacturer standard
6162-13-3300 6162-13-3320 6162-13-3110 (105111-4020) (105015-5210) (105041-7020)

Service standard indicates data using calibration test parts. Manufacture standard is data
for factory test parts.

(105780-0050)
(105780-2090) 8X4X600

8X2.4X1.400

ASTM D975 No.2 diesel fuel or equivalent

40 - 50

Rack positions
B to E are the refernce volume when adjusting the injection volume.

Marks * are

Governor perfomance curve


Rack 18:

I imi t :

(R,t

14.

9) tmm

400750 I (8401 240

900%

\ 990+25 TWE00611

Pump speed (r pm)

12-020-4 0

Injection

Pump Assembly

Number

6162-73-1733(106692-9020) ( ): lniection Pumo Manufactures Injection Pump Manufactuer Dart No.

Applicable Model

Machine Serial No.

Applicable Model S6D170-1

Engine Serial No.

Injection Pump Type

OEM for generator

PE-P DX

ZEXEL

I
Enqine Specification
Flywheel

Injection
Rotating Injection Injection

Pump. Specification _
direction Counterclockwise viewed from

(Without

fan)
351 {47OYl,500 386 {517Y1,800 (50 Hz) (60 Hz)

I
order interval

drive end

horsepower MWHPHrpm)

1-5-3-6-2-4 59 30 - 60 30 3.15 - 3.25


1

Maximum torque (Nm{kgmI/rpm)

Plunger prestroke (mm) Delivery valve


retraction volume (mm/st)

Pump tester capacity for Service standard

Motor:

7.5 kW

Calibration

Standard

1: lnjenction

pump manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions B to E are the refernce volume

Governor perfomance

curve

I imi t : 16+~*mm
i a:

hii n. 7. 3 E E .-S _ .z _

sDrin9

set:

5.8 5. 3

I 400 / 750flO 900: 500 Pump speed (r pm)

Min.

TWE00612

12-020-5 0

Injection Pump Assembly Number


6162-73-2222 (191000-3922) part No.

Applicable Model

Machine Serial No.

Applicable Model S6D170-1

Engine Serial No.

( ): Injection Pump Manufactures

D275A-2

Injection Pump Specification _ _


Rotating Injection direction order Counterclockwise viewed from drive end l-5-3-6-2-4

Enoine Soecification (Without fan)


Flywheel horsepower

WG-Wrpm) Maximum torque (Nm{knmI/rom)

302/1,800 1,981/1.300

{404/1,800} I202/1.300}

Calibration Standard

1 : lnjenction

pump manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data

test parts.

Rack positions

Governor perfomancecurve

16
14 12 < 10

; z .E :: 2

8 6 4 2

( R., Pul I ino start

Point)

6 Pump speed

a
(rpm)

IO

12 TWE00613

12-020-6 0

Machine Model

Engine Model

Injection Pump Type PEGZW

Pump Manufacturer DIESEL KIKI

Pump Assembly
6162-73-l 6162-73-I

Number
330 350 (I 03662-2140). (103662-2770). 4 1

EG550- 1

SAGD170-A-l

Injection

Timing
Unit Basis Allowance viewed

Rotating direction injection order injection interval Plunger pre-stroke Delivery valve retraction volume mm mm3

Counterclockwise from drive end l-5-3-6-2-4 60 3.8 120

Specification
5930 to 6030 I ~1

for engine with fan

(reference only)

3.75 to 3.85

Low idling:

rpm

Approx. 800

Calibration
ionditions

Standard
Unit Manufacturer standard (with nearly the same actual machine parts) (105015-5140) (I 05041-7020) mm 8x2.4x 1400 ASTM C kg/cm2 kg/cm2 43 to 47 300 1.6 D975 No. 2 diesel fuel or equivalent Service standard (with calibration test parts) ( 1

Nozzle part no. Nozzle holder part no. In ectron rpe (d/D x l/8x length) Test oil Oil temperature Nozzle opening pressure Transfer pump pressure ipecifications

Injection volume for manufacturer Rack osition P mm) Calibration basic point B Rack positions B to E are the reference volume when C adjusting the injection volume. D Marks * are average volumes. E iovernor performance 18.4 7.8 Pump speed (mm) 875 400

(cc/l OOst) standard Maximum variance between cylinder t2.08 20.95

Injectionvolume(cc/ for service standard

St) Maximum variance between cylinder

Basis

Allowance Each cyl. 51.5 to 52.5 * * * * 6.3 to 7.3

Basis

Allowance Each cyl. * * * *

52.0 6.8

Pump speed (rpm) GNumbers in parentheses are pump manufacturer part numbers

Machine Model EG550-1

Engine Model SAGDI 70-A-1

Injection Pump Type PEGZW

Pump Manufacturer DIESEL KlKl

Pump Assembly
6162-73-1331 6162-73-1332 6162-73-1333 6162-73-1334 6162-73-1351 6162-73-l 352 6162-73-1353 6162-73-1354

Number
(103662-2290) (103662-2292) (103662-3050) (103662-3051) (103662-2300) .... 1

. .. 1

(103662-2302)
(103662-3210) (103662-3212)

Injection

Timing
Unit Basis Allowance viewed

Rotating direction

Counterclockwise from drive end

Specification

for engine with fan

(reference only)

Low idling:

rpm

700 to 900

Calibration
Conditions

Standard
Unit Manufacturer standard (with nearly the same actual machine parts) (105015-5140) (105041-7020) mm 8~2.4~1400 ASTM C kg/cm* kg/cm2 43 to 47 300 1.6 Injection volume(cc/l for service standard OOst) Maximum variance between cylinder D975 No. 2 diesel fuel or equivalent Service standard (with calibration test parts) ( 1

Nozzle part no. Nozzle holder part no. In ectron rpe Cd/D x t/$x length) Test oil Oil temperature Nozzle opening pressure Transfer pump pressure Specifications

Injection volume for manufacturer Rack osition mm) P Calibration basic point
l

(cc/l OOst) standard Maximum variance between cylinder k2.08 kO.95

Pump rgrnd

Basis

Allowance Each cyl. 51.5 to 52.5 * * * * 6.3 to 7.3

Basis

Allowance Each cyl. * * * *

18.4 7.8

875 400

52.0 6.8

Rack positions 6 to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

B C D E

Sovernor

performance

M,n26

Pump speed (rpm) Numbers in parentheses are pump manufacturer part numbers

12-022 0

Pump Assembly Number


6162-73-1480 (103662-2870) 6162-73-1481 (103662-2871) ( ): Manufacturers part No.

Applicable Model HD465-3

Machine Serial No.

Applicable Model SAGD170-1 w/Single turbo w/Twin turbo

Engine Serial No.

Injection Pump Type PE-6ZWX

Pump Manufacturer DIESEL KIKI

10794 and up 10851 and LID

Injection Timing
Rotating direction Injection order Injection interval mm Counterclockwise viewed from drive end l-5-3-6-2-4 60 + 30

Engine specification
Rated horsepower 1 Maximum 1 High idling 1 Low idling torque HP/rpm kgm/rpm rpm rpm 730/2,100

I I

1 I

288/l

,400

2,250 to 2,3501 850 to 900

I
I

Plunger prestroke

3.8 + 0.05 120

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

Motor

7.5

KW

Calibration Standard
Conditions
standard indicates data using calibration test parts. * Manufacture standard is data for factory test.

Service standard
Nozzle part no. Nozzle holder part no. Injection Test oil ipe

Manufacturer 6162-13-3420 6162-13-3110

standard

- Service

(105780-0050) (105780-2090) mm 8x4x ASTM OC 175 1.6 Service standard (cc/ 100 St)
Maximum

(105015-6140) (105041-7020)

(O/D x l/g x length)

1500

8~2.4~1400

D975 No. 2 diesel fuel or equivalent 43 to 47 300 1.6 Manufacturer standard (cc/ 100 st
Maximum

Oil temperature

Nozzle opening pressure kg/cm Transfer pump pressure kg/cm Injection volume Rack point

Rack position

Pump speed

(mm)
15.3 Approx.
7.3

h-pm)
1050 425

Basis

Allowance

yJE$, cylinder 51.932 kO.723

Basis

Allowance Each cyl.

variance between cylinder

- Rack positions
B to E are the referBasic

point
B C D E

ence volume when adjusting the injection volume. - Marks * are average volumes.

48 3 Each cyl. . 47.8 to 48


5.17 * * * * 4.67 to 5.67

40.0 4.5

* * * *

Governor performance

( 425 - 1050 rpm)

Boost compensator

performance

(650 rpm)

Line 0: Line 0, :
Point Point 0: 0:

At boost pressure x
At boost pressure idling

or llMre
Or 1eSS pressure

:Y

Adjust low
Idling

at no boost set point

sub spring

Pump

speed

(rpm)

SEBH 4502-l

2-:23

Pump Assembly
6162-73-1462

Number

(103662-3023)

Applicable Model

Machine Serial No.

Applicable Model
SA6D170-A-1

Engine Serial No.


:;$;;io?p

1: Manufacturers Injection Pump Type PE-6zWX

part No. Pump Manufacturer DIESEL KIKI

HD465-3

(Single turbo) 11683 and up

Injection

Timing

Engine specification
Rated horsepower HP/rpm

730/2100

Plunger

pre-stroke

mm mm3/st

3.8 f

0.05 Pump tester capacity for Service standard Motor 7.5 KW

Delivery valve retraction volume

120

Calibration

Standard

bService standard
indicates data using calibration (Nozzle, Nozzle holder and injec-

) Manufacture
standard is data using factory test (For reference)

1Rack

positions B to E are the reference volume when adjusting

volume.

1Marks

* are average volumes.

Governor

performance

(425 Stop

1050

rpm)
5+1'6mm

Boost compensator

performance

(650

rpm)

lever 17.

Min.26 Or more

Rack limit 16. 5*:.'mm Boost comoensator stroke 4. 4fo.lmm 15.9 z L C .o '5 g +z 11.5 2
0 70+10 (340)

Z E g .-

15.3 I Min. 8. 8 Z Or more a z

1. 3
6.2

Boost pressure I. lM.1 0 720flD 1050:::

(mmHg)

Pump speed (rpm) TKE00124

12-023-l 0

Pump Assembly Number


6162-73-1510 (103662-3182)

Applicable Model

Machine Serial No.

Applicable Model SA6D170-A-1

Engine Serial No.

1: Manufacturers part No. I Pumo I lniection

HD465-5

IInjection Timing
Rotating Injection Injection Plunger direction order interval pre-stroke mm
I

Engine specification
Counterclockwise from drive end l-5-3-6-2-4 60 * 30 3.8 + 0.05 120 Pump tester capacity for Service standard Motor 7.5 KW viewed

Delivery valve retraction volume

mm3st

Calibration Standard
Service standard indicates data using calibration (Nozzle, Nozzle holder and injecManufacture standard is data using factory test (For reference)

Rack positions B to E are the reference volume when adjusting volume. Marks * are average volumes. Governor performance (475 Stop

1050 rpm) 18. 58 mm


mm 4. stroke 4*O-lmm

Boost compensator performance (750 rpm)

lever

Rack

I imi t 17. 98
Boost

compensator

17.4

13.0

;i (70) Boost pressure (34OIf20

(mmHg)

Pump

speed (rpm) TKEO0125

SEBH4881

12-023-2 0

6162-73-1410 (103662-3260) 6162-73-1571 (103662-3101) 6162-73-1572 (103662-3102)

Injection Pump Assembly Number

Applicable Model

Machine Serial No.

Applicable Model SA6D170-A-1

Engine Serial No.

( ): Injection Pump Manufactures

part No.

WA700-1

Injection Pump Specification


Rotating Injection Injection direction order interval
Counterclockwise drive end viewed from

Engine Specification
Flywheel horsepower
MW-Wrpm) 478/2,000 {641/2,000}

l-5-3-6-2-4 59 30 - 60 30 3.75 - 3.85 120

Maximum torque (NmIkgmYrpm) 2,810/1,400 High idling Low idling speed speed @pm) (rpm)

{286.5/1,400}

2240 - 2300 700 - 750 Motor: 7.5 kW

Plunger prestroke (mm) Delivery valve retraction volume (mm/st)

Pump tester capacity for Service standard

Calibration Standard

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes.

Governor

perfomancecurve

Boost compensatorperformance cuve

12. 01901

41.3(3101 )

Boost pressure (kPa{mmHaI

450+20

950+30

1135+25 TWE00614

Pump speed (rpm)

12-023-3 0

Pump Assembly Number


6162-73-1751 (103662-2911) :;$;:;$I;;;; [;;$:gf::8:81 ( ): Manufacturers part No.

Applicable Model EG550-1 EG580B-1 L

Machine Serial No.

Applicable Model SAGD170-1 SA6D170-A-1

Engine Serial No. 11500 and up 14173 and up

Injection Timing
Rotating direction Injection order Injection interval mm Counterclockwise viewed from drive end l-5-3-6-2-4 60 +_30

Engine specification
Rated horsepower Maximum High idling Low idling torque HP/rpm kgm/rpm rpm rpm 633/l ,500 731/1,800 Max. 1,560 Max. 1,872 50 Hz) 60 Hz)

50 Hz 60 Hz

700 to 900

Plunger pre-stroke

3.8 + 0.05 120

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

Motor

7.5

KW

Calibration Standard
Conditions
Service standard indicates data using calibration test parts. Manufacture standard is data for factory test. Nozzle part no. Nozzle holder part no. Injection ipe (O/D x I/! x length) Test oil mm

Service standard

Manufacturer 6162-13-3420 6162-13-3100

standard

(105780-0050)
(105780-2090) 8x4x ASTM
C 175 1 .6

(105015-6140) (105041-7020)

1,500

8 x 2.4 x 1,400

D975 No. 2 diesel fuel or equivalent 43 to47


300 1.6

Oil temperature

Nozzle opening pressure kg/cm* Transfer pump pressure kg/cm2

njection volume

Service standard

100 st)

Manufacturer

stand

Rack positions B to E are the reference volume when adjusting the injection volume. Marks l are average volumes.

E
Zovernor performance

I
rpm)

I*

(400 - 900

26 or
ITOE

Rack limit18.9oo*mm

400 500 750t10 or more Pump speed (rpm)

goo:o

SEBH4806

12-023-4 0

TESTING Injection

AND ADJUSTING Pump Assembly


(106682-9290) Pump Manufactures part No.

CALIBRATION Number

DATA

6162-73-2370

Applicable Model

Machine Serial No.

Applicable Model SA6D170-A-1

Engine Serial No.

( ): Injection

Pc1ooosP-1 (for LAYTON)

Injection
Rotating Injection Injection

Pump Specification
direction order interval (mm) Counterclockwise drive end l-5-3-6-2-4 5930 - 6030 viewed from

Engine Specification

Plunger prestroke

3.15 - 3.25

Delivery valve retraction volume (mm/st)

Calibration

Standard

) : lnjenction
Service

pump standard

manufactures

part number Manufacturer


6162-13-3702 6162-13-3720 6162-13-3712

tConditions . Service standard


indicates data using calibration test parts. Manufacture standard is data for factory test parts.

standard
(105111-4142) (105015-6700) (105041-7101)

Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder

(105780-8130) (105780-0050) (105780-2090)

part No.

Injection pipe (Outside diaxlnside dia.x Length) Test oil

(mm)

8X4X1,000 ASTM

8X2.4X1,450 D975 No.2 diesel fuel or eauivalent

Rack positions
B to E are the refernce volume when adjusting the injection volume. Marks are average volumes.

Injection

volume

Governor

perfomance

curve

Boost compensator

performance

cuve

Rack

limit

:la. sub

O-la. sprins sprins

2 (mm) set set stroke :3. l-3. 3 (mm)

Idline

Governor

I
17. 5 16. 7 10.

/ TBoost

compensator

I
(mm

t .I

0 Boost

6. 6-12. (50-901 pressure

39. 3-48.7 ~280-3801 LkPaImmHaI)

300 335

720 / 785-835 (ram)

\915-965 895-905

Pump speed

TWE00728

12-023-5 @

Pump Assembly
6162-73-2410 6162-73-2411

Number
(106682-4652) (106682-4850) part No. Applicable Model EPSAGDl70-A-1 Machine Serial No. Applicable Model SAGD170-1 Engine Serial No.

): Manufacturers

Injection
Rotating Injection Injection Plunger

Timing
direction order interval pre-stroke mm mms/st Counterclockwise viewed from drive end l-5-3-6-2-4 60 -I- 30

Enaine

SDecification
HP/rpm kgm/rpm rpm rpm ) 590/ 270/l 1950 1800 300 to 2050

1 Rated horsepower Maximum High idling 1 Low idling torque

750 to 850

3.2 f 0.05 120

Delivery valve retraction volume

Pump tester capacity for Service standard

Motor 7.5 KW

Calibration

Standard

) Service standard indicates data using calibration test parts. 1Manufacture standard is data for factory test.

positions B to E are the reference volume when adjusting the injection volume. 1Marks * are average volumes.

1Rack

Governor performance

ernor s~lina
Idling = E z z .p: _ 3 6. 5 6. 3 16.9

set sub splins

set

385 Pump sDeed (rpm)

30 0::: TKE00128

12-024 0

Injection
6162-73-1320

Pump Assembly
(103664-1321)

Number

Applicable Model

Machine Serial No.

Applicable Model
SA6D170-A-1

Engine Serial No.

( ): Injection Pump Manufactures

part No.

EG600BS-1

for generator
OEM

Injection
Rotating Injection Injection

Pump_ Specification .
direction order
I

Engine Specification
viewed from

(Without

fan)
477 {639H1,500 (50 Hz) 531 ~712)/1,800 (60 Hz) -

Counterclockwise

drive end l-5-3-6-2-4


I I

Flywheel horsepower (kW{HP}/rpm) Maximum torque (NmIkgmYrpm)


1

interval

59 30 - 60 30

High idling

speed

(rpm)

Max. 1,560 (50 Hz) Max. 1,872 (60 Hz)

1 Plunger prestroke (mm)

1
I

3.75 - 3.85

1 1Low idling speed


I I

(rpm)

I
I

700 - 900
Motor: 7.5 kW

Delivery valve retraction volume (mm/st)

Pump tester capacity for Service standard

Calibration

Standard

) : lnjenction

pump manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions B to E are the refernce volume when adjusting the injection volume.
Marks * are average volumes. C D

12-024- 1 0

6162-73-1341 6162-73-1342 6162-73-1343 ( ):lniection

Injection

Pump Assembly
(103662-2821) (103662-2822) (103662-3070)

Number

I
1

Applicable zdA /

Machine Serial No.

Applicable

Engine

/ ,A~~~,_,

Serial No.

Pump Manufactures Injection Pump Manufactuer

part No.

Injection Pump Type

PE-ZWx

ZEXEL

Injection
Rotating Injection Injection

Pump Specification
direction order interval Counterclockwise viewed from drive end 1-5-3-6-2-4 59 30 - 60 30 3.75 - 3.85 120

Engine Specification

(Without

fan)

Plunger prestroke (mm) Delivery valve retraction volume fmmVst)

Low idling

speed

@pm)

600 - 650 Motor: 7.5 kW

Pump tester capacity for Service standard

Calibration Conditions

Standard

) : lnjenction
Service

pump manufactures standard

part number Manufacturer standard

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes.
I I I

Governor

perfomance

curve
Rack

Min. 26

P
W

I imi t : 20:mm

300

1000:::\
Pump speed (rpm)

1080f25 TWE00618

-I2-024-2 0

Injection

Pump Assembly
(103662-3080)

Number

6162-73-1372

Applicable

Machine

Applicable

Engine

Model

Serial No.

Model
SA6D170-A-1

( 1:Injection Pump Manufactures

Serial No.

part No.
HD465-3 (with single turbocharger)

Injection
Rotating Injection Injection

Pump Specification
direction order interval Counterclockwise viewed from drive end l-5-3-6-2-4 59 30 - 60 30 3.75 - 3.85

Engine Specification

(Without

fan)

Plunger prestroke (mm) Delivery valve retraction volume (mmyst)

Calibration

Standard

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions

Governor

petfomance curve
lever:1 7. 5*t6mm

Min. 26

sator stroke: 2fO. E E E

7mm i.smm 15. 9

Min.8.8 15. 3

.2 a
: Ix 7. 3 6. 2

E E
.z c 13.9 : CL 0 21. 3f2. 7 (160&20) Boost Pressure 48. olt6. 7 (360f50)

z .-

I. lf0. 3 0

I I
425

I
720+30 aoof30 Pump speed (rpm)

L
1050:::\
1150+25

(kPs

{mmHg] )

TWE00619

12-024-3 0

Injection

Pump Assembly
(103662-3130) Pump

Number
I part No.

6162-73-1531 ( ): Injection Injection Pump Type

Applicable

Machine

Applicable No.

Engine

Model OEM for BRO

I 1

Serial

Model SA6D170-A-1

I 1

I
Serial No.

Manufactures Injection Pump Manufactuer

PE-ZWx

ZEXEL

njection
Rotating Injection Injection

Pump Specification
direction order interval (mm) Counterclockwise viewed from drive end l-5-3-6-2-4 59 30 - 60 30 3.75 - 3.85 120

Engine Specification
Flywheel horsepower

(Without

fan)
552/2,000 {740/2,000) {309/1,400~

(kWIHPI/rpm) Maximum High idling Low idling torque (Nm{kgmMrpm) speed speed &pm) (rpm)

3,030/1,400

2,150 - 2,250 750 - 850 Motor: 7.5 kW

Plunger prestroke

Delivery valve retraction volume (mmst)

Pump tester capacity for Service standard

Calibration

Standard

1 : lninnctinn ntlmn manllfxtttres

nart number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Governor

perfomance

curve Rack limit: (17.


2)':"mm Boost compensator stroke:

Boost compensator

performance

curve

;; (16. 7) E

21.3k2.7 ~160~201

48. 0f6. 7 1360*503

400 720f20

IOOO::! (815) llOOYc25

Boost Pressure (kPa{mmHe))

Pump speed (rpm)

TWE00621

12-024-4 0

Injection

Pump Assembly
(103662-3090) Pump

Number

6162-73-1550 ( 1: Injection

Applicable

Machine

Applicable

Engine

Manufactures Injection Pump Manufactuer ZEXEL

part No.

I I

Injection Pump Tvpe PE-ZWx

I
I

Injection
Rotating Injection Injection Plunger

Pump Specification
direction order interval prestroke (mm)
I

Engine Specification
viewed from Flywheel horsepower

(Without

fan)
386/2,100 {518/2,100~

Counterclockwise
driveend

(kWU-R/rpm)

l-5-3-6-2-4 59 30 - 60 30 3.75 - 3.85


I I I

Delivery valve retraction volume (mm/st)

120

Pump tester capacity for Service standard

Motor:

7.5 kW

Calibration

Standard

) : lnjenction

pump

manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Governor

perfomance

curve
Rack limit :17't'mm

Boost compensator

performance

curve

Min.26

Boost compensator stroke ~2. OfO. Adapter spring is not actuated

lmm

16. 5 -z E z z -G 4 : Dz 0 14.5 21. 3f2. 7 (160*201 48. 0f6. 7 (360f501

Boost pressure (kPaImmHa1) 0 425 Pump speed (rpm) 1050:::\ 1150525

TWE00623

12-024.

Injection

Pump Assembly
(103662-3110)

Number

6162-73-1612

Applicable Model

Machine Serial No.

Applicable Model SA6D170-A-1

Engine Serial No.

( 1: Injection Pump Manufactures

part No.

EPSAGD170-A-1

Injection
Rotating Injection 1 Injection

Pump Specification
direction order interval
Counterclockwise drive end viewed from

Engine Specification
Flywheel

(Without

fan)
534/2,000 {715/2,000) 2,922/1,400 {298/1,4001

horsepower NWWrpm)

l-5-3-6-2-4 59 30 - 60 30 3.75 - 3.85 120

Maximum torque INmIkgmYrpm) II High idling Low idling speed speed (rpm)

FM600 - 1,000 Motor: 7.5 kW

Plunger prestroke (mm) Delivery valve retraction volume (mm3st)

(rpm)

Pump tester capacity for Service standard

Calibration

Standard

1 1: lnjenction

pump manufactures

part number

lConditions - Service standard


indicates data using calibration test pans. pManufacture standard is data
for factory test parts.

An-d*

* Rack positions B to E are the refernce volume when adjusting the injection volume.

5Marks * are
average volumes.

Governor

perfomance

curve

Min. 26

Supplied as adapter spring is not actuated

12-024-6 I

Injection
6162-73-1640

Pump Assembly
(103662-3170)

Number

Applicable Model

Machine Serial No.

Applicable Model SA6D170-A-1

Engine Serial No.

( 1:Injection Pump Manufactures

part No.

OEM for marine

Injection
Rotating

Pump Specification
direction Counterclockwise viewed from
drive end

Engine Specification
Flywheel

(Without

fan)
552/2,000 {740/2,000}

horsepower (kW{HPYrpm)

Maximum torque (Nm{kgm}/rpm)

~~~

Calibration

Standard

1 : lnienction

oumo

manufactures

oart

number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions B to E are the ref-

ernce volume
when adjusting the injection volume. Marks * are average volumes. -

C D E

15.7 - 15.9

100

330

Governor

petfomance curve

Min. 26 h, //I//.,// C

Rack limit: 15.

7*f'mm

(15. 2) -z 10.7 E 7.7 z ..p (5.6) : PI

300 Pump speed (rpm)

1000:::

1075f.25 TWE00626

12-024-7 0

Injection
6162-73-1670

Pump Assembly
(103662-3230)

Number

Applicable

Machine

Applicable

Engine Serial No.

I
Model Serial No. part No. EM680A-1

I
Model SA6D170-A-1

( ): Injection Pump Manufactures

Injection
Rotating Injection Injection

Pump Specification
direction order interval
Counterclockwise

Engine Specification
viewed from

(Without

fan)
55212,000 {740/2,000} 2,100 - 2,200

drive end l-5-3-6-2-4 59 30 - 60 30 3.75 - 3.85


I

Flywheel horsepower (kWW/rpm) Maximum toraue (Nm{kamYrom) High idling Low idling speed speed (rpm) (rpm)
I

Plunger prestroke (mm) Delivery valve retraction volume (mmyst)

550 - 600 Motor: 7.5 kW

120

Pump tester capacity for Service standard

Calibration

Standard

( I

1 : lnjenction

pump manufactures

part number

tConditions .* Service standard


indicates data using calibration test parts.

Service standard
(105780-8130) (105780-0050) (I 05780-2090) 8X4X1,500 ASTM

Manufacturer standard
6162-13-3901 6162-13-3921 6162-13-3710 (105111-4350) (105015-8330) (105041-7060)

Nozzle & Nozzle holder Nozzle part No. Nozzle holder part No.

part No.

*Manufacture
standard is data
for factory test parts.

Injection pipe (Outside dia.x Inside dia.x Length ) (mm) Test oil Oil temperature (C)

8X2.4X1,400 D975 No.2 diesel fuel or equivalent 40-45

Nozzle opening pressure (MPaIkg/cm}) Transfer pump pressure (kPa{kg/cm})

17.2 1175) 157 Il.61 Service standard Injection (cc/l,000 st) Manufacturer

29.4 {300} 157 11.6) standard (cc/l,000 st)

njection

volume

Rack
point

Rack position

Pumo speed

Maximum

Maximum

Rack positions B to E are the refernce volume

(mm)
A(Basic point) (15.2)

(rpm)
1,000

volume

~~~~~~
cylinder

Injection volume
395 - 405

~~J~~~
cylinder

Max. 32

when adjusting the injection volume.


Marks t are

B
C

Approx. 7.7 (15.7)

300 100

40-50 (300)

Max. 12.6 -

average volumes.

Governor perfomance curve


Rack limit /

Boost compensator performance curve

(15. 7):*

mm

Min. 26 C 115. 2) E
E E

Boost
compensator stroke
/

:4fO.

1mm

0 2

(5. 6) 5 -------i

I
0 24. 0:::: { 18 0:::1 48. Of6. 7 (360*50)
(kPa(mmHej)

._

Boost pressure

Pump speed

(rpm)

107&25 TWE00627

12-024-8 0

Injection

Pump Assembly
(103682-0470)

Number

6162-73-1682 ( ): Injection

Applicable Model

Machine Serial No.

Applicable Model SA6D170-A-1

Engine Serial No.

Pump Manufactures

part No.

EM680A-A

~1
1 Plunger prestroke (mm)

Enaine SDecification
Counterclockwise viewed from

(Without

fan)
629/2,000 {842/2,0001 I336/1,400}

Flywheel horsepower (kW{HPMrpm) Maximum torque (NmIkgmllrpm) High idling speed (rpm) @pm)
I

3.295/1,400

2,100 - 2,200 550 - 600 Motor: 7.5 kW

3.75 - 3.85 120

I Low idling speed


Pump tester capacity for Service standard

Delivery valve retraction volume (mmst)

Calibration

Standard

) : lnjenction

pump manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes.

Injection volume

Injection volume

D E

Governor

perfomance

curve

Min. 26 ;h_ /////./// /

Rack Iimit:17~mm /I

;16.
211.1z .; a $ &

6.5

300
Pump speed (r pm)

1000:::\
075f25 TWE00629

12-024-9 0

Pump Assembly Number


6162-73-1151 (106692-4233) 6162-73-1520 (106692-4460) ( ): Manufacturers part No.

Applicable Model D375A-1

Machine Serial No. 15001andup

Applicable Model SAGDl70-B-1

Engine Serial No. 10332 11045

Injection Timing

Engine specification

Plunger pre-stroke

mm

2.4 & 0.05 90

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

Motor

7.5 KW

Calibration Standard
Conditions Service standard
Nozzle part no.

Manufacturer 6162-13-3520 6162-13-3100 8x2.4x

standard

t Service

standard

indicates data
using calibration

(105780-0050) (105780-2090)
mm

(105015-6160) (105041-7020) 1400

Manufacture

test parts. standard is data for factory test.

Nozzle holder part no. injection ipe


(O/D x l/g x length)

8 x 2.4 x 1400 ASTM

Test oil Oil temperature C

D975 No. 2 diesel fuel or equivalent 43 to 47

Nozzle opening pressure kg/cm2 Transfer pump pressure kg/cm2

175 1.6

265 1.6

Injection volume Rack point

Rack position (mm)

Pump speed (rpm)

Service standard

kc/ 100 st)


Maximum

Manufacturer

standard (cc/ 100 st


Maximum

Basis

Allowance

Ter$EK cylinder kO.342

Basis

Allowance

variance between cylinder

bRack positions
B to E are the reference volume when adjusting the injection volume. - Marks l are average volumes. Basic

point
B C D E

14.0
Ap rox %.8

900
325

38.44 Each cyl.


37.94 3.42 * 2.92

,34 o5 Each cyl.

to 38.94 to 3.95

3.5 * * * *

* * * 325 - 900 rpm) Boost compensator

Governor performance

performance

(400 rpm)

15.3 -? E : Z ._ 8 P Y P n

12.6

go+20

380+60

Boost pressure (mmHg)

Line @ Line @ Pump speed (rpm)

: :

At boost pressure 480 mmHg or more At boost pressure 0 mmHg

SEBH451 l-01

12-025 0

Pump Assembly Number


6162-73-l 250 (106692-4050) part No.

Applicable Model EG450-1 EG480-1

Machine Serial No.

Applicable Model SAGDI 70-B-1

Engine Serial No.

( ): Manufacturers
[I

Injection Timing
Rotating direction Injection order Injection interval mm Counterclockwise view from drive end l-5-3-6-2-4 60?30 2.420.05 90

Engine specification

~1

Plunger pre-stroke

Delivery valve _ retraction volume mm3/st

Pump tester capacity for Service standard

Motor

7.5

KW

Calibration Standard
Conditions
Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.

Service standard Nozzle part no.


Nozzle holder part no. injection ipe (O/D x l/g x length) Test oil mm

Manufacturer 6162-13-3320 6162-13-3110

standard

(105780-0050) (105780-2090) 8 x 3 x 600 ASTM OC 175 1.6 Service standard (cc/ 100 St) Maximum
Basis Allowance ~er$$~ cylinder

(105015-5210) (105041-7020)

8 x 2.4 x 1400

D975 No. 2 diesel fuel or equivalent 43 to 47 255 1.6 Manufacturer standard (cc/100 st

Oil temperature

Nozzle opening pressure kg/cm* Transfer pump pressure kg/cm2 Injection volume Rack point Rack position (mm) Pump speed
(r-pm)

Basis

Allowance

Maximum variance between cylinder

Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.

Basic

point
B C D E

14.5
Approx 5.4

900
400

47.25
3.95

Each cyl. 46.75 to 47.75


* * * * 3.45 to 4.45

kO.395

40.0
4.0

Each cyl.
* * * *

3overnor performance

( 400 - 900

rpm)

Ia+;
Rack limit:
///////I//// 14.5 14.5+b2

Pump speed (mm)

SEBH4730

12-026 0

Pump Assembly Number


6162-73-1251 6162-73-1252 6162-73-1253 6162-73-1254 (106692-4121) 6162-73-1430 (106692-4640) (106692-4122) 6162-73-1431 (106692-4642) (106692-4123) 6162-73-1432 (106692-9060) (106692-9040)

Applicable Model EG450-1 EG480-1 c

Machine Serial No.

Applicable Model SAGDI 70-B-1

Engine Serial No.

( 1: Manufacturers part No.

injection Timing
Rotating direction Injection order Counterclockwise view from drive end l-5-3-6-2-4

Engine specification
Rated horsepower Maximum High idling
I

HP/rpm kgm/rpm rpm rpm

48811500 544/1800

50H 60Hf

torque

Injection interval Low idling 2.4kO.05 90 mm

1:::

las

I%#:I

700 to 900

Plunger pre-stroke

Delivery valve retraction volume mm3/st

Pump tester capacity for Service standard

Motor

7.5

KW

Calibration Standard
Conditions Service standard Nozzle part no. Nozzle holder part no. Injection ipe (O/D x l/g x length) Test oil Oil temperature OC 175 1.6 Service standard h/100 St) Manufacturer (105780-0050) (105780-2090) mm 8 x 3 x 600 ASTM Manufacturer 6162-13-3220 6162-13-3110 standard

* Service

standard indicates data using calibration test parts.

(105015-5500) (105041-7020)

- Manufacture
is data for factorv test.
standard

8 x 2.4 x 1400

D975 No. 2 diesel fuel or equivalent 43 to 47 255 1.6 standard (cc/ 100 st Maximum variance between cylinder

Nozzle opening pressure kg/cm2 Transfer pump pressure kg/cm2 Injection volume Rack point

Rack position (mm)

Pump speed b-pm)

Basis

Allowance

- Rack positions
B to E are the reference volume when adjusting the injection volume. . Marks l are average volumes.

Basic

point

14.5
APV&

900 400

47 25 Each cyl. . 46.75 to 47.75


3.95 * * * * 3.45 to 4.45

Maximum Fert,E, Basis Allowance cylinder 4. o Each cyl. . AO.395 4.0 * * * *

B C D E

Governor performance

( 400 - 900

rpm)

400 ~~~ore750~10

900",0

Pump speed (rpm)

SEBH4731

12-027 0

Machine Model D375A-1

Engine Model SAGD170 S/N 11646 and up

Injection Pump Type PE-6P

Pump Manufacturer DIESEL KIKI

Pump Assembly
6162-73-2110

Number
(106682-4350). 0

1: Manufacturers part No.

Injection Timing
Unit Rotating direction Injection order Injection interval Plunger pre-stroke Delivery valve retraction volume mm mm3 Basis Allowance

Counterclockwise viewed from drive end l-5-3-6-2-4 60 3.2 120 5930 to 6030 3.15 to 3.25

Specification

for engine with fan (reference only)


508/l 267/I 800 300

Rated horsepower: HP/rpm

I Maximum torque:
High idling: Low idling:

kgm/rpm rpm rpm

I I

1950 to 2050 600to 700

Calibration
Conditions

Standard
Unit Manufacturer standard (with nearly the same actual machine parts) (105015-6700) (105041-7020) mm 8~2.4~1400 ASTM 0975 C kg/cm2 kg/cm2 40 to 45 265 1.6 Injection volume kc/ 1OOst) for manufacturer standard Rack Pump osition speed mm) (rpm) P Maximum variance between cylinder f 1.02 k-o.525 * * * * Boost compensator performance (400 rpm) Injection volumekx/ for service standard St) Maximum variance between cylinder No. 2 diesel fuel or equivalent Service standard (with calibration test parts)

Nozzle part no. Nozzle holder part no. In ectron rpe (d/D x l/l?x length) Test oil Oil temperature Nozzle opening pressure Transfer pump pressure ipecifications

( (

1 1

1I

1 : Referencedata

Basis

Allowance

Basis

Allowance

Calibration basic point

A L15.81

900 325

34.0 3.5

Each cyl. 33.8 to 34.2 * 3.35 to 3.65 * * *

Each cyl.

1 Rack positions

8 B to E are the reference volume when C adjustingthe injection volume. D Marks * are averE age volumes. performance

[ 6.51

;overnor

(325

900

rpm)

Rack K.l++= Ihrn,! mm W 117.6,


y 115.81 , y+ L_____ -$y., F_ .E 6 E z a : I? E E I % 1 Line @ At boost pressure 450 mmHg or nwre At boost pressure 0 mmHg B m

z 5 s Z

(17.6)

Line

2 (15.4) Y B cc 0

(150)

350 2 50

Boost pressure (mmHg)

SEBH452

2-:28

Pump Assembly
6162-73-2 6162-73-2

Number
Applicable Model D375A-2 Machine Serial 16001 No. and up spec.) Applicable Model SA6D170-B-1 Engine Serial 13551 No. and up

111 (106682-4355) 141 (106682-4422) part No.

( ): Manufacturers

(S.T.D and Cold weather

Injection
Rotating Injection Injection Plunaer

Timing
direction order interval ore-stroke mm/ mm3/st Counterclockwise drive end l-5-3-6-2-4 60 f 30 viewed from

Engine Specification
Rated horsepower Maximum High idling Low idlina 3.2 + 0.05 120 I I torque HP/rpm kgm/rpm rpm rom 525/l 267/l 1960 800 300 to 2040

I
I

600 to 700

I
1

Delivery valve retraction volume

Pump tester capacity for Service standard

Motor

7.5 KW

Calibration

Standard

erwce standard Indicates data using calibration test parts. Manufacture standard is data for factory test.

Rack positions B to E are the reference volume when adjusting the injection volume. Marks t are average volumes.

Governor performance
Rack

(325

900

rpm)

Boost compensator

performance

(500

rpm)

I imi

t: 18.

43 mm

compensator

stroke

16.4.

7090

3Oa50

Boost pressure

(mmHg)

325

72060 Pump speed (rpm)

900::: TKE00129

SEBH4774-01 12-028-

Pump Assembly
6162-73-2 6162-73-2

Number

112 (106682-4800) 142 (106682-4820) Dart No.

Applicable Model

Machine Serial No.

I I

Apolicable Model SAGD170-B-I

Enaine Serial No.

( ): Manufactures

I
D375A-2 (S.T.D)

15524 and up

Injection

Timing

Engine Specification
Rated horsepower Maximum (kw(HP)/rpm)

torque (Nm(kgm)/rpm)

Delivery valve retraction volume (mmst)

Pump tester capacity for Service standard

Motor:

7.5 KW

Calibration
Conditions

Standard Service standard


Nozzle part no. Nozzle holder part no. (105780 (105780 - 0050) - 2090)

Manufacturer standard
6162-13-3720 6162-13-3711 (105015-6700) (105041-7100)

- Service standard

indicates data using calibration test parts.

* Manufacture
standard

Injection pipe (O/D X I/D X length) Test oil Oil temperature Nozzle opening Transfer pressure

(mm)

8X4X1,000 ASTM D975 No.2 diesel 40-45 17.2 (175) 157 11.6) Service standard Basis Allowance Each cyl. * (cc/lOOst)
Max_imum

8 X 2.4 X 1,450 fuel or equivalent

is data

for factory test Darts.

(C) (MPa(kg/cm)) (KPafkaicm)) Pump speed


(v-n)

26.0 (265) 157 Manufacturer Basis 34.9 fl 61 (cc/lOOst)

pump pressure Rack position


(mm)

Injection

volume Rack point

standard

* Rack positions B to E are the ref-

~~$~$
cylinder

Allowance Each cyl. *

i variance
between cylinder

Maximum

erence volume
when adjusting the injection volume.

Basic point B C

15.2

900

f 1.173

APP~o~. 6.6

325

* *

3.5

* *

m Marks

* 0.489

* are average volumes.

Governor 18. I4

verformance(325-900rum) Rack limit: 18. d't'mm


compensator stroke

Boost

conpensatar

PerformancefSOOrPm)

rBoost

16. 4

13. 9 I

Boost

Pressure

(mmHo) TKE00132

\ \\\I\ 4lOUO 45om 325

HBO=o 1 OOO~o 7206~ 9 0 0::: TKE00130

Pump speed (rpm)

12-028-2

Pump Assembly Number


6162-73-2120 (106682-4380)

Applicable

Machine

Aoolicable

Enaine

Injection Timing
Rotating direction Injection Injection order interval mm
Counterclockwise viewed from drive end

Engine specification

l-5-3-6-2-4 60 f 30 3.2 + 0.05 120

~~

Plunger prestroke

Delivery valve -retraction volume mm3/st

Pump tester capacity for Service standard

Motor

7.5 KW

Calibration Standard
Conditions Service standard
indicates data using calibration test parts. Manufacture standard is data for factory test. Nozzle part no. Nozzle holder part no. Injection ipe (O/D x l/g x length) Test oil mm

Service standard

Manufacturer 6162- 13-3720 6162-13-3710

standard

(105780-0050)
(105780-2090) 8x3~600 ASTM C 175 1.6 Service standard (cc/ 100 St)
Maximum Basis

(105015-6700) (105041-7060)

8 x 2.4 x 1450 D975 No. 2 diesel fuel or equivalent 43 to 47 265 1.6 Manufacturer standard (cc/ 100 st
Maximum

Oil temperature

Nozzle opening pressure kg/cm* Transfer pump pressure kg/cm2 Injection volume Rack point Rack position (mm) Pump speed (rpm)

Allowance Each cyl. 32.32 to 32.72 *


* * *

ye:::, cylinder .g756 kO.348

Basis

Allowance Each cyl.

variance between cylinder

Rack positions B to E are the reference volume when adjusting the injection volume. Marks l are average volumes.
Basic

point B
C D E

12.2
APPJ~.

1050 425

32 52

33.55 3.0 *
* * *

2.32

2.12 to 2.52

Governor performance

( 425 - 1050 rpm)

Boost compensator performance

( 700rpm)

Boostcompensatw stroke 0.9kO.l 13.4 12.2 -G r d e z 5 z t $ 5 0 ; 8 m 12.2

z L 5 G L : Y P a: 6.3

11.3

Or 6.3 more
4.8

60125

Approx.200

Boost pressure (mmHg)

(300)*25 \ 530*25 425

12OOi25 (1100)

Pump speed (rpm)

SEBH4695

12-029 0

Pump Assembly

Number
Applicable Model Pc1000-1 Machine Serial No. Applicable Model SA6D170-B-1 Engine Serial No.

6162-73-2 130 (1066824430) 6162-73-2131 (1066824431) 6162-73-2 132 (106682-4560) 6162-73-2133 (1066824810) ( 1: Manufactures part No.

11763 and up

Injection
Rotating Injection 1Injection Plunger

Timing
direction order interval pre-stroke (mm) Counterclockwise
from viewed drive end

Engine Specification
Rated horsepower Maximum (kw(HP)/rpm) (542)/l ,700 (260)/1,300 I
1,800 - 1,900

l-5-3-6-2-4
60 2 30 3.2 + 0.05 120

torque (Nm(kgm)/rpm)
(rpm) (rpm)

1 1High
Low

idling idling

650 - 700 Motor: 7.5 KW

Delivery valve retraction volume (mm3jst)

Pump tester capacity for Service standard

Calibration

Standard

erwce standard indicates data using calibration test parts. Manufacture standard is data
test parts.

Rack positions B to E are the reference volume when adjusting the

Governor

perfomance

(335 - 850 rpm)

Boost compensator

perfomance

(500 rpm)

z .E s ..= : 0. Y 0 cz

16.3

13.8

7oC20

300*50

Boost pressure (mmHg)

he

300

81OQ5

850;;;

Lie@

: At boost pressure 300 mmHg Or more : Atb spressreOmmHg

00

Pump speed (rpm)

SEBH4694-01

12-030 0

Pump Assembly
6162-73-2420

Number
(106682-4661) Applicable Model Machine Applicable No. Model SAGD170-1-B-1 Engine

Serial

Serial

No.

): Manufacturers

part No.

EPSAGD170-B-1

lniection

Timina
direction order interval pre-stroke mm1 mm3/st

Engine

Specification

Rotating

Counterclockwise viewed from drive end l-5-3-6-2-4 60 f 30

Injection Injection 1 Plunger

3.2 f 0.05 120

Delivery valve retraction volume

Pump tester capacity for Service standard

Motor 7.5 KW

Calibration

Standard

standard indicates data using calibration test parts. Manufacture standard is data for factory test.
Service

Rack positions B to E are the reference volume


when adjusting the injection volume. Marks * are average volumes.

Governor performance

(415

900

rpm)

Boost compensator

performance

(700 rpm)

385

900;:: Pump speed (rpm)

12-030-l 0

Pump Assembly
6162-73-242

Number

1 (106682-4840) part No.

Applicable Model

Machine Serial No.

Applicable Model SA6D170-I-B-I

Engine Serial No.

( ): Manufactures

EPSAGD170-B-1

lniection .
Rotating
Injection I Injection

Timina
direction
order interval

Enaine Soecification
Counterclockwise
from drive I-5-3-6-2-4 60 t 30 viewed end

1 Rated horsepower 1Maximum

(kw(HP)/rpm)I

(540)/1,800 (251 VI ,300 1,950 - 2,050 750 - 850 Motor: 7.5 KW

torque (Nm(kgm)/rpm) (rpm) (rpm)

1
I

I I High

idling

I I

Plunger pre-stroke
Delivery valve retraction volume

(mm)
(mmst)

3.2 5 0.05 120

Low idling Pump tester capacity for Service standard

Calibration
Conditions

Standard
Service standard Manufacturer standard

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions B to E are the reference volume when adjusting the injection volume. Marks t are average volumes. Governor perfomance D E (415 - 900 rpm)

(16.2)

/ /

750 650

j 1

* *

1(36.0) 1* 1(36.6) 1t

35.5 - 36.5 36.1 -37.1

/ )

18: Governor Idling a 16.2 ..S z ..z _ 2 6.5 6. 3 ED s~lina set sub s~lina A

set

0 385

415 900::: Pump speed (rpm)

97w

TKE00131

12-030-2 0

Injection
6162-73-1711

Pump Assembly
(106692-4382)

Number

Applicable Model

Machine Serial No.

Applicable Model SA6D170-B-1 SA6D170-B-1

Engine Serial No.

6162-73-1760

(106692-4650) Pump Manufactures part No.

( 1: Injection

EPSAGD170-B-1 EPSAGD170-B-1 (Extreme cold weather)

Injection
Rotating Injection Injection Plunger

Pump Specification
direction order interval prestroke (mm)
I

Engine Specification
viewed from

(Without

fan)

Counterclockwise
drive end

l-5-3-6-2-4 59 30 - 60 30 2.35 - 2.45 90 High idling Low idling


Pump tester speed (rpm)

Max.

2,030

speed
capacity

(rpm)

600 - 1,000

Delivery valve retraction volume (mmst)

for Service

standard

Motor:

7.5 kW

Calibration

Standard

Service standard
indicates data using calibration test parts.

Manufacture standard is data


test parts.

Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes.

16.2

750

425 - 435

D
E

Governor

perfomance

curve
Rack limit

(16.

7) '~'mm

1 (15. 2) (9. 8)

E E .! , 2 (6. 8) 6.3

I0 400 / (870) +30\990+25 900::: 75OP


Pump speed (rpm)

L-

TWE00630

12-030-3 0

Injection

Pump Assembly
(106692-9070) Pump

Number

6162-73-1743
( ): Injection

Applicable Model

Machine Serial No.

Applicable Model SA6D170-B-1

Engine Serial No.

Manufactures

part No.

OEM for
generator

11

Injection
Rotating Injection 1Injection 1Plunger

Pump Specification
direction order interval prestroke (mm)
Counterclockwise drive end viewed from

Engine Specification
Flywheel

(Without

fan)
425 {570}/1,500 506 {6781/1,800 (50 Hz) (60 Hz)

horsepower (kW{HPYrpm)

l-5-3-6-2-4 59 30 - 60 30

2.35 ; 2.45

---I I
(

a:::
Maximum
I

torque (Nm{kgmI/rpm)

Delivery valve retraction volume (mmyst) I

Pump tester capacity for Service standard

Motor:

7.5 kW

Calibration

Standard

) : lnjenction

pump

manufactures

part number

erwce standard
indicates data

standard

is data

. Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are

Governor perfomance curve

spring

set:

Injection Pump Assembly Number 6162-73-1941 (1066824890)

Applicable Machine Model Serial No.

Applicable Engine Model


SA6D170-B-1

Serial No.

( 1:Injection Pump Manufactures part No.


Injection Pump Type PE-P (S7S) Injection Pump

OEM for generator

Manufactuer
ZEXEL

Injection Pump Specification


Rotating direction Counterclockwise viewed from drive end

Engine Specification (Without fan)


Flywheel horsepower
(kW{HP}/rpm) 386 {517)/1,500 458 I613Yl.800 (50 Hz) (60 Hz)

~~~
Calibration Standard Conditions
Service standard indicates data using calibration test parts. Manufacture standard is data for factory test parts. Nozzle & Nozzle holder Dart No. Nozzle part No.
Nozzle holder part No. Injection pipe (Outside dia.x Inside dia.x Length 1(mm) Test oil Oil temperature (C)

Maximum torque (Nm{kgml/rpm)

) : lnienction

pump manufactures

part number

I
1

Servicestandard
(105780-8130) (105780-0050) (105780-2090) 8 X 4 X 1,000 ASTM

Manufacturer standard

6162-13-7300 6162-13-7520 6162-13-3111

(1051114431) (105015-8790) (105041-7110)

8 X 2.4 X 1,400 or equivalent

D975 No.2 diesel fuel 40-45

Rack positions B to E are the refernce volume when adjusting the injection volume.

Marks * are average volumes.

Governor perfomancecurve
ck limit: 18:mm Idle spring is

17. 5 15.1 14.9

sprint

set:

z z .: _= t 7.0 6.4 6.1

,400

460f5 Pump speed

750f5

\ 1000*5 900f5 (r Pm)

TWE00632

12-030-5 0

Injection Pump Assembly Number


6162-73-1942 (1066824891) part No.

Applicable Model

Machine Serial No.

Applicable Model SA6D170-B-1

Engine Serial No.

( 1: Injection Pump Manufactures

OEM for generator

Injection Pump Specification


Rotating Injection Injection direction

Engine Specification (Without fan)


Flywheel horsepower
(kW{HPVrpm) 386 {517)/1,500 458 {6131/1.800 (50 Hz) (60 Hz)

I
order interval

Counterclockwise viewed from drive end l-5-3-6-2-4 59 30 - 60 30 2.95 - 3.05

Maximum torque (Nm{kgml/rpm)

Plunger prestroke (mm)


I

Delivery valve retraction volume (mm3bt)

120

Pump tester capacity for Service standard

Motor:

7.5 kW

Calibration Standard

Service standard indicates data using calibration Manufacture standard is data

Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes.

Governor perfomancecurve

et when supplied

(800) Pump speed (r pm)

TWE00633

12-030-6 0

Injection Pump Assembly Number


6162-73-1950 (106682-9130) part No.

Applicable Model

Machine Serial No.

Applicable Model SA6D170-B-1

Engine Serial No.

( ): Injection Pump Manufactures


/

D375 (BEML)

lniection Pump Specification . _


Rotating Injection Injection direction order interval Counterclockwise viewed from drive end 1-5-3-6-2-4 59 30 - 60 30 3.15 - 3.25
I I

Ennine Specification (Without fan)


Flywheel horsepower

(kW{HPYrpm) Maximum torque (Nm{kgml/rpm) High idling Low idling


I

380/1,800 3,432/1,300

{509/1,800} {248/1,300}

speed speed

(rpm) (rpm)
I

1,960 - 2,040 600 - 650


I

Plunger prestroke (mm) Delivery valve retraction volume (mm3/st)J

120

Pump tester capacity fnr Service ntnnriard

Motor:

7.5 kW

Calibration Standard

) : lnjenction

pump manufactures

part number Manufacturer


6162-14-3700 6162-13-3320 6162-13-3712

(Conditions
Service standard
indicates data using calibration test parts. Manufacture standard is data for factory test parts. Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (Outside dia.x Inside dia.x Length ) mm) Test oil Oil temperature (C)

Service standard
(105780-8130)

standard
(105111-4441) (105015-8600) (105041-7101)

(105780-0050)
(105780-2090) 8 X 4 X 1,000 ASTM

8X2.4X1.450

D975 No.2 diesel fuel or equivalent 40-45

Nozzle opening pressure (MPa{kg/cm])

17.2 {1751

26.0 {2651

Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes.

Injection

volume

Injection

volume

Governor

perfomance

curve
Rack I imit

Boost compensator

performance

curve

1 a:

: 17.

2oDmm

Boost compensator stroke ~2. 520.

1 mm

1
15. 5

4. 0

9. 3

+5mm/s KR;

Dz

I I. 5 1; 0 9. 3f2. 7 (701t20) 40. 0*6. 7 ~300+501

Boost

pressure

(kPa{mmHel

41Oi20
L

QdO::: (72d) i50 Pump speed (rpm)

TWE00634

12-030-7 0

Injection

Pump Assembly

Number

6162-73-2173 (1066824830)

Applicable Model

Machine Serial No.

Applicable Model SA6D170-B-1

Engine Serial No.

( ): Injection Pump Manufactures

part No.

OEM for generator

Injection
Rotating Injection Injection

Pump Specification
direction order interval Counterclockwise viewed from drive end l-5-3-6-2-4 59 30 - 60 30 2.95 - 3.05

Engine Specification

(Without

fan)
378 {5061/1,500 (50 Hz) 403 {539Vl,800 (60 Hz)

Flywheel horsepower (kW{HPYrpm) Maximum torque (NmIkgmI/rpm)

Plunger prestroke (mm)

veIlvery

valve retraction volume (mm/st)l

1 1 Pump tester capacity


fnr Cnnrim C+lnrl3rA

Motor:

7.5 kW

Calibration Conditions

Standard

1: lnienction

oumo manufactures

oart number

Service standard
1 Nozzle & Nozzle holder oart NO. Nozzle part No. Nozzle holder part No. Injection
(Outside

Manufacturer standard
6162-13-3201 f105111-4051)

Service standard indicates data using calibration test parts. Manufacture standard is data for factory test parts.

(105780-8130)

(105780-0050)
(105780-2090)

6162-13-3220 (105015-5500)
6162-13-3111 (105041-7110)

pipe
Length

dia.x Inside dim

) (mm)
(C)

8 X 4 X 1,000

8X2.4X1,450

Test oil

ASTM D975 No.2 diesel fuel or equivalent

I Oil

temoerature

I
17.2 {175} 157 Il.61 Service

40-45 25.0 1255) 157 Il.61 ,000 s-t) Maximum g$$z


cylinder

Nozzle opening pressure (MPa{kg/cm% Transfer pump pressure (kPa{kg/cm*))

Injection volume
Rack point Rack position (mm) Pump speed Wpm) 900 750

standard (cc/l

Manufacturer Injection

standard (cc/l,000 volume Maximum $$g$


cylinder

st)

bRack

positions B to E are the refernce volume AlBasic point) 16.0 when adjusting the 15.2 B injection volume. Marks * are C Approx. 9.3

Injection volume

380 - 390 365 - 375

Max. 23.1 -

400

35-45

Max. 12

average volumes.

Governor perfomance curve


18: ck limit:

19. ltmm

1;. ! 15: 2 E Min. 7. 9 E _ 6.4 Z 6. 2 Z ..Z _

spring

set:

3. 6fO. 3 500 PUIIIP speed 750f5 (r Pm) TWE00636

12-030-8 0

Injection Pump Assembly Number


6162-73-2380 ( ): Injection (106682-9350) Pump Manufactures part No.

Applicable Machine
Model OEM for 6-pole

Applicable Engine
Model SA6D170-B-1

Serial No.

Serial No.

Injection Pump Specification


Rotating Injection Injection direction order interval Counterclockwise viewed from drive end l-5-3-6-2-4 59 30 - 60 30 2.75 - 2.85
I I I

Engine Specification (Without fan)


Flywheel horsepower (kW{HPMrpm) Maximum torque (NmIkgmYrpm) fl
I

280/1,000

{375/1,000}

Plunger prestroke (mm)


Delivery valve retraction volume (mm/st)

120

Pump tester capacity for Service standard

Motor:

7.5 kW

Calibration Standard ionditions


Service standard
indicates data using calibration test parts.

f I

) : lnienction

oumo manufactures

oart number

Servicestandard
(105780-8130) (105780-0050) (105780-2090)

Manufacturerstandard
6162-14-3300 6162-14-3320 6162-13-3711 (105111-46601 (105025-0910) (105041-7101)

Nozzle & Nozzle holder part No.


Nozzle part No. Nozzle holder part No.

Manufacture standard is data


for factory test parts.

Injection pipe
(Outside dia.x Inside dia.x Length

) (mm)
(C)

8X4X1.000 ASTM

8 X 2.4 X 1,400 D975 No.2 diesel fuel or equivalent 40-45

Test oil Oil temoerature

Nozzle opening pressure &lPa{kg/cm%~ 1Transfer pump pressure (kPa{kg/cm*H1 Pump speed

17.2 {175} 157 Il.61

26.0 f2651 157 U.61

njection volume
Rack point Rack position

Service standard (cc/l,000 st)


Maximum

Manufacturer standard (cc/1,000 st]


Mqimum

Rack positions

(mm)

(rpm)
500 600 400

Injection volume 508 - 513 538 - 548 II-14

vba,EEkE
cylinder

Injection volume 419 448 25

g,zg!z
cylinder

B to E are the ref14.8 ernce volume AtBasicpoint) when adjusting the B 15.5 injection volume. . Marks * are C Approx. 6.8 average volumes. D E

Max. 18.7 Max. 7.5

Governor perfomance curve

Rack limit

is not actuated

400

\ 6001t5 520f5 Boost speed (rPm)

500f5

TWE00637

1Z-030-9 0

Injection Pump Assembly Number


6162-74-1750 (103684-0361) part No.

Applicable Model

Machine Serial No.

Applicable Model SAAGD170-1

Engine Serial No.

( 1:Injection Pump Manufactures

OEM for generator (50 Hz)

Injection Pump Specification


Rotating Injection Injection direction order interval Counterclockwise viewed from drive end l-5-3-6-2-4 59 30 - 60 30 3.55 - 3.65 180

Engine Specification (Without fan)


Flywheel horsepower (kW{HWrpm) Maximum torque (Nm{kgm}/rpm) High idling Low idling speed
speed

597/1,500 -

{800/1,500}

(rpm)
(rpm)

Max. 1,575
700 - 900

Plunger prestroke (mm) Delivery valve retraction volume (mmyst)

Pump tester capacity for Service standard

Motor:

7.5 kW

Calibration Standard

1 : lnjenction

pump manufactures

part number

t Service

standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions

B to E are the refernce volume when adjusting the injection volume.


Marks * are average volumes.

12-030- 10 0

TESTING Injection

AND ADJUSTING Pump Assembly Number

CALIBRATION

DATA

6162-74-1310 (103662-3350) (With electronic governor)

Applicable Model

Machine Serial No.

Applicable Model SA6D170-AE-1

Engine Serial No.

( 1:Injection
)

Pump

Manufactures

part No.

DENY0 generator DCAGOOSSK

Injection
Rotating
Injection

Pump Specification
direction
order Counterclockwise drive end viewed from

Engine Specification
Flywheel horsepower

(Without

fan)
iGross.50Hz) (Gross,GOHz)

(kW{HP)/rpm)

478 {641)/1,500 528 {708M1,800

1-5-3-6-2-4 59 30 - 60 30 (mm) 3.15 - 3.25 90

Maximum High idling Low idling

torque (Nm{kgm}/rpm) speed speed (rpm) (rpm)


Max.

Max. 1,570 (50 Hz)


1,880 (60 Hz)

Injection

interval
prestroke

1Plunger

700 - 900 Motor: 7.5 kW

Delivery valve retraction volume (mm31st)

Pump tester capacity for Service standard

Calibration

Standard

( I 1 I

1: lnjenction

pump

manufactures

part number

(Conditions . Service standard


indicates data using calibration test parts. . Manufacture standard is data for factory test parts.

Service standard

1 1 I

Manufacturer standard
6162-14-7600 6162-14-7620 5212-13-3111 (105111-4820) (105025-1850) (105041-7111)

Nozzle & Nozzle hn1d-r dart No. r


..v...v,

Nozzle part No. Nozzle holder part No.

Injection pipe (Outside dia.x Inside dia.x Length Test oil Oil temperature tiozzle opening pressure

) (mm)
ASTM (C) D975 No.2 diesel
40-45

8 X 2.4 X 1,450 fuel or equivalent

(MPa{kg/cm)) (kPa{kg/cm}) Pump speed Service standard Injection volume (cc/l,000 st) Manufacturer Injection

29.4 13001 157 {I .60} standard (cc/l,000


Maximurr

Transfer

pump pressure Rack voltage

njection volume
Rack positions B to E are the refernce volume when adjusting Rated tttt:;eyfion point Marks * are average volumes. Governor Low idling point 5.9 2.8 400 Rack position

st

Max.imum

(mm)

Irpm)

Ezz,,z cylinder

volume

~~~~~~
cylinder

13.2

1.36

865

* 543 t 5

Max. 44

*30*5

Max. 8

perfomance curve (Not specified)

12-30-11 @

TESTING

AND ADJUSTING Pump Assembly


(106682-4990) (106682-4991) Pump Manufactures part No.

CALIBRATION Number

DATA

Injection

6162-73-2174 6162-73-2175

Applicable Model OEM for generator (Prime use)

Machine Serial No.

Applicable Model SA6D170-B-1

Engine Serial No.

( ): Injection

Injection
Rotating Injection Injection firestroke

Pump Specification
direction order interval I (mm) ( Counterclockwise drive end l-5-3-6-2-4 59 30 - 60 30 2.95 - 3.05 120 viewed from

Engine Specification

(Without

fan1
378 {506)/l ,500 (Net) 403 {5391/l ,800 (Net) Max. 1,570 (50 Hz) Max. 1,880 (60 Hz) 700 - 900 Motor: 7.5 kW

Flywheel horsepower (kW{HPYrpm) 1Maximum torque (NmIkgmMrpm)I

I High idling I Low idling

speed
speed

(rpm)
(rpm)

Delivery valve retraction volume (mmst)

Pump tester capacity for Service standard

Calibration

Standard

) : lnjenction

pump

manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

Rack positions

Governor

perfomance

curve

urnmaximum

speed Rack

control iimit:l9.

spec. I-19. 3

(mm)
All speed idl ina set

Idling

sub

spring t)

set

Q=67-77 (mm3/s

0 Approx. Pump 500 speed 745-755 (rpm)

400 Pump speed from) TWE00729

12-30-12 G9

TESTING Injection
6162-73-2180 6162-73-2181 ( ): Injection

AND ADJUSTING Pump Assembly


(I 06682-4900) (106682-9000)

CALIBRATION Number

DATA

ApDiicable Model

Machine Serial No.

I I

Aoolicable Model
SAGD170-B-I

Enaine Serial No.

Pump

Manufactures

part No.

EG500-l,EG500B-1 EG500BS-1 OEM for generator

Injection
Rotating Injection Injection

Pump Specification
direction order interval (mm) Counterclockwise drive end l-5-3-6-2-4 59 30 - 60 30 2.95 - 3.05 120 viewed from

Engine Specification

(Without

fan)
385 {5241/l ,500 (50 Hz) 458 I611~/1,800 (60 Hz) Max. 1,560 (50 Hz) Max. 1,870 (60 Hz) 800 Motor: 7.5 kW

Flywheel horsepower (kWfHP)/rpm) Maximum High idling Low idling torque (Nm{kgm}/rpm) speed speed (rpm)

Plunger prestroke

(rpm)

Delivery valve retraction volume (mm3st)

Pump tester capacity for Service standard

Calibration

Standard

) : lnienction

oumo

manufactures

Dart number

* Service standard indicates data using calibration test parts. 5Manufacture standard is data test parts.

Rack positions B to E are the ref-

Governor pet-fomance curve

: -

19.7

2 ..2 a

17.6 17.4 9.3

400

750 900

Pumpspeed [r pm) TWE00730

12-30- 13 @

TESTING

AND

ADJUSTING

CALIBRATION

DATA

Injection

Pump Assembly
(106682-9220) (106682-9221) Pump

Number

6162-73-2340 6162-73-2341

Applicable Model

Machine Serial No.

Applicable Model SA6D170-B-1

Engine Serial No.

( ): Injection

Manufactures

part No.

OEM for generator (Standby

use)

Injection
Rotating Injection Injection Plunger

Pump Specification
direction order interval prestroke (mm) Counterclockwise drive end l-5-3-6-2-4 59 30 - 60 30 2.75 - 2.85 viewed from

Engine Specification

(Without

fan)
468 {636}/1,500 (50 Hz) 557 {7571/1,800 (60 Hz) Max. 1,575 (50 Hz) Max. 1,890 (60 Hz) 700 - 900

Flywheel horsepower (kW{HP)/rpm) Maximum High idling Low idling


I

torque (Nm{kgmYrpm) speed speed (rpm) (rpm)


I

Delivery valve retraction volume (mmst)

120

Pump tester capacity for Service standard

Motor:

7.5 kW

Calibration

Standard

1: lnjenction

pump

manufactures

part number

Service standard indicates data using calibration test parts. Manufacture standard is data test parts.

In.ection volume

Governor

perfomance

curve

Rack

I imit : 16. 5-l 5. 7 (mm)

Idlina sub sbrinu set Q=55-65 (mm/s t .I

Idline sub spring set Q=65-75 (mm3/st.)

745-755

Min. 900 TWE00731

Pump speed (rum)

12-30-14 60

TESTING Injection

AND ADJUSTING Pump Assembly


(106682-9351) Pump Manufactures part No.

CALIBRATION Number

DATA

6162-73-2381

Applicable Model

Machine Serial No.

Applicable Model SA6D170-B-1

Engine Serial No.

( ): injection

OEM for B-pole generator

17441 and up

lniection
Rotating Injection Injection Plunger

Pump. Specification .
direction order interval prestroke (mm) Counterclockwise drive end l-5-3-6-2-4 59 30 - 60 30 2.75 - 2.85 viewed from

Engine Specification

(Without

fan)

Maximum

torque (NmIkgmVrpm)

Delivery valve retraction volume (mm/st) I

Pump tester capacity for Service standard

Motor:

7.5 kW

Calibration
tonditions C

Standard

) : lnjenction
Service

pump standard

manufactures

part number Manufacturer


6162-14-3300 6162-14-3320 6162-13-3711

I
Nozzle & Nozzle holder part No.
Nozzle part No. Nozzle holder part No. Injection
(Outside

standard
(105111-4660) (105025-0910) (105041-7101)

Service standard

(105780-8130) (I 05780-0050) (I 05780-2090)

indicates data using calibration test parts.


Manufacture standard is data for factory test parts.

pipe
Inside dia.x Length

diax

) (mm)
(C)

8X4X1,000 ASTM

8 X 2.4 X 1,400 D975 No.2 diesel fuel or equivalent 40-45

Test oil Oil temperature

Nozzle opening pressure (MPaIkg/cm%

17.2 {I751 157 {I .6} Service standard (cc/l,000 st) Manufacturer

26.0 {265} 157 {I .S} standard (cc/1,000 st)


Maximum

1Transfer
njection volume
Rack point Rack positions B to E are the ref-

pump pressure (kPaikg/cm?) Rack position

Pump
speed

(mm) A(Basicpoint)
B C D

(mm) 500
600 400

Injection volume 498 - 508


538 - 548 II-14

Maximum variance between cylinder

Injection volume

~~!r~J~
cylinder

ernce volume
when adjusting the injection volume. Marks * are average volumes.

14.8
15.5 Approx. 6.8

Max. 18.7
Max. 7.5

419
448 25

Governor

perfomance

curve

Rack

limit

is

not

actuated

400

500f5
speed

\ 520f5

600f5 TWE00637

Boost

(rpm)

12-30-15 @

COOLING

SYSTEM

FAN BELT TENSION 4 2


1. Adjustment nut 2. Washer 3. Tension spring 4. Adjutment bolt

5. Tension pulley A. Protrusion of adjustment bolt

For D275A-2

6162F291

2 z z
Engine

Unit:

mm

model

Applicable machine

Dimension A

;6D170-1

Q area

SA6D170-A-1

HD465-3

58f5

12-031 69

REPLACING

FAN BELT AND

AQJUSTING

AUTO TENSIONER

Replacing Loosen locknut (1) and turn back adjustment (3). of approx. 50 cm in the to the screw

(2) as far as bracket Insert a bar with

a length

hole (418)

in bracket

(7). then

pull strongly

front and hold in position. The spring will extend and the tension pulley will

move to the inside. Remove the old belts and replace it with new bolts. * Replace the V-belts in a set (3 belts).

6162F1014

Adjusting Tighten tension adjustment screw pulley screw (2) (2), and when into the tip of with screw with

1.

adjustment (2) a further locknut (1). w *

comes then

contact

lever (4). tighten

adjustment

half turn,

lock it in position

Locknut

: 29.5

+ 2 kgm tension screw pulley lever (4) and operation,

If a gap appears the adjust

between

tip of adjustment in the same way.

(2) during

If the fan

belt screeches,

adjust

in the

same

way.
6162F668

12-032 0

TESTING AND ADJUSTING

PERFORMANCE TEST

PERFORMANCE TEST
RUN-IN STANDARD
Item

T
1 2 6 1,000 392 {401 314 I321 275 {281 29.4 139.4) 3 3 1,200 883 {901 706 (721 618 {63} 79.4 1106.51 3 300 - 66C 0 0 0 0

Order 4 3 1,200 1,373 {I401 1,098 {I121 961 1981 123.5 U65.61 5 10 1,500 2,059 12101 1,648 {I681 1,442 11471 231.7 1310.6) 10 1,500 2,059 f2101 6 Min. 5 1,800 2,452 {2501 1,961 {200> 1,716 I1751 331 1443.7)

Running time Engine speed Load D275A-2 716 mm 895 mm 1,023 mm Flywheel Horsepower

Running time Engine speed Load PC650-1 PC1 500-I 716 mm 895 mm 1,023 mm Flywheel Horsepower

3 550 - 700 0 0 0 0

6 1,000 392 I401 314 1321 275 1281 29.4 f39.4)

3 1,200 883 I901 706 I721 618 1631 79.4 I106.5)

3 1,200 1,373 {I401 1,098 {I121 961 1981 123.5 U65.61

Min. 5 1,600 2,648 (2701 2,118 f2161 1,853 11891 317.8 f426.0)

X2??
1,442 {I471 231.7 1310.61

Running time Engine speed Load S6D170-1 WA600-1 716 mm 895 mm 1,023 mm Flywheel Horsepower

min.

3 i50 - 700 0 0 0 0

6 1,000 392 1401 314 I321 275 {28) 29.4 I39.4)

3 1,200 883 I90) 706 {72) 618 I631 79.4 1106.5)

3 1,200 1,373 {I401 1,098 {I121 961 {981 123.5 U65.6)

10 1,500 2,059 I2101 1,648 11681 1,442 I1471 231.7 1310.61 10 1,800 1,157 {I181 922 1941 814 1831 155.9 {209.0)

Min. 5 2,000 2,157 I2201 1,726 {176) 1,510 1154) 323.6 t433.8)

Running time 5ngine speed _oad ND600-1 716 mm 895 mm 1,023 mm lywheel Horsepower

3 ;50 - 700 0 0 0 0

6 1,000 265 I271 216 (221 186 U9) 19.8 126.6)

3 1,300 530 154) 422 I431 373 I381 51.5 {69)

3 1,600 814 I831 647 {661 569 158) 97.8 I131.1)

Min. 5 2,000 2,403 f2451 1,922 U96) 1.677 I1711 433.9 I581.7) 10 1,500 4,219 1430) 474.5 I6361

Iunning

time

5 00 - 850

15 1,000 490 150) 36.6 I491

5 1,200 981 {loo) 88.0 Ill81

5 1,200 2,059 I2101 185 12481

20 1,500 3,138 13201 352.9 14731

ingine speed .oad iG550-1 716 mm 895 mm 1,023 mm :lywheel Horsepower * *

The values given for the output is the fan removed. _ The load (dynamometer) is given for the case of the arm length is 716 mm, 895 mm or 1,023 mm.

12-033 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST

t *

The table gives the standard The load for the dynamometer

values for machines

without

fan.

are at an arms length of 716 mm.

Engine model

,pplicable machine

Order Item 1 2 3 4 5 10 1,500 2,059 {2101 231.8 l310.6) 6

Running time Engine speed PS6D170-1 Load Flywheel Horsepower S6D170-1 Running time Engine speed EM for enerator Load Flywheel Horsepower

3 800 0

6 1,000 392 {401 29.4 I39.41

3 1,200 883 I901 79.4 1106.51

3 1,200 1,373 11401 123.6 1165.61

5 1,800 2,942 13001 397.4 1532.4)

3 50 - 800 0

6 1,000 392 I401 29.4 139.4)

3 1,200 883 I901 79.5 I106.5)

3 1,200 1,373 I1401 123.6 i165.61

10 1,500 2,059 {2101 231.8 1310.61

Min. 5 1,800 3,040 {3101 410.7 t550.21

Running time Engine speed Load Flywheel Horsepower

Running time Engine speed Load Flywheel Horsepower

Running time Engine speed Load Flywheel Horsepower

Running time Engine speed Load Flywheel Horsepower

12-034 0

TESTING AND ADJUSTING

PERFORMANCE TEST

* t *I Engine model

The values given for the output is the fan removed. The load (dynamometer)

: Mechanical
item

governor

is given for the case of the arm length is 716 mm, 895 mm or 1,023 mm. *2 : Electronic governor

liD465-5 Both nechanical Jectronic rovernor) Load

1 3 25 -950 *1 20 - 970 *i 0 0

2 6 1,000 392 {401 29.4 l39.4)

3 3 1,200 883 $01 79.5 UO6.5)

4 3 1,200 1,373 U401 123.6 {I 65.6)

5 10 1,500 2,511 {2561 282.6 C378.61

6 5 2,100 3,452 I3521 544.1 1728.9)

Running time Engine speed 716 mm 895 mm 1,023 mm Flywheel Horsepower

Running time Engine speed Load VA700-1 716 mm 895 mm 1,023 mm Flywheel Horsepower

5 700 0 0 0 0

15 1,000

5 1,200 883 (901 706 I721 618 f631 79.5 UO6.5)

5 1,600 1,667 I1701 1,334 I1361 1,167 {I191 200.2 1268.21

20 1800 2,452 {2501 1,961 I2001 1,716 I1751 331.2 I443.71

10 2,000 3,383 13451 2,707 I2761 2,368 I241.5) 507.8 t680.31

$zl 353 I36} 309 131.51 33.1 @I441

Running time Engine speed iG580-1 iG580B-1 iG600-1 .G600B-1 J;;T&s-l generator Load 716 mm 895 mm 1,023 mm Flywheel Horsepower

5 00 - 900 0 0 0 0

15 1,000 392 1401 314 {321 275 (281 29.4 139.4)

5 1,200 1,177 I1201 932 (951 824 1841 106.0 (142.0)

5 1,200 1,961 (2001 1,569 I1601 1,373 (140) 176.6 (236.6)

20 1,500 3,046 (3101 2,432 (2481 2,128 (1271 242.2 (458.5)

10 1,500 3,432 {3501 2,746 12801 2,403 12451 386.4 (517.7)

SAGDI 70-A-

Running time Engine speed Load EG580-BIL 716 mm 895 mm 1,023 mm Flywheel Horsepower

5 50 - 1,ooc 0 0 0 0

15 1,000 588 f601 471 I481 412 {421 44.1 159.11

5 1,200 1,177 I1201 941 {961 824 (841 105.9 (141.9)

5 1,200 2,354 (2401 1,883 11921 1,648 (1681 211.8 (283.91

20 1,500 3,530 1360) 2,824 (2881 2,471 12521 397.2 (532.4)

10 1,500 4,707 I480} 3,766 1384) 3,295 13361 529.6 i709.91

Running time Engine speed Load EPSAGDlTI( -A716 mm 895 mm 1,023 mm Flywheel Horsepower

5 800 0 0

15 1,000

5 1,200 883 {90} 79.5 I106.5)

5 1,600 1,765 (1801 212 12841

20 1,800 3,026 13081 407.7 (546.2)

10 2,000 3,060 I3631 534.3 t715.8)

z 33.1 (44.4)

l Z-035 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST

* *

The table gives the standard The load for the dynamometer

values for machines

without

fan.

are at an arms length of 716 mm.

Applicable machine

Order Item

1
Running time Engine speed 3 550 - 600 0

6 1,000 392 I401 29.4 i39.4)

3 1,200 883 I901 79.5 (106.5)

3 1,200 1,373 U40} 123.6 U65.61

10 1,500 2,579 (2631 290.4 I389.0)

Min. 5 2,000 3,658 {3731 549.1 1735.6)

EM680A EM680A-1 6M170-B-1

Load Flywheel Horsepower

Running time Engine speed EM680A-A Load Flywheel Horsepower

3 550 - 600 0

6 1,000 392 I401 29.4 (39.4)

3 1,200 883 (901 79.5 (106.51

3 1,200 1.373 (1401 123.6 (165.61

IO 1,500 2,511 (2561 282.6 (378.61

Min. 5 2,000 4,187 I427> 628.5 (842.01

Running time Engine speed H D465-5 (High altitude spec.) Load Flywheel Horsepower SA6D170-ARunning time OEM for at7yfr=r$r 633 HP) Flywheel Horsepower Engine speed Load

5 1,100 0

15 1,100 343 (351 28.3 t38.01

5 1,300 637 (651 62.2 i83.31

5 1,650 1,226 (125) 151.8 (203.41

20 1,900 1,863 (1901 265.7 (355.91

10 2,100 2,452 (2501 386.4 I517.71 2 z z

5 950 0

15 1,000 588 160) 44.2 (59.21

5 1,200 1,177 I1201 106.0 (142.0)

5 1,200 2,354 (2401 212.0 (284.01

20 1,500 3,530 13601 397.4 (532.41

IO 1,500 4,707 (4801 529.9 (709.91

Running time EG600BS-1 OEM for generator (Engine No. 15503andup Engine speed Load Flywheel Horsepower

5 700 - 900 0

15 1,000 490 (50) 29.4 (39.41

5 1,200 981 IlOO} 106.0 (142.01

5 1,200 1,961 I2001 176.6 (236.6)

20 1,500 2,942 (3001 342.2 (458.51

IO 1,500 3,923 I4001 386.4 (517.7)

Running time OEM for generator Engine speed Load Flywheel Horsepower

3 800 0

6 1,000 490 1501 47.8 (64.11

3 1,200 981 I1001 114.8 (153.8)

3 1,200 1,961 (2001 234.0 I313.5)

IO 1,500 2,942 I3001 441.6 (591.61

5 1,800 3,923 (4001 529.9 (940.61

12-035- 1 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST

The table gives the standard The load for the dynamometer

values for machines

without fan.

T
c1ooosPLoad

are at an arms length of 716 mm.

Item

-r
1 2 3 3 675 0 6 1,000 392 {401 29.4 139.4) 3 1,200 883 {901 79.5 1106.5)

Order 4 5 10 1,500 2,059 6

Running time Engine speed

3 1,200 1.373 {I401 123.6 1165.6)

Min. 5 1,750 3,472 1354) 456.3 I611.31

WO}
231.8 f310.61

Flywheel Horsepower

Running time 3EM for generator Standby .rse 581 kW :778 HP}) Engine speed Load Flywheel Horsepower SA6D170-ARunning time Engine speed 3EM for narine Load Flywheel Horsepower

3 700 - 900 0

6 1,000 637 165) 47.8 WI)

3 1,200 1,275 I1301 114.8 1153.8)

3 1,200 2,599 I2661 234.0 (313.5)

10 1,500 3,923 (4001 441.6 (591.61

5 1,800 5,198 I5301 702.1 (940.6)

3 575 0

9 1,260 922 I941 86.8 (116.3)

18 1,580 1,844 (188) 218.6 (292.8)

24 1,820 2,756 I2811 376.1 (503.81

6 2,000 3,677 I3751 552.0 (739.5)

Running time Engine speed -lD465-3 ,For ORAPI MINE Load Flywheel Horsepower

3 850 0

6 1,000 392 (401 29.4 (39.4)

3 1,200 883 1901 79.5 UO6.51

3 1,200 1,373 {I401 123.6 U65.61

10 1,500 2,511 (2661 282.4 I378.61

Min. 5 2,000 3,393 I3461 508.8 {682}

Running time Engine speed Load Flywheel Horsepower

Running time Engine speed Load Flywheel Horsepower

12-035-2 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST

t *

The values given for the output is the fan removed. The load (dynamometer) is given for the case of the arm length is 716 mm, 895 mm or 1,023 mm. Order Item
1

Engine model

2 6 1,000 392 {401 314 I321 275 I281 29.4 139.41

3 3 1,200 883 {901 706 {721 618 {631 79.4 1106.5) 3 1,200 785 {801 706 {721 618 I631 70.6 194.6) 3 1,200 883 1901 79.4 UO6.51 5 1,300 735 I751 588 I601 515 152.5) 71.6 {961

4 3 1,200 1,373 11401 1,098 11121 961 1981 123.5 {I 65.6) 3 1,200 1,569 I1601 1,255 11281 1,098 Cl121 141.2 i189.3) 3 1,200 1,373 11401 123.5 {I 65.6) 5 1,650 1,471 {I501 1,177 I1201 1,030 Cl051 182.0 {2441

5
10

6 Min. 5 1,800 2,942 {3001 2,354 12401 2,059 {2101 397.2 i532.4) Min. 5 1,800 3,119 {3181 2,495 i254.41 2,183 1222.6) 421.0 i564.41

Running time Engine speed Load D375A-1 716 mm 895 mm 1,023 mm Flywheel Horsepower Running time Engine speed Load D375A-2 895 mm 1,023 mm Flywheel Horsepower Running time Engine speed Load SA6D170-BPC1000-l 716 mm 895 mm 1,023 mm Flywheel Horsepower Running time Engine speed Load HD465-3 with single turbochage HD500-3 716 mm 895 mm 1,023 mm Flywheel Horsepower 716 mm

3 600 - 700 0

1,500 2,059 {2101 1,648 I1681 1,442 {I471 231.7 1310.61


IO

3 600 - 700 0 0 0 0

6 1,000 392 1401 314 {321 275 1281 29.4 t39.41 6 1,000 392 1401 29.4 139.4) 15 1,000 373 I381 298 130.41 359 I36.6) 28.0 137.5)

1,500 2,354 {240} 1,883 Cl921 1,648 (1681 264.8 1355.01 10 1,500 2,059 I2101 231.7 1310.6) 20 1,900 2,206 I2251 1,765 I1801 1,545 U57.5) 314.4 t421.51

3 650 - 700 0 0

Min. 5 1,700 3,236 I3301 412.6 1553.11


10

2 z z

5 850 - 900 0

2,100 2,942 {3001 2,354 {2401 2,059 {2101 463.4 1621.21

Running time Engine speed Pc1000-1 (High altitude spec.) Load 716 mm

3 800 0 0

6 1,000 343 1351 25.8 134.5)

3 1,200 686 {701 61.8 I82.81

3 1,200 1,373 {I401 123.6 I165.61

IO 1,500 2,059 {210} 231.8 t310.6)

5 1,800 2,746 I2801 350.3 I469.3)

Flywheel Horsepower

12-035-3 0

TESTING AND ADJUSTING

PERFORMANCE TEST

t *

The values given for the output is the fan removed. The load (dynamometer) is given for the case of the arm length is 716 mm, 895 mm or 1,023 mm.

Engine model

lingine :G450-1 _oad

Item

r
1
2 3 5 50 - 1,000 0 15 1,000 392 {401 40.3 158 5 1,200 1,177 11201 145.5 11951

Order 4 5 6

Qrnning time speed 716 mm

5 1,200 1,961 12001 242.5 1325)

20 1,500 3,040 {3101 470.0 I6301

10 1,500 3,432 {350> 530.4 17111

Yywheel Horsepower

bnning

time

3 00 - 900 0 0

6 1,000 392 1401 29.4 t39.41

3 1,200 883 {901 79.4 1106.5)

3 1,200 1,373 WON 123.5 (165.6)

10 1,500 2,059 I2101 231.7 (310.6)

Min. 5 1,800 3,481 {3551 470.0 I6301

Engine speed fG480-1 EG480B-1 EG500-1 EG500B-1 !G500BS-1 _oad 716 mm 895 mm 1,023 mm zlywheel Horsepower

krnning !ngine SA6D170-B?SA6D17( .B-1 _oad

time speed 716 mm

3 800 0

6 1,000 392 {40) 29.4 t39.41

3 1,200 883 I901 79.5 (106.51

3 1,200 1,373 U40> 123.6 U65.61

10 1,500 2,059 {2101 231.8 f310.61

Min. 5 1,800 3,138 {320} 458.5 t614.31

?ywheel Horsepower

Qrnning ingine :G480B-1 :For CIS) _oad

time speed 716 mm

3 150 f 100 0

6 1,000 40

3 1,200 90

3 1,200 140

10 1,500 210

5 1,800 355

-lywheel Horsepower

39.4

106.5

166

310.6

630

Running time EG500-1 EG500B-1 EG500BSOEM for generator Engine speed Load 716 mm

min.

3 800 0

6 1,000 490 1501 36.8 149.31

3 1,200 981 {IO01 88.3 {I 18.3)

3 1,200 1,961 {200} 176.6 f236.6)

IO 1,500 2,942 13001 331.2 1443.71

5 1,800 3,923 {4001 530.3 {710.01

Flywheel Horsepower

12-035-4 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST

t *

The table gives the standard The load for the dynamometer

values for machines

without

fan.

are at an arms length of 716 mm.

-r
Engine model Item 1 2 3 Running time OEM for ggyTrar 508 HP) Flywheel Horsepower 0 Engine speed Load 3 800 0 6 1,000 392 1401 29.4 (39.4) 3 1,200 883 1901 79.5 I106.5)

Order 4 5 6

3 1,200 1,373 U401 123.6 1165.6)

3 1,500 2,059 C2101 231.8 f310.61

5 1,800 3,727 {3801 503.4 l674.41

Running time OEM for r,n7epar 559 HP) Flywheel Horsepower Engine speed Load

3 800 0

6 1,000 539 155) 40.5 154.2)

3 1,200 1,079 UlOI 97.2 1130.2}

3 1,200 2,157 {2201 194.3 1260.3)

10 1,500 3,236 I3331 364.3 {488.1}

5 1,800 4,315 1440) 582.9 I780.91

Running time OEM for prime use g7rF$r 506 HP) Flywheel Horsepower SA6D170-BGnning 3EM for j-pole Jenerator 50Hz) time Engine speed Load

3 800 0

6 1,000 392 {401 29.4 C39.4)

3 1,200 834 I851 75.1 ClOO.61

3 1,200 1,667 I1701 150.1 {201.11

10 1,500 2,501 I2551 281.9 f377.61

5 1,800 3,334 I3401 375.4 1502.9) z z z

3 800 0

6 1,000 471 14481 35.3 C47.31

3 1,000 932 1951 69.9 {93.7}

3 1,000 1,863 {I901 139.8 U87.3)

10

5 1,200 3,727 13801 279.7 1374.7)

Engine speed _oad +wheel Horsepower

1,000
2,795 (2851 209.8 1281.01

3unning time IEM for j-pole gonezTtor %gine speed .oad lywheel Horsepower

3 800 0

6 1,000 490 I501 36.8 f49.3)

3 1,000 981 {loo} 73.6 198.6)

3 1,200 1,961 12001 176.6 I236.61

10 1,200 2,942 {3001 265.0 {355.0}

5 1,200 3,923 14001 353.3 1473.31

Iunning

time

3 00 - 850 0

6 1,000 392 I401 29.4 I39.41

3 1,200 1,177 {1201 106.0 U42.01

3 1,200 1,961 {2001 176.6 f236.61

10 1,500 3,040 13101 342.2 I458.51

5 1,500 3,432 13501 386.4 I517.7)

ingine speed IEM for generator .oad :lywheel Horsepower

12-035-5 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST

The table

gives the standard

values

for machines

without

fan.

Engine

r
qunning Engine VA600-1 EC regulaion) Load Running >ENYO generator xA6OOSSl Engine Load

The load for the dynamometer

are at an arms

length

of 716 mm.

Order Item 1 2 3 4 5 6

time speed

6
1,000 390 {401

3 1,200 880 190)

3 1,200 1,370 U40} 124 U681

10 1,500 2,060 12101 232 (315)

5 2,000 2,160 {2201 324 14401

Flywheel Horsepower

&

0%

time speed

6 1,000 490 1501

3 1,200 980 UOO}

3 1,200 1,960 {2001 176 {2401

10 1,500 2,940 (3001 331 1450)

5 1,800 3,920 {400} 529 {720}

Flywheel Horsepower

1%

{I%)

Running Engine Load

time speed

Flywheel Horsepower SA6D170-AERunning Engine Load Flywheel Horsepower time speed

Running Engine Load

time speed

Flywheel Horsepower

Running Engine Load

time speed

Flywheel Horsepower

12-035-6 @

TESTING

AND ADJUSTING

PERFORMANCE

TEST

* *

The table gives the standard The load for the dynamometer

values for machines

without

fan.

are at an arms length of 716 mm.

Engine model

Applicable machine

Item

r
1 2 3 3 800 0 6 1,000 785 I801 58.9 (78.9) 3 1,200 1,569 {I601 141.3 {I 89.3)

Order 4 5 6

Running time Engine speed ienerator 50 Hz only Load Flywheel Horsepower

3 1,200 3,089 {315} 278.2 t372.7)

IO 1,500 4,609 I4701 518.9 1695.11

5 1,750 6,374 16501 717.6 {961.4)

Running time Engine speed Load Flywheel Horsepower

Running time Engine speed Load Flywheel Horsepower

Running time Engine speed Load Flywheel Horsepower

Running time Engine speed Load Flywheel Horsepower

Running time Engine speed Load Flywheel Horsepower

12-035-7 69

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

PERFORMANCE

TEST CRITERIA
lDvnamometerload Arm length 716mm 2,409 -2,542 245.6-259.2) 2,924-3,100 298.2 -316.1) Arm length 895mm 1,927 -2,064 196.5 -207.4) 2,340 -2,480 238.6-252.91 (N {kg)) Arm length 1,023 mm 1,686 -1,779 171.9 -181.41 2,047 -2,169 208.7 -221.2) -

Engine model

.pplicable nachine

Test item

Specified value (fully equippe)

El nginespeed (rpm)

F 2,079 Nm/1,300 rpm 1212 kgm/1,300 rpm1 1,960-2,040 rpm 600-660 rpm

1,795-1,805 1 l,300-1,500 1,960-2,040 600-660

nAax. torque 275A-2 t iigh idling speed .owidling speed 1 :lywheel F Horsepower wlax.torque F

302 kW/1,600 rpm I405 HP/l,800 rpm) 2,030 Nm/1,200 rpm {207 kgm/1,200 rpm)

1,595 -1,605 l,lOO-1,300 1,700-1,800 650-700

1,818 -1,922 2,598- 2,747 2,078 -2,198 -224.1) ,185.4- 196.0) :264.9-280.11 :211.9 1,996-2,114 2,281 -2,417 2,852-3,021 :290.8-308.1) :232.6-246.5) ,203.5-215.6) -

C650-1 c1500-1

t 1
S6D170-1

f IVlax.torque
VA600-1 1,961 Nm/1,400 rpm I200 kgm/1,400 rpm} 2,200-2,300 rpm

1 !,995-2,005 1,250- 1,450 1 !,200-2,300 ; 650-700

2,143-2,270 1,711 -1,715 1,499 - 1,589 (218.5-231.51 (174.8-185.21 J52.9 - 162.0) 1,956- 2,046 2,236-2,338 2,795-2,922 (285.0-298.0) (228.0-238.41 :199.5-208.6) 8 z z

I I I I\nax.torque
VA600-1 idling speed I-ligh Low I idling speed

1,995-2,005 2,089 Nm/1,400 rpm (213 kgm/1,400 rpm) 2,200-2,300 rpm 650-700 rpm 1,300-1,500 !,300-2,400 : 650-700

2,334 - 2,471 1238-2521

1,634-1,730 1,867 -1,977 (190.4-201.61 [166.6-176.41

2,029 -2,152 2,319 -2,459 2,899-3,073 {295.6-313.41 {236.5-250.71 (206.9-219.4) -

12-036 0

TESTING
* * * * t *

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

The values in the table are indicated at standard conditions (Armospheric temperature 25-C, atmospheric pressure 196.8 kPa 1750 mm Hg}. The values given for dynamometer loads the output and torque are with the fan removed, so they differ from those of the secification. Values are standardized under thefollowinq conditions: Muffler; air cleaner installed; alternator idling; and air compressor (if installed) open. Dynamometer loads are given for the case of the arm length is 716 mm. Fuel used: ASTM D975 No. I or No. 2 diesel fuel. Lubricaton ooil used: CLASS-CO SAE30.

out put (kW {HP})


325.3 - 343.4 (435.8 - 460.1)

Torque (Nm {kgm))

Fuel consumption (set/500 cc)

Coolant temperature (C)

Lubrication Nil temperature (C)

Lubrication oil pressure &Pa h/cm2H 294 - 490 {3.0 - 5.0)

Exhaust temperature (C)

2,095 - 2,226 {213.6 - 226.4)

Min. 19.7

70-90
70-90

80-110

Max. 600

Min. 21.6

80-110

294 - 490
(3.0 - 5.0) Min. I47 {Min. 1.5} 343 - 490 13.5 - 5.01

Max. 650 -

311.9-329.9 {417.9 - 441.9) -

70-90

80-110

2,042 - 2,163 1208.2 - 220.6)

70-90

Min. 80

70-90

80-110

Max. 600

Min. 25.0 -

70-90

80-110

343 - 490 t3.0 - 5.01 Min. 147 {Min. 1.5) 294 - 490 13.0 - 5.01

Max. 650 -

321.6 - 340.8 1430.9 - 456.51

70-90

80-110

70-90

Min. 80

1,999 - 2,097 f203.8 - 213.81

Min. 19.2

70-90

80-110

Max. 600

2
G

Min. 22.2 -

70-90

80-110

294 - 490 f3.0 - 5.01 Min. 147 {Min. 1.5) 324 l3.3 -1

Max. 650

350.3 - 370.9 1469.3 - 496.9) -

2,075 - 2,230 {211.6 - 227.4)

70-90

80-110

Max. 600

Min. 17.5 -

70-90

80-110

70-90

so - 120

70-90

so - 120

Max. 650

70-90

so - 120

Min. 70

Min. 80

12-037 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Applicable machine

Test item

Specified

value

Engine speed (rpm)

Dynamometer (N {kg])

Load

Flywheel Horsepower Max. torque !PS6D170. High idling speel

385 kW/1,800 1516 PS/1,800

rpm rpm}

1,795 - 1,805 -

2,937 - 3,015 (299.5 - 307.51

324 {434 371 I497 kW/1,500 HP/l,500 kW/1,800 HP/l,800 rpm rpm} rpm rpm} (50 (50 (60 (60 Hz) Hz) Hz) Hz)

2,844 1290.0 2,736 1279.0 3,001 (50 Hz) 306.0) (50 Hz) 2,893 (60 Hz) 295.0) (60 Hz)

Low idling speer

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

Flywheel Horsepower 3EM for Jenerator Prime USE

Max. torque High idling speel Low idling speec

Max. 1,560 rpm Max. 1,872 rpm (50 Hz) (60 Hz)

Hz) Hz) Hz) Hz) 1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz) 3,119 I318.0 3,011 I307.0

- 3,589 - 366.0) -3,168 - 323.0) (50 Hz) (50 Hz) (60 Hz) (60 Hz) 8

700 - 800 rpm 355 {476 408 I547 kW/1,500 HP/l,500 kW/1,800 HP/l,800 rpm rpm} rpm rpm} (50 (50 (60 (60

S6D170-1 Flywheel Horsepower 3EM for generator Stand by use)

Max. torque High idling speel Low idling speec 345 {462 403 {539

Max. 1,575 rpm Max. 1,890 rpm (50 Hz) (60 Hz) Max. Max.

1,575 1,890 (50 Hz) (60 Hz)

3,109 t317.0 3,040 C310.0 - 3,197 (50 Hz) - 326.0) (50 Hz) - 3,128 (60 Hz) -319.0) (60 Hz) -

700 - 800 rpm kW/1,500 HP/l,500 kW/1,800 HP/l,800 rpm rpm} rpm rpm} (50 (50 (60 (60 Hz) Hz) Hz) Hz)

700 - 800 1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

Flywheel Horsepower 3EM for generator Power up

Max. torque High idling spee, Low idling speec

Max. 1,560 rpm Max. 1,872 rpm (50 Hz) (60 Hz)

Max. 1,560 Max. 1,872 (50 Hz) (60 Hz)

700 - 900 rpm

700 - 900

12-037-l 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

* *

The table gives the standard values using the JIS compensator factor. The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opem (if installed). The loads for the dynamometer are at an arms length of 716 mm Flywheel horsepower (kW {HP}) 396.9 - 407.9 f531.6 - 546.4) Torque (Nm (kgm}) Fuel consumption (set/200 cc) Coolant temperature (0 Lubrication #iItemperature (C) Lubrication oil pressure (kPa {kg/cm*}) 294 - 490 13.0 - 5.01 Exhaust temperature (C)

Min. 15.9

70-90 -

80-110 -

Max. 650

535.8 - 568.2 t717.8 - 761.2)

294 - 490 13.0 - 5.01

70-90

80-110

Min. 70

Min. 80

Min. 12.3

70-90

80-110

Max. 650

70-90 70-90

80-110 Min. 80

294 - 490 l3.0 - 5.01 Min. 147 {Min. 1.51

Max. 650 -

374.6 - 398.2 1501.9 - 533.8 2 z z -

Min. 16.5

70-85

80-110

294 - 490 (3.0 - 5.01

Max. 620

70-85 70-85

80-110 Min. 80

Min. 147 {Min. 1.51 343 - 490 it. I y; t3.5 - 5.01 Max. 600 Max. 650

350.3 {469.3 410.7 1550.2 360.4 (50 483.1} (50 423.2 (60 567.0}(60 Hi Hi Hz Hi

Min. 18.5 Min. 15.8

70-85 70-85

80-110 80-110 -

343 - 490 13.5 - 5.01 Min. 177 {Min. 1.8)

70-85

80-110 Min. 80

Min. 70

V-037-2 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

Test item

Specified value (fully equippe)

ngine speed (rpm)

l-

Dynamometer Arm length 716 mm 3,413 - 3,501 346.0 - 357.01 3,825 - 4,070 390.0 - 415.01 -

load (N {kg}) Arm length 1,023 mm 2,389 - 2,451 243.6 - 249.91 2,677 - 2,849 273.0 - 290.5)

Arm length 895 mm !,730 - 2,801 278.4 - 285.61 $060 - 3,256 312.0 - 332.01 -

Flywheel Horsepower iD465-3 with single urboharger, twir urboharger) Max. torque

504 kW/2,100 1702 HP/2,100 2,824 Nm/1,400 I288 kgm/1,400

rpm rpm} rpm rpm)

!,095 - 2,105

1,350 - 1,450

High idling spee

2,250 - 2,380 rpm

2,250 - 2,350 ;50 - 700 (*l) 140 - 940 (21

Low idling spee,

850 - 900 rpm

Flywheel Horsepower iD465-5 with mechnical governor) Max. torque

533 kWl2.100 I715 HP/2,100 2,971 Nm/1,400 {303 kgm/1,400

rpm rpm) rpm rpm}

$095 - 2,105

3,400 - 3,605 346.7 - 367.6; 4,081- 4,327 416.1 - 441.2: -

1,300 - 1,500

SA6D170-A-

High idling speem

2,400 - 2,500 rpm

?,400 - 2,500

2,626 - 2,788 267.8 - 284.3: 3,114-3,307 317.5 - 337.2

2,298 - 2,440 :234.3 - 248.8) 2,724 - 2,894 :277.8 - 295.1)

Low idling spee,

900 - 950 rpm

900 - 950

Flywheel Horsepower Max. torque NA700-1 High idling spee

478 kW/2,000 1641 HP&000 2,815 Nm/1,400 {287 kgm/l,400

rpm rpm1 rpm rpm1

2,000 - 2,050

3,282 - 3,485 334.7 - 355.4 3,892 - 4,134 396.9 - 421.5: -

1,300 - 1,500

2,240 - 2,300 rpm

2,240 - 2,300

Low idling speel

700 - 750 rpm

700 - 750

c1: With5 2 : With t

gte ruroocnarger n turbocharger

12-037-3 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

*
t * * * *

The values in the table are indicated at standard conditions (Armospheric temperature 25C, atmospheric pressure 196.8 kPa {750 mm Hg}. The values given for dynamometer loads the output and torque are with the fan removed, so they differ from those of the secification. Values are standardized under the following conditions: Muffler; air cleaner installed; alternator idling; and air compressor (if installed) open. Dynamometer loads are given for the case of the arm length is 716 mm. Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. Lubricaton ooil used: CLASS-CO SAE30.

out put (kW{HPI)


537.3 - 552 1720.0 - 739.5)

Torque (Nm {kgm))

Fuel consumption (set/500 cc)

Coolant temperature (C)

Lubrication )il temperature (C) 80-110

Lubrication oil pressure (kPa {kg/cm?) 196 - 392 i2.0 - 4.0) 196 -392 12.0 - 4.0) 196-392 i2.0 - 4.0) Min. 147 {Min. 1.51

Exhaust temperature (0

2,736 - 2,913 1279.0 - 297.01

Min. 12.0

70-90

Max. 550

535.8 - 568.2 1717.8 - 761.2)

Min. 15.5 -

70-90
70-90

80-110

Max. 600

80-110

Min. 11.6

70-90

Min. 80

70-90

80-110

Max. 650

2,922 - 3,099 t298.0 - 316.0)

70-90
70-90

80-110

Max. 670

80-110 Min. 147 {Min. 1.5) 294 - 490 (3.0 - 5.0)

Max. 650

70-90
492.6 - 523.1 1659.9 - 700.81

Min. 80

2,787 - 2,954 1284.2 - 301.81

Min. 13.6

70-95

80-110

2
G

70-95
70-80

80-110

294 - 490 I3.0 - 5.01 Min. 147 {Min. 1.5}

Max. 650

80-110

70-80

Min. 80

12-037-4 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

Applicable machine

Test item

Specified

value

Engine speed (rpm)

Dynamometer (N (kg])

Load

Flywheel Horsepower Max. torque Pc1ooosP~ High idling spee d

434 kWll.750 rpm (582 HP/l ,750 rpm) 2,731 Nm/1,300 (278 kgm/1,300 1,900 - 2,000 rpm rpm} rpm

1,745-

1,755

3,376 - 3,573 (344.3 - 364.31 3,808 - 4,038 (388.3 - 411.8) -

1,200 - 1,400

1,900 - 2,000

Low idling spee d

650 - 700 rpm

650 - 700

3,400 - 3,605 (348.7 - 367.6) 4,081 - 4,327 (416.1 - 441.21

Flywheel Horsepower HD465-5 (with electronic governor) Max. torque

533 kW/2,100 (715 HP/2,100 2,971 Nm/1,400 I303 kgm/1,400 2,330 - 2,400

rpm rpm) rpm rpml rpm

2,095 - 2,105

1,300 - 1,500

High idling spee d

2,330 - 2,440

2,377 - 2,526 (242.4 - 257.61 2,856 - 3,026 (291.9 - 308.61 8 z ;;;

Low idling spee d

920 - 970 rpm

920 - 970

Flywheel Horsepower HD465-5 (Hifh altitude spec Max. torque

387 kW/2,100 (518 HP/2,100 2,108 Nm/1,400 (215 kgm/1,400 2,330 - 2,400

rpm rpm} rpm rpml rpm

1,995 - 2,105

1,300 - 1,500

High idling spee d

2,330 - 2,400

Low idling spee d SA6D170-AFlywheel Horsepower Max. torque EM680A High idling spee d

1,075 - 1,125 rpm

1,075 - 2,400

3,496 - 3,677 (356.5 - 375.01 Min. 3,496 (Min. 356.5)

552 kW/2,000 (740 HP/2,000 2,501 Nm/1,400 {255 kgm/1,400 2,100 - 2,200

rpm rpm} rpm rpm) rpm

1,995 - 2,005

1,300 - 1,500

2,100 - 2,200

3,638 - 3,677 (371 - 375) Min. 4,328 (Min. 432.81

Low idling spee d

550 - 600 rpm

550 - 600

Flywheel Horsepower Max. torque EM680-A 6M170B-1 High idling spee d

552 kW/2,100 (740 HP/2,100 2,893 Nm/1,400 (295 kgm/1,400 2,100 - 2,200

rpm rpm} rpm rpm} rpm

2,000

1,300 - 1,500

2,100 - 2,200

Low idling spee d

550 - 600 rpm

550 - 600

Flywheel Horsepower Max. torque EM680A-A High idling spee d

629 kW/2,000 (842 HP/2,000 3,295 Nm/1,400 (336 kgm/1,400 2,100 - 2,200

rpm rpm} rpm rpml rpm

1,995 - 2,005

4,084 - 4,291 {416.5 - 437.51 Min. 4,602 (Min. 469.3)

1,300 - 1,500

2,100 - 2,200

--L
*I

Low idling spee d manne gear

550 - 600 rpm

550 - 600

: Without

12-037-5 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

*
*

The table gives the standard values using the JIS compensator factor. The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opem (if installed). The loads for the dvnamometer are at an arms length of 716 mm Flywheel horsepower (kW {HP)) 443.4 - 469.2 t594.1 - 628.61 2,727 - 2,892 {278.1 - 294.9) Fuel consumption (set/500 cc) Coolant temperature (0 Lubrication %I temperature YC) Lubrication oil pressure (kPa {kg/cm21) 343 - 490 13.5 - 5.0) 343 - 490 {3.5 - 5.0) 343 - 490 13.5 - 5.01 Min. 147 {Min. 1.5) 294 - 490 (3.0 - 5.0) Exhaust temperature (C)

Torque (Nm Ikgml)

Min. -

14.9

70-90

80-110

Max. 700

70-90

80-110

Max. 700 -

535.8 - 568.2 {717.8 - 761.2) 2,922 - 3,099 1298.0 - 316.0)

70-90

80-110

Min.

70-90

Min. 80

12.0 -

70-90

80-110

Max. 650

70-90

80-110 294 - 490 {3.0 - 5.0) Min. 147 {Min. 1.51 294 - 490 {3.0 - 5.0)

Max. 670 -

70-90

80-110

374.6 - 398.2 1501.9 - 533.41

Min. 2,050 - 2,167 {209 - 221) 16.5

70-90

Min. 80

70-85

80-110

Max. 620 -

70-85

80-110

524.8 - 552.0 (703.0 - 739.5)

70 - 85

80-110 Min. 147 {Min. 1.5) 294 - 490 13.0 - 5.01

Min. 2,501 {Min. 255.0) Min.

12.9

70 - 85

Min. 80

70 - 95

80-110

Max. 650

Min.

18.8

70 - 95

80-110

Max. 650 Min. 147 {Min. 1.5} 294 - 490 t3.0 - 5.0)

70 - 95

80-110

546.1 - 552.0 i731.6 - 739.5)

70-95

Min. 80

Min. 3,040 {Min. 310) -

Min. -

12.2

70 - 90

80-110

Max. 600

70-90

80-110

Max. 600 Min. 147 {Min. 1.5) 294 - 490 {3.0 - 5.0)

70 - 90

80-110

613.1 - 644.0 i821.3 - 862.8)

Min. 3,295 {Min. 336) Min.

10.7

70 - 90

Min. 80

70 - 90

80-110

Max. 600

Min. -

14.8

70 - 90

80-110

Max. 600 -

70 - 90

80-110 Min. 147 {Min. 1.5)

70-90

Min. 80

12-037-6 a9

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

splicable nachine

Test item

Specified value (fully equippe)

ingine speed (rpm)

Dynamometer Arm length 716 mm 4,008 - 4,242 408.7 - 432.6) 3,716 - 3,933 378.9 -401.11 0 0 0

load (N {kg)) Arm length 1,023 mm

Arm length 895 mm

+wheel (50Hz) Horsepower (60Hz) 3550-I High idling speed (50Hz) (60Hz) Low idling speed

431 kW/1,500 {578 HP/l,500 473 kW/1,800 {634 HP/l,800 Max. Max.

rpm rpm) rpm rpm}

1,495 - 1,505 1,795 - 1,805 Max. Max. 1,560 1,872

1,560 rpm 1,872 rpm rpm

700-800

750 z!C 50

3,301 - 3,405 336.6 - 347.2) 3,060 - 3,145 312.0 - 320.8)

!,888 - 2,979 Z94.5 - 303.81 !,677 - 2,753 !73.0 - 280.7)

+wheel (50Hz) -lorsepower (60Hz) 3580-I 35808-l iigh idling speed (50Hz) (60Hz) _ow idling speed

456 kW/1,500 {611 HP/l,500 502 kW/1,800 {673 HP/l,800 Max. Max.

rpm rpm} rpm rpm)

1,495-

1,505

4,126 - 4,256 420.7 - 434.0) 3,825 - 3,933 390.0 -461.11

1,795 - 1,805 Max. Max. 1,560 1,872

1,560 rpm 1,872 rpm

3,450 - 3,515 348.8 - 358.4)

700 - 900 rpm

700 - 900

3ywheel iorsepower

(50Hz)

472kW/1,500 I633 HP/l,500

rpm rpm)

1,495 - 1,505

4,276 - 4,393 1436 - 4481

!,993 - 3,075 $05.2 - 313.6}

35808-l

-iigh idling

speed (50Hz)

Max.

1,560 rpm

1,550 - 1,560

_ow idling SAGDI 70-A. -lywheel iorsepower 3600-I 36008-l 3600BS-1 IM for nerator

speed

700 - 900 rpm

700 - 900

4,249 - 4,381 433.3 - 446.7) 3,906 - 4,015 398.3 - 409.41 3,399 - 3,504 346.6 - 357.3) 3,124-3,212 318.6 - 327.51

1,974 - 3,066 103.3 - 312.61 1,734 - 2,810 !78.8 - 286.5)

(50Hz) (60Hz)

470 kW/1,500 {630 HP/l,500

rpm rpm)

1,495 - 1,505 1,795 - 1,805 Max. Max. 1,560 1,872

513 kW/l,SOO rpm 1688 HP/l,800 rpm} Max. Max. 1,560 rpm 1,872 rpm

iigh

idling

speed (50Hz) (60Hz)

3,304 - 3,503 (336.9 - 357.2 3,670 - 3,888 L374.2 - 396.5 2,643 - 2,803 L269.5 - 285.8 2,936 - 3,111 :299.4 - 317.2

2,312 - 2,452 235.8 - 250.0) 2,568 - 2,721 261.9 - 277.5)

_ow idling

speed

700 - 900 rpm

700 - 900

Flywheel Horsepower Max. torque PSAGDI? -A. High idling speec

440 kW/l,SOO rpm I590 HP/l,800 rpm) 2,648 Nm/l,300 I270 kgm/1,300 rpm rpm]

1,795 - 1,805

1,200 - 1,400

1,950 - 2,050 rpm

1,950 - 2,050

3,291 - 3,495 F335.6 - 356.4 3,786 - 4,020 L386.1 - 409.9

Low idling

speed

750 - 850 rpm

750 - 850

Flywheel Horsepower Max. torque

504 kW/2,000 {675 HP/2,000 2,795 Nm/1,300 I285 kgm/1,300

rpm rpm) rpm rpml

1,995 - 2,065

D465-3 or ORAP rllNE)

1,200 - 1,400

High idling

speec

2,250 - 2,350 rpm

2,250 - 2,350

Low idling

speed

840 - 860 rpm

840 - 860

12-038 0

TESTING
* t * * * *

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

The values in the table are indicated at standard conditions (Armospheric temperature 25C, atmospheric pressure 196.8 kPa {750 mm HgI. The values given for dynamometer loads the output and torque are with the fan removed, so they differ from those of the secification. Values are standardized under the following conditions: Muffler; air cleaner installed; alternator idling; and air compressor (if installed) open. Dynamometer loads are given for the case of the arm length is 716 mm. Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. Lubricaton ooil used: CLASS-CO SAE30. put (kW {HP))

out

Torque (Nm {kgm})

Fuel consumption (set/500 cc)

Coolant temperature (Cl

LL lbrication oil tlemperature (C) 80-115 80-115 80-115 SO-115 Min. 80

Lubrication oil pressure (kPa {kg/cm% 265 - 392 (2.7 - 4.0) 294 - 441 13.0 - 4.51 Min. 147 {Min. 1.51 265 - 392 {2.7 - 4.0) 294 - 441 13.0 - 4.51 Min. 147 {Min. 1.5)

Exhaust temperature (C)

450.6 - 477.4 I604.0 - 640.0) 501.3 - 531.2 I672.0 - 712.01

27.0 - 28.5 24.0 - 25.0 -

70-90 70-90 70-90 70-90 70-90

Max. 650 Max. 650 -

464.2 - 478.9 1622.2 - 641.9) 516.4531.1 t692.2 - 711.9)

Min. 26.0 Min. 23.4 -

70-85 70-85 70-85 70-85 70-85 -

80-110 80-110 80-110 80-110 Min. 80

Max. 650 Max. 650 -

480.3 - 494.2 W3.8 - 662.5) 8 z z -

Min. 13.7

70-85

80-110

265 - 392 (2.7 - 4.0)

Max. 650

70-85

80-110

478.1 - 492.8 WO.9 - 660.61 527.4 - 542.1 I707.0 - 726.7) 0 0 0

70-85 -

Min. 80

Min. 147 {Min. 1.5)

Min. 25.2 Min. 22.9 0 0 0

70-85 70-85 70-85 70-85 70-85

80-110 80-110 80-110 80-110 Min. 80

265 - 392 12.7 - 4.0) 294 - 441 13.0 - 4.5) Min. 147 {Min. 1.5) 294 - 441 {3.0 - 4.5) -

Max. 650 Max. 650 -

446.1 - 473.0 1598.0 - 634.01

2,628 - 2,785 1268 - 2841 -

Min. 14.4 -

70-85

80-110

Max. 650

70-85

80-110

70-85

80-110

Min. 147 {Min. 1.5) 294 - 490 I3.0 - 5.01 -

70-85 -

Min. 80

488.6 - 519.2 I655 - 6961

2,712 - 2,879 1276.5 - 293.61 -

Min. 25 -

80-110

Max. 680

80-110

80-110

Min. 147 {Min. 1.5)

Min. 80

12-039 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

Applicable machine

Test item 473 (633 546 (732

Specified

value

Engine speed (rpm) Hz) Hz) Hz) Hz)

Dynamometer (N {kg]) 4,276 I436 4,148 (423 4,395 4481 4,266 435) -

Load

?ywheel Horsepower

kW/1,500 HP/l,500 kW/1,800 HP/l,800

rpm rpm} rpm rpm1

(50 (50 (60 (60

1,495 - 1,805 (50 Hz) 1,795 - 1,805 (60 Hz)

(50 Hz) (50 Hz) (60 Hz) (60 Hz)

3EM for generator

Vlax. torque iigh idling specs _ow idling speel

Max. 1,560 rpm Max. 1,881 rpm (50 Hz) (60 Hz)

Max. 1,568 (50 Hz) Max. 1,881 (60 Hz) 700 - 900 Hz) Hz) Hz) Hz)

4,119-4,374 (420 - 4461 3,766 - 3,991 {384 - 4071 (50 Hz) (50 Hz) (60 Hz) (60 Hz)

950 - 900 rpm 470 kW/1,500 1630 HP/l,500 514 kW/1,800 {688 HP/l,800 rpm rpm} rpm rpm} (50 (50 (60 (60

+wheel Horsepower EGGOOBS- OEM for generator ;Engine No. 15503 and ur

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

Wax. torque High idling spee Low idling speem

Max. 1,568 rpm Max. 1,881 rpm (50 Hz) (60 Hz)

Max. 1,568 (50 Hz) Max. 1,881 (60 Hz) 700 - 900 Hz) Hz) Hz) Hz) 3,675 I374.7 3,449 f351.7 -

3,909 398.6) 3,666 373.81 (50 Hz) (50 Hz) (60 Hz) (60 Hz)

700 - 900 rpm 419 kW/1,500 (561 HP/l,500 467 kW/1,800 1625 HP/l,800 rpm rpm} rpm rpm} (50 (50 (60 (60

Flywheel Horsepower OEM for generator (Prime use

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

Max. torque High idling spee Low idling spee

Max. 1,568 rpm Max. 1,881 rpm (50 Hz) (60 Hz)

Max. 1,568 Max. 1,881 (50 Hz) (60 Hz)

700 - 900 rpm 581 {779 672 (900 kW/1,500 HP/l,500 kW/1,800 HP/l,800 rpm rpm} rpm rpm} (50 (50 (60 (60 Hz) Hz) Hz) Hz)

700 - 900

Min. 5,237 (50 Hz) {Min. 5341 (50 Hz) 5,080 - 5,384 (60 Hz) (518 - 549) (60 Hz)

SA6D170-AFlywheel Horsepower OEM for generator (::;d by

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

Max. torque High idling spee Low idling spee

Max. 1,575 rpm Max. 1,890 rpm (50 Hz) (60 Hz)

Max. 1,575 Max. 1,890 (50 Hz) (60 Hz)

3,589 - 3,677 (366 - 3751

700 - 900 rpm

700 - 900

Flywheel Horsepower Max. torque OEM for marine High idling spee

552 kW/2,000 I740 HP/2,000

rpm rpm}

1,995 - 2,005

2,100 - 2,200 rpm

2,100 - 2,200

3,560 - 3,724 {363 - 379.7) -

Low idling spee

550 - 600 rpm

550 - 600

Flywheel Horsepower EPSAGDli -A-l (512 kW/ 686 HF Max. torque

512 kW/1,800 rpm I686 HP/l ,800 rpm)

1,795 - 1,805

Max. 2,200 rpm

Max. 2,200

High idling spee

Low idling spee

600 - 1,000 rpm

600 - 1,000

12-039-l 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

t *

The table gives the standard values using the JIS compensator factor. The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opem (if installed). The loads for the dvnamometer are at an arms length of 716 mm Flywheel horsepower (kW WR) Fuel consumption (set/500 cc) Min. Min. 13.7 11.4 Coolant temperature (C) 70-85 70-85 70-85 Min. 70 Lubrication )il temperature (C) 80-110 80-110 80-110 Min. 80 Lubrication oil pressure Wa {kg/cm*)) 255 - 441 y.. I &1 12.6 - 4.5) 255 - 441 l2.6 - 4.5) Min. 147 {Min. I.51 343 - 441 $3.3 I &5; l3.5 - 4.5) 343 - 441 13.5 - 4.51 Min. 147 {Min. 1.5} 255 12.6 255 12.6 255 - 441 12.6 - 4.5) Min. 98 {Min. 1.0) 226 - 392 :i; 1 y. 12.3 - 4.0) 226 - 392 12.3 - 4.0) Min. 147 {Min. 1.5) 294 - 490 (3.0 - 5.01 294 - 490 c3.0 - 5.0) Min. 147 {Min. 1.5} 294 - 490 13.0 - 5.0) 294 - 490 13.0 - 5.0) Min. 147 {Min. 1.5) 441 4.5) 441 4.5) Exhaust temperature (C) Max. 650 Max. 650 -

Torque (Nm {kgrn))

480.6 1643.9 560.1 1750.3

- 494.6 (50 H2 - 662.6) (50 H2 - 576.3 (60 Hz -772.0) (60 Hi -

Min. Min. 14.0 12.4

463.7 1621.2 508.6 1681.3 - 492.4 (50 Hz - 629.6) (50 Hi - 539.5 (60 Hz -722.7) (60 H2

70 - 85 70-85 70-85

80 - 105 80 - 105 80 - 105 Min. 85

Max. 650 Max. 650 -

413.6 1554.1 465.9 1624.1 440.1 (50 Hz 589.6) (50 H2 495.3 (60 Hz 663.6) (60 H2 Min. {Min. 686.0 I919.0 589.5 (50 789.9) (50 - 727.2 (60 -974.2) (60 Hz Hz Hz H2

Min. Min. 15.0 13.3

Min. 70

70 - 85 70-85 70-85

80-110 80-110 80-110 Min. 80

Max. 650 Max. 650 -

8 z z

Min. 11.3

Min. 70

70-85 70-85 -

80-110 80-110 80-110 Min. 80

Max. 700 Max. 700 -

Min. 9.3

538.0 - 552.0 1720.8 - 739.5) -

Min. 12.4

70-85 Min. 70

80-90 -

90-110 -

Max. 650 -

80-90

90-110

533.9 - 558.9 i715.2 - 748.8) -

Min. 80

Min. 90

Min.

11.7

70-90 -

80-110 -

Max. 650 -

70-90

80-110

Min. 70

Min. 80

12-039-2

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

4pplicable machine

Test item

Specified value (fully equippe)

inginespeed @pm)

Dvnamometer Arm length 716mm

load (N {kg)) 4rm length 1,023 mm !,059-2,185 !lO.O-222.8) 1,560 -2,715 !61.0 -276.91 0 0 !,I20-2,246 !16.2-229.0) !,636-2,799 !68.8-285.4) 0 0 !,258- 2,389 Z30.3-243.6) !,478-2,622 252.7-267.4) 0 0 1,063-2,187 210.4-223.0) 1,389 - 2,519 243.6-256.91 0 0 8 ;;

Arm length 895mm

:lywheel Horsepower Wax.torque 1375A-1 iigh idling speed _owidling speed +wheel Horsepower Irlax.torque D375A-2 iigh idling speed _owidling speed +wheel Horsepower Max.torque Pc1000-1

309 kW/1,800 rpm {608 HP/l,800 rpm} 2,609 Nmil.300 rpm {266kgm/1,300rpm) 1,950-2,050 rpm 600-700 rpm

1,795 -1,805 1,200 -1,400 1,950 -2,050 600-700

2,354-2,497 2,942 -3,121 (300.0-318.3) (240.0-254.61 2,925 - 3,104 3,657 -3,880 (372.9-395.6) {298.3-316.5) 0 0 0 0

392 kW/1,800 rpm 1525 HP/l,800 rpm) 2,618 Nm/1,300 rpm 1267 kgm/1,300 rpm} 1,950-2,050 rpm 580-680 rpm

1,795-1,805 1,200- 1,400 1,950 -2,050 580-680

2,423- 2,567 3,029 -3,209 (308.9-327.2) i247.1-261.81 3,014-3,199 3,767 -3,999 (384.1-407.8) (307.3-326.21 0 0 0 0

405 kW/1,700rpm {542 HP/l,700 rpm} 2,550 Nm/1,300 rpm 1260 kgm/1,300rpm)

1,695-1,705 1,200-1,400 1,800-1,900 650-700

2,581 - 2,730 3,226-3,413 (329.0-348.0) (263.2-278.41 2,832 -2,997 3,540-3,746 {361.0-382.0) {288.8-305.61 0 0 0 0

SA6D170-B2,095 -2,105 HD465-3 Max.torque with single turbocharge HD500-3 High idling speed 2,481 Nm/1,400 rpm (253 kgm/1,400 rpm) 2.350-2.450 rpm 800-900
I

2,358 -2,499 2,947 -3,123 (300.5-318.5) 1240.4-254.8: 2,730 -2,879 3,413 -3,599 {348.0-367.0) 1278.4-293.6: 0 0 3,217-3,203 (328.0-326.6) 3,057 -3,230 {311.7-329.4) 0 0 0 0 0

1,300- 1,500 2,350-2,450 800-900

Low idling speed

rpm

Flywheel (50Hz) 351 kW/1,500 rpm (481 HP/l,500 rpm} Horsepower (60Hz) EG450-1 High idling speed (50Hz) (60Hz) 406kW/1,800 rpm (544 HP/l,800 rpm) Max.1,560 rpm Max. 1,872 rpm 950 -1,000 rpm

1,495-1,505 1,795-1,805 Max.1,560 Max. 1,872 950-1,000

Low idling speed

2,361-2,434 240.8-248.2) 2,226-2,292 227.0-233.7) 0 0 0

Flywheel (50Hz) 372 kW/1,500 rpm 1498 HP/l,500 rpm} Horsepower (60Hz) EG480-1 EG480B-1 High idling speed (50Hz) (60Hz) 416 kW/1,800 rpm (557 HP/l,800 rpm1 Max.1,560 rpm Max.1,872 rpm 700-900 rpm

1,495 -1,505 1,795 -1,805 Max. 1,560 Max. 1,872 700-900

2,699 -2,782 3,373 -3,478 {344.0-354.7) (275.2-283.7 2,545 -2,619 3,181 -3,274 (324.4-333.91 (259.5-267.1 0 0 0 0 0 0

Low idling speed

12-040 0

TESTING
* * * * * *

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

The values in the table are indicated at standard conditions (Armospheric temperature 25C. atmospheric pressure 196.8 kPa 1750 mm Hg}. The values given for dynamometer loads the output and torque are with the fan removed, so they differ from those of the secification. Values are standardized under the following conditions: Muffler; air cleaner installed; alternator idling; and air compressor (if installed) open. Dynamometer loads are given for the case of the arm length is 716 mm. Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. Lubricaton ooil used: CLASS-CO SAE30. put (kW {HP})

out

Torque (Nm {kgm))

Fuel consumption (set/500 cc)

Coolant temperature (C)

Lubrication #iItemperature (C)

Lubrication oil pressure (kPa {kg/cm% 294 - 490 {3.0 - 5.01 294 - 490 13.0 - 5.01 Min. 245 {Min. 2.5) 294 - 490 t3.0 - 5.01 294 - 490 13.0 - 5.01 Min. 147 {Min. 1.5) 343 - 490 (3.5 - 5.0) 343 - 490 (3.0 - 5.0) Min. 147 {Min. 1.5) 294 - 490 13.0 - 5.01 294 - 490 f3.0 - 5.01 Min. 147 {Min. 1.5) 245 - 392 (2.5 - 4.01 245 - 392 (3.0 - 4.51 245 - 392 {3.0 - 4.5) 265 - 392 12.7 - 4.0) 294 - 441 l3.0 - 4.5) Min. 147 {Min. 1.5)

Exhaust temperature (C)

397.3 - 421.5 I532.2 - 564.7)

2,569 - 2,778 I262.0 - 283.31 0

Min. 17.0

70-90

80 - 100

Max. 550

Min. 19.3 -

70-90

80 - 100

Max. 600 -

70-90

80 - 100

0
409.2 - 433.5 I546.2 - 590.8)

70-90

Min. 80

2,697 - 2,859 l275.0 - 291.51 0

Min. 16.5 -

70-90

80-110

Max. 650

0 0

70-90

80-110

Max. 650 -

70-90

80-110

70-90

Min. 80

411.4 - 435.7 t551.2 - 583.7) 2 z z 0 -

2,534 - 2,682 l258.4 - 273.51 0

Min. 16.3 -

70-90

80-110

Max. 700

70-90

80-110

Max. 700 -

70-90

80-110

70-90

Min. 80

457.9 - 485.5 1622.1 - 659.6) -

2,442 - 2,579 1249.0 - 263.01 0

Min. 13.1 -

70-85

80-

110

Max. 650

70-85

80-110

Max. 650 -

70-85

80-110

70-85

Min. 80

351.1 - 370.9 (50 Hz {477.0 - 504.01(50 H2 400.4- 423.2 (60 Hz W4.0 - 575.01(60 H2

0 0 0

23-27 26-30 -

70 - 100 70 - 100 70 - 100 70 - 100 70 - 100

100 - 120 100 - 120 100-120 100 - 120 Min. 100

Max. 680 Max. 650 -

516.0 - 532.0(50 Hz I508.8 - 524.61(50 H2 584.0 - 601.0 (60 H2 I575.8 - 592.61(60 Hz

0 0 0

Min. 17.5 Min. 15.5 -

70 - 85 70-85 70-85 70-85 70-85

80-110 80-110 80-110 80-110 Min. 80

Max. 650 Max. 650 -

12-041 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

Test item

Specified value (fully equippe) 383 kW/1,500 rpm (513 HP/l,500 rpm} 427 kW/1,800 rpm I572 HP/l,800 rpm} Max. 1,560 rpm Max. 1,872 rpm 700 - 900 rpm 408 kW/1,800 rpm I540 HP/l,800 rpm) 2,461 Nm/1,300 rpm (251 kgm/1,300 rpm) 1,950 - 2,050 rpm 750 - 850 rpm 359 kW/1,500 rpm {488 HP/l,500 rpm} 397 kW/1,500 rpm {540 HP/l,500 rpm} Max. 1,560 rpm 700 - 900 rpm

Sngine speec (rpm)

Dvnamometer load Arm length 716 mm 3,472 - 3,576 364.0 - 364.7 3,264 - 3,351 332.8 - 341.7 0 0 0 3,039 - 3,216 309.9 - 327.9 3,410 - 3,628 347.7 - 370.0 Arm length 895 mm 2,777 - 2,861 283.2 - 291.7 2,611 - 2,680 266.2 - 273.3 0 0 0 2,431 - 2,572 247.9 - 262.3 2,728 - 2,903 278.2 - 296.0 -

ir {kg})
Arm length 1,023 mm 2,430 - 2,503 247.8 - 255.2} 2,284 - 2,345 232.9 - 239.1) 0 0 0 2,127 - 2,251 216.9 - 229.5} 2,383 - 2,540 243.3 - 259.01

Flywheel (50Hz Horsepower (6OH2 iG550-1 iG500B-1 iG500BS-1 High idling speec (50Hz (6OH2 Low idling speec Flywheel Horsepower Max. torque SA6D170-B.PSA6D17( -BHigh idling speec Low idling speec Flywheel Horsepower (Prime use (Standby use) High idling speec Low idling speec

1,495 - 1,505 1,795 - 1,805 Max. 1,560 Max. 1,872 700 - 900

1,795 - 1,805 1,200 - 1,400 1,950 - 2,050 750 - 850

1,495 - 1,505 1,495 - 1,505 Max. 1,560 700 - 900

3,210 - 3,406 327.3 - 347.3 3,655 - 3,759 372.7 - 383.3, -

12-041-l 0

TESTING t
* *

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

* *
t

The values in the table are indicated at standard conditions (Armospheric temperature 25C, stmospheric pressure 196.8 kPa (750 mm Hg}. The values given for dynamometer loads the output and torque are with the fan removed, so they differ from those of the secification. Values are standardized under the following conditions: Muffler; air cleaner installed: alternator idling; and air compressor (if installed) ooen. Dynamometer loads are given for the case of the arm length is 716 mm. Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. Lubricaton ooil used: CLASS-CO SAE30. put (kW {HP})

out

Torque (Nm IkgmI)

Fuel consumption (set/500 cc)

Coolant temperature (0

Lubricatic oil temperai (C)

Lubrication oil pressure (kPa {kg/cm*}) 265 - 392 12.7 - 4.0} 294 - 441 13.0 - 4.5} Min. 147 {Min. I.51 294 - 441 I3.0 - 4.5) -

Exhaust temperature (C)

390.8 - 402.6 i523.6 - 539.3) 440.9 - 452.6 t590.6 - 606.41 0 0 0

Min. 17.1 Min. 15.2 -

70-85 70-85 70-65 70-85 70-85

80-110 80-110 80-110 80-110 Min. 80

Max. 650 Max. 650 -

410.3 - 434.2 f550.0 - 582.0)

2,442 - 2,599 {249 - 265)

Min. 15.8 -

70-85

80-110

Max. 650 -

70-85

80-110

357.3 - 378.0 {479 - 508)

70-85

80-110

Min. 147 {Min. 1.5} 265 - 392 12.7 - 4.0) 265 - 392 (2.7 - 4.01 Min. 147 {Min. 1.5}

70-85

Min. 80

Min. 17.5 Min. 15.9

70-85 70-85

80-110 80-110

Max. 650 Max. 650

2 b z

407.3 - 418.5 {546 - 5611

70-85

80-110

70-85

80-110

12-041-2 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

le

Test item

Engine speed frpm) 367 {492 416 {557 kW/1,500 HP/l,500 kW/1,800 HP/l ,800 rpm rpm) rpm rpm} (50 (50 (60 (60 Hz) Hz) Hz) Hz)

Dynamometer (N {kg]) 3,544 I361.4 3,357 1342.3 -

Load

I Flywheel
Horsepower

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

3,752 (50 Hz) 382.6) (50 Hz) 3,540 (60 Hz) 361 .O} (60 Hz)

OEM for generato r (Prime u!se)

I Max. torque High idling spee ILow idling spee, IFlywheel Horsepower 486 1543 457 {612

Max. 1,560 rpm Max. 1,890 rpm (50 Hz) (60 Hz)

Max. 1,560 (50 Hz) Max. 1,890 (60 Hz) 700 - 800 Hz) Hz) Hz) Hz) 3,544 i361.4 3,357 (342.3 -

3,752 (50 382.6) (50 3,540 (60 361 .O) (60 Hz) Hz) Hz) Hz)

700 - 800 rpm kW/1,500 HP/l,500 kW/1,800 HP/l,800 rpm rpm) rpm rpm) (50 (50 (60 (60

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

OEM for generato r v %rd b

IMax. torque IHigh idling spee ILow idling spee IFlywheel Horsepower

Max. 1,575 rpm Max. 1,890 rpm (50 Hz) (60 Hz)

Max. 1,575 (50 Hz) Max. 1,890 (60 Hz) 700 - 800

700 - 800 rpm

2,737 - 2,905 1279.1 - 296.2) 3,004 - 3,187 f306.3 - 325.0)

341 kW/1,700 rpm I457 HP/l ,700 rpm) 2,157 Nm/1,300 {220 kgm/1,300 rpm rpm1

1,695 - 1,705

Pc1000-1 I (High alti itude spel d

Max. torque

1,200 - 1,400

High idling spee

1,800 - 1,900 rpm

1,800 - 1,900

3,373 {344 3,168 1323 3,570 (50 Hz) 364) (50 Hz) 3,354 (60 Hz) 342) (60 Hz)

Low idling spee SA6D170-BIFlywheel Horsepower EG500-1 EG500B- 1 EG500BI i-1 Max. torque OEM for generato r (Engine Nc 1. IHigh idling spee 13265 and uPI Low idling spee 379 (508 ..~. 446 1598 383 1510 427 {572

680 - 780 rpm kW/1,500 HP/l,500 kW/1,800 HP/l,800 rpm rpm} rpm rpm) (50 (50 (60 (60 Hz) Hz) Hz) Hz)

680 - 780

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

Max. 1,568 rpm Max. 1,881 rpm (50 Hz) (60 Hz)

Max. 1,568 Max. 1,881 (50 Hz) (60 Hz)

3,432 1350 3,393 {346 3,521 (50 Hz) 359) (50 Hz) 3,481 (60 Hz) 355) (60 Hz)

700 - 900 rpm kW/1,500 HP/l ,..~ 500 kW/1,800 HP/l,800 rpm (50 Hz) roml _~_. Hz) (50 ~, r rpm (60 Hz) rpm) (60 Hz)

700 - 900

Flywheel Horsepower

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

OEM for generato r

Max. torque High idling spee Low idling spee 417 {559 492 1660

Max. 1,560 rpm Max. 1,872 rpm (50 Hz) (60 Hz)

Max. 1,560 Max. 1,872 (50 Hz) (60 Hz)

3,668 {374 3,638 {371 3,883 3961 3,854 3931 (50 Hz) 150 Hz) (60 Hz) (60 Hz)

700 - 900 rpm kW/1,500 HP/l,500 kW/1,800 HP/l,800 rpm rpm) rpm rpm) (50 (50 (60 (60 Hz) Hz) Hz) Hz)

700 - 900

Flywheel Horsepower

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)

OEM for generato r

IMax. torque IHigh idling spee Low idling spee

Max. 1,568 rpm Max. 1,881 rpm (50 Hz) (60 Hz)

Max. 1,568 Max. 1,881 (50 Hz) (60 Hz)

700 - 900 rpm

700 - 900

12-041-3 0

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

* *

The table gives the standard values using the JIS compensator factor. The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opem (if installed). The loads for the dynamometer are at an arms length of 716 mm Flywheel horsepower ikw {HP}) Fuel consumption (seci500 cc) Min. Min. 17.7 15.5 Coolant temperature (C) 70-95 70-95 70-95 70-95 Lubrication oil temperature (0 80-115 80-115 80-115 Min. 80 Lubrication oil pressure (kPa (kg/cm21) 265 {2.7 294 {3.0 Min. 98 {Min. l.O} 265 - 392 $9;: I4.i i3.0 - 4.5) Min. 98 {Min. 1.0) 392 - 539 (4.0 - 5.5) 392 4.0} 441 4.5) Exhaust temperature (C) Max. 680 Max. 680

Torque (Nm NgmI) Hz Hz Hz Hz

362.1 W35.1 412.9 l553.1

- 382.7 (50 -512.7) (50 - 436.4 (60 - 584.71 (60

398.9 1534.4 453.4 (607.4 422.5 566.0) 478.4 640.9) (50 (50 (60 (60 Hz Hz Hz Hz

Max. 680 Max. 680

Min. Min.

16.1 14.2 -

70-95 70-95 70-95 70-95

80-115 80-115 80-115 Min. 80

349.2 - 370.6 W37.8 - 496.5) 2,151 - 2,282 (219.3 - 232.7)

Min. -

18

70-90

90-110

Max. 650 -

70-90

90-110

379.0 (507.8 427.6 c572.9 402.6 (50 539.31 (50 454.1 (60 608.4) (60 Hz Hz Hz Hz Min. Min.

70-90

90-110

Min. 118 {Min. 1.2) 343 - 441 $3.3 I t.4 (3.5 - 4.5) 343 - 441 (3.5 - 4.51 Min. 176 {Min. l.S} 245 i2.5 245 (2.5 441 4.5) 441 4.51

Min. 70

Min. 90

Max. 600 Max. 620

17.1 14.4 -

70-85 70 - 85 70-85 Min. 70

80-110 80-110 80-110 Min. 80

385.7 (516.7 457.8 (613.3 396.7 (50 531.51 (50 471 .O (60 631.0) (60 Hz Hz Hz) Hz:

Min. Min. -

17.1 14.2

70 - 85 70-85 70-85 Min. 70

80-110 80-110 SO-110 Min. 80

Max. 650 Max. 680

245 - 441 12.5 - 4.5) Min. 147 {Min. 1.5} 245 12.5 245 {2.5 441 4.5) 441 4.5) Max. 650 Max. 650

412.9 1553.1 491.6 1658.6 -

437.9 586.7) 521.1 698.1)

(50 Hz) (50 Hz: (60 Hz: (60 Hz;

Min. Min. -

15.9 13.2

70-85 70-85 70-85 Min. 70

80-110 80-110 80-110 Min. 80

245 - 441 f2.5 - 4.5) Min. 147 {Min. 1.5)

12-041-4 @

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

Test item

Specified

value

Engine speed irpm) Hz) Hz) Hz) Hz)

Dynamometer (N ikgl) 3,315 {338 2,981 I304 -

Load

Flywheel Horsepower Max. torque High idling speed

378 1506 403 1539

kW/1,500 HP/l,500 kW/1,800 HP/l,800 -

rpm rpm} rpm rpm}

(50 (50 (60 (60

1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz) -

OEM for generator

3,511 (50 Hz) 358) (50 Hz) 3,158 (60 Hz) 21 I} (60 Hz) -

Max. Max.

1,568 rpm 1,881 rpm

(50 Hz) (60 Hz)

Max. Max.

1,568 (50 Hz) 1,881 (60 Hz) 700 - 900

3,393 - 3,491 1346 - 3561

Low idling

speed

700 - 900 rpm

Flywheel Horsepower Max. torque

445 kW/1,800 I597 HP/l,800 -

rpm rpm)

1,795 - 1,805 -

EPSAGD17( -B-

High idling

speed

Max. 2,200 rpm

Max. 2,200

3,169 1369 3,815 1389 3,834 (50 Hz) 3911(50 Hz) 4,031 (60 Hz) 41 I} (60 Hz) 8 z z

Low idling

speed 275 I369 345 I462

600 - 1,000 rpm kW/l,OOO rpm HP/l,000 rpm) kW/1,200 rpm HP/l,200 rpm) (50 (50 (60 (60 Hz) Hz) Hz) Hz)

600 - 1,000

Flywheel Horsepower OEM for 6-pole generator

995 - 1,505 (50 Hz) 1,1951,205 (60 Hz) -

SA6D170-B-

Max. torque High idling Low idling speed speed Max. Max.

1,045 rpm 1,254 rpm

(50 Hz) (60 Hz)

Max. Max.

1,045 (50 Hz) 1,254 (60 Hz) 750 - 850

750 - 850 rpm

12-041-5 63

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

*
+

The table gives the standard values using the JIS compensator factor. The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opem (if installed). The loads for the dynamometer are at an arms length of 716 mm Flywheel horsepower ikW {HP}) Fuel consumption (seci500 cc) Min. Min. 16.8 14.9 Coolant temperature (C) 70 - 85 70 - 85 70 - 85 70 - 85 Min. 70 Lubrication )il temperature (0 80-110 80-110 80-110 80-110 Min. 80 Lubrication oil pressure ikPa {kg/cm*}) 245 i2.5 245 12.5 441 4.5) 441 4.5) Exhaust temperature (C) Max. 600 Max. 620

Torque (Nm {kgm))

372.4 f498.9 401.9 1538.4 -

396.0 (50 530.51 (50 426.9 (60 571.91(60

245 - 441 12.5 - 4.5) 245 - 441 2.., 9.851 {Min. l.O} 294 - 490 t3.0 - 5.01

415.8 - 440.9 1557.1 - 590.61

Min.

15.3 -

75-85 -

90-110 -

Max. 640

75 - 85

80-110

294 - 490 I3.0 - 5.0) Min. 98 {Min. 1.0) 294 I3.0 343 13.5 441 4.5) 490 5.0)

Max. 650 Max. 700

271.6 f363.8 343.0 {459.5 2 z z 287.8 385.51 363.6 487.1) (50 (50 (60 (60 Hz: Hz1 Hz] Hz)

Min. 24.2 Min. 18.9

Min. 75

Min. 80

70-85 70-85

85-110 85-110

Min. 147

The SAA6D170-1 engine for the generator the generator at the front of the radiator. install the radiator and air-cooled and operate with the fan.

is equipped with an air-cooled aftercooler. When carrying out an output performance to a stand to give a same condition

The aircooled aftercooler is installed to test of the engine as an individual part, on the machine,

aftercooler

as when they are mounted

12-041-6 03

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

rpplicable machine

Test item

Specified

value

Engine speed (rpm)

Dynamometer (N Ngl)

Load

:lywheel Horsepower flax. torque VA600-1 IC regulaon)

305 kW

1,995 -2,005 1,300- 1,500 2,200-2,300 650-700 1,495-1,505 (50 Hz) 1,795-1,805 (60 Hz)

2,180 - 2,310 1223-235) 2,820 -2,940 1287-3001

1,960 Nm

iigh

idling

speed

2,200 - 2,300 rpm

4,190-4,380 (50 Hz) {420-4471(50 Hz) 3,780-4,020 (60 Hz) {386-411) (60 Hz)

.ow idling

speed.

650 - 700 rpm

'lywheel Horsepower ,ENYO enerator KzA600SSI K

470 kW 513 Kw

flax.

torque

Max.1,570 rpm Max.1,880 rpm 700-900rpm (50 Hz) (60 Hz) Max. Max.

1,570 (50 Hz) 1,880 (60 Hz) 700 - 900

iigh idling speed _owidling speed

SA6D170-AE.

12-041-7 63

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

* *

The table gives the standard values using the JIS compensator factor. The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opem (if installed). The loads for the dynamometer are at an arms length of 716 mm Flywheel horsepower WC-W) 328 - 346 (Gross) WI5 - 4701 (Gross) Torque N-n {kgm)) Fuel consumption (set/500 cc) Coolant temperature ('0 Lubrication ,il temperature (0 Lubrication oil pressure Wa {kg/cm2}) 280-490 12.8-5.01 Exhaust temperature (C)

Min. 18.7 2,010 -2,110 (Gross) {205-215) (Gross)

70-90

go-

110

Max.610 Max.650 -

Ain.13.8 (50 H2 Ain.12.0 (60 H2

70-90

90-110 90-110 90-110 85-110 85-110

280-490 {2.8-5.01 Min. 150 {Min. 1.5} 840-540 (50 Hz 3.5-5.5) (50 Hz 870-540 (60 Hz 3.8-5.5) (60 Hz

70-90

70-90 75-85 75-85

Max.650 Max.650

463 - 493 (Gross,50Hz) {630- 670NGross.50Hz) 511 -543(Gross,GOHz) {695- 7391(Gross,60Hz)

75-85 75-85

85-110 85-110

340-540 {3.5- 5.51 Min. {Min. 180 180)

1 Z-041 -8 @

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

Engine model

Applicable machine

Test item

Specified

value

Engine speed (rpn-0

Dynamometer (N {kg])

Load

Flywheel Horsepower Max. torque jenerator 50 Hz onl) High idling spee

597 kW/1,500 {800 HP/l,500 -

rpm (Net) rpmj (Net)

1,495 - 1,505 -

5,140 - 5,460 1524 - 557) -

Max.

1,570 rpm

Max. 1,570

Low idling speel

700 - 900 rpm

700 - 900

SAAGD170-1

12-041-9 03

TESTING

AND ADJUSTING

PERFORMANCE

TEST CRITERIA

* *

The table gives the standard values using the JIS compensator factor. The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opem (if installed). The loads for the dynamometer are at an arms length of 716 mm Flywheel horsepower (kW (HP}) 579 - 612 (Gross) {775 - 819) (Gross) Fuel consumption (set/500 cc) Coolant temperature (0 Lubrication lit temperature (C) Lubricatior oil pressun (kPa {kg/cm2 260 - 370 l2.6 - 3.8) I

Torque

(Nm ikgm})

1)

Exhaust temperature (C)

Min.

11.0

70 - 85 -

80-110 -

Max. 650

70-85

80-110

Min. 150 {Min. 1.5}

Min. 70

Min. 80

12-041-10 03

PRECAUTIONS INDEPENDENTLY *

WHEN

OPERATING

THE

ENGINE

If the engine is operated with a double tions will differ from

independently

on a bench condire-

lip seal fitted,

the lubricating

actual running conditions,

sulting in possible damage to the seal lip. 1. When running-in the engine or subjecting it to a bench test, use the rear seal shown in the diagram at right on all models for the duration of testing.

Clutch side -

Engine side _

6162F202

2.

After

completing

running-in or bench testing,fit

the correct rear seal.

23 k 0.6

Torque co&etier side or clutch side

Engine side H

6162F203

Precautions when fitting rear seal 1) A new rear seal is coated with event that grease. In the wipe it

it becomes soiled, however, (lithium grease).

clean with a cloth and coat it with about 1.2 to 1.6 cc of G2-Ll 2)

Be careful not to damage the rear seal when fitting it.

TESTING

AND

ADJUSTING

TOOL LIST

No.

Inspection and measuring item

Fault finding tool

Part No. 799-203-8001

Remarks Digital reading, pressure type 60 to 19,999 rpm 1 .lOO to 1.300 sensing

Engine speed

Multi-tachometer

Batten/ S.G. Battery, coolant tester 795-500-l001 Freezing temperature cooling water of

-5C

to -50c

Water temperature, oil temperature, air intake temperature Digital temperature gauge 790-101-1500 -99.9 - 1.299C Exhaust temperature

0 to 20 kg/cm*

0 to 50 kg/cm2

intake pressure, exhaust pressure

Pressure test kit

799-203-2002

0 to 1,000 mmHg

Blow-by pressure

D to 500 mmHz0

10

Air intake resistance

-100 to 0 mmHz0

11

Compression pressure

Compression gauge kit

795-502-1205

0 to 70 kg/cm

12

Blow-by pressure

Blow-by checker

799-201-I

503

D to 500 mmH,O

795-l 25-l 340

0.4, 1 .O mm

799-201-9000

Dirtiness 0 to 70% with standard color (Dirtiness % x l/10 = Bosch scale)

15

Water and fuel content in oil

Engine oil checker

799-201-6000

Provided with 6.1 and 0.2% water content standard samples.

11

1 Fuel injection pressure Fuel injection nozzle spray condition

/ Nozz,e teSter
Commercially available I to 300 kg/cm2

18

Coolant quality

Water quality tester

799-202-7001

JH, nitrite ion concentration

799-202-9001 Leakage in cooling water system Anemometer (Air speed gauge)

I to 2 kg/cm*

21

Radiator blockage (wind speed)

799-202-2001

I to 40 m/s

795-610-1000 22 Engine cranking 6162-234820 Commercially available

X24V

with starting engine series engine

:or 6D170-1

23

Electrical circuits

Tester

Zurrent, voltage,_resistance

12-043 0

TESTING

AND ADJUSTING

DATE

Engine model Applicable machine model C5Z sifica -tior 8 6 E b Lt I? Unit

T
PC650-1 PC1500-1 Standard 1,700-I ,800

S6Dl70-1

T
Tolerance Standard 2,200-2,300 650-700 Min. 100 Min. 100 ,800 650-700

WA600-1

item

Condition, etc. High idling speed

Tolerance 2,200-2,300 650-700 -

rpm rpm

1,700-I

Engine speed Low idling speed 650-700 Min. 100 Min. 100 Max. 380 Min. 800 Min. 650

Necessary starting speed Intake resistance Intake pressure Exhaust pressure (Turbine inlet pressure) Exhaust temperature (Turbine inlet temperature)

oc
-20C (with starting aid)

rpm
rpm mmH,C mmHg mmHg

762 700 550

762 540 570

At all speed At rated output At rated output

Max. 300 Min. 600 Min. 630

All speed (Intake air temp.: 2dC) Quick acceleration (Low idling + High idling) At rated output At high idling

Max. 650

Max. 700

Max. 650

Max. 700

Exhaust gas color

Bosch scale

Max. 6.5 Max. 2.5 Max. 2.0 0.4 1 .o

3.5 3.5 3.0 -

Max. 6.0 Max. 2.0 Max. 1.5 0.4 1.0

8.0 3.0 2.5

Valve clearance (When engine is hot or cold.) Compression pressure (SAEBO oil) Oil temperature: 40C to 60C (Engine speed) At rated output Water temperature: Min. 70C At rated output SAEBO oil Oil pressure (Oil temperature: Min. 8OCj SAEI OW oil At low idling SAEBO oil SAEI OW oil kg/cm kg/cm

8
20 (210-250) ;; z

20 (210-250)

kg/cm (rpm)

Min. 29 (21 O-250)

Min. 29 (210-250)

Blow-by pressure (SAE30 oil)

mmH,C

Max. 150

300

Max. 150

300

kg/cm kg/cm

3.5-5.0 3.04.5 Min. 1.5 Min. 1 .O

2.5 2.0 0.7 0.7

3.0-5.0 2.5-4.5 Min. 1.5 Min. 1 .O

2.4 1.8 0.7 0.7

Oil temperature Oil consumption ratio Fuel injection pressure Fuel injection timing E al t; > _ P .5 s *The Radiator pressure valve Fan speed Fan belt tension

All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester B.T.D.C. Opening pressure (Differential pressure)

SO-110

120

SO-

110

120

Max. 0.5

1 .o

Max. 0.5 55::s(-#1604: !65:?(#16044 42+1(-#16043 38*1(#16044 0.75 t 0.1

.o

kg/cm degree

255 + 3 +5 42 + 1

211 42 f 1

3) -) 3) -)

211 42 + 1

0.75 + 0.1 C650-1 j Cl 500-I) See page 12-031

1,200 f 30 _

values given in the Testing and Adjusting data are NOT for adjustment of the output.

1
0.75 f 0.1 1,200 f 30 -

Do not use these values as a guide to change the setting of the fuel injection pump.

12-044 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

S6D170-1 D275A-2 Standard 1,960 -2,040 600-660 Min. 100 Min. 100 Max.300 Min.900 Min.900 Max.650 Max. 6.0 Max. 1.3 Max. 1.0 0.4 2 z z 1.0 Min.29 (210-250) Tolerance I 1,960 -2,040 600-660 762 810 810 Max.700 8.0 2.3 2.0 20 (210-250) EPS6Dl70-1 Standard I Max.2,030 600-1,000 Min. 100 Min. 100 Max.300 Max.650 2.5 Max.2.0 0.4 1.0 Min.29 (210-250) 20 (210-250) Min.29 (210-250) 20 (210-250) Min.29 (210-250) 20 (210-250) Tolerance Max. 2,030 600-1,000 OEMforgenerator Standard Tolerance OEM for generator (Power up) Tolerance

Standard

Max.1.560(50Hz)Max. 1,560 (50Hz)Max. 1,560 (50Hz)Max.1,560(50Hz) Max.l.872(60Hz)Max.l,872(60Hz)Max.l.872(60Hz)Max.l.872(60Hz) 700-800 Min.100 700-800

762 -

700

!-I Min. 100 Max.300 -

762 -

700
I

3.5 3.0

I
I

650

700
I

650

Max. 3.0 -

Max.3.0 -

4.0 -

Max.300

600

Max.300

600

Max.400

800

Max.400

800

3.0- 5.0 2.5-4.5 Min.l.5 Min.l.0

2.5 1.8 0.7 0.7

3.0 - 5.0 2.5-4.5 Min. 1.0 Min. 1.0

2.4 1.8 0.7 0.7

3.3-4.5 2.6 -4.2 Min. 1.2 Min. 1.0

2.3 2.0 0.7 0.7

3.3 -4.5 2.6 -4.2 Min. 1.2 Min. 1.2

2.3 1.8 0.7 0.7

80-110

120

80-110

Max.0.5

1.0

Max. 0.5

270-278 37-39

220 37-39

260-268 41-43 41-43 0.65- 0.85 41-43 0.65-0.85 41-43 0.65-0.85 41-43 0.65 -0.85 41-43 0.65 -0.85

995-1,055 (50Hz) 995-1,055 (50Hz) 1,1931,267 (60Hz) 1,193 1,267 (60Hz)

12-044-l 0

Engine model Applicable machine model Clasisification

Itern

Condition, etc.

Unit

High idling speed 0 5 E 8 Y d Engine speed Low idling speed 0C -20C (with starting aid)

wm
wm rpm rpm mmH,C mmHg mmHg

Necessary starting speed Intake resistance Intake pressure

At all speed At rated output At rated output

: z 2

Exhaust pressure (Turbine inlet press re) Exhaust temperature (Turbine inlet temperature)

z
7 _c 2
-0

All speed (Intake air temp.: 20C1 Quick acceleration (Low idling-t High idling) At rated output At high idling Intake valve Exhaust valve Oil temperature: 4oc to 60C (Engine speed)

OC

& P E :

Exhaust gas color

Bosch scale I

Valve clearance (When engine is hot or cold.) Compression pressure (SAEBO oil)

mm mm

2 B al r .= w

kg/cm (rpm)

Blow-by pressure (SAE30 oil)

At rated output Water temperature: Min. 7OC At rated output SAEBO oil

mmH,C

kg/cm kg/cm kg/cm kg/cm

z t

Oil pressure (Oil temperature: Min. 80C)

SAElOW At low idling

oil

SAE30 oil SAElOW oil

.* 3
P

Oil temperature Oil consumption ratio Fuel injection pressure Fuel injection timing Radiator pressure valve Fan speed Fan belt tension

All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester B.T.D.C. Opening press re (Differential pressure) At rated engine speed Deflects when pushed with a force of 6 kg

z k g

kg/cm degree

.= a
8

z ?; P

kg/cm

rpm mm

*The

values given in the Testing and Adjusting data are NOT for adjustment of the output

Do not use these values as a guide to change the setting of the fuel injection pump.

12-044-2 03

TESTING AND ADJUSTING

TESTING AND ADJUSTING DATA

S6D170-1 H D465-3 (with twin turbochrger) Tolerance

SA6D170-A-1

r
Standard

HD465-5 Tolerance Standard

WA700-1 Tolerance

2,250 - 2,350 850 - 900


I

2,250 - 2,350 850 - 900 Min. 130 Min. 100

Min. 100 Min. 100

Min. 130 Min. 100

Max. 300

762 -

Max. 380 Min. 1,500 Min. 950 Max. 680

762 1,000 850 680

Max. 380 Min. 1,000 Min. 900 Max. 680

762 Min. 870 Min. 780 Max. 700

Max. 300 Min. 1,000 Min. 850 Max. 650

762 Min. 870 Min. 750 700

Max. 650

Max. 700

Max. 7.0 Max. 2.7 Max. 2.7 0.4 1.0 Min. 28 (210 - 250)

8.0

Max. 7.0 Max. 3.0 Max. 2.0

8.0 4.0 3.0

Max. 6.0 Max. 2.0 Max. 1.0

8.0 3.0 2.0

Z -

20 (210 - 250)

Min. 28 (210 - 250)

20 (210 - 250)

Min. 28 (210 - 250)

20 (210 - 250)

Max. 300

600

Max. 300

700

Max. 350

700

Max. 350

700

3.0 - 5.0 2.5 - 4.5 Min. 1.0 Min. 1.0

2.4 1.8 0.7 0.7

3.0 - 5.0

2.0

3.0 - 5.0 2.5 - 4.5

2.0 1.8 0.7 0.7

3.0 - 5.0 2.5 - 4.5 Min. 1.5 Min. 1.0

2.1 1.8 0.7 0.7

Min. 1.5 Min. 1.0

0.7 0.7

Min. 1.5 Min. 1.0

80-110

120

80-110

120

80-110

120

80-110

120

Max. 0.5

1.0

Max. 0.5

1.0

Max. 0.5

1.0

Max. 0.5

1.0

270 - 278 41 - 43 (up to 13764) 37 - 39 (13765 and up)

220

305 - 313 28 - 30 *2 35 - 37 *3 0.65 - 0.85

247 35-37

305 - 313 35-37

247 35 - 37

305 - 313

247

37 - 39 (-#14593) 37 - 39 (-#14593) 34 - 36 (#I4594) 34 - 36 (#14594-j

0.65 - 0.85

1,220 - 1,280

1,220 - 1,280 -

Ins

*I : For cold weather specifica 2 : With electronic governor *3 : With mechanical governor

12-045 0

Engine model Applicable machine model Condition, etc. Unit

SAGDI 70-A-1 ;G586-1, EG580B-1, EG600B-1 zG~OOBS-1, OEM for generator

EG550-1

High idling speed Low idling speed

rpm rpm

b
;

Necessary starting speed Intake resistance Intake pressure Exhaust pressure

0C
-20C (with starting aid)

wm
rpm mmH,C mmHg mmHg

Min. 100 Min. 100 Max. 450 1,200 (50H.z) 1,400 (60~2) 800 (50Hzj 1,000 (60Hzj

635 Max. 450 762

At all speed At rated output At rated output

: z ?; z 3 _c J 0

Max. 650 700

Exhaust temperature (Turbine inlet

All speed (intake air temp.: ZOC) Quick acceleration (Low idling-t High idling) At rated output At high idling Intake valve

Max. 650

Max. 650

5
2 B

Exhaust gas color

Bosch scale

Max. 3.0

4.0

mm mm

(When engine is Exhaust valve Oil temperature: 4OC to 60C (Engine speed) At rated output Water temperature: Min. 70C At rated output SAE30 oil Oil pressure (Oil temperature: Min. 80C) SAEIOW At low idling SAE30 oil SAEIOW oil kg/cm kg/cm2 Min. 1.5 Min. 1 .O 0.7 0.7 oil

kg/cm (rpm)

Min. 26 (21 O-250)

18 (210-250)

Min. 26

18

Blow-by pressure

mmH,C

Max. 280

400

Max. 400

800

kg/cm kg/cm

2.5 - 4.0

2.5 - 4.0

3.0 - 4.5 2.5 - 4.0 Min. 1.5

2.1 1.8 0.7 0.7

Oil temperature Oil consumption ratio

All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester

OC

80-

110

120

Max. 0.5

1 .o

---I--Min. 1 .O 80-110 120 Max. 0.5 1 .o 300;; 37 fl 247 37 fl

kg/cm*

300+ 3 +5

270

B.T.D.C.

1 ,

degree

g
j [ Fan speed Fan belt tension

Opening pressure (Differential pressure) At rated engine speed Deflects when pushed with a force of 6 kg

kg/cm ram mm

*The values given in the Testing and Adjusting data are NOT for adjustment of the output. Do not use these values as a guide to change the setting of the fuel injection pump.

12-046 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

SA6D170-A-1 EG580B-1L EPSAGD170-A-1 HD465_3(ForORAPAMINE) Tolerance

{Max. 1,560(50Hz) Max.l,560(50Hz)

2,300+ 50

2,300 k 50 85OklO

Min. 130 Min.100 300 -

Min.130 Min. 100 Max.350 762 1,100 380

650

;:: 0.4 2 z z 1.0 Min.26 (210-250)

- I- II I
700 4.5 3.5 0.4 18 210-250) 1.0 600

762

Min. 1,150

762 700 8.0 3.0 3.0 20 210-250)

700

680 6.0 2.0 2.0 0.4 1.0 Min.28 (210-250)

Max.650

2.5 2.0 20 210-250)

Max. 1.5 Max. 1.0

Min.28 (210-250)

300

Max.400

2.7-4.5 2.2 -4.0 Min. 1.5 Min. 1.0

1.9 1.5 0.7 0.7

3.0-4.5 Min. 1.0 -

800
2.0 0.7 -

700

3.0 - 5.0 2.5-4.5 Min. 1.5 Min. 1.0

2.1 1.8 0.7 0.7

80-110

120

80-110

120

)
0.75 * 0.1 1,020f26 0.75 f 0.1 1,020 + 26 0.75 k 0.1 1,230 k 40 1,230 + 40 1,250? 30

1.0

247 36+_1 0.75 * 0.1 1,250+ 30

Auto

tension

Auto tension

12-047 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

Engine model Applicable machine model etc.

SA6D170-A-1

Pc1ooosP-1

HD465-3 (With single turbocharger) Standard Tolerance

Item
1

Condition,

High idling speed Engine speed I Low idling speed

2,250 - 2,350 940 - 990

2,250 - 2,350 940 - 990

Necessary
starting speed

0C
-20C (with starting aid)

rpm
rpm kPa [mmHzOI kPa ImmHgI kPa ImmHg) C

Min. 100 Min. 100

7.5 1762) 700 5.0

Min. 130 Min. 100 Max. 3.7 {Max. 380) Min. 10.8 {Min. 1,100) Min. 10.3 {Min. 1,050) Max. 650 Max. 6.0 Max. 2.0 Max. 2.0 0.4 1.0 Min. 2.75 {Min. 28) (210 - 250) Max. 3.4 {Max. 350) 294 - 490 (3.5 - 5.0)

I Intake resistance
Intake pressure
IExhaust pressure /[Turbine inlet pressure) IExhuast temperature ,[Turbine inlet 1 temDerature)

At all speed At rated output At rated output All speed (intake air temp.: 20C) Quick acceleration (Low idling --f High idling)

Max. 2.9 {Max. 300) Max. 650

7.0

I Exhaust gas color

At rated output At high idling Intake valve Exhaust valve Oil temperature: 40C to 60C (Engine speed) At rated output Water temperature: Min. 70C At rated output SAW0 oil oil

Bosch scale

2.5 2.0 0.4 7 ~~ 1.0 Min. 2.55 {Min. 26)

%!I

Valve clearance (When engine is Hot or cold) Compression pressure (SAE30 oil)

mm mm MPa {kg/cm? (rpm)

I
1.77 {I81

1,96

{20)
(210 - 2501 6.9 I7001

(210-250)

(210-250)

Blow-by pressure (SAE30 oil)

Oil pressure (Oil temperature: Min. 80C)

SAElOW At low idling SAE30 SAEIOW

kPa {kg/cm21 kPa {kg/cm?

294 - 441 (3.0 - 4.5)

206 (2.1)

245 - 441 12.5 - 4.5) Min. 147 {Min. 1.5)

oil oil

kPa {kg/cm?

Min. 98 {Min. 1.0) 80-110 120

Oil temperature Oil consumption ratio Fuel injection pressure Fuel injection timing Radiator vavle pressure

All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester B.T.D.C. Opening pressure (Differential pressure) At rated engine speed

%
MPa {kg/cm21

Max. 0.5 26.5 - 27.3 (210 - 278)

1.0 21.6 (220)

Max. 0.5 29.9 - 30.7 (305 - 313) 37-39 64-83 {0.65 - 0.85) 1,220 - 1,280

1.0 24.2 (2471 37-39 64-83 IO.65 - 0.851 1,220 - 1,280

Fan speed

Fan belt tension *

Deflects when pushed with a force of 6 ko

mm

of the output. pump.

See page 12-031

The values given in the Testing and Adjusting Do not use these values as a guide to change

data are NOT for adjustment the setting of the fuel injection

12-047- 1 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

SA6D170-A-1 EM680A Standard Tolerance

r
550 - 600

EM680A-1 EM170B-1 Standard Tolerance

T
7.5 {762) -

EM680A-A Standard Tolerance

H D465-5 (High altitude spec.)

2,100 - 2,200 550 - 600 Min. 130 Min. 100 Max. 2.9 {Max. 3001 Min. 168 (Min. 1.3001

2,100 - 2,200

2,000 - 2,200 550 - 600 Min. 130 Min. 100 Max. 2.9 {Max. 300) Min. 155 (Min. 1,200} Min. 80 {Min. 620) Max. 600 Max. 2.0 Max. 2.0 0.4 1.0 Min. 2.75 {Min. 28) (210 - 250) Max. 2.9 {Max. 300) 294 - 490 l3.0 - 5.01 245 - 441 {2.5 - 4.5) Min. 147 {Min. 1.5} Min. 98 {Min. 1.0) 80-110

2,100 - 2,200 550 - 600 Min. 130 Min. 100 Max. 3.7 {Max. 380)

2,100 - 2,200 550 - 600

7.5 17621 700

7.5 {762)

Min. 130 Min. 100 Max. 2.9 {Max. 300) Min. 106 {Min. 820} Min. 95 {Min. 7401

Max. 550

60 3.0 2.0 1.96 (201 (210 - 250) 5.9 {6001 206 (2.1) 177 Il.81 I& {:?I 120 Max. 650 700

Max. 620

Max. 2.0 Max. 2.0 0.4 8 z z 1.0 Min. 2.75 (Min. 281 (210 - 250) Max. 3.4 {Max. 3501 294 - 490 (3.0 - 5.0) 245 - 441 (2.5 - 4.51 Min. 147 (Min. 1.5) Min. 98 {Min. 1.0) 80-110

Max. 1 .O Max. 0.5 0.4 1.0 Min. 2.75 {Min. 28) (210 - 250) Max. 3.4 {Max. 350) 294 - 490 13.0 - 5.0) 245 - 441 (2.5 - 4.51 Min. 147 {Min. 1.5) Min. 98 (Min. l.O} 80110

2.0 1.5 1.96 1201 (210 - 250) 6.9 (7001 Min. 2.75 {Min. 28) (210 - 250) 1.96 I201 (210 - 250)

2 1.96 {201 (210 - 250) 6.9 I7001

245 - 441 (2.5 - 4.5) Min. 147 {Min. 1.5} Min. 98 {Min. I.01 120

177 11.81 1:;) &

Max. 0.5 29.9 - 30.7 I305 - 3131 33-35

1.0 24.2 I2471 33-35 -

Max. 0.5 29.9 - 30.7 (305 - 3131 33-35 -

1.0 24.2 {247) 33-35 -

Max. 0.5 29.9 - 30.7 (305 - 3131 29-31 -

1.0 24.2 I2471 29-31 29.9 - 30.9 {305 - 3151 24.2 12471

17

15 - 19

12-047-2 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

Engine model Applicable machine model etc. Unit OEM for generator Standard Aax. 1,560 (50H; Aax. 1,872 (60H; 950 - 1,000 Min. 130 aid)

SA6D170-A-1 IG600BS-1, OEM for generator (Engine No. 15503 and up) Tolerance ax. 1,568 (50Hz) ax. 1,881 (60Hz) 700 - 900 Min. 130 Min. 100 Max. 3.9 {Max. 400) lax. 1,568 (50Hz) lax. 1,881 (60Hz) 700 - 900

Clas
sifica - tior 8 6 E b t a

Condition,

Tolerance Max. 1,560 (50Hi Max. 1,872 (60H2 950 - 1,000

High idling speed Low idling speed

vm wm

Necessary starting speed

0C
-20C (with starting

7.5 {762)

7.5 I7621

rpm
kPa rnmHz0) {I kPa

Min. 100 Max. 3.9 {Max. 400) -

Intake resistance Intake pressure Exhaust pressure Turbineinlet pressure) Ixhuast temperature :Turbine inlet :emperature)

At all speed At rated output At rated output All speed [intake air temp.: 20C) Quick acceleration [Low idling + High idling)

Imml-lg)
kPa

700

I mml-fg}
C

Max. 650

Max. 650

700

Bosch scale Max. 1.5 Max. 1.0 0.4 1.0 Min. 2.55 {Min. 26} (210 - 250) Max. 3.9 {Max. 400) 255 - 441 12.6 - 4.5) 216 - 392 {2.2 - 4.0) Min. 147 {Min. 1.5} Min. 98 {Min. 1.0) 80-110

2.5 2.0

Max. 1.2 Max. 1.0 0.4 1.0 Min. 2.55 {Min. 26) (210 - 250) Max. 3.9 {Max. 400) 343 - 441 13.5 - 4.5) 294 - 441 13.0 - 4.51 Min. 147 {Min. 1.5} Min. 98 {Min. l.O}

!xhaust

gas color

At rated output At high idling Intake valve Exhaust valve Oil temperature: 40C to 60C [Engine speed) At rated output Water temperature:

dalve clearance :When engine is iot or cold) Zompression oressure SAE30 oil)

mm mm MPa 1kg/cm? (rpm) kPa Min. 70C : { mmHz0 kPa (kg/cm? oil kPa (kg/cm21 kPa [kg/cm? oil kPa

1.77 (181 (210 - 250)

1.77 {18I (210 - 250) 7.8 {800}

8
z &

Blow-by pressure (SAE30 oil)

At rated output SAE30 oil Oil pressure (Oil temperature: Min. 80C) SAEIOW At low idling SAEJO oil SAEIOW Oil temperature Oil consumption ratio Fuel injection pressure Fuel injection timing Radiator vavle pressure All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester B.T.D.C. Opening pressure (Differential pressure) At rated engine speed

i(kg/cm?
C

120

80-110

%
MPa

Max. 0.5 29.7 - 30.9 1303-315) 33-35 64-83 to.65 - 0.85)

1.0 24.2 {247) 33-35 64-83 lo.65 - 0.85)

Max. 0.5 29.9 - 30.7 I305 - 313) 30-32 59-78 fO.6 - 0.8)

1.0 24.2 I2471 30-32 59-78 fO.6 - 0.8)

i(kg/cm?
degree kPa

i[kg/cm?

Fan speed

995 - 1,055 (50Hi 995 - 1,055 (50Hz ,192 - 1,266 (6Ok 1,192 - 1,266 (60H mm

95 - 1,055 (50Hz) 195 1,055 (50Hz) 192- 1,266 (60Hz: 192 - 1,266 (60Hz)

Fan belt tension *

Deflects when pushed with a force of 6 kg

of the output. pump.

The values given in the Testing and Adjusting Do not use these values as a guide to change

data are NOT for adjustment the setting of the fuel injection

12-047-3 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

SA6D170-A-1 OEM for generator (Prime use) Standard Tolerance

OEM for generator (Standby use) Standard Tolerance

OEM for marine Standard 2,100 - 2,200 550 - 600

EPSAGD170-A-1 512 kW (686 HP} Standard Max. 2,200 700 - 900 Min. 130 Min. 100 Max. 3.9 {Max. 400) Tolerance Max. 2,200 700 - 900

Max. 1,568(50Hz: Aax.1,566(50Hz Max. 1,981@Hz: Aax.1,981(60Hz 700 - 900 Min. 130 Min. 100 Max. 3.9 {Max. 400) 700 - 900

lax. 1,575(50Hz) Bax.1,575(50Hz) 2,100 - 2,200 lax. 1,890(60Hz) [ax. 1,890(60Hz) 700 - 900 Min. 130 Min. 100 Max. 4.9 {Max. 500) 700 - 900 550 - 600 Min. 130 Min. 100 Max. 2.9 {Max. 300)

7.5 {762)

7.5 {762)

700

700

Max. 650

Max. 650 700

Max. 700 Max. 2.5 Max. 2.5 0.4 1.0 Min. 2.55 {Min. 2.6) (210 - 250) Max. 3.9 {Max. 400) 226 - 392 12.3 - 4.0) 177-348 Il.8 - 3.5) Min. 147 {Min. 1.5) Min. 98 {Min. 1.0)

Max. 650

700

Max. 1.2 Max. 1.0 0.4 $ z 1.0 Min. 2.55 {Min. 2.6) (210 - 250) Max. 3.9 {Max. 400) 343 - 441 13.5 - 4.5) 294 - 441 13.0 - 4.5) Min. 147 {Min. 1.5) Min. 98 {Min. I.01 80-110

Max. 1.0 Max. 1.0 0.4 1.0 Min. 2.75 {Min. 28) (210 - 250) Max. 3.4 {Max. 350) 294 - 490 {3.0 - 5.0) 245 - 441 l2.5 - 4.5) r% r%

it 1.96

Max. 2.5 Max. 1.5 0.4 1.0 Min. 2.55 {Min. 26) (210 - 250) Max. 3.9 {Max. 4001 294 - 490 (3.0 - 5.0) 245 - 441 t2.5 - 4.5) Min. 147 {Min. 1.5) Min. 98 {Min. 1.0) 3.5 2.5

Z
1.77 (18) (210 - 250) 7.8 {800) 245 I2.5) 206 12.1)

2:;
1.77 U8I (210 - 250) 7.8 I8001 157 Il.61 127 Il.31

1.77 118) (210 - 250) 7.8 {8001

120)
(210 - 250)
6.9

{700) 206 (2.1)

120
1.0

80-110

120
1.0

90-110

120
1.0

80-110

120
1.0

Max. 0.5 29.9 - 30.7 1305 - 313)

Max. 0.5 29.9 - 30.7 {305 - 313) 33-35 59-78 IO.6 - 0.8)

Max. 0.5 29.9 - 30.7 I305 - 313) 33-35

Max. 0.5 29.9 - 30.7 I305 - 313) 36 - 38


39 - 59

24.2 {247I

24.2 {247) 33-35 59-78 to.6 - 0.8)

24.2 {247) 33-35

24.2 1247) 36-38


39-59

29 - 31 (50 Hz] 29 - 31 (50 Hz 31 - 33 (60 Hz] 31- 33 (60 Hz 59 - 78 IO.6 - 0.8) 59-78 CO.6 0.8) -

IO.4 - 0.6)

IO.4 - 0.6)

995- 1,055(50Hz) 395- 1,055(50Hz: 195 1,055(50Hz) 395- 1,055(50Hz) 1,192 1,266(60Hi ,192- 1,266(60H; 192- 1,266(6OH2 ,192- 1,266(60Hz -

12-047-4 0

Engine model Applicable machine model

SAGD170-6-l D375A-1 (Engine No. up to 11117) Unit Standard 1,950-2,050 600-700 Min. 130 Min. 100 Max. 380 Min. 1,100 Min. 900 Tolerance 1,950-2,050 600-700 635 825 810 D375A-1 (EngineNo. 11118andup) Standard 1.950-2.050 600-700 Min. 130 Min. 100 Max. 380 Min. 950 Min. 900 Tolerance 1,950-2,050 600-700 635 825 810

Item

Condition, etc. High idling speed

rpm rpm
I

Engine speed Low idling speed


I

Necessary starting speed Intake resistance Intake pressure Exhaust pressure (Turbine inlet pressure) Exhaust temperature (Turbine inlet temoeraturel

ooc
-20C (with starting aid) At all speed At rated output At rated output

rpm
rpm mmH,O mmHg mmHg

All speed (intake air temp.: 20C)

OC

Max. 650

Max. 650

Max. 650

Max. 650

Max. 7.0 Max. 4.5 Max. 1.5 Valve clearance (When engine is hot or cold) Intake valve Exhaust valve Oil temperature: 40C to 60C (Engine speed) I Blow-by pressure (SAEBO oil) At rated output Water temperature: Min. 70C At rated output SAEBO oil Oil pressure (Oil temperature: Min. 80C) SAElOW oil At low idling SAEBO oil SAElOW oil kg/cm* kg/cm2 Min. 1.5 Min. 1 .O I mmH?O Max. 280 mm mm 0.4 1 .o

8.0 5.5 2.5 -

Max. 6.0 Max. 2.5 Max. 1.5 0.4 1 .o

8.0 3.5 2.5 8

Compression pressure (SAEBO oil)

kgcm2 (rpm)

Min. 28 (21 O-250)

20 (21 O-250)

Min. 26 (21 O-250)

18 (21 O-250)

;o z

560

Max. 350

700

kg/cm2 kg/cm2

3.0 2.5 -

5.0 4.5

2.0 1.8 0.7 0.7

3.0 2.5 -

5.0 4.5

2.0 1.8 0.7 0.7

Min. 1.5 Min. 1 .O

Oil temperature

All speed (oil in oil pan)

80-110

120

80-110

120

Max. 0.5

1.0

Max. 0.5

1 .o

265 +15 +5 Fuel injection timing Radiator pressure valve Fan speed Fan belt tension + 6.T.D.C Opening pressure (Differential pressure) At rated engine speed Deflects when pushed with a force of 6 kg degree kg/cm* 38t 1

220 38* 1

265 + 3 +5 38il

220 38i 1

0.75 + 0.1

0.75 i 0.1

0.75 * 0.1

0.75 + 0.1

rpm mm

1,050 f 30

1,050 i 30

1,050 i 30

1,050 i 30

See page 12.031

The values given in the Testing and Adjusting data are NOT for adjustment of the output Do not use these values as a guide to change the setting of the fuel injection pump.

12-048 0

SAGDl70-8-1 D375A-2 Standard 2,000 + 40 Tolerance 2,000 i 40 HD465-3 (with single turbocharger) Standard 2.350-2.450 800-900 Min. Min. 130 100 Tolerance 2,350-2,450 800-900 762 Standard 1,850 zk 50 PC1 000-l Tolerance 1,850 f 50 Standard 1,800-l 950-I Min. Min. ,890 ,000 100 100 EG450-1 Tolerance 1,800-l 950-l 635 ,890 ,000

630 zt 50 Min. Min. 130 100

630 f 50 762 825 810

675 rt 25 Max. Min. 130 100

675 f 25 762 900 810

Max. 380 Min. 950 Min. 900

Max. 300 -

Max. 300 Min. 1,000

Max. 300 -

Min. 900

Max. 650 Max. 6.0 Max. 2.5 Max. 1 .O 0.4

Max. 650 8.0 3.5 2.0 -

Max. 650 Max. 6.0 Max. 2.0 Max. 1.5 0.4

Max. 700 8.0 3.0 2.5 -

Max. 650 Max. 3.0 Max. Max. 0.4 1.5 1 .O

700 5.0 2.5 2.0 -

Max. 650 Max. 2.0 0.4

Max. 650 2.5 -

1.o 2 ;;;
z Min. 26 (21 O-250)

18 (21 O-250)

1.o
Min. 28 (21 O-250) 20 (21 O-2.50)

1.o
Min. 26 (21 O-250)

18 (21 O-250)

1.o
Min. 28 (21 O-250)

20 (210-250)

Max. 350

700

Max. 350

700

Max. 400

800

Max. 200

400

3.0 2.5 Min. Min.

5.0 4.5 1.5 1 .O

2.1 1.8 0.7 0.7

3.0 2.5 Min. Min.

5.0 4.5 1.5 1 .O

2.1 1.8 0.7 0.7

3.5 3.0 Min. Min.

5.0 4.5 1.5 1 .O

2.5 2.1 0.7 0.7

2.5 -

4.0

2.5 -

4.0

Min. Min.

1.5 1 .O

0.7 0.7

80-110

120

80-

110

120

80-100

120

80-90

120

Max. 0.5

1 .o

Max. 0.5

1 .o

Max. 0.5

1.0

Max. 0.5

1 .o

265 f13 +5 381 0.75 1 + 0.1

220 38 + 1 0.75 i 1

265 +13 +5 42 * 1 See page 12-031

220 42 f 1 -

265 +13 +5 38 i 0.75 1

239 38 t 1 0.75 It 0.1

255 +13 +5 39 i 0.75 1

230 39 + 1 0.75 j: 0.1

i 0.1

i 0.1

l.lOOi33

l.lOOk33

95 f 25

950 * 25

1,020+25(50Hz) 1,224k30(60Hz) -

1,020t25(50Hz) 1,224+30(60Hz) -

The values given in the Testing and Adjusting Do not use these values as a guide to change

data are NOT for adjustment of the output the setting of the fuel injection pump.

12-049 8

Engine model Applicable machine model

SA6D170-6-l EG480-1, EG480B-1, EG500-1 EG500B-1, EG500B.B1 Unit Standard Tolerance EPSAGD170-B-1

Item

Condition, High idling speed

etc.

Standard

Tolerance

rpm rpm rpm rpm mmHs0 mmHg mmHg Min. 100 Max. 400 lin. 930(50Hz) lin.1,100(60Hz)

Engine speed Low idling speed ooc -20C (with starting aid)

Necessary starting speed

762 720 880

Min. 100 Max. 350 Min. 1,250

762 1,090

Exhaust temperature (Turbine inlet temperature)

All speed (intake air temp.: 20C) Quick acceleration (Low idling - High idling) At rated output At high idling

OC

Exhaust gas color

Bosch scale

mm mm

kg/cm2 (rpm)

Blow-by pressure (SAE30 oil)

At rated output Water temperature: Min. 70C At rated output SAE30 oil

mmH*O

Max. 400

800

Max. 400

800

kg/cm2 oil kg/cm2 kg/cm2 oil kg/cm2

3.0 2.5 -

4.5 4.0

2.1 1.8 0.7 0.7

3.0 -

4.5

2.0 0.7 -

Oil pressure (Oil temperature: Min. 80C)

SAElOW At low Idling SAEBO oil SAElOW

Min. 1.5 Min. 1 .O

Min. 1 .O -

011 temperature Oil consumption ratio Fuel injection pressure

All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester

OC

80-110

120

80-110

120

I
% Max. 0.5 1 .o

I
Max. 0.5

I
1.0

kg/cm*
degree

255 +I3 +5

211

265 ;L3

220

kg/cm2 Fan speed At rated engine speed Deflects when pushed with a force of 6 kg ,020+26(50Hz) .224+30(60Hz) 1,020i26(50Hz) 1,224+30(60Hz) 1.23Oi40 1,230 + 40

rpm mm

Fan belt tension *

Auto tension

The values given in the Testing and Adjusting data are NOT for adjustment of the output Do not use these values as a guide to change the setting of the fuel injection pump.

12-049-l 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

Engine model Applicable machine model etc.

SA6D170-B-1

EG480B-1

(For CIS)

OEM for generator 367 kW {492 HP} I50 Hz Standard lax. 1,560 (50Hz) lax. 1,872 (60Hz) 700 - 800 Min. 130 Min. 100 Tolerance lax. 1,560 (50Hz) lax. 1,872 (60Hz) 700 - 800

Clas
sifica - tiol z : E b t d

item

Condition,

High idling speed Engine speed Low idling speed

Necessary starting speed

0C
-20C (with starting aid) kPa [mmHzO} kPa 0-nmHg} kPa {mmHgI C 2.9 {3001 Min. 120 {Min. 930) Min. 85 {Min. 6601 650 7.5 I7621 {792301 68 15301 700

7.5 I7621

Intake resistance Intake pressure Exhaust pressure [Turbineinlet pressure) Exhuast temperature (Turbine inlet temoerature)

At all speed At rated output At rated output All speed (intake air temp.: 20C) Quick acceleration (Low idling + High idling)

Max. 2.9 {Max. 300) -

Max. 650 Max. 3.0 Max. 2.5 0.4 1.0 Min. 2.75 {Min. 281 (210 - 250) Max. 3.9 {Max. 4001 294 - 441 13.0 - 4.51 245 - 392 (2.5 - 4.0) Min. 147 {Min. 1.5) Min. 98 {Min. 1.01 80-110

-p/
mm mm MPa {kg/cm*} 0.4 4.0 2.0 -

Exhaust

gas color

At rated output At high idling Intake valve Exhaust valve Oil temperature: 40C to 60C (Engine speed) At rated output Water temperature: Min. 70C At rated output SAE30 oil

4.0 3.5

Valve clearance (When engine is Hot or cold) Compression pressure (SAE30 oil)

1.96

1.0 Min. 2.55 {Min. 26) (210 - 250)

1.77 1181 (210 - 250) 7.8 18001 186 (1.9) 147 (I.51 $1 $1 120

QOI
(210 - 250) 7.8 (800) 206 (1.8)

(rpm)
kPa (mmHnO1 kPa {kg/cm*} oil kPa {kg/cm3 kPa {kg/cm*} kPa {kg/cm} C

Blow-by pressure (SAESO oil)

&& 265 - 392 (2.7 - 4.0) 216-343 (2.2 - 3.5) Min. 147 {Min. 1.5) Min. 98 (Min. l.O} 80-110

Oil pressure (Oil temperature: Min. 80C)

SAElOW At low idling

SAESO oil SAElOW oil

Oil temperature Oil consumption ratio Fuel injection pressure Fuel injection timing Radiator vavle pressure

All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester B.T.D.C. Opening pressure (Differential pressure) At rated engine speed Deflects when pushed with a force of 6 kg the Testing and Adjusting

120

% MPa {kg/cm*} degree

0.5 25.5 - 26.3 1260 - 268) 41-43

1.0 20.7 I2111 41-43

Max. 0.5 25.5 - 26.3 (260 - 268) 41-43 64-83 IO.65 - 0.851

1.0 20.7 12111 41-43 64-83 IO.65 - 0.851

Fan speed

Fan belt tension * The values givenin

mm

Auto tension of the output. pump.

data are NOT for adjustment of the fuel injection

Do not use these values as a guide to change the setting

12-049-2 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

Engine model Applicable machine model etc. Unit Standard dax. 1,568 (50tb tiax. 1,881 (6OH2 700 - 800 Min. 130 Min. 100 Max. 2.9 {Max. 300)

SA6D170-B-1 IBS-1 :nerator 265 and up) Tolerance dax. 1,568 (50Hi lax. 1,861 (60H: 700 - 800

OEM for generator 379 kW I508 HP} / 50 Hz


Standard flax. 1,560 (50H2 dax. 1,872 (60H2 700 - 900 Min. 130 Min. 100 Tolerance dax. 1,560 (50Hz) Aax. 1,872 (6OHz) 700 - 900 -

:7

Item

Condition,

High idling speed Engine speed Low idling speed

rpm rpm

Necessary starting speed

0C
-20C (with starting aid)

vm vm
kPa (mmHnO1 kPa fmmHgI kPa ImmHgI C

7.5 f762) . .

7.5 (7621

Intake resistance Intake pressure Exhaust pressure [Turbine inlet pressure) Exhuast temperature (Turbine inlet temoerature)

At all speed At rated output At rated output All speed (intake air temp.: 20C) Quick acceleration (Low idling --3 High idling)

Max. 2.9 {Max. 300) -

Max. 650

700

700

Max. 650

Bosch scale Max. Max. 0.4 1.0 Min. 2.75 (Min. 28} (210 - 250) Max. 3.9 {Max. 400) 343-441 (3.5 - 4.5) 294 - 392 (3.0 - 4.01 Min. 177 (Min. 1.8} Min. 127 {Min. I.31 80-110 120 1.5 1.0

Max. 2.5 Max. 1.5 0.4 1.0 Min. 2.75 {Min. 28) (210 - 250) Max. 3.9 {Max. 400) 245 - 441 (2.5 - 4.5) 196 - 392 (2.0 - 4.0) Min. 147 {Min. 1.5) Min. 98 {Min. 1.0) 80-110

3.5 2.5

I Exhaust gas color

At rated output At high idling Intake valve Exhaust valve Oil temperature: 40C to 60C (Engine speed) At rated output Water temperature: Min. 70C At rated output SAE30 oil

2:
1.96

Valve clearance

mm mm MPa {kg/cm21 (rpm) kPa ImmHtO kPa

/ [When engine is
Hot or cold) Compression pressure (SAE30 oil)

I,96

(201
(210 - 250) 7.8 (8001 245 (2.5) 206 (2.1)

(201
(210 - 250)

z z

Blow-by pressure (SAE30 oil)

(kg/cm21
kPa Ikg/cn+I kPa

Oil pressure (Oil temperature: Min. 80C)

SAEIOW At low idling

oil

SAEBO oil SAEIOW oil

Ikg/cm21
kPa {kg/cm? C

Oil temperature Oil consumption ratio Fuel injection pressure Fuel injection timing Radiator vavle pressure

All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester B.T.D.C. Opening pressure (Differential pressure) At rated engine speed Deflects when pushed with aforceof6kg

120

%
MPa {kg/cm21 degree kPa {kg/cmI

Max. 0.5 25.5 - 26.3 (260 - 268) 35-37x1 31 -33 2 59-78 (0.6 - 0.8) 995 - 1,055 (50Hz ,192 - 1,266 (60H -

1.0 20.6 (21OI 35-37x1 31 -33 *2 59-78 IO.6 - 0.8) 395- 1,055 (50tk ,192 - 1,266 (60H -

Max. 0.5 25.5 - 26.3 1260 - 268) 35-37 )95 - 1,055 (50Hz ,192 - 1,266 (60H -

1.0 20.6 (2101 35 -37

Fan speed

wm
mm

395 - 1,055 (50Hz) ,192 - 1,266 (60Hz)

Fan belt tension

of the output. pump. *I *2 : Except EG500BS-1

The values given in the Testing and Adjusting

data are NOT for adjustment

Do not use these values as a guide to change the setting of the fuel injection

EG500BS-1

only

12-049-3 0

TESTING AND ADJUSTING

TESTING AND ADJUSTING DATA

Engine model Applicable machine model

SAGDI JO-B-I OEM folr gc merator (Stan db\l use) r Standard Tolerance lax. 1,568 (50Hz) lax. 1,881 (60Hz)

Condition,

etc. Max. 1,568 (50Hz) Max. 1,566 (50H2 Max. 1,881 (60Hz) Max. 1,881 (60H1

High idling speed Low idling speed

vm wm
rm
rpm kPa lmmHz0) kPa lmmHg)

Aax. 1,566 (50H; Aax. 1,681 (60H;

700 - 900
Min. 130 Min. 100 Max. 3.9 {Max. 400} -

700 - 900
7.5 1762) Max. 700

700 - 800
Min. 130 Min. 100 Max. 3.9 {Max. 400)

700 - 800

0C
-20C (with starting aid)

7.5
1762)

I
E ti 2 ti : _c Z
-0

Intake resistance Intake pressure

At all speed At rated output At rated output All speed (intake air temp.: 20C) Quick acceleration [Low idling + High idling) At rated output At high idling Intake valve

Max. 650

Exhaust pressure (Turbineinlet pressure) Exhuast temperature (Turbine inlet temperature)

700

2.5 2.0

Exhaust gas color

40C to 60C Min.27.5 {Min. 28} (210 - 250) kPa lmmHz0) Max. 3.9 {Max. 400) 7.8 1800) Max. 3.9 {Max. 400) 245 - 441 12.5 - 4.5) 196 - 392 (2.0 - 4.0} kPa {kg/cm*) Min. 147 {Min. 1.5} & Min. 147 {Min. 1.5} Min. 98 {Min. 1.01 80-110 120 1.96

(When engine

is Exhaust valve

& 8 : Bl I=

Compression pressure (SAE30 oil)

3il temperature:

1201
(210 - 250) 7.8 1800) I77 11.8) 137 11.4)

:Engine speed) 4t rated output Water temperature:

Blow-by pressure lSAE30 oil)

Min. JOY

At rated output SAE30 oil Oil pressure (Oil temperature: Min. 80C) SAElOW At low idling SAE30 oil SAElOW Oil temperature All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester B.T.D.C. oil oil

$ IYY 2

Max. 0.5 - 25.5 - 26.3 I260 - 268) 40-42 59-78 10.6 - 0.8)

1.0 20.6 1210) 40-42 59 - 78 iO.6 - 0.8) 95 - 1,055 (50Hz) 192- 1,266 (60Hz)

ti ?i ? .Z u *

Radiator

pressure

Opening pressure [Differential pressure) At rated engine speed Deflects when pushed with 3 force of 6 ka

{fi

l,,:

1:

995 - I 055 l50Hz) 995 - 1055 (50Hz) 95 - 1,055 (50Hz 1,192 - 1,266 (60Hz) 1,192 - 1,266 (6OH2 192 - 1,266 (60H;

Fan belt tension

of the output. pump.

The values given in the Testing and Adjusting

data are NOT for adjustment

Do not use these values as a guide to change the setting of the fuel injection

12-049-4 0

TESTING AND ADJUSTING

TESTING AND ADJUSTING DATA

Engine model Applicable machine model etc.

SA6D170-B-1 EPSAGD170-B-1 445 kW (597 HP} / 1,300 rpm OEM for 6-pole Standard generator Tolerance

Condition,

Unit

Standard

Tolerance Max. 2.200 600 - 1,000 7.5 17621 700 ;::

High idling speed Engine speed

Max. 2.200 600 - 1,000 Min. 130

Max. 1,947 (50Hz) Aax. 1,047 (50Hz) Max. 1,256 (6OHzl Aax. 1,256 (60Hz) 750 - 850 Min. 130 Min. 100 Max. 3.7 {Max. 380) Min. 123 (50Hz) {Min. 950) (50Hz) Min. 142 (6OHz) [Min. 1,100) (66Hz Max. 6700 Max. 0.5 1.0 750 - 850

Necessary starting speed

7.5 D621 -

-20C (with starting

aid) kPa {mmHzOl kPa {mmHgI kPa ImmHgI C

Min. 100 Max. 2.9 {Max. 300)

Intake resistance Intake pressure Exhaust pressure (Turbineinlet pressure) Exhuast temperature (Turbine inlet temperature)

At all speed At rated output At rated output All speed (intake air temp.: 20C) Quick acceleration (Low idling + High idling)

Max. 650

700

Bosch scale Max. 2.5 Max. 1.5 0.4 1.0 Min. 2.75 {Min. 27) (210 - 250)

2.0 1.5

Exhaust gas color

At rated output At high idling

Valve clearance (When engine is Hot or cold) Compression pressure (SAE30 oil) At rated output Water temperature:

0.4 1.0 Min. 2.45 {Min. 26) (210 - 250) Max. 3.9 {Max. 400)

Min.1.77 {Min. 18) (210 - 250)

2
z z

Blow-by pressure (SAE30 oil)

Min. 70C

kPa ImmHzO) kPa ikg/cm2} kPa {kg/cm*} kPa {kg/cm? ,k~,~m21 C 294 - 490 13.0 - 5.01 245 - 441 12.5 - 4.5) Min. 147 {Min. 1.51 Min. 98 {Min. 1.0) 80-110

At rated output SAE30 Oil pressure (Oil temperature: Min. 80C) SAEIOW At low idling SAE30 oil SAElOW Oil temperature Oil consumption ratio Fuel injection pressure Fuel injection timing Radiator vavle pressure Opening pressure (Differential pressure) All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) oil oil oil

I
I&

1.96

I20}

(210 - 250) 5.9 16001

206 t2.11 Min. 147 {Min. 1.5)

177 t1.81

&
120

I -

E)
120

85-110

Max. 0.5 25.5 - 26.3 I260 - 268) 41-43

1.0 21.5 {219} 18-20 39 - 59 CO.4 - 0.6) 59-78 10.6 - 0.81 989 - 1,051 59-78 IO.6 - 0.81 989 - 1,051

kPa {kg/cm?

39 - 59 IO.4 - 0.61

Fan speed

data are NOT for adjustment the setting of the fuel injection of the output. pump.

Fan belt tension * The values given in the Testing and Adjusting Do not use these values as a guide to change

8 - 12

8-12

12-049-5 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

DATA

Engine model Applicable Item machine model etc. Unit OEM for generator Standard

SAA6D170-1 (50 Hz)

Condition,

Tolerance

High idling speed Engine speed Low idling speed 0C -20C (with starting aid)

rpm rpm

Max. 1,568 700 - 900 Min. 130 Min. 100 Max. 4.4 {Max. 4501

Max.

1,568

700 - 900

Necessary starting speed

rpm vm
kPa [mmHzO; kPa {mml-lg} kPa ImmHg) C

Intake resistance Intake pressure Exhaust pressure (Turbine inlet pressure)

At all speed At rated output At rated output

Max. 650

~uh$~e~;e:en;netPeature speed All (intake air temp.: 20C) temperature) Quick acceleration (Low idling + High idling) At rated output At high idling Intake valve Exhaust valve

Bosch scale Max. 1.5 Max. 1.0 0.4 1.0 Min. 2.55 {Min. 26) (210 - 250) Max. 5.9 {Max. 6001 255 - 373 12.6 - 3.81 206 - 324 {2.1 - 3.3) Min. 147 {Min. 1.5) Min. 98 {Min. 1.0) 80-110 120

Exhaust

gas color

Valve clearance (When engine is Hot or cold)

mm mm MPa {kg/cm*1 (rpm)

1.77 I181 (210 - 250) 11.8 Il.2001

Blow-by pressure (SAE30 oil)

At rated output Water temperature: Min. 70C At rated output SAEBO oil

kPa (mmHz0 kPa {kg/cm*)

Oil pressure (Oil temperature: Min. 80C)

SAElOW At low idling

oil

kPa {kg/cm21 kPa {kg/cm? kPa {kg/cm21 C

SAE30 oil SAElOW oil

Oil temperature Oil consumption ratio Fuel injection pressure

All speed (oil in oil pan) At continuous rated output (Ratio of fuel consumption) Nozzle tester

% MPa {kg/cm*1 degree kPa {kg/cm?

Max. 0.5 29.9 - 30.7 1305 - 313) 23-25 59-78 IO.6 - 0.8) 1,240 - 1,310

Fan speed

At rated engine

speed

vm
mm

Fan belt tension t The values givenin

Deflects when pushed with a force of 6 kg the Testing and Adjusting

Autotensioner

Autotensioner of the output. pump.

data are NOT for adjustment

Do not use these values as a guide to change the setting of the fuel injection

12-049-6 0

FAN BELT TENSION

1. 2. 3. 4. 5. A.

Adjustment nut Washer Tension spring Adjustment bolt Tension pulley Protrusion of adjustment bolt

6162F291

Unit: mm Engine model Applicable machine PC650-1 PC1500-1 HD465-3


I

Dimension A

S6Dl?O-1

73 f 5

SAGDl70-A-1

5Bi5
I

SAGD 170-B-l

D375A-1 D375A-2

50 k 5

PC1 000-l

70 i: 5

TENSION
l

OF WA700-1

FAN BELT

Replacing Loosen locknut (1) and turn back adjustment (3). of approx. 50 cm in the to the screw

1.

(2) as far as bracket 2. insert a bar with

a length

hole (@18)

in bracket

(7), then

pull strongly

front and hold in position. 3. The spring it with * will extend and the tension pulley will

move to the inside. Remove the old belts and replace new bolts. the V-belts in a set (3 belts). Replace

6162F1014

Adjusting Tighten tension locknut w adjustment screw lever pulley (1). Locknut : 29.5 between f 2 kgm pulley lever (4) and operation, screw (2) (2). and when into the tip of with screw with

adjustment (2) a further

comes then

contact

(4). tighten

adjustment

half turn,

lock it in position

If a gap appears the adjust

tension screw

tip of adjustment in the same way.

(2) during

If the fan

belt screeches,

adjust

in the same

way.
6162F668

12-051 0

TROUBLESHOOTING
CONTENTS
Points to remember Method S-l s-2 Starting (Starting @ @ @ s-3 s-4 s-5 S-6 s-7 S-8 s-9 S-IO 2 z z S-l 1 s-12 s-13 s-14 s-15 S-16 when troubleshooting chart is poor

of using troubleshooting performance always

.......................................... .............................................

12-055 12-056 12-060 12-061 12-061 12-062 12-063 . ........... 12-064 12-065 12-066 12-067 12-068 12-069 12-070 12-071

takes time)

................................................

Enginedoesnotstart Engine Engine Exhaust turns

...................................................... ................................................... comes out does not start but no exhaust

does not turn

(Fuel is not being injected) (Fuel is being injected) Engine Engine Engine (Follow-up is poor)

..............................................

gas comes out but engine

.................................................

does not pick up smoothly ............................................ operations ............................................. (hunting) stops during

.................................... Engine lacks output (no power) .............................................. ................................. Exhaust gas is black (incomplete combustion)
does not rotate smoothly Oil consumption is excessive is excessive or water (or exhaust gas is blue) ...........................

Oil becomes

contaminated

quickly

Fuel consumption Oil pressure Oil level rises

........................................... ..............................................
spurts back, or water level goes down

Oil is in cooling water,

............

12-072 12-073 12-074 12-075 12-076 12-077

lamp lights up (drop in oil pressure) .............................................................

...............................

............................ Water temperature becomes too high (overheating) ................................................... Abnormal noise is made
Vibration is excessive ......................................................

POINTS TO REMEMBER WHEN TROUBLESHOOTING


Troubleshooting failure When carry carrying out the means out locating the basic cause of the failure, important method and carrying out swift the repairs, structure and ensuring and function. the that the But to problems

does not occur again. troubleshooting, as a guide the it is of course a quick in locating simply to understand is to carry out troubleshooting effectively, troubleshooting using

mentioned 1. Do not

by the operator disassemble is a failure

the cause 4. Confirming Check yourself problem chine. * When the the failure degree of the problem or operation machine that not the and make to judge of the for maa failure, or if there is some bejust

machine

cause there If the

if it is really

machine

is disassembled

immediately places

in the handling driving the does

because there is a fuilure: . Unrelated or unnecessary assembled . It becomes failure This means and money that there difficult

are also disof the of time 5.

re-enacting or the failure

failure,

be sure

investigation

to locate is not only parts,

the cause a waste

measurement worse.

on replacement

oil, and grease, of the out

Troubleshooting Narrow results Items * down 2 the causes of the failure and checks from the flow of the questions 4, then follow in the above

but this action For this starting order. 2. Questions ready reason

will also lose the confidence also, based it is important following

user and operator. to carry troubleshooting on full investigation before

the troubleshooting

chart to locate the failure. Basic procedure 1) 2) Start from investigate for troubleshooting places. places. the most probable related parts also. Start from the simple

and troubleshooting

the correct

to ask the user and operator other happen suddenly, been when than before or poor those al6. unusual occur the faihad the reported?

3)

1) Are there any problems 8 2) Did anything


lure occurred? 3) Did the failure of the condition the failure 4) 51 6) 3. What were curred? Had any repairs lure occurred? Had any similar failure machine

Basic action the failure cur again. To prevent the failure

to remedy

cause of failure if the root cause of the same failure to investigate remove the will OCwhy root

Even if the failure

is repaired,

z z

is not repaired,

before oc-

this, it is necessary occurred, and to

occurred? the conditions the failure

cause of the failure.

been carried

ot before before?

the fai-

occurred

Checks before troubleshooting

1) Check the oil level. 4 Check for any external


piping 3) 4) Other out and hydraulic maintenance Check the travel visually,

leakage equipment.

of oil from levers. check that

the

of the control items out any

can also be carried is

so carry necessary.

considered

12-055 @

METHOD OF USING TROUBLESHOOTING


This sections: ooting. pinpoint from without Next, are used the troubleshooting questions, The questions failure chart check is divided items, and items simple direct into three troubleshare used to inspection inspection causes to

CHART

and check causes or tools. or

high probability

that can be located

symptoms tools high

using troubleshooting troubleshooting to check the

probability

make final confirmation. [Questions] Sections sponds obtained items depending [Check items] The serviceman down carries out simple The down has that items the inspection under causes from to narrow The the causes. narrows that results he of 0 @ in from the @ + to that the can from @ in the chart items the be where The obtained user. on the right correanswers items from in the can @ be are user,

on the users level.

the chart on the right correspond serviceman @ information

to this. obtained

user and the rroubleshooting] Troubleshooting probability, been from marked

he has obtained

from his own inspection. is carried with gained as having out the the from in the causes highest order that of

starting

have and

probability

information

[Questions]

[Check items].

12-056 8

The Items

basic method

of using the troubleshooting and [Check items a high and chart items]

chart

is as

follows. listed for [Questions] with causes the Cause that have that have a with are 0, and marked turn, the has relationship of these, with 0. Check and the problem each of the [Questions] The vertical [Check for item&in where that marked highest the 0 or 0 in the number of points items (Causes) probable are marked probability

appeared.

column

is the most

cause,

so start troubleshooting mation of the cause.

for that item recent repair user, use

to make

final confir[QuesCause locating the for

%1. For [Confirm


tions] Section, with column

history] and

in the mark the for

2
G
z

1 !
A
the cause causes. when making %2, Use the

ask the to

as reference However, to narrow

of the failure.

do not use this down

calculations Cause

in the

column for long

as reference period)]

[Degree

of use (Operated section calculating the

in the the

[Questions]

as reference.

As a rule, do not locating to deter-

use it when

points for

cause,

but it can be included

if necessary

mine the order for troubleshooting.

%l

Confirm recent repair history Operated forlong period A A A

%2

Degree of use

12-057 0

- Example of troubleshooting
Let have us assume causal that [Clogged with is red]. three air this relationship

when exhaust gas is black


cleaner] problem: is taken [Exhaust to be the cause of black black], exhaust [Power gas. Three symptoms weakgas slowly became slowly became

er], and [Dust indicator If we causes. look from these

symptoms

to

find

the

causes,

we

find

that

there

is a relationship the most probable

with cause.

five

Let us explain

here the method

of using this causal

relationship

to pinpoint

12-058 8

Five causes Step 1 Clarify the relationship in the [Questions] and between [Check the three items] symptoms and

section

the five Cause items in the vertical column.

Step 2 marks where the hori-

Add zontal (1)

up the total of 0

and 0

lines for the three

symptoms

and the vertical 000 and 00 0 0 0

columns for the causes intersect. Clogged air cleaner element: turbocharger head: (3) (4) Clogged, Defective seized injection nozzle: contact of valve, valve seat: (2) Air leakage between

(5) Worn piston ring, cylinder:

Step 3 The calculations this in Step down 2 show air to the that cleaner the closest

relationship Follow 0. The

is with column

[Clogged

element].

troubleshooting item marked so carry should out return

area and carry out the troubleshooting Remedy and the is given exhaust as [Clean], gas color cleaning, _ to normal.

TROUBLESHOOTING
S-l

TABLE

Starting performance is poor (Starting always takes time) General causes why exhaust gas comes out but engine does not start Defective electrical system insufficient supply of fuel Insufficient intake of air Improper selection of fuel (At ambient temperature of -1 OC or below, use ASTM D975 No. 1) .lr Battery charging rate
l l l l

Causes

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/

E
E :

100%
temoerature 2ooc ooc -1 ooc 1.28 1.29 1.30

90% 1.26 1.27 1.28

80% 1.24 1.25 1.26

75% 1.23 1.24. 1.25

70 % 1.22 1.23 1.24

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* The specific gravity should be for the charging rate of 70% or more in the above table. In cold weather the specific gravity must be for the charging rate of at least 75% in the above table.
l

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1 Confirm recent repair history Degree of use Ease of starting z 9 5 ;i; Indicator lamp does not light up Engine oil must be added more frequently Replacement of filters has not been carried out according to operation manual Dust indicator is red Non-specified fuel has been used Type of oil is not used according to operation manual
,

Operated for long period Gradually became worse Starts when warm

3 0 - 0 Q

Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly, and combustion is irregular Blow-by gas is excessive Match marks on fuel injection pump are out of alignment Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) When comoression oressure is measured. it is found to be low When air cleaner element is insDected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged When feed pmp strainer is inspected directly, it is found to be clogged APS combustion portion does not become warm Voltage is 26 30V between alternator terminal B and terminal E
I ,
, /

-6

0 5 -

G - 5 -

Either specific gravity of electrolyte or voltage of battery is low

Some cylinders does not change engine speed when operating on reduced cylinders When check is made using delivery method, injection timing is found to be incorrect When control rack is pushed, it is found to be heavy or does not return (when blind plug at rear of pump is removed, it can be seen that plunger control sleeve does not move)

- - 0 -

1 When fuel cap is inspected directly, it is found to be clogged When overflow valve is inspected, it is found to be stiff, or always stays oper Legend 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

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12-060 @

S-2

Engine

does not start

@ Engine does not turn General causes why engine does not turn
l

Causes

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Internal parts of engine seized Ir If internal parts of the engine are seized, carry out troubleshooting for Engine stops during operations. Failure in power train Defective electrical system

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Confirm recent repair history !? E ._ zi %Degree of use Condition of horn when starting switch is turned ON Operated for long period Horn does not sound Horn sound level is low Rotating speed is slow When starting switch is turned to START, pinion moves out, but Makes grating noise Soon disenaaaes aaain
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Makes rattling noise and does not turn When starting switch is turned to START, pinion does not move out When starting switch is turned to ON, there is no clicking sound Battery terminal is loose When startina switch is turned to ON. linkaae does not move 1 When batterv is checked, batterv electrolvte is found to be low 1 Specific gravity of electrolvte, voltage of batten, is low For the following conditions 1) - 5). turn the starting switch OFF, connect the cord, and carry out troubleshooting at ON 1) When terminal B and terminal C of starting switch are connected, engin starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal C of safety relay are connected, engine starts

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4) When terminal of safety switch and terminal B of starting motor are con netted, engine starts 5) There is no 24V voltage between terminal B and terminal E of battery relav When rina aear is inspected directlv. tooth surface is found to be chiooed Does not move even when engine stop motor linkage is disconnected

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Legena 0: Possible cause (jugding from Questions and Check items) 0: Most orobable causes (iudaina from Questions and Check items) A: Possible causes due to-length-of use (used for a long period) e: Items confirm the cause

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Remedy

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12-061 Go

Engine

turns

but no exhaust injected)

gas comes

out

(Fuel is not being General out causes

why engine turns but no exhaust gas comes -

Causes

Supply of fuel impossible Supply of fuel is extremely Improper Standards selection small in winter) of fuel (particularly

for use of fuel

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Confirm recent repair history Degree of use Operated for long period

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Exhaust gas suddenly (when starting again) stopped coming out z .-o 5S Replacement of filters has not been carried out according to operation manual Fuel tank is found to be empty There is leakage from fuel piping, crushed piping Mud is stuck to fuel tank cap When starting switch is turned ON, linkage does not move When fuel filter is drained, fuel does not come out i Iu When engine is cranked with starting motor, .E 1) No fuel comes out even when fuel filter air bleed plug is_loosened % a, 2) No fuel spurts out even when injection pipe sleeve nut is loosened 5 1 Rust and water are found when fuel is drained Inspect injection pump directly When control rack is pushed, it is found to be heavy or does not return

z iT -

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When feed pump strainer is inspected directly, it is found to be clogged When fuel cap is inspected directly, it is found to be clogged Does not move even when engine stop motor linkage is disconnected Legend 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the-cause

r u $
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LT

12-062 0

Exhaust being

gas comes

out

but

engine

does

not

start

(Fuel

is

injected) causes why exhaust gas comes out but engine does not
Causes

General start

l l l l

Lack of rotating Insufficient Insufficient Improper

force due to defective of air of fuel and oil

electrical

system

supply of fuel intake selection

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on f rrm recent reoair historv Degree of use Suddenly failed to start When engine is cranked, abnormal noise is heard from around cylinder head Engine oil must be added more frequently Non-specified fuel has been used Reolacement of filters has not been carried out according to operation manual Type of oil is not used according to operaton manual Rust is found when fuel is drained Dust indicator is red Indicator lamp does not light up Starting motor cranks engine slowly Mud is stuck to fuel tank cao

Operated for long period

h -

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z
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a -

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When fuel lever is olaced at FULL position, it does not contact stopper When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping When exhaust manifold is touched immediately after starting engine, temperature of some cvlinders is low 1 When fuel filter is drained, no fuel comes out Even when fuel control lever is moved, fuel injection pump lever does not move Remove head cover and inspect directly When control rack is pushed, it is found to be heavy or does not return When compression pressure is measured, it is found to be low When fuel filter. strainer are insoected directlv, they are found to be clogged When feed pumo strainer is inspected directly, it is found to be clogged When air cleaner element is inspected directly, it is found to be clogged APS combustion portion does not become warm even when starting switch is turned HEAT Either specific gravity of electrolyte or voltage of battery is low When feed pump is operated, there is no response or pump is heavy Soeed of some cvlinders does not chancre when operating on reduced cylinders When fuel cap is inspected directly, it is found to be clogged Play, stiffness in fuel control lever linkage

- 0 - - - - Q : -

0 0

i - -

- - - - - -

5 -

5 - 5 -

0 G 5
5

Legend 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

5k

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S-3

Engine does not pick up smoothly (Follow-up


General causes why engine intake of air condition of fuel injection pump does not pick up smoothly

is poor)

l l l l l

Insufficient Improper Defective

lnsuff icient supply of fuel Use of improper fuel

fuel injection

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P 0Fk : _o $
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4 $
9
0 -

Replacement of filters has not been carried out according to operation manual Non-specified fuel has been used Engine oil must be added more frequently I .P 2 r3 Rust and water are found when fuel is drained Dust indicator is red Noise of interference is heard from around turbocharaer Engine pick-up suddenly became poor Color of exhaust gas Blue under light load
Black -.-_..

h 0 0

0 0 - 0 0

Clanging sound is heard from around cylinder head Mud is stuck to fuel tank cao There is leakage from fuel piping C 1 High idling speed under no load is normal, but speed suddenly drops when load is
am-died

0 D ii -

z 0 0 -

.N

There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately after starting engine, temperature oi some cvlinders is low 1 Blow-bv aas is excessive When air cleaner element is inspected directlv. it is found to be clwaed I When fuel filter, strainer are inspected directlv, thev are found to be cloooed When feed pump strainer is inspected directly, it is found to be clogged Some cylinders does not change engine speed when operating on reduced cylinders

-rr-.--

5 -

5 2 : E z -

Inspect feed pump When compression pressure is measured, it is found to be low When turbocharger is rotated bv hand, it is found to be heavy When valve clearance is checked directly, it is found to be outside standard value When fuel cap is inspected directlv, it is found to be clogged When feed pump is operated, operation is too light or too heavy When starting switch is turned ON, there is a clearance between stop lever and stoooer bolt .. When boost compensator diaphragm is inspected it is found to be broken, or pipe is crushed

c -

F -

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. . Legena
0: 8: A: 0: Possible cause (jugding from Questions and Check items) Most probable causes (judging from Questions and Check items) Possible causes due to length of use (used for a long period) Items confirm the cause

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s-4

Engine

stops during

operations

General causes why engine stops during operations


l l l

Internal parts of engine seized Insufficient supply of fuel Overheating + If there is overheating and the engine stops, carry out troubleshooting for overheating. Failure in power train + If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.

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55 e 2
m q Confirm recent repair history Degree of use Operated for long period Abnormal noise was heard and engine stopped suddenly Condition when engine stopped Engine overheated and stopped Ermine stopped slowlv ! There was hunting and engine stopped Fuel gauge lamp lights up Fuel tank is found to be empty Replacement of filters has not been carried out according to operation manual Non-soecified fuel has been used -

2 B
cl

m -

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a

0 -

0 -

h -

0 0 -

s
0 0 0
0 -

0 -

When feed oumo is ooerated. there is no resoonse or it is heaw Mud is stuck to fuel tank cap Engine turns, but stops when transmission control lever is operated

Try to turn by hand using barrmg tool

Rust and water are found when fuel is drained Metal particles are found when oil is drained Remove oil pan and inspect directly

- - - 0 - 0 - - G 5

0 G cu t+
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Remove head cover and inspect directly When gear train is inspected, it does not turn Turns when oumo auxiliarv eauioment is removed When fuel filter, strainer are insoected directlv. thev are found to be cloaaed When feed pump strainer is inspected directlv, it is found to be clogged Inspect feed pump directlv When control rack is pushed, it is found to be heavy or does not return
I

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B

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0

Legend 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

I I

Remedy

0 sE

CT

12-065 0

s-5

Engine
General

does not rotate


causes why engine

smoothly

(hunting)

does not rotate smoothly


Causes

Air in fuel system Defective governor mechanism

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1 Confirm recent repair history

Degree of use

0 Operated for long period 1: ;;;;,:r;;d range

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0 0 -

Occurs even when weed is raised Occurs on slopes

Fuel tank is found to be empty Replacement of filters has not been carried out according to operation manual Rust is found when fuel is drained Leakage from fuel piping

z al C % al 6

When feed pump is operated, 1) No response, light, return is quick 2) No response, light, return is normal Engine speed sometimes changes greatly Sometimes difficult to stop engine Seal on injection pump has come off When covernor lever is moved it is found to be stiff When injection pump is tested, governor is found to be improperly When control rack is pushed, it is found to be heavy or does not return

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When feed pump strainer is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be 1 Check fuel feed pumo LC sgend 0 : Possible cause (jugding from Questions and Check items) Q : Most probable causes (judging from Questions and Check items) A : Possible causes due to length of use (used for a long period) 0: Items confirm the cause

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12-066 0

S-6

Engine
Carry engine General

lacks output

(no power)
to decide (Measure if the cause engine is in the
Causes

out troubleshooting or in the machine.

stall speed)

causes why engine intake of air supply of fuel condition

lacks output
E

l l l

Insufficient Insufficient Improper

E
.E

of fuel injection

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ma
z
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0 Use of improper (if non-specified


l

fuel fuel is used, output drops) and lack of output, carry out

Lack of output due to overheating j, If there is overheating troubleshooting for overheating.

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Confirm recent repair history Dearee of use Power was lost 2 Engine oil must be added more frequently .g 5 2 Replacement Non-specified of filters has not been carried out according to operation fuel has been used manual

Operated for long period Suddenly Gradually

0 _ < -

Dust indicator is red Black Color of exhaust gas Noise of interference Blue under light load is heard from around turbocharger

c -

2 s i 0

s -

Blow-by gas is excessive Engine pickup is poor and combustion v) E m C ._ is irregular

High idling speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately ture of some cylinders is low There is hunting from engine (rotation after starting engine, tempera-

c _ CJ _ _ -

B
6

is irregular)

Clanging sound is heard from around cylinder head High idling speed of engine is low Leakage from fuel piping When injection pipe is held between fingers, there is no pulse, or there are cylinders with a weak pulse When air cleaner element is inspected directly, it is found to be clogged When turbocharger When compression : 5 is rotated by hand, it is found to be heavy pressure is measured, it is found to be low

c c, - 0 - _ - - C -

When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged

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% 3

Some cylinders does not change engine speed when operating on reduced cylinders When control rack is pushed, it is found to be heavy or does not return When valve clearance value is checked directly, it is found to be outside standard

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5
5
2
0

When lever is placed at FULL position, it does not contact stopper When feed pump is operated, operation is too light or too heavy

When fuel cao is insoected directly, it is found to be clogged Legend 0: Possible cause (jugding from Questions and Check Items) Q: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

S-7

Exhaust
General

gas is black (incomplete


causes why exhaust

combustion)

gas is black
Causes

Insufficient Improper Excessive

intake of air condition injection of fuel injection of fuel

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2

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I Dearee of use

Ooerated for lona oeriod

h -

0 z zi- - c
IN on -soecified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low

L\ h - 0

0 -

Seal on injection pump has come off sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakaae of air between turbocharaer and head. loose clamo When turbocharaer is rotated bv hand, it is found to be heaw When air cleaner is inspected directlv. it is found to be clogged When compression pressure is measured, it is found to be low 2 ._ B P B 2 e Some cylinders does not change engine speed when operating on reduced cylinders When check is made using delivery method, injection timing is fount to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value 1 When muffler is removed, exhaust gas color returns to normal

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When control rack is pushed, it is found to be heavy or does not return

Legend 0: Possible cause (jugding from Questions and Check items) @: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

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Oil consumption *
To prevent engine

is excessive
leaking

(or exhaust
up or down, 20 minutes

gas is blue)

oil from

do not run the continuously.

at idling for more than

(Both low and high idling) General causes why oil consumption combustion leakage of oil system of oil is excessive

l l l

Abnormal External Wear

of lubrication

B a
d
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3
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2
-

2 : P
= i %

2
Confirm recent repair history g 2 G 2 u Degree of use Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust gas is blue under light load Amount of blow-by gas Area around engine is dirty with oil There is oil in engine cooling water f = Y 4 5 When exhaust pipe is removed, inside is found to be dirty with oil Inside of turbocharger intake pipe is dirty with oil Oil level in clutch or TORQFLOW transmission damper case rises When oil level is checked with dipstick, it is found to be above H mark Clamps for intake system are loose If engine is run at low idling, oil leaks from joint of turbocharger and exhaust manifold Inside of joint bolt of injection pump and boost compensator pipe is wet with oil When compression pressure is measured, it is found to be low When breather element is inspected, it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage Excessive play of turbocharger shaft Check rear seal directly When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found to be dirty with oil Abncrmally excessive None Operated for long period

3 0 -

c k

I ____A Leyeno 0: Possible cause (jugding from Questions and Check items) Q: Most probable causes (judging from Questions and Check items) A: Possible causes due tolength-of use (used for a long period) 0: Items confirm the cause

I I
L
Remedy

12-069 8

S-9

Oil becomes
General

contaminated

quickly
contaminated wear quickly

causes why oil becomes

Intake of exhaust Clogging Improper Operation Interval

gas due to internal passage

of lubrication combustion oil

Use of improper between

under excessive oil change

load is too long


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6 a
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= 0
-0 (u

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2

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= 0 _

Confirm recent repair history E 2 5 z Degree of use Engine oil must be added more frequently Non-specified fuel has been used Blue under light load Color of exhaust gas Black Abnormally Amount E .= % a, 5 of blow-by gas None excessive Operated for long period

0 -

Oil filter caution lamp stays on even when oil pressure rises When oil filter is inspected, metal particles are found When exhaust pipe is removed, inside is found to be dirty with oil Engine oil temperature rises quickly it is found to be above H mark.

When oil level is checked with dipstic, When compression P .5 2 2 0 z c

pressure is measured,

it is found to be low

0 T YEi - 0 -ii - - - G - - < - -6 LF

2 0 5
T

0 _ -

2 % _ -

When breather element is inspected directly, it is found to be clogged with dirty oil, or hose is broken When oil filter is inspected directly, it is found to be clogged When oil cooler is inspected directly, it is found to be clogged Turbocharger drain tube is clogged shaft

5 :

5 2 0

Excessive play of turbocharger

When safety valve is inspected directly, spring is found to be catching or broken Legend 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

_;; 3
Remedy

-E

c? 1

ii

r
2 <

@z

12-070 0

S-l 0

Fuel consumption
General Leakage Improper Excessive causes of fuel condition injection why

is excessive
fuel consumption is excessive

of fuel of fuel

injection

-ii
0

g t; ._ a
27
x &

r ..5

P m
c

F
x
2

2 P
.2

9 E

2 8 -_
-s g
c m

Ii z

4
5

2 5

.L
.5

2 .P
1 Confirm recent repair history G

6 .z .% .c ? .t
2

E .m I
m 2

s .t(
.% .5 ? .-

d h 0 -

$ h 0 -

2 0 0 -G 5 -

0 Seal on injection pump has come off There is irregular combustion

x 0 -

Match mark on injection pump is misaligned

Enaine oil level rises and smells of diesel fuel Engine low idling speed is high Injection pump test shows that injection amount is too high P .6 2 I = 2 $ Some cylinders does not change engine speed when operating on reduced cylinders When control rack is pushed, it is found to be heavy or does not return When check is made using delivery method, injection timing is found to be incorrect Remove nozzle holder and inspect directly Remove feed pump and inspect directly When engine speed is measured, low idling speed is found to be high Legend 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions andtheck items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

-% -

x-

0 0 - - - -

7 -

-iiT - z - - - - T .k

-G 5 .L

r -

T T TiI iti s i % Et a lx E -

$ r
-

5
3

a -

oz -

12-07 1 @

S-1 1

Oil is in cooling
General Internal Internal

water,

or water

spurts

back, or water

level goes down

causes why oil is in cooling water


Causes

l l

leakage leakage

in lubrication

system

in cooling system

Confirm recent repair history : .Degree of use Increase in oil level Operated for long period Suddenly increased Gradually increased Hard water is being used as cooling water (corrosion resistor valve is closed)

cl 2 c1

/
: C % 0) 5 P .-

Engine oil level has risen, oil is cloudy white Excessive air bubbles inside radiator, water spurts back Hydraulic oil, torque converter, transmission oil is cloudy white When hydraulic oil, torque converter, transmission oil is drained, water comes out Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage Remove cylinder head and inspect directly Remove oil oan and insoect directlv

i;

2 I %
0

Inspect water pump E I_ . Legeno 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

12-072 8

S-1.2

Oil pressure
General lights up Leakage, system
l l l

lamp lights up (drop in oil pressure)


why oil pressure lamp

causes

clogging,

wear

of lubricating

Causes

Defective

oil pressure

control viscosity)

Use of improper Deterioration Standards

oil (improper

% a

of oil due to overheating for engine oil selection

z 0

Li
$ L

.% m

a E .al .g

6 a
T= 0

F ..g
.o
7

AMBIENT TEMPERATURE

z 5
5 = + =
0

a, 9

.o
P .Fi

z .- z
.5

.5

:!

P x 8 E _o
u Confirm recent repair history Degree of use

z h -

0 u -

z P 8

2 e
r)

E 5 D
2 = 0
(u .?

B _c

b E I

5i t

z
E
.y

P _c
8

5
1

2
k =
0

5
m .?

2
0
0 -

Operated for long period

h 0

Replacement of filters has not been carried out according to operation manual Caution lame liahts uo Non-soecified fuel has been used

G
1 Lights up at low idling

I
Condition when oil pressure lamp lights up

Lights up at low. high idling Lights up on slopes Sometimes lights up

Crushed piping, leakage from hydraulic piping (external) Oil level sensor lamo liohts uo When oil level in oil pan is checked, it is found to be low Metal particles are found when oil is drained Metal particles are stuck to oil filter element Oil is cloudy white or smells of diesel oil When oil filter is inspected directly, it is found to be cloooed , Remove oil pan and inspect directly Oil oumo rotation is heavy, there is play There is catching of relief valve, regulator valve, or spring, valve guide is broken When oil level sensor is replaced, oil pressure sensor lam goes out When oil pressure is measured, it is found to be within standard value 1 Check oil cooler ?gend : Possible cause Remedy (jugding from Questions and Check items) I Q: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

0 0 L

0 TT iT

-iii-

z 0 c

G -

3 2 iF - - 0 - - 0 Ti- 0 0 0 - F - C -

.o 2

F
3

m .E

.z
P
01

i :

5
0

$ 0 -

z -. -

E 0
-

0 %-

u
0

ii

2 u

r ii 1
0

z u u

u 4
LT

r -

G 0 -

is- z - - - - - - - - 0 H

0 Ti- - - - - 0 -

0 -

0 2 ,

1,

,-

2 -

a a

m .& 4 2 8 !? 0 LT oz oz
T

r
7
-

4 : oz

12-073 0

S-l

Oil level rises *


If there is oil in the cooling water, carry out

troubleshooting General Water

for Oil

is in cooling

water.

causes why oil level rises in oil (cloudy white) and smells of diesel fuel)

Causes

l l l

Fuel in oil (diluted,

Entry of oil from other component E

5 .-

F
0.

.a % t z
2

z t
2

E .-

% c

$
I

2 2 b
B

2
; P
c .P

P 0
f

z
k E

2
x
m

z 8 4

iz

z
P

z
m Confirm recent repair history Degree of use There is oil in radiator cooling water Exhaust oas is white When enaine is first started, drops of water come from muffler Leave radiator cap open. When engine is run at idling, an abnormal number of bubbles appear, or water spurts back Water pump breather hole is clogged with mud When water pump breather hole is cleaned, water comes out Oil level does down in TORQFLOW transmission. or damoer case Oil level does down in hvdraulic tank Enaine oil smells of diesel fuel Fuel is added more frequently Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage When compression pressure is measured, it is found to be low Remove water oumo and insoect directlv lnsoect rear seal directlv When pump auxiliary equipment is removed, seal is found to be broken Remove nozzle holder and inspect directly Remove injection pump and inspect directly There is improper contact of thermostat seat valve Remove oil q an and insoect directlv Pressure-tiahtness test of after-cooler core shows there is leakage Operated for long period -

&

P P
E d E P -

E t5
a, 9

z
In

F 7 0 .c n

.L
.5 2
m

b $

z
6

5 z
-

m P : ._
2

2 B %

I ._
.2
5

E & _c (u .> H 2 0 G 0 -

.E

F
P P

z
G

4f m

$ h -

G-

0 Q -

h G z .t B 2

4 -

$ ;5 - -

z h 0 5 T ii i?

m -

5 e

0 T

r T

-6 -

27 0 -

I Legend 0: Possible cause (jugding from Questions and Check items) Q: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

Remedy

4
LT

77 $ .;
-

-is 0 -6 z - - - - - - 5
5 T 5

; .i z =

4 z 5 oz if cc

P z t

12-074 8

S-l 4

Water
General

temperature
causes

becomes

too high (overheating)


becomes too high

why water

temperature

l l l l

Lack of cooling wind (deformation, Drop in heat dissipation Defective j, Rise in il temperature efficiency system cooling circulation

damage

of fan)

r
E?

of power train for chassis.

Carry out troubleshooting

c ;

6 6
0

s 4

s P i 5 g
E
0

2
2
E

s
0

2
h ? .-

7 z
2
c

m
L

2 x 8 z
u Confirm recent repair history Deoree of use Condition of overheating
9

_O

v -

Ooerated for lono oeriod Suddenly overheated Alwavs tends to overheat

h h - -

Water temperature

gauge

/ Rises quickly 1 Does not go down from red range

Radiator water level sensor lights up Fan belt whines under sudden load on cooling water hose

Cloudy white oil is floating

Coolino water flows out from overflow

Excessive air bubbles inside radiator, water sourts back Engine oil level has risen, oil is cloudv white Radiator shroud, inside of underguard are clogged with dirt or mud

When light bulb is held behind radiator, no light passes through Water is leaking because of cracks in hose or loose clamps Belt tension is found to be slack enters red ranae before enaine water temperature

Power train oil temoerature Temoerature Temperature difference difference

between top and bottom radiator tanks is excessive between top and bottom ratiator tanks is too small water filler port, the core is found to be cloggel it does not open at the crack

0 _ _ ii iTI_ - - 0 _ _ _ G - 5 _ - - - - _ _ .k L_

2 _ _ G _ _ _ _ 0 -

Y 0 6 _ -

When radiator is inspected through When a function ing temperature

test is carried out on the thermostat,

When water temoerature

is measured. it is found to be normal

When oil cooler is insoected directlv. it is found to be cloaaed When measurement low When compression is made with radiator cap tester, set pressure is found to be pressure is measured, it is found to be low

z _ 5 -

Remove oil pan and inspect directly Pressure-tightness test of cylinder head shows there is leakage Remedy

Legend 0: Possible cause (jugding from Questions and Check items) Q: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: items confirm the cause

m 8
L

u P
DC

a, ii
cc

12-075 @

S-l 5

Abnormal + Judge
noise.

noise is made
if the noise is an internal noise or an external
Causes

General

causes why abnormal due to defective combustion noise in from intake

noise is made parts

Abnormality Abnormal Air sucked

system

% i
5
a

z
u 5

: . / :
: j
2

_c ti

5 .- E t; 2 .2
.5

x?
_a

0
E k : f 8

P
.!

s ,_ t; .L
.E
m .?

.c

i : ,
1 Confirm recent reoair historv Dearee of use

$ g
9
0 -

I 0 aerated

for lona period

.g

Condition of abnormal noise Non-specified fuel has been used Engine oil must be added more frequently Color of exhaust gas Metal particles are found in oil filter Slow-by gas is excessive

1 Graduallv occurred 1 Suddenly occurred

( ) ) ( ) ) 4

$ -

j -

Blue under light load Slack

Noise of interference is heard from around turbocharger

E
.= P 6
(Y

Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately aftr starting engine, temperature of some cylinders is low Seal on injection pump has come off Abnormal noise is loud when accelerating engine 1 Clanging sound is heard from around cylinder head Leakage of air between turbocharger and cylinder head Vibrating noise is heard from around muffler 1 When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy Remove gear cover and inspect directly, (flywheel housing top cover) Some cylinders does not change engine speed when oeprating on reduced cylinder

0 0 0 0 -

G
5 ,

I I

0 -

2 .B e z B 2 e

When control rack is pushed, it is found to be heavy or does not return Injection pump test shows that injection amount is incorrect Fan is deformed, or belt is loose When valve clearance is checked directly, it is found to be outside standard value Remove cylinder head cover and inspect directly When muffler is removed, abnormal noise disappears Check for leakaae from air comoressor oioina Remove oil pan and inspect

s , ! ; P cc

0 -

0 5 .L

G - G - -

Legend 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

Remedy

u z 4 4 5

s5 oz a

12-076 Go

S-l 6

Vibration *
If there vibration,

is excessive
is abnormal noise together with the
Causes

carry out troubleshooting

for Abno-

rmal noise is made. General causes why vibration parts (abnormal alignment combustion is excessive breakage)

l l l

Defective Improper Abnormal

wear,

AZ

3 8
D

.z a

.s

-iz

a,

EL 4 m

I + .% 8 25

c .P

Confirm recent repair history Degree of use I .o 6 : 0 Condition of vibration Non-specified fuel has been used Operated for long period Suddenly Gradually increased increased

is r 57 bolts, broken cushion

Metal particles are found in oil filter Metal particles are found when oil is drained i S z 8 6 Oil pressure is low at low idling Vibration Vibration occurs at mid-range follows engine speed speed

E 5-

E * ? ._ $

s .; .% .F
0 -

2 -

B z P

53 b 8
E

55-

Exhaust gas is black Seal on injection pump has come off

Remove oil pan and inspect directlv 1 Remove side cover and inspect directlv Cherck directly for worn support pilot, play Inspect

directly for

loose engine mounting

ilu

When radial runout, face runout are measured, they are found to be Remove front cover. and inspect directlv.

Remove head cover and insvect directlv


pump test shows that iniection amount is incorrect

1 Injection

Legeno 0: Possible cause (jugding from Questions and Check items) 0: Most probable causes (judging from Questions and Check items) a: Possible causes due to length of use (used for a long period) 0: Items confirm the cause

r -

r gz :

x s.
Lz

12-077 0

TROUBLESHOOTING TABLE FOR ELECTRONIC GOVERNOR r

T .i t t

P,~_ Indication Item Trouble check method


Iheck time Action take to setta_ biity Green 0 Written data and read data are compared with each other when system is started, and they are different as a result. Signals are not output for a certain time after AD conversion is finished. Target value and actual value are not the same: NE < 150rpm. NE > 150rpm (Imm minimum) Output voltage of rack sensor circuit is out of specified range (Above 4.5V or below 0.5V). Software overrun: NE 2 115% Overspeed Hardware overrun: HE 2 2,300rpm Oil pressure switch is Hi (24V) and NE > 500rpm. ms GOV $LLN 2 settable 0 0

lamps

of Resetting condition
En3ine Iuns -

:onem
lorma -

Red

? Remarks ;ys-

Normal

C/U (RAN)

1
-r
I
I

When power is turned off ant started again, if en, gine is not under condition at left governor is reset. Same as above

C/U (AD converter)

IOOms GOV PULL Not 0 DOWN z;_ (Note I) table 10s Is GOV PULL

Governor servo error

Not @ Alternate c reFast Fast settable

Same as above

IfNE> 150rpm, set to 1 sec. nginf as oubll gain.

Racksensor circuit

Same as above

itop:

Overrun

Software: Same as above Hardware: NE 2 2,lOOrpm

E!Gzg
is output when software overrun is detected. Same as above

Oil pressure drop

6s

GOV pD;tJN

v r settabl

When power is tur ned off and startec again, if engine is not under conditior at left, aovernor is reset. Same as above

Water temperature rise NE sensor No. 1

Water temperature is Hi (24V). Second but first

switch

0.3s

GOVPULL 2 . DOWN ~~~i~

pulse is received one is not.

160 NE s

Re_ a SimultaNormal 0 neous control with setsecond pulse tabe tow tow Normal control (with frrst pulse) Pe;;& @ Alternate C Slow Slow

Reset when inpu signal become: normal.

NE Sensor No. 2

First pulse is received second one is not.

but

420 NE s

Same

as above

Speed control knob (Low idling)

Output voltage of speed control knob is out of specified range (Above 4.8V or below 0.2V). Output, voltage of frequency control knob is out of specified range (Above 4.8V or below 0.2V). Output voltage of droop adjustment is out of specified range (Above4.8V or below 0.2V).
IS

If speed contra lknob > 20% ant 0.2sec, normal.

tuns

ight nginr oublr Only in isochronous operation On& operation.

Frequency control knob

Fix to set median.

Re- 0 settable

@ Fast

Reset when inpu signal become: normal.

Droop adjustment error

IS

Fix to set median.

Re- 0 settable

@ Slow

Same as above

Note I) Note 2)

If a start signal

is input,

all AD data are controlled

normally

in the backup

mode.

(A servo

error

is not detected.) Then, after an interval of 6

Two or more codes are detected in the order seconds, the next pattern is indicated.) 0 : Going off, 0 : Lighting, @ : Slow flashing @ 0 : Alternate flashing, @ @ : Simultaneous GOV PULL DOWN means

of No.

(One pattern

is indicated

for 12 seconds.

Note 3)

(Period: flashing

4 seconds),

: Fast

flashing

(0.5: seconds),

Note 4) Note 5)

to pull back the fuel rack. is saved, and it is not cleared until the memory clear switch is pressed for 0.4 seconds.

The indication

of the lamps

12-078 69

Diagnosis

lamp indication

0 0 0

Lit out Quick flashing (0.25 second) (2 seconds)

@ @ 0

@ Simultaneous a Alternate @ Alternate

flashing

flashing quick flashing

@ Slow flashing

Diagnosis Indication type

lamp indication Green Red I0 0 0 0

Controller

system

Governor

servo system

@I

Rack sensor system

Overrun

1st speed sensor (engine)

@ pump)

2nd speed sensor (Fuel injection

@I

Low idling speed control

dial

Droop changeover

dial

l
0

(3

No indication

Normal

indication

12-079 @

1.

Controller

system

abnormality

5 YES YES 4 Is the rack drags in


Is the resistance value between E the injection cap removed.) pump? (Check with the rack

2. Governor

servo system

abnormality
4 (female1 a and% (female)OlB(female)

YES
r

(female@@

and

NO
ggifi Ower OFF

1&z&yL -

, NO

YES -

value between
~ Is the resistance YES value between and 2

0) and the resistance Z (female)@ and a

* Resistance *
p NO

q(female)@@)

tfamale)@(~j(female) 0) normal? p . Resistance value @(female)O and @

value between ~(female)O~i@) and @!(femalei&S~) 30.5 - 38.55 f2 Resistance value between Q(female) (@I@ 0) and

~(female)@X@:) 0.75 - 22.5 R * Disconnect KI:. Connect E. f.

1
Is the resistance value between a _ tfemale)@(Otfemale) 6)) and @%female) OIL0tfemale)@) normal? . Resistance 9-10.50 value -

@It@) normal?

- Resistance
9-10.5R * Power (Connect OFF * Disconnect

value

* Resistance * - Disconnect

(female)@ ia(female)@ 30.5 - 38.5 R value between zlfemale)@ ~!(female)O(~(female)Ol 0.75 - 22 n Power OFF 8, I.

and

a. &I, 3.)

NO

- Power
w. 0

OFF

NO

* Disconnect
,zl.

Electrical circuit diagram related to 1. and 2. above


Controller

Actuator

Racksensor

TAE00063

12-080 03

Cause

Remedy

Iontroller

abnormality

aulty fuel injection

pump

Replace.

aulty controller

Replace.

aulty harness 3-q-Bandfl)

(between

Replace (Repair the harness.)

aultyfuel

injection

pump

Replace

aulty harness (between g-fl-a,

Repair the harness

aulty fuel injection ump, faulty harness

Replace (Repair the harness)

12-081 03

3.

Rack sensor system

abnormality

YES 4
Is the resistance YES 3 Is the resistance value between I@ (female) 0 and q (female)O0l(female) 01 and the resistance value between q (female@ and @ (femaleK%Dfemale) normal? _ * Resistance (female)@
I

5 YES _ Is the rack drags in


the injection cap removed.) pump? (Check with the rack

value between n Ifemale@%@ and B (female)@@) . and the resistance value between m -

Power

0~

NO

YES -

Ifemale)@@) and B (female@%@J) normal? ~ NO Resistance value between ~3(female@X@

2 _

0)

30.5 - 38.55 R * Resistance value between acfemale) ~(female)@(@) 0.75 - 22.5 .C

q(female)@(@,)
0.

and and

@@I

q(female)a

NO and q (~(female)@) 30.5 - 38.5 L2 m(female)@ 0.75 - 22 R and

value

* Disconnect

Connect

!B. RI.

Is the resistance value between B ~female)OKWemale) 0) and m(femalei O(O(female@I) normal? * Resistance 9-10.5R value

* Resistance

value

. Resistance value between ~(female)Ot~_(female)O) - Power OFF -Disconnect G, LG. NO

9 - 10.5 n * Power OFF * Disconnect q I. (Connect @iI,3)

* Power

OFF . Disconnect %I,0 ,z.

NO

Electrical circuit diagram related to 3. above


Controller

Actuator

Rack

sensor

TAE00063

12-082 @

Cause

Remedy

Faulty fuel injection

pump

Replace.

Faulty controller

Replace.

_ Faulty harness q -_-mandg)

(between

Replace (Repair the harness.)

Faulty fuel injection

pump

Replace

Faulty harness (between El-O-B

Repair the harness

Faulty fuel injection pump, faulty harness

Replace (Repair the harness)

12-083 @

4.

Overrun

abnormality

I
1

Cause

Remedy

YES

The probable cause is located outside of the ekctronical governorsystem.

FHW/ _ (Overrun) - Power OFF * Disconnect @. NO Faulty fuel injection pump, faulty harness Replace, or repair the harness.

Electrical

circuit

diagram

related

to 4. above

El
Actuator [ = @)

El@

m
,A

rI !

@-------a m

1
I I

II

TAE00063

12-084 da

5.

1st speed

sensor

abnormality

Cause

Remedy

2 YES Is the resistance YES value between 1 r @(female)@ and a22.1 -2.5 kQ? * Power OFF . Disconnect a. - Connect 3. NO NO

Faulty controller

!eolace.

Is the resistance value between q _ (male)@ and E ~male~Z.l -2.5 I&? (Engine)

Faulty harness (between zl-7-B)

iepair or eplace.

- Power OFF * Disconnect 51.


sensor abnormality

W Faulty 1st speed sensor

leplace

6.

2nd

speed

2 YES Faulty controller Ieplace

value between 0

Faulty harness (between a-7J-a)

epair or splace

. Power OFF * Disconnect 3.

-aulty 2nd speed sensor

eplace

Electrical

circuit

diagram

related

to 5. and 6. above

Controller

2nd speed sensor

1st speed sensor

TAE00064

12-085 43

7. Low idling

speed

control

dial

abnormality

Cause

Remedy

2 YES Is the resistance YES value between 0 (female@ and q 1 (femaleY@ normal?

Controller

abnormality

Replace.

@-

Is the resistance NO . The resistance value between 0 value changes between approx. 0.5 - 5.5 kR. (female@ and u . Power OFF (female@ normal? p * Disconnect a. * The resistance -Turn the low idling speed control dial. value changes between approx. O.F-05.5 kR. . Power OFF * Disconnect a. -Turn the low idling speed control dial.

Faulty harness (between B@ and low idling speed control dial) Faulty low idling speed control dial orfaulty harness (between a@ and low idling speed control dial)

Repair the harness.

Replace or repair the harness.

Electrical

circuit diagram

related

to 7. above

Controller

Droop

control

dial

Low idling

speed control

dial +--

TAE00065

12-086 @

8. Droop control

dial abnormality

Cause

Remedy

2 YES Is the resistance YES value between 0 (female@ and q 1 (female)@normal?

Controller

abnormality

Replace.

Is the resistance value between q (female@ and B (female@normal?

- The

* The resistance value changes between approx. 0.!?5.5 kR. * Power OFF * Disconnect n. + Turn the droop control dial.

resistance NO value changes between approx. 0.5 - 5.5 kQ. * Power OFF - Disconnect q. -Turn the droop control dial. L

Faulty harness (between and droop control dial)

q@

Repair the harness.

Faultv drooo control dial or faul& harness (between H@ and droop control dial)

Replace or repair the harness.

Electrical circuit diagram related to 8. above

Controller 1

Droop control

dial

Low idling

speed control

dial

TAE00065

12-087 @

a 9.

Diagnosis

lamp fails to make indication

Cause

Remedy

1 p
Is the voltage between atcheck terminal)@ 0 oand generator body and the voltage between 0 and generator ~ body normal?

YES

Controller

abnormality

eplace.

* @I voltage -0 voltage * Power ON

NO +20 - +3OV 0 - c2V

Faulty harness (between a@(@), - g - ACC terminals or between a@ (BJ@)) and battery GND)

epair the arness.

Electrical circuit diagram related to 9. above

co2?d
grounding terminal
TAE00066

12-088 03

10. a.

Normal

indication between low idling speed and rated speed cannot be achieved.

Changeover

Cause

Remedy

1 YES

Controller

abnormality

Replace.

-K$Z?j$and

- Power * At the - At the

NO ON time of low idling speed: 20 - 30V time of rated speed: 0 - 2V

Faulty harness (between low idling speed/rated speed changeover switch - li: - controller)

Repair the harness.

Electrical

circuit

diagram

related

to 10. a. above

TAE00067

12-089 63

b.

Changeover

between

50Hz and 60Hz cannot

be achieved.

1 YES Is the continuity between E3female) @and a (female) @Snormal?

Controller

abnormality

Replace.

o-

- Disconnect -When 50Hz

El. NO is selected: Continuity is observed. -When60Hz is selected: Continuity is not observed.

Faulty harness (between 50160Hz changeover switch and controller)

Repair the harness.

Electrical

circuit diagram

related

to 10. b. above

Controller

C 0
50/60Hz changeover

1Z-090 @

c. *

Starting

failure

(the engine

cranks,

but no exhaust

smoke

is emitted.) outside of the electronical governor system first

Check for causes (such as abnormalities of all.

in the fuel system)

Remedy

YES 1 Is short-circuit observed between - B(female)@ and fl(female)@? - Power OFF * Disconnect a. NO

Faulty injection pump (Faulty harness)

Replace or repair.

00

2 YES Is short-circuit observed between Q(femal& (@03, q and (femaleKQ@)? OFF . Disconnect a.

Faulty harness (between @j-Y-fl)

Repair or replace.

- Power

NO

Faulty controller

Replace.

Electrical

circuit

diagram

related

to 10. c. above

qr Actuator [$r

El

Controller

0
1

Racksensor

34

@-----___

12-091 03

d.

Starting

failure

(the engine

fails to start,

although

but exhaust

smoke

is emitted.)

Cause

Remedy

YES 1

Faulty injection pump (Faulty harness)

Replace or repair.

YES 2

. Disconnect

d.

Isshort-circuit observed between - atfemale)@ NO @:, and q3(femafe) @&a,? - Power OFF * Disconnect
a.

Short-circuit of rack sensor harness between HI and IZ The probable cause is located outside of the electronical governor system. Faulty harness (between starting switch C terminal and 3)

Repair or replace.

3YE Isthe voltage between &Xfemale@$and E - (female)@ normal at NO thetimeof engine start? * 20 - 30Vfbattery voltage) - Disconnect a. * Power ON - Start the engine. Nr

Repair or eeplace.

Electrical

circuit

diagram

related

to 10. d. above

1
Actuator q-

Controller

r
Rack sensor

Controller

Starting switch C terminal

12-092 03

e. *

The engine

stops during governor check

running. system has been designed statuses to stop the engine has been produced. in any of the following cases. If the

This electronical engine 1. 2. 3. stops,

if any of the following stop switch is pressed.

The emergency The engine water The oil pressure

temperature is abnormal.

is abnormal.

1Z-093 @

11. Memory clear cannot is made by diagnosis


* * To execute cannot longer, If memory memory clear

be achieved lamp).
keep

by pressing

the memory

clear switch

(when

failure

indication

clear, when

pressing even

the

memory switch

clear

switch clear

for

5 seconds was kept

or longer. pressed for

(Memory

clear or

be achieved implement

the memory be achieved

clear

is pressed memory

momentarily.) switch 5 seconds

cannot

if the below.

the diagnosis

indicated

Cause

Remedy

1 YES

Ll
- Disconnect - Power OFF
-When -When

Faulty controller

If the continuity between Zl(female) aand@ normal? X3 NO clear switch is ON: Continuity clear switch is OFF: Continuity is observed. is not observed. -

Replace.

Faulty memory clear switch or faulty harness (between memory clear switch and controller)

Replace the switch or repair the harness.

memory memory

Electrical circuit diagram related to 11. above

Memory

clear switch

Controller

TAE00070

1Z-094 @

ENGINE
13 DISASSEMBLY
AND ASSEMBLY

.13-002 DISASSEMBLY ................................................ .13-019 Washing ...................................................... Washing cylinder block ............................. .13-019 Washing crankshaft ................................... .13-020 .13-021 Measuring parts ......................................... .13-027 ASSEMBLY ......................................................

The explanation for disassembly and assembly of the engine given in this section describes the procedure for the SA6D170-1 engine when using the repair stand. If a different engine or engine repair stand is used, or if the engine is not equipped with an aftercooler, the procedure may be different in places, but the operation is basically the same.

13-001 0

Special tools No. A Al

Part No.

Part Name Engine repair stand


l

I QW
1 1

790-501-2000 790-901-I 170

Repair stand bracket

B 1 790-476-1140 C 1 795-601-I

1 Lifting tool

I I

110 1 Push tool

1
795-100-I 191 Piston ring tool 1 Liner puller G 1 795-102-1300

Preparatory

work

1.

Washing l Before disassembling parts for any cracks of whole engine carefully disassembly work can

the engine, check all damage, then clean the with steam so that the be carried out swiftly.

1
remove starting motor assembly (I), alternator assembly (2), and electric wiring. 2) Cover all the openings of the engine with tape. 3) Using a washing machine, clean engine.

6162F669

1) Before washing,

2.

Setting engine stand l Prepare a stable engine stand that will prevent the engine from falling over, then set the engine assembly on the stand and secure it in position. Engin oil Drain engine oil.

3.

. A
Engine oil: Approx. 41a

II
13-002 0

-6162F671

1.

Water pump assembly I) Remove water tube (1). 2) Remove plate, then remove water tube (2). 3) Remove water pump assembly (3). *After removing the water pump, remove the drive shaft.

2.

Turbocharger drain tube Disconnect drain tube (I).

3.

Oil cooler 1) Remove water tube (I). 2) Remove oil cooler (2).

4.

Placing engine on the stand 1) Install bracket Al for the engine repair stand A using the threads for the oil cooler. 2) Raise engine assembly (I) and set it to the engine repair stand A. * Tighten the bolts on the engine repair stand securely.

5.

Air cleaner Remove air cleaner (1).

6.

Intake connector Remove bracket (I) and intake connector (2).

7.

Connector pipe 1) Remove boost compensator tube (I). 2) Remove plate, then remove connector (2).

pipe

8.

Fuel filter I) Disconnect fuel hose for APS. 2) Disconnect fuel hoses and remove fuel filter.

9.

After-cooler tube, lubrication tube 1) Disconnect after-cooler tube. 2) Disconnect turbocharger lubrication tube.

10. Fuel injection tube Remove clamp, and tube (I).

disconnect

fuel

injection

13-004 0

11. Oil filter Remove oil filter (I), then remove bracket. 12. Oil filler, oil level gauge 1) Remove oil filler (2). 2) Remove oil level gauge (3).

""'J

"I.) ._a

6162F680

13. Tension spring, tension pulley I) Loosen locknut (I), loosen bolt (2) to allow spring to expand, then remove tension spring (3).

Be careful not to get your fingers caught in the bracket.

2) Remove tension pulley assembly (4) and bracket as one unit. l Disassemble tension pulley assembly. i) Remove snap ring (51, then remove cover (6). ii) Remove lock plate (7). then remove holder (8). iii)Remove pulley assembly (9) from shaft. iv)Remove bearing (10). then remove snap ring (II), and take out spacer (12) and bearing (13). v) Remove oil seal (15) from pulley (14). vi)Remove plate (161, then remove seal (17), bearing (18), inner race (191, and seal (20).

22

6162F682

13-005 0

14. Corrosion resistor Using filter wrench, (1,.

remove

corrosion

resistors

15. Thermostat housing Remove thermostat housing (I). l Disassembly thermostat housing.

6162F685

i) Remove outlet pipe (2) and cover (3). ii) Remove thermostat (4). iii) Remove thermostat seal (5) from husing (6).

16. Turbocharger, exhaust manifold assembly 1) Sling turbocharger and exhaust manifold assembly (11, remove mounting bolts. 2) Remove turbocharger and exhaust manifold.

..

..

_ __

-.

17. Aftercooler, intake manifold assembly 1) Sling aftercooler and intake manifold assembly (I), remove mounting bolts. 2) Remove aftercooler and intake manifold assem bly.

Disassembly aftercooler and intake manifold. Remove joint (2) and connector (3). i) ii) Remove cover (4). iii) Remove core assembly (5) from intake manifold (6).

6162F689

13-007 0

18. Fuel injection pump assembly 1) Remove lubrication tube .between injection pump and cylinder block. 2) Screw lifting tool B into delivery valve thread, and sling assembly. 3) Pull out fuel injection pump assembly (1) to rear and remove. Fuel injection pump assembly. SAGDI 70 : 48 kg S6D170 : 30 kg
6162F690

19. Spill tube, head cover 1) Disconnect spill tube (I). 2) Disconnect turbocharger lubrication tube (2). 3) Disconnect connection (3) and remove head cover (4). * Screw forcing screws (Thread dia. = 14 mm, Pitch = 1.5 mm) into the places marked., and remove the head cover. * After removing the head cover, remove the nozzle seal from the head cover.

h_j
0
0
6162F693

20.

Rocker arm Remove rocker arm (1). *To prevent pressure on the push rod when installing, loosen the locknut and turn the adjustment screw (2) back 2 to 3 turns before removing the rocker arm assembly.

13-008 0

Disassemble rocker arm assembly. i) Remove locknut (1). then remove adjustment screw (2) from rocker arm (3). ii) Using push tool, remove bushing (4).

6162F695

6162F696

21. Crosshead Remove crosshead (1). 22. Push rod Remove push rod (2).

23. Injection nozzle holder Remove mounting bolts (I), then remove tion nozzle holder assembly (2).

injec-

24. Rocker arm housing I) Remove snap ring (I), then using push tool C, remove water manifold (2).

c-2 0
6162F699

2
6162F700

13-009 0

2) Remove rocker arm housing (3). 25. Cylinder head assembly Using eyebolt @ (Dia. = 12 mm, Pitch = 1.75 mm), remove cylinder head assembly (2). Cylinder head: 40 kg

-+y

6162F701

11

6162F702

Disassembly the cylinder head i) Using spring pusher D, compress spring, then remove valve cotter (3). ii) Remove retainer (4). iii) Remove outer spring (5). inner spring and valve lower seat.

6162F703

6162F70

iv)

Remove exhaust valves (7).

valves

(6) and

intake

6162F70E

26. Crankshaft pulley 1) Remove mechanical pump tubes (I). 2) Remove crankshaft pulley (2). * If an impact wrench is used to loosen the bolts, there is danger of damage to the thread, so loosen the bolts with a hand tool.

F6 164026

6162F706

6162F707

27. Vibration damper I) Remove spacer (3). 2) Sling vibration damper (4), then screw in forcing screw @ and remove vibration damper (4). * While tightening the forcing screw, take care not to drop the vibration damper.

28. Front support Lift out front support (I). Front support: See Weight Table

29. Cover Remove cover (2).

z z

2
30. Trunnion Tighten the forcing screw to remove trunnion (I). *When replacing the front seal, remove oil seal. 31. Timer Using tool E, remove timer (3). * Timer (3) is press fitted with a taper, so hit the end face of reamer bar E with a hammer to remove it.

6162F710

6162F711

32. Accessory drive pulley 1) Remove accessory drive pulley (4). 2) Remove pulley (5) for alternator drive. 33. Mechanical pump assembly Remove mechanical pump assembly.

34. Injection pump drive case Remove coupling (I), then pump drive case (2).

remove

injection

35. Cam follower 1) Remove cover (I). 2) Remove cam follower (2).

6162F714

36. Gear case cover Remove gear case cover (I). kg r?z Gear case cover: 48 kg

37. Camshaft assembly Remove mounting bolt from hole in cam gear, then pull out camshaft assembly (I). *When removing the camshaft, rotate it while pulling it out to prevent damage to the cam bushing. 6 kg Camshaft assembly: 32 kg

38. Main idler gear Remove mounting idler gear (2).

bolt (I),

then

remove

main

39. idler gear for water pump gear Remove mounting bolt (31, then gear (4) for water pump. 40. Idler gear for oil pump gear Remove mounting bolt ES), then gear (6) for oil pump.

remove

idler

remove

idler

41. Flywheel Using the sling bolts (thread dia. = 12 mm, pitch = 1.751, lift out flywheel (I). Flywheel: See Weight Table

*If

an impact wrench is used to loosen the bolts, there is danger of damage to the thread, so loosen the bolts with a hand tool.

F6164026

42. PTO drive gear 1) Remove steering pump drive gear (I). 2) Remove the six set bolts, and remove drive gear (2).

PTO

Remove 6 mounting bolts while supporting the PTO drive gear by hand. If the PTO drive gear is not supported, it may fall when the bolts are removed.

Disassemble PTO driving gear as follows: i) Remove bearing retainer (3) and shim (4).

6162F720

ii) iii)

Remove drive gear (5) and bearing (6). Remove bearing (7) from shaft (8).

5
43. Rear seal cover
Remove rear seal cover (I).

6162F721

t1

6162F722

44. Oil pan 1) iurn over repair stand to set oil pan at top. 2) Remove oil pan (I).

45. Oil strainer Remove bracket, then remove oil strainer (I). 46. Oil pump assembly 1) Remove tube (2). 2) Remove oil pump assembly (3).

6162F725

47. Gear case Remove gear case (I). Gear case: 30 kg

48. Flywheel housing Lift out flywheel housing assembly (1). Flywheel housing: 95 kg

6162F727

49. Piston cooling nozzle Remove piston cooling nozzle (I). *To avoid hitting the piston, rotate 90 to remove.

6162F729

50. Piston and connecting rod assembly I) Using dial gauge 0, measure connecting rod side clearance to act as a guide when assembling. l Check the stamped number on the connecting rod cap. i) The cap number and cylinder number must match. ii) The number is stamped on the cam side. * If there is no stamped mark, mark the cylinder No. with an electric pen before removing. Do not stamp a mark. 2) Rotate the crankshaft so that the piston to be removed is at bottom dead center. 3) Loosen connecting rod bolt 5 - 6 turns. * If an impact wrench is used to loosen the bolts, there is danger of damage to the thread, so loosen the bolts with a hand tool.

F6164026

4) Tap head of connecting rod bolt with a plastic hammer, then disassemble connecting rod cap and connecting rod. 5) Remove carbon from top wall of liner with fine sandpaper. 6) Rotate crankshaft, and align with top dead center, then remove connecting rod cap (2). 7) Push in piston and connecting rod from oil pan end.

8) Support piston at cylinder head end, and remove piston and connecting rod assembly. * Be careful not to damage the inside surface of the liner with the corner of the connecting rod when removing it. 9) Remove other piston and connecting rods in the same way. * Keep in a safe place and be careful not to damage the piston sliding surface and the bearing. * Assemble the connecting rod and cap temporarily and keep together with the bearing to prevent mistakes when reassembling. l Disassemble the piston and connecting rod assembly. i) Remove snap ring (4). ii) Support connecting rod (5) with hand, then pull out piston pin (61, and disassemble piston (7) and connecting rod. * If the piston pin is stiff and cannot be removed, heat it in hot water (IOOT [212Fl, 5 min.) before removing it.

iii) Remove snap ring on the opposite side. iv) Using piston ring tool F, remove piston ring (8). VI Remove oil ring expander (9). * Keep the piston, connecting rod, connecting rod bearing, piston ring, and piston pin in sets for each cylinder.

51. Crankshaft 1) Before removing the crankshaft, using dial gauge @ to measure end play of crankshaft, and use it as a guide when assembling. 2) Measure starting torque of crankshaft and use as a guide when assembling.

3) Remove mounting bolts (2) of main cap (I). 4) Insert bolt in hole of main cap, and move the main cap from side to side to remove it. *Thrust bearing is installed to the No. 6 cap, so after removing it, mark the assembly position.

5) Using nylon sling, lift off crankshaft (3). 6 kg Crankshaft assembly: 260 kg

6) Remove upper main bearing.

6162F740

55. Cylinder liner * Before removing cylinder liner, using dial indicator @ to measure protrusion of cylinder liner.

Using liner puller G, pull out cylinder liner (1).

WASHING
l

When washing, divide the parts into small parts and large parts, and wash the small parts in a bath like the one shown on the right. * Before washing disassembled parts, the gasket carbon with a wire brush. remove

*After washing, dry the washing fluid off completely with compressed air. (Be particularly careful that there is no washing fluid remaining in the bolt holes.)
6162F743

WASHING CYLINDER BLOCK


1)
Before washing the cylinder block, remove plugs from the oil line and cooling systems. the

2)

Use a washing machine such as shown on the right, and use the nozzle of a jet cleaner to wash the oil line and cooling systems thoroughly. Clean with a stiff wire brush to prevent any metal particles from remaining in the oil line. Use sandpaper to polish the O-ring contact surface smooth at the bottom of the liner bore and to remove the burrs and flashes from the liner bore. Dry off the cleaning fluid completely with compressed air. l Be particularity careful not to leave any cleaning fluid in the bolt holes. completely press fit the plugs in the oil line and cooling systems. Outside diameter of plug: Thread tightener

s Z Z

3)

4)

6162F744

5)

6)

(LT-2)

WASHING
l

CRANKSHAFT

If the engine is disassembled, wash the crankshaft before inspecting. 1) Clean the crankshaft with a steam cleaner, then use a wire brush like the one shown in the diagram on the right to clean all the oil holes. 2) After washing, dry the cleaning fluid off thoroughly with compressed air. 3) Use a small magnet to completely remove all the metal particles from the oil holes.

6162F74f

6162F747

3-k20

Before reassembling disassembled parts, check visually that there are no cracks, damage, or abnormal wear. If no abnormalities are found during the visual inspection, use an accurate measuring device to measure the specified position precisely. Action and judgement on whether the parts can be reused shall be in accordance with the maintenance standard.

2 ZY z

MEASURING CURVATURE OF CRANKSHAFT 1) Support the center of both ends of the crankshaft with lathes, put the indicator of the dial gauge perpendicularly in contact with the journal at the center, and set it to 0. 2) Rotate the crankshaft one turn, and measure the difference between the maximum reading and minimum readig of the dial gauge. * Do not measure with both ends of the crankshaft supported on V blocks. This method produces an error because of the eccentric wear of the journal.

MEASURING OUTSIDE DIAMETER OF JOURNAL 1) Using a micrometer, measure the outside diameter of the main journal and pin journal in the X and Y directions.

Pin journal (measure at 5 places) J

Main journal (measure at 3 places)

F6164143

13-021 0

MEASURING DEPTH OF CYLINDER LINER COUNTERBORE 1) Set depth gauge @ on gauge block 0, then set the gauge indicator to 0. 2) Set the gauge block parallel with the top surface of the cylinder block, and measure the depth of the counterbore. * Clean the counterbore and top surface of the cylinder block before measuring.

MEASURING MAIN BEARING BORE 1) Install the main bearing cap to the cylinder block, and tighten to the specified torque. 2) Using a dial bore gauge or inside micrometer, measure the main bearing bore. * When measuring the bore, measure in two directions (X and Y).

6162F757

MEASURING CURVATURE OF CAMSHAFT I) Support the center of both ends of the camshaft with lathes, put the indicator of the dial gauge perpendicularly in contact with the journal at the center, and set it to 0. 2) Rotate the camshaft one turn, and measure the difference between the maximum reading and minimum reading of the dial gauge. * Do not measure with both ends of the camshaft supported on V blocks. This method produces an error because of the eccentric wear of the journal.

6162F753

MEASURING OUTSIDE DIAMETER OF JOURNAL I) Using a micrometer, measure the outside diameter of the journal.

6162F754

MEASURING HEIGHT OF CAM 1) Using a micrometer, measure the intake and exhaust.

cam height H for

6162F755

13-023 0

MEASURING Special tool No. A

PISTON RING GROOVE

Part No. 795-901-I 120

Part Name Wear aauae

Q' W
1

Measuring keystone ring groove 1) Push piston ring wear gauge A lightly into the ring grooves of the top ring and second ring, and measure the wear of the ring groove. l If the shoulder of the wear gauge contacts the piston, replace the piston. *Carry out the measurement at several places.
Wear gauge

6162F756

Wear gauge

Measuring straight ring groove 1) Assemble a new ring in the oil ring groove, and measure the clearance at the top and bottom with a feeler gauge. * If the clearance is greater than the permissible limit, replace the piston.

!I-Good

Ill-Nogood
6162F757

MEASURING PISTON RING END GAP 1) Assemble the piston ring to the cylinder liner, push the piston ring into the area of the cylinder where there is least wear, then measure the piston ring end gap with a feeler gauge. * Insert the piston ring so that it is at right angles to the sliding portion of the liner.

13-024 0

Tighten the mounting bolts of the connecting rod cap to the specified torque. * Do not assemble the connecting rod bearing. Assemble a new piston pin in the hole at the small end of the connecting rod. * Coat the piston pin with grease (G2-LI) before installing. Support both ends of the piston pin on V blocks, and support both ends of the connecting rod on square blocks. Measure distance A between the big end and small end with a height gauge. Measure the inside diameter of the big end and small end. Calculate the value for the length B of the connecting rod as follows. Connecting = rod dimension B +A

F6164154

ID of big end + ID of small end 2


Measurement

1L.n

F6164

13-025 0

MEASURING CURVATURE, TWISTING OF CONNECTING ROD l Method for measuring curvature 1) Tighten the mounting bolts of the connecting rod cap to the specified torque. * Do not assemble the connecting rod bearing. 2) Assemble a new piston pin in the hole at the small end of the connecting rod, place V blocks on a flat surface, then set both end of the piston pin on the V block. * Coat the piston pin with grease (G2-LI) before installing. Stand the connecting rod perpendicularly, and 31 support both sides of the big end with square blocks. 4) Set the indicator of height gauge u at the front of the hole at the big end, set it in contact with the bottom, then set the gauge to 0. 5) Move the height gauge to the opposite side by a distance equal to the width of the big end, and read the measurement of the gauge.

F6164156

F6164157

Method of measuring twisting 1) From the condition described above, remove the square blocks, lay the connecting rod down, and support the big end on the tip of a conical jack. 2) Measure the big end in the same way as when measuring the curvature. l Calculate the value for the curvature and twisting as follows. Curvature, twising Dimension B x Actual measured value = Dimension A

\
Measurement nf iwistino F61 641 56

Measurement nf CIIrvlltllrl-?

13-026

ASSEMBLY
TIGHTENING BOLTS BY PLASTIC RANGE TURNING ANGLE METHOD The important bolts on the 170 Series engine use the plastic range turning angle method for tightening. This method uses special bolts, and by tightening the bolts to the load where the bolt starts to deform permanently (plastic range), it is possible to get an accurate, high tightening force. (Of the methods used for tightening bolts, the method using checking of the torque is the most common, but because of the influence of friction factors, it is difficult to control the tightening force accurately.) The tightening method using the plastic range turning angle method uses the initial tightening torque and the turning angle to tighten the bolts.

(Plastic

range)

Plastic range turning angle method

Torque method (Convertional method)

Elongation of bolt 615OF302-1

Bolts tightened with the plastic range turning angle method on the 170 Series engine. 1) Crankshaft pulley mounting bolts. (Only HD465) 2) Idler gear mounting bolts. 3) Flywheel mounting bolts. (HD465 only) With the plastic range turning angle method, there is a permanent deformation remaining after tightening. Therefore, there is a limit to the number of times that the bolt can be used, so please observe the following. 1) After tightening, make one punch mark. If any bolt has more than 5 punch marks, do not use it again; replace it with a new bolt. 2) When tightening to an angle greater than the specified angle, loosen completely before tightening again. (In this case, make two punch marks.) 3) The target for the tightening angle should be the standard value 2 tolerance.

13-027 0

Special tools No. A A B C D H I J K Part No. 790-501-2000 790-901-I 790-476-I 170 140 Part Name Engine repair stand
l

Qty
1 1 1 1 1 1 1 1 1

Repair stand bracket

Lifting tool Push tool Spring pusher Piston ring tool Liner driver Piston holder Wrench

795-601-1110 795-102-2102 795-100-I 191

795-250-1210 795-225-1700 790-331-I 110

Wash all parts clean, and check that there are no dents, scratches, or casting defects. Check also that all oil or water passages are clear before assembling. Before inserting the cylinder liner, take the following action with the cylinder block.

1) Remove the rust and scale from surfaces @


and @ with sandpaper until the machining surface appears. Polish portions @ and @ with #240 sandpaper so that the R surface is smooth. Polish portions @, @ and @with #240 snadpaper so that they become smooth. If the corner of the@portion is sharp or there are burrs, polish with a scraper or snadpaper. Be sure to finish this surrface particularly smoothly so that it does not scratch the Oring. If surface @ is pitted and rough, and cannot be corrected, replace the cylinder block. If surface @ and portions @ and @ are pitted and rough, finish them smoothly. Inspect the counterbore, and remove any burrs or flashes. If there are any metal particles or dirt on surface 0, the liner will not fit properly in close contact, and this may cause problems such as leakage of water or protrusion of liner. If there is any drooping, corrosion, or pitting left in the counterbore, carry out additional machining.
Counterbore Portion 0

2)
3)

Detail Q

Detail

P 6162F306

4) 5) 6)

13-028 0

1. *
l

Cylinder liner Replace the liner O-ring and clevis seal with new parts immediately before assembling the liner. Method of installing liner O-ring and clevis seal 1) Check the cylinder liner O-ring groove and outside circumference of the liner to confirm that there is no rust or pitting. l If the surface is rough and pitted, it may cause leakage of water, so replace the liner.

2) Coat the liner O-ring and clevis seal with clean


engine oil (SAE #30).

* Oil causes the clevis seal and O-ring swell and


deteriorate, so do not leave them soaking in oil. Use a brush and coat them with a small amount of oil immediately before assembly. 3) Assemble the liner O-ring and clevis seal to the liner as shown in the diagram on the right.

ne propylene

rubber)

ene propylene

rubber)

4) After installing the liner O-ring, check for twisting. If any twisting is found, use a smooth bar (approx. $10) to remove the twisting.

6136F303

* To prevent the clevis it is installed, press cumference so that it *Assemble the clevis side facing down.

seal from twisting when it around the whole cirfits into the seal groove. seal with the chamfered

Push into groove

6136FO29

13-029 0

5) Method of inserting cylinder liner i) Using a cloth, wipe off all the dirt and oil from the contact surface of the liner lip and the cylinder block counterbore. ii) Coat the mating surface of the cylinder block and cylinder liner counterbore with silicon-based gasket sealant (LG-6).

6162F759

*Width

of gasket sealant: o2.0 -

3.0 mm

Top surface of block

Mating portion of liner

Position to coatwith gasket sealant 62 I OF304 (coat the comer of the deck)

Make an overlap of 6 I!Z 6 mm at the beginning and end when coating with gasket sealant LG-6.

Overlap:

61?16mmm

I
.
When machining the bottom contact surface of the counterbore liner lip and using a shim. i) Coat the bottom of the shim thinly with gasket sealant LG-6, then assemble the shim. ii) Next, coat with gasket sealant LG-6 in the same way as when not using a shim.

62 I OF305

1
13-030 0

6162F760

6) Coat the liner O-ring, clevis seal, and cylinder block contact surface with a small amount of engine oil (SAE #30) immediately before press fitting the liner. * Coat the contact surface of the cylinder block uniformly around the whole circumference by hand.

\a

6162F761

7) Insert liner (I) into cylinder block, taking care not to damage O-ring. 8) Use your weight and push the liner in with both hands. jr If the liner does not go in smoothly when you apply your weight, there is danger that the O-ring may be damaged, so check the cylinder block for burrs of flashes.

9) Using a liner driver I, press fit cylinder liner (1) into the cylinder block. * Using the following procedure, squeeze out the gasket sealant coated on the counterbore. i) Tighten the cylinder head temporarily a used head gasket. Mounting bolt: 26 & 1 kgm with

ii)

Remove the cylinder head, and wipe off the gasket sealant that has been squeezed out from between the cylinder liner and cylinder block. If gasket sealant sticks to the grommet in the head gasket, the grommet will change shape and cause leakage of water, so be sure to wipe off all the gasket sealant.

Order for tightening cylinder head mounting bolts

RlG7F7fiA

10)After press fitting cylinder liner, use dial gauge @ to measure protrusion of cylinder liner. *When measuring the protrusion of the liner, hold the liner down with a plate to prevent the liner from coming up on the Oring when measuring. * Protrusion of cylinder liner: 0.07 - 0.15 mm * If it is not within the standard value, take the action given in the maintenance standard.

QJ

6162F765 1

2.

Crankshaft 1) Align protrusion of upper main bearing (1) with notch of cylinder block, then assemble in cylinder block. * Check that there is no dirt at the rear face of the bearing before tightening. Coat the inside surface of the bearing with engine oil (SAE #30). * Do not coat the rear surface of the bearing with oil. * Upper bearing: With oil hole

2) Check for the following before assembling the crankshaft. in the front, rear side i) Abnormality threaded portion (The bolt must go. in smoothly when turned by hand.) ii) Scratches or dents on the pin or main journal portion. iii) Dirt stuck to the inside of the oil hole.

3) Raise crankshaft (2), and assemble to mounting position, taking care not to hit the cylinder block.

4) Move crankshaft to one side, then coat upper thrust bearing (3) with engine oil (SAE #30), and install to No. 6 bearing so that side with oil groove is facing crankshaft end.

5) Align protrusion of lower bearing (4) with notch of main cap and install. * Check that there is no dirt at the rear face of the bearing before tightening. Coat the inside surface of the bearing with engine oil (SAE #30). * Do not coat the rear surface of the bearing with oil. * Lower bearing: No oil hole

6162F769

6162F770

6) For No. 6 main cap, knock in dowel pin so that protrusion from end face of cap is 3.0 - 3.5 mm, then install lower thrust bearing (5) on both sides. * Install the thrust bearing with the side with the groove on the crankshaft side.

I
7) Coat journal surface of crankshaft with engine oil (SAE #30), check that stamped number on main cap (6) matches number on cylinder block, then install main cap. 8) Coat mounting bolt thread and washer of main cap with engine oil (SAE #30), then screw in bolts, and insert main cap completely.

6162F771

F6164030

13-033 0

9) Tighten main cap mounting bolts as follows. *When tightening, start from the center and work in order to the outside. Tighten the bolts to the specified tightening torque using the following steps. w Main cap mounting bolt Unit: kgm Step 1st 2nd 3rd 4th 5th 6th Target 56 113 0 38 75 113 Range 51 to 61 107 to 118 Loosen completely 33 to 43 70 to 80 107 nto 118

10) After tightening main cap bolts, screw bolt into center bolt hole and measure starting torque of crankshaft. l Standard value: Max. 2.8 kgm

11)

Measure end play of crankshaft with dial gauge 0. 0.140 - 0.32 mm l End play: j, If it is within the standard value, take the action given in the maintenance standard.

3.

Piston, connecting rod assembly Assemble piston and connecting rod. i) Fit oil ring expander (I) in oil ring groove. ii) Using piston ring tool H, assemble oil ring, second ring, and top ring in order.

*Set each ring with the stamped mark facing up and install to the piston. * Place the end of the expander coil at 180 to the end gap of the oil ring.
6162F773 6162F774

3-:34

*Assemble diagram.

each piston

ring as shown

in the

lTf

Oil ring

I
iii) Install snap ring (2) on one side. iv) Heat piston (3) at 100C f212Fl for 5 minutes in a heating furnace. * If no heating furnace is available, heat in hot water at 100C [212Fl for 5 minutes. *When heating with hot water, clean the piston completely after setting it in position.

F6 164033

6162F775

6162F776

v)

Coat piston boss with engine oil (SAE #30), set front embossed casting letters on piston facing in same direction as part number casting letters on connecting rod, then insert piston pin (4). vi) Install snap ring (5) on opposite side. * Rotate the left and right snap rings to check that the snap rings are completely fitted into the ring groove.

vii) Align protrusion of connecting rod upper bearing (6) with notch of connecting rod, then install. * Check that there is no dirt at the rear face of the bearing before assembling. * Do not coat the rear surface of the bearing with oil. * Check that the hole in the bearing and the oil hole in the connecting rod are aligned.

13-035 0

viii)Align protrusion of connecting rod lower bearing (7) with notch.of connecting rod cap, then install. * Check that there is no dirt at the rear face of the bearing before assembling. * Do not coat the rear surface of the bearing with oil.
l

Method of inserting piston and connecting rod assembly . 1) Coat cylinder liner with engine oil (SAE #30). * Coat uniformly with engine oil around the whole circumference by hand.

6162F779

2) Rotate crankshaft and set pin journal at top


dead center for cylinder where be inserted. piston is to

3) Set embossed letters on connecting rod facing front of engine (stamped number is on camshaft side), then insert piston and connecting rod assembly into cylinder from head end.

Embossed letters (to face engine front)

Cylinder No. (to match cam) Y 6162F309

4) Align all piston rings as shown in diagram.

*o*.

000

6162F780

3-:36

5) Coat piston (SAE #30).

ring

uniformly

with

engine

oil

6) Tighten piston ring with piston ring holder J, then push in piston head with wooden bar.

7) Using connecting rod pulling tool shown in the diagram on the right, pull connecting rod, and fit it in close contact with crank pin journal. * Check that the connecting rod bearing is correctly in position. * To make a connecting rod pulling tool, weld a bar to an old connecting rod bolt. 8) Coat crankshaft pin journal with engine oil (SAE #30).

Approx. 500 mm

Connecting

rod bolt

Bar

2 z z 9) Rotate crankshaft 180 while pulling connecting rod. 10) Coat connecting rod lower bearing with engine oil (SAE #30), check cap number, then align with dowel pin, and install connecting rod cap (8). * When coating with engine oil, spread the oil with a finger over the whole part. * When assembling a new connecting rod, mark the cylinder number with an electric pen. Do not make a stamped mark.

F6164038

6162F732

Cylinder No.

F616403E

11) Coat thread and washer of connecting bolt with engine oil (SAE #30).

rod

12) Tighten connecting rod bolts in turn until connecting rod cap is in tight contact. f If an impact wrench is used to loosen the bolts, there is danger of damage to the thread, so loosen the bolts with a hand tool.

F6164030

F6164026

13) Rotate crankshaft 180 and repeat Steps I) to 12) to insert pistons in all cylinders.

14) Tighten the connecting

rod bolts as follows.

1st step: Tighten 20 & 1 kgm 2nd step: Using wrench K turn 90+A50 to tighten. l When not using wrench K, tighten as follows. i) 1st step: Tighten 20 k 1 kgm ii) 2nd step: Put a mark on the bolt and cap with a felt pen, then turn the bolt a further 90+h5 * After tightening, make one punch mark on the bolt head. If the bolt head has five punch marks, do not reuse it. Replace the bolt with a new bolt. *After assembling the connecting rod, check that the crankshaft rotates smoothly. ii)

i)

6162F763

After tightening, make punch mark on bolt head to indicate number of times of tightening

6206F303

15) Using dial gauge@, of connecting rod.

measure side clearance

*Standard for side clearance: 0.200 - 0.375 mm * If the connecting rod does not move, remove the connecting rod cap and check that there is no mistake in assembly, and that there are no burrs, or dirt caught anywhere. 4. Piston cooling nozzle Fit O-ring to cooling nozzle (I) and install. & * O-ring: Engine oil (SAE #30)

Before installing, check the curvature (angle) of the nozzle, and check that there is no clogging inside the nozzle. * Face the tip of the nozzle to the side with the mounting hole at the side, insert into the piston, taking care that it does not hit the piston, then turn 90 to install.

5.

Flywheel housing 1) Fit gasket to mounting surface of cylinder block, then using eyebolts (Thread dia. = 16 mm, Pitch = 2.0 mm), raise flywheel housing (I) and install to cylinder block.

Mounting bolt: 1st step: Tighten to 36 - 40 kgm 2nd step: Loosen completely 3rd step: Tighten to 40 - 44 kgm

*Tighten the mounting bolts of the flywheel housing as follows, in the order shown in the diagram. *The bolts are of different lengths, so be careful when installing them. 2) After installing flywheel housing, using dial gauge to measure face runout and radial runout. * l Face runout: Max. 0.20 mm l Radial runout: Max. 0.20 mm 3) Inspect stepped difference between cylinder block and flywheel housing. * Stepped difference at bottom surface: Max. 0.15 mm
6162F307

3-:39

6.

Gear case 1) Fit gasket to mounting surface of gear case. 2) Install gear case (I). Main idler gear Install main idler gear (I). *Assemble with the oil groove of the thrust bearing on the gear side. l Press fit the thrust plate to the shaft. a Coat the bolt thread and seat with engine oil (SEA#30), then tighten.

7.

*When installing the mounting bolts, screw in first at least 2-3 turns by hand, then tighten as fol,lows. (All models) m Idler gear mounting bolt:

(Thread size) x (Pitch)

Tightening

method

M16 x 1.5

30 - 35 kgm (Tighten by torque) 5 2 0.5 kgm 90+i Tighten an additional 31 f 4 kgm

Ml8 x 2.5

Ml8 x 1.5

go + ionTighten an additional

* After tightening, make one punch mark on the bolt head to indicate the number of times that the bolt has been used. If any bolt has four punch marks, do not reuse it. Replace it with a new bolt. *Align carefully with the match marks on the gear when installing.

8.

Camshaft Coat surface of camshaft journal with engine oil (SAE #30) and install camshaft (2). w Camshaft plate: 3.1 4.3 kgm

*When inserting the cam shaft, rotate it while inserting it in order to prevent damage to the cam bushing. *Align carefully with the match marks on the gear when installing.

qJ;

6162F786

9.

Idler gear for oil pump Install idler gear (2) for oil pump. m Idler gear mounting bolt:

(Thread size) x (Pitch) ( Ml6 x 1.5

Tightening method 30 - 35 kgm (Tighten by torque) 5 + 0.5 kgm

Ml8 x 2.5

90+iTighten

an additional

6162F787

31 f 4 kgm Ml8 x 1.5 80+iTighten an additional

Be sure to install the thrust bearing with the oil groove facing in the correct direction. Coat the bolt thread and seat with oil. When installing the mounting bolts, screw in first at least 2 - 3 turns by hand, then tighten fully. After tightening, make one punch mark on the bolt head to indicate the number of times that the bolt has been used. *Align carefully with the match marks on the gear when installing. 10. Idler gear for water pump Install idler gear (I) for water pump. *Align carefully with the match marks on the gear when installing. w Idler gear mounting bolt for water pump: Same as in Item 9 above

11

Injection pump drive case 1) Fit O-ring and install injection case (2). 2) Install coupling (1).

pump

drive

12. Timer Install timer (2) aligning tighten nut (I). m

it with the gear, then

T?mer nut: 147 - 196 Nm (15 - 20 kgm}

It Align the match marks on the timer and the gear surely. *Measure the backlash and end play of each gear with dial gauge 0. * Standard value of backlash and end play:

6162F310

Without a timer Backlash A B C D a b


C

End play 0.460 0.470 0.470 0.500 1 2 3 4 5 0.075 0.10 % 0.145 0.10 0.21 0.32 0.395 0.32

0.140 0.130 0.130 0.100 -

0.095 0.120 0.100 -

0.460 0.425 0.445

6 7 8

0.14 0.10 0.085 -

0.32 0.32 0.125

% End play (3) for machines with a timer (HD465 twin turbo, WA700 only) is 0.09 - 0.45 mm. For other machines the backlash and end play are as in the table above.

13-042 0

13. Gear case cover I) Stick gasket to mounting surface for gear case cover. 2) Install gear case cover (1). * Check the difference in level between the gear case, gear cover, and the bottom face of the cylinder block. * Difference in level of bottom face: Max. 0.15 mm

6162F715

14. Oil pump assembly I) Install oil pump assembly (3). .m Mounting bolt: 11.0 zb 1.5 kgm

2) Fit gasket, O-ring and install tube (2). 15. Oil strainer Fit gasket, then install oil strainer (1) and secure with bracket.

z z z 16. Oil pan * Before installing the oil pan, cut off the gaskets of the flywheel housing, gear case, and gear cover so that they are the same level as the cylinder block. Apply liquid gasket to the face of the oil pan, and install oil pan (1). & * Face of oil pan: Diameter Liquid gasket (LG-7) $1.6 2.0 mm

2
6162~725

of gasket sealant:

6162F724

17. Rear seal cover Fit O-ring and install rear seal cover (1). * Take care that the lip is not rolled up.

18. PTO drive gear * Assemble PTO drive gear as.follows: i) Install bearing (7) to shaft (8). ii) Install the snap ring to gear (5), then install bearing (6). * Coat the bearing portion with engine oil (SAE #30).

6162F722

iii) Install shim (4), then install retainer (3). * Bend the lock plate securely. *Confirm that the gear can rotate smoothly. If not, adjust the thickness of the shim.

6162F720

1) Install PTo drive gear (21, and then tighten six bolts. *After installing PTO drive gear, confirm that there is backlash between it and the PTO gear. * Backlash: 0.15 to 0.52 mm 2) Install steering pump drive gear (I). * Bend the lock plate securely.

lg. Flywheel 1) Using eyebolts (Thread dia. = 12 mm, Pitch = 1.75 mm), raise flywheel (I), mesh train gear and idler gear, then install flywheel and tighten bolts. * For engines with a PTO: When measuring the engine capacity, the inside of the PTO case cannot be lubricated, so remove the PTO drive gear and install the flywheel.

3-:44

2) Coat bolt thread and washer with engine oil (SAE #30) or anti-friction compound (LM-P). 3) Tighten bolts in turn until flywheel is in tight contact. * If an impact wrench is used to loosen the bolts, there is danger of damage to the thread, so loosen the bolts with a hand tool.

F6164030

F6164026

4) Secure flywheel and housing with stopper @), and tighten bolts. * Order of tightening

z
z

2
m Flywheel mounting bolt (HD465):

6162F792

1st step: Tighten to 20 t 2 kgm 2nd step: Tighten to 47 k 2 kgm 3rd step: Make marks on bolt and flywheel with felt pen, then tighten bolt an additional 90 + ZO

Flywheel mounting bolt (machines cept HD465): 1st step: 8 - 12 kg 2nd step: 28 - 32 kgm 3rd step: 53 - 57 kgm

ex-

5) Measure radial runout and face runout of flywheel. * Radial runout and face runout of flywheel

13-045 0

20. Cam follower I) Install cam follower with the pin. D Cam follower

assembly

(2), aligning

it

bolt: 9.2 - 10.6 kgm * Before installing the cam follower, wash the oil hole of the mounting bolt.

mounting

2) Install cover (1). a * Face of.cover: Diameter mm Liquid gasket (LG-7) sealant: $1.6 2.0

of gasket

21. Mechanical pump assembly Fit O-ring to mechanical pump assembly (6), then align with slit at tip of camshaft, and install. 22. Accessory drive pulley I) Fit O-ring and install drive pulley (5) for alternator. 2) Fit O-ring and install accessory drive pulley (4).

23. Trunnion 1) When press fitting front seal, use a tool. * After press fitting, check that the spring has not come out of position. & Lip of oil seal: Grease (G2-LI)

2) Fit O-ring and install trunnion (1). * Before installing the trunnion, clean off all dirt from the outside circumference of the crankshaft, then coat the whole circumference thinly with engine oil (SAE #30). * Take care that the lip is not rolled up. 24. Cover Install cover (2). & * Face of cover: Diameter Liquid gasket (LG-7) $1.6 2.0 mm

6162F794

of gasket sealant:

13-046 0

25. Front support Raise front support portion. &

(I)

and install to trunnion

Front support grease groove: Grease (G2-LI)

26. Vibration damper 1) Sling vibration damper pin, and install. 2) Install spacer (3).

(4), align with dowel

27. Crankshaft pulley 1) Install crankshaft mounting bolts. a

pulley (2) and tighten

with

Coat bolt thread and seat surface with engine oil (SAE #30), then tighten bolts. *When installing the mounting bolts, screw in first at least 2 - 3 turns by hand, then tighten as follows. w Crankshaft pulley mounting bolt:

II

6162F708

(1

6162F709

Unit: kgm Order 1st step 2nd step I HD465 only 40 + 3 78 f 3 Except HD465 7.5 I!I 2

25 f

If an. impact wrench is used to loosen the bolts, there is danger of damage to the thread, so loosen the bolts with a hand tool.

F6164026

F6164030

13-047 0

2) Fit gasket and install mechanical (I).

pump tubes

28. Cylinder head assembly l Assemble cylinder head as follows. i) Align with casting mark on cylinder head and assemble intake valve (7) and exhaust valve (6). & Valve stem: Engine oil (SAE #30) (Inside face of valve guide)

*The intake valve has the mark IN and the exhaust valve has the mark E on the bottom.

6162F705

ii)

Assemble valve blower seat to cylinder head, then assemble inner spring and outer spring (5). *The spring with the unequal pitch (WA600, WD600, WA700, HD465) is assembled with the narrow pitch at the head end. iii) Install retainer (4). iv) Using spring compressor D, compress spring, and fit valve cotter (3) in groove of valve stem.
6162F703 6162F704

Tap valve stem with plastic hammer and check that valve cotter is completely fitted. vi) When nozzle valve has been replaced, install nozzle holder to cylinder head, then use depth gauge to measure protrusion of nozzle. * Protrusion of nozzle: 4.9 - 5.7 mm VI

13-048 0

1) Check that there is no dirt or dust on cylinder head mounting surface or inside cylinder, then install gasket (9). *When installing the gasket, check that grommet (IO) has been properly installed and has not peeled off. There is danger that the head gasket Note: grommet may swell and change shape, so do not coat it with gasket sealant.

II

g
6162F796 I

2) Coat thread of head bolt and washer with antifriction compound (LM-P).

F6164067

3) Using eyebolts @ (Thread dia. = 12 mm, Pitch = 1.75 mm), install cylinder head assembly (2). 4) Screw in head bolts (1) at least 2 - 3 turns by hand, then tighten in order shown in diagram below.

1 do
6162F311

6162F702

1_L!--

6162F797

Cylinder head mounting

bolt:

Unit: kgm

3rd 4th

39 50.5

37.5 to 40.5 49 to 52

3-:49

29. Crosshead Install crosshead (1). a Guide pin: Engine oil (SAE #30)

* Adjust the crosshead as follows. i) Loosen locknut, and turn back adjustment screw. ii) Hold top surface of crosshead screw in adjustment screw. lightly, and

iii) After adjustment screw contacts valve stem, screw in a further 20. iv) Tighten locknut to hold in position. w * Locknut: 4.0 f 0.6 kgm

intake end

Install the crosshead so that the adjustment nut is at the exhaust end.
Exhaust end Adjustment nut F6164068

30. Rocker housing 1) Fit gasket, align tab of grommet with groove in gasket, then install. *The grommet has a top and bottom, so be sure to install it facing the right way up.

Tab

&,

0
F6164069

2) Fit O-ring, then rocker housing. & * O-ring:

insert water

manifold

(3) in

Engine oil (SAE #30)

If the O-ring is coated with engine oil and left for a long time, it will swell, so coat it with oil immediately before assembling it. * Insert the snap ring groove end into the rocker housing.
6162F799

3-iL50

3) Install rocker housing (3). w Mounting bolt: 10 2 0.5 kgm

4) Using push tool C, insert water manifold (2). 5) Secure water manifold with snap ring (1).

31. Injection nozzle assembly *Check that there is no dirt or dust inside the nozzle holder sleeve. (Mask it with a rubber cap.) I) Align line on nozzle body with line on plate, then set with lines facing front of engine, and install injection nozzle assembly (1).

2) When tightening 2 mounting bolts (2). tighten each in turn to a low torque, then gradually increase torque of each bolt in turn (approx. 0.5 kgm each time) to tighten to specified torque. Sr Do not reuse nylock bolts. Always replace them with new parts. w * Mounting bolt: 2.75 & 0.25 kgm the

Keep the difference in torque between two bolts to a maximum of 0.5 kgm.

Push rod Install push rod (I). * Check that the push rod is fitted properly into the socket of the cam follower.

33. Rocker arm assemblv Assemble rocker arm. Using push tool, align oil hole of bushing (4) i) and knock in rocker arm (3). ii) Assemble adjustment (I) to rocker arm. screw (2) and locknut

I
iii) Coat rocker shaft with engine oil (SAE #30), then set so that portion with plug is at exhaust end. iv) Set exhaust rocker arm (long arm) on left and intake rocker arm (short arm) on right, insert collar at center, then insert onto rocker shaft.

L.d
6162F695 6162F696

Intake

1
1) Install rocker arm assembly (I) and tighten mounting bolts. * Check that the ball of adjustment screw (2) is fitted properly into the socket of the push rod before tightening. *Assemble a spacer (length: 15 mm) to the short bolt and a washer to the long bolt. w Mounting bolt: 10 k 0.5 kgm

6162F804

34. Adjusting valve clearance Adjust valve clearance. For details, see TESTING AND ADJUSTING, justing valve clearance.

Ad-

13-052 0

Head cover, spill tube I) Fit gasket, install head cover (41, then tighten bolts temporarily. 2) Install nozzle seal and press fit with push tool. & Nozzle seal surface: Engine oil (SAE #30)

6162F692

3) Tighten head cover mounting shown in diagram. w Mounting bolt: (3).

bolts in order

3.25 & 0.25 kgm

4) Install connection 5) Install turbocharger

lubrication tube (2).

6) Install spill tube (I).

a
5 1

F6166057

36. Fuel injection pump assembly l Laminated coupling type 1) Knock key into drive shaft. 2) Screw lifting tool B into delivery valve thread, raise fuel injection pump assembly (I), then align key groove of pump coupling (2), and connect pump. 3) Tighten drive shaft mounting bolts (3) of coupling. 4) Align lines on coupling and bearing cover of injection pump, then tighten bolt (4). * If the mounting bolts are not tightened uniformly, the pump will be at an angle and will rotate against the drive shaft, and this will result in a change in the injection timing. * If there are no lines marked, or if the injection pump has been replaced, adjust the injection timing. For details, see TESTING AND ADJUSTING.

Key

6162F805

Flange type *When installing the flange type injection pump, align line a on the flange with line b on the injection pump flange. * If there are no lines marked, or if the injection pump has been replaced, adjust the injection timing. For details, see TESTING AND ADJUSTING. 1) Fit gasket, then install lubrication tube between injection pump and cylinder block.

6162F806

37. Aftercooler, intake manifold assembly l Assemble aftercooler and intake manifold assembly. i) Fit gasket, then assemble core assembly (5) to intake manifold (6). ii) Fit gasket, then install cover (4). D Mounting bolt: 3.0 & 0.5 kgm

iii) Fit gasket and O-ring, then align connector (3) and joint (2) with joint of cooler core, and install. a O-ring: Engine oil (SAE #30)

3
6162F689

1) Fit gasket, then install aftercooler manifold assembly (1). w Mounting bolt: 6.5 IfI 1.0 kgm

and intake

13-054 0

38. Turbocharger, exhaust manifold assembly Fit gasket, then install turbocharger and exhaust manifold assembly (1). & Mounting bolt thread: Anti-friction bolt:

compound

(LM-P)

w w

Mounting

11.25 I!I 1.25 kgm

D375A, PCIOOO, WA700, HD465-5 2 bolts (length: 50 mm): 8.5 & 0.5 kgm If the turbocharger has been replaced, the tightening torque for the turbocharger mounting bolts is as follows.
l

D375A-I,2

: 6.0 - 7.5 kgm : 4.5 (Serial No. up to 12867) 5.5 kgm (Serial No. 12868 and up)

WA600-1

: 6.0 -

7.5 kgm (Serial No. up to 12885) : 4.5 - 5.5 kgm (Serial No. 12886 and up)

WA700-1

: 6.0 -

7.5 kgm (Serial No. up to 12871) : 4.5 - 5.5 kgm (Serial No. 12872 and up)

6162F807

6162F686

PCIOOO-1

: 6.0 -

7.5 kgm (Serial No. up to 12887) : 4.5 - 5.5 kgm (Serial No. 12888 and up)

HD465-3, 5 : 10.0 - 12.5 kgm KTR130 (Serial No. upi0 11682) Single turb. - : 8.0 - 9.0 kgm ocharger (Serial No. 11683 and up)

6162F685

39. Thermostat case Assemble thermostat case. i) Using push tool 0, press fit thermostat seal (5) to housing (6). * Be careful that the seal is not at an angle when press fitting. ii) Assemble thermostat (4). iii) Fit gasket, then install cover (3) and outlet pipe (2). Install thermostat case (I

13-055 0

40. Corrosion resistor Install corrosion resistor (I). * Coat the seal and thread with engine oil (SAE #30). * After the seal surface comes into contact with the filter head, tighten a further 2/3 turns.

41. Tension spring, tension pulley l Assemble tension pulley. i) Press fit shaft (21) to bracket (22). ii) Install seal (20) to bracket (23), then assemble inner race (19). bearing (181, and seal (171, and install plate (16). Sr Coat the bearing and seal portion with grease (G2-LI). iii) Install oil seal (15) to pulley (14). iv) Assemble pulley to bracket (231, then assemble bearing (13) and spacer (121, and install snap ring (11). v) Install bearing (IO). vi) Fit holder (8), and tighten lock plate (7) with bolts. * Bend the lock plate securely. vii) Fit cover (61, then secure with snap ring (5).

14-7

23---d&&

:682

1) Insert spacer, then isntall tension pulley assembly (4) and bracket as one unit. 2) Install tension spring (3) and tighten bolt (21, then secure them with locknut (1). * The tension spring will be adjusted according to the tension of the fan belt after the engine assembly is mounted.

42. Oil filler, oil level gauge I) Fit gasket and install oil level gauge (3). 2) Fit gasket and install oil filler (2). 43. Oil filter Fit O-ring and install bracket, then install oil filter (I). * Coat the seal and thread with engine oil (SAE #30). * After the seal surface comes into contract with the filter head, tighten by hand a further 314 1 turn.

Fuel injection tube Install fuel injection tube (I) and secure it with the clamp. D Sleeve nut: 2.25 f 0.25 kgm (both pump and nozzle ends)

45. After-cooler

tube and oil filler tube 1) install lubrication tube for the turbocharger. 2) install O-ring and after-cooler tube, then secure them with the lockbolt.

46. Fuel filter I) Install fuel filters (I). 2) Fit gasket and connect fuel hoses (2). 3) Connect fuel hose (3) for APS.

47. Connector pipe I) Install O-ring and gasket, install connector pipe (2). then secure it with the plate. & * O-ring: Grease (G2-LI)

When connecting the piping to the turbocharger, center the piping so that the turbocharger is not twisted, then tighten.

2) Fit gasket and install tube (I) for boost compensator.

48. Intake connector Fit O-ring and install intake connector (2). Align the hole on it with the one on bracket (1). & * O-ring: Grease (G2-LI) between the connector

Insert a plain washer and the bracket.

49. Air cleaner assembly Fit gasket and install air cleaner assembly (I) and secure it with the band. m Band: 1.0 & 0.1 kgm

50. Setting off engine from engine stand 1) Lift the engine assembly (I) and remove the mounting bolts to separate the engine assembly from engine repair stand A. 2) Remove the bracket for the engine repair stand Al. * Prepare an engine stand, then place the engine on the stand and secure it in position.

13-058 0

51. Oil cooler 1) Fit gasket and install oil cooler (2). w Oil cooler mounting bolt: 6.75 & 0.75 kgm

2) Fit gasket and install water pipe (I).

52. Drain tube of turbocharger Fit gasket to both end faces, then install drain tube (I) for the turbocharger.

Water pump assembly 1) Install drive shaft. 2) Fit gasket and install water pump assembly (31, aligning it with the drive shaft. 3) Fit O-rings to both end faces. Install water pipe (2) and secure it with the plate. 4) Fit O-rings and gaskets to both end surfaces, then install water pipe (1).

54. Alternator assembly 1) Install bracket (5). 2) Install alternator (4) and temporarily nut (3).

tighten

3) Fit belt (2) to the pulley, and tighten the mounting bolts for adjustment plate (I). 4) Raise the alternator assembly with a bar, and adjust so that the deflection of the belt is approx. 15 mm when pressing .its center with 6 kg of force. Then tighten the bolt securely.

55. Starting motor assembly 1) Fit gasket and install starting motor (1).

6162F669

3-:60

ENGINE
14 MAINTENANCE
STAN

INTAKE ENGINE Valves Push

AND BODY

EXHAUST

SYSTEM

Turbocharger Cylider head Crosshead Cylinder

. . . . .. .

. _ ...
guide

.
.

14-002 14-004

and valve guide and crosshead rod and cam follower block

. Cylinder liner . .
Crankshaft Camshaft Timing gear ..

... . .. .. ....
..

. ..

. . . .

. .

14-005 . 14-006 14-007 14-010 14-011 14-012

. . 14-008

. .._........

. .

.. Piston, piston ring and piston pin . . Connecting rod . ... .. .


SYSTEM . . . . . . . . . . . . . . .._....... valve

..

.. . .

. 14-013 . . 14-013-2 . . 14-015

LUBRICATIOIN Oilpump

14-016 14-017 14-018

Oil pump relief valve, piston cooling valve and oil cooler by-pass COOLING ACCESSORY Air compressor SYSTEM . . . . . . . . . . . .._._..... Waterpump

...

..

14-020

170-1

SERIES

14-001 0

MAINTENANCE

STANDARD

INTAKE AND EXHAUST

SYSTEM

TURBOCHARGER
KTRI IO

6162F402 Unit: kam No. Check item Criteria Remedy

Permissible range 1 End play (play in axial direction) 0.08 - 0.18

Replace parts related to thrust

Radial play (play in radial direction)

0.25 - 0.60

Replace parts related to bearing

Permissible range 3 Outside diameter of journal bearing, inside diameter of center housing Shaft Hole Hole 23.00 - 23.03

I
4 Inside diameter of journal bearing, outside diameter of thrust collar Thickness of thrust bearing

I
..,:.

22.92 22.96
14.95 14.97

15.00 - 15.04

Replace 5

Turbine end 6 Thickness of seal ring Blower end Clearance between blower housing and impeller Tightening torque of blower impeller locknut ;i;;u;ing torque of V-band

1.85-

1.92

1.46-2.05

1.45 - 1.52

1.56-

1.65 Replace parts related to bearing

Clearance limit:

(Min.) 0.20

I
2.9 f0.3 kgm

Tighten 9 0.9 * 0.1 kgm

4-:02

170-1

SERIES

MAINTENANCE

STANDARD

INTAKE AND EXHAUST

SYSTEM

KTR130

\ \*
\ \ \

1 I

4
6162F401 6162F402

Unit: No.

mm

I
Check item

I
Criteria

I
Remedy

End play (play in axial direction)

Permissible range 0.08 - 0.18

Replace parts related to thrust

Radial play (play in radial direction

0.25 - 0.60

Replace parts related to bearing

Permissible range 3 Outside diameter of journal bearing, inside diameter of center housing Inside diameter of journal bearing, outside diameter of wheel shaft 4 Curvature of wheel shaft Repair limit: 0.010 (total deflection of indicator) Replace Shaft 29.89 - 29.94 Hole 30.00 - 30.04

19.95 - 19.97

20.00 - 20.05

Permissible range 5 Thickness of thrust bearing Width 5.86 - 5.92 6


I

Groove 6.00 - 6.04 2.96 - 3.05


I

Thickness of seal ring


I

2.85 - 2.92

Clearance between blower housing and impeller Tightening torque of blower impeller locknut Tightening torque of insert mounting bolt Tightening torque of V-band locknut

Clearance limit:

(Min.) 0.20

I
8.5 f 0.5 kgm

Replace parts related to bearing

I
9

I
Tighten

1.25 f 0.25 kgm

10

0.95 f 0.05 kgm

170-1 SERIES 4-:03

MAINTENANCE

STANDARD

INTAKE AND EXHAUST

SYSTEM

KTR150

F6166056

NO. Check item Criteria

Unit: Remedy

mm

1 2

End play (play in axial direction)

Permissible range 0.08 - 0.18

Replace parts related to thrust

Radial play (play in radial direction)

0.25 - 0.60

Replace parts related to bearing

Permissible range 3 Outside diameter of journal bearing, inside diameter of center housing Shaft 29.89 Inside diameter of journal bearing, outside diameter of wheel shaft Curvature of wheel shaft Permissible range 5 6 Thickness of seal ring Thickness of thrust bearing Width 5.86 - 5.92 2.85 - 2.92 Groove 6.00 - 6.04 2.96 - 3.05 19.95 - 19.97 20.00 - 20.05 - 29.94 Hole 30.00 - 30.04

Repair limit:

0.010

(total deflection of indicator)

Replace

Clearance between blower housing and impeller


I

Clearance limit:

(Min.) 0.20
I

Replace parts related to bearing

8 9

Tightening torque of blower impeller locknut Tightening torque of insert mounting bolt Tightening torque of turbine housing Tightening torque of V-band locknut

9.5 2 0.5 kgm I 3.75 i 0.25 kgm

10 -

5.75 f 0.25 kgm

0.9 f 0.1 kgm

14-003-l 0

MAINTENANCE

STANDARD

INTAKE AND EXHAUST

SYSTEM

TV77

615OF401-1

Unit: No. Check item Criteria Remedy

mm

2 z
G

1 Radial play of rotor 2 3 Tightening torque of blower housing bolt End play of rotor

Standard size 0.076 - 0.152 0.08 - 0.25 Target (kgm) 1.25 Step Tightening torque of back 4 plate mounting bolt 1 St step 2nd step 3rd step Standard size 5 Thickness of thrust bearing 2.315 Target 1.8 0 1.4

Repair limit 0.18 0.25 Range (kgm) 1.15 1.38 Range 1.6 - 2.0 Loosen completely 1.27 Repair limit 2.29
I

Rapair or replace

Tighten

1.50

Outside diameter Measuring point Point (A) Point (9)

Standard size 17.53 15.88. (total indicated runout)

Repair limit 17.48 15.88 Replace

Bend of wheel shaft

Bending:

Repair limit 0.010

Standard size 7 I wide diameter of center housing Inside diameter of back plate 17.475 Measuring point 8 Point(C) Point (D) Standard size 24.97 20.90 17.49 Repair limit 24.97 20.93 Repair limit

14-003-2 0

MAINTENANCE

STANDARD

ENGINE BODY

CYLINDER

HEAD
Tightening order of head mounting bolt

6 \

Tightening order of head cover mounting bolt

6 162F403A

F6170010578 Unit: mm

I
No. Check item Criteria Remedy

Distortion of cylinder head mounting surface

Tolerance Max. 0.05

Repair limit -z 0.1

f3epair by frinding >r replace

Protrusions of nozzles
I

Standard:

4.9 to 5.7 Range (kgm) 6.5 to 9.5

fqeplace noz2 sleeves :le

Order

/
Tightening torque of cylinder head mounting bolts 3 (Coat bolt threads and washer with anti-friction compound (LM-P)) 1st

Target value (kgm) 8.0

2nd

23.5

22.0 to 25.0

1 Tighten in sequence as I ndicated aIbove.

3rd
I

39.0 I 50.5

37.5 to 40.5

4th -

49.0 to 52.0

I
Target value (kgm)
4

I
Range (kgm)

Tightening torque of nozzle holder mounting bolt 2.75 I 2.5 to 3.0

I
3.25

Retighten 3.0 to 3.5

Tightening torque of cylinder head cover Tightening torque of rocker arm housing mounting bolt

10

9.5 - 10.5

14-004 8

170-1 SERIES

MAINTENANCE

STANDARD

ENGINE

BODY

VALVES AND VALVE GUIDE

1
SWE01035

No.

zz

I
2

Amount

of valve

sinking

Valve

head thickness

Valve seat angle

Outside stem

diameter

of intake

valve

MAINTENANCE

STANDARD

ENGINE

BODY

CROSSHEAD

AND

CROSSHEAD

GUIDE

6162F405

$ z z Unit: mm

No.

Check item Standard size 3.0 only 7.5 15

Criteria Tolerance +0.3 0 +0.3 0 +0.10 +0.05 +0.039 +0.028 Repair limit

Remedy

Depth of crosshead stem

Except H D465-5 HD4655

Replace 15.21

Inside diameter of crosshead

Outside diameter of crosshead guide

15

I
Clearance between crosshead. guide and crosshead

I
Standard clearance 0.011 to 0.072 Standard size

I I

15.00

I
I Adjust

Clearance limit 0.02 Tolerance Repair limit -0.3 I Replace Exhaust valve 1 .o 4.0 + 0.6 kgm Tighten 6.0 Itr0.6 kgm

Protrusion of crosshead guide 54

Intake valve 5 Valve clearance (at cold) 0.4 Except HD465-5 HD465-5 only (Serial No. 14203 and up)

Tightening torque of crosshead lock nut

4-:06

MAINTENANCE

STANDARD

ENGINE

BODY

PUSH

ROD AND

CAM

FOLLOWER

Unit: No. Check item Criteria

mm

Remedy

Standard size 1 Outside diameter of cam follower shaft 25.0

Tolerance

Repair limit

-0.040 -0.055

24.9

Inside diameter of cam follower lever

25.0

I
19.0

-0.020 0

25.0

Inside diameter of cam follower roller 3 Outside diameter of cam follower roller pin

+0.175 +0.150

19.2 Replace

19.0

+0.075 +0.065

19.0

Outside diameter of cam follower roller

41 .o

+0.050
+0.025

41.0

I
15.85

Diameter of push rod tip ball Inside diameter of push rod socket

kO.03

12.7

to.20

170-1 SERIES

14-007 0

MAINTENANCE

STANDARD

ENGINE

BODY

CYLINDER

BLOCK

& I

6162F407

Unit: No.

mm

Check item

I
Tolerance Standard size

Criteria

Remedy

Clearance between cylinder block and liner 190

Inside diamater of block

Outside diameter of liner:

Standard clearance

Clearance limit

Replace cylinder liner or block

0.050 to 0.160

I
Standard size Inside diameter of main bearing hole (lighten bolt to specified torque) Tolerance + 0.025 - 0.001

I
Repair limit -

148

Thickness of main bearing

- 0.038 - 0.051

Repair or replace

Inside diameter of main bearing

140

+0.127 + 0.076

140.20

14-008 0

170-1

SERIES

MAINTENANCE

STANDARD

ENGINE BODY

Unit: No. Check item Criteria

mm

I
Standard clearance

Remedy

Clearance limit 0.32 Interference 0.05 Tolerance +0.070 0 Repair limit Repair or replace limit

Clearance between main bearing and crankshaft journal

0.075 to 0.150 Standard interference

Interference between main bearing cap and cylinder block

0.080 to 0.160 Standard size

Inside diameter of camshaft bushing 4 Clearance between camshaft and journal

72

72.10

Standard clearance 0.080 to 0.180 Tolerance 0.09 Order 1st Target value (kgm) 56 113

Clearance limit 0.24 Repair limit 0.15 Range (kgm) 51 to 61 107 to 118 Loosen completely 38 75 113 33 to 43 70 to 80 107 to 118 Tighten

Distortion of cylinder head face

Tightening torque of main bearing cap bolt 6

2nd 3rd

K$at

bolt threads with engine 4th 5th 6th

170-1

SERIES

14-009

MAINTENANCE

STANDARD

ENGINE

BODY

CYLINDER

LINER

Detail P

F6166062

Jnit: mm No.

Check item

Criteria

Remedy Replace cylinder liner or block Repair limit

Protrusion of cylinder liner

Permissible range: 0.07 to 0.15 Difference among cylinders: 0.05 max.

2 z z

I
Inside diameter of cylinder liner 2 Roundness Cylindricity Outside diameter of cylinder liner (Counter bore lower part) 3

Standard size

Tolerance +0.04 0

170
I

170.24
i

Repair limit:

0.020

Repair limit: 0.015 Standard size 194.59 Tolerance 194.565 - 194.615

.
Interference of cylinder liner and block (Counter bore lower part) Outside diameter of cylinder liner (Counter bore part)

Standard interference:

0.025 to 0.135

Standard size 205.99

Tolerance 205.965 Interference: 0.085 to Clearance: 0.025 - 206.015

Replace cylinder liner

4 Clearance between cylinder liner and block (Counter bore part) Outside diameter of cylinder liner (O-ring part) 5 Clearance between cylinder liner and block (O-ring part) Standard clearance: 0.050 to 0.210 Standard size 190.4

Tolerance 190.34 190.40

Unevenness of counter bore depth

Tolerance -

Repair limit 0.03

Repair by grinding

14-010 0

MAINTENANCE

STANDARD

ENGINE

BODY

CRANKSHAFT

7TI

NO. Check item

2,i

5'

1,3

7'
Criteria

6162F409

Unit:

mm

Remedy

Size S.T.D.

Standard size 140.00 I

Tolerance

Repair limit 139.91 I

I
1 Outside diameter of main journal

0.75us 1 .oous S.T.D. 0.25US 2 Outside diameter of crank pin journal

139.25 139.00 108.00 107.75

139.16 138.91 107.91 107.66 Repair or replace

Journal roundness

Tolerance End play 0.140 to 0.320 Standard size Main bearing thickness (Center) Tolerance -0.040 -0.050

Repair limit 0.69 Standard interference Replace

3.90

Outside diameter of rear flange

170

I
Tolerance 0.09

xl.020

1
Repair limit 0.20

Bend of crankshaft (by indicator)

Tightening torque of crank wllev mountina bolt

See page 13644

Tighten

170-1

SERIES

14-011 0

MAINTENANCE STANDARD

ENGINE BODY

CAMSHAFT

6162F410

Unit: Check item Criteria

mm

Remedy

Standard size Intake side

Tolerance +0.440 WO.240 -0.310 -0.510

Repair limit

Cam height

62

61.37

Repair or replace

Exhaust side

61

59.64

Outside diameter of journal

72.00

-0.080 -0.110

71.86 Replace

Thrust plate thickness

10.00

-0.025 -0.060

6.85

Standard clearance 4 Camshaft end play 0.075 to 0.240 5 Bend of camshaft Repair limit:

Clearance limit 0.40 0.20 (by indicator) Replace thrust plate

Replace

14-012

170-1 SERIES

MAINTENANCE

STANDARD

ENGINE

BODY

TIMING

GEAR

INo Check item

:3
Criteria

6162F411

Unit:

mm

Main idler gear (large) and idler gear

Gear backlash

Clearance between main idler gear bushing and shaft

10

11 End play of idler gear 0.10 to 0.32 bearing

12

End play of oil pump idler gear Difference of timing gear case and cvlinder block lower steo

0.10 to 0.32 Repair or

13

Tolerance:

0.15

I replace

170-1

SERIES

14-013 cz

MAINTENANCE

STANDARD

ENGINE BODY

(HD46!5-5)

Unit:

mm

I
No. -

Check item

Criteria

Gear backlash

Water pump idler gear and water

Standard size 7 Clearance between main idler gear bushing and shaft

a
9 10 11 12 13 Iifference of timing gear case md cylinder block lower step Tolerance: 0.15 Repair or replace End play of oil pump idler gear Replace thrust ushing and shaft

4-oi3-1

MAINTENANCE

STANDARD

ENGINE

BODY

PISTON,
ALUMINIUM

PISTON
PISTON TYPE

RING AND

PISTON

PIN

Omm

6162F412 Unit: No. Check item Criteria mm

Remedy

Standard size
1

Tolerance

Repair limit

Outside diameter of piston (3.0 mm from bottom and at 2OC) 170

I
-0.257 -0.287

I
169.62

Ring groove

Ring thickness

Piston ring groove

~~

Oil ring

4.80

io.010 Standard clearance

-0.500 -0.075

0.3 Clearance limit

Replace

Piston ring gap

Inside diameter of piston pin boss

Outside diameter of piston pin

68

0 -0.006

67.98

I
14-013-2 8

170-1 SERIES

MAINTENANCE STANDARD

ENGINE BODY

FCD PISTON TYPE

6162F822

Unit: No. Check item Standard size 170 Criteria Repair limit 169.79

mm

Outside diameter of piston (3.0 mm from bottom and at 2OC)

Tolerance -0.075 -0.105 Tolerance

Standard size Ring groove Top ring 2 Piston ring groove 2nd ring Keystone -0.500 -0.075 Keystone Ring thickness

ClW$ce

Check with piston groove wear gauge

0.15

Replace

Oil ring

4.80

~.OlO Standard clearance

0.3

Clearance limit

Top ring 3 Piston ring gap 2nd ring

0.50 - 0.65 0.45 - 0.60 1.8

I
4

Oil ring Standard size

I
I

0.50 - 0.70

I I
Tolerance +0.044 +0.034 0 -0.006

Insidediameter
pin boss

of piston 68

Outside diameter of piston pin

68

14-Z4

170-1 SERIES

MAINTENANCE STANDARD

ENGINE BODY

CONNECTING ROD

6162F413

Unit: 2 z z Clearance between connecting rod bushing and piston pin 68 No. Check item Criteria Tolerance Shaft 0 -0.060 Standard size 115 Standard clearance 0.060 Size S. T. D. . 1 Connectina rod bearina 0.130 Standard size 3.500 Tolerance Hole +0.070 +0.050 0.050 - 0.075 Tolerance +0.025 0 Clearance limit 0.34 Repair limit 3.41 0.11 Remedy

mm

Standard size 1

Standard clearance

Clearance limit

Replace (the bushing is supplied as a semi-finished product)

Inside diameter of connecting rod big end

Clearance between inside diameter of connecting rod big end and crankshaft journal

Bend or twist of connecting rod

Repair limit of bend: 0.10 Repair limit of twist: 0.25 10.15 +0.03 kg

Connecting rod weight

Tightening torque of connecting rod cap (Coat bolt and nut threads with engine oil)

Order 1st 2nd

Target (kgm) 20 90

Range (kgm) 19-21 90 105O Tighten

14-015 0

MAINTENANCE

STANDARD

LUBRICATION

SYSTEM

OIL PUMP

5
6162F414

Unit: No. Check item

mm

Criteria

Remedy

Clearance between drive shaft and bushing 32

-0.025 -0.040

,/

;:::;;

10.040 too.075

Clearance between driven shaft and driven gear bushing

30

-0.020 -0.035

+0.030 +0.010

0.030 to 0.070

Replace

Clearance between outside diameter of gear and body

Main pump gear and body end play Tightening torque of mounting bolt

66

-0.115 -0.095

+0.035 0

0.095 to 0.150

6.9 f 1 .O kgm

Tighten

14-016 0

MAINTENANCE

STANDARD

LUBRICATION

SYSTEM

OIL PUMP RELIEF VALVE, PISTON OIL COOLER BY-PASS VALVE

COOLING

VALVE AND

6162F415

6162F416

6162F417

Unit:

mm

I
Check item Criteria

Main relief valve spring

Regulator valve spring

Main relief valve operating pressure Regulator valve operating pressure

Standard:

3.3 f 0.3 kg/cm

Standard:

8.0 * 0.8 kg/cm

Repair or replace spring

Piston cooling valve operating pressure Oil cooler by-pass valve operating pressure

Standard:

1.3 Tt:f

kg/cm2

Standard:

4.5 ?:0.5 kg/cm*

170-1 SERIES

4-:

MAINTENANCE STANDARD

COOLING SYSTEM

WATER PUMP

6162F418

f
No. Check item Criteria

Jnit: mm

Remedy

Standard size 1 Interference between front shaft and bearing 30

.
Shaft

Tolerance Hole

Standard interference

I I +0.015
0 0 -0.010 0 to 0.025

Interference between rear shaft and bearing

25

I
19.9

+0.010 0

-:.o,o
-0.025 -0.05

0 to 0.020
Replace

.3

Interference between rear shaft and impeller

I
I
0.23 to 0.66

+0.020 +0.005

0.030 to 0.070

I
Clearance limit -

Standard clearance 4 Clearance between impeller and connection

14-018

170-1 SERIES

MAINTENANCE

STANDARD

ACCESSORY

AIR COMPRESSOR

48

6162F419

14-020

170-1 SERIES

MAINTENANCE

STANDARD

ACCESSORY

Unit: No. Check item Criteria

mm

Remedy

Standardsie Inside diameter of cylinder 92

~~

I_

Tolerance +0.08 +O.lO

Repair limit

I
Replace crank case

Tolerance Standard size Clearance between piston and piston pin Shaft Hole

Standard clearance

Clearance limit Replace

Clearance between crankshaft and bushing

47

i-O.570 +0.550

M.662 +0.612 Tolerance

0.042 to 0.113

Replace bushing

Standard size Interference between crank case and bushing 51 Shaft +0.019 -0.006 Hole -0.086 -0.129 Tolerance Standard size Shaft Clearance between crankshaft and connecting rod 49 +0.162 +0.135 Hole

Standard interference

Clearance limit

Repair or replace crank case

0.08 to 0.13

Standard clearance

Clearance limit Replace

I
+0.225 +0.213 0.051 to 0.089 -

Clearance between crankshaft and support

47

+0.570 +0.550

+0.638 +0.612 Tolerance

0.042 to 0.089

Replace

Standard size 7 interference between crankshaft and coupling gear 25 Shaft Hole

Standard interference Replace

I
+0.489 a.476 Standard (kgm) i6.425 +0.400 0.051 to 0.089

Limit (kgm) Tighten 2 to 3.5

Tightening torque of cylinder head mounting bolt

170-1 SERIES

14-021 0

ENGINE 15
REPAIR AND REPLACEMENT OF PARTS

Table of special tools .................................. Cylinder head .............................................. Testing and inspecting ............................... Repairing mounting face of cylinder head by grinding.. .................... Replacing valve seat inserts ...................... Replacing nozzle holder sleeve ................. Replacing valve guide ................................ Replacing cross head guide.. ..................... Grinding the valve ...................................... Cylinder block ............................................. Testing and inspecting ............................... Grinding the top surface of cylinder block ......................................................... Replacing main metal cap.. ........................ Replacing cam bushing.. ............................ Crankshaft. .................................................. Repairing the crankshaft ............................ Connecting rod ........................................... Replacing crankshaft gear.. ........................ Replacing camshaft gear ........................... Replacing flywheel ring gear.. ...................

15-002 15-004 15-005 15-007 15-008 15-014 15-018 15-019 15-020 15-021 15-022 15-024 15-030 15-032 15-034 15-041 15-046 15-048 15-049 IO-050

15-001
0

REPAIR AND REPLACEMENT

OF PARTS

TABLE OF SPECIAL TOOLS

TABLE OF SPECIAL TOOLS


Operation

I ;ymbol
1 2 3 A 1- 1 4

Part No. 795-l 00-4800 795-l 00-3004 795-600-2510 795-600-2520 795-600-2531 795-600-2541 Puller

Part Name

Qtv 1

Remarks For valve seat

Push tool Push tool 1 Push tool Calking Calking Peening Push bar Push bar Driver Punch Holder

seat cutter

1 1 ( 1 1 1 1 1 1 1 1 1 1 1 1 1 For intake I For exhaust For intake For exhaust valve valve valve valve

Replacing

valve

seat

tool tool guide

5 1 2 I B 3 4 Replacing nozzle holder sleeve 5 1 2


I

795-600-2570 795-600-2110 795-600-I 191

795-600-2120 795-600-I 130

795-600-2130 795-600-I 140

Punch bushing Rollina Expander Cutter Guide bushina tester assembly remover driver guide I tool

795-600-2140 795-600-2150 795-600-2160 795-600-2170 1 790-553-1700 79A-471-1050

3 4 5

Pressure test of cylinder head Replacing guide Replacing guide Grinding Replacing bushing Replacing gear valve G

E F 1

I Coolant
Pump

II 1 1 1 I

795-600-2550 795-600-2560 795-140-6410 Commercially available

Valve guide 1 Valve auide CZzl,head

12 1 H I 1

crossheac

valve cam J

Valve

refacer set

1 1 1

795-250-1301 792-l 03-0400 790-101-2800

Push tool GriD Bearing

2 crankshaf K 1

puller

.-

I2I

790-101-2300

I Push puller

15002 0

REPAIR AND REPLACEMENT

OF PARTS

CYLINDER

HEAD

CYLINDER

HEAD

F6164091

1. Valve guide 2. Closshead guide 3. Fuel injection nozzle sleeve 4. O-ring 5. Cylinder head 6. O-ring 7. Pushrod tube 8. Valve seat insert

15004 0

REPAIR

AND

REPLACEMENT

OF PARTS

TESTING

AND

INSPECTING

TESTING
(1) Cylinder

AND INSPECTING
head Unit: mm

Inspection

item

Judgement Check for cracks (external

standards

Remedy

A. Cracks, leakage from cylinder head

l l

color check) test 10 min.) Grind to correct Repair by welding or replace

Check for air leakage with air pressure (3.0 - 3.5 kg/cm*, 30 sec.) Water pressure test (3.5 4.0 kg/cm*,

B. Distortion of top, bottom surface o cylinder head C. Damage to injection nozzle sleeve seat surface, contact width D. Protrusion of injection nozzle

Tolerance Max. 0.05

I I

Repair limit 0.1

Machine to repair or replace sleeve

Permissible

range: 4.9 -

5.7

Replace sleeve

io
E. Damage to valve seat surface or loosening of seat
l l l l

F6164092

Pitting of seat surface Check contact Airtighteness Tap cylinder between test head and check for looseness valve and seat surface

Correct seat surface or replace valve seat

F. Sinking of valve (both intake and exhaust) Standard 0.9 F6164093

value 1.5

Repair limit 2.1

Replace valve or valve seat

G. Thickness of valve head


_1

/
l

Angle

of seat surface 30 valve: 45O

Replace

Intake valve:

\ ; of valye head F6164094

Exhaust

-D

Thickness

15005
63

REPAIR AND REPLACEMENT

OF PARTS

TESTING

AND INSPECTING

Unit Inspection item Judgement standards

: mm

Remedy

H. Abnormality valve

in

Check if head has become surface Airtightness test

flat, check for cracks or piting of seat

l l

Check for play in cotter pin when Check for eccentric Check for hollow Outside diameter Standard I2 size wear

new cotter pin is inserted of stem.

in cotter

Replace

j groove.
l

or curvature

in stem end.

Correct

I. Outside stem

diameter

of intake valve Standard 11.94 value I I .92 Repair limit

11.90 Replace

Outside stem

diameter valve

Outside

diameter Standard 12 size Standard value Repair limit

of exhaust

11.908-11.893

I I .80

J. Inside diameter of valve guide (after head press fit) 12 1 I.981 11.999 12.10 Standard size Standard value Repair limit

K. Protrution valve guide

of

(after head press fit) Permissible range

: 23.4 -

23.9

Replace

F6164095

L. Outside guide

diameter Standard I5 size Standard 15.028 value 15.039 Repair limit

of crosshead

15.00

M. Protrution crosshead

of guide
B

E
2

6 t

Crosshead guide

Permissible

range

: 53.7 -

54.0

F6164096

15006 0

REPAIRING REPAIR AND REPLACEMENT OF PARTS CYLINDER

MOUNTING HEAD

FACE

OF

BY GRINDING

REPAIRING MOUNTING BY GRINDING


1. Grinding

FACE OF CYLINDER

HEAD

1) Remove 2) Remove

the valve seat inserts. VAVLE

For details,

see

REPLACING

SEAT INSERTS. For details, SLEEVES. HOLDER

the nozzle holder sleeves. NOZZLE

see REPLACING

3) Grind the cylinder head to remove the strained or corroded portions within the limit of the height of the cylinder If any grinding face
*

head (H). out, stamp with head the side


F6164097

is carried head of cyinder

of the

cylinder

an (R) mark. height (H):

Repair 139.55

limit

mm (Standard to remove roughness

size: 139.85

140.15) + * * * Amount Surface Flatness Difference the see per grinding: 0.10 of grinding 0.05 to 0.15 surface: within (deformation): limit: 0.3 mm per unit: 0.15 2 Z & 4) Press-fit details, INSERTS. 5) Press-fit the nozzle holder sleeves. For details, see REPLACING NOZZLE HOLDER SLEEVES. 2. . Check after grinding the standard 0.9 4.9 of nozzle: to 5.7 mm values to 1.5 mm one-size-larger REPLACING inserts. VAVLE max. For SEAT mm max. -rt Grinding 6s mm

in head height

Check the sinking of the valves and the protrusion of the nozzles are within + + Standard Allowable sinking protrusion of valves:

15007 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

VALVE SEAT INSERTS

REPLACING VALVE SEAT INSERTS


*
When repairing without replacing the valve seat insert (when there is surface roughness or stepped wear), correct with the amount of sinking of the valve within the repair limit of 2.1 mm

Confirm that the grindstone is not damaged, then install it to the shaft of the grinder without applying excessive force. Confirm that there is no play between the grindstone and shaft. When using the grinder, wear safety goggles. Install grindstone @to grinder 0. Install the sleeve and grinder after aligning the groove of sleeve @ with holder 0. Adjust the position of the grinder with set screw @.

Intake valve

it: mm

A
i)
ii)

head

6162F502A

Exhaust valve
#5&4*lj.O5 bf Unit: mm

der head

6162F503A

Checking for looseness of valve insert Tap the outside of the valve insert of the cylinder head with a hammer to check for any looseness of the valve insert. If the valve insert is loose or springs back, replace the insert. Pulling out the valve seat insert 1) Using the grinder of valve e seat puller Al, make grooves on the inserts to pull them out according to the following procedure. Ir Set the air pressure to 5 to 6 kg/cm*. * When replacing the grindstone of the grinder, shut off the compressed air. A Before using the grinder, run it for a minute to test it. After replacing the grindstone, run the grinder for three minutes to test it.

6162F504

15008 63

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

VALVE SEAT INSERTS

iii)

Adjust

the position

of the grinder so that @ will be at the then tighten the of the grinder to and slowly move it

the center of grindstone center of seat insert (l), iv) Fully rotate open the throttle the grindstone

set screw to secure the grinder.

until it contacts insert (1). VI Press the grindstone against the inside of w
6162F505

the insert, move it in a circular pattern, and make a groove about 1 mm deep.

2)

Pull out the insert with the puller head of valve seat puller Al according cedure. i) ii) Push three claws (a) of puller head @ Tighten screw the insert. * If the screw is tightened the insert will ficult to pull the @ @ @ tightening compretely iii) Place bridge place plates Tighten nut it out. too strongly, stop claws break and it will be difTherefore, the screw when @ inward by hand and put them in insert (1). to press the three claws against the groove on the inside surface of to the following pro-

contact the groove. over the puller head, then and 0 on the bridge.
6162F506A

to pull out the insert.

Al

F6164098A

15-009 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

VALVE SEAT INSERTS

2.

Machining valve seat insert mounting hole to oversize 1) Using valve seat cutter A2, machine the mounting hole to install a one-size-larger insert. l Dimensions of insert and mounting hole

hr dr

Bottom\surface of cylinder head 6162F502-1


l

/i

Intake valve side

I
Stamp on insert Insert O.D.(d,) 63.00+ O +o.080 Hight(h,) 8.5-z.,

I
I.D. (d2) 63.002:;;;

Unit: mm Mounting hole for insert Depth (h,) 12.5 zt 0.1 F6164099A

S.T.D.

0.25 OS

63.25;;:;;;

8.5:,,
I

63.25 :;:$j
I

12.5 f 0.1

2) If the talked portion of the mounting hole, is damaged remove it within the range of 1.00 mm oversize. If the damage portion cannot be removed within the range of 1 .OOmm oversize,
replace 3. the cylinder head.

Press fitting the insert 1) Using insert push toolA3,press-fit (1 ).

the insert

8 z z

Exhaust valve side


Unit: mm

A3

Stamp
0"

Insert O.D.(d,) Hight(h,)

Mounting hole for insert I.D. (d2) Depth (b)

insert

615F004A 0.75 0.S 61.75;;:;: 8.75& 61.75 ;:;:; 12.75 f 0.1

2) Check the sinking distance


1 .OO OS 62.00;;:;: 8.8& 62.00 ;:;:; 12.88 f 0.1

of the insert from cylinder head.

the *

mounting,

surface

of the

Inside surface roughness: 12.5s max. Mountting hole bottom roughness: 12.5s max. Concentricity of inside diameter of valve guide and inside diameter of insert hole: 0.05 mm (T.1.R) max. Rectangularity of inside diameter of valve guide and bottom of insert hole : 0.03 mm (T.1.R) max.

Standard sinking distance of insert: 3.9 to 4.2 mm

>&
I
o! m

F6164159

15-010 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

VALVE SEAT INSERTS

4.

Calking circumference of insert Calk the circumference of the exhaust valve seat insert as follows. * It is unnecessary to talk the insert for the intake valve. Differences between exhaust
New

valve inserts
Old

1
I OO- 500mm

Part No.

6162-13-1321 (2 per valve)


Part No. and size stamped on outside circumference

6162-13-1320 (2 per valve)


No stamp (Note: The oversize insert is stamped.)

Difference Need for calking after press

No

Yes

fitting Calking above. is not needed for any insert not listed

head

1) Set with the bottom surface of the cylinder 8


head facing up, and place on wooden blocks. * Leave enough space so that the valve guide does not contact the ground. Insert calking tools A4 and A5 into the valve guide. Hold calking tools A4 and A5 down with one hand, and hit around the whole circumference 15 times with the hammer to talk. * Check that there are no cracks in the talk portion and that the calking is uniform around the whole circumference.

z z

2)
3)

6162F816A

F6164160A

15011
0

REPAIR

AND

REPLACEMENT

OF PARTS

REPLACING

VALVE

SEAT

INSERTS

5.

Finishing

the seat surface with valve seat cutter intake Exhaust surface: side: 3.69 side: 3.79 and guide mm mm mm insert: side: 30 in the figure. surface: side: 45O

1) Finish the seat surface A2 as shown + * Angie Width of seat

of seat fininshing Intake Exhaust

Connectricity

of valve 0.07

(T.I R) max.
Unit: mm

2) Fit the seat surface a rough compound the and When valve turn the guide it with rubbing and

using the compound. of the valve thinly oil insert forms a pair with to rub the above with with it in that
3o 459+0.05
$57.4 * 0.05

Coat the seat surface that

mixed with

valve, then fit a rubbing both against the valve seat.

bar to the valve head, hands lightly

removes the

roughness, process no break to in

Intake

side

Exhaust

side

wipe off the compound. compound contact. 6. Final check * Standard sinking width repeat give a good contact

Then coat with a fine

surface

6162F507A

distance of contact Intake Exhaust

of valve 0.9 surface

(new): against mm ?c 0.2


Bottom surface of cylinder head

Lo

Unit:

mm

z z

to 1.5 mm
Bottom surface of cylmder head

-Sr Standarad valve:

side: 2.5 side: 2.8

* 0.2

Coat the seat surface with guide, surface, contact red lead (minium), push lightely and rotate surface, without

of the new valve thinly insert it in the valve insert


Intake side Exhaust side

against

the valve

1 O. Check the valve insert that the contact any breaks.

and confirm

is uniform or Make of the

F6164100

marks with a pencil on the seal surface new valve as shown in the diagram,

insert it in the valve guide, push lightly against the valve insert surface, that the pencil around marks uniformly and rotate 1 O. Check have been erased circumference.
Pencil ,(about marks 20

places)

the whole

F6164101

15-012 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

VALVE SEAT INSERTS

Air pressure testing method When carrying out an airtightness test with a vacuum tester, test as follows 1) Wipe off all the dirt, dust, and oil from the valve and valve seat surface with a cloth. 2) Assemble the valve, valve spring, retainer, and cotter, tap the tip of the valve stem with a plastic hammer 2 or 3 times directly from above to bring it into tight contact with the seat surface. 3) Fit a vacuum cup that matches the size of the valve in tight contact with the head surface. When doing this, to improve the airtightness of the vacuum cup, coat grease on the O-ring fitted to the vaccum cup, and fit it in tight contact with the flat surface of the head. (Be careful not to get any grease on the seat surface.) 4) Set the vacuum gauge, and check that the pressure drops less than 10 mmHg in 3 seconds. If it drops more than 10 mmHg in 3 seconds, check for any dirt on the seat surface, or rub the surface to correct it.
l

15013 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

NOZZLE HOLDER SLEEVE

REPLACING NOZZLE HOLDER SLEEVE


1. Cutting a hole at bottom of sleeve . Insert 12 mm diameter drill 0 in the hole at the bottom of the sleeve to make the hole.

2.

Removing the sleeve 1) Insert-push bar Bl inside the sleeve. 2) Using sleeve extraction tap 0, cut tap to about 25 mm depth from top face of sleeve. Add oil while cutting. + Sleeve extraction tap: M32, P q 2.0 3) Insert push bar 82 from the bottom of the head and tap with the hammer to remove the sleeve. 4) Remove the sleeve materials from the tap portion of portion a of the cylinder head. 5) Remove O-ring (2). Press-fitting the sleeve I) Install O-ring (2) to the cylinder head. 2) Insert sleeve (I) in the cylinder head, then insert sleeve driver B3 and lightly tap it until the sleeve contacts the seat surface. * Before installing the sleeve, clean the sleeve and seat. * Apply adhesive to the seat around the sleeve. & Seat: LT-2

F6164102

3.

F6164103A

8
z z

-----______

e
a

F6164104

F6164105A

15-014 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

NOZZLE HOLDER SLEEVE

4.

Calking the sleeve seat face 1) Fitthe sleeve seat with sleeve holder B5. w Tightening torque for sleeve holder: 2 kgm. B4

2) Install punch bushing Cl and insert sleeve


3) driver B4. Place support @ under the cylinder head to allow the bolt of the sleeve holder to move out. Hit the sleeve driver with a hammer to talk the seat surface. Lightly hit with a hammer several times. * Remove the sleeve holder and punch bushing. hole of sleeve
6162F511A

4)

5)

5.

Roll-fit the bottom

Using sleeve rolling tool C2, roll-fit bottom hole @ of sleeve (1). * Adjust the roll-fitting height with bearing collar @ so that the shaft of the rolling tool will protrude a little from the bottom hole. * Install the rolling tool to a radial drilling machine or upright drilling machine to roll-fitwith its own weight. + Rotating speed: 200 to 300 rpm

6.

Roll-fitting

the taper section of sleeve

Using sleeve expander C3, roll-fit the taper section of the sleeve. Set the roll-fitting amount with stopper @ of the expander. Install the expander to a radial drilling machine or upright drilling machine to roll-fitwith its own weight. Rotating speed: 200 to 300 rpm

6162F512A

6162F513A

15015 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

NOZZLE HOLDER SLEEVE

7.

Spot-facing the inside seat of the sleeve I) Using guide bushing C5 as the guide, spotface the seat with sleeve cutter C4. + Cut the seat little by little while checking the protrusion of the nozzle with the holder for measuring it and a dial gauge so that the protrusion of the nozzle will be within the specification. * Rotating speed: 500 to 600 rpm * Protrusion of nozzle: 4.9 to 5.7 mm 2) Remove all the metal chips and dust from the machined surface. Checking the leakage from the seat . Confirm that fluid does not leak through the sleeve seat in the air pressure test. (There must be no leakage for 30 seconds at an air pressure of 3.0 - 3.5 kg/cm2.) + When carrying out the air pressure test, install a used nozzle holder.

8.

6162F514A

15016 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

NOZZLE HOLDER SLEEVE

Water pressure testing method . If the area around the head has been corrected, test as follows. 1. Water Dressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Assemble tool E and tool F, and connect a hose to frange (I). 3) Apply water pressure (3.5 - 4.0 kg/cm2) for approx. 10 minutes, and check for any leakage from around the head. sr It is preferable to warm the whole cylinder head and carry out the test with hot water (82 - 93C).

2.

Air pressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Connect the pump hose to flange (I). 3) Place the head in a water bath, apply air pressure (3.0 - 3.5 kg/cm? for approx. 30 seconds, and check for any air leakage in the water. sr If the above test shows that there are cracks around the nozzle holder and plugs, replace the cylinder head.

F6164106A

2 Z Z

15017 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

VALVE GUIDE

REPLACING VALVE GUIDE


1. Removing the valve guide . Remove the valve guide with valve guide remover Gl.

6162F811A

2.

Press-fitting the valve guide 1) Press-fit the valve guide until the tip of valve guide driver G2 contacts the cylinder head. 2) Confirm that the protrusion of the valve guide is within specification. Ir Protrusion of valve guide: 23.7:::; mm * Inside diameter of valve guide hole in cylinder head: 19+~~021 mm

15018 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

CROSS HEAD GUIDE

REPLACING
1. Removing
l

CROSS HEAD GUIDE

the cross head guide

Using cross head guide puller H, pull out thje cross head guide. 1) As shown in the figure, hold the cross head to lock sleeve guide with collet @of the puller.

2) Tighten the collet with bolt 0 0. 3) Rotate guide. 4) Remove nut @and

pull out the cross head

burrs, fins, etc. from the mounting it.

place of the cross head guide and clean

615F019A

2.

Press-fitting
l

the cross head guide head with a copper its protrusion is

Insert the cross head guide in the cylinder head, then hit it into the cylinder bar or plastic + Protrusion hammer within specification of cross head guide Tolerance: + Inside diameter 54 -0.3 mm until

of crosshead guide hole: ,5 + 0.018 mm 0

15019 0

REPAIR

AND

REPLACEMENT

OF PARTS

GRINDING

THE

VALVE

GRINDING
1. Grinding
l

THE VALVE

the seat surface I. of valve seat: Intake valve: Exhaust 30

Grind the seat surface with valve refacer * Angle

valve: 45O

2.

Checking
l

after grinding that the thickness of the valve head, of the valve, and the contact surface of valve head of valve head

Confirm protrusion *

of the valve seat are within specification. Thickness


F6164107A

Ir Thickness

Repair limit Intake valve: Min. 2.9 mm (Standard Exhaust (Standard * Sinking of valve size 3.4 mm) size 3.5 mm) 0.9 1.5 mm
F6164108

valve: Min. 3.1 mm

Standard:

Repair limit: 2.1 mm

z z

Check the contact of the valve with the seat surface


l

using one of the following

methods. insert it in the

F6164109

Coat the seat surface of the ground valve thinly with red lead (minium), the valve guide, valve insert surface, push lightly against any breaks. on the seat in
Pencil (about marks 20

and confirm that the

contact is uniform without Make surface push marks with insert

a pencil

of the ground valve as shown lightly against the loo. valve

the diagram, surface, around

it in the valve guide, insert Check that the

places)

and rotate the whole

pencil marks have been erased uniformly circumference.


F6164101

15-020 0

REPAIR AND REPLACEMENT

OF PARTS

CYLINDER

BLOCK

CYLINDER BLOCK

HLE00055

1. 2. 3. 4. 5. 6. 7.

Cylinder liner Crevice seal O-ring Cylinder block Main bearing cap Main bearing cap bolt Camshaft bushing

15-021
0

REPAIR

AND

REPLACEMENT

OF PARTS

TESTING

AND

INSPECTING

TESTING
(1) Cylinder

AND INSPECTING
block Unit: mm Judgement Check for cracks (external Cylinder standards Remedy

inspection A. Cracks

item

color check) etc.

Replace

head bolts hole portion,

6. Correction of con tact at packing portion Check for water leakage caused by corrosion

Replace

I
C. Clearance liner from

F6164111

~~~
Clearance from liner

ji
190.34 190.40 190.19 190.29

zi%z!
0.05 0.21 Replace cylinder liner or block

F616411:

D. Inside diameter of camshaft bushing

Inside diameter Standard 72 size Standard 72.00 bearing Standard 0.24 value value 72.07 Repair limit 72.10 Replace bushing

Clearance

from camshaft Standard 0.08 -

clearance 0.18

E. Protrusion

of line

Permissible

range: 0.07

0.15 Replace cylinder liner or correct cylinder block

F6164113

F. Depth of counter. bore and corrosion of bottom surface

Depth of counterbore

Standard 14

size

Standard 14.00 -

value 14.05

Repair by machining, add shim

~6164114

Check for corrosion Repair limit 0.15 0.10 Repair by machining

G. Distortion, wear of cylinder head mounting surfac

Tolerance Overall top surface of block: Max. 0.09 Max. 0.05

For one cylinder:

15022 0

REPAIR

AND

REPLACEMENT

OF PARTS

TESTING

AND

INSPECTING

Unit: mm inspection item Judgement standards Remedy

H. inside diameter of main bearing mounting hole


l

Standard 148 Ran$bf

size

Standard 147.992 -

value 147.025 171.025

Repair -

limit

Tighten main bearing cap bolt and guide bolt at specifier torque

170.992

Replace I. Fitting of cap and cylinder z z z block

J. Inside diameter of counterbore, outside diameter of cylinder liner flange

Replace cylinder

liner

F6164117

Bottom

1 194.59

/ ~~$&I

Cylinder block Top

Standard size

Standard value

Repair limit

1 206.0
194.5

1 ;;,.,
194.48 194.54

I;,,,
194.46 194.57

Correct cylinder sleeve

block

Bottom

15023 0

REPAIR

AND

REPLACEMENT

OF PARTS

GRINDING

THE TOP

SURFACE

OF CYLINDER

BLOCK

GRINDING
Grinding

THE TOP SURFACE

OF CYLINDER

BLOCK

Grind off the strained and corroded portions of the cylinder block within the allowable height (H) of the cylinder block. Ir Use the followinga as a guide to decide when to grind to the top surface. If the top surface of the cylinder block is worn or corroded in the shape of the head gasket, and the amount of wear is more than 0.10 mm, grind the top surface. * If there are blackened portions on the cylinder liner contact surface of the counterbore (particularly in the front-to-rear direction), or there is speckled wear, and these portions extend over more than half of the contact width of the deck, and if grinding has been carried out on the top surface, correct the counterbore.

.c $

Wear

ofcounterbore

portion

% 3 _I I, \

1.

Grinding

top surface
F6164118

1) Measure the wear and strain of the top surface of the cylinder block, and if it is over the repair limit, grind the top surface. + Flatness of cylinder block (for one cylinder): Standard dimension: 0.05 mm Repair limit: 0.10 mm * Height of cylinder block (H): Standard dimension: 509.835 - 510.065 mm Repair limit: 509.5 mm + Roughness of top surface of cylinder block: Max. 12.5s

If grinding * * It * * Speed Speed

with

a grindstone

(for reference) to 1,950 m/min. mm

of grindstone: of table: depth/time:

1,650

15 to 30 m/min. 0.025 A461V Water-soluble ing lubricant grind1 to2mm

+ Grinding

Cross feed/time: Grindstone: Grinding lubricant:

HLE00058

15024 0

REPAIR AND REPLACEMENT

OF PARTS

GRINDING

THE TOP SURFACE

OF CYLINDER

BLOCK

2.

Grinding couterbore
After block, are grinding measure the top surface of the cylinder If or if there liner
Cylinder liner 12.5s / / Cylinder block v L (Liner Drotrusion)

Unit:mm

the depth of the counterbore. the standard portions dimension, on the cylinder

it is not within blackened surface contact wear,

of the counterbore direction), portions width extend

(particularly

in the front-to-rear and these half of the contact counterbore correcting, 14.05 mm. * Counterbore depth* if the 15.525

or there is speckled over more than

of the deck, correct the the repair limit. After depth with is within shims and 0.15
I

within

counterbore mm, combine

adjust so that the liner protrusion

is 0.07

depth L: dimension limit: 15.46 liner I: 0.15 12.5s with detail mm


Unit:mm

Standard Repair

14 + io5 mm

mm

F6164120

* Protrusion
+ * Roughness Machined

of cylinder

Standard shape:

value: 0.07

of counterbore: diagram

Max.

In accordance

for portion

a
cylinder

For the decide value. When

extra

amount

for counterbore amount that will

depth

L,

a machining

bring the

protrusion

of the cylindr liner within within the repair

the standard limit in cases

grinding

where the counterbore depth L exceeds the standard dimension, set the machining amount so that one shim can be used for each cylinder as shown in the table below.
Detail a F6164121

[Reference]

Adjustment

shims for counterbore Weight (kg)

depth
Ilnit. mm

Unit: mm

.Part No. 6162-29-2260 6162-29-2250 6162-29-2240 6162-29-2230 6162-29-2220 6162-29-2210

t 1 0.025

Remarks

1.50

1 0.004 1 0.002
1 0.001 0.001 0.001 0.001

1
1 1 \

1 0.80 1 0.50 0.26 0.20 0.16

1 0.025 1 0.025
0.025 0.020 0.016

Shim

T*t

F6164122

15-025 0

REPAIR AND REPLACEMENT

OF PARTS

GRINDING

THE TOP SURFACE

OF CYLINDER

BLOCK

3.

Checking and distinguishing after grinding and correcting


After grinding in the cylinder Remove height always * and correcting, check for scratches and oil holes on the flat surface around the water

block top surface. if the cylinder dimension, 509.8 block but mm),

all burrs completely.

After grinding the top surface,

H exceeds
the repair

the

standard

is within

limit (569.5

use an oversize

head gasket. 6162-19-1811

Oversize Thickness

head gasket part number: of plate: 2.4 mm (Standard: 2.0 mm) are stamped of the of the
Position Ds,r I.

Ir To distinguish, on the plate. After correcting, block

the letters stamp the

OS

top surface content

cylinder correction

according

to the

as shown

in the table below.

Table of letters to stamp


Oversize head gasket Shim Stamp

18,
(Size of letters: 5 10 mm) HLE00067

15026 0

REPAIR

AND

REPLACEMENT

OF PARTS

GRINDING

THE

TOP

SURFACE

OF CYLINDER

BLOCK

4.

Procedure gasket When fitting 6 +

for coating out the

bottom cylinder contact

of linei liner

lip with

sealant pulling it again, and press under LGcoat the surface

the counterbore

liner lip with gasket sealant part. available

as follows. Use the same procedure when using


The following is equivalent Three commercially to LG-6. SS-6OF
6162F759

a shim for the corresponding

sealant

l l

Bond: TBI 215

Nihon Hermetic:

1) Use a cloth to wipe off all the dirt and oil from the contact surface block counterbore.
Meting portion

of the liner lip and cylinder marked in the diagram line with

Top surface

of block

Of liner

2) Coat the position LG-6.


l

Make sealant

the

diameter 3 mm.

of the

of gasket

$2 -

Make the overlapping and ending the mm as shown

portion for beginning of sealant 6 f 6


Position to coat with gasket sealant

coating

in the diagram.

F6164124

When
l

using shims coating with the LG-6, bottom instll of the it to the shim deck way
-1

Overlap

amount

6 + 6 mm

After thinly Next,

portion of the block.


l

coat with

LG-6

in the same

as when

not using shims.

d
G-6 / (@2 -

F6164125

3 mm)

3) Press fit the liner in the cylinder When doing RF-I. is equivalent is not surface to the this, coat the lubricant

block.

1
rubber

seal with

+ RF-l

commercially coat the block oil

available

Daido Kagaku

Kogyo DS-50. and seal with of engine press fitting

+ If RF-1
contaet (SAE30) the liner.

available, of the O-ring amount

an extremely

small

immediately

before

F6164126

15-027 0

REPAIR AND REPLACEMENT

OF PARTS

GRINDING

THE TOP SURFACE

OF CYLINDER

BLOCK

4)

Coat the liner O-ring, clevis seal, and cylinder block contact surface with a small amount of engine oil (SAE #30) immediately before press fitting the liner. * Coat the contact surface of the cylinder block uniformly around the whole circumference by hand.

\+a

6162F761

5)

Insert liner (I) into the cylinder care not to damage the O-ring.

block, taking

6)

Use your weight and push the liner in with both hands. Ir If the liner does not go in smoothly when you apply your weight, there is danger that the O-ring may be damaged, so check the cylinder block for burrs or flashes.

7)

Using liner driver I, press fit cylinder liner (1) into the cylinder block. * Using the following procedure, squeeze out the gasket sealant coated on the counterbore. i) Tighten the cylinder head temporarily with a used head gasket. w Mounting bolt: 26 * 1 kgm

ii)

Ir

Remove the cylinder head, and wipe off the gasket sealant that has been squeezed out from between the cylinder liner and cylinder block. If gasket sealant sticks to the grommet in the head gasket, the grommet will be deformed, and this will cause leakage of water, so remove all the gasket sealant.

6162F764

15-028 0

REPAIR AND REPLACEMENT

OF PARTS

GRINDING

THE TOP SURFACE OF CYLINDER

BLOCK

8)

Loosen the cylinder head mounting bolts, remove the head, then wipe off the excess gasket sealant that has come out from the cylinder bore. a The gasket sealant that comes out may cause deformation of the head gasket grommet, so always carry out steps 4) and 5) without fail.

If the grommet is deformed into a heart shaDe. it blocks the water hole

and may cause the coolant.

leakage

of

/ /
Grommet

\ \
Water hole

F616417.7

15029 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

MAIN METAL CAP

REPLACING MAIN METAL CAP * When replacing the main metal cap, machine
the semi-finished part according to the following procedure. No. 1,2,3,4,5 and 7 Main cap 6162-29-1210 No. 6 Main cap 6162-29-l 250 ( 1 1. Machining the bore of main metal cap 1) Remove the cylinder liner 2) Install the replacement metal cap to the cylinder block and tighten it to specification. w * Mounting boltfor main metal cap: and seat with engine oil

Coat the thread SAE30

Unit: kgm Procedure 1 st step 2st step 3st step 4st step 5st step 6st step Target 56 113 0 38 75 113 51 -61 5) 107-118 Loosen completely 33-43 70-80 107-118 on the cylinder block Cut the inside of metal cap (I) little by little while checkinn its inside diameter. Cut until the cutting tool contacts the inside wall of cylinder block (2). Inside diameter of main cap: i) Machining dimension Tolerance: ii) 148+to25 mm Inside diameter of cap when main cap is tightened to specified torque after machining. Tolerance: 148$::%: mm Range

2 z &

Align the notches and cap.

3)

4)

Set the jig for mounting the cylinder block to the table of a horizontal boring machine. Install the cylinder block by mounting its hole for the liner to the datum plug of the jig. Center the arbor of the boring machine by applying a dial gauge to the inside wall of the two metal caps which have the largest pitch in the metal caps to b e used again.

(IO range above and below cap matching surface) Surface roughness: 12.5s max. Never cut the inside wall of the cylinder block.

HLE00060

15030 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

MAIN METAL CAP

2.

Correcting the width of the main metal cap (Modifvinn No. 6 main cap onlv) 1) lnskrtcast iron bushing @and pass arbor @I through. 2) Install facing tool @to the arbor. 3) Cut cap (I), until the cutting tool contacts the cylinder block. 4) Cut the opposite side in the same way. * Never cut the cylinder block.
6 I27F230

* +

Roughness Width

of surface facing thrust metal: 12.5 max. of main cap Tolerance:

Max.R0.5 1

HKE00068

15031 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

CAM BUSHING

REPLACING CAM BUSHING


* Before replacing the cam bushing, remove plug from the rear of the cylinder block. Removing No. 1 and No. 7 bushings the

1. .

As shown in the figure, assemble push tool @ and collar @ in push tool set Jl, and grip J2, then pull bushing (2) out of cylinder block (I) by hitting the grip.
6162F518A

2. .

Removing

No. 2 and No. 6 bushings

Assemble push bar 0, push tool 0, guide 0, and collar @ in push tool set Jl, then pull bushing (2) out of cylinder block (1) while hitting the bar.

c
6162F519

3. .

Removing

No. 3, No. 4, and No. 5 bushings

Assemble push bar 0, push tool 0, guide 0, and collar 8 in push tool set Jl, then pull bushing (2) out of cylinder block while hitting the bar.

2 1

6162F520

4. .

Press-fitting

No. 3, No. 4, and No. 5 bushings

Assemble tool set Jl and bushing (2), then fit the bushing until the end face of push tool @I contacts cylinder block (I). Ir Align the oil hole on the bushing. (This must be cared whenever fitting the bushings.)

6162F521

15-032 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

CAM BUSHING

5. .

Press-fitting

No. 2 and No. 6 bushings

Assemble tool set Jl and bushing (2), then fit the bushing until the end face of push tool @I contacts the cylinder block. * Align the oil hole on the bushing.

6162F522

6. .

Press-fitting

No. 1 and No. 7 bushings

Assemble tool set Jl, grip J2, and bushing (2), then fit the bushing until the end face of push tool @I contacts the cylinder block. Ir Align the oil hole on the bushing. Press-fit the plug to the rear of the cylinder block.
6162F523A

REPAIR AND REPLACEMENT

OF PARTS

CRANKSHAFT

CRANKSHAFT

HLE00062

1.

Crankshaft

Unit: mm Inspection A. Cranks 6. Damage Check for damage to the journal portion 1 Damage C. Clogging of oil hole Scratches seizure discoloration item Judgement Use a magnetic standards to check for cracks Replace If the damage is slight, correct with an oilstone or correct by lapping. Replace if there is seizure Correct Correct Remedy

flaw detector

to cap hole at front and rear end of oil hole

Check for clogging

15-034 0

REPAIR AND REPLACEMENT

OF PARTS

CRANKSHAFT

Unit: Inspection item Judgement Standard value 0.14 - 0.320 standards Repair 0.69 limit

mm

1
Repair 3.79 3.92 limit

Remedy

D. End play of crankshaft

Replace thrust bearing or correct with oversize

E. Thickness bearing

of thrust

Size STD 0.25 US 0.50 us 0.75 us 1 .oo us

Standard 4.0 4.125 4.25 4.375 4.5 Standard 108.00 107.75 107.50 107.25 107.00

size

Tolerance

-0.07 -0.12

4.04 4.17 4.29

_ Replace thrust bearing or correct crankshaft . with oversize

F. Outside diameter crankshaft pin journal

of

Size STD 0.25 US 0.50 us 0.75 us 1.00 us

size

Tolerance

Repair

limit

107.91 107.66 -:.022 107.41 107.16 106.91 Correct with undersize or replace

G. Out-of-roundness crankshaft pin

of

I. Outside diameter main journal

of

L. Curvature of crankshaft (total runout of indicator)

Standard Total coaxiality main journal of Max. 0.09 Max. 0.05

Repair 0.09 0.05

limit Replace

Coaxiality of neighboring journals

15-035 0

REPAIR AND REPLACEMENT

OF PARTS

CRANKSHAFT

Correcting surface journal portion


If the does roughness not fulfill

roughness

of crankshaft

of the the

crankshaft

journal the

portion surface

standard,

correct

roughness. 1. Cleaning Before 2. with air. Correcting 1) When machine Use a special the diagram polishing on the right. speed for the work use No. 320 dry polishing paper at 40 (belt up and machine as shown in surface correcting roughness with of journal special portion polishing and blowing polishing, brush with air and blow

the oil holes

i)

Set the rotating 50 rpm, type). honing journal. Perform

(do not use once width for each

oil), and move the paper

and down the whole journal ii) Next, replace journal right the handle by the movement. journal.

with No. 500 paper, coat the with honing oil, and move to the left and to move of the and do
Move handle to left and right, and move once up and down width of journal F6164131 z z

surface

of the machine amount Use this

of play to give fine movement smoothly width

once up and down the whole Move the paper not stop at any point. iii) Check the surface not within roughness,

and if it is with

the standard,

polish again once of the journal

up and down the width No. 500 paper.

F6164132

15-036 0

REPAIR AND REPLACEMENT

OF PARTS

CRANKSHAFT

2) When
(When

using a work clamp jig for polishing a special clamp polishing jig such grinding No. 800 oil: Honing 40 rpm time for Move one the journal clamp is the oil machine as shown machine is not in the under

available) Use a work diagram on the right. polising conditions.

Use a crankshaft the following Paper: Machining The polishing Work speed: approx. amount width down replace When

6 minutes. (approx.

of play of the clamp 5 mm), the journal in the axial

and journal up and direction.

and move

After completing honing

the honing of one journal, the pin journal, it is safer

the paper with new paper.

to carry out the work with the pin journal at the rotation center.
F6164133

3) Assembly use

of work

clamp

jig and

method

of

i) Jig for pin journal Assemble diagram component separate on the parts, pages.

and jig for main journal jig as shown For details the in the of the on right. see

the clamp

drawings

F6164134

15-037 0

REPAIR

AND

REPLACEMENT

OF PARTS

CRANKSHAFT

ii) Cut out a piece of No. 800 paper with the shape shown in the diagram on the right.
Make cuts of 20 mm length\ at approx. 10 mm intervals

Dimensions

of paper for pin journal 230 mm

IIIIIIIIIII

i E 9

iii) Take 2 pieces of paper prepared in Step ii), insert the top and bottom pieces in the slit of the clamp jig. then fix in position with tape. iv) Fit the journal in the clamp, and fix the ends of the lever with a rubber tube.
Cut out slit 2 portions

I I I I I I I I I n_,
Dimensions of paper for main journal

F6164135

3.

Measuring

surface

roughness

Standard for surface roughness Journal surface, thrust surface: Max. 0.8 S Using a surface roughness measuring tool, check that the roughness is within the standard. If no measuring tool is available, rub No. 1500 paper extremely lightely in the axial direction, and use a 30-times magnifying glass to inspect the pattern on the paper. If the horizontal lines can be seen to be connected it is within the standard value. If the lines cannot be seen to be connected, the roughness of the journal surface is excessive, so polish it again.
4. Cleaning after correcting surface roughness

z z

After correcting the surface roughness, always brush the oil hole and blow with air.
5. Check that there portion are no scratches and fillet or dents at

the journal

R portion.

Fix in position Bend to fit round

with tape w inside plate

.Rubber

shape

F6164136

15038 0

REPAIR AND REPLACEMENT

OF PARTS

CRANKSHAFT

Clamp jig parts drawing

(for pin journal)

@I Plate (2 are used for each jig)


Unit: mm I= 5 69 k 0.1 -i (10) 74

F==i
A

LLI
31.5

I
=H--

--t-F

/
STKM 13A

Section A-A
F6164137A

Handle (2 are used for each jig)

Umt: mm
132 450

F6164138A

15039 0

REPAIR AND REPLACEMENT

OF PARTS

CRANKSHAFT

Clamp jig parts drawing 0

(for main journal)

Plate (2 are used for each jig)


Unit: mm

t A 27.5

1 A

/
6.5 6.5 STKMI 3A

Section A-A
g=x Section

A-A

F6164139A

@I Handle (2 are used for each jig)


Unit: mm

F6164140A

REPAIR AND REPLACEMENT

OF PARTS

REPAIRING

THE CRANKSHAFT

REPAIRING THE CRANKSHAFT


.
If the crankshaft is worn or slightly seized or damaged, cut it to any one of the following thicknesses. Undersize dimensions: 0.25, 0.50,0.75, 1.00 mm If the crankshaft is bent or worn unevenly, replace it instead of repairing it. (A lot of skill is required to repair it.) Carefully finish section R of the fillet of the crankshaft, section r on the shoulder, and section R facing the hole. . Dimension Roughness of outside surface of pin journal, main journal: Max. 0.8s Tolls and jigs required for cutting 1) Magnetic flaw detector 2) Shore hardness tester 3) Etching kit 4) Crankshaft cutting machine 5) Crankshaft grinding machine 6) Roughness gauge 7) Ball gauge for measuring radii of fillets Min. 795-500-1140 Max. 795-500-I 150 Check before cutting 1) Visual check Check for cracks, damage, seizure, discoI: oration, wear, etc. to see if it can be repaired. 2) Hardness test of journal Hardness of journal (Shore hardness) Allowable range: 60 - 67 Hs Limit: 60 Hs If the hardness is below the limit, dispose of the crankshaft. 3) Torsion test

\ / IFof fillet
R

Dimension

\ c
/r
R: 6.5_g.s mm, Surface roughness r: 6.4 mm, Surface roughness
R
6127F231

1.6s 12.5s

Stroke

of oil hole on journal

Main journal

Pin journal

6127F233

Throw

of eccentric:

85-t,,,

mm

15041 0

REPAIR AND REPLACEMENT

OF PARTS

REPAIRING

THE CRANKSHAFT

2.

Check during and after cutting 1) Checking the round sections of fillets i) Confirm that the round sections of fillets are smoothly connected to the shoulders of journals. ii) Using ball gauges for measuring the radii of the fillets, confirm that each radii of the fillets, confirm that each radii is between the minimum and maximum limits. 3.

4) Measuring the bend (Alignment) l Measure the bend of the repaired crankshaft. l Measure the bend (alignment) at the following four places. i) Overall length alignment: 0.09 mm max. 0.05 mm max. ii) Adjoining alignment: 10.04 mm max. iii) Forward end alignment: iv) Rear end alignment: 0.03 mm max.

&tact

kk
point

Cutting the main journals Cut all the main journals to the same undersize. When cutting the main journals, count in the finishing allowance for grinding 0.007 to 0.008 mm. Undersized of main journal Unit: mm Size Basic dimension 140.000 139.750 139.500 139.250 139.000 -00.025 8 Z Z Allowable error

Contact point

6127F234

Minimum radius of fillet: 6.00 mm Maximum radius of fillet: 6.50 mm 2) Checking the seized surfaces by etching After cutting the journals, confirm that no parts were seized in the cutting procedure by the etching test. l If any seized part is found, cut the journal another 0.02 mm to apply the next undersize. l After etching the journals, neutralize and wash the checked surface, then apply oil.

S.T.D 0.25 US 0.50 us 0.75 us 1 .oo us

3) Magnetic flaw detecting l Before using the repaired crankshaft, confirm that there are no cracks on it by magnetic flaw detection. l Check the fillets of journals which are put in the critical area of each web of the crankshaft especially carefully. l After inspecting with a magneticflawdetector, always demagnetize the crankshaft.

Out of roudness and cylindricality of main journals (T.1.R). surface roughness. Allowable error: 0.010 mm max. Limit: 0.015 mm Surface roughness: 0.8s

Critical area of web of crankshaft

I 6127F235

15042 0

REPAIR AND REPLACEMENT

OF PARTS

REPAIRING

THE CRANKSHAFT

4.

Grinding the thrust bearing surface Jc It is not always required to grind the front and rear thrust bearing surfaces to the same undersize. * If the thrust bearing surfaces have been ground, confirm that the end play of the crankshaft is within the allowable range (For details, see DISASSEMBLY AND ASSEMBLY). . Undersizes of thrust bearing surfaces

5.

Grinding pin journals * Grind all the pin journals to the same undersize. * When grinding, count in finishing allowance for grinding 0.007 to 0.008 mm. . Undersizes of pin journal
Unit: Size S.T.D 3asic dimension 108.00 107.75 107.50 107.25 107.00 0 -0.022

mm

Ulowable error

Unit: Rear thrust S.T.D bearing

mm 0.25 US 0.50 us 0.75 us 1 .oo us

surface

1
0.25 0.S +0.050 64.25 o 64.310 64.50+;.05 64.560

Basic
dimension Limit Basic dimension Limit

64+:.050
64.060 64.25+;050 64.310

Out of roundness and cylindricality of pin journal (T.I.R), surface roughness Allowable error: 0.010 mm max. Limit: 0.015 mm Surface roughness: 0.8s

6.
.

Squareness (T.1.R)

of thrust bearing Limit: 0.04 mm

surface .

Correcting the width of the main journal and pin journal by grinding When correcting the worn surfaces of the main journals and pin journals, limit the grinding thickness to the minimum. Width of crank pin journal If cutting one side only: Standard: 72+i.074 mm Limit: 72.32 mm Width of main journal: 64+g.05 mm Standard: Limit: 64.30 mm Squareness of thrust bearing surface (T.1.R) Limit: 0.04 mm
Thickness of friction surface -L Journal

Friction surface 1 6 I27F236

15-043 0

REPAIR AND REPLACEMENT

OF PARTS

REPAIRING

THE CRANKSHAFT

7. . .

Correcting the grindstone Dress the grindstone each time one journal is ground. Grindstone dresser Tip angle: 75? I0 Radius of edge: 0.38 * 0.25 mm At the edge of the dresser, a diamond for industrial use must be embedded.

IO. Treatment after grinding Confirm that each dimension is within specification. . Carefully wash each section and apply oil to it. . When storing the crankshaft for a long time, support it at three points or hang it vertically. 11. Balancing (for reference) (Do not perform any repair which will have an adverse effect on the balance of the crank shaft.) . Limit of unbalance: 110 g.cm . Limits for reading the balance correctly Bend of crankshaft: 0.09 mm (T.1.R) Speed of crankshaft: 325 rpm max. . Balance the crankshaft with the crank gear installed or install a weight equivalent to the weight of the gear fixing key to the keyway. . To balance the crankshaft, make a hole on the counter weight with a drill or cut it. Limit of amount of counterweight to be removed: 56 g 6 max. Number of holes: 19 mm or 23 mm Diameter of hole: 50 mm max. Depth of hole: Distance between hole and side face: 3 mm min. Distance among holes: 5 mm min.

Adjust the machine for correcting the grindstone, and correct the edge of the grindstone to the radius of the fillet. When checking and correcting the grindstone edge, grind a wood bar for trial and use ball gauges. Preventing seizure caused by grinding 1) Use the plunge grinding method. 2) Use the overall width of the grindstone. Do not grind the bosses if possible. 3) Apply sufficient cooling oil. 4) Set the circumferential speed of the grindstone to 2,000 m/min when the speed of crankshaft is 50 rpm. 9. . Surface finishing Standard surface roughness 0.8s Journal: 1.6s max. Thrust bearing, fillet: 1-2s Tapered end: Bosses of pin and main journal: 3.2s max. Finishing allowance for grinding: 0.007 to 0.008 mm

8 z z

15-044 0

REPAIR AND REPLACEMENT

OF PARTS

REPAIRING

THE CRANKSHAFT

12. Procedure for measuring curvature of crankshaft and outside diameter of journal Method of measurement 1) When measuring the curvature, use No. 1 and No. 7 journals as the datum point, put the dial gauge in contact with the journal and set the dial to 0 at the peak. Then rotate one turn and read the minimum and maximum values.

Example of measuring curvature

F6164144

2)

Measure the outside diameter of the main journal in the XY direction (No. 1 - 2) at 2 places, and the outside diameter of the pin journal in the XY direction (No. 1 - 2) at 2 places with a micrometer or air micrometer.

Locations for measurement

12345

15-045 0

REPAIR AND REPLACEMENT

OF PARTS

CONNECTING

ROD

CONNECTING

ROD
1. 2. 3. 4. 5. 6. Bolt Washer Cap Dowel pin Connecting Bushing

rod

F6164151

Unit: mm Inspection A. Cracks B. Curvature, twisting Check for curvature or &vising


F6164152A

item

Judgement

standards flaw detector

Remedy

Check for cracks with a color check or magnetic

,,,I:::~

:,

I D
Replace

C. Clearance between connecting rod bushing and piston pin

Replace bushing, roughness of inside surface of bushing: Max. 2.4s Inside diameter of hole at big end Without bearing Standard 115 size

8 Z G,

D. Inside diameter of hole at big end of connecting rod

Tolerance

+0.026 0 Roughness of inside surface of hole at big end: Max. 6.35 Clearance from crankshaft bearing (with bearing) Standard clearance

Replace

1
I

Clearance 0.20

limit

0.058 - 0.132

Even if each part is within the repair limit, if it is above the clearance limit, replace the part (bearing, etc.) E. Thickness bearing of S.T.D U.S 0.125 0.250 0.375 0.500 F. Scratches on inside surface of bearing, seizure G. Distance between holes at big end and small end Standard 3.500 3.625 3.725 3.875 4.000 -0.029 -0.042 size Tolerance Repair limit 3.41 3.54 3.66 3.79 3.90 Replace, replace connecting rod also size

Check for scratches or seizure

Standard 305

1 I

Tolerance Replace -:.05

15046 0

REPAIR AND REPLACEMENT

OF PARTS

CONNECTING

ROD

Unit: mm Inspection item Judgement standards Remedy

H. Scratches at I shape portion of connecting rod (dents)

Check for scratches direction in area A

in horizontal

Check for grinder grain in horizontal direction in area A dents, regardless of size Replace if fingernail catches in fretting

F6164153 I

I. Fretting of mating surface of cap

Check for fretting

of mating

surface surface: Max. 6.3 S

Roughness Contact

of mating

of mating

surface:

Min. 70%

J. Scuffing of bolt seat surface

Scuffing

of cap bolt seat surface

I
I

Correct with oilstone Replace Replace washer Replace bolt

Scuffing

of bolt seat surface

Scuffing

of washer

surface of dowel of dowel pin pin hole

I
I
to bolt thread

2
W

K. Deformation dowel pin L. Damage

of

Check for deformation Check for deformation

G to bolt Check for cracks, damage Check for curvature of bolt Replace bolt

If it is impossible to measure all the items in this judgment standard (in particular, the localized wear of big internal circumference) after machining and rebuilding the connecting rod, do not carry out any rebuilding. The reason for this is that it is impossible to confirm the precision after machining and rebuilding the hole at the connecting rod big end. When deciding on whether to reuse or discard the connecting rod, if honing grain can be observed on hole surface at big end, measurement of big end hole surface roughness and wave is unnecessary.

15-047 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

CRANKSHAFT

GEAR

REPLACING CRANKSHAFT
1. . Removal of gear Make a scratch in the surface at the root of the teeth with a nrinder, then assemble tools Kl and K2 and turn nut @ to remove the gear. * If the gear cannot be removed in this way, make a scratch in the surface at the root of the teeth with a grinder, then heat the gear with a gas burner and knock the gear out with a copper rod. t Be careful not to damage the crankshaft. Press fitting gear 1) Check the gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock a new key into the key groove of the shaft. 3) Heat the gear for the specified time at the specified shrink-fitting temperature. * Gear shrink-fitting temperature: 200C Heating time: Min. 30 minutes 4) Put the timing mark of the gear on the outside, then use a hitting tool to press fit until the side face of the gear is in close contact with the crankshaft flange. * Knock in quickly before the gear becomes cool.

K2 /

6162F813A

2.

15048 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

CAMSHAFT

GEAR

REPLACING CAMSHAFT
1.

GEAR

Removal of gear Set the camshaft assembly on the press stand, then push the camshaft to remove the gear When setting the camshaft assembly on the press stand, be careful not to get your fingers caught between the press stand and the gear. Press fitting gear 1) Checkthe gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock a new key into the key groove of the shaft. 3) Assemble the thrust plate. 4) Heat the gear for the specified time at the specified shrink-fitting temperature. * Gear shrink-fitting temperature: 200C Heating time: Min. 30 minutes 5) Put the timing mark of the gear on the outside, then use a hitting tool to press fit until the side face of the gear is in close contact with the camshaft flange. Knock in quickly before the gear becomes * cool.

2.

15049 0

REPAIR AND REPLACEMENT

OF PARTS

REPLACING

FLYWHEEL RING GEAR

REPLACING FLYWHEEL RING GEAR


g Be careful not to let the flywheel you. fall and injure

1. .

Removal of gear Make a scratch in the surface at the root of the gear teeth with a grinder, then split with a chisel to remove. Be careful when handling the grinder and chisel. Press fitting gear 1) Check the gear mounting surface, and if there are any scratches, correct them with an oilstone. 3 Heat the gear for the specified time at the specified shrink-fitting temperature. sr Gear shrink-fitting temperature: Max. 200C Heating time: Min. 50 minutes 3) Set the chamfered face of the gear facing the flywheel, and press fit until the side face of the gear is in close contact with the flywheel.

a 2.

15-050
0

Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR 2 : : S E R DEPARTMENT: NAME: NAME OF COMPANY: LOCATION: PHONE NO: DATE:

MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:

PROBLEM:

Attach photo or sketch. If more space is needed, use another sheet.

1 FOR INTERNAL USE ONLY


CORRECTIVE ACTION:

PFMRl 081696