SEBE6161
Shop Manual
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
12
TESTING AND ADJUSTING
13
DISASSEMBLY
AND ASSEMBLY ................................................. 13-001
14
MAINTENANCE
STANDARD’ ........................................................... 14-001
....................................................... I 1-001
............................................................. 12-001
2 z
15
00-2 0
REPAIR AND REPLACEMENT
OF PARTS .............................. 15-001
'
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00-2-3 @
SAFETY
SAFETY
NOTICE
SAFETY SAFETY
NOTICE
IMPORTANT SAFETY NOTICE Proper
service
and
repair
is extremely
service and repair techniques are both effective designed
manual.
for the specific
injury to workers,
The cautions
by Komatsu
take the necessary
situation
machine
operation.
and described
in this manual
require the use of tools specially
is used to mark safety precautions
these symbols
should
arises or may possibly
always
arise, first consider
in operation
carefully
6. Decide
are extremely and
Manual
the machine.
out any greasing
read all the precautions which
dangerous.
Maintenance
BEFORE operating
1. Before carrying
a place
in the repair
Always
and parts in their
correct
to keep
places.
keep the work area clean and make
sure that there is no dirt or oil on the floor.
or repairs,
given on the decals
carrying
out any operation,
wear safety shoes and helmet.
Smoke
only in the areas provided
for smok-
ing. Never smoke while working.
loose work clothes,
always
. Always
or clothes with buttons
wear
safety glasses when
trained,
7. Before
adding
hitting
oil or making
wear
safety
glasses
repairs are needed, experienced
when
welder
or tracks
blade,
ripper,
bucket or any other work equipment
starting
work,
out welding gloves,
out the work,
apron,
al-
hand
shield, cap and other clothes suited for weld-
work.
to the
If this
equipment
is not possible,
from falling.
ating procedure
before
step of the operation.
agree on the operstarting.
form your fellow workers
with two Always
in-
before starting any
Before starting
work,
REPAIR signs on the controls
in the operator’s
compartment.
5. Keep all tools in good condition the correct way to use them.
In addition,
the
be sure
ing signs on them.
the
machine
with
or assembling, blocks,
jacks
support or stands
before starting work. 10. Remove
all mud and oil from
the steps or
other places used to get on and off the machine. Always steps when Never
and learn
insert
to lock all the control levers and hang warn-
9. When disassembling out any operation always
lower
safety pin or use blocks to prevent the work
carrying
or more workers,
the
from moving.
carry
welding
carrying
to prevent
and
ground.
ways
hang UNDER
8. Before
repairs,
always have a
work. When wear
grind-
etc.
any
on hard, level ground,
block the wheels machine
ing parts with a grinder, 3. If welding
FOR WORK
park the machine
parts with a hammer. . Always
PREPARATIONS
Do not wear
missing.
4. When
the tools
workshop
parts. Always
are fixed to the machine.
2. When
ing
care-
safety, and
keep tools and removed Mistakes
in this
be followed
actions to deal with the situation.
PRECAUTIONS
Read the Operation
The
purpose.
symbol A
the
accompanying
fully. If any dangerous
GENERAL
recommended
for safe
and safe. Some of these techniques
by Komatsu
To prevent
important
jump
impossible
use the handrails,
getting
ladders
or
on or off the machine.
on or off the machine. to use the handrails,
steps, use a stand to provide
If it is
ladders
or
safe footing.
00-3
SAFETY
SAFETY
PRECAUTIONS
DURING
19. Be sure to assemble
WORK
original 11 When or
removing
hydraulic
pressure
loosen them spurting Before
the oil filler cap, drain plug
slowly
measuring
to prevent
disconnecting
or removing
the pressure
when
or air circuits, completely
from
first the
and
oil in the circuits
the engine
is stopped,
20. When sure
installing that
high pressure
they
are hot
ful when
are
circuits.
so be careful
out any work
to cool
before
21 When
on the oil or water
Also,
13. Before starting work, remove the leads from Always
remove
(-) terminal
the lead from
first. use a hoist
or parts which
22. When
aligning
fingers
caught
ample
capacity.
Install
the lifting Use
23. When
equipment
which
has
a hoist
ting any other
or crane
and operate
the component
part. Do not work
15. When
removing
covers which
ternal
pressure
or under
always
leave two
hit-
with
any
wiring 17 When
bolts
from
a
in position
release
components,
or damage
the pres-
removing
be careful not
the wiring.
may cause electrical piping,
Damaged
fires.
stop the fuel or oil
from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor
Fuel or oil
can cause you to slip, or can
even start fires. 18. As a general
rule, do not use gasoline
to
wash parts. In particular,
use only the mini-
mum
washing
parts.
00-4
or rotate at
careful
to check
correctly.
Be careful
measuring
hydraulic
that the measuring
not to get your
pressure,
tool is correctly
of gasoline
when
electrical
removing
tracks of track-type When
removing
rates suddenly,
are under in-
pressure
sides. Slowly
removing
to break
violently
in a hole.
24. Take care when
from
sure, then slowly loosen the bolts to remove. 16. When
When
check assem-
at the correct
part still raised by the hoist or crane.
on opposite
parts, always torques.
bled before taking any measurements. equipment
to prevent
spring,
parts
two holes, never insert your
Check that the wire rope, chains and hooks lifting
care-
parts such as guards,
vibrate
or hand.
use
or installing
be particularly
fingers
are free from damage.
Damaged
connecting
tightening
protective
high speed,
make
so be extremely
check that
or crane.
Always
is be-
hoses,
not twisted.
that they are installed
14. When raising heavy components,
places.
by contact
installed.
assembling
installing
the negative
be sure
tubes for high pressure
use the specified
circuits.
the battery.
installing
are correctly
for the oil and water
carrying
slowly
parts with new parts.
hoses and wires,
tubes are dangerous,
not to get burned. Wait
installing
ing operated.
compo-
circuit. water
in their
with other parts when the machine
nents of the oil, water
12. The
Replace any damaged
that they will not be damaged
the oil from
out.
remove
all parts again
places.
. When
plugs,
NOTICE
or installing
the
machines.
the track,
the track
so never let anyone
either end of the track.
sepa-
stand at
FOREWORD
GENERAL
FOREWORD GENERAL This
shop
serviceman
manual
has been
an accurate
prepared
as an aid to improve
understanding
repairs and make judgements.
the
quality
of the product and by showing
Make sure you understand
of repairs
by giving
the
him the correct way to perform
the contents
of this manual
and use it to full
effect at every opportunity.
This shop manual
mainly
service workshop.
For ease of understanding,
chapters
are further
contains
divided
the necessary
technical
the manual
information is divided
for operations
performed
into the following
chapters;
in a these
into the each main group of components.
STRUCTURE AND FUNCTION This section
explains
an understanding
the structure
of the structure,
and function
of each component.
but also serves as reference
It serves not only to give
material
for troubleshooting.
TESTING AND ADJUSTING This
section
adjustments
explains
Troubleshooting
DISASSEMBLY This section assembling
checks
charts correlating
This section
before
and
after
performing
repairs,
as well
as
of the checks and repairs.
“Problems”
to “Causes” are also included
in this section.
AND ASSEMBLY explains
the order
each component,
MAINTENANCE
to be made
to be made at completion
to be followed
when
as well as precautions
removing,
installing,
disassembling
or
to be taken for these operations.
STANDARD gives the judgement
standards
when
inspecting
disassembled
parts.
NOTICE The
specifications
time
and
with
the
contained
without latest
any
advance
in this notice.
shop Use
manual the
are subject
specifications
to change given
in the
at any book
date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL VOLUMES
REVISED
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When
Chassis volume: Engine volume:
pages.
Issued for every machine model Issued for each engine series
Electrical volume: Attachments volume:
1
Each issued as one volume to cover all models
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION
AND
UPDATING
Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
EDITION
a manual
(@@@....I
MARK is revised,
is recorded
an edition
on the
bottom
mark of the
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
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):
Symbol
item
A
Safety
10 -3
TT Item number ~~~~~~~b.,.
*
(IO. Structure number
el kg
2 (Engine volume):
-F
Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.
Special technical precautions or other precautions for preserving standards are necesperforming
the
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tghteninc torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
12 - 5 TT
Special safety precautions are necessary when performing the work.
sary when work.
for
each item. Example
Caution
Remarks
oil, water or fuel must be added, and the capacity.
Places where
Oil, water Additional cated
pages:
by a hyphen
page number. Example:
Added
00-6
pages are indi-
(-) and number
after the
File as in the example.
IO-4
IO-5
Additional
Places where Drain
must
oil or water be drained, and quan-
tity to be drained.
12-203 12-203-I pages -C12_203_2 12-204
HOISTING
FOREWORD
HOISTING
INSTRUCTIONS
INSTRUCTIONS
HOISTING 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.
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
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
the part to the relative 2) Check for existence ing
interference
part caus-
the part to be re-
moved.
WIRE ROPES 1) Use
adequate
weight
ropes
79%
88%
71%
41% SAD00479
of another
with
100%
parts.
depending
of parts to be hoisted,
on the
referring
to
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.
the table below: 4)
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter mm
Allowa
e load
kN
tons
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
suspended.
18
35.3
3.6
(1000
20
43.1
4.4
10
*
r
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.
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle of the hook.
portion
When two ropes sling a load vertically, to 19.6 kN (2000 kg} of total weight This weight
kg1 when
hanging
angle.
two
becomes
ropes
9.8 kN
make
On the other
ropes are subjected
a 120”
hand, two
to an excessive
as large as 39.2 kN (4000
up
can be
force
kg1 if they sling
a 19.6 kN (2000 kg1 load at a lifting angle of 150”.
0 a
D
E,
88
16.7 0
ibid
(1400)
Q (1000)
% 600)
30 Lifting
60 anrle
90 (dearee)
120
150 SAD00480
00-7
COATING
FOREWORD
COATING
MATERIALS
MATERIALS
*
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
LT-IA
Part No.
Q'W
790-129-9030
150 g
Container
Main
I
l
LT-IB
790-129-9050
(2 pes.)
50 g
Polyethylene container
20 g
l
LT-2
09940-00030
790-129-9060 (Set of adhesive and hardening agent)
Adhesive:
LT-4
790-129-9040
250 g
Holtz MH 705
790-126-9120
75 g
LT-3
l
l
1 kg iardening
features
Used to prevent rubber gaskets, rubber ~ ~~ ~~ cushions, and cock plug from coming out.
ITubeTr-
Polyethylene container
applications,
used for
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
Can
agent: 500 g
Adhesives Polyethylene container
790-129-9140
50 g
Used as sealant
.
Used as heat-resisting ing engine.
. . .
Quick Cure Used bers,
Tube I
Three bond 1735
.
201
790-129-9130
29
Polyethylene container
I
Polyethylene container
I
Loctite 648-50
LG-1
Gasket sealant
00-8
LG-3
sealant
holes.
for repair-
I
I Aron-alpha
for machined
l
I l
l
I
hardening type adhesive time: within 5 sec. to 3 min. mainly for adhesion of metals, plastics and woods.
rub-
Quick hardenina tvoe adhesive Quick cure typejmax. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
79A-129-9110
790-129-9010
790-129-9070
200 g
Used as adhesive or sealant for gaskets and packing of power train case, etc.
1 kg
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
I
pipe, etc.
COATING
FOREWORD
Category
Komatsu code
Part No.
Q'W
Container
Main
. 790-129-9020
200 g
l
Tube
l
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
l
LG-5
790-129-9080
1 kg
Polyethylene container
l
Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc.
l
Gasket sealant
LG-6
09940-00011
250 g
Tube
l
l
* Features: LG-7
09920-00150
150 g
features
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.
l
LG-4
applications,
MATERIALS
Silicon
based,
quick
hardening
type - Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing,
Tube
etc. .
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
l
Molybdenum disulphide lubricant
.
G2-LI
SYG2-400LI SYG2-350LI SYG2-4OOLl-A SYGS-16OLI
Various
Used as heat-resisting engine.
sealant
for repairing
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.
l
General
purpose
type
Various
SYGA-1 6OCNLI l
SYG2-4OOCA SYG2-350CA
Grease
GP-CA
SYGS-4OOCA-A SYG2-160CA
Used for normal temperature, light load bearing at places in contact with water or steam.
Various
Various
SYGA-IEOCNCA Molybdenum disulphide lubricant
SYG2-400M
400 g (IO per
l
Belows
Used for places with
heavy
load
type
case)
00-9
FOREWORD
STANDARD
STANDARD STANDARD
TIGHTENING
TIGHTENING
Use these torques
TORQUE
TORQUE
TORQUES
for metric
TIGHTENING
OF BOLTS AND NUTS
bolts and nuts. (Always
use torque
wrench).
Width across fiats
Thread diameter of bolt I
I
mm
mm
Nm
kqm
6 8 IO 12 14
10 13 17 19 22
13.2+ 1.4 31+3 6657 113*10 177f19
1.35kO.15 3.2kO.3 6.7f0.7 11.5+1 18f2
279+30 382?39 549f59 745f83 927*103
28.5f3 39f4 56f6 76f8.5 94.5f 10.5
27 30 33 36 39
41 46 50 55 60
1320+140 1720+190 2210+240 2750+290 3290*340
135f15 175f20 225f25 280f30 335f35
I
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
7.85f 1.95 18.6f4.9 40.2f5.9 82.35k7.85
0.8f0.2 1.9f0.5 4.1f0.6 8.450.8
TIGHTENING
TORQUE
Use these torques Nominal
OF HOSE NUTS for hose nuts. Thread
No.
02 03 04 05 06 10 12 14
TIGHTENING
TORQUE
Use these torques Thread
diameter mm
00-10
Width
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
for split flange
IO 12
14 17
16
22
torque
Nm
kgm
24.5f 4.9 49k19.6 78.5k19.6 137.3k29.4 176.5f29.4 196.1*49 245.2f49 294.2+49
2.5rt0.5 5f2 8+2 14&3 18*3 20+5 2525 30*5
BOLTS
bolts.
across flat mm
Tightening
across flat mm
OF SPLIT FLANGE
Width
I
diameter mm
Tightening
I
Nm 65.7* 6.8 112k9.8 279*29
I
torque
kgm 6.7f0.7 11.5+1 28.5f3
FOREWORD
STANDARD
TIGHTENING
TORQUE
Use these torques Nominal
OF O-RING
Thread
No.
02 03.04 05,06 IO,12 14
BOSS CONNECTOR
diameter 14 20 24 33 42
TORQUE
Use these torques
Nominal
No.
Thread
TORQUES
Width
across flat mm
Tightening
I
I
torque
Nm
kgm
34.3* 4.9
3.5kO.5 9.5fl 14.5&Z 4356 89.5*13.5
93.1f9.8 142.1f19.6 421.4f58.8 877.1f 132.3
BOSS CONNECTOR
boss connector diameter
Width
Tighteni
across flat
I torque
mm
mm
Nm
kgm
8 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 -
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
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
36 -
OF FLARE NUT
Use these torques
for O-ring
Thread
Width
diameter
I
Varies depending on type of connector.
OF O-RING for O-ring
08 10 12 14 16 18 20 24 30 33 36 42 52
TIGHTENING
TORQUE
for O-ring boss connector
mm
TIGHTENING
TIGHTENING
SAD00483
boss connector
across flat
Tightening
torque
mm
mm
Nm
14
19
24.5f 4.9
18 22
24 27
49+ 19.6 78.5? 19.6
5+2 8k2
24 30
32 36
137.3k29.4 176.5ir29.4
1423 18k3
33 36 42
41 46 55
196.1f49 245.2+49 294.2f49
2Ok5 25f5 30+5
bm 2.5+ 0.5
00-l 1
FOREWORD
TIGHTENING
STANDARD
TORQUE
Use these torques Thread
FOR 102 ENGINE
SERIIES
diameter
Tightening
10 24 43 77
8 10 12
TORQUE
Thread
FOR 102 ENGINE
SERIIES
Tightening
Thread
00-12
torque kgm 0.81 1.02 1.22 2.45 3.67
8k2 lOf2 12 +2 24 f 4 36 + 5
8 10 12 14
FOR 102 ENGINE for tapered
screws
SERIIES
f 0.20 f 0.41 If: 0.61 f 1.22
Engine.
Nm
6
Use these torques
kgm 1.02 2.45 4.38 7.85
(EYE JOINTS)
diameter
TORQUE
torque
f2 f 4 6 z!z rk 12
for eye joints (unit: mm) of Cummins
mm
TIGHTENING
Engine.
Nm
6
Use these torques
NUTS)
for bolts and nuts (unit: mm) of Cummins
mm
TIGHTENING
(BOLT AND
TIGHTENING
(TAPERED
diameter
Engine.
Tightening Nm
II16 l/8 l/4 318 l/2 314 1
351 8+2 12f2 1552 24 + 4 36 k 5 60 k 9
0.20 0.20 0.20 0.41 0.51
SCREWS)
(unit: inch) of Cummins
inch
f + + f +
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
TORQUE
ELECTRIC WIRE CODE
FOREWORD
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
Applicable
Cali:rzD.
circuit
0.85
11
0.32
0.88
2.4
12
I
2
26
0.32
2.09
3.1
20
I Lighting,
signal etc.
4.6
37
Charging
and signal
59
Starting
(Glow plug)
5
65
I
I
0.32
5.23
I
15
84
0.45
13.36
40
85
0.80
42.73
60
127
I
100
\
I
217
CLASSIFICATION
1
0.80
63.84
0.80
I
1
109.1
Starting,
135~~~ I
Starting
13.6
178
Starting
17.6
230
Starting
lighting, signal etc.
BY COLOR AND CODE
Circuits1
Priority 1
Currerrtrating
Dia. yfmst$ndsCross section (mm*)
Starting
Lighting
Instrument
I
Other
Signal
I
I G
L
Yellow
Green
Blue
YR
GW
LW
Pri- Code man/ Color
W
B
B
R
Y
White
Black
Black
Red
Code
WR
-
BW
RW
Color
White & Red
-
Black & White
Code
WB
-
BY
!
2 Xed & White Yellow & Red Green & White Blue & White RB
YB
LR
GR
3 Black & YellowI Red & Black Yellow & Black Green & Red BR Black & Red ICode
I
-
I
-
& Green1
-
1
-
-
-
-
-
-
-
WG
5 IColorlWhite Code 6 Color
RY
I
YG
I
GY
Blue & Red I
LY
led & Yellow Yellow & Green Green & Yellow Blue & Yellow YL
RG
I
& Bluebreen
WJ
LB
GB
I
I
& Black1Blue & Black
GL
Red & Blue ly ellow &White Green & Blue
I
-
I
00-13
FOREWORD
CONVERSION
CONVERSION
TABLE
METHOD
THE CONVERSION
The
OF USING
Conversion
details
Table
of the method
TABLE
TABLE
in this section
is provided
of using the Conversion
to enable
Table,
simple
conversion
see the example
of figures.
For
given below.
EXAMPLE . 1.
Method Convert
of using the Conversion
Table to convert
from
millimeters
to inches
55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @. (2) Locate the number
5 in the row across the top, take this as @, then draw a perpendicular
line
down from @. (3) Take the point where from millimeters 2.
the two lines cross as 0.
to inches.
Therefore,
This point @ gives the value when
converting
55 mm = 2.165 inches.
Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal
point one place
to the left) to convert it to 55 mm. (2) Carry out the same procedure
as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters
to inches
1 mm = 0.03937
0
1
2
3
4
5;
6
7
8
9
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 i 0.591 i 0.984: 1.378: 1.772;
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
0 i . . . . . . . . . . . . . . 12.1651 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.126 . . . . . . . . . 2.047 2.087 1.969 2.008 50 @_.. 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
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
0 IO 20 30 40
00-l 4
in
FOREWORD
Millimeters
CONVERSION
TABLE
to Inches 7 mm
= 0.03937
in
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
0
Kilogram
to Pound
1 kg = 2.2046
0
0
lb
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-l5
FOREWORD
CONVERSIONTABLE
Literto U.S. Gallon 1C = 0.2642
1
2
3
0
0.264
0.528
0.793
1.057
1.321
1.585
IO
2.642
2.906
3.170
3.434
3.698
3.963
20
5.283
5.548
5.812
6.076
6.340
30
7.925
8.189
8.454
8.718
40
10.567
10.831
11.095
50
13.209
13.473
60
15.850
70
0
4
6
7
8
9
1.849
2.113
2.378
4.227
4.491
4.755
5.019
6.604
6.869
7.133
7.397
7.661
8.982
9.246
9.510
9.774
10.039
10.303
11.359
11.624
11.888
12.152
12.416
12.680
12.944
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
5
U.S. Gal
Literto U.K. Gallon
0
0
IC = 0.21997 U.K. Gal 1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
IO
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799 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
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-l 6
FOREWORD
CONVERSIONTABLE
kgm to ft. lb
r
1 kqm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
0
0
IO
00-17
CONVERSIONTABLE
FOREWORD
kg/cm*
to lb/in’ 1 kg/cm2 = 14.2233
0
3
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
5
6
7
2
1
4
8
lb/in2
9
0
0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109.
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-18
FOREWORD
CONVERSION
TABLE
Temperature Fahrenheit-Centigrade
Conversion
; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
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
in either Fahrenheit or Centigrade degrees.
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. 1°C = 33.8”F
“C
“F
“C
“F
“C
“F
“C
“F
-40.4
-40
-40.0
-11.7
11
51.8
7.8
46
114.8
27.2
81
117.8
-37.2
-35
-31.0
-11.1
12
53.6
8.3
47
116.6
27.8
82
179.6
-34.4
-30
-22.0
-10.6
13
55.4
8.9
48
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9
-20
-4.0
-9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
-28.3
-19
-2.2
-8.9
16
60.8
10.6
51
123.8
30.0
86
186.8
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
-26.7
-16
3.2
-7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
-26.1
-15
5.0
-6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
-25.6
-14
6.8
-6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
-25.0
-13
8.6
-5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
-24.4
-12
10.4
-5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
-23.9
-11
12.2
-4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
-23.3
-10
14.0
-3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
-22.8
-9
15.8
-3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
-22.2
-6
17.6
-2.8
27
80.6
16.7
62
143.6
36.1
97
206.6
-21.7
-7
19.4
-2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
-21.1
-6
21.2
-1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
-20.6
-5
23.0
-1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
-20.0
-4
24.8
-0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
-19.4
-3
26.6
0
32
89.6
19.4
67
152.6
43.3
110
230.0
-18.9
-2
28.4
0.6
33
91.4
20.0
68
154.4
46.1
115
239.0
-18.3
-1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
-17.8
0
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
-17.2
1
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
-16.7
2
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
-16.1
3
37.4
3.3
38
100.4
22.8
73
163.4
60.0
146
284.0
-15.6
4
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
-15.0
5
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
-14.4
6
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
-13.9
7
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
-13.3
8
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
-12.8
9
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
-12.2
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
00-l9
ENGINE 01 GENERAL
General view . . . . . . .. ......... Specifications ........................... General assembly drawing ................ Weight table ............................ Engine performance curve ................
170-1 SERIES
01-002 01-004 01-005
01-01 1 01-012
01-001
0
GENERAL VIEW
GENERAL
GENERAL
VIEW
S6D170-1 for PC650-1
‘\
1.
Corrosion resistor
2.
Crankcase breather
3.
intake manifold
4.
Fuel injection pump
5.
Fuel filter
6.
Oil filler
7.
Oil filter
8.
Vibration
9.
Turbocharger
damper
10.
Oil cooler
11.
Starting motor
12.
Alternator
13.
Water pump
6162POOZ
01-002
170-1 SERIES
GENERAL
SA6D170-A-1
GENERAL VIEW
for EG550-1
1. 2.
Fuel filter
3.
Oil filter
4.
Fuel injection pump
5.
Oil filler
6.
Oil level gauge
7.
Turbocharger
8.
Corrosion resister
9.
Alternator
10.
170-1 SERIES
After-cooler
Starting motor
01-003
SPECIFICATIONS
GENERAL
SPECIFICATIONS Engine model
Applicable
Number
of cylinders
S6D170-1
machine
- Bore x Stroke
Total piston displacement
D275A-2
mm
6-170x170
cc
23,150
Firing order
Pc1500-1 (Twin engine)
PC650-1
l-5-3-6-2-4
Overall
length
mm
1,860
2,029
2,029
mm
1,155
1,009
1,009
mm
2,070
1,875
1,875
mm
-
-
-
302/l ,800 (404/l ,800I
302/1,600 {404/1,600}
302/l ,600 {404/l ,600)
2,079/1,300 {212/l ,300)
2,030/1,200 {207/l ,200)
2,030/1,200 {207/1,200~
High idling
1,960 - 2,040
1,700 - 1,800
1,700 - 1,800
Low idling
600 - 660
650 - 700
650 - 700
219 {163}
224 {I671
224 I1671
2,620
2,375
2,375
Ovrall width Overall height (Excluding exhaust
pipe)
Overall height (Including exhaust
pipe)
Flywheel
horsepower
Maximum
Minimum
torque
fuel consumption
ratio
Dry weight
Bosch PE-PDx type
Fuel pump
Bosch RSUV centrifugal,
Governor
Lubricating
oil amount
all speed type
(refill capacity)
Coolant amount
Alternator
Starting
motor
Battery
24V, 50A
24V, 13A
24V, 13A
24V. 7.5kW x 2
24V, 7.5kW x 2
24V, 7.5kW x 2
12V 200Ah x 2
12V 170Ah x 2 I
I
I Turbocharger
Komatsu
KTRI IO
12V200Ahx2x2 I
Komatsu
KTR130
Komatsu
KTR130
Air compressor
-
Cummins single cylinder reciprocated type
Cummins single cylinder reciprocated type
Others
-
-
-
01-004 0
SPECIFICATIONS
GENERAL
S6D170-1 WA600-1 (Extreme cold weather)
WA600-1
WD600-1 (Cold weather)
WD600-1
6-170x
170
23,150 l-5-3-6-2-4
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)
(Net) (Net)
1,961/1,400 {200/1,400}
(Net) (Net)
305/2,000 (Net) {409/2,0001 (Net)
334/2,000 #48/2,000)
(Net) (Net)
1,961/1,400 {200/1,400~
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
2,200 - 2,300
2,300 - 2,400
2,300 - 2,400
650 - 700
650 - 700
650 - 700
650 - 700
212 1158) (Net)
212 {I581 (Net)
212 11581 (Net)
2,750
2,750
2,750
BOSCH PE-PDx type BOSCH
RSUV centrifugal,
(Net)
2,750
lOSCH RSUV centrifugal, all speed type
DENS0 NE (EP-11) type DENS0 RSUV-D centrifugal, all speed type
BOSCH
all speed typf
212 {I581
PE-P type
135
135
135
139
24V, 50A
24V, 50A
24V, 50A
24V, 50A
24V. 7.5kW x 2
24V, 7.5kW x 2
12V 200Ah
12V 200Ah
24V, 7.5kW x 2
24V, IlkWx2
12V 200Ah
12V 200Ah
x 2
-
x 2
x 2
KOMATSU KTRI IO type
KOMATSU KTRllO type
KOMATSU KTRIIO type
ZEXEL reciprocation single cylinder type
EXEL reciprocation, jingle cylinder type
‘EXEL reciprocation, single cylinder type
KOMATSU KTRllOtype ZEXEL reciprocation, single cylinder type
x 2
I
-
-
-
01-004-l 03
GENERAL
SPECIFICATIONS
Engine
model
Applicable
Number
of cylinders-Bore
Total piston Firing
S6D170-1
OEM ;;;ig,ee;erator
machine
x Stroke
displacement
mm
6-170x170
cc
23,150
order
length
Ovrall
width
Overall height (Excluding exhaust Overall height (Including exhaust
Flywheel Maximum
pipe)
pipe)
horsepower torque
mm
2,306
2,306
2,306
mm
1,048
1,048
1,048
mm
1,631
1,631
1,631
mm
-
-
-
kW/rpm +lP/rpm)
324/l ,500 (50 Hz) {434/1,500} (50 Hz)
355/1,500 (50 Hz) {476/1,5001 (50 Hz)
345/1,500 :462/1,500}
(50 Hz) (50 Hz)
IkgG?pmI
371/1,800 (60 Hz) {497/l ,800) (60 Hz)
408/1,800 (60 Hz) 1547/1,800) (60 Hz)
403/1,800 [539/1,800}
(60 Hz) (60 Hz)
Max. Max.
Max. Max.
Max. 1,560 (50 Hz) Max. 1,872 (60 Hz)
High idling
vm
Low idling Minimum
fuel consumption
ratio
Dry weight
kg
1,560 (50 Hz) 1,872 (60 Hz)
700 - 900
700 - 900
219 I1631
217 {162)
224 I1671
2,600
2,600
2,600
Bosch
PE-ZWx
type
oil amount
amount
Alternator
motor
Battery
Turbocharger
Air compressor
Others
01-004-2 0
(refill
capacity)
107 (96)
e e
(Engine
107 (96)
only 43)
z
Bosch RSUV centrifJgal, all speed type
type
(Engine
only
107 (96)
43)
(Engine
only
43)
24V, 13A
24V, 13A
24V, 13A
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, 7.5kW x 2
12V 200Ah
12V 200Ah
12V 200Ah
Komatsu
x 2
KTRI 10
Komatsu
x 2.
KTRI 10
-
Komatsu
x 2
KTRI 10 -
8 z
Bosch PE-PDx type
Bosch RSUV centrifugal, minimum maximum-speed
Governor
Coolant
1,775 (50 Hz) 1,890 (60 Hz)
700 - 900
Fuel pump
Lubricating
OEM for generator (Power up)
l-5-3-6-2-4
Overall
Starting
OEM for generator (Standby)
SPECIFICATIONS
GENERAL
T
Engine model
Applicable
Number
Total piston displacement
HD465-5 (Twin turbcharger)
HD465-3 (Twin turbcharger)
machine
of cylinders - Bore x Stroke
SA6D170-A-1
mm
6-170x170
cc
23,150
Firing order
WA700-1 “n$$~$~t~$ne
l-5-3-6-2-4
Overall
length
Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust
Flywheel
pipe)
1,877
1,989
2,391
mm
1,060
1,106
1,080
mm
1,692
1,678
2,017
kW/rpm IHP/rpm)
524/2,100 (Net) {702/2,1001 (Net)
534/2,100 {715/2,100)
(Net) (Net)
478/2,000 {641/2,0001
2,820/1,400 {288/1,4001
2,970/1,400(Net) {303/1,4001 (Net)
2,810/1,400 {287/1,4001
pipe)
horsepower
Maximum
mm
torque
Ikgi?prnl
(Net) (Net)
High idling
vm
2,300 - 2,400
2,300 - 2,400
2,240 - 2,300
Low idling
vm
630 - 680
850 - 900
700 - 750
g/kWh
221 (165)
211 {157)
208 {I 551
kg
2,480
2,750 JZlithexhaust brake
2,900
Minimum
fuel consumption
ratio
Dry weight
{g/HPh)
BOSCH PE-ZWx type
Fuel pump
BOSCH RFD minimum maximum-speed control type
Governor
BOSCH PE-ZWx type BOSCH RSUV centrifugal, all speed type
I Lubricating
oil amount
(refill capacity)
e e
170
174
24V, 50A
24V, 13A
24V, 13A
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
GARRET TV77 typex2
GARRET TV77 type x 2
CUMMINS single cylinder reciprocated type
ZEXEL single cylinder reciprocated type
ZEXEL single cylinder reciprocated type
With aftercooler, exhaust brake
With aftercooler
Coolant amount
Alternator
Starting
motor
Air compressor
Others
01-004-4 63
With aftercooler
SPECIFICATIONS
GENERAL
SAGDI 70-A-1
EG550-1
EG580-1 EG580B-1
EG600-l,EG600B-1 EG600BS-1 OEM for generctor
EG580B-IL
EPSAGD170-A-1
EG600BS-1 OEM for generctor (Engine No. 15503 and up)
6-170x170 23,150 l-5-3-6-2-4
2,015
2,603
2,603
2,603
2,601
2,603
1,048
1103
1,103
1,103
1,120
1,103
2,015
1,746
1,746
1,746
-
1,746
-
-
-
2,332
-
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)
472/1,500 (50 Hz) ;633/1,5001 (50 Hz)
1,700 - 1,800
Max. 1,560 (50 Hz) Max. 1,872 (60 Hz)
Vlax. 1,560 (50 Hz)
Max. 1,560 (50 Hz) Max. 1,872 (60 Hz)
1,950 - 2,050
Wax. 1,560 (50 Hz) Vlax. 1,881 (60 Hz)
650 - 700
700 - 900
700 - 900
700 - 900
750 - 850
700 - 900
230 {I711 (50 Hz) 236 1176) (60 Hz)
217 1162) (At rated output)
217 {162} (At rated output)
217 I1621 (At rated output)
231 1172) (At rated output)
217 1162) (At rated output)
2,650
2,770
2,770
2,750
2,850
2,770
-
8
-
-
470/1,500 (50 Hz) f630/1,5001 (50 Hz) 514/1,800 (60 Hz) 1688/1,800} (60 Hz) -
Bosch PE-ZWx type Bosch RSUV centrifugal,
all speed type
440/l ,800 {590/l ,800) 2,648/1,300 {270/1,300}
470/1,500 (50 Hz) 630/1,5001 (50 Hz) 514/1,800 (60 Hz) 688/1,8001 (60 Hz)
-
Bosch PE-P (PS7S) type
osch PE-ZWx type,
3osch RSUV centrif. ugal, all speed type
voodward PSG hyaulic type governor
119 (107)
139
;.::..,
24V, 13A 24V, 25A (opt)
24V, 13A 24V, 25A (opt)
24V, 13A
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, IlkWx2
24V, 7.5kW x 2
24V, llkWx2
24V. 7.5kW x 2
12V 170Ah x 2
12V 200Ah
12V 200Ah x 2
12V 200Ah x 2
12V 200Ah x 2
12V 200Ah x 2
KTR150
I
Komatsu
x 2
KTRI 50
Komatsu
KTR150
Komatsu
KTR150
24V, 50A
43)
24V, 13A
Komatsu
24V, 13A
(Engin&ly
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
SPECIFICATIONS
GENERAL
Engine model
Applicable
Number
of cylinders
SA6D170-A-1
- Bore x Stroke
Total piston displacement
HD465-5 (With electronic governor)
HD465-5 *I (Twin turbcharger)
machine
6-170x
mm
HD465-5 (Mechanical governor)
170
23,150
cc
Firing order
l-5-3-6-2-4
Overall
length
Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust
Flywheel
pipe)
pipe)
mm
1,989
1,989
1,989
mm
1,106
1,106
1,106
mm
1,678
1,678
1,678
mm
-
-
-
kW/rpm {HP/rpmI
horsepower
2,108/1,400 I215/1,4001
534/2,100 (Net) l2 015/2,100) Net) l2 43W.750 (Iuet) l3 (587/1,1501 (Net) *3
(Gross: (Gross1
534i2.100 {715/2,100} 2.971/1.400 {303/l ,400)
8 :
Maximum
E b ‘t lz
High idling
2,330 - 2,400
Low idling
1,075 - 1,125
920 - 970
900 - 950
211 {I571
211 {I571
211 I1571
2,750 JVith exhaust brake
2,670
Minimum
torque
386/2,100 (Gross) ~518/2,100~ (Gross1
tkgr$pm>
fuel consumption
ratio
gkWh {g/HPhl kg
Dry weight
2,600 (With;;;kee;haust
Fuel pump
3osch PE-ZWx typr
Governor
Bosch RSUV-D zentrifugal, minimun naximum-speed type
Lubricating
oil amount
(refill capacity)
Komatsu Electronic
*2 l3
2,330 - 2,400
KFE
Bosch PE-ZWx type
control
Bosch RSUV centrifJgal, all-speed type
(Xi,
Q
Q
Coolant amount
2,400-2,500 1.850-1.950
174
24V, 50A
174
24V, 50A
24V. 50A
24V. 7.5kW x 2
24V,llkWx2
24V, 7.5kW x 2
12V 200Ah x 4
12V 200Ah x 2
12V 200Ah x 2
Water cooled Gallet TV77 x 2
Gallet TV77 x 2
Gallet TV77 x 2
Air compressor
Zexel single cylinder reciprocated type
Zexel single cylinder reciprocated type
Zexel single cylinder reciprocated type
Others
With after cooler
With after cooler, exhaust brake
With after cooler
Starting
motor
Battery
Turbocharger
01-004-6
*I: l2: l3:
High altitude spec. en Power mode Economy mode
ne No. 15963 a
up to 15966
2 z z
SPECIFICATIONS
GENERAL
SA6D170-A-1
EG680A-1 6M170B-1
EM680A
EM680A-A
OEM for Marine engine
OEM for generator (Prime use)
2,603
-
2,603
1,048
-
1,048
1,756
-
1,756
-
-
-
OEM for generator
6-170x170 23,150 l-5-3-6-2-4
2,880 (With marine
gear)
2,841 With marine gear)
2,796 With marine
gear]
1,285 (With marine
gear)
1,137 With marine
gear)
1,150 With marine
gear)
1,757 (With marine
gear)
1,831 With marine
gear)
1,781 With marine
gear]
-
-
552/2,000 I740/2,000}
629/2,000 {842/2,0001
2,501/1,400 {255/l ,400)
2,893/l ,400 I295/1,4001
3,295/1,400 {336/1,4001
2
2,100 - 2,200
2,100 - 2,200
2,100 - 2,200
Max. 1,560 (50 Hz) Max. 1,872 (60 Hz)
2,100 - 2,200
Max. 1,568 (50 Hz) Max. 1,881 (60 Hz)
& z
550 - 600
550 - 600
550 - 600
950 - 1,000
550 - 600
700 - 900
217 {162)
211 {I571 (At rated output)
217 (157) (At rated output)
211 (157) (50 Hz) 217 I1621 (60 Hz)
211 1157)
211 1157) (50 Hz) 217 1162) (60 Hz)
2,750 (Withog;;Tarine
3,250 (Withw;;arine
2,720
2,500
2,720
-
55212,000 (740/2,000}
*4 *4
2,750 (Withw;r;;arine
473/1,500 (50 Hz) [633/1,500} (50 Hz) 546/1,800 (60 Hz) f732/1,800} (60 Hz) -
Bosch PE-ZWx Bosch RSUV centrifugal,
100
-
120 (108)
118
85
85
24V, 30A
24V, 25A
24V, 30A
24V, 13A 24V, 25A (opt)
24V, 13A 24V, 25A (opt)
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, 11 kW
24V. 7.5kW
12V 200Ah x 2
12V 200Ah x 2
12V 200Ah x 2
12V 200Ah x 2
12V 200Ah x 2
Komatsu
KTRI 10
Komatsu
-
-
-
With after cooler
With after cooler
With after cooler
Without marine gear With bypass filter
67 (60) 119 (107) opt
119 (107) 122 (110) *5
(Engine
KTRI 10
(50 Hz) (50 Hz) (60 Hz) (60 Hz)
all speed type
120 (108)
KTRI 10
419/1,500 I561/1,5001 467/1,800 {625/l ,800) -
type
(90)
Komatsu
*4: *5:
55212,000 {740/2,000}
Komatsu
KTRI 10
Komatsu
KTRllO
only 43)
24V, 13A 24V, 25A (opt) 24V, IlkW
12V 200Ah x 2
Komatsu
KTRIIO
-
With after cooler
With after cooler
With after cooler
01-004-7 0
SPECIFICATIONS
GENERAL
SA6D170-A-1
Applicable
Number
of cylinders-Bore
DEM for generator (Stanby use)
machine
x Stroke
Total piston displacement
mm
6-170x170
cc
23,150
Firing order
length
.P t
Ovrali width
i
Overall height (Excluding exhaust
6
Overall height (Including exhaust
Flywheel
pipe)
pipe)
mm
2,603
1,861
1,861
mm
1,048
1,060
1,060
mm
1,750
1,626
1,623
mm
-
-
-
515/2,100 (Net) {690/2,1001 (Net)
524/2,100 (Net) {702/2,1001 (Net)
2,824/1,400 {288/1,4001
2,824/1,400 {288/1,4001
kW/rpm {HP/rpm}
horsepower
Maximum
torque
{kgr%Pml
fuel consumption
ratio
Dry weight
700 - 900
850 - 900
850 - 900
g/kWh {g/I-W
211 11571 (50 Hz) 217 {1621(60 Hz)
219 (163)
221 (163)
kg
2,720
2,470
2,470
3osch PE-ZWx
Governor
3osch RSUV centrif, ugal, all speed type
Coolant amount
Alternator
Starting
motor
Battery
Turbocharger
(refill capacity)
e
e
01-004-8 0
Bosch PE-ZWx type
typf
Bosch RSUV centrifugal, minimum maximum-speed type
67 (60) 119 (107) opt
107 only 43)
170
170
24V, 13A 24V, 25A (Opt)
24V, 50A
24V, 50A
24V, 11 kW
24V, 7.5kW x 2
24V, 7.5kW x 2
12V 170Ah x 4
12V 170Ah x 4
(Engine
12V 200Ah
Komatsu
x 2
KTRI IO
Air compressor
Others
(Net) (Net)
2,250 - 2,350
Fuel pump
oil amount
(Net) (Net)
2,250 - 2,350
Low idling Minimum
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)
rPm
High idling
Lubricating
HD465-3 (Single turbocharger)
l-5-3-6-2-4
Overall
t?
H D465-3 (Single turbocharger)
With after cooler
Komatsu
KTRllO
Komatsu
KTRI 10
Cummins single cylinder reciprocated type
Cummins single cylinder reciprocated type
With after cooler
With after cooler
8 z z
SPECIFICATIONS
GENERAL
SA6D170-A-1
H D465-3 (For ORAPA MINE)
Pc1ooosP-1 (For LAYTON)
6-170x170 23,150 l-5-3-6-2-4
z
io z
1,861
2,373
1,060
1,909
1,626
1,080
-
-
485/2,000 (Net) {650/2,0001 (Net)
434/1,750 {582/1,750}
(Net) (Net)
2,800/l ,300 (Net) (285/1,300} (Net)
2,730/1,300 1279/1,3001
(Net) (Net)
2,250 - 2,350
1,900 - 2,000
840 - 860
650 - 700
216 I1611 (Net)
211 (Net) 11571 (Net)
2,480
2,555
BOSCH PE-ZWx wpe
IOSCH PE-P(PS7S1 type
BOSCH RFD minimun maximum-speed control 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
12V 200Ah
x 2
GARRET TV77 typex2 CUMMINS single cylinder reciprocated type With
aftercooler
x 2
KOMATSU KTRllOtype EXEL reciprocation jingle cylinder type With
aftercooler
01-004-9 63
SPECIFICATIONS
GENERAL
Engine model
Applicable
Number
of cylinders
SA6D170-B-1 D375A-1 IEngine Serial No. up to 11045)
machine
- Bore x Stroke
Total piston displacement
D375A-1 (Engine Serial No. 11046 and up)
mm
6-170x170
cc
23,150
Firing order
D375A-1 (Engine Serial No. 13551 and up)
l-5-3-6-2-4
t Overall
length
mm
2,017
2,017
2,017
mm
1,139
1,139
1,139
mm
1,746
1,746
1,746
mm
-
-
-
kW/rpm IHP/rpm)
379/1,800 {508/1,8001
379/l ,800 {508/1,800}
392/l ,800 {525/1,8001
tkgr%?pmI
2,609/l ,300 {266/l ,300)
2,609/l ,300 {266/l ,300)
2,618/1,300 {267/l ,300)
High idling
rpm
1,950 - 2,050
1,950 - 2,050
1,960 - 2,040
Low idling
rpm
600 - 700
600 - 700
580 - 680
g/kWh {g/HPh)
215 {I601
215 {160}
215 {ISO}
2,660
2,660
2,660
Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust
Flywheel
pipe)
horsepower
Maximum
Minimum
pipe)
torque
fuel consumption
ratio
kg
Dry weight
Fuel pump
losch PES-PDx typ
Governor
3osch RSUV centrif Jgal, all-speed type
Lubricating
Coolant
oil amount
amount
Alternator
Starting
motor
Battery
Turbocharger
Air compressor
Others
01-004-10 0
(refill capacity)
Bosch PE(PS7S) 3osch RSUV centrifugal,
z z
type all-speed
type
Q
Q
165
165
165
24V, 30A
24V, 35A (1104612802) 24V, 50A (12806-)
24V, 50A
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, 7.5kW x 2
12V 170Ah x 2
12V 170Ah x2
12V 170Ah x 2
Komatsu
KTRllO
Komatsu
KTRIIO
Komatsu
8
KTRI 10
-
-
-
With after cooler
With after cooler
With after cooler
SPECIFICATIONS
GENERAL
SA6D170-B-1
HD465-3 (Single turbocharger)
Pc1000-1
EG450-1
EG480-1 EG480B-1
EG500-1, EG500B-1 EG500BS-1 OEM for generator
EG500-1, EG500B-1 EG500BS-1 OEM for generator
6-170x170 23,150 l-5-3-6-2-4
2
(D z
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
451/2,100 {604/2,1001
2,550/1,300 I260/1,3001
2,481/1,400 {253/1,400}
354/1,500 (50 Hz) (481/1,5001 (50 Hz) 400/l ,800 (60 Hz) [544/1,8001 (60 Hz) -
37211,500 (50 Hz) l498/1,500~ (50 Hz) 416/l ,800 (60 Hz) (557/1,8001 (60 Hz) -
383/1,500 (50 Hz) {513/1,5001 (50 Hz) 427/1,800 (60 Hz) {572/1,8001 (60 Hz) -
383/1,500 (50 Hz) {513/1,500) (50 Hz) 427/l ,800 (60 Hz) {572/1,8001 (60 Hz) -
Max. Max.
Max. Max.
Max. Max.
1,560 (50 Hz) 1,872 (60 Hz)
1,572 (50 Hz) 1,890 (60 Hz)
1,568 (50 Hz) 1,881 (60 Hz)
1,800 - 1,900
1,800 - 1,900
1,800 - 1,890
650 - 700
650 - 700
950 - 1,000
750 - 850
750 - 850
700 - 900
217 1162) (At rated output)
217 I1621 (At rated output)
2,750
2,720
211 {157}
224 {I 67)
217 I1621
217 {162} (At rated output)
2,555
2,555
2,650
2,650
BOSCH PE-P(PS7S) type
BOSCH PE-ZWx type
BOSCH PES-PD type
BOSCH RSUV centrif ugal, ail-speed type
BOSCH RSUV-D :entrifugal, minimum naximum-speed type
BOSCH BOSCH
PE-ZWx
119 (107)
160
24V, 50A
24V, 50A
119 (107)
119 (107)
(Engin%ly
43)
PE-P(PS-7% type
lOSCH RSUVcentrifugal, all-speed type (with cocel spring)
BOSCH RSUV centrifugal, all-speed type
30SCH RSUV centrif ugal, all-speed type
(z,
160
type
(Enginiinly
43)
(Engine8tnly
43)
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
12V 200Ah
12V 200Ah
12V 200Ah
KOMATSU
KTRI 10
KTRI 10
ZEXEL single cylinder reciprocated type
ZEXEL single cylinder reciprocated type
With
With aftercooler
aftercooler
x 2
KTRllr
aftercooler
KTRI IO
KOMATSU
-
-
With
x 2
With
aftercooler
x 2
KTRllO
KOMATSU
aftercooler
KTRI 10
-
-
With
x 2
With
aftercooler
01-004-11 a3
GENERAL
SPECIFICATIONS
Engine model
Applicable
Number
of cylinders
machine
- Bore x Stroke
Total piston displacement
mm
6-170x170
cc
23,150
Firing order
l-5-3-6-2-4
Overall
length
Ovrall width Overall height (Excluding exhaust Overall height (Including exhaust
Flywheel
pipe)
pipe)
horsepower
Maximum
torque
mm
2,603
2,601
2,603
mm
1,100
1,120
1,048
mm
1,746
-
1,746
mm
-
2,332
-
kW/rpm WP/rpml
364/l ,500 ~488/1,500~
397f1.800 {540/1,800} 2,461/l ,300 {251/1,300}
-
Ikg:?pmpm)
367/1,500 (50 Hz) {492/1,5001(50 Hz) 416/1,800 (60 Hz) {557/1,800} (60 Hz)
-
1,950 - 2,050
Max. 1,560 (50 Hz) Max. 1,862 (60 Hz)
700 - 900
750 - 850
700 - 800
220 I1641 (At rated output)
231 {I721 (At rated output)
223 {I 661 (At rated output)
Dry weight
2,650
2,850
2,650
Fuel pump
Bosch PE-PDx type
Governor
Bosch RSUV centrifugal, all-speed type
High idling
rDm
Low idling
rpm g/kWh
Minimum
Lubricating
oil amount
Coolant amount
ratio
(refill capacity)
{g/HPM
1,560
motor
Battery
Turbocharger
Air compressor
Others
01-004-12 0
Bosch PE-P(PS7S) type 3osch RSUV centrif Jgal, all-speed type
Q
(Engine
120 only 43)
24V, IlkWx2
12V 200Ah x 4
Komatsu
KTR130
139
z
losch PES-PDx type 3osch RSUV centrifugal, all-speed type
(Engine8Znly
43)
24V, 25A
24V. 13A
24V, 11 kW
24V, 7.5kW x 2
12V 200Ah x 2
12V 200Ah x 2
Komatsu
KTR130
Komatsu
8 z
119 (107)
Q
24V, 13A
Alternator
Starting
fuel consumption
Max.
KTR130
-
-
-
With after cooler
With after cooler
With after cooler
SPECIFICATIONS
GENERAL
SA6D170-B-1
OEM for generator
OEM for generator (Stand by use)
OEM for generator
OEM for generator (Prime use)
6-170x
OEM for 6-Pole generator
170
23,150 l-5-3-6-2-4
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) -
417/1,500 (50 Hz) :559/1,5001 (50 Hz) 492/1,800 (60 Hz) :660/1,800~ (60 Hz) -
37811,500 (50 Hz) {506/1,5001(50 Hz) 403/1,800 (60 Hz) {539/1,800> (60 Hz) -
275/1,000 (50 Hz) :369/1,0001 (50 Hz) 345/1,200 (60 Hz) [462/1,2001 (60 Hz)
Max. Max.
Max. Max.
Vlax. 1,568 (50 Hz) Vlax. 1,881 (60 Hz)
Max. Max.
Max. 1,045 (50 Hz) Max. 1,254 (60 Hz)
-
8 z
1,572 (50 Hz) 1,890 (60 Hz)
1,560 (50 Hz) 1,872 (60 Hz)
1,568 (50 Hz) 1,881 (60 Hz)
700 - 800
700 - 900
700 - 900
700 - 900
223 {I 66) (At rated output)
217 {I621
217 1162)
224 {I 671
2,650
2,650
2,650
2,650
z
Bosch Bosch
119 (107)
(Engin%ly
(Engine
only 43)
type
all-speed
(Engine
Bosch RSUV centrifJgal, all-speed type
type
only 43)
(Engine
only 43)
24V, 13A 24V, 25A (Opt)
24V, 13A 24V, 25A (Opt)
24V. 7.5kW x 2
24V, 7.5kW x 2
24V, 7.5kW x 2
24V, 7.5kW
x 2
12V 200Ah
12V 200Ah
12V 200Ah
12V 200Ah
x 2
Komatsu
KTR130 -
With
after cooler
Komatsu
KTR130
Komatsu
-
With after cooler
x 2
KTR130
Komatsu
after cooler
KTR130
(Engine
With
after cooler
107 only 43)
24V, 11 kW
12V 200Ah
Komatsu
x 2
KTR130
-
-
-
With
122 (110)
67 (60) 119 (107) opt
24V, 13A 24V, 25A (opt)
x 2
(50 Hz) (60 Hz)
2,700
24V, 13A
x 2
217 {I601 217 {I621
Bosch PE-P(PS7S)
67 (60) 119 (107) opt
43)
750 - 850
PE-PDx type
RSUV centrifugal,
-
With
after cooler
01-004-13 0
SPECIFICATIONS
GENERAL
Engine
model
Applicable
Number
of cylinders
Total piston Firing
SA6D170-AE-1
WA600-1 (EC regulation)
machine
- Bore x Stroke
DENY0 generator DCAGOOSSK
mm
displacement
6-170x170
cc
23.2 {23,150} l-5-3-6-2-4
order
Overall
Ovrall
length
width
Overall height (Excluding exhaust
pipe)
Overall height (Including exhaust
Flywheel Maximum
mm
2,024
2,603
mm
1,136
1,062
mm
2,242
1,736
-
pipe)
kW/rpm {HP/rpm)
horsepower torque
ckgr!$pmpm)
High idling
305/2,000 (Net) {409/2,0001 (Net) 1,960/1,400 (Net1 {200/l ,400) (Net) 2,200 - 2,300
rpm
Low idling
170/l ,500 j30/1,500} j13/1,800 j88/1,800)
(Net, 50Hz) (Net, 50Hz (Net, 60Hz) (Net, 60Hz -
Max. Max.
1,570 (50 Hz) 1,880 (60 Hz)
650 - 700
700 - 900
212 (Net) {1581 (Net)
At rated flywheel horsepower !ll {157} (Net, 50Hzl !I8 11631 (Net, 60Hzl
Dry weight
2,900
2,770
Fuel pump
30SCH PE-PDx tyr
3OSCH PE-ZWx type
Minimum
fuel consumption
ratio
g/kWh Ig/HPh)
#OSCH RSUV centri ugal, all speed type
Governor
Lubricating
Coolant
oil amount
amount
Alternator
Starting
motor
Battery
Turbocharger
Air compressor
Others
01-004-14 03
(refill capacity)
ZEXEL electronic control type
119 (107)
e
e
135
(Engine
only
: 43)
24V, 50A
24V, 25A
24V, 7.5kW x 2
24V, 11 kW
12V 200Ah
x 2
KOMATSU KTRllOtype :EXEL reciprocatio single cylinder typ Aftercooler
12V 200Ah
x 2
KOMATSU KTR150 type
Aftercooler
SPECIFICATIONS
GENERAL
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)
(Engine’Znly
: 43)
24V, 13A
24V, 11 kW
12V 200Ah
x 2
KOMATSU KTRISO type
Air cooled aftercooler
01-004-15 63
/ GENERAL
GENERAL
GENERAL S6D170-1 .
LEFT
ASSEMBLY
ASSEMBLY
DRAWING
DRAWING
(for PC650-1) SIDE
VIEW
r
P
r
zi./
Wind c3
Zrankshaft center
I
lb/3 9
1851.9 20289
6162FOOl
170-1 SERIES
01-005
GENERAL
GENERAL
.
ASSEMBLY
DRAWING
RIGHT SIDE VIEW
16114
Exhaust 0
I
Crankshaft
1
Iii i i it
6162FOOZ
01-006
170-1 SERIES
GENERAL
GENERAL
l
ASSEMBLY
DRAWING
FRONT SIDE VIEW
1001.5
r
I
m
Crankshaft
6162FOO3
170-1
SERIES
01-007
GENERAL
GENERAL
l
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
SAGD170-A-1 .
ASSEMBLY
DRAWING
(for EG550-I)
LEFT SiDE VIEW
w
I II I” lt=i uu-
ILo
0 n
0 n
01
_
. ’
c. center
I
1
IIIII 0 0
0 0
2006.4
170-1 SERIES
0 l-009
GENERAL
GENERAL
l
ASSEMBLY
DRAWING
RIGHT SIDE VIEW
-
-
\ 1663.9
01-010
d ?
170-1 SERIES
GENERAL
.
GENERAL
ASSEMBLY
DRAWING
FRONT SIDE VIEW
-
170-1 SERIES
01-010-1
0
GENERAL
GENERAL
.
REAR
SIDE
DRAWING
VIEW
41.4
01-01 o-2 0
ASSEMBLY
243.4
_
170-1 SERIES
GENERAL
GENERAL
SA6D170-B-1 0
ASSEMBLY
DRAWING
(for D375A-1)
LEFT SIDE VIEW
Crankshaft center
/-
6162FOO9
170-1 SERIES
01-01 o-3 0
GENERAL
GENERAL
0
ASSEMBLY
DRAWING
RIGHT SIDE VIEW
r-n
b-4 -
6162FOlO I
01-010-4 0
170-1 SERIES
GENERAL
GENERAL
l
ASSEMBLY
DRAWING
FRONT SIDE VIEW
” I
6162FOll
170-l
SERIES
O’ -%“-5
GENERAL
GENERAL
0
REAR SIDE
ASSEMBLY
DRAWING
VIEW
Crankshaft
center
6162FO12
01-01 O-6 0
170-1 SERIES
WEIGHT
GENERAL
TABLE
WEIGHT TABLE Unit: kg
Item
No.
I
Turbocharger
2
Cylinder
-
17x2
KTRI 10
-
-
20
KTR 130
31
31
31
KTR 150
-
35
-
1
L
Cylinder spring
head assembly
Cylinder
3
Gear case cover
5
Xming
6
Oil pan
7
Flywheel
assembly
8
Flywheel
housing
9
Crankshaft
head, valve and valve
37
gear case
48
I
48
675
I
48
30
30
30
45
45
45
71:{ ;~~$tzl 51: WA600-1
Flywheel Ring gear
37
I 675
675
I
I
-
37‘
I
Cylinder block Main bearing cap Cylinder liner
block assembly
4
SA6D170-B-l I
I
TV77 1
SA6D170-A-1
S6D170-1
Component
I
48: HD465-3 122: EG550-1
43: D375A-1 122: EG450-1
8
Camshaft
10
Crankshaft Crank gear
assembly
Camshaft, plate
assembly
cam gear and thrust
95
95
92: D375A-1 117: EG450-1
270
270
270
31
31
31
I I
11
Piston and connecting assembly
12
Oil pump
13
Fuel injection
14
Water pump
15
Alternator
16
Starting
rod
Piston, piston ring, piston pin and connecting rod
I
21
21
I 21
21
I 21
21
48
31
20
20
20
15: { ‘p$~“5”0& 12: WA600-1
15
IO
motor
18
18
18
17
Air compressor
15
15
18
After cooler
pump
30: { ;$;;;;:J 31: WA600-1
65
43.5
01-011 0
ENGINE
GENERAL
ENGINE S6D170-1
PERFORMANCE
(for PC650-1,
PC1500-1)
horsepower:
410 HP/l,600
Flywheel Maximum
torque:
Minimum
fuel consumption
CURVE
CURVE
rpm
207 kgm/1,200 ratio:
PERFORMANCE
rpm
165 g/HP.h
150
I
I
I
I
I
I
I
400
600
800
1000
1200
1400
I\I
I
125
E
100
;
t75F
450
400
350 EI I
5 P ‘,
300
0
250
1600
1800
2000
Engine speed (rpm)
01-012 0
170-1 SERIES
GENERAL
S6D170-1 Flywheel
ENGINE
PERFORMANCE
CURVE
(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
Em Y
-100
J P
-75
z
- 50 - 25 -0
400
600
800
1000
1200
1400
1600
1800
2ooO
Engine speed (rpm)
170-1 SERIES
01-012-l @
ENGINE PERFORMANCE CURVE
GENERAL
S6D170-1 (for WDSOO-11 SA6D170-AE-1 (for WA600-1
EC regulation)
Flywheel horsepower
: 305 kWM09
Maximumtorque
: 1,960 Nm
HPV2,OOO
rpm
1200 kgml/l,400 rpm
E
9
s 200
0. I
3 Y
450
-2.000
150 -1.500
2 U L
100 -1,000
:
50
-500
0
-0
co a
450 300
400
; 3 0
350
:
300
250
co
200
L
250 150
200
x -
LL
150
100
100
I
150
100 50
50
0
50
0
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 @
ENGINE PERFORMANCE CURVE
GENERAL
S6D170-1
(for WDSOO-1)
Flywheel
: 334 kW (448 HP}/2,000 rpm
horsepower
Maximum
: 2,089 Nm {213 kgmV1,400 rpm
torque
z 250
/
200
150
100 3
&
2000 a 2 1500
1000
,”
1
500.
-: !500
cnn I!
500
I
350 450
0
300
400
350 250 3 a -
300
G
\
200 250
/
250-
I
\I
I
15C
200
150
Inn
L””
150 IOC
100
100 5c
50
(I-
50
0
::
800
1000
1400
1200 Ens
01-014 0
ine
1600 speed
1800 (rpmi
2000
2200
2400 SWEOIOZI
z 0 c
ENGINE PERFORMANCE CURVE
GENERAL
S6D170-1
(for EPS6D170-1)
Flywheel
E 550-
horsepower
3 1
400-
500-
: 385 kW {516 HP} 1,800 rpm
2 550
500 350-
450-
400-
450
300-
350250-
400
350
c ;
300-
S
300 200-
250-
200-
250
150-
150-
200
150 IOO-
IOO-
100 50-
50-
o-
50
o-
0
Engine
speed
(rpm)
SWE01022
01-014-l 0
GENERAL
S6D170-1
ENGINE PERFORMANCE CURVE
(OEM for generator)
Flywheel
horsepower
:
Prime
use
: 324 kW I434 HP} 1,500 rpm (50 Hz)
Stand
by use
: 355 kW (476 HP} 1,500 rpm (50 Hz)
371 kW 1497 HP} 1,800 rpm (60 Hz)
408 kW {547 HP} 1,800 rpm (60 Hz)
a
3 _b
1
600
450
2
408kW&07H@
400
500
/
600 355kW1476Hd
550
itandbrl
60Hz
50Hz
I
550
(Standbul
I
II
I
/I
/
500 350
450
400
300
+
I
371 kW(497HP) (Prime) 60Hz
350
:
250 300
1 200
z
250
I
I
324kWt434Hd
(Prime)
50Hz 250
z 200
150
150 100 100 50 50
0
0
_
.
1100
1200
1300
En9
01-014-2 0
1400
1500
i ne
speed
1600
(rpm)
1700
1800
1900 SWE01023
ENGINE PERFORMANCE CURVE
GENERAL
SA6D170-A-1 Flywheel
(PClOOOSP-1 for LAYTON) : 434 kW {582 HP}/l,750 rpm
horsepower
Maximum
: 2,731 Nm I278.5 kgm}/1,300 rpm
torque
E
E
3 400
4000
300
c 3000
200
-2000
100
-1000
0
-0
Yj m
a r
600-
3 2.
450
550-
z +-
600 550
400
500-
500 350
450-
450
400;
300
350-
250
a g
400
300200 250200-
250 150
200
150-
150
100 IOO50
50 0
!
50 0
0
::
BOO
1000
1100
1200
1300
Ens i ne
1400
speed
1500
1600
(rpm)
1700
1800
1900 SWE01024
01-014-3 G9
ENGINE PERFORMANCE CURVE
GENERAL
SAGD170-A-1
(for HD465-3
with single turbocharger)
Flywheel horsepower
: 524 kWi613
Maximumtorque
: 2,824 Nm (288 kgmI/1,400
HP}/2,100
rpm rpm
E
s 400
100
E 4000
3000
g
2000
:
1000
0
8
a
B
I:
Y
600
800
700
500
: 80(
70(
60(
600 400 <
500
50(
: 400
300
300 200 200
40(
30(
20( 100 lO(
100
0
0
c
800
1000
1200
1400
Engine
01-014-4 0
1600 speed
1600 (rpm)
2000
2200
2400 SWE01025
GENERAL
ENGINE PERFORMANCE CURVE
SAGD170-A-1 Flywheel Maximum
(for HD465-3
horsepower
with single turbocharger
: 524 kW (702 HP} 2,100 rpm : 2,824 Nm I288
torque
and twin turbocharger)
kgm1
1,400 rpm
E
s
s -400
-4000
-300
-3000
; u L
L1 1
800
3 2 600
700 500 600
z
-200
-2000
-100
-1000
-0
-0
:
2 800
-
700--
600 400
500
500
z 400
300
300
400
300 200
200
200 100
100
0
100
0
0
800
1000
1200
1400
Ens i ne
1600
speed
1800
(rpm)
2000
2200
2400 SWE01026
01-015 0
GENERAL
S6D170-AFlywheel
ENGINE PERFORMANCE
CURVE
1 (For HD465-5) horsepower:
715
HP/2,100
307
kgm/l,400
Maximum
torque:
Minimum
fuel consumption
ratio:
rpm rpm
150 g/HP.h
200
P 2 J P I-"
100
800
0 output /
\ \
I
f
I
I
l/l
I
I
I
I
I
I
II 0 800
1000
1200
1400
1600
1800
2000
2200
II
2400
Engine speed (rpm)
6162F817
O’-F
170-1 SERIES
ENGINE
GENERAL
SA6D170-A-1 Flywheel
(for HD465-3 horsepower
Maximum
torque
high altitude
PERFORMANCE
CURVE
spec.)
: 386 kW I518 HP) 2,100 rpm : 2,108 Nm 1215 kgm1 1,400 rpm
E
5
s 300
200
3000
2000 a, 2 0 If
&
100
1000
0
0
Y 3
600400500-
2 a
400-
G
300-
300-
zoo200-
I 200
100loo-
o-
100
o-
0
500
1000
Engine
2000
1500
speed
(rpm)
2500 SWE01027
01-016-l 0
GENaERAL
ENGINE PERFORMANCE,CURVE
S6D170-1
(For WA700-1)
Flywheel horsepower:
641 HP/2,000
Maximum torque:
286.5 kgm/l,400
rpm rpm
Minimum fuel consumption ratio: 153 g/HP.h
250
600-
,C
600
800
1000
1200
1400
1600
1800
2000
2200
Engine speed (rpm) F6161A012
170-1 SERIES
GENERAL
SA6D170-A-1
ENGINE
PERFORMANCE
CURVE
(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
200
190
4 2
180
.g
170
s '"a
100
Enginespeed x 100 (rpm)
o’-:‘8
1560
1870
170-l
SERIES
GENERAL
ENGINE PERFORMANCE
(EG5808-1)
SA6D170-A-1 Flywheel
CURVE
horsepower:
Fuel consumption
ratio:
611
HP/l,500
673
HP/l,800
160 g/HP.h
rpm (50
Hz)
rpm (60
Hz)
(Rated output)
800
600.
500
/
I 611 HP (50HZ)
400
I
I
I I \
I I I
I I I
300
I I I
I
I 200
, 1
100 --wFue’
ratio
180
-170 160
I
- 150
I
1000
1100
1200
1300
1400
-190
I
I I
I
CO.nsOmptiOn
200
1500
I 1600
1700
1800
1900
2000
Engine speed @pm) F6161A013
170-1 SERIES
01-ii19
ENGINE PERFORMANCE
GENERAL
SA6D170-A-1
(EG5808-1
Flywheel horsepower:
CURVE
L) 633 HP/l,500
rpm (50 Hz)
Fuel consumption ratio: 160 g/HP.h (Rated output)
800
500
E. 400 c 6'j s 300
200
220
i
--210
II
'-200
\I I
--190
,
180 I
lOO-------
,' /
1000
1100
1200
1300
1400
1500
s-170
I .-I
160
I I
1600
--150 1700
1800
F6161A020
O’-iJ 9-1
170-1 SERIES
GENERAL
ENGINE PERFORMANCE
SA6D170-A-1 Flywheel
CURVE
(EG600BS-1) horsepower:
Fuel consumption
ratio:
630
HP/l,500
rpm (50
Hz)
688
HP/l,800
rpm (60
Hz)
160 g/HP.h
(Rated output)
800
600
500
c I
sa s
400
220 210
0
300
!OO 190
200
100
z p \ = .P
180
5s ‘E
170
2
160
E 5 I=
150 1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
Engine speed (rpm) F6161A014
O’-Z20
170-1 SERIES
GENERAL
ENGINE
SA6D170-A-1 Flywheel
CURVE
(for EM680A) horsepower
Maximum
PERFORMANCE
torque
: 552 kW 1740 HP) 2,000 rpm : 2,501 Nm I255 kgm) 1,400 rpm
E
s
s
Torque
400
-4000
300
-3000
g m L
200
-2000
If
100 -1000
0
a 1
600-
i 0
3 24
600-
700500600:
500-
400-
400-
300-
:
300200200IOOIOO-
o-
o-
J-2’) . 1 600
II 600
1000
1200
En9 i ne
1400
speed
1600
(rpm)
1800
2000
2200 SWEOlOZtl
Ol -020- 1 0
GENERAL
ENGINE
SA6D170-A-1 Flywheel
(for EM680A-1,6M170B-1,
CURVE
engine)
: 552 kW (740 HP} 2,000 rpm
horsepower
Maximum
OEM for marine
PERFORMANCE
torque
: 2,893 Nm I295 kgm) 1,400 rpm
E
e
s -400
-4000
-300
-3000
; Is L
0 2
8OC
-200
-2000
.lOO
-1000
-0
-0
If
3 2.
600
700
600
z
500
0' 400
300
200
100
0
.. 800
1000
1200
1400
En9 ine
01-020-2 0
1600
speed
1800
(rpm)
2000
2200
2400 SWE01029
GENERAL
ENGINE
SA6D170-A-1 Flywheel Maximum
PERFORMANCE
(for EM680A-A) horsepower
: 629 kW I842 HP} 2,000 rpm
torque
: 3,295 Nm I336 kgm} 1,400 rpm
E
s
9
%
CURVE
400
-4000
300
-3000
200
-2000
100
-1000
0
-0
3 24
700900l300- 6007005006004005
500-
: 400-
300-
300200200looIOO-
\
100 A’
o-
o-
n ”
?! .\
600
800
1000
1200
1400
En9 i ne
1600
speed
1800
(rpm)
2000
2200
2400 SWE01030
01-020-3 0
GENERAL
ENGINE
SA6D170-A-1 Flywheel
& 800-
PERFORMANCE
(for EPSAGD170-A-l) horsepower
: 508 kW (680 HP1 2,000 rpm
Y 3
600-
700500;
600-
:
400500-
400-
300-
300200200tooloo-
o-
o-
800
1000
1200
1400
En9 ine
01-020-4 0
1600
speed
1800
(rpm)
2000
2200
2400 SWEOtO31
CURVE
GENERAL
ENGINE
SAGD170-B-1 Flywheel
PERFORMANCE
CURVE
(for D375A-1)
horsepower:
508 HP/l ,800 rpm
Maximum
torque:
Minimum
fuel consumption
266 kgm/l,300 ratio:
rpm
158 g/HP.h
280
260
240
T 2 S
220
: I-
200
c I50
800
1000
1200
1400 Engine
170-1 SERIES
speed
1600 (rpm)
1800
01-021 0
ENGINE PERFORMANCE
GENERAL
SAGD170-B-1 Flywheel
CURVE
(D375A-2) horsepower:
525
Maximum
torque:
Minimum
fuel consumption
HP/l
,800
267 kgm/l,300 ratio:
rpm rpm
158 g/HP.h
Torque
z 150
210
-200 -190
lOO-
180 -170 Fuel consumption ratio -
50
160 I
0
600
800
1000
1200
1400
1600
1800
2000
$ \ = .P ;;j ; 0 .E z C 8 Z I?
- 150
2200
Engine speed @pm) F6161A015
01-:22
170-1
SERIES
GENERAL
ENGINE PERFORMANCE
SAGD170-B-1 Flywheel
CURVE
(PCIOOO-1) horsepower:
542
HP/l
260
kgm/l,300
Maximum
torque:
Minimum
fuel consumption
250
ratio:
,700
rpm rpm
155 g/HP.h
_
1100
1200
1300
Engine
1400
speed
1500
1600
1700
1800
1900
(rpm) F6161A016
170-1 SERIES
GENERAL
SA6D170-B-1 Flywheel Maximum
ENGINE
(for PClOOO-1 high altitude horsepower torque
PERFORMANCE
CURVE
spec.)
: 341 kW {457 HP} 2,000 rpm : 2,157 Nm (220 kgm) 1,300 rpm
E
5
,” 400
-4000
300
-3000
200
-2000
100 0
Ene
01-023-l 0
i ne
speed
(rpm)
; D i
1000 t 0
SWE01032
GENERAL
ENGINE PERFORMANCE
SAGD170-B-1
(for HD465-3
with
CURVE
single turbocharger)
Flywheel horsepower:
613 HP/2,100
Maximum torque:
253 kgm/l,400
rpm rpm
Minimum fuel consumption ratio: 165 g/HP.h
250
200
50
0
7oc
600
500
z I 5 a 5 0
400 z 3oc
20(
200
: ‘,
Igo
z
180
; .o z E
170 Fuel consumption
\
1OC
ratio
160
z 8
150
2
\
C 1000
1200
1400
1600
Engine
1800
2000
2200
2300
2400
speed (rpm) F6161A017
O’-:24
170-1 SERIES
GENERAL
SA6D170-B-1 Flywheel
ENGINE
PERFORMANCE
CURVE
(for EG450-1)
horsepower:
481 HP/l,500
rpm (50 Hz)
544 HP/l ,800 rpm (60 Hz)
I HP/l
DO rpi -
600 0 HP,
/
h
k-
500 z I 2 n ‘; 0
I
w
/
lP/l ,E
I
1 rpm
I I
I
400
I I
300
I
I
1 i-I
I
I t I
I
I I I
I I I
:I I I
200
L
I I
I
CO
I
,mpti
I
I
I I
100
I + I
I I I
I
I I
I
12
13
14
15
16
17
16
19
Engine speed x 100 (rpm)
170-1 SERIES
O’-$25
ENGINE PERFORMANCE
GENERAL
SAGD170-B-1
CURVE
(EG480B-1)
Flywheel horsepower:
488 HP/l,500
rpm (50 Hz)
549 HP/l,800
rpm (60 Hz)
Fuel consumption ratio: 162 g / HP.h (Rated output)
220 210 200 190
E $ \ _a .P ;;; h :
180
.E
170
7 6 0 5 I?
160 150
Engine speed (rpm) F6161AO18’
01-026 0
170-1 SERIES
GENERAL
ENGINE PERFORMANCE
SAGD170-B-1 Flywheel
CURVE
(EG5OOBS-1) horsepower:
Fuel consumption
ratio:
513
HP/l
,500
572
HP/l,800
160 g/HP.h
rpm (50
Hz)
rpm (60
Hz)
(Rated output)
I \
600
,I
550
I
I
.I
500
I
111
I I
I I I
I I
350 Y
i
300
I I
I
I I 250
I
I
I
I
I I
I i
I
200
150
I I
! I
100
I I I
/
/ d* I 1100
1200
1300
1400
1500
I 1600
I I
/
50
1000
-
1
/I
-
I I
I 1700
1800
-
210
z
200
: p
190
.i
180
.$
170
2 2
160
i
50
: IL
-
2000
Engine speed(rpm) F6161A019
170-1 SERIES
O’-:27
ENGINE PERFORMANCE CURVE
GENERAL
SA6D170-B-1 Flywheel
(OEM for generator) :
horsepower
: 367 kW 1492 HP] 1,500 rpm (50 Hz)
Prime use
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
3 Y
I
450.
650
600
550
450.
400
500I350 45c l-
4oc l-
300
350I250
350 367kWI492Hd
(Prime)
50Hz 300l3 a
300200
250l-
250
201O- 15(
200
g
.-_
151D-
150
’
lot 101D-
100 51
51O-
O-
50
L
OLLI
1100
1200
1300
1400
Engine
01-028 0
1500
speed
1600
(rpm)
1700'
1800
1900 SWE01033
ENGINE
GENERAL
SA6D170-B-1
PERFORMANCE
CURVE
(for EPS6D170-B-1)
Flywheel horsepower :445 kW{597 HP)1,800rpm
CL 1
3 Y
500650-
600-
550-
650 450-
600
400-
500350450-
400-
3503 P
300-
250-
400
350 / 300
';' 300-
/
0
200250-
250
zoo-
150- 200
I
150looloo-
/ I
150
100 50-
50-
o-
o-
0
600
600
1000
1200
Engine
1400
1600
sPeed(rPm)
1600
2000
2200 SWE01034
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
ACCESSORY Air compressor mounting ..................... Air compressor. ...................................... ELECTRICAL SYSTEM Alternator ................................................ Starting motor ........................................ Wiring diagram ......................................
1 I-042 1 I-043 1 I-044 1 I-045 1 I-047
11-001
43
STRUCTURE
AND
GENERAL
FUNCTION
GENERAL
STRUCTURE
STRUCTURE
S6D170-1
6162FlOl
Camshaft
17.
Front seal
Rocker arm shaft
18.
Oil pump
19.
Connecting rod cap
Tappet
20.
Oil pan Main bearing cap
1.
Crank pulley
2.
Thermostat
10.
3.
Cylinder head
11. Push rod
4.
Fuel injection nozzle
12.
9.
5.
Rocker arm housing cover
13.
Rocker arm housing
21.
6.
Piston pin
14.
Cylinder block
22.
Crankshaft
7.
Intake valve
15.
Rear seal
23.
Ring gear
8.
Exhaust valve
16.
Vibration
24.
Flywheel
1 l-002
damper
170-1
SERIES
STRUCTURE
AND
FUNCTION
25.
Cylinder liner
26.
Piston
27.
Oil cooler
28.
Fuel injection pump
29.
Piston cooling nozzle
30.
Connecting rod
170-1 SERIES
GENERAL
STRUCTURE
6162F102
11-003
STRUCTURE
INTAKE S6D170-1
AND
FUNCTION
AND
INTAKE
EXHAUST
AND
EXHAUST
SYSTEM
SYSTEM
for PC650-1
Intake system
1.
Air cleaner
2.
Turbocharger
3.
Intake manifold
4.
Exhaust manifold
5.
Muffler
A.
Intake inlet
B.
Exhaust
6162F106
Exhaust system
6162F107
11-004 0
170-l SERIES
STRUCTURE
S6D170-1
AND
FUNCTION
INTAKE
AND
EXHAUST
SYSTEM
for PC1500-1
Intake system
1.
Air cleaner
2.
Turbocharger
3.
Intake manifold
4.
Exhaust manifold
5.
Muffler
Exhaust system A.
Intake inlet
6.
Exhaust
5
2
170-l SERIES
1 l-005
0
STRUCTURE
AND
FUNCTION INTAKE
ANQ
EXHAUST
SYSTEM
S6D170-1 for WA600-1 Intake system
a
Exhaust system
F6161A002
F6161A003
1 J-005 1
0
170-l SERIES
STRUCTURE
SA6D170-A-1
AND
FUNCTION
INTAKE
AND
EXHAUST
SYSTEM
for EG550-1 Intake system
b
F /--(--
3
1.
Air cleaner
2.
Turbocharger
3.
Intake manifold
4.
Exhaust manifold
5.
Muffler
Exhaust system
1 I-006 0
A.
Intake inlet
6.
Exhaust
170-l SERIES
STRUCTURE AND FUNCTION
INTAKE AND EXHAUST SYSTEM
SAGDI 70-A-1 for H D465-3 Intake system
2.
Turbocharger
3.
intake manifold
4.
Exhaust manifold
A.
Intake inlet
B.
Exhaust
Exhaust system
170-1 SERIES
l l -0060
1
STRUCTURE AND FUNCTION
INTAKE AND EXHAUST SYSTEM
SAGD170-B-1 for EG450-1 Intake system
1.
Air cleaner
2.
Turbocharger
3.
Intake manifold
4.
Exhaust manifold
5.
Muffler
A.
Intake inlet
B.
Exhaust
Exhaust system
1 l-006-2 0
170-1 SERIES
STRUCTURE AND FUNCTION
SAGD170-B-1
INTAKE AND EXHAUST SYSTEM
for D375A-1 Intake system
1 . Air cleaner 2.
Turbocharger
3.
Intake manifold
4.
Exhaust manifold
5.
Muffler
A.
Intake inlet
6.
Exhaust
Exhaust system
170-1 SERIES
11-006-3 0
STRUCTURE
AND
INTAKE
FUNCTION
AND
EXHAUST
SYSTEM
TURBOCHARGER .Q KTRllO
C
P
8
I
1.
Blower housing
a.
2.
Blower impeller
b. Oil outlet (to oil pan)
Oil inlet (from oil filter)
3.
Clamp
c. Air inlet
4.
Center housing
d. Air outlet
5. Journal bearing
e.
Exhaust inlet
6. shield
f.
Exhaust outlet
7. Turbine impeller 8.
Flinger
9.
Thrust bearing
e
9
TURBOCHARGER Type:
Komatsu KTRI
Overall length:
290 mm
Overall width:
305 mm
Overall height:
267 mm
Weight:
19 kg
Maximum
allowable rotation:
Maximum
charging: 46 kg/min.
Maximum Direction
94,000
allowable temperature of rotation
Lubrication
method:
10
rpm
(inlet):
75O’C max.
(view from blower side): Forced lubrication
Right
with
engine oil 10.
Turbin shaft
11.
Turbine housing
170-1 SERIES
1 l-007 0
INTAKE AND EXHAUST SYSTEM
STRUCTURE AND FUNCTION
KTR130
2
6162F108
1.
Blower housing
11.
Insert
2.
Blower impeller
12.
Thrust bearing
3.
Clamp
4.
Center housing
13.
Turbine shaft
5.
Journal bearing
a.
Oil inlet (from oil filter)
6.
Clamp
b.
Oil outlet (to oil pan)
Specifications * Type:
* Maximum l
c.
Air inlet l
8.
Turbine impeller
d.
Air outlet
9.
Turbine housing
e.
Exhaust inlet
Flinger
f.
Exhaust outlet
10.
“:O*
31 kg
- Continuous rotation: charging:
Appropriate
- Direction Shield
Komatsu KTR130
* Length x width x height: 366 x 358 x 323 mm *Weight:
7.
of turbocharger
temperature
of rotation
Lubrication
70,000
method:
rpm
32 kg/min. (inlet,‘C):
750°C
max.
(view from blower side): Forced lubrication engine oil
Right
with
170-l SERIES
STRUCTURE
AND
FUNCTION
INTAKE
AND
EXHAUST
SYSTEM
KTRl50 6
5
F6166009
1.
Blower housing
a.
Oil inlet (from oil filter)
2.
Blower impeller
b.
Oil outlet (to oil pan)
3.
Clamp
c.
Air inlet
4.
Center housing
d.
Air outlet
5.
Journal bearing
e.
Exhaust inlet
6.
Turbine impeller
f.
Exhaust outlet
7.
Turbine housing
8.
Flinger
9.
Thrust bearing
10.
Turbine shaft
170-l
SERIES
Specifications l
* * * *
Type:
of turbocharger
Komatsu KTR 150
Length x width x height: Weight:
350 x 289 x 358 mm
38 kg
Maximum
allowable rotation:
Maximum
charging:
*
Maximum
l
Direction
l
Lubrication
65,000
allowable temperature of rotation method:
rpm
78 kg/min. (inlet):
75O’C max.
(view from blower side): Forced lubrication engine oil
Right
with
1T8-’
STRUCTURE
AND
INTAKE
FUNCTION
AND
EXHAUST
SYSTEM
TV77
C
615OF106-1
1. Lock nut
12. Turbine housing
2. Blower housing
13.
3. Blower impeller
14. Turbine
4. Thrust collar
A
Air inlet
5. Back plate
B
Air outlet
Overall width
I
284 mm
6. Thrust bearing
C
Gas inlet
Overall height
I
264 mm
7. Seal ring
D
Gas outlet
8. Center housing
E
Oil inlet
9.
F
Oil outlet
Retaining ring
10. Journal bearing 11. Shroud
Piston ring
Type
CO. TV7705
.275mm
Overall length ~_______ ~7
Weight
17 kg
7
Continuous speed
90,000
Max. air supply
0.43 kglsec
Compression ratio Applicable Direction
1 l-008-2 0
GARRETT
impeller
exhaust temp. of rotation
I
rpm
3.4 Max. 700°C Clockwise (see from
I the blower side)
SERIES
170-l
STRUCTURE
AND
INTAKE
FUNCTION
AND
EXHAUST
SYSTEM
AFTER-COOLER
l!!!zll El I 0
170-1
0
SERIES
00 oo
0
0
1.
Cover
2.
After-cooler
0
body
o
0
0
~~[T~_fL!,: 0 0 0 0
;:
A:
From water pump
6:
To water manifold
O 0 O 0 0 O O O -Oo’oo0
0
1 l-009
STRUCTURE
AND
FUNCTION
ENGINE
BODY
ENGINE BODY CYLINDER HEAD
_ a-.
b
B4
A4
6162F109
1l-010 0
1.
Water manifold
a.
2.
Cylinder head
b.
Fuel (return)
3.
Rocker arm housing
c.
Oil (from main gallery)
4.
Rocker arm housing cover
d.
Tap for water temperature
5.
Valve guide
6.
Nozzle holder sleeve
7.
Tube
Coolant
(to thermostat)
gauge sensor
170-1
SERIES
STRUCTURE
AND
ENGINE
FUNCTION
Section A - A
BODY
Section B - B 6162FllO
Cylinder
head
. Direct-injection l
type, injection nozzle, 4-valve type
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.
Intake valve
8.
Lock nut
15.
Cam follower pin
2.
Exhaust valve
9.
Upper spring seat
16.
Cam follower
3.
Rocker arm
10.
Valve spring (outer)
17.
Cam follower;haft
4.
Collar
11.
Valve spring (inner)
18.
Adjustment screw
5.
Camshaft gear (No. of teeth: 48)
12.
Lower spring seat
19.
Lock nut
6.
Camshaft
13.
Push rod
20.
Cross head
7.
Adjustment screw
14.
Cam roller
11-012
a.
Oil (from oil pump)
170-1 SERIES
STRUCTURE
AND
ENGINE
FUNCTION
BODY
13
14 15 16 17
Exhaust side of No. 1 cylinder
intake side of No. 1 cylinder
6162F113
6162F112
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
CYLINDER
ENGINE
FUNCTION
BODY
BLOCK
\
\ 8
9 6162F115
1.
Front cover
8.
Main bearing
2.
Cylinder block
9.
Thrust bearing
3.
Cylinder linw
10.
Cam bushing
4.
Crevice seal
11.
Piston cooling nozzle
5.
O-ring (nitrile rubber:
black)
12.
Main bearing cap
6.
O-ring (silicone rubber:
red)
13.
Main bearing cap bolt
14.
Oil level gauge
7.
11-014
Front seal
170-1 SERIES
STRUCTURE
AND
ENGINE
FUNCTION
10
BODY
14
6162F116
Cylinder
block
- Crankshaft:
Seven bearings
- Camshaft:
Seven bearings
Cylinder
liner
- Wet type liner, tufftride
treatment
on bore surface
* Crevice seal, two O-rings
170-1 SERIES
1 J-015
STRUCTURE AND FUNCTION
MAIN
CIRCULATION
ENGINE BODY
PART
6162F117
1.
Piston pin
2.
Connecting rod
10.
Crank gear (No. of teeth:
3.
Connecting rod bushing
11.
Connecting rod bearing
4.
Piston
12.
Crankshaft
9.
Vibration
Crankshaft
damper 36)
* Special cast/forged
alloy, seven
bearings - Journal face:
High frequency
hardening 5.
Top ring
13.
6.
2nd ring
14.
Main bearing
7.
Oil ring
15.
Connecting rod cap
8.
Crankshaft
16.
Connecting rod bolt
(Outside
11-016 0
pulley
diameter:
Thrust bearing
200 mm)
170-1 SERIES
STRUCTURE
ALUMINUM
AND
ENGINE
FUNCTION
BODY
PISTON TYPE
Main bearing and connecting rod bearing * 34ayer Kelmet * Upper main bearing:
with oil groove
Piston * Lo-Ex aluminum
alloy
. Groove of top ring:
15
Niresist is cast on top ring.
* Thermal flow solid type (S6Dl70-1)
- 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
Hard chrome plating
Hard chrome plating
Hard chrome plating
S6D170-1 SAGD170-A-I SAGD170-B-1
6162Fllg
170-1 SERIES
STRUCTURE
FCD PISTON
AND FUNCTION
ENGINE BODY
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
2-face keystone eccentric barrel face
2nd ring
2-face keystone inner cut taper face
Oil ring
Bevel cutter with coil expander
SAGDl70-A-1 (HD465-5)
Hard chrome plating
Hard chrome plating
Hard chrome plating
(WA700: 14594 and up)
6162F819
11-017-l CD
STRUCTURE
AND
ENGINE
FUNCTION
BODY
TIMING GEAR
6162FlZO
i 1. Idler gear (No. of teeth:
6.
Idler gear (No. of teeth:
48)
7.
Crankshaft gear (No. of teeth:
8.
Oil pump driving gear (No. of teeth:
9.
Idler gear (No. of teeth:
2.
Cam gear (No. of teeth:
3.
Compressor driving gear (No. of teeth:
4.
Injection pump driving gear (No. of teeth: 48)
5.
Idler gear (No. of teeth:
24)
10.
11-018
.
571
30) 36)
33)
41)
Water pump driving gear (No. of teeth
:
20)
45)
170-1 SERIES
ENGINE BODY
STRUCTURE AND FUNCTION
h
Y
l-l
Section B - 6
SectionC-C
Section D - D (with timer)
Section d - D (without
timer)
SectionA-A
6162F121
170-1
SERIES
11-019
STRUCTURE
AND
FLYWHEEL
AND
1
ENGINE
FUNCTION
FLYWHEEL
BODY
HOUSING
2
6162F122
Tightening order of flywheel mounting bolt.
1.
Ring gear
2.
Flywheel
3.
Rear seal
4.
Flywheel housing
5.
Drain plug
Ring gear Applicable machine
No. of teeth 118
138
1 l-020 0
I
I
PC650, PClOOO, PC1 500, HD465-5 D275A-2, D355A. D375A. WA600. WD600, WA700, HD465-3, EG550
STRUCTURE
AND
LUBRICATION LUBRICATION
LUBRICATION
FUNCTION
SYSTEM
SYSTEM
SYSTEM
CHART
Oil pan Oil level sensor Oil pump Main relief valve Piston cooling valve Oil cooler $lcyler
by-pass
8. Oil filter 9. Safety valve 10.
Main gallery
11.
Crankshaft
12. Camshaft 13. Rot ker arm 14. Piston cooling nozzle 15. Timing gear 16. Fuel injection pump 17. Turbocharger 18. Mechanical pump
6162F123A
170-1 SERIES
19.
Oil pressure gauge
a.
To intake manifold
w.
Coolant
1 l-021 0
STRUCTURE
AND
LUBRICATION
FUNCTION
SYSTEM
OIL PUMP
6162F124
1 l-022
1.
Oil pump driving gear (No. of teeth:
2.
Oil pump body
3.
Bushing
4.
Drive shaft
5.
Bushing
6.
Pump cover
7.
Driven shaft
8.
Driven gear (No. of teeth:
9.
Bushing
33)
Oil pump
* Gear pump type * Oil pump speed: Engine speed x 1.091
12)
170-1
SERIES
STRUCTURE
AND
LUBRICATION
FUNCTION
OIL FILTER AND
SAFETY
SYSTEM
VALVE
6actionA-A 6162F125
1.
Safety valve cap
Oil filter
2.
Oil pressure sensor
- Filteration
3.
Filter bracket
4.
Filter element
Safety valve Cartridge
5.
Filter case
6.
Safety valve
7.
Valve spring
>
a.
From oil pump
b.
To engine each component
170-1 SERIES
area: 0.82 m2 x 2
- Cracking pressure (difference
pressure): 2.0 + 0.2 kg/cm2
1 l-023
STRUCTURE
AND
LUBRICATION
FUNCTION
SYSTEM
OIL COOLER S6D170-1 SAGD170-B-1
a
Section A - A
i-B
Section B - B
6162F126
11-024 0
1. Cooler cover
Oil cooler
2.
Cooler element
* Heat exchanged:
Min. 45000 area:
Kcel/hr.
3.
Drain cock
* Heat-transmitting
2.94 m2
a.
Coolant (from water pump)
* Oil flow capacity: 180 Urnin. * Water flow capacity: 890 Q/min.
b.
Oil (from oil pump)
c.
Oil (to engine each component)
170-1 SERIES
STRUCTURE
AND
LUBRICATION
FUNCTION
SYSTEM
SAGD170-A-1
Section A - A
Section B - B
1.
Cooler cover
Oil cooler
2.
Cooler element
-
3.
Drain cock
a.
Coolant (from water pump)
b.
Oil (from oil pump)
c.
Oil (to engine each component)
170-1 SERIES
Heat exchanged:
Min. 55000
Heat-transmitting
area: 4.146
Oil flow capacity:
Kcal/hr. m2
180 Q/min.
Water flow capacity:
890 Qlmin.
11-024-l 0
STRUCTURE
AND
OIL PUMP
LUBRICATION
FUNCTION
SYSTEM
RELIEF VALVE 1.
Plug Valve spring Valve body Relief valve Ball type valve (Main relief valve)
6.
Main relief valve spring
a.
From oil pump
b.
To oil pan
c.
From main gallery
Main relief valve
- Cracking pressure (difference
pressure):
8 f 1 kg/cm2 Oil-line
check valve
- Cracking pressure:
-0
3.3 f 0.3 kg/cm2
6162F127
OIL COOLER
BY-PASS
VALVE
1.
cap
2.
Valve spring
3.
Valve body
4.
By-pass valve
a.
From oil pump
b.
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
PISTON
COOLING
1
2
FUNCTION
LUBRICATION
SYSTEM
VALVE
3
4
1.
cap
2.
Valve spring
3.
Oil filter adapter
4.
Piston cooling valve
a.
From oil pump
b.
To piston cooling nozzle
c.
To cylinder block
Piston cooling valve * Cracking pressure:
1.3 2.:
kg/cm’
b 6162F129
11-026
170-1 SERIES
STRUCTURE
AND
LUBRICATION
FUNCTION
MECHANICAL
SYSTEM
PUMP
-f
-f
B
B
1.
Spring
2.
Plunger
3.
Plunger
4.
Plunger
5.
Pump body
6.
Worm
a.
Oil inlet (from main gallery)
b.
Oil outlet (to intake manifold)
% C 5 \
/
Section A - A
Section C - C
Section B - B
View 2
6162F130
Mechanical pump * Capacity: 10 + 1 cc/h x 2
* 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
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 seats of the valves to reduce the wear of the seats.
camshaft.
170-1
- The oil is sent from the main gallery into the pump,
SERIES
11-027
STRUCTURE
FUEL SYSTEM
AND
FUNCTION
FUEL SYSTEM FUEL SYSTEM
CHART
6162F131
1 l-028
1.
Fuel tank
2.
Fuel filter
3.
Fuel injection pump
4.
Feed pump
5.
Fuel injection nozzle
170-l
SERIES
STRUCTURE
AND
FUNCTION
FUEL INJECTION S6D170-1,
FUEL SYSTEM
PUMP
SAGD170-B-1
6162F132
1.
Injection pump driving gear (No. of teeth:
a.
Fuel (from fuel tank)
2.
Injection pump drive shaft
b.
Fuel (to fuel filter)
3.
Service meter output
c.
Fuel (from fuel filter)
4.
Fuel injection pump
d.
Fuel (to nozzle holder)
5.
Feed pump
e.
Oil (from main gallery)
6.
Governor
f.
Oil (to oil pan)
7.
Relay
8.
Solenoid
9.
Fuel filter
11-030 0
48)
170-1 SERIES
STRUCTURE
AND
FUEL
FUNCTION
SYSTEM
6162F133
Fuel injection pump * Maker:
Diesel Kiki
- Type:
PES-PD type
* Governor: * Lubrication
RSUV, centrifugal type, all-speed type method:
Forced lubrication
with engine
oil
170-1 SERIES
11-031 0
FUEL SYSTEM
STRUCTURE AND FUNCTION
SAGD170-A-1
4
1.
injection pump driving gear (No. of teeth:
i
i
48)
a.
Fuel (from fuel tank) Fuel (to fuel filter)
2.
injection pump drive shaft
b.
3.
Service meter output
c.
Fuel (from injection pump)
4.
Fuel injection pump
d.
Fuel (to nozzle holder)
5.
Feed pump
e.
Oil (from main gallery)
6.
Governor
f.
Oil (to oil pan)
7.
Relay
8.
Solenoid
9.
Fuel filter
11-031-l Cc
170-1 SERIES
STRUCTURE
AND
FUNCTION
FUEL SYSTEM
Fuel injection pump
* Maker: - Type:
Diesel Kiki PE-ZWX
* Governor: - Lubrication
type
RSUV, centrifugal type, ail-speed type Forced lubrication with engine oil method:
170-l SERIES
11-031-2 0
STRUCTURE
AND
FUEL
FUNCTION
FUEL INJECTION
SYSTEM
NOZZLE
1.
Nozzle holder
2.
Nozzle spring
3.
Nozzle
4.
Retaining cap
b
5.
Adjustment shim
a.
Fuel inlet
b.
Fuel return (To fuel tank)
IllI
FL IIll Ill’ II I’ IllI
II
1’ I ill’
I
6162F134A
Fuel injection nozzle - Maker: Diesel Kiki - Type:
Bosch DLL-S type, multiple
1 l-032 @
hole type
170-1
SERIES
STRUCTURE
AND
FUEL INJECTION For PES-PD
type
FUEL SYSTEM
FUNCTION
injection
PUMP
DRIVE
pump
7 5
8
6
-
Section
1
2
3
A--A
4 6162F135
1.
Fuel injection pump drive shaft
Tachometer drive
2.
Nut
- Tachometer drive shaft speed = Engine speed x l/2
3.
Tachometer
4.
Drive housing
5.
Pinion gear housing
6.
Tachometer
7.
Pihion gear (No. of teeth:
8.
Bushing
170-1 SERIES
drive gear (No. of teeth:
14)
drive shaft 14)
11-033 @
MAINTENANCE
For PE-ZWX
FUEL SYSTEM
STANDARD
tYpe injection
pump
Detail P
Section A-A
6162F135-1
Fuel injection pump drive shaft
Tachometer
2.
Nut
* Tachometer
1.
3.
Tachometer
4.
Drive housing
5.
Pinion gear housing
6.
Tachometer
7.
Pihion gear (No. of teeth:
8.
Bushing
11-033-l @
drive gear (No. of teeth:
drive drive shaft speed = Engine speed x l/2
14)
drive shaft 14)
170-1 SERIES
STRUCTURE
AND
FUNCTION
FUEL SYSTEM
FUEL FILTER
i
6162F136
1.
Air bleeding plug
2.
Filter bracket
3.
Filter element
4.
Filter case
a.
From feed pump
b.
TO fuel injection pump
Fuel filter l
Cartridge
11-034 0
Filtration area: 0.4 m2 x 2
STRUCTURE
AND
FUEL SYSTEM
FUNCTION
FUEL CUT SOLENOID B contact
(electricity
flows in ordinary
operations)
method
F621201037
*
Maker:
NIKKO
l
Type:
Sealed
* Rated voltage: * Operating current: * Stroke: * Weight: Inner
Cl
:
C2:
DC24ti Maximum:
35A max.
Continuity:
0.5A
max.
12 f 0.1 mm 2.7 kg
wiring
Pull-in coil Holding coil
FUNCTION *
DENKI
1. Shaft
5. Stop lever
2. Case
6. Return spring
3. Piston
7. Solenoid
4. Coil
8. Fuel control lever
Starting engine When the starting key is turned
on, the solenoid
is
energized. Solenoid
shaft
(1)
injection
pump
stop lever (5)
is electrically
attracted,
and fixing
pulling it in the
RUN position. .
Stopping engine When the starting key is turned
off, the solenoid is
de-energized. Injection
pump
stop lever (5) is returned
position (non-injection *
During
operation,
controlled *
to STOP
position) by return spring (6).
the
amount
of fuel
injection
is
by fuel control lever (8).
When installing
the fuel solenoid, adjust clearance A
referring to TESTING
AND
ADJUSTING. 6162F151
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
Y View
Z View
F6161A021
-$($Ejl’
1. Case
Pull-in coil
Pull-in coil
2. Coil
l$o
3. Return spring
Holding coil Holding coil After pull-in Before pull-in Inner wiring
4. Plunger 6134F166A
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
Holding coil: l
’1-?z4-2
Type: Operating current Pull-in coil:
Stroke:
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)
170-l SERIES
STRUCTURE
ENGINE
AND
FUEL
FUNCTION
SYSTEM
STOP MOTOR
Shape of cable tip 7(non-threaded stopper type)-
3
.--r--y-\ :_ A_:.,/
35 Stroke
Shape of cable tip (threaded stopper type)
-
I
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)
1. Motor assembly
’
8. E(AV 0.858)
Engine stop motor -
Maker:
Jidosha Denki Kogyo Co., Ltd.
2. Cover
-
Rated voltage:
DC24V
3. Cable assembly
* Operating force:
4. Cable clamp 5. Coil spring
*
Stroke:
*
Weight:
15 kg min. 35:::40
mm
1.2 kg_
6. Cable 7. Screw 8. Breather 9. Bracket assembly 10. Cover assembly
170-l
SERIES
1 l-034-3 0
STRUCTURE AND FUNCTION
STRUCTURAL
DRAWING
FUEL SYSTEM
(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
STRUCTURAL
FUEL
FUNCTION
DRAWING
SYSTEM
(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
DESCRIPTION
OF OPERATION
1.
(O” or 390°)
Stop condition
AND
SYSTEM
CIRCUITS
Battery 4+-i
The
above
drawing
shows the stopped
when a closed circuit has been formed. 2.
condition
assembly is stopped at the auto-stop position on the
The slider
P, side.
When switch is turned (when starting the motor) attery
b-i
1
When the switch is moved to the P, side (starting
bly, thereby starting the motor.
The slider assembly
switch ON), an electric current flows from the plus
starts to move in the direction
of the arrow at the
side contactor
same time as the roller starts to move.
plate through
the P2 auto-stop
ter-
minal and switch and into the armature shaft assem3.
Turning condition
(90’
in the drawing) Battery
Id7
I7b Electric current continues to pass through the arma-
slider assembly also continues to move in the direc-
ture
tion of the arrow.
turn.
shaft
assembly
and the
Because of the rotation
’’-ki?4-6
motor
continues
of the
to
rol,ler, the
170-l SERIES
STRUCTURE
4.
AND
FUEL
SYSTEM
When stopped (180’)
A closed circuit terminal 5.
FUNCTION
is formed
when the P, auto-stop
rides on the minus-side
contactor
plate,
and the motor comes to a sudden stop.
The slider
assembly also stops.
When switch is turned (when starting the motor) Batterv
When the switch is moved to the PI side (starting
thereby
switch OFF),
starts to move in the direction
contactor and switch 6.
an electric current flows from the plus
plate through
the PI auto-stop
and into the armature
Turning condition
(270°
terminal
starting
in the drawing)
the direction
to stop condition
turn.
170-l
of the arrow at the
shaft assembly,
Electric current continues to pass through the armaassembly
The slider assembly
same time as the roller starts to move.
ture
shaft
the motor.
and the
motor
continues
to
of the arrow.
Then the circuit returns
1.
The slider assembly also continues to move in
SERIES
11-34-7 0
STRUCTURE
AND
STARTING
FUNCTION
FUEL SYSTEM
AID
Auto priming system (APS)
6162F137 1.
Glow plug
6.
Hose
a.
To heater switch
2.
Clamp
7.
Bracket
b.
To APS controller
3.
Wiring harness
8.
Hose
c.
To APS controller
4.
cover
9.
Valve
d.
To heater switch
5.
Nozzle
a.
From fuel filter (Fuel1
170-1 SERIES
1 l-035
OUTLINE OF ELECTRONICAL electronical
governor
GOVERNOR made by ZEXEL)
SYSTEM
(with
OVERALL CONFIGURATION
! Injection
=-I
pump
/
1 /
stop output
Electronical
governor
50160Hz changeover
controller
) i
L
Fuse Low idle control dial
f
t
Start signal
t
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 @
6 z
CONTENTS
OF ELECTRONIC
VO.
GOVERNOR
CONTROL
Item
Contents
1
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.
2
Selection
of Li/rated
Low-idling
3
Adjustment
4
Adjustment of frequency (In isochronous control mode)
Rated speed is adjusted Adjustment range
5
Selection (In droop
Regulation is changed with droop from about 3% to 5%.
6
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.
7
Li isochronous
Engine
8
Selection
9
Emergency stop function (Error signal output)
speed
of Li speed
control
of frequency
Injection start
11
Overrun-preventive
12
Diagnosis
13
Memory
14
Sharp
15
Pre-operating
16
Overspeed testing (Used only during
(50/60Hz)
rate control
acceleration
is selected
with
speed
with
outside control f 50 rpm,
: Approx.
switch
input.
is kept constant
50Hz or 60Hz is selected
with
adjustment
knob. Judgment
during
low idling,
switch
input.
function
for
function
Fuel injection
rate is control
so that engine
high idling
regardless
limiting
function
Error signal speed
of rack
function test)
to outside
is reset.
off and stop signal
sliding
are taken
(See next item.)
When engine is accelerated sharply, prevent production of black smoke. Rack is moved to reduce at low temperature.
rises
easily.
If electronic governor system has trouble, set measures and error signal is output to outside. (See next item.) function
of load.
temperature to outside.
will start
If engine speed exceeds set value, fuel is turned is output to outside. Set value : (1) 2070rpm (by software) (2) 2300rpm (by hardware)
knob dur-
: 15 msec
knob during
Engine is stopped when oil pressure lowers, water or he engine overruns, and error signal is output
function
clearing
or rated speed
Engine speed is changed with the rpm adjustment control ing low idling. Lower limit : 700 rpm Upper limit : 900 rpm,
of droop (adjustment) control mode)
10
speed
full
resistance
rack position
before
is limited
engine
to
is started
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
2
SEE00127
1. Case 2. Connector 3. Mounting
11-035-3 @
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.
Electronical
governor
main
unit
1. 2. 3. 4. 5. 6. 7.
Housing Actuator Control rod Connector Copper plate Cover Lubrication outlet
eyebolt
6
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.
l
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 Fleming’s 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
Control position
plate
rod sensor
Copper I
plate
Connect0
Connector
rod
inear
DC motor 615OF176
615OFl77
2) Linear DC motor
, Coil assembly
Cover
Magnet
’
Pole
615OFl79
(Upper
11-035-5 @
side sectional
view)
3) Control .
Structural
rod position
sensor
.
view
Operation
diagram
Jw-
Large
Inductance 6150Fl82 615OFl81
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.
l
l
.
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 COOLING
COOLING
SYSTEM
SYSTEM
SYSTEM
CHART
6162F136
11-036
1.
Water pump
7.
Water manifold
2.
Oil cooler
8.
Thermostat
9.
Radiator
3.
Corrosion resistor
4.
Cylinder liner
10.
Fan
5.
Cylinder block
A.
From oil pump (oil)
6.
Thermostat switch
B.
To engine each component
(oil)
170-1
SERIES
STRUCTURE
AND
FUNCTION
COOLING
SYSTEM
WATER PUMP
6162F139
1.
Pump body
A.
From radiator
Water pump
2.
Impeller
B.
To oil cooler
* Water pump speed =
3.
Floating seal
4.
Water seal
5.
Pump shaft (rear)
6.
Pump shaft (front)
7.
Inlet housing
Engine speed x 1.8
* Flow capacity:
1050 !Z/min. (3,600
170-1 SERIES
rpm)
11-037
COOLING SYSTEM
STRUCTURE AND FUNCTION
FAN DRIVE l
FAN DRIVE
AND
TENSION
(For D275A-2,
D375A-1.2,
PULLEY PClOOO-1, HD465-3)
6162F140
1 l-038 0
1.
Tension spring
2.
Tension shaft
3.
Tension pulley
4.
Unit
Outside diameter for Pulley Applicable machine
Fan Pulley
Crankshaft Pulley
Tension Pulley
Fan pulley
D275A-2
328
200
150
5.
Fan belt
D375A- 1
342
200
150
6.
Crankshaft pulley
D375A-2
328
200
150
7.
Fan PClDDD-1
347
200
150
HD465-3
308
184
150
: mm
STRUCTURE
l
TENSION
AND FUNCTION
PULLEY
COOLING SYSTEM
(For D275A-2)
X /
\
5
\
fi Section
7
A-A
View
X
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
l
TENSION
AND
FUNCTION
PULLEY
(For D375A-1
/I
5
6
COOLING
l
2, PClOOO-1)
\
7
Section A - A
1.
Tension pulley shaft
2.
Roller bearing
3.
Tension pulley bracket
4.
Tension pulley (Outside diameter:
5.
Oil seal
6.
Ball bearing
7.
Spacer
8.
Stopper
SYSTEM
6162F141
150 mm)
1 l-039 0
STRUCTURE
AND
COOLING
FUNCTION
SYSTEM
FAN DRIVE AND TENSION PULLEY l
FAN
DRIVE
(For WA600,
WD600,
WA700,
HD465-5)
i
/’
\
/
/ I’
6
\_____P---
Fan pulley diameter
1.
Tension spring
2.
Tension shaft
3.
Tension pulley (Outside diameter:
4.
Fan pulley
5.
Fan belt
6.
Crankshaft pulley (Outside diameter:
7.
Fan
a.
Direction of wind
)
11-039-l 0
150 mm)
200 mm)
379
WA700
293
WA600
(A.C spec.), EG480B-1
STRUCTURE
l
TENSION
AND FUNCTION
COOLING
SYSTEM
PULLEY
5 I
8’
7
‘6
A-A SLE00255
1.
Tension
pulley
2.
Seal
3.
Inner
4.
Roller
5.
Tension
6.
Spacer
7.
Ball bearing
8.
Oil seal
shaft
race bearing pulley
(Outside
diameter:
150 mm)
1 l-039-2 0
STRUCTURE
AND
FUNCTION
CORROSION
COOLING
SYSTEM
RESISTOR
a
\
b
\
t-/
b Section X - X (Detail valve)
6162F142
1.
Head
2.
Element case
3.
Solid drug i (included 1,000 g)
a.
Coolant inlet
b.
Coolant outlet
Corrosion resistor Cartridge
11-040
- Filteration area: 0.13 m*
STRUCTURE
AND
FUNCTION
COOLING
SYSTEM
THERMOSTAT
1. Seal
b
2.
Thermostat
3.
Valve
4.
Body
5.
Piston
6.
Sensor
7.
Sleeve
8.
Wax
a.
From engine each component
b.
To water pump
c.
To radiator
6162F143
OPERATION
-._ At cold (close)
At warm (full open)
6162F144
Function Opening temperature: 76.5 f 2°C - Full opening temperature: 9O’C l
* Valve lift: Minimum 10 mm
170-l
SERIES
11-041
STRUCTURE
ACCESSORY
AND FUNCTION
(Diesel Kiki Air compressor) Without air delivery relief valve
PC1 000-l
ir 9 1
!
?;”
-_q
-.iSection
A-A
‘3
View 2
6162F655
1.
Flange
2.
Coupling
3.
Air compressor
4.
Air governor
1
Intake manifold
1
Air
a.
From intake
b.
To air tank (air)
manifold
c.
To thermostat
d.
From oil cooler (cooling water)
housing
(air) (cooling tiater)
Air circuit diagram
170-l
SERIES
6162F146
’’-Oi2-’
STRUCTURE
HD465-5,
ACCESSORY
AND FUNCTION
WA600-1,
WA700-1
(Diesel Kiki Air compressor) Without air delivery relief valve
A-A View 2
a
Air delivery relief valve
6162F620
1.
)
Flange
2.
Coupling
3.
Air compressor
a.
From intake
b.
To air tank (air)
manifold
c.
To thermostat
d.
From oil cooler (cooling water)
housing
Intake manifold 1
(air) (cooling water)
6162F821
’’-“G2-2
170-1 SERIES
STRUCTURE
AND
FUNCTION
ACCESSORY
AIR COMPRESSOR
6162F147
1.
Inlet valve seat
11.
Thrust washer
Air compressor
2.
Unloader valve body
12.
Crankshaft
* Maker: Cummins * Rated speed: 1,600 rpm
3.
Unloader valve spring
13.
Drive gear (No. of teeth
4.
Unloader valve cap
14.
Oil ring
5.
Head cap
15.
2nd ring
6.
Inlet valve
16.
Top ring
7.
Inlet valve spring
17.
Cylinder head
8.
Piston
9.
Crank case
a.
Air inlet
Connecting rod
b.
Air outlet
10.
170-1
SERIES
:
24)
(at engine rated speed)
* Discharge capacity:
245 Illmin.
(at rated speed) l
No. of cylinder - Bore x Stroke: 1 - 92.1 x 44.5
11-043 0
STRUCTURE AND FUNCTION
ELECTRICAL
ELECTRICAL SYSTEM
SYSTEM
ALTERNATOR
Inner connecting diagram 6162F148 1.
Alternator
Engine
S6D170-1
assembly
Applicable machine model PC650-1 PC1 500-l
Type
Delco-Remy,
2581-450,
Open type
Specifications
Pulley outside diameter (mm)
Weight
24V, 50A
95
15 kg
ALTERNATOR
BUILT-IN
REGULATOR
\
1.
Alternator
2.
Regulator
Wiring diagram F6166049
Engine
SAGD170-1
Applicable machine model D275A-2 WA600-1 WD600-1
Type
HD465-3 HD465-5
Pulley outside diameter (mm)
Weight
Sawafuji, Open type
WA700-1 SAGD170.A-1
Specification
24V. 75A Sawafuji. Open type
24V. 50A 95
D375A-1 (-12802) SA6D170-B-1
D375A-1 (12803 and up) D375A-2 PClOOO-1
Nikko Denki, Open type
24V. 35A
Sawafuji, Open type
24V. 50A
n-044-1 0
STRUCTURE
AND
ALTERNATOR
ELECTRICAL
FUNCTION
WITH
REGULATOR
Alternator R
B.E.F.R:
SYSTEM
Regulator
-----JJRl-----
Terminal Wiring diagram
Engine
6114F151
Tvw
Specifications
Pulley outside diameter (mm)
Weight
EG550-1
Nikko Denki, Open type
24V. 50A
95
15kg
EG5808-1 L
Nikko Denki, Closed type
24V. 13A
95
7.6 kg
EG450-1
Nikko Denki, Open type
24V. 13A
95
7.8 kg
Applicable machine model
SAGD170-A-1
SAGDI 70-B-1
’’-“ii4-2
STRUCTURE
ALTERNATOR
ELECTRICAL
AND FUNCTION
BUILT-IN
SYSTEM
REGULATOR
r
E-
B.E.R: Terminal
F6161 A022
Wiring diagram
Engine
Applicable machine model
Type
Specifications
Pulley outside diameter (mm)
Weight
SAGDI 70-A-1
EPSAGD170-A-1
Nikko Denki, Open type
24V. 25A
95
6.5 kg
SAGDl70-B-1
EPSAGDI 70-B-l
Nikko Denki, Open type
24V. 25A
95
6.5 kg
11-044-3 0
STRUCTURE
AND
STARTING
FUNCTION
ELECTRICAL
SYSTEM
MOTOR
6162F149
1.
Pinion gear
2.
Starting motor assembly
3.
Magnetic switch
4.
Safety relay
Applicable machine model
B, C, E, R, S: Terminal
Type
Specifications
No. of pinion teeth
Weight
Nikko Denki, Sealed type
24V. 7.5KW
11
18 kg
SAGDl70-A-1
Nikko Denki, Sealed type
24V, 7.5KW
SAGD170-B-1
Nikko Denki, Sealed type
24V. 7.5KW
Engine
S6D170-1
:;;;l$2 PC1500-1 WA600-1
I
11
I
11 I
18 kg
18 kg I
STRUCTURE
AND FUNCTION
ELECTRICAL
SYSTEM
EG580B-IL, EPSAGD170-A-1, EPSAGD170-B-1 EG480B-1 (For CIS -45°C spec.)
F6161 A023
Engine
1.
Pinion gear
2.
Starting
3.
Magnetic
4.
Safety relay
Applicable machine model
B, C, E, Fi, S: Terminal
motor assembly switch
Type
SA6D170-A-1
24V, IIKW
SA6D170-B-l EG480B-1 (-45°C spec.)
11-046 0
I
Specificatons
SAWAFUge Denki, Water tight, oil resistant type
Pulley outside diameter
Weight
19.5 kg
STRUCTURE
AND FUNCTION
ELECTRICAL
SYSTEM
F6161 A023
Pinion gear Starting Magnetic
B, C, E, I?, S: Terminal
motor assembly switch
Safety relay
Engine
S6D170-1
Applicable machine model WA600-1 (-50°C spec.)
Type SAWAFUge Denki, Water tight, oil resistant type
Specificatons
Pulley outside diameter
Weight
24V, IIKW
11
19.5 kg
11-046-l 0
STRUCTURE
AND
WIRING
DIAGRAM
SA6D170-A-1
170-1 SERIES
FUNCTION
ELECTRICAL
SYSTEM
(for EG550-1)
11-047 0
STRUCTURE
EG580B-1
AND FUNCTION
ELECTRICAL
SYSTEM
L
unit
Engine stop solenoid
m-@-Zergency
Water temperature unit nJ7-
9
stop
I
Fuse (30A)
Charge ammeter
Alternator
motor
OFF PREHEAT
j
O,,, START
Starting switch
F6161 A024
1 l-048 0
170-1 SERIES
ENGINE
12 TESTING
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
When
carrying
thorized
A
out
testing
pins, block the wheels,
When spurt
out
person checking out
and
and
adjusting,
and apply
or troubleshooting,
the parking
operations
with
two
stop
the
machine
on level
ground,
fit safety
brake.
or more
workers,
always
use signals,
and
do not allow
any
unau-
near the machine. the may
water
level,
cause
burns,
if the
radiator
so always
cap
wait
is removed
for
the
when
engine
the
to cool
engine down
is hot, before
boiling
water
checking
the
will water
level.
A A *A!
Be extremely
careful
not to touch
Be extremely
careful
not to get caught
Wh en removing release
the
the
internal
plugs
any hot parts. in the fan or any other
or caps
from
first.
Fit the
pressure
places
under
measuring
rotating
hydraulic tools
parts. pressure,
securely
before
water
pressure,
carrying
out
or air
any
pressure,
testing,
adjust-
ing, or troubleshooting. When
using the standard
be careful
of the following
The standard standards mating
values
for new
wear
during
the results
of various
in testing,
in the standard
and machines
operation standard
or as target values
tests and standard
with the repair
Do not use this standard
12-002 0
for judgement
for the new machines
judgement
together
table
adjusting,
or troubleshooting,
it is necessary
to
points.
machines
The failure erence
values
values
shipped values
from
when
in the standard values
and operation
values
carrying value
for machines history
table as a standard
table
the factory.
should
given
as reference
from
be used as values
the
for esti-
out repairs.
table
are values
shipped
of the machine for judging
are values They
claims.
from
using
estimated
the factory.
when judging
values
based
Use these values
failures.
on
for ref-
TESTING
AND
FUEL
ADJUSTING
ADJUSTING
ENGINE
STOP
SYSTEM
MOTOR
Procedure for adjusting engine stop motor
1.
Temporarily
assemble nut and bolt (1). then with
stop motor actuated, assemble ball joint (2). 2.
With stop motor and ball joint and stopper
actuated,
adjust nut and bolt (1)
(2) so that clearance of stop lever (3) bolt (4) at STOP
end is 1 f 0.5 mm,
then assemble fully. 3.
Switch
the stop motor
check the condition
on and off ten times, and
of the adjustment.
If neces-
sary, adjust ball joint (2). 4.
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
is OFF.
ance, adjust the hole position (If
there
is any clearance,
If there is any clearof the return spring
the output
power may
drop.)
569FlOl
170-l
SERIES
12-002- 1 0
TESTING
AND
FUEL SYSTEM
ADJUSTING
ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE) ADJUSTING FUEL (VALVE CRACKING 1. 2.
INJECTION PRESSURE PRESSURE)
Remove retaining cap (1). Remove
nozzle
(2).
spring
seat (3),
and nozzle
spring (4). 3.
Adjust
the
injection
pressure (valve cracking pres-
sure) by adjusting shim thickness (5). *
Injection thickness: m
4.
After
pressure adjusted Approx.
per 0.1
mm shim
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
DATA
AND
FOR Engine
FUEL SYSTEM
ADJUSTING
INJECTION model
PRESSURE
I
Shim
ADJUSTMENT contour
I
S6D170-1 SAGDI
a =
Shim thickness (Range)
I
Shim thickness (Interval)
4.5 mm 0.50
70-A-1
- 1.54
mm
0.02
mm
b=11.5mm
SAGDl70-B-1
Part No.
SHIMS
Thickness
(mm)
Part No.
Thickness
(mm)
DK150523-5000
0.50
DK150523-7800
1.06
DK150523-5100
0.52
DK150523-7900
1.08
DK150523-5200
0.54
DK150523-8000
1.10
DK150523-5300
0.56
DK150523-8100
1.12
DK150523-5400
0.58
DKl50523-8200
1.14
DK150523-5500
0.60
DK150523-8300
1.16
DKI
0.62
DKl50523-8400
1.18
DK150523-5700
0.64
DK150523-8500
1.20
DK150523-5800
0.66
DKl50523-8600
1.22
DKl50523-5900
0.68
DKl50523-8700
1.24
DK150523-6000
0.70
DK150523-8800
1.26
DK150523-6100
0.72
DK150523-8900
1.28
DKl50523-6200
0.74
DKl50523-9000
1.30
DKl50523-6300
0.76
DK150523-9100
1.32
DK150523-6400
0.18
DK150523-9200
1.34
DK150523-6500
0.80
DK150523-9300
1.36
DKI
0.82
DK150523-9400
1.38
DKl50523-6700
0.84
DK150523-9500
1.40
DK150523-6800
0.86
DK150523-9600
1.42
DK150523-6900
0.88
DKl50523-9700
1.44
DK150523-7000
0.90
DK150523-9800
1.46
DKl50523-7100
0.92
DKl50523-9900
1.48
DK150523-7200
0.94
DK150530-0000
1.50
DK150523-7300
0.96
DKI
1.52
DK150523-7400
0.98
DK150530-0200
DK150523-7500
1 .oo
DK150523-7600
1.02
DK150523-7700
1.04
50523-5600
50523-6600
50530-0100
1.54
c 170-1 SERIES
12-002-3 0
TESTING
AND
FUEL SYSTEM
ADJUSTING
CALIBRATION Machine Model
Engine Model
Pump Assembly Number
PC650-1 6 162-73-l
12-002-4 0
SAGDI 70-B-l
and
Page
up
170
PC 1500-I
EG550-1
Applicable Engine Serial Number
10025 S6D170-1
EG450-1
DATA
12-003 10126
and
up
6162-73-1251
10095
and
up
6 162-73-l
330
10001
-
6162-73-l
331
10053
and
10052
12-004
12-004-
SAGDI 70-A-1 up
12-004-2
170-1 SERIES
1
ENGINE
BODY
ADJUSTING Method 1. 2.
VALVE
of adjusting
Remove
valve
the cyliner
in the normal
at compression
align pointer damper
clearance
head cover.
Rotate the crankshaft No.1 cylinder
CLEARANCE
direction
to set
top dead center,
and
(3) with the 1.6 TOP mark on vibration
(2). When
rotating,
check
the
movement
of the intake valve of No.6 cylinder. *
When
No.1 cylinder
center,
3.
Adjust
the
No.6
the clearance
valve arrangement 4.
Next,
is near compression intake
rotate
direction remaining
top dead
moves
of the valves
(is open).
marked
0 in the
chart.
crankshaft
and
valve
adjust
one the
turn
valve
valves marked
in the
normal
clearance
*
Valve
arrangement
of the
0.
Cylinder No.
1
8 = Exhaust valve Intakevalve
2 E; z
*
To adjust
the valve clearance
of adjustment
screw
between
crosshead
turn
adjustment
the
loosen
(7), insert
(6) and rocker screw
locknut
feeler
until
(8)
gauge
A
6
3
2
0
0
0
0
5
4 0
0
0 0
7
5
6
0 0
0 0
6
arm (5), and the
clearance
is a sliding fit. +
Valve
clearance
(cold, warm) Unit: mm
5.
Tighten
the
locknut
to hold the adjustment
screw
in position. m *
Locknut:
6.9 + 1 kgm
It is also possible each valves
time
and
of each
to turn
adjust
the
cylinder
the
crankshaft
intake
according
and
120° exhaust
to the
firing
order. l
*
Firing order:
After tightening
1-5-3-6-2-4 the locknut,
check the clearance
again. 6162F658
12-003 @
1
MEASURING Method
COMPRESSION
of measuring
A
When
compression
measuring
not to touch
muffler,
or to get caught
-k Measure
pressure
the compression
careful
the
warmed
pressure,
be
manifold
or
exhaust in rotating
the compression
engine
PRESSURE
parts.
pressure
with the
up (oil temperature: 40 -
I.
Adjust For
60°C)
valve clearance. details,
12
see
ADJUSTING
VALVE
CLEARANCE. 2.
Remove
the nozzle holder
assembly
of the cylinder
to be measured. +
3.
Be careful
Install
not to let any dirt or dust get in.
adapter
assembly
Al
to the specified m
Connect
5.
Place
2.75
compressor
the fuel
position.
A
+ 0.25
kgm
gauge A to the adapter.
control
lever
Crank the engine
and measure
and tighten
torque.
Torque:
4.
in the mount of the nozzle holder
of the cylinder to be measured,
in the NO INJECTION with
the compression
If the fuel control NO INJECTION
the starting
motor
pressure.
lever is not placed
position,
in the
the fuel will spurt
out. Ir If the
adapter
amount *
For details pression
mount
is coated
of the
pressure,
TESTING,
standard
value
see TABLE
ADJUSTING,
a small
Torque:
’2-:04
2.25
+ 0.25
for the
com-
OF VALUES
FOR
AND
SHOOTING. m
with
of oil, it will reduce the leakage.
kgm
TROUBLE-
FUEL SYSTEM TESTING
AND
There are the following the fuel injection Aligning
l
methods
timing
match
mark when
Delivery
without
valve method when
When
using
replace
the copper
valve
with
starting *
new
1.
No.1
and
(flange
type)
Turn
the
Check *
always
of the delivery
these
parts
at the compression
adjusting
VALVE
by
crankshaft
pointer
crankshaft
2 z
cylinder
back
Rotate the crankshaft
and
method,
before
top dead
CLEARANCE
aligning
approx.
match
mark
45O from
No.1
TOP.
to align 3.
Prepare
see ADJUSTING
Testing
cylinder 2.
parts.
valve
and O-ring
then test and adjust.
For details,
l
delivery gasket
the injection
or replaced
the operation.
Set the center,
the
the injection
repair
assembling
pump that has been repaired *
TMING
pump.
assembling
engine
FUEL INJECTION
of testing and adjusting
of the injection
pump to the original l
ADJUSTlNG
damper
that
line
slowly
in the normal
( with the injection
line on
(1).
line a at the fuel
b at the
direction
timing
drive
injection
housing
If the lines are not aligned
end
adjust
pump
end
are aligned. at the oblong
hole of the flange.
z w
Bolt nut: 6.75
Testing
l
and
(laminated 1.
Follow
adjusting
coupling the same
for the flange 2.
Check
that
+ 0.75
by
aligning
match
mark
type) procedure
as for Steps
1 and 2
type.
the
lines
on the coupling
cover of the fuel injetion *
kgm
and bearing
pump are aligned.
If the lines are not aligned
adjust
at the oblong
hole of the coupling. w
Bolt nut:
Width across fiats of nut for coupling oblong hole
injection pump type Bosch PE-P, PE-PD
9.0 kO.5 I
I
*Bosch PE-ZWy
pump only.
kgm
19
Bosch PE-ZWx
* 6162-73-l
Tightening rorque for bolt of oblong hole
I 653
21
and 6162-73-l
I 682
7.75 + 0.25
16.Ok
are the
1.0
injection Oblong hole
6162F663
12-005 0
l
Testing
fuel
injection
timing
by
delivery
valve
methd *
Prepare ring
new
parts for the copper
of the
delivery
valve
gasket
before
and O-
starting
the
operation. 1.
Disconnect
fuel
injection
pipe
(1)
of
the
No.1
cylinder. 2.
Remove
delivery
valve
valve (3) and spring
holder
(2). take out delivery
(4), then
install
delivery
valve
holder (2) again. 3.
Place *
4.
the fuel
control
For injection
pumps
OPERATION
position.
Turn the crankshaft
lever
at the
with
a stop lever set to the
back 40 -
FULL
50°
position.
from top dead
center. 5.
Operate
the feed
slowly
in the
where
the fuel
pump
normal
and rotate direction.
stops flowing
the crankshaft
Check from
the
delivery
point valve
holder (2). 6.
197F402
Check
that
crankshaft
the
fuel
pulley
the point where
injection
timing
(5) and pointer
line
on
(6) are aligned
j,
BEYOND
injection
timing
line: Timing
+
BEFORE
injection
timing
line: Timing ADVANCED
If the test incorrect, portion
shows adjust
or at
at
the fuel stops flowing.
that
the fuel
at the
oblong
the
oblong
RETARDED
injection
timing
is
hole of the flange
hole
at the
laminated
coupling. 7.
Remove valve
delivery
valve holder (2), assemble
(3) an spring
(4)
then
install
delivery
delivery
valve
holder (2) again. +
When
assembling
careful Sr Always
replace
the delivery w
again,
wash
with fuel and be
not to let any dir dust stick to any part.
Delivery Note:
the copper
valve with
valve holder: 14.0
gasket
and O-ring
11.5 & 0.5 kgm
+ 1 .O kgm for the EPl 1 injec-
tion pump on the WD600. 8.
Connect w
12-006
fuel injection Sleeve
of
new parts.
pipe (1).
nut: 2.2 + 0.2 kgm
TESTING
ADJUSTING l
ADJUSTING
AND ADJUSTING
Continuous
FUEL CUT SOLENOID
FUEL CUT SOLENOID
type (continuous when operating) /3 Detail
2
3
P
6162~201
7. Solenoid 2. Stopper
This fugure
valve (FULL stopper
(-45°C).
pin)
is for PC650-1,
The linkage
PC1500-I
and the shape
that given here depending
3. Stop lever
differ from
4. Rod
in which the engine
5. Return spring
method
is mounted,
is fundamentally
and EG480B-1 of stop lever may upon the machine
however
the adjusting
the same.
6. Rod
8 & z
Adjusting method 1.
Stop the engine
2.
Adjust
3)
and loosen the nuts of rod (4).
rod (4), so that the solenoid
has a maximum
adjust
rod (7) so that the there is length C of 31
to 32 mm.
stroke of 12 mm. Then,
For EG550-1 Adjust
rod (4) so that there
0.4 + 0.1 mm between
injection
is clearance pump
A of
stopper
(2)
and stop lever (3), while pulling the rod to the RUN position 3.
Adjust
1)
with hand. the length of the return spring as follows.
For PC650-1,
PC1500-1,
EG450-I
and EG480B-1
(-45°C
spec.)
Adjust
rod (6) so that there is length B of 138 to
141 mm.
2)
For WA600-1 No need adjusting. (The return
spring
is installed
in the injection
pump.)
F6161A004
Turn on the engine solenoid
starting
key and confirm
that
has a stroke of 12 mm and there is clear-
ance A of 0.4 * 0.1 mm. After turning
on and off the key several
confirm the amount clearance Tighten
times,
re-
of the stroke of the solenoid and
A. up the nuts of the rod.
12-007 0
SAGDI 70-A-1 SAGDI 70-B-1 1.
Connect
(EG580B. (EG480B.
the solenoid
EGGOOBS) EG500BS)
and injection
pump with
the
rod. When
doing
returned
pin at the lever the
this,
FULL
is returned STOP
(SAGDI
adjust
to a position
bolt
70-B-1
end,
so that
1 -
the stop lever
1.5 mm from
and
so that
the
to a position
1.5 -
(SAGD170-A-1)
or
is
the stop
pump
stop
2.0 mm from limit
position
) when the solenoid shaft is pushed
in fully by hand.
2.
Pass electricity the solenoid OFF 2 -
through
3 times
in the operating smooth,
the solenoid
moves smoothly.
and check that there condition.
adjust
and check that
Turn the power
the
If the movement
linkage
to
ON/
is no change is not
improve
the
---
movement.
Y
u
‘--
6162F620
3.
After
checking
the engine,
pass electricity the engine
+
Problems
that the operation
check that output through
start then
the solenoid
caused by improper
. When free, clearance between stop lever and bolt at FULL side is too large (defective linkage)
adjustment
10 seconds.)
of solenoid.
* Solenoid coil burns out (when solenoid is half pulled). - Injection pump governor breaks or causes scuffing (Excessive force is brought to bear on lever).
- Amount of fuel injected drops, so engine output drODs.
Stoip pin at FULL end
and check that
stops. (It must stop within
-When electricity is passing, clearance between stop bolt and lever is 0.
12-008 0
is smooth,
is as specified,
Stop pin at STOP end Clearance 1.5-2.0mm
6162F621
SA6D170-A-1 1.
Connect
(EG5808-1 the solenoid
L)
and injection
pump with
the
rod. When
doing
returned
pin at the lever
this,
FULL
is returned
the STOP
and
Pass electricity
stop lever
the
pump
1.0 to 2.0 when
is
the stop stop
mm from
the solenoid
in fully by hand.
through
the solenoid
moves smoothly.
3 times
in the operating smooth,
the
so that
bolt (SAGD170-A-1)
the solenoid OFF 2 -
end,
so that
1 to 1.5 mm from
to a position
shaft is pushed
2.
adjust
to a position
and check that there condition.
adjust
and check that
Turn the power
the
If the movement
linkage
ON/
is no change
to
is not
improve
the
is smooth,
start
is as specified,
then
movement.
3.
After
checking
the engine,
pass electricity the engine
*
Problems
that the operation
check that output through
caused by improper
electricity is passing, clearance between stop bolt
- When
lever
and check that
stops. (It must stop within
* When and
the solenoid
is 0.
free, clearance between stop lever and bolt at FULL side is too large (defective linkage)
10 seconds.)
adjustment
- Solenoid
coil
of solenoid.
burns
out
(when solenoid * Injection pump breaks or causes (Excessive force to bear on lever).
is half pulled). governor scuffing is brought
- Amount of fuel drops, so engine
injected output
stop bolt
drops. F6161 A025
12-008-l 0
SA6D170-A-1 SAGD170-B-1 1.
After that
(EPSAGD170-A-1) (EPSAGD170-B-‘l)
pulling
rod (1) to solenoid
stop-lever
adjust
the length
clearance
OFF 2 -
stop-lever
through
so
operates,
1 .O to 1.5 mm
(2) and stopper
the solenoid
moves smoothly.
3 times
in the operating smooth,
side by hand
solenoid
(3) of
pump.
Pass electricity the solenoid
while
of rod to become
between
fuel injection
2.
works
and check that there condition.
adjust
and check that
Turn the power
the
If the movement
linkage
to
ON/
is no change is not
improve
the
is smooth,
start
is as specified,
then
movement.
3.
After
checking
the engine,
pass electricity the engine
*
Problems
that the operation
check that output through
the solenoid
and check that
stops. (It must stop within
caused
by improper
’ When electricity is passing, clearance between stop bolt and lever is 0.
adjustment
10 seconds.)
of solenoid.
* 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.
(HD465-3
Temporarily engine
FOR ADJUSTING
install
stop
STOP MOTOR
CABLE
HD465-5)
l
a ball joint
motor
ENGINE
to the cable
to connect
it to the
of the
injection
pump.
2.
Pull the
injection
ENGINE
STOP
temporarily secure *
the cable to bracket
Adjust 0.5
-
1.5
installed
Turn
position
operating
when
position
A between
when
the
the engine
can
engine
adjusting
2
fuel is
motor
is
is stopped).
be carried
the
the
stopper
stop
out
by adjusting
that the ball joint is screwed
tighten 5.
to the
clearance
mm
(when
amount After
with the cable
pump stop lever and the STOP
Adjustment
z z
(1).
spring).
so that
injection
and
stop).
(it is pulled
by a built-in
z
position,
Stop lever (3) is at the operating it is free
4.
by hand to the
stop motor is delivered
pulled (engine
3.
stop lever
INJECTION)
intall ball joint (2) to the stop lever, then
The engine
*
pump (NO
clearance
from
the
in. the
stoppers,
all nuts and bolts. the
engine
starting
switch
times to check that the engine smoothly. between
In particular,
check
stop lever (3) and STOP
-
1.5 mm when
*
Limit
*
Check
the engine
switches
are
built
ON/OFF
several
stop motor operates that
clearance
stopper
A
(4) is 0.5
is stopped. into
the
569FlOl
engine
stop
motor at both ends of the cable stroke. visually
that there
stop motor cable when
that the stop lever returns position.
The action
fuel injection *
Problems engine
is slack in the engine
the engine
is running
and
fully to the operating
of the spring
built
into the
pump keeps it at the oting position.
caused
by defective
adjustment
of the
stop motor cable
* Clearance
between stop lever and STOP stopper too large when engine stop motor cable is pulled.
* Engine does not stop.
is
* Clearance between stop lever and OPERATION stopper is too large when cable is free.
l
Stroke of engine
l
Stroke
of fuel
* Engine output drops because of drop in amount of fuel injected.
stop motor: 35 mm injection
pump
stop lever:
25 mm
12-009 @
S6D170-1 1.
(WA600-1,
Temporarily engine
WA700-1)
install
a ball joint
motor
to connect
stop
to the cable it to the
of the
injection
pump. 2.
Pull the STOP install stop
injection
(NO
pump
stop lever to the
INJECTION)
position,
and
ENGINE
temporarily
ball joint (2) to the stop lever. Then keep the lever
in contact
temporarily
install
with
the
STOP
cable
stopper
(4), and
to bracket
(1)
with
5
locknut (6). Ir The engine
stop motor is delivered
pulled (engine *
Stop lever (3) is at the operating it is free
(it is pulled
by a built-in 3.
*
5.
Turn
cable
locknut
(6) of bracket
to push the stop lever
STOP stopper (4)) so that the stop lever
The movement
Tighten
turn
securely
loose spring 4.
when
position 4
(in the direction
more against is pushed
position
out the operating
spring).
In this condition, (1) 2 turns
with the cable
stop).
against
the stopper.
for two turns
mechanism
is absorbed
by the
inside the motor.
all nuts and bolts.
the
engine
starting
switch
times to check that the engine operate
smoothly,
then
switches
are
ON/OFF
several
stop motor and cable
check the following
points
again. *
Limit
built
into
the
engine
stop
motor at both ends of the cable stroke. *
Check
that
there
is no clearance
lever (3) and stoppers engine
starting
switch
between
(4) and (5), both when is ON and when
l
Stroke of engine
l
Stroke of fuel injection
stop the
it is OFF.
stop motor: 35 mm pump stop lever: 30 mm
12-010 0
6162F642
ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE) 1. 2.
Remove retaining
cap (1).
Remove
(2),
nozzle
spring
seat
(3),
and
nozzle
spring (4). 3.
Adjust
the
injection
pressure
sure) by adjusting shim thickness * Injection pressure adjusted thickness: w 4.
After
Approx.
Retaining adjusting
fuel injection
cap:
the
(valve
cracking
pres-
(5). per 0.1
mm shim
15 kg/cm2 9 +_ 1 kgm
thickness
of shims,
check
the
pressure using nozzle tester.
6162F202
METHOD FOR INSTALLING SPEED SENSOR
(ADJUSTMENT)
OF ENGINE
Speed sensor mounting hole 0
Observe the instructions given below at the time of installing of the engine speed sensor (after it was dismounted).
1.
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.)
2.
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
3.
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.
I
SEE00059
SEE00060
12-011-l 03
DATA
FOR Engine
INJECTION model
PRESSURE Shim
ADJUSTMENT
a =
SAGDI
70-A-1
SAGDI
70-B-l
Part No.
Shim thickness (Range)
contour
S6D170-1
SHIMS Shim thickness (Interval)
4.5 mm 0.50
- 1.54
mm
0.02
mm
b=11.5mm
Thickness
(mm)
Part No.
Thickness
DKI
50523-5000
0.50
DKI 50523-7800
1.06
DKI
50523-5100
0.52
DK150523-7900
1.08
DKI
50523-5200
0.54
DKl50523-8000
1.10
DKI
50523-5300
0.56
DKI 50523-8100
1.12
DK150523-5400
0.58
DK150523-8200
1 .I4
DKI
50523-5500
0.60
DK150523-8300
1.16
DKI
50523-5600
0.62
DKI
1.18
DKI
50523-5700
0.64
DKl50523-8500
1.20
DKI
50523-5800
0.66
DKl50523-8600
1.22
DK150523-5900
0.68
DKI
50523-8700
1.24
DKI
0.70
DKI
50523-8800
1.26
DKl50523-6100
0.72
DKl50523-8900
1.28
DKI
50523-6200
0.74
DKl50523-9000
1.30
DKI
50523-6300
0.76
DK150523-9100
1.32
DKI
50523-6400
0.78
DKI
1.34
DK150523-6500
0.80
DK150523-9300
1.36
DKI
50523-6600
0.82
DKl50523-9400
1.38
DK’I 50523-6700
0.84
DKl50523-9500
1.40
DKI
0.86
DKI
50523-9600
1.42
DK150523-6900
0.88
DKI
50523-9700
1.44
DKI
0.90
DK150523-9800
1.46
DK150523-7100
0.92
DK150523-9900
1.48
DKI
50523-7200
0.94
DKI 50530-0000
1.50
DKI
50523-7300
0.96
DKI
1.52
DKI
50523-7400
0.98
DK150530-0200
DKI
50523-7500
1 .oo
50523-6000
50523-6800
50523-7000
DK150523-7600
1.02
DKl50523-7700
1 .04
50523-8400
50523-9200
50530-0100
1.54
(mm)
TESTING
CALIBRATION
AND ADJUSTING
CALIBRATION
I I SA6D170-A-1
I I
DATA
DATA
6162-73-1331
I
( EG550-1
1 12-022
6162-73-1332
I
1 EG550-1
I 12-022
6162-73-1333
EG550-1
12-022
6162-73-1334
EG550-1
12-022
6162-73-1341
EM680A
12-024-2
6162-73-1342
EM680A
12-024-2
6162-73-1343
I
1 EM680A
6162-73-1350
I
l
EG550-1
I 12-024-T (Extremecoldweather)
I 12-021
12-013 0
TESTING
AND ADJUSTING
Engine model
Pump
I I I
SAGD170-A-1
assembly
CALIBRATION
No.
Engine serialNo.
Applicable machine EG550-1
(Extreme cold weather)
12-022
6162-73-1352
EG550-1
(Extreme cold weather)
12-022
6162-73-1353
EG550-1
(Extreme cold weather)
12-022
6162-73-1354
EG550-1
(Extreme cold weather)
12-022
6162-73-1372
HD465-3
6162-73-1410
1 WA700-1
I 12-02T
HD465-3
1 12-023
HD465-3
1 12-023
6162-73-1481
I
l l
I I
12-024-3
6162-73-1482
HD465-3
12-023-I
6162-73-1510
HD465-5
12-023-2
6162-73-1531
OEMforBRO
12-024-4
I
6162-73-1550
I
1 HD465-5
1~12Z,
1
6162-73-1571
1 12-023-3
6162-73-1572
I 1
1 WA700-1
I
1 WA700-1
/ 12-023-3
I
6162-73-1612
EPSAGD170-A-1
12-0246
6162-73-1640
OEMfor
12-024-7
6162-73-1670
EM680A-1
12-024-8
6162-73-1682
EM680A-A
12-024-9
EG550-1,EG580B-1,EG580B-1-L
12-023-4
6162-73-1752
EG550-l,EG580B-1,
EG580B-1-L
12-023-4
6162-73-1753
EG550-l,EG580B-1,
EG580B-1-L
12-023-4
6162-73-2350
OEM
6162-73-2370
1 PCIOOOSP-1
I
by generator
(for Layton)
1 12-023-5
EPSAGD170-A-1
12-024
6162-73-2411
EPSAGD170-A-1
12-024
WA600-1
I I
(EC reguration)
12-016-I I
I
6162-74-1310
I DENYOgenerator DCAGOOSSK 1 12-030-11
6162-73-1151
D375A-1
12-025
6162-73-1250
EG450-1, EG480-1, EG500BS-1
12-026
6162-73-1251
EG450-l,EG480-l,EG500BS-1
12-027
6162-73-1252
EG450-l,EG480-1,
EG500BS-1
12-027
6162-73-1253
EG450-l,EG480-1,
EG500BS-1
12-027
1 EG450-1, EG480-1, EG500BS-1
12-027
10332-11045
6162-73-1254
I
for stand
6162-73-2410
6162-73-1583
SA6D170-B-1
marine
6162-73-1751
6162-73-1560 SA6D170-AE-1
6162-73-1430
6162-73-1431
6162-73-1432
12-013-l @
Page
6162-73-1351
6162-73-1480
DATA
EG450-1
I
(Extreme cold weather)
EG480-1 EG450-1
(Extreme cold weather) (Extremecoldweather)
EG500BS-1 EG450-1
(Extremecoldweather)
(Extreme cold weather)
EG500BS-1
(Extremecoldweather)
12-027
12-027
12-027
8 z &
TESTINGANDADJUSTING
CALIBRATION
DATA
Applicable machine
SA6D170-B-1
SAA6D170-1
-
6162-73-2121
HD500-3, HD465-3C
12-029
6162-73-2130
Pc1000-1
12-030
6162-73-2131
Pc1000-1
12-030
6162-73-2132
Pc1000-1
12-030
6162-73-2133
Pc1000-1
12-030
6162-73-2141
13551-15523
D375A-2
(Extreme cold weather)
12-028-I
6162-73-2142
15524and
D375A-2
(Extreme cold weather)
12-028-2
up
6162-73-2173
OEMforgenerator
12-030-8
6162-73-2174 6162-73-2175
OEMforgenerator (Prime use)
12-030-12
6162-73-2180 6162-73-2181
EG500-1,EG500B-1,EG500BS-1 OEMforgenerator
12-030-13
6162-73-2340 6162-73-2341
OEMforgenerator (Standby use)
12-030-14
6162-73-2380
OEM
for generator
12-030-8
6162-73-2381
OEMfor6-polegenerator
12-030-15
6162-73-2420
EPSAGD170-B-1
12-030-I
6162-73-2421
EPSAGD170-B-1
12-030-I
6162-74-1750
OEMforgenerator(50
Hz)
12-030-10
12-013-2 @
Engine Model
Injection Pump Type
Pump Manufacturer
S6D170-1
PEGZW
DIESEL KlKl
Machine Model
Pump Assembly 6162-73-l
E%b’
Injection
Number 170 (106692-4030)...2
Timing Basis
Unit
Allowance
I
Rotating direction
Counterclockwise from drive end
Injection order
l-5-3-6-2-4
Injection interval
60”
59”30’to60”30’
2.4
23.5 to 24.5
Plunger pre-stroke
mm
Delivery valve retraction volume
mm3
Calibration
viewed
Specification
I
90
for engine
with
fan (reference only)
Rated horsepower:
HP/rpm
41 O/l 800
Maximum
kgm/rpm
215/l
High idling:
rpm
1,700 to 1800
Low idling:
rpm
600 to 700
torque:
200
Standard
r Conditions
Unit
Manufacturer standard (with nearly the same actual machine parts)
Nozzle part no. Nozzle holder part no. In ectron pope (d/D x I/D x length)
mm
8~2.4~1400
Oil temperature
“C
43 to 47
Nozzle opening pressure
kg/cm2
255
Transfer pump pressure
kg/cm2
1.6
Service standard (with calibration test parts)
(105015-5210)
(
I
(105041-7020)
(
1
Test oil
ASTM D975 No. 2 diesel fuel or equivalent
ipecifications Injection volume (cc/l OOst) for manufacturer standard
Calibration basic point
’ Rack positions
l
B B to E are the reference volume when C adjusting the injection volume. D Marks * are average volumes. E
Injection volume(cc/ for service standard
Basis
Allowance
Maximum variance between cylinder
800
29.4
Each cyl. 28.9 to 29.9
21.18
335
5.1
*
20.51
Rack yrooion
Pump speed (rpm)
11.4 5.8
4.6
to
5.6
Basis
Each cyl. *
*
*
*
*
*
*
Ziovernor performance
L
Allowance
Pump speed (rpm) Numbers in parentheses
are pump manufacturer
part numbers.
st) Maximum variance between cylinder
Pump Assembly 6162-73-1171
Number
Applicable
(106692-4034)
Model
( ): Manufacture’s
Machine Serial
Applicable No.
Engine Serial
Model
No.
part No. PC650-1
S6D170-1
PC1500
S6D170-1
Injection
Timing
Rotating
direction
Injection
order
l-5-3-6-2-4
Maximum
Injection
interval
60” (59”30’ to 60”30’)
High idling
(rpm)
1,700 to 1,800
Plunger
pre-stroke
2.4 (23.5 to 24.5)
Low idling
(rpm)
600 to 700
Engine Specification Counterclockwise viewed from drive end
(mm)
Delivery valve retraction volume (mm’/st)
Calibration
90
Rated horsepower
(kw(HP)/rpm)
306(410)/1,800
torque (Nm(kgm)/rpm)
2108(215)/1,200
Pump tester capacity for Service standard
Motor:
7.5 KW
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
325 335
775+25
springset
BIJo:;:
Pump speed Wpm)
6162FZO3B
1Z-01 4-1 0
Pump Assembly Number 6162-73-1580 6162-73-I
I
(1066924352)
590 (I 066924410) part No.
( ): Manufacturer’s Injection Pump Type 1
Pump Manufacturer
1 DIESEL
PES-6PD
1
KIKI
I
1
Applicable Model
Applicable
Serial No.
WA600-1
10001 and up
WA600- 1 c
10001 and up
I
I
Machine
Injection Timing
Model
Serial No. 10490 and up
S6D170-1
II
II
II
I
Engine
I I
Engine specification Counterclockwise viewed from drive end
Rotating direction
HP/rpm
41512000
Maximum
kgm/rpm
200/l 400
torque
High idling
rpm
Low idling
rpm
2200 to 2300 650 to 700
I I
r
I
Pump tester capacity for Service standard
Delivery valve wtmctinn vnhlmo mm3/st
1
Rated horsepower
I
I Motor
7.5
KW
Calibration Standard Conditions
Service standard
- Service
standard indicates data using calibration test parts. * Manufacture standard is data for factory test.
Nozzle part no.
(I 05780-0050)
Nozzle holder part no.
(I 05780-2090)
Injection ipe (C/D x l/g x length)
Injection
mm
ASTM
D975
(I 05041-7020) 8~2.4~1400 No. 2 diesel fuel or equivalent 43 to 47
OC
Nozzle opening pressure kg/cm*
175
300
Transfer pump pressure
1.6
1.6
volume Rack point
standard
(105015-5210)
8 x 3 x 600
Test oil Oil temperature
Manufacturer
kg/cm*
Rack position
Pump speed
(mm)
(rpm)
Service standard
(cc/ 100 st)
Manufacturer
standard (cc/ 100 st
Maximum
Allowance
Basis
)$!$$E
Maximum
Basis
variance between
Allowance
cylinder Rack positions B to E are the reference volume when adjusting the injection volume. Marks l are average volumes.
Basic point B
Governor performance
0
%r?o
‘Ooo
28.05
350
3.93
27.55 *3.43
to 28.55 to
4.43
kO.393
Each cyl.
’ 4.7
*
*
*
D
*
*
E
*
*
II 3
11.4 A
cylinder 24 7
C
(350
I
Each cyl.
- 1000
rpm)
II
3 t.25 iJ.7 750;;;Jo
II P;:;,25 +10
Pump speed (rpm)
FORM
NO.
SEBH4567
12-015 0
I
Injection
Pump Assembly
Number
Applicable
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 Manufacture’s
Machine
Applicable
Serial No.
Model
part No.
Engine
Model
Serial No.
S6D170-1 S6D170
Injection
Pump Specification
Engine Specification
Plunger prestroke (mm)
2.35 - 2.45
Delivery valve retraction volume (mm’h)
90
Calibration
Low idling
1 1 : lnjenction
Service standard indicates data using calibration test pa ITS. Manufacture standard is data test parts.
curve (350 - 1,000 rpm)
/ 350
\ 700
/\1125+25
450'-25 (580) (g75)'201000~;~
Pump speed (rpm)
12-016 0
(rpm)
Pump tester capacity for Service standard
Standard
0
speed
i,
pump manufacture’s
650 - 700 Motor:
part number
7.5 kW
TESTING
AND
Injection
ADJUSTING
CALIBRATION
Pump Assembly
6162-73-1560 6162-73-1583
( ): Injection
Number
Pump
Manufacture’s Injection Pump Manufactuer
PES-PDX
ZEXEL
Pump Specification
Rotating
direction
Injection
order
Injection
interval
Plunger
prestroke
Applicable
Engine Specification
Counterclockwise drive end
viewed
from
Flywheel
(Without
horsepower
(kWiHPYrpm)
l-5-3-6-2-4
(mm)
Machine
Engine
part No.
Injection Pump Type
Injection
Applicable
(106692-9231) (I 06692-9002)
DATA
Maximum
torque (Nm{kgmI/rpmi
fan) 32112,000 {430/2,000} 2,010/1,400
{205/1,400)
59” 30’ - 60’ 30’
High idling
speed
Irpm)
2,200 - 2,300
2.35 - 2.45
Low idling
speed
(rpm)
700 - 750
Delivery valve retraction volume (mm”st)
Pump tester capacity for Service standard
90
Motor:
7.5 kW
test parts.
Injection
Rack positions B to E are the refernce volume when adjusting the
volume
injection
volume
Governor perfomance curve
‘;
12. 4 Il. 9
=
10.3
.-z z
1.3
:: a ;
6.8
=
6.0
0 350
1035f5 Pump speed (rpm)
TWE00606
12-016-l @
Injection
Pump Assembly
Number
6162-73-2150 (106682-4540) 6162-73-2151 (106682-4790) 6162-73-2160(106682-4670) ( ):Injection Pump Manufacture’s
Injection Pumo Tvoe
I
Model
direction
Injection
order
1 Injection
ZEXEL
1-5-3-6-2-4
(mm)
Delivery valve
1
I
Serial
No.
(rpm)
3.15 - 3.25
Low idling
speed
(rpm)
Pump tester capacity for Service standard
120
(
curve (325 - 900 rpm)
) : lnjenction
302/l ,800 (404/l ,800)
torque (NmIkgmYrpm) speed
test parts.
12-016-2 0
Maximum 1 High idling
Standard
perfomance
Flywheel horsepower (kW{HPYrpm)
59’ 30’ - 60’ 30’
Service standard indicates data using calibration test parts. Manufacture standard is data
Governor
Model
Enaine Soecification
drive end
I retraction volume (mm’istj I Calibration
No.
Engine
I
Counterclockwise viewed from
interval
1 Plunger prestroke
Serial
Applicable
part No.
Pump Specification
Rotating
Machine
Injection Pump Manufactuer
I Injection
Applicable
pump
manufacture’s
2,079/1,300 I
I212/1,3001
1,960 -2,040 600 - 660 Motor:
part number
7.5 kW
I
Pump Assembly Number 6162-73-2231
Applicable
(191000-3930)
Model
( ): Manufacturer’s part No.
Serial No.
Model
Engine Serial No.
S6D170-1
Engine specification
Rotating direction
Counterclockwise
1 Injection order
F%ZX,V!,V~
Applicable
WA600-1
Injection Timing
Plunger pre-stroke
Machine
I-5-3-6-2-4
I
Rated horsepower
viewed from drive end
HP/rpm
41512,000
I
I
3.2
mm
Pump tester capacity for Service standard
120
,mO mm3/st
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.
(093400-1800)
Nozzle holder part no.
(093100-0951)
Injection
ipe
(O/D x l/g x length)
ASTM
250 2.0
- Rack positions 6 to E are the reference volume when
40 to 45
Nozzle opening pressure kg/cm’
Rack point
Basic
adjusting the injection volume. - Marks * are aver-
age volumes.
Governor performance
point
B C
D975 No. 2 diesel fuel or equivalent
OC
Transfer pump pressure kg/cm* Injection volume
Rack position (mm)
Pump speed b-pm)
12.3
1000
13.4
700
L6.71
standard
6x2.2x650
mm
Test oil Oil temperature
Manufacturer
340
Service standard (cc/ 100 st)
Manufacturer
Maximum pig!‘, Basis cylinder
Basis
Allowance
23 o
.
Each cyl. 22.5 to 23.5
Max. 1.0
27.1
* 26.6 to 27.6
Max. 1 .O
*
*
Max. 1.0
*
5.0
4.8 to
5.2
standard (cc/
Allowance
Maximurr variance between cylinder
Each cyl.
D
*
*
E
*
*
( 340 - 1000 rpm)
300
1025+10 Pump speed (rpm)
st
SEBH4634
12-017 0
Injection
Pump Assembly
6162-73-2241 6162-73-2242 6162-73-2243
Number
Rotating
part No.
Serial No.
Standard
(
Conditions
Flywheel horsepower (kW{HPI/rom)
) : lnienction
oump manufacture’s
(093400-1800)
Nozzle
(093100-0951)
Manufacture standard is data
Injection pipe
holder
part No.
(Outside dia.x Inside dia.x Length lest
I454/2,000}
Dart number
Manufacturer standard
ASTM
Oil temperature Nozzle opening
pressure
pump pressure
Rack point
Rack positions B to E are the refernce volume A(Basic point) when adjusting the B injection volume. , Marks * are C average volumes. D
D975 No.2 diesel
1°C) 24.5 I2501
(kPaIkg/cm’))
Rack position
Pump speed
(mm)
(mm)
196 (2.01
Service standard (cc/l,000 st) Injection
volume
Max.imum g”,G$E cylinder
12.8
1,000
245 - 255
Max. 2.5
13.6
700
27.8 - 28.8
Max. 2.8
6.7
300
E
curve (300 - 1,000 rpm)
fuel or equivalent
40-45
(MPa{kg/cm’})
njection volume
perfomance
6 X 2.2 X 650
) (mm)
oil
Transfer
12-018 0
339/2,000
Nozzle & Nozzle holder part No.
test parts.
for factory test parts.
Serial No.
S6D170-1
Nozzle part No.
Governor
Model
Service standard
Service standard indicates data using calibration
Engine
Engine Specification
Counterclockwise viewed from drive end
direction
Applicable
WD600-1
Pump Specification
Calibration
Machine
Model
( ): Injection Pump Manufacture’s
Injection
Applicable
(191000-4260) (191000-4262) (191000-4263)
48-52
Max.
0.5
Manufacturer standard (cc/1,000 st) Injection
volume
Maximum ~~~~~~ cylinder
Injection
Pump Assembly
6162-73-2251 6162-73-2252
Number
part No.
WD600-1
direction
Injection
order
Injection
interval
Plunger prestroke (mm) Delivery valve retraction volume (mm’/stj
Calibration
Applicable
Engine
Model
Serial No.
S6D170-1
Engine Specification
Pump Specification
Rotating
Machine Serial No.
Model
( ): Injection Pump Manufacture’s
Injection
Applicable
(191000-4620) (191000-4222)
Counterclockwise viewed from drive end
339/2,000
2,089/1,400I213/1,400~
l-5-3-6-2-4
2,200 - 2,300
59’ 30’ - 60” 30’ 3.15 - 3.25
Low idling
(
Service standard indicates data using calibration test parts. Manufacture standard is data
Pump speed (rpm)
speed
(rpm)
Pump tester capacity for Service standard
120
Standard
I454/2,0001
) : lnjenction
pump manufacture’s
650 - 700 Motor:
part number
7.5 kW
1
1 I
Pump Assembly
Number
6162-73-2260
Applicable
Machine
Model
( ): Manufacturer’s
Injection
part No.
Counterclockwise
viewed from drive end
l-5-3-6-2-4
Injection order
Serial No.
S6D170-1
Rated horsepower
HP/rpm
4 15/2,000
Maximum
kgm/rpm
200/I
torque
High idling
rpm
Low idling
rpm
2,200
,400 to 2,300
mm
3.2
mm3/st
120
650 to 700
I Pump tester capacity for Service standard
Motor
7.5KW I
Standard
Conditions
*Service
standard indicates data using calibration test parts. * Manufacture standard is data for factory test.
Service standard Nozzle part no.
(093400-I
Nozzle holder part no.
(093100-0951)
Injection
ipe
(O/D x l/g x length)
ASTM
250 2.0
- Rack positions B to E are the reference volume when adjusting the injec-
Basic
tion volume.
are average volumes. l
Governor performance
D975 No. 2 diesel fuel or equivalent 40 to 45
Nozzle opening pressure kg/cm’
Rack point
Rack position (mm)
Pump speed (rpm)
Service standard
Basis
(CC/ 100 St)
Allowance
1000
23.0
Each cyl. 22.5 to 23.5
Max. 1.0
B
13.4
700
27.1
*26.6
Max. 1.0
C
Le.71
340
5.0
*
to 27.6
4.8 to 5.2
Manufacturer standard (cc/
Maximum rer!$$E Basis cylinder
12.3
point
Max. 1 .O
Allowance
* *
*
*
E
*
*
300
rpm)
1025210 Pump speed (rpm)
st
Maximum variance between cylinder
Each cyl.
D
( 340 - 1000
standard
800)
OC
Transfer pump pressure kg/cm’ Injection volume
Manufacturer
6 x 2.2 x 650
mm
Test oil
Oil temperature
- Marks
Model
60” f 30’
Injection interval
Calibration
Engine
Engine specification
Rotating direction
!%e+?%!~,m~
Serial No.
WA600-IC
Timing
Plunger pre-stroke
Applicable
(191000-4630)
SEBH4635X
Injection
Pump Assembly
6162-73-1192
Number
Applicable
(106692-4980)
*Serial
Model
( ): Injection Pump Manufacture’s
part No.
I
I
I
lniection
direction
Injection
order
1 Injection
1
Plunger prestroke (mm) Delivery valve retraction volume
Calibration
2.35
- 2.45
Standard
I 1High idling
speed
(rpm)
idling
speed
(rpm)
Low
Pump tester capacity for Service standard
(
) : lnjenction
pump manufacture’s
fan) 247/2,000
Maximum torque (NmIkgmYrpm)
90
(mm3M
(Without
horsepower (kWWWrpm)
59” 30’ - 60” 30’
Serial No.
S6D170-1
Flywheel
l-5-3-6-2-4
Engine
Model
Enoine Soecification
Counterclockwise viewed from drive end
interval
No.
D155 (BEML)
Puma, Soecification
Rotating
Applicable
Machine
1,442/1,400
I
{331/2,000}
{147/1,400~
2,150 -2,250
I
600 - 700 Motor:
7.5 kW
part number
(Conditions . 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
perfomance
18’:
0
curve
Rack
325
limit : IO.
O+~.'mm
750+20 (9;
Pump
speed
(rpm)
TWE00607
12-020-l 0
Injection Pump Assembly Number 6162-73-1163
Applicable
(106692-4970)
Model
( 1:Injection Pump Manufacture’s
part No.
direction
Injection
order
Injection
interval
Serial No.
Engine Serial
Model
No.
S6D170-1
Engine Specification (Without fan)
Counterclockwise drive end
viewed
from
l-5-3-6-2-4 59’ 30’ - 60” 30’
Plunger prestroke (mm) Delivery valve retraction volume
Applicable
D355 (BEML)
injection Pump Specification Rotating
Machine
2.35 - 2.45
(mm%)
Calibration Standard
I
\ . Inic,nrtinn
Service standard indicates data using calibration test parts. Manufacture standard is data test parts.
Governor perfomancecurve
Boost compensatorperformancecurve
mpensator
0
Boost 410f20 Pump speed
12-020-2 0
stroke
720f50 (rpm)
Pressure
(kPaImmHs1)
900::: TWE00606
Injection
Pump Assembly
Number
Applicable
6162-73-1212 (106692-4110) 6162-73-1214(106692-4113) 6162-73-1213 (106692-4111)6162-73-1215(106692-4990)
( ): Injection
Injection Rotating
Pump
Manufacture’s
Serial
Model
(Without
Flywheel horsepower (kW{HPl/rpm) Maximum
Standard
Engine No.
S6D170-1
Engine Specification
Counterclockwise viewed from drive end
‘~,‘~i Calibration
No.
OEM for generator
Pump Specification direction
Serial
Model
part No.
Applicable
Machine
1 ) : lnienction
fan) 329 I441~/1,500 (50 Hz) 380 I509M1,800 (60 Hz)
torque (NmIkgmMrpm)
DumD manufacture’s
Dart number
Conditions 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 E
Governor perfomance curve
18+;l,,,,,,l,,,Tk
limit :l4. 8:0"mm
le sub 'ring set: 3-t,smm
0
400 / Min. 500
75OtlO
\ Max. 945 900’b0
Pump speed (rpm)
TWE00610
12-020-3 0
Injection
Pump Assembly
6162-73-1721
Number
Applicable
(106692-4372)
Machine
Model ( 1: Injection
Pump Manufacture’s
part
No.
Applicable
Serial No.
I
Model
EPS6D170-1
Engine Serial No.
S6D170-1
ki
Injection
Pump Specification
Rotating
direction
Injection
order
Injection
interval
Engine Specification
l-5-3-6-2-4 59” 30’ - 60” 30’ 2.35 - 2.45
Delivery valve retraction volume (mm”sr)
Low idling
90
for Service
(
I
Conditions Service standard indicates data using calibration test parts. Manufacture standard is data
Injection pipe (Outside dia.x Inside dia.x Length ) (mm)
for factory
Test oil
(rpm)
) : lnienction
standard
oumo manufacture’s
Service standard
600 - 1,000 Motor:
7.5 kW
Dart number
Manufacturer standard
Nozzle & Nozzle holder part No.
(105780-8130)
6162-13-3300
(105111-4020)
Nozzle part No.
(105780-0050)
6162-13-3320
(105015-5210)
Nozzle holder part No.
(105780-2090)
6162-13-3110
(105041-7020)
8X4X600
(‘0
I
B to E are the refernce volume when adjusting the injection volume.
Marks * are
Governor perfomance curve Rack
8X2.4X1.400
ASTM D975 No.2 diesel fuel or equivalent
Oil temperature
Rack positions
I imi t :
(R,t
14.
9) ‘t’mm
18’:
400750 I (8401 240
900%
\ 990+25
Pump speed (r pm)
12-020-4 0
speed
Pump tester capacity
Standard
test parts.
fan)
drive end
Plunger prestroke (mm)
Calibration
(Without
viewed from
Counterclockwise
TWE00611
40 - 50
Injection
Pump Assembly
Number
Applicable
6162-73-1733(106692-9020)
Machine
Model ( ): lniection
Pumo Manufacture’s
Injection Pump Type
1
1
Rotating
ZEXEL
Injection
order
Injection
interval
Enqine Specification Flywheel
drive end
1-5-3-6-2-4
(Without
horsepower MWHPHrpm)
fan) 351 {47OYl,500 386 {517Y1,800
(50 Hz) (60 Hz)
Maximum torque (Nm{kgmI/rpm)
59” 30’ - 60’ 30’
Plunger prestroke (mm)
3.15 - 3.25 I
1
Delivery valve
Pump tester capacity for Service standard
retraction volume (mm’/st)
Calibration
Serial No.
Model
I
Counterclockwise viewed from
I
Engine
S6D170-1
I
Pump. Specification _ direction
Serial No.
OEM for generator
Injection Pump Manufactuer
PE-P DX
Injection
Dart No.
Applicable
Standard
(
1: lnjenction
pump manufacture’s
Motor:
7.5 kW
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’:
sDrin9
hii n. 7. 3
set:
E E .-S .-_ z _
5.8 5. 3
I 400
Min.
/ 750flO 900’: 500 Pump speed (r pm)
TWE00612
12-020-5 0
Injection Pump Assembly Number 6162-73-2222
(191000-3922)
Applicable
I
Machine
Model
( ): Injection Pump Manufacture’s
direction
Injection
order
Serial No.
l-5-3-6-2-4
Flywheel
horsepower
Maximum torque (Nm{knmI/rom)
(
1 : lnjenction
pump manufacture’s
Governor perfomancecurve
16 14 12
8 6
E :: 2
4
( R., Pul I ino start
Point)
2
0
2
4
6 Pump speed
12-020-6 0
a (rpm)
302/1,800
WG-Wrpm)
Rack positions
z .-
No.
Enoine Soecification (Without fan)
Counterclockwise viewed from drive end
test parts.
;
Serial
S6D170-1
Service standard indicates data using calibration test parts. Manufacture standard is data
10
Model
D275A-2
Calibration Standard
<
Engine
part No.
Injection Pump _ Specification _ Rotating
Applicable
IO
12 TWE00613
1,981/1.300
part number
{404/1,800} I202/1.300}
Machine Model
Engine Model
Injection Pump Type
Pump Manufacturer
EG550- 1
SAGD170-A-l
PEGZW
DIESEL KIKI
Unit
Allowance
Injection
Pump Assembly 6162-73-l 6162-73-I
Number 330 350
(I 03662-2140). (103662-2770).
4 1
Timing Basis
Rotating direction
Counterclockwise from drive end
injection order
l-5-3-6-2-4
injection interval
60”
59”30’
3.8
3.75 to 3.85
Plunger pre-stroke
mm
Delivery valve retraction volume
mm3
viewed
Specification
for engine with fan
to 60”30’ ~1
I
120 Low idling:
Calibration
(reference only)
rpm
Approx. 800
Standard
ionditions
Unit
Manufacturer standard (with nearly the same actual machine parts)
Service standard (with calibration test parts)
Nozzle part no.
(105015-5140)
(
1
Nozzle holder part no.
(I 05041-7020)
(
)
In ectron rpe (d/D x l/8x length)
mm
8x2.4x
1400
Test oil
ASTM
Oil temperature
“C
43 to 47
Nozzle opening pressure
kg/cm2
300
Transfer pump pressure
kg/cm2
1.6
D975
No. 2 diesel fuel or equivalent
ipecifications Injection volume for manufacturer
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
Rack osition Pmm)
Pump speed (mm)
18.4 7.8
(cc/l OOst) standard Maximum variance between cylinder
Basis
Allowance
875
52.0
Each cyl. 51.5 to 52.5
t2.08
400
6.8
*
20.95
6.3
Injectionvolume(cc/ for service standard
to
7.3
Basis
Allowance Each cyl. *
*
*
*
*
*
*
performance
Pump speed (rpm) GNumbers in parentheses
are pump manufacturer
part numbers
St) Maximum variance between cylinder
Machine Model EG550-1
Injection
Engine Model
Injection Pump Type
Pump Manufacturer
SAGDI
PEGZW
DIESEL KlKl
70-A-1
Pump Assembly
Timing Unit
Counterclockwise from drive end
.... 1
. .. 1
(103662-2302) (103662-3210) (103662-3212)
viewed
Specification
for engine with fan
Low idling:
Calibration
(103662-2290) (103662-2292) (103662-3050) (103662-3051) (103662-2300)
Allowance
Basis
Rotating direction
Number
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
rpm
(reference only)
700 to 900
Standard
Conditions
Unit
Manufacturer standard (with nearly the same actual machine parts)
Nozzle part no. Nozzle holder part no. In ectron rpe Cd/D x t/$x length)
mm
Service standard (with calibration test parts)
(105015-5140)
(
1
(105041-7020)
(
1
8~2.4~1400 ASTM
Test oil Oil temperature
“C
43 to 47
Nozzle opening pressure
kg/cm*
300
Transfer pump pressure
kg/cm2
1.6
D975
No. 2 diesel fuel or equivalent
Specifications Injection volume for manufacturer
Calibration basic point l
l
Rack positions 6 to E are the reference volume when adjusting the injection volume. Marks * are average volumes.
Sovernor
B
Rack osition Pmm)
Pump rgrnd
18.4 7.8
Maximum variance between cylinder
Basis
Allowance
875
52.0
Each cyl. 51.5 to 52.5
k2.08
400
6.8
*
kO.95
6.3
Injection volume(cc/l for service standard
(cc/l OOst) standard
to
7.3
Basis
Each cyl. * *
*
C D
*
*
E
*
*
performance
M,n26
Pump speed (rpm) Numbers in parentheses
12-022 0
Allowance
are pump manufacturer
part numbers
OOst) Maximum variance between cylinder
Pump Assembly Number
Applicable
6162-73-1480 (103662-2870) 6162-73-1481 (103662-2871) ( ): Manufacturer’s part No.
I
Injection Pump Type
Model
PE-6ZWX
Serial No.
Engine
Model
Serial No.
SAGD170-1
I
KIKI
Injection Timing
w/Single turbo
10794 and up
w/Twin
10851 and LID
turbo
Engine specification
Rotating direction
Counterclockwise viewed from drive end
Injection order
l-5-3-6-2-4
Injection
Applicable
HD465-3
Pump Manufacturer DIESEL
Machine
60” + 30’
Plunger prestroke
3.8 + 0.05
mm
HP/rpm
I
288/l
I
1
1 High idling
rpm
I
2,250 to 2,3501
1 Low idling
rpm
I
850 to 900
torque
I
I
Pump tester capacity for Service standard
120
730/2,100
kgm/rpm
1 Maximum
interval
Delivery valve retraction volume mm3/st
Rated horsepower
Motor
7.5
,400
KW
Calibration Standard Conditions
- Service
standard indicates data using calibration test parts. * Manufacture standard is data for factory test.
Service standard (105780-0050)
6162-13-3420
(105015-6140)
Nozzle holder part no.
(105780-2090)
6162-13-3110
(105041-7020)
Injection
ipe
(O/D x l/g x length)
8x4x
mm
8~2.4~1400
1500
ASTM
Test oil
D975 No. 2 diesel fuel or equivalent 43 to 47
OC
Nozzle opening pressure kg/cm’
175
300
Transfer pump pressure kg/cm’
1.6
1.6
volume Rack point
- Rack positions B to E are the refer-
standard
Nozzle part no.
Oil temperature
Injection
Manufacturer
Basic
ence volume when adjusting the injection volume. - Marks * are average volumes.
Pump speed
(mm)
h-pm)
point B
Governor performance
Rack position
15.3 Approx. 7.3
1050 425
Service standard
Manufacturer
yJE’$, cylinder
Allowance
Maximum
Basis
48 3 Each cyl. . 47.8 to 48
51.932
40.0
5.17
kO.723
4.5
*
4.67 to 5.67
Allowance
*
*
*
D
*
*
E
*
* Boost compensator
0
speed
performance
At boost pressure x
Line 0, :
At boost
Point
0:
Adjust low
Point
0:
Idling
pressure idling
sub spring
:Y
variance between cylinder
Each cyl.
C
( 425 - 1050 rpm)
standard (cc/ 100 st
Maximum
Basis
Line 0:
Pump
(cc/ 100 St)
(650 rpm)
or llMre Or 1eSS
at no boost
pressure
set point
(rpm)
SEBH 4502-l
’ 2-:23
I I
Pump Assembly 6162-73-1462
Number
Applicable
(103662-3023)
Machine
Model (
1: Manufacturer’s Injection Pump Type
Serial No.
SA6D170-A-1
DIESEL KIKI
Engine specification
pre-stroke
Calibration
‘:;$;;io?p
(Single turbo) 11683 and up
Rated horsepower
Plunger
Serial No.
Model
HD465-3
Timing
Delivery valve retraction volume
mm
3.8 f
/
730/2100
0.05 Pump tester capacity for Service standard
120
mm3/st
HP/rpm
Motor
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
Min.26 Or more
1050
lever 17.
rpm)
Boost compensator
performance
rpm)
5+1'6mm
Z E g .-
15.3 I Min. 8. 8 Z Or more a
15.9 z L C .o '5 g +z 11.5 2
1. 3
0
6.2
70+10
Boost pressure I. lM.1 0 720flD
1050:::
Pump speed (rpm) TKE00124
12-023-l 0
(650
Rack limit 16. 5*:.'mm Boost comoensator stroke 4. 4fo.lmm
z
Engine
Pump Manufacturer
PE-6zWX
Injection
part No.
Applicable
I
(340)
(mmHg)
7.5
KW
Pump Assembly Number 6162-73-1510
Applicable
Applicable
Machine
Engine
(103662-3182) Serial
Model
(
1: Manufacturer’s part No. I Pumo I lniection
direction
Injection
order
Injection
interval
Plunger
pre-stroke
Serial No.
Engine specification Counterclockwise from drive end
viewed
l-5-3-6-2-4 60” * 30’ mm
3.8 + 0.05
I
Delivery valve retraction volume
Model SA6D170-A-1
HD465-5
IInjection Timing Rotating
No.
Pump tester capacity for Service standard
120
mm3’st
Motor
7.5
KW
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
Rack
1050 rpm)
lever
Boost compensator performance (750 rpm)
18. 5’8 ‘mm
I imi t 17. 9’8 Boost
‘mm
compensator 4.
stroke 4*O-lmm
17.4
13.0
;i (70) Boost pressure
Pump
(34OIf20
(mmHg)
speed (rpm) TKEO0125
SEBH4881
12-023-2 0
Injection Pump Assembly Number
Applicable
6162-73-1410 (103662-3260) 6162-73-1571 (103662-3101) 6162-73-1572 (103662-3102)
Model
( ): Injection Pump Manufacture’s
part No.
direction
Injection
order
Injection
interval
Serial No.
Engine Serial
Model
No.
SA6D170-A-1
Engine Specification
Counterclockwise drive end
viewed
from
Flywheel horsepower MW-Wrpm)
59’ 30’ - 60” 30’
High idling
3.75 - 3.85
Low idling
Delivery valve retraction volume (mm’/st)
478/2,000
{641/2,000}
Maximum torque (NmIkgmYrpm) 2,810/1,400
l-5-3-6-2-4
Plunger prestroke (mm)
Applicable
WA700-1
Injection Pump Specification Rotating
Machine
speed speed
@pm)
2240 - 2300
(rpm)
700 - 750
Pump tester capacity for Service standard
120
{286.5/1,400}
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.
Governor
perfomancecurve
Boost compensatorperformancecuve
0
12. 01901
41.3(3101
Boost pressure (kPa{mmHaI
450+20
950+30
Pump speed (rpm)
12-023-3 0
)
1135+25 TWE00614
Pump Assembly Number 6162-73-1751
I
(103662-2911)
Applicable
Machine
Model
:;$;:;$I;;;; [;;$:gf::8:81 ( ): Manufacturer’s part No.
Serial No.
EG550-1
Injection order
l-5-3-6-2-4
interval
Plunger pre-stroke
SAGD170-1
11500 and up 14173 and up
I
Engine specification Counterclockwise viewed from drive end
Rotating direction
Injection
Serial No.
I
1
Engine
Model
SA6D170-A-1
EG580B-1 L
Injection Timing
Applicable
I
50 Hz) 60 Hz)
kgm/rpm
633/l ,500 731/1,800 -
High idling
rpm
Max. 1,560 Max. 1,872
50 Hz 60 Hz
Low idling
rpm
Rated horsepower
HP/rpm
Maximum
torque
60’ +_30 mm
3.8 + 0’.05
Delivery valve retraction volume mm3/st
700 to 900
Pump tester capacity for Service standard
120
Motor
7.5
KW
Calibration Standard Conditions
Service standard
Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.
Manufacturer
standard
Nozzle part no.
(105780-0050)
6162-13-3420
(105015-6140)
Nozzle holder part no.
(105780-2090)
6162-13-3100
(105041-7020)
Injection ipe (O/D x I/! x length)
mm
8x4x ASTM
Test oil
Oil temperature
8 x 2.4 x 1,400
1,500
D975 No. 2 diesel fuel or equivalent 43 to47
“C
Nozzle opening pressure kg/cm*
175
300
Transfer pump pressure
1 .6
1.6
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
I
(400 - 900
I*
rpm)
26 or ITOE
Rack limit18.9’oo*mm
0
400 500 750t10 or more Pump speed (rpm)
goo:o
SEBH4806
12-023-4 0
TESTING
AND ADJUSTING
Injection
Pump Assembly
6162-73-2370
CALIBRATION Number
Applicable
(106682-9290)
Machine Serial
Model
( ): Injection
Pump
Injection
Manufacture’s
part No.
direction
Injection
order
Injection
interval
No.
Engine Serial
Model
No.
SA6D170-A-1
Pc1ooosP-1 (for LAYTON)
Pump Specification
Rotating
Applicable
DATA
Engine Specification
Counterclockwise drive end
viewed from
l-5-3-6-2-4
Plunger prestroke
59’30’ (mm)
- 60”30’
3.15 - 3.25
Delivery valve retraction volume (mm’/st)
Calibration
Standard
tConditions . Service standard indicates data using calibration test parts. Manufacture standard is data for factory test parts.
(
) : lnjenction Service
pump
manufacture’s
standard
part number Manufacturer
standard
Nozzle & Nozzle holder part No.
(105780-8130)
6162-13-3702
(105111-4142)
Nozzle part No.
(105780-0050)
6162-13-3720
(105015-6700)
(105780-2090)
6162-13-3712
(105041-7101)
part No.
Nozzle holder
Injection pipe (Outside diaxlnside dia.x Length)
ASTM
Injection
Rack positions
8X2.4X1,450
8X4X1,000
(mm)
Test oil
D975 No.2 diesel fuel or eauivalent
volume
B to E are the refernce volume when adjusting the injection volume. ‘Marks are average volumes.
Governor
perfomance
curve
Boost compensator
Rack
limit
Idline
:la. sub
Governor
I
I
/
/ TBoost
performance
cuve
2 (mm)
O-la. sprins
set
sprins
set
compensator
stroke
:3.
l-3.
3 (mm)
17. 5 16. 7 10.
I (mm
t .I
0
0
300 335
720 / 785-835
Pump speed
\915-965 895-905
Boost
6. 6-12. (50-901 pressure
0
39. 3-48.7 ~280-3801 LkPaImmHaI)
(ram) TWE00728
12-023-5 @
Pump Assembly
Number
6162-73-2410 6162-73-2411
(
): Manufacturer’s
Injection
Timing
Rotating
direction
Injection
order
Injection
interval
Plunger
pre-stroke
Delivery valve retraction volume
Calibration
Applicable
(106682-4652) (106682-4850)
Model
part No.
Counterclockwise viewed from drive end l-5-3-6-2-4
3.2 f 0.05
mm mms/st
Model
1
Serial
No.
SAGD170-1
Enaine
SDecification
1 Rated horsepower Maximum
torque
HP/rpm
)
kgm/rpm
High idling
rpm
1 Low idling
rpm
Pump tester capacity for Service standard
120
Standard
positions B to E are the reference volume when adjusting the injection volume. 1Marks * are average volumes.
Governor performance
ernor s~lina Idling
set sub splins
set
16.9
p: _ 6. 5 6. 3
30 0:::
385 Pump sDeed (rpm)
TKE00128
12-024 0
No.
Engine
590/
1800
270/l
300
1950
I
to 2050
60° -I- 30’
1Rack
3
Serial
Applicable
EPSAGDl70-A-1
) Service standard indicates data using calibration test parts. 1Manufacture standard is data for factory test.
= E z z .-
Machine
I
750 to 850
Motor 7.5 KW
I
Injection
Pump Assembly
6162-73-1320
Number
Applicable
(103664-1321)
Serial No.
Model
( ): Injection Pump Manufacture’s
part No.
Applicable
Machine
Engine Serial
Model
No.
SA6D170-A-1
EG600BS-1
for generator OEM
Injection
Engine Specification
Pump_ Specification .
Rotating
direction
Injection
order
Counterclockwise
viewed from
drive end l-5-3-6-2-4 I
interval
1 Plunger prestroke (mm)
High idling
3.75 - 3.85
I
speed
(rpm)
1 1Low idling speed
(rpm)
I
Delivery valve retraction volume (mm’/st)
Calibration
(
Max. 1,560 (50 Hz) Max. 1,872 (60 Hz)
I
700 - 900
) : lnjenction
pump manufacture’s
I
I
I
I
Pump tester capacity for Service standard
Standard
1
I
59’ 30’ - 60’ 30’
1
fan) 477 {639H1,500 (50 Hz) 531 ~712)/1,800 (60 Hz)
Maximum torque (NmIkgmYrpm)
I
Injection
(Without
Flywheel horsepower (kW{HP}/rpm)
Motor:
7.5 kW
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
E
12-024- 1 0
Injection
Pump Assembly
6162-73-1341 6162-73-1342 6162-73-1343 ( ):lniection
I
zdA
/
Serial
Applicable No.
I
I
Pump Specification
Rotating
direction
Injection
order
Injection
interval
/ ,A~~~‘,_,
1
I
I
Engine Specification
(Without
59” 30’ - 60’ 30’ 3.75 - 3.85
Low idling
speed
(
) : lnjenction
Conditions
Service
Motor:
pump manufacture’s standard
test parts.
Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes. I
P W
0
I
curve Rack
I imi t : 20’:“mm
V
300
1000:::\ Pump speed (rpm)
1080f25 TWE00618
I
7.5 kW
part number Manufacturer
Service standard indicates data using calibration test parts. Manufacture standard is data
perfomance
600 - 650
@pm)
Pump tester capacity for Service standard
120
Standard
Min. 26
fan)
1-5-3-6-2-4
Delivery valve retraction volume fmmVst)
-I2-024-2 0
Serial No.
Counterclockwise viewed from drive end
Plunger prestroke (mm)
Governor
Engine
part No.
ZEXEL
I
Calibration
Machine
Injection Pump Manufactuer
PE-ZWx
Injection
Applicable
1
Pump Manufacture’s
Injection Pump Type
I
Number
(103662-2821) (103662-2822) (103662-3070)
standard
Injection
Pump Assembly
6162-73-1372
Number
Applicable
(103662-3080)
Model
( 1:Injection Pump Manufacture’s
Machine
Applicable
Serial No.
Model
Pump Specification
Rotating
direction
Injection
order
Injection
interval
Serial No.
part No. HD465-3 (with single turbocharger)
Injection
Engine
SA6D170-A-1
Engine Specification
(Without
fan)
Counterclockwise viewed from drive end l-5-3-6-2-4 59” 30’ - 60’ 30’
Plunger prestroke (mm)
3.75 - 3.85
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.
7mm i.smm
E E E
15. 9
Min.8.8 15. 3
E E
.2 a : Ix
.-z
.z c 13.9
7. 3 6. 2
: CL 0 I. lf0. 3 0
I I
I
425
L 720+30 aoof30
Pump speed (rpm)
48. olt6.7 (360f50)
21. 3f2. 7 (160&20) Boost Pressure
(kPs
{mmHg] )
1050:::\ 1150+25 TWE00619
12-024-3 0
Injection
Pump Assembly
6162-73-1531
Number
Applicable
(103662-3130)
I
( ): Injection
Pump
PE-ZWx
njection
part No.
ZEXEL
I
1
No.
Model
I Serial
No.
SA6D170-A-1
OEM for BRO
I
Engine Specification
Pump Specification
Rotating
direction
Injection
order
Injection
interval
Plunger prestroke
Counterclockwise viewed from drive end
Flywheel
(mm)
(Without
horsepower
Maximum
torque (Nm{kgmMrpm)
fan) 552/2,000
(kWIHPI/rpm)
l-5-3-6-2-4
Delivery valve retraction volume (mm”st)
Calibration
Serial
Engine
I 1
Injection Pump Manufactuer
Injection Pump Type
I
Manufacture’s
Model
Applicable
Machine
I 1
I
3,030/1,400
{740/2,000) {309/1,400~
59” 30’ - 60” 30’
High idling
speed
&pm)
2,150 - 2,250
3.75 - 3.85
Low idling
speed
(rpm)
750 - 850
Pump tester capacity for Service standard
120
I
Standard
Motor:
1 : lninnctinn ntlmn manllfxtttre’s
7.5 kW
nart number
Service standard indicates data using calibration test parts. Manufacture standard is data test parts.
Governor
perfomance
Boost compensator
curve Rack limit:
(17.
performance
curve
2)':"mm Boost compensator stroke:
;; (16. 7) E
0
0
400 720f20
IOOO::! (815) llOOYc25
Pump speed (rpm)
12-024-4 0
21.3k2.7 ~160~201
48. 0f6. 7 1360*503
Boost Pressure (kPa{mmHe))
TWE00621
Injection
Pump Assembly
6162-73-1550 ( 1: Injection
I I
Pump
Injection Pump Tvpe
I
Manufacture’s
Applicable
Injection
order
Injection
interval
Plunger
prestroke
Engine Specification
Counterclockwise driveend
viewed from
(Without
Flywheel horsepower
fan) 386/2,100
(kWU-R/rpm)
{518/2,100~
l-5-3-6-2-4 59” 30’ - 60” 30’ 3.75 - 3.85
(mm) I
I
Delivery valve retraction volume (mm’/st)
Calibration
Engine
I
Pump Specification direction
Applicable
I
I
ZEXEL
Rotating
Machine
part No.
Injection Pump Manufactuer
PE-ZWx
Injection
Number
(103662-3090)
I
Pump tester capacity for Service standard
120
Standard
I
(
) : lnjenction
pump
I
Motor:
manufacture’s
7.5 kW
part number
Service standard indicates data using calibration test parts. Manufacture standard is data test parts.
Governor
perfomance
curve
Boost compensator
performance
curve
Rack limit :17't'mm Boost compensator stroke ~2. OfO. Adapter spring is not actuated
Min.26
lmm
16. 5 -z E z z -G 4
14.5
: Dz 0
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
6162-73-1612
Number
Applicable
(103662-3110)
Machine
Model
( 1: Injection Pump Manufacture’s
Injection
part No.
direction
Injection
order
1 Injection
from
l-5-3-6-2-4
(Without
horsepower N’WWrpm)
Low idling
speed
(rpm)
speed
(rpm)
Pump tester capacity for Service standard
120
Standard
Flywheel
II High idling
3.75 - 3.85
Delivery valve retraction volume (mm3’st)
1 1: lnjenction
Serial No.
SA6D170-A-1
pump manufacture’s
fan) 534/2,000 {715/2,000)
Maximum torque INmIkgmYrpm)
59” 30’ - 60’ 30’
Plunger prestroke (mm)
Calibration
viewed
Engine
Model
Engine Specification
Counterclockwise drive end
interval
No.
EPSAGD170-A-1
Pump Specification
Rotating
Serial
Applicable
2,922/1,400
{298/1,4001
FM600 - 1,000 Motor:
7.5 kW
part number
lConditions - Service standard indicates data using calibration test pans. pManufacture standard is data for factory test parts.
An-d*
I
* 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
1I 2-024-6
0
-
Injection
Pump Assembly
6162-73-1640
Number
Applicable
(103662-3170)
Machine Serial No.
Model
( 1:Injection Pump Manufacture’s
Injection
part No.
OEM for marine
Pump Specification
Rotating
Flywheel
drive end
Engine Serial
Model
No.
SA6D170-A-1
Engine Specification
Counterclockwise viewed from
direction
Applicable
(Without
horsepower (kW{HPYrpm)
fan) 552/2,000
{740/2,000}
Maximum torque (Nm{kgm}/rpm)
~~~
Calibration
Standard
f
1 : lnienction
oumo
manufacture’s
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
15.7 - 15.9
100
Rack limit: 15.
7*f'mm
330
-
D E
Governor
petfomance curve
Min. 26 h, //I//.,// C
A
(15. 2) -z 10.7 E 7.7 z ..p (5.6) : PI
0
1000:::
300 Pump speed (rpm)
1075f.25 TWE00626
12-024-7 0
Injection
Pump Assembly
6162-73-1670
Number
Applicable
(103662-3230)
Machine Serial No.
Model
( ): Injection Pump Manufacture’s
Injection
part No.
direction
Injection
order
Injection
interval
Engine Specification
l-5-3-6-2-4
Plunger prestroke (mm)
59” 30’ - 60” 30’
High idling
speed
(rpm)
3.75 - 3.85
Low idling
speed
(rpm)
(
1 : lnjenction
2,100 - 2,200 550 - 600
I
part No.
7.5 kW
Motor:
pump manufacture’s
Service standard
I Nozzle & Nozzle holder
55212,000 {740/2,000}
Pump tester capacity for Service standard
120
Standard
tConditions .* Service standard
fan)
Maximum toraue (Nm{kamYrom)
I
Calibration
(Without
Flywheel horsepower (kWW/rpm)
drive end
Delivery valve retraction volume (mmyst)
Serial No.
SA6D170-A-1
viewed from
Counterclockwise
Engine
Model
EM680A-1
Pump Specification
Rotating
Applicable
I
I
part number
Manufacturer standard
(105780-8130)
6162-13-3901
(105111-4350)
Nozzle part No.
(105780-0050)
6162-13-3921
(105015-8330)
Nozzle holder part No.
(I 05780-2090)
6162-13-3710
(105041-7060)
standard is data
Injection pipe (Outside dia.x Inside dia.x Length ) (mm)
8X4X1,500
for factory test parts.
Test oil
indicates data using calibration test parts.
*Manufacture
njection
Oil temperature
40-45
(“C) 17.2 1175)
Transfer pump pressure (kPa{kg/cm’})
157 Il.61
Rack point
Rack position
Pumo speed
Service standard
(mm)
(rpm)
Injection
29.4 {300} 157 11.6)
(cc/l,000
st)
Manufacturer
standard (cc/l,000
Maximum
volume
~~~~~~
A(Basic point)
(15.2)
B
Approx. 7.7
300
C
(15.7)
100
t are
average volumes.
1,000
Injection volume
~~J~~~ cylinder
395 - 405
Max. 32
Max. 12.6 -
40-50 (300)
D
Governor perfomance curve
Boost compensator performance curve Rack limit
:
(15. 7)‘:‘*
mm
/
Boost
Min. 26
compensator stroke
:4fO.
1mm
/
C 115. 2) E E E
:
0 2
(5. 6)
I
5 -------i
0
._
24. 0:::: { 18 0:::1
Boost pressure
Pump speed
12-024-8 0
(rpm)
st)
Maximum
cylinder
when adjusting the injection volume. Marks
D975 No.2 diesel fuel or equivalent
Nozzle opening pressure (MPaIkg/cm’})
volume
Rack positions B to E are the refernce volume
8X2.4X1,400
ASTM
48. Of6. 7 (360*50) (kPa(mmHej)
107&25 TWE00627
Injection
Pump Assembly
6162-73-1682
Number
Applicable
(103682-0470)
Serial No.
Model ( ): Injection
Pump Manufacture’s
part No.
Counterclockwise viewed from
1
3.75 - 3.85
Delivery valve retraction volume (mm”st)
Standard
(Without
(
fan) 629/2,000
Maximum torque (NmIkgmllrpm)
3.295/1,400
speed
(rpm)
I Low idling speed
@pm)
Pump tester capacity for Service standard
120
Serial No.
Model
Flywheel horsepower (kW{HPMrpm)
High idling 1 Plunger prestroke (mm)
Engine
SA6D170-A-1
EM680A-A
Enaine SDecification
~1 Calibration
Applicable
Machine
) : lnjenction
pump manufacture’s
{842/2,0001 I336/1,400}
2,100 - 2,200 550 - 600 I
Motor:
7.5 kW
part number
Service standard indicates data using calibration test parts. Manufacture standard is data test parts.
Injection volume
Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are average volumes.
Injection volume
D E
Governor
perfomance
curve
Min. 26 ;h_
/
Rack Iimit:17’~‘mm
/////.‘///
;16.
/I
5
211.1.-z ; a
&’
$
6.5
0
1000:::\
300 Pump speed (r pm)
‘075f25
TWE00629
12-024-9 0
I
Pump Assembly Number 6162-73-1151 (106692-4233) 6162-73-1520 (106692-4460) ( ): Manufacturer’s part No.
Applicable
Machine
Model
Applicable Model
Serial No. 15001andup
D375A-1
Engine
I
Serial No.
SAGDl70-B-1
10332 -
11045
Engine specification
Injection Timing
Plunger pre-stroke
2.4 & 0.05
mm
Delivery valve retraction volume mm3/st
Pump tester capacity for Service standard
90
7.5 KW
Motor
Calibration Standard Conditions
t Service
Service standard
standard
indicates data using calibration
test parts.
’ Manufacture
(105780-0050)
6162-13-3520
(105015-6160)
Nozzle holder part no. injection ipe
(105780-2090)
6162-13-3100
(105041-7020)
8 x 2.4 x 1400
mm
ASTM
Test oil Oil temperature
8x2.4x
43 to 47
Nozzle opening pressure kg/cm2
265
Transfer pump pressure
1.6
1.6
Rack point
bRack positions Basic
Governor performance
point B
(
1400
D975 No. 2 diesel fuel or equivalent
“C 175
Injection volume
B to E are the reference volume when adjusting the injection volume. - Marks l are average volumes.
standard
Nozzle part no.
(O/D x l/g x length)
standard is data for factory test.
Manufacturer
kg/cm2
Service standard
Rack position (mm)
Pump speed (rpm)
Basis
14.0
900
38.44 Each cyl.
Ap rox %.8
325
Manufacturer
kc/ 100 st)
standard (cc/ 100 st Maximum
Maximum
3.42
Allowance
Ter$EK cylinder
Basis
Allowance
,34 o5 Each cyl.
37.94
to 38.94
-
’
* 2.92
to 3.95
kO.342
3.5
*
C
*
*
D
*
*
E
*
* Boost compensator
325 - 900 rpm)
variance between cylinder
performance
(400 rpm)
15.3 -? E : ‘Z ._ 8 P Y P n
12.6
0
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
Applicable
250 (106692-4050)
( ): Manufacturer’s
Model
part No.
Applicable Model
Serial No.
Engine Serial No.
SAGDI 70-B-1
EG450-1 EG480-1
[I
Injection Timing
Engine specification Counterclockwise view from drive end
Rotating direction
interval
Plunger pre-stroke
~1
’
l-5-3-6-2-4
Injection order Injection
Machine
60’?30’ 2.420.05
mm
Delivery valve _ retraction volume mm3/st
Pump tester capacity for Service standard
90
Motor
7.5
KW
Calibration Standard Conditions
Service standard
Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.
Manufacturer
Nozzle part no.
(105780-0050)
6162-13-3320
(105015-5210)
Nozzle holder part no.
(105780-2090)
6162-13-3110
(105041-7020)
injection ipe (O/D x l/g x length)
8 x 2.4 x 1400
8 x 3 x 600
mm
ASTM
Test oil
Oil temperature
D975 No. 2 diesel fuel or equivalent 43
OC
to
47
Nozzle opening pressure kg/cm*
175
255
Transfer pump pressure kg/cm2
1.6
1.6
Pump speed
Service standard
Injection volume
Rack position (mm)
Rack point
(r-pm)
(cc/ 100 St)
Manufacturer
standard (cc/100
Maximum Basis
Allowance
~er$$~
Basis
Allowance
cylinder Rack positions B to E are the reference volume when adjusting the injection volume. Marks * are average volumes.
standard
point
Basic
B
3overnor performance
14.5 Approx 5.4
900
47.25
400
3.95
Each cyl. 46.75 to 47.75 *
3.45
to 4.45
kO.395
40.0 4.0
Each cyl. *
C
*
*
D
*
*
E
*
*
( 400 - 900
rpm)
Ia+; Racklimit:
14.5+b2
///////I//// 14.5
Pump speed (mm)
12-026 0
st
Maximum variance between cylinder
SEBH4730
Pump Assembly Number 6162-73-1251 6162-73-1252 6162-73-1253 6162-73-1254
Applicable
(106692-4121) 6162-73-1430 (106692-4640) (106692-4122) 6162-73-1431 (106692-4642) (106692-4123) 6162-73-1432 (106692-9060) (106692-9040)
Machine
Model
Applicable
Serial No.
Engine
Model
EG450-1
Serial No.
SAGDI 70-B-1
EG480-1
( 1: Manufacturer’s part No. c
injection Timing
Engine specification Counterclockwise view from drive end
Rotating direction Injection order
l-5-3-6-2-4
I
Rated horsepower
HP/rpm
Maximum
kgm/rpm
torque
High idling
rpm
Low idling
rpm
Injection interval I
Plunger pre-stroke
mm
2.4kO.05
Delivery valve retraction volume mm3/st
50H 60Hf
1:::
I%#:I
las
700 to 900
Pump tester capacity for Service standard
90
48811500 544/1800
Motor
7.5
KW
Calibration Standard Conditions
Service standard
Manufacturer
standard
* Service
Nozzle part no.
(105780-0050)
6162-13-3220
(105015-5500)
(105780-2090)
6162-13-3110
(105041-7020)
- Manufacture
Nozzle holder part no. Injection ipe (O/D x l/g x length)
standard indicates data using calibration test parts.
is data for factorv test. standard
ASTM
43
OC
to
47
Nozzle opening pressure kg/cm2
175
255
1.6
1.6
Rack position (mm)
Pump speed
Service standard
14.5
900
Rack point
- Rack positions Basic
point
B
Governor performance
0
D975 No. 2 diesel fuel or equivalent
Transfer pump pressure kg/cm2 Injection volume
B to E are the reference volume when adjusting the injection volume. . Marks l are average volumes.
8 x 3 x 600
mm
Test oil Oil temperature
8 x 2.4 x 1400
APV&
b-pm)
400
Basis
h/100
Allowance
47 25 Each cyl. . 46.75 to 47.75 3.95
*
3.45 to
4.45
St)
Manufacturer
Maximum Fert,“E”, Basis Allowance cylinder 4. o Each cyl. . AO.395
4.0
C D
*
*
E
*
*
400 ~~~ore750~10
Pump speed (rpm)
Maximum variance between cylinder
*
*
( 400 - 900
standard (cc/ 100 st
*
rpm)
900",0
SEBH4731
12-027 0
Machine Model
Engine Model
D375A-1
SAGD170 S/N 11646 and up
Injection Pump Type
Pump Manufacturer
PE-6P
DIESEL KIKI
Pump Assembly
I
Number
6162-73-2110
(
0
(106682-4350).
1: Manufacturer’s part No.
Injection Timing Unit
Allowance
Basis
I
Rotating direction
Counterclockwise viewed from drive end
Injection order
l-5-3-6-2-4
Injection interval
60”
59”30’ to 60”30’
3.2
3.15 to 3.25
Plunger pre-stroke
mm
Delivery valve retraction volume
mm3
Calibration
Specification
800
kgm/rpm
267/I
300
High idling:
rpm
1950 to 2050
Low idling:
rpm
I Maximum torque:
600to
I I
700
Standard Service standard (with calibration test parts)
Manufacturer standard (with nearly the same actual machine parts)
Unit
Nozzle part no.
(105015-6700)
(
1
Nozzle holder part no.
(105041-7020)
(
1
In ectron rpe (d/D x l/l?x length) Test oil
8~2.4~1400
mm
ASTM 0975
Oil temperature
“C
40 to 45
Nozzle opening pressure
kg/cm2
265
Transfer pump pressure
kg/cm2
1.6
ipecifications
Calibration basic point
Basis
Allowance
Maximum variance between cylinder
900
34.0
Each cyl. 33.8 to 34.2
f 1.02
[ 6.51
325
3.5
* 3.35 to 3.65
k-o.525
8 B to E are the reference volume when C adjustingthe injection volume. D Marks * are averE age volumes. performance
Injection volumekx/ for service standard
Basis
-
900
rpm)
Maximum variance between cylinder
Allowance
* *
*
(325
St)
Each cyl.
A L15.81
1 Rack positions
;overnor
No. 2 diesel fuel or equivalent
Injection volume kc/ 1OOst) for manufacturer standard
1 : Referencedata Rack Pump osition speed (rpm) Pmm)
1
508/l
Rated horsepower: HP/rpm
120
Conditions
1I
for engine with fan (reference only)
*
*
*
* Boost compensator
performance
(400
rpm)
Rack Ihrn,! K.l++=mm W 117.6,
,
y 115.81
L_____
y’+
B m
-$y.,
-
F_ .E 6 E z a
E E I % 1
‘: I?
Line
@
At boost pressure 450 mmHg or nwre
Line
@
At boost pressure 0 mmHg
z 5
(17.6)
s ‘Z ‘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
111 (106682-4355) 141 (106682-4422)
( ): Manufacturer’s
Model
part No.
Serial
D375A-2
16001
Timing
Rotating
direction
Injection
order
Injection
interval
No.
viewed
from
l-5-3-6-2-4 60° f
ore-stroke
Calibration
13551
No. and up
Engine Specification Counterclockwise drive end
Rated horsepower
HP/rpm
525/l
800
Maximum
kgm/rpm
267/l
300
torque
High idling
Delivery valve retraction volume
SA6D170-B-1
Serial
spec.)
’
I
3.2 + 0.05
mm/ mm3/st
rpm
1960
to 2040
30’ Low idlina
Plunaer
Engine
Model
and up
(S.T.D and Cold weather
Injection
Applicable
Machine
rom
I 1
I
I
I
Pump tester capacity for Service standard
120
I
600 to 700
I
Motor
7.5 KW
I
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
I imi
-
900
rpm)
Boost compensator
performance
(500
rpm)
43 ‘mm
t: 18.
t
compensator
stroke
16.4.
0
Boost pressure
325
720’60 Pump speed (rpm)
3Oa50
7090
(mmHg)
900::: TKE00129
SEBH4774-01 12-028-
0
1
Pump Assembly 6162-73-2 6162-73-2
Number
I
112 (106682-4800) 142 (106682-4820)
( ): Manufacture’s
Applicable
I
Machine
Model
Serial
No.
Enaine
Model
Serial
No.
I
I
Dart No.
Apolicable
D375A-2
SAGD170-B-I
15524 and up
(S.T.D)
Injection
Timing
Engine Specification Rated horsepower Maximum
(kw(HP)/rpm)
torque (Nm(kgm)/rpm)
I
Delivery valve retraction volume (mm”st)
Calibration
Pump tester capacity for Service standard
Service standard
Conditions Nozzle part no.
indicates data using calibration test parts.
Nozzle holder
part no.
Injection pipe (O/D X I/D X length)
* Manufacture
(mm)
for factory test Darts.
Nozzle opening Transfer
6162-13-3720
(105015-6700)
(105780
- 2090)
6162-13-3711
(105041-7100)
pressure
pump pressure
Rack point
D975 No.2 diesel
(MPa(kg/cm’))
17.2 (175) 157 11.6)
(mm)
fuel or equivalent
40-45
(KPafkaicm’))
Rack position
* Rack positions B to E are the ref-
8 X 2.4 X 1,450
(“C)
volume
Service standard
Pump speed
26.0 (265) 157
(cc/lOOst)
Manufacturer
fl 61
standard
Max_imum
Basis
(v-n)
Allowance
~~$~$
erence volume
Basic point
15.2
900
APP~o~.6.6
325
I
Each cyl.
B
mMarks
* are average volumes.
Allowance
3.5
*
verformance(325-900rum) Rack limit:
Each cyl.
*
conpensatar
PerformancefSOOrPm)
18. d't'mm compensator
stroke
16. 4
13. 9 I
Boost
Pressure
(mmHo) TKE00132
0
\ \\\I\ 4lOUO 45om 325
HBO=o 1OOO~‘o 720’6~ 9 0 0:::
Pump speed (rpm) TKE00130
12-028-2
0
between cylinder
f 1.173
* 0.489
*
Boost
rBoost
i variance
*
*
D
18. I4
34.9
*
C
(cc/lOOst) Maximum
Basis
cylinder
when adjusting the injection volume.
Governor
- 0050)
ASTM
Oil temperature
Manufacturer standard
(105780
8X4X1,000
Test oil
is data
standard
7.5 KW
Standard
- Service standard
Injection
Motor:
I
Pump Assembly Number 6162-73-2120 (106682-4380)
Applicable
Injection Timing
order
Injection
interval
Plunger prestroke
Aoolicable
Enaine
Engine specification
Rotating direction Injection
Machine
Counterclockwise
viewed from drive end
~~
l-5-3-6-2-4 60” f 30’ mm
3.2 + 0.05
Delivery valve -retraction volume mm3/st
Pump tester capacity for Service standard
120
7.5 KW
Motor
Calibration Standard Conditions
Service standard
Service standard indicates data using calibration test parts. Manufacture standard is data for factory test.
standard
Nozzle part no.
(105780-0050)
6162- 13-3720
(105015-6700)
Nozzle holder part no.
(105780-2090)
6162-13-3710
(105041-7060)
Injection ipe (O/D x l/g x length)
8 x 2.4 x 1450
8x3~600
mm
ASTM
Test oil
Oil temperature
D975 No. 2 diesel fuel or equivalent
“C
43 to 47
Nozzle opening pressure kg/cm*
175
265
Transfer pump pressure kg/cm2
1.6
1.6
Injection volume
Rack position (mm)
Rack point
Rack positions B to E are the reference volume when adjusting the injection volume. Marks l are average volumes.
Manufacturer
Basic
.
Governor performance
point B
Pump speed (rpm)
12.2
1050
APPJ~.
425
Service standard
(cc/ 100 St)
Manufacturer
standard (cc/ 100 st Maximum
Maximum
32 52
.
2.32
ye:::“, cylinder
Allowance
Basis
Basis
Each cyl.
Each cyl. 32.32 to 32.72
‘“.g756
33.55
*
kO.348
3.0
2.12 to 2.52
*
C
*
*
D
*
*
E
*
*
( 425 - 1050 rpm)
variance between cylinder
Allowance
Boost compensator performance
( 700rpm)
Boostcompensatwstroke 0.9kO.l 13.4 12.2
-G r
6.3
d e z 5 z t $
z L 5 ‘G ‘L : Y P a:
Ormore 6.3
5 0 ‘; 8 m
4.8
0
(300)*25 \ 530*25 425
12.2
11.3
0
60125
Approx.200
Boost pressure (mmHg)
12OOi25 (1100)
Pump speed (rpm)
SEBH4695
12-029 0
1
Pump Assembly
Number
6162-73-2 130 (1066824430) 6162-73-2131 (1066824431) 6162-73-2 132 (106682-4560) 6162-73-2133 (1066824810) ( 1: Manufacture’s part No.
Applicable Model
Machine Serial
Applicable No.
Model
Pc1000-1
Injection
Timing
Rotating
direction
Injection
order
1Injection
interval
Plunger
pre-stroke
Serial
SA6D170-B-1
No.
11763 and up
Engine Specification Counterclockwise from
viewed
Rated horsepower
drive end
l-5-3-6-2-4
(mm)
Maximum
60° 2 30’
1 1High
3.2 + 0.05
Low
Delivery valve retraction volume (mm3jst)
Calibration
Engine
(kw(HP)/rpm)
(542)/l ,700
torque (Nm(kgm)/rpm)
idling
(rpm)
idling
(260)/1,300 I
- 1,900
650 - 700
(rpm)
Pump tester capacity for Service standard
120
1,800
Motor:
7.5 KW
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
z .E .-s .= : 0. Y 0 cz
perfomance
(500 rpm)
16.3
13.8
0
7oC20
300*50
Boost pressure (mmHg)
he
300
81OQ5
850;;;
Pump speed (rpm)
12-030 0
@
Li”e@
: At boost pressure 300 mmHg Or more : Atb spress”reOmmHg
00
SEBH4694-01
Pump Assembly
Number
6162-73-2420
Applicable
(106682-4661)
1
Model (
): Manufacturer’s
lniection
I
direction
Injection
order
Injection
interval
Calibration
Counterclockwise viewed from drive end
I
No.
Model
Engine
1
Serial
No.
SAGD170-1-B-1
Engine
Specification
I
l-5-3-6-2-4 60° f
pre-stroke
Delivery valve retraction volume
Serial
EPSAGD170-B-1
Timina
Rotating
1 Plunger
part No.
Applicable
Machine
30’
3.2 f 0.05
mm1
120
mm3/st
I
Pump tester capacity for Service standard
Motor 7.5 KW
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
385
(415
-
900
rpm)
Boost compensator
performance
(700 rpm)
900;:: Pump speed (rpm)
12-030-l 0
I
Pump Assembly 6162-73-242
Number
Applicable
1 (106682-4840)
Serial
Model
( ): Manufacture’s
Applicable
Machine No.
Rotating
direction
Injection
order
Counterclockwise from
drive
SA6D170-I-B-I
1 Rated horsepower 1Maximum
I I High
60’ t 30’
Plunger pre-stroke
Calibration
viewed end
I-5-3-6-2-4
interval
Delivery valve retraction volume
No.
Enaine Soecification
Timina
I Injection
Serial
Model
part No. EPSAGD170-B-1
lniection .
Engine
(mm)
3.2 5 0.05
torque (Nm(kgm)/rpm)
idling
(rpm)
Low idling
(rpm)
(540)/1,800
1
(251 VI ,300
I
1,950 - 2,050
Pump tester capacity for Service standard
120
(mm”st)
(kw(HP)/rpm)I
I
I I
750 - 850 Motor:
7.5 KW
Standard Service
Conditions
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
D
/
/ /
(16.2)
E
perfomance
750 650
(415 - 900 rpm)
18’: Governor Idling ED
a 16.2 ..S .-z
s~lina set sub s~lina
set
A
.z _ 2
6.5 6. 3
0
900:::
385 Pump speed (rpm)
12-030-2 0
97w
415
TKE00131
j 1
* *
1(36.0) 1* 1(36.6) 1t
35.5 - 36.5 36.1 -37.1
/ )
-
Injection
Pump Assembly
6162-73-1711
6162-73-1760
Applicable
(106692-4650)
( 1: Injection
Pump
Injection
Model
Manufacture’s
part No.
direction
Injection
order
Injection
interval prestroke
Machine Serial
Applicable No.
SA6D170-B-1
EPSAGD170-B-1 (Extreme cold weather)
SA6D170-B-1
Engine Specification
Counterclockwise
viewed
Engine Serial
Model
EPSAGD170-B-1
Pump Specification
Rotating
Plunger
Number
(106692-4382)
(Without
No.
fan)
from
drive end
l-5-3-6-2-4 59’ 30’ - 60” 30’
High idling
speed
(rpm)
2.35 - 2.45
Low idling
speed
(rpm)
(mm)
I
Max.
I
2,030
600 - 1,000
I
Delivery valve retraction volume (mm”‘st)
Calibration
Pump
90
tester
for Service
capacity
standard
Motor:
7.5 kW
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
C
750
425 - 435
-
D E
Governor
perfomance
curve Rack limit
:
(16.
7) '~'mm
1 (15. 2) (9. 8)
E E .!
(6. 8)
‘, 2
6.3
I0
400 / (870) +30\990+25 900::: 75O’P Pump speed (rpm)
L-
TWE00630
12-030-3 0
Injection
Pump Assembly
6162-73-1743
Number
Applicable
(106692-9070)
Machine
Model Pump
( ): Injection
Manufacture’s
part No.
Serial
Applicable No.
OEM for
Engine
Model
Serial
1 No.
SA6D170-B-1
generator
11
Injection
Pump Specification
Rotating
direction
Injection
order
1Injection
interval
1Plunger
prestroke
Engine Specification
Counterclockwise drive end
viewed
from
l-5-3-6-2-4 59’ 30’ - 60” 30’ (mm)
1
2.35 ; 2.45
---I I
I
Standard
data
standard
is data
(50 Hz) (60 Hz)
I
I
Pump tester capacity for Service standard
(
fan) 425 {570}/1,500 506 {6781/1,800
torque (Nm{kgmI/rpm)
) : lnjenction
pump
erwce standard indicates
(Without
horsepower (kW{HPYrpm)
a::“: Maximum
Delivery valve retraction volume (mmyst) I
Calibration
Flywheel
. Rack positions B to E are the refernce volume when adjusting the injection volume. Marks * are
l
Governor perfomance curve
spring
set:
manufacture’s
I
Motor:
part number
7.5 kW
Injection Pump Assembly Number 6162-73-1941 (1066824890)
Applicable Machine Model
( 1:Injection Pump Manufacture’s part No. Injection Pump Type
Injection
Serial No.
OEM for generator
Pump
Serial No.
Model SA6D170-B-1
Manufactuer
I
I
ZEXEL
PE-P (S7S)
Injection Pump Specification Rotating
Applicable Engine
(kW{HP}/rpm)
(50 Hz) (60 Hz)
Maximum torque (Nm{kgml/rpm)
Calibration Standard
(
) : lnienction
I
Conditions Nozzle & Nozzle holder Dart No. holder
part
pump manufacture’s
Servicestandard
1
No.
6162-13-7300
(1051114431)
(105780-0050)
6162-13-7520
(105015-8790)
(105780-2090)
6162-13-3111
(105041-7110)
Injection pipe (Outside dia.x Inside dia.x Length 1(mm)
8 X 4 X 1,000
Test oil
ASTM
Oil temperature
part number
Manufacturerstandard
1
(105780-8130)
Nozzle part No. Nozzle
386 {517)/1,500 458 I613Yl.800
Flywheel horsepower
‘~~~ Service standard indicates data using calibration test parts. Manufacture standard is data for factory test parts.
I
Engine Specification (Without fan)
Counterclockwise viewed from drive end
direction
I
(“C)
8 X 2.4 X 1,400
D975 No.2 diesel fuel
or equivalent
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
0
,400
750f5
460f5 Pump speed
\ 1000*5 900f5 (r Pm)
TWE00632
12-030-5 0
Injection Pump Assembly Number 6162-73-1942
Applicable
(1066824891)
Machine
Model
( 1: Injection Pump Manufacture’s
part No.
Serial
direction
I Injection
order
Injection
interval
Engine
Model
Serial No.
SA6D170-B-1
Engine Specification (Without fan)
Counterclockwise viewed from drive end
Flywheel horsepower
386 {517)/1,500 458 {6131/1.800
(kW{HPVrpm)
l-5-3-6-2-4
(50 Hz) (60 Hz)
Maximum torque (Nm{kgml/rpm)
59” 30’ - 60” 30’
Plunger prestroke (mm)
2.95 - 3.05 I
I
Delivery valve retraction volume (mm3bt)
120
I
I
Pump tester capacity for Service standard
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)
12-030-6 0
No.
OEM for generator
Injection Pump Specification Rotating
Applicable
TWE00633
Motor:
7.5 kW
Injection Pump Assembly Number 6162-73-1950
Applicable
(106682-9130)
Machine
Model
( ): Injection Pump Manufacture’s
part No.
Applicable
Serial
No.
Engine
Model
D375 (BEML)
I
Serial No.
SA6D170-B-1
/
lniection Pump. Specification _ Rotating
direction
Injection
order
Injection
interval
Ennine Specification (Without fan)
Counterclockwise viewed from drive end
Flywheel
Maximum torque (Nm{kgml/rpm)
59’ 30’ - 60” 30’ 3.15 - 3.25 I
I
Delivery valve retraction volume (mm3/st)J
High idling
speed
(rpm)
Low idling
speed
(rpm)
I
(
(Conditions
) : lnjenction
{248/1,300}
1,960 - 2,040 600 - 650 I
I
Motor:
pump manufacture’s
Service standard
indicates data using calibration test parts. Manufacture standard is data for factory test parts.
{509/1,800}
3,432/1,300
Pump tester capacity fnr Service ntnnriard
120
Calibration Standard
Service standard
380/1,800
(kW{HPYrpm)
1-5-3-6-2-4
Plunger prestroke (mm)
horsepower
7.5 kW
part number Manufacturer
standard
Nozzle & Nozzle holder part No.
(105780-8130)
6162-14-3700
Nozzle part No.
(105780-0050)
6162-13-3320
(105015-8600)
Nozzle holder part No.
(105780-2090)
6162-13-3712
(105041-7101)
Injection pipe (Outside dia.x Inside dia.x Length ) ‘mm)
8 X 4 X 1,000
Test oil
ASTM
Oil temperature
8X2.4X1.450
D975 No.2 diesel fuel or equivalent 40-45
(‘C)
Nozzle opening pressure (MPa{kg/cm’])
17.2 {1751
Injection
Rack positions B to E are the ref-
I
(105111-4441)
26.0 {2651
volume
Injection
volume
ernce volume when adjusting the injection volume. Marks * are average volumes.
Governor
1 a’:
perfomance
curve
Boost compensator
: 17.
Rack I imit
performance
curve
2’oD”mm
Boost compensator stroke ~2. 520.
I
1 mm
1 15. 5
4. 0
9. 3
+5mm’/s
t
:
I I. 5
Dz
1; 0
KR;
Boost
41Oi20
QdO::: (72d) i50 Pump speed (rpm)
9. 3f2. 7 (701t20)
pressure
40. 0*6. 7 ~300+501
(kPa{mmHel
1
TWE00634
L
12-030-7 0
Injection
Pump Assembly
Number
I
6162-73-2173 (1066824830)
Applicable
Machine Serial No.
Model
( ): Injection Pump Manufacture’s
Injection
part No.
Rotating
direction
Injection
order
Injection
interval
2.95 - 3.05 1 1 Pump tester capacity fnr
Standard
l
1 Nozzle & Nozzle holder oart NO.
I
C+lnrl3rA
oumo manufacture’s
Service standard
Motor:
7.5 kW
oart number
(105780-8130)
6162-13-3201
(105780-0050)
6162-13-3220 (105015-5500)
Nozzle holder part No.
(105780-2090)
6162-13-3111
Injection (Outside
pipe
dia.x Inside dim
Length
8 X 4 X 1,000
) (mm)
temoerature
(“C)
40-45 17.2 {175}
Transfer pump pressure (kPa{kg/cm*))
157 Il.61
Rack point
Rack position (mm)
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
D
Service
Pump speed Wpm)
limit:
volume
400
35-45
set:
3. 6fO. 3 750f5 TWE00636
st)
Maximum $$g$ cylinder
365 - 375
Z ..Z _
(r Pm)
Injection
standard (cc/l,000
380 - 390
spring
speed
Maximum g$$z
Manufacturer
750
E Min. 7. 9 E _ 6.4 Z 6. 2
500
157 Il.61 ,000 s-t)
900
19. l’t’mm
1;. ! 15: 2
25.0 1255)
cylinder
1’
ck
standard (cc/l
Injection volume
Governor perfomance curve
PUIIIP
(105041-7110)
8X2.4X1,450
I
Nozzle opening pressure (MPa{kg/cm%
18:’
f105111-4051)
ASTM D975 No.2 diesel fuel or equivalent
Test oil
I Oil
I
Manufacturer standard
Nozzle part No.
Injection volume
12-030-8 0
Cnnrim
1: lnienction
Conditions
average volumes.
fan) 378 {5061/1,500 (50 Hz) 403 {539Vl,800 (60 Hz)
59’ 30’ - 60” 30’
valve retraction volume (mm’/st)l
Service standard indicates data using calibration test parts. Manufacture standard is data for factory test parts.
No.
Maximum torque (NmIkgmI/rpm)
veIlvery
Calibration
(Without
Flywheel horsepower (kW{HPYrpm)
l-5-3-6-2-4
Plunger prestroke (mm)
I
Serial
SA6D170-B-1
Engine Specification
Counterclockwise viewed from drive end
Engine
Model
OEM for generator
Pump Specification
Applicable
I
Max. 23.1 -
Max. 12
Injection Pump Assembly Number 6162-73-2380
1
Model ( ): Injection
Pump Manufacture’s
part No.
direction
Injection
order
Injection
interval
59’ 30’ - 60’ 30’
for factory test parts.
280/1,000
{375/1,000}
fl
2.75 - 2.85 I
(mm’/st)
I
I
Pump tester capacity for Service standard
120
f
ionditions
Manufacture standard is data
Serial No.
Maximum torque (NmIkgmYrpm)
Calibration Standard
indicates data using calibration test parts.
Flywheel horsepower (kW{HPMrpm)
l-5-3-6-2-4
I
Service standard
I
Model SA6D170-B-1
Engine Specification (Without fan)
Counterclockwise viewed from drive end
Plunger prestroke (mm) Delivery valve retraction volume
Serial No.
OEM for 6-pole
Injection Pump Specification Rotating
Applicable Engine
Applicable Machine
(106682-9350)
I
) : lnienction
oumo manufacture’s
Servicestandard
7.5 kW
Motor:
oart number
Manufacturerstandard
Nozzle & Nozzle holder part No.
(105780-8130)
6162-14-3300
(105111-46601
Nozzle part No.
(105780-0050)
6162-14-3320
(105025-0910)
Nozzle holder part No.
(105780-2090)
6162-13-3711
(105041-7101)
Injection pipe (Outside
dia.x Inside dia.x Length
) (mm)
ASTM
Test oil Oil temoerature
1Transfer pump pressure
40-45
(kPa{kg/cm*H1
njection volume
Rack positions
D975 No.2 diesel fuel or equivalent
(‘C)
Nozzle opening pressure &lPa{kg/cm%~
Rack point
8 X 2.4 X 1,400
8X4X1.000
Rack position
Pump speed
(mm)
(rpm)
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
17.2 {175}
26.0 f2651
157 Il.61
157 U.61
Service standard (cc/l,000 st)
Manufacturer standard (cc/1,000 st]
Maximum
Injection volume
vba,EEkE
Mqimum
Injection volume
cylinder
500 600 400
508 - 513 538 - 548 II-14
Max. 18.7 Max. 7.5
g”,zg!z cylinder
419
-
448
-
25
-
E
Governor perfomancecurve
Rack limit
0
400
is not actuated
500f5
\ 6001t5 520f5 Boost speed (rPm)
TWE00637
1Z-030-9 0
Injection Pump Assembly Number 6162-74-1750
Applicable
(103684-0361)
Model
( 1:Injection Pump Manufacture’s
part No.
direction
Injection
order
Injection
interval
Plunger prestroke (mm) Delivery valve retraction volume (mmyst)
Calibration Standard
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
Serial
Applicable No.
OEM for generator (50 Hz)
Injection Pump Specification Rotating
Machine
Engine
Model
Serial
No.
SAAGD170-1
Engine Specification (Without fan)
Counterclockwise viewed from drive end l-5-3-6-2-4
Flywheel horsepower (kW{HWrpm)
597/1,500
Maximum torque (Nm{kgm}/rpm)
59” 30’ - 60” 30’
High idling
3.55 - 3.65
Low idling
speed speed
(rpm)
Max. 1,575
(rpm)
700 - 900
Pump tester capacity for Service standard
180
(
1 : lnjenction
{800/1,500} -
pump manufacture’s
Motor:
part number
7.5 kW
TESTING Injection
AND ADJUSTING Pump Assembly
CALIBRATION Number
Applicable
6162-74-1310 (103662-3350) (With electronic governor)
( 1:Injection
Pump
Machine
Model
Manufacture’s
part No.
Applicable
Serial
No.
Engine Serial
Model
DENY0 generator
DATA
No.
SA6D170-AE-1
DCAGOOSSK
)
Injection
Pump Specification
Rotating
direction
Injection
order
Injection
interval
1Plunger
Engine Specification
Counterclockwise drive end
Flywheel
Maximum
(rpm)
3.15 - 3.25
Low idling
speed
(rpm)
indicates data using calibration test parts. . Manufacture standard is data for factory test parts.
( I
Nozzle & Nozzle hn1d-r rdart No. ..v...v,
Nozzle part No. Nozzle holder
manufacture’s
1
1 I
1 I
pressure
(MPa{kg/cm)) (kPa{kg/cm’})
Rack position
Rack voltage
Pump speed
(mm)
w
Irpm)
13.2
1.36
865
5.9
2.8
400
7.5 kW
part number
Manufacturer standard 6162-14-7600
(105111-4820)
6162-14-7620
(105025-1850)
5212-13-3111
(105041-7111)
8 X 2.4 X 1,450 D975 No.2 diesel
fuel or equivalent
40-45
(‘C)
pump pressure
1,880 (60 Hz)
700 - 900
) (mm)
njection volume Rack positions B to E are the refernce volume when adjusting Rated tttt:;eyfion point
pump
Service standard
ASTM
tiozzle opening L
1: lnjenction
Test oil
Transfer
Max.
Motor:
part No.
Injection pipe (Outside dia.x Inside dia.x Length
Oil temperature
Max. 1,570 (50 Hz)
Pump tester capacity for Service standard
Standard
iGross.50Hz) (Gross,GOHz)
-
torque (Nm{kgm}/rpm) speed
90
fan)
478 {641)/1,500 528 {708M1,800
(kW{HP)/rpm)
High idling
(mm)
(Conditions . Service standard
(Without
horsepower
59’ 30’ - 60’ 30’
Delivery valve retraction volume (mm31st)
Marks * are average volumes.
from
1-5-3-6-2-4
prestroke
Calibration
viewed
29.4 13001 157 {I .60} Service standard
(cc/l,000
st)
Manufacturer
standard (cc/l,000
Max.imum
Injection
volume
Ezz,“,“z cylinder
st
Maximurr
Injection
volume
~~~~~~ cylinder
* 543 t 5
Max. 44
Low idling point
*30*5
Max. 8
perfomance curve (Not specified)
Governor
12-30-11 @
Injection
Pump Assembly
6162-73-2174 6162-73-2175
( ): Injection
Number
Applicable
(106682-4990) (106682-4991) Pump
Injection
part No.
direction
Injection
order
firestroke
I
Engine Serial
Model
(Without
Flywheel horsepower (kW{HPYrpm)
viewed from
1Maximum
I
fan1
-
torque (NmIkgmMrpm)I
I
59” 30’ - 60” 30’
I High idling
speed
(rpm)
Max. 1,570 (50 Hz) Max. 1,880 (60 Hz)
2.95 - 3.05
I Low idling
speed
(rpm)
700 - 900
(mm) (
Pump tester capacity for Service standard
120
Standard
(
) : lnjenction
pump
Motor:
manufacture’s
7.5 kW
part number
test parts.
Rack positions
curve
perfomance
urnmaximum
speed
control
Rack
iimit:l9.
spec. I-19.
3
(mm) All
Idling
sub
spring
Q=67-77 (mm3/s
Pump
12-30-12 G9
745-755
500 speed
(rpm)
speed
idl
ina
set
set t)
0 Approx.
No.
378 {506)/l ,500 (Net) 403 {5391/l ,800 (Net)
Service standard indicates data using calibration test parts. Manufacture standard is data
Governor
DATA
SA6D170-B-1
OEM for generator (Prime use)
l-5-3-6-2-4
Delivery valve retraction volume (mm”st)
Calibration
No.
Engine Specification
Counterclockwise drive end
interval
Applicable
Machine Serial
Model
Manufacture’s
Pump Specification
Rotating
Injection
CALIBRATION
AND ADJUSTING
TESTING
400 Pump
speed
from) TWE00729
TESTING
AND ADJUSTING
Injection
Pump Assembly
6162-73-2180
CALIBRATION Number
ApDiicable
(I 06682-4900)
6162-73-2181
(106682-9000)
( ): Injection
Pump
Serial
Model
Manufacture’s
part No.
I
Machine No.
EG500-l,EG500B-1
Aoolicable
Enaine
Model
I
DATA
Serial
No.
SAGD170-B-I
EG500BS-1 OEM for generator
Injection
Pump Specification
Rotating
direction
Injection
order
Injection
interval
Plunger prestroke
Engine Specification
Counterclockwise drive end l-5-3-6-2-4
(mm)
(Without
Flywheel horsepower (kWfHP)/rpm) Maximum
fan) 385 {5241/l ,500 (50 Hz) 458 I611~/1,800 (60 Hz) -
torque (Nm{kgm}/rpm)
59” 30’ - 60” 30’
High idling
speed
(rpm)
Max. 1,560 (50 Hz) Max. 1,870 (60 Hz)
2.95 - 3.05
Low idling
speed
(rpm)
800
Delivery valve retraction volume (mm3’st)
Calibration
viewed from
Pump tester capacity for Service standard
120
Standard
(
) : lnienction
oumo
manufacture’s
Motor:
7.5 kW
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
: -
2 .-.2 a
19.7
17.6 17.4 9.3
400
750 900
Pumpspeed [r pm) TWE00730
12-30- 13 @
TESTING
AND
Injection
CALIBRATION
ADJUSTING
Pump Assembly
6162-73-2340 6162-73-2341
( ): Injection
Pump
Injection
Number
Applicable
(106682-9220) (106682-9221) part No.
OEM for generator (Standby
direction
Injection
order
Injection
interval
Plunger
prestroke
No.
Counterclockwise drive end
(Without
Flywheel horsepower (kW{HP)/rpm)
viewed from
Maximum
2.75 - 2.85
Low idling
speed
Calibration
speed
(
1: lnjenction
pump
test parts.
In.ection volume
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.)
0
745-755
Min. 900
Pump speed (rum) TWE00731
12-30-14 60
700 - 900 I
Service standard indicates data using calibration test parts. Manufacture standard is data
Governor
Max. 1,575 (50 Hz) Max. 1,890 (60 Hz)
(rpm)
Pump tester capacity for Service standard
Standard
fan)
-
(rpm)
I
120
No.
468 {636}/1,500 (50 Hz) 557 {7571/1,800 (60 Hz)
torque (Nm{kgmYrpm)
High idling
59’ 30’ - 60” 30’
Delivery valve retraction volume (mm”st)
Serial
Model
use)
l-5-3-6-2-4
(mm)
Engine
SA6D170-B-1
Engine Specification
Pump Specification
Rotating
Serial
Model
Manufacture’s
Applicable
Machine
DATA
manufacture’s
I
Motor:
part number
7.5 kW
TESTING
CALIBRATION
AND ADJUSTING
Injection
Pump Assembly
6162-73-2381
Number
Applicable
(106682-9351)
Serial
Model
( ): injection
Pump
lniection
Manufacture’s
part No.
direction
Injection
order
Injection
interval
Plunger
prestroke
l-5-3-6-2-4
Maximum
17441 and up
fan)
torque (NmIkgmVrpm)
2.75 - 2.85
(mm)
Pump tester capacity for Service standard
Standard
Service standard
indicates data using calibration test parts. Manufacture standard is data for factory test parts.
(
) : lnjenction
I
Service
manufacture’s
standard
7.5 kW
part number Manufacturer
standard
(105780-8130)
6162-14-3300
(105111-4660)
Nozzle part No.
(I 05780-0050)
6162-14-3320
(105025-0910)
Nozzle holder part No.
(I 05780-2090)
6162-13-3711
(105041-7101)
Injection (Outside
pipe
diax
Inside
dia.x Length
ASTM
Oil temperature
40-45
pump pressure (kPaikg/cm?)
Rack point Rack positions B to E are the ref-
Pump
Rack position
speed
(mm)
(mm)
14.8
A(Basicpoint)
D975 No.2 diesel fuel or equivalent
(“C)
volume
when adjusting the injection volume. Marks * are average volumes.
8 X 2.4 X 1,400
8X4X1,000
) (mm)
Test oil
1Transfer
ernce volume
pump
Motor:
Nozzle & Nozzle holder part No.
Nozzle opening pressure (MPaIkg/cm%
17.2 {I751
26.0 {265}
157 {I .6}
157 {I .S}
Service standard
Injection volume
500
498 - 508 538 - 548
B
15.5
600
C
Approx. 6.8
400
II-14
(cc/l,000
st)
Maximum variance between cylinder
Max. 18.7 Max. 7.5
Manufacturer
standard (cc/1,000 st) Maximum
Injection volume
~~!r~J~ cylinder
419
-
448
-
25
-
D
perfomance
curve
Rack
0
(Without
No.
59’ 30’ - 60’ 30’
Ctonditions
Governor
Serial
Model
viewed from
I
njection
Engine
SA6D170-B-1
Engine Specification
Counterclockwise drive end
Delivery valve retraction volume (mm’/st) I
Calibration
No.
OEM for B-pole generator
Pump. Specification .
Rotating
Applicable
Machine
DATA
limit
400
Boost
is
not
actuated
500f5
\ 520f5
speed
(rpm)
600f5 TWE00637
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
I
6162F291
2 z z
Unit: Engine
model
Applicable machine
;6D170-1
4
SA6D170-A-1
1
mm
Dimension A
Q area
HD465-3
1
58f5
12-031 69
REPLACING
l
FAN BELT AND
AQJUSTING
AUTO TENSIONER
Replacing Loosen
locknut
(1) and turn back adjustment
(2) as far as bracket Insert
a bar with
hole (418)
screw
(3).
a length
in bracket
of approx.
(7). then
50 cm in the
pull strongly
4
to the
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
l
1.
Adjusting Tighten
adjustment
adjustment tension
screw
pulley
(2) a further
screw (2)
(2), and when
comes
lever (4). tighten
half turn,
then
into
the tip of
contact
adjustment
lock it in position
with screw with
locknut (1). w *
Locknut
If a gap appears the
+ 2 kgm
between
tip of adjustment
adjust *
: 29.5
tension screw
pulley
(2) during
lever (4) and operation,
in the same way.
If the fan
belt screeches,
adjust
in the
same
way. 6162F668
12-032 0
TESTING AND ADJUSTING
PERFORMANCE TEST
PERFORMANCE TEST RUN-IN STANDARD
T
Item
1
2
3
4
5
6
Running time
3
6
3
3
10
Min. 5
Engine speed
300 - 66C
1,000
1,200
1,200
1,500
1,800
716 mm
0
392 {401
883 {901
1,373 {I401
2,059 12101
2,452 {2501
895 mm
0
314 I321
706 (721
1,098 {I121
1,648 {I681
1,961 {200>
1,023 mm
0
275 {281
618 {63}
961 1981
1,442 11471
1,716 I1751
Flywheel Horsepower
0
29.4 139.4)
79.4 1106.51
123.5 U65.61
231.7 1310.6)
331 1443.7)
Running time
3
6
3
3
10
Min. 5
Engine speed
550 - 700
1,000
1,200
1,200
1,500
1,600
716 mm
0
392 I401
883 I901
1,373 {I401
2,059 f2101
2,648 (2701
895 mm
0
314 1321
706 I721
1,098 {I121
X2??
2,118 f2161
1,023 mm
0
275 1281
618 1631
961 1981
1,442 {I471
1,853 11891
0
29.4 f39.4)
79.4 I106.5)
123.5 U65.61
231.7 1310.61
317.8 f426.0)
3
6
3
3
10
Min. 5
i50 - 700
1,000
1,200
1,200
1,500
2,000
716 mm
0
392 1401
883 I90)
1,373 {I401
2,059 I2101
2,157 I2201
895 mm
0
314 I321
706 {72)
1,098 {I121
1,648 11681
1,726 {176)
1,023 mm
0
275 {28)
618 I631
961 {981
1,442 I1471
1,510 1154)
Flywheel Horsepower
0
29.4 I39.4)
79.4 1106.5)
231.7 1310.61
323.6 t433.8)
Running time
3
6
3
3
10
Min. 5
5ngine speed
;50 - 700
1,000
1,300
1,600
1,800
2,000
716 mm
0
265 I271
530 154)
814 I831
1,157 {I181
2,403 f2451
895 mm
0
216 (221
422 I431
647 {661
922 1941
1,922 U96)
1,023 mm
0
186 U9)
373 I381
569 158)
814 1831
1.677 I1711
‘lywheel Horsepower
0
19.8 126.6)
51.5 {69)
97.8 I131.1)
155.9 {209.0)
433.9 I581.7)
Iunning
5
15
5
5
20
10
00 - 850
1,000
1,200
1,200
1,500
1,500
490 150)
981 {loo)
2,059 I2101
3,138 13201
4,219 1430)
Load D275A-2
Load PC650-1 PC1 500-I
Flywheel Horsepower
Running time Engine speed Load S6D170-1
WA600-1
_oad ND600-1
time
ingine speed .oad iG550-1
716 mm
min.
123.5 U65.6)
895 mm
-
-
-
-
-
1,023 mm
-
-
-
-
-
36.6 I491
88.0 Ill81
:lywheel Horsepower * *
Order
185 12481
352.9 14731
474.5 I6361
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
Engine model
PERFORMANCE
AND ADJUSTING
The table gives the standard
*
The load for the dynamometer
values for machines
without
fan.
are at an arm’s length of 716 mm.
Order
,pplicable machine
PS6D170-1
t
TEST
Item 1
2
3
4
5
6
Running time
3
6
3
3
10
5
Engine speed
800
1,000
1,200
1,200
1,500
1,800
Load
0
392 {401
883 I901
1,373 11401
2,059 {2101
2,942 13001
Flywheel Horsepower
0
29.4 I39.41
79.4 1106.51
123.6 1165.61
231.8 l310.6)
397.4 1532.4)
Running time
3
6
3
3
10
Min. 5
1,500
1,800
S6D170-1
‘50 - 800
1,000
1,200
1,200
Load
0
392 I401
883 I901
1,373 I1401
2,059 {2101
3,040 {3101
Flywheel Horsepower
0
29.4 139.4)
79.5 I106.5)
123.6 i165.61
231.8 1310.61
410.7 t550.21
Engine speed ‘EM for enerator
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
PERFORMANCE TEST
TESTING AND ADJUSTING
*
The values given for the output is the fan removed.
t
The load (dynamometer)
*I
: Mechanical
l-
Engine model
governor
item
Running time Engine speed iD465-5 Both nechanical Jectronic rovernor)
Load
3
4
5
6
3
6
3
3
10
5
1,000
1,200
1,200
1,500
2,100
392 {401
883 $01
1,373 U401
2,511 {2561
3,452 I3521
25 -950 *1 20 - 970 *i
716 mm
0
895 mm
-
-
-
-
-
-
1,023 mm
-
-
-
-
-
-
29.4 l39.4)
79.5 UO6.5)
123.6 {I 65.6)
282.6 C378.61
544.1 1728.9)
Running time
5
15
5
5
20
10
Engine speed
700
1,000
1,200
1,600
1800
2,000 3,383 13451
$zl
883 (901
1,667 I1701
2,452 {2501
0
353 I36}
706 I721
1,334 I1361
1,961 I2001
2,707 I2761
0
309 131.51
618 f631
1,167 {I191
1,716 I1751
2,368 I241.5)
Flywheel Horsepower
0
33.1 @I441
79.5 UO6.5)
200.2 1268.21
331.2 I443.71
507.8 t680.31
Running time
5
15
5
5
20
10
Engine speed
‘00 - 900
1,000
1,200
1,200
1,500
1,500
1,961 (2001
3,046 (3101
3,432 {3501
716 mm
0
895 mm 1,023 mm
716 mm
0
392 1401
1,177 I1201
895 mm
0
314 {321
932 (951
1,569 I1601
2,432 (2481
2,746 12801
1,023 mm
0
275 (281
824 1841
1,373 (140)
2,128 (1271
2,403 12451
Flywheel Horsepower
0
29.4 139.4)
106.0 (142.0)
176.6 (236.6)
242.2 (458.5)
386.4 (517.7)
Running time
5
15
5
5
20
10
Engine speed
50 - 1,ooc
1,000
1,200
1,200
1,500
1,500
2,354 (2401
3,530 1360)
4,707 I480}
Load
generator
716 mm
0
588 f601
1,177 I1201
895 mm
0
471 I481
941 {961
1,883 11921
2,824 (2881
3,766 1384)
1,023 mm
0
412 {421
824 (841
1,648 (1681
2,471 12521
3,295 13361
Flywheel Horsepower
0
44.1 159.11
105.9 (141.9)
211.8 (283.91
397.2 (532.4)
529.6 i709.91
Running time
5
15
5
5
20
10
Engine speed
800
1,000
1,200
1,600
1,800
2,000
883 {90}
1,765 (1801
3,026 13081
3,060 I3631
Load EG580-BIL
Load EPSAGDlTI( -A-
2
0
VA700-1
SAGDI 70-A-
1
Flywheel Horsepower
Load
iG580-1 iG580B-1 iG600-1 .G600B-1 J;;T&s-l
is given for the case of the arm length is 716 mm, 895 mm or 1,023 mm. *2 : Electronic governor
716 mm
0
z
895 mm
-
-
-
-
-
-
1,023 mm
-
-
-
-
-
-
33.1 (44.4)
79.5 I106.5)
407.7 (546.2)
534.3 t715.8)
Flywheel Horsepower
0
212 12841
l Z-035 0
TESTING
AND ADJUSTING
EM680A-A
H D465-5 (High altitude spec.)
*
The table gives the standard
*
The load for the dynamometer
values for machines
TEST
without
fan.
are at an arm’s length of 716 mm.
Order
Applicable machine
EM680A EM680A-1 6M170-B-1
PERFORMANCE
Item
1
2
3
4
5
6
Running time
3
6
3
3
10
Min. 5
Engine speed
550 - 600
1,000
1,200
1,200
1,500
2,000
Load
0
392 I401
883 I901
1,373 U40}
2,579 (2631
3,658 {3731
Flywheel Horsepower
0
29.4 i39.4)
79.5 (106.5)
123.6 U65.61
290.4 I389.0)
549.1 1735.6)
Running time
3
6
3
3
Engine speed
550 - 600
1,000
1,200
1,200
1,500
2,000
Load
0
392 I401
883 (901
1.373 (1401
2,511 (2561
4,187 I427>
Flywheel Horsepower
0
29.4 (39.4)
79.5 (106.51
123.6 (165.61
282.6 (378.61
628.5 (842.01
Running time
5
15
5
5
20
10
Engine speed
1,100
1,100
1,300
1,650
1,900
2,100
0
343 (351
637 (651
1,226 (125)
1,863 (1901
2,452 (2501
2
0
28.3 t38.01
62.2 i83.31
151.8 (203.41
265.7 (355.91
386.4 I517.71
z
Load Flywheel Horsepower
IO
Min. 5
z
SA6D170-A-
OEM for at7yfr=r$r
Running time
5
15
5
5
20
IO
Engine speed
950
1,000
1,200
1,200
1,500
1,500
Load
0
588 160)
1,177 I1201
2,354 (2401
3,530 13601
4,707 (4801
Flywheel Horsepower
0
44.2 (59.21
106.0 (142.0)
212.0 (284.01
397.4 (532.41
529.9 (709.91
Running time
5
15
5
5
20
IO
Engine speed
700 - 900
1,000
1,200
1,200
1,500
1,500
Load
0
490 (50)
981 IlOO}
1,961 I2001
2,942 (3001
3,923 I4001
Flywheel Horsepower
0
29.4 (39.41
106.0 (142.01
176.6 (236.6)
342.2 (458.51
386.4 (517.7)
633 HP)
EG600BS-1 OEM for generator (Engine No. 15503andup
OEM for generator
12-035- 1 0
Running time
3
6
3
3
IO
5
Engine speed
800
1,000
1,200
1,200
1,500
1,800
Load
0
490 1501
981 I1001
1,961 (2001
2,942 I3001
3,923 (4001
Flywheel Horsepower
0
47.8 (64.11
114.8 (153.8)
234.0 I313.5)
441.6 (591.61
529.9 (940.61
TESTING
AND ADJUSTING
T ‘c1ooosP-
3EM for generator Standby .rse 581 kW :778 HP})
PERFORMANCE
Item
*
The table gives the standard
t
The load for the dynamometer
-r
values for machines
TEST
without fan.
are at an arm’s length of 716 mm.
Order 1
2
3
4
5
6
Running time
3
6
3
3
10
Min. 5
Engine speed
675
1,000
1,200
1,200
1,500
1,750
Load
0
392 {401
883 {901
1.373 {I401
2,059
WO}
3,472 1354)
Flywheel Horsepower
0
29.4 139.4)
79.5 1106.5)
123.6 1165.6)
231.8 f310.61
456.3 I611.31
Running time
3
6
3
3
10
5
Engine speed
700 - 900
1,000
1,200
1,200
1,500
1,800
Load
0
637 165)
1,275 I1301
2,599 I2661
3,923 (4001
5,198 I5301
Flywheel Horsepower
0
47.8 WI)
114.8 1153.8)
234.0 (313.5)
441.6 (591.61
702.1 (940.6)
Running time
3
9
18
24
6
Engine speed
575
1,260
1,580
1,820
2,000
Load
0
922 I941
1,844 (188)
2,756 I2811
3,677 I3751
Flywheel Horsepower
0
86.8 (116.3)
218.6 (292.8)
376.1 (503.81
552.0 (739.5)
Running time
3
6
3
3
10
Min. 5
Engine speed
850
1,000
1,200
1,200
1,500
2,000
Load
0
392 (401
883 1901
1,373 {I401
2,511 (2661
3,393 I3461
Flywheel Horsepower
0
29.4 (39.4)
79.5 UO6.51
123.6 U65.61
282.4 I378.61
508.8 {682}
SA6D170-A-
3EM for narine
-lD465-3 ,For ORAPI MINE
Running time Engine speed Load Flywheel Horsepower
Running time Engine speed Load Flywheel Horsepower
12-035-2 0
TESTING
AND ADJUSTING
t *
PERFORMANCE
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
Engine model
Item 1
4
5
6
3
6
3
3
10
Min. 5
600 - 700
1,000
1,200
1,200
1,500
1,800
0
392 {401
883 {901
1,373 11401
2,059 {2101
2,942 {3001
314 I321
706 {721
1,098 11121
1,648 I1681
2,354 12401
275 I281 29.4 139.41
618 {631
961 1981
2,059 {2101
79.4 1106.5)
123.5 {I 65.6)
1,442 {I471 231.7 1310.61
397.2 i532.4)
IO
Min. 5
716 mm 895 mm 1,023 mm
Flywheel Horsepower Running time
3
6
3
3
Engine speed
600 - 700
1,000
1,200
1,200
1,500
1,800
716 mm
0
392 1401
785 {801
1,569 I1601
2,354 {240}
3,119 {3181
895 mm
0
314 {321
706 {721
1,255 11281
1,883 Cl921
2,495 i254.41
1,023 mm
0
275 1281
618 I631
1,648 (1681
2,183 1222.6)
0
29.4 t39.41
70.6 194.6)
1,098 Cl121 141.2 i189.3)
264.8 1355.01
421.0 i564.41
Load D375A-2
Flywheel Horsepower Running time
3
6
3
3
10
Engine speed
650 - 700
1,000
1,200
1,200
1,500
Min. 5 1,700
716 mm
0
392 1401
883 1901
1,373 11401
2,059 I2101
3,236 I3301
895 mm
-
-
-
-
-
-
1,023 mm
-
-
-
-
-
-
Load PC1000-l
Flywheel Horsepower
0
29.4 139.4)
79.4 UO6.51
123.5 {I 65.6)
231.7 1310.6)
412.6 1553.11
Running time
5
15
5
5
20
10
Engine speed
850 - 900
1,000
1,300
1,650
1,900
2,100
0
373 I381
735 I751
2,206 I2251
2,942 {3001
298 130.41
588 I601
1,471 {I501 1,177 I1201
1,765 I1801
2,354 {2401
359 I36.6)
515 152.5)
1,030 Cl051
1,545 U57.5)
2,059 {2101
28.0 137.5)
71.6 {961
182.0 {2441
314.4 t421.51
463.4 1621.21
Load HD465-3 with single turbochage HD500-3
716 mm 895 mm 1,023 mm
Flywheel Horsepower
Running time
3
6
3
3
IO
5
Engine speed
800
1,000
1,200
1,200
1,500
1,800
0
343 1351
686 {701
1,373 {I401
2,059 {210}
2,746 I2801
0
25.8 134.5)
61.8 I82.81
123.6 I165.61
231.8 t310.6)
350.3 I469.3)
Load
716 mm
Flywheel Horsepower
12-035-3 0
3
Engine speed
D375A-1
Pc1000-1 (High altitude spec.)
2
Running time
Load
SA6D170-B-
TEST
2 z z
PERFORMANCE TEST
TESTING AND ADJUSTING
t
The values given for the output is the fan removed.
*
The load (dynamometer)
l-
Engine model
r
Item
6
5
20
10
1,200
1,500
1,500
0
392 {401
1,177 11201
1,961 12001
3,040 {3101
3,432 {350>
Yywheel Horsepower
0
40.3 158
145.5 11951
242.5 1325)
470.0 I6301
530.4 17111
bnning
3
6
3
3
10
Min. 5
‘00 - 900
1,000
1,200
1,200
1,500
1,800
716 mm
0
392 1401
883 {901
1,373 WON
2,059 I2101
3,481 {3551
895 mm
-
-
-
-
-
-
1,023 mm
-
-
-
-
-
-
231.7 (310.6)
470.0 I6301
_oad
speed 716 mm
time
_oad
zlywheel Horsepower
0
29.4 t39.41
79.4 1106.5)
123.5 (165.6)
krnning
3
6
3
3
10
Min. 5 1,800
time
800
1,000
1,200
1,200
1,500
0
392 {40)
883 I901
1,373 U40>
2,059 {2101
3,138 {320}
?ywheel Horsepower
0
29.4 t39.41
79.5 (106.51
123.6 U65.61
231.8 f310.61
458.5 t614.31
Qrnning
3
6
3
3
10
5 1,800
_oad
_oad
speed 716 mm
time speed 716 mm
-lywheel Horsepower
Running time EG500-1 EG500B-1 EG500BSOEM for generator
5
5
ingine :G480B-1 :For CIS)
4
1,200
!ngine SA6D170-B-
3
15
5 50 - 1,000
Engine speed
?SA6D17( .B-1
2
1,000
ingine
fG480-1 EG480B-1 EG500-1 EG500B-1 !G500BS-1
Order
1
Qrnning time
:G450-1
is given for the case of the arm length is 716 mm, 895 mm or 1,023 mm.
Engine speed Load
716 mm
Flywheel Horsepower
min.
150 f 100
1,000
1,200
1,200
1,500
0
40
90
140
210
355
0
39.4
106.5
166
310.6
630
3
6
3
3
IO
5
800
1,000
1,200
1,200
1,500
1,800
0
490 1501
981 {IO01
1,961 {200}
2,942 13001
3,923 {4001
0
36.8 149.31
88.3 {I 18.3)
176.6 f236.6)
331.2 1443.71
530.3 {710.01
12-035-4 0
TESTING
AND ADJUSTING
PERFORMANCE
t
The table gives the standard
*
The load for the dynamometer
-r
values for machines
TEST
without
fan.
are at an arm’s length of 716 mm.
Order
Engine model
Item
OEM for ggyTrar
1
2
3
4
5
Running time
3
6
3
3
3
5
Engine speed
800
1,000
1,200
1,200
1,500
1,800
Load
0
392 1401
883 1901
1,373 U401
2,059 C2101
3,727 {3801
Flywheel Horsepower
0
29.4 (39.4)
79.5 I106.5)
123.6 1165.6)
231.8 f310.61
503.4 l674.41
Running time
3
6
3
3
10
5
Engine speed
800
1,000
1,200
1,200
1,500
1,800
Load
0
539 155)
1,079 UlOI
2,157 {2201
3,236 I3331
4,315 1440)
Flywheel Horsepower
0
40.5 154.2)
97.2 1130.2}
194.3 1260.3)
364.3 {488.1}
582.9 I780.91
Running time
3
6
3
3
10
5
Engine speed
800
1,000
1,200
1,200
1,500
1,800
0
392 {401
834 I851
1,667 I1701
2,501 I2551
3,334 I3401
Flywheel Horsepower
0
29.4 C39.4)
75.1 ClOO.61
150.1 {201.11
281.9 f377.61
375.4 1502.9)
Gnning
3
6
3
3
10
5
800
1,000
1,000
1,000
1,000
1,200
508 HP)
OEM for r,n7epar 559 HP)
OEM for prime use g7rF$r
Load
506 HP)
6
z
SA6D170-B-
3EM for j-pole Jenerator 50Hz)
IEM for j-pole gonezTtor
time
Engine speed _oad
0
471 14481
932 1951
1,863 {I901
2,795 (2851
3,727 13801
+wheel Horsepower
0
35.3 C47.31
69.9 {93.7}
139.8 U87.3)
209.8 1281.01
279.7 1374.7)
3unning time
3
6
3
10
5
%gine speed
800
1,000
1,000
1,200
1,200
1,200
.oad
0
490 I501
981 {loo}
1,961 12001
2,942 {3001
3,923 14001
‘lywheel Horsepower
0
36.8 f49.3)
73.6 198.6)
176.6 I236.61
265.0 {355.0}
353.3 1473.31
Iunning
3
6
3
3
10
5
00 - 850
1,000
1,200
1,200
1,500
1,500
.oad
0
392 I401
1,177 {1201
1,961 {2001
3,040 13101
3,432 13501
:lywheel Horsepower
0
29.4 I39.41
106.0 U42.01
176.6 f236.61
342.2 I458.51
386.4 I517.7)
time
ingine speed IEM for generator
12-035-5 0
3
z z
TESTING
PERFORMANCE
AND ADJUSTING
r
Engine
qunning Engine VA600-1 EC regulaion)
Engine
values
for machines
are at an arm’s
without
length
fan.
of 716 mm.
2
3
4
5
6
6
3
3
10
5
1,000
1,200
1,200
1,500
2,000
390 {401
880 190)
1,370 U40}
2,060 12101
2,160 {2201
124 U681
232 (315)
324 14401
time speed
time speed
Flywheel Horsepower
Engine
gives the standard
1
Load
Running
The load for the dynamometer
Order
Flywheel Horsepower
>ENYO generator xA6OOSSl
The table
*
Item
Load
Running
*
TEST
&
0%
6
3
3
10
5
1,000
1,200
1,200
1,500
1,800
490 1501
980 UOO}
1,960 {2001
2,940 (3001
3,920 {400}
1%
{I%)
176 {2401
331 1450)
529 {720}
time speed
Load Flywheel Horsepower SA6D170-AERunning Engine
time speed
Load Flywheel Horsepower
Running Engine
time speed
Load Flywheel Horsepower
Running Engine
time speed
Load Flywheel Horsepower
12-035-6 @
TESTING
Engine model
AND ADJUSTING
Applicable machine
ienerator 50 Hz only
PERFORMANCE
Item
The table gives the standard
*
The load for the dynamometer
r
values for machines
without
fan.
are at an arm’s length of 716 mm.
Order 1
2
3
4
5
6
Running time
3
6
3
3
IO
5
Engine speed
800
1,000
1,200
1,200
1,500
1,750
Load
0
785 I801
1,569 {I601
3,089 {315}
4,609 I4701
6,374 16501
Flywheel Horsepower
0
58.9 (78.9)
141.3 {I 89.3)
278.2 t372.7)
518.9 1695.11
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
*
TEST
TESTING
PERFORMANCE
AND ADJUSTING
PERFORMANCE
Engine model
TEST CRITERIA
.pplicable nachine
Test item
Specified value (fullyequippe)
F
nAax. torque 275A-2 tiigh idlingspeed 1.owidling speed
C650-1 c1500-1
TEST CRITERIA
2,079 Nm/1,300 rpm 1212 kgm/1,300 rpm1 1,960-2,040 rpm 600-660
rpm
F:lywheel Horsepower
302 kW/1,600 rpm I405 HP/l,800 rpm)
Fwlax.torque
2,030 Nm/1,200 rpm {207 kgm/1,200 rpm)
Elnginespeed (rpm)
l-
Dvnamometerload
(N {kg))
Arm length 716mm
Arm length 895mm
Arm length 1,023 mm
1,795-1,805
2,409 -2,542 245.6-259.2)
1,927 -2,064 196.5 -207.4)
1,686 -1,779 171.9 -181.41
1l,300-1,500
2,924-3,100 298.2 -316.1)
2,340 -2,480 238.6-252.91
2,047 -2,169 208.7 -221.2)
1,960-2,040
-
-
-
600-660
-
-
-
1,595 -1,605
1,818 -1,922 2,598- 2,747 2,078 -2,198 :264.9-280.11 :211.9-224.1) ,185.4- 196.0)
l,lOO-1,300
1,996-2,114 2,281 -2,417 2,852-3,021 :290.8-308.1) :232.6-246.5) ,203.5-215.6)
t
1,700-1,800
-
-
-
1
650-700
-
-
-
S6D170-1 1!,995-2,005
2,143-2,270 1,711 -1,715 1,499 - 1,589 (218.5-231.51 (174.8-185.21 J52.9 - 162.0)
1,961 Nm/1,400 rpm I200 kgm/1,400 rpm}
11,250- 1,450
1,956- 2,046 2,236-2,338 2,795-2,922 (285.0-298.0) (228.0-238.41 :199.5-208.6)
2,200-2,300 rpm
;!,200-2,300
f IVlax.torque VA600-1
I
650-700
I
VA600-1
I-lighidlingspeed ILow
12-036 0
idling speed
-
-
-
-
-
1,634-1,730 1,867 -1,977 (190.4-201.61 [166.6-176.41
1,995-2,005
2,334 - 2,471 1238-2521
2,089 Nm/1,400 rpm (213 kgm/1,400 rpm)
1,300-1,500
2,029 -2,152 2,319 -2,459 2,899-3,073 {295.6-313.41 {236.5-250.71 (206.9-219.4)
2,200-2,300 rpm
:!,300-2,400
I I\nax.torque
-
650-700
rpm
650-700
-
-
-
-
-
8 z z
TESTING * * * * t *
2 G
z
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. Lubrication oil pressure &Pa h/cm2H
Exhaust temperature (‘C)
80-110
294 - 490 {3.0 - 5.0)
Max. 600
70-90
80-110
-
Max. 650
-
70-90
80-110
-
-
70-90
Min. 80
Min. I47 {Min. 1.5}
-
311.9-329.9 {417.9 - 441.9)
-
Min. 21.6
70-90
80-110
343 - 490 13.5 - 5.01
Max. 600
-
2,042 - 2,163 1208.2 - 220.6)
Min. 25.0
70-90
80-110
-
Max. 650
-
-
70-90
80-110
343 - 490 t3.0 - 5.01
-
-
-
70-90
Min. 80
Min. 147 {Min. 1.5)
-
294 - 490 13.0 - 5.01
out put (kW {HP})
Torque (Nm {kgm))
Fuel consumption (set/500 cc)
Coolant temperature (“C)
325.3 - 343.4 (435.8 - 460.1)
-
Min. 19.7
70-90
-
2,095 - 2,226 {213.6 - 226.4)
-
-
Lubrication Niltemperature (“C)
294 - 490 (3.0 - 5.0)
-
321.6 - 340.8 1430.9 - 456.51
-
Min. 19.2
70-90
80-110
-
1,999 - 2,097 f203.8 - 213.81
Min. 22.2
70-90
80-110
-
-
-
70-90
80-110
294 - 490 f3.0 - 5.01
-
-
-
-
70-90
80-110
Min. 147 {Min. 1.5)
-
350.3 - 370.9 1469.3 - 496.9)
-
Min. 17.5
70-90
so - 120
324 l3.3 -1
Max. 600
-
2,075 - 2,230 {211.6 - 227.4)
-
70-90
so - 120
-
-
-
70-90
so - 120
-
-
-
-
Min. 70
Min. 80
-
-
-
Max. 600
Max. 650
Max. 650
12-037 0
TESTING
PERFORMANCE
AND ADJUSTING
Applicable machine
Test item
Specified
Flywheel Horsepower
Engine speed (rpm)
value
385 kW/1,800 1516 PS/1,800
rpm rpm}
TEST CRITERIA
Dynamometer (N {kg])
Load
1,795 - 1,805
2,937 - 3,015 (299.5 - 307.51
Max. torque
-
-
-
High idling speel
-
-
-
Low idling speer
-
-
-
!PS6D170.
Flywheel Horsepower 3EM for Jenerator Prime USE
324 {434 371 I497
Max. 1,560 rpm Max. 1,872 rpm
Low idling speec S6D170-1 Flywheel Horsepower
355 {476 408 I547
3EM for generator Power up
Max. torque High idling spee, Low idling speec
12-037-l 0
Hz) Hz) Hz) Hz)
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)
(50 Hz) (60 Hz)
kW/1,500 HP/l,500 kW/1,800 HP/l,800
rpm rpm} rpm rpm}
(50 (50 (60 (60
Hz) Hz) Hz) Hz)
(50 Hz) (60 Hz)
kW/1,500 HP/l,500 kW/1,800 HP/l,800
-
-
3,119 I318.0 3,011 I307.0
rpm rpm} rpm rpm}
(50 (50 (60 (60
Hz) Hz) Hz) Hz)
(50 Hz) (60 Hz)
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)
700 - 900 rpm
Max. 1,560 Max. 1,872
(50 Hz) (50 Hz) (60 Hz) (60 Hz)
-
(50 Hz) (60 Hz)
-
Max. 1,560 rpm Max. 1,872 rpm
1,575 1,890
- 3,589 - 366.0) -3,168 - 323.0)
-
-
700 - 800
700 - 800 rpm
3,001 (50 Hz) 306.0) (50 Hz) 2,893 (60 Hz) 295.0) (60 Hz)
-
1,795 - 1,805 (60 Hz)
Max. Max.
-
-
-
Max. 1,575 rpm Max. 1,890 rpm
345 {462 403 {539
2,844 1290.0 2,736 1279.0
-
1,495 - 1,505 (50 Hz)
-
Low idling speec
Flywheel Horsepower
(50 (50 (60 (60
700 - 800 rpm
Max. torque High idling speel
rpm rpm} rpm rpm}
-
Max. torque High idling speel
3EM for generator Stand by use)
kW/1,500 HP/l,500 kW/1,800 HP/l,800
3,109 t317.0 3,040 C310.0
- 3,197 (50 Hz) - 326.0) (50 Hz) - 3,128 (60 Hz) -319.0) (60 Hz) -
(50 Hz) (60 Hz)
700 - 900
-
8
G
z
TESTING
* *
*
PERFORMANCE
AND ADJUSTING
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 arm’s length of 716 mm Flywheel horsepower (kW {HP})
Torque (Nm (kgm})
396.9 - 407.9 f531.6 - 546.4)
Fuel consumption (set/200 cc)
Coolant temperature (“0
Lubrication #iItemperature (“C)
80-110
Lubrication oil pressure (kPa {kg/cm*}) 294 - 490 13.0 - 5.01
Min. 15.9
70-90
-
-
-
70-90
80-110
-
-
-
Min. 70
Min. 80
-
535.8 - 568.2 t717.8 - 761.2)
Min. 12.3
70-90
80-110
-
-
-
-
-
Exhaust temperature (“C)
Max. 650
-
294 - 490 13.0 - 5.01
-
-
Max. 650
Max. 650
-
-
-
70-90
80-110
294 - 490 l3.0 - 5.01
-
-
-
70-90
Min. 80
Min. 147 {Min. 1.51
-
374.6 - 398.2 1501.9 - 533.8
Min. 16.5
70-85
80-110
294 - 490 (3.0 - 5.01
Max. 620
-
-
-
-
70-85
80-110
-
-
70-85
Min. 80
Min. 147 {Min. 1.51
-
Min. 18.5
70-85
80-110
343 - 490 it. I y;
Min. 15.8
70-85
80-110
2 z z
350.3 {469.3 410.7 1550.2 -
360.4 (50 483.1} (50 423.2 (60 567.0}(60
Hi Hi Hz Hi
-
-
-
-
-
-
-
t3.5 - 5.01
Max. 600 Max. 650
-
70-85
80-110
343 - 490 13.5 - 5.01
Min. 70
Min. 80
Min. 177 {Min. 1.8)
V-037-2 0
TESTING
PERFORMANCE
AND ADJUSTING
Engine model
Test item
Flywheel Horsepower iD465-3 with single urboharger, twir urboharger)
Max. torque
SA6D170-A-
504 kW/2,100 1702 HP/2,100 2,824 Nm/1,400 I288 kgm/1,400
rpm rpm} rpm rpm)
ngine speed (rpm)
l-
Dynamometer
load (N {kg})
Arm length 716 mm
Arm length 895 mm
Arm length 1,023 mm
!,095 - 2,105
3,413 - 3,501 346.0 - 357.01
!,730 - 2,801 278.4 - 285.61
2,389 - 2,451 243.6 - 249.91
1,350 - 1,450
3,825 - 4,070 390.0 - 415.01
$060 - 3,256 312.0 - 332.01
2,677 - 2,849 273.0 - 290.5)
High idling spee’
2,250 - 2,380 rpm
2,250 - 2,350
-
-
Low idling spee,
850 - 900 rpm
;50 - 700 (*l) 140 - 940 (‘21
-
-
Flywheel Horsepower iD465-5 with mechnical governor)
Specified value (fully equippe)
Max. torque
High idling speem
Low idling spee,
Flywheel Horsepower Max. torque
533 kWl2.100 I715 HP/2,100 2,971 Nm/1,400 {303 kgm/1,400
rpm rpm) rpm rpm}
TEST CRITERIA
$095 - 2,105
3,400 - 3,605 346.7 - 367.6;
1,300 - 1,500
4,081- 4,327 416.1 - 441.2:
2,400 - 2,500 rpm
?,400 - 2,500
-
-
-
900 - 950 rpm
900 - 950
-
-
-
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
2,626 - 2,788 267.8 - 284.3:
2,298 - 2,440 :234.3 - 248.8)
1,300 - 1,500
3,892 - 4,134 396.9 - 421.5:
3,114-3,307 317.5 - 337.2
2,724 - 2,894 :277.8 - 295.1)
NA700-1
c1: With5 “2 : With t
12-037-3 0
High idling spee
2,240 - 2,300 rpm
2,240 - 2,300
-
-
-
Low idling speel
700 - 750 rpm
700 - 750
-
-
-
gte ruroocnarger n turbocharger
TESTING
* t * * * *
AND ADJUSTING
out put (kW{HPI)
Torque (Nm {kgm))
537.3 - 552 1720.0 - 739.5)
-
-
2,736 - 2,913 1279.0 - 297.01
-
-
-
-
-
G
z
TEST CRITERIA
The values in the table are indicated at standard conditions (Armospheric temperature 25”C, 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.
535.8 - 568.2 1717.8 - 761.2)
2
PERFORMANCE
Fuel consumption (set/500 cc)
Coolant temperature (‘C)
Lubrication )il temperature (“C)
Lubrication oil pressure (kPa {kg/cm?)
Min. 12.0
70-90
80-110
196 - 392 i2.0 - 4.0)
Max. 550
Min. 15.5
70-90
80-110
196 -392 12.0 - 4.0)
Max. 600
-
70-90
80-110
196-392 i2.0 - 4.0)
-
70-90
Min. 80
Min. 147 {Min. 1.51
Min. 11.6
70-90
80-110
Max. 650
70-90
80-110
Max. 670
70-90
80-110
-
70-90
Min. 80
Min. 147 {Min. 1.5)
-
70-95
80-110
294 - 490 (3.0 - 5.0)
Max. 650
70-95
80-110
-
Max. 650
70-80
80-110
294 - 490 I3.0 - 5.01
70-80
Min. 80
Min. 147 {Min. 1.5}
2,922 - 3,099 t298.0 - 316.0)
492.6 - 523.1 1659.9 - 700.81
-
-
2,787 - 2,954 1284.2 - 301.81
Min. 13.6
-
-
-
Exhaust temperature (“0
-
12-037-4 0
TESTING
Engine model
AND ADJUSTING
Applicable machine
PERFORMANCE
Test item
Flywheel Horsepower Max. torque
Specified
value
434 kWll.750 rpm (582 HP/l ,750 rpm) 2,731 Nm/1,300 (278 kgm/1,300
rpm rpm}
Engine speed (rpm)
TEST CRITERIA
Dynamometer (N (kg])
Load
1,755
3,376 - 3,573 (344.3 - 364.31
1,200 - 1,400
3,808 - 4,038 (388.3 - 411.8)
1,900 - 2,000
-
650 - 700
-
2,095 - 2,105
3,400 - 3,605 (348.7 - 367.6)
1,300 - 1,500
4,081 - 4,327 (416.1 - 441.21
2,330 - 2,440
-
920 - 970
-
1,995 - 2,105
2,377 - 2,526 (242.4 - 257.61
1,300 - 1,500
2,856 - 3,026 (291.9 - 308.61
8 ;;;
1,745-
Pc1ooosP~ High idling spee d
Low idling spee d
Flywheel Horsepower HD465-5 (with electronic governor)
Max. torque
High idling spee d
Low idling spee d
Flywheel Horsepower HD465-5 (Hifh altitude spec
Max. torque
1,900 - 2,000
rpm
650 - 700 rpm
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
920 - 970 rpm
387 kW/2,100 (518 HP/2,100 2,108 Nm/1,400 (215 kgm/1,400
rpm rpm} rpm rpml
High idling spee d
2,330 - 2,400
rpm
2,330 - 2,400
-
Low idling spee d
1,075 - 1,125 rpm
1,075 - 2,400
-
1,995 - 2,005
3,496 - 3,677 (356.5 - 375.01
1,300 - 1,500
Min. 3,496 (Min. 356.5)
2,100 - 2,200
-
550 - 600
-
2,000
3,638 - 3,677 (371 - 375)
1,300 - 1,500
Min. 4,328 (Min. 432.81
2,100 - 2,200
-
SA6D170-AFlywheel Horsepower Max. torque
552 kW/2,000 (740 HP/2,000 2,501 Nm/1,400 {255 kgm/1,400
rpm rpm} rpm rpm)
EM680A High idling spee d
Low idling spee d
Flywheel Horsepower Max. torque EM680-A 6M170B-1 High idling spee d
Low idling spee d
Flywheel Horsepower Max. torque
2,100 - 2,200
rpm
550 - 600 rpm
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
550 - 600 rpm
629 kW/2,000 (842 HP/2,000 3,295 Nm/1,400 (336 kgm/1,400
rpm rpm} rpm rpml
550 - 600
1,995 - 2,005
4,084 - 4,291 {416.5 - 437.51
1,300 - 1,500
Min. 4,602 (Min. 469.3)
2,100 - 2,200
-
550 - 600
-
EM680A-A High idling spee d
--L *I
12-037-5 0
: Without
Low idling spee’ d manne
gear
2,100 - 2,200
rpm
550 - 600 rpm
z
TESTING
* *
*
PERFORMANCE
AND ADJUSTING
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 arm’s length of 716 mm Flywheel horsepower (kW {HP))
Torque (Nm Ikgml)
443.4 - 469.2 t594.1 - 628.61
-
-
535.8 - 568.2 {717.8 - 761.2)
Lubrication oil pressure (kPa {kg/cm21)
70-90
80-110
343 - 490 13.5 - 5.0)
Max. 700
-
70-90
80-110
343 - 490 {3.5 - 5.0)
Max. 700
-
70-90
80-110
343 - 490 13.5 - 5.01
-
-
70-90
Min. 80
Min. 147 {Min. 1.5)
-
70-90
80-110
294 - 490 (3.0 - 5.0)
70-90
80-110
70-90
80-110
294 - 490 {3.0 - 5.0)
-
70-90
Min. 80
Min. 147 {Min. 1.51
-
70-85
80-110
294 - 490 {3.0 - 5.0)
-
70-85
80-110
-
-
70 - 85
80-110
-
70 - 85
Min. 80
Min. 147 {Min. 1.5) 294 - 490 13.0 - 5.01
14.9
Min. 2,922 - 3,099 1298.0 - 316.0)
-
Lubrication %I temperature YC)
Min. 2,727 - 2,892 {278.1 - 294.9)
12.0 -
-
374.6 - 398.2 1501.9 - 533.41
Min. 2,050 - 2,167 {209 - 221)
-
16.5
-
-
524.8 - 552.0 (703.0 - 739.5)
-
Min.
12.9
70 - 95
80-110
-
Min. 2,501 {Min. 255.0)
Min.
18.8
70 - 95
80-110
-
70 - 95
80-110
-
70-95
Min. 80
-
546.1 - 552.0 i731.6 - 739.5)
-
-
Min. 3,040 {Min. 310)
Min.
12.2 -
-
-
613.1 - 644.0 i821.3 - 862.8)
-
Min.
Min. 3,295 {Min. 336)
Min.
-
-
-
70 - 90
80-110
70-90
80-110
70 - 90
80-110
Max. 650
Max. 670
Max. 620 -
-
-
Max. 650
Max. 650 Min. 147 {Min. 1.5} 294 - 490 t3.0 - 5.0)
-
Max. 600
Max. 600 -
70 - 90
Min. 80
Min. 147 {Min. 1.5)
10.7
70 - 90
80-110
294 - 490 {3.0 - 5.0)
Max. 600
14.8
70 - 90
80-110
-
Max. 600
70 - 90
80-110
70-90
Min. 80
-
-
Exhaust temperature (“C)
Coolant temperature (“0
Fuel consumption (set/500 cc)
-
Min. 147 {Min. 1.5)
-
12-037-6 a9
TESTING
Engine model
PERFORMANCE
AND ADJUSTING
splicable nachine
Test item
3550-I
Dynamometer Arm length 716 mm
rpm rpm)
1,495 - 1,505
4,008 - 4,242 408.7 - 432.6)
(60Hz)
473 kW/1,800 {634 HP/l,800
rpm rpm}
1,795 - 1,805
3,716 - 3,933 378.9 -401.11
speed (50Hz)
Max.
1,560 rpm
Max.
1,560
0
(60Hz)
Max.
1,872 rpm
Max.
1,872
0
speed
700-800
rpm
456 kW/1,500 {611 HP/l,500
rpm rpm}
1,495-
(60Hz)
502 kW/1,800 {673 HP/l,800
rpm rpm)
1,795 - 1,805
idling
0
750 z!C50
+wheel (50Hz) -lorsepower
iigh
L
T
431 kW/1,500 {578 HP/l,500
Low idling
35808-l
ingine speed (rpm)
+wheel (50Hz) Horsepower
High idling
3580-I 35808-l
Specified value (fully equippe)
1,505
TEST CRITERIA
load (N {kg))
Arm length 895 mm
Arm length 1,023 mm
-
-
-
-
4,126 - 4,256 420.7 - 434.0)
3,301 - 3,405 336.6 - 347.2)
!,888 - 2,979 Z94.5 - 303.81
3,825 - 3,933 390.0 -461.11
3,060 - 3,145 312.0 - 320.8)
!,677 - 2,753 !73.0 - 280.7)
speed (50Hz)
Max.
1,560 rpm
Max.
1,560
-
(60Hz)
Max.
1,872 rpm
Max.
1,872
-
-
-
700 - 900
-
-
-
1,495 - 1,505
4,276 - 4,393 1436 - 4481
1,550 - 1,560
-
700 - 900
-
700 - 900 rpm
-
_ow idling
speed
3ywheel iorsepower
(50Hz)
-iigh idling
speed (50Hz)
_ow idling
speed
-lywheel iorsepower
(50Hz)
470 kW/1,500 {630 HP/l,500
rpm rpm)
1,495 - 1,505
4,249 - 4,381 433.3 - 446.7)
3,399 - 3,504 346.6 - 357.3)
1,974 - 3,066 103.3 - 312.61
(60Hz)
513 kW/l,SOO rpm 1688 HP/l,800 rpm}
1,795 - 1,805
3,906 - 4,015 398.3 - 409.41
3,124-3,212 318.6 - 327.51
1,734 - 2,810 !78.8 - 286.5)
472kW/1,500 I633 HP/l,500
Max.
rpm rpm)
1,560 rpm
700 - 900 rpm
3,450 - 3,515 348.8 - 358.4)
-
!,993 - 3,075 $05.2 - 313.6}
-
-
SAGDI 70-A.
3600-I 36008-l 3600BS-1 IM for nerator
iigh
idling
_ow idling
speed (50Hz)
Max.
1,560 rpm
Max.
1,560
(60Hz)
Max.
1,872 rpm
Max.
1,872
speed
Flywheel Horsepower
12-038 0
-
-
-
-
700 - 900
440 kW/l,SOO rpm I590 HP/l,800 rpm)
1,795 - 1,805
3,304 - 3,503 (336.9 - 357.2
2,643 - 2,803 L269.5 - 285.8
2,312 - 2,452 235.8 - 250.0)
1,200 - 1,400
3,670 - 3,888 L374.2 - 396.5
2,936 - 3,111 :299.4 - 317.2
2,568 - 2,721 261.9 - 277.5)
rpm rpm]
High idling
speec
1,950 - 2,050 rpm
1,950 - 2,050
-
-
-
Low idling
speed
750 - 850 rpm
750 - 850
-
-
-
1,995 - 2,065
3,291 - 3,495 F335.6 - 356.4
-
-
1,200 - 1,400
3,786 - 4,020 L386.1 - 409.9
-
-
-
Flywheel Horsepower
D465-3 or ORAP rllNE)
-
700 - 900 rpm
2,648 Nm/l,300 I270 kgm/1,300
Max. torque PSAGDI? -A.
-
-
504 kW/2,000 {675 HP/2,000 2,795 Nm/1,300 I285 kgm/1,300
Max. torque
rpm rpm) rpm rpml
High idling
speec
2,250 - 2,350 rpm
2,250 - 2,350
Low idling
speed
840 - 860 rpm
840 - 860
TESTING * t * * * *
PERFORMANCE
AND ADJUSTING
TEST CRITERIA
The values in the table are indicated at standard conditions (Armospheric temperature 25”C, 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. Lubrication oil pressure (kPa {kg/cm%
put (kW {HP))
Torque (Nm {kgm})
Fuel consumption (set/500 cc)
Coolant temperature (‘Cl
LLlbrication oil tlemperature (“C) -
450.6 - 477.4 I604.0 - 640.0)
-
27.0 - 28.5
70-90
80-115
265 - 392 (2.7 - 4.0)
Max. 650
501.3 - 531.2 I672.0 - 712.01
-
24.0 - 25.0
70-90
80-115
294 - 441 13.0 - 4.51
Max. 650
-
70-90
80-115
-
70-90
SO-115
out
Exhaust temperature (‘C)
-
-
-
-
-
70-90
Min. 80
Min. 147 {Min. 1.51
-
464.2 - 478.9 1622.2 - 641.9)
-
Min. 26.0
70-85
80-110
265 - 392 {2.7 - 4.0)
Max. 650
516.4531.1 t692.2 - 711.9)
-
Min. 23.4
70-85
80-110
294 - 441 13.0 - 4.51
Max. 650
-
70-85
80-110
-
70-85
80-110
-
70-85
-
-
-
-
Min. 80
Min. 147 {Min. 1.5)
-
Max. 650
480.3 - 494.2 W3.8 - 662.5)
-
Min. 13.7
70-85
80-110
265 - 392 (2.7 - 4.0)
-
-
-
70-85
80-110
-
-
-
-
70-85
Min. 80
Min. 147 {Min. 1.5)
478.1 - 492.8 WO.9 - 660.61
-
80-110
265 - 392 12.7 - 4.0)
Max. 650 Max. 650
8 z z
-
527.4 - 542.1 I707.0 - 726.7)
-
0
0
-
70-85
Min. 22.9
70-85
80-110
294 - 441 13.0 - 4.5)
0
70-85
80-110
-
-
80-110
-
-
0
0
446.1 - 473.0 1598.0 - 634.01
Min. 25.2
70-85
0
70-85
Min. 80
Min. 147 {Min. 1.5)
Min. 14.4
70-85
80-110
294 - 441 {3.0 - 4.5)
-
Max. 650
2,628 - 2,785 1268 - 2841
-
70-85
80-110
-
-
-
-
70-85
80-110
-
-
-
-
70-85
Min. 80
Min. 147 {Min. 1.5)
-
80-110
294 - 490 I3.0 - 5.01
Max. 680
488.6 - 519.2 I655 - 6961
-
-
2,712 - 2,879 1276.5 - 293.61
-
80-110
-
-
-
-
-
80-110
-
-
-
-
Min. 80
Min. 25
Min. 147 {Min. 1.5)
12-039 0
TESTING
Engine model
PERFORMANCE
AND ADJUSTING
Applicable machine
?ywheel Horsepower
3EM for generator
Specified
Test item 473 (633 546 (732
470 kW/1,500 1630 HP/l,500 514 kW/1,800 {688 HP/l,800
OEM for generator (Prime use
Flywheel Horsepower OEM for generator (::;d
by
Max. torque High idling spee
(50 (50 (60 (60
Hz) Hz) Hz) Hz)
419 kW/1,500 (561 HP/l,500 467 kW/1,800 1625 HP/l,800
(50 Hz) (60 Hz)
rpm rpm} rpm rpm}
(50 (50 (60 (60
Hz) Hz) Hz) Hz)
Max. 1,568 rpm Max. 1,881 rpm
(50 Hz) (60 Hz)
(50 Hz) (50 Hz) (60 Hz) (60 Hz)
Max. 1,568 (50 Hz) Max. 1,881 (60 Hz)
-
700 - 900
-
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)
4,119-4,374 (420 - 4461 3,766 - 3,991 {384 - 4071
(50 Hz) (50 Hz) (60 Hz) (60 Hz)
-
Max. 1,568 (50 Hz) Max. 1,881 (60 Hz)
-
700 - 900
-
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 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)
rpm rpm} rpm rpm}
(50 (50 (60 (60
Hz) Hz) Hz) Hz)
(50 Hz) (60 Hz)
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)
(50 Hz) (60 Hz)
Max. 1,575 Max. 1,890
Min. 5,237 (50 Hz) {Min. 5341 (50 Hz) 5,080 - 5,384 (60 Hz) (518 - 549) (60 Hz)
-
-
Max. 1,575 rpm Max. 1,890 rpm
Max. 1,568 Max. 1,881
(50 Hz) (60 Hz)
-
1,995 - 2,005
3,589 - 3,677 (366 - 3751
-
-
-
High idling spee
2,100 - 2,200 rpm
2,100 - 2,200
-
Low idling spee
550 - 600 rpm
550 - 600
-
512 kW/1,800 rpm I686 HP/l ,800 rpm)
1,795 - 1,805
3,560 - 3,724 {363 - 379.7)
-
-
-
High idling spee
Max. 2,200 rpm
Max. 2,200
-
Low idling spee
600 - 1,000 rpm
600 - 1,000
-
Flywheel Horsepower Max. torque
700 - 900 rpm
552 kW/2,000 I740 HP/2,000
rpm rpm}
OEM for marine
Flywheel Horsepower
12-039-l 0
4,395 4481 4,266 435)
700 - 900
Low idling spee
EPSAGDli -A-l (512 kW/ 686 HF
-
-
700 - 900
700 - 900 rpm kW/1,500 HP/l,500 kW/1,800 HP/l,800
1,795 - 1,805 (60 Hz)
4,276 I436 4,148 (423
Load
-
-
581 {779 672 (900
1,495 - 1,805 (50 Hz)
-
700 - 900 rpm
Low idling spee SA6D170-A-
rpm rpm} rpm rpm}
Max. 1,568 rpm Max. 1,881 rpm
Max. torque High idling spee
(50 Hz) (60 Hz)
-
Low idling speem
Flywheel Horsepower
Hz) Hz) Hz) Hz)
950 - 900 rpm
Wax. torque High idling spee
(50 (50 (60 (60
Dynamometer (N {kg])
-
Max. 1,560 rpm Max. 1,881 rpm
_ow idling speel
+wheel Horsepower
rpm rpm} rpm rpm1
-
Vlax. torque iigh idling specs
EGGOOBS-’ OEM for generator ;Engine No. 15503 and ur
kW/1,500 HP/l,500 kW/1,800 HP/l,800
Engine speed (rpm)
value
TEST CRITERIA
Max. torque
TESTING
t *
AND ADJUSTING
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 arm’s length of 716 mm
*
Flywheel horsepower (kW WR) 480.6 1643.9 560.1 1750.3
463.7 1621.2 508.6 1681.3
8
PERFORMANCE
413.6 1554.1 465.9 1624.1
z z
Min. {Min. 686.0 I919.0
Torque (Nm {kgrn))
- 494.6 (50 H2 - 662.6) (50 H2 - 576.3 (60 Hz -772.0) (60 Hi
Coolant temperature (“C)
Lubrication )il temperature (“C)
Lubrication oil pressure Wa {kg/cm*)) 255 - 441 y.. I “&1
-
Min.
13.7
70-85
80-110
-
Min.
11.4
70-85
80-110
12.6 - 4.5)
Exhaust temperature (“C) Max. 650 Max. 650
-
-
-
-
-
-
-
-
-
-
70-85
80-110
255 - 441 l2.6 - 4.5)
-
-
-
-
Min. 70
Min. 80
Min. 147 {Min. I.51
-
343 - 441 $3.3” I &5;
- 492.4 (50 Hz - 629.6) (50 Hi - 539.5 (60 Hz -722.7) (60 H2
-
Fuel consumption (set/500 cc)
-
Min.
14.0
70 - 85
80 - 105
-
Min.
12.4
70-85
80 - 105
l3.5 - 4.5)
Max. 650 Max. 650
-
-
-
-
-
70-85
80 - 105
343 - 441 13.5 - 4.51
-
-
-
Min. 70
Min. 85
Min. 147 {Min. 1.5}
-
440.1 (50 Hz 589.6) (50 H2 495.3 (60 Hz 663.6) (60 H2
-
-
Min.
15.0
70 - 85
80-110
-
Min.
13.3
70-85
80-110
-
-
-
-
-
70-85
-
-
589.5 (50 789.9) (50 - 727.2 (60 -974.2) (60
Hz Hz Hz H2
-
-
Min.
11.3
Min. 9.3
-
-
-
255 12.6 255 12.6
-
-
441 4.5) 441 4.5)
Max. 650 Max. 650
-
-
80-110
255 - 441 12.6 - 4.5)
-
Min. 70
Min. 80
Min. 98 {Min. 1.0)
-
70-85
80-110
226 - 392 :‘i; 1 y.
70-85
80-110
-
-
12.3 - 4.0)
Max. 700 Max. 700
-
-
-
-
70-85
80-110
226 - 392 12.3 - 4.0)
-
-
-
Min. 70
Min. 80
Min. 147 {Min. 1.5)
-
538.0 - 552.0 1720.8 - 739.5)
Min.
12.4
-
80-90 -
-
-
533.9 - 558.9 i715.2 - 748.8)
-
-
-
-
Min.
11.7
90-110 -
294 - 490 (3.0 - 5.01
Max. 650
-
-
80-90
90-110
294 - 490 c3.0 - 5.0)
-
Min. 80
Min. 90
Min. 147 {Min. 1.5}
-
70-90
80-110
294 - 490 13.0 - 5.0)
Max. 650
-
-
-
-
70-90
80-110
294 - 490 13.0 - 5.0)
-
Min. 70
Min. 80
Min. 147 {Min. 1.5)
-
12-039-2
@
TESTING
Engine model
PERFORMANCE
AND ADJUSTING
4pplicable machine
Test item
:lywheel Horsepower Wax.torque 1375A-1 iigh idlingspeed
load (N {kg))
inginespeed @pm)
309 kW/1,800 rpm {608 HP/l,800 rpm}
1,795 -1,805
2,354-2,497 2,942 -3,121 (300.0-318.3) (240.0-254.61
!,059-2,185 !lO.O-222.8)
2,609 Nmil.300 rpm {266kgm/1,300rpm)
1,200 -1,400
2,925 - 3,104 3,657 -3,880 (372.9-395.6) {298.3-316.5)
1,560-2,715 !61.0-276.91
1,950-2,050 rpm
1,950 -2,050
rpm
600-700
Arm length 716mm
Arm length 895mm
4rm length 1,023 mm
0
0
0
0
0
0
+wheel Horsepower
392 kW/1,800 rpm 1525 HP/l,800 rpm)
1,795-1,805
2,423- 2,567 3,029 -3,209 (308.9-327.2) i247.1-261.81
!,I20-2,246 !16.2-229.0)
Irlax.torque
2,618 Nm/1,300 rpm 1267 kgm/1,300 rpm}
1,200- 1,400
3,014-3,199 3,767 -3,999 (384.1-407.8) (307.3-326.21
!,636-2,799 !68.8-285.4)
1,950-2,050 rpm
1,950 -2,050
D375A-2 iigh idlingspeed
580-680
_owidling speed +wheel Horsepower Max.torque Pc1000-1
rpm
580-680
0
0
0 !,258- 2,389 Z30.3-243.6)
2,550 Nm/1,300 rpm 1260 kgm/1,300rpm)
1,200-1,400
2,832 -2,997 3,540-3,746 {361.0-382.0) {288.8-305.61
!,478-2,622 252.7-267.4)
2,481 Nm/1,400 rpm (253 kgm/1,400 rpm) 2.350-2.450 rpm 800-900
Low idling speed
0
2,581 - 2,730 3,226-3,413 (329.0-348.0) (263.2-278.41
SA6D170-B-
High idlingspeed
0
1,695-1,705
650-700
HD465-3 Max.torque with single turbocharge
0
405 kW/1,700rpm {542 HP/l,700 rpm}
1,800-1,900
HD500-3
Dvnamometer
Specified value (fully equippe)
600-700
_owidling speed
T
TEST CRITERIA
rpm
0
0
0
0
0
0
2,095 -2,105
2,358 -2,499 2,947 -3,123 (300.5-318.5) 1240.4-254.8:
1,063-2,187 210.4-223.0)
1,300- 1,500
2,730 -2,879 3,413 -3,599 {348.0-367.0) 1278.4-293.6:
1,389 - 2,519 243.6-256.91
2,350-2,450
0
0
0
800-900
0
0
0
I
1,495-1,505
3,217-3,203 (328.0-326.6)
-
406kW/1,800 rpm (544 HP/l,800 rpm)
1,795-1,805
3,057 -3,230 {311.7-329.4)
-
High idling speed (50Hz)
Max.1,560 rpm
Max.1,560
0
-
(60Hz)
Max. 1,872 rpm
Max. 1,872
0
-
950 -1,000 rpm
950-1,000
0
-
Flywheel (50Hz) 351 kW/1,500 rpm (481 HP/l,500 rpm} Horsepower (60Hz) EG450-1
Low idling speed
2,699 -2,782 3,373 -3,478 {344.0-354.7) (275.2-283.7
2,361-2,434 240.8-248.2)
416 kW/1,800 rpm (557 HP/l,800 rpm1
1,795 -1,805
2,545 -2,619 3,181 -3,274 (324.4-333.91 (259.5-267.1
2,226-2,292 227.0-233.7)
High idlingspeed (50Hz)
Max.1,560 rpm
Max. 1,560
0
0
0
(60Hz)
Max.1,872 rpm
Max. 1,872
0
0
0
0
0
0
(60Hz)
Low idling speed
12-040 0
-
1,495 -1,505
Flywheel (50Hz) 372 kW/1,500 rpm 1498 HP/l,500 rpm} Horsepower
EG480-1 EG480B-1
-
700-900
rpm
700-900
8 ;;
z
TESTING * * * * * *
Lubrication oil pressure (kPa {kg/cm%
Exhaust temperature (“C)
Coolant temperature (‘C)
Lubrication #iItemperature (“C)
Min. 17.0
70-90
80 - 100
2,569 - 2,778 I262.0 - 283.31
Min. 19.3
70-90
80 - 100
0
0
-
70-90
80 - 100
294 - 490 13.0 - 5.01
-
0
0
-
70-90
Min. 80
Min. 245 {Min. 2.5)
-
294 - 490 t3.0 - 5.01
put (kW {HP})
Torque (Nm {kgm))
397.3 - 421.5 I532.2 - 564.7)
-
-
Fuel consumption (set/500 cc)
294 - 490 {3.0 - 5.01 -
Max. 550
Max. 600
409.2 - 433.5 I546.2 - 590.8)
-
Min. 16.5
70-90
80-110
-
2,697 - 2,859 l275.0 - 291.51
-
70-90
80-110
0
0
-
70-90
80-110
294 - 490 13.0 - 5.01
-
0
0
-
70-90
Min. 80
Min. 147 {Min. 1.5)
-
70-90
80-110
343 - 490 (3.5 - 5.0)
Max. 700
411.4 - 435.7 t551.2 - 583.7)
-
Min. 16.3
-
Max. 650
Max. 650
2,534 - 2,682 l258.4 - 273.51
-
70-90
80-110
-
Max. 700
0
0
-
70-90
80-110
343 - 490 (3.0 - 5.0)
-
0
0
-
70-90
Min. 80
Min. 147 {Min. 1.5)
-
294 - 490 13.0 - 5.01
-
z z
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 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
2
PERFORMANCE
AND ADJUSTING
457.9 - 485.5 1622.1 - 659.6)
-
Min. 13.1
70-85
80-
-
2,442 - 2,579 1249.0 - 263.01
-
70-85
80-110
0
0
-
70-85
80-110
294 - 490 f3.0 - 5.01
-
0
0
-
70-85
Min. 80
Min. 147 {Min. 1.5)
-
110
-
Max. 650
Max. 650
351.1 - 370.9 (50 Hz {477.0 - 504.01(50 H2
-
23-27
70 - 100
100 - 120
245 - 392 (2.5 - 4.01
Max. 680
400.4- 423.2 (60 Hz W4.0 - 575.01(60 H2
-
26-30
70 - 100
100 - 120
245 - 392 (3.0 - 4.51
Max. 650
0
-
70 - 100
100-120
0
-
70 - 100
0
-
70 - 100
-
-
100 - 120
-
-
Min. 100
245 - 392 {3.0 - 4.5)
-
516.0 - 532.0(50 Hz I508.8 - 524.61(50 H2
-
Min. 17.5
70 - 85
80-110
265 - 392 12.7 - 4.0)
Max. 650
584.0 - 601.0 (60 H2 I575.8 - 592.61(60 Hz
-
Min. 15.5
70-85
80-110
294 - 441 l3.0 - 4.5)
Max. 650
0
-
70-85
80-110
-
-
0
-
70-85
80-110
-
-
Min. 147 {Min. 1.5)
-
0
-
70-85
Min. 80
12-041 0
TESTING
AND ADJUSTING
Engine model
iG550-1 iG500B-1 iG500BS-1
PERFORMANCE
Test item
Specified value (fully equippe)
Sngine speec (rpm)
Flywheel (50Hz Horsepower
383 kW/1,500 rpm (513 HP/l,500 rpm}
(6OH2
12-041-l 0
Dvnamometer load
ir {kg})
Arm length 716 mm
Arm length 895 mm
Arm length 1,023 mm
1,495 - 1,505
3,472 - 3,576 364.0 - 364.7
2,777 - 2,861 283.2 - 291.7
2,430 - 2,503 247.8 - 255.2}
427 kW/1,800 rpm I572 HP/l,800 rpm}
1,795 - 1,805
3,264 - 3,351 332.8 - 341.7
2,611 - 2,680 266.2 - 273.3
2,284 - 2,345 232.9 - 239.1)
High idling speec (50Hz
Max. 1,560 rpm
Max. 1,560
0
0
0
(6OH2
Max. 1,872 rpm
Max. 1,872
0
0
0
700 - 900 rpm
700 - 900
0
0
0
Flywheel Horsepower
408 kW/1,800 rpm I540 HP/l,800 rpm)
1,795 - 1,805
3,039 - 3,216 309.9 - 327.9
2,431 - 2,572 247.9 - 262.3
2,127 - 2,251 216.9 - 229.5}
Max. torque
2,461 Nm/1,300 rpm (251 kgm/1,300 rpm)
1,200 - 1,400
3,410 - 3,628 347.7 - 370.0
2,728 - 2,903 278.2 - 296.0
2,383 - 2,540 243.3 - 259.01
High idling speec
1,950 - 2,050 rpm
1,950 - 2,050
-
-
-
Low idling speec
750 - 850 rpm
750 - 850
-
-
-
Flywheel Horsepower (Prime use
359 kW/1,500 rpm {488 HP/l,500 rpm}
1,495 - 1,505
3,210 - 3,406 327.3 - 347.3
-
-
(Standby use)
397 kW/1,500 rpm {540 HP/l,500 rpm}
1,495 - 1,505
3,655 - 3,759 372.7 - 383.3,
-
-
High idling speec
Max. 1,560 rpm
Max. 1,560
-
-
-
Low idling speec
700 - 900 rpm
700 - 900
-
-
-
Low idling speec
SA6D170-B-
T
TEST CRITERIA
.PSA6D17( -B-
TESTING t * *
* t
*
AND ADJUSTING
TEST CRITERIA
The values in the table are indicated at standard conditions (Armospheric temperature 25’C, 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})
Torque (Nm IkgmI)
Fuel consumption (set/500 cc)
Coolant temperature (“0
390.8 - 402.6 i523.6 - 539.3)
-
Min. 17.1
70-85
out
440.9 - 452.6 t590.6 - 606.41
2 b z
PERFORMANCE
Min. 15.2
Lubricatic oil temperai (‘C)
Lubrication oil pressure (kPa {kg/cm*})
Exhaust temperature (“C)
80-110
265 - 392 12.7 - 4.0}
Max. 650
70-85
80-110
294 - 441 13.0 - 4.5}
Max. 650
70-65
80-110
-
-
-
-
0
-
0
-
70-85
80-110
0
-
70-85
Min. 80
Min. 147 {Min. I.51
Min. 15.8
70-85
80-110
294 - 441 I3.0 - 4.5)
410.3 - 434.2 f550.0 - 582.0)
-
-
2,442 - 2,599 {249 - 265)
-
70-85
80-110
-
-
-
-
70-85
80-110
-
-
-
-
-
70-85
Min. 80
Min. 147 {Min. 1.5}
-
357.3 - 378.0 {479 - 508)
-
Min. 17.5
70-85
80-110
265 - 392 12.7 - 4.0)
Max. 650
407.3 - 418.5 {546 - 5611
-
Min. 15.9
70-85
80-110
265 - 392 (2.7 - 4.01
Max. 650
-
-
-
70-85
80-110
-
-
-
70-85
80-110
Min. 147 {Min. 1.5}
Max. 650
-
-
12-041-2 0
TESTING
PERFORMANCE
AND ADJUSTING
le
Engine model
e
IFlywheel Horsepower
OEM for generato r (Prime u!se)
Engine speed frpm)
Test item
367 {492 416 {557
kW/1,500 HP/l,500 kW/1,800 HP/l ,800
OEM for generato r v %rd b’
486 1543 457 {612
Pc1000-1 I (High alti itude spel d
Max. torque
-
rpm rpm) rpm rpm)
(50 (50 (60 (60
Hz) Hz) Hz) Hz)
Max. 1,560 (50 Hz) Max. 1,890 (60 Hz)
-
700 - 800
-
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)
3,544 i361.4 3,357 (342.3
-
3,752 (50 382.6) (50 3,540 (60 361 .O) (60
Max. 1,575 rpm Max. 1,890 rpm
(50 Hz) (60 Hz)
Max. 1,575 (50 Hz) Max. 1,890 (60 Hz)
700 - 800 rpm
700 - 800
-
341 kW/1,700 rpm I457 HP/l ,700 rpm)
1,695 - 1,705
2,737 - 2,905 1279.1 - 296.2)
1,200 - 1,400
3,004 - 3,187 f306.3 - 325.0)
2,157 Nm/1,300 {220 kgm/1,300
rpm rpm1
Low idling spee
680 - 780 rpm
680 - 780
-
383 1510 427 {572
kW/1,500 HP/l,500 kW/1,800 HP/l,800
IMax. torque IHigh idling spee Low idling spee’
Hz) Hz) Hz) Hz)
(50 Hz) (60 Hz)
700 - 900 rpm 379 (508 ..~. 446 1598
kW/1,500 HP/l ,..~ 500 kW/1,800 HP/l,800
rpm (50 Hz) roml (50 Hz) r _~_. ~, rpm (60 Hz) rpm) (60 Hz)
(50 Hz) (60 Hz)
-
Max. 1,568 Max. 1,881
-
(50 Hz) (60 Hz)
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)
rpm rpm) rpm rpm)
(50 (50 (60 (60
Hz) Hz) Hz) Hz)
Max. 1,568 rpm Max. 1,881 rpm
Max. 1,560 Max. 1,872
3,432 1350 3,393 {346
-
700 - 900 rpm
-
(50 Hz) (60 Hz)
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)
Max. 1,568 Max. 1,881
3,521 (50 Hz) 359) (50 Hz) 3,481 (60 Hz) 355) (60 Hz)
-
3,668 {374 3,638 {371
-
3,883 3961 3,854 3931
-
(50 Hz) (60 Hz)
3,570 (50 Hz) 364) (50 Hz) 3,354 (60 Hz) 342) (60 Hz)
-
700 - 900
700 - 900 rpm kW/1,500 HP/l,500 kW/1,800 HP/l,800
1,795 - 1,805 (60 Hz)
3,373 {344 3,168 1323
-
Max. 1,560 rpm Max. 1,872 rpm
417 {559 492 1660
1,495 - 1,505 (50 Hz)
700 - 900
-
Low idling spee
Flywheel Horsepower
(50 (50 (60 (60
-
Max. 1,568 rpm Max. 1,881 rpm
Max. torque High idling spee
rpm rpm} rpm rpm)
-
Low idling spee
Hz) Hz) Hz) Hz)
-
-
Flywheel Horsepower
Load
3,752 (50 Hz) 382.6) (50 Hz) 3,540 (60 Hz) 361 .O} (60 Hz)
1,800 - 1,900
EG500-1 EG500B- 1 EG500BI i-1 Max. torque OEM for generato r (Engine Nc1. IHigh idling spee 13265 and uPI
12-041-3 0
1,795 - 1,805 (60 Hz)
3,544 I361.4 3,357 1342.3
1,800 - 1,900 rpm
IFlywheel Horsepower
OEM for generato r
1,495 - 1,505 (50 Hz)
High idling spee
SA6D170-B-
OEM for generato r
kW/1,500 HP/l,500 kW/1,800 HP/l,800
-
ILow idling spee IFlywheel Horsepower
(50 Hz) (60 Hz)
700 - 800 rpm
IMax. torque IHigh idling spee
Hz) Hz) Hz) Hz)
Dynamometer (N {kg])
-
Max. 1,560 rpm Max. 1,890 rpm
ILow idling spee, IFlywheel Horsepower
(50 (50 (60 (60
-
IMax. torque High idling spee
rpm rpm) rpm rpm}
TEST CRITERIA
(50 Hz) (60 Hz)
700 - 900
-
(50 Hz) 150 Hz) (60 Hz) (60 Hz)
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 arm’s length of 716 mm Flywheel horsepower ikw {HP})
362.1 W35.1 412.9 l553.1
- 382.7 (50 -512.7) (50 - 436.4 (60 - 584.71 (60
Torque (Nm NgmI) Hz Hz Hz Hz
-
Fuel consumption (seci500 cc) 17.7
70-95
80-115
Min.
15.5
70-95
80-115
385.7 (516.7 457.8 (613.3
-
412.9 1553.1 491.6 1658.6 -
-
265 {2.7 294 {3.0
-
-
392 4.0} 441 4.5)
Exhaust temperature (“C) Max. 680 Max. 680
-
-
-
-
-
-
70-95
80-115
-
-
-
70-95
Min. 80
Min. 98 {Min. l.O}
-
265 - 392 $‘9’;: I”4.i
Max. 680
422.5 566.0) 478.4 640.9)
(50 (50 (60 (60
Hz Hz Hz Hz
349.2 - 370.6 W37.8 - 496.5)
-
-
Lubrication oil pressure (kPa (kg/cm21)
-
Min.
16.1
70-95
80-115
Min.
14.2
70-95
80-115
-
379.0 (507.8 427.6 c572.9
Lubrication oil temperature (“0
Min.
-
398.9 1534.4 453.4 (607.4 -
Coolant temperature (“C)
402.6 (50 539.31 (50 454.1 (60 608.4) (60
396.7 (50 531.51 (50 471 .O (60 631.0) (60
437.9 586.7) 521.1 698.1)
-
-
-
70-95
80-115
-
70-95
Min. 80
Min. 98 {Min. 1.0)
70-90
90-110
392 - 539 (4.0 - 5.5)
Min.
Hz Hz Hz Hz
Hz Hz Hz) Hz:
(50 Hz) (50 Hz: (60 Hz: (60 Hz;
i3.0 - 4.5)
18
-
Max. 680
-
Max. 650
2,151 - 2,282 (219.3 - 232.7)
-
70-90
90-110
-
-
-
-
70-90
90-110
-
-
-
-
Min. 70
Min. 90
Min. 118 {Min. 1.2)
-
343 - 441 $3.3” I t.4
Max. 600
Min.
17.1
70-85
80-110
Min.
14.4
70 - 85
80-110
(3.5 - 4.5)
-
-
-
70-85
80-110
343 - 441 (3.5 - 4.51
-
Min. 70
Min. 80
Min. 176 {Min. l.S}
-
Max. 620
-
245 i2.5 245 (2.5
-
441 4.5) 441 4.51
Min.
17.1
70 - 85
80-110
Min.
14.2
70-85
80-110
-
-
-
-
70-85
SO-110
245 - 441 12.5 - 4.5)
-
Min. 70
Min. 80
Min. 147 {Min. 1.5} 245 12.5 245 {2.5
-
441 4.5) 441 4.5)
Min.
15.9
70-85
80-110
Min.
13.2
70-85
80-110
-
-
-
-
70-85
80-110
245 - 441 f2.5 - 4.5)
-
Min. 70
Min. 80
Min. 147 {Min. 1.5)
Max. 650 Max. 680
Max. 650 Max. 650
12-041-4 @
TESTING
AND ADJUSTING
Engine model
PERFORMANCE
Test item
Flywheel Horsepower
OEM for generator
Specified
378 1506 403 1539
High idling
speed
12-041-5 63
Hz) Hz) Hz) Hz)
1,495 - 1,505 (50 Hz) 1,795 - 1,805 (60 Hz)
3,315 {338 2,981 I304
-
(50 Hz)
Max.
1,568 (50 Hz)
-
Max.
1,881 rpm
(60 Hz)
Max.
1,881 (60 Hz)
-
700 - 900 rpm
445 kW/1,800 I597 HP/l,800
Max. torque
-
700 - 900
rpm rpm)
1,795 - 1,805
-
-
3,393 - 3,491 1346 - 3561
High idling
speed
Max. 2,200 rpm
Max. 2,200
-
Low idling
speed
600 - 1,000 rpm
600 - 1,000
-
275 I369 345 I462
kW/l,OOO rpm HP/l,000 rpm) kW/1,200 rpm HP/l,200 rpm)
(50 (50 (60 (60
Hz) Hz) Hz) Hz)
995 - 1,505 (50 Hz) 1,195-
1,205 (60 Hz)
Load
3,511 (50 Hz) 358) (50 Hz) 3,158 (60 Hz) 21 I} (60 Hz) -
1,568 rpm
speed
Flywheel Horsepower
SA6D170-B-
(50 (50 (60 (60
Dynamometer (N ikgl)
Max.
Flywheel Horsepower
OEM for 6-pole generator
rpm rpm} rpm rpm} -
Max. torque
Low idling
EPSAGD17( -B-
kW/1,500 HP/l,500 kW/1,800 HP/l,800
Engine speed irpm)
value
TEST CRITERIA
3,169 1369 3,815 1389
-
3,834 (50 Hz) 3911(50 Hz) 4,031 (60 Hz) 41 I} (60 Hz) 8
-
Max. torque High idling
speed
Low idling
speed
Max. Max.
1,045 rpm 1,254 rpm
(50 Hz) (60 Hz)
750 - 850 rpm
Max. Max.
1,045 (50 Hz) 1,254 (60 Hz) 750 - 850
-
-
z z
TESTING
* +
*
AND ADJUSTING
PERFORMANCE
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 arm’s length of 716 mm Flywheel horsepower ikW {HP})
372.4 f498.9 401.9 1538.4 -
Torque (Nm {kgm))
396.0 (50 530.51 (50 426.9 (60 571.91(60
Fuel consumption (seci500 cc)
-
Min.
-
Min.
-
-
-
415.8 - 440.9 1557.1 - 590.61
-
271.6 f363.8 343.0 {459.5
-
287.8 385.51 363.6 487.1)
(50 (50 (60 (60
Hz: Hz1 Hz] Hz)
z
14.9
70 - 85
80-110
-
245 i2.5 245 12.5
-
80-110
-
70 - 85
80-110
-
Min. 70
Min. 80
75-85
90-110
-
-
{Min.’ l.O}
Max. 600 Max. 620
-
294 - 490 t3.0 - 5.01
Max. 640
75 - 85
80-110
294 - 490 I3.0 - 5.0)
-
-
-
Min. 75
Min. 80
Min. 98 {Min. 1.0)
-
-
Min. 24.2
70-85
85-110
Min.
70-85
85-110
18.9
294 I3.0 343 13.5
-
-
-
-
-
-
-
-
the radiator
Exhaust temperature (‘C)
-
245 - 441 12.5 - 4.5) 245 - 441 ‘2.., “9.851
-
and operate
441 4.5) 441 4.5)
-
-
70 - 85
15.3
Lubrication oil pressure ikPa {kg/cm*})
-
The SAA6D170-1 engine for the generator the generator at the front of the radiator. install
80-110
-
Min.
2 z
Lubrication )il temperature (“0
70 - 85
-
-
Coolant temperature (“C)
16.8
-
-
*
TEST CRITERIA
and air-cooled
-
Min.
-
is equipped with an air-cooled aftercooler. When carrying out an output performance
aftercooler
to a stand
to give a same condition
441 4.5) 490 5.0)
Max. 650 Max. 700
-
147
-
The aircooled aftercooler is installed to test of the engine as an individual part,
as when they are mounted
on the machine,
with the fan.
12-041-6 03
TESTING
PERFORMANCE
AND ADJUSTING
rpplicable machine
Test item
:lywheel Horsepower flax. torque VA600-1 IC regulaon)
Dynamometer (N Ngl)
1,995 -2,005
2,180 - 2,310 1223-235)
1,960 Nm
1,300- 1,500
2,820 -2,940 1287-3001
2,200-2,300
-
.ow idling
speed.
650 - 700 rpm
650-700
-
flax.
torque
Load
305 kW
2,200 - 2,300 rpm
_owidling speed
12-041-7 63
Engine speed (rpm)
speed
iigh idlingspeed
SA6D170-AE.
value
idling
iigh
'lywheel Horsepower ,ENYO enerator KzA600SSI K
Specified
TEST CRITERIA
470 kW
1,495-1,505 (50 Hz)
513 Kw
1,795-1,805 (60 Hz)
-
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
4,190-4,380 (50 Hz) {420-4471(50 Hz) 3,780-4,020 (60 Hz) {386-411) (60 Hz)
-
TESTING
* *
*
PERFORMANCE
AND ADJUSTING
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 arm’s length of 716 mm Flywheel horsepower W’C-W)
Torque N-n {kgm))
328 - 346 (Gross) WI5 - 4701 (Gross)
Min. 18.7
I
463 - 493 (Gross,50Hz) {630- 670NGross.50Hz) 511 -543(Gross,GOHz) {695- 7391(Gross,60Hz)
Coolant temperature ('0
Lubrication ,il temperature (“0
110
Lubrication oil pressure Wa {kg/cm2})
Exhaust temperature (“C)
280-490 12.8-5.01
Max.610
70-90
go-
-
70-90
90-110
-
-
70-90
90-110
280-490 {2.8-5.01
-
-
-
70-90
90-110
Min. 150 {Min. 1.5}
-
Ain.13.8 (50 H2
75-85
85-110
Ain.12.0 (60 H2
75-85
85-110
2,010 -2,110 (Gross) {205-215) (Gross)
-
Fuel consumption (set/500 cc)
-
-
Max.650
840-540 (50 Hz 3.5-5.5) (50 Hz 870-540 (60 Hz 3.8-5.5) (60 Hz
Max.650 Max.650
-
-
-
-
-
-
-
-
-
-
75-85
85-110
340-540 {3.5- 5.51
-
-
-
-
75-85
85-110
Min. {Min.
-
180 180)
1 Z-041 -8 @
TESTING
AND ADJUSTING
Engine model
Applicable machine
PERFORMANCE
Test item
Specified
Flywheel Horsepower
597 kW/1,500 {800 HP/l,500
value
Engine speed (rpn-0
rpm (Net) rpmj (Net)
1,495 - 1,505
5,140 - 5,460 1524 - 557)
-
-
Max. 1,570
-
700 - 900
-
-
Max. torque
TEST CRITERIA
Dynamometer (N {kg])
jenerator 50 Hz onl) High idling spee
Low idling speel
SAAGD170-1
12-041-9 03
Max.
1,570 rpm
700 - 900 rpm
Load
TESTING
* *
*
PERFORMANCE
AND ADJUSTING
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 arm’s length of 716 mm Flywheel horsepower (kW (HP}) 579 - 612 (Gross) {775 - 819) (Gross)
Torque
(Nm ikgm})
-
Fuel consumption (set/500 cc)
-
-
Lubrication lit temperature (‘C)
Lubricatior oil pressun (kPa {kg/cm2
80-110
260 - 370 l2.6 - 3.8)
-
-
-
-
70-85
80-110
-
-
Min. 70
Min. 80
Min.
11.0
-
Coolant temperature (‘0
70 - 85
Min. 150 {Min. 1.5}
I
1)
Exhaust temperature (“C)
Max. 650
-
-
-
-
-
12-041-10 03
PRECAUTIONS
WHEN
OPERATING
THE
ENGINE
INDEPENDENTLY *
If the engine is operated with
a double
tions will differ
independently
lip seal fitted, from
on a bench
the lubricating
condi-
actual running conditions,
re-
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.
Engine side
Clutch side
_
-
6162F202
2.
After
completing
running-in or bench testing,fit
I
the correct rear seal.
‘Torque co&etier side or clutch side
23 k 0.6
Engine side H
6162F203
*
Precautions when fitting rear seal 1)
A new rear seal is coated with event that
grease.
In the
it becomes soiled, however,
wipe it
clean with a cloth and coat it with about 1.2 to 1.6 cc of G2-Ll 2)
(lithium grease).
Be careful not to damage the rear seal when fitting it.
TESTING
No.
AND
ADJUSTING
Inspection and measuring item
1
Engine speed
2
Batten/ S.G.
TOOL LIST
Fault finding tool
Part No.
Multi-tachometer
799-203-8001
Battery, coolant tester
795-500-l001
Remarks Digital reading, pressure type 60 to 19,999 rpm
sensing
1 .lOO to 1.300
3
Freezing temperature cooling water
of
4
Water temperature, oil temperature, air intake temperature
5
Exhaust temperature
Digital temperature
gauge
790-101-1500
-5°C
to -50°c
-99.9
- 1.299”C
0 to 20 kg/cm*
0 to 50 kg/cm2
1
Pressure test kit
8
intake pressure, exhaust pressure
9
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
D to 500 mmH,O
15
11
Water and fuel content in oil
1 Fuel injection pressure
Engine oil checker
799-203-2002
503
0 to 1,000 mmHg
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)
799-201-6000
Provided with 6.1 and 0.2% water content standard samples.
Commercially available
I to 300 kg/cm2
799-202-7001
JH, nitrite ion concentration
799-202-9001
I to 2 kg/cm*
799-202-2001
I to 40 m/s
795-610-1000
X24V
6162-234820
:or 6D170-1
Commercially available
Zurrent, voltage,_resistance
/ Nozz,eteSter
Fuel injection nozzle spray condition
18
Coolant quality
Water quality tester
Leakage in cooling water system
21
Radiator blockage (wind speed)
22
Engine cranking
23
Electrical circuits
Anemometer (Air speed gauge)
Tester
with starting engine series engine
12-043 0
TESTING
AND ADJUSTING
DATE
T
Engine model
S6Dl70-1
C5Z sifica -tior 8 6 E b Lt I?
Condition, etc.
item
T
PC650-1 PC1500-1
Applicable machine model Unit
Standard 1,700-I
,800
Tolerance 1,700-I
,800
WA600-1
Tolerance
Standard
2,200-2,300
2,200-2,300
High idling speed
rpm
Low idling speed
rpm
650-700
o”c
rpm
Min. 100
-
Min. 100
-
rpm
Min. 100
-
Min. 100
-
Engine speed
Necessary starting speed
-20°C
(with starting aid)
650-700
650-700
650-700
Intake resistance
At all speed
mmH,C
Max. 380
762
Max. 300
762
Intake pressure
At rated output
mmHg
Min. 800
700
Min. 600
540
Exhaust pressure (Turbine inlet pressure)
At rated output
mmHg
Min. 650
550
Min. 630
570
Exh’aust temperature (Turbine inlet temperature)
All speed (Intake air temp.: 2dC)
“C
Max. 650
Max. 700
Max. 650
Max. 700
Exhaust gas color
Quick acceleration (Low idling + High idling) At rated output At high idling
Bosch scale
Valve clearance (When engine is hot or cold.)
Max. 6.5
3.5
Max. 6.0
8.0
Max. 2.5 Max. 2.0
3.5 3.0
Max. 2.0 Max. 1.5
3.0 2.5
0.4
-
0.4
-
1 .o
-
1.0
-
Min. 29
20
8 Compression pressure (SAEBO oil)
Oil temperature: 40°C to 60°C (Engine speed)
Blow-by pressure (SAE30 oil)
At rated output Water temperature: Min. 70°C At rated output SAEBO oil
Oil pressure (Oil temperature: Min. 8O’Cj
E al t; > _ .-P 5 s
kg/cm’
Min. 29
(rpm)
(21 O-250)
mmH,C
20 (210-250)
Max. 150
300
Max. 150
300
kg/cm’
3.5-5.0
2.5
3.0-5.0
2.4
SAEI OW oil
kg/cm’
3.04.5
2.0
2.5-4.5
1.8
SAEBO oil
kg/cm’
Min. 1.5
0.7
Min. 1.5
0.7
SAEI OW oil
kg/cm’
Min. 1 .O
0.7
Min. 1 .O
0.7
SO-110
120
SO-
120
At low idling
Oil temperature
All speed (oil in oil pan)
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
Fuel injection pressure
“C
1 .o
110
1
Max. 0.5
.o
%
Max. 0.5
Nozzle tester
kg/cm’
255 +’ 3 +5
211
55::s(-#1604: !65:?(#16044
3) -)
211
Fuel injection timing
B.T.D.C.
degree
42 + 1
42 f 1
42+1(-#16043 38*1(#16044
3)
42 + 1
Radiator pressure valve
Opening pressure (Differential pressure)
0.75 + 0.1 ‘C650-1 j ‘Cl 500-I)
Fan speed Fan belt tension
See page 12-031
*The
(210-250)
(210-250)
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 0
0.75 t 0.1
1,200 f 30 _
1 -)
0.75 f 0.1
1,200 f 30 -
;; z
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
DATA
S6D170-1 EPS6Dl70-1
D275A-2 Standard 1,960 -2,040 600-660 Min. 100 Min. 100
z z
I 1,960 -2,040 600-660 -
Standard I Max.2,030
Max. 2,030
Tolerance
Standard
700-800
Min. 100
-
Min.100
-
Min. 100
-
Min. 100
-
762
Max.300
810
-
Min.900
810
Max.650
Max. 6.0
8.0
-
Max. 1.3 Max. 1.0
2.3 2.0
2.5 Max.2.0
0.4
-
0.4
1.0
-
1.0
762 -
700
3.5 3.0
for generator (Power up)
Standard
Tolerance
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.900
Max.700
Tolerance
600-1,000
600-1,000
Max.300
Max.650
2
Tolerance
OEM
OEMforgenerator
!-I Max.300 -
I I
762 -
700
650
-
-
-
-
-
I
I -
Max. 3.0 -
700
650 I
-
Max.3.0 -
4.0 -
Min.29
20
Min.29
20
Min.29
20
Min.29
20
(210-250)
(210-250)
(210-250)
(210-250)
(210-250)
(210-250)
(210-250)
(210-250)
Max.300
600
Max.300
600
Max.400
800
Max.400
800
3.0- 5.0
2.5
3.0 - 5.0
2.4
3.3-4.5
2.3
3.3 -4.5
2.3
2.5-4.5
1.8
2.5-4.5
1.8
2.6 -4.2
2.0
2.6 -4.2
1.8
Min.l.5
0.7
Min. 1.0
0.7
Min. 1.2
0.7
Min. 1.2
0.7
Min.l.0
0.7
Min. 1.0
0.7
Min. 1.0
0.7
Min. 1.2
0.7
80-110
120
80-110
Max.0.5
1.0
Max. 0.5
220
260-268
270-278 37-39
37-39
41-43
41-43 0.65- 0.85
-
-
41-43
41-43
0.65-0.85
0.65-0.85
-
-
-
-
41-43 0.65 -0.85
41-43 0.65 -0.85
995-1,055(50Hz) 995-1,055(50Hz) 1,193-1,267(60Hz) 1,193 - 1,267(60Hz)
-
-
12-044-l 0
Engine model Applicable machine model Clasisification
“0 5 E 8 Y d
: z 2
z 7 _c 2
Itern
2 B al r .=
F
w
Unit
High idling speed
wm
Low idling speed
wm
0°C
rpm
Engine speed
Necessary starting speed
-20°C
(with starting aid)
Intake resistance
At all speed
mmH,C
At rated output
mmHg
Exhaust pressure (Turbine inlet press” re)
At rated output
mmHg
Exhaust temperature (Turbine inlet temperature)
All speed (Intake air temp.: 20°C1
Exhaust gas color
Quick acceleration (Low idling-t High idling) At rated output At high idling
OC
Intake valve
mm
Exhaust valve
mm
Compression pressure (SAEBO oil)
Oil temperature: 4o”c to 60°C (Engine speed)
Blow-by pressure (SAE30 oil)
At rated output Water temperature: Min. 7O’C
Oil pressure (Oil temperature: Min. 80°C)
:
.-* 3
Bosch scale
Valve clearance (When engine is hot or cold.)
SAElOW
kg/cm’ (rpm)
mmH,C
At rated output SAEBO oil
z t
rpm
Intake pressure
-0
& P E :
Condition, etc.
oil
kg/cm’ kg/cm’
At low idling SAE30 oil
kg/cm’
SAElOW
kg/cm’
oil
P
z k ’
g
E
z ?; P
.= a 8
*The
Oil temperature
All speed (oil in oil pan)
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
Fuel injection pressure
Nozzle tester
kg/cm’
Fuel injection timing
B.T.D.C.
degree
Radiator pressure valve
Opening press” re (Differential pressure)
kg/cm’
Fan speed
At rated engine speed
rpm
Fan belt tension
Deflects when pushed with a force of 6 kg
mm
“C
%
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
I
TESTING AND ADJUSTING DATA
TESTING AND ADJUSTING
SA6D170-A-1
S6D170-1 H D465-3 (with twin turbochrger) Tolerance
r
WA700-1
HD465-5 Standard
2,250 - 2,350
2,250 - 2,350
850 - 900
850 - 900
Min. 130
-
Min. 130
Min. 100
-
Min. 100
Tolerance
I
Standard
Tolerance
I
-
Min. 100 Min. 100
Max. 300
t
762 -
Max. 380
762
Max. 380
762
Max. 300
762
-
Min. 1,500
1,000
Min. 1,000
Min. 870
Min. 1,000
Min. 870
-
-
Min. 950
850
Min. 900
Min. 780
Min. 850
Min. 750
Max. 650
Max. 700
Max. 680
680
Max. 680
Max. 700
Max. 650
700
Max. 7.0
8.0
Max. 7.0
8.0
Max. 6.0
8.0
Max. 2.7 Max. 2.7
Z
Max. 3.0 Max. 2.0
4.0 3.0
Max. 2.0 Max. 1.0
3.0 2.0
0.4
-
1.0
-
Min. 28
20
Min. 28
20
Min. 28
20
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
Max. 300
600
Max. 300
700
Max. 350
700
Max. 350
700
3.0 - 5.0
2.0
3.0 - 5.0
2.0
3.0 - 5.0
2.1
2.5 - 4.5
1.8
2.5 - 4.5
1.8
3.0 - 5.0
2.4
2.5 - 4.5
1.8
Min. 1.0
0.7
Min. 1.5
0.7
Min. 1.5
0.7
Min. 1.5
0.7
Min. 1.0
0.7
Min. 1.0
0.7
Min. 1.0
0.7
Min. 1.0
0.7
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
220
305 - 313
247
305 - 313
247
305 - 313
247
28 - 30 *2 35 - 37 *3
35-37
41 - 43 (up to 13764) 37 - 39 (13765 and up)
-
0.65 - 0.85
0.65 - 0.85
1,220 - 1,280
1,220 - 1,280
-
*I : For cold weather specifica ‘2 : With electronic governor *3 : With mechanical governor
35-37
35 - 37
37 - 39 (-#14593) 37 - 39 (-#14593) 34 - 36 (#I4594) 34 - 36 (#14594-j
Ins
12-045 0
SAGDI 70-A-1
Engine model Applicable machine model Condition, etc.
b ‘;
d
Necessary starting speed
Unit
High idling speed
rpm
Low idling speed
rpm
0°C
wm
Min. 100
rpm
Min. 100
-
mmH,C
Max. 450 1,200 (50H.z) 1,400 (60~2)
635 -
-20°C
(with starting aid)
Intake resistance
At all speed
Intake pressure
At rated output
mmHg
At rated output
mmHg
800 (50Hzj 1,000 (60Hzj
-
“C
Max. 650
Max. 650
Exhaust pressure : z ?; z 3 _c J 0
5
;G586-1, EG580B-1, EG600B-1 zG~OOBS-1, OEM for generator
EG550-1
Exhaust temperature (Turbine inlet
Exhaust gas color
2 B
All speed (intake air temp.: ZO’C) Quick acceleration (Low idling-t High idling) At rated output At high idling
Bosch scale
Intake valve
mm
Exhaust valve
mm
Max. 450
762
Max. 650
700
Max. 3.0
4.0
Min. 26
18
(When engine is
Oil temperature: 4O’C to 60°C (Engine speed)
Blow-by pressure
At rated output Water temperature: Min. 70°C
kg/cm’
Min. 26
(rpm)
(21 O-250)
mmH,C
Max. 280
400
kg/cm’
2.5 - 4.0
2.5 - 4.0
At rated output SAE30 oil Oil pressure (Oil temperature: Min. 80°C)
SAEIOW
oil
kg/cm’
SAE30 oil
kg/cm’
Min. 1.5
0.7
SAEIOW
kg/cm2
Min. 1 .O
0.7
oil
All speed (oil in oil pan)
OC
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
%
Max. 0.5
kg/cm*
300+’ 3 +5
Nozzle tester
B.T.D.C.
j
8
0
[ Fan speed Fan belt tension
1 ,
80-
110
degree
Opening pressure (Differential pressure)
kg/cm’
At rated engine speed
ram
Deflects when pushed with a force of 6 kg
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
Max. 400
800
3.0 - 4.5
2.1
2.5 - 4.0
1.8
Min. 1.5
0.7
Min. 1 .O
0.7
At low idling
Oil temperature
g
18 (210-250)
120
1 .o
270
---I--80-110
Max. 0.5
300;;” 37 fl
120
1 .o
247 37 fl
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
DATA
SA6D170-A-1 EPSAGD170-A-1
EG580B-1L
HD465_3(ForORAPAMINE) Tolerance
-
{Max. 1,560(50Hz)Max.l,560(50Hz)
2,300+ 50
2,300 k 50 85OklO
Min. 130
-
Min.130
-
Min.100
-
Min. 100
-
300 -
762
650
;:: 0.4 2 z z
1.0 Min.26
Max.350
- I- II I -
700
4.5 3.5
Min. 1,150
762 1,100
-
Max.650
700
Max. 1.5 Max. 1.0
380
I
-
762 -
-
-
680
700
-
6.0
8.0
2.5 2.0
2.0 2.0
3.0 3.0
-
0.4
-
0.4
-
-
1.0
-
1.0
-
18
(210-250)
210-250)
300
600
20
Min.28 (210-250)
Max.400
2.7-4.5
1.9
3.0-4.5
2.2 -4.0
1.5
-
Min. 1.5
0.7
Min. 1.0
0.7
-
80-110
120
80-110
210-250)
20
Min.28 (210-250)
210-250)
800
Min. 1.0
700
2.0
3.0 - 5.0
2.1
-
2.5-4.5
1.8
0.7
Min. 1.5
0.7
-
Min. 1.0
0.7
120
)
1.0
247 36+_1
0.75 * 0.1
0.75 f 0.1
0.75 k 0.1
1,020f26
1,020 + 26
1,230 k 40
-
-
Auto
0.75 * 0.1 1,230 + 40
tension
1,250? 30
1,250+ 30
Auto tension
12-047 0
TESTING
TESTING
AND ADJUSTING
Engine model Applicable
machine
AND ADJUSTING
DATA
SA6D170-A-1
I
model
HD465-3 (With single turbocharger)
Pc1ooosP-1
Standard
Tolerance
High idling speed
2,250 - 2,350
2,250 - 2,350
Low idling speed
940 - 990
940 - 990
-
Min. 130
-
-
Min. 100
-
7.5 1762)
Max. 3.7 {Max. 380)
-
Min. 10.8 {Min. 1,100)
-
Min. 10.3 {Min. 1,050)
700
Max. 650
5.0
Max. 6.0
7.0
2.5 2.0
Max. 2.0 Max. 2.0
%!I
-
0.4
-
-
1.0
-
Condition,
Item
etc.
1
IEngine speed
Necessary starting speed
-20°C (with starting
IIntake resistance
At all speed
Intake pressure
At rated output
IExhaust pressure /[Turbineinlet pressure)
At rated output
IExhuast temperature ,[Turbine inlet 1temDerature)
aid)
rpm kPa [mmHzOI kPa ImmHgI
All speed (intake air temp.: 20°C)
Valve clearance (When engine is Hot or cold) Compression pressure (SAE30 oil)
Blow-by pressure (SAE30 oil)
Intake valve
Min. 100
Max. 650
Bosch scale
mm
0.4 7
Exhaust valve Oil temperature: 40°C to 60°C
~~
mm
1.0
MPa {kg/cm?
Min. 2.55 {Min. 26)
(rpm)
(Engine speed)
I
-
“C
At rated output At high idling
Min. 100
Max. 2.9 {Max. 300)
kPa ImmHg)
Quick acceleration (Low idling --f High idling) IExhaust gas color
I
rpm
0°C
1
(210-250)
I
1.77 {I81
1
(210-250)
At rated output Water temperature: Min. 70°C At rated output SAW0
Oil pressure (Oil temperature: Min. 80°C)
oil
At low idling SAE30
*
294 - 441 (3.0 - 4.5)
kPa {kg/cm21
206 (2.1)
(210 - 250)
(210 - 2501
Max. 3.4 {Max. 350)
6.9 I7001
{20)
oil
kPa {kg/cm?
245 - 441 12.5 - 4.5) Min. 147 {Min. 1.5)
kPa {kg/cm?
oil
SAEIOW
1,96
294 - 490 (3.5 - 5.0)
oil
SAElOW
Min. 2.75 {Min. 28)
Min. 98 {Min. 1.0)
1
Oil temperature
All speed (oil in oil pan)
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
Fuel injection pressure
Nozzle tester
Fuel injection timing
B.T.D.C.
Radiator vavle
Opening pressure (Differential pressure)
64-83 {0.65 - 0.85)
64-83 IO.65 - 0.851
Fan speed
At rated engine
1,220 - 1,280
1,220 - 1,280
Fan belt tension
Deflects when pushed with a force of 6 ko
pressure
% MPa {kg/cm21
I
120
Max. 0.5
1.0
Max. 0.5
1.0
26.5 - 27.3 (210 - 278)
21.6 (220)
29.9 - 30.7 (305 - 313)
24.2 (2471
37-39
speed
mm
-
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
12-047- 1 0
80-110
of the output. pump.
37-39
See page 12-031
TESTING
AND ADJUSTING
TESTING
AND ADJUSTING
DATA
SA6D170-A-1
r
EM680A
T
EM680A-1 EM170B-1
H D465-5 (High altitude spec.)
EM680A-A
Standard
Tolerance
Standard
Tolerance
Standard
Tolerance
2,100 - 2,200
2,100 - 2,200
2,000 - 2,200
-
2,100 - 2,200
2,100 - 2,200
550 - 600
550 - 600
550 - 600
-
550 - 600
550 - 600
Min. 130
-
Min. 130
-
Min. 130
-
Min. 130
-
Min. 100
-
Min. 100
-
Min. 100
-
Min. 100
-
Max. 2.9 {Max. 300)
7.5 {762)
Max. 3.7 {Max. 380)
7.5 {762)
Max. 2.9 {Max. 300)
-
Max. 2.9 {Max. 3001
7.5 17621
Min. 168 (Min. 1.3001
-
Min. 155 (Min. 1,200}
-
-
Min. 80 {Min. 620)
Max. 550
700
Max. 600
-
-
Max. 2.0 Max. 2.0
Max. 2.0 Max. 2.0
-
Min. 106 {Min. 820} Min. 95 {Min. 7401
60
Max. 650
700
-
-
3.0 2.0
Max. 1 .O Max. 0.5
Max. 620
2.0 1.5
8
1.0
2 -
z z
Min. 2.75 (Min. 281
1.96 {201
Min. 2.75 {Min. 28)
1.96 (201
Min. 2.75 {Min. 28)
1.96 1201
Min. 2.75 {Min. 28)
1.96 I201
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
Max. 3.4 {Max. 3501
6.9 I7001
Max. 2.9 {Max. 300)
5.9 {6001
Max. 3.4 {Max. 350)
6.9 (7001
294 - 490 (3.0 - 5.0)
294 - 490 l3.0 - 5.01
206 (2.1)
294 - 490 13.0 - 5.0)
245 - 441 (2.5 - 4.51
245 - 441 {2.5 - 4.5)
177 Il.81
245 - 441 (2.5 - 4.51
245 - 441 (2.5 - 4.5)
177 11.81
Min. 147 (Min. 1.5)
Min. 147 {Min. 1.5}
I&
Min. 147 {Min. 1.5)
Min. 147 {Min. 1.5}
1:;)
Min. 98 {Min. 1.0)
Min. 98 {Min. 1.0)
{:?I
Min. 98 (Min. l.O}
Min. 98 {Min. I.01
&
0.4
80-110
Max. 0.5 29.9 - 30.7 I305 - 3131 33-35
-
-
1.0 24.2 I2471
0.4
-
0.4
-
1.0
-
1.0
-
80-110
120
80-
110
120
Max. 0.5
1.0
Max. 0.5
1.0
29.9 - 30.7 (305 - 3131
24.2 {247)
29.9 - 30.7 (305 - 3131
24.2 I2471
33-35
33-35
33-35
29-31
-
-
-
-
-
-
-
17
15 - 19
-
24.2 12471
29.9 - 30.9 {305 - 3151
29-31
-
I
-
12-047-2 0
TESTING
TESTING
AND ADJUSTING
Engine model Applicable
Clas
Necessary starting speed
model
f Unit
etc.
OEM for generator Standard
IG600BS-1, OEM for generator (Engine No. 15503 and up)
Tolerance
Tolerance ax. 1,568 (50Hz) ax. 1,881 (60Hz)
lax. 1,568 (50Hz) lax. 1,881 (60Hz)
High idling speed
vm
Aax. 1,560 (50H; Aax. 1,872 (60H;
Max. 1,560 (50Hi Max. 1,872 (60H2
Low idling speed
wm
950 - 1,000
950 - 1,000
700 - 900
700 - 900
Min. 130
-
Min. 130
-
Min. 100
-
Min. 100
-
Max. 3.9 {Max. 400)
7.5 {762)
Max. 3.9 {Max. 400)
7.5 I7621
0°C -20°C (with starting
rpm
aid)
kPa
Intake resistance
At all speed
{IrnmHz0)
Intake pressure
At rated output
Imml-lg)
-
-
-
At rated output
kPa
I mml-fg}
-
-
-
-
Max. 650
700
Max. 650
700
-
-
-
Exhaust pressure Turbineinlet pressure) Ixhuast temperature :Turbine inlet :emperature)
kPa
All speed [intake air temp.: 20°C)
“C
Quick acceleration [Low idling + High idling) !xhaust
gas color
dalve clearance :When engine is iot or cold) Zompression oressure SAE30 oil)
Blow-by pressure (SAE30 oil)
At rated output At high idling
Max. 1.5 Max. 1.0
2.5 2.0
Max. 1.2 Max. 1.0
mm
0.4
-
0.4
-
Exhaust valve
mm
1.0
-
1.0
-
MPa 1kg/cm?
Min. 2.55 {Min. 26}
1.77 (181
Min. 2.55 {Min. 26)
1.77 {18I
(rpm)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
kPa Min. 70°C : { mmHz0
Max. 3.9 {Max. 400)
Max. 3.9 {Max. 400)
7.8 {800}
kPa (kg/cm?
255 - 441 12.6 - 4.5)
343 - 441 13.5 - 4.5)
kPa (kg/cm21
216 - 392 {2.2 - 4.0)
294 - 441 13.0 - 4.51
kPa [kg/cm?
Min. 147 {Min. 1.5}
Min. 147 {Min. 1.5}
kPa
Min. 98 {Min. 1.0)
Min. 98 {Min. l.O}
Oil temperature: 40°C to 60°C [Engine speed) At rated output Water temperature:
SAE30 oil Oil pressure (Oil temperature: Min. 80°C)
Bosch scale
Intake valve
At rated output
SAEIOW
oil
At low idling SAEJO oil SAEIOW
*
DATA
SA6D170-A-1
Condition,
sifica - tior 8 6 E b ‘t a”
machine
AND ADJUSTING
oil
i(kg/cm?
Oil temperature
All speed (oil in oil pan)
“C
80-110
120
80-110
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
%
Max. 0.5
1.0
Max. 0.5
Fuel injection pressure
Nozzle tester
MPa
29.7 - 30.9 1303-315)
24.2 {247)
29.9 - 30.7 I305 - 313)
Fuel injection timing
B.T.D.C.
Radiator vavle
Opening pressure (Differential pressure)
pressure
i(kg/cm? degree kPa
i[kg/cm?
33-35 64-83 to.65 - 0.85)
64-83 lo.65 - 0.85)
995 - 1,055 (50Hi 995 - 1,055 (50Hz ,192 - 1,266 (6Ok 1,192 - 1,266 (60H
Fan speed
At rated engine
Fan belt tension
Deflects when pushed with a force of 6 kg
speed
-
mm
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
12-047-3 0
33-35
of the output. pump.
30-32 59-78 fO.6 - 0.8)
1.0 24.2 I2471 30-32 59-78 fO.6 - 0.8)
95 - 1,055 (50Hz) 195- 1,055 (50Hz) 192- 1,266 (60Hz: 192 - 1,266 (60Hz)
-
8 z &
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
DATA
SA6D170-A-1 OEM for generator (Prime use) Standard
T
Tolerance
Max. 1,568(50Hz: Aax.1,566(50Hz Max. 1,981@Hz: Aax.1,981(60Hz
OEM for generator (Standby use) Standard
r
Tolerance
Tolerance
2,100 - 2,200
Max. 2,200
Max. 2,200
700 - 900
700 - 900
700 - 900
550 - 600
550 - 600
700 - 900
700 - 900
Min. 130
-
Min. 130
-
Min. 130
-
Min. 130
-
Min. 100
-
Min. 100
Min. 100
-
Min. 100
-
Max. 3.9 {Max. 400)
7.5 {762)
Max. 4.9 {Max. 500)
Max. 2.9 {Max. 300)
Max. 650
700
-
-
Max. 1.2 Max. 1.0
z
Standard
700 - 900
-
z
Standard
lax. 1,575(50Hz) Bax.1,575(50Hz) 2,100 - 2,200 lax. 1,890(60Hz) [ax. 1,890(60Hz)
-
$
EPSAGD170-A-1 512 kW (686 HP}
OEM for marine
Z
Max. 700 Max. 2.5 Max. 2.5
700
-
2:;
Max. 3.9 {Max. 400)
-
-
-
-
Max. 650
-
700
-
7.5 {762)
Max. 650
700
-
Max. 1.0 Max. 1.0
it
Max. 2.5 Max. 1.5
3.5 2.5
0.4
-
0.4
-
0.4
-
0.4
-
1.0
-
1.0
-
1.0
-
1.0
-
Min. 2.55 {Min. 2.6)
1.77 (18)
Min. 2.55 {Min. 2.6)
1.77 U8I
Min. 2.75 {Min. 28)
1.96
120)
Min. 2.55 {Min. 26)
1.77 118)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
Max. 3.9 {Max. 400)
7.8 {800)
Max. 3.9 {Max. 400)
7.8 I8001
Max. 3.4 {Max. 350)
6.9
{700)
Max. 3.9 {Max. 4001
7.8 {8001
343 - 441 13.5 - 4.5)
245 I2.5)
226 - 392 12.3 - 4.0)
157 Il.61
294 - 490 {3.0 - 5.0)
206 (2.1)
294 - 490 (3.0 - 5.0)
294 - 441 13.0 - 4.5)
206 12.1)
177-348 Il.8 - 3.5)
127 Il.31
245 - 441 l2.5 - 4.5)
245 - 441 t2.5 - 4.5)
Min. 147 {Min. 1.5)
Min. 147 {Min. 1.5)
r%
Min. 147 {Min. 1.5)
Min. 98 {Min. I.01
Min. 98 {Min. 1.0)
r%
Min. 98 {Min. 1.0)
80-110
120
80-110
120
90-110
120
80-110
120
Max. 0.5
1.0
Max. 0.5
1.0
Max. 0.5
1.0
Max. 0.5
1.0
29.9 - 30.7 1305 - 313)
24.2 {247I
29.9 - 30.7 {305 - 313)
24.2 {247)
29.9 - 30.7 I305 - 313)
24.2 {247)
29.9 - 30.7 I305 - 313)
24.2 1247)
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)
33-35 59-78 IO.6 - 0.8)
33-35 59-78 to.6 - 0.8)
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
-
-
33-35
33-35
-
-
-
36 - 38 39 - 59
36-38 39-59
IO.4 - 0.6)
IO.4 - 0.6)
-
-
-
-
-
-
12-047-4 0
Engine model
SAGD170-6-l D375A-1 (Engine No. up to 11117)
Applicable machine model
Item
Condition, etc. High idling speed
D375A-1 (EngineNo. 11118andup)
Unit
Standard
rpm
1,950-2,050
1,950-2,050
1.950-2.050
1,950-2,050
rpm
600-700
600-700
600-700
600-700
rpm
Min. 130
-
Min. 130
-
rpm
Min. 100
-
Min. 100
-
Tolerance
Standard
Tolerance
Engine speed Low idling speed I
I
ooc
Necessary starting speed
-20°C (with starting aid)
Intake resistance
At all speed
mmH,O
Max. 380
635
Max. 380
635
Intake pressure
At rated output
mmHg
Min. 1,100
825
Min. 950
825
Exhaust pressure (Turbine inlet pressure)
At rated output
mmHg
Min. 900
810
Min. 900
810
Exhaust temperature (Turbine inlet temoeraturel
All speed (intake air temp.: 20°C)
OC
Max. 650
Max. 650
Max. 650
Max. 650
Max. 7.0
8.0
Max. 6.0
8.0
Max. 4.5 Max. 1.5
5.5 2.5
Max. 2.5 Max. 1.5
3.5 2.5
Valve clearance (When engine is hot or cold)
Intake valve
mm
0.4
-
0.4
-
Exhaust valve
mm
1 .o
-
1 .o
-
Compression pressure (SAEBO oil)
Oil temperature: 40°C to 60°C (Engine speed)
8
I Blow-by pressure (SAEBO oil)
Oil temperature
+
(21 O-250)
Min. 26
20 (21 O-250)
(21 O-250)
18
;o
(21 O-250)
I At rated output Water temperature: Min. 70°C At rated output SAEBO oil
Oil pressure (Oil temperature: Min. 80°C)
kg’cm2 (rpm)
Min. 28
mmH?O
Max. 280
560
Max. 350
700
kg/cm2
3.0 -
5.0
2.0
3.0 -
5.0
2.0
SAElOW oil
kg/cm2
2.5 -
4.5
1.8
2.5 -
4.5
1.8
SAEBO oil
kg/cm*
Min. 1.5
0.7
Min. 1.5
0.7
SAElOW oil
kg/cm2
Min. 1 .O
0.7
Min. 1 .O
0.7
At low idling
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
220
265 +’ 3 +5
220
Fuel injection timing
6.T.D.C
degree
Radiator pressure valve
Opening pressure (Differential pressure)
kg/cm*
0.75 + 0.1
0.75 i 0.1
0.75 * 0.1
0.75 + 0.1
Fan speed
At rated engine speed
rpm
1,050 f 30
1,050 i 30
1,050 i 30
1,050 i 30
Fan belt tension
Deflects when pushed with a force of 6 kg
mm
38t
38*
1
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
1
38il
See page 12.031
38i
1
z
SAGDl70-8-1 HD465-3 (with single turbocharger)
D375A-2 Standard 2,000
+ 40
630 zt 50
2 ;;;
Tolerance 2,000
i 40
630 f 50
Tolerance
2.350-2.450
2,350-2,450
800-900
800-900
Standard 1,850
zk 50
675 rt 25
Tolerance 1,850
Standard
Tolerance
f 50
1,800-l
,890
1,800-l
,890
675 f 25
950-I
,000
950-l
,000
130
-
Min.
130
-
Max.
130
-
Min.
100
-
Min.
100
-
Min.
100
-
Min.
100
-
Min.
100
-
Max. 380
762
Max. 300
762
Min. 950
825
-
-
Min. 900
810
-
-
Max. 650
Max. 650
Max. 650
Max. 6.0
8.0
Max. 2.5 Max. 1 .O
3.5 2.0
0.4
1.o
(21 O-250)
762
Max. 300
635
900
-
-
Min. 900
810
-
-
Max. 700
Max. 650
700
Max. 650
Max. 650
Max. 6.0
8.0
Max. 3.0
5.0
-
-
Max. 2.0 Max. 1.5
3.0 2.5
Max. Max.
2.5 2.0
Max. 2.0
2.5
-
0.4
-
0.4
-
0.4
-
-
1.o
1.o
-
1.o
-
18
Min. 28
(21 O-250)
(21 O-250)
20 (21 O-2.50)
Max. 300 Min.
1,000
1.5 1 .O
Min. 26 (21 O-250)
18 (21 O-250)
Min. 28 (21 O-250)
Max. 350
700
Max. 350
700
Max. 400
800
Max. 200
3.0 -
5.0
2.1
3.0 -
5.0
2.1
3.5 -
5.0
2.5
2.5 -
2.5 -
4.5
1.8
2.5 -
4.5
1.8
3.0 -
4.5
2.1
4.0
20 (210-250)
400
2.5 -
4.0
Min.
1.5
0.7
Min.
1.5
0.7
Min.
1.5
0.7
Min.
1.5
0.7
Min.
1 .O
0.7
Min.
1 .O
0.7
Min.
1 .O
0.7
Min.
1 .O
0.7
110
120
80-100
120
80-90
120
80-110
120
80-
Max. 0.5
1 .o
Max. 0.5
1 .o
Max. 0.5
1.0
Max. 0.5
1 .o
265 f13 +5
220
265 +13 +5
220
265 +13 +5
239
255 +13 +5
230
381 0.75
1 + 0.1
l.lOOi33
38 + 1 0.75
i
l.lOOk33
42 * 1 1
42 f 1
-
-
-
38 i 0.75
1
i 0.1
95 f 25 See page 12-031
+
EG450-1
Min.
Min. 26
z
Standard
PC1 000-l
The values given in the Testing and Adjusting Do not use these values as a guide to change
38 t 1 0.75
It 0.1
950 * 25
39 i 0.75
1
i 0.1
1,020+25(50Hz) 1,224k30(60Hz) -
39 + 1 0.75
j: 0.1
1,020t25(50Hz) 1,224+30(60Hz) -
data are NOT for adjustment of the output the setting of the fuel injection pump.
12-049 8
Engine model Applicable
Item
SA6D170-6-l EG480-1, EG480B-1, EG500-1 EG500B-1, EG500B.B1
machine model
Condition,
I
etc.
Unit
Standard
EPSAGD170-B-1
Standard
Tolerance
Tolerance
High idling speed
rpm
Low idling speed
rpm
ooc
rpm
-20°C (with starting aid)
rpm
Min. 100
mmHs0
Max. 400 lin. 930(50Hz) lin.1,100(60Hz)
762 720 880
Max. 350
762
Min. 1,250
1,090
Max. 400
800
Max. 400
800
2.0
Engine speed
Necessary starting speed
mmHg
)
-
(
Min. 100
1
-
mmHg Exhaust temperature (Turbine inlet temperature)
All speed (intake air temp.: 20°C)
Exhaust gas color
Quick acceleration (Low idling - High idling) At rated output At high idling
OC
Bosch scale
mm mm
kg/cm2 (rpm)
Blow-by pressure (SAE30 oil)
At rated output Water temperature: Min. 70°C
mmH*O
At rated output kg/cm2
3.0 -
4.5
2.1
3.0 -
oil
kg/cm2
2.5 -
4.0
1.8
-
kg/cm2
Min. 1.5
0.7
oil
kg/cm2
Min. 1 .O
0.7
SAE30 oil Oil pressure (Oil temperature: Min. 80°C)
SAElOW
4.5
-
At low Idling SAEBO oil SAElOW
011 temperature
All speed (oil in oil pan)
OC
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
%
Fuel injection pressure
Nozzle tester
80-110
0.7
-
120
I
kg/cm*
Min. 1 .O
-
80-110
120
I
I
Max. 0.5
1 .o
Max. 0.5
1.0
255 +I3 +5
211
265 ;L3
220
degree
kg/cm2
*
Fan speed
At rated engine speed
rpm
,020+26(50Hz) .224+30(60Hz)
1,020i26(50Hz) 1,224+30(60Hz)
Fan belt tension
Deflects when pushed with a force of 6 kg
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.
12-049-l 0
1.23Oi40
1,230 + 40
Auto tension
TESTING
TESTING
AND ADJUSTING
Clas sifica - tiol
machine
I
model
Condition,
item
EG480B-1
(For CIS)
lax. 1,560 (50Hz) lax. 1,872 (60Hz)
Engine speed
Necessary starting speed
700 - 800
0°C
Min. 130
-
-20°C (with starting aid)
Min. 100
-
Max. 2.9 {Max. 300)
7.5 I7621
-
-
68 15301
-
-
700
Max. 650
-
-
kPa [mmHzO}
2.9 {3001
Intake pressure
At rated output
kPa 0-nmHg}
Min. 120 {Min. 930)
{792301
At rated output
kPa {mmHgI
Min. 85 {Min. 6601 650
All speed (intake air temp.: 20°C)
“C
7.5 I7621
Quick acceleration (Low idling + High idling) gas color
Valve clearance (When engine is Hot or cold) Compression pressure (SAE30 oil)
Blow-by pressure (SAESO oil)
-p/
At rated output At high idling
mm
Exhaust valve
mm
Oil temperature: 40°C to 60°C (Engine speed) At rated output Water temperature: Min. 70°C
SAE30 oil SAElOW
oil
At low idling SAESO oil SAElOW
*
4.0 2.0
Intake valve
At rated output
Oil pressure (Oil temperature: Min. 80°C)
lax. 1,560 (50Hz) lax. 1,872 (60Hz)
700 - 800
At all speed
Exhaust
Tolerance
Low idling speed
Intake resistance
Exhaust pressure [Turbineinlet pressure) Exhuast temperature (Turbine inlet temoerature)
OEM for generator 367 kW {492 HP} I50 Hz Standard
etc.
High idling speed z : E b ‘t d
DATA
SA6D170-B-1
Engine model Applicable
AND ADJUSTING
oil
0.4
I
1.0
I
Max. 3.0 Max. 2.5
4.0 3.5
-
0.4
-
-
1.0
1.96
MPa {kg/cm*}
Min. 2.55 {Min. 26)
1.77 1181
Min. 2.75 {Min. 281
(rpm)
(210 - 250)
(210 - 250)
(210 - 250)
(210 - 250)
7.8 18001
Max. 3.9 {Max. 4001
7.8 (800) 206 (1.8)
kPa (mmHnO1
&&
kPa {kg/cm*}
265 - 392 (2.7 - 4.0)
186 (1.9)
294 - 441 13.0 - 4.51
kPa {kg/cm3
216-343 (2.2 - 3.5)
147 (I.51
245 - 392 (2.5 - 4.0)
kPa {kg/cm*}
Min. 147 {Min. 1.5)
$1
Min. 147 {Min. 1.5)
kPa {kg/cm’}
Min. 98 (Min. l.O}
$1
Min. 98 {Min. 1.01
QOI
Oil temperature
All speed (oil in oil pan)
“C
80-110
120
80-110
120
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
%
0.5
1.0
Max. 0.5
1.0
Fuel injection pressure
Nozzle tester
MPa {kg/cm*}
25.5 - 26.3 1260 - 268)
20.7 I2111
25.5 - 26.3 (260 - 268)
20.7 12111
Fuel injection timing
B.T.D.C.
Radiator vavle
Opening pressure (Differential pressure)
pressure
degree
At rated engine speed
Fan belt tension
Deflects when pushed with a force of 6 kg the Testing and Adjusting
41-43
41-43 64-83 IO.65 - 0.851
Fan speed
The values given‘in
41-43
mm
Auto tension
data are NOT for adjustment
Do not use these values as a guide to change the setting
of the fuel injection
41-43 64-83 IO.65 - 0.851
-
of the output. pump.
12-049-2 0
TESTING
TESTING
AND ADJUSTING
:-
machine
IBS-1 :nerator 265 and up)
model
Condition,
Item
DATA
SA6D170-B-1
Engine model Applicable
AND ADJUSTING
Unit
etc.
-
Tolerance
Standard
OEM for generator 379 kW I508 HP} / 50 Hz Standard
Tolerance
7
rpm
Low idling speed
rpm
700 - 800
0°C
vm
Engine speed
Necessary starting speed
-20°C (with starting
Intake resistance
At all speed
Intake pressure
At rated output
Exhaust pressure [Turbineinlet pressure) Exhuast temperature (Turbine inlet temoerature)
aid)
All speed (intake air temp.: 20°C)
Valve clearance
dax. 1,568 (50Hi lax. 1,861 (60H:
Compression pressure (SAE30 oil)
Blow-by pressure (SAE30 oil)
700 - 900
Min. 130
-
Min. 130
-
vm
Min. 100
-
Min. 100
-
kPa (mmHnO1 kPa fmmHgI
Max. 2.9 {Max. 300)
Max. 2.9 {Max. 300)
7.5 (7621
-
-
-
-
-
-
-
Max. 650
700
Max. 650
700
-
-
“C
7.5 f762) . .
-
At rated output At high idling
Bosch scale
Max. Max.
1.5 1.0
*
Max. 2.5 Max. 1.5
2:
Intake valve
mm
0.4
-
0.4
Exhaust valve
mm
1.0
-
1.0
MPa {kg/cm21
Min. 2.75 (Min. 28}
1.96
(rpm)
(210 - 250)
(210 - 250)
(210 - 250)
Max. 3.9 {Max. 400)
7.8 (8001
Max. 3.9 {Max. 400)
Oil temperature: 40°C to 60°C (Engine speed) At rated output Water temperature: Min. 70°C
kPa ImmHtO
343-441 (3.5 - 4.5)
245 (2.5)
245 - 441 (2.5 - 4.5)
SAEIOW
kPa Ikg/cn+I
294 - 392 (3.0 - 4.01
206 (2.1)
196 - 392 (2.0 - 4.0)
oil
At low idling SAEBO oil
Ikg/cm21
Min. 177 (Min. 1.8}
Min. 147 {Min. 1.5)
SAEIOW
kPa {kg/cm?
Min. 127 {Min. I.31
Min. 98 {Min. 1.0)
kPa
oil
8
I,96
Min. 2.75 {Min. 28)
(201
(kg/cm21
kPa
3.5 2.5
-
SAE30 oil
At rated output
Oil pressure (Oil temperature: Min. 80°C)
dax. 1,560 (50Hz) Aax. 1,872 (6OHz)
700 - 900
/[When engine is Hot or cold)
flax. 1,560 (50H2 dax. 1,872 (60H2
700 - 800
kPa ImmHgI
At rated output
Quick acceleration (Low idling --3 High idling)
IExhaust gas color
dax. 1,568 (50tb tiax. 1,881 (6OH2
High idling speed
(201 (210 - 250)
Oil temperature
All speed (oil in oil pan)
“C
80-110
120
80-110
120
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
%
Max. 0.5
1.0
Max. 0.5
1.0
Fuel injection pressure
Nozzle tester
MPa {kg/cm21
25.5 - 26.3 (260 - 268)
20.6 (21OI
25.5 - 26.3 1260 - 268)
Fuel injection timing
B.T.D.C.
degree
35-37x1 31 -33 ‘2
35-37x1 31 -33 *2
35-37
Radiator vavle
Opening pressure (Differential pressure)
kPa {kg/cm’I
59-78 (0.6 - 0.8)
59-78 IO.6 - 0.8)
-
995 - 1,055 (50Hz ,192 - 1,266 (60H
395- 1,055 (50tk ,192 - 1,266 (60H
pressure
Fan speed
At rated engine speed
wm
Fan belt tension
Deflects when pushed with aforceof6kg
mm
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
12-049-3 0
20.6 (2101 35 -37
)95 - 1,055 (50Hz ,192 - 1,266 (60H
-
395 - 1,055 (50Hz) ,192 - 1,266 (60Hz)
-
of the output. pump.
*I
: Except EG500BS-1
*2
:
EG500BS-1
only
z z
TESTING AND ADJUSTING
TESTING AND ADJUSTING DATA
SAGDI JO-B-I
Engine model Applicable
machine
OEM folr gc merator (Stan db\lr use)
model
Condition,
etc.
Standard
I E
Low idling speed
wm
700 - 900
0°C
rm
Min. 130
-
Min. 130
rpm
Min. 100
-
Min. 100
-
kPa lmmHz0) kPa lmmHg)
Max. 3.9 {Max. 400}
7.5 1762)
Max. 3.9 {Max. 400)
1762)
At all speed
Intake pressure
At rated output
-0
6
m
Exhaust gas color
%
2
(When engine
700 - 900
-
At rated output All speed (intake air temp.: 20°C)
Compression pressure (SAE30 oil)
: ‘Bl I=
Blow-by pressure lSAE30 oil)
-
-
-
-
Max. 700
Oil pressure (Oil temperature: Min. 80°C)
2.5 2.0
Intake valve
-
Exhaust valve
-
3il temperature:
Min.27.5 {Min. 28}
40°C to 60°C :Engine speed)
pressure
Max. 3.9 {Max. 400)
7.8 1800)
SAE30 oil
245 - 441 12.5 - 4.5)
I77 11.8)
SAElOW
196 - 392 (2.0 - 4.0}
137 11.4)
4t rated output Water temperature:
Min. JOY
kPa lmmHz0)
Max. 3.9 {Max. 400)
7.8 1800)
oil
At low idling
kPa {kg/cm*)
Min. 147 {Min. 1.5}
&
u” *
Fan belt tension
Min. 147 {Min. 1.5} Min. 98 {Min. 1.01
oil
All speed (oil in oil pan)
80-110
120
At continuous rated output (Ratio of fuel consumption)
Max. 0.5
1.0
- 25.5 - 26.3 I260 - 268) 40-42
Opening pressure [Differential pressure)
{‘fi
l,,:
1
1”“:
Deflects when pushed with 3 force of 6 ka
The values given in the Testing and Adjusting
59-78 10.6 - 0.8)
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;
At rated engine speed
.-? Z
1201 (210 - 250)
B.T.D.C. Radiator
1.96
(210 - 250)
Nozzle tester
s
700
At rated output At high idling
SAElOW Oil temperature
7.5
-
SAE30 oil
ti ?i
Max. 650
700 - 800
Quick acceleration [Low idling + High idling)
At rated output
$ IYY 2
700 - 800
is
& 8
lax. 1,568 (50Hz) lax. 1,881 (60Hz)
vm
Intake resistance
Exhaust pressure (Turbineinlet pressure) Exhuast temperature (Turbine inlet temperature)
Aax. 1,566 (50H; Aax. 1,681 (60H;
High idling speed
-20°C (with starting aid)
ti 2 ti : _c Z
Max. 1,568 (50Hz) Max. 1,566 (50H2 Max. 1,881 (60Hz) Max. 1,881 (60H1
Tolerance
data are NOT for adjustment
Do not use these values as a guide to change the setting of the fuel injection
-
20.6 1210) 40-42 59 - 78 iO.6 - 0.8) 95 - 1,055 (50Hz) 192- 1,266 (60Hz)
-
of the output. pump.
12-049-4 0
TESTING AND ADJUSTING DATA
TESTING AND ADJUSTING
Engine model Applicable
machine
SA6D170-B-1 EPSAGD170-B-1 445 kW (597 HP} / 1,300 rpm
model
Condition,
1
etc.
Unit
Standard
Max. 2.200
High idling speed
Tolerance Max. 2.200
Engine speed
Necessary starting speed
-20°C (with starting
Intake resistance
At all speed
Intake pressure
At rated output
Exhaust pressure (Turbineinlet pressure) Exhuast temperature (Turbine inlet temperature)
aid)
At rated output All speed (intake air temp.: 20°C)
Exhaust gas color
At rated output At high idling
SAE30
oil
SAEIOW
oil
At low idling SAE30 oil SAElOW
750 - 850
Min. 130
-
Min. 130
-
Min. 100
-
Min. 100
-
-
Min. 123 (50Hz) {Min. 950) (50Hz)
-
kPa ImmHgI
-
-
Min. 142 (6OHz) [Min. 1,100) (66Hz
-
Max. 650
700
Max. 6700
700
-
-
-
-
Bosch scale
oil
-
0.4
-
1.0
-
1.0
-
1.96
I20}
Min. 2.45 {Min. 26)
Min.1.77 {Min. 18)
(210 - 250)
(210 - 250)
(210 - 250)
5.9 16001
Max. 3.9 {Max. 400)
I
294 - 490 13.0 - 5.01
kPa {kg/cm*}
245 - 441 12.5 - 4.5)
177 t1.81
kPa {kg/cm?
Min. 147 {Min. 1.51
I&
,k~,~m21
Min. 98 {Min. 1.0)
&
I -
120
85-110
“C
80-110
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
%
Max. 0.5
206 t2.11 Min. 147 {Min. 1.5)
39 - 59 IO.4 - 0.61
E) 120
21.5 {219}
41-43 kPa {kg/cm?
-
1.0
25.5 - 26.3 I260 - 268)
Opening pressure (Differential pressure)
2.0 1.5
0.4
kPa ikg/cm2}
Fuel injection timing
7.5 D’621
Max. 0.5 1.0
All speed (oil in oil pan)
pressure
Max. 3.7 {Max. 380)
;::
Oil temperature
Radiator vavle
7.5 17621
Max. 2.5 Max. 1.5
kPa ImmHzO)
Fuel injection pressure
*
750 - 850
(210 - 250)
At rated output
Oil pressure (Oil temperature: Min. 80°C)
600 - 1,000
-
Compression pressure (SAE30 oil)
Min. 70°C
Max. 1,947 (50Hz) Aax. 1,047 (50Hz) Max. 1,256 (6OHzl Aax. 1,256 (60Hz)
600 - 1,000
Min. 2.75 {Min. 27)
At rated output Water temperature:
Tolerance
Max. 2.9 {Max. 300)
Valve clearance (When engine is Hot or cold)
Blow-by pressure (SAE30 oil)
Standard
generator
kPa {mmHzOl kPa {mmHgI
“C
Quick acceleration (Low idling + High idling)
OEM for 6-pole
18-20 39 - 59 CO.4 - 0.6)
59-78 10.6 - 0.81
59-78 IO.6 - 0.81
Fan speed
-
989 - 1,051
989 - 1,051
Fan belt tension
-
8 - 12
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
12-049-5 0
of the output. pump.
8-12
2 z z
TESTING
TESTING
AND ADJUSTING
Item
machine
model
Condition,
I
DATA
SAA6D170-1
Engine model Applicable
AND ADJUSTING
f
etc.
OEM for generator
Unit
Standard
rpm
Max. 1,568
Low idling speed
rpm
700 - 900
0°C
rpm
Min. 130
vm
Min. 100
High idling speed
(50 Hz)
Tolerance
Max.
1,568
Engine speed
Necessary starting speed
-20°C (with starting
aid)
Intake resistance
At all speed
kPa [mmHzO;
Max. 4.4 {Max. 4501
Intake pressure
At rated output
kPa {mml-lg}
-
Exhaust pressure (Turbine inlet pressure)
At rated output
kPa ImmHg)
-
~uh$~e~;e:en;netPe’ature All speed (intake air temp.: 20°C) temperature)
Exhaust
gas color
Valve clearance (When engine is Hot or cold)
Blow-by pressure (SAE30 oil)
“C
Quick acceleration (Low idling + High idling) At rated output At high idling
Bosch scale
Max. 1.5 Max. 1.0
mm
0.4
-
Exhaust valve
mm
1.0
-
MPa {kg/cm*1
Min. 2.55 {Min. 26)
1.77 I181
(rpm)
(210 - 250)
(210 - 250)
kPa (mmHz0
Max. 5.9 {Max. 6001
11.8 Il.2001
kPa {kg/cm*)
255 - 373 12.6 - 3.81
kPa {kg/cm21
206 - 324 {2.1 - 3.3)
SAE30 oil
kPa {kg/cm?
Min. 147 {Min. 1.5)
SAElOW
kPa {kg/cm21
Min. 98 {Min. 1.0)
At rated output Water temperature: Min. 70°C
SAEBO oil SAElOW
oil
At low idling
oil
Oil temperature
All speed (oil in oil pan)
“C
80-110
Oil consumption ratio
At continuous rated output (Ratio of fuel consumption)
%
Max. 0.5
Fuel injection pressure
Nozzle tester
MPa {kg/cm*1
29.9 - 30.7 1305 - 313)
degree
t
Max. 650
Intake valve
At rated output
Oil pressure (Oil temperature: Min. 80°C)
Fan speed
At rated engine
Fan belt tension
Deflects when pushed with a force of 6 kg
The values given‘in
700 - 900
speed
the Testing and Adjusting
120
23-25
kPa {kg/cm?
59-78 IO.6 - 0.8)
vm
1,240 - 1,310
mm
Autotensioner
data are NOT for adjustment
Do not use these values as a guide to change the setting of the fuel injection
Autotensioner
1
of the output. pump.
12-049-6 0
FAN BELT TENSION
1. 2.
Washer
3.
Tension spring
4.
Adjustment bolt
5.
Tension pulley
A.
6162F291
Unit: mm Engine model
Applicable machine
Dimension A
PC650-1 PC1500-1
S6Dl?O-1
SAGDl70-A-1
73 f 5
HD465-3
5Bi5 I
I
D375A-1 D375A-2
SAGD 170-B-l
I
PC1 000-l
50 k 5
I
70 i: 5
Adjustment nut
Protrusion of adjustment bolt
TENSION l
1.
OF WA700-1
Replacing Loosen
locknut
(1) and turn back adjustment
(2) as far as bracket 2.
FAN BELT
insert
a bar with
hole (@18)
screw
(3).
a length
in bracket
of approx.
(7), then
50 cm in the
pull strongly
to the
front and hold in position. 3.
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
l
Adjusting Tighten
adjustment
adjustment tension
screw
pulley
(2) a further (1).
w
Locknut
the
(4). tighten then
: 29.5
f
between
tip of adjustment
adjust
(2). and when
comes
half turn,
locknut
If a gap appears
lever
screw (2)
into
the tip of
contact
adjustment
lock it in position
with screw with
2 kgm
tension screw
pulley
(2) during
lever (4) and operation,
in the same way.
If the fan
belt screeches,
adjust
in the same
way. 6162F668
12-051 0
TROUBLESHOOTING CONTENTS Points to remember Method S-l
Starting
troubleshooting
performance
(Starting s-2
when
of using troubleshooting always
chart
Engine
does not turn
@
Engine
turns
but no exhaust
comes
12-061
out
..............................................
gas comes out but engine
12-062
does not start 12-063
.................................................
does not pick up smoothly
(Follow-up
. ...........
............................................
is poor)
operations
12-064 12-065
Engine
s-5
12-066
s-7
.................................... Engine lacks output (no power) .............................................. ................................. Exhaust gas is black (incomplete combustion)
S-8
Oil consumption
...........................
12-069
s-9
Oil becomes
S-IO
Fuel consumption
S-l 1
Oil is in cooling water,
s-12
Oil pressure
s-13
Oil level rises
s-14 s-15
............................ Water temperature becomes too high (overheating) ................................................... Abnormal noise is made
S-16
Vibration
Engine
stops during
.............................................
s-4 S-6
2 z z
12-061
...................................................
(Fuel is being injected) Engine
12-060
......................................................
(Fuel is not being injected)
s-3
12-056
................................................
takes time)
@
Exhaust
12-055
is poor
Enginedoesnotstart
@
.......................................... .............................................
does not rotate smoothly
is excessive
contaminated
(hunting)
(or exhaust
gas is blue)
12-068
........................................... ..............................................
12-070
quickly
is excessive or water
spurts back, or water
lamp lights up (drop in oil pressure) .............................................................
is excessive
12-067
......................................................
level goes down
...............................
12-071
............
12-072 12-073 12-074 12-075 12-076 12-077
POINTS TO REMEMBER WHEN TROUBLESHOOTING Troubleshooting failure When carry
means
locating
the basic cause
of the failure,
and carrying
carrying out
out
the
mentioned
troubleshooting,
troubleshooting
by the operator
it is of course
effectively, as a guide
important
a quick
in locating
method
to understand is to carry
Do
not
disassemble
cause there If the
the
machine
simply
be-
is a failure
machine
is disassembled
immediately
because there is a fuilure: . Unrelated or unnecessary .
just
failure degree
difficult
places
are also dis-
the cause
is not only
a waste
and money
on replacement
For this
of the
problem
in the handling
of the
When
driving
failure,
the
problem
a failure,
But to problems
to judge
or if there
or operation
the
machine
be sure
measurement
parts,
oil, and grease,
5.
of the
for
is some
of the
ma-
that
does
and
the
not
re-enacting
investigation
make
the
or
failure
Troubleshooting Narrow results
reason
also,
it is important
based
to carry
on full investigation
and troubleshooting
following
out
Items
before
Questions
the correct
*
to ask the user and operator
1) Are there any problems ready
other
than
those
6. unusual
happen
before
the fai-
lure occurred? the
failure
occur
of the
the failure
occurred?
What were
2 -
suddenly,
machine
been
or
had
poor
when
the
before
the failure
from
the
in the above
the troubleshooting
flow
for troubleshooting
1)
Start from the simple
2)
Start from
3)
investigate
Basic action
places.
the most probable related
oc-
to remedy
Even if the failure
places.
parts also.
cause of failure
is repaired,
is not repaired,
if the root
cause
the same failure
of
will OC-
cur again. To prevent the
the conditions
of the failure and checks
4, then follow
Basic procedure
the failure
condition
the causes
al-
reported?
2) Did anything
down
of the questions
chart to locate the failure.
order.
4)
function.
using
of time
will also lose the confidence
troubleshooting
Did
the
if it is really
*
user and operator.
3)
and
worse. that there
but this action
z z
that the
chine.
to locate
This means
starting
structure
yourself
failure
8
and ensuring
troubleshooting
Check
the
It becomes
the
out
Confirming
assembled
2.
repairs,
the cause 4.
1.
out swift
does not occur again.
failure
this, it is necessary occurred,
and
to
to investigate remove
the
why root
cause of the failure.
curred? 51
Had any repairs
been carried
ot before
the fai-
lure occurred? 6) 3.
Had any similar
failure
occurred
before?
Checks before troubleshooting
1) Check the oil level. 4 Check for any external piping
and hydraulic
3)
Check the travel
4)
Other out
of the control
maintenance
visually,
considered
leakage
of oil from
the
equipment. items
so carry
out
levers.
can also be carried any
check
that
is
necessary.
12-055 @
METHOD OF USING TROUBLESHOOTING This
troubleshooting
sections: ooting.
The
pinpoint from
the
questions failure
is divided
check
items,
and check
high probability
without
causes
symptoms
troubleshooting
used
to
check
three
troublesh-
items
are used to
simple
inspection
tools.
tools
the
into
and
that can be located
or
using troubleshooting
Next, are
chart
questions,
high
or
direct
inspection
probability
causes
to
make final confirmation. [Questions] Sections
@ +
sponds
to
obtained items
@ in the chart
the
from that
depending
items the
can
on the right corre-
where
user.
be
answers
The
items
obtained
from
can
be
@
are
in the
user,
on the user’s level.
[Check items] The
serviceman
narrow
down
carries
out simple
the causes.
The
the chart on the right correspond The
serviceman
information
narrows
@
user and the
that results
he
of 0
under
to
@ in
to this.
down has
inspection
items the
causes
obtained
that
from
from
the
he has obtained
from his own inspection. rroubleshooting] Troubleshooting probability,
is carried
starting
been
marked
from
information
[Check items].
12-056 8
as
out
in the
with
the
causes
having
the
highest
gained
from
order that
of
have
probability
[Questions]
and
CHART
The
of using the troubleshooting
basic method
chart
is as
follows. Items
listed for [Questions]
relationship of these,
with
the Cause
causes
that
have
and [Check items
items]
that have a
are marked
with
probability
are
a high
0,
and
marked
with 0. Check and
problem the
each
of the
marked
[Questions]
appeared.
highest
and
the 0 or 0 in the The
number
vertical
of points
so start troubleshooting
[Check
chart
for
column
the
that
has
probable
to make
turn,
where
(Causes)
is the most
for that item
item&in
items
cause,
final confir-
mation of the cause.
%1. For [Confirm tions]
recent
Section,
1 ! column
with
the cause
when
repair
ask the
A
to
use
and
in the mark
as reference
of the failure.
making
history]
user,
However,
calculations
to
the for
[QuesCause locating
do not use this
narrow
down
the
as reference
for
causes.
%2,
Use the
[Degree
A
[Questions]
use it when
cause,
in the
Cause
column
of use (Operated section
for long
as reference.
calculating
the
but it can be included
period)]
in the
As a rule, do not
points for
locating
if necessary
the
to deter-
mine the order for troubleshooting.
2 G z
%l
Confirm recent repair history
%2
Degree of use
I Operated for’long period
A
A
I
A
12-057 0
- Example of troubleshooting Let
us assume
have
causal
that
[Clogged
relationship
er], and [Dust indicator If we causes.
12-058 8
look
from
these
Let us explain
with
when exhaust gas is black air
cleaner]
this
problem:
is taken
to
[Exhaust
be the
gas slowly
cause
of black
became
black],
exhaust [Power
gas.
Three
slowly
symptoms
became
weak-
is red]. three
symptoms
here the method
to
find
the
causes,
of using this causal
we
relationship
find
that
there
to pinpoint
is a relationship the most probable
with cause.
five
Five causes Step 1 Clarify the relationship in the
[Questions]
between
and
the three
[Check
items]
symptoms
section
and
the five Cause items in the vertical column.
Step 2
I
Add
up the total of 0
zontal
and 0
lines for the three
marks where
symptoms
the hori-
and the vertical
columns for the causes intersect. (1)
Clogged air cleaner element:
(2) Air leakage between
000
turbocharger
and
head:
00
(3)
Clogged,
seized injection nozzle:
0
(4)
Defective
contact of valve, valve seat:
0
(5) Worn piston ring, cylinder:
0
Step 3 The
calculations
in Step
relationship
is with
Follow
column
this
2 show
[Clogged down
air to
that
the
area and carry out the troubleshooting 0.
The
Remedy
cleaning, _ to normal.
and
the
the
cleaner
is given
as [Clean],
exhaust
gas color
closest
element].
troubleshooting item marked so carry should
out
return
TROUBLESHOOTING
TABLE
r
S-l
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 O°C or below, use ASTM D975 No. 1) .lr Battery charging rate
Causes
l
2
l
s ;i
l
$
l
100%
90%
80%
75%
70 %
temoerature 2ooc
1.28
1.26
1.24
1.23
1.22
ooc
1.29
1.27
1.25
1.24.
1.23
-1 ooc
1.30
1.28
1.26
1.25
1.24
* 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
,
I
‘/ <
” i i
i 1 : I
0 t(
/ f. i _
I
I
b : i i
Starts when warm
Dust indicator is red ,
Type of oil is not used according to operation manual
-
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
Q
-6
/
There is hunting from engine (rotation is irregular)
I
-
,
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 30V between alternator terminal B and terminal E
Either specific gravity of electrolyte or voltage of battery is low Some cylinders does not change engine speed when operating on reduced cylinders
a
c
5 -
- -
When check is made using delivery method, injection timing is found to be incorrect
I
-
G - -
,
When comoression oressure is measured. it is found to be low
Voltage is 26 -
$
0 - 5
Leakage from fuel piping
When air cleaner element is insDected directly, it is found to be clogged
6
c
3 0 - 0 - -
1
2) Little fuel comes out even when fuel filter air bleed plug is loosened
P
$ -
Gradually became worse
Non-specified fuel has been used
:
m‘
-
Replacement of filters has not been carried out according to operation manual
;i;
E
t;s 2 5
/ .
Engine oil must be added more frequently
5
2
2
Indicator lamp does not light up
z 9
5
c
Operated for long period
Ease of starting
E
z
/
I
1 Confirm recent repair history Degree of use
:
a zi h J $ 55
- -
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
12-060 @
I
i
z
.k
0
8
m
1 i
m
cr E
S-2
Engine
does not start
@ Engine does not turn
r
General causes why engine does not turn
Causes
l l
b
6
E
r, C
$ z
z
z :
E
$
5
2
‘E
m
zi a .?
&
Ek .-P L
2 5
2 -
Confirm recent repair history !? E ._ zi %-
Operated for long period
Condition of horn when starting switch is turned ON
Horn does not sound
a
Horn sound level is low Rotating speed is slow
/I
When starting switch is turned to START, pinion moves out, but
/I
-
Makes rattling noise and does not turn
Im
When starting switch is turned to START, pinion does not move out
C
When starting switch is turned to ON, there is no clicking sound
P 6
When startina switch is turned to ON. linkaae does not move
E
0
Battery terminal is loose
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
ii-
When rina aear is inspected directlv. tooth surface is found to be chiooed
2
B z
5 5 :: 0)
.’ ;
I
$ iT 0 - - z- - - - $ -
E
$
L
,z a, 3
z ._ ; I
.
I I _
Remedy
-
-
-
-
-
-
-
-
-
-
-
-
-
0 -
-
r-
-
or
b
Irr
r
or
z,
E
5 z z e E
E -
3
G
2
-
-
-
P
0
E
.-z
-
-
0 -
s
m m .E ;
r-
D -
-
0
3
x 2 ._
F -
0 -
-
P
E 5
$ -
-
Does not move even when engine stop motor linkage is disconnected
*
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
E
5 ii 8
E -
0” -
l -
-
5) There is no 24V voltage between terminal B and terminal E of battery relav
.-J t;
F
-
-
4) When terminal of safety switch and terminal B of starting motor are con netted, engine starts
2 3 L fti
.-6 8 ii 5 I i?i ._ 8 z .f B
-
l
3) When terminal B and terminal C of safety relay are connected, engine starts E
-
F 0 - - - - - - - -
2) When terminal B and terminal C of starting motor are connected, engine starts
I=
e m
c -
Makes grating noise Soon disenaaaes aaain -”
1
.-El 3
T
Degree of use
-
-
-
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
l
P
E
c 7
P $
a
12-061 Go
@
Engine
turns
but no exhaust
(Fuel is not being General
causes
gas comes
out
injected)
why engine turns but no exhaust gas comes
out
Causes
-
-
Supply of fuel impossible Supply of fuel is extremely Improper Standards
selection
small
of fuel (particularly
in winter)
for use of fuel
E
E ._ a
.-P .g
E
2 ::
z 1
1
5e a
$ .N
-z -
Confirm recent repair history Degree of use
Operated for long period
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
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
12-062 0
I
z iT -
F 5
u
2i 0 -
r-
-
u $
-
3
lx -
1
2 6 %
-
-3
$
H
0 -
K .k
m
E
LT
@
Exhaust being
General
gas comes
out
but
engine
does
not
start
(Fuel
is
injected) causes
why
exhaust
gas comes
out but engine
does not Causes
start
l
Lack of rotating
l
Insufficient
l
Insufficient
l
Improper
force due to defective
electrical
system
supply of fuel intake
of air
selection
of fuel and oil
6 ::
%JY ._ 2 $ E .E
2
E
7,
Y a
2
kl c
z 0E
P
Suddenly failed to start When engine is cranked, abnormal noise is heard from around cylinder head Engine oil must be added more frequently
- - - -
- - -
Q -
- - - -
-
g
5 0 -
Dust indicator is red Indicator lamp does not light up Starting motor cranks engine slowly Mud is stuck to fuel tank cao When fuel lever is olaced at FULL position, it does not contact stopper
/ E S z : 5
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
ii-
-
Play, stiffness in fuel control lever linkage 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
-
5 - 5 -
-
5k
5
-0
a -
-
G - G -
Type of oil is not used according to operaton manual Rust is found when fuel is drained
z
i- - -
h -
n
Non-specified fuel has been used Reolacement of filters has not been carried out according to operation manual
5
-
on f rrm recent reoair historv Operated for long period
2
:
- 0 - -
u -
1
2 5
.k
6 -
2
Degree of use
8
c c
.r_ 2 P m z E 9 8 0 0 - - - - - -
1 :: 8
Ic
.k
5 tl $ _c i 5 -z lj
3
-
-
-
-
: -
5 -
-
c 5_,
3
al
9 g & ii
I? E 8
z 2 e, .>
5
5 0 -
0 0
-
0 G 5
E
5
S-3
Engine does not pick up smoothly (Follow-up General
causes why engine
l
Insufficient
l
lnsuff icient supply of fuel
is poor)
does not pick up smoothly
intake of air
l
Improper
l
Use of improper
condition
l
Defective
of fuel injection
fuel
fuel injection
pump
B
k $
z
.c .e E
.E
E E
G
55
6
e
2
2
a
5
2
r
2 P E
P 0Fk : _o $
v -
v -
1 Confirm recent reoair historv Ooerated for lona oeriod
Replacement of filters has not been carried out according to operation manual
h 0 0
0 - 0
Non-specified fuel has been used Engine oil must be added more frequently I .P
0 -
0 -
am-died
0
D
There is hunting from engine (rotation is irregular)
5 -
ii -
-
-
c-
-
Rust and water are found when fuel is drained Dust indicator is red
2 r3
Noise of interference is heard from around turbocharaer Engine pick-up suddenly became poor Color of exhaust gas
/
Blue under light load Black -.-_..
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
-rr-.--
L
6
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
E
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
P
d
F t; 5
r=
Degree of use
z
‘t
-
F -
r”
2
4 $
5
c
P
B
.N
z -
9 0 -
0 0 -
s G -
7 0 i-
-
r-
When boost compensator diaphragm is inspected it is found to be broken, or pipe is crushed
.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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Engine
s-4
stops during
operations
General causes why engine stops during operations l 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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5e 5 2 m q Confirm recent repair history Degree of use
Abnormal noise was heard and engine stopped suddenly Engine overheated and stopped
Condition when engine stopped
E .o z 2
Ermine stopped slowlv ! There was hunting and engine stopped
Fuel gauge lamp lights up
a
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
/
-
-
0 -
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Operated for long period
When feed oumo is ooerated. there is no resoonse or it is heaw
- - - 0 - 0 - - -
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 Remove head cover and inspect directly
.-P
When gear train is inspected, it does not turn
6
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Turns when oumo auxiliarv eauioment is removed When fuel filter, strainer are insoected directlv. thev are found to be cloaaed
B
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When feed pump strainer is inspected directlv, it is found to be clogged Inspect feed pump directlv
G -
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When control rack is pushed, it is found to be heavy or does not return I
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
5
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Remedy
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Engine
does not rotate
General
causes why engine
s-5
l
Air in fuel system
l
Defective
governor
smoothly
(hunting)
does not rotate smoothly
1
Causes
-
mechanism
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1
Degree of use
1
Operated for long period
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Condition of hunting
1: ;;;;,:r;;d
range
Occurs even when weed is raised Occurs on slopes
Fuel tank is found to be empty
c 0 0
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
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When feed pump is operated, 1) No response, light, return is quick
-
-
-
-
2) No response, light, return is normal
G-
Sometimes difficult to stop engine
-Q
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When covernor lever is moved it is found to be stiff
-
-
Engine speed sometimes changes greatly
Seal on injection pump has come off
-
-
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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
When feed pump strainer is inspected directly, it is found to be clogged
-
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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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S-6
Engine Carry
lacks output
(no power)
out troubleshooting
engine General
or in the machine.
to decide (Measure
causes why engine
l
Insufficient
intake of air
l
Insufficient
supply of fuel
l
Improper
condition
0 Use of improper
is in the
stall speed)
Causes
lacks output E
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ma
of fuel injection
n
fuel
(if non-specified l
if the cause engine
5
fuel is used, output drops)
P
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Lack of output due to overheating j,
If there
is overheating
troubleshooting
and
lack of output,
carry
out
z
2
$
for overheating.
ai
Tl
Confirm recent repair history
1
Operated for long period
Power was lost
Replacement Non-specified
of filters has not been carried out according to operation
F
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d -
-
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manual
fuel has been used
Black Color of exhaust gas
Blue under light load
Noise of interference
is heard from around turbocharger
Blow-by gas is excessive Engine pickup is poor and combustion
is irregular
High idling speed under no load is normal, but speed suddenly drops when load is applied
B
When exhaust manifold is touched immediately ture of some cylinders is low
6
There is hunting from engine (rotation
after starting engine, tempera-
is irregular)
< -
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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
is rotated by hand, it is found to be heavy
-
When compression
pressure is measured, it is found to be low
-
When fuel filter, strainer are inspected directly, they are found to be clogged
: 5
When feed pump strainer
% 3
When control rack is pushed, it is found to be heavy or does not return
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Dust indicator is red
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2 Engine oil must be added more frequently .g 5 2
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Dearee of use
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Some cylinders does not change engine speed when operating on reduced cylinders
When valve clearance value
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is inspected directly, it is found to be clogged
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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
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When lever is placed at FULL position, it does not contact stopper
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Exhaust General
gas is black (incomplete causes
l
Insufficient
l
Improper
l
Excessive
why exhaust
combustion)
gas is black Causes
intake of air condition injection
-
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of fuel injection of fuel
%
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I Dearee of use
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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
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 Some cylinders does not change engine speed when operating on reduced cylinders
2 ._ B P
When check is made using delivery method, injection timing is fount to be incorrect
3
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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
I
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
oil from
leaking
(or exhaust up or down,
at idling for more than
20 minutes
gas is blue)
do not run the continuously.
(Both low and high idling) General
causes why oil consumption
l
Abnormal
l
External
l
Wear
combustion leakage
is excessive
of oil
of oil
of lubrication
system
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Degree of use
Operated for long period
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
Abncrmally excessive None
0 -
Area around engine is dirty with oil There is oil in engine cooling water f = Y 4 5
3 -
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
-
c-
When intake manifold is removed, inside is found to be dirty with oil
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
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Remedy
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12-069 8
S-9
Oil becomes General
contaminated
quickly
causes why oil becomes
l
Intake of exhaust
l
Clogging
of lubrication
l
Improper
combustion
l
Use of improper
l
Operation
l
Interval
gas due to internal
quickly
wear
-
-
passage
oil
under excessive between
contaminated
load
oil change
is too long
m .P a .g
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= 0 -0 (u
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Operated for long period
Degree of use Engine oil must be added more frequently Non-specified
0 -
fuel has been used Blue under light load
Color of exhaust gas
Black Abnormally
Amount E .= % a, 5
of blow-by gas
excessive
None
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
When oil level is checked with dipstic, When compression .-P 5 2 2 0 z c
-
it is found
pressure is measured,
to be above H mark.
it is found to be low
-
drain tube is clogged
Excessive play of turbocharger
shaft
I
E
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5 .:: 8
0
0
-
-
-
-
-
-
-
-
-
-
-
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F
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12-070 0
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2
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s
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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
P
D
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When oil cooler is inspected directly, it is found to be clogged Turbocharger
a
s %
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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
b
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Fuel consumption General
causes
l
Leakage
l
Improper
l
Excessive
why
is excessive fuel
consumption
is excessive
r
of fuel condition
of fuel
injection
of fuel
injection
-
-
-
-
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x
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Seal on injection pump has come off
2 P
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F 2
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2
$ -
h -
h -
0 -
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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 and’theck items) A: Possible causes due to length of use (used for a long period) 0: Items confirm the cause
I
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There is irregular combustion
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Oil is in cooling General
water,
or water
spurts
back, or water
level goes down
causes why oil is in cooling water Causes
l
Internal
leakage
in lubrication
system
l
Internal
leakage
in cooling system
Confirm recent repair history
.-:
cl 2 c1
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)
/ : 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
i;
Pressure-tightness test of cylinder head shows there is leakage
2 I %
Remove oil oan and insoect directlv
Remove cylinder head and inspect directly
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
lamp lights up (drop in oil pressure)
causes
why
oil
pressure
lamp
lights up
l
Leakage,
clogging,
l
Defective
l
Use of improper
l
Deterioration
wear
of lubricating
r
1
Causes
-
-
-
-
-
-
system
*
Standards
oil pressure
control
oil (improper
% a
viscosity)
of oil due to overheating for engine
Li
z 0
oil selection
z5
AMBIENT TEMPERATURE
5 = + =
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Fi
0
P x 8 E _o u Confirm recent repair history Degree of use
1
Operated for long period
h -
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Replacement of filters has not been carried out according to operation manual
0
Caution lame liahts uo
G
Non-soecified fuel has been used
0 -
0 TT -
0 -
0 -
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-
-
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L
-
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1 Lights up at low idling 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
I
?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
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Oil level rises
3
*
If there
is oil in the
troubleshooting General
cooling
for “Oil
water,
carry
is in cooling
out
water”.
causes why oil level rises
l
Water
l
Fuel in oil (diluted,
l
Entry of oil from other component
r
Causes
-
-
in oil (cloudy white) and smells
of diesel fuel)
F
‘5 .-
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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
I
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
12-074 8
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Pressure-tiahtness test of after-cooler core shows there is leakage Remedy
2
2
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When enaine is first started, drops of water come from muffler
‘Z
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Operated for long period
Exhaust oas is white
B
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There is oil in radiator cooling water
2
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Confirm recent repair history
‘E .-
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Degree of use
.a
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Water
temperature
General
causes
becomes
why water
too high (overheating)
temperature
l
Lack of cooling wind (deformation,
l
Drop in heat dissipation
l
Defective
l
Rise in il temperature j,
becomes
damage
too high
of fan)
r
efficiency
cooling circulation
system
of power train
Carry out troubleshooting
for chassis.
c ;
6 6 0
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s 4
z
s P i 5 g E
2
0
m L
2 x 8 z 9
u -
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Confirm recent repair history
I
Deoree of use Condition of overheating
Water temperature
Ooerated for lono oeriod
6
Suddenly overheated
1 Does not go down from red range
Radiator water level sensor lights up Fan belt whines
under sudden load
Cloudy white oil is floating
on cooling water
Coolino water flows out from overflow
hose
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
Power train oil temoerature
enters red ranae before enaine water temperature
Temoerature
difference
between top and bottom radiator tanks is excessive
Temperature
difference
between top and bottom ratiator tanks is too small
When radiator is inspected through When a function ing temperature
water filler port, the core is found to be cloggel
test is carried out on the thermostat,
When water temoerature
When compression
is measured. it is found to be normal
pressure is measured,
E
2
it is found to be low
test of cylinder head shows there is leakage
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
5
2 _ _ -
-
P
E
L_
m 8 L
$
Y 0 6 _ -
h .-?
_ - - -
.k
Remedy
0
7 z
G - 5
- - _ _ -
s
z
G _ _ _ _
is made with radiator cap tester, set pressure is found to be
Remove oil pan and inspect directly Pressure-tightness
i
2
it does not open at the crack
When oil cooler is insoected directlv. it is found to be cloaaed When measurement low
0 _ _ ii iTI - _ - - 0 _ _ _
Alwavs tends to overheat / Rises quickly
gauge
h - h
2
0 -
2 c
z_ -
-
5 -
u P
a, ii
DC
cc
P
4
12-075 @
S-l 5
Abnormal + Judge
noise is made if the
noise
is an internal
noise
or an external
noise. Causes
General
causes why abnormal
Abnormality Abnormal Air sucked
due to defective combustion
noise is made parts
% i
noise
in from intake
system
5 :
a
: . / : ” : j
u‘
?
5
i : ,
.5
E
.E
$ g
I
9
0
Dearee of use
E
.g
z
I
Condition of abnormal noise
-
I 0 aerated
for lona period
-
1 Graduallv occurred
(
1 Suddenly occurred
Non-specified fuel has been used Engine oil must be added more frequently Color of exhaust gas
Blue under light load
) ) (
Slack
) )
Metal particles are found in oil filter Slow-by gas is excessive
4
Noise of interference is heard from around turbocharger
E (Y
.= P 6
Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately aftr starting engine, temperature of some cylinders is low
Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head Vibrating noise is heard from around muffler
I
1 When compression pressure is measured, it is found to be low
I
When turbocharger is rotated by hand, it is found to be heavy Remove gear cover and inspect directly, (flywheel housing top cover)
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
k : f 8
5
$ -
j -
0 0 - 0 -
0 -
0
0 -
0 -
s-
Some cylinders does not change engine speed when oeprating on reduced cylinder
.c
m .?
-
Seal on injection pump has come off
1 Clanging sound is heard from around cylinder head
.-2 B e z B 2 e
-
0
_a
s ,_ t; .L
2
-
1 Confirm recent reoair historv
_c ti
x?
.!
i
2
.-5 E” t; 2 .2 P
2
z
x
-
5 -
G - G - -
-
G
-
,
0 5 -
Remove oil pan and inspect 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
12-076 Go
Remedy
, ! ;
u z 4 4 5 P cc
s5 oz a
.L
x
2
S-l 6
Vibration *
is excessive
If there
is abnormal
vibration,
noise
together
carry out troubleshooting
with
the
for “Abno-
General
causes why vibration
l
Defective
parts (abnormal
l
Improper
alignment
l
Abnormal
1
Causes
rmal noise is made”. is excessive
wear,
breakage)
combustion
AZ
0
3 8 D
5
.z a
r
EL 4 m E
-is
Confirm recent repair history Degree of use I .o 6 : 0
Operated for long period
Condition of vibration Non-specified
Suddenly
increased
Gradually
increased
fuel has been used
Metal particles are found in oil filter Metal particles are found when oil is drained Oil pressure is low at low idling
i S z 8 6
Vibration
occurs at mid-range
Vibration
follows engine speed
5-
speed
7 -
Exhaust gas is black Seal on injection
r-
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
directlyfor
loose engine mounting
bolts, broken cushion
i-
When radial runout, face runout are measured, they are found to be Remove front
I
cover. and inspect directlv.
Remove head cover and insvect directlv
1 Injection
pump test shows that iniection
-
amount is incorrect
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
lu
xs. Lz
.s
+I .% 8 25
0”
b
E
d
c .P
a,
-iz i
s .;.% .F
E * ? $ ._
B z P
E -
2 -
5-
3 -
r-
-
-
b 8
g-
5-
0 -
55-
rz
E
E
:
12-077 0
TROUBLESHOOTING TABLE FOR ELECTRONIC GOVERNOR r
T .i t t
P,~_ Indication Item
Trouble check method
Iheck time
Action take
to
bi’ity
Normal Written data and read data are compared with each other when system is started, and they are different as a result.
C/U (RAN)
1
Signals are not output for a certain time after AD conversion is finished.
C/U (AD converter)
-r
ms
10s Is
Racksensor circuit
Output voltage of rack sensor circuit is out of specified range (Above 4.5V or below 0.5V).
Overrun
Software overrun: NE 2 115% Overspeed Hardware overrun: HE 2 2,300rpm
Oil pressure drop
Oil pressure switch is Hi (24V) and NE > 500rpm.
Water temperature rise
Water temperature is Hi (24V).
NE sensor No. 1
Second but first
NE Sensor No. 2
First pulse is received second one is not.
Speed control knob (Low idling)
Output voltage of speed control knob is out of specified range (Above 4.8V or below 0.2V).
Frequency control knob
Output, voltage of frequency control knob is out of specified range (Above 4.8V or below 0.2V).
IS
Droop adjustment error
Output voltage of droop adjustment is out of specified range (Above4.8V or below 0.2V).
IS
GOV PULL
switch
but
6s
0.3s
160 NE s
420 NE s
GOV pD;tJN
Normal control (with frrst pulse)
Same
0
Not @ Alternate c reFast Fast settable
?‘“’ Remarks ;ys-
Iuns -
lorma -
em
as above
Same as above
IfNE> 150rpm, set to 1 sec.
itop:
nginf as ‘oubll gain.
E!Gzg
v r settabl
Pe;;&
is output when software overrunis detected.
When power is tur ned off and startec again, if engine is not under conditior at left, aovernor is reset. -
0
Reset when inpu signal become: normal.
@ Alternate C Slow Slow
Fix to set median.
Re- 0 settable
@
Fix to set median.
Re- 0 settable
@ Slow
all AD data are controlled
of No.
normally
Same
as above
Note 3)
0 : Going off, 0 : Lighting, @ : Slow flashing @ 0 : Alternate flashing, @ @ : Simultaneous
(Period: flashing
Note 4)
“GOV
Note 5)
The indication
4 seconds),
tuns
ight nginr ‘oublr Only in isochronous operation
Reset when inpu signal become: normal.
Fast
Same as above
On& operation.
in the backup
(One pattern
Same as above
Same as above
0
If speed contra lknob > 20% ant 0.2sec, normal.
If a start signal
12-078 69
When power is turned off ant started again, if en, gine is not under condition at left governor is reset.
Re_ a SimultaNormal 0 neous control with setsecond pulse tab’e ‘tow ‘tow
Two or more codes are detected in the order seconds, the next pattern is indicated.)
of the lamps
l
GOVPULL 2 . DOWN ~~~i~
Note 2)
means
0
Same as above
Note I)
PULL DOWN”
0
En3ine
Software: Same as above Hardware: NE 2 2,lOOrpm
pulse is received one is not.
is input,
Resetting condition
Red
0
IOOms GOV PULL Not 0 DOWN z;_ (Note I) table
Target value and actual value are not the same: NE < 150rpm. NE > 150rpm (Imm minimum)
I
2
Green
:on-
of
settable
Governor servo error
I
GOV $LLN
lamps
setta_
mode.
is indicated
@
: Fast
(A servo
error
for 12 seconds.
flashing
is not detected.) Then,
after an interval
(0.5: seconds),
to pull back the fuel rack. is saved,
and it is not cleared
until the memory
clear switch
is pressed
for 0.4 seconds.
of 6
Diagnosis
lamp indication
0
Lit
@
@ Simultaneous
0
out
@
a
0
Quick flashing
0
@ Alternate
@ Slow flashing
(0.25 second)
type
system
0
0
Governor
servo system
@
@I
Rack sensor system
8
0
Overrun
0
0
1st speed sensor (engine)
@
@
@I
@
a
@
l
(3
No indication
0
0
Normal
0
0
Low idling speed control
Droop changeover
indication
dial
dial
pump)
quick flashing
lamp indication Green Red I0 0
Controller
2nd speed sensor (Fuel injection
flashing
flashing
(2 seconds) Diagnosis
Indication
Alternate
12-079 @
1.
Controller
system
abnormality
5 YES YES 4 Is the rack drags in
2. Governor
servo system
YES
abnormality
Is the resistance value between E
the injection
pump?
(female@@
cap removed.)
(Check with the rack
and
NO 4
r (female1 a and% (female)OlB(female)
YES -
0) and the resistance Z (female)@ and a
value between 2
~ Is the resistance YES
value
1
@It@) normal?
Is the resistance
- Resistance
value between a _ tfemale)@(Otfemale) 6)) and @%female) OIL0tfemale)@) normal? . Resistance
between
_
q(female)@@)
and
value
* Power
OFF
* Disconnect (Connect
a.
8,
-
-
“Ower
OFF
, NO
1&z&yL
* Resistance *
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. p NO
(female)@ ia(female)@ 30.5 - 38.5 R value between zlfemale)@ ~!(female)O(~(female)Ol 0.75 - 22 n Power OFF
* Resistance * - Disconnect
9-10.5R -
tfamale)@(~j(female) 0) normal? p . Resistance value @(female)O and @
ggifi
and
I.
NO
&I, 3.)
value
9-10.50
- Power
OFF
NO
* Disconnect w.
0
,zl.
Electrical circuit diagram related to 1. and 2. above Controller
Actuator
r
t
Racksensor
TAE00063
12-080 03
Remedy
Cause
Iontroller
abnormality
aulty fuel injection
pump
aulty controller
aulty harness 3-q-Bandfl)
aultyfuel
Replace.
Replace.
(between
injection
pump
Replace (Repair the harness.)
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
YES
YES -
Is the resistance value between I@ (female) 0 and q (female)O0l(female) 01 and the resistance
0)
-
normal?
* Resistance
q(female)a (female)@
I
Is the resistance value
between
B
~female)OKWemale) 0) and m(femalei O(O(female@I) normal? * Resistance
* Resistance
-
value
9 - 10.5 n * Power OFF * Disconnect q I. (Connect @iI,3)
(Check with the rack
between
value
pump?
cap removed.) -
’ Power
NO
0~
m
Ifemale)@@) and B (female@%@J) normal? ~ NO Resistance value between ~3(female@X@
*
q(female)@(@,)
30.5 - 38.55 R * Resistance value between acfemale) ~(female)@(@) 0.75 - 22.5 .C -
_
the injection
value
value between q (female@ and @ (femaleK%Dfemale)
2 _
Is the resistance value between n Ifemale@%@ and B (female)@@) . and the resistance
3
5 YES _ Is the rack drags in
* Disconnect
0.
Connect
@@I
and and
!B. RI.
NO and q (~(female)@) 30.5 - 38.5 L2
. Resistance value between ~(female)Ot~_(female)O)
m(female)@ 0.75 - 22 R
and
- Power OFF -Disconnect G, LG. NO
value
9-10.5R
* Power
OFF . Disconnect %I,0 ,z.
NO
Electrical circuit diagram related to 3. above Controller
Actuator
Rack
sensor
1
TAE00063
12-082 @
Cause
-
Faulty fuel injection
-
Faulty controller
_ Faulty harness q -_-mandg)
)
Remedy
pump
Replace.
Replace.
(between
Faulty fuel injection
pump
Replace (Repair the harness.)
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
YES
-
Cause
Remedy
I
The probable cause is located outside of the ekctronical governorsystem.
FHW/ _ (Overrun)
Electrical
circuit
NO
- Power OFF * Disconnect @.
diagram
related
[
=
I
!
m
El@)
r-
Replace, or repair the harness.
to 4. above
El Actuator
Faulty fuel injection pump, faulty harness
@-------a m
@
,A
1 I I
II
TAE00063
12-084 da
5.
1st speed
sensor
abnormality
Cause
2 YES Is the resistance YES value between 1 r @(female)@ and a22.1 -2.5 kQ?
Is the resistance value between q _ (male)@ and E ~male~Z.l -2.5 I&?
- Power OFF * Disconnect 51.
(Engine)
6.
2nd
speed
sensor
* Power OFF . Disconnect a. - Connect 3.
NO
L
Remedy
Faulty controller
!eolace.
Faulty harness (between zl-7-B)
iepair or eplace.
W Faulty 1st speed sensor
NO
leplace
abnormality 2 YES
value between 0
. Power OFF * Disconnect 3.
Electrical
circuit
diagram
related
Faulty controller
Ieplace
Faulty harness (between a-7J-a)
epair or splace
-aulty 2nd speed sensor
eplace
to 5. and 6. above
Controller
2nd speed sensor
1st speed sensor
TAE00064
12-085 43
7. Low idling
speed
control
dial
abnormality
Remedy
Cause
2 YES Is the resistance YES value between 0 (female@ and q 1 (femaleY@ normal?
0
@-
Electrical
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.
circuit diagram
related
Controller
Replace.
abnormality
Faulty harness (between B@ and low idling speed control dial)
Repair the harness.
Faulty low idling speed control dial orfaulty harness (between a@ and low idling speed control dial)
Replace or repair the harness.
to 7. above
Controller
Droop
Low idling
control
dial
speed control
dial +--
I
TAE00065
12-086 @
8. Droop control
dial abnormality
Cause
2 YES Is the resistance YES value between 0 (female@ and q 1 (female)@normal?
Is the resistance value between q (female@ and B (female@normal?
- The
L
Controller
)
q@
Faulty harness (between and droop control dial)
Repair the harness.
Faultv drooo control dial or faul& harness (between H@ and droop control dial)
Replace or repair the harness.
resistance NO value changes between approx. 0.5 - 5.5 kQ. * Power OFF - Disconnect q. -Turn the droop control dial. L
* The resistance value changes between approx. 0.!?5.5 kR. * Power OFF * Disconnect n. + Turn the droop control dial.
Remedy
I
Replace.
abnormality
Electrical circuit diagram related to 8. above
Controller 1
Low idling
Droop control
dial
speed control
dial
TAE00065
12-087 @
a 9.
Diagnosis
lamp fails to make indication
Cause
Remedy
1 YES
Is the voltage between atcheck
p
terminal)@ 0
o-
Controller
abnormality
generator body and the voltage between 0 and generator ~ body normal?
* @I voltage -0 voltage * Power ON
-
L
NO +20 - +3OV 0 - c2V
Faulty harness (between a@(@), - g - ACC terminals or between a@ (BJ@)) and battery GND)
Electrical circuit diagram related to 9. above
co2?d grounding terminal
12-088 03
eplace.
and
TAE00066
epair the arness.
10.
Normal
indication
a.
Changeover
between
low idling speed
and rated
speed
cannot
be achieved.
Cause
1 YES
l
0
-K$Z?j$and
- Power * At the - At the
Electrical
circuit
diagram
-
NO ON time of low idling speed: 20 - 30V time of rated speed: 0 - 2V
related
-
Controller
abnormality
Faulty harness (between low idling speed/rated speed changeover switch - li: - controller)
Remedy
Replace.
Repair the harness.
to 10. a. above
TAE00067
12-089 63
b.
Changeover
between
50Hz and 60Hz cannot
be achieved.
1 YES
0
o-
Is the continuity between E3female) @and a (female) @Snormal?
- Disconnect -When 50Hz
El. NO is selected: Continuity is observed. -When60Hz is selected: Continuity is not observed.
Electrical
circuit diagram
related
to 10. b. above
Controller
0C 50/60Hz changeover
1Z-090 @
3
=
Controller
abnormality
-
Faulty harness (between 50160Hz changeover switch and controller)
Replace.
Repair the harness.
c. *
Starting
failure
(the engine
cranks,
but no exhaust
Check for causes (such as abnormalities
smoke
in the fuel system)
is emitted.) outside
of the electronical
governor
system
first
of all. Remedy
YES 1 Is short-circuit observed between - B(female)@ and fl(female)@? - Power OFF * Disconnect a. NO
00
2 YES Is short-circuit observed between Q(femal& (@03, and q (femaleKQ@)?
- Power
OFF . Disconnect a.
Electrical
circuit
diagram
related
-
NO
Actuator
r
Racksensor
0
G
[$r
Replace or repair.
Faulty harness (between @j-Y-fl)
Repair or replace.
Faulty controller
Replace.
to 10. c. above
qr
Faulty injection pump (Faulty harness)
@-----___
34
1
El
Controller
0
12-091 03
d.
Starting
failure
(the engine
fails to start,
although
but exhaust
smoke
is emitted.)
Cause
YES
4
1
YES
I
2
. Disconnect
d.
Isshort-circuit observed between - atfemale)@ NO @:, and q3(femafe) @&a,? - Power OFF * Disconnect
a.
3YE Isthe voltage between &Xfemale@$andE - (female)@ normal at NO thetimeof engine start? * 20 - 30Vfbattery voltage) - Disconnect a. * Power ON - Start the engine.
Electrical
circuit
diagram
related
Faulty injection pump (Faulty harness)
Replace or repair.
Short-circuit of rack sensor harness between HI and IZ
Repair or replace.
The probable cause is located outside of the electronical governor system. Faulty harness (between starting switch C terminal and 3)
to 10. d. above
1 Actuator
Nr
Remedy
Controller
q-
r Rack sensor
i
Controller
Starting switch C terminal
12-092 03
Repair or eeplace.
e.
The engine
*
This electronical engine
stops during
stops,
governor check
1.
The emergency
2.
The engine
3.
The oil pressure
water
running. system
has been designed
if any of the following stop
switch
temperature
statuses
to stop the engine has been
in any of the following
cases.
If the
produced.
is pressed. is abnormal.
is abnormal.
1Z-093 @
11. Memory clear cannot is made by diagnosis *
To execute cannot
*
memory
be achieved
If memory longer,
clear
implement
be achieved lamp).
clear, when
cannot
keep
by pressing
pressing
the memory be achieved
the diagnosis
the
clear even
indicated
the memory
memory switch
if the
clear
switch
is pressed memory
clear switch
for
(when
5 seconds
failure
or longer.
1 YES
-When -When
X3
memory memory
clear
switch
was
-
-
NO clear switch is ON: Continuity clear switch is OFF: Continuity
kept
pressed
is observed. is not observed.
clear switch
5 seconds
T
Remedy
Replace.
Faulty memory clear switch or faulty harness (between memory clear switch and controller)
Replace the switch or repair the harness.
I
Controller
TAE00070
1Z-094 @
for
Faulty controller
Electrical circuit diagram related to 11. above
Memory
clear
below.
If the continuity between Zl(female) aand@ normal?
- Disconnect - Power OFF
(Memory
momentarily.)
Cause
Ll
indication
or
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
1
No. A Al
Part No.
1
Part Name
790-501-2000
Engine repair stand
790-901-I
l
170
B 1 790-476-1140 C 1 795-601-I
I Q’W 1
Repair stand bracket
1 Lifting tool
110 1 Push tool
1
I
1
I
’
I
1
1 795-100-I
191
G 1 795-102-1300
Piston ring tool 1 Liner puller
l
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
6162F669
1) Before washing,
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.
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.
3.
Engin oil Drain engine oil.
. 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
pipe
(2). 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).
13-004 0
disconnect
fuel
injection
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
y
"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).
A
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,
remove
corrosion
resistors
(1,.
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.
..
..
_ __
-
-.
J
17. Aftercooler, intake manifold assembly 1) Sling aftercooler and intake manifold assembly (I), remove mounting bolts. 2) Remove aftercooler and intake manifold assem bly.
l
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
l
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
2 6162F699
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
l
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
iv)
Remove exhaust valves (7).
valves
(6) and
6162F70
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).
6162F710
2
z z
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.
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). r?zkg
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.
remove
idler
40. Idler gear for oil pump gear Remove mounting bolt ES), then gear (6) for oil pump.
remove
idler
41. Flywheel Using the sling bolts (thread dia. = 12 mm, pitch = 1.751, lift out flywheel (I). Flywheel:
*If
See Weight Table
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.
l
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).
44. Oil pan 1) iurn over repair stand to set oil pan at top. 2) Remove oil pan (I).
I
6162F721
t1
6162F722
45. Oil strainer Remove bracket, then remove oil strainer (I). 46. Oil pump assembly 1) Remove tube (2). 2) Remove oil pump assembly (3).
2
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 [212”Fl, 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
s Z Z
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.
3)
Clean with a stiff wire brush to prevent any metal particles from remaining in the oil line.
4)
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.
5)
Dry off the cleaning fluid completely with compressed air. l Be particularity careful not to leave any cleaning fluid in the bolt holes.
6)
completely press fit the plugs in the oil line and cooling systems.
w
Outside diameter
of plug: Thread tightener
(LT-2)
6162F744
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.
Y
6162F74f
6162F747
’3-k20
2 ZY z
l
Before reassembling disassembled parts, check visually that there are no cracks, damage, or abnormal wear.
l
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.
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
PISTON RING GROOVE
Special tool No. A
l
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.
6162F756
Wear gauge l
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
F6164154
B
ID of big end + ID of small end 2
+A
Measurement
Y
“1”L.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
l
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
13-026
/
1
\
A
Measurement nf CIIrvlltllrl-?
Measurement nf iwistino
F61 641 56
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.
l
l
Part No.
Part Name
Q’ty
A
790-501-2000
Engine repair stand
A
790-901-I
170
l
B
790-476-I
140
Lifting tool
1
C
795-601-1110
Push tool
1
D
795-102-2102
Spring pusher
1
H
795-100-I
Piston ring tool
1
I
795-250-1210
Liner driver
1
J
795-225-1700
Piston holder
1
K
790-331-I
Wrench
1
191
110
Repair stand bracket
1 1
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 @
2) 3)
4) 5) 6)
*
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.
13-028 0
Counterbore
Portion
0
Detail Q
Detail
P 6162F306
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
I
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.
1
I
I .
Overlap:
61?16mmm
62 I OF305
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.
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.
m
Mounting
bolt:
with
26 & 1 kgm
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
I
I
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
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.
6162F765 1
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
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.
6162F770
r
I
6162F771
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.
F6164030
13-033 0
I
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
Target
Range
1st
56
51 to 61
2nd
113
107 to 118
3rd
0
Loosen completely
4th
38
33 to 43
5th
75
70 to 80
6th
113
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)
3.
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.
Piston, connecting rod assembly Assemble piston and connecting rod. i) Fit oil ring expander (I) in oil ring groove.
l
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
’3-:34
6162F774
*Assemble diagram.
each piston
ring as shown
in the
lTf
’
Oil ring
F6 164033
I iii) Install snap ring (2) on one side. iv) Heat piston (3) at 100°C f212”Fl for 5 minutes in a heating furnace. * If no heating furnace is available, heat in hot water at 100°C [212”Fl for 5 minutes. *When heating with hot water, clean the piston completely after setting it in position.
6162F775
6162F776
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.
v)
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.
I
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
F6164038
I
2 z z
Bar
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. 0
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
i)
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.
I
6162F763
ii)
After tightening, make punch mark on bolt head to indicate number of times of tightening
#
6206F303
1
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.
m
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).
7.
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.
*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
Tightening
(Thread size) x (Pitch)
M16 x 1.5
bolt:
I
Ml8 x 2.5
30 - 35 kgm (Tighten by torque) 5 2 0.5 kgm 90+i””
Tighten an additional 31 f
Ml8 x 1.5
method
4 kgm
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
(Thread size) x (Pitch) ( Ml6 x 1.5
bolt:
Tightening method 30 - 35 kgm (Tighten by torque) 5 + 0.5 kgm
Ml8 x 2.5
90+i’“Tighten
an additional
31 f 4 kgm Ml8 x 1.5
80+i”“Tighten 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
11
Idler gear mounting bolt for water pump: Same as in Item 9 above
Injection pump drive case 1) Fit O-ring and install injection case (2). 2) Install coupling (1).
pump
drive
6162F787
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
End play
0.140 -
0.460
1
0.075 -
B
0.130 -
0.470
2
0.10 -
C
0.130 -
0.470
3
% 0.145 -
D
0.100 -
0.500
4
0.10 -
0.21 0.32 0.395 0.32
5
a b
0.095 -
0.460
6
0.14 -
0.32
C
0.120 -
0.425
7
0.10 -
0.32
d
0.100 -
0.445
8
0.085 -
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.
I
z z z
‘2 6162~725
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)
of gasket sealant:
$1.6 -
2.0 mm
17. Rear seal cover Fit O-ring and install rear seal cover (1). * Take care that the lip is not rolled up.
6162F724
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.
I
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
6162F720
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. *
I
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
3
6
2
z
6162F792
m
Flywheel mounting
bolt (HD465):
z 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”
D
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
mounting
bolt: 9.2 - 10.6 kgm * Before installing the cam follower, wash the oil hole of the mounting bolt.
2) Install cover (1). a
Face of.cover: *
Diameter mm
Liquid gasket (LG-7)
of gasket
sealant:
$1.6
-
2.0
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). & *
13-046 0
Face of cover: Diameter
Liquid gasket (LG-7)
of gasket sealant:
$1.6 -
2.0 mm
6162F794
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).
27. Crankshaft pulley 1) Install crankshaft mounting bolts. a
(4), align with dowel
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 HD465 only
Except HD465
1st step
40 + 3
7.5 I!I 2
2nd step I
78 f
Order
*
3
I
25 f
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.
F6164026
F6164030
13-047 0
1
2) Fit gasket and install mechanical
pump tubes
(I).
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.
I
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
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
6162F704
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
1
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
6162F702
1_L!--
6162F797
6162F311
m
Cylinder head mounting
bolt:
Unit: kgm
3rd
39
37.5 to 40.5
4th
50.5
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”.
intake end
iv) Tighten locknut to hold in position. w
Locknut: *
4.0 f
0.6 kgm
Install the crosshead so that the adjustment nut is at the exhaust end. Exhaust end Adjustment
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.
nut
F6164068
Tab
0
&,
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
Keep the difference in torque between two bolts to a maximum of 0.5 kgm.
the
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
L.d 6162F695
6162F696
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. 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
34. Adjusting valve clearance Adjust valve clearance. For details, see TESTING AND ADJUSTING, justing valve clearance.
13-052 0
Ad-
6162F804
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.
bolts in order
a 5
w
Mounting
bolt:
3.25 & 0.25 kgm
1
4) Install connection
(3).
5) Install turbocharger
lubrication tube (2).
6) Install spill tube (I).
3
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.
0
/
2
4
Key
F6166057
4
3
i
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.
l
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
13-054 0
Mounting
bolt:
6.5 IfI 1.0 kgm
and intake
38. Turbocharger, exhaust manifold assembly Fit gasket, then install turbocharger and exhaust manifold assembly (1). &
Mounting
bolt thread: Anti-friction
(LM-P)
w
Mounting
w
D375A, PCIOOO, WA700, HD465-5 2 bolts (length: 50 mm): 8.5 & 0.5 kgm
*
bolt:
compound
11.25 I!I 1.25 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
r
(Serial No. up to 12867) 5.5 kgm (Serial No. 12868 and up)
: 4.5 -
l
WA600-1
: 6.0 -
l
WA700-1
: 6.0 -
7.5 kgm (Serial No. up to 12885) : 4.5 - 5.5 kgm (Serial No. 12886 and up)
7.5 kgm (Serial No. up to 12871) : 4.5 - 5.5 kgm (Serial No. 12872 and up)
6162F807
6162F686
: 6.0 -
l
PCIOOO-1
7.5 kgm (Serial No. up to 12887) : 4.5 - 5.5 kgm (Serial No. 12888 and up)
l
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)
1
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
14-7
(5).
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)
Insert a plain washer and the bracket.
between
the connector
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).
I
’3-:60
‘1
6162F669
ENGINE 14 MAINTENANCE
STAN
INTAKE
AND
EXHAUST
ENGINE
.
.
.
14-002
BODY
Cylider head Valves
.
..
.
and valve guide
Crosshead Push
SYSTEM
. . .
Turbocharger
and crosshead
_ ...
. . . .
guide
rod and cam follower
. Cylinder liner . .
... . .. .. ....
Crankshaft
..
Cylinder
block
..
gear
LUBRICATIOIN Oilpump
.
..
.
.. . .
14-005 . 14-006
.
14-007
. . 14-008
. .
14-010 14-011 14-012
.. Piston, piston ring and piston pin . . Connecting rod . ... .. .
Timing
.
. ..
. .._........
Camshaft
14-004
.
. 14-013 . . 14-013-2 . . 14-015
SYSTEM . . . . . . . . . . . . . . .._.......
14-016
Oil pump relief valve, piston cooling valve and oil cooler by-pass COOLING
valve
14-017
SYSTEM
Waterpump
. . . . . . . . . . . .._._.....
14-018
ACCESSORY Air compressor
170-1
SERIES
.
...
.
..
14-020
14-001 0
MAINTENANCE
STANDARD
INTAKE AND EXHAUST
SYSTEM
TURBOCHARGER KTRI
IO
6162F402 Unit: kam No.
Check item
Criteria
Remedy
Permissible range End play (play in axial direction)
1
Radial play (play in radial direction)
2
I
Replace parts related to thrust
0.08 - 0.18
Replace parts related to bearing
0.25 - 0.60
I
Permissible range 3
Outside diameter of journal bearing, inside diameter of center housing
I
Shaft
I
4
Inside diameter of journal bearing, outside diameter of thrust collar
5
Thickness of thrust bearing
Hole
-
22.92 22.96 14.95 -
Hole
I
I
23.00 - 23.03
14.97
15.00 - 15.04
Replace
6
7
8
..,“:.
Turbine end
1.85-
Blower end
1.45 - 1.52
1.92
1.46-2.05
Thickness of seal ring
Clearance between blower housing and impeller Tightening torque of blower impeller locknut
1.56-
Clearance limit:
(Min.) 0.20
I 2.9 f0.3
1.65 Replace parts related to bearing
kgm Tighten
9
;i;;u;ing
torque of V-band
’4-:02
0.9 * 0.1 kgm
170-1
SERIES
MAINTENANCE
STANDARD
INTAKE AND EXHAUST
SYSTEM
KTR130
\ \*
1 I
\
1
8
2
5
\
\
4
3
6162F401
6162F402
Unit: No.
Check item
Criteria
2
Radial play (play in radial direction
3
Outside diameter of journal bearing, inside diameter of center housing
Remedy
Permissible range
End play (play in axial direction)
1
mm
I
I
I
Replace parts related to thrust
0.08 - 0.18
Replace parts related to bearing
0.25 - 0.60
Permissible range Hole
Shaft - 29.94
30.00 - 30.04
19.95 - 19.97
20.00 - 20.05
29.89 Inside diameter of journal bearing, outside diameter of wheel shaft 4 Curvature of wheel shaft
Repair limit:
Replace
0.010 (total deflection of indicator)
Permissible range 5
Thickness of thrust bearing
6
Groove
Width
Thickness of seal ring
5.86 - 5.92
6.00 - 6.04
2.85 - 2.92
2.96 - 3.05 I
I
I
7
Clearance between blower housing and impeller
8
Tightening torque of blower impeller locknut
8.5 f 0.5 kgm
9
Tightening torque of insert mounting bolt
1.25 f 0.25 kgm
10
Tightening torque of V-band locknut
0.95 f 0.05 kgm
I
Clearance limit:
Replace parts related to bearing
(Min.) 0.20
I I
Tighten
170-1 SERIES ’ 4-:03
MAINTENANCE
INTAKE AND EXHAUST
STANDARD
SYSTEM
KTR150
F6166056 Unit:
NO.
1
Criteria
Check item
Permissible range
End play (play in axial direction)
Radial play (play in radial direction)
3
Outside diameter of journal bearing, inside diameter of center housing
Remedy
Replace parts related to thrust
0.08 - 0.18
2
I
mm
Replace parts related to bearing
0.25 - 0.60
Permissible range Hole
Shaft 29.89
- 29.94
30.00 - 30.04
19.95 - 19.97
20.00 - 20.05
-
4
Inside diameter of journal bearing, outside diameter of wheel shaft
Repair limit:
Curvature of wheel shaft
0.010
Replace
(total deflection of indicator)
Permissible range 5 6
Thickness of seal ring
7
Clearance between blower housing and impeller
8
Tightening torque of blower impeller locknut
Groove
Width
Thickness of thrust bearing
5.86 - 5.92
6.00 - 6.04
2.85 - 2.92
2.96 - 3.05
Clearance limit:
I
I
-
9.5 2 0.5 kgm
I
I
9
Tightening torque of insert mounting bolt
3.75 i 0.25 kgm
10
Tightening torque of turbine housing
5.75 f 0.25 kgm
Tightening torque of V-band locknut
0.9 f 0.1 kgm
-
-
14-003-l 0
Replace parts related to bearing
(Min.) 0.20
MAINTENANCE
INTAKE AND EXHAUST
STANDARD
SYSTEM
TV77
615OF401-1
Unit: No.
2 z
Criteria
Check item
-
Remedy
Repair limit
Standard size 1
Radial play of rotor
G 2
End play of rotor
3
Tightening torque of blower housing bolt
0.076 - 0.152
0.18
0.08 - 0.25
0.25
Target (kgm)
Range (kgm)
Rapair or replace
-
1.25
Tightening torque of back 4
plate mounting bolt
-
1.15 -
1.38
Step
Target
Range
1 St step
1.8
1.6 - 2.0
2nd step
0
Loosen completely
3rd step
1.4
1.27 -
Tighten
1.50
Repair limit
Standard size 5
Thickness of thrust bearing 2.315
2.29 I
l
6
Outside diameter Measuring point Point (A) Point (9)
Bend of wheel shaft
l
Bending:
Repair limit 0.010
Standard size
Repair limit
17.53 15.88.
17.48 15.88
(total indicated runout)
Replace
7
Standard size
Repair limit
17.475
17.49
Inside diameter of back plate
-
Measuring point 8
mm
I wide diameter of center housing
Point(C) Point (D)
Standard size 24.97 20.90
Repair limit 24.97 20.93
14-003-2 0
MAINTENANCE
CYLINDER
STANDARD
ENGINE BODY
HEAD Tightening order of head mounting bolt
6\
5
4
Tightening order of head cover mounting bolt
6 162F403A
F6170010578 Unit:
mm
I No.
1
Check item
Criteria
Remedy
Tolerance
Distortion of cylinder head mounting surface
Repair limit -z
Max. 0.05 2
0.1
Protrusions of nozzles
Standard:
fqeplace noz2:le sleeves
4.9 to 5.7
I
Order
/
3
Tightening torque of cylinder head mounting bolts
1st
(Coat bolt threads and washer with anti-friction compound (LM-P))
2nd
Target value (kgm)
6.5 to 9.5
23.5
22.0 to 25.0
39.0
4th
50.5
-
1Tighten in sequence as Indicated aIbove.
37.5 to 40.5 I
I
49.0 to 52.0
I
I Target value (kgm) 4
Range (kgm)
8.0
3rd
f3epair by frinding ‘>r replace
Range (kgm)
Tightening torque of nozzle holder mounting bolt 2.75
5
Tightening torque of cylinder head cover
6
Tightening torque of rocker arm housing mounting bolt
14-004 8
I
2.5 to 3.0
I
I 3.25
10
I
Retighten 3.0 to 3.5
9.5 - 10.5
170-1 SERIES
MAINTENANCE
STANDARD
ENGINE
VALVES AND VALVE GUIDE
1 SWE01035
No.
8
z-
I
Amount
of valve
2
Valve
3
Valve seat angle
sinking
z
Outside stem
6
head thickness
diameter
of intake
valve
BODY
MAINTENANCE
STANDARD
CROSSHEAD
ENGINE
AND
CROSSHEAD
BODY
GUIDE
$
6162F405
z z Unit:
No.
Criteria
Check item
Depth of cross-
Standard size
Except H D465-5
head stem HD4655
only
3.0 7.5
+0.3 0
Inside diameter of crosshead
15
Outside diameter of crosshead guide
15
Repair limit
Replace
+0.10 +0.05
I
I
I Clearance between crosshead. guide and crosshead
Remedy
Tolerance +0.3 0
+0.039 +0.028
mm
15.21
15.00
I I
I I
Standard clearance
Clearance limit
0.011 to 0.072
0.02
Adjust
Standard size
Repair limit
Tolerance
Protrusion of crosshead guide 54
-“0.3 I
5
6
Intake valve
Exhaust valve
0.4
1 .o
Replace
Valve clearance (at cold)
Tightening torque of crosshead lock nut
’4-:06
Except HD465-5
4.0 + 0.6 kgm
HD465-5 only (Serial No. 14203 and up)
6.0 Itr0.6 kgm
Tighten
MAINTENANCE
PUSH
STANDARD
ROD AND
ENGINE
CAM
FOLLOWER
Unit: No.
1
2
Check item
Criteria
Tolerance
25.0
-0.040 -0.055
24.9
-0.020 0
25.0
19.0
+0.175 +0.150
19.2
19.0
+0.075 +0.065
25.0
I
Inside diameter of cam follower roller
/
Repair limit
3
Replace Outside diameter of cam follower roller pin
4
mm
Remedy
Standard size Outside diameter of cam follower shaft
Inside diameter of cam follower lever
BODY
Outside diameter of cam follower roller
41 .o
I
+0.050 +0.025
5
Diameter of push rod tip ball
15.85
kO.03
6
Inside diameter of push rod socket
12.7
to.20
170-1 SERIES
19.0
41.0
I
-
14-007 0
MAINTENANCE
STANDARD
CYLINDER
ENGINE
BODY
& I
BLOCK
6
6162F407
Unit: No.
I
Check item
Criteria
I Tolerance Standard size
1
Inside diamater of block
Clearance between cylinder block and liner
Outside diameter of liner:
190 Standard size
2
Thickness of main bearing
Inside diameter of main bearing
14-008 0
I
Remedy
Standard clearance
Clearance limit
Replace cylinder liner or block
0.050 to 0.160
I Inside diameter of main bearing hole (lighten bolt to specified torque)
mm
I Tolerance
148
+ 0.025 - 0.001
4
- 0.038 - 0.051
140
+0.127 + 0.076
Repair limit -
Repair or replace
140.20
170-1
SERIES
MAINTENANCE
ENGINE BODY
STANDARD
Unit: No.
Check item
Clearance between main bearing and crankshaft journal
2
Remedy
Criteria
I Standard clearance
Clearance limit
0.075 to 0.150
0.32 Interference
Standard interference Interference between main bearing cap and cylinder block
3
Inside diameter of camshaft bushing
mm
limit
0.05
0.080 to 0.160 Standard size
Tolerance
Repair limit
72
+0.070 0
72.10
Repair or replace
4 Clearance between camshaft and journal
Standard clearance
Clearance limit
0.080 to 0.180
0.24
Tolerance
Repair limit
0.09
0.15
Distortion of cylinder head face
5
Order
Tightening torque of main
Target value (kgm)
1st
56
2nd
113
Range (kgm) 51 to 61 107 to 118
bearing cap bolt 3rd
6
~
K$at
170-1
Tighten
Loosen completely
bolt threads with
SERIES
engine
4th
38
33 to 43
5th
75
70 to 80
6th
113
107 to 118
14-009
MAINTENANCE
ENGINE
STANDARD
CYLINDER
BODY
LINER
Detail P
F6166062
Jnit: mm No.
Check item
Criteria
I
I
Standard size
3
I
Tolerance
170.24 i
I
Roundness
Repair limit:
Cylindricity
Repair limit: 0.015
.
Tolerance 194.565
194.59
Interference of cylinder liner and block (Counter bore lower part) Outside diameter of cylinder liner (Counter bore part)
0.020
Standard size
Standard interference:
- 194.615
0.025 to 0.135
Tolerance
Standard size 205.99
205.965
Replace cylinder liner
- 206.015
4 Clearance between cylinder liner and block (Counter bore part) Outside diameter of cylinder liner (O-ring part)
Interference: 0.085 to Clearance: 0.025
Standard size
Tolerance 190.34 -
190.4
190.40
5 Clearance between cylinder liner and block (O-ring part)
6
Unevenness of counter bore depth
14-010 0
Standard clearance:
0.050 to 0.210
Tolerance
Repair limit
-
0.03
2 z z
Repair limit
+0.04 0
170
2
Outside diameter of cylinder liner (Counter bore lower part)
Replace cylinder liner or block
Permissible range: 0.07 to 0.15 Difference among cylinders: 0.05 max.
Protrusion of cylinder liner
Inside diameter of cylinder liner
Remedy
Repair by grinding
MAINTENANCE
STANDARD
CRANKSHAFT
ENGINE
BODY
7TI
-
2,i
5'
7'
1,3
6162F409
Unit: NO.
1
Check item
Criteria
I
Size
Standard size
I
S.T.D.
140.00
mm
Remedy
Tolerance
Repair limit
I
139.91 I
I
Outside diameter of main journal
2
Outside diameter of crank pin journal
3
” Journal roundness
0.75us
139.25
139.16
1 .oous
139.00
138.91
S.T.D.
108.00
107.91
0.25US
107.75
107.66
Repair or replace
.
Tolerance
Repair limit
0.140 to 0.320
0.69
End play
Main bearing thickness (Center)
Outside diameter of rear flange
I
Bend of crankshaft (by indicator)
Tightening torque of crank wllev mountina bolt
170-1
SERIES
I
Standard size
Tolerance
Standard interference
4
-0.040 -0.050
3.90
I
170
xl.020
-
1
Tolerance
Repair limit
0.09
0.20 See page 13644
Replace
Tighten
14-011 0
MAINTENANCE STANDARD
ENGINE BODY
CAMSHAFT
6162F410
Unit: Check item
Criteria
Standard size
Cam height
Remedy
Tolerance
Repair limit
Intake side
62
+0.440 WO.240
61.37
Exhaust side
61
-0.310 -0.510
59.64
72.00
-0.080 -0.110
71.86
Outside diameter of journal
mm
Repair or replace
Replace Thrust plate thickness
4
5
6.85
-0.025 -0.060
10.00
Standard clearance
Clearance limit
0.075 to 0.240
0.40
Camshaft end play
Bend of camshaft
14-012
Repair limit:
0.20 (by indicator)
Replace thrust plate
Replace
170-1 SERIES
MAINTENANCE
STANDARD
TIMING
ENGINE
GEAR
INo
BODY
Check item
’ :3
6162F411
Unit:
mm
Criteria
Main idler gear (large) and idler gear
Gear backlash
7
Clearance between main idler gear bushing and shaft
8
9
10
11
End play of idler gear
0.10 to 0.32
12
End play of oil pump idler gear
0.10 to 0.32
13
Difference of timing gear case and cvlinder block lower steo
170-1
SERIES
bearing
Tolerance:
0.15
Repair or
I replace
14-013 cz
MAINTENANCE
ENGINE BODY
STANDARD
’
(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
ushing and shaft
10 11 12
Replace thrust
End play of oil pump idler gear
13
Iifference of timing gear case md cylinder block lower step
’4-oi3-1
Tolerance:
0.15
Repair or replace
MAINTENANCE
PISTON, ALUMINIUM
STANDARD
PISTON
ENGINE
RING AND
PISTON
BODY
PIN
PISTON TYPE
Omm
6162F412 Unit: No.
I
Outside diameter of piston (3.0 mm from bottom and at 2O’C)
I
Piston ring groove
I
-0.257
170
169.62
-0.287
Ring groove
2
Repair limit
Tolerance
Standard size 1
Remedy
Criteria
Check item
mm
Ring thickness
~~
Oil ring
4.80
-0.500 -0.075
io.010
0.3 Clearance limit
Standard clearance
Replace
I
Piston ring gap
Inside diameter of piston pin boss
5
Outside diameter of piston pin
170-1 SERIES
68
0 -0.006
I
67.98
I 14-013-2 8
MAINTENANCE STANDARD
ENGINE BODY
FCD PISTON TYPE
6162F822
Unit: No.
1
Criteria
Check item Standard size
Outside diameter of piston (3.0 mm from bottom and at 2O’C)
Repair limit
Tolerance -0.075 -0.105
170
169.79
Tolerance
ClW$ce
Standard size Ring groove
2
Top ring
Keystone
2nd ring
Keystone
Oil ring
4.80
Piston ring groove
Ring thickness
Check with piston groove wear gauge
~.OlO
-0.500 -0.075
Standard clearance
3
5
0.50 - 0.65
2nd ring
0.45 - 0.60
Replace
0.3
Clearance limit
Piston ring gap
I 4
Top ring
0.15
Insidediameter
I
Standard size
0.50 - 0.70
II Tolerance
of piston
pin boss
Outside diameter of piston pin
14-Z4
I
Oil ring
1.8
68
+0.044 +0.034
68
0 -0.006
170-1 SERIES
mm
MAINTENANCE STANDARD
ENGINE BODY
CONNECTING ROD
6162F413
Unit: 2 z
No.
Check item
Criteria
z
1
Shaft
Clearance between connecting rod bushing and piston pin
3
Inside diameter of connecting rod big end
Clearance between inside diameter of connecting rod big end and crankshaft journal
_
5
I
Bend or twist of connecting rod
6
Connecting rod weight
7
Tightening torque of connecting rod cap (Coat bolt and nut threads with engine oil)
+0.070 +0.050
0.050
- 0.075
0.11
Tolerance
115
+0.025 0
Standard clearance 0.060
S. T. D. 1 Connectina rod bearina
Clearance limit
Standard size
Size
.
Standard clearance Hole
0 -0.060
68
2
Remedy
Tolerance
Standard size
-
mm
Replace (the bushing is supplied as a semi-finished product)
Clearance limit
0.130
0.34
Standard size
Tolerance
3.500
Repair limit 3.41
Repair limit of bend: 0.10 Repair limit of twist: 0.25
I
10.15 +0.03
Order
kg
Target (kgm)
1st
20
2nd
90”
Range (kgm) 19-21 90” -
Tighten 105O
14-015 0
MAINTENANCE
LUBRICATION
STANDARD
SYSTEM
OIL PUMP
0 W
‘5
2
z ’
6162F414
Unit: No.
1
Check item
Criteria
I
Clearance between drive shaft and bushing
Clearance between driven shaft and driven gear bushing
Remedy
I
I
;:::;;
10.040 too.075
I
I
32
-0.025 -0.040
30
-0.020 -0.035
+0.030 +0.010
0.030 to 0.070
-
66
-0.115 -0.095
+0.035 0
0.095 to 0.150
-
,/
mm
-
Replace
Clearance between outside diameter of gear and body
4
Main pump gear and body end play
5
Tightening torque of mounting bolt
14-016 0
6.9 f 1 .O kgm
Tighten
MAINTENANCE
LUBRICATION
STANDARD
OIL PUMP RELIEF VALVE, PISTON OIL COOLER BY-PASS VALVE
COOLING
6162F415
6162F416
SYSTEM
VALVE AND
6162F417
Unit:
mm
I Check item
Criteria
Main relief valve spring
Regulator valve spring
5
Main relief valve operating pressure
6
Standard:
3.3 f 0.3 kg/cm’
Regulator valve operating pressure
Standard:
8.0 * 0.8 kg/cm’
7
Piston cooling valve operating pressure
Standard:
1.3 Tt:f
8
Oil cooler by-pass valve operating pressure
Standard:
4.5 ?:0.5 kg/cm*
170-1 SERIES
I
Repair or replace spring
kg/cm2
’4-:’’
COOLING SYSTEM
MAINTENANCE STANDARD
WATER PUMP
6162F418
Jnit: mm
f No.
Check
Standard size 1
‘.3
Interference between rear shaft and bearing
Interference between rear shaft and impeller
Tolerance
. Shaft
Interference between front shaft and bearing
I
Clearance between impeller and connection
14-018
Hole
25
I 19.9
I
+0.015
0 -0.010
+0.010 0
-:.o,o
0
0 to 0.025
0 to 0.020 Replace
+0.020 +0.005
I
4
Standard interference
I 30
2
Remedy
Criteria
item
I
-0.025 -0.05
0.030 to 0.070
I
Standard clearance
Clearance limit
0.23 to 0.66
-
170-1 SERIES
MAINTENANCE
STANDARD
ACCESSORY
AIR COMPRESSOR
48
6162F419
14-020
170-1 SERIES
MAINTENANCE
STANDARD
ACCESSORY
Unit: No.
Check item
~~
I_
Tolerance
Inside diameter of cylinder
Tolerance Standard size Shaft
Clearance between piston and piston pin
Hole
i-O.570 +0.550
47
M.662 +0.612
Shaft
Interference between crank case and bushing
Hole
+0.019 -0.006
51
-0.086 -0.129 Tolerance
Standard size Shaft Clearance between crankshaft and connecting rod
Hole
-
Standard interference
Clearance limit
0.08 to 0.13
-
Standard clearance
Clearance limit
+0.225 +0.213
0.051 to 0.089
-
47
+0.570 +0.550
+0.638 +0.612
0.042 to 0.089
-
Hole
+0.489 a.476 Standard (kgm)
Replace bushing
Repair or replace crank case
Replace
Standard interference Replace
I 25
170-1 SERIES
0.042 to 0.113
+0.162 +0.135
interference between crankshaft and coupling gear
Tightening torque of cylinder head mounting bolt
Clearance limit
49
Tolerance
8
Standard clearance
Replace
Standard size 7
Replace crank case
I
Shaft
I
Replace
Tolerance
Clearance between crankshaft and support
Repair limit
I
Standard size
6
I
+0.08 +O.lO
92
Clearance between crankshaft and bushing
Remedy
Criteria
Standardsie
mm
i6.425 +0.400
0.051 to 0.089
Limit (kgm) Tighten
3
2 to 3.5
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 I ;ymbol
Operation
Replacing
valve
seat
Part No. 795-l 00-4800
Puller
2
795-l 00-3004
Push tool
795-600-2510
Push tool
c
I
Replacing guide
valve
Replacing guide
crossheac
Grinding Replacing bushing
cam
Replacing gear
crankshaf
15002 0
1
For intake
1
I For exhaust
Calking
tool
1
For intake
795-600-2541
Calking
tool
1
For exhaust
5
795-600-2570
Peening
1
795-600-2110
Push bar
1
2
795-600-I
Push bar
1
3
795-600-2120
Driver
1
4
795-600-I
Punch
1
5
795-600-2130
Holder
1
1
795-600-I
Punch bushing
1
2
795-600-2140
Rollina
1
3
795-600-2150
Expander
1
4
795-600-2160
Cutter
1
5
795-600-2170
Guide
790-553-1700
I Coolant
tester
79A-471-1050
Pump
assembly
795-600-2550
Valve guide
1
1 12 1 H
191
130
140
795-600-2560 795-140-6410
I
valve
1
seat cutter
795-600-2531
F G
Commercially available
(
tool
1
bushina
CZzl,head
driver
795-250-1301
Push tool
2
792-l 03-0400
GriD
1
790-101-2800
Bearing
I2I
790-101-2300
II 1 1
I
1
guide
refacer
1
I
remover
1 Valve auide
Valve
1
guide
set
1 1
J
K
.-
seat
1 Push tool
E
Pressure test of cylinder head
For valve
795-600-2520
4
Replacing nozzle holder sleeve
Remarks
Q’tv 1
1
3 A 1- 1
IB
Part Name
1 puller
I Push puller
1
I
valve valve valve valve
REPAIR AND REPLACEMENT
CYLINDER
OF PARTS
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
HEAD
REPAIR
AND
REPLACEMENT
TESTING (1)
Cylinder
TESTING
OF PARTS
AND
INSPECTING
AND INSPECTING head Unit: mm
Inspection
Judgement
item
A. Cracks, leakage from cylinder head
l l
l
Check for cracks (external
color check)
Check for air leakage with air pressure (3.0 - 3.5 kg/cm*, 30 sec.) Water
pressure
B. Distortion of top, bottom surface o cylinder head
Remedy
standards
test (3.5 -
4.0 kg/cm*,
Tolerance
10 min.)
Repair limit
I
Max. 0.05
Repair by welding or replace
test
Grind to correct
0.1
I
Machine to repair or replace sleeve
C. Damage to injection nozzle sleeve seat surface, contact width D. Protrusion of injection nozzle
Permissible
range: 4.9 -
5.7
Replace sleeve
F6164092
io E. Damage to valve seat surface or loosening of seat
l
Pitting of seat surface
l
Check contact
l
Airtighteness
l
Tap cylinder
between
Correct seat surface or replace valve seat
valve and seat surface
test head and check for looseness
F. Sinking of valve (both intake and exhaust) Standard 0.9 -
Repair limit
value
Replace valve or valve seat
2.1
1.5
F6164093
G. Thickness of valve head _1
/ l
Angle
of seat surface
Intake valve:
\
Exhaust
-D
;
Thickness
Replace
30°
valve: 45O
of valye
head
F6164094
15005 63
REPAIR AND REPLACEMENT
OF PARTS
TESTING
AND INSPECTING
Unit Inspection
Judgement
item
H. Abnormality
in
l
Check if head has become
standards
: mm
Remedy
flat, check for cracks or piting of seat
surface
valve l
Airtightness
l
Check for play in cotter pin when
test new cotter pin is inserted
in cotter
Replace
j groove.
I. Outside
diameter
l
Check for eccentric
l
Check for hollow
l
Outside
wear
or curvature
of stem.
in stem end.
Correct
diameter
of intake valve Standard
stem
size
I2 Outside
diameter
of exhaust
l
Outside
Standard
value
11.94
I I .92
-
Repair
limit
11.90 Replace
diameter
valve Standard
stem
size
12
Standard
value
11.908-11.893
Repair
limit
I I .80
J. Inside diameter Standard
of valve guide
size
Standard
value
Repair
limit
(after head press 1 I.981
12
fit)
K. Protrution
-
11.999
12.10
of
valve guide (after head press fit) Permissible
range
: 23.4 -
23.9
Repair
limit
F6164095
L. Outside
diameter Standard
of crosshead
size
Standard
value
guide 15.028
I5
M. Protrution crosshead
-
15.039
15.00
of guide
E
Crosshead guide
Q
‘B
2 6 t
15006 0
Permissible
F6164096
range
: 53.7 -
54.0
Replace
REPAIRING REPAIR
AND
REPLACEMENT
OF PARTS
CYLINDER
REPAIRING MOUNTING BY GRINDING 1.
FACE OF CYLINDER
MOUNTING HEAD
FACE
OF
BY GRINDING
HEAD
Grinding
1) Remove
the valve seat inserts.
REPLACING
2) Remove
VAVLE
For details,
the nozzle holder sleeves.
see REPLACING
see
SEAT INSERTS.
NOZZLE
For details,
HOLDER
SLEEVES.
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 *
of the
Repair
cylinder
limit
139.55
head (H).
is carried head
out, stamp with
of cyinder
mm (Standard
the side
an (R) mark.
head
height
F6164097
(H):
size: 139.85
-
140.15) +
Amount
to remove
per grinding:
*
Surface
roughness
of grinding
*
Flatness
0.10
to 0.15
mm
surface: within
(deformation):
-rt Grinding *
limit:
Difference
0.3
0.05
mm
in head height
per unit: 0.15
4) Press-fit details,
2 Z &
the see
6s
mm max.
one-size-larger REPLACING
max.
inserts. VAVLE
For SEAT
INSERTS. 5) Press-fit the nozzle holder sleeves. For details, see REPLACING NOZZLE HOLDER SLEEVES. 2. .
Check
after
grinding
Check the sinking of the valves and the protrusion of the nozzles are within +
Standard
+
Allowable
sinking
the standard
of valves:
protrusion
0.9
values to 1.5
mm
to 5.7
mm
of nozzle: 4.9
15007 0
REPAIR AND REPLACEMENT
REPLACING
OF PARTS
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
.
Intake valve
““it: mm
A
A i) ii)
head
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 @.
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.
l
15008 63
6162F504
REPAIR AND REPLACEMENT
iii)
Adjust
OF PARTS
the position
REPLACING
VALVE SEAT INSERTS
of the grinder so that
the center of grindstone
@
center of seat insert (l),
then tighten the
will be at the
set screw to secure the grinder. iv)
Fully rotate
open the throttle the grindstone
of the grinder to and slowly
move it
until it contacts insert (1). VI
Press the grindstone
against the inside of
the insert, move it in a circular pattern, and w
make a groove about 1 mm deep.
6162F505
2)
Pull out the insert with the puller head of valve seat puller Al according
to the following
pro-
cedure. i)
Push three claws (a) of puller head @
in-
ward by hand and put them in insert (1). ii)
Tighten screw
@
to press the three claws
against the groove on the inside surface of the insert. *
If the screw is tightened
break and it will be dif-
ficult
it out.
to pull
tightening compretely iii)
too strongly,
the insert will
Place bridge place plates Tighten
nut
the
Therefore,
screw when
the
stop claws
contact the groove. @ @ @
over the puller head, then and
0
on the bridge.
to pull out the insert.
6162F506A
Al
F6164098A
15-009 0
REPAIR AND REPLACEMENT
2.
REPLACING
OF PARTS
VALVE SEAT INSERTS
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 Insert
Stamp on insert
O.D.(d,)
S.T.D.
63.00+“’ O” +o.080
0.25 OS
Unit: mm
I
I
63.25;;:;;;
Mounting hole for insert Hight(h,)
I.D. (d2)
8.5-z.,
63.002:;;;
8.5:,,
12.5 zt 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,
12.5 f 0.1
63.25 :;:$j I
F6164099A
Depth (h,)
I
replace 3.
the cylinder
head.
Press fitting the insert 1) Using insert push toolA3,press-fit
the insert
(1 ).
l
Exhaust valve side Unit: mm
A3
Mounting hole for insert
Insert
Stamp 0"
insert
O.D.(d,)
Hight(h,)
I.D. (d2)
Depth (b)
615F004A 0.75 0.S
61.75;;:;:
8.75&
61.75 “;:;:;
12.75 f 0.1
1 .OO OS
62.00;;:;:
8.8&
62.00 “;:;:;
12.88 f 0.1
2) Check the sinking distance 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.
15-010 0
mounting,
surface
of the insert from
of the
cylinder
head.
Standard sinking distance of insert: 3.9 to 4.2 mm
E 4
>& I
o! m
F6164159
8 z z
REPAIR AND REPLACEMENT
OF PARTS
REPLACING
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
valve inserts
New
Old
6162-13-1321 (2 per valve)
6162-13-1320 (2 per valve)
VALVE SEAT INSERTS
1 I OO- 500mm
Part No.
Part No. and size stamped on outside circumference
Difference Need for calking after press
No
No stamp (Note: The oversize insert is stamped.)
Yes
fitting Calking above.
is not needed
head
for any insert not listed
1) Set with the bottom surface of the cylinder 8
z z
2) 3)
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.
6162F816A
F6164160A
15011 0
REPAIR
5.
AND
REPLACEMENT
Finishing
OF PARTS
A2 as shown Angie
of seat
Width
surface:
intake
of seat fininshing
side:
Connectricity
side: 3.69
of valve
Coat the seat surface guide
mm
and
mm
insert:
(T.I R) max. Unit:
using the compound.
a rough compound valve
mm
side: 3.79
guide
0.07 2) Fit the seat surface
30°
side: 45O
surface:
Exhaust
the
INSERTS
with valve seat cutter
Intake +
SEAT
in the figure. Exhaust
*
VALVE
the seat surface
1) Finish the seat surface +
REPLACING
of the valve thinly
mixed with
that
forms
with
oil insert
that
bar to the valve head,
and
hands
against When
it with
both
to rub
mm
* 0.05
it in
a pair with
valve, then fit a rubbing turn
$57.4
459+0.05
3o”
lightly
the valve seat. the
rubbing
removes
wipe off the compound. compound
and
repeat
give a good contact
the
roughness,
Intake
Exhaust
side
side
Then coat with a fine the
surface
above
process
to
with
no break
in
6162F507A
contact. 6.
Final check *
8
Standard
sinking
distance
of valve 0.9
-Sr Standarad
width
of contact
valve:
Intake
l
Coat the seat surface with
push
surface,
and rotate
contact
surface,
is uniform
l
lightely
surface
insert
against
mm
?c 0.2
it in the valve
the valve
insert
1 O”. Check the valve insert
Intake
side
Exhaust
side
that the contact
any breaks.
F6164100
or Make of the
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
uniformly
and rotate 1 O”. Check
pencil
marks
have
around
the whole
been
erased
Pencil ,(about
marks 20
places)
circumference.
F6164101
15-012 0
z z
Bottom surface of cylmder head
Bottom surface of cylinder head
against
* 0.2
side: 2.8
and confirm
without
Lo
mm
of the new valve thinly
red lead (minium),
guide,
Unit:
to 1.5 mm
side: 2.5
Exhaust
(new):
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).
3.
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
F6164103A
e
-
a
F6164104
F6164105A
15-014 0
z z
-----______
%
8
REPAIR AND REPLACEMENT
4.
OF PARTS
REPLACING
NOZZLE HOLDER SLEEVE
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)
4)
5)
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.
5.
Roll-fit the bottom
hole of sleeve
.
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
.
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
6162F511A
the taper section of sleeve
6162F512A
6162F513A
15015 0
REPAIR AND REPLACEMENT
OF PARTS
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.
8.
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.
15016 0
REPLACING
NOZZLE HOLDER SLEEVE
6162F514A
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
2.
2 Z Z
It is preferable to warm the whole cylinder head and carry out the test with hot water (82 - 93°C).
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
F6164106A
If the above test shows that there are cracks around the nozzle holder and plugs, replace the cylinder head.
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
REPLACING 1.
Removing l
OF PARTS
REPLACING
CROSS HEAD GUIDE
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,
guide with collet @of
hold the cross head
the puller.
2) Tighten the collet with bolt 0 0. 3) Rotate
nut @and
to lock sleeve
pull out the cross head
guide. 4) Remove
burrs, fins, etc. from the mounting
place of the cross head guide and clean
it.
615F019A
2.
Press-fitting l
the cross head guide
Insert the cross head guide in the cylinder head, then hit it into the cylinder bar or plastic
hammer
head with a copper
until
its protrusion
is
within specification +
Protrusion
of cross head guide Tolerance:
+
Inside diameter
54
’ -0.3
mm
of crosshead guide hole: ,5 + 0.018 mm 0
15019 0
REPAIR
AND
REPLACEMENT
GRINDING 1.
Grinding l
OF PARTS
VALVE
the seat surface
Angle
of valve seat: Intake valve: Exhaust
Checking l
THE
THE VALVE
Grind the seat surface with valve refacer *
2.
GRINDING
I.
30°
valve: 45O
after grinding
Confirm
that the thickness
protrusion
of the valve head,
of the valve, and the contact surface
of the valve seat are within specification. *
Thickness
of valve head
Ir Thickness
F6164107A
of valve head
Repair limit Intake valve: Min. 2.9 mm (Standard Exhaust
size 3.4 mm)
valve: Min. 3.1 mm (Standard
*
Sinking
of valve
size 3.5 mm)
Standard:
0.9 -
F6164108
8
1.5 mm
z z
Repair limit: 2.1 mm
*
Check the contact of the valve with the seat surface l
using one of the following
Coat the seat surface of the ground valve thinly with red lead (minium), the valve guide,
Make
marks
any breaks.
a pencil
on the
seat
of the ground valve as shown
the diagram, push
with
the
and confirm that the
contact is uniform without
surface
insert it in
push lightly against
valve insert surface,
l
F6164109
methods.
lightly
surface,
insert
against
and rotate
in
it in the valve guide, the loo.
valve
Pencil
marks
(about
20
places)
insert
Check that the
pencil marks have been erased uniformly around
15-020 0
the whole
circumference.
F6164101
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
TESTING (1)
Cylinder
REPLACEMENT
OF PARTS
TESTING
AND
INSPECTING
AND INSPECTING block Unit: mm
inspection
Judgement
item
A. Cracks
Check for cracks (external
l
Cylinder
Remedy
standards
color check)
head bolts hole portion,
Replace
etc.
6. Correction of con tact at packing portion Check for water leakage caused by corrosion
I C. Clearance liner
Replace
F6164111
from
~~~
zi%z!
ji
Clearance from liner
190.34
-
190.40
190.19
-
190.29
0.05
-
0.21 Replace cylinder liner or block
F616411:
D. Inside diameter of camshaft bushing
l
Inside diameter Standard
size
72 l
Clearance
from camshaft Standard 0.08
E. Protrusion
Standard
value
Repair limit
72.00
72.07
72.10 Replace bushing
bearing Standard
clearance -
-
0.18
of line
value
0.24
Permissible
range: 0.07
-
0.15 Replace cylinder liner or correct cylinder block
I
F. Depth of counter. bore and corrosion of bottom surface
G. Distortion, wear of cylinder head mounting surfac
’ \
F6164113
Depth of counterbore
Standard 14
~6164114
l
Overall
Standard
value
14.00
14.05
-
Repair by machining, add shim
Check for corrosion Repair limit
Tolerance top surface
For one cylinder:
15022 0
size
of block: Max. 0.09
0.15
Max. 0.05
0.10
Repair by machining
REPAIR
AND
REPLACEMENT
OF PARTS
TESTING
AND
INSPECTING
Unit: mm inspection
H. inside diameter of main bearing mounting hole l
Judgement
item
Tighten main bearing cap bolt and guide bolt at specifier torque
Standard 148 Ran$bf
Standard
size
@
standards
value
Remedy
Repair
147.992
-
147.025
-
170.992
-
171.025
-
limit
Replace I. Fitting of cap and cylinder
block
z z z
J. Inside diameter of counterbore, outside diameter of cylinder liner flange
Replace cylinder
F6164117
Bottom
1 194.59
Cylinder block
Standard size
Top
Bottom
1 206.0 194.5
/ ‘“~~$&I
Standard value
1 ‘““;;“,., 194.48 194.54
liner
-
Repair limit
I’““;“,‘,,
Correct cylinder sleeve
block
194.46 194.57
15023 0
REPAIR
AND
REPLACEMENT
GRINDING
GRINDING
OF PARTS
THE TOP SURFACE
THE TOP
OF CYLINDER
SURFACE
OF CYLINDER
BLOCK
BLOCK’
Grinding
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
z
Wear
ofcounterbore
portion
$ % 3 _I
I, \
1.
Grinding
top surface
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.
F6164118
+ 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
with
a grindstone
*
Speed
of grindstone:
*
Speed
of table:
+ Grinding It
depth/time:
Cross feed/time:
(for reference)
1,650
to 1,950 m/min.
15 to 30 m/min. 0.025
mm
1 to2mm
*
Grindstone:
A461V
*
Grinding
Water-soluble
lubricant:
grind-
ing lubricant
HLE00058
15024 0
REPAIR AND REPLACEMENT
2.
OF PARTS
GRINDING
THE TOP SURFACE
OF CYLINDER
Unit:mm
Grinding couterbore After
grinding
the
block,
measure
the depth of the counterbore.
it is not within are
contact
top surface
the standard
blackened
direction),
and these
portions
half of the contact counterbore correcting, 14.05
-
on
the
width
depth* if the
15.525
(Liner Drotrusion)
cylinder
-
If
or if there
cylinder
of the counterbore
in the front-to-rear wear,
of the
dimension,
portions
surface
liner Cylinder liner
(particularly
extend
/
over more than
the repair limit. After
counterbore
depth
mm, combine
with
Cylinder block
is within shims
is 0.07
-
and 0.15 I
mm. Counterbore
Repair
dimension limit:
Roughness
*
Machined
14 + io5
15.46
of cylinder
Standard +
I
depth L:
Standard
* Protrusion
v
/
of the deck, correct the
within
L 12.5s
or there is speckled
adjust so that the liner protrusion
*
BLOCK
F6164120
mm
liner I:
value: 0.07
of counterbore: shape:
mm
-
0.15
Max.
In accordance diagram
mm Unit:mm
12.5s with
for portion
detail
a cylinder
For the
extra
decide
amount
a machining
protrusion
for counterbore amount
that
will
of the cylindr liner within
depth
L,
bring the
the standard
value. When
grinding
within
the
repair
limit
in cases
where the counterbore depth L exceeds the standard dimension, set the machining amount Detail a
so that one shim can be used for each cylinder as shown
[Reference]
F6164121
in the table below.
Adjustment
shims for counterbore
Unit: mm
depth Ilnit. mm
.Part No. 6162-29-2260
T
1
1.50
t
Weight (kg)
1 0.025
1 0.004
Remarks
1
6162-29-2250
1 0.80
1 0.025
1 0.002
1
6162-29-2240
1 0.50
1 0.025
1 0.001
1
0.26
0.025
0.001
6162-29-2220
0.20
0.020
0.001
6162-29-2210
0.16
0.016
0.001
6162-29-2230
\
Shim
T*t
F6164122
15-025 0
REPAIR AND REPLACEMENT
3.
GRINDING
OF PARTS
THE TOP SURFACE
OF CYLINDER
BLOCK
Checking and distinguishing after grinding and correcting After grinding
and correcting,
on the flat surface in the cylinder Remove
all burrs completely.
H exceeds
is within always *
and oil holes
block top surface.
After grinding the top surface, height
check for scratches
around the water
the
the repair
limit (569.5
use an oversize
Oversize
if the cylinder
standard
block
dimension, -
509.8
but mm),
head gasket.
head gasket part number: 6162-19-1811
Thickness
of plate: 2.4 mm (Standard:
Ir To distinguish,
2.0 mm)
the letters
“OS”
are stamped
stamp
top surface
on the plate. After
correcting,
cylinder correction
block
according
as shown
the
to the
content
of the
Position Ds,r I.
of the
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
4.
AND
REPLACEMENT
Procedure gasket
for coating
bottom
When
pulling it again,
out the
of linei
cylinder
coat the
the counterbore
liner
contact
THE
TOP
SURFACE
OF CYLINDER
BLOCK
lip with
and press
surface
under
liner lip with gasket sealant
LG-
as follows. Use the same procedure when using
a shim for the corresponding +
GRINDING
sealant
fitting 6
OF PARTS
The following
part.
commercially
is equivalent
available
sealant
to LG-6.
l
Three
l
Nihon Hermetic:
Bond: TBI 215 SS-6OF 6162F759
1) Use a cloth to wipe off all the dirt and oil from the contact surface
Top surface
of the liner lip and cylinder
of block
block counterbore. Meting
2) Coat the position
marked
in the diagram
Of liner
portion
with
LG-6. l
Make
the
sealant l
diameter
$2 -
of the
Make the overlapping and ending
line
of gasket
3 mm. the
mm as shown
portion for beginning
coating
of sealant
6 f
Position to coat with gasket sealant
6
in the diagram.
F6164124
*
When l
using shims
After
coating
thinly
with
,
the
bottom
LG-6,
of the
shim
it to the
deck
in the same
way
instll
portion of the block. l
Next,
coat with
as when
LG-6
not using shims.
Overlap
amount
6 + 6 mm
-1
d
F6164125
G-6
(@2 -
3 mm)
/
3) Press fit the liner in the cylinder When
doing
this,
coat the
lubricant
RF-I.
+ RF-l
is equivalent
available
+ If RF-1 contaet
to
Daido Kagaku is not surface
an extremely (SAE30)
the
available,
small
1 rubber
commercially
Kogyo DS-50. coat
of the O-ring
immediately
block.
seal with
amount before
the
block
and seal with of engine press
oil
fitting
the liner. F6164126
15-027 0
REPAIR AND REPLACEMENT
4)
OF PARTS
GRINDING
THE TOP SURFACE
OF CYLINDER
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
5)
Insert liner (I) into the cylinder care not to damage the O-ring.
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
ii)
Ir
Mounting
6162F761
block, taking
bolt: 26 * 1 kgm
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.
I
15-028 0
BLOCK
6162F764
REPAIR AND REPLACEMENT
8)
OF PARTS
GRINDING
THE TOP SURFACE OF CYLINDER
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
BLOCK
If the grommet is deformed into a heart shaDe. it blocks the water hole and may cause the coolant.
/
The gasket sealant that comes out may cause deformation of the head gasket grommet, so always carry out steps 4) and 5) without fail.
/ / Grommet
R
leakage
of
\ \ 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
Coat the thread SAE30
boltfor main metal cap: and seat with engine
oil
Unit: kgm Procedure
Target
Range
1 st step
56
51 -61
2st step
113
3st step
0
4st step
38
33-43
5st step
75
70-80
6st step
113
5)
*
3)
4)
107-118 Loosen completely
Tolerance:
107-118
Align the notches and cap.
on the cylinder
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 ii)
block
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.
148+to25 mm
Inside diameter of cap when main cap is tightened to specified torque after machining. Tolerance:
148$::%:
mm
(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
2 z &
REPAIR AND REPLACEMENT
2.
REPLACING
OF PARTS
MAIN METAL CAP
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
of surface facing thrust metal: 12.5 max. of main cap Tolerance:
+
Width
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.
the
1.
Removing
.
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.
No. 1 and No. 7 bushings
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.
2
1
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.)
1
6162F521
15-032 0
REPAIR AND REPLACEMENT
OF PARTS
5.
Press-fitting
.
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.
REPLACING
CAM BUSHING
No. 2 and No. 6 bushings
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
item
A. Cranks
Judgement Use a magnetic
standards
flaw detector
to check for cracks
6. Damage Check for damage to the journal portion 1 Damage C. Clogging
15-034 0
of oil hole
Scratches seizure discoloration
to cap hole at front and rear end
Check for clogging
of oil hole
Remedy Replace If the damage is slight, correct with an oilstone or correct by lapping. Replace if there is seizure Correct Correct
REPAIR AND REPLACEMENT
OF PARTS
CRANKSHAFT
Unit: Inspection
item
D. End play of crankshaft
E. Thickness bearing
Size
of
G. Out-of-roundness crankshaft pin
of
I. Outside diameter main journal
of
L. Curvature of crankshaft (total runout of indicator)
Standard
1
standards Repair
Standard value 0.14 - 0.320
of thrust
F. Outside diameter crankshaft pin journal
Judgement
I
limit
Tolerance
Repair
limit
3.79 3.92
STD 0.25 US
4.0 4.125
0.50 us
4.25
0.75 us
4.375
4.17
1 .oo us
4.5
4.29
Size
Standard
size
Tolerance
_ Replace thrust bearing or correct crankshaft . with oversize
4.04
-0.07 -0.12
Repair
limit
STD
108.00
107.91
0.25 US
107.75
107.66
0.50 us
107.50
0.75 us
107.25
107.16
1.00 us
107.00
106.91
-:.022
Standard Total coaxiality main journal
of
Coaxiality of neighboring journals
Remedy
Replace thrust bearing or correct with oversize
0.69
size
mm
107.41
Repair
Max. 0.09
0.09
Max. 0.05
0.05
Correct with undersize or replace
limit Replace
15-035 0
REPAIR AND REPLACEMENT
Correcting surface journal portion If the does
roughness not
roughness
of the
fulfill
OF PARTS
the
of crankshaft
crankshaft
standard,
CRANKSHAFT
journal
correct
portion
the
surface
roughness. 1.
Cleaning Before
and blowing polishing,
with
brush
air
the oil holes
and blow
with air. 2.
Correcting
surface
1) When
roughness
correcting
with
of journal special
portion
polishing
machine Use a special the diagram
i)
polishing
Set the rotating -
50
rpm,
type).
as shown
speed for the work
and
Perform
honing
machine
in
on the right. use No. 320 dry polishing
paper
at 40 (belt
(do not use
oil), and move the paper
and down the whole journal
once
up
width for each
journal. ii)
Next, replace journal
the handle right
with No. 500 paper, coat the
surface by the
movement.
with
honing
of the machine amount Use this
oil, and move to the left and
of play to give fine movement
once up and down the whole journal.
Move the paper
to move
width
smoothly
of the
not stop at any point. iii) Check the surface not within
roughness,
the standard,
up and down the width
F6164131
and do
and if it is
polish again once of the journal
z Move handle to left and right, and move once up and down width of journal
with
No. 500 paper.
F6164132
15-036 0
z
REPAIR AND REPLACEMENT
2) When
OF PARTS
CRANKSHAFT
using a work clamp jig for polishing
(When
a special
polishing
machine
is not
jig such
as shown
in the
machine
under
available) Use a work diagram
clamp
on the right.
Use a crankshaft the following
grinding
polising
Paper:
No. 800
Machining
oil: Honing
Work speed: The
time
6 minutes.
amount
oil
40 rpm
polishing
approx.
conditions.
for
one
Move
the
of play of the clamp
width
(approx.
5 mm),
down
the journal
After completing replace When
journal clamp
is the
and journal
and move
in the axial
up and
direction.
the honing of one journal,
the paper with new paper. honing
the
pin journal,
it is safer
to carry out the work with the pin journal at the rotation
3) Assembly
center.
of work
F6164133
clamp
jig and
method
of
use i) Jig for pin journal Assemble diagram
on the
component separate
and jig for main journal
the clamp parts,
jig as shown
in the
For details
of the
right. see
the
drawings
on
pages.
F6164134
15-037 0
REPAIR
AND
REPLACEMENT
CRANKSHAFT
OF PARTS
ii) Cut out a piece of No. 800 paper with the shape shown in the diagram on the right.
Dimensions
230 Make cuts of 20 mm length\ at approx. 10 mm intervals
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.
of paper for pin journal
I I I I I I I I I n_, Cut out slit 2 portions 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
8
z z
roughness
After correcting the surface roughness, always brush the oil hole and blow with air. 5.
Check
that
the journal
there portion
are no scratches and fillet
or dents
at
R portion.
Fix in position Bend to fit round
.Rubber
with tape w
shape
inside
plate
F6164136
15038 0
REPAIR AND REPLACEMENT
Clamp jig parts drawing
CRANKSHAFT
OF PARTS
(for pin journal)
@I Plate (2 are used for each jig) Unit: mm 69 k 0.1
I=
74
(10)
-i 5
A
F==i A
LLI 31.5
I =H--
/
--t-F”
I
STKM 13A
Section A-A F6164137A
@
Handle (2 are used for each jig)
Umt:mm -
450
132
F6164138A
15039 0
REPAIR AND REPLACEMENT
Clamp jig parts drawing 0
OF PARTS
CRANKSHAFT
(for main journal)
Plate (2 are used for each jig) Unit:
mm
1 A
t A -
27.5
/ 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 .
.
l
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.
\c
\ /IF.
Dimension
R
of fillet
/r
r’
i
R: 6.5_g.s mm, Surface roughness r: 6.4 mm, Surface roughness
-
R
-
1.6s 12.5s
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
6127F231
.
Dimension
Main journal
Stroke
of oil hole on journal
Pin journal
6127F233
Throw
of eccentric:
85-t,,,
mm
15041 0
REPAIR AND REPLACEMENT
2.
OF PARTS
REPAIRING
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.
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.
kk
&tact
point
Contact point
6127F234
THE CRANKSHAFT
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
Minimum radius of fillet: 6.00 mm Maximum radius of fillet: 6.50 mm Size 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.
l
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.
Critical area of web of crankshaft
I 6127F235
15042 0
Basic dimension
S.T.D
140.000
0.25 US
139.750
0.50 us
139.500
0.75 us
139.250
1 .oo us
139.000
Allowable error
-00.025
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
8 Z Z
REPAIR AND REPLACEMENT
4.
REPAIRING
OF PARTS
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).
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
Undersizes
3asic dimension
Rear thrust
bearing
Basic dimension Limit Basic dimension
surface
64+:.050
0.25 0.S +0.050 64.25 o
64.060
64.310
64.25+;‘050
64.50+;.05’
64.310
64.560
.
6.
Squareness (T.1.R)
Ulowable error
of thrust bearing
S.T.D
108.00
0.25 US
107.75
0.50 us
107.50
0.75 us
107.25
1 .oo us
107.00
mm
1 S.T.D
.
mm
of thrust bearing surfaces Unit:
Limit
of pin journal Unit:
Size
.
THE CRANKSHAFT
surface .
Limit: 0.04 mm
.
0 -0.022
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
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
i
Friction surface 1 6 I27F236
15-043 0
REPAIR AND REPLACEMENT
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.
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
15-044 0
REPAIRING
OF PARTS
THE CRANKSHAFT
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.
l
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.
8 z z
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
CONNECTING
OF PARTS
CONNECTING
ROD
ROD 1. 2. 3. 4. 5. 6.
Bolt Washer Cap Dowel pin Connecting Bushing
rod
F6164151
Unit: mm Inspection
item
A. Cracks
Judgement
standards
Remedy
Check for cracks with a color check or magnetic
B. Curvature, twisting
,,,I:::~
flaw detector
I D
:,
Replace
Check for curvature or &vising F6164152A
C. Clearance between connecting rod bushing and piston pin
D. Inside diameter of hole at big end of connecting rod
Replace bushing, roughness of inside surface of bushing: Max. 2.4s Inside diameter of hole at big end Without bearing Standard
1
size
Tolerance
I
+0.026 0 Roughness of inside surface of hole at big end: Max. 6.35 Clearance from crankshaft bearing (with bearing) 115
Standard
clearance
0.058 - 0.132
1 I
Clearance
Replace
limit
0.20
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
F. Scratches on inside surface of bearing, seizure G. Distance between holes at big end and small end
15046 0
Standard
size
Tolerance
Repair limit
S.T.D
3.500
U.S 0.125
3.625
3.41
0.250
3.725
0.375
3.875
3.79
0.500
4.000
3.90
3.54 -0.029 -0.042
3.66
Check for scratches or seizure
Standard
Replace, replace connecting rod also size
1
Tolerance Replace
305
I
-:.05
8 Z G,
REPAIR AND REPLACEMENT
CONNECTING
OF PARTS
ROD
Unit: mm Inspection
item
Judgement
H. Scratches at I shape portion of connecting rod (dents)
standards
Check for scratches direction in area A
I
Remedy
in horizontal
Check for grinder grain in horizontal direction in area A
F6164153 I
I. Fretting of mating surface of cap
Check for fretting
Roughness Contact
J. Scuffing of bolt seat surface
2
K. Deformation dowel pin
T
W
of
of mating
surface
of mating
of mating
surface:
surface:
Scuffing
of cap bolt seat surface
Scuffing
of bolt seat surface
Scuffing
of washer
Replace if fingernail catches in fretting
Max. 6.3 S
Min. 70%
I I
I
surface
Check for deformation
of dowel
pin
Check for deformation
of dowel
pin hole
dents, regardless of size
Correct with oilstone Replace
bolt
Replace washer Replace
I
G L. Damage
to bolt
Check for cracks, damage Check for curvature
+
*
of bolt
to bolt thread
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.
K2 /
6162F813A
2.
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: 200°C 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.
15048 0
REPAIR AND REPLACEMENT
REPLACING CAMSHAFT 1.
a
2.
REPLACING
OF PARTS
CAMSHAFT
GEAR
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: 200°C 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.
15049 0
REPAIR AND REPLACEMENT
OF PARTS
REPLACING FLYWHEEL RING GEAR Be careful not to let the flywheel you.
g
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.
a
Be careful when handling the grinder and chisel.
2.
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. 200°C 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.
15-050 0
REPLACING
FLYWHEEL RING GEAR
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
1
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR 2
NAME OF COMPANY:
:
PHONE NO:
: S
DEPARTMENT:
E R
NAME:
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
LOCATION:
DATE:
