SEBD6161A16

SEBE6161A16
DIESEL ENGINE
© 2005 1
All Rights Reserved 00-1
Printed in Japan 02-05(02) (16)
CONTENTS
No. of page
01 GENERAL ........................................................................................................ 01-001
11 STRUCTURE AND FUNCTION ....................................................... 11-001
12 TESTING AND ADJUSTING ............................................................. 12-001
13 DISASSEMBLY AND ASSEMBLY ................................................. 13-001
14 MAINTENANCE STANDARD ............................................................ 14-001
15 REPAIR AND REPLACEMENT OF PARTS .............................. 15-001
00-2 6D170-1 SERIES

A
The affected pages are indicated by the use of the
Mark Indication Action required
following marks.
RevisionIt is requested Revision
that necessary Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number
actions be taken number
to these pages according to the number number number
c Page to be newly added Add
table below.
b Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously re-

vised or made aditions.
LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

number number number number number
b 00-1 (16) 01-004-14 (15) 01-025 (8) 11-026 11-044-3 (11)

00-2 (11) 01-004-15 (15) 01-026 (12) 11-027 11-045 (11)
b 00-2-1 (16) 01-004-16 (15) 01-027 (8) 11-028 11-046 (12)
b 00-2-2 (16) 01-005 01-028 (13) 11-030 (12) 11-046-1 (12)
b 00-2-3 (16) 01-006 01-029 (13) 11-031 (7) 11-047 (9)
00-3 01-007 01-030 (15) 11-031-1 (3) 11-048 (9)
00-4 01-008 01-031 (15) 11-031-2 (7)
00-5 01-009 11-032 (8) 12-001 (14)
00-6 01-010 11-001 (14) 11-033 (8) 12-002 (8)
00-7 01-010-1 (3) 11-002 11-033-1 (8) 12-002-1 (7)
00-8
01-010-2 (3) 11-003 11-034 (11) 12-002-2 (7)
00-9
01-010-3 (5) 11-004 (3) 11-034-1 (7) 12-002-3 (5)
00-10
01-010-4 (5) 11-005 (3) 11-034-2 (9) 12-002-4 (5)
00-11
00-12 01-010-5 (5) 11-005-1 (5) 11-034-3 (7) 12-003 (8)
00-13 01-010-6 (5) 11-006 (3) 11-034-4 (7) 12-004 (8)
00-14 01-011 (12) 11-006-1 (4) 11-034-5 (7) 12-005 (11)
00-15 01-012 (1) 11-006-2 (4) 11-034-6 (7) 12-006 (11)
00-16 01-012-1 (10) 11-006-3 (4) 11-034-7 (7) 12-007 (12)
00-17 01-013 (14) 11-007 (7) 11-035 12-008 (8)
00-18 01-014 (13) 11-008 (7) 11-035-1 (14) 12-008-1 (9)
00-19 01-014-1 (13) 11-008-1 (7) 11-035-2 (14) 12-008-2 (9)
00-20 01-014-2 (13) 11-008-2 (7) 11-035-3 (14) 12-009 (8)
00-21 01-014-3 (14) 11-009 11-035-4 (14) 12-010 (8)
00-22 01-014-4 (13) 11-010 (12) 11-035-5 (14) 12-011 (8)
01-015 (13) 11-011 11-035-6 (14) 12-011-1 (14)
01-001 (2) 01-016 (8) 11-012 11-036 12-012 (8)
01-002 01-016-1 (13) 11-013 (7) 11-037 12-013 (13)
01-003 01-017 (8) 11-014 11-038 (11) 12-013-1 (14)
01-004 (13) 01-018 (8) 11-015 11-038-1 (11) 12-013-2 (15)
01-004-1 (14) 01-019 (8) 11-016 (12) 11-039 (11) 12-014 (12)
01-004-2 (13) 01-019-1 (8) 11-017 (8) 11-039-1 (12) 12-014-1 (12)
01-004-4 (14) 01-020 (8) 11-017-1 (11) 11-039-2 (12) 12-015 (8)
01-004-5 (13) 01-020-1 (13) 11-018 11-040 12-016 (13)
01-004-6 (13) 01-020-2 (13) 11-019 11-041 12-016-1 (14)
01-004-7 (13) 01-020-3 (13) 11-020 (11) 11-042 (8) 12-016-2 (13)
01-004-8 (13) 01-020-4 (13) 11-021 (2) 11-042-1 (8) 12-017 (8)
01-004-9 (15) 01-021 (8) 11-022 11-042-2 (8) 12-018 (13)
01-004-10 (13) 01-022 (8) 11-023 11-043 (3) 12-019 (13)
01-004-11 (14) 01-023 (8) 11-024 (3) 11-044 (11) 12-020 (8)
01-004-12 (13) 01-023-1 (13) 11-024-1 (3) 11-044-1 (12) 12-020-1 (13)
01-004-13 (13) 01-024 (8) 11-025 (3) 11-044-2 (11) 12-020-2 (13)
6D170-1 SERIES 00-2-1

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12-020-3 (13) 12-035-1 (13) 12-051 (11) 13-012 (11) 14-003-1 (8)
12-020-4 (13) 12-035-2 (15) 12-053 (8) 13-013 (11) 14-003-2 (11)
12-020-5 (13) 12-035-3 (13) 12-055 (8) 13-014 (11) 14-004 (6)
12-020-6 (13) 12-035-4 (13) 12-056 (8) 13-015 (11) 14-005 (14)
12-021 (8) 12-035-5 (13) 12-057 (8) 13-016 (11) 14-006 (11)
12-022 (12) 12-035-6 (15) 12-058 (8) 13-017 (11) 14-007 (6)
12-023 (8) 12-035-7 (15) 12-059 (8) 13-018 (11) 14-008 (13)
12-023-1 (12) 12-036 (13) 12-060 (8) 13-019 (11) 14-009
12-023-2 (12) 12-037 (13) 12-061 (8) 13-020 (11) 14-010 (11)
12-023-3 (13) 12-037-1 (13) 12-062 (8) 13-021 (15) 14-011 (7)
12-023-4 (12) 12-037-2 (15) 12-063 (8) 13-022 (11) 14-012
12-023-5 (14) 12-037-3 (15) 12-064 (8) 13-023 (11) 14-013 (2)
12-024 (12) 12-037-4 (15) 12-065 (8) 13-024 (11) 14-013-1 (8)
12-024-1 (13) 12-037-5 (13) 12-066 (8) 13-025 (11) 14-013-2 (8)
12-024-2 (13) 12-037-6 (14) 12-067 (8) 13-026 (11) 14-014 (8)
12-024-3 (13) 12-038 (13) 12-068 (8) 13-027 (11) 14-015 (11)
12-024-4 (13) 12-039 (13) 12-069 (8) 13-028 (11) 14-016 (11)
12-024-5 (13) 12-039-1 (13) 12-070 (8) 13-029 (11) 14-017 (6)
12-024-6 (13) 12-039-2 (14) 12-071 (8) 13-030 (11) 14-018
12-024-7 (13) 12-040 (13) 12-072 (8) 13-031 (11) 14-020
12-024-8 (13) 12-041 (13) 12-073 (8) 13-032 (11) 14-021 (2)
12-024-9 (13) 12-041-1 (13) 12-074 (15) 13-033 (11)
12-024-10 (15) 12-041-2 (13) 12-075 (8) 13-034 (11) 15-001 (12)
12-025 (12) 12-041-3 (13) 12-076 (8) 13-035 (11) 15-002 (12)
12-026 (11) 12-041-4 (14) 12-077 (8) 13-036 (11) 15-004 (12)
12-027 (12) 12-041-5 (14) 12-078 (14) 13-037 (11) 15-005 (12)
12-028 (11) 12-041-6 (14) 12-079 (14) 13-038 (11) 15-006 (12)
12-028-1 (12) 12-041-7 (15) 12-080 (14) 13-039 (11) 15-007 (12)
12-028-2 (12) 12-041-8 (15) 12-081 (14) 13-040 (11) 15-008 (12)
12-029 (12) 12-041-9 (15) 12-082 (14) 13-041 (11) 15-009 (12)
12-030 (12) 12-041-10 (15) 12-083 (14) 13-042 (13) 15-010 (12)
12-030-1 (9) 12-042 (8) 12-084 (14) 13-043 (11) 15-011 (12)
12-030-2 (12) 12-043 (12) 12-085 (14) 13-044 (11) 15-012 (12)
12-030-3 (13) 12-044 (12) 12-086 (14) 13-045 (11) 15-013 (12)
12-030-4 (13) 12-044-1 (13) 12-087 (14) 13-046 (11) 15-014 (12)
12-030-5 (13) 12-044-2 (10) 12-088 (14) 13-047 (11) 15-015 (12)
12-030-6 (13) 12-045 (13) 12-089 (14) 13-048 (11) 15-016 (12)
12-030-7 (13) 12-046 (15) 12-090 (14) 13-049 (11) 15-017 (12)
12-030-8 (13) 12-047 (15) 12-091 (14) 13-050 (11) 15-018 (12)
12-030-9 (13) 12-047-1 (13) 12-092 (14) 13-051 (11) 15-019 (12)
12-030-10 (13) 12-047-2 (13) 12-093 (14) 13-052 (11) 15-020 (12)
12-030-11 (14) 12-047-3 (13) 12-094 (14) 13-053 (11) 15-021 (12)
12-030-12 (14) 12-047-4 (13) 13-054 (11) 15-022 (12)
12-030-13 (14) 12-048 (9) 13-001 (11) 13-055 (11) 15-023 (13)
12-030-14 (14) 12-049 (9) 13-002 (11) 13-056 (11) 15-024 (12)
12-030-15 (14) 12-049-1 (13) 13-003 (11) 13-057 (11) 15-025 (12)
12-030-16 (15) 12-049-2 (13) 13-004 (11) 13-058 (11) 15-026 (12)
12-030-17 (15) 12-049-3 (13) 13-005 (11) 13-059 (11) 15-027 (12)
12-030-18 (15) 12-049-4 (13) 13-006 (11) 13-060 (11) 15-028 (12)
12-031 (10) 12-049-5 (13) 13-007 (11) 15-029 (12)
12-032 (11) 12-049-6 (15) 13-008 (11) 14-001 (8) 15-030 (13)
12-033 (13) 12-049-7 (15) 13-009 (11) b 14-002 (16) 15-031 (12)
12-034 (13) 12-049-8 (15) 13-010 (11) c 14-002-1 (16) 15-032 (12)
12-035 (13) 12-050 (8) 13-011 (11) 14-003 (8) 15-033 (12)
00-2-2 6D170-1 SERIES

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15-034 (12)
15-035 (12)
15-036 (12)
15-037 (12)
15-038 (12)
15-039 (12)
15-040 (12)
15-041 (12)
15-042 (12)
15-043 (12)
15-044 (12)
15-045 (15)
15-046 (12)
15-047 (12)
15-048 (12)
15-049 (12)
15-050 (12)
6D170-1 SERIES 00-2-3

(16)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11 When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21 When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-) terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17 When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

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

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....I is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one

Attachments volume: volume to cover all REVISIONS
1 models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
See the page number on the bottom of the Symbol item Remarks
page. File the pages in correct order.
Special safety precautions are
A
Following examples show how to read the
Safety necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3
or other precautions for pre-
TT * Caution serving standards are neces-
Item number (IO. Structure sary when performing the
work.
~~~~~~~b.,. number for
Weight of parts of systems.
each item.
el
Caution necessary when se-
Weight lecting hoisting wire, or when
kg
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
TT -F Places that require special at-
Tghteninc
Unit number (1. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for Coat
hesives and lubricants, etc.
each item.
oil, water or fuel
Places where
Oil, water must be added, and the ca-
Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-) and number after the
Places where oil or water
page number. File as in the example. Drain must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
12-203-I
Added pages -C12_203_2
IO-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
g sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. 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 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. 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
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

ing a wide hanging angle from the hook.
(Standard “Z” or “S” twist ropes
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter r Allowa e load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg1 vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN (2000 kg} of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 (1000 kg1 when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg1 if they sling
30 98.1 10.0
a 19.6 kN (2000 kg1 load at a lifting angle
40 176.5 18.0 of 150”.
0
50 274.6 28.0 a
60 392.2 40.0 D
88 E,
16.7 0
* The allowable load value is estimated to ibid
(1400) Q
be one-sixth or one-seventh of the break- (1000) %
ing strength of the rope used. 600)
2) Sling wire ropes from the middle portion

30 60 90 120 150
of the hook. Lifting anrle (dearee) SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
* The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
Sr For coating materials not listed below, use the equivalent of products shown in this list.
Category omatsu code Part No. Q'W Container

I Main applications, features
Used to prevent rubber gaskets, rubber

LT-IA 790-129-9030 150 g ITubeTr- ~ ~~ ~~
cushions, and cock plug from coming out.
l Used in places requiring an immediately

effective, strong adhesive. Used for plas-
790-129-9050 20 g Polyethylene
LT-IB tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
l Features: Resistance to heat and chemi-

Polyethylene cals
LT-2 09940-00030 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790-129-9060 Adhesive: l Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT-3 sive and iardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene . Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz . Used as heat-resisting sealant for repair-

790-126-9120 75 g Tube
MH 705 ing engine.
I I
. Quick hardening type adhesive

Three bond Polyethylene . Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container . Used mainly for adhesion of metals, rub-
bers, plastics and woods.
I l Quick hardenina tvoe adhesive
I I
l Quick cure typejmax. strength after 30 min-
Aron-alpha Polyethylene
790-129-9130 29 utes)
201 container
l Used mainly for adhesion of rubbers, plas-
I I tics and metals.
Loctite
79A-129-9110
648-50
Used as adhesive or sealant for gaskets

790-129-9010 200 g
I
LG-1
and packing of power train case, etc.
Features: Resistance to heat

Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant 790-129-9070 to prevent seizure.
LG-3 1 kg
Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'W Container Main applications, features
l Features: Resistance to water, oil

. Used as sealant for flange surface, thread.
l Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
l Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
l Used as sealant for various threads, pipe

Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container l Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
l Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.
* Features: Silicon based, quick hardening

type
LG-7 09920-00150 150 g Tube - Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
Three bond . Used as heat-resisting sealant for repairing

790-129-9090 100 g Tube engine.
1211
l Used as lubricant for sliding portion (to pre-

LM-G 09940-00051 60 g Can
Molybde- vent from squeaking).
num
disulphide . Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
. Used as lubricant for linkage, bearings, etc.
SYG2-400LI l General purpose type

SYG2-350LI
G2-LI SYG2-4OOLl-A Various Various
SYGS-16OLI
SYGA-1 6OCNLI
l Used for normal temperature, light load

SYG2-4OOCA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GP-CA SYGS-4OOCA-A Various Various
SYG2-160CA
SYGA-IEOCNCA
Molybdenum 400 g l Used for places with heavy load

disulphide SYG2-400M (IO per Belows type
lubricant case)
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS
Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across fiats
I I
mm mm Nm kqm
6 10 13.2+ 1.4 1.35kO.15

8 13 31+3 3.2kO.3
IO 17 6657 6.7f0.7
12 19 113*10 11.5+1
14 22 177f19 18f2
279+30 28.5f3
382?39 39f4
549f59 56f6
745f83 76f8.5
927*103 94.5f 10.5
27 41 1320+140 135f15
30 46 1720+190 175f20
33 50 2210+240 225f25
36 55 2750+290 280f30
39 60 3290*340 335f35
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 7.85f 1.95 0.8f0.2
8 13 18.6f4.9 1.9f0.5
10 14 40.2f5.9 4.1f0.6
12 27 82.35k7.85 8.450.8
TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5f 4.9 2.5rt0.5
03 18 24 49k19.6 5f2
04 22 27 78.5k19.6 8+2
05 24 32 137.3k29.4 14&3
06 30 36 176.5f29.4 18*3
10 33 41 196.1*49 20+5
12 36 46 245.2f49 2525
14 42 55 294.2+49 30*5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

mm I mm I Nm I kgm
IO 14 65.7* 6.8 6.7f0.7
12 17 112k9.8 11.5+1
16 22 279*29 28.5f3
00-10
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Nominal No. I I I
mm mm Nm kgm
02 14 34.3* 4.9 3.5kO.5
03.04 20 Varies depending on 93.1f9.8 9.5fl
05,06 24 type of connector. 142.1f19.6 14.5&Z
IO,12 33 421.4f58.8 4356
14 42 877.1f 132.3 89.5*13.5
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tighteni I torque

Nominal No.
mm mm Nm kgm
08 8 14 7.35+ 1.47 0.75+0.15
10 10 17 11.27f 1.47 1.15~0.15
12 12 19 17.64f 1.96 I.85 0.2
14 14 22 22.54k 1.96 2.3f0.2
16 16 24 29.4& 4.9 3kO.5
18 18 27 39.2+ 4.9 4kO.5
20 20 30 49f 4.9 5f0.5
24 24 32 68.6+ 9.8 7&l
30 30 32 107.8f14.7 Ilk 1.5
33 33 - 127.4f19.6 13+2
36 36 36 151.9k24.5 15.5k2.5
42 42 - 210.7f29.4 21.5+3
52 52 - 323.4f 44.1 33* 4.5
TIGHTENING TORQUES OF FLARE NUT

SAD00483
mm mm Nm bm
14 19 24.5f 4.9 2.5+ 0.5
18 24 49+ 19.6 5+2
22 27 78.5? 19.6 8k2
24 32 137.3k29.4 1423
30 36 176.5ir29.4 18k3
33 41 196.1f49 2Ok5
36 46 245.2+49 25f5
42 55 294.2f49 30+5
00-l 1
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kgm
6 10 f2 1.02 f 0.20
8 24 f 4 2.45 f 0.41
10 43 z!z6 4.38 If:
0.61
12 77 rk 12 7.85 f 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kgm
6 8k2 0.81 f 0.20
8 lOf2 1.02 + 0.20
10 12 +2 1.22 + 0.20
12 24 f 4 2.45 f 0.41
14 36 + 5 3.67 + 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
II16 351 0.31 * 0.10
l/8 8+2 0.81 f 0.20
l/4 12f2 1.22 k 0.20
318 1552 1.53 f 0.41
l/2 24 + 4 2.45 f 0.41
314 36 k 5 3.67 f 0.51
1 60 k 9 6.12 f 0.92
00-12
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Currerrtrating Applicable circuit
Number of Dia. yfmst$ndsCross section Cali:rzD.
strands (mm*)
0.85 11 0.32 0.88 2.4 12 I Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 I Lighting, signal etc.
5 I 65 I 0.32 I 5.23 I 4.6 37 Charging and signal
15 84 0.45 13.36 59 Starting (Glow plug)
40 85 0.80 42.73 135~~~ I Starting
60 I 127 I 0.80 1 63.84 1 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
\ Circuits1
Prior- Starting Lighting Instrument Signal Other
ity I I I
Pri- Code
W B B R Y G L
1 !
man/
Color White Black Black Red Yellow Green Blue
Code WR - BW RW YR GW LW
2
Color White & Red - Black & White Xed & White Yellow & Red Green & White Blue & White
Code WB - BY RB YB GR LR
3
Black & YellowI Red & Black Yellow & Black Green & Red Blue & Red
BR RY I YG I GY I LY
Black & Red led & Yellow Yellow & Green Green & Yellow Blue & Yellow
ICode WG I - I - RG YL GB LB
5
IColorlWhite & Green1 - 1 - <ed & Green bellow & Bluebreen & Black1Blue & Black
Code - - - RL I WJ I GL I -
6
Color - - -
I
Red & Blue ly ellow &White Green & Blue I -
00-13
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5; 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 i 0.236 0.276 0.315 0.354

IO 0.394 0.433 0.472 0.512 0.551 0.591 i 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984: 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378: 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772; 1.811 1.850 1.890 1.929
0 i
@_.. . . . .
50. . . . . . . . .. . . . .
1.969 . . . . . . . . . . . . .
2.008. . . . . . . . . . . . . .
2.047. . . . . . . . . . . . . . .
2.087 . . . . . . . . . . . . .
2.126 . . . . . . . . . 12.1651 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-l 4
Millimeters to Inches
7 mm = 0.03937 in
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
Kilogram to Pound
1 kg = 2.2046 lb
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-l5
FOREWORD CONVERSIONTABLE
Literto U.S. Gallon

1C = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
IO 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Literto U.K. Gallon

IC = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
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
r
kgm to ft. lb
1 kqm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
IO 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
00-17
kg/cm* to lb/in’
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
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
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 . . . . . . .. ......... 01-002

Specifications ........................... 01-004
General assembly drawing ................ 01-005
Weight table ............................ 01-01 1
Engine performance curve ................ 01-012
170-1 SERIES 01-001

0
GENERAL GENERAL VIEW
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 damper
9. Turbocharger
10. Oil cooler
11. Starting motor
12. Alternator
13. Water pump
6162POOZ
01-002 170-1 SERIES

GENERAL GENERAL VIEW
SA6D170-A-1 for EG550-1
1. After-cooler
2. Fuel filter
3. Oil filter
5. Oil filler
6. Oil level gauge
7. Turbocharger
8. Corrosion resister
9. Alternator
10. Starting motor
170-1 SERIES 01-003

GENERAL SPECIFICATIONS
SPECIFICATIONS
Engine model S6D170-1
Pc1500-1
Applicable machine D275A-2 PC650-1
(Twin engine)
Number of cylinders - Bore x Stroke mm 6-170x170
Total piston displacement cc 23,150
Firing order l-5-3-6-2-4
Overall length mm 1,860 2,029 2,029
Ovrall width mm 1,155 1,009 1,009
Overall height
mm 2,070 1,875 1,875
(Excluding exhaust pipe)
Overall height - - -
mm
(Including exhaust pipe)
302/l ,800 302/1,600 302/l ,600

Flywheel horsepower (404/l ,800I {404/1,600} {404/l ,600)
2,079/1,300 2,030/1,200 2,030/1,200
Maximum torque {212/l ,300) {207/l ,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
Minimum fuel consumption ratio 219 {163} 224 {I671 224 I1671
Dry weight 2,620 2,375 2,375
Fuel pump Bosch PE-PDx type
Governor Bosch RSUV centrifugal, all speed type
Lubricating oil amount (refill capacity)
Coolant amount
Alternator 24V, 50A 24V, 13A 24V, 13A
Starting motor 24V. 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2
Battery 12V 170Ah x 2 12V 200Ah x 2 12V200Ahx2x2
I I
I I
Turbocharger Komatsu KTRI IO Komatsu KTR130 Komatsu KTR130
Cummins Cummins
Air compressor - single cylinder single cylinder
reciprocated type reciprocated type
Others - - -
01-004
0
S6D170-1
WA600-1
WD600-1
WA600-1 (Extreme cold WD600-1
(Cold weather)
weather)
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 (Net) 305/2,000 (Net) 334/2,000 (Net) 334/2,000 (Net)

{409/2,000) (Net) {409/2,0001 (Net) #48/2,000) (Net) {448/2,0001 (Net)
1,961/1,400 (Net) 1,961/1,400 (Net) 2,089/1,400 (Net) 2,089/1,400 (Net)
{200/1,400} (Net) {200/1,400~ (Net) I213/1,400} (Net) {213/1,4001 (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) 212 {I581 (Net)
2,750 2,750 2,750 2,750
DENS0 NE
BOSCH PE-PDx type BOSCH PE-P type (EP-11) type
DENS0 RSUV-D
BOSCH RSUV centrifugal, all speed typf lOSCH RSUV centrif- centrifugal,
ugal, all speed type all speed type
135 135 135 139
24V, 50A 24V, 50A 24V, 50A 24V, 50A
24V, 7.5kW x 2 24V, IlkWx2 24V. 7.5kW x 2 24V, 7.5kW x 2
12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2
KOMATSU KOMATSU KOMATSU KOMATSU

KTRllOtype KTRI IO type KTRllO type KTRIIO type
ZEXEL reciprocation, ZEXEL reciprocation EXEL reciprocation, ‘EXEL reciprocation,

single cylinder type single cylinder type jingle cylinder type single cylinder type
- - -
I -
01-004-l
03
Engine model S6D170-1
OEM ;;;ig,ee;erator OEM for generator OEM for generator

Applicable machine
(Standby) (Power up)
Number of cylinders-Bore x Stroke mm 6-170x170
Ovrall width mm 1,048 1,048 1,048
Overall height
mm 1,631 1,631 1,631
mm
kW/rpm 324/l ,500 (50 Hz) 355/1,500 (50 Hz) 345/1,500 (50 Hz)
Flywheel horsepower {434/1,500} (50 Hz)
+lP/rpm) {476/1,5001 (50 Hz) :462/1,500} (50 Hz)
371/1,800 (60 Hz) 408/1,800 (60 Hz) 403/1,800 (60 Hz)
Maximum torque {497/l ,800) (60 Hz)
IkgG?pmI 1547/1,800) (60 Hz) [539/1,800} (60 Hz)
High idling Max. 1,560 (50 Hz) Max. 1,775 (50 Hz) Max. 1,560 (50 Hz)
Max. 1,872 (60 Hz) Max. 1,890 (60 Hz) Max. 1,872 (60 Hz) 8
z
Low idling vm 700 - 900 700 - 900 700 - 900
z
Minimum fuel consumption ratio 219 I1631 217 {162) 224 I1671
Dry weight kg 2,600 2,600 2,600
Fuel pump Bosch PE-ZWx type Bosch PE-PDx type
Bosch RSUV centrifugal, Bosch RSUV centrif-

Governor
minimum maximum-speed type Jgal, all speed type
107 107 107

Lubricating oil amount (refill capacity) e (96) (96) (96)
Coolant amount e (Engine only 43) (Engine only 43) (Engine only 43)
Starting motor 24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2
Battery 12V 200Ah x 2 12V 200Ah x 2. 12V 200Ah x 2
Turbocharger Komatsu KTRI 10 Komatsu KTRI 10 Komatsu KTRI 10
Air compressor - -
Others
01-004-2
0
T
Engine model SA6D170-A-1
WA700-1
HD465-3 HD465-5
Applicable machine
(Twin turbcharger) (Twin turbcharger) “n$$~$~t~$ne
Ovrall width mm 1,060 1,106 1,080
Overall height
mm 1,692 1,678 2,017
Overall height
kW/rpm 524/2,100 (Net) 534/2,100 (Net) 478/2,000

Flywheel horsepower {702/2,1001 (Net) {715/2,100) (Net) {641/2,0001
IHP/rpm)
2,820/1,400 (Net) 2,970/1,400(Net) 2,810/1,400
Maximum torque
Ikgi?prnl {288/1,4001 (Net) {303/1,4001 (Net) {287/1,4001
High idling vm 2,300 - 2,400 2,300 - 2,400 2,240 - 2,300
Low idling vm 630 - 680 850 - 900 700 - 750
Minimum fuel consumption ratio g/kWh 221 (165) 211 {157) 208 {I 551
{g/HPh)
2,750
Dry weight kg 2,480 JZlithexhaust brake 2,900
BOSCH PE-ZWx
Fuel pump BOSCH PE-ZWx type
type
BOSCH RFD minimum BOSCH RSUV centrif-
Governor
maximum-speed control type ugal, all speed type
I
Lubricating oil amount (refill capacity) e
Coolant amount e 170 174
Battery 12V170Ahx2 12V 200Ah x 2 12V 200Ah x 2
GARRET TV77 GARRET TV77 GARRET TV77

Turbocharger typex2 typex2 type x 2
CUMMINS ZEXEL ZEXEL

Air compressor single cylinder single cylinder single cylinder
reciprocated type reciprocated type reciprocated type
With aftercooler,
Others With aftercooler With aftercooler
exhaust brake
01-004-4
63
SAGDI 70-A-1
EG600-l,EG600B-1 EG600BS-1
EG580-1
EG550-1 EG580B-IL EG600BS-1 EPSAGD170-A-1 OEM for generctor
EG580B-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) 456/1,500 (50 Hz) 470/1,500 (50 Hz) 470/1,500 (50 Hz)
I578/1,5001 (50 Hz) :611/1,500~ (50 Hz) 472/1,500 (50 Hz) f630/1,5001 (50 Hz) 440/l ,800 630/1,5001 (50 Hz)
473/1,800 (60 Hz) 503/1,800 (60 Hz) ;633/1,5001 (50 Hz) 514/1,800 (60 Hz) {590/l ,800) 514/1,800 (60 Hz)
{634/1,8001 (60 Hz) :673/1,8001 (60 Hz) 1688/1,800} (60 Hz) 688/1,8001 (60 Hz)
2,648/1,300
- - - -
{270/1,300}
-
8 1,700 - 1,800 Max. 1,560 (50 Hz) Max. 1,560 (50 Hz) Wax. 1,560 (50 Hz)
Vlax. 1,560 (50 Hz) 1,950 - 2,050
Max. 1,872 (60 Hz) Max. 1,872 (60 Hz) Vlax. 1,881 (60 Hz)
650 - 700 700 - 900 700 - 900 700 - 900 750 - 850 700 - 900
230 {I711 (50 Hz) 217 1162) 217 {162} 217 I1621 231 1172) 217 1162)
236 1176) (60 Hz) (At rated output) (At rated output) (At rated output) (At rated output) (At rated output)
2,650 2,770 2,770 2,750 2,850 2,770
Bosch PE-P
Bosch PE-ZWx type osch PE-ZWx type,
(PS7S) type
3osch RSUV centrif. voodward PSG hy-

Bosch RSUV centrifugal, all speed type
ugal, all speed type aulic type governor
119
(107)
139
;.::.., (Engin&ly 43)
24V, 13A 24V, 13A

24V, 13A 24V, 13A 24V, 13A 24V, 50A
24V, 25A (opt) 24V, 25A (opt)
I
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 x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2
Komatsu KTR150 Komatsu KTRI 50 Komatsu KTR150 Komatsu KTR150 Komatsu KTR150 Komatsu KTR150
- - - - - -
With after cooler With after cooler With after cooler With after cooler With after cooler With after cooler
01-004-5
0
HD465-5 HD465-5
HD465-5 *I
Applicable machine (With electronic (Mechanical
(Twin turbcharger)
governor) governor)
Number of cylinders - Bore x Stroke mm 6-170x 170
Ovrall width mm 1,106 1,106 1,106
Overall height
mm 1,678 1,678 1,678
mm
534/2,100 (Net) l2
015/2,100) Net) l2
kW/rpm 386/2,100 (Gross) 43W.750 (Iuet) l3 534i2.100
Flywheel horsepower ~518/2,100~ (Gross1 (587/1,1501 (Net) *3 {715/2,100}
{HP/rpmI
2,108/1,400 (Gross: 2.971/1.400
8 Maximum torque
tkgr$pm> I215/1,4001 (Gross1 {303/l ,400)
:
E High idling 2,330 - 2,400 2,400-2,500 *2 2,330 - 2,400 2
b 1.850-1.950 l3
‘t z
lz Low idling 1,075 - 1,125 920 - 970 900 - 950
z
Minimum fuel consumption ratio gkWh 211 {I571 211 {I571 211 I1571
{g/HPhl
2,600 2,750
Dry weight kg (With;;;kee;haust JVith exhaust brake 2,670
Fuel pump 3osch PE-ZWx typr Komatsu KFE Bosch PE-ZWx type
Bosch RSUV-D
zentrifugal, minimun Electronic control Bosch RSUV centrif-
Governor
naximum-speed type Jgal, all-speed type
Lubricating oil amount (refill capacity) Q (Xi,

Coolant amount Q 174 174
24V, 50A 24V, 50A 24V. 50A
Starting motor 24V. 7.5kW x 2 24V,llkWx2 24V, 7.5kW x 2
Battery 12V 200Ah x 4 12V 200Ah x 2 12V 200Ah x 2
Water cooled
Turbocharger Gallet TV77 x 2 Gallet TV77 x 2
Gallet TV77 x 2
Zexel Zexel Zexel
Air compressor single cylinder single cylinder single cylinder
reciprocated type reciprocated type reciprocated type
With after cooler,
Others With after cooler With after cooler
exhaust brake
*I: High altitude spec. en ne No. 15963 a up to 15966

l2: Power mode
01-004-6 l3: Economy mode
SA6D170-A-1
EG680A-1 OEM for OEM for generator

EM680A EM680A-A OEM for generator
6M170B-1 Marine engine (Prime use)
6-170x170
23,150
l-5-3-6-2-4
2,880 2,841 2,796 -

2,603 2,603
(With marine gear) With marine gear) With marine gear]
1,285 1,137 1,150 -

1,048 1,048
(With marine gear) With marine gear) With marine gear)
1,757 1,831 1,781 -

1,756 1,756
(With marine gear) With marine gear) With marine gear]
- - - - - -
473/1,500 (50 Hz) 419/1,500 (50 Hz)

55212,000 *4 552/2,000 629/2,000 [633/1,500} (50 Hz) 55212,000 I561/1,5001 (50 Hz)
(740/2,000} *4 I740/2,000} {842/2,0001 546/1,800 (60 Hz) {740/2,000} 467/1,800 (60 Hz)
f732/1,800} (60 Hz) {625/l ,800) (60 Hz)
2,501/1,400 2,893/l ,400 3,295/1,400
- - -
{255/l ,400) I295/1,4001 {336/1,4001
2,100 - 2,200 2,100 - 2,200 Max. 1,560 (50 Hz) 2,100 - 2,200 Max. 1,568 (50 Hz)
2 2,100 - 2,200
Max. 1,872 (60 Hz) Max. 1,881 (60 Hz)
&
z 550 - 600 550 - 600 550 - 600 950 - 1,000 550 - 600 700 - 900
211 {I571 217 (157) 211 (157) (50 Hz) 211 1157) (50 Hz)
217 {162) 211 1157)
(At rated output) (At rated output) 217 I1621 (60 Hz) 217 1162) (60 Hz)
2,750 2,750 3,250

(Withw;r;;arine (Withog;;Tarine (Withw;;arine 2,720 2,500 2,720
Bosch PE-ZWx type
Bosch RSUV centrifugal, all speed type
100 120 120 67 (60) 119 (107)

(90) (108) (108) 119 (107) opt 122 (110) *5
118 85 85 (Engine only 43)
24V, 13A 24V, 13A 24V, 13A

24V, 30A 24V, 25A 24V, 30A 24V, 25A (opt)
24V, 25A (opt) 24V, 25A (opt)
24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 11 kW 24V. 7.5kW 24V, IlkW
Komatsu KTRI 10 Komatsu KTRI 10 Komatsu KTRI 10 Komatsu KTRI 10 Komatsu KTRllO Komatsu KTRIIO
- - - -
With after cooler With after cooler With after cooler With after cooler With after cooler With after cooler
*4: Without marine gear

*5: With bypass filter
01-004-7
0
SA6D170-A-1
DEM for generator H D465-3 HD465-3

Applicable machine
(Stanby use) (Single turbocharger) (Single turbocharger)
Number of cylinders-Bore x Stroke mm 6-170x170
t?
.P Ovrali width mm 1,048 1,060 1,060
t
i Overall height
mm 1,750 1,626 1,623
6 (Excluding exhaust pipe)
mm
581/1,500 (50 Hz)

kW/rpm {779/1,5001 (50 Hz) 515/2,100 (Net) 524/2,100 (Net)
Flywheel horsepower {HP/rpm} 672/1,800 (60 Hz) {690/2,1001 (Net) {702/2,1001 (Net)
{900/1,800} (60 Hz)
2,824/1,400 (Net) 2,824/1,400 (Net)
Maximum torque -
{kgr%Pml {288/1,4001 (Net) {288/1,4001 (Net)
Max. 1,575 (50 Hz)

High idling rPm 2,250 - 2,350 2,250 - 2,350
8
Max. 1,890 (60 Hz)
z
Low idling 700 - 900 850 - 900 850 - 900
z
Minimum fuel consumption ratio g/kWh 211 11571 (50 Hz)

219 (163) 221 (163)
{g/I-W 217 {1621(60 Hz)
Dry weight kg 2,720 2,470 2,470
Fuel pump 3osch PE-ZWx typf Bosch PE-ZWx type
3osch RSUV centrif, Bosch RSUV centrifugal,

Governor
ugal, all speed type minimum maximum-speed type
67 (60)
Lubricating oil amount (refill capacity) e 119 (107) opt
107
Coolant amount e (Engine only 43)
170 170
24V, 13A
Alternator 24V, 50A 24V, 50A
24V, 25A (Opt)
Starting motor 24V, 11 kW 24V, 7.5kW x 2 24V, 7.5kW x 2
Turbocharger Komatsu KTRI IO Komatsu KTRllO Komatsu KTRI 10
Cummins Cummins
Air compressor single cylinder single cylinder
Others With after cooler With after cooler With after cooler
01-004-8
0
GENEFWL SPECIFICATIONS
HD465-3 PC1OOOSP-1
(For ORAPA MINE) (For LAYTON) sA6D170-M-1
485/2,000 (Net) 43411,750 (Net)

{650/2,000) (Net) t582/1,750) (Net)
2,80011,300 (Net) 2,730/1,300 (Net)
(28511,300) (Net) ~27911,300)(Net)
2,250 - 2,350 1,900 - 2,000
840 - 860 650 - 700
211 (Net) Rated i n fuel

216 {161} (Net) consumption
(157) (Net)
226 (168)
BOSCH PE-ZWX BOSCH PE-ZWX

w pe wpe
BOSCH RFD minimum tOSCH RSUV centrif- 3OSCH RSUV centrif-
maximum-speed
control type ugal, all speed type ugal, all speed type
100
43
Engine only
GARRET W 7 7 KOMATSU
type x 2 KTRllO type
CUMMINS EXEL reciprocation,
single cyl~nder jingle cylinder type
reciprocated type
With aftercooler With aftercooler
6D170-1 SERIES
Engine model SA6D170-B-1
D375A-1 D375A-1 D375A-1

Applicable machine IEngine Serial No. (Engine Serial No. (Engine Serial No.
up to 11045) 11046 and up) 13551 and up)
Ovrall width mm 1,139 1,139 1,139
Overall height
mm 1,746 1,746 1,746
mm
kW/rpm 379/1,800 379/l ,800 392/l ,800

Flywheel horsepower IHP/rpm) {508/1,8001 {508/1,800} {525/1,8001
2,609/l ,300 2,609/l ,300 2,618/1,300
Maximum torque tkgr%?pmI {266/l ,300) {266/l ,300) {267/l ,300)
High idling rpm 1,950 - 2,050 1,950 - 2,050 1,960 - 2,040 8

z
Low idling rpm 600 - 700 600 - 700 580 - 680
z
Minimum fuel consumption ratio g/kWh 215 {I601 215 {160} 215 {ISO}
{g/HPh)
Dry weight kg 2,660 2,660 2,660
Fuel pump losch PES-PDx typ Bosch PE(PS7S) type
3osch RSUV centrif 3osch RSUV centrifugal, all-speed type

Governor
Jgal, all-speed type
Lubricating oil amount (refill capacity) Q
Coolant amount Q 165 165 165
24V, 35A
Alternator 24V, 30A (11046- 12802) 24V, 50A
24V, 50A (12806-)
Battery 12V 170Ah x 2 12V 170Ah x2 12V 170Ah x 2
Turbocharger Komatsu KTRllO Komatsu KTRIIO Komatsu KTRI 10
Air compressor - - -
01-004-10
0
SA6D170-B-1
EG500-1, EG500B-1 EG500-1, EG500B-1

HD465-3 EG480-1
Pc1000-1 EG450-1 EG500BS-1 EG500BS-1
(Single turbocharger) EG480B-1
OEM for generator OEM for generator
6-170x170
23,150
l-5-3-6-2-4
2,373 2,373 2,577 2,603 2,603 2,603
1,909 1,909 1,048 1,048 1,048 1,048
1,080 1,080 1,809 1,746 1,746 1,746
- 2,275 - - -
354/1,500 (50 Hz) 37211,500 (50 Hz) 383/1,500 (50 Hz) 383/1,500 (50 Hz)
405/1,700 451/2,100 (481/1,5001 (50 Hz) l498/1,500~ (50 Hz) {513/1,5001 (50 Hz) {513/1,500) (50 Hz)
{542/1,7001 {604/2,1001 400/l ,800 (60 Hz) 416/l ,800 (60 Hz) 427/1,800 (60 Hz) 427/l ,800 (60 Hz)
[544/1,8001 (60 Hz) (557/1,8001 (60 Hz) {572/1,8001 (60 Hz) {572/1,8001 (60 Hz)
2,550/1,300 2,481/1,400 - - - -
I260/1,3001 {253/1,400}
Max. 1,560 (50 Hz) Max. 1,572 (50 Hz) Max. 1,568 (50 Hz)
1,800 - 1,900 1,800 - 1,900 1,800 - 1,890
2 Max. 1,872 (60 Hz) Max. 1,890 (60 Hz) Max. 1,881 (60 Hz)
(D
650 - 700 650 - 700 950 - 1,000 750 - 850 750 - 850 700 - 900
z
217 {162} 217 1162) 217 I1621
211 {157} 224 {I 67) 217 I1621
(At rated output) (At rated output) (At rated output)
2,555 2,555 2,650 2,650 2,750 2,720
BOSCH PE-P(PS7S) BOSCH PE-ZWx BOSCH PES-PD BOSCH PE-P(PS-7%

BOSCH PE-ZWx type type
type type type
BOSCH RSUV-D lOSCH RSUVcentrifugal,
BOSCH RSUV centrif 30SCH RSUV centrif BOSCH RSUV centrifugal,
:entrifugal, minimum all-speed type all-speed type
ugal, ail-speed type ugal, all-speed type
naximum-speed type (with cocel spring)
119 119 119

(z, (107) (107) (107)
160 160
(Engin%ly 43) (Enginiinly 43) (Engine8tnly 43)
24V, 50A 24V, 50A 24V, 50A 24V, 13A 24V, 13A 24V. 25A
24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2
KOMATSU KTRI 10 <OMATSU KTRI 10 <OMATSU KTRllr <OMATSU KTRI IO KOMATSU KTRllO KOMATSU KTRI 10
ZEXEL ZEXEL
single cylinder single cylinder - - - -
With aftercooler With aftercooler With aftercooler With aftercooler With aftercooler With aftercooler
01-004-11
a3
Engine model
Applicable machine
Ovrall width mm 1,100 1,120 1,048
Overall height -
mm 1,746 1,746
Overall height - -
mm 2,332
367/1,500 (50 Hz)

kW/rpm 364/l ,500 397f1.800 {492/1,5001(50 Hz)
Flywheel horsepower
WP/rpml ~488/1,500~ {540/1,800} 416/1,800 (60 Hz)
{557/1,800} (60 Hz)
2,461/l ,300
Maximum torque - -
Ikg:?pmpm) {251/1,300}
Max. 1,560 (50 Hz)

High idling rDm Max. 1,560 1,950 - 2,050
8
Max. 1,862 (60 Hz)
z
Low idling rpm 700 - 900 750 - 850 700 - 800
z
Minimum fuel consumption ratio g/kWh 220 I1641 231 {I721 223 {I 661
{g/HPM (At rated output) (At rated output) (At rated output)
Dry weight 2,650 2,850 2,650
Bosch PE-P(PS7S)
Fuel pump Bosch PE-PDx type losch PES-PDx type
type
Bosch RSUV centrif- 3osch RSUV centrif 3osch RSUV centrif-
Governor
ugal, all-speed type Jgal, all-speed type ugal, all-speed type
119
Lubricating oil amount (refill capacity) Q
(107)
120
Coolant amount Q 139
(Engine only 43) (Engine8Znly 43)
Alternator 24V, 13A 24V, 25A 24V. 13A
Starting motor 24V, IlkWx2 24V, 11 kW 24V, 7.5kW x 2
Turbocharger Komatsu KTR130 Komatsu KTR130 Komatsu KTR130
Air compressor - - -
01-004-12
0
SA6D170-B-1
OEM for generator OEM for generator OEM for 6-Pole

OEM for generator OEM for generator
(Stand by use) (Prime use) generator
6-170x 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) 379/1,500 (50 Hz) 417/1,500 (50 Hz) 37811,500 (50 Hz) 275/1,000 (50 Hz)
{543/1,5001 (50 Hz) {508/1,500~ (50 Hz) :559/1,5001 (50 Hz) {506/1,5001(50 Hz) :369/1,0001 (50 Hz)
457/1,800 (60 Hz) 446/1,800 (60 Hz) 492/1,800 (60 Hz) 403/1,800 (60 Hz) 345/1,200 (60 Hz)
{612/1,800} (60 Hz) {598/1,8001 (60 Hz) :660/1,800~ (60 Hz) {539/1,800> (60 Hz) [462/1,2001 (60 Hz)
- - - - -
Max. 1,572 (50 Hz) Max. 1,560 (50 Hz) Vlax. 1,568 (50 Hz) Max. 1,568 (50 Hz) Max. 1,045 (50 Hz)
8 Max. 1,890 (60 Hz) Max. 1,872 (60 Hz) Vlax. 1,881 (60 Hz) Max. 1,881 (60 Hz) Max. 1,254 (60 Hz)
z
700 - 800 700 - 900 700 - 900 700 - 900 750 - 850
z
223 {I 66) 217 {I601 (50 Hz)
217 {I621 217 1162) 224 {I 671
(At rated output) 217 {I621 (60 Hz)
2,650 2,650 2,650 2,650 2,700
Bosch PE-P(PS7S)
Bosch PE-PDx type
type
Bosch RSUV centrifugal, all-speed type Bosch RSUV centrif-
Jgal, all-speed type
119 67 (60) 67 (60) 122

(107) 119 (107) opt 119 (107) opt (110)
107
(Engine only 43) (Engine only 43) (Engine only 43)
(Engin%ly 43) (Engine only 43)
24V, 13A 24V, 13A 24V, 13A -

24V, 13A
24V, 25A (opt) 24V, 25A (Opt) 24V, 25A (Opt)
24V. 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 7.5kW x 2 24V, 11 kW
12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2
Komatsu KTR130 Komatsu KTR130 Komatsu KTR130 Komatsu KTR130 Komatsu KTR130
- - - - -
With after cooler With after cooler With after cooler With after cooler With after cooler
01-004-13
0
Engine model
WA600-1 DENY0 generator For MQ generator

Applicable machine (EC regulation) DCA6OOSSK DCA-6OOSS K
Number of cylinders - Bore x Stroke
Total piston displacement
Firing order
Overall length
m
.-In Ovrall width
Overall height
5 (Excluding exhaust pipe)
Overall height
7011,500 (Net, %Hz:

30512,000 (Net) W1,5001 (Net, 50Hi
Flywheel horsepower {40912,000) (Net) 1311,800 (Net, 60Hz:
1,96011,400 (Net) W1,8001 (Net, 60Hi
Maximum torque -
{20011,400} (Net)
c
CU
High idling 2,200 - 2,300 Aax. 1,570 (50 Hz1 Max. 1,890
0
flax. 1,880 (60 Hz1
.+
2 Low idling 650 - 700 700 - 900 800 - 850
At rated flywheel
Minimum fuel consumption ratio 212 (Net) horsepower 218
{I581 (Net) 11 {157) (Net, 50Hz {I621
18 { l a ) (Net, 60H2
Dry weight 2,770 2,770
Fuel pump IOSCH PE-PDx type OSCH PE-ZWXt ~ p BOSCH PE-PDx t y w
Governor IOSCH RSUV centrif- ZEXEL electronic BOSCH RSV centrif-

ugal, all speed lype control type ugal, all speed type
Coolant amount [Engine only :43) (Engine only : 43)
Alternator 24V, 25A
Starting motor 24V, I 1kW
Battery 12V 200Ah x 2
KOMATSU KOMATSU KOMATSU

Turbocharger KTRllO type KTRI 50 type KTRl50 type
Air compressor
!EXEL reciprocation - -
single cylinder type
Others Aftercooler Aftercooler Aftercooler
01 -004-
14 6D170-1 SERIES
63
Generator SAA6Dl70-P740 SAA6Dl70-P740 SU6D17O-P800

(50 Hz only) (50 Hz) (60 Hz) (50 Hz )
59711,500 (Net) 56811,500 59711,500

{800/1,500} (Net) (76211,500} (80011,500)
64211,500 74811,800 65611,500
{86111,5001 ~1,00311,800~ {88011,500)
Max. 1,568 Max. 1,882 Max. 1,568
Max. 1,570 Max. 1,575 Max. 1,890 Max. 1,575
700 - 900 700 - 900

At rated flywheel
horsepower 205 205
205 (Net) (153) {I531
(153) (Net)
2,650 2,650 2,650
BOSCH PE-ZWy type IOSCH PE-ZWy typ OSCH PE-ZWy type IOSCH PE-ZWy type
GAC electronic GAC electronic GAC electronic GAC electronic

governor contrpl type contrpl type contrpl type
147 147
(135) (135)
95 95 95
(Engine only : 43)
KOMATSU KOMATSU KOMATSU KOMATSU

KTRl5O type KTR150 type KTRl50 type KTR 150 type
Air cooled Air cooled Air cooled Air cooled

aftercooler aftercooler aftercooler aftercooler
6D170- 1 SERIES
Engine model
Applicable machine For M Q generator

DCA-5OOSSK
Number of cylinders - Bore x Stroke rnm
Total piston displacement e{cc)
Firing order
Overall length
Ovrall width
Overall height
Overall height
Flywheel horsepower
Maximum torque
High idling Max. 1,890
Low idling
Minimum fuel consumption ratio
Dry weight
- --
Fuel pump BOSCH PE-PDx typt
Governor BOSCH RSV cenmf-

ugal, all speed type
Coolant amount
(Engine only : 43)
Alternator 24V, 35A
Starting motor 24V, 1 1k W
12V 200Ah x 2
Turbocharger KOMATSU
KTR130 type
Air compressor -
Others Aftercooler
6D170-1 SERIES
/
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
S6D170-1 (for PC650-1)

. LEFT SIDE VIEW
r
P
zi./
Wind
c3
Zrankshaft center
lb/3 9
I
1851.9
20289
6162FOOl
170-1 SERIES 01-005

. RIGHT SIDE VIEW
16114
Exhaust
I 1
Crankshaft
Iii i i it
6162FOOZ
01-006 170-1 SERIES

l FRONT SIDE VIEW
1001.5
r I m
Crankshaft
6162FOO3
170-1 SERIES 01-007

l 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

SAGD170-A-1 (for EG550-I)

. LEFT SiDE VIEW
w I II I” lt=i _ . ’ c. center
I
uu- ILo 01 1
0
n 0
n IIIII
0
0 0
0
2006.4
170-1 SERIES
0 l-009
l RIGHT SIDE VIEW
- -
\ d
1663.9
?
01-010 170-1 SERIES

. FRONT SIDE VIEW
170-1 SERIES 01-010-1

0
. REAR SIDE VIEW
41.4 243.4 _
170-1 SERIES
01-01 o-2
0
SA6D170-B-1 (for D375A-1)

0 LEFT SIDE VIEW
Crankshaft
center
/-
6162FOO9
170-1 SERIES 01-01 o-3

0
0 RIGHT SIDE VIEW
r-n
b-4 -
6162FOlO
01-010-4 170-1 SERIES

0
GENERAL ASSEMBLY DRAWING
GENERAL
l FRONT SIDE VIEW
”
I
6162FOll
170-l SERIES
-%“-5
O’
0 REAR SIDE VIEW
Crankshaft center
6162FO12
01-01 O-6 170-1 SERIES

0
GENERAL WEIGHT TABLE
WEIGHT TABLE
Unit: kg
No. Item Component S6D170-1 SA6D170-A-1 SA6D170-B-l
I I I I
TV77 - 17x2 -
L
KTRI 10 - - 20
1 Turbocharger
KTR 130 31 31 31
KTR 150 - 35 -
Cylinder head, valve and valve

2 Cylinder head assembly 37 37‘ 37
spring
I I
Cylinder block
3 Cylinder block assembly Main bearing cap 675 675 675
Cylinder liner
1
4 Gear case cover
I I 48
I
48
I
48
5 Xming gear case 30 30 30
6 Oil pan 45 45 45
Flywheel 71:{ ;~~$tzl 48: HD465-3 43: D375A-1

7 Flywheel assembly
Ring gear 51: WA600-1 122: EG550-1 122: EG450-1
8
8 Flywheel housing 95 95 92: D375A-1
117: EG450-1
9 Crankshaft assembly Crankshaft

Crank 270 270 270
gear
Camshaft, cam gear and thrust

10 Camshaft assembly plate 31 31 31
I
I I
11 Piston and connecting rod Piston, piston ring, piston pin 21 21 21

assembly and connecting rod I I
12 Oil pump 21 21 21
13 Fuel injection pump 30: { ;$;;;;:J 48 31

31: WA600-1
14 Water pump 20 20 20
15 Alternator 15: { ‘p$~“5”0& 15 IO

12: WA600-1
16 Starting motor 18 18 18
17 Air compressor 15 15
18 After cooler 65 43.5
01-011
0
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE
S6D170-1 (for PC650-1, PC1500-1)
Flywheel horsepower: 410 HP/l,600 rpm
Maximum torque: 207 kgm/1,200 rpm
Minimum fuel consumption ratio: 165 g/HP.h
150
125 E
100 ;
I I I I I I I I\I I t75F
450
400
350
EI
I
- 300
5
P
‘,
0
250
400 600 800 1000 1200 1400 1600 1800 2000
Engine speed (rpm)
01-012 170-1 SERIES

0
S6D170-1 (for D275A-2)
Flywheel 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

@
S6D170-1 (for WDSOO-11

SA6D170-AE-1 (for WA600-1 EC regulation)
Flywheel horsepower : 305 kWM09 HPV2,OOO rpm
Maximumtorque : 1,960 Nm 1200 kgml/l,400 rpm
s 9
200 -2.000
150 -1.500 2
U
L
100 -1,000 :
50 -500
0 -0
0. 3 co
I Y a
450 450
400 300
; 350
3 250
0
: 300
co
200
L
250
150 200
x
-
LL 150 150 I
100
100 100
50
50 50
0 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
@
S6D170-1 (for WDSOO-1)
Flywheel horsepower : 334 kW (448 HP}/2,000 rpm

Maximum torque : 2,089 Nm {213 kgmV1,400 rpm
z
-: !500
/ 250
2000
200
a
2
1500 z
150 0
c
100 1000
3
& 1 ,”
500. cnn I! I 500
350
450 0
400 300
350
250
3
a
- 300
G
200 \
250 /
250-
I
\I
I
200 15C Inn

L””
150 150
IOC
100 100
5c
50 50
(I- 0 ::
800 1000 1200 1400 1600 1800 2000 2200 2400
SWEOIOZI
Ens ine speed (rpmi
01-014
0
S6D170-1 (for EPS6D170-1)
Flywheel horsepower : 385 kW {516 HP} 1,800 rpm
E 3
1 2
550-
400- 550
500-
500
350-
450-
450
400- 300- 400
350- 350
250-
c
; 300- 300
S 200-
250- 250
200- 150- 200
150- 150
IOO-
IOO- 100
50-
50- 50
o- o- 0
Engine speed (rpm) SWE01022
01-014-l
0
S6D170-1 (OEM for generator)
Flywheel horsepower :
Prime use : 324 kW I434 HP} 1,500 rpm (50 Hz)
371 kW 1497 HP} 1,800 rpm (60 Hz)
Stand by use : 355 kW (476 HP} 1,500 rpm (50 Hz)

408 kW {547 HP} 1,800 rpm (60 Hz)
a 3
1 _b 2 408kW&07H@ itandbrl
450 60Hz
600 /
600
355kW1476Hd (Standbul
50Hz
550 I I /
550
400 I II /I
500
500
350
450
400 300 I +
371 kW(497HP) (Prime)

60Hz
350
250 :
300 1 I I
324kWt434Hd (Prime)
200
50Hz
z 250 250
200 150
150
100
100
50
50
0 0 _ .
1100 1200 1300 1400 1500 1600 1700 1800 1900
En9 i ne speed (rpm) SWE01023
01-014-2
0
SA6D170-A-1 (PClOOOSP-1 for LAYTON)
Flywheel horsepower : 434 kW {582 HP}/l,750 rpm

Maximum torque : 2,731 Nm I278.5 kgm}/1,300 rpm
E
3 E
400 4000
300 c 3000 Yj
m
200 -2000 z
+-
100 -1000
a 3 0 -0
r 2.
600- 450
600
550- 550
400
500- 500
350
450- 450
400- 300 400
; 350-
a 250
g 300-
200
250- 250
200- 150 200
150- 150
100
IOO-
50
50
0 ! 0
50
0 ::
BOO 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900
Ens i ne speed (rpm) SWE01024
01-014-3
G9
SAGD170-A-1 (for HD465-3 with single turbocharger)
Flywheel horsepower : 524 kWi613 HP}/2,100 rpm
Maximumtorque : 2,824 Nm (288 kgmI/1,400 rpm
E
s E
400 4000
3000 g
2000 :
100 1000
a B
I: Y :
800 600
80(
700 70(
500
600 60(
400
< 500 50(
:
400 300 40(
300 30(
200
200 20(
100
100 lO(
0 0 c
800 1000 1200 1400 1600 1600 2000 2200 2400
01-014-4
0
SAGD170-A-1 (for HD465-3 with single turbocharger and twin turbocharger)
Flywheel horsepower : 524 kW (702 HP} 2,100 rpm

Maximum torque : 2,824 Nm I288 kgm1 1,400 rpm
E
s s
-400 -4000
-300 -3000 ;
u
L
-200 -2000 :
-100 -1000
-0 -0
L1 3
1 2 2
800 600
800
700 700-- -
500
600 600
400
z 500 500
z
400 300 400
300 300
200
200 200
100
100 100
0 0 0
800 1000 1200 1400 1600 1800 2000 2200 2400
Ens i ne speed (rpm) SWE01026
01-015
0
S6D170-A- 1 (For HD465-5)
Flywheel horsepower: 715 HP/2,100 rpm
Maximum torque: 307 kgm/l,400 rpm
P
200 2
J
P
I-"
100
800 0
output
/ \
\
f I I I l/l I I
I I I I
II
0
800 1000 1200 1400 1600 1800 2000 2200 2400
II
Engine speed (rpm)
6162F817
O’-F 170-1 SERIES

SA6D170-A-1 (for HD465-3 high altitude spec.)
Flywheel horsepower : 386 kW I518 HP) 2,100 rpm

Maximum torque : 2,108 Nm 1215 kgm1 1,400 rpm
E
s 5
3000
300
2000
200
a,
2
0
If
100 1000
0 0
& 3
Y
600-
400-
500-
2 400- 300-
a
G 300-
zoo-
I
200- 200
100-
loo- 100
o- o- 0
500 1000 1500 2000 2500
01-016-l
0
GENaERAL ENGINE PERFORMANCE,CURVE
S6D170-1 (For WA700-1)

Maximum torque: 286.5 kgm/l,400 rpm
250
600-
,C 600 800 1000 1200 1400 1600 1800 2000 2200
Engine speed (rpm)

F6161A012
170-1 SERIES
SA6D170-A-1 (for EG550-1)
Flywheel horsepower: 578 HP/l ,500 rpm (50 Hz)

634 HP/l,800 rpm (60 Hz)
800
600
c
I
s
P 500
'j
0
400
2
300 190 4
2
180 .g
s
200 170 '"a
100
Enginespeed x 100 (rpm) 1560 1870
170-l SERIES
o’-:‘8
SA6D170-A-1 (EG5808-1)
Flywheel horsepower: 611 HP/l,500 rpm (50 Hz)
673 HP/l,800 rpm (60 Hz)

Fuel consumption ratio: 160 g/HP.h (Rated output)
800
600.
500 / I
611 HP (50HZ) I I
I I
400 I I
\ I
I I
300 I I
I
200
I
I I -190
200 , I
180
I -170
I
1 I
100 --wFue’ CO.nsOmptiOn ratio I 160
I - 150
I
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Engine speed @pm)

F6161A013
170-1 SERIES
01-ii19
SA6D170-A-1 (EG5808-1 L)

800
500
E. 400
c
220
6'j
s i --210
300
II '-200
\I
I --190
200
, 180
I
s-170
lOO------- I
,' .-I 160
/
I
I --150
1000 1100 1200 1300 1400 1500 1600 1700 1800
F6161A020
O’-iJ
9-1 170-1 SERIES
SA6D170-A-1 (EG600BS-1)
688 HP/l,800 rpm (60 Hz)
800
600
500
c
I 400 220
sa z
s 210 p
0 \
300 !OO =
.P
190 5-
s
200 180 ‘E
170 2
E
100 160 5
I=
150
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Engine speed (rpm)

F6161A014
O’-Z20 170-1 SERIES

SA6D170-A-1 (for EM680A)
Flywheel horsepower : 552 kW 1740 HP) 2,000 rpm

Maximum torque : 2,501 Nm I255 kgm) 1,400 rpm
E
s s
400 -4000
300 -3000 g
Torque m
L
200 -2000 If
100 -1000
0 i 0
a 3
1 24
600- 600-
700-
500-
600-
: 500- 400-
400- 300-
300-
200-
200-
IOO-
IOO-
o- o- J-2’)
- . 1 II
600 600 1000 1200 1400 1600 1800 2000 2200
En9 i ne speed (rpm) SWEOlOZtl
Ol -020- 1
0
SA6D170-A-1 (for EM680A-1,6M170B-1, OEM for marine engine)
Flywheel horsepower : 552 kW (740 HP} 2,000 rpm

Maximum torque : 2,893 Nm I295 kgm) 1,400 rpm
E
s e
-400 -4000
-300 -3000 ;
Is
L
-200 -2000 If
.lOO -1000
-0 -0
0 3
2 2.
8OC 600
700
600
z 500
0'
400
300
200
100
0 ..
800 1000 1200 1400 1600 1800 2000 2200 2400
En9 ine speed (rpm) SWE01029
01-020-2
0
SA6D170-A-1 (for EM680A-A)
Flywheel horsepower : 629 kW I842 HP} 2,000 rpm

Maximum torque : 3,295 Nm I336 kgm} 1,400 rpm
E
9 s
400 -4000
300 -3000
200 -2000
100 -1000
0 -0
3
% 24
700-
900-
l300- 600-
700-
500-
600-
400-
5 500-
:
400- 300-
300-
200-
200-
loo-
IOO- 100 \
A’
o- o- n
”
?!
.\
600 800 1000 1200 1400 1600 1800 2000 2200 2400
En9 i ne speed (rpm) SWE01030
01-020-3
0
SA6D170-A-1 (for EPSAGD170-A-l)
Flywheel horsepower : 508 kW (680 HP1 2,000 rpm
& 3
Y
800- 600-
700-
500-
; 600-
: 400-
500-
400- 300-
300-
200-
200-
too-
loo-
o- o-
800 1000 1200 1400 1600 1800 2000 2200 2400
En9 ine speed (rpm) SWEOtO31
01-020-4
0
SAGD170-B-1 (for D375A-1)
Flywheel horsepower: 508 HP/l ,800 rpm
280
260
T
240 2
S
220 :
I-
200
800 1000 1200
Engine
1400
speed (rpm)
1600 1800
c I50
170-1 SERIES 01-021

0
SAGD170-B-1 (D375A-2)
Torque
z
- 210 $
\
150 -200 =
.P
;;j
-190 ;
0
lOO- 180 .E
-170 z
C
Fuel consumption ratio 8

50 - 160 Z
I?
I - 150
0
600 800 1000 1200 1400 1600 1800 2000 2200
Engine speed @pm)

F6161A015
01-:22 170-1 SERIES

SAGD170-B-1 (PCIOOO-1)
250 _
1100 1200 1300 1400 1500 1600 1700 1800 1900
Engine speed (rpm)
F6161A016
170-1 SERIES
SA6D170-B-1 (for PClOOO-1 high altitude spec.)
Flywheel horsepower : 341 kW {457 HP} 2,000 rpm

Maximum torque : 2,157 Nm (220 kgm) 1,300 rpm
,” 5
400 -4000
300 -3000 ;
D
200 -2000 i
100 1000
0 t 0
Ene i ne speed (rpm) SWE01032
01-023-l
0
SAGD170-B-1 (for HD465-3 with single turbocharger)

250
200
50
7oc
600
500
z 400
I
5
a z
5
0 3oc 200 :
‘,
Igo z
20( 180 ;
.o
z
170 E
\ Fuel consumption ratio 160 z

1OC 8
\
150 2
C
1000 1200 1400 1600 1800 2000 2200 2300 2400
Engine speed (rpm)

F6161A017
O’-:24 170-1 SERIES

SA6D170-B-1 (for EG450-1)

544 HP/l ,800 rpm (60 Hz)
I HP/l DO rpi
-
600
0 HP, /
h
z
I
500
k-
I
2 /
w lP/l ,E 1 rpm I
n I
‘; I
0
400
I
I
I
I I
1 I
I
300
i--
I
t
I
I I
I I
I I
:I
I I
200
I L
I I
I ,mpti I
CO
I
I I
I I
100 +
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
SAGD170-B-1 (EG480B-1)

549 HP/l,800 rpm (60 Hz)
Fuel consumption ratio: 162 g / HP.h (Rated output)
220
E
210 $
\
200 _a
.P
;;;
190 h
:
180 .E
170 7
6
0
160 5
I?
150
Engine speed (rpm)

F6161AO18’
01-026 170-1 SERIES
0
GENERAL
ENGINE PERFORMANCE CURVE
SAGD170-B-1 (EG5OOBS-1)
Flywheel horsepower: 513 HP/l ,500 rpm (50 Hz)
572 HP/l,800 rpm (60 Hz)

I
\
600
550
,I I
I
500 .I
111
I
I
I
I
I
I
I
350 I
Y
i
I
300 I
I
I
I
I
250 I I
I
I
200 I
I
I
I
i I -
210 z
150 ! 200 :
p
1
I I - 190 .i
100 I I 180 .$
I
/
I I 170
2
2
-
/
50 /
/I
I 160 i
d*
:
I 50 IL
I -
I
1000 1100 1200 1300 1400 1600
1500 1700 1800 2000
Engine speed(rpm)
F6161A019
170-1 SERIES
O’-:27
SA6D170-B-1 (OEM for generator)
Flywheel horsepower :
Prime use : 367 kW 1492 HP] 1,500 rpm (50 Hz)
416 kW (557 HP} 1,800 rpm (60 Hz)
Stand by use : 406 kW (543 HP) 1,500 rpm (50 Hz)

457 kW 1612 HP) 1,800 rpm (60 Hz)
a 3
I Y
450.
650
600 450.
550
400
500I-
350
45c l-
4oc l- 300
350I- 350
250 367kWI492Hd (Prime)
50Hz
300l- 300-
3 200
a 250l- 250
201O- 15( 200
.-_
151D- 150 ’
lot
101D- 100
51
51O- 50
-
O- L OLLI
1100 1200 1300 1400 1500 1600 1700' 1800 1900
01-028
0
SA6D170-B-1 (for EPS6D170-B-1)
Flywheel horsepower :445 kW{597 HP)1,800rpm
CL 3
1 Y
500-
650-
650
600- 450-
600
550-
400-
500-
350-
450-
400- 300- 400
350- 350
3 250-
/
P
';' 300- 300 /
0
200-
250- 250
I
zoo- 150- 200 /

I
150- 150
loo-
loo- 100
50-
50-
o- o- 0
600 600 1000 1200 1400 1600 1600 2000 2200
Engine sPeed(rPm) SWE01034
01-029
0
SA6Dl7OAE-I (for MQ generator DCA-6OOSSK)

Flywheel horsepower : 513 kW {590 HP} 1,800rpm (60Hz)
6D170-1SERIES
SA6D170BE-1 (for MQ generator DCA-500SSK)

Flywheel horsepower : 426 kW {572 HP} 1,800 rpm (60 Hz)
En9 i n e s p e e d (rpm)
6D170-1 SERIES
ENGINE
II STRUCTURE AND FUNCTION
GENERAL STRUCTURE.. ............................ 1 I-002
INTAKE AND EXHAUST SYSTEM

Intake and exhaus system ..................... 1 I-004
Turbocharger .......................................... 1 I-007
After-cooler.. ........................................... 1 I-009
ENGINE BODY
Cylinder head ......................................... 11-010
Valve system ........................................... II-012
Cylinder block ......................................... 1 I-014
Main circulation part .............................. 1 I-016
Timing gear.. ........................................... 1 I-018
Flywheel and flywheel housing ............ 1 I-020
LUBRICATION SYSTEM
Lubrication system chart ....................... 1 I-021
Oil pump ................................................. II-022
Oil filter and safety valve.. ..................... 1 I-023
Oil cooler ................................................ 1 I-024
Oil pump relief valve.. ............................ 1 I-025
Oil cooler by-pass valve ........................ 1 I-025
Piston cooling valve ............................... 1 I-026
Mechanical pump.. ................................. 1 I-027
FUEL SYSTEM
Fuel system chart.. ................................. 1 I-028
Fuel injection pump ............................... 1 I-030
Fuel injection nozzle ............................... 1 I-032
Fuel injection pump drive ...................... 1 I-033
Fuel filter.. ............................................... 1 I-034
Fuel cut solenoid ................................. 11-034-I
Engine stop motor .............................. 1 I-034-3
Starting aid ............................................. 1 I-035
Outline of electronical governor system
(with electronical governor made
by ZEXEL) .......................................... 11-035-I
COOLING SYSTEM
Cooling system chart.. ........................... 1 I-036
Water pump.. .......................................... 1 I-037
Fan drive and tension pulley.. ............... 1 I-038
Corrosioon resistor ................................ 1 I-040
Thermostar ............................................. 1 I-041
ACCESSORY
Air compressor mounting ..................... 1 I-042
Air compressor. ...................................... 1 I-043
ELECTRICAL SYSTEM
Alternator ................................................ 1 I-044
Starting motor ........................................ 1 I-045
Wiring diagram ...................................... 1 I-047
11-001
43
STRUCTURE AND FUNCTION GENERAL STRUCTURE
GENERAL STRUCTURE
S6D170-1
6162FlOl
1. Crank pulley 9. Camshaft 17. Front seal
2. Thermostat 10. Rocker arm shaft 18. Oil pump
3. Cylinder head 11. Push rod 19. Connecting rod cap
4. Fuel injection nozzle 12. Tappet 20. Oil pan
5. Rocker arm housing cover 13. Rocker arm housing 21. Main bearing cap
6. Piston pin 14. Cylinder block 22. Crankshaft
7. Intake valve 15. Rear seal 23. Ring gear
8. Exhaust valve 16. Vibration damper 24. Flywheel
1 l-002 170-1 SERIES

STRUCTURE AND FUNCTION GENERAL STRUCTURE
25. Cylinder liner
26. Piston 6162F102
27. Oil cooler
29. Piston cooling nozzle
30. Connecting rod
170-1 SERIES
11-003
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

S6D170-1 for PC650-1
Intake system
1. Air cleaner
2. Turbocharger
3. Intake manifold
4. Exhaust manifold
5. Muffler
A. Intake inlet
6162F106
B. Exhaust
Exhaust system
6162F107
11-004 170-l SERIES

0
S6D170-1 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
170-l SERIES 1 l-005

0
INTAKE ANQ EXHAUST SYSTEM
S6D170-1 for WA600-1
Intake system
F6161A002
Exhaust system
F6161A003
1 J-005 1
0 170-l SERIES
SA6D170-A-1 for EG550-1
Intake system
b 3
F 1. Air cleaner
2. Turbocharger
3. Intake manifold
/--(-- 4.
5.
Exhaust manifold
Muffler
Exhaust system
A. Intake inlet
6. Exhaust
1 I-006 170-l SERIES

0
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 -006- 1

0
SAGD170-B-1 for EG450-1
Intake system
1. Air cleaner
2. Turbocharger
3. Intake manifold
4. Exhaust manifold
5. Muffler
Exhaust system
A. Intake inlet
B. Exhaust
170-1 SERIES
1 l-006-2
0
SAGD170-B-1 for D375A-1
Intake system
1 . Air cleaner
2. Turbocharger
3. Intake manifold
4. Exhaust manifold
5. Muffler
Exhaust system
A. Intake inlet
6. Exhaust
170-1 SERIES 11-006-3

0
TURBOCHARGER
.Q
KTRllO
P
8
I
9
e
1. Blower housing a. Oil inlet (from oil filter) TURBOCHARGER

2. Blower impeller b. Oil outlet (to oil pan) Type: Komatsu KTRI 10
3. Clamp c. Air inlet

Overall length: 290 mm
Overall width: 305 mm
4. Center housing d. Air outlet
Overall height: 267 mm
5. Journal bearing e. Exhaust inlet Weight: 19 kg
6. shield
Maximum allowable rotation: 94,000 rpm
f. Exhaust outlet
Maximum charging: 46 kg/min.
7. Turbine impeller
Maximum allowable temperature (inlet): 75O’C max.
8. Flinger Direction of rotation (view from blower side): Right
9. Thrust bearing
Lubrication method: Forced lubrication with
engine oil
10. Turbin shaft
11. Turbine housing
170-1 SERIES 1 l-007

0
KTR130
6162F108
1. Blower housing 11. Insert Specifications of turbocharger
2. Blower impeller 12. Thrust bearing * Type: Komatsu KTR130
3. Clamp 13. Turbine shaft

* Length x width x height: 366 x 358 x 323 mm
*Weight: 31 kg
4. Center housing
- Continuous rotation: 70,000 rpm
5. Journal bearing a. Oil inlet (from oil filter) * Maximum charging: 32 kg/min.
l Appropriate temperature (inlet,‘C): 750°C max.
6. Clamp b. Oil outlet (to oil pan)
- Direction of rotation (view from blower side): Right
7. Shield c. Air inlet
l Lubrication method: Forced lubrication with
8. Turbine impeller d. Air outlet engine oil
9. Turbine housing e. Exhaust inlet
10. Flinger f. Exhaust outlet
170-l SERIES
“:O*
KTRl50
5 6
F6166009
1. Blower housing a. Oil inlet (from oil filter) Specifications of turbocharger
2. Blower impeller b. Oil outlet (to oil pan) l Type: Komatsu KTR 150
* Length x width x height: 350 x 289 x 358 mm
3. Clamp c. Air inlet
* Weight: 38 kg
4. Center housing d. Air outlet * Maximum allowable rotation: 65,000 rpm
5. Journal bearing e. Exhaust inlet * Maximum charging: 78 kg/min.
* Maximum allowable temperature (inlet): 75O’C max.
6. Turbine impeller f. Exhaust outlet
l Direction of rotation (view from blower side): Right
7. Turbine housing l Lubrication method: Forced lubrication with
8. Flinger engine oil
9. Thrust bearing
10. Turbine shaft
170-l SERIES
1T8-’
TV77
C 615OF106-1
1. Lock nut 12. Turbine housing
2. Blower housing 13. Piston ring

Type GARRETT CO. TV7705
3. Blower impeller 14. Turbine impeller
Overall length
~_______ ~7 .275mm
4. Thrust collar A Air inlet
B Air outlet Overall width I 284 mm

5. Back plate
6. Thrust bearing C Gas inlet Overall height I 264 mm
7. Seal ring D Gas outlet

Weight 17 kg
7
8. Center housing E Oil inlet
Continuous speed 90,000 rpm
9. Retaining ring F Oil outlet
Max. air supply 0.43 kglsec
10. Journal bearing
11. Shroud Compression ratio 3.4

I
Applicable exhaust temp. Max. 700°C
Clockwise (see from

Direction of rotation
I the blower side)
1 l-008-2 SERIES 170-l

0
AFTER-COOLER
l!!!zll
El I 0 0 00
oo 0 0 0 o
0 0 ~~[T~_fL!,:
0 0 0 0 ;: O
0 O
0 O
0 O O -Oo’-
0oo-0
1. Cover A: From water pump
2. After-cooler body 6: To water manifold
170-1 SERIES 1 l-009

STRUCTURE AND FUNCTION ENGINE BODY
ENGINE BODY
CYLINDER HEAD
_
a-
-.
A4 B4
6162F109
1. Water manifold a. Coolant (to thermostat)
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 gauge sensor
5. Valve guide
6. Nozzle holder sleeve
7. Tube
1l-010 170-1 SERIES

0
ENGINE BODY
Section A - A Section B - B
6162FllO
Cylinder head
. Direct-injection type, injection nozzle, 4-valve type

l Separate type (1 -head for 1 -cylinder)
Valve seat
. Press fitted into cylinder head of intake valve and

exhaust valves.
11-011
170-1 SERIES
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 a. Oil (from oil pump)
11-012 170-1 SERIES

13
14
15
16
17
intake side of No. 1 cylinder Exhaust side of No. 1 cylinder
6162F112 6162F113
Valve timing
TDC (Top Dead Center)
Camshaft
l Special cast/forged alloy, 7 bearings
- Cam face and journal face: High frequency hardening
close BDC
(Bottom Dead Center)
6162F114
170-1 SERIES 11-013

0
CYLINDER 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
7. Front seal 14. Oil level gauge
11-014 170-1 SERIES

14
10
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

MAIN CIRCULATION PART
6162F117
1. Piston pin 9. Vibration damper Crankshaft
2. Connecting rod 10. Crank gear (No. of teeth: 36) * Special cast/forged alloy, seven
3. Connecting rod bushing

bearings
11. Connecting rod bearing
- Journal face: High frequency
4. Piston 12. Crankshaft
hardening
5. Top ring 13. Thrust bearing
6. 2nd ring 14. Main bearing
7. Oil ring 15. Connecting rod cap
8. Crankshaft pulley 16. Connecting rod bolt

(Outside diameter: 200 mm)
11-016 170-1 SERIES

0
ALUMINUM 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: Niresist is cast
on top ring.
15
* 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 Piston ring
‘T Engine Top ring 2nd ring Oil ring
P-face keystone 2-face keystone Bevel cutter with

barrel face inner cut taper face coil expander
S6D170-1
SAGD170-A-I Hard chrome plating Hard chrome plating Hard chrome plating
SAGD170-B-1
6162Fllg
170-1 SERIES
FCD PISTON TYPE
Main bearing, connecting rod

bearing
l 34ayer Kelmet
l Upper main bearing:
with oil groove
Piston (FCD piston type)
l Ductile special iron casting

with thin structure
0 Thermal flow shaker type
l Forced lubricating oil cool-
ing by piston cooling
Al6
--
+
2 6162Fll8
Piston Piston ring
Shaker type Engine Top ring 2nd ring Oil ring
2-face keystone 2-face keystone inner Bevel cutter with coil

eccentric barrel face cut taper face expander
SAGDl70-A-1
(HD465-5) Hard chrome plating Hard chrome plating Hard chrome plating
(WA700:
14594 and up)
6162F819
11-017-l
CD
TIMING GEAR
6162FlZO
i
1. Idler gear (No. of teeth: 571 6. Idler gear (No. of teeth: 30) .
2. Cam gear (No. of teeth: 48) 7. Crankshaft gear (No. of teeth: 36)
3. Compressor driving gear (No. of teeth: 24) 8. Oil pump driving gear (No. of teeth: 33)
4. Injection pump driving gear 9. Idler gear (No. of teeth: 41)

(No. of teeth: 48)
10. Water pump driving gear (No. of teeth : 20)
5. Idler gear (No. of teeth: 45)
11-018 170-1 SERIES

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

FLYWHEEL AND FLYWHEEL HOUSING
1 2
6162F122
Tightening order of flywheel
1. Ring gear
mounting bolt.
2. Flywheel
3. Rear seal
4. Flywheel housing
5. Drain plug
Ring gear
No. of teeth Applicable machine
118 PC650, PClOOO, PC1 500, HD465-5

I
D275A-2, D355A. D375A. WA600. WD600,

138
I WA700, HD465-3, EG550
1 l-020
0
STRUCTURE AND FUNCTION LUBRICATION SYSTEM
LUBRICATION SYSTEM
LUBRICATION 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
19. Oil pressure gauge
a. To intake manifold
w. Coolant
6162F123A
170-1 SERIES 1 l-021

0
OIL PUMP
6162F124
1. Oil pump driving gear (No. of teeth: 33) Oil pump
2. Oil pump body * Gear pump type

3. Bushing
* Oil pump speed: Engine speed x 1.091
4. Drive shaft
5. Bushing
6. Pump cover
7. Driven shaft
8. Driven gear (No. of teeth: 12)
9. Bushing
1 l-022 170-1 SERIES

OIL FILTER AND SAFETY VALVE
6actionA-A
6162F125
1. Safety valve cap Oil filter
2. Oil pressure sensor - Filteration area: 0.82 m2 x 2
3. Filter bracket
4. Filter element Safety valve

Cartridge
5. Filter case - Cracking pressure (difference pressure):
>
6. Safety valve 2.0 + 0.2 kg/cm2
7. Valve spring
a. From oil pump
b. To engine each component
170-1 SERIES
1 l-023
OIL COOLER
S6D170-1
SAGD170-B-1
i-B Section A - A
Section B - B
6162F126
1. Cooler cover Oil cooler
2. Cooler element * Heat exchanged: Min. 45000 Kcel/hr.
3. Drain cock * Heat-transmitting area: 2.94 m2

* Oil flow capacity: 180 Urnin.
a. Coolant (from water pump)
* Water flow capacity: 890 Q/min.
b. Oil (from oil pump)
c. Oil (to engine each component)
11-024 170-1 SERIES

0
SAGD170-A-1
Section A - A
Section B - B
1. Cooler cover Oil cooler

2. Cooler element - Heat exchanged: Min. 55000 Kcal/hr.
3. Drain cock
- Heat-transmitting area: 4.146 m2
- Oil flow capacity: 180 Q/min.
a. Coolant (from water pump)
- Water flow capacity: 890 Qlmin.
b. Oil (from oil pump)
c. Oil (to engine each component)
170-1 SERIES 11-024-l

0
OIL PUMP 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

-0 - Cracking pressure: 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
PISTON COOLING VALVE
1. cap
1 2 3 4 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’
6162F129
11-026 170-1 SERIES

MECHANICAL PUMP
1. Spring
2. Plunger
3. Plunger
4. Plunger
5. Pump body
-f -f
B B 6. Worm
a. Oil inlet
(from main gallery)
%
C b. Oil outlet
(to intake mani-
fold)
5
\ /
Section A - A Section B - B
View 2
Section C - C
6162F130
Mechanical pump
* Capacity: 10 + 1 cc/h x 2 - The oil is sent from the main gallery into the pump,
* The mechanical pump is a worm pump used to increase and sent out from the two outlets of the pump to the
the wear resistance of the intake valve seat. two intake manifolds through the oil tubes. The oil is
*The pump is driven by the slit shaft connected to the sprayed in the intake manifolds by the intake air onto
camshaft. the seats of the valves to reduce the wear of the seats.
170-1 SERIES 11-027

FUEL SYSTEM STRUCTURE AND FUNCTION
FUEL SYSTEM
FUEL SYSTEM CHART
6162F131
1. Fuel tank
2. Fuel filter
4. Feed pump
5. Fuel injection nozzle
170-l SERIES
1 l-028
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL INJECTION PUMP
S6D170-1, SAGD170-B-1
6162F132
1. Injection pump driving gear (No. of teeth: 48) 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
11-030 170-1 SERIES

0
6162F133
Fuel injection pump
* Maker: Diesel Kiki

- Type: PES-PD type
* Governor: RSUV, centrifugal type, all-speed type
* Lubrication method: Forced lubrication with engine
oil
170-1 SERIES 11-031

0
SAGD170-A-1
4 i i
1. injection pump driving gear (No. of teeth: 48) a. Fuel (from fuel tank)
2. injection pump drive shaft b. Fuel (to fuel filter)
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 170-1 SERIES

Cc
FUEL SYSTEM
Fuel injection pump

* Maker: Diesel Kiki
- Type: PE-ZWX type
* Governor: RSUV, centrifugal type, ail-speed type
- Lubrication method: Forced lubrication with engine oil
11-031-2
170-l SERIES
0
FUEL INJECTION NOZZLE
1. Nozzle holder
2. Nozzle spring
3. Nozzle
b
4. Retaining cap
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 hole type
1 l-032 170-1 SERIES

@
FUEL INJECTION PUMP DRIVE
For PES-PD type injection pump
7
5
6 8
-
Section A--A
1 2 3 4
6162F135
1. Fuel injection pump drive shaft Tachometer drive
2. Nut - Tachometer drive shaft speed = Engine speed x l/2

3. Tachometer drive gear (No. of teeth: 14)
4. Drive housing
5. Pinion gear housing
6. Tachometer drive shaft
7. Pihion gear (No. of teeth: 14)
8. Bushing
170-1 SERIES
11-033
@
MAINTENANCE STANDARD FUEL SYSTEM
For PE-ZWX tYpe injection pump
Section A-A Detail P

6162F135-1
1. Fuel injection pump drive shaft Tachometer drive
2. Nut * Tachometer drive shaft speed = Engine speed x l/2
3. Tachometer drive gear (No. of teeth: 14)
4. Drive housing
5. Pinion gear housing
6. Tachometer drive shaft
7. Pihion gear (No. of teeth: 14)
8. Bushing
11-033-l 170-1 SERIES

@
FUEL SYSTEM
FUEL FILTER
6162F136
1. Air bleeding plug

Fuel filter
2. Filter bracket
l Filtration area: 0.4 m2 x 2
3. Filter element
Cartridge
4. Filter case
a. From feed pump
b. TO fuel injection pump
11-034
0
FUEL CUT SOLENOID

B contact (electricity flows in ordinary operations) method
F621201037
* Maker: NIKKO DENKI

l Type: Sealed
* Rated voltage: DC24ti
* Operating current: Maximum: 35A max.
Continuity: 0.5A max.
* Stroke: 12 f 0.1 mm
* Weight: 2.7 kg
Inner wiring
1. Shaft 5. Stop lever

Cl : Pull-in coil
C2: Holding coil 2. Case 6. Return spring
3. Piston 7. Solenoid
4. Coil 8. Fuel control lever

FUNCTION
* Starting engine
When the starting key is turned on, the solenoid is

energized.
Solenoid shaft (1) is electrically attracted, pulling
injection pump stop lever (5) and fixing 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 to STOP
position (non-injection position) by return spring (6).
* During operation, the amount of fuel injection is

controlled 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.
A contact (electricity flows when stopped) method
EG580B-1 L
-Y
02F082-K
Z View Y View
F6161A021
Pull-in coil Pull-in coil 1. Case
-$($Ejl’ l$o 2. Coil

Holding coil Holding coil 3. Return spring
Before pull-in After pull-in
4. Plunger
Inner wiring
6134F166A
FUNCTION FUEL SOLENOID

When stopping the engine, the solenoid is energized, l Maker: NIPPON DENS0
the solenoid plunger is electrically attracted, and the Made by synchro start
stop lever of the injection pump is moved by a rod (EG5808-1 L)
to the stop (non-injection) position. As a result, the l Type: Sealed
fuel is cut off and the engine is brought to a stop. l Operating current
Accordingly, this solenoid is used only when the Pull-in coil: 20A max.
engine is being stopped; it is in free condition during 37A (EG580B-1 L)
ordinary operations. Holding coil: 5A max.
0.4A (EG580B-1 L)
l Stroke: 27 mm
25 mm (EG580B-1 L)
’1-?z4-2 170-l SERIES

ENGINE STOP MOTOR
Shape of cable tip

7(non-threaded stopper type)-
.--r--y-\
:_ A_:.,/
35
Stroke
Shape of cable tip

- (threaded stopper type)
Stroke
Made by AMP Co.,

Econoseal connector,
2. Not used (filler plug added)

/ J. Not used (filler plug added)
B(AV 0.85LR)
. Not used (filler plug added)
5. p, (AV 0.85LW)
’ 8. E(AV 0.858)
Engine stop motor

1. Motor assembly
- Maker: Jidosha Denki Kogyo Co., Ltd.
2. Cover - Rated voltage: DC24V
3. Cable assembly * Operating force: 15 kg min.
* Stroke:
4. Cable clamp 35:::40 mm
5. Coil spring * Weight: 1.2 kg_
6. Cable
7. Screw
8. Breather
9. Bracket assembly
10. Cover assembly
170-l SERIES 1 l-034-3

0
STRUCTURAL DRAWING (1)
1. Gear cover assembly
2. Slider assembly
3. Armature shaft
4. Contactor assembly
5. Roller
6. Worm wheel assembly
7. Motor assembly
8. Gear case assembly
’’-“o34-4 170-l SERIES

STRUCTURAL DRAWING (2)
1. Gear cover assembly
2. Motor assembly
3. Cable clamp
4. Cable assembly
5. Gear case assembly
170-l SERIES
1 l-034-5
0
DESCRIPTION OF OPERATION AND CIRCUITS
1. Stop condition (O” or 390°)

Battery
4+-i
The above drawing shows the stopped condition assembly is stopped at the auto-stop position on the
when a closed circuit has been formed. The slider P, side.
2. 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 plate through the P2 auto-stop ter- same time as the roller starts to move.
minal and switch and into the armature shaft assem-
3. Turning condition (90’ in the drawing)

Battery
I7b Id7
Electric current continues to pass through the arma- slider assembly also continues to move in the direc-
ture shaft assembly and the motor continues to tion of the arrow.
turn. Because of the rotation of the rol,ler, the
170-l SERIES
’’-ki?4-6
4. When stopped (180’)
A closed circuit is formed when the P, auto-stop and the motor comes to a sudden stop. The slider
terminal rides on the minus-side contactor plate, assembly also stops.
5. When switch is turned (when starting the motor)
Batterv
When the switch is moved to the PI side (starting thereby starting the motor. The slider assembly
switch OFF), an electric current flows from the plus starts to move in the direction of the arrow at the
contactor plate through the PI auto-stop terminal same time as the roller starts to move.
and switch and into the armature shaft assembly,
6. Turning condition (270° in the drawing)
Electric current continues to pass through the arma- the direction of the arrow. Then the circuit returns
ture shaft assembly and the motor continues to to stop condition 1.
turn. The slider assembly also continues to move in
170-l SERIES 11-34-7

0
STARTING 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 GOVERNOR SYSTEM (with
electronical governor made by ZEXEL)
OVERALL CONFIGURATION
! Injection pump / 1 /
=-I
stop output
50160Hz
Electronical governor controller 6
) changeover
z
i
L
Fuse
Low idle - Start signal
control dial t
f t
Battery
SAE00126
. The electronical governor system is com-

posed of fuel injection pump governor unit
(actuator driven), electronical governor con-
troller, controller mounting panel, switches,
dials, sensors and others. The electronical
governor controller has a built-in microcom-
puter and it runs the engine by driving the
governor actuator under the running condi-
tions specified by contents of control set in
the microcomputer, external switches, dials,
etc.
11-035-l
@
CONTENTS OF ELECTRONIC GOVERNOR CONTROL
VO. Item Contents
1 Selection of droop/isochronous Droop control (Revolution changes according to the load) or isoch-
ronous control (Revolution is kept at the rated speed, regardless of
the load) is selected with switch input.
2 Selection of Li/rated speed Low-idling speed or rated speed is selected with switch input.
3 Adjustment of Li speed Engine speed is changed with the rpm adjustment control knob dur-
ing low idling.
Upper limit : 900 rpm, Lower limit : 700 rpm
4 Adjustment of frequency Rated speed is adjusted with outside control knob.

(In isochronous control mode) Adjustment range : Approx. f 50 rpm, Judgment : 15 msec
5 Selection of droop (adjustment) Regulation is changed with droop adjustment knob during high idling
(In droop control mode) from about 3% to 5%.
6 Adjustment Hi speed Engine speed is adjusted with speed control switches (Speed rais-
(In droop control mode) ing switch and speed lowering switch) during high idling.
Speed adjustment range : Approx. i_i}lOOrpm
Adjusting speed : Approx. 5rpm/sec, Judgment: 50msec
Initial set engine speed (set when power is reset) is shown in sepa-
rate table.
7 Li isochronous control Engine speed is kept constant during low idling, regardless of load.
8 Selection of frequency (50/60Hz) 50Hz or 60Hz is selected with switch input.
9 Emergency stop function Engine is stopped when oil pressure lowers, water temperature rises
(Error signal output) or he engine overruns, and error signal is output to outside.
10 Injection rate control function for Fuel injection rate is control so that engine will start easily.
start
11 Overrun-preventive function If engine speed exceeds set value, fuel is turned off and stop signal
is output to outside.
Set value : (1) 2070rpm (by software)
(2) 2300rpm (by hardware)
12 Diagnosis function If electronic governor system has trouble, set measures are taken
and error signal is output to outside. (See next item.)
13 Memory clearing function Error signal to outside is reset. (See next item.)
14 Sharp acceleration limiting speed When engine is accelerated sharply, full rack position is limited to
prevent production of black smoke.
15 Pre-operating function of rack Rack is moved to reduce sliding resistance before engine is started
at low temperature.
16 Overspeed testing function While Li/Hi selector switch is set to Hi position, overspeed opera-
(Used only during test) tion can be executed with external input. Engine speed is adjusted
with speed control switch in droop control mode and with control
knob in isochronous control mode.
11-035-2
@
CONTROLLER
SEE00127
1. Case Function
2. Connector . The controller produces signals for control-
3. Mounting bolt ling the fuel injection pump for the engine
with signals received from sensors and
switches which are installed on the panel
and externally located.
The controller possesses a self-diagnostic
function, and abnormalities are displayed on
the LED.
11-035-3
@
Electronical governor main unit
1. Housing
2. Actuator
3. Control rod
4. Connector
5. Copper plate
6. Cover
7. Lubrication outlet eyebolt
615OFl76
The electronical governor is roughly corn- The actual injection rate is controlled by
posed of housing, actuator and cover. these series of motions. That is, the injection
The actuator is composed of linear DC mo- rate is controlled at the optimum level that
tor, link and control rod position sensor. It corresponds to the machine running condi-
operates in accordance with signals from the tions as a result of arithmetic processing
control unit. executed in the control unit.
The linear DC motor causes the coil assem- The linear DC motor is composed of magnet
bly to make up/down motions in accordance unit that supplies magnetic field, pole unit
with signals from the control unit and causes that leads the magnetic field and coil assem-
the coil assembly to become still so that the bly that makes up and down motions.
control rod reaches the target position. (It is The operating principle of the DC motor is
because arithmetic processing is executed in based on Fleming’s left-hand rule, as it is
the control unit.) related to the force applied to current leads
The motion of the linear DC motor is further in a magnetic field.
transmitted to the connector through the l When the current fed to the coil is of direc-
link, and the fuel injection rate is increased/ tion A, the magnetic force is applied in direc-
decreased when the control rod moves right- tion C. When the current fed to the coil is of
ward/leftward. direction B, the magnetic force is applied in
That is, the injection rate increases when the direction D. When the direction and magni-
coil assembly moves upward, and the injec- tude of the current fed to the coil are control-
tion rate decreases when the coil assembly led, therefore, the coil assembly can be
moves downward. moved up/down, and it is possible to cause
The copper plate at the connector end is the the control rod to be still at an arbitrary
control rod position sensor. It senses the position by the feedback from the position
control rod position and feeds it back to the sensor.
linear DC motor.
11-035-4
@
1) Actuator
Control rod
Copper plate Copper plate
position sensor I
Connector Connect0
rod
inear DC motor
615OF176
615OFl77
2) Linear DC motor
, Coil assembly
Cover
Magnet
’ Pole
615OFl79
(Upper side sectional view)
11-035-5
@
3) Control rod position sensor
. Structural view . Operation diagram
Jw- Large
Inductance
6150Fl82
615OFl81
1. Copper plate (fixed)

2. Compensator coil
3. E-core
4. Copper plate (movable)
5. Sensing coil
6. Copper plate
. This position sensor is located at the center l That is, the counter electromotive force gen-
of the governor top for sensing if the control erated in the coil changes when the position
rod is actually located at the correct position .of the copper plate changes.
with respect to the target position instructed l Another coil and copper plate are provided
from the control unit. for compensation. They compensate for im-
. This position sensor is composed of E-core pedance changes such as temperature
shown above and sensing coils and copper changes.
plates of two sets. . The sensing accuracy is increased by ab-
. One of copper plates is installed to the end sorbing the abnormality caused by the influ-
of the control rod, and another copper plate ence of temperature, etc. through sensing of
is fixed to the E-core. the control rod position by the ratio (ratio of
. This position sensor senses changes in the counter electromotive force) of impedances
coil inductance (may be considered as im- of two sensing coils.
pedance 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.
11-035-6
@
STRUCTURE ‘AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM CHART
6162F136
1. Water pump 7. Water manifold
2. Oil cooler 8. Thermostat
3. Corrosion resistor 9. Radiator
4. Cylinder liner 10. Fan
5. Cylinder block A. From oil pump (oil)
6. Thermostat switch B. To engine each component (oil)
11-036 170-1 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 Engine speed x 1.8
4. Water seal
* Flow capacity: 1050 !Z/min.
(3,600 rpm)
5. Pump shaft (rear)
6. Pump shaft (front)
7. Inlet housing
170-1 SERIES 11-037

FAN DRIVE AND TENSION PULLEY
l FAN DRIVE (For D275A-2, D375A-1.2, PClOOO-1, HD465-3)
6162F140
1. Tension spring Outside diameter for Pulley Unit : mm
2. Tension shaft Applicable Crankshaft Tension

Fan Pulley
machine Pulley Pulley
3. Tension pulley
4. 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
1 l-038
0
l TENSION PULLEY (For D275A-2)
X
/ \ \
5 fi 7
Section 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
l TENSION PULLEY (For D375A-1 l 2, PClOOO-1)
/I
5 6
\ 7
Section A - A
6162F141
2. Roller bearing
3. Tension pulley bracket
5. Oil seal
6. Ball bearing
7. Spacer
8. Stopper
1 l-039
0
FAN DRIVE AND TENSION PULLEY
l FAN DRIVE (For WA600, WD600, WA700, HD465-5)
/
/’
\ /
I’
6 \_____P---
1. Tension spring Fan pulley diameter
2. Tension shaft
)
4. Fan pulley
5. Fan belt 379 WA700
6. Crankshaft pulley (Outside diameter: 200 mm) 293 WA600 (A.C spec.), EG480B-1
7. Fan
a. Direction of wind
11-039-l
0
l TENSION PULLEY
8’ 7 ‘6
A-A
SLE00255
2. Seal
3. Inner race
4. Roller bearing
6. Spacer
7. Ball bearing
8. Oil seal
1 l-039-2
0
CORROSION RESISTOR
a b
\ \ t-/
Section X - X (Detail valve)
6162F142
1. Head Corrosion resistor

2. Element case - Filteration area: 0.13 m*
Cartridge
3. Solid drug i
(included 1,000 g)
a. Coolant inlet
b. Coolant outlet
11-040
COOLING SYSTEM
THERMOSTAT
1. Seal
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
b 6162F143
OPERATION
-._
At cold (close) At warm (full open)
6162F144
Function
l Opening temperature: 76.5 f 2°C
- Full opening temperature: 9O’C
* Valve lift: Minimum 10 mm
170-l SERIES
11-041
STRUCTURE AND FUNCTION ACCESSORY
PC1 000-l (Diesel Kiki Air compressor)

Without air delivery relief valve
r
i-
1 !
9
?;”
-_q ‘3
-.i-
Section A-A
View 2
6162F655
1. Flange
1 Intake manifold 1
2. Coupling
3. Air compressor Air
4. Air governor
a. From intake manifold (air)

b. To air tank (air)
c. To thermostat housing (cooling tiater)
d. From oil cooler (cooling water)
Air circuit diagram

6162F146
170-l SERIES
’’-Oi2-’
HD465-5, WA600-1, WA700-1 (Diesel Kiki Air compressor)

Without air delivery relief valve
A-A
View 2
Air delivery relief valve
6162F620
) Intake manifold 1
1. Flange
2. Coupling
3. Air compressor
a. From intake manifold (air)

b. To air tank (air)
c. To thermostat housing (cooling water)
d. From oil cooler (cooling water)
6162F821
’’-“G2-2 170-1 SERIES

AIR COMPRESSOR
6162F147
1. Inlet valve seat 11. Thrust washer Air compressor

2. Unloader valve body 12. Crankshaft * Maker: Cummins
3. Unloader valve spring 13. Drive gear (No. of teeth : 24) * Rated speed: 1,600 rpm
(at engine rated speed)
4. Unloader valve cap 14. Oil ring
* Discharge capacity: 245 Illmin.
5. Head cap 15. 2nd ring (at rated speed)
6. Inlet valve 16. Top ring l No. of cylinder - Bore x Stroke:
1 - 92.1 x 44.5
7. Inlet valve spring 17. Cylinder head
8. Piston
9. Crank case a. Air inlet
10. Connecting rod b. Air outlet
170-1 SERIES 11-043

0
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ALTERNATOR
Inner connecting diagram

6162F148
1. Alternator assembly
Applicable Pulley outside

Engine Type Specifications diameter Weight
machine model
(mm)
PC650-1
S6D170-1 Delco-Remy, 2581-450, Open type 24V, 50A 95 15 kg
PC1 500-l
ALTERNATOR BUILT-IN REGULATOR
-
\
1. Alternator
2. Regulator
Wiring diagram
F6166049
Pulley outside
Applicable
Engine Type Specification diameter Weight
machine model
(mm)
D275A-2
SAGD170-1 WA600-1 Sawafuji, Open type
WD600-1
WA700-1 24V. 75A
SAGD170.A-1 HD465-3 Sawafuji. Open type

24V. 50A
HD465-5
95
D375A-1
Nikko Denki, Open type 24V. 35A
(-12802)
SA6D170-B-1 D375A-1
(12803 and up)
Sawafuji, Open type 24V. 50A
D375A-2
PClOOO-1
n-044-1
0
ALTERNATOR WITH REGULATOR
Alternator Regulator
R
-----JJRl-----
B.E.F.R: Terminal
Wiring diagram 6114F151
Pulley outside
Applicable
Engine
machine model Tvw Specifications diameter Weight
(mm)
EG550-1 Nikko Denki, Open type 24V. 50A 95 15kg
SAGD170-A-1
EG5808-1 L Nikko Denki, Closed type 24V. 13A 95 7.6 kg
SAGDI 70-B-1 EG450-1 Nikko Denki, Open type 24V. 13A 95 7.8 kg
’’-“ii4-2
ALTERNATOR BUILT-IN REGULATOR
B.E.R: Terminal E- Wiring diagram F6161 A022
Pulley outside
Applicable Specifications diameter Weight
Engine Type
machine model (mm)
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
STARTING MOTOR
6162F149
1. Pinion gear B, C, E, R, S: Terminal
2. Starting motor assembly
3. Magnetic switch
4. Safety relay
Applicable No. of
Engine Type Specifications Weight
machine model pinion teeth
:;;;l$2
S6D170-1 Nikko Denki, Sealed type 24V. 7.5KW 11 18 kg
PC1500-1
WA600-1
SAGDl70-A-1 Nikko Denki, Sealed type 24V, 7.5KW 11 18 kg

I I
SAGD170-B-1 Nikko Denki, Sealed type 24V. 7.5KW 11 18 kg

I I
EG580B-IL, EPSAGD170-A-1, EPSAGD170-B-1

EG480B-1 (For CIS -45°C spec.)
F6161 A023
1. Pinion gear B, C, E, Fi, S: Terminal
3. Magnetic switch
4. Safety relay
I
Engine Type Specificatons Weight
machine model diameter
SA6D170-A-1 24V, IIKW 19.5 kg
SA6D170-B-l
EG480B-1 SAWAFUge Denki, Water tight,
(-45°C spec.) oil resistant type
11-046
0
F6161 A023
Pinion gear B, C, E, I?, S: Terminal
Starting motor assembly
Magnetic switch
Safety relay

Engine
machine model Type Specificatons
diameter
Weight
WA600-1 SAWAFUge Denki, Water tight,

S6D170-1 oil resistant type 24V, IIKW 11 19.5 kg
(-50°C spec.)
11-046-l
0
WIRING DIAGRAM
SA6D170-A-1 (for EG550-1)
170-1 SERIES 11-047

0
EG580B-1 L
Engine stop solenoid unit

Water temperature
unit
9
nJ7-
m-@-Zergency stop
I Fuse (30A)
Charge ammeter
Alternator
motor
OFF
PREHEAT j O,,,
START
Starting switch
F6161 A024
1 l-048 170-1 SERIES

0
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 When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit safety
pins, block the wheels, and apply the parking brake.
A When carrying out operations with two or more workers, always use signals, and do not allow any unau-
thorized person near the machine.
A When checking the water level, if the radiator cap is removed when the engine is hot, boiling water will
spurt out and may cause burns, so always wait for the engine to cool down before checking the water
level.
A Be extremely careful not to touch any hot parts.
A Be extremely careful not to get caught in the fan or any other rotating parts.
*A! Wh en removing the plugs or caps from places under hydraulic pressure, water pressure, or air pressure,
release the internal pressure first. Fit the measuring tools securely before carrying out any testing, adjust-
ing, or troubleshooting.
When using the standard values table for judgement in testing, adjusting, or troubleshooting, it is necessary to
be careful of the following points.
The standard values for the new machines in the standard values table are values given as reference from the
standards for new machines and machines shipped from the factory. They should be used as values for esti-
mating wear during operation or as target values when carrying out repairs.
The failure judgement standard values in the standard value table are values using estimated values based on
the results of various tests and standard values for machines shipped from the factory. Use these values for ref-
erence together with the repair and operation history of the machine when judging failures.
Do not use this standard values table as a standard for judging claims.
12-002
0
TESTING AND ADJUSTING FUEL SYSTEM
ADJUSTING ENGINE STOP 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 actuated, adjust nut and bolt (1)
and ball joint (2) so that clearance of stop lever (3)
and stopper bolt (4) at STOP end is 1 f 0.5 mm,
then assemble fully.
3. Switch the stop motor on and off ten times, and
check the condition of the adjustment. If neces-
sary, adjust ball joint (2).
4. Check that the engine stops.
[Precautions]
1) When the stop motor is actuated, the stop lever (3)
and stopper 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. If there is any clear-
ance, adjust the hole position of the return spring
(If there is any clearance, the output power may
drop.)
569FlOl
170-l SERIES 12-002- 1

0
ADJUSTING FUEL INJECTION PRESSURE

(VALVE CRACKING PRESSURE)
1. Remove retaining cap (1).
2. 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 pressure adjusted per 0.1 mm shim
thickness: Approx. 15 kg/cm2
m Retaining cap: 9 + 1 kgm
4. After adjusting the thickness of shims, check the

fuel injection pressure using nozzle tester.
6162F202
12-002-2 170-1 SERIES

0
DATA FOR INJECTION PRESSURE ADJUSTMENT SHIMS
Engine model
I Shim contour
I
Shim thickness
(Range)
I
Shim thickness
(Interval)
S6D170-1 a = 4.5 mm
SAGDI 70-A-1 0.50 - 1.54 mm 0.02 mm
b=11.5mm
SAGDl70-B-1
Part No. 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 50523-5600 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 50523-6600 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 50530-0100 1.52
DK150523-7400 0.98 DK150530-0200 1.54
DK150523-7500 1 .oo
DK150523-7600 1.02
DK150523-7700 1.04
170-1 SERIES 12-002-3

0
CALIBRATION DATA
Applicable Engine
Machine Model Engine Model Pump Assembly Number Page
Serial Number
PC650-1 10025 and up
S6D170-1 6 162-73-l 170 12-003
PC 1500-I 10126 and up
EG450-1 SAGDI 70-B-l 6162-73-1251 10095 and up 12-004
6 162-73-l 330 10001 - 10052 12-004- 1
EG550-1 SAGDI 70-A-1
6162-73-l 331 10053 and up 12-004-2
12-002-4 170-1 SERIES

0
ENGINE BODY
ADJUSTING VALVE CLEARANCE
Method of adjusting valve clearance
1. Remove the cyliner head cover.
2. Rotate the crankshaft in the normal direction to set
No.1 cylinder at compression top dead center, and
align pointer (3) with the 1.6 TOP mark on vibration
damper (2). When rotating, check the movement
of the intake valve of No.6 cylinder.
* When No.1 cylinder is near compression top dead
center, the No.6 intake valve moves (is open).
3. Adjust the clearance of the valves marked 0 in the

valve arrangement chart.
4. Next, rotate crankshaft one turn in the normal
* Valve arrangement
direction and adjust the valve clearance of the
remaining valves marked 0. Cylinder No. 1 2 3 4 5 6
8 = Exhaust valve 0 0 0 0 0 0
Intakevalve 0 0 0 0 0 0
2
E;
z * To adjust the valve clearance loosen locknut (8)
6 5 7 6
of adjustment screw (7), insert feeler gauge A
between crosshead (6) and rocker arm (5), and
turn the adjustment screw until 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 to turn the crankshaft 120°

each time and adjust the intake and exhaust
valves of each cylinder according to the firing
order.
l Firing order: 1-5-3-6-2-4
* After tightening the locknut, check the clearance
again.
6162F658 1
12-003
@
MEASURING COMPRESSION PRESSURE
Method of measuring compression pressure
A When
careful
measuring
not to touch
the compression
the exhaust
pressure,
manifold
be
or
muffler, or to get caught in rotating parts.
-k Measure the compression pressure with the
engine warmed up (oil temperature:
40 - 60°C)
I. Adjust valve clearance.

For details, see 12 ADJUSTING VALVE
CLEARANCE.
2. Remove the nozzle holder assembly of the cylinder

to be measured.
+ Be careful not to let any dirt or dust get in.
3. Install adapter Al in the mount of the nozzle holder

assembly of the cylinder to be measured, and tighten
to the specified torque.
m Torque: 2.75 + 0.25 kgm
4. Connect compressor gauge A to the adapter.
5. Place the fuel control lever in the NO INJECTION

position. Crank the engine with the starting motor
and measure the compression pressure.
A If the fuel control

NO INJECTION
lever is not placed
position,
in the
the fuel will spurt
out.
Ir If the adapter mount is coated with a small

amount of oil, it will reduce the leakage.
* For details of the standard value for the com-
pression pressure, see TABLE OF VALUES FOR
TESTING, ADJUSTING, AND TROUBLE-
SHOOTING.
m Torque: 2.25 + 0.25 kgm
’2-:04
FUEL SYSTEM
TESTING AND ADJUSTlNG FUEL INJECTION TMING
There are the following methods of testing and adjusting
the fuel injection timing of the injection pump.
l Aligning match mark when assembling the injection
pump to the original engine without repair
l Delivery valve method when assembling the injection
pump that has been repaired or replaced
* When using the delivery valve method, always
replace the copper gasket and O-ring of the delivery
valve with new parts. Prepare these parts before
starting the operation.
* Set the No.1 cylinder at the compression top dead
center, then test and adjust.
For details, see ADJUSTING VALVE CLEARANCE
l Testing and adjusting by aligning match mark

(flange type)
1. Turn the crankshaft back approx. 45O from No.1

cylinder TOP.
2. Rotate the crankshaft slowly in the normal direction
to align pointer ( with the injection timing line on
crankshaft damper (1).
3. Check that line a at the fuel injection pump end
2 and line b at the drive housing end are aligned.

z * If the lines are not aligned adjust at the oblong
z hole of the flange.
w Bolt nut: 6.75 + 0.75 kgm
l Testing and adjusting by aligning match mark

(laminated coupling type)
1. Follow the same procedure as for Steps 1 and 2

for the flange type.
2. Check that the lines on the coupling and bearing
cover of the fuel injetion pump are aligned.
* If the lines are not aligned adjust at the oblong
hole of the coupling.
w Bolt nut:
Width across fiats of Tightening rorque for

injection
nut for coupling bolt of oblong hole
pump type
oblong hole kgm
Bosch
19 9.0 kO.5
PE-P, PE-PD
I
Bosch
PE-ZWx I 7.75 + 0.25
*Bosch
PE-ZWy I
21
I 16.Ok 1.0
* 6162-73-l 653 and 6162-73-l 682 are the injection

Oblong hole 6162F663
pump only.
12-005
0
l Testing fuel injection timing by delivery valve
methd
* Prepare new parts for the copper gasket and O-
ring of the delivery valve before starting the
operation.
1. Disconnect fuel injection pipe (1) of the No.1

cylinder.
2. Remove delivery valve holder (2). take out delivery

valve (3) and spring (4), then install delivery valve
holder (2) again.
3. Place the fuel control lever at the FULL position.

* For injection pumps with a stop lever set to the
OPERATION position.
4. Turn the crankshaft back 40 - 50° from top dead

center.
5. Operate the feed pump and rotate the crankshaft

slowly in the normal direction. Check the point
where the fuel stops flowing from delivery valve
holder (2).
197F402
6. Check that the fuel injection timing line on
crankshaft pulley (5) and pointer (6) are aligned at
the point where the fuel stops flowing.
j, BEYOND injection timing line: Timing RETARDED
+ BEFORE injection timing line: Timing ADVANCED
If the test shows that the fuel injection timing is

incorrect, adjust at the oblong hole of the flange
portion or at the oblong hole at the laminated
coupling.
7. Remove delivery valve holder (2), assemble delivery

valve (3) an spring (4) then install delivery valve
holder (2) again.
+ When assembling again, wash with fuel and be
careful not to let any dir dust stick to any part.
Sr Always replace the copper gasket and O-ring of
the delivery valve with new parts.
w Delivery valve holder: 11.5 & 0.5 kgm

Note: 14.0 + 1 .O kgm for the EPl 1 injec-
tion pump on the WD600.
8. Connect fuel injection pipe (1).
w Sleeve nut: 2.2 + 0.2 kgm
12-006
TESTING AND ADJUSTING ADJUSTING FUEL CUT SOLENOID
ADJUSTING FUEL CUT SOLENOID

l Continuous type (continuous when operating)
/3
2 Detail P 3
6162~201
7. Solenoid valve This fugure is for PC650-1, PC1500-I and EG480B-1

2. Stopper (FULL stopper pin) (-45°C). The linkage and the shape of stop lever may
3. Stop lever differ from that given here depending upon the machine
4. Rod in which the engine is mounted, however the adjusting
5. Return spring method is fundamentally the same.
6. Rod
8
Adjusting method
&
z 3) For EG550-1
1. Stop the engine and loosen the nuts of rod (4).
2. Adjust rod (4), so that the solenoid has a maximum Adjust rod (7) so that the there is length C of 31
stroke of 12 mm. to 32 mm.
Then, adjust rod (4) so that there is clearance A of
0.4 + 0.1 mm between injection pump stopper (2)
and stop lever (3), while pulling the rod to the RUN
position with hand.
3. Adjust the length of the return spring as follows.
1) 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 starting key and confirm that

solenoid 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 times, re-
confirm the amount of the stroke of the solenoid and
clearance A.
Tighten up the nuts of the rod.
12-007
0
SAGDI 70-A-1 (EG580B. EGGOOBS)
SAGDI 70-B-1 (EG480B. EG500BS)
1. Connect the solenoid and injection pump with the

rod.
When doing this, adjust so that the stop lever is
returned to a position 1 - 1.5 mm from the stop
pin at the FULL end, and so that the pump stop
lever is returned to a position 1.5 - 2.0 mm from
the STOP bolt (SAGD170-A-1) or limit position
(SAGDI 70-B-1 ) when the solenoid shaft is pushed
in fully by hand.
2. Pass electricity through the solenoid and check that

the solenoid moves smoothly. Turn the power ON/
OFF 2 - 3 times and check that there is no change
in the operating condition. If the movement is not
smooth, adjust the linkage to improve the
movement. --- Y u ‘--
6162F620
3. After checking that the operation is smooth, start

Stoip pin at
the engine, check that output is as specified, then FULL end
pass electricity through the solenoid and check that
the engine stops. (It must stop within 10 seconds.)
+ Problems caused by improper adjustment of solenoid.

Stop pin at
STOP end
-When electricity is passing, * Solenoid coil burns out
clearance between stop bolt (when solenoid is half pulled). Clearance
and lever is 0. - Injection pump governor 1.5-2.0mm
breaks or causes scuffing
(Excessive force is brought
to bear on lever).
6162F621
. When free, clearance between - Amount of fuel injected

stop lever and bolt at FULL drops, so engine output
side is too large (defective drODs.
linkage)
12-008
0
SA6D170-A-1 (EG5808-1 L)
1. Connect the solenoid and injection pump with the

rod.
When doing this, adjust so that the stop lever is
returned to a position 1 to 1.5 mm from the stop
pin at the FULL end, and so that the pump stop
lever is returned to a position 1.0 to 2.0 mm from
the STOP bolt (SAGD170-A-1) when the solenoid
shaft is pushed in fully by hand.

movement.

the engine, check that output is as specified, then
* Problems caused by improper adjustment of solenoid.
* When electricity is passing, - Solenoid coil burns out

clearance between stop bolt (when solenoid is half pulled).
and lever is 0. * Injection pump governor
(Excessive force is brought
to bear on lever).
stop bolt
- When free, clearance between - Amount of fuel injected
stop lever and bolt at FULL drops, so engine output
side is too large (defective drops.
linkage) F6161 A025
12-008-l
0
SA6D170-A-1 (EPSAGD170-A-1)
SAGD170-B-1 (EPSAGD170-B-‘l)
1. After pulling rod (1) to solenoid side by hand so

that stop-lever works while solenoid operates,
adjust the length of rod to become 1 .O to 1.5 mm
clearance between stop-lever (2) and stopper (3) of
fuel injection pump.

movement.

the engine, check that output is as specified, then
* Problems caused by improper adjustment of solenoid.
’ When electricity is passing, * Solenoid coil burns out 2

clearance between stop bolt (when solenoid is half pulled).
and lever is 0. - Injection pump governor
(Excessive force is brought Detail P
to bear on lever).
F6161 A026
12-008-2
co
PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE
SAGD170-A-I (HD465-3 l HD465-5)
1. Temporarily install a ball joint to the cable of the

engine stop motor to connect it to the injection
pump.
2. Pull the injection pump stop lever by hand to the

ENGINE STOP (NO INJECTION) position, and
temporarily intall ball joint (2) to the stop lever, then
secure the cable to bracket (1).
* The engine stop motor is delivered with the cable
pulled (engine stop).
* Stop lever (3) is at the operating position when
2
it is free (it is pulled to the operating position
by a built-in spring).
3. Adjust so that clearance A between the fuel

injection pump stop lever and the STOP stopper is
0.5 - 1.5 mm when the engine stop motor is
installed (when the engine is stopped).
Adjustment can be carried out by adjusting the
amount that the ball joint is screwed in.
4. After adjusting the clearance from the stoppers,

tighten all nuts and bolts.
z 5. Turn the engine starting switch ON/OFF several

z times to check that the engine stop motor operates
z smoothly. In particular, check that clearance A
between stop lever (3) and STOP stopper (4) is 0.5
- 1.5 mm when the engine is stopped. 569FlOl
* Limit switches are built into the engine stop
motor at both ends of the cable stroke.
* Check visually that there is slack in the engine
stop motor cable when the engine is running and
that the stop lever returns fully to the operating
position. The action of the spring built into the
fuel injection pump keeps it at the oting position.
* Problems caused by defective adjustment of the
engine stop motor cable
* Clearance between stop lever and STOP stopper * Engine does not stop.
istoo large when engine stop motor cable is
pulled.
* Clearance between stop lever and OPERATION * Engine output drops because of drop in
stopper is too large when cable is free. amount of fuel injected.
l Stroke of engine stop motor: 35 mm

l Stroke of fuel injection pump stop lever: 25 mm
12-009
@
S6D170-1 (WA600-1, WA700-1)
1. Temporarily install a ball joint to the cable of the

engine stop motor to connect it to the injection
pump.
2. Pull the injection pump stop lever to the ENGINE

STOP (NO INJECTION) position, and temporarily
install ball joint (2) to the stop lever. Then keep the
stop lever in contact with STOP stopper (4), and
temporarily install the cable to bracket (1) with 5
locknut (6).
Ir The engine stop motor is delivered with the cable
pulled (engine stop).
* Stop lever (3) is at the operating position when
it is free (it is pulled out the operating position
by a built-in spring). 4
3. In this condition, turn cable locknut (6) of bracket

(1) 2 turns (in the direction to push the stop lever
more against STOP stopper (4)) so that the stop lever
is pushed securely against the stopper.
* The movement for two turns is absorbed by the
loose spring mechanism inside the motor.
4. Tighten all nuts and bolts.
5. Turn the engine starting switch ON/OFF several

times to check that the engine stop motor and cable 6162F642
operate smoothly, then check the following points

again.
* Limit switches are built into the engine stop
motor at both ends of the cable stroke.
* Check that there is no clearance between stop
lever (3) and stoppers (4) and (5), both when the
engine starting switch is ON and when it is OFF.
l Stroke of engine stop motor: 35 mm
l Stroke of fuel injection pump stop lever:
30 mm
12-010
0
1. Remove retaining cap (1).
2. 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 pressure adjusted per 0.1 mm shim
thickness: Approx. 15 kg/cm2
w Retaining cap: 9 +_ 1 kgm
4. After adjusting the thickness of shims, check the

fuel injection pressure using nozzle tester.
6162F202
METHOD FOR INSTALLING (ADJUSTMENT) OF ENGINE
SPEED SENSOR
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 fly-
wheel.
-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
I SEE00059
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 ter-
mination of adjustment.
SEE00060
12-011-l
03
DATA FOR INJECTION PRESSURE ADJUSTMENT SHIMS
Shim thickness Shim thickness

Engine model Shim contour
(Range) (Interval)
S6D170-1 a = 4.5 mm
SAGDI 70-A-1 0.50 - 1.54 mm 0.02 mm
b=11.5mm
SAGDI 70-B-l
Part No. Thickness (mm) Part No. Thickness (mm)
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 50523-8400 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 50523-6000 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 50523-9200 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 50523-6800 0.86 DKI 50523-9600 1.42
DK150523-6900 0.88 DKI 50523-9700 1.44
DKI 50523-7000 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 50530-0100 1.52
DKI 50523-7400 0.98 DK150530-0200 1.54
DKI 50523-7500 1 .oo
DK150523-7600 1.02
DKl50523-7700 1 .04
TESTING AND ADJUSTING CALIBRATION DATA
CALIBRATION DATA
I 6162-73-1331 I ( EG550-1 1 12-022
I 6162-73-1332 I 1 EG550-1 I 12-022

6162-73-1333 EG550-1 12-022
SA6D170-A-1
6162-73-1334 EG550-1 12-022
6162-73-1341 EM680A 12-024-2
6162-73-1342 EM680A 12-024-2
I 6162-73-1343 I 1 EM680A I 12-024-T
I 6162-73-1350 I l EG550-1 (Extremecoldweather) I 12-021
12-013
0
Engine model Pump assembly No. Engine serialNo. Applicable machine Page
6162-73-1351 EG550-1 (Extreme cold weather) 12-022
6162-73-1372 HD465-3 12-024-3
I 6162-73-1410 I 1 WA700-1 I 12-02T

I 6162-73-1480 I l HD465-3 1 12-023
I 6162-73-1481 I l HD465-3 1 12-023
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,
SAGD170-A-1 1 6162-73-1571 I 1 WA700-1 1 12-023-3

I 6162-73-1572 1 1 WA700-1 / 12-023-3
6162-73-1612 EPSAGD170-A-1 12-0246
6162-73-1640 OEMfor marine 12-024-7

6162-73-1670 EM680A-1 12-024-8 8
z
6162-73-1682 EM680A-A 12-024-9 &
6162-73-1751 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 for stand by generator
I 6162-73-2370 I 1 PCIOOOSP-1 (for Layton) 1 12-023-5

6162-73-2410 EPSAGD170-A-1 12-024
6162-73-2411 EPSAGD170-A-1 12-024
6162-73-1560
WA600-1 (EC reguration) 12-016-I
SA6D170-AE-1 6162-73-1583 I
I I I
6162-74-1310 I DENYOgenerator DCAGOOSSK 1 12-030-11

6162-73-1151 10332-11045 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
6162-73-1254 1 EG450-1, EG480-1, EG500BS-1 12-027

SA6D170-B-1
EG450-1 (Extreme cold weather)
I 6162-73-1430
I EG480-1 (Extreme cold weather)
12-027
EG450-1 (Extremecoldweather)
6162-73-1431 12-027
EG500BS-1 (Extremecoldweather)
EG450-1 (Extreme cold weather)

6162-73-1432 12-027
EG500BS-1 (Extremecoldweather)
12-013-l
@
Engine model 1
8
Pump assembly No. 1
1
Engine serial No. 1
I
Applicable machine 1
I
Page
6162-73-1520 1 10332-13550 1 D375A-1 (Extreme cold weather) 1 12-025

6162-73-1711 EPSA6D170-B-1 12-030-3
6162-73-1743 OEM for generator 12-030-4
1 6162-73-1941 1 1 OEM for generator 1 12-030-5

1 6162-73-1942 1 1 OEM for generator
1 6162-73-1950 1 1 BEML D375 1 12-030-7
1 6162-73-2112 1 15524 and u p 1 D375A-2

1 6162-73-2120 I 11437 and u p 1 HD500-3, HD465-3C 1 12-029
6162-73-2133 PC1000-1 12-030

6162-73-2141 13551 - 15523 D375A-2 (Extreme cold weather) 12-028-1
1 6162-73-2142 I 15524 and UD I D375A-2 (Extreme cold weather) 1 12-028-2
1 OEM for generator
I OEM for generator
(Prime use)
EG500-1, EG500B-1, EG500BS-1 12-030-13
OEM for generator
OEM for generator
(Standby use)
6162-73-2380 OEM for generator 12-030-8
6162-73-2381 OEM for 6-pole generator 12-030-15
For M Q generator
SA6D 170AE- 1 6162-74-1310 12-030-16
DCA-600SSK
For M Q generator
DCA-500SSK
SAA6D170-1 6162-74-1750 SA6D170-M-1 1 OEM for generator (50 Hz) 12-030-10
6D170-1 SERIES
Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
S6D170-1 PEGZW DIESEL KlKl 6162-73-l 170 (106692-4030)...2
E%b’
Injection Timing
Unit Basis Allowance I

Counterclockwise viewed
Rotating direction
from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60” 59”30’to60”30’ Rated horsepower: HP/rpm 41 O/l 800
Plunger pre-stroke mm 2.4 23.5 to 24.5 I Maximum torque: kgm/rpm 215/l 200
Delivery valve
90 High idling: rpm 1,700 to 1800
retraction volume mm3
Low idling: rpm 600 to 700

Calibration Standard
r
Conditions Unit Manufacturer standard Service standard
(with nearly the same actual machine parts) (with calibration test parts)
Nozzle part no. (105015-5210) ( I

Nozzle holder part no. (105041-7020) ( 1
In ectron pope
mm 8~2.4~1400
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature “C 43 to 47
Nozzle opening pressure kg/cm2 255
Transfer pump pressure kg/cm2 1.6
ipecifications
Injection volume (cc/l OOst) Injection volume(cc/ st)
for manufacturer standard for service standard
Rack Pump Maximum Maximum

Basis variance variance
yrooion speed Allowance Basis Allowance
between between
(rpm)
cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 11.4 800 29.4 28.9 to 29.9 21.18
’ Rack positions B 5.8 335 5.1 * 4.6 to 5.6 20.51 *

B to E are the refer-
ence volume when C * *
adjusting the injec-
tion volume. D * *
l Marks * are aver-
age volumes. E * *
Ziovernor performance
L Pump speed (rpm)
Numbers in parentheses are pump manufacturer part numbers.

Pump Assembly Number Applicable Machine Applicable Engine
6162-73-1171 (106692-4034)
Model Serial No. Model Serial No.
( ): Manufacture’s part No.
PC650-1 S6D170-1
PC1500 S6D170-1
Injection Timing Engine Specification

Rotating direction Rated horsepower (kw(HP)/rpm) 306(410)/1,800
from drive end
Injection order l-5-3-6-2-4 Maximum torque (Nm(kgm)/rpm) 2108(215)/1,200
Injection interval 60” (59”30’ to 60”30’) High idling (rpm) 1,700 to 1,800
Plunger pre-stroke (mm) 2.4 (23.5 to 24.5) Low idling (rpm) 600 to 700
Delivery valve Pump tester capacity
retraction volume (mm’/st) 90 Motor: 7.5 KW
for Service standard
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
Rack positions
B to E are rhe ref-
erence volume
when adjusting rhe
injection volume.
Govern& perfomance
Governor springset
325 335 775+25 BIJo:;:
Pump speed Wpm)

6162FZO3B
1Z-01 4-1
0
Pump Assembly Number
6162-73-1580 (1066924352) I Applicable
Model
Machine
Serial No. Model

Applicable Engine
Serial No.
6162-73-I 590 (I 066924410)
( ): Manufacturer’s part No.
WA600-1 10001 and up S6D170-1 10490 and up
Injection Pump
Pump Type Manufacturer WA600- 1 c 10001 and up
1 PES-6PD 1 DIESEL KIKI 1 I II II II I

1 I I I I
Injection Timing Engine specification
Rotating direction
Counterclockwise
viewed from drive end
Rated horsepower HP/rpm 41512000 1
Maximum torque kgm/rpm 200/l 400
High idling rpm 2200 to 2300
Low idling rpm 650 to 700

I I
r I
Delivery valve
wtmctinn vnhlmo mm3/st I Pump tester capacity
for Service standard I
Motor 7.5 KW
I
Conditions Service standard Manufacturer standard

- Service standard
Nozzle part no. (105015-5210)
indicates data (I 05780-0050)
using calibration Nozzle holder part no. (I 05780-2090) (I 05041-7020)
test parts.
* Manufacture Injection ipe
(C/D x l/g x length) mm 8 x 3 x 600 8~2.4~1400
standard is data
for factory test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature OC 43 to 47
Nozzle opening pressure kg/cm* 175 300

Transfer pump pressure kg/cm* 1.6 1.6
Injection volume Service standard (cc/ 100 st) Manufacturer standard (cc/ 100 st
Rack Pump
Rack
position speed Maximum Maximum
point
(mm) (rpm) Basis Allowance )$!$$E Basis Allowance variance
between
cylinder cylinder
Rack positions
Each cyl. 24 7 Each cyl.
B to E are the refer- Basic point 11.4
ence volume when ‘Ooo 28.05 27.55 to 28.55 - ’
adjusting the injec- A
B %r?o 350 3.93 *3.43 to 4.43 kO.393 4.7 *
tion volume.
Marks l are aver- C * *
age volumes.
D * *
E * *
Governor performance (350 - 1000 rpm)
I II II II
0
3 3 t.25
iJ.7 750;;;Jo P;:;,25
+10
Pump speed (rpm) FORM NO. SEBH4567
12-015
0
Injection Pump Assembly Number
Applicable Machine Applicable Engine
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) Model Serial No. Model Serial No.
( ): Injection Pump Manufacture’s part No.
S6D170-1
S6D170
Injection Pump Specification Engine Specification
Plunger prestroke (mm) 2.35 - 2.45 Low idling speed (rpm) 650 - 700
retraction volume (mm’h) 90 Motor: 7.5 kW
Calibration Standard 1 1 : lnjenction pump manufacture’s part number
Service standard
indicates data
using calibration
test pa ITS.
Manufacture
standard is data
test parts.
curve (350 - 1,000 rpm)
/ i,
0 350 \ 700 /\1125+25

450'-25 (580) (g75)'201000~;~
Pump speed (rpm)
12-016
0

6162-73-1560 (106692-9231)
6162-73-1583 (I 06692-9002)
Injection Injection Pump
Pump Type Manufactuer
PES-PDX ZEXEL
Injection Pump Specification Engine Specification (Without fan)

Counterclockwise viewed from Flywheel horsepower
Rotating direction 32112,000 {430/2,000}
drive end (kWiHPYrpm)
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgmI/rpmi 2,010/1,400 {205/1,400)
Injection interval 59” 30’ - 60’ 30’ High idling speed Irpm) 2,200 - 2,300
retraction volume (mm”st) 90 Motor: 7.5 kW
test parts.
Injection volume injection volume

Rack positions
B to E are the ref-
ernce volume
when adjusting the
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
@
6162-73-2150 (106682-4540)
6162-73-2151 (106682-4790)
6162-73-2160(106682-4670) Model Serial No. Model I Serial No.
( ):Injection Pump Manufacture’s part No.
Pumo Tvoe I Manufactuer
ZEXEL
I I
Injection Pump Specification Enaine Soecification

Rotating direction 302/l ,800 (404/l ,800)
drive end (kW{HPYrpm)
Injection order 1-5-3-6-2-4 Maximum torque (NmIkgmYrpm) 2,079/1,300 I212/1,3001
1 Injection interval 59’ 30’ - 60’ 30’ 1 High idling speed (rpm) I 1,960 -2,040 I
1 Plunger prestroke (mm) 1 3.15 - 3.25 Low idling speed (rpm) 600 - 660

I retraction volume (mm’istj I 120 Motor: 7.5 kW
Calibration Standard ( ) : lnjenction pump manufacture’s part number
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
Governor perfomance curve (325 - 900 rpm)
12-016-2
0
6162-73-2231 (191000-3930)
WA600-1 S6D170-1
Rotating direction Counterclockwise viewed from drive end Rated horsepower HP/rpm 41512,000 I
1 Injection order I I-5-3-6-2-4 I
Plunger pre-stroke mm 3.2

Pump tester capacity
Motor 7.5 KW
F%ZX,V!,V~ ,mO mm3/st 120 for Service standard

* Service standard
indicates data
using calibration Nozzle holder part no. (093100-0951)
test parts.
Injection ipe
. Manufacture 6x2.2x650
(O/D x l/g x length) mm
standard is data
Nozzle opening pressure kg/cm’ 250

Transfer pump pressure kg/cm* 2.0
Injection volume Service standard (cc/ 100 st) Manufacturer standard (cc/ st
Rack Pump
Rack
position speed Maximum Maximurr
point
(mm) b-pm) Basis Allowance pig!‘, Basis Allowance variance
between
cylinder cylinder
- Rack positions 23 o Each cyl. Each cyl.
6 to E are the refer- Basic point 12.3 1000 . Max. 1.0
ence volume when 22.5 to 23.5
adjusting the injec- *
B 13.4 700 27.1 * 26.6 to 27.6 Max. 1 .O
tion volume.
- Marks * are aver- C L6.71 340 5.0 * 4.8 to 5.2 Max. 1.0 *
age volumes.
D * *
E * *
Governor performance ( 340 - 1000 rpm)
300 1025+10
Pump speed (rpm) SEBH4634
12-017
0
6162-73-2241 (191000-4260) Applicable Machine Applicable Engine
6162-73-2242 (191000-4262)
6162-73-2243 (191000-4263) Model Serial No. Model Serial No.
WD600-1 S6D170-1

Rotating direction 339/2,000 I454/2,000}
drive end (kW{HPI/rom)
Calibration Standard ( ) : lnienction oump manufacture’s Dart number

Service standard Nozzle & Nozzle holder part No.
indicates data
Nozzle part No. (093400-1800)
using calibration
test parts. Nozzle holder part No. (093100-0951)
Manufacture Injection pipe
6 X 2.2 X 650
standard is data (Outside dia.x Inside dia.x Length ) (mm)
for factory lest oil ASTM D975 No.2 diesel fuel or equivalent
test parts.
Oil temperature 1°C) 40-45
Nozzle opening pressure (MPa{kg/cm’}) 24.5 I2501
Transfer pump pressure (kPaIkg/cm’)) 196 (2.01
njection volume Service standard (cc/l,000 st) Manufacturer standard (cc/1,000 st)
Rack Rack Pump
point position speed Max.imum Maximum
(mm) (mm) Injection volume g”,G$E Injection volume ~~~~~~
Rack positions
cylinder cylinder
B to E are the ref-
ernce volume A(Basic point) 12.8 1,000 245 - 255 Max. 2.5
when adjusting the
injection volume. , B 13.6 700 27.8 - 28.8 Max. 2.8
Marks * are C 6.7 300 48-52 Max. 0.5
average volumes. D
E
Governor perfomance curve (300 - 1,000 rpm)
12-018
0
Injection Pump Assembly Number Applicable Machine Applicable Engine
6162-73-2251 (191000-4620)
WD600-1 S6D170-1

Counterclockwise viewed from
Rotating direction
drive end
339/2,000 I454/2,0001 1
Injection order l-5-3-6-2-4 2,089/1,400I213/1,400~ 1

Injection interval 59’ 30’ - 60” 30’ 2,200 - 2,300 I
retraction volume (mm’/stj 120
Motor: 7.5 kW
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
Pump speed (rpm)

6162-73-2260 (191000-4630)
WA600-IC S6D170-1
Rotating direction Counterclockwise viewed from drive end Rated horsepower HP/rpm 4 15/2,000
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 200/I ,400
High idling rpm 2,200 to 2,300

Injection interval 60” f 30’
Plunger pre-stroke mm 3.2 I

Motor 7.5KW
!%e+?%!~,m~ mm3/st 120 for Service standard
I

*Service standard
Nozzle part no.
indicates data (093400-I 800)
using calibration Nozzle holder part no. (093100-0951)
test parts.
* Manufacture Injection ipe
(O/D x l/g x length) mm 6 x 2.2 x 650
standard is data
Nozzle opening pressure kg/cm’ 250

Transfer pump pressure kg/cm’ 2.0
Injection volume Service standard (CC/ 100 St) Manufacturer standard (cc/ st
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance rer!$$E Basis Allowance between
cylinder cylinder
- Rack positions Each cyl. Each cyl.
B to E are the refer- Basic point 12.3 1000 23.0 Max. 1.0
ence volume when 22.5 to 23.5
adjusting the injec- B *
tion volume. 13.4 700 27.1 *26.6 to 27.6 Max. 1.0
- Marks are aver-
l
C Le.71 340 5.0 * 4.8 to 5.2 Max. 1 .O *
age volumes.
D * *
E * *
300 1025210
Pump speed (rpm) SEBH4635X
6162-73-1192 (106692-4980)
Model *Serial No. Model Serial No.
D155 (BEML) S6D170-1
I I I
lniection Puma, Soecification Enoine Soecification (Without fan)

Rotating direction drive end
247/2,000 {331/2,000}
(kWWWrpm)
Injection order l-5-3-6-2-4 Maximum torque (NmIkgmYrpm) 1,442/1,400 {147/1,400~
1 Injection interval 1 59” 30’ - 60” 30’ I 1High idling speed (rpm) I 2,150 -2,250 I

90 Motor: 7.5 kW
retraction volume (mm3M for Service standard
(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 ref-
ernce volume
when adjusting thl
injection volume.
Marks * are
average volumes.
18’:
Rack limit : IO. O+~.'mm
0 325 750+20
(9;
12-020-l
0
6162-73-1163 (106692-4970)
( 1:Injection Pump Manufacture’s part No.
D355 (BEML) S6D170-1
injection Pump Specification Engine Specification (Without fan)

Rotating direction
drive end
Injection order l-5-3-6-2-4
Injection interval 59’ 30’ - 60” 30’
Plunger prestroke (mm) 2.35 - 2.45

Delivery valve
retraction volume (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 stroke
0 Boost Pressure (kPaImmHs1)

410f20 720f50 900:::
12-020-2
0
6162-73-1212 (106692-4110) 6162-73-1214(106692-4113)
6162-73-1213 (106692-4111)6162-73-1215(106692-4990)
OEM for S6D170-1
generator

Counterclockwise viewed from Flywheel horsepower 329 I441~/1,500 (50 Hz)
Rotating direction (kW{HPl/rpm) 380 I509M1,800 (60 Hz)
drive end
‘~,‘~i
Maximum torque (NmIkgmMrpm)
Calibration Standard 1 ) : lnienction 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 ref-
ernce volume
when adjusting the
injection volume.
Marks * are C
average volumes. D
E
18+;l,,,,,,l,,,Tk limit :l4. 8:0"mm
le sub
'ring set:
3-t,smm
0 400 / 75OtlO \ Max. 945

Min. 500 900’b0
12-020-3
0
6162-73-1721 (106692-4372)
Model Serial No. Model I Serial No.
( 1: Injection Pump Manufacture’s part No.
EPS6D170-1 S6D170-1
ki

Rotating direction
drive end
Injection interval 59” 30’ - 60” 30’
Plunger prestroke (mm) 2.35 - 2.45 Low idling speed (rpm) 600 - 1,000
retraction volume (mm”sr) 90 Motor: 7.5 kW
Calibration Standard ( ) : lnienction oumo manufacture’s Dart number
Conditions I Service standard Manufacturer standard

Service standard Nozzle & Nozzle holder part No. (105780-8130) 6162-13-3300 (105111-4020)
indicates data
using calibration Nozzle part No. (105780-0050) 6162-13-3320 (105015-5210)
test parts. Nozzle holder part No. (105780-2090) 6162-13-3110 (105041-7020)
8X4X600 8X2.4X1.400
for factory Test oil ASTM D975 No.2 diesel fuel or equivalent
test parts.
Oil temperature (‘0 I 40 - 50
Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
Marks * are
Rack I imi t : (R,t 14. 9) ‘t’mm

18’:
400750 I 900% \
(8401 240 990+25
Pump speed (r pm) TWE00611
12-020-4
0
6162-73-1733(106692-9020)
( ): lniection Pumo Manufacture’s Dart No.
OEM for S6D170-1
Injection Injection Pump generator
1 PE-P DX 1 ZEXEL I
I
Injection Pump. Specification

_ Enqine Specification (Without fan)
Counterclockwise viewed from Flywheel horsepower 351 {47OYl,500 (50 Hz)
Rotating direction
drive end MWHPHrpm) 386 {517Y1,800 (60 Hz)
I
Injection order 1-5-3-6-2-4 Maximum torque (Nm{kgmI/rpm)
Injection interval 59” 30’ - 60’ 30’

1 I

retraction volume (mm’/st) Motor: 7.5 kW
Calibration Standard ( 1: lnjenction pump manufacture’s part 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
I imi t : 16+~*mm
i a’:
sDrin9 set:
hii n. 7. 3
E
E
.-S
.-_
5.8
5. 3
z
_
400 / 750flO 900’:

Min. 500
12-020-5
0
6162-73-2222 (191000-3922) I
D275A-2 S6D170-1
Injection Pump
_ Specification
_ Enoine Soecification (Without fan)
Rotating direction 302/1,800 {404/1,800}
drive end WG-Wrpm)
Injection order l-5-3-6-2-4 Maximum torque (Nm{knmI/rom) 1,981/1.300 I202/1.300}
Calibration Standard ( 1 : lnjenction pump manufacture’s part number
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
Rack positions
Governor perfomancecurve
16
14
12
< 10
; 8
z
.- 6
E
:: 4
2 ( R., Pul I ino start Point)
2
0 2 4 6 a IO 12
12-020-6
0
Injection Pump
EG550- 1 SAGD170-A-l PEGZW DIESEL KIKI 6162-73-l 330 (I 03662-2140). 4
6162-73-I 350 (103662-2770). 1
Injection Timing
Unit Basis Allowance
Rotating direction
from drive end
injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
injection interval 60” 59”30’ to 60”30’
Plunger pre-stroke mm 3.8 3.75 to 3.85 ~1

I
Delivery valve
120
retraction volume mm3
Low idling: rpm Approx. 800

Manufacturer standard Service standard

ionditions Unit
Nozzle part no. (105015-5140) ( 1
Nozzle holder part no. (I 05041-7020) ( )

In ectron rpe
mm 8x2.4x 1400
(d/D x l/8x length)
ipecifications
Injection volume (cc/l OOst) Injectionvolume(cc/ St)
Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (mm)
cylinder cylinder
basic point 18.4 875 52.0 51.5 to 52.5 t2.08
Rack positions B 7.8 400 6.8 * 6.3 to 7.3 20.95 *

tion volume. D * *
Marks * are aver-
age volumes. E * *
iovernor performance
Pump speed (rpm)
GNumbers in parentheses are pump manufacturer part numbers

Injection Pump
EG550-1 SAGDI 70-A-1 PEGZW DIESEL KlKl 6162-73-1331 (103662-2290) .... 1
6162-73-1332 (103662-2292)
6162-73-1333 (103662-3050)
6162-73-1334 (103662-3051)
6162-73-1351 (103662-2300) . .. 1
6162-73-l 352 (103662-2302)
Injection Timing 6162-73-1353 (103662-3210)
6162-73-1354 (103662-3212)
Unit Basis Allowance
Rotating direction
from drive end
Specification for engine with fan (reference only)
Low idling: rpm 700 to 900


Conditions Unit
Nozzle part no. (105015-5140) ( 1

In ectron rpe
mm 8~2.4~1400
Cd/D x t/$x length)
Nozzle opening pressure kg/cm* 300
Specifications
Injection volume (cc/l OOst) Injection volume(cc/l OOst)
Maximum Maximum
Rack Pump
variance variance
osition rgrnd Basis Allowance Basis Allowance
between between
Pmm) cylinder cylinder
basic point 18.4 875 52.0 51.5 to 52.5 k2.08
l Rack positions B 7.8 400 6.8 * 6.3 to 7.3 kO.95 *

6 to E are the refer-
tion volume. D * *
l Marks * are aver-
age volumes. E * *
Sovernor performance
M,n26
Pump speed (rpm)
Numbers in parentheses are pump manufacturer part numbers
12-022
0
6162-73-1480 (103662-2870)
HD465-3 SAGD170-1
I Injection
Pump Type
Pump
Manufacturer I w/Single turbo 10794 and up
PE-6ZWX DIESEL KIKI w/Twin turbo 10851 and LID

Counterclockwise Rated horsepower HP/rpm 730/2,100
Rotating direction
viewed from drive end I
1 Maximum torque kgm/rpm 1 288/l ,400 I
1 High idling rpm I 2,250 to 2,3501
Injection interval 60” + 30’
1 Low idling rpm I 850 to 900 I
Plunger prestroke mm 3.8 + 0.05
Delivery valve
retraction volume mm3/st 120 I Pump tester capacity
for Service standard I Motor 7.5 KW
I

- Service standard
Nozzle part no. (105780-0050) 6162-13-3420 (105015-6140)
indicates data
using calibration Nozzle holder part no. (105780-2090) 6162-13-3110 (105041-7020)
test parts.
Injection ipe
* Manufacture (O/D x l/g x length) mm 8x4x 1500 8~2.4~1400
standard is data
Nozzle opening pressure kg/cm’ 175 300
Transfer pump pressure kg/cm’ 1.6 1.6
Injection volume
Pump Service standard (cc/ 100 St) Manufacturer standard (cc/ 100 st
Rack
Rack
point variance
(mm) h-pm) Basis Allowance yJE’$, Basis Allowance between
cylinder cylinder
- Rack positions 48 3 Each cyl. Each cyl.
B to E are the refer- Basic point 15.3 1050 . 51.932 40.0
ence volume when 47.8 to 48
adjusting the injec- Approx.
B 7.3 425 5.17 * 4.67 to 5.67 kO.723 4.5 *
tion volume.
- Marks * are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 425 - 1050 rpm) Boost compensator performance (650 rpm)
Line 0: At boost pressure x or llMre
0
Line 0, : At boost pressure :Y Or 1eSS
Point 0: Adjust low idling at no boost pressure
Point 0: Idling sub spring set point
Pump speed (rpm)
SEBH 4502-l
’ 2-:23
I
6162-73-1462 (103662-3023)
( 1: Manufacturer’s part No.
HD465-3 SA6D170-A-1 ‘:;$;;io?p
Injection Pump
Pump Type Manufacturer (Single turbo)
11683 and up
PE-6zWX DIESEL KIKI

Rated horsepower HP/rpm / 730/2100
Plunger pre-stroke mm 3.8 f 0.05

Delivery valve Pump tester capacity for
120 Motor 7.5 KW
retraction volume mm3/st Service 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 ref-
erence volume
when adjusting
volume.
1Marks * are aver-
age volumes.
Governor performance (425 - 1050 rpm) Boost compensator performance (650 rpm)
Stop lever 17. 5+1'6mm

Min.26 Rack limit 16. 5*:.'mm
Or more
Boost comoensator stroke 15.9
4. 4fo.lmm z
L
Z C
E .o
g
.- 15.3 '5
I Min. 8. 8 g
Z Or more +z 11.5
a
2
1. 3
z 6.2
0 70+10 (340)
Boost pressure (mmHg)
I. lM.1
0
720flD 1050:::
Pump speed (rpm)

TKE00124
12-023-l
0
6162-73-1510 (103662-3182)
( 1: Manufacturer’s part No. SA6D170-A-1
HD465-5
I lniection I Pumo
IInjection Timing Engine specification
Rotating direction Counterclockwise viewed

from drive end
Injection interval 60” * 30’
Plunger pre-stroke mm 3.8 + 0.05

I
Delivery valve Pump tester capacity for
120 Motor 7.5 KW
retraction volume mm3’st Service standard
Service standard
indicates data
using calibration
(Nozzle, Nozzle
holder and injec-
Manufacture
standard is data
using factory test
(For reference)
Rack positions
B to E are the ref-
erence volume
when adjusting
volume.
Marks * are aver-
age volumes.
Stop lever 18. 5’8 ‘mm

Rack I imi t 17. 9’8 ‘mm
Boost compensator stroke

17.4
4. 4*O-lmm
13.0
;i
(70) (34OIf20
Pump speed (rpm)

TKEO0125
SEBH4881
12-023-2
0
6162-73-1410 (103662-3260)
6162-73-1571 (103662-3101)
WA700-1 SA6D170-A-1

drive end MW-Wrpm)
Injection order l-5-3-6-2-4 Maximum torque (NmIkgmYrpm) 2,810/1,400 {286.5/1,400}
Injection interval 59’ 30’ - 60” 30’ High idling speed @pm) 2240 - 2300
retraction volume (mm’/st) 120 Motor: 7.5 kW
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.
Governor perfomancecurve Boost compensatorperformancecuve
0 12. 01901 41.3(3101

Boost pressure (kPa{mmHaI )
450+20 950+30 1135+25

12-023-3
0
6162-73-1751 (103662-2911) I Applicable Machine I Applicable Engine
:;$;:;$I;;;; [;;$:gf::8:81 Model Serial No. Model Serial No.

EG550-1 SAGD170-1 11500 and up
EG580B-1 L SA6D170-A-1 14173 and up

1 I I

Counterclockwise 633/l ,500 50 Hz)
Rotating direction Rated horsepower HP/rpm 731/1,800 60 Hz)
Maximum torque kgm/rpm -
Max. 1,560 50 Hz
High idling rpm Max. 1,872 60 Hz
Injection interval 60’ +_30
Plunger pre-stroke mm 3.8 + 0’.05

Delivery valve Motor 7.5 KW
120 for Service standard
retraction volume mm3/st

Service standard
indicates data
Nozzle part no. (105780-0050) 6162-13-3420 (105015-6140)
test parts.
Injection ipe
Manufacture 8x4x 1,500 8 x 2.4 x 1,400
(O/D x I/! x length) mm
standard is data
Oil temperature “C 43 to47

Transfer pump pressure kg/cm2 1 .6 1.6
njection volume Service standard 100 st) Manufacturer stand
Rack positions
ence volume when
tion volume.
Marks l are aver-
age volumes.
E I I I*
Zovernor performance (400 - 900 rpm)
26 or
ITOE
Rack limit18.9’oo*mm
0 400 500 750t10 goo:o

or more
Pump speed (rpm)

SEBH4806
12-023-4
0

6162-73-2370 (106682-9290)
Pc1ooosP-1 SA6D170-A-1
(for LAYTON)

Rotating direction
drive end
Injection interval 59’30’ - 60”30’

Delivery valve
retraction volume (mm’/st)
tConditions Service standard Manufacturer standard

. Service standard Nozzle & Nozzle holder part No. (105780-8130) 6162-13-3702 (105111-4142)
indicates data
Nozzle part No. (105780-0050) 6162-13-3720 (105015-6700)
using calibration
8X4X1,000 8X2.4X1,450
standard is data (Outside diaxlnside
dia.x
Length) (mm)
for factory Test oil ASTM D975 No.2 diesel fuel or eauivalent
test parts.
Injection volume
Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
‘Marks are
average volumes.
Governor perfomance curve Boost compensator performance cuve
Rack limit :la. O-la. 2 (mm)

Idline sub sprins set
Governor sprins set
I I / / TBoost compensator stroke :3. l-3. 3 (mm)
17. 5
16. 7
10. I
(mm t .I
0 6. 6-12. 0 39. 3-48.7

(50-901 ~280-3801
Boost pressure LkPaImmHaI)

0 300 335 720 / \915-965
785-835 895-905
Pump speed (ram)

TWE00728
12-023-5
@
6162-73-2410 (106682-4652)
( ): Manufacturer’s part No. EPSAGDl70-A-1 SAGD170-1
Injection Timing Enaine SDecification
Rotating
Injection
direction
order
Counterclockwise
l-5-3-6-2-4
1 1 Rated horsepower
Maximum torque
HP/rpm
kgm/rpm
) 590/
270/l
1800
300
I
High idling rpm 1950 to 2050

Injection interval 60° -I- 30’
1 Low idling rpm I 750 to 850 I
Plunger pre-stroke mm 3.2 f 0.05
mms/st 120 for Service standard
retraction volume
) Service standard
indicates data
using calibration
test parts.
1Manufacture
standard is data
for factory test.
1Rack positions
B to E are the ref-
erence volume
when adjusting the
injection volume.
1Marks * are aver-
age volumes.
Governor performance
ernor s~lina set

Idling sub splins set
= 16.9
E
z
z
.-
p:
_
3 6. 5
6. 3
385 30 0:::
Pump sDeed (rpm)
TKE00128
12-024
0
6162-73-1320 (103664-1321)
EG600BS-1 SA6D170-A-1
OEM for
generator
Injection Pump_ Specification

. Engine Specification (Without fan)
Counterclockwise viewed from Flywheel horsepower 477 {639H1,500 (50 Hz)
Rotating direction drive end (kW{HP}/rpm) 531 ~712)/1,800 (60 Hz)
Injection order l-5-3-6-2-4 Maximum torque (NmIkgmYrpm) -
I I I 1
Max. 1,560 (50 Hz)
Injection interval 59’ 30’ - 60’ 30’ High idling speed (rpm) Max. 1,872 (60 Hz)
1 Plunger prestroke (mm) 1
I
3.75 - 3.85 1 1Low idling speed
I I
(rpm) I
I
700 - 900 I
I
retraction volume (mm’/st) Motor: 7.5 kW
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 C
average volumes. D
E
12-024- 1
0
Injection
6162-73-1341
Pump Assembly
(103662-2821)
Number
I Applicable Machine Applicable Engine
6162-73-1342 (103662-2822)
6162-73-1343 (103662-3070) 1 zdA / Serial No. / ,A~~~‘,_, 1 Serial No.
( ):lniection Pump Manufacture’s part No.
I PE-ZWx I ZEXEL I I I I

Rotating direction
drive end
Injection order 1-5-3-6-2-4
Plunger prestroke (mm) 3.75 - 3.85 Low idling speed @pm) 600 - 650
retraction volume fmmVst) 120 Motor: 7.5 kW

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.
I I I
Rack I imi t : 20’:“mm
P
Min. 26
W V
0 300 1000:::\
1080f25
-I2-024-2
0
6162-73-1372 (103662-3080)
HD465-3 SA6D170-A-1
(with single
turbocharger)

Rotating direction Counterclockwise viewed from
drive end

Delivery valve
retraction volume (mmyst)
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 15. 9
E 15. 3
Min.8.8 E
E
.-
2 .-z
a
.-
: 7. 3
z
Ix
6. 2 c 13.9
:
CL
0 21. 3f2. 7 48. olt6.7
I I (160&20) (360f50)
I. lf0. 3 L
I Boost Pressure (kPs {mmHg] )
0 425 720+30 1050:::\
aoof30 1150+25
12-024-3
0
Injection Pump Assembly Number Applicable Engine
Applicable Machine
6162-73-1531 (103662-3130) I I I I
I Model 1 Serial No. 1 Model 1 Serial No.
OEM for BRO SA6D170-A-1
I PE-ZWx I
ZEXEL
I
njection Pump Specification Engine Specification (Without fan)

Rotating direction 552/2,000 {740/2,000)
drive end (kWIHPI/rpm)
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgmMrpm) 3,030/1,400 {309/1,400~
Injection interval 59” 30’ - 60” 30’ High idling speed &pm) 2,150 - 2,250

120 Motor: 7.5 kW
retraction volume (mm”st) for Service standard
Calibration Standard I 1 : lninnctinn ntlmn manllfxtttre’s nart 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. 2)':"mm

Boost compensator
stroke:
;; (16. 7)
E
0 21.3k2.7 48. 0f6. 7

~160~201 1360*503
Boost Pressure (kPa{mmHe))

0 400 720f20 IOOO::!
(815) llOOYc25
12-024-4
0
Applicable Machine I Applicable Engine
6162-73-1550 (103662-3090)
I Injection
Pump Tvpe I
Injection Pump
Manufactuer I
I PE-ZWx ZEXEL
I

Rotating direction 386/2,100 {518/2,100~
driveend (kWU-R/rpm)

I I I I I
retraction volume (mm’/st) 120 Motor: 7.5 kW
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
Rack limit :17't'mm

Boost
Min.26 compensator stroke ~2. OfO. lmm
Adapter spring
is not actuated
16. 5
-z
E
z
z
-G
4 14.5
:
Dz
0 21. 3f2. 7 48. 0f6. 7
(160*201 (360f501
Boost pressure (kPaImmHa1)
0 425 1050:::\
1150525
12-024.
6162-73-1612 (103662-3110)
EPSAGD170-A-1 SA6D170-A-1

Rotating direction 534/2,000 {715/2,000)
drive end N’WWrpm)
Injection order l-5-3-6-2-4 Maximum torque INmIkgmYrpm) 2,922/1,400 {298/1,4001
1 Injection interval 59” 30’ - 60’ 30’ II High idling speed (rpm) FM-
retraction volume (mm3’st) 120 Motor: 7.5 kW
Calibration Standard 1 1: lnjenction pump manufacture’s part number

lConditions
- Service standard
indicates data
using calibration
test pans.
pManufacture
standard is data
for factory
test parts. An-d*
-
* Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
5Marks * are
average volumes.
Min. 26
Supplied as adapter
spring is not actuated
1I 2-024-6
0
6162-73-1640 (103662-3170)
OEM for marine SA6D170-A-1

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 C 15.7 - 15.9 100 330 -
average volumes. D
E
Governor petfomance curve
Min. 26
Rack limit: 15. 7*f'mm
h,
//I//.,//
C
A
(15. 2)
-z 10.7
E
- 7.7
z
.-
.-
p (5.6)
:
PI
0 300 1000:::
Pump speed (rpm) 1075f.25 TWE00626
12-024-7
0
6162-73-1670 (103662-3230) I I
EM680A-1 SA6D170-A-1

Rotating direction 55212,000 {740/2,000}
drive end (kWW/rpm)
Injection order l-5-3-6-2-4 Maximum toraue (Nm{kamYrom) -
Injection interval 59” 30’ - 60” 30’ High idling speed (rpm) 2,100 - 2,200
I I
retraction volume (mmyst) 120 Motor: 7.5 kW

tConditions I Service standard Manufacturer standard
.* Service standard Nozzle & Nozzle holder part No. (105780-8130) 6162-13-3901 (105111-4350)
indicates data
Nozzle part No. (105780-0050) 6162-13-3921 (105015-8330)
using calibration
test parts. Nozzle holder part No. (I 05780-2090) 6162-13-3710 (105041-7060)
*Manufacture Injection pipe
(Outside dia.x Inside dia.x Length ) (mm)
8X4X1,500 8X2.4X1,400
standard is data
test parts.
Oil temperature (“C) 40-45
Nozzle opening pressure (MPaIkg/cm’}) 17.2 1175) 29.4 {300}
Transfer pump pressure (kPa{kg/cm’}) 157 Il.61 157 11.6)
njection volume
Service standard (cc/l,000 st) Manufacturer standard (cc/l,000 st)
Rack Rack Pumo
point position speed Maximum Maximum
(mm) (rpm) Injection volume ~~~~~~ Injection volume ~~J~~~
Rack positions
cylinder cylinder
B to E are the ref-
ernce volume A(Basic point) (15.2) 1,000 395 - 405 Max. 32
when adjusting the
injection volume. B Approx. 7.7 300 40-50 Max. 12.6
Marks t are C (15.7) 100 (300) -
average volumes. D
Rack limit : (15. 7)‘:‘* mm

/
Min. 26 Boost
compensator stroke :4fO. 1mm
/
C
115. 2) E
E
E
: (5. 6)
I
0
2 5 -------i
0 24. 0:::: 48. Of6. 7
{ 18 0:::1 (360*50)
._
Boost pressure (kPa(mmHej)
107&25
12-024-8
0
6162-73-1682 (103682-0470)
EM680A-A SA6D170-A-1
Enaine SDecification (Without fan)
~1 Counterclockwise viewed from Flywheel horsepower

(kW{HPMrpm)
Maximum torque (NmIkgmllrpm)
High idling speed (rpm)

629/2,000
3.295/1,400
{842/2,0001
I336/1,400}
2,100 - 2,200
1 Plunger prestroke (mm) 1 3.75 - 3.85 I Low idling speed @pm) 550 - 600
I

120 Motor: 7.5 kW
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
Injection volume Injection volume

Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
Marks * are
average volumes. D
E
Min. 26
Rack Iimit:17’~‘mm
;h_ /
/////.‘/// /I
;16. 5
211.1-
.-z
; &’
a
$ 6.5
0 300 1000:::\
Pump speed (r pm) ‘075f25 TWE00629
12-024-9
0
6162-73-1670 ( 103662-3230)
( ): Injection Pump Manufacture's part No.
P U ~TDv ~ e Manufactuer
. .
Infection Pumo Soecification Engine
- Specification (Without fan)
Flywheel horsepower
Rotating direction Anticlock wise (kW{HP)/rpm)
6721{go01 I2100
1 Injection order --
I 1-5-3-6-2-4 1 IMaximum torque (~m{kgml/rpm)l - 1
Injection interval 59" 30' - 60' 30' High idling speed (rpm) 2,250 - 2,350
I I
Delivery valve 120 Pump tester capacity
[retraction volume (mm31st)l f n r SP~VICPstanc1arfi
Calibration Standard ( ) : Inienction D U ~ manufacture's

D art number
ionditions Service standard Manufacturer standard

Service standard Nozzle & Nozzle holder part No.
indicates data
Nozzle part No. (105780-0050)
using calibration
test parts. Nozzle holder part No. (105780-20901
Manufacture Injection pipe 8X4X1.500
standard is data (Outsidedia.x Inside dia.x Length 1 (mm)
test parts. Oil temperature (OC) 40 - 45
Nozzle opening pressure (~~aikg/crn'))l 17.2 (175)
Transfer pump pressure (kPafkg/crn'tl 1 157 (1.6)
njection volume Service standard ( ~ ~ 1 1 , 0 0
st]
0 Manufacturer standard (cc/1,000 st)
Rack Rack pump
Rack positions
B to E are the ref-
point position
(mm)
speed
(rpm) Injection volume
Maximum
IS.:^;
cylinder
Injection volume =:^
Maximum
cylinder
ernce volume AlBasic point) 19.0 1,050 Max. 385 - 395 15.6
I
when adjusting the
injection volume. 10.5 300 Max. Observation ~ ~ ~ ~ 0 . 1 ~
Marks are C 23.0+" 100 Observation -

average volumes. D
E
I_____I____________\__ kPa
O 16.012.7 78. 5 t 8 . 7 I n m H g l
il2011Ol ~5QOi501
Boost P r e s s u r e
Â¥A stop lever stoc~edlÃˆhe sceed lever i s f u l l )
TVE00770
6D170-1SERIES
6162-73-1151 (106692-4233)
I Applicable Machine Applicable Engine I
D375A-1 15001andup SAGDl70-B-1 10332 - 11045
Plunger pre-stroke mm 2.4 & 0.05

retraction volume mm3/st

t Service standard
Nozzle part no. (105780-0050) 6162-13-3520 (105015-6160)
indicates data
test parts.
’ Manufacture injection ipe
(O/D x l/g x length)
8 x 2.4 x 1400 8x2.4x 1400
mm
standard is data
Nozzle opening pressure kg/cm2 175 265
Transfer pump pressure kg/cm2 1.6 1.6
Injection volume Service standard kc/ 100 st) Manufacturer standard (cc/ 100 st
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance Ter$EK Basis Allowance between
cylinder cylinder
bRack positions 38.44 Each cyl. ,34 o5 Each cyl.
B to E are the refer- Basic point 14.0 900
ence volume when 37.94 to 38.94 - ’
adjusting the injec- Ap rox 3.5 *
B %.8 325 3.42 * 2.92 to 3.95 kO.342
tion volume.
- Marks l are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 325 - 900 rpm) Boost compensator performance (400 rpm)
15.3
-?
E
:
‘Z
._
8 12.6
P
Y
P
n
0 go+20 380+60
Line @ : At boost pressure 480 mmHg or more

Line @ : At boost pressure 0 mmHg
Pump speed (rpm)
SEBH451 l-01
12-025
0
6162-73-l 250 (106692-4050)
SAGDI 70-B-1
EG450-1
[I EG480-1

Counterclockwise
Rotating direction
view from drive end
Injection order l-5-3-6-2-4 ’ ~1
Injection interval 60’?30’
Plunger pre-stroke mm 2.420.05

_ retraction volume mm3/st

Service standard 6162-13-3320 (105015-5210)
indicates data
test parts.
injection ipe 8 x 2.4 x 1400
Manufacture
mm
8 x 3 x 600
(O/D x l/g x length)
standard is data
Injection volume Service standard (cc/ 100 St) Manufacturer standard (cc/100 st
Rack Pump
Rack
point variance
(mm) (r-pm) Basis Allowance ~er$$~ Basis Allowance
between
cylinder cylinder
Rack positions Each cyl. Each cyl.
B to E are the refer- Basic point 14.5 900 40.0
ence volume when 47.25 46.75 to 47.75 -
adjusting the injec- Approx 3.95 * 3.45 to 4.45 kO.395 4.0 *
B 400
tion volume. 5.4
Marks * are aver- C * *
age volumes.
D * *
E * *
3overnor performance ( 400 - 900 rpm)
Ia+;
Racklimit: 14.5+b2
///////I////
14.5
Pump speed (mm)

SEBH4730
12-026
0
6162-73-1251 (106692-4121) 6162-73-1430 (106692-4640)
6162-73-1252 (106692-4122) 6162-73-1431 (106692-4642) Model Serial No. Model Serial No.
6162-73-1253 (106692-4123) 6162-73-1432 (106692-9060)
EG450-1 SAGDI 70-B-1
6162-73-1254 (106692-9040)
( 1: Manufacturer’s part No. EG480-1
injection Timing Engine specification

Counterclockwise 48811500 50H
Rotating direction Rated horsepower HP/rpm 544/1800 60Hf
view from drive end
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm
High idling
I
rpm 1::: las I%#:I
Injection interval
I
Plunger pre-stroke mm 2.4kO.05

retraction volume mm3/st 90 for Service standard

* Service standard
Nozzle part no. (105780-0050) 6162-13-3220 (105015-5500)
indicates data
test parts.
- Manufacture Injection ipe
(O/D x l/g x length) mm 8 x 3 x 600 8 x 2.4 x 1400
standard is data
for factorv test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Nozzle opening pressure kg/cm2 175 255
Injection volume Service standard h/100 St) Manufacturer standard (cc/ 100 st
Rack Pump
Rack
point variance
(mm) b-pm) Basis Allowance Fert,“E”, Basis Allowance between
cylinder cylinder
- Rack positions 47 25 Each cyl. 4. o Each cyl.
B to E are the refer- Basic point 14.5 900 .
ence volume when 46.75 to 47.75 - .
adjusting the injec- B APV& 400 3.95 * 3.45 to 4.45 AO.395 4.0 *
tion volume.
. Marks l are aver- C * *
age volumes.
D * *
E * *
0 400 ~~~ore750~10 900",0
Pump speed (rpm)

SEBH4731
12-027
0
Injection Pump
Machine Model Engine Model Manufacturer Pump Assembly Number
Pump Type I
D375A-1 SAGD170 PE-6P DIESEL KIKI 6162-73-2110 (106682-4350). 0
S/N 11646 and up
( 1: Manufacturer’s part No.
Injection Timing
Unit Basis Allowance I

Rotating direction
from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 508/l 800
Plunger pre-stroke mm 3.2 3.15 to 3.25 I Maximum torque: kgm/rpm 267/I 300
I
Delivery valve 120 High idling: 1950 to 2050
retraction volume mm3 rpm I
Low idling: rpm 600to 700
Conditions Unit (with calibration test parts)
(with nearly the same actual machine parts)
Nozzle part no. (105015-6700) ( 1

In ectron rpe 8~2.4~1400
mm
(d/D x l/l?x length)
Test oil ASTM 0975 No. 2 diesel fuel or equivalent
ipecifications
Injection volume kc/ 1OOst) Injection volumekx/ St)
1I 1 : Referencedata for manufacturer standard for service standard
Maximum Maximum
Rack Pump variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder

basic point A L15.81 900 34.0 33.8 to 34.2 f 1.02
1 Rack positions 8 [ 6.51 325 3.5 * 3.35 to 3.65 k-o.525 *

adjustingthe injec-
tion volume. D * *
1 Marks * are aver-
age volumes. E * *
;overnor performance (325 - 900 rpm) Boost compensator performance (400 rpm)
Rack
Ihrn,!
K.l++=mm
W
117.6, ,
y y’+ B
m
115.81 L_____
z (17.6)
-$y., - Line @ At boost pressure
450 mmHg or nwre 5
F_
Line @ At boost pressure
s
.E E
0 mmHg
‘Z
E
6
E I ‘2 (15.4)
%
z Y
a 1
‘: B
cc 0 350 2 50
I? (150)
SEBH452’
’2-:28
6162-73-2 111 (106682-4355)
6162-73-2 141 (106682-4422) Model Serial No. Model Serial No.
( ): Manufacturer’s part No. D375A-2 16001 and up SA6D170-B-1 13551 and up
(S.T.D and Cold weather spec.)

Counterclockwise viewed from Rated horsepower HP/rpm 525/l 800
Rotating direction
drive end
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 267/l 300
High idling ’ rpm 1960 to 2040

Injection interval 60° f 30’
Low idlina rom 600 to 700
I I
Plunaer ore-stroke mm/ 3.2 + 0.05 I I I 1
Delivery valve
retraction volume
mm3/st 120 I Pump tester capacity
for Service standard I
Motor 7.5 KW
I
erwce standard
Indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test.
Rack positions
ence volume when
tion volume.
Marks t are aver-
age volumes.
Rack I imi t: 18. 43 ‘mm
t compensator stroke
16.4.
0 7090 3Oa50
325 720’60 900:::

Pump speed (rpm)
TKE00129
SEBH4774-01
12-028- 1
0
6162-73-2 112 (106682-4800)
I Applicable Machine I Apolicable Enaine
6162-73-2 142 (106682-4820) Model Serial No. Model Serial No.

( ): Manufacture’s Dart No. I I
D375A-2 SAGD170-B-I 15524 and up
(S.T.D)

Rated horsepower (kw(HP)/rpm)
Maximum torque (Nm(kgm)/rpm)

retraction volume (mm”st) for Service standard Motor: 7.5 KW
- Service standard Nozzle part no. (105780 - 0050) 6162-13-3720 (105015-6700)
indicates data
Nozzle holder part no. (105780 - 2090) 6162-13-3711 (105041-7100)
using calibration
test parts. Injection pipe
(O/D X I/D X length) (mm) 8X4X1,000 8 X 2.4 X 1,450
* Manufacture
standard is data Test oil ASTM D975 No.2 diesel fuel or equivalent
for factory Oil temperature (“C) 40-45
test Darts.
Nozzle opening pressure (MPa(kg/cm’)) 17.2 (175) 26.0 (265)
Transfer pump pressure (KPafkaicm’)) 157 11.6) 157 fl 61
Injection volume
Service standard (cc/lOOst) Manufacturer standard (cc/lOOst)
Rack Rack Pump
point position speed Max_imum Maximum
(mm) (v-n) Basis Allowance ~~$~$ Basis Allowance
i variance
* Rack positions between
cylinder cylinder
B to E are the ref-
Each cyl. Each cyl.
erence volume Basic point 15.2 900 34.9 f 1.173
when adjusting the
I
injection volume. B * *
C APP~o~.6.6
325 * 3.5 * * 0.489
mMarks * are aver- D * *
age volumes.
Governor verformance(325-900rum) Boost conpensatar PerformancefSOOrPm)
18. I4 Rack limit: 18. d't'mm
rBoost compensator stroke
16. 4
13. 9
I
Boost Pressure (mmHo)
TKE00132
0
\ \\\I\
4lOUO 45om HBO=o 1OOO~‘o
325 720’6~ 9 0 0:::
Pump speed (rpm)
TKE00130
12-028-2
0
Pump Assembly Number I Applicable Machine Aoolicable Enaine 1
6162-73-2120 (106682-4380)
Rotating direction Counterclockwise viewed from drive end
Injection order l-5-3-6-2-4 ~~
Injection interval 60” f 30’
Plunger prestroke mm 3.2 + 0.05

-retraction volume mm3/st

Service standard Nozzle part no. (105780-0050) 6162- 13-3720 (105015-6700)
indicates data
test parts.
Injection ipe
Manufacture 8x3~600 8 x 2.4 x 1450
(O/D x l/g x length) mm
standard is data
Injection volume Service standard (cc/ 100 St) Manufacturer standard (cc/ 100 st
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance ye:::“, Basis Allowance
between
cylinder cylinder
Rack positions 32 52 Each cyl. Each cyl.
B to E are the refer- Basic point 12.2 1050 .
ence volume when 32.32 to 32.72 ‘“.g756 33.55
adjusting the injec- . B APPJ~.
425 2.32 * 2.12 to 2.52 kO.348 3.0 *
tion volume.
Marks l are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 425 - 1050 rpm) Boost compensator performance ( 700rpm)
Boostcompensatwstroke 0.9kO.l
13.4 -G
12.2 r 12.2
d
e
z z
L 5
z
5 t 11.3
‘G
‘L 6.3 $
: Ormore
6.3 5
Y 0 0 60125 Approx.200
P ‘;
a: 4.8 8
m
0 (300)*25 \ 530*25 12OOi25

425 (1100)
Pump speed (rpm)

SEBH4695
12-029
0
6162-73-2 130 (1066824430)
6162-73-2131 (1066824431) Applicable Machine Applicable Engine
6162-73-2 132 (106682-4560)
6162-73-2133 (1066824810) Model Serial No. Model Serial No.
( 1: Manufacture’s part No.
Pc1000-1 SA6D170-B-1 11763 and up

Rotating direction Rated horsepower (kw(HP)/rpm) (542)/l ,700
from drive end
Injection order l-5-3-6-2-4 Maximum torque (Nm(kgm)/rpm) (260)/1,300
1Injection interval 60° 2 30’ 1 1High idling (rpm) I 1,800 - 1,900
Plunger pre-stroke (mm) 3.2 + 0.05 Low idling (rpm) 650 - 700

retraction volume (mm3jst) 120 Motor: 7.5 KW
erwce standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
Rack positions
B to E are the ref-
erence volume
when adjusting the
Governor perfomance (335 - 850 rpm) Boost compensator perfomance (500 rpm)
z 16.3
.E
.-s
.=
:
0. 13.8
Y
0
cz
0 7oC20 300*50
he @ : At boost pressure 300 mmHg Or more

300 Li”e@ : Atb spress”reOmmHg
00
81OQ5 850;;;
Pump speed (rpm)

SEBH4694-01
12-030
0
6162-73-2420 (106682-4661)
Model 1 Serial No. Model 1 Serial No.
( ): Manufacturer’s part No. EPSAGD170-B-1 SAGD170-1-B-1
lniection Timina Engine Specification
IRotating direction
I
Counterclockwise
viewed from drive end I
Injection interval 60° f 30’
1 Plunger pre-stroke mm1 3.2 f 0.05 I Pump tester capacity

mm3/st 120 for Service standard I
retraction volume
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test.
Rack positions
B to E are the ref-
erence volume
when adjusting the
injection volume.
Marks * are aver-
age volumes.
385 900;::
Pump speed (rpm)
12-030-l
0
6162-73-242 1 (106682-4840)
( ): Manufacture’s part No.
EPSAGD170-B-1 SA6D170-I-B-I
lniection
. Timina Enaine Soecification
Counterclockwise
Rotating direction from drive
viewed
end
1 Rated horsepower (kw(HP)/rpm)I (540)/1,800 I
Injection order I-5-3-6-2-4 1Maximum torque (Nm(kgm)/rpm) 1 (251 VI ,300 I

I Injection interval 60’ t 30’
I I High idling (rpm) I 1,950 - 2,050 I
Plunger pre-stroke (mm) 3.2 5 0.05 Low idling (rpm) 750 - 850

120 Motor: 7.5 KW
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
Rack positions
B to E are the ref-
erence volume
when adjusting the
injection volume.
Marks t are aver- D / (16.2) / 750 j * 1(36.0) 1* 35.5 - 36.5 / -

age volumes.
E / 650 1 * 1(36.6) 1t 36.1 -37.1 ) -
Governor perfomance (415 - 900 rpm)
18’:
Governor s~lina set

Idling sub s~lina set
ED A
a 16.2
..S
.-z
.-
z
_
2 6.5
6. 3
0 415 97w
385 900:::
Pump speed (rpm)
TKE00131
12-030-2
0
6162-73-1711 (106692-4382)
EPSAGD170-B-1 SA6D170-B-1
EPSAGD170-B-1 SA6D170-B-1
(Extreme cold
weather)

Rotating direction
drive end
Injection interval 59’ 30’ - 60” 30’ High idling speed (rpm) I Max. 2,030 I
I

retraction volume (mm”‘st) 90 Motor: 7.5 kW
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 C 16.2 750 425 - 435 -
average volumes. D
E
Rack limit : (16. 7) '~'mm
(15. 2)
(9. 8)
E
E
.! (6. 8)
‘, 6.3
2
I- L-
0 400 / (870) +30\990+25
75O’P 900:::
12-030-3
0
Applicable Machine Applicable Engine 1
6162-73-1743 (106692-9070)
OEM for SA6D170-B-1
generator
11

Counterclockwise viewed from Flywheel horsepower 425 {570}/1,500 (50 Hz)
Rotating direction
drive end (kW{HPYrpm) 506 {6781/1,800 (60 Hz)
a::“:
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgmI/rpm)
1Injection interval 59’ 30’ - 60” 30’ ---I

1Plunger prestroke (mm) 1 2.35 ; 2.45 I I I I
IDelivery valve
retraction volume (mmyst) I
Motor: 7.5 kW
erwce standard
indicates data
standard is data
. Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
l Marks * are
spring set:
6162-73-1941 (1066824890)
OEM for SA6D170-B-1
PE-P (S7S) ZEXEL I I I I

Counterclockwise viewed from Flywheel horsepower 386 {517)/1,500 (50 Hz)
Rotating direction
drive end (kW{HP}/rpm) 458 I613Yl.800 (60 Hz)
‘~~~
Maximum torque (Nm{kgml/rpm)
Calibration Standard ( ) : lnienction pump manufacture’s part number
Conditions I Servicestandard Manufacturerstandard

Service standard Nozzle & Nozzle holder Dart No. 1 (105780-8130) 1 6162-13-7300 (1051114431)
indicates data
Nozzle part No. (105780-0050) 6162-13-7520 (105015-8790)
using calibration
(Outside dia.x Inside dia.x Length 1(mm)
8 X 4 X 1,000 8 X 2.4 X 1,400
standard is data
test parts.
Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
Marks * are
average volumes.
ck limit: 18’:‘mm
Idle spring is
17. 5
- 15.1
: 14.9 sprint set:
z
z.-
: 7.0
_= 6.4
t 6.1
0 ,400 460f5 750f5 \ 1000*5

900f5
Pump speed (r Pm) TWE00632
12-030-5
0
6162-73-1942 (1066824891)
OEM for SA6D170-B-1
generator

Counterclockwise viewed from Flywheel horsepower 386 {517)/1,500 (50 Hz)
Rotating direction
drive end (kW{HPVrpm) 458 {6131/1.800 (60 Hz)
I
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgml/rpm)

I I I I
retraction volume (mm3bt) 120 Motor: 7.5 kW
Service standard
indicates data
using calibration
Manufacture
standard is data
Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
Marks * are
average volumes.
et when supplied
(800)
12-030-6
0
6162-73-1950 (106682-9130) I
D375 (BEML) SA6D170-B-1
lniection Pump. Specification

_ Ennine Specification (Without fan)
Injection order 1-5-3-6-2-4 Maximum torque (Nm{kgml/rpm) 3,432/1,300 {248/1,300}
Injection interval 59’ 30’ - 60” 30’ High idling speed (rpm) 1,960 - 2,040
I I I I I
retraction volume (mm3/st)J 120 Motor: 7.5 kW
fnr Service ntnnriard
(Conditions Service standard Manufacturer standard I

indicates data
using calibration
Nozzle part No. (105780-0050) 6162-13-3320 (105015-8600)
8 X 4 X 1,000 8X2.4X1.450
standard is data (Outside dia.x Inside dia.x Length ) ‘mm)
test parts.
Oil temperature (‘C) 40-45
Nozzle opening pressure (MPa{kg/cm’]) 17.2 {1751 26.0 {2651
Injection volume Injection volume

Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
Marks * are
average volumes.
1 a’: Rack I imit : 17. 2’oD”mm
Boost
compensator stroke ~2. 520. 1 mm
I 1
4. 0 15. 5
9. 3
I I. 5
+5mm’/s t :
Dz
1;
KR; 0 9. 3f2. 7 40. 0*6. 7
(701t20) ~300+501
Boost pressure (kPa{mmHel 1
41Oi20 (72d) i50 QdO:::

L
12-030-7
0
6162-73-2173 (1066824830) I Applicable Machine I Applicable Engine

OEM for SA6D170-B-1
generator

Counterclockwise viewed from Flywheel horsepower 378 {5061/1,500 (50 Hz)
Rotating direction
drive end (kW{HPYrpm) 403 {539Vl,800 (60 Hz)
Injection order l-5-3-6-2-4 Maximum torque (NmIkgmI/rpm)
Injection interval 59’ 30’ - 60” 30’

veIlvery valve 1 1 Pump tester capacity
I retraction volume (mm’/st)l fnr Cnnrim C+lnrl3rA I Motor: 7.5 kW I
Calibration Standard l 1: lnienction oumo manufacture’s oart number

Service standard 1 Nozzle & Nozzle holder oart NO. (105780-8130) 6162-13-3201 f105111-4051)
indicates data
using calibration
Nozzle part No. (105780-0050) 6162-13-3220 (105015-5500)
8 X 4 X 1,000 8X2.4X1,450
standard is data (Outside dia.x Inside dim Length ) (mm)
test parts.
I Oil temoerature (“C) I 40-45
Nozzle opening pressure (MPa{kg/cm% 17.2 {175} 25.0 1255)
Transfer pump pressure (kPa{kg/cm*)) 157 Il.61 157 Il.61
Injection volume Service standard (cc/l ,000 s-t) Manufacturer standard (cc/l,000 st)
Rack Rack Pump
(mm) Wpm) Injection volume g$$z Injection volume $$g$
bRack positions
cylinder cylinder
B to E are the ref-
ernce volume AlBasic point) 16.0 900 380 - 390 Max. 23.1
when adjusting the
B 15.2 750 365 - 375 -
injection volume.
Marks * are C Approx. 9.3 400 35-45 Max. 12
average volumes. D 1’
ck limit: 19. l’t’mm

18:’
1;. !
15: 2 spring set:
E Min. 7. 9
E
_ 6.4
Z 6. 2
Z
.-
.Z
_
3. 6fO. 3
500 750f5
PUIIIP speed (r Pm) TWE00636
12-030-8
0
6162-73-2380 (106682-9350)
Model 1 Serial No. Model I Serial No.
OEM for 6-pole SA6D170-B-1

drive end (kW{HPMrpm)
Injection order l-5-3-6-2-4 Maximum torque (NmIkgmYrpm)
Injection interval 59’ 30’ - 60’ 30’ fl

I I I I

120 Motor: 7.5 kW
retraction volume (mm’/st) for Service standard
Calibration Standard f ) : lnienction oumo manufacture’s oart number
ionditions I Servicestandard Manufacturerstandard

Service standard Nozzle & Nozzle holder part No. (105780-8130) 6162-14-3300 (105111-46601
indicates data
Nozzle part No. (105780-0050) 6162-14-3320 (105025-0910)
using calibration
8X4X1.000 8 X 2.4 X 1,400
test parts.
Oil temoerature (‘C) 40-45
Nozzle opening pressure &lPa{kg/cm%~ 17.2 {175} 26.0 f2651
1Transfer pump pressure (kPa{kg/cm*H1 157 Il.61 157 U.61
njection volume Service standard (cc/l,000 st) Manufacturer standard (cc/1,000 st]
Rack Rack Pump
point position speed Maximum Mqimum
(mm) (rpm) Injection volume vba,EEkE Injection volume g”,zg!z
Rack positions cylinder cylinder
B to E are the ref-
ernce volume AtBasicpoint) 14.8 500 508 - 513 Max. 18.7 419 -
when adjusting the
B 15.5 600 538 - 548 - 448 -
injection volume. .
Marks * are C Approx. 6.8 400 II-14 Max. 7.5 25 -
average volumes. D
E
Rack limit is not actuated
0 400 500f5\ 6001t5

520f5
Boost speed (rPm) TWE00637
1Z-030-9
0
6162-74-1750 (103684-0361)
OEM for SAAGD170-1
generator
(50 Hz)

drive end (kW{HWrpm)
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgm}/rpm) -
Injection interval 59” 30’ - 60” 30’ High idling speed (rpm) Max. 1,575

retraction volume (mmyst) 180 Motor: 7.5 kW
t Servicestandard
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.
12-030- 10
0

6162-74-1310 (103662-3350)
(With electronic governor) Model Serial No. Model Serial No.
DENY0 generator SA6D170-AE-1
) DCAGOOSSK

Counterclockwise viewed from Flywheel horsepower 478 {641)/1,500 iGross.50Hz)
Rotating direction
drive end (kW{HP)/rpm) 528 {708M1,800 (Gross,GOHz)
Injection order 1-5-3-6-2-4 Maximum torque (Nm{kgm}/rpm) -
Injection interval 59’ 30’ - 60’ 30’ High idling speed Max. 1,570 (50 Hz)
(rpm) Max. 1,880 (60 Hz)
1Plunger prestroke (mm) 3.15 - 3.25 Low idling speed (rpm) 700 - 900
retraction volume (mm31st) 90 Motor: 7.5 kW

(Conditions I Service standard 1 Manufacturer standard
. Service standard Nozzle & Nozzle hn1d-r rdart No. 1
..v...v, 1 6162-14-7600 (105111-4820)
indicates data I I
Nozzle part No. 6162-14-7620 (105025-1850)
using calibration
test parts. Nozzle holder part No. 5212-13-3111 (105041-7111)
. Manufacture Injection pipe
8 X 2.4 X 1,450
test parts.
Oil temperature (‘C) 40-45
tiozzle opening pressure (MPa{kg/cm)) 29.4 13001

Transfer pump pressure (kPa{kg/cm’}) 157 {I .60}
L
njection volume Service standard (cc/l,000 st) Manufacturer standard (cc/l,000 st
Rack Rack Pump
Rack positions position voltage speed Max.imum Maximurr
B to E are the (mm) w Irpm) Injection volume Ezz,“,“z Injection volume ~~~~~~
refernce volu- cylinder cylinder
me when
adjusting Rated
tttt:;eyfion point 13.2 1.36 865 * 543 t 5 Max. 44
Marks * are Low

average
idling 5.9 2.8 400 *30*5 Max. 8
volumes.
point

(Not specified)
12-30-11
@

6162-73-2174 (106682-4990)
OEM for SA6D170-B-1
generator
(Prime use)
Injection Pump Specification Engine Specification (Without fan1

Counterclockwise viewed from Flywheel horsepower 378 {506)/l ,500 (Net)
Rotating direction 403 {5391/l ,800 (Net)
I
l-5-3-6-2-4 1Maximum torque (NmIkgmMrpm)I -
Injection order I
Max. 1,570 (50 Hz)
Injection interval I 59” 30’ - 60” 30’ I High idling speed (rpm) Max. 1,880 (60 Hz)
700 - 900
firestroke (mm) ( 2.95 - 3.05 I Low idling speed (rpm)
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
Rack positions
urnmaximum speed control spec.
Rack iimit:l9. I-19. 3 (mm)
All speed idl ina set
Idling sub spring set

Q=67-77 (mm3/s t)
0 400
Approx. 500 745-755
Pump speed from)
Pump speed (rpm)
TWE00729
12-30-12
G9

ApDiicable Machine I Aoolicable Enaine
6162-73-2180 (I 06682-4900)
I
EG500-l,EG500B-1 SAGD170-B-I
EG500BS-1
OEM for generator

Counterclockwise viewed from Flywheel horsepower 385 {5241/l ,500 (50 Hz)
Rotating direction
drive end (kWfHP)/rpm) 458 I611~/1,800 (60 Hz)
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgm}/rpm) -
Max. 1,560 (50 Hz)

Injection interval 59” 30’ - 60” 30’ High idling speed (rpm) Max. 1,870 (60 Hz)
Plunger prestroke (mm) 2.95 - 3.05 Low idling speed (rpm) 800
retraction volume (mm3’st) 120 Motor: 7.5 kW
Calibration Standard ( ) : lnienction oumo manufacture’s Dart number
* Service standard
indicates data
using calibration
test parts.
5Manufacture
standard is data
test parts.
Rack positions
B to E are the ref-
Governor pet-fomance curve
: 19.7
- 17.6
2 17.4
.-
-.- 9.3
2
a
400 750 900

Pumpspeed [r pm)
TWE00730
12-30- 13
@

Applicable Machine
6162-73-2340 (106682-9220)
OEM for SA6D170-B-1
generator
(Standby use)

Counterclockwise viewed from Flywheel horsepower 468 {636}/1,500 (50 Hz)
Rotating direction drive end (kW{HP)/rpm) 557 {7571/1,800 (60 Hz)
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgmYrpm) -
Max. 1,575 (50 Hz)

Injection interval 59’ 30’ - 60” 30’ High idling speed (rpm) Max. 1,890 (60 Hz)
I I I

Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
test parts.
In.ection volume
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

Applicable Machine
6162-73-2381 (106682-9351)
( ): injection Pump Manufacture’s part No.
OEM for B-pole SA6D170-B-1 17441 and up
generator
lniection Pump. Specification

. Engine Specification (Without fan)
Rotating direction
drive end
Injection order l-5-3-6-2-4 Maximum torque (NmIkgmVrpm)
Injection interval 59’ 30’ - 60’ 30’
Delivery valve
Iretraction volume (mm’/st) I
Motor: 7.5 kW
Ctonditions I Service standard Manufacturer standard

indicates data
Nozzle part No. (I 05780-0050) 6162-14-3320 (105025-0910)
using calibration
test parts. Nozzle holder part No. (I 05780-2090) 6162-13-3711 (105041-7101)
8X4X1,000 8 X 2.4 X 1,400
standard is data (Outside diax Inside dia.x Length ) (mm)
test parts.
Nozzle opening pressure (MPaIkg/cm% 17.2 {I751 26.0 {265}
1Transfer pump pressure (kPaikg/cm?) 157 {I .6} 157 {I .S}
njection volume Service standard (cc/l,000 st) Manufacturer standard (cc/1,000 st)
Rack Rack Pump
variance
(mm) (mm) Injection volume between Injection volume ~~!r~J~
Rack positions cylinder cylinder
B to E are the ref-
ernce volume A(Basicpoint) 14.8 500 498 - 508 Max. 18.7 419 -
when adjusting the
B 15.5 600 538 - 548 - 448 -
injection volume.
Marks * are C Approx. 6.8 400 II-14 Max. 7.5 25 -
average volumes. D
Rack limit is not actuated
0 400 500f5 \ 600f5

520f5
Boost speed (rpm) TWE00637
12-30-15
@

6162-73-1944 1 Applicable Machine
Model Serial No. Model

Applicable Engine
Serial No.
( ): Injection Pump Manufacture's part No.
For MQ SA6D170BE-1
I DCA-500SSK

Rotating direction
drive end ( kW{HP},rpm)
44O{59l}/l,800(6OHz)(Gross)
Injection order 1-5-3-6-2-4 Maximum torque (Nm{kqm}/rpm) -
Injection interval 59' 30' - 60- 30' High idling speed (rpm) Max. 1,890 (60Hz)
Plunger prestroke (mm) 2.95 - 3.05 L o w idling

- speed (ram) 700 - 900
I I I I
Delivery valve
retraction vo~ume (mm3'st)l 120
Motor: 7.5 kW
Calibration Standard ( ) : Injenction p u m p manufacture's part number
conditions 1 Service standard 1 Manufacturer standard

Service standard I Nozzle & Nozzle holder oart No. 1 - I -
indicates data
using calibration Nozzle part No. (105780-0050) 1 6162-13-7520 (105015-8790)
test parts. Nozzle holder part No. (105780-2090) 1 6162-13-3112 (105041-7111)
8 X 4 X 1,000 8 X 2.4 X 1,400
standard is data (Outsidedia.x Inside di8.x Length 1 (mm)
test parts.
Oil temperature CC) 1 40 - 45
Nozzle opening pressure (~~afkglcm'~1 17.2 {175} 26 {2651
Transfer pump pressure (kPafkgIcm7) 157 {1.6} 157 (1.6)
njection volume Service standard (cc/1,000 st) Manufacturer standard ~cc/1,000st)
Rack Rack Pump
Rack positions
(mm) (rprn) Injection volume
cylinder
Injection volume Ez
cylinder
B to E are the ref-
ernce volume AlBasic point)
when adjusting tht
injection volume. .
*
Marks are C
average volumes. D
E
There is no Governor performance chart because of the mounting fuel injection pump with electronic governor.
6D170-1 SERIES
Pump Assembly N u m b e r
6162-74-1751 (103684 - 0370)
1 Applicable Machine 1 Applicable Engine 1
1 Model 1 Serial No. 1 Model 1 Serial No. 1
1
( ): Manufacture's Dart No.
ln~ectiOn
Pump Type
1 Pump Manufactuer 1 OEM for
generator
57 S ZEXEL
Injection Timina
Rotating direction Clockwise Rated horsepower (kW(HPl,r m)
792.9{1062.9)/1,500(Gross)
Injection order 1-5-3-6-2-4 Maximum torque (Nrn{kgrn}/rpm) -
Injection interval 59' 30' - 60" 30' High idling (rprn) Max. 1,575
Plunger prestroke (mrn) 2.95 - 3.05 L o w idling (rpm)

, 700 - 900
I
retraction volume (mm"stl~ 120 Motor: 7.5 kW
Calibration Standard ( : Manufacture's oart No.

conditions Service standard Manufacturer standard
Service standard Nozzle part No. (105780-0050) 6162-14-3421(105025-2230)
indicates data
using calibration Nozzle holder part No. 1105780-2090) 6162-13-3712 (105041-7101)
test parts. Injection pipe 8 X 4 X 1,000
(Outsided1a.x Inside dia.x Length > lmm) 6 X 2.2 X 725
Manufacture
standard is data Test oil ASTM D975 No.2 diesel fuel or equivalent
for factory Oil temperature (*c) 40 - 45
test parts.
Nozzle ooenina oressure (MPatka/cm211 17.2 (175) 1 24.5 (250)
Transfer pump pressure (kPafkgIcm'l) 157 {1.6} 157 U.61
njection volume Service standard Manufacturer standard
Rack Rack Pump
Injection volurn variance Injection volume variance
(mm) Wpm)
Rack positions (cc/lOOO st) cyl,nder(%)
between (cc/lOOO st) cylinder(%:
between
B to E are the ref-
ernce volume AlBasic point) 16.4 900 695 - 709 Â4 528
I 1 I I 1 I
when adjusting the
injection volume. 1 8.0 1 400 1 38.5 - 42.5 1 Â±1 1 20
1 16.9 1 100 1 580 - 600 - 550 1
Governor petfomance curve (Governor less)
6D1 70-1 SERIES

COOLING SYSTEM
FAN BELT TENSION
4 2
1. Adjustment nut
2. Washer
3. Tension spring
4. Adjutment bolt
5. Tension pulley
A. Protrusion of adjustment bolt
For D275A-2
6162F291
2
z
z Unit: mm
Engine model Applicable machine Dimension A
;6D170-1 4 Q area
SA6D170-A-1 1 HD465-3 1 58f5
12-031
69
REPLACING FAN BELT AND AQJUSTING AUTO TENSIONER
l Replacing
Loosen locknut (1) and turn back adjustment screw

(2) as far as bracket (3).
Insert a bar with a length of approx. 50 cm in the 4

hole (418) in bracket (7). then pull strongly 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 Adjusting
1. Tighten adjustment screw (2), and when the tip of

adjustment screw (2) comes into contact with
tension pulley lever (4). tighten adjustment screw
(2) a further half turn, then lock it in position with
locknut (1).
w Locknut : 29.5 + 2 kgm
* If a gap appears between tension pulley lever (4) and

the tip of adjustment screw (2) during operation,
adjust 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
Item
T Order
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
Load 392 883 1,373 2,059 2,452

716 mm 0
{401 {901 {I401 12101 {2501
D275A-2 314 706 1,098 1,648 1,961
895 mm 0
I321 (721 {I121 {I681 {200>
1,023 mm 275 618 961 1,442 1,716
0
{281 {63} 1981 11471 I1751
Flywheel 29.4 79.4 123.5 231.7 331
Horsepower 0
139.4) 1106.51 U65.61 1310.6) 1443.7)
Engine speed 550 - 700 1,000 1,200 1,200 1,500 1,600

Load 392 883 1,373 2,059 2,648
716 mm 0
I401 I901 {I401 f2101 (2701
PC650-1
PC1 500-I 895 mm 314 706 1,098 2,118
0
1321 I721 {I121 X2?? f2161
1,023 mm 275 618 961 1,442 1,853
0
1281 1631 1981 {I471 11891
Flywheel 29.4 79.4 123.5 231.7 317.8
Horsepower 0
f39.4) I106.5) U65.61 1310.61 f426.0)
Running time min. 3 6 3 3 10 Min. 5
Engine speed i50 - 700 1,000 1,200 1,200 1,500 2,000

Load 392 883 1,373 2,059 2,157
716 mm 0
1401 I90) {I401 I2101 I2201
S6D170-1 WA600-1 314 706 1,098 1,648
895 mm 0 1,726
I321 {72) {I121 11681 {176)
1,023 mm 0 275 618 961 1,442 1,510
{28) I631 {981 I1471 1154)
Flywheel 29.4 79.4 123.5 231.7 323.6
Horsepower 0
I39.4) 1106.5) U65.6) 1310.61 t433.8)
5ngine speed ;50 - 700 1,000 1,300 1,600 1,800 2,000

_oad 265 530 814 1,157 2,403
716 mm 0
I271 154) I831 {I181 f2451
ND600-1 216 422 647 922 1,922
895 mm 0
(221 I431 {661 1941 U96)
1,023 mm 186 373 569 814 1.677
0
U9) I381 158) 1831 I1711
‘lywheel 19.8 51.5 97.8 155.9 433.9
0
Horsepower 126.6) {69) I131.1) {209.0) I581.7)
Iunning time 5 15 5 5 20 10
ingine speed 00 - 850 1,000 1,200 1,200 1,500 1,500
.oad 490 981 2,059 3,138 4,219

716 mm
150) {loo) I2101 13201 1430)
iG550-1
895 mm - - - - -
1,023 mm - - - - -
:lywheel 36.6 88.0 185 352.9 474.5

Horsepower I491 Ill81 12481 14731 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
t The table gives the standard values for machines without fan.
* The load for the dynamometer are at an arm’s length of 716 mm.
Order
Engine ,pplicable
Item
model machine
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
PS6D170-1 392 883 1,373 2,059 2,942

Load 0
{401 I901 11401 {2101 13001
Flywheel 29.4 79.4 123.6 231.8 397.4

0 1165.61 l310.6) 1532.4)
Horsepower I39.41 1106.51
S6D170-1
Engine speed ‘50 - 800 1,000 1,200 1,200 1,500 1,800
‘EM for 392 883 1,373 2,059 3,040

enerator Load 0
I401 I901 I1401 {2101 {3101
Flywheel 29.4 79.5 123.6 231.8 410.7

0 i165.61 1310.61 t550.21
Horsepower 139.4) I106.5)
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
* The values given for the output is the fan removed.

t The load (dynamometer) is given for the case of the arm length is 716 mm, 895 mm or 1,023 mm.
*I : Mechanical governor *2 : Electronic governor
Engine
model
l- Running time
item
3
1 2
6
3
3
4
3
5
10
6
Engine speed 25 -950 *1 1,000 1,200 1,200 1,500 2,100

20 - 970 *i
iD465-5 Load 392 883 1,373 2,511 3,452
716 mm 0
Both {401 $01 U401 {2561 I3521
nechanical
895 mm - - - - - -
Jectronic
rovernor)
1,023 mm - - - - - -
Flywheel 29.4 79.5 123.6 282.6 544.1

0
Horsepower l39.4) UO6.5) {I 65.6) C378.61 1728.9)
Engine speed 700 1,000 1,200 1,600 1800 2,000
Load 883 1,667 2,452 3,383

716 mm 0
$zl (901 I1701 {2501 13451
VA700-1 353 706 1,334 1,961 2,707
895 mm 0
I36} I721 I1361 I2001 I2761
309 618 1,167 1,716 2,368
1,023 mm 0
131.51 f631 {I191 I1751 I241.5)
Flywheel 33.1 79.5 200.2 331.2 507.8
0
Horsepower @I441 UO6.5) 1268.21 I443.71 t680.31
Engine speed ‘00 - 900 1,000 1,200 1,200 1,500 1,500

iG580-1
Load 392 1,177 1,961 3,046 3,432
iG580B-1 716 mm 0
iG600-1 1401 I1201 (2001 (3101 {3501
SAGDI 70-A- .G600B-1 314 932 1,569 2,432 2,746
895 mm 0
J;;T&s-l {321 (951 I1601 (2481 12801
275 824 1,373 2,128 2,403
generator 1,023 mm 0
(281 1841 (140) (1271 12451
Flywheel 29.4 106.0 176.6 242.2 386.4
0 (458.5) (517.7)
Horsepower 139.4) (142.0) (236.6)
Engine speed 50 - 1,ooc 1,000 1,200 1,200 1,500 1,500
Load 588 1,177 2,354 3,530 4,707

716 mm 0
f601 I1201 (2401 1360) I480}
EG580-BIL 471 941 1,883 2,824 3,766
895 mm 0
I481 {961 11921 (2881 1384)
412 824 1,648 2,471 3,295
1,023 mm 0
{421 (841 (1681 12521 13361
Flywheel 44.1 105.9 211.8 397.2 529.6
0
Horsepower 159.11 (141.9) (283.91 (532.4) i709.91
Engine speed 800 1,000 1,200 1,600 1,800 2,000
Load 883 1,765 3,026 3,060

716 mm 0
z {90} (1801 13081 I3631
EPSAGDlTI(
-A- 895 mm - - - - - -
1,023 mm - - - - - -
Flywheel 33.1 79.5 212 407.7 534.3

0 (546.2) t715.8)
Horsepower (44.4) I106.5) 12841
l Z-035
0
* The table gives the standard values for machines without fan.
Order
Applicable
Item
machine
1 2 3 4 5 6
Engine speed 550 - 600 1,000 1,200 1,200 1,500 2,000

EM680A
EM680A-1 392 883 1,373 2,579 3,658
Load 0
6M170-B-1 I401 I901 U40} (2631 {3731
Flywheel 29.4 79.5 123.6 290.4 549.1

0
Horsepower i39.4) (106.5) U65.61 I389.0) 1735.6)
Running time 3 6 3 3 IO Min. 5
Engine speed 550 - 600 1,000 1,200 1,200 1,500 2,000
EM680A-A 392 883 1.373 2,511 4,187

Load 0
I401 (901 (1401 (2561 I427>
Flywheel 29.4 79.5 123.6 282.6 628.5

0
Horsepower (39.4) (106.51 (165.61 (378.61 (842.01
Engine speed 1,100 1,100 1,300 1,650 1,900 2,100

H D465-5
(High alti- 343 637 1,226 1,863
Load 0
tude spec.) (351 (651 (125) (1901 2,452
(2501 2
z
Flywheel 28.3 62.2 151.8 265.7 386.4
0 z
Horsepower t38.01 i83.31 (203.41 (355.91 I517.71
SA6D170-A-
Running time 5 15 5 5 20 IO
Engine speed 950 1,000 1,200 1,200 1,500 1,500

OEM for
at7yfr=r$r 588 1,177 2,354 3,530 4,707
Load 0
633 HP) 160) I1201 (2401 13601 (4801
Flywheel 44.2 106.0 212.0 397.4 529.9

0
Horsepower (59.21 (142.0) (284.01 (532.41 (709.91
Running time 5 15 5 5 20 IO
EG600BS-1 Engine speed 700 - 900 1,000 1,200 1,200 1,500 1,500
OEM for
generator 490 981 1,961 2,942 3,923
Load 0
(Engine No. (50) IlOO} I2001 (3001 I4001
15503andup
Flywheel 29.4 106.0 176.6 342.2 386.4
0
Horsepower (39.41 (142.01 (236.6) (458.51 (517.7)
Running time 3 6 3 3 IO 5
Engine speed 800 1,000 1,200 1,200 1,500 1,800

OEM for
generator
Load 490 981 1,961 2,942 3,923
0
1501 I1001 (2001 I3001 (4001
Flywheel 47.8 114.8 234.0 441.6 529.9

0
Horsepower (64.11 (153.8) I313.5) (591.61 (940.61
12-035- 1
0
* The load for the dynamometer are at an arm's length of 716 mm.
Order
Engine Applicable Item -
model machine
4 5 6
Running time 3 10 Min. 5

Engine speed 1,200 1,500 1,750
Load 1,373 2,059 3,472

(1401 (210) (354)
Flywheel 123.6 231.8 456.3
Horsepower {165.6) (310.61 1611.3)
Ã‘Ã‘Ã
Running time
OEM for Engine speed

generator
(Standby Load
use 581 k\ft
{778 HP1)
Flywheel
Horsepower
Running time
Engine speed
Load
Flywheel
Horsepower
Running time
Ã
3
‘Ã‘Ã
10 Min. 5
Engine speed 1,200 1,500 2,000
HD465-3
(For ORAPL 1,373 2,511 3,393
Load
{I401 {256) (3461
Flywheel 123.6 282.4 508.8
Horsepower {165.6} {378.6) {682}
Running time
Engine speed
Load
I
(The performance test i s n o t done a t factory.)
Flywheel
Horsepower
Running time
Engine speed
Load
Flywheel
Horsepower
6D170-1 SERIES
t The values given for the output is the fan removed.

Order
Engine
Item
model
1 2 3 4 5 6
Engine speed 600 - 700 1,000 1,200 1,200 1,500 1,800
Load 392 883 1,373 2,059 2,942

716 mm 0
{401 {901 11401 {2101 {3001
D375A-1 314 706 1,098 1,648 2,354
895 mm
I321 {721 11121 I1681 12401
275 618 961 1,442 2,059
1,023 mm
I281 {631 1981 {I471 {2101
Flywheel 29.4 79.4 123.5 231.7 397.2
Horsepower 139.41 1106.5) {I 65.6) 1310.61 i532.4)
Running time 3 6 3 3 IO Min. 5
Engine speed 600 - 700 1,000 1,200 1,200 1,500 1,800
Load 392 785 1,569 2,354 3,119

716 mm 0
1401 {801 I1601 {240} {3181
D375A-2
314 706 1,255 1,883 2,495
895 mm 0
{321 {721 11281 Cl921 i254.41
1,023 mm 275 618 1,098 1,648 2,183

0
1281 I631 Cl121 (1681 1222.6)
Flywheel 29.4 70.6 141.2 264.8 421.0
0
Horsepower t39.41 194.6) i189.3) 1355.01 i564.41
Running time 3 6 3 3 10 Min. 5 2

Engine speed 650 - 700 1,000 1,200 1,200 1,500 1,700 z
z
Load 392 883 1,373 2,059 3,236
716 mm 0
1401 1901 11401 I2101 I3301
SA6D170-B- PC1000-l - - - - - -
895 mm
1,023 mm - - - - - -
Flywheel 29.4 79.4 123.5 231.7 412.6

Horsepower 0
139.4) UO6.51 {I 65.6) 1310.6) 1553.11
Engine speed 850 - 900 1,000 1,300 1,650 1,900 2,100
Load 373 735 1,471 2,206 2,942

716 mm 0
HD465-3 I381 I751 {I501 I2251 {3001
with single
298 588 1,177 1,765 2,354
turbochage 895 mm
130.41 I601 I1201 I1801 {2401
HD500-3
359 515 1,030 1,545 2,059
1,023 mm
I36.6) 152.5) Cl051 U57.5) {2101
Flywheel 28.0 71.6 182.0 314.4 463.4
Horsepower 137.5) {961 {2441 t421.51 1621.21
Running time 3 6 3 3 IO 5
Engine speed 800 1,000 1,200 1,200 1,500 1,800

Pc1000-1
(High alti- Load 343 686 1,373 2,059 2,746
716 mm 0
tude spec.) 1351 {701 {I401 {210} I2801
Flywheel 25.8 61.8 123.6 231.8 350.3
0
Horsepower 134.5) I82.81 I165.61 t310.6) I469.3)
12-035-3
0
t The values given for the output is the fan removed.

r
l-
Order
Engine Item
model
1 2 3 4 5 6
Qrnning time 5 15 5 5 20 10
ingine speed 50 - 1,000 1,000 1,200 1,200 1,500 1,500
_oad 392 1,177 1,961 3,040 3,432

:G450-1 716 mm 0
{401 11201 12001 {3101 {350>
Yywheel 40.3 145.5 242.5 470.0 530.4

0
Horsepower 158 11951 1325) I6301 17111
bnning time 3 6 3 3 10 Min. 5
Engine speed ‘00 - 900 1,000 1,200 1,200 1,500 1,800
_oad 392 883 1,373 2,059 3,481

fG480-1 716 mm 0
EG480B-1 1401 {901 WON I2101 {3551
EG500-1 - - - - - -
EG500B-1 895 mm
!G500BS-1
1,023 mm - - - - - -
zlywheel 29.4 79.4 123.5 231.7 470.0

0
Horsepower t39.41 1106.5) (165.6) (310.6) I6301
krnning time 3 6 3 3 10 Min. 5
!ngine speed 800 1,000 1,200 1,200 1,500 1,800

?SA6D17(
_oad 392 883 1,373 2,059 3,138
SA6D170-B- .B-1 716 mm 0
{40) I901 U40> {2101 {320}
?ywheel 29.4 79.5 123.6 231.8 458.5

0
Horsepower t39.41 (106.51 U65.61 f310.61 t614.31
Qrnning time 3 6 3 3 10 5
ingine speed 150 f 100 1,000 1,200 1,200 1,500 1,800

:G480B-1
:For CIS) _oad 210 355
716 mm 0 40 90 140
-lywheel 310.6 630

0 39.4 106.5 166
Horsepower
Running time min. 3 6 3 3 IO 5
EG500-1 Engine speed 800 1,000 1,200 1,200 1,500 1,800

EG500B-1
EG500BS- Load 490 981 1,961 2,942 3,923
OEM for 716 mm 0
1501 {IO01 {200} 13001 {4001
generator
Flywheel 36.8 88.3 176.6 331.2 530.3
0
Horsepower 149.31 {I 18.3) f236.6) 1443.71 {710.01
12-035-4
0
t The table gives the standard values for machines without fan.
-r Order
Engine
Item
model
1 2 3 4 5 6
Engine speed 800 1,000 1,200 1,200 1,500 1,800

OEM for
ggyTrar 392 883 1,373
Load 0 2,059 3,727
1401 1901 U401 C2101 {3801
508 HP)
Flywheel 29.4 79.5 123.6 231.8 503.4
0
Horsepower (39.4) I106.5) 1165.6) f310.61 l674.41
Engine speed 800 1,000 1,200 1,200 1,500 1,800

OEM for
r,n7epar 539 1,079 2,157 3,236
Load 0 4,315
155) UlOI {2201 I3331 1440)
559 HP)
Flywheel 40.5 97.2 194.3 364.3 582.9
0
Horsepower 154.2) 1130.2} 1260.3) {488.1} I780.91
OEM for Engine speed 800 1,000 1,200 1,200 1,500 1,800
prime use
g7rF$r 392 834 1,667
Load 0 2,501 3,334
{401 I851 I1701 I2551 I3401 z
506 HP)
z
Flywheel 29.4 75.1 150.1 281.9 375.4
Horsepower 0 z
C39.4) ClOO.61 {201.11 f377.61 1502.9)
SA6D170-B-
Gnning time 3 6 3 3 10 5
Engine speed 800 1,000 1,000 1,000 1,000 1,200

3EM for
j-pole
_oad 471 932 1,863 2,795 3,727
Jenerator 0
14481 1951 {I901 (2851 13801
50Hz)
+wheel 35.3 69.9 139.8 209.8 279.7
0
Horsepower C47.31 {93.7} U87.3) 1281.01 1374.7)
3unning time 3 6 3 3 10 5
%gine speed 800 1,000 1,000 1,200 1,200 1,200

IEM for
j-pole
.oad 490 981 1,961 2,942 3,923
gonezTtor 0
I501 {loo} 12001 {3001 14001
‘lywheel 36.8 73.6 176.6 265.0 353.3
0
Horsepower f49.3) 198.6) I236.61 {355.0} 1473.31
Iunning time 3 6 3 3 10 5
ingine speed 00 - 850 1,000 1,200 1,200 1,500 1,500

IEM for
.oad 392 1,177 1,961 3,040 3,432
generator 0
I401 {1201 {2001 13101 13501
:lywheel 29.4 106.0 176.6 342.2 386.4
Horsepower 0
I39.41 U42.01 f236.61 I458.51 I517.7)
12-035-5
0
Engine Applicable Order
model machine Item
Running time min.
WA600-1
[EC regula
Engine speed
1 rPm
N
tion) Load
{kg1
Flywheel kW
Horsepower {HP}
Running time min.
DENY0
Engine speed 1 rprn
enerator N
i?CA600SS Load
{kg1
Flywheel kW
Horsepower {HP)
Running time min.

Engine speed rPm
For MQ
generator N
DCA- Load
(kg)
500SSK
Flywheel kW
Horsepower {HP}
Running time min.

Engine speed
N
Load
{kg)
Flywheel kW
Horsepower (HP1
Running time min.
For MQ
generator
Engine speed
1 rPm
N
DCA- Load
{kg1
500SSK
Flywheel kW
Horsepower {HP}
Running time min.

Engine speed rPm
Load N
{kg)
Flywheel kW
Horsepower {HPI
60170-1 SERIES
Order
Engine Applicable
machine Item
model
Running time 1 min.

Engine speed 1 rPm
Generator
(50 Hz only Load
Flywheel
Horsepower
Running time
Engine speed
SAA6D170-
P740 Load
Flywheel
Horsepower
Running time
Engine speed
SAA6D170-
P800 Load
Flywheel
Horsepower
Running time min.

Engine speed 1 rPm
Load
Flywheel
Horsepower
Running time min.

Engine speed 1 rPm
Load
Flywheel
Horsepower
Running time min.

Engine speed 1 rPm
Load
Flywheel
Horsepower
L
6D170-1SERIES
TESTING AND ADJUSTING PERFORMANCE TEST CRITERIA
PERFORMANCE TEST CRITERIA
l- Dvnamometerload (N {kg))
Engine .pplicable Specified value Elnginespeed
nachine
Test item
(fullyequippe) Arm length Arm length Arm length
model (rpm)
716mm 895mm 1,023 mm
F 2,409 -2,542 1,927 -2,064 1,686 -1,779

1,795-1,805
245.6-259.2) 196.5 -207.4) 171.9 -181.41
2,079 Nm/1,300 rpm 2,924-3,100 2,340 -2,480 2,047 -2,169

nAax. torque 1l,300-1,500 208.7 -221.2)
1212 kgm/1,300 rpm1 298.2 -316.1) 238.6-252.91
275A-2
tiigh idlingspeed 1,960-2,040 rpm 1,960-2,040 - - -
1.owidling speed 600-660 rpm 600-660 - - -
F:lywheel 302 kW/1,600 rpm 2,598- 2,747 2,078 -2,198 1,818 -1,922
1,595 -1,605
Horsepower I405 HP/l,800 rpm) :264.9-280.11 :211.9-224.1) ,185.4- 196.0)
2,030 Nm/1,200 rpm 2,852-3,021 2,281 -2,417 1,996-2,114

Fwlax.torque l,lOO-1,300
{207 kgm/1,200 rpm) :290.8-308.1) :232.6-246.5) ,203.5-215.6)
C650-1
c1500-1
t 1,700-1,800 - - -
1 650-700 - - -
S6D170-1
f 2,143-2,270 1,711 -1,715 1,499 - 1,589
1!,995-2,005
(218.5-231.51 (174.8-185.21 J52.9 - 162.0)
1,961 Nm/1,400 rpm 2,795-2,922 2,236-2,338 1,956- 2,046 8

IVlax.torque 11,250- 1,450
I200 kgm/1,400 rpm} (285.0-298.0) (228.0-238.41 :199.5-208.6) z
VA600-1
- - - z
I 2,200-2,300 rpm ;!,200-2,300
I 650-700 - - -
I 2,334 - 2,471 1,867 -1,977 1,634-1,730

1,995-2,005
1238-2521 (190.4-201.61 [166.6-176.41
2,089 Nm/1,400 rpm 2,899-3,073 2,319 -2,459 2,029 -2,152

I\nax.torque 1,300-1,500
(213 kgm/1,400 rpm) {295.6-313.41 {236.5-250.71 (206.9-219.4)
VA600-1
I-lighidlingspeed 2,200-2,300 rpm :!,300-2,400 - -
ILow idling speed 650-700 rpm 650-700 - - -
12-036
0
* 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.
t Fuel used: ASTM D975 No. I or No. 2 diesel fuel.
* Lubricaton ooil used: CLASS-CO SAE30.
Fuel Coolant Lubrication Lubrication Exhaust

out put Torque consumption temperature Niltemperature oil pressure temperature
(kW {HP}) (Nm {kgm)) (set/500 cc) (“C) (“C) &Pa h/cm2H (‘C)
325.3 - 343.4 - 294 - 490

Min. 19.7 70-90 80-110 Max. 600
(435.8 - 460.1) {3.0 - 5.0)
- 2,095 - 2,226 - -
70-90 80-110 Max. 650
{213.6 - 226.4)
- - 294 - 490 -
70-90 80-110
(3.0 - 5.0)
- - - Min. I47 -
70-90 Min. 80
{Min. 1.5}
311.9-329.9 - 343 - 490

Min. 21.6 70-90 80-110 Max. 600
{417.9 - 441.9) 13.5 - 5.01
- 2,042 - 2,163 -
Min. 25.0 70-90 80-110 Max. 650
1208.2 - 220.6)
- - 343 - 490 -
70-90 80-110
t3.0 - 5.01
- - Min. 147 -
70-90 Min. 80
{Min. 1.5)
321.6 - 340.8 - 294 - 490

Min. 19.2 70-90 80-110 Max. 600
1430.9 - 456.51 13.0 - 5.01
2 - 1,999 - 2,097
f203.8 - 213.81
Min. 22.2 70-90 80-110 - Max. 650
G
z - - - 70-90 80-110
294 - 490
f3.0 - 5.01
-
- - - Min. 147 -
70-90 80-110
{Min. 1.5)
350.3 - 370.9 - 324 -

Min. 17.5 70-90 so - 120 Max. 600
1469.3 - 496.9) l3.3 -1
- 2,075 - 2,230 - 70-90 so - 120 - Max. 650

{211.6 - 227.4)
- - - 70-90 so - 120 -
- - - Min. 70 Min. 80 -
12-037
0
Applicable Engine speed Dynamometer Load

Test item Specified value
machine (rpm) (N {kg])
Flywheel 385 kW/1,800 rpm 2,937 - 3,015

1,795 - 1,805
Horsepower 1516 PS/1,800 rpm} (299.5 - 307.51
Max. torque - - -
!PS6D170.
High idling speel - - -
Low idling speer - - -
324 kW/1,500 rpm (50 Hz) 2,844 - 3,001 (50 Hz)

Flywheel {434 HP/l,500 rpm} (50 Hz) 1,495 - 1,505 (50 Hz) 1290.0 - 306.0) (50 Hz)
Horsepower 371 kW/1,800 rpm (60 Hz) 2,736 - 2,893 (60 Hz)
I497 HP/l,800 rpm} (60 Hz) 1,795 - 1,805 (60 Hz) 1279.0 - 295.0) (60 Hz)
3EM for
Max. torque - - -
Jenerator
Prime USE
Max. 1,560 rpm (50 Hz) - -
High idling speel - -
Max. 1,872 rpm (60 Hz)
Low idling speec 700 - 800 rpm - -

S6D170-1
355 kW/1,500 rpm (50 Hz) 3,119 - 3,589 (50 Hz)
Flywheel {476 HP/l,500 rpm} (50 Hz) 1,495 - 1,505 (50 Hz) I318.0 - 366.0) (50 Hz)
Horsepower 408 kW/1,800 rpm (60 Hz) 3,011 -3,168 (60 Hz)
I547 HP/l,800 rpm} (60 Hz) 1,795 - 1,805 (60 Hz) I307.0 - 323.0) (60 Hz)
3EM for 8
generator Max. torque - - - G
Stand by
use)
High idling speel
Max. 1,575 rpm (50 Hz) Max. 1,575 (50 Hz) - z
Max. 1,890 rpm (60 Hz) Max. 1,890 (60 Hz)
Low idling speec 700 - 800 rpm 700 - 800 -
345 kW/1,500 rpm (50 Hz) 3,109 - 3,197 (50 Hz)

Flywheel {462 HP/l,500 rpm} (50 Hz) 1,495 - 1,505 (50 Hz) t317.0 - 326.0) (50 Hz)
{539 HP/l,800 rpm} (60 Hz) 1,795 - 1,805 (60 Hz) C310.0 -319.0) (60 Hz)
3EM for
Max. torque - - -
generator
Power up
Max. 1,560 rpm (50 Hz) Max. 1,560 (50 Hz) -
High idling spee,
Max. 1,872 rpm (60 Hz) Max. 1,872 (60 Hz)
Low idling speec 700 - 900 rpm 700 - 900 -
12-037-l
0
** 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 Fuel Coolant Lubrication Lubrication Exhaust

horsepower Torque consumption temperature )iltemperature oil pressure temperature
(kW {HPH (Nm (kgm)) (secI200 ec) CC) OC) (kPa {kg/cm2)) (-0
Min. 15.9 70 - 90 80-110 Max. 650
- - - -
- 70 - 90 80-110 -
- Min. 70 Min. 80 -
Min. 12.3 294 - 490

80-110 (3.0 - 5.0} Max. 650
- - - Max. 650
- 80-110 294 - 490 -

{3.0 - 5.01
- Min. 80 Min. 147
(Min. 1.5)
-
Min. 16.5 80-110 294 - 490 Max. 620

(3.0 - 5.0)
- -
8 0 - 110 -
Min. 80 Min. 147
{Min. 1.5)
Min. 18.5 70 - 85 80-110 -

343 490
Max. 600
{3.5 - 5.0)
Min. 15.8 70 - 85 80-110 -
343 490 Max. 650
-
{3.5 5.01
- - - - -
- 70 - 85 80-110
343 - 490
(3.5 - 5.01
-
- Min. 70 Min. 80 Min. 177
{Min. 1.8)
-
6D170-1 SERIES
- Dynamometer load (N {kg])

Engine Applicable Test item Specified value Engine speed
model machine (fully equippe) lrpm) Arm length Arm length Arm length
-- 716 m m 895 m m 1,023 m m
Flywheel 504 kW/2,100 rpm

Horsepower (702 HP/2,100 rpm)
IHD465-3
,[with single Max. torque
2,824 Nm/1,400 rprn
turbo- {288 k / l , 4 0 0 rpm)
Icharger, twii
turbo- High idling speed 2,250 - 2,380 rpm
,charger)
Low idling speed 850 - 900 rpm
-
Horsepower (715 HP/2,100 rpm}
IHD465-5 2,971 Nm/1,400 rpm

,(with (303 kgm/1,400 rpm)
mechnical
governor) High idling speed 2,400 - 2,500 rprn
1
-
Horsepower {641 HP/2,000 rprn}
2,815 Nm/1,400 rpm
Max. torque {287 kgm/1,400 rpml
High idling speed 2,240 - 2,300 rprn

-
Max. flywheel 900 HPI - 2,100 rpm
Horsepower
High idling speed 2,300 Â 50 rpm
Low idling speed 600*? rprn
--
1 : Withs lie turbocharger

*2: With t 1 turbocharger
6D170-1 SERIES
* The values in the table are indicated at standard conditions (Armospheric temperature 25"C, atmospheric pressure 196.8
kPa (750 m m Hg}.
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 S A E ~ O .
Out put
(kW (HPH
Torque
(Nm (kgm)) 1 cE$$iyFr Coolant
temperature
CC)
Lubrication
ail temperature
CC)
Lubrication
oil pressure
(kPa {kg/cm2})
Exhaust
temperature
CC)
- Min. 12.0 80- 170 196 - 392

{2.0 - 4.0} Max. 550
2,736 - 2,913 Min. 15.5 80- I I O

(279.0 - 297.0) Max. 600
80- 110 -
Min. 80 Min. 147 -

{Min. 1.5)
- Min. 11.6 80 - 110 294 - 490

Max. 650
(3.0 - 5.0)
80-110 Max. 670
80-110 -
Min. 80
Min. 147
{Min. 1.5) I -
- Min. 13.6 80-110 Max. 650
80- 110 - Max. 650
80-110
Min. 147
Min. 80 {Min. 1.5) -
3.0 - 5.0 Max. 650 + 3t

Min. 10.0
- fat rated fuel
consumption}
Min. 1.0
6D 1 70-1 SERIES
Engine Applicable Engine speed Dynamometer Load

model machine (rpm) (N (kg])
Flywheel 434 kWll.750 rpm 3,376 - 3,573

1,745- 1,755
Horsepower (582 HP/l ,750 rpm) (344.3 - 364.31
2,731 Nm/1,300 rpm 3,808 - 4,038

Max. torque 1,200 - 1,400
(278 kgm/1,300 rpm} (388.3 - 411.8)
Pc1ooosP~
High idling spee d 1,900 - 2,000 rpm 1,900 - 2,000 -
Low idling spee d 650 - 700 rpm 650 - 700 -
Flywheel 533 kW/2,100 rpm 3,400 - 3,605

2,095 - 2,105
Horsepower (715 HP/2,100 rpm) (348.7 - 367.6)
HD465-5 2,971 Nm/1,400 rpm 4,081 - 4,327

Max. torque 1,300 - 1,500
(with I303 kgm/1,400 rpml (416.1 - 441.21
electronic
governor) High idling spee d 2,330 - 2,400 rpm 2,330 - 2,440 -
Flywheel 387 kW/2,100 rpm 2,377 - 2,526

1,995 - 2,105
Horsepower (518 HP/2,100 rpm} (242.4 - 257.61
2,108 Nm/1,400 rpm 2,856 - 3,026 8

HD465-5 Max. torque 1,300 - 1,500
(215 kgm/1,400 rpml (291.9 - 308.61
(Hifh alti- z
tude spec ;;;
Low idling spee d 1,075 - 1,125 rpm 1,075 - 2,400 -

SA6D170-A-
Flywheel 552 kW/2,000 rpm 3,496 - 3,677
1,995 - 2,005
Horsepower (740 HP/2,000 rpm} (356.5 - 375.01
2,501 Nm/1,400 rpm Min. 3,496

Max. torque 1,300 - 1,500
{255 kgm/1,400 rpm) (Min. 356.5)
EM680A
Flywheel 552 kW/2,100 rpm 3,638 - 3,677

2,000
Horsepower (740 HP/2,100 rpm} (371 - 375)
2,893 Nm/1,400 rpm Min. 4,328

Max. torque 1,300 - 1,500
EM680-A (295 kgm/1,400 rpm} (Min. 432.81
6M170B-1
Low idling spee d 550 - 600 rpm 550 - 600
Flywheel 629 kW/2,000 rpm 4,084 - 4,291

1,995 - 2,005
Horsepower (842 HP/2,000 rpm} {416.5 - 437.51
3,295 Nm/1,400 rpm Min. 4,602

Max. torque 1,300 - 1,500
(336 kgm/1,400 rpml (Min. 469.3)
EM680A-A
-
--L
*I : Without
Low idling spee’ d
manne gear
550 - 600 rpm 550 - 600
12-037-5
0
* The table gives the standard values using the JIS compensator factor.
* The values in the table are the standard values for machines with the
* The loads for the dvnamometer are at an arm’s length of 716 mm

Torque consumption temperature %I temperature oil pressure temperature
horsepower
(Nm Ikgml) (set/500 cc) (“0 YC) (kPa {kg/cm21) (“C)
(kW {HP))
443.4 - 469.2 343 - 490

Min. 14.9 70-90 80-110 Max. 700
t594.1 - 628.61 13.5 - 5.0)
2,727 - 2,892 - 343 - 490

70-90 80-110 Max. 700
{278.1 - 294.9) {3.5 - 5.0)
- 343 - 490 -
70-90 80-110
13.5 - 5.01
- - Min. 147
- 70-90 Min. 80 -
{Min. 1.5)
535.8 - 568.2 294 - 490

Min. 12.0 70-90 80-110 Max. 650
{717.8 - 761.2) (3.0 - 5.0)
2,922 - 3,099 - 70-90 80-110 Max. 670

1298.0 - 316.0)
294 - 490 -
70-90 80-110
{3.0 - 5.0)
Min. 147
- - 70-90 Min. 80 -
{Min. 1.51
374.6 - 398.2 294 - 490

Min. 16.5 70-85 80-110 Max. 620
1501.9 - 533.41 {3.0 - 5.0)
2,050 - 2,167 - 70-85 80-110 - -

{209 - 221)
- - 70 - 85 80-110 -
- - Min. 147
- 70 - 85 Min. 80
{Min. 1.5)
-
524.8 - 552.0 - 294 - 490

Min. 12.9 70 - 95 80-110 Max. 650
(703.0 - 739.5) 13.0 - 5.01
- Min. 2,501
Min. 18.8 70 - 95 80-110 Max. 650
{Min. 255.0)
- 70 - 95 80-110 -
-
- - Min. 147 -
70-95 Min. 80
{Min. 1.5}
546.1 - 552.0 - 294 - 490

Min. 12.2 70 - 90 80-110 Max. 600
i731.6 - 739.5) t3.0 - 5.0)
- Min. 3,040 - 70-90 80-110 Max. 600

{Min. 310)
- 70 - 90 80-110 -
- Min. 147
- - 70 - 90 Min. 80 -
{Min. 1.5)
613.1 - 644.0 - 294 - 490

Min. 10.7 70 - 90 80-110 Max. 600
i821.3 - 862.8) {3.0 - 5.0)
Min. 3,295
Min. 14.8 70 - 90 80-110 - Max. 600
{Min. 336)
- - - 70 - 90 80-110 -
Min. 147 -
70-90 Min. 80
{Min. 1.5)
12-037-6
a9
T Dynamometer load (N {kg))

Engine splicable Specified value ingine speed
Test item Arm length Arm length Arm length
model nachine (fully equippe) (rpm)
716 mm 895 mm 1,023 mm
+wheel (50Hz) 431 kW/1,500 rpm 4,008 - 4,242 -

1,495 - 1,505
Horsepower {578 HP/l,500 rpm) 408.7 - 432.6)
(60Hz) 473 kW/1,800 rpm 3,716 - 3,933
1,795 - 1,805
{634 HP/l,800 rpm} 378.9 -401.11
3550-I High idling speed -
Max. 1,560 rpm Max. 1,560 0
(50Hz)
(60Hz) Max. 1,872 rpm Max. 1,872 0
Low idling speed 700-800 rpm 750 z!C50 0 - -
+wheel (50Hz) 456 kW/1,500 rpm 4,126 - 4,256 3,301 - 3,405 !,888 - 2,979
1,495- 1,505
-lorsepower {611 HP/l,500 rpm} 420.7 - 434.0) 336.6 - 347.2) Z94.5 - 303.81
(60Hz) 502 kW/1,800 rpm 3,825 - 3,933 3,060 - 3,145 !,677 - 2,753
1,795 - 1,805
{673 HP/l,800 rpm) 390.0 -461.11 312.0 - 320.8) !73.0 - 280.7)
3580-I
iigh idling speed - -
35808-l Max. 1,560 rpm Max. 1,560
(50Hz)
(60Hz) Max. 1,872 rpm Max. 1,872 - - -
_ow idling speed 700 - 900 rpm 700 - 900 - - -
3ywheel (50Hz) 472kW/1,500 rpm 4,276 - 4,393 3,450 - 3,515 !,993 - 3,075
1,495 - 1,505
iorsepower I633 HP/l,500 rpm) 1436 - 4481 348.8 - 358.4) $05.2 - 313.6}
-iigh idling speed - - -

35808-l L Max. 1,560 rpm 1,550 - 1,560
(50Hz)
_ow idling speed 700 - 900 rpm 700 - 900 - -
SAGDI 70-A.
-lywheel (50Hz) 470 kW/1,500 rpm 4,249 - 4,381 3,399 - 3,504 1,974 - 3,066
1,495 - 1,505
iorsepower {630 HP/l,500 rpm) 433.3 - 446.7) 346.6 - 357.3) 103.3 - 312.61
(60Hz) 513 kW/l,SOO rpm 3,906 - 4,015 3,124-3,212 1,734 - 2,810
3600-I 1,795 - 1,805
1688 HP/l,800 rpm} 398.3 - 409.41 318.6 - 327.51 !78.8 - 286.5)
36008-l
3600BS-1 iigh idling speed - -
IM for Max. 1,560 rpm Max. 1,560
(50Hz)
nerator - - -
(60Hz) Max. 1,872 rpm Max. 1,872
_ow idling speed 700 - 900 rpm 700 - 900 - -
Flywheel 440 kW/l,SOO rpm 3,304 - 3,503 2,643 - 2,803 2,312 - 2,452
1,795 - 1,805
Horsepower I590 HP/l,800 rpm) (336.9 - 357.2 L269.5 - 285.8 235.8 - 250.0)
2,648 Nm/l,300 rpm 3,670 - 3,888 2,936 - 3,111 2,568 - 2,721

Max. torque 1,200 - 1,400
I270 kgm/1,300 rpm] L374.2 - 396.5 :299.4 - 317.2 261.9 - 277.5)
PSAGDI?
-A.
High idling speec 1,950 - 2,050 rpm 1,950 - 2,050 - - -
Low idling speed 750 - 850 rpm 750 - 850 - - -
Flywheel 504 kW/2,000 rpm 3,291 - 3,495 - -

1,995 - 2,065
Horsepower {675 HP/2,000 rpm) F335.6 - 356.4
2,795 Nm/1,300 rpm 3,786 - 4,020 - -

Max. torque 1,200 - 1,400
D465-3 I285 kgm/1,300 rpml L386.1 - 409.9
or ORAP
rllNE) -
High idling speec 2,250 - 2,350 rpm 2,250 - 2,350
Low idling speed 840 - 860 rpm 840 - 860
12-038
0
* The values in the table are indicated at standard conditions (Armospheric temperature 25”C, atmospheric pressure 196.8
kPa {750 mm HgI.
t The values given for dynamometer loads the output and torque are with the fan removed, so they differ from those of the
secification.
* (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.
Fuel Coolant LLlbrication Lubrication Exhaust

out put Torque consumption temperature oil tlemperature oil pressure temperature
(kW {HP)) (Nm {kgm}) (set/500 cc) (‘Cl (“C) (kPa {kg/cm% (‘C)
-
450.6 - 477.4 - 265 - 392

27.0 - 28.5 70-90 80-115 Max. 650
I604.0 - 640.0) (2.7 - 4.0)
501.3 - 531.2 - 294 - 441
24.0 - 25.0 70-90 80-115 Max. 650
I672.0 - 712.01 13.0 - 4.51
- 70-90 80-115 - -
- 70-90 SO-115 - -
- Min. 147 -
70-90 Min. 80
{Min. 1.51
464.2 - 478.9 - 265 - 392

Min. 26.0 70-85 80-110 Max. 650
1622.2 - 641.9) {2.7 - 4.0)
516.4- 531.1 - 294 - 441
Min. 23.4 70-85 80-110 Max. 650
t692.2 - 711.9) 13.0 - 4.51
- 70-85 80-110 - -
- 70-85 80-110 - -
- Min. 147 -
70-85 Min. 80
{Min. 1.5)
-
480.3 - 494.2 - 265 - 392

Min. 13.7 70-85 80-110 Max. 650
W3.8 - 662.5) (2.7 - 4.0)
8
z - - - 70-85 80-110 -
z
- - - Min. 147
70-85 Min. 80
{Min. 1.5)
-
478.1 - 492.8 - 265 - 392

Min. 25.2 70-85 80-110 Max. 650
WO.9 - 660.61 12.7 - 4.0)
527.4 - 542.1 - 294 - 441
Min. 22.9 70-85 80-110 Max. 650
I707.0 - 726.7) 13.0 - 4.5)
0 0 70-85 80-110 - -
0 0 70-85 80-110 - -
Min. 147 -
0 0 70-85 Min. 80
{Min. 1.5)
446.1 - 473.0 - 294 - 441

Min. 14.4 70-85 80-110 Max. 650
1598.0 - 634.01 {3.0 - 4.5)
2,628 - 2,785 - 70-85 80-110 - -

1268 - 2841
- - 70-85 80-110 - -
- - Min. 147 -
70-85 Min. 80
{Min. 1.5)
-
488.6 - 519.2 - 294 - 490

Min. 25 80-110 Max. 680
I655 - 6961 I3.0 - 5.01
- 2,712 - 2,879 - 80-110 - -

1276.5 - 293.61
- - - 80-110 - -
- - Min. 147
Min. 80
{Min. 1.5)
12-039
0
Engine Applicable Engine speed Dynamometer Load

model machine (rpm) (N {kg])
473 kW/1,500 rpm (50 Hz) 4,276 - 4,395 (50 Hz)

?ywheel (633 HP/l,500 rpm} (50 Hz) 1,495 - 1,805 (50 Hz) I436 - 4481 (50 Hz)
(732 HP/l,800 rpm1 (60 Hz) 1,795 - 1,805 (60 Hz) (423 - 435) (60 Hz)
3EM for Vlax. torque - - -

generator
iigh idling specs

Max. 1,560 rpm (50 Hz) Max. 1,568 (50 Hz) -
Max. 1,881 rpm (60 Hz) Max. 1,881 (60 Hz)
_ow idling speel 950 - 900 rpm 700 - 900 -
470 kW/1,500 rpm (50 Hz) 4,119-4,374 (50 Hz)

+wheel 1630 HP/l,500 rpm} (50 Hz) 1,495 - 1,505 (50 Hz) (420 - 4461 (50 Hz)
{688 HP/l,800 rpm} (60 Hz) 1,795 - 1,805 (60 Hz) {384 - 4071 (60 Hz)
EGGOOBS-’
OEM for - - -
generator Wax. torque
;Engine No.
15503 and ur High idling spee
Max. 1,568 rpm (50 Hz) Max. 1,568 (50 Hz) -
Max. 1,881 rpm (60 Hz) Max. 1,881 (60 Hz)
Low idling speem 700 - 900 rpm 700 - 900 -
419 kW/1,500 rpm (50 Hz) 3,675 - 3,909 (50 Hz)

Flywheel (561 HP/l,500 rpm} (50 Hz) 1,495 - 1,505 (50 Hz) I374.7 - 398.6) (50 Hz)
1625 HP/l,800 rpm} (60 Hz) 1,795 - 1,805 (60 Hz) f351.7 - 373.81 (60 Hz)
OEM for - -
generator Max. torque
(Prime use
Max. 1,568 rpm (50 Hz) Max. 1,568 (50 Hz)
High idling spee Max. 1,881 (60 Hz)
Max. 1,881 rpm (60 Hz)
Low idling spee 700 - 900 rpm 700 - 900 -

SA6D170-A-
581 kW/1,500 rpm (50 Hz) Min. 5,237 (50 Hz)
Flywheel {779 HP/l,500 rpm} (50 Hz) 1,495 - 1,505 (50 Hz) {Min. 5341 (50 Hz)
(900 HP/l,800 rpm} (60 Hz) 1,795 - 1,805 (60 Hz) (518 - 549) (60 Hz)
OEM for
generator Max. torque - - -
(::;d by
High idling spee
Max. 1,575 rpm (50 Hz) Max. 1,575 (50 Hz) -
Max. 1,890 rpm (60 Hz) Max. 1,890 (60 Hz)
Flywheel 552 kW/2,000 rpm 3,589 - 3,677

1,995 - 2,005
Horsepower I740 HP/2,000 rpm} (366 - 3751
Max. torque - - -
OEM for
marine
High idling spee 2,100 - 2,200 rpm 2,100 - 2,200 -
Flywheel 512 kW/1,800 rpm 3,560 - 3,724

1,795 - 1,805
Horsepower I686 HP/l ,800 rpm) {363 - 379.7)
EPSAGDli Max. torque - - -

-A-l
(512 kW/
686 HF High idling spee Max. 2,200 rpm Max. 2,200 -
Low idling spee 600 - 1,000 rpm 600 - 1,000 -
12-039-l
0
t The table gives the standard values using the JIS compensator factor.
* The loads for the dvnamometer are at an arm’s length of 716 mm

Torque consumption
horsepower temperature )il temperature oil pressure temperature
(Nm {kgrn)) (set/500 cc)
(kW WR) (“C) (“C) Wa {kg/cm*)) (“C)
480.6 - 494.6 (50 H2 - 255 - 441

Min. 13.7 70-85 80-110 Max. 650
1643.9 - 662.6) (50 H2 y.. I “&1
560.1 - 576.3 (60 Hz - Min. 11.4 70-85 80-110 Max. 650
1750.3 -772.0) (60 Hi 12.6 - 4.5)
- - - - - - -
- - - 70-85 80-110
255 - 441 -
l2.6 - 4.5)
- - - Min. 70 Min. 80
Min. 147 -
{Min. I.51
463.7 - 492.4 (50 Hz - 343 - 441

Min. 14.0 70 - 85 80 - 105 Max. 650
1621.2 - 629.6) (50 Hi $3.3” I &5;
508.6 - 539.5 (60 Hz - Min. 12.4 70-85 80 - 105 Max. 650
1681.3 -722.7) (60 H2 l3.5 - 4.5)
- - - - - -
- - 70-85 80 - 105
343 - 441 -
13.5 - 4.51
- - - Min. 70 Min. 85
Min. 147 -
{Min. 1.5}
413.6 - 440.1 (50 Hz - 255 - 441

Min. 15.0 70 - 85 80-110 Max. 650
1554.1 - 589.6) (50 H2 12.6 - 4.5)
465.9 - 495.3 (60 Hz - 255 - 441
Min. 13.3 70-85 80-110 Max. 650
1624.1 - 663.6) (60 H2 12.6 - 4.5)
8
z - - - - - -
z
- - 70-85 80-110
255 - 441 -
12.6 - 4.5)
- - - Min. 70 Min. 80
Min. 98 -
{Min. 1.0)
Min. 589.5 (50 Hz - 226 - 392

Min. 11.3 70-85 80-110 Max. 700
{Min. 789.9) (50 Hz :‘i; 1 y.
686.0 - 727.2 (60 Hz
Min. 9.3 70-85 80-110 Max. 700
I919.0 -974.2) (60 H2 12.3 - 4.0)
- - - - -
- - 70-85 80-110
226 - 392 -
12.3 - 4.0)
- - Min. 70 Min. 80
Min. 147 -
{Min. 1.5)
538.0 - 552.0 294 - 490

Min. 12.4 80-90 90-110 Max. 650
1720.8 - 739.5) (3.0 - 5.01
- - - - -
294 - 490 -
80-90 90-110
c3.0 - 5.0)
- - - Min. 80 Min. 90
Min. 147 -
{Min. 1.5}
533.9 - 558.9 - 294 - 490

Min. 11.7 70-90 80-110 Max. 650
i715.2 - 748.8) 13.0 - 5.0)
- - - - - -
294 - 490 -
70-90 80-110
13.0 - 5.0)
Min. 147 -
Min. 70 Min. 80
{Min. 1.5)
12-039-2
@
T Dvnamometer load (N {kg))

Engine 4pplicable Specified value inginespeed
Test item Arm length Arm length 4rm length
model machine (fully
equippe) @pm)
716mm 895mm 1,023 mm
:lywheel 309 kW/1,800 rpm 2,942 -3,121 2,354-2,497 !,059-2,185

1,795 -1,805 !lO.O-222.8)
Horsepower {608 HP/l,800 rpm} (300.0-318.3) (240.0-254.61
2,609 Nmil.300 rpm 3,657 -3,880 2,925 - 3,104 1,560-2,715

Wax.torque 1,200 -1,400 !61.0-276.91
{266kgm/1,300rpm) (372.9-395.6) {298.3-316.5)
1375A-1
iigh idlingspeed 1,950-2,050 rpm 1,950 -2,050 0 0 0
_owidling speed 600-700 rpm 600-700 0 0 0
+wheel 392 kW/1,800 rpm 3,029 -3,209 2,423- 2,567 !,I20-2,246

1,795-1,805 !16.2-229.0)
Horsepower 1525 HP/l,800 rpm) (308.9-327.2) i247.1-261.81
2,618 Nm/1,300 rpm 3,767 -3,999 3,014-3,199 !,636-2,799

Irlax.torque 1,200- 1,400 !68.8-285.4)
1267 kgm/1,300 rpm} (384.1-407.8) (307.3-326.21
D375A-2
iigh idlingspeed 1,950-2,050 rpm 1,950 -2,050 0 0 0
_owidling speed 580-680 rpm 580-680 0 0 0
+wheel 405 kW/1,700rpm 3,226-3,413 2,581 - 2,730 !,258- 2,389

1,695-1,705 Z30.3-243.6)
Horsepower {542 HP/l,700 rpm} (329.0-348.0) (263.2-278.41
2,550 Nm/1,300 rpm 3,540-3,746 2,832 -2,997 !,478-2,622 8

Max.torque 1,200-1,400 252.7-267.4) ;;
1260 kgm/1,300rpm) {361.0-382.0) {288.8-305.61
Pc1000-1
1,800-1,900 0 0 0
z
650-700 0 0 0
SA6D170-B-
2,947 -3,123 2,358 -2,499 1,063-2,187
2,095 -2,105 210.4-223.0)
(300.5-318.5) 1240.4-254.8:
HD465-3 2,481 Nm/1,400 rpm 3,413 -3,599 2,730 -2,879 1,389 - 2,519
Max.torque 1,300- 1,500 243.6-256.91
with single (253 kgm/1,400 rpm) {348.0-367.0) 1278.4-293.6:
turbocharge
HD500-3 High idlingspeed 2.350-2.450 rpm 2,350-2,450 0 0 0
Low idling speed 800-900 rpm 800-900 0 0 0

I
Flywheel (50Hz) 351 kW/1,500 rpm 3,217-3,203

1,495-1,505
Horsepower (481 HP/l,500 rpm} (328.0-326.6) -
(60Hz) 406kW/1,800 rpm 3,057 -3,230 -
1,795-1,805 -
(544 HP/l,800 rpm) {311.7-329.4)
EG450-1 High idling speed 0 -
Max.1,560 rpm Max.1,560
(50Hz)
(60Hz) Max. 1,872 rpm Max. 1,872 0 -
Low idling speed 950 -1,000 rpm 950-1,000 0 - -
Flywheel (50Hz) 372 kW/1,500 rpm 3,373 -3,478 2,699 -2,782 2,361-2,434
1,495 -1,505
Horsepower 1498 HP/l,500 rpm} {344.0-354.7) (275.2-283.7 240.8-248.2)
(60Hz) 416 kW/1,800 rpm 3,181 -3,274 2,545 -2,619 2,226-2,292

1,795 -1,805
(557 HP/l,800 rpm1 (324.4-333.91 (259.5-267.1 227.0-233.7)
EG480-1
High idlingspeed 0 0 0
EG480B-1 Max.1,560 rpm Max. 1,560
(50Hz)
(60Hz) Max.1,872 rpm Max. 1,872 0 0 0
Low idling speed 700-900 rpm 700-900 0 0 0
12-040
0
* The values in the table are indicated at standard conditions (Armospheric temperature 25°C. atmospheric pressure 196.8
kPa 1750 mm Hg}.
secification.
* (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.
Fuel Coolant Lubrication Lubrication Exhaust

out put Torque consumption temperature #iItemperature oil pressure temperature
(kW {HP}) (Nm {kgm)) (set/500 cc) (‘C) (“C) (kPa {kg/cm% (“C)
397.3 - 421.5 - 294 - 490

Min. 17.0 70-90 80 - 100 Max. 550
I532.2 - 564.7) {3.0 - 5.01
- 2,569 - 2,778 -
Min. 19.3 70-90 80 - 100 Max. 600
I262.0 - 283.31
- 294 - 490 -
0 0 70-90 80 - 100
13.0 - 5.01
- Min. 245 -
0 0 70-90 Min. 80
{Min. 2.5)
409.2 - 433.5 - 294 - 490

Min. 16.5 70-90 80-110 Max. 650
I546.2 - 590.8) t3.0 - 5.01
- 2,697 - 2,859 - - Max. 650

70-90 80-110
l275.0 - 291.51
- 294 - 490 -
0 0 70-90 80-110
13.0 - 5.01
- Min. 147 -
0 0 70-90 Min. 80
{Min. 1.5)
411.4 - 435.7 - 343 - 490

Min. 16.3 70-90 80-110 Max. 700
t551.2 - 583.7) (3.5 - 5.0)
2 - 2,534 - 2,682 - - Max. 700

70-90 80-110
l258.4 - 273.51
z
z - 343 - 490 -
0 0 70-90 80-110
(3.0 - 5.0)
- Min. 147 -
0 0 70-90 Min. 80
{Min. 1.5)
457.9 - 485.5 - 294 - 490

Min. 13.1 70-85 80- 110 Max. 650
1622.1 - 659.6) 13.0 - 5.01
- 2,442 - 2,579 - - Max. 650

70-85 80-110
1249.0 - 263.01
- 294 - 490 -
0 0 70-85 80-110
f3.0 - 5.01
- Min. 147 -
0 0 70-85 Min. 80
{Min. 1.5)
351.1 - 370.9 (50 Hz - 245 - 392

23-27 70 - 100 100 - 120 Max. 680
{477.0 - 504.01(50 H2 (2.5 - 4.01
400.4- 423.2 (60 Hz - 245 - 392
26-30 70 - 100 100 - 120 Max. 650
W4.0 - 575.01(60 H2 (3.0 - 4.51
0 - 70 - 100 100-120 - -
0 - 70 - 100 100 - 120 - -
- 245 - 392 -
0 70 - 100 Min. 100
{3.0 - 4.5)
516.0 - 532.0(50 Hz - 265 - 392

Min. 17.5 70 - 85 80-110 Max. 650
I508.8 - 524.61(50 H2 12.7 - 4.0)
584.0 - 601.0 (60 H2 - 294 - 441
Min. 15.5 70-85 80-110 Max. 650
I575.8 - 592.61(60 Hz l3.0 - 4.5)
0 - 70-85 80-110 - -
0 - 70-85 80-110 - -
- Min. 147 -
0 70-85 Min. 80
{Min. 1.5)
12-041
0
Engine Specified value Sngine speec

T Dvnamometer load ir {kg})
Test item
model (fully equippe) (rpm) Arm length Arm length Arm length
716 mm 895 mm 1,023 mm
Flywheel (50Hz 383 kW/1,500 rpm 3,472 - 3,576 2,777 - 2,861 2,430 - 2,503
Horsepower 1,495 - 1,505
(513 HP/l,500 rpm} 364.0 - 364.7 283.2 - 291.7 247.8 - 255.2}
(6OH2 427 kW/1,800 rpm 3,264 - 3,351 2,611 - 2,680 2,284 - 2,345
1,795 - 1,805
I572 HP/l,800 rpm} 332.8 - 341.7 266.2 - 273.3 232.9 - 239.1)
iG550-1
iG500B-1 High idling speec
Max. 1,560 rpm Max. 1,560 0 0 0
iG500BS-1 (50Hz
(6OH2 Max. 1,872 rpm Max. 1,872 0 0 0
Low idling speec 700 - 900 rpm 700 - 900 0 0 0
Flywheel 408 kW/1,800 rpm 3,039 - 3,216 2,431 - 2,572 2,127 - 2,251
I540 HP/l,800 rpm) 309.9 - 327.9 247.9 - 262.3 216.9 - 229.5}
2,461 Nm/1,300 rpm 3,410 - 3,628 2,728 - 2,903 2,383 - 2,540

Max. torque 1,200 - 1,400
.PSA6D17( (251 kgm/1,300 rpm) 347.7 - 370.0 278.2 - 296.0 243.3 - 259.01
SA6D170-B-
-B-
High idling speec 1,950 - 2,050 rpm 1,950 - 2,050 - - -
Low idling speec 750 - 850 rpm 750 - 850 - - -
Flywheel Horse- 359 kW/1,500 rpm 3,210 - 3,406 - -

power (Prime use 1,495 - 1,505
{488 HP/l,500 rpm} 327.3 - 347.3
397 kW/1,500 rpm 3,655 - 3,759 - -

(Standby use) 1,495 - 1,505
{540 HP/l,500 rpm} 372.7 - 383.3,
High idling speec Max. 1,560 rpm Max. 1,560 - - -
Low idling speec 700 - 900 rpm 700 - 900 - - -
12-041-l
0
t The values in the table are indicated at standard conditions (Armospheric temperature 25’C, stmospheric pressure 196.8
kPa (750 mm Hg}.
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.
t Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
Fuel Coolant Lubricatic Lubrication Exhaust

out put Torque
consumption temperature oil temperai oil pressure temperature
(kW {HP}) (Nm IkgmI) (set/500 cc) (“0 (‘C) (kPa {kg/cm*}) (“C)
390.8 - 402.6 - 265 - 392

Min. 17.1 70-85 80-110 Max. 650
i523.6 - 539.3) 12.7 - 4.0}
440.9 - 452.6 294 - 441
Min. 15.2 70-85 80-110 Max. 650
t590.6 - 606.41 13.0 - 4.5}
0 - 70-65 80-110 - -
0 - 70-85 80-110 - -
- Min. 147 -
0 70-85 Min. 80
{Min. I.51
410.3 - 434.2 - 294 - 441

Min. 15.8 70-85 80-110 Max. 650
f550.0 - 582.0) I3.0 - 4.5)
- 2,442 - 2,599 - 70-85 80-110 - -

{249 - 265)
- - 70-85 80-110 - -
- - - 70-85 Min. 80
Min. 147 -
{Min. 1.5}
357.3 - 378.0 - 265 - 392

Min. 17.5 70-85 80-110 Max. 650
{479 - 508) 12.7 - 4.0)
407.3 - 418.5 -
2
- {546 - 5611
Min. 15.9 70-85 80-110
265 - 392
(2.7 - 4.01
Max. 650
b
z - - - 70-85 80-110 - -
- - - 70-85 80-110
Min. 147 -
{Min. 1.5}
12-041-2
0
Engine le Engine speed Dynamometer Load

Test item
model e frpm) (N {kg])
367 kW/1,500 rpm (50 Hz) 3,544 - 3,752 (50 Hz)

IFlywheel {492 HP/l,500 rpm) (50 Hz) 1,495 - 1,505 (50 Hz) I361.4 - 382.6) (50 Hz)
{557 HP/l ,800 rpm} (60 Hz) 1,795 - 1,805 (60 Hz) 1342.3 - 361 .O} (60 Hz)
OEM for IMax. torque - -

generato r
(Prime u!se) Max. 1,560 rpm (50 Hz) Max. 1,560 (50 Hz)
High idling spee -
Max. 1,890 rpm (60 Hz) Max. 1,890 (60 Hz)
ILow idling spee, 700 - 800 rpm 700 - 800 -
486 kW/1,500 rpm (50 Hz) 3,544 - 3,752 (50 Hz)

IFlywheel 1543 HP/l,500 rpm) (50 Hz) 1,495 - 1,505 (50 Hz) i361.4 - 382.6) (50 Hz)
{612 HP/l,800 rpm) (60 Hz) 1,795 - 1,805 (60 Hz) (342.3 - 361 .O) (60 Hz)
OEM for
generato r IMax. torque - -
v
%rd b’ Max. 1,575 rpm (50 Hz) Max. 1,575 (50 Hz)
IHigh idling spee
Max. 1,890 rpm (60 Hz) Max. 1,890 (60 Hz)
ILow idling spee 700 - 800 rpm 700 - 800 -
IFlywheel 341 kW/1,700 rpm 2,737 - 2,905

1,695 - 1,705
Horsepower I457 HP/l ,700 rpm) 1279.1 - 296.2)
2,157 Nm/1,300 rpm 3,004 - 3,187

Pc1000-1 I Max. torque 1,200 - 1,400
{220 kgm/1,300 rpm1 f306.3 - 325.0)
(High alti i-
tude spel d
High idling spee 1,800 - 1,900 rpm 1,800 - 1,900 -

SA6D170-B-
383 kW/1,500 rpm (50 Hz) 3,373 - 3,570 (50 Hz)
IFlywheel 1510 HP/l,500 rpm} (50 Hz) 1,495 - 1,505 (50 Hz) {344 - 364) (50 Hz)
EG500-1 1,795 - 1,805 (60 Hz)
{572 HP/l,800 rpm) (60 Hz) 1323 - 342) (60 Hz)
EG500B- 1
EG500BI i-1
OEM for Max. torque - - -
generato r
(Engine Nc1. IHigh idling spee
Max. 1,568 rpm (50 Hz) Max. 1,568 (50 Hz) -
13265 and uPI Max. 1,881 rpm (60 Hz) Max. 1,881 (60 Hz)
379 kW/1,500 rpm (50 Hz) 3,432 - 3,521 (50 Hz)

Flywheel ..~.
(508 HP/l ,..~
500 r _~_.
roml ~,
(50 Hz) 1,495 - 1,505 (50 Hz) 1350 - 359) (50 Hz)
1598 HP/l,800 rpm) (60 Hz) 1,795 - 1,805 (60 Hz) {346 - 355) (60 Hz)
OEM for Max. torque - - -

generato r
Max. 1,560 rpm (50 Hz) Max. 1,560 (50 Hz) -
High idling spee
Max. 1,872 rpm (60 Hz) Max. 1,872 (60 Hz)
417 kW/1,500 rpm (50 Hz) 3,668 - 3,883 (50 Hz)

Flywheel {559 HP/l,500 rpm) (50 Hz) 1,495 - 1,505 (50 Hz) {374 - 3961 150 Hz)
1660 HP/l,800 rpm) (60 Hz) 1,795 - 1,805 (60 Hz) {371 - 3931 (60 Hz)
OEM for IMax. torque - - -

generato r
Max. 1,568 rpm (50 Hz) Max. 1,568 (50 Hz) -
IHigh idling spee
Max. 1,881 rpm (60 Hz) Max. 1,881 (60 Hz)
Low idling spee’ 700 - 900 rpm 700 - 900
12-041-3
0
* The loads for the dynamometer are at an arm’s length of 716 mm

Torque
horsepower consumption temperature oil temperature oil pressure temperature
(Nm NgmI) (seci500 cc)
ikw {HP}) (“C) (“0 (kPa (kg/cm21) (“C)
362.1 - 382.7 (50 Hz - 265 - 392

Min. 17.7 70-95 80-115 Max. 680
W35.1 -512.7) (50 Hz {2.7 - 4.0}
412.9 - 436.4 (60 Hz 294 - 441
Min. 15.5 70-95 80-115 Max. 680
l553.1 - 584.71 (60 Hz {3.0 - 4.5)
- - - - - -
- - - 70-95 80-115 - -
- - - 70-95 Min. 80
Min. 98 -
{Min. l.O}
398.9 - 422.5 (50 Hz 265 - 392

Min. 16.1 70-95 80-115 Max. 680
1534.4 - 566.0) (50 Hz $‘9’;: I”4.i
453.4 - 478.4 (60 Hz
Min. 14.2 70-95 80-115 Max. 680
(607.4 - 640.9) (60 Hz i3.0 - 4.5)
- - - -
- 70-95 80-115 -
- - 70-95 Min. 80
Min. 98
{Min. 1.0)
349.2 - 370.6 392 - 539

Min. 18 70-90 90-110 Max. 650
W37.8 - 496.5) (4.0 - 5.5)
2,151 - 2,282 - 70-90 90-110 - -

(219.3 - 232.7)
- - 70-90 90-110 - -
- - Min. 70 Min. 90
Min. 118 -
{Min. 1.2)
379.0 - 402.6 (50 Hz 343 - 441

Min. 17.1 70-85 80-110 Max. 600
(507.8 - 539.31 (50 Hz $3.3” I t.4
427.6 - 454.1 (60 Hz
Min. 14.4 70 - 85 80-110 Max. 620
c572.9 - 608.4) (60 Hz (3.5 - 4.5)
- - - -
- 343 - 441
70-85 80-110
(3.5 - 4.51
- Min. 176
Min. 70 Min. 80
{Min. l.S}
385.7 - 396.7 (50 Hz 245 - 441

Min. 17.1 70 - 85 80-110 Max. 650
(516.7 - 531.51 (50 Hz i2.5 - 4.5)
457.8 - 471 .O (60 Hz) 245 - 441
Min. 14.2 70-85 80-110 Max. 680
(613.3 - 631.0) (60 Hz: (2.5 - 4.51
- - -
- 245 - 441
70-85 SO-110
12.5 - 4.5)
- Min. 147
Min. 70 Min. 80
{Min. 1.5}
412.9 - 437.9 (50 Hz) 245 - 441

Min. 15.9 70-85 80-110 Max. 650
1553.1 - 586.7) (50 Hz: 12.5 - 4.5)
491.6 - 521.1 (60 Hz: 245 - 441
Min. 13.2 70-85 80-110 Max. 650
1658.6 - 698.1) (60 Hz; {2.5 - 4.5)
- - -
- 245 - 441
70-85 80-110
f2.5 - 4.5)
- Min. 147
Min. 70 Min. 80
{Min. 1.5)
12-041-4
@
Engine Engine speed Dynamometer Load

model irpm) (N ikgl)
378 kW/1,500 rpm (50 Hz) 3,315 - 3,511 (50 Hz)

Flywheel 1,495 - 1,505 (50 Hz)
1506 HP/l,500 rpm} (50 Hz) {338 - 358) (50 Hz)
Horsepower
403 kW/1,800 rpm (60 Hz) 2,981 - 3,158 (60 Hz)
1539 HP/l,800 rpm} (60 Hz) 1,795 - 1,805 (60 Hz)
I304 - 21 I} (60 Hz)
Max. torque - - -
OEM for
generator High idling speed Max. 1,568 rpm (50 Hz) Max. 1,568 (50 Hz) -
Max. 1,881 rpm (60 Hz) Max. 1,881 (60 Hz) -
Low idling speed 700 - 900 rpm 700 - 900 -
Flywheel 445 kW/1,800 rpm 3,393 - 3,491

I597 HP/l,800 rpm) 1346 - 3561
Max. torque - -
EPSAGD17(
-B-
High idling speed Max. 2,200 rpm Max. 2,200 -
Low idling speed 600 - 1,000 rpm 600 - 1,000 -
275 kW/l,OOO rpm (50 Hz) 3,169 - 3,834 (50 Hz)

Flywheel 995 - 1,505 (50 Hz)
I369 HP/l,000 rpm) (50 Hz) 1369 - 3911(50 Hz)
Horsepower
345 kW/1,200 rpm (60 Hz) 3,815 - 4,031 (60 Hz)
I462 HP/l,200 rpm) (60 Hz) 1,195- 1,205 (60 Hz)
1389 - 41 I} (60 Hz)
OEM for 8
Max. torque - -
SA6D170-B- 6-pole - z
generator z
Max. 1,045 rpm (50 Hz) Max. 1,045 (50 Hz) -
High idling speed
Max. 1,254 rpm (60 Hz) Max. 1,254 (60 Hz)
Low idling speed 750 - 850 rpm 750 - 850 -
12-041-5
63
+ The values in the table are the standard values for machines with the
* The loads for the dynamometer are at an arm’s length of 716 mm

Torque
horsepower consumption temperature )il temperature oil pressure temperature
(Nm {kgm)) (seci500 cc)
ikW {HP}) (“C) (“0 ikPa {kg/cm*}) (‘C)
372.4 - 396.0 (50 - 245 - 441

Min. 16.8 70 - 85 80-110 Max. 600
f498.9 - 530.51 (50 i2.5 - 4.5)
401.9 - 426.9 (60 - 245 - 441
Min. 14.9 70 - 85 80-110 Max. 620
1538.4 - 571.91(60 12.5 - 4.5)
- - - - - -
- 245 - 441 -
70 - 85 80-110
12.5 - 4.5)
- 245 - 441 -
70 - 85 80-110
‘2.., “9.851
- - - Min. 70 Min. 80 -
{Min.’ l.O}
415.8 - 440.9 - 294 - 490

Min. 15.3 75-85 90-110 Max. 640
1557.1 - 590.61 t3.0 - 5.01
- - - -
- 294 - 490 -
75 - 85 80-110
I3.0 - 5.0)
- - - Min. 75 Min. 80
Min. 98 -
{Min. 1.0)
271.6 - 287.8 (50 Hz: - 294 - 441

Min. 24.2 70-85 85-110 Max. 650
f363.8 - 385.51 (50 Hz1 I3.0 - 4.5)
343.0 - 363.6 (60 Hz] 343 - 490
Min. 18.9 70-85 85-110 Max. 700
{459.5 - 487.1) (60 Hz) 13.5 - 5.0)
2
z
- - - -
z
- - -
- - - - Min. 147 -
* The SAA6D170-1 engine for the generator is equipped with an air-cooled aftercooler. The aircooled aftercooler is installed to
the generator at the front of the radiator. When carrying out an output performance test of the engine as an individual part,
install the radiator and air-cooled aftercooler to a stand to give a same condition as when they are mounted on the machine,
and operate with the fan.
12-041-6
03
Engine Applicable Engine speed

model machine
Test item I Specified value
(rpm)
Dynamometer Load
(N {kg])
Flywheel 305 kW
Horsepower (409 HP}
WA600-1
(EC regula-
tion)
Max. torque
High idling speed

I 2,200 - 2,300 rprn
Low idling speed 1 650 -700 rpm
4,190 - 4,380 (50 HZ)

Flywheel 470 kW {631 HP} (50 Hz) 1,495 - 1,505 (50 Hz) M20 - 4471 (50 Hz)
Horsepower 3,780 - 4,020 (60 ~ 2 )
513 kW {688 HP} (60 Hz) 1,795 - 1,805 (60 HZ) (386 - 41 11 (60 Hz)
DENY0
-
8enerator
CA~OOSSI
Max. torque
I -
Max. 1,570 rpm (50 Hz)
I Max. 1,570 (50 HZ)
Max. 1,880 rpm (60 Hz) Max. 1,880 (60 Hz)
Low idling speed1 700 - 900 rprn 1 700 - 900
Flywheel 513 kW/1,800 rpm (Net, 60 Hz) 1,795 - 1,805

Horsepower {688 HP/1,800 rpml (Net, 60 Hz)
For MQ
KSrtor
600SSK
High idling speed
Low idling speed

I
Flywheel
Horsepower
High idling speed
Low idling speed
Flywheel 426 kW/1,800 rpm (Net, 60 Hz:

Horsepower {572 HP/1,800 rpml (Net, 60 Hz;
For M Q
generator High idling speed
DCA-
5WSSK
Low idling speed 700 - 900 rprn
6D170-1SERIES
cornoressor ooem (if installed).
* The loads for the dynamometer are at an arm's length of 716 mrn
Flywheel Coolant Lubrication Lubrication Exhaust

horsepower temperature )iltemperature oil pressure temperature
(kW (HI']) CC) CC) (kPa {kg/cm21) TI
328 - 346 (Gross) - Min. 18.7

(445 -4701 (Gross) Max. 610
,010 - 2.110 (Gross)

{205 - 215) (Gross!
I -
Max. 650
Min. 150
{Min. 1.5)
-
- Min. 13.8 (50 Hz Max. 650
- Min. 12.0 (60 Hz Max. 650
340 - 540
(3.5 - 5.5)
Min. 180
{Min. 180)
- (Gross) 392 - 539 Max. 650

t685 - 729) (Gross) (4.0 - 5.5)
-
Min. 120
{Min. 1.2)
427 - 454 (Gross1 392 - 539 Max. 650

{573 - 6081 (Gross) 14.0 - 5.5)
- -
Min. 120 -
(Min. 1.21
6D170-1 SERIES
Engine Ipplicable Test item Specified value Engine speed Dynamometer Load
model machine (rpm) (N {kg])
Flywheel 597 kW/1,500 rprn (Net) 1,495 - 1,505

Horsepower 800 HP/1,500 rpm} (Net)
Max. torque
Senerator
50 Hz only
High idling speed Max. 1,570 rprn Max. 1,570
Low idling speed 700 - 900 rprn 700 - 900
Flywheel 568 kW/1,500 rprn 1,495 - 1,505

Horsepower (50 Hz) {762 HP/l,500 rpm}
Flywheel 662 kW/1,800 rprn 1,795 - 1,805
Horsepower (60 Hz) {887 HP/I,800 rprnl
5AA6D170. High idling speed
'740 Max. 1,568 rprn Max. 1,568 rprn
(50 Hz)
High idling speed Max. 1,882 rprn Max. 1,882 rprn
(60 Hz)
Low idling speed 700 - 900 rprn 700 - 900 rprn
Flywheel Horsepower 597 kW/1,500 rpm 1,495 - 1,505

(Prime power)(50Hz) 0300 HP/1,500 rprnl
Flywheel Horsepower 656 kW/1,500 rprn 1,495 - 1,505
(Standby power)(50Hz; 1880 HP/1,500 rpml
(Prime power)(50Hz)
(Standby powerX5OHz;
Low idling speed 700 - 900 rprn 700 - 900 rprn
6D170-1 SERIES
The table gives the standard values using the JIS compensator factor.
* The loads for the dynamometer are at an arm's lenath of 716 rnm

horsepower Torque temperature ail temperatur.
(kW (HP)) ( N (kgmu
~ (secj500 cc) CC) CC) (kPa {kg/cm21)
-
579 - 612 (Gross)

(775 - 819) (Gross) Min. 11.0 70 - 85 Max. 650
70 - 85
Min. 70 Min. 80 Min. 150

(Min. 1.5)
- 1 Min. 7.3 80 - 110 Max. 650
- 1 Min. 6.3 8 0 - 110 Max. 650
80 - 110 -
8 0 - 110 -
Min. 80 Min. 147

{Min. 1.5)
-
- 1 Min. 7.0 80 - 110 Max. 650
8 0 - 110 Max. 700
80-110
80-110
Min. 80 Min. 147

{Min. 1.51
1 _
6D170-1 SERIES
PRECAUTIONS WHEN OPERATING THE ENGINE
INDEPENDENTLY
* If the engine is operated independently on a bench

with a double lip seal fitted, the lubricating condi-
tions will differ from 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.
Clutch side Engine side

- _
6162F202
I
2. After completing running-in or bench testing,fit 23 k 0.6
the correct rear seal.
‘Torque co&etier
side or clutch side Engine side
H
6162F203
* Precautions when fitting rear seal
1) A new rear seal is coated with grease. In the

event that it becomes soiled, however, wipe it
clean with a cloth and coat it with about 1.2 to
1.6 cc of G2-Ll (lithium grease).
2) Be careful not to damage the rear seal when fit-

ting it.
TESTING AND ADJUSTING TOOL LIST
No. Inspection and measuring item Fault finding tool Part No. Remarks
Digital reading, pressure sensing

1 Engine speed Multi-tachometer 799-203-8001
type 60 to 19,999 rpm
2 Batten/ S.G. 1 .lOO to 1.300

Battery, coolant tester 795-500-l001
Freezing temperature of
3 -5°C to -50°c
cooling water
Water temperature, oil temperature,

4
air intake temperature
Digital temperature gauge 790-101-1500 -99.9 - 1.299”C
5 Exhaust temperature
0 to 20 kg/cm*
0 to 50 kg/cm2
8 intake pressure, exhaust pressure

1 Pressure test kit 799-203-2002 0 to 1,000 mmHg
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 503 D to 500 mmH,O
795-l 25-l 340 0.4, 1 .O mm
Dirtiness 0 to 70% with standard

799-201-9000 color
(Dirtiness % x l/10 = Bosch scale)
Provided with 6.1 and 0.2% water

15 Water and fuel content in oil Engine oil checker 799-201-6000
content standard samples.
11 1 Fuel injection pressure / Nozz,eteSter

Commercially
I to 300 kg/cm2
available
Fuel injection nozzle spray condition
18 Coolant quality Water quality tester 799-202-7001 JH, nitrite ion concentration
799-202-9001 I to 2 kg/cm*
Leakage in cooling water system
Anemometer
21 Radiator blockage (wind speed) 799-202-2001 I to 40 m/s
(Air speed gauge)
795-610-1000 X24V with starting engine

22 Engine cranking
6162-234820 :or 6D170-1 series engine
Commercially
23 Electrical circuits Tester Zurrent, voltage,_resistance
available
12-043
0
TESTING AND ADJUSTING DATE
Engine model T S6Dl70-1
C5Z
Applicable machine model
PC650-1
PC1500-1 T WA600-1
sifica item Condition, etc. Unit Standard Tolerance Standard Tolerance

-tior
High idling speed rpm 1,700-I ,800 1,700-I ,800 2,200-2,300 2,200-2,300
8 Engine speed
6 Low idling speed rpm 650-700 650-700 650-700 650-700
E
b
Lt o”c rpm Min. 100 - Min. 100 -
Necessary
I?
starting speed
-20°C (with starting aid) rpm Min. 100 - Min. 100 -
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 At rated output mmHg Min. 650 550 Min. 630 570
pressure)
Exh’aust tempera-
All speed Max. 650
ture (Turbine inlet “C Max. 650 Max. 700 Max. 700
(Intake air temp.: 2dC)
temperature)
Quick acceleration Max. 6.0 8.0
Max. 6.5 3.5
(Low idling + High idling) Bosch
Exhaust gas color 3.5 Max. 2.0 3.0
At rated output scale Max. 2.5
At high idling Max. 2.0 3.0 Max. 1.5 2.5
Valve clearance 0.4 - 0.4 -

(When engine is
hot or cold.) 1 .o - 1.0 -
8
Compression Oil temperature: ;;
kg/cm’ Min. 29 20 Min. 29 20
pressure 40°C to 60°C z
(SAEBO oil) (Engine speed) (rpm) (21 O-250) (210-250) (210-250) (210-250)
At rated output
Blow-by pressure Max. 150 300
Water temperature: mmH,C Max. 150 300
(SAE30 oil)
Min. 70°C
At rated output
SAEBO oil 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
Oil pressure
(Oil temperature: At low idling
Min. 8O’Cj 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
Oil temperature All speed (oil in oil pan) “C SO-110 120 SO- 110 120
Oil consumption At continuous rated output .o

% Max. 0.5 1 .o Max. 0.5 1
ratio (Ratio of fuel consumption)
Fuel injection 211 55::s(-#1604: 3) 211

Nozzle tester kg/cm’ 255 +’ 3
pressure +5 !65:?(#16044 -)
Fuel injection 42 f 1 42+1(-#16043 3) 42 + 1
1
B.T.D.C. degree 42 + 1
timing 38*1(#16044 -)
Radiator pressure Opening pressure 0.75 t 0.1 0.75 f 0.1
E 0.75 + 0.1
al valve (Differential pressure)
t;
>
_ ‘C650-1 j
Fan speed 1,200 f 30 1,200 f 30
‘Cl 500-I)
.-P
5
s Fan belt tension See page 12-031 _ -
-
*The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.
12-044
0
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA
S6D170-1
OEM for generator

D275A-2 EPS6Dl70-1 OEMforgenerator (Power up)
Standard Tolerance Standard Tolerance Standard Tolerance Standard Tolerance
Max.1.560(50Hz)Max. 1,560(50Hz)Max. 1,560(50Hz)Max.1,560(50Hz)

1,960 -2,040 I 1,960 -2,040 I Max.2,030 Max. 2,030
Max.l.872(60Hz)Max.l,872(60Hz)Max.l.872(60Hz)Max.l.872(60Hz)
600-660 600-660 600-1,000 600-1,000 700-800 700-800
Min. 100 - Min. 100 - Min.100 -

Min. 100
Max.300
Min.900
-
762
810
Min. 100
Max.300
-
-
762
-
!-I
-
Min. 100
Max.300
-
-
762
- - -
I
Min.900 810 - - - -
Max.650 Max.700 Max.650 700 650 700 650 700

I I
Max. 6.0 8.0 - - I - I - -
Max. 1.3 2.3 2.5 3.5 Max. 3.0 Max.3.0 4.0

Max. 1.0 2.0 Max.2.0 3.0 - - -
0.4 - 0.4
2 1.0 - 1.0
z
Min.29 20 Min.29 20 Min.29 20 Min.29 20
z
(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
270-278 220 260-268
37-39 37-39 41-43 41-43 41-43 41-43 41-43 41-43
0.65- 0.85 0.65-0.85 0.65-0.85 0.65 -0.85 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
Clasi-
sifica- Itern Condition, etc. Unit
tion
High idling speed wm

“0 Engine speed
5 Low idling speed wm
E
8
Y 0°C rpm
Necessary
d
starting speed
-20°C (with starting aid) rpm
Intake resistance At all speed mmH,C

Intake pressure At rated output mmHg
Exhaust pressure
: (Turbine inlet At rated output mmHg
z
2 press” re)
z Exhaust tempera-
All speed
7 ture (Turbine inlet OC
_c (Intake air temp.: 20°C1
temperature)
2
-0 Quick acceleration
& (Low idling-t High idling) Bosch
Exhaust gas color
P At rated output scale
E At high idling
:
I
Valve clearance Intake valve mm
(When engine is
hot or cold.) Exhaust valve mm
Compression Oil temperature:

kg/cm’
2 pressure 4o”c to 60°C
B (SAEBO oil) (Engine speed) (rpm)
al
r
.=
F Blow-by pressure
At rated output
w Water temperature: mmH,C
(SAE30 oil)
Min. 7O’C
At rated output
SAEBO oil kg/cm’
SAElOW oil kg/cm’
: Oil pressure
z (Oil temperature: At low idling
t Min. 80°C) SAE30 oil kg/cm’
SAElOW oil kg/cm’
.-*
P
3 Oil temperature All speed (oil in oil pan) “C
Oil consumption At continuous rated output

%
Fuel injection
Nozzle tester kg/cm’
z k pressure
’ g Fuel injection
B.T.D.C. degree
timing
Radiator pressure Opening press” re

kg/cm’
E valve (Differential pressure)
z
?;
Fan speed At rated engine speed rpm
P
.=
a Deflects when pushed with mm
8 Fan belt tension
a force of 6 kg
*The values given in the Testing and Adjusting data are NOT for adjustment of the output
12-044-2
03
S6D170-1 SA6D170-A-1
H D465-3
(with twin turbochrger)
Tolerance
r Standard
HD465-5
Tolerance Standard
WA700-1
Tolerance
I
2,250 - 2,350 2,250 - 2,350
850 - 900 850 - 900

I
Min. 100 - Min. 130 - Min. 130
Min. 100 Min. 100 - Min. 100
Max. 300 762 Max. 380 762 Max. 380 762 Max. 300 762
- - Min. 1,500 1,000 Min. 1,000 Min. 870 Min. 1,000 Min. 870
t
- - 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. 3.0 4.0 Max. 2.0 3.0

Max. 2.7 Z Max. 2.0 3.0 Max. 1.0 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 2.4 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 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
41 - 43 (up to 13764) 28 - 30 *2 35-37 35 - 37 37 - 39 (-#14593) 37 - 39 (-#14593)

35-37
37 - 39 (13765 and up) 35 - 37 *3 34 - 36 (#I4594) 34 - 36 (#14594-j
0.65 - 0.85 0.65 - 0.85
1,220 - 1,280 1,220 - 1,280
- - -
*I : For cold weather specifica Ins

‘2 : With electronic governor
*3 : With mechanical governor
12-045
0
Engine model
EG580-1, EG580B-1, EG600B-1

-
EG600BS-1. OEM for generator
Itern Condition, etc. Unit Standard Tolerance Standard Tolerance

-
High idling speed
,545Â±15(50H /lax.l,560(50Hz 1 r
Engine speed
,863i 9(60Hz /lax.l,872(60Hz :I n
Low idling speed 800 Â 100 800 Â 100
-
Min. 1 0 0 Min. 130
Necessary
starting speed - 2 0 ' ~ (with starting aid) 1 rPm Min. 100 Min. 100
Intake resistance A t all speed Max. 450 Max. 450

1,200 (50Hz)
Intake pressure At rated output
1,400 (60Hz)
Exhaust pressure 800 150Hz)
(Turbine inlet At rated output
1,000 (60Hz)
pressure)
Exhaust tempera-
All speed Max. 650 Max. 650
ture (Turbine inlet Max. 650
temperature) (intake air temp.: 20Â°C
-
Quick acceleration Max.9.8
Exhaust gas color Max. 3.0
At rated output
A t high idling Max. 2.0
--
I
Valve clearance Intake valve rnm
(When engine is
hot or cold) Exhaust valve
mm --
Compression Oil temperature: Min. 26
pressure 4 0 C to 6 0 ~ Min. 26
(SAE30 oil) (Engine speed) (210-250)
-
A t rated output
Blow-by pressure Max. 280 Max. 400
Water temperature:
(SAE30 oil) Min. 70Â°
--
At rated output
SAE30 oil
SAElOW oil
Oil pressure SAE15W-40
(Oil temperature:
Min. 8 0 0 At l o w idring
SAE30 oil Min. 1.5 Min. 1.5
SAElOW oil
SAE15W-40 Min. 1.0 Min. 1.0
--
Oil temperature All speed (oil in oil pan)
I OC
8 0 - 110
!I
Max. 0.5 Max. 0.5
ratio (Ratio of fuel consumption) %
-- --
Fuel injection
Nozzle tester
pressure
Fuel injection
timing
B.T.D.C. 1 degrei
Radiator pressure Opening pressure

(Differential pressure) kglcm
valve
!) 1
Fan speed At rated engine speed
Fan belt tension

Deflects when pushed with mm
a force of 6 kg
*The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide t o change the setting of the fuel injection pump.
HD465-3(For ORAPA MINE)
Standard
P Tolerance
Max. 1,560(50Hz) Hax. 1,560(50Hz)

Standard
2,000Â 50
Tolerance Standard Tolerance
2,300Â 50
Standard
2,300Â 50
Tolerance
800 Â 100 800 Â 100 800 Â 100 850 k 10
Min. 130
Min. 100 -
-
762
! Min. 130
Min. 100
Max. 350
Min. 130
Min. 100
Min. 130
Max. 300 Max. 300

- Min. 1,150 Max. 300 Max. 300
- -
700
1 Max. 650 Max. 650
Torque converter selection is

Max. 1.5 done by A.D.E.,so there is no
criteria value
3.5 Max. 1.0
0.4 0.4
1 .o 1.0
Min. 26 Min. 28 Min. 28 Min. 28

(210-2501 (210-250)
6 4 Max. 400 350 Max. 400 1 800
3.0 - 5.0
1.5 - 2.5 - 4.5
Min. 1.5 0.7 Min. 1.0 Min. 1.5

Min. 1.0 0.7 - Min. 1.0
Max. 0.5 1.0 1 Max. 0.5 Max. 0.5 Max. 0.5 1 1.0
- I Auto tension Auto tension
6D170-1 SERIES
HD465-3
I Pc1ooosP-1
(With single turbocharger)
Item Condition, etc. Standard Tolerance

1
High idling speed 2,250 - 2,350 2,250 - 2,350

IEngine speed
Low idling speed 940 - 990 940 - 990
I I
0°C rpm Min. 100 - Min. 130
Necessary
starting speed
kPa Max. 2.9 7.5 Max. 3.7

IIntake resistance At all speed
[mmHzOI {Max. 300) {Max. 380)
1762)
kPa Min. 10.8
Intake pressure At rated output -
ImmHgI - {Min. 1,100)
IExhaust pressure kPa
/[Turbineinlet pressure) At rated output - Min. 10.3
ImmHg) - {Min. 1,050)
IExhuast temperature All speed
,[Turbine inlet “C Max. 650 700 Max. 650
(intake air temp.: 20°C)
1temDerature)
Quick acceleration Max. 6.0 7.0
5.0
(Low idling --f High idling)
Bosch
IExhaust gas color
At rated output scale 2.5 Max. 2.0
At high idling 2.0 Max. 2.0 %!I
Valve clearance Intake valve mm 0.4 - 0.4 -

(When engine is 7 ~~ I
Hot or cold) Exhaust valve mm 1.0 - 1.0 -
Oil temperature: MPa Min. 2.55 1.77 Min. 2.75 1,96

Compression
pressure
40°C to 60°C {kg/cm? {Min. 26) {I81 {Min. 28) {20)
(SAE30 oil)
(Engine speed) (rpm) 1 (210-250) 1 (210-250) (210 - 250) (210 - 2501
At rated output
Blow-by pressure Max. 3.4 6.9
Water temperature:
(SAE30 oil) {Max. 350) I7001
Min. 70°C
At rated output 294 - 490

SAW0 oil (3.5 - 5.0)
kPa 294 - 441 206 245 - 441
Oil pressure SAElOW oil
{kg/cm21 (3.0 - 4.5) (2.1) 12.5 - 4.5)
(Oil temperature:
Min. 80°C) At low idling kPa Min. 147
SAE30 oil {kg/cm? {Min. 1.5)
kPa Min. 98
SAEIOW oil
{kg/cm? 1 {Min. 1.0)
Oil temperature All speed (oil in oil pan) 80-110 120

ratio (Ratio of fuel consumption) % I Max. 0.5 1.0 Max. 0.5 1.0
Fuel injection MPa 26.5 - 27.3 21.6 29.9 - 30.7 24.2

Nozzle tester
pressure {kg/cm21 (210 - 278) (220) (305 - 313) (2471
Fuel injection B.T.D.C. 37-39 37-39

timing
Radiator pressure Opening pressure 64-83 64-83

vavle (Differential pressure) {0.65 - 0.85) IO.65 - 0.851
Fan speed At rated engine speed 1,220 - 1,280 1,220 - 1,280
Deflects when pushed with - -

Fan belt tension mm See page 12-031
a force of 6 ko
* The values given in the Testing and Adjusting data are NOT for adjustment of the output.
12-047- 1
0
SA6D170-A-1
EM680A
r EM680A-1
EM170B-1 T EM680A-A
H D465-5
(High altitude spec.)
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 7.5 Max. 2.9 7.5 Max. 3.7 7.5 Max. 2.9
{Max. 3001 17621 {Max. 300) {762) {Max. 380) {762) {Max. 300)
Min. 168 - Min. 155 - Min. 106
(Min. 1.3001 (Min. 1,200} {Min. 820}
- - Min. 80 Min. 95
{Min. 620) - {Min. 7401
Max. 550 700 Max. 600 60 Max. 650 700 Max. 620
- - - - - -
Max. 2.0 Max. 2.0 3.0 Max. 1 .O 2.0
Max. 2.0 2 Max. 2.0 2.0 Max. 0.5 1.5
0.4 - 0.4 - 0.4 -
8 1.0 - 1.0 - 1.0 -
z Min. 2.75 1.96 Min. 2.75 1.96 Min. 2.75 1.96 Min. 2.75 1.96
z (Min. 281 {201 {Min. 28) (201 {Min. 28) 1201 {Min. 28) I201
(210 - 250) (210 - 250) (210 - 250) (210 - 250) (210 - 250) (210 - 250) (210 - 250) (210 - 250)
Max. 3.4 6.9 Max. 2.9 5.9 Max. 3.4 6.9

{Max. 3501 I7001 {Max. 300) {6001 {Max. 350) (7001
294 - 490 294 - 490 206 294 - 490

(3.0 - 5.0) l3.0 - 5.01 (2.1) 13.0 - 5.0)
245 - 441 245 - 441 177 245 - 441 245 - 441 177
(2.5 - 4.51 {2.5 - 4.5) Il.81 (2.5 - 4.51 (2.5 - 4.5) 11.81
Min. 147 Min. 147 Min. 147 Min. 147
(Min. 1.5) {Min. 1.5} I& {Min. 1.5) {Min. 1.5} 1:;)
Min. 98 Min. 98 Min. 98 Min. 98
{Min. 1.0) {Min. 1.0) {:?I (Min. l.O} {Min. I.01 &
80-110 80-110 120 80- 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
29.9 - 30.7 24.2 29.9 - 30.7 24.2 29.9 - 30.7 24.2 29.9 - 30.9 24.2
I305 - 3131 I2471 (305 - 3131 {247) (305 - 3131 I2471 {305 - 3151 12471
33-35 33-35 33-35 33-35 29-31 29-31
- - - - -
- - -
- - -
17 15 - 19
I -
12-047-2
0
IG600BS-1, OEM for generator

Applicable machine model OEM for generator
f (Engine No. 15503 and up)
Clas
sifica Condition, etc. Unit Standard Tolerance Tolerance
- tior
Aax. 1,560 (50H; Max. 1,560 (50Hi ax. 1,568 (50Hz) lax. 1,568 (50Hz)
High idling speed vm Aax. 1,872 (60H; Max. 1,872 (60H2 ax. 1,881 (60Hz) lax. 1,881 (60Hz)
8
6 Low idling speed wm 950 - 1,000 950 - 1,000 700 - 900 700 - 900
E
b - -
‘t 0°C Min. 130 Min. 130
Necessary
a” starting speed
kPa Max. 3.9 7.5 Max. 3.9 7.5

Intake resistance At all speed
{IrnmHz0) {Max. 400) {762) {Max. 400) I7621
kPa
Imml-lg)
- - -
Exhaust pressure kPa

Turbineinlet pressure) At rated output
I mml-fg}
- - - -
Ixhuast temperature All speed
:Turbine inlet “C Max. 650 700 Max. 650 700
:emperature) [intake air temp.: 20°C)
Quick acceleration - - -
[Low idling + High idling)
Bosch
!xhaust gas color
At rated output scale Max. 1.5 2.5 Max. 1.2
At high idling Max. 1.0 2.0 Max. 1.0
dalve clearance Intake valve mm 0.4 - 0.4 -

:When engine is
iot or cold) Exhaust valve mm 1.0 - 1.0 -
8
Oil temperature: MPa Min. 2.55 1.77 Min. 2.55 1.77 z
Zompression
40°C to 60°C 1kg/cm? {Min. 26} (181 {Min. 26) {18I &
oressure
SAE30 oil)
[Engine speed) (rpm) (210 - 250) (210 - 250) (210 - 250) (210 - 250)
At rated output
Blow-by pressure kPa Max. 3.9 Max. 3.9 7.8
Water temperature:
(SAE30 oil) Min. 70°C : { mmHz0 {Max. 400) {Max. 400) {800}
At rated output kPa 255 - 441 343 - 441

SAE30 oil (kg/cm? 12.6 - 4.5) 13.5 - 4.5)
SAEIOW oil kPa 216 - 392 294 - 441

Oil pressure (kg/cm21 {2.2 - 4.0) 13.0 - 4.51
(Oil temperature:
Min. 80°C) At low idling kPa Min. 147 Min. 147
SAEJO oil [kg/cm? {Min. 1.5} {Min. 1.5}
SAEIOW oil kPa Min. 98 Min. 98

i(kg/cm? {Min. 1.0) {Min. l.O}
Oil temperature All speed (oil in oil pan) “C 80-110 120 80-110

% Max. 0.5 1.0 Max. 0.5 1.0

Nozzle tester
pressure i(kg/cm? 1303-315) {247) I305 - 313) I2471
Fuel injection B.T.D.C. degree 33-35 33-35 30-32 30-32

timing
Radiator pressure Opening pressure kPa 64-83 64-83 59-78 59-78

vavle (Differential pressure) i[kg/cm? to.65 - 0.85) lo.65 - 0.85) fO.6 - 0.8) fO.6 - 0.8)
995 - 1,055 (50Hi 995 - 1,055 (50Hz 95 - 1,055 (50Hz) 195- 1,055 (50Hz)
,192 - 1,266 (6Ok 1,192 - 1,266 (60H 192- 1,266 (60Hz: 192 - 1,266 (60Hz)

Fan belt tension mm
a force of 6 kg
12-047-3
0
SA6D170-A-1
OEM for generator

(Prime use)
Standard Tolerance
T OEM for generator
(Standby use)
Standard Tolerance
r Standard
OEM for marine
Standard
EPSAGD170-A-1
512 kW (686 HP}
Tolerance
Max. 1,568(50Hz: Aax.1,566(50Hz lax. 1,575(50Hz) Bax.1,575(50Hz)

2,100 - 2,200 2,100 - 2,200 Max. 2,200 Max. 2,200
Max. 1,981@Hz: Aax.1,981(60Hz lax. 1,890(60Hz) [ax. 1,890(60Hz)
700 - 900 700 - 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 7.5 Max. 4.9 Max. 2.9 Max. 3.9 7.5
{Max. 400) {762) {Max. 500) {Max. 300) {Max. 400) {762)
- - - -
- - - - - - -
Max. 650 700 Max. 700 700 Max. 650 700 Max. 650 700
- - - - - - -
Max. 1.2 Max. 2.5 Max. 1.0 Max. 2.5 3.5
Max. 1.0 Z Max. 2.5 2:; Max. 1.0 it Max. 1.5 2.5
0.4 - 0.4 - 0.4 - 0.4 -

1.0 - 1.0 - 1.0 - 1.0 -
$
z Min. 2.55 1.77 Min. 2.55 1.77 Min. 2.75 1.96 Min. 2.55 1.77
z {Min. 2.6) (18) {Min. 2.6) U8I {Min. 28) 120) {Min. 26) 118)
(210 - 250) (210 - 250) (210 - 250) (210 - 250) (210 - 250) (210 - 250) (210 - 250) (210 - 250)
Max. 3.9 7.8 Max. 3.9 7.8 Max. 3.4 6.9 Max. 3.9 7.8
{Max. 400) {800) {Max. 400) I8001 {Max. 350) {700) {Max. 4001 {8001
343 - 441 245 226 - 392 157 294 - 490 206 294 - 490
13.5 - 4.5) I2.5) 12.3 - 4.0) Il.61 {3.0 - 5.0) (2.1) (3.0 - 5.0)
294 - 441 206 177-348 127 245 - 441 245 - 441
13.0 - 4.5) 12.1) Il.8 - 3.5) Il.31 l2.5 - 4.5) t2.5 - 4.5)
Min. 147 Min. 147 Min. 147
{Min. 1.5) {Min. 1.5) r% {Min. 1.5)
Min. 98 Min. 98 Min. 98
{Min. I.01 {Min. 1.0) r% {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 24.2 29.9 - 30.7 24.2 29.9 - 30.7 24.2 29.9 - 30.7 24.2
1305 - 313) {247I {305 - 313) {247) I305 - 313) {247) I305 - 313) 1247)
29 - 31 (50 Hz] 29 - 31 (50 Hz 33-35 33-35 33-35 33-35 36 - 38 36-38
31 - 33 (60 Hz] 31- 33 (60 Hz
59 - 78 59-78 59-78 59-78 - - 39 - 59 39-59

IO.6 - 0.8) CO.6- 0.8) IO.6 - 0.8) to.6 - 0.8) IO.4 - 0.6) IO.4 - 0.6)
995- 1,055(50Hz) 395- 1,055(50Hz: 195- 1,055(50Hz) 395- 1,055(50Hz) - - - -

1,192- 1,266(60Hi ,192- 1,266(60H; 192- 1,266(6OH2 ,192- 1,266(60Hz
- - - - - -
12-047-4
0
Engine model SAGD170-6-l
D375A-1 D375A-1
(Engine No. up to 11117) (EngineNo. 11118andup)
Item Condition, etc. Unit Standard Tolerance Standard Tolerance
High idling speed rpm 1,950-2,050 1,950-2,050 1.950-2.050 1,950-2,050

Engine speed
Low idling speed rpm 600-700 600-700 600-700 600-700
I I
Necessary
ooc rpm Min. 130 - Min. 130 -
starting speed Min. 100 -
-20°C (with starting aid) rpm Min. 100 -
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 At rated output mmHg Min. 900 810 Min. 900 810
pressure)
Exhaust tempera-
All speed
ture (Turbine inlet OC Max. 650 Max. 650 Max. 650 Max. 650
temoeraturel
Max. 7.0 8.0 Max. 6.0 8.0

Max. 4.5 5.5 Max. 2.5 3.5
Max. 1.5 2.5 Max. 1.5 2.5

(When engine is
hot or cold) Exhaust valve mm 1 .o - 1 .o -
8
Compression Oil temperature: Min. 28 20 Min. 26 18 ;o
pressure 40°C to 60°C kg’cm2
(Engine speed) (rpm) (21 O-250) (21 O-250) (21 O-250) (21 O-250) z
(SAEBO oil)
I I
At rated output
Blow-by pressure
Water temperature: mmH?O Max. 280 560 Max. 350 700
(SAEBO oil)
Min. 70°C
At rated output
SAEBO oil 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
Oil pressure
(Oil temperature: At low idling
Min. 80°C) 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
Oil temperature All speed (oil in oil pan) 80-110 120 80-110 120
Max. 0.5 1.0 Max. 0.5 1 .o
265 +15 220 265 +’ 3 220

+5 +5
Fuel injection
6.T.D.C degree 38t 1 38* 1 38il 38i 1
timing

kg/cm* 0.75 + 0.1 0.75 i 0.1 0.75 * 0.1 0.75 + 0.1
valve (Differential pressure)
Fan speed At rated engine speed rpm 1,050 f 30 1,050 i 30 1,050 i 30 1,050 i 30
Deflects when pushed with mm

Fan belt tension See page 12.031
a force of 6 kg
+ The values given in the Testing and Adjusting data are NOT for adjustment of the output
12-048
0
SAGDl70-8-1
HD465-3
D375A-2 PC1 000-l EG450-1
(with single turbocharger)
Standard Tolerance Standard Tolerance Standard Tolerance Standard Tolerance
2,000 + 40 2,000 i 40 2.350-2.450 2,350-2,450 1,850 zk 50 1,850 f 50 1,800-l ,890 1,800-l ,890
630 zt 50 630 f 50 800-900 800-900 675 rt 25 675 f 25 950-I ,000 950-l ,000
Min. 130 - Min. 130 - Max. 130 - Min. 100 -
Min. 100 - Min. 100 - Min. 100 - Min. 100 -
Max. 380 762 Max. 300 762 Max. 300 762 Max. 300 635
Min. 950 825 - - Min. 1,000 900 - -
Min. 900 810 - - Min. 900 810 - -
Max. 650 Max. 650 Max. 650 Max. 700 Max. 650 700 Max. 650 Max. 650
Max. 6.0 8.0 Max. 6.0 8.0 Max. 3.0 5.0 - -
Max. 2.5 3.5 Max. 2.0 3.0 Max. 1.5 2.5

Max. 1 .O 2.0 Max. 1.5 2.5 Max. 1 .O 2.0 Max. 2.0 2.5
0.4 - 0.4 - 0.4 - 0.4 -
1.o - 1.o 1.o - 1.o -

2
;;; Min. 26 18 Min. 28 20 Min. 26 18 Min. 28 20
z
(21 O-250) (21 O-250) (21 O-250) (21 O-2.50) (21 O-250) (21 O-250) (21 O-250) (210-250)
Max. 350 700 Max. 350 700 Max. 400 800 Max. 200 400
3.0 - 5.0 2.1 3.0 - 5.0 2.1 3.5 - 5.0 2.5 2.5 - 4.0 2.5 - 4.0
2.5 - 4.5 1.8 2.5 - 4.5 1.8 3.0 - 4.5 2.1
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
80-110 120 80- 110 120 80-100 120 80-90 120
Max. 0.5 1 .o Max. 0.5 1 .o Max. 0.5 1.0 Max. 0.5 1 .o
265 f13 220 265 +13 220 265 +13 239 255 +13 230
+5 +5 +5 +5
381 1 38 + 1 42 * 1 42 f 1 38 i 1 38 t 1 39 i 1 39 + 1
0.75 + 0.1 0.75 i 1 - - 0.75 i 0.1 0.75 It 0.1 0.75 i 0.1 0.75 j: 0.1
l.lOOi33 l.lOOk33 - 95 f 25 950 * 25 1,020+25(50Hz) 1,020t25(50Hz)

1,224k30(60Hz) 1,224+30(60Hz)
See page 12-031 - -
+ The values given in the Testing and Adjusting data are NOT for adjustment of the output
12-049
8
Engine model SA6D170-6-l
EG480-1, EG480B-1, EG500-1

Applicable machine model EPSAGD170-B-1
EG500B-1, EG500B.B1

I
High idling speed rpm
Engine speed
Low idling speed rpm
ooc rpm
Necessary
starting speed
-20°C (with starting aid) rpm Min. 100 ) - ( Min. 100 1 -
mmHs0 Max. 400 762 Max. 350 762
lin. 930(50Hz) 720
mmHg lin.1,100(60Hz) 880 Min. 1,250 1,090
mmHg
Exhaust tempera-
All speed
ture (Turbine inlet OC
temperature)
Quick acceleration
(Low idling - High idling) Bosch
Exhaust gas color
At rated output scale
At high idling
mm
mm
kg/cm2
(rpm)
At rated output
Blow-by pressure mmH*O Max. 400 800 Max. 400 800
Water temperature:
(SAE30 oil)
Min. 70°C
At rated output
SAE30 oil kg/cm2 3.0 - 4.5 2.1 3.0 - 4.5 2.0
SAElOW oil kg/cm2 2.5 - 4.0 1.8 - -
Oil pressure
(Oil temperature: At low Idling
Min. 80°C) SAEBO oil kg/cm2 Min. 1.5 0.7 Min. 1 .O 0.7
SAElOW oil kg/cm2 Min. 1 .O 0.7 - -
011 temperature All speed (oil in oil pan) OC 80-110 120 80-110 120

I I I
% Max. 0.5 1 .o Max. 0.5 1.0
Fuel injection
Nozzle tester kg/cm* 255 +I3 211 265 ;L3 220
pressure +5
degree
kg/cm2
Fan speed At rated engine speed ,020+26(50Hz) 1,020i26(50Hz)

rpm 1.23Oi40 1,230 + 40
.224+30(60Hz) 1,224+30(60Hz)

Fan belt tension mm Auto tension
a force of 6 kg
* The values given in the Testing and Adjusting data are NOT for adjustment of the output
12-049-l
0
OEM for generator

I EG480B-1 (For CIS)
367 kW {492 HP} I50 Hz
Clas
sifica item Condition, etc. Standard Tolerance
- tiol
lax. 1,560 (50Hz) lax. 1,560 (50Hz)
High idling speed
lax. 1,872 (60Hz) lax. 1,872 (60Hz)
z Engine speed
: Low idling speed 700 - 800 700 - 800
E
b -
‘t 0°C Min. 130
Necessary
d starting speed
-20°C (with starting aid) Min. 100 -
kPa 2.9 7.5 Max. 2.9 7.5

Intake resistance At all speed {Max. 300)
[mmHzO} {3001 I7621 I7621
kPa Min. 120
Intake pressure At rated output - -
0-nmHg} {Min. 930) {792301
At rated output Min. 85 68 - -
[Turbineinlet pressure)
{mmHgI {Min. 6601 15301
Exhuast temperature All speed
(Turbine inlet “C 650 700 Max. 650
temoerature)
Quick acceleration - -
(Low idling + High idling)
Exhaust gas color
At rated output -p/ 4.0 Max. 3.0 4.0
At high idling 2.0 Max. 2.5 3.5

(When engine is
I I
Oil temperature: MPa Min. 2.55 1.77 Min. 2.75 1.96
Compression
pressure
40°C to 60°C {kg/cm*} {Min. 26) 1181 {Min. 281 QOI
(SAE30 oil)
(Engine speed) (rpm) (210 - 250) (210 - 250) (210 - 250) (210 - 250)
At rated output
Blow-by pressure kPa 7.8 Max. 3.9 7.8
Water temperature:
(SAESO oil) (mmHnO1 && 18001 {Max. 4001 (800)
Min. 70°C
At rated output kPa 265 - 392 186 294 - 441 206

SAE30 oil {kg/cm*} (2.7 - 4.0) (1.9) 13.0 - 4.51 (1.8)
kPa 216-343 147 245 - 392
Oil pressure SAElOW oil
{kg/cm3 (2.2 - 3.5) (I.51 (2.5 - 4.0)
(Oil temperature:
SAESO oil {kg/cm*} {Min. 1.5) $1 {Min. 1.5)
kPa Min. 98 Min. 98
SAElOW oil
{kg/cm’} (Min. l.O} $1 {Min. 1.01
Oil temperature All speed (oil in oil pan) “C 80-110 120 80-110 120

% 0.5 1.0 Max. 0.5 1.0

Nozzle tester
pressure {kg/cm*} 1260 - 268) I2111 (260 - 268) 12111
Fuel injection B.T.D.C. 41-43 41-43 41-43 41-43

degree
timing
Radiator pressure Opening pressure 64-83 64-83

vavle (Differential pressure) IO.65 - 0.851 IO.65 - 0.851
Deflects when pushed with -

Fan belt tension mm Auto tension
a force of 6 kg
* The values given‘in the Testing and Adjusting data are NOT for adjustment of the output.
12-049-2
0

-
IBS-1
OEM for generator
Applicable machine model :nerator
265 and up)
379 kW I508 HP} / 50 Hz
-
:-
7
dax. 1,568 (50tb dax. 1,568 (50Hi flax. 1,560 (50H2 dax. 1,560 (50Hz)
High idling speed rpm tiax. 1,881 (6OH2 lax. 1,861 (60H: dax. 1,872 (60H2 Aax. 1,872 (6OHz)
Engine speed
Low idling speed rpm 700 - 800 700 - 800 700 - 900 700 - 900
0°C vm Min. 130 - Min. 130 -

Necessary
starting speed
-20°C (with starting aid) vm Min. 100 - Min. 100 -
-
kPa Max. 2.9 7.5 Max. 2.9 7.5
Intake resistance At all speed (mmHnO1 {Max. 300) . .
f762) {Max. 300) (7621
kPa
Intake pressure At rated output - - -
fmmHgI
[Turbineinlet pressure) At rated output - - - -
ImmHgI
(Turbine inlet “C Max. 650 700 Max. 650 700
temoerature) -
Quick acceleration - - - -
(Low idling --3 High idling) Bosch
IExhaust gas color
At rated output scale Max. 1.5 Max. 2.5 3.5
At high idling Max. 1.0 2: Max. 1.5 2.5
Valve clearance Intake valve mm 0.4 - 0.4

/[When engine is
8
Oil temperature: MPa Min. 2.75 1.96 Min. 2.75 I,96 z
Compression
pressure
40°C to 60°C {kg/cm21 (Min. 28} (201 {Min. 28) (201 z
(SAE30 oil) (Engine speed) (rpm) (210 - 250) (210 - 250) (210 - 250) (210 - 250)
At rated output
Blow-by pressure kPa Max. 3.9 7.8 Max. 3.9
Water temperature:
(SAE30 oil) ImmHtO {Max. 400) (8001 {Max. 400)
Min. 70°C
At rated output kPa 343-441 245 245 - 441

SAE30 oil (kg/cm21 (3.5 - 4.5) (2.5) (2.5 - 4.5)
kPa 294 - 392 206 196 - 392
Oil pressure SAEIOW oil
Ikg/cn+I (3.0 - 4.01 (2.1) (2.0 - 4.0)
(Oil temperature:
SAEBO oil Ikg/cm21 (Min. 1.8} {Min. 1.5)
kPa Min. 127 Min. 98
SAEIOW oil
{kg/cm? {Min. I.31 {Min. 1.0)

% Max. 0.5 1.0 Max. 0.5 1.0

Nozzle tester
pressure {kg/cm21 (260 - 268) (21OI 1260 - 268) (2101
Fuel injection B.T.D.C. degree 35-37x1 35-37x1 35-37 35 -37

timing 31 -33 ‘2 31 -33 *2
Radiator pressure Opening pressure kPa 59-78 59-78 -

vavle (Differential pressure) {kg/cm’I (0.6 - 0.8) IO.6 - 0.8)
995 - 1,055 (50Hz 395- 1,055 (50tk )95 - 1,055 (50Hz 395 - 1,055 (50Hz)
Fan speed At rated engine speed wm ,192 - 1,266 (60H ,192 - 1,266 (60H ,192 - 1,266 (60H ,192 - 1,266 (60Hz)
Deflects when pushed with - - -

Fan belt tension mm
aforceof6kg
-
* The values given in the Testing and Adjusting data are NOT for adjustment of the output. *I : Except EG500BS-1
Do not use these values as a guide to change the setting of the fuel injection pump. *2 : EG500BS-1 only
12-049-3
0
Engine model SAGDI JO-B-I
Applicable machine model OEM folr gcmerator

(Stan db\lr use)
Condition, etc. Standard Tolerance
Max. 1,568 (50Hz) Max. 1,566 (50H2 Aax. 1,566 (50H; lax. 1,568 (50Hz)
High idling speed vm Max. 1,881 (60Hz) Max. 1,881 (60H1 Aax. 1,681 (60H; lax. 1,881 (60Hz)
Low idling speed wm 700 - 900 700 - 900 700 - 800 700 - 800
0°C rm Min. 130 - Min. 130
I
kPa Max. 3.9 7.5 Max. 3.9 7.5
lmmHz0) {Max. 400} 1762) {Max. 400) 1762)
kPa
E Intake pressure At rated output lmmHg) - - -
ti Exhaust pressure
2 (Turbineinlet pressure) At rated output - -
ti Exhuast temperature All speed
: (Turbine inlet
(intake air temp.: 20°C) Max. 700 Max. 650 700
_c temperature)
Z Quick acceleration
-0 -
[Low idling + High idling)
6 Exhaust gas color
At rated output
m 2.5
% At high idling 2.0
2 Intake valve -
(When engine is
Exhaust valve -
Compression
3il temperature: Min.27.5 1.96
40°C to 60°C {Min. 28} 1201
& pressure
8 (SAE30 oil)
:Engine speed) (210 - 250) (210 - 250)
:
‘Bl 4t rated output
Blow-by pressure kPa Max. 3.9 7.8 Max. 3.9 7.8
I= Water temperature:
lSAE30 oil) lmmHz0) {Max. 400) {Max. 400)
Min. JOY 1800) 1800)
At rated output 245 - 441 I77

SAE30 oil 12.5 - 4.5) 11.8)
SAElOW oil 196 - 392 137

Oil pressure
(2.0 - 4.0} 11.4)
$ (Oil temperature:
IYY Min. 80°C) At low idling kPa Min. 147 Min. 147
2 SAE30 oil {kg/cm*) {Min. 1.5} & {Min. 1.5}
SAElOW oil Min. 98

{Min. 1.01
Oil temperature All speed (oil in oil pan) 80-110 120
At continuous rated output

(Ratio of fuel consumption) Max. 0.5 1.0
Nozzle tester - 25.5 - 26.3 20.6

I260 - 268) 1210)
B.T.D.C. 40-42 40-42
s
ti
[Differential pressure) {‘fi l,,: 1 1”“:
59-78
10.6 - 0.8)
59 - 78
iO.6 - 0.8)
?i 995 - I 055 l50Hz) 995 - 1055 (50Hz) ‘95 - 1,055 (50Hz 95 - 1,055 (50Hz)
At rated engine speed
1,192 - 1,266 (60Hz) 1,192 - 1,266 (6OH2 192 - 1,266 (60H; 192- 1,266 (60Hz)
.-?
Z
Deflects when pushed with
u” Fan belt tension
3 force of 6 ka
- -
12-049-4
0
EPSAGD170-B-1
Applicable machine model OEM for 6-pole generator
445 kW (597 HP} / 1,300 rpm
Condition, etc. 1 Unit Standard Tolerance Standard Tolerance
Max. 2.200 Max. 1,947 (50Hz) Aax. 1,047 (50Hz)

High idling speed Max. 2.200
Max. 1,256 (6OHzl Aax. 1,256 (60Hz)
Engine speed
600 - 1,000 600 - 1,000 750 - 850 750 - 850
Min. 130 - Min. 130 -

Necessary
starting speed
-20°C (with starting aid) Min. 100 - Min. 100 -
kPa Max. 2.9 7.5 Max. 3.7 7.5

{mmHzOl {Max. 300) 17621 {Max. 380) D’621
kPa Min. 123 (50Hz)
{mmHgI
- - -
{Min. 950) (50Hz)
(Turbineinlet pressure) At rated output - - Min. 142 (6OHz) -
ImmHgI [Min. 1,100) (66Hz
(Turbine inlet “C Max. 650 700 Max. 6700 700
temperature)
Quick acceleration - - - -
(Low idling + High idling)
Bosch
Exhaust gas color
At rated output scale Max. 2.5 ;:: Max. 0.5
1.0 2.0
At high idling Max. 1.5 1.5
Valve clearance 0.4 - 0.4 -

(When engine is
- -
Hot or cold) 1.0 1.0
2
Min. 2.75 1.96 Min. 2.45 Min.1.77 z
I
Compression
{Min. 27) I20} {Min. 26) {Min. 18) z
pressure
(SAE30 oil)
(210 - 250) (210 - 250) (210 - 250) (210 - 250)
At rated output
Blow-by pressure kPa 5.9 Max. 3.9
Water temperature:
(SAE30 oil) Min. 70°C ImmHzO) 16001 {Max. 400)
At rated output kPa 294 - 490 206

SAE30 oil ikg/cm2} 13.0 - 5.01 t2.11
kPa 245 - 441 177 - -
Oil pressure SAEIOW oil
{kg/cm*} 12.5 - 4.5) t1.81
(Oil temperature:
At low idling kPa Min. 147 Min. 147
Min. 80°C)
SAE30 oil {kg/cm? {Min. 1.51 I& {Min. 1.5) E)
SAElOW oil ,k~,~m21
Min. 98
{Min. 1.0) & I - -

Max. 0.5 1.0
ratio (Ratio of fuel consumption) %
Fuel injection 25.5 - 26.3 21.5

pressure I260 - 268) {219}
Fuel injection
41-43 18-20
timing
Radiator pressure Opening pressure kPa 39 - 59 39 - 59 59-78 59-78

vavle (Differential pressure) {kg/cm? IO.4 - 0.61 CO.4 - 0.6) 10.6 - 0.81 IO.6 - 0.81
Fan speed - 989 - 1,051 989 - 1,051
Fan belt tension - 8 - 12 8-12
12-049-5
0
Engine model
Applicable machine model For MQ generator For MQ generator

DCA-600SSK DCA-500SSK
- -
Item 1 Condition, etc. Unit Standard Tolerance Standard Tolerance .
High idling speed Max. 1,890 Max. 1,890 Max. 1,890 Max. 1,890
Engine speed (60 Hz) (60 Hz) (60 Hz) (60 Hz)
800':1 800 800 Â 100 800 Â 100
Necessary Min. 130 Min. 130

Min. 100 Min. 100
Intake resistance 1 At all speed Max. 3.9

{Max. 400)
Max. 3.9
{Max. 400)
Intake pressure 1 At rated output - -
Exhaust pressure
(Turbine inlet At rated output - -
pressure)
Exhuast tempera- All speed
ture (Turbine inlet (intake air temp.: 20Â°C Max. 650 Max. 650
temperature)
Quick acceleration
(Low idling -> High idling) Bosch scale
- -
Exhaust gas color At rated Bosch scale Max. 1.2 Max. 1.2
1 At high idling Bosch scale Max. 1.0 Max. 1.0
Valve clearance Intake valve mm
(When engine is
Hot or cold) Exhaust valve
Compression Oil temperature: Min. 2.5 Min. 2.5

pressure 40% to 60Â° {Min. 26) IMin. 26)
(SAE30 oil) (Engine speed)
MOW-bypressure
(SAE30 oil)
cse: Min. 70Â°
Max. 400 Max. 400
rated output
SAE30 or 392 - 539 392 - 539
SAE 15w-40 oil i4.0 - 5.5) (4.0 - 5.5)
Oil pressure
(Oil temperature: SAE10W oil 343 - 490 343 - 490
Min. 80Â°C low idling i3.5 - 5.0) f3.5 - 5.0)
SAE30 or fin. 147 (1.5)
SAE 15w-40 oil Min. 147 (1.5
SAEIOW oil Min. 98 0.0) Min. 98 tl.0)
Oil temperature 1 All speed (oil i n oil pan) 90 - 110 90 - 110

ratio (Ratio of fuel consumption) Max. 0.5 Max. 0.5
Fuel injection
pressure I Nozzle MPa {kg/cm21
30 - 30.7
(305 - 3131
Fuel injection BT,D.C. degree
timing
vavle (Differential pressure)
1,230 Â 40 1,225 Â 40
Fan speed At rated engine speed (60 Hz) (60 Hz)
Fan belt tension Deflects when pushed with

a force of 60 N {6 kg) i u t o tension Auto tension
Do not use these values as a guide t o change the setting of the fuel injection pump.
Engine revolution speed 210 - 250 rpm
6D170-1 SERIES
---
Engine model
Applicable machine model OEM for generator (50 Hz) SAA6D170-P740 (50 Hz)
-
Clas
sifica Item Condition, etc. Unit Standard 1 Tolerance Standard Tolerance
- ti01
E
High idling speed (Prime)
(Standby)
rPm
r Pm
Max. 1,568 1 Max. 1,568 Max. 1,568
Max. 1,575
Max. 1,568
Max. 1,575
Engine speed
(0 Low idling speed r Pm 700 - 900 700 - 900
E
2
Necessary
ooc rPm Min. 130 Min. 130
w
Q- starting speed
-
Intake resistance
-20% (with starting aid)
At all speed
r Pm
<Pa(mmH20)
4Min. 100 Min. 110
1ax.4.41(450
Intake pressure At rated output kPa {mmHg}
CD
.- Exhaust pressure
(Turbine inlet At rated output kPa {mmHg} -
E
+-
3
.s"
pressure)
Exhuast tempera-
ture (Turbine inlet
temperature)
All speed
(intake air temp.: 20Â°C OC Max. 650 1 700 Max. 650
tD
-0
Quick acceleration
Bosch scale
-
(Low idling Ã‘ High idling)
(0 Exhaust gas color At rated output Bosch scale Max. 1.5 Max. 1.5
.-
x
-
w
(0
Valve clearance
At high idling
Intake valve
Bosch scale Max. 1.0 Max. 1.0
(When engine is
hot or cold) Exhaust valve
-
Compression Oil temperature: Min. 2.55 Min. 2.55
>
-0
0 pressure 40% t o 60Â° (Min. 26) (Min. 261
.Q (SAE30 oil) (Engine speed) (200 - 250)
0>
.-0) A t rated output
Blow-by pressure Water temperature: 1ax.5.88{600
LU (SAE30 oil) Min. 70Â°
-
At rated output
255 - 372
SAE30 oil 12.6 - 3.81
:
.-
Oil pressure
(Oil temperature:
Min. 80Â°C
SAEIOW oil
At low idling
206 - 323
(2.1 - 3.31
s-
1
SAE30 oil Ain. 147 (1.51
.-z
,a SAEIOW oil M i . 98 11.0) 69 10.7) Wn. 98 (1.0)
en
.-
.Q Oil temperature All speed (oil in oil pan) 80 - 110
__I

ratio (Ratio of fuel consumption) Max. 0.5
-
Fuel injection Nozzle tester 29.9 - 30.7
-E pressure MPa {kg/cm2} (305 - 313}
W E
.2 9 Fuel injection B.T.D.C. degree 26 - 28
timing
-
kPa {kglcrn? 59 - 78
0)
,a
vavle (Differential pressure) t0.6 - 0.8)
>
0) Fan speed At rated engine speed rPm 1,240 - 1,310
-
.-
0
Fan belt tension Deflects when pushed with mm 1
'Auto tension Auto tension 'Auto tensior
-u a force of 60 N (6 kg}
* Engine revolution speed 210 - 250 rpm
6D170-1 SERIES
SAA6D170-P740 (60 Hz) SAA6D170-P800 (50 Hz) 1

Standard Tolerance Standard Tolerance 1 Standard
Max. 1,882 Max. 1,882 Max. 1,568

Max. 1,890 Max. 1,890 Max. 1,575 Max. 1,575
700 - 900 700 - 900 700 - 900 700 - 900
-
Min. 130 Min. 130

Min. 110 Min. 110
Max. 4.41 {450 lax. 4.41 (450

- -
Max. 650 Max. 650
Max. 1.5 Max. 1.5

Max. 1.0 Max. 1.0
Min. 2.55 Min. 2.55

(Min. 26) {Min. 26)
(200 - 250) (200 - 250)
Max. 5.88{6001
206 - 323
(2.1 - 3.31
Min. 147 {1.5) Win. 147 (1.5)
Min. 98 (1.0) Min. 98 (1.0)
Max. 0.5 Max. 0.5
Auto tension 4uto tension
6D170-1 SERIES
FAN BELT TENSION
1. Adjustment nut
2. Washer
3. Tension spring
4. Adjustment bolt
5. Tension pulley
A. Protrusion of adjustment bolt
6162F291
Unit: mm
Engine model Applicable machine Dimension A
PC650-1
S6Dl?O-1 73 f 5
PC1500-1
SAGDl70-A-1 HD465-3 5Bi5

I I
D375A-1
50 k 5
D375A-2
SAGD 170-B-l
I PC1 000-l I 70 i: 5
TENSION OF WA700-1 FAN BELT
l Replacing
1. Loosen locknut (1) and turn back adjustment screw

(2) as far as bracket (3).
2. insert a bar with a length of approx. 50 cm in the

hole (@18) in bracket (7), then 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 screw (2). and when the tip of

adjustment screw (2) comes into contact with
tension pulley lever (4). tighten adjustment screw
(2) a further half turn, then lock it in position with
locknut (1).
w Locknut : 29.5 f 2 kgm
If a gap appears between tension pulley lever (4) and

the tip of adjustment screw (2) during operation,
adjust in the same way.
If the fan belt screeches, adjust in the same way.
6162F668
12-051
0
TROUBLESHOOTING
CONTENTS
Points to remember when troubleshooting .......................................... 12-055

Method of using troubleshooting chart ............................................. 12-056
S-l Starting performance is poor
(Starting always takes time) ................................................ 12-060
s-2 Enginedoesnotstart ...................................................... 12-061
@ Engine does not turn ................................................... 12-061
@ Engine turns but no exhaust comes out
(Fuel is not being injected) .............................................. 12-062
@ Exhaust gas comes out but engine does not start
(Fuel is being injected) ................................................. 12-063
s-3 Engine does not pick up smoothly
(Follow-up is poor) ............................................ . ........... 12-064
s-4 Engine stops during operations ............................................. 12-065
s-5 Engine does not rotate smoothly ....................................
(hunting) 12-066
S-6 Engine lacks output (no power) .............................................. 12-067
s-7 Exhaust gas is black (incomplete combustion) ................................. 12-068
S-8 Oil consumption is excessive (or exhaust gas is blue) ........................... 12-069
s-9 Oil becomes contaminated quickly ........................................... 12-070
S-IO Fuel consumption is excessive .............................................. 12-071
2 S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ............ 12-072
z ............................... 12-073
s-12 Oil pressure lamp lights up (drop in oil pressure)
z
s-13 Oil level rises ............................................................. 12-074
s-14 Water temperature becomes too high (overheating) ............................ 12-075
s-15 Abnormal noise is made ................................................... 12-076
S-16 Vibration is excessive ...................................................... 12-077
POINTS TO REMEMBER WHEN TROUBLESHOOTING
Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs, and ensuring that the
failure does not occur again.
When carrying out troubleshooting, it is of course important to understand the structure and function. But to
carry out the troubleshooting effectively, a quick method is to carry out troubleshooting using the problems
mentioned by the operator as a guide in locating the cause
4. Confirming failure
1. Do not disassemble the machine simply be- Check the degree of the problem to judge for
cause there is a failure yourself if it is really a failure, or if there is some
If the machine is disassembled immediately just problem in the handling or operation of the ma-
because there is a fuilure: chine.
. Unrelated or unnecessary places are also dis- * When driving the machine and re-enacting
assembled the failure, be sure that the investigation or
. It becomes difficult to locate the cause of the measurement does not make the failure
failure worse.
This means that there is not only a waste of time
and money on replacement parts, oil, and grease, 5. Troubleshooting
but this action will also lose the confidence of the Narrow down the causes of the failure from the
user and operator. results of the questions and checks in the above
For this reason also, it is important to carry out Items 2 - 4, then follow the troubleshooting flow
troubleshooting based on full investigation before chart to locate the failure.
starting and troubleshooting following the correct * Basic procedure for troubleshooting
order. 1) Start from the simple places.
2) Start from the most probable places.
2. Questions to ask the user and operator 3) investigate related parts also.
1) Are there any problems other than those al-
ready reported? 6. Basic action to remedy cause of failure
8 2) Did anything unusual happen before the fai- Even if the failure is repaired, if the root cause of
z lure occurred? the failure is not repaired, the same failure will OC-
z 3) Did the failure occur suddenly, or had the cur again.
condition of the machine been poor before To prevent this, it is necessary to investigate why
the failure occurred? the failure occurred, and to remove the root
4) What were the conditions when the failure oc- cause of the failure.
curred?
51 Had any repairs been carried ot before the fai-
lure occurred?
6) Had any similar failure occurred before?
3. Checks before troubleshooting

1) Check the oil level.
4 Check for any external leakage of oil from the
piping and hydraulic equipment.
3) Check the travel of the control levers.
4) Other maintenance items can also be carried
out visually, so carry out any check that is
considered necessary.
12-055
@
METHOD OF USING TROUBLESHOOTING CHART
This troubleshooting chart is divided into three
sections: questions, check items, and troublesh-
ooting. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection
without using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in @ are
items that can be obtained from the user,
depending on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from his own inspection.
rroubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
12-056
8
The basic method of using the troubleshooting chart is as
follows.
Items listed for [Questions] and [Check items] that have a
relationship with the Cause items are marked with 0, and
of these, causes that have a high probability are marked
with 0.
Check each of the [Questions] and [Check item&in turn,
and marked the 0 or 0 in the chart for items where the
problem appeared. The vertical column (Causes) that has
the highest number of points is the most probable cause,
so start troubleshooting for that item to make final confir-
mation of the cause.
%1. For [Confirm recent repair history] in the [Ques-
tions] Section, ask the user, and mark the Cause
1
column with A to use as reference for locating
the cause of the failure. However, do not use this
when making calculations to narrow down the
causes.
%2, Use the A in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference. As a rule, do not
use it when calculating the points for locating the
cause, but it can be included if necessary to deter-
mine the order for troubleshooting.
!
2 %l Confirm recent repair history
I I
G %2 Degree of use Operated for’long period A A A
z
12-057
0
- Example of troubleshooting when exhaust gas is black
Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weak-
er], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
12-058
8
Five causes
Step 1
Clarify the relationship between the three symptoms

in the [Questions] and [Check items] section and
the five Cause items in the vertical column.
I Step 2
Add up the total of 0 and 0 marks where the hori-

zontal lines for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element: 000
(2) Air leakage between 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 2 show that the closest

relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item marked
0. The Remedy is given as [Clean], so carry out
cleaning, and the exhaust gas color should return
_ to normal.
TROUBLESHOOTING TABLE
r
S-l Starting performance is poor (Starting always takes time)
General causes why exhaust gas comes out but engine
Causes
does not start
l Defective electrical system
l insufficient supply of fuel 2
s
l Insufficient intake of air ;i
l Improper selection of fuel (At ambient temperature of $
-1 O°C or below, use ASTM D975 No. 1) :
a zi
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.lr Battery charging rate J h
$ 55
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100% 90% 80% 75% 70 % I

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temoerature ‘/
< 2 :
2ooc 1.28 1.26 1.24 1.23 1.22 c
” 0 P
ooc 1.29 1.27 1.25 1.24. 1.23 / f. t( 6
-1 ooc 1.30 1.28 1.26 1.25 1.24 i
i _
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c
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/ .
m‘
* The specific gravity should be for the charging rate of 70% or more in i I -
2 5
the above table. b
i 1 :
l In cold weather the specific gravity must be for the charging rate of at
least 75% in the above table. : I i i $ 3
-
1 Confirm recent repair history
- -
Degree of use Operated for long period 1
- -
Ease of starting
Gradually became worse
- -
Starts when warm
- -
z
9
Indicator lamp does not light up
- -
5
Engine oil must be added more frequently
- -
Replacement of filters has not been carried out according to operation
;i; 0
manual
- -
Dust indicator is red
-
Non-specified fuel has been used , 0
- -
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,
Q
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 / -6
Leakage from fuel piping 0
- 5
There is hunting from engine (rotation is irregular) , G
When comoression oressure is measured. it is found to be low
- -
When air cleaner element is insDected directly, it is found to be clogged I
-
When fuel filter, strainer are inspected directly, they are found to be clogged ,
- 5
-
When feed pmp strainer is inspected directly, it is found to be clogged
- -
APS combustion portion does not become warm
- -
Voltage is 26 - 30V between alternator terminal B and terminal E - -
- -
Either specific gravity of electrolyte or voltage of battery is low
- -
Some cylinders does not change engine speed when operating on reduced
a cylinders - -
c When check is made using delivery method, injection timing is found to be
incorrect
- -
When control rack is pushed, it is found to be heavy or does not return
(when blind plug at rear of pump is removed, it can be seen that plunger 0
I control sleeve does not move)
- -
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
m
z .k
0: Possible cause (jugding from Questions and Check items) I 1 m
0: Most probable causes (judging from Questions and Check items) 0 8
A: Possible causes due to length of use (used for a long period)
i i
cr E
0: Items confirm the cause
12-060
@
S-2 Engine does not start
@ Engine does not turn
General causes why engine does not turn

r Causes
- - -
1
l Internal parts of engine seized
Ir If internal parts of the engine are seized, carry out .-El
3
troubleshooting for “Engine stops during operations”. b
l Failure in power train 6
E
l Defective electrical system
r,
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- - - - - - -
Confirm recent repair history
- - - - - -
!?
Degree of use Operated for long period
- ii-
- - - - -
E
._ Condition of horn when starting Horn does not sound
- - - - 0
- - -
zi switch is turned ON
%-
Horn sound level is low
- - - - - - -
a Rotating speed is slow
- - - - -
Makes grating noise c
- F
- - -
/I When starting switch is turned to
START, pinion moves out, but Soon disenaaaes aaain
-” -
-
-
iT - - -
-
-
/I Makes rattling noise and does not turn 0
- - 0
- - - - -
Im
E When starting switch is turned to START, pinion does not move out 0
- - - - - -
- z-
-
C When starting switch is turned to ON, there is no clicking sound
- - - - -
P Battery terminal is loose
- - - - D
-
6 When startina switch is turned to ON. linkaae does not move
- - - - - F
- r-
1 When batterv is checked, batterv electrolvte is found to be low
- - - - - - -
1 Specific gravity of electrolvte, voltage of batten, is low
For the following conditions 1) - 5). turn the starting switch OFF, connect the
- - - - - - -
cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are connected, engin
starts
2) When terminal B and terminal C of starting motor are connected, engine
- - - - - - -
l
starts
3) When terminal B and terminal C of safety relay are connected, engine
- - - - - - -
0
starts
4) When terminal of safety switch and terminal B of starting motor are con
- - - - - - -
E 0
I= netted, engine starts
5) There is no 24V voltage between terminal B and terminal E of battery
- - - - - - -
l
relav
-
r-
- - - - -
When rina aear is inspected directlv. tooth surface is found to be chiooed
- - - -
Does not move even when engine stop motor linkage is disconnected c
* . I or b Irr r or 7
Legena
0: Possible cause (jugding from Questions and Check items) Remedy - P 0 s P
z,
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0: Most orobable causes (iudaina from Questions and Check items) I 3 $
A: Possible causes due to-length-of use (used for a long period) _ E
-
E a
e: Items confirm the cause
12-061
Go
@ Engine turns but no exhaust gas comes out
(Fuel is not being injected)
General causes why engine turns but no exhaust gas comes

Causes
out - -
Supply of fuel impossible

Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Standards for use of fuel E

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- -
0

- - -
- -
Exhaust gas suddenly (when starting again) stopped coming out z
- - -
z
.-o
Replacement of filters has not been carried out according to operation manual
- - -
5-
Fuel tank is found to be empty
- 0
-
S There is leakage from fuel piping, crushed piping
- - K
-
- - -
When starting switch is turned ON, linkage does not move
- - -
i
Iu
When fuel filter is drained, fuel does not come out
- - -
.E
1) No fuel comes out even when fuel filter air bleed plug is_loosened
% - -
5
a, 2) No fuel spurts out even when injection pipe sleeve nut is loosened iT
- - -
” 1 Rust and water are found when fuel is drained
- - -
Inspect injection pump directly
- - -
- -
r- - -
- - -
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 I
u .k
0: Possible cause (jugding from Questions and Check items) $ m
0: Most probable causes (judging from Questions and Check items) 3 E
lx LT
A: Possible causes due to length of use (used for a long period) -
0: Items confirm the-cause
12-062
0
@ Exhaust gas comes out but engine does not start (Fuel is
being injected)
General causes why exhaust gas comes out but engine does not
Causes
start
l Lack of rotating force due to defective electrical system

l Insufficient supply of fuel
l Insufficient intake of air
l Improper selection of fuel and oil
6
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- - - - -
Ic on f rrm recent reoair historv
- - -
Degree of use 1 Operated for long period h
- -
a
- - -
Suddenly failed to start
- - - - -
When engine is cranked, abnormal noise is heard from around cylinder head
- - - - -
- - - -
Non-specified fuel has been used 0
- - -
Reolacement of filters has not been carried out according to operation manual G
- G
- - - -
Type of oil is not used according to operaton manual
- - - -
Rust is found when fuel is drained ii- - - -
- 6
- - - -
Indicator lamp does not light up
- - -
Starting motor cranks engine slowly
- - - -
Mud is stuck to fuel tank cao
- - - 0
-
When fuel lever is olaced at FULL position, it does not contact stopper
- - - - 0
-
/
1) Little fuel comes out even when injection pump sleeve nut is loosened
0
E - - - -
S 2) Little fuel comes out even when fuel filter air bleed plug is loosened i- - - - -
z
: There is leakage from fuel piping
- - - - -
5 When exhaust manifold is touched immediately after starting engine, temperature of
Q
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
- -
0
Remove head cover and inspect directly
- - - - -
- - - - -
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 5
- - - -
When air cleaner element is inspected directly, it is found to be clogged - 5
- - - -
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
- - -
5
-
Play, stiffness in fuel control lever linkage
- G
-
-
Legend
0: Possible cause (jugding from Questions and Check items)
0: Most probable causes (judging from Questions and Check items) 5k
5 3 3
c 5_, 5
E
5
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up smoothly

l lnsuff icient supply of fuel
l Improper condition of fuel injection
l Use of improper fuel
l Defective fuel injection pump
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0
-
1 Confirm recent reoair historv
- -
Degree of use Ooerated for lona oeriod h - -
Replacement of filters has not been carried out according to operation manual 0 0 - -
Non-specified fuel has been used
- 0
0 - - -
I
- -
.P Rust and water are found when fuel is drained 0
- 0
- - -
2 - - -
r3 Noise of interference is heard from around turbocharaer
- - 0
Engine pick-up suddenly became poor
- - 0
- 7
-
Blue under light load
- - -
/
Color of exhaust gas
-.-_..
Black
- - s
- -
Clanging sound is heard from around cylinder head
- - - -
Mud is stuck to fuel tank cao
- - -
There is leakage from fuel piping
- - - 0
-
C High idling speed under no load is normal, but speed suddenly drops when load is
1
L
am-died
-rr-.--
0 D
- -
6 There is hunting from engine (rotation is irregular)
When exhaust manifold is touched immediately after starting engine, temperature oi
5
- ii
- - -
some cvlinders is low
1 Blow-bv aas is excessive
- - - -
- -
When air cleaner element is inspected directlv. it is found to be clwaed
c-
- - - -
I When fuel filter, strainer are inspected directlv, thev are found to be cloooed
- - -
- F
- - - -
Some cylinders does not change engine speed when operating on reduced cylinders
- - - - -
E
5
Inspect feed pump
- - - - -
2
When compression pressure is measured, it is found to be low
- - - -
: When turbocharger is rotated bv hand, it is found to be heavy
- - G
- - -
E
z
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
- - - i-
When feed pump is operated, operation is too light or too heavy
- - - - r-
When starting switch is turned ON, there is a clearance between stop lever and
. . bolt
stoooer
- - - - -
When boost compensator diaphragm is inspected it is found to be broken, or pipe is
crushed
.Legena .
iiT
m :h
0:
8:
Possible cause (jugding from Questions and Check items)
Most probable causes (judging from Questions and Check items) i 5
J J
i?
r z
s-4 Engine stops during operations
General causes why engine stops during operations
l Internal parts of engine seized

l Insufficient supply of fuel
l Overheating
+ If there is overheating and the engine stops, carry out
z
5
i
troubleshooting for overheating. z
l Failure in power train u
+ If the engine stops because of a failure in the power train, i
:: 5
carry out troubleshooting for the chassis. L %i
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- - - -
- - -
Degree of use Operated for long period h
-
Abnormal noise was heard and engine stopped suddenly 0
- 0
- - 0
-
Engine overheated and stopped
Condition when engine - - -
E
stopped Ermine stopped slowlv
- - 0 -
.o ! There was hunting and engine stopped 0
z - - - -
2 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
- - s
Non-soecified fuel has been used * 0 0
-
/ When feed oumo is ooerated. there is no resoonse or it is heaw
- - 0
- -
- - - -
Engine turns, but stops when transmission control lever is operated
- - - -
- - -
Try to turn by hand using barrmg tool
0
- - -
- 0
- - -
- - -
Rust and water are found when fuel is drained
- - 0 -
Metal particles are found when oil is drained 0
Remove oil pan and inspect directly
- - -
Remove head cover and inspect directly G
- - -
.-P When gear train is inspected, it does not turn G
6 - - - -
2 Turns when oumo auxiliarv eauioment is removed
- - -
t
B When fuel filter, strainer are insoected directlv. thev are found to be cloaaed
- - s- -
a When feed pump strainer is inspected directlv, it is found to be clogged
- - -
c
Inspect feed pump directlv
- - - G
-
I
5 T
- cu
Legend
0: Possible cause (jugding from Questions and Check items) Remedy
s E0 ri t+
0: Most probable causes (judging from Questions and Check items) I s
CT I 2
0
E
I
A: Possible causes due to length of use (used for a long period) I
12-065
0
s-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly
l Air in fuel system

- - -
Causes 1
l Defective governor mechanism
u
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- - - -
- - - _
1 Degree of use 1 Operated for long period
- - -
j ;;:;;z 1: ;;;;,:r;;d range c - - -
0 - -
Condition of hunting
: Occurs even when weed is raised 0 0
- -
2
;; Occurs on slopes
- c - -
?
CJ Fuel tank is found to be empty
- c
- - _
Replacement of filters has not been carried out according to operation
manual
- - - - _
Rust is found when fuel is drained
- - - - - -
Leakage from fuel piping
- - - - - -
When feed pump is operated,
z
al
1) No response, light, return is quick
- - - - -
C 2) No response, light, return is normal
- - -
%
al Engine speed sometimes changes greatly G- - - - a
-
6 Sometimes difficult to stop engine
-Q
,ii-
- - _
Seal on injection pump has come off
c-
G-
- - - -
When covernor lever is moved it is found to be stiff 7
- - - - -
When injection pump is tested, governor is found to be improperly
c-
- - - -
- - z- -
_
- - 5-
- -
- - - - - -
When fuel filter, strainer are inspected directly, they are found to be
- - - - -
1 Check fuel feed pumo
- - - - - 5m
LCsgend
0 : Possible cause (jugding from Questions and Check items)
z
5 4
s
5 is s
Q : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period) -a
a
‘0’
a B ‘D
u
5
r
12-066
0
S-6 Engine lacks output (no power)
Carry out troubleshooting to decide if the cause is in the

engine or in the machine. (Measure engine stall speed)
Causes
General causes why engine lacks output
E
E
l Insufficient supply of fuel .E
ma
n
0 Use of improper fuel z
5 5 6
(if non-specified fuel is used, output drops) %
P
l Lack of output due to overheating m s 1
:
e
j, If there is overheating and lack of output, carry out
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troubleshooting for overheating. $ z n8
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.2 8 z .L;
.5 m 2 .E
P .?
;
2 s
: 1 i “0
c d c s
- - -
Confirm recent repair history -
- -
Dearee of use 1 Operated for long period
- ii- - -
Suddenly - -
Power was lost
Gradually 0
_ 0
- - -
2 -
.g Engine oil must be added more frequently - _ - -
5 Replacement of filters has not been carried out according to operation manual - - -
2 <
Non-specified fuel has been used - - - -
Dust indicator is red - - - -
Black - _ - -
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 c_ - - c
c -, ,
v) High idling speed under no load is normal, but speed suddenly drops when load C
E
m
C
is applied - - - -
._ When exhaust manifold is touched immediately after starting engine, tempera- CJ
B ture of some cylinders is low - _ -
6 There is hunting from engine (rotation is irregular) _ - 0
- -
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 -
G
- -
:
When fuel filter, strainer are inspected directly, they are found to be clogged - - -
- When feed pump strainer is inspected directly, it is found to be clogged - -
5
_z Some cylinders does not change engine speed when operating on reduced cylinders 5
- _ -
%
3
When control rack is pushed, it is found to be heavy or does not return - - -
When valve clearance is checked directly, it is found to be outside standard
value _ - -
When lever is placed at FULL position, it does not contact stopper - - -
When feed pump is operated, operation is too light or too heavy - -
When fuel cao is insoected directly, it is found to be clogged 5
- u
Legend
0: Possible cause (jugding from Questions and Check Items)
.k
z ii 5
Q: Most probable causes (judging from Questions and Check items) if 2
P r 0
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black
Causes
l Insufficient intake of air - -
l Excessive injection of fuel
F %
.P .N
6 :
.% 5
.c
Q ;;;
2 z :
=
a t
TJ E 3 J
E : i! z :
&
1
E 0
.E
$
.-E .-P ? z s E
0
F
e
.‘y
E ._ 2 k 2 2 al
Y
5 % 6
.-P
.E s
.- .-E z z
c
.P z
c
u
ii L zi
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e
.‘y
ti
.% L E
i(
.L L
.s El z .5 .5 2 8 .5 a
72
2
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0.
2 $ .-F $ 2
0
.-2 .-z
B E $ 8 ; 8 t;
ii G
-z
2
1 I 2
2
v 0 p $ p $ 2 z
- - - - - - - -
- - - - -
I Dearee of use I Ooerated for lona oeriod h
- L\
- h - - -
i-
- -
- 0 - - - - 0
- -
z
- 0
- - - -
0
- - -
- zi- - - - - - - -
- c
- - - - - -
0
- - - -
0 0
- -
0
- 0
- - - -
0 0
- -
IN on -soecified fuel has been used
- - 0
- - - - - 0
- -
Noise of interference is heard from around turbocharger
- - - - - - -
Dust indicator is red z
- - - - - - - -
Blow-by gas is excessive
- iT
- - - - -
Engine pickup is poor and combustion is irregular
- - z
- - - 0
- 0 0
- 0
- -
When exhaust manifold is touched immediately after starting engine
Q 0
temperature of some cylinders is low
- - - - - - - -
- - - iF
- - - - -
- - - - G-
- - - -
sound is heard from around cylinder head
- - - - G
- - -
Exhaust noise is abnormal
- - 0
- - - - 0 - -
ZY
-
Muffler is crushed
- - - - - - Q - - -
Leakaae of air between turbocharaer and head. loose clamo
- - - - - - 0 - - -
When turbocharaer is rotated bv hand, it is found to be heaw
- - - - - - - -
When air cleaner is inspected directlv. it is found to be clogged r- - - - - - -
- r- - - - - r- - -
Some cylinders does not change engine speed when operating on
2 0
._
B
reduced cylinders
- - - - - - - - -
P When check is made using delivery method, injection timing is fount
0
3 to be incorrect
- - - - - - - -
B
2
Injection pump test shows that injection amount is incorrect
- - - -
r- - - - -
e When valve clearance is checked directly it is found to be outside
0
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
- -
0
-
Legend ;;_ -E - -
u T iti
0: Possible cause (jugding from Questions and Check items) E s 5 s5 54
1 s ifi _m
@: Most probable causes (judging from Questions and Check 2 E 5 i+
a
$ mp8
items)
0 (r
- E 9 -a a az
5
S-8 Oil consumption is excessive (or exhaust gas is blue)
* To prevent oil from leaking up or down, do not run the

engine at idling for more than 20 minutes continuously.
(Both low and high idling)
General causes why oil consumption is excessive
l Abnormal combustion of oil

l External leakage of oil
l Wear of lubrication system
B
a
d
3
.c
&I
2
‘-
2
:P
=
%
2
3
-
-
g
-
2
G
Oil consumption suddenly increased
-
2
u
-
Engine oil becomes contaminated quickly
-
Exhaust gas is blue under light load
-
Amount of blow-by gas
Abncrmally excessive
-
None
Area around engine is dirty with oil 0
-
There is oil in engine cooling water
-
When exhaust pipe is removed, inside is found to be dirty with oil
f
=
-
Inside of turbocharger intake pipe is dirty with oil
Y
4
-
Oil level in clutch or TORQFLOW transmission damper case rises
5 -
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 breather element is inspected, it is found to be clogged with dirty oil
There is external leakage of oil from engine c-
Pressure-tightness test of oil cooler shows there is leakage
-
Excessive play of turbocharger shaft
-
Check rear seal directly
-
When intake manifold is removed, dust is found inside
-
When intake manifold is removed, inside is found to be dirty with oil
I ____A
Leyeno
I
k
Q: Most probable causes (judging from Questions and Check items) I
Remedy x
r”
A: Possible causes due tolength-of use (used for a long period) L
12-069
8
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly
Intake of exhaust gas due to internal wear -

l
-
l Clogging of lubrication passage
l Improper combustion
l Use of improper oil
l Operation under excessive load
l Interval between oil change is too long m
.P
a
.g
a 6
E
23 b
P
E
s b r”
z .c
i a ::
se, .E
z 2 s _c
=
0 I %
D
5
.-
5m E
-0
(u
F P :: .?
F
$ E 8 8 5 2
-s 2
0 P 2 =
0 0 0
-
0
- - - -
Confirm recent repair history - - - - _
E Degree of use Operated for long period -

x- - - -
2
Engine oil must be added more frequently - - - - 0
-
5
Non-specified fuel has been used 0
- - - - - -
z
Blue under light load - - - - -
Black - - - -
Abnormally excessive - 0
- 0
- - - _
Amount of blow-by gas
None - - - -
E
.= Oil filter caution lamp stays on even when oil pressure rises T - - 0
- -
%
a, When oil filter is inspected, metal particles are found YEi
- 0 - - - -
5 When exhaust pipe is removed, inside is found to be dirty with oil - --ii - -
Engine oil temperature rises quickly - - G - - - 2
When oil level is checked with dipstic, it is found to be above H mark. - - - - %
-
When compression pressure is measured, it is found to be low - < - - - - -
When breather element is inspected directly, it is found to be clogged with dirty
.-P oil, or hose is broken - - - - -
5 -6
2
When oil filter is inspected directly, it is found to be clogged - - - - -
2 When oil cooler is inspected directly, it is found to be clogged - - 5
- - -
0
z Turbocharger drain tube is clogged - - - 5
- - -
c Excessive play of turbocharger shaft - - - - _
When safety valve is inspected directly, spring is found to be catching or broken 5 -
- -
_;; 3 T
Legend
s LF
: ii 4 r
z -E
2 2
0: Most probable causes (judging from Questions and Check items)
2 c? 1 2
0 @z <
12-070
0
S-l 0 Fuel consumption is excessive
General causes why fuel consumption is excessive
l
Leakage
Improper
of fuel
condition of fuel injection
r - - - - -
l Excessive injection of fuel

-ii 0
g .-r”
t;
._ .5
a 9
& E E
27 F 2 2
P 2
P 8
x -_
m .2 m
x E 4
-s
Ii z .-E
g
c
2
c
.-6 m s
.-
5 z I t(
.L .% .%
.5 .c 5 .5
m
.-2 .-? 2 .-?
G t B e
P 2 I
d $ 2 0”
- - - -
-
h
- h
- x-
- -
0
- - -
0
- -0 - -
- - -
0
- - 0
- - 0 -
- - - - - -
- - - - -
There is irregular combustion x
- - - - - -
0 0
- - - - -
Match mark on injection pump is misaligned
- - -G
- - - -
- - - -
Enaine oil level rises and smells of diesel fuel
- - - -iiT
- -G
-
Engine low idling speed is high
- - - - z - -
Injection pump test shows that injection amount is too high - - - - -
.-P
Some cylinders does not change engine speed when operating on reduced cylinders -%
- - - - -
6
2
-
7
- - - -
I
When check is made using delivery method, injection timing is found to be incorrect - - 5
- - -
=
2
Remove nozzle holder and inspect directly - - -
T
- 5
-
$ Remove feed pump and inspect directly - - -
-
When engine speed is measured, low idling speed is found to be high
- -
r- -
Legend
I T T
TiI .L
0: Possible cause (jugding from Questions and Check items) i iti s .k
m 5 m
0: Most probable causes (judging from Questions and’theck items) % Et a $
r
3
a oz
e
A: Possible causes due to length of use (used for a long period) -
E lx
- - - - -
12-07 1
@
S-1 1 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
Causes
l Internal leakage in lubrication system
l Internal leakage in cooling system

.-:
cl Suddenly increased
Increase in oil level
2 Gradually increased
c1
Hard water is being used as cooling water (corrosion resistor valve is closed)
/ Engine oil level has risen, oil is cloudy white
: Excessive air bubbles inside radiator, water spurts back
C
% Hydraulic oil, torque converter, transmission oil is cloudy white
0)
5 When hydraulic oil, torque converter, transmission oil is drained, water comes out
.-P
i; Pressure-tightness test of cylinder head shows there is leakage
2
I Remove cylinder head and inspect directly
% Remove oil oan and insoect directlv
0
E Inspect water pump
I_
Legeno
.
0: Most probable causes (judging from Questions and Check items)
12-072
8
S-1.2 Oil pressure lamp lights up (drop in oil pressure)
General causes why oil pressure lamp

lights up
l Leakage, clogging, wear of lubricating

r - - -
Causes
- - -
1
system
l Defective oil pressure control
%
a
l Use of improper oil (improper viscosity)
Deterioration of oil due to overheating
.% .-F
l m .g
Li a 6
a .o
5i
z .-E T=
7
t
* Standards for engine oil selection 0
al 0 b I
a, :! E
z5 9
.g .5
B z
AMBIENT TEMPERATURE .-z z E 5
_c I 2
.o $ D P 5 z i
5
= .5 2e 2 z _c 1 k
+
= .-P L =0 8
5 = :
0 Fi z r)
(u
E
.‘y
6 m
0
m .z
P x P 2 .? .o F .? .E
P
8 E 8 E 2 z 3
5
0 5 01
-z
2
-z
_o E
-3 $
0 0
-2
u u 0 C 0
- - - - - -
- - - - - - -
Degree of use 1 Operated for long period
Replacement of filters has not been carried out according
h
- h
- - -
iF
- - - - -. -
to operation manual 0
- - - - - - - - - -
Caution lame liahts uo G - - - - - 0 - - - -
Non-soecified fuel has been used 0
- 0 - - - - - - - - -
I 1 Lights up at low idling

- TT
- 0 - - -
Condition when oil pres- Lights up at low. high idling
- - -iii-
-
G
- - 0 0
Ti- - 0
- - - - 0
-
- -F
sure lamp lights up Lights up on slopes
- - - - - -
Sometimes lights up
- - - - - - G
- is-
- 0
- 0
- -
Crushed piping, leakage from hydraulic piping (external)
- - - - - - - z- - -
Oil level sensor lamo liohts uo
- - - - - F - - - Ti-
- - -
When oil level in oil pan is checked, it is found to be low
- - - - r- - - - - - -
Metal particles are found when oil is drained
- iT - - - - - - - - -
Metal particles are stuck to oil filter element
- z
- - - 0
- - - - - - - -
Oil is cloudy white or smells of diesel oil
- - - - - - - - - - - -
When oil filter is inspected directly, it is found to be
0 0
cloooed
- - - - - - - - - -
, Remove oil pan and inspect directly
- -
r- z- - - - - - - -
Oil oumo rotation is heavy, there is play
- - - - %-
- - - - - - - -
There is catching of relief valve, regulator valve, or spring,
valve guide is broken
L - - - - -
0
-
0
- - - - 1-
When oil level sensor is replaced, oil pressure sensor lam 2
0
goes out
- - - - - - - - - - - ,
-
When oil pressure is measured, it is found to be within
0 ,
standard value
- - - - - - - - - - - ,-
r
1 Check oil cooler
I - - - - u
- - - - Tm 7
?gend
: Possible cause Remedy ii
c
ii 5 4 2 H
5
.&
4 2 4
2 a 0 LT8 oz
!? :
-2
u 1 ‘u E
(jugding from Questions and Check items)
Q: Most probable causes I
0 u 0 u -
LT a a oz oz
-
(judging from Questions and Check items)
12-073
0
S-13 Oil level rises
* If there is oil in the cooling water, carry out

troubleshooting for "Oil is i n cooling water".
Causes
General causes why oil level rises
Water in oil (cloudy white)

Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component

ÂDegree of use
K
1 Operated for long period
5 There is oil in radiator cooling water
When engine is first started, drops of water come from muffler

Leave radiator cap open. When engine is run at idling, an abnormal
number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
- -
When water pump breather hole is cleaned, water comes out

v i l level does down in TORQFLOW transmission, or damper case
5 Oil level does down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently
Pressure-tightness test of cylinder head shows there is leakage
When comoression pressure is measured, it is found to be low
Remove water pump and inspect directly
'
Inspect rear seal directly
2 When ~ u m auxiliary
p equipment is removed. seal is found to be
- broken
n
g Remove nozzle holder and inspect directly
--
p o v e injection pump and inspect directly

There is improper contact of thermostat seat valve
-
Remove oil pan and inspect directly
Pressure-tightness test of after-cooler core shows there is leakage
I
1 Remedy
Legend
0: Most probable causes (judging from Questions and Check
items)
Â¥Items confirm the cause
S-l 4 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high
l
Lack of cooling wind (deformation,
Drop in heat dissipation efficiency
damage of fan) r
l Defective cooling circulation system
l Rise in il temperature of power train
j, Carry out troubleshooting for chassis.
c E?
; s
6 4
6 2
0
E s
z 2
E
s
0
P i 2 $
5 g
2
z 7
z
m h
0 L 2
2 x .-? c
5 Y
8 z 0
9
u
_O
v 2 6
- - - -
Confirm recent repair history - -
Deoree of use I Ooerated for lono oeriod
- h
h - - -
6
Condition of overheating
Suddenly overheated
- _
Alwavs tends to overheat 0
_ 0
- _ -
Water temperature gauge
/ Rises quickly
_ - - -
1 Does not go down from red range
- - _ -
Radiator water level sensor lights up
- - - -
Fan belt whines under sudden load
- - - -
Cloudy white oil is floating on cooling water
- _ -
Coolino water flows out from overflow hose
- _ G
- -
Excessive air bubbles inside radiator, water sourts back _ - -
Engine oil level has risen, oil is cloudv white
- - z-
Radiator shroud, inside of underguard are clogged with dirt or mud ii - - -
When light bulb is held behind radiator, no light passes through iTI
- - _ -
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 i - - -
Temperature difference between top and bottom ratiator tanks is too small G
- - _
When radiator is inspected through water filler port, the core is found to be cloggel
- 5
- _ -
When a function test is carried out on the thermostat, it does not open at the crack
ing temperature _ - - -
When water temoerature is measured. it is found to be normal
- - - -
When oil cooler is insoected directlv. it is found to be cloaaed - - - -
When measurement is made with radiator cap tester, set pressure is found to be 0
low - - - -
- _ -
Remove oil pan and inspect directly _ - -
5
-
Pressure-tightness test of cylinder head shows there is leakage
-
Legend
u a,
.k L_
m P ii
Q: Most probable causes (judging from Questions and Check items) P 8
L
P
DC
4
cc
A: Possible causes due to length of use (used for a long period) E
0: items confirm the cause
12-075
@
S-l 5 Abnormal noise is made
+ Judge if the noise is an internal noise or an external

noise.
Causes
General causes why abnormal noise is made
Abnormality due to defective parts

Abnormal combustion noise %
i
Air sucked in from intake system
5
:
a
z
x u‘
: . 2 _c
? 5 ti
/ x?
: .-5 E” 0
t; 2 _a
.2 .c
” .5 s
,_ E
: P t;
.L k
.!
j 2 .E :
2 m
f
i $ .?
5 8
i g I
9
: , 0 $ j
- - -
1 Confirm recent reoair historv
- - -
Dearee of use I 0 aerated for lona period
- - -
I 1 Graduallv occurred
Condition of abnormal noise - - -
1 Suddenly occurred ( -
E Non-specified fuel has been used 0 0
.g - - -
z Engine oil must be added more frequently ) - -
Blue under light load ) - - -
Slack ( - - -
Metal particles are found in oil filter ) - - -
Slow-by gas is excessive ) - - -
Noise of interference is heard from around turbocharger 4 - -
Engine pickup is poor and combustion is irregular 0
- - -
E When exhaust manifold is touched immediately aftr starting engine, tempera-
(Y
.= ture of some cylinders is low
0 0
- - -
P Seal on injection pump has come off G
6 0 0 5 0
Abnormal noise is loud when accelerating engine
- - - -
1 Clanging sound is heard from around cylinder head ,
- - - -
Leakage of air between turbocharger and cylinder head
- - - -
Vibrating noise is heard from around muffler
- - - -
1 When compression pressure is measured, it is found to be low I
- - - -
When turbocharger is rotated by hand, it is found to be heavy I - - -
Remove gear cover and inspect directly, (flywheel housing top cover)
- - 5
-
Some cylinders does not change engine speed when oeprating on reduced cylinder s- - -
.-2 When control rack is pushed, it is found to be heavy or does not return
- G
- -
B
e
Injection pump test shows that injection amount is incorrect
- - G
- -
B
z Fan is deformed, or belt is loose
- - - -
2 When valve clearance is checked directly, it is found to be outside standard
e value
- - - -
Remove cylinder head cover and inspect directly
- - - -
When muffler is removed, abnormal noise disappears
- - - -
Check for leakaae from air comoressor oioina
- - - -
Remove oil pan and inspect
Legend , u z
0: Possible cause (jugding from Questions and Check items) Remedy ! 4 4 5 .L
x
0: Most probable causes (judging from Questions and Check items) ; P
cc
s5
oz a 2
12-076
Go
S-l 6 Vibration is excessive
* If there is abnormal noise together with the

vibration, carry out troubleshooting for “Abno-
Causes 1
rmal noise is made”.
General causes why vibration is excessive
l Defective parts (abnormal wear, breakage)

l Improper alignment
l Abnormal combustion
AZ
0 b
3
8 E -iz
a,
D
d
5 .s c i
.z
a +I .P
s
.-
r .% E
* ;.%
EL 8 .F
4
m 25 ? $
._
E 0” B z
-is E 2 P
- -
0
-
r- - - -
- -
I
.o Condition of vibration
Suddenly increased
5-
- 5-
-
6
:
Gradually increased
- - - 5-
-
0 Non-specified fuel has been used
- - - -
Metal particles are found in oil filter
- - - -
Metal particles are found when oil is drained
- - - -
S
i
Oil pressure is low at low idling
Vibration occurs at mid-range speed
- - - -
z -
8
Vibration follows engine speed 7
- 5-
- 3
-
6 Exhaust gas is black
- - - 5-
-
- - - -
Remove oil pan and inspect directlv
- - - -
1 Remove side cover and inspect directlv
- - -
Cherck directly for worn support pilot, play i-
- - - -
Inspect directlyfor loose engine mounting bolts, broken cushion
- - - -
- - - -
When radial runout, face runout are measured, they are found to be
- - -
Remove front cover. and inspect directlv.
- r- -
I Remove head cover and insvect directlv - - - r-
Legeno
1 Injection pump test shows that iniection amount is incorrect
lu
- b g-
0: Possible cause (jugding from Questions and Check items) xs. 8 z
E
0: Most probable causes (judging from Questions and Check
Lz E :
-items)
a: Possible causes due to length of use (used for a long period)
12-077
0
TROUBLESHOOTING TABLE FOR ELECTRONIC GOVERNOR
T P,~_ Indication of :on-

?‘“’
.i
r Item Trouble check method Iheck Action to setta_ lamps Resetting En-
Remarks
time take condition 3ine ;ys-
t
bi’ity Green Red
em
Normal 0 0 Iuns lorma
t
- -
C/U Written data and read data ms GOV $LLN 2 0 l When power is
(RAN) are compared with each turned off ant
other when system is set- started again, if en,
1
table gine is not under
started, and they are differ-
condition at left
ent as a result. governor is reset.
C/U (AD Signals are not output for IOOms GOV PULL Not 0 0 Same as above
converter) a certain time after AD con- DOWN z;_
version is finished. (Note I) table
-r Governor
servo error
Target value and actual
value are not the same:
10s
Is
GOV PULL Not @ Alternate
re-
set-
Fast
c
Fast
Same as above
IfNE>
150rpm,
NE < 150rpm.
I NE > 150rpm
table set to 1
I
(Imm minimum) sec.
nginf
Racksensor Output voltage of rack sen- Same as above as
circuit sor circuit is out of speci- itop:
‘oubll
fied range gain.
(Above 4.5V or below 0.5V).
E!Gzg
Overrun Software overrun: Software: is output
NE 2 115% Overspeed Same as above when
Hardware overrun: Hardware: software
HE 2 2,300rpm NE 2 2,lOOrpm overrunis
detected.
Oil pressure Oil pressure switch is Hi 6s GOV pD;tJN v 0 When power is tur Same as
drop (24V) and NE > 500rpm. r ned off and startec above
set- again, if engine is
tabl not under conditior
at left, aovernor is
reset. -
Water tem- Water temperature switch 0.3s GOVPULL 2 . 0 Same as above
perature rise is Hi (24V). DOWN ~~~i~
Re_ a Simulta-
NE sensor Second pulse is received 160 Normal neous 0 Reset when inpu
No. 1 but first one is not. NE s control with set- signal become:
second pulse tab’e ‘tow ‘tow normal.
NE Sensor First pulse is received but 420 Normal Pe- @ Alternate C

No. 2 second one is not. NE s control (with ;;& Slow Slow Same as above
frrst pulse)
Speed Output voltage of speed If speed contra

ight
control knob control knob is out of speci- lknob > 20% ant
tuns nginr
(Low idling) fied range 0.2sec, normal.
‘oublr
(Above 4.8V or below 0.2V).
Frequency Output, voltage of fre- IS Fix to set Re- 0 @ Reset when inpu Only in
control knob quency control knob is out median. set- Fast signal become: isochro-
table nous
of specified range normal.
opera-
(Above 4.8V or below 0.2V). tion
Droop Output voltage of droop IS Fix to set Re- 0 @ Same as above On&
adjustment adjustment is out of speci- median. set- Slow
table opera-
error fied range
(Above4.8V or below 0.2V). tion.
Note I) If a start signal is input, all AD data are controlled normally in the backup mode. (A servo error is not detected.)
Note 2) Two or more codes are detected in the order of No. (One pattern is indicated for 12 seconds. Then, after an interval of 6
seconds, the next pattern is indicated.)
Note 3) 0 : Going off, 0 : Lighting, @ : Slow flashing (Period: 4 seconds), @ : Fast flashing (0.5: seconds),
@ 0 : Alternate flashing, @ @ : Simultaneous flashing
Note 4) “GOV PULL DOWN” means to pull back the fuel rack.
Note 5) The indication of the lamps is saved, and it is not cleared until the memory clear switch is pressed for 0.4 seconds.
12-078
69
Diagnosis lamp indication
0 Lit @ @ Simultaneous flashing

0 out @ a Alternate flashing
0 Quick flashing (0.25 second) 0 @ Alternate quick flashing
@ Slow flashing (2 seconds)
Diagnosis lamp indication

Indication type GreenRed
I0 0
Controller system 0 0
Governor servo system @ @I
Rack sensor system 8 0
Overrun 0 0
1st speed sensor (engine) @ @
2nd speed sensor (Fuel injection pump) @I @
Low idling speed control dial a @
Droop changeover dial l (3
No indication 0 0
Normal indication 0 0
12-079
@
1. Controller system abnormality
YES 5 YES
-
4 Is the rack drags in
Is the resistance the injection pump?
value between E (Check with the rack
2. Governor servo system abnormality YES (female@@ and cap removed.)
NO
4 r ggifi - “Ower OFF
(female1 a and% 1&z&yL , NO

YES (female)OlB(female)
- 0) and the resistance -
value between Z * Resistance value between ~(female)O~i@) and
(female)@ and a @!(femalei&S~) 30.5 - 38.55 f2
~
2
tfamale)@(~j(female) * Resistance value between Q(female) (@I@ 0) and
0) normal? ~(female)@X@:) 0.75 - 22.5 R
Is the resistance
p * Disconnect KI:. Connect E‘. f.
YES value between _ . Resistance value p
q(female)@@) and @(female)O and @ NO
1 @It@) normal? (female)@ ia(female)@ 30.5 - 38.5 R
Is the resistance * Resistance value between zlfemale)@ and
value between a
- Resistance value ~!(female)O(~(female)Ol 0.75 - 22 n
_ tfemale)@(Otfemale)
9-10.5R * Power OFF
6)) and @%female) - * Power OFF - Disconnect 8, I.
OIL0tfemale)@) * Disconnect a. NO
normal? (Connect &I, 3.)
. Resistance 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
Cause Remedy
Iontroller abnormality
aulty fuel injection pump Replace.
aulty controller Replace.
Replace
aulty harness (between
(Repair the
3-q-Bandfl)
harness.)
aultyfuel injection pump Replace
aulty harness (between Repair the

g-fl-a, harness
Replace
aulty fuel injection
(Repair the
ump, faulty harness
harness)
12-081
03
3. Rack sensor system abnormality
YES 5 YES
_
4 Is the rack drags in
Is the resistance the injection pump?
value between n (Check with the rack
YES Ifemale@%@ and cap removed.)
B (female)@@)
3 NO
. and the resistance - ’ Power 0~
Is the resistance value between m
value between I@ Ifemale)@@) and
(female) 0 and q B (female@%@J)
YES (female)O0l(female) normal?
- 01 and the resistance - - ~ NO
value between q * Resistance value between ~3(female@X@ and
(female@ and @ q(female)@(@,) 30.5 - 38.55 R
2
_ (femaleK%Dfemale) * Resistance value between acfemale) @@I and
0) normal? ~(female)@(@) 0.75 - 22.5 .C
- * Disconnect 0. Connect !B. RI.
_ * Resistance value
q(female)a and q NO
(female)@ (~(female)@) 30.5 - 38.5 L2
I
Is the resistance - . Resistance value between m(female)@ and
* Resistance value ~(female)Ot~_(female)O) 0.75 - 22 R
value between B
9 - 10.5 n - Power OFF
~female)OKWemale)
0) and m(femalei
* Power OFF -Disconnect G, LG.
O(O(female@I) * Disconnect q I. NO
normal? (Connect @iI,3)
* Resistance value
9-10.5R
* Power OFF NO
. Disconnect
%I,0 ,z.
Electrical circuit diagram related to 3. above
Controller
Actuator
Rack sensor
TAE00063
12-082
@
Cause Remedy
- Faulty fuel injection pump Replace.
- Faulty controller Replace.
Replace
_ Faulty harness (between
(Repair the
q -_-mandg)
harness.)
) Faulty fuel injection pump Replace
Faulty harness (between Repair the

El-O-B harness
Replace
Faulty fuel injection
(Repair the
pump, faulty harness
harness)
12-083
@
4. Overrun abnormality
I Cause I Remedy
The probable cause is located

1 YES
- outside of the ekctronical
governorsystem.
FHW/
_ Faulty fuel injection Replace, or repair

- Power OFF NO pump, faulty harness the harness.
(Overrun)
* Disconnect @.
El El- m
Actuator [ = @) @
r- @-------- 1 ,A
! I
I a
I
m
II
-
TAE00063
12-084
da
5. 1st speed sensor abnormality
Cause Remedy
2 YES
L Faulty controller !eolace.
Is the resistance
YES value between
1 r @(female)@ and
Is the resistance - a22.1 -2.5 kQ? Faulty harness (between iepair or
value between q _ * Power OFF NO zl-7-B) eplace.
(male)@ and E . Disconnect a.
~male~Z.l -2.5 I&?
- Connect 3.
(Engine) - Power OFF W Faulty 1st speed sensor
* Disconnect 51. NO leplace
6. 2nd speed sensor abnormality

2 YES
Faulty controller Ieplace
Faulty harness (between epair or

value between 0
a-7J-a) splace
. Power OFF
* Disconnect 3. -aulty 2nd speed sensor eplace
Electrical circuit diagram related to 5. and 6. above
Controller
2nd speed sensor
1st speed sensor
TAE00064
12-085
43
7. Low idling speed control dial abnormality
Cause Remedy
2 YES
Controller abnormality Replace.
Is the resistance
YES value between 0
(female@ and q
1 Faulty harness (between
- (femaleY@ normal? Repair the
Is the resistance B@ and low idling speed
. The resistance NO harness.
value between 0 control dial)
0 @- (female@ and u - value changes between approx. 0.5 - 5.5 kR.
(female@ normal? . Power OFF
Faulty low idling speed
p * Disconnect a.
control dial orfaulty
* The resistance -Turn the low idling speed control dial. harness (between a@
Replace or repair
value changes the harness.
between approx. O.F-05.5 kR. and low idling speed
. Power OFF control dial)
* Disconnect a.
-Turn the low idling speed control dial.
Controller
Droop control dial
Low idling speed control dial

+-- I
TAE00065
12-086
@
8. Droop control dial abnormality
Cause I Remedy
2 YES
L Controller abnormality Replace.
Is the resistance
YES value between 0
1 (female@ and q
Faulty harness (between
- (female)@normal? Repair the
Is the resistance ) q@ and droop control
value between q - The resistance NO dial)
harness.
(female@ and B value changes between approx. 0.5 - 5.5 kQ.
(female@normal? * Power OFF
- Disconnect q. Faultv drooo control dial or
* The resistance -Turn the droop control dial. L faul& harness (between
Replace or repair
value changes the harness.
between approx. 0.!?5.5 kR. H@ and droop control dial)
* Power OFF
* Disconnect n.
+ Turn the droop control dial.
Controller
1
Droop control dial
Low idling speed control dial
TAE00065
12-087
@
a 9. Diagnosis lamp fails to make indication
Cause Remedy
1
Is the voltage YES
Controller abnormality eplace.
p between atcheck
terminal)@ and
generator body and -
0 o- the voltage between Faulty harness (between
0 and generator L
a@(@), - g - ACC epair the
~ body normal? NO terminals or between a@ arness.
* @I voltage +20 - +3OV (BJ@)) and battery GND)
-0 voltage 0 - c2V
* Power ON
co2?d
grounding
terminal
TAE00066
12-088
03
10. Normal indication
a. Changeover between low idling speed and rated speed cannot be achieved.
Cause Remedy
1 YES
- Controller abnormality Replace.
l 0 -K$Z?j$and -
low idling speed/rated Repair the
- Power ON NO speed changeover switch harness.
* At the time of low idling speed: 20 - 30V - li: - controller)
- At the time of rated speed: 0 - 2V
Electrical circuit diagram related to 10. a. above
TAE00067
12-089
63
b. Changeover between 50Hz and 60Hz cannot be achieved.
1 YES
= Controller abnormality Replace.
Is the continuity
between E3female)
0 o- @and a (female)
@Snormal? Repair the
- 50160Hz changeover
harness.
- Disconnect El. NO switch and controller)
-When 50Hz 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
3
1Z-090
@
c. Starting failure (the engine cranks, but no exhaust smoke is emitted.)
* Check for causes (such as abnormalities in the fuel system) outside of the electronical governor system first
of all.
Remedy
YES Faulty injection pump Replace or

1 (Faulty harness) repair.
Is short-circuit
00
observed between
- B(female)@ and - 2 YES Faulty harness (between Repair or
fl(female)@? Is short-circuit @j-Y-fl) replace.
- observed between
- Power OFF - Q(femal&
* Disconnect a. NO (@03,and q
(femaleKQ@)?
- Power OFF NO
. Disconnect a.
Electrical circuit diagram related to 10. c. above
Controller
q- El
G 0
0
r Actuator [$r
@-----___
r 1
Racksensor
34
12-091
03
d. Starting failure (the engine fails to start, although but exhaust smoke is emitted.)
Cause Remedy
YES Faulty injection pump Replace or

4
(Faulty harness) repair.
1
YES Short-circuit of rack

I sensor harness between
Repair or
2 replace.
Isshort-circuit HI and IZ
observed between
The probable cause is
. Disconnect d. - atfemale)@
NO @:, and q3(femafe) 3YE located outside of the
@&a,? Isthe voltage between electronical governor
&Xfemale@$andE system.
- Power OFF - (female)@ normal at -
* Disconnect a. NO thetimeof engine
start? Repair or
starting switch C terminal
* 20 - 30Vfbattery Nr eeplace.
and 3)
voltage)
- Disconnect a.
* Power ON
- Start the engine.
Electrical circuit diagram related to 10. d. above
1 Controller
Actuator q-
r
Rack sensor
Controller
Starting switch
C terminal
12-092
03
e. The engine stops during running.
* This electronical governor system has been designed to stop the engine in any of the following cases. If the
engine stops, check if any of the following statuses has been produced.
1. The emergency stop switch is pressed.

2. The engine water temperature is abnormal.
3. The oil pressure is abnormal.
1Z-093
@
11. Memory clear cannot be achieved by pressing the memory clear switch (when failure indication
is made by diagnosis lamp).
* To execute memory clear, keep pressing the memory clear switch for 5 seconds or longer. (Memory clear
cannot be achieved when the memory clear switch is pressed momentarily.)
* If memory clear cannot be achieved even if the memory clear switch was kept pressed for 5 seconds or
longer, implement the diagnosis indicated below.
Cause
T Remedy
1 YES
Ll
If the continuity
between Zl(female)
aand@ Faulty memory clear
normal? Replace the
switch or faulty harness
switch or repair
- (between memory clear
- Disconnect X3 NO the harness.
switch and controller)
- Power OFF
-When memory clear switch is ON: Continuity is observed.
-When memory clear switch is OFF: Continuity is not observed.
I
Memory clear switch

Controller
TAE00070
1Z-094
@
ENGINE
13 DISASSEMBLY AND ASSEMBLY
DISASSEMBLY ................................................ .13-002

Washing ...................................................... .13-019
Washing cylinder block ............................. .13-019
Washing crankshaft ................................... .13-020
Measuring parts ......................................... .13-021
ASSEMBLY ...................................................... .13-027
* The explanation for disassembly and assembly of the engine given in this
section describes the procedure for the SA6D170-1 engine when using the
repair stand.
* If a different engine or engine repair stand is used, or if the engine is not

equipped with an aftercooler, the procedure may be different in places, but
the operation is basically the same.
13-001
0
Special tools
No. 1 Part No. 1 Part Name I Q’W

A 790-501-2000 Engine repair stand 1
Al 790-901-I 170 l Repair stand bracket 1
B 1 790-476-1140 1 Lifting tool I 1

C 1 795-601-I 110 1 Push tool I ’
1
795-100-I 191 Piston ring tool
G 1 795-102-1300 1 Liner puller I 1
l Preparatory work
1. Washing
l Before disassembling the engine, check all
parts for any cracks of damage, then clean the
whole engine carefully with steam so that the
disassembly work can be carried out swiftly.
‘1 6162F669
1) Before washing, remove starting motor as-

sembly (I), alternator assembly (2), and elec-
tric 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 en-
gine assembly on the stand and secure it in
position.
3. Engin oil
Drain engine oil.
.
A Engine oil: Approx. 41a
II -6162F671
13-002
0
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 en-
gine 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 disconnect fuel injection
tube (I).
13-004
0
11. Oil filter
Remove oil filter (I), then remove bracket.
12. Oil filler, oil level gauge

1) Remove oil filler (2).
2) Remove oil level gauge (3).
""'J 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
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 as-
sembly (11, remove mounting bolts.
2) Remove turbocharger and exhaust manifold.
.. .. _ __ - -. J
17. Aftercooler, intake manifold assembly

1) Sling aftercooler and intake manifold assem-
bly (I), remove mounting bolts.
2) Remove aftercooler and intake manifold as-
sem bly.
l Disassembly aftercooler and intake mani-

fold.
i) Remove joint (2) and connector (3).
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 in-
stalling, loosen the locknut and turn the ad-
justment screw (2) back 2 to 3 turns before re-
moving the rocker arm assembly.
13-008
0
l Disassemble rocker arm assembly.
i) Remove locknut (1). then remove adjust-
ment 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 injec-
tion nozzle holder assembly (2).
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 6162F701 11 6162F702
l Disassembly the cylinder head

i) Using spring pusher D, compress spring,
then remove valve cotter (3).
ii) Remove retainer (4).
iii) Remove outer spring (5). inner spring and
valve lower seat.
6162F703 6162F70
iv) Remove exhaust valves (6) and intake

valves (7).
6162F70E

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 forc-
ing 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 re-
move 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 remove injection
pump drive case (2).
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 bolt (I), then remove main
idler gear (2).
39. idler gear for water pump gear

Remove mounting bolt (31, then remove idler
gear (4) for water pump.
40. Idler gear for oil pump gear

Remove mounting bolt ES), then remove idler
gear (6) for oil pump.
41. Flywheel
Using the sling bolts (thread dia. = 12 mm, pitch
= 1.751, lift out flywheel (I).
Flywheel: See Weight Table
*If an impact wrench is used to loosen the

bolts, there is danger of damage to the thread,
so loosen the bolts with a hand tool.
% F6164026
42. PTO drive gear

1) Remove steering pump drive gear (I).
2) Remove the six set bolts, and remove PTO
drive gear (2).
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) Remove drive gear (5) and bearing (6).

iii) Remove bearing (7) from shaft (8).
5’ 6162F721 t1 6162F722
43. Rear seal cover

Remove rear seal cover (I).
44. Oil pan I

1) iurn over repair stand to set oil pan at top.
2) Remove oil pan (I).
45. Oil strainer
Remove bracket, then remove oil strainer (I).
46. Oil pump assembly

1) Remove tube (2).
2) Remove oil pump assembly (3).
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

Remove piston cooling nozzle (I).
*To avoid hitting the piston, rotate 90” to re-
move.
6162F729
50. Piston and connecting rod assembly
I) Using dial gauge 0, measure connecting rod
side clearance to act as a guide when assem-
bling.
l Check the stamped number on the connect-
ing 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.
%
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 re-
move piston and connecting rod assembly.
* Be careful not to damage the inside surface
of the liner with the corner of the connect-
ing 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 tem-
porarily 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 disas-
semble 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 cylin-
der.
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 po-
sition.
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 indi-
cator @ 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, remove

the gasket carbon with a wire brush.
*After washing, dry the washing fluid off com-

pletely with compressed air.
(Be particularly careful that there is no wash-
ing fluid remaining in the bolt holes.)
6162F743
WASHING CYLINDER BLOCK
1) Before washing the cylinder block, remove the

plugs from the oil line and cooling systems.
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.
s 3) Clean with a stiff wire brush to prevent any metal

Z particles from remaining in the oil line.
Z
4) Use sandpaper to polish the O-ring contact sur-
face smooth at the bottom of the liner bore and 6162F744
to remove the burrs and flashes from the liner

bore.
5) Dry off the cleaning fluid completely with com-

pressed air.
l Be particularity careful not to leave any clean-
ing 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)
WASHING CRANKSHAFT
l If the engine is disassembled, wash the crank-

shaft 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 thor-
oughly with compressed air.
3) Use a small magnet to completely remove all
the metal particles from the oil holes.
Y 6162F74f
6162F747
’3-k20
MEASURING PARTS
Before reassembling disassembled parts, check

visually that there are no cracks, damage, or ab-
normal wear.
If no abnormalities are found during the visual

inspection, use an accurate measuring device to
measure the specified position precisely.
Action and judgement on whether the parts can

be reused shall be in accordance with the main-
tenance 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 crank-
shaft supported on V blocks. This method pro-
duces an error because of the eccentric wear
of the journal.
MEASURING OUTSIDE DIAMETER OF JOURNAL

1) Using a micrometer, measure the outside diame-
ter of the main journal and pin journal in the X
and Y directions.
Pin journal (measure at 5 places)

0
'
12345
l l l l l
1 Main journal (measure at 3 olaces) F6164143
6D170-1SERIES
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 di-
rections (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 per-
pendicularly in contact with the journal at the cen-
ter, 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 diame-
ter of the journal.
6162F754
MEASURING HEIGHT OF CAM

1) Using a micrometer, measure cam height H for
the intake and exhaust.
6162F755
13-023
0
MEASURING PISTON RING GROOVE
Special tool
No. Part No. Part Name Q' W

A 795-901-I 120 Wear aauae 1
l 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.
6162F756
l If the shoulder of the wear gauge contacts
the piston, replace the piston.
*Carry out the measurement at several
places.
Wear gauge Wear gauge
l Measuring straight ring groove

1) Assemble a new ring in the oil ring groove,
and measure the clearance at the top and bot-
tom with a feeler gauge.
* If the clearance is greater than the permis-
sible 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 F6164154
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 con-
necting rod as follows.
Connecting rod dimension B

ID of big end + ID of small end
= +A
2 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 bear-
ing.
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) be-
F6164156
fore installing.
31 Stand the connecting rod perpendicularly, and
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 con-
tact 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.
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. 1
Curvature, twising A
Measurement Measurement F61 641 56
Dimension B x Actual measured nf CIIrvlltllrl-? nf iwistino
= Dimension A value
13-026
ASSEMBLY
TIGHTENING BOLTS BY PLASTIC RANGE

TURNING ANGLE METHOD
The important bolts on the 170 Series engine use
the plastic range turning angle method for tight-
ening.
This method uses special bolts, and by tighten-
ing 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 af-
ter 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. Part No. Part Name Q’ty

A 790-501-2000 Engine repair stand 1
A 790-901-I 170 l Repair stand bracket 1
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 191 Piston ring tool 1
I 795-250-1210 Liner driver 1
J 795-225-1700 Piston holder 1
K 790-331-I 110 Wrench 1
l 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 as-
sembling.
l Before inserting the cylinder liner, take the fol-

lowing action with the cylinder block.
1) Remove the rust and scale from surfaces @

and @ with sandpaper until the machining Counterbore Portion 0
surface appears.
2) Polish portions @ and @ with #240 sandpa-
per so that the R surface is smooth.
3) Polish portions @, @ and @with #240 snad-
paper so that they become smooth. Detail Q
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 O-
Detail P
ring. 6162F306
4) If surface @ is pitted and rough, and cannot
be corrected, replace the cylinder block.
5) If surface @ and portions @ and @ are pitted
and rough, finish them smoothly.
6) Inspect the counterbore, and remove any
burrs or flashes. If there are any metal par-
ticles 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 protru-
sion of liner.
* If there is any drooping, corrosion, or pitting
left in the counterbore, carry out additional
machining.
13-028
0
1. Cylinder liner
* Replace the liner O-ring and clevis seal with new
parts immediately before assembling the liner.
l 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. ne propylene rubber)
3) Assemble the liner O-ring and clevis seal to ene propylene rubber)
the liner as shown in the diagram on the right.
4) After installing the liner O-ring, check for

twisting. If any twisting is found, use a
smooth bar (approx. $10) to remove the twist-
ing.
6136F303
* To prevent the clevis seal from twisting when

it is installed, press it around the whole cir-
cumference so that it fits into the seal groove.
Push into groove
*Assemble the clevis seal with the chamfered
side facing down.
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

(coat the comer of the deck) 62 I OF304
* Make an overlap of 6 I!Z 6 mm at the begin- 1

ning and end when coating with gasket
sealant LG-6.
I , Overlap: 61?16mmm
I 62 I OF305
. When machining the bottom contact sur-

face 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 6162F760
13-030
0
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 with

a used head gasket.
m Mounting bolt: 26 & 1 kgm
ii) Remove the cylinder head, and wipe off Order for tightening
cylinder head
the gasket sealant that has been squeezed mounting bolts
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.
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 O-
ring when measuring.
* Protrusion of cylinder liner:
0.07 - 0.15 mm
* If it is not within the standard value, take the
action given in the maintenance standard.
QJ 6162F765 1
2. Crankshaft
1) Align protrusion of upper main bearing (1)
with notch of cylinder block, then assemble in
cylinder block.
* Check that there is no dirt at the rear face of
the bearing before tightening. Coat the in-
side 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.
i) Abnormality in the front, rear side
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 mount-

ing position, taking care not to hit the cylinder
block.
4) Move crankshaft to one side, then coat upper
thrust bearing (3) with engine oil (SAE #30),
and install to No. 6 bearing so that side with
oil groove is facing crankshaft end.
5) Align protrusion of lower bearing (4) with

notch of main cap and install.
* Check that there is no dirt at the rear face of
the bearing before tightening. Coat the in-
side surface of the bearing with engine oil
(SAE #30).
* Do not coat the rear surface of the bearing
with oil.
* Lower bearing: No oil hole
6162F769 6162F770
6) For No. 6 main cap, knock in dowel pin so that r

protrusion from end face of cap is 3.0 - 3.5
mm, then install lower thrust bearing (5) on
both sides.
* Install the thrust bearing with the side with
the groove on the crankshaft side.
I 6162F771 I
7) Coat journal surface of crankshaft with engine

oil (SAE #30), check that stamped number on
main cap (6) matches number on cylinder
block, then install main cap.
8) Coat mounting bolt thread and washer of
main cap with engine oil (SAE #30), then
screw in bolts, and insert main cap com-
pletely.
F6164030
13-033
0
9) Tighten main cap mounting bolts as follows.
*When tightening, start from the center and
work in order to the outside. Tighten the
bolts to the specified tightening torque us-
ing 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) Measure end play of crankshaft with dial

gauge 0.
l End play: 0.140 - 0.32 mm
j, If it is within the standard value, take the
action given in the maintenance standard.
3. Piston, connecting rod assembly

l Assemble piston and connecting rod.
i) Fit oil ring expander (I) in oil ring groove.
ii) Using piston ring tool H, assemble oil
ring, second ring, and top ring in order.
*Set each ring with the stamped mark facing

up and install to the piston.
* Place the end of the expander coil at 180” to
the end gap of the oil ring.
6162F773 6162F774
’3-:34
*Assemble each piston ring as shown in the
diagram.
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 min-
utes 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 pis-
ton completely after setting it in position.
6162F775 6162F776
v) Coat piston boss with engine oil (SAE

#30), set front embossed casting letters on
piston facing in same direction as part
number casting letters on connecting rod,
then insert piston pin (4).
vi) Install snap ring (5) on opposite side.
* Rotate the left and right snap rings to
check that the snap rings are com-
pletely fitted into the ring groove.
vii) Align protrusion of connecting rod upper

bearing (6) with notch of connecting rod,
then install.
* Check that there is no dirt at the rear
face of the bearing before assembling.
* Do not coat the rear surface of the bear-
ing 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
I 6162F779
whole circumference by hand.
2) Rotate crankshaft and set pin journal at top

dead center for cylinder where piston is to
be inserted.
3) Set embossed letters on connecting rod

facing front of engine (stamped number is
on camshaft side), then insert piston and
Embossed letters
connecting rod assembly into cylinder from / (to face engine front)
head end.
Cylinder No. (to match cam) Y
6162F309
4) Align all piston rings as shown in diagram.
*o*.
‘000
6162F780
’3-:36
5) Coat piston ring uniformly with engine oil
(SAE #30).
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 jour-
Approx. 500 mm
nal.
* Check that the connecting rod bearing is cor-
rectly in position.
* To make a connecting rod pulling tool, weld a
bar to an old connecting rod bolt.
Connecting rod bolt Bar
8) Coat crankshaft pin journal with engine oil
(SAE #30).
F6164038
2 I
z
z
9) Rotate crankshaft 180” while pulling connect-
ing rod.
10) Coat connecting rod lower bearing with en-
gine 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 rod
bolt with engine oil (SAE #30).
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
thread, so loosen the bolts with a hand
tool.
F6164030
F6164026
13) Rotate crankshaft 180” and repeat Steps I) to

12) to insert pistons in all cylinders.
14) Tighten the connecting rod bolts as follows.
i) 1st step: Tighten 20 & 1 kgm I 6162F763 1
ii) 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 After tightening, make
marks, do not reuse it. Replace the bolt with a punch mark on bolt head
to indicate number of
new bolt. times of tightening
*After assembling the connecting rod, check
that the crankshaft rotates smoothly.
# 6206F303
15) Using dial gauge@, measure side clearance
of connecting rod.
*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.

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 clog-
ging inside the nozzle.
* Face the tip of the nozzle to the side with the
mounting hole at the side, insert into the pis-
ton, 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 care-
ful 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 bolt:
(Thread size) x (Pitch) Tightening method
30 - 35 kgm
M16 x 1.5 (Tighten by torque)
I
5 2 0.5 kgm
Ml8 x 2.5
90+i”” Tighten an additional
31 f 4 kgm
Ml8 x 1.5 go + ionTighten an additional
* After tightening, make one punch mark on the

bolt head to indicate the number of times that
the bolt has been used. If any bolt has four
punch marks, do not reuse it. Replace it with a
new bolt.
*Align carefully with the match marks on the
gear when installing.
8. Camshaft
Coat surface of camshaft journal with engine oil
(SAE #30) and install camshaft (2).
w Camshaft plate: 3.1 - 4.3 kgm
*When inserting the cam shaft, rotate it while

inserting it in order to prevent damage to the
cam bushing.
qJ‘;” 6162F786
9. Idler gear for oil pump
Install idler gear (2) for oil pump.
m Idler gear mounting bolt:
(Thread size) x (Pitch) ( Tightening method
Ml6 x 1.5 30 - 35 kgm

(Tighten by torque)
5 + 0.5 kgm
Ml8 x 2.5
90+i’“Tighten an additional
6162F787
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 direc-
tion.
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.

10. Idler gear for water pump

Install idler gear (I) for water pump.
w Idler gear mounting bolt for water pump:

Same as in Item 9 above
11 Injection pump drive case

1) Fit O-ring and install injection pump drive
case (2).
2) Install coupling (1).
12. Timer
Install timer (2) aligning it with the gear, then
tighten nut (I).
m 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 End play

A 0.140 - 0.460 1 0.075 - 0.21
B 0.130 - 0.470 2 0.10 - 0.32
C 0.130 - 0.470 3 % 0.145 - 0.395
D 0.100 - 0.500 4 0.10 - 0.32
a 5
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.
z I ‘2
6162~725
z
z
16. Oil pan
* Before installing the oil pan, cut off the gas-
kets 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: Liquid gasket (LG-7)
* Diameter of gasket sealant: $1.6 - 2.0 mm 6162F724
17. Rear seal cover

Fit O-ring and install rear seal cover (1).
* Take care that the lip is not rolled up.
18. PTO drive gear
* Assemble PTO drive gear as.follows:
i) Install bearing (7) to shaft (8).
ii) Install the snap ring to gear (5), then in-
stall 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 6162F720
1) Install PTo drive gear (21, and then tighten six

bolts.
*After installing PTO drive gear, confirm that
there is backlash between it and the PTO
gear.
* Backlash: 0.15 to 0.52 mm
2) Install steering pump drive gear (I).

lg. Flywheel
1) Using eyebolts (Thread dia. = 12 mm, Pitch =
1.75 mm), raise flywheel (I), mesh train gear
and idler gear, then install flywheel and
tighten bolts.
* For engines with a PTO:
When measuring the engine capacity, the
inside of the PTO case cannot be lubricated,
so remove the PTO drive gear and install
the flywheel.
’3-:44
2) Coat bolt thread and washer with engine oil I
(SAE #30) or anti-friction compound (LM-P).

3) Tighten bolts in turn until flywheel is in tight
contact.

F6164030
% F6164026
4) Secure flywheel and housing with stopper @),

and tighten bolts.
* Order of tightening
3 6
2 6162F792
z 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 ex-

cept HD465):
1st step: 8 - 12 kg
2nd step: 28 - 32 kgm
3rd step: 53 - 57 kgm
5) Measure radial runout and face runout of fly-

wheel.
* Radial runout and face runout of flywheel
13-045
0
20. Cam follower
I) Install cam follower assembly (2), aligning it
with the pin.
D Cam follower 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: Liquid gasket (LG-7)
* Diameter of gasket sealant: $1.6 - 2.0

mm
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 alter-
nator.
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 circumfer-
ence thinly with engine oil (SAE #30). 6162F794
* Take care that the lip is not rolled up.
24. Cover
Install cover (2).
& Face of cover: Liquid gasket (LG-7)
* Diameter of gasket sealant: $1.6 - 2.0 mm
13-046
0
25. Front support
Raise front support (I) and install to trunnion
portion.
& Front support grease groove:

Grease (G2-LI)
26. Vibration damper

1) Sling vibration damper (4), align with dowel
pin, and install.
2) Install spacer (3).

1) Install crankshaft pulley (2) and tighten with
mounting bolts.
a 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 1
Unit: kgm
Order HD465 only Except HD465
1st step 40 + 3 7.5 I!I 2
2nd step I 78 f 3 I 25 f 2
* If an. impact wrench is used to loosen the

F6164026
F6164030
13-047
0
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 as-
sembled with the narrow pitch at the
head end.
iii) Install retainer (4).
iv) Using spring compressor D, compress
spring, and fit valve cotter (3) in groove of
valve stem.
6162F703 6162F704
VI Tap valve stem with plastic hammer and

check that valve cotter is completely fit-
ted.
vi) When nozzle valve has been replaced, in-
stall nozzle holder to cylinder head, then
use depth gauge to measure protrusion of
nozzle.
* Protrusion of nozzle: 4.9 - 5.7 mm
13-048
0
1) Check that there is no dirt or dust on cylinder
head mounting surface or inside cylinder,
then install gasket (9).
*When installing the gasket, check that
grommet (IO) has been properly installed
and has not peeled off.
Note: There is danger that the head gasket
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 anti-

friction 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 lightly, and

screw in adjustment screw.
iii) After adjustment screw contacts valve stem,

intake end
screw in a further 20”.
iv) Tighten locknut to hold in position.
w Locknut: 4.0 f 0.6 kgm
* Install the crosshead so that the adjust-

ment nut is at the exhaust end.
Exhaust end
Adjustment nut F6164068
30. Rocker housing

1) Fit gasket, align tab of grommet with groove
in gasket, then install.
*The grommet has a top and bottom, so be Tab
sure to install it facing the right way up.
&,
0
0
F6164069
2) Fit O-ring, then insert water manifold (3) in

rocker housing.
& O-ring: 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 the

two bolts to a maximum of 0.5 kgm.
Push rod
Install push rod (I).
* Check that the push rod is fitted properly into

the socket of the cam follower.
33. Rocker arm assemblv
Assemble rocker arm.
i) Using push tool, align oil hole of bushing (4)
and knock in rocker arm (3).
ii) Assemble adjustment screw (2) and locknut

(I) to rocker arm.
L.d
I 6162F695 6162F696
iii) Coat rocker shaft with engine oil (SAE #30),

then set so that portion with plug is at ex-
haust 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
6162F804
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, Ad-
justing valve clearance.
13-052
0
Head cover, spill tube
I) Fit gasket, install head cover (41, then tighten
bolts temporarily.
2) Install nozzle seal and press fit with push tool.
& Nozzle seal surface:

Engine oil (SAE #30)
6162F692
a
3) Tighten head cover mounting bolts in order
shown in diagram.
5
w Mounting bolt: /
3.25 & 0.25 kgm
4) Install connection (3).

1
0 2
5) Install turbocharger lubrication tube (2).
6) Install spill tube (I).

3 4
F6166057
36. Fuel injection pump assembly

Key 3 4
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 cou-
pling.
4) Align lines on coupling and bearing cover of
injection pump, then tighten bolt (4).
* If the mounting bolts are not tightened uni- i
6162F805
formly, the pump will be at an angle and
will rotate against the drive shaft, and this
will result in a change in the injection tim-
ing.
* If there are no lines marked, or if the injec-
tion pump has been replaced, adjust the in-
jection timing. For details, see TESTING
AND ADJUSTING.
l 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 injec-
tion pump has been replaced, adjust the in-
jection timing. For details, see TESTING
AND ADJUSTING.
1) Fit gasket, then install lubrication tube be-
tween injection pump and cylinder block.
6162F806
37. Aftercooler, intake manifold assembly

l Assemble aftercooler and intake manifold as-
sembly.
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 and intake

manifold assembly (1).
w Mounting bolt: 6.5 IfI 1.0 kgm
13-054
0
38. Turbocharger, exhaust manifold assembly
Fit gasket, then install turbocharger and exhaust
manifold assembly (1).
& Mounting bolt thread:

Anti-friction compound (LM-P)
w Mounting bolt: 11.25 I!I 1.25 kgm
w D375A, PCIOOO, WA700, HD465-5

2 bolts (length: 50 mm): 8.5 & 0.5 kgm
* If the turbocharger has been replaced, the

tightening torque for the turbocharger mount-
ing bolts is as follows.
l D375A-I,2 : 6.0 - 7.5 kgm r

(Serial No. up to 12867)
: 4.5 - 5.5 kgm
(Serial No. 12868 and up)
l WA600-1 : 6.0 - 7.5 kgm

: 4.5 - 5.5 kgm
l WA700-1 : 6.0 - 7.5 kgm

6162F807 6162F686
: 4.5 - 5.5 kgm
l PCIOOO-1 : 6.0 - 7.5 kgm

: 4.5 - 5.5 kgm
l HD465-3, 5 : 10.0 - 12.5 kgm

KTR130 (Serial No. upi0 11682)
ocharger 1
Single turb. - : 8.0 - 9.0 kgm
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
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 as-
semble 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 as-
semble bearing (13) and spacer (121, and
install snap ring (11).
v) Install bearing (IO). 14-7
vi) Fit holder (8), and tighten lock plate (7)
with bolts.
vii) Fit cover (61, then secure with snap ring
(5).
23---d&& /
:682
1) Insert spacer, then isntall tension pulley as-
sembly (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 accord-
ing 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 se-
cure 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 turbo-

charger, center the piping so that the turbo-
charger is not twisted, then tighten.
2) Fit gasket and install tube (I) for boost com-

pensator.
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 between the connector

and the bracket.
49. Air cleaner assembly

Fit gasket and install air cleaner assembly (I) and
secure it with the band.
m Band: 1.0 & 0.1 kgm
50. Setting off engine from engine stand

1) Lift the engine assembly (I) and remove the
mounting bolts to separate the engine assem-
bly from engine repair stand A.
2) Remove the bracket for the engine repair
stand Al.
* Prepare an engine stand, then place the en-
gine 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 tighten
nut (3).
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 ap-
prox. 15 mm when pressing .its center with 6
kg of force. Then tighten the bolt securely.

1) Fit gasket and install starting motor (1).
I ‘1 6162F669
’3-:60
ENGINE
14 MAINTENANCE STAN

Turbocharger . . . . . . 14-002
ENGINE BODY
Cylider head . .. . _ . 14-004
Valves and valve guide ... . . 14-005
Crosshead and crosshead guide . . 14-006
Push rod and cam follower . . 14-007
Cylinder block. ... . .. . . . . 14-008
Cylinder liner . . .. .... .. . 14-010
Crankshaft .. .. . .._........ . 14-011
Camshaft .. 14-012
Timing gear . . .. .. . . . 14-013
Piston, piston ring and piston pin . . . . 14-013-2
Connecting rod . ... .. . . . 14-015
LUBRICATIOIN SYSTEM
Oilpump . . . . . . . . . . . . . . .._....... 14-016
Oil pump relief valve, piston cooling
valve and oil cooler by-pass valve 14-017
COOLING SYSTEM
Waterpump . . . . . . . . . . . .._._..... 14-018
ACCESSORY
Air compressor . ... . .. 14-020
170-1 SERIES 14-001

0
MAINTENANCE STANDARD TURBOCHARGER
TURBOCHARGER
KTR110
14-002 6D170-1 SERIES

(16)
MAINTENANCE STANDARD TURBOCHARGER
Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit Replace parts
End play
1 related to
(play in axial direction) 0.08 – 0.13 0.18 thrust
Replace parts
Radial play
2 0.25 – 0.44 0.60 related to
(play in radial direction) bearing
Tolerance Repair limit

Standard size
Outside diameter of journal bearing, Shaft Hole Shaft Hole
3
inside diameter of center housing
–0.050 +0.021
25 24.92 25.03
–0.067 0
Inside diameter of journal bearing, –0.032 +0.009

17 16.95 17.04
4 outside diameter of wheel shaft –0.043 –0.003
Curvature of wheel shaft Repair limit: 0.010 (total deflection of indicator)

Standard size
Width Groove Width Groove
5 Thickness of thrust bearing
–0.08 +0.02
5 4.86 5.04
–0.10 0 Replace
Standard size Tolerance Repair limit
Ring –0.08
Turbine 2.3 2.15
–0.10
end
–0.01
Groove 2.3 2.35
–002
Thickness
6 –0.08
of seal ring Ring 2 1.85
–0.10
Blower –0.03
1 Ring 2 2.05
end –0.04
Groove
–0.11
2 Ring 4 4.05
–0.12
Replace parts
Clearance between blower housing
7 Clearance limit: (Min.) 0.20 related to
and impeller
bearing
6D170-1 SERIES 14-002-1

(16)
MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM
KTR130
\ \* 1 I
\ \ \
1 8 5 2 3 4
6162F401 6162F402
Unit: mm
I I I
End play Permissible range Replace parts

1
(play in axial direction) related to thrust
0.08 - 0.18
Radial play Replace parts

2 0.25 - 0.60
(play in radial direction related to bearing
Permissible range
Outside diameter of journal
3 bearing, inside diameter of Shaft Hole
center housing
29.89 - 29.94 30.00 - 30.04
Inside diameter of journal

bearing, outside diameter of 19.95 - 19.97 20.00 - 20.05
wheel shaft
4
Curvature of wheel shaft Repair limit: 0.010 (total deflection of indicator) Replace
Permissible range
5 Thickness of thrust bearing Width Groove
5.86 - 5.92 6.00 - 6.04
6 Thickness of seal ring 2.85 - 2.92 2.96 - 3.05
I I I
Clearance between blower Replace parts

7 Clearance limit: (Min.) 0.20
housing and impeller related to bearing
I
Tightening torque of blower
8 8.5 f 0.5 kgm
impeller locknut
I I
Tightening torque of insert
9 mounting bolt 1.25 f 0.25 kgm Tighten
Tightening torque of V-band

10 locknut 0.95 f 0.05 kgm
170-1 SERIES
’ 4-:03
KTR150
F6166056
Unit: mm
-
NO. Check item Criteria Remedy
I
Permissible range Replace parts
End play
1 related to thrust
(play in axial direction)
0.08 - 0.18
-
Radial play Replace parts

2 0.25 - 0.60
(play in radial direction) related to bearing
Permissible range
Outside diameter of journal
3 bearing, inside diameter of Shaft Hole
center housing
29.89 - 29.94 30.00 - 30.04
-
Inside diameter of journal
bearing, outside diameter of 19.95 - 19.97 20.00 - 20.05
wheel shaft
4
Curvature of wheel shaft Repair limit: 0.010 (total deflection of indicator) Replace
-
Permissible range
5 Thickness of thrust bearing Width Groove
5.86 - 5.92 6.00 - 6.04

-
6 Thickness of seal ring 2.85 - 2.92 2.96 - 3.05
Clearance between blower Replace parts

7 Clearance limit: (Min.) 0.20
housing and impeller related to bearing
I I

8 impeller locknut
9.5 2 0.5 kgm
-
I I
Tightening torque of insert
9 3.75 i 0.25 kgm
mounting bolt
Tightening torque of turbine

10 5.75 f 0.25 kgm
housing
-
Tightening torque of V-band
0.9 f 0.1 kgm
locknut
-
14-003-l
0
TV77
615OF401-1
Unit: mm
2 - Standard size Repair limit

z 1 Radial play of rotor
G 0.076 - 0.152 0.18 Rapair or replace
2 End play of rotor 0.08 - 0.25 0.25

-
Target (kgm) Range (kgm)
3
housing bolt
1.25 1.15 - 1.38
Step Target Range
Tightening torque of back 1 St step 1.8 1.6 - 2.0 Tighten

4
plate mounting bolt
2nd step 0 Loosen completely
3rd step 1.4 1.27 - 1.50

-
Standard size Repair limit
5 Thickness of thrust bearing
2.315 2.29
- I
l Outside diameter
Measuring point
Point (A) 17.53 17.48

6 Bend of wheel shaft Point (9) 15.88. 15.88
l Bending: Repair limit 0.010 (total indicated runout) Replace

-
7 Inside diameter of back plate
17.475 17.49
-
Measuring point Standard size Repair limit
I wide diameter of center
8
housing Point(C) 24.97 24.97
Point (D) 20.90 20.93
14-003-2
0
MAINTENANCE STANDARD ENGINE BODY
CYLINDER HEAD
Tightening order of
head mounting bolt
6\ 5 4
Tightening order of head

cover mounting bolt
6 162F403A
F6170010578
Unit: mm
I
Tolerance Repair limit f3epair by

Distortion of cylinder head
1 -z frinding
mounting surface ‘>r replace
Max. 0.05 0.1
2 Protrusions of nozzles fqeplace noz-

Standard: 4.9 to 5.7
2:le sleeves
I
Order Target value Range

(kgm) (kgm)
/
Tightening torque of cylinder 1st 8.0 6.5 to 9.5
head mounting bolts
1Tighten in
3 (Coat bolt threads and 2nd 23.5 22.0 to 25.0 sequence as
washer with anti-friction Indicated
compound (LM-P)) aIbove.
3rd 39.0 37.5 to 40.5
I I
4th 50.5 49.0 to 52.0

-
I I
Target value (kgm) Range (kgm)
4
Tightening torque of nozzle
holder mounting bolt
2.75 2.5 to 3.0
I I
Retighten
Tightening torque of cylinder
5 3.25 3.0 to 3.5
head cover I I
Tightening torque of rocker arm

6 10 9.5 - 10.5
housing mounting bolt
14-004 170-1 SERIES

8
VALVES AND VALVE GUIDE
1
SWE01035
No.
Amount of valve sinking

8 I
z-
z
2 Valve head thickness
3 Valve seat angle
Outside diameter of intake valve

stem
6
CROSSHEAD AND CROSSHEAD GUIDE
6162F405 $
z
Unit: mm

Except
Depth of cross- H D465-5 +0.3
3.0
head stem 0
+0.3 -
HD4655 only 7.5 0
Replace
+0.10
Inside diameter of crosshead 15 15.21
+0.05
Outside diameter of +0.039

15 15.00
crosshead guide I +0.028 I I
I I I I
Standard clearance Clearance limit
Clearance between crosshead. Adjust
guide and crosshead
0.011 to 0.072 0.02
Protrusion of crosshead guide

-
54
-“0.3
I
Replace
Intake valve Exhaust valve
5 Valve clearance (at cold)
0.4 1 .o
Tightening torque of crosshead Except HD465-5 4.0 + 0.6 kgm

6 Tighten
lock nut HD465-5 only
(Serial No. 14203 and up) 6.0 Itr0.6 kgm
’4-:06
PUSH ROD AND CAM FOLLOWER
Unit: mm

Outside diameter of cam
1
follower shaft -0.040
25.0 24.9
-0.055
Inside diameter of cam -0.020

2 25.0 25.0
follower lever 0
I /
Inside diameter of cam +0.175

19.0 19.2
follower roller +0.150
3 Replace
Outside diameter of cam +0.075
19.0 19.0
follower roller pin +0.065
4
Outside diameter of cam
41 .o
+0.050 41.0
follower roller +0.025
I I
5 Diameter of push rod tip ball 15.85 kO.03
Inside diameter of push rod

6 12.7 to.20 -
socket
170-1 SERIES 14-007

0
CYLINDER BLOCK &

I
6162F407
Unit: mm
No.
I Check item
I
Criteria Remedy
Tolerance
Standard Clearance
Standard size Replace
clearance limit
Clearance between cylinder Inside dia- Outside dia- cylinder
1
block and liner mater of block meter of liner: liner or
block
190 0.050 to 0.160
I I
Inside diameter of main
bearing hole
(lighten bolt to specified 148 + 0.025 -
torque) - 0.001
2 Thickness of main bearing 4 - 0.038 Repair or

- 0.051 replace
Inside diameter of main +0.127

140 140.20
bearing + 0.076
I
14-008 170-1 SERIES

0
Unit: mm

I
Clearance between main
2
bearing and crankshaft journal
0.075 to 0.150 0.32
Standard interference Interference limit

Interference between main
3
bearing cap and cylinder block
0.080 to 0.160 0.05
Repair or
replace
Inside diameter of camshaft
bushing +0.070
72 72.10
0
4
Clearance between camshaft
and journal
0.080 to 0.180 0.24

Distortion of cylinder head
5
face
0.09 0.15
Order Target value (kgm) Range (kgm)
1st 56 51 to 61
Tightening torque of main 2nd 113 107 to 118

bearing cap bolt
6 3rd Loosen completely Tighten
~ bolt threads with
K$at engine 4th 38 33 to 43
5th 75 70 to 80
6th 113 107 to 118
170-1 SERIES 14-009

CYLINDER LINER
Detail P
F6166062
Jnit: mm
Replace cyl-
Permissible range: 0.07 to 0.15 2
Protrusion of cylinder liner inder liner
Difference among cylinders: 0.05 max.
or block z
I Standard size I Tolerance I Repair limit z
Inside diameter of cylinder

liner +0.04
170 170.24
0
2
I i
Roundness Repair limit: 0.020
Cylindricity Repair limit: 0.015
Outside diameter of cylinder Standard size Tolerance

liner
(Counter bore lower part) 194.59 194.565 - 194.615
3 .
Interference of cylinder liner
and block Standard interference: 0.025 to 0.135
Replace
(Counter bore lower part)
cylinder
Tolerance liner
Outside diameter of cylinder Standard size
liner
(Counter bore part) 205.99 205.965 - 206.015
4
Clearance between cylinder
Interference: 0.085 to
liner and block
Clearance: 0.025
(Counter bore part)
Outside diameter of cylinder Standard size Tolerance

liner
(O-ring part) 190.4 190.34 - 190.40
5
Clearance between cylinder
liner and block Standard clearance: 0.050 to 0.210
(O-ring part)

Unevenness of counter bore Repair by
6 grinding
depth - 0.03
14-010
0
CRANKSHAFT
7TI
- 2,i 5' 1,3 7' 6162F409

Unit: mm
NO. Check item Criteria Remedy
I Size Standard size Tolerance Repair limit I
I S.T.D. 140.00
I I
139.91
Outside diameter of main

1
journal
0.75us 139.25 139.16
1 .oous 139.00 138.91

Repair or
replace
S.T.D. 108.00 107.91
0.25US 107.75 107.66
2
Outside diameter of crank .
pin journal
3 ”
Journal roundness

End play
0.140 to 0.320 0.69
Standard size Tolerance Standard interference Replace

Main bearing thickness
(Center) -0.040
4 3.90
-0.050
Outside diameter of rear

flange
I
170
I xl.020
1
-

Bend of crankshaft
(by indicator)
0.09 0.20
Tightening torque of crank

See page 13644 Tighten
wllev mountina bolt I
170-1 SERIES 14-011

0
CAMSHAFT
6162F410
Unit: mm
Check item Criteria Remedy
+0.440
Intake side 62 61.37 Repair or
Cam height WO.240
replace
-0.310
Exhaust side 61 -0.510 59.64
Outside diameter of journal 72.00 -0.080 71.86

-0.110
Replace
Thrust plate thickness 10.00 -0.025 6.85

-0.060

Replace
4 Camshaft end play
thrust plate
0.075 to 0.240 0.40
5 Bend of camshaft Repair limit: 0.20 (by indicator) Replace
14-012 170-1 SERIES

TIMING GEAR
I-
’ :3 6162F411 Unit: mm
No Check item Criteria
Main idler gear (large) and idler gear
Gear backlash
Clearance between main idler

7
gear bushing and shaft
10
-
bearing
11 End play of idler gear 0.10 to 0.32
12 End play of oil pump idler gear 0.10 to 0.32
Difference of timing gear case Repair or

13 Tolerance: 0.15
and cvlinder block lower steo I replace
170-1 SERIES 14-013

cz
(HD46!5-5)
Unit: mm
I
No. Check item Criteria
-
Gear backlash
Water pump idler gear and water
Standard size
Clearance between main idler
7
gear bushing and shaft
9
ushing and shaft
-
10
-
Replace thrust
11
-
12 End play of oil pump idler gear
-
13 Iifference of timing gear case
Tolerance: 0.15 Repair or replace
md cylinder block lower step
’4-oi3-1
PISTON, PISTON RING AND PISTON PIN
ALUMINIUM PISTON TYPE
Omm
6162F412
Unit: mm
Outside diameter of piston I I I

1 -0.257
(3.0 mm from bottom and 170 169.62
at 2O’C) -0.287
Ring groove Ring thickness
2 Piston ring groove ~~
-0.500
Oil ring 4.80 io.010 0.3
-0.075 Replace
Standard clearance Clearance limit I
Piston ring gap
Inside diameter of piston

pin boss
5 Outside diameter of piston pin 68

0
-0.006 I
67.98
I
170-1 SERIES 14-013-2
8
FCD PISTON TYPE
6162F822
Unit: mm
No. Check item Criteria

Outside diameter of piston
1 (3.0 mm from bottom and -0.075
at 2O’C) 170 169.79
-0.105
Tolerance ClW$ce
Standard size
Ring groove Ring thickness
Top ring Keystone

2 Piston ring groove Check with piston groove
wear gauge 0.15
Replace
2nd ring Keystone
-0.500 -
Oil ring 4.80 ~.OlO -0.075 0.3
Top ring 0.50 - 0.65

3 Piston ring gap
2nd ring 0.45 - 0.60 1.8
I Oil ring
I
I
0.50 - 0.70 II
Standard size Tolerance
4
Insidediameter of piston
pin boss +0.044
68
+0.034
0
5 Outside diameter of piston pin 68
-0.006
14-Z4 170-1 SERIES

CONNECTING ROD
6162F413
Unit: mm
2 No. Check item Criteria Remedy

z
z Tolerance
Standard Standard Clearance Replace
size clearance limit (the bushing is
Clearance between connecting Shaft Hole supplied as a
1
rod bushing and piston pin semi-finished
0 +0.070
68 0.050 - 0.075 0.11 product)
-0.060 +0.050
Inside diameter of connecting Standard size Tolerance

2
rod big end +0.025
115
0
Clearance between inside Standard clearance Clearance limit
3 diameter of connecting rod big _
end and crankshaft journal 0.060 - 0.130 0.34
Size Standard size Tolerance Repair limit
S. T. D. 3.500 3.41
. 1 Connectina rod bearina
5
IBend or twist of connecting rod
I
Repair limit of bend: 0.10
Repair limit of twist: 0.25
6 Connecting rod weight 10.15 +0.03 kg
Order Target (kgm) Range (kgm)

Tightening torque of connecting
rod cap
7 1st 20 19-21 Tighten
(Coat bolt and nut threads
with engine oil)
2nd 90” 90” - 105O
14-015
0
MAINTENANCE STANDARD LUBRICATION SYSTEM
OIL PUMP
W
2 ‘5 z
6162F414 ’
Unit: mm
Clearance between drive shaft I I I I

1
and bushing
-0.025
32
-0.040
,/ ;:::;; 10.040 too.075 I -
Clearance between driven shaft -0.020 +0.030 Replace

30 0.030 to 0.070 -
and driven gear bushing -0.035 +0.010
Clearance between outside

diameter of gear and body
4 Main pump gear and body

66 -0.115
-0.095 +0.035 0.095 to 0.150 -
end play 0
Tightening torque of
5 6.9 f 1 .O kgm Tighten
mounting bolt
14-016
0
MAINTENANCE STANDARD LUBRICATION SYSTEM
OIL PUMP RELIEF VALVE, PISTON COOLING VALVE AND

OIL COOLER BY-PASS VALVE
6162F415 6162F416 6162F417
Unit: mm
I
Check item Criteria
Main relief valve spring
Regulator valve spring
Main relief valve operating Standard: 3.3 f 0.3 kg/cm’

5 pressure I
Regulator valve operating
6 Standard: 8.0 * 0.8 kg/cm’
pressure Repair or
replace
spring
Piston cooling valve operating
7 Standard: 1.3 Tt:f kg/cm2
pressure
Oil cooler by-pass valve

8 Standard: 4.5 ?:0.5 kg/cm*
operating pressure
170-1 SERIES
’4-:’’
MAINTENANCE STANDARD COOLING SYSTEM
WATER PUMP
6162F418
Jnit: mm
f
Tolerance Standard
Standard size . interference
Shaft Hole
Interference between front
1
shaft and bearing I
30 I +0.015 0
0 to 0.025
0 -0.010
Interference between rear shaft +0.010

2 25
-:.o,o 0 to 0.020
and bearing 0
I
Replace
‘.3
Interference between rear shaft
and impeller
19.9
I
I
+0.020
+0.005 I
-0.025
-0.05
I
0.030 to 0.070

Clearance between impeller
4
and connection -
0.23 to 0.66
14-018 170-1 SERIES

MAINTENANCE STANDARD ACCESSORY
AIR COMPRESSOR
48
6162F419
14-020 170-1 SERIES

MAINTENANCE STANDARD ACCESSORY
Unit: mm
Standardsie ~~ I_ Tolerance I Repair limit I

Replace
Inside diameter of cylinder
+0.08 crank case
92
+O.lO
Tolerance
Standard size Standard Clearance
clearance limit
Shaft Hole
Clearance between piston
Replace
and piston pin I
Clearance between crankshaft i-O.570 M.662 Replace

47 0.042 to 0.113 -
and bushing +0.550 +0.612 bushing
Tolerance Clearance
Standard size Standard
interference limit
Shaft Hole Repair or
Interference between crank replace
case and bushing crank case
+0.019 -0.086
51 0.08 to 0.13 -
-0.006 -0.129
Tolerance
Standard Clearance
Standard size
clearance limit
Shaft Hole
Clearance between crankshaft Replace
and connecting rod I
+0.162 +0.225
49 0.051 to 0.089 -
+0.135 +0.213
Clearance between crankshaft +0.570 +0.638 Replace

6 47 0.042 to 0.089 -
and support +0.550 +0.612
Tolerance
Standard size Standard
interference
Shaft Hole
interference between crankshaft Replace
7
and coupling gear I
+0.489 i6.425
25 0.051 to 0.089
a.476 +0.400
Standard (kgm) Limit (kgm)

Tightening torque of cylinder Tighten
8
head mounting bolt
3 2 to 3.5
170-1 SERIES 14-021

0
ENGINE
REPAIR AND REPLACEMENT
15 OF PARTS
Table of special tools .................................. 15-002

Cylinder head .............................................. 15-004
Testing and inspecting ............................... 15-005
Repairing mounting face of
cylinder head by grinding.. .................... 15-007
Replacing valve seat inserts ...................... 15-008
Replacing nozzle holder sleeve ................. 15-014
Replacing valve guide ................................ 15-018
Replacing cross head guide.. ..................... 15-019
Grinding the valve ...................................... 15-020
Cylinder block ............................................. 15-021
Testing and inspecting ............................... 15-022
Grinding the top surface of cylinder
block ......................................................... 15-024
Replacing main metal cap.. ........................ 15-030
Replacing cam bushing.. ............................ 15-032
Crankshaft. .................................................. 15-034
Repairing the crankshaft ............................ 15-041
Connecting rod ........................................... 15-046
Replacing crankshaft gear.. ........................ 15-048
Replacing camshaft gear ........................... 15-049
Replacing flywheel ring gear.. ................... IO-050
15-001
0
REPAIR AND REPLACEMENT OF PARTS TABLE OF SPECIAL TOOLS
TABLE OF SPECIAL TOOLS
Operation I ;ymbol Part No. Part Name Q’tv Remarks
1 795-l 00-4800 Puller 1 For valve seat
2 795-l 00-3004 Push tool seat cutter 1
795-600-2510 Push tool 1 For intake valve

3
Replacing valve seat A 1- 1 795-600-2520 1 Push tool ( 1 I For exhaust valve
4 795-600-2531 Calking tool 1 For intake valve
795-600-2541 Calking tool 1 For exhaust valve
5 795-600-2570 Peening guide 1
1 795-600-2110 Push bar 1
2 795-600-I 191 Push bar 1
IB 3 795-600-2120 Driver 1
4 795-600-I 130 Punch 1
Replacing nozzle 5 795-600-2130 Holder 1

holder sleeve Punch bushing 1
1 795-600-I 140
2 795-600-2140 Rollina tool 1

Ic 3 795-600-2150 Expander 1
4 795-600-2160 Cutter 1
5 795-600-2170 Guide bushina 1
Pressure test of E 1 790-553-1700 I Coolant tester I II

cylinder head F 79A-471-1050 Pump assembly 1
Replacing valve 1 795-600-2550 Valve guide remover 1

G
guide 12 1 795-600-2560 1 Valve auide driver I 1 I
Replacing crossheac CZzl,head guide

H 795-140-6410
guide
Grinding valve I Commercially available Valve refacer 1
1 795-250-1301 Push tool set 1

Replacing cam
J
bushing 2 792-l 03-0400 GriD 1
Replacing crankshaf 1 790-101-2800 Bearing puller 1

K
gear
.- I2I 790-101-2300 I Push puller
15002
0
REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD
CYLINDER HEAD
F6164091
1. Valve guide
2. Closshead guide
3. Fuel injection nozzle sleeve
4. O-ring
5. Cylinder head
6. O-ring
7. Pushrod tube
8. Valve seat insert
15004
0
REPAIR AND REPLACEMENT OF PARTS TESTING AND INSPECTING
TESTING AND INSPECTING
(1) Cylinder head

Unit: mm
Inspection item Judgement standards Remedy
A. Cracks, leakage l Check for cracks (external color check)

from cylinder Repair by
l Check for air leakage with air pressure test
head welding or
(3.0 - 3.5 kg/cm*, 30 sec.)
replace
l Water pressure test (3.5 - 4.0 kg/cm*, 10 min.)
B. Distortion of top, Repair limit

Tolerance I Grind to
bottom surface o
cylinder head correct
Max. 0.05 0.1
I
C. Damage to injec- Machine to
tion nozzle sleeve repair or
seat surface, replace
contact width sleeve
D. Protrusion of
injection nozzle
Replace
Permissible range: 4.9 - 5.7 sleeve
F6164092
io
E. Damage to valve l Pitting of seat surface Correct seat
seat surface or l Check contact between valve and seat surface surface or
loosening of seat replace valve
l Airtighteness test
seat
l Tap cylinder head and check for looseness
F. Sinking of valve
(both intake and
exhaust)
Standard value Repair limit Replace valve
or valve seat
0.9 - 1.5 2.1
F6164093
G. Thickness of
valve head
_1
/
l Angle of seat surface Replace
Intake valve: 30°

\ Exhaust valve: 45O
-D ; -
Thickness of valye head
F6164094
15005
63
Unit : mm
H. Abnormality in l Check if head has become flat, check for cracks or piting of seat
valve surface
l Airtightness test
Replace
l Check for play in cotter pin when new cotter pin is inserted in cotter
j groove.
l Check for eccentric wear or curvature of stem.
l Check for hollow in stem end. Correct
I. Outside diameter l Outside diameter

of intake valve
stem Standard size Standard value Repair limit
I2 11.94 - I I .92 11.90
Replace
Outside diameter l Outside diameter
of exhaust valve
stem Standard size Standard value Repair limit
12 11.908-11.893 I I .80
J. Inside diameter
of valve guide Standard size Standard value Repair limit
(after head press
fit) 12 1 I.981 - 11.999 12.10
K. Protrution of
valve guide
(after head press
fit)
Permissible range : 23.4 - 23.9 Replace
F6164095
L. Outside diameter
of crosshead Standard size Standard value Repair limit
guide
I5 15.028 - 15.039 15.00
M. Protrution of
Crosshead
crosshead guide guide
E
Q
‘B
2
6
t
Permissible range : 53.7 - 54.0
F6164096
15006
0
REPAIRING MOUNTING FACE OF
REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD BY GRINDING
REPAIRING MOUNTING FACE OF CYLINDER HEAD

BY GRINDING
1. Grinding
1) Remove the valve seat inserts. For details, see
REPLACING VAVLE SEAT INSERTS.
2) Remove the nozzle holder sleeves. For details,
see REPLACING NOZZLE HOLDER SLEEVES.
3) Grind the cylinder head to remove the strained
or corroded portions within the limit of the
height of the cylinder head (H).
If any grinding is carried out, stamp the side
face of the cylinder head with an (R) mark. F6164097
* Repair limit of cyinder head height (H):
139.55 mm (Standard size: 139.85 -
140.15)
+ Amount to remove per grinding:
0.10 to 0.15 mm
* Surface roughness of grinding surface:
within 6s
* Flatness (deformation): 0.05 mm max.
-rt Grinding limit: 0.3 mm
* Difference in head height per unit:
0.15 max.
4) Press-fit the one-size-larger inserts. For
2
details, see REPLACING VAVLE SEAT
Z
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 the standard values
+ Standard sinking of valves: 0.9 to 1.5 mm
+ Allowable protrusion of nozzle:
4.9 to 5.7 mm
15007
0
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE SEAT INSERTS
REPLACING VALVE SEAT INSERTS

* When repairing without replacing the valve
seat insert (when there is surface roughness
A Confirm that the grindstone is not
damaged, then install it to the shaft
or stepped wear), correct with the amount of of the grinder without applying ex-
sinking of the valve within the repair limit of cessive force.
2.1 mm Confirm that there is no play be-
tween the grindstone and shaft.
. Intake valve
““it:
mm A When using the grinder, wear safety
goggles.
i) Install grindstone @to grinder 0.

ii) Install the sleeve and grinder after
aligning the groove of sleeve @ with
head
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 cyl- 6162F504
inder head with a hammer to check for any
looseness of the valve insert. If the valve in-
sert is loose or springs back, replace the in-
sert.
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 pro-
cedure.
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.
l After replacing the grindstone, run
the grinder for three minutes to
test it.
15008
63
REPAIR AND REPLACEMENT OF PARTS
REPLACING VALVE SEAT INSERTS
iii) Adjust the position of the grinder so that

the center of grindstone @ will be at the
center of seat insert (l), then tighten the
set screw to secure the grinder.
iv) Fully open the throttle of the grinder to
rotate the grindstone 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
make a groove about 1 mm deep. w
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 too strongly,
the insert will break and it will be dif-
ficult to pull it out. Therefore, stop
tightening the screw when the claws
compretely contact the groove.
iii) Place bridge @ over the puller head, then
place plates @ and 0 on the bridge.
Tighten nut @ to pull out the insert. 6162F506A
Al
F6164098A
15-009
0
2. Machining valve seat insert mounting hole to

oversize
1) Using valve seat cutter A2, machine the
mounting hole to install a one-size-larger
insert.
l Dimensions of insert and mounting hole
hr \
dr
Bottom\surface of cylinder head
6162F502-1 /i
l Intake valve side
Unit: mm
I I
Stamp Insert Mounting hole for insert
on
insert O.D.(d,) Hight(h,) I.D. (d2) F6164099A
Depth (h,)
S.T.D. 63.00+“’ O”
+o.080 8.5-z., 63.002:;;; 12.5 zt 0.1
2) If the talked portion of the mounting hole, is
0.25 OS 63.25;;:;;; 8.5:,, 63.25 :;:$j 12.5 f 0.1 damaged remove it within the range of 1.00
I I mm oversize. If the damage portion cannot be
removed within the range of 1 .OOmm oversize,
replace the cylinder head.
3. Press fitting the insert 8

z
1) Using insert push toolA3,press-fit the insert
z
(1 ).
l Exhaust valve side

Unit: mm
A3
Stamp Insert Mounting hole for insert
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
2) Check the sinking distance of the insert from

1 .OO OS 62.00;;:;: 8.8& 62.00 “;:;:; 12.88 f 0.1
the mounting, surface of the cylinder head.
* Standard sinking distance of insert:
Inside surface roughness: 12.5s max. 3.9 to 4.2 mm
Mountting hole bottom roughness:
12.5s max. E
Concentricity of inside diameter of 4
>&
valve guide and inside diameter of I
o!
m
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. F6164159
15-010
0
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 in-
take valve.
* Differences between exhaust valve inserts 1

New Old
I OO- 500mm
6162-13-1321 6162-13-1320
Part No.
(2 per valve) (2 per valve)
Part No. and size No stamp (Note:

Difference stamped on out- The oversize in-
side circumference sert is stamped.)
Need for calk-

ing after press No Yes head
fitting
Calking is not needed for any insert not listed

above.
1) Set with the bottom surface of the cylinder

head facing up, and place on wooden blocks.
* Leave enough space so that the valve
8 guide does not contact the ground.
z 2) Insert calking tools A4 and A5 into the valve
z guide.
6162F816A
3) 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.
F6164160A
15011
0
5. Finishing the seat surface

1) Finish the seat surface with valve seat cutter
A2 as shown in the figure.
+ Angie of seat surface: intake side: 30°
Exhaust side: 45O
* Width of seat fininshing surface:
Intake side: 3.69 mm
Exhaust side: 3.79 mm
+ Connectricity of valve guide and insert:
0.07 mm (T.I R) max.
Unit: mm
2) Fit the seat surface using the compound.
459+0.05 $57.4 * 0.05
Coat the seat surface of the valve thinly with
a rough compound mixed with oil insert it in
the valve guide that forms a pair with that
valve, then fit a rubbing bar to the valve head, 3o”
and turn it with both hands to rub lightly
against the valve seat.
When the rubbing removes the roughness, Intake side Exhaust side
wipe off the compound. Then coat with a fine

compound and repeat the above process to
give a good contact surface with no break in 6162F507A
contact.
6. Final check 8
* Standard sinking distance of valve (new): Unit: mm z

Lo
0.9 to 1.5 mm z
-Sr Standarad width of contact surface against Bottom surface Bottom surface
of cylinder head of cylmder head
valve: Intake side: 2.5 * 0.2 mm
Exhaust side: 2.8 ?c 0.2
l Coat the seat surface of the new valve thinly

with red lead (minium), insert it in the valve
guide, push lightely against the valve insert
surface, and rotate 1 O”. Check the valve insert Intake side Exhaust side
contact surface, and confirm that the contact
is uniform without any breaks. F6164100
l or
Make marks with a pencil on the seal surface
of the new valve as shown in the diagram,
insert it in the valve guide, push lightly against
the valve insert surface, and rotate 1 O”. Check Pencil marks
that the pencil marks have been erased ,(about 20 places)
uniformly around the whole circumference.
F6164101
15-012
0
Air pressure testing method

l 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 plas-
tic hammer 2 or 3 times directly from above
to bring it into tight contact with the seat sur-
face.
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 con-
tact 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 sec-
onds. If it drops more than 10 mmHg in 3
seconds, check for any dirt on the seat sur-
face, or rub the surface to correct it.
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.
F6164102
+ 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 por-
tion 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 in-
sert sleeve driver B3 and lightly tap it until
the sleeve contacts the seat surface.
8
* Before installing the sleeve, clean the F6164103A
z
sleeve and seat. z
e
* Apply adhesive to the seat around the
sleeve. -----______ -
& Seat: LT-2
%
a
F6164104
F6164105A
15-014
0
4. Calking the sleeve seat face

1) Fitthe sleeve seat with sleeve holder B5.
w Tightening torque for sleeve holder: B4
2 kgm. /
2) Install punch bushing Cl and insert sleeve
driver B4.
3) Place support @ under the cylinder head to
allow the bolt of the sleeve holder to move
out.
4) Hit the sleeve driver with a hammer to talk
the seat surface.
* Lightly hit with a hammer several times.
5) Remove the sleeve holder and punch bush-
ing.
6162F511A
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 col-
lar @ so that the shaft of the rolling tool will
protrude a little from the bottom hole.
* Install the rolling tool to a radial drilling ma-
chine or upright drilling machine to roll-fitwith
its own weight.
+ Rotating speed: 200 to 300 rpm
6. Roll-fitting the taper section of sleeve

. Using sleeve expander C3, roll-fit the taper sec-
tion of the sleeve. 6162F512A
Set the roll-fitting amount with stopper @ of

the expander.
Install the expander to a radial drilling ma-
chine or upright drilling machine to roll-fitwith
its own weight.
Rotating speed: 200 to 300 rpm
6162F513A
15015
0
7. Spot-facing the inside seat of the sleeve

I) Using guide bushing C5 as the guide, spot-
face 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, 6162F514A
install a used nozzle holder.
15016
0
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 leak-
age from around the head.
sr It is preferable to warm the whole cylinder

head and carry out the test with hot water (82
- 93°C).
2. Air pressure test

F6164106A
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 pres-
sure (3.0 - 3.5 kg/cm? for approx. 30 seconds,
and check for any air leakage in the water.
2
Z sr If the above test shows that there are cracks
Z 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 re-
mover 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 cyl-
inder head: 19+~~021 mm
15018
0
REPAIR AND REPLACEMENT OF PARTS REPLACING CROSS HEAD GUIDE
REPLACING CROSS HEAD GUIDE

,
1. Removing the cross head guide

l Using cross head guide puller H, pull out thje
cross head guide.
1) As shown in the figure, hold the cross head
guide with collet @of the puller.
2) Tighten the collet with bolt 0 to lock sleeve
0.
3) Rotate nut @and 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 the cross head guide

l Insert the cross head guide in the cylinder head,
then hit it into the cylinder head with a copper
bar or plastic hammer until its protrusion is
within specification
+ Protrusion of cross head guide
Tolerance: 54 ’
-0.3 mm
+ Inside diameter of crosshead guide hole:
,5 + 0.018 mm
0
15019
0
REPAIR AND REPLACEMENT OF PARTS GRINDING THE VALVE
GRINDING THE VALVE
1. Grinding the seat surface

l Grind the seat surface with valve refacer I.
* Angle of valve seat: Intake valve: 30°
Exhaust valve: 45O
2. Checking after grinding

l Confirm that the thickness of the valve head,
protrusion of the valve, and the contact surface
of the valve seat are within specification.
* Thickness of valve head F6164107A
Ir Thickness of valve head

Repair limit
Intake valve: Min. 2.9 mm
(Standard size 3.4 mm)
Exhaust valve: Min. 3.1 mm
(Standard size 3.5 mm) F6164108
* Sinking of valve Standard: 0.9 - 1.5 mm

8
Repair limit: 2.1 mm
z
z
* Check the contact of the valve with the seat

F6164109
surface using one of the following methods.
l Coat the seat surface of the ground valve
thinly with red lead (minium), insert it in
the valve guide, push lightly against the
valve insert surface, and confirm that the
contact is uniform without any breaks.
l Make marks with a pencil on the seat

surface of the ground valve as shown in
Pencil marks
the diagram, insert it in the valve guide, (about 20 places)
push lightly against the valve insert
surface, and rotate loo. Check that the
pencil marks have been erased uniformly
around the whole circumference. F6164101
15-020
0
REPAIR AND REPLACEMENT OF PARTS CYLINDER BLOCK
CYLINDER BLOCK
HLE00055
1. Cylinder liner
2. Crevice seal
3. O-ring
4. Cylinder block
5. Main bearing cap
6. Main bearing cap bolt
7. Camshaft bushing
15-021
0
TESTING AND INSPECTING
(1) Cylinder block

Unit: mm
inspection item Judgement standards Remedy
A. Cracks l Check for cracks (external color check)

Replace
Cylinder head bolts hole portion, etc.
6. Correction of con
tact at packing
portion
Check for water leakage

Replace
caused by corrosion
I F6164111
C. Clearance from
liner
~~~ ji zi%z!
Clearance from liner
190.34 - 190.40 190.19 - 190.29 0.05 - 0.21
Replace
cylinder liner
or block
F616411:
D. Inside diameter l Inside diameter

of camshaft Standard size Standard value Repair limit
bushing
72 72.00 - 72.07 72.10
Replace
l Clearance from camshaft bearing bushing
Standard clearance Standard value
0.08 - 0.18 0.24
E. Protrusion of line
Permissible range: 0.07 - 0.15
Replace
cylinder liner
or correct
cylinder block
I ’ \ F6164113
Depth of counterbore
F. Depth of counter. Standard size Standard value
bore and corro- Repair by
sion of bottom 14.00 - 14.05 machining,
14
surface add shim
~6164114 l Check for corrosion
G. Distortion, wear Tolerance Repair limit

of cylinder head
Repair by
mounting surfac Overall top surface of block: Max. 0.09 0.15 machining
For one cylinder: Max. 0.05 0.10
15022
0
Unit: mm
inspection item Judgement standards Remedy
H. inside diameter
of main bearing Standard size Standard value Repair limit
mounting hole
148 147.992 - 147.025 -
l Tighten main
bearing cap
170.992 - 171.025 -
bolt and guide Ran$bf @
bolt at specifier
torque
Replace
I. Fitting of cap and
cylinder block
z
z
z
J. Inside diameter
of counterbore,
outside diameter
of cylinder liner
Replace
flange cylinder liner
F6164117 Bottom 1 194.59 / ‘“~~$&I -
Cylinder Standard Standard Repair

block size value limit
Correct
Top 1 206.0 1 ‘““;;“,., I’““;“,‘,, cylinder block
sleeve
194.48 - 194.46 -
Bottom 194.5
194.54 194.57
15023
0
REPAIR AND REPLACEMENT OF PARTS GRINDING THE TOP SURFACE OF CYLINDER BLOCK
GRINDING THE TOP SURFACE OF CYLINDER 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 (partic-
ularly in the front-to-rear direction), or there is .c
z Wear ofcounterbore portion
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 3
_I
surface, correct the counterbore. I,
1. Grinding top surface

1) Measure the wear and strain of the top surface F6164118
of the cylinder block, and if it is over the repair
limit, grind the top surface.
+ Flatness of cylinder block (for one cylinder):

Standard dimension: 0.05 mm
* Height of cylinder block (H):
Standard dimension:
509.835 - 510.065 mm
+ Roughness of top surface of cylinder block:
Max. 12.5s
If grinding with a grindstone (for reference)
* Speed of grindstone: 1,650 to 1,950

m/min.
* Speed of table: 15 to 30 m/min.
+ Grinding depth/time: 0.025 mm
It Cross feed/time: 1 to2mm
* Grindstone: A461V
* Grinding lubricant: Water-soluble grind-
ing lubricant
HLE00058
15024
0
2. Grinding couterbore Unit:mm
After grinding the top surface of the cylinder (Liner Drotrusion)
block, measure the depth of the counterbore. If

-
it is not within the standard dimension, or if there
are blackened portions on the cylinder liner
Cylinder liner
contact surface of the counterbore (particularly L
in the front-to-rear direction), or there is speckled 12.5s
wear, and these portions extend over more than / v
half of the contact width of the deck, correct the /
counterbore depth* within the repair limit. After

Cylinder block
correcting, if the counterbore depth is within
14.05 - 15.525 mm, combine with shims and
adjust so that the liner protrusion is 0.07 - 0.15
I I
mm.
* Counterbore depth L:
Standard dimension 14 + io5 mm
F6164120

* Protrusion of cylinder liner I:
Standard value: 0.07 - 0.15 mm
Unit:mm
+ Roughness of counterbore: Max. 12.5s
* Machined shape: In accordance with detail
diagram for portion a
cylinder
For the extra amount for counterbore depth L,

decide a machining amount that will bring the
protrusion of the cylindr liner within 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 in the table below. F6164121
Unit: mm
[Reference] Adjustment shims for counterbore depth
Ilnit. mm
Weight
.Part No. T t Remarks
(kg)
6162-29-2260 1 1.50 1 0.025 1 0.004 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
6162-29-2230 0.26 0.025 0.001
6162-29-2220 0.20 0.020 0.001
6162-29-2210 0.16 0.016 0.001
Shim T*t
F6164122
15-025
0
3. Checking and distinguishing after grinding and

correcting
After grinding and correcting, check for scratches
on the flat surface around the water and oil holes
in the cylinder block top surface.
Remove all burrs completely.
After grinding the top surface, if the cylinder block
height H exceeds the standard dimension, but
is within the repair limit (569.5 - 509.8 mm),
always use an oversize head gasket.
* Oversize head gasket part number:
6162-19-1811
Thickness of plate: 2.4 mm
(Standard: 2.0 mm)
Ir To distinguish, the letters “OS” are stamped
on the plate.
After correcting, stamp the top surface of the Position
Ds,r I.
cylinder block according to the content of the
correction as shown in the table below.
Table of letters to stamp
Oversize head
Shim Stamp
gasket
18,
(Size of letters: 5 - 10 mm)
HLE00067
15026
0
4. Procedure for coating bottom of linei lip with

gasket sealant
When pulling out the cylinder liner and press
fitting it again, coat the contact surface under
the counterbore liner lip with gasket sealant LG-
6 as follows. Use the same procedure when using
a shim for the corresponding part.
+ The following commercially available sealant
is equivalent to LG-6.
l Three Bond: TBI 215
l Nihon Hermetic: SS-6OF
6162F759
1) Use a cloth to wipe off all the dirt and oil from
the contact surface of the liner lip and cylinder Top surface of block
block counterbore.
Meting portion Of liner
2) Coat the position marked in the diagram with
LG-6.
l Make the diameter of the line of gasket
sealant $2 - 3 mm.
l Make the overlapping portion for beginning
Position to coat
and ending the coating of sealant 6 f 6 with gasket sealant
mm as shown in the diagram.
F6164124
* When using shims , Overlap amount 6 + 6 mm

-1
l After coating the bottom of the shim
thinly with LG-6, instll it to the deck
d
portion of the block.
l Next, coat with LG-6 in the same way
as when not using shims.
F6164125
G-6 (@2 - 3 mm)

/
3) Press fit the liner in the cylinder block. 1

When doing this, coat the seal with rubber
lubricant RF-I.
+ RF-l is equivalent to the commercially
available Daido Kagaku Kogyo DS-50.
+ If RF-1 is not available, coat the block
contaet surface of the O-ring and seal with
an extremely small amount of engine oil
(SAE30) immediately before press fitting
the liner.
F6164126
15-027
0
4) Coat the liner O-ring, clevis seal, and cylinder

block contact surface with a small amount of
engine oil (SAE #30) immediately before press
fitting the liner.
* Coat the contact surface of the cylinder
block uniformly around the whole circum-
ference by hand.
\+a 6162F761
5) Insert liner (I) into the cylinder block, taking

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 Mounting bolt: 26 * 1 kgm
ii) Remove the cylinder head, and wipe

off the gasket sealant that has been
squeezed out from between the cyl-
inder liner and cylinder block.
Ir If gasket sealant sticks to the grom-
met in the head gasket, the grommet
will be deformed, and this will cause
leakage of water, so remove all the
gasket sealant.
I 6162F764
15-028
0
8) Loosen the cylinder head mounting bolts, re-

If the grommet is
move the head, then wipe off the excess gas- deformed into a heart shaDe.
ket sealant that has come out from the cylin- it blocks the water hole
and may cause leakage of
der bore. / the coolant.
R
a The gasket sealant that comes out may
cause deformation of the head gasket
grommet, so always carry out steps 4)
and 5) without fail.
/ \
/ \
Grommet Water hole
F616417.7
15029
0
REPAIR AND REPLACEMENT OF PARTS REPLACING MAIN METAL CAP
REPLACING MAIN METAL CAP

* When replacing the main metal cap, machine
the semi-finished part according to the follow-
ing 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 specifica-
tion.
w Mounting boltfor main metal cap:
* Coat the thread and seat with engine oil

SAE30
Unit: kgm
Procedure Target Range
1 st step 56 51 -61
5) Cut the inside of metal cap (I) little by little
2st step 113 107-118 while checkinn its inside diameter.
3st step 0 Loosen completely Cut until the cutting tool contacts the
inside wall of cylinder block (2).
4st step 38 33-43 Inside diameter of main cap:
5st step 75 70-80 i) Machining dimension
2
Tolerance: 148+to25 mm z
6st step 113 107-118
ii) Inside diameter of cap when main &
cap is tightened to specified
* Align the notches on the cylinder block
torque after machining.
and cap.
Tolerance: 148$::%: mm
3) Set the jig for mounting the cylinder block (IO” range above and be-
to the table of a horizontal boring ma- low cap matching surface)
chine.
Install the cylinder block by mounting its Surface roughness: 12.5s max.
hole for the liner to the datum plug of the Never cut the inside wall of the cylin-
jig. der block.
4) Center the arbor of the boring machine
by applying a dial gauge to the inside wall
of the two metal caps which have the larg-
est pitch in the metal caps to b e used
again.
HLE00060
15030
0
REPAIR AND REPLACEMENT OF PARTS REPLACING MAIN METAL CAP
2. Correcting the width of the main metal cap

(Modifvinn No. 6 main cap onlv)
1) lnskrtcast iron bushing @and pass arbor @I
through.
2) Install facing tool @to the arbor.
3) Cut cap (I), until the cutting tool contacts the
cylinder block.
4) Cut the opposite side in the same way.
* Never cut the cylinder block.
6 I27F230
* Roughness of surface facing thrust metal:

12.5 max.
+ Width of main cap Tolerance: Max.R0.5 1
HKE00068
15031
0
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM BUSHING
REPLACING CAM BUSHING

* Before replacing the cam bushing, remove the
plug from the rear of the cylinder block.
1. Removing No. 1 and No. 7 bushings

. 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 hit-
ting the grip.
6162F518A
2. Removing No. 2 and No. 6 bushings

. Assemble push bar 0, push tool 0, guide 0, and
collar @ in push tool set Jl, then pull bushing (2)
out of cylinder block (1) while hitting the bar. 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) 2
out of cylinder block while hitting the bar.
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 con-
tacts cylinder block (I).
Ir Align the oil hole on the bushing. (This must 1
be cared whenever fitting the bushings.)
6162F521
15-032
0
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM BUSHING
5. Press-fitting No. 2 and No. 6 bushings

. Assemble tool set Jl and bushing (2), then fit the
bushing until the end face of push tool @I con-
tacts the cylinder block.
* Align the oil hole on the bushing.
6162F522
6. Press-fitting No. 1 and No. 7 bushings

. Assemble tool set Jl, grip J2, and bushing (2),
then fit the bushing until the end face of push tool
@I contacts the cylinder block.
Ir Align the oil hole on the bushing.
* Press-fit the plug to the rear of the cylinder block. 6162F523A

REPAIR AND REPLACEMENT OF PARTS CRANKSHAFT
CRANKSHAFT
HLE00062
1. Crankshaft
Unit: mm
A. Cranks Use a magnetic flaw detector to check for cracks Replace
6. Damage If the damage is slight,

Check for damage to Scratches correct with an oilstone
the journal portion seizure or correct by lapping.
discoloration Replace if there is
1
seizure
Damage to cap hole at front and rear end Correct
C. Clogging of oil hole Check for clogging of oil hole Correct
15-034
0
Unit: mm
Inspection item
I
Judgement standards
1 Remedy
D. End play of crank- Standard value Repair limit Replace thrust

shaft 0.14 - 0.320 0.69 bearing or cor-
rect with oversize
E. Thickness of thrust Size Standard size Tolerance Repair limit

bearing
STD 4.0 3.79
0.25 US 4.125 3.92 _ Replace thrust
bearing or cor-
0.50 us 4.25 -0.07 4.04 rect crankshaft
-0.12 . with oversize
0.75 us 4.375 4.17
1 .oo us 4.5 4.29
F. Outside diameter of Size Standard size Tolerance Repair limit

crankshaft pin
journal STD 108.00 107.91
0.25 US 107.75 107.66

0.50 us 107.50 -:.022 107.41 Correct with
undersize or
0.75 us 107.25 107.16 replace
1.00 us 107.00 106.91
G. Out-of-roundness of
crankshaft pin
I. Outside diameter of
main journal
L. Curvature of crank- Standard Repair limit

shaft
Total coaxiality of
(total runout of Max. 0.09 0.09 Replace
main journal
indicator)
Coaxiality of neigh-
Max. 0.05 0.05
boring journals
15-035
0
Correcting surface roughness of crankshaft

journal portion
If the roughness of the crankshaft journal portion

does not fulfill the standard, correct the surface
roughness.
1. Cleaning and blowing with air

Before polishing, brush the oil holes and blow
with air.
2. Correcting surface roughness of journal portion
1) When correcting with special polishing
machine
Use a special polishing machine as shown in
the diagram on the right.
i) Set the rotating speed for the work at 40
- 50 rpm, and use No. 320 paper (belt
type). Perform dry polishing (do not use
honing oil), and move the paper once up
and down the whole journal width for each
journal.
ii) Next, replace with No. 500 paper, coat the
journal surface with honing oil, and move
the handle of the machine to the left and
right by the amount of play to give fine
movement. Use this movement to move
once up and down the whole width of the z
F6164131
journal. Move the paper smoothly and do z
not stop at any point. Move handle to left and right,

iii) Check the surface roughness, and if it is and move once up and down
width of journal
not within the standard, polish again once
up and down the width of the journal with
No. 500 paper.
F6164132
15-036
0
2) When using a work clamp jig for polishing

(When a special polishing machine is not
available)
Use a work clamp jig such as shown in the
diagram on the right.
Use a crankshaft grinding machine under
the following polising conditions.
Paper: No. 800
Machining oil: Honing oil
Work speed: 40 rpm
The polishing time for one journal is
approx. 6 minutes. Move the clamp the
amount of play of the clamp and journal
width (approx. 5 mm), and move up and
down the journal in the axial direction.
After completing the honing of one journal,
replace the paper with new paper.
When honing the pin journal, it is safer
to carry out the work with the pin journal
at the rotation center.
F6164133
3) Assembly of work clamp jig and method of

use
i) Jig for pin journal and jig for main journal
Assemble the clamp jig as shown in the
diagram on the right. For details of the
component parts, see the drawings on
separate pages.
F6164134
15-037
0
ii) Cut out a piece of No. 800 paper with the Dimensions of paper for pin journal
shape shown in the diagram on the right. 230 mm
Make cuts of
20 mm length\
at approx.
10 mm intervals
IIIIIIIIIII i
iii) Take 2 pieces of paper prepared in Step E
ii), insert the top and bottom pieces in the 9
slit of the clamp jig. then fix in position
with tape.
I I I I I I I I I n_,
Cut out slit 2
portions
iv) Fit the journal in the clamp, and fix the
Dimensions of paper for main journal
ends of the lever with a rubber tube.
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
8
measuring tool is available, rub No. 1500 paper
extremely lightely in the axial direction, and use
z
a 30-times magnifying glass to inspect the
z
pattern on the paper. If the horizontal lines can
be seen to be connected it is within the standard
value. If the lines cannot be seen to be connected,
the roughness of the journal surface is excessive,
so polish it again.
4. Cleaning after correcting surface roughness

After correcting the surface roughness, always
brush the oil hole and blow with air.
5. Check that there are no scratches or dents at

the journal portion and fillet R portion.
Fix in position with tape .Rubber

w
Bend to fit round shape inside plate
F6164136
15038
0
Clamp jig parts drawing (for pin journal)
@I Plate (2 are used for each jig)
Unit: mm
69 k 0.1
I= (10) 74
-i
5
A
F==i LLI
A
31.5
I I
/
=H-- --t-F” STKM 13A
Section A-A
F6164137A
@ Handle (2 are used for each jig)
Umt:mm
450
-
132
F6164138A
15039
0
Clamp jig parts drawing (for main journal)
0 Plate (2 are used for each jig)

Unit: mm
t 1
A 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

. If the crankshaft is worn or slightly seized or Roughness of outside surface of pin journal,
damaged, cut it to any one of the following main journal: Max. 0.8s
thicknesses.
Undersize dimensions: Tolls and jigs required for cutting
0.25, 0.50,0.75, 1.00 mm 1) Magnetic flaw detector
\c
. If the crankshaft is bent or worn unevenly, re- 2) Shore hardness tester
place it instead of repairing it. (A lot of skill is 3) Etching kit
required to repair it.) 4) Crankshaft cutting machine
l Carefully finish section R of the fillet of the 5) Crankshaft grinding machine
\
crankshaft, section r on the shoulder, and sec- 6) Roughness gauge
tion R facing the hole. 7) Ball gauge for measuring radii of fillets
Min. 795-500-1140
/IF-
. Dimension of fillet Max. 795-500-I 150
Check before cutting

R 1) Visual check
Check for cracks, damage, seizure, discoI:
oration, wear, etc. to see if it can be re-
/r paired.
R: 6.5_g.s mm, 2) Hardness test of journal
r’ Surface roughness 1.6s Hardness of journal (Shore hardness)
r: 6.4 mm, Allowable range: 60 - 67 Hs
Surface roughness 12.5s Limit: 60 Hs
i
If the hardness is below the limit, dispose
R of the crankshaft.
-
- 3) Torsion test
6127F231
Stroke
. Dimension of oil hole on journal
Main journal Pin journal
6127F233
Throw of eccentric: 85-t,,, mm
15041
0
2. Check during and after cutting 4) Measuring the bend (Alignment)

1) Checking the round sections of fillets l Measure the bend of the repaired crankshaft.
i) Confirm that the round sections of fillets l Measure the bend (alignment) at the following
are smoothly connected to the shoulders four places.
of journals. i) Overall length alignment: 0.09 mm max.
ii) Using ball gauges for measuring the radii ii) Adjoining alignment: 0.05 mm max.
of the fillets, confirm that each radii of the iii) Forward end alignment: 10.04 mm max.
fillets, confirm that each radii is between iv) Rear end alignment: ‘0.03 mm max.
the minimum and maximum limits.
3. Cutting the main journals
kk
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.
&tact point Contact point 6127F234 Undersized of main journal
Minimum radius of fillet: 6.00 mm Unit: mm

Maximum radius of fillet: 6.50 mm
Size Basic dimension Allowable error
2) Checking the seized surfaces by etching
l After cutting the journals, confirm that no S.T.D 140.000
parts were seized in the cutting procedure by 0.25 US 139.750
the etching test. 0.50 us 139.500 8
-00.025
l If any seized part is found, cut the journal 0.75 us 139.250 Z
another 0.02 mm to apply the next undersize. Z
1 .oo us 139.000
l After etching the journals, neutralize and
wash the checked surface, then apply oil.
Out of roudness and cylindricality of main
3) Magnetic flaw detecting
journals (T.1.R). surface roughness.
l Before using the repaired crankshaft, confirm
Allowable error: 0.010 mm max.
that there are no cracks on it by magnetic flaw
Limit: 0.015 mm
detection.
Surface roughness: 0.8s
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
4. Grinding the thrust bearing surface 5. Grinding pin journals

Jc It is not always required to grind the front * Grind all the pin journals to the same
and rear thrust bearing surfaces to the undersize.
same undersize. * When grinding, count in finishing allow-
* If the thrust bearing surfaces have been ance for grinding 0.007 to 0.008 mm.
ground, confirm that the end play of the
crankshaft is within the allowable range . Undersizes of pin journal
(For details, see DISASSEMBLY AND AS-
Unit: mm
SEMBLY).
Size 3asic dimension Ulowable error
. Undersizes of thrust bearing surfaces
S.T.D 108.00
Unit: mm
0.25 US 107.75
Rear thrust bearing surface
0.50 us 107.50 0
1 -0.022
S.T.D 0.25 0.S 0.75 us 107.25
Basic +0.050 1 .oo us 107.00
dimension 64+:.050 64.25 o
Limit 64.060 64.310 . Out of roundness and cylindricality of pin

Basic journal (T.I.R), surface roughness
dimension 64.25+;‘050 64.50+;.05’ Allowable error: 0.010 mm max.
Limit: 0.015 mm
Limit 64.310 64.560 Surface roughness: 0.8s
6. Correcting the width of the main journal

. Squareness of thrust bearing surface and pin journal by grinding
(T.1.R) . When correcting the worn surfaces of the
Limit: 0.04 mm main journals and pin journals, limit the grind-
ing 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:
Standard: 64+g.05 mm
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
7. Correcting the grindstone IO. Treatment after grinding

. Dress the grindstone each time one journal is l Confirm that each dimension is within speci-
ground. fication.
. Grindstone dresser . Carefully wash each section and apply oil to
Tip angle: 75”? I0 it.
Radius of edge: 0.38 * 0.25 mm . When storing the crankshaft for a long time,
At the edge of the dresser, a diamond for in- support it at three points or hang it vertically.
dustrial use must be embedded.
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.
Adjust the machine for correcting the grind- . To balance the crankshaft, make a hole on the
stone, and correct the edge of the grindstone counter weight with a drill or cut it.
to the radius of the fillet. Limit of amount of counterweight to be re-
When checking and correcting the grindstone moved: 56 g
edge, grind a wood bar for trial and use ball Number of holes: 6 max.
gauges. Diameter of hole: 19 mm or 23 mm 8
Depth of hole: 50 mm max. z
Preventing seizure caused by grinding Distance between hole and side face: z
1) Use the plunge grinding method. 3 mm min.
2) Use the overall width of the grindstone. Distance among holes: 5 mm min.
Do not grind the bosses if possible.
3) Apply sufficient cooling oil.
4) Set the circumferential speed of the grind-
stone to 2,000 m/min when the speed of
crankshaft is 50 rpm.
9. Surface finishing
. Standard surface roughness
Journal: 0.8s
Thrust bearing, fillet: 1.6s max.
Tapered end: 1-2s
Bosses of pin and main journal: 3.2s max.
Finishing allowance for grinding:
0.007 to 0.008 mm
15-044
0
12. Procedure for measuring curvature of crank-

shaft 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.
E x a m c l e o f measuring
curvature
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.
6D170-1 SERIES
REPAIR AND REPLACEMENT OF PARTS CONNECTING ROD
CONNECTING ROD
1. Bolt
2. Washer
3. Cap
4. Dowel pin
5. Connecting rod
6. Bushing
F6164151
Unit: mm
A. Cracks Check for cracks with a color check or magnetic flaw detector
B. Curvature,
twisting ,,,I:::~ :, I D
Check for curvature Replace
or &vising
F6164152A
C. Clearance be- Replace bush-

tween connecting ing, rough-
rod bushing and ness of inside 8
piston pin surface of
Z
bushing: Max.
2.4s G,
D. Inside diameter of Inside diameter of hole at big end

hole at big end of Without bearing
connecting rod Standard size 1 Tolerance
115
0I
+0.026
Roughness of inside surface of hole at big end: Max. 6.35

Clearance from crankshaft bearing (with bearing) Replace
Standard clearance 1 Clearance limit
0.058 - 0.132 I 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 of Standard size Tolerance Repair limit

bearing
S.T.D 3.500 3.41
U.S 0.125 3.625 3.54
0.250 3.725 -0.029 3.66
-0.042
0.375 3.875 3.79
0.500 4.000 3.90
F. Scratches on Check for scratches or seizure Replace, re-

inside surface of place connect-
bearing, seizure ing rod also
G. Distance between Standard size 1 Tolerance
holes at big end Replace
and small end 305
I -:.05
15046
0
REPAIR AND REPLACEMENT OF PARTS CONNECTING ROD
Unit: mm

I
H. Scratches at I
shape portion of
connecting rod
(dents) Check for scratches in horizontal
direction in area A
Check for grinder grain in horizontal

direction in area A
dents, regard-
F6164153
I less of size
I. Fretting of mating Check for fretting of mating surface Replace if

surface of cap fingernail
Roughness of mating surface: Max. 6.3 S
catches in
Contact of mating surface: Min. 70% fretting
J. Scuffing of bolt
seat surface
Scuffing of cap bolt seat surface
I Correct with
oilstone
Scuffing of bolt seat surface Replace bolt

I
Scuffing of washer surface

I Replace
washer
2
T
K. Deformation of Check for deformation of dowel pin
Replace
W
dowel pin Check for deformation of dowel pin hole I
G
L. Damage to bolt Check for cracks, damage to bolt thread
Replace bolt
Check for curvature of 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 unneces-
sary.
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. K2
* 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.
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 out-
side, 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 OF PARTS REPLACING CAMSHAFT GEAR
REPLACING CAMSHAFT GEAR

1. Removal of gear
Set the camshaft assembly on the press stand,
then push the camshaft to remove the gear
a When setting the camshaft assembly on the

press stand, be careful not to get your fingers
caught between the press stand and the 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
* Gear shrink-fitting temperature: 200°C
5) Put the timing mark of the gear on the out-
side, 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
REPLACING FLYWHEEL RING

GEAR
g Be careful not to let the flywheel fall and injure
you.
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.

1) Check the gear mounting surface, and if there
are any scratches, correct them with an oil-
stone.
3 Heat the gear for the specified time at the
sr Gear shrink-fitting temperature: Max. 200°C
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
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
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

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SEBE6161A16

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

11 STRUCTURE AND FUNCTION ....................................................... 11-001

12 TESTING AND ADJUSTING ............................................................. 12-001

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

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

15 REPAIR AND REPLACEMENT OF PARTS .............................. 15-001

00-2 6D170-1 SERIES

( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

b 00-1 (16) 01-004-14 (15) 01-025 (8) 11-026 11-044-3 (11)

6D170-1 SERIES 00-2-1

00-2-2 6D170-1 SERIES

6D170-1 SERIES 00-2-3

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Electrical volume: Each issued as one

. If a part cannot be smoothly removed from

Wire ropes 4) Do not sling a heavy load with ropes form-

20 43.1 4.4 hanging angle. On the other hand, two

2) Sling wire ropes from the middle portion

Category omatsu code Part No. Q'W Container

Used to prevent rubber gaskets, rubber

l Used in places requiring an immediately

l Features: Resistance to heat and chemi-

790-129-9060 Adhesive: l Used as adhesive or sealant for metal, glass

Holtz . Used as heat-resisting sealant for repair-

. Quick hardening type adhesive

I l Quick hardenina tvoe adhesive

Used as adhesive or sealant for gaskets

Features: Resistance to heat

l Features: Resistance to water, oil

l Used as sealant for various threads, pipe

l Features: Silicon based, resistance to heat,

* Features: Silicon based, quick hardening

Three bond . Used as heat-resisting sealant for repairing

l Used as lubricant for sliding portion (to pre-

SYG2-400LI l General purpose type

l Used for normal temperature, light load

Molybdenum 400 g l Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Thread diameter Width

6 10 13.2+ 1.4 1.35kO.15

Thread diameter Width

TIGHTENING TORQUE OF HOSE NUTS

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tighteni I torque

TIGHTENING TORQUES OF FLARE NUT

Thread diameter Width across flat Tightening torque