SEBES6161000 OEM USE >]IOIP IMTA\INTU AIL KOMATSU 6D170-1 SERIES DIESEL ENGINE APPLICABLE ENGINE MODELS $6D170-1 SA6D170-B-1 SA6D170-A-1 eje KOMATSUCONTENTS 11 STRUCTURE AND FUNCTION ......... 12 TESTING AND ADJUSTING 13 DISASSEMBLY AND ASSEMBLY .... 14 MAINTENANCE STANDARD ........ Aree 15 REPAIR AND REPLACEMENT OF PARTS ........... 170-1 SERIES No. of page W-4 15-1Ad important SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this ‘manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. » To prevent injury to workers, the symbols AM and a are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, t consider safety, and take the necessary actions to deal with the situation. A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1.Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing * Always wear safety glasses when hitting parts with a hammer. © Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4.When carrying out any operation with two ‘or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the ‘controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 170-1 SERIES 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking, Never smoke while working. PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, Park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving, 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10, Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, 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 on to 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 mir mum of gasoline when washing electrical parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. © When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure Circuits. Also, check that connecting parts are correctly installed 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. 170-1 SERIESFOREWORD: 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 chapters for each main group of ‘components; these chapters are further divided into the following sections. 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. Contact your KOMATSU distributor for the latest information. 170-1 SERIES 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models, Electrical volume: Attachments volume : ‘These various volumes are designed to avoid du- Plicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up- to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page umber. Example 1 (Chassis volume}: 21-3 Unit number (2. Power train) tem number (1. Structure and Function) Consecutive page number for each item Example 2 (Engine volume): 12-410 Unit number (1. Engine) tern number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by @ hyphen (-) and number after the page ‘number. File as in the example. Example 214 12.203 21-41 12-203-1 21-4.2-}— Added pages {19 203.2 21-8 12-204 00-6 REVISED EDITION MARK (O@@. When 2 manual is revised, an edition mark is recorded on the bottom outside comer of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are ‘marked with the following symbols. Symbot | tem Remarks Special safety precautions are A necessary when performing the work. Sefety Extra special safety precautions are necessary when performing the work because it is under internal pressure. ok ‘Special technical precautions or other precautions for 7k | Caution [preserving standards are necessary when performing the work [Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Weight Places that require special attention for the tightening torque during assembly. Tighten- ing torque| Places to be coated with Coat | adhesives and lubricants etc. Places where oil, water or fuel Oil, water | must be added, and the capacity. Places where oll or water must Drain | be drained, and quantity to be drained. [te fe|>] 8] & 170-1 SERIESHOISTING INSTRUCTIONS HOISTING INSTRUCTIONS BA Hresvy parts (25 ka or more) mustbe lifted with a hoist etc. In the Disassembly and As- sembly section, every part weighing 25 kg,or ‘more is indicated clearly with the symbol -5—> If @ part cannot be smoothly removed from the ‘machine by hoisting, the following checks should be made: © Check for removal of all bolts fastening the part to the relative parts. © Check for existence of another part causing interference with the part to be removed. . Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “S" twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 10 112 14 12.5 16 14 22 16 28 18 36 20 44 224 56 30 100 40 18.0 50 28.0 60 400 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. 170-1 SERIES Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have ‘maximum strength at the middle portion. 100% = 88% 9% 1% 1G 3} Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically ‘wound on to the load. A Singing with one rope may cause turning Of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling @ heavy load with ropes forming a wide hanging angle from the hook. ‘When hoisting & load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This, weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. A A kg gf a [bs0d i, * aaa a Lit ante 50085 00-7STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections ot “Disassembly and Assembly”. Thread diameter Width of bolt across flat (mm) (rom) kgm Nm — 6 10 1.354015 13.2414 8 13 3.2203 31.4429 10 7 6.7407 65.7268 12 19 11.5410 112498 14 22 18.0+20 177219 16 24 28523 27929 18 27 39x4 383239 20 30 56+6 54958 22 32 76+8 745+78 24 36 94.510 927498 27 a 135215 13202140 30 46 175420 1720190 33 50 225425 22102240 36 55 280+30 27502290 39 60 335435 32802340 | This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are 10 be used, or which require tightening to otherwise specified torque. + Nm (newton meter): 1Nm & 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts, ‘Thread diameter Width Tightening torque ‘ofbalt across flats (mm) (mm) kgm Nm 10 14 67207 65.7268 12 "7 11.61 112298 16 22 28523 27929 00-8 170-1 SERIESSTANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared, Sealing surtace a am) = ..., Thread diameter} Width across flats Tightening torque Of nut part ‘of nut part (oom) (com) kgm Nm —_|—__ 14 19 25205 24549 18 24 5x2 494196 22 27 B42 78.5+19.6 24 32 1423 13734294 30 36 18+3 17652294 33 a 20+5 196.1449 36 48 2545 245.2449 42 55 3045 294.249 COATING MATERIALS ‘The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomencatre Kometsucooe ‘Appcations uta Used to appt ubber pads, rubber gokets, and cork pgs ae Used 0 app a, ie, eta oncmealz ports when east tong sels needed. Adhesives d ue Preventing bots, euts and plugs trom tosening ad leaking oi Provides an aitight, electra insulting wea urs od for cumin surfaces, 6-1 Used wih gashats and pecking to increase sealing ettct. iss Heatesistant gasket for precombuston chambers and exhaust piping Laue gosket {sed by teat on mounting races onthe fal rive and vansmiasion cases tes Urhkness ster ightonng O07 — G08 mm) ‘sed by taf to ea grease iting, epgred scron ftings and tapered erew ad {tops a arouses of ess than 0 mmin ameter ‘articton compoura ‘Applet beanngs ond taper shafts to facta pres-fiting and to onan nc ume eet el prevent sticking, burning or rusting Grasse a ‘Roped to bearings sing parts and ol seal for ubrication, rust (Chiu greased prevention and fesitation of assembling work Vaseline Used for protecting battory electrode terminals from corrosion 170-1 SERIES *LT-2i also called LOCTITE in the shop manualsELECTRIC WIRE CODE ea A LH Example 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. CLASSIFICATION BY THICKNESS. O5WB indicates a cable having a nominal number 05 and white coating with black stripe. Topper wie Nomina! om Coble. | Curentrating Applicabe circuit number Number | Die. of strands | Cross section | immi iy Strands trom tre += o " 032 ose 24 12 | staring. igntng, signal ete 2 aol ose 209 34 20 | Lighting signal ee 05 65 032 523 45 37 | charging anc signa 18 a 04s 1336 70 58 | Starting (Giow plan) 40 85 0.80 4273 ne 135 | stating 60 1 | oto e384 136 178 | storing 100 27 080 1091 178 230 | Starting CLASSIFICATION BY COLOR AND CODE Create Priory staring | charging | Lichtin Signal | instrument | other Classieator coae ® w @ ¢ Y v 1 | Primary Color Beck Write Fed Green Yellow Bhe code ow wa ew ow YR iw 2 Color | Bleck white | whites Rea | Rea& White [Green White | Votow & Red | Bw & White Code By we oo A v8 iF 3 Coior | Black & Yetow | Write & Black | Red& Block | Green&Res [Yelow Bleck | Blue Rod Aurion code aR we Ry ow ve ty 4 oor | Bieck& red | White &6uw | Red &voiow [Green Vetow [Yelow& Green | Biv & Yalow code . wy aG oe w ie 5 Color = [wate voiow | Res Green | Greend Black | Yelow Bue | Bice Block ‘ode : we RL oe Yw 6 Color = [Write acreen | Feaaaue | Greenaiaive [Yetow & white 00-10 170-1 SERIESIi STRUCTURE AND FUNCTION 170-1 SERIES ENGINE GENERAL STRUCTURE... INTAKE AND EXHAUST SYSTEM Intake and exhaust system . Turbocharger After-cooler . ENGINE BODY Cylinder head Valve system Cylinder block Main circulation part Timing gear . Flywheel and flywheel hous LUBRICATION SYSTEM Lubrication systemchart .. ilpump Oilfiter and safety valve . Oil cooler .... Main relief valve Oil cooler by-pass valve - Piston cooling valve Mechanical pump .. FUEL SYSTEM Fuel system chert Fuel injection pump Fuel injection nozzle . Fuel injection pump drive . Fuel fter : Fuel solenoid Engine stop motor .. Starting aid . COOLING SYSTEM Cooling system chart Water pump .. Fan drive and tension pulley . Corrosion resistor Thermostat .. ‘ACCESSORY Air compressor mounting Aircompressor ........ ELECTRICAL SYSTEM Alternator . Starting motor Ww 2 1-4 214 11-18 14-16 214-18 11-20 14-22 11-24 11-26 11-27 : . 11-28 11-29 11-30 11-32 11-32 11-33 11-34 11-35 - 11-36 11-40 11-41 11-42 11-43 11-45 11-50 11-51 . 11-62 11-53 11-87 . 11-58 11-59 a 11-60 11-61 : . 11-63, 11-1STRUCTURE AND FUNCTION. GENERAL STRUCTURE 11-2 8 1" ‘Crank pulley ‘Thermostat tinder hood Fuel injection norzie Rocker arm housing cover Piston pin Intake valve Exhaust valve 10. u 12. 13, 4, 18, 16, GENERAL STRUCTURE Camshatt FRocker arm shaft Push rod Tapper Rocker arm housing Cylinder block Rear seat Vibration damper ere2ri01 17. Front seat 18. Olt pump 19. Connecting rod cap 20. oi pan 21. Main bearing cap 22, Crankshaft 23. Ring gcer 24, Fiywhee! 170-1 SERIESSTRUCTURE AND FUNCTION GENERAL STRUCTURE B. 7 8 0 25. Cylinder liner 26. Piston ere2r102 27. Oil cooler 28. Fuel injection pump 8 Piston cooling nozzle 20. Connecting rod 170-1 SERIES 11-3STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM INTAKE AND EXHAUST SYSTEM Intake system ere2rt07 11-4 170-1 SERIESSTRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM Air cleaner ‘Turbocharger Intake manifota Exhaust manifold 5. Muttier > Foe inet Exhaurt 170-1 SERIES 11-5STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM Intake system 1. Aircleaner 2, Turbocharger 3. Intake manifoid 4. Exhaust manifold 5. Muffler Fe161Ao02 Exhaust system A. Intake inlet BL Exhaust Fer61A003 170-1 SERIESSTRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM Intake system A. Intake inlet 8. Exhaust 170-1 SERIES 11-711-8 170-1 SERIESSTRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM 170-1 SERIES 11-9STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM Intake system 11-10 170-1 SERIESSTRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM TURBOCHARGER | | \ \ \ : 1 i i pL, => A / Lia é oO a 4 5 6 1 e a 1. Blower housing 12. Oil inlet (rom ot fter) 2. Blower impeller . Olt outet (to oi pant 3. Clamp Air inter 4. Conter housing 4. Ait outter 5, Journal bearing Exhaust inlet 8. Turbine imposter 4. Exhaust outlet 7. Turbine housing 8. Invert 170-1 SERIES 11-11STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM (2) KTR130 1 1 3 4 5 & 1 § : . gs a Li + A >t + \\ | 7 ) 0 on ue a @ ovezrioe 1. lone housing 18. tar Specifications of turbocharger 2. Blower inal 12, Thru bearing “Type: Komatsu KTR130 SS oe eeoran + Length x width x aight: 368 x 368 x 228 mm : = Weight: 31 kg 2 ee eee + Continuous rotati 70,000 rpm 5. Joural baring 8. inet rom otter) + Maximum charging: 32 kg/min, oo Coy + Appropriate temperature (inlet,°C): 750°C max. * Direction of rotation (view from blower Right al & Able + Lubrication method: Forced 8. Turbine impair a. About 8. Turbine housing Exhaust ine 10. stinger Benaust outer 11-12 170-1 SERIESSTRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM (3) KTR150 Turbine housing 1. Blower housing 2, Oi inet (from oi fi 2. Blower impetier . Oil outer (to oi pan} 3. Clamp fe Airinlot 4, Gamer housing 4. Air outlet 5. Journal bering 6. Exhaust inlet 6. Turbine impetier 4. Exhaust outlet 2 8. 170-1 SERIES 11-13STRUCTURE AND FUNCTION (4) Tv7705 1. Lock nut 2. Blower housing 3. Blower impeller 4. Thrust collar 5. Back plate 6. Thrust bearing 7. Seal ring 8. Center housing 9. Retaining ring 0. Journal bearing 4. 11-14 Turbine housing Piston ring Turbine impeller Air inlet Air outlet Gas inlet Gas outlet Oi inter Oil outlet INTAKE AND EXHAUST SYSTEM W 12 3 14 s1s0F108 170-1 SERIESSTRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM AFTER-COOLER 1. Cover ‘A: From water pune 2. Aftercooter body B: To water manifold 170-1 SERIES 11-15‘STRUCTURE AND FUNCTION ENGINE BODY ENGINE BODY CYLINDER HEAD as O50 cL e —— 71d ‘ Fi Fi y 1 e ereari08 1. Water manifold 8 Coolant (to radiator) 2. Cylinder heed Fuel (rewind 3. locker arm housing © Oil from main gatery? 4. Rocker arm houting cover 4. Tap for water temperature gauge sensor 5. Volve guide 6. Nozze holder steve 7. Tube 11-16 170-1 SERIESSTRUCTURE AND FUNCTION ENGINE BODY Section 8 - 8 sr62F110 Cylinder head + Directinjection type, injection nozzle, 4-valve type + Separate type (1-head for 1-cylinder) Valve seat + Press fitted into cylinder head of intake valve and exhaust valves. 170-1 SERIES 11-17STRUCTURE AND FUNCTION VALVE SYSTEM ENGINE BODY - Intake valve 1 2. 3. 4 .. 6. 2 Exhaust veve Foocker aren Cotter CComshatt sear (No.of teeth: 48) Comshate ‘Adjustment seron 11-18 Lock nut Upper spring seat ‘Valve spring (outer) |= Valve spring (inner) Lower spring seat 3. Push rod Cam roller rear 18. Cam follower pin 16. Cam follower 17, Cam follower shaft 48, Adjustment serow 19, Lock mut 20. Cros head Oil (from oil pune) 170-1 SERIESSTRUCTURE AND FUNCTION ENGINE BODY Intake ie of No einer East se of No, 1 elindr evezrsna evezrnia Valve timing THe (Top Dead Centr) trae opin 3530" mnt ove Camshaft + Special cast/forged alloy, 7 bearings 230" + Cam face and journal face: High frequency hardening ae Exhaust open’ @ eo (Bottom Dead Center) Intake 20" close erezein4 170-1 SERIES 11-19STRUCTURE AND FUNCTION ENGINE BODY CYLINDER BLOCK 1 2 / 8 n ; i } i 1 8 4 ete2ri1s 1. Front cover 8. Main bearing 2. Cylinder Block 8. Thrust bearing 3. Oylinder tier 10, Com bushing 4. Crevice sea 11. Piston cooling nozzle 8. Oring (nitrite rubber: black) 12. Main bearing cap 6. Oring (silicone rubber: red) 18. Main bearing eap bolt 7. Front sea 14. Oil evel gauge 11-20 170-1 SERIESSTRUCTURE AND FUNCTION ENGINE BODY 4 8 a over Cylinder block “Crankshaft: Seven bearings * Camshaft: Seven bearings Cylinder tiner + Wet type liner, tufftride treatment on bore surface * Crevice seal, two O-rings 170-1 SERIES 11-21STRUCTURE AND FUNCTION ENGINE BODY MAIN CIRCULATION PART me oo e1e2e7 1. Piston pin 9. Vibration damper Crankshaft 2. connecting rod 10, Crank wor (No.of teeth: 26)» Special cast/forged alloy, seven 3. Connecting od bushing 11. Connecting rod baring beorings 5 aoe So + Journal face: High frequency 5. Top ing 13. Thru bearing | 6. 2nd ing 14, Main baring 1. Oiring 18. Connecting rod ean 8 crank pulley 16. Connecting rod bolt (Outside diameter: 200 mm) 11-22 170-1 SERIESSTRUCTURE AND FUNCTION a 4 | | ENGINE BODY Main bearing and connecting rod bearing + Sayer Kelmet + Upper main bearing: with oll groove Piston * Lo-Ex aluminum alloy 18 = Groove of top ring: Niresst is cast (on top ring. + Thermal flow solid type (S6D170-1) + Thermal flow shaker type | 18 (SA6D170-A-1) ($A6D170-8-1) + Forced cooling with piston cooling Connecting rod + Forged alloy steet Piston ring Engine model Top ha 2dcng ig Keyaone. Reyne With ci eran Sota. ar en lau ssor70. aed ae SA80170-81| Had crome plated. |Mod cie ted, ord crome ltd Seeotro1 z as _ot 170-1 SERIES 11-23STRUCTURE AND FUNCTION. ENGINE BODY TIMING GEAR 1. lr gear (No. of teeth: 57) 6 lor gear (No, of teth: 20) 2. Cam gear (No, of teth: 48) 7. Grankshatt gear (No. of teeth: 6) ‘3. Compressor driving geor (No.of teeth: 24) 8. Oil pump driving gear (No. of teeth: 33) 4. Injection pump devin ear 9. ler gear (No.of toeth: 41) (Wo, of tects: 10. Water pump criving ger (No. of teeth: 20) 5. Idler gear (No.of teeth: 48) 11-24 170-1 SERIESSTRUCTURE AND FUNCTION ENGINE BODY ‘Section D — D (with timer) 170-1 SERIES 11-25STRUCTURE AND FUNCTION ENGINE BODY FLYWHEEL AND FLYWHEEL HOUSING ‘Thread dia. 10 mm, pitch 1.5 mm, 24 points ere2e122 1s ringome iot wets 198 Tahtening order offre! mounting bolt 2. Fea 3. Rear seal qa 6 4 Pa noi 1 ‘ 1 1 i: § i 4 11-26 170-1 SERIESSTRUCTURE AND FUNCTION LUBRICATION SYSTEM LUBRICATION SYSTEM LUBRICATION SYSTEM CHART Olt pan it evel zensor oi elit valve Piston cooling valve Ott cooler 1 Oil cooler by-pass vane 3. Oi filter Sofety vale Main gallery Crankshaft 2. Camshaft 3. Rocker sem Piston cooling owe Timing geor Fue injection pump . Turbocharger ‘Mechanical pump 3. Oil pressure gauge “To intake manifold 1. Coolant erezri2a4 170-1 SERIES 11-27‘STRUCTURE AND FUNCTION OIL PUMP LUBRICATION SYSTEM 1. Olt pump driving gear (No of teeth: 33) | pump body Bushing Driv shaft Bushing Pump cover Driven share Driven gear (No.of teeth: 12) ee xeaeen Bushing 11-28 ere2ri24 il pump + Gear pump type * Oil pump speed: Engine speed x 1.091 170-1 SERIESSTRUCTURE AND FUNCTION LUBRICATION SYSTEM OIL FILTER AND SAFETY VALVE Safety vale cap il pressure sensor Fier bracket Filter element } cartridge Filter case Sefery valve Valve soring From oll pump ‘To engine each component 170-1 SERIES oi + Filteration area: 0.82 m? x2 iter Safety valve + Cracking pressure (difference pressure): 2.0+0.2 kg/om* 11-29‘STRUCTURE AND FUNCTION LUBRICATION SYSTEM OIL COOLER $6D170-1 SA6D170-8-1 t { Section 8 — B e162F126 1. Cooler cover Oil cooler 2. Cooler element + Heat exchanged: Min. 45000 Keal hr. 3 Drain cock 8. Coolant (from water pump) + Water flow capacity: 890 2/min, from oi pump) Oil (to engine each component) 11-30 170-1 SERIESSTRUCTURE AND FUNCTION LUBRICATION SYSTEM € sheen f Section 8 — 8 SA6D170-A-1 Cooter cover Oil cooler (Cooter element + Heat exchanged: Min. 55000 Keal/hr. Drain cock + Heat-transmitting area: 4.146 m? + Oil flow capacity: 180 &/min. ee ee + Water flow capacity: 890 ¢/min, it (rom oit pump) it 10 engine esch component) 170-1 SERIES 11-31STRUCTURE AND FUNCTION LUBRICATION SYSTEM MAIN RELIEF VALVE Plug 2. Valve spring Valve body Folie vave Ball type valve (Main rai valve) Main role vlve spring From oil pump veo = Tocil pan From main galery Main roto valve 4 — | . + Cracking pressure (difference pressure): WY B21 kg/m? : Oil-tine check valve ~ * Cracking pressure: 3.3 0.3 kg/em? 6 e162F127 OIL COOLER BY-PASS VALVE cap Velve spring Vaive body By-pass valve 8. From oil pump b. Tooit finer Oil cooler by-pass valve * Cracking pressure: 4.5 + 0.5 kg/em? orezri28 11-32 170-1 SERIESSTRUCTURE AND FUNCTION LUBRICATION SYSTEM STRUCTURE AND FUNCTION “LUBRICATION SYSTEM. PISTON COOLING VALVE cap Valve spring (it fitter adapter Piston cooting vate From oil pump ‘To piston cooling nozzle ‘To evlinder block Piston cooling valve * Cracking pressure: 1.3 *9:3 kgjem? Cracking pressure: 1.3 #09 kai erezri28 170-1 SERIES 11-33STRUCTURE AND FUNCTION MECHANICAL PUMP Mechanical pump + Capacity: 1021 ech x 2 + The mechanical pump is a worm pump used to increase the wear resistance of the intake valve seat. * The pump is driven by the slit shaft connected to the camshaft. 11-34 LUBRICATION SYSTEM 1. Spring Plunger Plunger Plunger Pump body Worm 2 Olt inlet (rom main gallery) b. Olt ouuer {to intake mani- fod) 6162F120 “The oil is sent from the main gallery into the pump, and sent out from the two outlets of the pump to the two intake manifolds through the oil tubes. The oil is sprayed in the intake manifolds by the intake air onto ‘the seats of the valves to reduce the wear of the seats. 170-1 SERIESSTRUCTURE AND FUNCTION FUEL SYSTEM FUEL SYSTEM FUEL SYSTEM CHART Fuel tank Fuel fiter Fuel injection pure Feed pump Fue injeetion nozale 170-1 SERIES 11-35STRUCTURE AND FUNCTION FUEL INJECTION PUMP $6D170-1, SA6D170-8-1 FUEL SYSTEM Injection pump driving gear (No. of teeth: 48) Injection pump driveshaft ‘Service meter output Ful injection pure Feed pump Governor Relay Solenoid Fuel fier 11-36 1. Fuel (from fuel tank) b. 4 ' Fuel (to fuel fier) Fuel (from injection pump) Fuel (20 nozzle holder) it {rom main gallery) (it (to oi pan} 170-1 SERIESSTRUCTURE AND FUNCTION FUEL SYSTEM STRUCTURE AND FUNCTION FUEL SYSTEM ere2ri23 Fuel injection pump + Maker: Diesel Kiki FUEL SYSTEM Made by AMP Co, Econostal connecior, BP male 7D 2. Not used (filer pug added) 1..Not used (filler plug added) 4. BIAV085LR) 3.P, (AVOBSLY) "6. Not used (filler plug added) 7, AAV 0.5L) S.P.IAVOSELW) 8. E(AV0.858) ‘ 4 10 1. Motor assembly Engine stop motor + Maker: Jidosha Denki Kogyo Co., Ltd 2 Cor + Rated voltage: DC24V 3. Cable assembly + Operating force: 15 kg min. 4. Cable clamp Sheed 3553 9m 8. Coil spring + Wei 1.2kg 6. Cable 7. Screw 8. Breather 8. Bracket assembly 10. Cover assembly 170-1 SERIES 11-45STRUCTURE AND FUNCTION FUEL SYSTEM STRUCTURAL DRAWING (1) 1. Gear cover assembly 2. Slider assembly 3. Armature shaft 4, Contactor assembly 6. Roller 6. Worm wheel assembly 7. Motor assembly 8 Gear case assembly 11-46 170-1 SERIESSTRUCTURE AND FUNCTION FUEL SYSTEM STRUCTURAL DRAWING (2) |. Gear cover assembly Motor assembly Cable clamp Cable assembly Gear case assembly 1 2 3 4. 5. 170-1 SERIES 11-47STRUCTURE AND FUNCTION DESCRIPTION OF OPERATION AND CIRCUITS 1. Stop condition (0° or 360°) ‘armarure shale oss contact plate FUEL SYSTEM A Bottery i ‘Contact plate on plus ie Autostop position | tn Pe, ‘The above drawing shows the stopped condition ‘when a closed circuit has been formed. The slider 2. When switch is turned (when starting the motor) th assembly is stopped at the auto-stop position on the P, side, TX autostop position fon, side When the switch is moved to the Pz side (starting switch ON), an electric current flows from the plus side contactor plate through the P autostop ter- minal and switch and into the armature shaft assem- 3. Turning condition (90° in the drawing) bly, thereby starting the motor. The slider assembly starts to move in the direction of the arrow at the same time as the roller starts to move. Electric current continues to pass through the arma- ture shaft assembly and the motor continues to tum, Because of the rotation of the roller, the 11-48 slider assembly also continues to move in the direc: tion of the arrow. 170-1 SERIESSTRUCTURE AND FUNCTION 4. When stopped (180°) FUEL SYSTEM A closed circuit is formed when the P2 auto-stop terminal rides on the minusside contactor plate, 5. When switch is turned (when starting the motor) When the switch is moved to the P; side (starting switch OFF), an electric current flows from the plus contactor plate through the Py auto-stop terminal ‘and switch and into the armature shaft assembly, 6. Turning condition (270° in the drawing) ‘and the motor comes to a sudden stop. The slider assembly also stops. thereby starting the motor. The slider assembly starts to move in the direction of the arrow at the same time as the roller starts to move, Electric current continues to pass through the arma- ture shaft assembly and the motor continues to ‘turn. ‘The slider assembly also continues to move in 170-1 SERIES the direction of the arrow. Then the circuit returns ‘to stop condition 1. 11-49STRUCTURE AND FUNCTION FUEL SYSTEM STARTING AID ‘Auto priming system (APS) erezria7 Glow plug 6. Howe ci To heater switch 2. Clamp, 7. Bracket b. To APS comolier 3. Wiring harness 8. Howe © To APS controller 4. Cover 9. Valve 4. To heater switch 5. Nozzle (6. From fuel iter (Fuel) 11-50 170-1 SERIESSTRUCTURE AND FUNCTION COOLING SYSTEM COOLING SYSTEM COOLING SYSTEM CHART 6 ie 2 erezri3e 1. Water pump 7. Water manifold 2. Oileooler 8. Thermostat 3. Corrosion resistor 8. Radiator 4. Oyler tiner 10. Fan 5. ylinder block ‘A. Fromoil pump (oil {6 Thermostat switch “To engine each component (oil) 170-1 SERIES 11-51‘STRUCTURE AND FUNCTION WATER PUMP COOLING SYSTEM Pump body ‘A. From radiator B. Toil cooler Floating seat Water set Pump shaft (rear) Pump shaft (front) housing 11-52 e162F139 Water pump + Water pump speed Engine speed x 1.8 + Flow capacity: 1050 &/min, (3,600 rpm) 170-1 SERIESSTRUCTURE AND FUNCTION COOLING SYSTEM FAN DRIVE AND TENSION PULLEY (For construction machines) 170-1 SERIES 11-53STRUCTURE AND FUNCTION COOLING SYSTEM 4, Tension pulley (Outside diameter: 148 mm) 5. Oils 6. Ball bearing 7. Spacer 8. Stopper 11-54 170-1 SERIESSTRUCTURE AND FUNCTION COOLING SYSTEM (For generators) “Tension spring “Tension shaft Tension pulley (Outside diameter: 150 mm) Fan pulley (Outside diameter: 332 mm! Fan bat Crankshaft pulley (Outside diameter: 200 mm Fen Dieection of wind 170-1 SERIES 11-55STRUCTURE AND FUNCTION COOLING SYSTEM ‘Tension pulley shaft Re all bearing Spacer Stopper 11-56 170-1 SERIESSTRUCTURE AND FUNCTION COOLING SYSTEM CORROSION RESISTOR Section X — X (Detail valve) ereari42 1. Hees Corrosion resistor 2. Element esse + Filteration area: 0.13 m* Cartridge 3. Solid aru (included 1,000 9) 8. Coolant inter . Coolant outer 170-1 SERIES 11-57,STRUCTURE AND FUNCTION COOLING SYSTEM THERMOSTAT ‘Sensor Steove 5. Wax From engine ach ‘component. ‘To water pump Pex eoeene To radiator oreartaa ‘At cold (cose) ‘At warm (full open) ereariae Function + Opening temperature: 76.5 + 2°C ing temperature: 90°C Minimum 10 mm 11-58 170-1 SERIESSTRUCTURE AND FUNCTION ACCESSORY ACCESSORY AIR COMPRESSOR MOUNTING Flange Coupling Air compressor ‘Air (from intake manifold) 1% 2. 3. 4. Ai governor b. e ‘Ale (t ait tank) Coolant (to water pump) Intake manifold Coolant rom water pup “| ware Water Ar governor operating pressure ae ry *Unioad pressure: 8.4 *9-4 kg/em? Gear jeomoresso| ma coe Or *Onload pressure: 7.0 10-3 kg/cm? ae eee eee erezries Air circuit diagram 170-1 SERIES 11-59STRUCTURE AND FUNCTION ACCESSORY AIR COMPRESSOR 1 ty 4 5 n ‘i 6 oY 16. 15. 1 “4 i 1 8 13 2 " 10 8 orezrta7 1. Inlet valve seat 11, Thrust washer ‘Air compressor 2. Unloader valve body 12. Crankshatt + Maker: Cummins 3. Unlosder valve spring 13. Drive gar (No. of teeth: 24) praca: a0 oe {at engine rated speed) bo males te * Discharge capacity: 245 £/min. 5. Head cap 18. 2nd ring {at rated speed) ee 46, Top ring * No. of eylinder — Bore x Stroke: 192.1 x 44.5 7. niet valve spring 17. Olinger mead 8. Piston 8. Crank case 2 Air inl 10. Connecting rod b. Air outlet 11-60 170-1 SERIESSTRUCTURE AND FUNCTION ELECTRICAL SYSTEM ALTERNATOR ELECTRICAL SYSTEM Jnner connecting sagram rearvas 1. Alternator asombly Engine Toe Specifications | Pulley outside | Weight = Delco-Remy, 2651-450, Open type | 24v, 508 98 15k sep1701 Sewaful, Open type 24V, 50A 98 12k sA60170.A4 | Nikko Denki, Open type 24v, 50a 95 18k 8a60170-8:1 | Nikko Denki, Onen type 24V, 354 98 10Ke 170-1 SERIES 11-61STRUCTURE AND FUNCTION ALTERNATOR WITH REGULATOR BERR: Terminal Alternator ELECTRICAL SYSTEM ° Regulator Wicing degra ensaiss Engine ype sprcifctions | Pulley eusioe | yign SABOI70.A41 Nikko Denki, Open type 24,50 95 18h3 saso170.81 Nikko Denki, Open ype av, 128 96 7810 11-62 170-1 SERIESSTRUCTURE AND FUNCTION ELECTRICAL SYSTEM STARTING MOTOR erezrt49 1, Pliner 8.0,6,R,8: Termin! 2. Stating moor atenbty 2. Moartic itch 4. satay ey Eni Tyee Soeatiasons | gyN®-et, | — welt saot701 wnao eis smite — | zevrsew | 1 180 saeor7oat | wikkooenw.seansnor — | aav.rsxw | 1 1814 sasor70es | witkoomesseamaivn — | zav.raxw | an 18k 170-1 SERIES 11-63ENGINE 12 TESTING AND ADJUSTING FUEL SYSTEM Adjusting fuel solenoid 12-2 Adjusting engine stop motor : 12-3 Adjusting fuel injection pressure 12-4 Testing and adjusting tool ist 12-7 ‘TROUBLESHOOTING 2 12-9 170-1 SERIES 12-1TESTING AND ADJUSTING FUEL SYSTEM ADJUSTING FUEL SOLENOID FUEL SYSTEM B contact (electricity flows in ordinary operation) type Solenoid Stopper Stop lever Rod Rod s62F201 Adjusting method ‘Stop the engine and loosen the nuts of rod (4). 2, Adjust rod (4), so that the solenoid has a maximum stroke of 12 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, Turn on the engine starting key and confirm that solenoid has a stroke of 12 mm and there is elear- ance A of 0.40.1 mm, 4. After turning on and off the key several times, reconfirm the amount of the stroke of the solenoid and clearance A. 5. Tighten up the nuts of the rod, 12-2 Return spring A contact (electricity flows when stopped) type 1. Arrod forms a link between the solenoid and injec: tion pump. At this time, when the stop lever re- turns 1 £0. mm from the stop pin on the RUN side and the solenoid shaft is pushed by hand, the stop lever of the pump will be set in a position in which it has returned 1 + 0.5 mm from the stop pin, 2, Next, energize the solenoid and see if its movement is smooth, Turn the starting switch ON and OFF two to three times and confirm that the operation Condition does not change. If the operation is not smooth, adjust the linkage and carefully observe the movement. 3. Confirmation of Functions After confirming that the operation is smooth, start ‘the engine and confirm that the rated output can be ‘Obtained, Next, energize the solenoid and confirm ‘that the engine stops. (The engine should stop with- in 10 sec.) ‘Failures caused by faulty adjustment of solenoid ~ the clearance between the stop bolt and lever ls Owhen the solenoid i ‘nly partly ule) fnergized. + Breakage or scuffing of the injection pump gov. ‘rnor lan undue fores vill be applied to the over “When there ira large] » Engine power will nor Clearance between the be'generated because ftop lever and RUN side bot of fuel injection vahen the lever i roe Afauttytinkage) 170-1 SERIESTESTING AND ADJUSTING ADJUSTING ENGINE STOP MOTOR rocedure 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 + 0.8 mm, ‘then assemble fully. 3, Switch the stop motor on and off ten times, and ccheck 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 olear- ‘ance, adjust the hole position of the return spring (6). (If there is any clearance, the output power may drop.) 170-1 SERIES FUEL SYSTEM Fera610¢ Detail of stop lever Fere6105, 12-3TESTING AND ADJUSTING FUEL SYSTEM ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE) 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 (6). + Injection pressure adjusted per 0.1 mm shim ‘thickness: Approx. 15 kg/om? GBI Retaining cap: 9+ 1 kgm 4. After adjusting the thickness of shims, check the fuel injection pressure using nozzle tester. 162202 12-4 170-1 SERIESTESTING AND ADJUSTING FUEL SYSTEM DATA FOR INJECTION PRESSURE ADJUSTMENT SHIMS Engine model ‘im contour Shir thckree Shim hiekess seo1701 ers SABDI70.A4 — 0.50 — 1.84 mm 0.020% SAGD170-8-41 b=11.5 mm] Part No. ‘Thine rm) art No. “Wicks rm) (ok160528-5000 050 'DK150622.7800 1.06 k160522-5100 os2 1k150522-7900 1.08 10522-5200 os 1k150622.8000 110 10k150522.5900 ose k150522.8100 12 x180522.6400 ose 1k180522-8200 1a 1k150623-5600 080 1k 150529-8900 116 1k150622-5600 os 19k 150528-8400 138 x1 0520-5700 ose 10523-9500 120 k160529-5800 086 9k15052.8600 12 k180520-8900 ose 10k 18052.8700 124 10523-6000 070 ‘0k150522.8800 128 10523-6100 on 19x150522.8900 128 bx150523-6200 om 1ok150623.8000 130 10523-6900 076 1k150522.8100 132 0x150822.6400 o7 1k150522.8200 134 10K150622.6500 020 k150522.8200 126 19k150522.6600 os k180622.0400 138 10k150522.6700 ose ok 150522.0800 140 19k150522.6800 026 1k180523.8600 saz 19x150822.6900 ose ok150522.8700 148 19k150622-7000 090 k150622.8800 146 19k150622.7100 os 1k150523.8000 148 10k150622.7200 094 1k 150590-0000 1.80 10k150522-7200 096 1k150680.0100 182 1bk150522-7400 a9 10k160680.0200 188 1K150523.7500 1.00 1k150523-7600 102 x1 50523-7700 108 170-1 SERIES 12-5TESTING AND ADJUSTING FUEL SYSTEM PRECAUTIONS WHEN OPERATING THE ENGINE INDEPENDENTLY If the engine is operated independently on a bench oe 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 se e162F202 2. After completing running‘n or bench testing, fit 23406. the correct rear seal ‘Torque converter side or clutch side — + Precautions when fitting rear seal srezr203 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-L1 (lithium grease), 2). Be careful not to damage the rear seal when fi ting 12-6 170-1 SERIESTESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST PERFORMANCE TEST No. | Inspection and measuring item Fut fining tool PartNo. orks aa z Digital reading, presureconsing 1 | Ensine seed uteach 799-202.2000 | Distal radia resin 2 | sonery ss. 1.400 0 1.200| = Battery coolant tester | 795:500-1000 Freezing temperature 7 3 | cooling water -8'C 10 -s0°C Water tompersture, oll temperature, 4 oro 200% Biintake temperature Tomrminortempeetre | 790800:1900 5 | Exnaurt temperature 0 x0 1.000" 6 | Lubrication ot pressure 0 1010 kale? 7 | Fut pressure 0 020 kslem* 8 | ‘take presure,exneut presure | Enuinepremure measxing | 799.203.2002 [010 1.500 mtg 9 | Blow-by prewure © t0 1,000 mm, 0 10 | Airintake resistance 1,000 100 mmHt,0 11 | Compression pressure Ccomoresson gee kit | 796-5021208 [010 70 kalem® 12 | Blowby pressure Blow-by checker 790201-1803 |0 0.600 mmH,0 12 | vate clearance Feelr gauge 796.125.3940 | 0.41.0 mm Dirtinss 0 0 70% with standard 14 | extus ox color Handy smoke checker | 799:201.0000 | solar {Birines x 1/10 » Bosch scale) Provided with 01 and 0.2% water 18 | Water and fuel content ino Engine ol hacker 790-201-6000 | Provided with 0.1 end 0.2 16 | Fuel injection pressure Nozale tester Commercisy | 0 300 kafem* 17 | Fue injection nozzle spray condition 18 | coolant quatty Weter quality teeter 72202-7001 | pH, nitrite ton concentration 19 | Pressure valve performance Radiator cop tester 7092029001 Jo 10 2kafem* 20 | Leakage in cooling water system “Anemometer 21 | Raciator blockage (wind specs) | Anemometer 7902022001 |1 10.40 mie Cranking kt 795810-1000 | DC24V wit starting engine 22 | Engine cranking Baring device 6162:23-4820 | For 60170- series engine 23 | electrical circuits Tester Comererial'y | Curent, woltage, resistance ‘ualable 170-1 SERIES 12-7: TROUBLESHOOTING : CONTENTS No.of page METHOD OF READING TROUBLESHOOTNG TABLE. 1210 TROUBLESHOOTING TABLE 1. Staring detective or badness raz 2. Engine stopped tring operation 246 9, Engine nuns sbromaty. ee 4 Fuelconsumpton too igh 12468 5. Lackot power a7 6. Exhaust gsis bck. 1243 7. Exhaust gas is blue a1 8 Ob consumption oo gh 1220 8. Ollvel rises 1221 10, ilqucky becomes dy 1222 11. Engine oil pressure gauge indicator fluctuates abnormally ........ 12.23 12. Lack of oil pressure 12-24 13. Oilin cooling system = 12-25 14. Water temperature does not rise. .... 12-25 15. Water temperature rises excessively . : 12.26 16. Toomuch vibration .. : ae : 12.27 17. Abnormal noise emitted ............ : ae 1228 18. Excessive wear of engine parts ...... : : fo 2 19. Engine does not start because of fault in electrical system ........ oe a220 : 20. Battery does not charge . 212-31 170-1 SERIES 12-9TESTING AND ADJUSTING TROUBLESHOOTING METHOD OF READING TROUBLESHOOTING TABLE DESCRIPTION OF SYMBOLS USED IN TROUBLESHOOTING TABLE ‘The following symbols are used in the “Remedy” column to indicate the method of eliminating the cause of a fault X: Replace; Repai A: Adjusting; CC: Clean METHOD OF READING TROUBLESHOOTING TABLE ‘© The symbol O in the table is inserted only for causes which can be diagnosed. If a cause cannot be diag- nosed, the corresponding box is left blank. If the result of problems 1 using the troubleshooting table shown at right is abnormal, the cause of the trouble can be assumed to lie between a and d. Be- cause it is not possible to make a problems regarding @, it is necessary to perform the next problems (owing to the possibilty of a multiple fault) If the result of problems 1 is normal, the cause of the fault does not lie between a and d. In such a case, be- fore diagnosing the cause as e, however, carry out a ‘check by means of problems 2 or 5. ‘¢ If now the result of problems 1 is abnormal and the Example 1 result of problems 2 normal, the cause is one of a, for d. In addition, if the result of problems 3 is ab normal, the cause will be narrowed down to one of b ‘or d. To determine which of b or d is the actual ‘cause, perform problems 4. ‘© If the result of problemsis abnormal, blacken out the corresponding O in the table and then perform the oy seeasary next problems on these causes in order tonarrow the “°" Dtetiemy ly causes. Probleme lo Example 1: Problems 1 + Abnormal Probleme 2 Nomar | From the table of © Problems 3 > Abrovma | mle 1, the cause of Problems 4 Normal | the faut ib Example 2: From the table of e) ample 2, the cause of the fault ise. ‘+ In example 2, itis evident that the cause is @ without carrying out problems 2, however pro: blems 2 is performed by way of an additional check, Problems 1 -> Normal Problems 2 Abnormal 12-10 170-1 SERIESTESTING AND ADJUSTING TROUBLESHOOTING Example 3: Problems 1 Abnormal | From the table of ex: Problems 2+ Normal} ample 3, the cause is Problems 3-+ Normal | one of a, cand. Continue problems 4 From the table of ex- Problems 4 > Normal Problems 6 Normal | smple 31, the cause ise. z elefele 2 el Te 2 Ono 4 2) \@ . ele) Exam From the table of ex Problems 1-> Abnormal | Se ihe couse a Problems 2» Normal f S™Pa a Pec Continue problems 4 Problems 3» Abnormal | From the table of ex- Problems 4 -> Abnormal the cause Problems 5 -+ Normal ‘As can be seen from the above examples, sary to perform all of the problems. Also, looking at a particular cause, no matter how many ‘+ marks there are in the column corresponding to that cause, it will ceare to be an actual cause if there is even ‘one @ mark in the same eolumn, not neces- 170-1 SERIES 12-11TESTING AND ADJUSTING TROUBLESHOOTING eee TROUBLESHOOTING TROUBLESHOOTING TABLE 1. Starting defective or badness. 1) Engine does not turn, Questions to ask operator before starting trouble- shooting 1. Did machine stop suddenly during operation? > Damage or seizure of internal parts. 2. Did machine make abnormal noise during opera- aura bered note , 5 z als Cause: battery charging rate i [sé ee 8 3/5 i 2 eres | saox | cox | an | rx | 20m lL E/E/ | Ie] ele, Tempera es /8//4] | [3] [Flee 26 v2e | s28|ias|azslim |g Is/2/3/3/ 8} FJ Fie ef [oom fa Bala fle], /#/8/2/s/¢ Tee 120 | 128 | 126 | 125 | 128 eee das al AGUA eee oer geass 70% charging rate, 3/2/3/z/2/3/3/2/2/2/8/3 + Im cold weather, specific gravity must be at eRe e/g /e/R/s aif least figure for 75% charging rat. #/E//2/ (2/8/88 /2 /E/2 efefelefe]*]e/e/ififefi no. | Peon ner [fo aoa ao PRE] S When sting tn paring witch 9 START: Bi Ro sound of rnon owns oe 1 | 2) Pinion grates, oO 3) Pinion engages but does not turn. 0} O |O} O Jalo| 2 | Bstelna tenons ion ornate . Weg nung gn bara oo é 3 | 2) Moves backlash only. °o 3) Can be turned in reverse direction. bo }ire rove hed cor. When checking av cot, i 4 | citer ioc: wr When eeckina ve iO 5 | Eaten Whar chain era patsy] TS ae fo ‘The following symbols are used to indicate the ection {o> taken when a cause of fllure is located X: Replace A: Adjust 2: Repair ©: Clean 12-12 170-1 SERIESTESTING AND ADJUSTING 2) Engine turns but no exhaust gas is emitted. ‘Check before troubleshooting 7 1, Is there any fuel in fuel tank? 2. Is fuel feed valve open? 3. Is fuel piping leaking or damaged between fuel tank and injection pump? 4, Is there any leak from fuel filter? 5. Is there any water, rust or sludge mixed with fuel be taken when a cause offilure is located X: Reploce 2 Repair AL Adjust 2 Clean 170-1 SERIES 12-13TESTING AND ADJUSTING TROUBLESHOOTING 3) Exhaust gas is emitted but engine does not start. If there is always great difficulty in starting, lack of ‘output power is a possible cause, so perform this troubleshooting. 2, Is SAE3O oil being used at temperatures below 0°C? (Oil viscosity is too high) > At temperature below 0°C, use SAE1OW oil, 3, Is ASTM D975 No, 2 diesel fuel being used at tem- peratures below — 10°C? (Clogging caused by precipitated parafin) -> Use ASTM D975 No. 1 at ‘temperature below — 10°C. 4, Is fuel control lever bent? Is there any play? Is the pin out of place? No. Problems remedy fc] a |'a |x fox/ x xblex/ax, © xa} ‘Wha toring aarine woich to HEAT. Tat ord Wepwreuas® | 5 1 | SP ’Rtegrming sytem moune doesnot become warm 2) Check fe piping of euto-riming yee | Rotating weed of sarting motor to dow to ark 2 | engine. 0} ‘When checking beer electroiis lawl or pei S| aravity i t00 tow, 0} 4 | Enaine mars iar cleaner element removed 0 «| When removing injection ump tppet cover, contra) o ‘nok and ung go not move: 6 | BRE een rote wih ari we ol 7 | Comoresion presire it low; blow i hia 5 | vate cance not proper vel, | @ | triscton ting not proper portion, 5 7c lane doesnot apie air 10 | (ator maineorance) lo} The following symbols are used to indicate the action 10>e taken when a cause of fllue is located. X: Replace 4: Repair A: Adjust C: Clean 12-14 170-1 SERIESTESTING AND ADJUSTING 2. Engine stopped during operation. Questions to ask operator before troubleshooting. 1. Did engine stop slowly? -> Fuel supply cut. 2, Did engine stop suddenly? ~ Internal parts damag- ed or seized. 3. Did engine make abnormal noise? -> Parts damag- ed. Check before troubleshooting 1, Is there any fuel in fuel tank? 2. Is fuel control lever bent? Is there any play? Is the pin out of place? 3. Is fuel pipi tank and injection pump. 4, Is beed hole of fuel tank cap clogged? No, Problems 9 leaking or damaged between fuel TROUBLESHOOTING 1. | Starting motor eranks engine, but engine stone if gear shift Ievr is moved to any speed position. Starting motor does not crank engine. 11) Engine does not turn when eranking engine with barring tool. 2) Engine turns backlash distance only 3) Engine can be turned in reverse direction, 13. | No-fuel comes out even if injection pump bleed plug Is Toosened and priming pump operated. ‘When cranking engine with starting motor; 1) Injection pump (coupling) dose not rotate, 2) No fel comes out even if njtction pump bls 4 | 7 plug lorened. ae 3) No fuel spurts out even if injection pipe sloeve nut Is fooeened ‘When removing injection pump tappet cover, control ‘ack does not move, ee 170-1 SERIES Pee eieny 1to-be taken when a cause of failure it located. X: Replace ‘a: Repair AL Adjust : Clean The following symbols are uted to indicate the ection 12-15TESTING AND ADJUSTING ‘3. Engine runs abnormally. TROUBLESHOOTING 4, Fuel consumption too high. 11 Engine speed is too * Before starting the troubleshooting, ask the-operator cause Remedy why he noticed the fuel consumption was too high. ‘2 | Governor function defective Aa Cause Remedy tb | Governor adjustment defective External leakage of fust; 2) Engine does not stop. Cause Remedy Fuel tank, injection pump, | fuel ter and piping, xh {Common eaure wen fuel consumo- thon increas suddeniy) Fuel control lever linkage is bent: 2 | trees too much play: pin is out of ‘orition; something is catching. b | !tjgction pump control rack function fective Injection pump function defective © | art other than comret rack) Exoorive ful iniection, | Fal | poorfuel conmumpton ton this : ‘case exhaust gas is ). houet pa A xaos Bo meas Interna leakage of fut xe ‘Leakage from fuel tube inside 7 | mate ead cover Chanoe (inthiscam, ol oe rie and ot |i xah sols of tarnene) | Governor function defective 3) Hunting, couse Remedy ir sucking into system between oa * | fuer tank and feed pump 'b__ | Governor function defective xAA © | Governor adjustment defective a 6 | Itiection pump contro rack function detactve xh Set injection pump and governor on test stand. ‘when adjusting, ‘* Making up fuel pump by injecting more fuel than standard may damaged engine. 12-16 “The following symbols ae used to indicate the action tobe taken when a cause of failure is located. X: Replace ‘a: Repsie A: Adjust ©: Clean 170-1 SERIESTESTING AND ADJUSTING 5, Lack of power. % If lack of power is accompanied by black exhaust 92s, follow problems “6. Black exhaust smoke.” ‘* First troubleshoot whether the cause is in the en- gine or in the chassis as follows. ‘Measure torque conver ‘At torque converter oll stall sped. leachometer) ‘erpeeture aprox. and at Forward NG. [Goa higheit speed i A Serta [Problem with foeien with does not move, caer") (eee + Judge mainly checking for track tension, brake function, acceleration and engine hi when mounting DIRECT transmission, ‘Check before troubleshooting 1. Is fuel piping damaged or fuel leaking between fuel tank and injection pump? 2, Is bleed hole of fuel tank cap clogged? 3. Is tube damaged or leaking between injection ‘pump and nozzle holder? 4, Is incorrect fuel being used? 5. Is there any water, rust or sludge mixed with fuel drained from fuel tank? (Injection pump or nozzle are frequent causes of failure, (Check strainer clogged when no fuel comes out.) No. Probleme Fomedy TROUBLESHOOTING | Even with fuel control lever at FULL position, iniee tion pur lever doesnot contact to the fuletopper. When operating priming pump; 1"'No reaction or sight reection and quick return, 2) No reaction or slight reaction with normal return, (3 | No.fuel comes out eve if injection pump bleed plug istoosened and priming pum operated, 4 | Improper enginerunning happens by hunting, 5 | When checking wth nozzle eter, injection spray le fective or inection pressure i ow, 6 | No uel sours out even if injection pipe sleeve ut fs toowened, 7 | Some cylinder ite or no pulae when injection pipe is held between fingers. ‘Viner removing injection pump tappet cover and 8 | checking movement of control rack, does not move imoothiy. 170-1 SERIES 12-17TESTING AND ADJUSTING 6. Exhaust gas is black. ‘Check before troubleshooting 1. Is dust indicator red? > Air cleaner element clogged. 2, Is injection pump seal out of position? -> Pump out of adjustment (excessive injection), 3. Is air leaking between turbocharger and cylinder head? 4. Is standard spec. machine operating at high alti- tude? No Probleme Remedy 1 | Exhaust gos color improves when air cleaner element Isremoved. 2 | When checking with nozzle terter, defective injection spray ls defective or injection pressure stow. ‘Match marks of injection pump flange and coupling 13 | srarive case are not properly aligned. Checking injection timing by delivery method shows timing i out of adjurtment. 4 | Blowby is excenive, 5 | Compression pressure is ack, 6 | Valve clearance is too large oF to0 small. 7_| Exhaust gas color improves when muffler is removed. 8 | Turbocharger is sugoish when turned by hands. ‘9. | Exhaust gos color improves whan ins ion pump Is replaced, 12-18 X: Replace AL Adjust The following symbols are uted to indicate the ection tobe taken when a cause of fallueis located. TROUBLESHOOTING 2: Repair c 170-1 SERIES7, Exhaust gas is blue. (Combustion of engine oil) Check before troubleshooting 1, Has engine continued to run for over 20 mins at {ow idling? ~ Oil coming up into cylinder, oil leak from seal at turbocharger turbine side. 2. Has engine continued to run for over 20 mins ‘at high idling? > Oil coming up or down into ‘oylinder, oil leak from seal at turbocharger blower side. ‘3. Is turbocharger oil return pipe damaged? ~ oil leak from turbocharger seal. 1. | Inside of turbocharger intake pipe i costed with ol, 2 | Turbocharger shaft play is excessive. 3. | Compression pressure is ack. 4 | Blow. is excessive. lo 55 | When checking breather element, it is clogged with ‘6 | Remove cylinder head. When checking intake valve [cy _and valve guide, the clearance of ther ibis, 170-1 SERIES The foliowing symbols are used to indicate the action tobe taken when a cause of failure is located, X: Replace ‘a: Repair A: Adjust C: Clean 12-19TESTING AND ADJUSTING 8. Oil consumption too high. Before starting the problems, ask the operator why he noticed the fuel consumption was too high. + If answer isi “Oil consumption was high and e: haust ges was blue”, follow problems “7, Ex- hhaust gas is blue Check before troubleshooting * Is engine or engine lower part coated with oil, (Remove soll or mud, then check.) (it leaking out of engine (check around engine. TROUBLESHOOTING 2 | Cooting water is mixed with engine it Oil in main clutch or TORGFLOW transmission or dary 12-20 The following symbols are used to indicate the action tobe taken when a cause of fllue is located X: Replace ‘8: Repair AL Adjust ©: Clean 170-1 SERIESTESTING AND ADJUSTING 9. Oil level rises. (Mixed water or fuel) (Check before troubleshooting + Is the cooler of engine oil dirt — white? > Mixed water, 1 | Witer mixed with engine ot, TROUBLESHOOTING 2 | Fuet mixed with engine oi 5 2 | Olin main cutch or TOROF LOW transmission ‘or damper decreases. 9 “4. | Seol or seal contact face of hydraulic pump drive ‘Shaft is worn or damaged. 170-1 SERIES ‘The following symbols are used to Indicate the action 1t0_be taken when a cause of failure is located X: Replace ‘: Repair AL Adjust ©: Clean 12-21TESTING AND ADJUSTING 10. Oil quickly becomes dirty. Before starting the troubleshooting, ask the oper- ator the following questions. 1, Were oil and oil filter changed in accordance with ‘the “Operation and Maintenance Manual”? 2. Was improper oil used? Probleme Remedy /xA/ x | xis No. ‘Exhaust gas is blue when engine lsum at high epeed with ight fad. ‘Compression pressure is lack. ° Blow-by is excativ, 3 ‘ter running at high iain for approx, 10 mins. ol can be seen leaking from turbocharger turbine outlet, ° * 12-22 TROUBLESHOOTING 4 5 | Turbocharger shaft pay is excesve If the above problems does not reveal the cause, a common secondary cause of dirty oil is carbon from incom- plete combustion mixing with the oll. In this case follow problems in “6. Exhaust gas is black”. ‘The following symbols are used to indicate the action 10-be taken when 2 cause of fsilure is located, X: Replace ’a: Repair AL Adjust ©: Clean 170-1 SERIESTESTING AND ADJUSTING TROUBLESHOOTING 11, Engine oil pressure gauge indicator fluctuates abnormally. No. Probleme 7 | Olttevel in ott pan i t00 tow, {Check whether oil consumption is excesiv.) 2 | Fluctuation stops when gauge is replaced, 2 | Mounts in intrument panel are too, (Check direct) 14 | Rleaulator valve is etched, sring i fatigue, valve lor valve guide s damaged, (Check directly) 170-1 SERIES The following symbols are used to indicate the action 1to>be taken when a cause of fallue is located X: Replace ‘a: Repair As Adjust : lean 12-23TESTING AND ADJUSTING TROUBLESHOOTING aC33~“é$seeensevecs CCT ROUBLESHOOTING 12, Lack of oil pressure, (At engine speed of over 700 rpm, indicator of ‘engine oil pressure gauge isto left of “green range”) Question to be asked before starting trouble- shooting. {s 10W oil being used at temperatures above O°C? No. Olt lek fom hose or ta 1 | tcheck for sions of external ct eskege). ° 2 | water or fuel mixed with ol ‘o| 3 | Olin oll pans ack tno sign of externa oi leskege). To 4 | ovine oi presure i normal if gauge is replaced. io Olt hot, tube are clogged or demeged. © | check directly ° | Olt titers coused and safety valve function ie defective, (Cheek direetiy) io 7 | Mgt panicles are cought in ol ter element. REO.WA lott alysis! shows abnormality. lo} '@ | Remove oll pan, When checking oil sroiner i a logged or oll pipe is damage. Feoultor vale ctching spin fetgued, vie 8 | orate guide damaged (Check directv) ° 10 | Oitpump does not rotate smoothly and all ume shaft play is excessive. jlo The following symbols ae used to indiate the action to>be taken when a cause of fire is lcsted. X: Replace ‘: Repair A: Adjust : lean 12-24 170-1 SERIESTESTING AND ADJUSTING TROUBLESHOOTING 13. Oil in cooling system. ‘Cause Remedy 2 | Pipe broken in oil cooler, x (O-ring damaged b | Heed gasket damaged x © | Ovtinder head eracked x | cyiinder block cracked x 14, Water temperature does not rise, Water temperature gauge indicator is to left of “green range”. % In cold weather operation, if reversible fan ‘and radiator shutters are not fitted, the en- gine may not warm up. No. Probleme 1 | water temperature rises if gouge is replaced, ‘| When thermostat i removed, it is found to say open; 2 | orpertarmence test shown cracking temperatures” |) to low. The following symbols are used to Indicate the action t0>be taken when a caus of fallure is locate, X: Replace 4: Repair A: Adjust ©: Clean 170-1 SERIES 12-25TESTING AND ADJUSTING 18, Water temperature rises excessively. (Water temperature gauge indicator goes to right of “green range’; engine overheats) Bi Nover remove the reietor cap when the tom pero el igh Boling watery spurt ut tro eau rou borne 4 Wher the erune vereas, stpoing the engine ineveiny teas wr ro eoger eons by the water pomp. "Ase rest the tempurture of the pars being cooted res sarpty sn tis may ee ecige cae areas oe ae Before starting the troubleshooting, ask the oper- ator the following questions. 1. Is antifreeze being used in summer? 2. Is water being supplied according to the “Opera- tion and Maintenance Manual” ‘Check before troubleshooting 1, Is machine being operated under excessive load? 2. Is fan damaged or deformed? 3, Is belt groove of fan pulley or erank pulley worn? 4, Are radiator shutter and reversible fan being used properly? No.| Probleme Remedy TROUBLESHOOTING 1 | Coolant eve is too tow. 2 | Cooting water mixed with ol. 3 | Fenbele loosens. “4 | Radiator core is damaged or clogged with mud or ous rmperature between upper and lower 6 | Radiator is only stghtiy warm, 7 | Remove thermostat and check Ft, itis normal open), 8 | inate omperatur gage is replaced, i returns ° * If exhaust smoke is black, follow problems "6. Exhaust gas is black”. 12-26 “The following symbols ere used to indicate the action tobe taken when a cause of falure is located, X: Replace ‘8: Repair A: Adjutt ©: Clean 170-1 SERIESTESTING AND ADJUSTING 16. Too much vibration. TROUBLESHOOTING No.| Problems Remedy 1 | Engine mounting bolts re toate. (Check directv) Vibration damper i not warm to touch after oper 2 | tion, during operation, gar nine fe ateo excessive jlo 3 | Ala mixed in fuel system lo Engine uns abnormally ot low idling, (No arin Fuel 4 | ina exhaust eo color normal ° 5 | Exhoust ges inblack. | Wetor tmperature doesnot rie or res sowiy. I 7 | When checking injection nozzle with nozzle tester, n- Jeetion spray i defective or infection pressures to | tfestion pump sels aut of position, injection pump isout of adlustment. (Cheek airesty with tert stand) ‘9 | When loosening lection pie sleeve natin order at Jw iling, speed of some eviinder does not change. 10 | Ot pressure i low at tow ing emove cylinder ead when shocking fi, the Teppet oF 11 | ntake'end exhaust valves are abmormals| Pe 12 | The wear and clearance of front support pilot are fr 170-1 SERIES 12-27TESTING AND ADJUSTING 17. Abnormal noise emitted. * When noises indicating internal damaged are be- {ng emitted continuing to operate the machine ‘may make the damage worte. As far as possible, classify the abnormal noise to make location of the cause easier. ‘Type of noise; + Interface + Abnormal combustion Gears Internal, external Engine, power train Problems TROUBLESHOOTING 1. | Exterat or interference engine noise ooeure. 2 | Exhaust as is black, Combustion noise i abnormal, Tajeetion pump sal out of pasion. (Check injection volume on test stand.) ‘Water temperature does not rise. 6 | Vibration damper i nat warm to touch ater operation uring operation, gear noe is also excesive, 7 | When loosening injection pipe sleeve nut and setting engine to low idling, engine sped does nat cher Veve clearance is t00 large or too small Compression pressure slack; Blowy Is excesive, 10 lection spray Is detective or injection presture i om. Remove ol pan. When checking it, internal engine 11 | noises excessive, 12 | Remove gear cover. Gear noise is occured, When removing cylinder heed, Internal engine noe 13 | igexcestve. tit (Other causes of abnormal noise (direct check) ‘Cause Remedy The following symbols are used to indicate the action to>be taken when a couse of failure is located, PTO gear demaged or worn X: Replace 2: Repair ‘Air compressor darnaged AS Adjust ©: Chean “Turbocharger damaged 12-28 170-1 SERIESTESTING AND ADJUSTING TROUBLESHOOTING 18. Excessive wear of engine parts. Before starting the troubleshooting, ask the opera- ‘tor the following questions. 1. Is the specified oil being used? 2. Is the specified fuel being used? 3. Is the air cleaner element cleaned and replaced according to the “Operation and Maintenance Manual"? 4. Is the fuel filter element cleaned and replaced ‘according to the “Operation and Maintenance Manuat”? 5. Are the engine oil and oil filter element replaced ‘according to the “Operation and Maintenance rapid gear shifting? 7. 1s the machine warmed up before operation, and left idling before stopping engine ac- cording to the “Operation and Maintenance Manual"? wena eer mime | i; No. Probleme Remedy 1. | Diet gots into engine. (Check directv) eee ee 2 | ier o Fuel is mixed with ol. (See problems", Oil level lo 3 | ice") Water is mixed with ol, (See problems”, Oil level se" lO} = | Qian, (See problems 10, Oi quckiy becomes lo Sey were drains ov when ful tank ran pl & | removed O| The following symbols are used to indicate the action 1t0_be taken when 2 cause of fllure is located. X: Replace ‘8: Repair A: Adjust ©: Clean 170-1 SERIES 12-29TESTING AND ADJUSTING TROUBLESHOOTING 19. Engine does not start because of fault in electrical system. (Check starting circuit) BA Wren checking, tke care not 10 be eaugh in fon or other rotating ports engine sears, Check before troubleshooting 1. Is battery electrolyte level or specific gravity too low? ‘Check starting circuit for broken or disconnected wires, loose terminals or short circuits (Visual check) Battery ++ Safety relay <> Starting switch <> Battery relay switch > Battery 3, Immediately after repair, mistaken wiring con- nection is possible cause, When problems 1-1) “Engine does not turn’ ‘ives cause i “Electrical system defective”, use this problems. 1 terminals (B) and (C) of starting motor are connected, pinion maves out, 1 | Sparks are produced by this test io ‘When pinion movement Is confirmed, ciscan- neet-erminal immediatly 2 | {terminals (8) and (C) of starting switch are connected, engine will tart ‘Wterminas (b) and (E) of batery relay switch a 3 | connected, engine wil start, plug terminal of safety itch is connected to 4 | terminal (8) or (+) of starting motor, engine wil start. Oo | Eseminas 6) and () of wey rea re connected, |. ‘Starting motor does not turn even if No, 1 warting ‘motor terminals (8) and (C) are conne ‘The following symbols are used to indicate the action 10>be taken when a cause of fslure is located, X: Replace 3: Repair AS Adjust ©: Clean, 12-30 170-1 SERIESTESTING AND ADJUSTING TROUBLESHOOTING 20. Battery does not charge, (Check charging circuit) BA Wen checking, tke care not 10 be caught in fan or other rotating parte if engine starts Take care ato not 10 cause short ict, Before starting the troubleshooting, ask the opera- tor if the battery is old (in use for 2 or more years). Check before troubleshooting 1. Is alternator drive belt loose? 2. Check charging circuit for broken or disconnected wires, loose terminals or short circuits. (Visual ccheck, continuity check) Battery <> Starting switch > Ammeter <—> Alternator — Battery relay switch —> Battery. 3. Do lamps or heater exceed specified limit? Are they left on? * When engine is stopped and charged lamp stays on, or ammeter indicator deflects to one side, lamps are still on, or there isa short circuit, 4, Following repairs, mistaken wiring connec tion is possible cause. No. Probleme Remedy fd /dx) Ax [ax] x ‘During operation, detlaction of ammeter and charging 1 | amp are normal ° Continuity teat using taster shows; 1Y'Little oro continuity when terminals (AC) and (6) O of starting ewitch ae Connected. (with switch ON) 2. [72 When te sarin avian ON canto BEF Tne contiouty 31 Little oF no continuity between (+) terminal and 2} terminal of ammeter or charging lamp, ° 3 1 Run engine at medium speed (1,000 ~ 1,500 rpm) ona ‘ease charingvotoge with tse “ester does not show charging voltage (26 — 30V) 3 | petween terminal (E) and (Ft) of alternator jO}o] 0 “The following symbols are uted to indicate the ection tobe taken when a cause of failure is located. X: Replace 2: Repair A: Adjust, ©: Clean 170-1 SERIES 12-31ENGINE 13 DISASSEMBLY AND ASSEMBLY GENERAL Disassembly 13- 3 Assembly .... 13-21 ‘* The description of overall engine disassembly and assembly given in this section is based on the SAGD170-1 engine, assuming the use of an overhaul stand. ‘* The work procedure may differ slightly from that given here depending upon the ma chine in which the engine is mounted and also the particular stand used, however it is fundamentally the same. Use the correct service tools when performing disassembly and assembly. 170-1 SERIES 13-1GENERAL DISASSEMBLY CONTENTS No. Item Page No. ttem Page 1. | Starting motor 13-4 30. | Front support 1341 2 | Alternator 13-4 31 | Cover 1341 3. | Water pump 13-4 32. | Trunnion 1342 4 | Turbocharger oit drain tube 13-6 33. | Timer assembly 1342 5 | Oitcooter 13-5 34 | Accessory pulley 1342 6 | Placing engine on the stand 13-5 35. | Mechanical pump assembly 1342 7 | Aircleaner 13-5 36 | Injection pump drive case 1342 8 | Intake connector 13-6 37 | Cam follower assembly 1313 9 | Connector pipe 13-6 38 | Gear case cover 13413 10 | Fuel fitter 13-6 39. | Camshaft assembly 1314 11 | Aftercooler tube and lubrication | 13-6 40. | Main idler gear 1344 tube 41 | Idler gear for water pump gear | 13-14 12. | Fuel injection tube 13-6 42 | Idler gear for oi! pump gear 1344 13 | oitfinter 13-7 43 | Flywheo! 1344 14 | oit filer and oit love! 13-7 ae 44 | PTO drive gear 1345 15 | Tension spring and tension pulley | 13-7 ie paey 45 | Rear seal cover 1345 16 | Corrosion resistor 13-7 46 | Oilpan 13.15 17 | Thermostat case 13-7 47 | Strainer 1346 18 | Turbocharger and exhaust 13-8 ‘manifold assembly 48 | Oil pump piping 1346 19 | Aftercooler and intake manifold | 13-8 49. | Oil pump 13416 assembly 80 | Gear case 1346 20 | Fuel injection pump 13-8 fe ae tu cover : 2 | es ee 52. | Piston cooling nozzle 13417 Rocker arm assemb 3-9 oe . : 53 | Piston and connecting rod 1347 23. | crosshead 13-9 assombly 24 | Push rod 13-9 54 | Crankshatt assembly 13418 25 | Nozzle holder 13-9 85 | Cylinder liner 1319 26 | Rocker arm housing 1340 27 | Cylinder head 1340 28 | Crankshaft pulley 1341 28 | Vibration damper 1311 13-2 170-1 SERIESDISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY GENERAL DISASSEMBLY Prepared special toot ‘Marke PartNo. PartName | Q'ty ‘| 790-601-2000 | Engine repair stand | 1 ‘A, | 790-001-1170 | + Repair stand bracket | 1 8 _ | 796-102-4210 | Spring compressor | 1 © | 795-100-1181 | Timer remover 1 'D__| 795-100-1101 | Piston ring toot 1 © | 795-102-1300 | Liner puller 1 ‘© Preparation work 1. Cleaning Remove sand and soil from the engine, before disassembling it. 2. Engine stand Prepare the stable stand on which the engine can be placed securely. 3. Drain oil Drain the engine oil. ‘wer Engine oll pan: Approx.4t & 170-1 SERIES 13-3DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY 1. Starting motor 1) Remove starting motor (1). 2) Remove starting motor (2), 2. Alternator 1) Remove adjustment plate (1), then loosen the ‘mounting bolt and nut, and remove belt (2) 2) Remove mounting bolt and nut (3), and remove alternator (4). 3) Remove bracket (5). 7, 3, Water pump (See photo No. 6162°007, 6162P008) 1) Disconnect water pipe (1). 2) Remove the plate, then disconnect water pipe (2. 3) Remove water pump (3). 4) Remove the drive shaft, Bp yt & 3 Pretice, Sa tae ferezroo7! 13-4 170-1 SERIESDISASSEMBLY AND ASSEMBLY 4. Turbocharger oil drain tube Remove turbocharger oil drain tube (1). 5. Oil cooler 1) Remove water tube (1). 2) Remove oil cooler (2). 6. Placing engine on the stand 1) Install bracket A, for the engine repair stand ‘A.using the threads for the oil cooler. 2) Hang engine assembly (1) and set it to the en- sine repair stand A. % Tighten the bolts on the engine repair stand seourely. 7. Air cleaner Remove air cleaner (1). 170-1 SERIES GENERAL DISASSEMBLY 13-5DISASSEMBLY AND ASSEMBLY 8, Intake connector 1) Remove bracket (1). 2) Disconnect intake connector (2). 9. Connector pipe 1) Disconnect tube for boost compensator (1). 2) Remove the plate, and disconnect connector Pipe (2). 10, Fuel fi 1) Disconnect fuel hose for APS. . 2) Disconnect fuel hoses and remove fuel filter. 11. After-cooler tube and lubrication tube 1) Disconnect after-cooler tube, 2) Disconnect turbocharger lubrication tube, 12, Fuel injection tube Remove the clamp, and disconnect fuel injection ‘tube (1), 13-6 GENERAL DISASSEMBLY forezror 170-1 SERIESDISASSEMBLY AND ASSEMBLY 13, Oil filter Remove oil filters (1) and the bracket, 14, Oil filler and oil level gauge 1) Remove oll filler (2). 2) Remove ofl level gauge (3). 15, Tension spring and tension pulley 1) Loosen lock nut (1) and bolt (2) and remove ‘tension spring (3) by lengthening it. 2) Remove tension pulley (4). 16. Corrosion resistor Remove corrosion resistors (1). 17, Thermostat case Remove thermostat case (1). % Disassemble thermostat case as follows: 1) Remove case cover and remove thermostat. 170-1 SERIES GENERAL DISASSEMBLYDISASSEMBLY AND ASSEMBLY 2) Remove thermostat seal (3). 18. Turbocharger and exhaust manifold assembly Lift out turbocharger and exhaust manifold assem- bly (1) asa unit. 19, After-cooler and intake manifold assembly Lift out after-cooler and intake manifold assem- bly (1) asa unit. 20. Fuel injection pump 1) Disconnect tubric ‘tube (1). 2) Remove fuel injection pump (2). GENERAL DISASSEMBLY srezr114 170-1 SERIESDISASSEMBLY AND ASSEMBLY 21. Spill tube, he 1) Disconnect spill tube (1), 2), Disconnect turbocharger lubrication tube (2). 3) Disconnect connection (3) and remove head ‘cover (4). 4) Remove rubber packing (5) from head cover (4). 22. Rocker arm assembly Remove rocker arm assembly (1). * When installing the rocker arm, loosen the lock rut and loosen adjustment screw (2) 2 to 3 turns to prevent the push rod from pushing up. 23. Crosshead Remove crosshead (1), 24. Push rod Remove push rod (2). 25, Nozzle holder Remove mounting bolt (1), and remove nozzle holder (2). 170-1 SERIES GENERAL DISASSEMBLY 13-9DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY 28. Rocker arm housing 1) Remove pin (1), and hit move it ipe (2) with a bar to 2) Remove rocker arm housing (3). 27. Cylinder head 1) Remove cylinder head mounting bolt (1) 2) Fit sting bot @ (thread dia. 12 mm, pitch = 1.78) and lift out cylinder head (2). CE) oytindr head: 40 kg % Disassemble cylinder head assembly as follows: j) Using tool B, compress spring (3), then re- move the valve cotter. i) Remove retainer (4) and valve spring (6). i) Remove lower seat (6), then remove intake valve (7) and exhaust vaive (8). 1627038 13-10 170-1 SERIESDISASSEMBLY AND ASSEMBLY 28. Crankshaft pulley 1) Disconnect lubrication pipe (1). 2) Remove crankshaft pulley (2). 29, Vibration damper 1) Remove spacer (1). 2) Titten forcing screw @) to remove damper @. ‘* While tightening the forcing screw, take care ‘not to drop the vibration damper. 30. Front support Lift out front support (1). 31, Cover Remove cover (1). 170-1 SERIES GENERAL DISASSEMBLY 1627029) e1e2P042| 13-11DISASSEMBLY AND ASSEMBLY 32. Trunnion Tighten the forcing screw to remove trunnion (1). ‘* When replacing the front seal, remove oil seal (2). 33, Timer assembly Using tool C, remove timer assembly (3). ‘* Hit the end face of tool C with a hammer to re- ‘move timer assembly which is force-fitted. ‘34, Accessory pulley 1) Remove accessory pulley (4). 2) Remove pulley (5) for alternator belt. 35, Mechanical pump assembly Remove mechanical pump assembly. 36. Injection pump drive cate Remove coupling (1), then remove i GENERAL DISASSEMBLY rez? e162P088 jection pump j drive case (2), 13-12 170-1 SERIESDISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY ‘37. Cam follower assembly 1) Remove cover (1). 2) Remove cam follower assembly (2). 38. Gear case cover Remove 24 bolts (4), then remove gear case cover (1) 170-1 SERIES 13-13DISASSEMBLY AND: ASSEMBLY GENERAL DISASSEMBLY 39, Camshaft assembly Remove camshaft assembly (1). % Remove the camshaft assembly by rotatir protect the cam bushing from being damaged. C5) camshaft assembly: 32 kg 40. Main idler gear Remove mounting bolt (1), then remove main idler ear (2). 41. Idler gear for water pump gear Remove mounting bolt (3), then remove idler gear assembly (4) for water pump gear. 42. Idler gear for oil pump gear Remove mounting bolt (5), then remove idler gear (6) for oil pump gear. 43, Flywheel Using the sling bolts (thread dia. 12 mm, pitch = 1.75), lift out flywhee! (1) 13-14 170-1 SERIESDISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY 1) Remove steering pump drive gear (1) from the case hole. 2) Remove the six set bolts, and remove PTO drive gear (2). A. Bmore 6 mounting bolts while sup Porting the PTO drive gear by hand. If the PTO drive gear is not supported, it ‘may fall when the bolts are removed. + Disassemble PTO driving gear as follows: i) Remove bearing retainer (3) and shim (4). 61627057 48. Rear seal cover Remove rear seal cover (1), 46, Oil pan Remove oil pan (1). 170-1 SERIES 13-15DISASSEMBLY AND ASSEMBLY 47. Strainer Remove oil strainer (1). 48. Oil pump piping Disconnect tube (3). 49. Oil pump Remove oil pump (1). 50. Gear case Remove gear case (1). 51. Flywheel housing Lift out flywheel housing assembly (1) Flywheel housing: 290 kg 13-16 GENERAL DISASSEMBLY 170-1 SERIESDISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY 52, Piston cooling nozzle Remove piston cooling nozzle (1). ‘53, Piston and connecting rod assembly 1) Check the No. embossed on the connecting rod cap. (Check that the cap'No. and cylinder No. agree with each other and that the embossed mark is fon the cam side.) % If there is no mark, emboss @ mark before dismounting the cap. 2) Rotate crankshaft so that the piston to be re- ‘moved locates to the B.D.C. position, 3) Remove carbon deposits from the upper wall of the liner using fine sandpaper. If necesay, use dial gauge @) to mensre the end play ofthe connecting rod before removing the piston and connecting rod tssombly. 4) Remove bolt (1) of connecting rod cap. ae. 62Po8a, '5) Remove connecting rod cap (2) together with the connecting rod bearing while tapping it lightly with a plastic hammer to prevent damag- ing the thread of the connecting rod bolt. 6) Extract the piston and connecting rod assembly from the oil pan side using a wooden rod or the like. During this operation, support the posi- tion at the cylinder head side to prevent damag- ing the inside of the cylinder liner. * Temporarily fit the connecting rod and cap to- gether, and place them along side the bearing so a to ensure that these part are assembled to- gether correctly. ‘* Disassemble piston and connecting rod assembly i) Remove the snap ring. a , extract piston pin (3) and disconnect the - ¢ 3 170-1 SERIES 13-17,DISASSEMBLY AND ASSEMBLY iii) Remove piston ring (4) using tool D. % Arrange the piston, connecting rod, bear- ing, piston ring and piston pin of each cylinder No. together. 54. Crankshaft assembly 1% I necessary, use dial gauge (@) to measure the ‘end play of the crankshaft before removing the crankshatt assembly. 1) Remove mounting bolt (2) of main bearing cap, a. 2). Install bolt into the main bearing cap hole, and, remove the cap while moving it, * Check the position of thrust bearing install- ed the No. 6 main bearing cap, 3) Lift out erankshat (8) using avon ang. CEE) crankshatt assembly: 260 ky 4) Remove upper bearing. 13-18 GENERAL DISASSEMBLY 6162P072, 8162P072 170-1 SERIESDISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY 55. Cylinder liner % If necessary, measure the liner protrusion using dial gauge 2). Remove cylinder liner (1) using too! E. 170-1 SERIES 13-19GENERAL ASSEMBLY CONTENTS No. teem Page No. Item Page + | Cylinder tiner 1322 32 | Nozzle holder 1337 | crankshatt 13:24 33 | Push rod 1337 3 | Piston and connecting rod 13.26 34 | Rocker arm assembly 13.37 assembly, 35 | Adjustment of vave clearance | 1338 4. | Piston cooling nozzle 13.28 36 | Head cover and spill tube 1338, 5 | Flywheel housing asembi 13:28 i 2 v 37 Fuel injection pump 13:39 6 | Gearcase 1329 38 | After-cooler and intake manifold | 13:39 7 | tater gear 13.29 assembly 8 | camshaft assembly 13.29 39 | Turbocharger and exhaust 1339 manifold assembly @ | taler gear for oi! pump 1330 40 | Thermostat case 13.40 10 Idler gear for water pump 13-30 a 41. | Corrosion resistor 1340 11. | Injection pump drive case 13.30 42 | Tension pulley and tension spring | 13-4 12° | Timer assembly 13-30, ares sales! ° 43 | Oilfiller and tevel gauge guide | 13.40 13 | Gear cover 13-31 epee 44 | Oi ter assembly 1340 16 | ov pump 1331 | 45 | Fuel injection tube 13.41 15 | Piping for oil pump 13-31 46 | Aftercooler tube and oi iter | 13-41 16 | Strainer 1331 tube 17 | Oil pan 1331 47 | Fuel fiter assembly 1341 18 | Rearseal cover 1332 48 | Connector pipe 1341 19 | PTO drive goar 1332 49 | Intake connector 1341 20 | Fiywheet 1338 50 | Aircleaner assembly 1342 21 | Com follower assembly 13.33 51 | Setting off engine from engine | 1342 22 Mechanical pump assembly 13-33 ual 23 =| Accessory pulley 13-33 52 | Oil cooler 1342 | eo 53. | Drain tube of turbocharger 1342 S| aa | 54 | Water pump assombly 1343, oo o 55 | Akeretor 13.43 27 | Vibration damper 13-34 86 | Starting motor mad 28 | crank pulley 13.38 29 | cylinder head assembly 13.96 30. | Rocker arm housing 1338 31_|_Crosthead assembly 13.37 13-20 170-1 SERIESDISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY Prepared special tool Tok Pacname [ery A Encne eared [7208018170 | Repair wanatrcter | 1 8 | 7957022102 | Serncommenor | © | 726100761 | Paton soo! 7 7oeaa611 | ner rier 7 : 790-101-5221 Grip, i. © | _7esa261700 | Peson rower 1 # | 7asa6-0 | Fier ae 7 170-1 SERIES GENERAL ASSEMBLY 13-21DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY 1. Cylinder finer % Be sure to use the new liner O-rings whenever the liner is removed. ‘* Method of installing the liner O-ring and clevis seals: 1) Confirm that the grooves for the liner O- rings and the liner are not made coarse by pitting, rusting, ete, + I coarse, replace the liner to prevent water leakage. 2) Apply engine oll CLASS CD SAE3O to the ‘grooves of the liner, O-rings and clevis sea. 3) Install the clevis seal to the upper section of the liner groove while pressing the all round of clevis seal when inserting the liner. 4) Install the finer O-ring and cle shown below. seal as (levis sea) ‘Black (Nii rubber Cylinder tinge ‘Grange (Silicone rubber) ) 61625205 13-22 170-1 SERIESDISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY % Before inserting the cylinder liner, prepare the cylinder block according to the following pro- cedure, 1) Remove the sale and rust from face @) and with sandpaper until the machine sur- face appears. 2) Polish portions @ and @ with sandpaper No. 60 ors 0 achieve a sooth curve 3) Polish portions ®, @® and © with sand- paper No. 60 or so. If there are sharp edges ‘or burrs on the curved surface, remove them with @ scraper or sandpaper. Finish this sur face especially smoothly to protect the O- rings from damage. e162F206 4) is pitted and can not be repaired, replace the cylinder block, 8) If face @ and portions @ and © ae pit- ted, finish them smoothly or chamfer them as shown in the figure at right. 6) Inspect the counterbore and remove burrs and fins, if any. If there are metal tips or dust on face ©), the liner will not perfectly ‘and will not have the correct amount of pro- jection, so water will leak. 4% If the counterbore is worn or pitted, re pair it, 170-1 SERIES 13-23DISASSEMBLY AND ASSEMBLY 4% Method of inserting the cylinder liner: 1) Apply engine oil CLASS CD SAE30 to the ‘O-ring grooves of cylinder block and O-ring. 2) With the ‘"T" stamped on the upper surface of the liner facing forward, insert the into the cylinder block, taking care not to ‘damage the O-ring. 3) Push in the liner with your weight. % If the liner cannot be inserted smoothly ‘when pushed hard, the O-ring may be damaged. Check the cylinder block for burrs and fins. 4) Forcesit cylinder liner (1) into the eylinder block using liner drive F. 5) After foreeitting the eylinder liner, meas- ure the amount of projection of the eyinder liner with dial gauge C1). 4 When maturing the amount of projec- tion of the cylinder line, press the liner firmly with the plate to protect it from being floated by the Oxing. + Amount of projection einer liner 0.07 00.18 mm 2. Crankshaft 1). Align the projection of upper bearing (1) with the notch on the cylinder block, and assemble them, % Check the reverse side of the bearing for foreign matter and apply engine oll CLASS CD SAE30 to the inside face of the bearing. ‘* When replacing the crank gear, put the gear in an electric furnace or similar device and hheat it at 200°C for about 30 minutes for shrink fitting. 13-24 GENERAL ASSEMBLY a stozrcee 170-1 SERIES