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SEBM008107

DIESEL ENGINE

2005 1
All Rights Reserved
Printed in Japan 02-05(02)

00-1
(7)

CONTENTS
No. of page

01

GENERAL ............................................................................................................ 01-1

11

STRUCTURE AND FUNCTION

12

TESTING AND ADJUSTING ................................................................. 12-1

13

DISASSEMBLY AND ASSEMBLY ..................................................... 13-1

14

MAINTENANCE STANDARD ............................................................... 14-1

15

REPAIR AND REPLACEMENT OF PARTS

00-2
1

........................................................... 11-1

.................................. 15-1

6D170-2

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6D170-2

TESTING AND ADJUSTING

FUEL SYSTEM

8. Rotate the crankshaft again in the normal direction and set to specified dimension c.
Specified dimension c:
4.19 +0.27
0.24 mm (BTDC 160.5)
(PC1100-6: 10001 20300)
5.29 +0.30
0.28 mm (BTDC 180.5)
(PC1100-6: 20301 and up)
7.86 +0.35
0.35 mm (BTDC 220.5)
(PC1100-6: tropical specification)
6.520.2 mm (20 before top dead center)
(D275-2)
7.80.2 mm (22 before top dead center)
(D375A-3, PC1000-1, PC1100-6:
tropical specification, WA700-3,
HD465-5)
Always rotate the crankshaft in the normal direction to align the position.
Continue to rotate the crankshaft and confirm
that the dial gauge reads 00.2 mm when the
No.1 cylinder is at the TOP (top dead center)
(the needles of the dial gauge rotate in the
reverse direction). If the indicated value is
beyond 00.2 mm, repeat 5 and 6 above.

9. At this time, check that fuel injection timing line


a on the fuel injection pump is aligned with line
b on the coupling.
10. If the lines are not aligned, loosen bolt (4) in the
oblong hole and move the coupling to align the
lines, then tighten the bolt.
11. After the adjustment, install the No. 1 nozzle
holder assembly according to INSTALLING
NOZZLE ASSEMBLY.

6D170-2

12-7
5

TESTING AND ADJUSTING

FUEL SYSTEM

Testing fuel injection timing by delivery valve


method.
Prepare new parts for the copper gasket and
O-ring of the delivery valve before starting the
opration.

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 positon.
For injection pumps with a stop lever set to
the OPERATION position.
4. Turn the crankshaft back 4050 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).
6. Check that the dial gauge reads specified dimension c at the point where the fuel stops flowing.
BELOW specified dimension:
Timing RETARDED
ABOVE specified dimension:
Timing ADVANCED
If the test shows that the fuel injection timing is
incorrct, adjust at the oblong hole of the flange
potrion ot 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.
Always replace the copper gasket and O-ring
of the delivery valvve with new parts.
3 Delivery valve holder:
113 5 Nm {11.5 0.5 kgm}
Note: 137 10 Nm {14.0 1.0 kgm} for
EP11 injection pump on the WD6003.
8. Connect fuel injection pipe (1).
3 Sleeve mut: 22 2 Nm {2.2 10.2 kgm}

12-8
3

6D170-2

TESTING AND ADJUSTING DATA

TESTING AND ADJUSTING

TESTING AND ADJUSTING DATA


S6D170-2

Engine model
Applicable machine model

Cooling system

Fuel
system

Lubrication system

Engine body

Intake and exhaust system

Performance

Classification

Item

Condition, etc.

D275A-2
Unit

Standard

Tolerance

High idling speed

rpm

2,000 40

2,000 40

Low idling speed

rpm

630 30

630 30

Necessary
starting speed

0C

rpm

Min. 130

-20C (with starting aid)

rpm

Min. 100

Intake resistance
Intake pressure
Exhaust pressure
(Turbine inlet
pressure)
Exhuast temperature (Turbine inlet
temperature)

At all speed
At rated output

kPa {mmH2O} Max. 3 {300}


7.5 {762}
kPa {mmHg} Min.126.7{950} 111.3 {850}

At rated output

kPa {mmHg}

Min.106.7{800}

96.0 {720}

Max. 650

700

Bosch scale
Bosch scale
Bosch scale

Max. 6.0

8.0

Max. 1.5
Max. 1.0

2.5
2.0

Engine speed

Exhaust gas color

All speed
(intake air temp.: 20C)
Quick acceleration
(Low idling High idling)
At rated output
At high idling

Valve clearance
(When engine is
Hot or cold)

Intake valve

mm

0.4

Exhaust valve

mm

1.0

Compression
pressure
(SAE30 or
SAE15w40 oil)

Oil temperature:
40C to 60C
(Engine speed:
210 250 rpm)

Mpa
{kg/cm2}

Min. 2.9
{Min. 30}

2.1
{21}

Blow-by pressure
(SAE30 or
SAE15w40 oil)

At rated output
kPa {mmH2O} Max. 3.9{400}
Water temperature:
Min. 70C

Oil pressure
(Oil temperature:
Min. 80C)

At rated output
SAE30 or
SAE 15w40 oil
SAE10W oil
At low idling
SAE30 or
SAE 15w40 oil
SAE10W oil

206 {2.1}
176 {1.8}

kPa {kg/cm2}

Min. 118 {1.2}

78 {0.8}

kPa {kg/cm2}

Min. 98 {1.0}

69 {0.7}

kPa {kg/cm2}

Oil temperature

All speed (oil in oil pan)

80 100

120

Oil consumption
ratio

At continuous rated output


(Ratio of fuel consumption)

Max. 0.5

1.0

Fuel injection
pressure

Nozzle tester

MPa {kg/cm2}

26.5 27.3
{270 278}

18.8
{274}

Fuel injection
timing

B.T.D.C.

Radiator pressure
vavle

Opening pressure
(Differential pressure)

kPa {kg/cm2}

Fan speed

At rated engine speed

rpm

1,200 40

1,200 40

Fan belt tension

Deflects when pushed with


a force of 58.8 N {6 kg}

mm

Auto tension
(

degree

Tolerance

7.9 {800}

392 539
{4.0 5.5}
343 490
{3.5 5.0}

kPa {kg/cm2}

Standard

200.5 {Std} 200.5 {Std}


200.5 {Cold} 200.5 {Cold}

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.

12-138
5

6D170-2

TESTING AND ADJUSTING DATA

TESTING AND ADJUSTING

SAA6D170-2

Engine model
Applicable machine model

Cooling system

Fuel
system

Lubrication system

Engine body

Intake and exhaust system

Performance

Classification

Item

Condition, etc.

HD465-5 (up to 4625)

WA700-3
Unit

Standard

Tolerance

Standard

Tolerance

High idling speed

rpm

2,270 30

2,270 30

2,450 50

2,450 50

Low idling speed

rpm

725 25

725 25

675 25

675 25

Necessary
starting speed

0C

rpm

Min. 130

Min. 130

-20C (with starting aid)

rpm

Min. 100

Min. 100

Intake resistance
Intake pressure
Exhaust pressure
(Turbine inlet
pressure)
Exhuast temperature (Turbine inlet
temperature)

At all speed
At rated output

kPa {mmH2O}

Max.3 {300}
Min. 120{900}

7.5 {762}
96 {720}

Max.3 {300}

7.5 {762}

Min. 126.7{950} 113.3 {850}

At rated output

kPa {mmHg} Min. 113.3{850}

100 {750}

Min. 126.7{950} 113.3 {850}

Engine speed

Exhaust gas color

All speed
(intake air temp.: 20C)
Quick acceleration
(Low idling High idling)
At rated output
At high idling

kPa {mmHg}

Max. 650

700

Max. 670

700

Bosch scale
Bosch scale
Bosch scale

Max. 4.5

5.5

Max. 4.5

5.5

Max. 1.0
Max. 0.5

2.0
1.5

Max. 1.5
Max. 1.0

2.5
2.0

Valve clearance
(When engine is
Hot or cold)

Intake valve

mm

0.4

0.4

Exhaust valve

mm

1.0

1.0

Compression
pressure
(SAE30 or
SAE15w40 oil)

Oil temperature:
40C to 60C
(Engine speed:
210 250 rpm)

Mpa
{kg/cm2}

Min. 2.9
{Min. 30}

2.1
{21}

Min. 2.76
{Min. 28}

1.96
{20}

Blow-by pressure
(SAE30 or
SAE15w40 oil)

At rated output
kPa {mmH2O} Max. 3.9{400}
Water temperature:
Min. 70C

7.9 {800}

Max. 3.9{400}

7.9 {800}

Oil pressure
(Oil temperature:
Min. 80C)

At rated output
SAE30 or
SAE 15w40 oil
SAE10W oil
At low idling
SAE30 or
SAE 15w40 oil
SAE10W oil

392 539
{4.0 5.5}
343 490
{3.5 5.0}

206 {2.1}
176 {1.8}

kPa {kg/cm2}

Min. 118 {1.2}

69 {0.7}

kPa {kg/cm2}

Min. 98 {1.0}

69 {0.7}

kPa {kg/cm2}
kPa {kg/cm2}

392 539
{4.0 5.5}
343 490
{3.5 5.0}
Min. 118 {1.2}
Min. 98 {1.0}

206 {2.1}
176 {1.8}
69 {0.7}
69 {0.7}

Oil temperature

All speed (oil in oil pan)

80 100

120

80 110

120

Oil consumption
ratio

At continuous rated output


(Ratio of fuel consumption)

Max. 0.5

1.0

Max. 0.5

1.0

Fuel injection
pressure

Nozzle tester

MPa {kg/cm2}

29.9 30.7
{305 313}

24.2
{247.2}

29.9 30.7
{305 313}

24.2
{247.2}

Fuel injection
timing

B.T.D.C.

degree

22 0.5

22 0.5

22 0.5

22 0.5

Radiator pressure
vavle

Opening pressure
(Differential pressure)

kPa {kg/cm2}

68.6 14.7
{0.7 0.15}

68.6 14.7
{0.7 0.15}

Fan speed

At rated engine speed

rpm

1,104 33

1,104 33

1,250 30

1,250 30

Fan belt tension

Deflects when pushed with


a force of 58.8 N {6 kg}

mm

The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

12-140
5

6D170-2

TESTING AND ADJUSTING DATA

TESTING AND ADJUSTING

SAA6D170-2
HD465 (4626 and up)

PC1100-6 (10001 20300)

PC1100-6 (20301 and up)

PC1100-6
(Tropical specification)

Standard

Tolerance

Standard

Tolerance

Standard

Tolerance

Standard

Tolerance

2,350 2,450

2,350 2,450

1,960 2,040

1,960 2,040

1,960 2,040

1,960 2,040

1,960 2,040

1,960 2,040

750 780

750 780

705 755

705 755

705 755

705 755

705 755

705 755

Min. 130

Min. 130

Min. 130

Min. 130

Min. 100

Min. 110

Min. 100

Min. 100

Max. 2.90 {300}


Min. 130 {950}

7.50 {762}
110 {850}

Max. 2.90 {300}


Min. 120 {900}

7.50 {762}
100 {720}

Max. 2.9 {300}


Min. 120 {900}

7.5 {762}
96 {720}

Max. 2.9 {300}


Min. 120 {900}

7.5 {762}
96 {720}

Min. 130 {950}

110 {850}

Min. 120 {900}

100 {720}

Min. 120 {900}

96 {720}

Min. 120 {900}

96 {720}

Max. 670

700

Max. 650

700

Max. 650

700

Max. 650

700

Max. 4.5

6.0

Max. 4.5

5.5

Max. 4.5

5.5

Max. 4.5

5.5

Max. 1.5
Max. 1.0

2.5
2.0

Max. 1.5
Max. 1.0

2.5
2.0

Max. 1.5
Max. 1.0

2.5
2.0

Max. 1.5
Max. 1.0

2.5
2.0

0.4

0.4

0.4

0.4

1.0

1.0

1.0

1.0

Min. 2.9
{Min. 30}

2.1
{21}

Min. 2.9
{Min. 30}

2.1
{21}

Min. 2.9
{Min. 30}

2.1
{21}

Min. 2.9
{Min. 30}

2.1
{21}

Max. 3.9{400}

7.9 {800}

Max. 3.9{400}

7.9 {800}

Max. 3.9{400}

7.9 {800}

Max. 3.9{400}

7.9 {800}

390 540
{4.0 5.5}
340 490
{3.5 5.0}

210 {2.1}
180 {1.8}

390 540
{4.0 5.5}
340 490
{3.5 5.0}

280 {2.8}
250 {2.5}

392 539
{4.0 5.5}
343 490
{3.5 5.0}

275 {2.8}
245 {2.5}

392 539
{4.0 5.5}
343 490
{3.5 5.0}

275 {2.8}
245 {2.5}

Min. 120 {1.2}

70 {0.7}

Min. 120 {1.2}

70 {0.7}

Min. 118 {1.2}

69 {0.7}

Min. 118 {1.2}

69 {0.7}

Min. 100 {1.0}

70 {0.7}

Min. 100 {1.0}

70 {0.7}

Min. 98 {1.0}

69 {0.7}

Min. 98 {1.0}

69 {0.7}

80 110

120

80 110

120

80 110

120

80 110

120

Max. 0.2

0.5

Max. 0.2

0.5

0.2

1.0

0.2

1.0

29.9 30.7
{305 313}

27.3
{278}

26.5 27.3
{270 278}

21.5
{219}

26.5 27.3
{270 278}

21.5
{219}

26.5 27.3
{270 278}

21.5
{219}

21.5 22.5

16 16.5

17.5 18.5

21.5 22.5

1,160 1,240

1,160 1,240

1,050 1,110

1,050 1,110

1,046 1,110

1,046 1,110

1,046 1,110

1,046 1,110

Auto tension
(

Auto tension
(

6D170-2

12-141
5

MAINTENANCE STANDARD

TURBOCHARGER

TURBOCHARGER
KTR110

14-2
(7)

6D170-2

TURBOCHARGER

MAINTENANCE STANDARD

Unit: mm

No.
1

Check item

Criteria

End play
(play in axial direction)

Remedy

Standard size

Repair limit

0.08 0.13

0.18

0.25 0.44

0.60

Radial play
(play in radial direction)

Tolerance

Replace parts
related to
thrust
Replace parts
related to
bearing

Repair limit

Standard size
3

Outside diameter of journal bearing,


inside diameter of center housing

Inside diameter of journal bearing,


outside diameter of wheel shaft

Shaft

Hole

Shaft

Hole

25

0.050
0.067

+0.021
0

24.92

25.03

17

0.032
0.043

+0.009
0.003

16.95

17.04

Curvature of wheel shaft

Repair limit: 0.010 (total deflection of indicator)


Tolerance

Repair limit

Standard size
5

Thickness of thrust bearing


5

Groove

0.08
0.10

+0.02
0

4.86

5.04
Repair limit

2.3

0.08
0.10

2.15

2.3

0.01
002

2.35

0.08
0.10

1.85

1 Ring

0.03
0.04

2.05

2 Ring

0.11
0.12

4.05

Groove
Ring
Blower
end

Width

Tolerance

Turbine
end

Groove

Standard size
Ring

Thickness
of seal ring

Width

Replace

Groove

Clearance between blower housing


and impeller

6D170-2

Clearance limit: (Min.) 0.20

Replace parts
related to
bearing

14-2-1
(7)

MAINTENANCE STANDARD

TURBOCHARGER

KTR130

Unit: mm

No.

Check item

End play

Radial play

Outside diameter of journal


bearing.
Inner diameter of ceter
housing

Inner diameter of journal


bearing.
Outside diameter of wheel
shaft

Criteria
Standard

Repair limit

0.08 0.13

0.18

0.25 0.43

0.60

Tolerance

Repair limit

Hole

Shaft

Hole

30

0.060
0.080

+0.020
0

29.89

30.04

20

0.030
0.045

+0.015
0

19.95

20.05

Replace

Repair limit: 0.010 (Total indicated runout)


Tolerance

Repair limit

Standard
size

Shaft

Hole

Shaft

Hole

0.80
0.11

+0.02
0

5.86

6.04

0.08
0.10

0.03
0.04

2.85

3.05

Thickness of seal ring

Clearance between blower


housing and impeller

Tightening torque of
blower impeller locknut

78.5 88.3 Nm {8.0 9.0 kgm}

Tightening torque of
insrt bolt

11.7 14.7 Nm {1.2 1.5 kgm}

10

Tightening torque of
V-band locknut

7.8 9.8 Nm {0.8 1.0 kgm}

(7)

Replace parts

Shaft

Thickness of thrust bearing

14-2-2

Replace parts

Standard
size

Bend wheel shaft

Remedy

Tolerance: (min.) 0.20

Replace parts

Tighten

6D170-2