Shop Manual 12V170-2 Series Sebm036601 PDF

SEBM036601
© 2005
All Rights Reserved
Printed in Japan 02-05(02) 00-1
(1)
CONTENTS
No. of page
01 GENERAL ........................................................................................................................... 01-1
11 STRUCTURE AND FUNCTION ........................................................................ 11-1
12 TESTING AND ADJUSTING ............................................................................... 12-1
13 DISASSEMBLY AND ASSEMBLY ................................................................ 13-1
14 MAINTENANCE STANDARD ........................................................................... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ........................................ 15-1
00-2 12V170-2
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
q 00-1 (1) 11-8 12-8 12-131 13-4
00-2 11-9 12-9 12-132 13-5
Q 00-2-1 (1) 11-10 12-10 12-133 13-6
Q 00-2-2 (1) 11-11 12-11 12-134 13-7
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00-6 11-15 12-15 12-138 13-11
00-7 11-16 12-16 12-139 13-12
00-8 11-17 12-17 12-140 13-13
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00-18 11-27 12-106 12-207 13-23
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00-22 11-31 12-110 12-211 13-27
11-32 12-111 12-212 13-28
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01-2 11-35 12-113 12-214 13-30
01-4 11-36 12-114 12-215 13-31
01-6 11-37 12-115 12-216 13-32
01-7 11-38 12-116 12-217 13-33
01-8 11-39 12-117 12-218 13-34
01-9 11-40 12-118 12-219 13-35
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01-11 11-44 12-120 12-221 13-37
01-50 11-45 12-121 12-222 13-38
01-51 11-46 12-122 12-223 13-39
01-52 12-123 12-224 13-40
12-1 12-124 12-225 13-41
11-1 12-2 12-125 12-226 13-42
11-2 12-3 12-126 12-227 13-43
11-3 12-4 12-127 13-44
11-4 12-5 12-128 13-1 13-45
11-5 12-6 12-129 13-2 13-46
11-6 12-7 12-130 13-3 13-47
12V170-2 00-2-1
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13-49 14-16 15-47
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13-53 14-20 15-51
13-54 14-22 15-52
13-55 14-23 15-53
13-56 14-24 15-54
13-57 14-25
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13-59 15-1
13-60 15-2
13-61 15-3
13-62 15-4
13-63 15-5
13-64 15-6
13-65 15-7
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13-67 15-9
13-68 15-10
13-69 15-11
13-70 15-12
13-71 15-13
13-72 15-14
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13-74 15-16
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13-76 15-18
13-77 15-19
13-78 15-20
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13-80 15-22
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13-82 15-24
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q 14-2 (1) 15-34
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00-2-2 12V170-2
(1)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
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 onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
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" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ 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.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
APPLICABLE MACHINE................................... 01- 2

SPECIFICATIONS............................................. 01- 4
GENERAL ASSEMBLY DRAWING................... 01- 6
WEIGHT TABLE................................................ 01-11
ENGINE PERFORMANCE CURVE .................. 01-50
12V170-2 01-1
GENERAL APPLICABLE MACHINE
APPLICABLE MACHINE
Engine Engine serial No. Applicable machine
D575A-3 (Super dozer) Bulldozer

SA12V170E-2
D575A-3 (Ripper) Bulldozer
01-2 12V170-2
GENERAL SPECIFICATIONS
SPECIFICATIONS
Engine model SA12V170E-2
D575A-3 D575A-3
Applicable machine
(Super dozer) (Ripper)
Number of cylinders – Bore x Stroke mm 12 – 170 x 170
Total piston displacement l {cc} 46.3 {46,300}
Firing order R1 – L6 – R5 – L2 – R3 – L4 – R6 – L1 – R2 – L5 – R4 – L3
Overall length mm 2,766

Dimensions
Overall width mm 1,720
Overall height (excluding exhaust pipe) mm 2,805
Overall height (including exhaust pipe) mm —
Flyweel horsepower kW {HP}/rpm 863 {1,157}/1,800 (Net) 783 {1,050}/1,800 (Net)
Maximum torque Nm {kgm}/rpm 5,660 {577}/1,300 (Net) 5,080 {518}/1,300 (Net)

Performance
High idling speed rpm 1,950 – 2,050 1,950 – 2,050
Low idling speed rpm 600 – 700 600 – 700
Minimum fuel consumption ratio g/kW•h{g/HP•h} 211 {157} 211 {157}
Dry weight kg 6,680
Fuel pump KOMATSU high pressure in-line type x 2
Governor Electronic control allspeed type
Lubricating oil amount (refill capacity) l 195
Coolant amount l 298
Alternator 24V, 75A
Starting motor 24V, 11kW x 2
Battery 12V, 200Ah x 4
Turbocharger KOMATSU KTR110L x 2 (water cooled type)
Air compressor —
Others With after cooler
01-4 12V170-2
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

SA12V170E-2 VIEW FROM LEFT SIDE (D575A-3)
a. Center of crankshaft
b. Rear face of flywheel housing
01-6 12V170-2
SA12V170E-2 VIEW FROM RIGHT SIDE (D575A-3)
b. Rear face of flywheel housing
12V170-2 01-7
SA12V170E-2 VIEW FROM FRONT (D575A-3)
b. Center of cylinder liner
01-8 12V170-2
SA12V170E-2 VIEW FROM REAR (D575A-3)
a. Crankshaft center
b. Cylinder liner center
12V170-2 01-9
DIMENSION TABLE
a These dimensions are reference values for
use when installing to a test bench.
Dimensions for each part (mm)

Engine Machine model
A B C D E F G H
SA12V170E-2 D575A-3 2,288 294 1,745 785 517 869 670 700
01-10 12V170-2
GENERAL WEIGHT TABLE
WEIGHT TABLE
Unit: kg
SA12V170E-2
No. Item Component
D575A-3
1 Turbocharger KTR110L (water cooled type) 24 x 2
Cylinder head, valve and valve

2 Cylinder head assembly 37
spring
Cylinder block, main bearing cap

3 Cylinder block assembly 1,500
and cylinder liner
4 Gear case cover 106
5 Timing gear case 80
6 Oil pan 118
7 Flywheel assembly Flywheel and ring gear 99
8 Flywheel housing 147
9 Crankshaft assembly Crankshaft 419
10 Camshaft assembly Camshaft, cam gear and thrust plate 33
Piston, piston ring, piston pin and

11 Piston and connecting rod assembly 21
connecting rod
12 Oil pump 45
Left bank: 47
13 Fuel injection pump
Right bank: 30
14 Water pump 33
15 Alternetor 13
16 Starting motor 20 x 2
17 After cooler 26
18 Air compressor —
19 Oil cooler 148
20 Vibration damper 115
21 Fan 123
22 Filter bracket 127
23 Front support 21
24 Rear support 68
25 Crank pulley 29
26 Tension pulley assembly 38
12V170-2 01-11
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE

Engine Engine serial No. Machine model Page
D575A-3 (Super dozer) 01-51

SA12V170E-2
D575A-3 (Ripper) 01-52
01-50 12V170-2
SA12V170E-2 (FOR D575A-3 SUPER DOZER)

Flywheel horsepower: 917 kW {1,230 HP} /1,800 rpm (Gross)
Maximum torque: 5,820 Nm {594 kgm} /1,300 rpm (Gross)
12V170-2 01-51
SA12V170E-2 (FOR D575A-3 RIPPER)

Flywheel horsepower: 843 kW {1,130 HP} /1,800 rpm (Gross)
Maximum torque: 5,240 Nm {535 kgm} /1,300 rpm (Gross)
01-52 12V170-2
11 STRUCTURE AND FUNCTION
GENERAL STRUCTURE ...................................11- 2

AIR CLEANER ...................................................11- 4
TURBOCHARGER.............................................11- 5
AFTER-COOLER ...............................................11- 6
CYLINDER HEAD ..............................................11- 8
CYLINDER BLOCK ............................................11-10
MAIN REVOLVING PART ..................................11-12
VALVE SYSTEM ................................................11-14
TIMING GEAR ...................................................11-16
FLYWHEEL AND FLYWHEEL HOUSING..........11-18
LUBRICATION SYSTEM CHART ......................11-19
OIL PUMP ..........................................................11-20
OIL FILTER, SAFETY VALVE ............................11-21
BYPASS FILTER ................................................11-22
OIL COOLER .....................................................11-23
OIL COOLER BYPASS VALVE ..........................11-24
PISTON COOLING VALVE ................................11-24
FUEL SYSTEM CHART .....................................11-25
FUEL INJECTION PUMP...................................11-26
FUEL PIPING .....................................................11-28
FUEL INJECTION PUMP DRIVE.......................11-30
FUEL INJECTION NOZZLE ...............................11-31
FUEL FILTER .....................................................11-32
COOLING SYSTEM CHART..............................11-34
WATER PUMP ...................................................11-36
WATER PUMP DRIVE .......................................11-37
THERMOSTAT ...................................................11-38
CORROSION RESISTOR..................................11-39
FAN DRIVE AND TENSION PULLEY ................11-40
ALTERNATOR....................................................11-42
STARTING MOTOR ...........................................11-44
STARTING AID ..................................................11-46
12V170-2 11-1
STRUCTURE AND FUNCTION GENERAL STRUCTURE
GENERAL STRUCTURE
1. Fuel injection pump 9. Head cover 17. Flywheel

2. Intake value 10. Rocker arm housing 18. Ring gear
3. Fuel injection nozzle 11. Cylinder head 19. Rear seal
4. Exhaust value 12. Turbocharger 20. Main bearing cap
5. Piston (FCD piston type) 13. Cam follower 21. Crankshaft
6. Rocker arm shaft 14. Camshaft 22. Oil pan
7. After-cooler 15. Cylinder block 23. Connecting rod
8. Push rod 16. Flywheel housing
11-2 12V170-2
STRUCTURE AND FUNCTION GENERAL STRUCTURE
24. Oil pump 29. Cross head

25. Front seal 30. Cylinder liner
26. Vibration damper 31. Piston cooling nozzle
27. Gear case cover 32. Water pump
28. Rocker arm 33. Oil cooler
12V170-2 11-3
STRUCTURE AND FUNCTION AIR CLEANER
AIR CLEANER
KOMACLONE TYPE (MULTICYCLONE a Details may differ according to the machine model.
TYPE)
EGB TYPE
1. Inner element A. Intake air port

2. Outer element B. To turbocharger (intake air port)
3. Air cleaner casing C. To muffler (dust)
4. Precleaner
Dust discharge method

Engine Machine model Type No. of elements
for precleaner
Komaclone, multicyclone Automatic discharge Inner cylinder 1,

SA12V170E-2 D575A-3
type (EGB type) (exhaust ejector) Outer cylinder 1
11-4 12V170-2
STRUCTURE AND FUNCTION TURBOCHARGER
TURBOCHARGER
KTR110L (WATER COOLED TYPE)
1. Blower housing 10. Thrust metal SPECIFICATIONS

2. V-band 11. Seal ring Type: Komatsu KTR110L
3. Defuser plate 12. Blower impeller (water cooled type)
4. Center housing Overall length:308mm
(water-cooled center A. Intake inlet Overall width: 305mm
housing is option) B. Intake outlet Overall height:287mm
5. Shroud C. Exhaust inlet Weight: 22.5 kg
6. Turbine housing D. Exhaust outlet
7. Turbine impeller E. Oil inlet
8. Seal ring F. Oil outlet
9. Metal G. Cooling water
12V170-2 11-5
STRUCTURE AND FUNCTION AFTER-COOLER
AFTER-COOLER
1. After-cooler body A: From water pump

B: To water manifold
C: Air inlet
D: Air outlet
11-6 12V170-2
STRUCTURE AND FUNCTION CYLINDER HEAD
CYLINDER HEAD
1. Water manifold
2. Rocker arm housing
3. Rocker arm housing cover
4. Cylinder head
5. Valve guide
6. Fuel injection nozzle
11-8 12V170-2
STRUCTURE AND FUNCTION CYLINDER HEAD
SPECIFICATION
Cylinder head
• Direct-injection type, fuel 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.
12V170-2 11-9
STRUCTURE AND FUNCTION CYLINDER BLOCK
CYLINDER BLOCK
1. Cylinder block
2. Cylinder liner
3. Crevice seal
4. O-ring
5. O-ring
6. Piston cooling nozzle
7. Main bearing cap
8. Main bearing cap side bolt
9. Main bearing cap bolt
10. Oil pan
11-10 12V170-2
STRUCTURE AND FUNCTION CYLINDER BLOCK
SPECIFICATION
Cylinder block
• Crankshaft: 7 bearing
• Camshaft: 7 bearings
Cylinder liner
• Wet type liner, tufftride treatment on bore surface
Liner seal
Top: Clevis seal (Ethylene propylene)
Middle: O-ring (Ethylene propylene: black)
Bottom: O-ring (Silicone rubber: red)
12V170-2 11-11
STRUCTURE AND FUNCTION MAIN REVOLVING PART
MAIN REVOLVING PART
1. Piston pin 9. Connecting rod bolt

2. Connecting rod 10. Crankshaft
3. Piston (FCD piston type) 11. Connecting rod bearing
4. Top ring 12. Connecting rod cap
5. 2nd ring 13. Crank gear
6. Oil ring (No. of teeth: 55)
7. Flywheel 14. Vibration damper
8. Thrust bearing
11-12 12V170-2
STRUCTURE AND FUNCTION MAIN REVOLVING PART
SPECIFICATION
• Special alloy steel forging, 7 bearings
• Journal surface: Induction hardening
Main bearing, connecting rod bearing

• 3-layer kelmet
• Upper main bearing: With oil groove
Connecting rod
• Alloy steel forging
Crankshaft
• Closed die forging
• Journal portion fillet portion: Induction hardening
Piston
Type Shaker type
• Ductile casting
• Forced lubricating oil cooling by piston cooling
nozzle
Piston ring
Engine Top ring 2nd ring Oil ring
Keystone Keystone Bevel cutter with coil expander,

Barrel face, inner cut, hard Inner cut, taper face, hard hard chrome plating
chrome plating chrome plating
SA12V170E-2
12V170-2 11-13
STRUCTURE AND FUNCTION VALVE SYSTEM
VALVE SYSTEM
11-14 12V170-2
STRUCTURE AND FUNCTION VALVE SYSTEM
1. Camshaft gear (No. of teeth: 44) 6. Collar

2. Camshaft 7. Cross head
3. Intake valve 8. Push rod
4. Exhaust valve 9. Cam follower
5. Rocker arm
SPECIFICATION
Camshaft
• Special carbon steel forging, 7 bearings
• Cam face and journal face: Induction hardening
Firing order
R1 – L6 – R5 – L2 – R3 – L4 – R6 – L1 – R2 – L5
– R4 – L3
12V170-2 11-15
STRUCTURE AND FUNCTION TIMING GEAR
TIMING GEAR
1. Water pump drive gear (No. of teeth: 34) 8. Idler gear (No. of teeth: 33)
2. Idler gear (No. of teeth:55) 9. Camshaft gear (No. of teeth: 44)
3. Camshaft gear (No. of teeth: 44) 10. Idler gear (No. of teeth: 85)
4. Idler gear (No. of teeth: 35) 11. Idler gear (No. of teeth: 34)
5. Fuel injection pump drive gear (No. of teeth: 36) 12. Crankshaft gear (No. of teeth: 55)
6. Fuel injection pump drive gear (No. of teeth: 36) 13. Oil pump drive gear (No. of teeth: 47)
7. Idler gear (No. of teeth: 27) 14. Idler gear (No. of teeth: 27)
11-16 12V170-2
STRUCTURE AND FUNCTION TIMING GEAR
12V170-2 11-17
STRUCTURE AND FUNCTION FLYWHEEL AND FLYWHEEL HOUSING
FLYWHEEL AND FLYWHEEL HOUSING
1. Flywheel housing
2. Rear seal (Lay down type)
3. Bracket
4. Flywheel
5. Ring gear (No. of teeth: 151)
11-18 12V170-2
STRUCTURE AND FUNCTION LUBRICATION SYSTEM CHART
LUBRICATION SYSTEM CHART
1. Oil pan 8. Main relief valve 15. Main gallery

2. Oil pump 9. Regulator valve 16. Rocker arm
3. Oil cooler bypass valve 10. Fuel injection pump 17. Piston cooling nozzle
4. Oil cooler 11. Turbocharger 18. Timing gear
5. Oil filter 12. Crankshaft 19. Bypass filter
6. Safety valve 13. Piston
7. Piston cooling valve 14. Camshaft W: Cooling water
12V170-2 11-19
STRUCTURE AND FUNCTION OIL PUMP
OIL PUMP
1. Idler gear (No. of teeth: 27) SPECIFICATION

2. Oil pump drive gear (No. of teeth: 47) Oil pump
3. Main pump body • Type: Gear type
4. Scavenging pump body • Speed: Engine speed x 1.170
5. Driven gear
6. Drive gear Oil pump relief valve
7. Main relief valve • Cracking pressure: 981 ± 98 kPa {10 ± 1 kg/cm2}
8. Regulator valve
Oil cooler regulator valve
a. Oil pump inlet (from oil pan) • Cracking pressure: 412 ± 29 kPa {4.2 ± 0.3 kg/cm2}
b. Oil pump outlet
c. Scavenging pump inlet
d. Scavenging pump outlet
11-20 12V170-2
STRUCTURE AND FUNCTION OIL FILTER, SAFETY VALVE
OIL FILTER, SAFETY VALVE
1. Filter bracket SECIFICATION

2. Filter case Oil filter
3. Filter element (Cartridge) • Filtration area: 0.84 m2 x 4 sets
4. Safety valve
Safety valve
a. Oil (from oil pump) • Cracking pressure (difference pressure):
b. Oil (to engine each component) 196 ± 20 kPa {2.0 ± 0.2 kg/cm2}
12V170-2 11-21
STRUCTURE AND FUNCTION BYPASS FILTER
BYPASS FILTER
1. Cover SPECIFICATION
2. Filter bracket • Filtration area: 1.4 m2 x 3
3. Cover
4. Filter (cartridge)
A. Oil outlet
B. Oil inlet
11-22 12V170-2
STRUCTURE AND FUNCTION OIL COOLER
OIL COOLER
1. Oil cooler cover SPECIFICATION

2. Oil cooler element Oil cooler
• Heat exchanged: Min. 105,600 Kcal/hr.
a. Coolant (from water pump) • Heat-transmitting area: 4.32 m2 (1.44 m2 x 3 sets)
b. Coolant (to engine each component) • Oil flow capacity: 465 l/min.
c. Oil (from oil pump) • Water flow capacity: 2,000 l/min.
d. Oil (to engine each component)
e. Oil (from oil filter)
f. Oil (to oil filter)
g. Coolant (to after cooler)
12V170-2 11-23
STRUCTURE AND FUNCTION OIL COOLER BYPASS VALVE, PISTON COOLING VALVE
OIL COOLER BYPASS VALVE
1. Cap SPECIFICATION
2. Spring • Cracking pressure: 392 ± 40 kPa {4.0 ± 0.4 kg/cm2}
3. Valve body
4. Piston
a. From oil pump

b. To oil filter
PISTON COOLING VALVE
1. Cap SPECIFICATION
2. Piston cooling valve • Cracking pressure: 127 ± 9.8 kPa {1.3 ± 0.1 kg/cm2}
3. Valve body
a. Oil (form oil filter)

b. Oil (to piston cooling nozzle)
11-24 12V170-2
STRUCTURE AND FUNCTION FUEL SYSTEM CHART
FUEL SYSTEM CHART

WITH ELECTRONICAL GOVERNOR
1. Fuel tank 6. Electronic control fuel injection pump (for L bank)

2. Hand priming pump 7. Fuel injection nozzle
3. Feed pump 8. Overflow valve
4. Fuel filter 9. Emergency stop solenoid valve (x2)
5. Electronic control fuel injection pump (for R bank)
12V170-2 11-25
STRUCTURE AND FUNCTION FUEL INJECTION PUMP
FUEL INJECTION PUMP

WITH KOMATSU ELECTRONICAL GOVERNOR
1. Delivery valve 7. Gear pump 11. Tappet

2. Plunger barrel Seen from rear 12. Pump housing
3. Plunger Left: Oil 13. Tappet guide
4. Hydraulic piston Seen from rear 14. Spring seat
5. Hydraulic control valve (metering) Right: Fuel
6. Hydraulic control valve 8. Center bearing
(fuel injection timing adjustment) 9. Camshaft
10. Roller
11-26 12V170-2
STRUCTURE AND FUNCTION FUEL INJECTION PUMP
SYSTEM DIAGRAM
1. Rack position sensor 4. Hydraulic control valve A. Fuel

2. Control rack 5. Gear pump B. Oil pressure
3. Hydraulic piston
12V170-2 11-27
STRUCTURE AND FUNCTION FUEL PIPING
FUEL PIPING
a The actual engine may be different because of
modifications.
1. Fuel injection pump (Right bank) 9. Fuel spill tube (Left bank)
2. Fuel injection pipe (Right bank No.1 cylinder) 10. Fuel injection pipe (Left bank No.6 cylinder)
8. Fuel spill tube (Right bank) 16. Fuel injection pump (Left bank)
11-28 12V170-2
STRUCTURE AND FUNCTION FUEL PIPING
17. Fuel inlet pipe (Right bank)

18. Fuel outlet pipe (Right bank)
19. Priming pump
20. Priming pump
21. Fuel inlet pipe (Left bank)
22. Fuel outlet pipe (Left bank)
12V170-2 11-29
STRUCTURE AND FUNCTION FUEL INJECTION PUMP DRIVE
FUEL INJECTION PUMP DRIVE
1. Fuel injection pump

2. Gear case
3. Drive shaft
4. Drive gear (No. of teeth: 36)
5. Idler gear (No. of teeth: 35)
11-30 12V170-2
STRUCTURE AND FUNCTION FUEL INJECTION NOZZLE
FUEL INJECTION NOZZLE
1. Nozzle holder SPECIFICATION

2. Nozzle spring • Maker: ZEXEL
3. Nozzle • Type: Bosch DLL-S type, multiple hole type
• Fuel injection pressure: 29.4 +1.3 +13 2
4. Nozzle nut +0.5 MPa {300 +5 kg/cm }
5. Adjustment shim
a. Fuel inlet
b. Return-fuel outlet
12V170-2 11-31
STRUCTURE AND FUNCTION FUEL FILTER
FUEL FILTER
1. Air bleeding plug SPECIFICATION

2. Filter bracket • Filtration area: 1 m2 x 3 sets
3. Filter case
4. Filter element (cartridge)
a. Fuel (from feed pump)

b. Fuel (to fuel injection pump)
11-32 12V170-2
STRUCTURE AND FUNCTION COOLING SYSTEM CHART
COOLING SYSTEM CHART
11-34 12V170-2
STRUCTURE AND FUNCTION COOLING SYSTEM CHART
1. Water pump
2. Corrosion resistor
3. Oil cooler
4. Cylinder block
5. Cylinder head
6. Cylinder liner
7. After-cooler
8. Water manifold
9. Thermostat
10. Radiator
11. Turbocharger
12. Jiggle valve
a The jiggle valve allows the air to flow, but does

not allow the water to flow. This makes it possi-
ble to reduce the time taken to warm up the
engine coolant.
12V170-2 11-35
STRUCTURE AND FUNCTION WATER PUMP
WATER PUMP
1. Pump body SPECIFICATION

2. Impeller • Water pump speed: Engine speed x 1.628
3. Floating seal • Flow capacity: 2,000 l/min. {at 3,235 rpm}
4. Water seal
5. Pump shaft (rear)
6. Pump shaft (front)
A. Water inlet (from radiator)

B. Water outlet (to oil cooler)
11-36 12V170-2
STRUCTURE AND FUNCTION WATER PUMP DRIVE
WATER PUMP DRIVE
1. Water pump
2. Spline shaft
3. Drive gear (No. of teeth: 34)
4. Housing
5. Ball bearing
12V170-2 11-37
STRUCTURE AND FUNCTION THERMOSTAT
THERMOSTAT
1. Thermostat housing A. When cold (close) SPECIFICATIONS

2. Water manifold B. When hot (as individual part)
3. Thermostat (fully open) Cracking temperature:76.5 ± 2°C
4. Thermostat housing a. From engine each Full open temperature:90°C
5. Seal component Valve lift: Min. 10mm
6. Valve b. To water pump
7. Body c. To radiator
8. Piston
9. Heat sensing portion
10. Sleeve
11. Inflation agent
11-38 12V170-2
STRUCTURE AND FUNCTION CORROSION RESISTOR
CORROSION RESISTOR
1. Head SPECIFICATION
2. Element case (cartridge) • Filtration area: 0.373 m2 x 2 sets
3. Solid drug (included 1,000 g)
4. Cock
a. Coolant inlet
b. Coolant outlet
12V170-2 11-39
STRUCTURE AND FUNCTION FAN DRIVE AND TENSION PULLEY
FAN DRIVE AND TENSION PULLEY
1. Fan pulley (outside diameter: 480 mm)

2. Fan belt
3. Crank pulley (outside diameter: 221 mm)
4. Tension pulley (outside diameter: 157 mm)
5. Grease nipple
6. Tension spring
7. Tension bracket
11-40 12V170-2
STRUCTURE AND FUNCTION ALTERNATOR
ALTERNATOR
75A WITH BUILT-IN REGULATOR (OPEN TYPE)
modifications.
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Alternator
3. Terminal R 6B. Regulator
4. Terminal E
5. Terminal B
Unit: mm
Pulley diameter Weight
Engine Machine model Type Specification
(mm) (kg)
SA12V170E-2 D575A-3 Sawafuji Denki, open type 24V, 75A 93 12.5
11-42 12V170-2
STRUCTURE AND FUNCTION STARTING MOTOR
STARTING MOTOR
11KW
modifications.
11-44 12V170-2
STRUCTURE AND FUNCTION STARTING MOTOR
1. Pinion gear
2. Starting motor assembly
3. Magnetic switch
4. Terminal B
5. Terminal C
6. Safety relay
7. Connector
8. External wiring diagram (2-pin connector type)
8A. To alternator Terminal R
8B. To key switch terminal C
8C. Controller
9. External wiring diagram (3-pin connector type)
9A. Ground
9B. To alternator terminal R
9C. To keyswitch terminal C
9D. Controller
S. To starting switch terminal C

R. To alternator terminal R
E. To ground
No. of Weight Connector

Engine Machine model Type Specification
pinion teeth (kg) type
Sawafuji Denki water-

SA12V170E-2 D575A-3 24V, 11 kW 11 20 G
proof, oilproof type
12V170-2 11-45
STRUCTURE AND FUNCTION STARTING AID
STARTING AID
ETHER STARTING AID
modifications.
1. Aftercooler inlet (Right bank)

2. Nozzle (Right bank)
3. Ether piping
4. Nozzle (Left bank)
5. Aftercooler inlet (Left bank)
11-46 12V170-2
12 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR TESTING, ADJUSTING AND

TROUBLESHOOTING ....................................................................................................... 12- 2
TESTING AND ADJUSTING TOOL LIST ........................................................................... 12- 4
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE ................................................................................. 12- 5
TESTING AND ADJUSTING OF FUEL INJECTION TIMING
(WITH KOMATSU ELECTRONICAL GOVERNOR) ........................................................ 12- 7
MEASURING COMPRESSION PRESSURE .................................................................. 12-10
MEASURING BLOW-BY ..................................................................................................12-11
ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE) .......... 12-12
INSTALLING ENGINE SPEED SENSOR (WITH ELECTRONIC GOVERNOR) ............. 12-13
TESTING AND ADJUSTING ALTERNATOR BELT AND FAN BELT .............................. 12-14
DATA FOR FUEL INJECTION PRESSURE ADJUSTMENT SHIMS ............................... 12-15
FUEL INJECTION PUMP CALIBRATION DATA .............................................................. 12-16
PERFORMANCE TEST ................................................................................................... 12-50
PERFORMANCE TEST CRITERIA.................................................................................. 12-70
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE).................... 12-101
TROUBLESHOOTING OF MECHANICAL SYSTEM (S MODE) ................................... 12-201
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the
k When carrying out work together with other workers, always use signals and do not let unauthorized peo-
safety pins, and blocks to prevent the machine from moving.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
ple near the machine.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
the water is still hot, the water will spurt out and cause burns.
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the table is the estimated value for the shipped machine baced on the results
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.
3. These standard values are not the standards used in dealing with claims.
12V170-2 12-1
STANDARD VALUE TABLE FOR TESTING, ADJUSTING
TESTING AND ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE FOR TESTING, ADJUSTING AND

TROUBLESHOOTING
Applicable machine model D575A-3 (Super dozer) D575A-3 (Ripper)
Classi- Standard Permissible Standard Permissible

Item Condition, etc. Unit
fication value value value value
High idling speed rpm 1,950 – 2,050 1,950 – 2,050 1,950 – 2,050 1,950 – 2,050
Engine speed
Performance
Low idling speed rpm 600 – 700 600 – 700 600 – 700 600 – 700
Atmosphric temperature at rpm

0°C (without starting aid) Min. 100 – Min. 100 –
Necessary starting
speed Atmosphric temperature at
-20°C (with starting aid) rpm Min. 100 – Min. 100 –
Pa Max. 3,920 7,470 Max. 3,920 7,470

Intake resistance At all speed
{mmH2O} {Max. 400} {762} {Max. 400} {762}
Intake pressure At rated output kPa – – – –

{mmHg}
Exhaust pressure kPa

(Turbine inlet pressure) At rated output – – – –
Intake and exhaust system
{mmHg}
Exhaust temperature
All speeds (25°C) °C Max. 680 Max. 700 Max. 680 Max. 700
(Turbineinlet temperature)
Quick acceleration Bosch Max. 6.0 8.0 Max. 6.0 8.0

scale
Exhaust gas color Bosch

At rated output scale Max. 1.5 2.5 Max. 1.5 2.5
Bosch
At high idling scale Max. 1.0 2.0 Max. 1.0 1.5
Intake valve mm 0.4 – 0.4 –

Valve clearance
(When engine is cold)
Exhaust valve mm 1.0 – 1.0 –
Oil temperature: 40 – 60 °C
MPa Min. 2.7 1.9 Min. 2.7 1.9
Engine body
Compression pressure (Engine speed: 2

120 – 150 rpm) {kg/cm
} {Min. 28} {19.6} {Min. 28} {19.6}
At rated output
kPa Max. 58.8 118 Max. 58.8 118
Blow-by pressure (Water temperature:
{mmH2O} {Max. 600} {1,200} {Max. 600} {1,200}
Min. 60°C)
kPa 373 – 490 196 373 – 490 196

At high idling (SAE30)
{kg/cm2} {3.8 – 5.0} {2.0} {3.8 – 5.0} {2.0}
kPa 343 – 470 157 343 – 470 157

At high idling (SAE10W) {kg/cm2}
Oil pressure {3.5 – 4.8} {1.6} {3.5 – 4.8} {1.6}
Lubrication system
(Oil temperature:
Min.80°C) kPa Min. 118 78 Min. 118 78
At low idling (SAE30) {kg/cm2} {Min. 1.2} {0.8} {Min. 1.2} {0.8}
kPa Min. 98 69 Min. 98 69

At low idling (SAE10W) {kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}
Oil temperature All speeds (Oil in oil pan) °C 80 – 110 120 80 – 110 120
At continuous rated output

Oil consumption ratio (Ratio of fuel consumption) % Max. 0.5 1.0 Max. 0.5 1.0
a 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.
12-2 12V170-2
STANDARD VALUE TABLE FOR TESTING, ADJUSTING
TESTING AND ADJUSTING AND TROUBLESHOOTING
Applicable machine model D575A-3 (Super dozer) D575A-3 (Ripper)
Classi- Item Condition, etc. Unit

Standard Permissible Standard Permissible
fication value value value value
+ 1.3 + 1.3
Fuel system
Fuel injection MPa 29.4 + 0.5 24.2 29.4 + 0.5 24.2

Nozzle tester
pressure {kg/cm2} {300 ++ 13
5
} {247} {300 ++ 13
5
} {247}
Fuel injection timing B.T.D.C degree 19±1 19±1 17±1 17±1
Opening pressure kPa

Radiator pressure valve – – – –
Cooling system
(Differential pressure) {kg/cm2}
Fan speed At rated engine speed rpm – – – –
Between alternator and fan

Fan belt tension mm – – – –
pulley
a The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values ad a guide to change the setting of the fuel injection pump.
12V170-2 12-3
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING TOOL LIST
No. Inspection and measuring item Fault finding tool Part No. Remarks
Digital display
1 Engine speed Multi-tachometer 799-203-8000
L: 60 – 2,000 rpm M: 60 – 20,000 rpm
2 Battery S.G. 1,100 – 1,300

Battery, coolant tester 795-500-1000
3 Freezing temperature of cooling -5 – -50°C
water
Water temperature, oil tempera-

4 0 – 200°C
ture, air intake temperature
Digital temperature gauge 790-101-6000
5 Exhaust temperature 0 – 1,000°C
6 Lubrication oil pressure 0 – 981 kPa {0 – 10 kg/cm2}
7 Fuel pressure 0 – 1,960 kPa {0 – 20 kg/cm2}
8 Intake pressure, exhaust pres- Pressure test kit 799-203-2002 0 – 14.7kPa {0 – 1,500 mmH2O}
sure
9 Blow-by pressure 0 – 9.8kPa {0 – 1,000 mmH2O}
10 Air intake resistance -9.8 – 0kPa {-100 – 0 mmH2O}
11 Compression pressure Compression gauge kit 795-502-1205 0 – 6,860 kPa {0 – 70 kg/cm2}
12 Blow-by pressure Blow-by checker 799-201-1504 0 – 4.9 kPa {0 – 500 mmH2O}
13 Valve clearance Feeler gauge 795-125-1340 0.4, 1.0 mm
Dirtiness 0 – 70% with standard color

14 Exhaust gas color Handy smoke checker 799-201-9000
(Dirtiness % x 1/10 C Bosch scale)
15 Water and fuel content in oil Engine oil checker 799-201-6000 Provided with 0.1 and 0.2%
water content standard samples.
16 Fuel injection pressure

Nozzle tester Commercially 0 – 29,400 kPa {0 – 300 kg/cm2}
Fuel injection nozzle spray con- available
17
dition
18 Coolant quality Water quality tester 799-202-7001 pH, nitrite ion concentration
19 Pressure valve performance

Radiator cap tester 799-202-9001 0 – 196 kPa {0 – 2 kg/cm2}
Leakage in cooling water
20 system
21 Radiator blockage (wind speed) Anemometer 799-202-2001 1 – 40 m/s

(Air speed gauge)
Cranking kit 799-610-1000 DC24V with staring engine

22 Engine cranking
Barring device 6162-23-4820 For 170 series engine
Commercially
23 Electrical circuits Tester Current, voltage, resistance
available
12-4 12V170-2
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

1. Remove fuel injection pipe (1), spill tube (3), and
head cover (2).
2. Watching the movement of valve R1 on the right

side of the cylinder head, rotate the crankshaft
forward to bring the R1 cylinder to the compres-
sion top dead center and set the stamp line of
R1-6TOP of damper (4) to pointer (5).
a When the intake valve and exhaust valve of

the R1 cylinder doe not move, the R1 cylin-
der is at the compression top dead center.
a If the intake valve of the R1 cylinder lowers,
rotate the crankshaft one ore turn and set the
stamp line of R1-6TOP of the damper to the
pointer.
3. Loosen locknut (7) of adjustment screw (6) of the

R1 cylinder and insert feeler gauge A of the
specified clearance between cross head (9) and
rocker arm (8), and then tighten adjustment
screw (6) to a degree that you can move the
feeler gauge lightly.
4. Tighten locknut (7) at this position to fix the

adjustment screw.
3 Locknut:
67.7 ± 9.8 Nm {6.9 ± 1.0 kgm}
5. After adjusting the valve clearance of the R1 cyl-

inder, rotate the crankshaft forward to set the
pointer to the stamp line of L1-6TOP of the
damper, and then adjust the valve clearance of
the L6 cylinder according to the procedures in
steps 3 and 4.
6. Adjust the valve clearances of the other cylinders

in the firing order.
12V170-2 12-5
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
a Firing order: R1 – L6 – R5 – L2 – R3 – L4 – R6 –
L1 – R2 – L5 – R4 – L3
(The number in the figure shows
firing order.)
12-6 12V170-2
TESTING AND ADJUSTING TESTING AND ADJUSTING OF FUEL INJECTION TIMING
TESTING AND ADJUSTING OF FUEL INJECTION TIMING (WITH

KOMATSU ELECTRONICAL GOVERNOR)
Test and adjust the fuel injection timing of the injec-
tion pump as follows.
• When assembling to the same engine without
repairing the fuel injection pump, or when replac-
ing with a new fuel injection pump, adjust by
aligning the match marks.
• When replacing with a disassembled and repaired
injection pump, adjust using the delivery valve
method.
a If the delivery valve method is used, the cop-
per gasket and O-ring for the delivery valve
must be replaced with new parts, so have
new parts available when using this method.
a If the delivery valve method is used, there is
danger of dust getting in from outside, so use
this method only if there are no match mark
lines a and b. In all other cases use the
match mark method.
• Testing and adjustment by aligning match marks

1. Set with the right No. 1 cylinder at the TOP posi-
tion, then rotate the crankshaft 35 – 40° in the
opposite direction.
2. Rotate the crankshaft slowly in the normal direc-

tion, and align the fuel injection timing line on
damper (1) with pointer (2).
3. Check that line a on the fuel injection pump is

aligned with line b on the fuel injection pump
mounting flange. If No. 6 cylinder is at the TOP
position, line b may be on the opposite side, so
rotate the crankshaft one turn and align the
match marks properly at the No.1 cylinder TOP
position.
a If the stamp lines are not matched to each

other, loosen bolts (3) at the oblong holes of
the fuel injection pump mounting flange and
mounting bolts (4), and then move the injec-
tion pump to match the stamp lines and
tighten the bolts.
3 Bolt (3) at flange mounting oblong hole:
Tighten to specified torque.
3 Mounting bolt (4):
Tighten to specified torque.
12V170-2 12-7
• Testing and adjusting with delivery valve

method
1. Disconnect fuel injection pipe (5) of right No. 1
cylinder.
a Before disconnecting the pipe, wipe off all
the fuel at the top of the fuel injection pump
to prevent dust from entering.
2. Remove delivery valve holder (6).
3. Remove spring (7) and delivery valve (8) from

delivery valve holder (6), then assemble delivery
valve holder (6) again.
a When doing this, assemble the same O-ring
and copper gasket that were removed.
(Replace with new parts after adjusting)
4. Remove rack stopper bolt (9), then tighten rack

pusher bolt [1] to move the rack.
a Tighten the rack pusher bolt until it contacts
the rack piston, then tighten it a further 8
turns.
a Rack pusher bolt part number: 01016-30850
5. Set with the right No. 1 cylinder at the TOP posi-

tion, then rotate the crankshaft 35 – 40° in the
opposite direction.
6. Operate the priming pump and rotate the crank-

shaft slowly in the normal direction. Check the
point where the fuel stops flowing from the deliv-
ery valve holder (6).
7. Check that the fuel injection timing line on the

vibration damper and the pointer are aligned at
the point where the fuel stops flowing.
a BEYOND fuel injection timing line:
Timing RETARDED
a BEFORE fuel injection timing line:
Timing ADVANCED
12-8 12V170-2
• If the results of the test show that the fuel injec-

tion timing is incorrect, adjust the fuel injection
timing as follows.
1) Set with the right No. 1 cylinder at the TOP
position, then rotate the crankshaft 35 – 40°
in the opposite direction.
2) Rotate the crankshaft slowly in the normal
direction, and align the fuel injection timing
line on damper (1) and pointer (2) correctly.
3) Loosen bolt (3) in the oblong hole of the fuel
injection pump mounting flange, operate the
priming pump, and turn the whole pump a lit-
tle at a time. Stop at the point where fuel
stops flowing from the delivery valve holder.
4) Tighten the bolt (3) in the oblong hole of the
fuel injection pump mounting flange and
mounting bolt (4).
a Check the fuel injection timing again to
confirm that the fuel injection timing is
correctly adjusted.
a After adjusting, remove the delivery valve

holder (12), assemble the delivery valve and
spring (11), then install the delivery valve
holder (12) again.
a Always replace the copper gasket (13) and
O-ring of the delivery valve with new parts. If
the old parts are used, they may cause fuel
leakage.
Be careful not to mistake the mounting posi-
tion of the copper gasket (13).
a Replace rack pusher bolt [1] and rack stop-
per bolt (9). (If they are not replaced, there is
danger that the engine may overrun.)
3 Order for tightening delivery valve holder • Be careful to assemble the copper gasket (13) in
(10) the correct mounting position (below the seat).
Unit: Nm {kgm}
1st step 147 – 156.9 {15 – 16}
2nd step Return to 0
3rd step 147 – 156.9 {15 – 16}
4th step Return to 0
5th step 147 – 156.9 {15 – 16}
12V170-2 12-9
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

k Be careful not to touch any hot places when
installing of removing the measuring tools.
a Raise the temperature of the cooling water to the

operating range before measuring.
1. Adjust the valve clearance.

a For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Remove the nozzle holder assembly of the cylin-

der to be measured.
a Be careful not to let dirt or dust get inside.
3. Install adapter [1] in the mount of the nozzle

holder assembly.
3 Adapter: 26.9 ± 2.5 Nm
{2.75 ± 0.25 kgm}
4. Connect compression gauge assembly [2] to the

adapter.
k When measuring the compression pres-

sure, be careful not to touch any hot parts
or to get caught in the rotating parts.
5. Place the fuel control lever in the NO INJEC-

TION position. Crank the engine with the starting
motor and measure the compression pressure.
a Measure the compression pressure at the
point where the pressure gauge indicator
remains steady.
k If the fuel control lever is not placed at the

NO INJECTION position, fuel will spurt out.
a If the adapter mount is coated with a small

amount of oil, it will reduce the leakage.
a For details of the standard values for the
compression pressure, see TESTING AND
ADJUSTING DATA.
a When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
12-10 12V170-2
TESTING AND ADJUSTING MEASURING BLOW-BY
MEASURING BLOW-BY
a Raise the coolant temperature to the operating
range before measuring.
1. Install blow-by checker nozzle [1] to the end of

breather hose (3). Connect that nozzle and
blow-by checker pressure gauge [3] by blow-by
checker tube [4].
2. Install blow-by checker nozzles [2] to the other 2

breather hoses (1) and (2).
a Stop the outlets of these 2 nozzles as shown
by A.
k When measuring, take care not to touch a

hot part or get caught in a rotating part.
3. While stalling the torque converter and running

the engine at high idling, measure the blow-by
pressure with blow-by checker pressure gauge
[3].
a Take care not to overheat the torque con-
verter. (If it is overheated, the red range of
the torque converter oil temperature gauge
becomes bright.)
Reference:
Blow-by varies greatly according to the condition of
the engine. Therefore, if the blow-by value is consid-
ered abnormal, check for problems connected with
defective blow-by, such as excessive oil consump-
tion, defective exhaust gas color, and prematurely
dirty or deteriorated oil.
12V170-2 12-11
TESTING AND ADJUSTING ADJUSTING FUEL INJECTION PRESSURE
ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING

PRESSURE)
a Wash off any carbon or paint stuck to the nozzle
holder.
a Using a nozzle tester, check the fuel injection
pressure (cracking pressure) and spray condi-
tion. If any abnormality is found, replace nozzle
(2) and the nozzle holder assembly.
1. Remove retaining cap (1).
2. Remove nozzle (2), spring seat (3), and nozzle

spring (4).
3. Adjust the fuel injection pressure (valve cracking

pressure) by adjusting shim thickness (5).
a Injection pressure adjusted per 0.1 mm shim
thickness: Approx. 1.5 MPa {15 kg/cm2}
a When adjusting the shims, always wash with
clean fuel before assembling.
a After completion of adjustment, fit a protec-
tive cap to the fuel inlet port of the nozzle
holder to prevent dirt from getting in.
3 Method of tightening retaining cap

1st step: Tighten 78.5 Nm {8 kgm}
2nd step: Loosen completely
3rd step: Tighten 78.5 Nm {8 kgm}
4th step: Loosen completely
5th step: Tighten 88.3 ± 9.8 Nm
{9 ± 1 kgm}
4. After adjusting the thickness of shims, check the
fuel injection pressure using nozzle tester.
12-12 12V170-2
INSTALLING ENGINE SPEED SENSOR
TESTING AND ADJUSTING (WITH ELECTRONIC GOVERNOR)
INSTALLING ENGINE SPEED SENSOR (WITH ELECTRONIC

GOVERNOR)
The removal and installation procedure of the engine
speed sensor is as follows.
• Install speed sensor (1) and screw it in until its tip

contacts ring gear (2). Then, turn the sensor
back 3/4 - 1 turn, and secure it with lock nut (3).
a After the adjustment, confirm that cranking is
smooth.
12V170-2 12-13
TESTING AND ADJUSTING ALTERNATOR
TESTING AND ADJUSTING BELT AND FAN BELT
TESTING AND ADJUSTING ALTERNATOR BELT AND FAN BELT

ADJUSTING FAN BELT TENSION
Since the fan belt tension is adjusted automatically
by the auto-tensioner, it doe not need to be adjusted
usually. After the fan belt is replaced, however,
adjust it tension.
1. Loosen locknut (1) and turn adjustment bolt (3)

until no tension is applied to tension spring (2),
and then remove the fan belt.
2. Install a new fan belt and turn adjustment bolt (3)

until dimension A becomes the following value to
tense tension spring (2), and then tighten locknut
(1).
3 Locknut (1):
98 – 122 Nm {10.0 – 12.5 kgm}
Dimension A: 36 mm
ADJUSTING ALTERNATOR BELT TENSION

1. Testing
Press the intermediate point between the alternator
pulley and alternator drive pulley with a force of
about 98.1N {10kg} and see if belt deflection B at
this time is as follows.
Dimension B: 8 – 10 mm
2. Adjusting
1) Loosen the bolts and nuts (1), (2), and (3).
2) Adjust turnbuckle (4) to set deformation B of
the alternator belt to the following value.
3) After adjusting, tighten the bolts and nuts (1),
(2), and (3).
Dimension B: 8 – 10 mm
12-14 12V170-2
TESTING AND ADJUSTING DATA FOR FUEL INJECTION PRESSURE ADJUSTMENT SHIMS
DATA FOR FUEL INJECTION PRESSURE ADJUSTMENT SHIMS
Engine model Shim contour Shim thickness Shim thickness

(Range) (mm) (Interval) (mm)
a = 4.5 mm
SA12V170E-2 0.50 – 1.54 0.02
b = 11.5 mm
Part No. Thickness (mm) Part No. Thickness (mm)
DK150523-5000 0.50 DK150523-7700 1.04
DK150523-5100 0.52 DK150523-7800 1.06
DK150523-5200 0.54 DK150523-7900 1.08
DK150523-5300 0.56 DK150523-8000 1.10
DK150523-5400 0.58 DK150523-8100 1.12
DK150523-5500 0.60 DK150523-8200 1.14
DK150523-5600 0.62 DK150523-8300 1.16
DK150523-5700 0.64 DK150523-8400 1.18
DK150523-5800 0.66 DK150523-8500 1.20
DK150523-5900 0.68 DK150523-8600 1.22
DK150523-6000 0.70 DK150523-8700 1.24
DK150523-6100 0.72 DK150523-8800 1.26
DK150523-6200 0.74 DK150523-8900 1.28
DK150523-6300 0.76 DK150523-9000 1.30
DK150523-6400 0.78 DK150523-9100 1.32
DK150523-6500 0.80 DK150523-9200 1.34
DK150523-6600 0.82 DK150523-9300 1.36
DK150523-6700 0.84 DK150523-9400 1.38
DK150523-6800 0.86 DK150523-9500 1.40
DK150523-6900 0.88 DK150523-9600 1.42
DK150523-7000 0.90 DK150523-9700 1.44
DK150523-7100 0.92 DK150523-9800 1.46
DK150523-7200 0.94 DK150523-9900 1.48
DK150523-7300 0.96 DK150530-0000 1.50
DK150523-7400 0.98 DK150530-0100 1.52
DK150523-7500 1.00 DK150530-0200 1.54
DK150523-7600 1.02
12V170-2 12-15
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP CALIBRATION DATA
Engine Fuel injection pump Applicable engine Machine Page

assembly number serial number model
6553-00-1701 (Left bank)

SA12V170E-2 D575A-3
6553-00-1801 (Right bank)
12-16 12V170-2
Injection Pump Assembly Number

6553-00-1701 (Left bank, Electric governor)
6553-00-1801 (Right bank, Electric governor) Applicable Machine Applicable Engine
Model Serial No. Model Serial No.
( ): Injection pump manufacturer's part No. D575A-3 SA12V170E-2
(Super dozer)
Injection Pump Injection Pump
Type Manufacturer
KFE6S135 KOMATSU
Injection pump specification Engine Specification
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 863 {1,157} / 1,800 (NET)
Injection order 1-5-3-6-2-4 Maximum torque (Nm {kgm} / rpm) 5,660 {557} / 1,300 (NET)
Injection interval 60° ± 20' High idling speed (rpm) 1,950 – 2,050
Plunger pre-stroke (mm) 5.3 ± 0.05 Low idling speed (rpm) 600 – 700
Delivery valve (mm3/st) – Pump tester capacity

retraction volume Motor 7.5 kW
for Service standard
Calibration Standard ( ): Injection pump manufacturer's part number
Service standard Manufacturer's standard
Conditions Nozzle & nozzle holder part No. (105780-8130)
• Service standard Nozzle part No. (105780-0050)

indicates data Nozzle holder part No. (105780-2090)
using calibration
test parts. Injection pipe (mm)
(Outside dia. × inside dia. × length) 8 × 4 × 1,000
• Manufacturer Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard is data
for factory test. Oil temperature (°C) 40 – 45
2
Nozzle opening pressure (MPa {kg/cm }) 17.7 – 18.2 {180 – 186}
Transfer pump pressure (kPa {kg/cm2}) –
Service standard (cc/1000 st.) Manufacturer standard

Injection volume (cc/1000 st.)
Prestroke Rack Rack Pump
• Rack positions pressure voltage position speed Maximum Maximum
2 Injection Injection
B to E are the ref- (kg/cm ) (V) (mm) (rpm)
volume
variance
volume
variance
erence volume between cylinder between cylinder
when
adjusting the Rated 2.56 12.8
injection point 9.0 ± 0.01 ± 0.4 1,050 522 ± 4 ± 4%
volume.
• Marksaare Low
average idling Approx. Approx.
5.0 300 60 ± 5 ± 15%
volumes. point 1.25 6.3
Governor performance curve

(Not specified)
12V170-2 12-17
Injection Pump Assembly Number

6553-00-1701 (Left bank, Electric governor)
6553-00-1801 (Right bank, Electric governor) Applicable Machine Applicable Engine
Model Serial No. Model Serial No.
( ): Injection pump manufacturer's part No. D575A-3 SA12V170E-2
(Ripper)
Injection Pump Injection Pump
Type Manufacturer
KFE6S135 KOMATSU
Injection pump specification Engine Specification
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 783 {1,050} / 1,800 (NET)
Injection order 1-5-3-6-2-4 Maximum torque (Nm {kgm} / rpm) 5,080 {518} / 1,300 (NET)
Injection interval 60° ± 20' High idling speed (rpm) 1,950 – 2,050
Plunger pre-stroke (mm) 5.3 ± 0.05 Low idling speed (rpm) 600 – 700
Delivery valve (mm3/st) – Pump tester capacity

retraction volume Motor 7.5 kW
for Service standard
Calibration Standard ( ): Injection pump manufacturer's part number
Service standard Manufacturer's standard
Conditions Nozzle & nozzle holder part No. (105780-8130)
• Service standard Nozzle part No. (105780-0050)

indicates data Nozzle holder part No. (105780-2090)
using calibration
test parts. Injection pipe (mm)
(Outside dia. × inside dia. × length) 8 × 4 × 1,000
• Manufacturer Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard is data
for factory test. Oil temperature (°C) 40 – 45
2
Nozzle opening pressure (MPa {kg/cm }) 17.7 – 18.2 {180 – 186}
Transfer pump pressure (kPa {kg/cm2}) –
Service standard (cc/1000 st.) Manufacturer standard

Injection volume (cc/1000 st.)
Prestroke Rack Rack Pump
• Rack positions pressure voltage position speed Maximum Maximum
2 Injection Injection
B to E are the ref- (kg/cm ) (V) (mm) (rpm)
volume
variance
volume
variance
erence volume between cylinder between cylinder
when
adjusting the Rated 2.56 12.8
injection point 9.0 ± 0.01 ± 0.4 1,050 522 ± 4 ± 4%
volume.
• Marksaare Low
average idling Approx. Approx.
5.0 300 60 ± 5 ± 15%
volumes. point 1.25 6.3
Governor performance curve

(Not specified)
12-18 12V170-2
TESTING AND ADJUSTING PERFORMANCE TEST
PERFORMANCE TEST
RUN-IN STANDARD
a The table gives the standard values for machines
without fan.
a The loads for the dynamometer are at an arm's
length of 716 mm.
Applicable
Engine model machine Item 1 2 3 4 5 6
Running time min 5 15 5 5 20 10
Engine speed rpm 650 ± 50 1,050 1,320 1,650 1,910 2,100

D575A-3
(Ripper)
Load N {kg) 0 {0} 775 {79} 1,550 {158} 3,090 {315} 4,640 {473} 6,180 {630}
Output kW {HP} 0 {0} 61 {82} 154 {206} 382 {513} 614 {823} 973 {1,304}
SA12V170E-2
Running time min 5 15 5 5 20 10
D575A-3 Engine speed rpm 650 ± 50 900 1,125 1,400 1,620 1,800
(Super
dozer) Load N {kg} 0 {0} 785 {80} 1,570 {160} 3,190 {325} 4,810 {490} 6,800 {693}
Output kW {HP} 0 {0} 53 {71} 132 {177} 333 {447} 584 {783} 918 {1,230}
12-50 12V170-2
TESTING AND ADJUSTING PERFORMANCE TEST CRITERIA
PERFORMANCE TEST CRITERIA

a The values in the table are indicated at standard conditions (Atmospheric temperature 25°C, atmospheric
pressure 100 kPa {750 mmHg}.
a The values given for dynamomater loads the output and torque are with the fan removed, so they differ from
those of the specification.
a Values are standardized under the following conditions: muffler air cleaner installed; alternator idling; and air
compressor (if installed) open.
Dynamometer (N {kg})
Engine
Engine Applicable Test item Specified value speed
model machine (fully equipped) (rpm) Arm length 716 mm
Flywheel horsepower 783 kW/1,800 rpm 1,800 ± 5 6,057 – 6,429

{1,050 HP/1,800 rpm} (NET) {618 – 656}
Max. torque 5,080 Nm/1,300 rpm 1,300 ± 50 7,095 – 7,536

{518 kgm/1,300 rpm} (NET) {724 – 769}
D575A-3
(Ripper)
High idling speed 2,000 ± 50 rpm 2,000 ± 50 –
Low idling speed 650 ± 50 rpm 650 ± 50 –

SA12V170-1
Flywheel horsepower 863 kW/1,800 rpm 1,800 ± 5 6,590 – 6,894
{1,157 HP/1,800 rpm} (NET) {672 – 703}
5,660 Nm/1,300 rpm 7,844 – 8,384

Max. torque {577 kgm/1,300 rpm} (NET) 1,300 ± 50 {804 – 855}
D575A-3
(Super
dozer)
High idling speed 2,000 ± 50 rpm 2,000 ± 50 –
Low idling speed 650 ± 50 rpm 650 ± 50 –
12-70 12V170-2
TESTING AND ADJUSTING PERFORMANCE TEST CRITERIA
a Fuel used: ASTM D975 No. 2 diesel fuel.

a Lubrication oil used: CLASS-CO SAE30.
Fuel Lubrication oil

Output Torque consumption Coolant Lubrication oil pressure Exhaust
(kW {HP}) (Nm {kgm}) (sec. /500 cc) temperature (°C) temperature (°C) (MPa {kg/cm2}) temperature (°C)
818 – 868 – Min. 15.1 70 – 85 80 – 110 0.34 – 0.49 Max. 650

{1,096 – 1,164} {3.5 – 5.0}
– 5,087 – 5,400 – 70 – 85 80 – 110 – Max. 680

{519 – 551}
– – – 70 – 85 80 – 110 0.34 – 0.49 –

{3.5 – 5.0}
– – – 70 – 85 80 – 110 Min. 0.12 –

{Min. 1.2}
890 – 944 – Min. 14.5 70 – 85 80 – 110 0.27 – 0.41 Max. 650

{1,193 – 1,266} {2.8 – 4.2}
5,648 – 6,001
– {576 – 612} – 70 – 85 80 – 110 – Max. 680
0.27 – 0.41
– – – 70 – 85 80 – 110 {2.8 – 4.2} –
0.1 –
– – – 70 – 85 80 – 110 {1.0 – } –
12V170-2 12-71
TROUBLESHOOTING OF
ENGINE CONTROLLER SYSTEM
(E MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE .... 12-102
E-1 [E0401] Abnormality in engine controller power source voltage is displayed ....................................12-110
E-3 [E0403] Mistaken connection in engine controller is displayed..........................................................12-111
E-4 [E0405] Abnormality in fuel control dial system is displayed .............................................................12-112
E-5 [E0406] Abnormality in deceleration potentiometer is displayed .......................................................12-114
E-6 [E0407] Abnormality in shoe slip control command value is displayed .............................................12-116
E-7 [E0409] Abnormality in engine speed sensor A system is displayed.................................................12-117
E-8 [E0410] Abnormality in engine speed sensor B system is displayed.................................................12-118
E-9 [E0411] Abnormality in right rack sensor system is displayed ...........................................................12-119
E-10 [E0412] Abnormality in left rack sensor system is displayed ............................................................ 12-120
E-11 [E0413] Abnormality in rack sensor power source system is displayed ........................................... 12-121
E-12 [E0421] Short circuit in right governor solenoid system is displayed ................................................ 12-122
E-13 [E0422] Disconnection in right governor solenoid system is displayed ............................................ 12-123
E-14 [E0423] Short circuit in left governor solenoid system is displayed .................................................. 12-124
E-15 [E0424] Disconnection in left governor solenoid system is displayed............................................... 12-125
E-16 [E0425] Short circuit in right governor cut relay system is displayed................................................ 12-126
E-17 [E0426] Disconnection in left governor cut relay system is displayed .............................................. 12-127
E-18 [E0427] Short circuit in left governor cut relay system is displayed .................................................. 12-128
E-19 [E0428] Disconnection in left governor cut relay system is displayed .............................................. 12-129
E-20 [E0433] Short circuit in left pre-stroke solenoid system is displayed ................................................ 12-130
E-21 [E0434] Disconnection in left pre-stroke solenoid system isdisplayed.............................................. 12-131
E-22 [E0435] Abnormality in engine water temperature sensor system is displayed................................ 12-132
E-23 [E0437] Abnormality in right governor servo is displayed ................................................................. 12-133
E-24 [E0438] Abnormality in left governor servo is displayed ................................................................... 12-134
E-25 [E0440] Disconnection solenoid power source 1 system is displayed.............................................. 12-135
E-26 [E0441] Disconnection in power supply system 2 of solenoid is displayed ...................................... 12-135
E-27 [E0442] Abnormality in engine controller backup power source system is displayed....................... 12-136
E-28 [E0443] Abnormality in engine controller switch power source system is displayed ........................ 12-137
E-29 [E0455] Engine overheating is displayed.......................................................................................... 12-138
E-30 [E0456] Short circuit in right pre-stroke solenoid system is displayed .............................................. 12-139
E-31 [E0457] Disconnection in right pre-stroke solenoid system is displayed .......................................... 12-140
E-32 Engine does not rotate when starting switch is turned to ON position.............................................. 12-142
E-33 Engine does not stop when starting switch is turned to OFF position .............................................. 12-145
12V170-2 12-101
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
User Service Abnormal system Nature of abnormality
code code
Abnormality in engine * When controller power source voltage is Max. (Except starting)
E0401 controller power source 1. Defective controlle
voltage
* When engine controller connector LE31 and connector LE51 are mistakenly connected
CALL 1. Mistaken connection of connector LE31 and connector LE51
Mistaken connection in 2. Controller LE31 (1) short circuiting with ground
E0403
engine controller 3. Defective contact or disconnection in wiring harness between controller LE51 (1) and
chassis ground
4. Defective controller
* When input voltage from fuel control dial is less than 0.3 V or more than 4.75 V
1. Defective fuel control dial
2. Short circuit with power source, short circuit with ground, defective contact, or discon-
Abnormality in fuel nection in wiring harness between controller LE31 (6) and fuel control dial FCS (1)
E0405
control dial system 3. Short circuit with power source, short circuit with ground, defective contact, or discon-
nection in wiring harness between controller LE32 (1) and fuel control dial FCS (2)
4. Defective contact or disconnection in wiring harness between controller LE31 (16) and
fuel control dial FCS (3)
* When input voltage from deceleration potentiometer is less than 0.3 V or more than
4.75 V
1. Defective deceleration potentiometer
Abnormality in deceler- 2. Short circuit with power source, short circuit with ground, defective contact, or discon-
E0406 ation potentiometer nection in wiring harness between controller LE31 (6) and fuel control dial DCL (1)
system 3. Short circuit with power source, short circuit with ground, defective contact, or discon-
nection in wiring harness between controller LE32 (11) and fuel control dial DCL (2)
fuel control dial FCD (3)
* When input voltage from machine controller is less than 0.3 V or more than 4.75 V
Abnormality in shoe 1. Defective machine controller
E0407 slip control command 2. Short circuit with power source, short circuit with ground, defective contact, or discon-
value nection in wiring harness between controller LE31 (9) and SSC controller NGICN2 (11)
* When input margine from engine speed sensor A from B becomes more than 300 rpm
CALL after engine is started
03 1. Defective left engine speed sensor
Abnormality in engine 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
E0409
speed sensor A system controller LE31 (3) and speed sensor RRL (1)
speed sensor RRL (2)
* When input margine from engine speed sensor B from A becomes more than 300 rpm
after engine is started
1. Defective right engine speed sensor
Abnormality in engine 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
E0410
speed sensor B system controller LE31 (2) and speed sensor RRR (1)
speed sensor RRR (2)
* When input voltage from rack sensor is less than 0.15 V or more than 4.5 V
1. Defective right rack sensor
2. Short circuit with ground, short circuit with power source, defective contact, or discon-
nection in wiring harness between controller LE21 (16) and rack sensor LER (1)
Abnormality in right 3. Defective contact or disconnection in wiring harness between controller LE51 (1) and
E0411 rack sensor LER (2)
rack sensor system
12-102 12V170-2
Condition when normal Action by controller when Problem that appears onmachine
(voltage, current, resistance) abnormality is detected when there is abnormality
• Voltage between LE11 (7) – (8)(16): 20 – 30 V 1. Lights up caution lamp, sounds alarm 1. Engine cannot be controlled
• Voltage between LE11 (9)(17) – (8)(16) buzzer
: 20 – 30 V 2. Stops engine
• Voltage between LE31 (1) – chassis: 20 – 30 V 1. Lights up caution lamp, sounds alarm
• Voltage between LE51 (1) – chassis: Max. 1 V buzzer
—
• Voltage between LE31 (6) – (16): 4.8 – 5.4 V 1. Lights up caution lamp, sounds alarm 1. Engine speed cannot be controlled
• Voltage between LE32 (1) – LE31 (16) buzzer
: 0.3 – 4.75 V 2. Controls with deceleration potentiom-
eter signal
3. After machine is stopped (neutral),
fixes engine speed at 1300 rpm
• Voltage between LE31 (6) – (16): 4.8 – 5.4 V 1. Lights up caution lamp, sounds alarm 1. Engine speed cannot be controlled
• Voltage between LE32 (11) – LE31 (16) buzzer
: 0.3 – 4.75 V 2. Controls with fuel control dial signal
3. After machine is stopped (neutral),
fixes engine speed at 1300 rpm
• Voltage between LE31 (9) – chassis 1. Lights up caution lamp, sounds alarm 1. Shoe slip control is not actuated
: 0.3 – 4.75 V buzzer
2. Controls with fuel control dial signal
3. After machine is stopped, stops shoe
slip control function
• Resistance of speed sensor: 500 – 1000 z 1. Lights up caution lamp, sounds alarm
• Voltage between LE31 (3) – (14): 0.5 – 3.0 V buzzer
(AC range) 2. Controls with signal from engine
speed sensor B —
• Resistance of speed sensor: 500 – 1000 z 1. Lights up caution lamp, sounds alarm
• Voltage between LE31 (2) – (14): 0.5 – 3.0 V buzzer
(AC range) 2. Controls with signal from engine
speed sensor A —
• Voltage between LE31 (7) – LE51 (1) 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
: 0.15 – 4.5 V buzzer
• Voltage between LE31 (17) – LE51 (1) 2. Sets right fuel injection pump to NO
: 0.15 – 4.5 V INJECTION condition
12V170-2 12-103

code code
* When input from rack sensor is less than 0.15 V or more than 4.5 V
1. Defective left rack sensor
nection in wiring harness between controller LE21 (16) and rack sensor LEL (1)
Abnormality in left rack 3. Defective contact or disconnection in wiring harness between controller LE51 (1) and
E0412 rack sensor LEL (2)
sensor system
nection in wiring harness between controller LE31 (8) and rack sensor LEL (3)
CALL 5. Short circuit with ground, short circuit with power source, defective contact, or discon-
03 nection in wiring harness between controller LE31 (18) and rack sensor LEL (4)
* When power source voltage of rack sensor is less than 3.4 V
1. Defective right rack sensor or left rack sensor
Abnormality in rack 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
E0413 sensor power source controller LE21 (16) and right rack sensor LER (1) or left rack sensor LEL (1)
system 3. Defective contact or disconnection in wiring harness between right rack sensor LER (2)
or left rack sensor LEL (2) and chassis
* When output current to governor solenoid is more than 2.1 A
1. Defective right governor solenoid
Short circuit in right 2. Short circuit with ground or short circuit with power source in wiring harness between
E0421 governor solenoid controller LE21 (7) and governor solenoid GSR (1)
system 3. Short circuit with power source in wiring harness between controller LE21 (17) and gov-
ernor solenoid GSR (2)
* When output current to governor solenoid is less than 0.1 A
1. Defective right governor solenoid
Disconnection in right 2. Defective contact or disconnection in wiring harness between controller LE21 (7) and
E0422 governor solenoid governor solenoid GSR (1)
system 3. Short circuit with ground, defective contact, or disconnection in wiring harness between
controller LE21 (17) and governor solenoid GSR (2)
CALL
* When output current to governor solenoid is more than 2.1 A
1. Defective left governor solenoid
Short circuit in left 2. Short circuit with ground or short circuit with power source in wiring harness between
E0423 governor solenoid controller LE21 (8) and governor solenoid GSL (1)
system 3. Short circuit with power source in wiring harness between controller LE21 (18) and gov-
ernor solenoid GSL (2)
* When output current to governor solenoid is less than 0.1 A
1. Defective left governor solenoid
Disconnection in left 2. Defective contact or disconnection in wiring harness between controller LE21 (8) and
E0424 governor solenoid governor solenoid GSL (1)
controller LE21 (18) and governor solenoid GSL (2)
* When output voltage to right governor cut relay is more than 5 – 15 V
Short circuit in right 1. Defective right governor cut relay
E0425 governor cut relay 2. Short circuit with power source in wiring harness between controller LE11 (4) and relay
system GCR (2)
* When output voltage to right governor cut relay is less than 2 V
1. Defective right governor cut relay
Disconnection in right 2. Defective contact or disconnection in wiring harness between starting switch ACC termi-
E01 E0426 governor cut relay nal and relay GCL (1)
controller LE11 (4) and relay GCR (2)
* When output voltage to left governor cut relay is more than 5 – 15 V
Short circuit in left 1. Defective left governor cut relay
E0427 governor cut relay 2. Short circuit with power source in wiring harness between controller LE11 (5) and relay
system GCL (2)
12-104 12V170-2
• Voltage between LE31 (8) – LE51 (1) 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
: 0.15 – 4.5 V buzzer
• Voltage between LE31 (18) – LE51 (1) 2. Sets left fuel injection pump to NO
: 0.15 – 4.5 V INJECTION condition
• Voltage between LE21 (6) – chassis 1. Lights up caution lamp, sounds alarm 1. Lacks power
: 3.5 – 5.4 V buzzer
2. Reduces engine output by 20%
• Resistance of solenoid: 10 – 21 z 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
buzzer
buzzer
buzzer
buzzer
• Resistance of relay: 200 – 900 z

• Voltage between LE11 (4) and (13): 20 – 30 V
— —

— —

— —
12V170-2 12-105

code code
* When output voltage to left governor cut relay is less than 2 V
1. Defective left governor cut relay
Disconnection in left 2. Defective contact or disconnection in wiring harness between starting switch ACC termi
E01 E0428 governor cut relay nal and relay GCL (1)
controller LE11 (5) and relay GCL (2)
* When output current to pre-stroke solenoid is more than 4 A
1. Defective left pre-stroke solenoid
Short circuit in left 2. Short circuit with ground or short circuit with power source in wiring harness between
E0433 pre-stroke solenoid controller LE21 (10) and pre-stroke solenoid PSL (1)
system 3. Short circuit with power source in wiring harness between controller LE21 (20) and pre-
stroke solenoid PSL (2)
* When output current to pre-stroke solenoid is more than 0.2 A
1. Defective left pre-stroke solenoid
Disconnection in left 2. Defective contact or disconnection in wiring harness between controller LE21 (10) and
E0434 pre-stroke solenoid pre-stroke solenoid PSL (1)
CALL
03
controller LE21 (20) and pre-stroke solenoid PSL (2)
* When input voltage from engine water temperature sensor is less than 0.3 V or more
than 4.7 V
1. Defective engine water temperature sensor
Abnormality in engine 2. Short circuit with power source, short circuit with ground, defective contact, or discon-
E0435 water temperature nection in wiring harness between controller LE32 (5), monitor panel CN2 (1) – engine
sensor system water temperature sensor (1)
3. Defective contact or disconnection in wiring harness between engine water temperature
sensor 402 (2) and chassis ground
4. Defective controller or monitor panel
1. Defective right governor solenoid system or rack sensor system (governor command
Abnormality in right value and rack sensor signal do not match)
E0437
governor servo 2. Abnormality in solenoid power source R system
1. Defective left governor solenoid system or rack sensor system (governor command
Abnormality in left value and rack sensor signal do not match)
E0438
governor servo 2. Abnormality in solenoid power source L system
* When controller switch power source is more than 24 V but solenoid power source R is
less than 5 V
Disconnection in 1. Defective right governor cut relay
CALL E0440 solenoid power source 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
1 system controller LE21 (1) and relay GCR (6)
3. Defective contact or disconnection in wiring harness between LE21 (21) and chassis
ground
* When controller switch power source is more than 24 V but solenoid power source L is
less than 5 V
Disconnection in 1. Defective left governor cut relay
E0441 solenoid power source 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
2 system controller LE21 (12) and relay GCL (6)
3. Defective contact or disconnection in wiring harness between LE21 (21) and chassis
ground
* When backup power source voltage is more than 5 V lower than switch power source
Abnormality in engine voltage
E0442 controller backup 1. Blown fuse 1
power source system 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
controller LE11 (7) and fuse 1
CALL 3. Defective controller
03 * When switch power source voltage is more than 5 V lower than backup power source
Abnormality in engine voltage
E0443 controller switch power 1. Defective starting switch
source system 2. Short circuit with ground, defective contact, or disconnection in wiring harness between
controller LE11 (9)(17) and starting switch ACC terminal
12-106 12V170-2
• Voltage between E11 (5) and (14): 20 – 30 V
— —
• Resistance of solenoid: 10 – 21 z 1. Lights up caution lamp, sounds alarm 1. Lacks power

buzzer

buzzer
• Resistance of sensor: 3.8 – 80 k z 1. Lights up caution lamp, sounds alarm

buzzer
2. Controls with with engine water tem-
perature taken as 90° C
—
1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank

buzzer
— 2. Sets right fuel injection pump to NO
INJECTION condition
1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
buzzer
— 2. Sets left fuel injection pump to NO
INJECTION condition
• Voltage between E21 (1) and (21): 20 – 30 V 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
buzzer
• Voltage between E21 (12) and (21): 20 – 30 V 1. Lights up caution lamp, sounds alarm 1. Engine runs on one bank
buzzer
• Voltage between E11 (7) and (8)(16): 20 – 30 V 1. Lights up caution lamp, sounds alarm
buzzer
2. Drives with switch power source
—
• Voltage between E11 (9)(17) and (8)(16) 1. Lights up caution lamp, sounds alarm
: 20 – 30 V buzzer
2. Drives with backup power source —
12V170-2 12-107

code code
* When engine water temperature is more than 105 °C
— E0455 Engine overheating
* When output current to pre-stroke solenoid is more than 4 A

1. Defective right pre-stroke solenoid
Short circuit in right 2. Short circuit with ground or short circuit with power source in wiring harness between
E0456 pre-stroke solenoid controller LE21 (9) and pre- stroke solenoid PSR (1)
system 3. Short circuit with power source in wiring harness between controller LE21 (19) and pre-
stroke solenoid PSR (2)
* When output current to pre-stroke solenoid is more than 0.2 A
CALL 1. Defective right pre-stroke solenoid
03 Disconnection in right 2. Defective contact or disconnection in wiring harness between controller LE21 (9) and
E0457 pre-stroke solenoid pre-stroke solenoid PSR (1)
controller LE21 (19) and pre-stroke solenoid PSR (2)
* Harness logic does not match with model code.
Abnormality in engine 1. Disconnection, defective contact, or short circuit with chassis ground in wiring harness
E0492 controller specification between LE52 and SEL
selection 2. Defective model connector SEL
3. Defective engine controller
* Neutral signal LE51 (5) is different from LE51 (6).
Abnormality in neutral 1. Disconnection, defective contact, or short circuit with chassis ground in wiring harness
E01 E0272 between LE51 and TMCN2
signal system
2. Defective engine controller
3. Defective transmission controller
12-108 12V170-2
1. Lights up caution lamp, sounds alarm 1. Engine speed does not go up from
buzzer low idling
2. Runs engine at low idling
buzzer

buzzer
Starts engine with engine horsepower 1. Lacks power

reduced.
—
— — —
12V170-2 12-109
TROUBLESHOOTING E-1
E-1 [E0401] Abnormality in engine controller power source voltage is

displayed
a If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that
the service code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause Remedy
YES
Go to E-27 —
1
Is service code
[E0442] displayed,
too? 2 YES
Go to E-28
Is service code
• Turn starting switch [E0443] displayed,
ON. NO too?
Defective engine controller Replace
• Turn starting switch NO
ON.
12-110 12V170-2
TROUBLESHOOTING E-3
E-3 [E0403] Mistaken connection in engine controller is displayed

a Check that connectors LE31, LE32, LE51, and LE52 on the chassis side are properly connected to the
engine controller.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Is voltage between
LE51 (1) and chas-
sis ground normal? Defective contact or discon-
nection in wiring harness Repair or
• Turn starting switch NO between LE51 (female) (1) replace
– chassis ground
ON.
• Max. 1 V
E-3 Related electrical circuit diagram
12V170-2 12-111
TROUBLESHOOTING E-4
E-4 [E0405] Abnormality in fuel control dial system is displayed

Cause Remedy
YES
2
YES Is voltage between Defective contact or discon-

LE32 (1) and chas- YES nection in wiring harness Repair or
sis ground normal? 3 between LE32 (female) (1) replace
– FCS (female) (2)
• Turn starting switch Is voltage between
ON. FCS (2) and chas-
NO sis ground nor- 4 YES
• 0.3 – 4.75 V mal? Defective fuel control dial Replace
If FCS is disconnect-
ed, does resistance
• Turn starting switch between LE32 (fe-
1 ON. NO male) (1) and chassis Short circuit with chassis
• 0.3 – 4.75 V ground normal? ground in wiring harness Repair or
Is voltage between • Turn starting NO between LE32 (female) (1)
– FCS (female) (2) replace
LE31 (6) and (16) switch OFF.
normal? • Disconnect FCS and
LE32.
• Min. 1 Mz Defective contact or discon-
• Turn starting switch
6 YES nection in wiring harness Repair or
ON.
• 4.8 – 5.4 V between LE31 (female) (16) replace
Is resistance be- – FCS (female) (3)
YES tween FCS (male)
(1) and (3) normal?
5 Defective fuel control dial Replace
Is voltage between
OFF.
FCS (1) and chas-
NO sis ground normal? • Disconnect FCS.
Defective contact or discon-
• 4.0 – 6.0 kz YES nection in wiring harness Repair or
• Turn starting switch 7 between E31 (female) (6) – replace
ON. FCS (female) (1)
Is voltage between
• 4.8 – 5.4 V LE31 (6) and chas-
NO sis ground normal? 8 YES
Defective fuel control dial Replace
If FCS is disconnect-
ed, does resistance
ON. NO male) (6) and chassis Short circuit with chassis
OFF. and FCS (female) (1)
• Disconnect FCS and
LE31.
• Min. 1 Mz
12-112 12V170-2
TROUBLESHOOTING E-4
12V170-2 12-113
TROUBLESHOOTING E-5
E-5 [E0406] Abnormality in deceleration potentiometer is displayed

Cause Remedy
YES
2
Is voltage between
YES LE32 (11) and Defective contact or discon-
chassis ground YES nection in wiring harness Repair or
normal? 3 between LE32 (female) (11) replace
– DCL (female) (2)
ON. DCL (2) and chas-
• 0.3 – 4.75 V NO sis ground nor- 4 YES Defective deceleration po-
mal? Replace
If DCL is disconnect- tentiometer
• Turn starting switch ed, does resistance
between LE32 (fe-
1 ON. NO male) (11) and chas- Short circuit with chassis
• 0.3 – 4.75 V sis ground normal? ground in wiring harness Repair or
Is voltage between • Turn starting switch NO between LE32 (female) (11) replace
LE31 (6) and (16) OFF. – DCL (female) (2)
normal? • Disconnect FCD and
LE32.
• Turn starting switch • Min. 1 Mz Defective contact or discon-
ON. 6 YES nection in wiring harness Repair or
• 4.8 – 5.4 V between LE31 (female) (16) replace
Is resistance be- – DCL (female) (3)
YES tween DCL (male)
(1) and (3) normal?
5 Defective deceleration po-
Replace
• Turn starting switch NO tentiometer
Is voltage between OFF.
DCL (1) and chas- • Disconnect DCL.
NO sis ground normal? Defective contact or discon-
• 4.0 – 6.0 kz YES nection in wiring harness Repair or
• Turn starting switch 7 between LE31 (female) (6) replace
ON. Is voltage between
• 4.8 – 5.4 V LE31 (6) and chas-
NO sis ground normal? 8 YES Defective deceleration po-
Replace
If DCL is disconnect- tentiometer
ed, does resistance
ON. NO male) (6) and chassis Short circuit with chassis
OFF.
• Disconnect FCD
and LE31.
• Min. 1 Mz
12-114 12V170-2
TROUBLESHOOTING E-5
12V170-2 12-115
TROUBLESHOOTING E-6
E-6 [E0407] Abnormality in shoe slip control command value is

displayed
Cause Remedy
YES
1
Short circuit with chassis
Is voltage between 3 YES ground in wiring harness Repair or
LE31 (9) and (16) Is resistance be- between LE31 (female) (9) replace
– NGICN2 (female) (11)
normal? YES tween LE31 (fe-
male) (9) and
2 NGICN2 (female) Defective contact or discon-
• Turn starting switch (11) normal? nection in wiring harness Repair or
ON. Is voltage between
NGICN2 (11) and • Turn starting switch NO between LE31 (female) (9) replace
• 0.3 – 4.75 V – NGICN2 (female) (11)
NO chassis ground OFF.
normal? • Disconnect LE31 and NGICN2.
• Max. 1z
• Turn starting switch Defective steering
Replace
ON. NO controller
• 0.3 – 4.75 V
12-116 12V170-2
TROUBLESHOOTING E-7
E-7 [E0409] Abnormality in engine speed sensor A system is displayed

a If the starting switch was turned off after the abnormality occurred, start engine and check that the service
code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause Remedy
2 YES Wrong adjustment of en-

gine speed sensor A Adjust
If speed sensor A
YES is adjusted, is serv-
ice code P dis-
played?
• See TESTING AND NO
1
ADJUSTING.
Is resistance be- • Start engine. Defective contact, disconnec-
tween LE31 (fe- tion or short circuit with chas- Repair or
4 YES
male) (2) and (14) sis ground in wiring harness replace
normal? Is resistance be- between LE31 (female) (2) –
YES tween LE31 (female) RRR (female) (1)
3 (2) and RRR (fe-
OFF. male) (1) normal?
• Disconnect LE31. nection in wiring harness Repair or
Is resistance be- between LE31 (female) (14) replace
• 500 – 1,000z • Turn starting switch NO
tween RRR (male) – RRR (female) (2)
NO (1) and (2) normal? OFF.
• Disconnect LE31 and RRR.
• Turn starting switch • Max. 1z Defective engine speed
Replace
OFF. NO sensor A
• Disconnect RRR.
• 500 – 1,000z
12V170-2 12-117
TROUBLESHOOTING E-8
E-8 [E0410] Abnormality in engine speed sensor B system is displayed

a If the starting switch was turned off after the abnormality occurred, start engine and check that the service
code displays “E” at the head. (If “P” is displayed, the condition has returned to normal.)
Cause Remedy
2 YES Wrong adjustment of en-

gine speed sensor B Adjust
If speed sensor B
YES is adjusted, is serv-
ice code P dis-
played?
1 • See TESTING AND NO
ADJUSTING.
Is resistance be- Defective contact, discon-
• Start engine. nection or short circuit with
tween LE31 (fe-
4 YES chassis ground in wiring Repair or
male) (3) and (14) harness between LE31 (fe-
Is resistance be- replace
normal? male) (3) – RRL (female)
YES tween LE31 (fe- (1) – M41 (female) (1)
• Turn starting switch 3 male) (3) and RRL
OFF. (female) (1) normal? Defective contact or discon-
• Disconnect LE31. Is resistance be- nection in wiring harness Repair or
• 500 – 1,000z tween RRL (male)
NO (1) and (2) normal? OFF. – RRL (female) (2)
• Disconnect LE31 and RRL.
• Max. 1z Defective engine speed
Replace
OFF. NO sensor B
• Disconnect RRL.
• 500 – 1,000z
12-118 12V170-2
TROUBLESHOOTING E-9
E-9 [E0411] Abnormality in right rack sensor system is displayed

a If the operation can be continued, perform the checks in Steps 1 and 2 under the operating condition where
a trouble occurs.
Cause Remedy
YES
1
Is voltage between nection in wiring harness be-
LE31 (7) and (17) YES tween LE31 (female) (7) – Repair or
normal? 2 LER (female) (3) or between replace
LE31 (female) (17) – LER (fe-
• Turn starting switch Is voltage between male) (4)
ON. LER (3) and (4) Defective right rack sensor
NO normal? 3 YES
• 0.15 – 4.5 V or fuel injection pump inter- Replace
If LE31 is discon- nal defect
• Turn starting switch nected, does resist-
ance between LER Short circuit with chassis
ON.
• 0.15 – 4.5 V
NO (female) (3) and (2) ground in wiring harness
and between (4) between LE31 (female) (7) Repair wiring
and (2) normal? harness or
– LER (female) (3) or
OFF. – LER (female) (4)
• Disconnect LE31 and LER.
• 50 kz – 1 Mz
12V170-2 12-119
TROUBLESHOOTING E-10
E-10 [E0412] Abnormality in left rack sensor system is displayed

a If the operation can be continued, perform the checks in Steps 1 and 2 under the operating condition where
a trouble occurs.
Cause Remedy
YES
1
Is voltage between nection in wiring harness be-
LE31 (8) and (18) YES tween LE31 (female) (8) – Repair or
normal? 2 LEL (female) (3) or between replace
LE31 (female) (18) – LEL (fe-
male) (4)
ON. LEL (3) and (4) Defective right rack sensor
NO normal? 3 YES
• 0.15 – 4.5 V or fuel injection pump inter- Replace
If LE31 is discon- nal defect
• Turn starting switch nected, does resist-
ance between LEL Short circuit with chassis
ON.
• 0.15 – 4.5 V NO (female) (3) and (2) ground in wiring harness
and between (4) between LE31 (female) (8) Repair wiring
and (2) normal? – LEL (female) (3) or be- harness or
• Turn starting switch NO tween LE31 (female) (18) – replace
OFF. LEL (female) (4)
• Disconnect LE31 and LEL.
• 50 kz– 1 Mz
12-120 12V170-2
E-11 [E0413] Abnormality in rack sensor power source system is

displayed
Cause Remedy
YES
1 Defective contact, discon-

nection or short circuit with
Is resistance be- 3 YES chassis ground in wiring Repair or
tween LE21 (fe- harness between LE21 (fe- replace
male) (16) and Is voltage between
YES LER (1) and chas- male) (16) – LER (female)
LE51 (female) (1) (1) – LEL (female) (1)
normal? sis ground and be-
2 tween LEL (1) and
• Turn starting switch chassis ground
Is resistance be- nection in wiring harness Repair or
OFF. tween LER (male) normal?
between LER (female) (2) – replace
• Disconnect LE21 (1) and (2) and be- • Turn starting switch NO LEL (female) (2) – chassis
and LE51. NO tween LEL (male) ON. ground
• Min. 500 kz (1) and (2) normal? • 3.5 – 5.4 V
• Turn starting switch Defective rack sensor hav-
OFF. Replace
NO ing abnormal resistance
• Disconnect LE21
and LE51.
• Min. 500 kz
12V170-2 12-121
E-12 [E0421] Short circuit in right governor solenoid system is displayed

Cause Remedy
YES
1
Is voltage between Short circuit with chassis
LE2 (female) (7) 3 YES ground or power source in
Repair or
and (17) and be- wiring harness between
tween (7), (17) and
If GSR is discon- LE2 (female) (7) – GSR (fe- replace
chassis ground as YES nected, does voltage male) (1)
shown in Table 1? 2 between LE2 (fe-
male) (17) and chas- Short circuit with power
Is resistance be- sis ground normal?
• Turn starting switch tween GSR (male) source in wiring harness Repair or
OFF. (1) and (2) and be- • Disconnect GSR NO between LE2 (female) (17) replace
• Disconnect LE2. NO tween (1), (2) and and LE2. – GSR (female) (2)
chassis ground as • Turn starting switch ON.
shown in Table 2?
• Max. 1 V Defective right governor
• Turn starting switch Replace
NO solenoid
OFF.
• Disconnect GSR.
Table 1 Table 2
LE2 (female) Resistance GSR (male) Resistance
Between (7) – (17) 10 – 21 z Between (1) – (2) 10 – 21 z
Between (7), (17) – chassis Min. 1 M z Between (1), (2) – chassis Min. 1 M z
12-122 12V170-2
E-13 [E0422] Disconnection in right governor solenoid system is

displayed
Cause Remedy
YES
1
Is voltage between Defective contact, disconnec-
LE2 (female) (7) 3 YES tion or short circuit with chas-
sis ground in wiring harness Repair or
and (17) and be-
tween (7), (17) and between LE2 (female) (17) – replace
chassis ground as YES Is voltage between GSR (female) (2)
GSR (1) and chas-
shown in Table 1? 2
sis ground nor- Short circuit with power
• Turn starting switch Is resistance be- mal?
tween GSR (male) source in wiring harness Repair or
OFF. • Turn starting switch NO between LE2 (female) (7) – replace
(1) and (2) and be-
• Disconnect LE2. GSR (female) (1)
NO tween (1), (2) and ON.
chassis ground as • 20 – 30 V
shown in Table 2?
• Turn starting switch Defective right governor Replace
OFF. NO solenoid
• Disconnect GSR.
Table 1 Table 2
LE2 (female) Resistance GSR (male) Resistance
12V170-2 12-123
E-14 [E0423] Short circuit in left governor solenoid system is displayed

Cause Remedy
YES
1
Is voltage between Short circuit with chassis
LE2 (female) (8) 3 YES ground or power supply in
wiring harness between Repair or
and (18) and be- replace
tween (8), (18) and If GSL is disconnect- LE2 (female) (8) – GSL (fe-
chassis ground as YES ed, does voltage be- male) (1)
shown in Table 1? 2 tween LE2 (female)
Is resistance be- (18) and chassis Short circuit with power
• Turn starting switch tween GSL (male) ground normal? source in wiring harness Repair or
OFF. (1) and (2) and be- • Disconnect GSL NO between LE2 (female) (18) replace
• Disconnect LE2. NO tween (1), (2) and and LE2. – GSL (female) (2)
chassis ground as • Turn starting switch ON.
shown in Table 2?
• Max. 1 V
• Turn starting switch Defective left governor Replace
OFF. NO solenoid
• Disconnect GSL.
Table 1 Table 2
LE2 (female) Resistance GSL (male) Resistance
Between 8) – (18) 10 – 21 z Between (1) – (2) 10 – 21 z
Between (8), (18) – chassis Min. 1 Mz Between (1), (2) – chassis Min. 1 M z
12-124 12V170-2
E-15 [E0424] Disconnection in left governor solenoid system is displayed

Cause Remedy
YES
1
Is voltage between Defective contact, disconnec-
LE2 (female) (8) 3 YES tion or short circuit with chas- Repair or
and (17) and be- sis ground in wiring harness replace
tween (8), (18) and Is voltage between between LE2 (female) (18) –
chassis ground as YES GSL (1) and chas- GSL (female) (2)
shown in Table 1? 2 sis ground nor- Short circuit with power
• Turn starting switch Is resistance be- mal? source in wiring harness be- Repair or
tween GSL (male) tween LE2 (female) (8) – replace
OFF. (1) and (2) and be- • Turn starting switch NO
• Disconnect LE2. NO tween (1), (2) and GSl (female) (1)
ON.
chassis ground as • 20 – 30 V
shown in Table 2?
Defective left governor Replace
• Turn starting switch NO solenoid
OFF.
• Disconnect GSL
Table 1 Table 2
LE2 (female) Resistance GSL (male) Resistance
12V170-2 12-125
E-16 [E0425] Short circuit in right governor cut relay system is displayed
Cause Remedy
Disconnection or defective
2 YES contact in wiring harness
Repair or re-
between LE11 (17) (female)
place
(4) – relay or defective con-
YES Is resistance be- troller
tween (1) and (2)
in relay normal?
Defective governor cutout
Replace
1) 200 – 900 z NO relay
2) Turn starting switch
1 OFF. Disconnection or defective
3) Disconnect relay. 5 YES contact in wiring harness Repaair or re-
Is voltage between between LE2 (21) (female) place
Can engine start? YES LE11 (17), (4) and (1) – relay – power supply
chassis ground
4 normal?
Short circuit in wiring har-
ness between LE11 (17) Repair or re-
Is resistance be- 1) 20 – 30 V NO (female) (4) – relay or de- place
YES 2) Turn starting switch fective controller
tween (3) and (6) in
relay normal? ON.
3 3) Turn starting motor
1) Max. 1 z ON.
Is resistance be- 2) Turn starting switch 4) Use T-adapter. Defective governor cutout
tween (1) and (2) Replace
OFF. NO relay
NO in relay normal?
3) Disconnect relay.
1) 200 – 900 z
2) Turn starting switch Defective governor cutout
OFF. Replace
NO relay
12-126 12V170-2
E-17 [E0426] Disconnection in left governor cut relay system is displayed

Cause Remedy
Repair or re-
place
tween (1) and (2)
in relay normal?
Replace
1) 200 – 900 z NO relay
chassis ground
4 normal?
relay normal? ON.
1) Max. 1 z ON.
OFF. NO relay
NO in relay normal?
1) 200 – 900 z
OFF. Replace
NO relay
12V170-2 12-127
E-18 [E0427] Short circuit in left governor cut relay system is displayed
Cause Remedy
Repair or re-
place
tween (1) and (2)
in relay normal?
Replace
1) 200 – 900 z NO relay
chassis ground
4 normal?
relay normal? ON.
1) Max. 1 z ON.
OFF. NO relay
NO in relay normal?
1) 200 – 900 z
OFF. Replace
NO relay
12-128 12V170-2
E-19 [E0428] Disconnection in left governor cut relay system is displayed

Cause Remedy
Repair or re-
place
tween (1) and (2)
in relay normal?
Replace
1) 200 – 900 z NO relay
chassis ground
4 normal?
relay normal? ON.
1) Max. 1 z ON.
OFF. NO relay
NO in relay normal?
1) 200 – 900 z
OFF. Replace
NO relay
12V170-2 12-129
E-20 [E0433] Short circuit in left pre-stroke solenoid system is displayed

Cause Remedy
YES
1
Is resistance be- Short circuit with chassis
tween LE2 (fe- ground or power supply in
male) (10) and (2) 3 YES Repair or
wiring harness between
and between (10), If PSL is disconnect- LE2 (female) (10) – PSL replace
(20) and chassis YES ed, does voltage be- (female) (1)
ground as shown 2 tween LE2 (female)
in Table 1? Is resistance be- (20) and chassis Short circuit with power
tween PSL (male) ground normal? source in wiring harness Repair or
(1) and (2) and be- • Disconnect PSL NO between LE2 (female) (20) replace
OFF. – PSL (female) (2)
tween (1), (2) and and LE2.
• Disconnect LE2. NO chassis ground as • Turn starting switch ON.
shown in Table 2?
• Max. 1 V Defective left pre-stroke
NO solenoid
OFF.
• Disconnect PSL.
Table 1 Table 2
LE2 (female) Resistance PSL (male) Resistance
12-130 12V170-2
E-21 [E0434] Disconnection in left pre-stroke solenoid system

isdisplayed
Cause Remedy
YES
1
tween LE2 (fe- 3 YES nection or short circuit with
male) (10) and (2) chassis ground in wiring har- Repair or
and between (10), Is voltage between ness between LE2 (female) replace
(20) and chassis YES PSL (female) (1) (20) – PSL (female) (2)
ground as shown 2 and chassis
in Table 1? Is resistance be- Defective contact or discon-
ground normal? nection in wiring harness Repair or
tween PSL (male)
• Turn starting switch (1) and (2) and be- • Turn starting switch NO between LE2 (female) (10) – replace
OFF. PSL (female) (1)
NO tween (1), (2) and ON.
• Disconnect LE2. chassis ground as • 20 – 30 V
shown in Table 2?
Defective left pre-stroke
NO solenoid
OFF.
• Disconnect PSL.
Table 1 Table 2
LE2 (female) Resistance PSL (male) Resistance
12V170-2 12-131
E-22 [E0435] Abnormality in engine water temperature sensor system is

displayed
Cause Remedy
YES
1
Defective contact, discon-
Is resistance be- nection or short circuit with
tween LE32 (fe- 3 YES chassis ground in wiring Repair or
male) 5 and chas- harness between E32 (fe- replace
sis ground as Is resistance be- male) (5) – 402 (female) (1)
shown in following YES tween 402 (fe- – CN2 (female) (1)
table? 2 male) and chassis
ground normal? Defective contact or discon-
• Turn starting switch Is resistance be- nection in wiring harness Repair or
OFF. tween 402 (fe- • Turn starting switch NO between CN2 (female) (2) – replace
• Disconnect LE32. NO male) (1) and 2 as OFF. chassis ground
shown in following
table? • Disconnect 402.
• Turn starting switch • Max. 1z Defective engine water Replace
OFF. NO temperature sensor
• Disconnect 402.
Table
Engine water temperature Resistance
10 – 100 °C 80 – 3.8 kz
12-132 12V170-2
E-23 [E0437] Abnormality in right governor servo is displayed

Cause Remedy
2 YES Defective fuel injection

What is voltage pump
YES range between
1 LE31 (20) (7) and
(17)? Defective rack sensor or
Is voltage between NO fuel injection pump
1) 0.15 – 4.5 V
LE31 (20) (7) and
(17) normal?
ON.
3) Warm up engine.
1) 0.15 – 4.5 V See E-9
2) Turn starting switch NO
ON.
12V170-2 12-133
E-24 [E0438] Abnormality in left governor servo is displayed

Cause Remedy
2 0.15 – 0.56 V Defective fuel injection

What is voltage pump
YES range between
1 LE31 (20) (8) and
(18)? Defective rack sensor or
Is voltage between 0.57 – 4.5 V fuel injection pump
1) 0.15 – 4.5 V
LE31 (20) (8) and
(18) normal?
ON.
3) Warm up engine.
1) 0.15 – 4.5 V See E-10
2) Turn starting switch NO
ON.
12-134 12V170-2
TROUBLESHOOTING E-25, E-26
E-25 [E0440] Disconnection solenoid power source 1 system is displayed

Cause Remedy
Go to E-17 —
E-26 [E0441] Disconnection in power supply system 2 of solenoid is

displayed
Cause Remedy
Go to E-19. —
12V170-2 12-135
E-27 [E0442] Abnormality in engine controller backup power source sys-

tem is displayed
a Check that fuse 1 is not broken. (If it is broken, check the circuit related to it for short circuit with chassis
ground.)
Cause Remedy
YES
1
Is voltage between
E11 (7) and (8), Defective contact or discon-
(16) normal?
between E11 (female) (8) replace
Is voltage between (16) – chassis ground
• Turn starting switch E11 (7) and chas-
OFF. NO sis ground nor- Defective contact or discon-
• 20 – 30 V mal? Repair or
nection in wiring harness
• Turn starting switch NO between E11 (female) (7) – replace
fuse 1
OFF.
• 20 – 30 V
12-136 12V170-2
E-28 [E0443] Abnormality in engine controller switch power source

system is displayed
ground.)
Cause Remedy
YES
1
Is voltage between
E11 (9), (17) and Defective contact or discon-
(8), (16) normal?
between E11 (female) (8), replace
Is voltage between (16) – chassis ground
• Turn starting switch E11 (9), (17) and
ON. NO chassis ground Defective contact or discon-
• 20 – 30 V normal? nection in wiring harness Repair or
between E11 (female) (9), replace
• Turn starting switch NO (17) – ACC terminal of
ON. starting switch
• 20 – 30 V
12V170-2 12-137
E-29 [E0455] Engine overheating is displayed

Cause Remedy
Problem probably caused Check according

1 YES to displayed
by other abnormality
Is any other serv- occurring at same time. service code.
ice code displayed,
too? Go to
Problem probably caused
troubleshooting
• Turn starting switch NO by abnormality in engine.
for engine.
ON.
12-138 12V170-2
E-30 [E0456] Short circuit in right pre-stroke solenoid system is

displayed
Cause Remedy
YES
1
Is resistance be- Short circuit with chassis
tween E21 (fe- 3 YES ground or power supply in
male) (9) and (19) wiring harness between Replace
If E14 is disconnect- E21 (female) (9) – E14 (fe-
and between (9), YES ed, does voltage be-
(19) and chassis male) (1)
2 tween E21 (female)
ground as shown (19) and chassis Short circuit with power
in Table 1? Is resistance be-
tween E14 (male) ground normal? source in wiring harness be- Repair or
• Turn starting switch (1) and (2) and between E21 (female) (19) – replace
• Disconnect E14 NO E14 (female) (2)
OFF. tween (1), (2) and and E21.
NO chassis ground as
• Disconnect E21. • Turn starting switch ON.
shown in Table 2? • Max. 1 V
• Turn starting switch Defective right pre-stroke
Replace
OFF. NO solenoid
• Disconnect E14.
Table 1 Table 2
E21 (female) Resistance E14 (female) Resistance
12V170-2 12-139
E-31 [E0457] Disconnection in right pre-stroke solenoid system is

displayed
Cause Remedy
YES
1
tween E21 (fe- nection or short circuit with
male) (9) and (19) 3 YES chassis ground in wiring har- Repair or
and between (9), Is voltage between ness between E21 (female) replace
(19) and chassis YES E14 (1) and chas- (19) – E14 (female) (2)
ground as shown 2 sis ground nor-
in Table 1? Is resistance be- Defective contact or discon-
tween E14 (male) mal? nection in wiring harness Repair or
(1) and (2) and be- • Turn starting switch NO between E21 (female) (9) – replace
OFF. E14 (female) (1)
tween (1), (2) and
• Disconnect E21. NO chassis ground as
ON.
shown in Table 2? • 20 – 30 V
• Turn starting switch Defective right pre-stroke
Replace
OFF. NO solenoid
• Disconnect E14.
Table 1 Table 2
E21 (female) Resistance E14 (female) Resistance
12-140 12V170-2
E-32 Engine does not rotate when starting switch is turned to ON

position
a Check that any service code is not displayed. (If any service code is displayed, check according to it.)
ground.)
a When performing any part of troubleshooting, turn the parking lever to the LOCK position.
5 YES
Is connection of
YES power supply har-
ness between start-
ing motor and bat-
tery relay normal?
4
• Check visually. NO
Is voltage between a Check both sides.
YES 103 (2), 104 (2)
and chassis YES
ground normal?
• Turn starting switch 6
ON. If ANR is discon-
• Max. 1 V nected, does voltage 7 YES
between 103 (2),
NO 104 (2) and chassis If 220 is disconnect-
3 ground normal? ed, does voltage be-
tween 103 (2), 104
Is voltage between • Disconnect ANR. NO (2) and chassis
YES 103 (1), 104 (1) • Turn starting switch ground normal?
and chassis ON. • Disconnect 220. NO
ground normal? • Max. 1 V • Turn starting switch ON.
• Turn starting switch • Max. 1 V
to START position. 9 YES
• 20 – 30 V Is resistance be-
YES tween TL2 (male)
(1) and (3) nor-
8 mal?
2 Is voltage be- • Turn starting switch NO
tween TL2 (3) and OFF.
YES Does operating NO chassis ground • Disconnect TL2.
sound of battery • Max. 1z
normal? 10 YES
relay come out?
to START position. terminal C of start-
• Turn starting switch ing switch and
ON and OFF. • 20 – 30 V NO chassis ground
• 20 – 30 V normal?
a Check both sides. • Turn starting switch NO
to START position.
• 20 – 30 V
YES
1 11
Is voltage between
Are voltage and terminal B of
specific gravity of battery relay and YES
NO chassis ground
battery normal?
normal? 12
• Voltage: Min. 24 V terminal BR of
• Specific gravity: ON. starting switch and
• 20 – 30 V NO chassis ground 13 YES
Min. 1.26
a Check both sides. normal? Is resistance be-
• Turn starting switch tween terminals B
ON. NO and BR of starting
• 20 – 30 V switch normal?
• Disconnect NO
terminals B and BR
of starting switch.
• Turn starting switch ON.
• Max. 10z
NO
12-142 12V170-2
Cause Remedy
Defective starting motor Replace
Defective connection in
power supply harness be- Repair or
tween starting motor and replace
battery relay
Defective alternator Replace
Defective diode (220) Replace
Short circuit with power

source in wiring harness be-
tween 103 (female) (2) Ð 104 Repair or
(female) (2) – CNR or 220 replace
(male) (2)
nection in wiring harness be- Repair or
tween TL2 (female) (1) – 103 replace
(female) (1) – 104 (female) (1)
Defective neutral safety

switch Replace

Repair or
between terminal C (280) of
replace
starting switch – TL2 (fe-
male) (3)
Defective starting switch Replace
Defective battery relay Replace

between terminal BR (260) Repair or
of starting switch – terminal replace
BR of battery relay
between terminal B (250) of Repair or
starting switch – terminal B replace
of battery relay
Defective battery Replace
12V170-2 12-143
12-144 12V170-2
E-33 Engine does not stop when starting switch is turned to OFF position
a Check that any service code is not displayed. (If any service code is displayed, check according to it.)
Cause Remedy
YES
1
Is voltage between Short circuit with power

E11 (9), (17) and source in wiring harness be-
2 YES
(8), (16) normal? tween E11 (female) (9), (17) Repair or
Is resistance be- replace
– terminal ACC of starting
• Turn starting switch tween terminals B switch
OFF. NO and ACC of start-
• Max. 1 V ing switch normal?
OFF.
• Disconnect terminals
B and ACC.
• Min. 1 Mz
12V170-2 12-145
TROUBLESHOOTING
(S-MODE)
Points to remember when troubleshooting.................................................................................................. 20-202

Method of using troubleshooting charts ...................................................................................................... 20-203
S- 1 Starting performance is poor (Starting always takes time) ............................................................... 20-208
S- 2 Engine does not start
(1) Engine does not turn ................................................................................................................. 20-209
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected) ................................. 20-210
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ...........................20-211
S- 3 Engine does not pick-up smoothly (Follow-up is poor) ..................................................................... 20-212
S- 4 Engine stops during operations (with electronical governor) ............................................................ 20-213
S- 5 Engine does not rotate smoothly (Hunting) (with electronical governor) .......................................... 20-214
S- 6 Engine lacks output (no power) (with electronical governor) ............................................................ 20-215
S- 7 Exhaust gas is black (incomplete combustion) (with electronical governor)..................................... 20-216
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-217
S- 9 Oil becomes contaminated quickly ................................................................................................... 20-218
S-10 Fuel consumption is excessive (with electronical governor) ............................................................. 20-219
S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-220
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ................................................................ 20-221
S-13 Oil level rises .................................................................................................................................... 20-222
S-14 Water temperature becomes too high (Overheating)........................................................................ 20-223
S-15 Abnormal noise is made ................................................................................................................... 20-224
S-16 Vibration is excessive ....................................................................................................................... 20-225
S-17 Abnormality in governor servo system is displayed in troubleshooting for engine controller............ 20-226
12V170-2 12-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fit-
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
ted.
k If the radiator cap is removed when the engine is hot water may spurt out and cause burns, so wait for the
allow any unauthorized person to come near.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
engine to cool down before starting troubleshooting.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion. However, a short cut to effective troubleshooting is to ask the operator various questions to form
some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4. Confirming failure

to disassemble the components. Confirm the extent of the failure yourself, and
If components are disassembled immediately judge whether to handle it as a real failure or as
any failure occurs: a problem with the method of operation, etc.
• Parts that have no connection with the failure a When operating the machine to reenact the
or other unnecessary parts will be disassem- troubleshooting symptoms, do not carry out
bled. any investigation or measurement that may
• It will become impossible to find the cause of make the problem worse.
the failure. 5. Troubleshooting
It will also cause a waste of manhours, parts, or Use the results of the investigation and inspec-
oil or grease, and at the same time, will also lose tion in Items 2 – 4 to narrow down the causes of
the confidence of the user or operator. failure, then use the troubleshooting flowchart to
For this reason, when carrying out troubleshoot- locate the position of the failure exactly.
ing, it is necessary to carry out thorough prior a The basic procedure for troubleshooting is as
investigation and to carry out troubleshooting in follows.
accordance with the fixed procedure. 1) Start from the simple points.
2. Points to ask user or operator 2) Start from the most likely points.
1) Have any other problems occurred apart 3) Investigate other related parts or infor-
from the problem that has been reported? mation.
2) Was there anything strange about the 6. Measures to remove root cause of failure
machine before the failure occurred? Even if the failure is repaired, if the root cause of
3) Did the failure occur suddenly, or were there the failure is not repaired, the same failure will
problems with the machine condition before occur again.
this? To prevent this, always investigate why the prob-
4) Under what conditions did the failure occur? lem occurred. Then, remove the root cause.
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred
before?
3. Checks before troubleshooting
1) Check the oil level.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
5) Other maintenance items can be checked
externally, so check any item that is consid-
ered to be necessary.
12-202 12V170-2
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in (B) are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
12V170-2 12-203
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items] in
turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for that
item to make final confirmation of the cause.
*1. For [Confirm recent repair history] in the

[Questions] Section, ask the user, and mark
the Cause column with E to use as refer-
ence for locating the cause of the failure.
Defective injection pump (excessive injection)

However, do not use this when making cal-
culations to narrow down the causes.
*2. Use the E in the Cause column as refer-
ence for [Degree of use (Operated for long
Seized turbocherger, interference
Clogged, seized injection nozzle

period)] in the [Questions] section as refer-
Clogged air cleaner element

ence. As a rule, do not use it when calculat-
Worn piston ring, cylinder
Improper injection timing

ing the points for locating the cause, but it
can be included if necessary to determine
the order for troubleshooting.
*1 Confirm recent repair history

*2 Degree of use Operated for long period
12-204 12V170-2
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
Causes
Leakage of air between turbocharger and cylinder head
Defective fuel injection pump (rack, plunger seized)

Defective variable prestroke spool, solenolid
Defective contact of valve and valve seat
Clogged, seized fuel injection nozzle
Seized turbocharger, interference
Worn piston ring, cylinder liner
Improper fuel injection timing

Improper valve clearance

Crushed, clogged muffler
Legend
: Possible causes (judging from Questions and Check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Confirm recent repair history

Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel is being used
Noise of interference is heard from around turbocharger
Dust indicator lamp is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Check items
Match marks on fuel injection pump are out of alignment

Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and cylinder head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Troubleshooting
Stop fuel injection to one cylinder at a time. If there is no change in

engine speed, that cylinder is not working
When check is made using delivery method, fuel injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy, or does not return
Check sliding of spool, solenoid at variable prestroke end
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Remedy
12-206 12V170-2
Five causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the five
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marked where the
horizontal lines for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element]. Follow
this column down to the troubleshooting area and carry
out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
12V170-2 12-207
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)

(with mechanical governor)
General causes why starting performance is poor
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel Causes
(At ambient temperature of –10°C [–14°F] or below, use
Defective fuel injection pump (rack, plunger stuck and worm plunger)
Leakage, clogging, entry of air and dust in fuel system
Defective operation of governor oil pump relief valve

ASTM D975 No. 1, and –10°C [–14°F] or above, use
ASTM D975 No. 2 diesel fuel.)
a Battery charging rate.
Clogged fuel filter, priming pump strainer

Charging rate
Defective contact of valve, valve seat

Ambient 100 % 90 % 80 % 75 % 70 %
Clogged fuel tank air breather hole

Defective electric intake air heater
temperature
Clogged governor oil supply pipe

Defective or deteriorated battery
Defective fuel injection timing

20°C [68°F] 1.28 1.26 1.24 1.23 1.22
Defective fuel injection nozzle
Clogged governor oil strainer

0°C [32°F] 1.29 1.27 1.25 1.24 1.23
Defective overflow valve

–10°C [–14°F] 1.30 1.28 1.26 1.25 1.24
Defective alternator
Defective regulator
• The specific gravity should exceed the value for the
charging rate of 70% in the above table.
• In cold weather the specific gravity must exceed the
value for the charging rate of 75% in the above table.
Gradually became worse
Ease of starting
Starts when warm
Questions
Engine takes time to start after warming up

Indicator lamp does not light up
Replacement of filters has not been carried out according to operation manual
Dust indicator is red
Non-specified fuel has been used
Battery charge lamp is ON
Starting motor cranks engine slowly
Engine does not pick up smoothly, and combustion is irregular
Check items
Mud is stuck to fuel tank cap

When engine is cranked with starting motor,
1) Little fuel comes out even when injection piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
Entry of water and dust in fuel

When air element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Heater mount does not become warm
Troubleshooting
Voltage is 26 – 30V between alternator terminal B and terminal E Yes

with engine at low idling No
Either specific gravity of electrolyte or voltage of battery is low
Stop fuel injection to one cylinder at a time. If there is no change in engine
speed, that cylinder is not working
When check is made using delivery method, injection timing is found to be incorrect
When control rack is pushed, it does not return
When fuel cap is inspected directly, it is found to be clogged
When overflow valve is inspected, it is found to be stiff, or always stays open
When governor oil supply pipe is inspected directly, it is found to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Crean
Clean
Clean
Clean
Clean
Remedy
12-208 12V170-2
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn

Causes
• Internal parts of engine seized
a If internal parts of the engine are seized,
carry out troubleshooting for “Engine stops
during operations”.
• Failure in power train
• Defective electrical system
Defective safety relay or safety switch
Defective battery terminal connection

Defective wiring of starting circuit
Defective starting switch

Defective starting motor
Defective battery relay

Broken ring gear
Questions
Degree of use of machine Operated for long period
Condition of horn when Horn does not sound

starting switch is turned ON Horn sound level is low
Rotating speed is low
When starting switch is Makes grating noise
turned to START, pinion
Soon disengages again
moves out, but
Makes rattling noise and does not turn
Check items
When starting switch is turned to START, pinion does not move out
Carry out troubleshooting for "E-1, Defective wiring of starting circuit"
When starting switch is turned to ON, there is no clicking sound

Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 4), turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are connected,
engine starts
Troubleshooting
2) When terminal B and terminal C of starting motor are connected,

engine starts
3) When terminal B and terminal C of safety relay are connected,

engine does not start
4) When terminal of safety switch and terminal B of starting motor are

connected, engine starts
When ring gear is inspected directly, tooth surface is found to be

chipped
Replace
Replace
Replace
Replace
Replace
Replace
Correct
—
Remedy
12V170-2 12-209
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected) (with electronical gover-
nor) (including cases with V-type engine where there is fuel injection for the bank on only one
side)
General causes why engine turns but no exhaust gas

comes out
• Supply of fuel impossible Causes
• Supply of fuel is extremely small
Defective operation of governor oil pump relief valve (*1)

• Improper selection of fuel (particularly in winter)
Defective fuel injection pump (seized plunger, rack)

Standards for use of fuel
Broken fuel injection pump drive shaft, key
Seized governor oil pump gear, shaft (*1)

Defective fuel cut solenoid (valve stuck)
Seized, broken feed pump (gear, shaft)
AMBIENT TEMPRATURE
Clogged governor oil supply pipe (*1)

Type of

fuel -22 -4 14 32 50 68 86 104°F
Clogged governor oil strainer (*1)

Governor spool valve struck (*1)
-30 -20 -10 0 10 20 30 40°C
Clogged priming pump strainer
Clogged, leaking fuel piping

Clogged fuel filter, strainer
ASTM D975 No.2
Diesel fuel
ASTM D975 No.1
Improper fuel used

Lack of fuel
Exhaust gas suddenly (when starting again) stopped coming out
Replacement of filters has not been carried out according to operation
Questions
manual
Fuel tank is found to be empty

There is leakage from fuel piping
When fuel filter is drained, fuel does not come out
1) Fuel injection pump coupling does not turn
Check items
2) No fuel comes out even when fuel filter air bleed plug is loosened
3) No fuel comes out even when fuel injection pump air bleed plug is
loosened
4) No fuel spurts out even when fuel injection pipe sleeve nut is
loosened
Rust and water are found when fuel tank is drained
Inspect fuel injection pump directly

Conrol rack does not move
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found to be
clogged
Troubleshooting
When priming pump strainer is inspected directly, it is found to be

clogged
Inspect fuel cut solenoid directly
Inspect governor oil pump directly
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found to be
clogged
When governor oil strainer (Inlet and inside of gear pump) is inspected
directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
Add
*1 : See "S-17 Abnormality in governor servo system is displayed is troubleshooting for engine controller".
12-210 12V170-2
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not

start (Fuel is being injected)
General causes why exhaust smoke comes out but Causes
Defective, broken valve system (valve, rocker lever, etc.)

engine not start
Defective fuel injection pump (rack, plunger stuck, worm plunger)
Leakage, clogging, entry of air and dust in fuel system

• Lack of rotating force due to defective electrical
system
Clogged fuel injection nozzle, defective spray

Clogged air breather hole in fuel tank cap

Defective intake of fuel control lever

• Improper selection of fuel and oil

Viscosity of engine oil is high

Improper fuel used

Suddenly failed to start
When engine is cranked, abnormal noise is heard from around head
Questions
Non-specified fuel has being used

Replacement of filters has not been carried out according to
Operation Manual
Rust is found when fuel tank is drained
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items
1) Little fuel comes out even when fuel injection pump sleeve nut is
loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
When fuel control lever is moved, fuel injection pump lever does not
move
Remove cylinder head cover and check directly

clogged
Troubleshooting
When feed pump strainer is inspected directly, they are found to be

clogged
When air cleaner element is inspected directly, it is found to be clogged
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, operation is too light or too heavy
When nozzle holder is inspected directly, it is found to be clogged
Play, stiffness in fuel control lever linkage
When engine oil is inspected directly, it is found to have high viscosity
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
12V170-2 12-211
TROUBLESHOOTING S-3
S-3 Engine does not pick-up smoothly

(Follow-up is poor)
General causes why engine does not pick up smoothly

Causes
• Improper condition of fuel injction
Defective fuel injection pump (rack, plunger stuck, worn plunger)

Broken boost compensation diaphragm of fuel injection pump
Clogged, leaking fuel piping, entry of air and dust in piping
• Improper fuel used
• Defective injection pump
Clogged air breather hole in fuel tank cap



Defective priming pump
Operation Manual
Questions

Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied

When fuel filter, strainer are inspected directly, they are
found to be clogged
Troubleshooting

When feed pump is inspected directly, it is found to be abnormal
When valve clearance is checked directly, it is found to be
Broken boost compensator diaphragm, crushed pipng
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12-212 12V170-2
TROUBLESHOOTING S-4
S-4 Engine stops during operations (with electronical governor)

(including cases with V-type engine where there is fuel injection for the bank on only on side)
General causes why engine stops during operations

• Internal parts of engine sized Causes
Defective operation of governor oil pump relief valve (*1)

Defective injection pump (rack, plunger stuck) (*1)
• Overheating
a If there is overheating and the engine stops,
Broken valve system (valve, rocker lever, etc.)

carry out troubleshooting for overheating.
Sized governor oil pump gear, shaft (*1)

• Failure in power train
Broken, seized piston, connecting rod
Clogged governor oil supply pipe (*1)

a If the engine stops because of a failure in the

Broken, seized crankshaft bearing
Broken pump auxiliary equipment

Broken fuel pump drive shaft, key
Clogged governor oil strainer (*1)

power train, carry out troubleshooting for the
Failure in chassis power train

machine.
Broken, seized gear, shaft

Broken, seized gear train
Lack of fuel
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
stopped
Engine stopped slowly
Questions
There was hunting and engine stopped

Fuel gauge lamp lights up
Replacement of filters has not been carried out according to operation
manual
Non-specified fuel has been used
When feed pump is operated, there is no response or it is heavy
Engine rotates, but stops when transmission control lever is operated
Does not turn at all
Check items
Try to turn by hand using Turns in opposite direction

barring tool
Moves amount of backlash
Shaft does not turn
Carry out troubleshooting for "machine"

Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove cylinder head cover and inspect directly
When gear train is inspected, it does not turn
Turns when pump auxiliary equipment is removed
Troubleshooting

found to be clogged
When priming pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
Control rack does not move
Inspect governor oil pump directly
When governor oil supply pipe is inspected directly, it is found to
be clogged
When governor oil strainer is inspected directly, it is found to
be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
Add
*1 : See "S-17 Abnormality in governor servo system is displayed is troubleshooting for engine controller".
12V170-2 12-213
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (Hunting) (with electronical governor)
General causes why engine does not rotate smoothly

• Air in fuel system
• Defective governor mechanism
Causes
Defective operation of governor (Defective adjustment)
Clogged, air in circuit between fuel tank and feed pump

Clogged, air in circuit between feed pump and injection nozzle
Defective adjusting of governor (solenoid spool)
Clogged governor oil pump inlet port filter, pipe

Defective fuel injection pump (worn plunger)
Clogged governor oil pump screen filter
Defective operation of control rack
Clogged feed pump strainer

Low speed is too low
Lack of fuel
Occurs at certain speed range
Occurs at low idling
Condition of hunting
Questions
Occurs even when speed is raised

Occurs on slopes
Replacement of filters has not been carried out according
to operation manual
Rust is found when fuel is drained
When feed pump is operated,
1) No response, light, return is quick
Check items
2) No response, light, return is normal

Engine speed sometimes rises too high
Engine is sometimes difficult to stop
Entry of water and dust
Governor lever (solenoid plunger) is stiff

Spool valve is stiff
Troubleshooting

clogged
When governor oil pump screen filter is inspected, it is found to be
clogged
When governor oil pump inlet filter, oil supply pipe are inspected,
they are found to be clogged
Replace
Replace
Repair
Repair
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
12-214 12V170-2
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power) (with electronical governor)
(With V-type engine, for cases where there is injec-

tion for only one bank, go to troubleshooting S-2 (2)
or S-4.)
General causes why engine lacks output Causes

Worn and seized fuel injection pump plunger
Defective variable prestroke spool, solenoid

• Improper fuel used
(if non-specified fuel is used, output drops)

• Lack of output due to overtaking

a If there is overheating and insufficient output,

Clogged feed pump strainer
carry out troubleshooting for overheating.


Suddenly
Power was lost
Gradually
Questions

Replacement of filters has not been carried out according
to operation manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
High idling speed of engine is low

found to be clogged
Troubleshooting

When valve clearance is checked directly, it is found to be
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Clean
Clean
Clean
Remedy
12V170-2 12-215
TROUBLESHOOTING S-7
S-7 Exhaust gas is black (incomplete combustion) (with electronical governor)
General causes why exhaust gas is black

Causes

Defective variable prestroke spool, solenolid
Defective contact of valve and valve seat
Clogged, seized fuel injection nozzle


Crushed, clogged muffler
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Check items

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and cylinder head, loose clamp

When air cleaner is inspected directly, it is found to be clogged
Troubleshooting

When check is made using delivery method, fuel injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust gas color returns to normal
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Remedy
12-216 12V170-2
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
a To prevent the oil from leaking up down, do not

run the engine at idling for more than 20 minutes
continuously. (Both low and high idling)
Causes
General causes why oil consumption is excessive
• Abnormal combustion of oil
Turbocharger
• External leakage of oil
• Wear of lubrication system
Defective fuel injection pump (worn plunger)

• Oil suction by fuel injection pump
Leakage from oil pan or cylinder head

Clogged breather or breather hose
Dust sucked in from intake system

Leakage from oil filter or oil cooler
Leakage from oil pan drain plug

Worn valve (stem, guide)

Worn seal at turbine end
Too much engine added

Worn seal at blower end
Leakage from oil piping
Worn, broken rear seal

Broken piston ring
Broken oil cooler

Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When intake pipe is removed, inside is dirty with oil
Oil level in clutch or TORQFLOW transmission damper chamber rises
Oil is above H level on oil level gauge
Clamps for intake system are loose
Full color is extermely dark (Engine oil in fuel)

When breather element is inspected, it is found to be
Troubleshooting
clogged with dirty oil

There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
When rear seal is inspected directly, abnormality is found in seal surface
When intake manifold is removed, dust is found inside
When head cover is removed, inside is found to be abnormally dirty
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
12V170-2 12-217
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

• Intake of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper combustion
• Improper oil used Causes
• Operation under excessive load
• Oil change interval long
Worn seal at turbocharger turbine end

Clogged breather, breather hose
Clogged turbocharger drain pipe

Too much engine oil added

Worn valve (stem, guide)
Exhaust smoke is black

Defective safety valve
Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used
Black
Excessive
Carry out troubleshooting for “S-7, Exhaust smoke is black”.

Amount of blow-by gas
None
Oil filter caution lamp stays on even when oil temperature rises
Check items
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
Oil is above H level on oil level gauge
When compression pressure is measured it is found to be low

When breather element is inspected directly, hose is broken
or is found to be clogged with dirty oil
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be
catching or broken
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
12-218 12V170-2
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive (with electronical governor)
General causes why fuel consumption is excessive

• Leakage of fuel
Causes
Defective fuel injection pump, gear pump oil seal

Defective injection pump (excessive injection)
Defective variable prestroke spool, solenoid

External leakage from fuel piping, fuel filter
Leakage of fuel inside head cover
Defective injection pump plunger
Defective injection nozzle spray

Questions
More than for other machines of same

Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust gas color
White
There is irregular combustion
Check items

Match mark on fuel injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
Fuel injection pump test shows that fuel injection amount is excessive
Troubleshooting

When check is made using delivery method, fuel injection timing is found
to be incorrect
Remove cylinder head cover and directly
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust
Remedy
12V170-2 12-219
S-11 Oil is in cooling water, or water spurts

back, or water level goes down
General causes why oil is in cooling water

• Internal leakage in lubrication system
• Internal leakage in cooling system
Causes
Broken cylinder liner O-ring, holes caused by pitting
Clogged breather of water pump, defective seal

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block

Broken oil cooler core, O-ring

Questions

Gradually increased
Oil level
Suddenly increased
Hard water is being used as cooling water (corrosion resisteor valve
Check items
is closed)
Engine oil level has risen, oil is cloudy white
Excessive air bubbles inside radiator, spurts back

Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage

When cylinder head is removed, and cylinder liner is inspected directly,
it is found to be abnormal
When oil pan is removed, and liner and cylinder block are inspected
directly, they are found to be abnormal
When water pump is inspected, it is found to be abnormal
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
12-220 12V170-2
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)
General causes why oil pressure lamp lights up

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Deterioration of oil due to overheating
Causes
• Improper oil used (improper viscosity)
a Standards for engine oil selection

AMBIENT TEMPERATURE
Type of
fuluid -22 - 4 14 32 50 68 86 104°F
Clogged, broken oil pipe inside oil pan

-30 -20 10 0 10 20 30 40°C
Leaking, crushed hydraulic piping

SAE 30
Clogged strainer inside oil pan
Defective oil pressure sensor

Broken suction pipe brazing
Defective main relief valve
Defective oil level sensor

SAE 10W
Defective regulator valve

Insufficient oil in oil pan
Worn bearing, journal
Engine oil
Defective oil pump

SAE 10W-30
Water, fuel in oil

Clogged oil filter
SAE 15W-40

Questions

Operation Manual
Caution lamp lights up
Non-specified oil is being used
Lights up at low idling
Condition when oil pressure Lights up at low, high idling
caution lamp lights up
Lights up on slopes
Sometimes lights up
There is clogging, leakage from hydraulic piping (external)
Oil level sensor lamp lights up
Check items
When oil level in oil pan is checked, it is found to be low

Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
Carry out troubleshooting
When oil filter is inspected, it is found to be clogged

for “S-13 Oil level rises”
Troubleshooting
When oil pan is removed and inspected directly, it is found to be

abnormal
Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
When oil pressure is measured, it is found to be within standard value
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Clean
Remedy
Add
12V170-2 12-221
S-13 Oil level rises
a If there is oil in the cooling water, carry out trou-

bleshooting for “Oil is in cooling water”.
General causes why oil level rises
• Water in oil (cloudy white)
Causes
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
Defective part inside fuel injection pump (flange type)

Clogged water pump breather hole, defective seal
Damaged liner O-ring, holes made by pitting

Worn, damaged rear seal surface

Defective nozzle holder sleeve
Broken oil cooler core, O-ring
Cracks inside cylinder block

Defective feed pump seal
Defective nozzle holder
Questions

There is oil in radiator cooling water
Exhaust smoke is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling,
an abnormal number of bubbles appear, or water spurts back
Check items
Water pump breather hole is clogged with mud

When water pump breather hole is cleaned, water comes out
Oil level goes down in clutch, TORQFLOW transmission, or damper
chamber
Engine oil smells of diesel fuel

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
When water pump is removed and inspected directly, it is found to be

abnormal
When real seal is inspected directly, it is found to be abnormal
When nozzle holder is removed and inspected directly, it is found to be
abnormal
Remove fuel injection pump and inspect directly
When feed pumps is inspected directly, it is found to be abnormal
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
12-222 12V170-2
S-14 Water temperature becomes too high (Overheating)
General causes why water temperature becomes too high

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train Causes
a Carry out troubleshooting for machine
Defective water temperature gauge, water temperature sensor
Damaged cylinder liner O-ring, holes made by pitting
Rise in torque converter oil temperature

Defective thermostat (does not open)

Defective radiator pressure valve
Fan belt slipping, worn fan pulley
Clogged, crushed radiator fins
Clogged, broken oil cooler

Insufficient cooling water
Cracks in cylinder block

Clogged radiator core
Confirm recent repair history Broken water pump

Suddenly overheated
Condition of overheating
Questions
Always tends to overheat
Water temperature gauge

Rises quickly
range does not move
Radiator water level sensor lights up

Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
Radiator fins, inside of underguard are clogged with dirt or mud

When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
Belt tension is found to be slack
Power train oil level enters red range before engine water temperature
Temperature difference between top and bottom radiator tanks

is excessive
"H-9 Torque converter becomes hot".
Temperature difference between top and bottom radiator tanks

is slight
Carry out troubleshooting for
Carry out troubleshooting for
When water filler port is inspected, core is found to be clogged

Troubleshooting
When function test is carried out on thermostat, it does not

"S-13 Oil level rises".
open even at cracking temperature

When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
When cylinder head is given pressure resistance tast, there is found to
be leakage
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Add
12V170-2 12-223
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an external

noise.
General causes why abnormal noise is made

Causes
• Abnormality due to defective parts

• Abnormal combustion noise
Defect inside muffler (dividing board out of position)

Defective fuel injection pump (excessive injection)
• Air sucked in from intake system
Broken valve system (valve, rocker lever, etc.)
Seized crankshaft connecting rod bearing

Excessive wear of piston ring, cylinder liner
Deformed fan, interference of fan belt

Clogged, seized nozzle holder
Improper gear train backlash

Confirm recent repair history Missing, seized bushing
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Check items

Seal on fuel injection pump has come off
Abnormal noise is loud when accelerating engine
Vibrating noise is heard from around muffler

When gear cover is removed and inspected directly, it is found to be
abnormal
Troubleshooting

Fuel injection pump test shows that fuel injection amount is incorrect
Fan is deformed
When valve clearance is checked, it is found to be outside
standard value
When cylinder head cover is removed and inspected directly, it is
found to be abnormal
When muffer is removed, abnormal noise disappears
When oil pan is removed and inspected, it is found to be abnormal
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Remedy
12-224 12V170-2
S-16 Vibration is excessive
a If there is abnormal noise together with the vibra-

tion, carry out troubleshooting for “Abnormal
noise is made”.
Causes
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment
• Abnormal combustion
Defective fuel injection pump (excessive injection)

Defective valve system (valve, rocker lever, etc.)
Misalignment between engine and power train
Loose engine mounting bolts, broken cushion
Worn connecting rod, main bearing
Worn balancer, cam bushing
Improper gear train backlash
Defective vibration damper

Broken part inside damper
Clogged nozzle holder

Worn support pilot
Questions
Suddenly become black

Condition of vibration
Gradually become black
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
There is play in crankshaft pulley
Seal on fuel injection pump has come off
Stop fuel injection to one cylinder at time. If there is no change in
engine vibration, that cylinder is not worling

abnormal
When cylinder head cover is removed and inspected directly, it is
found to be abnormal
abnormal
Troubleshooting
When support pilot is inspected directly, it is found that there is wear

and play
When engine monting bolts are inspected directly, it is found that
there are loose bolts, broken cushion
When damper is removed and inspected directly, it is found to be
abnormal
When radial runout, face runout are measured, they are found to be
out-side standard valve
When cylinder head cover is removed and inspected directly, it is found
to be abnormal
Fuel injection pump test shows that fuel injection amount is incorrect
When nozzle holder is inspected directly it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
12V170-2 12-225
S-17 Abnormality in governor servo system is displayed in troubleshooting for engine

controller
The following is the troubleshooting for the engine, containing the Cause
causes and remedies, to be carried when there is abnormality in the
Rack
governor servo system. Mechanical system of fuel
sensor
injection pump
system
Legend
E : Operating condition of engine in which this trouble can occur
Defective adjustment or rack sensor output voltage

EE : Operating condition of engine in which this trouble can occur
particularly
Wear of power piston contract part of rack

Stiffness or scuffing of rack power piston
Q
Stiffness or scuffing of plunger or barrel

: Possible cause of this trouble
w : Particularly possible cause of this trouble
Stiffness or scuffing of control rack

q : Diagnosis item
Breakage of rack return spring
Defective rack stopper bolt
Defective rack sensor

Operating condition of engine
Error code No.
At start In operation In acceleration In deceleration
G-10 [C019] EE E EE Q Q Q Q Q w Q
Inspection item
or
G-11 [C01A] E EE Q Q Q w Q w Q
Abnormal engine oil pressure lamp lights up
Engine oil is dirty particularly
When rack stopper bolt at rear of fuel injection pump is removed and rack piston is
pushed with clean screwdriver, rack does not move or does not return. q q q q
When engine is stopped and key is turned ON, rack output voltage measured with T-
adapter is out of range of 0.15 - 0.56 (V).
q q q q
Engine oil feed tube and joint are clogged.
Governor oil inlet filter is clogged.
If oil pump relief valve is of former ball type, replace it with one of spool type. If it is
difficult to obtain relief valve of spool type, push existing valve in clean fuel or
disassemble and clean it.
Diagnosis
When oil pump relief valve of new spool type is pushed with screwdriver from screw
side, it is stiff or scuffed.
O-ring at threaded part of oil pump relief valve is damaged or hardened extremely.
Governor oil outlet strainer is clogged or damaged.
When gear pump plate is removed and rotated with burring tool to check gear pump,
gear or shaft does not rotate.
Wire cable of governor solenoid has grounding fault or short circuit and resistance
between connector 2 pins is out of range of 10 - 21 z.
Push rod of governor solenoid is stiff or scuffed.
When governor solenoid is removed and spool is checked, it is stiff or scuffed.
Oil drain pipe to engine oil pan is clogged.

injection pump
injection pump
injection pump
Replace fuel
Replace fuel
Replace fuel
Remedy
Replace
(*1)
(*1)
*1. See ABNORMALITY IN RACK SENSOR SYSTEM (E-9, E-10).
12-226 12V170-2
Cause
Condition of
Oil pressure control system
engine oil
Oil supply Governor oil control system
system
Gear pump Solenoid Spool/Bushing
(1) In this case, the solenoid current may decrease and abnormality may
occur in the governor solenoid system.
See the troubleshooting for the governor solenoid system (E-12 - 15).
Stiffness, scuffing, or wear of governor spool

Stiffness or scuffing of push rod of governor
Breakage of governor spool return spring

Clogging or breakage of oil outlet screen
(2) In this case, the solenoid current may increase and abnormality may
occur in the governor solenoid system.
Breakage or scuffing of gear or shaft
Defective wire of governor solenoid
Clogging of oil drain pipe to oil pipe

See the troubleshooting for the governor solenoid system (E-12 - 15).
Low oil level or deterioration of oil

(3) In this case, the rack voltage may rise and abnormality may occur in
Malfunction of oil relief valve
the rack sensor system.

Clogging of oil supply line
See the troubleshooting for the rack sensor system (E-9 - 10).
Clogging of oil inlet filter
(4) In this case, the rack voltage may lower and abnormality may occur in
the rack sensor system.
See the troubleshooting for the rack sensor system (E-9 - 10).
solenoid
Note
Q Q Q w Q Q Q (1) (3)
w w Q w w Q Q w Q (2) (4)
q
q
q q
q
Add or replace
injection pump
Replace fuel
See the troubleshooting for

See the troubleshooting for the
Clean or
Clean or
Clean or
Clean or
Clean or
the governor solenoid system

Replace
Replace
replace
replace
replace
replace
replace
rack sensor system (E-9, E10).

(E-12 - E15).
12V170-2 12-227
13 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ....................... 13- 3 25. Cylinder head covers............................... 13-17
PRECAUTIONS WHEN CARRYING OUT 26. Nozzle holders......................................... 13-18
OPERATION .................................................. 13- 4 27. Rocker arm housing assembly ................ 13-18
SPECIAL TOOL LIST....................................... 13- 6 28. Push rod .................................................. 13-18
GENERAL DISASSEMBLY.............................. 13- 7 29. Cross head .............................................. 13-18
1. Cleaning................................................... 13- 7 30. Cylinder head assembly .......................... 13-18
2. Setting engine stand ................................ 13- 7 31. Oil pump assembly .................................. 13-20
3. Coolant and engine oil ............................. 13- 7 32. Starting motor assemblies ....................... 13-20
4. Air cleaner and muffler assembly............. 13- 7 33. Flywheel .................................................. 13-21
5. Oil filter tubes ........................................... 13- 8 34. Flywheel housing..................................... 13-21
6. Oil filter..................................................... 13- 8 35. Vibration damper ..................................... 13-21
7. Fuel tube .................................................. 13- 8 36. Drive case assembly ............................... 13-21
8. Filter bracket ............................................ 13- 9 37. Retainer and front support....................... 13-22
9. Exhaust manifold cover 38. Gear case cover and timer case cover.... 13-22
(Right side is shown in figure).................. 13- 9 39. Fuel injection pump drive case ................ 13-22
10. Turbocharger assembly ........................... 13- 9 40. Air intake manifold ................................... 13-22
11. Exhaust connector ................................... 13-11 41. Cam follower............................................ 13-23
12. Coolant tube, turbocharger pipe, and 42. Gear train................................................. 13-23
exhaust tube ............................................ 13-11 43. Camshaft assemblies .............................. 13-23
13. Aftercooler assembly ............................... 13-11 44. Gear case ................................................ 13-24
14. Plate and case ......................................... 13-12 45. Main gallery plug, oil plug, and cooling
15. Fuel injection pipe and spill tube.............. 13-12 valve ........................................................ 13-24
16. Fuel piping ............................................... 13-13 46. Side covers ............................................. 13-24
17. Lubrication tubes...................................... 13-13 47. Piston cooling nozzles ............................. 13-24
18. Fuel injection pump assembly.................. 13-14 48. Engine set................................................ 13-25
19. Exhaust manifolds.................................... 13-14 49. Pistons and connecting rod assemblies .. 13-25
20. Water pump assembly ............................. 13-15 50. Crankshaft ............................................... 13-26
21. Oil cooler assembly.................................. 13-15 51. Cylinder liner............................................ 13-27
22. Oil pan...................................................... 13-16 CLEANING ...................................................... 13-28
23. Air vent tubes ........................................... 13-16 MEASURING PARTS ...................................... 13-29
24. Thermostat assembly............................... 13-17
12V170-2 13-1
GENERAL ASSEMBLY ....................................13-34 33. Rocker housing........................................ 13-72
1. Cylinder liner ............................................13-36 34. Injection nozzle assembly........................ 13-73
2. Crankshaft................................................13-39 35 Push rod .................................................. 13-73
3. Piston and connecting rod assembly .......13-43 36. Rocker arm assembly .............................. 13-74
4. Setting engine stand ................................13-48 37. Adjusting valve clearance ........................ 13-74
5. Piston cooling nozzles .............................13-48 38. Aftercooler assembly ............................... 13-75
6. Side covers ..............................................13-48 39. Water tubes ............................................. 13-75
7. Main gallery plug, oil plug, and cooing 40. Head cover .............................................. 13-76
plug ..........................................................13-48 41. Thermostat case assembly...................... 13-76
8. Gear case ................................................13-48 42. Fuel injection pump assembly ................. 13-77
9. Camshaft assembly..................................13-50 43. Air vent tubes........................................... 13-78
10. Gear train .................................................13-51 44. Muffler bracket ......................................... 13-79
11. Cam follower ............................................13-53 45. Spill hoses ............................................... 13-79
12. Air intake manifold ...................................13-54 46. Fuel injection pump lubrication tubes ...... 13-79
13. Pump drive case ......................................13-55 47. Fuel supply and overflow pipe ................. 13-80
14. Backlash and end play of gears...............13-56 48. Fuel injection tubes.................................. 13-80
15. Front shaft ................................................13-57 49. Exhaust manifold ..................................... 13-81
16. Gear case cover.......................................13-57 50. Water tube and turbocharger piping ........ 13-82
17. Timer cover ..............................................13-58 51. Exhaust connector ................................... 13-82
18. Water pump drive case ............................13-58 52. Turbocharger assembly ........................... 13-83
19. Compressor drive case ............................13-59 53. Exhaust manifold cover
20. Breather connector ..................................13-60 (Right one is shown in the figure) ............ 13-84
21. Front seal .................................................13-60 54. Oil filler..................................................... 13-84
22. Front support............................................13-60 55. Bypass tube ............................................. 13-85
23. Vibration damper......................................13-61 56. Blow-by hose ........................................... 13-85
24. Piston cooling valve .................................13-62 57. Oil pump assembly .................................. 13-85
25. Oil cooler assembly..................................13-63 58. Oil pan ..................................................... 13-86
26. Water pump assembly .............................13-64 59. Oil level sensor and drain valve............... 13-86
27. Flywheel housing assembly .....................13-65 60. Filter bracket ............................................ 13-86
28. Rear seal..................................................13-66 61. Fuel tube.................................................. 13-87
29. Flywheel...................................................13-66 62. Oil filter .................................................... 13-87
30. Starting motor assemblies........................13-68 63. Oil filter tube ............................................ 13-87
31. Cylinder head assembly...........................13-68 64. Air intake pipe .......................................... 13-87
32. Cross head...............................................13-72 65. Air cleaner and muffler assembly ............ 13-88
13-2 12V170-2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
2) Any special techniques applying only to the installation procedure are marked [*1], and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation proce-
dure it applies to.
(Example)
REMOVAL OF QQQQ ASSEMBLY........... Title of operation
k ................................................................ Precautions related to safety when carrying out the operation
1. (1) ............................................ Step in operation
a ............................................................ Technique or important point to remember when removing
(1).
2. EEEE (2) ........................................... [*1] Indicates that a technique is listed for use during installa-
tion
3. T T T T assembly (3)
6 ...................................................... Quantity of oil or water drained
INSTALLATION OF QQQQ ASSEMBLY ... Title of operation
• Carry out installation in the reverse order to removal.
[*1] .......................................................... Technique used during installation
a ............................................................ Technique or important point to remember when installing
EEEE (2)
• Adding water, oil .............................. Step in operation
a ...................................................... Point to remember when adding water or oil
5................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
12V170-2 13-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210(Nut), 07222-00210(Plug)
03 07376-50315 07221-20315(Nut), 07222-00312(Plug)
04 07376-50422 07221-20422(Nut), 07222-00414(Plug)
05 07376-50522 07221-20522(Nut), 07222-00515(Plug)
06 07376-50628 07221-20628(Nut), 07222-00616(Plug)
10 07376-51034 07221-21034(Nut), 07222-01018(Plug)
12 07376-51234 07221-21234(Nut), 07222-01219(Plug)
2) Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
13-4 12V170-2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins or lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydaulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
12V170-2 13-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t........ Cannot be substituted, must always be installed (used).
q........ Extremely useful if available or, can be substituted with commercially available part.
a New/remodel : N ........ Tools with new part numbers, newly developed for this model
: R ........ Tools with upgraded part numbers, remodeled from items already available for other
models
: Blank.. Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special (See SKETCHES
OF SPECIAL TOOLS).
remode
Neces-
Sketch
Q’ty
New/
sity
Component Symbol Part No. Part Name Remarks
Disassembly, assembly of
A 790-476-1140 Lifting tool t 1
engine assembly
Disassembly, assembly of
B 790-471-1001 Lifting tool t 1
engine assembly
Removal, installation of valve
C 790-102-4210 Spring pusher t 1
spring
Measurement of piston ring
D 795-901-1120 Wear gauge q 1
groove
Removal, installation of piston
E 795-100-1191 Piston ring tool t 1
ring
Removal, installation of main
F 795-215-1320 Socket q 1
bearing cap
Removal, installation of main
G 790-102-1100 Power wrench q 1
bearing cap
Removal of main bearing cap H 790-472-1010 Remover t 1
Removal of cylinder liner I 795-102-1301 Liner puller t 1
Insertion of cylinder liner J 765-250-1210 Liner driver t 1
Installation of piston assembly K 795-225-1700 Piston holder t 1
Measurement of valve
L 795-125-1380 Feeler gauge q 1
clearance
Tightening of connecting rod
M 790-331-1110 Wrench q 1
cap
Insertion of front seal N 795-602-1100 Installer t 1
Insertion of rear seal O 765-602-1200 Installer t 1
Installation of coolant manifold P 765-601-1110 Push tool t 1
13-6 12V170-2
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY
GENERAL DISASSEMBLY
1. Cleaning
Before disassembling the engine, check its parts
for cracking and damage, and then clean it gen-
erally and carefully with steam for quick disas-
sembly.
1) Before cleaning the engine, remove starting
motor assembly (1), alternator assembly, and
electric wires.
2) Cover every opening of the engine with
tapes.
3) Clean the engine with a cleaning machine.

a In particular, carefully clean each joint
where sand and dirt are accumulated
easily.
2. Setting engine stand

Prepare a stable engine stand and fix the engine
assembly on it so that it will not tip over.
4 Engine assembly: Approx. 6,650 kg

(Weight depends on the model)
3. Coolant and engine oil

Drain the engine coolant and engine oil.
6 Engine oil: Approx. 195 l
4. Air cleaner and muffler assembly

1) Disconnect hose (1).
2) Remove plate (2).
3) Remove cover (3) and exhaust connector

(4).
12V170-2 13-7
4) Lift off air cleaner and muffler assembly (5).

a Sling the air cleaner lightly and pull it out
of the air intake connector to remove.
4 Air cleaner and muffler assembly: 610 kg
5) Remove air intake pipes (6), (7), (8), and (9).
5. Oil filter tubes

Remove tubes (1) and (2).
6. Oil filter
Using a filter wrench, remove oil filter (3).
7. Fuel tube
1) Remove fuel tube (1).
2) Remove cover (2).
3) Disconnect joint (3).
13-8 12V170-2
8. Filter bracket
Lift off filter bracket (1).
9. Exhaust manifold cover (Right side is shown

in figure)
Referring to the figure, remove the exhaust man-
ifold cover.
• Remove the exhaust manifold cover on the
left side, too.
10. Turbocharger assembly

1) Referring to the figure, remove the cover.
12V170-2 13-9
2) Remove air intake connector (1) and connec-

tor (2) together. (Right side is shown in fig-
ure)
• Remove the connectors on the left side,
too.
3) Remove coolant tubes (3) and (4).
4) Disconnect lubrication tube (5).
5) Disconnect drain tube (6).
6) Lift off turbocharger assemblies (7) and (8).
13-10 12V170-2
11. Exhaust connector

Remove exhaust connector (1) of the turbo-
charger and bracket (2).
12. Coolant tube, turbocharger pipe, and exhaust

tube
1) Remove clamp (1) and coolant tube (2).
2) Remove the clamp and turbocharger lubrica-
tion tubes (3) and (4).
3) Remove connector (10).
4) Remove turbocharger drain tubes (5) and
(6).
5) Remove exhaust tube (7) and coupling (8).

6) Remove coolant tube (9).
7) Remove bracket (11).
13. Aftercooler assembly

1) Remove the mounting bolts and lift off after-
cooler assembly (1).
12V170-2 13-11
2) Remove connectors (2), (3), and (4) and

tube (5).
3) Remove right and left connectors (6).
4) Remove right and left covers (9).

5) Remove cores (10) and (11) from case (12).
14. Plate and case

Remove mounting bolts (1), plate (2), and case
(3).
15. Fuel injection pipe and spill tube

1) Remove 12 fuel injection pipes (1) from the
right and left banks.
13-12 12V170-2
2) Remove 10 spill tubes (2) and tube (3) and

(4).
16. Fuel piping

Referring to the figure, remove the fuel supply
pipe and overflow pipe.
17. Lubrication tubes

1) Remove tubes (1) and (2).
2) Remove tubes (3) and (4).
12V170-2 13-13
18. Fuel injection pump assembly

1) Remove the mounting bolts. Using tool A, lift
off fuel injection pump assembly (1) from the
right bank.
4 Fuel injection pump assembly: 40 kg
2) Remove the mounting bolts. Using tool A, lift

fuel injection pump assembly (2) from the left
bank.
4 Fuel injection pump assembly: 40 kg

19. Exhaust manifolds

1) Remove 4 manifolds (1).
3) Remove manifolds (3) and (4).
5) Remove manifolds (6) and (7).
13-14 12V170-2
20. Water pump assembly

1) Remove flange (1), clamp (2), and tube (3).
2) Remove the plug. Using [1] (10 mm, P = 1.5
mm), remove drive shaft (4).
3) Remove the bracket and water pump assem-
bly (5).
21. Oil cooler assembly

1) Sling oil cooler assembly (1) temporarily and
remove the mounting bolts, and then remove
the oil cooler assembly.
a The oil cooler mounting bolts are differ-
ent from the exhaust manifold inside
cover mounting bolts. Keep them sepa-
rately.
a Make marks on the mounting positions of
the oil cooler mounting bolts on the oil
cooler.
2) Disassemble the oil cooler assembly accord-

ing to the following procedure.
i) Remove bypass valve (2).
ii) Remove cover and element assembly (5)

from housing (4).
12V170-2 13-15
iii) Remove elements (6), (7), and (8) from

cover (3).
22. Oil pan

1) Sling the engine and block the oil pan hori-
zontally.
2) Remove the mounting bolts and oil pan (1).
23. Air vent tubes

1) Remove tubes (1), (2), and (3).
2) Remove tubes (4), (5), and (6).
3) Remove hose (7).
13-16 12V170-2
24. Thermostat assembly

2) Remove tube (2).
3) Remove right and left thermostats (3).

5) Disassemble each thermostat according to

the following procedure.
i) Remove connector (5).
ii) Remove cover (11) and 2 thermostats
(7).
25. Cylinder head covers

1) Remove joint (1).
2) Remove the mounting bolts and each head
cover (2).
3) Remove seal (3).
12V170-2 13-17
26. Nozzle holders

Remove mounting bolts (1) and each nozzle
holder (2).
27. Rocker arm housing assembly

1) Remove snap ring (1) and pipe (2).
2) Remove the mounting bolts and each rocker
arm housing assembly.
a When installing the rocker arm, loosen
the locknut, and then loosen adjustment
screw (5) by 2 – 3 turns to prevent the
push rod from pushing up.
28. Push rod

Remove push rod (1).
29. Cross head

Remove cross head (1a).
30. Cylinder head assembly

1) Remove the mounting bolts, leaving 1 or 2 of
them.
13-18 12V170-2
2) Using tool B, sling cylinder head assembly

(2), remove the mounting bolts, and then
remove the cylinder head assembly.
4 Cylinder head assembly: 37 kg
a Disassemble the cylinder head assembly accord-

i) Using spring compressor C, compress spring
(1) and remove the valve cotter.
a When spring compressor C is used, the
cylinder head moves. Accordingly, fix
the cylinder head with a vice (C-clamp),
etc.
ii) Remove retainer (2) and valve spring (1).
iii) Remove lower seat (3).
iv) Remove intake valve (4) and exhaust valve

(5).
12V170-2 13-19
31. Oil pump assembly

2) Remove suction tube (2).
4) Using transmission jack [1], remove oil pump

assembly (4).
32. Starting motor assemblies

Remove starting motor assemblies (1) and (2).
13-20 12V170-2
33. Flywheel
1) Using eyebolt [1] (10 mm, P = 1.75 mm), sling
flywheel (3) temporarily.
2) Using bolt [2] (12 mm, P = 1.75 mm), remove
flywheel (3).
4 Flywheel: 97 kg
34. Flywheel housing

1) Lift off flywheel housing (4).
2) Remove rear seal (5).
35. Vibration damper

Sling vibration damper (2) temporarily and
remove the mounting bolts, and then remove
vibration damper (2).
36. Drive case assembly

1) Remove mounting bolts (1). Using a bolt (8
mm, P = 1.25 mm), remove water pump
drive case (2).
2) Remove mounting bolts (3). Using a bolt (8
mm, P = 1.25 mm), remove air compressor
drive case (4).
12V170-2 13-21
37. Retainer and front support

1) Remove front support (1).
2) Remove retainer (2).
38. Gear case cover and timer case cover

1) Remove timer case cover (1).
2) Remove gear case cover (2).
39. Fuel injection pump drive case

Using eyebolt [1] (10 mm, P = 1.5 mm), remove
fuel injection pump drive case (1).
40. Air intake manifold

Remove air intake manifold (1).
13-22 12V170-2
41. Cam follower

Remove cam follower (1).
a Since the cam follower must be installed in
the correct direction, put a No. to it.
42. Gear train

Remove each center bolt and idler gears (1), (2),
(3), (4), (5), and (6).
43. Camshaft assemblies

1) Rotate the camshaft and remove mounting
bolts (1) through the hole of cam gear (3).
2) Remove camshafts (2) from the right bank

and left bank.
a When removing each camshaft, rotate
and pull it out so that the cam bushings
will not be damaged.
12V170-2 13-23
44. Gear case

Lift off gear case (1).
45. Main gallery plug, oil plug, and cooling valve

1) Remove cooling valve (1).
oil plug (2).
main gallery plug (3).
46. Side covers

Remove each side covers.
47. Piston cooling nozzles

Remove the mounting bolts and each piston
cooling nozzle (1).
a If a piston is at the bottom dead center, the
cooling nozzle for it cannot be removed. In
this case, rotate the crankshaft.
13-24 12V170-2
48. Engine set

Set a stable stand on the floor and place the
engine on it with the side down.
a Set the engine so that the right bank liner will
be horizontal and remove the pistons and
connecting rod assemblies. Next, set the
engine so that the left bank liner will be hori-
zontal and remove the left pistons and con-
necting rod assemblies.
49. Pistons and connecting rod assemblies

1) Check the stamp No. of each connecting rod
cap.
a Check that the stamp No. of the connect-
ing rod cap is matched to the cylinder
No.
a If there is not a stamp No., stamp the cyl-
inder No. before removing.
2) Rotate the crankshaft to bring the piston to
be removed to the bottom dead center.
3) Remove carbon from the liner with fine sand-
paper.
a Before remove the piston and connecting
rod assembly, measure the end play of
the connecting rod with dial gauge [1].
4) Remove connecting rod cap bolts (2).
5) Hit the connecting rod bolts lightly with a
plastic hammer, etc. and remove connecting
rod cap (1) and connecting rod bearing
together.
6) Push the piston and connecting rod assem-

bly with a wood bar from the oil pan side to
pull them out toward the cylinder head side,
holding piston (3) with the hand. When pull-
ing them out, take care not to damage the
inside of the liner with the connecting rod.
a Before removing the piston and connect-
ing rod assembly, rotate the crankshaft
until the connecting rod does not touch
balancer (4).
a Since each connecting rod and cap are
used a set, keep their bearings and them
as a set so that you can install them cor-
rectly.
12V170-2 13-25
a Disassemble the piston and connecting

rod assembly according to the following
procedure.
i) Remove the snap ring.
ii) Holding connecting rod (1) with the
hand, pull out piston pin (2) and sep-
arate the connecting rod from piston
(3).
a If you cannot remove the piston, put
it in hot water, and then remove it
again.
iii) Using piston ring tool E, Remove pis-
ton ring (4).
a Arrange the piston, connecting rod,
connecting rod bearing, piston ring,
and piston pin for each cylinder.
50. Crankshaft
1) Turn over the cylinder block to bring the
crankshaft to the upper side.
a Before removing the crankshaft, mea-
sure its end play with dial gauge [1] for
reference for assembly.
2) Remove side bolt (1) of the main cap.
3) Using socket F and power wrench G, remove

mounting bolts (2) of main cap (3).
4) Insert tool H in the hole of main bearing cap
(3). While swinging the cap with tool H,
remove the main bearing.
a The thrust bearing is fitted to the main
cap. Check its position.
13-26 12V170-2
5) Lift off crankshaft (4), taking care not to hit it

against the cylinder block.
4 Crankshaft: 419 kg
6) Remove upper main bearing (5).

7) Remove upper thrust bearing (6).
51. Cylinder liner

1) Before removing the cylinder liner, measure
the projection of the cylinder liner with dial
gauge [1] for reference for assembly.
2) Using liner puller I, pull out cylinder liner (1).
12V170-2 13-27
DISASSEMBLY AND ASSEMBLY CLEANING
CLEANING
1) When cleaning the parts, classify them into a
small parts group and a large parts group. Clean
the small parts in a cleaning tank like one shown
at right.
a Before cleaning each part, remove gasket,

carbon, etc. from it with a wire brush.
a After cleaning the parts, blow off the cleaning

liquid with compressed air. (In particular,
remove all the cleaning liquid from each bolt
hole.)
Cleaning cylinder block

1) Before cleaning the cylinder block, remove the
plugs of the oil line and cooling system.
2) Prepare a cleaning machine like one shown at
right and clean the oil line and cooling system
perfectly with a jet cleaner nozzle.
3) Clean the oil line with a hard wire brush to
remove all the metallic material.
4) Remove burrs from the O-ring contact face at the
bottom of each liner bore with sandpaper.
5) Blow off all the cleaning liquid with compressed
air. (In particular, remove all the cleaning liquid
from each bolt hole.)
6) Press fit the plugs of the oil line and cooling sys-
2 Periphery of plug: Adhesive (LT-2)

tem perfectly.
Cleaning crankshaft
After disassembling the engine, clean the crank-
shaft before inspecting it.
1) Clean the crankshaft with a steam cleaner.
Clean each oil hole with a wire brush like one
shown at right.
2) After cleaning, blow off all the cleaning liquid
with compressed air.
3) Using a small grindstone, remove all the
metallic material from each oil hole.
13-28 12V170-2
DISASSEMBLY AND ASSEMBLY MEASURING PARTS
MEASURING PARTS
• Before assembling the disassemble parts, check
them visually for cracking, damage, abnormal
wear, etc.
• If no abnormality is found by visual inspection,

measure the specified parts accurately with cor-
rect measuring instruments.
• Check each part if it is usable according to the

"Maintenance standard".
MEASURING BEND OF CRANKSHAFT

1) Hold the centers of both ends of the crankshaft
with a lathe, apply the probe of a dial gauge per-
pendicularly to the central journal, and set the
dial gauge pointer to "0".
2) Rotate the crankshaft by 1 turn and read the
maximum value and minimum value indicated by
the dial gauge.
a If the bend is measured by supporting both
ends of the crankshaft on V-blocks, an error
caused by uneven wear of the journal is con-
tained in the measured value. Accordingly,
do not measure by this method.
MEASURING OUTSIDE DIAMETERS OF THE

CRANKSHAFT JOURNALS
1) Using a micrometer, measure the outside diame-
ters of the main journal and pin journal in the
directions of X and Y.
A: Pin journal (measure at 5 places)

B: Main journal (measure at 3 places)
12V170-2 13-29
MEASURING COUNTERBORE DEPTH OF CYLIN-

DER LINER
1) Set depth gauge [5] to gauge block [4] and set
the gauge pointer to "0".
2) Set the gauge block in parallel with the cylinder
block top and measure the counterbore depth.
a Before measuring, clean the cylinder block
top and counterbore.
MEASURING MAIN BEARING BORE

1) Install the main bearing cap to the cylinder block
and tighten it to the specified torque.
2) Using a dial bore gauge or inside micrometer [6],
measure the main bearing bore.
a Measure the bore in the 2 directions of X and

Y.
MEASURING BEND OF CAMSHAFT

1) Hold the centers of both ends of the camshaft
with a lathe, apply the probe of dial gauge [2]
perpendicularly to the central journal, and set the
dial gauge pointer to "0".
k If both ends of the camshaft are pressed

too strongly with the lathe, the camshaft will
be bent. Take care.
2) Rotate the camshaft by 1 turn and read the max-
imum value and minimum value indicated by the
dial gauge.
a If the bend is measured by supporting both
ends of the camshaft on V-blocks, an error
caused by uneven wear of the journal is con-
tained in the measured value. Accordingly,
do not measure by this method.
13-30 12V170-2
MEASURING OUTSIDE DIAMETER OF CAM-

SHAFT JOURNAL
1) Using micrometer [3], measure the outside diam-
eter of the journal.
MEASURING CAM HEIGHT

1) Using micrometer [3], measure height H of the
intake cam and exhaust cam.
MEASURING PISTON RING GROOVE

• Measuring keystone ring groove
Lightly push piston ring wear gauge D in the top
ring groove and second ring groove to measure
the wear of the grooves.
• If the shoulder of the wear gauge touches the

piston, replace the piston.
a Measure at several places.
• Measuring strainer ring groove

Set a new ring to the oil ring groove and mea-
sure the top and bottom clearances with feeler
gauges.
a If the clearance exceeds the limit, replace
the piston.
12V170-2 13-31
MEASURING CLOSED GAP OF PISTON RING

1) Set the piston ring to the minimum worn part of
the cylinder liner and measure its closed gap
with feeler gauge [7].
a Push in the piston ring so that it will be at a
right angle to the sliding part of the liner.
MEASURING CONNECTING ROD LENGTH

1) Tighten the connecting rod cap mounting bolts to
the specified torque.
a Do not install the connecting rod bearing.
2) Install a new piston pin to the small end hole of

the connecting rod.
a When installing the piston pin, apply Grease
(G2-LI) to it.
3) Support both ends of the piston pin on V-blocks

and support both ends of the connecting rod on
square blocks.
4) Measure distance A between the large end and

small end with a height gauge.
5) Measure the inside diameters of the large end

and small end.
• Obtain connecting rod length B by the following

calculation.
Inside diameter of large end Inside diameter of small end
B= 2 + 2 +A
13-32 12V170-2
MEASURING BEND AND DISTORTION OF CON-

NECTING ROD
• Method of measuring bend
1) Tighten the connecting rod cap mounting
bolts to the specified torque.
a Do not install the connecting rod bearing.
2) Install a new piston pin to the small end hole
of the connecting rod. Place V-blocks on a
surface plate and set both ends of the piston
pin on those V-blocks.
a When installing the piston pin, apply
Grease (G2-LI) to it.
3) Erect the connecting rod and support both
sides of the large end on square blocks.
4) Apply the probe of height gauge [1] to the
lowest part before the large end hole and set
the gauge pointer to "0".
5) Move the height gauge toward the opposite
side by the width of the large end and read it.
• Method of measuring torsion

1) Remove the square blocks from the above
condition and bring the connecting rod down
and support the large end on the conical end
of a jack.
2) Measure the large end by the method of
measuring the bend.
• Obtain the bend and torsion by the fol-
lowing calculation.
Dimension B
Bend/Torsion = Dimension A x Measured
value
12V170-2 13-33
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY
GENERAL ASSEMBLY
Tightening bolt by plastic-region angle tighten-
ing method
• The important bolts of the engine are tightened
by the plastic-region angle tightening method. In
this method, special bolts are used and they are
tightened to the load at which they start perma-
nent deformation (in the plastic region) to obtain
accurate and high tightening torque.
a Generally, tightness of bolts is controlled with
tightening torque. It is difficult, however, to con-
trol the tightening torque because of effects of
the coefficient of friction.
• In the plastic-region angle tightening method, the
tightness of the bolts is controlled with the initial
tightening torque and tightening angle.
• Bolt of this engine tightened by plastic-region
angle tightening method
1) Connecting rod cap mounting bolt
a If a bolt is tightened by the plastic-region angle
tightening method, it has permanent strain.
Accordingly, the number of using times of the
bolt is limited. Observe the following precau-
tions.
1) After tightening each bolt, make a punch
mark on it. If there are 5 punch marks on a
bolt, do not use that bolt any more but
replace it.
2) If a bolt is tightened more than the specified
angle, loosen it completely, and then tighten
it again. (Make 2 punch marks at in this
case.)
3) Tighten each bolt to the standard value in the
range of standard value ± tolerance as long
as possible.
13-34 12V170-2
• Clean each part and check it for a bruise, flaw,

cavity, etc.
When assembling, check that each oil/coolant
passage is through.
Preparation work
• Before inserting the cylinder liners, prepare the
cylinder block according to the following proce-
dure.
1) Remove rust, scales, etc. from faces A and
B with sandpaper until the machined sur-
faces appear.
2) Polish parts R and r with sandpaper of #240
smoothly.
3) Polish parts B, R, and r with sandpaper of
#240 smoothly.
If part R is sharp or has burrs, finish it with a
scraper or sandpaper smoothly. Finish this
surface very smoothly so that it will not dam-
age the O-ring.
4) If face R is pitted and cannot be repaired,
replace the cylinder block.
5) If face A or parts R or r is pitted, finish it
smoothly.
6) Check the counterbore and remove burrs. If
there are metal chips or dirt on face C, the
liner will not fit, and the can cause coolant
leakage and insufficient projection of the
liner.
a If the counterbore is drooped, corroded,
or pitted, repair it.
12V170-2 13-35
1. Cylinder liner
a Replace the liner O-ring and clevis seal just
before installing the liner.
• Method of fitting liner O-ring and clevis seal
1) Check that the O-ring groove and outside of
the cylinder liner are not rusted or pitted.
a If the O-ring groove and outside of the
cylinder liner are pitted, coolant will leak.
Replace the liner in this case.
2) Apply clean engine oil (SAE 30) to the liner
O-ring and clevis seal.
a If the clevis seal and O-ring are left in the
oil, they will swell and will be deterio-
rated. Do not leave them in the oil.
a Apply a little amount of oil to the clevis
seal and O-ring just before fitting them.
3) Fit the liner O-ring and clevis seal to the liner

as shown in the figure at right.
4) After fitting the liner O-ring, check it for twist.

If it is twisted, straighten it with a smooth rod
(approx. 10 mm in diameter).
a Press all periphery of the clevis seal so

that it will be fitted to the seal groove
without being twisted.
a Fit the clevis seal with the chamfered

side down.
13-36 12V170-2
• Method of inserting cylinder liner

1) Wipe off dirt and oil from the counterbore and
liner flange contact face of the cylinder block with
cloth.
2) Apply silicone gasket sealant (LG-6) to the coun-
terbore fitting parts of the cylinder block and cyl-
inder liner.
a Diameter of gasket sealant line: ø1.5 – 2.0 mm
a Overlap the starting part and finishing part of

the gasket sealant (LG-6) by 6 ± 6 mm.
3) Apply a little amount of engine oil (SAE 30) to the

contact faces of the liner O-ring, clevis seal, and
cylinder block just before inserting the cylinder
liner.
a Apply the engine oil evenly with the hand all
over the cylinder block contact face.
12V170-2 13-37
4) Direct the stamp "T" on the top of cylinder liner

(1) forward and insert cylinder liner (1) in the cyl-
inder block, taking care not to damage the O-
ring.
5) Applying your weight, push in the cylinder liner
with both hands.
a When you apply your weight, if the liner does
not go in smoothly, the O-ring may be dam-
aged. In this case, check the cylinder block
for burrs.
6) Using cylinder liner driver J, press fit cylinder

liner (1) to the cylinder block.
a Force the gasket sealant applied to the coun-

terbore out according to the following proce-
dure.
i) Using a used head gasket, install the cyl-
inder head.
a Tighten cylinder head bolts (3) tempo-
3 Mounting bolt (Temporarily tightening):

rarily in the order shown at right.
255.0 ± 9.8 Nm {26 ± 1 kgm}

ii) Remove the cylinder head and wipe off
the gasket sealant forced out of the
clearance between the cylinder liner and
cylinder block.
a If the gasket sealant sticks to the
grommet of the head gasket, the
grommet will be deformed, and that
can cause coolant leakage. Accord-
ingly, wipe off the gasket sealant.
7) After press fitting the cylinder liner, measure the

projection of the cylinder liner with dial gauge [1].
a When measuring the projection of the liner,
tighten the liner with the plate so that it will
not be floated by the O-ring.
a Projection of cylinder liner: 0.07 – 0.15
mm
a If the projection is out of the standard, take a
remedy according to the "Maintenance stan-
dard".
13-38 12V170-2
2. Crankshaft
1) Install upper main bearing (5) to the cylinder
block, matching its projection to the cut of the
cylinder block.
a Before installing the bearing, check that
its back side is free of foreign matter. Do
not apply oil to the back side.
a The upper main bearing has an oil hole.
2) Drive in dowel pin (3) so that it will project
from the block end by 6.3 – 7.2 mm, and then
install thrust bearing (6) on the upper side.
a Install the thrust bearing with the grooved
face on the crankshaft side.
3) Apply engine oil (SAE 30) to the inside of the

upper main bearing.
4) Before installing the crankshaft, check the

following items.
i) Check the threads on the front and rear
sides for abnormality. (The bolts must be
screwed lightly with the hand.)
ii) Check the pin journal and main journal
for a flaw and a bruise.
iii) Check the oil holes for dirt.
5) Sling the crankshaft, direct the stamp "R" at

its end toward the rear side (flywheel side) of
the cylinder block, and set pin No. 4 to the
top dead center.
a The thrust bearing side of the cylinder
block is the rear side.
12V170-2 13-39
6) Place crankshaft (4) slowly on the main bear-

ings, taking care not to hit it against the cylin-
der block.
a When installing, take care extremely not
to interfere with the counterweight.
7) Push the front end of the crankshaft with the
hand to move it toward the rear side.
8) Apply engine oil (SAE 30) to thrust bearing

(3) and install it with the oil groove out.
9) Install lower main bearing (7), matching its

projection to the cut of the main cap.
a The lower main bearing does not have
an oil hole.
10) Drive in the dowel pin of the No. 7 cap so
that it will project from the cap end by 6.3 –
7.2 mm, and then install thrust bearings (3)
on both sides.
a Install the thrust bearings with the
grooved faces on the crankshaft side.
11) Apply engine oil (SAE 30) to the journal and

rotate the crankshaft by 180°.
a When installing the No. 7 main cap,
rotate the crankshaft to bring the No. 8
counterweight to the lowest position to
prevent it from interfering with the No. 7
main cap.
13-40 12V170-2
12) Install guide bars [1] to the main cap mount-

ing bolt holes. Check that the stamp No. of
main cap (2) and the cylinder block No. are
the same, and then install the main cap.
a When installing the main cap, direct the
face of the embossed part No. toward the
front side of the engine.
13) Apply engine oil (SAE 30) to the threads of

the main cap mounting bolts, main cap seat,
and washers, and then tighten the bolts alter-
nately to fix the main cap perfectly.
14) Tighten the main cap mounting bolts with

socket wrench F and power tool G according
to the following procedure.
a Tighten the bolts in order from the central
one toward outside according to the fol-
3 Main cap mounting bolt:

lowing table.
Unit: Nm {kgm}
Step Target Range
1st time 785 {80} 706 – 863 {72 – 88}
2nd time 1,570 {160} 1,490 – 1,650 {72 – 88}
3rd time Loosen perfectly.
4th time 539 {55} 460 – 618 {47 – 63}
5th time 1,080 {110} 1,000 – 1,160 {102 – 118}
6th time 1,570 {160} 1,490 – 1,650 {152 – 168}
12V170-2 13-41
15) Apply engine oil (SAE 30) to the thread of

side bolt (1) and washer, and then tighten the
side bolt.
a Tighten the side bolt according to the fol-
3 Side bolt:
lowing procedure.
Unit: Nm {kgm}
Step Target Range
1st time 275 {28} 245 – 304 {25 – 31}
2nd time 559 {57} 530 – 588 {54 – 60}
3rd time Loosen perfectly.
4th time 186 {19} 157 – 216 {16 – 22}
5th time 373 {38} 343 – 402 {35 – 41}
6th time 559 {57} 530 – 588 {54 – 60}
16) Measuring starting torque of crankshaft

i) Screw a bolt in the center bolt hole and
measure the rotation resistance of the
crankshaft.
a Standard value: 27.5 Nm {2.8 kgm}
a The crankshaft must rotate smoothly.
17) Measure the end play of the crankshaft with

dial gauge [1].
a End play: 0.14 – 0.32 mm
a Pry the center between the bolts of coun-
terweight W and measure the end play.
a If the end play is out of the standard
range, take a remedy according to the
maintenance standard.
18) Checking position of counterweights

Using feeler gauges, measure the clearance
between the side of parts A and B of each
counterweight and the machined bulkhead
face of the cylinder block.
• Measure at 12 places of parts A and B.
a Standard clearance at part A and B:
Min. 1.1 mm
a Difference of clearance between parts A
and B: Max. 0.6 mm
13-42 12V170-2
3. Piston and connecting rod assembly

Assemble the piston and connecting rod assem-
bly according to the following procedure.
i) Fit oil ring expander (1) to the oil ring groove.
ii) Using piston ring tool E, fit the oil ring, sec-
ond ring, and top ring in order.
a Fit each ring to the piston with the stamp
mark side up.
a The abutment joint of the coil of the
expander must be at 180° to the close
gap of the oil ring.
a Fit each piston ring as shown in the figure.
iii) Install snap ring (2) to either side.

iv) Heat piston (3) in an oven at 100°C for 5 min-
utes.
a If there is not an oven, heat the piston in
water at 100°C for 5 minutes.
a If the piston is heated in hot water, clean
it perfectly after setting it.
v) Apply engine oil (SAE 30) to the piston boss

and insert piston pin (4), directing the cham-
fered face of the connecting rod toward the
"EX" mark.
vi) Install snap ring (5) to the opposite side.
a Rotate the right and left snap rings to
check that they are fitted to the ring
grooves perfectly.
12V170-2 13-43
vii) Install connecting rod upper bearing (6),

matching its projection to the cut of the con-
necting rod.
a Check that the hole of the bearing is
matched to the oil hole of the connecting
rod.
vii) Install connecting rod lower bearing (7),
matching its projection to the cut of the con-
necting rod.
• Method of inserting piston and connecting

rod assembly
1) Apply engine oil (SAE 30) to the cylinder
liner.
a Apply the engine oil evenly with the hand
all over the cylinder liner.
2) Rotate the crankshaft to bring the pin journal
of the cylinder to insert the piston to the top
dead center (for each cylinder).
3) Check the No. of piston and connecting rod
assembly (3) and insert it as shown in the fig-
ure.
a Left bank side [A]:
Install the assembly so that the
embossed letters "EX" on the piston skirt
will be on the rear side of the engine.
a Right bank side [B]:
Install the assembly so that the
embossed letters "EX" on the piston skirt
will be on the front side of the engine.
13-44 12V170-2
4) Set the closed gap of each piston ring as shown in the figure.
5) Apply engine oil (SAE 30) to the piston rings

evenly.
6) Shrink the piston rings with piston ring holder

K and push in the piston head.
7) Using connecting rod puller [1], pull the con-

necting rod and fit it to the pin journal.
a Check that the connecting rod bearing is
fitted to the correct position.
a Make the connecting rod puller by weld-
ing a bar to a connecting rod bolt.
8) Apply engine oil (SAE 30) to the crank pin

journal.
9) Pulling the connecting rod, rotate the crank-

shaft by 180°.
12V170-2 13-45
10) Apply engine oil (SAE 30) to connecting rod

lower bearing (9), check the cap No., and
install connecting rod cap (10), matching it to
the dowel pin.
a Spread the engine oil with the fingers all
over the bearing.
a When installing a new connecting rod,

write the cylinder No. with an electric
pen, etc. (Do not stamp the No.)

the connecting rod bolts and washers.
12) Tighten connecting rod bolts (11) alternately

to fix the connecting rod cap perfectly.
a If the bolts are tightened with an impact
wrench, etc., their threads may be
scuffed. Accordingly, tighten them with
the hand.
13-46 12V170-2
13) Rotate the crankshaft by 180° and insert the

piston and connecting rod assembly to the
other bank according to the procedures in
steps 1) - 12).
14) Tighten the connecting rod bolts according to

• Tighten the bolts in the order of the num-
bers in the figure.
1st time: Tighten to 108 – 118 Nm {11.0 –
12.0 kgm}.
2nd time: Loosen fully.
3rd time: Tighten to 108 – 118 Nm {11.0 –
12.0 kgm} again.
4th time: Using wrench M, tighten by 70° ± 5°.
a When not using wrench M, tighten the

bolts according to the following proce-
dure.
1st time: Tighten to 108 – 118 Nm {11.0 –
12.0 kgm}.
2nd time: Loosen fully.
3rd time: Tighten to 108 – 118 Nm {11.0 –
12.0 kgm} again.
4th time: Make marks on the bolt head and
cap seat with a marker, and then
tighten by 70° ± 5°.
a After tightening each bolt, make a punch
mark on it. If there are 5 punch marks on
a bolt, do not use that bolt any more but
replace it.
a After installing the connecting rod, check
that the crankshaft rotates smoothly.
15) Using dial gauge [1], measure the side clear-

ance of the connecting rod.
a Standard side clearance:
0.400 – 0.563 mm
a If the connecting rod does not move,
remove the connecting rod cap and
check for installation of wrong parts,
burrs, and foreign matter.
12V170-2 13-47
4. Setting engine stand

Turn over the cylinder block and place and
secure it on the engine stand.
5. Piston cooling nozzles

Fit the O-rings and install piston cooling nozzles
(1).
a Insert each nozzle with its tip directed side-
way and the mounting hole up, taking care
not to interfere with the piston, and turn it by
90° to install.
a Before installing the nozzle, check its bend
(angle) for unevenness.
a If the piston is at the bottom dead center, the
cooling nozzle cannot be inserted. In this
case, rotate the crankshaft.
6. Side covers
Install each side cover.
7. Main gallery plug, oil plug, and cooing plug

1) Fit the O-ring and install main gallery plug
(3).
2) Fit the O-ring and install oil plug (2).
3) Fit the seal ring to cooling valve (1) and fit
the O-rings (2 pieces) to the cover, and then
install cooling valve (1).
a If the cooler insider cover has been
removed, install it first.
8. Gear case
1) Install idle gear flange (2) to the cylinder
3 Mounting bolt:
block.
65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}
13-48 12V170-2
2) Fit grommets to the 3 places marked with a

on the gear case.
3) Apply gasket sealant (LG-7) to part A of the

cylinder block shown at right.
a Line diameter: ø1.0 – 2.0 mm
a Apply gasket sealant (LG-7) to the gear
case mounting bolts, and then tighten
those bolts within 5 minutes.
a When applying gasket sealant (LG-7),

take care not to stick it to an oil hole, a
grommet, etc.
12V170-2 13-49
4) Sling gear case (1) and install it to the cylin-

der block.
5) Tighten the 6 temporary mounting bolts
marked with a alternately to fit the gear case
to the block.
6) Tighten 14 bolts marked with e.
3 Mounting bolt:
177 ± 19.6 Nm {18 ± 2 kgm}
a After tighten the mounting bolts, remove
the 6 temporary mounting bolts.
a Temporary mounting bolt: 01010-31490
9. Camshaft assembly
1) Apply engine oil (SAE 30) to the cam bush-
ing and install camshaft assembly (1).
a Insert the camshaft, rotating it slowly so
that it will not damage the cam bushing.
k When inserting the camshaft, take care
not catch your finger in it.
a The identification marks of C of the cam-

shaft gears are made at the following
points.
Right bank cam: Root of tooth
Left bank cam: Tip of tooth
a Method of distinguishing camshafts
Right bank cam: Dimension L1 is short.
Left bank cam: Dimension L2 is long.
13-50 12V170-2
a Positions of match marks of gear train
2) Match the mounting hole of the thrust plate

and tighten the nylon lock bolt.
a Use a new nylon lock bolt.
3 nylon lock bolt:
38.2 ± 6.9 Nm {3.9 ± 0.7 kgm]
3) Install the camshaft gear, matching its match

mark C.
10. Gear train

1) Match marks "A" of main idler gear (6) and
crankshaft gear.
12V170-2 13-51
2) Match marks "B" of the cam gear and idler
3 Mounting bolt:
gear.
319 ± 24.5 Nm {32.6 ± 2.5 kgm}

3) Check the position of each mark and tighten
3 Mounting bolt:
mounting bolt (17) of the idler gear.
319 ± 24.5 Nm {32.5 ± 2.5 kgm}
4) Press fit bushing (9) to water pump drive

gear (13).
5) Put bearings (8) to both sides of gear (13)
and set shaft (10).
6) Install plate (7).
7) Set gear (13), matching its mark "G".
3 Mounting bolt:
8) Tighten bolt (12).
292 ± 17.2 Nm {29.75 ± 1.75 kgm}
9) Coat the center bolt with engine oil (SAE 30)
3 Center bolt:
and tighten it.
292 ± 17.2 Nm {29.75 ± 1.75 kgm}

10) Install compressor idler gear (3) and tighten
3 Mounting bolt:
the mounting bolt.
292 ± 17.2 Nm {29.75 ± 1.75 kgm}
13-52 12V170-2
11) Install timer idler gear (2), matching mark
3 Mounting bolt:
"D", and tighten the mounting bolt.
292 ± 17.2 Nm {29.75 ± 1.75 kgm}
12) Install timer idler gear (1), matching mark
3 Mounting bolt:
"E", and tighten the mounting bolt.
292 ± 17.2 Nm {29.75 ± 1.75 kgm}
11. Cam follower

1) Drive dowel ring (2) in the cylinder block.
3 Mounting bolt:
2) Install cam follower assembly (1).
97.1 ± 6.9 Nm {9.9 ± 0.7 kgm}
12V170-2 13-53
a The holes to install the shafts for the R1 and

L6 cam followers are different from the other
cylinders.
12. Air intake manifold

1) Fit grommet (3) to the air intake manifold.
2) Fit gasket (4) and set plate (5). At this time,

do not apply any adhesive to the gasket.
3) Install air intake manifold (2).
4) Fit gasket (6) and install air intake manifold
3 Mounting bolt:
(1).
63.7 ± 9.8 Nm {6.5 ± 1.0 kgm}
13-54 12V170-2
• Bolt tightening order for front side
• Bolt tightening order for rear side
13. Pump drive case

1) Pump drive case sub-assembly
• Referring to the figure at right, assemble
the sub-assembly.
a Press fit the bushings marked with (*),
and then machine their inside.
For the machining dimensions, see the
3 Nut (1):
maintenance standard.
588 ± 29.4 Nm {60 ± 3 kgm}
2) Fit the grommet to the drive case mounting

face. Fig the gasket and install pump drive
3 Mounting bolt:
case (2).
113 ± 9.8 Nm {11.5 ± 1.0 kgm}
12V170-2 13-55
14. Backlash and end play of gears

1) Using dial gauge [1], measure the backlash
and end play of each gear.
a For the specified values, see the table.
a Check the match marks of the gear train
again.
• Backlash table Unit: mm

Position Specified value
A 0.179 – 0.478
B 0.115 – 0.429
C 0.126 – 0.418
D 0.093 – 0.451
E 0.098 – 0.445
F 0.084 – 0.460
G 0.184 – 0.469
H 0.123 – 0.577
I 0.084 – 0.460
J 0.133 – 0.468
K 0.136 – 0.428
L 0.123 – 0.478
M 0.122 – 0.478
• End play table Unit: mm

Position Specified value
1 0.12 – 0.42
2 0.09 – 0.45
3 0.10 – 0.35
4 0.10 – 0.35
5 0.075 – 0.211
6 0.075 – 0.211
7 0.10 – 0.35
8 0.14 – 0.32
9 0.05 – 0.15
10 0 – 0.95
11 0.10 – 0.35
12 0.10 – 0.32
13 0.095 – 0.155
14 0 – 0.95
13-56 12V170-2
15. Front shaft

Sling front shaft (1) and install it to the crank-
shaft, and then tighten the center bolt tempo-
rarily.
a Use nylon ropes to sling the front shaft so
that the outside surface of the front shaft will
not be damaged.
16. Gear case cover

1) Fit the grommets to the 4 places marked with
a on the gear case.
2) Fitting the gasket and install gear case cover

(1), using guide bolt [1].
a Tighten the bolt nearest to the dowel pin
marked with a first, then tighten the
3 Mounting bolt (14 mm):

other bolts in order outward.
3 Mounting bolt (12 mm):

177 ± 19.8 Nm {18 ± 2 kgm}
113 ± 9.8 Nm {11.5 ± 1.0 kgm}
12V170-2 13-57
17. Timer cover
3 Mounting bolt:
1) Fit the gasket and install timer cover (1).
113 ± 9.8 Nm {11.5 ± 1.0 kgm}
2) There are 2 blind plugs (marked with a)

installed on the back side. When installing
the timer cover, take care of the bolt length.
• Mounting bolt 01011-81210
18. Water pump drive case

• Assemble the water pump drive case accord-
i) Press fit shaft (9) to gear (8).
a Heat the gear at 260°C for 45 – 60
minutes.
ii) Match the assembly marks of bearing
(7), spacer (6), and bearing (5), and
install those parts to case (4).
iii) Press fit the bearing outer race to case
(4).
iv) Fix the bearing outer race with snap ring
(3).
v) Pressing the bearing inner race, press fit
the case assembly to shaft (9).
vi) Install snap ring (2).
13-58 12V170-2
1) Rotate the crankshaft to change the position

of weight (10) of the idler gear.
a When the water pump drive case is
installed, the gear interferes with the
weight. To avoid this, rotate the crank-
shaft until the weight disappears.
2) Fit the O-ring and install water pump drive

case (1).
a Install the case so that the embossed
2 O-ring: Engine oil (SAE 30)

part No. will be at the top.
3 Mounting bolt:
65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}
19. Compressor drive case

1) Fit the O-ring and install compressor drive

case (2).
3 Mounting bolt:
65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}

2) Fit the O-ring and install cover (1).
12V170-2 13-59
20. Breather connector

Fit the gaskets and install breather connector (1).
21. Front seal

a Before installing the front seal, remove all the
dirt and dust from the periphery of the front
shaft and apply engine oil (SAE 30) all over
the front shaft.
1) Insert front seal (1) straight.
a Before inserting the front seal, check that
the seal lip surface is free of dirt and
dust.
2) Using installer N, press fit the front seal.
22. Front support
2 Inside of front support: Grease (G2-LI)

Lift and install front support (1).
13-60 12V170-2
23. Vibration damper

1) Sling vibration damper (2) and install it to the
front shaft.

the bolts and washers.
3) Tighten the bolts alternately until the damper
is fitted.
wrench, their threads may be scuffed.
Accordingly, tighten them with a hand.
a Tighten the bolts in the order shown at

right.
a Tighten the mounting bolts according to
3 Mounting bolt:
Unit: Nm {kgm}
Step Target Range
1st time 73.6 {7.5} 53.9 – 93.2 {5.5 – 9.5}
2nd time 245 {25} 226 – 265 {23 – 27}
3rd time 637 {65} 618 –657 {63 – 67}
12V170-2 13-61
4) After tightening the damper mounting bolts,
3 Center bolt:
tighten the center bolt of the shaft.
279 ± 29.4 Nm {28.5 ± 3.0 kgm}
5) Install pointer (I), matching it to the stamp

line of "TOP R1" of the vibration damper.
a Set dial gauge [1] and rotate the crank-
shaft forward to bring the piston of the R1
cylinder to the top dead center and set
the pointer to the stamp line of "TOP R1".
24. Piston cooling valve

• Assemble the piston cooling valve according
to the following procedure.
i) Install plunger (4) and spring (3) to body
(5). Fit the O-ring and install plug (2).
a When assembling, check that there
is not dirt or dust between the
plunger and body.
1) Fit the grommet to the cooling valve and oil

cooler mounting plate and install piston cool-
3 Mounting bolt:
ing valve (1).
65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}
13-62 12V170-2
25. Oil cooler assembly

• Assemble the oil cooler according to the fol-
lowing procedure.
i) Fit the gasket and O-ring to cover (3),
install cores (8), (7), and (6), and tighten
the nuts.
ii) Fit the gasket to cover and core assem-
3 Mounting bolt:
bly (5) and install housing (4).
65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}
iii) Fit the gasket and install bypass valve

(2).
1) Install O-ring (9) and washer (10).

a Since the O-ring comes off easily, apply
gasket sealant to it when installing.
a Fit the O-ring to the oil cooler side.
12V170-2 13-63
2) Using a guide bolt, install oil cooler assembly
3 Mounting bolt:
(1).
65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}
26. Water pump assembly

1) Remove the 2 mounting bolts at the rear of
the water pump and install bracket (6) there
with those bolts.
2) Fit the O-ring and install water pump assem-

bly (5).
3) Tighten the 2 mounting bolts on the oil filler

side.
4) Install shaft (4), matching it to the spline.

5) Fit the seal packing and install plug (3).
a Tighten the plugs into the water pump
drive case and the compressor drive
3 Plug: 235 ± 19.6 Nm {24 ± 2 kgm}

case.
13-64 12V170-2
6) Fit the O-ring and tighten flange (2) tempo-

rarily.
7) Fit the O-rings to both sides and tighten con-

nector (1) temporarily.
a Tighten the bolts in the following order.

3
i) Tighten the flange bolts temporarily
to 9.8 Nm {1 kgm}.
ii) Tighten the water pump side of the
connector to 65.7 ± 6.9 Nm {6.7 ± 0.7
kgm}.
iii) Tighten the flange bolts temporarily
to 65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}.
27. Flywheel housing assembly

1) Apply gasket sealant (LG-7) to the parts of
the cylinder block shown at right.
a Line diameter: ø1.0 – 2.0 mm
a Apply gasket sealant (LG-7) to the fly-
wheel housing mounting bolts, and then
tighten those bolts within 5 minutes.
a When applying gasket sealant (LG-7),
take care not to stick it to an oil hole, a
grommet, etc.
2) Using a guide bolt, install flywheel housing
2 Threads of bolts and washers:

(1).
Engine oil (SAE 30)
12V170-2 13-65
3 Mounting bolt
Unit: Nm {kgm}
Step Tightening torque
1st time 392 – 539 {40 – 55}
2nd time 490 – 539 {50 – 55}
a Loosen the bolts after tightening

them at the first time, then tighten
them again at the second time.
28. Rear seal

a Before installing the rear seal, remove all the
dirt and dust from the periphery of the rear
shaft and apply engine oil (SAE 30) all over
the rear shaft.
1) Insert rear seal (1) straight.
a Before inserting the rear seal, check that
the seal lip surface is free of dirt and
dust.
2) Using installer O, press fit the rear seal.
29. Flywheel
1) Using eyebolt [1] (12 mm, P = 1.75), install
flywheel (1).
a Match the hole on the flywheel side to
the dowel pin on the rear shaft side.
13-66 12V170-2

the bolts and washers.
3) Tighten the bolts alternately until the flywheel

is fitted.
wrench, their threads may be scuffed.
Accordingly, tighten them with a hand.
4) Fix the flywheel and housing with stopper [1]

and tighten the bolts.
3 Mounting bolt
Unit: Nm {kgm}
Step Target Range
1st time 73.6 {7.5} 53.9 – 93.2 {5.5 – 9.5}
2nd time 245 {25} 226 – 265 {23 – 27}
3rd time 637 {65} 618 – 657 {63 – 67}
5) Measure the radial runout and facial runout

of the flywheel.
a Radial runout A : Max. 0.13 mm
a Facial runout B : Max. 0.28 mm
12V170-2 13-67
30. Starting motor assemblies

1) Fit the gasket and install starting motors (3)
and (2).
2) Connect the connector and fix wiring harness
(1) the clamp.
31. Cylinder head assembly

• Assemble the cylinder head according to the
following procedure.
i) Install intake valves (7) and exhaust
valves (6), matching them to the
embossed marks on the underside of the
2 Valve stem (Inside of valve guide):

cylinder head.
Engine oil (SAE 30)

a Each intake valve is stamped with
"BN" on its bottom. Each exhaust
valve is stamped with "X" on its bot-
tom.
ii) Insert valve lower seat (8) to the cylinder
head.
iii) Install the inner spring and outer spring
(5).
a Install the springs with the wider-
pitch side up.
iv) Install retainer (4).
v) Using spring compressor C, fit valve cot-

ter (3) to the groove of the valve stem.
13-68 12V170-2
vi) Lightly hit the valve stem with a plastic

hammer to check that the valve cotter is
fitted perfectly.
1) Fit the O-ring and install connector (2) to the

cylinder head.
2) Check that the cylinder head mounting face

and inside of the cylinders are free of dirt and
foreign matter and install cylinder head gas-
ket (9).
a When installing the cylinder head gasket,
check that grommet (10) is fitted nor-
mally.
k If the cylinder head gasket comes in
contact with gasket sealant, it may be
swelled and deformed. Accordingly, do
not apply gasket sealant.
3) Using sling A, install cylinder head assembly

(1).
a Apply engine oil (SAE 30) to the mating
faces of the O-ring and air intake mani-
fold and check that the O-ring will not
move when the cylinder head is installed.
12V170-2 13-69
a Lower the cylinder head (1) to the head

of the dowel pin, and then install it,
pressing it toward the air intake manifold
and matching it to the dowel pin.
a Apply anti-friction compound (LM-P) to

the threads and washers of the head
bolts.
a Screw in the bolts by 2 – 3 turns with the
fingers, and then tighten them to the
specified torque in order.
a Tighten the cylinder head bolts in the

order shown at right.
13-70 12V170-2
3 Mounting bolt:
1st time : 98.0 ± 9.8 {10 ± 1 kgm}
2nd time : 186.2 ± 4.9 Nm {19 ± 5 kgm}
3rd time : 1) When using tool M
Using the angle-tightening
wrench (tool M), tighten the
+15°
bolts by 60° 0 in the order
of (1) – (6).
2) When not using tool M
Make marks on the bolts and
cylinder head with a marker,
and then tighten the bolts by
+15°
60° 0 in the order of (1) –
(6).
a After tightening each bolt, make a punch

mark on it.
a If there are 5 punch marks on a bolt, do
not use that bolt any more but replace it.
12V170-2 13-71
32. Cross head
2 Guide pin: Engine oil (SAE 30)

1) Install cross head (1).
2) Adjust the cross head according to the fol-

lowing procedure.
i) Loosen the locknut and return the adjust-
ment screw.
ii) Pressing the top of the cross head lightly
with the fingers, tighten the adjustment
screw.
iii) After the adjustment screw touches the
valve stem, tighten it further by 20° .
3 Locknut:
iv) At this position, tighten the locknut.
50.96 – 64.68 Nm {5.2 – 6.6 kgm}

a When installing the cross head,
direct the adjustment nut side toward
the exhaust side.
33. Rocker housing

1) Fit the gasket and install the rocker housing,
matching the claw of the grommet to the
groove of the gasket.
a Install the grommet with the correct side
up.
2) Fit the O-ring and insert washing machine (3)
2 O-ring:
in the rocker housing.
Rubber lubricant (RF-1) or soap water

a Never apply oil to the O-ring.
a Insert the snap ring groove side in the
rocker housing.
13-72 12V170-2
3 Mounting bolt:
3) Install rocker housing (1).
93.1 – 102.9 Nm {9.5 – 10.5 kgm}

4) Using push tool P, insert water manifold (2).
5) Fix the water manifold with the snap ring.
34. Injection nozzle assembly

a Check that the inside of the nozzle holder
sleeve is free of dirt and foreign matter.
(Mask the opening of the sleeve with a rub-
ber cap.)
1) Install injection nozzle assembly (1), match-
ing the stamp line of the nozzle body to the
stamp line of the plate and directing those
stamp lines to the front side of the engine.
2) Tighten 2 mounting bolts (2) alternately and

gradually (by about 4.9 Nm {0.5 kgm}) to the
specified torque.
a Do not reuse the nylon lock bolts but replace
3 Mounting bolt:
them with new ones.
26.95 ± 2.45 Nm {2.75 ± 0.25 kgm}

a Limit the torque difference between the 2
mounting bolts to 4.9 Nm {0.5 kgm}.
35 Push rod
Install push rod (1).
a Check that the push rod is fitted securely to

the socket of the cam follower.
12V170-2 13-73
36. Rocker arm assembly

Assemble the rocker arm according to the follow-
ing procedure.
i) Drive bushing (4) in rocker arm (3), matching
its oil hole.
ii) Install adjustment screw (2) and locknut (1)
to the rocker arm.
iii) Coat the rocker shaft with engine oil (SAE

30) and direct its plug side toward the
exhaust side.
iv) Set the exhaust rocker arm (longer one) to
the left side, the intake rocker arm (shorter
one) to the right side, and the collar to the
center, and insert the rocker shaft.
1) Install rocker arm assembly (1) and tighten

the mounting bolts.
a When tightening the mounting bolts,
check that the ball of adjustment screw
(2) is fitted securely to the socket of the
push rod.
a Set the spacers (15 mm long) to the
short bolts and set the washers to the
3 Mounting bolt:
long bolts.
93.1 – 102.9 Nm {9.5 – 10.5 kgm}
37. Adjusting valve clearance

Referring to TESTING AND ADJUSTING, Adjust-
ing valve clearance, adjust the valve clearance.
13-74 12V170-2
38. Aftercooler assembly

1) Assemble the aftercooler according to the
following procedure.
i) Fit the gasket to case (12) and set cores
(11) and (10).
ii) Fit the gasket and install right and left
covers (9).
iii) Fit the gasket and install outside connec-
tor (6).
iv) Fit the gasket and plate and install center
connector (3).
v) Fit the O-ring and set tube (5) to connec-
2 O-ring:
tor (3).

vi) Fit the gasket and install connectors (2)
and (4).
2) Fit the gasket and install aftercooler assem-

bly (1).
39. Water tubes
2 O-ring:
Fit the O-ring and install water tubes (2) and (1).
12V170-2 13-75
40. Head cover

1) Fit the gasket, install head cover (3), and
tighten the mounting bolts temporarily.
2) Install the nozzle seal and press fit it with the
2 Nozzle sea mounting face:

push tool.
Engine oil (SAE 30)
3) Tighten the head cover mounting bolts in the
3 Mounting bolt:
order shown in the figure.
31.9 ± 2.5 Nm {3.25 ± 0.25 kgm}

4) Install connection (2).
5) Install spill tube (1).
41. Thermostat case assembly

1) Assemble the thermostat case.
i) Install seal (9) to thermostat case (8).
a When installing the seal, direct it
toward the bypass.
ii) Using push tool [1], drive seal in lightly.
iii) Install thermostat (7).

iv) Fit gasket (10) and install cover (11) to
case (8).
v) Fit gasket (6) and install connector (5).
13-76 12V170-2
2) Fit the O-rings and install thermostat assem-
2 O-ring:
blies (3) to the right and left banks.

3) Install bracket (12).
4) Fit the gaskets to the right and left banks and

install water pipe (2).
42. Fuel injection pump assembly

1) Install coupling (2) to the drive shaft.
a Match the parts having no spline teeth.
2) Rotate fuel injection pump spline (3) to

match it to the part of the coupling having no
spline teeth.
12V170-2 13-77
3) Fit the O-rings and install fuel injection pump

assemblies (1) and (2) to the right and left

banks, using hanging tool B.
a When installing the injection pump

assemblies, match them to the spline
grooves.
a When installing the injection pump
assemblies, take care not to break the O-
rings.
Left pump Right pump

4) Match stamp line (4) of the drive case to
stamp line (5) of the injection pump and
tighten the mounting bolts temporarily.
43. Air vent tubes

1) Set air vent tubes (1) – (6) to the rocker arm
housing.
3 Joint bolt:
2) Fit the seal and tighten the joint bolt.
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}

3) Install hose (7).
13-78 12V170-2
44. Muffler bracket

Install muffler bracket (1) to the cylinder block
3 Mounting bolt:
and tighten the mounting bolts (4 pieces).
2 Mounting bolt: Engine oil (SAE 30)

745 ± 83.4 Nm {76.0 ± 8.5 kgm}
45. Spill hoses

Install tubes (3) and (4) and 10 spill tubes (2).
46. Fuel injection pump lubrication tubes

Fit the gaskets and install tubes (1), (2), (3), and
(4).
12V170-2 13-79
47. Fuel supply and overflow pipe

Referring to the figure, install the fuel supply and
overflow pipe.
48. Fuel injection tubes

Install 12 fuel injection pipes (1) to the right and
3 Sleeve nut:
left banks.
22.1 ± 2.5 Nm {2.25 ± 0.25 kgm}
13-80 12V170-2
49. Exhaust manifold

2) Fit gaskets (9) to the right-bank exhaust
manifold and install R1 – R8 in order.
3) Fit gaskets (9) to the left-bank exhaust mani-
2 Manifold connection:
fold and install L1 – L8 in order.
2 Mounting bolt:
Anti-friction compound (LM-P)
Anti-friction compound (LM-P)

a Since the heat-resistant bolts are used,
observe their tightening torque.
4) Procedure for mounting right-bank exhaust
manifold
i) Install R1 – R4.
ii) Tighten R4 permanently.
iii) Tighten R1 – R3 permanently. (See step
5).)
iv) Install R5 – R8.
v) Tighten R5 – R8 permanently. (See step
5).)
a When tightening manifold R3 perma-
nently, move it forward as much as possi-
ble.
5) Tightening order of right-bank exhaust mani-
fold mounting bolts (Tighten the mounting
bolts of 3 cylinders in the order shown at
right.)
a Only 1 bolt hole of each exhaust manifold
([2], [3], or [12]) is smaller than the other
bolt holes. Be sure to tighten the bolt of
this hole first.
3 Mounting bolt:
1st time:39.2 – 58.8 Nm {4 – 6 kgm}

2nd time:78.4 – 88.2 Nm {8 – 9 kgm}
12V170-2 13-81
6) Procedure for mounting left-bank exhaust

manifold
i) Install L1 – L4.
ii) Tighten L4 permanently.
iii) Tighten L1 – L3 permanently. (See step
7).)
iv) Install L5 – L8.
v) Tighten L5 – L8 permanently. (See step
7).)
a When tightening manifold L3 perma-
nently, move it forward as much as possi-
ble.
7) Tightening order of left-bank exhaust mani-
fold mounting bolts (Tighten the mounting
bolts of 3 cylinders in the order shown at
right.)
a Only 1 bolt hole of each exhaust manifold
([1], [2], or [3]) is smaller than the other
bolt holes. Be sure to tighten the bolt of
this hole first.
3 Mounting bolt:
1st time:39.2 – 58.8 Nm {4 – 6 kgm}

2nd time:78.4 – 88.2 Nm {8 – 9 kgm}
50. Water tube and turbocharger piping

1) Install water tube (9).
2) Install connector (10).
3) Install turbocharger lubrication tubes (3) and
(4).
4) Install water tube (2) and clamp (1).
51. Exhaust connector

2) Fit the seal rings to both sides of exhaust
connector (1).
3) Install exhaust connector (1).
13-82 12V170-2
52. Turbocharger assembly

1) Fit the seal rings and fit the gaskets to the
connector side, and then install right and left
turbocharger assemblies (7) and (8).
2) Fit the gaskets and connect drain tubes (6).
3) Connect lubrication tube (5).

4) Fit the gaskets and install coolant tubes (4)
and (3).
5) Air intake connector assemblies (Right and

left)
i) Fit the O-ring to connector (2) and set
2 O-ring: Engine oil (SAE #30)

them to connector (1).
ii) Fit the gasket and install connector (1).
12V170-2 13-83
iii) When installing the connector, referring

to the drawing of the turbocharger shield
cover.
53. Exhaust manifold cover (Right one is shown

in the figure)
Referring to the drawing of the exhaust manifold
cover, install the exhaust manifold cover.
• Install the left exhaust manifold cover simi-
larly.
54. Oil filler

1) Install oil filler (1).
3) Install oil gauge (3).
13-84 12V170-2
55. Bypass tube

1) Install tube (1).
2 Periphery of tube:
2) Install hose (3) to tube (1).
3 Clamp bolt:
Gasket sealant (ThreeBond #1212)
8.8 ± 0.5 Nm {90 ± 5 kgm}

3) Install tube (2).
56. Blow-by hose

1) Install breather (1).
2) Install tubes (2), (3), and (4).
57. Oil pump assembly

1) Fit the O-ring and install oil pump assembly
(4), supporting it on a garage jack, etc.

3) Fit the O-ring and install tube (2) and (1).
12V170-2 13-85
58. Oil pan
2 Oil pan: Gasket sealant (LG-7)

1) Apply gasket sealant to oil pan (1).
a Line diameter: ø2 – 3 mm
2) Install oil pan (1), supporting it on a garage
3 Mounting bolt:
jack, etc.
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
59. Oil level sensor and drain valve

2) Install case (5).
3 Level sensor:
3) Fit the O-ring and install level sensor (4).
275 ± 29.4 Nm {28 ± 3 kgm}
4) Install hoses (3) and (2).

5) Fit the O-ring and install hose (1).
60. Filter bracket

Sling and install filter bracket (1).
13-86 12V170-2
61. Fuel tube

1) Install joint (3).
2) Install cover (2).
3) Install fuel tube (1).
62. Oil filter

Install oil filter (3).
63. Oil filter tube

Fit the O-rings and install tubes (1) and (2).
64. Air intake pipe

1) Install connectors (7) and (8) to air cleaner
connector (1).
Apply engine oil to O-rings (9).
2) Assemble connector (13), (14), and (15) tem-
porarily and install them to connector (7).
3) Tighten bolts and nuts of the connector
flanges and align the connectors.
5) Fix the connectors with brackets (22) and
(23).
Oblong mounting holes are made so that the
brackets can move in any direction.
12V170-2 13-87
65. Air cleaner and muffler assembly

1) Fit the O-ring to the connector and apply
engine oil (SAE #30) to it, and then set them
to the air cleaner side.
Do not apply anything other than the engine
oil.
2) Inserting the connector in the air intake pipe,
install air cleaner and muffler assembly (5).
3) Fit the seal ring and install exhaust connec-

tor (4).
4) Install cover (3).

13-88 12V170-2
14 MAINTENANCE STANDARD
TURBOCHARGER ................................................................. 14- 2

CYLINDER HEAD ................................................................... 14- 4
VALVES AND VALVE GUIDE ................................................. 14- 5
CROSSHEAD AND CROSSHEAD GUIDE ............................ 14- 6
ROCKER ARM SHAFT ........................................................... 14- 7
PUSH ROD AND CAM FOLLOWER ...................................... 14- 8
CYLINDER BLOCK ................................................................ 14-10
CYLINDER LINER .................................................................. 14-12
CAMSHAFT ............................................................................ 14-13
CRANKSHAFT ....................................................................... 14-14
TIMING GEAR ........................................................................ 14-16
PISTON .................................................................................. 14-17
CONNECTING ROD ............................................................... 14-18
FLYWHEEL, FLYWHEEL HOUSING ...................................... 14-19
OIL PUMP .............................................................................. 14-20
OIL PUMP RELIEF VALVE, PISTON COOLING VALVE,
OIL COOLER BYPASS VALVE AND OIL FILTER
SAFETY VALVE ................................................................... 14-22
WATER PUMP ........................................................................ 14-24
THERMOSTAT ....................................................................... 14-25
12V170-2 14-1
MAINTENANCE STANDARD TURBOCHARGER
TURBOCHARGER
KTR110L
14-2 12V170-2
(1)
MAINTENANCE STANDARD TURBOCHARGER
Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit Replace parts
End play
1 related to
(play in axial direction) 0.08 – 0.13 0.18 thrust
Replace parts
Radial play
2 0.25 – 0.44 0.60 related to
(play in radial direction) bearing
Tolerance Repair limit

Standard size
Outside diameter of journal bearing, Shaft Hole Shaft Hole
3
inside diameter of center housing
–0.050 +0.021
25 24.92 25.03
–0.067 0
Inside diameter of journal bearing, –0.032 +0.009

17 16.95 17.04
4 outside diameter of wheel shaft –0.043 –0.003
Curvature of wheel shaft Repair limit: 0.010 (total deflection of indicator)

Standard size
Width Groove Width Groove
5 Thickness of thrust bearing
–0.08 +0.02
5 4.86 5.04
–0.10 0 Replace
Standard size Tolerance Repair limit
Ring –0.08
Turbine 2.3 2.15
–0.10
end
–0.01
Groove 2.3 2.35
–002
Thickness
6 –0.08
of seal ring Ring 2 1.85
–0.10
Blower –0.03
1 Ring 2 2.05
end –0.04
Groove
–0.11
2 Ring 4 4.05
–0.12
Replace parts
Clearance between blower housing
7 Clearance limit: (Min.) 0.20 related to
and impeller
bearing
12V170-2 14-3
(1)
MAINTENANCE STANDARD CYLINDER HEAD
CYLINDER HEAD
Unit: mm
Tolerance Repair limit Replace by

Distortion of cylinder head
1 mounting surface grinding or
Max. 0.05 0.1 replace
2 Protrusions of nozzles Standard : 4.9 – 5.7 Replace nozzle

sleeves
Order Target Range

Nm {kgm} Nm {kgm}
1st step 77.5 {7.9} 62.5 – 92 {6.4 – 9.4}

Tightening torque of cylinder
head mounting bolts Tighten in
3 2nd step 230 {23.5} 215 – 245 {22.0 – 25.0} sequence as
(Coat bolt threads and washer indicated above
with anti-friction compound
(LM-P) 3rd step 380 {39.0} 480 – 510 {49.0 – 52.0}
4th step 495 {50.5} 480 – 510 {49.0 – 52.0}
Target Range
Tightening torque of nozzle Nm {kgm} Nm {kgm}
4
holder mounting bolt
27.0 {2.75} 25 – 29 {2.5 – 3.0}
Retighten
5 Tightening torque of cylinder 31.9 {3.25} 29 – 34 {3.0 – 3.5}
head cover
6 Tightening torque of rocker 98 {10.0} 98 – 105 {9.5 – 10.5}

arm hosing mounting bolt
14-4 12V170-2
MAINTENANCE STANDARD VALVES AND VALVE GUIDE
VALVES AND VALVE GUIDE
Unit: mm
Standard Repair limit

1 Amount of valve sinking Replace valve
Intake and or seat
exhaust valve 0.9 – 1.5 0.8 – 2.1

2 Valve head thickness Intake valve 3.4 ± 0.005 2.9 Replace valve
Exhaust valve 3.5 ± 0.005 3.1
Standard Tolerance
3 Valve seat angle Intake valve 60° ± 0°10'
Exhaust valve 45° ± 0°10'
Standard size Tolerance Repair limit Replace
Outside diame- – 0.060
ter of valve Intake valve 11.90
– 0.080
stem 12.0
– 0.092
4 Exhaust valve – 0.107 11.80
Bend of valve stem Repair limit: 0.02 (Total indicated runout, for 100) Replace valve
Inside diameter of valve – 0.001
guide (after head press fit) 12.0 – 0.019 12.10
5 Protrusion of valve guide 23.7 + 0.2 —

(after head press fit) – 0.3
Valve Free length Installed length Installed leoad Load limit
187 ± 10 N
Inner 59.3 47.0 {19.07 ± 1 kg} 169 N {17.2 kg}
Close
363 ± 19 N
Valve spring Outer 66.1 52.0 {37.0 ± 1.9 kg} 327 N {33.3 kg} Replace
6 Inner 59.3 32.5 407 ± 21 N 365 N {37.2 kg}

{41.55 ± 2 kg}
Open
893 ± 46 N
Outer 66.1 37.5 {91.1 ± 4.6 kg} 804 N {82.0 kg}
Inner spring
Squars of valve spring Repair limit: 2°
Outer spring
12V170-2 14-5
MAINTENANCE STANDARD CROSSHEAD AND CROSSHEAD GUIDE
CROSSHEAD AND CROSSHEAD GUIDE
Unit: mm

1 Depth of crosshead stem + 0.3
3.0 0 3.41
+ 0.10 Replace
2 Inside diameter of crosshead 15.0 15.21
+ 0.05
Outside diameter of + 0.039
crosshead guide 15.0 + 0.028 15.00
3 Clearance between Standard clearance Clearance limit

crosshead guide and Replace
crosshead 0.011 – 0.072 0.021
Standard size Tolerance

4 Protrusion of crosshead Repair
guide 0
54.0 – 0.3
Tightening torque of
5 crosshead lock nut 51 – 64.5 Nm {5.2 – 6.6 kgm} Tighten
14-6 12V170-2
MAINTENANCE STANDARD ROCKER ARM SHAFT
ROCKER ARM SHAFT
Unit: mm
Standard Tolerance Allowable limit

Outside diameter of rocker Replace rock-
arm shaft + 0.062
34.8 + 0.049 34.83 er arm shaft
Inside diameter of rocker arm 34.8 + 0.163 34.978 Replace rock-

shaft hole (with bushing) + 0.087 er arm
Inside diameter of rocker arm 0
1 shaft hole (without bushing) 36.5 – 0.025 —
Standard Clearance limit Replace rock-

Clearance between rocker
arm and rocker arm shaft er arm or rock-
0.025 – 0.114 0.148 er arm shaft
Bend of rocker arm shaft Repair limit: 0.05 (Total indicator reading) Replace rock-
er arm shaft
Tightening torque of rocker
2 arm adjustment nut 67.5 ± 1 Nm {6.9 ± 1.0 kgm} Retighten
12V170-2 14-7
MAINTENANCE STANDARD PUSH ROD AND CAM FOLLOWER
PUSH ROD AND CAM FOLLOWER
Unit: mm
Standard Tolerance Allowable limit

Outside diameter of cam
1 follower shaft – 0.038
24.8 – 0.053 24.7
2 Inside diameter of cam 24.8 + 0.021 24.85

follower shaft hole 0
Inside diameter of cam + 0.033
3 follower roller hole 19.0 + 0.015 —
Inside diameter of cam 19.0 + 0.177 19.2

follower roller + 0.157 Replace
4
Outside diameter of cam + 0.075
follower roller pin 19.0 + 0.063 19.0
Outside diameter of cam + 0.275

5 follower roller 41.0 + 0.250 41.0
6 Radius of push rod tip ball 7.983 0 —

– 0.05
Inside radius of push rod
7 socket 6.5 ± 0.1 —
14-8 12V170-2
MAINTENANCE STANDARD CYLINDER BLOCK
CYLINDER BLOCK
14-10 12V170-2
MAINTENANCE STANDARD CYLINDER BLOCK
Unit: mm
+ 0.030
– 0.015
171 —
Range of A
Inside diameter of main + 0.025
bearing hole (Tighten by – 0.008
specified torque)
1 Size Standard size Tolerance Repair limit
STD 4.5 4.41
Thickness of main bearing 0.25 US 4.625 4.54

(Center) – 0.050 Repair or
0.5 US 4.75 – 0.060 4.66
replace
0.75 US 4.875 4.79
1.0 US 5.0 4.91
Inside diameter of main bearing 162 + 0.145 162.2
(Tighten by specified torque) + 0.110
Standard interference Clearance limit
Interference between main Upper side Clearance Interference
0.063
2 bearing cap and cylinder 0.045 – 0.013
block
Clearance Interference
Lower side 0.055 – 0.009 0.059

Inside diameter of camshaft
bushing 72 + 0.007 72.10
3 0
Inside diameter of cylinder + 0.030
block cam bush hole 75 0 — Repair

Distortion of cylinder head Repair or
4 mounting surface replace
Max. 0.09 Max. 0.15
Order Target value Nm {kgm} Range Nm {kgm}

1st 785 {80} 705 – 865 {72 – 88}
Tightening torque of main 2nd 1,550 {160} 1,500 – 1,650 {152 – 168}
bearing cap mounting bolt
5 (Coat bolt threads and 3rd Loosen completely
washer with engine oil) 4th 540 {55} 410 – 620 {42 – 63}
5th 1,100 {110} 1,000 – 1,150 {102 – 118}
6th 1,550 {160} 1,500 – 1,650 {152 – 168} Tighten
1st 275 {28} 245 – 305 {25 – 31}
2nd 560 {57} 530 – 591 {54 – 60}
Tightening torque of main
bearing cap side bolt 3rd Loosen completely
6
(Coat bolt threads and 4th 185 {19} 155 – 215 {16 – 22}
washer with engine oil)
5th 375 {38} 345 – 400 {35 – 41}
6th 560 {57} 530 – 596 {54 – 60}
12V170-2 14-11
MAINTENANCE STANDARD CYLINDER LINER
CYLINDER LINER
Unit: mm
Replace
1 Protrusion of cylinder liner Permissible range: 0.07 – 0.15 cylinder liner or
block
Inside 170 + 0.040 170.24

2 diameter 0
Roundness Repair limit: 0.020
Cylinder liner
Cylindricity Repair limit: 0.015
Outside diameter of cylinder Standard size Tolerance
liner
(Counter bore lower part) 194.59 ± 0.025
3
Interference of cylinder liner
and block Interference Interference
(Counter bore lower part) 0.025 – 0.135 Replace
cylinder liner
liner
(Counter bore upper part) 205.99 ± 0.05
4
Clearance between cylinder Interference Clearance
liner and block - 0.085 – 0.025
(Counter bore upper part)
liner
(O-ring part) 190.24 ± 0.05
5
Clearance between cylinder
liner and block Standard clearance: 0.050 – 0.210
(O-ring part)
Unevenness of counter bore
depth 14 + 0.05 Repair by
6 0 grinding or
add shim
Cylinder liner flange 14.12 + 0.03
thickness 0
14-12 12V170-2
MAINTENANCE STANDARD CAMSHAFT
CAMSHAFT
Unit: mm
Intake side 62.00 + 0.441 61.37

1 Cam height + 0.241
Exhaust – 0.312 Replace
61.00 59.64
side – 0.512
– 0.080
2 Outside diameter of journal 72.00 – 0.110 71.86
3 Thrust plate thickness 10.00 – 0.025 9.93

– 0.061
Standard clearance Clearance limit Replace thrust
plate
4 Camshaft end play
0.075 – 0.211 0.40
Runout of all main journal: Max. 0.04

5 Bend of camshaft Replace
Runout of journal adjoin each other: Max. 0.02
Standard clearance Clearance limit
6 Camshaft journal thickness Replace
0.08 – 0.18 0.24 cam bushing
12V170-2 14-13
MAINTENANCE STANDARD CRANKSHAFT
CRANKSHAFT
Unit: mm
Size Standard size Tolerance Repair limit
S.T.D 162.00 161.98
0.25 US 161.75 161.73

Outside diameter of main
journal 0
(Except No.4 journal) 0.50 US 161.50 161.48
– 0.020 Repair or
1 replace
0.75 US 161.25 161.23
1.00 US 161.00 160.98

Main journal roundness
0 – 0.010 0.010
14-14 12V170-2
MAINTENANCE STANDARD CRANKSHAFT
Unit: mm
S.T.D 162.00 161.94
0.25 US 161.75 161.69

Outside diameter of No.4
journal 0.50 US 161.50 – 0.040 161.44
– 0.060
2 Replace
0.75 US 161.25 161.19
1.00 US 161.00 160.94

No.4 journal roundness
0 – 0.010 0.010
S.T.D 124.00 123.98
0.25 US 123.75 123.73

Outside diameter of crank pin 0
journal 0.50 US 123.50 – 0.020 123.48
3 0.75 US 123.25 123.23
1.00 US 123.00 122.98

Crank pin journal roundness
0 – 0.010 0.10
– 0.053 Replace
Crank pin bearing thickness 3.5 – 0.040 3.43

4 End play
0.140 – 0.320 0.50

5 Outside diameter of rear
flange 220 ± 0.1 219.7

Runout of all main Max. 0.09 0.09
6 Bend of crankshaft journal
(Runout indicator)
Runout of journal
adjoin each other Max. 0.05 0.05
Target Nm {kgm} Range Nm {kgm}
1st 73.5 {7.5} 54 – 93 {5.5 – 9.5}

Tightening torque of vibration
7 damper mounting bolt 2nd 245 {25.0} 225 – 265 {23 – 27} Tighten
3rd 635 {65.0} 620 – 655 {63 – 67}
12V170-2 14-15
MAINTENANCE STANDARD TIMING GEAR
TIMING GEAR
Unit: mm
Standard
Measuring point clearance
1
Fuel injection pump gear 0.09 – 0.45
2 Cam gear 0.075 – 0.211
Crank gear 0.14 – 0.32 Replace

3 End play lashing
4 Water pump gear 0 – 0.92
5 Oil pump idler gear 0.10 – 0.32
6 Oil pump gear 0.095 – 0.155
Measuring point Repair limit
A Crank gear and idler gear 0.179 – 0.478
B Idler gear and cam gear 0.115 – 0.429
C Cam gear and cam gear 0.126 – 0.418
D Cam gear and idler gear 0.093 – 0.451
E Idler gear and idler gear 0.098 – 0.445

— Gear backlash Replace
F Idler gear and fuel injection pump gear 0.084 – 0.460
G Idler gear and fuel injection pump gear 0.084 – 0.460
H Crank gear and idler gear 0.148 – 0.469
J Idler gear and water pump gear 0.136 – 0.428
K Crank gear and idler gear 0.023 – 0.577
L Idler gear and oil pump gear 0.133 – 0.468
14-16 12V170-2
MAINTENANCE STANDARD PISTON
PISTON
FCD PISTON TYPE
Unit: mm
Outside diameter of piston Standard Tolerance Repair limit

1 (3.0 mm from bottom and at – 0.257
20°C) 170 (90° to boss) 169.62
– 0.287
Tolerance Clearance
Measuring Standard limit (Clear-
point size Ring ance with
Ring groove thickness new ring)
2 Width of piston ring groove Top ring Keystone Check with piston 0.15
2nd ring Keystone groove wear gauge 0.15
- 0.050 –
Oil ring 4.8 ± 0.01 - 0.075 0.3
Replace
Measuring point Standard Clearance limit
Top ring 0.50 – 0.65
3 Piston ring gap
2nd ring 0.45 – 0.60 1.0
Oil ring 0.50 – 0.70
Standard Tolerance Repair limit
Inside diameter of piston pin
4 hole + 0.014
68 + 0.004 68.04
Outside diameter of piston 0

5 pin 68 – 0.006 67.98
12V170-2 14-17
MAINTENANCE STANDARD CONNECTING ROD
CONNECTING ROD
Unit: mm
Standard Tolerance Standard Clearance

Clearance between size clearance limit
1 connecting rod bushing and Shaft Hole
piston pin 0 + 0.069 0.050 –
68 0.11 Replace
–0.006 + 0.050 0.075
Standard size Tolerance
Inside diameter of connecting
2 rod big end (without bearing) + 0.029
131 0
Inside diameter of connecting Standard size Tolerance Repair limit
rod big end (with bearing) Repair or
3 (Tighten bearing cap bolt with + 0.135 replace
124 + 0.080 124.18
specified torque)
Clearance between inside Standard clearance Clearance limit
diameter of connecting rod
4 big end and crankshaft 0.080 – 0.155 0.20
journal (with bearing)
STD 3.500 3.41
Connecting rod bearing 0.125 US 3.625 3.54 Replace
5 thickness – 0.040
(Center) 0.250 US 3.750 – 0.053 3.66
0.375 US 3.875 3.79
0.500 US 4.000 3.90
Bend or twist of connecting • With bushing Repair limit of bend: 0.10 • Without bushing Bend: 0.20
6 rod Repair limit of twist: 0.50 Twist: 0.50
Connecting rod assembly
7 weight 10.756 ± 0.04kg —
Order Target Nm {kgm} Range Nm {kgm}

Tightening torque of
connecting rod cap bolt 1st 78.5 {8} 73.5 – 83.5 {7.5 –8.5}
8 Tighten
(Coat bolt and nut threads 2nd 115 {11.5} 110 – 120 {11 – 12}
with engine oil)
3rd 70° 65 – 75°
Distance between Standard size Tolerance Repair limit

Repair or
9 connecting rod big end and 0 replace
small end 340 – 0.05 —
14-18 12V170-2
MAINTENANCE STANDARD FLYWHEEL, FLYWHEEL HOUSING
FLYWHEEL, FLYWHEEL HOUSING

*1. Tightening order of flywheel housing
*2. Tightening order of flywheel
Unit: mm
Radial runout of flywheel

1 housing Repair limit: 0.25
Face runout of flywheel

2 housing Repair limit: 0.25
Repair or
replace
3 Radial runout of flywheel Repair limit: 0.28
4 Face runout of flywheel Repair limit: 0.13
Tightening torque of flywheel Step Nm {kgm} Tighten in se-

housing mounting bolts quence as
5 (Coat bolt and threads with 1st 392 – 539 {40 – 55} indicated
engine oil) 2nd 490 – 539 {50 – 55} above (*1)
Order Nm {kgm}
Tightening torque of flywheel Tighten in se-
mounting bolts 1st 53.9 – 93.1 {5.5 – 9.5} quence as
6 (Coat bolt and threads with indicated
engine oil) 2nd 225.4 – 264.6 {23.0 – 27.0}
above (*2)
3rd 617.4 – 656.6 {63.0 – 67.0}
12V170-2 14-19
MAINTENANCE STANDARD OIL PUMP
OIL PUMP
Unit: mm
Tolerance Standard Clearance

Standard clearance limit
Axial clearance between Shaft Hole
1 pump gear and body
– 0.035 + 0.095 0.095 –
97 0 + 0.115 0.150 —
Radial clearance between + 0.05 + 0.30

2 pump gear and body 80 + 0.02 + 0.24 0.19 – 0.28 —
Radial clearance between

scavenging pump gear and + 0.05 + 0.30 0.19 – 0.28
3 80 + 0.02 + 0.24 —
body
Clearance between pump 0 – 0.069 0.053 –
4 drive gear and drive shaft 40 – 0.016 – 0.091 0.091 —
Replace
Interference
Clearance between idler 0 + 0.055 0.053 –
5 shaft and bushing 52 – 0.016 + 0.030 —
0.091
Clearance between drive 0 + 0.059 0.040 –
6 gear shaft or driven gear 40 – 0.016 + 0.040 0.075 —
shaft and bushing
Backlash between idler gear
7 and oil pump drive gear 0.133 – 0.468 —
8 End play of idler gear 0.10 – 0.32 —
Tightening torque of driven

9 gear shaft mounting bolt 295 – 345 Nm {30 – 35 kgm} Tightening
14-20 12V170-2
OIL PUMP RELIEF VALVE, PISTON COOLING VALVE, OIL COOLER
MAINTENANCE STANDARD BYPASS VALVE AND OIL FILTER SAFETY VALVE
OIL PUMP RELIEF VALVE, PISTON COOLING VALVE, OIL

COOLER BYPASS VALVE AND OIL FILTER SAFETY VALVE
A. Oil pump relief valve

B. Oil filter safety valve
C. Piston cooling valve
D. Oil cooler bypass valve
14-22 12V170-2
OIL PUMP RELIEF VALVE, PISTON COOLING VALVE, OIL COOLER
MAINTENANCE STANDARD BYPASS VALVE AND OIL FILTER SAFETY VALVE
Unit: mm

Installed
1 Main relief valve spring Free length length Installed load Free length Installed load
98.6 70.0 693N {70.7kg} — 624N {63.6kg}
2 Regulator valve spring 105.0 73.0 314N {32kg} — 282N {28.8kg} Replace
3 Piston cooling valve spring 140.0 89.5 127N {12.9kg} — 114N {11.6kg}
Oil cooler bypass valve

4 spring 80.0 76.0 76N {7.7kg} — 68N {6.9kg}
5 Oil filter safety valve spring 82.0 65.7 76N {7.7kg} — 68N {6.9kg}
6 Main relief valve set pressure 0.98 ± 0.1 Mpa: {10.0 ± 1.0 kg/cm2}
7 Regulator valve set pressure 0.41 ± 0.03 Mpa: {4.2 ± 0.3 kg/cm2}
Piston cooling valve set

8 pressure 0.13 ± 0.01 Mpa: {1.3 ± 0.1 kg/cm2} Adjust shim
Oil cooler bypass valve set

9 pressure 0.39 ± 0.04 Mpa: {4.0 ± 0.4 kg/cm2}
Oil filter safety valve set

10 pressure 0.20 ± 0.02 Mpa: {2.0 ± 0.2 kg/cm2}
11 Plug tightening torque 195 ± 10 Nm: {20 ± 1 kgm} Tighten
Tolerance Standard
Standard clearance
Clearance between main Shaft Hole
12 relief valve and body
– 0.025 + 0.039
36 – 0.064 0 0.025 – 0.103
Clearance between regulator 0 + 0.047

13 valve and body 34 – 0.03 + 0.026 0.026 – 0.077 Replace body
or valve
Clearance between piston – 0.025 + 0.039
14 cooling valve and body 36 – 0.050 0 0.025 – 0.089
Clearance between oil filter – 0.051 + 0.025

15 safety valve and body 25.4 – 0.076 – 0.025 0.026 – 0.101
Clearance between oil cooler – 0.051 + 0.025

16 by-pass valve body 25.4 – 0.076 – 0.025 0.026 – 0.101
12V170-2 14-23
MAINTENANCE STANDARD WATER PUMP
WATER PUMP
Unit: mm
Tolerance Standard
Standard size
Interference between front Shaft Hole interference
1 shaft and bearing
+ 0.018 0
45 + 0.002 – 0.012 0.002 – 0.030
Interference between rear + 0.018 0
2 shaft and bearing 35 + 0.002 – 0.012 0.002 – 0.030
Interference between rear + 0.054 + 0.009
3 shaft and impeller 25 + 0.041 – 0.016 0.032 – 0.070
Clearance between impeller Standard clearance Clearance limit

4 Replace
and connection 0.63 – 1.41 —
Interference between bearing 0 + 0.016 Clearance: 0.031
5 and body 85 – 0.015 – 0.006 Interference: 0.006
Interference between bearing 0 + 0.013 Clearance: 0.026
6 and body 72 – 0.013 – 0.006 Interference: 0.006
Interference between water + 0.150 + 0.030 Clearance: 0.020
7 seal and body 52 + 0.050 0 Interference: 0.150
Interference between oil seal + 0.40 + 0.046 Clearance: 0.154
8 and body 55 + 0.20 0 Interference: 0.400
14-24 12V170-2
MAINTENANCE STANDARD THERMOSTAT
THERMOSTAT
Unit: mm
Lift of thermostat to fully open Min 9mm

position (Soak the valve in oil bath at 90°C for 4 to 5 minutes to check)
1 Check that the valve closes fully when the water temperature has Replace
Opening/closing of gone down to 76.5°C from 90°C when the valve was fully open.
thermostat (Soak the valve in a water bath for 4 to 5 minutes to check)
12V170-2 14-25
15 REPAIR AND REPLACEMENT
OF PARTS
TABLE OF SPECIAL TOOLS ................................... 15- 2

TESTING AND INSPECTING CYLINDER
HEAD .................................................................... 15- 3
REPAIRING MOUNTING FACE OF CYLINDER
HEAD BY GRINDING ............................................ 15- 6
REPLACING VALVE SEAT INSERTS ...................... 15- 7
REPLACING NOZZLE HOLDER SLEEVE .............. 15-13
CYLINDER HEAD PRESSURE TEST
METHOD ............................................................... 15-16
REPLACING VALVE GUIDE .................................... 15-17
REPLACING CROSS HEAD GUIDE ....................... 15-18
GRINDING VALVE ................................................... 15-19
TESTING AND INSPECTING CYLINDER
BLOCK .................................................................. 15-20
GRINDING TOP SURFACE OF CYLINDER
BLOCK .................................................................. 15-23
REPLACING MAIN BEARING CAP ......................... 15-29
REPLACING CAM BUSHING .................................. 15-32
TESTING CRANKSHAFT ........................................ 15-34
CORRECTING SURFACE ROUGHNESS OF
CRANKSHAFT JOURNAL PORTION ................... 15-36
GRINDING CRANKSHAFT ...................................... 15-41
TESTING AND INSPECTING CONNECTING
ROD ...................................................................... 15-50
REPLACING CONNECTING ROD SMALL END
BUSHING .............................................................. 15-52
REPLACING CAMSHAFT GEAR ............................. 15-53
REPLACING FLYWHEEL RING GEAR ................... 15-54
12V170-2 15-1
REPAIR AND REPLACEMENT OF PARTS TABLE OF SPECIAL TOOLS
TABLE OF SPECIAL TOOLS
Operation Symbol Part No. Part Name Q'ty Remarks
1 795-100-4800 Puller 1 For valve seat
2 795-100-3004 Seat cutter 1
795-600-2510 Push tool 1 For intake valve

3
Replacing valve seat A 795-600-2520 Push tool 1 For exhaust valve
795-600-2531 Calking tool 1 For intake valve

4
795-600-2541 Calking tool 1 For exhaust valve
5 795-600-2570 Peening guide 1
1 795-600-2110 Push bar 1
2 795-600-1191 Push bar 1
B 3 795-600-2120 Driver 1
4 795-600-1130 Punch 1
5 795-600-2130 Holder 1
Replacing nozzle holder
sleeve
1 795-600-1140 Punch bushing 1
2 795-600-2140 Rolling tool 1
C 3 795-600-2150 Expander 1
4 795-600-2160 Cutter 1
5 795-600-2170 Guide bushing 1
E 795-553-1700 Coolant tester 1

Pressure test of cylinder head
F 79A-471-1050 Pump assembly 1
1 795-600-2550 Valve guide remover 1

Replacing valve guide G
2 795-600-2560 Valve guide driver 1
Replacing crosshead guide H 795-140-6410 Crosshead guide pulle 1
Commercially
Grinding valve I available Valve refacer 1
1 795-250-1301 Push tool set 1

Replacing cam bushing J
2 792-103-0400 Grip 1
K 795-903-1101 Push tool (KIT) 1
1 • 795-903-1111 • Push tool

Replacing connecting rod 2 • 795-903-1120 • Push tool
small end bushing
K
3 • 795-903-1130 • Block
4 • 795-903-1150 • Nut
15-2 12V170-2
REPAIR AND REPLACEMENT OF PARTS TESTING AND INSPECTING CYLINDER HEAD
TESTING AND INSPECTING CYLINDER HEAD
1. Valve guide
2. Closshead guide
3. Fuel injection nozzle sleeve
4. O-ring
5. Cylinder head
6. O-ring
7. Pushrod tube
8. Valve seat insert
12V170-2 15-3
TESTING AND INSPECTING

Unit: mm
Inspection item Judgement standards Remedy
• Check for cracks (external color check)

Repair by
A. Cracks, leakage from • Check for water leakage with air pressure test
welding or
cylinder head (0.3 – 0.35 MPa {3.0 – 3.5 kg/cm2}, 30sec.)
replace
• Water pressure test (0.35 – 0.4 MPa {3.5 – 4.0 kg/cm2}, 10 min.)
B. Distortion of top, bot- Tolerance Repair limit

tom surface of cylin- Grind to correct
der head Max. 0.05 0.1
C. Damage to injection
Machine to repair
nozzle sleeve seat sur- —
or replace sleeve
face, contact width
D. Protrusion of injection Permissible range: 4.9 – 5.7

Replace sleeve
nozzle a
• Pitting of seat surface Correct seat sur-

E. Damage to valve seat
• Check contact between valve and seat surface face or
surface or loosening of
• Airtighteness test replace valve
seat
• Tap cylinder head and chek for looseness seat
F. Sinking of valve b Standard value Repair limit

Replace valve or
(both intake and 0.9 – 1.5 2.1 valve seat
exhaust)
• Thickness of valve head d

Standard value Repair limit
Intake valve 3.4 2.9
Exhaust valve 3.5 2.4
• Angle of seat surface c

G. Thickness of valve Intake valve: 30° Replace
head Exhaust valve: 45°
15-4 12V170-2
Unit: mm
• Check if head has become flat, check for ctacks or pitting of seat surface
• Airtightness test
Replace
• Check for play in cotter when new cotter is inserted in cotter groove.
H. Abnormality in valve
• Check for eccentric wear or curvature of stem.
• Check for dent in stem end. Correct
• Outside diameter
I. Outside diameter of Standard size Standard value Repair limit Replace
valve stem
12 11.908 – 11.893 11.80
J. Inside diameter of Standard size Standard value Repair limit

valve guide
12 11.981 – 11.999 12.10
K. Protrution of valve Permissible range: 23.4 – 23.9

guide e Replace
L. Outside diameter of Standard size Standard value Repair limit

crosshead guide 15 15.028 – 15.039 15.00
M. Protrution f of Permissible range: 53.7 – 54.0

Correct
crosshed guide (2)
12V170-2 15-5
REPAIRING MOUNTING FACE OF CYLINDER HEAD
REPAIR AND REPLACEMENT OF PARTS BY GRINDING
REPAIRING MOUNTING FACE OF CYLINDER HEAD

BY GRINDING
1. Grinding
1) Remove the valve seat inserts. For details,
see REPLACING VAVLE SEAT INSERTS.
2) Remove the nozzle holder sleeves. For
details, see REPLACING NOZZLE HOLDER
SLEEVES.
3) Grind the cylinder head to remove the
strained or corroded portions within the limit
of the height of the cylinder head H.
If any grinding is carried out, stamp the side
face of the cylinder head with an R mark.
a Repair limit of cyinder head height (H):
139.55 mm
(Standard size:139.85 – 140.15)
a Amount to remove per grinding:
0.10 – 0.15 mm
a Surface roughness of grinding surface:
within: 6S
a Flatness (deformation): Max. 0.05 mm
a Grinding limit: 0.3 mm
a Difference in head height between 6 cyl-
inders: Max. 0.15 mm
4) Press-fit the one-size-larger inserts. For details,
see REPLACING VALVE SEAT INSERTS.
5) Press-fit the nozzle holder sleeves. For details,
s e e RE P L A C E NG N O Z ZL E H O L DE R
SLEEVES.
2. Check after grinding

• Check the sinking of the valves and protrusion of
the nozzle are within the standard values
a Standard sinking of valves: 0.9 – 1.5 mm
a Allowable protrusion of nozzle: 4.9 – 5.7 mm
15-6 12V170-2
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE SEAT INSERTS
REPLACING VALVE SEAT INSERTS

a When repairing without replacing the valve seat • Intake valve
insert (when there is surface roughness or
stepped wear), repair with the amount of sinking
of the valve is within the repair limit of 2.1 mm.
Machining drawings of new valve seat inserts is
shown on the right.
a Checking for looseness of valve seat insert
Tap the outside of the valve insert of the cylinder
head with a hammer to check for any looseness
of the valve seat insert. If the valve seat insert is
loose or springs back, replace the insert.
1. Pulling out the valve seat insert

1) Using the grinder of valve e seat puller A1,
make grooves on the inserts to pull them out • Exhaust valve
according to the following procedure.
a Set the air pressure to 0.5 – 0.6MPa {5 – 6
kg/cm2}.
a When replacing the grindstone of the grinder,
shut off the compressed air.
k Before using the grinder, run it for one

minute to check abnormality.
• After replacing the grindstone, run the
grinder for three minutes to test it.
k Confirm that the grindstone is not dam-

aged, then install it to the shaft of the
grinder without applying excessive force.
Confirm that there is no play between the
grindstone and shaft.
k When using the grinder, wear safety gog-

gles.
i) Install grindstone [5] to grinder [1].

ii) Install the sleeve and grinder after align-
ing the groove of sleeve [3] with holder
[2].
Adjust the position of the grinder with set
screw [4].
12V170-2 15-7
iii) Adjust the position of the grinder so that

the center of grindstone [5] will be at the
center of insert (1), then tighten the set
screw to secure the grinder.
iv) Fully open the throttle of the grinder to
rotate the grindstone and slowly move it
until it contacts insert (1).
v) Press the grindstone against the inside

of the insert, move it in a circular pattern,
and make a groove about 1 mm deep.
2) Pull out the insert with the puller head of

valve seat puller A1 according to the follow-
ing procedure.
i) Push three claws a of puller head [6]
inward by hand and put them in insert
(1).
ii) Tighten screw [8] to press the three
claws against the groove on the inside
surface of the insert.
a If the screw is tightened too strongly,
the insert will break and it will be diffi-
cult to pull it out. Therefore, stop
tightening the screw when the claws
compretely contact the groove.
iii) Place bridge [9] over the puller head,
then place plates [10] and [11] on the
bridge. tighten nut [12] to pull out the
insert.
15-8 12V170-2
a Lower the shank by utilizing its weight and record • Dimensions of insert and mounting hole
its position (Measure dimension l).
a Install sleeve expander K to a radial drilling
machine or a upright drilling machine and press
it down lightly by 4 – 6 mm from the position to
which the shank is lowered by its weight.
Note) When installing sleeve expander K to the
drilling machine, pull up the shank.
a Rotating speed: 100 – 200 rpm
2. Machining valve seat insert mounting hole to

oversize
1) Using valve seat cutter A2, machine the
mounting hole to install a one-size-larger
insert
• Intake valve side Unit: mm
Insert Mounting hole for

Stamp insert
on
insert Hight Depth
O.D.(a) (b) I.D. (c) (d)
+ 0.100 0 + 0.020
S.T.D. 63.00 + 0.080 8.5 - 0.1 63.00 - 0.010 12.5±0.1
+ 0.100 0
0.25 O.S 63.25 + 0.080 8.5 - 0.1 63.25 +- 0.020
0.010 12.5±0.1
0.50 O.S 63.50 ++ 0.100

0.080 8.62
0
- 0.1 63.50 +- 0.020
0.010 12.62±0.1
0.75 O.S 63.75 ++ 0.100

0.080 8.75
0
- 0.1 63.75 +- 0.020
0.010 12.75±0.1
+ 0.100 0 + 0.020
1.00 O.S 64.00 + 0.080 8.88 - 0.1 64.00 - 0.010 12.88±0.1
• Exhaust valve side Unit: mm

Mounting hole for
Stamp Insert insert
on
insert Hight Depth
O.D.(a) (b) I.D. (c) (d)
+ 0.020
S.T.D. 61.00 ++0.080
0.100
8.5 0
- 0.1 61.00 - 0.010 12.5±0.1
+ 0.020
0.25 O.S 61.25 ++0.080
0.100
8.5 0
- 0.1 61.25 - 0.010 12.5±0.1
+ 0.020
0.50 O.S 61.50 ++0.080
0.100
8.62 0
- 0.1 61.50 - 0.010 12.62±0.1
+ 0.100 0 + 0.020
0.75 O.S 61.75 +0.080 8.75 - 0.1 61.75 - 0.010 12.75±0.1
+ 0.020
1.00 O.S 62.00 ++0.080
0.100
8.88 0
- 0.1 62.00 - 0.010 12.88±0.1
a Inside diameter surface roughness:

Max. 12.5S
a Mounting hole bottom roughness:Max. 12.5S
a Concentricity of inside diameter of valve
guide and inside diameter of insert hole:
0.05 mm (T.l.R) max.
a Rectangularity of inside diameter of valve
guide and bottom of insert hole:
Max. 0.03 mm (T.l.R)
12V170-2 15-9
2) If the calked portion of the mounting hole is

damaged, remove it within the range of
1.00mm oversize. If the damage portion can-
not be removed within the range of 1.00mm
oversize, replace the cylinder head.
3. Press fitting the insert

1) Using insert push tool A3, press-fit the insert.
2) Check the sinking distance of the insert from

the mounting surface of the cylinder head
a Srandard sinking distance a of insert:
3.9 – 4.2 mm
15-10 12V170-2
a Caulking around insert

• Using caulking tool A4, peening guide A5,
and a hammer, caulk around the insert.
4. Finishing the seat surface

1) Finish the seat surface with valve seat cutter
A2 as shown in the figure.
a Angle of seat surface: Intake side: 30°
Exhaust side: 45°
a Width of seat fininshing surface:
Intake side: 3.69 mm
Exhaust side: 3.79 mm
a Connectricity of valve guide and insert:
Max. 0.07 mm (T.I.R)
2) Fit the seat surface using the compound.
Coat the seat surface of the valve thinly with
a rough compound mixed with oil insert it in
the valve guide that forms a pair with that
valve, then fit a rubbing bar to the valve
head, and turn it with both hands to rub
lightly against the valve seat.
When the rubbing removes the roughness,
wipe off the compound. Then coat with a fine
compound and repeat the above process to
give a good contact surface with no break in
contact.
3) Fit a vacuum cup that matches the size of

the valve in tight contact with the head sur-
face. When doing this, to improve the air-
tightness of the vacuum cup, coat grease on
the O-ring fitted to the vaccum cup, and fit it
in tight contact with the flat surface of the
head.
(Be careful not to get any grease on the seat
surface.)
4) Set the vacuum gauge to 93.3 kPa {700
mmHg}, and check that the pressure drops
less than 1.3 kPa {10 mmHg} in 3 seconds.
If it drops more than 1.3 kPa {10 mmHg} in 3
seconds, check for any dirt on the seat sur-
face, or rub the surface to correct it.
12V170-2 15-11
5. Final check
a Standard sinking distance of valve (new):
Intake side a: 0.9 – 1.5 mm
Exhaust side b: 0.9 – 1.5 mm
a Standarad width of contact sutface against
valve: New (Referance)
Intake side c: 3.4 mm
Exhaust side d: 2.8 mm
• Coat the seat surface of the new valve thinly

with red lead (minium), insert it in the valve
guide, push lightely against the valve insert
surface, and rotate 10 ° . Check the valve
insert contact surface, and confirm that the
contact is uniform without any breaks.
• or
Mark marks A (approx. 20 places) with a
pencil on the seal surface of the new valve
as shown in the diagram, insert it in the valve
guide, push lightly against the valve insert
surface, and rotate 10°. Check that the pencil
marks have been erased uniformly around
the whole circumference.
• When carrying out an airtightness test with a
vacuum tester, test as follows
1) Wipe off all the dirt, dust, and oil from the
valve and valve seat surface with a cloth.
2) Assmble the valve, valve spring, retainer,
and cotter, tap the tip of the valve stem with a
plastic hammer 2 or 3 times directly from
above to bring it into tight contact with the
seat sutface.
15-12 12V170-2
REPAIR AND REPLACEMENT OF PARTS REPLACING NOZZLE HOLDER SLEEVE
REPLACING NOZZLE HOLDER SLEEVE

1. Cutting a hole at bottom of sleeve
• Insert 12 mm diameter drill [1] in the hole at
the bottom of the sleeve to make the hole.
2. Removing the sleeve

1) Insert push bar B1 inside the sleeve.
2) Using sleeve extraction tap [2], cut tap to
about 25 mm depth from top face of sleeve.
Add oil while cutting.
a Sleeve extraction tap: M32, P = 2.0
3) Insert push bar B2 from the bottom of the
head and tap with the hammer to remove the
sleeve.
4) Remove the sleeve materials from the tap
portion of portion a of the cylinder head.
5) Remove O-ring (2).
3. Press-fitting the sleeve

1) Install O-ring (2) to the cylinder head.
2) Insert sleeve (1) in the cylinder head, then
insert sleeve driver B3 and lightly tap it until
the sleeve contacts the seat surface.
a Before installing the sleeve, clean the
sleeve and seat.
a Apply adhesive to the seat around the
sleeve.
2 Seat: LT-2
12V170-2 15-13
4. Calking the sleeve seat face

1) Fit the sleeve seat with sleeve holder B5.
3 Tightening torque for sleeve holder:
19.6 Nm {2 kgm}
2) Install punch bushing C1 and insert sleeve

driver B4.
3) Place support [3] under the cylinder head to
allow the bolt of the sleeve holder to move
out.
4) Hit the sleeve driver with a hammer to calk
the seat surface.
a Lightly hit with a hammer several times.
5) Remove the sleeve holder and punch bush-
ing.
5. Roll-fit the bottom hole of sleeve

• Using sleeve rolling tool C2, roll-fit bottom hole b
of sleeve (1).
a Adjust the roll-fitting height with bearing col-
lar [4] so that the shaft of the rolling tool will
protrude a little from the bottom hole.
a Install the rolling tool to a radial drilling
machine or upright drilling machine to roll-fit
with its own weight.
6. Roll-fitting the taper section of sleeve

• Using sleeve expander C3, roll-fit the taper sec-
tion of the sleeve.
a Set the roll-fitting amount with stopper [5] of
the expander.
a Install the expander to a radial drilling
machine or upright drilling machine to roll-fit
with its own weight.
15-14 12V170-2
7. Sport-facing the inside seat of the sleeve

1) Using guide bushing C5 as the guide, spot-
face the seat with sleeve cutter C4.
a Cut the seat little by little while checking
the protrusion of the nozzle with the
holder for measuring it and a dial gauge
so that the protrusion of the nozzle will
be within the specification.
a Protrusion of nozzle: 4.9 – 5.7 mm
2) Remove all the metal chips and dust from the
machined surface.
8. Checking the leakage from the seat

• Confirm that fluid does not leak through the
sleeve seat in the air pressure test. (There
must be no leakage for 30 seconds at an air
pressure of 0.4 ± 0.03 MPa {4 ± 0.3 kg/cm2})
When carrying out the air pressure test, intall
a used nozzle holder.
12V170-2 15-15
REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD PRESSURE TEST METHOD
CYLINDER HEAD PRESSURE TEST METHOD

• If the area around the head has been corrected,
test as follows.
1. Water pressure test

1) Tighten the nozzle holder assembly to the
specified torque.
2) Assemble tool E and tool F, and connect a
hose to frange (1).
3) Apply water pressure 0.35 – 0.4 MPa {3.5 –
4.0 kg/cm 2 } for approx. 10 minutes, and
check for any leakage from around the head.
a It is preferable to warm the whole cylinder

head and carry out the test with hot water (82
– 93°C).
2. Air pressure test

1) Tighten the nozzle holder assembly to the
specified torque.
2) Connect the pump hose to flange (1).
3) Place the head in a water bath, apply air
pressure 0.3 – 0.35 MPa {3.0 – 3.5 kg/cm2}
for approx. 30 seconds, and check for any air
leakage in the water.
a If the above test shows that there are cracks

around the nozzle holder and plugs, replace
the cylinder head.
15-16 12V170-2
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE GUIDE
REPLACING VALVE GUIDE

1. Removing the valve guide
• Remove the valve guide with valve guide
remover G1.
2. Press-fitting the valve guide

1) Press-fit the valve guide until the tip of valve
guide driver G2 contacts the cylinder head.
2) Confirm that the protrusion of the valve guide
is within specification.
a Protrusion of valve guide: 23.7 - 0.3 mm
+ 0.2
a Inside diameter of valve guide hole in cylin-

der head: 19 + 00.021 mm
12V170-2 15-17
REPAIR AND REPLACEMENT OF PARTS REPLACING CROSS HEAD GUIDE
REPLACING CROSS HEAD GUIDE

1. Removing the cross head guide
• Using cross head guide puller H, pull out the
cross head guide.
1) As show in the figure, hold the cross head
guide with collect [5] of the puller.
2) Tighten the collect with bolt [1] to lock sleeve
[2].
3) Rotate nut [3] and pull out the cross head
guide.
4) Remove burrs, fins, etc. from the mounting
place of the cross head guide and clean it.
2. Press-fitting the cross head guide

• Insert the cross head guide in the cylinder
head, then hit it into the cylinder head with a
copper bar or plastic hammer until its protru-
sion is within specification.
a Protrusion of cross head guide Toletance:
0
54 - 0.3 mm
a Inside diameter of crosshead guide hole:
+ 0.081
15 0 mm
15-18 12V170-2
REPAIR AND REPLACEMENT OF PARTS GRINDING VALVE
GRINDING VALVE
1. Grinding the seat surface
• Grind the seat sutface with valve refacer I.
a Angle of valve seat a: Intake valve:30°
EXhaust valve: 45°
2. Checking after grinding

• Confirm that the thickness of the valve head,
protrusion of the valve, and the contact sur-
face of the valve seat are within specifica-
tion.
a Thickness of valve head b

Repair limit
Intake valve: 2.9 mm
(Standard size 3.4 mm)
Exhaust valve: 3.1 mm
(Standard size 3.5 mm)
a Sinking of valve
Standard: 0.9 – 1.5 mm
Repair limit: 2.1 mm
a Check the contact of the valve with the seat

surface using one of the following methods.
• Coat the seat surface of the ground valve
thinly with red lead (minium), insert it in
the valve guide, push lightly against the
valve seat insert surface, and rotate 10°
and confirm that the contact is uniform
without any breaks.
• Make marks with a pencil on the seat

surface of the ground valve as shown in
the diagram, insert it in the valve guide,
push lightly against the valve seat insert
surface, and rotate 10° . Check that the
pencil marks A have been erased uni-
formly around the whole circumference.
12V170-2 15-19
REPAIR AND REPLACEMENT OF PARTS TESTING AND INSPECTING CYLINDER BLOCK
TESTING AND INSPECTING CYLINDER BLOCK
1. Cylinder liner
2. Crevice seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing cap side bolt
6. Main bearing cap
7. Main bearing cap bolt
8. Camshaft bushing
15-20 12V170-2

Unit: mm
• Check for cracks (external color check)

A. Cracks Replace
• Cylinder head bolts hole portion, etc.
B. Correction of contact Check for water leakage Replace

at packing portion a caused by corrosion
Standard value
Standard Standard
size Inside diame- Onside diam- Clearance
ter of block eter of liner
190.24 190.34 – 190.40 190.19 – 190.29 0.05 – 0.21
C. Clearance b between Replace cylinder

liner and cylinder block liner or block
• Inside diameter
Standard size Standard value Repair limit
72 72.00 – 72.07 72.10
D. Inside diameter of
Replace bushing
camshaft bushing • Clearance between camshaft bearing and cylinder block
Standard clearance Standard value
0.08 – 0.18 0.24
• Protrusion of liner
Permissible range: 0.07 – 0.15
Replace cylinder
E. Protrusion of liner c liner or correct
cylinder block
F. Depth of counter-bore Standard size Standard value Repair by

d and corrosion of machining, add
bottom surface 14 14.00 – 14.05 shim
• Check for corrosion
12V170-2 15-21
Unit: mm
G. Distortion, wear of cyl- Standard size Repair limit Repair by

inder head mounting
Overall top surface of block: Max. 0.09 0.15 machining
surface
For one cylinder: Max. 0.05 0.10
Standard size Standard value Repair limit

171 170.985 – 171.030 –
H. Inside diameter of 171 (within range e) 170.992 – 171.025 –
main bearing mounting
hole
• Tighten main bearing

cap bolt and side bolt
with specified torque
Replace
Standard Interference Clearance limit

Clearance Interference
Upper 0.045 – 0.013 0.063
Lower 0.055 – 0.009 0.059

I. Interference f of cap
and cylinder block
Cylinder liner
Outside Standerd Standerd Repair
diameter size value limit
Replace
205.965 cylinder liner
Top g 205.99 – –
206.015
194.565
J. Inside diameter of Bottom h 194.59 – –
counterbore, outside 194.615
diameter of cylinder
liner flange
Cylinder block
Inside Standerd Standerd Repair
diameter size value limit Correct
cylinder block
205.93 – 205.92 – sleeve
Top g 206.0
205.99 206.02
194.48 – 194.46 –
Bottom h 194.5
194.54 194.57
15-22 12V170-2
REPAIR AND REPLACEMENT OF PARTS GRINDING TOP SURFACE OF CYLINDER BLOCK
GRINDING TOP SURFACE OF CYLINDER BLOCK

Grinding
Grind off the strained and corroded portions of the
cylinder block within the allowable height d of the
cylinder block.
a If the top surface A of the cylinder block is worn
or corroded in the shape of the head gasket, and
the amonut of wear a is more than 0.10 mm,
grind the top surface.
a If there are blackened portions on the cylinder
liner contact surface of the counterbore (partic-
ularly in the front-to-rear direction), or there is
speckled wear, and these portions extend over
more than half of the contact width of the deck,
and if grinding has been carried out on th top
surface, correct the counterbore B.
1. Grinding top surface

1) Measure the wear and strain of the tops sur-
face of the cylinder block, and if it over the
repair limit, grind the top surface.
Unit: mm
Standard
dimension Repair limit
Flatness of cylinder block

(for one cylinder) 0.05 0.10
0
Height of cylinder block d 545 - 0.1 544.5
Roughness of top surface
of cylinder block Max. 12.5S
If grinding with a grindstone (for reference)

a Speed of grindstkone: 1,650 – 1,950 m/min.
a Speed of table: 15 – 30 m/min.
a Grinding depth/time: 0.025 mm
a Cross feed/time: 1 – 2 mm
a Grindstone: A461V
a Grinding lubricant: Water-soluble
grinding lubricant
12V170-2 15-23
2. Grinding couterbore
After grinding the top surface of the cylinder
block , measure the depth of the counterbore. If it
is not within the standard dimension, or if there
are blackened portions on the cylinder liner
contact surface of the counterbore (patricularly in
the front-to-rear direction), or there is speckled
wear, and these portions extend over more than
half of the contact width of the deck, correct the
counterbore depth f within the repair limit. After
correcting, if the counterbore depth f is within
14.05 – 15.525 mm, combine with shims and
adjust so that the liner protrusion e is 0.07 – 0.15
mm.
Unit: mm
Standard
dimension Repair limit
+ 0.05
Counterbore depth f 14 0 15.525
Protrusion e of cylinder
liner – 0.07 – 0.15
Roughness of counter-
bore Max. 12.5S
Machined shape In accordance with detail

diagram for portion b
For the extra amount for counterbore depth f,

decide a machining amount that will bring the
protrusion e of the cylinder liner within the atan-
dard value.
When grinding within the repair limit in cases
where the counterbore depth f exceeds the stan-
dard dimension, set the machining amount so
that one shim can be used for each cylinder as
shown in the table below.
[Reference] Adjustment shims for counterbore depth

Unit: mm
Weight
Part No. T t (kg) Remarks
6162-29-2260 1.50 0.025 0.004

6162-29-2250 0.80 0.025 0.002
6162-29-2240 0.50 0.025 0.001
6162-29-2230 0.26 0.025 0.001
6162-29-2220 0.20 0.020 0.001
6162-29-2210 0.16 0.016 0.001
15-24 12V170-2
3. Checking and distinguishing after grinding

and correcting
After grinding and correcting, check for scratches
on the flat surface around the water and oil holes
in the cylinder block top surface.
Remove all burrs completely.
After grinding the top surface, if the cylinder
block height d exceeds the standard dimension,
but is within the repair limit (544.5 – 544.8 mm),
always use an oversize head gasket.
a Oversize head gasket part number:
6164-19-1813
Thickness of plate: 2.4mm
(standard: 2.0mm)
a To distinguish, the letters "OS" are stamped
on the plate.
After correcting, stamp the top surface c of the
cylinder block according to the content of the
correction as shown in the table below.
Talbe of letters to stamp

Oversize
head gaske Shim Stamp
for correction
– – Not needed
Parts used
Q – OS
– Q SH
Q Q WS
(Size of letters: 5 – 10mm)
12V170-2 15-25
4. Procedure for coating gasket sealant to cylin-

der block counterbore
When pulling out the cylinder liner and press fit-
ting it again, coat gasket sealant LG-6 to the
contact surface of the liner flange as follows. Use
the same procedure when using a shim for the
corresponding part.
a The following commercially available seal-
ant is equivalent to LG-6.
• Three Bond: TB1215
• Nihon Hermetic: SS-60F
1) Use a cloth to wipe off all the dirt and oil from
the contact surface of the liner flange and
cylinder block counterbore.
2) Coat the position marked in the diagram with
LG-6.
• Make the diameter of the line of gasket
sealant 2 – 3 mm.
• Make the overlapping portion for begin-
ning and ending the coating of sealant 6
± 6mm as shown in the diagram.
a When using shims

• After coating the bottom of the shim
thinly with LG-6, install it to the deck
portion of the block.
• Next, coat with LG-6 in the same way
as when not using shims.
3) Press fit the liner in the cylinder block.

When doing this, coat the seal and O-ring
with rubber lubricant RF-1.
a RF-1 is equivalent to the commercially
available Daido Kagaku Kogyo DS-50.
a If RF-1 is not available, coat the O-ring
and seal contact surface with an
extremely small amount of engine oil
(SAE30) immediately before press fitting
the liner.
a Coat the contact surface of the cylinder
block uniformly around the whole circum-
ference by hand.
15-26 12V170-2
4) Coat the liner O-ring, clevis seal, and cylin-

der block contact surface with a small
amount of engine oil (SAE = 30) immediately
before press fitting the liner.
a Coat the contact surface of the cylinder block
uniformly around the whole circumference by
hand.
5) Insert liner (1) facing liner top face stamp "W"

to front into the cylinder block, taking care
not to damage the O-ring.
6) Use your weight and push the liner in with
both hands.
a If the liner does not go in smoothly when you
apply your weight, there is danger that the O-
ring may be damaged, so check the cylinder
block for burrs or flashes.
7) Using liner driver I, press fit cylinder liner (1)

into the cylinder block.
a Using the following procedure, squeeze out
the gasket sealant coated on the counter-
bore.
i) Tighten the cylinder head temporarily
with a used head gasket.
3 Mounting bolt:
255 ± 10 Nm {26 ± 1 kgm}
• Tighten order of head bolt
12V170-2 15-27
ii) Remove the cylinder head, and wipe off

the gasket sealant that has been
squeezed out from between the cylinder
liner and cylinder block.
a If gasket sealant sticks to grommet in the
head gasket, the grommet will be
deformed into the shape of a heart, and
this may cause leakage of the coolant
into water hole. To prevent this, wipe off
the gasket sealant.
a Be sure to perform i) and ii).
15-28 12V170-2
REPAIR AND REPLACEMENT OF PARTS REPLACING MAIN BEARING CAP
REPLACING MAIN BEARING CAP

a When replacing the main bearing cap, machine
the semi-finished part according to the following
procedure.
No. 1 – 6 Main cap 6164-29-1210
No. 7 Main cap 6164-29-1210
1. Machining the bore of main bearing cap

1) Remove the cylinder liner
2) Install the replacement bearing cap to the
cylinder block and tighten it to specification.
3 Main bearing cap mounting bolt:
a Coat the thread and seat with engine oil
Unit: Nm {kgm}
Procedure Target Range 5) Cut the inside of bearing cap (1) little by little
1st step 785 {80} 706 – 863 {72 – 88} while checking its inside diameter.
2nd step 1,570 {160} 1,490 – 1,650 {152 – 168}
a Cut until the cutting tool contacts the
inside wall of cylinder block (2).
3rd step 0 {0} Loosen completely
a Inside diameter of main cap:
4th step 539 {55} 461 – 618 {47 – 63} i) Machining dimension
5th step 1,080 {110} 1,000 – 1,160 {102 – 118} + 0.025
Tolerance: 171 0 mm
6th step 1,570 {160} 1,490 – 1,650 {152 – 168} ii) Inside diameter of cap when main cap is
3 Main bearing cap side bolt:

ti ghtene d to spe cif ied torq ue after
machining.
+ 0.030
a Coat the thread and seat with engine oil Tolerance: 171 - 0.015 mm
+ 0.025
Unit: Nm {kgm} 171 - 0.008 mm
Procedure Target Range (Range of 10° above and below joint face
of cap)
1st step 275 {28} 245 – 304 {25 – 31}
a Surface roughness: Max. 12.5S
2nd step 559 {57} 530 – 588 {54 – 60} a Never cut the inside wall of the cylinder
3rd step 0 {0} Loosen completely block.
4th step 186 {19} 157 – 216 {16 – 22}
5th step 373 {38} 343 – 402 {35 – 41}
6th step 559 {57} 530 – 588 {54 – 60}
a Align the notches on the cylinder block and

cap.
3) Set the jig for mounting the cylinder block to
the table of a horizontal boring machine.
Install the cylinder block by mounting its hole
for the liner to the datum plug of the jig.
4) Center the arbor of the boring machine by
applying a dial gauge to the inside wall of the
two bearing caps which have the largest
pitch in the caps to be used again.
12V170-2 15-29
REPAIR AND REPLACEMENT OF PARTS REPLACING MAIN BEARING CAP
2. Correcting the width of the main bearing cap

(Modifying No. 7 main cap only)
1) Insert cast iron bushing [1] and pass arbor [2]
through.
2) Install facing tool [3] to the arbor.
3) Cut cap (1), until the cutting tool contacts the
cylinder block.
4) Cut the opposite side in the same way.
a Roughness of surface facing thrust bearing:
Max. 12.5S
a Never cut the cylinder block.
a Width of main bearing cap: Tolerance
15-30 12V170-2
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM BUSHING
REPLACING CAM BUSHING

a Before replacing the cam bushing, remove the
plug from the rear of the cylinder block.
1. Removing No. 1 and No. 7 bushings

• As shown in the figure, assemble push tool [3]
and collar [6] in push tool set J1, and grip J2,
then pull bushing (2) out of cylinder block (1) by
hitting the grip.
2. Removing No. 2 and No. 6 bushings

• Assemble push bar [1], push tool [3], guide [5],
and collar [6] in push tool set J1, then pull bush-
ing (2) out of cylinder block (1) while hitting the
bar.
3. Removing No. 3, No.4 and No. 5 bushings

• Assemble push bar [1], push tool [3], guide [5],
and collar [6] in push tool set J1, then pull bush-
ing (2) out of cylinder block (1) while hitting the
bar.
• After pulling out bushing, remove burrs and fins

from bushing mounting holes, and clean it.
4. Press-fitting No. 3, No. 4 and No. 5 bushings

• Assemble tool set J1 and bushing (2), then fit the
bushing until the end face of push tool [3] con-
tacts cylinder block (1).
a Align the oil hole on the bushing. (This must
be cared whenever fitting the bushings.)
15-32 12V170-2
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM BUSHING
5. Press-fitting No. 2. and No. 6 bushings

• Assemble tool set J1 and bushing (2), then fit the
bushing until the end face of push tool [3] con-
tacts the cylinder block.
a Align the oil hole on the bushing.
6. Press-fitting No. 1 and No. 7 bushings

• Assemble tool set J1, grip J2, and bushing (2),
then fit the bushing until the end face of push tool
[3] contacts the cylinder block.
a Align the oil hole on the bushing.
a Press-fit the plug to the rear of the cylinder block.
• Measure the inside diameter of the bushing with

inside gauge.
• Check the clearance between the bushing and
shaft. If the clearance is out of the allowable
range or the shaft does not pass through
smoothly, correct the inside of the bushing with a
reamer.
• If the inside of the bushing has been cor-
rected with a reamer, remove the all chips
from the oil holes and oil grooves.
a Inside diameter of cam bushing: 72 - 0 mm

+ 0.070
a Clearance of camshaft journal:

0.080 – 0.180 mm
12V170-2 15-33
REPAIR AND REPLACEMENT OF PARTS TESTING CRANKSHAFT
TESTING CRANKSHAFT
1. Crankshaft
2. Counterweight
3. Counterweight bolt
TESTING
Unit: mm
A. Cracks Use a magnetic flaw detector to check for cracks Replace

If the damage is
Scratches slight, correct with
Check for damage to the journal Seizure an oilstone or cor-
portion Discoloration rect by lapping.
Replace if there is
seizure
Damage to cap hole at front and rear end Correct
B. Damage
If you can feel fret-
Fretting on counterweight mounting face ting with finger nail,
replace.
If dowel pin is
Interference of sides of counterweight with cylinder block and bruise deformed, replace
on counterweight surface it.
Replace bolt.
C. Clogging of oil hole Check for clogging of oil hole Correct
15-34 12V170-2
REPAIR AND REPLACEMENT OF PARTS TESTING CRANKSHAFT
Unit: mm
Standard value Repair limit Replace thrust

D. End play of crank- bearing or correct
shaft 0.140 – 0.320 0.50 with oversize
Size Standard Tolerance Repair limit

size
STD 8.0 7.79 Replace thrust
E. Thickness of thrust
bearing 0.25 US 8.125 7.92 bearing or correct
-0.07 crankshaft with
0.50 US 8.25 -0.12 8.04 oversize
0.75 US 8.375 8.17
1.00 US 8.5 8.29
Size Standard Tolerance Repair limit

size
F. Outside diameter STD 124.00 123.98
of crankshaft pin 0.25 US 123.75 123.73
journal 0
0.50 US 123.50 -0.020 123.48 Correct with under-
size or replace
0.75 US 123.25 123.23
1.00 US 123.00 122.98
G. Out-of-roundness Standard value Repair limit
of crankshaft pin
journal 0 – 0.010 0.010
H. Clearance of Replace connect-
crankshaft pin jour- 0.08 – 0.155 0.20 ing rod bearing
nal
Standard
Size size Tolerance Repair limit
STD 162.00 161.98

I. Outside diameter 0.25US 161.75 161.73
of main journal 0
0.50US 161.50 161.48 Correct with under-
-0.020 size or replace
0.75US 161.25 161.23
1.00US 161.00 160.98
J. Out-of-roundness Standard value Repair limit
of main journal 0 – 0.010 0.010
K. Clearance of main 0.110 – 0.165 0.21 Replace main bear-
journal ing
L. Curvature of Total coaxiality of
crankshaft main journal Max. 0.09 0.09 Replace
(total runout of
indicator) Coaxiality of neigh- Max. 0.05 0.05
boring journals
12V170-2 15-35
CORRECTING SURFACE ROUGHNESS
REPAIR AND REPLACEMENT OF PARTS OF CRANKSHAFT JOURNAL PORTION
CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT

JOURNAL PORTION
If the roughness of the crankshaft journal portion
does not fulfill the standard, correct the surface
roughness.
1. Cleaning and blowing with air

Before polishing, brush the oil holes and blow
with air.
2. Correcting surface roughness of journal por-

tion
1) When correcting with special polishing
machine
Use a special polishing machine as shown in
the diagram on the right.
i) Set the rotating speed for the work at 40
– 50 rpm, and use No. 320 paper (belt
type). Perform dry polishing (do not use
honing oil), and move the paper once up
and down the whole journal width for
each joutnal. Move the paper smoothly
and do not stop at any point.
ii) Next, replace with No. 500 paper, coat
the jounal surface with honing oil, and
move the handle (1) of the machine to
the left and right by the amount of play to
give fine movement. Use this movement
to move once up and down the whole
width of the jounal. Move the paper
smoothly and do not stop at any point.
iii) Check the surface roughness, and if it is
not within the standard, polish again
once up and down the width of the
journol with No. 500 paper.
15-36 12V170-2
2) When using a work clamp jig for polishing

(When a special polishing machine is not
available)
Use a work clamp jig such as shown in the
diagram on the right.
i) Use a crankchaft grinding machine under
the following polishing conditions.
Paper: No. 800
Machining oil: Honing oil
Work speed: 40 rpm
ii) The polishing time for one journal is
approx. 6 minutes. Move the clamp the
amount of play of the clamp and joutnal
width (approx. 5 mm), and move up and
down the journal in the axial direction.
After completing the honing of one jour-
nal, replace the paper with new paper.
When honing the pin journal, it is safter
to carry out the work with the pin journal
is the rotation center.
3) Assembly of work clamp jig and method of

use
i) Cramping jig (plate (1) and handle (2))for
pin journal and main jounal is assembled
as shown in the diagram on the right. For
details of the component parts, see the
drawings on sepatate pages.
12V170-2 15-37
Dimension of paper for pin journal

ii) Cut out a piece of No. 800 paper with the
shape shown in the diagram on the right.
Unit: mm
Position For pin For main

journal journal
Dimension a 205 –
Dimension b 95 –
Dimension c – 255
Dimension d – 88
a Make cuts of 20mm length at approx.

10mm intervals.
a Cut out slit portion B. Dimension of paper for main journal
iii) Insert two pieces of paper (1) prepared in

Step ii) into upper and lower slits (2) of
the clamp jig, then fix in position c with
tape.
iv) Fit the journal in the clamp, and fix the
ends of the lever, with a ruber tube (3).
Bend D portion along a curve inside the
plate.
3. Measuring surface roughness

Standard for surface roughness
Journal surface, trust surface: Max. 0.8S
Using a surface roughness measuring tool,
check that the roughness is within the standard.
If measuring tool is not available, rub No. 1500
paper extremely lightely in the axial direction,and
use a 30-times magnifying galss to inspect the
pattern on the paper. If the horizontal lines can
be seen to be connected it is within the standard
value. If the lines canot be seen to be connected,
the roughness of the journal surface is not within
standard, so polish it again.
4. Cleaning after correcting surface roughness

After correcting the surface roughness, always
brush the oil hole and blow with air.
5. Check that there are no scratches or dents at the

journal portion and fillet R portion.
15-38 12V170-2
Clamp jig parts drawing (for pin journal)
1) Plate (2 are used for each jig) Unit: mm
2) Handle (2 are used for each jig) Unit: mm
12V170-2 15-39
Clamp jig parts drawing (for main journal)
1) Plate (2 are used for each jig) Unit: mm
2) Handle (2 are used for each jig) Unit: mm
15-40 12V170-2
REPAIR AND REPLACEMENT OF PARTS GRINDING CRANKSHAFT
GRINDING CRANKSHAFT
• If the crankshaft is worn or slightly seized or
damaged, machine it to any one of the following
thicknesses.
Undersize dimensions: 0.25, 0.50, 0.75, 1.00
mm
• If the crankshaft is bent or worn unevenly,
replace it instead of repairing it. (A lot of skill is
required to repair it.)
• Carefully finish section R of the fillet of the crank-
shaft, section r on the shoulder, and section R
facing the hole.
• Finishing dimensions of fillet

+ 0.5
R: 8.25 0 mm, Main journal portion
Surface roughness 3.2S
r: 8.5 ± 0.5mm,
Surface roughness 12.5S
• Finishing dimensions for main journal and pin

journal are show in diagram in the right.
Pin journal portion
12V170-2 15-41
• Roughness of outside surface of pin journal,

main journal: Max. 0.8S
a Tools and jigs required for machining

1) Magnetic flaw detector
2) Shore hardness tester
3) Etching kit (Acid corrosion inspection)
4) Crankshaft cutting machine
5) Crankshaft grinding machine
6) Roughness gauge
7) Ball gauge for measuring radii of fillet R
Min. 795-500-1140
Max.795-500-1150
1. Inspecting before machining

1) Visual inspection
Check for cracks, damage, discoloration
caused by seizure, and wear, and judge if it
is possible to correct by grinding.
2) Inspecting hardness of journal surface Hard-
ness of journal surface (Shore hardness)
Standard range: 69 – 81 Hs
Repair limit: 69 Hs
If it is below the repair limit, discard the part.
3) Inspection for torsion
0
Throw tolerance: 85 -0.10 mm (Half of stroke a)
Horizontal displacement (differance between
throw b of No.1 cylinder and rearmost cylin-
der) repair limit: 0.94 mm
Variation in throw b between cylinders: Less
than 0.20 mm
If it is outside the repair limit, discard the part.
2. Check during and after machining

1) Checking the round sections of fillet R
i) Cofirm that the round sections of fillet R
are smoothly connected to the shoulders
of journals,
ii) Using ball gauges [1] for measuring the
radii of the fillet R, confirm that each radii
of the fillet R is between minimum and
maximum limits.
15-42 12V170-2
Fillet R minimum radius:8.25 mm Critical area A of web of crankshaft

Fillet R maximum radius:8.75 mm
2) Checking the seized surfaces by etching

(acid corrosion)
• After grinding the jounals, confirm that there
is no seizures due to grinding by the etching
test.
• If any seized part is found, grind the journal
another 0.02 mm to apply the next under-
size.
• After etching the journals, neutralize and
wash the checked surface, then apply oil.
3) Magetic flaw detecting
• Before using the repaired crankshaft, confirm
that there are no cracks on it by magneric
flaw detection.
• Check the fillets of journals which are put in
the critical area A of each web of the crank-
shaft especially carefully.
• After inspecting with a magnetic flaw detec-
tor, always demagnetize the crankshaft.
4) Measuring the bend (Alignment)
• Confirm that the bend of ground crankshaft is
within standard by measuaring.
• Measure the bend (alignment) at the follow-
ing four places.
i) Overall length alignment:
Permissible range Max. 0.09 mm
ii) Adjoining alignment:
iii) Forward end alignment:
iv) Rear end alignment:
Permissible range Max. 0.025mm
3. Grinding the main journals

a Grinde all the main journals to the same
undersize.
a When grinding the main journals, count in
the finishing allowance for grinding 0.007 –
0.008 mm
12V170-2 15-43
• Undersizes of main journal

Unit: mm
Size Basic dimension Tolerance
S.T.D 162.000
0.25 US 161.750
0.50 US 161.500 0
-0.020
0.75 US 161.250
1.00 US 161.000
• Roundness, cylindricality of main journal (T.I.R)
and surface roughness
Permissible range: Max. 0.010 mm
Surface roughness: 0.8S
4. Grinding the thrust bearing surface
a It is not always required to grind the front and

rear thrust bearing surfaces to the same
undersize.
a If the thrust bearing surfaces have been
ground, confirm that the end play of the
crankshaft is within the permissible range
(For detai ls, see DISASS EMBLY AND
ASSEMBLY).
• Undersizes of thrust bearing surfaces
Unit: mm
Rear thrust bearing surface
S.T.D 0.25 O.S 0.50 O.S
Basic + 0.050 + 0.050 + 0.050
77 0 77.250 0 77.500
Front thrust bearing surface
0
dimension
S.T.D
Repair
limit 77.050 77.310 77.560
Basic + 0.050 + 0.050 + 0.050
77.250 0 77.500 0 77.750 0
0.25 dimension
O.S Repair
limit 77.310 77.560 77.810
Basic + 0.050 + 0.050 + 0.050
77.500 0 77.750 0 78.000 0
0.50 dimension
O.S Repair
limit 77.560 77.810 78.050
• Squareness of thrust bearing surface (T.I.R)
Limit: 0.02 mm
15-44 12V170-2
5. Grinding pin journals

a Grind all the pin journals to the same under-
size.
a When grinding, count in finishing allowance
for grinding 0.007 to 0.008 mm.
• Undersizes of pin journal

Unit: mm
Size Basic dimension Tolerance
S.T.D 124.000
0.25 US 123.750
0.50 US 123.500 0
-0.022
0.75 US 123.250
1.00 US 123.000
• Roundness and cylindricality of pin journal
(T.I.R) and surface roughness
Permissible range: Max. 0.010 mm
Rpair limit: 0.010 mm
Surface roughness: 0.8S
6. Correcting the width of the main journal and

pin journal by grinding
• When correcting the worn surfaces C and D of
the main journals A and pin journals B, limit the
grinding thickness to the minimum.
a: Worn surface thickness
• Width of crank pin journal
If cutting one side only:
Standard: 128 + 0.063
0 mm
Squareness of thrust bearing surface (T.I.R)
Limit: 0.02 mm
12V170-2 15-45
7. Correcting the grindstone

• Dress the grindstone each time one journal is
ground.
• Grindstone dresser
Tip angle a: 75 ± 1°
Radius of edge b: 0.38 ± 0.25 mm
At the edge of the dresser, a diamond for indus-
trial use must be embedded.
• Adjust the machine for correcting the grindstone,

and correct the edge of the grindstone to the
radius of the fillet.
• When checking and correcting the grindstone
edge, grind a wood bar for trial and use ball
gauges.
8. Preventing seizure caused by grinding

1) Use the plunge grinding method.
2) Use the overall width of the grindstone.
Do not grind the bosses if possible.
3) Apply sufficient cooling oil.
4) Set the circumferential speed of the grind-
stone to 2,000 m/min when the speed of
crankshaft is 40 rpm.
9. Surface finishing
• Standard surface roughness
Journal : 0.8S
Thrust bearing, fillet : Max. 1.6S
Tapered end: 1 – 2 S
Bosses of pin and main journal: Max. 3.2S
• Finishing allowance for grinding:
0.007 – 0.008 mm
10. Treatment after grinding

• Confirm that each dimension is within specifica-
tion.
• Carefully wash each section and apply oil to it.
• When storing the crankshaft for a long time, sup-
port it at three points or hang it vertically.
15-46 12V170-2
11. Balancing (for reference)

(Do not perform any repair which will have an
adverse effect on the balance of the crank shaft.)
• Limit of unbalance: 110 gcm
• Limits for reading the balance correctly
Bend of crankshaft: 0.05 mm (T.I.R)
Speed of crankshaft: Max. 325 rpm
• Balance the crankshaft with the crank gear
installed or install a weight equivalent to the
weight of the gear fixing key to the keyway.
• To balance the crankshaft, make a hole on the
counter weight with a drill or grind it.
Limit amount of counterweight to be removed:
56 g
Drill holes direction: Radial direction
Number of holes: Max. 6
Diameter of hole: Max. 25 mm
Depth of hole: Max. 30 mm
Center of hole:
Must be aligned with counterweight.
(Misalignment: Max. 0.5 mm)
Distance among holes:
Must be 12° or more to center.
12V170-2 15-47
12. Procedure for measuring curvature of crank-

shaft and outside diameter of journal
1) When measuring the curvature, use No. 1
and No. 7 journals as the datum point, put
the dial gauge in contact with the journal and
set the dial to 0 at the peak.
Then rotate one turn and read the minimum
and maximum values.
2) Measure the outside diameter of the main

journal in the XY direction (No. 1 – 2) at 2
places, and the outside diameter of the pin
journal in the XY direction (No. 1 – 2) at 2
places with a micrometer or air micrometer.
15-48 12V170-2
13. Procedure for disassembly and assembly of

counterweight
Tighten the bolts in the order given below. (Plas-
tic range rotating angle method)
1) Coat the bolt thread and seat, and both faces
of the hard washer completely with clean
engine oil (EO30-CD)
2) Tighten the 2 bolts of the counterweight in
turn to 265 ± 20 Nm {27 ± 2 kgm}. After
tightening the second bolt, check that the
torque of the bolt tightened first is also within
the tolerance.
3) Put match marks A on the bolt head and
counter weight with paint or felt pen, then
+ 30°
turn the angle a (90° 0 ) to tighten in turn.
4) When tightening the bolts again, use new
bolts, and dispose of the old bolts.
a The crankshaft and counterweight are bal-

anced as an assembly, so when assembling,
always assemble so that the counterweight
is installed in its original position.
To do this, there are numbers (1 – 8)
stamped on the outside circumference of the
counterweight, so assemble in order from 1
to 8 starting from the front.
Portion B: There is an "R" mark at the
end face at the rear.
Portion C: There is a "1" mark on the
outside surface and or end
face.
a Be sure to perform i) and ii).
12V170-2 15-49
REPAIR AND REPLACEMENT OF PARTS TESTING AND INSPECTING CONNECTING ROD
TESTING AND INSPECTING CONNECTING ROD
1. Bolt
2. Washer
3. Cap
4. Dowel pin
5. Connecting rod
6. Bushing

Unit: mm
A. Cracks Check for cracks with a color check or magnetic flaw detector Replace
Check for curvature or twisting

B. Curvature, twisting a: Twisting 0.25 Replace
b: Curvature 0.10
Standard Tolerance Standard Clearance Replace bush-

C. Clearance between size clearance limit ing, roughness of
connecting rod bush- Shaft Hole inside surface of
ing and piston pin 0 +0.068 bushing: Max.
68 0.050 – 0.074 0.11 2.4S
- 0.006 - 0.050
• Inside diameter of hole at big Standard size Tolerance

end
• Without bearing +0.029
131 0
• Roughness of inside surface of
hole at big end: Max. 6.3S
D. Inside diameter of hole • Clearance between crankshaft
at big end of connect- journal (with bearing) Standard Clearance Replace
ing rod clearance limit
0.080 – 0.155 0.20
Even if each part is within the repair
limit, if it is above the clearance limit,
replace the part (bearing, etc.)

S.T.D 3.500 3.41
0.125 U.S 3.625 3.54
E. Thickness of bearing -0.040
0.250 U.S 3.725 -0.053 3.66
0.375 U.S 3.875 3.79
0.500 U.S 4.000 3.90
15-50 12V170-2
REPAIR AND REPLACEMENT OF PARTS TESTING AND INSPECTING CONNECTING ROD
Unit: mm
F. Scratches on inside Replace, replace

surface of bearing, sei- Check for scratches or seizure connecting rod
zure also
G. Distance between Standard size Tolerance

holes at big end and 0 Replace
small end 340
-0.05
• Check for scratches B in horizontal Replace

direction in area A
• Check for grinder grain in horizontal
H. Scratches at I shape direction in area A
prttion of connecting
rod (dents)
• Check for scraches Replace if there

are any dents,
regardless of
size
Check for fretting of mating surface Replace if

I. Fretting of mating sur- fingernail
face of cap • Roughness of mating surface: Max. 6.3 S catches in
• Contact of mating sutface: Min. 70% fretting
Correct with oil-

Scuffing of cap bolt seat surface
stone
J. Scuffing of bolt seat
surface Scuffing of bolt seat surface Replace bolt
Scuffing of washer surface Replace washer
K. Deformation of dowel • Check for deformation of dowel pin

Replace
pin • Check for deformation of dowel pin hole
• Check for cracks, damage to bolt thread

L. Damage to bolt Replace bolt
• Check for curvature of bolt
a If it is impossible to measure all the items in this judgment standard (in particular, the localized wear of big
internal circumference) after machining and rebuilding the connecting rod, do not carry out any rebuilding.
The reason for this is that it is impossible to confirm the precision after machining and rebuilding the hole at
the connecting rod big end.
a When deciding on whether to reuse or discard the connecting rod, if honing grain can be observed on hole
surface at big end, measurement of big end hole surface roughness and wave is unnecessary.
12V170-2 15-51
REPAIR AND REPLACEMENT OF PARTS REPLACING CONNECTING ROD SMALL END BUSHING
REPLACING CONNECTING ROD SMALL END BUSHING

1. Removal of connecting rod bushing
1) Set the connecting rod (2) on tool K3.
2) Using tools K1 and K3, remove the connect-
ing rod bushing (1) with a press.
a After removing the bushing, remove any
burrs or dirt, and clean the mounting hole of
the bushing.
2. Press fitting connecting rod bushing

1) Set the connecting rod (2) on tool K3.
2) Assemble the connecting rod bushing (1) to
tool K1, then set tool K2 and secure with tool
K4 so that it does not move.
a Align the connecting rod bushing oil hole and
the connecting rod oil hole.
3) Push tool K1 with a press and press fit the
connecting rod bushing (1).
• The bushing is a semi-finished product, and the
inside diameter is small, so the piston pin will not
fit.
After press fitting the bushing, machine the
inside diameter of the bushing with a reamer or
honing machine.
a After machining, remove all the metal parti-
cles from the oil hole and oil groove.
a Surface roughness of inside diameter after
machining bushing: Within 3.2 S
15-52 12V170-2
REPAIR AND REPLACEMENT OF PARTS REPLACING CAMSHAFT GEAR
REPLACING CAMSHAFT GEAR

1. Removal of gear
Set the camshaft assembly on the press stand,
then push the camshaft to remove the gear
k When setting the camshaft assembly on the

press stand, be careful not to get your fingers
caught between the press stand and the gear.
2. Press fitting gear

1) Check the gear mounting surface, key groove,
and flange surface, and if there are any
scratches, correct them with an oilstone.
2) Knock a new key into the key groove of the
shaft.
3) Assemble the thrust plate.
4) Heat the gear for the specified time at the
specified shrink-fitting temperature.
a Gear shrink-fitting temperature: 240 – 260 °C
Heating time: Min. 45 minutes
5) Put the timing mark of the gear on the out-
side, then use a hitting tool to press fit until
the side face of the gear is in close contact
with the camshaft flange.
a Knock in quickly before the gear becomes
cool.
12V170-2 15-53
REPAIR AND REPLACEMENT OF PARTS REPLACING FLYWHEEL RING GEAR
REPLACING FLYWHEEL RING GEAR

k Be careful not to let the flywheel fall and injure
you.
1. Removal of gear
• Make a scratch in the surface at the root of the
gear teeth with a grinder, then split with a chisel
to remove.
k Be careful when handling the grinder and

chisel.
2. Press fitting gear

1) Check the gear mounting surface, and if
there are any scratches, correct them with an
oilstone.
2) Heat the gear for the specified time at the
specified shrink-fitting temperature.
a Gear shrink-fitting temperature: 295 – 305 °C
Heating time: Min. 45 minutes
3) Set the chamfered face of the gear facing the
flywheel, and press fit until the side face of
the gear is in close contact with the flywheel.
15-54 12V170-2

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SEBM036601

11 STRUCTURE AND FUNCTION ........................................................................ 11-1

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

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

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

15 REPAIR AND REPLACEMENT OF PARTS ........................................ 15-1

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE