Komatsu 170-3 Series Shop Manual Download Page 22 | Manualshive

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Komatsu 170-3 Series Shop Manual Download Page 22

FOREWORD

CONVERSION TABLE

00-20

kg/cm

2

to lb/in

2

1kg/cm

2

= 14.2233 lb/in

2

0

1

2

3

4

5

6

7

8

9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

0

142.2

284.5

426.7

568.9

711.2

853.4

995.6

1138

1280

1422

1565

1707

1849

1991

2134

2276

2418

2560

2702

2845

2987

3129

3271

3414

14.2

156.5

298.7

440.9

583.2

725.4

867.6

1010

1152

1294

1437

1579

1721

1863

2005

2148

2290

2432

2574

2717

2859

3001

3143

3286

3428

28.4

170.7

312.9

455.1

597.4

739.6

881.8

1024

1166

1309

1451

1593

1735

1877

2020

2162

2304

2446

2589

2731

2873

3015

3158

3300

3442

42.7

184.9

327.1

469.4

611.6

753.8

896.1

1038

1181

1323

1465

1607

1749

1892

2034

2176

2318

2460

2603

2745

2887

3030

3172

3314

3456

56.9

199.1

341.4

483.6

625.8

768.1

910.3

1053

1195

1337

1479

1621

1764

1906

2048

2190

2333

2475

2617

2759

2901

3044

3186

3328

3470

71.1

213.4

355.6

497.8

640.1

782.3

924.5

1067

1209

1351

1493

1636

1778

1920

2062

2205

2347

2489

2631

2773

2916

3058

3200

3343

3485

85.3

227.6

369.8

512.0

654.3

796.5

938.7

1081

1223

1365

1508

1650

1792

1934

2077

2219

2361

2503

2646

2788

2930

3072

3214

3357

3499

99.6

241.8

384.0

526.3

668.5

810.7

953.0

1095

1237

1380

1522

1664

1806

1949

2091

2233

2375

2518

2660

2802

2944

3086

3229

3371

3513

113.8

256.0

398.3

540.5

682.7

825.0

967.2

1109

1252

1394

1536

1678

1821

1963

2105

2247

2389

2532

2674

2816

2958

3101

3243

3385

3527

128.0

270.2

412.5

554.7

696.9

839.2

981.4

1124

1266

1408

1550

1693

1835

1977

2119

2262

2404

2546

2688

2830

2973

3115

3257

3399

3542

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Summary of Contents for 170-3 Series

Page 1: ...00 1 SEBM023412 2008 All Rights Reserved Printed in Japan 10 08 02 12 ProCarManuals com...

Page 2: ...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 7...

Page 3: ...11 28 Mark Page Revision number 11 29 11 30 11 31 11 32 11 33 11 34 11 35 11 36 11 37 11 38 11 39 11 40 11 41 11 43 11 44 11 45 2 11 46 2 11 47 2 11 48 9 11 49 9 11 50 2 11 51 9 11 52 6 11 53 9 11 53...

Page 4: ...1 12 366 1 12 367 1 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 13 9 13 10 13 11 13 12 13 13 13 14 Mark Page Revision number 13 15 13 16 13 17 13 18 13 19 13 20 13 21 13 22 13 23 13 24 13 25 13 26 2 13 2...

Page 5: ...shield cap and other clothes suited for welding work 4 When carrying out any operation with two or more workers always agree on the operating procedure before starting Always inform your fellow worke...

Page 6: ...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 c...

Page 7: ...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 adj...

Page 8: ...Additional pages Additional pages are indicated by a hyphen and number after the page number File as in the example Example 10 4 10 4 1 10 4 2 10 5 REVISED EDITION MARK When a manual is revised an edi...

Page 9: ...h one rope alone but sling with two or more ropes symmetrically wound onto the load k Slinging with one rope may cause turning of the load during hoisting untwisting of the rope or slipping of the rop...

Page 10: ...rom 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...

Page 11: ...sliding pre vention ring 1 contacts contact surface a of the hexagonal portion at the male end 2 Hold in the condition in Step 1 and push until cover 3 contacts contact surface a of the hexagonal por...

Page 12: ...1735 790 129 9140 50 g Polyethylene container Quick hardening type adhesive Cure time within 5 sec to 3 min Used mainly for adhesion of metals rubbers plastics and woods Aron alpha 201 790 129 9130 2...

Page 13: ...for cab glass Used as primer for cab side Using limit 4 months SUNSTAR GLASSPRIMER 580 SUPER 20 ml Glass container Used as primer for glass side Using limit 4 months SUNSTAR PAINT PRIMER 435 95 22M 5...

Page 14: ...59 74 98 123 153 190 1 2 1 5 2 8 3 5 6 7 5 10 12 5 15 5 19 5 16 18 20 22 24 24 27 30 32 36 235 285 320 400 455 565 610 765 785 980 23 5 29 5 33 41 46 5 58 62 5 78 80 100 27 30 33 36 39 41 46 50 55 60...

Page 15: ...idth across flat Tightening torque Nm kgm mm mm Range Target 02 03 04 05 06 10 12 14 14 20 24 33 42 Varies depending on type of connector 35 63 3 5 6 5 84 132 8 5 13 5 128 186 13 0 19 0 363 480 37 0 4...

Page 16: ...ghtening torque mm Nm kgm 6 8 10 12 14 8 2 10 2 12 2 24 4 36 5 0 81 0 20 1 02 0 20 1 22 0 20 2 45 0 41 3 67 0 51 Thread diameter Tightening torque inch Nm kgm 1 16 1 8 1 4 3 8 1 2 3 4 1 3 1 8 2 12 2 1...

Page 17: ...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 Priori ty Circuits Classi...

Page 18: ...e 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 16...

Page 19: ...315 0 709 1 102 1 496 1 890 2 283 2 677 3 071 3 465 3 858 0 354 0 748 1 142 1 536 1 929 2 323 2 717 3 110 3 504 3 898 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0 22 05 44 09 66 14 88 18 110 23...

Page 20: ...1 22 983 25 625 2 113 4 755 7 397 10 039 12 680 15 322 17 964 20 605 23 247 25 889 2 378 5 019 7 661 10 303 12 944 15 586 18 228 20 870 23 511 26 153 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0...

Page 21: ...3 1106 6 1179 0 1251 3 1323 6 1396 0 28 9 101 3 173 6 245 9 318 3 390 6 462 9 535 2 607 6 679 9 752 2 824 6 896 9 969 2 1041 5 1113 9 1186 2 1258 5 1330 9 1403 2 36 2 108 5 180 8 253 2 325 5 397 8 47...

Page 22: ...176 2318 2460 2603 2745 2887 3030 3172 3314 3456 56 9 199 1 341 4 483 6 625 8 768 1 910 3 1053 1195 1337 1479 1621 1764 1906 2048 2190 2333 2475 2617 2759 2901 3044 3186 3328 3470 71 1 213 4 355 6 497...

Page 23: ...9 4 8 9 8 3 7 8 7 2 6 7 6 1 5 6 5 0 4 4 3 9 3 3 2 8 2 2 1 7 1 1 0 6 0 0 6 1 1 1 7 2 2 2 8 3 3 3 9 4 4 5 0 5 6 6 1 6 7 7 2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36...

Page 24: ...asuring 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 mmH2...

Page 25: ...170 3 SERIES 01 1 Applicable machine 01 2 Specifications 01 4 Overall drawing 01 5 3 Weight table 01 16 Engine performance curve 01 17 01 GENERAL 11 ProCarManuals com...

Page 26: ...D375A 5 Bulldozer SAA6D170E 3 PC1250 7 WA600 3 WA700 3 WD600 3 HD465 7 HD605 7 Generator Hydraulic excavator Wheel loader Wheel loader Wheel dozer Dump truck Dump truck Generator SAA6D170E2 3 DCA 800S...

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Page 28: ...Maximum torque Nm kgm rpm 2 650 270 1 300 Net 2 120 216 1 400 Net High idling speed rpm 2 000 40 2 170 30 Low idling speed rpm 750 50 700 25 Minimum fuel consumption ratio g kWh g HPh 224 167 221 165...

Page 29: ...725 25 700 25 900 25 750 50 212 157 222 163 218 160 211 155 3 100 2 900 2 870 2 740 Trochoid gear pump KOMATSU HPI system Electronic control type 67 56 64 60 67 56 67 56 Engine side 47 Engine side 47...

Page 30: ...1 800 60Hz Net 752 1 008 1 800 50Hz Net Maximum torque Nm kgm rpm High idling speed rpm Max 1 575 50Hz Max 1 890 60Hz Max 1 890 60Hz Low idling speed rpm 800 50 875 25 Minimum fuel consumption ratio...

Page 31: ...Net Max 1 575 Max 1 575 800 100 800 100 Rated output 203 151 50Hz Rated output 203 151 50Hz 2 565 2 565 Trochoid gear pump KOMATSU HPI system Electronic control type 141 135 141 135 Engine side 47 Eng...

Page 32: ...S GENERAL OVERALL DRAWING SA6D170E 3 VIEW FROM LEFT SIDE D375A 5 a Center of crankshaft b Rear face of flywheel housing a The actual engine may be different because of modifications OVERALL DRAWING 11...

Page 33: ...170 3 SERIES 01 5 4 GENERAL SA6D170E 3 VIEW FROM RIGHT SIDE D375A 5 a The actual engine may be different because of modifications OVERALL DRAWING 11 ProCarManuals com...

Page 34: ...170 3 SERIES GENERAL SA6D170E 3 VIEW FROM FRONT D375A 5 a Center of crankshaft c Center of cylinder liner a The actual engine may be different because of modifications OVERALL DRAWING 11 ProCarManual...

Page 35: ...SERIES 01 5 6 GENERAL SA6D170E 3 VIEW FROM REAR D375A 5 a Center of crankshaft c Center of cylinder liner a The actual engine may be different because of modifications OVERALL DRAWING 11 ProCarManual...

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Page 37: ...3 SERIES GENERAL SAA6D170E 3 VIEW FROM LEFT SIDE WA600 3 OVERALL DRAWING a Center of crankshaft b Rear face of flywheel housing a The actual engine may be different because of modifications 9 ProCarMa...

Page 38: ...ES 01 7 GENERAL SAA6D170E 3 VIEW FROM RIGHT SIDE WA600 3 a Center of crankshaft b Rear face of flywheel housing OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCarM...

Page 39: ...170 3 SERIES GENERAL SAA6D170E 3 VIEW FROM FRONT WA600 3 a Center of crankshaft b Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCarManual...

Page 40: ...SERIES 01 9 GENERAL SAA6D170E 3 VIEW FROM REAR WA600 3 a Center of crankshaft b Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCarManuals...

Page 41: ...01 10 170 3 SERIES GENERAL SAA6D170E 3 VIEW FROM TOP WA600 3 a Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCarManuals com...

Page 42: ...S 01 11 GENERAL SAA6D170E 3 VIEW FROM LEFT SIDE GENERATOR a Center of crankshaft b Rear face of flywheel housing OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCar...

Page 43: ...SERIES GENERAL SAA6D170E 3 VIEW FROM RIGHT SIDE GENERATOR a Center of crankshaft b Rear face of flywheel housing OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCar...

Page 44: ...ERIES 01 13 GENERAL SAA6D170E 3 VIEW FROM FRONT GENERATOR a Center of crankshaft b Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCarManua...

Page 45: ...170 3 SERIES GENERAL SAA6D170E 3 VIEW FROM REAR GENERATOR a Center of crankshaft b Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCarManua...

Page 46: ...170 3 SERIES 01 15 GENERAL SAA6D170E 3 VIEW FROM TOP GENERATOR a Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCarManuals com...

Page 47: ...ENERAL SAA6D170E2 3 VIEW FROM LEFT SIDE DCA 800SSK2 DENYO GENERATOR a Center of crankshaft b Rear face of flywheel housing OVERALL DRAWING a The actual engine may be different because of modifications...

Page 48: ...ENERAL SAA6D170E2 3 VIEW FROM RIGHT SIDE DCA 800SSK2 DENYO GENERATOR a Center of crankshaft b Rear face of flywheel housing OVERALL DRAWING a The actual engine may be different because of modification...

Page 49: ...IES GENERAL SAA6D170E2 3 VIEW FROM FRONT DCA 800SSK2 DENYO GENERATOR a Center of crankshaft b Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10...

Page 50: ...5 4 GENERAL SAA6D170E2 3 VIEW FROM REAR DCA 800SSK2 DENYO GENERATOR a Center of crankshaft b Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10 P...

Page 51: ...5 170 3 SERIES GENERAL SAA6D170E2 3 VIEW FROM TOP DCA 800SSK2 DENYO GENERATOR a Center of cylinder liner OVERALL DRAWING a The actual engine may be different because of modifications 10 ProCarManuals...

Page 52: ...l pan 45 105 1 66 6 Flywheel assembly Flywheel Ring gear 34 WA600 3 141 7 Flywheel housing 93 WA600 3 134 8 Crankshaft assembly Crankshaft crank gear 2 pcs 264 264 264 9 Camshaft assembly Camshaft cam...

Page 53: ...NE PERFORMANCE CURVE Engine Engine serial No Applicable machine Page SA6D170E 3 D375A 5 01 18 SAA6D170E 3 WA600 3 01 19 WA700 3 01 19 1 WD600 3 01 20 PC1250 7 01 21 HD465 7 HD605 7 01 22 ENGINE PERFOR...

Page 54: ...01 18 170 3 SERIES GENERAL SA6D170E 3 D375A 5 Flywheel horsepower 391 kW 524 HP 1 800 rpm Net Maximum torque 2 650 Nm 270 kgm 1 300 rpm Net ENGINE PERFORMANCE CURVE 3 ProCarManuals com...

Page 55: ...170 3 SERIES 01 19 GENERAL SAA6D170E 3 WA600 3 Flywheel horsepower 337 kW 452 HP 2 000 rpm Net Maximum torque 2 120 Nm 216 kgm 1 400 rpm Net ENGINE PERFORMANCE CURVE ProCarManuals com...

Page 56: ...01 19 1 170 3 SERIES GENERAL ENGINE PERFORMANCE CURVE SAA6D170E 3 WA700 3 Flywheel horsepower 478 kW 641 HP 2 000 rpm Net Maximum torque 2 806 Nm 286 kgm 1 400 rpm Net 9 ProCarManuals com...

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Page 58: ...01 20 170 3 SERIES GENERAL SAA6D170E 3 WD600 3 Flywheel horsepower 370 kW 497 HP 2 000 rpm Net Maximum torque 2 391 Nm 244 kgm 1 400 rpm Net ENGINE PERFORMANCE CURVE 9 ProCarManuals com...

Page 59: ...170 3 SERIES 01 21 GENERAL SAA6D170E 3 PC1250 7 Flywheel horsepower 485 kW 651 HP 1 800 rpm Net Maximum torque 2 913 Nm 297 kgm 1 300 rpm Net ENGINE PERFORMANCE CURVE 9 ProCarManuals com...

Page 60: ...01 22 170 3 SERIES GENERAL SAA6D170E 3 HD465 7 HD605 7 Flywheel horsepower 533 kW 715 HP 2 000 rpm Net Maximum torque 3 207 Nm 327 kgm 1 400 rpm Net ENGINE PERFORMANCE CURVE 9 ProCarManuals com...

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Page 62: ...the dust is separated by the centrif ugal force of guide vane 3 More than 99 9 of the remaining dust is removed by primary ele ment 4 and the cleaned air then passes through safety element 5 and outle...

Page 63: ...OMA CLONE MULTICYCLONE TYPE 1 Inner element 2 Outer element 3 Check valve 4 Tube 34 pcs 5 Precleaner 6 Body of air cleaner A Air inlet B To turbocharger sucked air C To muffler dust 9 a The actual eng...

Page 64: ...poke type with evacuator valve Radial seal type 11 a The actual engine may be different because of modifications a The shape is subject to machine models 1 Inner 2 Outer 3 Check vane 4 Primary elemen...

Page 65: ...ng 5 Turbine impeller 6 Seal ring 7 Journal bearing 8 Turbing shaft 9 Thrust bearing 10 Blower impeller A Air intake B Air output C Exhaust inlet port D Exhaust outlet port E Oil inlet port F Oil outl...

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Page 68: ...5 Shroud 6 Turbine housing 7 Turbine impeller 8 Seal ring 9 Metal 10 Thrust metal 11 Snap ring 12 Blower impeller A Intake inlet B Intake outlet C Exhaust inlet D Exhaust outlet E Oil inlet F Oil out...

Page 69: ...hroud 6 Turbine housing 7 Turbine impeller 8 Seal ring 9 Metal 10 Thrust metal 11 Seal ring 12 Blower impeller A Intake inlet B Intake outlet C Exhaust inlet D Exhaust outlet E Oil inlet F Oil outlet...

Page 70: ...00 3 AFTERCOOLER a The specifications are subject to change according to modification etc a The shape is subject to machine models a The illustration shows the engine for WA600 3 1 Tank 2 Side support...

Page 71: ...R COOLED TYPE SAA6D170E 3 Generator a The specifications are subject to change according to modification etc a The shape is subject to machine models 1 Tank 2 Side support 3 Tube 4 Fin a Intake air po...

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Page 83: ...bearings Journal surface cam surface Induction hardening Valve timing D375A 5 WA600 3 WA700 3 WD600 3 PC1250 7 VALVE SYSTEM No 1 cylinder injector Injector plunger timing Valve timing HD465 7 generato...

Page 84: ...r valve 5 Oil cooler 6 Thermo valve 7 Oil filter 15 Auxiliary equipment drive gear front side 16 Oil pressure gauge 17 Turbocharger W Cooling water 8 Safety valve 9 Main gallery 10 Crankshaft 11 Camsh...

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Page 107: ...75A 5 FAN TENSION PULLEY 1 Tension shaft 2 Spring 3 Roller bearing 4 Tension bracket 5 Spacer 6 Tension pulley outside diameter 150 mm 7 Ball bearing 8 Oil seal 9 Grease nipple a The actual engine may...

Page 108: ...tment bolt 5 Tension pulley bracket 6 Fan pulley 7 Fan a Direction of wind Model Fan pulley Crankshaft pulley Tension pulley Direction of wind from fan WA600 3 WD600 3 352 230 150 Blows out WA700 3 38...

Page 109: ...pring 3 Roller bearing 4 Tension bracket 5 Spacer 6 Tension pulley outside diameter 150 mm 7 Ball bearing 8 Oil seal 9 Grease nipple 10 Grease nipple 11 Adjustment bolt a The actual engine may be diff...

Page 110: ...D375A 5 ALTERNATOR a The actual engine may be different because of modifications 1 Drive pulley pulley outside diameter 200 mm 2 Alternator pulley pulley outside diameter 85 mm 3 Alternator 4 Alternat...

Page 111: ...pulley outside diameter 182 mm 2 Alternator pulley pulley outside diameter 85 mm 3 Alternator 4 Alternator mounting bolt 5 Adjustment bolt 6 Locknut 7 V belt 9 a The actual engine may be different bec...

Page 112: ...r mm Weight kg SA6D170E 3 D375A 5 If equipped Sawafuji Denki open type 24V 60A 85 11 a The actual engine may be different because of modifications ALTERNATOR 6 1 Alternator 2 Alternator pulley 3 Termi...

Page 113: ...nal R Engine Machine model Type Specification Pulley diameter mm Weight kg SA6D170E 3 D375A 5 If equipped Sawafuji Denki open type 24V 75A 85 12 5 SAA6D170E 3 WA600 3 WA700 3 WD600 3 Sawafuji Denki op...

Page 114: ...on Pulley diameter mm Weight kg SAA6D170E 3 PC1250 7 Nikko Denki Open type brushless 24V 50A 85 11 HD465 7 Nikko Denki Open type brushless 24V 50A 85 11 HD605 7 Nikko Denki Open type brushless 24V 50A...

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Page 116: ...ector type SA6D170E 3 D375A 5 Nikko Denki water proof oil proof type 27V 7 5kWx2 11 18 G D SAA6D170E 3 WA600 3 WA700 3 Nikko Denki water proof oil proof type 27V 7 5kWx2 11 18 G C WD600 3 HD465 7 HD60...

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Page 120: ...EATER SA6D170E 3 1 Heater assembly 2 Body 3 Terrminal SPECIFICATIONS Heater type Coil heater Rated voltage 22V DC Rated current 36 A Capacity 0 8 kW 0 4 kW x 2 a The actual engine may be different bec...

Page 121: ...R SAA6D170E 3 6 a The actual engine may be different because of modifications STARTING AID 1 Terminal 2 Body 3 Heater coil 4 Connection diagram SPECIFICATIONS Heater type Electrical intake air heater...

Page 122: ...11 Measuring blow by pressure 12 12 Measuring oil pressure 12 13 Handling equipment in fuel circuit 12 13 Measuring fuel circuit pressure 12 14 Visual inspection of return fuel 12 15 Bleeding air from...

Page 123: ...ax 4 5 Max 1 0 Max 0 5 5 5 2 0 1 5 Valve clearance Intake valve Exhaust valve mm mm 0 32 0 62 Engine proper Compression pressure Oil temperature 40 60 C engine speed 210 250 rpm MPa kg cm2 Min 2 9 Min...

Page 124: ...00 Min 650 7 5 762 113 3 850 96 0 720 700 Max 4 5 Max 1 0 Max 0 5 5 5 2 0 1 5 Max 4 5 Max 1 0 Max 0 5 5 5 2 0 1 5 Max 1 0 Max 0 8 2 0 2 0 0 32 0 62 0 32 0 62 0 32 0 62 Min 2 9 Min 30 2 1 21 Min 2 9 Mi...

Page 125: ...output Bosch index Max 1 0 Max 0 8 2 0 2 0 Valve clearance Intake valve Exhaust valve mm mm 0 32 0 62 Engine proper Compression pressure Oil temperature 40 60 C engine speed 210 250 rpm MPa kg cm2 Mi...

Page 126: ...in 106 7 Min 800 Min 690 7 5 762 113 3 850 96 0 720 750 Max 4 5 Max 1 0 Max 0 5 5 5 2 0 1 5 Max 1 0 Max 0 8 2 0 2 0 Max 1 0 Max 0 8 2 0 2 0 0 32 0 62 0 32 0 62 0 32 0 62 Min 2 9 Min 30 2 1 21 Min 2 9...

Page 127: ...Bosch index Max 1 0 Max 0 8 2 0 2 0 Valve clearance Intake valve Exhaust valve mm mm 0 32 0 62 Engine proper Compression pressure Oil temperature 40 60 C engine speed 210 250 rpm MPa kg cm2 Min 2 9 M...

Page 128: ...d temperature sensor For generator IMTS Measurement of resistance If the condition is within the range shown in the table below it is normal 1 Turn starting switch OFF 2 Disconnect connec tor Pin Heig...

Page 129: ...the range shown in the table below it is normal 1 Turn starting switch OFF 2 Disconnect connec tor Fuel pump pressure sensor PMPR Measurement of voltage If the condition is within the range shown in t...

Page 130: ...table below it is normal 1 Turn starting switch OFF 2 Disconnect connec tor Fuel rail actuator RAIL Measurement of resistance If the condition is within the range shown in the table below it is normal...

Page 131: ...ng for injector D Heat gun surface temperature gauge 795 799 5510 For carry out troubleshooting of injector Exhaust color E Handy smoke tester 799 201 9000 Smoke meter Commercially available Compressi...

Page 132: ...ir temperature sensor For coolant temperature sensor 4 Socket A 795 799 5540 For fuel temperature sensor 5 Cable 795 799 5540 cummins No 3824774 Atmospheric pressure Fuel rail pressure sensor Timing r...

Page 133: ...ST TEMPERATURE OVERALL ENGINE Wait for the exhaust manifold temperature to go down before removing or installing the measur ing equipment 1 Remove exhaust temperature measurement plug 1 Since the exha...

Page 134: ...of the heat gun to mark a of each cylinder to pre vent dispersion of the measurement results caused by difference of the measuring points 6 Compensate the measured value for each cylin der 12 minutes...

Page 135: ...lve clearance insert feeler gauge G2 into clearance c between rocker arm 1 and crosshead 2 and adjust the valve clearance with adjustment screw 3 Insert the feeler gauge and turn the adjust ment screw...

Page 136: ...e table below when carrying out the operation Cylinder at compression top and cylinder for adjustment of injector 4 Loosen lock nut 2 then fully loosen adjustment screw 1 of the injector to be adjuste...

Page 137: ...emove the injector see DISASSEMBLY AND ASSEMBLY 4 Install adapter assemblies F2 to the all cylinders and secure them with the holders Install each adapter assembly with the hole for taking out the inj...

Page 138: ...bolt thread seat Engine oil E030CD Rocker arm assembly mounting bolt 235 2 254 8 Nm 24 26 kgm Adjust the valve clearance For details see ADJUSTING VALVE CLEARANCE Adjust the injector For details see T...

Page 139: ...roblems may occur if dirt or dust get in so always be careful of the following points When carrying out inspection or maintenance of the fuel line pay more attention than usual to prevent dirt or dust...

Page 140: ...l condition 2 Measuring fuel pump outlet pressure with oil pressure gauge 1 Connect adapter B1 hose B2 and pressure gauge B4 to outlet pressure measuring cou pler 2 2 Start the engine and measure the...

Page 141: ...4 11 60 1 41 1 000 2 42 0 21 1 25 0 14 12 70 1 41 1 100 2 59 0 21 1 34 0 14 13 70 1 41 1 200 2 76 0 21 1 46 0 14 14 90 1 41 VISUAL INSPECTION OF RETURN FUEL The fuel used for control of the timing rai...

Page 142: ...ves at the supply side and return side of the fuel tank At the same time check that there is ample fuel in the tank 2 Fill the fuel filter with fuel Do this only after the fuel filter has been replace...

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Page 147: ...e single lip type oil seal shown in the dia gram below as a test consumable part Seal Part No 6162 25 4251 When using a double lip type the lubricating conditions are different so there is danger of d...

Page 148: ...ING AND ADJUSTING ARRANGEMENT OF CONTROL DEVICES AND ELECTRIC CIRCUIT DIAGRAM FOR HPI Arrangement of control devices for troubleshooting ARRANGEMENT OF CONTROL DEVICES AND ELECTRIC CIRCUIT DIAGRAM FOR...

Page 149: ...pheric pressure sensor AAPR 5 Boost pressure sensor IMPR 6 Intake air temperature sensor IMTS 7 Oil pressure sensor OPS 8 Fuel temperature sensor FLTP 9 Water temperature sensor CLTP 10 Speed sensor S...

Page 150: ...12 24 170 3 SERIES TESTING AND ADJUSTING Electric circuit diagram For troubles shooting ARRANGEMENT OF CONTROL DEVICES AND ELECTRIC CIRCUIT DIAGRAM FOR HPI ProCarManuals com...

Page 151: ...0 0 6 1 000 305 31 23 31 3 1 200 620 63 55 74 3 1 200 1 275 130 115 154 10 1 500 1 885 192 212 284 5 2 000 2 470 252 370 497 PC1250 7 Operating time Engine speed Dynamometer load Output min rpm N kg...

Page 152: ...pm 2 170 30 rpm 700 25 rpm 2 000 5 1 400 100 2 170 30 700 25 rpm WA700 3 Rated horsepower Max torque net High idling speed Low idling speed 478kW 641HP 2 000 rpm 2 806Nm 286kg 1 400 rpm 2 240 30 rpm 7...

Page 153: ...Min 1 2 Max 650 Max 650 70 90 70 90 70 90 70 90 90 110 90 110 90 110 80 110 343 539 3 5 5 5 343 539 3 5 5 5 343 539 3 5 5 5 Min 118 Min 1 2 Max 650 Max 650 70 90 70 90 70 90 70 90 90 110 90 110 90 11...

Page 154: ...torque net High idling speed Low idling speed 585 kW 1 800 rpm 784 HP 1 800 rpm Max 1 890 rpm 800 50 rpm 1 800 5 Max 1 890 800 50 4 210 4 450 429 454 SAA6D170E2 3 DCA 800SSK2 DENYO GENERATOR Rated ho...

Page 155: ...07 70 90 70 90 70 90 70 90 90 110 90 110 90 110 80 110 343 539 3 5 5 5 343 539 3 5 5 5 343 539 3 5 5 5 Min 118 Min 1 2 Max 650 Max 650 733 771 986 1 037 70 90 70 90 70 90 70 90 90 110 90 110 90 110 80...

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Page 157: ...up is poor 12 110 S 4 Engine stops during operations 12 110 2 S 5 Engine does not rotate smoothly hunting 12 112 S 6 Engine lacks output or lacks power 12 112 2 S 7 Exhaust smoke is black incomplete c...

Page 158: ...also lose the confidence of the user or operator For this reason when carrying out troubleshoot ing it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accor...

Page 159: ...has obtained from the user and the results of that he has obtained from his own inspection Troubleshooting Troubleshooting is carried out in the order of probability starting with the causes that hav...

Page 160: ...uffler Worn piston ring cylinder liner Defective fuel pump Defective injector Cut worn injector O ring Failure timing rail pressure sensor Defective timing rail actuator Marked Causes Inspect air clea...

Page 161: ...ner element 2 Defective contact of valve valve seat 3 Leakage of air between turbocharger and head 4 Worn piston ring cylinder liner 5 Defective timing rail pressure sensor Step 3 The calculation in S...

Page 162: ...it is found to be low Inspect fuel pump directly Inspect fuel shut off valve directly Inspect timing rail actuator screen directly When temperature of exhaust gas of each cylinder is measured there ar...

Page 163: ...nifold temperature sensor Defective fuel rail actuator Marked 1 Defective timing rail actuator Marked 1 Defective fuel pump actuator Marked 1 Causes S 1 1 If the following error codes are displayed ca...

Page 164: ...and terminal C of starting motor are connected engine starts When terminal B and terminal C of safety relay are connected engine starts When terminal of safety switch and terminal B of starting motor...

Page 165: ...strainer directly Inspect fuel pump drive shaft directly Inspect fuel shut off valve directly When starting switch is turned to START voltage 24V is not generated between fuel shut off valve connector...

Page 166: ...e sensor Defective fuel rail actuator Marked 1 Defective timing rail actuator Marked 1 Defective fuel pump actuator Marked 1 10 S 2 1 If the following error codes are displayed carry out the troublesh...

Page 167: ...fuel pump directly Inspect timing rail actuator screen directly When temperature of exhaust gas of each cylinder is measured there are some cylinders that are low When specific gravity of electrolyte...

Page 168: ...d temperature sensor Defective fuel rail actuator Marked 1 Defective timing rail actuator Marked 1 Defective fuel pump actuator Marked 1 Clogged fuel rail actuator S 2 10 1 If the following error code...

Page 169: ...spect valve clearance directly When pressure at outlet port of fuel pump is measured it is found to vary Inspect fuel filter strainer directly When negative pressure at inlet port of fuel pump is meas...

Page 170: ...ing between turbocharger and cylinder head Causes S 3 1 If the following error codes are displayed carry out the troubleshooting in EA mode or EB mode If any of the following error codes is not displa...

Page 171: ...el filter strainer directly When negative pressure at inlet port of fuel pump is measured it is found to be high When pressure at outlet port of fuel pump is measured it is found to be low When temper...

Page 172: ...or Marked Defective fuel pump actuator Marked Defective fuel shut off valve Clogged fuel inlet circuit Causes S 4 1 If the following error codes are displayed carry out the troubleshooting in EA mode...

Page 173: ...p is measured it is found to be low When temperature of injector of each cylinder is measured there are some cylinders that are low When flow of spill fuel is checked visually it is found to be low In...

Page 174: ...mp pressure sensor Defective fuel pump actuator Marked 1 Defective in throttle sensor Defective in speed sensor Clogged fuel rail actuator screen Clogged timing rail actuator screen Causes 7 S 5 1 If...

Page 175: ...filter strainer directly When negative pressure at inlet port of fuel pump is measured it is found to be high When pressure at outlet port of fuel pump is measured it is found to be low When temperatu...

Page 176: ...mp actuator Marked 1 High resistance or clogged fuel circuit Defective throttle sensor Defective controller calibration data Causes S 6 1 If the following error codes are displayed carry out the troub...

Page 177: ...bocharger and cylinder head directly When pressure at outlet port of fuel pump is measured it is found to be low When temperature of injector of each cylinder is measured there are some cylinders that...

Page 178: ...f any of the following error codes is not displayed they are not probably the cause of the trouble In this case inspect the other devices for the cause 112 E 83 Abnormality in timing rail actuator 2 I...

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Page 181: ...p is measured it is found to be low Abnormality in fuel rail pressure sensor system is indicated 1 Abnormality in timing rail pressure sensor system is indicated 1 When flow of return fuel is checked...

Page 182: ...aulic oil transmission oil on machine side is cloudy white When hydraulic oil transmission oil on machine side is drained water is found Questions Check items Carry out pressure tightness test of cyli...

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Page 344: ...step 578 10 Nm 58 1 0 kgm 3rd step Tighten 90 a After tightening the bolts make 1 punch mark a each on the head of each bolt do not make a punch mark when using a new bolt 30 0 8 Using dial gauge mea...

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Page 377: ...14 2 170 3 SERIES MAINTENANCE STANDARD TURBOCHARGER KTR110L TURBOCHARGER 8 ProCarManuals com...

Page 378: ...nside diameter of journal bearing outside diameter of wheel shaft 17 0 032 0 043 0 009 0 003 16 95 17 04 Curvature of wheel shaft Repair limit 0 010 total deflection of indicator 5 Thickness of thrust...

Page 379: ...14 3 1 170 3 SERIES MAINTENANCE STANDARD S500 TURBOCHARGER 10 ProCarManuals com...

Page 380: ...nside diameter of journal bearing outside diameter of wheel shaft 17 0 032 0 043 0 009 0 003 16 95 17 04 Curvature of wheel shaft Repair limit 0 010 total deflection of indicator 5 Thickness of thrust...

Page 381: ...14 3 3 170 3 SERIES MAINTENANCE STANDARD HOLSET TURBOCHARGER 10 ProCarManuals com...

Page 382: ...mm No Check item Criteria Remedy 1 End play play in axial direction Standard size Repair limit Replace related to thrust 0 025 0 152 2 Radial play play in radial direction 0 254 0 787 Replace related...

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Page 384: ...3 2 8 3 Angle of valve seat Standard Tolerance Replace Intake valve 30 0 15 Exhaust valve 45 0 15 4 Outside diameter of valve stem Intake valve Standard size Tolerance Repair limit 12 0 060 0 080 11...

Page 385: ...0 05 13 21 3 Outside diameter of cross head guide 13 0 039 0 028 13 00 Clearance between cross head guide and crosshead Standard clearance Clearance limit Adjust 0 011 0 072 4 Protrusion of crosshead...

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Page 399: ...ushing Shaft Hole 52 0 027 0 040 0 055 0 0 027 0 095 0 25 2 Clearance of idler gear in axial direction Standard clearance Clearance limit Replace thrust bearing 0 04 0 18 0 3 Backlash of each gear Pos...

Page 400: ...e Clearance limit clearance from new ring Link groove Link thickness Top ring 2nd ring Keystone Keystone Check with piston loop wear gauge or check clearance from new ring 0 15 Oil ring 4 00 0 05 0 03...

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Page 407: ...5 TESTING AND INSPECTING CYLINDER BLOCK 15 16 GRINDING THE TOP SURFACE OF CYLINDER BLOCK 15 19 REPLACING MAIN BEARING CAP 15 25 REPLACING CAM BUSHING 15 27 TESTING AND INSPECTING CRANKSHAFT 15 29 CORR...

Page 408: ...est of cylinder head E 795 611 1500 Coolant tester 1 F 79A 471 1050 Pump assembly 1 Replacing valve guide G 1 795 611 1610 Valve guide remover 1 2 795 611 1620 Valve guide driver 1 Replacing crosshead...

Page 409: ...NT OF PARTS 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 7 TESTING AND INSPE...

Page 410: ...e D Protrusion of injector Replace cylinder head or injector E Damage to valve seat surface or loosening of seat Dent of seat surface Check contact between valve and seat surface Airtighteness test Ta...

Page 411: ...e Outside diameter Replace J Inside diameter of valve guide after press fitted to head Replace K Protrution of valve guide after press fitted to head L Outside diameter of crosshead guide M Protrution...

Page 412: ...Standard size 150 95 151 05 mm a Amount to remove per grinding 0 10 0 15 mm a Surface roughness of grinding surface Top surface 12 5S Under surface 4S a Flatness deformation Max 0 05 mm a Grinding lim...

Page 413: ...he air pressure to 490 588 kPa 5 to 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 a After re...

Page 414: ...ep 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 scr...

Page 415: ...tamp on insert Insert Mounting hole for insert O D d1 Hight h1 I D d2 Depth h2 S T D 64 00 8 5 64 00 11 4 0 1 0 25 O S 64 25 8 5 64 25 11 4 0 1 0 50 O S 64 50 8 62 64 50 11 52 0 1 0 75 O S 64 75 8 75...

Page 416: ...at 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 bo...

Page 417: ...tester 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 spr...

Page 418: ...ressure 343 392 kPa 3 5 4 0 kg cm2 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...

Page 419: ...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...

Page 420: ...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 cro...

Page 421: ...ng of valve Standard sinking 0 39 protrusion 0 21 mm Repair limit sinking 0 8mm a Check the contact of the valve with the seat surface using one of the following methods Coat the seat surface of the g...

Page 422: ...5 16 170 3 SERIES 7 TESTING AND INSPECTING CYLINDER BLOCK 1 Cylinder liner 2 Crevice seal 3 O ring 4 Cylinder block 5 Main bearing cap 6 Main bearing cap bolt 7 Camshaft bushing TESTING AND INSPECTING...

Page 423: ...ard valve Replace bushing E Protrusion of liner Replace cylinder liner or correct cylinder block F Depth of counter bore and corro sion of bot tom surface Repair by machining add shim Check for water...

Page 424: ...de diameter of cylinder liner flange Replace cylinder liner Replace cylinder block Standard size Repair limit Overall top surface of block Max 0 09 For one cylinder Max 0 05 0 15 0 15 Standard size St...

Page 425: ...s 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 1 Grinding top surface 1 Measure the wear and strain of the...

Page 426: ...rea to adjust the depth of part c of the counterbore Machining dimension of part d Max 0 4 mm Machining dimension of part e Max 0 7 mm Machining dimension of part f 0 Max 0 06 mm Angle of part g to ce...

Page 427: ...56 488 96 mm always use an oversize head gasket a Oversize head gasket part number 6240 19 1810 Thickness of plate 2 4mm standard 2 0mm a To distinguish the letters OS are stamped on the plate After c...

Page 428: ...diameter of the line of gasket sealant 2 3 mm Make the overlapping portion b for begin ning and ending the coating of sealant 6 6mm as shown in the diagram c Top surface of cylinder block d Mating por...

Page 429: ...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 che...

Page 430: ...en the cylinder liner and cylinder block a If gasket sealant sticks to grommet 1 in the head gasket the grommet will be deformed into the shape of a heart and this may cause leakage of the coolant int...

Page 431: ...olt 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 ar...

Page 432: ...the opposite side in the same way a Surface roughness of thrust bearing Max 12 5 S a Do not cut the cylinder block side a Dimensions of main cap Radius R Max 0 5 mm Surface roughness of part d Max 12...

Page 433: ...1 while hitting the bar 3 Removing No 3 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 a...

Page 434: ...s matched to the oil hole of the cylinder block a Match the oil hole of the bushing Measure the inside diameter of the bushing with inside gauge Check the clearance between the bushing and shaft If th...

Page 435: ...tic flaw detector to check for cracks Replace B Damage Check for damage to the jour nal portion Scratches Seizure Discoloration If the damage is slight correct with an oilstone or cor rect by lapping...

Page 436: ...50 107 41 0 75 US 107 25 107 16 1 00 US 107 00 106 91 G Out of roundness of crankshaft pin journal Standard value Repair limit 0 0 010 0 010 H Clearance of crankshaft pin jour nal 0 058 0 132 0 18 Rep...

Page 437: ...e 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 ea...

Page 438: ...he 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 pa...

Page 439: ...th rubber band g 3 Measuring surface roughness Standard for surface roughness Main journal and pin journal Max 0 6 S Using a surface roughness measuring tool check that the roughness is within the sta...

Page 440: ...5 34 170 3 SERIES CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION 7 Clamp jig parts drawing for pin journal 1 Plate 2 are used for each jig a Width of slit Unit mm 2 Handle 2 are used for e...

Page 441: ...ACEMENT OF PARTS CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION Clamp jig parts drawing for main journal 1 Plate 2 are used for each jig a Width of slit Unit mm 2 Handle 2 are used for eac...

Page 442: ...g the hole Finishing dimensions of fillet R 6 5 mm Surface roughness 1 6S Finishing dimensions for main journal and pin journal are show in diagram in the right 1 Oil hole of main journal See figure a...

Page 443: ...Lower limit 74 HS When using with output below 750 PS Permissible range 60 67 HS Lower limit 60 HS The hardness of the spare crankshaft is 74 81 HS On the other hand the hardness of the crankshaft of...

Page 444: ...2 mm to the next undersize After inspecting neutralize and clean the inspected parts and apply rust preventive oil 3 Magnaflux inspection Before using the repaired crankshaft inspect it by magnaflux i...

Page 445: ...ave been ground confirm that the end play of the crankshaft is within the permissible range For details see DISASSEMBLY AND ASSEMBLY Undersizes of thrust bearing surfaces Unit mm Squareness of thrust...

Page 446: ...ecting the width of the main journal and pin journal by grinding When correcting the worn surfaces c of the main journals a and pin journals b limit the grinding thickness to the minimum d Thickness o...

Page 447: ...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 cranks...

Page 448: ...nkshaft Max 325 rpm Make the following correction to balance the crankshaft Rear key way 66 gcm Front reamed hole 31 5 gcm To balance the crankshaft make a hole on the counter weight with a drill or g...

Page 449: ...tum 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 journ...

Page 450: ...ing Measure parallelism a and torsion b After installing pin bushing Standard size Tolerance Standard clearance Clear ance limit Shaft Hole 68 0 020 0 026 0 049 0 030 0 030 0 075 0 075 Standard size T...

Page 451: ...ax 6 3 S Contact of mating sutface Min 70 Replace if fingernail catches in fretting J Scuffing of bolt seat surface Scuffing of cap bolt seat surface Correct with oil stone Scuffing of bolt seat surfa...

Page 452: ...t 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...

Page 453: ...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...

Page 454: ...dling 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...

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