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REPAIR AND REPLACEMENT OF PARTS

15-2

170-3 SERIES

(7)

TABLE OF SPECIAL TOOLS

Operation

Symbol

Part No.

Part Name

Q'ty

Remarks

Replacing valve seat

A

1

795-100-4801

Puller

1

For valve seat

2

795-100-3005

Seat cutter

1

3

795-611-1410

Push tool

1

For intake valve

795-611-1420

Push tool

1

For exhaust valve

Pressure test 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 guide

H

795-611-1700

Crosshead guide pulle

1

1

Grinding valve

I

Commercially 

available

Valve refacer

1

Replacing cam bushing

J

1

795-621-1600

Push tool set

1

2

792-103-0400

Grip

1

Replacing crankshaft gear

K

1

790-101-2800

Bearing puller

1

2

790-101-2300

Push puller

1

TABLE OF SPECIAL TOOLS

ProCarManuals.com

Содержание 170-3 Series

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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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Страница 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...

Страница 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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Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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