Komatsu 170E-7 Series Engine Shop Manual SEN06580-09 – PDF DOWNLOAD

Komatsu 170E-7 Series Engine Shop Manual SEN06580-09 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 170E-7 Series Engine Shop Manual SEN06580-09 – PDF DOWNLOAD

Language : English
Pages : 646
Downloadable : Yes
File Type : PDF
Size: 24.7 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 170E-7 Series Engine Shop Manual SEN06580-09 – PDF DOWNLOAD

The Komatsu 170E-7 Series Engine Shop Manual is a comprehensive guide to servicing, maintaining, and repairing the Komatsu 170E-7 diesel engine. This engine is commonly used in a variety of heavy equipment, including excavators, bulldozers, and other construction machinery.

The manual is published by Komatsu, a leading manufacturer of heavy equipment and diesel engines. It is designed to provide detailed information on the engine to qualified mechanics and technicians, enabling them to service and repair the engine to the highest standards.

The manual is divided into several sections, each of which provides specific information on different aspects of the engine. The sections include:

1. General information: This section provides an overview of the engine, including its specifications, features, and operating principles. It also includes information on safety precautions, tools, and equipment needed for maintenance and repair.
2. Inspection and adjustment: This section provides detailed instructions on how to inspect and adjust various components of the engine, including the cylinder head, valves, fuel system, and cooling system.
3. Engine disassembly and assembly: This section provides step-by-step instructions on how to disassemble and assemble the engine. It includes detailed diagrams and illustrations to help users understand each step of the process.
4. Troubleshooting: This section provides a comprehensive list of potential problems that may arise with the engine, along with diagnostic procedures to help identify and fix these issues.
5. Maintenance: This section provides information on the regular maintenance tasks that should be performed on the engine, including oil changes, filter replacements, and other routine tasks.
6. Reassembly and testing: This section provides detailed instructions on how to reassemble the engine after repairs have been made. It also includes information on how to test the engine to ensure that it is functioning properly.
7. Service data: This section provides detailed technical data on the engine, including torque specifications, compression pressures, and other important information.

The manual is written in clear, concise language and is filled with detailed diagrams and illustrations to help users understand each step of the process. It is an essential tool for anyone who works with Komatsu diesel engines and can help to ensure that the engine is maintained and repaired to the highest standards.

However, it should be noted that the manual is designed for use by qualified mechanics and technicians and should not be used by individuals without the appropriate training and experience. The manual is also specifically for the Komatsu 170E-7 engine and should not be used as a reference for other engines in the Komatsu lineup.

TABLE OF CONTENTS:

Komatsu 170E-7 Series Engine Shop Manual SEN06580-09 – PDF DOWNLOAD

COVER………………………………………………………………………………………………………………………………… 1
00 INDEX AND FOREWORD…………………………………………………………………………………………………………………. 3
INDEX……………………………………………………………………………………………………………………………. 4
ABBREVIATION LIST…………………………………………………………………………………………………………………. 6
FOREWORD, SAFETY, BASIC INFORMATION…………………………………………………………………………………………………. 12
HOW TO READ THE ENGINE SHOP MANUAL………………………………………………………………………………………………. 12
SAFETY NOTICE FOR OPERATION…………………………………………………………………………………………………….. 14
PRECAUTIONS TO PREVENT FIRE…………………………………………………………………………………………………….. 22
ACTIONS IF FIRE OCCURS…………………………………………………………………………………………………………. 24
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS……………………………………………………………………………………… 25
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS…………………………………………………………………………………….. 26
PRECAUTIONS FOR DEF……………………………………………………………………………………………………………. 27
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING………………………………………………………………………………… 27
PRECAUTIONS FOR ADDING……………………………………………………………………………………………………… 27
PRECAUTIONS FOR STORING…………………………………………………………………………………………………….. 27
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE………………………………………………………………………………………. 27
THE OTHER PRECAUTIONS………………………………………………………………………………………………………. 27
STORE AdBlue/DEF………………………………………………………………………………………………………………. 28
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT……………………………………………………………………………………… 29
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS……………………………………………………………………………. 32
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT…………………………………………………………………………………….. 39
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT……………………………………………………………………………………. 41
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT………………………………………………………………………………….. 42
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER…………………………………………………………………………………….. 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER……………………………………………………………. 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER……………………………………………………………. 44
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER……………………………………………………………. 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…………………………………………………………………………. 47
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR………………………………………………………………………….. 51
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…………………………………………………………………… 52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…………………………………………………………………. 54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…………………………………………………………………. 55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE…………………………………………………………….. 57
HOW TO READ ELECTRICAL WIRE CODE………………………………………………………………………………………………… 58
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…………………………………………………………………………………….. 62
STANDARD TIGHTENING TORQUE TABLE………………………………………………………………………………………………… 65
CONVERSION TABLE………………………………………………………………………………………………………………. 72
01 SPECIFICATIONS…………………………………………………………………………………………………………………….. 77
CONTENTS…………………………………………………………………………………………………………………………. 78
ABBREVIATION LIST…………………………………………………………………………………………………………………. 79
SPECIFICATIONS……………………………………………………………………………………………………………………. 85
OUTLINE OF EXHAUST GAS REGULATION……………………………………………………………………………………………….. 85
SYSTEM DIAGRAM OF ENGINE COMPLIED WITH TIER 4 AND EU STAGE V REGULATION………………………………………………………….. 86
IMPROVED POINTS OF ENGINE COMPLIED WITH TIER 4 AND EU STAGE V REGULATION AGAINST TIER3 REGULATION…………………………………… 87
SYSTEM DIAGRAM OF ENGINE OTHER THAN ENGINE COMPLIED WITH TIER 4 AND EU STAGE V REGULATION………………………………………….. 88
LIST OF APPLICABLE MACHINES: 170E-7……………………………………………………………………………………………… 89
SPECIFICATIONS………………………………………………………………………………………………………………… 90
SPECIFICATIONS: SAA6D170E-7 (D375A-8, D375A-8E0, D375AI-8, D375AI-8E0)…………………………………………………………… 90
SPECIFICATIONS: SAA6D170E-7 (HD465-8, HD465-8E0, HD605-8, HD605-8E0)…………………………………………………………….. 91
SPECIFICATIONS: SAA6D170E-7 (PC1250-11, PC1250-11E0, PC1250LC-11, PC1250SP-11, PC1250SP-11E0)………………………………………. 92
SPECIFICATIONS: SAA6D170E-7 (PC1250-11R, PC1250SP-11R)…………………………………………………………………………. 93
SPECIFICATIONS: SAA6D170E-7 (WA600-8, WA600-8E0)………………………………………………………………………………. 94
ENGINE GENERAL VIEW……………………………………………………………………………………………………………. 95
ENGINE GENERAL VIEW: SAA6D170E-7 (D375A-8, D375A-8E0, D375AI-8, D375AI-8E0)………………………………………………………. 95
ENGINE GENERAL VIEW: SAA6D170E-7 (HD465-8, HD465-8E0, HD605-8, HD605-8E0)………………………………………………………… 99
ENGINE GENERAL VIEW: SAA6D170E-7 (PC1250-11, PC1250-11E0, PC1250LC-11, PC1250SP-11, PC1250SP-11E0)…………………………………..103
ENGINE GENERAL VIEW: SAA6D170E-7 (PC1250-11R, PC1250SP-11R)……………………………………………………………………..107
ENGINE GENERAL VIEW: SAA6D170E-7 (WA600-8, WA600-8E0)…………………………………………………………………………..111
WEIGHT TABLE…………………………………………………………………………………………………………………..115
WEIGHT TABLE: 170E-7………………………………………………………………………………………………………..115
ENGINE PERFORMANCE CURVE………………………………………………………………………………………………………..118
ENGINE PERFORMANCE CURVE: SAA6D170E-7 (D375A-8, D375A-8E0, D375AI-8, D375AI-8E0)…………………………………………………..118
ENGINE PERFORMANCE CURVE: SAA6D170E-7 (HD465-8, HD465-8E0, HD605-8, HD605-8E0)…………………………………………………….119
ENGINE PERFORMANCE CURVE: SAA6D170E-7 (PC1250-11, PC1250-11R, PC1250-11E0, PC1250LC-11, PC1250SP-11, PC1250SP-11E0, PC1250SP-11R)……….120
ENGINE PERFORMANCE CURVE: SAA6D170E-7 (WA600-8, WA600-8E0)………………………………………………………………………121
10 STRUCTURE AND FUNCTION………………………………………………………………………………………………………………123
CONTENTS………………………………………………………………………………………………………………………….124
ABBREVIATION LIST………………………………………………………………………………………………………………….127
UREA SCR SYSTEM……………………………………………………………………………………………………………………133
LAYOUT DRAWING OF UREA SCR SYSTEM………………………………………………………………………………………………..133
UREA SCR SYSTEM DIAGRAM…………………………………………………………………………………………………………137
FUNCTION OF UREA SCR SYSTEM……………………………………………………………………………………………………..139
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM………………………………………………………………………………………….139
INDUCEMENT STRATEGY…………………………………………………………………………………………………………141
COMPONENT PARTS OF UREA SCR SYSTEM……………………………………………………………………………………………….155
AdBlue/DEF MIXING TUBE………………………………………………………………………………………………………155
SCR ASSEMBLY……………………………………………………………………………………………………………….156
AdBlue/DEF TANK…………………………………………………………………………………………………………….158
AdBlue/DEF PUMP…………………………………………………………………………………………………………….161
AdBlue/DEF INJECTOR…………………………………………………………………………………………………………162
AdBlue/DEF HOSE…………………………………………………………………………………………………………….163
AdBlue/DEF TANK HEATING VALVE………………………………………………………………………………………………..164
ENGINE SYSTEM……………………………………………………………………………………………………………………..165
LAYOUT OF ENGINE COMPONENTS……………………………………………………………………………………………………..165
LAYOUT DRAWING OF ENGINE COMPONENTS…………………………………………………………………………………………..165
INTAKE AND EXHAUST SYSTEM PARTS………………………………………………………………………………………………….167
LAYOUT DRAWING OF AIR INTAKE AND EXHAUST SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………….167
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………….168
FUNCTION OF INTAKE AND EXHAUST SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………..168
LAYOUT DRAWING OF AIR INTAKE AND EXHAUST SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………170
CIRCUIT DIAGRAM OF AIR INTAKE AND EXHAUST SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………..171
FUNCTION OF INTAKE AND EXHAUST SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………..171
AIR CLEANER………………………………………………………………………………………………………………..172
ENGINE MAIN BODY PARTS………………………………………………………………………………………………………….173
CYLINDER HEAD………………………………………………………………………………………………………………173
CYLINDER BLOCK……………………………………………………………………………………………………………..175
MAIN MOVING PARTS…………………………………………………………………………………………………………..178
VIBRATION DAMPER……………………………………………………………………………………………………………181
TIMING GEAR………………………………………………………………………………………………………………..182
FRONT COVER………………………………………………………………………………………………………………..184
VALVE SYSTEM……………………………………………………………………………………………………………….185
FLYWHEEL AND FLYWHEEL HOUSING………………………………………………………………………………………………..188
TURBOCHARGER SYSTEM…………………………………………………………………………………………………………….189
CIRCUIT DIAGRAM OF VGT SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………….189
FUNCTION OF VGT SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………………..190
VGT (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………………………………………192
FUNCTION OF TURBOCHARGER SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………….196
FUNCTION OF TURBOCHARGER SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V)…………………………………197
TURBOCHARGER (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………..198
EGR SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………………………………..201
EGR VALVE (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………………………………………204
EGR COOLER (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………………………………..206
MIXING CONNECTOR (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………………………………..207
AIR INTAKE MANIFOLD (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………….208
KCCV SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………………………….209
KCCV (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………………………………..213
KDPF (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………………………………..215
MUFFLER (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………………….219
LUBRICATION SYSTEM……………………………………………………………………………………………………………..220
LAYOUT DRAWING OF COMPONENT PARTS OF LUBRICATION SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V)…………………………….220
CIRCUIT DIAGRAM OF LUBRICATION SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………..221
LAYOUT DRAWING OF COMPONENT PARTS OF LUBRICATION SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)….222
CIRCUIT DIAGRAM OF LUBRICATION SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………….223
ENGINE OIL PUMP…………………………………………………………………………………………………………….224
ENGINE BOOST OIL PUMP (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………………………225
ENGINE OIL FILTER…………………………………………………………………………………………………………..227
ENGINE OIL COOLER…………………………………………………………………………………………………………..228
ENGINE OIL PAN……………………………………………………………………………………………………………..230
FUEL SYSTEM……………………………………………………………………………………………………………………231
LAYOUT DRAWING OF FUEL SYSTEM PARTS…………………………………………………………………………………………..231
CIRCUIT DIAGRAM OF FUEL SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………………………………232
FUNCTION OF FUEL SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………………………….233
OPERATION OF FUEL SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………………233
LAYOUT DRAWING OF COMPONENT PARTS OF FUEL SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………..234
FUNCTION OF FUEL SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………235
OPERATION OF FUEL SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………..235
CRI SYSTEM…………………………………………………………………………………………………………………235
SUPPLY PUMP………………………………………………………………………………………………………………..241
COMMON RAIL………………………………………………………………………………………………………………..244
INJECTOR…………………………………………………………………………………………………………………..247
FUEL DOSING SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………………………………250
FUEL PREFILTER……………………………………………………………………………………………………………..253
FUEL MAIN FILTER……………………………………………………………………………………………………………254
COOLING SYSTEM…………………………………………………………………………………………………………………255
LAYOUT DRAWING OF COMPONENT PARTS OF COOLING SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………255
CIRCUIT DIAGRAM OF COOLING SYSTEM (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………256
LAYOUT DRAWING OF COMPONENT PARTS OF COOLING SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V)……………….258
CIRCUIT DIAGRAM OF COOLING SYSTEM (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………..259
COOLANT FILTER (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………260
WATER PUMP…………………………………………………………………………………………………………………261
THERMOSTAT…………………………………………………………………………………………………………………262
ELECTRICAL SYSTEM………………………………………………………………………………………………………………….264
COMPONENT PARTS OF ELECTRICAL SYSTEM……………………………………………………………………………………………..264
ALTERNATOR…………………………………………………………………………………………………………………264
ALTERNATOR MOUNTING…………………………………………………………………………………………………………268
STARTING MOTOR……………………………………………………………………………………………………………..269
ENGINE WIRING HARNESS……………………………………………………………………………………………………….273
ENGINE CONTROLLER…………………………………………………………………………………………………………..278
FUEL FEED PUMP……………………………………………………………………………………………………………..308
FUEL FEED PUMP SWITCH……………………………………………………………………………………………………….309
SENSOR………………………………………………………………………………………………………………………..311
LAYOUT DRAWING OF ENGINE SENSOR (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………..311
LAYOUT DRAWING OF ENGINE SENSOR (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V)…………………………………316
STRUCTURE OF AMBIENT PRESSURE SENSOR………………………………………………………………………………………….319
FUNCTION OF AMBIENT PRESSURE SENSOR…………………………………………………………………………………………..319
STRUCTURE OF ENGINE OIL PRESSURE SENSOR……………………………………………………………………………………….320
FUNCTION OF ENGINE OIL PRESSURE SENSOR………………………………………………………………………………………..320
STRUCTURE OF CHARGE PRESSURE SENSOR…………………………………………………………………………………………..321
FUNCTION OF CHARGE PRESSURE SENSOR……………………………………………………………………………………………321
STRUCTURE OF CHARGE TEMPERATURE SENSOR………………………………………………………………………………………..322
FUNCTION OF CHARGE TEMPERATURE SENSOR…………………………………………………………………………………………322
STRUCTURE OF COOLANT TEMPERATURE SENSOR……………………………………………………………………………………….323
FUNCTION OF COOLANT TEMPERATURE SENSOR………………………………………………………………………………………..323
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR……………………………………………………………………………………..324
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR………………………………………………………………………………………324
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR……………………………………………………………………………………..325
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR………………………………………………………………………………………325
STRUCTURE OF COMMON RAIL PRESSURE SENSOR………………………………………………………………………………………326
FUNCTION OF COMMON RAIL PRESSURE SENSOR……………………………………………………………………………………….326
STRUCTURE OF EGR VALVE LIFT SENSOR (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………………..327
FUNCTION OF EGR VALVE LIFT SENSOR…………………………………………………………………………………………….327
STRUCTURE OF VGT SPEED SENSOR (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………………….328
FUNCTION OF VGT SPEED SENSOR…………………………………………………………………………………………………328
STRUCTURE OF VGT POSITION SENSOR (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………………….329
FUNCTION OF VGT POSITION SENSOR………………………………………………………………………………………………329
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………..330
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR……………………………………………………………………………….330
STRUCTURE OF DOSING FUEL PRESSURE SENSOR (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)………………………………..331
FUNCTION OF DOSING FUEL PRESSURE SENSOR……………………………………………………………………………………….331
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………332
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR………………………………………………………………..332
STRUCTURE OF CRANKCASE PRESSURE SENSOR………………………………………………………………………………………..333
FUNCTION OF CRANKCASE PRESSURE SENSOR…………………………………………………………………………………………333
STRUCTURE OF ENGINE OIL LEVEL SENSOR………………………………………………………………………………………….334
FUNCTION OF ENGINE OIL LEVEL SENSOR…………………………………………………………………………………………..334
STRUCTURE OF AIR CLEANER CLOGGING SENSOR………………………………………………………………………………………335
FUNCTION OF AIR CLEANER CLOGGING SENSOR……………………………………………………………………………………….335
20 STANDARD VALUE TABLE………………………………………………………………………………………………………………..337
CONTENTS………………………………………………………………………………………………………………………….338
ABBREVIATION LIST………………………………………………………………………………………………………………….339
STANDARD VALUE TABLE FOR ENGINE……………………………………………………………………………………………………..345
STANDARD VALUE TABLE FOR ENGINE: SAA6D170E-7 (D375A-8, D375A-8E0, D375AI-8, D375AI-8E0)………………………………………………..345
STANDARD VALUE TABLE FOR ENGINE: SAA6D170E-7 (HD465-8, HD465-8E0, HD605-8, HD605-8E0)………………………………………………….347
STANDARD VALUE TABLE FOR ENGINE: SAA6D170E-7 (PC1250-11, PC1250-11E0, PC1250LC-11, PC1250SP-11, PC1250SP-11E0)……………………………349
STANDARD VALUE TABLE FOR ENGINE: SAA6D170E-7 (PC1250-11R, PC1250SP-11R)………………………………………………………………351
STANDARD VALUE TABLE FOR ENGINE: SAA6D170E-7 (WA600-8, WA600-8E0)……………………………………………………………………353
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD……………………………………………………………………………………..355
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D170E-7 (D375A-8, D375A-8E0, D375AI-8, D375AI-8E0)………………………………..355
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D170E-7 (HD465-8, HD465-8E0, HD605-8, HD605-8E0)………………………………….357
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D170E-7 (PC1250-11, PC1250-11E0, PC1250LC-11, PC1250SP-11, PC1250SP-11E0)……………359
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D170E-7 (PC1250-11R, PC1250SP-11R)………………………………………………361
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D170E-7 (WA600-8, WA600-8E0)……………………………………………………363
50 DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………………………….365
CONTENTS………………………………………………………………………………………………………………………….366
ABBREVIATION LIST………………………………………………………………………………………………………………….367
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY……………………………………………………………………………………….373
HOW TO READ THIS MANUAL…………………………………………………………………………………………………………373
COATING MATERIALS LIST………………………………………………………………………………………………………….375
SPECIAL TOOLS LIST……………………………………………………………………………………………………………..379
SKETCHES OF SPECIAL TOOLS……………………………………………………………………………………………………….381
ENGINE SYSTEM……………………………………………………………………………………………………………………..382
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY…………………………………………………………………………………………382
METHOD FOR DISASEMBLING ENGINE GENERALLY………………………………………………………………………………………384
METHOD FOR ASEMBLING ENGINE GENERALLY…………………………………………………………………………………………460
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…………………………………………………………………………………………..563
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY………………………………………………………………………………………563
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY…………………………………………………………………………………….574
REMOVE AND INSTALL ENGINE FRONT OIL SEAL………………………………………………………………………………………….586
METHOD FOR REMOVING ENGINE FRONT OIL SEAL……………………………………………………………………………………..586
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL……………………………………………………………………………………587
REMOVE AND INSTALL ENGINE REAR OIL SEAL…………………………………………………………………………………………..589
METHOD FOR REMOVING ENGINE REAR OIL SEAL………………………………………………………………………………………589
METHOD FOR INSTALLING ENGINE REAR OIL SEAL…………………………………………………………………………………….590
60 MAINTENANCE STANDARD………………………………………………………………………………………………………………..595
CONTENTS………………………………………………………………………………………………………………………….596
ABBREVIATION LIST………………………………………………………………………………………………………………….597
ENGINE SYSTEM……………………………………………………………………………………………………………………..603
INTAKE AND EXHAUST SYSTEM PARTS………………………………………………………………………………………………….603
MAINTENANCE STANDARD OF VGT (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………………………………………603
MAINTENANCE STANDARD OF TURBOCHARGER (FOR ENGINES OTHER THAN ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)…………………..604
ENGINE MAIN BODY PARTS………………………………………………………………………………………………………….606
MAINTENANCE STANDARD OF CYLINDER HEAD…………………………………………………………………………………………606
MAINTENANCE STANDARD OF CYLINDER BLOCK………………………………………………………………………………………..608
MAINTENANCE STANDARD OF CYLINDER LINER………………………………………………………………………………………..610
MAINTENANCE STANDARD OF CRANKSHAFT……………………………………………………………………………………………612
MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD………………………………………………………………………………614
MAINTENANCE STANDARD OF PISTON……………………………………………………………………………………………….615
MAINTENANCE STANDARD OF CONROD……………………………………………………………………………………………….617
MAINTENANCE STANDARD OF VIBRATION DAMPER………………………………………………………………………………………619
MAINTENANCE STANDARD OF TIMING GEAR…………………………………………………………………………………………..620
MAINTENANCE STANDARD OF CAMSHAFT……………………………………………………………………………………………..624
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE………………………………………………………………………………….625
MAINTENANCE STANDARD OF ROCKER ARM……………………………………………………………………………………………627
MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE……………………………………………………………………………………628
MAINTENANCE STANDARD OF FLYWHEEL……………………………………………………………………………………………..629
LUBRICATION SYSTEM……………………………………………………………………………………………………………..631
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP…………………………………………………………………………631
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP (FOR ENGINES COMPLIED WITH TIER 4 AND EU STAGE V REGULATION)……………..634
MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER……………………………………………………………………….635
COOLING SYSTEM…………………………………………………………………………………………………………………636
MAINTENANCE STANDARD OF OIL COOLER……………………………………………………………………………………………636
MAINTENANCE STANDARD OF WATER PUMP……………………………………………………………………………………………637
MAINTENANCE STANDARD OF THERMOSTAT……………………………………………………………………………………………638
INDEX…………………………………………………………………………………………………………………………………639