COMPONENT CODE A 1
REF NO.
DATE
AT04815
Jun. 7, 2004
Page 1 of 6
(C)
SUBJECT:
IMPROVED INJECTOR FOR d170E-3 SERIES ENGINE
PURPOSE:
To introduce modification procedure to increase the durability of the injector spring for the d170E-3 Series engines when it breaks
APPLICATION:
HD465-7 Dump Trucks
HD605-7 Dump Trucks
WA600-3 Wheel Loaders
WD600-3 Wheel Dozers
WA700-3 Wheel Loaders
D375A-5 Bulldozers
PC1250-7 Hydraulic Excavators
A6D170E-KC-3 Engines
170CUM-IND Engines
170CUM-PG-3 Engines
A6D170E-G1-3 Engines
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






 Refer to page 6







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FAILURE CODE: A1LOFF
DESCRIPTION:
Part Name
s:
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Part No.
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2. List of parts
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1. Introduction
When the injector spring for the d170E-3 Series engines breaks, repair the failure following the modification procedure described in this Service News.
tp
6560-11-1114
(6560-11-1113)
Injector
(Injector)
Purpose of part
Q'ty






 Replacement






6
(6)
D375-5, HD465-7,
HD605-7, PC1250-7,
A6D170E-CC-3,
A6D170E-KC-3
6
(6)
A6D170E-CG-3
A6D170E-G2-3
170CUM-PG-3
6
(6)
(6)
A6D170E-G1-3
WA600-3E, WD600-3
WA700-3E
Injector
(Injector)
6560-11-1213
(6560-11-1212)
(6560-11-1211)
Injector
(Injector)
(Injector)
6560-11-1414
(6560-11-1413)
(6560-11-1412)
Injector
(Injector)
(Injector)
6
(6)
(6)
6240-11-8810
Gasket
6
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6560-11-1812
(6560-11-1811)
Printed in Japan
(02)1
Remarks
Common for all the
machine models
AT04815
Page 2 of 6
3. Details of the modification
1) Details of the improvements
The injector has been improved to increase its durability.
2) Outline of the modification
Replace the injector with the improved one.
Refer to the descriptions given below regarding the identification method for the
improved injector.
The identification color of the injector spring can be seen through the hole (a).
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Improved injector: Sky blue
Current injector: White
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Confirm that the sky blue identification color can be seen.
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Fig. 1
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3) Modification procedure
Regarding the details of the disassembly and assembly procedures, refer to the
Shop Manual.
Replace all the gaskets, seals and O-rings which have been removed with new
parts.
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1. Remove the head cover (2) of the engine.
Tightening torque for the bolt (1): 9.8 ± 1.0 Nm
(1.0 ± 0.1 kgm)
Fig. 2
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2. Loosen the adjust screws (3), (4) and (5). After that, loosen the bolt (6) to remove
the rocker arm ass'y (7).
Fig. 3
AT04815
Tightening torque for the bolt (6): 235.2 – 254.8 Nm
(24 – 26 kgm)
Page 3 of 6
3. Loosen the bolt (8) and replace the injector (9).
Fig. 4
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4. Install the rocker arm ass'y as per the Shop Manual.
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Tightening procedure for the bolt (8)
1 Apply engine oil #30 to the threads and the bearing surface of the bolt.
2 Tighten the bolt at the tightening torque of 24.5 – 34.3 (2.5 – 3.5 kgm).
3 Tighten the bolt further by 90° – 120° toward the tightening direction.
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Fig. 5
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Adjusting method for the injector setting load: Refer to page 4.
Adjusting method for the valve clearance: Refer to page 5.
Tightening torque for the bolt (6): 235.2 – 254.8 Nm (24 – 26 kgm)
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5. Install the head cover (2) of the engine.
Tightening torque for the bolt (1): 9.8 ±1.0 Nm
(1.0 ± 0.1 kgm)
Fig. 6
AT04815
Page 4 of 6
TESTING AND ADJUSTING
ADJUSTING INJECTOR SET LOAD
ADJUSTING INJECTOR SET
LOAD
6.
Hold adjustment screw (1) in position, then
tighten locknut (2).
~ Locknut: 205.8 - 245 Nm {21 - 25 kgm}
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1. Remove the cover of the flywheel housing, then
install barring device G1.
7. After completing the adjustment, set to the origi-
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the normal direction to set No. 1 cylinder at compression top dead center, and align pointer b
with the [1.6TOP] line a on the crankshaft pulley.
Watch the movement of the rocker arm and
check that the No. 1 cylinder is at the compression stroke. (If the rocker arms for both
the intake and exhaust sides move only the
amount of the valve clearance, the cylinder is
at the compression stroke.)
The cylinder where at compression top is different from the cylinder where the injector is
being adjusted, so check the table below
when carrying out the operation.
Cylinder at compression top and cylinder for
adjustment of injector:
±
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±
3. Using barring device G 1, rotate the crankshaft in
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Compression top
1
5
3
6
2
4
Injector to adjust
2
4
1
5
3
6
Loosen lock nut (2), then fully loosen adjustment
screw (1) of the injector to be adjusted, then
tighten it by hand.
Check that the socket at the tip of the rocker
arm and the ball of the push rod are both fitted securely into the injector and push rod,
respectively.
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4.
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nal position.
~ Cylinder head mounting bolt :
9.8 1.0 Nm {1 0.1 kgm}
2. Remove the cylinder head cover.
5. Tighten adjustment screw (1), repeat the loosening operation, then tighten finally.
~ Adjustment screw:
1st time : 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
2nd time: Loosen fully
3rd time : 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
4th time : Loosen fully
5th time : 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
12-10
®
AT04815
170-3 SERIES
Page 5 of 6
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
5. Tighten locknut (4) to hold adjustment screw (3)
in position.
~Locknut:
*
57.8 - 77.4 Nm {5.9 - 7.9 kgm}
After tightening the locknut, check the clearance again.
3.
Using barring device G1, rotate the crankshaft in
the normal direction to set No. 1 cylinder at compression top dead center, and align pointer b
with the [1.6TOP] line a on the crankshaft pulley.
At compression top dead center, the valve
rocker arm can be moved by hand by the
amount of the valve clearance. If the rocker
arm does not move, the crankshaft is not at
compression dead center, so rotate it one
more turn.
6. Turn the crankshaft 120° each time in the normal
direction and repeat the procedure in Steps 3 to
5 to adjust the valves of each cylinder according
to the firing order.
Firing order : 1 - 5 - 3 - 6 - 2 - 4
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Remove the cylinder head cover.
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2.
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1. Remove the cover of the flywheel housing, then
install barring device G1.
7. After completing the measurement, set to the
original condition.
~ Cylinder head cover mounting bolt:
9.8±1.0 Nm {1±0.1 kgm}
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4. To adjust the valve 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 adjustment screw until the clearance is a sliding fit.
Valve clearance
Intake valve: 0.32 mm
Exhaust valve: 0.62 mm
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170-3 SERIES
12-9
@
AT04815
Page 6 of 6
Check table for the serial numbers of main machine models applicable to this modification
Serial No. of the engine
No.
Applicable
machine model
Machines shipped with the
modification
completed
#311590 ~
#52001 ~ #52131
#52132 ~
WA600-3D
#311590 ~
#53001 ~ #53054
#53055 ~
3
WA600-AC-3
From the next
shipment
–
4
WA600-3
#311590 ~
#54001 ~ #54013
#54014 ~
5
WD600-3
#311590 ~
#50001 ~ #50012
#50013 ~
6
WA700-3
#311590 ~
#51001 ~ #51024
#51025 ~
7
HD465-7
#311590 ~
#7001 ~ #7269
#7270 ~
8
HD605-7
#311590 ~
#7001 ~ #7129
#7130 ~
9
D375A-5
#311590 ~
#18001 ~ #18254
#18255 ~
10
PC1250-7
#311590 ~
#20001 ~ #20169
#20170 ~
11
A6D170E-G1-3
#311327 ~
12
A6D170E-KC
13
170CUM-PG3
14
170CUM-IND
15
#311590 ~
#311590 ~
#311590 ~
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19
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AT04815
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~ #310648
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Machines
in the field
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WA600-3A
Engines shipped with the
modification
completed
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1
Engines
in the field
Serial No. of the machine