Teste & Ajuste

para o Tier3 Engine

1, Teste de pressão de impulso

2, Teste de temperatura dos gases de escape
3, Ajuste da folga da válvula
4, Teste de pressão de compressão
5, Teste de pressão de sopro
6, Teste de pressão do óleo do motor
7, Manuseio de peças do sistema de combustível
8, Liberando a pressão residual do sistema de combustível
9, Teste de pressão de combustível
10, modo de corte do cilindro de manuseio
11, Manuseamento Sem modo de manivela de injeção
12, Teste de retorno de combustível e quantidade de vazament
Ref. No. : 5022-01-00E
1
3, Adjusting valve clearance

Item de manutenção periódica a cada 2000h

125E-5 107E-1

In case of Tier3 engines with 4 valves.

You must adjust valve clearance when replacing the injectors.

2
3, Ajuste da folga da válvula
Como verificar a posição No. 1
Top

95E-5 sem ponteiro

1,4 Top : Entalhe correspondente do anel
do sensor Ne
e marca '1,4 Top' na capa.

3
3, Adjusting valve clearance

How to check No. 1 Top position

95E-5 without pointer

1,4 Top : Remove the plug (c) on flywheel housing .
Matching hole on flywheel and white paint mark on fly wheel.

Barring
You can use barring tool for 102 engine.
Or you can use center bolt for mounting crank pulley.
(Turning only tighten direction.)
4
3, Adjusting valve clearance

How to check No. 1 Top position

107E-1 without pointer

1,6 Top : There is a groove on dumper. Set this groove top direction.

Barring
You can use barring tool for 102 engine.
Or you can use bolt for mounting dumper.
(Turning only tighten direction.)
5
3, Adjusting valve clearance
How to check No. 1 Top position
(on shop manual)

Turning crankshaft and set notch on

sensor ring(c) to Ne sensor block(b).

[CAUTION]
When setting this position cylinders
below are not compression top dead
center.(76-88 deg BTDC)

4D107 : No. 1,4 6D107 : No. 1,6

４Ｄ１０７ ６Ｄ１０７
№ １ ２ ３ ４ № １ ２ ３ ４ ５ ６
ＥＸ ● ○ ● ○ ＥＸ ● ○ ○ ● ● ○
ＩＮ ○ ● ○ ● ＩＮ ○ ● ○ ● ○ ●
6
3, Adjusting valve clearance

How to check No. 1 Top position

114E-3
1,6 top : Set paint mark to top direction.
or
Set the curved line on supply pump gear
to top direction.
(A cap for supply pump gear is removable easily.)

Barring
You can use barring tool for 102 engine.
Or you can use bolt for mounting dumper.
(Turning only tighten direction.)
7
3, Adjusting valve clearance

How to check No. 1 Top position

125/140E-5 / 12V140E-3 with pointer
1,6 top : Set curved line on dumper to a pointer.

Barring
You can use bolt for mounting dumper.
(Turning only tighten direction.)

12V140 & 170

Special barring tool is installed as standard.
12V140E-3 You can use it for barring.

8
3, Adjusting valve clearance

How to check No. 1 Top position

170E-5
There is a checking hole on flywheel housing beside of supply pump.(Remove a
plug before checking.)
No.1 Top :Set the notch(1 notch) on supply pump gear to checking hole.(If you fine
2 notches ,it’s No. 6 top position.

170E-5

Barring
170
Special barring tool is installed as standard.
You can use it for barring.
9
3, Adjusting valve clearance

Valve clearance for Tier3 engine

Model Intake Exhaust

95 0.35 0.50
107 0.25 0.51
114 0.30 0.56
125 0.33 0.71
140 0.35 0.57
170 0.32 0.62
10
Testing for Rail Press Low Error

CA559 Rail Press Low Error

Logic for detecting CA559

The error code 'CA559' appear when there is a difference
between command rail pressure and actual rail pressure.

ECM Actual
Rail Press
Pressure
sensor
Common
rail
Feed back
Calculation for
control
Command IMV current
(Fuel delivery of ＩＭＶ
Rail Press
supply pump)
Ex) Rail pressure doesn't
Big increase even when supply
difference Pump is working with
maximum fuel delivery.
‘CA559’ (IMV open fully)

11
 Testing for Rail Press Low Error

Cause of ‘CA559’ Items should be

inspected
[supply pump can’t suck the fuel] 1, Testing fuel pressure
-Clogging Pre-filter of low pressure circuit
-Clogging Main filter -main filter input pressure
-Air into the suction hose
-Feed pump failure
-Etc.

[Fuel leak from CR components] 2, Checking CR components

Measuring
-Fuel leak from pressure limiter -fuel leak amount from pressure limiter
-supply pump failure -fuel return amount from supply pump
-Injector failure -fuel return amount from injectors.

12
 Testing for Rail Press Low Error

107E-1 HPCRI System diagram

Injector

Injector

Injector

Injector

Injector

Injector
2, Checking
Injector drive current CR components
Fuel return
from Injectors
Sensor signal

Sensor Common Rail Fuel leak from

Pressure lmiter
Pressure limiter
ECM

Fuel return from

IMV drive current Fuel Tank
supply pump
ＩＭＶ Supply
Feed Pump
Pump

Main Filter Pre-Filter

1, Checking low pressure fuel circuit

13
 9, Measuring fuel pressure 95E-5 Engine

95E-5

Supply pump assy

Feed Pump

Main filter
Measuring Main filter input pressure
(Negative Pressure)
Priming Pre filter
Pump Standard Value
-49 – 0 [kPa]
(-0.5 – 0 [kg/cm2])
Tank
@Hi idle
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9, Measuring fuel pressure 107E-1 Engine

107E-1 Engine

Measuring main filter inlet pressure

@ Lo idle or No-Injection cranking

Standard Value
@ Lo idle
0.5 – 1.3 [MPa](5.1 – 13.3 [kg/cm2])
@ No-Injection cranking
0.3 – 1.1 [MPa] (3.1 – 11.1 [kg/cm2])
15
9, Measuring fuel pressure 125 &up Engine

Ex.) 125E-5

Measuring Main filter inlet pressure

(using Air bleeding plug on filter head)

Standard Value
@Hi idle 0.15 – 0.3 [kPa](1.5 – 3.0 [kg/cm2])

16
9, Measuring fuel pressure 107 Engine

Ex. )Measuring fuel pressure of fuel return circuit

Measuring fuel pressure of fuel return circuit

Standard Value
@Lo idle
Less than 0.02 [MPa](0.19 [kg/cm2])

@No-Injection cranking
Less than 0.02 [MPa](0.19 [kg/cm2])
17
9, Measuring fuel pressure 107 Engine

Ex. )Measuring fuel pressure of Negative pressure circuit

Supply Pump

Main-Filter

Pre-Filter
Feed Pump

Measuring fuel pressure of feed pump inlet

Standard value
@Hi idle
Less than -50.7 [kPa] (-380 [-380mmHg])
18
12, Testing fuel return and leak amount

Measuring fuel leak amount from pressure limiter 2, Connect a drain hose
for measuring.

Ex. )107 E-1

1, Remove the hose.

3, The end of hose put

into the graduated
cylinder.

19
12, Testing fuel return and leak amount

Standard Value
95E-5
@Hi-idle
Fuel leak amount 0 [cc/min] (Max, 20 [cc/min])

114E-3
@Lo idle
Fuel leak amount Under 30 drops / min

125/140 E-5
@ 1600[rpm] with Rated output
Fuel leak amount Less than 10 [cc/min]

170 E-5
@ 1600[rpm] with Rated output
Operating T/C Stall test or Hydraulic relief test
Fuel leak amount Less than 10 [cc/min]

20
12, Testing fuel return and leak amount

Measuring fuel return amount from supply pump

1, Remove fuel return 2, The end of hose put
hose from supply into the graduated
pump cylinder.
Only 107/114

107E-1
Standard value
@Lo idle Less than 400 [cc/25sec]
114E-3
@Lo idle
Less than 300 [cc/30sec]
@No-Injection cranking
Less than 200 [cc/30sec]

Don’t keep cranking over 20 seconds.

21
 12, Testing fuel return and leak amount

Measuring fuel return amount from Injectors

1, Remove return pipe 2, The end of hose put
Ex. )107 E-1 and install measuring into the graduated
hose cylinder.

95E-5
Measuring at each engine speed with rated
output after warming up.
Standard Value
@1600[rpm] 190 [cc/min]
@1700[rpm] 200 [cc/min]
@1800[rpm] 210 [cc/min]
@1900[rpm] 220 [cc/min]
@2000[rpm] 230 [cc/min]
107E-1
Measuring after warming up.
Standard Value
@Lo idle Less than 180 [cc/min]
@No-Injection cranking Less than 190 [cc/min]
114E-3
Measuring after warming up.
Standard Value
@Lo idle Less than 300 [cc/45sec]
@No-Injection cranking Less than 100 [cc/30sec]
22
 12, Testing fuel return and leak amount

Measuring fuel return amount from Injectors

1, Install the measuring hose on fuel return block

125/140/170 Engine
Measuring at each engine speed with rated
output after warming up.
Standard Value
@1600[rpm] 960 [cc/min]
@1700[rpm] 1020 [cc/min]
@1800[rpm] 1080 [cc/min]
例〔６Ｄ１２５〕 @1900[rpm] 1140 [cc/min]
@2000[rpm] 1200 [cc/min]

2, Place the other end of

the hose into the
graduated cylinder.

23