Machine Systems
SAA6D170E-5
Engine D375A-6
SAA6D170E-5
Komatsu America Corp.
Cartersville Georgia USA
Copyright © 2009 All rights reserved.
Copyright © 2009 Training Presentation CTT0005609E0
Engine
Objectives
By completing this lesson, you will:
● Have a better
understanding of the engine
and its components
● Correct diagnostics and
troubleshooting procedures
● Correct engine test
methods
Copyright © 2009 Training Presentation CTT0005609E0
Engine
Machine Specific Installations (Right Side)
1. Muffler
5
2. Coolant Pump 1
3. Starters
4. Turbo
5. Air Intake Box
6
6. EGR Valve
4
7. Heater Valves
8. Powertrain 3
cooler
7 8
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Engine
Machine Specific Installations (Left Side)
1. Alternator
2. A/C Compressor
3. Oil Filters
4. Main Fuel 4
Filter 1
5. Pre Filters
6. ECM
7. Fill Tube
8. Dip Stick 2
3
6
7 5
8
Copyright © 2009 Training Presentation CTT0005609E0
Engine
HPCR Fuel System
1. High Pressure
Pump
2. ECM (engine 2
control
module)
3. Inlet to High 5
Pressure
Pump
4. Fuel Overflow
valve
5. Fuel Rail
3
6. Gear Pump
inlet line from
Pre-filter 7
7. Gear Pump 4
outlet to main
filter 6
Copyright © 2009 Training Presentation CTT0005609E0
Engine
HPCR Fuel System
8. High pressure
outlet to fuel
rail
9. Injector X 6 9
10. Fuel Tank
11. Main Fuel
Filter
12. Pre Fuel Filter
X2 10
13. PCV Valve 8
14. Electric 14 11
Priming Pump
15. Manual
Priming Pump 13
16. Gear Pump
15 12
16
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Engine
Engine Fuel System Components
● High Pressure Pump
● Injector
● Fuel Rail
● Mechanical Priming Pump
● Electric Priming Pump
● Fuel Tank
● Main Filters
● Pre Filters
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Engine
High Pressure Supply Pump
1. High Pressure Pump 2
2. Priming Pump
3. PCV Valve 3
4. Air Bleed Valve
5. Feed Pump 5
4 1
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Engine
Injector and Cylinder Head
1. Cylinder Head 2
2. Fuel Injector
3. Fuel Connector Tube 1
3
2
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Engine
Fuel Rail
3
1. Fuel Rail
2. Spray Prevention Caps
3. Pressure Limiter
4. Pressure Sensor
4
5. Main Fuel Filter
1
2
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Engine
Mechanical Priming Pump
1
1. Priming Pump
2. High Pressure Pump
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Engine
Electrical Fuel Priming Pump
1. Electric Pump
2. Pump Mounted on Engine
1
3. ECM
4. Pre Filters
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Engine
Fuel Tank
1
1. Fuel Tank
2. Additional Sump
3. Fuel Shut Off
4. Sediment Drain
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Engine
Main Filter
1. Main Filter
2. Air Bleed Valve
3. Pre Filter
1 2
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Engine
Pre Filters
1. Pre Filters
1
2. Sediment Bowl
3. ECM
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Engine
Engine Electrical Sensors and Switches
● NE Sensor
● G Sensor (back up sensor)
● Coolant Temperature
● Fuel Temperature
● Oil Pressure
● Oil Temperature
● Ambient Pressure
● Boost Pressure
● Intake Temperature
● Boost Temperature
● Exhaust Temperature
● Blow by Pressure
● Engine Oil Level
● Air Cleaner Clogging
● EGR Position
● Coolant Level
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Engine
Sensor (NE Speed Sensor)
NE Engine
Speed
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Engine
Sensor (G Sensor)
G Engine
Speed
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Engine
Sensor (Coolant Temperature)
Coolant
Temp
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Engine
Sensor (Fuel Temperature)
Fuel
Temp
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Engine
Sensor (Oil Pressure and Temperature)
Oil
Pressure
Oil
Temperature
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Engine
Sensor (Atmospheric Pressure)
Atmospheric
Pressure
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Engine
Sensor (Boost Pressure)
Boost
Pressure
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Engine
Sensor (Intake Temperature)
Intake
Temp
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Engine
Sensor (Boost Temperature)
Boost
Temperature
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Engine
Sensor (Exhaust Temperature)
Exhaust
Temperature
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Engine
Sensor (Blow By Pressure)
Blow By
Sensor
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Engine
Sensor (Air Cleaner Clogging)
Air Cleaner
Clogging
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Engine
Sensor (EGR Position)
EGR
Position
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Engine
Sensor (Coolant Level)
Coolant
Level
Copyright © 2009 Training Presentation CTT0005609E0
Engine
Testing Engine
● Engine Speed
● Boost Pressure
● Exhaust Temperature
● Blow By Pressure
● Engine Oil Pressure
● Fuel Supply Pressure
● Bleeding Air From Fuel System
● Measuring Engine Fan speed
● Measuring Fan Hydraulic Circuit Pressure
Copyright © 2009 Training Presentation CTT0005609E0
Engine
Testing (Engine Speed)
1. Adjustment Code 0530 for
Stall speeds
2. Adjustment Code 0007 for
Maximum High Idle Decel
Cut Mode
1
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Engine
Testing (Boost Pressure)
1. Using Monitoring Mode for
Testing Boost Pressure 1
2. Using PM Clinic Mode For
Testing Boost Pressure
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Engine
Testing (Exhaust Temperature)
1
1. Using Warm Up Function
2. Using PM Clinic to Monitor
Exhaust Temperature
3. Using Monitoring Function
to Monitor Exhaust
Temperature
3
2
Copyright © 2009 Training Presentation CTT0005609E0
Engine
Testing (Blow By Pressure)
1
1. Testing Blow By Pressure
Using the PM Clinic Mode
2. Testing Engine Blow By
Using the Monitoring Mode
Function
3. Test Blow By Pressure
using the Engine Test Kit
2
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Engine
Testing (Engine Oil Pressure)
1
1. Testing Engine Oil
Pressure Using Monitoring
Code Function
2. Remove Oil Pressure Test
Plug
3. Testing Engine Oil
Pressure Using manual
Gauge
3 2
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Engine
Testing (Fuel Pressure Supply)
1. Testing Fuel Supply 3
Pressure
2. Install Test Fitting in Fuel
Bleeder
3. Test Low Pressure Supply
1
Only
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Engine
Testing (Bleeding Air From Fuel Circuit)
1. Fuel Tank Valve 2
2. Air Bleeding Valve
3. Priming Pump On/Off
switch
4. Pump Operation Lamp
3
4
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Engine
Testing (Measuring Fan Speed)
1. Testing Fan Speed Using
Adjustment Mode 1
2. Testing Fan Speed Using
Electronic Photo Tach
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Engine
Testing (Fan Circuit Oil Pressure)
1. Testing Fan Circuit Oil
pressure Using Test 2
Gauge
2. Using 100% Fan Speed
Mode of the Adjustment
Mode
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Engine
Testing (Bleeding Air From Fan Pump)
1. Hydraulic Oil Level
2. Air Bleeder for HPV90
2 3
Pump
3. Air Bleeder for HPV30
Pump
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Engine
FIN
Copyright © 2009 Training Presentation CTT0005609E0
