How to calibrate the cylinder of Yanmar 3TNV and 4TNV engines

This article describes how to calibrate the cylinders of Yanmar 3TNV and 4TNV engines

 

 

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1) Slight uneven worn, flawed, etc. shall be

corrected by honing only.    If the cylinder is

unevenly worn partially, flawed or otherwise

damaged and cannot be repaired simply by

honing, rebore the cylinder first and then hone. See 4.4.5.(1)(c) for the boring dimension.

2) Items to be prepared for honing

l Flex-Hone

(see No.8 of 4.1.2 in Chapter 4)

l Electric drill

l Honing fluid

(50:50 mixture of lube oil and diesel oil)

 

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3) Apply the honing fluid to the Flex-Hone and turn   the electric drill at 300 to 1200 rpm.    Then insert the Flex-Hone into the cylinder bore while turning it, and move it up and down for about 30 sec. to   obtain a honing mark with a cross hatch angle of

30 to 40 .

[NOTICE]

1) Avoid faster revolution than 1200 rpm since it may cause breakdown.

2) Do not insert or extract the Flex-Hone in    stopped state because the cylinder will be 

                                                                              

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Caterpillar 311F LRR EXCAVATOR Troubleshooting of Oil in Coolant

caterpillar 311F LRR EXCAVATOR Oil in Coolant Possible Causes

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 • Engine Oil Cooler

 • Cylinder Head Gasket 

• Cylinder Head 

• Cylinder Block

Troubleshooting Test Procedure: 

1. Engine Oil Cooler

A. Drain the coolant from the cooling system. Drain the lubricating oil from the engine oil cooler. Refer to the Operation and Maintenance Manual for more information.

  B. Check the engine oil cooler for leaks. Refer to Systems Operation, Testing and Adjusting, "Cooling System" for the correct procedure. Result and Action: 

A leak was found in the engine oil cooler. Install a new oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" and Disassembly and Assembly, "Engine Oil Cooler - Install" for the correct procedure. Flush the cooling system. Refer to the Operation and Maintenance Manual for the correct procedure. Refill the cooling system with the appropriate coolant. For recommended coolant and volume,

  2. Cylinder Head Gasket

A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove". 

 

 B. Inspect the cylinder head gasket for damage and any signs of leaks   

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Results and Actions:

Result: The cylinder head gasket shows no signs of damage or leaks. 

Install a new cylinder head gasket, then install the cylinder head. Refer to

 Disassembly and Assembly, "Cylinder Head - Install".   

Result: The cylinder head gasket shows signs of damage or leaks.

Go to Test Step 3.  

 3. Cylinder Head

A. Inspect the cylinder head for cracks.

 

Perform a leak test on the cylinder head. Refer to Systems Operation, Testing and Adjusting, "Cylinder Head - Inspect" for the correct procedure.

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Result and Actions:

 Damage was found in the cylinder head.

Repair or replace the cylinder head.

  Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

 Result: No damage found in cylinder head.

 

  4. Cylinder Block A. Inspect cylinder block upper surface for signs of wear and leaks. Refer to Systems Operation, Testing, and Adjusting, "Cylinder Block - Inspect" for the proper procedure.

  Result and Action:

: Damage found in cylinder block. Repair or replace cylinder block. Inspect top deck. Refer to Reuse and Reconditioning Guide for the proper inspection procedure. Result: No damage found in cylinder block. Install cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

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Caterpillar excavator air conditioning fault code: MID 122 - CID 0168 - FMI 00 troubleshooting

 About this article：Caterpillar excavator air conditioning fault code: MID 122 - CID 0168 - FMI 00 troubleshooting

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All R134a products for air conditioning and heating for all Caterpillar machines

NOTE: The Schrader valves used on the high and low pressure sides of the A/C system are located in the 149-2491 A/C Connector Assembly which contains the 3E-4051 Seal Cap and 3E-4057 Valve Assembly on the low pressure side. The 236-9888 A/C Connector Assembly which contains the 3E-4052 Seal Cap and 3E-4058 Valve Assembly on the high pressure side. NOTE: The portable flushing unit is only permitted when using 153-8538 Refrigerant Flushing Fluid and all procedures should be performed in accordance with Testing and Adjusting, SENR5664, "Refrigerator Systems - Flushing". Refrigerant flushing fluid may only be reused after filtering.

 Conditions that generate this code:

This diagnostic code is logged when the diagnostic circuitry within Product Link detects a system voltage greater than 32 VDC.

Possible causes of this fault are as follows:

• A charging system component has failed. 

 • A harness wire has failed. 

• There is a fault in the Product Link, but Product Link is not likely to be   

NOTE: Determine if a battery charger or welder is in use on the machine. Disconnect any charger or welder in use.

Recheck for diagnostic codes. 

TEST PROCEDURE 1. CHECK PRODUCT LINK SYSTEM VOLTAGE. 

A. Start the engine and run it at high idle for 5 to 10 minutes.

B. Measure the system voltage between the "Unswitched Power" and "Ground" contacts. Pin 52 is the "Unswitched Power" terminal and pin 65 is the "Ground" terminal. 

Expected Results:

The voltage is 11 VDC to 32 VDC.

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Result:

• OK - The voltage is 11 VDC to 32 VDC. Product Link should not log this diagnostic code.

Repair: Clear the diagnostic code from Product Link using Caterpillar Electronic Technician (Cat ET). If the voltage is OK and Product Link logs this diagnostic code again, the Product Link may need to be replaced. Before replacing the Product Link, contact your Caterpillar Technical Communicator.

STOP

• NOT OK - Voltage is not 11 VDC to 32 VDC. Go to Test Step 2. TEST STEP 2. CHECK THE ALTERNATOR. A. Run the engine at high idle for 5 to 10 minutes. 

 B. Measure the voltage output at the battery terminals.  

EXPECTED RESULT:

The voltage should be less than 32 VDC. RESULTS:

• OK - Voltage is less than 32 VDC. The battery may be faulty. Go to Test Step 3.

 • NOT OK - Voltage is greater than 32 VDC. Troubleshoot the alternator. The voltage regulator may be faulty. If the condition is not corrected, go to Test Step 3. TEST STEP 3. CHECK THE BATTERY VOLTAGE. Turn the key start switch to the OFF position. Measure the voltage at the battery terminals.  

EXPECTED RESULT: The voltage should be less than 32 VDC.

Result: • OK - Voltage is less than 32 DCV. Go to Test Step 4. 

            • NO - Voltage is greater than 32 VDC. 

Repair: Refer to Special Instruction, REHS0354, "Charging System Troubleshooting".

If the condition is not corrected, go to Test Step 4. 

Test Step 4. Check each ECM on the machine.

Check the recorded diagnostic codes for other ECMs installed on the machine. Compare each ECM that has a recorded "CID 168 FMI 00" code for the same time period.

Note: The recorded service meter hours (SMH) may be different. The difference between the current SMH and the recorded SMH is significant.

Expected Results: Other "CID 168 FMI 00" diagnostic codes may be found on other Electronic Control Modules (ECMs).

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 Result:

 • Yes - Additional "CID 168 FMI 00" diagnostic codes can be found on other Electronic Control Modules (ECMs). Fix: Clear fault if all of the following occur: https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... Wednesday, October 17, 2018

◦ No faults were found in the charging system.

 ◦ No faults were found in the wiring. 

◦ The fault has recurred several times. 

Monitor the module and machine for further faults. If the fault recurs, the Product Link module is not the problem since other Electronic Control Modules are showing the same fault. Recheck system voltages.

Stop • No - Additional "CID 168 FMI 00" diagnostic codes cannot be found on other Electronic Control Modules (ECMs). Fix: Clear fault if all of the following occur: 

◦ No faults were found in the charging system. 

 ◦ No fault is found in the wiring. 

 ◦ The fault has recurred several times. Monitor the module and machine for further faults. If the fault recurs, the Product Link module may be faulty. The Product Link should be replaced. Refer to Systems Operation, Troubleshooting, Testing and Adjusting, "Electronic Control Module (ECM) - Replace". After replacing the Product Link, recheck the system and check the status of the diagnostic codes. 

 Stop

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307E and 307E2 Mini Hydraulic Excavators How to Release Hydraulic System Pressure Before Repairing the Hydraulic System

307E and 307E2 Mini Hydraulic Excavators Hydraulic System Pressure - Release Procedure Description: 

Before servicing a hydraulic circuit, you must release the hydraulic pressure in that circuit. Before disconnecting or removing any hydraulic lines from the following hydraulic circuits, release the pressure in that circuit.

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Before servicing a hydraulic circuit, you must release the hydraulic pressure in that circuit. Before disconnecting or removing any hydraulic lines from the following hydraulic circuits, release the pressure in that circuit. 

  Boom Hydraulic Circuit Aa23051448

Stick Hydraulic Circuit

Bucket Hydraulic Circuit

Swing Hydraulic Circuit

Travel Hydraulic Circuit

 Attachment Hydraulic Circuit (if equipped)

 Pilot Hydraulic Circuit

Return Hydraulic Circuit

 

  NOTE: Refer to the Disassembly and Assembly Manual for additional information on servicing specific hydraulic circuit components.

Hydraulic Pressure Relief for a Single Hydraulic Circuit   

                                               WARNING!

Hot oil or hydraulic fluid pressure can cause personal injury.

Hydraulic oil pressure remains in the hydraulic system after the engine is stopped. Serious injury could result if pressure is not relieved before servicing the hydraulic system.

 Before removing hydraulic system components or lines, make sure all work tools are lowered to the ground and the hydraulic oil is cold. Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with bare hands.

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NOTICE：

 During inspection, maintenance, testing, adjustment, and repair of the product, care must be taken to ensure that drained fluid is contained. Have a suitable container ready to collect fluid before opening any compartment or disassembling any component that contains fluid. 

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for appropriate tools and supplies for collecting and containing fluids on Cat products.

 

 
Perform the following steps to relieve hydraulic pressure from a single hydraulic circuit of the main hydraulic system.

1. Park the machine on level ground. 

2. Fully retract the stick cylinder rod. Position the bucket so that it is parallel to the ground. Lower the boom until the bucket is level on the ground. Refer to Illustration 1.

 3. Shut off the engine. 

 4. Turn the engine start switch to the ON position, but do not start the engine. 

5. Place the hydraulic start control lever in the unlocked position. 

 6. Move the joystick or pedal to the FULL STROKE position for only the hydraulic circuit that needs service. This will relieve high pressure in that single hydraulic circuit only. This will also relieve any pressure that may be present in the pilot hydraulic circuit. Note: If the hydraulic circuit that needs service requires an operating switch to be activated, activate the appropriate operating switch on the hydraulic circuit. 

7. Place the hydraulic start control lever in the LOCKED position. 

8. Turn the engine start switch to the OFF position.

  9. Slowly loosen the filler plug on the hydraulic tank to relieve pressure from the hydraulic tank. The filler plug should remain loosened for at least 45 seconds. This will relieve any pressure that may be present in the return hydraulic circuit. 

10. Tighten the fill plug on the hydraulic tank to the specified torque. 11. Pressure is now relieved in the single hydraulic circuit that requires service and lines and components may be disconnected or removed from that circuit.  

  Dispose of all fluids in accordance with local regulations and requirements.

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