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Shop
Manual
170E-5 SERIES
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
170E-5 Series
170E-5 Series 1
SEN00192-04 00 Index and foreword
01 Specification SEN00194-01
Specification and technical data SEN00195-01
40 Troubleshooting SEN00201-00
General information on troubleshooting SEN00369-00
Troubleshooting of mechanical system (S-mode) SEN00370-00
Troubleshooting of electrical system (E-mode), Part 1 SEN00371-00
Troubleshooting of electrical system (E-mode), Part 2 SEN00372-00
2 170E-5 Series
00 Index and foreword SEN00192-04
Table of contents 1
00 Index and foreword
Index SEN00192-04
Organization list of the shop manual ....................................................................................... 2
Table of contents ..................................................................................................................... 3
01 Specification
Specification and technical data SEN00195-01
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 5
General view............................................................................................................................ 10
Weight table............................................................................................................................. 19
Engine performance curves..................................................................................................... 20
170E-5 Series 3
SEN00192-04 00 Index and foreword
40 Troubleshooting
General information on troubleshooting SEN00369-00
Points on troubleshooting ........................................................................................................ 2
Error code and failure code table............................................................................................. 4
Troubleshooting of mechanical system (S-mode) SEN00370-00
Method of using troubleshooting charts................................................................................... 3
S-1 Starting performance is poor ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 8
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operations......................................................................................... 13
S-5 Engine does not rotate smoothly....................................................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 18
4 170E-5 Series
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170E-5 Series 5
SEN00192-04 00 Index and foreword
6 170E-5 Series
SEN00192-04
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (01)
8
SEN00193-01
170E-5 Series
170E-5 Series 1
SEN00193-01 00 Index and foreword
Safety notice 1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 170E-5 Series
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3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
170E-5 Series 3
SEN00193-01 00 Index and foreword
4 170E-5 Series
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q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
170E-5 Series 5
SEN00193-01 00 Index and foreword
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
6 170E-5 Series
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3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
170E-5 Series 7
SEN00193-01 00 Index and foreword
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 170E-5 Series
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170E-5 Series 9
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10 170E-5 Series
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
170E-5 Series 11
SEN00193-01 00 Index and foreword
12 170E-5 Series
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2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
170E-5 Series 13
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14 170E-5 Series
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
170E-5 Series 15
SEN00193-01 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
16 170E-5 Series
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6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
170E-5 Series 17
SEN00193-01 00 Index and foreword
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
18 170E-5 Series
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2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
170E-5 Series 19
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(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 170E-5 Series
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
170E-5 Series 21
SEN00193-01 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
22 170E-5 Series
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Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
170E-5 Series 23
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a Fig. A a Fig. B
24 170E-5 Series
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170E-5 Series 25
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5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
26 170E-5 Series
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8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
170E-5 Series 27
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Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
28 170E-5 Series
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Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
170E-5 Series 29
SEN00193-01 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 170E-5 Series
00 Index and foreword SEN00193-01
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
170E-5 Series 31
SEN00193-01 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
32 170E-5 Series
SEN00193-01
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 11-05 (01)
34
SEN00195-01
170E-5 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 5
General view ...................................................................................................................................... 10
Weight table ....................................................................................................................................... 19
Engine performance curves ............................................................................................................... 20
170E-5 Series 1
SEN00195-01 01 Specification
Outline 1
1. Applicable machine
2 170E-5 Series
01 Specification SEN00195-01
2. Outline of engine
q The 170E-5 engine is a high-performance and 4) To secure the high output of the engine, the
high-efficiency engine, which passed strict twin cooling nozzle to cool the piston employed
emission regulations (USA: EPA Regulations for 170E-3 and after models is improved to
for 2006, EU: Regulations for 2006, Japan: increase the durability of the piston and lower
Construction machinery regulations for 2006) the back side temperature of the piston. As a
and attained low fuel consumption, low noise, result, the lubricating oil on the piston is not
better exhaust gas color, and high acceleration exposed to high temperature, thus it is not
performance. Accordingly, this newly devel- deteriorated. Since the high-pressure fuel
oped engine is suitable as a power source of injection system controlled electronically is
construction machinery and industrial machin- employed, less soot is produced and the drain-
ery used for various purposes. ing interval of the oil is lengthened.
q The 170E-5 engine is the successor to the 5) The common rail high-pressure fuel injection
170E-3 engine. While it is an in-line 6-cylinder, system controlled electronically is employed.
water-cooled, 4-stroke diesel engine, it is This system can inject the fuel at high pressure
equipped with the common rail direct injection of 160 MPa {1,600 kg/cm2} from the low-speed
system and cooled EGR system of new tech- range to the high-speed range. In addition,
nologies. this system can control the form of injection
most properly by electronic control according
1) The main components of the cooled EGR sys- to the speed and load. By heightening the
tem are the EGR cooler of corrugated tube injection accuracy and employing multiple
type made of newly developed special stain- injection, exhaust gas of the cleanest level in
less steel and the EGR valve driven hydrauli- the world, good exhaust gas color, low fuel
cally and controlled electronically which consumption, and low noise are realized simul-
KOMATSU developed by itself. The cooled taneously.
EGR system secures the optimum EGR rate
from the low-speed range to the high-speed 6) The main fuel filter of high efficiency and the
range to attain both clean exhaust gas and low pre-fuel filter are installed as standard so that
fuel consumption with the bypass assist circuit the low grade fuel in the market (equivalent to
consisting of the venturi system and bypass Class NAS12) can be used. In addition, the
valve which has the same function and struc- priming pump used for replacing the filters is
ture as those of the EGR valve. electrified to improve serviceability.
2) The special EGR oil pump is employed to gen- 7) The high-quality piston which is made of cast
erate high oil pressure (1.47 MPa {15 kg/cm2}) iron and has the 2-stage combustion chamber
as the drive power source of the EGR valve of a new shape is employed. This piston has a
driven hydraulically and controlled electroni- less coefficient of thermal expansion, a reen-
cally. This pump has sufficient delivery for the trant combustion chamber, and a shaker cool-
EGR valve and increased output of the engine. ing gallery. As a result, clean exhaust gas,
As a result, the reliability and durability of the good exhaust gas color, and low fuel consump-
engine are improved. tion are attained simultaneously, and high
durability and reliability are also obtained.
3) The 170E-5 engine has 3 combination filters of
high performance and high efficiency to meet 8) By using the above-mentioned high-pressure
the requirements of the EGR system and high- fuel injection system controlled electronically,
dispersion oil and improve the ability to capture the multiple injection and injection characteris-
the soot in the oil. In addition, the recom- tics are set most properly to improve the start-
mended sub-materials for operation (oil and ability and reduce the white exhaust smoke
fuel) are changed to improve the reliability and when the temperature is low.
durability of the engine.
9) Engine controller is mounted on the engine
and equipped with the automatic high-altitude
compensation function, the engine can be
operated at high altitude without replacing the
controller. As a result, the serviceability is
improved.
170E-5 Series 3
SEN00195-01 01 Specification
4 170E-5 Series
01 Specification SEN00195-01
Specifications 1
(Gross)
No-load max. speed
rpm 7,900 ± 20
(High idle speed)
No-load min. speed
rpm 720 ± 30
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated output 227 {169}
{g/HP·h}
Dry weight kg 2,970
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 80 (80)
Quantity of coolant l 44 (For only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 7.5kW × 2
Battery — 12V, 200Ah × 2
Turbocharger — KOMATSU KTR130E
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
170E-5 Series 5
SEN00195-01 01 Specification
(Gross)
No-load max. speed
rpm 2,000 ± 40
(High idle speed)
No-load min. speed
rpm 900 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated output 218 {162}
{g/HP·h}
Dry weight kg 3,140
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 80 (80)
Quantity of coolant l 44 (For only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 11kW × 2
Battery — 12V, 200Ah × 2
Turbocharger — KOMATSU KTR130E
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
6 170E-5 Series
01 Specification SEN00195-01
(Gross)
No-load max. speed
rpm 2,000 ± 50
(High idle speed)
No-load min. speed
rpm 800 ± 25
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated output 227 {169}
{g/HP·h}
Dry weight kg 3,050
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 80 (80)
Quantity of coolant l 44 (For only engine)
Alternator — 24V, 90A
Starting motor — 24V, 11kW × 2
Battery — 12V, 200Ah × 2
Turbocharger — KOMATSU KTR130E
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
170E-5 Series 7
SEN00195-01 01 Specification
(Gross)
No-load max. speed
rpm 2,270 ± 50
(High idle speed)
No-load min. speed
rpm 750 ± 50
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated output 216 {161}
{g/HP·h}
Dry weight kg 3,120
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 80 (80)
Quantity of coolant l 44 (For only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 7.5kW × 2
Battery — 12V, 200Ah × 2
Turbocharger — KOMATSU KTR130E
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
8 170E-5 Series
SEN00195-01 01 Specification
General view 1
SAA6D170E-5 (Left side of engine)
Applicable machine: D375A-5
1. Center of crankshaft
2. Rear face of flywheel housing
10 170E-5 Series
01 Specification SEN00195-01
1. Center of crankshaft
2. Center of cylinder liner
170E-5 Series 11
SEN00195-01 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
12 170E-5 Series
01 Specification SEN00195-01
1. Center of crankshaft
2. Center of cylinder liner
170E-5 Series 13
SEN00195-01 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
14 170E-5 Series
01 Specification SEN00195-01
1. Center of crankshaft
2. Center of cylinder liner
170E-5 Series 15
SEN00195-01 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
16 170E-5 Series
01 Specification SEN00195-01
1. Center of crankshaft
2. Center of cylinder liner
170E-5 Series 17
SEN00195-01 01 Specification
Dimensions table
Unit: mm
Dimension of each part
Engine Machine
A B C D E F G H
D375A-5 1,854 2,130 550 25 — — 1,107 1,300
PC1250-8 1,800 2,032 560 222 — 1,000 1,185 1,215
SAA6D170E-5 WA600-6 1,795 1,935 543 41 41 930 1,060 1,154
HD465-7
2,044 1,732 550 210 — 346 396 1,243
HD605-7
a These dimensions are given for reference when the engine is set on a test bench.
18 170E-5 Series
01 Specification SEN00195-01
Weight table 1
Unit: kg
No. Item Main parts SAA6D170E-5
D375A-5 33.5
PC1250-8 36
1 Turbocharger KOMATSU KTR130E WA600-6 33.5
HD465-7
36
HD605-7
Cylinder head, valve,
2 Cylinder head assembly 46.5 × 6
valve spring
Cylinder block, bearing,
3 Cylinder block assembly 750
cap, cylinder liner
4 Front cover 47
5 Oil pan 56
D375A-5 82
PC1250-8 80
6 Flywheel assembly Flywheel, ring gear WA600-6 36
HD465-7
43
HD605-7
D375A-5 170
PC1250-8 150
7 Flywheel housing assembly WA600-6 150
HD465-7
150
HD605-7
8 Crankshaft assembly Crankshaft, crank gear 265
Camshaft, cam gear,
9 Camshaft assembly 51
thrust plate
Piston, piston ring, piston pin,
10 Piston and connecting rod assembly 22 × 6
connecting rod
11 Oil pump 10.2
12 Fuel supply pump 14.8
13 Water pump 16.2
24V, 60A 11
14 Alternator
24V, 90A 19
24V, 7.5kW 18
15 Starting motor
24V, 11kW 18
16 EGR oil pump 5.5
17 EGR valve 9.8
18 EGR cooler 11.5
19 EGR bypass valve ( 1) 9.8
170E-5 Series 19
SEN00195-01 01 Specification
20 170E-5 Series
01 Specification SEN00195-01
170E-5 Series 21
SEN00195-01 01 Specification
22 170E-5 Series
01 Specification SEN00195-01
170E-5 Series 23
SEN00195-01 01 Specification
24 170E-5 Series
SEN00195-01 01 Specification
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 11-05 (01)
26 170E-5 Series
SEN00197-01
170E-5 Series
170E-5 Series 1
SEN00197-01 10 Structure, function and maintenance standard
2 170E-5 Series
SEN00197-01 10 Structure, function and maintenance standard
A: Air inlet
B: To turbocharger (Intake air)
C: To muffler (Dust)
4 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
Number of
Engine Applicable machine Type Evacuator valve
elements
HD465-7 1 inner cylinder,
SAA6D170E-5 FRG (Radial seal type) Automatic discharge
HD605-7 1 outer cylinder
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (2).
q The dust and water separated by guide vane
(3) swirl along the inside wall of body (9) and
enter evacuator valve (6) and then are dis-
charged out automatically.
170E-5 Series 5
SEN00197-01 10 Structure, function and maintenance standard
Turbocharger 1
Model name: KTR130E (Water-cooled)
6 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Lubrication of turbocharger
q Engine oil supplied from above center housing
(3) lubricates each bearing and sliding part,
and then returns through the hole at the bottom
of the center housing to the engine oil pan.
170E-5 Series 7
SEN00197-01 10 Structure, function and maintenance standard
8 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit
1 End play (Play in axial direction)
0.08 – 0.13 0.18
Replace core
2 Radial play (Play in radial direction) 0.36 – 0.55 0.77 assembly
Clearance between blower housing
3 Clearance limit (Min.): 0.18
and impeller
170E-5 Series 9
10 Structure, function and maintenance standard SEN00197-01
EGR system 1
Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and trouble-
shooted, a serious trouble is prevented.
170E-5 Series 11
SEN00197-01 10 Structure, function and maintenance standard
a The above illustration shows the engine for HD465-7 and HD605-7.
12 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor ( 1)
7. Bypass piping ( 1)
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for open-
ing EGR valve (1) most properly according to
the load on the engine to attain both clean
exhaust gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust
gas (EGR gas) flows from the exhaust mani-
fold through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3)
flows through EGR valve (1) and mixes with
the intake air in venturi system (4), and then
flows in the air intake manifold.
q In the operating range where the boost pres-
sure is higher than the exhaust pressure on the
high load side, the EGR gas does not flow to
the air intake side easily. At this time, the
engine controller opens bypass valve (2). ( 1)
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the
exhaust pressure rises and more EGR gas
mixes with the intake air. ( 1)
170E-5 Series 13
SEN00197-01 10 Structure, function and maintenance standard
14 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
EGR cooler
Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to
increase the gas density, or the EGR effi-
ciency.
Structure
q The EGR cooler is a multi-tube heat
exchanger. When the high-temperature EGR
gas flows through heat exchange tube (1), it is
cooled by the coolant flowing outside of the
tube.
q Heat exchange tube (1) is made of corrosion-
resistant stainless steel and corrugated to
increase the cooling efficiency.
170E-5 Series 15
SEN00197-01 10 Structure, function and maintenance standard
Venturi system
Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), ven-
turi nozzle (1), and diffuser (3).
Operation
q The boost pressure increased by the turbo-
charger is set negative temporarily with the
venturi effect of the throat to take the EGR gas
into the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake
air flows through diffuser (3), its pressure is
increased again to the normal level and then it
flows in the intake manifold.
16 170E-5 Series
SEN00197-01 10 Structure, function and maintenance standard
Engine unit 1
Cylinder head 1
a. Fuel return
1. Cylinder head
2. Rocker arm housing
3. Cylinder head cover
4. Valve guide
5. Injector
6. Coolant air bleeder tube
18 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Specifications
Cylinder head
q Direct injection type
q 4-valve type
q Split type (1 cylinder, 1 head)
170E-5 Series 19
SEN00197-01 10 Structure, function and maintenance standard
a Tighten the cylinder head mounting bolts in the order of (1) – (9).
Unit: mm
No. Check item Criteria Remedy
Strain of cylinder head Tolerance Repair limit Correct by grind-
1
mounting surface Max. 0.05 0.1 ing or replace
Engine Standard Replace nozzle
2 Projection of nozzle
SAA6D170E-5 2.3 – 2.9 gasket
Bolt No. Procedure Target (Nm{kgm}) Range (Nm{kgm})
Tightening torque of cyl-
inder head mounting bolt 1st stage 245 {25} 235 – 255 {24 – 26}
Tighten in order
3 (apply anti-friction com- (1) – (7) 2nd stage 382 {39} 373 – 392 {38 – 40}
shown above
pound to bolt threads and 3rd stage Retighten 90° 90(+30/0)°
washer)
(8) – (9) — 98 {10} 93 – 103 {9.5 – 10.5}
Tightening torque of Target (Nm {kgm}) Range (Nm {kgm})
4
injector mounting bolt 66.7 {6.75} 58.8 – 73.5 {6 – 7.5}
Tightening torque of
5 rocker arm housing 86{8.75} 78 – 93 {8.0 – 9.5}
mounting bolt
Target (Nm {kgm}) Range (Nm {kgm}) Tighten
Tightening torque of cyl- No.1, 3 – 6
6 10 {1} 9 – 11 {0.9 – 1.1}
inder head cover cylinders
No.2 cylinder 66.7 {6.75} 58.8 – 73.5 {6 – 7.5}
Tightening torque of fuel Target (Nm {kgm}) Range (Nm {kgm})
7
injection pipe 41.7 {4.25} 39.2 – 44.1 {4 – 4.5}
20 170E-5 Series
SEN00197-01 10 Structure, function and maintenance standard
Cylinder block 1
22 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Specifications
Cylinder block Liner ring
q Crankshaft section: 7 bearings q Upper : Clevis seal
q Camshaft section: High cam type, 7 bearings q Middle : O-ring (Ethylene-propylene rubber)
q Main cap bolt: Plastic-region tightening q Lower : O-ring (Silicone rubber)
Front seal
q End seal with dust cover
Piston cooling
q With piston cooling nozzle (2 pieces for each
cylinder)
Cylinder liner
q Wet type
q Machining on inside: Plateau honing,Tufftriding
170E-5 Series 23
SEN00197-01 10 Structure, function and maintenance standard
24 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
size Inside diame- Outside diame- clearance limit Replace cylin-
Clearance between cylin-
1 ter of block ter of block der liner or
der block and liner
–0.00 –0.11 block
190.4 0.05 – 0.16 —
–0.06 –0.16
Inside diameter of main Standard size Tolerance Repair limit
bearing fitting hole
(Tighten bolt to specified +0.025
148 —
torque) –0.001
Replace
–0.038
Thickness of main bearing 4.0 —
2 –0.051
Inside diameter of main +0.127
140 140.20
bearing +0.076
Clearance between main Standard clearance Clearance limit
bearing and crankshaft
bearing 0.076 – 0.152 0.32
170E-5 Series 25
SEN00197-01 10 Structure, function and maintenance standard
Cylinder liner 1
Unit: mm
No. Check item Criteria Remedy
Permissible range: 0.07 – 0.15 Replace cylinder liner or
1 Projection of cylinder liner
Difference between cylinders: Max. 0.05 cylinder block
Standard size Tolerance Repair limit
+0.040
170 170.24
+0.000
Inside diameter
2
of cylinder liner Roundness 0.020 0.08
of inside
Cylindrical-
0.020 0.08
ity of inside
Outside diameter of cylinder Standard size Tolerance
liner (at bottom of counter-
bore portion) 194.5 194.565 – 194.615
3
Interference of cylinder liner
and block (at bottom of coun- Standard interference: 0.025 – 0.135 Replace cylinder liner
terbore portion)
Outside diameter of cylinder Standard size Tolerance
liner (at counterbore portion) 206 205.965 – 206.015
4 Interference of cylinder liner Standard clearance Clearance limit
and block (at counterbore Interference: 0.85 to
portion) —
Clearance: 0.025
Outside diameter of cylinder Standard size Tolerance
liner (at O-ring) 190.40 190.24 – 190.29
5
Clearance between cylinder Standard clearance Clearance limit
liner and block (at O-ring) 0.05 – 0.16 —
Dispersion of depth of coun- Standard Repair limit
6 Correct by grinding
terbore — 0.05
26 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
170E-5 Series 27
SEN00197-01 10 Structure, function and maintenance standard
Piston
Type: Shaker type
Made of ductile cast iron
Forced cooling with lubricating oil through piston
cooling nozzles (2 pieces/cylinder)
Specifications
Crankshaft
Made of forged special alloy steel, 7 bearings
Journal: Induction hardening
Camshaft
Journal and fillet: Induction hardening
28 170E-5 Series
SEN00197-01 10 Structure, function and maintenance standard
Crankshaft 1
30 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Unit: mm
No. Check item Criteria Remedy
Size Standard size Tolerance Repair limit
S.T.D. 140 139.91
Outside diameter of main 0.25 U.S. 139.75 139.66
1 –0.000
journal 0.50 U.S. 139.50 139.41
–0.025
0.75 U.S. 139.25 139.16
1.00 U.S. 139.00 138.91 Use undersize
Size Standard size Tolerance Repair limit journal or replace
S.T.D. 108.00 107.91
Outside diameter of crank 0.25 U.S. 107.75 107.66
2 –0.000
pin journal 0.50 U.S. 107.50 107.41
–0.022
0.75 U.S. 107.25 107.16
1.00 U.S. 107.00 106.91
Standard Repair limit
3 Roundness of journal Main journal Max. 0.010 0.015
Crank pin journal Max. 0.010 0.015
Tolerance Repair limit
4 End play
0.14 – 0.32 0.6
Standard size Tolerance Repair limit Replace
Thickness of main bearing
5 –0.038
(Median) 4.0 3.90
–0.051
Outside diameter of rear
6 170 ±0.019 —
flange
Bend or crankshaft (Overall Tolerance Repair limit
7
swing of indicator) 0.09 0.09
Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque of crank 1st stage 74 {7.5} 54 – 93 {5.5 – 9.5}
8 Tighten
pulley mounting bolt 2nd stage 245 {25} 226 – 265 {23 – 27}
3rd stage 637 {65} 618 – 657 {63 – 67}
170E-5 Series 31
SEN00197-01 10 Structure, function and maintenance standard
Camshaft 1
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Intake +0.103
78.233 78.00 Correct or
1 Height of cam cam –0.103
replace
Exhaust +0.103
77.252 77.00
cam –0.103
–0.035
2 Outside diameter of journal 90 89.98
–0.005
Replace
–0.00
3 Thickness of thrust plate 5 3.20
–0.05
Standard clearance Clearance limit Replace thrust
4 End play of camshaft
0.05 – 0.20 0.40 plate
5 Bend of camshaft Repair limit: 0.20 (Overall swing of indicator) Replace
32 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Connecting rod 1
Unit: mm
No. Check item Criteria Remedy
Tolerance Standard
Clearance between con- Standard size Clearance limit Replace (Spare
Shaft Hole clearance
1 necting rod bushing and bushing is half
piston pin –0.000 +0.049 worked)
68 0.030 – 0.055 0.075
–0.006 +0.030
Standard size Tolerance
Inside diameter of connect-
2 +0.026
ing rod large end hole 115
–0.000
Clearance between con- Standard clearance Clearance limit
3 necting rod large end bear-
ing and crankshaft bearing 0.058 – 0.132 0.34
170E-5 Series 33
SEN00197-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Outside diameter of pis- Standard size Tolerance Repair limit
1 ton (at 3.0 mm from pis- 170 –0.135
ton bottom and 20°C) 169.79
(At right angles to boss) –0.165
Tolerance Clearance limit
Standard
Ring Ring (When ring is
size
groove thickness new)
Check with piston groove
2 Piston ring groove Top ring Keystone wear gauge or check
0.15
second ring Keystone clearance between
piston and new ring
+0.05 –0.01 Replace
Oil ring 4.00 0.3
+0.03 –0.03
Standard clearance Clearance limit
Closed gap of piston Top ring 0.50 – 0.65
3
ring Second ring 0.70 – 0.85 1.8
Oil ring 0.50 – 0.70
Standard size Tolerance
Diameter of piston pin
4 +0.044
hole 68
+0.034
Outside diameter of pis- –0.000
5 68
ton pin –0.006
34 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
1. Rear seal
2. Ring gear (Number of teeth: 118 (Only D375A-5: 138))
3. Flywheel
4. Flywheel housing
5. Engine speed sensor
6. Burring device (Service tool)
170E-5 Series 35
SEN00197-01 10 Structure, function and maintenance standard
Vibration damper 1
1. Crank pulley
2. Pin (between crankshaft and crank pulley)
3. Pin (between crank pulley and vibration damper)
4. Vibration damper
5. Bolt (between crank pulley and vibration damper)
6. Bolt (between crankshaft and crank pulley)
36 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Gear train 1
Front side (for driving auxiliaries)
170E-5 Series 37
SEN00197-01 10 Structure, function and maintenance standard
Front side
38 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between idler size clearance limit
Shaft Hole
1 gear (large) bushing and
shaft +0.014 +0.063 0.025 – Replace bush-
47.6 0.25
+0.001 +0.039 0.062 ing
Clearance between idler
+0.014 +0.063 0.025 –
2 gear (medium) bushing and 47.6 0.25
+0.001 +0.039 0.062
shaft
Clearance of idler gear Standard clearance Clearance limit
3
(large) in axial direction 0.05 – 0.17 0.34 Replace thrust
Clearance of idler gear bearing
4 0.05 – 0.17 0.34
(medium) in axial direction
Level difference between
underside surfaces of gear Correct or
5 Tolerance: 0.15
train case cover and cylin- replace
der block
Posi-
Check parts Standard Repair limit
tion
Crank gear and main idler gear
A 0.134 – 0.326 0.5
(large)
Crank gear and main idler gear
B 0.114 – 0.320 —
(medium)
— Backlash of each gear Replace
Idler gear (medium) and alternator
C 0.114 – 0.320 0.5
drive gear
Idler gear (large) and water pump
D 0.121 – 0.333 0.5
drive gear
Idler gear (large) and oil pump
E 0.121 – 0.333 0.5
drive gear
170E-5 Series 39
SEN00197-01 10 Structure, function and maintenance standard
Timing gear 1
Rear side (for driving camshaft)
A: Timing mark
(Between crankshaft gear and idler gear)
B: Timing mark
(Between idler gear and crankshaft gear)
C: Timing mark
(Between camshaft gear and supply pump drive gear)
40 170E-5 Series
SEN00197-01 10 Structure, function and maintenance standard
42 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between idler size Shaft Hole clearance limit Replace bush-
1
gear bushing and shaft –0.027 +0.055 0.027 – ing
52 0.25
–0.040 +0.000 0.095
Clearance of idler gear in Standard clearance Clearance limit Replace thrust
2
axial direction 0.04 – 0.18 0.3 bearing
Posi-
Check parts Standard Repair limit
tion
Crank gear and main idler gear
A 0.155 – 0.412 0.6
(large)
— Backlash of each gear Replace
Idler gear (small) and camshaft
B 0.145 – 0.380 0.6
gear
Camshaft gear and fuel supply
C 0.007 – 0.559 0.6
pump drive gear
170E-5 Series 43
SEN00197-01 10 Structure, function and maintenance standard
Valve system 1
44 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Specifications
Camshaft: Made of special carbon steel, 7 bear-
ings
Journal and cam: Induction hardening
170E-5 Series 45
SEN00197-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit
Replace valve
1 Sinking distance of valve Intake and
0 0.80 or valve seat
exhaust valves
Standard size Tolerance Repair limit
2 Thickness of valve lip Intake valve 3.2 — 2.7 Replace valve
Exhaust valve 3.3 — 2.8
Standard Tolerance
3 Valve seat angle Intake valve 30° ±0°15'
Exhaust valve 45° ±0°15'
Standard size Tolerance Repair limit
Intake –0.060
Diameter of 11.90
valve –0.080
valve stem 12
4 Exhaust –0.092
11.80
valve –0.107
Inside diameter of valve –0.001 Replace
12 12.10
guide –0.019
5 Projection of valve guide 43 ±0.5 —
Installed load Allowable load
Free length Installed length
(N {kg}) (N {kg})
Valve spring
647 ± 65
6 99.6 87.4 608 {62.0}
{66.0 ± 6.6}
Perpendicularity of valve
Repair limit: 2°
spring
46 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance
Outside diameter of rocker Replace rocker arm
arm shaft –0.0150 shaft
45.0
–0.0280
170E-5 Series 47
SEN00197-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Depth of cross head stem
1 +0.3
receiver 7.5 —
+0.0
Inside diameter of cross +0.10 Replace
2 13 13.21
head +0.05
Outside diameter of cross +0.039
13 13.00
head guide +0.028
3
Clearance between cross Standard clearance Clearance limit
Adjust
head guide and cross head 0.011 – 0.072 —
Projection of cross head Standard size Tolerance
4
guide 86 ±0.25
Replace
Intake valve Exhaust valve
5 Valve clearance (cold)
0.32 0.62
Tightening torque of cross
6 59 ± 6Nm {6.0 ± 0.6 kgm} Tighten
head locknut
48 170E-5 Series
10 Structure, function and maintenance standard SEN00197-01
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Outside diameter cam fol-
1 –0.038
lower shaft 25 25
–0.053
Inside diameter of cam fol- +0.021
2 25 25
lower lever +0.000
Inside diameter of cam fol-
25.167 ±0.01 25.3
lower roller
3
Outside diameter of cam fol- +0.075 Replace
25 25
lower roller pin +0.063
Outside diameter of cam fol- +0.025
4 50 49.75
lower roller +0.000
Diameter of ball at push rod –0.0
5 15.836 —
end –0.2
Inside diameter of push rod –0.0
6 16.676 —
socket –0.2
170E-5 Series 49
SEN00197-01
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 11-05 (01)
50
SEN00198-01
170E-5 Series
170E-5 Series 1
SEN00198-01 10 Structure, function and maintenance standard
2 170E-5 Series
SEN00198-01 10 Structure, function and maintenance standard
Lubrication system 1
Lubrication system diagram 1
4 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
W. Coolant
1. Oil pan
2. Oil level sensor
3. Oil pump
4. Regulator valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Main gallery
10. Crankshaft
11. Camshaft
12. Rocker arm
13. Piston cooling nozzle
14. Timing gear (Rear side)
15. Auxiliary equipment drive gear (Front side)
16. Oil pressure gauge
17. Turbocharger
18. Bypass valve ( 1)
19. EGR valve
20. EGR oil pump
170E-5 Series 5
SEN00198-01 10 Structure, function and maintenance standard
Oil pump 1
1. Bushing Specifications
2. Drive gear (Number of teeth: 10) Type: Gear pump
3. Oil pump body Speed: Engine speed × 1.45
4. Drive shaft
5. Bushing
6. Pump cover
7. Oil pump drive gear (Number of teeth: 38)
8. Bushing
9. Driven gear (Number of teeth: 10)
10. Driven shaft
6 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
1. Valve
2. Spring
170E-5 Series 7
SEN00198-01 10 Structure, function and maintenance standard
8 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
size Thickness of Depth of clearance limit
Clearance of pump gear in
1 gear body
axial direction
0 +0.067 0.040 – 0.040 –
54
–0.030 +0.040 0.097 0.097
Tolerance Replace gear
Standard Outside Standard Clearance
size Inside diam- clearance limit
Clearance of pump gear in diameter of
2 eter of body
radial direction gear
–0.15 +0.04
54.99 0.15 – 0.25 0.15 – 0.25
–0.21 0
Standard Tolerance Clearance
Interference
Interference of driven shaft size Shaft Hole limit
3
and cover +0.090 +0.040 0.030 –
18 —
+0.070 +0.022 0.068
Interference of driven gear +0.090 +0.021 0.044 –
4 21 —
and bushing +0.065 0 0.090
Standard Tolerance Standard Clearance
Clearance between driven size Shaft Hole clearance limit
5
shaft and driven gear bushing +0.090 +0.147 0.032 – 0.032 –
18
+0.070 +0.122 0.077 0.077
Clearance between driven +0.090 +0.129 0.012 – 0.012 – Replace
6 18 bushing
shaft and body +0.070 +0.102 0.059 0.059
Clearance between drive +0.106 +0.173 0.040 – 0.040 –
7 18
shaft and bushing +0.088 +0.146 0.085 0.085
Standard Tolerance
Interference —
8 Interference of pump gear size Shaft Hole
and drive shaft +0.106 +0.064 0.024 –
18 —
+0.088 +0.043 0.063
Interference of body and +0.090 +0.021 0.044 –
9 21 —
body bushing +0.065 0 0.090
Interference of pump drive +0.106 +0.065 0.023 –
10 18 —
gear and drive shaft +0.088 +0.047 0.059
Tightening torque of pump
11 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm} Tighten
cover mounting bolt
Standard size Repair limit
Installed
Installed Installed load
12 Main relief valve spring Free length Free length load Replace
length N {kg}
N {kg}
— — 716 {73.0} — —
Main relief valve operating Correct or
13 Standard: 883 ± 49 kPa {9.0 ± 0.5 kg/cm2}
pressure replace spring
170E-5 Series 9
SEN00198-01 10 Structure, function and maintenance standard
10 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Oil cooler 1
Unit: mm
No. Check item Criteria Remedy
Full opening lift of thermo- Min. 8 mm (Check after soaking valve in oil tank at 100°C for 4 –
stat 5 minutes)
5 Check that valve closes fully when its temperature is lowered from Replace
Opening and closing of ther-
100°C for full opening to 85°C. (Check after soaking valve in oil
mostat
tank for 4 – 5 minutes)
170E-5 Series 11
SEN00198-01 10 Structure, function and maintenance standard
Fuel system 1
CRI system diagram 1
12 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
170E-5 Series 13
SEN00198-01 10 Structure, function and maintenance standard
2. Control system
14 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
q The CRI system consists of the fuel supply q If the TWV is turned on (energized), the fuel
pump, common rail, injector, engine controller circuit is so changed that the high-pressure
to control them, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The discharge rate is controlled by turning on q If the TWV is turned off (de-energized), the fuel
and off the PCV (pressure control valve) of the circuit is so changed that the high-pressure
fuel supply pump according to the electric sig- fuel will be applied to the control chamber
nals from the engine controller. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers and finishes fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
170E-5 Series 15
SEN00198-01 10 Structure, function and maintenance standard
16 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Operation
170E-5 Series 17
SEN00198-01 10 Structure, function and maintenance standard
18 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
2. Common rail
1) Flow damper
Function
q The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
Operation
When fuel is not injected
q Piston (2) is in contact with stopper (1) (initial
position).
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
170E-5 Series 19
SEN00198-01 10 Structure, function and maintenance standard
1. Ball
2. Housing
3. Spring
4. Guide
5. Body
20 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
3. Injector
Outline
q The function of the injector is to inject the high-
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
170E-5 Series 21
SEN00198-01 10 Structure, function and maintenance standard
Structure
22 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q At this time, the high-pressure fuel in the com-
(8), nozzle (1) is closed and the fuel is not mon rail is applied to pressure control chamber
injected. (8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q If solenoid (6) is kept energized, the fuel injec-
tion rate is increased to the maximum.
170E-5 Series 23
SEN00198-01 10 Structure, function and maintenance standard
24 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Various controls
q The CRI system controls the fuel injection rate 2. Fuel injection timing control function
and fuel injection timing more properly than the q The fuel injection timing control function is
mechanical governor or timer of the conven- employed instead of the function of the con-
tional fuel injection pump. ventional timer. It controls the fuel injection
q For the control of the system, calculations nec- timing most properly from the engine speed
essary to the engine controller are performed and fuel injection rate.
fr om th e si gn als se nt fr om the s en so rs
installed to the engine and machine.
q The energizing timing and energizing period of 3. Fuel injection pressure control function
the injector are so controlled that the optimum (Common rail fuel pressure control function)
quantity of fuel will be injected in the optimum q The fuel injection pressure control function
timing. (common rail fuel pressure control function) is
a function of measuring the fuel pressure with
1. Fuel injection rate control function the common rail fuel pressure sensor and
q The fuel injection rate control function is feeding it back to the engine controller to con-
employed instead of the function of the con- trol the delivery of the fuel supply pump.
ventional governor. It controls the fuel injection q This function performs pressure feedback con-
according to the signals of engine speed and trol so that the fuel injection pressure will be
accelerator angle so that the fuel injection rate the same as the optimum value (command
will be most proper. value) set according to the engine speed and
fuel injection rate.
170E-5 Series 25
SEN00198-01 10 Structure, function and maintenance standard
4. Various sensors
26 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
170E-5 Series 27
SEN00198-01 10 Structure, function and maintenance standard
28 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
170E-5 Series 29
SEN00198-01 10 Structure, function and maintenance standard
A: Mounting screw: M6
Tightening torque:
5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring
30 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
A: Pressure inlet
B: Mounting screw: M5
Tightening torque:
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
q The following graph shows the output charac-
teristics of the atmospheric pressure sensor.
170E-5 Series 31
SEN00198-01 10 Structure, function and maintenance standard
8) Engine controller
32 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
170E-5 Series 33
SEN00198-01 10 Structure, function and maintenance standard
Fuel piping 1
34 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
170E-5 Series 35
SEN00198-01 10 Structure, function and maintenance standard
Fuel filter 1
Main fuel filter
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.06 m2
36 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
1. Filter head
2. Cartridge
Specifications
With water separator
170E-5 Series 37
SEN00198-01 10 Structure, function and maintenance standard
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
38 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
1. Engine controller
2. Engine controller cooler
Outline
q The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
170E-5 Series 39
SEN00198-01 10 Structure, function and maintenance standard
Cooling system 1
Cooling system diagram 1
40 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Water pump 1
170E-5 Series 41
SEN00198-01 10 Structure, function and maintenance standard
Thermostat 1
42 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
1. Seal
2. Thermostat
3. Valve
4. Body
5. Piston
6. Heat sensing portion
7. Sleeve
8. Inflating portion
Specifications
Opening temperature: 76.5 ± 2°C
Full opening temperature: 90°C
Valve lift: Min. 9 mm
Unit: mm
No. Check item Criteria Remedy
Full opening lift of ther-
Min. 9 mm (Check after soaking in oil tank at 90°C for 4 – 5 minutes)
mostat
2 Check that valve closes fully when its temperature is lowered from Replace
Opening and closing of
90°C for full opening to 76.5°C. (Check after soaking valve in oil tank
thermostat
for 4 – 5 minutes)
170E-5 Series 43
SEN00198-01 10 Structure, function and maintenance standard
Corrosion resistor 1
44 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
170E-5 Series 45
SEN00198-01 10 Structure, function and maintenance standard
Fan drive 1
HD465-7, HD605-7
1. Crankshaft pulley
2. Fan belt
3. Tension pulley
4. Adjustment bolt
5. Tension pulley bracket
6. Fan pulley
7. Fan
a. Direction of wind
46 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Electrical equipment 1
Alternator 1
Alternator mounting
170E-5 Series 47
SEN00198-01 10 Structure, function and maintenance standard
WA600-6
48 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Alternator
Outside diam-
Applicable
Engine Type Specification eter of pulley Weight (kg)
machine
(mm)
Open type (brushless), manufac-
D375A-5 24V, 60A
tured by NIKKO DENKI
Open type (brushless), manufac-
PC1250-8 24V, 60A
tured by NIKKO DENKI
SAA6D170E-5
Open type (brushless), manufac-
HD465-7 24V, 60A
tured by NIKKO DENKI
Open type (brushless), manufac-
HD605-7 24V, 60A
tured by NIKKO DENKI
170E-5 Series 49
SEN00198-01 10 Structure, function and maintenance standard
Outside diam-
Applicable
Engine Type Specification eter of pulley Weight (kg)
machine
(mm)
Open type (brushless), manufac-
D375A-5 24V, 90A
tured by NIKKO DENKI
Open type (brushless), manufac-
PC1250-8 24V, 90A
tured by NIKKO DENKI
Open type (brushless), manufac-
SAA6D170E-5 WA600-6 24V, 90A
tured by NIKKO DENKI
Open type (brushless), manufac-
HD465-7 24V, 90A
tured by NIKKO DENKI
Open type (brushless), manufac-
HD605-7 24V, 90A
tured by NIKKO DENKI
50 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Starting motor 1
For 7.5 kW
170E-5 Series 51
SEN00198-01 10 Structure, function and maintenance standard
Safety relay
Applicable Specifica- No. of pin- Connector
Engine Type Weight (kg) mounting
machine tion ion teeth type
type
NIKKO DENKI 27V, 7.5kW
D375A-5 11 18 G E
(Water-proof, oil-proof type) x2
NIKKO DENKI 27V, 7.5kW
SAA6D170E-5 HD465-7 11 18 G C
(Water-proof, oil-proof type) x2
NIKKO DENKI 27V, 7.5kW
HD605-7 11 18 G C
(Water-proof, oil-proof type) x2
52 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
For 11 kW
170E-5 Series 53
SEN00198-01 10 Structure, function and maintenance standard
Starting aid 1
Electrical intake air heater
For SAA6D170E-5
1. Terminal Specifications
2. Body Type of heater: Electrical intake air heater
3. Heater coil Rated voltage: 22 V (DC)
4. Electric circuit diagram Rated current: 111 A
54 170E-5 Series
10 Structure, function and maintenance standard SEN00198-01
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q The engine controller cooler is equipped to
cool the engine controller with the fuel to
secure the reliability of the mounted engine
controller.
q Vibrations are damped by the vibration-proof
rubber.
Unified specifications of engine controller
q Engine controller CM850 which is common
part for the other engine is employed
170E-5 Series 55
SEN00198-01 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 11-05 (01)
56 170E-5 Series
SEN00367-00
170E-5 Series
170E-5 Series 1
SEN00367-00 20 Standard value table
Standard value
Judgement
Item Measurement conditions Unit for new
criteria
machine
High idle speed rpm 1,830 ± 20 1,830 ± 20
Speed
Low idle speed rpm 750 ± 20 750 ± 20
Necessary At 0°C (without starting aid) rpm 125 —
speed for starting At –20°C (with starting aid) rpm 85 —
Air intake kPa Max. 3.73 7.5
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 155 141
At rated output
pressure {mmHg} {Min. 1,160} {1,060}
Air intake and exhaust system
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {Min. 3.5} {2.1}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.1 0.08
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % Max. 0.1 0.2
output
Function of
kPa
radiator pressure Cracking pressure (Differential pressure) — —
{kg/cm2}
valve
Cooling system
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Hydraulically Hydraulically
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm driven on driven on
machine side machine side
Alternator belt —
Deflection under finger pressure of 98 N {10 kg} mm —
tension (Auto-tension)
2 170E-5 Series
20 Standard value table SEN00367-00
Engine SAA6D170E-5
Machine model PC1250-7
Performance Category
Standard value
Judgement
Item Measurement conditions Unit for new
criteria
machine
High idle speed rpm 2,000 ± 40 2,000 ± 40
Speed
Low idle speed rpm 900 ± 25 900 ± 25
Necessary At 0°C (without starting aid) rpm 125 —
speed for starting At –20°C (with starting aid) rpm 85 —
Air intake kPa Max. 3.73 7.5
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 160 147
At rated output
pressure {mmHg} {Min. 1,200} {1,100}
Air intake and exhaust system
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {Min. 3.5} {2.1}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.1 0.08
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % Max. 0.1 0.2
output
Function of
kPa
radiator pressure Cracking pressure (Differential pressure) — —
{kg/cm2}
valve
Cooling system
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Hydraulically Hydraulically
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm driven on driven on
machine side machine side
Alternator belt —
Deflection under finger pressure of 98 N {10 kg} mm —
tension (Auto-tension)
170E-5 Series 3
SEN00367-00 20 Standard value table
Engine SAA6D170E-5
Machine model WA600-6
Performance Category
Standard value
Judgement
Item Measurement conditions Unit for new
criteria
machine
High idle speed rpm 2,000 ± 50 2,000 ± 50
Speed
Low idle speed rpm 800 ± 25 800 ± 25
Necessary At 0°C (without starting aid) rpm 125 —
speed for starting At –20°C (with starting aid) rpm 85 —
Air intake kPa Max. 3.73 7.5
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 147 133
At rated output
pressure {mmHg} {Min. 1,100} {1,000}
Air intake and exhaust system
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {Min. 3.5} {2.1}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.1 0.08
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % Max. 0.1 0.2
output
Function of
kPa
radiator pressure Cracking pressure (Differential pressure) — —
{kg/cm2}
valve
Cooling system
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Hydraulically Hydraulically
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm driven on driven on
machine side machine side
Alternator belt —
Deflection under finger pressure of 98 N {10 kg} mm —
tension (Auto-tension)
4 170E-5 Series
20 Standard value table SEN00367-00
Engine SAA6D170E-5
HD465-7
Machine model
HD605-7
Performance Category
Standard value
Judgement
Item Measurement conditions Unit for new
criteria
machine
High idle speed rpm 2,270 ± 50 2,270 ± 50
Speed
Low idle speed rpm 750 ± 50 750 ± 50
Necessary At 0°C (without starting aid) rpm 125 —
speed for starting At –20°C (with starting aid) rpm 85 —
Air intake kPa Max. 3.73 7.5
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 160 147
At rated output
pressure {mmHg} {Min. 1,200} {1,100}
Air intake and exhaust system
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {Min. 3.5} {2.1}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.1 0.08
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % Max. 0.1 0.2
output
Function of
kPa
radiator pressure Cracking pressure (Differential pressure) — —
{kg/cm2}
Cooling system
valve
Fan speed At rated speed rpm 1,190 ± 30 1,190 ± 30
— —
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm
(Auto-tension) (Auto-tension)
Alternator belt —
Deflection under finger pressure of 98 N {10 kg} mm —
tension (Auto-tension)
170E-5 Series 5
SEN00367-00 20 Standard value table
Engine SAA6D170E-5
Machine model D375A-5
Procedure
Item
1 2 3 4 5
Running time min. 1.5 4.5 9 12 3
Speed rpm 750 1,134 1,422 1,638 1,800
Dynamometer load N {kg} 0 {0} 1,329 {135} 2,119 {216} 2,759 {281} 3,348 {341}
Output kW {HP} 0 {0} 113 {152} 226 {303} 339 {455} 452 {606}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D170E-5
Machine model D375A-5
Test item Rated output Max. torque High idle speed Low idle speed
Specification value 452 kW/1,800 rpm 3,020 Nm/1,300 rpm
— 1,830 ± 20 rpm 750 ± 20 rpm
(Gross value) {606 HP/1,800 rpm} {308 kgm/1,300 rpm}
Speed rpm 1,800 1,300 1,830 ± 20 750 ± 20
N 3,246 – 3,452 4,089 – 4,335
Dynamometer load — —
{kg} {331 – 352} {417 – 442}
kW 438 – 466
Output (Gross value) — — —
{HP} {588 – 624}
Nm 2,932 – 3,109
Torque (Gross value) — — —
{kgm} {299 – 317}
Fuel consumption sec/500cc Min. 14 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 343 – 539 343 – 539 343 – 539 Min. 118
pressure {kg/cm2} {3.5 – 5.5} {3.5 – 5.5} {3.5 – 5.5} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
6 170E-5 Series
20 Standard value table SEN00367-00
Running-in standard
Engine SAA6D170E-5
Machine model PC1250-7
Procedure
Item
1 2 3 4 5
Running time min. 1.5 4.5 9 12 3
Speed rpm 750 1,134 1,422 1,638 1,800
Dynamometer load N {kg} 0 {0} 1,513 {154} 2,414 {246} 3,143 {321} 3,814 {389}
Output kW {HP} 0 {0} 129 {173} 257 {345} 386 {518} 515 {690}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D170E-5
Machine model PC1250-7
Test item Rated output Max. torque High idle speed Low idle speed
Specification value 515 kW/1,800 rpm 3,025 Nm/1,300 rpm
— 2,000 ± 40 rpm 900 ± 25 rpm
(Gross value) {690 HP/1,800 rpm} {308.5 kgm/1,300 rpm}
Speed rpm 1,800 1,300 2,000 ± 40 900 ± 25
N 3,697 – 3,932 4,089 – 4,354
Dynamometer load — —
{kg} {377 – 401} {417 – 444}
kW 499 – 530
Output (Gross value) — — —
{HP} {669 – 711}
Nm 2,932 – 3,119
Torque (Gross value) — — —
{kgm} {299 – 318}
Fuel consumption sec/500cc Min. 13 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 343 – 539 343 – 539 343 – 539 Min. 118
pressure {kg/cm2} {3.5 – 5.5} {3.5 – 5.5} {3.5 – 5.5} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 670 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
170E-5 Series 7
SEN00367-00 20 Standard value table
Running-in standard
Engine SAA6D170E-5
Machine model WA600-6
Procedure
Item
1 2 3 4 5
Running time min. 1.5 4.5 9 12 3
Speed rpm 750 1,134 1,422 1,638 1,800
Dynamometer load N {kg} 0 {0} 1,163 {119} 1,855 {189} 2,416 {246} 2,931 {299}
Output kW {HP} 0 {0} 99 {133} 198 {265} 297 {398} 396 {531}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D170E-5
Machine model WA600-6
Test item Rated output Max. torque High idle speed Low idle speed
Specification value 396 kW/1,800 rpm 2,594 Nm/1,000 rpm
— 2,000 ± 50 rpm 800 ± 25 rpm
(Gross value) {530 HP/1,800 rpm} {264.5 kgm/1,000 rpm}
Speed rpm 1,800 1,000 2,000 ± 50 800 ± 25
N 2,844 – 3,020 3,521 – 3,727
Dynamometer load — —
{kg} {290 – 308} {359 – 380}
kW 384 – 407
Output (Gross value) — — —
{HP} {515 – 546}
Nm 2,520 – 2,667
Torque (Gross value) — — —
{kgm} {257 – 272}
Fuel consumption sec/500cc Min. 16 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 343 – 539 343 – 539 343 – 539 Min. 118
pressure {kg/cm2} {3.5 – 5.5} {3.5 – 5.5} {3.5 – 5.5} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
8 170E-5 Series
20 Standard value table SEN00367-00
Running-in standard
Engine SAA6D170E-5
HD465-7
Machine model
HD605-7
Procedure
Item
1 2 3 4 5
Running time min. 1.5 4.5 9 12 3
Speed rpm 750 1,260 1,580 1,820 2,000
Dynamometer load N {kg} 0 {0} 1,459 {149} 2,328 {237} 3,031 {309} 3,677 {375}
Output kW {HP} 0 {0} 138 {185} 276 {370} 414 {555} 552 {740}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D170E-5
HD465-7
Machine model
HD605-7
Test item Rated output Max. torque High idle speed Low idle speed
Specification value 552 kW/2,000 rpm 3,324 Nm/1,400 rpm
— 2,270 ± 50 rpm 750 ± 50 rpm
(Gross value) {740 HP/2,000 rpm} {339 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,270 ± 50 750 ± 50
N 3,570 – 3,795 4,501 – 4,776
Dynamometer load — —
{kg} {364 – 387} {459 – 487}
kW 535 – 569
Output (Gross value) — — —
{HP} {718 – 762}
Nm 3,226 – 3,423
Torque (Gross value) — — —
{kgm} {329 – 349}
Fuel consumption sec/500cc Min. 12 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 343 – 539 343 – 539 343 – 539 Min. 118
pressure {kg/cm2} {3.5 – 5.5} {3.5 – 5.5} {3.5 – 5.5} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 680 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
170E-5 Series 9
SEN00367-00
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 10-05 (01)
10
SEN00368-00
170E-5 Series
170E-5 Series 1
SEN00368-00 30 Testing and adjusting
2 170E-5 Series
30 Testing and adjusting SEN00368-00
Testing air boost pres- 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
sure 799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust tem-
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
perature
Adjusting Commercially
C Clearance gauge 1 Air intake: 0.35 mm
valve clearance available
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
795-611-1220 Adapter 1
Testing compression 2
D 6261-71-6150 Gasket 1
pressure
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Testing blow-by pres-
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
sure
Pressure gauge: 2.5, 5.9, 39.2, 58.8
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Testing oil pressure F
Pressure gauge: 0.98 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
799-101-5230 Nipple 1 14 x 1.5 mm
3
6215-81-9720 O-ring 1
Pressure gauge: 2.5, 5.9, 39.2, 58.8
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure G {600 kg/cm2}
2 799-101-5160 Nipple 1
Pressure gauge: 0.98 MPa
3 799-401-2320 Gauge 1
{10 kg/cm2}
1 6167-11-6640 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 φ5 mm x 2 – 3 m
Testing leakage from available
pressure limiter and Commercially
H 4 Hose 1 φ15 mm x 2 – 3 m
return rate from injec- available
tor
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
170E-5 Series 3
SEN00368-00 30 Testing and adjusting
4 170E-5 Series
30 Testing and adjusting SEN00368-00
Testing air boost pressure 1 3. Run the engine at the rated output and test the
air boost pressure.
a Testing tools for air boost pressure a When testing with the engine mounted on
Symbol Part No. Part name the machine, test on the condition
described in the shop manual for the
799-201-2202 Boost gauge kit
A machine.
790-401-2220 Hose
170E-5 Series 5
SEN00368-00 30 Testing and adjusting
6 170E-5 Series
30 Testing and adjusting SEN00368-00
170E-5 Series 7
SEN00368-00 30 Testing and adjusting
8 170E-5 Series
30 Testing and adjusting SEN00368-00
6. Install adapter D2 to the mounting hole on the 9. After finishing testing, remove the testing tools
injector and the compression gauge D1. and return the removed parts.
a Fit the gasket to the injector end without a Install the injector and fuel high-pressure
fail tube according to the following procedure.
a Fix the adapter with the injector holder 1) Install gasket (10) and O-rings (11) and
and adaptor. (12).
3 Holder mounting bolt: a Take care not to install O-ring (11) to
58.8 – 73.5 Nm {6.0 – 7.5 kgm} the groove (b).
a Apply a little amount of engine oil to the 2 O-ring: Engine oil
connecting parts of the adapter and gauge 2) Fit adaptor (9) to injector (8), and press it
so that air will not leak easily. in as a unit to the cylinder head by hand.
7. Connect the INSITE (bench test tool) to the 3) Install holder (7), and temporarily tighten
engine and set the engine in the no-injection bolt (13) and washer (14).
cranking mode. 2 Spherical part of washer: Engine oil
k If the engine is not set in the no-injec- 4) Install the fuel high-pressure tube, and
tion cranking mode, it will start and will temporarily tighten sleeve nut (5).
be dangerous. Accordingly, be sure to
set the engine in this mode. 5) Fully tighten bolt (13).
8. Rotate the engine with the starting motor and 3 Bolt:
measure the compression pressure. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Read the pressure gauge pointer when it 6) Fully tighten sleeve nut (5).
is stabilized. 3 Sleeve nut:
39.2 – 44.1 Nm {4 – 4.5 kgm}
170E-5 Series 9
SEN00368-00 30 Testing and adjusting
10 170E-5 Series
30 Testing and adjusting SEN00368-00
170E-5 Series 11
SEN00368-00 30 Testing and adjusting
12 170E-5 Series
30 Testing and adjusting SEN00368-00
170E-5 Series 13
SEN00368-00 30 Testing and adjusting
14 170E-5 Series
30 Testing and adjusting SEN00368-00
170E-5 Series 15
SEN00368-00 30 Testing and adjusting
Testing leakage from pressure limiter and return rate from injector 1
H Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
16 170E-5 Series
30 Testing and adjusting SEN00368-00
Leakage
Measurement conditions
(cc/min)
At stall or relief Max. 10
170E-5 Series 17
SEN00368-00 30 Testing and adjusting
3. Testing return rate from injector 5) After finishing testing, stop the engine.
18 170E-5 Series
30 Testing and adjusting SEN00368-00
170E-5 Series 19
SEN00368-00 30 Testing and adjusting
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, check is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
20 170E-5 Series
30 Testing and adjusting SEN00368-00
170E-5 Series 21
SEN00368-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
22
SEN00369-00
170E-5 Series
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points on troubleshooting..................................................................................................................... 2
Error code and failure code table ......................................................................................................... 4
170E-5 Series 1
SEN00369-00 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
2 170E-5 Series
40 Troubleshooting SEN00369-00
170E-5 Series 3
SEN00369-00 40 Troubleshooting
4 170E-5 Series
40 Troubleshooting SEN00369-00
170E-5 Series 5
SEN00369-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
6
SEN00370-00
170E-5 Series
40 Troubleshooting 1
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 3
Method of using troubleshooting charts ............................................................................................... 3
S-1 Starting performance is poor ......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 8
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operations ................................................................................................... 13
S-5 Engine does not rotate smoothly ................................................................................................. 14
S-6 Engine lacks output (or lacks power)........................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 18
S-9 Oil becomes contaminated quickly .............................................................................................. 19
S-10 Fuel consumption is excessive.................................................................................................. 20
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 21
S-12 Oil pressure drops ..................................................................................................................... 22
170E-5 Series 1
SEN00370-00 40 Troubleshooting
2 170E-5 Series
40 Troubleshooting SEN00370-00
Questions:
Items to be drawn from the user or operator. They
correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can
be drawn from the user or operator, depending on
their level.
Check items:
Simple check items used by the serviceman to nar-
row the causes. They correspond to C in the chart
on the right.
Causes:
Items to be narrowed from the questions and check
items.
The serviceman narrows down the probable
causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying
the narrowed causes finally in order from the most
probable one by applying troubleshooting tools or
direct inspection.
170E-5 Series 3
SEN00370-00 40 Troubleshooting
4 170E-5 Series
40 Troubleshooting SEN00370-00
5 items of [causes] have causal relationship with these 3 items of [questions] and [check items].
Let us explain the method of using this causal relationship in “step 1” to “step 3” in the figure below to narrow
the [causes] to lead to [troubleshooting].
170E-5 Series 5
SEN00370-00 40 Troubleshooting
Defective injector
ingly, even if the starting operation is carried out,
the engine may not start until the crankshaft
revolves 2 turns at maximum. This phenomenon
does not indicate a trouble, however.
Confirm recent repair history
Degree of use of
Operated for long period E E E E E
machine
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow out w w
cranked with start- If spill hose from injector is disconnected,
ing motor, w
little fuel spills
Check items
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
6 170E-5 Series
40 Troubleshooting SEN00370-00
170E-5 Series 7
SEN00370-00 40 Troubleshooting
When EGR cooler inlet gas piping is removed, coolant containing antifreeze flows out (*1). q
Inspect flywheel ring gear directly q
Carry out troubleshooting
on applicable machine
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
Turn starting switch When terminal B and terminal C of starting switch are connected, q
OFF, connect cord, engine starts
and carry out trouble- When terminal B and terminal C at safety relay outlet are connected,
shooting at ON q
engine starts
Even if terminal B and terminal C at safety relay outlet are connected,
q
engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
8 170E-5 Series
40 Troubleshooting SEN00370-00
170E-5 Series 9
SEN00370-00 40 Troubleshooting
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q w Q
cranked with out
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
10 170E-5 Series
40 Troubleshooting SEN00370-00
wiring harness
q Insufficient intake of air
q Improper selection of fuel
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow out Q w w
cranked with starting
motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of w
some cylinders is low
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
170E-5 Series 11
SEN00370-00 40 Troubleshooting
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12 170E-5 Series
40 Troubleshooting SEN00370-00
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
170E-5 Series 13
SEN00370-00 40 Troubleshooting
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-mode q
Carry out troubleshooting according to “Abnormality in bypass valve servo (*2)” in E-mode q
When air is bled from fuel system, air comes out q
Troubleshooting
or replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
Clean
Add
14 170E-5 Series
40 Troubleshooting SEN00370-00
(air leakage)
error in electrical system)
Suddenly Q Q Q Q
Questions
Replacement of filters has not been carried out according to Operation and Maintenance w
Manual
Black w w
Exhaust smoke color
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of some w
cylinders is low
High idle speed under no load is normal, but speed suddenly drops when load is applied w w Q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q q
change
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
170E-5 Series 15
SEN00370-00 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
16 170E-5 Series
40 Troubleshooting SEN00370-00
170E-5 Series 17
SEN00370-00 40 Troubleshooting
Turbocharger
When EGR valve is removed, exhaust port is found to be dirty with oil q
Inspect breather and breather hose directly q
When compression pressure is measured, it is found to be low q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
18 170E-5 Series
40 Troubleshooting SEN00370-00
See S-7
Inspect breather and breather tube directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
170E-5 Series 19
SEN00370-00 40 Troubleshooting
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
20 170E-5 Series
40 Troubleshooting SEN00370-00
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Remedy
—
170E-5 Series 21
SEN00370-00 40 Troubleshooting
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte- w
nance Manual
Indicates pressure drop at low idle w Q Q
Valve and spring of oil pump relief valve are fatigued, damaged
Inspect oil filter directly q
Relief valve of EGR oil pump is damage, oil leaks from it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)” in E- q
mode
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Clean
Clean
Clean
Remedy
—
Add
22 170E-5 Series
40 Troubleshooting SEN00370-00
When EGR cooler inlet gas piping is removed, coolant containing antifreeze flows out (*1). q
When compression pressure is measured, it is found to be low q
Remove and inspect head cover directly q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
170E-5 Series 23
SEN00370-00 40 Troubleshooting
24 170E-5 Series
40 Troubleshooting SEN00370-00
Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or
mud w w
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
170E-5 Series 25
SEN00370-00 40 Troubleshooting
Gradually occurred Q Q Q
Abnormal noise
Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained Q w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around EGR gas piping w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low w Q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
26 170E-5 Series
40 Troubleshooting SEN00370-00
Replace
Replace
Adjust
Remedy
170E-5 Series 27
SEN00370-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
28
SEN00371-00
170E-5 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode)............................................................................................... 4
Information in troubleshooting table ..................................................................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure ............................................................................ 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 8
E-3 Code [122/CA122] Charge Air Press Sensor High Error ............................................................... 9
E-4 Code [123/CA123] Charge Air Press Sensor Low Error...............................................................11
E-5 Code [131/CA131] Throttle Sensor High Error ............................................................................ 12
E-6 Code [132/CA132] Throttle Sensor Low Error............................................................................. 16
E-7 Code [135/CA135] Oil Press. Sensor High Error......................................................................... 17
E-8 Code [141/CA141] Oil Press. Sensor Low Error ......................................................................... 19
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 20
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 22
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error........................................................... 24
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ........................................................... 26
170E-5 Series 1
SEN00371-00 40 Troubleshooting
2 170E-5 Series
SEN00371-00 40 Troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
4 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 5
SEN00371-00 40 Troubleshooting
6 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 7
SEN00371-00 40 Troubleshooting
8 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 9
SEN00371-00 40 Troubleshooting
10 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 11
SEN00371-00 40 Troubleshooting
12 170E-5 Series
SEN00371-00 40 Troubleshooting
14 170E-5 Series
40 Troubleshooting SEN00371-00
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC1250-8)
170E-5 Series 15
SEN00371-00 40 Troubleshooting
16 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 17
SEN00371-00 40 Troubleshooting
18 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 19
SEN00371-00 40 Troubleshooting
20 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 21
SEN00371-00 40 Troubleshooting
22 170E-5 Series
SEN00371-00 40 Troubleshooting
24 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 25
SEN00371-00 40 Troubleshooting
26 170E-5 Series
SEN00371-00 40 Troubleshooting
28 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 29
SEN00371-00 40 Troubleshooting
30 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 31
SEN00371-00 40 Troubleshooting
32 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 33
SEN00371-00 40 Troubleshooting
34 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 35
SEN00371-00 40 Troubleshooting
36 170E-5 Series
SEN00371-00 40 Troubleshooting
38 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 39
SEN00371-00 40 Troubleshooting
40 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 41
SEN00371-00 40 Troubleshooting
42 170E-5 Series
SEN00371-00 40 Troubleshooting
44 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 45
SEN00371-00 40 Troubleshooting
46 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 47
SEN00371-00 40 Troubleshooting
48 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 49
SEN00371-00 40 Troubleshooting
50 170E-5 Series
SEN00371-00 40 Troubleshooting
k High voltage (maximum of 65 V) is used in the electric circuit of the fuel injector. Referring to
Testing and adjusting, “Handling of high-voltage circuit of controller”, take care of an electric
shock and a leak.
52 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 53
SEN00371-00 40 Troubleshooting
k High voltage (maximum of 65 V) is used in the electric circuit of the fuel injector. Referring to
Testing and adjusting, “Handling of high-voltage circuit of controller”, take care of an electric
shock and a leak.
54 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 55
SEN00371-00 40 Troubleshooting
k High voltage (maximum of 65 V) is used in the electric circuit of the fuel injector. Referring to
Testing and adjusting, “Handling of high-voltage circuit of controller”, take care of an electric
shock and a leak.
56 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 57
SEN00371-00 40 Troubleshooting
k High voltage (maximum of 65 V) is used in the electric circuit of the fuel injector. Referring to
Testing and adjusting, “Handling of high-voltage circuit of controller”, take care of an electric
shock and a leak.
58 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 59
SEN00371-00 40 Troubleshooting
k High voltage (maximum of 65 V) is used in the electric circuit of the fuel injector. Referring to
Testing and adjusting, “Handling of high-voltage circuit of controller”, take care of an electric
shock and a leak.
60 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 61
SEN00371-00 40 Troubleshooting
k High voltage (maximum of 65 V) is used in the electric circuit of the fuel injector. Referring to
Testing and adjusting, “Handling of high-voltage circuit of controller”, take care of an electric
shock and a leak.
62 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 63
SEN00371-00 40 Troubleshooting
64 170E-5 Series
SEN00371-00 40 Troubleshooting
66 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 67
SEN00371-00 40 Troubleshooting
68 170E-5 Series
SEN00371-00 40 Troubleshooting
70 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 71
SEN00371-00 40 Troubleshooting
72 170E-5 Series
40 Troubleshooting SEN00371-00
Circuit diagram related to throttle sensor of accelerator pedal type (Case of WA600)
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Operating range: Operating range of accelerator
pedal
170E-5 Series 73
SEN00371-00 40 Troubleshooting
74 170E-5 Series
40 Troubleshooting SEN00371-00
170E-5 Series 75
SEN00371-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
76
SEN00372-00
170E-5 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode)............................................................................................... 3
E-41 Code [449/CA449] Rail Press. Very High Error ........................................................................... 3
E-42 Code [451/CA451] Rail Press. Sensor High Error ....................................................................... 4
E-43 Code [452/CA452] Rail Press. Sensor Low Error........................................................................ 6
E-44 Code [553/CA553] Rail Press. High Error ................................................................................... 7
E-45 Code [559/CA559] Rail Press. Low Error .................................................................................... 8
E-46 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 12
E-47 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 14
E-48 Code [757/CA757] All Persistent Data Lost Error...................................................................... 15
E-49 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 16
E-50 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 18
E-51 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 19
E-52 Code [1626/CA1626] Bypass Valve Solenoid Current High Error ............................................. 20
E-53 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error .............................................. 22
170E-5 Series 1
SEN00372-00 40 Troubleshooting
2 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 3
SEN00372-00 40 Troubleshooting
4 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 5
SEN00372-00 40 Troubleshooting
6 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 7
SEN00372-00 40 Troubleshooting
8 170E-5 Series
40 Troubleshooting SEN00372-00
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
170E-5 Series 9
SEN00372-00 40 Troubleshooting
B. Check with INSITE or machine monitor (Abnormality record function, monitoring function, and
Good NG
reduced cylinder mode function)
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Measured
Code Displayed item Checking condition Unit (Reference Good NG
value
value)
Low idle rpm <By models>
High idle rpm <By models>
*1 Engine speed
Equivalent to rating
rpm <By models>
<By models>
Low idle % 0
*2 Throttle opening
High idle % 100
Fuel injection com- Equivalent to rating
*3 mm3 — — —
mand <By models>
4 Common rail pres- Equivalent to rating
*4 MPa
sure command <By models>
Common rail fuel Equivalent to rating
*5 MPa
pressure <By models>
Low idle CA — — —
Fuel injection timing High idle CA — — —
*6
command Equivalent to rating
CA — — —
<By models>
Equivalent to rating
*7 Boost pressure kPa — — —
<By models>
Engine coolant tem-
*8 Low idle °C — — —
perature
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Measured
Function Reduced cylinder Checking condition Unit (Reference Good NG
value
value)
No. 1 cylinder Low idle rpm — — —
5 No. 2 cylinder Low idle rpm — — —
No. 3 cylinder Low idle rpm — — —
*10
No. 4 cylinder Low idle rpm — — —
No. 5 cylinder Low idle rpm — — —
No. 6 cylinder Low idle rpm — — —
10 170E-5 Series
40 Troubleshooting SEN00372-00
Standard value
Measured
C. Check of fuel circuit pressure Checking condition Unit (Reference Good NG
value
value)
MPa Min. 0.15
6 Fuel low-pressure circuit pressure High idle
{kg/cm2} {Min. 1.5}
Standard value
Measured
E. Check of leakage and return rate Checking condition Unit (Reference Good NG
value
value)
No-load, full stall, or
11 Leakage through pressure limiter cc/min Max. 10
relief
Equivalent to rating
cc/min 960
<By models> 1,600 rpm
Equivalent to rating Speed:
cc/min 1,020
<By models> 1,700 rpm
Equivalent to rating
12 Return rate from injector cc/min 1,080
<By models> 1,800 rpm
Equivalent to rating
cc/min 1,140 Return rate:
<By models> 1,900 rpm
Equivalent to rating
cc/min 1,200
<By models> 2,000 rpm
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
170E-5 Series 11
SEN00372-00 40 Troubleshooting
12 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 13
SEN00372-00 40 Troubleshooting
14 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 15
SEN00372-00 40 Troubleshooting
16 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 17
SEN00372-00 40 Troubleshooting
18 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 19
SEN00372-00 40 Troubleshooting
20 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 21
SEN00372-00 40 Troubleshooting
22 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 23
SEN00372-00 40 Troubleshooting
24 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 25
SEN00372-00 40 Troubleshooting
26 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 27
SEN00372-00 40 Troubleshooting
28 170E-5 Series
40 Troubleshooting SEN00372-00
Circuit diagram related to throttle sensor of accelerator pedal type (Case of WA600)
170E-5 Series 29
SEN00372-00 40 Troubleshooting
30 170E-5 Series
40 Troubleshooting SEN00372-00
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC1250-8)
170E-5 Series 31
SEN00372-00 40 Troubleshooting
32 170E-5 Series
40 Troubleshooting SEN00372-00
E-62 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error 1
170E-5 Series 33
SEN00372-00 40 Troubleshooting
34 170E-5 Series
40 Troubleshooting SEN00372-00
E-63 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error 1
170E-5 Series 35
SEN00372-00 40 Troubleshooting
36 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 37
SEN00372-00 40 Troubleshooting
38 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 39
SEN00372-00 40 Troubleshooting
40 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 41
SEN00372-00 40 Troubleshooting
42 170E-5 Series
40 Troubleshooting SEN00372-00
170E-5 Series 43
SEN00372-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
44
SEN00765-00
170E-5 Series
170E-5 Series 1
SEN00765-00 50 Disassembly and assembly
Assembly
q In Assembly section, the work procedures, pre-
cautions and know-how for carrying out those
procedures, and quantity of the oil and coolant
added are described.
q The meanings of the symbols used in Assem-
bly section are as follows.
k : Precautions related to safety in execution
of work
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
2 170E-5 Series
50 Disassembly and assembly SEN00765-00
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resis-
ThreeBond tant, vibration-resistant, impact-resistant seal-
419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
170E-5 Series 3
SEN00765-00 50 Disassembly and assembly
Cate-
Komatsu code Part No. Q'ty Container Main features and applications
gory
• Used to lubricate sliding portions.
disulfide lubricant
SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
4 170E-5 Series
50 Disassembly and assembly SEN00765-00
Cate-
Komatsu code Part No. Q'ty Container Main features and applications
gory
• “S” is used for high-temperature season
SUNSTAR
(April – October) and “W” for low-tempera-
PENGUINE
Polyethylene ture season (November – April) as adhe-
SEAL 580 417-926-3910 320 ml
container sive for glass.
SUPER “S” or
(Using limit: 4 months after date of manu-
“W”
Adhesive
facture)
• Used as adhesive for glass.
Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
170E-5 Series 5
SEN00765-00 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Work item Part No. Part name Remarks
6 170E-5 Series
SEN00765-00 50 Disassembly and assembly
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (01)
8 170E-5 Series
SEN00766-00
170E-5 Series
170E-5 Series 1
SEN00766-00 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them. a Remove the cover and then disconnect
PFUEL section (2) on the engine top sur-
2. Setting engine assembly face.
1) Place engine assembly (1) on stable
engine stands (Block [1]) so that it may not
tip over.
a The weight depends on the applica-
ble machines.
4 Engine assembly: 3,100 kg
5. Air piping
1) Lift air piping (1) temporarily.
2) Remove clamp (2) and then lift off air pip-
ing (1).
4 Air piping: 15 kg
2 170E-5 Series
50 Disassembly and assembly SEN00766-00
6. Turbocharger assembly
1) Remove 2 water pipes (1) and 2 oil pipes
2) Remove bracket (3).
(2).
170E-5 Series 3
SEN00766-00 50 Disassembly and assembly
9. EGR cooler
1) Remove water pipes (1) and (2).
2) Remove EGR cooler (3).
a Remove it by separating at position
(A).
12. Air conditioner compressor
Remove engine air conditioner compressor (1).
4 170E-5 Series
50 Disassembly and assembly SEN00766-00
14. Pulley, tensioner and air conditioner com- 16. Oil filter and filter head assembly
pressor bracket 1) Remove oil tubes (1).
1) Remove pulley (1). 2) Remove filter head and oil filter assembly
2) Tighten bolt (2). (2).
3) Attach stopper bolt [1] to the position on 3) Remove bracket (3).
tensioner (3) indicated in the figure.
a Maintain the stopper bolt in this posi-
tion before installing tensioner (3)
again.
4) Remove tensioner (3).
5) Remove air conditioner compressor
bracket (4).
170E-5 Series 5
SEN00766-00 50 Disassembly and assembly
6 170E-5 Series
50 Disassembly and assembly SEN00766-00
23. Supply pump assembly 5) Adjust positioning of the supply pump and
1) Remove wiring harness (1) from rear side drive gear according to the following pro-
of the supply pump. cedure.
2) Remove fuel tube (2). a Pull out pin A of barring device (8)
and then push in hexagonal portion B
to engage the gear and crank the
gear.
1] Rotate barring device (8) for cranking.
170E-5 Series 7
SEN00766-00 50 Disassembly and assembly
a The figure shows, for your refer- 25. Intake manifold assembly
ence, the state after removing 1) Remove bracket (1), spill tube (2) and
the supply pump drive gear. peripheral parts.
8 170E-5 Series
50 Disassembly and assembly SEN00766-00
2) Remove stopper (2) and then slide bypass 28. Front hanger and water housing
tube (3) upward. 1) Remove bracket (1) and water tube (2).
3) Remove water pump assembly (4).
170E-5 Series 9
SEN00766-00 50 Disassembly and assembly
10 170E-5 Series
50 Disassembly and assembly SEN00766-00
34. Crosshead
Remove crossheads (1).
170E-5 Series 11
SEN00766-00 50 Disassembly and assembly
3) Remove the cylinder head gasket. 5] Remove intake valve (6) and exhaust
4) Disassemble the cylinder head assembly valve (7) from cylinder head (8).
according to the following procedure.
1] Using tool B, compress the valve
spring and then remove valve cotter
(2).
12 170E-5 Series
50 Disassembly and assembly SEN00766-00
39. Drive housing assembly 41. Suction pipe and under plate
Remove drive housing assembly (1). 1) Install under plate (1) temporarily with sev-
eral oil pan mounting bolts.
2) Remove brackets (2) and (3) and then
remove suction pipe (4).
3) Separate the gasket sealant.
4) Remove the temporarily attached mount-
ing bolts and then remove plate (1) using
a jack.
4 Under plate: 25 kg
170E-5 Series 13
SEN00766-00 50 Disassembly and assembly
14 170E-5 Series
50 Disassembly and assembly SEN00766-00
3) Remove dust seal (2) and oil seal (3) from 48. Oil pump assembly
the front cover. Remove oil pump assembly (1).
a Dust seal is provided only on the
vehicle-mounted engines alone.
170E-5 Series 15
SEN00766-00 50 Disassembly and assembly
16 170E-5 Series
50 Disassembly and assembly SEN00766-00
170E-5 Series 17
SEN00766-00 50 Disassembly and assembly
18 170E-5 Series
50 Disassembly and assembly SEN00766-00
5] Using tool F, remove top ring (8) and 4) Remove main bearing metal (2) and 2
second ring (9). thrust wafers (3) from main cap (1).
a Thrust washers are provided on No. 6
main cap alone.
a Maintain them on the main cap No.
basis using a tag or the like.
170E-5 Series 19
SEN00766-00 50 Disassembly and assembly
20 170E-5 Series
SEN00766-00 50 Disassembly and assembly
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (01)
22 170E-5 Series
SEN00767-00
170E-5 Series
170E-5 Series 1
SEN00767-00 50 Disassembly and assembly
1. Cylinder block
1) Set cylinder block (1) on blocks [1].
2. Cylinder liner
a Replace the O-ring and clevis seal with
new ones.
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not rough-
ened because of rusting or pitting. If those
parts are roughened, replace the cylinder
liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
2) Before inserting the cylinder liners, pre- etc. in the groove of the liner.
pare the cylinder block according to the a Fit the clevis seal with the chamfered
following procedure. side down. When fitting it, press it
1] Using a piece of sand paper, polish against the seal groove all round so
and remove rusts and scales on faces that it will not be twisted.
(a) of O-ring guide section and (b) of
O-ring bored section until the
machine surface is exposed.
2 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 3
SEN00767-00 50 Disassembly and assembly
7) Using tool H, press fit cylinder liner (1) to 9) Remove cylinder head assembly (5).
the cylinder block. a Wipe off gasket sealant running over
to the cylinder block top surface.
10) Using dial gauge [2], measure projection
of the cylinder liner.
a When measuring the line projection
from the block surface, use the block
top surface as the datum plane.
a Standard cylinder liner projection:
0.07 – 0.15 mm
a When the projection is out of the stan-
dard, correct it referencing “Struc-
t ur e , fu nc t io n a nd ma i nt en an c e
standard“.
4 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 5
SEN00767-00 50 Disassembly and assembly
6 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 7
SEN00767-00 50 Disassembly and assembly
8 170E-5 Series
50 Disassembly and assembly SEN00767-00
2] Install shaft (3) and spacer (2). a (B) mark is used in the succeeding
a When installing the spacer, direct processes.
its V-grooved face to outside.
170E-5 Series 9
SEN00767-00 50 Disassembly and assembly
8. Camshaft assembly
1) Lift and insert camshaft assembly (1) to
the cylinder block.
a First, lift the center portion of the cam-
shaft to insert to the cylinder block.
After inserting about 1/3 of the shaft
body, lift the gear side again and
insert it while aligning the camshaft
and bushing hole.
4 Camshaft assembly: 80 kg
a When installing, match (B) mark on
the camshaft gear and (B) mark on
the idler gear (smaller one). 9. Measurement of gear backlash (Rear)
3 Camshaft assembly mounting bolt:
Measure backlash of the rear timing gear using
98 – 122.5 Nm {10 – 12.5 kgm} dial gauge [1].
a When measuring the backlash, set the dial
gauge in the tooth end of the crankshaft
gear or camshaft gear and then fix the
idler gear.
10 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 11
SEN00767-00 50 Disassembly and assembly
12 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 13
SEN00767-00 50 Disassembly and assembly
14 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 15
SEN00767-00 50 Disassembly and assembly
16 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 17
SEN00767-00 50 Disassembly and assembly
18 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 19
SEN00767-00 50 Disassembly and assembly
20 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 21
SEN00767-00 50 Disassembly and assembly
22 170E-5 Series
50 Disassembly and assembly SEN00767-00
2] Install rocker arm (5) for air intake 32. Adjusting valve clearance
valve and rocker arm (4) for exhaust 1) Rotate the crankshaft forward to remove
valve on shaft (6). plug (1) situated in the left of the flywheel
a Insert respective rocker arm at a housing.
position where the riveted side of
the shaft faces the front side of
the engine.
170E-5 Series 23
SEN00767-00 50 Disassembly and assembly
24 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 25
SEN00767-00 50 Disassembly and assembly
26 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 27
SEN00767-00 50 Disassembly and assembly
2) Install gasket and then thermostat housing 44. Supply pump assembly
(1). 1) Install supply pump assembly (12) along
with supply pump drive case (11).
2) Install gasket (10).
28 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 29
SEN00767-00 50 Disassembly and assembly
6) Install fuel tube (2) and wiring harness (1). 6) Install a rubber cap on the sleeve nut.
3 Fuel tube joint bolt (Supply pump a When fitting the rubber cap, direct its
side): slit toward out of the engine.
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Fuel tube joint bolt (Relay block
side): 54 – 93 Nm {5.5 – 9.5 kgm}
30 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 31
SEN00767-00 50 Disassembly and assembly
52. Pulley, tensioner and air conditioner com- 54. Air conditioner compressor
pressor bracket Install air conditioner compressor (1).
1) Install air conditioner compressor bracket
(4).
2) Install tensioner (3).
3) Tighter bolt (2).
4) Pull out stopper bolt [1].
5) Install pulley (1).
32 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 33
SEN00767-00 50 Disassembly and assembly
34 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 35
SEN00767-00 50 Disassembly and assembly
36 170E-5 Series
50 Disassembly and assembly SEN00767-00
170E-5 Series 37
SEN00767-00 50 Disassembly and assembly
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (01)
38 170E-5 Series
SEN00768-00
170E-5 Series
170E-5 Series 1
SEN00768-00 50 Disassembly and assembly
2 170E-5 Series
50 Disassembly and assembly SEN00768-00
12. Remove oil tube (17) and bracket (18) from Installation
fuel supply pump (16). [*7] q Carry out installation in the reverse order to
removal.
[*1]
3 Nut: Fuel tube (4)
Joint bolt (Supply pump side):
14.5 – 19.6 Nm {1.51 – 1.99 kgm}
Joint bolt (Supply pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Fuel tube (5)
Joint bolt:
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Flare nut: 58.8 – 78.4 Nm {6.0 – 8.0 kgm}
3 Fuel tube (6)
Joint bolt:
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Flare nut: 84 – 132 Nm {8.5 – 13.5 kgm}
[*2]
3 Oil tube (14)
Joint bolt (Supply pump side):
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
3 Joint bolt (Block side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*3]
3 Fuel tube (8)
Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Flare nut: 54 – 93 Nm {5.5 – 9.5 kgm}
[*4]
k When handling the high-pressure piping
and clamp, care should be paid to following
points.
q It is strictly prohibited to modify bending a high-
pressure piping to use it again or to use a high-
pressure piping in an unspecified location.
q When installing a clamp, be sure to install a
genuine clamp securely using the specified
torque.
q After installation of the high-pressure piping
and clamp is complete, make sure that a 10
mm clearance minimum is provided between
the high-pressure piping and adjacent wiring
harness. When the clearance is less than 10
mm, secure the necessary space by adjusting
the wiring harness position.
170E-5 Series 3
SEN00768-00 50 Disassembly and assembly
[*5]
3 Supply pump mounting bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Bracket (15) mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
[*6]
a Insert the fuel supply pump shaft aligning it to
the coupling of the supply pump drive case.
a The spline is not provided in one location on
the coupling and shaft. This location deter-
mines the installation position.
q The figure shows an example of the coupling
on the supply pump drive case. (Spline is miss-
ing in Section A.)
[*7]
3 Oil tube (17) joint bolt:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
(Supply pump side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(Bracket side)
3 Bracket (18) mounting bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
4 170E-5 Series
50 Disassembly and assembly SEN00768-00
170E-5 Series 5
SEN00768-00 50 Disassembly and assembly
Procedure for installing standard seal 2) Hold the metal ring of seal (1) with both hands
a Before installing the seal, check that the end and push it in firmly.
corners and lip sliding surfaces of crankshaft 3) After pushing in the seal, remove plastic inside
(4) are free from flaw, burr, and rust of the cylinder (3).
housing. a When removing the inside cylinder, take
a When installing seal (1), do not apply oil or care not to damage the seal lip.
grease to the shaft and seal lip (a). Wipe off
the oil from the shaft.
a Never remove inside plastic cylinder (3) of the
standard spare seal before installing the seal.
6 170E-5 Series
50 Disassembly and assembly SEN00768-00
2. Front oil seal 2) Using tool K, press fit oil seal (1) to the front
case until dimension (a) is obtained. (When the
Removal dust seal is not provided)
a For the work up to removal of the damper, see a Oil seal press fitting dimension (a): 18.5 mm
the shop manual for the applicable machine.
1) Remove front oil seal (1).
170E-5 Series 7
SEN00768-00 50 Disassembly and assembly
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (01)
8 170E-5 Series