Saa6d170e-5 Shop Manual

SEN00190-06
ENGINE
170E-5 SERIES
SEN00192-06
ENGINE 1SHOP MANUAL
170E-5 Series
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 3
170E-5 Series 1
SEN00192-06 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00190-06
00 Index and foreword SEN00191-06

Index SEN00192-06 q
Foreword and general information SEN00193-03 q
01 Specification SEN00194-02
Specification and technical data SEN00195-02
10 Structure, function and maintenance standard SEN00196-02

Structure, function and maintenance standard, Part 1 SEN00197-02
20 Standard value table SEN00199-02

Standard service value table SEN00367-02 q
30 Testing and adjusting SEN00200-01

Testing and adjusting SEN00368-01 q
40 Troubleshooting SEN00201-01
General information on troubleshooting SEN00369-01 q
Troubleshooting of electrical system (E-mode), Part 1 SEN00371-01 q
Troubleshooting of electrical system (E-mode), Part 2 SEN00372-01 q
Troubleshooting of mechanical system (S-mode) SEN00370-01 q
50 Disassembly and assembly SEN00202-01

General information on disassembly and assembly SEN00765-01 q
Disassembly and assembly, Part 1 (With EGR) SEN00766-01 q
Disassembly and assembly, Part 2 (EGR-less) SEN00767-01 q
Disassembly and assembly, Part 3 SEN00768-01 q
2 170E-5 Series
Table of contents 1
00 Index and foreword
Index SEN00192-06
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00193-03

Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00195-02
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 14
Weight table............................................................................................................................. 31
Engine performance curves..................................................................................................... 33
10 Structure, function and maintenance standard

Intake and exhaust system ......................................................................................................... 4
Air cleaner ............................................................................................................................... 4
Turbocharger ........................................................................................................................... 6
EGR system ............................................................................................................................ 11
Engine unit .................................................................................................................................. 18
Cylinder head .......................................................................................................................... 18
Cylinder block .......................................................................................................................... 22
Cylinder liner............................................................................................................................ 26
Main moving parts ................................................................................................................... 27
Crankshaft ............................................................................................................................... 30
Camshaft ................................................................................................................................. 32
Connecting rod ........................................................................................................................ 33
Piston, piston ring and piston pin............................................................................................. 34
Flywheel and flywheel housing................................................................................................ 35
Vibration damper ..................................................................................................................... 36
Gear train................................................................................................................................. 37
Timing gear.............................................................................................................................. 42
Valve system ........................................................................................................................... 46
Valve and valve guide.............................................................................................................. 48
Rocker arm and shaft .............................................................................................................. 49
Crosshead and guide .............................................................................................................. 50
Tappet and push rod................................................................................................................ 51

Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4
Oil pump .................................................................................................................................. 8
Oil filter and safety valve ......................................................................................................... 12
170E-5 Series 3
Oil cooler.................................................................................................................................. 13
Fuel system ................................................................................................................................. 14
CRI system diagram ................................................................................................................ 14
Outline of CRI system.............................................................................................................. 15
Fuel piping ............................................................................................................................... 36
Fuel filter .................................................................................................................................. 38
Electric priming pump .............................................................................................................. 40
Engine controller cooler ........................................................................................................... 41
Cooling system............................................................................................................................ 42
Cooling system diagram .......................................................................................................... 42
Water pump ............................................................................................................................. 44
Thermostat............................................................................................................................... 45
Corrosion resistor .................................................................................................................... 47
Fan drive.................................................................................................................................. 49
Electrical equipment .................................................................................................................... 50
Alternator ................................................................................................................................. 50
Alternator belt tension.............................................................................................................. 51
Starting aid............................................................................................................................... 57
Engine controller...................................................................................................................... 58
20 Standard value table

Standard service value table SEN00367-02
Standard service value table for testing, adjusting, and troubleshooting ................................. 2
Running-in standard and performance test standard .............................................................. 10
30 Testing and adjusting

Testing and adjusting SEN00368-01
Testing and adjusting (With EGR) ............................................................................................... 3
Testing and adjusting tools list ................................................................................................. 3
Sketches of special tools ......................................................................................................... 5
Testing air boost pressure........................................................................................................ 6
Testing exhaust temperature ................................................................................................... 7
Adjusting valve clearance ........................................................................................................ 8
Testing compression pressure ................................................................................................. 10
Testing blow-by pressure ......................................................................................................... 12
Testing engine oil pressure ...................................................................................................... 13
Testing EGR valve and bypass valve drive oil pressure .......................................................... 14
Handling fuel system parts ...................................................................................................... 16
Releasing residual pressure in fuel system ............................................................................. 16
Testing fuel pressure................................................................................................................ 17
Reduced cylinder mode operation ........................................................................................... 18
No-injection cranking ............................................................................................................... 18
Testing leakage from pressure limiter and return rate from injector......................................... 19
Bleeding air from fuel circuit .................................................................................................... 22
Testing fuel system for leakage ............................................................................................... 24
Handling controller voltage circuit............................................................................................ 25
Testing and adjusting (EGR-less)................................................................................................ 26
Testing and adjusting tools list ................................................................................................. 26
Testing air boost pressure........................................................................................................ 28
Testing exhaust temperature ................................................................................................... 29
Adjusting valve clearance ........................................................................................................ 30
Testing compression pressure ................................................................................................. 32
Testing blow-by pressure ......................................................................................................... 34
Testing engine oil pressure ...................................................................................................... 35
Handling fuel system parts ...................................................................................................... 36
Releasing residual pressure in fuel system ............................................................................. 36
Testing fuel pressure................................................................................................................ 37
4 170E-5 Series
Reduced cylinder mode operation........................................................................................... 38

No-injection cranking ............................................................................................................... 38
Testing leakage from pressure limiter and return rate from injector ........................................ 39
Bleeding air from fuel circuit .................................................................................................... 42
Testing fuel system for leakage ............................................................................................... 44
Handling controller voltage circuit............................................................................................ 45
40 Troubleshooting
General information on troubleshooting SEN00369-01
Points on troubleshooting ........................................................................................................ 2
Error code and failure code table ............................................................................................ 4
Information in troubleshooting table ........................................................................................ 6
Troubleshooting of electrical system (E-mode), Part 1 SEN00371-01
E-1 Code [111/CA111] Engine controller Internal Failure ........................................................ 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 6
E-3 Code [122/CA122] Charge Air Press Sensor High Error .................................................. 7
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error....................................... 10
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............................................................... 20
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 22
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 24
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error.................................... 26
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error .................................... 28
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 28
E-14 Code [212/CA212] Oil Temp. Sensor High Error ............................................................ 30
E-15 Code [213/CA213] Oil Temp. Sensor Low Error ............................................................. 32
E-16 Code [221/CA221] Ambient Air Press. Sensor High Error.............................................. 33
E-17 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 36
E-18 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 37
E-19 Code [234/CA234] Eng. Overspeed ............................................................................... 40
E-20 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error.................................................... 42
E-21 Code [263/CA263] Fuel Temp. Sensor High Error .......................................................... 44
E-22 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 46
E-23 Code [271/CA271] PCV1 Short Error ............................................................................. 48
E-24 Code [272/CA272] PCV1 Open Error ............................................................................. 50
E-25 Code [273/CA273] PCV2 Short Error ............................................................................. 52
E-26 Code [274/CA274] PCV2 Open Error ............................................................................. 54
E-27 Code [322/CA322] Injector #1 System Open/Short Error ............................................... 56
E-33 Code [342/CA342] Engine Controller Data Matching Error ............................................ 68
E-34 Code [351/CA351] INJ. Drive Circuit Error ..................................................................... 70
E-35 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 72
E-36 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 74
E-37 Code [431/CA431] Idle Validation SW Low error ............................................................ 78
E-38 Code [432/CA432] Idle Validation Process error ............................................................ 80
E-39 Code [441/CA441] Battery voltage low error .................................................................. 81
E-40 Code [442/CA442] Battery voltage high error ................................................................. 81
Troubleshooting of electrical system (E-mode), Part 2 SEN00372-01
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 ........................................................... 7
170E-5 Series 5
E-44 Code [553/CA553] Rail Press. High Error....................................................................... 8

E-45 Code [559/CA559] No-Pressure feed by supply pump 1 ................................................ 10
E-46 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 16
E-47 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 18
E-48 Code [757/CA757] All Persistent Data Lost Error ........................................................... 19
E-49 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 20
E-50 Code [1228/CA1228] EGR Valve Servo Error 1.............................................................. 22
E-51 Code [1625/CA1625] EGR Valve Servo Error 2.............................................................. 23
E-52 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit ................................... 24
E-53 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error ..................................... 26
E-54 Code [1628/CA1628] Bypass Valve Servo Error 1.......................................................... 27
E-55 Code [1629/CA1629] Bypass Valve Servo Error 2.......................................................... 28
E-56 Code [1631/CA1631] BP valve Lift Position Sensor High Error ...................................... 29
E-57 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ....................................... 31
E-58 Code [1633/CA1633] KOMNET Error ............................................................................. 31
E-59 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 32
E-60 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 36
E-61 Code [2249/CA2249] No-pressure feed by supply pump 2............................................. 36
E-62 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error................................... 37
E-63 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error.................................... 39
E-64 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error ......................................... 40
E-65 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error ......................................... 42
E-66 Code [2555/CA2555] Grid Heater Relay Open Error ...................................................... 43
E-67 Code [2556/CA2556] Grid Heater Relay Short Error ...................................................... 44
E-68 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate ................................................... 46
E-69 Code [(146)/B@BCNS] Eng. Overheat ........................................................................... 46
E-70 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate ............................................ 47
Troubleshooting of mechanical system (S-mode) SEN00370-01
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
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 23
S-14 Coolant temperature becomes too high (overheating).................................................... 25
S-15 Abnormal noise is made.................................................................................................. 26
S-16 Vibration is excessive...................................................................................................... 27
S-17 Air cannot be bled from fuel circuit.................................................................................. 28
50 Disassembly and assembly

General information on disassembly and assembly SEN00765-01
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 3
Special tools list ....................................................................................................................... 6
Sketches of special tools ......................................................................................................... 8
Disassembly and assembly, Part 1 (With EGR) SEN00766-01
General disassembly of engine ............................................................................................... 2
General assembly of engine .................................................................................................... 22
6 170E-5 Series
Disassembly and assembly, Part 2 (EGR-less) SEN00767-01

General disassembly of engine ............................................................................................... 2
General assembly of engine.................................................................................................... 21
Disassembly and assembly, Part 3 SEN00768-01
Removal and installation of fuel supply pump unit .................................................................. 2
Rear oil seal............................................................................................................................. 7
170E-5 Series 7
SEN00192-06
KOMATSU 170E-5 Series engine
Form No. SEN00192-06
2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
8
SEN00193-03
ENGINE 1SHOP MANUAL
170E-5 Series
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
170E-5 Series 1
Safety notice 1 (Rev. 2007/03)

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.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
Wearing protective goggles
wear loose work clothes, or clothes with 7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc. Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 170E-5 Series
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
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 170E-5 Series
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
warning lamp, and check safety. 25 55.3 5.6
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
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 170E-5 Series
How to read the shop manual 1
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.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
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.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
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.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
170E-5 Series 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
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.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
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.
2 Coat Places to be coated with adhesives, etc. during 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 { }.
8 170E-5 Series
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the standard size and the range of differ-
ence from the standard size is called the
tolerance.
q The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
0.022
120
0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
170E-5 Series 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the standard clear- between them is increased to a certain
ance, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the clearance limit.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
standard value, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value interference limit.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the allowable
value.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 170E-5 Series
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
170E-5 Series 11
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.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 170E-5 Series
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
170E-5 Series 13
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 the 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.
14 170E-5 Series
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
170E-5 Series 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 170E-5 Series
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.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
170E-5 Series 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
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.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 170E-5 Series
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
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 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 107 170, 12V140 engine
q 107E-1 q Various temperature sensors
q 114E-3 Example)
q 125E-5 Intake air temperature sensor in
q 140E-5 intake manifold: TIM
q 170E-5 Fuel temperature sensor: TFUEL
q 12V140E-3 Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
1. Slide lock type etc.
(FRAMATOME-3, FRAMATOME-2) Disconnect the connector by pulling lock
q 107 170, 12V140 engines (B) (on the wiring harness side) of connec-
q Various pressure sensors and NE tor (2) outward.
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE (107 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 170E-5 Series
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
170E-5 Series 21
q 125 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 170E-5 Series
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
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.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(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)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX 50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
170E-5 Series 23
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
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
f of nominal No. denotes flexible.
24 170E-5 Series
3. Color codes table
(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.
4. Types of circuits and color codes
(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
170E-5 Series 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 170E-5 Series
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
170E-5 Series 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
28 170E-5 Series
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
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 29
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
contacts contact surface (a) of the hexag-
30 170E-5 Series
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
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-
170E-5 Series 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5
8 13 27 34 2.8 3.5
10 17 59 74 6.0 7.5
12 19 98 123 10.0 12.5
14 22 153 190 15.5 19.5
16 24 235 285 23.5 29.5
18 27 320 400 33.0 41.0
20 30 455 565 46.5 58.0
22 32 610 765 62.5 78.0
24 36 785 980 80.0 100.0
27 41 1,150 1,440 118 147
30 46 1,520 1,910 155 195
33 50 1,960 2,450 200 250
36 55 2,450 3,040 250 310
39 60 2,890 3,630 295 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0
8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
a Fig. A a Fig. B
32 170E-5 Series
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 74 6.0 7.5
12 17 98 123 10.0 12.5
16 22 235 285 23.5 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 63 { 3.5 6.5} 44 { 4.5}
03,04 20 Varies depending 84 132 { 8.5 13.5} 103 {10.5}
05,06 24 on type of connec- 128 186 {13.0 19.0} 157 {16.0}
10,12 33 tor. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1,010 {76.0 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}
10 10 17 9.81 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 { 9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 127.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
170E-5 Series 33
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.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
No. of across Thread diame-
Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 54 { 3.5 5.5} 9/16-18UN 14.3
02 19 44 { 4.5}
34 63 { 3.5 6.5} 14
22 54 93 { 5.5 9.5} 74 { 7.5} 11/16-16UN 17.5
03
24 59 98 { 6.0 10.0} 78 { 8.0} 18
04 27 84 132 { 8.5 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
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
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
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.
Thread size Tightening torque

mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51
34 170E-5 Series
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.
Thread size Tightening torque

inch Nm kgm
1/16 31 0.31 0.10
1/8 82 0.81 0.20
1/4 12 2 1.22 0.20
3/8 15 2 1.53 0.20
1/2 24 4 2.45 0.41
3/4 36 5 3.67 0.51
1 60 9 6.12 0.92
170E-5 Series 35
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
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 170E-5 Series
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
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
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 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
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
38 170E-5 Series
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 39
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.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
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
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 170E-5 Series
170E-5 Series 41
SEN00193-03
2007 KOMATSU
All Rights Reserved
42
SEN00195-02
ENGINE 1SHOP MANUAL
170E-5 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 6
General view ...................................................................................................................................... 14
Weight table ....................................................................................................................................... 31
Engine performance curves ............................................................................................................... 33
170E-5 Series 1
SEN00195-02 01 Specification
Outline 1
1. Applicable machine
Engine Engine serial No. Applicable machine

D375A-5E0
Bulldozer
D375A-5R
PC1250-8
Hydraulic excavator
PC1250-8R
WA600-6
SAA6D170E-5 Wheel loader
WA600-6R
HD465-7E0
Dump truck
HD465-7R
HD605-7E0
Dump truck
HD605-7R
2 170E-5 Series
2. Outline of engine
(with EGR)
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
10) The improved type of the KTR130 turbo-

charger which is manufactured by KOMATSU
and has been employed for many engines and
has high reliability and high performance is
mounted. Besides; the efficiency of the blower
impeller is heightened and the strength of its
material is improved to obtain higher efficiency
and pressure ratio. Since the design of the
shaft is improved to increase the reliability,
high performance is obtained from the low-
speed range to the high-speed range. As a
result, the engine has high performance and
consumes less fuel and attains high reliability.
11) The cylinder block is changed partly to add the

cooled EGR system. Since its overall length,
overall width, and overall height are the same
as before, however, its compactness is main-
tained.
4 170E-5 Series
(EGR-less)
q The 170E-5 engine is a high-performance and 5) The high-quality piston which is made of cast
high-efficiency engine, which attained low fuel iron and has the 2-stage combustion chamber
consumption and low noise. Accordingly, this of a new shape is employed. This piston has a
newly developed engine is suitable as a power less coefficient of thermal expansion, a reen-
source of construction machinery and indus- trant combustion chamber, and a shaker cool-
trial machinery used for various purposes. ing gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consump-
q The 170E-5 engine is the successor to the tion are attained simultaneously, and high
170E-3 engine. While it is an in-line 6-cylinder, durability and reliability are also obtained.
water-cooled, 4-stroke diesel engine, it is
equipped with the common rail direct injection 6) By using the above-mentioned high-pressure
system. fuel injection system controlled electronically,
the multiple injection and injection characteris-
1) The 170E-5 engine has 3 combination filters of tics are set most properly to improve the start-
high performance and high efficiency to meet ability and reduce the white exhaust smoke
the requirements of the high-dispersion oil and when the temperature is low.
improve the ability to capture the soot in the oil.
In addition, the recommended sub-materials 7) Engine controller is mounted on the engine
for operation (oil and fuel) are changed to and equipped with the automatic high-altitude
improve the reliability and durability of the compensation function, the engine can be
engine. operated at high altitude without replacing the
controller. As a result, the serviceability is
2) To secure the high output of the engine, the improved.
twin cooling nozzle to cool the piston employed
for 170E-3 and after models is improved to 8) The improved type of the KTR130 turbo-
increase the durability of the piston and lower charger which is manufactured by KOMATSU
the back side temperature of the piston. As a and has been employed for many engines and
result, the lubricating oil on the piston is not has high reliability and high performance is
exposed to high temperature, thus it is not mounted. Besides; the efficiency of the blower
deteriorated. Since the high-pressure fuel impeller is heightened and the strength of its
injection system controlled electronically is material is improved to obtain higher efficiency
employed, less soot is produced and the drain- and pressure ratio. Since the design of the
ing interval of the oil is lengthened. shaft is improved to increase the reliability,
high performance is obtained from the low-
3) The common rail high-pressure fuel injection speed range to the high-speed range. As a
system controlled electronically is employed. result, the engine has high performance and
This system can inject the fuel at high pressure consumes less fuel and attains high reliability.
of 160 MPa {1,600 kg/cm2} from the low-speed
range to the high-speed range. In addition,
this system can control the form of injection
most properly by electronic control according
to the speed and load. By heightening the
injection accuracy and employing multiple
injection, exhaust gas of the cleanest level in
the world, good exhaust gas color, low fuel
consumption, and low noise are realized simul-
taneously.
4) The main fuel filter of high efficiency and the

pre-fuel filter are installed as standard so that
the low grade fuel in the market (equivalent to
Class NAS13) can be used. In addition, the
priming pump used for replacing the filters is
electrified to improve serviceability.
170E-5 Series 5
Specifications 1
Engine name SAA6D170E-5
Applicable machine D375A-5E0
Number of cylinders Bore Stroke mm 6 170 170
Total displacement l {cc} 23.15 {23,152}
Firing order 153624
Overall length mm 1,823
Dimensions
Overall width mm 1,157

Overall height (excluding exhaust pipe) mm 1,697
Overall height (including exhaust pipe) mm
452 {606}/1,800
Rated output kW{HP}/rpm
(Gross)
3,020 {308}/1,300
Max. torque Nm{kgm}/rpm
Performance
(Gross)
No-load max. speed
rpm 1,900 20
(High idle speed)
No-load min. speed
rpm 720 30
(Low idle speed)
g/kWh
Fuel consumption ratio at rated output 227 {169}
{g/HPh}
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
6 170E-5 Series

Applicable machine D375A-5R
Firing order 153624
Dimensions

452 {606}/1,800
(Gross)
3,020 {308}/1,300
Performance
(Gross)
No-load max. speed
rpm 1,900 20
(High idle speed)
No-load min. speed
rpm 750 30
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 3,029
Air compressor
With cooled EGR
170E-5 Series 7

Applicable machine PC1250-8
Firing order 153624
Dimensions

515 {690}/1,800
(Gross)
3,025 {308.5}/1,300
Performance
(Gross)
No-load max. speed
rpm 2,000 40
(High idle speed)
No-load min. speed
rpm 900 25
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 3,140
Starting motor 24V, 11kW 2
Air compressor
With cooled EGR
8 170E-5 Series

Applicable machine PC1250-8R
Firing order 153624
Dimensions

515 {690}/1,800
(Gross)
3,025 {308.5}/1,300
Performance
(Gross)
No-load max. speed
rpm 2,000 40
(High idle speed)
No-load min. speed
rpm 900 25
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 3,156
Air compressor
With cooled EGR
170E-5 Series 9

Applicable machine WA600-6
Firing order 153624
Dimensions

396 {531}/1,800
(Gross)
2,594 {264.5}/1,000
Performance
(Gross)
No-load max. speed
rpm 2,000 50
(High idle speed)
No-load min. speed
rpm 800 25
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 3,050
Alternator 24V, 90A
Air compressor
With cooled EGR
10 170E-5 Series

Applicable machine WA600-6R
Firing order 153624
Dimensions

396 {531}/1,800
(Gross)
2,594 {264.5}/1,000
Performance
(Gross)
No-load max. speed
rpm 2,000 50
(High idle speed)
No-load min. speed
rpm 800 25
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 3,180
Alternator 24V, 90A
Air compressor
With cooled EGR
170E-5 Series 11

Applicable machine HD465-7E0, HD605-7E0
Firing order 153624
Dimensions

552 {740}/2,000
(Gross)
3,324 {339}/1,400
Performance
(Gross)
No-load max. speed
rpm 2,270 50
(High idle speed)
No-load min. speed
rpm 750 50
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 3,120
Air compressor
With cooled EGR
12 170E-5 Series

Applicable machine HD465-7R, HD605-7R
Firing order 153624
Dimensions

552 {740}/2,000
(Gross)
3,324 {339}/1,400
Performance
(Gross)
No-load max. speed
rpm 2,270 50
(High idle speed)
No-load min. speed
rpm 750 50
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 3,028
Air compressor
With cooled EGR
170E-5 Series 13
General view 1
SAA6D170E-5 (Left side of engine)
Applicable machine: D375A-5E0
a The shape is subject to machine models.

a For the dimensions of each part, see the last page of the general view.
1. Center of crankshaft
2. Rear face of flywheel housing
14 170E-5 Series
SAA6D170E-5 (Front side of engine)

Applicable machine: D375A-5E0

2. Center of cylinder liner
170E-5 Series 15

Applicable machine: D375A-5R

16 170E-5 Series

Applicable machine: D375A-5R

170E-5 Series 17

Applicable machine: PC1250-8

18 170E-5 Series

Applicable machine: PC1250-8

170E-5 Series 19

Applicable machine: PC1250-8R

20 170E-5 Series

Applicable machine: PC1250-8R

170E-5 Series 21

Applicable machine: WA600-6

22 170E-5 Series

Applicable machine: WA600-6

170E-5 Series 23

Applicable machine: WA600-6R

24 170E-5 Series

Applicable machine: WA600-6R

170E-5 Series 25

Applicable machine: HD465-7E0, HD605-7E0

26 170E-5 Series

Applicable machine: HD465-7E0, HD605-7E0

170E-5 Series 27

Applicable machine: HD465-7R, HD605-7R

28 170E-5 Series

Applicable machine: HD465-7R, HD605-7R

170E-5 Series 29
Dimensions table
Unit: mm
Dimension of each part
Engine Machine
A B C D E F G H
D375A-5E0
1,854 2,130 550 25 1,107 1,300
D375A-5R
PC1250-8
1,800 2,032 560 222 1,000 1,185 1,215
PC1250-8R
SAA6D170E-5 WA600-6
1,795 1,935 543 41 41 930 1,060 1,154
WA600-6R
HD465-7E0
HD465-7R
2,044 1,732 550 210 346 396 1,243
HD605-7E0
HD605-7R
a These dimensions are given for reference when the engine is set on a test bench.
30 170E-5 Series
Weight table 1
(with EGR)
Unit: kg
No. Item Main parts SAA6D170E-5
D375A-5E0 33.5
PC1250-8 36
1 Turbocharger KOMATSU KTR130E WA600-6 33.5
HD465-7E0
36
HD605-7E0
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-5E0 82
PC1250-8 80
6 Flywheel assembly Flywheel, ring gear WA600-6 36
HD465-7E0
43
HD605-7E0
D375A-5E0 170
PC1250-8 150
7 Flywheel housing assembly WA600-6 150
HD465-7E0
150
HD605-7E0
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
1: There may not be equipped according to the machine model.
170E-5 Series 31
(EGR-less)
Unit: kg
No. Item Main parts SAA6D170E-5
D375A-5R 41
PC1250-8R 43.5
1 Turbocharger KOMATSU KTR130E WA600-6R 41
HD465-7R
43.5
HD605-7R
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-5R 82
PC1250-8R 80
6 Flywheel assembly Flywheel, ring gear WA600-6R 36
HD465-7R
43
HD605-7R
D375A-5R 170
PC1250-8R 150
7 Flywheel housing assembly WA600-6R 150
HD465-7R
150
HD605-7R
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
32 170E-5 Series
Engine performance curves 1
Engine Engine serial No. Applicable machine Page

D375A-5E0
34
D375A-5R
PC1250-8
35
PC1250-8R
SAA6D170E-5 WA600-6
36
WA600-6R
HD465-7E0
HD465-7R
37
HD605-7E0
HD605-7R
170E-5 Series 33
SAA6D170E-5 (Applicable machine: D375A-5E0, D375A-5R)
Rated output: 452 kW {606 HP}/1,800 rpm (Gross)

Max. torque: 3,020 Nm {308 kgm}/1,300 rpm (Gross)
34 170E-5 Series
SAA6D170E-5 (Applicable machine: PC1250-8, PC1250-8R)

Max. torque: 3,025 Nm {308.5 kgm}/1,300 rpm (Gross)
170E-5 Series 35
SAA6D170E-5 (Applicable machine: WA600-6, WA600-6R)

Max. torque: 2,594 Nm {264.5 kgm}/1,000 rpm (Gross)
36 170E-5 Series
SAA6D170E-5 (Applicable machine: HD465-7E0, HD465-7R, HD605-7E0, HD605-7R)

Max. torque: 3,324 Nm {339 kgm}/1,400 rpm (Gross)
170E-5 Series 37
SEN00195-02
2006 KOMATSU
All Rights Reserved
38
SEN00197-02
ENGINE 1SHOP MANUAL
170E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 1
Intake and exhaust system ............................................................................................................................. 4
Air cleaner ............................................................................................................................................ 4
Turbocharger........................................................................................................................................ 6
EGR system ........................................................................................................................................11
Engine unit .................................................................................................................................................... 18
Cylinder head ..................................................................................................................................... 18
Cylinder block..................................................................................................................................... 22
Cylinder liner ...................................................................................................................................... 26
Main moving parts .............................................................................................................................. 27
Crankshaft.......................................................................................................................................... 30
Camshaft ............................................................................................................................................ 32
170E-5 Series 1
SEN00197-02 10 Structure, function and maintenance standard
Connecting rod ................................................................................................................................... 33

Piston, piston ring and piston pin ....................................................................................................... 34
Flywheel and flywheel housing........................................................................................................... 35
Vibration damper ................................................................................................................................ 36
Gear train ........................................................................................................................................... 37
Timing gear......................................................................................................................................... 42
Valve system ...................................................................................................................................... 46
Valve and valve guide ........................................................................................................................ 48
Rocker arm and shaft ......................................................................................................................... 49
Crosshead and guide ......................................................................................................................... 50
Tappet and push rod........................................................................................................................... 51
2 170E-5 Series
Intake and exhaust system 1

Air cleaner 1
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
A: Air inlet
B: To turbocharger (Intake air)
C: To muffler (Dust)
1. Inner element 4. Tube

2. Outer element 5. Pre-cleaner
3. Check valve 6. Air cleaner body
Applicable Method of discharging Number of ele-

Engine Type
machine dust from pre-cleaner ments
D375A-5E0
D375A-5R
PC1250-8 Automatic discharge 1 inner element
SAA6D170E-5 Komaclone, multi-cyclone (ERB type)
PC1250-8R (Exhaust ejector) 1 outer element
WA600-6
WA600-6R
4 170E-5 Series
FRG type
[Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]
1. Inlet 6. Evacuator valve

2. Outlet 7. Dust pan
3. Guide vane 8. Guide plate (Sleeve)
4. Primary element 9. Body
5. Safety element 10. Element
Number of
Engine Applicable machine Type Evacuator valve
elements
HD465-7E0
HD465-7R 1 inner cylinder,
SAA6D170E-5 FRG (Radial seal type) Automatic discharge
HD605-7E0 1 outer cylinder
HD605-7R
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
Turbocharger 1
Model name: KTR130E (Water-cooled)
6 170E-5 Series
A: Intake air inlet Structure and operation of turbocharger

B: Intake air outlet q The turbocharger has turbine impeller (6)
C: Exhaust gas inlet which is rotated by the high-speed exhaust
D: Exhaust gas outlet gas. Blower impeller (11) on the same shaft
E: Oil inlet with the turbine impeller is also rotated to
F: Oil outlet supercharge the engine with air.
G: Coolant q The shaft connecting the turbine impeller and
blower impeller is usually made in one unit
1. Blower housing together with the turbine impeller. The blower
2. V-band impeller is fixed with a nut to the opposite shaft
3. Center housing end of the turbine impeller.
4. Shield q The shaft rotates at very high speed of 50,000
5. Turbine housing 100,000 rpm and receives the thrust load
6. Turbine impeller generated by the intake air and exhaust gas
7. Seal ring and applied to the impellers.
8. Journal bearing q Accordingly, the shaft is supported on cylindri-
9. Thrust bearing cal floating journal bearing (8) and thrust bear-
10. Seal ring ing (9).
11. Blower impeller q Center housing (3) supports the bearings and
has oil passages to lubricate the bearings.
Specifications q The lubricated parts, exhaust side, and air
Model: KOMATSU KTR130E intake side are sealed by seal rings (7), (10).
(Water-cooled) q Turbine housing (5) houses turbine impeller (6)
Overall length: 343 mm and leads the exhaust gas from the exhaust
Overall width: 390 mm manifold to the turbine impeller. The exhaust
Overall height: 344 mm gas rotates the impeller at high speed and
Weight: 35.5 kg flows out of the engine.
q Blower housing (1) houses blower impeller and
leads the sucked air to the blower impeller.
The air compressed by the blower impeller is
fed forcibly to the engine.
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
Model name: KTR130E
8 170E-5 Series
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
EGR system 1
No. Component part Function

Controls the gas flow from the exhaust system to the air intake system.
EGR valve (driven hydrau-
1 Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the
lically)
exhaust gas flows to the air intake valve.
Opens the bypass valve when the boost pressure (PIN) is higher than the exhaust
pressure (PEX).
2 Bypass valve ( 1)
Makes the intake air flow to the exhaust side to increase the exhaust pressure so
that the exhaust gas will be returned to the air intake side easily.
3 EGR cooler Lowers the exhaust temperature and returns the exhaust gas to the air intake side.
4 Venturi system Generates negative pressure with the venturi effect and takes in the exhaust gas.
Controls the EGR according to the operating condition.
5 Each sensor
Troubleshoots the system.
1: There may not be equipped according to the machine model.
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
a The above illustration shows the engine for HD465-7E0 and HD605-7E0.
12 170E-5 Series
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)
1: There may not be equipped according to the

machine model.
170E-5 Series 13
EGR valve and bypass valve
A: Oil inlet 1. Stick prevention device

B: Oil outlet 2. Oil pressure control valve
C: EGR gas passage (EGR valve) 3. Solenoid
D: Boost air passage (Bypass valve) ( 1) 4. Position sensor
5. Hydraulic piston
6. Spring
7. Valve
Function q Valve (7) is closed by spring (6) but pushed

q The EGR valve controls the EGR gas. open by hydraulic piston (5) to an opening ratio
q This valve is driven hydraulically and its open- in proportion to the control oil pressure.
ing ratio is controlled electronically. q The valve opening ratio is sensed with position
sensor (4) installed to hydraulic piston (5) and
Operation set to the specified opening ratio by controlling
q The oil pressure (engine oil) of 1.47 MPa {15 the solenoid current.
kg/cm2} supplied to oil inlet (A) is reduced by q The bypass valve assists the EGR gas by
oil pressure control valve (2). increasing the exhaust pressure. ( 1)
q Hydraulic piston (5) generates pressing force q The structure and operation of the EGR
from the reduced oil pressure. bypass valve are the same as those of the
q The control oil pressure can be changed with EGR valve.
the drive current of solenoid (3).
machine model.
14 170E-5 Series
EGR cooler
A: EGR gas inlet D: Coolant outlet

B: EGR gas outlet E: Air bleeder
C: Coolant inlet
1. Heat exchange tube (Corrugated tube)
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
Venturi system
A: Air inlet 1. Venturi nozzle

B: EGR gas inlet 2. Throat
3. Diffuser
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
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
Specifications
Cylinder head
q Direct injection type
q 4-valve type
q Split type (1 cylinder, 1 head)
Valve seat insert

q Intake valve insert
q Exhaust valve insert
Both of these inserts are press fitted to the seats.
170E-5 Series 19
a Tighten the cylinder head mounting bolts in the order of (1) (9).
Unit: mm
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
Cylinder block 1
1. Front cover 8. Main bearing

2. Cylinder block 9. Main bearing cap
3. Cylinder liner 10. Main bearing cap bolt
4. Clevis seal 11. Front oil seal
5. Liner O-ring 12. Piston cooling nozzle
6. Liner O-ring 13. Oil level gauge
7. Thrust bearing
22 170E-5 Series
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
24 170E-5 Series
Unit: mm
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
Interference of cap and Standard interference Interference limit

3
cylinder block 0.090 0.140 0.05
Standard size Tolerance Repair limit Correct or
Inside diameter of cam-
shaft bushing +0.222 replace
90 90.23
4 +0.112
Clearance of camshaft Standard clearance Clearance limit
bearing 0.077 0.217 0.25
Strain of cylinder head Tolerance Repair limit
5
mounting face 0.09 0.15
Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque of main
bearing cap mounting bolt 1st stage 284 {29} 270 299 {27.5 30.5}
6 Retighten
(Apply engine oil to 2nd stage 569 {58} 559 579 {57.0 59.0}
threads and washer)
3rd stage Retighten 90 90(+30/0)
170E-5 Series 25
Cylinder liner 1
A. Cylinder liner section

B. Cylinder block section
Unit: mm
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)
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
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
Main moving parts 1

a No. in ( ) is used to indicate the same part at a
different place or explain a part from a different
angle. Accordingly, see the part of that No.
1. Piston pin 10. Thrust bearing

2. Connecting rod 11. Crankshaft
3. Connecting rod bushing 12. Connecting rod cap
4. Piston (FCD piston type) 13. Connecting rod cap bolt
5. Top ring 14. Connecting rod bearing
6. Second ring 15. Crank gear (Number of teeth: 55)
7. Oil ring 16. Vibration damper
8. Camshaft drive gear (Number of teeth: 63) 17. Crank pulley
9. Main bearing
170E-5 Series 27
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
Main bearing and connecting rod bearing

3-layer kelmet Piston rings
Upper main bearing: With oil groove Top ring (1) : Inner cut, barrel face, ion plating
Second ring (2) : Inner cut, taper face, hard chro-
Connecting rod mium-plated
Made of forged alloy steel Oil ring (3) : Bevel cutter, surface nitriding
Camshaft
Journal and fillet: Induction hardening
28 170E-5 Series
Crankshaft 1
30 170E-5 Series
Unit: mm
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
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
Camshaft 1
Unit: mm
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
Connecting rod 1
Unit: mm
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
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
Size Standard size Tolerance Repair limit

S.T.D. 3.500 3.41
Replace
Thickness of bearing (at 0.25 U.S. 3.625 3.54
4 0.029
center) 0.50 U.S. 3.750 3.66
0.042
0.75 U.S. 3.875 3.79
1.00 U.S. 4.000 3.91
Bend and twist of connect- Bend limit: 0.10
5
ing rod Twist limit: 0.25
6 Weight of connecting rod 10.29 0.03 kg
Tightening torque of con- Procedure Target (Nm {kgm}) Range (Nm {kgm})
necting rod cap mounting 1st stage 196 {20} 186 206 {19 21}
8 Tighten
bolt (Apply engine oil to bolt
threads and washer) 2nd stage Retighten 90 Retighten 90 (+15/0)
170E-5 Series 33
Piston, piston ring and piston pin 1

FCD piston type
Unit: mm
Outside diameter of pis- Standard size Tolerance Repair limit
1 ton (at 3.0 mm from pis- 170 0.135
ton bottom and 20C) 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
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
Flywheel and flywheel housing 1
1. Rear seal
2. Ring gear (Number of teeth: 118 (D375A-5E0, D375A-5R: 138))
3. Flywheel
4. Flywheel housing
5. Engine speed sensor
6. Burring device (Service tool)
170E-5 Series 35
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
Gear train 1
(with EGR)
Front side (for driving auxiliaries)
1. Oil pump drive gear (Number of teeth: 38)

2. Water pump drive gear (Number of teeth: 31)
3. Idler gear (Number of teeth: 84)
4. Crankshaft gear (Number of teeth: 55)
5. EGR oil pump drive gear (Number of teeth: 43)
7. Alternator drive gear (Number of teeth: 55)
170E-5 Series 37
Front side
38 170E-5 Series
(EGR-less)
Front side (for driving auxiliaries)

2. Water pump drive gear (Number of teeth: 31)
6. Alternator drive gear (Number of teeth: 55)
170E-5 Series 39
Front side
40 170E-5 Series
(with EGR, EGR-less)

Unit: mm
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)
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 41
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)

4. Camshaft gear (Number of teeth: 70)
5. Fuel supply pump drive gear (Number of teeth:
70)
42 170E-5 Series
44 170E-5 Series
Unit: mm
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
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 45
Valve system 1
a No. in ( ) is used to indicate the same part at a

different place or explain a part from a different
angle. Accordingly, see the part of that No.
1. Intake valve 12. Cross head

2. Exhaust valve 13. Adjustment screw
3. Rocker arm (for intake) 14. Locknut
4. Rocker arm (for exhaust) 15. Push rod (for intake)
5. Camshaft 16. Push rod (for exhaust)
6. Camshaft gear (Number of teeth: 70) 17. Injector
7. Lower spring seat 18. Cam roller
8. Spring 19. Cam follower pin
9. Upper spring seat 20. Cam follower
10. Locknut (for cross head) 21. Cam follower shaft
11. Adjustment screw (for cross head) 22. Oil seal (for intake and exhaust)
46 170E-5 Series
Intake/Exhaust side of No. 1 cylinder Valve timing
Specifications
Camshaft: Made of special carbon steel, 7 bear-
ings
Journal and cam: Induction hardening
170E-5 Series 47
Valve and valve guide 1
Unit: mm
Replace valve
1 Sinking distance of valve Intake and
0 0.80 or valve seat
exhaust valves
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 30 015'
Exhaust valve 45 015'
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
48 170E-5 Series
Rocker arm and shaft 1

Intake valve and exhaust valve
Unit: mm
Outside diameter of rocker Replace rocker arm
arm shaft 0.0150 shaft
45.0
0.0280
1 Inside diameter of rocker +0.099

45.0 Replace rocker arm
arm bushing +0.024
Clearance between rocker Standard clearance Clearance limit
Replace rocker arm
arm shaft and rocker arm
0.039 0.127 0.16 shaft or rocker arm
bushing
Valve Standard Tolerance
2 Valve clearance (cold) Intake valve 0.32 Adjust
0.02
Exhaust valve 0.62
Tightening torque of lock- Target (Nm {kgm}) Range (Nm {kgm})
3 nut of rocker arm adjust- Tighten
ment screw 68 {6.9} 58 77 {5.9 7.9}
170E-5 Series 49
Crosshead and guide 1
Unit: mm
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
50 170E-5 Series
Tappet and push rod 1

Intake valve and exhaust valve
Unit: mm
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 51
SEN00197-02
2006 KOMATSU
All Rights Reserved
52
SEN00198-02
ENGINE 1SHOP MANUAL
170E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram ................................................................................................................. 4
Oil pump............................................................................................................................................... 8
Oil filter and safety valve .................................................................................................................... 12
Oil cooler ............................................................................................................................................ 13
Fuel system................................................................................................................................................... 14
CRI system diagram........................................................................................................................... 14
Outline of CRI system ........................................................................................................................ 15
Fuel piping.......................................................................................................................................... 36
Fuel filter ............................................................................................................................................ 38
Electric priming pump......................................................................................................................... 40
170E-5 Series 1
Engine controller cooler...................................................................................................................... 41

Cooling system.............................................................................................................................................. 42
Cooling system diagram..................................................................................................................... 42
Water pump ........................................................................................................................................ 44
Thermostat ......................................................................................................................................... 45
Corrosion resistor ............................................................................................................................... 47
Fan drive ............................................................................................................................................ 49
Electrical equipment...................................................................................................................................... 50
Alternator............................................................................................................................................ 50
Starting motor ..................................................................................................................................... 54
Starting aid ......................................................................................................................................... 57
Engine controller ................................................................................................................................ 58
2 170E-5 Series
Lubrication system 1
Lubrication system diagram 1
(with EGR)
4 170E-5 Series
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

machine model.
170E-5 Series 5
(EGR-less)
6 170E-5 Series
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
14. Timing gear (Rear side)
15. Auxiliary equipment drive gear (Front side)
16. Oil pressure gauge
17. Turbocharger
170E-5 Series 7
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
8. Bushing
9. Driven gear (Number of teeth: 10)
10. Driven shaft
8 170E-5 Series
Oil pump relief valve
1. Valve
2. Spring
170E-5 Series 9
10 170E-5 Series
Unit: mm
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
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
Interference of pump gear size Shaft Hole
8
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 11
Oil filter and safety valve 1
A. From oil pump Specifications

B. To each part of engine Oil filter
Filtration area: 0.44 m2 3
1. Safety valve
2. Filter bracket Safety valve
3. Cartridge Operating pressure (Differential pressure):
441 19.6 kPa {4.5 0.2 kg/cm2}
12 170E-5 Series
Oil cooler 1
a. Water drain Specifications

b. Oil inlet Oil cooler thermo-valve
c. To each part of engine (Oil) Opening temperature: 85C 1.5C
d. Water inlet Full opening temperature: 100C
Full opening lift: Min. 8 mm
1. Thermostat cover
2. Thermostat (Thermo-valve) Oil cooler
3. Cooler cover Oil cooler: 2 units are installed.
4. Cooler element Heat exchange capacity: Min. 60,000 kcal/h
Oil flow rate: 280 l/min
Water flow rate: 890 l/min
Number of cooler element stages: 9
Heat dissipation surface: 0.65 m2
Unit: mm
Full opening lift of thermo- Min. 8 mm (Check after soaking valve in oil tank at 100C for 4
stat 5 minutes)
5 Check that valve closes fully when its temperature is lowered from Replace
Opening and closing of ther-
100C for full opening to 85C. (Check after soaking valve in oil
mostat
tank for 4 5 minutes)
170E-5 Series 13
Fuel system 1
CRI system diagram 1
a CRI is an abbreviation for common rail injection.
1. NE speed sensor 9. Fuel supply pump 10. Common rail

2. Engine controller 9A. PCV 11. High pressure injection pipe
3. Injector 9B. High pressure pump 12. Flow damper
4. Orifice (for bleeding air) 9C. Priming pump 13. Pressure limiter
5. Fuel tank 9D. Feed pump 14. Electric priming pump
6. Pre-fuel filter 9E. Relief valve 15. Engine controller cooler
7. Main fuel filter 9F. Bkup speed sensor
8. Overflow valve (G sensor)
14 170E-5 Series
Outline of CRI system 1

Outline 1. Fuel system
q The CRI system checks the condition of the
engine (engine speed, accelerator angle, cool-
ant temperature, etc.) with sensors.
q The microcomputer of the CRI system controls
the fuel injection rate, fuel injection timing, fuel
injection pressure, etc. totally to operate the
engine under the best condition.
q The CRI system has a diagnosis function and
an alarm function, with which the computer of
the system checks the main component parts
and notifies the operator of detected failures.
q In addition, the CRI system has a failsafe func-
tion which stops the engine when a certain
parts fail and a backup function which contin-
ues the operation by changing the control
method in such a case.
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
q The fuel system distributes the high-pressure

fuel supplied by the fuel supply pump to the
cylinders through the common rail.
q The solenoid valve in the injector opens and
closes the nozzle needle valve to start and fin-
ish injection.
170E-5 Series 15
2. Control system
q The engine controller calculates and controls

the energizing timing and energizing period of
the injector with the signals from the sensors
installed to the machine to inject proper quan-
tity of fuel in proper timing.
q The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
16 170E-5 Series
Structure and operation of CRI system
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 17
Structure and operation of component parts 1

1. Fuel supply pump
1. 3-top cam 6. No. 2 high-pressure pump

2. Overflow valve 7. Priming pump
3. Drive coupling 8. Feed pump
4. No. 1 high-pressure pump 9. Gear for Bkup speed sensor (G sensor)
5. PCV (Pump control valve)
Outline q Since the number of the times of feeding fuel

q The fuel supply pump consists of priming to the common rail is the same as the number
pump (7), feed pump (8), and high-pressure of the times of fuel injection, the common rail
pumps (4) and (6). fuel pressure is smooth and stable.
q The function of the fuel supply pump is to gen- q The fuel fed by high-pressure pumps (4) and
erate common rail fuel pressure by controlling (6) to the common rail is divided as follows.
the fuel delivery. q No. 1 high pressure pump (on the drive cou-
pling side) (4) compensates for drop of the
Structure common rail fuel pressure caused by fuel
q High-pressure pumps (4) and (6) have the injection into the No. 1, 3, and 5 cylinders.
pressure feed systems similar to those of the q No. 2 high-pressure pump (on the feed pump
conventional in-line fuel injection pump and the side) (6) compensates for drop in the common
PCVs (pressure control valves) for each cylin- rail fuel pressure caused by fuel injection into
der to control the fuel delivery. the No. 2, 4, and 6 cylinders.
q By employing 3-top cam (1), the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.
18 170E-5 Series
Operation
q (A): During the lowering stroke of the plunger,

the PCV is open and the low-pressure fuel
is sucked in the plunger chamber through
the PCV.
q (B): While the PCV is not energized and is open
after the plunger starts the rising stroke, the
sucked fuel is returned through the PCV
without being pressurized.
q (C): If the PCV is energized and closed in the
timing for the necessary delivery, the return
passage is closed and the pressure in the
plunger chamber rises. Accordingly, the
fuel is fed through the delivery valve (check
valve) to the common rail. That is, the
quantity of the fuel corresponding to the
plunger lift after the PCV is closed is the
delivery. The delivery is changed and the
common rail fuel pressure is controlled by
changing the opening timing of the PCV.
q (D): After the cam passes the maximum lift
point, the plunger starts the lowering stroke
and the pressure in it lowers. At this time,
the delivery valve closes to stop feeding the
fuel. Since the PCV is de-energized, it
opens and the low-pressure fuel is sucked
in the plunger chamber, or the state of (A)
starts again.
170E-5 Series 19
1) PCV (Pressure control valve) 2) Feed pump

q The PCV adjusts the fuel delivery from the fuel q The feed pump built in the fuel supply pump
supply pump to adjust the common rail fuel assembly draws the fuel from the fuel tank and
pressure. The delivery from the fuel supply sends it through the fuel filter to the high-pres-
pump to the common rail is decided by the tim- sure pump chamber.
ing of energizing the PCV. q The outer and inner rotors of the feed pump
are rotated by the camshaft.
q The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.
20 170E-5 Series
2. Common rail
Structure When fuel is stopped

q Common rail (4) distributes the high-pressure q If the fuel flows out abnormally because of a
fuel from the high-pressure pump to the injec- burst of the piping, etc., piston (2) moves to the
tors of the cylinders. right stroke end.
q Common rail (4) is equipped with common rail q The tip of piston (2) contacts seat (b) to stop
fuel pressure sensor (2), flow dampers (1), and the fuel.
pressure limiter (3). q Once the fuel is stopped, piston (2) does not
q The fuel injection pipes are connected to flow return to the initial position until the engine is
dampers (1) to send the high-pressure fuel to stopped.
the injectors.
q The piping of the pressure limiter (3) is
returned to the fuel tank.
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.
When fuel is injected

q The fuel pressure is applied to piston (2),
which compresses spring (3) and moves to the
right.
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
170E-5 Series 21
2) Pressure limiter 3) Common rail fuel pressure sensor

q If abnormally high pressure is generated, the q The common rail fuel pressure sensor is
pressure limiter opens to release that pres- installed to the common rail to sense the fuel
sure. pressure.
q If the common rail fuel pressure reaches about q This sensor is a semiconductor pressure sen-
220 MPa {2,156 kg/cm2}, the pressure limiter sor, which utilizes the phenomenon that the
operates (opens). electric resistance of silicon changes according
q If the common rail fuel pressure lowers to 30 to pressure applied to it.
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
q Under the normal condition, the pressure lim-
iter does not reset itself (close) until the engine
is stopped.
1. Ball
2. Housing
3. Spring
4. Guide
5. Body
22 170E-5 Series
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 23
Structure
1. Inlet connector 7. Orifice (in)

2. Terminal 8. Pressure control chamber
3. Upper body 9. Control piston
4. Solenoid 10. Spring
5. Valve body 11. Pressure pin
6. Orifice (out) 12. Nozzle assembly
q The injector consists of the nozzle section, ori-

fice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve sec-
tion.
24 170E-5 Series
A: No fuel injection C: Finish of fuel injection

B: Start of fuel injection D: From common rail
1. Nozzle 5. Valve body

2. Control piston 6. Solenoid
3. Orifice (in) 7. Spring
4. Orifice (out) 8. Pressure control chamber
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 25
Electric circuit diagram
k Since high voltage (65 V) is applied to the

wiring harnesses connected to the engine
controller, COMMON 1 and COMMON 2 of
the supply pump, and TWV #1 #6 of the
injector, take care not get an electric shock.
26 170E-5 Series
Various controls
a Parts marked with * (3 places) are installed to only the engines with EGR.
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 control 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 27
4. Various sensors
a Nos. 1 12 in the above illustration correspond to title Nos. 1) 12).

a The above illustration shows the engine for PC1250-8.
a Parts *10 and *11 are installed to only the engines with EGR.
28 170E-5 Series
170E-5 Series 29
a Nos. 1 12 in the above illustration correspond to title Nos. 1) 12).

a The above illustration shows the engine for HD465-7E0 and HD605-7E0.
a Parts *10 and *11 are installed to only the engines with EGR.
30 170E-5 Series
170E-5 Series 31
1) Common rail pressure sensor 4) Charge pressure sensor

q This sensor is used to sense the charge pres-
2) Oil pressure sensor sure (boost pressure).
3) Charge temperature sensor

q The charge temperature sensor senses the
intake air temperature (boost temperature) and
sends it to the engine controller.
q The sensor unit is a thermistor the resistance
of which changes according to the tempera-
ture. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
A: Mounting screw: M6
Tightening torque:
5.5 0.5 Nm {0.56 0.05 kgm}
1. Sensor
2. O-ring
q The following graph shows the output charac-

teristics of the charge pressure sensor.
32 170E-5 Series
5) Bkup speed sensor (G sensor) 6) Atmospheric pressure sensor

(Cylinder No. sensor) q This sensor is used to correct altitude.
q Similarly to the NE speed sensor, this sensor
utilizes the pulses of 0 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120.
q In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
A: Pressure inlet
B: Mounting screw: M5
Tightening torque:
4.5 0.5 Nm {0.46 0.05 kgm}
teristics of the atmospheric pressure sensor.
170E-5 Series 33
7) NE speed sensor (Crank angle sensor)

q If the signal hole made on the flywheel passes
the sensor, the magnetic line of force changes.
q If the magnetic line of force changes, the out-
put of the Hall element sensor changes linearly
and it is converted into pulse of 0 5 V by the
wave form shaping circuit in the sensor, and
then output.
10) Bypass valve position sensor (Applicable

machine: PC1250-8, HD465-7E0, HD605-7E0)
(with EGR)
11) EGR valve position sensor (with EGR)

q This sensor senses the opening and closing
positions of the EGR valve and bypass valve.
8) Engine controller
9) Fuel temperature sensor

q The fuel temperature sensor senses the fuel
temperature and sends it to the engine control-
ler. The sensor unit is a thermistor the resis-
tance of which changes according to the
temperature.
q The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the com-
puter and the resistance of the thermistor.
1. EGR and bypass valve position sensors

teristics of the position sensor.
34 170E-5 Series
12) Coolant temperature sensor

q The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
q The sensor unit is a thermistor the resistance
of which changes according to the tempera-
ture. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
170E-5 Series 35
Fuel piping 1
a The above illustration shows the engine for WA600-6.

Specifications A: Fuel inlet

Fuel supply pump B: To engine controller cooler
Manufacturer: DENSO CORPORATION C: To main fuel filter
Model: DENSO ECD-U2 D: From main fuel filter
Lubrication method: E: To injector
Forced lubrication with engine oil F: Return fuel
(Between overflow valve and main fuel tank)
G: Return fuel
(Between injector and main fuel tank)
36 170E-5 Series
a The above illustration shows the engine for WA600-6.

1. Overflow valve 11. PCV

2. Air bleeding tube 12. Priming pump (sub)
3. Fuel injection pipe (No. 1 cylinder) 13. Feed pump
4. Fuel injection pipe (No. 2 cylinder) 14. Fuel supply pump drive gear
5. Fuel injection pipe (No. 3 cylinder) (Number of teeth: 48)
6. Fuel injection pipe (No. 4 cylinder) 15. High pressure pump
7. Fuel injection pipe (No. 5 cylinder) 16. Oil inlet pipe (for pump lubricating oil)
8. Fuel injection pipe (No. 6 cylinder) 17. Electric priming pump
9. Common rail 18. Pre-fuel filter
10. Fuel return pipe 19. Main fuel filter
170E-5 Series 37
Fuel filter 1
Main fuel filter
A: Fuel inlet
B: Fuel outlet
1. Air bleeding pipe adapter

2. Filter head
3. Cartridge
Specifications
Filtration area: 1.06 m2
38 170E-5 Series
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
1. Filter head
2. Cartridge
Specifications
With water separator
170E-5 Series 39
Electric priming pump 1
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
40 170E-5 Series
Engine controller cooler 1
A: Fuel IN (From feed pump of fuel supply pump)

B: Fuel OUT (Main fuel filter)
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 41
Cooling system 1
Cooling system diagram 1
(with EGR)
A. From oil pump (Oil)

B. To each part of engine (Oil)
1. Water pump 6. Water manifold (in cylinder block)

2. Oil cooler 7. Thermostat
3. Corrosion resistor 8. Radiator
4. Cylinder liner 9. Fan
5. Cylinder block 10. EGR cooler
42 170E-5 Series
(EGR-less)
A. From oil pump (Oil)

B. To each part of engine (Oil)
1. Water pump 6. Water manifold (in cylinder block)

2. Oil cooler 7. Thermostat
3. Corrosion resistor 8. Radiator
4. Cylinder liner 9. Fan
5. Cylinder block
170E-5 Series 43
Water pump 1

a. From radiator 1. Pump body 7. Water pump drive gear
b. To oil cooler 2. Impeller (Number of teeth: 31)
c. From thermostat 3. Floating seal 8. Inlet housing
d. Breather hole 4. Water seal
(for draining water) 5. Oil seal Specifications
6. Pump shaft Speed: Engine speed 1.77
Delivery: 800 l/min (at 3,730 rpm)
Unit: mm
Tolerance Standard
Standard size
Interference of pump shaft and Shaft Hole interference
9
bearing (front)
+0.011 0
25 0.002 0.021
+0.002 0.010
Interference of pump shaft and +0.011 0
10 25 0.002 0.021 Replace
bearing (rear) +0.002 0.010
Interference of pump shaft and +0.018 0.025
11 19.9 0.031 0.068
impeller +0.006 0.050
Clearance between impeller and Standard clearance Clearance limit
12
connection 0.26 0.68
44 170E-5 Series
Thermostat 1
170E-5 Series 45
A: When cold (Fully closed)

B: When hot (Fully open)
a. From each part of engine
b. To water pump
c. To radiator
1. Seal
2. Thermostat
3. Valve
4. Body
5. Piston
6. Heat sensing portion
7. Sleeve
8. Inflating portion
Specifications
Opening temperature: 76.5 2C
Full opening temperature: 90C
Valve lift: Min. 9 mm
Unit: mm
Full opening lift of ther-
Min. 9 mm (Check after soaking in oil tank at 90C for 4 5 minutes)
mostat
2 Check that valve closes fully when its temperature is lowered from Replace
Opening and closing of
90C for full opening to 76.5C. (Check after soaking valve in oil tank
thermostat
for 4 5 minutes)
46 170E-5 Series
Corrosion resistor 1
A: Coolant inlet Specifications

B: Coolant outlet
Filtration area 0.13 m2 0.19 m2 0.37 m2
1. Head Quantity of
400 g 600 g 1,000 g
2. Cartridge anti-corrosion agent
3. Element
4. Inhibitor (Solid anti-corrosion agent)
5. Spring
6. Stop valve
170E-5 Series 47
Corrosion resistor mounting
1. Tube (Return from corrosion resistor)

2. Corrosion resistor head
3. Corrosion resistor cartridge
4. Tube (To corrosion resistor)
48 170E-5 Series
Fan drive 1
HD465-7E0, HD605-7E0, HD465-7R, HD605-7R
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
170E-5 Series 49
Electrical equipment 1
Alternator 1
Alternator mounting

a The above illustration shows the engine for WA600-6, WA600-6R.
1. Drive pulley (Pitch circle of pulley: 180 mm)

2. Alternator pulley (Pitch circle of pulley: 80 mm)
3. Alternator
4. Alternator mounting bolt
5. Fix bolt (when replacing belt)
6. Locknut
7. Belt
8. Alternator belt tension pulley.
50 170E-5 Series
Alternator belt tension
WA600-6, WA600-6R
1. Tension shaft 6. Spacer

2. Spring 7. Tension pulley (Outside diameter: 150 mm)
3. Roller bearing 8. Ball bearing
4. Tension bracket 9. Grease fitting
5. Oil seal 10. Adjustment bolt
170E-5 Series 51
Alternator
With built-in regulator (Open type, 60A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal E 6C. Regulator
5. Terminal R
Outside diam-
Applicable
Engine Type Specification eter of pulley Weight (kg)
machine
(mm)
D375A-5E0 Open type (brushless), manufac-
24V, 60A
D375A-5R tured by NIKKO DENKI
PC1250-8 Open type (brushless), manufac-
24V, 60A
PC1250-8R tured by NIKKO DENKI
SAA6D170E-5
HD465-7E0 Open type (brushless), manufac-
24V, 60A
HD465-7R tured by NIKKO DENKI
24V, 60A
52 170E-5 Series
With built-in regulator (Open type, 90A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal E 6C. Regulator
5. Terminal R
Outside diam-
Applicable
Engine Type Specification eter of pulley Weight (kg)
machine
(mm)
D375A-5E0 Open type (brushless), manufac-
24V, 90A
D375A-5R tured by NIKKO DENKI
PC1250-8 Open type (brushless), manufac-
24V, 90A
PC1250-8R tured by NIKKO DENKI
WA600-6 Open type (brushless), manufac-
SAA6D170E-5 24V, 90A
WA600-6R tured by NIKKO DENKI
24V, 90A
24V, 90A
170E-5 Series 53
Starting motor 1
For 7.5 kW
1. Pinion gear S: To starting switch terminal C

2. Starting motor assembly R: To alternator terminal R
3. Magnetic switch E: To ground
4. Terminal B
5. Terminal C
6. Safety relay
7. External wiring diagram (2-pin connector type)
7A. Safety relay position
7B. Starting motor position
8. External wiring diagram (3-pin connector type)
8A. Safety relay position
8B. Starting motor position
54 170E-5 Series
Safety relay
Applicable Specifica- No. of pin- Connector
Engine Type Weight (kg) mounting
machine tion ion teeth type
type
D375A-5E0 NIKKO DENKI 27V, 7.5kW
11 18 G E
D375A-5R (Water-proof, oil-proof type) x2
HD465-7E0 NIKKO DENKI 27V, 7.5kW
SAA6D170E-5 11 18 G C
HD465-7R (Water-proof, oil-proof type) x2
HD605-7E0 NIKKO DENKI 27V, 7.5kW
11 18 G C
HD605-7R (Water-proof, oil-proof type) x2
170E-5 Series 55
For 11 kW
E: To chassis ground 1. Pinion gear

R: To alternator terminal R 2. Starting motor assembly
S: To starting switch terminal C 3. Magnetic switch
4. Terminal B
5. Terminal C
6. Safety relay
7. External electric circuit diagram
[2-pole connector type]
7A. Safety relay section
7B. Starting motor section
Applicable No. of pinion

Engine Type Specification Weight (kg) Connector type
machine teeth
Waterproof, oilproof,
PC1250-8
manufactured 24V, 11kW 12 18 B
PC1250-8R
by NIKKO DENKI
SAA6D170E-5
Waterproof, oilproof,
WA600-6
manufactured 24V, 11kW 12 18 B
WA600-6R
by NIKKO DENKI
56 170E-5 Series
Starting aid 1
Electrical intake air heater
For SAA6D170E-5
a The shape is subject to change for modification, etc.
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
170E-5 Series 57
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
58 170E-5 Series
SEN00198-02
2006 KOMATSU
All Rights Reserved
60
SEN00367-02
ENGINE 1SHOP MANUAL
170E-5 Series
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ......................................................................... 10
170E-5 Series 1
SEN00367-02 20 Standard value table
Standard service value table 1

Standard service value table for testing, adjusting, and troubleshooting
Engine SAA6D170E-5
Machine model D375A-5E0
Performance Category
Standard value
Judgement
Item Measurement conditions Unit for new
criteria
machine
High idle speed rpm 1,900 20 1,900 20
Speed
Low idle speed rpm 750 20 750 20
Necessary At 0C (without starting aid) rpm 125
speed for starting At 20C (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. 141.3 128
At rated output
pressure {mmHg} {Min. 1,060} {960}
Exhaust kPa Min. 159.3 146
At rated output
pressure {mmHg} {Min. 1,195} {1,095}
Air intake and exhaust system
Exhaust
Whole speed range (20C ) C Max. 700 730
temperature
%
Max. 25 35
At sudden acceleration (Low High) (Bosch
(Max. 2.5) (3.5)
index)
Exhaust gas color Bosch
At rated output Max. 1.5 2.5
index
Bosch
At high idle Max. 1.0 2.0
index
Valve clearance Intake valve mm 0.32
(at cold) Exhaust valve mm 0.62
MPa Min. 1.18
EGR valve and At low idle
{kg/cm2} {Min. 12}
bypass valve
drive pressure MPa Min. 1.43
At high idle
{kg/cm2} {Min. 14.6}
Compression Engine oil temperature: 40 60C MPa Min. 2.94 2.1
pressure Engine speed: 210 250 rpm {kg/cm2} {Min. 30} {21}
Body
Blow-by At rated output kPa Max. 3.43 9.41

pressure Engine coolant temperature: Min. 70C {mmH2O} {Max. 350} {960}
At rated output SAE0W30E0S MPa Min. 0.39 0.24
Engine oil temperature: Min. 80C SAE5W40E0S {kg/cm2} {Min. 4.0} {2.4}
Lubrication system
Engine oil
SAE10W30DH
pressure At low idle MPa Min. 0.12 0.08
SAE15W40DH
Engine oil temperature: Min. 80C SAE30DH {kg/cm2} {Min. 1.2} {0.8}
Engine oil
Whole speed range C 90 110 120
temperature
Ratio to fuel consumption at continuous rated
Oil consumption % Max. 0.1 0.3
output
Function of
kPa
radiator pressure Cracking pressure (Differential pressure)
{kg/cm2}
valve
Cooling system
Hydraulically driven on
Fan speed At rated speed rpm
machine side
Hydraulically driven on
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm
machine side
Alternator belt
Deflection under finger pressure of 98 N {10 kg} mm
tension (Auto-tension)
2 170E-5 Series
Engine SAA6D170E-5
Machine model D375A-5R
Standard value
Judgement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 113.3 100
At rated output
pressure {mmHg} {Min. 850} {750}
Exhaust kPa Min. 120 106.6

At rated output
Exhaust
temperature
%
Max. 35 45
(Max. 3.5) (4.5)
index)
index
Bosch
index
Body

Lubrication system
Engine oil
SAE10W30DH
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm driven on driven on
Alternator belt
170E-5 Series 3
Engine SAA6D170E-5
Machine model PC1250-8
Standard value
Judgement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 160 147
At rated output
Exhaust kPa Min. 148 134.6
At rated output
Exhaust
temperature
%
Max. 45 55
(Max. 4.5) (5.5)
index)
index
Bosch
index
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve
At high idle
{kg/cm2} {Min. 14.6}
Body

pressure Engine coolant temperature: Min. 70C {mmH2O} {Max. 350} {1,320}
Lubrication system
Engine oil
SAE10W30DH
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt
4 170E-5 Series
Engine SAA6D170E-5
Machine model PC1250-8R
Standard value
JudgRement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 116 102.6
At rated output
Exhaust kPa Min. 123 109

At rated output
Exhaust
temperature
%
Max. 45 55
(Max. 4.5) (5.5)
index)
index
Bosch
index
Body

Lubrication system
Engine oil
SAE10W30DH
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt
170E-5 Series 5
Engine SAA6D170E-5
Machine model WA600-6
Standard value
Judgement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 126.6 113.3
At rated output
At rated output
Exhaust
temperature
%
Max. 40 50
(Max. 4.0) (5.0)
index)
index
Bosch
index
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve
At high idle
{kg/cm2} {Min. 14.6}
Body

Lubrication system
Engine oil
SAE10W30DH
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt
6 170E-5 Series
Engine SAA6D170E-5
Machine model WA600-6R
Standard value
Judgement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 94 80.6
At rated output
Exhaust kPa Min. 110.6 97.3

At rated output
Exhaust
temperature
%
Max. 40 50
(Max. 4.0) (5.0)
index)
index
Bosch
index
Body

Lubrication system
Engine oil
SAE10W30DH
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt
170E-5 Series 7
Engine SAA6D170E-5
HD465-7E0
Machine model
HD605-7E0
Standard value
Judgement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 160 147
At rated output
At rated output
Exhaust
temperature
%
Max. 40 50
(Max. 4.0) (5.0)
index)
index
Bosch
index
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve
At high idle
{kg/cm2} {Min. 14.6}
Body

Lubrication system
Engine oil
SAE10W30DH
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
Cooling system
valve
Fan speed At rated speed rpm 1,142 1,142

(Auto-tension) (Auto-tension)
Alternator belt
8 170E-5 Series
Engine SAA6D170E-5
HD465-7R
Machine model
HD605-7R
Standard value
Judgement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 130.6 117.3
At rated output

At rated output
Exhaust
temperature
%
Max. 40 50
(Max. 4.0) (5.0)
index)
index
Bosch
index
Body

Lubrication system
Engine oil
SAE10W30DH
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
Cooling system
valve
Fan speed At rated speed rpm 1,142 1,142

(Auto-tension) (Auto-tension)
Alternator belt
170E-5 Series 9
Running-in standard and performance test standard 1

Running-in standard
Engine SAA6D170E-5
Machine model D375A-5E0, D375A-5R
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} 1,327 {135} 2,117 {216} 2,757 {281} 3,345 {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.
Performance test standard
Engine SAA6D170E-5
Machine model D375A-5E0, D375A-5R
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
1,900 20 rpm 750 20 rpm
(Gross value) {606 HP/1,800 rpm} {308 kgm/1,300 rpm}
Speed rpm 1,800 1,300 1,900 20 750 20
N 3,245 3,446 4,089 4,344
Dynamometer load
{kg} {331 351} {417 443}
kW 438 465
Output (Gross value)
{HP} {587 624}
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 392 539 294 539 392 539 Min. 118
pressure {kg/cm2} {4.0 5.5} {3.0 5.5} {4.0 5.5} {Min. 1.2}
Max. 650 (-5E0) Max. 700 (-5E0)
Exhaust temperature C
Max. 630 (-5R ) Max. 680 (-5R )
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 Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
10 170E-5 Series
Running-in standard
Engine SAA6D170E-5
Machine model PC1250-8, PC1250-8R
Procedure
Item
1 2 3 4 5
Speed rpm 900 1,134 1,422 1,638 1,800
Output kW {HP} 0 {0} 129 {173} 257 {345} 386 {518} 515 {690}
Engine SAA6D170E-5
Machine model PC1250-8, PC1250-8R
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 4,097 4,354
Dynamometer load
{kg} {377 401} {418 444}
kW 499 530
{HP} {669 711}
Nm 2,932 3,119
{kgm} {299 318}
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Max. 680 (-8 ) Max. 720 (-8 )
Max. 650 (-8R) Max. 700 (-8R)
170E-5 Series 11
Running-in standard
Engine SAA6D170E-5
Machine model WA600-6, WA600-6R
Procedure
Item
1 2 3 4 5
Speed rpm 800 1,134 1,422 1,638 1,800
Output kW {HP} 0 {0} 99 {133} 198 {266} 297 {398} 396 {531}
Engine SAA6D170E-5
Machine model WA600-6, WA600-6R
2,000 50 rpm 800 25 rpm
(Gross value) {531 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 3,510 3,727
Dynamometer load
{kg} {290 308} {358 380}
kW 384 407
{HP} {515 546}
Nm 2,520 2,667
{kgm} {257 272}
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Max. 650 (-6 ) Max. 680 (-6 )
Max. 600 (-6R) Max. 710 (-6R)
12 170E-5 Series
Running-in standard
Engine SAA6D170E-5
HD465-7E0, HD465-7R
Machine model
HD605-7E0, HD605-7R
Procedure
Item
1 2 3 4 5
Speed rpm 750 1,260 1,580 1,820 2,000
Output kW {HP} 0 {0} 138 {185} 276 {370} 414 {555} 552 {740}
Engine SAA6D170E-5
HD465-7E0, HD465-7R
Machine model
HD605-7E0, HD605-7R
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 3,788 4,501 4,776
Dynamometer load
{kg} {364 386} {459 487}
kW 535 568
{HP} {718 762}
Nm 3,226 3,423
{kgm} {329 349}
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Max. 670 (-7E0) Max. 710 (-7E0)
Max. 650 (-7R ) Max. 680 (-7R )
170E-5 Series 13
SEN00367-02
2007 KOMATSU
All Rights Reserved
14
SEN00368-01
ENGINE 1SHOP MANUAL
170E-5 Series
30 Testing and adjusting 1

Testing and adjusting
Testing and adjusting (With EGR)................................................................................................................... 3
Testing and adjusting tools list ............................................................................................................. 3
Sketches of special tools...................................................................................................................... 5
Testing air boost pressure .................................................................................................................... 6
Testing exhaust temperature................................................................................................................ 7
Adjusting valve clearance .................................................................................................................... 8
Testing compression pressure ........................................................................................................... 10
Testing blow-by pressure ................................................................................................................... 12
Testing engine oil pressure ................................................................................................................ 13
Testing EGR valve and bypass valve drive oil pressure .................................................................... 14
Handling fuel system parts ................................................................................................................. 16
Releasing residual pressure in fuel system........................................................................................ 16
Testing fuel pressure .......................................................................................................................... 17
Reduced cylinder mode operation ..................................................................................................... 18
No-injection cranking.......................................................................................................................... 18
Testing leakage from pressure limiter and return rate from injector ................................................... 19
170E-5 Series 1
SEN00368-01 30 Testing and adjusting
Bleeding air from fuel circuit ............................................................................................................... 22

Testing fuel system for leakage .......................................................................................................... 24
Handling controller voltage circuit ...................................................................................................... 25
Testing and adjusting (EGR-less).................................................................................................................. 26
Testing and adjusting tools list............................................................................................................ 26
Testing air boost pressure .................................................................................................................. 28
Testing exhaust temperature .............................................................................................................. 29
Adjusting valve clearance................................................................................................................... 30
Testing compression pressure............................................................................................................ 32
Testing blow-by pressure.................................................................................................................... 34
Testing engine oil pressure................................................................................................................. 35
Handling fuel system parts ................................................................................................................. 36
Releasing residual pressure in fuel system........................................................................................ 36
Testing fuel pressure .......................................................................................................................... 37
Reduced cylinder mode operation...................................................................................................... 38
No-injection cranking.......................................................................................................................... 38
Testing leakage from pressure limiter and return rate from injector ................................................... 39
Bleeding air from fuel circuit ............................................................................................................... 42
Testing fuel system for leakage .......................................................................................................... 44
Handling controller voltage circuit ...................................................................................................... 45
2 170E-5 Series
Testing and adjusting (With EGR) 1

Testing and adjusting tools list 1
Testing and Sym-
Part No. Part name Q'ty Remarks
adjusting item bol
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 1,299C
perature
Adjusting Commercially Air intake: 0.35 mm
C Clearance gauge 1
valve clearance available Air exhaust: 0.62 mm
1 795-502-1590 Compression gauge 1 0 7 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, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
Testing engine oil {600 kg/cm2}
F
pressure Pressure gauge: 1 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
795T-690-1110 Block 1
1 01435-00835 Bolt 2
Testing drive pressure 07000-E2012 O-ring 3
of EGR valve and K Pressure gauge: 2.5, 6, 40, 60 MPa
bypass valve 2 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
3 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
Testing fuel pressure G 2 799-101-5160 Nipple 1
795-471-1450 Adapter 1
3 For M8 plug
07005-00812 Seal washer 1
4 799-401-2320 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 5 mm x 2 3 m
Testing leakage from available
pressure limiter and Commercially
H 4 Hose 1 16 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
Testing and Sym-

adjusting item bol
799-601-4130 T-adapter For Ne sensor
799-601-4330 Socket For Bkup sensor
799-601-4240 Socket For atmospheric pressure sensor
799-601-4250 Socket For boost pressure sensor
799-601-9420 T-adapter For common rail pressure
799-601-4150 T-adapter For oil pressure sensor
795-799-5540 T-adapter For boost temperature sensor
For coolant temperature sensor
795-799-5530 T-adapter
For fuel temperature sensor
Troubleshooting for For EGR valve solenoid
799-601-9020 T-adapter
controllers, sensors, J For bypass valve solenoid
and actuators For EGR valve solenoid
799-601-9030 T-adapter
For bypass valve stroke sensor
799-601-9430 T-adapter For supply pump PCV
799-601-9020 T-adapter For injector
799-601-4260 T-adapter For controller (4-pole)
799-601-9320 T-box
For 24-pole type
799-601-9310 Plate
799-601-4350 T-box For 60-pole type
4 170E-5 Series
Sketches of special tools 1
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
K1 Block
170E-5 Series 5
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
k Be careful not to touch any hot part when

removing or installing the testing tools.
a The test point is subject to machine models.
1. Remove plug (1) (PT 1/8) from the rear of the

intake manifold.
4. After finishing testing, remove the testing tools

and return the removed parts.
2. Install nipple [1] of boost gauge kit A and con-

nect it to gauge [2].
a Alternatively, install a measurement screw (R1/

8) to the tube to be connected between the tur-
bocharger outlet tube and aftercooler, and
install nipple [1] of boost gauge kit A and con-
6 170E-5 Series
Testing exhaust temperature 1

a Testing tool for exhaust temperature
Symbol Part No. Part name
B 799-101-1502 Digital thermometer
k Remove and install the testing tools after

the exhaust manifold temperature has low-
ered.
1. Remove exhaust temperature pickup plug (1)

from the bottom of the exhaust manifold.
a You may measure at either front or rear
plug.
3 Plug (1):
2.9 5.9 Nm {0.3 0.6 kgm}
2. Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
3. Run the engine and test the exhaust tempera-

ture in the whole speed range.
a When testing with the engine mounted on
the machine, test on the condition
machine.
170E-5 Series 7
Adjusting valve clearance 1 3. Rotate the crankshaft forward to align the

notch (a) of the supply pump drive gear with
a Adjusting tool for valve clearance the center of inspection hole on the left side of
Symbol Part No. Part name timing gear case.
a Rotate the engine with the cranking device
Commercially
C Clearance gauge on the rear left of engine.
available
a On the left of next figure, the compression
1. Remove covers (1) and (2) and bracket (3), top dead center of No. 1 cylinder is shown
and remove 6 cylinder head covers (4). and on the right, the top dead center of
No. 6 cylinder is shown.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm can
be moved by the valve clearance with the
hand. If the rocker arm cannot be moved,
rotate the crankshaft one more turn.
2. Remove the plug (5) from left side timing gear

case of the flywheel housing.
4. When the No. 1 cylinder is at the compression

top dead center, adjust the valve clearance
indicated by q of the valve layout plan.
a Loosen locknut (9) of adjustment screw
(8), insert clearance gauge C in the clear-
ance between crosshead (7) and rocker
arm (6), and adjust the valve clearance
with adjustment screw (8) to a degree that
you can move the clearance gauge lightly.
a Valve clearance
q Air intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
5. While fixing adjustment screw (8), tighten lock-

nut (9).
3 Locknut:
57.8 77.4 Nm {5.9 7.9 kgm}
a After tightening the locknut, check the
valve clearance again.
8 170E-5 Series
6. Rotate the crackshaft forward one turn and

adjust the valve clearance indicated by Q of
the valve layout plan.
a The adjustment method is the same as
above.
7. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
{No.1, 3, 4, 5, 6 cylinders}
9.8 1.0 Nm {1.0 0.1 kgm}
{No.2 cylinder}
58.8 73.5 Nm {6 7.5 kgm}
3 Plug (5): 58.8 78.4 Nm {6.0 8.0 kgm}
170E-5 Series 9
Testing compression pressure 1

a Testing tools for compression pressure

1 795-502-1590 Compression gauge
795-611-1220 Adapter
2
D 6261-71-6150 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get a Insert the pin (indicated by the arrow) at
caught in a rotating part. the end of the tool D3 into hole a of adap-
a Measure the compression pressure after the tor (9), and pull out the injector by moving
engine is warmed up (Engine oil temperature: the weight of tool D3 up and down.
40 60C).
1. Remove covers (1) and (2) and bracket (3).
2. Remove cylinder head cover (4) of the cylinder

to be tested for compression pressure.
3. Adjust the valve clearance of the cylinder to be

inspected. For details, see "Adjusting valve
clearance".
4. Disconnect fuel high-pressure tube (5) and

injector wiring harness (6).
a Remove the terminal on the injector side
and the mounting bolt on the rocker hous-
ing side, and remove the injector wiring
harness from the injector.
a Loosen the 2 terminal nuts alternately.
5. Remove holder (7) and adaptor, and remove

injector (8).
10 170E-5 Series
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 adapter 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
a When inspecting with the engine mounted 4) Install fuel high-pressure tube (5), and
on the machine, set the engine in the no- temporarily tighten the sleeve nut.
injection cranking mode by operating the
monitor panel. 5) Fully tighten bolt (13).
k If the engine is not set in the no-injec- 3 Bolt:
tion cranking mode, it will start and will 58.8 73.5 Nm {6.0 7.5 kgm}
be dangerous. Accordingly, be sure to 6) Fully tighten the sleeve nut of fuel high-
set the engine in this mode. pressure tube (5).
8. Rotate the engine with the starting motor and 3 Sleeve nut:
measure the compression pressure. 39.2 44.1 Nm {4 4.5 kgm}
a Read the pressure gauge pointer when it
is stabilized.
170E-5 Series 11
a Install the injector wiring harness accord- Testing blow-by pressure 1

ing to the following procedure.
1) Assemble injector wiring harness (6) from a Testing tool for blow-by pressure
the inside of rocker arm housing and fix
the connector side with plate (15). Symbol Part No. Part name
E 799-201-1504 Blow-by checker
1. Install nozzle [1] of blow-by checker E to the

end of breather hose (1).
2. Connect hose [2], and then connect it to gauge

[3].
2)Fit spacer (16) and fix it with bolt (17).

3)Alternately tighten nuts (18) on the injector
side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
3. Run the engine at the rated output and test the

blow-by pressure.
machine.
a Tighten the cylinder head cover mounting

bolt with the following torque.
{No.1, 3, 4, 5, 6 cylinders}
9.8 1.0 Nm {1.0 0.1 kgm}
{No.2 cylinder}
58.8 73.5 Nm {6 7.5 kgm}

12 170E-5 Series
Testing engine oil pressure 1

a Testing tools for oil pressure

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
F 2 799-401-2320 Hydraulic tester
799-101-5230 Nipple
3
6215-81-9720 O-ring
1. Remove oil pressure pickup plug (1) from the

cylinder block. 4. After finishing testing, remove the testing tools
2. Connect nipple F3 and connect it to hydraulic

tester F2.
3. Run the engine at the rated output and low idle

and test the oil pressure.
machine.
170E-5 Series 13
Testing EGR valve and bypass 4. Install EGR valve drive oil supply tube (1) to
valve drive oil pressure 1 the top of tool K1 and tighten flange mounting
bolts (2) on the EGR valve side.
a Testing instruments for EGR valve and bypass 3 Flange mounting bolt (2):
valve drive oil pressure 27 34 Nm {2.8 3.5 kgm}

795T-690-1110 Block
1 01435-00835 Bolt
K 07000-E2012 O-ring
2 799-101-5002 Hydraulic tester
3 790-261-1204 Digital hydraulic tester
a The measuring position depends on the appli-

cable machine.
1. Remove the peripheral parts as necessary.

The incidental work depends on the applicable
machine.
a The incidental work depends on the appli- 5. Install the nipple (component part of K2) to
cable machine. measuring hole (a) (size: PT 1/8) of took K1
and connect hydraulic tester K2.
2. Remove flange mounting bolts (2) of EGR Reference: Since the maximum oil pressure to
valve drive oil supply tube (1) on the EGR be measured will be about 3 MPa {30 kg/cm2},
valve side and clamp mounting bolts (3). select a proper pressure gauge in the kit.
3. Install tool K1 to the EGR valve oil supply area.

3 Mounting bolt (4) (component part of
K1): 27 34 Nm {2.8 3.5 kgm}
14 170E-5 Series
6. Run the engine and measure the oil pressure

at low idle and high idle.
a When measuring with the engine mounted
on the applicable machine, measure
under the condition described in the shop
manual for the machine.
7. After finishing measurement, remove the mea-

suring instruments and return the removed
parts.
a Replace the flange O-ring on the EGR
valve side with new one.
3 Flange mounting bolt (2):

27 34 Nm {2.8 3.5 kgm}
3 Clamp mounting bolt (3):
58.8 73.5 Nm {6 7.5 kgm}
170E-5 Series 15
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump Fuel filter Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump Common rail Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. If a filter ping the engine until the residual pressure
other than the genuine one is used, the fuel in the fuel circuit is released. (Do not start
system may have a trouble. Accordingly, the work just after stopping the engine
never use such a filter. since there is residual pressure.)
16 170E-5 Series
Testing fuel pressure 1

a Testing tools for fuel pressure 3. Install adapter G3 and install nipple G2 to adapter
G3, then connect gauge G4. (M8 plug type)
1
2 799-101-5160 Nipple
G
795-471-1450 Adapter
3
07005-00812 Seal washer
4 799-401-2320 Gauge
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure cir- 4. Run the engine at high idle and measure the
cuit from the supply pump through the fuel pressure.
common rail to the injector is very high, it a If the fuel pressure is in the following
cannot be measured. range, it is normal.
1. Remove plug (1).

Engine speed Fuel pressure
a Plug (1) is a PT1/8 plug or an M8 plug,
depending on the time of manufacture. Min. 0.15 MPa
High idle
{Min. 1.5 kg/cm2}
2. Install nipple G2 and connect it to gauge G4

(PT1/8 plug type).
3 Plug (1):
6.9 14.7 Nm {0.7 1.5 kgm} (PT1/8 Plug)
7.8 9.8 Nm {0.8 1.0 kgm} (M8 Plug)
170E-5 Series 17
Reduced cylinder mode operation1 No-injection cranking 1

a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after the machine
lows. or engine unit has been stored for a long
1. This operation is used to find out a cylinder period, the no-injection cranking is performed
which does not output power normally (or, to lubricate the engine parts and protect them
combustion in it is abnormal). from seizure.
2. When a cylinder is selected for the reduced a Perform the no-injection cranking mode opera-
cylinder mode operation, if the engine speed tion with the engine mounted on the machine
and output do not change from the normal or connected to INSITE.
operation (all-cylinder operation), that cylinder Before performing, see Testing method in the
has 1 or more defects. The possible defects shop manual for the machine or INSITE.
are as follows.
q Leakage of compression air through cylin-
der head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (bench
test kit).
Before performing, see Testing method in
the shop manual for the machine or
INSITE.
18 170E-5 Series
Testing leakage from pressure limiter and return rate from injector 1
a Regarding engines which return spill fuel from

the injector from the return block installed on
the intake manifold to the fuel tank, test it
according to the following procedure (Figure
shows WA600-6 for an example).
a Testing tools for pressure limiter leakage and
injector return rate
1 6167-11-6640 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
H Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare a receiving pan of about 20 l to

receive the fuel flowing out during the test.
170E-5 Series 19
1. Preparation work 2. Testing leakage from pressure limiter

1) Remove tube (3) between common rail (1) 1) Lay test hose H3 so that it will not slacken
and block (2). and put its end in the receiving pan.
2) Insert spacer H1 on block (2) side and 2) Connect INSITE (bench test tool) to the
tighten the removed joint bolt again. engine and set it so that it can check the
a Connect the return pipe to the fuel engine speed.
tank again, too. q Or set on the machine so that it can
a Be sure to fit the gaskets to both ends check the engine speed.
of the spacer. 3) Start the engine and keep its speed at
rated output.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Leakage
Measurement conditions
(cc/min)
At rated output Max. 10
3) Insert joint H2 on common rail (1) side and

tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
20 170E-5 Series
3. Testing return rate from injector
1) Remove the hose at spill outlet (4), con- 4. Work after finishing testing
nect test hose H4, and put its end in the After finishing all testing, remove the testing
receiving pan. tools and return the removed parts.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
q Or set on the machine so that it can
check the engine speed.
3) Run the engine at the rated output.
the return rate in 1 minute with measuring
cylinder H5.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Limit of return rate (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
170E-5 Series 21
Bleeding air from fuel circuit 1 4. Turn ON switch (3) of electric priming pump
(2) installed to the chassis.
Reference: a The electric priming pump operates and
q The electric priming pump switch is installed to lamp (4) blinks.
the chassis.
q Each figure shows HD465-7E0 for an example.
a Bleed air from the fuel circuit in the following
cases according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first
time after the fuel piping or supply pump is
replaced
a If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
1. Turn the starting switch to the OFF position.
2. Check that the fuel valve on the fuel tank side

is open. a The electric priming pump has a timer in it
to start and stop itself automatically (See
3. Turn lever (1) of the air bleeding piping to the the following figure).
parallel position with the piping to open the cir- a The electric priming pump stops while the
cuit valve. lamp is blinking. This phenomenon is not
abnormal, however.
a If the switch is turned to the OFF position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
k While the electric priming pump is
operating, pressure is applied to the
fuel circuit. Do not loosen the air
bleeding plug at this time, since the
fuel may spout out.
Reference: The operating procedure sticker is

stuck near the air bleeding piping lever.
5. After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
6. If the fuel was used up or the fuel piping or

supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (3) ON after the
electric priming pump stops automatically.
22 170E-5 Series
7. When lamp (4) goes off, the air bleeding work

is completed.
8. Turn lever (1) of the air bleeding piping to the

cross position with the piping to close the cir-
cuit valve.
9. Start the engine with the starting motor.

a Do not operate the starting motor continu-
ously for more than 20 seconds.
q After starting the engine, run it at low
idle for about 5 minutes to bleed all air
from the fuel circuit.
q Stop the engine and check that the air
bleeding valve is closed.
10. If the engine does not start, try to start it again
according to the following procedure.
k When starting the engine, check that there
is no person around it.
a Carry out the work with the air bleeding
valve closed. (Do not open the air bleed-
ing valve after step 7.)
a After the engine fails to start, wait for
about 2 minutes before trying to start
again.
1) Turn the electric priming pump switch ON.
2) While the electric priming pump is operat-
ing, crank the engine.
q If the engine does not start, repeat the
above operation.
a If the engine fails to start, wait for about 2
minutes and try to start again.
3) After starting the engine, run it at low idle
for about 5 minutes to bleed all air from
the fuel circuit.
4) Stop the engine and check that the air
5) After the above operation, start the engine
normally.
170E-5 Series 23
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.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
24 170E-5 Series
Handling controller voltage

circuit 1
1. When disconnecting or connecting a connector
between the engine controller and engine, be
sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
170E-5 Series 25
Testing and adjusting (EGR-less) 1

Testing and adjusting tools list 1
Testing and Sym-
adjusting item bol
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 1,299C
perature
Adjusting Commercially Air intake: 0.35 mm
C Clearance gauge 1
valve clearance available Air exhaust: 0.62 mm
1 795-502-1590 Compression gauge 1 0 7 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
{25, 60, 400, 600 kg/cm2}
1
Testing engine oil {600 kg/cm2}
F
pressure Pressure gauge: 1 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
{25, 60, 400, 600 kg/cm2}
1
{600 kg/cm2}
Testing fuel pressure G 2 799-101-5160 Nipple 1
795-471-1450 Adapter 1
3 For M8 plug
07005-00812 Seal washer 1
4 799-401-2320 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 5 mm x 2 3 m
Testing leakage from available
pressure limiter and Commercially
H 4 Hose 1 16 mm x 2 3 m
return rate from injec- available
tor
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
26 170E-5 Series
Testing and Sym-

adjusting item bol
799-601-4130 T-adapter For Ne sensor
799-601-4330 Socket For Bkup sensor
799-601-4240 Socket For atmospheric pressure sensor
799-601-4250 Socket For boost pressure sensor
799-601-9420 T-adapter For common rail pressure
799-601-4150 T-adapter For oil pressure sensor
795-799-5540 T-adapter For boost temperature sensor
Troubleshooting for For coolant temperature sensor
795-799-5530 T-adapter
controllers, sensors, J For fuel temperature sensor
and actuators 799-601-9430 T-adapter For supply pump PCV
799-601-9020 T-adapter For injector
799-601-9320 T-box
For 24-pole type
799-601-9310 Plate
799-601-4350 T-box For 60-pole type
170E-5 Series 27
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
799-201-2202 Boost gauge kit
A machine.
790-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
1. Remove plug (1) (PT 1/8) from the rear of the

intake manifold.

2. Install nipple [1] of boost gauge kit A and con-

a Alternatively, install a measurement screw (R1/

8) to the tube to be connected between the tur-
bocharger outlet tube and aftercooler, and
install nipple [1] of boost gauge kit A and con-
28 170E-5 Series
Testing exhaust temperature 1

a Testing tool for exhaust temperature
B 799-101-1502 Digital thermometer
k Remove and install the testing tools after

the exhaust manifold temperature has low-
ered.
1. Remove exhaust temperature pickup plug (1)

from the bottom of the exhaust manifold.
a You may measure at either front or rear
plug.
3 Plug (1):
2.9 5.9 Nm {0.3 0.6 kgm}
2. Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
3. Run the engine and test the exhaust tempera-

ture in the whole speed range.
machine.
170E-5 Series 29
Adjusting valve clearance 1 3. Rotate the crankshaft forward to align the

notch (a) of the supply pump drive gear with
a Adjusting tool for valve clearance the center of inspection hole on the left side of
Symbol Part No. Part name timing gear case.
a Rotate the engine with the cranking device
Commercially
C Clearance gauge on the rear left of engine.
available
a On the left of next figure, the compression
1. Remove covers (1) and (2) and bracket (3), top dead center of No. 1 cylinder is shown
and remove 6 cylinder head covers (4). and on the right, the top dead center of
No. 6 cylinder is shown.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm can
be moved by the valve clearance with the
hand. If the rocker arm cannot be moved,
rotate the crankshaft one more turn.
2. Remove the plug (5) from left side timing gear

case of the flywheel housing.
4. When the No. 1 cylinder is at the compression

indicated by q of the valve layout plan.
a Loosen locknut (9) of adjustment screw
(8), insert clearance gauge C in the clear-
ance between crosshead (7) and rocker
arm (6), and adjust the valve clearance
with adjustment screw (8) to a degree that
you can move the clearance gauge lightly.
a Valve clearance
q Air intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
5. While fixing adjustment screw (8), tighten lock-

nut (9).
3 Locknut:
57.8 77.4 Nm {5.9 7.9 kgm}
30 170E-5 Series
6. Rotate the crankshaft forward one turn and

adjust the valve clearance indicated by Q of
the valve layout plan.
a The adjustment method is the same as
above.
7. After finishing adjustment, return the removed

parts.
{No.1, 3, 4, 5, 6 cylinders}
9.8 1.0 Nm {1.0 0.1 kgm}
{No.2 cylinder}
58.8 73.5 Nm {6 7.5 kgm}
3 Plug (5): 58.8 78.4 Nm {6.0 8.0 kgm}
170E-5 Series 31
Testing compression pressure 1

a Testing tools for compression pressure

1 795-502-1590 Compression gauge
795-611-1220 Adapter
2
D 6261-71-6150 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get a Insert the pin (indicated by the arrow) at
caught in a rotating part. the end of the tool D3 into hole a of adap-
a Measure the compression pressure after the tor (9), and pull out the injector by moving
engine is warmed up (Engine oil temperature: the weight of tool D3 up and down.
40 60C).
1. Remove covers (1) and (2) and bracket (3).
2. Remove cylinder head cover (4) of the cylinder

to be tested for compression pressure.
3. Adjust the valve clearance of the cylinder to be

inspected. For details, see "Adjusting valve
clearance".
4. Disconnect fuel high-pressure tube (5) and

injector wiring harness (6).
a Remove the terminal on the injector side
and the mounting bolt on the rocker hous-
ing side, and remove the injector wiring
harness from the injector.
5. Remove holder (7) and adaptor, and remove

injector (8).
32 170E-5 Series
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 adapter 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
a When inspecting with the engine mounted 4) Install fuel high-pressure tube (5), and
on the machine, set the engine in the no- temporarily tighten the sleeve nut.
injection cranking mode by operating the
monitor panel. 5) Fully tighten bolt (13).
k If the engine is not set in the no-injec- 3 Bolt:
tion cranking mode, it will start and will 58.8 73.5 Nm {6.0 7.5 kgm}
be dangerous. Accordingly, be sure to 6) Fully tighten the sleeve nut of fuel high-
set the engine in this mode. pressure tube (5).
8. Rotate the engine with the starting motor and 3 Sleeve nut:
measure the compression pressure. 39.2 44.1 Nm {4 4.5 kgm}
a Read the pressure gauge pointer when it
is stabilized.
170E-5 Series 33
a Install the injector wiring harness accord- Testing blow-by pressure 1

ing to the following procedure.
1) Assemble injector wiring harness (6) from a Testing tool for blow-by pressure
the inside of rocker arm housing and fix
the connector side with plate (15). Symbol Part No. Part name
E 799-201-1504 Blow-by checker
1. Install nozzle [1] of blow-by checker E to the

end of breather hose (1).
2. Connect hose [2], and then connect it to gauge

[3].
2)Fit spacer (16) and fix it with bolt (17).

3)Alternately tighten nuts (18) on the injector
side.
3 Nut: 2 0.2 Nm {0.2 0.02 kgm}
3. Run the engine at the rated output and test the

blow-by pressure.
machine.
a Tighten the cylinder head cover mounting

bolt with the following torque.
{No.1, 3, 4, 5, 6 cylinders}
9.8 1.0 Nm {1.0 0.1 kgm}
{No.2 cylinder}
58.8 73.5 Nm {6 7.5 kgm}

34 170E-5 Series
Testing engine oil pressure 1

a Testing tools for oil pressure

1
F 2 799-401-2320 Hydraulic tester
799-101-5230 Nipple
3
6215-81-9720 O-ring
1. Remove oil pressure pickup plug (1) from the

cylinder block. 4. After finishing testing, remove the testing tools
2. Connect nipple F3 and connect it to hydraulic

tester F2.
3. Run the engine at the rated output and low idle

and test the oil pressure.
machine.
170E-5 Series 35
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump Fuel filter Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump Common rail Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. If a filter ping the engine until the residual pressure
other than the genuine one is used, the fuel in the fuel circuit is released. (Do not start
system may have a trouble. Accordingly, the work just after stopping the engine
never use such a filter. since there is residual pressure.)
36 170E-5 Series
Testing fuel pressure 1

a Testing tools for fuel pressure 3. Install adapter G3 and install nipple G2 to adapter
G3, then connect gauge G4. (M8 plug type)
1
2 799-101-5160 Nipple
G
795-471-1450 Adapter
3
07005-00812 Seal washer
4 799-401-2320 Gauge
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the 4. Run the engine at high idle and measure the
common rail to the injector is very high, it fuel pressure.
cannot be measured. a If the fuel pressure is in the following
range, it is normal.
1. Remove plug (1).
a Plug (1) is a PT1/8 plug or an M8 plug,
Engine speed Fuel pressure
depending on the time of manufacture.
Min. 0.15 MPa
High idle
{Min. 1.5 kg/cm2}
2. Install nipple G2 and connect it to gauge G4

(PT1/8 plug type).
3 Plug (1):
6.9 14.7 Nm {0.7 1.5 kgm} (PT1/8 Plug)
7.8 9.8 Nm {0.8 1.0 kgm} (M8 Plug)
170E-5 Series 37
Reduced cylinder mode No-injection cranking 1

operation 1 a No-injection cranking means to crank the
a Reduced cylinder mode operation means to engine with the starting motor while all the
run the engine with the fuel injectors of 1 or injections are stopped electrically. The pur-
more cylinders disabled electrically to reduce pose and effect of this operation are as follows.
the number of effective cylinders. The pur- q Before the engine is started after the machine
poses and effects of this operation are as fol- or engine unit has been stored for a long
lows. period, the no-injection cranking is performed
1. This operation is used to find out a cylinder to lubricate the engine parts and protect them
which does not output power normally (or, from seizure.
combustion in it is abnormal). a Perform the no-injection cranking mode opera-
2. When a cylinder is selected for the reduced tion with the engine mounted on the machine
cylinder mode operation, if the engine speed or connected to INSITE.
and output do not change from the normal Before performing, see Testing method in the
operation (all-cylinder operation), that cylinder shop manual for the machine or INSITE.
has 1 or more defects. The possible defects
are as follows.
q Leakage of compression air through cylin-
der head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (bench
test kit).
Before performing, see Testing method in
the shop manual for the machine or
INSITE.
38 170E-5 Series
Testing leakage from pressure limiter and return rate from injector 1
a Regarding engines which return spill fuel from

the injector from the return block installed on
the intake manifold to the fuel tank, test it
a Testing tools for pressure limiter leakage and
injector return rate
1 6167-11-6640 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
H Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare a receiving pan of about 20 l to

receive the fuel flowing out during the test.
170E-5 Series 39
1. Preparation work 2. Testing leakage from pressure limiter

1) Remove tube (3) between common rail (1) 1) Lay test hose H3 so that it will not slacken
and block (2). and put its end in the receiving pan.
2) Insert spacer H1 on block (2) side and 2) Connect INSITE (bench test tool) to the
tighten the removed joint bolt again. engine and set it so that it can check the
a Connect the return pipe to the fuel engine speed.
tank again, too. q Or set on the machine so that it can
a Be sure to fit the gaskets to both ends check the engine speed.
of the spacer. 3) Start the engine and keep its speed at
rated output.
the leakage in 1 minute with measuring
cylinder H5.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Leakage
Measurement conditions
(cc/min)
At rated output Max. 10
3) Insert joint H2 on common rail (1) side and

tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
40 170E-5 Series
3. Testing return rate from injector
1) Remove the hose at spill outlet (4), con- 4. Work after finishing testing
nect test hose H4, and put its end in the After finishing all testing, remove the testing
receiving pan. tools and return the removed parts.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
q Or set on the machine so that it can
check the engine speed.
3) Run the engine at the rated output.
the return rate in 1 minute with measuring
cylinder H5.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Limit of return rate (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
170E-5 Series 41
Bleeding air from fuel circuit 1 4. Turn ON switch (3) of electric priming pump
(2) installed to the chassis.
Reference: a The electric priming pump operates
q The electric priming pump switch is installed to and lamp (4) blinks.
the chassis.
q Each figure shows HD465-7R for an example.
a Bleed air from the fuel circuit in the following
cases according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first
time after the fuel piping or supply pump is
replaced
a If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
1. Turn the starting switch to the OFF position.
2. Check that the fuel valve on the fuel tank side a The electric priming pump has a timer in it
is open. to start and stop itself automatically (See
the following figure).
a Turn lever (1) of the air bleeding pip- a The electric priming pump stops while the
ing to the parallel position with the lamp is blinking. This phenomenon is not
piping to open the circuit valve. abnormal, however.
a If the switch is turned to the OFF position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
k While the electric priming pump is
operating, pressure is applied to the
fuel circuit. Do not loosen the air
bleeding plug at this time, since the
fuel may spout out.
3. Reference: The operating procedure sticker is

stuck near the air bleeding piping lever.
5. After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
6. If the fuel was used up or the fuel piping or

supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (3) ON after the
electric priming pump stops automatically.
42 170E-5 Series
7. When lamp (4) goes off, the air bleeding work

is completed.
a Turn lever (1) of the air bleeding pip-

ing to the cross position with the pip-
ing to close the circuit valve.
8. Start the engine with the starting motor.

q After starting the engine, run it at low
idle for about 5 minutes to bleed all air
from the fuel circuit.
q Stop the engine and check that the air
9. If the engine does not start, try to start it again
k When starting the engine, check that there
is no person around it.
a Carry out the work with the air bleeding
valve closed. (Do not open the air bleed-
ing valve after step 7.)
a After the engine fails to start, wait for
about 2 minutes before trying to start
again.
1) Turn the electric priming pump switch ON.
2) While the electric priming pump is operat-
ing, crank the engine.
q If the engine does not start, repeat the
above operation.
a If the engine fails to start, wait for about 2
minutes and try to start again.
3) After starting the engine, run it at low idle
for about 5 minutes to bleed all air from
the fuel circuit.
4) Stop the engine and check that the air
5) After the above operation, start the engine
normally.
170E-5 Series 43
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.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.

leakage.
for fuel leakage.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
44 170E-5 Series
Handling controller voltage

circuit 1
1. When disconnecting or connecting a connector
between the engine controller and engine, be
sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
170E-5 Series 45
SEN00368-01
2007 KOMATSU
All Rights Reserved
46
SEN00369-01
ENGINE 1SHOP MANUAL
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
Information in troubleshooting table ..................................................................................................... 6
170E-5 Series 1
SEN00369-01 40 Troubleshooting
General information on troubleshooting 1

Points on troubleshooting 1
k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
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.
1. When carrying out troubleshooting, do not 3. Check before troubleshooting

hurry to disassemble the components. 1) Check for symptoms of any abnormality in
If components are disassembled immediately the machine and engine.
after any failure occurs: 2) Be sure to check the "Checks before start-
q Parts that have no connection with the fail- ing" items.
ure or other unnecessary parts will be dis- 3) Check other inspection items, if neces-
assembled. sary.
q It will become impossible to find the cause 4) Some other maintenance items can be
of the failure. checked externally, so check any item that
It will also cause a waste of manhours, parts, is considered to be necessary.
or oil or grease, and at the same time, will also 5) Check the controller for display of an error.
lose the confidence of the user or operator.
For this reason, when carrying out trouble- 4. Confirming failure
shooting, it is necessary to carry out thorough Confirm the extent of the failure yourself, and
prior investigation and to carry out trouble- judge whether to handle it as a real failure or
shooting in accordance with the fixed proce- as a problem with the method of operation, etc.
dure. a When operating the machine or engine to
reenact the troubleshooting symptoms, do
2. Points to ask user or operator not carry out any investigation or mea-
1) Have any other problems occurred apart surement that may make the problem
from the problem that has been reported? worse.
2) Was there anything strange about the
machine before the failure occurred? 5. Troubleshooting
3) Did the failure occur suddenly, or were Use the results of the investigation and inspec-
there problems with the machine condition tion in Items 2 4 to narrow down the causes
before this? of failure, then use the troubleshooting matrix
4) Under what conditions did the failure to locate the position of the failure exactly.
occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before as follows.
the failure? When were these repairs car- 1) Start from the simple points.
ried out? 2) Start from the most likely points.
6) Has the same kind of failure occurred 3) Investigate other related parts or informa-
before? tion.
2 170E-5 Series
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again. To prevent this, always inves-
tigate why the problem occurred. Then,
remove the root cause.
170E-5 Series 3
Error code and failure code table1
INSITE Machine failure Reference

Failure phenomenon
error code code document No.
111 CA111 Engine Controller Internal Failure
115 CA115 Eng. Ne and Bkup Speed Sensor Error
122 CA122 Charge (boost) Air Press Sensor High Error
123 CA123 Charge (boost) Air Press Sensor Low Error
131 CA131 Throttle Sensor High Error
132 CA132 Throttle Sensor Low Error
135 CA135 Oil Press. Sensor High Error
141 CA141 Oil Press. Sensor Low Error
144 CA144 Coolant Temp. Sensor High Error
145 CA145 Coolant Temp. Sensor Low Error
153 CA153 Charge (boost) Air Temp. Sensor High Error
154 CA154 Charge (boost) Air Temp. Sensor Low Error
187 CA187 Sensor Sup. 2 Volt. Low Error
212 CA212 Oil Temp. Sensor High Error
213 CA213 Oil Temp. Sensor Low Error
221 CA221 Ambient Air Press. Sensor High Error
222 CA222 Ambient Air Press. Sensor Low Error
227 CA227 Sensor Sup. 2 Volt. High Error
234 CA234 Eng. Overspeed
Troubleshooting of
238 CA238 Ne Speed Sensor Sup. Volt. Error electrical system
263 CA263 Fuel Temp. Sensor High Error (E-mode), Part 1
SEN00371-01
265 CA265 Fuel Temp. Sensor Low Error
271 CA271 PCV1 Short Error
272 CA272 PCV1 Open Error
273 CA273 PCV2 Short Error
274 CA274 PCV2 Open Error
322 CA322 Injector #1 System Open/Short Error
342 CA342 Engine controller data matching error
351 CA351 INJ. Drive Circuit Error
352 CA352 Sensor Sup. 1 Volt. Low Error
386 CA386 Sensor Sup. 1 Volt. High Error
431 CA431 Idle Validation SW error
432 CA432 Idle Validation Process error
441 CA441 Battery voltage low error
442 CA442 Battery voltage high error
4 170E-5 Series
INSITE Machine failure Reference

Failure phenomenon
error code code document No.
449 CA449 Rail Press. Very High Error
451 CA451 Rail Press. Sensor High Error
452 CA452 Rail Press. Sensor Low Error
553 CA553 Rail Press. High Error
559 CA559 No-pressure feed by supply pump 1
689 CA689 Eng. Ne Speed Sensor Error
731 CA731 Eng. Bkup Speed Sensor Phase Error
757 CA757 All Persistent Data Lost Error
778 CA778 Eng. Bkup Speed Sensor Error
1228 CA1228 EGR Valve Servo Error 1 ["with EGR" only]
1625 CA1625 EGR Valve Servo Error 2 ["with EGR" only]
Bypass Valve Solenoid Drive Short Circuit
1626 CA1626
["with EGR" only]
Bypass Valve Solenoid Drive Open Error
1627 CA1627
["with EGR" only]
1628 CA1628 Bypass Valve Servo Error 1 ["with EGR" only]
1629 CA1629 Bypass Valve Servo Error 2 ["with EGR" only]
BP valve Lift Position Sensor High Error Troubleshooting of
1631 CA1631 electrical system
["with EGR" only]
(E-mode), Part 2
BP valve Lift Position Sensor Low Error
1632 CA1632 SEN00372-01
["with EGR" only]
1633 CA1633 KOMNET Error
2185 CA2185 Throttle Sens. Sup. Volt. High Error
2186 CA2186 Throttle Sens. Sup. Volt. Low Error
2249 CA2249 No-pressure feed by supply pump 2
EGR Valve Lift Position Sensor High Error
2271 CA2271
["with EGR" only]
EGR Valve Lift Position Sensor Low Error
2272 CA2272
["with EGR" only]
EGR Valve Solenoid Current High Error
2351 CA2351
["with EGR" only]
EGR Valve Solenoid Current Low Error
2352 CA2352
["with EGR" only]
2555 CA2555 Grid Heater Relay open Error
2556 CA2556 Grid Heater Relay short Error
(143) B@BAZG Eng. Oil press. Torque Derate
(146) B@BCNS Eng. Overheat
(415) B@BAZG Eng. Oil press. Low Speed Derate
a INSITE error code:

An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of
the failure is confirmed with the INSITE.
a Machine failure code:
An failure code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the
failure is confirmed with the machine monitor, etc. on the machine side.
170E-5 Series 5
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code Failure code

Display on Display on Trouble Problem that appears on engine
INSITE applicable machine
Contents of
Contents of trouble detected by engine controller
trouble
Action of con- Action taken by engine controller to protect system or devices when engine controller detects
troller trouble
Problem that
appears on Problem that appears on engine as result of action taken by engine controller (shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Causes Standard value in normal state/Remarks on troubleshooting
<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1 <Troubles in wiring harness>

Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each other
Possible causes General causes why vibra- abnormally.
and standard tion is excessive
value in normal (Given numbers are refer- <Precautions for troubleshooting>
state ence numbers, which do not 1) Method of indicating connector No. and handling of T-
indicate priority) adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 If connector No. has no marks of male and female, dis-
connect connector and insert T-adapters in both male side
and female side.
If connector No. has marks of male and female, dis-
connect connector and connect T-adapter to only male
side or female side.
2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as
explained below for troubleshooting, unless otherwise spec-
4 ified.
Connect positive (+) lead to pin No. or wiring harness
entered on front side.
Connect negative () lead to pin No. or wiring harness
entered on rear side.
6 170E-5 Series
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
Connector No.: Indicates (Model Number of pins) and
(Color).
170E-5 Series 7
SEN00369-01
2007 KOMATSU
All Rights Reserved
8
SEN00371-01
ENGINE 1SHOP MANUAL
170E-5 Series
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 4
E-1 Code [111/CA111] Engine controller Internal Failure ..................................................................... 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 6
E-3 Code [122/CA122] Charge Air Press Sensor High Error ............................................................... 7
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error ................................................. 10
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 ......................................................................... 20
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 22
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 24
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error .............................................. 26
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error............................................... 28
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error..................................................................... 29
170E-5 Series 1
E-14 Code [212/CA212] Oil Temp. Sensor High Error ....................................................................... 30

E-15 Code [213/CA213] Oil Temp. Sensor Low Error ........................................................................ 32
E-16 Code [221/CA221] Ambient Air Press. Sensor High Error......................................................... 33
E-17 Code [222/CA222] Ambient Air Press. Sensor Low Error ......................................................... 36
E-18 Code [227/CA227] Sensor Sup. 2 Volt. High Error .................................................................... 37
E-19 Code [234/CA234] Eng. Overspeed .......................................................................................... 40
E-20 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error............................................................... 42
E-21 Code [263/CA263] Fuel Temp. Sensor High Error..................................................................... 44
E-22 Code [265/CA265] Fuel Temp. Sensor Low Error ..................................................................... 46
E-23 Code [271/CA271] PCV1 Short Error ........................................................................................ 48
E-24 Code [272/CA272] PCV1 Open Error ........................................................................................ 50
E-25 Code [273/CA273] PCV2 Short Error ........................................................................................ 52
E-26 Code [274/CA274] PCV2 Open Error ........................................................................................ 54
E-27 Code [322/CA322] Injector #1 System Open/Short Error .......................................................... 56
E-33 Code [342/CA342] Engine Controller Data Matching Error ....................................................... 68
E-34 Code [351/CA351] INJ. Drive Circuit Error ................................................................................ 70
E-35 Code [352/CA352] Sensor Sup. 1 Volt. Low Error..................................................................... 72
E-36 Code [386/CA386] Sensor Sup. 1 Volt. High Error .................................................................... 74
E-37 Code [431/CA431] Idle Validation SW Low error ....................................................................... 78
E-38 Code [432/CA432] Idle Validation Process error ....................................................................... 80
E-39 Code [441/CA441] Battery voltage low error ............................................................................. 81
E-40 Code [442/CA442] Battery voltage high error............................................................................ 81
2 170E-5 Series
170E-5 Series 3
Troubleshooting of electrical system (E-mode), Part 1 1

E-1 Code [111/CA111] Engine controller Internal Failure 1

Trouble Engine controller Internal Failure
111 CA111
Contents of
Abnormality occurred in controller.
trouble
Action of con-
None in particular.
troller
Problem that
appears on Engine runs normally but it may stop during operation or may not be able to start.
machine
Related infor-
Different machine models may have different connector Nos.
mation

Check fuse or circuit breaker of machine for defect directly.
1 Defective fuse (If fuse is burnt out or circuit breaker is tripped, circuit probably has
ground fault.)
a Prepare with starting switch OFF, then carry out troubleshoot-
Disconnection in wiring har- ing without turning starting switch ON.
ness
Wiring harness between CE03 (female) (3), Resis-
2 (Disconnection in wiring or Max. 1 z
(4) battery (+) tance
defective contact in connec-
tor) Wiring harness between CE03 (female) (1), Resis-
Possible causes Max. 1 z
(2) chassis ground tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state Ground fault in wiring har- ing without turning starting switch ON.
ness Wiring harness between CE03 (female) (3), Resis-
3 Min. 1 Mz
(Short circuit with GND cir- (4) battery (+) and chassis ground tance
cuit)
Wiring harness between CE03 (female) (1), Resis-
Min. 1 Mz
(2) chassis ground and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
4 Defective engine controller
CE03 Voltage
Between (3), (4) (1), (2) 20 30 V
4 170E-5 Series
Circuit diagram related to controller power supply
170E-5 Series 5
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error 1

Trouble Eng. Ne and Bkup Speed Sensor Error
115 CA115
Contents of
Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
trouble
Action of con-
None in particular.
troller
Problem that
Engine cannot be started (if engine has been stopped).
appears on
Engine stops (if engine has been running).
machine
Related infor-
mation

Defective Ne speed sensor
1 Carry out troubleshooting for code [689/CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for code [778/CA778].
system
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal of flywheel, etc.)
value in normal Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
state 4
speed sensor installation of sensor, internal of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) tive connection (wrong connection).
If causes 1 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
6 170E-5 Series
E-3 Code [122/CA122] Charge Air Press Sensor High Error 1

Trouble Charge Air Press Sensor High Error
122 CA122
Contents of
Signal voltage in charge pressure sensor circuit is abnormally high.
trouble
Action of con-
Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
troller
Problem that
appears on Acceleration performance of engine drops.
machine
Related infor-
mation

Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out trouble-
1
ply system shooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure PIM Voltage
2 sensor Between (1) (3) Power supply 4.75 5.25 V
(Internal trouble)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Possible causes ing without turning starting switch ON.
and standard Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal ness Max. 1 z
PIM (female) (1) tance
state 3 (Disconnection in wiring or
defective contact in connec- Wiring harness between ENG (female) (47) Resis-
Max. 1 z
tor) PIM (female) (3) tance
Wiring harness between ENG (female) (44) Resis-
Max. 1 z
PIM (female) (2) tance
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between ENG (female) (37) Resis-
Min. 1 Mz
ness PIM (female) (1) and chassis ground tance
4
(Short circuit with GND cir- Wiring harness between ENG (female) (47) Resis-
cuit) Min. 1 Mz
PIM (female) (3) and chassis ground tance
Min. 1 Mz
PIM (female) (2) and chassis ground tance
170E-5 Series 7

Wiring harness between ENG (female) (37)
PIM (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (47) PIM (female) tance
Short circuit in wiring har- (3)
ness Wiring harness between ENG (female) (37)
5
(With another wiring har- PIM (female) (1) and wiring harness Resis-
Possible causes Min. 1 Mz
ness) between ENG (female) (44) PIM (female) tance
and standard
value in normal (2)
state Wiring harness between ENG (female) (47)
PIM (female) (3) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (44) PIM (female) tance
(2)
or start engine and carry out troubleshooting.
6 Defective engine controller ENG Voltage
Between (37) (47) Power supply 4.75 5.25 V
Between (44) (47) Signal 0.3 4.7 V
Circuit diagram related to charge pressure sensor

a For "with EGR"
8 170E-5 Series
a For "EGR-less"
170E-5 Series 9
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error 1

Trouble Charge (boost) Air Press Sensor Low Error
123 CA123
Contents of
Signal voltage in charge (boost) pressure sensor circuit is abnormally low.
trouble
Action of con-
Fixes charge (boost) pressure (400 kPa {4.1 kg/cm2}) and continues operation.
troller
Problem that
appears on Acceleration performance of engine drops.
machine
Related infor-
mation
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for E-3 Code [122/CA122].
state
10 170E-5 Series
170E-5 Series 11
E-5 Code [131/CA131] Throttle Sensor High Error 1

Throttle sensor of accelerator pedal type (Case of WA600-6)

Trouble Throttle Sensor High Error
131 CA131
Contents of
Signal voltage in throttle sensor circuit is abnormally high.
trouble
Action of con- Sets throttle angle with signal other than throttle sensor signal and continues operation
troller (depending on each model)
Problem that
appears on Different problems occur on different machine models.
machine
Related infor-
mation

Defective sensor power sup- If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
ply system troubleshooting for it first.
L17 Accelerator pedal Voltage
All range
Between (1) (3) 4.75 5.25 V
(Power supply)
Defective accelerator pedal (9 2% of source
2 Released
(Internal trouble) voltage)
Between (2) (3)
(73 2% of source
Pressed
voltage)
Possible causes too, for another cause of trouble, and then judge.
and standard
state ing without turning starting switch ON.
Disconnection in wiring har- Wiring harnesses between E18 (female) (22) Resis-
ness Max. 1 z
L17 (female) (1) tance
3 (Disconnection in wiring or
defective contact in connec- Wiring harness between E18 (female) (9) Resis-
Max. 1 z
tor) L17 (female) (2) tance
Wiring harness between E18 (female) (23) Resis-
Max. 1 z
Ground fault in wiring har- Wiring harness between E18 (female) (22) Resis-
Min. 1 Mz
ness L17 (female) (1) and chassis ground tance
4
(Short circuit with GND cir- Wiring harness between E18 (female) (9) Resis-
cuit) Min. 1 Mz
L17 (female) (2) and chassis ground tance
Min. 1 Mz
12 170E-5 Series

Possible causes E18 Accelerator pedal Voltage
and standard All range
value in normal Between (22) (23) 4.75 5.25 V
5 Defective engine controller (Power supply)
state
(9 2% of source
Released
voltage)
Between (9) (23)
(73 2% of source
Pressed
voltage)
Circuit diagram related to throttle sensor of accelerator pedal type (Case of WA600-6)
170E-5 Series 13
Throttle sensor of fuel control dial type (Case of PC1250-8)

Trouble Throttle Sensor High Error
131 CA131
Contents of
Signal voltage in throttle sensor circuit is abnormally high.
trouble
Problem that
machine
Related infor-
mation

Defective sensor power sup- If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
ply system troubleshooting for it first.
Defective fuel control dial E06 (male) Resistance

2
(Internal trouble) Between (1) (3) 4.0 6.0 kz
Between (2) (1) 0.25 5.0 kz
Between (2) (3) 0.25 5.0 kz
Disconnection in wiring har- Wiring harnesses between E02 (female) (22) Resis-
ness Max. 1 z
E06 (female) (1) tance
Possible causes defective contact in connec- Wiring harnesses between E02 (female) (9) Resis-
Max. 1 z
and standard tor) E06 (female) (2) tance
value in normal Wiring harness between E02 (female) (23) Resis-
state Max. 1 z
Ground fault in wiring har- Wiring harness between E02 (female) (22) Resis-
Min. 1 Mz
ness E06 (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
E06 (female) (2) and chassis ground tance
Min. 1 Mz
E06 (female) (3) and chassis ground tance
5 Defective engine controller E02 Voltage
14 170E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC1250-8)
170E-5 Series 15
E-6 Code [132/CA132] Throttle Sensor Low Error 1

Trouble Throttle Sensor Low Error
132 CA132
Contents of trouble Signal voltage in throttle sensor circuit is abnormally low.
Sets throttle angle with signal other than throttle signal and continues operation (depending on
Action of controller
each model).
Problem that appears
Different problems occur on different machine models.
on machine
Related information
Possible causes and Cause Standard value in normal state/Remarks on troubleshooting

standard value in nor-
mal state Carry out troubleshooting for E-5 Code [131/CA131].
16 170E-5 Series
E-7 Code [135/CA135] Oil Press. Sensor High Error 1

Trouble Oil Press. Sensor High Error
135 CA135
Contents of
Signal voltage in oil pressure sensor circuit is abnormally high.
trouble
Action of con-
Sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation.
troller
Problem that
appears on
machine
Related infor-
mation

1
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
POIL Voltage
Defective oil pressure sensor
2 Between (1) (2) Power supply 4.75 5.25 V
(Internal trouble)
and standard Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal ness Max. 1 z
POIL (female) (1) tance
state 3 (Disconnection in wiring or
Max. 1 z
tor) POIL (female) (2) tance
Max. 1 z
POIL (female) (3) tance
Min. 1 Mz
ness POIL (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
POIL (female) (2) and chassis ground tance
Min. 1 Mz
POIL (female) (3) and chassis ground tance
170E-5 Series 17

POIL (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (47) POIL (female) tance
5
(With another wiring har- POIL (female) (1) and wiring harness Resis-
ness) between ENG (female) (13) POIL (female) tance
and standard
value in normal (3)
POIL (female) (2) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (13) POIL (female) tance
(3)
Circuit diagram related to oil pressure sensor

a For "with EGR"
18 170E-5 Series
a For "EGR-less"
170E-5 Series 19
E-8 Code [141/CA141] Oil Press. Sensor Low Error 1

Trouble Oil Press. Sensor Low Error
141 CA141
Contents of
Signal voltage in oil pressure sensor circuit is abnormally low.
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

and standard
state
20 170E-5 Series
170E-5 Series 21
E-9 Code [144/CA144] Coolant Temp. Sensor High Error 1

Trouble Coolant Temp. Sensor High Error
144 CA144
Contents of trouble Signal voltage in coolant temperature sensor circuit is abnormally high.
Action of controller Fixes coolant temperature (90C) and continues operation.
Engine starting performance decreases during low temperature.
on machine
Related information Different machine models may have different connector Nos.
Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out trouble-
shooting without turning starting switch ON.
Coolant
TWTR (male) Resistance
temperature
Defective coolant tempera-
1 ture sensor (Internal trou- 0C 30 37 k
ble) 25C 9.3 10.7 k
Between (A) (B) 50C 3.2 3.8 k
80C 1.0 1.3 k
95C 700 800
Disconnection in wiring har- shooting without turning starting switch ON.
ness (Disconnection in wir- Wiring harness between ENG
2 Resistance Max. 1
ing or defective contact in (female) (15) TWTR (female) (A)
Possible causes and connector)
standard value in nor- Wiring harness between ENG
Resistance Max. 1
mal state (female) (38) TWTR (female) (B)
Ground fault in wiring har- shooting without turning starting switch ON.
3 ness (Short circuit with GND Wiring harness between ENG
circuit) (female) (15) TWTR (female) (A) Resistance Min. 1 M
and chassis ground
Coolant
ENG (female) Resistance
temperature
4 Defective engine controller 0C 30 37 k

25C 9.3 10.7 k
Between (15) (38) 50C 3.2 3.8 k
80C 1.0 1.3 k
95C 700 800
22 170E-5 Series
Circuit diagram related to coolant temperature sensor

a For "with EGR"
a For "EGR-less"
170E-5 Series 23
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error 1

Trouble Coolant Temp. Sensor Low Error
145 CA145
Contents of trouble Signal voltage in coolant temperature sensor circuit is abnormally low.
Action of controller Fixes coolant temperature (90C) and continues operation.
on machine
Related information

mal state Carry out troubleshooting E-9 Code [144/CA144].
24 170E-5 Series
170E-5 Series 25
E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error 1

Trouble Charge (boost) Air Temp. Sensor High Error
153 CA153
Contents of trouble Signal voltage in charge (boost) temperature sensor circuit is abnormally high.
Action of controller Fixes charge (boost) temperature (intake air temperature) (70C) and continues operation.
on machine

Intake air tem-
TIM (male) Resistance
perature
Defective charge (boost) 0C 29 36 k
1 temperature sensor (Inter-
25C 9 11 k
nal trouble) Between (A) (B)
40C 4.9 5.8 k
100C 600 700
Between (A) chas-
All range Min. 1 M
sis ground
Disconnection in wiring har- shooting without turning starting switch ON.
ness (Disconnection in wir- Wiring harness between ENG
Possible causes and 2 Resistance Max. 1
ing or defective contact in (female) (23) TIM (female) (A)
connector)
mal state Wiring harness between ENG
Resistance Max. 1
(female) (47) TIM (female) (B)
Ground fault in wiring har- shooting without turning starting switch ON.
3 ness (Short circuit with GND Wiring harness between ENG
circuit) (female) (23) TIM (female) (A) and Resistance Min. 1 M
chassis ground
Intake air tem-
perature
4 Defective engine controller 0C 29 36 k
25C 9 11 k
Between (23) (47)
40C 4.9 5.8 k
100C 600 700
26 170E-5 Series
Circuit diagram related to charge temperature sensor

a For "with EGR"
a For "EGR-less"
170E-5 Series 27
E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error 1

Trouble Charge (boost) Air Temp. Sensor Low Error
154 CA154
Contents of trouble Signal voltage in charge temperature sensor circuit is abnormally low.
Action of controller Fixes charge (boost) temperature (intake air temperature) (70C) and continues operation.
on machine
Related information

mal state Carry out troubleshooting E-11 Code [153/CA153].
28 170E-5 Series
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error 1

Trouble Sensor Sup. 2 Volt. Low Error
187 CA187
Contents of
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
Operates Bkup speed sensor with signals of Ne speed sensor.
Action of con- Sets charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
troller Limits output of EGR valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Limits output of common rail pressure sensor and continues operation (Limits common rail pres-
sure).
Problem that
appears on Output drops.
machine
Related infor-
mation

and standard
state
170E-5 Series 29
E-14 Code [212/CA212] Oil Temp. Sensor High Error 1

(For VHMS)

Trouble Oil Temp. Sensor High Error
212 CA212
Contents of
Signal voltage in oil temperature sensor circuit is abnormally high.
trouble
Action of con-
Fixes oil temperature (100C) and continues operation.
troller
Problem that
appears on
machine
Related infor-
mation

TOIL (male) Oil temperature Resistance
Defective oil temperature 0C 30 37 k
1 sensor
25C 9.3 10.7 k
(Internal trouble)
Between (A) (B) 50C 3.2 3.8 k
80C 1.0 1.3 k
95C 700 800
ness
Wiring harnesses between ENG (female) Resis-
Possible causes 2 (Disconnection in wiring or Max. 1 z
(17) TOIL (female) (A) tance
and standard defective contact in connec-
value in normal tor) Wiring harnesses between ENG (female) Resis-
Max. 1 z
state (47) TOIL (female) (B) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
3
cuit) Min. 1 Mz
TOIL (female) (A) and chassis ground tance
ENG (female) Oil temperature Resistance
0C 30 37 k
25C 9.3 10.7 k
Between (17) (47) 50C 3.2 3.8 k
80C 1.0 1.3 k
95C 700 800
30 170E-5 Series
Circuit diagram related to oil temperature sensor

a For "with EGR"
a For "EGR-less"
170E-5 Series 31
E-15 Code [213/CA213] Oil Temp. Sensor Low Error 1

(For VHMS)

Trouble Oil Temp. Sensor Low Error
213 CA213
Contents of
Signal voltage in oil temperature sensor circuit is abnormally low.
trouble
Action of con-
Fixes oil temperature (100C) and continues operation.
troller
Problem that
appears on
machine
Related infor-
mation

and standard
state
32 170E-5 Series
E-16 Code [221/CA221] Ambient Air Press. Sensor High Error 1

Trouble Ambient Air Press. Sensor High Error
221 CA221
Contents of
Signal voltage in atmospheric pressure sensor circuit is abnormally high.
trouble
Action of con- Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues opera-
troller tion.
Problem that
machine
Related infor-
mation

1
PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal trouble) Between (2) (3) Signal 0.3 4.7 V
Possible causes
and standard
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal Max. 1 z
ness PAMB (female) (1) tance
state
Max. 1 z
tor) PAMB (female) (3) tance
Max. 1 z
PAMB (female) (2) tance
Min. 1 Mz
ness PAMB (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
PAMB (female) (3) and chassis ground tance
Min. 1 Mz
PAMB (female) (2) and chassis ground tance
170E-5 Series 33

PAMB (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (38) PAMB tance
Short circuit in wiring har- (female) (3)
5
(With another wiring har- PAMB (female) (1) and wiring harness Resis-
ness) between ENG (female) (3) PAMB (female) tance
and standard
value in normal (2)
PAMB (female) (3) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (3) PAMB (female) tance
(2)
Between (37) (38) 4.75 5.25 V
Between (3) (38) 0.3 4.7 V
Circuit diagram related to atmospheric pressure sensor

a For "with EGR"
34 170E-5 Series
a For "EGR-less"
170E-5 Series 35
E-17 Code [222/CA222] Ambient Air Press. Sensor Low Error 1

Trouble Ambient Air Press. Sensor Low Error
222 CA222
Contents of
Signal voltage in atmospheric pressure sensor circuit is abnormally low.
trouble
Action of con- Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues opera-
troller tion.
Problem that
machine
Related infor-
mation

and standard
state
36 170E-5 Series
E-18 Code [227/CA227] Sensor Sup. 2 Volt. High Error 1

Trouble Sensor Sup. 2 Volt. High Error
227 CA227
Contents of
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
Operates Bkup speed sensor with signals of Ne speed sensor.
Action of con- Sets charge (boost) pressure (400 kPa {4.1 kg/cm2}) and continues operation.
troller Limits output of EGR valve lift sensor and bypass valve lift sensor and closes EGR valve and bypass
valve. [with EGR only]
Sets atmospheric pressure (52.44 kPa {0.53 kg/cm2}) and continues operation.
Problem that
machine
Related infor-
mation

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Disconnect devices at Charge (boost) pres-
right in order. If error PIM connector
Defective sensor (Internal sure sensor
2 code disappears
trouble)
when a device is dis- Atmospheric pres-
PAMB connector
connected, that sure sensor
device has a defect in EGR valve lift sensor
SEGR connector
it. (*: "with EGR" only) (*)
Bypass valve posi-
SBP connector
tion sensor (*)
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard Disconnection in wiring har- ing without turning starting switch ON.
value in normal ness
state 3 (Disconnection in wiring or Max. 1 z
each sensor +5 V terminal (female) tance
tor) Wiring harness between ENG (female) (47) Resis-
Max. 1 z
each sensor +5 V terminal (female) tance
Ground fault in wiring har-
ness Resis-
4 each sensor +5 V terminal (female) and Min. 1 Mz
(Short circuit with GND cir- tance
chassis ground
cuit)
Min. 1 Mz
each sensor (female) and chassis ground tance
Short circuit in wiring har- ing without turning starting switch ON.
5
(With another wiring har- each sensor +5 V terminal (female) and Resis-
ness) Min. 1 Mz
wiring harness between ENG (female) (47) tance
each sensor GND terminal (female)
170E-5 Series 37

Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal 6 Defective engine controller
state ENG Voltage
Between (37) (47) 4.75 5.25 V
Circuit diagram related to sensor power supply 2 (5 V)

a For "with EGR"
38 170E-5 Series
a For "EGR-less"
170E-5 Series 39
E-19 Code [234/CA234] Eng. Overspeed 1

Trouble Eng. Overspeed
234 CA234
Contents of trouble Engine speed is above operating range.
Action of controller Limits fuel injection rate until engine speed lowers to operating range.
Engine speed fluctuates.
on machine
Related information

If another failure code is indicated, carry out troubleshooting for
1 Defective related system
it.
Possible causes and
standard value in nor- Way of use may be improper. Teach proper way of use to oper-
2 Improper way of use
mal state ator.
If causes 1 and 2 are not detected, engine controller may be
3 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
40 170E-5 Series
170E-5 Series 41
E-20 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error 1

Trouble Ne Speed Sensor Sup. Volt. Error
238 CA238
Contents of
Abnormality occurred in engine Ne speed sensor circuit power supply (5 V) circuit.
trouble
Action of con- Controls Ne speed sensor with signals of Bkup speed sensor.
troller Limits output and continues operation.
Problem that Output drops.
appears on Running engine stops (when Bkup speed sensor is also abnormal).
machine Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related infor-
mation

Disconnect devices at
Defective Ne speed sensor right in order. If error
1 code disappears
(Internal trouble)
when a device is dis- Ne speed sensor NE connector
connected, that
device has a defect in
it.
ness
NE (female) (1) tance
and standard
ness Wiring harness between ENG (female) (16) Resis-
3 Min. 1 Mz
(Short circuit with GND cir- NE (female) (1) and chassis ground tance
cuit) Wiring harness between ENG (female) (48) Resis-
Min. 1 Mz
NE (female) (2) and chassis ground tance
4
(With another wiring har- NE (female) (1) and wiring harness Resis-
ness) Min. 1 Mz
between ENG (female) (48) NE (female) tance
(2)
ENG Voltage
Between (16) (48) 4.75 5.25 V
42 170E-5 Series
Circuit diagram related to Ne speed sensor power supply
170E-5 Series 43
E-21 Code [263/CA263] Fuel Temp. Sensor High Error 1

Trouble Fuel Temp. Sensor High Error
263 CA263
Contents of
Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Substitutes coolant temperature sensor for fuel temperature sensor for correction of injection rate.
Action of con-
(When coolant temperature sensor also has an abnormality, fixes fuel temperature (95C) and con-
troller
tinues operation.)
Problem that
appears on
machine
Related infor-
mation

TFUEL (male) Fuel temperature Resistance
Defective fuel temperature 0C 30 37 k
1 sensor
25C 9.3 10.7 k
(Internal trouble)
Between (A) (B) 50C 3.2 3.8 k
80C 1.0 1.3 k
95C 700 800
ness
Possible causes 2 (Disconnection in wiring or Max. 1 z
TFUEL (female) (A) tance
and standard defective contact in connec-
value in normal tor) Wiring harness between ENG (female) (47) Resis-
Max. 1 z
state TFUEL (female) (B) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
3
cuit) Min. 1 Mz
TFUEL (female) (A) and chassis ground tance
ENG (female) Fuel temperature Resistance
0C 30 37 k
25C 9.3 10.7 k
Between (30) (47) 50C 3.2 3.8 k
80C 1.0 1.3 k
95C 700 800
44 170E-5 Series
Circuit diagram related to fuel temperature sensor

a For "with EGR"
a For "EGR-less"
170E-5 Series 45
E-22 Code [265/CA265] Fuel Temp. Sensor Low Error 1

Trouble Fuel Temp. Sensor Low Error
265 CA265
Contents of
Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
Substitutes coolant temperature sensor for fuel temperature sensor for correction of injection rate.
Action of con-
(When coolant temperature sensor also has an abnormality, fixes fuel temperature (95C) and con-
troller
tinues operation.)
Problem that
appears on
machine
Related infor-
mation

and standard
state
46 170E-5 Series
170E-5 Series 47
E-23 Code [271/CA271] PCV1 Short Error 1

Trouble PCV1 Short Error
271 CA271
Contents of
There is short circuit in PCV1 circuit of supply pump.
trouble
Action of con-
None in particular.
troller
Problem that
appears on
machine
While engine is running normally, pulse voltage of about 24 V is applied to PCV (1). This pulse volt-
Related infor-
age cannot be measured with circuit tester.
mation

Defective supply pump PCV1 (male) Resistance
1 PCV1
(Internal trouble) Between (1) (2) 2.3 5.3 z
Between (1), (2) chassis
Min. 1 Mz
ground
Ground fault in wiring har- ing without turning starting switch ON.
2 Min. 1 Mz
(Short circuit with GND cir- PCV1 (female) (1) tance
Possible causes cuit) Wiring harness between ENG (female) (5) Resis-
and standard Min. 1 Mz
PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with
3 24 V circuit) in wiring har- Voltage Max. 1 V
PCV1 (female) (1) and chassis ground
ness
Voltage Max. 1 V
Between (4) (5) 2.3 5.3 z
Min. 1 Mz
ground
48 170E-5 Series
Circuit diagram related to supply pump PCV1
170E-5 Series 49
E-24 Code [272/CA272] PCV1 Open Error 1

Trouble PCV1 Open Error
272 CA272
Contents of
There is disconnection in PCV1 circuit of supply pump.
trouble
Action of con-
None in particular.
troller
Problem that
appears on
machine
Related infor-
mation

1 PCV1
(Internal disconnection) Between (1) (2) 2.3 5.3 z
Min. 1 Mz
ground
ness
Possible causes
and standard Max. 1 z
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
3 Min. 1 Mz
(Short circuit with GND cir- PCV1 (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
PCV1 (female) (2) and chassis ground tance
Between (4) (5) 2.3 5.3 z
Min. 1 Mz
ground
50 170E-5 Series
170E-5 Series 51
E-25 Code [273/CA273] PCV2 Short Error 1

Trouble PCV2 Short Error
273 CA273
Contents of
There is short circuit in PCV2 circuit of supply pump.
trouble
Action of con-
None in particular.
troller
Problem that
appears on
machine
Related infor-
mation

1 PCV2
Min. 1 Mz
ground
2 Min. 1 Mz
Possible causes cuit) Wiring harness between ENG (female) (10) Resis-
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
ness
Voltage Max. 1 V
Between (9) (10) 2.3 5.3 z
Min. 1 Mz
ground
52 170E-5 Series
170E-5 Series 53
E-26 Code [274/CA274] PCV2 Open Error 1

Trouble PCV2 Open Error
274 CA274
Contents of
There is disconnection in PCV2 circuit of supply pump.
trouble
Action of con-
None in particular.
troller
Problem that
appears on
machine
Related infor-
mation

Defective supply pump ing without turning starting switch ON.
1 PCV2
PCV2 (male) Resistance
(Internal disconnection)
Between (1) (2) 2.3 5.3 z
ness
and standard
3 Min. 1 Mz
Min. 1 Mz
Between (9) (10) 2.3 5.3 z
Min. 1 Mz
ground
54 170E-5 Series
170E-5 Series 55
E-27 Code [322/CA322] Injector #1 System Open/Short Error 1

Trouble Injector #1 System Open/Short Error
322 CA322
Contents of
There is disconnection or short circuit in injector No. 1 circuit.
trouble
Action of con-
None in particular.
troller
Problem that
Output drops.
appears on
Rotation is unstable.
machine
While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injec-
Related infor-
tor. This pulse voltage cannot be measured with circuit tester.
mation

Defective injector No. 1 INJ (male) Resistance
1
Min. 1 Mz
ground
ness
INJ (female) (1) tance
and standard
3 Min. 1 Mz
(Short circuit with GND cir- INJ (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
INJ (female) (12) and chassis ground tance
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouble-
4
harness of another cylinder shooting for it, too.
Between (45) (53) 0.4 1.1 z
Min. 1 Mz
ground
56 170E-5 Series
Circuit diagram related to injector #1
170E-5 Series 57

323 CA323
Contents of
trouble
Action of con-
None in particular.
troller
Problem that
Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
Possible causes
value in normal
3 Min. 1 Mz
cuit)
Min. 1 Mz
4
Between (46) (60) 0.4 1.1 z
Min. 1 Mz
ground
58 170E-5 Series
170E-5 Series 59

324 CA324
Contents of
trouble
Action of con-
None in particular.
troller
Problem that
Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
Possible causes
value in normal
3 Min. 1 Mz
cuit)
Min. 1 Mz
4
Between (55) (52) 0.4 1.1 z
Min. 1 Mz
ground
60 170E-5 Series
170E-5 Series 61

325 CA325
Contents of
trouble
Action of con-
None in particular.
troller
Problem that
Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
Possible causes
value in normal
3 Min. 1 Mz
cuit)
Min. 1 Mz
4
Between (57) (59) 0.4 1.1 z
Min. 1 Mz
ground
62 170E-5 Series
170E-5 Series 63

331 CA331
Contents of
trouble
Action of con-
None in particular.
troller
Problem that
Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
Possible causes
value in normal
3 Min. 1 Mz
cuit)
Min. 1 Mz
4
Between (54) (51) 0.4 1.1 z
Min. 1 Mz
ground
64 170E-5 Series
170E-5 Series 65

332 CA332
Contents of
trouble
Action of con-
None in particular.
troller
Problem that
Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
Possible causes
value in normal
3 Min. 1 Mz
cuit)
Min. 1 Mz
4
Between (56) (58) 0.4 1.1 z
Min. 1 Mz
ground
66 170E-5 Series
170E-5 Series 67
E-33 Code [342/CA342] Engine Controller Data Matching Error 1

Trouble Engine Controller Data Matching Error
342 CA342
Contents of trouble Matching error occurred in engine controller data.
Action of controller None in particular.
Problem that appears Engine continues operation normally, but it may stop during operation or may not be able to
on machine start.
Related information

68 170E-5 Series
170E-5 Series 69
E-34 Code [351/CA351] INJ. Drive Circuit Error 1

Trouble INJ. Drive Circuit Error
351 CA351
Contents of
Abnormality occurred in injector drive circuit.
trouble
Action of con-
Limits output and continues operation (Limits common rail pressure).
troller
Problem that
machine
Related infor-
mation

If another failure code (injector system error code) is indicated, carry
out troubleshooting for it.
Check fuse or circuit breaker of machine for defect directly.
2 Defective fuse (If fuse is burnt out or circuit breaker is tripped, circuit probably has
ground fault.)
ness
Wiring harness between CE03 (female) (3) Resis-
battery (+) tance
Possible causes defective contact in connec-
and standard tor) Wiring harness between CE03 (female) (1) Resis-
Max. 1 z
value in normal chassis ground tance
ness Wiring harness between CE03 (female) (3) Resis-
4 Min. 1 Mz
(Short circuit with GND cir- battery (+) and chassis ground tance
cuit) Wiring harness between CE03 (female) (1) Resis-
Min. 1 Mz
chassis ground and chassis ground tance
CE03 Voltage
Between (3) (1) 20 30 V
70 170E-5 Series
Circuit diagram related to controller power supply
170E-5 Series 71
E-35 Code [352/CA352] Sensor Sup. 1 Volt. Low Error 1

Trouble Sensor Sup. 1 Volt. Low Error
352 CA352
Contents of
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of con- Limits output of common rail pressure sensor and continues operation (Limits common rail pres-
troller sure).
Problem that
machine
Related infor-
mation

and standard
state
72 170E-5 Series
170E-5 Series 73
E-36 Code [386/CA386] Sensor Sup. 1 Volt. High Error 1

Trouble Sensor Sup. 1 Volt. High Error
386 CA386
Contents of
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of con- Limits output of common rail pressure sensor and continues operation (Limits common rail pres-
troller sure).
Problem that
machine
Related infor-
mation

Defective sensor (Internal right in order. If error Ne sensor NE connector
2 code disappears
trouble)
when a device is dis-
connected, that
device has a defect in Fuel pressure sensor PFUEL connector
it.
ness Max. 1 z
PFUEL (female) (1) tance
Max. 1 z
tor) NE (female) (1) tance
Possible causes
each sensor (female) tance
value in normal
Min. 1 Mz
ness PFUEL (female) (1) and chassis ground tance
4
cuit) Max. 1 z
Min. 1 Mz
each sensor (female) and chassis ground tance
Short circuit in wiring har- PFUEL (female) (1) and wiring harness Resis-
Min. 1 Mz
ness between ENG (female) (47) each sensor tance
5
(With another wiring har- (female)
ness)
NE (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (47) each sensor tance
(female)
74 170E-5 Series

Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal 6 Defective engine controller ENG Voltage
state
Between (16) (48) and
4.75 5.25 V
(33) (47)
Circuit diagram related to sensor power supply 1 (5 V)

a For "with EGR"
170E-5 Series 75
a For "EGR-less"
76 170E-5 Series
170E-5 Series 77
E-37 Code [431/CA431] Idle Validation SW Low error 1


Trouble Idle Validation SW Low error
431 CA431
Contents of
Abnormality occurred in idle validation switch circuit
trouble
Action of con-
Sets throttle angle to certain value and continues operation (depending on each model).
troller
Problem that
appears on
machine
Related infor-
mation

L17 Signal name Voltage
Defective accelerator pedal Between (5) (4) Signal 1 See Fig. 1 in the next
1
(Internal trouble) Between (6) (4) Signal 2 page.
Defective power supply of and carry out troubleshooting.
2
idle validation switch 4.5
Between C30 (1) and (2) Voltage
5.5 V
Possible causes
Disconnection in wiring har- Wiring harness between E18 (female) (32) Resis-
and standard ness Max. 1 z
value in normal L17 (female) (4) tance
state Wiring harness between E18 (female) (11) Resis-
defective contact in connec- Max. 1 z
tor) L17 (female) (5) tance
Max. 1 z
Wiring harness between L04 (female) (34) Resis-
Max. 1 z
C30 (female) (1) tance
Ground fault in wiring har- Wiring harness between L02 (female) (4) Resis-
Max. 1 z
ness C30 (female) (2) tance
4
cuit) Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
78 170E-5 Series

Wiring harness between E18 (female) (32)
Hot short (Short circuit with Voltage Max. 1 V
L17 (female) (4) and chassis ground
5 24 V circuit) in wiring har-
Possible causes ness Wiring harness between E18 (female) (11)
Voltage Max. 1 V
and standard L17 (female) (5) and chassis ground
value in normal Wiring harness between E18 (female) (1)
Voltage Max. 1 V
state L17 (female) (6) and chassis ground
6 Defective engine controller E18 Signal name Voltage
Between (11) (32) Signal 1
See Fig. 1.
Between (1) (32) Signal 2
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 79
E-38 Code [432/CA432] Idle Validation Process error 1

Trouble Idle Validation Process error
432 CA432
Contents of
Abnormality occurred in processing of idle validation switch circuit.
trouble
Action of con-
Sets throttle angle to certain value and continues operation (depending on each model).
troller
Problem that
appears on
machine
Related infor-
mation

and standard
state
80 170E-5 Series
E-39 Code [441/CA441] Battery voltage low error 1

Trouble Battery voltage low error
441 CA441
Contents of trouble Power supply voltage is abnormally low.
on machine start.
Related information

E-40 Code [442/CA442] Battery voltage high error 1

Trouble Battery voltage high error
442 CA442
Contents of trouble Power supply voltage is abnormally high.
on machine start.
Related information

170E-5 Series 81
SEN00371-01
2007 KOMATSU
All Rights Reserved
82
SEN00372-01
ENGINE 1SHOP MANUAL
170E-5 Series
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 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........................................................................ 7
E-44 Code [553/CA553] Rail Press. High Error ................................................................................... 8
E-45 Code [559/CA559] No-pressure feed by supply pump 1 ........................................................... 10
E-46 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 16
E-47 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 18
E-48 Code [757/CA757] All Persistent Data Lost Error...................................................................... 19
E-49 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 20
E-50 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 22
E-51 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 23
E-52 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit ............................................. 24
E-53 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error ............................................... 26
170E-5 Series 1
E-54 Code [1628/CA1628] Bypass Valve Servo Error 1 .................................................................... 27

E-55 Code [1629/CA1629] Bypass Valve Servo Error 2 .................................................................... 28
E-56 Code [1631/CA1631] BP valve Lift Position Sensor High Error................................................. 29
E-57 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ................................................. 31
E-58 Code [1633/CA1633] KOMNET Error........................................................................................ 31
E-59 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 32
E-60 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 36
E-61 Code [2249/CA2249] No-pressure feed by supply pump 2 ....................................................... 36
E-62 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error ............................................. 37
E-63 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error .............................................. 39
E-64 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error.................................................... 40
E-65 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error ................................................... 42
E-66 Code [2555/CA2555] Grid Heater Relay Open Error................................................................. 43
E-67 Code [2556/CA2556] Grid Heater Relay Short Error................................................................. 44
E-68 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate.............................................................. 46
E-69 Code [(146)/B@BCNS] Eng. Overheat...................................................................................... 46
E-70 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate....................................................... 47
2 170E-5 Series
Troubleshooting of electrical system (E-mode), Part 2 1

E-41 Code [449/CA449] Rail Press. Very High Error 1

Trouble Rail Press. Very High Error
449 CA449
Contents of
Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of con-
troller
Problem that
machine
Related infor-
mation

and standard
state
170E-5 Series 3
E-42 Code [451/CA451] Rail Press. Sensor High Error 1

Trouble Rail Press. Sensor High Error
451 CA451
Contents of
Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of con-
troller
Problem that
machine
Related infor-
mation

1
PFUEL Voltage
Defective common rail pres-
2 sure sensor
(Internal trouble) Between (2) (3) Signal 0.25 4.6 V
Possible causes
and standard
value in normal
ness Max. 1 z
state PFUEL (female) (1) tance
Max. 1 z
tor) PFUEL (female) (2) tance
Max. 1 z
PFUEL (female) (3) tance
Min. 1 Mz
ness PFUEL (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
PFUEL (female) (2) and chassis ground tance
Min. 1 Mz
PFUEL (female) (3) and chassis ground tance
4 170E-5 Series

PFUEL (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (25) PFUEL tance
Short circuit in wiring har- (female) (2)
5
(With another wiring har- PFUEL (female) (1) and wiring harness Resis-
ness) between ENG (female) (47) PFUEL tance
and standard
value in normal (female) (3)
PFUEL (female) (2) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (47) PFUEL tance
(female) (3)
Between (33) (47) 4.75 5.25 V
Between (25) (47) 0.25 4.6 V
Circuit diagram related to common rail pressure sensor

a For "with EGR"
170E-5 Series 5
a For "EGR-less"
6 170E-5 Series
E-43 Code [452/CA452] Rail Press. Sensor Low Error 1

Trouble Rail Press. Sensor Low Error
452 CA452
Contents of
Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of con-
troller
Problem that
machine
Related infor-
mation

and standard
state
170E-5 Series 7
E-44 Code [553/CA553] Rail Press. High Error 1

Trouble Rail Press. High Error
553 CA553
Contents of
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of con-
None in particular.
troller
Problem that
appears on
machine
Related infor-
mation

2 Use of improper fuel Check fuel used directly (for high viscosity).
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out
3
Possible causes common rail pressure sensor troubleshooting for code [451/CA451] (E-42).
and standard Defective mechanical system
value in normal 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
state sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
8 170E-5 Series
170E-5 Series 9
E-45 Code [559/CA559] No-pressure feed by supply pump 1 1

Trouble No-pressure feed by supply pump 1
559 CA559
Contents of
Supply pump does not feed fuel (level 1).
trouble
Action of con-
Limits common rail pressure.
troller
Problem that
machine
Related infor-
mation

2 Use of improper fuel Check fuel used directly (for high viscosity).
a For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting,
Defective low-pressure cir-
3 Testing fuel pressure.
cuit device
Pressure in fuel low-pressure
Min. 0.15 MPa {Min. 1.5 kg/cm2}
circuit (At high idle)
4 Clogging of filter or strainer a For contents of troubleshooting, see Note 2.
Supply pump PCV may have electric trouble. Carry out trouble-
Defective electrical system of
5 shooting for following codes [271/CA271 (E-23), [272/CA272 (E-
supply pump PCV
24), [273/CA273] (E-25), 274/CA274] (E-26).
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
6
sure sensor ness for damage.
Possible causes
and standard a For testing of leakage from pressure limiter, see Testing and
value in normal adjusting, Testing leakage from pressure limiter and return rate
state from injector.
7 Defective pressure limiter
Leakage from pressure limiter
(At equivalent to rated operation Max. 10 cc/min
(by models))
a For testing of return rate (spill) from injector, see Testing and
adjusting, Testing leakage from pressure limiter and return rate
from injector.
Speed at rated operation Return (Spill) limit from injector
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for no-
pressure feed.
10 170E-5 Series
<For "with EGR">

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 11
<For "EGR-less">
Note 1: When low-pressure circuit is defective, check the following:
q Fuel level
q Clogged fuel tank breather
q Water separator/Prefilter filled with water
q Clogged fuel filter
q Clogged screen in water separator
q Stuck or worn feed pump, clogged filter
q Leakage or clogged low-pressure fuel pipe
q Bypass valve malfunction, defective assembly of other parts (See Fig. 1.)
q Fuel in oil pan (fuel leakage in 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.
q Fuel filter: Replace. (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it. (See Fig. below.)
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
12 170E-5 Series
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
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>
*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
*10
170E-5 Series 13
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}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
Standard value
Measured
E. Check of leakage and return rate Checking condition Unit (Reference Good NG
value
value)
At rated output
11 Leakage through pressure limiter cc/min Max. 10
<by models>
cc/min 960
<By models> 1,600 rpm
Equivalent to rating Speed:
cc/min 1,020
12 Return rate from injector cc/min 1,080
cc/min 1,140 Return rate:
cc/min 1,200
*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.
14 170E-5 Series
170E-5 Series 15
E-46 Code [689/CA689] Eng. Ne Speed Sensor Error 1

Trouble Eng. Ne Speed Sensor Error
689 CA689
Contents of
Abnormality occurred in engine Ne speed sensor circuit.
trouble
Action of con-
Operates with signals of Bkup speed sensor.
troller
Problem that
Running engine stops (when Bkup speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related infor-
mation

Defective sensor power sup-
1 If code [238/CA238] is indicated, carry out troubleshooting for it first.
ply system
ness Max. 1 z
Max. 1 z
tor) NE (female) (2) tance
Max. 1 z
Min. 1 Mz
ness NE (female) (1) and chassis ground tance
3
cuit) Min. 1 Mz
Possible causes Wiring harness between ENG (female) (27) Resis-
value in normal
state
Min. 1 Mz
4
(With another wiring har- NE (female) (1) and wiring harness Resis-
ness) Min. 1 Mz
(3)
Min. 1 Mz
(3)
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for
part defect.
If causes 1 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
16 170E-5 Series

and standard
value in normal If causes 1 6 are not detected, engine controller may be defective.
state (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to engine Ne speed sensor
170E-5 Series 17
E-47 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error 1

Trouble Eng. Bkup Speed Sensor Phase Error
731 CA731
Contents of
Abnormal phase is detected in engine Bkup sensor circuit.
trouble
Action of con-
Controls with signals of engine Ne speed sensor.
troller
Problem that
Running engine stops (when Ne speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related infor-
mation

Possible causes
Defective engine Ne speed Engine Ne speed sensor may have trouble. Carry out troubleshoot-
and standard 1
sensor system ing for code [689/CA689] (E-46).
value in normal
state Defective engine Bkup Engine Bkup speed sensor may have trouble. Carry out trouble-
2
speed sensor system shooting for code [778/CA778] (E-49).
18 170E-5 Series
E-48 Code [757/CA757] All Persistent Data Lost Error 1

Trouble All Persistent Data Lost Error
757 CA757
Contents of trouble All data in engine controller are lost.
on machine start.
Related information

170E-5 Series 19
E-49 Code [778/CA778] Eng. Bkup Speed Sensor Error 1

Trouble Eng. Bkup Speed Sensor Error
778 CA778
Contents of
Abnormality occurred in engine Bkup speed sensor circuit.
trouble
Action of con-
Operates with signals of Ne speed sensor.
troller
Problem that
Running engine stops (when Ne speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related infor-
mation

1
ness Max. 1 z
G (female) (1) tance
Max. 1 z
tor) G (female) (2) tance
Max. 1 z
G (female) (3) tance
Min. 1 Mz
ness G (female) (1) and chassis ground tance
3
cuit) Min. 1 Mz
G (female) (2) and chassis ground tance
Possible causes
G (female) (3) and chassis ground tance
value in normal
Resis-
G (female) (1) and between ENG (female) Min. 1 Mz
Short circuit in wiring har- tance
(47) G (female) (2)
ness
4 Wiring harness between ENG (female) (37)
(With another wiring har- Resis-
ness) G (female) (1) and between ENG (female) Min. 1 Mz
tance
(26) G (female) (3)
Resis-
G (female) (2) and between ENG (female) Min. 1 Mz
tance
(26) G (female) (3)
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly
part for defect.
If causes 1 5 are not detected, engine Bkup speed sensor may be
Defective engine Bkup
6 defective. (Since trouble is in system, troubleshooting cannot be
speed sensor
carried out.)
If causes 1 6 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
20 170E-5 Series
Circuit diagram related to engine Bkup speed sensor

a For "with EGR"
a For "EGR-less"
170E-5 Series 21
E-50 Code [1228/CA1228] EGR Valve Servo Error 1 1

a This code applies to only with EGR.
Trouble EGR Valve Servo Error 1
1228 CA1228
Contents of
Abnormality (level 1) occurred in EGR valve servo.
trouble
Action of
Performs open control.
controller
Problem that
appears on
machine
Related
information

it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, Measuring EGR valve and bypass valve drive
pressure.
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure
Low idle Min. 1.18 MPa {12 kg/cm2}
High idle Min. 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting,
Testing engine oil pressure.
Possible causes
Engine speed Engine oil pressure
and standard Defective engine oil pressure
value in normal 3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
system (main circuit)
state High idle Min. 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for
mechanical system (S-12 Oil pressure lowers).
Defective oil pump for EGR
4 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
5 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping for
6 Check oil return piping for EGR valve circuit directly.
EGR valve
7 Defective EGR valve Check mechanical section of EGR valve directly.
8 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
ried out.)
22 170E-5 Series
E-51 Code [1625/CA1625] EGR Valve Servo Error 2 1

Trouble EGR Valve Servo Error 2
1625 CA1625
Contents of
Abnormality (level 2) occurred in EGR valve servo.
trouble
Action of con- Limits output and continues operation.
troller Closes EGR valve and bypass valve.
Problem that
machine
Related infor-
mation

and standard
state
170E-5 Series 23
E-52 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit 1

Trouble Bypass Valve Solenoid Drive Short Circuit
1626 CA1626
Contents of trouble There is short circuit in drive circuit of bypass valve solenoid.
Limits output and continues operation.
Action of controller
Closes EGR valve and bypass valve.
Output drops.
on machine

Defective bypass valve shooting without turning starting switch ON.
1
solenoid (Internal trouble) BP (male) Resistance
Between (1) (2) 10 21
Disconnection in wiring shooting without turning starting switch ON.
harness (Disconnection Wiring harness between ENG (female)
2 Resistance Max. 1
in wiring or defective con- (31) BP (female) (1)
tact in connector)
Wiring harness between ENG (female)
Resistance Max. 1
(11) BP (female) (2)
Possible causes and Ground fault in wiring
(31) BP (female) (1) and chassis Resistance Min. 1 M
standard value in nor- 3 harness (Short circuit
ground
mal state with GND circuit)
(11) BP (female) (2) and chassis Resistance Min. 1 M
ground
a Prepare with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.
Hot short (Short circuit
(31) BP (female) (1) and chassis Voltage Max. 1 V
4 with 24V circuit) in wiring
ground
harness
(11) BP (female) (2) and chassis Voltage Max. 1 V
ground
Defective engine control- shooting without turning starting switch ON.
5
ler ENG (female) Resistance
Between (31) (11) 10 21
24 170E-5 Series
Circuit diagram related to bypass valve solenoid & lift sensor
170E-5 Series 25
E-53 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error 1

Trouble Bypass Valve Solenoid Drive Open Error
1627 CA1627
Contents of
Disconnection occurred in bypass valve solenoid drive circuit.
trouble
Problem that
machine
Related infor-
mation

and standard
state
26 170E-5 Series
E-54 Code [1628/CA1628] Bypass Valve Servo Error 1 1

Trouble Bypass Valve Servo Error 1
1628 CA1628
Contents of
Abnormality (level 1) occurred in bypass valve servo.
trouble
Action of
Performs open control.
controller
Problem that
appears on
machine
Related
information

it.
a For measurement of bypass valve drive pressure, see Testing
and adjusting, Measuring EGR valve and bypass valve drive
oil pressure.
Improper bypass valve drive Engine speed Bypass valve drive pressure
2
pressure
Low idle Min. 1.18 MPa {12 kg/cm2}
High idle Min. 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting,
"Testing engine oil pressure".
Possible causes
Engine speed Engine oil pressure
and standard Defective engine oil pressure
value in normal 3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
system (main circuit)
state High idle Min. 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for
mechanical system (S-12 Oil pressure lowers).
Defective oil pump for bypass
4 Check oil pump and relief valve for bypass valve circuit directly.
valve
Defective oil feed piping for
5 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping for
6 Check oil return piping for bypass valve circuit directly.
bypass valve
7 Defective bypass valve Check mechanical section of bypass valve directly.
8 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
ried out.)
170E-5 Series 27
E-55 Code [1629/CA1629] Bypass Valve Servo Error 2 1

Trouble Bypass Valve Servo Error 2
1629 CA1629
Contents of
Abnormality (level 2) occurred in bypass valve servo.
trouble
Problem that
machine
Related infor-
mation

and standard
state
28 170E-5 Series
E-56 Code [1631/CA1631] BP valve Lift Position Sensor High Error 1

Trouble BP valve Lift Position Sensor High Error
1631 CA1631
Contents of
Signal voltage in bypass valve lift sensor circuit is abnormally high.
trouble
Action of Limits output and continues operation.
controller Closes EGR valve and bypass valve.
Problem that
machine
Related
information

If code [187/CA187] or [227/CA227] is indicated, carry out trou-
1 Defective sensor power supply
bleshooting for it first.
SBP Voltage
Defective bypass valve lift sen- and carry out troubleshooting.
2
sor (Internal trouble) SBP Voltage
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
Possible causes
and standard
value in normal
state Disconnection in wiring har- Wiring harness between ENG (female) Resis-
ness Max. 1 z
(37) SBP (female) (1) tance
defective contact in connector) Wiring harness between ENG (female) Resis-
Max. 1 z
(38) SBP (female) (2) tance
Wiring harness between ENG (female) Resis-
Max. 1 z
(29) SBP (female) (3), (4) tance
Resis- Min.
(37) SBP (female) (1) and chassis
tance 1 Mz
ground
Ground fault in wiring harness
4
(Short circuit with GND circuit) Wiring harness between ENG (female) Resis- Min.
(38) SBP (female) (2) and chassis
tance 1 Mz
ground
Resis- Min.
(29) SBP (female) (3), (4) and chassis
tance 1 Mz
ground
170E-5 Series 29

(37) SBP (female) (1) and Resis- Min.
wiring harness between ENG (female) (38) tance 1 Mz
SBP (female) (2)
Short circuit in wiring harness Wiring harness between ENG (female)
Possible causes 5
(With another wiring harness) (37) SBP (female) (1) and Resis- Min.
and standard wiring harness between ENG (female) (29) tance 1 Mz
value in normal SBP (female) (3), (4)
state
(38) SBP (female) (2) and Resis- Min.
wiring harness between ENG (female) (29) tance 1 Mz
SBP (female) (3), (4)
ENG Voltage
Between (37) (38) 4.75 5.25V
Circuit diagram related to bypass valve solenoid & lift sensor
30 170E-5 Series
E-57 Code [1632/CA1632] BP valve Lift Position Sensor Low Error 1

Trouble BP valve Lift Position Sensor Low Error
1632 CA1632
Contents of
Signal voltage in bypass valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related infor-
mation

and standard
state
E-58 Code [1633/CA1633] KOMNET Error 1

Trouble KOMNET Error
1633 CA1633
Contents of trouble Abnormality occurred in circuit of KOMNET communication with machine.
Action of controller Operates in default mode or maintains condition when abnormality occurs.
on machine
Related information

Possible causes and This fault is detected and indicated when KOMNET communi-
standard value in nor- Carry out troubleshooting cation with machine monitor or controller on the machine side
mal state 1
on machine side is abnormal. Accordingly, contents of troubleshooting depends
on machine model. See Shop manual for machine.
170E-5 Series 31
E-59 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error 1


Trouble Throttle Sens. Sup. Volt. High Error
2185 CA2185
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Problem that
machine
Related infor-
mation

Defective accelerator pedal right in order.
1 If error code disap-
(Internal trouble)
pears when a device Accelerator pedal L17 connector
is disconnected, that
it.
ness
Possible causes tor) Wiring harness between E18 (female) (23) Resis-
Max. 1 z
and standard L17 (female) (3) tance
ness Wiring harness between E18 (female) (22) Resis-
3 Min. 1 Mz
(Short circuit with GND cir- L17 (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
ness
4 Wiring harness between E18 (female) (22)
ness) L17 (female) (1) and wiring harness between Min. 1 Mz
tance
E18 (female) (23) L17 (female) (3)
E18 Voltage
Between (22) (23) 4.75 5.25 V
32 170E-5 Series
170E-5 Series 33
Throttle sensor of fuel control dial type (Case of PC1250-8)

Trouble Throttle Sens. Sup. Volt. High Error
2185 CA2185
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Problem that
machine
Related infor-
mation

Defective fuel control dial right in order.
1 If error code disap-
(Internal trouble)
pears when a device Fuel control dial E06 connector
is disconnected, that
it.
ness
Possible causes tor) Wiring harness between E02 (female) (23) Resis-
Max. 1 z
and standard E06 (female) (3) tance
3 Min. 1 Mz
(Short circuit with GND cir- E06 (female) (1) tance
cuit) Wiring harness between E02 (female) (23) Resis-
Min. 1 Mz
ness
4 Wiring harness between E02 (female) (22)
ness) E06 (female) (1) and wiring harness between Min. 1 Mz
tance
E02 (female) (23) E06 (female) (3)
E02 Voltage
Between (22) (23) 4.75 5.25 V
34 170E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC1250-8)
170E-5 Series 35
E-60 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error 1

Trouble Throttle Sens. Sup. Volt. Low Error
2186 CA2186
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.
trouble
Problem that
machine
Related infor-
mation

and standard
state
E-61 Code [2249/CA2249] No-pressure feed by supply pump 2 1

Trouble No-pressure feed by supply pump 2
2249 CA2249
Contents of
Supply pump does not feed fuel (level 2).
trouble
Action of con-
Limits common rail pressure.
troller
Problem that
machine
Related infor-
mation

and standard
state
36 170E-5 Series
E-62 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error 1
Trouble EGR Valve Lift Position Sensor High Error
2271 CA2271
Contents of
Signal voltage in EGR valve lift sensor circuit is abnormally high.
trouble
Action of Limits output and continues operation.
controller Closes EGR valve and bypass valve.
Problem that
machine
Related
information

If code [187/CA187] or [227/CA227] is indicated, carry out trou-
1 Defective sensor power supply
bleshooting for it first.
SEGR Voltage
Defective EGR valve lift sensor and carry out troubleshooting.
2
(Internal trouble) SEGR Voltage
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
Possible causes
and standard
value in normal
state Wiring harness between ENG (female)
Resis-
(37) SEGR (female) (1) and chassis Max. 1 z
Disconnection in wiring har- tance
ground
ness (Disconnection in wiring
3
or defective contact in connec- Wiring harness between ENG (female) Resis-
tor) (47) SEGR (female) (2) and chassis Max. 1 z
tance
ground
Resis-
(19) SEGR (female) (3), (4) and chassis Max. 1 z
tance
ground
Wiring harness between ENG (female) Resis- Min.
Ground fault in wiring harness (37) SEGR (female) (1) tance 1 Mz
4
(Short circuit with GND circuit) Wiring harness between ENG (female) Resis- Min.
(47) SEGR (female) (2) tance 1 Mz
Wiring harness between ENG (female) Resis- Min.
(19) SEGR (female) (3), (4) tance 1 Mz
170E-5 Series 37

Resis- Min.
(37) SEGR (female) (1) and between
tance 1 Mz
ENG (female) (47) SEGR (female) (2)
Short circuit in wiring harness Wiring harness between ENG (female)

Possible causes 5 (37) SEGR (female) (1) and between Resis- Min.
(with another wiring harness)
and standard ENG (female) (19) SEGR (female) (3), tance 1 Mz
value in normal (4)
state Wiring harness between ENG (female)
(47) SEGR (female) (2) and between Resis- Min.
ENG (female) (19) SEGR (female) (3), tance 1 Mz
(4)
ENG Voltage
Between (37) (47) 4.75 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
38 170E-5 Series
E-63 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error 1
Trouble EGR Valve Lift Position Sensor Low Error
2272 CA2272
Contents of
Signal voltage in EGR valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related infor-
mation

and standard
state
170E-5 Series 39
E-64 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error 1

Trouble EGR Valve Solenoid Drive Short Error
2351 CA2351
Contents of
Short circuit occurred in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related infor-
mation

Defective EGR valve sole- ing without turning starting switch ON.
1 noid
EGR (male) Resistance
(Internal trouble)
Between (1) (2) 10 21 z
ness
EGR (female) (1) tance
Max. 1 z
EGR (female) (2) tance
and standard Ground fault in wiring har-
value in normal ness Wiring harness between ENG (female) (22) Resis-
3 Min. 1 Mz
state (Short circuit with GND cir- EGR (female) (1) and chassis ground tance
Min. 1 Mz
EGR (female) (2) and chassis ground tance
EGR (female) (1) and chassis ground
ness
Voltage Max. 1 V
EGR (female) (2) and chassis ground
Between (22) (11) 10 21 z
40 170E-5 Series
Circuit diagram related to EGR valve solenoid & lift sensor
170E-5 Series 41
E-65 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error 1

Trouble EGR Valve Solenoid Drive Open Error
2352 CA2352
Contents of
Disconnection occurred in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related infor-
mation

and standard
state
42 170E-5 Series
E-66 Code [2555/CA2555] Grid Heater Relay Open Error 1

Trouble Grid Heater Relay Open Error
2555 CA2555
Contents of
Disconnection occurred in intake air heater relay circuit.
trouble
Action of con-
None in particular.
troller
Problem that
appears on Starting performance at low temperature is poor.
machine
Related infor-
mation

and standard
state
170E-5 Series 43
E-67 Code [2556/CA2556] Grid Heater Relay Short Error 1

Trouble Grid Heater Relay Short Error
2556 CA2556
Contents of
Short circuit occurred in intake air heater relay circuit.
trouble
Action of con-
None in particular.
troller
Problem that
appears on Starting performance at low temperature is poor.
machine
Related infor- Heater relay drive condition depends on machine model.
mation Different machine models may have different connector Nos.

Defective intake air heater ing without turning starting switch ON.
1 relay
R18 (male) Resistance
(Internal trouble)
Between (1) (2) 200 400 z
ness
R18 (female) (1) tance
tor) Wiring harness between E02 (female) (42) Resis-
Max. 1 z
Possible causes R18 (female) (2) tance
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state Ground fault in wiring har-
3 Min. 1 Mz
(Short circuit with GND cir- R18 (female) (1) and chassis ground tance
cuit) Wiring harness between E02 (female) (42) Resis-
Min. 1 Mz
R18 (female) (2) and chassis ground tance
E02 Heater relay Voltage
4 Defective engine controller Under operating
Max. 1 V
condition
Between (40) (42)
Under stopping
20 30 V
condition
44 170E-5 Series
Circuit diagram related to intake air heater relay (Example)
170E-5 Series 45
E-68 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate 1

Trouble Eng. Oil press. Torque Derate
(143) B@BAZG
Contents of
Engine oil pressure is below operating range.
trouble
Action of con-
Limits output and continues operation (Limits fuel injection rate and engine speed).
troller
Problem that
machine
Related infor-
mation

and standard This fault is indicated on only machine side when detected. Accord-
value in normal Carry out troubleshooting on
1 ingly, contents of troubleshooting depends on machine model. See
state machine side
Shop manual for machine.
E-69 Code [(146)/B@BCNS] Eng. Overheat 1

Trouble Eng. Overheat
(146) B@BCNS
Contents of
Engine coolant temperature is above operating range.
trouble
Action of con-
Limits output and continues operation.
troller
Problem that
machine
Related infor-
mation

state machine side
46 170E-5 Series
E-70 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate 1

Trouble Eng. Oil press. Low Speed Derate
(415) B@BAZG
Contents of
Engine oil pressure is below operating range.
trouble
Action of con-
Limits output and continues operation (Limits fuel injection rate and engine speed).
troller
Problem that
machine
Related infor-
mation

state machine side
170E-5 Series 47
SEN00372-01
2007 KOMATSU
All Rights Reserved
48
SEN00370-01
ENGINE 1SHOP MANUAL
170E-5 Series
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
S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 23

S-14 Coolant temperature becomes too high (overheating) .............................................................. 25
S-15 Abnormal noise is made ............................................................................................................ 26
S-16 Vibration is excessive ................................................................................................................ 27
S-17 Air cannot be bled from fuel circuit ............................................................................................ 28
2 170E-5 Series
Troubleshooting of mechanical system (S-mode) 1

Method of using troubleshooting charts 1
The troubleshooting chart consists of the questions, check items, causes, and troubleshooting blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
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.
Items listed in the [Questions] and [Check items]

and related to the [Causes] are marked with E,Q
and w.
E : Causes to be referred to for questions and
check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked
with Q
a When narrowing the causes, apply the items

marked with w before those marked with Q.
When narrowing the causes, do not apply the
items marked with E. (If no items have other
marks and the causes cannot be narrowed,
however, you may apply them.)
170E-5 Series 3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that when Color of exhaust gas is black occurs, the relevant items of [questions] and [check
items] are the following 3 symptoms: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
4 170E-5 Series
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
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
(Coolant in exhaust pipe) ["with EGR" only]

Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

q
Clogged air breather hole of fuel tank cap

Defective contact of valve and valve seat
Defective alternator (generator section)

Defective alternator (regulator section)
q Insufficient intake of air
Stuck, seized supply pump plunger

Improper selection of fuel
Defective intake air heater system

q
Defective or deteriorated battery

Clogged feed pump gauze filter
q Coolant in exhaust pipe ["with EGR" only]
Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
a The common rail fuel injection system (CRI) con-
Cracked EGR cooler

trols the fuel injection timing electrically. Accord-
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
machine Operated for long period E E E E E
Starting perfor- Became worse gradually Q Q w w Q Q

mance Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters has not been carried out according to Operation and Mainte-
w w w Q Q
nance Manual
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if installed)
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
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 exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When EGR cooler inlet gas piping is removed, coolant containing antifreeze flows out
q
(*1) ["with EGR" only]
When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Troubleshooting
Inspect fuel filter, element directly q

Inspect fuel feed pump gauze filter directly q
Carry out troubleshooting according to No-pressure feed by supply pump (*2) in E- q
mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
For *1 and *2, see the next page. Remedy
6 170E-5 Series
*1: EGR cooler inlet gas piping

Loosen 4 mounting bolts (1) on the EGR cooler inlet gas piping and confirm for coolant flowage.
A slight amount of flocculated water generated when exhaust gas is cooled may flow out; there is no
problem if it is clear and colorless.
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
170E-5 Series 7
S-2 Engine does not start 1
a) Engine does not turn Causes
Cracked EGR cooler (Coolant in exhaust pipe) ["with EGR" only]

General causes why engine does not turn
q Internal parts of engine seized:

See S-4 Engine stops during operations
q Water hammer caused by coolant which entered cylinder
Defective starting motor (safety relay section)

q Defective electrical system
q Problem in drive devices on applicable machine side
Defective connection of battery terminal
Defective starting motor (motor section)

Defective or deteriorated battery
Defective steering circuit wiring

Broken flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of use of Operated for long period E E E

machine
Condition of horn when Horn does not sound Q Q w
starting switch is
turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Speed of rotation is low Q w
Check items
When starting switch is

turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn w Q Q w
When EGR cooler inlet gas piping is removed, coolant containing antifreeze flows out (*1).
["with EGR" only] q
Inspect flywheel ring gear directly q

Carry out troubleshooting
on applicable machine
q
Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, they are low
There is not voltage (20 30 V) between battery relay terminal B and
q
terminal E
Turn starting switch When terminal B and terminal C of starting switch are connected,
engine starts q
OFF, connect cord,
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

For *1, see the next page.
8 170E-5 Series

170E-5 Series 9
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke
comes out

q Fuel is not being supplied
Wrong connection of supply pump PCV

q Supply of fuel is extremely small
Seized, abnormally worn feed pump

q Improper selection of fuel (particularly in winter)
Defective operation flow damper

Broken supply pump shaft, key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Confirm recent repair history E
Degree of use of
Questions
Operated for long period E E E

machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Replacement of filters has not been carried out according to Operation and
w w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
Check items
Fuel is leaking from fuel piping w
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

Inspect fuel filter directly q
Inspect feed pump gauze filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to No-pressure feed by supply pump (*1)
in E-mode q q q q
Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality q

in PCV2 (*3) in E-mode
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add

10 170E-5 Series
c) Exhaust smoke comes out but engine does not Causes
start (fuel is being injected)
Leaking or clogged fuel system, entry of air

Defective coolant temperature sensor,

General causes why exhaust smoke comes out but
Defective intake air heater system

Clogged injector, defective spray
engine does not start
Worn piston ring, cylinder liner
Defective, deteriorated battery

Worn dynamic valve system
Clogged fuel filter, strainer

(Valve, rocker lever, etc.)
q Lack of rotating force due to defective electrical
Use of improper fuel

system
q Insufficient supply of fuel
wiring harness
q Improper selection of fuel

Degree of use of
machine Operated for long period E E E E
Suddenly failed to start w w Q

Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation and Maintenance
w w w
Manual
When engine is preheated or when temperature is low, preheating monitor does not indi-
w
cate normally (if monitor is installed)
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is not fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
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

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting
Inspect fuel filter, strainer directly q

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-
q
mode
When injector unit is tested, spray condition is bad q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally q
(if coolant temperature gauge is installed)
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
170E-5 Series 11
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Causes
Defective EGR valve or bypass valve ["with EGR" only]

Seized turbocharger, interference of turbocharger

q Defective injection condition of fuel

q Controller is controlling in derate mode
Defective operation of flow damper
Clogged injector, defective spray

(limiting injection rate (output) because of an error in

(Large leakage from injector)

electrical system)

Improper valve clearance
q EGR valve is stuck open ["with EGR" only]
(There is much EGR gas and intake of air is insuffi-
cient)

Degree of use of
machine Operated for long period E E E E E E
Questions
Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation and Maintenance w w w
Manual
When priming pump is operated, it makes no reaction or it is heavy w Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some
Q w
cylinders is low
Blue under light load w
Exhaust smoke color
w Q w w
Check items
Black
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 w

Carry out troubleshooting according to Abnormality in EGR valve servo (*1) or "Abnormal-
q
ity in bypass valve servo (*1)" in E-mode ["with EGR" only]
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting according to No-pressure feed by supply pump (*2) 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
Adjust
Clean
Clean
Clean
Remedy
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-mode
12 170E-5 Series
S-4 Engine stops during operations 1
General causes why engine stops during operations Causes
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)
Problem in drive devices on applicable machine side

q Seized parts inside engine
Insufficient supply of fuel
Defective engine controller power supply wiring

q
q There is overheating

q Problem in drive devices on applicable machine side
Broken, seized piston, connecting rod

Carry out troubleshooting on applicable machine

Broken, seized crankshaft bearing
Broken supply pump shaft, key
Defective starting switch wiring

Leaking, clogged fuel piping
Broken, seized feed pump

Broken, seized gear train
Degree of use of machine Operated for long period E E
Abnormal noise was heard and engine stopped suddenly w w w w Q w Q w w
Condition when engine Engine overheated and stopped w Q Q

Questions
stopped Engine stopped slowly w Q Q Q Q

There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
w w
Manual
Fuel level monitor indicates low level (if monitor is installed) w
Metal particles are found when oil is drained w w w
Check items
Does not turn at all w w
When engine is cranked by Turns in opposite direction w

hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w
Inspect piston, connecting rod directly q
Inspect crankshaft bearing directly q
Inspect gear train directly q

Troubleshooting
Inspect feed pump directly q
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
Inspect controller power supply wiring q
Inspect starting switch wiring q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Remedy

Add
170E-5 Series 13
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Causes
Defective operation of flow damper (Large leakage from injector)

q Air in fuel system
q Defective speed sensor (Error at degree that it is not
indicated)
Defective operation of bypass valve ["with EGR" only]

Defective operation of EGR valve ["with EGR" only]
q Defective EGR valve ["with EGR" only]
Clogged injector, defective spray (dirt in injector)

q Defective bypass valve
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Low setting of low idle speed

Degree of use of machine Operated for long period E E E E
Occurs at a certain speed range Q Q Q Q Q
Questions
Occurs at low idle w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and Maintenance w w
Manual
Check
items
Rust and water are found when fuel tank is drained Q Q

Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in E-mode
q
["with EGR" only]
Carry out troubleshooting according to Abnormality in bypass valve servo (*2) in E-mode
q
["with EGR" only]
q
Troubleshooting
When air is bled from fuel system, air comes out

q q
change
Carry out troubleshooting according to Abnormality in engine Ne speed sensor (*3) in E-
q
mode
Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*4) in
q
E-mode
or replace
or replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
Clean
Add

*3: Code [689/CA689] in E-mode
*4: Code [778/CA778] in E-mode
14 170E-5 Series
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Causes
Defective fuel temperature sensor, wiring harness

Defective charge pressure sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Defective installation of charge pressure sensor

Defective drive of injector (signal, solenoid)

Improper selection of fuel

q
Air leakage from air intake piping

There is overheating:

q
Leaking, clogged fuel piping

See S-14 Coolant temperature becomes too

high (Overheating)
q Controller is controlling in derate mode
(limiting injection rate (output) because of an
(air leakage)
error in electrical system)
Degree of use of Operated for long period E E E E E

machine
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Replacement of filters has not been carried out according to Operation and Maintenance w
Manual
Oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w w
Exhaust smoke color
When exhaust manifold is touched immediately after starting engine, temperature of some w
cylinders is low

Check items
High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q

Troubleshooting
change
Inspect charge pressure sensor mount directly q
Carry out troubleshooting according to Abnormality in charge pressure sensor (*2) in E- q

mode
Carry out troubleshooting according to Abnormality in fuel temperature sensor (*3) in E- q

mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy

170E-5 Series 15
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head

Defective EGR valve or bypass valve ["with EGR" only]
Defective coolant temperature sensor, wiring harness


q Excessive injection of fuel
Clogged fuel spill piping (on cylinder head side)


q There is overheating:

See S-14 Coolant temperature becomes too high
Improper fuel injection pressure

(Overheating)
Crushed, clogged muffler

Controller is controlling in derate mode (limiting injec-
Abnormally worn injector
Improper injection timing

q
Clogged, seized injector

tion rate (output) because of an error in electrical
system)
q EGR valve is stuck open ["with EGR" only]
(There is much EGR gas and intake of air is insuffi-
cient)
Degree of use of
Operated for long period E E E E E
machine
Suddenly became black w Q Q Q
Questions
Exhaust smoke color Gradually became black w Q Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
cylinders is low w

Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

Carry out troubleshooting according to Abnormality in EGR valve servo (*1) or "Abnormal-
q
ity in bypass valve servo (*1)" in E-mode ["with EGR" only]
q q
Troubleshooting
When compression pressure is measured, it is found to be low

When muffler is removed, exhaust color improves q
Carry out troubleshooting according to No-pressure feed by supply pump (*2) in E-mode q q
q
change
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*3) in
q
E-mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
For *1, *2, and *3, see the next page.
16 170E-5 Series

170E-5 Series 17
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Causes
Turbocharger
Oil leakage from EGR valve or bypass valve ["with EGR" only]
q Abnormal consumption of oil
q Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously)
q External leakage of oil
Oil leakage from oil pan, cylinder head, etc.

q Wear of parts in lubrication system
Worn, damaged valve (stem, guide, seal)

Dust sucked in from intake system
Clogged breather, breather hose

Worn seal at turbocharger end
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
E E E E E
Questions
Operated for long period

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w
Exhaust smoke is blue under light load Q w w
Excessive Q Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Excessive play of turbocharger shaft q q
Troubleshooting
When EGR valve or bypass valve is removed, exhaust port is found to be

dirty with oil ["with EGR" only] q
Inspect breather and breather hose directly 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
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
18 170E-5 Series
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Causes
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine side
Entry of exhaust gas into oil due to internal wear
Worn EGR valve guide ["with EGR" only]

q
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather, breather hose

Use of improper oil

q
Defective oil filter safety valve

q Operation under excessive load
Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
E E E E
Questions
Degree of use of machine Operated for long period

Non-specified fuel is being used Q
Oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging w Q
Metal particles are found when oil filter is drained Q Q
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Exhaust smoke color

Black w
Excessive Q Q w
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is found to be dirty with oil ["with EGR" only] q
Troubleshooting
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
Replace
Clean
Clean
Remedy

170E-5 Series 19
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Causes
Defective coolant temperature sensor, wiring harness

q Leakage of fuel
q Defective condition of fuel injection (fuel pressure, injection condition)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of use of E E E
Questions

machine
More than for other machines of same model Q Q Q
Condition of fuel
consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
w w
ders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Exhaust smoke Black Q Q Q

color White Q
Remove and inspect head cover directly q

Troubleshooting
Inspect feed pump oil seal directly q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q q
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in E-mode q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

20 170E-5 Series
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
Damaged cylinder liner O-ring, hole caused by pitting
Broken hydraulic oil cooler or power train oil cooler

q Internal leakage in lubrication system
q Internal leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head, head gasket
Broken oil cooler core, O-ring

Cracks inside cylinder block
on applicable machine side

Degree of use of
E E
Questions
machine Operated for long period
Increase of oil Suddenly occurred Q Q Q

level Gradually occurred Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w
When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q

Inspect cylinder block, liner directly q q
Troubleshooting
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy

170E-5 Series 21
S-12 Oil pressure drops 1
General causes why oil pressure drops Causes
Leaking EGR hydraulic piping ["with EGR" only]

Leakage, clogging, wear or lubrication system
Defective oil pressure sensor, wiring harness

q
Leaking, crushed, clogged hydraulic piping

Defective EGR oil pump ["with EGR" only]
q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan
Defective oil pump relief valve

Clogged strainer in oil pan
Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E E
Questions
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
Oil pressure moni- Indicates pressure drop at low, high idle Q w w w Q Q Q

tor (if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop (if monitor is installed) w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q Q
Metal particles are found in oil filter q

Inspect oil pan strainer, pipe directly q q
Troubleshooting
Oil pump rotation is heavy, there is play in oil pump q

See S-13
Valve and spring of oil pump relief valve are fatigued, damaged q
Inspect oil filter directly q
Relief valve of EGR oil pump is damaged, oil leaks from it ["with EGR" only] q
Inspect EGR hydraulic piping directly ["with EGR" only] q
Carry out troubleshooting according to Abnormality in oil pressure sensor (*1) in E-
mode q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy

Add
22 170E-5 Series
S-13 Oil level rises (Entry of coolant or fuel) 1
General causes why oil level rises Causes
Defective seal of auxiliary equipment (pump, compressor)

Cracked EGR cooler (Entry of coolant) ["with EGR" only]
q Coolant in oil (milky)

Fuel in oil (smells diluted diesel fuel)
Clogged or defective seal of water pump drain hole

q
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in

coolant

Fuel leakage inside head cover
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

(breather hole)
Questions
Degree of use of Operated for long period E E E E

machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q Q
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bub-
w Q
bles appears, or coolant spurts back
Check items
Exhaust smoke is white Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, water is found w
Oil level in clutch or damper chamber of machine is low w
Oil level in hydraulic tank of machine is low w
When EGR cooler inlet gas piping is removed, coolant containing antifreeze flows out (*1). q
["with EGR" only]
Troubleshooting
Remove and inspect head cover directly q

Inspect cylinder block, liner directly q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
For *1, see the next page.
170E-5 Series 23

24 170E-5 Series
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too Causes

high
External leakage of coolant from EGR cooler ["with EGR" only]

q Lack of cooling air (deformation, damage of fan)

q Drop in heat dissipation efficiency
q Problem in coolant circulation system
q Rise in oil temperature in power train
Defective radiator cap (pressure valve)
Rise in power train oil temperature on

Defective coolant temperature gauge
Defective operation of thermostat
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
Clogged, broken oil cooler
applicable machine side

Clogged radiator core
Broken water pump
Lack of coolant
Degree of use of
Operated for long period E E E E E
machine
Questions
Condition of over- Suddenly overheated Q Q w Q

heating Always tends to overheat Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or
w w
mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant temperature (if oil
w
temperature gauge and coolant temperature gauge are installed)
Inspect EGR cooler for coolant leakage ["with EGR" only] q

Inspect cylinder liner directly q
Inspect oil cooler directly q

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is carried out, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy

Add
170E-5 Series 25
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Causes
Deformed cooling fan, loose fan belt, interference of fan belt

Defective inside of muffler (dividing board out of position)
q Abnormality due to defective parts
Leakage of air between turbocharger and cylinder head

q Abnormal combustion
Cracked, leaking EGR gas piping ["with EGR" only]

Broken dynamic valve system (valve, rocker lever)
Interference of turbocharger, seized turbocharger
q Air sucked in from intake system
(abnormality in coolant temperature sensor)

Excessive wear of piston ring, cylinder liner
a Judge if the noise is an internal noise or an external
noise before starting troubleshooting.
Removed, seized gear train bushing

a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Improper fuel injection timing

Improper gear train backlash
engine sound becomes a little larger. This does not
Clogged, seized injector

indicate abnormality, however.
Dirt caught in injector

a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little
larger for up to about 5 seconds. This does not indi-
cate abnormality, however.

Degree of use of
Operated for long period E
machine
Questions
Gradually occurred Q Q Q
Abnormal noise
Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained Q w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping
w
["with EGR" only]
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
w Q
cylinders is low
Exhaust smoke Blue under light load w

color Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q

Inspect EGR gas piping directly ["with EGR" only] q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
change
Abnormal noise is heard only when engine is started q
Confirm with INSITE or with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
26 170E-5 Series
S-16 Vibration is excessive 1
General causes why vibration is excessive Causes
Misalignment between engine and devices on applicable machine side

q Defective parts (abnormal wear, breakage)
Misalignment between engine and chassis
Broken output shaft, parts in damper on applicable machine side

q
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry

out troubleshooting for S-15 Abnormal noise is made, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
Worn front support spigot joint portion

Improper gear train backlash
Worn camshaft bushing
Degree of use of
E E E E
Questions

machine
Condition of vibra- Suddenly increased Q Q

tion Gradually increased Q Q Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
170E-5 Series 27
S-17 Air cannot be bled from fuel circuit 1

(After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but
stalls.)
General causes why air cannot be bled Cause
q Electric priming pump does not operate.
Defective wiring harness of electric priming pump

Fuel is not supplied or is supplied very little.
Improper setting of air bleeding valve (Closed)

q
Fuel valve or air bleeding valve is not set properly.
Malfunction of electric priming pump switch

q
Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.
Improper setting of fuel valve (Closed)

Fuel return piping is clogged.
Malfunction of electric priming pump

q
Clogged fuel tank cap breather hole
Clogged water separator screen

Clogged air bleeding piping
Low battery charge level

Clogged fuel filter
Low fuel level
Questions
Degree of use of Operated for long period E E

machine
Fuel tank is empty w
Fuel tank cap breather hole is clogged w
Check items
Switch lamp does not blink w w Q

When electric priming Lamp blinks but pump operation sound is not heard w w
pump switch is operated
Pump operation sound is heard but fuel does not flow out
Q Q Q Q w w w Q Q
of hose soon
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming system directly (See Note 2) q q
Check water separator screen directly q
Check fuel filter for clogging (See failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Charge
Clean
Add
Remedy
28 170E-5 Series
Note 1: Check of air bleeding piping for clogging (The figure is an example of WA600-6)
q Remove joint bolt (1) and blow clean compressed air into hole (b) of the orifice to check for clogging.
q Remove air bleeding pipings (2), (3) and blow compressed air against its both ends to check for clog-
ging.
170E-5 Series 29
Note 2: Electric priming pump does not operate or does not stop automatically
a The connector names, connector Nos. and configuration circuit diagrams shown here are examples for
explanation.
Contents of
Electric priming pump does not operate or does not stop automatically
trouble
Related
information

1 Low battery charge level Battery charge level may be low. Check battery directly.
Defective circuit breaker If circuit breaker CBF4 is turned OFF, circuit probably has ground
2
CBF4 fault. (Check cause No. 5)
Disconnection in wiring har- a Prepare with battery ground cable disconnected, then connect it
ness (Power supply system) and carry out troubleshooting (since power supply is unswitched).
3
(Disconnection in wiring or
defective contact in connector) Between EP3 (1) (2) Voltage 20 30 V
a Prepare with battery ground cable disconnected, then connect

battery and turn electric priming pump ON and carry out trouble-
shooting.
Disconnection in wiring
harness (Drive power supply Lamp blinks but stops in about 5 seconds.
system) Between EP2 (1) (2) Voltage 20 30 V
4
(Disconnection in wiring or a Prepare with battery ground cable disconnected, then carry out
defective contact in troubleshooting without reconnecting (since power supply is
connector) unswitched).
Between EP3 (female) (2) and chassis Resis-
Max. 1 z
ground tance
a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible
unswitched).
causes and
standard value Wiring harness between EP3 (female) (1)
Resis-
in normal state circuit breaker CBF4 (R15) and chassis Min. 1 Mz
tance
Ground fault in wiring harness ground
5
(Contact with GND circuit) Wiring harness between EP3 (female) (3) Resis-
Min. 1 Mz
EP2 (female) (1) and chassis ground tance
Wiring harness between EP3 (female) (4) Resis-
Min. 1 Mz
EP2 (female) (2) and chassis ground tance
Between EP2 (female) (1) (2) and chassis Resis-
13z
ground tance
a Prepare with battery ground cable disconnected, then connect
battery and turn electric priming pump ON and carry out trouble-
shooting.
Defective electric priming Between EP3 (3) (4) Voltage 20 30 V
pump switch Lamp blinks but output voltage is improper.
6
(Malfunction or automatic stop Results of troubleshooting steps 1 4 are normal and lamp does
failure) not blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective.
(Turn toggle switch OFF to stop pump and then replace switch.)
Lamp blinks but stops in about 5 seconds.
Overload on electric priming
7 a If pump is overloaded, power supply is turned OFF automatically
pump
to protect circuit (Priming switch is reset automatically).
30 170E-5 Series

a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible unswitched).
causes and Resis-
Between EP2 (male) (1) (2) 13z
standard value 8 Trouble in electric priming tance
in normal state pump
Resis-
Between EP2 (male) (1) pump body Min. 1 Mz
tance
Resis-
Between EP2 (male) (2) pump body Min. 1 Mz
tance
Circuit diagram related to electric priming pump (Example)
170E-5 Series 31
SEN00370-01
2007 KOMATSU
All Rights Reserved
32
SEN00765-01
ENGINE 1SHOP MANUAL
170E-5 Series
50 Disassembly and assembly1

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 3
Special tools list.................................................................................................................................... 6
Sketches of special tools...................................................................................................................... 8
170E-5 Series 1
SEN00765-01 50 Disassembly and assembly
General information on disassembly and assembly 1

How to read this manual 1
Disassembly
q In Disassembly section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q The meanings of the symbols used in Disas-
sembly section are as follows.
k Precautions related to safety in execution
of work
a : Know-how or precautions for work
6 : Quantity of oil or coolant drained
4 : Weight of part or component
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
5 : Quantity of oil or coolant to be added

4 : Weight of part or component
2 170E-5 Series
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number 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-
Gasket sealant
tant 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.
Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
Used to seal transfer case, etc.
170E-5 Series 3
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
Can be coated with paint.
Gasket sealant
LG-10 Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E Can be coated with paint.
LG-11 Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube Gasket sealant used to repair engine.
1211
Molybdenum
Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
Used to lubricate linkages, bearings, etc.
Feature: Seizure and scuffing prevention com-

compound
prevention
pound with metallic super-fine-grain, etc.

Seizure
LC-G
Can Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
4 170E-5 Series
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR S is used for high-temperature season
PENGUINE and W for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER S or (Using limit: 4 months after date of manu-
W facture)
Adhesive
Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
170E-5 Series 5
Special tools list 1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they must be locally manufactured).
a Necessity : t ........ Cannot be substituted, should always be installed (used)
: q ........ Extremely useful if available, can be substituted with commercially available part
a New/Remodel : N......... Tools newly developed for this model and given new part Nos.
: R......... Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank .. Tools already available for other models, usable without any modification
a Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Work item Part No. Part name Remarks
Removal and installation of 795-799-5410 Adapter t 1

A
injector assembly 795-799-5420 Remover t 1
795-102-2102 Spring pusher t 1
795-102-2110 Handle 1
795-102-2120 Bracket 1
Removal and installation of 795-102-4210 Bracket 1
B
valve spring on cylinder head 01016-50830 Bolt 1
01580-10806 Nut 1
01144-31270 Stud 1
01580-11210 Nut 1
795-621-1110 Bracket t 2
Lifting of engine assembly C 790-103-1520 Shackle t 2
01016-31090 Bolt t 4
Disassembly and assembly of 1 790-501-2001 Engine repair stand t 1
D
engine assembly 2 790-901-1180 Bracket t 1
Removal and installation of
F 795-100-1191 Piston ring tool t 1
piston ring
Pulling out of cylinder liner G 795-102-1301 Liner puller t 1
795-225-1512 Liner driver t 1
Press fitting of cylinder liner H 795-101-5221 Grip t 1
01010-81250 Bolt t 1
Insertion of piston assembly J 795-921-1100 Piston holder t 1
1 795-931-1100 Seal puller assembly t 1
2 795T-621-1180 Push tool t 1 N Q Press-fitting of oil seal
Press fitting of front oil seal
K 795T-621-1171 Push tool t 1 R Q Press-fitting of dust seal
and dust seal
3 795-902-1460 Bolt t 3
01582-02218 Nut t 3
1 795-931-1100 Seal puller assembly t 1
795T-621-1161 Push tool t 1 R Q Press-fitting of standard
2
01050-32235 Bolt t 5 seal and sleeved seal
Press fitting of rear oil seal L
795T-621-1190 Push tool t 1 N Q Press-fitting of sleeved seal
3 (For 1st stage of 2-stage
01050-32245 Bolt t 5 press fitting)
6 170E-5 Series
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Work item Part No. Part name Remarks
Commercially IN: 0.32 mm

Adjusting valve clearance M Clearance gauge q 1
available EX: 0.62 mm
N 79A-212-4201 Socket kit t 1 For 12-angle bolt
bolt
Measurement of wear of piston
P 795-901-1120 Wear gauge t 1 For measurement of parts
ring groove
Press fitting of valve stem seal Q 795-611-1170 Driver t 1
S 795T-675-1110 Socket q 1 N Q
high pressure piping
170E-5 Series 7
Sketches of special tools 1

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
K2 Push tool (For oil seal)
K3 Push tool (For dust seal)
8 170E-5 Series
L2 Push tool
L3 Push tool
170E-5 Series 9
S Socket
10 170E-5 Series
170E-5 Series 11
SEN00765-01
2007 KOMATSU
All Rights Reserved
12
SEN00766-01
ENGINE 1SHOP MANUAL

2SHOP
170E-5 Series

Disassembly and assembly, Part 1
(With EGR)
Disassembly and assembly, Part 1 (With EGR).............................................................................................. 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 22
170E-5 Series 1
Disassembly and assembly, Part 1 (With EGR) 1

General disassembly of engine 1
a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
Take care.
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
4. Starting motor assembly

Remove wiring harness (1) and then remove
starting motor assembly (2).
2) Drain the engine coolant and engine oil.

a The quantity of the oil depends on the
applicable machines.
6 Engine oil: Approx. 80 l
3. Engine wiring harness

Disconnect the connector and terminal to
remove engine wiring harness (1) from the
engine assembly.
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
6. Turbocharger assembly
1) Remove 2 water pipes (1) and 2 oil pipes
2) Remove bracket (3).
(2).
3) Remove clamp (4) and then remove EGR

2) Lift turbocharger assembly (3) temporarily
tube (5).
and then remove the mounting bolt.
4) Remove clamp (6), 2 tubes (7) and then
3) Lift and remove turbocharger assembly
remove EGR tube (8).
(3).
4 Turbocharger assembly: 55 kg
8. Exhaust manifold assembly

1) Lift exhaust manifold assembly (1) tempo-
7. EGR tube
rarily and then remove the mounting bolt.
1) Remove clamps (1) and then remove bot-
2) Lift and remove exhaust manifold assem-
tom bypass tube (2).
bly (1).
a The bypass valve is not installed on
4 Exhaust manifold assembly: 40 kg
some applicable machines.
170E-5 Series 3
11. Auxiliary equipment belt

1) Tighten adjustment bolt (1) and then
release tension of tensioner (2) from auxil-
iary equipment belt (3).
2) Remove auxiliary equipment belt (3).
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).
10. EGR valve

1) Remove oil tubes (1) to (4).
2) Remove EGR valve (5) and then bypass 13. Alternator
valve (6). 1) Remove oil filter (1) on the front side.
a The bypass valve is not installed on a This work must be done to make a
some applicable machines. space for removing the alternator
mounting bolts.
2) Remove alternator (2).
3) Temporarily install oil filter (1), if necessary.
4 170E-5 Series
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 Use a bolt M10 x 1.5 with a stem 90
mm long as stopper bolt [1].
a Maintain the stopper bolt [1] in this
position before installing tensioner (3)
again.
4) Remove tensioner (3).
5) Remove air conditioner compressor
bracket (4).
17. Pre-fuel filter and filter head assembly

1) Remove fuel tubes (1) and (2) from the fil-
ter head.
2) Remove pre-fuel filter and filter head
assembly (3).
15. Main fuel filter and filter head assembly

1) Remove fuel tubes (1) and (2) from the fil-
ter head.
2) Remove clamp (3) and then remove main
fuel filter and filter head assembly (4).
18. Fuel tube

1) Remove cover (1).
2) Remove the clamp and then remove fuel
tubes (2) to (6).
170E-5 Series 5
19. Breather, cover and wiring harness a If tool S is not available, disconnect
1) Remove breather and hose assembly (1). the sleeves on the injector side from
2) Remove all covers (2) on the engine top above.
face.
3) Remove wiring harness and plate assem-
bly (3).
q Tool S
20. High-pressure piping

1) Remove rubber caps from high-pressure
pipings (1) and (2).
2) Before removing the high-pressure piping,
blow compressed air against the pipe joint
sufficiently to prevent foreign matter from
entering the system.
3) Remove high-pressure pipings (1) and (2)
provided between the supply pump and
common rail.
21. Corrosion resistor and filter head assembly

1) Remove water tube (1) from the filter
bracket.
2) Remove corrosion resistor and filter head
assembly (2).
4) Remove rubber caps from high-pressure

pipings (3) to (8).
5) Remove clamp from the high-pressure
pipings.
a Before removing them, paint a mark-
ing of the installation position.
6) Remove high-pressure pipings (3) to (8).
a Before removing the high-pressure
pipes, blow air against the pipe joints
thoroughly to prevent foreign matter
from entering the pipes.
a Loosen the sleeves on the injector
side with tool S.
6 170E-5 Series
22. Air intake connector 4) Separate the gasket sealant and then
Remove air intake connector (1). remove cover (7).
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.
3) Remove fuel tubes (3) and (4) and oil

tubes (5) and (6) from the supply pump.
2] In the position shown in the figure,

lead positioning bar [1] through the
flange and housing of supply pump
drive gear (9) and supply pump drive
case.
a The positioning bar used shall be
11 mm in diameter and 180 mm
in length at minimum.
170E-5 Series 7
3] Remove supply pump drive gear (9). 8) Remove supply pump drive case (12).
a The figure shows, for your refer- 24. Common rail

ence, the state after removing 1) Remove fuel tube (1) and peripheral parts.
the supply pump drive gear. 2) Remove common rail (2).
6) Remove bracket (10). 25. Intake manifold assembly

7) Remove drive supply pump assembly 1) Remove bracket (1), spill tube (2) and
(11). peripheral parts.
8 170E-5 Series
2) Lift intake manifold assembly (3) tempo- 27. Thermostat housing and thermostat
rarily and then remove the mounting bolt. 1) Remove thermostat housing (1).
3) Lift and remove intake manifold assembly
(3).
4 Air intake manifold assembly:
110 kg
2) Remove thermostats (2) from thermostat

housing (1).
26. Water pump assembly

1) Remove water pipe (1).
28. Front hanger and water housing

1) Remove bracket (1) and water tube (2).
2) Remove stopper (2) and then slide bypass

tube (3) upward.
3) Remove water pump assembly (4).
170E-5 Series 9
2) Lift up front hanger (3) temporarily and 2) Remove plate (4) and then push injector
then remove the mounting bolts. harness (6) inside the engine along with
3) Lift and remove front hanger (3) along with grommet (5).
water housing (4). 3) Remove injector harness (6) from inside of
4 Front hanger: 65 kg the engine.
29. Cylinder head cover 31. Rocker arm assembly

Remove cover (1) and then remove cylinder 1) Loosen locknuts (1) and then loosen
head covers (2). adjustment screws (2) to the maximum.
a Make sure that the rocker arm is free
in its move without being applied with
the valve tension.
2) Remove rocker arm assembly (3).
a Using a tag or the like, record the
parts installation positions so that
they may be stored without being
mixed up.
30. Injector harness

1) Remove terminal mounting nut (1), har-
ness fixing bolts (2) and spacer (3).
a Loosen the 2 terminal nuts alter-
nately.
10 170E-5 Series
3) Remove exhaust rocker arm (4) and air 34. Crosshead

intake rocker arm (5) from shaft (6). Remove crossheads (1).
32. Push rod 35. Fuel injector assembly

Remove push rods (1). 1) Remove injector holder (1).
33. Rocker housing 2) Using tool A, remove fuel injector assem-

Remove rocker housing (1). bly (2).
a Hitch the tip of tool A to hole (a) on
the injector and then pull it out.
a Do not grip the solenoid valve at the
top of the injector to pull off the injec-
tor.
170E-5 Series 11
36. Cylinder head assembly 2] Remove spring seat (3).

1) Remove the coolant air bleeding pipe. 3] Remove valve spring (4).
2) Lift and remove cylinder head assembly
(1).
4 Cylinder head assembly: 50 kg
a If the cylinder head assembly is
removed with the injector assembly
being installed on it, the injector
assembly might project through the
bottom of the cylinder head assembly.
Thus, it is required to prevent interfer-
ence between the injector assembly
and floor with blocks or equivalent.
4] Remove valve stem seal (5).
3) Remove the cylinder head gasket.

4) Disassemble the cylinder head assembly
1] Using tool B, compress the valve
spring and then remove valve cotter 5] Remove intake valve (6) and exhaust
(2). valve (7) from cylinder head (8).
a Check the installed positions of
the valve and related parts and
keep them so that they will not be
mixed up.
12 170E-5 Series
37. Oil cooler assembly 40. Oil pan

Remove oil cooler assembly (1). 1) Support the front and rear side of oil pan
(1) with blocks [1].
2) Remove all oil pan mounting bolts (2).
3) Separate the gasket sealant.
38. Oil level gauge, oil filler pipe, fuel feed

pump and engine controller
1) Remove oil level gauge (1).
2) Remove oil filler pipe (2). 4) Using tools C, lift the engine and then
3) Remove fuel tube (3) and then remove remove oil pan (1).
fuel feed pump (4). 4 Oil pan: 85 kg
4) Remove engine controller (5), cooling

plate (6) and bracket (7).
5) Remove block (8).
5) Securely support the engine again using

blocks [1].
a See "Setting engine assembly" in
Item 2 above.
39. Drive housing assembly
Remove drive housing assembly (1).
170E-5 Series 13
41. Suction pipe and under plate 2) Remove cam follower assembly (2).
1) Install under plate (1) temporarily with sev- a Rotate the crankshaft using a barring
eral oil pan mounting bolts. device to move the piston to the posi-
2) Remove brackets (2) and (3) and then tion indicated below and remove it.
remove suction pipe (4). q No. 1 compression top dead center:
3) Separate the gasket sealant. Allows removal of No. 1 and No. 5.
4) Remove the temporarily attached mount-
ing bolts and then remove plate (1) using q No. 2 compression top dead center:
a jack. Allows removal of No. 2 and No. 4.
4 Under plate: 30 kg
q No. 3 compression top dead center:
Allows removal of No. 3 and No. 6.
a An unremovable cam follower assem-
bly indicates it is not situated at the
compression top dead center. In this
case, rotate the crankshaft one more
turn.
42. Cam follower assembly

1) Remove cam follower cover (1).
a The cam follower cover is made of
cast iron or aluminum and its installed
position is subject to its material.
Accordingly, when removing it, check
its material and position.
(The installed position is subject to 3) Disassemble the cam follower in the fol-
the applicable machine.) lowing procedure.
1] Remove snap ring (3).
2] Remove cam follower (4) from shaft
(5).
3] Remove snap ring (6) from shaft (5).
14 170E-5 Series
43. Cam cover 46. Front cover

Remove bracket (1) and cam cover (2). 1) Lift up front cover (1) temporarily and then
remove the mounting bolts.
2) Lift and remove front cover (1).
4 Front cover: 50 kg
44. Vibration damper

1) Lift vibration damper (1) temporarily and
then remove the mounting bolts.
2) Lift and remove vibration damper (1). 3) Remove dust seal (2) and oil seal (3) from
4 Vibration damper: 45 kg the front cover.
a Dust seal is provided only on the
vehicle-mounted engines alone.
45. EGR oil pump

Remove EGR oil pump (1).
47. Front idler gear assembly
1) Remove idler gear (larger one) (1).
2) Remove idler gear (smaller one) (2).
170E-5 Series 15
3) Remove spacer (3) and shaft (4) from idler 50. Flywheel assembly
gears (large and small gears). 1) Lift flywheel assembly (1) temporarily and
a The same structure is employed for then remove the mounting bolt.
both the large and small gears. 2) Lift and remove flywheel assembly (1).
4 Flywheel assembly: 40 85 kg
a The weight varies largely with the
48. Oil pump assembly

Remove oil pump assembly (1).
51. Flywheel housing
1) Remove Ne speed sensor (1) and barring
device (2).
49. Engine mount

1) Remove the front engine mount.
2) Remove rear engine mount (1).
4 Rear engine mount: 30 kg
a The weight varies with the applicable 2) Lift flywheel housing (3) temporarily and
machines. then remove the mounting bolts.
3) Lift and remove flywheel assembly (3).
4 Flywheel housing: 150 180 kg
16 170E-5 Series
4) Remove rear oil seal (4) from the flywheel 53. Rear idler gear assembly
housing. 1) Remove rear idler gear assembly (1).
52. Camshaft assembly 2) Disassemble the idler gear in the following

1) Along with the camshaft gear, lift and procedure.
remove camshaft assembly (1) to the 1] Remove spacer (2) from shaft (3).
engine rear side.
a When pulling it out, lift the gear side
temporarily and then remove it align-
ing the shaft center of the camshaft
and bushing.
a Adjust the camshaft lifting position
again as approximately 2/3 of its body
is pulled out and then pull it out com-
pletely.
a Rotate it fitly during above operation
in order to avoid interference with the
bushing.
4 Camshaft: 55 kg
2] Separate gear (larger one) (4) from

another (smaller one) (5).
170E-5 Series 17
54. Installation to engine repair stand 56. Piston and connecting rod assembly
Using tools C, lift engine assembly (1) being 1) Move the piston of the cylinder to be
attached with tool D2 and then attach tool D1 removed to the bottom dead center posi-
to the assembly. tion by rotating the crankshaft.
4
2) Loosen the connecting rod bolt by 5 to 6
Engine assembly: Approx. 1,600 kg
turns.
a Lightly strike the connecting rod head
with a plastic hammer to separate the
connecting rod cap from the connect-
ing rod.
3) Move the piston to the top dead center
position by rotating the crankshaft.
4) Remove connecting rod cap (1).

1) Raise the cylinder block to make the cylin-
der level.
2) Rotate the crankshaft to set No. 1 to No. 3
pistons to the following positions.
Allows removal of No. 1 and No. 6
pistons.
5) Remove connecting rod bearing (2) from
connecting rod cap (1).
a Maintain them on the cylinder No.
pistons.
basis using a tag or the like.
pistons.
3) Sequentially remove 6 each of cooling
nozzles (1) and (2).
6) Push the connecting rod from the crank-

shaft side to remove the piston and con-
nection rod assembly (3).
a When removing the piston and con-
necting rod assembly, support the
assembly at the cylinder side so that
it may not fall off. Then push the con-
necting rod end portion to remove the
assembly.
18 170E-5 Series
a Pull the assembly horizontally so that 3] Remove piston pin (6).

the connecting rod may not damage 4] Remove connecting rod (7).
the cylinder liner. a The connecting rod and cap are
a Maintain them on the cylinder No. a set of parts. Thus they must be
basis using a tag or the like. assembled together temporarily
after the disassembly so that
they may not be slit from each
other.
7) Disassemble the piston and connecting

rod assembly according to the following
procedure.
1] Remove connecting rod bearing (4). 5] Using tool F, remove top ring (8) and
second ring (9).
2] Remove 2 snap rings (5).

6] Remove oil ring (10) from piston (11).
170E-5 Series 19
57. Crankshaft assembly

1) Set the crankshaft side up.
2) Remove the main cap mounting bolt.
3) For removal, sway main cap (1) back and
forth using the mounting bolt.
a Thrust washers are provided for No. 6
main cap. Thus reasonable care must
be exercised to prevent their falling
off.
6) Remove main bearing metal (5) and 2

thrust washers (6).
a Thrust washers are provided on No.6
alone.
a Maintain them on the bearing No.

thrust washers (3) from main cap (1).
a Thrust washers are provided on No. 6
main cap alone.
a Maintain them on the main cap No.
58. Cylinder liner

1) Set the cylinder head side up.
2) Using tool G, remove cylinder liner (1).
5) Lift and remove crankshaft assembly (4).

a Thrust washers are provided for No. 6
bearing. Thus reasonable care must
off.
4 Crankshaft assembly: 270 kg
20 170E-5 Series
59. Cylinder block

Using tools C, lift and remove cylinder
block (1) from tool D1.
4 Cylinder block assembly: 800 kg
170E-5 Series 21
General assembly of engine 1 2] Polish parts (c) and (d) using No. 240
or so sand paper until a smooth
a The shapes, quantity, locations, etc. of the Rounded surface results.
parts depend on each applicable machine. a If rounded part is sharp or has
Take care. burrs, finish it with a scraper or
a Clean each part carefully, and check it for sandpaper. Finish this surface
bruise, flaw, cavity, etc. Make sure each oil or particularly smoothly so that it will
coolant path is through. not damage the O-ring.
a If face (a) and part (c) are pitted,
Tightening bolts by plastic-region turning angle finish them smoothly.
method a If part (d) is so pitted that it can-
a Bolts tightened by plastic-region turning angle not be repaired, replace the cyl-
method inder block.
q Cylinder head mounting bolt 3] Check face (e) of the counterbored
q Main cap mounting bolt part and remove burrs.
q Connecting rod cap mounting bolt a If chips or dusts is on a level sur-
q Flywheel mounting bolt face, the liner does not fit and
q Idler gear (rear side) mounting bolt coolant may leak and the projec-
a If the plastic-region turning angle method is tion of the liner may become
applied, the tightened bolts have permanent improper consequently.
strain. Accordingly, the allowable number of a Drooping, corrosion or pitting
using times of each bolt is limited.Observe the must be repaired, if any.
fol low ing pr ec auti ons b efor e usi ng thi s
approach.
q Check each mounting bolt head for punch
marks. If there are punch marks more
than the specified numbers, replace the
bolt.
a For details, refer to respective relevant sec-
tions in this document.
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.
22 170E-5 Series
a When installing O-rings (2) and (3),

refer to the following.
q O-ring (2): Black
q O-ring (3): Red
2 Clevis seal and O-ring:
Rubber lubricant (RF-1)
a RF-1: DAIDO CHEMICAL INDUSTRY
CO., LTD.
When RF-1 is not available, apply
clean engine oil SAE No. 30.
a Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
4) Apply gasket sealant to the parts of the

cylinder block and cylinder liner which will
fit to the counterboared parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counter-
boared parts of the cylinder block and
liner flange.
2 Cylinder block:
Gasket sealant (LG-6)
q Gasket sealant: 2 3 mm in diame-
ter
q Overlap (a) of gasket sealant:
6 6 mm
a If the applied gasket sealant is left for
a long time, its surface becomes
hard. Accordingly, install the cylinder
block to the cylinder head within 50
minutes.
3) After fitting the liner O-ring, check it for

twist. If it is twisted, correct it with a
smooth rod (about 10 mm in diameter).
5) Insert cylinder liner (1) in the cylinder

block slowly, taking care not to damage
the O-ring.
6) Push in cylinder liner (1) further by both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be dam-
aged. In this case, stop the work and
check the cylinder block for burrs.
170E-5 Series 23
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.
8) Install the head gasket and then tempo-

rarily assemble cylinder head assembly
(5).
a The head gasket used may be a sec-
ondhand article.
a The cylinder head may be an inde-
pendent product or already assem-
bled with the head gasket.
a 7 main mounting bolts shall be used
for the tightening. Tighten them in the
following order.
3 Cylinder head bolt:
245 265 Nm {25 27 kgm}
3. Setting to engine repair stand
1) Install tools D2 and C to cylinder block (1).
24 170E-5 Series
2) Lift cylinder block (1) and install it to tool

D1.
4 Cylinder block: 850 kg
5) Install main bearing metal (2) to main cap

(1).
a When installing, fit in the projection on
4. Crankshaft assembly the bearing metal to the notch on the
1) Invert the cylinder block to set the oil pan main cap.
side to the upper. 2 Main bearing metal inner surface:
2) Install 7 main bearing metals (5) to the cyl- Engine oil (EO30)
inder block. 6) Install 2 thrust washers (3).
a Note that the upper main bearing a Thrust washer is provided only on
metal is not identical with the lower both sides of No. 6 main cap.
main bearing metal. An oil hole is
drilled on the upper bearing. Check it
before installation.
the bearing metal to the notch on the
cylinder block.
2 Main bearing metal inner surface:
Engine oil (EO30)
3) Install 2 thrust washers (6).
a Thrust washer is provided only on
both sides of No. 6 bearing.
7) Install main cap (1).

a When installing the main cap, align
the bearing number and then set the
stamped (F) face toward the front
side of the engine.
a Check the punch mark on the mount-
ing bolt head. If 5 marks are punched,
replace it with a new one without
using it.
2 Threaded portion and seat of main
cap mounting bolt: Engine oil (EO30)
4) Lift crankshaft assembly (4) and assemble 3 Main cap mounting bolt:
it to the mounting position. 1st time: 284 15 Nm {29 1.5 kgm}
4 Crankshaft assembly: 270 kg 2nd time: 568 10 Nm {58 1.0 kgm}
a When installing the crankshaft, take 3rd time: 90 (+30/0) retightening
care not to hit it against the cylinder
block.
170E-5 Series 25
a After tightening the bolt, apply a

punch mark (a) on its head (this mark
shall not be applied to a new bolt).
5. Piston and connecting rod assembly

1) Assemble the piston and connecting rod
assembly according to the following pro-
cedure.
1] Install oil ring (10) to piston (11).
a Connect both ends of the expander
and then place it in the ring inner
groove.
2] Using tool F, install second ring (9)

and top ring (8).
a When installing the piston ring,
set the letter-stamped side up.
8) Measure the end play of the crankshaft

using dial gauge [1].
a Standard end play: 0.14 0.32 mm
a When the end play is out of the stan-
t ur e , fu n ct i on a n d ma i nt en an c e
standard.
26 170E-5 Series
3] Set the abutment joint of each piston

ring to the position shown in the fol-
lowing figure.
6] Install connecting rod metal (4).

a When installing, fit in the projec-
tion on the bearing metal to the
4] Set connecting rod (7) on the piston
notch on the connecting rod.
and then insert piston pin (6).
a When using a new connecting
rod, apply a marking cylinder
number to both the connecting
rod and cap using an electric
pen.
a When installing the connecting
rod, set the cast letters EX on the
side face of the piston and the
cast letters Part No. on the con-
necting rod side face in the same
direction.
2) Set the cylinder block upper face to the

lateral direction.
3) Move the pin journal of the cylinder to the
top dead center position by rotating the
crankshaft.
4) Using tool J, insert piston and connecting
rod assembly (3) to the cylinder.
2 Piston ring: Engine oil (EO30)
a Insert the piston directing the cast let-
ters EX to the front side of the engine.
5] Install 2 snap rings (5).

a Make sure the rings are securely
placed in the ring groove.
170E-5 Series 27
5) Install connecting rod bearing metal (2) to

connecting rod cap.
6) Install connecting rod cap (1).

a Set the cylinder number mark on the
connecting rod cap and the connect-
ing rod in the same direction when
installing them.
using it. 7) Measure side clearance of the connecting
2 Connecting rod mounting bolt and rod using dial gauge [1].
washer: Engine oil (EO30) a Standard side clearance:
3 Connecting rod cap mounting bolt: 0.200 0.374 mm
1st time: 196 10 Nm {20 1 kgm} a When the side clearance is out of the
2nd time: 90 (+15/0) retightening standard, determine the cause by dis-
a After tightening the bolt, apply a assembling it again.

1) Rotate the crankshaft to set No. 1 No. 3
q No. 1 top dead center position:
Piston cooling nozzles of the No. 1
and No. 6 pistons can be installed.
28 170E-5 Series
q No.2 top dead center position:

2) Install 6 each of piston cooling nozzles (1)
and (2) in order.
a Install the piston cooling nozzles hav-
ing the stamps of (F) to the front side
of the cylinder and install those hav-
ing the stamps of (R1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the 2) Raise and invert the engine to set the oil
mounting bolt. pan side to the bottom.
3 Piston cooling nozzle mounting bolt: 3) Install rear idler gear assembly (1).
27.4 34.3 Nm {2.8 3.5 kgm} a When installing the rear idler gear
assembly, direct the stamped letters
in front side of the shaft to the top
side (cylinder head side).
7. Rear idler gear assembly

1) Assemble the rear idler gear assembly
1] Install gear (larger one) (4) to another
(smaller one) (5). a When installing, match (A) mark on
3 Idler gear mounting bolt: the crankshaft gear to (A) mark on the
98 123 Nm {10.0 12.5 kgm} idler gear (larger one).
2] Install shaft (3) and spacer (2).

a When installing the spacer, direct a (B) mark is used in the succeeding
its V-grooved face (a) to cylinder processes.
block side.
170E-5 Series 29

using it.
2 Threaded portion and seat of mount-
ing bolt: Engine oil (EO30)
3 Rear idler gear mounting bolt:
1st time: 56.8 11.8 Nm {5.8 1.2 kgm}
2nd time: 90 120 retightening
2) Measure end play of the camshaft using

dial gauge [1].
t ur e , fu nc t io n a nd ma i nt en an c e
standard.
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: 55 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.
30 170E-5 Series
a Standard backlash: 11. Front idler gear assembly

1) Install shaft (4) and spacer (3) to gears (2)
Measuring
Backlash (mm) and (1).
position
a Insert the shaft to a side of the gear
a 0.155 0.412 bearing on which the projection is
b 0.145 0.380 smaller than the other side.
a When installing the spacer, direct its
a When the backlash is out of the standard, chamfered portion of the bore to the
correct it referencing Structure, function gear.
and maintenance standard. a The same structure is employed for
both the large and small gears.
2) Install idler gear (smaller one) (2) and idler

gear (larger one) (1).
3 Idler gear mounting bolt:
245 309 Nm {25.0 31.5 kgm}

Fit the square ring and then install oil pump
assembly (1).
a For adhesion of the square ring and
pump, Hi-Tack 98D from Loctite or equiva-
lent adhesive should be used.
170E-5 Series 31
12. Measurement of gear backlash (Front) 13. Front cover

Measure backlash of the front idler gear and 1) Fit the gasket and then lift and install front
other gears using dial gauge [1]. covers (1).
a When measuring the backlash, set the dial a Make sure that displacement or
gauge in the tooth end position of the tar- pinching is not observed on the gas-
get gear of measurement and then fix the ket.
counterpart gear. 4 Front cover: 50 kg
a Standard backlash:
Measuring
Backlash (mm)
position
a 0.114 0.320
b 0.134 0.362
c 0.114 0.320
d 0.121 0.333
e 0.121 0.333
a When the backlash is out of the standard,

correct it referencing Structure, function
and maintenance standard.
2) Install the O-ring and plate (4).
3) Using tool K2, press fit oil seal (2) to the

front case until dimension (a) is obtained.
(When the dust seal is not provided)
a Oil seal press fitting dimension (a):
18.5 mm
32 170E-5 Series
4) Using tool K3, press fit dust seal (3) to the 2) Lift and install flywheel housing (3).
front case until dimension (b) is obtained. 4 Flywheel housing: 150 180 kg
a Dust seal press fitting dimension (b): a The weight varies with the applicable
2 mm (protruded from the front cover machine.
end face)
a Dust seal is provided only for the
vehicle-mounted engines.
3) Tighten the mounting bolts (1 11) in the

following order.
2 Flywheel housing mounting bolt and
washer: Engine oil (EO30)
3 Flywheel housing mounting bolts
1) Apply gasket sealant.
a Diameter of the gasket sealant line
(1 11):
shall be 2 to 3 mm and it should be
1st time: 352.8 392 Nm {36 40 kgm}
applied as indicated in the figure.
2 Flywheel housing:
2nd time: Loosen them once
3rd time: 392 431.2 Nm {40 44 kgm}
4) Tighten mounting bolts (12) (18) in the
order shown in the figure.
(12 18):
98 122.5 Nm {10 12.5 kgm}
a When installing bolts (14) and (18),
apply adhesive to their threaded
parts.
2 Threaded parts of bolts (14) and (18):
Adhesive (LT-2)
Reference: New bolts have been
coated with adhesive.
170E-5 Series 33
5) Install rear seal. 2] Set sleeve (7) of the rear seal to the
a Check the Teflon seal (Laydown lip end of crankshaft (5) and tighten the
seal) by checking the wear of the 5 bolts (45 mm) evenly to press fit
shaft and replace it with the Standard sleeve and rear seal assembly (6)
seal or Sleeved seal. until the end of tool L3 reaches the
a If the shaft is worn to the degree of end of crankshaft (5).
luster (If wear which you feel with
your finger is less than 10 m m) and
does not have any flaw, install the
standard seal. In other cases, install
the sleeved seal.
a The left one in the following figure is
the standard seal and the right one is
the sleeved seal.
3] Remove tool L3 and install tool L2.

a Tighten tool L2 first until it
reaches the bolt (45 mm) and
then tighten the bolt (35 mm).
4] Tighten the 5 bolts evenly to press fit
sleeve and rear assembly (6) until the
end of tool L2 reaches the end of
q Procedure for installing standard seal crankshaft (5).
Tighten the bolt evenly to press fit rear seal (4) a Rear seal driving depth (a): 20
until the end face of tool L2 reaches the end of mm from end of crankshaft
crankshaft (5). a After press fitting the seal,
a Press fit dimension (a) (from the end face remove the red sealant layer
of the shaft: 20 mm). from its periphery.
a After press fitting the seal, remove the red
sealant layer from its periphery.
15. Under plate

1) Raise and invert the engine to move the
q Procedure for installing sleeved seal
oil pan side to the top.
a When installing the rear seal, do not apply
2) Apply gasket sealant and then install
oil or grease to the shaft and sleeve inside
under plate (1).
2 Under plate: Gasket sealant (LG-7)
cylinder surface (C).
1] Set sleeve and rear seal assembly (6)
to tool L3.
2 Sleeve inside cylinder surface
applied to the entire perimeter as
(C): Gasket sealant (LG-7)
shown below.
34 170E-5 Series
a Tighten 4 inside positions and several 3) Lift down engine assembly (1) on blocks
outside positions temporarily using [1] and then remove tools C and tool D2.
the bolts until installation of the suc-
tion tube and oil pan is completed.
17. Flywheel assembly

1) Lift and install flywheel assembly (1).
4 Flywheel assembly: 40 85kg
using it.
a Prevent rotation of the flywheel by fix-
ing the space between the flywheel
and flywheel housing.
a Tighten the mounting bolts in the fol-
lowing order.
2 Flywheel assembly mounting bolt:
Engine oil (EO30)
16. Removal from engine repair stand 3 Flywheel assembly mounting bolt:
1) Raise and invert the engine to move the 1st time: 196.1 19.6 Nm {20 2 kgm}
cylinder head side to the top. 2nd time: 460.9 19.6 Nm {47 2 kgm}
2) Using tool C, lift and remove engine 3rd time: 90 120 retightening
assembly (1) from tool D1. a After tightening the bolt, make a
punch mark (a) on its head. (When a
new bolt is used, do not make a
punch mark on its head.)
170E-5 Series 35
2) Fit the gasket and then install burring

device (2).
3) Install Ne speed sensor (1).
3 Ne speed sensor mounting bolt:
4.9 7.9 Nm {0.5 0.8 kgm}
4) Using dial gauge [1], measure the radial

and facial runout of the flywheel.
a Standard radial and facial runout:
Measuring items Tolerance (mm)
Radial runout 0.13
0.0005 x Diameter of
Facial runout
measuring point
a When the measured value is out of

the standard, determine the cause by
disassembling the flywheel again.
36 170E-5 Series
18. Engine mount

1) Install rear engine mount (1).
2] Install supply pump drive gear (9)

while setting it to positioning rod [1].
2) Install front support.
19. Supply pump drive gear and drive case

1) Fit the O-ring and install drive case (12).
3] Check that stamps "C" on idler gear

(15) and supply pump drive gear (9)
are set to part (A).
4] Check that the dowel pin is in dowel
2) Position the drive case and drive gear pin hole (B) of supply pump drive
according to the following procedure. gear (9).
1] Pass positioning rod [1] through
flange (14) of the supply pump drive
case and housing (13) as shown in
the figure.
a As the positioning rod, use a
metal rod 11 mm in diameter and
at least 180 mm in length.
a Check that there is stamp "C" at
part (A) of idler gear (15).
170E-5 Series 37
3) Apply gasket sealant and install cover (7). 21. Cam cover
a Apply gasket sealant in a form of 1) Install the O-ring and then install cam
string 2 3 mm in diameter as shown cover (2).
in the figure. 2) Install plate (1) with O-ring.
a Apply gasket sealant to the flywheel
housing.
2 Flywheel housing (Cover mounting
face): Gasket sealant (LG-7)

Lift and install vibration damper (1).
4 Vibration damper: 45 kg
a When tightening the mounting bolts, pre-
vent rotation of the damper by fixing the
space between the flywheel and flywheel
housing.
3 Vibration damper mounting bolt:
1st time: 53.9 93.1 Nm {5.5 9.5 kgm}
2nd time: 225.4 264.6 Nm {23 27 kgm}
3rd time: 617.4 656.6 Nm {63 67 kgm}
20. EGR oil pump

Install EGR oil pump (1).
a When installing bolt (a), check that its
stem length is 25 mm. If a wrong bolt is
installed, it will interfere with the parts in
the engine.
38 170E-5 Series

1) Assemble the cam follower assembly
1] Install snap spring (6) to shaft (5).
2] Install 2 cam followers (4) to shaft (5).
a Insert the cam followers so that
the shaft side being driven with
the ball may be directed toward
the front side of the engine.
3] Install snap rings (3).
4) Install the O-ring and then install cam fol-

lower cover (1).
a When installing the cam follower
cover, check its material (cast iron or
aluminum) and install to its original
position.
(The installed position is subject to
the applicable machine.)
a Mounting bolts tightening torque
depends on the position (material of
2) Crank the crankshaft to set No. 1 No. 3 the cover). (The standard torque is
pistons to the following positions. used for tightening the cast iron-made
q No.1 compression top dead center: cover.)
No . 1 and No. 5 p is tons c an be 3 Cam follower cover mounting bolts
installed. (Aluminum-made cover):
q No.2 compression top dead center: 9.8 0.98 Nm {1.0 0.1 kgm}
No . 2 and No. 4 p is tons c an be
installed.
q No.3 compression top dead center:
No . 3 and No. 6 p is tons c an be
installed.
a The cylinder must be set to the com-
pression top dead center position.
When insertion of the cam follower is
not available, the piston is not situ-
ated at the compression top dead
center. In this case, rotate the crank-
shaft one more turn.
3) Install 6 cam follower assemblies (2) in
order.
a Check that the cam follower shaft on
which the ball is driven is directed
toward the front side of the engine.
3 Cam follower assembly mounting
bolt:
90.2 104.0 Nm {9.2 10.6 kgm}
170E-5 Series 39
24. Cylinder head assembly 5] Using tool B, compress the valve

1) Assemble the cylinder head assembly spring and then install 8 valve cotters
according to the following procedure. (2).
1] Install 2 intake valves (6) and 2 a After installing the valve cotters, bring
exhaust valves (7) on cylinder head down the cylinder head sideways and
(8). then hit the valve stem lightly with a
plastic hammer to make sure that the
valve cotters are securely fitted in to
the respective valve stems.
2] Using tool Q, press fit 4 valve stem

seals (5).
2) Install the cylinder head gasket.
3) Lift and install cylinder head assembly (1).
using it.
lowing order.
2 Cylinder head assembly mounting bolt:
Molybdenum disulfide grease (LM-P)
3 Cylinder head mounting bolts (1 7):
1st time: 245 9.8 Nm {25 1 kgm}
2nd time: 382.5 9.8 Nm {39 1 kgm}
3] Install 4 valve springs (4). 3rd time: 90 120 retightening
4] Install 4 spring seat (3). 3 Cylinder head mounting bolts (8 and 9):
93.2 103 kgm {9.5 10.5 kgm}
a After tightening the main bolt, apply a
40 170E-5 Series
25. Fuel injector

a Check that the inside of the injector sleeve
is free from dirt.
2 O-ring: Engine oil (EO30)
1) Install gasket (4) and O-rings (5) and (6) to
fuel injector (3).
a Take care not to install O-ring (5) to
groove (A) at the center.
2) Insert fuel injector (3) to adapter (7) and
injector holder (1), and then insert them to
the cylinder head while directing injector
connector (8) to the high-pressure piping
insertion hole.
3) Fit ball washer (10) to holder mounting

bolt (9) and then tighten injector holder (1)
temporarily.
2 Ball washer: Engine oil (EO30)
a After positioning with the high pres-
sure piping, tighten the holder mount-
ing bolt (9).
4) Install coolant air bleeding tube.

3 Air bleeding tube joint bolt (Cylinder
head side):
9.8 12.7 Nm {1.0 1.3 kgm}
3 Air bleeding tube joint bolt (EGR
cooler side):
24.5 34.3 Nm {2.5 3.5 kgm}
170E-5 Series 41
26. Crosshead 27. Rocker housing

1) Install 12 crossheads (1). Apply gasket sealant and then install rocker
housing (1).
2 Rocker housing: Gasket sealant (LG-7)
a Diameter of the gasket sealant line shall
be 2 to 3 mm and it should be applied
along the housing groove as shown below.
a Install O-ring (OR) without fail.
3 Rocker housing mounting bolt:
78.4 93.2 Nm {8.0 9.5 kgm}
2) Adjust the crosshead according to the fol-

lowing procedure.
1] Loosen locknut (2) and then loosen
adjustment screw (3) until it is
detached from valve stem (4).
2] Using your finger, hold down the
crosshead face contacting the rocker
arm to maintain contact between the
push rod side valve stem and cross-
head.
3] Tighten adjustment screw (3) gradu-
ally to locate the position where
adjustment screw (3) comes into con-
tact with valve stem (4).
4] Screw in adjustment screw (3) further
by 20 to 30 from the position where it
was contacted against valve stem (4).
5] Tighten locknut (2) while stopping
move of adjustment screw (3) by
hand.
3 Locknut:
53.0 64.7 Nm {5.4 6.6 kgm}
28. Push rod
Install 12 push rods (1).
a Check that the push rod end is securely
placed in the cam follower socket.
42 170E-5 Series
29. Rocker arm assembly

1) Assemble the rocker arm assembly
1] Install adjustment screw (2) on rocker
arms (4) and (5), and then install lock
nut (1).
a Screw in adjustment screw (2)
until its spherical part touches
rocker arms (4) and (5).
30. Adjusting valve clearance

1) Rotate the crankshaft forward to remove
plug (1) situated in the left of the flywheel
housing.
a The location of plug (1) is subject to
the applicable machine.
2] Install rocker arm (5) for air intake

valve and rocker arm (4) for exhaust
valve on shaft (6).
a Insert respective rocker arm at a
position where the riveted side of
the shaft faces the front side of
the engine.
2) Align notch (a) of the supply pump drive

gear to the center of the inspection hole.
a The left side and right side of the fig-
ure represent No.1 cylinder compres-
sion top dead center and No.6
cylinder compression top dead cen-
ter, respectively.
a When the cylinder is at the compres-
sion top dead center, the rocker arm
2) Install 6 rocker arm assemblies (3).
can be moved by the valve clearance
a When installing, direct the wider seat
by hand. If the rocker arm cannot be
of the shaft to the rocker arm housing.
moved, rotate the crankshaft one
a Make sure that the spherical part of
more turn.
adjustment screw is securely placed
in the push rod socket.
a When tightening the mounting bolt,
check that adjustment screw (2) is not
pushing the push rod.
2 Threaded portion and seat of rocker
arm assembly mounting bolt:
Engine oil (EO30)
3 Rocker arm assembly mounting bolt:
235.2 254.8 Nm {24 26 kgm}
170E-5 Series 43
a The figure is example of PC1250-8, 5) Rotate the crankshaft forward by one turn
WA600-6 and HD465-7E0. to adjust the valve clearance being indi-
cated with Q mark in the valve layout plan.
a The adjustment procedure is the
same as above.
a Rotate the crankshaft using barring

device (2) located in the rear left side
of the engine.
6) After adjustment, install plug (1).

3) When No. 1 cylinder is at the compression 3 Plug:
top dead center, adjust the valve clear- 58.8 78.4 Nm {6.0 8.0 kgm}
ance indicated by q in the valve layout
plan. 31. Injector harness
a When adjusting, loosen locknut (4) of 1) Install injector harness (6).
adjustment screw (3) and insert clear- a Insert the harness through inside of
ance gauge M between crosshead (5) the engine while directing projection
and rocker arm (6). Then, using (A) of the grommet upward.
adjustment screw (3), adjust the
clearance to a degree that allows the
gauge to slightly move.
a Standard valve clearance (In cold
state)
q Intake valve: 0.32 0.02 mm
q Exhaust valve: 0.62 0.02 mm
4) While fixing adjustment screw (3), tighten
locknut (4).
3 Locknut:
57.8 77.4 Nm {5.9 7.9 kgm}
44 170E-5 Series
2) Insert grommet (5) to the rocker housing 32. Cylinder head cover
and then fix it using plate (4). 1) Install cylinder head cover (2) temporarily.
a Install the cylinder head cover tempo-
rarily so that foreign matter will not
enter.
a Tighten the cylinder head cover
mounting bolts permanently after
tightening the injector holder mount-
ing bolts.
2) Install bracket (1).
a Bracket (1) is not installed on some
3) Install spacer (7).

slit (B) toward the upperside.
33. Air intake manifold assembly

1) Lift and install air intake manifold assem-
bly (3).
110 kg
4) Install terminal mounting nut (8) and wiring

harness fixing bolt (9) temporarily in this
order.
a The order reverse to the above does
not allow the terminal to reach the
injector, disabling the connection.
5) Tighten terminal mounting nut (8) and wir-
ing harness fixing bolt (9) in this order.
a Tighten the terminal nuts alternately.
3 Terminal mounting nut:
2 0.2 Nm {0.2 0.02 kgm}
170E-5 Series 45

lowing order.
35. High-pressure pipes and brackets

k When handling the high-pressure pipe
and clamp, observe the following.
3) Install spill tube (2).
3 Spill tube joint bolt:
q Never bend the high-pressure pipe to
correct before installing or use it for
19.6 29.4 Nm {2.0 3.0 kgm}
another section.
q Install the specified clamp to the
specified position securely.
q After the high-pressure pipe and
clamp are installed, check that the
high-pressure pipe is at least 10 mm
apart from the wiring harness around
it. If not, adjust the wiring harness to
secure the distance.
k Before installing the high-pressure
pipe, check it. If it has any defect,
replace it since fuel may leak.
q Check the taper seal of the connect-
ing part (Part (a): Part of 2 mm from
the end) for visible lengthwise slit (b)
and dent (c).
34. Common rail
q Check part (d) (End of the taper seal:
1) Install common rail (2).
3 Common rail mounting bolt:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
59.0 74.0 Nm {6.0 7.5 kgm}
your nail can feel.
2) Install fuel tube (1).
3 Fuel tube joint bolt (Common rail
side):
17.7 22.6 Nm {1.8 2.3 kgm}
3 Fuel tube joint bolt (Block side):
9.8 12.7 Nm {1.0 1.3 kgm}
46 170E-5 Series
1) Fit O-ring (2) to high-pressure pipe sleeve a When installing the only high-pres-
(1) and tighten sleeve nut (3) temporarily sure pipe without removing the fuel
while setting the sleeve to the injector con- injector (for example, when replacing
nector. Tighten sleeve nut (4) on the com- only the high-pressure pipe with new
mon rail side, too. one), follow the procedure below.
2 O-ring: Engine oil (EO30) q Tighten sleeve nut (3) by 2 turns
a Take care that the high-pressure pipe with the hand into the threads of
will not lean. the fuel injector and then tighten
it with the spanner.
a If sleeve nut (3) does not catch the
threads, turn the spanner while press-
ing the sleeve nut end with a small
rod etc. toward the injector.
4) Install the clamps to the high-pressure
pipe according to the following procedure.
1] Finger tighten 17 high-pressure pipe
clamps (5) as shown in the figure.
2] Finger tighten clamp bracket (6) on
the common rail side and clamp (7)
and then tighten clamp (7) to the
specified torque.
3 Clamp bolt on common rail
side:
2) Tighten injector holder (1) permanently. 9.8 1.0 Nm {1 0.1 kgm}
a While pulling the high-pressure pipe 3] Tighten clamp bracket (6) on the
in the opposite direction to the injec- common rail side to the specified
tor, tighten bolt (8). torque.
3 Injector holder mounting bolt: 4] Tighten high-pressure pipe clamp (5)
58.9 73.5 Nm {6.0 7.5 kgm} to the specified torque.
3 Clamp bolt on high-pressure
pipe side:
11.8 14.7 Nm {1.2 1.5 kgm}
5) Install rubber cap (8) to the sleeve nut on
the common rail side.
a Install the rubber cap with the slit
down.
3) Using a spanner-type torque wrench,

tighten high-pressure pipe sleeve nuts (3)
and (4).
3 Sleeve nut:
39.2 44.1 Nm {4 4.5 kgm}
a Tighten the sleeve nuts while they are
dry.
a After finishing the work, check that O-
ring (2) is not projected from the
sleeve.
170E-5 Series 47
6) Fit the O-rings and install 6 cylinder head 37. Oil pan
cover (3). 1) Apply gasket sealant to the oil pan.
a Only the tightening torque for the No. 2 Oil pan: Gasket sealant (LG-7)
2 cylinder mounting bolts is different. a Diameter of the gasket sealant line
3 Cylinder head cover mounting shall be 2 to 3 mm and it should be
bolts: applied as shown below.
No. 1, 3, 4, 5, 6 cylinder:
9.8 1.0 Nm {1.0 0.1 kgm}
No. 2 cylinder:
58.8 73.5 Nm {6 7.5 kgm}
2) Lift the engine assembly again, set oil pan

(1) under the cylinder block and then bring
down the engine assembly again on the
block.
36. Suction pipe 3) Push up oil pan (1) bottom with a jack and
1) Lift the engine assembly and then set then install the mounting bolt using guide
blocks under the engine mount. Then bolt [1].
bring down the engine assembly again. 4 Oil pan: 85 kg
a Make sure the engine is kept in a suf-
ficiently stable state.
2) Install the O-ring and suction tube (4),
then install brackets (3) and (2).
a As positioning of the suction tube and
bracket is completed, tighten the
mounting bolt.
3 Clamping nut:
10.8 26.4 Nm {1.1 2.7 kgm}
a After installing the suction tube,
remove all bolts that temporarily pro-
vided on under plate (1).
48 170E-5 Series

Install O-ring and then install drive housing
assembly (1).

1) Install corrosion resistor and filter head
assembly (2).
39. Oil level gauge, oil filler pipe, fuel feed 2) Install water tubes (1) on the filter bracket.
pump and engine controller 3 Water tube joint bolt:
1) Install O-ring and then install block (8). 24.5 34.3 Nm {2.5 3.5 kgm}
2) Install bracket (7) and cooling plate (6).
3) Install engine controller (5).
3 Engine controller:
24 Nm {2.4 kgm}
4) Install fuel feed pump (4).
5) Install bracket and fuel tube (3).
3 Fuel tube union nut:
43 47 Nm {4.4 4.8 kgm}
3 Fuel tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
6) Install oil filler pipe (2).
7) Install oil level gauge (1).
a Install the oil level gauge according to
the following procedure.
q Degrease the periphery of the bush- 41. Oil cooler assembly
ing and then apply adhesive to it. Install oil cooler assemblies (1).
q Insert the nut from the bottom of the
guide, get the sleeve through and
then lead the guide through the bush-
ing.
q Tighten the nut holding down the
guide with your hand until the guide
becomes unmovable. Then further
tighten the nut with the specified
torque.
2 Periphery of oil level gauge bushing:
Adhesive (LT-4)
3 Oil level gauge:
44.1 58.8 Nm {4.5 6.0 kgm}
170E-5 Series 49
42. Front hanger and water housing 2) Install gasket and then thermostat housing
1) Lift and install front hanger (3) along with (1).
water housing (4).
4 Front hanger: 65 kg

1) Install water pump assembly (4).
2) Install water tube (2) and bracket (1). 2) Slide bypass tube (3) down and then fix it
3 Water tube joint bolt: using stopper (2).
24.5 34.3 Nm {2.8 3.5 kgm}
(Water housing side)
9.8 12.7 Nm {1.0 1.3 kgm}
(Cylinder head side)
3) Install water pipe (1).

a The type of water pipe (1) is subject
to the applicable machine.
43. Thermostat housing and thermostat

1) Install thermostats (2) on thermostat hous-
ing (1).
50 170E-5 Series
45. Supply pump assembly a Install tube (7) as shown in the figure.
1) Install supply pump assembly (11). k If tube (7) is installed near the
2) Install bracket (10). pump by mistake, the supply pump
a Insert the fuel supply pump shaft in will be broken.
the coupling of the supply pump drive
case.
a There is 1 unsplined part each on the
coupling side and shaft side, which
are used to position the coupling and
shaft.
q The figure shows the coupling of the
supply pump drive case. (Part A is
the unsplined part.)
4) Install fuel tube (2) and wiring harness (1).

3 Fuel tube joint bolt (Supply pump
side):
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}
3) Install oil tubes (6) and (5) and fuel tubes

(4) and (3).
3 Oil tube (6) joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
3 Oil tube (5) joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
3 Fuel tube (3) joint bolt:
14.8 19.6 Nm {1.51 1.99 kgm}
3 Fuel tube (3) union nut:
43 47 Nm {4.4 4.8 kgm}
14.8 19.6 Nm {1.51 1.99 kgm}
170E-5 Series 51
46. High-pressure piping 47. Air intake connector

k When handling the high-pressure pip- Install air intake connector (1).
ing and clamp, care should be paid to
following points.
q It is strictly prohibited to modify bend-
ing 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 mini-
mum is provided between the high-
pressure piping and adjacent wiring
harness. When the clearance is less
than 10 mm, secure the necessary 48. Breather, cover and wiring harness
space by adjusting the wiring harness 1) Install O-ring and then wiring harness and
position. plate assembly (3).
1) Install high-pressure pipings (1) and (2) 2) Install engine top covers (2).
temporarily on the common rail and fuel 3) Install breather and hose assembly (1).
supply pump. 3 Breather mounting bolt:
2) Install the bracket and clamp temporarily. 24.5 29.4 Nm {2.5 3.0 kgm}
3) Tighten the sleeve nuts of high-pressure
pipings (1) and (2) with the specified
torque.
a Tighten the sleeve nut in dry state.
3 High-pressure piping sleeve nut:
39.2 44.1 Nm {4.0 4.5 kgm}
4) Tighten the clamp with the specified
torque.
3 Clamping bolt:
9.8 1.0 Nm {1 0.1 kgm}
5) Tighten the bracket mounting bolt with the
specified torque.
6) Install a rubber cap on the sleeve nut.
a When fitting the rubber cap, direct its
slit toward out of the engine.
49. Fuel tube
1) Install fuel tubes (2), (4), (5), (6).
a Fuel tube (3) has been installed in the
previous step.
19.6 29.4 Nm {2.0 3.0 kgm}
3 Fuel tube (4), (5), (6)
q Joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
q Union nut:
24 27 Nm {2.4 2.7 kgm}
2) Install cover (1).
52 170E-5 Series

1) Install main fuel filter and filter head
assembly (4).
2) Install fuel tubes (2) and (1).
3 Fuel tubes (1) joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
7.8 9.8 Nm {0.8 1.0 kgm}
3) Fix filter using clamp (3).
50. Pre-fuel filter and filter head assembly

2) Install pre-fuel filter and filter head assem-
bly (3).
3) Install fuel tubes (2) and (1) on the filter
head.
3 Fuel tube (1) union nut (Filter head
side):
43 47 Nm {4.4 4.8 kgm}
4) Tighten air bleeding plug (5).

a One of two types of air bleeding plugs
(5) is used, depending on the time of
manufacture.
3 Air bleeding plug
q PT1/8 taper plug:
6.9 14.7 Nm {0.7 1.5 kgm}
q M8 plug:
7.8 9.8 Nm {0.8 1.0 kgm}
51. Oil filter and filter head assembly

2) Install filter head and oil filter assembly (2).
a Install the filter on the front side tem-
porarily since it must be removed
when the alternator is installed.
3) Install O-ring and then oil tubes (1).
53. Pulley, tensioner and air conditioner com-

pressor bracket
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).
170E-5 Series 53
56. Belt of auxiliary equipment

1) Install auxiliary equipment belt (3).
2) Loosen adjustment bolt (1) and give the
tension of tensioner (2) to auxiliary equip-
m e nt b el t ( 3 ) u nt i l d im en s i on ( a ) is
obtained.
Dimension (a): 90 mm
3) Tension the locknut of adjustment bolt (1).
54. Alternator
1) Remove oil filter (1) on the front side.
2) Install alternator (2).
3) Install oil filter (1).
a Insert the mounting bolt in the rear side
toward the front side. (If it is inserted in the
front side, it cannot be pulled out when the
engine is mounted on the machine.)
57. EGR valve
1) Install EGR valve (5).
2) Install oil tubes (1) (4).
3 Oil tubes (1), (2) sleeve nut (Relay
block side):
24 27 Nm {2.4 2.7 kgm}
3 Oil tubes (3), (4) joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
55. Air conditioner compressor

Install air conditioner compressor (1).
58. EGR cooler

1) Install EGR cooler (3).
2) Apply silicone sealant (Shin-Etsu Chemi-
cal KE45W or equivalent) to the hose
insertion part (hatched part A) of the water
tube and then insert the water tube in the
water hose.
54 170E-5 Series
2) Lift and install exhaust manifold assembly

(1).
3) Install coolant pipings (2) and (1).

3 Water tube (2) joint bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
3 Water tube (2) union bolt:
14.7 24.5 Nm {1.5 2.5 kgm} a Tighten the mounting bolts in the fol-
3 Water tube (2) union bolt locknut: lowing order.
19.6 44 Nm {2.0 4.5 kgm} 2 Exhaust manifold mounting bolt:
a When tightening the union nut, hold Seizure prevention compound (LC-G)
the union bolt with a spanner to pre- (NEVER-SEEZ (Bostic Inc.) or equivalent)
vent their breakage. 3 Exhaust manifold mounting bolt:
1st time: 39.2 58.8 Nm {4.0 6.0 kgm}
2nd time: 98.1 122.6 Nm {10 12.5 kgm}

1) When the exhaust manifold assembly is
currently split, apply liquid adhesive (heat 60. Bypass tube and EGR tube
resistant sealant) to connection (A) (in two 1) Install bypass tube (8) and then fix it with
positions) prior to the assembly. clamp (7).
2 Exhaust manifold connection: a A separate torque shall be used for
Liquid adhesive (Holtz MH 705) the stainless steel bolt alone. (The
standard torque is applicable to the
other bolts.)
2 Bypass tube mounting bolt (All bolts):
Seizure prevention compound (LC-G)
(NEVER-SEEZ (Bostik Inc.) or equivalent)
3 Bypass tube mounting bolt (Stainless
steel bolt):
44.1 53.9 Nm {4.5 5.5 kgm}
170E-5 Series 55
2) Install EGR tube (6) and then fix it with 61. Bracket
clamp (5). Install bracket (1) on the top face of No. 2
a A separate torque shall be used for rocker cover.
the stainless steel bolt alone. (The
standard torque is applicable to the
other bolts.)
2 EGR tube mounting bolt (All bolts):
3 EGR tube mounting bolt (Stainless
steel bolt):
44.1 53.9 Nm {4.5 5.5 kgm}

1) Lift and install turbocharger assembly (1).
2 Turbocharger mounting bolt and
nut:
nut:
3) Install brackets (3) and (4). 78.5 88.3 Nm {8.0 9.0 kgm}
4) Install EGR tube (2) and then fix it with 2) Install 2 water pipes (1) and 2 oil pipes (2).
clamps (1). 3 Oil pipe joint bolt (Cylinder block
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Water pipe joint bolt (Turbocharger
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Water pipe joint bolt (Cylinder block
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Water pipe union bolt (End of air
vent tube):
53.9 73.5 Nm {5.5 7.5 kgm}
3 Locknut for water pipe union bolt:
24.5 59 Nm {2.5 6 kgm}
56 170E-5 Series
3 Intermediate hose clamp: 65. Engine wiring harness

3.3 0.49 Nm {0.34 0.05 kgm} 1) Install engine wiring harness (1) on the
engine assembly and then connect the
connector and terminal.
63. Air piping

Lift and install air piping (1) and then fix it with
clamp (2). 2) Install the cover on PFUEL section (2) on
4
the engine top face after its installation.
Air piping: 15 kg
3 Clamping nut:
34.3 44.1 Nm {3.5 4.5 kgm}
3 Hose clamp:
9.8 1.0 Nm {1.0 0.1 kgm}
66. Sensor tightening torque

When a sensor is replaced, tighten a new sen-
sor to the following torque.
64. Starting motor assembly Sensor name Tightening torque

Install starting motor assemblies (2) and then Ne speed 4.9 7.9 Nm {0.5 0.8 kgm}
connect wiring harness (1). Fuel temperature 23 3 Nm {2.35 0.3 kgm}
Coolant tempera-
23 3 Nm {2.35 0.3 kgm}
ture
Engine oil pressure 23 3 Nm {2.35 0.3 kgm}
Fuel pressure Never disassemble.
Intake air tempera-
23 3 Nm {2.35 0.3 kgm}
ture
Engine oil tempera-
23 3 Nm {2.35 0.3 kgm}
ture
170E-5 Series 57
67. Checking of fuel leakage 9) Check the fuel piping and devices for fuel
a If fuel supply pump (1), common rail (2), or leakage.
high-pressure piping (3) is removed and a Check mainly around the high-pres-
installed, after assembling the engine, sure circuit parts coated with the color
check for fuel leakage according to the fol- checker for fuel leakage.
lowing procedure. a If any fuel leakage is detected, repair
it and check again from step 2).
a If no fuel leakage is detected, the
check is completed.
a Clean and degrease the engine and the

parts around it in advance so that you can
test it easily for fuel leakage.
1) Spray color checker (developer) over the
fuel supply pump, common rail, fuel injec-
tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
3) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
4) Run the engine at low idle.
leakage.
6) Run the engine at high idle.
leakage.
8) Run the engine at high idle and load it.
a When checking while the components
to be checked are mounted on the
machine, stall the torque converter or
relieve the hydraulic pump.
58 170E-5 Series
170E-5 Series 59
SEN00766-01
2007 KOMATSU
All Rights Reserved
60
SEN00767-01
ENGINE 1SHOP MANUAL

2SHOP
170E-5 Series

(EGR-less)
Disassembly and assembly, Part 2 (EGR-less) .............................................................................................. 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 21
170E-5 Series 1
Disassembly and assembly, Part 2 (EGR-less) 1

General disassembly of engine 1
a Since the shapes, quantity, locations, etc. of
the parts depend on each applicable machine,
check them before starting the work.
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. 4. Blow-by tube and covers
1) Remove blow-by tube (1).
2. Setting engine assembly 2) Remove covers (2) and (3).
1) Place engine assembly (1) on a stable
engine stand (block [1]) so that it will not
tip over.
a The weight depends on the applica-
ble machines.
4 Engine assembly: 2,900 kg
5. Engine wiring harness assembly

Disconnect the connectors and terminals,
remove the wiring harness clamp, and remove
engine wiring harness assembly (1) from the
engine assembly.
2) Drain the engine coolant and engine oil.

a The quantity of the oil depends on the
6 Engine oil: Approx. 80 l
3. Air piping
1) Disconnect connecting clamp (1) of the
turbocharger and air piping.
2) Remove 3 U-clamps (2) and air piping (3).
2 170E-5 Series
6. Starting motor assemblies

1) Remove connector bracket (1).
2) Remove wiring harness (2) and starting
motor assemblies (3) and (4).
5) Sling turbocharger assembly (5) and

6) Lift off turbocharger assembly (5).
7. Exhaust temperature sensor
1) Disconnect the 4 wiring harness clamps.
2) Remove exhaust temperature sensor (1).
3) Remove brackets (2), (3) and (4).

1) Sling exhaust manifold assembly (1) and
2) Lift off exhaust manifold assembly (1).
8. Turbocharger assembly 4 Exhaust manifold assembly: 35 kg
1) Remove water tube (1) and bracket
together.
2) Remove the clamp and turbocharger out-
let tube (2).
3) Remove the 2 clamps and water tube (3).
4) Remove the 2 clamps and turbocharger
inlet tube (4).
170E-5 Series 3
10. Cover and brackets 13. Alternator assembly

1) Remove cover (1). 1) Remove oil filter (1) on the front side.
2) Remove brackets (2) and (3). a Carry out this work to secure a space
for pulling out the alternator mounting
bolts.
2) Remove alternator assembly (2).
3) Install oil filter (1) as necessary.
11. Auxiliary machine belt

1) Tighten adjustment bolt (1) and relieve
auxiliary machine belt (3) of the tension of
tensioner (2).
2) Remove auxiliary machine belt (3). 14. Pulley, tensioner and air conditioner com-
pressor bracket
1) Remove pulley (1).
2) Tighten bolt (2).
3) Install stopper bolt [1] to tensioner (3) as
shown in the figure.
a Use a bolt M10 x 1.5 with a stem 90
mm long as stopper bolt [1].
a Maintain the stopper bolt [1] in this
position before installing tensioner (3)
again.
4) Remove tensioner (3).
5) Remove air conditioner compressor
bracket (4).
12. Air conditioner compressor assembly

Remove air conditioner compressor assembly
(1).
4 170E-5 Series
15. Main fuel filter and filter head assembly 18. Corrosion resistor and filter head assembly
1) Remove the 5 clamps (1) and remove fuel 1) Remove water tube (1) from the filter
tubes (2), (3) and (4) from the filter head. head.
2) Remove main fuel filter and filter head 2) Remove corrosion resistor and filter head
assembly (5). assembly (2).
16. Oil filter and filter head assembly 19. Cover

1) Remove bracket (1), clamp (2) and oil Remove cover (1).
tubes (3) and (4).
2) Remove filter head and oil filter assembly
(5).
20. Fuel prefilter and filter head assembly

1) Remove the 3 clamps and remove fuel
tube (1) from the filter head.
17. Fuel filter and filter head assembly 2) Remove fuel tube (2).
1) Remove the clamp and remove fuel tube 3) Remove fuel prefilter and filter head
(1) from the filter head. assembly (3).
2) Remove fuel filter and filter head assem-
bly (2).
170E-5 Series 5
21. Electric priming pump, block and air bleed- 23. Lubrication tube
ing valve 1) Remove the 2 clamps and lubrication tube
1) Remove the 9 clamps and fuel tubes (1), (1).
(2), (3), (4) and (5). 2) Remove adapter (2).
2) Remove block (6).
3) Remove electric priming pump (7).
4) Remove air bleeding valve (8) and bracket
together.
24. Brackets
Remove brackets (1), (2), (3), (4), (5), (6) and
(7).
22. Engine controller and cooling plate

1) Remove engine controller (1).
2) Remove fuel hose (2) and cooling plate
(3).
25. Cover and plate

2) Disconnect 6 wiring harness connectors
(2).
3) Remove plate (3).
6 170E-5 Series
26. Supply pump assembly 2) Pull out pin (3) of barring device (2) and
1) Remove fuel tube (1). push in the barring device to mesh it with
2) Remove 4 rubber caps (4) from high-pres- the gear.
sure pipes (2) and (3). 3) Rotate barring device (2) to crank the
3) Remove 3 clamps (5) and high-pressure engine and set mark (C) of the supply
pipes (2) and (3). pump drive gear to that of the cam gear.
4) Remove supply pump drive gear (4).

5) Remove 4 mounting bolts (7) and supply
pump assembly (8).
5) Remove drive case (5).

170E-5 Series 7
28. Brackets and high-pressure pipes

1) Remove brackets (1) and (2).
2) Remove 17 clamps (3) from the high-pres-
sure pipes.
a Before removing the clamps, make
their location marks with paint.
3) Remove the rubber caps from high-pres-
sure pipes (4), (5), (6), (7), (8) and (9).
4) Remove high-pressure pipes (4), (5), (6),
(7), (8) and (9).
a Loosen the sleeves on the injector
side with tool S. 30. Spill tube
a If tool S is not available, disconnect Remove spill tube (1).
the sleeves on the injector side from
above.
31. Air connector, electrical intake air heater,

and housing and connector assembly
q Tool S 1) Remove air connector (1) and electrical
intake air heater (2).
2) Remove housing and venturi connector
assembly (3).
29. Common rail

1) Remove brackets (1), (2) and (3).
2) Remove fuel tube (4) and its peripheral
parts.
3) Remove common rail (5).
4) Remove fuel junction block (6).
8 170E-5 Series
32. Air intake manifold assembly 34. Thermostat housing and thermostat
1) Sling air intake manifold assembly (1) and 1) Remove thermostat housing (1).
2) Lift off air intake manifold assembly (1).
90 kg
2) Remove thermostats (2) from thermostat

housing (1).

1) Remove water pipe (1).

1) Remove bracket (1) and water tube (2).
2) Remove stopper (2) and move bypass

tube (3) up.
3) Remove water pump assembly (4).
2) Sling front hanger (3) and remove the

mounting bolts.
3) Lift off water housing (4) and front hanger
(3) together.
170E-5 Series 9
3) Remove plate (4) and push in grommet (5)

and injector wiring harness (6) together.
4) Remove injector wiring harness (6) from
inside of the engine.
36. Cylinder head cover and tube

1) Remove water tube (1).
2) Remove cover (2) and cylinder head cov-
ers (3).
a Cover (2) is not installed on some 38. Rocker arm assembly
applicable machines. 1) Loosen locknuts (1) and loosen adjust-
ment screws (2) fully.
a Check that the rocker arm does not
receive any tension and is free.
2) Remove rocker arm assembly (3).
a Put a location tag to each removed
rocker arm assembly so that you will
not mistake it for another.
37. Injector wiring harness

1) Loosen terminal mounting nut (1) to dis-
connect the wiring harness.
2) Remove wiring harness fixing bolts (2)
and spacer (3).
3) Remove exhaust rocker arm (4) and

intake rocker arm (5) from shaft (6).
10 170E-5 Series
39. Push rod 42. Fuel injector assembly

Remove push rods (1). 1) Remove injector holder (1).
40. Rocker housing 2) Using tool A, remove fuel injector assem-

Remove rocker housing (1). bly (2).
a Hitch the tip of tool A to hole (a) on
the injector and then pull it out.
a Do not grip the solenoid valve at the
top of the injector to pull off the injec-
tor.
41. Crosshead
Remove crossheads (1).
43. Cylinder head assembly

1) Lift off cylinder head assembly (1).
a If the cylinder head assembly is
removed with the injector assembly
i ns tal le d, the i nj ec tor as s emb ly
projects from the cylinder head bot-
tom. Accordingly, prevent the injector
from interfering with the floor by using
a block etc.
170E-5 Series 11
4] Remove valve stem seal (5).
2) Remove the cylinder head gasket.

3) Disassemble the cylinder head assembly 5] Remove air intake valve (6) and
according to the following procedure. exhaust valve (7) from cylinder head
1] Using tool B, compress the valve (8).
spring and remove valve cotter (2). a Check the installed positions of
the valve and related parts and
keep them so that they will not be
mixed up.
2] Remove spring seat (3).

3] Remove valve spring (4).
44. Oil cooler assembly

Remove oil cooler assembly (1).
12 170E-5 Series
45. Drive housing assembly 4) Using tools C, sling the engine and
1) Remove cover (1). remove oil pan (1).
2) Remove drive housing assembly (2). 4 Oil pan: 85 kg
46. Oil level gauge and oil filler pipe 5) Support the engine again securely with
1) Remove oil level gauge (1). block [1].
2) Remove oil filler pipe (2). a See 2 "Setting engine assembly".
48. Suction pipe and underplate

1) Install underplate (1) temporarily with sev-
eral oil pan mounting bolts.
2) Remove brackets (2) and (3) and suction
pipe (4).
3) Disconnect the gasket sealant.
4) Remove the bolts tightened temporarily
and then remove underplate (1), using a
jack etc.
4 Underplate: 30 kg
47. Oil pan

1) Support the front and rear of oil pan (1)
with blocks [1].
2) Remove all oil pan mounting bolts (2).
3) Disconnect the gasket sealant.
170E-5 Series 13

1) Remove cam follower cover (1).

1) Sling vibration damper (1) and remove the
2) Remove cam follower assembly (2). mounting bolts.
a Rotate the crankshaft with the barring 2) Lift off vibration damper (1).
device to set the piston to the follow- 4 Vibration damper: 45 kg
ing positions and remove the cam fol-
lower assembly.
q No. 1 compression top dead cen-
ter: No. 1 and No. 5 cam follower
can be removed.
can be removed.
can be removed.
a If the cam follower assembly cannot
be pulled out, the piston is not at the
compression top dead center. In this
case, rotate the crankshaft 1 more
turn. 51. Front cover
1) Lift up front cover (1) temporarily and then
2) Lift and remove front cover (1).
4 Front cover: 50 kg
3) Disassemble the cam follower according

to the following procedure.
1] Remove snap rings (3).
2] Remove cam followers (4) from shaft
(5).
3] Remove snap rings (6) from shaft (5).
14 170E-5 Series
3) Remove dust seal (2) and oil seal (3) from 53. Oil pump assembly
the front cover. Remove oil pump assembly (1).
a Dust seal is provided only on the
vehicle-mounted engines alone.
54. Engine mount

1) Remove the front engine mount.
52. Front idler gear assembly 2) Remove rear engine mount (1).
1) Remove idler gear (larger one) (1). 4 Rear engine mount: 30 kg
2) Remove idler gear (smaller one) (2). a The weight varies with the applicable
machines.
3) Remove spacer (3) and shaft (4) from idler

gears (large and small gears). 55. Flywheel assembly
a The same structure is employed for 1) Lift flywheel assembly (1) temporarily and
both the large and small gears. then remove the mounting bolt.
170E-5 Series 15
56. Flywheel housing 57. Camshaft assembly

1) Remove Ne speed sensor (1) and barring 1) Along with the camshaft gear, lift and
device (2). remove camshaft assembly (1) to the
engine rear side.
a When pulling it out, lift the gear side
temporarily and then remove it align-
ing the shaft center of the camshaft
and bushing.
a Adjust the camshaft lifting position
again as approximately 2/3 of its body
is pulled out and then pull it out com-
pletely.
a Rotate it fitly during above operation
in order to avoid interference with the
bushing.
4 Camshaft: 55 kg
2) Lift flywheel housing (3) temporarily and

then remove the mounting bolts.
4 Flywheel housing: 150 180 kg
4) Remove rear oil seal (4) from the flywheel

housing.
16 170E-5 Series
58. Rear idler gear assembly 59. Installation to engine repair stand
1) Remove rear idler gear assembly (1). Using tools C, lift engine assembly (1) being
attached with tool D2 and then attach tool D1
to the assembly.
4 Engine assembly: Approx. 1,600 kg
2) Disassemble the idler gear in the following

procedure.
1] Remove spacer (2) from shaft (3).
1) Raise the cylinder block to make the cylin-
der level.
2) Rotate the crankshaft to set No. 1 to No. 3
pistons.
pistons.
pistons.
3) Sequentially remove 6 each of cooling
2] Separate gear (larger one) (4) from
nozzles (1) and (2).
another (smaller one) (5).
170E-5 Series 17
61. Piston and connecting rod assembly a Pull the assembly horizontally so that
1) Move the piston of the cylinder to be the connecting rod may not damage
removed to the bottom dead center posi- the cylinder liner.
tion by rotating the crankshaft. a Maintain them on the cylinder No.
2) Loosen the connecting rod bolt by 5 to 6 basis using a tag or the like.
turns.
a Lightly strike the connecting rod head
with a plastic hammer to separate the
connecting rod cap from the connect-
ing rod.
3) Move the piston to the top dead center
position by rotating the crankshaft.
4) Remove connecting rod cap (1).
7) Disassemble the piston and connecting

rod assembly according to the following
procedure.
1] Remove connecting rod bearing (4).
5) Remove connecting rod bearing (2) from

2] Remove 2 snap rings (5).
6) Push the connecting rod from the crank-

shaft side to remove the piston and con-
nection rod assembly (3).
a When removing the piston and con-
necting rod assembly, support the
assembly at the cylinder side so that
it may not fall off. Then push the con-
necting rod end portion to remove the
assembly.
18 170E-5 Series
3] Remove piston pin (6). 62. Crankshaft assembly

4] Remove connecting rod (7). 1) Set the crankshaft side up.
a The connecting rod and cap are 2) Remove the main cap mounting bolt.
a set of parts. Thus they must be 3) For removal, sway main cap (1) back and
assembled together temporarily forth using the mounting bolt.
after the disassembly so that a Thrust washers are provided for No. 6
they may not be slit from each main cap. Thus reasonable care must
other. be exercised to prevent their falling
off.
5] Using tool F, remove top ring (8) and

second ring (9). 4) Remove main bearing metal (2) and 2
thrust washers (3) from main cap (1).
a Thrust washers are provided on No. 6
main cap alone.
a Maintain them on the main cap No.
6] Remove oil ring (10) from piston (11).
170E-5 Series 19
5) Lift and remove crankshaft assembly (4). 64. Cylinder block

a Thrust washers are provided for No. 6 Using tools C, lift and remove cylinder
bearing. Thus reasonable care must block (1) from tool D1.
4
Cylinder block assembly: 800 kg
off.
4 Crankshaft assembly: 270 kg

thrust washers (6).
a Thrust washers are provided on No.6
alone.
a Maintain them on the bearing No.
63. Cylinder liner

1) Set the cylinder head side up.
2) Using tool G, remove cylinder liner (1).
20 170E-5 Series
General assembly of engine 1 2] Polish parts (c) and (d) using No. 240
or so sand paper until a smooth
a The shapes, quantity, locations, etc. of the Rounded surface results.
parts depend on each applicable machine. a If rounded part is sharp or has
Take care. burrs, finish it with a scraper or
a Clean each part carefully, and check it for sandpaper. Finish this surface
bruise, flaw, cavity, etc. Make sure each oil or particularly smoothly so that it will
coolant path is through. not damage the O-ring.
a If face (a) and part (c) are pitted,
Tightening bolts by plastic-region turning angle finish them smoothly.
method a If part (d) is so pitted that it can-
a Bolts tightened by plastic-region turning angle not be repaired, replace the cyl-
method inder block.
q Cylinder head mounting bolt 3] Check face (e) of the counterbored
q Main cap mounting bolt part and remove burrs.
q Connecting rod cap mounting bolt a If chips or dusts is on a level sur-
q Flywheel mounting bolt face, the liner does not fit and
q Idler gear (rear side) mounting bolt coolant may leak and the projec-
a If the plastic-region turning angle method is tion of the liner may become
applied, the tightened bolts have permanent improper consequently.
strain. Accordingly, the allowable number of a Drooping, corrosion or pitting
using times of each bolt is limited.Observe the must be repaired, if any.
fol low ing pr ec auti ons b efor e u si ng this
approach.
q Check each mounting bolt head for punch
marks. If there are punch marks more
than the specified numbers, replace the
bolt.
a For details, refer to respective relevant sec-
tions in this document.
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.
170E-5 Series 21
a When installing O-rings (2) and (3),

refer to the following.
q O-ring (2): Black
q O-ring (3): Red
2 Clevis seal and O-ring:
Rubber lubricant (RF-1)
a RF-1: DAIDO CHEMICAL INDUSTRY
CO., LTD.
When RF-1 is not available, apply
clean engine oil SAE No. 30.
a Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
4) Apply gasket sealant to the parts of the

cylinder block and cylinder liner which will
fit to the counterboared parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counter-
boared parts of the cylinder block and
liner flange.
2 Cylinder block:
q Gasket sealant: 2 3 mm in diame-
ter
q Overlap (a) of gasket sealant:
6 6 mm
a If the applied gasket sealant is left for
a long time, its surface becomes
hard. Accordingly, install the cylinder
block to the cylinder head within 50
minutes.
3) After fitting the liner O-ring, check it for

twist. If it is twisted, correct it with a
smooth rod (about 10 mm in diameter).
5) Insert cylinder liner (1) in the cylinder

block slowly, taking care not to damage
the O-ring.
6) Push in cylinder liner (1) further by both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be dam-
aged. In this case, stop the work and
check the cylinder block for burrs.
22 170E-5 Series
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-
t ur e , fu nc t io n a nd ma i nte n an c e
standard.
8) Install the head gasket and then tempo-

rarily assemble cylinder head assembly
(5).
a The head gasket used may be a sec-
ondhand article.
a The cylinder head may be an inde-
pendent product or already assem-
bled with the head gasket.
a 7 main mounting bolts shall be used
for the tightening. Tighten them in the
following order.
3 Cylinder head bolt:
245 265 Nm {25 27 kgm}
3. Setting to engine repair stand
1) Install tools D2 and C to cylinder block (1).
170E-5 Series 23
2) Lift cylinder block (1) and install it to tool

D1.
4 Cylinder block: 850 kg
5) Install main bearing metal (2) to main cap

(1).
4. Crankshaft assembly the bearing metal to the notch on the
1) Invert the cylinder block to set the oil pan main cap.
side to the top. 2 Main bearing metal inner surface:
2) Install 7 main bearing metals (5) to the cyl- Engine oil (EO30)
inder block. 6) Install 2 thrust washers (3).
a Note that the upper main bearing a Thrust washer is provided only on
metal is not identical with the lower both sides of No. 6 main cap.
main bearing metal. An oil hole is
drilled on the upper bearing. Check it
before installation.
cylinder block.
2 Main bearing metal inner surface:
Engine oil (EO30)
3) Install 2 thrust washers (6).
a Thrust washer is provided only on
both sides of No. 6 bearing.
7) Install main cap (1).

a When installing the main cap, align
the bearing number and then set the
stamped (F) face toward the front
side of the engine.
using it.
2 Threaded portion and seat of main
cap mounting bolt: Engine oil (EO30)
4) Lift crankshaft assembly (4) and assemble 3 Main cap mounting bolt:
it to the mounting position. 1st time: 284 15 Nm {29 1.5 kgm}
4 Crankshaft assembly: 270 kg 2nd time: 568 10 Nm {58 1.0 kgm}
a When installing the crankshaft, take 3rd time: 90 (+30/0) retightening
care not to hit it against the cylinder
block.
24 170E-5 Series

5. Piston and connecting rod assembly

1) Assemble the piston and connecting rod
assembly according to the following pro-
cedure.
1] Install oil ring (10) to piston (11).
a Connect both ends of the expander
and then place it in the ring inner
groove.
2] Using tool F, install second ring (9)

and top ring (8).
a When installing the piston ring,
set the letter-stamped side up.
8) Measure the end play of the crankshaft

using dial gauge [1].
t ur e , fu n ct i on a n d ma i nt en an c e
standard.
170E-5 Series 25
3] Set the abutment joint of each piston

ring to the position shown in the fol-
lowing figure.
6] Install connecting rod metal (4).

a When installing, fit in the projec-
tion on the bearing metal to the
4] Set connecting rod (7) on the piston
notch on the connecting rod.
and then insert piston pin (6).
a When using a new connecting
rod, apply a marking cylinder
number to both the connecting
rod and cap using an electric
pen.
a When installing the connecting
rod, set the cast letters EX on the
side face of the piston and the
cast letters Part No. on the con-
necting rod side face in the same
direction.
2) Set the cylinder block upper face to the

lateral direction.
3) Move the pin journal of the cylinder to the
top dead center position by rotating the
crankshaft.
4) Using tool J, insert piston and connecting
rod assembly (3) to the cylinder.
2 Piston ring: Engine oil (EO30)
a Insert the piston directing the cast let-
ters EX to the front side of the engine.
5] Install 2 snap rings (5).

a Make sure the rings are securely
placed in the ring groove.
26 170E-5 Series
5) Install connecting rod bearing metal (2) to

connecting rod cap.
6) Install connecting rod cap (1).

a Set the cylinder number mark on the
connecting rod cap and the connect-
ing rod in the same direction when
installing them.
using it. 7) Measure side clearance of the connecting
2 Connecting rod mounting bolt and rod using dial gauge [1].
washer: Engine oil (EO30) a Standard side clearance:
3 Connecting rod cap mounting bolt: 0.200 0.374 mm
1st time: 196 10 Nm {20 1 kgm} a When the side clearance is out of the
2nd time: 90 (+15/0) retightening standard, determine the cause by dis-
a After tightening the bolt, apply a assembling it again.

1) Rotate the crankshaft to set No. 1 No. 3
q No. 1 top dead center position:
170E-5 Series 27
q No.2 top dead center position: a When installing the spacer, direct
Piston cooling nozzles of the No. 2 its V-grooved face (a) to cylinder
and No. 5 pistons can be installed. block side.
2) Install 6 each of piston cooling nozzles (1)
and (2) in order.
a Install the piston cooling nozzles hav-
ing the stamps of (F) to the front side
of the cylinder and install those hav-
ing the stamps of (R1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the
mounting bolt.
3 Piston cooling nozzle mounting bolt:
27.4 34.3 Nm {2.8 3.5 kgm} 2) Raise and invert the engine to set the oil
pan side to the bottom.
3) Install rear idler gear assembly (1).
a When installing the rear idler gear
assembly, direct the stamped letters
in front side of the shaft to the top
side (cylinder head side).
7. Rear idler gear assembly

1) Assemble the rear idler gear assembly
1] Install gear (larger one) (4) to another
(smaller one) (5).
98 123 Nm {10.0 12.5 kgm}
a When installing, match (A) mark on
the crankshaft gear to (A) mark on the
idler gear (larger one).
2] Install shaft (3) and spacer (2).
28 170E-5 Series
a (B) mark is used in the succeeding

processes.
using it.
2 Threaded portion and seat of mount-
ing bolt: Engine oil (EO30)
3 Rear idler gear mounting bolt:
1st time: 56.8 11.8 Nm {5.8 1.2 kgm}
2nd time: 90 120 retightening
2) Measure end play of the camshaft using

dial gauge [1].
t ur e , fu nc t io n a nd ma i nte n an c e
standard.
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: 55 kg
a When installing, match (B) mark on
the camshaft gear and (B) mark on
the idler gear (smaller one).
3 Camshaft assembly mounting bolt:
98 122.5 Nm {10 12.5 kgm}
170E-5 Series 29
9. Measurement of gear backlash (Rear)

Measure backlash of the rear timing gear using
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.
Measuring
Backlash (mm)
position
a 0.155 0.412
b 0.145 0.380
a When the backlash is out of the standard, 11. Front idler gear assembly
correct it referencing Structure, function 1) Install shaft (4) and spacer (3) to gears (2)
and maintenance standard. and (1).
a Insert the shaft to a side of the gear
bearing on which the projection is
smaller than the other side.
chamfered portion of the bore to the
gear.
a The same structure is employed for
both the large and small gears.
2) Install idler gear (smaller one) (2) and idler

gear (larger one) (1).
245 309 Nm {25.0 31.5 kgm}

Fit the square ring and then install oil pump
assembly (1).
a For adhesion of the square ring and
pump, Hi-Tack 98D from Loctite or equiva-
lent adhesive should be used.
30 170E-5 Series
12. Measurement of gear backlash (Front) 13. Front cover

Measure backlash of the front idler gear and 1) Fit the gasket and then lift and install front
other gears using dial gauge [1]. covers (1).
a When measuring the backlash, set the dial a Make sure that displacement or
gauge in the tooth end position of the tar- pinching is not observed on the gas-
get gear of measurement and then fix the ket.
counterpart gear. 4 Front cover: 50 kg
Measuring
Backlash (mm)
position
a 0.114 0.320
b 0.134 0.362
c 0.114 0.320
d 0.121 0.333
e 0.121 0.333
a When the backlash is out of the standard,

correct it referencing Structure, function
and maintenance standard.
2) Install the O-ring and plate (4).
3) Using tool K2, press fit oil seal (2) to the

front case until dimension (a) is obtained.
(When the dust seal is not provided)
a Oil seal press fitting dimension (a):
18.5 mm
170E-5 Series 31
4) Using tool K3, press fit dust seal (3) to the 2) Lift and install flywheel housing (3).
front case until dimension (b) is obtained. 4 Flywheel housing: 150 180 kg
a Dust seal press fitting dimension (b): a The weight varies with the applicable
2 mm (protruded from the front cover machine.
end face)
a Dust seal is provided only for the
vehicle-mounted engines.
3) Tighten the mounting bolts (1 11) in the

following order.
2 Flywheel housing mounting bolt and
washer: Engine oil (EO30)
1) Apply gasket sealant.
(1 11):
1st time: 352.8 392 Nm {36 40 kgm}
applied as indicated in the figure.
2 Flywheel housing:
2nd time: Loosen them once
3rd time: 392 431.2 Nm {40 44 kgm}
4) Tighten mounting bolts (12) (18) in the
(12 18):
98 122.5 Nm {10 12.5 kgm}
a When installing bolts (14) and (18),
apply adhesive to their threaded
parts.
2 Threaded parts of bolts (14) and (18):
Adhesive (LT-2)
Reference: New bolts have been
coated with adhesive.
32 170E-5 Series
5) Install rear seal 2] Set sleeve (7) of the rear seal to the
a Check the Teflon seal (Laydown lip end of crankshaft (5) and tighten the
seal) by checking the wear of the 5 bolts (45 mm) evenly to press fit
shaft and replace it with the Standard sleeve and rear seal assembly (6)
seal or Sleeved seal. until the end of tool L3 reaches the
a If the shaft is worn to the degree of end of crankshaft (5).
luster (If wear which you feel with
your finger is less than 10 m m) and
does not have any flaw, install the
standard seal. In other cases, install
the sleeved seal.
a The left one in the following figure is
the standard seal and the right one is
the sleeved seal.
3] Remove tool L3 and install tool L2.

a Tighten tool L2 first until it
reaches the bolt (45 mm) and
then tighten the bolt (35 mm).
4] Tighten the 5 bolts evenly to press fit
sleeve and rear assembly (6) until the
end of tool L2 reaches the end of
crankshaft (5).
q Procedure for installing standard seal
a Rear seal driving depth (a): 20
Tighten the bolt evenly to press fit rear seal (4)
mm from end of crankshaft
until the end face of tool L2 reaches the end of
a After press fitting the seal,
crankshaft (5).
remove the red sealant layer
a Press fit dimension (a) (from the end face
from its periphery.
of the shaft: 20 mm)
sealant layer from its periphery.
15. Under plate

1) Raise and invert the engine to move the
q Procedure for installing sleeved seal oil pan side to the top.
a When installing the rear seal, do not apply 2) Apply gasket sealant and then install
oil or grease to the shaft and sleeve inside under plate (1).
cylinder surface (C). 2 Under plate: Gasket sealant (LG-7)
1] Set sleeve and rear seal assembly (6) a Diameter of the gasket sealant line
to tool L3. shall be 2 to 3 mm and it should be
2 Sleeve inside cylinder surface applied to the entire perimeter as
(C): Gasket sealant (LG-7) shown below.
170E-5 Series 33
a Tighten 4 inside positions and several 3) Lift down engine assembly (1) on blocks
outside positions temporarily using [1] and then remove tools C and tool D2.
the bolts until installation of the suc-
tion tube and oil pan is completed.
17. Flywheel assembly

1) Lift and install flywheel assembly (1).
using it.
a Prevent rotation of the flywheel by fix-
ing the space between the flywheel
and flywheel housing.
lowing order.
2 Flywheel assembly mounting bolt:
Engine oil (EO30)
16. Removal from engine repair stand 3 Flywheel assembly mounting bolt:
1) Raise and invert the engine to move the 1st time: 196.1 19.6 Nm {20 2 kgm}
cylinder head side to the top. 2nd time: 460.9 19.6 Nm {47 2 kgm}
2) Using tool C, lift and remove engine 3rd time: 90 120 retightening
assembly (1) from tool D1. a After tightening the bolt, make a
punch mark (a) on its head. (When a
new bolt is used, do not make a
punch mark on its head.)
34 170E-5 Series
2) Fit the gasket and then install burring

device (2).
3) Install Ne speed sensor (1).
3 Ne speed sensor mounting bolt:
4.9 7.9 Nm {0.5 0.8 kgm}
4) Using dial gauge [1], measure the radial

and facial runout of the flywheel.
a Standard radial and facial runout:
Measuring items Tolerance (mm)
Radial runout 0.13
0.0005 x Diameter of
Facial runout
measuring point
a When the measured value is out of

the standard, determine the cause by
disassembling the flywheel again.
170E-5 Series 35
18. Engine mount

1) Install rear engine mount (1).
2] Install supply pump drive gear (4)

while setting it to positioning rod [1].
2) Install front support.

1) Fit the O-ring and install drive case (5).
3] Check that stamps "C" on idler gear

(8) and supply pump drive gear (4)
are set to part (A).
4] Check that the dowel pin is in dowel
2) Position the drive case and drive gear pin hole (B) of supply pump drive
according to the following procedure. gear (4).
1] Pass positioning rod [1] through
flange (6) of the supply pump drive
case and housing (7) as shown in the
figure.
a As the positioning rod, use a
metal rod 11 mm in diameter and
at least 180 mm in length.
a Check that there is stamp "C" at
part (A) of idler gear (8).
36 170E-5 Series
3) Apply gasket sealant and install cover (1).

a Apply gasket sealant in a form of
string 2 3 mm in diameter as shown
in the figure.
a Apply gasket sealant to the flywheel
housing.
2 Flywheel housing (Cover mounting
face): Gasket sealant (LG-7)

1) Assemble the cam follower assembly
1] Install snap spring (6) to shaft (5).
2] Install 2 cam followers (4) to shaft (5).
a Insert the cam followers so that
the shaft side being driven with
the ball may be directed toward
the front side of the engine.
3] Install snap rings (3).

Lift and install vibration damper (1).
4 Vibration damper: 45 kg
2) Crank the crankshaft to set No. 1 No. 3
a When tightening the mounting bolts, pre- pistons to the following positions.
vent rotation of the damper by fixing the q No.1 compression top dead center:
space between the flywheel and flywheel No. 1 and No. 5 pi sto ns c an b e
housing. installed.
3 Vibration damper mounting bolt: q No.2 compression top dead center:
1st time: 53.9 93.1 Nm {5.5 9.5 kgm} No. 2 and No. 4 pi sto ns c an b e
2nd time: 225.4 264.6 Nm {23 27 kgm} installed.
3rd time: 617.4 656.6 Nm {63 67 kgm} q No.3 compression top dead center:
No. 3 and No. 6 pi sto ns c an b e
installed.
a The cylinder must be set to the com-
pression top dead center position.
When insertion of the cam follower is
not available, the piston is not situ-
ated at the compression top dead
center. In this case, rotate the crank-
shaft one more turn.
170E-5 Series 37
3) Install 6 cam follower assemblies (2) in 22. Cylinder head assembly

order. 1) Assemble the cylinder head assembly
a Check that the cam follower shaft on according to the following procedure.
which the ball is driven is directed 1] Install 2 intake valves (6) and 2
toward the front side of the engine. exhaust valves (7) on cylinder head
3 Cam follower assembly mounting (8).
bolt:
90.2 104.0 Nm {9.2 10.6 kgm}
2] Using tool Q, press fit 4 valve stem

seals (5).
4) Install the O-ring and then install cam fol-
lower cover (1).
a When installing the cam follower
cover, check its material (cast iron or
aluminum) and install to its original
position.(The installed position is sub-
ject to the applicable machine.)
a Mounting bolts tightening torque
depends on the position (material of
the cover). (The standard torque is
used for tightening the cast iron-made
cover.)
3 Cam follower cover mounting bolts
(Aluminum-made cover):
9.8 0.98 Nm {1.0 0.1 kgm} 3] Install 4 valve springs (4).
4] Install 4 spring seat (3).
38 170E-5 Series
5] Using tool B, compress the valve

spring and then install 8 valve cotters
(2).
6] After installing the valve cotters, bring
down the cylinder head sideways and
then hit the valve stem lightly with a
plastic hammer to make sure that the
valve cotters are securely fitted in to
the respective valve stems.
2) Install the cylinder head gasket.

3) Lift and install cylinder head assembly (1).
using it.
lowing order.
2 Cylinder head assembly mounting bolt:
Molybdenum disulfide grease (LM-P)
3 Cylinder head mounting bolts (1 7):
1st time: 245 9.8 Nm {25 1 kgm}
2nd time: 382.5 9.8 Nm {39 1 kgm}
3rd time: 90 120 retightening
3 Cylinder head mounting bolts (8 and 9):
93.2 103 kgm {9.5 10.5 kgm}
a After tightening the main bolt, apply a 4) Install coolant air bleeding tube.
punch mark (a) on its head (this mark 3 Air bleeding tube joint bolt (Cylinder
shall not be applied to a new bolt). head side):
9.8 12.7 Nm {1.0 1.3 kgm}
3 Air bleeding tube joint bolt (Other
side):
24.5 34.3 Nm {2.5 3.5 kgm}
170E-5 Series 39
23. Fuel injector assembly 24. Crosshead

a Check that the inside of the injector sleeve 1) Install 12 crossheads (1).
is free from dirt etc.
1) Install gasket sealant (3) and O-rings (4)
and (5) to fuel injector (2).
a Take care not to install O-ring (4) to
groove (A) at the center.
2) Insert fuel injector (2) in adapter (6) and
injector holder (1) and then insert injector
connector (7) in the cylinder head, direct-
ing it toward the high-pressure pipe inser-
tion hole.
2) Adjust the crosshead according to the fol-

lowing procedure.
1] Loosen locknut (2) and then loosen
adjustment screw (3) until it is
detached from valve stem (4).
2] Using your finger, hold down the
crosshead face contacting the rocker
arm to maintain contact between the
push rod side valve stem and cross-
head.
3] Tighten adjustment screw (3) gradu-
3) Fit spherical washer (9) to bolt (8) and
ally to locate the position where
tighten injector holder (1).
2 Spherical washer: Engine oil (EO30)
adjustment screw (3) comes into con-
tact with valve stem (4).
a Tighten the holder mounting bolt after
4] Screw in adjustment screw (3) further
positioning it to the high-pressure
by 20 to 30 from the position where it
pipe.
was contacted against valve stem (4).
5] Tighten locknut (2) while stopping
move of adjustment screw (3) by
hand.
3 Locknut:
53.0 64.7 Nm {5.4 6.6 kgm}
40 170E-5 Series
25. Rocker housing 27. Rocker arm assembly

Apply gasket sealant and then install rocker 1) Assemble the rocker arm assembly
housing (1). according to the following procedure.
2 Rocker housing: Gasket sealant (LG-7) 1] Install adjustment screw (2) on rocker
a Diameter of the gasket sealant line shall arms (4) and (5), and then install lock
be 2 to 3 mm and it should be applied nut (1).
along the housing groove as shown below. a Screw in adjustment screw (2)
a Install O-ring (OR) without fail. until its spherical part touches
3 Rocker housing mounting bolt: rocker arms (4) and (5).
78.4 93.2 Nm {8.0 9.5 kgm}
2] Install rocker arm (5) for air intake

valve and rocker arm (4) for exhaust
valve on shaft (6).
a Insert respective rocker arm at a
position where the riveted side of
the shaft faces the front side of
the engine.
26. Push rod

Install 12 push rods (1).
a Check that the push rod end is securely
placed in the cam follower socket.
2) Install 6 rocker arm assemblies (3).

a When installing, direct the wider seat
of the shaft to the rocker arm housing.
a Make sure that the spherical part of
adjustment screw is securely placed
in the push rod socket.
a When tightening the mounting bolt,
check that adjustment screw (2) is not
pushing the push rod.
2 Threaded portion and seat of rocker
arm assembly mounting bolt:
Engine oil (EO30)
3 Rocker arm assembly mounting bolt:
235.2 254.8 Nm {24 26 kgm}
170E-5 Series 41
a The figure is example of PC1250-8R,

WA600-6R and HD465-7R.
28. Adjusting valve clearance

1) Rotate the crankshaft forward to remove
a Rotate the crankshaft using barring
plug (1) situated in the left of the flywheel
device (2) located in the rear left side
housing.
of the engine.
a The location of plug (1) is subject to
the applicable machine.
3) When No. 1 cylinder is at the compression

indicated by q in the valve layout plan.
2) Align notch (a) of the supply pump drive
a When adjusting, loosen locknut (1) of
gear to the center of the inspection hole.
adjustment screw (2) and insert clear-
a The left side and right side of the fig-
ance gauge M between crosshead
ure represent No.1 cylinder compres-
and rocker arm (3). Then, using
sion top dead center and No.6
adjustment screw (2), adjust the
cylinder compression top dead cen-
clearance to a degree that allows the
ter, respectively.
gauge to slightly move.
a When the cylinder is at the compres-
a Standard valve clearance (In cold
sion top dead center, the rocker arm
state)
can be moved by the valve clearance
q Intake valve: 0.32 0.02 mm
by hand. If the rocker arm cannot be
q Exhaust valve: 0.62 0.02 mm
moved, rotate the crankshaft one
4) While fixing adjustment screw (2), tighten
more turn.
locknut (1).
3 Locknut:
57.8 77.4 Nm {5.9 7.9 kgm}
5) Rotate the crankshaft forward by one turn
to adjust the valve clearance being indi-
cated with Q mark in the valve layout plan.
a The adjustment procedure is the
same as above.
42 170E-5 Series
2) Insert grommet (5) to the rocker housing

and then fix it using plate (4).
3) Install spacer (3).

slit (B) toward the upperside.
6) After adjustment, install plug (1).

3 Plug:
58.8 78.4 Nm {6.0 8.0 kgm}
29. Injector harness

1) Install injector harness (6).
4) Install terminal mounting nuts (1) and wir-
a Insert the harness through inside of
ing harness fixing bolts (2) temporarily in
the engine while directing projection
this order.
(A) of the grommet upward.
a The order reverse to the above does
not allow the terminal to reach the
injector, disabling the connection.
5) Tighten terminal mounting nuts (1) and
wiring harness fixing bolts (2) in this order.
a Tighten the terminal nuts alternately.
3 Terminal mounting nut:
2 0.2 Nm {0.2 0.02 kgm}
170E-5 Series 43
30. Cylinder head cover and tube

1) Install cylinder head cover (3) temporarily.
a Install the cylinder head cover tempo-
rarily so that foreign matter will not
enter.
a Tighten the cylinder head cover
mounting bolts permanently after
tightening the injector holder mount-
ing bolts.
2) Install water tube (1).
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
a Cover (2) is not installed on some
32. Air intake manifold assembly
Sling and install air intake manifold assembly
(1).
4 Air intake manifold assembly: 90 kg

1) Sling and install water housing (4) and
front hanger (3) together.
q Tighten the mounting bolts in the numeric

2) Install water tube (2) and bracket (1).

3 Water tube joint bolt
(Water housing side):
24.5 34.3 Nm {2.5 3.5 kgm}
(Cylinder head side):
9.8 12.7 Nm {1.0 1.3 kgm}
44 170E-5 Series
33. Spill tube 35. High-pressure pipes and brackets

Install spill tube (1). k When handling the high-pressure pipe
3 Spill tube joint bolt: and clamp, observe the following.
19.6 29.4 Nm {2.0 3.0 kgm} q Never bend the high-pressure pipe to
correct before installing or use it for
another section.
k Before installing the high-pressure
pipe, check it. If it has any defect,
replace it since fuel may leak.
q Check the taper seal of the connect-
ing part (Part "a": Part of 2 mm from
34. Common rail the end) for visible lengthwise slit "b"
1) Install fuel junction block (6). and dent "c".
2) Install common rail (5). q Check part "d" (End of the taper seal:
3 Common rail mounting bolt: Part at 2 mm from the end) for
59.0 74.0 Nm {6.0 7.5 kgm} stepped-type wear (fatigue) which
3) Install fuel tube (4). your nail can feel.
3 Fuel tube joint bolt (Common rail
side):
17.7 22.6 Nm {1.8 2.3 kgm}
3 Fuel tube joint bolt (Block side):
9.8 12.7 Nm {1.0 1.3 kgm}
4) Install brackets (3), (2) and (1).
1) Fit O-ring (2) to high-pressure pipe sleeve

(1) and tighten sleeve nut (3) temporarily
while setting the sleeve to the injector con-
nector. Tighten sleeve nut (4) on the com-
mon rail side, too.
a Take care that the high-pressure pipe
will not lean.
170E-5 Series 45
a If sleeve nut (3) does not catch the

threads, turn the spanner while press-
ing the sleeve nut end with a small
rod etc. toward the injector.
4) Install the clamps to the high-pressure
pipe according to the following procedure.
1] Finger tighten 17 high-pressure pipe
clamps (5) as shown in the figure.
2] Finger tighten clamp bracket (6) on
the common rail side and clamp (7)
and then tighten clamp (7) to the
specified torque.
3 Clamp bolt on common rail
side:
9.8 1.0 Nm {1 0.1 kgm}
2) Tighten injector holder (1) permanently. 3] Tighten clamp bracket (6) on the
a While pulling the high-pressure pipe common rail side to the specified
in the opposite direction to the injec- torque.
tor, tighten bolt (8). 4] Tighten high-pressure pipe clamp (5)
3 Injector holder mounting bolt: to the specified torque.
58.9 73.5 Nm {6.0 7.5 kgm} 3 Clamp bolt on high-pressure
pipe side:
11.8 14.7 Nm {1.2 1.5 kgm}
5) Install rubber cap (8) to the sleeve nut on
the common rail side.
a Install the rubber cap with the slit
down.
3) Using a spanner-type torque wrench,

tighten high-pressure pipe sleeve nuts (3)
and (4).
3 Sleeve nut:
39.2 44.1 Nm {4 4.5 kgm}
a Tighten the sleeve nuts while they are
dry. 6) Fit the O-rings and install 6 cylinder head
a After finishing the work, check that O- covers (3).
ring (2) is not projected from the a Only the tightening torque for the No.
sleeve. 2 cylinder mounting bolts is different.
a When installing the only high-pres- 3 Cylinder head cover mounting
sure pipe without removing the fuel bolts:
injector (for example, when replacing No. 1, 3, 4, 5, 6 cylinder:
only the high-pressure pipe with new 9.8 1.0 Nm {1.0 0.1 kgm}
one), follow the procedure below. No. 2 cylinder:
q Tighten sleeve nut (3) by 2 turns 58.8 73.5 Nm {6 7.5 kgm}
with the hand into the threads of
the fuel injector and then tighten
it with the spanner.
46 170E-5 Series
7) Install brackets (2) and (1). 37. Oil pan

1) Apply gasket sealant to the oil pan.
2 Oil pan: Gasket sealant (LG-7)
a Apply gasket sealant in a form of
string 2 3 mm in diameter as shown
in the figure.
36. Suction pipe

1) Sling the engine assembly, set a block
under the engine mount, and lower the
engine assembly again.
a Check that the engine assembly is
fully stabilized. 2) While slinging the engine assembly again,
2) Fit the O-ring and install suction pipe (4) set oil pan (1) under the cylinder block and
and install brackets (3) and (2). lower the engine assembly onto the block.
2 O-ring: Engine oil (EO30) 3) Using guide bolt [1], push up oil pan (1)
a Position the suction pipe and brack- with a jack etc. from underside and install
ets and then tighten the mounting the mounting bolts.
bolts. 4 Oil pan: 85 kg
3 Clamp nut:
10.8 26.4 Nm {1.1 2.7 kgm}
a After installing the suction pipe,
remove all the bolts installed tempo-
rarily to underplate (1).
38. Oil level gauge and oil filler pipe

1) Install oil filler pipe (2).
2) Install oil level gauge (1).
a Install the oil level gauge according to
the following procedure.
q Degrease the periphery of the bush-
ing and coat it with adhesive.
q Insert the nut from underside of the
guide, pass the sleeve through, and
pass the guide through the bushing.
q While holding the guide, tighten the
nut. After the guide is fixed, tighten
the nut to the specified torque.
2 Periphery of oil level gauge:
Adhesive (LT-4)
170E-5 Series 47
3 Oil level gauge:

44.1 58.8 Nm {4.5 6.0 kgm}
41. Oil cooler assembly

Fit the gasket and install oil cooler assembly (1).

1) Fit the O-ring and install drive housing
assembly (2).
a When installing bolt (a), check that its
stem length is 20 mm. If a wrong bolt
is installed, it will interfere with the
parts in the engine.
42. Thermostat housing and thermostat

1) Install thermostats (2) to thermostat hous-
ing (1).
40. Housing and connector assembly, electri-

cal intake air heater and air connector
1) Fit the gasket and install housing and ven-
turi connector assembly (3).
2) Fit the gasket and install electrical intake
air heater (2) and air connector (1).
a When installing the electrical intake
air heater, take care its direction (flow
direction of the heater).
48 170E-5 Series
2) Fit the gasket and install thermostat hous- 44. Supply pump assembly
ing (1). 1) Install supply pump assembly (8), tighten
mounting bolts (7), and install bracket (6).
a Insert the fuel supply pump shaft in
the coupling of the supply pump drive
case.
a There is 1 unsplined part each on the
coupling side and shaft side, which
are used to position the coupling and
shaft.
q The figure shows the coupling of the
supply pump drive case. (Part A is
the unsplined part.)

1) Install water pump assembly (4).
2) Move bypass tube (3) down and fix it with
stopper (2).
3) Fit the gasket and install water pipe (1).

a The type of water pipe (1) is subject
to the applicable machine.
170E-5 Series 49
k When handling the high-pressure pipe 45. Cover and plate

and clamp, observe the following. 1) Install plate (3).
q Never bend the high-pressure pipe to 2) Connect 6 wiring harness connectors (2)
correct before installing or use it for to the plate.
another section. 3) Install cover (1).
1) Install high-pressure pipes (2) and (3)
temporarily to the common rail and fuel
supply pump.
2) Install the bracket and clamp temporarily.
3) Tighten the sleeve nuts of high-pressure
pipes (2) and (3) to the specified torque.
3 High-pressure pipe sleeve nut:
39.2 44.1 Nm {4.0 4.5 kgm} 46. Brackets
4) Tighten clamp (5) to the specified torque. Install brackets (1), (2), (3), (4), (5), (6) and (7).
3 Clamp bolt:
9.8 1.0 Nm {1.0 0.1 kgm}
5) Tighten the bracket mounting bolts to the
specified torque.
6) Install 4 rubber caps (4) to the sleeve nuts.
a Install each rubber cap with the slit
toward the outside of the engine.
7) Install fuel tube (1).
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Fuel tube sleeve nut (Junction
block side):
54 93 Nm {5.5 9.5 kgm}
47. Lubrication tube
1) Fit the O-ring and install adapter (2).
2) Install oil tube (1).
3 Oil tube joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
3) Connect the 2 tube clamps.
50 170E-5 Series
48. Engine controller and cooling plate a Fit the washers to the bottom of the
1) Install cooling plate (3). clamp.
3 Cooling plate mounting bolt: 8) Install fuel tube (1) and install the 1 clamp.
58.8 73.5 Nm {6 7.5 kgm} 3 Fuel tube joint bolt (Air intake mani-
2) Install fuel hose (2). fold side):
3 Hose sleeve nut (Cooler side): 24.5 34.3 Nm {2.5 3.5 kgm}
84 132 Nm {8.5 13.5 kgm} 3 Fuel tube sleeve nut (Fuel inlet/out-
3 Hose joint bolt (Supply pump side): let block side):
14.8 19.6 Nm {1.51 1.99 kgm} 24 27 Nm {2.4 2.7 kgm}
3) Install engine controller (1). a Fit the washers to the bottom of the
3 Engine controller mounting bolt: clamp.
24 Nm {2.4 kgm}
50. Fuel prefilter and filter head assembly

49. Electric priming pump, block and air bleed- 1) Install fuel prefilter and filter head assem-
ing valve bly (3).
1) Install air bleeding valve (8) and bracket 2) Install fuel tube (2) to the filter head.
together. 3 Fuel tube sleeve nut (Filter head
2) Install electric priming pump (7). side):
3) Install block (6). 43 47 Nm {4.4 4.8 kgm}
4) Install fuel tube (5). 3 Fuel tube joint bolt (Supply pump
3 Fuel tube joint bolt: side):
19.6 29.4 Nm {2.0 3.0 kgm} 14.8 19.6 Nm {1.51 1.99 kgm}
5) Install fuel tube (4) and install the 3 3) Install fuel tube (1) to the filter head and
clamps. install the 3 clamps.
3 Fuel tube joint bolt: 3 Fuel tube joint bolt:
7.8 9.8 Nm {0.8 1.0 kgm} 19.6 29.4 Nm {2.0 3.0 kgm}
a Fit the washers to the bottom of the
clamp.
6) Install fuel tube (3) and install the 1 clamp.
3 Fuel tube joint bolt (Fuel inlet/outlet
block side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Fuel tube sleeve nut (Cooling plate
side):
43 47 Nm {4.4 4.8 kgm}
7) Install fuel tube (2) and install the 3
clamps.
3 Fuel tube joint bolt (Junction block
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Fuel tube sleeve nut (Fuel inlet/out-
let block side:
24 27 Nm {2.4 2.7 kgm}
170E-5 Series 51
51. Cover 53. Fuel filter and filter head assembly

Install cover (1). 1) Install fuel filter and filter head assembly
(2).
2) Install fuel tube (1) and install the 1 clamp.
3 Fuel tube joint bolt (Filter head
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Fuel tube sleeve nut (Fuel inlet/out-
let block side):
24 27 Nm {2.4 2.7 kgm}

1) Install corrosion resistor and filter head
assembly (2).
2) Install water tube (1) to the filter bracket.
3 Water tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
54. Oil filter and filter head assembly

1) Install oil filter and filter head assembly
(5).
a Install the front filter temporarily since
it will be removed when the alternator
is installed.
2) Fit the O-ring, install oil tubes (3) and (4),
and install bracket (1).
a Install the yellow-painted tube out.
3) Install clamp (2).
52 170E-5 Series

1) Install main fuel filter and filter head
assembly (5).
clamps.
3 Fuel tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
side):
14.8 19.6 Nm {1.51 1.99 kgm}
clamps.
3 Fuel tube joint bolt (Main fuel filter
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Fuel tube joint bolt (Supply pump 57. Alternator assembly
side): 1) Remove front oil filter (1).
14.8 19.6 Nm {1.51 1.99 kgm} 2) Install alternator assembly (2).
4) Install fuel tube (2) and install the 1 clamp. a Insert the mounting bolts from the
3 Fuel tube joint bolt: rear side toward the front side. (If
7.8 9.8 Nm {0.8 1.0 kgm} they are inserted from the front side,
a Fit the washers to the top and bottom they cann ot be pul led out wh en
of the clamp. mounted on the machine.
5) Install 5 clamps (1). 3) Install front oil filter (1).
56. Pulley, tensioner and air conditioner com- 58. Air conditioner compressor
pressor bracket Install air conditioner compressor (1).
1) Install air conditioner compressor bracket
(4).
2) Install tensioner (3).
3) Tighten bolt (2).
4) Pull out stopper bolt [1].
5) Install pulley (1).
170E-5 Series 53
59. Auxiliary machine belt

1) Install auxiliary machine belt (3).
2) Loosen adjustment bolt (1) to dimension
"a" to give the tension of tensioner (2) to
auxiliary machine belt (3).
Dimension "a": 90 mm
3) Tighten the locknut of adjustment bolt (1).
2) Sling exhaust manifold assembly (1), fit

the gaskets, and install the exhaust mani-
fold assembly.
60. Cover and brackets

1) Install brackets (3) and (2).
a Tighten the mounting bolts in the

numeric order shown in the figure.
2 Exhaust manifold mounting bolt:
2 Exhaust manifold mounting bolt:
1st time:
61. Exhaust manifold assembly 39.2 58.8 Nm {4.0 6.0 kgm}
1) If the exhaust manifold assembly was dis- 2nd time:
assembled, apply adhesive (heat-resistant 98.1 122.6 Nm {10 12.5 kgm}
sealant) to joints (A) (2 places) and
assembly the exhaust manifold assembly.
2 Exhaust manifold joint:
Liquid adhesive (Holtz MH705)
54 170E-5 Series

1) Sling turbocharger assembly (5), fit the
gasket, and install the turbocharger
assembly.
nut:
nut:
78.5 88.3 Nm {8.0 9.0 kgm}
63. Exhaust temperature sensor

1) Install brackets (4), (3) and (2).
2) Install exhaust temperature sensor (1).
3 Exhaust temperature sensor:
2.9 5.9 Nm {0.3 0.6 kgm}
3) Install the 4 wiring harness clamps.
2) Fit the gasket, install turbocharger inlet

tube (4), and install the 2 clamps.
3 Oil tube joint bolt (Cylinder block
side):
24.5 34.3 Nm {2.5 3.5 kgm}
3) Install water tube (3).
3 Oil tube joint bolt (Cylinder block
side):
24.5 34.3 Nm {2.5 3.5 kgm}
4) Fit the gasket, install turbocharger outlet 64. Starting motor assemblies
tube (2), and install the 1 clamp. 1) Install starting motor assemblies (4) and
5) Install water tube (1) and bracket together. (3) and connect wiring harness (2).
3 Water tube joint bolt (Turbocharger 2) Install bracket (1) and connect the wiring
side): harness connector.
24.5 34.3 Nm {2.5 3.5 kgm}
3 Water tube sleeve nut (Air vent
tube side):
24.5 59.0 Nm {2.5 6.0 kgm}
3 Water tube union bolt (End of air
vent tube):
53.9 73.5 Nm {5.5 7.5 kgm}
170E-5 Series 55
65. Engine wiring harness assembly 68. Sensor tightening torque

Install engine wiring harness (1) to the engine When a sensor is replaced, tighten a new sen-
assembly and connect the connectors and ter- sor to the following torque.
minals.
Sensor name Tightening torque
Ne speed 4.9 7.9 Nm {0.5 0.8 kgm}
Fuel temperature 23 3 Nm {2.35 0.3 kgm}
Coolant tempera-
23 3 Nm {2.35 0.3 kgm}
ture
Engine oil pressure 23 3 Nm {2.35 0.3 kgm}
Fuel pressure Never disassemble.
Intake air tempera-
23 3 Nm {2.35 0.3 kgm}
ture
Engine oil tempera-
23 3 Nm {2.35 0.3 kgm}
ture
66. Blow-by tube and covers

1) Install covers (3) and (2). 69. Checking of fuel leakage
2) Install blow-by tube (1). a If fuel supply pump (1), common rail (2), or
high-pressure piping (3) is removed and
installed, after assembling the engine,
check for fuel leakage according to the fol-
lowing procedure.
67. Air piping

1) Sling air piping (3) and fix it with U-clamp
(2).
3 U-clamp nut:
34.3 44.1 Nm {3.5 4.5 kgm} a Clean and degrease the engine and the
2) Tighten connecting hose clamp (1) of the parts around it in advance so that you can
turbocharger and air piping. test it easily for fuel leakage.
3 Hose clamp: 1) Spray color checker (developer) over the
9.8 1.0 Nm {1.0 0.1 kgm} fuel supply pump, common rail, fuel injec-
tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
leakage.
4) Run the engine at low idle.
leakage.
56 170E-5 Series

6) Run the engine at high idle.
leakage.
8) Run the engine at high idle and load it.
a When checking while the components
to be checked are mounted on the
machine, stall the torque converter or
relieve the hydraulic pump.
leakage.
a If no fuel leakage is detected, the
check is completed.
170E-5 Series 57
SEN00767-01
2007 KOMATSU
All Rights Reserved
58
SEN00768-01
ENGINE 1SHOP MANUAL
170E-5 Series

Disassembly and assembly, Part 3 ................................................................................................................. 2
Removal and installation of fuel supply pump unit ............................................................................... 2
Rear oil seal ......................................................................................................................................... 7
170E-5 Series 1
Disassembly and assembly, Part 3 1

Removal and installation of fuel 8. Remove clamps (10) to (12). [*4]
supply pump unit 1 9. Remove high-pressure pipings (13) and (14).
[*4]
Removal
1. Move engine harness (1) situated around the
fuel supply pump.
2. Remove stays (2).
10. Remove bracket (15). [*5]
3. Remove harness bracket (3).

4. Remove fuel tubes (4) to (6). [*1]
5. Remove oil tube (7). [*2]
11. Removal fuel supply pump (16). [*6]

a Leave fuel supply pump drive case (17) on
the engine.
6. Disconnect wiring harness (8) from the fuel

supply pump.
7. Remove fuel tube (9). [*3]
2 170E-5 Series
12. Remove oil tube (18) and bracket (19) 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 (Main fuel filter 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}
Sleeve nut: 43 47 Nm {4.4 4.8 kgm}
3 Fuel tube (6)
Joint bolt:
14.8 19.6 Nm {1.51 1.99 kgm}
[*2]
3 Oil tube (7)
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 (9)
Joint bolt: 24.5 34.3 Nm {2.5 3.5 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.
k Before installing the high-pressure piping,
check it for the following defects. If there is
any of these defects, it can cause fuel leak-
age. Accordingly, replace the high-pressure
piping.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
170E-5 Series 3
q Check part (d) (end of the taper seal: Part [*6]

at 2 mm from the end) for stepped-type a Insert the fuel supply pump shaft aligning it to
wear (fatigue) which your nail can feel. 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.)
a Install the high-pressure piping between the

common rail and fuel supply pump in the fol-
lowing procedure.
1) Install high-pressure pipings (12) and (13)
temporarily on the common rail and fuel
supply pump.
2) Install the bracket and clamp temporarily.
3) Tighten the sleeve nuts of high-pressure [*7]
pipings (12) and (13) with the specified 3 Oil tube (18) joint bolt:
torque. 7.9 12.7 Nm {0.8 1.3 kgm}
3 High-pressure piping sleeve nut: (Supply pump side)
39.2 44.1 Nm {4.0 4.5 kgm} 9.8 12.7 Nm {1.0 1.3 kgm}
4) Tighten the clamp with the specified (Bracket side)
torque. 3 Bracket (19) mounting bolt:
3 Clamping bolt: 19.6 29.4 Nm {2.0 3.0 kgm}
9.8 1.0 Nm {1 0.1 kgm}
5) Tighten the bracket mounting bolt with the a Exchange 4 gaskets (G):
specified torque. Part number is 07005-01012
6) Install rubber cap on the sleeve nut.
[*5]
3 Bracket (15) mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
4 170E-5 Series
Replacement of oil seal of engine a CS: Crankshaft

mounted on machine
1. Front oil seal
Removal
a For the work up to removal of the crankshaft
pulley (vibration damper), see the shop manual
for the applicable machine.
1) Remove dust seal (1).
a Dust seal is equipped with only the
engines mounted on vehicles.
2) Remove front oil seal (2) in the following pro-
cess.
Installation
Install front oil seal (2) according to the following
procedure.
a Before installing the seal, check that the end
corners and lip sliding surfaces of the crank-
shaft are free from flaw, burr, and rust of the
housing.
a When installing the seal, do not apply oil or
grease to the shaft and seal lip. Wipe off the oil
from the shaft.
1) Install the oil seal with the side having the
stamp of "IN" on the inside of the engine.
a The side having the stamp of "OUT" must be
on the outside of the engine.
1] Replace the tip of tool K1 with the a Take care not to mistake the direction of the
hook type one. plastic inside cylinder.
2] Hitch the hook to the hoop of front
seal (2).
3] Remove front seal with impact of slide
hammer (SH).
q Tool K1
170E-5 Series 5
2) Using tool K2, press fit oil seal (2) to the front
case until dimension (a) is obtained. (When the
dust seal is not provided)
a Oil seal press fitting dimension (a): 18.5 mm
3) Using tool K3, press fit dust seal (2) to the front
case until dimension (b) is obtained. (When the
dust seal is provided)
a Dust seal press fitting dimension (b):
2 mm (Projection out of the front cover
end face)
a Dust seal is provided only for the vehicle-
mounted engines.
6 170E-5 Series
2. Rear oil seal Installation

a For the work up to removal of the flywheel, a Check the Teflon seal (Laydown lip seal) by
see the shop manual for the applicable checking the wear of the shaft and replace it
machine. with the Standard seal or Sleeved seal.
a For the standard seal and seal with a If the shaft is worn to the degree of luster (If
sleeve, see "Installation". wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
Removal of standard seal the standard seal. In other cases, install the
Hitch the end of tool L1 to the metal ring of sleeved seal.
seal (1) and pull out the seal with impacts of a The left one in the following figure is the stan-
slide hammer [1]. dard seal and the right one is the sleeved seal.
a Before pulling out the seal, drive in it a lit-
tle to separate it from the housing for the
ease of removal.
a Do not use a drill, etc. since chips may
enter the engine.
Removal of sleeved seal

1) Hitch the end of tool L1 to the metal ring of
seal (1) and pull out the seal with impacts
of slide hammer [1].
a Before pulling out the seal, drive in it
a little to separate it from housing (2)
for the ease of removal.
2) Cut and remove sleeve (3) with a chisel
and a hammer.
a When cutting the sleeve, take care
extremely not to damage crankshaft
(4).
a Remove all the chips.
170E-5 Series 7
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.
4) Tighten bolts evenly until the end face of tool

L2 reaches the end face of crankshaft (4) to
press fit seal (1).
1) Set the large inside diameter side (b) of plastic sealant layer from its periphery.
inside cylinder (3) to the end of crankshaft (4).
a Extremely take care not to mistake the
direction of the plastic inside cylinder.
8 170E-5 Series
Procedure for installing sleeved seal

a When installing the rear seal, do not apply oil
or grease to the shaft and sleeve inside cylin-
der surface (C).
1) Set sleeve and rear seal assembly (6) to
tool L3.
2 Sleeve inside cylinder surface (C):
2) Set sleeve (7) of the rear seal to the end of
crankshaft (5) and tighten the 5 bolts (45
mm) evenly to press fit sleeve and rear
seal assembly (6) until the end of tool L3
reaches the end of crankshaft (5).
3) Remove tool L3 and install tool L2.

a Tighten tool L2 first until it reaches
the bolt (45 mm) and then tighten the
bolt (35 mm).
4) Tighten the 5 bolts evenly to press fit
sleeve and rear seal assembly (6) until the
end of tool L2 reaches the end of crank-
shaft (5).
a Rear seal driving depth (a): 20 mm
from end of crankshaft
a After press fitting the seal, remove the
red sealant layer from its periphery.
170E-5 Series 9
SEN00768-01
2007 KOMATSU
All Rights Reserved
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Saa6d170e-5 Shop Manual

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SEN00190-06

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual................................................................................................................ 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00190-06

00 Index and foreword SEN00191-06

10 Structure, function and maintenance standard SEN00196-02

20 Standard value table SEN00199-02

30 Testing and adjusting SEN00200-01

50 Disassembly and assembly SEN00202-01

Foreword and general information SEN00193-03

10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 2 SEN00198-02

20 Standard value table

30 Testing and adjusting

Reduced cylinder mode operation........................................................................................... 38

E-44 Code [553/CA553] Rail Press. High Error....................................................................... 8

50 Disassembly and assembly

Disassembly and assembly, Part 2 (EGR-less) SEN00767-01

KOMATSU 170E-5 Series engine

Form No. SEN00192-06

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Safety notice 1 (Rev. 2007/03)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.