SEN00190-13.pdf D170-5

SEN00190-13
ENGINE 170E -5 SERIES

SEN00192-13
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
SEN00192-13 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 ............................................................ SEN00190-13
00 Index and foreword ......................................................................................................... SEN00191-13

Index ............................................................................................................................... SEN00192-13 q
Foreword and general information .................................................................................. SEN00193-04
01 Specification.................................................................................................................... SEN00194-05
Specification and technical data...................................................................................... SEN00195-05
10 Structure, function and maintenance standard ............................................................... SEN00196-06

Structure, function and maintenance standard, Part 1.................................................... SEN00197-06
Structure, function and maintenance standard, Part 2.................................................... SEN00198-05
20 Standard value table ....................................................................................................... SEN00199-05

Standard service value table........................................................................................... SEN00367-05
30 Testing and adjusting ...................................................................................................... SEN00200-04

Testing and adjusting ...................................................................................................... SEN00368-04
40 Troubleshooting .............................................................................................................. SEN00201-03

General information on troubleshooting.......................................................................... SEN00369-03
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00371-02
Troubleshooting of electrical system (E-mode), Part 2 ................................................... SEN00372-01
Troubleshooting of mechanical system (S-mode)........................................................... SEN00370-02
50 Disassembly and assembly ............................................................................................ SEN00202-05

General information on disassembly and assembly ....................................................... SEN00765-03
Disassembly and assembly, Part 1 (With EGR).............................................................. SEN00766-04 q
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00767-04 q
Disassembly and assembly, Part 3 ................................................................................. SEN00768-02
90 Repair and replacement of parts..................................................................................... SEN05193-02

Information related to repair and replacement ................................................................ SEN05194-02
Parts related to cylinder head ......................................................................................... SEN05195-01
Parts related to cylinder block......................................................................................... SEN05196-01
2 170E-5 Series
00 Index and foreword SEN00192-13
Table of contents 1
00 Index and foreword
Index SEN00192-13
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00193-04
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 SEN00195-05
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 16
Weight table............................................................................................................................. 33
Engine performance curves..................................................................................................... 35
10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 1 SEN00197-06
Air cleaner ............................................................................................................................... 4
Turbocharger ........................................................................................................................... 6
EGR system ............................................................................................................................ 11
Cylinder head .......................................................................................................................... 18
Cylinder block .......................................................................................................................... 22
Cylinder liner............................................................................................................................ 26
Main moving parts ................................................................................................................... 28
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
Structure, function and maintenance standard, Part 2 SEN00198-05
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
170E-5 Series 3
Fuel piping ............................................................................................................................... 38

Fuel filter .................................................................................................................................. 40
Electric priming pump .............................................................................................................. 42
Engine controller cooler ........................................................................................................... 43
Cooling system............................................................................................................................ 44
Cooling system diagram .......................................................................................................... 44
Water pump ............................................................................................................................. 46
Thermostat............................................................................................................................... 48
Fan drive.................................................................................................................................. 50
Electrical equipment .................................................................................................................... 52
Alternator ................................................................................................................................. 52
Starting motor .......................................................................................................................... 56
Starting aid............................................................................................................................... 59
Engine controller...................................................................................................................... 60
20 Standard value table

Standard service value table SEN00367-05
Standard service value table for testing, adjusting, and troubleshooting ................................. 2
Running-in standard and performance test standard .............................................................. 12
30 Testing and adjusting

Testing and adjusting SEN00368-04
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........................................................................................................ 29
Testing exhaust temperature ................................................................................................... 30
Adjusting valve clearance ........................................................................................................ 31
Testing compression pressure ................................................................................................. 33
Testing blow-by pressure ......................................................................................................... 35
Testing engine oil pressure ...................................................................................................... 36
Handling fuel system parts ...................................................................................................... 37
Releasing residual pressure in fuel system ............................................................................. 37
Testing fuel pressure................................................................................................................ 38
Reduced cylinder mode operation ........................................................................................... 39
No-injection cranking ............................................................................................................... 39
Testing leakage from pressure limiter and return rate from injector......................................... 40
Bleeding air from fuel circuit .................................................................................................... 43
4 170E-5 Series
Testing fuel system for leakage ............................................................................................... 45

Handling controller voltage circuit............................................................................................ 46
40 Troubleshooting
General information on troubleshooting SEN00369-03
Points on troubleshooting ........................................................................................................ 2
Error code and failure code table ............................................................................................ 4
Information in troubleshooting table ........................................................................................ 6
Connection table for connector pin numbers ........................................................................... 8
T- branch box and T- branch adapter table ............................................................................. 44
Troubleshooting of electrical system (E-mode), Part 1 SEN00371-02
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
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
E-44 Code [553/CA553] Rail Press. High Error....................................................................... 8
E-45 Code [559/CA559] No-pressure feed by supply pump 1 ................................................ 10
170E-5 Series 5
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) SEN00370-02
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 SEN00765-03
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Disassembly and assembly, Part 1 (With EGR) SEN00766-04
General disassembly of engine ............................................................................................... 2
General assembly of engine .................................................................................................... 22
Disassembly and assembly, Part 2 (EGR-less) SEN00767-04
General disassembly of engine ............................................................................................... 2
General assembly of engine .................................................................................................... 22
6 170E-5 Series
Disassembly and assembly, Part 3 SEN00768-02

Removal and installation of fuel supply pump unit .................................................................. 2
Replacement of oil seal of engine mounted on machine......................................................... 5
90 Repair and replacement of parts

Information related to repair and replacement SEN05194-02
Flowchart ................................................................................................................................. 2
Special tool table ..................................................................................................................... 4
Parts related to cylinder head SEN05195-01
Part names related to cylinder head........................................................................................ 2
Testing and inspection of cylinder head................................................................................... 3
Pressure test of cylinder head ................................................................................................. 5
Replacement of valve guide .................................................................................................... 5
Replacement of valve seat insert ............................................................................................ 6
Replacement of crosshead guide ............................................................................................ 14
Repair of cylinder head mounting face by grinding ................................................................. 15
Repair of valve by grinding ...................................................................................................... 16
Parts related to cylinder block SEN05196-01
Part names related to cylinder block ....................................................................................... 2
Testing and inspection of cylinder block .................................................................................. 3
Part names related to crankshaft............................................................................................. 6
Testing and inspection of crankshaft ....................................................................................... 7
Part names related to connecting rod...................................................................................... 8
Testing and inspection of connecting rod ................................................................................ 9
Replacement of flywheel ring gear .......................................................................................... 10
Replacement of crankshaft gear.............................................................................................. 11
Replacement of camshaft gear................................................................................................ 12
Replacement of main bearing metal cap ................................................................................. 13
Replacement of connecting rod small end bushing................................................................. 15
Replacement of cam bushing .................................................................................................. 16
Replacement of engine rear seal............................................................................................. 18
Repair of cylinder block top by grinding................................................................................... 19
Repair of counterbore by grinding ........................................................................................... 20
Check and identification after repair by grinding...................................................................... 22
Gasket sealant application procedure ..................................................................................... 23
Repair of crankshaft by grinding .............................................................................................. 26
Improvement of surface roughness of crankshaft journal........................................................ 31
170E-5 Series 7
SEN00192-13
KOMATSU 170E-5 Series engine
Form No. SEN00192-13
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 02-11
8
SEN00193-04
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. 2008/08)
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. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
q Always wear safety glasses when hit- Wearing protective goggles
7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 170E-5 Series
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. larly careful to check that they are
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
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 well seen
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
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
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- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
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,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
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 chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
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 or allow-

able dimension
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, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
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 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 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 95, 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 engines

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 95, 125 – 170, 12V140 engines 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 sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (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-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
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.
a The following table applies 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 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
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 applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
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
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
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 face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. 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 — —
34 170E-5 Series
8. 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 8±2 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
9. 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.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
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.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–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
SEN00193-04
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)
42
SEN00195-05
ENGINE 1SHOP MANUAL
170E-5 Series
01 Specification 1
Specification and technical data
Outline............................................................................................................................................................. 2
Specifications .................................................................................................................................................. 6
General view ................................................................................................................................................. 16
Weight table .................................................................................................................................................. 33
Engine performance curves .......................................................................................................................... 35
170E-5 Series 1
SEN00195-05 01 Specification
Outline 1
1. Applicable machine
Engine Engine serial No. Applicable machine

D375A-5E0
D375A-5R
Bulldozer
D375A-6
D375A-6R
PC1250-8
Hydraulic excavator
PC1250-8R
SAA6D170E-5 WA600-6
Wheel loader
WA600-6R
WD600-6 Wheel dozer
HD465-7E0
Dump truck
HD465-7R
HD605-7E0
Dump truck
HD605-7R
2 170E-5 Series
01 Specification SEN00195-05
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.
and attained low fuel consumption, low noise, As a result, the lubricating oil on the piston is
better exhaust gas color, and high acceleration not exposed to high temperature, thus it is not
performance. deteriorated.
Accordingly, this newly developed engine is Since the high-pressure fuel injection system
suitable as a power source of construction controlled electronically is employed, less soot
machinery and industrial machinery used for is produced and the draining interval of the oil
various purposes. 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.
nologies. In addition, this system can control the form of
injection most properly by electronic control
1) The main components of the cooled EGR sys- according to the speed and load.
tem are the EGR cooler of corrugated tube By heightening the injection accuracy and
type made of newly developed special stain- employing multiple injection, exhaust gas of
less steel and the EGR valve driven hydrauli- the cleanest level in the world, good exhaust
cally and controlled electronically which gas color, low fuel consumption, and low noise
KOMATSU developed by itself. are realized simultaneously.
The cooled EGR system secures the optimum
EGR rate from the low-speed range to the 6) The main fuel filter of high efficiency and the
high-speed range to attain both clean exhaust pre-fuel filter are installed as standard so that
gas and low fuel consumption with the bypass the low grade fuel in the market (equivalent to
assist circuit consisting of the venturi system Class NAS12) can be used.
and bypass valve which has the same function In addition, the priming pump used for replac-
and structure as those of the EGR valve. ing the filters is electrified to improve service-
ability.
2) The special EGR oil pump is employed to gen-
erate high oil pressure (1.47 MPa {15 kg/cm2}) 7) The high-quality piston which is made of cast
as the drive power source of the EGR valve iron and has the 2-stage combustion chamber
driven hydraulically and controlled electroni- of a new shape is employed. This piston has a
cally. less coefficient of thermal expansion, a reen-
This pump has sufficient delivery for the EGR trant combustion chamber, and a shaker cool-
valve and increased output of the engine. As a ing gallery.
result, the reliability and durability of the engine As a result, clean exhaust gas, good exhaust
are improved. gas color, and low fuel consumption are
attained simultaneously, and high durability
3) The 170E-5 engine has 3 combination filters of and reliability are also obtained.
high performance and high efficiency to meet
the requirements of the EGR system and high- 8) By using the above-mentioned high-pressure
dispersion oil and improve the ability to capture fuel injection system controlled electronically,
the soot in the oil. the multiple injection and injection characteris-
In addition, the recommended sub-materials tics are set most properly to improve the start-
for operation (oil and fuel) are changed to ability and reduce the white exhaust smoke
improve the reliability and durability of the when the temperature is low.
engine.
170E-5 Series 3
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.
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 pres-
sure 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 reli-
ability.
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. of a new shape is employed. This piston has a
Accordingly, this newly developed engine is less coefficient of thermal expansion, a reen-
suitable as a power source of construction trant combustion chamber, and a shaker cool-
machinery and industrial machinery used for ing gallery.
various purposes. As a result, clean exhaust gas, good exhaust
gas color, and low fuel consumption are
q The 170E-5 engine is the successor to the attained simultaneously, and high durability
170E-3 engine. While it is an in-line 6-cylinder, 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. and has been employed for many engines and
As a result, the lubricating oil on the piston is has high reliability and high performance is
not exposed to high temperature, thus it is not mounted.
deteriorated. Besides; the efficiency of the blower impeller is
Since the high-pressure fuel injection system heightened and the strength of its material is
controlled electronically is employed, less soot improved to obtain higher efficiency and pres-
is produced and the draining interval of the oil sure ratio.
is lengthened. Since the design of the shaft is improved to
increase the reliability, high performance is
3) The common rail high-pressure fuel injection obtained from the low-speed range to the high-
system controlled electronically is employed. speed range.
This system can inject the fuel at high pressure As a result, the engine has high performance
of 160 MPa {1,600 kg/cm2} from the low-speed and consumes less fuel and attains high reli-
range to the high-speed range. ability.
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 simultaneously.
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 replac-
ing the filters is electrified to improve service-
ability.
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 — 1–5–3–6–2–4
Overall length mm 1,853
Dimensions
Overall width mm 1,225

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 224.4 {167}
{g/HPh}
Dry weight kg 2,970
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 86 (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-6
Dimensions

474.4 {636}/1,800
(Gross)
3,020 {308}/1,300
Performance
(Gross)
No-load max. speed
rpm 1,900 ± 25
(High idle speed)
No-load min. speed
rpm 720 ± 30
(Low idle speed)
g/kWh
Fuel consumption ratio at rated output 225.7 {168}
{g/HPh}
Dry weight kg 2,970
With cooled EGR
170E-5 Series 7

Applicable machine D375A-5R
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
Fuel consumption ratio at rated output 211 {157}
{g/HPh}
Dry weight kg 3,035
8 170E-5 Series

Applicable machine D375A-6R
Dimensions

474.4 {636}/1,800
(Gross)
3,020 {308}/1,300
Performance
(Gross)
No-load max. speed
rpm 1,900 ± 25
(High idle speed)
No-load min. speed
rpm 750 ± 25
(Low idle speed)
g/kWh
{g/HPh}
Dry weight kg 3,035
170E-5 Series 9

Applicable machine PC1250-8
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
With cooled EGR
10 170E-5 Series

Applicable machine PC1250-8R
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
170E-5 Series 11

Applicable machine WA600-6, WD600-6
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
With cooled EGR
12 170E-5 Series

Applicable machine WA600-6R
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
170E-5 Series 13

Applicable machine HD465-7E0, HD605-7E0
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
With cooled EGR
14 170E-5 Series

Applicable machine HD465-7R, HD605-7R
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
170E-5 Series 15
General view 1
SAA6D170E-5 (Left side of engine)
Applicable machine: D375A-5E0, D375A-6
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
16 170E-5 Series
SAA6D170E-5 (Front side of engine)

Applicable machine: D375A-5E0, D375A-6

2. Center of cylinder liner
170E-5 Series 17

Applicable machine: D375A-5R, D375A-6R

18 170E-5 Series

Applicable machine: D375A-5R, D375A-6R

170E-5 Series 19

Applicable machine: PC1250-8

20 170E-5 Series

Applicable machine: PC1250-8

170E-5 Series 21

Applicable machine: PC1250-8R

22 170E-5 Series

Applicable machine: PC1250-8R

170E-5 Series 23

Applicable machine: WA600-6, WD600-6

24 170E-5 Series

Applicable machine: WA600-6, WD600-6

170E-5 Series 25

Applicable machine: WA600-6R

26 170E-5 Series

Applicable machine: WA600-6R

170E-5 Series 27

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

28 170E-5 Series

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

170E-5 Series 29

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

30 170E-5 Series

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

170E-5 Series 31
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
D375A-6
1,854 2,130 550 25 — — 1,107 1,286
D375A-6R
PC1250-8
1,800 2,032 560 222 — 1,000 1,185 1,215
PC1250-8R
SAA6D170E-5
WA600-6, WD600-6
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.
32 170E-5 Series
Weight table 1
(with EGR)
Unit: kg
No. Item Main parts SAA6D170E-5
D375A-5E0
33.5
D375A-6
PC1250-8 36
1 Turbocharger KOMATSU KTR130E WA600-6
33.5
WD600-6
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
D375A-6
PC1250-8 80
6 Flywheel assembly Flywheel, ring gear WA600-6
36
WD600-6
HD465-7E0
43
HD605-7E0
D375A-5E0
170
D375A-6
PC1250-8 150
7 Flywheel housing assembly WA600-6
150
WD600-6
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 33
(EGR-less)
Unit: kg
No. Item Main parts SAA6D170E-5
D375A-5R
41
D375A-6R
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 840
cap, cylinder liner
4 Front cover 47
5 Oil pan 56
D375A-5R
82
D375A-6R
PC1250-8R 80
6 Flywheel assembly Flywheel, ring gear
WA600-6R 36
HD465-7R
43
HD605-7R
D375A-5R
170
D375A-6R
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
34 170E-5 Series
Engine performance curves 1
Engine Engine serial No. Applicable machine Page

D375A-5E0
36
D375A-5R
D375A-6
37
D375A-6R
PC1250-8
38
PC1250-8R
SAA6D170E-5
WA600-6, WD600-6
39
WA600-6R
HD465-7E0
HD465-7R
40
HD605-7E0
HD605-7R
170E-5 Series 35
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)
36 170E-5 Series
SAA6D170E-5 (Applicable machine: D375A-6, D375A-6R)
Rated output: 474.4 kW {636 HP}/1,800 rpm (Gross)

170E-5 Series 37
SAA6D170E-5 (Applicable machine: PC1250-8, PC1250-8R)

Max. torque: 3,025 Nm {308.5 kgm}/1,300 rpm (Gross)
38 170E-5 Series
SAA6D170E-5 (Applicable machine: WA600-6, WA600-6R, WD600-6)

Max. torque: 2,594 Nm {264.5 kgm}/1,000 rpm (Gross)
170E-5 Series 39
SAA6D170E-5 (Applicable machine: HD465-7E0, HD465-7R, HD605-7E0, HD605-7R)

40 170E-5 Series
170E-5 Series 41
SEN00195-05
© 2010 KOMATSU
All Rights Reserved
42
SEN00197-06
ENGINE 1SHOP MANUAL
170E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 1
Air cleaner....................................................................................................................................................... 4
Turbocharger................................................................................................................................................... 6
EGR system...................................................................................................................................................11
Cylinder head................................................................................................................................................ 18
Cylinder block ............................................................................................................................................... 22
Cylinder liner ................................................................................................................................................. 26
Main moving parts......................................................................................................................................... 28
Crankshaft..................................................................................................................................................... 30
Camshaft....................................................................................................................................................... 32
Connecting rod.............................................................................................................................................. 33
Piston, piston ring and piston pin .................................................................................................................. 34
170E-5 Series 1
SEN00197-06 10 Structure, function and maintenance standard
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
10 Structure, function and maintenance standard SEN00197-06
170E-5 Series 3
Air cleaner 1
ERB type
[Air cleaner of automatic exhaust gas discharge type (Radial seal type)]
A: Air inlet C: To muffler (Dust)

B: To turbocharger (Intake air)
1. Inner element 4. Tube

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

Engine Type
machine dust from pre-cleaner elements
D375A-5E0
D375A-5R
D375A-6
D375A-6R
Automatic discharge 1 inner element
SAA6D170E-5 PC1250-8 Komaclone, multi-cyclone (ERB type)
(Exhaust ejector) 1 outer element
PC1250-8R
WA600-6
WA600-6R
WD600-6
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
10 170E-5 Series
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
170E-5 Series 17
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})
—
injection pipe 41.7 {4.25} 39.2 – 44.1 {4 – 4.5}
20 170E-5 Series
170E-5 Series 21
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 diameter Outside diame- clearance limit Replace cylin-
Clearance between cylin-
1 of block ter of block der liner or
der block and liner
0 –0.11 block
190.4 0.05 – 0.21 —
–0.06 –0.21
Inside diameter of main Standard size Tolerance Repair limit
bearing fitting hole
(Tighten bolt to specified +0.025
148 —
torque) 0
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 0.20
Interference of cap and Standard interference Interference limit

3
cylinder block 0.080 – 0.159 0.05
Standard size Tolerance Repair limit Correct or
Inside diameter of cam-
shaft bushing +0.222 replace
90 90.251
4 +0.112
Clearance of camshaft Standard clearance Clearance limit
bearing 0.077 – 0.217 0.284
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 105° 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
Inside diameter
2
of cylinder liner Roundness 0.025 0.08
of inside
Cylindrical-
0.025 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
170E-5 Series 27
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
28 170E-5 Series
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
170E-5 Series 29
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
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
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
78.233 ±0.100 77.63 Correct or
1 Height of cam cam
replace
Exhaust
77.252 ±0.100 76.65
cam
+0.035
2 Outside diameter of journal 90 89.98
+0.005
Replace
0
3 Thickness of thrust plate 5 4.75
–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 +0.049 worked)
68 0.030 – 0.055 0.090
–0.006 +0.030
Inside diameter of connect-
2 +0.026
ing rod large end hole 115
0
Clearance between con- Standard clearance Clearance limit
3 necting rod large end bear-
ing and crankshaft bearing 0.058 – 0.132 0.18

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 10.26 ± 0.13 kg
Tightening torque of con- Procedure Target (Nm {kgm}) Range (Nm {kgm})
necting rod cap mounting 1st stage 196 {20} 186 – 206 {19 – 21}
7 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 Standard size Tolerance Repair limit
1 piston (at 46.7 mm from 170 –0.070
piston bottom and 20°C) (At right angles to boss) 169.845
–0.110
Tolerance Clearance limit
Standard
Ring Ring (When ring is
size
groove thickness new)
*1 Check with piston
2 Piston ring groove Top ring Keystone groove wear gauge or
0.15
Second ring Keystone check clearance between
piston and new ring
+0.03 –0.01 Replace
Oil ring 4.00 0.3
+0.01 –0.03
Standard clearance Clearance limit
Closed gap of piston Top ring 0.50 – 0.65 1.2
3
ring Second ring 0.70 – 0.85 2.0
Oil ring 0.50 – 0.70 2.0
Diameter of piston pin
4 +0.054
hole 68
+0.034
Outside diameter of pis- 0
5 68
ton pin –0.006
a *1 Part No.(Groove wear gauge) : 795-901-1120
34 170E-5 Series
Flywheel and flywheel housing 1
1. Rear seal
2. Ring gear (Number of teeth: 118 (D375A-5E0, D375A-5R, D375A-6, D375A-6R: 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 – 0.362 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
170E-5 Series 43
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 0.095
Clearance of idler gear in Standard clearance Clearance limit Replace thrust
2
axial direction 0.12 – 0.2 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
0.21 – 0.39 0.80 or valve seat
exhaust valves
2 Thickness of valve lip Intake valve 3.2 — 2.7 Replace valve
Exhaust valve 3.3 — 2.9
Standard Tolerance
3 Valve seat angle Intake valve 30° ±0°15'
Exhaust valve 45° ±0°15'
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 12.18
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 87.4 547 {55.8}
{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
Inside diameter of cross +0.10
2 13 13.21
head +0.05
Outside diameter of cross +0.039 Replace
13 13.00
head guide +0.028
3
Clearance between cross Standard clearance Clearance limit
head guide and cross head 0.011 – 0.072 —
Projection of cross head Standard size Tolerance
4
guide 86 ±0.25
Tightening torque of cross
5 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 of cam
1 –0.038
follower shaft 25 25
–0.053
Inside diameter of cam +0.021
2 25 25.07
follower lever 0
Inside diameter of cam
25.167 ±0.01 25.3
follower roller
3
Outside diameter of cam +0.075 Replace
25 25
follower roller pin +0.063
Outside diameter of cam +0.025
4 50 49.75
follower roller 0
Diameter of ball at push rod 0
5 15.836 —
end –0.2
Inside diameter of push rod 0
6 16.676 —
socket –0.2
170E-5 Series 51
SEN00197-06
© 2010 KOMATSU
All Rights Reserved
52
SEN00198-05
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.......................................................................................................................................... 38
Fuel filter ............................................................................................................................................ 40
Electric priming pump......................................................................................................................... 42
170E-5 Series 1
Engine controller cooler...................................................................................................................... 43

Cooling system.............................................................................................................................................. 44
Cooling system diagram..................................................................................................................... 44
Water pump ........................................................................................................................................ 46
Thermostat ......................................................................................................................................... 48
Fan drive ............................................................................................................................................ 50
Electrical equipment...................................................................................................................................... 52
Alternator............................................................................................................................................ 52
Starting motor ..................................................................................................................................... 56
Starting aid ......................................................................................................................................... 59
Engine controller ................................................................................................................................ 60
2 170E-5 Series
170E-5 Series 3
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 +0.049 0.039 –
18 —
+0.088 +0.028 0.068
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: 85°C ± 1.5°C
d. Water inlet Full opening temperature: 100°C
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 100°C for 4 – 5
stat minutes)
5 Check that valve closes fully when its temperature is lowered from Replace
Opening and closing of ther-
100°C for full opening to 85°C. (Check after soaking valve in oil
mostat
tank for 4 – 5 minutes)
170E-5 Series 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 Operation
q Common rail (4) distributes the high-pressure When fuel is not injected
fuel from the high-pressure pump to the injec- q Piston (2) is in contact with stopper (1) (initial
tors of the cylinders. position).
q Common rail (4) is equipped with common rail q The fuel for static leakage is supplied through
fuel pressure sensor (2), flow dampers (1), and orifice (a) of piston (2) and clearance in the
pressure limiter (3). sliding parts.
q The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to When fuel is injected
the injectors. q The fuel pressure is applied to piston (2),
q The piping of the pressure limiter (3) is which compresses spring (3) and moves to the
returned to the fuel tank. right.
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
When fuel is stopped
q If the fuel flows out abnormally because of a
burst of the piping, etc., piston (2) moves to the
right stroke end.
q The tip of piston (2) contacts seat (b) to stop
the fuel.
q Once the fuel is stopped, piston (2) does not
return to the initial position until the engine is
stopped.
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.
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}
q The following graph shows the output charac-
teristics of the atmospheric pressure sensor.
170E-5 Series 33
7) NE speed sensor (Crank angle sensor) 8) Engine controller

q If the signal hole made on the flywheel passes
the sensor, the magnetic line of force changes. 9) Fuel temperature sensor
q If the magnetic line of force changes, the out- q The fuel temperature sensor senses the fuel
put of the Hall element sensor changes linearly temperature and sends it to the engine control-
and it is converted into pulse of 0 – 5 V by the ler. The sensor unit is a thermistor the resis-
wave form shaping circuit in the sensor, and tance of which changes according to the
then output. 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.
34 170E-5 Series
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.
1. EGR and bypass valve position sensors
q The following graph shows the output characteristics of the position sensor.
170E-5 Series 35
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.
36 170E-5 Series
170E-5 Series 37
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)
38 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 39
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
40 170E-5 Series
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
1. Filter head
2. Cartridge
Specifications
With water separator
170E-5 Series 41
Electric priming pump 1
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
42 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 43
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. Thermostat

2. Oil cooler 7. Radiator
3. Cylinder liner 8. Fan
4. Cylinder block 9. EGR cooler
5. Water manifold (in cylinder block)
44 170E-5 Series
(EGR-less)
A. From oil pump (Oil)

B. To each part of engine (Oil)
1. Water pump 5. Water manifold (in cylinder block)

2. Oil cooler 6. Thermostat
3. Cylinder liner 7. Radiator
4. Cylinder block 8. Fan
170E-5 Series 45
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 —
46 170E-5 Series
170E-5 Series 47
Thermostat 1
48 170E-5 Series
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 ± 2°C
Full opening temperature: 90°C
Valve lift: Min. 9 mm
Unit: mm
Full opening lift of ther-
Min. 9 mm (Check after soaking in oil tank at 90°C for 4 – 5 minutes)
mostat
2 Check that valve closes fully when its temperature is lowered from Replace
Opening and closing of
90°C for full opening to 76.5°C. (Check after soaking valve in oil tank
thermostat
for 4 – 5 minutes)
170E-5 Series 49
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
50 170E-5 Series
170E-5 Series 51
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
52 170E-5 Series
Alternator belt tension
WA600-6, WA600-6R, WD600-6
1. Tension shaft 6. Spacer

2. Spring 7. Tension pulley (Outside diameter: 100 mm)
3. Roller bearing 8. Ball bearing
4. Tension bracket 9. Grease fitting
5. Oil seal 10. Adjustment bolt
170E-5 Series 53
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
Applicable Outside diameter

Engine Type Specification Weight (kg)
machine of pulley (mm)
D375A-5E0 Open type (brushless), manufac-
24V, 60A
D375A-5R tured by NIKKO DENKI
D375A-6 Open type (brushless), manufac-
24V, 60A
PC1250-8 Open type (brushless), manufac-
SAA6D170E-5 24V, 60A
PC1250-8R tured by NIKKO DENKI
HD465-7E0 Open type (brushless), manufac-
24V, 60A
HD465-7R tured by NIKKO DENKI
24V, 60A
54 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
Applicable Outside diameter

machine of pulley (mm)
D375A-5E0 Open type (brushless), manufac-
24V, 90A
D375A-6 Open type (brushless), manufac-
24V, 90A
PC1250-8 Open type (brushless), manufac-
24V, 90A
PC1250-8R tured by NIKKO DENKI
SAA6D170E-5
WA600-6, WD600-6 Open type (brushless), manufac-
24V, 90A
WA600-6R tured by NIKKO DENKI
24V, 90A
24V, 90A
170E-5 Series 55
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
56 170E-5 Series
Safety relay
Applicable Specifica- No. of pinion Connector
Engine Type Weight (kg) mounting
machine tion teeth type
type
D375A-5E0 NIKKO DENKI 24V, 7.5kW
11 18 G D
D375A-5R (Water-proof, oil-proof type) x2
D375A-6 NIKKO DENKI 24V, 7.5kW
11 18 G D
D375A-6R (Water-proof, oil-proof type) x2
SAA6D170E-5
HD465-7E0 NIKKO DENKI 24V, 7.5kW
11 18 G D
HD465-7R (Water-proof, oil-proof type) x2
HD605-7E0 NIKKO DENKI 24V, 7.5kW
11 18 G D
HD605-7R (Water-proof, oil-proof type) x2
170E-5 Series 57
For 11 kW
E: To chassis ground 4. Terminal B

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

machine teeth type
D375A-5E0
(if equipped)
D375A-5R
(if equipped) Water-proof, oil-proof, manufactured
24V, 11kW 11 18 G
D375A-6 by NIKKO DENKI
(if equipped)
SAA6D170E-5 D375A-6R
(if equipped)
PC1250-8 Water-proof, oil-proof, manufactured
24V, 11kW 11 18 G
PC1250-8R by NIKKO DENKI
WA600-6
Water-proof, oil-proof, manufactured
WA600-6R 24V, 11kW 11 18 G
by NIKKO DENKI
WD600-6
58 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: 110 A
170E-5 Series 59
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
60 170E-5 Series
170E-5 Series 61
SEN00198-05
© 2010 KOMATSU
All Rights Reserved
62
SEN00367-05
ENGINE 1SHOP MANUAL
170E-5 Series
20 Standard value table 1

Standard service value table
Standard service value table for testing, adjusting, and troubleshooting ........................................................ 2
Running-in standard and performance test standard.................................................................................... 12
170E-5 Series 1
SEN00367-05 20 Standard value table
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 0°C (without starting aid) rpm 125 —
speed for starting At –20°C (with starting aid) rpm 85 —
Air intake kPa Max. 3.73 7.5
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 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 (20°C ) °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 – 60°C 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. 70°C {mmH2O} {Max. 350} {960}
At rated output SAE0W30EOS MPa Min. 0.39 0.24
Engine oil temperature: Min. 80°C SAE5W40EOS {kg/cm2}
Lubrication system
Engine oil {Min. 4.0} {2.4}

SAE10W30DH
pressure At low idle SAE15W40DH MPa Min. 0.12 0.08
Engine oil temperature: Min. 80°C 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
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
20 Standard value table SEN00367-05
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

SAE10W30DH
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 D375A-6
Standard value
Judgement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 155 141
At rated output
Exhaust kPa Min. 173 159
At rated output
Exhaust
temperature
%
Max. 25 35
(Max. 2.5) (3.5)
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

SAE10W30DH
pressure At low idle MPa Min. 0.12 0.08
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Fan speed At rated speed rpm
machine side
machine side
Alternator belt —
4 170E-5 Series
Engine SAA6D170E-5
Machine model D375A-6R
Standard value
Judgement
criteria
machine
Speed
Whole speed range
Air boost kPa Min. 144 130.6
At rated output
Exhaust kPa Min. 133.3 120

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

Lubrication system

SAE10W30DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt —
170E-5 Series 5
Engine SAA6D170E-5
Machine model PC1250-8
Standard value
Judgement
criteria
machine
Speed
Whole speed range
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. 70°C {mmH2O} {Max. 350} {1,320}
Lubrication system

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 PC1250-8R
Standard value
JudgRement
criteria
machine
Speed
Whole speed range
At rated output

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

Lubrication system

SAE10W30DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt —
170E-5 Series 7
Engine SAA6D170E-5
Machine model WA600-6, WD600-6
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

SAE10W30DH
SAE15W40DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt —
8 170E-5 Series
Engine SAA6D170E-5
Machine model WA600-6R
Standard value
Judgement
criteria
machine
Speed
Whole speed range
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

SAE10W30DH
Engine oil
temperature
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt —
170E-5 Series 9
Engine SAA6D170E-5
HD465-7E0
Machine model
HD605-7E0
Standard value
Judgement
criteria
machine
Speed
Whole speed range
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

SAE10W30DH
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 —
10 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

SAE10W30DH
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 11
Running-in standard and performance test standard

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.
12 170E-5 Series
Running-in standard
Engine SAA6D170E-5
Machine model D375A-6, D375A-6R
Procedure
Item
1 2 3 4 5
Speed rpm 750 1,134 1,422 1,638 1,800
Output kW {HP} 0 {0} 119 {160} 237 {317} 356 {477} 474.4 {636}
Engine SAA6D170E-5
Machine model D375A-6, D375A-6R
Specification value 474.4 kW/1,800 rpm 3,020 Nm/1,300 rpm
— 1,900 ± 25 rpm 750 ± 25 rpm
Speed rpm 1,800 1,300 1,900 ± 25 750 ± 25
N 3,408 – 3,619 4,089 – 4,344
{kg} {348 – 369} {417 – 443}
kW 460.1 – 488.6
{HP} {617 – 655}
Nm 2,932 – 3,109
{kgm} {299 – 317}
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Max. 670 (-6) Max. 700 (-6)
Max. 650 (-6R) Max. 680 (-6R)
170E-5 Series 13
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
{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)
14 170E-5 Series
Running-in standard
Engine SAA6D170E-5
Machine model WA600-6, WA600-6R, WD600-6
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, WD600-6
— 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
{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)
170E-5 Series 15
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
Speed rpm 2,000 1,400 2,270 ± 50 750 ± 50
N 3,570 – 3,788 4,501 – 4,776
{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 )
16 170E-5 Series
170E-5 Series 17
SEN00367-05
© 2010 KOMATSU
All Rights Reserved
18
SEN00368-04
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
SEN00368-04 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
Sketches of special tools.................................................................................................................... 28
Testing air boost pressure .................................................................................................................. 29
Testing exhaust temperature .............................................................................................................. 30
Adjusting valve clearance................................................................................................................... 31
Testing compression pressure............................................................................................................ 33
Testing blow-by pressure.................................................................................................................... 35
Testing engine oil pressure................................................................................................................. 36
Handling fuel system parts ................................................................................................................. 37
Releasing residual pressure in fuel system........................................................................................ 37
Testing fuel pressure .......................................................................................................................... 38
Reduced cylinder mode operation...................................................................................................... 39
No-injection cranking.......................................................................................................................... 39
Testing leakage from pressure limiter and return rate from injector ................................................... 40
Bleeding air from fuel circuit ............................................................................................................... 43
Testing fuel system for leakage .......................................................................................................... 45
Handling controller voltage circuit ...................................................................................................... 46
2 170E-5 Series
30 Testing and adjusting SEN00368-04
Testing and adjusting (With EGR) 1

Testing and adjusting tools list
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 – 1,299°C
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 Gauge 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 φ5 mm x 2 – 3 m
Testing leakage from available
pressure limiter and Commercially
return rate from injec-
H 4 Hose 1 φ16 mm x 2 – 3 m
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
21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
— Socket 1
available Applicable engine serial No.:
Removal and installa- 510001 – 511178
tion of engine coolant
temperature sensor 19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
— 795T-981-1010 Socket 1
Applicable engine serial No.:
511179 and up
4 170E-5 Series
Sketches of special tools
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
K1: Block
Socket
170E-5 Series 5
Testing air boost pressure 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

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 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 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.
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

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
a Measure the compression pressure after the adapter (9), and pull out the injector by
engine is warmed up (Engine oil temperature: moving the weight of tool D3 up and down.
40 – 60°C).
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 adapter, 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 adapter. (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 adapter (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: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
tion cranking mode, it will start and will 6) Fully tighten the sleeve nut of fuel high-
be dangerous. Accordingly, be sure to pressure tube (5).
set the engine in this mode. 3 Sleeve nut:
8. Rotate the engine with the starting motor and 39.2 – 44.1 Nm {4 – 4.5 kgm}
measure the compression pressure.
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

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 Symbol Part No. Part name
the connector side with plate (15).
E 799-201-1504 Blow-by checker
1. Install nozzle [1] of blow-by checker E to the

end of blow-by 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

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

oil filter head.
2. Connect nipple F3 and connect it to gauge 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 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.

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

with gauge [1] 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 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system
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 3. Install adapter G3 and install nipple G2 to adapter

G3, then connect gauge G4. (M8 plug type)
a Testing tools for fuel pressure
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 priming pump through the
engine controller cooler and fuel filter to the
supply pump.
k
4. Run the engine at high idle and measure the
Since the pressure in the high-pressure cir- fuel pressure.
cuit from the supply pump through the a If the fuel pressure is in the following
common rail to the injector is very high, it range, it is normal.
cannot be measured.
Engine speed Fuel pressure
1. Remove plug (1). Min. 0.15 MPa
High idle
a Plug (1) is a PT1/8 plug or an M8 plug, {Min. 1.5 kg/cm2}
depending on the time of manufacture.
2. Install nipple G2 and connect it to gauge G4 5. After finishing testing, remove the testing tools
(PT1/8 plug type). and return the removed parts.
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 operation No-injection cranking

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
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 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 9. Inspect the fuel piping and devices for fuel
k
leakage.
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. 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
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 – 1,299°C
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 Gauge 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 φ5 mm x 2 – 3 m
Testing leakage from available
pressure limiter and Commercially
return rate from injec-
H 4 Hose 1 φ16 mm x 2 – 3 m
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
21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
— Socket 1
available Applicable engine serial No. :
Removal and installa- 610001 – 610243
tion of engine coolant
temperature sensor 19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
— 795T-981-1010 Socket 1
Applicable engine serial No. :
610244 and up
170E-5 Series 27

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
Socket
28 170E-5 Series
Testing air boost pressure 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-
170E-5 Series 29
Testing exhaust temperature

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.
30 170E-5 Series
Adjusting valve clearance 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}
170E-5 Series 31
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}
32 170E-5 Series
Testing compression pressure

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
a Measure the compression pressure after the
adapter (9), and pull out the injector by
engine is warmed up (Engine oil temperature:
moving the weight of tool D3 up and down.
40 – 60°C).
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 adapter, and remove

injector (8).
170E-5 Series 33
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 adapter. (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 adapter (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: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
tion cranking mode, it will start and will 6) Fully tighten the sleeve nut of fuel high-
be dangerous. Accordingly, be sure to pressure tube (5).
set the engine in this mode. 3 Sleeve nut:
8. Rotate the engine with the starting motor and 39.2 – 44.1 Nm {4 – 4.5 kgm}
measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
34 170E-5 Series
a Install the injector wiring harness accord- Testing blow-by pressure

1) Assemble injector wiring harness (6) from a Testing tool for blow-by pressure
the inside of rocker arm housing and fix Symbol Part No. Part name
the connector side with plate (15).
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}

170E-5 Series 35
Testing engine oil pressure

a Testing tools for oil pressure
1
F 2 799-401-2320 Gauge
799-101-5230 Nipple
3
6215-81-9720 O-ring
1. Remove oil pressure pickup plug (1) from the

oil filter head.
2. Connect nipple F3 and connect it to gauge F2.
3. Run the engine at the rated output and low idle

and test the oil pressure.
machine.
36 170E-5 Series
Handling fuel system parts Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system
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.)
170E-5 Series 37
Testing fuel pressure 3. Install adapter G3 and install nipple G2 to adapter

G3, then connect gauge G4. (M8 plug type)
a Testing tools for fuel pressure
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 priming 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, Min. 0.15 MPa
High idle
depending on the time of manufacture. {Min. 1.5 kg/cm2}
2. Install nipple G2 and connect it to gauge G4

(PT1/8 plug type). 5. After finishing testing, remove the testing tools
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)
38 170E-5 Series
Reduced cylinder mode operation No-injection cranking

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.
170E-5 Series 39
Testing leakage from pressure limiter and return rate from injector
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.
40 170E-5 Series
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.
170E-5 Series 41
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
42 170E-5 Series
Bleeding air from fuel circuit 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.
170E-5 Series 43
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.
44 170E-5 Series
Testing fuel system for leakage 9. Inspect the fuel piping and devices for fuel
k
leakage.
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.
170E-5 Series 45
Handling controller voltage circuit

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.
46 170E-5 Series
170E-5 Series 47
SEN00368-04
© 2010 KOMATSU
All Rights Reserved
48
SEN00369-03
ENGINE 1SHOP MANUAL
170E-5 Series
40 Troubleshooting 1
General information on troubleshooting
Points on troubleshooting ............................................................................................................................... 2
Error code and failure code table .................................................................................................................... 4
Information in troubleshooting table................................................................................................................ 6
Connection table for connector pin numbers .................................................................................................. 8
T- branch box and T- branch adapter table ................................................................................................... 44
170E-5 Series 1
SEN00369-03 40 Troubleshooting
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
40 Troubleshooting SEN00369-03
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
SEN00371-02
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 a 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
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
8 170E-5 Series
170E-5 Series 9
10 170E-5 Series
170E-5 Series 11
12 170E-5 Series
170E-5 Series 13
14 170E-5 Series
170E-5 Series 15
16 170E-5 Series
170E-5 Series 17
18 170E-5 Series
170E-5 Series 19
20 170E-5 Series
170E-5 Series 21
22 170E-5 Series
170E-5 Series 23
24 170E-5 Series
170E-5 Series 25
26 170E-5 Series
170E-5 Series 27
28 170E-5 Series
170E-5 Series 29
30 170E-5 Series
170E-5 Series 31
32 170E-5 Series
170E-5 Series 33
34 170E-5 Series
170E-5 Series 35
36 170E-5 Series
170E-5 Series 37
38 170E-5 Series
170E-5 Series 39
40 170E-5 Series
170E-5 Series 41
42 170E-5 Series
170E-5 Series 43
T- branch box and T- branch adapter table 1

(Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
44 170E-5 Series
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
170E-5 Series 45
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
46 170E-5 Series
170E-5 Series 47
SEN00369-03
© 2009 KOMATSU
All Rights Reserved
48
SEN00371-02
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-
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 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
Wiring harness between ENG (female) (47) Resis-
defective contact in connec- Max. 1 z
tor) – PIM (female) (3) tance
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 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
Wiring harness between E18 (female) (9) – Resis-
tor) L17 (female) (2) tance
Max. 1 z
L17 (female) (3) tance
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 Wiring harnesses between E02 (female) (9) Resis-
and standard tor) – E06 (female) (2) tance
value in normal Wiring harness between E02 (female) (23) – Resis-
state Max. 1 z
E06 (female) (3) tance
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
Between (9) – (23) Signal 0.5 – 4.5 V
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
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)
Between (13) – (47) Signal 0.3 – 4.7 V
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 (90°C) 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- 0°C 30 – 37 kΩ
ble) 25°C 9.3 – 10.7 kΩ
Between (A) – (B) 50°C 3.2 – 3.8 kΩ
80°C 1.0 – 1.3 kΩ
95°C 700 – 800 Ω
Disconnection in wiring har- shooting without turning starting switch ON.
ness (Disconnection in wir- Wiring harness between ENG
2 Resistance Max. 1 Ω
ing or defective contact in (female) (15) – TWTR (female) (A)
Possible causes and connector)
Wiring harness between ENG
standard value in nor- Resistance Max. 1 Ω
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 MΩ
and chassis ground
Coolant
ENG (female) Resistance
temperature
4 Defective engine controller 0°C 30 – 37 kΩ

25°C 9.3 – 10.7 kΩ
Between (15) – (38) 50°C 3.2 – 3.8 kΩ
80°C 1.0 – 1.3 kΩ
95°C 700 – 800 Ω
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 (90°C) 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) (70°C) and continues operation.
on machine

Intake air tem-
TIM (male) Resistance
perature
Defective charge (boost) 0°C 29 – 36 kΩ
1 temperature sensor (Inter-
25°C 9 – 11 kΩ
nal trouble) Between (A) – (B)
40°C 4.9 – 5.8 kΩ
100°C 600 – 700 Ω
Between (A) – chas-
All range Min. 1 MΩ
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 Ω
ing or defective contact in (female) (23) – TIM (female) (A)
connector)
mal state Wiring harness between ENG
Resistance Max. 1 Ω
(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 MΩ
chassis ground
Intake air tem-
perature
4 Defective engine controller 0°C 29 – 36 kΩ
25°C 9 – 11 kΩ
Between (23) – (47)
40°C 4.9 – 5.8 kΩ
100°C 600 – 700 Ω
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) (70°C) 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 (100°C) and continues operation.
troller
Problem that
appears on
machine
Related infor-
mation

TOIL (male) Oil temperature Resistance
Defective oil temperature 0°C 30 – 37 kΩ
1 sensor
25°C 9.3 – 10.7 kΩ
(Internal trouble)
Between (A) – (B) 50°C 3.2 – 3.8 kΩ
80°C 1.0 – 1.3 kΩ
95°C 700 – 800 Ω
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-
tor) Wiring harnesses between ENG (female) Resis-
value in normal 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
0°C 30 – 37 kΩ
25°C 9.3 – 10.7 kΩ
Between (17) – (47) 50°C 3.2 – 3.8 kΩ
80°C 1.0 – 1.3 kΩ
95°C 700 – 800 Ω
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 (100°C) 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
ness Max. 1 z
state – PAMB (female) (1) tance
tor) – PAMB (female) (3) tance
Wiring harness between ENG (female) (3) – Resis-
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 (95°C) and con-
troller
tinues operation.)
Problem that
appears on
machine
Related infor-
mation

TFUEL (male) Fuel temperature Resistance
Defective fuel temperature 0°C 30 – 37 kΩ
1 sensor
25°C 9.3 – 10.7 kΩ
(Internal trouble)
Between (A) – (B) 50°C 3.2 – 3.8 kΩ
80°C 1.0 – 1.3 kΩ
95°C 700 – 800 Ω
ness
Possible causes 2 (Disconnection in wiring or Max. 1 z
– TFUEL (female) (A) tance
and standard defective contact in connec-
value in normal 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
0°C 30 – 37 kΩ
25°C 9.3 – 10.7 kΩ
Between (30) – (47) 50°C 3.2 – 3.8 kΩ
80°C 1.0 – 1.3 kΩ
95°C 700 – 800 Ω
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 (95°C) 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-
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.
ness Wiring harness between ENG (female) (4) – Resis-
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
Wiring harness between ENG (female) (4) –
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-
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 defective contact in connec-
tor) Wiring harness between ENG (female) (5) – Resis-
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) Wiring harness between ENG (female) (5) – Resis-
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-
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-
– PCV2 (female) (2) and chassis ground tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
ness
Voltage Max. 1 V
– PCV2 (female) (2) and chassis ground
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-
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
– PCV2 (female) (2) tance
and standard
3 Min. 1 Mz
cuit)
Min. 1 Mz
– PCV2 (female) (2) and chassis ground tance
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-
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
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-
troller
Problem that
• Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
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-
troller
Problem that
• Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
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-
troller
Problem that
• Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
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-
troller
Problem that
• Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
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-
troller
Problem that
• Output drops.
appears on
machine
Related infor-
mation

1
Min. 1 Mz
ground
ness
value in normal
3 Min. 1 Mz
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
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
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) Wiring harness between ENG (female) (16)
– 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) page.
Between (6) – (4) Signal 2
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-
ness L17 (female) (4) tance
value in normal
state Wiring harness between E18 (female) (11) – Resis-
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
See Fig. 1.
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
SEN00371-02
© 2009 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
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-
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- “Testing fuel pressure”.
3
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
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
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 Ω
Disconnection in wiring shooting without turning starting switch ON.
harness (Disconnection Wiring harness between ENG (female)
2 Resistance Max. 1 Ω
in wiring or defective con- (31) – BP (female) (1)
tact in connector)
Wiring harness between ENG (female)
Resistance Max. 1 Ω
(11) – BP (female) (2)
Possible causes and Ground fault in wiring
(31) – BP (female) (1) and chassis Resistance Min. 1 MΩ
standard value in nor- 3 harness (Short circuit
ground
mal state with GND circuit)
(11) – BP (female) (2) and chassis Resistance Min. 1 MΩ
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 Ω
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
Between (3) – (2) Signal 0.8 – 1.2 V
Between (4) – (2) Signal 0.8 – 1.2 V
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
Between (3) – (2) Signal 0.8 – 1.2 V
Between (4) – (2) Signal 0.8 – 1.2 V
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
tor) Wiring harness between ENG (female) (11) – Resis-
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
cuit) Wiring harness between ENG (female) (11) – Resis-
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-
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-
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
SEN00370-02
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]
Leaking or clogged fuel piping, entry of air

q Insufficient supply of fuel
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
Defective intake air heater system

q Improper selection of fuel
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
Operated for long period E E E E E
machine
Starting perfor- Became worse gradually Q Q w w Q Q

mance w w
Questions
Engine starts easily when warm

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
Check items
little fuel spills

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
q
Carry out troubleshooting
Inspect flywheel ring gear directly

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
When terminal B and terminal C of starting switch are connected,
Turn starting switch
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
Questions
Degree of use of
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
Leaking or clogged fuel system, entry of air

start (fuel is being injected)
Defective coolant temperature sensor,

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

Clogged injector, defective spray
Worn piston ring, cylinder liner
Defective, deteriorated battery

engine does not start
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
wiring harness

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

Non-specified fuel is being used w w w w
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
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
Defective engine controller power supply wiring

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
Engine overheated and stopped w Q Q
Questions
Condition when engine

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
Defective operation of bypass valve ["with EGR" only]

indicated)
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
Manual w w

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-
mode q
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)


Air leakage from air intake piping

q There is overheating:
Leaking, clogged fuel piping

See “S-14 Coolant temperature becomes too

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

machine
Q Q Q Q
Questions
Suddenly
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
w
Check items
When engine is cranked, interference sound is generated around turbocharger
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
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q q
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
Abnormally worn injector
Improper injection timing

q Controller is controlling in derate mode (limiting injec-
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
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
When exhaust manifold is touched immediately after starting engine, temperature of some w
cylinders is low
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
Worn EGR valve guide ["with EGR" only]
q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather, breather hose

q Use of improper oil
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
w w
Check items
There are excessive air bubbles in radiator, coolant spurts back

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

q q
Troubleshooting
Inspect cylinder block directly

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]

Defective oil pressure sensor, wiring harness
q Leakage, clogging, wear or lubrication system
Leaking, crushed, clogged hydraulic piping

Defective EGR oil pump ["with EGR" only]
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the
Operation and Maintenance Manual is not observed.
Clogged, broken pipe in oil pan

q Deterioration of oil due to overheating
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 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
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 block 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

Dirt caught in injector
indicate abnormality, however.
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
When exhaust manifold is touched immediately after starting engine, temperature of some
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
q 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)
Broken output shaft, parts in damper on applicable machine side

q Misalignment between engine and chassis
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

Improper setting of air bleeding valve (Closed)
q Fuel is not supplied or is supplied very little.
Malfunction of electric priming pump switch

q Fuel valve or air bleeding valve is not set properly.
Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.
Improper setting of fuel valve (Closed)
Malfunction of electric priming pump

q Fuel return piping is clogged.
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-
1–3z
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) 1–3z
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
SEN00370-02
© 2009 KOMATSU
All Rights Reserved
32
SEN00765-03
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............................................................................................................................ 4
Special tools list.................................................................................................................................... 7
Sketches of special tools...................................................................................................................... 9
170E-5 Series 1
SEN00765-03 50 Disassembly and assembly
General information on disassembly and assembly 1

How to read this manual (Rev. 2009.1) 1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished

q Various special tools are illustrated for the local
manufacture.
2 170E-5 Series
50 Disassembly and assembly SEN00765-03
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
q Various special tools are illustrated for the local
manufacture.
170E-5 Series 3
Coating materials list 1

(Rev. 2009.02)
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 seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 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-7 790-129-9170 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.
4 170E-5 Series
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
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
Seizure
pound with metallic super-fine-grain, etc.

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.
Grease
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
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 (*)
170E-5 Series 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• 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.
Grease
• 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.
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)
6 170E-5 Series
Special tools list 1
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented 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
Measuring the liner 1 795-502-1121 Holder t 1
I
Projetion 2 790-101-2310 Block q 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
170E-5 Series 7
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Work item Part No. Part name Remarks
1 795-931-1100 Seal puller assembly t 1

795T-621-1161 Push tool t 1 R Q Press-fitting of standard
2
Press fitting of rear oil seal L 01050-32235 Bolt t 5 seal and sleeved seal
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)
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
8 170E-5 Series
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)
170E-5 Series 9
L2 Push tool
L3 Push tool
10 170E-5 Series
S Socket
170E-5 Series 11
SEN00765-03
© 2010 KOMATSU
All Rights Reserved
12
SEN00766-04
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) If necessay, remove nut (13), washer (14),
coupling (15) and key (16) from supply
pump assembly (11).
a The figure shows, for your refer-

ence, the state after removing 9) Remove supply pump drive case (12).
the supply pump drive gear.
24. Common rail

6) Remove bracket (10). 1) Remove fuel tube (1) and peripheral parts.
7) Remove drive supply pump assembly 2) Remove common rail (2).
(11).
8 170E-5 Series
25. Intake manifold assembly 2) Remove stopper (2) and then slide bypass
1) Remove bracket (1), spill tube (2) and tube (3) upward.
peripheral parts. 3) Remove water pump assembly (4).
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).
170E-5 Series 9
28. Front hanger and water housing 30. Injector harness

1) Remove bracket (1) and water tube (2). 1) Remove terminal mounting nut (1), har-
ness fixing bolts (2) and spacer (3).
a Loosen the 2 terminal nuts alter-
nately.
2) Lift up front hanger (3) temporarily and

then remove the mounting bolts.
3) Lift and remove front hanger (3) along with
water housing (4). 2) Remove plate (4) and then push injector
4 Front hanger: 65 kg harness (6) inside the engine along with
grommet (5).
3) Remove injector harness (6) from inside of
the engine.
29. Cylinder head cover

Remove cover (1) and then remove cylinder
head covers (2).
31. Rocker arm assembly
1) Loosen locknuts (1) and then loosen
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.
10 170E-5 Series
33. Rocker housing

Remove rocker housing (1).
3) Remove exhaust rocker arm (4) and air

intake rocker arm (5) from shaft (6).
34. Crosshead
Remove crossheads (1).
32. Push rod

Remove push rods (1).
35. Fuel injector assembly
1) Remove injector holder (1).
170E-5 Series 11
2) Using tool A, remove fuel injector assem- 3) Remove the cylinder head gasket.
bly (2). 4) Disassemble the cylinder head assembly
a Hitch the tip of tool A to hole (a) on according to the following procedure.
the injector and then pull it out. 1] Using tool B, compress the valve
a Do not grip the solenoid valve at the spring and then remove valve cotter
top of the injector to pull off the injec- (2).
tor.
2] Remove spring seat (3).

3] Remove valve spring (4).
36. Cylinder head assembly
1) Remove the coolant air bleeding pipe.
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).
12 170E-5 Series
5] Remove intake valve (6) and exhaust 5) Remove block (8).

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.
39. Drive housing assembly

Remove drive housing assembly (1).
37. Oil cooler assembly

Remove oil cooler assembly (1).
40. Oil pan

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).
3) Remove fuel tube (3) and then remove
fuel feed pump (4).
4) Remove engine controller (5), cooling
plate (6) and bracket (7).
170E-5 Series 13
4) Using tools C, lift the engine and then 42. Cam follower assembly
remove oil pan (1). 1) Remove cam follower cover (1).
4 Oil pan: 85 kg 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
the applicable machine.)
5) Securely support the engine again using

blocks [1].
a See "Setting engine assembly" in
Item 2 above.
41. Suction pipe and under plate

1) Install under plate (1) temporarily with sev- 2) Remove cam follower assembly (2).
eral oil pan mounting bolts. a Rotate the crankshaft using a barring
2) Remove brackets (2) and (3) and then device to move the piston to the posi-
remove suction pipe (4). tion indicated below and remove it.
3) Separate the gasket sealant. q No. 1 compression top dead center:
4) Remove the temporarily attached mount- Allows removal of No. 1 and No. 5.
ing bolts and then remove plate (1) using
a jack. q No. 2 compression top dead center:
4 Under plate: 30 kg Allows removal of No. 2 and No. 4.
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.
14 170E-5 Series
3) Disassemble the cam follower in the fol- 45. EGR oil pump
lowing procedure. Remove EGR oil pump (1).
1] Remove snap ring (3).
2] Remove cam follower (4) from shaft
(5).
3] Remove snap ring (6) from shaft (5).
46. Front cover

1) Lift up front cover (1) temporarily and then
remove the mounting bolts.
2) Lift and remove front cover (1).
43. Cam cover 4 Front cover: 50 kg
Remove bracket (1) and cam cover (2).
3) Remove dust seal (2) and oil seal (3) from

44. Vibration damper the front cover.
1) Lift vibration damper (1) temporarily and a Dust seal is provided only on the
then remove the mounting bolts. vehicle-mounted engines alone.
2) Lift and remove vibration damper (1).
4 Vibration damper: 45 kg
170E-5 Series 15
47. Front idler gear assembly 49. Engine mount

1) Remove idler gear (larger one) (1). 1) Remove the front engine mount.
2) Remove idler gear (smaller one) (2). 2) Remove rear engine mount (1).
4 Rear engine mount: 30 kg
a The weight varies with the applicable
machines.
3) Remove spacer (3) and shaft (4) from idler

gears (large and small gears).
a The same structure is employed for
both the large and small gears. 50. Flywheel assembly
1) Lift flywheel assembly (1) temporarily and
then remove the mounting bolt.
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).
16 170E-5 Series
51. Flywheel housing 52. 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

4 Flywheel housing: 150 – 180 kg
53. Rear idler gear assembly

1) Remove rear idler gear assembly (1).
4) Remove rear oil seal (4) from the flywheel

housing.
170E-5 Series 17
2) Disassemble the idler gear in the following 55. Piston cooling nozzle
procedure. 1) Raise the cylinder block to make the cylin-
1] Remove spacer (2) from shaft (3). 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.
pistons.
pistons.
3) Sequentially remove 6 each of cooling
nozzles (1) and (2).
a Maintain them on the cylinder No.
basis using a tag or the like.
2] Separate gear (larger one) (4) from
another (smaller one) (5).
56. Piston and connecting rod assembly

1) Move the piston of the cylinder to be
removed to the bottom dead center posi-
54. Installation to engine repair stand
tion by rotating the crankshaft.
Using tools C, lift engine assembly (1) being
2) Loosen the connecting rod bolt by 5 to 6
attached with tool D2 and then attach tool D1
turns.
to the assembly.
a Lightly strike the connecting rod head
4 Engine assembly: Approx. 1,600 kg 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).
18 170E-5 Series
5) Remove connecting rod bearing (2) from 7) Disassemble the piston and connecting
connecting rod cap (1). rod assembly according to the following
a Maintain them on the cylinder No. procedure.
basis using a tag or the like. 1] Remove connecting rod bearing (4).
6) Push the connecting rod from the crank- 2] Remove 2 snap rings (5).
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.
a Pull the assembly horizontally so that
the connecting rod may not damage
the cylinder liner.
170E-5 Series 19
3] Remove piston pin (6). 57. 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).
5) Lift and remove crankshaft assembly (4).

a Thrust washers are provided for No. 6
bearing. Thus reasonable care must
be exercised to prevent their falling
off.
4 Crankshaft assembly: 270 kg
20 170E-5 Series
58. Cylinder liner

1) Set the cylinder head side up.
2) Using tool G, remove cylinder liner (1).
6) Remove main bearing metal (5) and 2

thrust washers (6).
a Thrust washers are provided on No.6
alone. 59. Cylinder block
a Maintain them on the bearing No. Using tools C, lift and remove cylinder
basis using a tag or the like. 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.
following precautions be fore using 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.
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 I1, I2, measure projection of the cyl-
inder liner.
a When measuring the liner projection,
tighten the liner with tool I2 to prevent
it from being floated by the O-ring.
a When measuring the liner 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-
ture , fun ctio n an d m a inten a n ce
8) Install the head gasket and then tempo- standard“.
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).

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-
ture, function and maintenance
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 (1).
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).

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].
tu re , fun ctio n an d m a inten a n ce
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 (Front cover end face)
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
14. Flywheel housing
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. q Procedure for installing sleeved seal

a Check the Teflon seal (Laydown lip a When installing the rear seal, do not apply
seal) by checking the wear of the oil or grease to the shaft and sleeve inside
shaft and replace it with the “Standard cylinder surface (C).
seal” or “Sleeved seal”. 1] Set sleeve and rear seal assembly (6)
a When wear on the shaft is not serious to tool L3.
and only makes it look lustrous (depth 2 Sleeve inside cylinder surface
of wear is 10 mm or less when (C): Gasket sealant (LG-7)
checked with finger cushion) and no 2] Set sleeve (7) of the rear seal to the
scratch is recognized, assemble the end of crankshaft (5) and tighten the
standard seal (A). When the above is 5 bolts (45 mm) evenly to press fit
not applicable, assemble sleeved sleeve and rear seal assembly (6)
seal (B). until the end of tool L3 reaches the
a (3): Shows the plastic inside cylinder end of crankshaft (5).
doubling the assembly guide.
a (5): Shows the sleeve.
a Don't remove assembly guide (3)
from rear seal (2) until the assembly
is complete.
a Handle rear seal (2) and sleeve (5) as
an integral part. Don't try to separate
them.
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).
a After press fitting the seal, remove the red
sealant layer from its periphery.
34 170E-5 Series
15. Under plate 16. Removal from engine repair stand

1) Raise and invert the engine to move the 1) Raise and invert the engine to move the
oil pan side to the top. cylinder head side to the top.
2) Apply gasket sealant and then install 2) Using tool C, lift and remove engine
under plate (1). assembly (1) from tool D1.
2 Under plate: Gasket sealant (LG-7)
applied to the entire perimeter as
shown below.
a Tighten 4 inside positions and several
outside positions temporarily using
the bolts until installation of the suc-
tion tube and oil pan is completed.
3) Lift down engine assembly (1) on blocks

[1] and then remove tools C and tool D2.
170E-5 Series 35
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)
1st time: 196.1 ± 19.6 Nm {20 ± 2 kgm}
2nd time: 460.9 ± 19.6 Nm {47 ± 2 kgm}
3rd time: 90 – 120° retightening
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.)
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
36 170E-5 Series
a When the measured value is out of 2) Position the drive case and drive gear
the standard, determine the cause by according to the following procedure.
disassembling the flywheel again. 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).
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).
170E-5 Series 37
3] Check that stamps "C" on idler gear 20. EGR oil pump
(15) and supply pump drive gear (9) Install EGR oil pump (1).
are set to part (A). a When installing bolt (a), check that its
4] Check that the dowel pin is in dowel stem length is 25 mm. If a wrong bolt is
pin hole (B) of supply pump drive installed, it will interfere with the parts in
gear (9). the engine.
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)
22. Vibration damper

Lift and install vibration damper (1).
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}
38 170E-5 Series
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}
23. Cam follower assembly

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. 4) Install the O-ring and then install cam fol-
3] Install snap rings (3). 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
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}
2) Crank the crankshaft to set No. 1 – No. 3

q No.1 compression top dead center:
No . 1 an d No . 5 pist on s can b e
installed.
installed.
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 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

1) Install key (16), coupling (15) and washer
(14) to supply pump assembly (11), then
tighten with nut (13).
a Be careful not to forget the key (16)
when installing the coapling (15).
3 Nut:
176 – 196 Nm {18 – 20 kgm}
4) 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}
2) Install supply pump assembly (11). 3 Fuel tube (3) union nut:
3) Install bracket (10). 43 – 47 Nm {4.4 – 4.8 kgm}
a Insert the fuel supply pump shaft in 3 Fuel tube (4) joint bolt:
the coupling of the supply pump drive 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
case. a Install tube (7) as shown in the figure.
a There is 1 unsplined part each on the k If tube (7) is installed near the
coupling side and shaft side, which pump by mistake, the supply pump
are used to position the coupling and will be broken.
shaft.
q The figure shows the coupling of the
supply pump drive case. (Part A is
the unsplined part.)
170E-5 Series 51
5) Install fuel tube (2) and wiring harness (1). a When fitting the rubber cap, direct its
3 Fuel tube joint bolt (Supply pump slit toward out of the engine.
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}
47. Air intake connector

Install air intake connector (1).
46. High-pressure piping

k When handling the high-pressure pip-
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 48. Breather, cover and wiring harness
sure that a 10 mm clearance mini- 1) Install O-ring and then wiring harness and
mum is provided between the high- plate assembly (3).
pressure piping and adjacent wiring 2) Install engine top covers (2).
harness. When the clearance is less 3) Install breather and hose assembly (1).
than 10 mm, secure the necessary 3 Breather mounting bolt:
space by adjusting the wiring harness 24.5 – 29.4 Nm {2.5 – 3.0 kgm}
position.
1) Install high-pressure pipings (1) and (2)
temporarily on the common rail and fuel
supply pump.
2) Install the bracket and clamp temporarily.
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 49. Fuel tube
specified torque. 1) Install fuel tubes (2), (4), (5), (6).
6) Install a rubber cap on the sleeve nut.
52 170E-5 Series
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).

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).
170E-5 Series 53
53. Pulley, tensioner and air conditioner com-

55. Air conditioner compressor
pressor bracket
Install air conditioner compressor (1).
1) Install air conditioner compressor bracket
(4).
2) Install tensioner (3).
3) Tighter bolt (2).
4) Pull out stopper bolt [1].
5) Install pulley (1).
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-
ment belt (3) until dimension (a) is
obtained.
54. Alternator
Dimension (a): 90 mm
1) Remove oil filter (1) on the front side.
3) Tension the locknut of adjustment bolt (1).
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.)
54 170E-5 Series
57. EGR valve a When tightening the union nut, hold

1) Install EGR valve (5). the union bolt with a spanner to pre-
2) Install oil tubes (1) – (4). vent their breakage.
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}

1) When the exhaust manifold assembly is
currently split, apply liquid adhesive (heat
resistant sealant) to connection (A) (in two
positions) prior to the assembly.
2 Exhaust manifold connection:
58. EGR cooler Liquid adhesive (Holtz MH 705)
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.
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}
3 Water tube (2) union bolt locknut:
19.6 – 44 Nm {2.0 – 4.5 kgm}

lowing order.
2 Exhaust manifold mounting bolt:
170E-5 Series 55
Seizure prevention compound (LC-G) 3) Install brackets (3) and (4).

(NEVER-SEEZ (Bostic Inc.) or equivalent)
1st time: 39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2nd time: 98.1 – 122.6 Nm {10 – 12.5 kgm}
4) Install EGR tube (2) and then fix it with

clamps (1).
60. Bypass tube and EGR tube

1) Install bypass tube (8) and then fix it with
clamp (7).
a A separate torque shall be used for
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}
61. Bracket
2) Install EGR tube (6) and then fix it with
Install bracket (1) on the top face of No. 2
clamp (5).
rocker cover.
a A separate torque shall be used for
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}
56 170E-5 Series
62. Turbocharger assembly 63. Air piping

1) Lift and install turbocharger assembly (1). Lift and install air piping (1) and then fix it with
4 Turbocharger assembly: 55 kg clamp (2).
2 Turbocharger mounting bolt and
4 Air piping: 15 kg
nut:
Seizure prevention compound (LC-G) 3 Clamping nut:
(NEVER-SEEZ (Bostik Inc.) or equivalent) 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
3 Turbocharger mounting bolt and 3 Hose clamp:
nut: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
78.5 – 88.3 Nm {8.0 – 9.0 kgm}
64. Starting motor assembly

Install starting motor assemblies (2) and then
2) Install 2 water pipes (1) and 2 oil pipes (2).
3 Oil pipe joint bolt (Cylinder block
connect wiring harness (1).
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}
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.
170E-5 Series 57
2) Install the cover on PFUEL section (2) on a Clean and degrease the engine and the
the engine top face after its installation. 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
it and check again from step 2).
4) Run the engine at low idle.
66. Sensor tightening torque leakage.
When a sensor is replaced, tighten a new sen- a Check mainly around the high-pres-
sor to the following torque. sure circuit parts coated with the color
Sensor name Tightening torque a If any fuel leakage is detected, repair
Ne speed 4.9 – 7.9 Nm {0.5 – 0.8 kgm}
6) Run the engine at high idle.
Fuel temperature 23 ± 3 Nm {2.35 ± 0.3 kgm} 7) Check the fuel piping and devices for fuel
Coolant tempera- leakage.
23 ± 3 Nm {2.35 ± 0.3 kgm}
ture a Check mainly around the high-pres-
Engine oil pressure 23 ± 3 Nm {2.35 ± 0.3 kgm} sure circuit parts coated with the color
Fuel pressure Never disassemble.
Intake air tempera- it and check again from step 2).
23 ± 3 Nm {2.35 ± 0.3 kgm}
ture
8) Run the engine at high idle and load it.
Engine oil tempera- a When checking while the components
23 ± 3 Nm {2.35 ± 0.3 kgm}
ture to be checked are mounted on the
machine, stall the torque converter or
67. Checking of fuel leakage relieve the hydraulic pump.
a If fuel supply pump (1), common rail (2), or 9) Check the fuel piping and devices for fuel
high-pressure piping (3) is removed and leakage.
installed, after assembling the engine, a Check mainly around the high-pres-
check for fuel leakage according to the fol- sure circuit parts coated with the color
lowing procedure. checker for fuel leakage.
a If no fuel leakage is detected, the
check is completed.
58 170E-5 Series
170E-5 Series 59
SEN00766-04
© 2011 KOMATSU
All Rights Reserved
60
SEN00767-04
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 .............................................................................................................. 22
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 27. Supply pump drive gear and drive case
1) Remove fuel tube (1). 1) Remove cover (1).
2) Remove 4 rubber caps (4) from high-pres-
sure pipes (2) and (3).
3) Remove 3 clamps (5) and high-pressure
pipes (2) and (3).
2) Pull out pin (3) of barring device (2) and

push in the barring device to mesh it with
the gear.
3) Rotate barring device (2) to crank the
engine and set mark (C) of the supply
pump drive gear to that of the cam gear.

5) Remove 4 mounting bolts (7) and supply
pump assembly (8).
4) Remove supply pump drive gear (4).
6) If necessary, remove nut (9), washer (10),

coupling (11) and key (12) from supply
pump assembly (8).
170E-5 Series 7
5) Remove drive case (5). q Tool S
28. Brackets and high-pressure pipes 29. Common rail

1) Remove brackets (1) and (2). 1) Remove brackets (1), (2) and (3).
2) Remove 17 clamps (3) from the high-pres- 2) Remove fuel tube (4) and its peripheral
sure pipes. parts.
a Before removing the clamps, make 3) Remove common rail (5).
their location marks with paint. 4) Remove fuel junction block (6).
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.
a If tool S is not available, disconnect
the sleeves on the injector side from
above.
30. Spill tube

Remove spill tube (1).
31. Air connector, electrical intake air heater,

and housing and connector assembly
1) Remove air connector (1) and electrical
intake air heater (2).
8 170E-5 Series
2) Remove housing and venturi connector 3) Remove water pump assembly (4).
assembly (3).

32. Air intake manifold assembly 1) Remove thermostat housing (1).
1) Sling air intake manifold assembly (1) and
2) Lift off air intake manifold assembly (1).
90 kg
2) Remove thermostats (2) from thermostat

housing (1).

1) Remove water pipe (1).
2) Remove stopper (2) and move bypass

tube (3) up.
170E-5 Series 9
35. Front hanger and water housing 37. Injector wiring harness
1) Remove bracket (1) and water tube (2). 1) Loosen terminal mounting nut (1) to dis-
connect the wiring harness.
2) Remove wiring harness fixing bolts (2)
and spacer (3).
2) Sling front hanger (3) and remove the

mounting bolts.
3) Lift off water housing (4) and front hanger
(3) together.
4 Front hanger: 65 kg 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). 38. Rocker arm assembly
a Cover (2) is not installed on some 1) Loosen locknuts (1) and loosen adjust-
applicable machines. ment screws (2) fully.
a Check that the rocker arm does not
receive any tension and is free.
2) Remove rocker arm assembly (3).
10 170E-5 Series
a Put a location tag to each removed 40. Rocker housing

rocker arm assembly so that you will Remove rocker housing (1).
not mistake it for another.
41. Crosshead
3) Remove exhaust rocker arm (4) and Remove crossheads (1).
intake rocker arm (5) from shaft (6).
42. Fuel injector assembly

39. Push rod 1) Remove injector holder (1).
Remove push rods (1).
170E-5 Series 11
2) Using tool A, remove fuel injector assem- 1] Using tool B, compress the valve
bly (2). spring and remove valve cotter (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.
2] Remove spring seat (3).

3] Remove valve spring (4).
43. Cylinder head assembly

1) Lift off cylinder head assembly (1).
a If the cylinder head assembly is
removed with the injector assembly
installed, the injector assemb ly
projects from the cylinder head bot-
tom. Accordingly, prevent the injector
from interfering with the floor by using
a block etc.
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
exhaust valve (7) from cylinder head
(8).
a Check the installed positions of
the valve and related parts and
12 170E-5 Series
keep them so that they will not be 46. Oil level gauge and oil filler pipe
mixed up. 1) Remove oil level gauge (1).
2) Remove oil filler pipe (2).

Remove oil cooler assembly (1). 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.

2) Remove drive housing assembly (2).
4) Using tools C, sling the engine and

remove oil pan (1).
4 Oil pan: 85 kg
170E-5 Series 13
5) Support the engine again securely with 2) Remove cam follower assembly (2).
block [1]. a Rotate the crankshaft with the barring
a See 2 "Setting engine assembly". device to set the piston to the follow-
ing positions and remove the cam fol-
48. Suction pipe and underplate lower assembly.
1) Install underplate (1) temporarily with sev- q No. 1 compression top dead cen-
eral oil pan mounting bolts. ter: No. 1 and No. 5 cam follower
2) Remove brackets (2) and (3) and suction can be removed.
pipe (4). q No. 2 compression top dead cen-
3) Disconnect the gasket sealant. ter: No. 2 and No. 4 cam follower
4) Remove the bolts tightened temporarily can be removed.
and then remove underplate (1), using a q No. 3 compression top dead cen-
jack etc. ter: No. 3 and No. 6 cam follower
4 Underplate: 30 kg 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.

1) Remove cam follower cover (1).
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
50. Vibration damper 52. Front idler gear assembly

1) Sling vibration damper (1) and remove the 1) Remove idler gear (larger one) (1).
mounting bolts. 2) Remove idler gear (smaller one) (2).
2) Lift off vibration damper (1).
3) Remove spacer (3) and shaft (4) from idler

gears (large and small gears).
51. Front cover a The same structure is employed for
1) Lift up front cover (1) temporarily and then both the large and small gears.
2) Lift and remove front cover (1).
4 Front cover: 50 kg

Remove oil pump assembly (1).
3) Remove dust seal (2) and oil seal (3) from

the front cover.
a Dust seal is provided only on the
vehicle-mounted engines alone.
170E-5 Series 15
54. Engine mount 56. Flywheel housing

1) Remove the front engine mount. 1) Remove Ne speed sensor (1) and barring
2) Remove rear engine mount (1). device (2).
4 Rear engine mount: 30 kg
a The weight varies with the applicable
machines.
2) Lift flywheel housing (3) temporarily and

55. Flywheel assembly 4 Flywheel housing: 150 – 180 kg
1) Lift flywheel assembly (1) temporarily and a The weight varies largely with the
then remove the mounting bolt. applicable machines.
4) Remove rear oil seal (4) from the flywheel

housing.
16 170E-5 Series
57. 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).

1) Remove rear idler gear assembly (1).
59. Installation to engine repair stand

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
170E-5 Series 17
60. Piston cooling nozzle 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.
pistons.
pistons.
3) Sequentially remove 6 each of cooling
nozzles (1) and (2).
a Maintain them on the cylinder No. 5) Remove connecting rod bearing (2) from
basis using a tag or the like. connecting rod cap (1).

1) Move the piston of the cylinder to be
removed to the bottom dead center posi-
6) Push the connecting rod from the crank-
tion by rotating the crankshaft.
shaft side to remove the piston and con-
2) Loosen the connecting rod bolt by 5 to 6
nection rod assembly (3).
turns.
a When removing the piston and con-
a Lightly strike the connecting rod head
necting rod assembly, support the
with a plastic hammer to separate the
assembly at the cylinder side so that
connecting rod cap from the connect-
it may not fall off. Then push the con-
ing rod.
necting rod end portion to remove the
3) Move the piston to the top dead center
assembly.
position by rotating the crankshaft.
a Pull the assembly horizontally so that
the connecting rod may not damage
the cylinder liner.
18 170E-5 Series
3] Remove piston pin (6).

4] Remove connecting rod (7).
a The connecting rod and cap are
a set of parts. Thus they must be
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
62. Crankshaft assembly 5) Lift and remove crankshaft assembly (4).

1) Set the crankshaft side up. a Thrust washers are provided for No. 6
2) Remove the main cap mounting bolt. bearing. Thus reasonable care must
3) For removal, sway main cap (1) back and be exercised to prevent their falling
forth using the mounting bolt. off.
a Thrust washers are provided for No. 6 4 Crankshaft assembly: 270 kg
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
4) Remove main bearing metal (2) and 2 alone.
thrust washers (3) from main cap (1). a Maintain them on the bearing No.
a Thrust washers are provided on No. 6 basis using a tag or the like.
main cap alone.
a Maintain them on the main cap No.
20 170E-5 Series
63. Cylinder liner

1) Set the cylinder head side up.
2) Using tool G, remove cylinder liner (1).
64. 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.
following precautions be fore using 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.
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:
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 I1, I2, measure projection of the cyl-
inder liner.
a When measuring the liner projection,
tighten the liner with tool I2 to prevent
it from being floated by the O-ring.
a When measuring the liner 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-
ture , fun ctio n an d m a inten a n ce
8) Install the head gasket and then tempo- standard”.
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).
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.
170E-5 Series 25


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].
ture, function and maintenance
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 (1).
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:
28 170E-5 Series
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).

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).
170E-5 Series 29
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].
tu re , fun ctio n an d m a inten a n ce
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}
30 170E-5 Series
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.
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
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)
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
14. Flywheel housing
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.
170E-5 Series 33
5) Install rear seal q Procedure for installing sleeved seal

a Check the Teflon seal (Laydown lip a When installing the rear seal, do not apply
seal) by checking the wear of the oil or grease to the shaft and sleeve inside
shaft and replace it with the “Standard cylinder surface (C).
seal” or “Sleeved seal”. 1] Set sleeve and rear seal assembly (6)
a When wear on the shaft is not serious to tool L3.
and only makes it look lustrous (depth 2 Sleeve inside cylinder surface
of wear is 10 mm or less when (C): Gasket sealant (LG-7)
checked with finger cushion) and no 2] Set sleeve (7) of the rear seal to the
scratch is recognized, assemble the end of crankshaft (5) and tighten the
standard seal (A). When the above is 5 bolts (45 mm) evenly to press fit
not applicable, assemble sleeved sleeve and rear seal assembly (6)
seal (B). until the end of tool L3 reaches the
a (3): Shows the plastic inside cylinder end of crankshaft (5).
doubling the assembly guide.
a Don't remove assembly guide (3)
from rear seal (2) until the assembly
is complete.
a Handle rear seal (2) and sleeve (5) as
an integral part. Don't try to separate
them.
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)
34 170E-5 Series
15. Under plate

1) Raise and invert the engine to move the
oil pan side to the top.
2) Apply gasket sealant and then install
under plate (1).
2 Under plate: Gasket sealant (LG-7)
applied to the entire perimeter as
shown below.
a Tighten 4 inside positions and several
outside positions temporarily using
the bolts until installation of the suc-
tion tube and oil pan is completed.
3) Lift down engine assembly (1) on blocks

[1] and then remove tools C and tool D2.
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
16. Removal from engine repair stand and flywheel housing.
1) Raise and invert the engine to move the a Tighten the mounting bolts in the fol-
cylinder head side to the top. lowing order.
2) Using tool C, lift and remove engine 2 Flywheel assembly mounting bolt:
assembly (1) from tool D1. Engine oil (EO30)

1st time: 196.1 ± 19.6 Nm {20 ± 2 kgm}
2nd time: 460.9 ± 19.6 Nm {47 ± 2 kgm}
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 (4)

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 (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).
170E-5 Series 37
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).
20. Vibration damper

Lift and install vibration damper (1).
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 pistons can be
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 pistons can be
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 pistons can 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.
38 170E-5 Series
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).
170E-5 Series 39
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}
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}
40 170E-5 Series
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}
170E-5 Series 41
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}
42 170E-5 Series
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.
170E-5 Series 43
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}
44 170E-5 Series
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
31. Front hanger and water housing

1) Sling and install water housing (4) and
front hanger (3) together.
4 Front hanger: 65 kg
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}
170E-5 Series 45
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.
46 170E-5 Series
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.
170E-5 Series 47
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)
48 170E-5 Series
3 Oil level gauge:

44.1 – 58.8 Nm {4.5 – 6.0 kgm}

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.

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).
170E-5 Series 49
2) Fit the gasket and install thermostat hous- 44. Supply pump assembly
ing (1). 1) Install key (12), coupling (11) and washer
(10) to suplly pump assembly (8), then
tighten with nut (9).
a Be careful not to forget the key (12)
when installing tne coapling (11).
3 Nut:
176 – 196 Nm {18 – 20 kgm}

1) Install water pump assembly (4).
2) Move bypass tube (3) down and fix it with
stopper (2).
2) 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.)
3) Fit the gasket and install water pipe (1).

a The type of water pipe (1) is subject
to the applicable machine.
50 170E-5 Series
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.
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).
3 Fuel tube joint bolt (Supply pump
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}
170E-5 Series 51
47. Lubrication tube 5) Install fuel tube (4) and install the 3
1) Fit the O-ring and install adapter (2). clamps.
2) Install oil tube (1). 3 Fuel tube joint bolt:
3 Oil tube joint bolt: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
9.8 – 12.7 Nm {1.0 – 1.3 kgm} a Fit the washers to the bottom of the
3) Connect the 2 tube clamps. 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}
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}
52 170E-5 Series
3) Install fuel tube (1) to the filter head and 53. Fuel filter and filter head assembly
install the 3 clamps. 1) Install fuel filter and filter head assembly
3 Fuel tube joint bolt: (2).
19.6 – 29.4 Nm {2.0 – 3.0 kgm} 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}
51. Cover
Install cover (1).
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).

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}
170E-5 Series 53

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}
3 Fuel tube joint bolt (Supply pump
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 th ey cannot be pulled out whe n
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).
54 170E-5 Series
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.
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)
170E-5 Series 55
62. Turbocharger assembly 53.9 – 73.5 Nm {5.5 – 7.5 kgm}

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
tube (2), and install the 1 clamp. 64. Starting motor assemblies
5) Install water tube (1) and bracket together. 1) Install starting motor assemblies (4) and
3 Water tube joint bolt (Turbocharger (3) and connect wiring harness (2).
side): 2) Install bracket (1) and connect the wiring
24.5 – 34.3 Nm {2.5 – 3.5 kgm} harness connector.
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):
56 170E-5 Series
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.
170E-5 Series 57

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.
58 170E-5 Series
170E-5 Series 59
SEN00767-04
© 2011 KOMATSU
All Rights Reserved
60
SEN00768-02
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}
Sleeve nut: 43 – 47 Nm {4.4 – 4.8 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}
Sleeve nut: 24 – 27 Nm {2.4 – 2.7 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.
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
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)
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 q Tool L1

a For the work up to removal of the flywheel,
see the shop manual for the applicable
machine.
a For the standard seal and seal with
sleeve, see "Installation".
Removal of rear seal

a Take care in the removal not to damage
the seal installation position on the fly-
wheel housing and the seal contact sur-
face on the crankshaft.
a Before removing, slightly drive the seal in
once to free it from fixation.
a When rear seal (2) is fixed too hard to the
flywheel housing (FWH), remove the fol-
lowing procedure.
a The left one in the following figure is the
standard seal and the right one is the
sleeved seal.
1) Replace the tip of tool L1 with the drill type
one.
2) Drill several holes about 3 mm in diameter
into rear seal (2).
3) Set tool L1 to the drilled hole. (Tip: Drill
type)
4) Remove rear seal with impact of slide
hammer (SH).
a When the sleeve is attached, cut sleeve
(5) using a gad and hammer to remove it.
a Take care not to damage crankshaft (4).
a Remove all the chips.
170E-5 Series 7
Installation q Procedure for installing standard seal

a Don't apply gear oil to the seal lip surface.
a Check the Teflon seal (Laydown lip seal) by 1) Contact larger inner diameter side (b) of
checking the wear of the shaft and replace it plastic inside cylinder (3) of rear seal (2)
with the “Standard seal” or “Sleeved seal”. against the end face of crankshaft (4).
a When wear on the shaft is not serious and only a Take care not to mistake the direction
makes it look lustrous (depth of wear is 10 mm of the plastic inside cylinder.
or less when checked with finger cushion) and
no scratch is recognized, assemble the stan-
dard seal (A). When the above is not applica-
ble, assemble sleeved seal (B).
a (3): Shows the plastic inside cylinder doubling
the assembly guide.
a Don't remove assembly guide (3) from rear
seal (2) until the assembly is complete.
a Handle rear seal (2) and sleeve (5) as an inte-
gral part. Don't try to separate them.
2) Applying equal force to both hands, push

in the hoop of rear seal (2).
3) After pushing in rear seal (2), remove
plastic inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
a Clean, degrease and then dry the contact sur-

face between the rear seal and flywheel hous-
ing.
a Clean foreign matter deposited on the seal lip
surface (surface around the crankshaft) and
then degrease and dry the surface.
a Check the crankshaft end face corner and lip
siding surface for scratches due to the hous-
ing, burrs or rusts.
4) Tighten bolts evenly until the end face of tool
L2 reaches the end face of crankshaft (4) to
press fit seal (1).
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
SEN00768-02
© 2009 KOMATSU
All Rights Reserved
10
SEN05194-02
ENGINE 1SHOP MANUAL
170E-5 Series

Information related to repair and replacement
Flowchart ........................................................................................................................................................ 2
Special tool table ............................................................................................................................................. 4
Sketches of special tools ................................................................................................................................ 6
170E-5 Series 1
SEN05194-02 90 Repair and replacement of parts
Flowchart
Repair of cylinder block top and counterbore by grinding
a For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
a If the judgment of No. 9 is NO, examine A. If the result is NO again, examine B.
2 170E-5 Series
90 Repair and replacement of parts SEN05194-02
170E-5 Series 3
Special tool table

Replacement/Rebuilding
Symbol Part No. Part name Q'ty Remarks
item
Pressure test of cylinder A 790-553-1701 Coolant tester 1 KIT
head B 79A-471-1050 Pump assembly 1
Replacement of valve 1 795-100-1522 Push tool 1
C
guide 2 795-411-1310 Push tool 1
D 795-100-4801 Seat puller 1 For valve seat insert
1 795-611-1410 Push tool 1 For intake valve
E
2 795-611-1420 Push tool 1 For exhaust valve
795-100-3005 Seat cutter 1 KIT
795-100-3100 Body assembly 1
795-100-3200 Micrometer 1
1
795-100-3300 Gauge 1
Replacement of valve seat 795-100-3401 Tool head 1
insert 795-100-3601 Head support 1
F 2 795-100-3710 Cutter 1 For oversize machining
3 795-100-3720 Cutter 1 For 30°
4 795-100-3730 Cutter 1 For 45°
795-100-4611 Pilot 1 f12.000 mm
795-100-4621 Pilot 1 f12.010 mm
5
795-100-4631 Pilot 1 f12.020 mm
795-100-4641 Pilot 1 f12.030 mm
Replacement of crosshead 1 795-140-6410 Guide puller 1
G
guide 2 795-130-1310 Guide driver 1
Commercially
Repair of valve by grinding H Valve refacer 1
available
Check of main bearing
Commercially
mounting hole inside J Alignment bar 1
available
diameter
Replacement of crankshaft 1 790-101-2800 Bearing puller 1
K
gear 2 790-101-2300 Push puller 1
L 795-240-6401 Push tool 1 KIT
1 795-240-6411 Push tool 1
Replacement of connecting
2 795-240-6420 Push tool 1
rod small end bushing L
3 795-240-6431 Block 1
4 795-240-6440 Nut 1
M 795T-621-1700 Push tool 1 KIT
1 790-250-1310 Bar 1
2 790-472-1050 Bar 1
Replacement of cam
3 795-250-1320 Bar 1
bushing M
4 795T-621-1710 Push tool 1
5 795T-621-1720 Guide 1
6 795T-621-1730 Collar 1
4 170E-5 Series
Replacement/Rebuilding
Symbol Part No. Part name Q'ty Remarks
item
N 795-931-1100 Seal puller assembly 1
1 795-931-1170 Case 1
2 795-931-1160 Screw 1
Replacement of engine 3 795-931-1150 Seal puller 1
rear seal N 4 795-931-1140 Rod 1
5 795-931-1130 Adapter 1
6 795-931-1120 Rod 1
7 795-931-1110 Hammer 1
170E-5 Series 5
Sketches of special tools 1

M Push tool
M4 Push tool
6 170E-5 Series
M5 Guide
M6 Collar
170E-5 Series 7
SEN05194-02
© 2010 KOMATSU
All Rights Reserved
8
SEN05195-01
ENGINE 1SHOP MANUAL
170E-5 Series

Parts related to cylinder head
Part names related to cylinder head ............................................................................................................... 2
Testing and inspection of cylinder head .......................................................................................................... 3
Pressure test of cylinder head ........................................................................................................................ 5
Replacement of valve guide............................................................................................................................ 5
Replacement of valve seat insert.................................................................................................................... 6
Replacement of crosshead guide ................................................................................................................. 14
Repair of cylinder head mounting face by grinding ....................................................................................... 15
Repair of valve by grinding ........................................................................................................................... 16
170E-5 Series 1
Part names related to cylinder head
1. Cylinder head
2. Crosshead guide
3. Valve guide
4. Valve seat insert (exhaust side)
5. Valve (exhaust valve)
6. Valve (intake valve)
7. Valve seat insert (intake side)
2 170E-5 Series
Testing and inspection of cylinder head

Unit: mm
Inspection item Criteria Remedy
• Presence of crack (External dye check)
• Water jacket: No leakage for 30 seconds at test air pressure of
Water leakage from and crack 0.30 – 0.35 MPa {3.0 – 3.5 kg/cm2}. Replace cylinder
• Fuel line hole: No leakage for 30 seconds at test air pressure of
of cylinder head head
0.02 MPa {0.2 kg/cm2}.
• Air passage: No leakage for 30 seconds at test air pressure of
0.30 – 0.35 MPa {3.0 – 3.5 kg/cm2}.
Top: 0.06
Repair by grinding
Distortion of cylinder head top Bottom: 0.06
or replace cylinder
and bottom Inside of 8 around machined hole: 0.008 head
Inside of 8 around water hole: 0.008
Damage and contact width of Repair by grinding
injection nozzle seat surface or replace
a See Fig. A Replace cylinder
Projection of injector nozzle head, injector or
Allowable range of projection (a): 2.33 – 2.97 gasket
• Presence of dent on valve seat insert contact surface Repair valve seat
Damage of valve contact
• Check of contact surfaces of valve and valve seat insert insert contact
surface of valve seat insert or
looseness of valve seat insert • Airtightness test surface or replace
• Looseness (Hit cylinder head lightly) valve seat insert
a See Fig. B
Valve sinking quantity Sink (b)
Replace valve or
(both intake and exhaust Standard value Repair limit
valve seat insert
valves)
(Sink) 0.39 – (Projection) 0.21 (Sink) 0.80
a See Fig. C
Valve head thickness (d)
Valve Standard value Repair limit
Intake 3.2 2.7
Valve head thickness
Exhaust 3.3 2.9
Valve seat contact surface angle (c) Replace valve
Intake valve: 30°
Exhaust valve: 45°
• Deformation of head into dish shape
• Presence of crack or dent on seat contact surface of valve
• Airtightness test
Abnormality in valve
• Play when new cotter pin is inserted in cotter groove
• Uneven wear or bend of valve stem
• Presence of dent at valve stem end
Valve Standard size Standard value Repair limit
Outside diameter of valve Intake 12 11.920 – 11.940 11.90
Replace valve
stem
Exhaust 12 11.893 – 11.908 11.80
Intake 12 11.981 – 11.998 12.18

Inside diameter of valve guide
Replace valve
Exhaust 12 11.981 – 11.998 12.18
guide
a See Fig. D
Projection of valve guide
Allowable range of projection (e): 42.5 – 43.5
Standard size Standard value Repair limit
Outside diameter of crosshead Replace crosshead
guide 13 13.028 – 13.039 13.00 guide
Projection of crosshead guide a See Fig. E Repair crosshead

Allowable range of projection (f): 85.75 – 86.25 guide
170E-5 Series 3
Illustrations related to testing and inspection table
Fig. A Fig. D
a: Projection e: Projection
1. Injector
2. Cylinder head Fig. E
3. Gasket
Fig. B
f: Projection
1. Crosshead guide
2. Cylinder head
b: Sink
Fig. C
c: Valve seat contact surface angle

d: Valve head thickness
4 170E-5 Series
Pressure test of cylinder head Replacement of valve guide

a Pressure test tools a Valve guide replacement tools
Symbol Part No. Part name Symbol Part No. Part name
A 795-611-1900 Coolant tester 1 795-100-1522 Push tool
C
B 79A-471-1050 Pump assembly 2 795-411-1310 Push tool
Pulling out of valve guide

q Using tool C1, pull out the valve guide.
q If the cylinder head parts were repaired, per-

form the test according to the following proce-
dure.
Press fitting of valve guide
Water pressure test 1. Press fit the valve guide until the tool C2 end
1. Combine tools A and B and connect the hose touches the cylinder head.
to the cylinder head.
2. Check that the projection of the valve guide is
2. Apply water pressure (0.35 – 0.40 MPa {3.5 – within the standard value.
4.0 kg/cm2}) for about 10 minutes and check
around the cylinder head for leakage.
a Warm the whole cylinder head and then per-

form the test with hot water at 80 – 95°C.
k Take care in handling the hot cylinder head
and water to avoid being burnt or scalded.
Air pressure test

1. Connect the air compressor hose to the cylin-
der head.
2. Put the cylinder head in a water tub, apply air

pressure (0.30 – 0.35 MPa {3.0 – 3.5 kg/cm2}
a Projection tolerance of valve guide:
for about 30 seconds, and check for air leak-
43 ± 0.5 mm
age.
a Diameter of cylinder head valve guide hole:
f19 +0.021 mm
a If any crack is detected in the cylinder head by 0
the above tests, replace the cylinder head.
170E-5 Series 5
Replacement of valve seat insert Exhaust valve
a Valve seat insert replacement tools

D 795-100-4801 Seat puller
1 795-611-1410 Push tool
E
2 795-611-1420 Push tool
1 795-100-3005 Seat cutter
2 795-100-3710 Cutter
F 3 795-100-3720 Cutter
4 795-100-3730 Cutter
5 795-100-4611 Pilot
Repair by machining
q When not replacing but repairing the valve Intake valve
seat insert by machining (when its surface is
roughened or it is worn steppedly), machine it
so that the valve sink quantity will be within the
allowable limit.
Machining dimensions of new valve seat insert

Intake valve Exhaust valve
Seat surface angel (a) 30° 45°
Finished width (b) 3.5 mm 4 mm
Outside diameter (c) 62 ± 0.05 mm 60.4 ± 0.05 mm
Inside diameter (d) — 53 mm
Seat surface roughness Max. 3.2S
Check of valve seat insert for looseness

q Check the valve seat insert of the cylinder
head for looseness by hitting around it lightly
with a hammer.
q If the valve seat insert is loose and springs
back, replace it.
6 170E-5 Series
Pulling out of valve seat insert

k Keep the air pressure at 0.5 – 0.6 MPa {5 – 6
kg/cm2} during the work.
k When replacing the grinding stone, stop
the air.
k Before starting the grinding work, perform
a trial operation of the grinder for 1 minute
and ensure that the grinder is normal.
a After replacing the grinding stone, perform
a trial operation for 3 minutes.
k Ensure that the grinding stone is free from
damage and install it to the grinder shaft
with no play.
k
6. Push in 3 claws (10) of puller head (9) of tool D
When using the grinder, put on safety
with the hand and put them in valve seat insert
glasses.
(a).
When pulling out with seat puller of tool D
7. Tighten screw (12) to press 3 claws (10)
1. Install grinding stone (4) to grinder (1).
against the inside groove of valve seat insert
(a).
2. While matching the groove of sleeve (2), insert a If screw (12) is tightened too strongly, the
the grinder in holder (3). insert will be broken and become difficult
(Adjust the grinder position with set screw (5).) to pull out. Accordingly, stop tightening
when 3 claws (10) reach the groove fully.
3. Adjust the position of grinder (1) so that the
center of grinding stone (4) will be at the center
8. Put bridge (8) in the outside of puller head (9),
of valve seat insert (a) and then tighten set
place plates (11) and (7) on the bridge, and
screw (5) to fix grinder (1). tighten nut (6) to pull out valve seat insert (a).
4. Rotate grinding stone (4) and move it slowly
until it touches valve seat insert (a).
5. While lightly pressing grinding stone (4)

against the inside surface of valve seat insert
(a), make a groove about 1 mm deep all
around the inside surface of valve seat insert
(a).
170E-5 Series 7
Press fitting of valve seat insert

1. Using tool E1 or E2, press fit standard valve
seat insert (a) with press (d).
2. Measure sinking quantity (f) of valve seat

insert (a) from cylinder head bottom (e).
a Sinking quantity (f) of valve seat insert (a)
Intake side: 2.7 – 3.0 mm
Exhaust side: 2.4 – 2.7 mm
8 170E-5 Series
170E-5 Series 9
Oversize machining of valve seat insert

mounting hole
q Using tool F1 and attached cutter F2, increase
the valve seat insert mounting hole to the next
oversize.
a Limit the increase of the mounting hole diame-

ter to 1.0 mm. If the hole diameter needs to be
increased more than 1.0 mm, replace the cylin-
der head.
Machining dimensions of valve seat insert and mounting hole

Intake valve side Unit: mm
Valve seat insert Valve seat insert mounting hole
Valve seat insert size
d1 c1 d2 c2 r
Standard 64.0 +0.105 8.5 +0.1 64.0 +0.019 11.4 ± 0.1 0.4 +0.1
+0.080 0 0 0
0.25 OS 64.25 +0.105 8.5 +0.1 64.25 +0.019 11.4 ± 0.1 0.4 +0.1
+0.080 0 0 0
0.50 OS 64.5 +0.105 8.62 +0.1 64.5 +0.019 11.52 ± 0.1 0.4 +0.1
+0.080 0 0 0
0.75 OS 64.75 +0.105

+0.080 8.75 +0.1
0 64.75 +0.019
0 11.65 ± 0.1 0.4 +0.1
0
1.00 OS 65.0 +0.105 8.88 +0.1 65.0 +0.019 11.78 ± 0.1 0.4 +0.1
+0.080 0 0 0
a OS: Oversize
Exhaust valve side Unit: mm

Valve seat insert Valve seat insert mounting hole
Valve seat insert size
d1 c1 d2 c2 r
Standard 63.60 +0.100 9.7 +0.1 63.60 +0.019 12.3 ± 0.1 0.4 +0.1
+0.080 0 0 0
0.25 OS 63.85 +0.100 9.7 +0.1 63.85 +0.019 12.3 ± 0.1 0.4 +0.1
+0.080 0 0 0
0.50 OS 64.10 +0.100 9.82 +0.1 64.10 +0.019 12.42 ± 0.1 0.4 +0.1
+0.080 0 0 0
0.75 OS 64.35 +0.100 9.95 +0.1 64.35 +0.019 12.55 ± 0.1 0.4 +0.1
+0.080 0 0 0
1.00 OS 64.60 +0.100 10.08 +0.1 64.60 +0.019 12.68 ± 0.1 0.4 +0.1
+0.080 0 0 0
a OS: Oversize
10 170E-5 Series
Valve seat insert Finish machining of valve contact surface

of valve seat insert
1. Using tool F1 and attached cutters F3 and F4,
machine the valve contact surface of the valve
seat insert to the following dimensions.
a Select tool F5 which will be inserted in the
valve guide with no clearance.
Valve seat insert mounting hole
Intake valve Exhaust valve

Seat surface angel (a) 30° 45°
Finished width (b) 3.5 mm 4 mm
Outside diameter (c) 62 ± 0.05 mm 60.4 ± 0.05 mm
Inside diameter (d) — 53 mm
Seat surface roughness Max. 3.2S
g: Cylinder head bottom Intake valve
a Inside finished surface roughness: Max. 12.5S

a Mounting hole bottom surface roughness:
Max. 12.5S
a Concentricity of valve guide hole and valve
seat insert hole: Max. 0.07 mm (TIR)
a Squareness of valve guide hole to valve seat
insert hole bottom: Max. 0.03 mm (TIR)
a TIR is an abbreviation for Total Indicator Read-
ing, which is the difference between the maxi-
mum and minimum readings in runout
measurement.
Exhaust valve
170E-5 Series 11
2. Fit the contact surface of the valve seat insert Final inspection
to the valve by using compound. q Thinly apply red lead to the valve seat insert
1) Thinly apply rough compound mixed with contact surface of a new valve and insert that
oil to the seat surface of a valve and insert valve in the valve guide.
that valve in the valve guide. q Lightly press the valve against the valve seat
2) Install the fitting rod to the valve head and insert and rotate it 10°.
lightly hit valve against the valve seat q Check the valve seat insert contact surface of
while rotating it with both hands to fit the the valve and ensure that the contact is even
valve to the valve seat. and is not broken.
3) After the valve and valve seat are fitted q Or, make marks (m) (about 20 places) on the
and their surfaces become smooth, wipe valve seat insert contact surface of a new
off the compound. valve with a pencil and insert that valve in the
4) Apply fine compound and fit the valve and valve guide.
valve seat again similarly to the above q Lightly press the valve against the valve seat
until they are fitted to each other without insert and rotate it 10°.
breakage. q Ensure that all the pencil marks (m) have been
erased evenly.
a Concentricity of contact surfaces of valve
guide and valve seat insert:
Max. 0.07 mm (TIR)
ing, which is the difference between the maxi-
mum and minimum readings in runout
measurement.
a Sinking quantity and projection (c) of valve (1):

(Sink) 0.39 – (Projection) 0.21 mm
EV: Exhaust valve

IV: Intake valve
d: Cylinder head bottom
12 170E-5 Series
Airtightness test
q When performing an airtightness test with a
vacuum tester, follow the procedure shown
below.
1. Wipe off dirt and oil with cloths from the valve
and valve seat insert seat.
2. Install the valve spring, retainer, cotter and

valve.
3. Lightly hit the valve stem end 2 – 3 times from

straight above with a plastic hammer to fit the
seat.
4. Fit the vacuum cup of the valve size to the

head surface.
5. Apply grease to the O-ring to be fitted to the

vacuum cup for better airtightness of the vac-
uum cup and fit the vacuum cup to the flat face
of the head.
a Take care that the grease will not stick to
the seat surface.
6. Set the vacuum gauge to 93.3 kPa {700

mmHg}. If the maximum vacuum drop in 3 sec-
onds is 1.3 kPa {10 mmHg} or less, it is accept-
able.
a If the vacuum drop exceeds 1.3 kPa {10
mmHg}, check the seat surface for dirt or
repair it by fitting.
170E-5 Series 13
Replacement of crosshead guide Press fitting of crosshead guide

q Using tool G2, insert crosshead guide (a) in
a Crosshead guide replacement tools cylinder head (b) and press fit it with a copper
Symbol Part No. Part name or plastic hammer until the projection is within
1 795-140-6410 Guide puller the tolerance.
G
2 795-130-1310 Guide driver
a Projection tolerance of crosshead guide:
86 ± 0.25 mm
a Diameter of cylinder head crosshead guide
Pulling out of crosshead guide hole: f13 +0.008
–0.010 mm
q Using tool G1, pull out crosshead guide (a)
from cylinder head (b).
1. Hold crosshead guide (a) with collet (4) of the
puller.
2. Tighten collet (4) with bolt (1) to lock sleeve

(2).
3. Rotate nut (3) and pull out the crosshead

guide.
4. Remove burrs and fins from and clean the

crosshead guide mounting portion.
14 170E-5 Series
Repair of cylinder head mounting

face by grinding
Grinding
1. Remove the valve seat insert.
q For the removal procedure, see "Replace-
ment of valve seat insert".
2. Remove the distortion and corrosion of the cyl-

inder head by grinding within the tolerance of
cylinder head height (a).
q Stamp "R" on the left side of the cylinder
head.
a Cylinder head height (a)

Limit of size: 150.65 mm
Standard dimension: 150.95 – 151.05 mm
a Limit after grinding: 150.65 mm
a Grinding depth by 1 grinding: 0.10 – 0.15 mm
a Ground surface roughness
Top: 12.5S
Bottom: 4S
a Flatness (Distortion): Max. 0.05 mm
a Grinding depth limit: 0.3 mm
a Difference in head height (a) for 1 unit:
Max. 0.15 mm
3. Press fit the valve seat insert of the next over-

size.
q For the press fitting procedure, see
"Replacement of valve seat insert".
Check after repair by grinding

q Measure the sinking quantity of the valve and
projection of the injector and ensure that they
are within the standard values and then adjust
if necessary.
a Valve sinking quantity:
(Sink) 0.39 – (Projection) 0.21 mm
a Allowable range of injector projection:
2.33 – 2.97 mm
170E-5 Series 15
Repair of valve by grinding a Apply dial gauge (1) to the facial runout mea-
suring point of seat contact surface (c) of the
a Valve grinding tool valve and rotate the valve to measure its facial
Symbol Part No. Part name runout while pressing it toward left (d).
Commercially Intake valve: Max. 0.045 mm (TIR)
H Valve refacer
available Exhaust valve: Max. 0.030 mm (TIR)
Grinding of seat contact surface of valve ing, which is the difference between the maxi-
q Using tool H, grind the seat contact surface of mum and minimum readings in runout
the valve. measurement.
a Seat contact surface angle of valve (a) e: Block

Intake valve: 30°
Exhaust valve: 45° a Check the contact of the seat contact surface
of the valve by either of the following methods.
Check after grinding Red lead
q Measure the valve head thickness, sinking q Thinly apply red lead to the seat contact sur-
quantity of the valve, and contact of the seat face of the ground valve and insert that valve
contact surface of the valve, and ensure that in the valve guide.
they are within the standard values. q Lightly press the valve against the valve seat
a Allowable limit of valve head thickness (b) insert and rotate it 10°.
Intake valve: q Check the valve seat insert contact surface of
Min. 2.7 mm (Standard size: 3.2 mm) the valve and ensure that the contact is even
Exhaust valve: and is not broken.
Min. 2.9 mm (Standard size: 3.3 mm)
Pencil
a Valve sinking quantity
q Make marks (f) (about 20 places) on the seat
Standard: (Sink) 0.39 – (Projection) 0.21 mm
contact surface of the ground valve with a pen-
Allowable limit: (Sink) 0.80 mm
cil and insert that valve in the valve guide.
q Lightly press the valve against the valve seat
insert and rotate it 10°.
q Ensure that all the pencil marks (f) have been
erased evenly.
16 170E-5 Series
170E-5 Series 17
SEN05195-01
© 2010 KOMATSU
All Rights Reserved
18
SEN05196-01
ENGINE 1SHOP MANUAL
170E-5 Series

Parts related to cylinder block
Part names related to cylinder block............................................................................................................... 2
Testing and inspection of cylinder block.......................................................................................................... 3
Part names related to crankshaft .................................................................................................................... 6
Testing and inspection of crankshaft............................................................................................................... 7
Part names related to connecting rod ............................................................................................................. 8
Testing and inspection of connecting rod........................................................................................................ 9
Replacement of flywheel ring gear................................................................................................................ 10
Replacement of crankshaft gear ....................................................................................................................11
Replacement of camshaft gear ..................................................................................................................... 12
Replacement of main bearing metal cap ...................................................................................................... 13
Replacement of connecting rod small end bushing ...................................................................................... 15
Replacement of cam bushing ....................................................................................................................... 16
Replacement of engine rear seal .................................................................................................................. 18
Repair of cylinder block top by grinding ........................................................................................................ 19
Repair of counterbore by grinding................................................................................................................. 20
Check and identification after repair by grinding ........................................................................................... 22
Gasket sealant application procedure........................................................................................................... 23
Repair of crankshaft by grinding ................................................................................................................... 26
Improvement of surface roughness of crankshaft journal ............................................................................. 31
170E-5 Series 1
Part names related to cylinder block
1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing metal cap bolt
6. Main bearing metal cap
7. Camshaft bushing
2 170E-5 Series
Testing and inspection of cylinder block

Unit: mm
Presence of crack (External dye check)
Crack
Cylinder head bolt hole etc. Replace cylinder
a See Fig. A block
Repair of contact of packing
Water leakage caused by corrosion
a See Fig. B
Standard value
Standard Replace cylinder
Standard size Bore of Outside diameter
Clearance to cylinder liner clearance liner or cylinder
cylinder block of cylinder liner block
190.40 190.34 – 190.40 190.19 – 190.29 0.05 – 0.21
Inside diameter
90 90.112 – 90.222 90.251
Inside diameter of camshaft Replace camshaft
bushing Clearance to camshaft bearing bushing
Standard clearance Allowable clearance
0.077 – 0.217 0.284
Replace cylinder
a See Fig. C
Projection of cylinder liner liner or repair
Allowable range: 0.07 – 0.15 cylinder block
a See Fig. D
Presence of corrosion
Depth and bottom corrosion of Repair by cutting
Standard size Standard value
counterbore Add shim
14 14.00 – 14.05
Tolerance Repair limit
Distortion and wear of cylinder In all cylinder block Repair by cutting
head mounting face top of 1 cylinder Max. 0.09 0.15
Max. 0.05 0.10
Main bearing mounting hole a See Fig. E
diameter Standard size Standard value Repair limit
• Tighten main bearing metal 148
cap bolt to specified torque 148.000 – 148.025 — Replace cylinder
(Without bearing metal) block
Fit of main bearing metal cap a See Fig. F
and cylinder block
(Interference) Standard fit 0.080 – 0.159 (Interference)
a See Fig. G
Cylinder liner
Replace cylinder
205.965 – liner
Upper section 206.0 —
206.015
Inside diameter of counterbore
and outside diameter of Lower section 194.5 194.565 – —
cylinder liner flange 194.615
Cylinder block
Upper section 206.0 205.93 – 205.99 205.92 – 206.02 Replace cylinder
block
Lower section 194.5 194.48 – 194.54 194.46 – 194.57
170E-5 Series 3
Illustrations related to testing and inspection table
Fig. A Fig. D
a: Packing portion f: Depth of counterbore
Fig. B Fig. E
b: Clearance g: Inside diameter
Fig. C Fig. F
c: Cylinder liner h: Fit

d: Cylinder block
e: Projection
4 170E-5 Series
Fig. G
i: Upper section
j: Lower section
170E-5 Series 5
Part names related to crankshaft
1. Crankshaft
2. Main bearing metal (upper)
3. Main bearing metal (lower)
4. Thrust metal
6 170E-5 Series
Testing and inspection of crankshaft

Unit: mm
Crack Check for crack by magnaflux inspection Replace crankshaft
If damaged slightly,
Presence of damage in journal repair with oilstone
• Flaw
or by lapping.
• Seizure
Damage If seized, replace
• Discoloration
crankshaft
Repair or replace
Damage of tap holes at front and rear ends crankshaft
Clogging of oil hole Presence of clogged oil hole Repair
Standard value Repair limit Replace thrust
End play of crankshaft metal or replace
0.140 – 0.320 0.6 with oversize parts
Standard 4.000 3.79
Replace thrust
0.25 US 4.125 3.92 metal or replace
Thrust metal thickness –0.07 with oversize
0.50 US 4.250 –0.12 4.04
crankshaft
0.75 US 4.375 4.17
1.00 US 4.500 4.29
Standard 108.00 107.91
0.25 US 107.75 107.66
Outside diameter of crankpin 0
journal 0.50 US 107.50 –0.022 107.41
Replace with
0.75 US 107.25 107.16 undersize parts or
1.00 US 107.00 106.91 replace crankshaft
Standard value Repair limit
Roundness of crankpin journal
0 – 0.010 0.015
Clearance in crankpin journal 0.058 – 0.132 0.18 Replace connecting

rod bearing metal
Standard 140.00 139.91
Outside diameter of crank 0.25 US 139.75 139.66
main journal 0
0.50 US 139.50 –0.025 139.41 Replace with
0.75 US 139.25 139.16 undersize parts or
replace crankshaft
1.00 US 139.00 138.91
Standard value Repair limit
Roundness of crankpin journal
0 – 0.010 0.015
Clearance in crankpin journal 0.076 – 0.152 0.20 Replace connecting

rod bearing metal
Concentricity of
Bend of crankshaft Max. 0.15 0.15
all main journals
(Total indicator reading)
Concentricity of
Max. 0.07 0.07
adjacent journals
Replace crankshaft
Main bearing metal thickness
(at center) –0.038
4.0 3.90
–0.051
Outside diameter of rear 170 ±0.019 —
flange
170E-5 Series 7
Part names related to connecting rod
1. Connecting rod bolt

2. Washer
3. Cap
4. Dowel pin
5. Bearing metal (lower)
6. Bearing metal (upper)
7. Rod
8. Small end bushing
8 170E-5 Series
Testing and inspection of connecting rod

Unit: mm
Crack Check for crack by dye check or magnaflux inspection
a See Fig. H Replace connecting
Parallelism and twist of small Parallelism: 0.1 Twist: 0.25 rod
and large end holes of (After small end bushing is installed)
connecting rod a Deviation of center axis of piston pin hole 305 mm above center of
connecting rod on basis of crank pin hole
Standard Tolerance Standard Allowable Replace small end
size Shaft Hole clearance clearance bushing
Clearance between Surface roughness
connecting rod small end of inside of small
bushing and piston pin 0 +0.049
68 0.030 – 0.055 0.090 end bushing
–0.006 +0.030
Max. 1.6S
• Large end hole diameter +0.026
• Without bearing metal. 115
0
• Inside surface roughness of large
end hole: Max. 6.3S Standard Allowable Replace bearing
Connecting rod large end hole clearance clearance metal or connecting
diameter • Clearance to crankshaft bearing
(with bearing metal) rod
0.058 – 0.132 0.18
Even if dimensions of each part are within allowable limits, if any
clearance exceeds allowable clearance, replace parts (bearing metal etc.)
Standard 3.500 3.41
0.25 US 3.625 3.54 Replace bearing
Bearing metal thickness –0.029 metal
0.50 US 3.750 –0.042 3.66
0.75 US 3.875 3.79
1.00 US 4.000 3.91
Replace bearing
Flaw on inside of or seizure of
bearing metal Presence of flaw and seizure metal or connecting
rod
Distance between large and Replace connecting
small end hole centers 305 0 rod
–0.05
Replace connecting
rod
a See Fig. J
Streak and bruise on I-portion • Presence of lateral streak If there is bruise,
of connecting rod • Presence of lateral grinding mark and bruise replace connecting
rod regardless of
size of bruise
a See Fig. K
Presence of fretting on mating face If fretting is felt with
Fretting on cap mating face • Mating face roughness: Max. 6.3 S nail, replace
• Fitted area of mating face: Min. 70% connecting rod
However, non-fitted area must not be in range of (f).
Scuffing on cap bolt seat surface Repair with oilstone
Scuffing on bolt seat surface Scuffing on bolt seat surface Replace bolt
Scuffing on washer surface Replace washer

• Presence of deformation of dowel pin Replace connecting
Deformation of dowel pin
• Presence of deformation of dowel pin hole rod
• Presence of crack and/or damage on threaded portion of bolt
Damage of bolt Replace bolt
• Presence of bend of bolt
a If all the items of this criteria (particularly the wave of the large end hole) cannot be measured after the
connecting rod is rebuilt, do not rebuild since the accuracy of the connecting rod large end hole after
rebuilding cannot be confirmed.
a Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on it.
170E-5 Series 9
Fig. H Replacement of flywheel ring gear

k Take care not to throw down the flywheel
and get hurt by mistake.
Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder and break the gear to remove
with a chisel.
k Take care in handling the grinder and
chisel.
Press fitting of gear

1. Check the gear mounting face. If there is a
flaw, repair with an oilstone.
a: Parallelism: 0.1
b: Twist: 0.25 2. Heat the gear at the specified shrink fit temper-
1. Piston pin hole ature for a certain time.
2. Crank pin hole a Gear shrink fit temperature: Max. 200°C
(Below ring gear tempering temperature)
Fig. J Heating time: Min. 20 min
3. Press fit the gear with the chamfered side

directed toward the flywheel until its side con-
tacts the flywheel.
c: Inspection range
d: Streaks
e: Lengthwise direction
Fig. K
f: Inspection range
10 170E-5 Series
Replacement of crankshaft gear 4. Using the drive tool, press fit the gear with the
timing mark out until its side contacts the
a Crankshaft gear replacement tools crankshaft flange.
Symbol Part No. Part name a Press fit the gear quickly before it cools
1 790-101-2800 Bearing puller down.
K
2 790-101-2300 Push puller
Removal of gear
q Make a notch at the tooth bottom of the gear
with a grinder, assemble tools K1 and K2, and
rotate the nut to pull out the gear.
a If the gear cannot be pulled out by the above
method, make a notch at the tooth bottom of
the gear with a grinder, heat the gear with a
gas burner, and drive out the gear with a cop-
per rod etc.
a Take care not to damage the crankshaft.

1. Check the gear mounting face, key way and
flange surface. If there is a flaw, repair with an
oilstone.
2. Drive a new key into the key way of the crank-

shaft.
3. Heat the gear at the specified shrink fit temper-

ature for a certain time.
a Gear shrink fit temperature: Max. 170°C
Heating time: Min. 30 min
170E-5 Series 11
Replacement of camshaft gear

k When setting the camshaft assembly on the
press stand, take care not to catch your fin-
gers between the press stand and the gear.
Removal of gear
Set the camshaft assembly on the press stand and
press the camshaft to pull out the gear.

1. Check the gear mounting face, key way and
flange surface. If there is a flaw, repair with an
oilstone.
2. Drive a new key into the key way of the cam-

shaft.
3. Install the thrust plate.
4. Heat the gear at the specified shrink fit temper-

ature for a certain time.
a Gear shrink fit temperature: Max. 140°C
Heating time: Min. 30 min
5. Using the drive tool, press fit the gear with the
timing mark out until its side contacts the cam-
shaft flange.
a Press fit the gear quickly before it cools
down.
12 170E-5 Series
Replacement of main bearing 5. While checking the inside diameter of main

metal cap bearing metal cap (1), cut little by little.
a Cut to the degree that the boring bar tool
a When replacing the main bearing metal cap, almost touches the inside of cylinder block
work on the semi-finished cap according to the (2).
following procedure and install it. a Inside diameter of main bearing metal cap
q Machining dimension
Repair parts Tolerance: 148 +0.025
0 mm
Part No. Part name a Finished surface roughness: Max. 12.5S
6150-29-1210 No. 1, 2, 3, 4, 5, 7 main bearing metal cap a Do not cut the inside surface of the cylin-
der block.
6150-29-1250 No. 6 main bearing metal cap
Inside machining of main bearing metal cap

1. Remove the cylinder liner.
2. Install the replacement main bearing metal cap

to the cylinder block and tighten it to the speci-
fied torque.
a Match the notches of the cylinder block
and main bearing metal cap to each other.
2 Main bearing metal cap mounting bolt:
Apply engine oil to threaded portion
and seat.
a Tighten with the angle tightening wrench
at the 3rd time. Side machining of main bearing metal cap
3 Main bearing metal cap mounting bolt: (Machine only No. 6 main bearing metal cap)
Unit: Nm {kgm} 1. Insert cast iron bushing (3) and pass arbor (4)
Step Target Range through it.
1st time 284 {29} 270 – 299 {27.5 – 30.5}
2. Install facing tool (5) to the arbor.
2nd time 569 {58} 559 – 579 {57.0 – 59.0}
3. Cut main bearing metal cap (1) to the degree
3rd time 105° 90° +30°
0 that facing tool almost touches the cylinder
block surface.
3. Set the cylinder block mounting jig on the table
of the horizontal boring machine and install the
cylinder block by fitting its cylinder liner mount-
ing hole to the datum line of the jig.
4. Apply dial gauges to the inside of the 2 main

bearing metal caps at the longest pitch among
the caps to be used to center the arbor of the
boring machine.
170E-5 Series 13
4. Cut the opposite side similarly.

a Thrust metal mounting surface roughness:
Max. 12.5S
a Do not cut the cylinder block.
a Dimensions of main bearing metal cap
q Dimension (R): Max. 0.5 mm
q Surface roughness of part (d):
Max. 12.5S
q Inside width (a) of main bearing metal cap:
0
56 –0.030 mm
q Outside diameter (b) of thrust metal
mounting face: 175 ± 0.2 mm
q Depth (c) of thrust metal mounting face:
2.5 ± 0.2 mm
q Dimension (R) of thrust metal mounting
face: Max. 0.5 mm
q Outside width (e) of main bearing metal
cap: 61 ± 0.5 mm
14 170E-5 Series
Replacement of connecting rod Press fitting of bushing

small end bushing 1. Set the connecting rod to block (3) of tool L.
a Connecting rod small end bushing replace- 2. Install the bushing to push tool (1), set push
ment tool tool (4), and fix them with nut (2).
Symbol Part No. Part name a Match the oil holes of the bushing and
L 795-240-6401 Push tool (KIT) connecting rod to each other.
3. Drive push tool (1) with the press to press fit

Pulling out of bushing
the bushing.
1. Set the connecting rod to block (3) of tool L.
a Since the bushing is semi-finished, its
inside diameter is small and the piston pin
2. Using push tool (1) and nut (2), drive out the
does not go through it.
busing with the press.
After press fitting the bushing, machine its
a After removing the bushing, remove sharp
inside with a reamer or a honing machine
edges and burrs from and clean the bush-
according to the maintenance standard.
ing mounting hole.
a After machining, remove all the chips from
the oil hole and oil groove.
a The inside surface roughness of the
machined bushing must be maximum of
1.6S.
170E-5 Series 15
Replacement of cam bushing 3. Pulling out of No. 3, No. 4 and No. 5 bushings
1) Assemble bar (1), push tool (2), collar (3)
a Cam bushing replacement tools and guide (4).
Symbol Part No. Part name 2) While hitting bar (1), drive out the bushing
M 795T-621-1700 Push tool (KIT) from the cylinder block.
a Before replacing the cam bushing, remove the

plug at the rear of the cylinder block.
Removal
1. Pulling out of No. 1 and No. 7 bushings
1) Assemble push tool (2), collar (3) and bar
(1) of tool M.
2) While hitting bar (1), drive out the bushing
from the cylinder block.
4. After removing the bushing, remove burrs and

foreign matter from and clean the bushing
mounting hole.
Installation
a Cam bushing installation drawing
2. Pulling out of No. 2 and No. 6 bushings

1) Assemble bar (1), push tool (2), collar (3)
and guide (4).
2) While hitting bar (1), drive out the bushing
from the cylinder block.
1. Press fitting of No. 3, No. 4 and No. 5 bushings

1) 1) Install bar (1), push tool (2), collar (3)
and guide (4) to the bushing.
a When installing the bushing, direct its
cut-out portion toward the rear of the
block.
a Match the oil holes of the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d b u s h i n g ar e
matched to each other.
16 170E-5 Series
4. Measurement after bushing is press fitted

1) Using dial inside gauge (a), measure the
inside diameter of the bushing.
2. Press fitting of No. 2 and No. 6 bushings

1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
2) Press fit the bushing until the oil holes of 2) Measure the clearance between the bush-
th e c y l i n d e r b l o c k a n d b u s h i n g a r e ing and shaft. If it is out of the allowable
matched to each other. range or the shaft does not go through
a Match the oil holes of the bushing. smoothly, repair the inside of the bushing
with a reamer.
a After repairing the inside of the bush-
ing with a reamer, remove all the
chips from the oil hole and oil groove.
a Inside diameter of cam bushing:
f90 +0.222
+0.112 mm
a Clearance to camshaft journal:
0.077 – 0.217 mm
3. Press fitting of No. 1 and No. 7 bushings

1) Install bar (1), push tool (2) and collar (3)
to the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d b u s h i n g a r e
matched to each other.
a Match the oil holes of the bushing.
170E-5 Series 17
Replacement of engine rear seal Installation of rear seal (with sleeve)

a When installing, do not apply oil, grease, etc.
a Engine rear seal replacement tools to the crankshaft surface and inside wall (c) of
Symbol Part No. Part name the sleeve.
N 795-931-1100 Seal puller assembly 1. Set the sleeve and rear seal assembly (d) to
push tool (3) of tool N.
a When installing the Teflon seal (laydown lip 2 Inside wall of sleeve:
seal), check the wear condition of the shaft and Gasket seal (LG-7)
select the "standard seal" or "sleeved seal" to
install. 2. Set the rear seal sleeve to the crankshaft end
a If the crankshaft is worn to a degree of luster and tighten 5 pressing bolts (4) (Stem length:
(you can feel the wear with the cushion of your 45 mm) evenly to press fit rear seal assembly
finger and the wear depth is maximum of (d) until push tool (3) contacts the crankshaft.
10 µm) and there is no scratch, install the
"standard seal". In other cases, install the
"sleeved seal".
a The left one in the following figure is the "stan-
dard seal" and the right one is the "sleeved
seal".
3. Remove push tool (3) and install push tool (1).

a Replace the pressing bolts with the ones
the stem length of which is 35 mm.
4. Tighten the 5 pressing bolts evenly to press fit

rear seal assembly (d) until push tool (1) con-
tacts the crankshaft.
Installation of rear seal (without sleeve) a Rear seal press fitting dimension (from
Tighten pressing bolts (2) evenly to press fit rear shaft end) (a): 20 mm
seal (b) until push tool (1) of tool N touches the a After press fitting the rear seal, remove
crankshaft end. the red sealant sticking to around the
a Rear seal press fitting dimension (from shaft mounting hole.
end) (a): 20 mm
a After press fitting the rear seal, remove the red
sealant sticking to around the mounting hole.
18 170E-5 Series
Repair of cylinder block top by Grinding of top

grinding q Measure the corrosion quantity, wear quantity
and distortion of the cylinder block top. If any of
Grinding them has exceeded the allowable limit, grind
Remove the distortion and corrosion of the cylinder the top.
Unit: mm
block top by grinding within the tolerance of cylinder
block height (H). Standard size Repair limit
a If the cylinder block top is worn and corroded in Flatness of cylinder block
top (in each cylinder) 0.05 0.10
the shape of the head gasket and wear quan-
tity (b) is 0.10 mm or more, grind the cylinder Cylinder block height (H) 489.0 ± 0.04 488.56
block top.
Cylinder block top
a If the cylinder liner contact surface of counter- surface roughness
Max. 12.5S
bore portion (a) is blackened and grained (par-
ticularly in the forward and backward directions
of the cylinder block) more than a half of the
contact width or the cylinder block top needs to
be ground, repair the counterbore portion.
When grinding with grinding stone

(Reference)
a Grinding speed: 1,650 – 1,950 m/min
a Table speed: 15 – 30 m/min
a Grinding depth by 1 grinding: 0.025 mm
a Cross feed for 1 grinding: 1 – 2 mm
a Grinding stone: A461V
a Grinding fluid: Water soluble grinding fluid
170E-5 Series 19
Repair of counterbore by grinding q Machine only the hatched part of depth of

counterbore portion (e).
q After grinding the top of cylinder block (a), q Machining dimension of part (f): Max. 0.4 mm
measure the counterbore depth. If the result is q Machining dimension of part (g): Max. 0.7 mm
out of the standard dimension or the cylinder q Machining dimension of part (h):
liner (b) contact surface of the counterbore is 0 – Max. 0.06 mm
blackened and grained (particularly in the for- q Angle of part (i) to cylinder center (straight
ward and backward directions) more than a line): 90° +30'
0
half of the contact surface, repair within the q Remove burrs and sharp edges from the
allowable limit of counterbore depth (d). tapered portion etc.
q If the counterbore depth after the repair is q (j) is the cylinder center.
14.05 – 15.525 mm, adjust cylinder liner pro- q (l) is 0.2 – 0.4 mm.
jection (c) to 0.07 – 0.15 mm with shims.
Unit: mm
Standard size Repair limit
Counterbore depth (d) 14 +0.05

0 15.46
Cylinder liner projection (c) — 0.07 – 0.15

Counterbore surface
roughness Max. 12.5S
Grinding shape See figure below
20 170E-5 Series
q Set the machining margin of counterbore por-

tion depth (d) so that the cylinder liner projec-
tion will be within the standard value.
q If counterbore portion depth (d) exceeds the
standard dimension and the counterbore por-
tion needs to be ground within the allowable
limit, set the machining margin so that 1 shim
(1) shown below will be used for 1 cylinder.
Shims for adjusting counterbore depth

(reference)
Weight
Part No. T t Remarks
(kg)
6162-29-2260 1.50 0.025 0.004
6162-29-2250 0.80 0.025 0.002
6162-29-2240 0.50 0.025 0.001
6162-29-2230 0.26 0.025 0.001
6162-29-2220 0.20 0.020 0.001
6162-29-2210 0.16 0.016 0.001
a Outside diameter (m) and inside diameter (n)

of shim (1) are as follows.
q (m): 205.5 ± 0.15 mm
q (n): 194.6 +0.030
0 mm
170E-5 Series 21
Check and identification after q After repairing, stamp the contents of repair on
repair by grinding the cylinder block top (cast surface) (a).
a The flywheel side of the cylinder block is indi-
q After repairing by grinding, check the flat por- cated by the arrow.
tions around the water and oil holes on the cyl-
inder block top for flaw. Oversize head
gasket Shim Stamp
q Remove burrs and sharp edges sufficiently.
— — Unnecessary
Spare parts
q After grinding the top, if cylinder block height
Q
used
(H) is larger than the standard dimension and — OS
within allowable limit (488.56 – 488.96 mm), be — Q SH
sure to use the oversize head gasket. Q Q SW
Unit: mm Stamp letter size shall be 5 – 10 mm.
Head gasket Part No. Plate thickness
Standard 6240-11-1811 2.0
Oversize 6240-19-1810 2.4
a The 2 letters of "OS" are stamped on the plate

for identification.
22 170E-5 Series
Gasket sealant application

procedure
q When press fitting the cylinder liner again after
pulling it out, apply gasket sealant LG-6 to the
surface of the counterbore which will be con-
tact with the underside of the liner flange
When using a shim to this part, apply the gas-
ket sealant similarly, too.
a The following gasket sealants commercially

available are equivalent to LG-6.
q THREEBOND, TB1215
q NIHON HERMETICS, SS-60F
When shim is used
q Thinly apply LG-6 to underside (e) of shim
(1) and fit the shim to the block deck.
q Apply LG-6 to gasket sealant application
area (a) similarly to the case when no
shim is used.
1. Wipe off dirt, oil etc. with cloths from the con-
tact surfaces of the cylinder block counterbore
and liner flange.
2. Apply LG-6 to gasket sealant application area

(a).
q The string diameter must be f2 – 3.
q Overlap length (b) of the starting and end-
ing points must be 6 ± 6 mm.
q (c) is the block top.
q (d) is the liner fitting portion.
170E-5 Series 23
3. Press fit liner to the cylinder block. At this time, 7. Using liner driver (2), press fit the cylinder liner
apply rubber lubricant (RF-1) to the liner O-ring to the cylinder block.
and seal. a Squeeze out the gasket sealant applied to
a DS-50 manufactured by DAIDO CHEMI- the counterbore according to the following
CAL INDUSTRY is equivalent to RF-1. procedure.
a IF RF-1 is not available, apply a very little
amount of engine oil (SAE30) to the O-
ring and block contact surface of the seal
just before press fitting the liner.
a Evenly apply engine oil all over the cylin-
der block contact surface with the hand.
4. Apply a little amount of engine oil (SAE30) to

the liner O-ring, clevis seal and cylinder block
contact surface just before press fitting the
liner.
a Evenly apply the engine oil all over the cyl-
inder block contact surface with the hand.
8. Using the used head gasket, tighten the cylin-

der head temporarily.
3 Mounting bolt:
255 ± 10 Nm {26 ± 1 kgm}
a Tighten the head bolts in the order shown
below.
5. Insert the liner in the cylinder block, directing

stamp "GN" on its top forward and taking care
not to damage the O-ring.
6. Push in the liners with both hands, applying

your weight.
a If the liner is not inserted smoothly when
you apply your weight, check the cylinder
block for burrs and sharp edges since the
O-ring may be damaged.
24 170E-5 Series
9. Take out the cylinder head and wipe off the

gasket sealant projected from between the cyl-
inder liner and cylinder block.
a If the gasket sealant sticks to grommet (3)
of the head gasket, it deforms the grom-
met into a heart shape and can cause
coolant leakage into water hole (4).
Accordingly, wipe off the gasket sealant
thoroughly.
a Be sure to perform steps 8 and 9.
170E-5 Series 25
Repair of crankshaft by grinding Pin journal oil hole (See figure below)
q Finish part (d) with sandpaper.
q When the crankshaft is worn, seized or dam- q Check part (e) extremely carefully since
aged slightly and needs to be repaired, grind it quenching crack tends to occur in that part.
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
q If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high tech-
nologies)
q Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.
Finish dimensions of fillet portion

0
(R): 6.5 –0.5 mm
Surface roughness: 1.6S
q Finish the main journal and pin journal accord-

q The outside surface roughness of the pin jour-
Main journal oil hole (See figure below) nal and main journal must be maximum of
q Dimension of tapered part (a) of oil hole: 16 mm 0.6S.
q Angle (b) of tapered part of oil hole: 120°
q Surface roughness of oil hole top (c): Equipment necessary for grinding
1.6S (Finished with sandpaper) q Magnaflux inspection machine
q Dimension of parts (R) at 2 places: 1 – 2 mm q Shore hardness tester
q Etching kit
q Crankshaft grinding machine
q Crankshaft polishing machine
q Surface roughness gauge
q Fillet (R) gauge
26 170E-5 Series
Inspection before repair by grinding
Visual check
q Check for crack, damage, discoloration by sei-
zure, wear, etc. and judge if the crankshaft can
be repaired by grinding.
Hardness check of journal surface

Allowable range: 63 – 69 HS
Allowable limit: 63 HS
a If the hardness is below the allowable limit, dis-
card the crankshaft.
Check for twist

0
Tolerance of throw (a): 85 –0.15 mm Check for grinding burn mark by etching
Allowable limit of horizontal displacement (differ- q After repairing by grinding, check that there is
ence in throw between No. 1 cylinder and rearmost no grinding burn mark by etching inspection.
cylinder): 0.15 mm q If any burn mark is detected, grind about 0.02
Dispersion of throw (a) among cylinders: Max. 0.15 mm again to the next undersize dimension.
If any of the above items is out of the allowable Undersizes: 0.25, 0.50, 0.75, 1.00 mm
limit, discard the crankshaft. q After checking, neutralize and clean the
q Dimension (b) is the stroke. checked surface and apply rust preventive oil.
Magnaflux inspection
q Before using the repaired crankshaft, check it
by magnaflux inspection to ensure that it has
no crack.
q Extremely closely check journal fillet portion (a)
which is in the dangerous area of each web of
the crankshaft.
q After the magnaflux inspection, be sure to
demagnetize the crankshaft.
Measurement of bend (Measurement of align-

ment)
q Measure the bend of the ground crankshaft
Check during and after repair by grinding and ensure that it is within the standard value.
q Measure the bend (alignment) at the following
Check of fillet (R) portion 4 places.
q Check that each fillet (R) portion is connected Tolerance of overall length alignment:
to the journal shoulder smoothly. Max. 0.150 mm
q Using fillet (R) gauges [1] and [2], check that Tolerance of adjacent alignment:
"dimension (R)" is between the minimum value Max. 0.070 mm
gauge and maximum value gauge. Tolerance of front end alignment: Max. 0.04 mm
q (c) is the contact point of minimum value Tolerance of rear end alignment: Max. 0.03 mm
gauge.
q (d) are the contact points of maximum value
gauge.
Fillet (R) Min. radius: 6.00 mm
Max. radius: 6.50 mm
170E-5 Series 27
Grinding of main journal Grinding of pin journal

a Grind all the main journals to the same under- a Grind all the pin journals to the same under-
size. size.
a When grinding, leave the polish finishing mar- a When grinding, leave the polish finishing mar-
gin of 0.007 – 0.008 mm. gin of 0.007 – 0.008 mm.
Undersize dimensions of main journal Undersize dimensions of pin journal

Unit: mm Unit: mm
Size Standard size Tolerance Size Standard size Tolerance
Standard 140.000 Standard 108.000
0.25 US 139.750 0.25 US 107.750
0 0
0.50 US 139.500 0.50 US 107.500
–0.025 –0.022
0.75 US 139.250 0.75 US 107.250
1.00 US 139.000 1.00 US 107.000
Roundness, cylindricality (TIR) and surface Roundness, cylindricality (TIR) and surface
roughness of main journal roughness of pin journal
Roundness: 0.010 mm Roundness: 0.010 mm
Cylindricality: 0.010 mm Cylindricality: 0.010 mm
Surface roughness: 0.6S Surface roughness: 0.6S
Grinding of thrust surface (#6) Grinding of sides of main journal and pin journal
a It is not always required to grind the thrust sur- q When repairing worn surfaces (c) of main jour-
faces of the front and rear to the same under- nal (a) and pin journal (b), limit the grinding
size dimension. quantity to the minimum.
a If the thrust surface was repaired by grinding, q (d) is thickness of worn surface.
ensure that the end play of the crankshaft is q Width of crankpin journal
within the allowable range. Standard: 72 +0.074
0 mm
(See the section of general assembly) Allowable limit: 72.074 mm
Undersize dimensions of thrust surface q Width of main journal (#6 only)
Unit: mm Standard: 64 +0.5
0 mm
Rear thrust surface Allowable limit: 64.56 mm
Standard 0.25 OS
Standard size 64 +0.050
0 64.25 +0.050
0
Standard
Front thrust
surface
Repair limit 64.060 64.310
Standard size 64.25 +0.050

0 64.50 +0.050
0
0.25 OS
Repair limit 64.310 64.560
q Squareness of thrust surface (TIR)

Permissible deviation: 0.04 mm
28 170E-5 Series
Dressing of grinding stone Finishing of surface

q Dress the grinding stone for each journal. q Surface roughness standard
q Grinding stone dresser Journal surface (c): 0.6S
Grooving angle (a): 75° ± 1° Thrust surface and fillet portion (d): Max. 1.6S
Tip diameter (b): 0.38 ± 0.25 mm Front seal insertion portion (e) (Range of 32 –
Use a cylindrical copper rod of the above form 85 mm from end): 1 – 2S (Finished with sand-
having an industrial diamond embedded in its paper)
tip. End portion (f) (Range of 32 mm from end):
q Adjust the grinding stone edge to the arc of the 3.2S
fillet with the grinding stone modifying device. q Polish finishing margin: 0.007 – 0.008 mm
Test and correct the grinding stone edge by
grinding a piece of wood on trial, while check-
ing with gauges.
Work after repair by grinding

q Ensure again that each dimension is as speci-
fied.
Prevention of grinding burn q Clean each part thoroughly and apply rust-pre-
q Apply the flange grinding method. ventive oil.
q Use all the width of the grinding stone. q When storing the crankshaft for a long period,
Avoid grinding the boss surface. support it on 3 points or keep it erected with a
q Apply cooling oil sufficiently. sling.
q Set the standard peripheral speed of the grind-
ing stone to 2,000 m/min when the crankshaft Balancing (Reference)
rotation speed is 50 rpm. Avoid performing repair that may affect the crank-
shaft balancing.
q Allowable limit of unbalance: 110 gcm
Limits for reading balance accurately
Bend of crankshaft: 0.150 mm (TIR)
Rotation speed of crankshaft: Max. 325 rpm
q When balancing, perform the following correc-
tions.
Rear key way: 66 gcm
Reamed hole: 119 gcm
q Correct the balance by drilling holes in or grind
the counterweight, if necessary.
Repair quantity limit of counterweight: 56 g
Drilling direction: Radial direction
Number of holes: Max. 6
Hole diameter: 19 mm or 23 mm
Hole depth: Max. 50 mm
Distance between hole and side: Min. 3 mm
Distance between holes: Min. 5 mm.
170E-5 Series 29
Measuring procedure for bend and outside

diameter of journal portion
1. Measure the bend on the basis of the #1 and
#7 journals. Apply the dial gauge to the journal
to be measured, set the dial to 0 at the top, and
rotate the crankshaft 1 turn and read the mini-
mum and maximum values.
2. Measure the outside diameter of the main jour-

nal in directions (X) and (Y) at 2 places ((1)
and (2)) and that of the pin journal in directions
(X) and (Y) at 2 places ((1) and (2)) with a
micrometer or an air micrometer.
30 170E-5 Series
Improvement of surface 3. Check the surface roughness with the stan-

roughness of crankshaft journal dard piece.
a Measure the surface roughness of the
q If the surface roughness of the crankshaft jour- journal by comparing it with the standard
nal does not satisfy the standard value, piece.
improve it. Surface roughness standard (Pin journal
a Before starting polishing, brush the oil holes of and main journal)
the crankshaft and blow air into them. Journal surface: Max. 0.8S
Round part: Max. 3.2S
Improvement of journal surface roughness 4. Check the surface roughness. If it does not
satisfy the standard, make round polishing with
When improving with special polishing the sandpaper #500 again between both ends.
machine a After improving the surface roughness, be
q Use the special polishing machine shown sure to brush the oil holes and blow air
below. into them.
a Ensure that there is no flaw or bruise on
the journal portion and the round part of
each fillet.
If there is any flaw or bruise, polish again
from step 1.
1. Set the workpiece rotation speed to 40 – 50

rpm and use sandpaper of #320 (belt type).
Make round polishing of each journal between
both ends with the sandpaper in the dry state
without using honing oil.
Move the sandpaper smoothly without stop-
ping at a place.
2. Replace the sandpaper with one of #500.

Apply honing oil to the journal surface. Make
round polishing with the sandpaper between
both ends of the journal, while operating
machine handle (1) to vibrate the sandpaper
by the play.
Move the sandpaper smoothly without stop-
ping at a place.
170E-5 Series 31
When using clamp jig for polishing (When spe- Assembly and using procedure of clamp jig
cial polishing machine is not available) 1. Assemble the clamp jigs for the pin journal and
q Use the clamp jig shown below. main journal as shown in the following figure.
1. Use the crankshaft grinding machine and pol- 2. Cut off sandpaper of #800 to the shapes (a)
ish under the following condition. and (b) shown below.
Sandpaper: #800 q (a) is for the pin journal and its size is as
Cutting oil: Honing oil follows.
Rotation speed of crankshaft: 40 rpm L: 205 mm, W: 95 mm
q (b) is for the main journal and its size is as
2. Set the polishing time to about 6 minutes for follows.
each journal. Polish by moving the clamp jig in L: 255mm, W: 88 mm
the axial direction of the journal between both a Make slits (c) 20 mm long on both sides of
ends of the play (about 5 mm) between the the sandpaper at intervals of 10 mm and
clamp jig and journal width. cut off one part at each end (d).
After finishing honing the journal, replace the
sandpaper with new one.
When honing the pin journal, set it to the cen-
ter of rotation for safety.
32 170E-5 Series
3. Insert 2 pieces of upper and lower sandpapers

(a) or (b) prepared in step 2 into slits (e) and fix
their ends with tape (f).
4. Fold slit portion (d) of the sandpaper along the

round part of the clamp jig.
5. Hold the journal with the clamp and fix the

lever ends with rubber tube (g) etc.
Measurement of surface roughness

Surface roughness standard
q Check with the surface roughness tester that
the surface roughness of the main journal and
pin journal is within the standard of 0.6S.
q If tester is not available, lightly rub the journal
in the axial direction with sandpaper of #1500
and observe the surface through a 30x power
magnifier. If the cross lines made with the
sandpaper are connected, the surface rough-
ness is within the standard value.
q If the cross lines are not connected, the journal
surface is rougher. In this case, polish again.
Cleaning after improving surface roughness

q After improving the surface roughness, be sure
to brush the oil holes and blow air into them.
q Ensure that there is no flaw or bruise on the
journal portion and the round part of each fillet.
170E-5 Series 33
Clamp jig parts drawing (for pin journal)

Plate (Use 2 pieces for 1 jig)
Handle (Use 2 pieces for 1 jig)
34 170E-5 Series
Clamp jig parts drawing (for main journal)

Plate (Use 2 pieces for 1 jig)
Handle (Use 2 pieces for 1 jig)
170E-5 Series 35
SEN05196-01
© 2009 KOMATSU
All Rights Reserved
36

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SEN00190-13

ENGINE 170E -5 SERIES

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

00 Index and foreword ......................................................................................................... SEN00191-13

10 Structure, function and maintenance standard ............................................................... SEN00196-06

20 Standard value table ....................................................................................................... SEN00199-05

30 Testing and adjusting ...................................................................................................... SEN00200-04

40 Troubleshooting .............................................................................................................. SEN00201-03

50 Disassembly and assembly ............................................................................................ SEN00202-05

90 Repair and replacement of parts..................................................................................... SEN05193-02

10 Structure, function and maintenance standard

Fuel piping ............................................................................................................................... 38

20 Standard value table

30 Testing and adjusting

Testing fuel system for leakage ............................................................................................... 45

E-46 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 16

50 Disassembly and assembly

Disassembly and assembly, Part 3 SEN00768-02

90 Repair and replacement of parts

KOMATSU 170E-5 Series engine

Form No. SEN00192-13

ENGINE 1SHOP MANUAL

00 Index and foreword 1

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

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

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 or allow-

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.

2. Disassembly and maintenance work in the

4. Do not let any dirt or dust get in during