Saa6d170e-5 HPCR Egr Sen00190-04

SEN00190-04
Shop
Manual
170E-5 SERIES
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2006 Komatsu

Printed in U.S.A.
Komatsu America Corp.
June 2006
SEN00192-04
ENGINE 1SHOP MANUAL
170E-5 Series
00 Index and foreword 1

Index
Organization list of the shop manual.................................................................................................... 2

Table of contents .................................................................................................................................. 3
170E-5 Series 1
SEN00192-04 00 Index and foreword
Organization list of the 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 SEN00190-04
00 Index and foreword SEN00191-04

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

Structure, function and maintenance standard, Part 1 SEN00197-01
20 Standard value table SEN00199-00

Standard service value table SEN00367-00
30 Testing and adjusting SEN00200-00

Testing and adjusting SEN00368-00
40 Troubleshooting SEN00201-00
General information on troubleshooting SEN00369-00
Troubleshooting of mechanical system (S-mode) SEN00370-00
Troubleshooting of electrical system (E-mode), Part 1 SEN00371-00
50 Disassembly and assembly SEN00202-00

General information on disassembly and assembly SEN00765-00 Q
Disassembly and assembly, Part 1 SEN00766-00 Q
2 170E-5 Series
Table of contents 1
00 Index and foreword
Index SEN00192-04
Organization list of the shop manual ....................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00193-01

Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 6
Explanation of terms for maintenance standard ...................................................................... 8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code ................................................................................................ 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table.............................................................................................. 24
Conversion table...................................................................................................................... 28
01 Specification
Specification and technical data SEN00195-01
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 5
General view............................................................................................................................ 10
Weight table............................................................................................................................. 19
Engine performance curves..................................................................................................... 20
10 Structure, function and maintenance standard

Intake and exhaust system ......................................................................................................... 4
Air cleaner ............................................................................................................................... 4
Turbocharger ........................................................................................................................... 6
EGR system ............................................................................................................................ 11
Engine unit .................................................................................................................................. 18
Cylinder head .......................................................................................................................... 18
Cylinder block .......................................................................................................................... 22
Cylinder liner............................................................................................................................ 26
Main moving parts ................................................................................................................... 27
Crankshaft ............................................................................................................................... 30
Camshaft ................................................................................................................................. 32
Connecting rod ........................................................................................................................ 33
Piston, piston ring and piston pin............................................................................................. 34
Flywheel and flywheel housing................................................................................................ 35
Vibration damper ..................................................................................................................... 36
Gear train................................................................................................................................. 37
Timing gear.............................................................................................................................. 40
Valve system ........................................................................................................................... 44
Valve and valve guide.............................................................................................................. 46
Rocker arm and shaft .............................................................................................................. 47
Crosshead and guide .............................................................................................................. 48
Tappet and push rod................................................................................................................ 49

Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4
Oil pump .................................................................................................................................. 6
Oil filter and safety valve ......................................................................................................... 10
Oil cooler ................................................................................................................................. 11
170E-5 Series 3
Fuel system ................................................................................................................................. 12

CRI system diagram ................................................................................................................ 12
Outline of CRI system.............................................................................................................. 13
Fuel piping ............................................................................................................................... 34
Fuel filter .................................................................................................................................. 36
Electric priming pump .............................................................................................................. 38
Engine controller cooler ........................................................................................................... 39
Cooling system............................................................................................................................ 40
Cooling system diagram .......................................................................................................... 40
Water pump ............................................................................................................................. 41
Thermostat............................................................................................................................... 42
Corrosion resistor .................................................................................................................... 44
Fan drive.................................................................................................................................. 46
Electrical equipment .................................................................................................................... 47
Alternator ................................................................................................................................. 47
Alternator belt tension.............................................................................................................. 48
Starting aid............................................................................................................................... 54
Engine controller...................................................................................................................... 55
20 Standard value table

Standard service value table SEN00367-00
Standard service value table for testing, adjusting, and troubleshooting ................................. 2
Running-in standard and performance test standard .............................................................. 6
30 Testing and adjusting

Testing and adjusting SEN00368-00
Testing and adjusting tools list ................................................................................................. 3
Testing air boost pressure........................................................................................................ 5
Testing exhaust temperature ................................................................................................... 6
Adjusting valve clearance ........................................................................................................ 7
Testing compression pressure ................................................................................................. 8
Testing blow-by pressure ......................................................................................................... 11
Testing oil pressure.................................................................................................................. 12
Handling fuel system parts ...................................................................................................... 13
Releasing residual pressure in fuel system ............................................................................. 13
Testing fuel pressure................................................................................................................ 14
Reduced cylinder mode operation ........................................................................................... 15
No-injection cranking ............................................................................................................... 15
Testing leakage from pressure limiter and return rate from injector......................................... 16
Bleeding air from fuel circuit .................................................................................................... 19
Testing fuel system for leakage ............................................................................................... 20
Handling controller voltage circuit............................................................................................ 21
40 Troubleshooting
General information on troubleshooting SEN00369-00
Points on troubleshooting ........................................................................................................ 2
Error code and failure code table............................................................................................. 4
Troubleshooting of mechanical system (S-mode) SEN00370-00
Method of using troubleshooting charts................................................................................... 3
S-1 Starting performance is poor ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 8
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operations......................................................................................... 13
S-5 Engine does not rotate smoothly....................................................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 18
4 170E-5 Series
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
Information in troubleshooting table ........................................................................................ 4
E-1 Code [111/CA111] ECM Critical Internal Failure................................................................ 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 8
E-3 Code [122/CA122] Charge Air Press Sensor High Error .................................................. 9
E-4 Code [123/CA123] Charge Air Press Sensor Low Error ................................................... 11
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 12
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 16
E-7 Code [135/CA135] Oil Press. Sensor High Error .............................................................. 17
E-8 Code [141/CA141] Oil Press. Sensor Low Error............................................................... 19
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 20
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 22
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error ................................................ 24
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ................................................ 26
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 26
E-14 Code [212/CA212] Oil Temp. Sensor High Error ............................................................ 28
E-15 Code [213/CA213] Oil Temp. Sensor Low Error ............................................................. 30
E-16 Code [221/CA221] Ambient Air Press. Sensor High Error.............................................. 31
E-17 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 33
E-18 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 34
E-19 Code [234/CA234] Eng. Overspeed ............................................................................... 36
E-20 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error.................................................... 38
E-21 Code [263/CA263] Fuel Temp. Sensor High Error.......................................................... 40
E-22 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 42
E-23 Code [271/CA271] PCV1 Short Error ............................................................................. 44
E-24 Code [272/CA272] PCV1 Open Error ............................................................................. 46
E-25 Code [273/CA273] PCV2 Short Error ............................................................................. 48
E-26 Code [274/CA274] PCV2 Open Error ............................................................................. 50
E-27 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ................................. 52
E-33 Code [342/CA342] Calibration Code Incompatibility ....................................................... 64
E-34 Code [351/CA351] INJ. Drive Circuit Error ..................................................................... 66
E-35 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 68
E-36 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 70
E-37 Code [431/CA431] Idle Validation SW Low error ............................................................ 72
E-38 Code [432/CA432] Idle Validation Process error ............................................................ 74
E-39 Code [441/CA441] Battery voltage low error .................................................................. 75
E-40 Code [442/CA442] Battery voltage high error ................................................................. 75
E-41 Code [449/CA449] Rail Press. Very High Error .............................................................. 3
E-42 Code [451/CA451] Rail Press. Sensor High Error .......................................................... 4
E-43 Code [452/CA452] Rail Press. Sensor Low Error ........................................................... 6
E-44 Code [553/CA553] Rail Press. High Error....................................................................... 7
E-45 Code [559/CA559] Rail Press. Low Error ....................................................................... 8
E-46 Code [689/CA689] Eng. Ne Speed Sensor Error............................................................ 12
E-47 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 14
170E-5 Series 5
E-48 Code [757/CA757] All Persistent Data Lost Error ........................................................... 15

E-49 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 16
E-50 Code [1228/CA1228] EGR Valve Servo Error 1.............................................................. 18
E-51 Code [1625/CA1625] EGR Valve Servo Error 2.............................................................. 19
E-52 Code [1626/CA1626] Bypass Valve Solenoid Current High Error................................... 20
E-53 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error.................................... 22
E-54 Code [1628/CA1628] Bypass Valve Servo Error 1.......................................................... 23
E-55 Code [1629/CA1629] Bypass Valve Servo Error 2.......................................................... 24
E-56 Code [1631/CA1631] BP valve Lift Position Sensor High Error ...................................... 25
E-57 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ....................................... 27
E-58 Code [1633/CA1633] KOMNET Dtalink Timeout Error ................................................... 27
E-59 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 28
E-60 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 32
E-61 Code [2249/CA2249] Rail Press. Very Low Error ........................................................... 32
E-62 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error................................... 33
E-63 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error.................................... 35
E-64 Code [2351/CA2351] EGR Valve Solenoid Current High Error....................................... 36
E-65 Code [2352/CA2352] EGR Valve Solenoid Current Low Error ....................................... 38
E-66 Code [2555/CA2555] Grid Heater Relay Volt. Low Error ................................................ 39
E-67 Code [2556/CA2556] Grid Heater Relay Volt. High Error ............................................... 40
E-68 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate ................................................... 42
E-69 Code [(146)/B@BCNS] Eng. Overheat ........................................................................... 42
E-70 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate ............................................ 43
50 Disassembly and assembly

General information on disassembly and assembly SEN00765-00
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 3
Special tools list ....................................................................................................................... 6
Disassembly and assembly, Part 1 SEN00766-00
General disassembly of engine ............................................................................................... 2
General assembly of engine .................................................................................................... 2
Removal and installation of fuel supply pump unit................................................................... 2
Replacement of oil seal of engine mounted on machine ......................................................... 5
6 170E-5 Series
SEN00192-04
KOMATSU 170E-5 Series engine
Form No. SEN00192-04
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 02-06 (01)
8
SEN00193-01
ENGINE 1SHOP MANUAL
170E-5 Series
00 Index and foreword 1

Foreword and general information
Foreword and general information .................................................................................................................. 2
Safety notice ........................................................................................................................................ 2
How to read the shop manual .............................................................................................................. 6
Explanation of terms for maintenance standard................................................................................... 8
Handling electric equipment and hydraulic component...................................................................... 10
How to read electric wire code ........................................................................................................... 18
Method of disassembling and connecting push-pull type coupler...................................................... 21
Standard tightening torque table ........................................................................................................ 24
Conversion table ................................................................................................................................ 28
170E-5 Series 1
Foreword and general information (Rev. 2005/11)
Safety notice 1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
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 welding work, alw ays wear w elding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to 1 Good arrangement
keep tools and removed parts. Always
2 Correct work clothes
keep the tools and parts in their correct
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water, 4 Making and checking signs
or oil on the floor. Smoke only in the areas Prohibition of operation and handling by
5
provided for smoking. Never smoke while unlicensed workers
working. 6 Safety check before starting work
3) When carrying out any operation, always Wearing protective goggles
wear safety shoes and helmet. Do not 7
(for cleaning or grinding work)
wear loose work clothes, or clothes with
Wearing shielding goggles and protectors
buttons missing. 8
(for welding work)
q Always wear safety glasses when hit-
ting parts with a hammer. 9 Good physical condition and preparation
q Always wear safety glasses when Precautions against work which you are
10
grinding parts with a grinder, etc. not used to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always 2. Preparations for work
inform your fellow workers before starting 1) Before adding oil or making any repairs,
any step of the operation. Before starting park the machine on hard and level
work, hang UNDER REPAIR signs in the ground, and apply the parking brake and
operator's compartment. block the wheels or tracks to prevent the
5) Only qualified workers must carry out work machine from moving.
and operation which require license or 2) Before starting work, lower the work
qualification. equipment (blade, ripper, bucket, etc.) to
6) Keep all tools in good condition, learn the the ground. If this is not possible, insert
correct way to use them, and use the the lock pin or use blocks to prevent the
proper ones of them. Before starting work, work equipment from falling. In addition,
thoroughly check the tools, machine, fork- be sure to lock all the control levers and
lift, service car, etc. hang warning signs on them.
2 170E-5 Series
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
170E-5 Series 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with one 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.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
170E-5 Series 5
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.
6 170E-5 Series
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 { }.
170E-5 Series 7
Explanation of terms for maintenance standard 1

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

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

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

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 170E-5 Series
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 size of a hole is smaller than the be replaced or repaired.
size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
170E-5 Series 9
Handling 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.
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.
10 170E-5 Series
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
splash water over the connector. The con-
nector 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 con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other
appropriate action before passing electric-
ity 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.
170E-5 Series 11
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.
12 170E-5 Series
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
170E-5 Series 13
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.
14 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 15
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.
16 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 17
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

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

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
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
18 170E-5 Series
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”.
170E-5 Series 19
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 – – – – – – –
20 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 21
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-
22 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 23
Standard tightening torque table 1

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

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
24 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 25
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. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
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
26 170E-5 Series
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
170E-5 Series 27
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 two 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
28 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 29
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
30 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 31
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–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
32 170E-5 Series
SEN00193-01
© 2005 KOMATSU
All Rights Reserved
34
SEN00195-01
ENGINE 1SHOP MANUAL
170E-5 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 5
General view ...................................................................................................................................... 10
Weight table ....................................................................................................................................... 19
Engine performance curves ............................................................................................................... 20
170E-5 Series 1
SEN00195-01 01 Specification
Outline 1
1. Applicable machine
Engine Engine serial No. Applicable machine

D375A-5 Bulldozer
PC1250-8 Hydraulic excavator
SAA6D170E-5 WA600-6 Wheel loader
HD465-7 Dump truck
HD605-7 Dump truck
2 170E-5 Series
2. Outline of engine
q The 170E-5 engine is a high-performance and 4) To secure the high output of the engine, the
high-efficiency engine, which passed strict twin cooling nozzle to cool the piston employed
emission regulations (USA: EPA Regulations for 170E-3 and after models is improved to
for 2006, EU: Regulations for 2006, Japan: increase the durability of the piston and lower
Construction machinery regulations for 2006) the back side temperature of the piston. As a
and attained low fuel consumption, low noise, result, the lubricating oil on the piston is not
better exhaust gas color, and high acceleration exposed to high temperature, thus it is not
performance. Accordingly, this newly devel- deteriorated. Since the high-pressure fuel
oped engine is suitable as a power source of injection system controlled electronically is
construction machinery and industrial machin- employed, less soot is produced and the drain-
ery used for various purposes. ing interval of the oil is lengthened.
q The 170E-5 engine is the successor to the 5) The common rail high-pressure fuel injection
170E-3 engine. While it is an in-line 6-cylinder, system controlled electronically is employed.
water-cooled, 4-stroke diesel engine, it is This system can inject the fuel at high pressure
equipped with the common rail direct injection of 160 MPa {1,600 kg/cm2} from the low-speed
system and cooled EGR system of new tech- range to the high-speed range. In addition,
nologies. this system can control the form of injection
most properly by electronic control according
1) The main components of the cooled EGR sys- to the speed and load. By heightening the
tem are the EGR cooler of corrugated tube injection accuracy and employing multiple
type made of newly developed special stain- injection, exhaust gas of the cleanest level in
less steel and the EGR valve driven hydrauli- the world, good exhaust gas color, low fuel
cally and controlled electronically which consumption, and low noise are realized simul-
KOMATSU developed by itself. The cooled taneously.
EGR system secures the optimum EGR rate
from the low-speed range to the high-speed 6) The main fuel filter of high efficiency and the
range to attain both clean exhaust gas and low pre-fuel filter are installed as standard so that
fuel consumption with the bypass assist circuit the low grade fuel in the market (equivalent to
consisting of the venturi system and bypass Class NAS12) can be used. In addition, the
valve which has the same function and struc- priming pump used for replacing the filters is
ture as those of the EGR valve. electrified to improve serviceability.
2) The special EGR oil pump is employed to gen- 7) The high-quality piston which is made of cast
erate high oil pressure (1.47 MPa {15 kg/cm2}) iron and has the 2-stage combustion chamber
as the drive power source of the EGR valve of a new shape is employed. This piston has a
driven hydraulically and controlled electroni- less coefficient of thermal expansion, a reen-
cally. This pump has sufficient delivery for the trant combustion chamber, and a shaker cool-
EGR valve and increased output of the engine. ing gallery. As a result, clean exhaust gas,
As a result, the reliability and durability of the good exhaust gas color, and low fuel consump-
engine are improved. tion are attained simultaneously, and high
durability and reliability are also obtained.
3) The 170E-5 engine has 3 combination filters of
high performance and high efficiency to meet 8) By using the above-mentioned high-pressure
the requirements of the EGR system and high- fuel injection system controlled electronically,
dispersion oil and improve the ability to capture the multiple injection and injection characteris-
the soot in the oil. In addition, the recom- tics are set most properly to improve the start-
mended sub-materials for operation (oil and ability and reduce the white exhaust smoke
fuel) are changed to improve the reliability and when the temperature is low.
durability of the engine.
9) Engine controller is mounted on the engine
and equipped with the automatic high-altitude
compensation function, the engine can be
operated at high altitude without replacing the
controller. As a result, the serviceability is
improved.
170E-5 Series 3
10) The improved type of the KTR130 turbo-

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

cooled EGR system. Since its overall length,
overall width, and overall height are the same
as before, however, its compactness is main-
tained.
4 170E-5 Series
Specifications 1
Engine name SAA6D170E-5

Applicable machine D375A-5
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 1,823
Dimensions
Overall width mm 1,157

Overall height (excluding exhaust pipe) mm 1,697
Overall height (including exhaust pipe) mm —
452 {606}/1,800
Rated output kW{HP}/rpm
(Gross)
3,020 {308.0}/1,300
Max. torque Nm{kgm}/rpm
Performance
(Gross)
No-load max. speed
rpm 7,900 ± 20
(High idle speed)
No-load min. speed
rpm 720 ± 30
(Low idle speed)
g/kW·h
Fuel consumption ratio at rated output 227 {169}
{g/HP·h}
Dry weight kg 2,970
Fuel supply pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil (Refill capacity) l 80 (80)
Quantity of coolant l 44 (For only engine)
Alternator — 24V, 60A, 90A
Starting motor — 24V, 7.5kW × 2
Battery — 12V, 200Ah × 2
Turbocharger — KOMATSU KTR130E
Air compressor — —
Others — With air-cooled aftercooler
With cooled EGR
170E-5 Series 5

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/kW·h
{g/HP·h}
Dry weight kg 3,140
Starting motor — 24V, 11kW × 2
With cooled EGR
6 170E-5 Series

Applicable machine WA600-6
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/kW·h
{g/HP·h}
Dry weight kg 3,050
Alternator — 24V, 90A
Starting motor — 24V, 11kW × 2
With cooled EGR
170E-5 Series 7

Applicable machine HD465-7, HD605-7
Dimensions

552 {740}/2,000
(Gross)
3,324 {339.0}/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/kW·h
{g/HP·h}
Dry weight kg 3,120
Starting motor — 24V, 7.5kW × 2
With cooled EGR
8 170E-5 Series
General view 1
SAA6D170E-5 (Left side of engine)
Applicable machine: D375A-5
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
10 170E-5 Series
SAA6D170E-5 (Front side of engine)

Applicable machine: D375A-5

2. Center of cylinder liner
170E-5 Series 11

Applicable machine: PC1250-8

12 170E-5 Series

Applicable machine: PC1250-8

170E-5 Series 13

Applicable machine: WA600-6

14 170E-5 Series

Applicable machine: WA600-6

170E-5 Series 15

Applicable machine: HD465-7, HD605-7

16 170E-5 Series

Applicable machine: HD465-7, HD605-7

170E-5 Series 17
Dimensions table
Unit: mm
Dimension of each part
Engine Machine
A B C D E F G H
D375A-5 1,854 2,130 550 25 — — 1,107 1,300
PC1250-8 1,800 2,032 560 222 — 1,000 1,185 1,215
SAA6D170E-5 WA600-6 1,795 1,935 543 41 41 930 1,060 1,154
HD465-7
2,044 1,732 550 210 — 346 396 1,243
HD605-7
a These dimensions are given for reference when the engine is set on a test bench.
18 170E-5 Series
Weight table 1
Unit: kg
No. Item Main parts SAA6D170E-5
D375A-5 33.5
PC1250-8 36
1 Turbocharger KOMATSU KTR130E WA600-6 33.5
HD465-7
36
HD605-7
Cylinder head, valve,
2 Cylinder head assembly 46.5 × 6
valve spring
Cylinder block, bearing,
3 Cylinder block assembly 750
cap, cylinder liner
4 Front cover 47
5 Oil pan 56
D375A-5 82
PC1250-8 80
6 Flywheel assembly Flywheel, ring gear WA600-6 36
HD465-7
43
HD605-7
D375A-5 170
PC1250-8 150
7 Flywheel housing assembly WA600-6 150
HD465-7
150
HD605-7
8 Crankshaft assembly Crankshaft, crank gear 265
Camshaft, cam gear,
9 Camshaft assembly 51
thrust plate
Piston, piston ring, piston pin,
10 Piston and connecting rod assembly 22 × 6
connecting rod
11 Oil pump 10.2
12 Fuel supply pump 14.8
13 Water pump 16.2
24V, 60A 11
14 Alternator
24V, 90A 19
24V, 7.5kW 18
15 Starting motor
24V, 11kW 18
16 EGR oil pump 5.5
17 EGR valve 9.8
18 EGR cooler 11.5
19 EGR bypass valve ( 1) 9.8
1: There may not be equipped according to the machine model.
170E-5 Series 19
Engine performance curves 1
Engine Engine serial No. Applicable machine Page

D375A-5 21
PC1250-8 22
SAA6D170E-5
WA600-6 23
HD465-7, HD605-7 24
20 170E-5 Series
SAA6D170E-5 (Applicable machine: D375A-5)
Rated output: 452 kW {606 HP}/1,800 rpm (Gross)

Max. torque: 3,020 Nm {308.0 kgm}/1,300 rpm (Gross)
170E-5 Series 21
SAA6D170E-5 (Applicable machine: PC1250-8)

22 170E-5 Series
SAA6D170E-5 (Applicable machine: WA600-6)

170E-5 Series 23
SAA6D170E-5 (Applicable machine: HD465-7, HD605-7)

24 170E-5 Series
© 2005 KOMATSU
All Rights Reserved
26 170E-5 Series
SEN00197-01
ENGINE 1SHOP MANUAL
170E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 1
Intake and exhaust system ............................................................................................................................. 4
Air cleaner ............................................................................................................................................ 4
Turbocharger........................................................................................................................................ 6
EGR system ........................................................................................................................................11
Engine unit .................................................................................................................................................... 18
Cylinder head ..................................................................................................................................... 18
Cylinder block..................................................................................................................................... 22
Cylinder liner ...................................................................................................................................... 26
Main moving parts .............................................................................................................................. 27
Crankshaft.......................................................................................................................................... 30
Camshaft ............................................................................................................................................ 32
170E-5 Series 1
SEN00197-01 10 Structure, function and maintenance standard
Connecting rod ................................................................................................................................... 33

Piston, piston ring and piston pin ....................................................................................................... 34
Flywheel and flywheel housing........................................................................................................... 35
Vibration damper ................................................................................................................................ 36
Gear train ........................................................................................................................................... 37
Timing gear......................................................................................................................................... 40
Valve system ...................................................................................................................................... 44
Valve and valve guide ........................................................................................................................ 46
Rocker arm and shaft ......................................................................................................................... 47
Crosshead and guide ......................................................................................................................... 48
Tappet and push rod........................................................................................................................... 49
2 170E-5 Series
Intake and exhaust system 1

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

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

Engine Type
machine dust from pre-cleaner ments
D375A-5
Automatic discharge 1 inner element
SAA6D170E-5 PC1250-8 Komaclone, multi-cyclone (ERB type)
(Exhaust ejector) 1 outer element
WA600-6
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
HD465-7 1 inner cylinder,
SAA6D170E-5 FRG (Radial seal type) Automatic discharge
HD605-7 1 outer cylinder
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (2).
q The dust and water separated by guide vane
(3) swirl along the inside wall of body (9) and
enter evacuator valve (6) and then are dis-
charged out automatically.
170E-5 Series 5
Turbocharger 1
Model name: KTR130E (Water-cooled)
6 170E-5 Series
A: Intake air inlet Structure and operation of turbocharger

B: Intake air outlet q The turbocharger has turbine impeller (6)
C: Exhaust gas inlet which is rotated by the high-speed exhaust
D: Exhaust gas outlet gas. Blower impeller (11) on the same shaft
E: Oil inlet with the turbine impeller is also rotated to
F: Oil outlet supercharge the engine with air.
G: Coolant q The shaft connecting the turbine impeller and
blower impeller is usually made in one unit
1. Blower housing together with the turbine impeller. The blower
2. V-band impeller is fixed with a nut to the opposite shaft
3. Center housing end of the turbine impeller.
4. Shield q The shaft rotates at very high speed of 50,000
5. Turbine housing – 100,000 rpm and receives the thrust load
6. Turbine impeller generated by the intake air and exhaust gas
7. Seal ring and applied to the impellers.
8. Journal bearing q Accordingly, the shaft is supported on cylindri-
9. Thrust bearing cal floating journal bearing (8) and thrust bear-
10. Seal ring ing (9).
11. Blower impeller q Center housing (3) supports the bearings and
has oil passages to lubricate the bearings.
Specifications q The lubricated parts, exhaust side, and air
Model: KOMATSU KTR130E intake side are sealed by seal rings (7), (10).
(Water-cooled) q Turbine housing (5) houses turbine impeller (6)
Overall length: 343 mm and leads the exhaust gas from the exhaust
Overall width: 390 mm manifold to the turbine impeller. The exhaust
Overall height: 344 mm gas rotates the impeller at high speed and
Weight: 35.5 kg flows out of the engine.
q Blower housing (1) houses blower impeller and
leads the sucked air to the blower impeller.
The air compressed by the blower impeller is
fed forcibly to the engine.
Lubrication of turbocharger
q Engine oil supplied from above center housing
(3) lubricates each bearing and sliding part,
and then returns through the hole at the bottom
of the center housing to the engine oil pan.
170E-5 Series 7
Model name: KTR130E
8 170E-5 Series
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit
1 End play (Play in axial direction)
0.08 – 0.13 0.18
Replace core
2 Radial play (Play in radial direction) 0.36 – 0.55 0.77 assembly
Clearance between blower housing
3 Clearance limit (Min.): 0.18
and impeller
170E-5 Series 9
EGR system 1
No. Component part Function

• Controls the gas flow from the exhaust system to the air intake system.
EGR valve (driven hydrau-
1 • Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the
lically)
exhaust gas flows to the air intake valve.
• Opens the bypass valve when the boost pressure (PIN) is higher than the exhaust
pressure (PEX).
2 Bypass valve ( 1)
• Makes the intake air flow to the exhaust side to increase the exhaust pressure so
that the exhaust gas will be returned to the air intake side easily.
3 EGR cooler • Lowers the exhaust temperature and returns the exhaust gas to the air intake side.
4 Venturi system • Generates negative pressure with the venturi effect and takes in the exhaust gas.
• Controls the EGR according to the operating condition.
5 Each sensor
• Troubleshoots the system.
1: There may not be equipped according to the machine model.
Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and trouble-
shooted, a serious trouble is prevented.
170E-5 Series 11
a The above illustration shows the engine for HD465-7 and HD605-7.
12 170E-5 Series
1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor ( 1)
7. Bypass piping ( 1)
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for open-
ing EGR valve (1) most properly according to
the load on the engine to attain both clean
exhaust gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust
gas (EGR gas) flows from the exhaust mani-
fold through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3)
flows through EGR valve (1) and mixes with
the intake air in venturi system (4), and then
flows in the air intake manifold.
q In the operating range where the boost pres-
sure is higher than the exhaust pressure on the
high load side, the EGR gas does not flow to
the air intake side easily. At this time, the
engine controller opens bypass valve (2). ( 1)
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the
exhaust pressure rises and more EGR gas
mixes with the intake air. ( 1)
1: There may not be equipped according to the

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

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

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

B: EGR gas outlet E: Air bleeder
C: Coolant inlet
1. Heat exchange tube (Corrugated tube)
Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to
increase the gas density, or the EGR effi-
ciency.
Structure
q The EGR cooler is a multi-tube heat
exchanger. When the high-temperature EGR
gas flows through heat exchange tube (1), it is
cooled by the coolant flowing outside of the
tube.
q Heat exchange tube (1) is made of corrosion-
resistant stainless steel and corrugated to
increase the cooling efficiency.
170E-5 Series 15
Venturi system
A: Air inlet 1. Venturi nozzle

B: EGR gas inlet 2. Throat
3. Diffuser
Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), ven-
turi nozzle (1), and diffuser (3).
Operation
q The boost pressure increased by the turbo-
charger is set negative temporarily with the
venturi effect of the throat to take the EGR gas
into the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake
air flows through diffuser (3), its pressure is
increased again to the normal level and then it
flows in the intake manifold.
16 170E-5 Series
Engine unit 1
Cylinder head 1
a. Fuel return
1. Cylinder head
2. Rocker arm housing
3. Cylinder head cover
4. Valve guide
5. Injector
6. Coolant air bleeder tube
18 170E-5 Series
Specifications
Cylinder head
q Direct injection type
q 4-valve type
q Split type (1 cylinder, 1 head)
Valve seat insert

q Intake valve insert
q Exhaust valve insert
Both of these inserts are press fitted to the seats.
170E-5 Series 19
a Tighten the cylinder head mounting bolts in the order of (1) – (9).
Unit: mm
Strain of cylinder head Tolerance Repair limit Correct by grind-
1
mounting surface Max. 0.05 0.1 ing or replace
Engine Standard Replace nozzle
2 Projection of nozzle
SAA6D170E-5 2.3 – 2.9 gasket
Bolt No. Procedure Target (Nm{kgm}) Range (Nm{kgm})
Tightening torque of cyl-
inder head mounting bolt 1st stage 245 {25} 235 – 255 {24 – 26}
Tighten in order
3 (apply anti-friction com- (1) – (7) 2nd stage 382 {39} 373 – 392 {38 – 40}
shown above
pound to bolt threads and 3rd stage Retighten 90° 90(+30/0)°
washer)
(8) – (9) — 98 {10} 93 – 103 {9.5 – 10.5}
Tightening torque of Target (Nm {kgm}) Range (Nm {kgm})
4
injector mounting bolt 66.7 {6.75} 58.8 – 73.5 {6 – 7.5}
Tightening torque of
5 rocker arm housing 86{8.75} 78 – 93 {8.0 – 9.5}
mounting bolt
Target (Nm {kgm}) Range (Nm {kgm}) Tighten
Tightening torque of cyl- No.1, 3 – 6
6 10 {1} 9 – 11 {0.9 – 1.1}
inder head cover cylinders
No.2 cylinder 66.7 {6.75} 58.8 – 73.5 {6 – 7.5}
Tightening torque of fuel Target (Nm {kgm}) Range (Nm {kgm})
7
injection pipe 41.7 {4.25} 39.2 – 44.1 {4 – 4.5}
20 170E-5 Series
Cylinder block 1
1. Front cover 8. Main bearing

2. Cylinder block 9. Main bearing cap
3. Cylinder liner 10. Main bearing cap bolt
4. Clevis seal 11. Front oil seal
5. Liner O-ring 12. Piston cooling nozzle
6. Liner O-ring 13. Oil level gauge
7. Thrust bearing
22 170E-5 Series
Specifications
Cylinder block Liner ring
q Crankshaft section: 7 bearings q Upper : Clevis seal
q Camshaft section: High cam type, 7 bearings q Middle : O-ring (Ethylene-propylene rubber)
q Main cap bolt: Plastic-region tightening q Lower : O-ring (Silicone rubber)
Front seal
q End seal with dust cover
Piston cooling
q With piston cooling nozzle (2 pieces for each
cylinder)
Cylinder liner
q Wet type
q Machining on inside: Plateau honing,Tufftriding
170E-5 Series 23
24 170E-5 Series
Unit: mm
Tolerance
Standard Standard Clearance
size Inside diame- Outside diame- clearance limit Replace cylin-
Clearance between cylin-
1 ter of block ter of block der liner or
der block and liner
–0.00 –0.11 block
190.4 0.05 – 0.16 —
–0.06 –0.16
Inside diameter of main Standard size Tolerance Repair limit
bearing fitting hole
(Tighten bolt to specified +0.025
148 —
torque) –0.001
Replace
–0.038
Thickness of main bearing 4.0 —
2 –0.051
Inside diameter of main +0.127
140 140.20
bearing +0.076
Clearance between main Standard clearance Clearance limit
bearing and crankshaft
bearing 0.076 – 0.152 0.32
Interference of cap and Standard interference Interference limit

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

B. Cylinder block section
Unit: mm
Permissible range: 0.07 – 0.15 Replace cylinder liner or
1 Projection of cylinder liner
Difference between cylinders: Max. 0.05 cylinder block
Standard size Tolerance Repair limit
+0.040
170 170.24
+0.000
Inside diameter
2
of cylinder liner Roundness 0.020 0.08
of inside
Cylindrical-
0.020 0.08
ity of inside
Outside diameter of cylinder Standard size Tolerance
liner (at bottom of counter-
bore portion) 194.5 194.565 – 194.615
3
Interference of cylinder liner
and block (at bottom of coun- Standard interference: 0.025 – 0.135 Replace cylinder liner
terbore portion)
liner (at counterbore portion) 206 205.965 – 206.015
4 Interference of cylinder liner Standard clearance Clearance limit
and block (at counterbore Interference: 0.85 to
portion) —
Clearance: 0.025
liner (at O-ring) 190.40 190.24 – 190.29
5
Clearance between cylinder Standard clearance Clearance limit
liner and block (at O-ring) 0.05 – 0.16 —
Dispersion of depth of coun- Standard Repair limit
6 Correct by grinding
terbore — 0.05
26 170E-5 Series
Main moving parts 1

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

2. Connecting rod 11. Crankshaft
3. Connecting rod bushing 12. Connecting rod cap
4. Piston (FCD piston type) 13. Connecting rod cap bolt
5. Top ring 14. Connecting rod bearing
6. Second ring 15. Crank gear (Number of teeth: 55)
7. Oil ring 16. Vibration damper
8. Camshaft drive gear (Number of teeth: 63) 17. Crank pulley
9. Main bearing
170E-5 Series 27
Piston
Type: Shaker type
Made of ductile cast iron
Forced cooling with lubricating oil through piston
cooling nozzles (2 pieces/cylinder)
Specifications
Crankshaft
Made of forged special alloy steel, 7 bearings
Journal: Induction hardening
Main bearing and connecting rod bearing

3-layer kelmet Piston rings
Upper main bearing: With oil groove Top ring (1) : Inner cut, barrel face, ion plating
Second ring (2) : Inner cut, taper face, hard chro-
Connecting rod mium-plated
Made of forged alloy steel Oil ring (3) : Bevel cutter, surface nitriding
Camshaft
Journal and fillet: Induction hardening
28 170E-5 Series
Crankshaft 1
30 170E-5 Series
Unit: mm
Size Standard size Tolerance Repair limit
S.T.D. 140 139.91
Outside diameter of main 0.25 U.S. 139.75 139.66
1 –0.000
journal 0.50 U.S. 139.50 139.41
–0.025
0.75 U.S. 139.25 139.16
1.00 U.S. 139.00 138.91 Use undersize
Size Standard size Tolerance Repair limit journal or replace
S.T.D. 108.00 107.91
Outside diameter of crank 0.25 U.S. 107.75 107.66
2 –0.000
pin journal 0.50 U.S. 107.50 107.41
–0.022
0.75 U.S. 107.25 107.16
1.00 U.S. 107.00 106.91
3 Roundness of journal Main journal Max. 0.010 0.015
Crank pin journal Max. 0.010 0.015
Tolerance Repair limit
4 End play
0.14 – 0.32 0.6
Standard size Tolerance Repair limit Replace
Thickness of main bearing
5 –0.038
(Median) 4.0 3.90
–0.051
Outside diameter of rear
6 170 ±0.019 —
flange
Bend or crankshaft (Overall Tolerance Repair limit
7
swing of indicator) 0.09 0.09
Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque of crank 1st stage 74 {7.5} 54 – 93 {5.5 – 9.5}
8 Tighten
pulley mounting bolt 2nd stage 245 {25} 226 – 265 {23 – 27}
3rd stage 637 {65} 618 – 657 {63 – 67}
170E-5 Series 31
Camshaft 1
Unit: mm
Intake +0.103
78.233 78.00 Correct or
1 Height of cam cam –0.103
replace
Exhaust +0.103
77.252 77.00
cam –0.103
–0.035
2 Outside diameter of journal 90 89.98
–0.005
Replace
–0.00
3 Thickness of thrust plate 5 3.20
–0.05
Standard clearance Clearance limit Replace thrust
4 End play of camshaft
0.05 – 0.20 0.40 plate
5 Bend of camshaft Repair limit: 0.20 (Overall swing of indicator) Replace
32 170E-5 Series
Connecting rod 1
Unit: mm
Tolerance Standard
Clearance between con- Standard size Clearance limit Replace (Spare
Shaft Hole clearance
1 necting rod bushing and bushing is half
piston pin –0.000 +0.049 worked)
68 0.030 – 0.055 0.075
–0.006 +0.030
Inside diameter of connect-
2 +0.026
ing rod large end hole 115
–0.000
Clearance between con- Standard clearance Clearance limit
3 necting rod large end bear-
ing and crankshaft bearing 0.058 – 0.132 0.34
Size Standard size Tolerance Repair limit

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

FCD piston type
Unit: mm
Outside diameter of pis- Standard size Tolerance Repair limit
1 ton (at 3.0 mm from pis- 170 –0.135
ton bottom and 20°C) 169.79
(At right angles to boss) –0.165
Tolerance Clearance limit
Standard
Ring Ring (When ring is
size
groove thickness new)
Check with piston groove
2 Piston ring groove Top ring Keystone wear gauge or check
0.15
second ring Keystone clearance between
piston and new ring
+0.05 –0.01 Replace
Oil ring 4.00 0.3
+0.03 –0.03
Standard clearance Clearance limit
Closed gap of piston Top ring 0.50 – 0.65
3
ring Second ring 0.70 – 0.85 1.8
Oil ring 0.50 – 0.70
Diameter of piston pin
4 +0.044
hole 68
+0.034
Outside diameter of pis- –0.000
5 68
ton pin –0.006
34 170E-5 Series
Flywheel and flywheel housing 1
1. Rear seal
2. Ring gear (Number of teeth: 118 (Only D375A-5: 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
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
Unit: mm
Standard Tolerance Standard Clearance
Clearance between idler size clearance limit
Shaft Hole
1 gear (large) bushing and
shaft +0.014 +0.063 0.025 – Replace bush-
47.6 0.25
+0.001 +0.039 0.062 ing
Clearance between idler
+0.014 +0.063 0.025 –
2 gear (medium) bushing and 47.6 0.25
+0.001 +0.039 0.062
shaft
Clearance of idler gear Standard clearance Clearance limit
3
(large) in axial direction 0.05 – 0.17 0.34 Replace thrust
Clearance of idler gear bearing
4 0.05 – 0.17 0.34
(medium) in axial direction
Level difference between
underside surfaces of gear Correct or
5 Tolerance: 0.15
train case cover and cylin- replace
der block
Posi-
Check parts Standard Repair limit
tion
Crank gear and main idler gear
A 0.134 – 0.326 0.5
(large)
B 0.114 – 0.320 —
(medium)
— Backlash of each gear Replace
Idler gear (medium) and alternator
C 0.114 – 0.320 0.5
drive gear
Idler gear (large) and water pump
D 0.121 – 0.333 0.5
drive gear
Idler gear (large) and oil pump
E 0.121 – 0.333 0.5
drive gear
170E-5 Series 39
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)
1. Crankshaft gear (Number of teeth: 63)

4. Camshaft gear (Number of teeth: 70)
5. Fuel supply pump drive gear (Number of teeth:
70)
40 170E-5 Series
42 170E-5 Series
Unit: mm
Clearance between idler size Shaft Hole clearance limit Replace bush-
1
gear bushing and shaft –0.027 +0.055 0.027 – ing
52 0.25
–0.040 +0.000 0.095
Clearance of idler gear in Standard clearance Clearance limit Replace thrust
2
axial direction 0.04 – 0.18 0.3 bearing
Posi-
Check parts Standard Repair limit
tion
A 0.155 – 0.412 0.6
(large)
— Backlash of each gear Replace
Idler gear (small) and camshaft
B 0.145 – 0.380 0.6
gear
Camshaft gear and fuel supply
C 0.007 – 0.559 0.6
pump drive gear
170E-5 Series 43
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)
44 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 45
Valve and valve guide 1
Unit: mm
Replace valve
1 Sinking distance of valve Intake and
0 0.80 or valve seat
exhaust valves
2 Thickness of valve lip Intake valve 3.2 — 2.7 Replace valve
Exhaust valve 3.3 — 2.8
Standard Tolerance
3 Valve seat angle Intake valve 30° ±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 12.10
guide –0.019
5 Projection of valve guide 43 ±0.5 —
Installed load Allowable load
Free length Installed length
(N {kg}) (N {kg})
Valve spring
647 ± 65
6 99.6 87.4 608 {62.0}
{66.0 ± 6.6}
Perpendicularity of valve
Repair limit: 2°
spring
46 170E-5 Series
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 47
Crosshead and guide 1
Unit: mm
Depth of cross head stem
1 +0.3
receiver 7.5 —
+0.0
Inside diameter of cross +0.10 Replace
2 13 13.21
head +0.05
Outside diameter of cross +0.039
13 13.00
head guide +0.028
3
Clearance between cross Standard clearance Clearance limit
Adjust
head guide and cross head 0.011 – 0.072 —
Projection of cross head Standard size Tolerance
4
guide 86 ±0.25
Replace
Intake valve Exhaust valve
5 Valve clearance (cold)
0.32 0.62
Tightening torque of cross
6 59 ± 6Nm {6.0 ± 0.6 kgm} Tighten
head locknut
48 170E-5 Series
Tappet and push rod 1

Intake valve and exhaust valve
Unit: mm
Outside diameter cam fol-
1 –0.038
lower shaft 25 25
–0.053
Inside diameter of cam fol- +0.021
2 25 25
lower lever +0.000
Inside diameter of cam fol-
25.167 ±0.01 25.3
lower roller
3
Outside diameter of cam fol- +0.075 Replace
25 25
lower roller pin +0.063
Outside diameter of cam fol- +0.025
4 50 49.75
lower roller +0.000
Diameter of ball at push rod –0.0
5 15.836 —
end –0.2
Inside diameter of push rod –0.0
6 16.676 —
socket –0.2
170E-5 Series 49
SEN00197-01
© 2005 KOMATSU
All Rights Reserved
50
SEN00198-01
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............................................................................................................................................... 6
Oil filter and safety valve .................................................................................................................... 10
Oil cooler .............................................................................................................................................11
Fuel system................................................................................................................................................... 12
CRI system diagram........................................................................................................................... 12
Outline of CRI system ........................................................................................................................ 13
Fuel piping.......................................................................................................................................... 34
Fuel filter ............................................................................................................................................ 36
Electric priming pump......................................................................................................................... 38
170E-5 Series 1
Engine controller cooler...................................................................................................................... 39

Cooling system.............................................................................................................................................. 40
Cooling system diagram..................................................................................................................... 40
Water pump ........................................................................................................................................ 41
Thermostat ......................................................................................................................................... 42
Corrosion resistor ............................................................................................................................... 44
Fan drive ............................................................................................................................................ 46
Electrical equipment...................................................................................................................................... 47
Alternator............................................................................................................................................ 47
Starting motor ..................................................................................................................................... 51
Starting aid ......................................................................................................................................... 54
Engine controller ................................................................................................................................ 55
2 170E-5 Series
Lubrication system 1
Lubrication system diagram 1
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
Oil pump 1
1. Bushing Specifications
2. Drive gear (Number of teeth: 10) Type: Gear pump
3. Oil pump body Speed: Engine speed × 1.45
4. Drive shaft
5. Bushing
6. Pump cover
7. Oil pump drive gear (Number of teeth: 38)
8. Bushing
9. Driven gear (Number of teeth: 10)
10. Driven shaft
6 170E-5 Series
Oil pump relief valve
1. Valve
2. Spring
170E-5 Series 7
8 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 —
8 Interference of pump gear size Shaft Hole
and drive shaft +0.106 +0.064 0.024 –
18 —
+0.088 +0.043 0.063
Interference of body and +0.090 +0.021 0.044 –
9 21 —
body bushing +0.065 0 0.090
Interference of pump drive +0.106 +0.065 0.023 –
10 18 —
gear and drive shaft +0.088 +0.047 0.059
Tightening torque of pump
11 30.9 ± 3.4 Nm {3.15 ± 0.35 kgm} Tighten
cover mounting bolt
Standard size Repair limit
Installed
Installed Installed load
12 Main relief valve spring Free length Free length load Replace
length N {kg}
N {kg}
— — 716 {73.0} — —
Main relief valve operating Correct or
13 Standard: 883 ± 49 kPa {9.0 ± 0.5 kg/cm2}
pressure replace spring
170E-5 Series 9
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}
10 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 –
stat 5 minutes)
5 Check that valve closes fully when its temperature is lowered from Replace
Opening and closing of ther-
100°C for full opening to 85°C. (Check after soaking valve in oil
mostat
tank for 4 – 5 minutes)
170E-5 Series 11
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)
12 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 13
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.
14 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 15
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.
16 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 17
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.
18 170E-5 Series
2. Common rail
Structure When fuel is stopped

q Common rail (4) distributes the high-pressure q If the fuel flows out abnormally because of a
fuel from the high-pressure pump to the injec- burst of the piping, etc., piston (2) moves to the
tors of the cylinders. right stroke end.
q Common rail (4) is equipped with common rail q The tip of piston (2) contacts seat (b) to stop
fuel pressure sensor (2), flow dampers (1), and the fuel.
pressure limiter (3). q Once the fuel is stopped, piston (2) does not
q The fuel injection pipes are connected to flow return to the initial position until the engine is
dampers (1) to send the high-pressure fuel to stopped.
the injectors.
q The piping of the pressure limiter (3) is
returned to the fuel tank.
1) Flow damper
Function
q The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
Operation
When fuel is not injected
q Piston (2) is in contact with stopper (1) (initial
position).
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
When fuel is injected

q The fuel pressure is applied to piston (2),
which compresses spring (3) and moves to the
right.
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
170E-5 Series 19
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
20 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 21
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.
22 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 23
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.
24 170E-5 Series
Various controls
q The CRI system controls the fuel injection rate 2. Fuel injection timing control function
and fuel injection timing more properly than the q The fuel injection timing control function is
mechanical governor or timer of the conven- employed instead of the function of the con-
tional fuel injection pump. ventional timer. It controls the fuel injection
q For the control of the system, calculations nec- timing most properly from the engine speed
essary to the engine controller are performed and fuel injection rate.
fr om th e si gn als se nt fr om the s en so rs
installed to the engine and machine.
q The energizing timing and energizing period of 3. Fuel injection pressure control function
the injector are so controlled that the optimum (Common rail fuel pressure control function)
quantity of fuel will be injected in the optimum q The fuel injection pressure control function
timing. (common rail fuel pressure control function) is
a function of measuring the fuel pressure with
1. Fuel injection rate control function the common rail fuel pressure sensor and
q The fuel injection rate control function is feeding it back to the engine controller to con-
employed instead of the function of the 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 25
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 PC1250-7.
26 170E-5 Series
170E-5 Series 27
a Nos. 1 – 12 in the above illustration correspond to title Nos. 1) – 12).

a The above illustration shows the engine for HD465-7 and HD605-7.
28 170E-5 Series
170E-5 Series 29
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.
30 170E-5 Series
5) Bkup speed sensor (G sensor) 6) Atmospheric pressure sensor

(Cylinder No. sensor) q This sensor is used to correct altitude.
q Similarly to the NE speed sensor, this sensor
utilizes the pulses of 0 – 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120°.
q In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
A: Pressure inlet
B: Mounting screw: M5
Tightening torque:
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
teristics of the atmospheric pressure sensor.
170E-5 Series 31
7) NE speed sensor (Crank angle sensor)

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

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

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

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

teristics of the position sensor.
32 170E-5 Series
12) Coolant temperature sensor

q The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
q The sensor unit is a thermistor the resistance
of which changes according to the tempera-
ture. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
170E-5 Series 33
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)
34 170E-5 Series

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 35
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
36 170E-5 Series
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
1. Filter head
2. Cartridge
Specifications
With water separator
170E-5 Series 37
Electric priming pump 1
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
38 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 39
Cooling system 1
Cooling system diagram 1
A. From oil pump (Oil)

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

2. Oil cooler 7. Thermostat
3. Corrosion resistor 8. Radiator
4. Cylinder liner 9. Fan
5. Cylinder block 10. EGR cooler
40 170E-5 Series
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 —
170E-5 Series 41
Thermostat 1
42 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 43
Corrosion resistor 1
A: Coolant inlet Specifications

B: Coolant outlet
Filtration area 0.13 m2 0.19 m2 0.37 m2
1. Head Quantity of
400 g 600 g 1,000 g
2. Cartridge anti-corrosion agent
3. Element
4. Inhibitor (Solid anti-corrosion agent)
5. Spring
6. Stop valve
44 170E-5 Series
Corrosion resistor mounting
1. Tube (Return from corrosion resistor)

2. Corrosion resistor head
3. Corrosion resistor cartridge
4. Tube (To corrosion resistor)
170E-5 Series 45
Fan drive 1
HD465-7, HD605-7
1. Crankshaft pulley
2. Fan belt
3. Tension pulley
4. Adjustment bolt
5. Tension pulley bracket
6. Fan pulley
7. Fan
a. Direction of wind
46 170E-5 Series
Electrical equipment 1
Alternator 1
Alternator mounting

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.
170E-5 Series 47
Alternator belt tension
WA600-6
1. Tension shaft 6. Spacer

2. Spring 7. Tension pulley (Outside diameter: 150 mm)
3. Roller bearing 8. Ball bearing
4. Tension bracket 9. Grease fitting
5. Oil seal 10. Adjustment bolt
48 170E-5 Series
Alternator
With built-in regulator (Open type, 60A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal E 6C. Regulator
5. Terminal R
Outside diam-
Applicable
Engine Type Specification eter of pulley Weight (kg)
machine
(mm)
Open type (brushless), manufac-
D375A-5 24V, 60A
tured by NIKKO DENKI
PC1250-8 24V, 60A
SAA6D170E-5
HD465-7 24V, 60A
HD605-7 24V, 60A
170E-5 Series 49
With built-in regulator (Open type, 90A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Field coil
3. Terminal B 6B. Initial excitation resistor
4. Terminal E 6C. Regulator
5. Terminal R
Outside diam-
Applicable
Engine Type Specification eter of pulley Weight (kg)
machine
(mm)
D375A-5 24V, 90A
PC1250-8 24V, 90A
SAA6D170E-5 WA600-6 24V, 90A
HD465-7 24V, 90A
HD605-7 24V, 90A
50 170E-5 Series
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
170E-5 Series 51
Safety relay
Applicable Specifica- No. of pin- Connector
Engine Type Weight (kg) mounting
machine tion ion teeth type
type
NIKKO DENKI 27V, 7.5kW
D375A-5 11 18 G E
(Water-proof, oil-proof type) x2
SAA6D170E-5 HD465-7 11 18 G C
HD605-7 11 18 G C
52 170E-5 Series
For 11 kW
E: To chassis ground 1. Pinion gear

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

Engine Type Specification Weight (kg) Connector type
machine teeth
Waterproof, oilproof,
PC1250-8 manufactured 24V, 11kW 12 18 B
by NIKKO DENKI
SAA6D170E-5
Waterproof, oilproof,
WA600-6 manufactured 24V, 11kW 12 18 B
by NIKKO DENKI
170E-5 Series 53
Starting aid 1
Electrical intake air heater
For SAA6D170E-5
a The shape is subject to change for modification, etc.
1. Terminal Specifications
2. Body Type of heater: Electrical intake air heater
3. Heater coil Rated voltage: 22 V (DC)
4. Electric circuit diagram Rated current: 111 A
54 170E-5 Series
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q The engine controller cooler is equipped to
cool the engine controller with the fuel to
secure the reliability of the mounted engine
controller.
q Vibrations are damped by the vibration-proof
rubber.
Unified specifications of engine controller
q Engine controller CM850 which is common
part for the other engine is employed
170E-5 Series 55
© 2005 KOMATSU
All Rights Reserved
56 170E-5 Series
SEN00367-00
ENGINE 1SHOP MANUAL
170E-5 Series
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ........................................................................... 6
170E-5 Series 1
SEN00367-00 20 Standard value table
Standard service value table 1

Standard service value table for testing, adjusting, and troubleshooting
Engine SAA6D170E-5
Machine model D375A-5
Performance Category
Standard value
Judgement
Item Measurement conditions Unit for new
criteria
machine
High idle speed rpm 1,830 ± 20 1,830 ± 20
Speed
Low idle speed rpm 750 ± 20 750 ± 20
Necessary At 0°C (without starting aid) rpm 125 —
speed for starting At –20°C (with starting aid) rpm 85 —
Air intake kPa Max. 3.73 7.5
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Air boost kPa Min. 155 141
At rated output
pressure {mmHg} {Min. 1,160} {1,060}
Air intake and exhaust system
Exhaust kPa Min. 167 153

At rated output
Exhaust
Whole speed range (20°C ) °C Max. 650 700
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 —
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 SAE0W30E0S MPa Min. 0.34 0.21
Lubrication system
Engine oil temperature: Min. 80°C SAE5W40E0S {kg/cm2} {Min. 3.5} {2.1}
Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.1 0.08
Engine oil temperature: Min. 80°C SAE30DH {kg/cm2} {Min. 1.0} {0.8}
Oil temperature Whole speed range °C 90 – 110 120
Ratio to fuel consumption at continuous rated
Oil consumption % Max. 0.1 0.2
output
Function of
kPa
radiator pressure Cracking pressure (Differential pressure) — —
{kg/cm2}
valve
Cooling system
Hydraulically Hydraulically
Fan speed At rated speed rpm driven on driven on
machine side machine side
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm driven on driven on
Alternator belt —
Deflection under finger pressure of 98 N {10 kg} mm —
tension (Auto-tension)
2 170E-5 Series
Engine SAA6D170E-5
Machine model PC1250-7
Standard value
Judgement
criteria
machine
Speed
Whole speed range
At rated output

At rated output
Exhaust
temperature
%
Max. 25 35
(Max. 2.5) (3.5)
index)
index
Bosch
index
Body

pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 350} {1,320}
Lubrication system
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt —
170E-5 Series 3
Engine SAA6D170E-5
Machine model WA600-6
Standard value
Judgement
criteria
machine
Speed
Whole speed range
At rated output

At rated output
Exhaust
temperature
%
Max. 25 35
(Max. 2.5) (3.5)
index)
index
Bosch
index
Body

pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 350} {960}
Lubrication system
output
Function of
kPa
{kg/cm2}
valve
Cooling system
Alternator belt —
4 170E-5 Series
Engine SAA6D170E-5
HD465-7
Machine model
HD605-7
Standard value
Judgement
criteria
machine
Speed
Whole speed range
At rated output

At rated output
Exhaust
temperature
%
Max. 25 35
(Max. 2.5) (3.5)
index)
index
Bosch
index
Body

pressure Engine coolant temperature: Min. 70°C {mmH2O} {Max. 350} {1,320}
Lubrication system
output
Function of
kPa
{kg/cm2}
Cooling system
valve
Fan speed At rated speed rpm 1,190 ± 30 1,190 ± 30
— —
Fan belt tension Deflection under finger pressure of 98 N {10 kg} mm
(Auto-tension) (Auto-tension)
Alternator belt —
170E-5 Series 5
Running-in standard and performance test standard 1

Running-in standard
Engine SAA6D170E-5
Procedure
Item
1 2 3 4 5
Running time min. 1.5 4.5 9 12 3
Speed rpm 750 1,134 1,422 1,638 1,800
Dynamometer load N {kg} 0 {0} 1,329 {135} 2,119 {216} 2,759 {281} 3,348 {341}
Output kW {HP} 0 {0} 113 {152} 226 {303} 339 {455} 452 {606}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
Engine SAA6D170E-5
Test item Rated output Max. torque High idle speed Low idle speed
Specification value 452 kW/1,800 rpm 3,020 Nm/1,300 rpm
— 1,830 ± 20 rpm 750 ± 20 rpm
(Gross value) {606 HP/1,800 rpm} {308 kgm/1,300 rpm}
Speed rpm 1,800 1,300 1,830 ± 20 750 ± 20
N 3,246 – 3,452 4,089 – 4,335
Dynamometer load — —
{kg} {331 – 352} {417 – 442}
kW 438 – 466
Output (Gross value) — — —
{HP} {588 – 624}
Nm 2,932 – 3,109
Torque (Gross value) — — —
{kgm} {299 – 317}
Fuel consumption sec/500cc Min. 14 — — —
Coolant temperature °C 70 – 90 70 – 90 70 – 90 70 – 90
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 343 – 539 343 – 539 343 – 539 Min. 118
pressure {kg/cm2} {3.5 – 5.5} {3.5 – 5.5} {3.5 – 5.5} {Min. 1.2}
Exhaust temperature °C Max. 650 Max. 650 — —
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
6 170E-5 Series
Running-in standard
Engine SAA6D170E-5
Procedure
Item
1 2 3 4 5
Speed rpm 750 1,134 1,422 1,638 1,800
Output kW {HP} 0 {0} 129 {173} 257 {345} 386 {518} 515 {690}
Engine SAA6D170E-5
— 2,000 ± 40 rpm 900 ± 25 rpm
(Gross value) {690 HP/1,800 rpm} {308.5 kgm/1,300 rpm}
Speed rpm 1,800 1,300 2,000 ± 40 900 ± 25
N 3,697 – 3,932 4,089 – 4,354
{kg} {377 – 401} {417 – 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
170E-5 Series 7
Running-in standard
Engine SAA6D170E-5
Procedure
Item
1 2 3 4 5
Speed rpm 750 1,134 1,422 1,638 1,800
Output kW {HP} 0 {0} 99 {133} 198 {265} 297 {398} 396 {531}
Engine SAA6D170E-5
— 2,000 ± 50 rpm 800 ± 25 rpm
(Gross value) {530 HP/1,800 rpm} {264.5 kgm/1,000 rpm}
Speed rpm 1,800 1,000 2,000 ± 50 800 ± 25
N 2,844 – 3,020 3,521 – 3,727
{kg} {290 – 308} {359 – 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
8 170E-5 Series
Running-in standard
Engine SAA6D170E-5
HD465-7
Machine model
HD605-7
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
HD465-7
Machine model
HD605-7
— 2,270 ± 50 rpm 750 ± 50 rpm
(Gross value) {740 HP/2,000 rpm} {339 kgm/1,400 rpm}
Speed rpm 2,000 1,400 2,270 ± 50 750 ± 50
N 3,570 – 3,795 4,501 – 4,776
{kg} {364 – 387} {459 – 487}
kW 535 – 569
{HP} {718 – 762}
Nm 3,226 – 3,423
{kgm} {329 – 349}
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
170E-5 Series 9
SEN00367-00
© 2005 KOMATSU
All Rights Reserved
10
SEN00368-00
ENGINE 1SHOP MANUAL
170E-5 Series
30 Testing and adjusting 1

Testing and adjusting
Testing and adjusting ...................................................................................................................................... 3
Testing and adjusting tools list ............................................................................................................. 3
Testing air boost pressure .................................................................................................................... 5
Testing exhaust temperature................................................................................................................ 6
Adjusting valve clearance .................................................................................................................... 7
Testing compression pressure ............................................................................................................. 8
Testing blow-by pressure ....................................................................................................................11
Testing oil pressure ............................................................................................................................ 12
Handling fuel system parts ................................................................................................................. 13
Releasing residual pressure in fuel system........................................................................................ 13
Testing fuel pressure .......................................................................................................................... 14
Reduced cylinder mode operation ..................................................................................................... 15
No-injection cranking.......................................................................................................................... 15
Testing leakage from pressure limiter and return rate from injector ................................................... 16
Bleeding air from fuel circuit............................................................................................................... 19
Testing fuel system for leakage.......................................................................................................... 20
170E-5 Series 1
SEN00368-00 30 Testing and adjusting
Handling controller voltage circuit ...................................................................................................... 21
2 170E-5 Series
Testing and adjusting 1

Testing and adjusting tools list 1
Testing and Sym-
Part No. Part name Q'ty Remarks
adjusting item bol
Testing air boost pres- 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
sure 799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust tem-
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
perature
Adjusting Commercially
C Clearance gauge 1 Air intake: 0.35 mm
valve clearance available
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
795-611-1220 Adapter 1
Testing compression 2
D 6261-71-6150 Gasket 1
pressure
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Testing blow-by pres-
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
sure
Pressure gauge: 2.5, 5.9, 39.2, 58.8
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Testing oil pressure F
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
799-101-5230 Nipple 1 14 x 1.5 mm
3
6215-81-9720 O-ring 1
Pressure gauge: 2.5, 5.9, 39.2, 58.8
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure G {600 kg/cm2}
2 799-101-5160 Nipple 1
3 799-401-2320 Gauge 1
{10 kg/cm2}
1 6167-11-6640 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 φ5 mm x 2 – 3 m
Testing leakage from available
pressure limiter and Commercially
H 4 Hose 1 φ15 mm x 2 – 3 m
return rate from injec- available
tor
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
170E-5 Series 3
Testing and Sym-

Part No. Part name Q'ty Remarks
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
799-601-4180 T-adapter — For EGR gas 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
controllers, sensors, J 799-601-9020 T-adapter —
For bypass valve solenoid
and actuators
For EGR valve solenoid
799-601-9030 T-adapter —
For bypass valve stroke sensor
799-601-9430 T-adapter — For supply pump PCV
799-601-9020 T-adapter — For injector
799-601-4260 T-adapter — For controller (4-pole)
799-601-9320 T-box —
For 24-pole type
799-601-9310 Plate —
799-601-4350 T-box — For 60-pole type
4 170E-5 Series
Testing air boost pressure 1 3. Run the engine at the rated output and test the
air boost pressure.
a Testing tools for air boost pressure a When testing with the engine mounted on
Symbol Part No. Part name the machine, test on the condition
described in the shop manual for the
799-201-2202 Boost gauge kit
A machine.
790-401-2220 Hose
k Be careful not to touch any hot part when

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

intake manifold. Alternatively, install a mea-
surement screw (R1/8) to the tube to be con-
nected between the turbocharger outlet tube
and aftercooler, and install nipple [1] of boost
gauge kit A and connect it to gauge [2].
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].
170E-5 Series 5
Testing exhaust temperature 1

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

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

from the bottom of the exhaust manifold.
a You may measure at either front or rear
plug.
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.
6 170E-5 Series
Adjusting valve clearance 1 a Loosen locknut (9) of adjustment screw

(8), insert clearance gauge C in the clear-
a Adjusting tool for valve clearance ance between crosshead (7) and rocker
Symbol Part No. Part name arm (6), and adjust the valve clearance
with adjustment screw (8) to a degree that
Commercially
C Clearance gauge you can move the clearance gauge lightly.
available
a Valve clearance
1. Remove covers (1) and (2) and bracket (3), q Air intake valve: 0.32 mm
and remove 6 cylinder head covers (4). q Exhaust valve: 0.62 mm
4. 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.
5. Rotate the crackshaft forward one turn and

adjust the valve clearance indicated by Q of
the valve layout plan.
a The adjustment method is the same as
above.
2. Rotate the crankshaft forward to align the

notch (a) of the supply pump drive gear with
the center of inspection hole on the left side of
timing gear case.
a Rotate the engine with the cranking device
on the rear left of engine.
a On the left of figure below, the compres-
sion top dead center of No. 1 cylinder is
shown and on the right, the top dead cen-
ter 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.
6. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
3. When the No. 1 cylinder is at the compression
top dead center, adjust the valve clearance {No.1, 3, 4, 5, 6 cylinders}
indicated by q of the valve layout plan. 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 7
Testing compression pressure 1

a Testing tools for compression pressure

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

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

injector (8).
8 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 injector end without a Install the injector and fuel high-pressure
fail tube according to the following procedure.
a Fix the adapter with the injector holder 1) Install gasket (10) and O-rings (11) and
and adaptor. (12).
3 Holder mounting bolt: a Take care not to install O-ring (11) to
58.8 – 73.5 Nm {6.0 – 7.5 kgm} the groove (b).
a Apply a little amount of engine oil to the 2 O-ring: Engine oil
connecting parts of the adapter and gauge 2) Fit adaptor (9) to injector (8), and press it
so that air will not leak easily. in as a unit to the cylinder head by hand.
7. Connect the INSITE (bench test tool) to the 3) Install holder (7), and temporarily tighten
engine and set the engine in the no-injection bolt (13) and washer (14).
cranking mode. 2 Spherical part of washer: Engine oil
k If the engine is not set in the no-injec- 4) Install the fuel high-pressure tube, and
tion cranking mode, it will start and will temporarily tighten sleeve nut (5).
be dangerous. Accordingly, be sure to
set the engine in this mode. 5) Fully tighten bolt (13).
8. Rotate the engine with the starting motor and 3 Bolt:
measure the compression pressure. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Read the pressure gauge pointer when it 6) Fully tighten sleeve nut (5).
is stabilized. 3 Sleeve nut:
39.2 – 44.1 Nm {4 – 4.5 kgm}
170E-5 Series 9
a Install the injector wiring harness accord-

ing to the following procedure.
1) Assemble injector wiring harness (6) from
the inside of rocker arm housing and fix
the connector side with plate (15).
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}
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}
10 170E-5 Series
Testing blow-by pressure 1

a Testing tool for blow-by pressure

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].
3. Run the engine at the rated output and test the

blow-by pressure.
machine.

170E-5 Series 11
Testing oil pressure 1

a Testing tools for oil pressure

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

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

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

and test the oil pressure.
machine.
12 170E-5 Series
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. If a filter ping the engine until the residual pressure
other than the genuine one is used, the fuel in the fuel circuit is released. (Do not start
system may have a trouble. Accordingly, the work just after stopping the engine
never use such a filter. since there is residual pressure.)
170E-5 Series 13
Testing fuel pressure 1

a Testing tools for fuel pressure 3. Run the engine at high idle and measure the
fuel pressure.
Symbol Part No. Part name a If the fuel pressure is in the following
range, it is normal.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
G Engine speed Fuel pressure
2 799-101-5160 Nipple
Min. 0.15 MPa
3 799-401-2320 Gauge High idle
{Min. 1.5 kg/cm2}
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove plug (1).

2. Install nipple G2 and connect it to gauge G3.
14 170E-5 Series
Reduced cylinder mode operation1 No-injection cranking 1

a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after the machine
lows. or engine unit has been stored for a long
1. This operation is used to find out a cylinder period, the no-injection cranking is performed
which does not output power normally (or, to lubricate the engine parts and protect them
combustion in it is abnormal). from seizure.
2. When a cylinder is selected for the reduced a Perform the no-injection cranking mode opera-
cylinder mode operation, if the engine speed tion with the engine mounted on the machine
and output do not change from the normal or connected to INSITE (troubleshooting kit).
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 (trou-
are as follows. bleshooting kit).
q Leakage through cylinder 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 (trouble-
shooting kit).
Before performing, see Testing method in
the shop manual for the machine or
INSITE (troubleshooting kit).
170E-5 Series 15
Testing leakage from pressure limiter and return rate from injector 1
a Regarding engines which return spill fuel from

the injector from the return block installed on
the intake manifold to the fuel tank, test it
according to the following procedure (the figure
indicates WA600).
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 an oil pan of about 20 l to receive the

fuel flowing out during the test.
16 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 oil 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. 3) Start the engine and keep its speed to
a Be sure to fit the gaskets to both ends 1,600 rpm with no load.
of the spacer. 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 stall or relief 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.
170E-5 Series 17
3. Testing return rate from injector 5) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
1) Remove the hose at spill outlet (4), con-

nect test hose H4, and put its end in the oil
pan.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
3) Run the engine at the rated output.
4) After the engine speed is stabilized, test
the return rate 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 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
18 170E-5 Series
Bleeding air from fuel circuit 1

a In the following cases, bleed air according to
this procedure.
q When the fuel filter is replaced
q When the fuel is used up
q When starting the engine first after the fuel
piping or supply pump is replaced
a After replacing the fuel filter, do not fill fuel into
either the main filter or pre-fuel filter.
1. Place the starting switch to the “ON” position.
2. Press down the electric priming pump switch

(1) installed in the engine room to the “ON”
position. 3. If the specified time (approx. 6.5 min.) has
a Lamp (2) flashes and the electric priming passed, lamp (2) is automatically turns off and
pump starts. the electric priming pump stops.
a If you have replaced the fuel filter only, air
bleeding is completed.
4. If the fuel in the fuel circuit is bled, for example,

when the fuel is used up or the fuel piping or
supply pump is replaced, press down the
switch (1) to the “ON” position again after the
electric priming pump automatically stops.
5. Air bleeding is complete when lamp (2) is

turned off.
6. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a The internal timer of this switch automati- a If the engine does not start, there may be
cally starts and stops the electric priming still air in the low-pressure circuit. In this
pump (see the figure). case, repeat the above procedure from
a The electric priming pump stops while the step 1.
lamp is flashing. This is completely nor-
mal.
a Pressing down the switch to the “OFF”
position during flashing of the lamp turns
off the lamp and the electric priming pump
stops.
k The fuel circuit is pressurized during
operation of the electric priming pump.
Do not loosen the air bleeding plug;
this may cause the fuel to shoot into
air.
170E-5 Series 19
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, check is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

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

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

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

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

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

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
20 170E-5 Series
Handling controller voltage circuit1

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 21
SEN00368-00
© 2006 KOMATSU
All Rights Reserved
22
SEN00369-00
ENGINE 1SHOP MANUAL
170E-5 Series
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points on troubleshooting..................................................................................................................... 2
Error code and failure code table ......................................................................................................... 4
170E-5 Series 1
SEN00369-00 40 Troubleshooting
General information on troubleshooting 1

Points on troubleshooting 1
k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 3. Check before troubleshooting

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

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

Failure phenomenon
error code code
111 CA111 ECM Critical Internal Failure
115 CA115 Eng. Ne and Bkup Speed Sensor Error
122 CA122 Charge Air Press Sensor High Error
123 CA123 Charge 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 Air Temp. Sensor High Error
154 CA154 Charge 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
238 CA238 Ne Speed Sensor Sup. Volt. Error
263 CA263 Fuel Temp. Sensor High Error
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 (L/B #1) System Open/Short Error
342 CA342 Calibration Code Incompatibility
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 Low error
432 CA432 Idle Validation Process error
441 CA441 Battery voltage low error
442 CA442 Battery voltage high error
449 CA449 Rail Press. Very High Error
451 CA451 Rail Press. Sensor High Error
4 170E-5 Series
INSITE Machine failure

Failure phenomenon
error code code
452 CA452 Rail Press. Sensor Low Error
553 CA553 Rail Press. High Error
559 CA559 Rail Press. Low Error
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
1625 CA1625 EGR Valve Servo Error 2
1626 CA1626 Bypass Valve Solenoid Current High Error
1627 CA1627 Bypass Valve Solenoid Current Low Error
1628 CA1628 Bypass Valve Servo Error 1
1629 CA1629 Bypass Valve Servo Error 2
1631 CA1631 BP valve Lift Position Sensor High Error
1632 CA1632 BP valve Lift Position Sensor Low Error
1633 CA1633 KOMNET Dtalink Timeout Error
2185 CA2185 Throttle Sens. Sup. Volt. High Error
2186 CA2186 Throttle Sens. Sup. Volt. Low Error
2249 CA2249 Rail Press. Very Low Error
2271 CA2271 EGR Valve Lift Position Sensor High Error
2272 CA2272 EGR Valve Lift Position Sensor Low Error
2351 CA2351 EGR Valve Solenoid Current High Error
2352 CA2352 EGR Valve Solenoid Current Low Error
2555 CA2555 Grid Heater Relay Volt. Low Error
2556 CA2556 Grid Heater Relay Volt. High 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
SEN00369-00
© 2006 KOMATSU
All Rights Reserved
6
SEN00370-00
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
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

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

q
Clogged air breather hole of fuel tank cap

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

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

Improper selection of fuel
Defective intake air heater system

q
Defective or deteriorated battery

Clogged feed pump gauze filter
q Coolant in exhaust pipe
Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
(Coolant in exhaust pipe)
a The common rail fuel injection system (CRI) recog-
Cracked EGR cooler

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

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

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

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
(*1) q
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, strainer 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
change q
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
Correct
Correct
Clean
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)
Defective starting motor (safety relay section)

General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

q Internal parts of engine seized:
See “S-4 Engine stops during operations”
Defective or deteriorated battery
Defective steering circuit wiring

q Water hammer caused by coolant which entered cylinder
q Defective electrical system
Broken flywheel ring gear
Defective starting switch

Problem in drive devices on applicable machine side
Defective battery relay

q

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). q
Inspect flywheel ring gear directly q
Carry out troubleshooting
on applicable machine
Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminal B and

q
terminal E
Turn starting switch When terminal B and terminal C of starting switch are connected, q
OFF, connect cord, engine starts
and carry out trouble- When terminal B and terminal C at safety relay outlet are connected,
shooting at ON q
engine starts
Even if terminal B and terminal C at safety relay outlet are connected,
q
engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
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
Degree of use of
Questions
machine Operated for long period E E E
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
Maintenance Manual w w E Q
When fuel tank is inspected, it is found to be empty w

Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
Check items
Fuel is leaking from fuel piping w
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q w Q
cranked with out
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q

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

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

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

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

Defective coolant temperature sensor,

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

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

Worn dynamic valve system
Clogged fuel filter, strainer

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

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

Degree of use of
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

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
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
Correct
Clean
Clean
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
Seized turbocharger, interference of turbocharger

Insufficient supply of fuel

q

q Defective injection condition of fuel
Defective operation of flow damper

Clogged injector, defective spray

Controller is controlling in derate mode

q
(Large leakage from injector)

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

Improper valve clearance
electrical system)
q EGR valve is stuck open
Stuck EGR valve

(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

Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-mode q
q
Troubleshooting
Inspect valve clearance directly

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
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy

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
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

Leaking, clogged fuel piping
Broken, seized feed pump

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

Questions
stopped Engine stopped slowly w Q Q

There was hunting and engine stopped w 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 Q Q
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

Troubleshooting
Inspect gear train directly q
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
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
170E-5 Series 13
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Causes
Defective operation of flow damper (Large leakage from injector)

q Air in fuel system
q Defective speed sensor (Error at degree that it is not
indicated)
q Defective EGR valve
Clogged injector, defective spray (dirt in injector)

q Defective bypass valve
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness
Defective operation of bypass valve
Defective operation of EGR valve

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 bypass valve servo (*2)” in E-mode q
Troubleshooting

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

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

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

Defective drive of injector (signal, solenoid)

Improper selection of fuel

q
Air leakage from air intake piping

There is overheating:

q
Leaking, clogged fuel piping

See “S-14 Coolant temperature becomes too

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

machine
Suddenly Q Q Q Q
Questions
Power was lost

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

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

Troubleshooting
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q q
change
Inspect boost 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 coolant temperature sensor, wiring harness

• Insufficient intake of air

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)”

Controller is controlling in derate mode (limiting injec-
Crushed, clogged muffler
Abnormally worn injector

q
Improper injection timing

Clogged, seized injector
tion rate (output) because of an error in electrical
system)
Stuck EGR valve

q EGR valve is stuck open
(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
cylinders is low Q w

Check items

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

Troubleshooting

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 oil pan, cylinder head, etc.

q Abnormal consumption of oil
Worn, damaged valve (stem, guide, seal)

q Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
Dust sucked in from intake system
Oil leakage from EGR valve stem

Clogged breather, breather hose
minutes continuously)
Worn seal at turbocharger end
Oil leakage from oil drain plug

External leakage of oil
Worn, damaged rear oil seal

q
Oil leakage from oil cooler
Oil leakage from oil piping

q Wear of parts in lubrication system
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
machine Operated for long period
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 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 is removed, exhaust port is found to be dirty with oil 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
Correct
Correct
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 end
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

Use of improper oil

q
Defective oil filter safety valve

q Operation under excessive load
Worn valve, valve guide

Worn EGR 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 Q
Metal particles are found when oil filter is drained Q Q w
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 Q
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 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
Clean
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 timing)
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
Operated for long period

machine
More than for other machines of same model Q Q Q
Condition of fuel Gradually increased Q Q
consumption
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
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
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
Correct
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
Operated for long period

machine
Increase of oil Suddenly occurred Q Q Q

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

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

Replace
Replace
Replace
Replace
Replace
Remedy
—
170E-5 Series 21
S-12 Oil pressure drops 1
General causes why oil pressure drops Causes
Defective oil pressure sensor, wiring harness

Leaking, crushed, clogged hydraulic piping
q Leakage, clogging, wear or lubrication system
q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

Clogged strainer in oil pan
Defective EGR oil pump

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

q
See S-13
Valve and spring of oil pump relief valve are fatigued, damaged
Inspect oil filter directly q
Relief valve of EGR oil pump is damage, oil leaks from it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)” in E- q
mode
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Clean
Clean
Clean
Remedy
—
Add
22 170E-5 Series
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)

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”
Cracked EGR cooler (Entry of 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
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
Remove and inspect head cover directly q
Troubleshooting
Inspect cylinder block, liner directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
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

q Lack of cooling air (deformation, damage of fan)
External leakage of coolant from EGR cooler

q Drop in heat dissipation efficiency
Defective radiator cap (pressure valve)

q Problem in coolant circulation system
Rise in power train oil temperature on

Defective coolant temperature gauge
q Rise in oil temperature in power train
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
mud w w
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 q

Inspect cylinder liner directly q
Inspect oil cooler directly q

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

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

while it is not warmed up sufficiently. Accordingly, the
Improper fuel injection timing

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

indicate abnormality, however.
Dirt caught in injector

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

Degree of use of
machine Operated for long period E
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
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
cylinders is low w Q
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 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
Correct
Correct
Correct
Correct
Adjust
Remedy
26 170E-5 Series
S-16 Vibration is excessive 1
General causes why vibration is excessive Causes
Misalignment between engine and devices on applicable machine side

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

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

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

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

Improper gear train backlash
Worn camshaft bushing
Degree of use of
E E E E
Questions
machine Operated for long period
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
SEN00370-00
© 2006 KOMATSU
All Rights Reserved
28
SEN00371-00
ENGINE 1SHOP MANUAL
170E-5 Series
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode)............................................................................................... 4
Information in troubleshooting table ..................................................................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure ............................................................................ 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 8
E-3 Code [122/CA122] Charge Air Press Sensor High Error ............................................................... 9
E-4 Code [123/CA123] Charge Air Press Sensor Low Error...............................................................11
E-5 Code [131/CA131] Throttle Sensor High Error ............................................................................ 12
E-6 Code [132/CA132] Throttle Sensor Low Error............................................................................. 16
E-7 Code [135/CA135] Oil Press. Sensor High Error......................................................................... 17
E-8 Code [141/CA141] Oil Press. Sensor Low Error ......................................................................... 19
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 20
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 22
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error........................................................... 24
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ........................................................... 26
170E-5 Series 1
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error..................................................................... 26

E-14 Code [212/CA212] Oil Temp. Sensor High Error ....................................................................... 28
E-15 Code [213/CA213] Oil Temp. Sensor Low Error ........................................................................ 30
E-16 Code [221/CA221] Ambient Air Press. Sensor High Error......................................................... 31
E-17 Code [222/CA222] Ambient Air Press. Sensor Low Error ......................................................... 33
E-18 Code [227/CA227] Sensor Sup. 2 Volt. High Error .................................................................... 34
E-19 Code [234/CA234] Eng. Overspeed .......................................................................................... 36
E-20 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error............................................................... 38
E-21 Code [263/CA263] Fuel Temp. Sensor High Error..................................................................... 40
E-22 Code [265/CA265] Fuel Temp. Sensor Low Error ..................................................................... 42
E-23 Code [271/CA271] PCV1 Short Error ........................................................................................ 44
E-24 Code [272/CA272] PCV1 Open Error ........................................................................................ 46
E-25 Code [273/CA273] PCV2 Short Error ........................................................................................ 48
E-26 Code [274/CA274] PCV2 Open Error ........................................................................................ 50
E-27 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ............................................ 52
E-33 Code [342/CA342] Calibration Code Incompatibility.................................................................. 64
E-34 Code [351/CA351] INJ. Drive Circuit Error ................................................................................ 66
E-35 Code [352/CA352] Sensor Sup. 1 Volt. Low Error..................................................................... 68
E-36 Code [386/CA386] Sensor Sup. 1 Volt. High Error .................................................................... 70
E-37 Code [431/CA431] Idle Validation SW Low error ....................................................................... 72
E-38 Code [432/CA432] Idle Validation Process error ....................................................................... 74
E-39 Code [441/CA441] Battery voltage low error ............................................................................. 75
E-40 Code [442/CA442] Battery voltage high error............................................................................ 75
2 170E-5 Series
Troubleshooting of electrical system (E-mode) 1

Information in troubleshooting table 1
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code Failure code

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

• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes General causes why vibra- abnormally.
and standard tion is excessive
value in normal (Given numbers are refer- <Precautions for troubleshooting>
state ence numbers, which do not 1) Method of indicating connector No. and handling of T-
indicate priority) adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of “male” and “female”, dis-
connect connector and insert T-adapters in both male side
and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise spec-
4 ified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or wiring harness
entered on rear side.
4 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 5
E-1 Code [111/CA111] ECM Critical Internal Failure 1

Trouble ECM Critical Internal Failure
111 CA111
Contents of
• Defect occurred in controller.
trouble
Action of con-
• None in particular.
troller
Problem that
appears on • Sometimes machine stops during operation or stopped engine cannot be started.
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
battery (+) tance
defective contact in connec-
tor) Wiring harness between CE03 (female) (1) – Resis-
Possible causes Max. 1 z
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- battery (+) and chassis ground tance
cuit)
Min. 1 Mz
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) – (1) 20 – 30 V
6 170E-5 Series
Circuit diagram related to controller power supply
170E-5 Series 7
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-
• Stops engine.
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.)
8 170E-5 Series
E-3 Code [122/CA122] Charge Air Press Sensor High Error 1

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

Defective sensor power sup- If code [187/CA187] or [227/CA227] is indicated, carry out trouble-
1
ply system shooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure PIM Voltage
2 sensor Between (1) – (3) Power supply 4.75 – 5.25 V
(Internal trouble)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Possible causes ing without turning starting switch ON.
and standard Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal ness Max. 1 z
– PIM (female) (1) tance
state 3 (Disconnection in wiring or
defective contact in connec- Wiring harness between ENG (female) (47) Resis-
Max. 1 z
tor) – PIM (female) (3) tance
Wiring harness between ENG (female) (44) Resis-
Max. 1 z
– PIM (female) (2) tance
ing without turning starting switch ON.
Ground fault in wiring har- Wiring harness between ENG (female) (37) Resis-
Min. 1 Mz
ness – PIM (female) (1) and chassis ground tance
4
(Short circuit with GND cir- Wiring harness between ENG (female) (47) Resis-
cuit) Min. 1 Mz
– PIM (female) (3) and chassis ground tance
Min. 1 Mz
– PIM (female) (2) and chassis ground tance
170E-5 Series 9

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- (2)
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 (3)
state Wiring harness between ENG (female) (47)
– PIM (female) (2) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (44) – PIM (female) tance
(3)
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
10 170E-5 Series
E-4 Code [123/CA123] Charge Air Press Sensor Low Error 1

Trouble Charge Air Press Sensor Low Error
123 CA123
Contents of
• Signal voltage in charge pressure sensor circuit is abnormally low.
trouble
Action of con-
• Fixes charge pressure (400 kPa {4.1 kg/cm2}) and continues operation.
troller
Problem that
appears on • Acceleration performance of engine drops.
machine
Related infor-
mation
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
170E-5 Series 11
E-5 Code [131/CA131] Throttle Sensor High Error 1

Throttle sensor of accelerator pedal type (Case of WA600)

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

Defective sensor power sup- If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
ply system troubleshooting for it first.
L17 Accelerator pedal Voltage
All range
Between (1) – (3) 4.75 – 5.25 V
(Power supply)
Defective accelerator pedal (9 ± 2% of source
2 Released
(Internal trouble) voltage)
Between (2) – (3)
(73 ± 2% of source
Pressed
voltage)
Possible causes too, for another cause of trouble, and then judge.
and standard
state ing without turning starting switch ON.
Disconnection in wiring har- Wiring harnesses between E18 (female) (22) Resis-
ness Max. 1 z
– L17 (female) (1) tance
3 (Disconnection in wiring or
defective contact in connec- Wiring harness between E18 (female) (9) – Resis-
Max. 1 z
tor) L17 (female) (2) tance
Wiring harness between E18 (female) (23) – Resis-
Max. 1 z
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
Throttle sensor of fuel control dial type (Case of PC1250-8)

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

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

2
(Internal trouble) Between (1) – (3) 4.0 – 6.0 kz
Between (2) – (1) 0.25 – 5.0 kz
Between (2) – (3) 0.25 – 5.0 kz
Disconnection in wiring har- Wiring harnesses between E02 (female) (22) Resis-
ness Max. 1 z
– E06 (female) (1) tance
Possible causes defective contact in connec- Wiring harnesses between E02 (female) (9) Resis-
Max. 1 z
and standard tor) – E06 (female) (2) tance
value in normal Wiring harness between E02 (female) (23) – Resis-
state Max. 1 z
E06 (female) (3) tance
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)
– POIL (female) (1) tance
Max. 1 z
tor) – POIL (female) (2) tance
Max. 1 z
– POIL (female) (3) tance
Min. 1 Mz
ness – POIL (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
– POIL (female) (2) and chassis ground tance
Min. 1 Mz
– POIL (female) (3) and chassis ground tance
170E-5 Series 17

– POIL (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (47) – POIL (female) tance
5
(With another wiring har- – POIL (female) (1) and wiring harness Resis-
ness) between ENG (female) (13) – POIL (female) tance
and standard
value in normal (3)
– POIL (female) (2) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (13) – POIL (female) tance
(3)
Between (13) – (47) Signal 0.3 – 4.7 V
Circuit diagram related to oil pressure sensor
18 170E-5 Series
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
170E-5 Series 19
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.
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-
Defective coolant tempera- shooting without turning starting switch ON.
1 ture sensor (Internal trou- Coolant temper-
TWTR (male) Resistance
ble) ature
Between (A) – (B) 10 – 100°C 0.6 – 20 kΩ
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)
standard value in nor- Wiring harness between ENG
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
shooting without turning starting switch ON.
4 Defective engine controller Coolant temper-
ENG (female) Resistance
ature
Between (15) – (38) 10 – 100°C 0.6 – 20 kΩ
20 170E-5 Series
Circuit diagram related to coolant temperature sensor
170E-5 Series 21
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].
22 170E-5 Series
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error 1

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

Defective charge tempera- Intake air tem-
TIM (male) Resistance
1 ture sensor (Internal trou- perature
ble) Between (A) – (B) 10 – 100°C 0.5 – 20 kΩ
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
(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
4 Defective engine controller Intake air tem-
perature
Between (23) – (47) 10 – 100°C 0.5 – 20 kΩ
24 170E-5 Series
Circuit diagram related to charge temperature sensor
170E-5 Series 25
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error 1

Trouble Charge 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 temperature (intake air temperature) (70°C) and continues operation.
on machine
Related information

mal state Carry out troubleshooting E-11 Code [153/CA153].
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.
• 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
26 170E-5 Series
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

Defective oil temperature ing without turning starting switch ON.
1 sensor
TOIL (male) Oil temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
ness
Wiring harnesses between ENG (female) Resis-
Possible causes 2 (Disconnection in wiring or Max. 1 z
(17) – TOIL (female) (A) tance
and standard defective contact in connec-
value in normal tor) Wiring harnesses between ENG (female) Resis-
Max. 1 z
state (47) – TOIL (female) (B) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
3
cuit) Min. 1 Mz
– TOIL (female) (A) and chassis ground tance
ENG (female) Oil temperature Resistance
Between (17) – (47) 10 – 100°C 0.6 – 20 kz
28 170E-5 Series
Circuit diagram related to oil temperature sensor
170E-5 Series 29
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
30 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 (50.99 kPa {0.52 kg/cm2}) and continues opera-
troller tion.
Problem that
machine
Related infor-
mation

1
PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal trouble) Between (2) – (3) Signal 0.3 – 4.7 V
Possible causes
and standard
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal Max. 1 z
ness – PAMB (female) (1) tance
state
Max. 1 z
tor) – PAMB (female) (3) tance
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 31

– 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
32 170E-5 Series
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 (50.99 kPa {0.52 kg/cm2}) and continues opera-
troller tion.
Problem that
machine
Related infor-
mation

and standard
state
170E-5 Series 33
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 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.
• Sets atmospheric pressure (50.99 kPa {0.52 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
Defective sensor (Internal right in order. If error Charge pressure sen- PIM connector
2 code disappears sor
trouble)
when a device is dis- Atmospheric pres-
connected, that PAMB connector
sure sensor
device has a defect in
EGR valve lift sensor SEGR connector
it.
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 (female) tance
tor) Wiring harness between ENG (female) (47) Resis-
Max. 1 z
Ground fault in wiring har- ing without turning starting switch ON.
ness Wiring harness between ENG (female) (37) Resis-
4 Min. 1 Mz
(Short circuit with GND cir- – each sensor (female) and chassis ground tance
cuit) Wiring harness between ENG (female) (47) Resis-
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 (female) and wiring harness Resis-
ness) Min. 1 Mz
between ENG (female) (47) – each sensor tance
(female)
34 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
state ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to sensor power supply 2 (5 V)
170E-5 Series 35
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.)
36 170E-5 Series
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

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
it.
ness
– NE (female) (1) tance
and standard
3 Min. 1 Mz
(Short circuit with GND cir- – NE (female) (1) and chassis ground tance
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
38 170E-5 Series
Circuit diagram related to Ne speed sensor power supply
170E-5 Series 39
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
Action of con-
• Fixes fuel temperature (90°C) and continues operation.
troller
Problem that
appears on
machine
Related infor-
mation

Defective fuel temperature ing without turning starting switch ON.
1 sensor
TFUEL (male) Fuel temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
ness
Possible causes 2 (Disconnection in wiring or Max. 1 z
– TFUEL (female) (A) tance
and standard defective contact in connec-
value in normal tor) Wiring harness between ENG (female) (47) Resis-
Max. 1 z
state – TFUEL (female) (B) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
3
cuit) Min. 1 Mz
– TFUEL (female) (A) and chassis ground tance
ENG (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100°C 0.6 – 20 kz
40 170E-5 Series
Circuit diagram related to fuel temperature sensor
170E-5 Series 41
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 (90°C) and con-
troller
tinues operation.)
Problem that
appears on
machine
Related infor-
mation

and standard
state
42 170E-5 Series
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
Related infor-
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
ness Wiring harness between ENG (female) (4) – Resis-
2 Min. 1 Mz
(Short circuit with GND cir- PCV1 (female) (1) tance
Possible causes cuit)
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
44 170E-5 Series
Circuit diagram related to supply pump PCV1
170E-5 Series 45
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
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
46 170E-5 Series
170E-5 Series 47
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)
– 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
48 170E-5 Series
170E-5 Series 49
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
Min. 1 Mz
– PCV2 (female) (2) and chassis ground tance
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
50 170E-5 Series
E-27 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error 1

Trouble Injector #1 (L/B #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
Related infor-
mation

Defective injector No. 1 INJ (male) Resistance
1
Min. 1 Mz
ground
ness
– INJ (female) (1) tance
Possible causes
value in normal
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
Between (45) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
k High voltage (maximum of 65 V) is used in the electric circuit of the fuel injector. Referring to
Testing and adjusting, “Handling of high-voltage circuit of controller”, take care of an electric
shock and a leak.
52 170E-5 Series
Circuit diagram related to injector #1
170E-5 Series 53

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
Possible causes
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (46) – (60) 0.4 – 1.1 z
Min. 1 Mz
ground
shock and a leak.
54 170E-5 Series
170E-5 Series 55

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
Possible causes
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (55) – (52) 0.4 – 1.1 z
Min. 1 Mz
ground
shock and a leak.
56 170E-5 Series
170E-5 Series 57

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
Possible causes
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (57) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
shock and a leak.
58 170E-5 Series
170E-5 Series 59

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
Possible causes
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (54) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
shock and a leak.
60 170E-5 Series
170E-5 Series 61

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
Possible causes
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (56) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
shock and a leak.
62 170E-5 Series
170E-5 Series 63
E-33 Code [342/CA342] Calibration Code Incompatibility 1

Trouble Calibration Code Incompatibility
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

64 170E-5 Series
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
1 Defective related system
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
battery (+) tance
Possible causes defective contact in connec-
and standard tor) Wiring harness between CE03 (female) (1) – Resis-
Max. 1 z
value in normal chassis ground tance
ness Wiring harness between CE03 (female) (3) – Resis-
4 Min. 1 Mz
(Short circuit with GND cir- battery (+) and chassis ground tance
cuit) Wiring harness between CE03 (female) (1) – Resis-
Min. 1 Mz
chassis ground and chassis ground tance
CE03 Voltage
Between (3) – (1) 20 – 30 V
66 170E-5 Series
Circuit diagram related to controller power supply
170E-5 Series 67
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
68 170E-5 Series
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

right in order. If error Atmospheric
Defective sensor (Internal PAMB connector
2 code disappears pressure sensor
trouble)
when a device is dis-
connected, that Bypass valve lift
device has a defect in SBP connector
sensor
it.
ness Max. 1 z
– PFUEL (female) (1) tance
tor) – NE (female) (3) tance
and standard
state
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- Wiring harness between ENG (female) (33)
ness – PFUEL (female) (1) and wiring harness Resis-
5 Min. 1 Mz
(With another wiring har- between ENG (female) (47) – each sensor tance
ness) (female)
Min. 1 Mz
70 170E-5 Series

Possible causes a Prepare with starting switch OFF, then turn starting switch ON
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)
170E-5 Series 71
E-37 Code [431/CA431] Idle Validation SW Low error 1


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

L17 Signal name Voltage
Defective accelerator pedal Between (5) – (4) Signal 1 See Fig. 1 in the next
1
(Internal trouble) Between (6) – (4) Signal 2 page.
Disconnection in wiring har- Wiring harness between E18 (female) (32) – Resis-
ness Max. 1 z
defective contact in connec- Wiring harness between E18 (female) (11) – Resis-
Max. 1 z
tor) L17 (female) (5) tance
Possible causes
and standard Wiring harness between E18 (female) (1) – Resis-
Max. 1 z
value in normal L17 (female) (6) tance
Min. 1 Mz
ness L17 (female) (4) and chassis ground tance
3
cuit) Min. 1 Mz
Min. 1 Mz
Wiring harness between E18 (female) (32) –
Hot short (Short circuit with Voltage Max. 1 V
L17 (female) (4) and chassis ground
4 24 V circuit) in wiring har-
ness Wiring harness between E18 (female) (11) –
Voltage Max. 1 V
Wiring harness between E18 (female) (1) –
Voltage Max. 1 V
72 170E-5 Series

Possible causes
value in normal 5 Defective engine controller E18 Signal name Voltage
state Between (11) – (32) Signal 1
See Fig. 1.
Between (1) – (32) Signal 2
Circuit diagram related to throttle sensor of accelerator pedal type (Case of WA600)
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Operating range: Operating range of accelerator
pedal
170E-5 Series 73
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
74 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 75
SEN00371-00
© 2006 KOMATSU
All Rights Reserved
76
SEN00372-00
ENGINE 1SHOP MANUAL
170E-5 Series
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode)............................................................................................... 3
E-41 Code [449/CA449] Rail Press. Very High Error ........................................................................... 3
E-42 Code [451/CA451] Rail Press. Sensor High Error ....................................................................... 4
E-43 Code [452/CA452] Rail Press. Sensor Low Error........................................................................ 6
E-44 Code [553/CA553] Rail Press. High Error ................................................................................... 7
E-45 Code [559/CA559] Rail Press. Low Error .................................................................................... 8
E-46 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 12
E-47 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 14
E-48 Code [757/CA757] All Persistent Data Lost Error...................................................................... 15
E-49 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 16
E-50 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 18
E-51 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 19
E-52 Code [1626/CA1626] Bypass Valve Solenoid Current High Error ............................................. 20
E-53 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error .............................................. 22
170E-5 Series 1
E-54 Code [1628/CA1628] Bypass Valve Servo Error 1 .................................................................... 23

E-55 Code [1629/CA1629] Bypass Valve Servo Error 2 .................................................................... 24
E-56 Code [1631/CA1631] BP valve Lift Position Sensor High Error................................................. 25
E-57 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ................................................. 27
E-58 Code [1633/CA1633] KOMNET Dtalink Timeout Error .............................................................. 27
E-59 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 28
E-60 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 32
E-61 Code [2249/CA2249] Rail Press. Very Low Error ...................................................................... 32
E-62 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error ............................................. 33
E-63 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error .............................................. 35
E-64 Code [2351/CA2351] EGR Valve Solenoid Current High Error ................................................. 36
E-65 Code [2352/CA2352] EGR Valve Solenoid Current Low Error .................................................. 38
E-66 Code [2555/CA2555] Grid Heater Relay Volt. Low Error........................................................... 39
E-67 Code [2556/CA2556] Grid Heater Relay Volt. High Error .......................................................... 40
E-68 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate.............................................................. 42
E-69 Code [(146)/B@BCNS] Eng. Overheat...................................................................................... 42
E-70 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate....................................................... 43
2 170E-5 Series
Troubleshooting of electrical system (E-mode) 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
ness – PFUEL (female) (1) tance
state
Max. 1 z
tor) – PFUEL (female) (2) tance
Max. 1 z
– PFUEL (female) (3) tance
Min. 1 Mz
ness – PFUEL (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
– PFUEL (female) (2) and chassis ground tance
Min. 1 Mz
– PFUEL (female) (3) and chassis ground tance
4 170E-5 Series

– PFUEL (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (25) – PFUEL tance
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
170E-5 Series 5
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
6 170E-5 Series
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.
170E-5 Series 7
E-45 Code [559/CA559] Rail Press. Low Error 1

Trouble Rail Press. Low Error
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 cir-
Min. 0.15 MPa {Min. 1.5 kg/cm2}
cuit
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
Possible causes sure sensor ness for damage.
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
Max. 10 cc/min
Leakage from pressure limiter
(at full stall or relief)
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”.
8 170E-5 Series
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
170E-5 Series 9
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
10 170E-5 Series
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)
No-load, full stall, or
11 Leakage through pressure limiter cc/min Max. 10
relief
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.
170E-5 Series 11
E-46 Code [689/CA689] Eng. Ne Speed Sensor Error 1

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

Defective sensor power sup-
1 If code [238/CA238] is indicated, carry out troubleshooting for it first.
ply system
ness Max. 1 z
Max. 1 z
tor) – NE (female) (2) tance
Max. 1 z
Min. 1 Mz
ness – NE (female) (1) and chassis ground tance
3
cuit) Min. 1 Mz
Possible causes
value in normal
– NE (female) (1) and wiring harness Resis-
Min. 1 Mz
4
(With another wiring har- – NE (female) (1) and wiring harness Resis-
ness) Min. 1 Mz
(3)
– NE (female) (2) and wiring harness Resis-
Min. 1 Mz
(3)
If causes 1 – 4 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
5 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
If causes 1 – 4 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
12 170E-5 Series
Circuit diagram related to engine Ne speed sensor
170E-5 Series 13
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).
14 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 15
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 • Limits output and continues operation.
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) (A) tance
Max. 1 z
tor) – G (female) (B) tance
Max. 1 z
– G (female) (C) tance
Min. 1 Mz
ness – G (female) (A) and chassis ground tance
3
cuit) – G (female) (B) and chassis ground tance
and standard
value in normal Wiring harness between ENG (female) (26) Resis-
Min. 1 Mz
state – G (female) (C) and chassis ground tance
Resis-
– G (female) (A) and between ENG (female) Min. 1 Mz
Short circuit in wiring har- tance
(47) – G (female) (B)
ness
4 Wiring harness between ENG (female) (37)
(With another wiring har- Resis-
ness) – G (female) (A) and between ENG (female) Min. 1 Mz
tance
(26) – G (female) (C)
Resis-
– G (female) (B) and between ENG (female) Min. 1 Mz
tance
(29) – G (female) (C)
If causes 1 – 4 are not detected, engine Bkup speed sensor may be
Defective engine Bkup
5 defective. (Since trouble is in system, troubleshooting cannot be
speed sensor
carried out.)
16 170E-5 Series
Circuit diagram related to engine Bkup speed sensor
170E-5 Series 17
E-50 Code [1228/CA1228] EGR Valve Servo Error 1 1

Trouble EGR Valve Servo Error 1
1228 CA1228
Contents of
• Abnormality (level 1) occurred in EGR valve servo.
trouble
Action of con-
• Performs open control.
troller
Problem that
appears on
machine
Related infor-
mation

a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Engine Engine oil pressure
Defective engine oil pressure
2 Low idle 0.08 MPa {0.8 kg/cm2}
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for
and standard mechanical system (S-12 Oil pressure lowers).
value in normal
state Defective oil pump for EGR
3 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
4 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping for
5 Check oil return piping for EGR valve circuit directly.
EGR valve
6 Defective EGR valve Check mechanical section of EGR valve directly.
18 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 19
E-52 Code [1626/CA1626] Bypass Valve Solenoid Current High Error 1

Trouble Bypass Valve Solenoid Current High Error
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)
(11) – BP (female) (2)
Wiring harness between ENG (female)
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
20 170E-5 Series
Circuit diagram related to bypass valve solenoid & lift sensor
170E-5 Series 21
E-53 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error 1

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

and standard
state
22 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 con-
• Performs open control.
troller
Problem that
appears on
machine
Related infor-
mation

a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Engine Engine oil pressure
Defective engine oil pressure
2 Low idle 0.08 MPa {0.8 kg/cm2}
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for
and standard mechanical system (S-12 Oil pressure lowers).
value in normal
state Defective oil pump for
3 Check oil pump and relief valve for bypass valve circuit directly.
bypass valve
Defective oil feed piping for
4 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping for
5 Check oil return piping for bypass valve circuit directly.
bypass valve
6 Defective bypass valve Check mechanical section of bypass valve directly.
170E-5 Series 23
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
24 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
Problem that
machine
Related infor-
mation

1
SBP Voltage
Defective bypass valve lift
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor (Internal trouble)
– SBP (female) (1) tance
Max. 1 z
tor) – SBP (female) (2) tance
Max. 1 z
– SBP (female) (3), (4) tance
Min. 1 Mz
ness – SBP (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
– SBP (female) (2) and chassis ground tance
Min. 1 Mz
– SBP (female) (3), (4) and chassis ground tance
170E-5 Series 25

– SBP (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (38) – SBP (female) tance
5
Possible causes (With another wiring har- – SBP (female) (1) and wiring harness Resis-
and standard ness) Min. 1 Mz
value in normal (3), (4)
state
– SBP (female) (2) and wiring harness Resis-
Min. 1 Mz
(3), (4)
ENG Voltage
Between (37) – (38) 4.75 – 5.25 V
Circuit diagram related to bypass valve solenoid & lift sensor
26 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 Dtalink Timeout Error 1

Trouble KOMNET Dtalink Timeout 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 27
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
Ground fault in wiring har-
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) Wiring harness between E18 (female) (23) – Resis-
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
28 170E-5 Series
Circuit diagram related to throttle sensor of accelerator pedal type (Case of WA600)
170E-5 Series 29
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
Ground fault in wiring har-
3 Min. 1 Mz
(Short circuit with GND cir- E06 (female) (1) tance
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
30 170E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC1250-8)
170E-5 Series 31
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] Rail Press. Very Low Error 1

Trouble Rail Press. Very Low Error
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
32 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
Problem that
machine
Related infor-
mation

1
Defective EGR valve lift sen- SEGR Voltage
2 sor Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal trouble)
– SEGR (female) (1) tance
Max. 1 z
tor) – SEGR (female) (2) tance
Max. 1 z
– SEGR (female) (3), (4) tance
Min. 1 Mz
ness – SEGR (female) (1) and chassis ground tance
4
cuit) Min. 1 Mz
– SEGR (female) (2) and chassis ground tance
Min. 1 Mz
– SEGR (female) (3), (4) and chassis ground tance
170E-5 Series 33

– SEGR (female) (1) and wiring harness Resis-
Min. 1 Mz
between ENG (female) (47) – SEGR tance
5
Possible causes (With another wiring har- – SEGR (female) (1) and wiring harness Resis-
and standard ness) Min. 1 Mz
value in normal (female) (3), (4)
state
– SEGR (female) (2) and wiring harness Resis-
Min. 1 Mz
(female) (3), (4)
ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
34 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 35
E-64 Code [2351/CA2351] EGR Valve Solenoid Current High Error 1

Trouble EGR Valve Solenoid Current High 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
36 170E-5 Series
Circuit diagram related to EGR valve solenoid & lift sensor
170E-5 Series 37
E-65 Code [2352/CA2352] EGR Valve Solenoid Current Low Error 1

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

and standard
state
38 170E-5 Series
E-66 Code [2555/CA2555] Grid Heater Relay Volt. Low Error 1

Trouble Grid Heater Relay Volt. Low Error
2555 CA2555
Contents of
• Disconnection occurred in intake air heater relay circuit.
trouble
Action of con-
troller
Problem that
appears on • Starting performance when temperature is low is poor
machine
Related infor-
mation

and standard
state
170E-5 Series 39
E-67 Code [2556/CA2556] Grid Heater Relay Volt. High Error 1

Trouble Grid Heater Relay Volt. High 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 when temperature is low 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
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
40 170E-5 Series
Circuit diagram related to intake air heater relay (Case of PC1250-8)
170E-5 Series 41
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
42 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 43
SEN00372-00
© 2006 KOMATSU
All Rights Reserved
44
SEN00765-00
ENGINE 1SHOP MANUAL
170E-5 Series
50 Disassembly and assembly1

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 3
Special tools list.................................................................................................................................... 6
170E-5 Series 1
SEN00765-00 50 Disassembly and assembly
General information on disassembly and assembly 1

How to read this manual 1
Disassembly
q In Disassembly section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q The meanings of the symbols used in Disas-
sembly section are as follows.
k Precautions related to safety in execution
of work
a : Know-how or precautions for work
6 : Quantity of oil or coolant drained
4 : Weight of part or component
Assembly
q In Assembly section, the work procedures, pre-
cautions and know-how for carrying out those
procedures, and quantity of the oil and coolant
added are described.
q The meanings of the symbols used in Assem-
bly section are as follows.
k : Precautions related to safety in execution
of work
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5 : Quantity of oil or coolant to be added

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

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 No. Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resis-
ThreeBond tant, vibration-resistant, impact-resistant seal-
419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
170E-5 Series 3
Cate-
Komatsu code Part No. Q'ty Container Main features and applications
gory
• Used to lubricate sliding portions.
disulfide lubricant
LM-G 09940-00051 60 g Can

Molybdenum
(to prevent squeaking)

• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type.
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
SYG2-350CA
• Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
under light load in contact with water or steam.
SYG2-160CA
SYGA-160CNCA
Grease
Molybdenum SYG2-400M 400 g x 10 Bellows-type

disulfide grease SYG2-400M-A 400 g x 20 container • Used for parts under heavy load.
LM-G (G2-M) SYGA-16CNM 16 kg Can
Hyper White SYG2-400T-A • Seizure resistance and heat resistance higher
400 g Bellows-type
Grease G2-T, SYG2-16CNT than molybdenum disulfide grease.
container
G0-T (*) SYG0-400T-A (*) • Not conspicuous on machine since color is
16 kg Can
*: 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 (*)
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)
4 170E-5 Series
Cate-
Komatsu code Part No. Q'ty Container Main features and applications
gory
• “S” is used for high-temperature season
SUNSTAR
(April – October) and “W” for low-tempera-
PENGUINE
Polyethylene ture season (November – April) as adhe-
SEAL 580 417-926-3910 320 ml
container sive for glass.
SUPER “S” or
“W”
Adhesive
facture)
• Used as adhesive for glass.
Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Adhesive for cab glass

Sikaflex 256HV container
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
TOSSEAL 381
facture)
170E-5 Series 5
Special tools list 1

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

A
tor 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 valve 795-102-4210 • Bracket 1
B
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 piston
F 795-100-1191 Piston ring tool t 1
ring
Pulling out of cylinder liner G 795-102-1301 Liner puller t 1
795-225-1512 Liner driver t 1
Press fitting of cylinder liner H 795-101-5221 Grip t 1
01010-81250 Bolt t 1
Insertion of piston assembly J 795-225-1700 Piston holder t 1
795-621-1140 Push tool t 1
Press fitting of front oil seal and
K 795-902-1460 Bolt t 3
dust seal
01582-02218 Nut t 3
795-621-1130 Push tool t 1
Press fitting of rear oil seal L
01050-32280 Bolt t 5
Commercially IN: 0.32 mm
Adjusting valve clearance M Clearance gauge q 1
available EX: 0.62 mm
Removal and installation of bolt N 79A-212-4201 Socket kit t 1 For 12-angle bolt
Measurement of wear of piston For measurement of
P 795-901-1120 Wear gauge t 1
ring groove parts
Press fitting of valve stem seal Q 795-611-1170 Driver t 1
Pulling out rear oil seal R 795-931-1100 Seal puller q 1
6 170E-5 Series
© 2006 KOMATSU
All Rights Reserved
8 170E-5 Series
SEN00766-00
ENGINE 1SHOP MANUAL

2SHOP
170E-5 Series

Disassembly and assembly, Part 1
Disassembly and assembly, Part 1 ................................................................................................................. 2
General disassembly of engine............................................................................................................ 2
170E-5 Series 1
Disassembly and assembly, Part 1 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: 35 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 Maintain the stopper bolt in this posi-
tion 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).
3) Remove bracket (4).
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

1) Remove breather and hose assembly (1).
2) Remove all covers (2) on the engine top
face.
3) Remove wiring harness and plate assem-
bly (3).
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).
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.
22. Air intake connector

Remove air intake connector (1).
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).
6 170E-5 Series
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.
3] Remove supply pump drive gear (9).
4) Separate the gasket sealant and then

remove cover (7).
170E-5 Series 7
a The figure shows, for your refer- 25. Intake manifold assembly
ence, the state after removing 1) Remove bracket (1), spill tube (2) and
the supply pump drive gear. peripheral parts.
6) Remove bracket (10). 2) Lift intake manifold assembly (3) tempo-

7) Remove drive supply pump assembly (12) rarily and then remove the mounting bolt.
along with supply pump drive case (11). 3) Lift and remove intake manifold assembly
(3).
4 Air intake manifold assembly:
110 kg
24. Common rail

1) Remove fuel tube (1) and peripheral parts.
2) Remove common rail (2).
26. Water pump assembly
1) Remove water pipe (1).
8 170E-5 Series
2) Remove stopper (2) and then slide bypass 28. Front hanger and water housing
tube (3) upward. 1) Remove bracket (1) and water tube (2).
3) Remove water pump assembly (4).
2) Lift up front hanger (3) temporarily and

27. Thermostat housing and thermostat then remove the mounting bolts.
1) Remove thermostat housing (1). 3) Lift and remove front hanger (3) along with
water housing (4).
4 Front hanger: 65 kg
2) Remove thermostats (2) from thermostat

housing (1).
Remove cover (1) and then remove cylinder
head covers (2).
170E-5 Series 9
30. Injector harness

1) Remove terminal mounting nut (1), har-
ness fixing bolts (2) and spacer (3).
3) Remove exhaust rocker arm (4) and air

intake rocker arm (5) from shaft (6).
2) Remove plate (4) and then push injector

harness (6) inside the engine along with
grommet (5).
3) Remove injector harness (6) from inside of
the engine.
32. Push rod

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

Remove rocker housing (1). bly (2).
a Hitch the tip of tool A to hole (a) on
the injector and then pull it out.
a Do not grip the solenoid valve at the
top of the injector to pull off the injec-
tor.
34. Crosshead
Remove crossheads (1).
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
35. Fuel injector assembly and floor with blocks or equivalent.
1) Remove injector holder (1).
170E-5 Series 11
3) Remove the cylinder head gasket. 5] Remove intake valve (6) and exhaust
4) Disassemble the cylinder head assembly valve (7) from cylinder head (8).
according to the following procedure.
1] Using tool B, compress the valve
spring and then remove valve cotter
(2).
37. Oil cooler assembly

Remove oil cooler assembly (1).
2] Remove spring seat (3).

3] Remove valve spring (4).
38. Oil level gauge, oil filler pipe, fuel feed

pump and engine controller
1) Remove oil level gauge (1).
2) Remove oil filler pipe (2).
4] Remove valve stem seal (5).
3) Remove fuel tube (3) and then remove
fuel feed pump (4).
4) Remove engine controller (5), cooling
plate (6) and bracket (7).
5) Remove block (8).
12 170E-5 Series
39. Drive housing assembly 41. Suction pipe and under plate
Remove drive housing assembly (1). 1) Install under plate (1) temporarily with sev-
eral oil pan mounting bolts.
2) Remove brackets (2) and (3) and then
remove suction pipe (4).
3) Separate the gasket sealant.
4) Remove the temporarily attached mount-
ing bolts and then remove plate (1) using
a jack.
4 Under plate: 25 kg
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.
42. Cam follower assembly

1) Remove cam follower cover (1).
4) Using tools C, lift the engine and then

remove oil pan (1).
4 Oil pan: 85 kg
2) Remove cam follower assembly (2).

a Rotate the crankshaft using a barring
device to move the piston to the posi-
tion indicated below and remove it.
q No. 1 compression top dead center:
Allows removal of No. 1 and No. 5.


5) Securely support the engine again using
blocks [1].
a See "Setting engine assembly" in
Item 2 above.
170E-5 Series 13
a An unremovable cam follower assem- 44. Vibration damper

bly indicates it is not situated at the 1) Lift vibration damper (1) temporarily and
compression top dead center. In this then remove the mounting bolts.
case, rotate the crankshaft one more 2) Lift and remove vibration damper (1).
turn. 4 Vibration damper: 45 kg
3) Disassemble the cam follower in the fol-

lowing procedure. 45. EGR oil pump
1] Remove snap ring (3). Remove EGR oil pump (1).
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
43. Cam cover remove the mounting bolts.
Remove bracket (1) and cam cover (2). 2) Lift and remove front cover (1).
4 Front cover: 50 kg
14 170E-5 Series
3) Remove dust seal (2) and oil seal (3) from 48. Oil pump assembly
the front cover. Remove oil pump assembly (1).
a Dust seal is provided only on the
vehicle-mounted engines alone.
49. Engine mount

1) Remove the front engine mount.
47. Front idler gear assembly 2) Remove rear engine mount (1).
1) Remove idler gear (larger one) (1). 4 Rear engine mount: 25 kg
2) Remove idler gear (smaller one) (2).
50. Flywheel assembly

3) Remove spacer (3) and shaft (4) from idler 1) Lift flywheel assembly (1) temporarily and
gears (large and small gears). then remove the mounting bolt.
a The same structure is employed for 2) Lift and remove flywheel assembly (1).
both the large and small gears. 4 Flywheel assembly: 40 kg
a The weight varies largely with the
applicable machines. (Reference:
Weight of some models is 80 kg)
170E-5 Series 15
51. Flywheel housing 5) Remove sleeve (5) from the crankshaft.

1) Remove Ne speed sensor (1) and barring
device (2).
52. Camshaft assembly

1) Along with the camshaft gear, lift and
2) Lift flywheel housing (3) temporarily and remove camshaft assembly (1) to the
then remove the mounting bolts. engine rear side.
3) Lift and remove flywheel assembly (3). a When pulling it out, lift the gear side
4 Flywheel housing: 150 kg 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: 80 kg
4) Remove rear oil seal (4) from the flywheel

housing.
16 170E-5 Series
53. Rear idler gear assembly

1) Remove rear idler gear assembly (1).

1) Raise the cylinder block to make the cylin-
der level.
2) Disassemble the idler gear in the following
2) Rotate the crankshaft to set No. 1 to No. 3
procedure.
pistons to the following positions.
1] Remove spacer (2) from shaft (3).
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-
tion by rotating the crankshaft.
54. Installation to engine repair stand 2) Loosen the connecting rod bolt by 5 to 6
Using tools C, lift engine assembly (1) being turns.
attached with tool D2 and then attach tool D1 a Lightly strike the connecting rod head
to the assembly. with a plastic hammer to separate the
4
connecting rod cap from the connect-
Engine assembly: Approx. 1,600 kg
ing rod.
170E-5 Series 17
3) Move the piston to the top dead center

position by rotating the crankshaft.
4) Remove connecting rod cap (1).
7) Disassemble the piston and connecting

rod assembly according to the following
procedure.
5) Remove connecting rod bearing (2) from 1] Remove connecting rod bearing (4).
connecting rod cap (1).
a Maintain them on the cylinder No.
2] Remove 2 snap rings (5).
6) Push the connecting rod from the crank-

shaft side to remove the piston and con-
nection rod assembly (3).
a When removing the piston and con-
necting rod assembly, support the
assembly at the cylinder side so that
it may not fall off. Then push the con-
necting rod end portion to remove the
assembly.
a Pull the assembly horizontally so that
the connecting rod may not damage
the cylinder liner.
a Maintain them on the cylinder No. 3] Remove piston pin (6).
basis using a tag or the like. 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.
18 170E-5 Series
5] Using tool F, remove top ring (8) and 4) Remove main bearing metal (2) and 2
second ring (9). thrust wafers (3) from main cap (1).
a Thrust washers are provided on No. 6
main cap alone.
a Maintain them on the main cap No.
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
57. Crankshaft assembly

1) Set the crankshaft side up.
2) Remove the main cap mounting bolt.
3) For removal, sway main cap (1) back and
forth using the mounting bolt.
a Thrust washers are provided for No. 6
main cap. Thus reasonable care must
be exercised to prevent their falling
off.
170E-5 Series 19
6) Remove main bearing metal (5) and 2

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

1) Set the cylinder head side up.
2) Using tool G, remove cylinder liner (1).
59. Cylinder block

Using tools C, lift and remove cylinder
block (1) from tool D1.
4 Cylinder block assembly: 800 kg
20 170E-5 Series
© 2006 KOMATSU
All Rights Reserved
22 170E-5 Series
SEN00767-00
ENGINE 1SHOP MANUAL

2SHOP
170E-5 Series

General assembly of engine ................................................................................................................ 2
170E-5 Series 1

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 part (R) is sharp or has burrs,
Take care. finish it with a scraper or sandpa-
a Clean each part carefully, and check it for per. Finish this surface particu-
bruise, flaw, cavity, etc. Make sure each oil or larly smoothly so that it will not
coolant path is through. damage the O-ring.
a If face (a) and part (c) are pitted,
Tightening bolts by plastic-region turning angle finish them smoothly.
method a If part (d) is so pitted that it can-
a Bolts tightened by plastic-region turning angle not be repaired, replace the cyl-
method inder block.
q Cylinder head mounting bolt 3] Check face (e) of the counterbored
q Main cap mounting bolt part and remove burrs.
q Connecting rod cap mounting bolt a If chips or dusts is on a level sur-
q Flywheel mounting bolt face, the liner does not fit and
q Idler gear (rear side) mounting bolt coolant may leak and the projec-
a If the plastic-region turning angle method is tion of the liner may become
applied, the tightened bolts have permanent improper consequently.
strain. Accordingly, the allowable number of a Drooping, corrosion or pitting
using times of each bolt is limited.Observe the must be repaired, if any.
fol low ing pr ec auti ons b efor e usi ng thi s
approach.
q Check each mounting bolt head for punch
marks. If there are punch marks more
than the specified numbers, replace the
bolt.
a For details, refer to respective relevant sec-
tions in this document.
1. Cylinder block
1) Set cylinder block (1) on blocks [1].
2. Cylinder liner
a Replace the O-ring and clevis seal with
new ones.
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not rough-
ened because of rusting or pitting. If those
parts are roughened, replace the cylinder
liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
2) Before inserting the cylinder liners, pre- etc. in the groove of the liner.
pare the cylinder block according to the a Fit the clevis seal with the chamfered
following procedure. side down. When fitting it, press it
1] Using a piece of sand paper, polish against the seal groove all round so
and remove rusts and scales on faces that it will not be twisted.
(a) of O-ring guide section and (b) of
O-ring bored section until the
machine surface is exposed.
2 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 3
7) Using tool H, press fit cylinder liner (1) to 9) Remove cylinder head assembly (5).
the cylinder block. a Wipe off gasket sealant running over
to the cylinder block top surface.
10) Using dial gauge [2], measure projection
of the cylinder liner.
a When measuring the line projection
from the block surface, use the block
top surface as the datum plane.
a Standard cylinder liner projection:
0.07 – 0.15 mm
a When the projection is out of the stan-
dard, correct it referencing “Struc-
t ur e , fu nc t io n a nd ma i nt en an c e
standard“.
8) Install the head gasket and then tempo-

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

D1.
4 Cylinder block: 850 kg
4 170E-5 Series
4. Crankshaft assembly 5) Install main bearing metal (2) to main cap

1) Invert the cylinder block to set the oil pan (1).
side to the bottom. a When installing, fit in the projection on
2) Install 7 main bearing metals (5) to the cyl- the bearing metal to the notch on the
inder block. main cap.
a Note that the upper main bearing 2 Main bearing metal inner surface:
metal is not identical with the lower Engine oil (EO30)
main bearing metal. An oil hole is 6) Install 2 thrust washers (3).
drilled on the upper bearing. Check it a Thrust washer is provided only on
before installation. both sides of No. 6 main cap.
a When installing, fit in the projection on
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
4) Lift crankshaft assembly (4) and assemble using it.
it to the mounting position. 2 Threaded portion and seat of main
4 Crankshaft assembly: 270 kg cap mounting bolt: Engine oil (EO30)
a When installing the crankshaft, take 3 Main cap mounting bolt:
care not to hit it against the cylinder 1st time: 284 ± 15 Nm {29 ± 1.5 kgm}
block. 2nd time: 568 ± 10 Nm {58 ± 1.0 kgm}
3rd time: 90 (+30/0)° retightening
170E-5 Series 5
a After tightening the bolt, apply a

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

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

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

using dial gauge [1].
a Standard end play: 0.14 – 0.32 mm
a When the end play is out of the stan-
t ur e , fu n ct i on a n d ma i nt en an c e
standard“.
6 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) Move the pin journal of the cylinder to the

top dead center position by rotating the
crankshaft.
3) 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 7
4) Install connecting rod bearing metal (2) to

connecting rod cap (1).
a When installing, fit in the projection on
the bearing metal to the notch on the
connecting rod cap.
5) 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. 6) 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.
8 170E-5 Series
q No.2 top dead center position:

q No.3 top dead center position:
2) Install 6 each of piston cooling nozzles (1)
and (2) in order.
a Install the piston cooling nozzles hav-
ing the stamps of (F) to the front side
of the cylinder and install those hav-
ing the stamps of (R1) to the rear side
of the cylinder.
a Push in each piston cooling nozzle
with the hand until its flange touches
the cylinder block and then tighten the 2) Raise and invert the engine to set the oil
mounting bolt. pan side to the bottom.
3 Piston cooling nozzle mounting bolt: 3) Install rear idler gear assembly (1).
27.4 – 34.3 Nm {2.8 – 3.5 kgm} a When installing the rear idler gear
assembly, direct the stamped letters
in front side of the shaft to the top
side (cylinder head side).
7. Rear idler gear assembly

1) Assemble the rear idler gear assembly
1] Install gear (larger one) (4) to another
a When installing, match (A) mark on
(smaller one) (5).
3 Idler gear mounting bolt:
the crankshaft gear to (A) mark on the
idler gear (larger one).
98 – 123 Nm {10.0 – 12.5 kgm}
2] Install shaft (3) and spacer (2). a (B) mark is used in the succeeding
a When installing the spacer, direct processes.
its V-grooved face to outside.
170E-5 Series 9

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
a After tightening the bolt, apply a
2) Measure end play of the camshaft using

dial gauge [1].
a Standard end play: 0.05 – 0.20 mm
a When the end play is out of the stan-
t ur e , fu nc t io n a nd ma i nt en an c e
standard“.
8. Camshaft assembly
1) Lift and insert camshaft assembly (1) to
the cylinder block.
a First, lift the center portion of the cam-
shaft to insert to the cylinder block.
After inserting about 1/3 of the shaft
body, lift the gear side again and
insert it while aligning the camshaft
and bushing hole.
4 Camshaft assembly: 80 kg
a When installing, match (B) mark on
the camshaft gear and (B) mark on
the idler gear (smaller one). 9. Measurement of gear backlash (Rear)
3 Camshaft assembly mounting bolt:
Measure backlash of the rear timing gear using
98 – 122.5 Nm {10 – 12.5 kgm} dial gauge [1].
a When measuring the backlash, set the dial
gauge in the tooth end of the crankshaft
gear or camshaft gear and then fix the
idler gear.
10 170E-5 Series
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}
10. Oil pump assembly

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 11
12. Measurement of gear backlash (Front)

Measure backlash of the front idler gear and
other gears using dial gauge [1].
a When measuring the backlash, set the dial
gauge in the tooth end position of the tar-
get gear of measurement and then fix the
counterpart gear.
a Standard backlash:
Measuring
Backlash (mm)
position
a 0.114 – 0.320
b 0.134 – 0.362
c 0.114 – 0.320
2) Install the O-ring and plate (4).
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“.
3) Using tool K, 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
4) Using tool K, press fit dust seal (3) to the

13. Front cover front case until dimension (b) is obtained.
1) Fit the gasket and then lift and install front a Dust seal press fitting dimension (b):
covers (1). 2 mm (protruded from the front cover
a Make sure that displacement or end face)
pinching is not observed on the gas- a Dust seal is provided only for the
ket. vehicle-mounted engines.
4 Front cover: 50 kg
12 170E-5 Series
3 Flywheel housing mounting bolts

(1 – 11):
1st time: 352.8 – 392 Nm {36 – 40 kgm}
2nd time: Loosen them once
3rd time: 392 – 431.2 Nm {40 – 44 kgm}
3) Tighten mounting bolts (12) – (18) in the
order shown in the figure.
3 Flywheel housing mounting bolts
(12 – 18):
98 – 122.5 Nm {10 – 12.5 kgm}
14. Flywheel housing

1) Apply gasket sealant and then lift and
install flywheel housing (3).
4 Flywheel housing: 150 kg
a Diameter of the gasket sealant line
shall be 2 to 3 mm and it should be
applied as indicated in the figure.
2 Flywheel housing:
Gasket sealant (LG-7)
4) Using tool L, press fit oil seal (4).

a Continue the fitting until the inside
end face of the tool touches the
crankshaft.
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)
2) Tighten the mounting bolts (1 – 11) in the applied to the entire perimeter as
following order. shown below.
2 Flywheel housing mounting bolt and a Tighten 4 inside positions and several
washer: Engine oil (EO30) outside positions temporarily using
the bolts until installation of the suc-
tion tube and oil pan is completed.
170E-5 Series 13
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).
4 Flywheel assembly: 40 kg
a The weight varies largely with the
applicable machines. (Reference:
Weight of some models is 80 kg)
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)

3 Flywheel assembly mounting bolt:
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.)
14 170E-5 Series
2) Fit the gasket and then install burring

device (2).
3) Install Ne speed sensor (1).
3 Ne speed sensor mounting bolt:
4.9 – 7.9 Nm {0.5 – 0.8 kgm}
4) Using dial gauge [1], measure the radial

and facial runout of the flywheel.
a Standard radial and facial runout:
Measuring items Tolerance (mm)
Radial runout 0.13
0.0005 x Diameter of
Facial runout
measuring point
a When the measured value is out of

the standard, determine the cause by
disassembling the flywheel again.
170E-5 Series 15
18. Engine mount 21. Vibration damper

1) Install rear engine mount (1). Lift and install vibration damper (1).
4 Vibration damper: 45 kg
a When tightening the mounting bolts, pre-
vent rotation of the damper by fixing the
space between the flywheel and flywheel
housing.
3 Vibration damper mounting bolt:
1st time: 53.9 – 93.1 Nm {5.5 – 9.5 kgm}
2nd time: 225.4 – 264.6 Nm {23 – 27 kgm}
3rd time: 617.4 – 656.6 Nm {63 – 67 kgm}
2) Install front support.
19. EGR oil pump

Install EGR oil pump (1).
22. 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.
20. Cam cover 3] Install snap rings (3).
1) Install the O-ring and then install cam
cover (2).
2) Install plate (1) with O-ring.
16 170E-5 Series
2) Crank the crankshaft to set No. 1 – No. 3

q No.1 compression top dead center:
No . 1 and No. 5 p is tons c an be
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 23. Cylinder head assembly
center. In this case, rotate the crank- 1) Assemble the cylinder head assembly
shaft one more turn. according to the following procedure.
3) Install 6 cam follower assemblies (2) in 1] Install 2 intake valves (6) and 2
order. exhaust valves (7) on cylinder head
a Check that the cam follower shaft on (8).
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}
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 Install the cast iron-made cover on
No. 2 and No. 6 cylinders.
a Aluminum-made cover shall be
installed on other cylinders.
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 3] Install 4 valve springs (4).
(No. 1, 3, 4 and 5 cylinders): 4] Install 4 spring seat (3).
9.8 ± 0.98 Nm {1.0 ± 0.1 kgm}
170E-5 Series 17
a After tightening the main bolt, apply a

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).
4 Cylinder head assembly: 50 kg
using it.
a Tighten the mounting bolts in the fol-
lowing order.
2 Cylinder head assembly mounting bolt:
Molybdenum disulfide grease (LM-P)
3 Cylinder head mounting bolts (1 – 7):
1st time: 245 ± 9.8 Nm {25 ± 1 kgm}
2nd time: 382.5 ± 9.8 Nm {39 ± 1 kgm}
3rd time: 90 – 120° retightening
3 Cylinder head mounting bolts (8 and 9):
93.2 – 103 kgm {9.5 – 10.5 kgm}
18 170E-5 Series
4) Install coolant air bleeding tube. 2) Install bracket (1).

3 Air bleeding tube joint bolt (Cylinder 3) Install spill tube (2).
head side): 3 Spill tube joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm} 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Air bleeding tube joint bolt (EGR
cooler side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
24. Air intake manifold assembly

1) Lift and install air intake manifold assem-
bly (3).
4 Air intake manifold assembly:
110 kg
25. Common rail

1) Install common rail (2).
3 Common rail mounting bolt:
59.0 – 74.0 Nm {6.0 – 7.5 kgm}
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):
a Tighten the mounting bolts in the fol- 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
lowing order.
170E-5 Series 19
26. Fuel injector 3 Injector holder mounting bolt:

a Check that the inside of the injector sleeve 58.9 – 73.5 Nm {6.0 – 7.5 kgm}
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.
6) After tightening the injector holder, remove

the high-pressure piping and install the
other injectors in order according to the
above procedure.

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
3) Fit ball washer (10) to bolt (9) and then again or to use a high-pressure piping
tighten injector holder (1) temporarily. in an unspecified location.
2 Ball washer: Engine oil (EO30) q When installing a clamp, be sure to
install a genuine clamp securely
using the specified torque.
q After installation of the high-pressure
piping and clamp is complete, make
sure that a 10 mm clearance mini-
mum is provided between the high-
pressure piping and adjacent wiring
harness. When the clearance is less
than 10 mm, secure the necessary
space by adjusting the wiring harness
position.
k Before installing the high-pressure pip-
ing, check it for the following defects.
If there is any of these defects, it can
cau se fu el leakage. Accord in gly,
4) Insert high-pressure piping sleeve nut (11)
replace the high-pressure piping.
in the hole to insert the fuel high-pressure
q Check the taper seal of the connect-
piping and fix it temporarily, matching it to
ing part (Part (a): Part of 2 mm from
injector connector (8).
the end) for visible lengthwise slit (b)
a Tighten the sleeve nut on the com-
and dent (c).
mon rail side temporarily, too, to pre-
q Check part (d) (end of the taper seal:
vent leaning of the high-pressure
Part at 2 mm from the end) for
piping.
stepped-type wear (fatigue) which
5) Tighten injector holder (1) permanently.
your nail can feel.
a While pulling the high-pressure piping
in the opposite direction to the injec-
tor, tighten bolt (9).
20 170E-5 Series
3) Install the clamp to the high-pressure pip-

ing in the following procedure.
1] Install 17 high-pressure pipings
clamps (5) as shown in the following
figure, and then tighten them tempo-
rarily by hand.
2] Install clamp bracket (6) on the com-
mon rail side and clamp (7) tempo-
rarily by hand, and then tighten clamp
(7) with the specified torque.
3 Common rail side clamp bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3] Tighten clamp bracket (6) on the
common rail side with the specified
torque.
1) Fit O-ring (2) to high-pressure piping
4] Tighten clamp (5) on the high-pres-
sleeve (1). Matching them to the injector
sure piping with the specified torque.
3 High-pressure piping side clamp
connector, tighten sleeve nut (3) and
sleeve nut (4) on the common rail side
bolt:
temporarily.
2 O-ring: Engine oil (EO30)
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
4) Install rubber cap (8) on the sleeve nut on
the common rail side.
a When installing it, direct the slit down-
ward.
2) Tighten high-pressure piping sleeve nuts

(3) and (4) permanently with spanner-type
torque wrench.
3 Sleeve nut:
28. Crosshead
39.2 – 44.1 Nm {4 – 4.5 kgm}
1) Install 12 crossheads (1).
a After finishing the work, check O-ring
(2) is not projected from the end of
the sleeve.
a When installing the high-pressure pip-

ing without removing the fuel injector
(for example, when replacing only the
high-pressure piping with new one),
follow the procedure below.
q Tighten sleeve nut (3) by 2 turns
by hand into the threads of the
fuel injector and then tighten it
with the spanner.
a If sleeve nut (3) does not catch
the threads, press its end with a
small rod, etc. toward the injector
and turn the spanner.
170E-5 Series 21
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 30. Push rod
was contacted against valve stem (4). Install 12 push rods (1).
5] Tighten locknut (2) while stopping a Check that the push rod end is securely
move of adjustment screw (3) by placed in the cam follower socket.
hand.
3 Locknut:
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
31. Rocker arm assembly

1) Assemble the rocker arm assembly
29. Rocker housing
Apply gasket sealant and then install rocker
1] Install adjustment screw (2) on rocker
housing (1).
2 Rocker housing: Gasket sealant (LG-7)
arms (4) and (5), and then install lock
nut (1).
a Diameter of the gasket sealant line shall
a Screw in adjustment screw (2)
be 2 to 3 mm and it should be applied
until its spherical part touches
along the housing groove as shown below.
3 Rocker housing mounting bolt:
rocker arms (4) and (5).
78.4 – 93.2 Nm {8.0 – 9.5 kgm}
22 170E-5 Series
2] Install rocker arm (5) for air intake 32. Adjusting valve clearance
valve and rocker arm (4) for exhaust 1) Rotate the crankshaft forward to remove
valve on shaft (6). plug (1) situated in the left of the flywheel
a Insert respective rocker arm at a housing.
position where the riveted side of
the shaft faces the front side of
the engine.
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-
2) Install 6 rocker arm assemblies (3). ure represent No.1 cylinder compres-
a When installing, direct the wider seat sion top dead center and No.6
of the shaft to the rocker arm housing. cylinder compression top dead cen-
a Make sure that the spherical part of ter, respectively.
adjustment screw is securely placed a When the cylinder is at the compres-
in the push rod socket. sion top dead center, the rocker arm
a When tightening the mounting bolt, can be moved by the valve clear-
check that adjustment screw (2) is not ance by hand. If the rocker arm can-
pushing the push rod. not be moved, rotate the crankshaft
2 Threaded portion and seat of rocker one more turn.
arm assembly mounting bolt:
Engine oil (EO30)
3 Rocker arm assembly mounting bolt:
235.2 – 254.8 Nm {24 – 26 kgm}
170E-5 Series 23
a Rotate the crankshaft using barring

device (2) located in the rear left side
of the engine.
6) After adjustment, install plug (1).

3 Plug:
3) When No. 1 cylinder is at the compression 58.8 – 78.4 Nm {6.0 – 8.0 kgm}
top dead center, adjust the valve clear-
ance indicated by q in the valve layout 33. Injector harness
plan. 1) Install injector harness (6).
a When adjusting, loosen locknut (4) of a Insert the harness through inside of
adjustment screw (3) and insert clear- the engine while directing projection
ance gauge M between crosshead (5) (A) of the grommet upward.
and rocker arm (6). Then, using
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}
a After tightening the locknut, check the
valve clearance again.
5) Rotate the crankshaft forward by one turn 2) Insert grommet (5) to the rocker housing
to adjust the valve clearance being indi- and then fix it using plate (4).
cated with Q mark in the valve layout plan.
a The adjustment procedure is the
same as above.
24 170E-5 Series
3) Install spacer (7).

a When installing the spacer, direct its
projection (B) toward the outside.
35. Suction pipe

1) Lift the engine assembly and then set
blocks under the engine mount. Then
4) Install terminal mounting nut (8) and wiring bring down the engine assembly again.
harness fixing bolt (9) temporarily in this a Make sure the engine is kept in a suf-
order. ficiently stable state.
a The order reverse to the above does 2) Install the O-ring and suction tube (4),
not allow the terminal to reach the then install brackets (3) and (2).
injector, disabling the connection. 2 O-ring: Engine oil (EO30)
5) Tighten terminal mounting nut (8) and wir- a As positioning of the suction tube and
ing harness fixing bolt (9) in this order. bracket is completed, tighten the
a Tighten the terminal nuts alternately. mounting bolt.
3 Terminal mounting nut: 3 Clamping nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm} 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).

1) Install the O-ring and then install 6 cylinder
head covers (2).
a A different tightening torque is
employed for No. 2 cylinder mounting
bolt alone.
No.1, 3, 4, 5 and 6 cylinders:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
No. 2 cylinder:
58.8 – 73.5 Nm {6 – 7.5 kgm}
2) Install bracket (1).
170E-5 Series 25
36. Oil pan 37. Drive housing assembly

1) Apply gasket sealant to the oil pan. Install O-ring and then install drive housing
2 Oil pan: Gasket sealant (LG-7) assembly (1).
applied as shown below.
38. Oil level gauge, oil filler pipe, fuel feed

pump and engine controller
1) Install O-ring and then install block (8).
2) Lift the engine assembly again, set oil pan 2) Install bracket (7) and cooling plate (6).
(1) under the cylinder block and then bring 3) Install engine controller (5).
down the engine assembly again on the 3 Engine controller:
block. 24 Nm {2.4 kgm}

3) Push up oil pan (1) bottom with a jack and 4) Install fuel field pump (4).
then install the mounting bolt using guide 5) Install bracket and fuel tube (3).
bolt [1]. 3 Fuel tube union nut:
4 Oil pan: 85 kg 84 – 132 Nm {8.5 – 13.5 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-
ing and then apply adhesive to it.
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}
26 170E-5 Series
41. Front hanger and water housing

1) Lift and install front hanger (3) along with
water housing (4).
4 Front hanger: 65 kg
39. Corrosion resistor and filter head assembly

1) Install corrosion resistor and filter head
assembly (2).
2) Install water tubes (1) on the filter bracket.
3 Water tube joint bolt: 2) Install water tube (2) and bracket (1).
24.5 – 34.3 Nm {2.5 – 3.5 kgm} 3 Water tube joint bolt:
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)
40. Oil cooler assembly

Install oil cooler assemblies (1).
42. Thermostat housing and thermostat

1) Install thermostats (2) on thermostat hous-
ing (1).
170E-5 Series 27
2) Install gasket and then thermostat housing 44. Supply pump assembly
(1). 1) Install supply pump assembly (12) along
with supply pump drive case (11).
2) Install gasket (10).
43. Water pump assembly

1) Install water pump assembly (4).
2) Slide bypass tube (3) down and then fix it 3) Adjust positioning of the supply pump and
using stopper (2). drive gear according to the following pro-
cedure.
1] At the position shown in the figure,
lead positioning bar [1] through flange
(13) and housing (14) of supply pump
drive case.
a The positioning bar used shall be
11 mm in diameter and 180 mm
in length at minimum.
a Make sure that the stamped (C)
is marked in part (A) of idler gear
(15).
3) Install water pipe (1).
28 170E-5 Series
2] Install supply pump drive gear (9)

conforming to positioning bar [1].
3] Make sure that the stamped (C) of

idler gear (15) and supply pump drive
gear (9) are matched in part (A).
4] Make sure that the knock pin is
inserted to knock pin hole (B) on sup-
ply pump drive gear (9).
5) 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}
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Fuel tube (3) joint bolt:
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Fuel tube (3) union nut:
4) Apply gasket sealant and then install
84 – 132 Nm {8.5 – 13.5 kgm}
3 Fuel tube (4) joint bolt:
cover (7).
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
applied as shown below.
a Apply gasket sealant to the flywheel
housing side.
2 Flywheel housing (Cover installation
face): Gasket sealant (LG-7)
170E-5 Series 29
6) Install fuel tube (2) and wiring harness (1). 6) Install a rubber cap on the sleeve nut.
3 Fuel tube joint bolt (Supply pump a When fitting the rubber cap, direct its
side): slit toward out of the engine.
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Fuel tube joint bolt (Relay block
side): 54 – 93 Nm {5.5 – 9.5 kgm}
46. Air intake connector

Install air intake connector (1).

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
sure that a 10 mm clearance mini-
mum is provided between the high- 47. Breather, cover and wiring harness
pressure piping and adjacent wiring 1) Install O-ring and then wiring harness and
harness. When the clearance is less plate assembly (3).
than 10 mm, secure the necessary 2) Install engine top covers (2).
space by adjusting the wiring harness 3) Install breather and hose assembly (1).
position. 3 Breather mounting bolt:
1) Install high-pressure pipings (1) and (2) 24.5 – 29.4 Nm {2.5 – 3.0 kgm}
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.
3 High-pressure piping sleeve nut:
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
4) Tighten the clamp with the specified
torque.
3 Clamping bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
5) Tighten the bracket mounting bolt with the
specified torque.
30 170E-5 Series
48. Fuel tube

1) Install fuel tubes (2) – (6).
3 Fuel tube (6) joint bolt (Air intake
manifold side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2) Install cover (1).
51. Main fuel filter and filter head assembly

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}
49. Pre-fuel filter and filter head assembly 3 Fuel tube (2) joint bolt:
1) Install bracket (4). 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
2) Install pre-fuel filter and filter head assem- 3) Fix filter using clamp (3).
bly (3).
3) Install fuel tubes (2) and (1) on the filter
head.
3 Fuel tube (1) union nut (Filter head
side):
58.8 – 78.4 Nm {6.0 – 8.0 kgm}
4) Tighten air bleeding plug (5).

3 Air bleeding plug:
9.8 – 19.6 Nm {1.0 – 2.0 kgm}
50. Oil filter and filter head assembly

1) Install bracket (3).
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 31
52. Pulley, tensioner and air conditioner com- 54. Air conditioner compressor
pressor bracket Install air conditioner compressor (1).
1) Install air conditioner compressor bracket
(4).
2) Install tensioner (3).
3) Tighter bolt (2).
4) Pull out stopper bolt [1].
5) Install pulley (1).
55. Belt of auxiliary equipment

1) Install auxiliary equipment belt (3).
2) Loosen adjustment bolt (1) and give the
tension of tensioner (2) to auxiliary equip-
m e nt b el t ( 3 ) u nt i l d im en s i on ( a ) is
obtained.
53. Alternator Dimension (a): 90 mm
a Insert the mounting bolt in the rear side 3) Tension the locknut of adjustment bolt (1).
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.)
1) Remove oil filter (1) on the front side.
2) Install alternator (2).
32 170E-5 Series
56. EGR valve

1) Install EGR valve (5).
2) Install oil tubes (1) – (4).
3 Oil tubes (1), (2) sleeve nut (Relay
block side):
54 – 93 Nm {5.5 – 9.5 kgm}
3 Oil tubes (3), (4) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
58. Exhaust manifold assembly

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:
Liquid adhesive (Holtz MH 705)
57. EGR cooler

1) Install EGR cooler (3).
2) Apply silicone sealant (Shin-Etsu Chemi-
cal RE45W 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).
4 Exhaust manifold assembly: 35 kg
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}
aTighten the mounting bolts in the fol-

lowing order.
2 Exhaust manifold mounting bolt:
170E-5 Series 33
3 Exhaust manifold mounting bolt: 3) Install brackets (3) and (4).

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).
59. 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):
3 Bypass tube mounting bolt (Stainless
steel bolt):
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
2) Install EGR tube (6) and then fix it with
clamp (5).
a A separate torque shall be used for
the stainless steel bolt alone. (The
60. Bracket
standard torque is applicable to the
Install bracket (1) on the top face of No. 2
other bolts.)
2 EGR tube mounting bolt (All bolts):
rocker cover.
3 EGR tube mounting bolt (Stainless
steel bolt):
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
34 170E-5 Series
61. Turbocharger assembly 62. 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:
Molybdenum disulfide grease (LM-P) 3 Clamping nut:
3 Turbocharger mounting bolt and 39.3 – 44.1 Nm {3.5 – 4.5 kgm}
nut: 3 Hose clamp:
78.5 – 88.3 Nm {8.0 – 9.0 kgm} 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
63. Starting motor assembly

2) Install 2 water pipes (1) and 2 oil pipes (2).
3 Oil pipe joint bolt (Cylinder block
Install starting motor assemblies (2) and then
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:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
170E-5 Series 35
64. Engine wiring harness 66. Checking of fuel leakage

1) Install engine wiring harness (1) on the a If fuel supply pump (1), common rail (2), or
engine assembly and then connect the high-pressure piping (3) is removed and
connector and terminal. installed, after assembling the engine,
check for fuel leakage according to the fol-
lowing procedure.
2) Install the cover on PFUEL section (2) on

the engine top face after its installation.
a Clean and degrease the engine and the
parts around it in advance so that you can
test it easily for fuel leakage.
1) Spray color checker (developer) over the
fuel supply pump, common rail, fuel injec-
tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
3) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
65. Sensor tightening torque 4) Run the engine at low idle.
When a sensor is replaced, tighten a new sen- 5) Check the fuel piping and devices for fuel
sor to the following torque. leakage.
Sensor name Tightening torque sure circuit parts coated with the color
Ne speed 4.9 – 7.9 Nm {0.5 – 0.8 kgm}
Fuel temperature 23 ± 3 Nm {2.35 ± 0.3 kgm} it and check again from step 2).
Coolant tempera- 6) Run the engine at high idle.
23 ± 3 Nm {2.35 ± 0.3 kgm}
ture 7) Check the fuel piping and devices for fuel
Engine oil pressure 23 ± 3 Nm {2.35 ± 0.3 kgm} leakage.
Fuel pressure Never disassemble.
Intake air tempera- checker for fuel leakage.
23 ± 3 Nm {2.35 ± 0.3 kgm}
ture
Engine oil 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.
a When checking while the components
to be checked are mounted on the
machine, stall the torque converter or
relieve the hydraulic pump.
36 170E-5 Series
9) Check the fuel piping and devices for fuel

leakage.
it and check again from step 2).
a If no fuel leakage is detected, the
check is completed.
170E-5 Series 37
© 2006 KOMATSU
All Rights Reserved
38 170E-5 Series
SEN00768-00
ENGINE 1SHOP MANUAL
170E-5 Series

Removal and installation of fuel supply pump unit ............................................................................... 2
Replacement of oil seal of engine mounted on machine ..................................................................... 5
170E-5 Series 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 (8). [*3]
2 170E-5 Series
12. Remove oil tube (17) and bracket (18) from Installation
fuel supply pump (16). [*7] q Carry out installation in the reverse order to
removal.
[*1]
3 Nut: Fuel tube (4)
Joint bolt (Supply pump side):
14.5 – 19.6 Nm {1.51 – 1.99 kgm}
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Fuel tube (5)
Joint bolt:
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Flare nut: 58.8 – 78.4 Nm {6.0 – 8.0 kgm}
3 Fuel tube (6)
Joint bolt:
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Flare nut: 84 – 132 Nm {8.5 – 13.5 kgm}
[*2]
3 Oil tube (14)
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
3 Joint bolt (Block side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*3]
3 Fuel tube (8)
Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Flare nut: 54 – 93 Nm {5.5 – 9.5 kgm}
[*4]
k When handling the high-pressure piping
and clamp, care should be paid to following
points.
q It is strictly prohibited to modify bending a high-
pressure piping to use it again or to use a high-
pressure piping in an unspecified location.
q When installing a clamp, be sure to install a
genuine clamp securely using the specified
torque.
q After installation of the high-pressure piping
and clamp is complete, make sure that a 10
mm clearance minimum is provided between
the high-pressure piping and adjacent wiring
harness. When the clearance is less than 10
mm, secure the necessary space by adjusting
the wiring harness position.
170E-5 Series 3
a Install the high-pressure piping between the

common rail and fuel supply pump in the fol-
lowing procedure.
1) Install high-pressure pipings (12) and (13)
temporarily on the common rail and fuel
supply pump.
2) Install the bracket and clamp temporarily.
3) Tighten the sleeve nuts of high-pressure
pipings (12) and (13) with the specified
torque.
3 High-pressure piping sleeve nut:
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
4) Tighten the clamp with the specified
torque.
3 Clamping bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
5) Tighten the bracket mounting bolt with the
specified torque.
6) Install rubber cap on the sleeve nut.
[*5]
3 Supply pump mounting bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Bracket (15) mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
[*6]
a Insert the fuel supply pump shaft aligning it to
the coupling of the supply pump drive case.
a The spline is not provided in one location on
the coupling and shaft. This location deter-
mines the installation position.
q The figure shows an example of the coupling
on the supply pump drive case. (Spline is miss-
ing in Section A.)
[*7]
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
(Supply pump side)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(Bracket side)
3 Bracket (18) mounting bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
4 170E-5 Series
Replacement of oil seal of engine

mounted on machine 1
1. Rear oil seal
a For the work up to removal of the flywheel,
see the shop manual for the applicable
machine.
Removal of standard seal

Hitch the end of tool R to the metal ring of seal
(1) and pull out the seal with impacts of slide
hammer [1].
a Before pulling out the seal, drive in it a lit-
tle to separate it from the housing for the
ease of removal.
a Do not use a drill, etc. since chips may Installation
enter the engine. a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
with the “Standard seal” or “Sleeved seal”.
a If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
the standard seal. In other cases, install the
sleeved seal.
a The left one in the following figure is the stan-
dard seal and the right one is the sleeved seal.
Removal of sleeved seal

1) Hitch the end of tool R to the metal ring of
seal (1) and pull out the seal with impacts
of slide hammer [1].
a Before pulling out the seal, drive in it
a little to separate it from housing (2)
for the ease of removal.
2) Cut and remove sleeve (3) with a chisel
and a hammer.
a When cutting the sleeve, take care
extremely not to damage crankshaft
(4).
a Remove all the chips.
a The left one in the figure is the stan-
dard seal and the right one is the
sleeved seal.
170E-5 Series 5
Procedure for installing standard seal 2) Hold the metal ring of seal (1) with both hands
a Before installing the seal, check that the end and push it in firmly.
corners and lip sliding surfaces of crankshaft 3) After pushing in the seal, remove plastic inside
(4) are free from flaw, burr, and rust of the cylinder (3).
housing. a When removing the inside cylinder, take
a When installing seal (1), do not apply oil or care not to damage the seal lip.
grease to the shaft and seal lip (a). Wipe off
the oil from the shaft.
a Never remove inside plastic cylinder (3) of the
standard spare seal before installing the seal.
4) Tighten bolts evenly until the end face of tool L

reaches the end face of crankshaft (4) to press
fit seal (1).
a After press fitting the seal, remove the red
1) Set the large inside diameter side (b) of plastic sealant layer from its periphery.
inside cylinder (3) to the end of crankshaft (4).
a Extremely take care not to mistake the
direction of the plastic inside cylinder.
6 170E-5 Series
2. Front oil seal 2) Using tool K, press fit oil seal (1) to the front
case until dimension (a) is obtained. (When the
Removal dust seal is not provided)
a For the work up to removal of the damper, see a Oil seal press fitting dimension (a): 18.5 mm
the shop manual for the applicable machine.
1) Remove front oil seal (1).
3) Using tool K, press fit dust seal (2) to the front

case until dimension (b) is obtained. (When the
dust seal is provided)
Installation a Dust seal press fitting dimension (b):
Install front oil seal (1) according to the following 2 mm (Projection out of the front cover
procedure. end face)
a Before installing the seal, check that the end a Dust seal is provided only for the vehicle-
corners and lip sliding surfaces of the crank- mounted engines.
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.
a Take care not to mistake the direction of the
plastic inside cylinder.
170E-5 Series 7
© 2006 KOMATSU
All Rights Reserved
8 170E-5 Series

Saa6d170e-5 HPCR Egr Sen00190-04

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SEN00190-04

Copyright 2006 Komatsu

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Organization list of the shop manual.................................................................................................... 2

Organization list of the shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00190-04

00 Index and foreword SEN00191-04

10 Structure, function and maintenance standard SEN00196-01

20 Standard value table SEN00199-00

30 Testing and adjusting SEN00200-00

50 Disassembly and assembly SEN00202-00

Foreword and general information SEN00193-01

10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 2 SEN00198-01

Fuel system ................................................................................................................................. 12

20 Standard value table

30 Testing and adjusting

S-9 Oil becomes contaminated quickly ................................................................................... 19

E-48 Code [757/CA757] All Persistent Data Lost Error ........................................................... 15

50 Disassembly and assembly

KOMATSU 170E-5 Series engine

Form No. SEN00192-04

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Foreword and general information (Rev. 2005/11)

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

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

Handling 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