Komatsu 170E-5 Series Diesel Engine Shop Manual – PDF DOWNLOAD

Description

Komatsu 170E-5 Series Diesel Engine Shop Manual

FILE DETAILS:

Komatsu 170E-5 Series Diesel Engine Shop Manual 

Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model:  170E-5 Series Engine
Book Code: SEN00190-13
Language: English
Pages: 687
File Format: Portable Document Format (PDF)

KOMATSU 170E-5 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 170E-5 Series Diesel Engine Shop Manual 

How to read the shop manual:

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 disassembly 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):

•  Chassis volume
  This section gives hydraulic circuit diagrams and electrical circuit diagrams.
•  Engine volume
  This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu 170E-5 Series Diesel Engine Shop Manual

COVER
....................................................................................  1
00 Index and foreword.....................................................................  0
	Index.................................................................................  2
		Composition of shop manual........................................................  3
		Table of contents.................................................................  4
	Foreword and general information...................................................... 10
		Safety notice..................................................................... 11
		How to read the shop manual....................................................... 16
		Explanation of terms for maintenance standard..................................... 18
		Handling of electric equipment and hydraulic component............................ 20
		Handling of connectors newly used for engines..................................... 29
		How to read electric wire code.................................................... 32
		Precautions when carrying out operation........................................... 35
		Method of disassembling and connecting push-pull type coupler..................... 38
		Standard tightening torque table.................................................. 41
		Conversion table.................................................................. 45
01 Specification..........................................................................  0
	Specification and technical data...................................................... 52
		Outline........................................................................... 53
		Specifications.................................................................... 57
		General view...................................................................... 67
		Weight table...................................................................... 84
		Engine performance curves......................................................... 86
10 Structure, function and maintenance standard...........................................  0
	Structure, function and maintenance standard, Part 1.................................. 94
		Air cleaner....................................................................... 97
		Turbocharger...................................................................... 99
		EGR system........................................................................104
		Cylinder head.....................................................................111
		Cylinder block....................................................................115
		Cylinder liner....................................................................119
		Main moving parts.................................................................120
		Crankshaft........................................................................123
		Camshaft..........................................................................125
		Connecting rod....................................................................126
		Piston, piston ring and piston pin................................................127
		Flywheel and flywheel housing.....................................................128
		Vibration damper..................................................................129
		Gear train........................................................................130
		Timing gear.......................................................................135
		Valve system......................................................................139
		Valve and valve guide.............................................................141
		Rocker arm and shaft..............................................................142
		Crosshead and guide...............................................................143
		Tappet and push rod...............................................................144
	Structure, function and maintenance standard, Part 2..................................146
		Lubrication system................................................................149
			Lubrication system diagram....................................................149
			Oil pump......................................................................153
			Oil filter and safety valve...................................................157
			Oil cooler....................................................................158
		Fuel system.......................................................................159
			CRI system diagram............................................................159
			Outline of CRI system.........................................................160
			Fuel piping...................................................................183
			Fuel filter...................................................................185
			Electric priming pump.........................................................187
			Engine controller cooler......................................................188
		Cooling system....................................................................189
			Cooling system diagram........................................................189
			Water pump....................................................................191
			Thermostat....................................................................193
			Fan drive.....................................................................195
		Electrical equipment..............................................................197
			Alternator....................................................................197
			Starting motor................................................................201
			Starting aid..................................................................204
			Engine controller.............................................................205
20 Standard value table...................................................................  0
	Standard service value table..........................................................208
		Standard service value table for testing, adjusting, and troubleshooting..........209
		Running-in standard and performance test standard.................................219
30 Testing and adjusting..................................................................  0
	Testing and adjusting.................................................................226
		Testing and adjusting (With EGR)..................................................228
			Testing and adjusting tools list..............................................228
			Sketches of special tools.....................................................230
			Testing air boost pressure....................................................231
			Testing exhaust temperature...................................................232
			Adjusting valve clearance.....................................................233
			Testing compression pressure..................................................235
			Testing blow-by pressure......................................................237
			Testing engine oil pressure...................................................238
			Testing EGR valve and bypass valve drive oil pressure.........................239
			Handling fuel system parts....................................................241
			Releasing residual pressure in fuel system....................................241
			Testing fuel pressure.........................................................242
			Reduced cylinder mode operation...............................................243
			No-injection cranking.........................................................243
			Testing leakage from pressure limiter and return rate from injector...........244
			Bleeding air from fuel circuit................................................247
			Testing fuel system for leakage...............................................249
			Handling controller voltage circuit...........................................250
		Testing and adjusting (EGR-less)..................................................251
			Testing and adjusting tools list..............................................251
			Sketches of special tools.....................................................253
			Testing air boost pressure....................................................254
			Testing exhaust temperature...................................................255
			Adjusting valve clearance.....................................................256
			Testing compression pressure..................................................258
			Testing blow-by pressure......................................................260
			Testing engine oil pressure...................................................261
			Handling fuel system parts....................................................262
			Releasing residual pressure in fuel system....................................262
			Testing fuel pressure.........................................................263
			Reduced cylinder mode operation...............................................264
			No-injection cranking.........................................................264
			Testing leakage from pressure limiter and return rate from injector...........265
			Bleeding air from fuel circuit................................................268
			Testing fuel system for leakage...............................................270
			Handling controller voltage circuit...........................................271
40 Troubleshooting........................................................................  0
	General information on troubleshooting................................................274
		Points on troubleshooting.........................................................275
		Error code and failure code table.................................................277
		Information in troubleshooting table..............................................279
		Connection table for connector pin numbers........................................281
		T- branch box and T- branch adapter table.........................................317
	Troubleshooting of electrical system (E-mode), Part 1.................................322
		Troubleshooting of electrical system (E-mode), Part 1.............................325
			E-1 Code [111/CA111] Engine controller Internal Failure.......................325
			E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error......................327
			E-3 Code [122/CA122] Charge Air Press Sensor High Error.......................328
			E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error................331
			E-5 Code [131/CA131] Throttle Sensor High Error...............................333
			E-6 Code [132/CA132] Throttle Sensor Low Error................................337
			E-7 Code [135/CA135] Oil Press. Sensor High Error.............................338
			E-8 Code [141/CA141] Oil Press. Sensor Low Error..............................341
			E-9 Code [144/CA144] Coolant Temp. Sensor High Error..........................343
			E-10 Code [145/CA145] Coolant Temp. Sensor Low Error..........................345
			E-11 Code [153/CA153] Charge (boost) Air Temp. Sensor High Error..............347
			E-12 Code [154/CA154] Charge (boost) Air Temp. Sensor Low Error...............349
			E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error...........................350
			E-14 Code [212/CA212] Oil Temp. Sensor High Error.............................351
			E-15 Code [213/CA213] Oil Temp. Sensor Low Error..............................353
			E-16 Code [221/CA221] Ambient Air Press. Sensor High Error....................354
			E-17 Code [222/CA222] Ambient Air Press. Sensor Low Error.....................357
			E-18 Code [227/CA227] Sensor Sup. 2 Volt. High Error..........................358
			E-19 Code [234/CA234] Eng. Overspeed..........................................361
			E-20 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error........................363
			E-21 Code [263/CA263] Fuel Temp. Sensor High Error............................365
			E-22 Code [265/CA265] Fuel Temp. Sensor Low Error.............................367
			E-23 Code [271/CA271] PCV1 Short Error........................................369
			E-24 Code [272/CA272] PCV1 Open Error.........................................371
			E-25 Code [273/CA273] PCV2 Short Error........................................373
			E-26 Code [274/CA274] PCV2 Open Error.........................................375
			E-27 Code [322/CA322] Injector #1 System Open/Short Error.....................377
			E-28 Code [323/CA323] Injector #5 System Open/Short Error.....................379
			E-29 Code [324/CA324] Injector #3 System Open/Short Error.....................381
			E-30 Code [325/CA325] Injector #6 System Open/Short Error.....................383
			E-31 Code [331/CA331] Injector #2 System Open/Short Error.....................385
			E-32 Code [332/CA332] Injector #4 System Open/Short Error.....................387
			E-33 Code [342/CA342] Engine Controller Data Matching Error...................389
			E-34 Code [351/CA351] INJ. Drive Circuit Error................................391
			E-35 Code [352/CA352] Sensor Sup. 1 Volt. Low Error...........................393
			E-36 Code [386/CA386] Sensor Sup. 1 Volt. High Error..........................395
			E-37 Code [431/CA431] Idle Validation SW Low error............................399
			E-38 Code [432/CA432] Idle Validation Process error...........................401
			E-39 Code [441/CA441] Battery voltage low error...............................402
			E-40 Code [442/CA442] Battery voltage high error..............................402
	Troubleshooting of electrical system (E-mode), Part 2.................................404
		Troubleshooting of electrical system (E-mode), Part 2.............................406
			E-41 Code [449/CA449] Rail Press. Very High Error.............................406
			E-42 Code [451/CA451] Rail Press. Sensor High Error...........................407
			E-43 Code [452/CA452] Rail Press. Sensor Low Error............................410
			E-44 Code [553/CA553] Rail Press. High Error..................................411
			E-45 Code [559/CA559] No-pressure feed by supply pump 1.......................413
			E-46 Code [689/CA689] Eng. Ne Speed Sensor Error..............................419
			E-47 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error......................421
			E-48 Code [757/CA757] All Persistent Data Lost Error..........................422
			E-49 Code [778/CA778] Eng. Bkup Speed Sensor Error............................423
			E-50 Code [1228/CA1228] EGR Valve Servo Error 1...............................425
			E-51 Code [1625/CA1625] EGR Valve Servo Error 2...............................426
			E-52 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit.............427
			E-53 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error................429
			E-54 Code [1628/CA1628] Bypass Valve Servo Error 1............................430
			E-55 Code [1629/CA1629] Bypass Valve Servo Error 2............................431
			E-56 Code [1631/CA1631] BP valve Lift Position Sensor High Error..............432
			E-57 Code [1632/CA1632] BP valve Lift Position Sensor Low Error...............434
			E-58 Code [1633/CA1633] KOMNET Error..........................................434
			E-59 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error..................435
			E-60 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error...................439
			E-61 Code [2249/CA2249] No-pressure feed by supply pump 2.....................439
			E-62 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error.............440
			E-63 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error..............442
			E-64 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error..................443
			E-65 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error...................445
			E-66 Code [2555/CA2555] Grid Heater Relay Open Error..........................446
			E-67 Code [2556/CA2556] Grid Heater Relay Short Error.........................447
			E-68 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate........................449
			E-69 Code [(146)/B@BCNS] Eng. Overheat........................................449
			E-70 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate.....................450
	Troubleshooting of mechanical system (S-mode).........................................452
		Troubleshooting of mechanical system (S-mode).....................................454
			Method of using troubleshooting charts........................................454
			S-1 Starting performance is poor..............................................457
			S-2 Engine does not start.....................................................459
			S-3 Engine does not pick up smoothly..........................................463
			S-4 Engine stops during operations............................................464
			S-5 Engine does not rotate smoothly...........................................465
			S-6 Engine lacks output (or lacks power)......................................466
			S-7 Exhaust smoke is black (incomplete combustion)............................467
			S-8 Oil consumption is excessive (or exhaust smoke is blue)...................469
			S-9 Oil becomes contaminated quickly..........................................470
			S-10 Fuel consumption is excessive............................................471
			S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....472
			S-12 Oil pressure drops.......................................................473
			S-13 Oil level rises (Entry of coolant or fuel)...............................474
			S-14 Coolant temperature becomes too high (overheating).......................476
			S-15 Abnormal noise is made...................................................477
			S-16 Vibration is excessive...................................................478
			S-17 Air cannot be bled from fuel circuit.....................................479
50 Disassembly and assembly...............................................................  0
	General information on disassembly and assembly.......................................484
		General information on disassembly and assembly...................................485
			How to read this manual.......................................................485
			Coating materials list........................................................487
			Special tools list............................................................490
			Sketches of special tools.....................................................492
	Disassembly and assembly, Part 1 (With EGR)...........................................496
		Disassembly and assembly, Part 1 (With EGR).......................................497
			General disassembly of engine.................................................497
			General assembly of engine....................................................517
	Disassembly and assembly, Part 2 (EGR-less)...........................................556
		Disassembly and assembly, Part 2 (EGR-less).......................................557
			General disassembly of engine.................................................557
			General assembly of engine....................................................577
	Disassembly and assembly, Part 3......................................................616
		Disassembly and assembly, Part 3..................................................617
			Removal and installation of fuel supply pump unit.............................617
			Replacement of oil seal of engine mounted on machine..........................620
90 Repair and replacement of parts........................................................  0
	Information related to repair and replacement.........................................626
		Flowchart.........................................................................627
		Special tool table................................................................629
		Sketches of special tools.........................................................631
	Parts related to cylinder head........................................................634
		Part names related to cylinder head...............................................635
		Testing and inspection of cylinder head...........................................636
		Pressure test of cylinder head....................................................638
		Replacement of valve guide........................................................638
		Replacement of valve seat insert..................................................639
		Replacement of crosshead guide....................................................647
		Repair of cylinder head mounting face by grinding.................................648
		Repair of valve by grinding.......................................................649
	Parts related to cylinder block.......................................................652
		Part names related to cylinder block..............................................653
		Testing and inspection of cylinder block..........................................654
		Part names related to crankshaft..................................................657
		Testing and inspection of crankshaft..............................................658
		Part names related to connecting rod..............................................659
		Testing and inspection of connecting rod..........................................660
		Replacement of flywheel ring gear.................................................661
		Replacement of crankshaft gear....................................................662
		Replacement of camshaft gear......................................................663
		Replacement of main bearing metal cap.............................................664
		Replacement of connecting rod small end bushing...................................666
		Replacement of cam bushing........................................................667
		Replacement of engine rear seal...................................................669
		Repair of cylinder block top by grinding..........................................670
		Repair of counterbore by grinding.................................................671
		Check and identification after repair by grinding.................................673
		Gasket sealant application procedure..............................................674
		Repair of crankshaft by grinding..................................................677
		Improvement of surface roughness of crankshaft journal............................682

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]