Komatsu Engine 170E -5 SERIES Shop Manual SEN00190-17 – PDF DOWNLOAD

Description

Komatsu Engine 170E -5 SERIES Shop Manual SEN00190-17 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Engine 170E -5 SERIES Shop Manual SEN00190-17 – PDF DOWNLOAD

Language : English
Pages :688
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Engine 170E -5 SERIES Shop Manual SEN00190-17 – PDF DOWNLOAD

1. General precautions

k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu Engine 170E -5 SERIES Shop Manual SEN00190-17 – PDF DOWNLOAD

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 5
Foreword and general information 11
Safety notice 12
How to read the shop manual 17
Explanation of terms for maintenance standard 19
Handling of electric equipment and hydraulic component 21
Handling of connectors newly used for engines 30
How to read electric wire code 33
Precautions when carrying out operation 36
Method of disassembling and connecting push-pull type coupler 39
Standard tightening torque table 42
Conversion table 46
01 Specification 53
Specification and technical data 53
Outline 54
Specifications 58
General view 68
Weight table 85
Engine performance curves 87
10 Structure, function and maintenance standard 95
Structure, function and maintenance standard, Part 1 95
Air cleaner 98
Turbocharger100
EGR system105
Cylinder head112
Cylinder block116
Cylinder liner120
Main moving parts122
Crankshaft124
Camshaft126
Connecting rod127
Piston, piston ring and piston pin128
Flywheel and flywheel housing129
Vibration damper130
Gear train131
Timing gear136
Valve system140
Valve and valve guide142
Rocker arm and shaft143
Crosshead and guide144
Tappet and push rod145
Structure, function and maintenance standard, Part 2147
Lubrication system150
Lubrication system diagram150
Oil pump154
Oil filter and safety valve158
Oil cooler159
Fuel system160
CRI system diagram160
Outline of CRI system161
Fuel piping184
Fuel filter186
Electric priming pump188
Engine controller cooler189
Cooling system190
Cooling system diagram190
Water pump192
Thermostat194
Fan drive196
Electrical equipment198
Alternator198
Starting motor202
Starting aid205
Engine controller206
20 Standard value table209
Standard service value table209
Standard service value table for testing, adjusting, and troubleshooting210
Running-in standard and performance test standard220
30 Testing and adjusting227
Testing and adjusting227
Testing and adjusting (With EGR)229
Testing and adjusting tools list229
Sketches of special tools231
Testing air boost pressure232
Testing exhaust temperature233
Adjusting valve clearance234
Testing compression pressure236
Testing blow-by pressure238
Testing engine oil pressure239
Testing EGR valve and bypass valve drive oil pressure240
Handling fuel system parts242
Releasing residual pressure in fuel system242
Testing fuel pressure243
Reduced cylinder mode operation244
No-injection cranking244
Testing leakage from pressure limiter and return rate from injector245
Bleeding air from fuel circuit248
Testing fuel system for leakage250
Handling controller voltage circuit251
Testing and adjusting (EGR-less)252
Testing and adjusting tools list252
Sketches of special tools254
Testing air boost pressure255
Testing exhaust temperature256
Adjusting valve clearance257
Testing compression pressure259
Testing blow-by pressure261
Testing engine oil pressure262
Handling fuel system parts263
Releasing residual pressure in fuel system263
Testing fuel pressure264
Reduced cylinder mode operation265
No-injection cranking265
Testing leakage from pressure limiter and return rate from injector266
Bleeding air from fuel circuit269
Testing fuel system for leakage271
Handling controller voltage circuit272
40 Troubleshooting275
General information on troubleshooting275
Points on troubleshooting276
Error code and failure code table278
Information in troubleshooting table280
Connection table for connector pin numbers282
T- branch box and T- branch adapter table318
Troubleshooting of electrical system (E-mode), Part 1323
Troubleshooting of electrical system (E-mode), Part 1326
E-1 Code [111/CA111] Engine controller Internal Failure326
E-2 Code [115/CA115] Eng Ne and Bkup Speed Sensor Error328
E-3 Code [122/CA122] Charge Air Press Sensor High Error329
E-4 Code [123/CA123] Charge (boost) Air Press Sensor Low Error332
E-5 Code [131/CA131] Throttle Sensor High Error334
E-6 Code [132/CA132] Throttle Sensor Low Error338
E-7 Code [135/CA135] Oil Press Sensor High Error339
E-8 Code [141/CA141] Oil Press Sensor Low Error342
E-9 Code [144/CA144] Coolant Temp Sensor High Error344
E-10 Code [145/CA145] Coolant Temp Sensor Low Error346
E-11 Code [153/CA153] Charge (boost) Air Temp Sensor High Error348
E-12 Code [154/CA154] Charge (boost) Air Temp Sensor Low Error350
E-13 Code [187/CA187] Sensor Sup 2 Volt Low Error351
E-14 Code [212/CA212] Oil Temp Sensor High Error352
E-15 Code [213/CA213] Oil Temp Sensor Low Error354
E-16 Code [221/CA221] Ambient Air Press Sensor High Error355
E-17 Code [222/CA222] Ambient Air Press Sensor Low Error358
E-18 Code [227/CA227] Sensor Sup 2 Volt High Error359
E-19 Code [234/CA234] Eng Overspeed362
E-20 Code [238/CA238] Ne Speed Sensor Sup Volt Error364
E-21 Code [263/CA263] Fuel Temp Sensor High Error366
E-22 Code [265/CA265] Fuel Temp Sensor Low Error368
E-23 Code [271/CA271] PCV1 Short Error370
E-24 Code [272/CA272] PCV1 Open Error372
E-25 Code [273/CA273] PCV2 Short Error374
E-26 Code [274/CA274] PCV2 Open Error376
E-27 Code [322/CA322] Injector #1 System Open/Short Error378
E-28 Code [323/CA323] Injector #5 System Open/Short Error380
E-29 Code [324/CA324] Injector #3 System Open/Short Error382
E-30 Code [325/CA325] Injector #6 System Open/Short Error384
E-31 Code [331/CA331] Injector #2 System Open/Short Error386
E-32 Code [332/CA332] Injector #4 System Open/Short Error388
E-33 Code [342/CA342] Engine Controller Data Matching Error390
E-34 Code [351/CA351] INJ Drive Circuit Error392
E-35 Code [352/CA352] Sensor Sup 1 Volt Low Error394
E-36 Code [386/CA386] Sensor Sup 1 Volt High Error396
E-37 Code [431/CA431] Idle Validation SW Low error400
E-38 Code [432/CA432] Idle Validation Process error402
E-39 Code [441/CA441] Battery voltage low error403
E-40 Code [442/CA442] Battery voltage high error403
Troubleshooting of electrical system (E-mode), Part 2405
Troubleshooting of electrical system (E-mode), Part 2407
E-41 Code [449/CA449] Rail Press Very High Error407
E-42 Code [451/CA451] Rail Press Sensor High Error408
E-43 Code [452/CA452] Rail Press Sensor Low Error411
E-44 Code [553/CA553] Rail Press High Error412
E-45 Code [559/CA559] No-pressure feed by supply pump 1414
E-46 Code [689/CA689] Eng Ne Speed Sensor Error420
E-47 Code [731/CA731] Eng Bkup Speed Sensor Phase Error422
E-48 Code [757/CA757] All Persistent Data Lost Error423
E-49 Code [778/CA778] Eng Bkup Speed Sensor Error424
E-50 Code [1228/CA1228] EGR Valve Servo Error 1426
E-51 Code [1625/CA1625] EGR Valve Servo Error 2427
E-52 Code [1626/CA1626] Bypass Valve Solenoid Drive Short Circuit428
E-53 Code [1627/CA1627] Bypass Valve Solenoid Drive Open Error430
E-54 Code [1628/CA1628] Bypass Valve Servo Error 1431
E-55 Code [1629/CA1629] Bypass Valve Servo Error 2432
E-56 Code [1631/CA1631] BP valve Lift Position Sensor High Error433
E-57 Code [1632/CA1632] BP valve Lift Position Sensor Low Error435
E-58 Code [1633/CA1633] KOMNET Error435
E-59 Code [2185/CA2185] Throttle Sens Sup Volt High Error436
E-60 Code [2186/CA2186] Throttle Sens Sup Volt Low Error440
E-61 Code [2249/CA2249] No-pressure feed by supply pump 2440
E-62 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error441
E-63 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error443
E-64 Code [2351/CA2351] EGR Valve Solenoid Drive Short Error444
E-65 Code [2352/CA2352] EGR Valve Solenoid Drive Open Error446
E-66 Code [2555/CA2555] Grid Heater Relay Open Error447
E-67 Code [2556/CA2556] Grid Heater Relay Short Error448
E-68 Code [(143)/B@BAZG] Eng Oil press Torque Derate450
E-69 Code [(146)/B@BCNS] Eng Overheat450
E-70 Code [(415)/B@BAZG] Eng Oil press Low Speed Derate451
Troubleshooting of mechanical system (S-mode)453
Troubleshooting of mechanical system (S-mode)455
Method of using troubleshooting charts455
S-1 Starting performance is poor458
S-2 Engine does not start460
S-3 Engine does not pick up smoothly464
S-4 Engine stops during operations465
S-5 Engine does not rotate smoothly466
S-6 Engine lacks output (or lacks power)467
S-7 Exhaust smoke is black (incomplete combustion)468
S-8 Oil consumption is excessive (or exhaust smoke is blue)470
S-9 Oil becomes contaminated quickly471
S-10 Fuel consumption is excessive472
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)473
S-12 Oil pressure drops474
S-13 Oil level rises (Entry of coolant or fuel)475
S-14 Coolant temperature becomes too high (overheating)477
S-15 Abnormal noise is made478
S-16 Vibration is excessive479
S-17 Air cannot be bled from fuel circuit480
50 Disassembly and assembly485
General information on disassembly and assembly485
How to read this manual486
Coating materials list488
Special tools list491
Sketches of special tools493
Disassembly and assembly, Part 1 (With EGR)497
Disassembly and assembly, Part 1 (With EGR)498
General disassembly of engine498
General assembly of engine518
Disassembly and assembly, Part 2 (EGR-less)557
Disassembly and assembly, Part 2 (EGR-less)558
General disassembly of engine558
General assembly of engine578
Disassembly and assembly, Part 3617
Disassembly and assembly, Part 3618
Removal and installation of fuel supply pump unit618
Replacement of oil seal of engine mounted on machine621
90 Repair and replacement of parts627
Information related to repair and replacement627
Flowchart628
Special tool table630
Sketches of special tools632
Parts related to cylinder head635
Part names related to cylinder head636
Testing and inspection of cylinder head637
Pressure test of cylinder head639
Replacement of valve guide639
Replacement of valve seat insert640
Replacement of crosshead guide648
Repair of cylinder head mounting face by grinding649
Repair of valve by grinding650
Parts related to cylinder block653
Part names related to cylinder block654
Testing and inspection of cylinder block655
Part names related to crankshaft658
Testing and inspection of crankshaft659
Part names related to connecting rod660
Testing and inspection of connecting rod661
Replacement of flywheel ring gear662
Replacement of crankshaft gear663
Replacement of camshaft gear664
Replacement of main bearing metal cap665
Replacement of connecting rod small end bushing667
Replacement of cam bushing668
Replacement of engine rear seal670
Repair of cylinder block top by grinding671
Repair of counterbore by grinding672
Check and identification after repair by grinding674
Gasket sealant application procedure675
Repair of crankshaft by grinding678
Improvement of surface roughness of crankshaft journal683

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24