Komatsu 170 Series Engine Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu 170-3, 170E-5, 8V170-1, 12V170-1, 12V170-2, 6D170-1, 6D170-2 Series Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu 170-3, 170E-5, 8V170-1, 12V170-1, 12V170-2, 6D170-1, 6D170-2 Series Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,907 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBD6161A16 - 6D170-1 Series Diesel Engine Shop Manual.pdf
SEBD61700104 - 8V170-1 Series Diesel Engine Shop Manual.pdf
SEBD61800104 - 12V170-1 Series Diesel Engine Shop Manual.pdf
SEBE61800105 - 12V170-1 Series Engine Shop Manual.pdf
SEBES6161000 - 6D170-1 Series Diesel Engine Shop Manual.pdf
SEBM008107 - 6D170-2 Series Diesel Engine Shop Manual.pdf
SEBM023407 - 170-3 Series Diesel Engine Shop Manual.pdf
SEBM023412 - 170-3 Series (QSK23) Diesel Engine Shop Manual.pdf
SEBM036601 - 12V170-2 Series Engine Shop Manual.pdf
SEN00190-13 - 170E-5 Series Engine Shop Manual.pdf
MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...25
APPLICABLE MACHINE...26
SPECIFICATIONS...28
OVERALL DRAWING...32
WEIGHT TABLE...52
ENGINE PERFORMANCE CURVE...53
11 STRUCTURE AND FUNCTION...61
INTAKE AND EXHAUST SYSTEM...62
AIR CLEANER...62
TURBOCHARGER...65
AFTER COOLER...70
ENGINE BODY...72
CYLINDER HEAD...72
CYLINDER BLOCK...74
MAIN CIRCULATION SYSTEM...76
FLYWHEEL AND FLYWHEEL HOUSING...78
VIBRATION DAMPER...79
GEAR TRAIN...80
TIMING GEAR...81
VALVE SYSTEM...82
LUBRICATION SYSTEM...84
LUBRICATION SYSTEM DIAGRAM...84
OIL PUMP...85
OIL FILTER, SAFETY VALVE...87
OIL COOLER...88
FUEL SYSTEM ...89
FUEL SYSTEM DIAGRAM...89
ENGINE CONTROLLER CONTROL SYSTEM...91
FUEL PUMP PRESSURE CONTROL CIRCUIT...94
FUEL PUMP...95
INJECTOR...99
HPI FUEL INJECTION SYSTEM...100
FUEL COOLER...101
FUEL FILTER...102
COOLING SYSTEM...103
COLING SYSTEM DIAGRAM...103
WATER PUMP...104
THERMOSTAT...105
FAN, TENSION PULLEY...106
ELECTRICAL EQUIPMENT...110
ALTERNATOR...110
STARTING MOTOR...116
STARTING AID...118
12 TESTING AND ADJUSTING...122
STANDARD VALUE TABLE FOR TROULESHOOTING...123
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...128
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...131
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)...133
MEASURING EXHAUSTTEMPERATURE (OVERALL ENGINE)...133
TROUBLESHOOTING FOR INJECTOR...134
ADJUSTING VALVE CLEARANCE...135
ADJUSTING INJECTOR SET LOAD...136
MEASURING COMPRESSION PRESSURE...137
MEASURING BLOW-BY PRESSURE...138
MEASURING OIL PRESSURE...139
HANDLING EQUIPMENT IN FUEL CIRCUIT...139
MEASRING FUEL CICUIT PRESSURE...140
VIDUAL INSPECTION OF RETURN FUEL...141
BLEEDING AIR FROM FUEL CIRCUIT...142
ADJUSTING SPEED SENSOR...143
REPLACING AND ADJUSTING FAN BELT...144
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...146
PRECAUTIONS WHEN OPERATION ENGINE AS AN INDVIDUAL PART...147
ARRANGEMENT OF CONTROL DEVICES AND ELECTRIC CIRCUIT FOR HPI...148
RUN-IN STANDARD...151
PERFORMANCE TEST STANDARDS...152
TROUBLESHOOTING OF MECHANICAL SYSTEM (S MODE)...157
POINTS TO REMEMBER WHEN TROUBLESHOOTING...158
METHOD OF USING TROUBLESHOOTING CHARTS...159
S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)...162
S-2 ENGINE DOES NOT START...164
a) ENGINE DOES NOT TURN...164
b) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...165
c) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...167
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...169
S-4 ENGINE STOPS DURING OPERATIONS...171
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...173
S-6 ENGINE LACKS OUTPUT (NO LACKS POWER)...175
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...177
S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...179
S-9 OIL BECOMES CONTAMINATED QUICKLY...180
S-10 FUEL CONSUMPTION IS EXCESSIVE...181
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...182
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...183
S-13 OIL LEVEL RISES...184
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...185
S-15 ABNORMAL NOISE IS MADE...186
S-16 VIBRATION IS EXCESSIVE...187
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM OF ENGINE FOR CONSTRUCTION EQUIPMENT (EA MODE)...188
POINTS TO REMEMBER WHEN TROUBLESHOOTING...190
METHOD OF USING TROUBLESHOOTING CHARTS...192
ERROR CODE DISPLAY AND POINTS TO REMEMBER WHEN TROUBLESHOOTING...193
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED...197
EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)...207
EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR)...207
EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)...208
EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)...209
EA-5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...211
EA-6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)...212
EA-7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL)...213
EA-8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL)...214
EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)...215
EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)...216
EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)...217
EA-12 ERROR CODE [131] (ABNORMALITY IN THROTTLE SENSOR SYSTEM HIGH LEVEL)...218
EA-13 ERROR CODE [132] (ABNORMALITY IN THROTTLE SENSOR SYSTEM LOW LEVEL)...219
EA-14 ERROR CODE [133] (ABNORMALITY IN REMOTE THROTTLE SENSOR SYSTEM HIHG LEVEL)...219
EA-15 ERROR CODE [134] (ABNORMALITY IN REMOTE THROTTLE SENSOR SYSTEM LOW LEVEL)...220
EA-16 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...221
EA-17 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL)...222
EA-18 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))...223
EA-19 ERROR CODE [144] (ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...224
EA-20 ERROR CODE [145] (ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM LOW LEVEL)...225
EA-21 ERROR CODE [151] (ABNORMALITY RISE IN WATER TEMPERATURE)...225
EA-22 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...226
EA-23 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMERATURE SENSOR SYSTEM LOW LEVEL)...226
EA-24 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL)...227
EA-25 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW)...228
EA-26 ERROR CODE [234] (OVERSPEED)...229
EA-27 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)...230
EA-28 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)...231
EA-29 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)...231
EA-30 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...232
EA-31 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL)...232
EA-32 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)...233
EA-33 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)...234
EA-34 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION)...235
EA-35 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)...235
EA-36 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)...237
EA-37 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2))...237
EA-38 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE)...238
EA-39 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM)...240
EA-40 ERROR CODE [432] (IDLING VALIDATION PROCESS ERROR)...241
EA-41 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL)...242
EA-42 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL)...242
EA-43 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...243
EA-44 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)...244
EA-45 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)...245
EA-46 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)...246
EA-47 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)...246
EA-48 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)...246
EA-49 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM)...247
EA-50 ERROR CODE [529] (ABNORMALITY IN DUAL OUTPUT SOLENOID B SYSTEM)...248
EA-51 ERROR CODE [551] (ABNORMALITY 2 IN IDLING VALIDATION SWITCH SYSTEM)...248
EA-52 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)...249
TROUBLESHOOTING OF CONTROLLER SYSTEM OF ENGING FOR GENERATOR EQUIPMENT...251
POINTS TO REMEMBER WHEN TROUBLESHOOTING...252
METHOD OF USING TROUBLESHOOTING CHARTS...254
ERROR CODE DISPLAY AND POINTS TO REMEMBER WHEN TROUBLESHOOTING...255
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED...258
EB-1 ERROR CODE [E-10] (ABNORMALITY IN POWER SOURCE VOLTAGE SYSTEM)...266
EB-2 ERROR CODE [E-16] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)...267
EB-3 ERROR CODE [E-1b] (ABNORMALITY IN ENGING SPEED SENSOR A SYSTEM)...268
EB-4 ERROR CODE [E-1C] (ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM)...269
EB-5 ERROR CODE [E-21] (MISTAKEN OF CONNECTION OF WIRING HARNESS CONNECTOR)...270
EB-6 ERROR CODE [E-22] (OVERRUN)...271
EB-7 ERROR CODE [E-23] (OVERHEAT)...271
EB-9 ERROR CODE [E-34] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM)...273
EB-10 ERROR CODE [E-56] (ABNORMALITY IN SOLENOID POWER SOURCE 1 SYSTEM)...274
EB-11 ERROR CODE [E-57] (ABNORMALITY IN SOLENOID POWER SOURCE 2 SYSTEM)...275
EB-12 ERROR CODE [E-58] (ABNORMALITY IN BACKUP POWER SOURCE SYSTEM)...276
EB-13 ERROR CODE [E-59] (ABNORMALITY IN SWITCH POWER SOURCE SYSTEM)...277
EB-14 ERROR CODE [E-70] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...278
EB-15 ERROR CODE [E-71] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOE LEVEL)...279
EB-16 ERROR CODE [E-72] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM IN RANGE)...280
EB-17 ERROR CODE [E-73] (ABNORMALITY IN FUEL RAIL ACTUATOR)...281
EB-18 ERROR CODE [E-75] (ABNORMALITY WITH ELECTRIC CURRENT IN FUEL RAIL ACTUATOR SYSTEM)...282
EB-19 ERROR CODE [E-80] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...284
EB-20 ERROR CODE [E-81] (ABNORMALITY IN TMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)...285
EB-21 ERROR CODE [E-82] (ABNORMALITY IN TIMING RAIL PRESSURE SRNSOR SYSTEM IN RANGE)...286
EB-22 ERROR CODE [E-83] (ABNORMALITY IN TIMING RAIL ACTUATOR)...288
EB-23 ERROR CODE [E-85] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYATEM)...289
EB-24 ERROR CODE [E-90] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL)...290
EB-25 ERROR CODE [E-91] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL)...291
EB-26 ERROR CODE [E-93] (ABNORMALITY IN FUEL PUMP ACTUATOR)...292
EB-27 ERROR CODE [E-95] (ABNORMALITY WITH ELECTRIC CURRENT IN FUEL PUMP ACTUATOR SYSTEM)...293
EB-28 ERROR CODE [E-A0] (ABNORMALITY IN FUEL SHUT-OFF VALVE)...294
EB-29 ERROR CODE [E-A1] (ABNORMALITY IN STARTING SWITCH ON SIGNAL SYSTEM)...295
EB-30 ERROR CODE [E-A2] (ABNORMALITY IN POWER SOURCE RETENTION RELAY SYSTEM)...296
EB-31 ERROR CODE [E-A3] (ABNORMALITY IN EMERGENCY STOP SIGNAL INPUT)...297
EB-32 ERROR CODE [E-b0] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL)...298
EB-33 ERROR CODE [E-b1] (ABNORMALITY IN ATMOSPHERIC PRESSUER SENSOR SYSTEM LOW LEVEL)...299
EB-34 ERROR CODE [E-b2] (ABNORMALITY IN BOOST AIR PRESSURE SENSOR SYSTEM HIGH LEVEL)...300
EB-35 ERROR CODE [E-b3] (ABNORMALITY IN BOOST AIR PRESSURE SENSOR SYSTEM LOW LEVEL)...301
EB-36 ERROR CODE [E-b4] (ABNORMALITY IN BOOST AIR PRESSURE SENSOR SYSTEM IN RANGE)...302
EB-37 ERROR CODE [E-b6] (ABNORMALITY IN DROOP ADJUSTMENT VOLUME SYSTEM)...302
EB-38 ERROR CODE [E-b7] (ABNORMALITY IN RATED SPEED ADJUSTMENT VOLUME SYSTEM)...304
EB-39 ERROR CODE [E-b8] (ABNORMALITY IN LI SPEED ADJUSTMENT VOLUME SYSTEM)...306
EB-40 ERROR CODE [E-b9] (ABNORMALITY IN LAMP IME ADJUSTMENT VOLUME SYSTEM)...308
EB-41 ERROR CODE [E-bA] (ABNORMALITY IN P CONSTANT ADJUSTMENT VOLUME SYSTEM)...310
EB-42 ERROR CODE [E-bb] (ABNORMALITY I CONSTANT ADJUSTMENT VOLUME SYSTEM)...312
EB-43 ERROR CODE [E-bC] (ABNORMALITY IN D CONSTANT ADJUSTMENT VOLUME SYSTEM)...314
EB-44 ERROR CODE [E-bd] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM)...316
EB-45 ERROR CODE [E-bE] (ABNORMALITY RISE IN FUEL TEMPERATURE)...317
13 DISASSEMBLY AND ASSEMBLY...318
METHOD OF USING MANUAL...319
PRECAUTIONS WHEN CARRYING OUT OPERATION...320
SPECIAL TOOL LIST...322
DISASSEMBLY OF ENGINE...324
WASHING PARTS...370
MEASURING PARTS...371
14 MAINTENANCE STANDARD...376
NTAKE AND EXHAUST SYSTEM...377
TURBOCHARGER...377
ENGINE BODY...383
CYLINDER HEAD...383
VALVE, VALVE GUIDE...384
CROSSHAD AND CROSSHEAD GUIDE...385
TAPPET AND PUSH ROD...386
ROCKERR ARM...388
CYLINDER BLOCK...390
CYLINDRE LINER...392
CRANKSHAFT...393
CAMSHAFT...395
GEAR TRAIN...396
TIMING GEAR...398
PISTON, PISTON RING, PISTON PIN...400
CONNECTING ROD...401
LUBRICATION SYSTEM...402
OIL PUMP...402
OIL COOLER...404
COOLING SYSTEM...405
WATER PUMP...405
THERMOSTAT...406
15 REPAIR AND REPLACEMENT OF PARTS...407
TABLE OF SPECIAL TOOLS...408
TESTING AND INSPECTING CYINDER HEAD...409
REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING...412
REPLACING VALVE SEAT INSERTS...413
PRESSURE TEST METHOD...418
REPLACING VALVE GUIDE...419
REPLACING CROSS HEAD GUIDE...420
GRINDING VALVE...421
TESTING AND INSPECTING CYLINDER BLOCK...422
GRINDING THE TOP SURFACE OF CYLINDER BLOCK...425
REPLACING MAIN BEARING CAP...431
REPLACING CAM BUSHING...433
TESTING AND INSPECTING CRANKSHAFT...435
CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION...437
REPAIRING CRANKSHAFT...442
TESTING AND INSPECTING OF CONNECTING ROD...450
REPLACING CRANKSHAFT GEAR...452
REPLACING CAMSHAFT GEAR...453
REPLACING FLYWHEEL RING GEAR...454
