SAA6D170E-5

SEN00190-02

ENGINE

170E -5 SERIES

SEN00192-02

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

SEN00192-02

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 accordingly.

Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN00190-02

00 Index and foreword Index Foreword and general information

SEN00191-02 SEN00192-02 q SEN00193-01 q

01 Specification Specification and technical data

SEN00194-01 SEN00195-01 q

10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 Structure, function and maintenance standard, Part 2

SEN00196-01 SEN00197-01 q SEN00198-01 q

20 Standard value table Standard service value table

SEN00199-00 SEN00367-00

2

170E-5 Series

00 Index and foreword

SEN00192-02

Table of contents

1

00 Index and foreword Index SEN00192-02 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 Structure, function and maintenance standard, Part 1 SEN00197-01 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 Structure, function and maintenance standard, Part 2 SEN00198-01 Lubrication system ......................................................................................................................

4 Lubrication system diagram.....................................................................................................

4 Oil pump ..................................................................................................................................

6 Oil filter and safety valve ......................................................................................................... 10 Oil cooler ................................................................................................................................. 11

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SEN00192-02

00 Index and foreword

Fuel system .................................................................................................................................

CRI system diagram ................................................................................................................

Outline of CRI system..............................................................................................................

Fuel piping ...............................................................................................................................

Fuel filter ..................................................................................................................................

Electric priming pump ..............................................................................................................

Engine controller cooler ...........................................................................................................

Cooling system............................................................................................................................

Cooling system diagram ..........................................................................................................

Water pump .............................................................................................................................

Thermostat...............................................................................................................................

Corrosion resistor ....................................................................................................................

Fan drive..................................................................................................................................

Electrical equipment ....................................................................................................................

Alternator .................................................................................................................................

Alternator belt tension..............................................................................................................

Starting aid...............................................................................................................................

Engine controller......................................................................................................................

12 12 13 34 36 38 39 40 40 41 42 44 46 47 47 48 54 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

4

170E-5 Series

00 Index and foreword

170E-5 Series

SEN00192-02

5

00 Index and foreword

KOMATSU 170E-5 Series engine Form No. SEN00192-02

Š 2005 KOMATSU All Rights Reserved Printed in Japan 11-05 (01)

6

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

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1

SEN00193-01

00 Index and foreword

Foreword and general information Safety notice

(Rev. 2005/11)

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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

1.

2

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine.

1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.

2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc.

4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs in the operator's compartment.

5) Only qualified workers must carry out work and operation which require license or qualification.

6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, alw ays wear w elding gloves, apron, shielding goggles, cap and other clothes suited for welding work.

Before starting work, warm up your body thoroughly to start work under good condition.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs Prohibition of operation and handling by 5 unlicensed workers 6 Safety check before starting work Wearing protective goggles 7 (for cleaning or grinding work) Wearing shielding goggles and protectors 8 (for welding work) 9 Good physical condition and preparation Precautions against work which you are 10 not used to or you are used to too much 2.

Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving.

2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

170E-5 Series

00 Index and foreword

3) 4)

3.

When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work.

Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the 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 machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out.

2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.

3) Before starting work, stop the engine.

When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts.

4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first.

5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

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 wiring. Damaged wiring may cause electrical fires.

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SEN00193-01

8)

9) 10)

11)

12)

13) 14) 15)

16)

When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires.

As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.

Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated.

When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check 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 installed.

When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

When measuring hydraulic pressure, check that the measuring tools are correctly assembled.

Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

3

SEN00193-01

4.

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.

3) Keep putting on gloves during sling work.

(Put on leather gloves, if available.)

4) Measure the weight of the load by the eye and check its center of gravity.

5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.

6) Do not sling a load with 1 wire rope alone.

If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

7) Limit the hanging angle to 60째, as a rule.

Do not sling a heavy load with ropes forming 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 allowable 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 sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended.

This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120째. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150째, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

00 Index and foreword

8)

When installing wire ropes to an angular load, apply pads to protect the wire ropes.

If the load is slippery, apply proper material to prevent the wire rope from slipping.

9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.

10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

170E-5 Series

00 Index and foreword

If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly.

13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN00193-01

13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state.

14) If you find an obstacle around the hoist, stop the operation.

15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

q

5.

6.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.

Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4.

1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety.

2) Observe the signs for sling work.

3) Operate the hoist at a safe place.

4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail.

5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging.

6) Do not raise or lower a load while the 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 immediately in an emergency.

170E-5 Series

7.

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard “Z� twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

a

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

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SEN00193-01

How to read the shop manual q q q

1.

00 Index and foreword

1

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.

Materials and specifications are subject to change without notice.

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.

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) 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

00 Index and foreword

3.

4.

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.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically.

Symbol

Item

k

Safety

a

Caution

4

Weight

3

Tightening torque

2

5.

SEN00193-01

Coat

5

Oil, coolant

6

Drain

Remarks Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving standards are necessary when performing work.

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Places that require special attention for tightening torque during assembly.

Places to be coated with adhesives, etc. during assembly.

Places where oil, etc. must be added, and capacity.

Places where oil, etc. must be drained, and quantity to be drained.

Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

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SEN00193-01

00 Index and foreword

Explanation of terms for maintenance standard

1

The maintenance standard values necessary for judgment of products and parts are described by the following 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 temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference 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 120

Tolerance –0.022 –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 indicated by the same standard size and different tolerances of the hole and shaft.

The tightness of fit is decided by the tolerance.

Indication of size of rotating shaft and hole and relationship drawing of them

q

Example: Standard size 60

8

Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

170E-5 Series

00 Index and foreword

2.

Standard clearance and standard value q The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.

3.

Standard interference q When the size of a hole is smaller than the 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 product 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 various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.

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5.

Clearance limit q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.

6.

Interference limit q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.

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SEN00193-01

Handling electric equipment and hydraulic component

00 Index and foreword

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, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring.

Compared with other electrical components fitted 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 (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

2)

10

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

170E-5 Series

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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 soldering may be damaged, or the wiring may be broken.

4)

High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), 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 connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained.

Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

5)

Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface 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 compressed 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 compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

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11

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3.

Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting.

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 connectors apart. a Never pull with one hand.

2] q

12

00 Index and foreword

When removing from clips 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 stoppers. 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 connectors 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 disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

170E-5 Series

00 Index and foreword

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 damage to the connector pins.

Check that there is no damage or breakage to the outside of the connector. 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 breakage, 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 stopper clicks into position.

3] Correct any protrusion of the boot and any misalignment of the wiring harness.

For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected 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 respectively, push them in until they click 2 times.

1.

2. q q

SEN00193-01

Male connector Female connector Normal locking state (Horizontal): a, b, d Incomplete locking state (Diagonal): c

170E-5 Series

13

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4)

14

00 Index and foreword

Drying wiring harness If there is any oil or dirt on the wiring harness, 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 follows.

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 compressed 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 connector.

After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

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4.

Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control 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 controller.

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 connectors 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 disconnecting 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 connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.

4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

170E-5 Series

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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 performance 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 cleaning 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

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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 equipment, 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 circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

170E-5 Series

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17

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How to read electric wire code a

1

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 symbols. 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 nominal 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 indicated.)

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) Type

Symbol

Low-voltage wire for automobile

AV

Thin-cover low-voltage wire for automobile

AVS

Heat-resistant low-voltAEX age wire for automobile

18

Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

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2.

SEN00193-01

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 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.)

AVS Standard CovAV Standard er D AEX Standard

8

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“f” of nominal No. denotes flexible”.

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3.

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Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red 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 Charge Ground Start Light Instrument Signal Type of circuit Others

20

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

WG

–

–

–

–

–

–

–

–

–

–

–

–

–

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

–

–

–

–

–

–

–

–

–

–

– –

–

R B R D Y G L

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

YW GL

– – – –

Gr Br –

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SEN00193-01

Method of disassembling and connecting push-pull type coupler k k

1

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.

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.

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21

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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 hexagonal 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 disconnect it. (Fig. 8)

2.

Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

22

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SEN00193-01

Type 3 1.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect 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 hexagonal portion at the male end. (Fig. 13)

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23

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Standard tightening torque table 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 mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6 – 7.5 98 – 123 10 – 12.5 153 – 190 15.5 – 19.5 235 – 285 23.5 – 29.5 320 – 400 33 – 41 455 – 565 46.5 – 58 610 – 765 62.5 – 78 785 – 980 80 – 100 1,150 – 1,440 118 – 147 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12

24

1

Width across flats mm 10 13 14 27

Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

a Fig. B

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2.

Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt mm 10 12 16

3.

Width across flats mm 14 17 22

Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5

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 mm 14 20 24 33 42

Nominal No. 02 03,04 05,06 10,12 14

4.

SEN00193-01

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor.

363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

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 No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

170E-5 Series

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

25

SEN00193-01

5.

00 Index and foreword

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}

Nominal No. of hose

Width across flats

02

19 22 24 27 32 36 41 46 55

03 04 05 06 (10) (12) (14)

6.

Range

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Thread size (mm) – 14 – 18 22 24 30 33 36 42

Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

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.

mm 6 8 10 12 14

Tightening torque Bolt Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 –

BANJO bolt kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 –

Nm 8± 2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

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 mm 6 8 10 12 14

26

Target

34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Thread size

7.

Taper seal

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

170E-5 Series

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8.

SEN00193-01

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 inch 1/16 1/8 1/4 3/8 1/2 3/4 1

170E-5 Series

Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

27

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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 horizontal 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

(A)

28

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

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SEN00193-01

Millimeters to inches

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

170E-5 Series

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

29

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Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

30

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

170E-5 Series

00 Index and foreword

SEN00193-01

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

170E-5 Series

31

SEN00193-01

00 Index and foreword

Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade 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.

°C –40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

°F –40.0 –31.0 –22.0 –13.0 –4.0

°C –11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

°F 51.8 53.6 55.4 57.2 59.0

°C 7.8 8.3 8.9 9.4 10.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

32

1°C = 33.8°F °F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0

46 47 48 49 50

°F 114.8 116.6 118.4 120.2 122.0

°C 27.2 27.8 28.3 28.9 29.4

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

170E-5 Series

00 Index and foreword

170E-5 Series

SEN00193-01

33

SEN00193-01

KOMATSU 170E-5 Series engine Form No. SEN00193-01

Š 2005 KOMATSU All Rights Reserved Printed in Japan 11-05 (01)

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

SAA6D170E-5

2

Engine serial No.

Applicable machine D375A-5

Bulldozer

PC1250-8

Hydraulic excavator

WA600-6

Wheel loader

HD465-7

Dump truck

HD605-7

Dump truck

170E-5 Series

01 Specification

SEN00195-01

2. Outline of engine q

The 170E-5 engine is a high-performance and high-efficiency engine, which passed strict emission regulations (USA: EPA Regulations for 2006, EU: Regulations for 2006, Japan: Construction machinery regulations for 2006) and attained low fuel consumption, low noise, better exhaust gas color, and high acceleration performance. Accordingly, this newly developed engine is suitable as a power source of construction machinery and industrial machinery used for various purposes.

4)

To secure the high output of the engine, the twin cooling nozzle to cool the piston employed for 170E-3 and after models is improved to increase the durability of the piston and lower the back side temperature of the piston. As a result, the lubricating oil on the piston is not exposed to high temperature, thus it is not deteriorated. Since the high-pressure fuel injection system controlled electronically is employed, less soot is produced and the draining interval of the oil is lengthened.

q

The 170E-5 engine is the successor to the 170E-3 engine. While it is an in-line 6-cylinder, water-cooled, 4-stroke diesel engine, it is equipped with the common rail direct injection system and cooled EGR system of new technologies.

5)

1)

The main components of the cooled EGR system are the EGR cooler of corrugated tube type made of newly developed special stainless steel and the EGR valve driven hydraulically and controlled electronically which KOMATSU developed by itself. The cooled EGR system secures the optimum EGR rate from the low-speed range to the high-speed range to attain both clean exhaust gas and low fuel consumption with the bypass assist circuit consisting of the venturi system and bypass valve which has the same function and structure as those of the EGR valve.

The common rail high-pressure fuel injection system controlled electronically is employed.

This system can inject the fuel at high pressure of 160 MPa {1,600 kg/cm2} from the low-speed range to the high-speed range. In addition, this system can control the form of injection most properly by electronic control according to the speed and load. By heightening the injection accuracy and employing multiple injection, exhaust gas of the cleanest level in the world, good exhaust gas color, low fuel consumption, and low noise are realized simultaneously.

6)

The main fuel filter of high efficiency and the pre-fuel filter are installed as standard so that the low grade fuel in the market (equivalent to Class NAS12) can be used. In addition, the priming pump used for replacing the filters is electrified to improve serviceability.

7)

The high-quality piston which is made of cast iron and has the 2-stage combustion chamber of a new shape is employed. This piston has a less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas, good exhaust gas color, and low fuel consumption are attained simultaneously, and high durability and reliability are also obtained.

8)

By using the above-mentioned high-pressure fuel injection system controlled electronically, the multiple injection and injection characteristics are set most properly to improve the startability and reduce the white exhaust smoke when the temperature is low.

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.

2)

The special EGR oil pump is employed to generate high oil pressure (1.47 MPa {15 kg/cm2}) as the drive power source of the EGR valve driven hydraulically and controlled electronically. This pump has sufficient delivery for the EGR valve and increased output of the engine.

As a result, the reliability and durability of the engine are improved.

3)

The 170E-5 engine has 3 combination filters of high performance and high efficiency to meet the requirements of the EGR system and highdispersion oil and improve the ability to capture the soot in the oil. In addition, the recommended sub-materials for operation (oil and fuel) are changed to improve the reliability and durability of the engine.

170E-5 Series

3

SEN00195-01

01 Specification

10) The improved type of the KTR130 turbocharger 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 lowspeed 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 maintained.

4

170E-5 Series

01 Specification

SEN00195-01

Specifications

1 Engine name

SAA6D170E-5

Applicable machine

D375A-5 mm l {cc} —

6 – 170 × 170 23.15 {23,152} 1–5–3–6–2–4

Overall length

mm

1,823

Overall width

mm

1,157

Overall height (excluding exhaust pipe)

mm

1,697

Overall height (including exhaust pipe)

mm

—

Rated output

kW{HP}/rpm

452 {606}/1,800 (Gross)

Max. torque

Nm{kgm}/rpm

3,020 {308.0}/1,300 (Gross)

No-load max. speed (High idle speed)

rpm

7,900 ± 20

No-load min. speed (Low idle speed)

rpm

720 ± 30

g/kW·h {g/HP·h}

227 {169}

Dry weight

kg

2,970

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

l

80 (80)

Quantity of coolant

l

44 (For only engine)

Alternator Starting motor Battery

— — —

24V, 60A, 90A 24V, 7.5kW × 2 12V, 200Ah × 2

Turbocharger Air compressor Others

— — —

KOMATSU KTR130E — With air-cooled aftercooler With cooled EGR

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

170E-5 Series

5

SEN00195-01

01 Specification

Engine name

SAA6D170E-5

Applicable machine

PC1250-8 mm l {cc} —

6 – 170 × 170 23.15 {23,152} 1–5–3–6–2–4

Overall length

mm

1,783

Overall width

mm

1,176

Overall height (excluding exhaust pipe)

mm

1,707

Overall height (including exhaust pipe)

mm

—

Rated output

kW{HP}/rpm

515 {690}/1,800 (Gross)

Max. torque

Nm{kgm}/rpm

3,025 {308.5}/1,300 (Gross)

No-load max. speed (High idle speed)

rpm

2,000 ± 40

No-load min. speed (Low idle speed)

rpm

900 ± 25

g/kW·h {g/HP·h}

218 {162}

Dry weight

kg

3,140

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

l

80 (80)

Quantity of coolant

l

44 (For only engine)

Alternator Starting motor Battery

— — —

24V, 60A, 90A 24V, 11kW × 2 12V, 200Ah × 2

Turbocharger Air compressor Others

— — —

KOMATSU KTR130E — With air-cooled aftercooler With cooled EGR

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

6

170E-5 Series

01 Specification

SEN00195-01

Engine name

SAA6D170E-5

Applicable machine

WA600-6 mm l {cc} —

6 – 170 × 170 23.15 {23,152} 1–5–3–6–2–4

Overall length

mm

1,784

Overall width

mm

1,115

Overall height (excluding exhaust pipe)

mm

1,752

Overall height (including exhaust pipe)

mm

—

Rated output

kW{HP}/rpm

396 {531}/1,800 (Gross)

Max. torque

Nm{kgm}/rpm

2,594 {264.5}/1,000 (Gross)

No-load max. speed (High idle speed)

rpm

2,000 ± 50

No-load min. speed (Low idle speed)

rpm

800 ± 25

g/kW·h {g/HP·h}

227 {169}

Dry weight

kg

3,050

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

l

80 (80)

Quantity of coolant

l

44 (For only engine)

Alternator Starting motor Battery

— — —

24V, 90A 24V, 11kW × 2 12V, 200Ah × 2

Turbocharger Air compressor Others

— — —

KOMATSU KTR130E — With air-cooled aftercooler With cooled EGR

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

170E-5 Series

7

SEN00195-01

01 Specification

Engine name

SAA6D170E-5

Applicable machine

HD465-7, HD605-7 mm l {cc} —

6 – 170 × 170 23.15 {23,152} 1–5–3–6–2–4

Overall length

mm

1,867

Overall width

mm

1,243

Overall height (excluding exhaust pipe)

mm

1,732

Overall height (including exhaust pipe)

mm

—

Rated output

kW{HP}/rpm

552 {740}/2,000 (Gross)

Max. torque

Nm{kgm}/rpm

3,324 {339.0}/1,400 (Gross)

No-load max. speed (High idle speed)

rpm

2,270 ± 50

No-load min. speed (Low idle speed)

rpm

750 ± 50

g/kW·h {g/HP·h}

216 {161}

Dry weight

kg

3,120

Fuel supply pump Governor

— —

DENSO ECD-U2 Electronic control type

Quantity of lubricating oil (Refill capacity)

l

80 (80)

Quantity of coolant

l

44 (For only engine)

Alternator Starting motor Battery

— — —

24V, 60A, 90A 24V, 7.5kW × 2 12V, 200Ah × 2

Turbocharger Air compressor Others

— — —

KOMATSU KTR130E — With air-cooled aftercooler With cooled EGR

Performance

Dimensions

Number of cylinders – Bore × Stroke Total displacement Firing order

Fuel consumption ratio at rated output

8

170E-5 Series

01 Specification

170E-5 Series

SEN00195-01

9

SEN00195-01

General view

01 Specification

1

SAA6D170E-5 (Left side of engine) Applicable machine: D375A-5

a a

The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.

1.

2.

Center of crankshaft Rear face of flywheel housing

10

170E-5 Series

01 Specification

SEN00195-01

SAA6D170E-5 (Front side of engine) Applicable machine: D375A-5

a a

The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.

1.

2.

Center of crankshaft Center of cylinder liner

170E-5 Series

11

SEN00195-01

01 Specification

SAA6D170E-5 (Left side of engine) Applicable machine: PC1250-8

a a

The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.

1.

2.

Center of crankshaft Rear face of flywheel housing

12

170E-5 Series

01 Specification

SEN00195-01

SAA6D170E-5 (Front side of engine) Applicable machine: PC1250-8

a a

The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.

1.

2.

Center of crankshaft Center of cylinder liner

170E-5 Series

13

SEN00195-01

01 Specification

SAA6D170E-5 (Left side of engine) Applicable machine: WA600-6

a a

The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.

1.

2.

Center of crankshaft Rear face of flywheel housing

14

170E-5 Series

01 Specification

SEN00195-01

SAA6D170E-5 (Front side of engine) Applicable machine: WA600-6

a a

The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.

1.

2.

Center of crankshaft Center of cylinder liner

170E-5 Series

15

SEN00195-01

01 Specification

SAA6D170E-5 (Left side of engine) Applicable machine: HD465-7, HD605-7

a a

The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.

1.

2.

Center of crankshaft Rear face of flywheel housing

16

170E-5 Series

01 Specification

SEN00195-01

SAA6D170E-5 (Front side of engine) Applicable machine: HD465-7, HD605-7

a a

The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.

1.

2.

Center of crankshaft Center of cylinder liner

170E-5 Series

17

SEN00195-01

01 Specification

Dimensions table Unit: mm Engine

SAA6D170E-5

a

18

Machine

Dimension of each part A

B

C

D

E

D375A-5

1,854

2,130

PC1250-8

1,800

2,032

WA600-6

1,795

HD465-7 HD605-7

2,044

F

G

H

550

25

560

222

—

—

1,107

1,300

—

1,000

1,185

1,215

1,935

543

41

41

930

1,060

1,154

1,732

550

210

—

346

396

1,243

These dimensions are given for reference when the engine is set on a test bench.

170E-5 Series

01 Specification

SEN00195-01

Weight table

1 Unit: kg

No.

1

Item

Turbocharger

Main parts

KOMATSU KTR130E

SAA6D170E-5 D375A-5

33.5

PC1250-8

36

WA600-6

33.5

HD465-7 HD605-7

36

2

Cylinder head assembly

Cylinder head, valve, valve spring

3

Cylinder block assembly

Cylinder block, bearing, cap, cylinder liner

4

Front cover

47

5

Oil pan

56

6

7

Flywheel assembly

Flywheel, ring gear

Flywheel housing assembly

46.5 Ă— 6 750

D375A-5

82

PC1250-8

80

WA600-6

36

HD465-7 HD605-7

43

D375A-5

170

PC1250-8

150

WA600-6

150

HD465-7 HD605-7

150

8

Crankshaft assembly

Crankshaft, crank gear

265

9

Camshaft assembly

Camshaft, cam gear, thrust plate

51

10

Piston and connecting rod assembly

Piston, piston ring, piston pin, connecting rod

11

Oil pump

10.2

12

Fuel supply pump

14.8

13

Water pump

22 Ă— 6

16.2 24V, 60A

11

24V, 90A

19

24V, 7.5kW

18

14

Alternator

15

Starting motor

16

EGR oil pump

5.5

17

EGR valve

9.8

18

EGR cooler

11.5

19

EGR bypass valve ( 1)

9.8

24V, 11kW

18

1: There may not be equipped according to the machine model.

170E-5 Series

19

SEN00195-01

01 Specification

Engine performance curves Engine

SAA6D170E-5

20

Engine serial No.

1 Applicable machine

Page

D375A-5

21

PC1250-8

22

WA600-6

23

HD465-7, HD605-7

24

170E-5 Series

01 Specification

SEN00195-01

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

SEN00195-01

01 Specification

SAA6D170E-5 (Applicable machine: PC1250-8) Rated output: 515 kW {690 HP}/1,800 rpm (Gross) Max. torque: 3,025 Nm {308.5 kgm}/1,300 rpm (Gross)

22

170E-5 Series

01 Specification

SEN00195-01

SAA6D170E-5 (Applicable machine: WA600-6) Rated output: 396 kW {531 HP}/1,800 rpm (Gross) Max. torque: 2,594 Nm {264.5 kgm}/1,000 rpm (Gross)

170E-5 Series

23

SEN00195-01

01 Specification

SAA6D170E-5 (Applicable machine: HD465-7, HD605-7) Rated output: 552 kW {740 HP}/2,000 rpm (Gross) Max. torque: 3,324 Nm {339.0 kgm}/1,400 rpm (Gross)

24

170E-5 Series

01 Specification

170E-5 Series

SEN00195-01

25

SEN00195-01

01 Specification

KOMATSU 170E-5 Series engine Form No. SEN00195-01

Š 2005 KOMATSU All Rights Reserved Printed in Japan 11-05 (01)

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

10 Structure, function and maintenance standard

170E-5 Series

SEN00197-01

3

SEN00197-01

10 Structure, function and maintenance standard

Intake and exhaust system

1

Air cleaner

1

ERB type [Air cleaner of automatic exhaust gas discharge type (Radial seal type)]

a

The shape is subject to machine models.

A: B: C:

Air inlet To turbocharger (Intake air) To muffler (Dust)

1.

2.

3.

Inner element Outer element Check valve

4.

5.

6.

Tube Pre-cleaner Air cleaner body

Engine

Applicable machine

Type

Method of discharging dust from pre-cleaner

Number of elements

SAA6D170E-5

D375A-5 PC1250-8 WA600-6

Komaclone, multi-cyclone (ERB type)

Automatic discharge (Exhaust ejector)

1 inner element 1 outer element

4

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

FRG type [Air cleaner of cyclone pack type with evacuator valve (Radial seal type)]

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

Inlet Outlet Guide vane Primary element Safety element

6.

7.

8.

9.

10.

Evacuator valve Dust pan Guide plate (Sleeve) Body Element

Engine

Applicable machine

Type

Evacuator valve

Number of elements

SAA6D170E-5

HD465-7 HD605-7

FRG (Radial seal type)

Automatic discharge

1 inner cylinder, 1 outer cylinder

Structure q The size of the body is reduced from the conventional type without changing the diameter of the element. q Since the inlet is set in the tangential direction, air is given sufficient centrifugal force by the simple spiral guide vane, not by the guide plate.

170E-5 Series

Operation q Air containing dust is sucked in vertically through inlet (1) and the dust is separated by the centrifugal effect of guide vane (3). q More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the engine through safety element (5) and outlet (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 discharged out automatically.

5

SEN00197-01

Turbocharger

10 Structure, function and maintenance standard

1

Model name: KTR130E (Water-cooled)

6

170E-5 Series

10 Structure, function and maintenance standard

A: B: C: D: E: F: G:

Intake air inlet Intake air outlet Exhaust gas inlet Exhaust gas outlet Oil inlet Oil outlet Coolant

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Blower housing V-band Center housing Shield Turbine housing Turbine impeller Seal ring Journal bearing Thrust bearing Seal ring Blower impeller

Specifications Model: KOMATSU KTR130E (Water-cooled) Overall length: 343 mm Overall width: 390 mm Overall height: 344 mm Weight: 35.5 kg

SEN00197-01

Structure and operation of turbocharger q The turbocharger has turbine impeller (6) which is rotated by the high-speed exhaust gas. Blower impeller (11) on the same shaft with the turbine impeller is also rotated to supercharge the engine with air. q The shaft connecting the turbine impeller and blower impeller is usually made in one unit together with the turbine impeller. The blower impeller is fixed with a nut to the opposite shaft end of the turbine impeller. q The shaft rotates at very high speed of 50,000 – 100,000 rpm and receives the thrust load generated by the intake air and exhaust gas and applied to the impellers. q Accordingly, the shaft is supported on cylindrical floating journal bearing (8) and thrust bearing (9). q Center housing (3) supports the bearings and has oil passages to lubricate the bearings. q The lubricated parts, exhaust side, and air intake side are sealed by seal rings (7), (10). q Turbine housing (5) houses turbine impeller (6) and leads the exhaust gas from the exhaust manifold to the turbine impeller. The exhaust gas rotates the impeller at high speed and 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 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.

q

170E-5 Series

7

SEN00197-01

10 Structure, function and maintenance standard

Model name: KTR130E

8

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

Unit: mm No.

Check item

1

End play (Play in axial direction)

2

Radial play (Play in radial direction)

3

Clearance between blower housing and impeller

170E-5 Series

Criteria

Remedy

Standard

Repair limit

0.08 – 0.13

0.18

0.36 – 0.55

0.77

Replace core assembly

Clearance limit (Min.): 0.18

9

SEN00197-01

10

10 Structure, function and maintenance standard

170E-5 Series

10 Structure, function and maintenance standard

EGR system

No. 1

SEN00197-01

1

Component part

Function

• Controls the gas flow from the exhaust system to the air intake system.

EGR valve (driven hydrau• Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the lically) exhaust gas flows to the air intake valve.

2

Bypass valve ( 1)

• Opens the bypass valve when the boost pressure (PIN) is higher than the exhaust pressure (PEX).

• 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.

5

Each sensor

• Controls the EGR according to the operating condition.

• Troubleshoots the system.

1: There may not be equipped according to the machine model.

Features 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 troubleshooted, a serious trouble is prevented. q

170E-5 Series

11

SEN00197-01

a

12

10 Structure, function and maintenance standard

The above illustration shows the engine for HD465-7 and HD605-7.

170E-5 Series

10 Structure, function and maintenance standard

1.

2.

3.

4.

5.

6.

7.

8.

9.

SEN00197-01

EGR valve Bypass valve EGR cooler Venturi system EGR valve position sensor Bypass valve position sensor ( 1) Bypass piping ( 1) EGR piping EGR oil pump

Operation q The engine controller outputs signals for opening 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 manifold 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 pressure 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

SEN00197-01

10 Structure, function and maintenance standard

EGR valve and bypass valve

A: B: C: D:

Oil inlet Oil outlet EGR gas passage (EGR valve) Boost air passage (Bypass valve) ( 1)

Function q The EGR valve controls the EGR gas. q This valve is driven hydraulically and its opening ratio is controlled electronically.

Operation The oil pressure (engine oil) of 1.47 MPa {15 kg/cm2} supplied to oil inlet (A) is reduced by oil pressure control valve (2). q Hydraulic piston (5) generates pressing force from the reduced oil pressure. q The control oil pressure can be changed with the drive current of solenoid (3). q

14

1.

2.

3.

4.

5.

6.

7.

Stick prevention device Oil pressure control valve Solenoid Position sensor Hydraulic piston Spring Valve

q

Valve (7) is closed by spring (6) but pushed open by hydraulic piston (5) to an opening ratio in proportion to the control oil pressure.

The valve opening ratio is sensed with position sensor (4) installed to hydraulic piston (5) and set to the specified opening ratio by controlling the solenoid current.

The bypass valve assists the EGR gas by increasing the exhaust pressure. ( 1) The structure and operation of the EGR bypass valve are the same as those of the EGR valve.

q

q q

1: There may not be equipped according to the machine model.

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

EGR cooler

A: B: C:

EGR gas inlet EGR gas outlet Coolant inlet

1.

Heat exchange tube (Corrugated tube)

D: E:

Coolant outlet Air bleeder

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 efficiency.

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 corrosionresistant stainless steel and corrugated to increase the cooling efficiency.

170E-5 Series

15

SEN00197-01

10 Structure, function and maintenance standard

Venturi system

A: B:

Air inlet EGR gas inlet

1.

2.

3.

Venturi nozzle Throat Diffuser

Structure q The EGR gas and intake air mix together in the venturi system. q The venturi system consists of throat (2), venturi nozzle (1), and diffuser (3).

Operation The boost pressure increased by the turbocharger 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. q

16

170E-5 Series

10 Structure, function and maintenance standard

170E-5 Series

SEN00197-01

17

SEN00197-01

10 Structure, function and maintenance standard

Engine unit Cylinder head

a

The shape is subject to machine models.

a.

Fuel return

1.

2.

3.

4.

5.

6.

Cylinder head Rocker arm housing Cylinder head cover Valve guide Injector Coolant air bleeder tube

18

1 1

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

Specifications Cylinder head q Direct injection type q 4-valve type q Split type (1 cylinder, 1 head) Valve seat insert Intake valve insert q Exhaust valve insert Both of these inserts are press fitted to the seats. q

170E-5 Series

19

SEN00197-01

a

10 Structure, function and maintenance standard

Tighten the cylinder head mounting bolts in the order of (1) – (9).

Unit: mm No.

Check item

1

Strain of cylinder head mounting surface

2

Projection of nozzle

3

Tightening torque of cylinder head mounting bolt (apply anti-friction compound to bolt threads and washer)

4

Tightening torque of injector mounting bolt

5

Tightening torque of rocker arm housing mounting bolt

Criteria

Remedy

Tolerance

Repair limit

Max. 0.05

0.1

Engine

Standard

SAA6D170E-5

2.3 – 2.9

Bolt No. (1) – (7)

Procedure

Target (Nm{kgm}) Range (Nm{kgm}) 245 {25}

235 – 255 {24 – 26}

2nd stage

382 {39}

373 – 392 {38 – 40}

3rd stage

Retighten 90°

90(+30/0)°

—

98 {10}

93 – 103 {9.5 – 10.5}

Target (Nm {kgm})

Range (Nm {kgm})

66.7 {6.75}

58.8 – 73.5 {6 – 7.5}

86{8.75}

78 – 93 {8.0 – 9.5} Target (Nm {kgm})

6

7

20

Tightening torque of cylinder head cover Tightening torque of fuel injection pipe

Replace nozzle gasket

1st stage

(8) – (9)

Correct by grinding or replace

Tighten in order shown above

Range (Nm {kgm}) Tighten

No.1, 3 – 6 cylinders

10 {1}

9 – 11 {0.9 – 1.1}

No.2 cylinder

66.7 {6.75}

58.8 – 73.5 {6 – 7.5}

Target (Nm {kgm})

Range (Nm {kgm})

41.7 {4.25}

39.2 – 44.1 {4 – 4.5}

170E-5 Series

10 Structure, function and maintenance standard

170E-5 Series

SEN00197-01

21

SEN00197-01

Cylinder block

1.

2.

3.

4.

5.

6.

7.

22

Front cover Cylinder block Cylinder liner Clevis seal Liner O-ring Liner O-ring Thrust bearing

10 Structure, function and maintenance standard

1

8.

9.

10.

11.

12.

13.

Main bearing Main bearing cap Main bearing cap bolt Front oil seal Piston cooling nozzle Oil level gauge

170E-5 Series

10 Structure, function and maintenance standard

Specifications Cylinder block q Crankshaft section: 7 bearings q Camshaft section: High cam type, 7 bearings q Main cap bolt: Plastic-region tightening

SEN00197-01

Liner ring q Upper : Clevis seal q Middle : O-ring (Ethylene-propylene rubber) q Lower : O-ring (Silicone rubber)

Front seal q End seal with dust cover Piston cooling With piston cooling nozzle (2 pieces for each cylinder)

q

Cylinder liner q Wet type q Machining on inside: Plateau honing,Tufftriding

170E-5 Series

23

SEN00197-01

24

10 Structure, function and maintenance standard

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

Unit: mm No.

1

Check item

Clearance between cylinder block and liner

Criteria Standard size

Standard Clearance Inside diame- Outside diame- clearance Replace cylinlimit ter of block ter of block der liner or block –0.00 –0.11 0.05 – 0.16 — –0.06 –0.16

190.4 Inside diameter of main bearing fitting hole (Tighten bolt to specified torque) 2

Standard size

Tolerance

Repair limit

148

+0.025 –0.001

—

Thickness of main bearing

4.0

–0.038 –0.051

—

Inside diameter of main bearing

140

+0.127 +0.076

140.20

Clearance between main bearing and crankshaft bearing 3

4

Remedy

Tolerance

Interference of cap and cylinder block Inside diameter of camshaft bushing

Replace

Standard clearance

Clearance limit

0.076 – 0.152

0.32

Standard interference

Interference limit

0.090 – 0.140

0.05

Standard size

Tolerance

Repair limit

90

+0.222 +0.112

90.23

Clearance of camshaft bearing

Standard clearance

Clearance limit

0.077 – 0.217

0.25

5

Strain of cylinder head mounting face

Tolerance

Repair limit

0.09

0.15

6

Tightening torque of main bearing cap mounting bolt (Apply engine oil to threads and washer)

170E-5 Series

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st stage

284 {29}

270 – 299 {27.5 – 30.5}

2nd stage

569 {58}

559 – 579 {57.0 – 59.0}

3rd stage

Retighten 90°

90(+30/0)°

Correct or replace

Retighten

25

SEN00197-01

10 Structure, function and maintenance standard

Cylinder liner

A. B.

1

Cylinder liner section Cylinder block section Unit: mm

No. 1

2

3

Check item Projection of cylinder liner

5

6

26

Remedy

Permissible range: 0.07 – 0.15 Difference between cylinders: Max. 0.05

Replace cylinder liner or cylinder block

Standard size

Tolerance

Repair limit

170

+0.040 +0.000

170.24

Inside diameter of cylinder liner Roundness of inside

0.020

0.08

Cylindricality of inside

0.020

0.08

Outside diameter of cylinder liner (at bottom of counterbore portion) Interference of cylinder liner and block (at bottom of counterbore portion) Outside diameter of cylinder liner (at counterbore portion)

4

Criteria

Standard size

Tolerance

194.5

194.565 – 194.615

Standard interference: 0.025 – 0.135 Standard size

Tolerance

206

205.965 – 206.015

Standard clearance

Clearance limit

Interference: 0.85 to Clearance: 0.025

—

Outside diameter of cylinder liner (at O-ring)

Standard size

Tolerance

190.40

190.24 – 190.29

Clearance between cylinder liner and block (at O-ring)

Standard clearance

Clearance limit

0.05 – 0.16

—

Dispersion of depth of counterbore

Standard

Repair limit

—

0.05

Interference of cylinder liner and block (at counterbore portion)

Replace cylinder liner

Correct by grinding

170E-5 Series

10 Structure, function and maintenance standard

Main moving parts

1

a a

The shape is subject to machine models.

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.

2.

3.

4.

5.

6.

7.

8.

9.

Piston pin Connecting rod Connecting rod bushing Piston (FCD piston type) Top ring Second ring Oil ring Camshaft drive gear (Number of teeth: 63) Main bearing

170E-5 Series

SEN00197-01

10.

11.

12.

13.

14.

15.

16.

17.

Thrust bearing Crankshaft Connecting rod cap Connecting rod cap bolt Connecting rod bearing Crank gear (Number of teeth: 55) Vibration damper Crank pulley

27

SEN00197-01

10 Structure, function and maintenance standard

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 Upper main bearing: With oil groove Connecting rod Made of forged alloy steel

Piston rings Top ring (1) : Inner cut, barrel face, ion plating Second ring (2) : Inner cut, taper face, hard chromium-plated Oil ring (3) : Bevel cutter, surface nitriding

Camshaft Journal and fillet: Induction hardening

28

170E-5 Series

10 Structure, function and maintenance standard

170E-5 Series

SEN00197-01

29

SEN00197-01

Crankshaft

30

10 Structure, function and maintenance standard

1

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

Unit: mm No.

1

2

3

Check item

Outside diameter of main journal

Outside diameter of crank pin journal

Roundness of journal

4

End play

5

Thickness of main bearing (Median)

6

Outside diameter of rear flange

7

Bend or crankshaft (Overall swing of indicator)

8

Tightening torque of crank pulley mounting bolt

170E-5 Series

Criteria Size

Standard size

S.T.D.

140

0.25 U.S.

139.75

0.50 U.S.

139.50

0.75 U.S.

139.25

1.00 U.S.

139.00

Size

Standard size

Remedy Tolerance

Repair limit 139.91 139.66

–0.000 –0.025

139.41 139.16 138.91

Tolerance

Repair limit

S.T.D.

108.00

107.91

0.25 U.S.

107.75

107.66

0.50 U.S.

107.50

0.75 U.S.

107.25

1.00 U.S.

107.00

–0.000 –0.022

107.41 107.16 106.91

Standard

Repair limit

Main journal

Max. 0.010

0.015

Crank pin journal

Max. 0.010

0.015

Tolerance

Repair limit

0.14 – 0.32

0.6

Standard size

Tolerance

Repair limit

4.0

–0.038 –0.051

3.90

170

±0.019

—

Tolerance

Use undersize journal or replace

Replace

Repair limit

0.09

0.09

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st stage

74 {7.5}

54 – 93 {5.5 – 9.5}

2nd stage

245 {25}

226 – 265 {23 – 27}

3rd stage

637 {65}

618 – 657 {63 – 67}

Tighten

31

SEN00197-01

10 Structure, function and maintenance standard

Camshaft

1

Unit: mm No.

1

Check item

Height of cam

Criteria

Remedy

Standard size

Tolerance

Repair limit

Intake cam

78.233

+0.103 –0.103

78.00

Exhaust cam

77.252

+0.103 –0.103

77.00

2

Outside diameter of journal

90

–0.035 –0.005

89.98

3

Thickness of thrust plate

5

–0.00 –0.05

3.20

4

End play of camshaft

5

Bend of camshaft

32

Correct or replace

Replace

Standard clearance

Clearance limit

0.05 – 0.20

0.40

Repair limit: 0.20 (Overall swing of indicator)

Replace thrust plate Replace

170E-5 Series

10 Structure, function and maintenance standard

Connecting rod

SEN00197-01

1

Unit: mm No.

1

Check item Clearance between connecting rod bushing and piston pin

2

Inside diameter of connecting rod large end hole

3

Clearance between connecting rod large end bearing and crankshaft bearing

4

Thickness of bearing (at center)

Criteria Standard size 68

Tolerance Shaft

Hole

–0.000 –0.006

+0.049 +0.030

Remedy Standard clearance

Clearance limit Replace (Spare bushing is half worked) 0.030 – 0.055 0.075

Standard size

Tolerance

115

+0.026 –0.000

Standard clearance

Clearance limit

0.058 – 0.132

0.34

Size

Standard size

Tolerance

S.T.D.

3.500

3.41

0.25 U.S.

3.625

3.54

0.50 U.S.

3.750

0.75 U.S.

3.875

1.00 U.S.

4.000

–0.029 –0.042

5

Bend and twist of connecting rod

Bend limit: 0.10

6

Weight of connecting rod

10.29 ± 0.03 kg

8

Tightening torque of connecting rod cap mounting bolt (Apply engine oil to bolt threads and washer)

170E-5 Series

Repair limit Replace

3.66 3.79 3.91

Twist limit: 0.25 Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st stage

196 {20}

186 – 206 {19 – 21}

2nd stage

Retighten 90°

Retighten 90 (+15/0)°

Tighten

33

SEN00197-01

10 Structure, function and maintenance standard

Piston, piston ring and piston pin

1

FCD piston type

Unit: mm No. 1

Check item

Criteria

Standard size Outside diameter of piston (at 3.0 mm from pis170 ton bottom and 20°C) (At right angles to boss)

Tolerance

Repair limit

–0.135 –0.165

169.79

Standard size 2

Piston ring groove

Top ring second ring

Keystone Keystone

Oil ring

4.00

Tolerance Ring groove

Closed gap of piston ring

4

Diameter of piston pin hole

5

Outside diameter of piston pin

34

Top ring

Ring thickness

Clearance limit (When ring is new)

Check with piston groove wear gauge or check clearance between piston and new ring +0.05 +0.03

Standard clearance 3

Remedy

0.15

–0.01 –0.03

0.3

Replace

Clearance limit

0.50 – 0.65

Second ring

0.70 – 0.85

Oil ring

0.50 – 0.70

1.8

Standard size

Tolerance

68

+0.044 +0.034

68

–0.000 –0.006

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

Flywheel and flywheel housing 1

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

6.

Rear seal Ring gear (Number of teeth: 118 (Only D375A-5: 138)) Flywheel Flywheel housing Engine speed sensor Burring device (Service tool)

170E-5 Series

35

SEN00197-01

Vibration damper

10 Structure, function and maintenance standard

1

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

6.

Crank pulley Pin (between crankshaft and crank pulley) Pin (between crank pulley and vibration damper) Vibration damper Bolt (between crank pulley and vibration damper) Bolt (between crankshaft and crank pulley)

36

170E-5 Series

10 Structure, function and maintenance standard

Gear train

SEN00197-01

1

Front side (for driving auxiliaries)

1.

2.

3.

4.

5.

6.

7.

Oil pump drive gear (Number of teeth: 38) Water pump drive gear (Number of teeth: 31) Idler gear (Number of teeth: 84) Crankshaft gear (Number of teeth: 55) EGR oil pump drive gear (Number of teeth: 43) Idler gear (Number of teeth: 67) Alternator drive gear (Number of teeth: 55)

170E-5 Series

37

SEN00197-01

10 Structure, function and maintenance standard

Front side

38

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

Unit: mm No.

1

Check item Clearance between idler gear (large) bushing and shaft

2

Clearance between idler gear (medium) bushing and shaft

3

Clearance of idler gear (large) in axial direction

4

Clearance of idler gear (medium) in axial direction

5

Level difference between underside surfaces of gear train case cover and cylinder block

Criteria Standard size

Remedy

Shaft

Hole

Standard clearance

Clearance limit

47.6

+0.014 +0.001

+0.063 +0.039

0.025 – 0.062

0.25

47.6

+0.014 +0.001

+0.063 +0.039

0.025 – 0.062

0.25

Standard clearance

Clearance limit

0.05 – 0.17

0.34

0.05 – 0.17

0.34

Check parts

Correct or replace Standard

Repair limit

A

Crank gear and main idler gear (large)

0.134 – 0.326

0.5

B

Crank gear and main idler gear (medium)

0.114 – 0.320

—

C

Idler gear (medium) and alternator 0.114 – 0.320 drive gear

0.5

D

Idler gear (large) and water pump 0.121 – 0.333 drive gear

0.5

E

Idler gear (large) and oil pump drive gear

0.5

— Backlash of each gear

Replace bushing

Replace thrust bearing

Tolerance: 0.15 Position

170E-5 Series

Tolerance

0.121 – 0.333

Replace

39

SEN00197-01

10 Structure, function and maintenance standard

Timing gear

1

Rear side (for driving camshaft)

A: B: C: 1.

2.

3.

4.

5.

40

Timing mark (Between crankshaft gear and idler gear) Timing mark (Between idler gear and crankshaft gear) Timing mark (Between camshaft gear and supply pump drive gear) Crankshaft gear (Number of teeth: 63) Idler gear (Number of teeth: 72) Idler gear (Number of teeth: 40) Camshaft gear (Number of teeth: 70) Fuel supply pump drive gear (Number of teeth: 70)

170E-5 Series

10 Structure, function and maintenance standard

170E-5 Series

SEN00197-01

41

SEN00197-01

42

10 Structure, function and maintenance standard

170E-5 Series

10 Structure, function and maintenance standard

SEN00197-01

Unit: mm No.

1

2

Check item Clearance between idler gear bushing and shaft

Criteria Standard size 52

Clearance of idler gear in axial direction Position

Remedy

Shaft

Hole

Standard clearance

–0.027 –0.040

+0.055 +0.000

0.027 – 0.095

Clearance limit Replace bushing 0.25

Standard clearance

Clearance limit

0.04 – 0.18

0.3

Check parts

Replace thrust bearing

Standard

Repair limit

A

Crank gear and main idler gear (large)

0.155 – 0.412

0.6

B

Idler gear (small) and camshaft gear

0.145 – 0.380

0.6

C

Camshaft gear and fuel supply pump drive gear

0.007 – 0.559

0.6

— Backlash of each gear

170E-5 Series

Tolerance

Replace

43

SEN00197-01

Valve system

10 Structure, function and maintenance standard

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.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Intake valve Exhaust valve Rocker arm (for intake) Rocker arm (for exhaust) Camshaft Camshaft gear (Number of teeth: 70) Lower spring seat Spring Upper spring seat Locknut (for cross head) Adjustment screw (for cross head)

44

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Cross head Adjustment screw Locknut Push rod (for intake) Push rod (for exhaust) Injector Cam roller Cam follower pin Cam follower Cam follower shaft Oil seal (for intake and exhaust)

170E-5 Series

10 Structure, function and maintenance standard

Intake/Exhaust side of No. 1 cylinder

SEN00197-01

Valve timing

Specifications Camshaft: Made of special carbon steel, 7 bearings Journal and cam: Induction hardening

170E-5 Series

45

SEN00197-01

10 Structure, function and maintenance standard

Valve and valve guide

1

Unit: mm No.

Check item

1

Sinking distance of valve

2

Thickness of valve lip

Criteria

Remedy

Standard

Repair limit

0

0.80

Intake and exhaust valves

Standard size

Tolerance

Repair limit

Intake valve

3.2

—

2.7

Exhaust valve

3.3

—

2.8

Standard 3

4

5

Valve seat angle

Diameter of valve stem

Intake valve Exhaust valve

Intake valve

30°

±0°15'

45°

±0°15'

Standard size

Tolerance

Repair limit

–0.060 –0.080

11.90

–0.092 –0.107

11.80

Inside diameter of valve guide

12

–0.001 –0.019

12.10

Projection of valve guide

43

±0.5

—

Free length

Installed length

Installed load (N {kg})

Allowable load (N {kg})

99.6

87.4

647 ± 65 {66.0 ± 6.6}

608 {62.0}

Valve spring 6 Perpendicularity of valve spring

46

Replace valve

Tolerance

Exhaust valve

12

Replace valve or valve seat

Replace

Repair limit: 2°

170E-5 Series

10 Structure, function and maintenance standard

Rocker arm and shaft

SEN00197-01

1

Intake valve and exhaust valve

Unit: mm No.

Check item Outside diameter of rocker arm shaft

1

3

Valve clearance (cold) Tightening torque of locknut of rocker arm adjustment screw

170E-5 Series

Remedy Tolerance

45.0

–0.0150 –0.0280

45.0

+0.099 +0.024

Standard clearance

Clearance limit

0.039 – 0.127

0.16

Inside diameter of rocker arm bushing Clearance between rocker arm shaft and rocker arm bushing

2

Criteria Standard size

Valve

Standard

Intake valve

0.32

Exhaust valve

0.62

Replace rocker arm shaft Replace rocker arm Replace rocker arm shaft or rocker arm

Tolerance ±0.02

Target (Nm {kgm})

Range (Nm {kgm})

68 {6.9}

58 – 77 {5.9 – 7.9}

Adjust

Tighten

47

SEN00197-01

10 Structure, function and maintenance standard

Crosshead and guide

1

Unit: mm No.

Check item

Tolerance

Repair limit

7.5

+0.3 +0.0

—

Inside diameter of cross head

13

+0.10 +0.05

13.21

Outside diameter of cross head guide

13

+0.039 +0.028

13.00

Depth of cross head stem receiver

2

4

Clearance between cross head guide and cross head Projection of cross head guide

5

Valve clearance (cold)

6

Tightening torque of cross head locknut

48

Remedy

Standard size

1

3

Criteria

Standard clearance

Clearance limit

0.011 – 0.072

—

Standard size

Tolerance

86

±0.25

Intake valve

Exhaust valve

0.32

0.62 59 ± 6Nm {6.0 ± 0.6 kgm}

Replace

Adjust

Replace

Tighten

170E-5 Series

10 Structure, function and maintenance standard

Tappet and push rod

SEN00197-01

1

Intake valve and exhaust valve

Unit: mm No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

25

–0.038 –0.053

25

1

Outside diameter cam follower shaft

2

Inside diameter of cam follower lever

25

+0.021 +0.000

25

Inside diameter of cam follower roller

25.167

±0.01

25.3

Outside diameter of cam follower roller pin

25

+0.075 +0.063

25

4

Outside diameter of cam follower roller

50

+0.025 +0.000

49.75

5

Diameter of ball at push rod end

15.836

–0.0 –0.2

—

6

Inside diameter of push rod socket

16.676

–0.0 –0.2

—

3

170E-5 Series

Replace

49

SEN00197-01

KOMATSU 170E-5 Series engine Form No. SEN00197-01

Š 2005 KOMATSU All Rights Reserved Printed in Japan 11-05 (01)

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

SEN00198-01

10 Structure, function and maintenance standard

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

10 Structure, function and maintenance standard

170E-5 Series

SEN00198-01

3

SEN00198-01

10 Structure, function and maintenance standard

Lubrication system

1

Lubrication system diagram

1

a

4

The shape is subject to machine models.

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

W. Coolant 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Oil pan Oil level sensor Oil pump Regulator valve Oil cooler Thermo-valve Oil filter Safety valve Main gallery Crankshaft Camshaft Rocker arm Piston cooling nozzle Timing gear (Rear side) Auxiliary equipment drive gear (Front side) Oil pressure gauge Turbocharger Bypass valve ( 1) EGR valve EGR oil pump

1: There may not be equipped according to the machine model.

170E-5 Series

5

SEN00198-01

10 Structure, function and maintenance standard

Oil pump

1

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Bushing Drive gear (Number of teeth: 10) Oil pump body Drive shaft Bushing Pump cover Oil pump drive gear (Number of teeth: 38) Bushing Driven gear (Number of teeth: 10) Driven shaft

6

Specifications Type: Gear pump Speed: Engine speed Ă— 1.45

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Oil pump relief valve

1.

2.

Valve Spring

170E-5 Series

7

SEN00198-01

8

10 Structure, function and maintenance standard

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Unit: mm No.

1

Check item

Clearance of pump gear in axial direction

Criteria Standard size 54

Tolerance Thickness of gear

Depth of body

0 –0.030

+0.067 +0.040

Remedy Standard clearance

Clearance limit

0.040 – 0.097

0.040 – 0.097

Standard clearance

Clearance limit

0.15 – 0.25

0.15 – 0.25

Interference

Clearance limit

Replace gear

Tolerance 2

Clearance of pump gear in radial direction

Standard size

54.99

3

4

5

Interference of driven shaft and cover Interference of driven gear and bushing Clearance between driven shaft and driven gear bushing

Standard size

Outside diameter of gear

Inside diameter of body

–0.15 –0.21

+0.04 0

Tolerance Shaft

Hole

18

+0.090 +0.070

+0.040 +0.022

0.030 – 0.068

—

21

+0.090 +0.065

+0.021 0

0.044 – 0.090

—

Standard size

Tolerance Shaft

Hole

Standard clearance

Clearance limit

18

+0.090 +0.070

+0.147 +0.122

0.032 – 0.077

0.032 – 0.077

6

Clearance between driven shaft and body

18

+0.090 +0.070

+0.129 +0.102

0.012 – 0.059

0.012 – 0.059

7

Clearance between drive shaft and bushing

18

+0.106 +0.088

+0.173 +0.146

0.040 – 0.085

0.040 – 0.085

Interference

—

8

Interference of pump gear and drive shaft

Standard size

Tolerance Shaft

Hole

18

+0.106 +0.088

+0.064 +0.043

0.024 – 0.063

—

9

Interference of body and body bushing

21

+0.090 +0.065

+0.021 0

0.044 – 0.090

—

10

Interference of pump drive gear and drive shaft

18

+0.106 +0.088

+0.065 +0.047

0.023 – 0.059

—

11

Tightening torque of pump cover mounting bolt

30.9 ± 3.4 Nm {3.15 ± 0.35 kgm} Standard size

12 Main relief valve spring

Main relief valve operating 13 pressure

170E-5 Series

Free length

Installed length

—

—

Replace bushing

Tighten

Repair limit

Installed load Free length N {kg} 716 {73.0}

—

Standard: 883 ± 49 kPa {9.0 ± 0.5 kg/cm2}

Installed load N {kg}

Replace

— Correct or replace spring

9

SEN00198-01

10 Structure, function and maintenance standard

Oil filter and safety valve

a

The shape is subject to machine models.

A. B.

From oil pump To each part of engine

1.

2.

3.

Safety valve Filter bracket Cartridge

10

1

Specifications Oil filter Filtration area: 0.44 m2 × 3 Safety valve Operating pressure (Differential pressure): 441 ± 19.6 kPa {4.5 ± 0.2 kg/cm2}

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Oil cooler

1

a. b. c. d.

Water drain Oil inlet To each part of engine (Oil) Water inlet

1.

2.

3.

4.

Thermostat cover Thermostat (Thermo-valve) Cooler cover Cooler element

Specifications Oil cooler thermo-valve Opening temperature: 85°C ± 1.5°C Full opening temperature: 100°C Full opening lift: Min. 8 mm Oil cooler Oil cooler: 2 units are installed.

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

No.

Check item Full opening lift of thermostat

5

Criteria

Remedy

Min. 8 mm (Check after soaking valve in oil tank at 100°C for 4 – 5 minutes)

Check that valve closes fully when its temperature is lowered from Replace Opening and closing of ther100°C for full opening to 85°C. (Check after soaking valve in oil mostat tank for 4 – 5 minutes)

170E-5 Series

11

SEN00198-01

10 Structure, function and maintenance standard

Fuel system

1

CRI system diagram

1

a

CRI is an abbreviation for common rail injection.

1.

2.

3.

4.

5.

6.

7.

8.

NE speed sensor Engine controller Injector Orifice (for bleeding air) Fuel tank Pre-fuel filter Main fuel filter Overflow valve

12

9.

Fuel supply pump 9A. PCV 9B. High pressure pump 9C. Priming pump 9D. Feed pump 9E. Relief valve 9F. Bkup speed sensor (G sensor)

10.

11.

12.

13.

14.

15.

Common rail High pressure injection pipe Flow damper Pressure limiter Electric priming pump Engine controller cooler

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Outline of CRI system Outline q The CRI system checks the condition of the engine (engine speed, accelerator angle, coolant 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 function which stops the engine when a certain parts fail and a backup function which continues the operation by changing the control method in such a case.

1 1. Fuel system

Configuration The CRI system is divided by the function into the fuel system and control system.

q

q

q

170E-5 Series

The fuel system distributes the high-pressure fuel supplied by the fuel supply pump to the cylinders through the common rail.

The solenoid valve in the injector opens and closes the nozzle needle valve to start and finish injection.

13

SEN00198-01

10 Structure, function and maintenance standard

2. Control system

q

q

14

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 quantity of fuel in proper timing.

The control system is roughly divided by the electric parts into the sensors, computer, and actuators.

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Structure and operation of CRI system

q

q

q

q

q

q

q

q

The CRI system consists of the fuel supply pump, common rail, injector, engine controller to control them, and sensors.

The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump.

The discharge rate is controlled by turning on and off the PCV (pressure control valve) of the fuel supply pump according to the electric signals from the engine controller.

The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders.

The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail.

A feedback control is applied so that the actual fuel pressure will match to the command pressure set according to the engine speed and the load on the engine.

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.

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

q

q

q

If the TWV is turned on (energized), the fuel circuit is so changed that the high-pressure fuel in the control chamber will flow through the orifice. As a result, the needle valve is raised to start fuel injection by the nozzle cracking pressure of the high-pressure fuel on the nozzle side.

If the TWV is turned off (de-energized), the fuel circuit is so changed that the high-pressure fuel will be applied to the control chamber through the orifice. As a result, the needle valve lowers and finishes fuel injection.

Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn on the TWV and the length of the turn-on time of the TWV.

15

SEN00198-01

10 Structure, function and maintenance standard

Structure and operation of component parts

1

1. Fuel supply pump

1.

2.

3.

4.

5.

3-top cam Overflow valve Drive coupling No. 1 high-pressure pump PCV (Pump control valve)

Outline q The fuel supply pump consists of priming pump (7), feed pump (8), and high-pressure pumps (4) and (6). q The function of the fuel supply pump is to generate common rail fuel pressure by controlling the fuel delivery.

Structure High-pressure pumps (4) and (6) have the pressure feed systems similar to those of the conventional in-line fuel injection pump and the PCVs (pressure control valves) for each cylinder to control the fuel delivery. 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. q

16

6.

7.

8.

9.

No. 2 high-pressure pump Priming pump Feed pump Gear for Bkup speed sensor (G sensor)

q

Since the number of the times of feeding fuel to the common rail is the same as the number of the times of fuel injection, the common rail fuel pressure is smooth and stable.

The fuel fed by high-pressure pumps (4) and (6) to the common rail is divided as follows.

No. 1 high pressure pump (on the drive coupling side) (4) compensates for drop of the common rail fuel pressure caused by fuel injection into the No. 1, 3, and 5 cylinders.

No. 2 high-pressure pump (on the feed pump side) (6) compensates for drop in the common rail fuel pressure caused by fuel injection into the No. 2, 4, and 6 cylinders.

q q

q

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Operation

q

q

q

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. (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.

(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. (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

SEN00198-01

1) PCV (Pressure control valve) q

The PCV adjusts the fuel delivery from the fuel supply pump to adjust the common rail fuel pressure. The delivery from the fuel supply pump to the common rail is decided by the timing of energizing the PCV.

10 Structure, function and maintenance standard

2) Feed pump q

q q

18

The feed pump built in the fuel supply pump assembly draws the fuel from the fuel tank and sends it through the fuel filter to the high-pressure pump chamber.

The outer and inner rotors of the feed pump are rotated by the camshaft.

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.

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

2. Common rail Structure q Common rail (4) distributes the high-pressure fuel from the high-pressure pump to the injectors of the cylinders. q Common rail (4) is equipped with common rail fuel pressure sensor (2), flow dampers (1), and pressure limiter (3). q The fuel injection pipes are connected to flow dampers (1) to send the high-pressure fuel to the injectors. q The piping of the pressure limiter (3) is returned to the fuel tank.

1)

When fuel is stopped q If the fuel flows out abnormally because of a burst of the piping, etc., piston (2) moves to the right stroke end. q The tip of piston (2) contacts seat (b) to stop the fuel. q Once the fuel is stopped, piston (2) does not return to the initial position until the engine is stopped.

Flow damper

Function 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. q

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

SEN00198-01

2) q

q

q

q

1.

2.

3.

4.

5.

20

Pressure limiter If abnormally high pressure is generated, the pressure limiter opens to release that pressure.

If the common rail fuel pressure reaches about 220 MPa {2,156 kg/cm2}, the pressure limiter operates (opens).

If the common rail fuel pressure lowers to 30 MPa {310 kg/cm2}, the pressure limiter resets itself (closes) to maintain the pressure.

Under the normal condition, the pressure limiter does not reset itself (close) until the engine is stopped.

10 Structure, function and maintenance standard

3) q

q

Common rail fuel pressure sensor The common rail fuel pressure sensor is installed to the common rail to sense the fuel pressure.

This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the electric resistance of silicon changes according to pressure applied to it.

Ball Housing Spring Guide Body

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

3. Injector

Outline q The function of the injector is to inject the highpressure fuel from the common rail into each combustion chamber of the engine in the optimum 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 nozzle and controls the fuel injection rate. q The hydraulic piston transmits the force generated by the pressure in the control chamber to the needle valve of the nozzle. q The nozzle sprays the fuel.

170E-5 Series

21

SEN00198-01

10 Structure, function and maintenance standard

Structure

1.

2.

3.

4.

5.

6.

Inlet connector Terminal Upper body Solenoid Valve body Orifice (out)

q

The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic piston section, and 2-way solenoid valve section.

22

7.

8.

9.

10.

11.

12.

Orifice (in) Pressure control chamber Control piston Spring Pressure pin Nozzle assembly

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

A: B:

No fuel injection Start of fuel injection

C: D:

Finish of fuel injection From common rail

1.

2.

3.

4.

Nozzle Control piston Orifice (in) Orifice (out)

5.

6.

7.

8.

Valve body Solenoid Spring Pressure control chamber

3)

Finish of fuel injection (C) If solenoid (6) is de-energized, valve body (5) is lowered by spring (7) and the fuel passage is closed.

At this time, the high-pressure fuel in the common rail is applied to pressure control chamber (8) suddenly and nozzle (1) is closed quickly, fuel injection is finished sharply.

Operation 1) q q

2) q

q

q q

No fuel injection (A) While solenoid (6) is not energized, valve body (5) is pressed down by spring (7).

Since the high-pressure fuel is applied from the common rail to pressure control chamber (8), nozzle (1) is closed and the fuel is not injected.

q

q

Start of fuel injection (B) If solenoid (6) is energized, valve body (5) is pulled up by the electromagnetic force and the fuel passage is opened.

Since the fuel in pressure control chamber (8) flows out through orifices (3) and (4), nozzle (1) rises and fuel injection pump starts.

The fuel injection rate is increased gradually by the function of orifices (3) and (4).

If solenoid (6) is kept energized, the fuel injection rate is increased to the maximum.

170E-5 Series

23

SEN00198-01

10 Structure, function and maintenance standard

Electric circuit diagram

k

24

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.

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Various controls

q

q

q

The CRI system controls the fuel injection rate and fuel injection timing more properly than the mechanical governor or timer of the conventional fuel injection pump.

For the control of the system, calculations necessary to the engine controller are performed fr om th e si gn als se nt fr om the s en so rs installed to the engine and machine.

The energizing timing and energizing period of the injector are so controlled that the optimum quantity of fuel will be injected in the optimum timing.

2. Fuel injection timing control function q

3. Fuel injection pressure control function q

1. Fuel injection rate control function q

The fuel injection rate control function is employed instead of the function of the conventional governor. It controls the fuel injection according to the signals of engine speed and accelerator angle so that the fuel injection rate will be most proper.

170E-5 Series

The fuel injection timing control function is employed instead of the function of the conventional timer. It controls the fuel injection timing most properly from the engine speed and fuel injection rate.

q

(Common rail fuel pressure control function) The fuel injection pressure control function (common rail fuel pressure control function) is a function of measuring the fuel pressure with the common rail fuel pressure sensor and feeding it back to the engine controller to control the delivery of the fuel supply pump.

This function performs pressure feedback control so that the fuel injection pressure will be the same as the optimum value (command value) set according to the engine speed and fuel injection rate.

25

SEN00198-01

10 Structure, function and maintenance standard

4. Various sensors

a a

26

Nos. 1 – 12 in the above illustration correspond to title Nos. 1) – 12).

The above illustration shows the engine for PC1250-7.

170E-5 Series

10 Structure, function and maintenance standard

170E-5 Series

SEN00198-01

27

SEN00198-01

a a

28

10 Structure, function and maintenance standard

Nos. 1 – 12 in the above illustration correspond to title Nos. 1) – 12).

The above illustration shows the engine for HD465-7 and HD605-7.

170E-5 Series

10 Structure, function and maintenance standard

170E-5 Series

SEN00198-01

29

SEN00198-01

1)

Common rail pressure sensor

10 Structure, function and maintenance standard

4) q

2)

Oil pressure sensor

3)

Charge temperature sensor The charge temperature sensor senses the intake air temperature (boost temperature) and sends it to the engine controller.

The sensor unit is a thermistor the resistance of which changes according to the temperature. 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.

q

q

30

Charge pressure sensor This sensor is used to sense the charge pressure (boost pressure).

A:

Mounting screw: M6 Tightening torque: 5.5 Âą 0.5 Nm {0.56 Âą 0.05 kgm}

1.

2.

Sensor O-ring

q

The following graph shows the output characteristics of the charge pressure sensor.

170E-5 Series

10 Structure, function and maintenance standard

5) q

q

q

q

Bkup speed sensor (G sensor) (Cylinder No. sensor) 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.

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°.

In addition to the above teeth, one more tooth is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine.

The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and Bkup speed sensor pulse.

SEN00198-01

6) q

A: B:

q

170E-5 Series

Atmospheric pressure sensor This sensor is used to correct altitude.

Pressure inlet Mounting screw: M5 Tightening torque: 4.5 ± 0.5 Nm {0.46 ± 0.05 kgm} The following graph shows the output characteristics of the atmospheric pressure sensor.

31

SEN00198-01

7) q q

10 Structure, function and maintenance standard

NE speed sensor (Crank angle sensor) If the signal hole made on the flywheel passes the sensor, the magnetic line of force changes.

If the magnetic line of force changes, the output 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 The fuel temperature sensor senses the fuel temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the temperature.

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.

q

q

32

1.

EGR and bypass valve position sensors

q

The following graph shows the output characteristics of the position sensor.

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

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 temperature. 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

SEN00198-01

10 Structure, function and maintenance standard

Fuel piping

a a

The above illustration shows the engine for WA600-6.

The shape is subject to machine models.

Specifications Fuel supply pump Manufacturer: DENSO CORPORATION Model: DENSO ECD-U2 Lubrication method: Forced lubrication with engine oil

34

1

A: B: C: D: E: F:

Fuel inlet To engine controller cooler To main fuel filter From main fuel filter To injector Return fuel (Between overflow valve and main fuel tank) G: Return fuel (Between injector and main fuel tank)

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

a a

The above illustration shows the engine for WA600-6.

The shape is subject to machine models.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Overflow valve Air bleeding tube Fuel injection pipe (No. 1 cylinder) Fuel injection pipe (No. 2 cylinder) Fuel injection pipe (No. 3 cylinder) Fuel injection pipe (No. 4 cylinder) Fuel injection pipe (No. 5 cylinder) Fuel injection pipe (No. 6 cylinder) Common rail Fuel return pipe

170E-5 Series

11.

12.

13.

14.

15.

16.

17.

18.

19.

PCV Priming pump (sub) Feed pump Fuel supply pump drive gear (Number of teeth: 48) High pressure pump Oil inlet pipe (for pump lubricating oil) Electric priming pump Pre-fuel filter Main fuel filter

35

SEN00198-01

10 Structure, function and maintenance standard

Fuel filter

1

Main fuel filter

a

The shape is subject to machine models.

A: B:

Fuel inlet Fuel outlet

1.

2.

3.

Air bleeding pipe adapter Filter head Cartridge

Specifications Filtration area: 1.06 m2

36

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Pre-fuel filter

a

The shape is subject to machine models.

A: B:

Fuel inlet Fuel outlet

1.

2.

Filter head Cartridge

Specifications With water separator

170E-5 Series

37

SEN00198-01

Electric priming pump

A: B:

Fuel IN Fuel OUT

1.

2.

Connector Vibration prevention rubber

38

10 Structure, function and maintenance standard

1

170E-5 Series

10 Structure, function and maintenance standard

Engine controller cooler

A: B:

Fuel IN (From feed pump of fuel supply pump) Fuel OUT (Main fuel filter)

1.

2.

Engine controller Engine controller cooler

SEN00198-01

1

Outline q The fuel is circulated as refrigerant through engine controller cooler (2) to prevent engine controller (1) from overheating.

170E-5 Series

39

SEN00198-01

10 Structure, function and maintenance standard

Cooling system

1

Cooling system diagram

1

A. B.

From oil pump (Oil) To each part of engine (Oil)

1.

2.

3.

4.

5.

Water pump Oil cooler Corrosion resistor Cylinder liner Cylinder block

40

6.

7.

8.

9.

10.

Water manifold (in cylinder block) Thermostat Radiator Fan EGR cooler

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Water pump

1

a

The shape is subject to machine models.

a. b. c. d.

From radiator To oil cooler From thermostat Breather hole (for draining water)

1.

2.

3.

4.

5.

6.

7.

Pump body Impeller Floating seal Water seal Oil seal Pump shaft

Water pump drive gear (Number of teeth: 31) Inlet housing

8.

Specifications Speed: Engine speed × 1.77 Delivery: 800 l/min (at 3,730 rpm) Unit: mm

No.

9

Check item Interference of pump shaft and bearing (front)

Criteria Standard size

Remedy

Tolerance

Standard interference

Shaft

Hole

25

+0.011 +0.002

0 –0.010

0.002 – 0.021

10

Interference of pump shaft and bearing (rear)

25

+0.011 +0.002

0 –0.010

0.002 – 0.021 Replace

11

Interference of pump shaft and impeller

19.9

+0.018 +0.006

–0.025 –0.050

0.031 – 0.068

12

Clearance between impeller and connection

170E-5 Series

Standard clearance

Clearance limit

0.26 – 0.68

—

41

SEN00198-01

Thermostat

a

42

10 Structure, function and maintenance standard

1

The shape is subject to machine models.

170E-5 Series

10 Structure, function and maintenance standard

A: B: a. b. c.

When cold (Fully closed) When hot (Fully open) From each part of engine To water pump To radiator

1.

2.

3.

4.

5.

6.

7.

8.

Seal Thermostat Valve Body Piston Heat sensing portion Sleeve Inflating portion

SEN00198-01

Specifications Opening temperature: 76.5 ± 2°C Full opening temperature: 90°C Valve lift: Min. 9 mm

Unit: mm No.

2

Check item

Criteria

Full opening lift of thermostat

Min. 9 mm (Check after soaking in oil tank at 90°C for 4 – 5 minutes)

Opening and closing of thermostat

Check that valve closes fully when its temperature is lowered from 90°C for full opening to 76.5°C. (Check after soaking valve in oil tank for 4 – 5 minutes)

170E-5 Series

Remedy

Replace

43

SEN00198-01

10 Structure, function and maintenance standard

Corrosion resistor

1

a

The shape is subject to machine models.

A: B:

Coolant inlet Coolant outlet

Specifications

1.

2.

3.

4.

5.

6.

Head Cartridge Element Inhibitor (Solid anti-corrosion agent) Spring Stop valve

Quantity of anti-corrosion agent

44

Filtration area

0.13 m2

0.19 m2

0.37 m2

400 g

600 g

1,000 g

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Corrosion resistor mounting

a

The shape is subject to machine models.

1.

2.

3.

4.

Tube (Return from corrosion resistor) Corrosion resistor head Corrosion resistor cartridge Tube (To corrosion resistor)

170E-5 Series

45

SEN00198-01

10 Structure, function and maintenance standard

Fan drive

1

HD465-7, HD605-7

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

6.

7.

Crankshaft pulley Fan belt Tension pulley Adjustment bolt Tension pulley bracket Fan pulley Fan

a.

Direction of wind

46

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Electrical equipment

1

Alternator

1

Alternator mounting

a a

The shape is subject to machine models.

The above illustration shows the engine for WA600-6.

1.

2.

3.

4.

5.

6.

7.

8.

Drive pulley (Pitch circle of pulley: 180 mm) Alternator pulley (Pitch circle of pulley: 80 mm) Alternator Alternator mounting bolt Fix bolt (when replacing belt) Locknut Belt Alternator belt tension pulley.

170E-5 Series

47

SEN00198-01

10 Structure, function and maintenance standard

Alternator belt tension WA600-6

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

Tension shaft Spring Roller bearing Tension bracket Oil seal

48

6.

7.

8.

9.

10.

Spacer Tension pulley (Outside diameter: 150 mm) Ball bearing Grease fitting Adjustment bolt

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Alternator With built-in regulator (Open type, 60A)

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

Alternator Alternator pulley Terminal B Terminal E Terminal R

Engine

6.

Applicable machine

Type

Specification

D375A-5

Open type (brushless), manufactured by NIKKO DENKI

24V, 60A

PC1250-8

Open type (brushless), manufactured by NIKKO DENKI

24V, 60A

HD465-7

Open type (brushless), manufactured by NIKKO DENKI

24V, 60A

HD605-7

Open type (brushless), manufactured by NIKKO DENKI

24V, 60A

SAA6D170E-5

170E-5 Series

Internal electric circuit diagram 6A. Field coil 6B. Initial excitation resistor 6C. Regulator

Outside diameter of pulley Weight (kg) (mm)

49

SEN00198-01

10 Structure, function and maintenance standard

With built-in regulator (Open type, 90A)

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

Alternator Alternator pulley Terminal B Terminal E Terminal R

Engine

SAA6D170E-5

50

6.

Applicable machine

Internal electric circuit diagram 6A. Field coil 6B. Initial excitation resistor 6C. Regulator

Type

Specification

D375A-5

Open type (brushless), manufactured by NIKKO DENKI

24V, 90A

PC1250-8

Open type (brushless), manufactured by NIKKO DENKI

24V, 90A

WA600-6

Open type (brushless), manufactured by NIKKO DENKI

24V, 90A

HD465-7

Open type (brushless), manufactured by NIKKO DENKI

24V, 90A

HD605-7

Open type (brushless), manufactured by NIKKO DENKI

24V, 90A

Outside diameter of pulley Weight (kg) (mm)

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

Starting motor

1

For 7.5 kW

a

The shape is subject to machine models.

1.

2.

3.

4.

5.

6.

7.

Pinion gear Starting motor assembly Magnetic switch Terminal B Terminal C Safety relay External wiring diagram (2-pin connector type) 7A. Safety relay position 7B. Starting motor position External wiring diagram (3-pin connector type) 8A. Safety relay position 8B. Starting motor position

8.

170E-5 Series

S: R: E:

To starting switch terminal C To alternator terminal R To ground

51

SEN00198-01

Engine

10 Structure, function and maintenance standard

Applicable machine

Type

Specification

No. of pinWeight (kg) ion teeth

Safety relay mounting type

Connector type

D375A-5

NIKKO DENKI 27V, 7.5kW (Water-proof, oil-proof type) x2

11

18

G

E

SAA6D170E-5 HD465-7

NIKKO DENKI 27V, 7.5kW (Water-proof, oil-proof type) x2

11

18

G

C

HD605-7

NIKKO DENKI 27V, 7.5kW (Water-proof, oil-proof type) x2

11

18

G

C

52

170E-5 Series

10 Structure, function and maintenance standard

SEN00198-01

For 11 kW

a

The shape is subject to machine models.

E: R: S:

To chassis ground To alternator terminal R To starting switch terminal C

Engine

Pinion gear Starting motor assembly Magnetic switch Terminal B Terminal C Safety relay External electric circuit diagram [2-pole connector type] 7A. Safety relay section 7B. Starting motor section

Applicable machine

Type

Specification

No. of pinion teeth

PC1250-8

Waterproof, oilproof, manufactured

by NIKKO DENKI

24V, 11kW

12

18

B

WA600-6

Waterproof, oilproof, manufactured

by NIKKO DENKI

24V, 11kW

12

18

B

SAA6D170E-5

170E-5 Series

1.

2.

3.

4.

5.

6.

7.

Weight (kg) Connector type

53

SEN00198-01

10 Structure, function and maintenance standard

Starting aid

1

Electrical intake air heater For SAA6D170E-5

a

The shape is subject to change for modification, etc.

1.

2.

3.

4.

Terminal Body Heater coil Electric circuit diagram

54

Specifications Type of heater: Electrical intake air heater Rated voltage: 22 V (DC) Rated current: 111 A

170E-5 Series

10 Structure, function and maintenance standard

Engine controller

SEN00198-01

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

SEN00198-01

10 Structure, function and maintenance standard

KOMATSU 170E-5 Series engine Form No. SEN00198-01

Š 2005 KOMATSU All Rights Reserved Printed in Japan 11-05 (01)

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

Lubrication system

Body

Air intake and exhaust system

Performance Category

Standard service value table for testing, adjusting, and troubleshooting Engine

SAA6D170E-5

Machine model

D375A-5 Unit

Standard value for new machine

Judgement criteria

High idle speed

rpm

1,830 ± 20

1,830 ± 20

Low idle speed

rpm

750 ± 20

750 ± 20

rpm

125

—

rpm

85

—

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.5 {762}

Item

Speed

Measurement conditions

At 0°C (without starting aid) Necessary speed for starting At –20°C (with starting aid) Air intake resistance

Whole speed range

Air boost pressure

At rated output

kPa {mmHg}

Min. 155 {Min. 1,160}

141 {1,060}

Exhaust pressure

At rated output

kPa {mmHg}

Min. 167 {Min. 1,250}

153 {1,150}

Exhaust temperature

Whole speed range (20°C )

°C

Max. 650

700

At sudden acceleration (Low → High)

% (Bosch index)

Max. 25 (Max. 2.5)

35 (3.5)

At rated output

Bosch index

Max. 1.5

2.5

At high idle

Bosch index

Max. 1.0

2.0

Valve clearance (at cold)

Intake valve

mm

0.32

—

mm

0.62

—

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 210 – 250 rpm

MPa {kg/cm2}

Min. 2.94 {Min. 30}

2.1 {21}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 3.43 {Max. 350}

9.41 {960}

MPa {kg/cm2}

Min. 0.34 {Min. 3.5}

0.21 {2.1}

Oil pressure

SAE0W30E0S At rated output Engine oil temperature: Min. 80°C SAE5W40E0S SAE10W30DH At low idle SAE15W40DH Engine oil temperature: Min. 80°C SAE30DH

MPa {kg/cm2}

Min. 0.1 {Min. 1.0}

0.08 {0.8}

Oil temperature

Whole speed range

°C

90 – 110

120

Oil consumption

Ratio to fuel consumption at continuous rated output

%

Max. 0.1

0.2

kPa {kg/cm2}

—

—

Exhaust gas color

Exhaust valve

Cooling system

Function of radiator pressure Cracking pressure (Differential pressure) valve

2

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N {10 kg}

mm

Hydraulically driven on machine side

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N {10 kg}

mm

— (Auto-tension)

—

170E-5 Series

Lubrication system

Body

Air intake and exhaust system

Performance Category

20 Standard value table

SEN00367-00

Engine

SAA6D170E-5

Machine model

PC1250-7 Unit

Standard value for new machine

Judgement criteria

High idle speed

rpm

2,000 ± 40

2,000 ± 40

Low idle speed

rpm

900 ± 25

900 ± 25

rpm

125

—

rpm

85

—

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.5 {762}

Item

Speed

Measurement conditions

At 0°C (without starting aid) Necessary speed for starting At –20°C (with starting aid) Air intake resistance

Whole speed range

Air boost pressure

At rated output

kPa {mmHg}

Min. 160 {Min. 1,200}

147 {1,100}

Exhaust pressure

At rated output

kPa {mmHg}

Min. 161 {Min. 1,210}

148 {1,110}

Exhaust temperature

Whole speed range (20°C )

°C

Max. 670

700

At sudden acceleration (Low → High)

% (Bosch index)

Max. 25 (Max. 2.5)

35 (3.5)

At rated output

Bosch index

Max. 1.5

2.5

At high idle

Bosch index

Max. 1.0

2.0

Valve clearance (at cold)

Intake valve

mm

0.32

—

mm

0.62

—

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 210 – 250 rpm

MPa {kg/cm2}

Min. 2.94 {Min. 30}

2.1 {21}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 3.43 {Max. 350}

12.94 {1,320}

MPa {kg/cm2}

Min. 0.34 {Min. 3.5}

0.21 {2.1}

Oil pressure

SAE0W30E0S At rated output Engine oil temperature: Min. 80°C SAE5W40E0S SAE10W30DH At low idle SAE15W40DH Engine oil temperature: Min. 80°C SAE30DH

MPa {kg/cm2}

Min. 0.1 {Min. 1.0}

0.08 {0.8}

Oil temperature

Whole speed range

°C

90 – 110

120

Oil consumption

Ratio to fuel consumption at continuous rated output

%

Max. 0.1

0.2

kPa {kg/cm2}

—

—

Exhaust gas color

Exhaust valve

Cooling system

Function of radiator pressure Cracking pressure (Differential pressure) valve Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N {10 kg}

mm

Hydraulically driven on machine side

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N {10 kg}

mm

— (Auto-tension)

—

170E-5 Series

3

Lubrication system

Body

Air intake and exhaust system

Performance Category

SEN00367-00

20 Standard value table

Engine

SAA6D170E-5

Machine model

WA600-6 Unit

Standard value for new machine

Judgement criteria

High idle speed

rpm

2,000 ± 50

2,000 ± 50

Low idle speed

rpm

800 ± 25

800 ± 25

rpm

125

—

rpm

85

—

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.5 {762}

Item

Speed

Measurement conditions

At 0°C (without starting aid) Necessary speed for starting At –20°C (with starting aid) Air intake resistance

Whole speed range

Air boost pressure

At rated output

kPa {mmHg}

Min. 147 {Min. 1,100}

133 {1,000}

Exhaust pressure

At rated output

kPa {mmHg}

Min. 155 {Min. 1,160}

141 {1,060}

Exhaust temperature

Whole speed range (20°C )

°C

Max. 650

700

At sudden acceleration (Low → High)

% (Bosch index)

Max. 25 (Max. 2.5)

35 (3.5)

At rated output

Bosch index

Max. 1.5

2.5

At high idle

Bosch index

Max. 1.0

2.0

Valve clearance (at cold)

Intake valve

mm

0.32

—

mm

0.62

—

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 210 – 250 rpm

MPa {kg/cm2}

Min. 2.94 {Min. 30}

2.1 {21}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 3.43 {Max. 350}

9.41 {960}

MPa {kg/cm2}

Min. 0.34 {Min. 3.5}

0.21 {2.1}

Oil pressure

SAE0W30E0S At rated output Engine oil temperature: Min. 80°C SAE5W40E0S SAE10W30DH At low idle SAE15W40DH Engine oil temperature: Min. 80°C SAE30DH

MPa {kg/cm2}

Min. 0.1 {Min. 1.0}

0.08 {0.8}

Oil temperature

Whole speed range

°C

90 – 110

120

Oil consumption

Ratio to fuel consumption at continuous rated output

%

Max. 0.1

0.2

kPa {kg/cm2}

—

—

Exhaust gas color

Exhaust valve

Cooling system

Function of radiator pressure Cracking pressure (Differential pressure) valve

4

Fan speed

At rated speed

rpm

Hydraulically driven on machine side

Hydraulically driven on machine side

Fan belt tension

Deflection under finger pressure of 98 N {10 kg}

mm

Hydraulically driven on machine side

Hydraulically driven on machine side

Alternator belt tension

Deflection under finger pressure of 98 N {10 kg}

mm

— (Auto-tension)

—

170E-5 Series

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

20 Standard value table

SEN00367-00

Engine

SAA6D170E-5

Machine model

HD465-7 HD605-7 Unit

Standard value for new machine

Judgement criteria

High idle speed

rpm

2,270 ± 50

2,270 ± 50

Low idle speed

rpm

750 ± 50

750 ± 50

rpm

125

—

Item

Speed

Measurement conditions

At 0°C (without starting aid) Necessary speed for starting At –20°C (with starting aid)

rpm

85

—

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.5 {762}

At rated output

kPa {mmHg}

Min. 160 {Min. 1,200}

147 {1,100}

Exhaust pressure

At rated output

kPa {mmHg}

Min. 161 {Min. 1,210}

148 {1,110}

Exhaust temperature

Whole speed range (20°C )

°C

Max. 680

700

At sudden acceleration (Low → High)

% (Bosch index)

Max. 25 (Max. 2.5)

35 (3.5)

At rated output

Bosch index

Max. 1.5

2.5

At high idle

Bosch index

Max. 1.0

2.0

Air intake resistance

Whole speed range

Air boost pressure

Exhaust gas color

Valve clearance (at cold)

Intake valve

mm

0.32

—

Exhaust valve

mm

0.62

—

Compression pressure

Engine oil temperature: 40 – 60°C Engine speed: 210 – 250 rpm

MPa {kg/cm2}

Min. 2.94 {Min. 30}

2.1 {21}

Blow-by pressure

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 3.43 {Max. 350}

12.94 {1,320}

MPa {kg/cm2}

Min. 0.34 {Min. 3.5}

0.21 {2.1}

Oil pressure

SAE0W30E0S At rated output Engine oil temperature: Min. 80°C SAE5W40E0S SAE10W30DH At low idle SAE15W40DH Engine oil temperature: Min. 80°C SAE30DH

MPa {kg/cm2}

Min. 0.1 {Min. 1.0}

0.08 {0.8}

Oil temperature

Whole speed range

°C

90 – 110

120

Oil consumption

Ratio to fuel consumption at continuous rated output

%

Max. 0.1

0.2

kPa {kg/cm2}

—

—

rpm

1,190 ± 30

1,190 ± 30 — (Auto-tension) —

Function of radiator pressure Cracking pressure (Differential pressure) valve Fan speed

At rated speed

Fan belt tension

Deflection under finger pressure of 98 N {10 kg}

mm

— (Auto-tension)

Alternator belt tension

Deflection under finger pressure of 98 N {10 kg}

mm

— (Auto-tension)

170E-5 Series

5

SEN00367-00

20 Standard value table

Running-in standard and performance test standard

1

Running-in standard Engine

SAA6D170E-5

Machine model

D375A-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 a

This table shows the values when the fan is not installed.

The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA6D170E-5

Machine model

D375A-5

Test item

Rated output

Max. torque

High idle speed

Low idle speed

1,830 ± 20 rpm

750 ± 20 rpm

Specification value (Gross value)

—

Speed

rpm

1,800

1,300

1,830 ± 20

750 ± 20

Dynamometer load

N {kg}

3,246 – 3,452 {331 – 352}

4,089 – 4,335 {417 – 442}

—

—

Output (Gross value)

kW {HP}

438 – 466 {588 – 624}

—

—

—

Torque (Gross value)

Nm {kgm}

—

2,932 – 3,109 {299 – 317}

—

—

Fuel consumption

sec/500cc

Min. 14

—

—

—

Coolant temperature

°C

70 – 90

70 – 90

70 – 90

70 – 90

Lubricating oil temperature

°C

90 – 110

90 – 110

90 – 110

90 – 110

Lubricating oil pressure

kPa {kg/cm2}

343 – 539 {3.5 – 5.5}

343 – 539 {3.5 – 5.5}

343 – 539 {3.5 – 5.5}

Min. 118 {Min. 1.2}

Exhaust temperature

°C

Max. 650

Max. 650

—

—

a a

452 kW/1,800 rpm 3,020 Nm/1,300 rpm {606 HP/1,800 rpm} {308 kgm/1,300 rpm}

a a a

This table shows the standard values obtained by using the JIS correction coefficients.

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.

This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator.

The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Use ASTM No. 1 or No. 2 diesel fuel as fuel.

Use SAE15W-40 as lubricating oil.

6

170E-5 Series

a

20 Standard value table

SEN00367-00

Running-in standard Engine

SAA6D170E-5

Machine model

PC1250-7 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}

1,513 {154}

2,414 {246}

3,143 {321}

3,814 {389}

Output

kW {HP}

0 {0}

129 {173}

257 {345}

386 {518}

515 {690}

a a

This table shows the values when the fan is not installed.

The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA6D170E-5

Machine model

PC1250-7

Test item

Rated output

Max. torque

Low idle speed

2,000 ± 40 rpm

900 ± 25 rpm

Specification value (Gross value)

—

Speed

rpm

1,800

1,300

2,000 ± 40

900 ± 25

Dynamometer load

N {kg}

3,697 – 3,932 {377 – 401}

4,089 – 4,354 {417 – 444}

—

—

Output (Gross value)

kW {HP}

499 – 530 {669 – 711}

—

—

—

Torque (Gross value)

Nm {kgm}

—

2,932 – 3,119 {299 – 318}

—

—

Fuel consumption

sec/500cc

Min. 13

—

—

—

Coolant temperature

°C

70 – 90

70 – 90

70 – 90

70 – 90

Lubricating oil temperature

°C

90 – 110

90 – 110

90 – 110

90 – 110

Lubricating oil pressure

kPa {kg/cm2}

343 – 539 {3.5 – 5.5}

343 – 539 {3.5 – 5.5}

343 – 539 {3.5 – 5.5}

Min. 118 {Min. 1.2}

Exhaust temperature

°C

Max. 650

Max. 670

—

—

a a a a a a

515 kW/1,800 rpm 3,025 Nm/1,300 rpm {690 HP/1,800 rpm} {308.5 kgm/1,300 rpm}

High idle speed

This table shows the standard values obtained by using the JIS correction coefficients.

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.

This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator.

The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Use ASTM No. 1 or No. 2 diesel fuel as fuel.

Use SAE15W-40 as lubricating oil.

170E-5 Series

7

SEN00367-00

20 Standard value table

Running-in standard Engine

SAA6D170E-5

Machine model

WA600-6 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}

1,163 {119}

1,855 {189}

2,416 {246}

2,931 {299}

Output

kW {HP}

0 {0}

99 {133}

198 {265}

297 {398}

396 {531}

a a

This table shows the values when the fan is not installed.

The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA6D170E-5

Machine model

WA600-6

Test item

Rated output

Max. torque

Low idle speed

2,000 ± 50 rpm

800 ± 25 rpm

Specification value (Gross value)

—

Speed

rpm

1,800

1,000

2,000 ± 50

800 ± 25

Dynamometer load

N {kg}

2,844 – 3,020 {290 – 308}

3,521 – 3,727 {359 – 380}

—

—

Output (Gross value)

kW {HP}

384 – 407 {515 – 546}

—

—

—

Torque (Gross value)

Nm {kgm}

—

2,520 – 2,667 {257 – 272}

—

—

Fuel consumption

sec/500cc

Min. 16

—

—

—

Coolant temperature

°C

70 – 90

70 – 90

70 – 90

70 – 90

Lubricating oil temperature

°C

90 – 110

90 – 110

90 – 110

90 – 110

Lubricating oil pressure

kPa {kg/cm2}

343 – 539 {3.5 – 5.5}

343 – 539 {3.5 – 5.5}

343 – 539 {3.5 – 5.5}

Min. 118 {Min. 1.2}

Exhaust temperature

°C

Max. 650

Max. 650

—

—

a a

396 kW/1,800 rpm 2,594 Nm/1,000 rpm {530 HP/1,800 rpm} {264.5 kgm/1,000 rpm}

High idle speed

a a a

This table shows the standard values obtained by using the JIS correction coefficients.

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.

This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator.

The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Use ASTM No. 1 or No. 2 diesel fuel as fuel.

Use SAE15W-40 as lubricating oil.

8

170E-5 Series

a

20 Standard value table

SEN00367-00

Running-in standard Engine

SAA6D170E-5

Machine model

HD465-7 HD605-7 Procedure

Item

1

2

3

4

5

Running time

min.

1.5

4.5

9

12

3

Speed

rpm

750

1,260

1,580

1,820

2,000

Dynamometer load

N {kg}

0 {0}

1,459 {149}

2,328 {237}

3,031 {309}

3,677 {375}

Output

kW {HP}

0 {0}

138 {185}

276 {370}

414 {555}

552 {740}

a a

This table shows the values when the fan is not installed.

The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA6D170E-5

Machine model

HD465-7 HD605-7

Test item

Rated output

Max. torque

High idle speed

Low idle speed

2,270 ± 50 rpm

750 ± 50 rpm

Specification value (Gross value)

—

Speed

rpm

2,000

1,400

2,270 ± 50

750 ± 50

Dynamometer load

N {kg}

3,570 – 3,795 {364 – 387}

4,501 – 4,776 {459 – 487}

—

—

Output (Gross value)

kW {HP}

535 – 569 {718 – 762}

—

—

—

Torque (Gross value)

Nm {kgm}

—

3,226 – 3,423 {329 – 349}

—

—

Fuel consumption

sec/500cc

Min. 12

—

—

—

Coolant temperature

°C

70 – 90

70 – 90

70 – 90

70 – 90

Lubricating oil temperature

°C

90 – 110

90 – 110

90 – 110

90 – 110

Lubricating oil pressure

kPa {kg/cm2}

343 – 539 {3.5 – 5.5}

343 – 539 {3.5 – 5.5}

343 – 539 {3.5 – 5.5}

Min. 118 {Min. 1.2}

Exhaust temperature

°C

Max. 650

Max. 680

—

—

a a a a a a

552 kW/2,000 rpm 3,324 Nm/1,400 rpm {740 HP/2,000 rpm} {339 kgm/1,400 rpm}

This table shows the standard values obtained by using the JIS correction coefficients.

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.

This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator.

The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Use ASTM No. 1 or No. 2 diesel fuel as fuel.

Use SAE15W-40 as lubricating oil.

170E-5 Series

9

SEN00367-00

KOMATSU 170E-5 Series engine Form No. SEN00367-00

Š 2005 KOMATSU All Rights Reserved Printed in Japan 10-05 (01)

10