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170-3 Series
Komatsu 170-3 Series Manuals
Manuals and User Guides for Komatsu 170-3 Series. We have
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Komatsu 170-3 Series manuals available for free PDF download: Shop Manual
Komatsu 170-3 Series Shop Manual (455 pages)
DIESEL ENGINE
Brand:
Komatsu
| Category:
Engine
| Size: 22.84 MB
Table of Contents
Contents
2
Safety Notices
5
Preparations for Work
5
Precautions During Work
6
Manual Sections Contents
7
How to Read the Manual
8
Symbols
8
Hoisting
9
Wire Ropes
9
Disassembling, Connecting Push-Pull Type Coupler
10
Coating Materials
12
Standard Tightening Torque
14
Electric Wire Code
17
Conversion Table
18
General Information
25
Applicable Machine
26
Specifications
28
Overall Drawing
32
Product View
32
Weight Table
52
Engine Performance Curve
53
Structure and Function
61
Air Cleaner
62
Turbocharger Description
65
Holset
69
Aftercooler Description
70
Cylinder Head Description
72
Cylinder Block Description
74
Main Circulation System Description
76
Flywheel and Flywheel Housing Description
78
Vibration Damper Description
79
Gear Train Description
80
Timing Gear Description
81
Valve System Description
82
Lubrication System Diagram
84
Oil Pump Description
85
Oil Cooler Description
88
Fuel System Diagram
89
Outline of HPI System
90
Engine Controller Control System Description
91
Fuel Pump Pressure Control Circuit Description
94
Fuel Pump Description
95
Injector Description
99
HPI Fuel Injection System Description
100
Fuel Cooler Description
101
Fuel Filter Description
102
Cooling System Diagram
103
Water Pump Description
104
Thermostat Description
105
Fan, Tension Pulley Description
106
Alternator Description
110
Alternator with Built-In Regulator
112
Starting Motor Description
116
Starting Aid
118
Electrical Heater Mounting
118
Testing and Adjusting
122
Standard Value Table for Troubleshooting
123
Standard Value Table for Electrical Parts
128
Tools for Testing, Adjusting and Troubleshooting
131
Measuring Exhaust Temperature (Overall Engine)
133
Measuring Intake Air Pressure (Boost Pressure)
133
Troubleshooting for Injector
134
Adjusting Valve Clearance
135
Adjusting Injector Set Load
136
Measuring Compression Pressure
137
Measuring Blow-By Pressure
138
Measuring Oil Pressure
139
Handling Equipment in Fuel Circuit
139
Measuring Fuel Circuit Pressure
140
Visual Inspection of Return Fuel
141
Bleeding Air from Fuel Circuit
142
Adjusting Speed Sensor
143
Replacing and Adjusting Fan Belt
144
Testing and Adjusting Alternator Belt Tension
146
Precautions When Operating Engine as an Individual Part
147
Arrangement of Control Devices and Electric Circuit Diagram for HPI
148
Controller Pump Valve
149
Sensors
149
Actuator
149
Electric Circuit Diagram
150
Run-In Standard
151
Performance Test Standards
152
Table of Contents
157
Troubleshooting of Mechanical System (S Mode)
157
Points to Remember When Troubleshooting
158
Method of Using Troubleshooting Charts
159
Example of Troubleshooting When Exhaust Gas Is Black
160
Method of Using Troubleshooting Chart
160
Starting Performance Is Poor (Starting Always Takes Time)
162
A) Engine Does Not Turn
164
B) Engine Turns but no Exhaust Smoke Comes out (Fuel Is Not Being Injected)
165
C) Exhaust Smoke Comes out but Engine Does Not Start (Fuel Is Being Injected)
167
Engine Does Not Pick up Smoothly (Follow-Up Is Poor)
169
Engine Stops During Operations
171
Engine Does Not Rotate Smoothly (Hunting)
173
Engine Lacks Output (or Lacks Power)
175
Exhaust Smoke Is Black (Incomplete Combustion)
177
Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)
179
Oil Becomes Contaminated Quickly
180
Fuel Consumption Is Excessive
181
Oil Is in Cooling Water, or Water Spurts Back, or Water Level Goes down
182
Oil Pressure Caution Lamp Lights up (Drop in Oil Pressure)
183
Oil Level Rises
184
Water Temperature Becomes too High (Overheating)
185
Abnormal Noise Is Made
186
Vibration Is Excessive
187
Troubleshooting of Controller System of Engine
188
Error Code Display
193
Table of Error Codes
195
Action Taken by Controller When Error Code Is Displayed
197
Abnormality in Controller Memory
207
Abnormality in Timing Rail Actuator
207
Abnormality with Electric Current in Timing Rail Actuator System
208
Abnormality in Engine Speed Sensor 2 System
209
Abnormality in Timing Rail Pressure Sensor System High Level
211
Abnormality in Timing Rail Pressure Sensor System Low Level
212
Abnormality in Fuel Pump Pressure Sensor System High Level
213
Abnormality in Fuel Pump Pressure Sensor System Low Level
214
Abnormality in Engine Speed Sensor 1 System
215
Abnormality in Boost Pressure Sensor System High Level
216
Abnormality in Boost Pressure Sensor System Low Level
217
Abnormality in Throttle Sensor System High Level
218
Abnormality in Throttle Sensor System Low Level
219
Abnormality in Remote Throttle Sensor System High Level
219
Abnormality in Oil Pressure Sensor System High Level
221
Abnormality in Oil Pressure Sensor System Low Level
222
Abnormal Drop in Oil Pressure (Level 1)
223
Abnormality in Water Temperature Sensor System High Level
224
Abnormality in Water Temperature Sensor System Low Level
225
Abnormal Rise in Water Temperature
225
Abnormality in Intake Air Temperature Sensor System High Level
226
Abnormality in Atmospheric Pressure Sensor System High Level
227
Abnormality in Atmospheric Pressure Sensor System Low Level
228
Overspeed
229
Abnormality in Fuel Shut-Off Valve System Voltage
230
Abnormality in Fuel Shut-Off Valve
231
Abnormal Rise in Fuel Temperature
231
Abnormality in Fuel Temperature Sensor System High Level
232
Abnormality in Fuel Pump Actuator System Current
233
Abnormality in Fuel Pump Actuator
234
Abnormality in Controller Internal Communication
235
Abnormality in Controller Power down
235
Abnormality in Preheating Heater Control System
237
Abnormality in Timing Rail Pressure Sensor System in Range
238
Abnormality 1 in Idling Validation Switch System
240
Idling Validation Process Error
241
Abnormality in Fuel Rail Pressure Sensor System High Level
243
Abnormality in Fuel Rail Pressure Sensor System Low Level
244
Abnormality in Fuel Rail Actuator System Current
245
Abnormality in Fuel Rail Actuator Control
246
Abnormality in Dual Output Solenoid a System
247
Abnormality in Dual Output Solenoid B System
248
Abnormality in Fuel Rail Pressure Sensor in Range
249
Troubleshooting of Controller System for Generator Equipment (EB Mode)
251
Abnormality in Power Source Voltage System
266
Abnormality in Engine Speed Sensor a System
268
Mistaken of Connection of Wiring Harness Connector
270
Overrun
271
Overheat
271
Abnormal Drop in Oil Pressure
272
Abnormality in Coolant Temperature Sensor System
273
Abnormality in Solenoid Power Source 1 System
274
Abnormality in Solenoid Power Source 2 System
275
Abnormality in Backup Power Source System
276
Abnormality in Switch Power Source System
277
Abnormality in Fuel Rail Pressure Sensor System in Range
280
Abnormality in Fuel Rail Actuator
281
Abnormality with Electric Current in Fuel Rail Actuator System
282
Abnormality with Electric Current in Fuel Pump Actuator System
293
Abnormality in Starting Switch on Signal System
295
Abnormality in Power Source Retention Relay System
296
Abnormality in Emergency Stop Signal Input
297
Abnormality in Boost Air Pressure Sensor System High Level
300
Abnormality in Boost Air Pressure Sensor System Low Level
301
Abnormality in Droop Adjustment Volume System
302
Abnormality in Rated Speed Adjustment Volume System
304
Abnormality in Li Speed Adjustment Volume System
306
Abnormality in Lamp Time Adjustment Volume System
308
Abnormality in P Constant Adjustment Volume System
310
Abnormality in Constant Adjustment Volume System
312
Abnormality in D Constant Adjustment Volume System
314
Abnormality in Fuel Temperature Sensor System
316
Disassembly and Assembly
318
When Removing or Installing Unit Assemblies
319
Special Tool List
322
Disassembly of Engine
324
Assembly of Engine
340
Adjustment of Injector
361
Adjustment of Valve Clearance
361
Washing Parts
370
Washing Cylinder Block
370
Measuring Parts
371
Washing Crankshaft
371
Measuring Curvatuve of Crankshaft
371
Measuring Outside Diameter of Crankshaft Journal
371
Measuring Depth of Cylinder Liner Counterbore
372
Measuring Main Bearing Bore
372
Measuring Curvatuve of Camshaft
372
Measuring Piston Ring Groove
373
Measuring Piston Ring End Gap
373
Measuring Height of Cam
373
Measuring Outside Diameter of Camshaft Journal
373
Measuring Length of Connecting Rod
374
Measuring Curvature, Twisting of Connecting Rod
374
Maintenance Standard
376
Turbocharger
377
Holset Drawing
381
Cylinder Head
383
Valve, Valve Guide
384
Crosshead and Crosshead Guide
385
Tappet and Push Rod
386
Intake Valve, Exhaust Valve
386
Injector
387
Rocker Arm
388
Cylinder Block
390
Cylinder Liner
392
Crankshaft
393
Camshaft
395
Gear Train
396
Timing Gear
398
Piston, Piston Ring, Piston Pin
400
Connecting Rod
401
Oil Pump, Relief Valve
402
Oil Cooler
404
Water Pump
405
Thermostat
406
Repair and Replacement of Parts
407
Table of Special Tools
408
Testing and Inspecting Cylinder Head
409
Repairing Mounting Face of Cylinder Head by Grinding
412
Replacing Valve Seat Inserts
413
Pressure Test Method
418
Replacing Valve Guide
419
Replacing Cross Head Guide
420
Grinding Valve
421
Testing and Inspecting Cylinder Block
422
Grinding the Top Surface of Cylinder Block
425
Replacing Main Bearing Cap
431
Replacing Cam Bushing
433
Testing and Inspecting Crankshaft
435
Correcting Surface Roughness of Crankshaft Journal Portion
437
Repairing Crankshaft
442
Testing and Inspecting of Connecting Rod
450
Replacing Crankshaft Gear
452
Replacing Camshaft Gear
453
Replacing Flywheel Ring Gear
454
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Komatsu 170-3 Series Shop Manual (433 pages)
Brand:
Komatsu
| Category:
Engine
| Size: 53.91 MB
Table of Contents
Table of Contents
2
General
7
Structure and Function
7
Testing and Adjusting
108
Standard Value Table for Troubleshooting
111
Standard Value Table for Electrical Parts
112
Tools for Testing, Adjusting, and Troubleshooting
115
Troubleshooting for Injector
118
Adjusting Injector Set Load
120
Measuring Compression Pressure
121
Measuring Blow-By Pressure
122
Handling Equipment in Fuel Circuit
123
Measuring Oil Pressure
123
Measuring Fuel Circuit Pressure
124
Visual Inspection of Return Fuel
125
Adjusting Speed Sensor
127
Bleeding Air from Fuel Circuit
127
Replacing and Adjusting Fan Belt
128
Testing and Adjusting Alternator Belt Tension
130
Precautions When Operating Engine as an Individual Part
131
Arrangement of Control Devices and Electric Circuit Diagram for HPI
132
Run-In Standard
135
Performance Test Standards
136
Troubleshooting of Mechanical System (S Mode)
139
Points to Remember When Troubleshooting
140
Troubleshooting
140
Method of Using Troubleshooting Chart
142
Starting Performance Is Poor (Starting Always Takes Time)
144
Engine Does Not Start
146
A) Engine Does Not Turn
146
B) Engine Turns but no Exhaust Smoke Comes out (Fuel Is Not Being Injected)
147
C) Exhaust Smoke Comes out but Engine Does Not Start (Fuel Is Being Injected)
149
Engine Does Not Pick up Smoothly (Follow-Up Is Poor)
151
Engine Stops During Operations
153
Engine Does Not Rotate Smoothly (Hunting)
155
Engine Lacks Output (or Lacks Power)
157
Exhaust Smoke Is Black (Incomplete Combustion)
159
S-10 Fuel Consumption Is Excessive
163
S-11 Oil Is in Cooling Water, or Water Spurts Back, or Water Level Goes down
164
Oil Pressure Caution Lamp Lights up (Drop in Oil Pressure)
165
S-13 Oil Level Rises
166
Water Temperature Becomes too High (Overheating)
167
S-15 Abnormal Noise Is Made
168
Table of Contents
172
Error Code [451] (Abnormality in Fuel Rail Pressure Sensor System High Level)
226
Error Code [452] (Abnormality in Fuel Rail Pressure Sensor System Low Level)
227
Error Code [455] (Abnormality in Fuel Rail Actuator System Current)
228
Error Code [467] (Abnormality in Timing Rail Actuator Control)
229
Error Code [468] (Abnormality in Fuel Rail Actuator Control)
229
Error Code [514] (Abnormality in Fuel Rail Actuator)
229
Error Code [527] (Abnormality in Dual Output Solenoid a System)
230
Error Code [529] (Abnormality in Dual Output Solenoid B System)
231
Error Code [551] (Abnormality 2 in Idling Validation Switch System)
231
Error Code [554] (Abnormality in Fuel Rail Pressure Sensor in Range)
232
Troubleshooting of Controller System of Engine for Generator Equipment (Eb Mode)
234
Points to Remember When Troubleshooting
235
Method of Using Troubleshooting Charts
237
Error Code Display and Points to Remember When Troubleshooting
238
Action Taken by Controller and Condition of Machine When Error Code Is Displayed
241
Error Code [E-10] (Abnormality in Power Source Voltage System)
249
Error Code [E-16] (Abnormality in Fuel Shut-Off Valve System Voltage)
249
Error Code [E-1B] (Abnormality in Engine Speed Sensor a System)
251
Error Code [E-1C] (Abnormality in Engine Speed Sensor B System)
252
Error Code [E-21] (Mistaken of Connection of Wiring Harness Connector)
253
Error Code [E-22] (Overrun)
254
Error Code [E-23] (Overheat)
254
Error Code [E-24] (Abnormal Drop in Oil Pressure)
255
Error Code [E-34] (Abnormality in Coolant Temperature Sensor System)
256
Error Code [E-56] (Abnormality in Solenoid Power Source 1 System)
257
Error Code [E-57] (Abnormality in Solenoid Power Source 2 System)
258
Error Code [E-58] (Abnormality in Backup Power Source System)
259
Error Code [E-59] (Abnormality in Switch Power Source System)
260
Error Code [E-70] (Abnormality in Fuel Rail Pressure Sensor System High Level)
261
Error Code [E-71] (Abnormality in Fuel Rail Pressure Sensor System Low Level)
262
Error Code [E-72] (Abnormality in Fuel Rail Pressure Sensor System in Range)
263
Error Code [E-73] (Abnormality in Fuel Rail Actuator)
264
Error Code [E-75] (Abnormality with Electric Current in Fuel Rail Actuator System)
265
Error Code [E-80] (Abnormality in Timing Rail Pressure Sensor System High Level)
267
Error Code [E-81] (Abnormality in Timing Rail Pressure Sensor System Low Level)
268
Error Code [E-82] (Abnormality in Timing Rail Pressure Sensor System in Range)
269
Error Code [E-83] (Abnormality in Timing Rail Actuator)
271
Error Code [E-85] (Abnormality with Electric Current in Timing Rail Actuator System)
272
Error Code [E-90] (Abnormality in Fuel Pump Pressure Sensor System High Level)
273
Error Code [E-91] (Abnormality in Fuel Pump Pressure Sensor System Low Level)
274
Error Code [E-93] (Abnormality in Fuel Pump Actuator)
275
Error Code [E-95] (Abnormality with Electric Current in Fuel Pump Actuator System)
276
Error Code [E-A0]
277
Error Code [E-A1] (Abnormality in Starting Switch on Signal System)
278
Error Code [E-A2] (Abnormality in Power Source Retention Relay System)
279
Error Code [E-A3] (Abnormality in Emergency Stop Signal Input)
280
Error Code [E-B0] (Abnormality in Atmospheric Pressure Sensor System High Level)
281
Error Code [E-B1] (Abnormality in Atmospheric Pressure Sensor System Low Level)
282
Error Code [E-B2] (Abnormality in Boost Air Pressure Sensor System High Level)
283
Error Code [E-B3] (Abnormality in Boost Air Pressure Sensor System Low Level)
284
Error Code [E-B4] (Abnormality in Boost Air Pressure Sensor System in Range)
285
Error Code [E-B6] (Abnormality in Droop Adjustment Volume System)
285
Error Code [E-B7] (Abnormality in Rated Speed Adjustment Volume System)
287
Error Code [E-B8] (Abnormality in Li Speed Adjustment Volume System)
289
Error Code [E-B9] (Abnormality in Lamp Time Adjustment Volume System)
291
Error Code [E-Ba] (Abnormality in P Constant Adjustment Volume System)
293
Error Code [E-Bb] (Abnormality I Constant Adjustment Volume System)
295
Error Code [E-Bc] (Abnormality in D Constant Adjustment Volume System)
297
Error Code [E-Bd] (Abnormality in Fuel Temperature Sensor System)
299
Error Code [E-Be] (Abnormal Rise in Fuel Temperature)
300
13 Disassembly and Assembly
301
14 Maintenance Standard
359
Repair and Replacement of Parts
386
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