Komatsu 12V170-1 Series Engine Shop Manual SEBE61800105 – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 12V170-1 Series Engine Shop Manual SEBE61800105 – PDF DOWNLOAD
FOREWORD:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
STRUCTURE AND FUNCTION
This 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.
TESTING AND ADJUSTMENTS
This sections explains checks to be made before and after performing repairs, as well as adjustments to be
made at completion of the checks and repairs.
Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.
REMOVAL AND INSTALLATION
This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu 12V170-1 Series Engine Shop Manual SEBE61800105 – PDF DOWNLOAD
COVER 1
CONTENTS 2
01 GENERAL 25
SPECIFICATIONS 26
ENGINE PERFORMANCE CURVE 30
WEIGHT TABLE 41
11 STRUCTURE AND FUNCTION 43
GENERAL STRUCTURE 44
INTAKE AND EXHAUST SYSTEM 46
AFTER-COOLER 46
TURBOCHARGER 47
ENGINE BODY 50
CYLINDER HEAD 50
VALVE SYSTEM 51
CYLINDER BLOCK 53
MAIN REVOLVING PART 54
TIMING GEAR 55
FLYWHEEL AND FLYWHEEL HOUSING 57
LUBRICATION SYSTEM 58
LUBRICATION SYSTEM CHART 58
OIL PUMP 60
OIL FILTER 61
OIL COOLER 63
OIL COOLER BYPASS VALVE 64
PISTON COOLING VALVE 64
MECHANICAL PUMP 65
FUEL SYSTEM 66
FUEL SYSTEM CHART 66
FUEL INJECTION PUMP 69
FEED PUMP 70
FUEL INJECTION NOZZLE 71
FUEL INJECTION PUMP DRIVE 72
FUEL FILTER 74
INJECTION PUMP RACK CONTROLLER 75
AUTOMATIC TIMER 77
FUEL SOLENOID 78
ENGINE STOP MOTOR 79
COOLING SYSTEM 84
COOLING SYSTEM CHART 84
WATER PUMP 86
WATER PUMP DRIVE 88
FAN DRIVE AND TENSION PULLEY 89
CORROSION RESISTOR 92
THERMOSTAT 93
ACCESSORY 94
AIR COMPRESSOR MOUNTING 94
AIR COMPRESSOR 95
ALTERNATOR WITH REGULATOR 96
STARTING MOTOR 97
AIR STARTING MOTOR 98
12 TESTING AND ADJUSTING 99
COOLING SYSTEM 100
CHECKING AND ADJUSTING FAN BELT TENSION 100
CHECKING AND ADJUSTING ALTERNATOR BELT TENSION 101
ENGINE BODY 102
ADJUSTING VALVE CLEARANCE 102
MEASURING COMPRESSION PRESSURE 103
MEASURING BLOW-BY 104
FUEL SYSTEM 105
TESTING AND ADJUSTING FUEL INJECTION TIMING 105
ADJUSTING FUEL INJECTION PUMP RACK LINKAGE 107
ADJUSTING ENGINE STOP MOTOR 108
ADJUSTING ENGINE SPEED SENSOR 109
ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE) 110
FUEL INJECTION PUMP CALIBRATION DATA 112
PERFORMANCE TEST 119
RUN-IN STANDARD 119
PERFORMANCE TEST CRITERIA 121
TESTING AND ADJUSTING DATA 125
TESTING AND ADJUSTING TOOL LIST 129
TROUBLESHOOTING 131
POINTS TO REMEMBER WHEN TROUBLESHOOTING 132
METHOD OF USING TROUBLESHOOTING CHART 133
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 137
S-2 ENGINE DOES NOT START 138
(1) ENGINE DOES NOT TURN 138
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 139
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 140
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR) 141
S-4 ENGINE STOPS DURING OPERATIONS 142
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 143
S-6 ENGINE LACKS OUTPUT (NO POWER) 144
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 145
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 146
S-9 OIL BECOMES CONTAMINATED QUICKLY 147
S-10 FUEL CONSUMPTION IS EXCESSIVE 148
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 149
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 150
S-13 OIL LEVEL RISES 151
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 152
S-15 ABNORMAL NOISE IS MADE 153
S-16 VIBRATION IS EXCESSIVE 154
13 DISASSEMBLY AND ASSEMBLY 155
GENERAL DISASSEMBLY CONTENTS 156
DISASSEMBLY 157
1 WASHING 157
2 SETTING ENGINE STAND 157
3 ENGINE COOLING WATER AND ENGINE OIL 157
4 BY-PASS FILTER (D575A-2,575A-2SD) 158
5 AIR CLEANER AND MUFFLER ASSEMBLY 158
6 TUBE FOR OIL FILTER 159
7 OIL FILTER 159
8 CORROSION RESISTOR 159
9 FUEL TUBE 159
10 FILTER BRACKET 159
11 EXHAUST MANIFOLD COVER 160
12 TURBOCHARGER ASSEMBLY 160
13 EXHAUST CONNECTOR 162
14 WATER TUBE,TURBOCHARGER LUBRICATION TUBE,EXHAUST TUBE 162
15 BRACKET,OIL CONNECTOR,BREATHER 162
16 WATER TUBE 163
17 AFTER-COOLER ASSEMBLY 163
18 PLATE,CASE 164
19 FUEL INJECTION PIPES,SPILL TUBES 164
20 FUEL TUBES 165
21 LUBRICATION HOSES,BOOST COMPENSATOR HOSE 166
22 LUBRICATION TUBES (D575A-2,D575A-2SD) 167
22A MECHANICAL PUMP ASSEMBLY (EXCEPT D575A-2,D575A-2SD) 167
23 FUEL INJCTION PUMP ASSEMBLY 167
24 EXHAUST MANIFOLD 169
25 ALTERNAOR ASSEMBLY (EXCEPT D575A-2,D575A-2SD) 169
26 WATER PUMP ASSEMBLY 169
27 AIR COMPRESSOR ASSEMBLY (EXCEPT D575A-2,D575A-2SD) 169
28 OIL COOLER ASSEMBLY 170
29 OIL PAN 171
30 AIR VENT TUBE 171
31 THERMOSTAT ASSEMBLY 171
32 CYLINDER HEAD COVERS 172
33 NOZZLE HOLDERS 172
34 ROCKER ARM HOUSING ASSEMBLY 173
35 PUSH RODS 173
36 CROSSHEADS 173
37 CYLINDER HEAD ASSEMBLY 173
38 OIL PUMP ASSEMBLY 174
39 STARTING MOTOR ASSEMBLY 175
40 FLYWHEEL 175
41 FLYWHEEL HOUSING 176
42 CRANKSHAFT PULLEY,VIBRATION DAMPER 176
43 DRIVE CASE ASSEMBLY 176
44 RETAINER,FRONT SUPPORT 176
45 GEAR CASE COVER,TIMER CASE COVER 177
46 TIMER ASSEMBLY 177
47 FUEL INJECTION PUMP DRIVE CASE 177
48 INTAKE MANIFOLD 177
49 CAM FOLLOWER 178
50 GEAR TRAIN 178
51 CAMSHAFT ASSEMBLY 178
52 GEAR CASE 179
53 MAIN GALLERY PLUG,OIL PLUG,COOLING VALVE 179
54 SIDE COVER 179
55 PISTON COOLING NOZZLE 180
56 CHANGING POSITION OF ENGINE 180
57 PISTON AND CONNECTING ROD ASSEMBLY 180
58 CRANKSHAFT 181
59 CYLINDER LINER 182
GENERAL ASSEMBLY CONTENTS 183
ASSEMBLY 185
1 CYLINDER LINER 186
2 CRANKSHAFT 188
3 PISTON,CONNECTING ROD ASSEMBLY 192
4 CHANGING POSITION OF ENGINE 197
5 PISTON COOLING NOZZLE 197
6 SIDE COVER 197
7 MAIN GALLERY PLUG,OIL PLUG,COOLING VALVE 197
8 GEAR CASE 197
9 CAMSHAFT ASSEMBLY 199
10 GEAR TRAIN 200
11 CAM FOLLOWER 202
12 INTAKE MANIFOLD 202
13 PUMP DRIVE CASE 203
14 AUTO TIMER ASSEMBLY 203
15 FRONT SHAFT 205
16 GEAR CASE COVER 205
17 TIMER COVER 206
18 WATER PUMP DRIVE CASE 206
19 COMPRESSOR DRIVE CASE 208
20 BREATHER CONNECTOR 208
21 FRONT SEAL 209
22 FRONT SUPPORT 209
23 VIBRATION DAMPER 209
24 PISTON COOLING VALVE 211
25 OIL COOLER ASSEMBLY 211
26 WATER PUMP ASSEMBLY 213
27 FLYWHEEL HOUSING ASSEMBLY 214
28 REAR SEAL 215
29 FLYWHEEL 216
30 STARTING MOTOR ASSEMBLIES 217
31 CYLINDER HEAD ASSEMBLY 217
32 CROSSHEAD 220
33 ROCKER HOUSING 220
34 PUSH ROD 221
35 ROCKER ARM ASSEMBLY 221
36 INJECTION NOZZLE ASSEMBLY 223
37 AFTERCOOLER ASSEMBLY 223
38 WATER TUBES 224
39 HEAD COVER 224
40 THERMOSTAT CASE ASSEMBLIES 225
41 FUEL INJECTION PUMP ASSEMBLY 226
42 AIR VENT TUBE 228
43 MUFFLER BRACKET 228
44 SPILL HOSES 229
45 LUBRICATION TUBES 229
46 BOOST COMPENSATOR HOSE 229
47 FUEL AIR VENT HOSES 229
48 INJECTION PUMP LUBRICATION PIPING 230
49 FUEL SUPPLY,OVERFLOW PIPES 230
50 FUEL INJECTION TUBES 230
51 BRAKET,OIL CONNECTOR 230
52 EXHAUST MANIFOLD 231
53 TURBOCHARGER LUBRICATION PIPING,COOLANT WATER PIPING 232
54 EXHAUST CONNECTOR 232
55 TURBOCHARGER ASSEMBLY 233
56 EXHAUST MANIFOLD COVER 234
57 OIL FILLER 234
58 BYPASS TUBE 235
59 BLOWBY HOSE 235
60 OIL PUMP ASSEMBLY 235
61 OIL PAN 236
62 OIL LEVEL SENSOR,DRAIN VALVE 236
63 FILTER BRACKET 237
64 FUEL TUBE 237
65 CORROSION RESISTOR 237
66 OIL FILTER 237
67 TUBE FOR OIL FILTER 237
68 INTAKE PIPES 237
69 AIR CLEANER,MUFFLER ASSEMBLY 238
70 BYPASS FILTER ASSEMBLY 238
14 MAINTENANCE STANDARD 239
INTAKE AND EXHAUST SYSTEM 240
TURBOCHARGER 240
ENGINE BODY 242
CYLINDER HEAD 242
VALVES AND VALVE GUIDE 243
CROSSHEAD AND CROSSHEAD GUIDE 244
ROCKER ARM SHAFT 245
PUSH ROD AND CAM FOLLOWER 246
CYLINDER BLOCK 247
CYLINDER LINER 249
CAMSHFT 250
CRANKSHAFT 251
PISTON 253
CONNECTING ROD 254
TIMING GEAR 255
FLYWHEEL, FLYWHEEL HOUSING 256
LUBRICATION SYSTEM 257
OIL PUMP 257
MAIN RELIEF VALVE, PISTON COOLING VALVE AND OIL COOLER BYPASS VALVE 258
COOLING SYSTEM 259
WATER PUMP 259
15 REPAIR AND REPLACEMENT OF PARTS 260
CYLINDER HEAD 261
TESTING AND INSPECTING 262
REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING 264
REPLACING VALVE SEAT INSERTS 265
REPLACING NOZZLE HOLDER SLEEVE 270
REPLACING VALVE GUIDE 274
REPLACING CROSS HEAD GUIDE 275
GRINDING THE VALVE 276
CYLINDER BLOCK 277
TESTING AND INSPECTING 278
GRINDING THE TOP SURFACE OF CYLINDER BLOCK 280
REPLACING MAIN METAL CAP 285
REPLACING CAM BUSHING 287
CRANKSHAFT 288
REPLACING THE CRANKSHAFT 295
CONNECTING ROD 303
REPLACING CAM GEAR 307
REPLACING FLYWHEEL RING GEAR 307
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