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KOMATSU 8V170-1 SERIES ENGINE SHOP MANUAL SEBE61700104 – PDF DOWNLOAD
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Description
KOMATSU 8V170-1 SERIES ENGINE SHOP MANUAL SEBE61700104 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 8V170-1 SERIES ENGINE SHOP MANUAL SEBE61700104 – PDF DOWNLOAD
Language : English
Pages : 333
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 8V170-1 SERIES ENGINE SHOP MANUAL SEBE61700104 – PDF DOWNLOAD
COVER..................................................................................... 1 CONTENTS.................................................................................. 2 01 GENERAL................................................................................ 13 GENERAL VIEW.......................................................................... 14 SPECIFICATIONS........................................................................ 15 GENERAL ASSEMBLY DRAWING.............................................................. 16 WEIGHT TABLE.......................................................................... 28 ENGINE PERFORMANCE CURVE.............................................................. 29 11 STRUCTURE AND FUNCTION................................................................. 32 GENERAL STRUCTURE..................................................................... 33 INTAKE AND EXHAUST SYSTEM............................................................. 35 INTAKE SYSTEM..................................................................... 35 EXHAUST SYSTEM.................................................................... 36 TURBOCHARGER...................................................................... 37 ENGINE BODY........................................................................... 38 CYLINDER HEAD..................................................................... 38 VALVE SYSTEM...................................................................... 40 CYLINDER BLOCK.................................................................... 42 MAIN REVOLVING SYSTEM............................................................. 43 TIMING GEAR....................................................................... 44 FLYWHEEL AND FLYWHEEL HOUSING..................................................... 46 LUBRICATION SYSTEM.................................................................... 47 LUBRICATION SYSTEM CHART.......................................................... 47 OIL PUMP.......................................................................... 48 OIL FILTER AND SAFETY VALVE....................................................... 49 OIL COOLER ....................................................................... 50 OIL COOLER BYPASS VALVE........................................................... 51 PISTON COOLING VALVE.............................................................. 51 MECHANICAL PUMP................................................................... 52 FUEL SYSTEM........................................................................... 53 FUEL SYSTEM CHART................................................................. 53 FUEL INJECTION PUMP............................................................... 54 FUEL INJECTION NOZZLE............................................................. 68 FEED PUMP......................................................................... 69 FUEL INJECTION PUMP DRIVE......................................................... 72 TIMER............................................................................. 73 FUEL FILTER....................................................................... 76 STARTING AID...................................................................... 77 ENGINE STOP MOTOR................................................................. 78 COOLING SYSTEM........................................................................ 83 COOLING SYSTEM CHART.............................................................. 83 WATER PUMP........................................................................ 84 WATER PUMP DRIVE.................................................................. 85 FAN DRIVE AND TENSION PULLEY...................................................... 86 CORROSION RESISTOR................................................................ 87 THERMOSTAT........................................................................ 88 ACCESSORY............................................................................. 89 AIR COMPRESSOR MOUNTING........................................................... 89 AIR COMPRESSOR.................................................................... 90 ALTERNATOR WITH REGULATOR......................................................... 91 STARTING MOTOR.................................................................... 92 12 TESTING AND ADJUSTING.................................................................. 93 COOLING SYSTEM........................................................................ 94 CHECKING AND ADJUSTING ALTERNATOR BELT TENSION.................................... 94 ENGINE BODY........................................................................... 96 ADJUSTING VALVE CLEARANCE......................................................... 96 FUEL SYSTEM........................................................................... 97 TESTING AND ADJUSTING FUEL INJECTION TIMING....................................... 97 ADJUSTING FUEL INJECTION TIMING BY DELIVERY CHECK................................. 98 ADJUSTING FUEL INJECTION NOZZLE CRACKING PRESSURE................................. 99 ADJUSTING ENGINE STOP MOTOR CABLE ................................................101 FUEL INJECTION PUMP CALIBRATION DATA..............................................103 PERFORMANCE TEST......................................................................107 RUN-IN STANDARD...................................................................107 PERFORMANCE TEST CRITERIA.........................................................108 TESTING AND ADJUSTING TOOL LIST...................................................110 TESTING AND ADJUSTING DATA........................................................111 TROUBLESHOOTING.......................................................................113 POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................115 METHOD OF USING TROUBLESHOOTING CHART.............................................116 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).....................120 S-2 ENGINE DOES NOT START.........................................................121 ① ENGINE DOES NOT TURN........................................................121 ② ENGINE TURNS BUT NO EXHAUST COMES OUT (FUEL IS NOT BEING INJECTED)..........122 ③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....123 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..........................124 S-4 ENGINE STOPS DURING OPERATIONS................................................125 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).....................................126 S-6 ENGINE LACKS OUTPUT (NO POWER)................................................127 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)..................................128 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).........................129 S-9 OIL BECOMES CONTAMINATED QUICKLY..............................................130 S-10 FUEL CONSUMPTION IS EXCESSIVE................................................131 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN......132 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...........................133 S-13 OIL LEVEL RISES..............................................................134 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING0.............................135 S-15 ABNORMAL NOISE IS MADE.......................................................136 S-16 VIBRATION IS EXCESSIVE.......................................................137 13 DISASSEMBLY AND ASSEMBLY...............................................................138 GENERAL ..............................................................................139 DISASSEMBLY.......................................................................139 WASHING...........................................................................178 WASHING CYLINDER BLOCK........................................................180 WASHING CRANKSHAFT............................................................181 MEASRUING AND INSPECTION PARTS....................................................182 MEASURING PARTS...............................................................183 MEASURING CURVATURE OF CRANKSHAFT.........................................183 MEASURING OUTSIDE DIAMETER OF JOURNAL.....................................183 MEASURING DEPTH OF CYLINDER LINER COUNTERBORE.............................184 MEASURING MAIN BEARING BORE...............................................184 MEASURING CURVATURE OF CAMSHAFT...........................................185 MEASURING OUTSIDE DIAMETER OF JOURNAL.....................................185 MEASURING HEIGHT OF CAM...................................................185 MEASURING PISTON RING GROOVE..............................................186 MEASURING PISTON RING END GAP.............................................186 ASSEMBLY..........................................................................187 14 MAINTENANCE STANDARD...................................................................265 INTAKE AND EXHAUST SYSTEM ............................................................266 TURBOCHARGER......................................................................266 ENGINE BODY...........................................................................267 CYLINDER HEAD.....................................................................267 VALVE AND VALVE GUIDE.............................................................268 ROCKER ARM SHAFT..................................................................269 CROSSHEAD.........................................................................270 CAM FOLLOWER AND PUSH ROD.........................................................271 CYLINDER BLOCK....................................................................272 CYLINDER LINER....................................................................274 CAMSHAFT..........................................................................275 CRANKSHAFT........................................................................276 PISTON............................................................................278 CONNECTING ROD....................................................................279 TIMING GEAR.......................................................................280 FLYWHEEL AND FLYWHEEL HOUSING.....................................................282 LUBRICATION SYSTEM....................................................................283 OIL PUMP..........................................................................283 MAIN RELIEF VALVE, PISTON COOLING VALVE AND OIL COOLER BYPASS VALVE...............284 COOLING SYSTEM........................................................................285 WATER PUMP........................................................................285 15 REPAIR AND REPLACEMENT OF PARTS........................................................286 CYLINDER HEAD.........................................................................287 TESTING AND INSPECTION................................................................288 REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING..................................290 REPLACING VALVE SEAT INSERTS..........................................................291 REPLACING NOZZLE HOLDER SLEEVE........................................................296 REPLACING VALVE GUIDE.................................................................300 REPLACING CROSS HEAD GUIDE............................................................301 GRINDING THE VALVE....................................................................302 CYLINDER BLOCK........................................................................303 TESTING AND INSPECTION................................................................304 GRINDING THE TOP SURFACE OF CYLINDER BLOCK............................................306 REPLACING MAIN METAL CAP..............................................................311 REPLACING CAM BUSHING.................................................................313 CRANKSHAFT............................................................................314 REPLACING THE CRANKSHAFT..............................................................321 CONNECTING ROD........................................................................329 REPLACING CAM GEAR....................................................................333 REPLACING FLYWHEEL RING GEAR..........................................................333
DESCRIPTION:
KOMATSU 8V170-1 SERIES ENGINE SHOP MANUAL SEBE61700104 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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 lull effect at every opportunity.
This shop manual mainly contain: the necessary technical information for operations performed in a service workshop.
For ease of understanding. the manual is divided into chapters for 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 servos not only to give an understanding of the structure, but also serves or; reference material for troubleshooting.
TESTING AND ADJUSTING
This section 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.
DISASSEMBLY AND ASSEMBLY
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
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 02/01/2025
