Komatsu 12V170-1 Series Diesel Engine Shop Manual SEBE61800104 – PDF DOWNLOAD

Komatsu 12V170-1 Series Diesel Engine Shop Manual SEBE61800104 – PDF DOWNLOAD

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Komatsu 12V170-1 Series Diesel Engine Shop Manual SEBE61800104 – PDF DOWNLOAD

Language : English
Pages : 305
Downloadable : Yes
File Type : PDF
Size: 29.2 MB

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Komatsu 12V170-1 Series Diesel Engine Shop Manual SEBE61800104 – PDF DOWNLOAD

• The Komatsu 12V170-1 Series Diesel Engine Shop Manual SEBE61800104 is a comprehensive guidebook that provides detailed technical information and instructions on how to operate, maintain, and repair the Komatsu 12V170-1 series diesel engines. These engines are commonly used in heavy construction and mining equipment, as well as power generation applications.
• The manual is organized into several sections, each providing detailed information on specific topics. These sections include specifications, structure and function, testing and adjusting, disassembly and assembly, maintenance, and troubleshooting.
• The specifications section of the manual provides detailed information on the engine’s physical and operational characteristics, including its dimensions, weight, performance, and power output. It also provides information on the engine’s cooling system, fuel system, and lubrication system.
• The structure and function section of the manual provides an overview of the engine’s internal components and their functions. This section includes detailed diagrams and descriptions of the engine’s various components, such as the cylinder block, cylinder head, crankshaft, pistons, and valves.
• The testing and adjusting section of the manual provides instructions on how to test and adjust the engine’s various components to ensure they are functioning correctly. This section includes detailed procedures for testing and adjusting the engine’s fuel injection system, valve clearances, and oil pressure.
• The disassembly and assembly section of the manual provides step-by-step instructions on how to disassemble and reassemble the engine’s various components. This section includes detailed diagrams and photographs to guide the user through the process.
• The maintenance section of the manual provides information on routine maintenance tasks that should be performed to keep the engine in good working condition. This section includes instructions on how to perform tasks such as changing the engine oil and replacing the air filter.
• The troubleshooting section of the manual provides guidance on how to diagnose and resolve common issues that may arise with the engine. This section includes a list of common symptoms and their likely causes, as well as step-by-step instructions for troubleshooting and resolving each issue.
• Overall, the Komatsu 12V170-1 Series Diesel Engine Shop Manual SEBE61800104 is an essential resource for anyone who operates, maintains, or repairs these powerful diesel engines. With its detailed technical information and comprehensive instructions, this manual is an invaluable tool for ensuring the efficient and reliable operation of Komatsu 12V170-1 series engines in heavy equipment applications.

TABLE OF CONTENTS:

Komatsu 12V170-1 Series Diesel Engine Shop Manual SEBE61800104 – PDF DOWNLOAD

MAIN MENU…………………………………………………………………………. 0
COVER…………………………………………………………………………….. 1
CONTENTS………………………………………………………………………….. 2
01 GENERAL………………………………………………………………………… 22
SPECIFICATIONS…………………………………………………………………. 23
ENGINE PERFORMANCE CURVE………………………………………………………… 27
WEIGHT TABLE…………………………………………………………………… 39
11 STRUCTURE AND FUNCTION ………………………………………………………….. 41
GENERAL STRUCTURE ……………………………………………………………… 42
INTAKE AND EXHAUST SYSTEM ………………………………………………………. 44
AFTER-COOLER ………………………………………………………………. 44
TURBOCHARGER ………………………………………………………………. 45
ENGINE BODY …………………………………………………………………… 48
CYLINDER HEAD ……………………………………………………………… 48
VALVE SYSTEM……………………………………………………………….. 49
CYLINDER BLOCK …………………………………………………………….. 51
MAIN REVOLVING PART…………………………………………………………. 52
TIMING GEAR………………………………………………………………… 53
FLYWHEEL AND FLYWHEEL HOUSING………………………………………………… 55
LUBRICATION SYSTEM …………………………………………………………….. 56
LUBRICATION SYSTEM CHART (With bypass filter) …………………………………. 56
OIL PUMP ………………………………………………………………….. 58
OIL FILTER…………………………………………………………………. 59
OIL COOLER ………………………………………………………………… 61
OIL COOLER BYPASS VALVE……………………………………………………… 62
PISTON COOLING VALVE………………………………………………………… 62
MECHANICAL PUMP…………………………………………………………….. 63
FUEL SYSTEM …………………………………………………………………… 64
FUEL SYSTEM CHART ………………………………………………………….. 64
FUEL INJECTION PUMP ………………………………………………………… 67
FEED PUMP …………………………………………………………………. 68
FUEL INJECTION NOZZLE ………………………………………………………. 69
FUEL INJECTION PUMP DRIVE …………………………………………………… 70
FUEL FILTER ……………………………………………………………….. 72
INJECTION PUMP RACK CONTROLLER ………………………………………………. 73
AUTOMATIC TIMER…………………………………………………………….. 75
FUEL SOLENOID ……………………………………………………………… 76
ENGINE STOP MOTOR…………………………………………………………… 77
COOLING SYSTEM ………………………………………………………………… 82
COOLING SYSTEM CHART ……………………………………………………….. 82
WATER PUMP…………………………………………………………………. 84
WATER PUMP DRIVE……………………………………………………………. 86
FAN DRIVE AND TENSION PULLEY…………………………………………………. 87
CORROSION RESISTOR………………………………………………………….. 90
THERMOSTAT ………………………………………………………………… 91
ACCESSORY……………………………………………………………………… 92
AIR COMPRESSOR MOUNTING …………………………………………………….. 92
AIR COMPRESSOR……………………………………………………………… 93
ALTERNATOR WITH REGULATOR……………………………………………………. 94
STARTING MOTOR……………………………………………………………… 95
AIR STARTING MOTOR …………………………………………………………. 96
12 TESTING AND ADJUSTING …………………………………………………………… 97
COOLING SYSTEM ………………………………………………………………… 98
CHECKING AND ADJUSTING FAN BELT TENSION ………………………………………. 98
CHECKING AND ADJUSTING ALTERNATOR BELT TENSION ………………………………… 99
ENGINE BODY ……………………………………………………………………100
ADJUSTING VALVE CLEARANCE ……………………………………………………100
MEASURING COMPRESSION PRESSURE………………………………………………..101
MEASURING BLOW-BY …………………………………………………………..102
FUEL SYSTEM ……………………………………………………………………103
TESTING AND ADJUSTING FUEL INJECTION TIMING ……………………………………103
ADJUSTING FUEL INJECTION PUMP RACK LINKAGE …………………………………….105
ADJUSTING ENGINE STOP MOTOR ………………………………………………….106
ADJUSTING ENGINE SPEED SENSOR ………………………………………………..107
ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE) …………………….108
FUEL INJECTION PUMP CALIBRATION DATA ………………………………………….110
PERFORMANCE TEST ……………………………………………………………….118
RUN-IN STANDARD …………………………………………………………….118
PERFORMANCE TEST CRITERIA ……………………………………………………120
TESTING AND ADJUSTING DATA……………………………………………………124
TESTING AND ADJUSTING TOOL LIST……………………………………………….128
TROUBLESHOOTING…………………………………………………………………130
POINTS TO REMEMBER WHEN TROUBLESHOOTING ……………………………………….131
METHOD OF USING TROUBLESHOOTING CHART ………………………………………..132
S-1 Starting performance is poor (Starting always takes time) ……………………136
S-2 Engine does not start ……………………………………………………137
(1) Engine does not turn………………………………………………….137
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)……138
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)….139
S-3 Engine does not pick-up smoothly (Follow-up is poor) ………………………..140
S-4 Engine stops during operations ……………………………………………141
S-5 Engine does not rotate smoothly (Hunting) ………………………………….142
S-6 Engine lacks output (No power) ……………………………………………143
S-7 Exhaust smoke is black (Incomplete combustion) …………………………….144
S-8 Oil consumption is excessive (Or exhaust smoke is blue) ……………………..145
S-9 Oil becomes contaminated quickly ………………………………………….146
S-10 Fuel consumption is excessive ……………………………………………147
S-11 Oil is in cooling water, or water spurts back, or water level goes down ………148
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ………………….149
S-13 Oil level rises ………………………………………………………..150
S-14 Water temperature becomes too high (Overheating) …………………………..151
S-15 Abnormal noise is made ………………………………………………….152
S-16 Vibration is excessive ………………………………………………….153
13 DISASSEMBLY AND ASSEMBLY………………………………………………………….154
DISASSEMBLY…………………………………………………………………….156
ASSEMBLY……………………………………………………………………….184
14 MAINTENANCE STANDARD……………………………………………………………..238
INTAKE AND EXHAUST SYSTEM ……………………………………………………..239
TURBOCHARGER ……………………………………………………………….239
COOLING SYSTEM …………………………………………………………………258
WATER PUMP …………………………………………………………………258
ENGINE BODY…………………………………………………………………….241
CYLINDER HEAD……………………………………………………………….241
VALVES AND VALVE GUIDE……………………………………………………….242
CROSSHEAD AND CROSSHEAD GUIDE…………………………………………………243
ROCKER ARM SHAFT…………………………………………………………….244
PUSH ROD AND CAM FOLLOWER…………………………………………………….245
CYLINDER BLOCK………………………………………………………………246
CYLINDER LINER………………………………………………………………248
CAMSHAFT……………………………………………………………………249
CRANKSHAFT………………………………………………………………….250
PISTON……………………………………………………………………..252
CONNECTING ROD………………………………………………………………253
TIMING GEAR…………………………………………………………………254
FLYWHEEL, FLYWHEEL HOUSING……………………………………………………255
LUBRICATION SYSTEM………………………………………………………………256
OIL PUMP……………………………………………………………………256
MAIN RELIEF VALVE, PISTON COOLING VALVE AND OIL COOLER BYPASS VALVE……………….257
COOLING SYSTEM………………………………………………………………….258
WATER PUMP………………………………………………………………….258
15 REPAIR AND REPLACEMENT OF PARTS……………………………………………………259
CYLINDER HEAD…………………………………………………………………..260
TESTING AND INSPECTING……………………………………………………….261
REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING…………………………….263
REPLACING VALVE SEAT INSERTS………………………………………………….264
REPLACING NOZZLE HOLDER SLEEVE………………………………………………..269
REPLACING VALVE GUIDE………………………………………………………..273
REPLACING CROSS HEAD GUIDE……………………………………………………274
GRINDING THE VALVE…………………………………………………………..275
CYLINDER BLOCK………………………………………………………………….276
TESTING AND INSPECTING……………………………………………………….277
GRINDING THE TOP SURFACE OF CYLINDER BLOCK……………………………………..279
REPLACING MAIN METAL CAP……………………………………………………..284
REPLACING CAM BUSHING………………………………………………………..286
CRANKSHAFT………………………………………………………………….287
REPAIRING THE CRANKSHAFT……………………………………………………..294
CONNECTING ROD………………………………………………………………301
REPLACING THE CAM GEAR……………………………………………………….305
REPLACING FLYWHEEL RING GEAR………………………………………………….305