Komatsu 12v170-1 Series Engine Shop Manual SEBEB61800105 – PDF DOWNLOAD

Komatsu 12v170-1 Series Engine Shop Manual SEBEB61800105 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 12v170-1 Series Engine Shop Manual SEBEB61800105 – PDF DOWNLOAD

Language : English
Pages : 307
Downloadable : Yes
File Type : PDF
Size: 18 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 12v170-1 Series Engine Shop Manual SEBEB61800105 – PDF DOWNLOAD

The Komatsu 12v170-1 Series Engine Shop Manual SEBEB61800105 is a comprehensive guide that provides detailed information on the maintenance, repair, and overhaul of the 12v170-1 series engine. This engine is used in a variety of Komatsu equipment, including large construction machinery and mining equipment.

• The manual is organized into several sections, each covering a different aspect of the engine. The first section provides an overview of the engine, including its specifications and performance data. This section also includes a table of contents, a list of illustrations, and a list of symbols and abbreviations used throughout the manual.
• The second section of the manual covers engine inspection and measurement procedures. This section provides step-by-step instructions for checking and measuring various components of the engine, including the cylinder block, crankshaft, and connecting rods. The manual includes detailed illustrations to help the reader understand the procedures.
• The third section covers engine disassembly and assembly procedures. This section provides instructions for removing and installing various components of the engine, including the cylinder head, pistons, and crankshaft. The manual also includes torque specifications for each component.
• The fourth section covers engine testing and adjusting procedures. This section provides instructions for testing and adjusting various components of the engine, including the fuel injection system, the turbocharger, and the valve clearance. The manual includes detailed illustrations to help the reader understand the procedures.
• The fifth section covers engine maintenance procedures, including routine maintenance and inspections. This section provides instructions for maintaining the engine to ensure its continued performance and longevity.
• The sixth section covers engine troubleshooting and diagnosis procedures. This section provides instructions for diagnosing and troubleshooting various engine problems, including starting problems, low power output, and excessive smoke. The manual includes a troubleshooting chart and detailed illustrations to help the reader diagnose and fix the problem.
• Overall, the Komatsu 12v170-1 Series Engine Shop Manual SEBEB61800105 is an essential tool for anyone working on or maintaining this engine. The manual is available in print or digital formats, making it a convenient and accessible resource for mechanics and technicians. It is designed to be user-friendly and easy to understand, with clear instructions and detailed illustrations. With this manual, you can ensure that your Komatsu equipment is operating at its best and avoid costly repairs and downtime.

TABLE OF CONTENTS:

Komatsu 12v170-1 Series Engine Shop Manual SEBEB61800105 – 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