Komatsu 12V170-2 Series Engine Shop Manual SEBM036601 – PDF DOWNLOAD

Komatsu 12V170-2 Series Engine Shop Manual SEBM036601 – PDF DOWNLOAD

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Komatsu 12V170-2 Series Engine Shop Manual SEBM036601 – PDF DOWNLOAD

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Komatsu 12V170-2 Series Engine Shop Manual SEBM036601 – PDF DOWNLOAD

• The Komatsu 12V170-2 Series Engine Shop Manual SEBM036601 is a comprehensive guidebook that provides detailed technical information and instructions on how to operate, maintain, and repair the Komatsu 12V170-2 series diesel engines. These engines are commonly used in large mining trucks, generators, and other heavy equipment.
• 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 12V170-2 Series Engine Shop Manual SEBM036601 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 12V170-2 series engines in heavy equipment applications.

TABLE OF CONTENTS:

Komatsu 12V170-2 Series Engine Shop Manual SEBM036601 – PDF DOWNLOAD

COVER………………………………………………………………………………………… 1
CONTENTS……………………………………………………………………………………… 2
01 GENERAL……………………………………………………………………………………. 25
APPLICABLE MACHINE…………………………………………………………………………. 26
SPECIFICATIONS…………………………………………………………………………….. 27
GENERAL ASSEMBLY DRAWING……………………………………………………………………. 28
WEIGHT TABLE………………………………………………………………………………. 33
ENGINE PERFORMANCE CURVE……………………………………………………………………. 34
11 STRUCTURE AND FUNCTION………………………………………………………………………. 37
GENERAL STRUCTURE………………………………………………………………………….. 38
AIR CLEANER……………………………………………………………………………….. 40
TURBOCHARGER………………………………………………………………………………. 41
AFTER-COOLER………………………………………………………………………………. 42
CYLINDER HEAD……………………………………………………………………………… 43
CYLINDER BLOCK…………………………………………………………………………….. 45
MAIN REVOLVING PART………………………………………………………………………… 47
VALVE SYSTEM………………………………………………………………………………. 49
TIMING GEAR……………………………………………………………………………….. 51
FLYWHEEL AND FLYWHEEL HOUSING……………………………………………………………….. 53
LUBRICATION SYSTEM CHART……………………………………………………………………. 54
OIL PUMP …………………………………………………………………………………. 55
OIL FILTER, SAFETY VALVE……………………………………………………………………. 56
BYPASS FILTER……………………………………………………………………………… 57
OIL COOLER………………………………………………………………………………… 58
OIL COOLER BYPASS VALVE…………………………………………………………………….. 59
PISTON COOLING VALVE……………………………………………………………………….. 59
FUEL SYSTEM CHART………………………………………………………………………….. 60
FUEL INJECTION PUMP………………………………………………………………………… 61
FUEL PIPING……………………………………………………………………………….. 63
FUEL INJECTION PUMP DRIVE…………………………………………………………………… 65
FUEL INJECTION NOZZLE………………………………………………………………………. 66
FUEL FILTER……………………………………………………………………………….. 67
COOLING SYSTEM CHART……………………………………………………………………….. 68
WATER PUMP………………………………………………………………………………… 70
WATER PUMP DRIVE…………………………………………………………………………… 71
THERMOSTAT………………………………………………………………………………… 72
CORROSION RESISTOR…………………………………………………………………………. 73
FAN DRIVE AND TENSION PULLEY………………………………………………………………… 74
ALTERNATOR………………………………………………………………………………… 75
STARTING MOTOR…………………………………………………………………………….. 76
STARTING AID………………………………………………………………………………. 78
12 TESTING AND ADJUSTING……………………………………………………………………….. 79
STANDARD VALUE TABLE FOR TESTING,ADJUST AND TROUBLESHOOTING…………………………………….. 80
TESTING AND ADJUSTING TOOL LIST……………………………………………………………… 82
ADJUSTING VALVE CLEARANCE…………………………………………………………………… 83
TESTING AND ADJUSTING OF FUEL INJECTION TIMING(WITH KOMATSU ELECTRONICAL GOVERNOR)………………… 85
MEASURING COMPRESSION PRESSURE………………………………………………………………. 88
MEASURING BLOW-BY………………………………………………………………………….. 89
ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE)…………………………………….. 90
INSTALLING ENGINE SPEED SENSOR (WITH ELECTRONIC GOVERNOR)………………………………………. 91
TESTING AND ADJUSTING ALTERNATOR BELT AND FAN BELT ……………………………………………. 92
DATA FOR FUEL INJECTION PRESSURE ADJUSTMENT SHIMS……………………………………………… 93
FUEL INJECTION PUMP CALIBRATION DATA…………………………………………………………. 94
PERFORMANCE TEST…………………………………………………………………………… 97
PERFORMANCE TEST CRITERIA…………………………………………………………………… 98
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM(E MODE)…………………………………………….100
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…………………….101
E-1 [E0401] ABNORMALITY IN ENGINE CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED…………………109
E-3 [E0403] MISTAKEN CONNECTION IN ENGINE CONTROLLER IS DISPLAYED…………………………….110
E-4 [E0405] ABNORMALITY IN FUEL CONTROL DIAL SYSTEM IS DISPLAYED……………………………..111
E-5 [E0406] ABNORMALITY IN DECELERATION POTENTIOMETER IS DISPLAYED……………………………113
E-6 [E0407] ABNORMALITY IN SHOE SLIP CONTROL COMMAND VALUE IS DISPLAYED……………………….115
E-7 [E0409] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM IS DISPLAYED………………………….116
E-8 [E0410] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM IS DISPLAYED………………………….117
E-9 [E0411] ABNORMALITY IN RIGHT RACK SENSOR SYSTEM IS DISPLAYED……………………………..118
E-10 [E0412] ABNORMALITY IN LEFT RACK SENSOR SYSTEM IS DISPLAYED …………………………….119
E-11 [E0413] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM IS DISPLAYED………………………120
E-12 [E0421] SHORT CIRCUIT IN RIGHT GOVERNOR SOLENOID SYSTEM IS DISPLAYED……………………..121
E-13 [E0422] DISCONNECTION IN RIGHT GOVERNOR SOLENOID SYSTEM IS DISPLAYED……………………..122
E-14 [E0423] SHORT CIRCUIT IN LEFT GOVERNOR SOLENOID SYSTEM IS DISPLAYED………………………123
E-15 [E0424] DISCONNECTION IN LEFT GOVERNOR SOLENOID SYSTEM IS DISPLAYED………………………124
E-16 [E0425] SHORT CIRCUIT IN RIGHT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED……………………125
E-17 [E0426] DISCONNECTION IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED……………………..126
E-18 [E0427] SHORT CIRCUIT IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED……………………..127
E-19 [E0428] DISCONNECTION IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED……………………..128
E-20 [E0433] SHORT CIRCUIT IN LEFT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED…………………….129
E-21 [E0434] DISCONNECTION IN LEFT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED…………………….130
E-22 [E0435] ABNORMALITY IN ENGINE WATER TEMPERATURE SENSOR SYSTEM IS DISPLAYED………………..131
E-23 [E0437] ABNORMALITY IN RIGHT GOVERNOR SERVO IS DISPLAYED………………………………..132
E-24 [E0438] ABNORMALITY IN LEFT GOVERNOR SERVO IS DISPLAYED ………………………………..133
E-25 [E0440] DISCONNECTION SOLENOID POWER SOURCE 1 SYSTEM IS DISPLAYED………………………..134
E-26 [E0441] DISCONNECTION IN POWER SUPPLY SYSTEM 2 OF SOLENOID IS DISPLAYED…………………..134
E-27 [E0442] ABNORMALITY IN ENGINE CONTROLLER BACKUP POWER SOURCE SYSTEM IS DISPLAYED…………..135
E-28 [E0443] ABNORMALITY IN ENGINE CONTROLLER SWITCH POWER SOURCE SYSTEM IS DISPLAYED…………..136
E-29 [E0455] ENGINE OVERHEATING IS DISPLAYED……………………………………………….137
E-30 [E0456] SHORT CIRCUIT IN RIGHT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED……………………138
E-31 [E0457] DISCONNECTION IN RIGHT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED……………………139
E-32 ENGINE DOES NOT ROTATE WHEN STARTING SWITCH IS TURNED TO ON POSITION……………………..140
E-33 ENGINE DOES NOT STOP WHEN STARTING SWITCH IS TURNED TO OFF POSITION………………………143
TROUBLESHOOTING (S-MODE)…………………………………………………………………….144
POINTS TO REMEMBER WHEN TROUBLESHOOTING……………………………………………………145
METHOD OF USING TROUBLESHOOTING CHARTS…………………………………………………….146
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)…………………………………150
S-2 ENGINE DOES NOT START………………………………………………………………..151
(1) ENGINE DOES NOT TURN……………………………………………………………..151
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)…………………152
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)……………..153
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY(FOLLOW-UP IS POOR)……………………………………..154
S-4 ENGINE STOPS DURING OPERATIONS(WITH ELECTRONICAL GOVERNOR)……………………………….155
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)(WITH ELECTRONICAL GOVERNOR)………………………156
S-6 ENGINE LACKS OUTPUT (NOT POWER)(WITH ELECTRONICAL GOVERNOR)………………………………157
S-7 EXHAUST GAS IS BLACK(INCOMPLETE COMBUSTION)(WITH ELECTRONICAL GOVERNOR)……………………158
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)…………………………………..159
S-9 OIL BECOMES CONTAMINATED QUICKLY………………………………………………………160
S-10 FUEL CONSUMPTION IS EXCESSIVE(WITH ELECTRONICAL GOVERNOR)……………………………….161
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN……………………….162
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)………………………………163
S-13 OIL LEVEL RISES…………………………………………………………………….164
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)………………………………………..165
S-15 ABNORMAL NOISE IS MADE………………………………………………………………166
S-16 VIBRATION IS EXCESSIVE………………………………………………………………167
S-17 ABNORMALITY IN GOVERNOR SERVO SYSTEM IS DISPLAYED IN TROUBLESHOOTING FOR ENGINE CONTROLLER….168
13 DISASSEMBLY AND ASSEMBLY……………………………………………………………………..170
METHOD OF USING MANUAL………………………………………………………………………172
PRECAUTIONS WHEN CARRYING OUT OPERATION……………………………………………………….173
SPECIAL TOOL LIST ………………………………………………………………………….175
GENERAL DISASSEMBLY…………………………………………………………………………176
1.CLEANING……………………………………………………………………………..176
2.SETTING ENGINE STAND…………………………………………………………………..176
3.COOLANT AND ENGINE OIL…………………………………………………………………176
4.AIR CLEANER AND MUFFLER ASSEMBLY………………………………………………………..176
5.OIL FILTER TUBES………………………………………………………………………177
6.OIL FILTER …………………………………………………………………………..177
7.FUEL TUBE…………………………………………………………………………….177
8.FILTER BACKET ………………………………………………………………………..178
9.EXHAUST MANIFOLD COVER (RIGHT SIDE IS SHOWN IN FIGURE)…………………………………….178
10.TURBOCHARGER ASSEMBLY…………………………………………………………………178
11.EXHAUST CONNECTOR…………………………………………………………………….180
12.COOLANT TUBE,TURBOCHARGER PIPE,AND EXHAUST TUBE………………………………………….180
13.AFTERCOOLER ASSEMBLY………………………………………………………………….180
14.PLATE AND CASE……………………………………………………………………….181
15.FUEL INJECTION PIPE AND SPILL TUBE……………………………………………………..181
16.FUEL PIPING …………………………………………………………………………182
17.LUBRICATION TUBES…………………………………………………………………….182
18.FUEL INJECTION PUMP ASSEMBLY…………………………………………………………..183
19.EXHAUST MANIFOLDS…………………………………………………………………….183
20.WATER PUMP ASSEMBLY…………………………………………………………………..184
21.OIL COOLER ASSEMBLY…………………………………………………………………..184
22.OIL PAN …………………………………………………………………………….185
23.AIR VENT TUBES……………………………………………………………………….185
24.THERMOSTAT ASSEMBLY…………………………………………………………………..186
25.CYLINDER HEAD COVERS………………………………………………………………….186
26.NOZZLE HOLDERS……………………………………………………………………….187
27.ROCKER ARM HOUSING ASSEMBLY……………………………………………………………187
28.PUSH ROD…………………………………………………………………………….187
29.CROSS HEAD…………………………………………………………………………..187
30.CYLINDER HEAD ASSEMBLY………………………………………………………………..187
31.OIL PUMP ASSEMBLY…………………………………………………………………….189
32.STARTING MOTOR ASSEMBLY……………………………………………………………….189
33.FLYWHEEL ……………………………………………………………………………190
34.FLYWHEEL HOUSING……………………………………………………………………..190
35.VIBRATION DAMPER …………………………………………………………………….190
36.DRIVE CASE ASSEMBLY…………………………………………………………………..190
37.RETAINER AND FRONT SUPPORT…………………………………………………………….191
38.GEAR CASE COVER AND TIMER CASE COVER……………………………………………………191
39.FUEL INJECTION PUMP DRIVE CASE…………………………………………………………191
40.AIR INTAKE MANIFOLD…………………………………………………………………..191
41.CAM FOLLOWER ………………………………………………………………………..192
42.GEAR TRAIN…………………………………………………………………………..192
43.CAMSHAFT ASSEMBLIES…………………………………………………………………..192
44.GEAR CASE …………………………………………………………………………..193
45.MAIN GALLERY PLUG,OIL PLUG,AND COOLING VALVE…………………………………………….193
46.SIDE COVERS………………………………………………………………………….193
47.PISTON COOLING NOZZLES………………………………………………………………..193
48.ENGINE SET…………………………………………………………………………..194
49.PISTONS AND CONNECTING ROD ASSEMBLIES…………………………………………………..194
50.CRANKSHAFT…………………………………………………………………………..195
51.CYLINDER LINER……………………………………………………………………….196
CLEANING…………………………………………………………………………………..197
MEASURING PARTS…………………………………………………………………………….198
GENERAL ASSEMBLY……………………………………………………………………………203
1.CYLINDER LINER………………………………………………………………………..205
2.CRANKSHAFT……………………………………………………………………………208
3.PISTON AND CONNECTING ROD ASSEMBLY………………………………………………………212
4.SETTING ENGINE STAND…………………………………………………………………..217
5.PISTON COOLING NOZZLES…………………………………………………………………217
6.SIDE COVERS…………………………………………………………………………..217
7.MAIN GALLERY PLUG,OIL PLUG,AND COOLING PLUG………………………………………………217
8.GEAR CASE…………………………………………………………………………….217
9.CAMSHAFT ASSEMBLY……………………………………………………………………..219
10.GEAR TRAIN ………………………………………………………………………….220
11.CAM FOLLOWER…………………………………………………………………………222
12.AIR INTAKE MANIFOLD…………………………………………………………………..223
13.PUMP DRIVE CASE………………………………………………………………………224
14.BACKLASH AND END PLAY OF GEARS…………………………………………………………225
15.FRONT SHAFT …………………………………………………………………………226
16.GEAR CASE COVER………………………………………………………………………226
17.TIMER COVER………………………………………………………………………….227
18.WATER PUMP DRIVE CASE…………………………………………………………………227
19.COMPRESSOR DRIVE CASE…………………………………………………………………228
20.BREATHER CONNECTOR……………………………………………………………………229
21.FRONT SEAL ………………………………………………………………………….229
22.FRONT SUPPORT………………………………………………………………………..229
23.VIBRATION DAMPER……………………………………………………………………..230
24.PISTON COOLING VALVE………………………………………………………………….231
25.OIL COOLER ASSEMBLY…………………………………………………………………..232
26.WATER PUMP ASSEMBLY…………………………………………………………………..233
27.FLYWHEEL HOUSING ASSEMBLY……………………………………………………………..234
28.REAR SEAL …………………………………………………………………………..235
29.FLYWHEEL…………………………………………………………………………….235
30.STARTING MOTOR ASSEMBLIES……………………………………………………………..237
31.CYLINDER HEAD ASSEMBLY………………………………………………………………..237
32.CROSS HEAD…………………………………………………………………………..241
33.ROCKER HOUSING……………………………………………………………………….241
34.INJECTION NOZZLE ASSEMBLY……………………………………………………………..242
35.PUSH ROD…………………………………………………………………………….242
36.ROCKER ARM ASSEMBLY…………………………………………………………………..243
37.ADJUSTING VALVE CLEARANCE……………………………………………………………..243
38.AFTERCOOLER ASSEMBLY………………………………………………………………….244
39.WATER TUBES………………………………………………………………………….244
40.HEAD COVER…………………………………………………………………………..245
41.THERMOSTAT CASE ASSEMBLY………………………………………………………………245
42.FUEL INJECTION PUMP ASSEMBLY…………………………………………………………..246
43.AIR VENT TUBES……………………………………………………………………….247
44.MUFFLER BRACKET………………………………………………………………………248
45.SPILL HOSES………………………………………………………………………….248
46.FUEL INJECTION PUMP LUBRICATION TUBES…………………………………………………..248
47.FUEL SUPPLY AND OVERFLOW PIPE………………………………………………………….249
48.FUEL INJECTION TUBES………………………………………………………………….249
49.EXHAUST MANIFOLD……………………………………………………………………..250
50.WATER TUBE AND TURBOCHARGER PIPING……………………………………………………..251
51.EXHAUST CONNECTOR…………………………………………………………………….251
52.TURBOCHARGER ASSEMBLY…………………………………………………………………252
53.EXHAUST MANIFOLD COVER(RIGHT ONE IS SHOWN IN THE FIGURE)………………………………….253
54.OIL FILLER…………………………………………………………………………..253
55.BYPASS TUBE………………………………………………………………………….254
56.BLOW-BY HOSE…………………………………………………………………………254
57.OIL PUMP ASSEMBLY…………………………………………………………………….254
58.OIL PAN …………………………………………………………………………….255
59.OIL LEVEL SENSOR AND DRAIN VALVE……………………………………………………….255
60.FILTER BRACKET……………………………………………………………………….255
61.FUEL TUBE……………………………………………………………………………256
62.OIL FILTER…………………………………………………………………………..256
63.OIL FILTER TUBE………………………………………………………………………256
64.AIR INTAKE PIPE………………………………………………………………………256
65.AIR CLEANER AND MUFFLER ASSEMBLY……………………………………………………….257
14 MAINTENANCE STANDARD…………………………………………………………………………258
TURBOCHARGER……………………………………………………………………………….259
CYLINDER HEAD………………………………………………………………………………261
VALVES AND VALVE GUIDE………………………………………………………………………262
CROSSHEAD AND CROSSHEAD GUIDE………………………………………………………………..263
ROCKER ARM SHAFT……………………………………………………………………………264
PUSH ROD AND CAM FOLLOWER……………………………………………………………………265
CYLINDER BLOCK……………………………………………………………………………..266
CYLINDER LINER……………………………………………………………………………..268
CAMSHAFT…………………………………………………………………………………..269
CRANKSHAFT…………………………………………………………………………………270
TIMING GEAR………………………………………………………………………………..272
POSTON…………………………………………………………………………………….273
CONNECTING ROD……………………………………………………………………………..274
FLYWHEEL,FLYWHEEL HOUSING …………………………………………………………………..275
OIL PUMP…………………………………………………………………………………..276
OIL PUMP RELIEF VALVE,PISTON COOLING VALVE,OIL COOLER BYPASS VALVE AND OIL FILTER SAFETY VALVE………277
WATER PUMP…………………………………………………………………………………279
THERMOSTAT…………………………………………………………………………………280
15 REPAIR AND REPLACEMENT OF PARTS………………………………………………………………281
TABLE OF SPECIAL TOOLS………………………………………………………………………282
TESTING AND INSPECTING CYLINDER HEAD………………………………………………………….283
REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING……………………………………………286
REPLACING VALVE SEAT INSERTS…………………………………………………………………287
REPLACING NOZZLE HOLDER SLEEVE……………………………………………………………….293
CYLINDER HEAD PRESSURE TEST METHOD……………………………………………………………296
REPLACING VALVE GUIDE……………………………………………………………………….297
REPLACING CROSS HEAD GUIDE…………………………………………………………………..298
GRINDING VALVE……………………………………………………………………………..299
TESTING AND INSPECTING CYLINDER BLOCK…………………………………………………………300
GRINDING TOP SURFACE OF CYLINDING BLOCK……………………………………………………….303
REPLACING MAIN BEARING CAP…………………………………………………………………..309
REPLACING CAM BUSHING……………………………………………………………………….311
TESTING CRANKSHAFT………………………………………………………………………….313
CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION………………………………………315
GRINDING CRANKSHAFT…………………………………………………………………………320
TESTING AND INSPECTING CONNECTING ROD…………………………………………………………329
REPLACING CONNECTING ROD SMALL END BUSHING…………………………………………………….331
REPLACING CAMSHAFT GEAR……………………………………………………………………..332
REPLACING FLYWHEEL RING GEAR ………………………………………………………………..333