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Komatsu 12V170-1 Diesel Engine Shop Manual SEBE61800104 – PDF DOWNLOAD
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Komatsu 12V170-1 Diesel Engine Shop Manual
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Description
Komatsu 12V170-1 Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 12V170-1 Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: SA12V170-1, 12V170-1 Diesel Engine
Book Code: SEBE61800104
Language: English
Pages: 305
File Format: Portable Document Format (PDF)
KOMATSU 12V170-1 DIESEL ENGINE SHOP MANUAL SEBE61800104 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 12V170-1 Diesel Engine Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
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 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 thissection.
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.
TABLE OF CONTENTS:
Komatsu 12V170-1 Diesel Engine Shop Manual
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
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