Komatsu 12V170-1 Series Engine Shop Manual SEBM028506 – PDF DOWNLOAD

Description

Komatsu 12V170-1 Series Engine Shop Manual SEBM028506 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 12V170-1 Series Engine Shop Manual SEBM028506 – PDF DOWNLOAD

FOREWORD:
GENERAL:

• 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 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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together

TABLE OF CONTENTS:

Komatsu 12V170-1 Series Engine Shop Manual SEBM028506 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 25
SPECIFICATIONS 26
ENGINE PERFORMANCE CURVE 30
WEIGHT TABLE 41
11 STRUCTURE AND FUNCTION 44
GENERAL STRUCTURE 45
INTAKE AND EXHAUST SYSTEM 47
AFTER-COOLER 47
TURBOCHARGER 48
ENGINE BODY 51
CYLINDER HEAD 51
VALVE SYSTEM 53
CYLINDER BLOCK 55
MAIN REVOLVING PART 56
TIMING GEAR 57
FLYWHEEL AND FLYWHEEL HOUSING 59
LUBRICATION SYSTEM 60
LUBRICATION SYSTEM CHART 60
OIL PUMP 62
OIL FILTER 63
OIL COOLER 65
OIL COOLER BYPASS VALVE 66
PISTON COOLING VALVE 66
MECHANICAL PUMP 67
FUEL SYSTEM 68
FUEL SYSTEM CHART 68
FUEL INJECTION PUMP 71
FEED PUMP 72
FUEL INJECTION NOZZLE 73
FUEL INJECTION PUMP DRIVE 74
FUEL FILTER 76
INJECTION PUMP RACK CONTROLLER 77
AUTOMATIC TIMER 79
FUEL SOLENOID 80
ENGINE STOP MOTOR 81
COOLING SYSTEM 86
COOLING SYSTEM CHART 86
WATER PUMP 88
WATER PUMP DRIVE 90
FAN DRIVE AND TENSION PULLEY 91
CORROSION RESISTOR 94
THERMOSTAT 95
ACCESSORY 96
AIR COMPRESSOR MOUNTING 96
AIR COMPRESSOR 97
ALTERNATOR WITH REGULATOR 98
STARTING MOTOR 99
AIR STARTING MOTOR 100
12 TESTING AND ADJUSTING 102
COOLING SYSTEM 103
CHECKING AND ADJUSTING FAN BELT TENSION 103
CHECKING AND ADJUSTING ALTERNATOR BELT TENSION 104
ENGINE BODY 105
ADJUSTING VALVE CLEARANCE 105
MEASURING COMPRESSION PRESSURE 106
MEASURING BLOW-BY 107
FUEL SYSTEM 109
TESTING AND ADJUSTING OF FUEL INJECTION TIMING 109
ADJUSTING FUEL INJECTION PUMP RACK LINKAGE 111
ADJUSTING ENGINE STOP MOTOR 112
ADJUSTING ENGINE SPEED SENSOR 113
ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE) 114
FUEL INJECTION PUMP CALIBRATION DATA 116
PERFORMANCE TEST 124
RUN-IN STANDARD 124
PERFORMANCE TEST CRITERIA 126
TESTING AND ADJUSTING DATA 130
TESTING AND ADJUSTING TOOL LIST 134
TROUBLESHOOTING 137
POINTS TO REMEMBER WHEN TROUBLESHOOTING 138
METHOD OF USING TROUBLESHOOTING CHART 139
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME) 144
S-2 ENGINE DOES NOT START 145
(1) ENGINE DOES NOT TURN 145
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 146
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 147
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY(FOLLOW-UP IS POOR) 148
S-4 ENGINE STOPS DURING OPERATIONS 149
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 150
S-6 ENGINE LACKS OUTPUT (NOT POWER) 151
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 152
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 153
S-9 OIL BECOMES CONTAMINATED QUICKLY 154
S-10 FUEL CONSUMPTION IS EXCESSIVE 155
S-11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 156
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 157
S-13 OIL LEVEL RISES 158
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 159
S-15 ABNORMAL NOISE IS MADE 160
S-16 VIBRATION IS EXCESSIVE 161
13 DISASSEMBLY AND ASSEMBLY 162
GENERAL DISASSEMBLY CONTENTS 163
DISASSEMBLY 164
ASSEMBLY 192
14 MAINTENANCE STANDARD 246
INTAKE AND EXHAUST SYSTEM 247
TURBOCHARGER 247
VALVE AND VALVE GUIDE 249
VALVES AND VALVE GUIDE 250
CROSSHEAD AND CROSSHEAD GUIDE 251
ROCKER ARM SHAFT 252
PUSH ROD AND CAM FOLLOWER 253
CYLINDER BLOCK 255
CYLINDER LINER 257
CAMSHAFT 258
CRANKSHAFT 259
POSTON 261
CONNECTING ROD 262
TIMING GEAR 263
FLYWHEEL, FLYWHEEL HOUSING 264
LUBRICATION SYSTEM 265
OIL PUMP 265
MAIN RELIEF VALVE, POSITION COOLNG VALVE AND OIL COOLER BYPASS VAVLE 266
COOLING SYSTEM 267
WATER PUMP 267
15 REPAIR AND REPLACEMENT OF PARTS 268
TABLE OF SPECIAL TOOLS 269
TESTING AND INSPECTING CYLINDER HEAD 270
REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING 273
REPLACING VALVE SEAT INSERTS 274
REPLACING NOZZLE HOLDER SLEEVE 280
CYLINDER HEAD PRESSURE TEST METHOD 283
REPLACING VALVE GUIDE 284
REPLACING CROSS HEAD GUIDE 285
GRINDING VALVE 286
TESTING AND INSPECTING CYLINDER BLOCK 287
GRINDING TOP SURFACE OF CYLINDING BLOCK 290
REPLACING MAIN BEARING CAP 296
REPLACING CAM BUSHING 299
TESTING CRANKSHAFT 301
CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION 303
GRINDING CRANKSHAFT 308
TESTING AND INSPECTING CONNECTING ROD 317
REPLACING CONNECTING ROD SMALL END BUSHING 319
REPLACING CAMSHAFT GEAR 320
REPLACING FLYWHEEL RING GEAR 321

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