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Komatsu 12V170-2 Series Diesel Engine Shop Manual – PDF DOWNLOAD
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Komatsu 12V170-2 Series Diesel Engine Shop Manual
Book Code: SEBM036601
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Description
Komatsu 12V170-2 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 12V170-2 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 12V170-2 Series Engine
Book Code: SEBM036601
Language: English
Pages: 333
File Format: Portable Document Format (PDF)
KOMATSU 12V170-2 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 12V170-2 Series Diesel Engine Shop Manual
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 12V170-2 Series Diesel Engine Shop Manual
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
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