Komatsu 8V170-1 Series Engine Shop Manual SEBE61700104 – PDF DOWNLOAD

Description

Komatsu 8V170-1 Series Engine Shop Manual SEBE61700104 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 8V170-1 Series Engine Shop Manual SEBE61700104 – PDF DOWNLOAD

FOREWORD:

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
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 ADJUSTMENTS
This sections 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 this section.
REMOVAL AND INSTALLATION
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.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu 8V170-1 Series Engine Shop Manual SEBE61700104 – PDF DOWNLOAD

MAIN MENU 0
CONTENTS 2
01 GENERAL 13
GENERAL VIEW 14
SPECIFICATIONS 15
GENERAL ASSEMBLY DRAWING 16
WEIGHT TABLE 28
ENGINE PERFORMANCE CURVE 29
11 STRUCTURE AND FUNCTION 33
GENERAL STRUCTURE 34
INTAKE AND EXHAUST SYSTEM 36
INTAKE SYSTEM 36
EXHAUST SYSTEM 37
TURBOCHARGER 38
ENGINE BODY 40
CYLINDER HEAD 40
VALVE SYSTEM 42
CYLINDER BLOCK 44
MAIN REVOLVING SYSTEM 45
TIMING GEAR 46
FLYWHEEL AND FLYWHEEL HOUSING 48
LUBRICATION SYSTEM 49
LUBRICATION SYSTEM CHART 49
OIL PUMP 50
OIL FILTER AND SAFETY VALVE 51
OIL COOLER 52
OIL COOLER BYPASS VALVE 53
PISTON COOLING VALVE 53
MECHANICAL PUMP 54
FUEL SYSTEM 55
FUEL SYSTEM CHART 55
FUEL INJECTION PUMP 56
FUEL INJECTION NOZZLE 71
FEED PUMP 72
FUEL INJECTION PUMP DRIVE 75
TIMER 76
FUEL FILTER 79
STARTING AID 80
ENGINE STOP MOTOR 81
COOLING SYSTEM 87
COOLING SYSTEM CHART 87
WATER PUMP 88
WATER PUMP DRIVE 89
FAN DRIVE AND TENSION PULLEY 90
CORROSION RESISTOR 91
THERMOSTAT 92
ACCESSORY 93
AIR COMPRESSOR MOUNTING 93
AIR COMPRESSOR 94
ALTERNATOR WITH REGULATOR 95
STARTING MOTOR 96
12 TESTING AND ADJUSTING 97
COOLING SYSTEM 98
CHECKING AND ADJUSTING ALTERNATOR BELT TENSION 98
ENGINE BODY 100
ADJUSTING VALVE CLEARANCE 100
FUEL SYSTEM 101
TESTING AND ADJUSTING FUEL INJECTION TIMING 101
ADJUSTING FUEL INJECTION TIMING BY DELIVERY CHECK 102
ADJUSTING FUEL INJECTION NOZZLE CRACKING PRESSURE 103
ADJUSTING ENGINE STOP MOTOR CABLE 105
FUEL INJECTION PUMP CALIBRATION DATA 107
PERFORMANCE TEST 111
RUN-IN STANDARD 111
PERFORMANCE TEST CRITERIA 112
TESTING AND ADJUSTING TOOL LIST 114
TESTING AND ADJUSTING DATA 116
TROUBLESHOOTING 119
POINTS TO REMEMBER WHEN TROUBLESHOOTING 121
METHOD OF USING TROUBLESHOOTING CHART 122
S-1 Starting performance is poor (Starting always takes time) 126
S-2 Engine does not start 127
1 Engine does not turn 127
2 Engine turns but no exhaust comes out (Fuel is not being injected) 128
3 Exhaust gas comes out but engine does not start (Fuel is 129
S-3 Engine does not pick up smoothly (Follow-up is poor) 130
S-4 Engine stops during operations 131
S-5 Engine does not rotate smoothly (hunting) 132
S-6 Engine lacks output (no power) 133
S-7 Exhaust gas is black (incomplete combustion) 134
S-8 Oil consumption is excessive (or exhaust gas is blue) 135
S-9 Oil becomes contaminated quickly 136
S-10 Fuel consumption is excessive 137
S-11 Oil is in cooling water, or water spurts back, or water level goes down 138
S-12 Oil pressure lamp lights up (drop in oil pressure) 139
S-13 Oil level rises 140
S-14 Water temperature becomes too high (overheating) 141
S-15 Abnormal noise is made 142
S-16 Vibration is excessive 143
13 DISASSEMBLY AND ASSEMBLY 145
GENERAL 148
DISASSEMBLY 148
WASHING 187
WASHING CYLINDER BLOCK 189
WASHING CRANKSHAFT 190
MEASURING AND INSPECTING PARTS 191
MEASURING PARTS 192
MEASURING CURVATURE OF CRANKSHAFT 192
MEASURING OUTSIDE DIAMETER OF JOURNAL 192
MEASURING DEPTH OF CYLINDER LINER COUNTERBORE 193
MEASURING MAIN BEARING BORE 193
MEASURING CURVATURE OF CAMSHAFT 194
MEASURING OUTSIDE DIAMETER OF JOURNAL 194
MEASURING HEIGHT OF CAM 194
MEASURING PISTON RING GROOVE 195
MEASURING PISTON RING END GAP 195
ASSEMBLY 199
14 MAINTENANCE STANDARD 275
INTAKE AND EXHAUST SYSTEM 276
TURBOCHARGER 276
ENGINE BODY 277
CYLINDER HEAD 277
VALVE AND VALVE GUIDE 278
ROCKER ARM SHAFT 279
CROSSHEAD 280
CAM FOLLOWER AND PUSH ROD 281
CYLINDER BLOCK 282
CYLINDER LINER 284
CAMSHAFT 285
CRANKSHAFT 286
PISTON 288
CONNECTING ROD 289
TIMING GEAR 290
FLYWHEEL AND FLYWHEEL HOUSING 292
LUBRICATION SYSTEM 293
OIL PUMP 293
MAIN RELIEF VALVE, PISTON COOLING VALVE AND OIL COOLER BYPASS VALVE 294
COOLING SYSTEM 295
WATER PUMP 295
15 REPAIR AND REPLACEMENT OF PARTS 297
CYLINDER HEAD 298
TESTING AND INSPECTING 299
REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING 301
REPLACING VALVE SEAT INSERTS 302
REPLACING NOZZLE HOLDER SLEEVE 307
REPLACING VALVE GUIDE 311
REPLACING CROSS HEAD GUIDE 312
GRINDING THE VALVE 313
CYLINDER BLOCK 314
TESTING AND INSPECTING 315
GRINDING THE TOP SURFACE OF CYLINDER BLOCK 317
REPLACING MAIN METAL CAP 322
REPLACING CAM BUSHING 324
CRANKSHAFT 325
REPAIRING THE CRANKSHAFT 332
CONNECTING ROD 340
REPLACING CAM GEAR 344
REPLACING FLYWHEEL RING GEAR 344

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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