Komatsu 12V170-1 Series Diesel Engine Shop Manual SEBM028506

Description

• Model List:
  • 12V170-1 Series Diesel Engine

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. SPECIFICATIONS
• 3.2. ENGINE PERFORMANCE CURVE
• 3.3. WEIGHT TABLE
• 4. STRUCTURE AND FUNCTION
• 4.1. GENERAL STRUCTURE
• 4.2. INTAKE AND EXHAUST SYSTEM
• 4.2.1. MAIN REVOLVING PART
• 4.2.2. TIMING GEAR
• 4.2.3. FLYWHEEL AND FLYWHEEL HOUSING
• 4.3. LUBRICATION SYSTEM
• 4.3.1. LUBRICATION SYSTEM CHART
• 4.3.2. OIL PUMP
• 4.3.3. OIL FILTER
• 4.3.4. OIL COOLER
• 4.3.5. OIL COOLER BYPASS VALVE
• 4.3.6. PISTON COOLING VALVE
• 4.3.7. MECHANICAL PUMP
• 4.4. FUEL SYSTEM
• 4.4.1. FUEL SYSTEM CHART
• 4.4.2. FUEL INJECTION PUMP
• 4.4.3. FEED PUMP
• 4.4.4. FUEL INJECTION NOZZLE
• 4.4.5. FUEL INJECTION PUMP DRIVE
• 4.4.6. FUEL FILTER
• 4.4.7. INJECTION PUMP RACK CONTROLLER
• 4.4.8. AUTOMATIC TIMER
• 4.4.9. FUEL SOLENOID
• 4.4.10. ENGINE STOP MOTOR
• 4.5. COOLING SYSTEM
• 4.5.1. COOLING SYSTEM CHART
• 4.5.2. WATER PUMP
• 4.5.3. WATER PUMP DRIVE
• 4.5.4. FAN DRIVE AND TENSION PULLEY
• 4.5.5. CORROSION RESISTOR
• 4.5.6. THERMOSTAT
• 4.6. ACCESSORY
• 4.6.1. AIR COMPRESSOR MOUNTING
• 4.6.2. AIR COMPRESSOR
• 4.6.3. ALTERNATOR WITH REGULATOR
• 4.6.4. STARTING MOTOR
• 4.6.5. AIR STARTING MOTOR
• 5. TESTING AND ADJUSTING
• 5.1. COOLING SYSTEM
• 5.1.1. CHECKING AND ADJUSTING FAN BELT TENSION
• 5.1.2. CHECKING AND ADJUSTING ALTERNATOR BELT TENSION
• 5.2. ENGINE BODY
• 5.2.1. ADJUSTING VALVE CLEARANCE
• 5.2.2. MEASURING COMPRESSION PRESSURE
• 5.2.3. MEASURING BLOWBY
• 5.3. FUEL SYSTEM
• 5.3.1. TESTING AND ADJUSTING OF FUEL INJECTION TIMING
• 5.3.2. ADJUSTING FUEL INJECTION PUMP RACK LINKAGE
• 5.3.3. ADJUSTING ENGINE STOP MOTOR
• 5.3.4. ADJUSTING ENGINE SPEED SENSOR
• 5.3.5. ADJUSTING FUEL INJECTION PRESSURE (VALVE CRACKING PRESSURE)
• 5.3.6. FUEL INJECTION PUMP CALIBRATION DATA
• 5.4. PERFORMANCE TEST
• 5.4.1. RUNIN STANDARD
• 5.4.2. PERFORMANCE TEST CRITERIA
• 5.4.3. TESTING AND ADJUSTING DATA
• 5.4.4. TESTING AND ADJUSTING TOOL LIST
• 5.5. TROUBLESHOOTING
• 5.5.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.5.2. METHOD OF USING TROUBLESHOOTING CHART
• 5.5.3. S1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)
• 5.5.4. S2 ENGINE DOES NOT START
• 5.5.4.1. ENGINE DOES NOT TURN
• 5.5.4.2. ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)
• 5.5.4.3. EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
• 5.5.5. S3 ENGINE DOES NOT PICKUP SMOOTHLY(FOLLOWUP IS POOR)
• 5.5.6. S4 ENGINE STOPS DURING OPERATIONS
• 5.5.7. S5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
• 5.5.8. S6 ENGINE LACKS OUTPUT (NOT POWER)
• 5.5.9. S7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
• 5.5.10. S8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
• 5.5.11. S9 OIL BECOMES CONTAMINATED QUICKLY
• 5.5.12. S10 FUEL CONSUMPTION IS EXCESSIVE
• 5.5.13. S11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
• 5.5.14. S12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
• 5.5.15. S13 OIL LEVEL RISES
• 5.5.16. S14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
• 5.5.17. S15 ABNORMAL NOISE IS MADE
• 5.5.18. S16 VIBRATION IS EXCESSIVE
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. GENERAL DISASSEMBLY CONTENTS
• 6.2. DISASSEMBLY
• 6.3. ASSEMBLY
• 7. MAINTENANCE STANDARD
• 7.1. INTAKE AND EXHAUST SYSTEM
• 7.1.1. TURBOCHARGER
• 7.1.2. VALVE AND VALVE GUIDE
• 7.1.3. VALVES AND VALVE GUIDE
• 7.1.4. CROSSHEAD AND CROSSHEAD GUIDE
• 7.1.5. ROCKER ARM SHAFT
• 7.1.6. PUSH ROD AND CAM FOLLOWER
• 7.1.7. FLYWHEEL, FLYWHEEL HOUSING
• 7.2. LUBRICATION SYSTEM
• 7.2.1. OIL PUMP
• 7.2.2. MAIN RELIEF VALVE, POSITION COOLNG VALVE AND OIL COOLER BYPASS VAVLE
• 7.3. COOLING SYSTEM
• 7.3.1. WATER PUMP
• 8. REPAIR AND REPLACEMENT OF PARTS
• 8.1. TABLE OF SPECIAL TOOLS
• 8.2. TESTING AND INSPECTING CYLINDER HEAD
• 8.3. REPAIRING MOUNTING FACE OF CYLINDER HEAD BY GRINDING
• 8.4. REPLACING VALVE SEAT INSERTS
• 8.5. REPLACING NOZZLE HOLDER SLEEVE
• 8.6. CYLINDER HEAD PRESSURE TEST METHOD
• 8.7. REPLACING VALVE GUIDE
• 8.8. REPLACING CROSS HEAD GUIDE
• 8.9. GRINDING VALVE
• 8.10. TESTING AND INSPECTING CYLINDER BLOCK
• 8.11. GRINDING TOP SURFACE OF CYLINDING BLOCK
• 8.12. REPLACING MAIN BEARING CAP
• 8.13. REPLACING CAM BUSHING
• 8.14. TESTING CRANKSHAFT
• 8.15. CORRECTING SURFACE ROUGHNESS OF CRANKSHAFT JOURNAL PORTION
• 8.16. GRINDING CRANKSHAFT
• 8.17. TESTING AND INSPECTING CONNECTING ROD
• 8.18. REPLACING CONNECTING ROD SMALL END BUSHING
• 8.19. REPLACING CAMSHAFT GEAR
• 8.20. REPLACING FLYWHEEL RING GEAR