Komatsu 12V170-1 Diesel Engine Service Repair Manual

Shop
Manual
SEBE61800104
12v17
DIESEL ENGINE
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America lntemational Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add lmprovements at any time without Incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
March 1997 Copyright 1997 Komatsu America International Company

CONTENTS
No. of page
01 GENERAL ............................................................................................................01-1
11 STRUCTURE AND FUNCTION ........................................................... II-I
12 TESTING AND ADJUSTING ................................................................ 12-1
13 DISASSEMBLY AND ASSEMBLY .................................................... 13-1
14 MAINTENANCE STANDARD ............................................................... 14-1
Q
z
15 REPAIR AND REPLACEMENT OF PARTS .................................. 15-1
00-2
0

SAFETY SAFETY NOTKZE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs,
read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
. Always wear safety glasses when hitting
parts with a hammer.
. Always wear safety glasses when grind-
ing parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the
work. When carrying out welding work, al-
ways wear welding gloves, apron, hand
shield, cap and other clothes suited for weld-
ing work.
When carrying out any operation with two
or more workers, always agree on the oper-
ating procedure before starting. Always in-
form your fellow workers before starting any
step of the operation. Before starting work,
hang UNDER REPAIR signs on the controls
in the operator’s compartment.
Keep all tools in good condition and learn
the correct way to use them.
6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for smok-
ing. Never smoke while working.
7. Before adding oil or making any repairs,
park the machine on hard, level ground, and
block the wheels or tracks to prevent the
machine from moving.
8. Before starting work, lower blade, ripper,
bucket or any other work equipment to the
ground. If this is not possible, insert the
safety pin or use blocks to prevent the work
equipment from falling. In addition, be sure
to lock all the control levers and hang warn-
ing signs on them.
PREPARATIONS FOR WORK
9. When disassembling or assembling, support
the machine with blocks, jacks or stands
before starting work.
IO. Remove all mud and oil from the steps or
other places used to get on and off the ma-
chine. Always use the handrails, ladders or
steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
00-3

SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11.
12.
13.
When removing the oil filler cap, drain plug
or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from
spurting out.
Before disconnecting or removing compo-
nents of the oil, water or air circuits, first
remove the pressure completely from the
circuit.
The water and oil in the circuits are hot
when the engine is stopped, so be careful
not to get burned.
Wait for the oil and water to cool before
carrying out any work on the oil or water
circuits.
Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (-1 terminal first.
14. When raising heavy components, use a hoist
or crane.
Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has
ample capacity.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
slowly to prevent the component from hit-
ting any other .part. Do not work with any
part still raised by the hoist or crane.
15. When removing covers which are under in-
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to
wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
19. Be sure to assemble all parts again in their
original places.
Replace any damaged parts with new parts.
. When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is be-
ing operated.
20. When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
ful when installing tubes for high pressure
circuits. Also, check that connecting parts
are correctly installed.
21. When assembling or installing parts, always
use the specified tightening torques. When
installing protective parts such as guards,
or parts which vibrate violently or rotate at
high speed, be particularly careful to check
that they are installed correctly.
22. When aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that the measuring tool is correctly assem-
bled before taking any measurements.
24. Take care when removing or installing the
tracks of track-type machines.
When removing the track, the track sepa-
rates suddenly, so never let anyone stand at
either end of the track.
00-4

FOREWORD GENERAL
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.
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 this section.
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.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5

FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying
out repairs. They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume:
I
Each issued as one
volume to cover all
models
When a manual is revised, an edition mark
(@@@....I is recorded on the bottom of the
pages.
REVISIONS
These various volumes are designed to avoid
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
ment volumes be available.
Revised pages are shown in the LIST OF RE-
VISED PAGES next to the CONTENTS page.
SYMBOLS
DISTRIBUTION AND UPDATlNG
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the
page. File the pages in correct order.
2. Following examples show how to read the
page number.
Example 1 (Chassis volume):
10 -3
Item number (IO. Structure
and Function)
Consecutive page number for
each item.
Example 2 (Engine volume):
Unit number (I. Engine)
Item number (2. Testing and
Adjusting)
Consecutive page number for
each item.
3. Additional pages: Additional pages are indi-
cated by a hyphen (-1 and number after the
page number. File as in the example.
Example:
10-4 12-203
So that the shop manual can be of ample prac-
tical use, important safety and quality portions
are marked with the following symbols.
Symbol
a
*
&I
kg
%b
4
Item
Safety
Caution
Weight
ighteninc
torque
Coat
Xl, water
Drain
Remarks
Special safety precautions are
necessary when performing
the work.
Special technical precautions
or other precautions for pre-
serving standards are neces-
sary when performing the
work.
Weight of parts of systems.
Caution necessan/ when se-
lecting hoisting wire, or when
working posture is important,
etc.
Places that require special at-
tention for the tightening
torque during assembly.
Places to be coated with ad-
hesives and lubricants, etc.
Places where oil, water or fuel
must be added, and the ca-
pacity.
Places where oil or water
must be drained, and quan-
tity to be drained.
10-4-I -
1O-4-2
k Added pages -~~~~f~~I~
10-5 12-204
00-6

01 GENERAL
Specifications ............................................... Ol- 2
Engine performance curve .......................... Ol- 4
Weight table .................................................. 01-16
01-l
0

GENERAL SPECIFICATIONS
SPECIFICATIONS
Engine model SA12V170-1
Applicable machine
Number of cylinders - Bore x Stroke
Total piston displacement
Firing order
-
F
.2
2
i
.-
n
Overall length
Overall width
Overall height
(excluding exhaust pipe)
Overall height
(including exhaust pipe)
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Minimum fuel
consumption ratio
Dry weight
Fuel pump
Lubricating oil amount (refill capacity)
Coolant amount
Alternator 24V, 75A
Starting motor
Battery
mm
e ICC)
D575A-2 D575A-2
Engine serial No. Engine serial No.
10024-10096 10097 and up
12-170x170
46.3 (46,300)
Rl-L6-R5-L2-R3-L4-R6-Ll-R2-L5-R4-L3
mm 2,766 2,766
mm 1,720 1,720
mm 2,805 2,805
mm - -
kW/rpm
{HP/rpmI
kW/rpm
{kgm/rpmI
rpm
rpm
g/kW l h
{g/HP l h}
Turbocharger
Air compressor
Others
784/l ,800
11.O~~rY&8001
5,000/1,300
{51~(;;001
1,950 - 2,050
600 - 700
215
11601
6,210
BOSCH PE-ZWX type
BOSCH RSUV centrifugal,
allspeed type
137 (127)
24V, llkWx2
12V200Ah x 4
KOMATSU KTR130 x 2
(water cooled type)
With after cooler With after cooler
78411,800
{1,0~~~$300~
5,000/1,300
{51~0$$00~
1,950 - 2,050
600 - 700
215
11601
6,210
BOSCH PES-P(PS7S) type
allspeed type
137 (127)
298
24V, 75A
24V, llkWx2
12V200Ah x 4
KOMATSU KTRISO x 2
(water cooled type)
-
01-2
0

SA12V170-1
D575A-2SD
(Super Dozer)
HD1200-1 HD1200M-1
12-170x170
46.3 {46,300}
2,766
1,720
2,805
-
858/I ,800
~1.150/1.800~
z 5,660/l ,300
%
{57;~;;001
z 1,950 - 2,050
600 - 700
215
{I601
6,650 5,350 5,280
BOSCH PE-P(PS7S) type BOSCH PES-ZWX type
allspeed type
BOSCH RSUV centrifugal, allspeed type
137 (127) 131 (106) 121 (106)
298 280 I 480
24V. 75A
24V, IlkWx 2
12V200Ah x 4
KOMATSU KTR130 x 2
(water cooled type)
With after cooler
2,346
1,704
1,839
2,346
1,657
1,793
- -
960/2,100 87812,100
{I ,2w~;oo~ ~l,l~~Q2~;00~
5,190/1,400 4,640/l ,400
{53~cv&OOI {47;~$001
2,300 - 2,400 2,300 - 2,400
600 - 700 600 - 700
211 209
11571 I1561
24V, 75A 24V, 75A
Air starter 37.5 kW Air starter 37.5 kW
12V200Ah x 4 12V200Ah x 4
KOMATSU KTR130 x 2
ZEXEL recipro caution
single cylinder x 2
With after cooler
KOMATSU KTR130 x 2
ZEXEL recipro caution
single cylinder x 2
With after cooler
01-3
0

I
Engine model SA12V170-1
Applicable machine EGI 100-l Generator
Number of cylinders - Bore x Stroke
Total piston displacement
Firing order
mm
e {cc)
12-170x170
46.3 {46,300}
Overall length
Overall width
Overall height
(excluding exhaust pipe)
Overall height
(including exhaust pipe)
mm
mm
mm
mm
2,697
1,500
2,000
2,340
1,420
1,977
- -
Flywheel horsepower kW/rpm
IHP/rpmI
874/l ,500 (50Hz)
{I .170/l ,500) (50Hz)
Maximum horsepower kW/rpm
0-fP/rpmI
862/1,500 (50Hz)
{1,160/1,500~ (50H.z)
950/1,800 (60Hz)
{1,27O/I(;C$ (6OHz)
950/l ,500 (50Hz)
~1,270/1,500~ (50Hz)I
1,040/l ,800 (60Hz)
{1,390/1(8~~)I (60Hz)
860/l ,800 i6bHz)
{1,29o’:iu8~~; (60Hz)
-
High idling speed rpm Max.1.560 (at rated, 50Hz
jax.1,580 (at maximum, 50
Max.1,870 (at rated, 60Hz
rlax.1,890 (at maximum, 601
Max. 1,560 (50Hz)
Max. 1,890 (60Hz)
Low idlingn speed
Fuel consumption ratio
rpm 900 - 1,000 700 - 900
g/kW l h 216 (at rated) 216 (at rated)
{g/HP l W (161) (at rated) {I611 (at rated)
Dry weight kg 5,600 5,450
Fuel pump BOSCH PE-ZWX type
Governor BOSCH RSUV centrifugal, allspeed type
Lubricating oil amount (refill capacity) e
Coolant amount e
Alternator
Starting motor
Battery
24V, 35A 24V, 35A
24V, llkWx2 24V, IlkWx2
12V200Ah x 4 12V200Ah x 4
!
Turbocharger
Air compressor
Others
KOMATSU KTR150 x 2 KOMATSU KTR150 x 2
-
I -
With after cooler
I
With after cooler
01-3-l
0
* : optional parts

I
01-3-2

GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE
SA12V170-1 (FOR D575A-2)
Flywheel horsepower: 783 KW (1,050 HP)/1,800 rpm
Maximum torque: 5,001 Nm (510 kgm)/1,300 rpm
I -
, -
z
‘z
1300
1200
1100
1000
900
600
700
600
/
500 I
400
300 I
200 I
100 -
I
0 600 600 1000 1200 1400 1600 I600 2000 2200 2400
Eneine speed (rpm) SAE00237
01-4
0

SA12V170-1 (FOR D575A-2SD)
;; 1100
i2
z 1000
900
a00
s 700
2
600
4oc
3OC
2OC
lO(
c
600
500
400
300
200
;j
5 100
1300 0
1200
1100
1000
900
1 I I
600
700
600
500 I
/
400
300 I,
200 I
100
I
0 600 600 1000 1200 1400 1600 I600 2000 2200 2400
Engine speed (rpm)
I
6000
5000
4000
,”
- 3000 E
:
- 2000
- 1000
-0
SAE00236
01-5
0

SAlPV170-1 (FOR HD1200-1)
1300 - 1000 -
1300
1200 -
900 - 1200
1100 -
II00
600 -
1000 -
1000
900 - ‘0°
900
600 -
600 - 800
2 700 -
700
s 500 -
600 - 600
400 -
500 - 500
400 - 300 - 400
300 - 300
200 -
200 - 200
100 -
100 - 100
o- o-
0 600 600 1000 1200 1400 1600 1600 2000 2200 2400
Engine speed (rpm)
600 6000
500
I
5000
400 4000
t
2
300 3000 :
F
200 - 2000
100 - 1000
0 -0
SAE00239
01-6
0

SA12V170-1 (FOR HD1200M-1)
z ‘j; z
5 Y s
1300- IOOO-
1300
1200 -
900 - 1200
1100 -
1100
600 -
1000 -
1000
900 - ‘0°
900
600 -
600 - 600
D
2 700 -
700
s 500 -
600 - 600
400 -
500 - 500
400 - 300 - 400
300 - 300
200 -
200 - 200
100 -
too - 100
o- o-
0 600 600 1000 1200 1400 1600 I600 2000 2200 2400
Engine speed (rpm) SAE00240
01-7
0

SA12V170-1 (HD1200M-1)
. Left side view
P
2061.2
Rear face of
flywheel housing
F6166002
01-8
0

SA12V170-1 (HD1200M-1)
l Right side view
Rear face of
flywheel ho1 Cooling water inlet 2; x 1.5 Fuel outlet
2324.6
ICrankshaft center
7
F6166003
01-9
0

SA12V170-1 (HD1200M-1)
. Front side view
Bypass water inlet

899
I- 402 380

PTl/2 fuel inlet
:center
F6166004
01-10
0

SAlZV170-1 (HD1200M-1)
. Rear side view
529 529
4-24 hole
1
d
c
Crankshaft center
657.5 I 657.5
F6166005
01-11
0

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SA12V170-1 (D575A-2SD)
. Left side view
21893
a
PT l/8 inlet
for car heate

l/2 outlet port
lr car heater
SAE00241
01-12
0

GENERAL
ENGINE PERFORMANCE CURVE
SAlPV170-1 (D575A-2SD)
l Right side view
Boost Pressure
pickup port

To Fuel Tank
From Fuel Tank
From Fuel Filter
To Fuel Filter
L 1994.4 -I
SAE00242
01-13
0

SA12V170-1 (D575A-2SD)
. Front side view
----
---_
566. a 544. a J
SAE00243
01-14
0

Komatsu 12V170-1 Diesel Engine Service Repair Manual

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