Komatsu 12V170-1 Diesel Engine Service Repair Manual

SEBE61800104

Shop Manual

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

12

TESTING AND ADJUSTING

13

DISASSEMBLY

AND ASSEMBLY

14

MAINTENANCE

STANDARD

........................................................... II-I

................................................................ 12-1

.................................................... 13-1

............................................................... 14-1

Q z

15

00-2 0

REPAIR AND REPLACEMENT

OF PARTS .................................. 15-1

SAFETY NOTKZE

SAFETY

SAFETY SAFETY

NOTICE

IMPORTANT SAFETY NOTICE Proper

service

and

repair

is extremely

service and repair techniques are both effective designed

manual.

recommended

for safe

by Komatsu

and safe. Some of these techniques

by Komatsu

To prevent

important

for the specific

injury to workers,

The cautions

fully. If any dangerous take the necessary

situation

operation.

and described

A

in this manual

require the use of tools specially

is used to mark safety precautions

these symbols

should

arises or may possibly

always

arise, first consider

in operation

carefully

6. Decide

are extremely

BEFORE operating

a place

in the

repair

2. When

Always

or repairs,

Smoke

to keep

places.

keep the work area clean and make

sure that there is no dirt or oil on the floor.

given on the decals

only in the areas provided

for smok-

ing. Never smoke while working.

are fixed to the machine. carrying

out any operation,

wear safety shoes and helmet. loose work clothes,

always

wear

or clothes with buttons

safety glasses

when

hitting

parts with a hammer. . Always

wear

trained,

safety

glasses

when

welder

park the machine

on hard, level ground,

and

block the wheels

or tracks

the

8. Before

from moving. blade,

ripper,

bucket or any other work equipment

starting

work,

work,

apron,

al-

hand

shield, cap and other clothes suited for welding work.

to the

If this

equipment

is not possible,

from falling.

with two

or more workers,

always agree on the oper-

ating procedure

before

starting.

Always

in-

form your fellow workers before starting any Before starting

work,

REPAIR signs on the controls compartment.

in good condition

In addition,

the

be sure

ing signs on them.

the

machine

with

before starting IO. Remove

or assembling, blocks,

jacks

support or stands

work.

all mud and oil from

the steps or

other places used to get on and off the machine. Always steps when Never

and learn

insert

to lock all the control levers and hang warn-

9. When disassembling out any operation

the correct way to use them.

lower

safety pin or use blocks to prevent the work

gloves,

in the operator’s

to prevent

ground.

out welding

step of the operation.

repairs,

have a

carrying

carrying

any

out the

welding

Keep all tools

oil or making

carry

ways

hang UNDER

adding

always

work. When wear

grind-

etc.

repairs are needed, experienced

7. Before

machine

ing parts with a grinder, 3. If welding

PREPARATIONS FOR WORK

Do not wear

missing. . Always

When

workshop

parts. Always

the tools and parts in their correct

Manual

the machine.

out any greasing

read all the precautions which

dangerous.

and Maintenance

1. Before carrying

care-

safety, and

keep tools and removed Mistakes

in this

be followed

actions to deal with the situation.

GENERAL PRECAUTIONS

Read the Operation

The

purpose.

the symbol

accompanying

machine

jump

impossible

use the handrails,

getting

ladders

or

on or off the machine.

on or off the machine. to use the handrails,

steps, use a stand to provide

If it is

ladders

or

safe footing.

00-3

SAFETY

SAFETY

PRECAUTIONS

DURING

19. Be sure to assemble

WORK

original 11. When or

removing

hydraulic

pressure

loosen them spurting

the oil filler cap, drain plug

slowly

measuring

to prevent

plugs,

the oil from

Before

disconnecting

nents

of the oil, water the

or removing

pressure

compo-

or air circuits, completely

first

from

the

circuit.

12. The

and

installing

the engine

is stopped,

that they will not be damaged

out any work

20. When

installing

sure that

high pressure

they

are

ful when

installing

so be careful

circuits.

Also,

to cool before

on the oil or water

circuits.

13. Before starting work, remove the leads from the battery.

Always

the negative

(-1 terminal

remove

the lead from

use a hoist

aligning

fingers

caught

ample

capacity.

Install

the lifting

23. When

equipment

which

has

places.

Use a hoist to prevent

or crane

and operate from

hit-

ting any other .part. Do not work

with

any

part still raised by the hoist or crane.

15. When

removing

covers which

ternal

pressure

or under

pressure

spring,

always

leave two

bolts

sides. Slowly

are under infrom

a

in position

release the pres-

removing

components,

or damage

may cause electrical removing

be careful not

the wiring.

piping,

Damaged

fires.

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. rule, do not use gasoline

to

wash parts. In particular,

use only the mini-

mum

washing

parts.

00-4

to check

correctly.

Be careful

not to get your

in a hole.

measuring

hydraulic

that the measuring

of gasoline

when

24. Take care when

pressure,

tool is correctly

electrical

removing

tracks of track-type When

removing

rates suddenly,

sure, then slowly loosen the bolts to remove.

18. As a general

or rotate at

careful

check assem-

at the correct

the component

17. When

When

bled before taking any measurements. equipment

slowly

wiring

torques.

such as guards,

two holes, never insert your

Check that the wire rope, chains and hooks are free from damage.

parts

parts, always

violently

be particularly

or hand.

lifting

parts

or parts which vibrate

22. When

care-

connecting

tightening

protective

fingers

use

so be extremely

or installing

use the specified

high speed,

Damaged

tubes for high pressure

check that

or crane.

Always

is be-

hoses, make

not twisted.

that they are installed

first.

14. When raising heavy components,

to break

by contact

installed.

21. When assembling installing

on opposite

be sure

ing operated.

are correctly

for the oil and water

carrying

16. When

parts with new parts.

hoses and wires,

are hot

oil in the circuits

not to get burned.

Wait

Replace any damaged . When

tubes are dangerous,

water

when

all parts again in their

places.

with other parts when the machine

out.

remove

NOTICE

or installing

the

machines.

the track, the track so never let anyone

either end of the track.

sepa-

stand at

GENERAL

FOREWORD

FOREWORD GENERAL This

shop

serviceman

manual

has been

an accurate

prepared

as an aid to improve

understanding

repairs and make judgements.

the quality

of the product and by showing

Make sure you understand

of repairs

by giving

the

him the correct way to perform

the contents

of this manual

and use it to full

information

for operations

performed

in a

into the following

chapters;

these

effect at every opportunity.

This shop manual

mainly

service workshop.

For ease of understanding,

chapters

are further

contains

divided

the necessary

technical

the manual

is divided

into the each main group of components.

STRUCTURE AND FUNCTION This section explains an understanding

the structure

of the structure,

and function

of each component.

but also serves as reference

It serves not only to give

material

for troubleshooting.

TESTING AND ADJUSTING This

section

adjustments

explains

charts correlating

before

and

after

performing

repairs,

as well

as

of the checks and repairs.

“Problems”

to “Causes” are also included

in this section.

AND ASSEMBLY

This section

explains

assembling

each component,

MAINTENANCE

to be made

to be made at completion

Troubleshooting

DISASSEMBLY

checks

the order to be followed

when

as well as precautions

removing,

installing,

disassembling

or

to be taken for these operations.

STANDARD

This section gives the judgement

standards

when

inspecting

disassembled

parts.

NOTICE The

specifications

contained

time

and

without

any

with

the

latest

advance

in this notice.

shop

manual

Use the

are

subject

specifications

to change given

in the

at any book

date.

00-5

HOW TO READ THE SHOP MANUAL

FOREWORD

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:

When

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series

pages.

Electrical volume: Attachments volume:

I

Each issued as one volume to cover all models

These various volumes are designed to avoid duplicating the same information.

Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available.

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.

a manual

(@@@....I

is revised,

is recorded

an edition

on the

bottom

mark of the

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

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):

Symbol

Item

Remarks

a

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems.

Caution necessan/ when selecting hoisting wire, or when working posture is important, etc.

ighteninc torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

Xl, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.

10 -3 Item number (IO. Structure and Function) Consecutive page number for each item.

Example

2 (Engine

*

&I kg

volume):

Unit number (I. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.

3. Additional cated

pages:

by a hyphen

page number.

Example: 10-4 10-4-I k 1O-4-2 10-5

00-6

Additional

pages are indi-

(-1 and number

after the

File as in the example.

12-203 Added

pages -~~~~f~~I~ 12-204

%b 4

01

GENERAL

...............................................

Specifications Engine performance curve ..........................

Weight table ..................................................

Ol- 2 Ol- 4 01-16

01-l 0

GENERAL

SPECIFICATIONS

SPECIFICATIONS Engine

model

Applicable

Number

of cylinders

Total piston Firing

SA12V170-1

machine

- Bore x Stroke

displacement

D575A-2

D575A-2

Engine serial No. 10024-10096

Engine serial No. 10097 and up

mm

12-170x170

e ICC)

46.3 (46,300)

order

Rl-L6-R5-L2-R3-L4-R6-Ll-R2-L5-R4-L3

Overall

length

mm

2,766

2,766

.2

Overall

width

mm

1,720

1,720

2 .-i

Overall height (excluding exhaust

pipe)

mm

2,805

2,805

Overall height (including exhaust

mm

-

-

pipe)

F

n

Flywheel

horsepower

kW/rpm {HP/rpmI

784/l ,800 11 .O~~rY&8001

78411,800 {1,0~~~$300~

Maximum

torque

kW/rpm {kgm/rpmI

5,000/1,300 {51~(;;001

5,000/1,300 {51~0$$00~

High idling

speed

rpm

1,950 - 2,050

1,950 - 2,050

Low idling

speed

rpm g/kW {g/HP

600 - 700

600 - 700

215 11601

215 11601

6,210

6,210

Minimum fuel consumption ratio

l

h

l

h}

Dry weight

BOSCH

Fuel pump

Lubricating

Coolant

oil amount

(refill

type

BOSCH

BOSCH RSUV centrifugal, allspeed type

BOSCH

capacity)

Battery

Turbocharger

298

24V, 75A

24V, 75A

24V, llkWx2

24V, llkWx2

12V200Ah

x 4

KOMATSU KTR130 x 2 (water cooled type)

12V200Ah

01-2 0

x 4

KOMATSU KTRISO x 2 (water cooled type) -

Air compressor Others

type

137 (127)

amount

motor

PES-P(PS7S)

RSUV centrifugal, allspeed type

137 (127)

Alternator Starting

PE-ZWX

With

after cooler

With

after cooler

GENERAL

SPECIFICATIONS

SA12V170-1

D575A-2SD (Super Dozer)

HD1200-1

HD1200M-1

12-170x170 46.3 {46,300} Rl-L6-R5-L2-R3-L4-R6-Ll-R2-L5-R4-L3

2,766

2,346

2,346

1,720

1,704

1,657

2,805

1,839

1,793

-

-

-

858/I ,800 ~1.150/1.800~

960/2,100 {I ,2w~;oo~

87812,100 ~l,l~~Q2~;00~

5,660/l ,300 {57;~;;001

5,190/1,400 {53~cv&OOI

4,640/l ,400 {47;~$001

1,950 - 2,050

2,300 - 2,400

2,300 - 2,400

600 - 700

600 - 700

600 - 700

215 {I601

211 11571

209 I1561

6,650

5,350

5,280

z % z

BOSCH

PE-P(PS7S)

type

BOSCH RSUV centrifugal, allspeed type

BOSCH

BOSCH PES-ZWX

type

RSUV centrifugal,

allspeed

137 (127)

131 (106)

298

280

24V. 75A

24V, 75A

24V, IlkWx

2

12V200Ah

x 4

KOMATSU KTR130 x 2 (water cooled type)

Air starter

KOMATSU

121 (106)

24V, 75A

x 4

KTR130 x 2

ZEXEL recipro caution single cylinder x 2 With after cooler

With

480

I

37.5 kW

12V200Ah

type

after cooler

Air starter

37.5 kW

12V200Ah

KOMATSU

x 4

KTR130 x 2

ZEXEL recipro caution single cylinder x 2 With after cooler

01-3 0

GENERAL

SPECIFICATIONS

Engine

Applicable

Number

of cylinders

Total piston Firing

I

model

SA12V170-1

machine

- Bore x Stroke

displacement

EGI 100-l

mm

12-170x170 46.3 {46,300}

e {cc)

Rl-L6-R5-L2-R3-L4-R6-Ll-R2-L5-R4-L3

order

Overall

length

Overall width Overall height (excluding exhaust Overall height (including exhaust

Flywheel

mm

2,340

2,697

mm

1,420

1,500

pipe)

mm

1,977

2,000

pipe)

mm

-

-

kW/rpm IHP/rpmI

862/1,500 (50Hz) {1,160/1,500~ (50H.z) 950/1,800 (60Hz) {1,27O/I(;C$ (6OHz)

874/l ,500 (50Hz) {I .170/l ,500) (50Hz) 860/l ,800 i6bHz) {1,29o’:iu8~~; (60Hz)

kW/rpm 0-fP/rpmI

950/l ,500 (50Hz) ~1,270/1,500~ (50Hz)I 1,040/l ,800 (60Hz) {1,390/1(8~~)I (60Hz)

-

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

horsepower

Maximum

horsepower

High idling

speed

Low idlingn

speed

Fuel consumption

rpm g/kW {g/HP

ratio

Dry weight

l

h

l

W

700 - 900 216 (at rated) {I611 (at rated)

5,600

5,450

BOSCH BOSCH

Coolant

oil amount

amount

(refill

capacity)

Battery

Air compressor Others

01-3-l 0

RSUV centrifugal,

type allspeed

type

e

motor

Turbocharger

PE-ZWX

e

Alternator Starting

1,560 (50Hz) 1,890 (60Hz)

900 - 1,000

kg

Governor

Max. Max.

216 (at rated) (161) (at rated)

Fuel pump

Lubricating

Generator

24V, 35A

24V, 35A

24V, llkWx2

24V, IlkWx2

12V200Ah

!

KOMATSU

x 4

KTR150

-

With after cooler

12V200Ah

x 2

KOMATSU

I I

x 4

KTR150 x 2

With after cooler

* : optional

parts

GENERAL

SPECIFICATIONS

I

01-3-2

ENGINE

GENERAL

ENGINE PERFORMANCE SA12V170-1

PERFORMANCE

CURVE

CURVE

(FOR D575A-2)

Flywheel horsepower: Maximum torque:

783 KW (1,050 HP)/1,800 rpm 5,001 Nm (510 kgm)/1,300 rpm

z

‘z 1300

1200

1100 I -

, -

1000

900

600

700

600 /

500

I

400 300

I

200

I

100 I 0

600

600

1000

1200

1400

1600

Eneine speed

01-4 0

I600

(rpm)

2000

2200

2400 SAE00237

ENGINE

GENERAL

SA12V170-1

PERFORMANCE

CURVE

(FOR D575A-2SD)

Flywheel horsepower: Maximum torque:

858 KW (1,150 HP)/1,800 rpm 5,658 Nm (577 kgm)/1,300 rpm

600

500

400

300

6000

I 5000

4000

,”

- 3000

E :

200

- 2000

;j 5

100

- 1000

1300

0

-0

1200 1100

;;

1100

i2

z

1000

900

s

1000

900

a00

600

700

700

600

600

1

I I

2

500

I /

4oc

400

3OC

300

I,

200

2OC

lO(

I

100 I

c 0

600

600

1000

1400

1200 Engine

I600

1600 speed

(rpm)

2000

2200

2400 SAE00236

01-5 0

GENERAL

ENGINE

SAlPV170-1

PERFORMANCE

CURVE

(FOR HD1200-1)

Flywheel horsepower: Maximum torque:

962 KW (1,290 HP)/2,100 rpm 5,197 Nm (530 kgm)/1,400 rpm

600

6000

500

5000

4000

400 I

3000

300

-

1000

1200

-

1100

-

1000

-

900

-

600

-

700

-

2 s

600

-

500

-

400

-

300

-

200

900

-

600

-

- 1000

0

-0

1200

‘0°

900

600

-

500

-

800

700

600 400

500

300

-

200

-

100

-

400

300

200

100

o0

600

600

1000

1200

1400 Engine

01-6 0

100

1000

-

o-

- 2000

II00

-

100

200

1300

1600 speed

1600 (rpm)

2000

2200

: F

t

1300

2

2400 SAE00239

GENERAL

ENGINE

PERFORMANCE

CURVE

SA12V170-1 (FOR HD1200M-1) Flywheel horsepower: Maximum torque:

z IOOO-

1300-

D 2

z s

‘j; Y

5

878 KW (1,177 HP)/2,100 rpm 4,638 Nm (473 kgm)/1,400 rpm

1300

1200

-

1100

-

1000

-

900

-

600

-

700

-

s 600

-

500

-

400

-

300

-

200

-

too

-

900

-

600

-

1100

1000 ‘0°

900

600

-

500

-

600

700

600 400

500

300

-

200

-

400

300

200 100

o-

1200

100

o0

600

600

1000

1200

1400 Engine

1600 speed

I600 (rpm)

2000

2200

2400 SAE00240

01-7 0

ENGINE

GENERAL

PERFORMANCE

CURVE

SA12V170-1 (HD1200M-1) .

Left side view

P

2061.2

Rear face of flywheel

housing

F6166002

01-8 0

ENGINE

GENERAL

SA12V170-1 l

PERFORMANCE

CURVE

(HD1200M-1)

Right side view

I

Crankshaft center

7

Rear face of flywheel ho1

Cooling water inlet

2; x 1.5 Fuel outlet

2324.6

F6166003

01-9 0

GENERAL

ENGINE

SA12V170-1 .

PERFORMANCE

(HD1200M-1)

Front side view

899

Bypass

water

inlet

\

: center

\ PTl/2

I-

402

fuel

inlet

380

F6166004

01-10 0

CURVE

GENERAL

ENGINE

PERFORMANCE

CURVE

SAlZV170-1 (HD1200M-1) .

Rear side view

529

529

Crankshaft center

4-24 hole

c 1

d

657.5

I

657.5

F6166005

01-11 0

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GENERAL

ENGINE

SA12V170-1 .

PERFORMANCE

CURVE

(D575A-2SD)

Left side view

21893

a

PT l/8 inlet for car heate

\

l/2 outlet lr car heater

port

SAE00241

01-12 0

ENGINE

GENERAL

SAlPV170-1 l

PERFORMANCE

CURVE

(D575A-2SD)

Right side view

Boost pickup

Pressure port \

To

Fuel

Tank

From Fuel Tank Filter From Fuel To Fuel Filter

L

1994.4

-I

SAE00242

01-13 0

GENERAL

SA12V170-1 .

ENGINE

PERFORMANCE

(D575A-2SD)

Front side view

----

---_

566. a

544. a

J SAE00243

01-14 0

CURVE