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
14
MAINTENANCE
........................................................... II-I
................................................................ 12-1
AND ASSEMBLY
STANDARD
.................................................... 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
or clothes with buttons
safety glasses
trained,
adding
when
hitting
oil or making
wear
safety
glasses
repairs are needed, experienced
when
welder
always carry
work. When
carrying
out welding
ways
welding
gloves,
wear
grind-
etc. have a out the work,
apron,
al-
hand
shield, cap and other clothes suited for welding work. out any operation
or more workers, ating procedure
with two
always agree on the operbefore
starting.
Always
in-
form your fellow workers before starting any step of the operation.
Before starting
work,
REPAIR signs on the controls
in the operator’s Keep all tools
or tracks
compartment.
in good condition
the correct way to use them.
to prevent
and the
blade,
ripper,
bucket or any other work equipment
to the
starting
ground.
If this
work,
lower
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 warning 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
repairs,
from moving.
9. When disassembling
carrying
hang UNDER
8. Before
any
on hard, level ground,
block the wheels machine
ing parts with a grinder, 3. If welding
7. Before
park the machine wear
parts with a hammer. . Always
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
to prevent
plugs,
the oil from
disconnecting
or removing
of the oil, water
remove
the
pressure
compo-
or air circuits, completely
first
from
the
circuit. 12. The
and
oil in the circuits
the engine
is stopped,
are hot
so be careful
installing
for the oil and water
carrying
out any work
to cool before
on the oil or water
circuits.
the battery.
Always
the negative
(-1 terminal
remove
the lead from
20. When
installing
sure that
high pressure
they
are
ful when circuits.
installing Also,
use a hoist
21. When assembling
aligning
fingers
caught
lifting
ample
capacity.
Install
the lifting
23. When
equipment
which
has
Use a hoist
or crane
and operate
the component
from
hit-
with
any
part still raised by the hoist or crane. 15. When
removing
covers which
ternal
pressure
or under
always
leave two
wiring 17. When
are under in-
pressure bolts
sides. Slowly
removing
from
a
in position
release the pres-
components,
or damage
removing
be careful not
the wiring.
may cause electrical 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. 18. As a general
rule, do not use gasoline
to
wash parts. In particular,
use only the mini-
mum
washing
parts.
00-4
When
violently
or rotate at
careful
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.
to break
torques.
such as guards,
check assem-
at the correct
ting any other .part. Do not work
16. When
parts, always
bled before taking any measurements. equipment
to prevent
on opposite
parts
two holes, never insert your
Check that the wire rope, chains and hooks use
parts
be particularly
or hand.
are free from damage.
care-
connecting
tightening
protective
or parts which vibrate
22. When
Damaged
so be extremely
or installing
use the specified
high speed,
hoses, make
tubes for high pressure
check that
fingers
Always
is be-
installed.
or crane.
spring,
by contact
not twisted.
that they are installed
first.
14. When raising heavy components,
places.
be sure
ing operated.
installing
13. Before starting work, remove the leads from
slowly
parts with new parts.
hoses and wires,
that they will not be damaged
are correctly
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.
Before nents
measuring
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
effect at every opportunity.
This shop manual
mainly
service workshop.
For ease of understanding,
chapters
are further
contains
divided
the necessary
technical
the manual
information is divided
for operations
performed
into the following
chapters;
in a these
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
This section assembling
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 explains
the order to be followed
each component,
MAINTENANCE
to be made
to be made at completion
Troubleshooting
DISASSEMBLY
checks
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
time
and
with
the
contained
without latest
any
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
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.
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
Remarks
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.
%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 46.3 (46,300)
e ICC)
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
mm
2,805
2,805
mm
-
-
F
n
Overall height (including exhaust
Flywheel
pipe) pipe)
kW/rpm {HP/rpmI
horsepower
Maximum
784/l ,800 11 .O~~rY&8001
kW/rpm {kgm/rpmI
torque
High idling
speed
rpm
Low idling
speed
rpm g/kW {g/HP
Minimum fuel consumption ratio
l
l
5,000/1,300 {51~(;;001
5,000/1,300 {51~0$$00~
1,950 - 2,050
1,950 - 2,050
600 - 700
600 - 700
215 11601
215 11601
6,210
6,210
h
h}
Dry weight
BOSCH
Fuel pump
PE-ZWX
type
BOSCH RSUV centrifugal, allspeed type
Lubricating
Coolant
oil amount
(refill
capacity)
BOSCH BOSCH
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
78411,800 {1,0~~~$300~
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
2,346
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;~$001
1,950 - 2,050
2,300 - 2,400
2,300 - 2,400
600 - 700
600 - 700
600 - 700
215 {I601
211 11571
209 I1561
6,650
5,350
5,280
z % z
2,766
BOSCH
PE-P(PS7S)
BOSCH PES-ZWX
type
BOSCH RSUV centrifugal, allspeed type
BOSCH
RSUV centrifugal,
137 (127)
131 (106)
298
280
24V. 75A
24V, 75A
24V, IlkWx 12V200Ah
2 x 4
KOMATSU KTR130 x 2 (water cooled type)
Air starter
KOMATSU
With
type
480
I
24V, 75A
x 4
KTR130 x 2
ZEXEL recipro caution single cylinder x 2 With after cooler
allspeed
121 (106)
37.5 kW
12V200Ah
type
after cooler
Air starter
37.5 kW
12V200Ah
KOMATSU
x 4
KTR130 x 2
ZEXEL recipro caution single cylinder x 2 With after cooler
01-3 0
GENERAL
SPECIFICATIONS
Engine
Applicable
Number
of cylinders
Total piston Firing
I
model
SA12V170-1
machine
- Bore x Stroke
displacement
EGI 100-l
mm
12-170x170 46.3 {46,300}
e {cc)
Rl-L6-R5-L2-R3-L4-R6-Ll-R2-L5-R4-L3
order
Overall
length
Overall width Overall height (excluding exhaust
pipe)
Overall height (including exhaust
Flywheel
pipe)
horsepower
Maximum
High idling
Low idlingn
horsepower
speed
speed
Fuel consumption
mm
2,340
2,697
mm
1,420
1,500
mm
1,977
2,000
mm
-
-
kW/rpm IHP/rpmI
862/1,500 (50Hz) {1,160/1,500~ (50H.z) 950/1,800 (60Hz) {1,27O/I(;C$ (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
rpm g/kW {g/HP
ratio
Dry weight
l
l
h
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 :
;j 5
1300
200
- 2000
100
- 1000
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
2
900
-
600
-
-
600
-
700
-
s 600
-
500
-
400
-
300
-
200
‘0°
0
-0
1200
600
-
500
-
800
700
600 400
500
300
-
200
-
100
-
400
300
200
100
o0
600
600
1000
1200
1400 Engine
01-6 0
- 1000
900
-
o-
100
1000
-
100
- 2000
II00
-
900
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-
1300
1200
-
1100
-
1000
D 2
z s
‘j; Y
5
878 KW (1,177 HP)/2,100 rpm 4,638 Nm (473 kgm)/1,400 rpm
900
-
600
-
1100
-
900
-
600
-
700
-
s 600
-
500
-
400
-
300
-
200
-
too
-
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