Komatsu 125-3 Series Diesel Engine Shop Manual SEBM024208 – PDF DOWNLOAD

Description

Komatsu 125-3 Series Diesel Engine Shop Manual

FILE DETAILS:

Komatsu 125-3 Series Diesel Engine Shop Manual

Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: SAA6D125E-3, SA6D125E-3, 125-3 Series Diesel Engine
Serial Number: –
Book Code: SEBM024208
Language: English
Pages: 349
File Format: Portable Document Format (PDF)

DESCRIPTION:

Komatsu 125-3 Series Diesel Engine Shop Manual

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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
Disassembly and assembly:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
Maintenance standard:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”.
Others:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu 125-3 Series Diesel Engine Shop Manual

MAIN MENU.............................................................................................................................................  0
COVER.................................................................................................................................................  1
CONTENTS..............................................................................................................................................  2
01 GENERAL............................................................................................................................................ 26
	OUTLINE........................................................................................................................................... 27
	SPECIFICATIONS.................................................................................................................................... 30
	GENERAL ASSEMBLY DRAWING.......................................................................................................................... 34
	WEIGHT TABLE...................................................................................................................................... 47
	ENGINE PERFORMANCE CURVE.......................................................................................................................... 48
11 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD....................................................................................................... 57
	GENERAL STRUCTURE................................................................................................................................. 58
	INTAKE, EXHAUST SYSTEM............................................................................................................................ 62
		INTAKE, EXHAUST SYSTEM........................................................................................................................ 62
		AIR CLEANER................................................................................................................................... 68
		TURBOCHARGER.................................................................................................................................. 69
		AFTERCOOLER................................................................................................................................... 70
	ENGINE BODY....................................................................................................................................... 72
		CYLINDER HEAD................................................................................................................................. 72
		CYLINDER BLOCK................................................................................................................................ 75
		CYLINDER LINER................................................................................................................................ 79
		MAIN CIRCULATION SYSTEM....................................................................................................................... 80
		CRANKSHAFT.................................................................................................................................... 82
		PISTON........................................................................................................................................ 83
		CONNECTING ROD................................................................................................................................ 85
		FLYWHEEL AND FLYWHEEL HOUSING................................................................................................................. 86
		VIBRATION DAMPER.............................................................................................................................. 88
		TIMING GEAR................................................................................................................................... 90
		VALVE MECHANISM............................................................................................................................... 93
		CAMSHAFT...................................................................................................................................... 95
		CAM FOLLOWER AND PUSH ROD..................................................................................................................... 96
		VALVE AND VALVE GUIDE......................................................................................................................... 97
		ROCKER ARM SHAFT.............................................................................................................................. 99
		CROSSHEAD.....................................................................................................................................100
	LUBRICATION SYSTEM................................................................................................................................101
		LUBRICATION SYSTEM DIAGRAM....................................................................................................................101
		OIL PUMP......................................................................................................................................102
		OIL FILTER....................................................................................................................................105
		OIL COOLER....................................................................................................................................107
	FUEL SYSTEM.......................................................................................................................................109
		FUEL SYSTEM DIAGRAM...........................................................................................................................109
		OUTLINE OF CRI SYSTEM.........................................................................................................................110
		FUEL PIPING...................................................................................................................................123
		FUEL COOLER...................................................................................................................................125
		FUEL FILTER...................................................................................................................................126
	COOLING SYSTEM....................................................................................................................................127
		COOLING SYSTEM CHART..........................................................................................................................127
		WATER PUMP....................................................................................................................................128
		THERMOSTAT....................................................................................................................................131
		CORROSION RESISTOR............................................................................................................................133
	ELECTRICAL SYSTEM.................................................................................................................................134
		ALTERNATOR MOUNTING...........................................................................................................................134
		ALTERNATOR....................................................................................................................................136
		STARTING MOTOR................................................................................................................................140
		STARTING AID..................................................................................................................................142
12 TESTING AND ADJUSTING, TROUBLESHOOTING.............................................................................................................144
	TESTING AND ADJUSTING DATA........................................................................................................................146
	STANDARD VALUE TABLE FOR ELECTRICAL PARTS.........................................................................................................151
	TESTING AND ADJUSTING TOOL LIST...................................................................................................................153
	TESTING AND ADJUSTING.............................................................................................................................154
		MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE).................................................................................................154
		MEASURING EXHAUST TEMPERATURE.................................................................................................................155
		ADJUSTING VALVE CLEARANCE.....................................................................................................................157
		MEASURING COMPRESSION PRESSURE................................................................................................................159
		MEASURING BLOW-BY PRESSURE....................................................................................................................161
		MEASURING ENGINE OIL PRESSURE.................................................................................................................162
		MEASURING FUEL PRESSURE.......................................................................................................................163
		ADJUSTING ENGINE SPEED SENSOR.................................................................................................................164
		TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................................................................165
		HANDLING EQUIPMENT IN FUEL SYSTEM.............................................................................................................171
		RELEASING REMAINING PRESSURE IN FUEL SYSTEM...................................................................................................171
		BLEEDING AIR FROM FUEL CIRCUIT................................................................................................................172
		REDUCED CYLINDER MODE OPERATION FOR ENGINE....................................................................................................174
		CHECKING FOR LEAKAGE IN FUEL SYSTEM...........................................................................................................175
		ADJUSTING ENGINE STOP MOTOR LEVER.............................................................................................................176
		CALIBRATION DATA..............................................................................................................................178
		PERFORMANCE TEST..............................................................................................................................180
			RUN-IN STANDARD...........................................................................................................................180
			PERFORMANCE TEST STANDARDS................................................................................................................182
	TROUBLESHOOTING...................................................................................................................................188
		TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....................................................................................................188
			POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................189
			METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................190
			S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)..............................................................................193
			S-2 ENGINE DOES NOT START.................................................................................................................194
			S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)...................................................................................197
			S-4 ENGINE STOPS DURING OPERATIONS........................................................................................................198
			S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)..............................................................................................199
			S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)...................................................................................................200
			S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION).........................................................................................201
			S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)................................................................................202
			S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................................203
			S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................................204
			S-11 OIL IS IN COOLING WATER(OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)..............................................................205
			S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)............................................................................206
			S-13 OIL LEVEL RISES(WATER, FUEL IN OIL)..................................................................................................207
			S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....................................................................................208
			S-15 ABNORMAL NOISE IS MADE...............................................................................................................209
			S-16 VIBRATION IS EXCESSIVE...............................................................................................................210
		TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).................................................................................................211
			POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................213
			METHOD OF USING TROUBLESHOOTING FLOWCHART.................................................................................................214
			ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................215
			ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED..........................................................218
			E-1 ERROR CODE [E-1b] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]........................................................................226
			E-2 ERROR CODE [E-1C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM].........................................................................227
			E-3 ERROR CODE [E-20] [ABNORMALITY IN MODEL SELECTION SYSTEM].............................................................................228
			E-4 ERROR CODE [E-22] [OVERRUN]...........................................................................................................229
			E-5 ERROR CODE [E-23] [OVERHEAT]..........................................................................................................229
			E-6 ERROR CODE [E-24] [DROP IN OIL PRESSURE]..............................................................................................230
			E-7 ERROR CODE [E-30] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]....................................................................231
			E-8 ERROR CODE [E-31] [ABNORMALITY IN THROTTLE SENSOR SYSTEM].............................................................................233
			E-9 ERROR CODE [E-34] [ABNORMALITY IN WATER TEMPERATURE HIGH-TEMPERATURE SENSOR SYSTEM]...................................................236
			E-10 ERROR CODE [E-36] [ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]........................................................................237
			E-11 ERROR CODE [E-3C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]......................................................................239
			E-12 ERROR CODE [E-3d] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]....................................................................240
			E-13 ERROR CODE [E-50] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]..........................................................241
			E-14 ERROR CODE [E-51] [ABNORMALITY IN PREHEAT RELAY COIL SYSTEM].........................................................................242
			E-15 ERROR CODE [E-54] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]........................................................................243
			E-16 ERROR CODE [E-56] [POWER SOURCE SYSTEM ABNORMALITY 1]................................................................................244
			E-17 ERROR CODE [E-57] [POWER SOURCE SYSTEM ABNORMALITY 2]................................................................................246
			E-18 ERROR CODE [E-5A] [ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL].....................................................247
			E-19 ERROR CODE [E-6A] [ABNORMALITY IN WATER TEMPERATURE LOW-TEMPERATURE SENSOR SYSTEM]...................................................248
			E-20 ERROR CODE [E-70] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]...................................................................249
			E-21 ERROR CODE [E-71] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]...................................................................250
			E-22 ERROR CODE [E-74] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]....................................................................251
			E-23 ERROR CODE [E-75] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]....................................................................252
			E-24 ERROR CODE [E-77] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]...........................................................253
			E-25 ERROR CODE [E-79] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1];ERROR CODE [E-7A] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2]....254
			E-26 ERROR CODE [E-7b] [FUEL SUPPLY PUMP NON-FORCE FEED 1];ERROR CODE [E-7C] [FUEL SUPPLY PUMP NON-FORCE FEED 2]..........................255
			E-27 ERROR CODE [E-7d] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE].........................................................................257
			E-28 ERROR CODE [E-80] [DEFECTIVE CONTROLLER].............................................................................................257
			E-29 ERROR CODE [E-81] [DISCONNECTION IN NO.1 FUEL INJECTOR SYSTEM].......................................................................258
			E-30 ERROR CODE [E-82] [DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM].......................................................................259
			E-31 ERROR CODE [E-83] [DISCONNECTION IN NO.3 FUEL INJECTOR SYSTEM].......................................................................260
			E-32 ERROR CODE [E-84] [DISCONNECTION IN NO.4 FUEL INJECTOR SYSTEM].......................................................................261
			E-33 ERROR CODE [E-85] [DISCONNECTION IN NO.5 FUEL INJECTOR SYSTEM].......................................................................262
			E-34 ERROR CODE [E-86] [DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM].......................................................................263
			E-35 ERROR CODE [E-8A] [SHORT CIRCUIT IN NO.1, NO.2, NO.3, FUEL INJECTOR SYSTEM]..........................................................264
			E-36 ERROR CODE [E-8b] [SHORT CIRCUIT IN NO.4, NO.5, NO.6 FUEL INJECTOR SYSTEM]...........................................................267
13 DISASSEMBLY AND ASSEMBLY...........................................................................................................................270
	METHOD OF USING MANUAL............................................................................................................................272
	PRECAUTIONS WHEN CARRYING OUT OPERATION...........................................................................................................273
	SPECIAL TOOL LIST.................................................................................................................................275
	SKETCHES OF SPECIAL TOOLS.........................................................................................................................276
	GENERAL DISASSEMBLY...............................................................................................................................277
		1. PREPARATION WORK...........................................................................................................................277
		2. STARTING MOTOR.............................................................................................................................277
		3. TURBOCHARGER LUBRICANT RETURN TUBE.........................................................................................................277
		4. RADIATOR LOWER HOSE........................................................................................................................277
		5. ENGINE OIL COOLER..........................................................................................................................277
		6. ADAPTER FOR ENGINE OVERHAULING.............................................................................................................278
		7. RADIATOR UPPER HOSE........................................................................................................................278
		8. EXHAUST MUFFLER............................................................................................................................278
		9. FAN SECURING BRACKET.......................................................................................................................278
		10. TURBOCHARGER LUBRICATION TUBE.............................................................................................................278
		11. TURBOCHARGER AND EXHAUST MANIFOLD.........................................................................................................278
		12. FUEL FILTER ASSEMBLY......................................................................................................................278
		13. OIL FILTER................................................................................................................................279
		14. WIRING HARNESS............................................................................................................................279
		15. TAKE OFF AIR CLEANER SECURING BRACKET (1).................................................................................................279
		16. TAKE OFF EXHAUST MUFFLER SECURING BRACKET (2).............................................................................................279
		17. TAKE OFF EACH HIGH-PRESSURE TUBE CLAMP (3)................................................................................................279
		18. SUCTION MANIFOLD ASSEMBLY.................................................................................................................279
		19. SUPPLY PUMP...............................................................................................................................279
		20. COMMON RAIL...............................................................................................................................280
		21. SPILL PIPE................................................................................................................................281
		22. HEAD COVER................................................................................................................................281
		23. INJECTOR HARNESS..........................................................................................................................281
		24. ROCKER ARM................................................................................................................................281
		25. PUSH ROD..................................................................................................................................281
		26. INJECTOR..................................................................................................................................281
		27. NOZZLE TIP................................................................................................................................282
		28. CROSSHEAD.................................................................................................................................282
		29. ROCKER ARM HOUSING........................................................................................................................283
		30. INJECTOR HARNESS CONNECTOR................................................................................................................283
		31. THERMOSTAT................................................................................................................................283
		32. CAM FOLLOWER COVER........................................................................................................................283
		33. CAM FOLLOWER..............................................................................................................................283
		34. CYLINDER HEAD ASSEMBLY....................................................................................................................283
		35. SETTING TO ENGINE OVERHAUL STAND..........................................................................................................284
		36. OIL PAN...................................................................................................................................284
		37. FLYWHEEL..................................................................................................................................284
		38. FLYWHEEL HOUSING..........................................................................................................................284
		39. DAMPER....................................................................................................................................285
		40. FRONT SUPPORT.............................................................................................................................285
		41. FRONT COVER...............................................................................................................................285
		42. WATER PUMP................................................................................................................................285
		43. CAMSHAFT..................................................................................................................................285
		44. OIL PUMP..................................................................................................................................285
		45. IDLER GEAR................................................................................................................................285
		46. OIL SUCTION PIPE..........................................................................................................................286
		47. PISTON COOLING NOZZLE.....................................................................................................................286
		48. PISTON AND CONNECTING ROD ASSEMBLY........................................................................................................286
		49. CRANKSHAFT................................................................................................................................287
		50. CYLINDER LINER............................................................................................................................288
	GENERAL ASSEMBLY..................................................................................................................................289
		PREPARATION WORK..............................................................................................................................289
		1. CYLINDER LINER.............................................................................................................................290
		2. CRANKSHAFT.................................................................................................................................291
		3. PISTON AND CONNECTING ROD ASSEMBLY.........................................................................................................294
		4. PISTON COOLING NOZZLE......................................................................................................................297
		5. OIL SUCTION PIPE...........................................................................................................................298
		6. IDLER GEAR.................................................................................................................................298
		7. OIL PUMP...................................................................................................................................298
		8. CAMSHAFT...................................................................................................................................299
		9. CAM FOLLOWERS..............................................................................................................................299
		10. CAM FOLLOWER COVERS.......................................................................................................................299
		11. WATER PUMP................................................................................................................................299
		12. FUEL SUPPLY PUMP DRIVING GEAR.............................................................................................................299
		13. FRONT COVER...............................................................................................................................300
		14. FLYWHEEL HOUSING..........................................................................................................................301
		15. REAR SEAL.................................................................................................................................302
		16. FLYWHEEL..................................................................................................................................304
		17. DAMPER....................................................................................................................................304
		18. OIL PAN...................................................................................................................................305
		19. REMOVING ENGINE ASSEMBLY FROM ENGINE OVERHAUL STAND.......................................................................................305
		20. SETTING ENGINE ASSEMBLY ON BLOCKS.........................................................................................................305
		21. CYLINDER HEAD.............................................................................................................................305
		22. CYLINDER HEAD ASSEMBLY....................................................................................................................305
		23. ROCKER ARM HOUSING........................................................................................................................307
		24. ASSEMBLING INJECTOR HARNESS CONNECTOR TO ROCKER ARM HOUSING...............................................................................307
		25. CROSSHEAD.................................................................................................................................307
		26. PUSH ROD..................................................................................................................................308
		27. ROCKER ARM................................................................................................................................308
		28. ADJUSTING VALVE CLEARANCE.................................................................................................................308
		29. NOZZLE TIP................................................................................................................................308
		30. FUEL INJECTOR.............................................................................................................................310
		31. HEAD COVER................................................................................................................................310
		32. SPILL PIPE................................................................................................................................310
		33. THERMOSTAT................................................................................................................................311
		34. ENGINE OIL COOLER.........................................................................................................................311
		35. ENGINE COOLING WATER TEMPERATURE SENSOR...................................................................................................311
		36. ENGINE OIL SUPPLY TUBE....................................................................................................................311
		37. HIGH-PRESSURE TUBE FOR COMMON RAIL........................................................................................................311
		38. SUCTION MANIFOLD..........................................................................................................................312
		39. ENGINE OIL FILTER.........................................................................................................................313
		40. FUEL FILTER...............................................................................................................................313
		41. TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY................................................................................................313
		42. STARTING MOTOR............................................................................................................................313
		43. FAN BRACKET LIFTING HOOK..................................................................................................................314
		44. WIRING HARNESS............................................................................................................................314
		45. AIR CLEANER...............................................................................................................................314
		46. EXHAUST MUFFLER...........................................................................................................................314
15 REPAIR AND REPLACEMENT OF PARTS....................................................................................................................315
	CYLINDER HEAD.....................................................................................................................................316
		REPLACING VALVE SEAT INSERT...................................................................................................................316
		REPLACING NOZZLE HOLDER SLEEVE................................................................................................................321
		REPLACING VALUE GUIDE.........................................................................................................................324
		REPLACING CROSS HEAD GUIDE....................................................................................................................325
		GRINDING THE VALVE............................................................................................................................326
		GRINDING THE FITTING FACE OF CYLINDER HEAD....................................................................................................326
		PRESSURE TEST.................................................................................................................................327
	CYLINDER BLOCK....................................................................................................................................328
		REPLACING CAM BUSHING.........................................................................................................................328
		REPLACING CAM GEAR............................................................................................................................331
		REPLACING FLYWHEEL RING GEAR..................................................................................................................331
		REPLACING ENGINE REAR SEAL....................................................................................................................332
		REPLACING CONNECTING ROD SMALL END BUSHING....................................................................................................337
		REPLACING MAIN BEARING CAP....................................................................................................................338
		GRINDING CRANKSHAFT...........................................................................................................................340
		REPLACING WEAR SLEEVE(WHEN EQUIPPED WITH SLEEVE)..............................................................................................349

KOMATSU 125-3 SERIES DIESEL ENGINE SHOP MANUAL SEBM024208 – PDF DOWNLOAD:

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.