Komatsu 125E-5 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 125E-5 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 125E-5 Series Engine
Book Code: SEN00177-14
Language: English
Pages: 647
File Format: Portable Document Format (PDF)
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 125E-5 Series Diesel Engine Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu 125E-5 Series Diesel Engine Shop Manual
COVER .................................................................................... 1 00 Index and foreword..................................................................... 0 Index................................................................................. 4 Composition of shop manual........................................................ 5 Table of contents................................................................. 6 Foreword and general information...................................................... 12 Safety notice..................................................................... 13 How to read the shop manual....................................................... 18 Explanation of terms for maintenance standard..................................... 20 Handling of electric equipment and hydraulic component............................ 22 Handling of connectors newly used for engines..................................... 31 How to read electric wire code.................................................... 34 Precautions when carrying out operation........................................... 37 Method of disassembling and connecting push-pull type coupler..................... 40 Standard tightening torque table.................................................. 43 Conversion table.................................................................. 47 01 Specification.......................................................................... 0 Specification and technical data...................................................... 54 Outline........................................................................... 55 Specifications.................................................................... 59 General view...................................................................... 73 Weight table...................................................................... 98 Engine performance curves.........................................................101 10 Structure, function and maintenance standard........................................... 0 Structure, function and maintenance standard, Part 1..................................110 General structure.................................................................113 Air intake and exhaust unit.......................................................115 Air cleaner.......................................................................119 Turbocharger......................................................................121 Aftercooler.......................................................................128 EGR system........................................................................129 Cylinder head.....................................................................136 Cylinder block....................................................................139 Cylinder liner....................................................................143 Main moving parts.................................................................144 Crankshaft........................................................................146 Camshaft..........................................................................147 Cam follower and push rod.........................................................148 Piston, piston ring and piston pin................................................149 Connecting rod....................................................................151 Flywheel and flywheel housing.....................................................152 Vibration damper..................................................................157 Timing gear.......................................................................159 Valve system......................................................................167 Valve and valve guide.............................................................171 Rocker arm and shaft..............................................................173 Crosshead and guide...............................................................174 Structure, function and maintenance standard, Part 2..................................176 Lubrication system................................................................179 Lubrication system diagram....................................................179 Oil pump......................................................................183 Main relief valve.............................................................184 EGR oil pump..................................................................185 Oil filter....................................................................186 Safety valve..................................................................188 Oil cooler....................................................................189 Fuel system.......................................................................191 CRI system diagram............................................................191 Outline of CRI system.........................................................193 Fuel piping...................................................................215 Fuel cooler...................................................................217 Fuel filter...................................................................218 Electric priming pump.........................................................220 Engine controller cooler......................................................221 Cooling system....................................................................223 Cooling system diagram........................................................223 Water pump....................................................................225 Thermostat....................................................................227 Corrosion resistor............................................................229 Electrical equipment..............................................................230 Alternator....................................................................230 Starting motor................................................................237 Electrical intake air heater..................................................241 Engine controller.............................................................242 20 Standard value table................................................................... 0 Standard service value table..........................................................244 Standard service value table......................................................245 Standard service value table for testing, adjusting, and troubleshooting......245 Running-in standard and performance test standard.............................258 30 Testing and adjusting.................................................................. 0 Testing and adjusting.................................................................268 Testing and adjusting (With EGR)..................................................270 Testing and adjusting tools list..............................................270 Sketches of special tools.....................................................272 Testing air boost pressure....................................................273 Testing exhaust temperature...................................................274 Adjusting valve clearance.....................................................275 Testing compression pressure..................................................276 Testing blow-by pressure......................................................278 Testing engine oil pressure...................................................279 Measuring EGR valve and bypass valve drive pressure...........................280 Handling fuel system parts....................................................281 Releasing residual pressure in fuel system....................................281 Testing fuel pressure.........................................................282 Reduced cylinder mode operation...............................................283 No-injection cranking.........................................................283 Testing leakage from pressure limiter and return rate from injector...........284 Bleeding air from fuel circuit................................................287 Testing fuel system for leakage...............................................289 Adjusting speed sensor........................................................290 Testing and adjusting alternator belt tension.................................291 Handling controller voltage circuit...........................................292 Testing and adjusting (EGR-less)..................................................293 Testing and adjusting tools list..............................................293 Sketches of special tools.....................................................295 Testing air boost pressure....................................................296 Testing exhaust temperature...................................................297 Adjusting valve clearance.....................................................298 Testing compression pressure..................................................299 Testing blow-by pressure......................................................301 Testing engine oil pressure...................................................302 Handling fuel system parts....................................................303 Releasing residual pressure in fuel system....................................303 Testing fuel pressure.........................................................304 Reduced cylinder mode operation...............................................305 No-injection cranking.........................................................305 Testing leakage from pressure limiter and return rate from injector...........306 Bleeding air from fuel circuit................................................308 Testing fuel system for leakage...............................................310 Adjusting speed sensor........................................................311 Testing and adjusting alternator belt tension.................................312 Handling controller voltage circuit...........................................313 40 Troubleshooting........................................................................ 0 General information on troubleshooting................................................316 General information on troubleshooting............................................317 Points on troubleshooting.....................................................317 Error code and failure code table.............................................319 Information in troubleshooting table..........................................323 Troubleshooting of electrical system (E-mode), Part 1.................................326 Troubleshooting of electrical system (E-mode), Part 1.............................329 E-1 Code [111/CA111] ECM Critical Internal Failure............................329 E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error......................331 E-3 Code [122/CA122] Charge Air Press Sensor High Error.......................333 E-4 Code [123/CA123] Charge Air Press Sensor Low Error........................335 E-5 Code [131/CA131] Throttle Sensor High Error...............................337 E-6 Code [132/CA132] Throttle Sensor Low Error................................341 E-7 Code [135/CA135] Oil press. Sensor High Error.............................343 E-8 Code [141/CA141] Oil press. Sensor Low Error..............................345 E-9 Code [144/CA144] Coolant Temp. Sensor High Error..........................347 E-10 Code [145/CA145] Coolant Temp. Sensor Low Error..........................349 E-11 Code [153/CA153] Charge Air Temp. Sensor High Error......................351 E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error.......................353 E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error...........................354 E-14 Code [221/CA221] Ambient Air Press. Sensor High Error....................355 E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error.....................357 E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error..........................359 E-17 Code [234/CA234] Eng. Overspeed..........................................361 E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error........................363 E-19 Code [263/CA263] Fuel Temp. Sensor High Error............................365 E-20 Code [265/CA265] Fuel Temp. Sensor Low Error.............................367 E-21 Code [271/CA271] PCV1 Short Error........................................369 E-22 Code [272/CA272] PCV1 Open Error.........................................371 E-23 Code [273/CA273] PCV2 Short Error........................................373 E-24 Code [274/CA274] PCV2 Open Error.........................................375 E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error............377 E-26 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error............379 E-27 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error............381 E-28 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error............383 E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error............385 E-30 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error............387 E-31 Code [342/CA342] Calibration Code Incompatibility........................389 E-32 Code [351/CA351] INJ. Drive Circuit Error................................391 E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error...........................393 E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error..........................395 E-35 Code [431/CA431] Idle Validation SW Low error............................397 E-36 Code [432/CA432] Idle Validation Process error...........................399 E-37 Code [441/CA441] Battery voltage low error...............................399 E-38 Code [442/CA442] Battery voltage high error..............................400 Troubleshooting of electrical system (E-mode), Part 2.................................402 Troubleshooting of electrical system (E-mode), Part 2.............................404 E-39 Code [449/CA449] Rail Press. Very High Error.............................404 E-40 Code [451/CA451] Rail Press. Sensor High Error...........................405 E-41 Code [452/CA452] Rail Press. Sensor Low Error............................407 E-42 Code [553/CA553] Rail Press. High Error..................................407 E-43 Code [554/CA554] Rail Press Sensor In Range Error........................408 E-44 Code [559/CA559] Rail Press. Low Error...................................409 E-45 Code [689/CA689] Eng. Ne Speed Sensor Error..............................413 E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error......................415 E-47 Code [757/CA757] All Persistent Data Lost Error..........................416 E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error............................417 E-49 Code [1228/CA1228] EGR Valve Servo Error 1...............................419 E-50 Code [1625/CA1625] EGR Valve Servo Error 2...............................420 E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error..............421 E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error...............423 E-53 Code [1628/CA1628] Bypass Valve Servo Error 1............................424 E-54 Code [1629/CA1629] Bypass Valve Servo Error 2............................425 E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error..............427 E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error...............429 E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error.........................429 E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error......................430 E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error.....................431 E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error..................433 E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error...................437 E-62 Code [2249/CA2249] Rail Press. Very Low Error............................438 E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error.............439 E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error..............441 E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error.................443 E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error..................445 E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error.....................446 E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error....................447 E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate........................449 E-70 Code [(146)/B@BCNS] Eng. Overheat........................................449 E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate.....................450 Troubleshooting of mechanical system (S-mode).........................................452 Troubleshooting of mechanical system (S-mode).....................................455 Method of using troubleshooting charts........................................455 S-1 Starting performance is poor..............................................459 S-2 Engine does not start.....................................................461 S-3 Engine does not pick up smoothly..........................................465 S-4 Engine stops during operations............................................466 S-5 Engine does not rotate smoothly...........................................467 S-6 Engine lacks output (or lacks power)......................................468 S-7 Exhaust smoke is black (incomplete combustion)............................469 S-8 Oil consumption is excessive (or exhaust smoke is blue)...................471 S-9 Oil becomes contaminated quickly..........................................472 S-10 Fuel consumption is excessive............................................473 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....474 S-12 Oil pressure drops.......................................................475 S-13 Oil level rises (Entry of coolant or fuel)...............................476 S-14 Coolant temperature becomes too high (overheating).......................478 S-15 Abnormal noise is made...................................................479 S-16 Vibration is excessive...................................................480 50 Disassembly and assembly............................................................... 0 General information on disassembly and assembly.......................................482 General information on disassembly and assembly...................................483 How to read this manual.......................................................483 Coating materials list........................................................485 Special tools list............................................................488 Disassembly and assembly, Part 1 (With EGR)...........................................490 Disassembly and assembly, Part 1 (With EGR).......................................491 General disassembly of engine.................................................491 General assembly of engine....................................................506 Disassembly and assembly, Part 2 (EGR-less)...........................................538 Disassembly and assembly, Part 2 (EGR-less).......................................539 General disassembly of engine.................................................539 General assembly of engine....................................................553 Disassembly and assembly, Part 3......................................................586 Disassembly and assembly, Part 3..................................................587 Removal and installation of fuel supply pump unit.............................587 Replacement of oil seal of engine mounted on machine..........................589 90 Repair and replacement of parts........................................................ 0 Information related to repair and replacement.........................................594 Flowchart.........................................................................595 Special tool table................................................................597 Special tool sketch...............................................................599 Parts related to cylinder head........................................................602 Part names related to cylinder head...............................................603 Testing and inspection of cylinder head...........................................604 Pressure test of cylinder head....................................................606 Replacement of valve guide........................................................606 Replacement of valve seat insert..................................................607 Replacement of crosshead guide....................................................614 Repair of valve by grinding.......................................................615 Parts related to cylinder block.......................................................618 Part names related to cylinder block..............................................619 Testing and inspection of cylinder block..........................................620 Part names related to crankshaft..................................................623 Testing and inspection of crankshaft..............................................624 Part names related to connecting rod..............................................625 Testing and inspection of connecting rod..........................................626 Replacement of flywheel ring gear.................................................628 Replacement of camshaft gear......................................................628 Replacement of main bearing metal cap.............................................629 Replacement of connecting rod small end bushing...................................631 Replacement of cam bushing........................................................632 Replacement of engine rear seal...................................................634 Replacement of wear sleeve (when sleeve is installed).............................638 Repair of crankshaft by grinding..................................................639
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