Komatsu 125E-7 Series Engine Shop Manual SEN06495-07 – PDF DOWNLOAD 

Description

Komatsu 125E-7 Series Engine Shop Manual SEN06495-07 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 125E-7 Series Engine Shop Manual SEN06495-07 – PDF DOWNLOAD 

Language : English
Pages : 494
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu 125E-7 Series Engine Shop Manual SEN06495-07 – PDF DOWNLOAD 

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 6
FOREWORD, SAFETY, BASIC INFORMATION 12
HOW TO READ THE ENGINE SHOP MANUAL 12
SAFETY NOTICE FOR OPERATION 14
PRECAUTIONS TO PREVENT FIRE 22
ACTIONS IF FIRE OCCURS 24
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 25
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 26
PRECAUTIONS FOR DEF 27
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 27
PRECAUTIONS FOR ADDING 27
PRECAUTIONS FOR STORING 27
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 27
THE OTHER PRECAUTIONS 27
STORE AdBlue/DEF 28
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 29
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 32
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 39
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 41
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 42
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 44
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 47
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 51
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 57
HOW TO READ ELECTRICAL WIRE CODE 58
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 62
STANDARD TIGHTENING TORQUE TABLE 65
CONVERSION TABLE 72
01 SPECIFICATIONS 77
CONTENTS 78
ABBREVIATION LIST 79
SPECIFICATIONS 85
OUTLINE OF EXHAUST GAS REGULATION 85
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION 86
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION 87
LIST OF APPLICABLE MACHINES: 125E-7 88
SPECIFICATIONS 89
SPECIFICATIONS: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 89
SPECIFICATIONS: SAA6D125E-7 (HM300-5) 90
SPECIFICATIONS: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 91
SPECIFICATIONS: SAA6D125E-7 (WA470-8) 92
SPECIFICATIONS: SAA6D125E-7 (WA480-8) 93
ENGINE GENERAL VIEW 94
ENGINE GENERAL VIEW: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 94
ENGINE GENERAL VIEW: SAA6D125E-7 (HM300-5) 98
ENGINE GENERAL VIEW: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 102
ENGINE GENERAL VIEW: SAA6D125E-7 (WA470-8) 106
ENGINE GENERAL VIEW: SAA6D125E-7 (WA480-8) 110
WEIGHT TABLE 114
WEIGHT TABLE: 125E-7 114
ENGINE PERFORMANCE CURVE 116
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 116
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (HM300-5) 117
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 118
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA470-8) 119
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA480-8) 120
10 STRUCTURE AND FUNCTION 121
CONTENTS 122
ABBREVIATION LIST 124
UREA SCR SYSTEM 130
LAYOUT DRAWING OF UREA SCR SYSTEM 130
UREA SCR SYSTEM DIAGRAM 135
FUNCTION OF UREA SCR SYSTEM 136
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM 136
INDUCEMENT STRATEGY 139
COMPONENT PARTS OF UREA SCR SYSTEM 153
AdBlue/DEF MIXING TUBE 153
SCR ASSEMBLY 154
AdBlue/DEF TANK 156
AdBlue/DEF PUMP 158
AdBlue/DEF INJECTOR 159
AdBlue/DEF HOSE 160
AdBlue/DEF TANK HEATING VALVE 161
ENGINE SYSTEM 162
LAYOUT OF ENGINE COMPONENTS 162
LAYOUT DRAWING OF ENGINE COMPONENTS 162
INTAKE AND EXHAUST SYSTEM PARTS 164
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM 164
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM 165
FUNCTION OF INTAKE AND EXHAUST SYSTEM 165
AIR CLEANER 167
ENGINE MAIN BODY PARTS 168
CYLINDER HEAD 168
CYLINDER BLOCK 170
MAIN MOVING PARTS 173
VIBRATION DAMPER 176
TIMING GEAR 178
FRONT COVER 180
VALVE SYSTEM 181
FLYWHEEL AND FLYWHEEL HOUSING 184
TURBOCHARGER SYSTEM 185
CIRCUIT DIAGRAM OF VGT SYSTEM 185
FUNCTION OF VGT SYSTEM 186
VGT 188
EGR SYSTEM 192
EGR VALVE 195
EGR COOLER 197
MIXING CONNECTOR 198
KCCV SYSTEM 199
KCCV VENTILATOR 203
KDPF 205
LUBRICATION SYSTEM 209
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS 209
LUBRICATION SYSTEM CIRCUIT DIAGRAM 210
ENGINE OIL PUMP 211
ENGINE BOOST OIL PUMP 212
ENGINE OIL FILTER 213
ENGINE OIL COOLER 214
ENGINE OIL PAN 216
FUEL SYSTEM 217
LAYOUT DRAWING OF FUEL SYSTEM PARTS 217
FUEL SYSTEM CIRCUIT DIAGRAM 218
FUNCTION OF FUEL SYSTEM 219
OPERATION OF FUEL SYSTEM 219
CRI SYSTEM 220
SUPPLY PUMP 224
COMMON RAIL 227
INJECTOR 230
FUEL DOSING SYSTEM 234
FUEL PREFILTER 236
FUEL MAIN FILTER 237
COOLING SYSTEM 238
LAYOUT DRAWING OF COOLING SYSTEM PARTS 238
COOLING SYSTEM CIRCUIT DIAGRAM 239
WATER PUMP 240
THERMOSTAT 241
ELECTRICAL SYSTEM 243
COMPONENT PARTS OF ELECTRICAL SYSTEM 243
ALTERNATOR 243
ALTERNATOR MOUNTING 247
STARTING MOTOR 248
ENGINE WIRING HARNESS 252
ENGINE CONTROLLER 254
FUEL FEED PUMP 262
FUEL FEED PUMP SWITCH 263
SENSOR 264
LAYOUT DRAWING OF ENGINE SENSOR 264
STRUCTURE OF AMBIENT PRESSURE SENSOR 268
FUNCTION OF AMBIENT PRESSURE SENSOR 268
STRUCTURE OF ENGINE OIL PRESSURE SENSOR 269
FUNCTION OF ENGINE OIL PRESSURE SENSOR 269
STRUCTURE OF CHARGE PRESSURE SENSOR 270
FUNCTION OF CHARGE PRESSURE SENSOR 270
STRUCTURE OF CHARGE TEMPERATURE SENSOR 271
FUNCTION OF CHARGE TEMPERATURE SENSOR 271
STRUCTURE OF COOLANT TEMPERATURE SENSOR 272
FUNCTION OF COOLANT TEMPERATURE SENSOR 272
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR 273
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 273
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR 274
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 274
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 275
FUNCTION OF COMMON RAIL PRESSURE SENSOR 275
STRUCTURE OF EGR VALVE LIFT SENSOR 276
FUNCTION OF EGR VALVE LIFT SENSOR 276
STRUCTURE OF VGT SPEED SENSOR 277
FUNCTION OF VGT SPEED SENSOR 277
STRUCTURE OF VGT POSITION SENSOR 278
FUNCTION OF VGT POSITION SENSOR 278
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR 279
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR 279
STRUCTURE OF DOSING FUEL PRESSURE SENSOR 280
FUNCTION OF DOSING FUEL PRESSURE SENSOR 280
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 281
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 281
STRUCTURE OF CRANKCASE PRESSURE SENSOR 282
FUNCTION OF CRANKCASE PRESSURE SENSOR 282
STRUCTURE OF ENGINE OIL LEVEL SENSOR 283
FUNCTION OF ENGINE OIL LEVEL SENSOR 283
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 284
FUNCTION OF AIR CLEANER CLOGGING SENSOR 284
20 STANDARD VALUE TABLE 285
CONTENTS 286
ABBREVIATION LIST 287
STANDARD VALUE TABLE FOR ENGINE 293
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 293
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (HM300-5) 295
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 297
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA470-8) 299
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA480-8) 301
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD 303
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 303
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (HM300-5) 305
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 307
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA470-8) 309
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA480-8) 311
50 DISASSEMBLY AND ASSEMBLY 313
CONTENTS 314
ABBREVIATION LIST 315
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 321
HOW TO READ THIS MANUAL 321
COATING MATERIALS LIST 323
SPECIAL TOOLS LIST 327
SKETCHES OF SPECIAL TOOLS 329
ENGINE SYSTEM 332
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY 332
METHOD FOR DISASEMBLING ENGINE GENERALLY 333
METHOD FOR ASEMBLING ENGINE GENERALLY 369
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 431
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 431
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 434
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 441
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 441
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 442
REMOVE AND INSTALL ENGINE REAR OIL SEAL 445
METHOD FOR REMOVING ENGINE REAR OIL SEAL 445
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 447
60 MAINTENANCE STANDARD 451
CONTENTS 452
ABBREVIATION LIST 453
ENGINE SYSTEM 459
INTAKE AND EXHAUST SYSTEM PARTS 459
MAINTENANCE STANDARD OF VGT 459
ENGINE MAIN BODY PARTS 460
MAINTENANCE STANDARD OF CYLINDER HEAD 460
MAINTENANCE STANDARD OF CYLINDER BLOCK 462
MAINTENANCE STANDARD OF CYLINDER LINER 464
MAINTENANCE STANDARD OF CRANKSHAFT 466
MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD 467
MAINTENANCE STANDARD OF PISTON 469
MAINTENANCE STANDARD OF CONROD 471
MAINTENANCE STANDARD OF VIBRATION DAMPER 473
MAINTENANCE STANDARD OF TIMING GEAR 474
MAINTENANCE STANDARD OF CAMSHAFT 476
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE 477
MAINTENANCE STANDARD OF ROCKER ARM 479
MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE 480
MAINTENANCE STANDARD OF FLYWHEEL 481
LUBRICATION SYSTEM 483
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP 483
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP 484
MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER 485
COOLING SYSTEM 486
MAINTENANCE STANDARD OF ENGINE OIL COOLER 486
MAINTENANCE STANDARD OF WATER PUMP 487
MAINTENANCE STANDARD OF THERMOSTAT 488
INDEX 489

DESCRIPTION:

Komatsu 125E-7 Series Engine Shop Manual SEN06495-07 – PDF DOWNLOAD 

Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.

IMAGES PREVIEW OF THE MANUAL:

S.V 20/12/24