Komatsu 125E-7 Series Engine Shop Manual SEN06495-11 – PDF DOWNLOAD 

Description

Komatsu 125E-7 Series Engine Shop Manual SEN06495-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 125E-7 Series Engine Shop Manual SEN06495-11 – PDF DOWNLOAD 

Language : English
Pages : 510
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 125E-7 Series Engine Shop Manual SEN06495-11 – 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.

TABLE OF CONTENTS:

Komatsu 125E-7 Series Engine Shop Manual SEN06495-11 – PDF DOWNLOAD 

COVER 1
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, HM300-5E0) 90
SPECIFICATIONS: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 91
SPECIFICATIONS: SAA6D125E-7 (WA470-8, WA470-8E0) 92
SPECIFICATIONS: SAA6D125E-7 (WA475-10) 93
SPECIFICATIONS: SAA6D125E-7 (WA480-8, WA480-8E0) 94
ENGINE GENERAL VIEW 95
ENGINE GENERAL VIEW: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 95
ENGINE GENERAL VIEW: SAA6D125E-7 (HM300-5, HM300-5E0) 99
ENGINE GENERAL VIEW: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 103
ENGINE GENERAL VIEW: SAA6D125E-7 (WA470-8, WA470-8E0) 107
ENGINE GENERAL VIEW: SAA6D125E-7 (WA475-10) 111
ENGINE GENERAL VIEW: SAA6D125E-7 (WA480-8, WA480-8E0) 115
WEIGHT TABLE 119
WEIGHT TABLE: 125E-7 119
ENGINE PERFORMANCE CURVE 122
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 122
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (HM300-5, HM300-5E0) 123
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 124
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA470-8, WA470-8E0) 125
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA475-10) 126
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA480-8, WA480-8E0) 127
10 STRUCTURE AND FUNCTION 129
CONTENTS 130
ABBREVIATION LIST 132
UREA SCR SYSTEM 138
LAYOUT DRAWING OF UREA SCR SYSTEM 138
UREA SCR SYSTEM DIAGRAM 143
FUNCTION OF UREA SCR SYSTEM 144
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM 144
INDUCEMENT STRATEGY 146
COMPONENT PARTS OF UREA SCR SYSTEM 160
AdBlue/DEF MIXING TUBE 160
SCR ASSEMBLY 161
AdBlue/DEF TANK 163
AdBlue/DEF PUMP 165
AdBlue/DEF INJECTOR 166
AdBlue/DEF HOSE 167
AdBlue/DEF TANK HEATING VALVE 168
ENGINE SYSTEM 169
LAYOUT OF ENGINE COMPONENTS 169
LAYOUT DRAWING OF ENGINE COMPONENTS 169
INTAKE AND EXHAUST SYSTEM PARTS 171
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM 171
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM 172
FUNCTION OF INTAKE AND EXHAUST SYSTEM 172
AIR CLEANER 174
ENGINE MAIN BODY PARTS 176
CYLINDER HEAD 176
CYLINDER BLOCK 178
MAIN MOVING PARTS 181
VIBRATION DAMPER 184
TIMING GEAR 186
FRONT COVER 188
VALVE SYSTEM 189
FLYWHEEL AND FLYWHEEL HOUSING 192
TURBOCHARGER SYSTEM 193
CIRCUIT DIAGRAM OF VGT SYSTEM 193
FUNCTION OF VGT SYSTEM 194
VGT 196
EGR SYSTEM 200
EGR VALVE 203
EGR COOLER 205
MIXING CONNECTOR 206
KCCV SYSTEM 207
KCCV VENTILATOR 211
KDPF 213
LUBRICATION SYSTEM 217
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS 217
LUBRICATION SYSTEM CIRCUIT DIAGRAM 218
ENGINE OIL PUMP 219
ENGINE BOOST OIL PUMP 220
ENGINE OIL FILTER 221
ENGINE OIL COOLER 222
ENGINE OIL PAN 224
FUEL SYSTEM 225
LAYOUT DRAWING OF FUEL SYSTEM PARTS 225
FUEL SYSTEM CIRCUIT DIAGRAM 226
FUNCTION OF FUEL SYSTEM 227
OPERATION OF FUEL SYSTEM 227
CRI SYSTEM 228
SUPPLY PUMP 232
COMMON RAIL 235
INJECTOR 238
FUEL DOSING SYSTEM 242
FUEL PREFILTER 244
FUEL MAIN FILTER 245
COOLING SYSTEM 246
LAYOUT DRAWING OF COOLING SYSTEM PARTS 246
COOLING SYSTEM CIRCUIT DIAGRAM 247
WATER PUMP 248
THERMOSTAT 249
ELECTRICAL SYSTEM 251
COMPONENT PARTS OF ELECTRICAL SYSTEM 251
ALTERNATOR 251
ALTERNATOR MOUNTING 255
STARTING MOTOR 256
ENGINE WIRING HARNESS 260
ENGINE CONTROLLER 262
FUEL FEED PUMP 270
FUEL FEED PUMP SWITCH 271
SENSOR 272
LAYOUT DRAWING OF ENGINE SENSOR 272
STRUCTURE OF AMBIENT PRESSURE SENSOR 276
FUNCTION OF AMBIENT PRESSURE SENSOR 276
STRUCTURE OF ENGINE OIL PRESSURE SENSOR 277
FUNCTION OF ENGINE OIL PRESSURE SENSOR 277
STRUCTURE OF CHARGE PRESSURE SENSOR 278
FUNCTION OF CHARGE PRESSURE SENSOR 278
STRUCTURE OF CHARGE TEMPERATURE SENSOR 279
FUNCTION OF CHARGE TEMPERATURE SENSOR 279
STRUCTURE OF COOLANT TEMPERATURE SENSOR 280
FUNCTION OF COOLANT TEMPERATURE SENSOR 280
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR 281
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 281
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR 282
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 282
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 283
FUNCTION OF COMMON RAIL PRESSURE SENSOR 283
STRUCTURE OF EGR VALVE LIFT SENSOR 284
FUNCTION OF EGR VALVE LIFT SENSOR 284
STRUCTURE OF VGT SPEED SENSOR 285
FUNCTION OF VGT SPEED SENSOR 285
STRUCTURE OF VGT POSITION SENSOR 286
FUNCTION OF VGT POSITION SENSOR 286
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR 287
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR 287
STRUCTURE OF DOSING FUEL PRESSURE SENSOR 288
FUNCTION OF DOSING FUEL PRESSURE SENSOR 288
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 289
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 289
STRUCTURE OF CRANKCASE PRESSURE SENSOR 290
FUNCTION OF CRANKCASE PRESSURE SENSOR 290
STRUCTURE OF ENGINE OIL LEVEL SENSOR 291
FUNCTION OF ENGINE OIL LEVEL SENSOR 291
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 292
FUNCTION OF AIR CLEANER CLOGGING SENSOR 292
20 STANDARD VALUE TABLE 293
CONTENTS 294
ABBREVIATION LIST 295
STANDARD VALUE TABLE FOR ENGINE 301
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 301
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (HM300-5, HM300-5E0) 303
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 305
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA470-8, WA470-8E0) 307
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA475-10) 309
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA480-8, WA480-8E0) 311
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD 313
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 313
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (HM300-5, HM300-5E0) 315
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (PC490LC-11, PC490LCI-11) 317
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA470-8, WA470-8E0) 319
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA475-10) 321
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA480-8, WA480-8E0) 323
50 DISASSEMBLY AND ASSEMBLY 325
CONTENTS 326
ABBREVIATION LIST 327
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 333
HOW TO READ THIS MANUAL 333
COATING MATERIALS LIST 335
SPECIAL TOOLS LIST 340
SKETCHES OF SPECIAL TOOLS 342
ENGINE SYSTEM 345
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY 345
METHOD FOR DISASSEMBLING ENGINE GENERALLY 346
METHOD FOR ASSEMBLING ENGINE GENERALLY 383
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 448
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 448
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 450
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 457
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 457
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 458
REMOVE AND INSTALL ENGINE REAR OIL SEAL 460
METHOD FOR REMOVING ENGINE REAR OIL SEAL 460
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 461
60 MAINTENANCE STANDARD 467
CONTENTS 468
ABBREVIATION LIST 469
ENGINE SYSTEM 475
INTAKE AND EXHAUST SYSTEM PARTS 475
MAINTENANCE STANDARD OF VGT 475
ENGINE MAIN BODY PARTS 476
MAINTENANCE STANDARD OF CYLINDER HEAD 476
MAINTENANCE STANDARD OF CYLINDER BLOCK 478
MAINTENANCE STANDARD OF CYLINDER LINER 480
MAINTENANCE STANDARD OF CRANKSHAFT 482
MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD 483
MAINTENANCE STANDARD OF PISTON 485
MAINTENANCE STANDARD OF CONROD 487
MAINTENANCE STANDARD OF VIBRATION DAMPER 489
MAINTENANCE STANDARD OF TIMING GEAR 490
MAINTENANCE STANDARD OF CAMSHAFT 492
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE 493
MAINTENANCE STANDARD OF ROCKER ARM 495
MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE 496
MAINTENANCE STANDARD OF FLYWHEEL 497
LUBRICATION SYSTEM 499
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP 499
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP 500
MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER 501
COOLING SYSTEM 502
MAINTENANCE STANDARD OF ENGINE OIL COOLER 502
MAINTENANCE STANDARD OF WATER PUMP 503
MAINTENANCE STANDARD OF THERMOSTAT 504
INDEX 505

S.V 18/12/24