Komatsu ENGINE 125E -7 SERIES Shop Manual SEN06495-11 – PDF DOWNLOAD

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Komatsu ENGINE 125E -7 SERIES Shop Manual SEN06495-11 – PDF DOWNLOAD

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Komatsu ENGINE 125E -7 SERIES Shop Manual SEN06495-11 – PDF DOWNLOAD

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

DESCRIPTION:

Komatsu ENGINE 125E -7 SERIES Shop Manual SEN06495-11 – PDF DOWNLOAD

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE ENGINE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
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 ENGINE 125E -7 SERIES 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 TABLE119
WEIGHT TABLE: 125E-7119
ENGINE PERFORMANCE CURVE122
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 FUNCTION129
CONTENTS130
ABBREVIATION LIST132
UREA SCR SYSTEM138
LAYOUT DRAWING OF UREA SCR SYSTEM138
UREA SCR SYSTEM DIAGRAM143
FUNCTION OF UREA SCR SYSTEM144
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM144
INDUCEMENT STRATEGY146
COMPONENT PARTS OF UREA SCR SYSTEM160
AdBlue/DEF MIXING TUBE160
SCR ASSEMBLY161
AdBlue/DEF TANK163
AdBlue/DEF PUMP165
AdBlue/DEF INJECTOR166
AdBlue/DEF HOSE167
AdBlue/DEF TANK HEATING VALVE168
ENGINE SYSTEM169
LAYOUT OF ENGINE COMPONENTS169
LAYOUT DRAWING OF ENGINE COMPONENTS169
INTAKE AND EXHAUST SYSTEM PARTS171
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM171
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM172
FUNCTION OF INTAKE AND EXHAUST SYSTEM172
AIR CLEANER174
ENGINE MAIN BODY PARTS176
CYLINDER HEAD176
CYLINDER BLOCK178
MAIN MOVING PARTS181
VIBRATION DAMPER184
TIMING GEAR186
FRONT COVER188
VALVE SYSTEM189
FLYWHEEL AND FLYWHEEL HOUSING192
TURBOCHARGER SYSTEM193
CIRCUIT DIAGRAM OF VGT SYSTEM193
FUNCTION OF VGT SYSTEM194
VGT196
EGR SYSTEM200
EGR VALVE203
EGR COOLER205
MIXING CONNECTOR206
KCCV SYSTEM207
KCCV VENTILATOR211
KDPF213
LUBRICATION SYSTEM217
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS217
LUBRICATION SYSTEM CIRCUIT DIAGRAM218
ENGINE OIL PUMP219
ENGINE BOOST OIL PUMP220
ENGINE OIL FILTER221
ENGINE OIL COOLER222
ENGINE OIL PAN224
FUEL SYSTEM225
LAYOUT DRAWING OF FUEL SYSTEM PARTS225
FUEL SYSTEM CIRCUIT DIAGRAM226
FUNCTION OF FUEL SYSTEM227
OPERATION OF FUEL SYSTEM227
CRI SYSTEM228
SUPPLY PUMP232
COMMON RAIL235
INJECTOR238
FUEL DOSING SYSTEM242
FUEL PREFILTER244
FUEL MAIN FILTER245
COOLING SYSTEM246
LAYOUT DRAWING OF COOLING SYSTEM PARTS246
COOLING SYSTEM CIRCUIT DIAGRAM247
WATER PUMP248
THERMOSTAT249
ELECTRICAL SYSTEM251
COMPONENT PARTS OF ELECTRICAL SYSTEM251
ALTERNATOR251
ALTERNATOR MOUNTING255
STARTING MOTOR256
ENGINE WIRING HARNESS260
ENGINE CONTROLLER262
FUEL FEED PUMP270
FUEL FEED PUMP SWITCH271
SENSOR272
LAYOUT DRAWING OF ENGINE SENSOR272
STRUCTURE OF AMBIENT PRESSURE SENSOR276
FUNCTION OF AMBIENT PRESSURE SENSOR276
STRUCTURE OF ENGINE OIL PRESSURE SENSOR277
FUNCTION OF ENGINE OIL PRESSURE SENSOR277
STRUCTURE OF CHARGE PRESSURE SENSOR278
FUNCTION OF CHARGE PRESSURE SENSOR278
STRUCTURE OF CHARGE TEMPERATURE SENSOR279
FUNCTION OF CHARGE TEMPERATURE SENSOR279
STRUCTURE OF COOLANT TEMPERATURE SENSOR280
FUNCTION OF COOLANT TEMPERATURE SENSOR280
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR281
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR281
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR282
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR282
STRUCTURE OF COMMON RAIL PRESSURE SENSOR283
FUNCTION OF COMMON RAIL PRESSURE SENSOR283
STRUCTURE OF EGR VALVE LIFT SENSOR284
FUNCTION OF EGR VALVE LIFT SENSOR284
STRUCTURE OF VGT SPEED SENSOR285
FUNCTION OF VGT SPEED SENSOR285
STRUCTURE OF VGT POSITION SENSOR286
FUNCTION OF VGT POSITION SENSOR286
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR287
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR287
STRUCTURE OF DOSING FUEL PRESSURE SENSOR288
FUNCTION OF DOSING FUEL PRESSURE SENSOR288
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR289
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR289
STRUCTURE OF CRANKCASE PRESSURE SENSOR290
FUNCTION OF CRANKCASE PRESSURE SENSOR290
STRUCTURE OF ENGINE OIL LEVEL SENSOR291
FUNCTION OF ENGINE OIL LEVEL SENSOR291
STRUCTURE OF AIR CLEANER CLOGGING SENSOR292
FUNCTION OF AIR CLEANER CLOGGING SENSOR292
20 STANDARD VALUE TABLE293
CONTENTS294
ABBREVIATION LIST295
STANDARD VALUE TABLE FOR ENGINE301
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 STANDARD313
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 ASSEMBLY325
CONTENTS326
ABBREVIATION LIST327
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY333
HOW TO READ THIS MANUAL333
COATING MATERIALS LIST335
SPECIAL TOOLS LIST340
SKETCHES OF SPECIAL TOOLS342
ENGINE SYSTEM345
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY345
METHOD FOR DISASSEMBLING ENGINE GENERALLY346
METHOD FOR ASSEMBLING ENGINE GENERALLY383
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY448
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY448
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY450
REMOVE AND INSTALL ENGINE FRONT OIL SEAL457
METHOD FOR REMOVING ENGINE FRONT OIL SEAL457
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL458
REMOVE AND INSTALL ENGINE REAR OIL SEAL460
METHOD FOR REMOVING ENGINE REAR OIL SEAL460
METHOD FOR INSTALLING ENGINE REAR OIL SEAL461
60 MAINTENANCE STANDARD467
CONTENTS468
ABBREVIATION LIST469
ENGINE SYSTEM475
INTAKE AND EXHAUST SYSTEM PARTS475
MAINTENANCE STANDARD OF VGT475
ENGINE MAIN BODY PARTS476
MAINTENANCE STANDARD OF CYLINDER HEAD476
MAINTENANCE STANDARD OF CYLINDER BLOCK478
MAINTENANCE STANDARD OF CYLINDER LINER480
MAINTENANCE STANDARD OF CRANKSHAFT482
MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD483
MAINTENANCE STANDARD OF PISTON485
MAINTENANCE STANDARD OF CONROD487
MAINTENANCE STANDARD OF VIBRATION DAMPER489
MAINTENANCE STANDARD OF TIMING GEAR490
MAINTENANCE STANDARD OF CAMSHAFT492
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE493
MAINTENANCE STANDARD OF ROCKER ARM495
MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE496
MAINTENANCE STANDARD OF FLYWHEEL497
LUBRICATION SYSTEM499
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP499
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP500
MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER501
COOLING SYSTEM502
MAINTENANCE STANDARD OF ENGINE OIL COOLER502
MAINTENANCE STANDARD OF WATER PUMP503
MAINTENANCE STANDARD OF THERMOSTAT504
INDEX505

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24