Komatsu ENGINE SEN00177-20 125E -5 SERIES Shop Manual SEN00177-20 – PDF DOWNLOAD

Description

Komatsu ENGINE SEN00177-20 125E -5 SERIES Shop Manual SEN00177-20 – PDF DOWNLOAD

FILE DETAILS:

Komatsu ENGINE SEN00177-20 125E -5 SERIES Shop Manual SEN00177-20 – PDF DOWNLOAD

Language : English
Pages :666
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu ENGINE SEN00177-20 125E -5 SERIES Shop Manual SEN00177-20 – PDF DOWNLOAD

1. General precautions

k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine.

• For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
• 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc.
• 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
• 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

TABLE OF CONTENTS:

Komatsu ENGINE SEN00177-20 125E -5 SERIES Shop Manual SEN00177-20 – PDF DOWNLOAD

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 5
Foreword and general information 11
Safety notice 12
How to read the shop manual 17
Explanation of terms for maintenance standard 19
Handling of electric equipment and hydraulic component 21
Handling of connectors newly used for engines 30
How to read electric wire code 33
Precautions when carrying out operation 36
Method of disassembling and connecting push-pull type coupler 39
Standard tightening torque table 42
Conversion table 46
01 Specification 53
Specification and technical data 53
Outline 54
Specifications 58
General view 74
Weight table110
Engine performance curves113
10 Structure, function and maintenance standard125
Structure, function and maintenance standard, Part 1125
General structure128
Air intake and exhaust unit130
Air cleaner134
Turbocharger136
Aftercooler143
EGR system144
Cylinder head151
Cylinder block154
Cylinder liner158
Main moving parts159
Crankshaft161
Camshaft162
Cam follower and push rod163
Piston, piston ring and piston pin164
Connecting rod166
Flywheel and flywheel housing167
Vibration damper172
Timing gear174
Valve system182
Valve and valve guide186
Rocker arm and shaft188
Crosshead and guide189
Structure, function and maintenance standard, Part 2191
Lubrication system194
Lubrication system diagram194
Oil pump198
Main relief valve199
EGR oil pump200
Oil filter201
Safety valve203
Oil cooler204
Fuel system206
CRI system diagram206
Outline of CRI system208
Structure and operation of component parts211
Fuel piping230
Fuel filter232
Electric priming pump234
Engine controller cooler235
Cooling system236
Cooling system diagram236
Water pump238
Thermostat240
Electrical equipment242
Alternator242
Starting motor252
Electrical intake air heater256
Engine controller257
20 Standard value table259
Standard service value table259
Standard service value table260
Standard service value table for testing, adjusting, and troubleshooting260
Running-in standard and performance test standard276
30 Testing and adjusting287
Testing and adjusting287
Testing and adjusting (With EGR)289
Testing and adjusting tools list289
Sketches of special tools291
Testing air boost pressure292
Testing exhaust temperature293
Adjusting valve clearance294
Testing compression pressure295
Testing blow-by pressure297
Testing engine oil pressure298
Measuring EGR valve and bypass valve drive pressure299
Handling fuel system parts300
Releasing residual pressure in fuel system300
Testing fuel pressure301
Reduced cylinder mode operation302
No-injection cranking302
Testing leakage from pressure limiter and return rate from injector303
Bleeding air from fuel circuit306
Testing fuel system for leakage308
Adjusting speed sensor309
Testing and adjusting alternator belt tension310
Handling controller voltage circuit311
Testing and adjusting (EGR-less)312
Testing and adjusting tools list312
Sketches of special tools314
Testing air boost pressure315
Testing exhaust temperature316
Adjusting valve clearance317
Testing compression pressure318
Testing blow-by pressure320
Testing engine oil pressure321
Handling fuel system parts322
Releasing residual pressure in fuel system322
Testing fuel pressure323
Reduced cylinder mode operation324
No-injection cranking324
Testing leakage from pressure limiter and return rate from injector325
Bleeding air from fuel circuit327
Testing fuel system for leakage329
Adjusting speed sensor330
Testing and adjusting alternator belt tension331
Handling controller voltage circuit332
40 Troubleshooting335
General information on troubleshooting335
General information on troubleshooting336
Points on troubleshooting336
Error code and failure code table338
Information in troubleshooting table342
Troubleshooting of electrical system (E-mode), Part 1345
Troubleshooting of electrical system (E-mode), Part 1348
E-1 Code [111/CA111] ECM Critical Internal Failure348
E-2 Code [115/CA115] Eng Ne and Bkup Speed Sensor Error350
E-3 Code [122/CA122] Charge Air Press Sensor High Error352
E-4 Code [123/CA123] Charge Air Press Sensor Low Error354
E-5 Code [131/CA131] Throttle Sensor High Error356
E-6 Code [132/CA132] Throttle Sensor Low Error360
E-7 Code [135/CA135] Oil press Sensor High Error362
E-8 Code [141/CA141] Oil press Sensor Low Error364
E-9 Code [144/CA144] Coolant Temp Sensor High Error366
E-10 Code [145/CA145] Coolant Temp Sensor Low Error368
E-11 Code [153/CA153] Charge Air Temp Sensor High Error370
E-12 Code [154/CA154] Charge Air Temp Sensor Low Error372
E-13 Code [187/CA187] Sensor Sup 2 Volt Low Error373
E-14 Code [221/CA221] Ambient Air Press Sensor High Error374
E-15 Code [222/CA222] Ambient Air Press Sensor Low Error376
E-16 Code [227/CA227] Sensor Sup 2 Volt High Error378
E-17 Code [234/CA234] Eng Overspeed380
E-18 Code [238/CA238] Ne Speed Sensor Sup Volt Error382
E-19 Code [263/CA263] Fuel Temp Sensor High Error384
E-20 Code [265/CA265] Fuel Temp Sensor Low Error386
E-21 Code [271/CA271] PCV1 Short Error388
E-22 Code [272/CA272] PCV1 Open Error390
E-23 Code [273/CA273] PCV2 Short Error392
E-24 Code [274/CA274] PCV2 Open Error394
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error396
E-26 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error398
E-27 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error400
E-28 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error402
E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error404
E-30 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error406
E-31 Code [342/CA342] Calibration Code Incompatibility408
E-32 Code [351/CA351] INJ Drive Circuit Error410
E-33 Code [352/CA352] Sensor Sup 1 Volt Low Error412
E-34 Code [386/CA386] Sensor Sup 1 Volt High Error414
E-35 Code [431/CA431] Idle Validation SW Low error416
E-36 Code [432/CA432] Idle Validation Process error418
E-37 Code [441/CA441] Battery voltage low error418
E-38 Code [442/CA442] Battery voltage high error419
Troubleshooting of electrical system (E-mode), Part 2421
Troubleshooting of electrical system (E-mode), Part 2423
E-39 Code [449/CA449] Rail Press Very High Error423
E-40 Code [451/CA451] Rail Press Sensor High Error424
E-41 Code [452/CA452] Rail Press Sensor Low Error426
E-42 Code [553/CA553] Rail Press High Error426
E-43 Code [554/CA554] Rail Press Sensor In Range Error427
E-44 Code [559/CA559] Rail Press Low Error428
E-45 Code [689/CA689] Eng Ne Speed Sensor Error432
E-46 Code [731/CA731] Eng Bkup Speed Sensor Phase Error434
E-47 Code [757/CA757] All Persistent Data Lost Error435
E-48 Code [778/CA778] Eng Bkup Speed Sensor Error436
E-49 Code [1228/CA1228] EGR Valve Servo Error 1438
E-50 Code [1625/CA1625] EGR Valve Servo Error 2439
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error440
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error442
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1443
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2444
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error446
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error448
E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error448
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error449
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error450
E-60 Code [2185/CA2185] Throttle Sens Sup Volt High Error452
E-61 Code [2186/CA2186] Throttle Sens Sup Volt Low Error456
E-62 Code [2249/CA2249] Rail Press Very Low Error457
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error458
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error460
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error462
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error464
E-67 Code [2555/CA2555] Grid Heater Relay Volt Low Error465
E-68 Code [2556/CA2556] Grid Heater Relay Volt High Error466
E-69 Code [(143)/B@BAZG] Eng Oil press Torque Derate468
E-70 Code [(146)/B@BCNS] Eng Overheat468
E-71 Code [(415)/B@BAZG] Eng Oil press Low Speed Derate469
Troubleshooting of mechanical system (S-mode)471
Troubleshooting of mechanical system (S-mode)474
Method of using troubleshooting charts474
S-1 Starting performance is poor478
S-2 Engine does not start480
S-3 Engine does not pick up smoothly484
S-4 Engine stops during operations485
S-5 Engine does not rotate smoothly486
S-6 Engine lacks output (or lacks power)487
S-7 Exhaust smoke is black (incomplete combustion)488
S-8 Oil consumption is excessive (or exhaust smoke is blue)490
S-9 Oil becomes contaminated quickly491
S-10 Fuel consumption is excessive492
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)493
S-12 Oil pressure drops494
S-13 Oil level rises (Entry of coolant or fuel)495
S-14 Coolant temperature becomes too high (overheating)497
S-15 Abnormal noise is made498
S-16 Vibration is excessive499
50 Disassembly and assembly501
General information on disassembly and assembly501
General information on disassembly and assembly502
How to read this manual502
Coating materials list504
Special tools list507
Disassembly and assembly, Part 1 (With EGR)509
General disassembly of engine510
General assembly of engine525
Disassembly and assembly, Part 2 (EGR-less)557
Disassembly and assembly, Part 2 (EGR-less)558
General disassembly of engine558
General assembly of engine572
Disassembly and assembly, Part 3605
Disassembly and assembly, Part 3606
Removal and installation of fuel supply pump unit606
Replacement of oil seal of engine mounted on machine608
90 Repair and replacement of parts613
Information related to repair and replacement613
Flowchart614
Special tool table616
Special tool sketch618
Parts related to cylinder head621
Part names related to cylinder head622
Testing and inspection of cylinder head623
Pressure test of cylinder head625
Replacement of valve guide625
Replacement of valve seat insert626
Replacement of crosshead guide633
Repair of valve by grinding634
Parts related to cylinder block637
Part names related to cylinder block638
Testing and inspection of cylinder block639
Part names related to crankshaft642
Testing and inspection of crankshaft643
Part names related to connecting rod644
Testing and inspection of connecting rod645
Replacement of flywheel ring gear647
Replacement of camshaft gear647
Replacement of main bearing metal cap648
Replacement of connecting rod small end bushing650
Replacement of cam bushing651
Replacement of engine rear seal653
Replacement of wear sleeve (when sleeve is installed)657
Repair of crankshaft by grinding658

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24