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

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

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

Language : English
Pages : 490
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Engine SEN06495-07 125E-7 Series Shop Manual – 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 FUNCTION121
CONTENTS.122
ABBREVIATION LIST124
UREA SCR SYSTEM130
LAYOUT DRAWING OF UREA SCR SYSTEM130
UREA SCR SYSTEM DIAGRAM135
FUNCTION OF UREA SCR SYSTEM136
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM.136
INDUCEMENT STRATEGY139
COMPONENT PARTS OF UREA SCR SYSTEM.153
AdBlue/DEF MIXING TUBE.153
SCR ASSEMBLY.154
AdBlue/DEF TANK156
AdBlue/DEF PUMP158
AdBlue/DEF INJECTOR159
AdBlue/DEF HOSE160
AdBlue/DEF TANK HEATING VALVE161
ENGINE SYSTEM162
LAYOUT OF ENGINE COMPONENTS162
LAYOUT DRAWING OF ENGINE COMPONENTS162
INTAKE AND EXHAUST SYSTEM PARTS164
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM164
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM165
FUNCTION OF INTAKE AND EXHAUST SYSTEM165
AIR CLEANER167
ENGINE MAIN BODY PARTS.168
CYLINDER HEAD168
CYLINDER BLOCK.170
MAIN MOVING PARTS173
VIBRATION DAMPER.176
TIMING GEAR178
FRONT COVER180
VALVE SYSTEM.181
FLYWHEEL AND FLYWHEEL HOUSING184
TURBOCHARGER SYSTEM185
CIRCUIT DIAGRAM OF VGT SYSTEM185
FUNCTION OF VGT SYSTEM.186
VGT188
EGR SYSTEM.192
EGR VALVE195
EGR COOLER.197
MIXING CONNECTOR.198
KCCV SYSTEM199
KCCV VENTILATOR203
KDPF.205
LUBRICATION SYSTEM.209
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS.209
LUBRICATION SYSTEM CIRCUIT DIAGRAM.210
ENGINE OIL PUMP211
ENGINE BOOST OIL PUMP212
ENGINE OIL FILTER213
ENGINE OIL COOLER214
ENGINE OIL PAN.216
FUEL SYSTEM217
LAYOUT DRAWING OF FUEL SYSTEM PARTS217
FUEL SYSTEM CIRCUIT DIAGRAM218
FUNCTION OF FUEL SYSTEM219
OPERATION OF FUEL SYSTEM.219
CRI SYSTEM.220
SUPPLY PUMP224
COMMON RAIL227
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 SYSTEM243
COMPONENT PARTS OF ELECTRICAL SYSTEM.243
ALTERNATOR.243
ALTERNATOR MOUNTING247
STARTING MOTOR.248
ENGINE WIRING HARNESS252
ENGINE CONTROLLER254
FUEL FEED PUMP.262
FUEL FEED PUMP SWITCH263
SENSOR.264
LAYOUT DRAWING OF ENGINE SENSOR264
STRUCTURE OF AMBIENT PRESSURE SENSOR.268
FUNCTION OF AMBIENT PRESSURE SENSOR268
STRUCTURE OF ENGINE OIL PRESSURE SENSOR269
FUNCTION OF ENGINE OIL PRESSURE SENSOR.269
STRUCTURE OF CHARGE PRESSURE SENSOR270
FUNCTION OF CHARGE PRESSURE SENSOR.270
STRUCTURE OF CHARGE TEMPERATURE SENSOR.271
FUNCTION OF CHARGE TEMPERATURE SENSOR271
STRUCTURE OF COOLANT TEMPERATURE SENSOR272
FUNCTION OF COOLANT TEMPERATURE SENSOR.272
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR273
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR.273
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR274
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR.274
STRUCTURE OF COMMON RAIL PRESSURE SENSOR.275
FUNCTION OF COMMON RAIL PRESSURE SENSOR275
STRUCTURE OF EGR VALVE LIFT SENSOR.276
FUNCTION OF EGR VALVE LIFT SENSOR276
STRUCTURE OF VGT SPEED SENSOR277
FUNCTION OF VGT SPEED SENSOR.277
STRUCTURE OF VGT POSITION SENSOR.278
FUNCTION OF VGT POSITION SENSOR278
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR279
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR.279
STRUCTURE OF DOSING FUEL PRESSURE SENSOR.280
FUNCTION OF DOSING FUEL PRESSURE SENSOR280
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR.281
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR281
STRUCTURE OF CRANKCASE PRESSURE SENSOR.282
FUNCTION OF CRANKCASE PRESSURE SENSOR282
STRUCTURE OF ENGINE OIL LEVEL SENSOR.283
FUNCTION OF ENGINE OIL LEVEL SENSOR283
STRUCTURE OF AIR CLEANER CLOGGING SENSOR.284
FUNCTION OF AIR CLEANER CLOGGING SENSOR284
20 STANDARD VALUE TABLE285
CONTENTS.286
ABBREVIATION LIST287
STANDARD VALUE TABLE FOR ENGINE293
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 STANDARD303
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 ASSEMBLY313
CONTENTS.314
ABBREVIATION LIST315
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY321
HOW TO READ THIS MANUAL321
COATING MATERIALS LIST.323
SPECIAL TOOLS LIST.327
SKETCHES OF SPECIAL TOOLS329
ENGINE SYSTEM332
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY332
METHOD FOR DISASEMBLING ENGINE GENERALLY.333
METHOD FOR ASEMBLING ENGINE GENERALLY369
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY431
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 SEAL441
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL442
REMOVE AND INSTALL ENGINE REAR OIL SEAL445
METHOD FOR REMOVING ENGINE REAR OIL SEAL.445
METHOD FOR INSTALLING ENGINE REAR OIL SEAL.447
60 MAINTENANCE STANDARD451
CONTENTS.452
ABBREVIATION LIST453
ENGINE SYSTEM459
INTAKE AND EXHAUST SYSTEM PARTS459
MAINTENANCE STANDARD OF VGT459
ENGINE MAIN BODY PARTS.460
MAINTENANCE STANDARD OF CYLINDER HEAD460
MAINTENANCE STANDARD OF CYLINDER BLOCK.462
MAINTENANCE STANDARD OF CYLINDER LINER.464
MAINTENANCE STANDARD OF CRANKSHAFT.466
MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD467
MAINTENANCE STANDARD OF PISTON.469
MAINTENANCE STANDARD OF CONROD.471
MAINTENANCE STANDARD OF VIBRATION DAMPER.473
MAINTENANCE STANDARD OF TIMING GEAR474
MAINTENANCE STANDARD OF CAMSHAFT.476
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE477
MAINTENANCE STANDARD OF ROCKER ARM.479
MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE480
MAINTENANCE STANDARD OF FLYWHEEL.481
LUBRICATION SYSTEM.483
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP483
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP484
MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER485
COOLING SYSTEM.486
MAINTENANCE STANDARD OF ENGINE OIL COOLER486
MAINTENANCE STANDARD OF WATER PUMP.487
MAINTENANCE STANDARD OF THERMOSTAT.488
INDEX489

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

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G. B 12/12/24