Komatsu 125-3 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 125-3 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: SAA6D125E-3, SA6D125E-3, 125-3 Series Diesel Engine
Serial Number: –
Book Code: SEBM024208
Language: English
Pages: 349
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu 125-3 Series Diesel Engine Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
Testing and adjusting:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
Maintenance standard:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”.
Others:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu 125-3 Series Diesel Engine Shop Manual
MAIN MENU............................................................................................................................................. 0 COVER................................................................................................................................................. 1 CONTENTS.............................................................................................................................................. 2 01 GENERAL............................................................................................................................................ 26 OUTLINE........................................................................................................................................... 27 SPECIFICATIONS.................................................................................................................................... 30 GENERAL ASSEMBLY DRAWING.......................................................................................................................... 34 WEIGHT TABLE...................................................................................................................................... 47 ENGINE PERFORMANCE CURVE.......................................................................................................................... 48 11 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD....................................................................................................... 57 GENERAL STRUCTURE................................................................................................................................. 58 INTAKE, EXHAUST SYSTEM............................................................................................................................ 62 INTAKE, EXHAUST SYSTEM........................................................................................................................ 62 AIR CLEANER................................................................................................................................... 68 TURBOCHARGER.................................................................................................................................. 69 AFTERCOOLER................................................................................................................................... 70 ENGINE BODY....................................................................................................................................... 72 CYLINDER HEAD................................................................................................................................. 72 CYLINDER BLOCK................................................................................................................................ 75 CYLINDER LINER................................................................................................................................ 79 MAIN CIRCULATION SYSTEM....................................................................................................................... 80 CRANKSHAFT.................................................................................................................................... 82 PISTON........................................................................................................................................ 83 CONNECTING ROD................................................................................................................................ 85 FLYWHEEL AND FLYWHEEL HOUSING................................................................................................................. 86 VIBRATION DAMPER.............................................................................................................................. 88 TIMING GEAR................................................................................................................................... 90 VALVE MECHANISM............................................................................................................................... 93 CAMSHAFT...................................................................................................................................... 95 CAM FOLLOWER AND PUSH ROD..................................................................................................................... 96 VALVE AND VALVE GUIDE......................................................................................................................... 97 ROCKER ARM SHAFT.............................................................................................................................. 99 CROSSHEAD.....................................................................................................................................100 LUBRICATION SYSTEM................................................................................................................................101 LUBRICATION SYSTEM DIAGRAM....................................................................................................................101 OIL PUMP......................................................................................................................................102 OIL FILTER....................................................................................................................................105 OIL COOLER....................................................................................................................................107 FUEL SYSTEM.......................................................................................................................................109 FUEL SYSTEM DIAGRAM...........................................................................................................................109 OUTLINE OF CRI SYSTEM.........................................................................................................................110 FUEL PIPING...................................................................................................................................123 FUEL COOLER...................................................................................................................................125 FUEL FILTER...................................................................................................................................126 COOLING SYSTEM....................................................................................................................................127 COOLING SYSTEM CHART..........................................................................................................................127 WATER PUMP....................................................................................................................................128 THERMOSTAT....................................................................................................................................131 CORROSION RESISTOR............................................................................................................................133 ELECTRICAL SYSTEM.................................................................................................................................134 ALTERNATOR MOUNTING...........................................................................................................................134 ALTERNATOR....................................................................................................................................136 STARTING MOTOR................................................................................................................................140 STARTING AID..................................................................................................................................142 12 TESTING AND ADJUSTING, TROUBLESHOOTING.............................................................................................................144 TESTING AND ADJUSTING DATA........................................................................................................................146 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.........................................................................................................151 TESTING AND ADJUSTING TOOL LIST...................................................................................................................153 TESTING AND ADJUSTING.............................................................................................................................154 MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE).................................................................................................154 MEASURING EXHAUST TEMPERATURE.................................................................................................................155 ADJUSTING VALVE CLEARANCE.....................................................................................................................157 MEASURING COMPRESSION PRESSURE................................................................................................................159 MEASURING BLOW-BY PRESSURE....................................................................................................................161 MEASURING ENGINE OIL PRESSURE.................................................................................................................162 MEASURING FUEL PRESSURE.......................................................................................................................163 ADJUSTING ENGINE SPEED SENSOR.................................................................................................................164 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................................................................165 HANDLING EQUIPMENT IN FUEL SYSTEM.............................................................................................................171 RELEASING REMAINING PRESSURE IN FUEL SYSTEM...................................................................................................171 BLEEDING AIR FROM FUEL CIRCUIT................................................................................................................172 REDUCED CYLINDER MODE OPERATION FOR ENGINE....................................................................................................174 CHECKING FOR LEAKAGE IN FUEL SYSTEM...........................................................................................................175 ADJUSTING ENGINE STOP MOTOR LEVER.............................................................................................................176 CALIBRATION DATA..............................................................................................................................178 PERFORMANCE TEST..............................................................................................................................180 RUN-IN STANDARD...........................................................................................................................180 PERFORMANCE TEST STANDARDS................................................................................................................182 TROUBLESHOOTING...................................................................................................................................188 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....................................................................................................188 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................189 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................190 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)..............................................................................193 S-2 ENGINE DOES NOT START.................................................................................................................194 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)...................................................................................197 S-4 ENGINE STOPS DURING OPERATIONS........................................................................................................198 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)..............................................................................................199 S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)...................................................................................................200 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION).........................................................................................201 S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)................................................................................202 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................................203 S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................................204 S-11 OIL IS IN COOLING WATER(OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)..............................................................205 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)............................................................................206 S-13 OIL LEVEL RISES(WATER, FUEL IN OIL)..................................................................................................207 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....................................................................................208 S-15 ABNORMAL NOISE IS MADE...............................................................................................................209 S-16 VIBRATION IS EXCESSIVE...............................................................................................................210 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).................................................................................................211 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................213 METHOD OF USING TROUBLESHOOTING FLOWCHART.................................................................................................214 ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................215 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED..........................................................218 E-1 ERROR CODE [E-1b] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]........................................................................226 E-2 ERROR CODE [E-1C] [ABNORMALITY IN G REVOLUTION SENSOR SYSTEM].........................................................................227 E-3 ERROR CODE [E-20] [ABNORMALITY IN MODEL SELECTION SYSTEM].............................................................................228 E-4 ERROR CODE [E-22] [OVERRUN]...........................................................................................................229 E-5 ERROR CODE [E-23] [OVERHEAT]..........................................................................................................229 E-6 ERROR CODE [E-24] [DROP IN OIL PRESSURE]..............................................................................................230 E-7 ERROR CODE [E-30] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]....................................................................231 E-8 ERROR CODE [E-31] [ABNORMALITY IN THROTTLE SENSOR SYSTEM].............................................................................233 E-9 ERROR CODE [E-34] [ABNORMALITY IN WATER TEMPERATURE HIGH-TEMPERATURE SENSOR SYSTEM]...................................................236 E-10 ERROR CODE [E-36] [ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]........................................................................237 E-11 ERROR CODE [E-3C] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]......................................................................239 E-12 ERROR CODE [E-3d] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]....................................................................240 E-13 ERROR CODE [E-50] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]..........................................................241 E-14 ERROR CODE [E-51] [ABNORMALITY IN PREHEAT RELAY COIL SYSTEM].........................................................................242 E-15 ERROR CODE [E-54] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]........................................................................243 E-16 ERROR CODE [E-56] [POWER SOURCE SYSTEM ABNORMALITY 1]................................................................................244 E-17 ERROR CODE [E-57] [POWER SOURCE SYSTEM ABNORMALITY 2]................................................................................246 E-18 ERROR CODE [E-5A] [ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL].....................................................247 E-19 ERROR CODE [E-6A] [ABNORMALITY IN WATER TEMPERATURE LOW-TEMPERATURE SENSOR SYSTEM]...................................................248 E-20 ERROR CODE [E-70] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]...................................................................249 E-21 ERROR CODE [E-71] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]...................................................................250 E-22 ERROR CODE [E-74] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]....................................................................251 E-23 ERROR CODE [E-75] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]....................................................................252 E-24 ERROR CODE [E-77] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]...........................................................253 E-25 ERROR CODE [E-79] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1];ERROR CODE [E-7A] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2]....254 E-26 ERROR CODE [E-7b] [FUEL SUPPLY PUMP NON-FORCE FEED 1];ERROR CODE [E-7C] [FUEL SUPPLY PUMP NON-FORCE FEED 2]..........................255 E-27 ERROR CODE [E-7d] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE].........................................................................257 E-28 ERROR CODE [E-80] [DEFECTIVE CONTROLLER].............................................................................................257 E-29 ERROR CODE [E-81] [DISCONNECTION IN NO.1 FUEL INJECTOR SYSTEM].......................................................................258 E-30 ERROR CODE [E-82] [DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM].......................................................................259 E-31 ERROR CODE [E-83] [DISCONNECTION IN NO.3 FUEL INJECTOR SYSTEM].......................................................................260 E-32 ERROR CODE [E-84] [DISCONNECTION IN NO.4 FUEL INJECTOR SYSTEM].......................................................................261 E-33 ERROR CODE [E-85] [DISCONNECTION IN NO.5 FUEL INJECTOR SYSTEM].......................................................................262 E-34 ERROR CODE [E-86] [DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM].......................................................................263 E-35 ERROR CODE [E-8A] [SHORT CIRCUIT IN NO.1, NO.2, NO.3, FUEL INJECTOR SYSTEM]..........................................................264 E-36 ERROR CODE [E-8b] [SHORT CIRCUIT IN NO.4, NO.5, NO.6 FUEL INJECTOR SYSTEM]...........................................................267 13 DISASSEMBLY AND ASSEMBLY...........................................................................................................................270 METHOD OF USING MANUAL............................................................................................................................272 PRECAUTIONS WHEN CARRYING OUT OPERATION...........................................................................................................273 SPECIAL TOOL LIST.................................................................................................................................275 SKETCHES OF SPECIAL TOOLS.........................................................................................................................276 GENERAL DISASSEMBLY...............................................................................................................................277 1. PREPARATION WORK...........................................................................................................................277 2. STARTING MOTOR.............................................................................................................................277 3. TURBOCHARGER LUBRICANT RETURN TUBE.........................................................................................................277 4. RADIATOR LOWER HOSE........................................................................................................................277 5. ENGINE OIL COOLER..........................................................................................................................277 6. ADAPTER FOR ENGINE OVERHAULING.............................................................................................................278 7. RADIATOR UPPER HOSE........................................................................................................................278 8. EXHAUST MUFFLER............................................................................................................................278 9. FAN SECURING BRACKET.......................................................................................................................278 10. TURBOCHARGER LUBRICATION TUBE.............................................................................................................278 11. TURBOCHARGER AND EXHAUST MANIFOLD.........................................................................................................278 12. FUEL FILTER ASSEMBLY......................................................................................................................278 13. OIL FILTER................................................................................................................................279 14. WIRING HARNESS............................................................................................................................279 15. TAKE OFF AIR CLEANER SECURING BRACKET (1).................................................................................................279 16. TAKE OFF EXHAUST MUFFLER SECURING BRACKET (2).............................................................................................279 17. TAKE OFF EACH HIGH-PRESSURE TUBE CLAMP (3)................................................................................................279 18. SUCTION MANIFOLD ASSEMBLY.................................................................................................................279 19. SUPPLY PUMP...............................................................................................................................279 20. COMMON RAIL...............................................................................................................................280 21. SPILL PIPE................................................................................................................................281 22. HEAD COVER................................................................................................................................281 23. INJECTOR HARNESS..........................................................................................................................281 24. ROCKER ARM................................................................................................................................281 25. PUSH ROD..................................................................................................................................281 26. INJECTOR..................................................................................................................................281 27. NOZZLE TIP................................................................................................................................282 28. CROSSHEAD.................................................................................................................................282 29. ROCKER ARM HOUSING........................................................................................................................283 30. INJECTOR HARNESS CONNECTOR................................................................................................................283 31. THERMOSTAT................................................................................................................................283 32. CAM FOLLOWER COVER........................................................................................................................283 33. CAM FOLLOWER..............................................................................................................................283 34. CYLINDER HEAD ASSEMBLY....................................................................................................................283 35. SETTING TO ENGINE OVERHAUL STAND..........................................................................................................284 36. OIL PAN...................................................................................................................................284 37. FLYWHEEL..................................................................................................................................284 38. FLYWHEEL HOUSING..........................................................................................................................284 39. DAMPER....................................................................................................................................285 40. FRONT SUPPORT.............................................................................................................................285 41. FRONT COVER...............................................................................................................................285 42. WATER PUMP................................................................................................................................285 43. CAMSHAFT..................................................................................................................................285 44. OIL PUMP..................................................................................................................................285 45. IDLER GEAR................................................................................................................................285 46. OIL SUCTION PIPE..........................................................................................................................286 47. PISTON COOLING NOZZLE.....................................................................................................................286 48. PISTON AND CONNECTING ROD ASSEMBLY........................................................................................................286 49. CRANKSHAFT................................................................................................................................287 50. CYLINDER LINER............................................................................................................................288 GENERAL ASSEMBLY..................................................................................................................................289 PREPARATION WORK..............................................................................................................................289 1. CYLINDER LINER.............................................................................................................................290 2. CRANKSHAFT.................................................................................................................................291 3. PISTON AND CONNECTING ROD ASSEMBLY.........................................................................................................294 4. PISTON COOLING NOZZLE......................................................................................................................297 5. OIL SUCTION PIPE...........................................................................................................................298 6. IDLER GEAR.................................................................................................................................298 7. OIL PUMP...................................................................................................................................298 8. CAMSHAFT...................................................................................................................................299 9. CAM FOLLOWERS..............................................................................................................................299 10. CAM FOLLOWER COVERS.......................................................................................................................299 11. WATER PUMP................................................................................................................................299 12. FUEL SUPPLY PUMP DRIVING GEAR.............................................................................................................299 13. FRONT COVER...............................................................................................................................300 14. FLYWHEEL HOUSING..........................................................................................................................301 15. REAR SEAL.................................................................................................................................302 16. FLYWHEEL..................................................................................................................................304 17. DAMPER....................................................................................................................................304 18. OIL PAN...................................................................................................................................305 19. REMOVING ENGINE ASSEMBLY FROM ENGINE OVERHAUL STAND.......................................................................................305 20. SETTING ENGINE ASSEMBLY ON BLOCKS.........................................................................................................305 21. CYLINDER HEAD.............................................................................................................................305 22. CYLINDER HEAD ASSEMBLY....................................................................................................................305 23. ROCKER ARM HOUSING........................................................................................................................307 24. ASSEMBLING INJECTOR HARNESS CONNECTOR TO ROCKER ARM HOUSING...............................................................................307 25. CROSSHEAD.................................................................................................................................307 26. PUSH ROD..................................................................................................................................308 27. ROCKER ARM................................................................................................................................308 28. ADJUSTING VALVE CLEARANCE.................................................................................................................308 29. NOZZLE TIP................................................................................................................................308 30. FUEL INJECTOR.............................................................................................................................310 31. HEAD COVER................................................................................................................................310 32. SPILL PIPE................................................................................................................................310 33. THERMOSTAT................................................................................................................................311 34. ENGINE OIL COOLER.........................................................................................................................311 35. ENGINE COOLING WATER TEMPERATURE SENSOR...................................................................................................311 36. ENGINE OIL SUPPLY TUBE....................................................................................................................311 37. HIGH-PRESSURE TUBE FOR COMMON RAIL........................................................................................................311 38. SUCTION MANIFOLD..........................................................................................................................312 39. ENGINE OIL FILTER.........................................................................................................................313 40. FUEL FILTER...............................................................................................................................313 41. TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY................................................................................................313 42. STARTING MOTOR............................................................................................................................313 43. FAN BRACKET LIFTING HOOK..................................................................................................................314 44. WIRING HARNESS............................................................................................................................314 45. AIR CLEANER...............................................................................................................................314 46. EXHAUST MUFFLER...........................................................................................................................314 15 REPAIR AND REPLACEMENT OF PARTS....................................................................................................................315 CYLINDER HEAD.....................................................................................................................................316 REPLACING VALVE SEAT INSERT...................................................................................................................316 REPLACING NOZZLE HOLDER SLEEVE................................................................................................................321 REPLACING VALUE GUIDE.........................................................................................................................324 REPLACING CROSS HEAD GUIDE....................................................................................................................325 GRINDING THE VALVE............................................................................................................................326 GRINDING THE FITTING FACE OF CYLINDER HEAD....................................................................................................326 PRESSURE TEST.................................................................................................................................327 CYLINDER BLOCK....................................................................................................................................328 REPLACING CAM BUSHING.........................................................................................................................328 REPLACING CAM GEAR............................................................................................................................331 REPLACING FLYWHEEL RING GEAR..................................................................................................................331 REPLACING ENGINE REAR SEAL....................................................................................................................332 REPLACING CONNECTING ROD SMALL END BUSHING....................................................................................................337 REPLACING MAIN BEARING CAP....................................................................................................................338 GRINDING CRANKSHAFT...........................................................................................................................340 REPLACING WEAR SLEEVE(WHEN EQUIPPED WITH SLEEVE)..............................................................................................349
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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