Komatsu DBA127 Engine SEN07001-05 (Preview)
00 Index and Foreword
– Index
– Foreword, Safety, Basic Information
— How to Read the Engine Shop Manual
— Safety Notice for Operation
— Precautions to Prevent Fire
— Procedures If Fire Occurs
— Precautions for Disposing of Waste Materials
— Engine Technology to Conform Exhaust Gas Emission
— Precautions for DEF
— General Character and Precautions for Handling
— Precautions for Adding
— Precautions for Storage
— Precautions for Fire Hazard and Leakage
— Other Precautions
— Store DEF
— Precautions When You Handle Hydraulic Equipment
— Precautions When You Disconnect and Connect Pipings
— Precautions When You Handle Electrical Equipment
— Precautions When You Handle Fuel System Equipment
— Precautions When You Handle Intake System Equipment
— Disconnect and Connect Push-Pull Type Coupler
— How to Disconnect and Connect Type 1 Push-Pull Type Coupler
— How to Disconnect and Connect Type 2 Push-Pull Type Coupler
— How to Disconnect and Connect Type 3 Push-Pull Type Coupler
— Precautions for Disconnection and Connection of Connectors
— How to Disconnect and Connect Deutsch Connector
— How to Disconnect and Connect Slide Lock Type Connector
— How to Disconnect and Connect Connector with Lock to Pull
— How to Disconnect and Connect Connector with Lock to Push
— How to Disconnect and Connect Connector with Housing to Rotate
— How to Read the Codes for Electric Cable
— Explanation of Terms for Maintenance Standard
— Standard Tightening Torque Table
— Conversion Table
— Abbreviation List
01 Specifications
– Table of Contents
– Specifications
— Outline of Exhaust Gas Regulation
— System Diagram of Engine (1-Stage Turbocharger Specification)
— System Diagram of Engine (2-Stage Turbocharger Specification)
— List of Applicable Machines: DBA127
— Specifications
— Specifications:DBA127 (D175AX-10)
— Specifications: DBA127 (HM460-6)
— Specifications: DBA127 (WA475-11, WA475-11E0)
— Specifications: DBA127 (WA485-11, WA485-11E0)
— Engine General View
— Engine General View:DBA127(D175AX-10)
— Engine General View:DBA127(HM460-6)
— Engine General View: DBA127 (WA475-11, WA475-11E0, WA485-11, WA485-11E0)
— Weight Table
— Weight Table: DBA127
— Engine Performance Curve
— Engine Performance Curve: DBA127(D175AX-10)
— Engine Performance Curve: DBA127 (HM460-6)
— Engine Performance Curve: DBA127 (WA475-11, WA475-11E0)
— Engine Performance Curve: DBA127 (WA485-11, WA485-11E0)
10 Structure and Function
– Table of Contents
– Engine System
— Layout of Engine Components
— Layout Drawing of Urea SCR System
— Layout Drawing of Engine Components
— Intake and Exhaust System Parts
— Layout Drawing of Intake and Exhaust System (1-Stage Turbocharger Specification)
— Intake and Exhaust System Circuit Diagram (1-Stage Turbocharger Specification)
— Function of Intake and Exhaust System (1-Stage Turbocharger Specification)
— Layout Drawing of Intake and Exhaust System (2-Stage Turbocharger Specification)
— Intake and Exhaust System Circuit Diagram (2-Stage Turbocharger Specification)
— Function of Intake and Exhaust System (2-Stage Turbocharger Specification)
— Air Cleaner
— Intake Air Heater
— Turbocharger
— Oil Mist Separator
— Exhaust Throttle Valve
— Turbo Bypass Valve
— KDPF Assembly
— DEF Mixing Device
— SCR Assembly
— Urea SCR System
— Types of Regeneration Function
— Engine Main Body Parts
— Cylinder Head
— Cylinder Block
— Main Drive Parts
— Vibration Damper
— Timing Gear
— Front Cover
— Valve System
— Flywheel and Flywheel Housing
— Lubrication System
— Layout Drawing of Lubrication System Parts
— Lubrication System Circuit Diagram
— Engine Oil Pump
— Engine Oil Filter
— Engine Oil Cooler
— Oil Cooler Thermo Valve
— Engine Oil Pan
— Fuel System
— Layout Drawing of Fuel System Parts
— Fuel System Circuit Diagram
— CRI System
— Fuel Dosing System
— Supply Pump
— Common Rail
— Injector
— Fuel Prefilter
— Fuel Main Filter
— Cooling System
— Layout Drawing of Cooling System Parts
— Cooling System Circuit Diagram
— Drive Pulley
— Water Pump
— Thermostat
– Electrical System
— Component Parts of Electrical System
— Alternator
— Starting Motor
— Engine Wiring Harness
— Engine Controller
— Fuel Feed Pump
— Fuel Feed Pump Switch
— Sensor
— Layout Drawing of Engine Sensor (1-Stage Turbocharger Specification)
— Layout Drawing of Engine Sensor (2-Stage Turbocharger Specification)
— Structure of Intake Manifold Pressure and Temperature Sensor
— Function of Intake Manifold Pressure and Temperature Sensor
— Structure of Ambient Pressure Sensor
— Function of Ambient Pressure Sensor
— Structure of Engine Oil Pressure Sensor
— Function of Engine Oil Pressure Sensor
— Structure of Charge Pressure Sensor
— Function of Charge Pressure Sensor
— Structure of Charge Temperature Sensor
— Function of Charge Temperature Sensor
— Structure of Coolant Temperature Sensor
— Function of Coolant Temperature Sensor
— Structure of NE (Crankshaft) Speed Sensor
— Function of NE (Crankshaft) Speed Sensor
— Structure of Bkup (Camshaft) Speed Sensor
— Function of Bkup (Camshaft) Speed Sensor
— Structure of Common Rail Pressure Sensor
— Function of Common Rail Pressure Sensor
— Structure of Turbocharger Speed Sensor
— Function of Turbocharger Speed Sensor
— Structure of Dosing Fuel Pressure Sensor
— Function of Dosing Fuel Pressure Sensor
— Structure of KDPF Differential Pressure and Outlet Pressure Sensor
— Function of KDPF Differential Pressure and Outlet Pressure Sensor
— Structure of Blowby Pressure Sensor
— Function of Blowby Pressure Sensor
— Structure of Engine Oil Level Sensor
— Function of Engine Oil Level Sensor
— Structure of Engine Oil Temperature Sensor
— Function of Engine Oil Temperature Sensor
— Structure of Fuel Temperature Sensor
— Function of Fuel Temperature Sensor
— Structure of Oil Mist Separator Sensor
— Function of Oil Mist Separator Sensor
— Structure of Exhaust Throttle Valve (with Built-in Position Sensor)
— Function of Exhaust Throttle Valve (with Built-in Position Sensor)
— Structure of Turbo Bypass Valve Sensor
— Function of Turbo Bypass Valve Sensor
20 Standard Value Table
– Table of Contents
– Standard Value Table for Engine
— Standard Value Table for Engine: DBA127(D175AX-10)
— Standard Value Table for Engine: DBA127 (HM460-6)
— Standard Value Table for Engine: DBA127 (WA475-11, WA475-11E0, WA485-11, WA485-11E0)
– Running-in Standard and Performance Test Standard
— Running-in Standard and Performance Test Standard: DBA127 (D175AX-10)
— Running-in Standard and Performance Test Standard: DBA127 (HM460-6)
— Running-in Standard and Performance Test Standard: DBA127 (WA475-11, WA475-11E0)
— Running-in Standard and Performance Test Standard: DBA127 (WA485-11, WA485-11E0)
50 Disassembly and Assembly
– Table of Contents
– Precautions Before Work
– Related Information on Disassembly and Assembly
— How to Read This Manual
— Coating Materials List
— Special Tool List
— Sketches of Special Tools
– Engine System
— Disassemble Engine Generally
— Preparation
— How to Remove Fuel Main Filter and Engine Oil Filter
— How to Remove Heat Insulation Cover and Protective Cover
— How to Remove Heat Insulation Cover and Protective Cover (2-Stage Turbocharger Specification)
— How to Remove Turbo Air Intake Connector
— How to Remove Turbocharger Air Supply Connector (2-Stage Turbocharger Specification)
— How to Remove Engine Wiring Harness and Engine Controller
— How to Remove Engine Wiring Harness and Engine Controller (2-Stage Turbocharger Specification)
— How to Remove Breather Tube and Oil Mist Separator
— How to Remove Breather Tube and Oil Mist Separator (2-Stage Turbocharger Specification)
— How to Remove Oil Filter Head and Oil Filler Tube
— How to Remove Oil Filter Head and Oil Filler Tube (2-Stage Turbocharger Specification)
— How to Remove Cylinder Head Cover
— How to Remove Low Pressure Fuel Piping
— How to Remove Low Pressure Fuel Piping (2-Stage Turbocharger Specification)
— How to Remove Common Rail, High-Pressure Pipe, and Injection Pipe
— How to Remove V-Belt, Alternator, Idler Pulley, and Auto-Tensioner
— How to Remove V-Belt, Alternator, Idler Pulley, and Auto-Tensioner (2-Stage Turbocharger Specification)
— How to Remove Air Intake Connector and Cover
— How to Remove Air Intake Connector and Cover (2-Stage Turbocharger Specification)
— How to Remove Air Conditioner Compressor
— How to Remove Front Hanger
— How to Remove Front Hanger (2-Stage Turbocharger Specification)
— How to Remove Rear Hanger
— How to Remove Rear Hanger (2-Stage Turbocharger Specification)
— How to Remove Exhaust Throttle Valve, Turbocharger, and Exhaust Manifold
— How to Remove Exhaust Throttle Valve, Turbocharger, and Exhaust Manifold (2-Stage Turbocharger Specification)
— How to Remove Starting Motor
— How to Remove Thermostat
— How to Remove Thermostat (2-Stage Turbocharger Specification)
— How to Remove Rocker Housing
— How to Remove Injector Assembly
— How to Remove Rocker Arm, Camshaft, and Cam Idler Gear
— How to Remove Cylinder Head
— How to Remove Oil Cooler
— How to Remove Front Support, and Damper and Pulley Assembly
— How to Remove Oil Level Gauge, Engine Oil Pan, Suction Tube, and Stiffener Plate
— How to Remove Oil Level Gauge, Engine Oil Pan, Suction Tube, and Stiffener Plate (2-Stage Turbocharger Specification)
— How to Remove Flywheel
— How to Remove Flywheel (2-Stage Turbocharger Specification)
— How to Remove Engine Rear Oil Seal
— How to Remove Flywheel Housing
— How to Remove Water Pump
— How to Remove Front Cover and Engine Front Oil Seal
— How to Remove Supply Pump, Timing Gear, and Engine Oil Pump
— How to Remove Piston Cooling Nozzle
— How to Remove Piston and Connecting Rod
— How to Remove Crankshaft
— How to Remove Cylinder Liner
— How to Assemble Engine Generally
— How to Install Cylinder Liner
— How to Install Crankshaft
— How to Install Piston and Connecting Rod
— How to Install Piston Cooling Nozzle
— How to Install Supply Pump, Timing Gear, and Oil Pump
— How to Install Front Cover
— How to Install Engine Front Oil Seal
— How to Install Water Pump
— How to Install Flywheel Housing
— How to Install Engine Rear Oil Seal
— How to Install Flywheel
— How to Install Flywheel (2-Stage Turbocharger Specification)
— How to Install Oil Level Gauge, Engine Oil Pan, Suction Tube, and Stiffener Plate
— How to Install Oil Level Gauge, Engine Oil Pan, Suction Tube, and Stiffener Plate (2-Stage Turbocharger Specification)
— How to Install Front Support, and Damper and Pulley Assembly
— How to Install Oil Cooler
— How to Install Cylinder Head
— How to Install Rocker Arm, Camshaft, and Cam Idler Gear
— How to Install Injector Assembly
— How to Install Rocker Housing
— How to Install Thermostat
— How to Install Thermostat (2-Stage Turbocharger Specification)
— How to Install Starting Motor
— How to Install Exhaust throttle valve, Turbocharger, and Exhaust Manifold
— How to Install Exhaust Throttle Valve, Turbocharger, and Exhaust Manifold (2-Stage Turbocharger Specification)
— How to Install Rear Hanger
— How to Install Rear Hanger (2-Stage Turbocharger Specification)
— How to Install Front Hanger
— How to Install Front Hanger (2-Stage Turbocharger Specification)
— How to Install Air Conditioner Compressor
— How to Install Air Intake Connector and Cover
— How to Install Air Intake Connector and Cover (2-Stage Turbocharger Specification)
— How to Install V-Belt, Alternator, Idler Pulley, and Auto-Tensioner
— How to Install V-Belt, Alternator, Idler Pulley, and Auto-Tensioner (2-Stage Turbocharger Specification)
— How to Install Common Rail, High-Pressure Pipe, and Injection Pipe
— How to Install Low Pressure Fuel Piping
— How to Install Low Pressure Fuel Piping (2-Stage Turbocharger Specification)
— How to Install Cylinder Head Cover
— How to Install Oil Filter Head and Oil Filler Tube
— How to Install Oil Filter Head and Oil Filler Tube (2-Stage Turbocharger Specification)
— How to Install Breather Tube and Oil Mist Separator
— How to Install Breather Tube and Oil Mist Separator (2-Stage Turbocharger Specification)
— How to Install Engine Wiring Harness and Engine Controller
— How to Install Engine Wiring Harness and Engine Controller (2-Stage Turbocharger Specification)
— How to Install Turbo Air Intake Connector
— How to Install Turbocharger Air Supply Connector (2-Stage Turbocharger Specification)
— How to Install Heat Insulation Cover and Protective Cover
— How to Install Heat Insulation Cover and Protective Cover (2-Stage Turbocharger Specification)
— How to Install Fuel Main Filter and Engine Oil Filter
60 Maintenance Standard
– Table of Contents
– Engine System
— Intake and Exhaust System Parts
— Maintenance Standard for Turbocharger (1-Stage Turbocharger Specification)
— Maintenance Standard for Turbocharger (2-Stage Turbocharger Specification)
— Engine Main Body Parts
— Maintenance Standard for Cylinder Head
— Maintenance Standard for Cylinder Block
— Maintenance Standard for Cylinder Liner
— Maintenance Standard for Crankshaft
— Maintenance Standard for Piston
— Maintenance Standard for Connecting Rod
— Maintenance Standard for Vibration Damper
— Maintenance Standard for Timing Gear
— Maintenance Standard for Camshaft
— Maintenance Standard for Valve and Valve Guide
— Maintenance Standard for Rocker Arm
— Maintenance Standard for Flywheel (WA475-11, WA475-11E0, WA485-11, WA485-11E0)
— Maintenance Standard for Flywheel (HM460-6, D175AX-10)
— Lubrication System
— Maintenance Standard for Engine Oil Pump
— Maintenance Standard for Safety Valve of Engine Oil Filter
— Cooling System
— Maintenance Standard for Engine Oil Cooler
— Maintenance Standard for Water Pump
— Maintenance Standard for Thermostat
Index
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