Komatsu SAA6D125E-3, SA6D125E-3 Diesel Engines SEBM024207 (Preview)
COVER
CONTENTS
01 GENERAL
OUTLINE
SPECIFICATIONS
GENERAL ASSEMBLY DRAWING
WEIGHT TABLE
ENGINE PERFORMANCE CURVE
11 STRUCTURE AND FUNCTION,MAINTENANCE STANDARD
GENERAL STRUCTURE
INTAKE,EXHAUST SYSTEM
INTAKE,EXHAUST SYSTEM
AIR CLEANER
TURBOCHARGER
AFTERCOOLER
ENGINE BODY
CYLINDER HEAD
CYLINDER BLOCK
CYLINDER LINER
MAIN CIRCULATION SYSTEM
CRANKSHAFT
PISTON
CONNECTING ROD
FLYWHEEL AND FLYWHEEL HOUSING
VIBRATION DAMPER
TIMING GEAR
VALVE MECHANISM
CAMSHAFT
CAM FOLLOWER AND PUSH ROD
VALVE AND VALVE GUIDE
ROCKER ARM SHAFT
CROSSHEAD
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
OIL PUMP
OIL FILTER
OIL COOLER
FUEL SYSTEM
FUEL SYSTEM DIAGRAM
OUTLINE OF CRI SYSTEM
FUEL PIPING
FUEL COOLER
FUEL FILTER
COOLING SYSTEM
COOLING SYSTEM CHART
WATER PUMP
THERMOSTAT
CORROSION RESISTOR
ELECTRICAL SYSTEM
ALTERNATOR MOUNTING
ALTERNATOR
STARTING MOTOR
STARTING AID
12 TESTING AND ADJUSTING,TROUBLESHOOTING
TESTING AND ADJUSTING DATA
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING
MEASURING INTAKE AIR PRESSURE(BOOT PRESSURE)
MEASURING EXHAUST TEMPERATURE
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING FUEL PRESSURE
ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING FUEL INJECTION TIMING
HANDLING EQUIPMENT IN FUEL SYSTEM
RELEASING REMAINING PRESSURE IN FUEL SYSTEM
BLEEDING AIR FROM FUEL CIRCUIT
REDUCED CYLINDER MODE OPERATION FOR ENGINE
CHECKING FOR LEAKAGE IN FUEL SYSTEM
ADJUSTING ENGINE STOP MOTOR LEVER
CALIBRATION DATA
PERFORMANCE TEST
RUN-IN STANDARD
PERFORMANCE TEST STANDARDS
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM(S MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER(OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES(WATER, FUEL IN OIL)
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING FLOWCHART
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED
E-1 ERROR CODE[E-1B][ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM]
E-2 ERROR CODE[E-1C][ABNORMALITY IN G REVOLUTION SENSOR SYSTEM]
E-3 ERROR CODE[E-20][ABNORMALITY IN MODEL SELECTION SYSTEM]
E-4 ERROR CODE[E-22][OVERRUN]
E-5 ERROR CODE[E-23][OVERHEAT]
E-6 ERROR CODE[E-24][DROP IN OIL PRESSURE]
E-7 ERROR CODE[E-30][ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM]
E-8 ERROR CODE[E-31][ABNORMALITY IN THROTTLE SENSOR SYSTEM]
E-9 ERROR CODE[E-34][ABNORMALITY IN WATER TEMPERATURE HIGH-TEMPERATURE SENSOR SYSTEM]
E-10 ERROR CODE[E-36][ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM]
E-11 ERROR CODE[E-3C][ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM]
E-12 ERROR CODE[E-3D][ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM]
E-13 ERROR CODE[E-50][ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM]
E-14 ERROR CODE[E-51][ABNORMALITY IN PREHEAT RELAY COIL SYSTEM]
E-15 ERROR CODE[E-54][SHORT CIRCUIT IN STARTING SWITCH C SYSTEM]
E-16 ERROR CODE[E-56][POWER SOURCE SYSTEM ABNORMALITY 1]
E-17 ERROR CODE[E-57][POWER SOURCE SYSTEM ABNORMALITY 2]
E-18 ERROR CODE[E-5A][ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL]
E-19 ERROR CODE[E-6A][ABNORMALITY IN WATER TEMPERATURE LOW-TEMPERATURE SENSOR SYSTEM]
E-20 ERROR CODE[E-70][EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM]
E-21 ERROR CODE[E-71][EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM]
E-22 ERROR CODE[E-74][DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM]
E-23 ERROR CODE[E-75][DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM]
E-24 ERROR CODE[E-77][ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM]
E-25 ERROR CODE[E-79][COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1];ERROR CODE[E-7A][COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2]
E-26 ERROR CODE[E-7B][FUEL SUPPLY PUMP NON-FORCE FEED 1];ERROR CODE[E-7C][FUEL SUPPLY PUMP NON-FORCE FEED 2]
E-27 ERROR CODE[E-7D][ABNORMALITY IN COMMON RAIL FUEL PRESSURE]
E-28 ERROR CODE[E-80][DEFECTIVE CONTROLLER]
E-29 ERROR CODE[E-81][DISCONNECTION IN NO.1 FUEL INJECTOR SYSTEM]
E-30 ERROR CODE[E-82][DISCONNECTION IN NO.2 FUEL INJECTOR SYSTEM]
E-31 ERROR CODE[E-83][DISCONNECTION IN NO.3 FUEL INJECTOR SYSTEM]
E-32 ERROR CODE[E-84][DISCONNECTION IN NO.4 FUEL INJECTOR SYSTEM]
E-33 ERROR CODE[E-85][DISCONNECTION IN NO.5 FUEL INJECTOR SYSTEM]
E-34 ERROR CODE[E-86][DISCONNECTION IN NO.6 FUEL INJECTOR SYSTEM]
E-35 ERROR CODE[E-8A][SHORT CIRCUIT IN NO.1,NO.2,NO.3,FUEL INJECTOR SYSTEM]
E-36 ERROR CODE[E-8B][SHORT CIRCUIT IN NO.4,NO.5,NO.6 FUEL INJECTOR SYSTEM]
13 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
GENERAL DISASSEMBLY
1.PREPARATION WORK
2.STARTING MOTOR
3.TURBOCHARGER LUBRICANT RETURN TUBE
4.RADIATOR LOWER HOSE
5.ENGINE OIL COOLER
6.ADAPTER FOR ENGINE OVERHAULING
7.RADIATOR UPPER HOSE
8.EXHAUST MUFFLER
9.FAN SECURING BRACKET
10.TURBOCHARGER LUBRICATION TUBE
11.TURBOCHARGER AND EXHAUST MANIFOLD
12.FUEL FILTER ASSEMBLY
13.OIL FILTER
14.WIRING HARNESS
15.AIR CLEANER SECURING BRACKET
16.EXHAUST MUFFLER SECURING BRACKET
17.HIGH PRESSURE TUBE CLAMP
18.SUCTION MANIFOLD ASSEMBLY
19.SUPPLY PUMP
20.COMMON RAIL
21.SPILL PIPE
22.HEAD COVER
23.INJECTOR HARNESS
24.ROCKER ARM
25.PUSH ROD
26.INJECTOR
27.NOZZLE TIP
28.CROSSHEAD
29.ROCKER ARM HOUSING
30.INJECTOR HARNESS CONNECTOR
31.THERMOSTAT
32.CAM FOLLOWER COVER
33.CAM FOLLOWER
34.CYLINDER HEAD
35.SETTING ENGINE ON ENGINE OVERHAUL STAND
36.OIL PAN
37.FLYWHEEL
38.FLYWHEEL HOUSING
39.DAMPER
40.FRONT SUPPORT
41.FRONT COVER
42.WATER PUMP
43.CAMSHAFT
44.OIL PUMP
45.IDLER GEAR
46.OIL SUCTION PIPE
47.PISTON COOLING NOZZLE
48.PISTON AND CONNECTING ROD ASSEMBLY
49.CRANKSHAFT
50.CYLINDER LINER
GENERAL ASSEMBLY
PREPARATION WORK
1.CYLINDER LINER
2.CRANKSHAFT
3.PISTON AND CONNECTING ROD ASSEMBLY
4.PISTON COOLING NOZZLE
5.OIL SUCTION PIPE
6.IDLER GEAR
7.OIL PUMP
8.CAMSHAFT
9.CAM FOLLOWER
10.CAM FOLLOWER COVER
11.WATER PUMP
12.SUPPLY PUMP DRIVING GEAR
13.FRONT COVER
14.FLYWHEEL HOUSING
15.REAR SEAL
16.FLYWHEEL
17.DAMPER
18.OIL PAN
19.REMOVING ENGINE FROM ENGINE OVERHAUL STAND
20.SETTING ENGINE ON ENGINE STAND
21.CYLINDER HEAD
22.CYLINDER HEAD ASSEMBLY
23.ROCKER ARM HOUSING
24.INSTALLING INJECTOR HARNESS CONNECTOR TO ROCKER ARM HOUSING
25.CROSSHEAD
26.PUSH ROD
27.ROCKER ARM
28.ADJUSTING VALVE CLEARANCE
29.NOZZLE TIP
30.INJECTOR
31.HEAD COVER
32.SPILL PIPE
33.THERMOSTAT
34.ENGINE OIL COOLER
35.ENGINE COOLING WATER TEMPERATURE SENSOR
36.ENGINE OIL SUPPLY TUBE
37.COMMON RAIL AND HIGH PRESSURE TUBE
38.SUCTION MANIFOLD
39.ENGINE OIL FILTER
40.FUEL FILTER
41.TURBOCHARGER AND SUCTION MANIFOLD ASSEMBLIES
42.STARTING MOTOR
43.FAN BRACKET LIFTING HOOK
44.WIRING HARNESS
45.AIR CLEANER
46.EXHAUST MUFFLER
15 REPAIR AND REPLACEMENT OF PARTS
CYLINDER HEAD
REPLACING VALVE SEAT INSERT
REPLACING NOZZLE HOLDER SLEEVE
REPLACING VALUE GUIDE
REPLACING CROSS HEAD GUIDE
GRINDING THE VALVE
GRINDING THE FITTING FACE OF CYLINDER HEAD
PRESSURE TEST
CYLINDER BLOCK
REPLACING CAM BUSHING
REPLACING CAM GEAR
REPLACING FLYWHEEL RING GEAR
REPLACING ENGINE REAR SEAL
REPLACING CONNECTING ROD SMALL END BUSHING
REPLACING MAIN BEARING CAP
GRINDING CRANKSHAFT
REPLACING WEAR SLEEVE(WHEN EQUIPPED WITH SLEEVE)
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