Komatsu Engine 125-3 series workshop service manual

Description Komatsu Engine 125-3 series workshop service manual

Komatsu Engine SA6D125E-3, SAA6D125E-3 series pdf workshop service & repair manual

Technical data, specifications, maintenance, troubleshooting, testing, schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS

GENERAL
OUTLINE
SPECIFICATIONS
GENERAL ASSEMBLY DRAWING
WEIGHT TABLE
ENGINE PERFORMANCE CURVE

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
GENERAL STRUCTURE
INTAKE, EXHAUST SYSTEM
ENGINE BODY
LUBRICATION SYSTEM
FUEL SYSTEM
COOLING SYSTEM
ELECTRICAL SYSTEM

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)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

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 assembly
35. Setting to 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
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 followers
10. Cam follower covers
11. Water pump
12. Fuel supply pump driving gear
13. Front cover
14. Flywheel housing
15. Rear seal
16. Flywheel
17. Damper
18. Oil pan
19. Removing engine assembly from engineoverhaul stand
20. Setting engine assembly on blocks
21. Cylinder head
22. Cylinder head assembly
23. Rocker arm housing
24. Assembling injector harness connector torocker arm housing
25. Crosshead
26. Pushrod
27. Rocker arm
28. Adjusting valve clearance
29. Nozzle tip
30. Fuel 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. High-pressure tube for common rail
38. Suction manifold
39. Engine oil filter
40. Fuel filter
41. Turbocharger and exhaust manifold assembly
42. Starting motor
43. Fan bracket lifting hook
44. Wiring harness
45. Air cleaner
46. Exhaust muffler

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)