Introduction to the structural features of Komatsu excavator (PC400-7 and PC200-8) SAA6D125E-3 and SAA6D107E-1 diesel engines

 (1) The SAA6D125E-3 diesel engine complies with strict emission regulations: US EPA standards (2001 regulations), European 2002 regulations, and Japanese construction equipment 2003 regulations. It is a high-performance, high-efficiency, low-fuel-consumption, low-noise diesel engine with improved exhaust color and improved acceleration performance.

  2024 HITACHI All in One Tool 3.13 with MPDR 3.32+Security 3.17

(2) Both the SAA6D125E-3 and SAA6D107E-1 diesel engines are in-line, 6-cylinder, water-cooled, direct injection diesel engines.

(3) The SAA6D125E-3 and SAA6D107E-1 diesel engines use an electronically controlled common rail fuel injection system, which injects high-pressure fuel at a pressure of 118MPa, providing optimal injection control to match speed and load, thereby improving diesel engine emission performance and reducing fuel consumption and noise.

(4) The piston is made of high-quality steel and cast in a vibration cooling furnace, with Komatsu's traditional minimum thermal expansion, which improves diesel engine reliability and life. 

(5) The SAA6D125E-3 and SAA6D107E-1 diesel engines use an electronically controlled common rail fuel injection system and an optimal divergence characteristic design during low-temperature starting, which improves starting performance and reduces white smoke emissions. 

(6) The turbocharger used in the 125E-2 diesel engine has been improved so that the air supply cycle can control the impact of the compressor end, optimize performance, and have a wider speed range from low speed to high speed, and lower fuel consumption. 

 Hitachi Workshop Service Manual 2019 PDF Download

(7) The thickness of the top surface of the cylinder block has been increased to prevent deformation after long-term operation and make remanufacturing easier. In addition, the main body rigidity has been improved by increasing the rigidity of the main ribs, reducing deformation and vibration under load and preventing the generation of various noises.

(8) The fuel pump size of the electronic common rail fuel injection system is 1/3 of that of the ordinary inline fuel injection system. In addition, the mounting seat is replaced by a flange, which is tightly connected to the timing gearbox to reduce noise. 

 

 

(9) The air filter is changed from a common end face seal to a radial seal to prevent dust from entering and damaging parts. In addition, the 5-segment display type air filter clogging sensor can provide accurate information on the cleaning time.

(10) The oil filter is a high-performance and high-efficiency filter. 

(11) The fuel filter is a high-performance and high-efficiency special fuel filter that can filter out small particles of dirt and protect the electronic common rail fuel injection system

(12) If the electronic control unit determines that the diesel engine is operating abnormally, a warning will be issued and the system will be switched to emergency escape mode. 

(13) When the diesel engine is started at a very low temperature, if the diesel engine speed suddenly increases, overloading will apply excessive load to the bearings before sufficient lubrication, which will reduce the service life of the diesel engine. In particular, overloading will damage the

floating bearing of the turbocharger. In order to prevent this from happening, a turbine protection system is installed to limit the diesel engine speed.

  Hitachi Excavator Diagnostic Tool for ZX-5A ZX-5B ZX-5G ZX-1 ZX-3 Series 

 

How to maintain and service the Deutz BFM1013/BFM2012 engine intake system

 The most basic function of the intake system is to provide sufficient, dry and clean air to the engine while minimizing the intake temperature. Because the entry of unclean, dusty air into the cylinder is the main cause of abnormal wear of engine cylinder bores, valves, valve rings and valves. When dust enters the engine, it will cause excessive:

 

Deutz Diagnostic Tool Communicator for Deutz Engine DECOM Controllers 

*Valve wear

 *Cylinder liner wear

 *Piston ring wear Will cause: 

*Increased oil consumption 

*Difficult starting 

*Lack of power 

*Reduced life 

1  . Maintenance of air filters Most of the early wear problems of engines on the market are related to the use and maintenance of air filters. It is absolutely necessary to use high-quality air and properly maintain air filters. 1. Be sure to use designated high-quality air filters. There are many counterfeit and inferior air filters on the market. When purchasing, you must distinguish the authenticity and make multiple comparisons. You must never install unqualified air filters on your vehicle! Many users think that it doesn't matter if they install counterfeit and inferior air filters, as long as they clean the air filters frequently, but this is not the case. We recommend users to use Shanghai Fleetguard air filters, Changchun Fuao air filters, Langfang air filters, and Bengbu air filters. 

2.   Correct installation of air filters is also very important. When disassembling and installing air filters, do not miss the plastic deflector on the filter element, and install it correctly. Because the blades on the cover will cause the air to rotate, 80% of the dust is separated under the action of centrifugal force and collected in the dust cup. The dust reaching the filter paper is 20% of the inhaled dust, and the total filtration efficiency is about 99.7%.

Correct use of air filters will double the life of diesel engine related components. Improper use of air filters or use of inferior air filters will inevitably cause premature engine wear, damage to the supercharger impeller, oil burning, power failure and other faults, or even premature scrapping. In order to ensure that diesel engine products can play their functions correctly, please choose high-quality air filters and use them correctly.

 

 Deutz Serpic 2012 EPC Download & Installation Service Finial Version

 

 Mismatched filter element

  "The filter element must be installed correctly

 

Be sure to purchase the filter from the engine manufacturer to ensure that the filter and air filter housing match perfectly. "Unmatched filter cores will cause unfiltered air to enter the intake system. Click here to add a spare tear

 

Air filter element is broken 

     * Before installation, be sure to carefully check whether the air filter element is broken * Put a light bulb in the air filter element to check through the light  

 

 

 The connecting hose on the air intake side is damaged 

 

 Intake pipe deformation, air leakage

  

 2024 Deutz SerDia 4.0 SerDia2010 14.1.9.3 Highest Level 6 Diagnostic Software

   

Intake pipe deformed, leaking 

* Leakage at the pipe clamp, even after tightening. 

 * Unfiltered air enters the engine directly. 

* Intake pipe must be replaced 

 

 

 

 

 The air intake pipe is deformed and leaking Leakage at the pipe clamp may occur even after tightening.

 

 

 

 Damage caused by dust 1. Wear of intake surface 

 

 

 

 

 

 

 

* Dust entering the engine acts as an abrasive, causing wear on the valve surface. 

* Incorrect valve clearance. 

* Low cylinder pressure, which ultimately leads to difficulty starting and insufficient power

 

 Damage caused by dust 2. Wear of intake valve stem

 

 

 

* Increased amount of lubricating oil between the valve guide and valve stem. 

* Carbon deposits form on the valve. 

* Oil consumption may increase.

 

 

 

 Damage caused by dust 3. Carbon deposits on the exhaust port

 

 

 

 * If the wear is caused by dust, carbon deposits will be found at the exhaust port.

 

 Damage caused by dust 5. Cylinder liner wear

 

 

 

 

 

 

* Between the top and bottom dead centers of the piston, you can clearly feel the wear marks with your fingers.

 

  * The original honing marks on the cylinder wall will disappear

 

 

 

 Damage caused by dust 6. Piston ring wear

 

 

     *  The piston ring surface and side surfaces are worn. 

    *   The oil ring groove is worn beyond the wear limit.

  *   This ultimately leads to increased oil consumption.

 

 

Damage caused by dust 7. Piston ring gap

 

 * Wear on the piston ring surface will increase the piston ring opening clearance and reduce the tension between the piston ring and the cylinder wall. 

 * The greatest wear occurs on the first ring and the oil ring. 

* The above figure shows a worn piston ring.

  * The following figure shows a correct piston ring.