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KOMATSU 125-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM006411 – PDF DOWNLOA
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Description
KOMATSU 125-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM006411 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 125-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM006411 – PDF DOWNLOAD
Language : English
Pages : 388
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 125-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM006411 – PDF DOWNLOAD
COVER....................................................................................... 1 CONTENTS.................................................................................... 2 LIST OF REVISED PAGE........................................................................ 3 SAFETY...................................................................................... 7 SAFETY NOTICE........................................................................... 7 FOREWORD.................................................................................... 9 GENERAL................................................................................. 9 HOW TO READ THE SHOP MANUAL............................................................. 10 HOISTING INSTRUCTIONS................................................................... 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.............................. 12 COATING MATERIALS....................................................................... 14 STANDARD TIGHTENING TORQUE.............................................................. 16 ELECTRIC WIRE CODE...................................................................... 19 CONVERSION TABLE........................................................................ 20 UNITS................................................................................... 26 01 General.................................................................................. 27 APPLICABLE MACHINE...................................................................... 28 SPECIFICATIONS.......................................................................... 30 GENERAL ASSEMBLY DRAWING................................................................ 40 ENGINE PERFORMANCE CURVE................................................................ 60 WEIGHT TABLE............................................................................ 78 11 STRUCTURE AND FUNCTION................................................................... 79 GENERAL STRUCTURE....................................................................... 80 INTAKE AND EXHAUST SYSTEM............................................................... 82 INTAKE AND EXHAUST SYSTEM........................................................... 82 AIR CLEANER.........................................................................100 TURBOCHARGER........................................................................102 AFTERCOOLER.........................................................................105 ENGINE BODY.............................................................................108 CYLINDER HEAD.......................................................................108 CYLINDER BLOCK......................................................................110 MAIN CIRCULATION PART...............................................................112 TIMING GEAR.........................................................................114 VALVE SYSTEM........................................................................116 FLYWHEEL AND FLYWHEEL HOUSING.......................................................118 LUBRICATION SYSTEM......................................................................122 LUBRICATION SYSTEM CHART............................................................122 OIL PUMP............................................................................124 REGULATOR VALVE.....................................................................126 OIL FILTER..........................................................................127 BYPASS FILTER.......................................................................128 OIL COOLER..........................................................................129 FUEL SYSTEM.............................................................................131 FUEL SYSTEM CHART...................................................................131 FUEL INJECTION PUMP.................................................................132 FUEL 2-STAGE SET CONTROL MOTOR MOUNT................................................138 ENGINE STOP MOTOR, 2-STAGE SET CONTROL MOTOR........................................139 MAGNETIC SWITCH AND FUEL SOLENOID...................................................144 BOOST COMPENSATOR...................................................................147 FUEL INJECTION NOZZLE...............................................................148 FUEL FILTER.........................................................................149 COOLING SYSTEM..........................................................................151 COOLING SYSTEM CHART................................................................151 WATER PUMP..........................................................................152 THERMOSTAT..........................................................................154 CORROSION RESISTOR..................................................................155 FAN DRIVE...........................................................................156 ELECTRICAL SYSTEM.......................................................................160 ALTERNATOR..........................................................................160 STARTING MOTOR......................................................................165 ELECTRICAL INTAKE AIR HEATER........................................................168 ACCESSORY...............................................................................170 AIR COMPRESSOR......................................................................170 12 TESTING AND ADJUSTING....................................................................173 ADJUSTING ENGINE SPEED SENSOR...........................................................175 ENGINE BODY.............................................................................176 ADJUSTING VALVE CLEARANCE...........................................................176 MEASURING COMPRESSION PRESSURE......................................................177 FUEL SYSTEM.............................................................................178 TESTING AND ADJUSTING FUEL INJECTION TIMING.........................................178 TESTING AND ADJUSTING FUEL CUT SOLENOID.............................................184 ADJUSTING ENGINE STOP MOTOR LEVER...................................................185 FUEL INJECTION PUMP CALIBRATION DATA................................................187 PERFORMANCE TEST........................................................................218 RUN-IN STANDARD.....................................................................218 PERFORMANCE TEST CRITERIA...........................................................222 TROUBLESHOOTING.........................................................................231 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................233 METHOD OF USING TROUBLESHOOTING CHART...............................................234 S-1 Starting performance is poor (Starting always takes time).......................238 S-2 Engine does not start...........................................................239 (1) Engine does not turn........................................................239 (2) Engine turns but no exhaust comes out (Fuel is not being injected)..........240 (3) Exhaust gas comes out but engine does not start (Fuel is being injected)....241 S-3 Engine does not pick up smoothly (Follow-up is poor)............................242 S-4 Engine stops during operations..................................................243 S-5 Engine does not rotate smoothly (hunting).......................................244 S-6 Engine lacks output (no power)..................................................245 S-7 Exhaust smoke is black (incomplete combustion)..................................246 S-8 Oil consumption is excessive (or exhaust smoke is blue).........................247 S-9 Oil becomes contaminated quickly................................................248 S-10 Fuel consumption is excessive..................................................249 S-11 Oil is in cooling water, or water spurts back, or water level goes down........250 S-12 Oil pressure caution lamp lights up (drop in oil pressure).....................251 S-13 Oil level rises................................................................252 S-14 Water temperature becomes too high (overheating)...............................253 S-15 Abnormal noise is made.........................................................254 S-16 Vibration is excessive.........................................................255 TESTING AND ADJUSTING TOOL LIST.........................................................256 TESTING AND ADJUSTING DATA..............................................................258 13 DISASSEMBLY AND ASSEMBLY.................................................................271 DISASSEMBLY.............................................................................271 SPECIAL TOOL LIST...................................................................272 1. Starting motor assembly..........................................................273 2. Engine oil cooler assembly.......................................................273 3. Setting to tool A1 (overhaul stand)..............................................273 4. Fan..............................................................................274 5. Engine mounts....................................................................274 6. Air cleaner, bracket assembly....................................................274 7. Turbocharger, exhaust manifold assembly..........................................275 8. Corrosion resistor and piping, wiring............................................275 9. Engine oil filter................................................................275 10. Lubrication valve...............................................................276 11. Fuel filter.....................................................................276 12. Fuel injection pipes............................................................276 13. Aftercooler assembly............................................................276 14. Fuel injection pump assembly....................................................277 15. Alternator assembly.............................................................277 16. Thermostat housing, water pump..................................................278 17. Fan pulley, drive assembly......................................................278 18. Front support...................................................................278 19. Crankshaft pulley, vibration damper.............................................279 20. Air vent tube, spill pipe.......................................................279 21. Head covers.....................................................................279 22. Nozzle holders..................................................................279 23. Rocker arms.....................................................................280 24. Crossheads......................................................................280 25. Push rods.......................................................................280 26. Rocker arm housings.............................................................280 27. Cylinder head assemblies........................................................281 28. Oil pan.........................................................................281 29. Flywheel........................................................................282 30. Rear seal.......................................................................282 31. Flywheel housing................................................................283 32. Front cover.....................................................................283 33. Fuel injection pump drive gear..................................................283 34. Cam follower covers.............................................................284 35. Cam followers...................................................................284 36. Camshaft........................................................................284 37. Oil pump........................................................................285 38. Idler gear......................................................................285 39. Oil suction pipe................................................................285 40. Piston and connecting rod assembly..............................................286 41. Crankshaft......................................................................287 42. Piston cooling nozzle...........................................................288 43. Cylinder liner..................................................................289 ASSEMBLY................................................................................291 1. Cylinder liner...................................................................293 2. Piston cooling nozzle............................................................295 3. Crankshaft.......................................................................295 4. Piston and connecting rod assembly...............................................298 5. Oil suction pipe.................................................................303 6. Idler gear.......................................................................303 7. Oil pump.........................................................................303 8. Camshaft.........................................................................304 9. Cam followers....................................................................304 10. Cam follower covers.............................................................304 11. Drive gear of fuel injection pump...............................................305 12. Fuel injection pump assembly....................................................306 13. Adjusting fuel injection timing.................................................307 14. Front cover.....................................................................308 15. Crankshaft pulley, vibration damper.............................................308 16. Flywheel housing................................................................308 17. Rear seal.......................................................................310 18. Flywheel........................................................................312 19. Oil pan.........................................................................314 20. Cylinder head assemblies........................................................314 21. Rocker arm housings.............................................................316 22. Push rods.......................................................................316 23. Crossheads......................................................................317 24. Rocker arms.....................................................................317 25. Adjusting valve clearance.......................................................318 26. Nozzle holders..................................................................318 27. Head covers.....................................................................319 28. Spill pipe, air vent tube.......................................................319 29. Pulley, front support...........................................................319 30. Drive sensor, tubes, bracket....................................................320 31. Water pump, thermostat housing..................................................320 32. Alternator assembly.............................................................321 33. Adjusting V-belts...............................................................321 34. Aftercooler assembly............................................................321 35. Fuel injection pump pipes.......................................................322 36. Lubrication valve...............................................................322 37. Engine oil filter...............................................................323 38. Corrosion resistor..............................................................323 39. Turbocharger, exhaust manifold assembly.........................................323 40. Air cleaner.....................................................................324 41. Engine mounts...................................................................324 42. Fan.............................................................................325 43. Resetting engine in engine stand................................................325 44. Engine oil cooler assembly......................................................325 45. Starting motor assembly.........................................................325 Filling with oil....................................................................325 14 MAINTENANCE STANDARD.....................................................................327 INTAKE AND EXHAUST SYSTEM...............................................................328 TURBOCHARGER........................................................................328 ENGINE BODY.............................................................................330 CYLINDER HEAD.......................................................................330 VALVE AND VALVE GUIDE...............................................................332 ROCKER ARM SHAFT....................................................................334 CROSSHEAD...........................................................................335 CYLINDER BLOCK......................................................................336 CYLINDER LINER......................................................................338 CRANKSHAFT..........................................................................339 CAMSHAFT............................................................................340 CAM FOLLOWER AND PUSH ROD...........................................................341 TIMING GEAR.........................................................................342 PISTON, PISTON RING AND PISTON PIN..................................................344 CONNECTING ROD......................................................................348 VIBRATION DAMPER....................................................................349 FLYWHEEL AND FLYWHEEL HOUSING.......................................................350 COOLING SYSTEM..........................................................................351 WATER PUMP AND THERMOSTAT...........................................................351 OIL COOLER..........................................................................352 LUBRICATION SYSTEM......................................................................353 OIL PUMP............................................................................353 MAIN RELIEF VALVE...................................................................354 REGULATOR VALVE AND SAFETY VALVE....................................................355 ACCESSORY...............................................................................356 AIR COMPRESSOR......................................................................356 15 REPAIR AND REPLACEMENTOF PARTS...........................................................357 REPLACING VALVE SEAT INSERTS............................................................358 REPLACING NOZZLE HOLDER SLEEVE..........................................................362 REPLACING VALVE GUIDE...................................................................364 REPLACING CROSS HEAD GUIDE..............................................................364 GRINDING THE VALVE......................................................................365 GRINDING THE FITTING FACE OF CYLINDER HEAD..............................................365 REPLACING CAM BUSHING...................................................................366 REPLACING CAM GEAR......................................................................368 REPLACING FLYWHEEL RING GEAR............................................................368 PRESSURE TEST...........................................................................369 REPLACING ENGINE REAR SEAL..............................................................370 REPLACING CONNECTING ROD SMALL END BUSHING..............................................375 REPLACING MAIN BEARING CAP..............................................................376 GRINDING CRANKSHAFT.....................................................................379 REPLACING WEAR SLEEVE (When equipped with sleeve).......................................388
DESCRIPTION:
KOMATSU 125-2 SERIES DIESEL ENGINE SHOP MANUAL SEBM006411 – PDF DOWNLOAD
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
S.S 19/12/24
