Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 – PDF DOWNLOAD

Description

Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 – PDF DOWNLOAD

FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

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

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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