Service Manual for Komatsu 125-3 Series Engine SEBM024208 PDF

Description

Komatsu 125-3 Series Diesel Engine Shop Manual SEBM024208 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 125-3 Series Diesel Engine Shop Manual SEBM024208 – PDF DOWNLOAD

Language : English
Pages : 365
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 125-3 Series Diesel Engine Shop Manual SEBM024208 – 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 125-3 Series Diesel Engine Shop Manual SEBM024208 – PDF DOWNLOAD 

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 6
SAFETY NOTICE 6
FOREWORD 8
GENERAL 8
HOW TO READ THE SHOP MANUAL 9
HOISTING INSTRUCTIONS 10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 11
COATING MATERIALS 13
STANDARD TIGHTENING TORQUE 15
ELECTRIC WIRE CODE 18
CONVERSION TABLE 19
UNITS 25
01 GENERAL 26
OUTLINE 27
SPECIFICATIONS 30
GENERAL ASSEMBLY DRAWING 35
WEIGHT TABLE 48
ENGINE PERFORMANCE CURVE 49
11 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 58
GENERAL STRUCTURE 59
INTAKE, EXHAUST SYSTEM 63
INTAKE, EXHAUST SYSTEM 63
AIR CLEANER 69
TURBOCHARGER 70
AFTERCOOLER 71
ENGINE BODY 73
CYLINDER HEAD 73
CYLINDER BLOCK 77
CYLINDER LINER 80
MAIN CIRCULATION SYSTEM 82
CRANKSHAFT 84
PISTON 86
CONNECTING ROD 88
FLYWHEEL AND FLYWHEEL HOUSING 89
VIBRATION DAMPER 91
TIMING GEAR 94
VALVE MECHANISM 98
CAMSHAFT 100
CAM FOLLOWER AND PUSH ROD 101
VALVE AND VALVE GUIDE 102
ROCKER ARM SHAFT 104
CROSSHEAD 105
LUBRICATION SYSTEM 106
LUBRICATION SYSTEM DIAGRAM 106
OIL PUMP 107
OIL FILTER 110
OIL COOLER 112
FUEL SYSTEM 114
FUEL SYSTEM DIAGRAM 114
OUTLINE OF CRI SYSTEM 115
FUEL PIPING 128
FUEL COOLER 130
FUEL FILTER 131
COOLING SYSTEM 133
COOLING SYSTEM CHART 133
WATER PUMP 134
THERMOSTAT 137
CORROSION RESISTOR 139
ELECTRICAL SYSTEM 140
ALTERNATOR MOUNTING 140
ALTERNATOR 142
STARTING MOTOR 146
STARTING AID 148
12 TESTING AND ADJUSTING, TROUBLESHOOTING 151
TESTING AND ADJUSTING 152
TESTING AND ADJUSTING DATA 153
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 158
TESTING AND ADJUSTING TOOL LIST 160
MEASURING INTAKE AIR PRESSURE ( BOOT PRESSURE ) 161
MEASURING EXHAUST TEMPERATURE 162
ADJUSTING VALVE CLEARANCE 164
MEASURING COMPRESSION PRESSURE 166
MEASURING BLOW-BY PRESSURE 168
MEASURING ENGINE OIL PRESSURE 169
MEASURING FUEL PRESSURE 170
ADJUSTING ENGINE SPEED SENSOR 171
TESTING AND ADJUSTING FUEL INJECTION TIMING 172
HANDLING EQUIPMENT IN FUEL SYSTEM 178
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 178
BLEEDING AIR FROM FUEL CIRCUIT 179
REDUCED CYLINDER MODE OPERATION FOR ENGINE 181
CHECKING FOR LEAKAGE IN FUEL SYSTEM 182
ADJUSTING ENGINE STOP MOTOR LEVER 183
CALIBRATION DATA 185
PERFORMANCE TEST 188
RUN-IN STANDARD 187
PERFORMANCE TEST STANDARDS 189
TROUBLESHOOTING OF ENGINE SYSTEM ( S MODE) 196
POINTS TO REMEMBER WHEN TROUBLESHOOTING 197
METHOD OF USING TROUBLESHOOTING CHART 198
S-1 STARTING PERFORMANCE IS POOR ( STARTING ALWAYS TAKES TIME ) 202
S-2 ENGINE DOES NOT START 203
S-3 ENGINE DOES NOT PICK UP SMOOTHLY ( FOLLOW-UP IS POOR ) 206
S-4 ENGINE STOPS DURING OPERATION 207
S-5 ENGINE DOES NOT ROTATE SMOOTHLY ( HUNTING ) 208
S-6 ENGINE LACKS OUTPUT ( OR LACKS POWER ) 209
S-7 EXHAUST SMOKE IS BLACK ( INCOMPLETE COMBUSTION ) 210
S-8 OIL CONSUMPTION IS EXCESSIVE ( OR EXHAUST SMOKE IS BLUE ) 211
S-9 OIL BECOMES CONTAMINATED QUICKLY 212
S-10 FUEL CONSUMPTION IS EXCESSIVE 213
S-11 OIL IS IN COOLING WATER ( OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN ) 214
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP ( DROP IN OIL PRESSURE ) 215
S-13 OIL LEVEL RISES ( WATER, FUEL IN OIL ) 216
S-14 WATER TEMPERATURE BECOMES TOO HIGH ( OVERHEATING ) 217
S-15 ABNORMAL NOISE IS MADE 218
S-16 VIBRATION IS EXCESSIVE 219
TROUBLESHOOTING OF ELECTRICAL SYSTEM ( E MODE ) 220
POINTS TO REMEMBER WHEN TROUBLESHOOTING 222
METHOD OF USING TROUBLESHOOITNG FLOWCHART 223
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING 224
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED 227
E-1 ERROR CODE [E-1b] [ABNORMALITY IN NE REVOLUTION SENSOR SYSTEM] 236
E-2 ERROR CODE [E-1c] [ ABNORMALITY IN G REVOLUTION SENSOR SYSTEM] 237
E-3 ERROR CODE [ E-20] [ABNORMALITY IN MODEL SELECTION SYSTEM] 238
E-4 ERROR CODE [ E-22] [OVERRUN] 239
E-5 ERROR CODE [E-23] [OVERHEAT] 239
E-6 ERROR CODE [E-24] [DROP IN OIL PRESSURE] 240
E-7 ERROR CODE [E-30] [ABNORMALITY IN IDLING VALIDATION SIGNAL SYSTEM] 241
E-8 ERROR CODE [E-31] [ABNORMALITY IN THROTTLE SENSOR SYSTEM] 243
E-9 ERROR CODE [E-34] [ABNORMALITY IN WATER TEMPERATURE HIGH-TEMPERATURE SENSOR SYSTEM] 246
E-10 ERROR CODE [E-36] [ABNORMALITY IN OIL PRESSURE SWITCH SYSTEM] 247
E-11 ERROR CODE [E-3c] [ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM] 249
E-12 ERROR CODE [E-3d] [ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM] 250
E-13 ERROR CODE [E-50] [ABNORMALITY IN PREHEATING RELAY CONNECTING POINT SYSTEM] 251
E-14 ERROR CODE [E-51] [ABNORMALITY IN PREHEAT RELAY COIL SYSTEM] 252
E-15 ERROR CODE [E-54] [SHORT CIRCUIT IN STARTING SWITCH C SYSTEM] 253
E-16 ERROR CODE [E-56] [POWER SOURCE SYSTEM ABNORMALITY 1] 255
E-17 ERROR CODE [E-57] [POWER SOURCE SYSTEM ABNORMALITY 2] 257
E-18 ERROR CODE [E-5A] [ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL] 258
E-19 ERROR CODE [E-6A] [ABNORMALITY IN WATER TEMPERATURE LOW-TEMPERATURE SENSOR SYSTEM] 259
E-20 ERROR CODE [E-70] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM] 260
E-21 ERROR CODE [E-71] [EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM] 261
E-22 ERROR CODE [E-74] [DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM] 262
E-23 ERROR CODE [E-75] [DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM] 263
E-24 ERROR CODE [E-77] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM] 264
E-25 ERROR CODE [E-79] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY1] ERROR CODE [E-7A] [COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2] 265
E-26 ERROR CODE [E-7b] [FUEL SUPPLY PUMP NON-FORCE FEED 1] ERROR CODE [E-7C] [FUEL SUPPLY PUMP NON-FORCE FEED 2] 267
E-27 ERROR CODE [E-7d] [ABNORMALITY IN COMMON RAIL FUEL PRESSURE] 269
E-28 ERROR CODE [E-80] [DEFECTIVE CONTROLLER] 269
E-29 ERROR CODE [E-81] [DISCONNECTION IN NO 1 FUEL INJECTOR SYSTEM] 270
E-30 ERROR CODE [E-82] [DISCONNECTION IN NO 2 FUEL INJECTOR SYSTEM] 271
E-31 ERROR CODE [E-83] [DISCONNECTION IN NO 3 FUEL INJECTOR SYSTEM] 272
E-32 ERROR CODE [E-84] [DISCONNECTION IN NO 4 FUEL INJECTOR SYSTEM] 273
E-33 ERROR CODE [E-85] [DISCONNECTION IN NO 5 FUEL INJECTOR SYSTEM] 274
E-34 ERROR CODE [E-86] [DISCONNECTION IN NO 6 FUEL INJECTOR SYSTEM 275
E-35 ERROR CODE [E-8A] [SHORT CIRCUIT IN NO 1, NO 2, NO 3 FUEL INJECTOR SYSTEM 276
E-36 ERROR CODE [E-8b] [SHORT CIRCUIT IN NO 4, NO 5, NO 6 FUEL INJECTOR SYSTEM] 279
13 DISASSEMBLY AND ASSEMBLY 282
METHOD OF USING MANUAL 284
PRECAUTIONS WHEN CARRYING OUT OPERATION 285
SPECIAL TOOL LIST 287
SKETCHES OF SPECIAL TOOLS 288
GENERAL DISASSEMBLY 289
1 PREPARATION WORK 289
2 STARTING MOTOR 289
3 TURBOCHARGER LUBRICANT RETURN TUBE 289
4 RADIATOR LOWER HOSE 289
5 ENGINE OIL COOLER 289
6 ADAPTER FOR ENGINE OVERHAULING 290
7 RADIATOR UPPER HOSE 290
8 EXHAUST MUFFLER 290
9 FAN SECURING BRACKET 290
10 TURBOCHARGER LUBRICATION TUBE 290
11 TURBOCHARGER AND EXHAUST MANIFOLD 290
12 FUEL FILTER ASSEMBLY 290
13 OIL FILTER 291
14 WIRING HARNESS 291
15 AIR CLEANER SECURING BRACKET 291
16 EXHAUST MUFFLER SECURING BRACKET 291
17 HIGH PRESSURE TUBE CLAMP 291
18 SUCTION MANIFOLD ASSEMBLY 291
19 SUPPLY PUMP 291
20 COMMON RAIL 292
21 SPILL PIPE 293
22 HEAD COVER 293
23 INJECTOR HARNESS 293
24 ROCKER ARM 293
25 PUSH ROD 293
26 INJECTOR 293
27 NOZZLE TIP 294
28 CROSSHEAD 294
29 ROCKER ARM HOUSING 295
30 INJECTOR HARNESS CONNECTOR 295
31 THERMOSTAT 295
32 CAM FOLLOWER COVER 295
33 CAM FOLLOWER 295
34 CYLINDER HEAD 295
35 SETTING ENGINE ON ENGINE OVERHAUL STAND 296
36 OIL PAN 296
37 FLYWHEEL 296
38 FLYWHEEL HOUSING 296
39 DAMPER 297
40 FRONT SUPPORT 297
41 FRONT COVER 297
42 WATER PUMP 297
43 CAMSHAFT 297
44 OIL PUMP 297
45 IDLER GEAR 297
46 OIL SUCTION PIPE 298
47 PISTON COOLING NOZZLE 298
48 PISTION AND CONNECTING ROD ASSEMBLY 298
49 CRANKSHAFT 299
50 CYLINDER LINER 300
GENERAL ASSEMBLY 301
PREPARATION WORK 301
1 CYLINDER LINER 302
2 CRANKSHAFT 303
3 PISTON AND CONNECTING ROD ASSEMBLY 306
4 PISTION COOLING NOZZLE 309
5 OIL SUCTION PIPE 310
6 IDLER GEAR 310
7 OIL PUMP 310
8 CAMSHAFT 311
9 CAM FOLLOWER 311
10 CAM FOLLOWER COVER 311
11 WATER PUMP 311
12 SUPPLY PUMP DRIVING GEAR 311
13 FRONT COVER 312
14 FLYWHEEL HOUSING 313
15 REAR SEAL 314
16 FLYWHEEL 316
17 DAMPER 316
18 OIL PAN 317
19 REMOVING ENGINE FROM ENGINE OVERHAUL STAND 317
20 SETTING ENGINE ON ENGINE STAND 317
21 CYLINDER HEAD 317
22 CYLINDER HEAD ASSEMBLY 317
23 ROCKER ARM HOUSING 319
24 INSTALLING INJECTOR HARNESS CONNECTOR TO ROCKER ARM HOUSING 319
25 CROSSHEAD 319
26 PUSH ROD 320
27 ROCKER ARM 320
28 ADJUSTING VALVE CLEARANCE 320
29 NOZZLE TIP 320
30 FUEL INJECTOR 322
31 HEAD COVER 322
32 SPILL PIPE 322
33 THERMOSTAT 323
34 ENGINE OIL COOLER 323
35 ENGINE COOLING WATER TEMPERATURE SENSOR 323
36 ENGINE OIL SUPPLY TUBE 323
37 COMMON RAIL AND HIGH PRESSURE TUBE 323
38 SUCTION MANIFOLD 324
39 ENGINE OIL FILTER 325
40 FUEL FILTER 325
41 TURBOCHARGER AND SUCTION MANIFOLD ASSEMBLIES 325
42 STARTING MOTOR 325
43 FAN BRACKET LIFTING HOOK 326
44 WIRING HARNESS 326
45 AIR CLEANER 326
46 EXHAUST MUFFLER 326
15 REPAIR AND REPLACEMENT OF PARTS 328
CYLINDER HEAD 330
REPLACING VALVE SEAT INSERT 330
REPLACING NOZZEL HOLDER SLEEVE 335
REPLACING VALVE GUIDE 338
REPLACING CROSS HEAD GUIDE 339
GRINDING THE VALVE 340
GRINDING THE FITTING FACE OF CYLINDER HEAD 340
PRESSURE TEST 341
CYLINDER BLOCK 343
REPLACING CAM BUSHING 343
REPLACING CAM GEAR 346
REPLACING FLYWHEEL RING GEAR 346
REPLACING ENGINE REAR SEAL 347
REPLACING CONNECTING ROD SMALL END BUSHING 352
REPLACING MAIN BEARING CAP 353
GRINDING CRANKSHAFT 356
REPLACING WEAR SLEEVE ( When equipped with sleeve ) 365

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24