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Komatsu 125-2 Series Diesel Engine Shop Manual- PDF DOWNLOAD
Komatsu 125-2 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 125-2 Series Diesel Engine Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM006410
Total Pages : 366
DESCRIPTION:
Komatsu 125-2 Series Diesel Engine Shop Manual
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.
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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling eachr component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
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
COVER....................................................................................... 1 CONTENTS.................................................................................... 2 01 GENERAL.................................................................................. 26 APPLICABLE MACHINE...................................................................... 27 SPECIFICATIONS.......................................................................... 28 GENERAL ASSEMBLY DRAWING................................................................ 38 ENGINE PERFORMANCE CURVE................................................................ 57 WEIGHT TABLE............................................................................ 75 11 STRUCTURE AND FUNCTION................................................................... 76 GENERAL STRUCTURE....................................................................... 77 INTAKE AND EXHAUST SYSTEM............................................................... 79 INTAKE AND EXHAUST SYSTEM........................................................... 79 AIR CLEANER......................................................................... 95 TURBOCHARGER........................................................................ 96 AFTERCOOLER......................................................................... 99 ENGINE BODY.............................................................................101 CYLINDER HEAD.......................................................................101 CYLINDER BLOCK......................................................................103 MAIN CIRCULATION PART ..............................................................105 TIMING GEAR.........................................................................107 VALVE SYSTEM........................................................................109 FLYWHEEL AND FLYWHEEL HOUSING.......................................................111 LUBRICATION SYSTEM......................................................................115 LUBRICATION SYSTEM CHART............................................................115 OIL PUMP............................................................................117 REGULATOR VALVE.....................................................................119 OIL FILTER..........................................................................120 BYPASS FILTER.......................................................................121 OIL COOLER..........................................................................122 FUEL SYSTEM.............................................................................123 FUEL SYSTEM CHART...................................................................123 FUEL INJECTION PUMP.................................................................124 FUEL 2-STAGE SET CONTROL MOTOR MOUNT................................................130 ENGINE STOP MOTOR,2-STAGE SET CONTROL MOTOR.........................................131 MAGNETIC SWITCH AND FUEL SOLENOID...................................................136 BOOST COMPENSATOR...................................................................139 FUEL INJECTION NOZZLE...............................................................140 FUEL FILTER.........................................................................141 COOLING SYSTEM..........................................................................142 COOLING SYSTEM CHART................................................................142 WATER PUMP..........................................................................143 THERMOSTAT..........................................................................145 CORROSION RESISTOR..................................................................146 FAN DRIVE...........................................................................147 ELECTRICAL SYSTEM.......................................................................151 ALTERNATOR..........................................................................151 STARTING MOTOR......................................................................156 ELECTRICAL INTAKE AIR HEATER........................................................158 ACCESSORY...............................................................................160 AIR COMPRESSOR......................................................................160 12 TESTING AND ADJUSTING....................................................................162 ADJUSTING ENGINE SPEED SENSOR...........................................................164 ENGINE BODY.............................................................................165 ADJUSTING VALVE CLEARANCE...........................................................165 MEASURING COMPRESSION PRESSURE......................................................166 FUEL SYSTEM.............................................................................167 TESTING AND ADJUSTING FUEL INJECTION TIMING.........................................167 TESTING AND ADJUSTING FUEL CUT SOLENOID.............................................173 ADJUSTING ENGINE STOP MOTOR LEVER...................................................174 FUEL INJECTION PUMP CALIBRATION DATA................................................176 PERFORMANCE TEST........................................................................204 RUN-IN STANDARD.....................................................................204 PERFORMANCE TEST CRITERIA...........................................................208 TROUBLESHOOTING.........................................................................216 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................218 METHOD OF USING TROUBLESHOOTING CHART...............................................219 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).......................223 S-2 ENGINE DOES NOT START...........................................................224 (1) ENGINE DOES NOT TURN........................................................224 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)......225 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....226 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)............................227 S-4 ENGINE STOPS DURING OPERATIONS..................................................228 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).......................................229 S-6 ENGINE LACKS OUTPUT (NO POWER)..................................................230 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)....................................231 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...........................232 S-9 OIL BECOMES CONTAMINATED QUICKLY................................................233 S-10 FUEL CONSUMPTION IS EXCESSIVE..................................................234 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN..........235 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).............................236 S-13 OIL LEVEL RISES................................................................237 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...............................238 S-15 ABNORMAL NOISE IS MADE.........................................................239 S-16 VIBRATION IS EXCESSIVE.........................................................240 TESTING AND ADJUSTING TOOL LIST.........................................................241 TESTING AND ADJUSTING DATA..............................................................242 13 DISASSEMBLY AND ASSEMBLY.................................................................254 DISASSEMBLY.............................................................................254 SPECIAL TOOL LIST...................................................................255 1.STARTING MOTOR ASSEMBLY.......................................................256 2.ENGINE OIL COOLER.............................................................256 3.RESETTING TO TOOL A1 (OVERHAUL STAND).........................................256 4.FAN...........................................................................257 5.ENGINE MOUNTS.................................................................257 6.AIR CLEANER,BRACKET ASSEMBLY..................................................257 7.TURBOCHARGER,EXHAUST MANIFOLD ASSEMBLY........................................258 8.CORROSION RESISTOR AND PIPING,WIRING..........................................258 9.ENGINE OIL FILTER.............................................................258 10.LUBRICATION VALVE............................................................259 11.FUEL FILTER ASSEMBLY.........................................................259 12.FUEL INJECTION PIPES.........................................................259 13.AFTERCOOLER ASSEMBLY.........................................................259 14.FUEL INJECTION PUMP..........................................................260 15.ALTERNATOR ASSEMBLY..........................................................260 16.THERMOSTAT HOUSING,WATER PUMP................................................261 17.FAN PULLEY,DRIVE ASSEMBLY....................................................261 18.FRONT SUPPORT ...............................................................261 19.CRANKSHAFT PULLEY,VIBRATION DAMPER...........................................262 20.AIR VENT TUBE,SPILL PIPE.....................................................262 21.HEAD COVERS..................................................................262 22.NOZZLE HOLDERS...............................................................262 23.ROCKER ARMS..................................................................263 24.CROSSHEADS...................................................................263 25.PUSH RODS....................................................................263 26.ROCKER ARM HOUSINGS..........................................................263 27.CYLINDER HEAD ASSEMBLIES.....................................................264 28.OIL PAN......................................................................264 29.FLYWHEEL.....................................................................265 30.REAR SEAL....................................................................265 31.FLYWHEEL HOUSING.............................................................266 32.FRONT COVER..................................................................266 33.FUEL INJECTION PUMP DRIVE GEAR...............................................266 34.CAM FOLLOWER COVERS..........................................................267 35.CAM FOLLOWERS................................................................267 36.CAMSHAFT.....................................................................267 37.OIL PUMP.....................................................................268 38.IDLER GEAR...................................................................268 39.OIL SUCTION PIPE.............................................................268 40.PISTON AND CONNECTING ROD ASSEMBLY...........................................269 41.CRANKSHAFT...................................................................270 42.PISTON COOLING NOZZLE........................................................271 43.CYLINDER LINER...............................................................272 ASSEMBLY................................................................................273 1.CYLINDER LINER....................................................................275 2.PISTON COOLING NOZZLE.............................................................277 3.CRANKSHAFT........................................................................277 4.PISTON AND CONNECTING ROD ASSEMBLY................................................280 5.OIL SUCTION PIPE..................................................................285 6.IDLER GEAR........................................................................285 7.OIL PUMP..........................................................................285 8.CAMSHAFT..........................................................................286 9.CAM FOLLOWERS.....................................................................286 10.CAM FOLLOWER COVERS..............................................................286 11.DRIVE GEAR OF FUEL INJECTION PUMP................................................287 12.FUEL INJECTION PUMP ASSEMBLY.....................................................288 13.ADJUSTING FUEL INJECTION TIMING..................................................289 14.FRONT COVER......................................................................290 15.CRANKSHAFT PULLEY,VIBRATION DAMPER...............................................290 16.FLYWHEEL HOUSING.................................................................290 17.REAR SEAL........................................................................292 18.FLYWHEEL.........................................................................294 19.OIL PAN..........................................................................296 20.CYLINDER HEAD ASSEMBLIES.........................................................296 21.ROCKER ARM HOUSINGS..............................................................298 22.PUSH RODS........................................................................298 23.CROSSHEADS.......................................................................299 24.ROCKER ARMS......................................................................299 25.ADJUSTING VALVE CLEARANCE........................................................300 26.NOZZLE HOLDERS...................................................................300 27.HEAD COVERS......................................................................301 28.SPILL PIPE,AIR VENT TUBE.........................................................301 29.PULLEY,FRONT SUPPORT.............................................................301 30.DRIVE SENSOR,TUBES,BRACKET.......................................................302 31.WATER PUMP,THERMOSTAT HOUSING....................................................302 32.ALTERNATOR ASSEMBLY..............................................................303 33.ADJUSTING V-BELTS................................................................303 34.AFTERCOOLER ASSEMBLY.............................................................303 35.FUEL INJECTION PUMP PIPING.......................................................304 36.LUBRICATION VALVE................................................................304 37.ENGINE OIL FILTER................................................................305 38.CORROSION RESISTOR...............................................................305 39.TURBOCHARGER,EXHAUST MANIFOLD ASSEMBLY...........................................305 40.AIR CLEANER......................................................................306 41.ENGINE MOUNTS....................................................................306 42.FAN..............................................................................307 43.RESETTING ENGINE IN ENGINE STAND.................................................307 44.ENGINE OIL COOLER ASSEMBLY.......................................................307 45.STARTING MOTOR ASSEMBLY..........................................................307 ・REFILLING WITH OIL.................................................................307 14 MAINTENANCE STANDARD.....................................................................308 TURBOCHARGER............................................................................309 CYLINDER HEAD...........................................................................311 VALVE AND VALVE GUIDE...................................................................312 ROCKER ARM SHAFT........................................................................314 CROSSHEAD...............................................................................315 CYLINDER BLOCK..........................................................................316 CYLINDER LINER..........................................................................318 CRANKSHAFT..............................................................................319 CAMSHAFT................................................................................320 CAM FOLLOWER AND PUSH ROD...............................................................321 TIMING GEAR.............................................................................322 PISTON,PISTON RING AN PISTON PIN........................................................323 CONNECTING ROD..........................................................................327 VIBRATION DAMPER........................................................................328 FLYWHEEL AND FLYWHEEL HOUSING...........................................................329 WATER PUMP AND THERMOSTAT...............................................................330 OIL COOLER..............................................................................331 OIL PUMP................................................................................332 MAIN RELIEF VALVE.......................................................................333 REGULATOR VALVE AND SAFETY VALVE........................................................334 AIR COMPRESSOR..........................................................................335 15 REPAIR AND REPLACEMENT OF PARTS..........................................................336 REPLACING VALVE SEAT INSERTS............................................................337 REPLACING NOZZLE HOLDER SLEEVE..........................................................341 REPLACING VALVE GUIDE...................................................................343 REPLACING CROSS HEAD GUIDE..............................................................343 GRINDING THE VALVE......................................................................344 GRINDING OF FITTING FACE OF CYLINDER HEAD...............................................344 REPLACING CAM BUSHING...................................................................345 REPLACING CAM GEAR......................................................................347 REPLACING FLYWHEEL RING GEAR............................................................347 PRESSURE TEST...........................................................................348 REPLACING ENGINE REAR SEAL..............................................................349 REPLACING CONNECTING ROD SMALL END BUSHING..............................................354 REPLACING MAIN BEARING CAP..............................................................355 GRINDING CRANKSHAFT.....................................................................357 REPLACING WEAR SLEEVE (WHEN EQUIPPED WITH SLEEVE).......................................366
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