Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006410
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Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006410

$50.00

  • Type Of Manual: Shop Manual
  • Manual ID: SEBM006410
  • Format: PDF
  • Size: 36.9MB
  • Number of Pages: 399
Category:

Description

  • Model List:

    • 125-2 Series Diesel Engine
  • 0.1. APPLICABLE MACHINE
  • 0.2. SPECIFICATIONS
  • 0.3. GENERAL ASSEMBLY DRAWING
  • 0.4. ENGINE PERFORMANCE CURVE
  • 0.5. WEIGHT TABLE
  • 1. STRUCTURE AND FUNCTION
  • 1.1. GENERAL STRUCTURE
  • 1.2. INTAKE AND EXHAUST SYSTEM
  • 1.2.1. INTAKE AND EXHAUST SYSTEM
  • 1.2.2. MAIN CIRCULATION PART
  • 1.2.3. TIMING GEAR
  • 1.2.4. VALVE SYSTEM
  • 1.2.5. FLYWHEEL AND FLYWHEEL HOUSING
  • 1.3. LUBRICATION SYSTEM
  • 1.3.1. LUBRICATION SYSTEM CHART
  • 1.3.2. OIL PUMP
  • 1.3.3. REGULATOR VALVE
  • 1.3.4. OIL FILTER
  • 1.3.5. BYPASS FILTER
  • 1.3.6. OIL COOLER
  • 1.4. FUEL SYSTEM
  • 1.4.1. FUEL SYSTEM CHART
  • 1.4.2. FUEL INJECTION PUMP
  • 1.4.3. BOOST COMPENSATOR
  • 1.4.4. FUEL INJECTION NOZZLE
  • 1.4.5. FUEL FILTER
  • 1.4.6. MAGNETIC SWITCH (FUEL CUT SOLENOID)
  • 1.4.7. FUEL 2STAGE SET CONTROL MOTOR MOUNT
  • 1.4.8. ENGINE STOP MOTOR, 2STAGE SET CONTROL MOTOR
  • 1.5. COOLING SYSTEM
  • 1.5.1. COOLING SYSTEM CHART
  • 1.5.2. WATER PUMP
  • 1.5.3. THERMOSTAT
  • 1.5.4. CORROSION RESISTOR
  • 1.5.5. FAN DRIVE
  • 1.6. ELECTRICAL SYSTEM
  • 1.6.1. ALTERNATOR
  • 1.6.2. STARTING MOTOR
  • 1.6.3. ELECTRICAL INTAKE AIR HEATER
  • 1.7. ACCESSORY
  • 1.7.1. AIR COMPRESSOR
  • 2. TESTING AND ADJUSTING
  • 2.1. ADJUSTING ENGINE SPEED SENSOR
  • 2.2. ENGINE BODY
  • 2.2.1. ADJUSTING VALVE CLEARANCE
  • 2.2.2. MEASURING COMPRESSION PRESSURE
  • 2.3. FUEL SYSTEM
  • 2.3.1. CHECKING AND ADJUSTING FUEL INJECTION TIMING
  • 2.3.2. TESTING AND ADJUSTING FUEL CUT SOLENOID
  • 2.3.3. ADJUSTING ENGINE STOP MOTOR LEVER
  • 2.3.4. FUEL INJECTION PUMP CALIBRATION DATA
  • 2.4. PERFORMANCE TEST
  • 2.4.1. RUNIN STANDARD
  • 2.4.2. PERFORMANCE TEST CRITERIA
  • 2.5. TROUBLESHOOTING
  • 2.5.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
  • 2.5.2. METHOD OF USING TROUBLESHOOTING CHART
  • 2.5.3. S1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
  • 2.5.4. S2 ENGINE DOES NOT START
  • 2.5.4.1. ENGINE DOES NOT TURN
  • 2.5.4.2. ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)
  • 2.5.4.3. EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
  • 2.5.5. S3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOWUP IS POOR)
  • 2.5.6. S4 ENGINE STOPS DURING OPERATIONS
  • 2.5.7. S5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
  • 2.5.8. S6 ENGINE LACKS OUTPUT (NO POWER)
  • 2.5.9. S7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
  • 2.5.10. S8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
  • 2.5.11. S9 OIL BECOMES CONTAMINATED QUICKLY
  • 2.5.12. S10 FUEL CONSUMPTION IS EXCESSIVE
  • 2.5.13. S11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
  • 2.5.14. S12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
  • 2.5.15. S13 OIL LEVEL RISES
  • 2.5.16. S14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
  • 2.5.17. S15 ABNORMAL NOISE IS MADE
  • 2.5.18. S16 VIBRATION IS EXCESSIVE
  • 2.6. TESTING AND ADJUSTING TOOL LIST
  • 2.7. TESTING AND ADJUSTING DATA
  • 3. DISASSEMBLY AND ASSEMBLY
  • 3.1. DISASSEMBLY
  • 3.1.1. SPECIAL TOOL LIST
  • 3.1.2. STARTING MOTOR ASSEMBLY
  • 3.1.3. STARTING MOTOR ASSEMBLY
  • 3.1.4. SETTING TO ENGINE OVERHAUL STAND
  • 3.1.6. ENGINE MOUNTS
  • 3.1.7. AIR CLEANER, BRACKET ASSEMBLY
  • 3.1.8. TURBOCHARGER, EXHAUST MANIFOLD ASSEMBLY
  • 3.1.9. CORROSION RESISTOR AND PIPING WIRING
  • 3.1.10. ENGINE OIL FILTER
  • 3.1.11. LUBRICATION VALVE
  • 3.1.12. FUEL FILTER
  • 3.1.13. FUEL INJECTION PIPES
  • 3.1.14. AFTERCOOLER ASSEMBLY
  • 3.1.15. FUEL INJECTION PUMP ASSEMBLY
  • 3.1.16. ALTERNATOR ASSEMBLY
  • 3.1.17. THERMOSTAT HOUSING, WATER PUMP
  • 3.1.18. FAN PULLEY, DRIVE ASSEMBLY
  • 3.1.19. FRONT SUPPORT
  • 3.1.20. CRANKSHAFT PULLEY, VIBRATION DAMPER
  • 3.1.21. AIR VENT TUBE, SPILL PIPE
  • 3.1.22. HEAD COVERS
  • 3.1.23. NOZZLE HOLDERS
  • 3.1.24. ROCKER ARMS
  • 3.1.25. CROSSHEADS
  • 3.1.26. PUSH RODS
  • 3.1.27. ROCKER ARM HOUSINGS
  • 3.1.28. CYLINDER HEAD ASSEMBLIES
  • 3.1.29. OIL PAN
  • 3.1.30. FLYWHEEL
  • 3.1.31. REAR SEAL
  • 3.1.32. FLYWHEEL HOUSING
  • 3.1.33. FRONT COVER
  • 3.1.34. FUEL INJECTION PUMP DRIVE GEAR
  • 3.1.35. CAM FOLLOWER COVERS
  • 3.1.36. CAM FOLLOWERS
  • 3.1.37. CAMSHAFT
  • 3.1.38. OIL PUMP
  • 3.1.39. IDLER GEAR
  • 3.1.40. OIL SUCTION PIPE
  • 3.1.41. PISTON, CONNECTING ROD ASSEMBLY
  • 3.1.42. CRANKSHAFT
  • 3.1.43. PISTON COOLING NOZZLE
  • 3.1.44. CYLINDER LINER
  • 3.2. ASSEMBLY
  • 3.2.1. CYLINDER LINER
  • 3.2.2. PISTON COOLING NOZZLE
  • 3.2.3. CRANKSHAFT
  • 3.2.4. PISTON AND CONNECTING ROD ASSEMBLY
  • 3.2.5. OIL SUCTION PIPE
  • 3.2.6. IDLER GEAR
  • 3.2.7. OIL PUMP
  • 3.2.8. CAMSHAFT
  • 3.2.9. CAM FOLLOWERS
  • 3.2.10. CAM FOLLOWERS COVERS
  • 3.2.11. FUEL PUMP DRIVE GEAR
  • 3.2.12. FUEL INJECTION PUMP ASSEMBLY
  • 3.2.13. ADJUSTING FUEL INJECTION TIMING
  • 3.2.14. FRONT COVER
  • 3.2.15. CRANKSHAFT PULLEY, VIBRATION DAMPER
  • 3.2.16. FLYWHEEL HOUSING
  • 3.2.17. REAR SEAL
  • 3.2.18. FLYWHEEL
  • 3.2.19. OIL PAN
  • 3.2.20. CYLINDER HEAD ASSEMBLIES
  • 3.2.21. ROCKER ARM HOUSINGS
  • 3.2.22. PUSH RODS
  • 3.2.23. CROSSHEADS
  • 3.2.24. ROCKER ARMS
  • 3.2.25. ADJUSTING VALVE CLEARANCE
  • 3.2.26. NOZZLE HOLDERS
  • 3.2.27. HEAD COVERS
  • 3.2.28. SPILL PIPE, AIR VENT TUBE
  • 3.2.29. PULLEY, FRONT SUPPORT
  • 3.2.30. DRIVE SENSOR, TUBES, BRACKET
  • 3.2.31. THERMOSTAT HOUSING, WATER PUMP
  • 3.2.32. ALTERNATOR ASSEMBLY
  • 3.2.33. ADJUSTING VBELTS
  • 3.2.34. AFTERCOOLER ASSEMBLY
  • 3.2.35. FUEL INJECTION PUMP PIPES
  • 3.2.36. LUBRICATION VALVE
  • 3.2.37. ENGINE OIL FILTER
  • 3.2.38. CORROSION RESISTOR AND PIPING, WIRING
  • 3.2.39. TURBOCHARGER, EXHAUST MANIFOLD ASSEMBLY
  • 3.2.40. AIR CLEANER, BRACKET ASSEMBLY
  • 3.2.41. ENGINE MOUNTS
  • 3.2.43. MOVING TO ENGINE OVERHAUL STAND
  • 3.2.44. ENGINE OIL COOLER ASSEMBLY
  • 3.2.45. STARTING MOTOR ASSEMBLY
  • 3.2.46. FILLING WITH OIL
  • 4. MAINTENANCE STANDARD
  • 4.1. INTAKE AND EXHAUST SYSTEM
  • 4.1.1. TURBOCHARGER
  • 4.2. ENGINE BODY
  • 4.2.1. CYLINDER HEAD
  • 4.2.2. VALVE AND VALVE GUIDE
  • 4.2.3. ROCKER ARM SHAFT
  • 4.2.4. CAM FOLLOWER AND PUSH ROD
  • 4.2.5. TIMING GEAR
  • 4.2.6. PISTON, PISTON RING AND PISTON PIN
  • 4.2.7. CONNECTING ROD
  • 4.2.8. VIBRATION DAMPER
  • 4.2.9. FLYWHEEL AND FLYWHEEL HOUSING
  • 4.3. COOLING SYSTEM
  • 4.3.1. WATER PUMP AND THERMOSTAT
  • 4.3.2. OIL COOLER
  • 4.4. LUBRICATION SYSTEM
  • 4.4.1. OIL PUMP
  • 4.4.2. MAIN RELIEF VALVE
  • 4.4.3. REGULATOR VALVE AND SAFETY VALVE
  • 4.5. ACCESSORY
  • 4.5.1. AIR COMPRESSOR
  • 5. REPAIR AND REPLACEMENT OF PARTS
  • 5.1. REPLACING VALVE SEAT INSERTS
  • 5.2. REPLACING NOZZLE HOLDER SLEEVE
  • 5.3. REPLACING VALVE GUIDE
  • 5.4. REPLACING CROSS HEAD GUIDE
  • 5.5. GRINDING THE VALVE
  • 5.6. GRINDING OF FITTING FACE OF CYLINDER HEAD
  • 5.7. REPLACING CAM BUSHING
  • 5.8. REPLACING CAM GEAR
  • 5.9. REPLACING FLYWHEEL RING GEAR
  • 5.10. PRESSURE TEST
  • 5.11. REPLACING ENGINE REAR SEAL
  • 5.12. REPLACING CONNECTING ROD SMALL END BUSHING
  • 5.13. REPLACING MAIN BEARING CAP
  • 5.14. GRINDING CRANKSHAFT
  • 5.15. REPLACING WEAR SLEEVE (WHEN EQUIPPED WITH SLEEVE)
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