Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411

Description

• Model List:
  • 125-2 Series Diesel Engine

• 1. COVER
• 2. CONTENTS
• 3. LIST OF REVISED PAGE
• 4. SAFETY
• 4.1. SAFETY NOTICE
• 5. FOREWORD
• 5.1. GENERAL
• 5.2. HOW TO READ THE SHOP MANUAL
• 5.3. HOISTING INSTRUCTIONS
• 5.4. METHOD OF DISASSEMBLING, CONNECTING PUSHPULL TYPE COUPLER
• 5.5. COATING MATERIALS
• 5.6. STANDARD TIGHTENING TORQUE
• 5.7. ELECTRIC WIRE CODE
• 5.8. CONVERSION TABLE
• 5.9. UNITS
• 6. General
• 6.1. APPLICABLE MACHINE
• 6.2. SPECIFICATIONS
• 6.3. GENERAL ASSEMBLY DRAWING
• 6.4. ENGINE PERFORMANCE CURVE
• 6.5. WEIGHT TABLE
• 7. STRUCTURE AND FUNCTION
• 7.1. GENERAL STRUCTURE
• 7.2. INTAKE AND EXHAUST SYSTEM
• 7.2.1. INTAKE AND EXHAUST SYSTEM
• 7.2.2. MAIN CIRCULATION PART
• 7.2.3. TIMING GEAR
• 7.2.4. VALVE SYSTEM
• 7.2.5. FLYWHEEL AND FLYWHEEL HOUSING
• 7.3. LUBRICATION SYSTEM
• 7.3.1. LUBRICATION SYSTEM CHART
• 7.3.2. OIL PUMP
• 7.3.3. REGULATOR VALVE
• 7.3.4. OIL FILTER
• 7.3.5. BYPASS FILTER
• 7.3.6. OIL COOLER
• 7.4. FUEL SYSTEM
• 7.4.1. FUEL SYSTEM CHART
• 7.4.2. FUEL INJECTION PUMP
• 7.4.3. FUEL 2STAGE SET CONTROL MOTOR MOUNT
• 7.4.4. ENGINE STOP MOTOR, 2STAGE SET CONTROL MOTOR
• 7.4.5. MAGNETIC SWITCH AND FUEL SOLENOID
• 7.4.6. BOOST COMPENSATOR
• 7.4.7. FUEL INJECTION NOZZLE
• 7.4.8. FUEL FILTER
• 7.5. COOLING SYSTEM
• 7.5.1. COOLING SYSTEM CHART
• 7.5.2. WATER PUMP
• 7.5.3. THERMOSTAT
• 7.5.4. CORROSION RESISTOR
• 7.5.5. FAN DRIVE
• 7.6. ELECTRICAL SYSTEM
• 7.6.1. ALTERNATOR
• 7.6.2. STARTING MOTOR
• 7.6.3. ELECTRICAL INTAKE AIR HEATER
• 7.7. ACCESSORY
• 7.7.1. AIR COMPRESSOR
• 8. TESTING AND ADJUSTING
• 8.1. ADJUSTING ENGINE SPEED SENSOR
• 8.2. ENGINE BODY
• 8.2.1. ADJUSTING VALVE CLEARANCE
• 8.2.2. MEASURING COMPRESSION PRESSURE
• 8.3. FUEL SYSTEM
• 8.3.1. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 8.3.2. TESTING AND ADJUSTING FUEL CUT SOLENOID
• 8.3.3. ADJUSTING ENGINE STOP MOTOR LEVER
• 8.3.4. FUEL INJECTION PUMP CALIBRATION DATA
• 8.4. PERFORMANCE TEST
• 8.4.1. RUNIN STANDARD
• 8.4.2. PERFORMANCE TEST CRITERIA
• 8.5. TROUBLESHOOTING
• 8.5.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 8.5.2. METHOD OF USING TROUBLESHOOTING CHART
• 8.5.3. S1 Starting performance is poor (Starting always takes time)
• 8.5.4. S2 Engine does not start
• 8.5.4.1. Engine does not turn
• 8.5.4.2. Engine turns but no exhaust comes out (Fuel is not being injected)
• 8.5.4.3. Exhaust gas comes out but engine does not start (Fuel is being injected)
• 8.5.5. S3 Engine does not pick up smoothly (Followup is poor)
• 8.5.6. S4 Engine stops during operations
• 8.5.7. S5 Engine does not rotate smoothly (hunting)
• 8.5.8. S6 Engine lacks output (no power)
• 8.5.9. S7 Exhaust smoke is black (incomplete combustion)
• 8.5.10. S8 Oil consumption is excessive (or exhaust smoke is blue)
• 8.5.11. S9 Oil becomes contaminated quickly
• 8.5.12. S10 Fuel consumption is excessive
• 8.5.13. S11 Oil is in cooling water, or water spurts back, or water level goes down
• 8.5.14. S12 Oil pressure caution lamp lights up (drop in oil pressure)
• 8.5.15. S13 Oil level rises
• 8.5.16. S14 Water temperature becomes too high (overheating)
• 8.5.17. S15 Abnormal noise is made
• 8.5.18. S16 Vibration is excessive
• 8.6. TESTING AND ADJUSTING TOOL LIST
• 8.7. TESTING AND ADJUSTING DATA
• 9. DISASSEMBLY AND ASSEMBLY
• 9.1. DISASSEMBLY
• 9.1.1. SPECIAL TOOL LIST
• 9.1.2. Starting motor assembly
• 9.1.3. Engine oil cooler assembly
• 9.1.4. Setting to tool A1 (overhaul stand)
• 9.1.6. Engine mounts
• 9.1.7. Air cleaner, bracket assembly
• 9.1.8. Turbocharger, exhaust manifold assembly
• 9.1.9. Corrosion resistor and piping, wiring
• 9.1.10. Engine oil filter
• 9.1.11. Lubrication valve
• 9.1.12. Fuel filter
• 9.1.13. Fuel injection pipes
• 9.1.14. Aftercooler assembly
• 9.1.15. Fuel injection pump assembly
• 9.1.16. Alternator assembly
• 9.1.17. Thermostat housing, water pump
• 9.1.18. Fan pulley, drive assembly
• 9.1.19. Front support
• 9.1.20. Crankshaft pulley, vibration damper
• 9.1.21. Air vent tube, spill pipe
• 9.1.22. Head covers
• 9.1.23. Nozzle holders
• 9.1.24. Rocker arms
• 9.1.25. Crossheads
• 9.1.26. Push rods
• 9.1.27. Rocker arm housings
• 9.1.28. Cylinder head assemblies
• 9.1.29. Oil pan
• 9.1.30. Flywheel
• 9.1.31. Rear seal
• 9.1.32. Flywheel housing
• 9.1.33. Front cover
• 9.1.34. Fuel injection pump drive gear
• 9.1.35. Cam follower covers
• 9.1.36. Cam followers
• 9.1.37. Camshaft
• 9.1.38. Oil pump
• 9.1.39. Idler gear
• 9.1.40. Oil suction pipe
• 9.1.41. Piston and connecting rod assembly
• 9.1.42. Crankshaft
• 9.1.43. Piston cooling nozzle
• 9.1.44. Cylinder liner
• 9.2. ASSEMBLY
• 9.2.1. Cylinder liner
• 9.2.2. Piston cooling nozzle
• 9.2.3. Crankshaft
• 9.2.4. Piston and connecting rod assembly
• 9.2.5. Oil suction pipe
• 9.2.6. Idler gear
• 9.2.7. Oil pump
• 9.2.8. Camshaft
• 9.2.9. Cam followers
• 9.2.10. Cam follower covers
• 9.2.11. Drive gear of fuel injection pump
• 9.2.12. Fuel injection pump assembly
• 9.2.13. Adjusting fuel injection timing
• 9.2.14. Front cover
• 9.2.15. Crankshaft pulley, vibration damper
• 9.2.16. Flywheel housing
• 9.2.17. Rear seal
• 9.2.18. Flywheel
• 9.2.19. Oil pan
• 9.2.20. Cylinder head assemblies
• 9.2.21. Rocker arm housings
• 9.2.22. Push rods
• 9.2.23. Crossheads
• 9.2.24. Rocker arms
• 9.2.25. Adjusting valve clearance
• 9.2.26. Nozzle holders
• 9.2.27. Head covers
• 9.2.28. Spill pipe, air vent tube
• 9.2.29. Pulley, front support
• 9.2.30. Drive sensor, tubes, bracket
• 9.2.31. Water pump, thermostat housing
• 9.2.32. Alternator assembly
• 9.2.33. Adjusting Vbelts
• 9.2.34. Aftercooler assembly
• 9.2.35. Fuel injection pump pipes
• 9.2.36. Lubrication valve
• 9.2.37. Engine oil filter
• 9.2.38. Corrosion resistor
• 9.2.39. Turbocharger, exhaust manifold assembly
• 9.2.40. Air cleaner
• 9.2.41. Engine mounts
• 9.2.43. Resetting engine in engine stand
• 9.2.44. Engine oil cooler assembly
• 9.2.45. Starting motor assembly
• 9.2.46. Filling with oil
• 10. MAINTENANCE STANDARD
• 10.1. INTAKE AND EXHAUST SYSTEM
• 10.1.1. TURBOCHARGER
• 10.2. ENGINE BODY
• 10.2.1. CYLINDER HEAD
• 10.2.2. VALVE AND VALVE GUIDE
• 10.2.3. ROCKER ARM SHAFT
• 10.2.4. CAM FOLLOWER AND PUSH ROD
• 10.2.5. TIMING GEAR
• 10.2.6. PISTON, PISTON RING AND PISTON PIN
• 10.2.7. CONNECTING ROD
• 10.2.8. VIBRATION DAMPER
• 10.2.9. FLYWHEEL AND FLYWHEEL HOUSING
• 10.3. COOLING SYSTEM
• 10.3.1. WATER PUMP AND THERMOSTAT
• 10.3.2. OIL COOLER
• 10.4. LUBRICATION SYSTEM
• 10.4.1. OIL PUMP
• 10.4.2. MAIN RELIEF VALVE
• 10.4.3. REGULATOR VALVE AND SAFETY VALVE
• 10.5. ACCESSORY
• 10.5.1. AIR COMPRESSOR
• 11. REPAIR AND REPLACEMENTOF PARTS
• 11.1. REPLACING VALVE SEAT INSERTS
• 11.2. REPLACING NOZZLE HOLDER SLEEVE
• 11.3. REPLACING VALVE GUIDE
• 11.4. REPLACING CROSS HEAD GUIDE
• 11.5. GRINDING THE VALVE
• 11.6. GRINDING THE FITTING FACE OF CYLINDER HEAD
• 11.7. REPLACING CAM BUSHING
• 11.8. REPLACING CAM GEAR
• 11.9. REPLACING FLYWHEEL RING GEAR
• 11.10. PRESSURE TEST
• 11.11. REPLACING ENGINE REAR SEAL
• 11.12. REPLACING CONNECTING ROD SMALL END BUSHING
• 11.13. REPLACING MAIN BEARING CAP
• 11.14. GRINDING CRANKSHAFT
• 11.15. REPLACING WEAR SLEEVE (When equipped with sleeve)