Komatsu 125-3 Series Diesel Engine Shop Manual SEBM024208

Description

• Model List:
  • 125-3 Series Diesel Engine

• 0.1. GENERAL ASSEMBLY DRAWING
• 0.2. WEIGHT TABLE
• 0.3. ENGINE PERFORMANCE CURVE
• 1. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
• 1.1. GENERAL STRUCTURE
• 1.2. INTAKE, EXHAUST SYSTEM
• 1.2.1. INTAKE, EXHAUST SYSTEM
• 1.2.2. MAIN CIRCULATION SYSTEM
• 1.2.3. CRANKSHAFT
• 1.2.4. PISTON
• 1.2.5. CONNECTING ROD
• 1.2.6. FLYWHEEL AND FLYWHEEL HOUSING
• 1.2.7. VIBRATION DAMPER
• 1.2.8. TIMING GEAR
• 1.2.9. VALVE MECHANISM
• 1.2.10. CAMSHAFT
• 1.2.11. CAM FOLLOWER AND PUSH ROD
• 1.2.12. VALVE AND VALVE GUIDE
• 1.2.13. ROCKER ARM SHAFT
• 1.2.14. CROSSHEAD
• 1.3. LUBRICATION SYSTEM
• 1.3.1. LUBRICATION SYSTEM DIAGRAM
• 1.3.2. OIL PUMP
• 1.3.3. OIL FILTER
• 1.3.4. OIL COOLER
• 1.4. FUEL SYSTEM
• 1.4.1. FUEL SYSTEM DIAGRAM
• 1.4.2. OUTLINE OF CRI SYSTEM
• 1.4.3. FUEL PIPING
• 1.4.4. FUEL COOLER
• 1.4.5. FUEL FILTER
• 1.5. COOLING SYSTEM
• 1.5.1. COOLING SYSTEM CHART
• 1.5.2. WATER PUMP
• 1.5.3. THERMOSTAT
• 1.5.4. CORROSION RESISTOR
• 1.6. ELECTRICAL SYSTEM
• 1.6.1. ALTERNATOR MOUNTING
• 1.6.2. ALTERNATOR
• 1.6.3. STARTING MOTOR
• 1.6.4. STARTING AID
• 2. TESTING AND ADJUSTING, TROUBLESHOOTING
• 2.1. TESTING AND ADJUSTING DATA
• 2.2. STANDARD VALUE TABLE FOR ELECTRICAL PARTS
• 2.3. TESTING AND ADJUSTING TOOL LIST
• 2.4. TESTING AND ADJUSTING
• 2.4.1. MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE)
• 2.4.2. MEASURING EXHAUST TEMPERATURE
• 2.4.3. ADJUSTING VALVE CLEARANCE
• 2.4.4. MEASURING COMPRESSION PRESSURE
• 2.4.5. MEASURING BLOWBY PRESSURE
• 2.4.6. MEASURING ENGINE OIL PRESSURE
• 2.4.7. MEASURING FUEL PRESSURE
• 2.4.8. ADJUSTING ENGINE SPEED SENSOR
• 2.4.9. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 2.4.10. HANDLING EQUIPMENT IN FUEL SYSTEM
• 2.4.11. RELEASING REMAINING PRESSURE IN FUEL SYSTEM
• 2.4.12. BLEEDING AIR FROM FUEL CIRCUIT
• 2.4.13. REDUCED CYLINDER MODE OPERATION FOR ENGINE
• 2.4.14. CHECKING FOR LEAKAGE IN FUEL SYSTEM
• 2.4.15. ADJUSTING ENGINE STOP MOTOR LEVER
• 2.4.16. CALIBRATION DATA
• 2.4.17. PERFORMANCE TEST
• 2.5. TROUBLESHOOTING
• 2.5.1. TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
• 2.5.2. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 3. DISASSEMBLY AND ASSEMBLY
• 3.1. METHOD OF USING MANUAL
• 3.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 3.3. SPECIAL TOOL LIST
• 3.4. SKETCHES OF SPECIAL TOOLS
• 3.5. GENERAL DISASSEMBLY
• 3.5.1. PREPARATION WORK
• 3.5.2. STARTING MOTOR
• 3.5.3. TURBOCHARGER LUBRICANT RETURN TUBE
• 3.5.4. RADIATOR LOWER HOSE
• 3.5.5. ENGINE OIL COOLER
• 3.5.6. ADAPTER FOR ENGINE OVERHAULING
• 3.5.7. RADIATOR UPPER HOSE
• 3.5.8. EXHAUST MUFFLER
• 3.5.9. FAN SECURING BRACKET
• 3.5.10. TURBOCHARGER LUBRICATION TUBE
• 3.5.11. TURBOCHARGER AND EXHAUST MANIFOLD
• 3.5.12. FUEL FILTER ASSEMBLY
• 3.5.13. OIL FILTER
• 3.5.14. WIRING HARNESS
• 3.5.15. TAKE OFF AIR CLEANER SECURING BRACKET (1)
• 3.5.16. TAKE OFF EXHAUST MUFFLER SECURING BRACKET (2)
• 3.5.17. TAKE OFF EACH HIGHPRESSURE TUBE CLAMP (3)
• 3.5.18. SUCTION MANIFOLD ASSEMBLY
• 3.5.19. SUPPLY PUMP
• 3.5.20. COMMON RAIL
• 3.5.21. SPILL PIPE
• 3.5.22. HEAD COVER
• 3.5.23. INJECTOR HARNESS
• 3.5.24. ROCKER ARM HOUSING
• 3.5.25. INJECTOR HARNESS CONNECTOR
• 3.5.26. THERMOSTAT
• 3.5.27. CAM FOLLOWER COVER
• 3.5.28. CAM FOLLOWER
• 3.5.29. CYLINDER HEAD ASSEMBLY
• 3.5.30. SETTING TO ENGINE OVERHAUL STAND
• 3.5.31. OIL PAN
• 3.5.32. FLYWHEEL
• 3.5.33. FLYWHEEL HOUSING
• 3.5.34. DAMPER
• 3.5.35. FRONT SUPPORT
• 3.5.36. FRONT COVER
• 3.5.37. WATER PUMP
• 3.5.38. CAMSHAFT
• 3.5.39. OIL PUMP
• 3.5.40. IDLER GEAR
• 3.5.41. OIL SUCTION PIPE
• 3.5.42. PISTON COOLING NOZZLE
• 3.5.43. PISTON AND CONNECTING ROD ASSEMBLY
• 3.5.44. CRANKSHAFT
• 3.5.45. CYLINDER LINER
• 3.6. GENERAL ASSEMBLY
• 3.6.1. PREPARATION WORK
• 3.6.2. CYLINDER LINER
• 3.6.3. CRANKSHAFT
• 3.6.4. PISTON AND CONNECTING ROD ASSEMBLY
• 3.6.5. PISTON COOLING NOZZLE
• 3.6.6. OIL SUCTION PIPE
• 3.6.7. IDLER GEAR
• 3.6.8. OIL PUMP
• 3.6.9. CAMSHAFT
• 3.6.10. CAM FOLLOWERS
• 3.6.11. CAM FOLLOWER COVERS
• 3.6.12. WATER PUMP
• 3.6.13. FUEL SUPPLY PUMP DRIVING GEAR
• 3.6.14. FRONT COVER
• 3.6.15. FLYWHEEL HOUSING
• 3.6.16. REAR SEAL
• 3.6.17. FLYWHEEL
• 3.6.18. DAMPER
• 3.6.19. OIL PAN
• 3.6.20. REMOVING ENGINE ASSEMBLY FROM ENGINE OVERHAUL STAND
• 3.6.21. SETTING ENGINE ASSEMBLY ON BLOCKS
• 3.6.22. CYLINDER HEAD
• 3.6.23. CYLINDER HEAD ASSEMBLY
• 3.6.24. ROCKER ARM HOUSING
• 3.6.25. ASSEMBLING INJECTOR HARNESS CONNECTOR TO ROCKER ARM HOUSING
• 3.6.26. CROSSHEAD
• 3.6.27. PUSH ROD
• 3.6.28. ROCKER ARM
• 3.6.29. ADJUSTING VALVE CLEARANCE
• 3.6.30. NOZZLE TIP
• 3.6.31. FUEL INJECTOR
• 3.6.32. HEAD COVER
• 3.6.33. SPILL PIPE
• 3.6.34. THERMOSTAT
• 3.6.35. ENGINE OIL COOLER
• 3.6.36. ENGINE COOLING WATER TEMPERATURE SENSOR
• 3.6.37. ENGINE OIL SUPPLY TUBE
• 3.6.38. HIGHPRESSURE TUBE FOR COMMON RAIL
• 3.6.39. SUCTION MANIFOLD
• 3.6.40. ENGINE OIL FILTER
• 3.6.41. FUEL FILTER
• 3.6.42. TURBOCHARGER AND EXHAUST MANIFOLD ASSEMBLY
• 3.6.43. STARTING MOTOR
• 3.6.44. FAN BRACKET LIFTING HOOK
• 3.6.45. WIRING HARNESS
• 3.6.46. AIR CLEANER
• 3.6.47. EXHAUST MUFFLER
• 4. REPAIR AND REPLACEMENT OF PARTS
• 4.1. CYLINDER HEAD
• 4.1.1. REPLACING VALVE SEAT INSERT
• 4.1.2. REPLACING NOZZLE HOLDER SLEEVE
• 4.1.3. REPLACING VALUE GUIDE
• 4.1.4. REPLACING CROSS HEAD GUIDE
• 4.1.5. GRINDING THE VALVE
• 4.1.6. GRINDING THE FITTING FACE OF CYLINDER HEAD
• 4.1.7. PRESSURE TEST
• 4.2. CYLINDER BLOCK
• 4.2.1. REPLACING CAM BUSHING
• 4.2.2. REPLACING CAM GEAR
• 4.2.3. REPLACING FLYWHEEL RING GEAR
• 4.2.4. REPLACING ENGINE REAR SEAL
• 4.2.5. REPLACING CONNECTING ROD SMALL END BUSHING
• 4.2.6. REPLACING MAIN BEARING CAP
• 4.2.7. GRINDING CRANKSHAFT
• 4.2.8. REPLACING WEAR SLEEVE(WHEN EQUIPPED WITH SLEEVE)