Komatsu 125-3 Series Diesel Engine Shop Manual SEBM024209

Description

• Model List:
  • 125-3 Series Diesel Engine

• 1. COVER
• 2. CONTENTS
• 3. LIST OF REVISED PAGES
• 4. SAFETY
• 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. OUTLINE
• 6.2. SPECIFICATIONS
• 6.3. GENERAL ASSEMBLY DRAWING
• 6.4. WEIGHT TABLE
• 6.5. ENGINE PERFORMANCE CURVE
• 7. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
• 7.1. GENERAL STRUCTURE
• 7.2. INTAKE, EXHAUST SYSTEM
• 7.2.1. INTAKE, EXHAUST SYSTEM
• 7.2.2. MAIN CIRCULATION SYSTEM
• 7.2.3. CRANKSHAFT
• 7.2.4. PISTON
• 7.2.5. CONNECTING ROD
• 7.2.6. FLYWHEEL AND FLYWHEEL HOUSING
• 7.2.7. VIBRATION DAMPER
• 7.2.8. TIMING GEAR
• 7.2.9. VALVE MECHANISM
• 7.2.10. CAMSHAFT
• 7.2.11. CAM FOLLOWER AND PUSH ROD
• 7.2.12. VALVE AND VALVE GUIDE
• 7.2.13. ROCKER ARM SHAFT
• 7.2.14. CROSSHEAD
• 7.3. LUBRICATION SYSTEM
• 7.3.1. LUBRICATION SYSTEM DIAGRAM
• 7.3.2. OIL PUMP
• 7.3.3. MAIN RELIFE VALVE
• 7.3.4. OIL FILTER
• 7.3.5. SAFETY VALVE
• 7.3.6. OIL COOLER
• 7.4. FUEL SYSTEM
• 7.4.1. FUEL SYSTEM DIAGRAM
• 7.4.2. OUTLINE OF CRI SYSTEM
• 7.4.3. FUEL PIPING
• 7.4.4. FUEL COOLER
• 7.4.5. 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
• 7.6. ELECTRICAL SYSTEM
• 7.6.1. ALTERNATOR MOUNTING
• 7.6.2. ALTERNATOR
• 7.6.3. STARTING MOTOR
• 7.6.4. STARTING AID
• 8. TESTING AND ADJUSTING, TROUBLESHOOTING
• 8.1. TESTING AND ADJUSTING DATA
• 8.2. STANDARD VALUE TABLE FOR ELECTRICAL PARTS
• 8.3. TESTING AND ADJUSTING TOOL LIST
• 8.4. TESTING AND ADJUSTING
• 8.4.1. MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE)
• 8.4.2. MEASURING EXHAUST TEMPERATURE
• 8.4.3. ADJUSTING VALVE CLEARANCE
• 8.4.4. MEASURING COMPRESSION PRESSURE
• 8.4.5. MEASURING BLOWBY PRESSURE
• 8.4.6. MEASURING ENGINE OIL PRESSURE
• 8.4.7. MEASURING FUEL PRESSURE
• 8.4.8. ADJUSTING ENGINE SPEED SENSOR
• 8.4.9. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 8.4.10. HANDLING EQUIPMENT IN FUEL SYSTEM
• 8.4.11. RELEASING REMAINING PRESSURE IN FUEL SYSTEM
• 8.4.12. BLEEDING AIR FROM FUEL CIRCUIT
• 8.4.13. REDUCED CYLINDER MODE OPERATION FOR ENGINE
• 8.4.14. CHECKING FOR LEAKAGE IN FUEL SYSTEM
• 8.4.15. ADJUSTING ENGINE STOP MOTOR LEVER
• 8.5. CALIBRATION DATA
• 8.6. PERFORMANCE TEST
• 8.6.1. RUNIN STANDARD
• 8.6.2. PERFORMANCE TEST STANDARDS
• 8.7. TROUBLESHOOTING
• 8.7.1. TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
• 8.7.2. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 9. DISASSEMBLY AND ASSEMBLY
• 9.1. METHOD OF USING MANUAL
• 9.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 9.3. SPECIAL TOOL LIST
• 9.4. SKETCHES OF SPECIAL TOOLS
• 9.5. GENERAL DISASSEMBLY
• 9.5.1. Preparation work
• 9.5.2. Starting motor
• 9.5.3. Turbocharger lubricant return tube
• 9.5.4. Radiator lower hose
• 9.5.5. Engine oil cooler
• 9.5.6. Adapter for engine overhauling
• 9.5.7. Radiator upper hose
• 9.5.8. Exhaust muffler
• 9.5.9. Fan securing bracket
• 9.5.10. Turbocharger lubrication tube
• 9.5.11. Turbocharger and exhaust manifold
• 9.5.12. Fuel filter assembly
• 9.5.13. Oil filter
• 9.5.14. Wiring harness
• 9.5.15. Air cleaner securing bracket
• 9.5.16. Exhaust muffler securing bracket
• 9.5.17. High pressure tube clamp
• 9.5.18. Suction manifold assembly
• 9.5.19. Supply pump
• 9.5.20. Common rail
• 9.5.21. Spill pipe
• 9.5.22. Head cover
• 9.5.23. Injector harness
• 9.5.24. Rocker arm housing
• 9.5.25. Injector harness connector
• 9.5.26. Thermostat
• 9.5.27. Cam follower cover
• 9.5.28. Cam follower
• 9.5.29. Cylinder head assembly
• 9.5.30. Setting to engine overhaul stand
• 9.5.31. Oil pan
• 9.5.32. Flywheel
• 9.5.33. Flywheel housing
• 9.5.34. Damper
• 9.5.35. Front support
• 9.5.36. Front cover
• 9.5.37. Water pump
• 9.5.38. Camshaft
• 9.5.39. Oil pump
• 9.5.40. Idler gear
• 9.5.41. Oil suction pipe
• 9.5.42. Piston cooling nozzle
• 9.5.43. Piston and connecting rod assembly
• 9.5.44. Crankshaft
• 9.5.45. Cylinder liner
• 9.6. GENERAL ASSEMBLY
• 9.6.1. Cylinder liner
• 9.6.2. Crankshaft
• 9.6.3. Piston and connecting rod assembly
• 9.6.4. Piston cooling nozzle
• 9.6.5. Oil suction pipe
• 9.6.6. Idler gear
• 9.6.7. Oil pump
• 9.6.8. Camshaft
• 9.6.9. Cam followers
• 9.6.10. Cam follower covers
• 9.6.11. Water pump
• 9.6.12. Fuel supply pump driving gear
• 9.6.13. Front cover
• 9.6.14. Flywheel housing
• 9.6.15. Rear seal
• 9.6.16. Flywheel
• 9.6.17. Damper
• 9.6.18. Oil pan
• 9.6.19. Removing engine assembly from engineoverhaul stand
• 9.6.20. Setting engine assembly on blocks
• 9.6.21. Cylinder head
• 9.6.22. Cylinder head assembly
• 9.6.23. Rocker arm housing
• 9.6.24. Assembling injector harness connector torocker arm housing
• 9.6.25. Crosshead
• 9.6.26. Pushrod
• 9.6.27. Rocker arm
• 9.6.28. Adjusting valve clearance
• 9.6.29. Nozzle tip
• 9.6.30. Fuel injector
• 9.6.31. Head cover
• 9.6.32. Spill pipe
• 9.6.33. Thermostat
• 9.6.34. Engine oil cooler
• 9.6.35. Engine cooling water temperature sensor
• 9.6.36. Engine oil supply tube
• 9.6.37. Highpressure tube for common rail
• 9.6.38. Suction manifold
• 9.6.39. Engine oil filter
• 9.6.40. Fuel filter
• 9.6.41. Turbocharger and exhaust manifold assembly
• 9.6.42. Starting motor
• 9.6.43. Fan bracket lifting hook
• 9.6.44. Wiring harness
• 9.6.45. Air cleaner
• 9.6.46. Exhaust muffler
• 10. REPAIR AND REPLACEMENT OF PARTS
• 10.1. CYLINDER HEAD
• 10.1.1. REPLACING VALVE SEAT INSERT
• 10.1.2. REPLACING NOZZLE HOLDER SLEEVE
• 10.1.3. REPLACING VALUE GUIDE
• 10.1.4. REPLACING CROSS HEAD GUIDE
• 10.1.5. GRINDING THE VALVE
• 10.1.6. GRINDING THE FITTING FACE OF CYLINDER HEAD
• 10.1.7. PRESSURE TEST
• 10.2. CYLINDER BLOCK
• 10.2.1. REPLACING CAM BUSHING
• 10.2.2. REPLACING CAM GEAR
• 10.2.3. REPLACING FLYWHEEL RING GEAR
• 10.2.4. REPLACING ENGINE REAR SEAL
• 10.2.5. REPLACING CONNECTING ROD SMALL END BUSHING
• 10.2.6. REPLACING MAIN BEARING CAP
• 10.2.7. GRINDING CRANKSHAFT
• 10.2.8. REPLACING WEAR SLEEVE (When equipped with sleeve)