Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411

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Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 - Image 4

Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 - Image 5

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Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411

$40.00

Type Of Manual: Shop Manual
Manual ID: SEBM006411
Format: PDF
Size: 13.0MB
Number of Pages: 388

Category: Komatsu Shop Manual PDF

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)

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