PDF Shop Manual Komatsu 125-2 Series Diesel Engine - 2 MB
This shop manual contains all the necessary information for the disassembly, inspection, and reassembly of the Komatsu 125-2 Series Diesel Engine.
It includes detailed specifications, torque settings, and step-by-step procedures for a complete overhaul.
This is an essential resource for engine mechanics and machine shops rebuilding this powerful and reliable Komatsu engine.
Ensure your engine rebuild is done to factory standards with this guide.
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SEBM006411
DIESEL ENGINE
© 2021 1
All Rights Reserved
Printed in Japan 12-21(01) 00-1
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FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted
Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the
machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-
sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the
hook.
00-7
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FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
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TESTING AND ADJUSTING FUEL SYSTEM
(CALIBRATION DATA)
Injection Pump Assembly Number Applicable Machine Applicable Engine
6151-72-1570 (106692-9360)
Model Serial No. Model Serial No.
( ): Injection pump manufacturer’s part No. CS210-1 S6D125-2
Injection Injection pump
Pump Type Manufacturer
PE-P(PS3000) BOSCH
Injection pump specification Engine Specification
Rotating direction Counterclockwise Flywheel horsepower (kW {HP}) / rpm) 163 {218}/2,000 (Gross)
Injection order 1–5–3–6–2–4 Maximum torque (Nm {kgm}/ rpm) 954 {97.3}/1,300 (Gross)
Injection interval 60° ± 30’ High idling speed (rpm) 2,200 ± 50
Plunger pre-stroke (mm) 3.75 ± 0.75 Low idling speed (rpm) 650 +50
+0
Delivery valve (mm3/st) Pump tester capacity
retraction volume 60 Motor 7.5 kW
for Service standard
Calibration Standard ( ): Injection pump manufacturer’s part number
Service standard Manufacturer standard
Conditions Nozzle & nozzle holder part No. (105780-8140) 6151-12-3400 (105111-4600)
Nozzle part No. (105780-0000) 6151-12-3420 (105025-0750)
‡ Service standard
indicates data Nozzle holder part No. (105780-2080) 6152-12-3110 (105041-7130)
using calibration Injection pipe (mm) 8 x 3 x 600 6 x 2.2 x 720
test parts. (Outside dia. x inside dia. x length)
‡ Manufacturer Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard is data Oil temperature (°C) 40 to 45
for factory test.
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 24.5 {250}
Transfer pump pressure (kPa{kg/cm2}) 157 {1.6} 157 {1.6}
615002
615002
Service standard (cc/1000 st.) Manufacturer standard (cc/1000 st.)
Injection volume Rack Pump
Rack Maximum Maximum
point position speed Injection Injection
‡ Rack positions (mm) (rpm) variance variance
volume between cylinder volume between cylinder
B to E are the
reference volume A
when adjusting 8.6 1,000 fl114 ± 2 ±3 fl133 –
(Basic point)
the injection
volume. B 8.6 650 fl132 ± 3 ±4 fl147.5 –
‡ Marks fl are C Approx. 6.0 325 fl15 ± 1.5 ±15 fl15 –
average volumes. E – 100 fl145 +20
+0 – fl150 –
Governor performance curve Boost compensator performance curve
12-12-21
8
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