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KOMATSU 6D125-2 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD
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Description
KOMATSU 6D125-2 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 6D125-2 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 257
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 6D125-2 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD
COVER...................................................................................... 1 CONTENTS................................................................................... 3 SAFETY..................................................................................... 4 FOREWORD................................................................................... 6 01 GENERAL................................................................................. 24 APPLICABLE MACHINE..................................................................... 25 SPECIFICATIONS......................................................................... 26 GENERAL ASSEMBLY DRAWING............................................................... 27 ENGINE PERFORMANCE CURVE............................................................... 31 WEIGHT TABLE........................................................................... 33 11 STRUCTURE AND FUNCTION.................................................................. 34 GENERAL STRUCTURE...................................................................... 35 INTAKE AND EXHAUST SYSTEM.............................................................. 37 INTAKE AND EXHAUST SYSTEM.......................................................... 37 AIR CLEANER........................................................................ 41 TURBOCHARGER....................................................................... 42 AFTERCOOLER........................................................................ 45 ENGINE BODY............................................................................ 46 CYLINDER HEAD...................................................................... 46 CYLINDER BLOCK..................................................................... 48 MAIN CIRCULATION PART.............................................................. 50 TIMING GEAR........................................................................ 52 VALVE SYSTEM....................................................................... 54 FLYWHEEL AND FLYWHEEL HOUSING...................................................... 56 LUBRICATION SYSTEM..................................................................... 59 LUBRICATION SYSTEM CHART........................................................... 59 OIL PUMP........................................................................... 61 REGULATOR VALVE.................................................................... 63 OIL FILTER......................................................................... 64 BYPASS FILTER...................................................................... 65 OIL COOLER......................................................................... 66 FUEL SYSTEM............................................................................ 67 FUEL SYSTEM CHART.................................................................. 67 FUEL INJECTION PUMP................................................................ 68 MAGNETIC SWITCH AND FUEL SOLENOID.................................................. 71 BOOST COMPENSATOR.................................................................. 74 FUEL INJECTION NOZZLE.............................................................. 75 FUEL FILTER........................................................................ 76 COOLING SYSTEM......................................................................... 77 COOLING SYSTRM CHART............................................................... 77 WATER PUMP......................................................................... 78 THERMOSTAT......................................................................... 80 CORROSION RESISTOR................................................................. 81 FAN DRIVE.......................................................................... 82 ELECTLICAL SYSTEM...................................................................... 83 ALTERNATOR......................................................................... 83 STARTING MOTOR..................................................................... 87 ELECTRICAL INTANKE AIR HEATER...................................................... 89 ACCESSORY.............................................................................. 91 AIR COMPRESSOR..................................................................... 91 12 TESTING AND ADJUSTING................................................................... 93 ADJUSTING ENGINE SPEED SENSOR.......................................................... 95 ENGINE BODY............................................................................ 96 ADJUSTING VALVE CLEARANCE.......................................................... 96 MEASURUNG COMPRESSION PRESSURE..................................................... 97 FUEL SYSTEM............................................................................ 98 TESTING AND ADJUSTING FUEL INJECTION TIMING........................................ 98 TESTING AND ADJUSTING FUEL CUT SOLENOID............................................104 ADJUSTING ENGINE STOP MOTOR LEVER..................................................105 FUEL INJECTION PUMP CALIBRATION DATA...............................................107 PERFORMANCE TEST.......................................................................112 RUN-IN STANDARD....................................................................112 PERFORANCE TEST CRITERIA...........................................................113 TROUBLESHOOTING........................................................................115 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................117 METHOD OF SING TROUBLESHOOTING CHART...............................................118 S-1 Starting performance is poor(Starting always takes time).......................122 S-2 Engine does not start..........................................................123 (1) Engine does not turn.......................................................123 (2) Engine turns but no exhaust gas comes out(Fuel is not being injected)......124 (3) Exhaust gas comes out but engine does not start(Fuel is being injected)....125 S-3 Engine does not pick up smoothly(Follow-up is poor)............................126 S-4 Engine stops during opertions..................................................127 S-5 Engine does not rotate smoothly(hunting).......................................128 S-6 Engine lacks output(no power)..................................................129 S-7 Exhaust gas is black(incomplete combustion)....................................130 S-8 Oil consumption is excessive(or exhaust gas is blue)...........................131 S-9 Oil becomes contaminated quickly...............................................132 S-10 Fuel consumption excessive....................................................133 S-11 Oil is cooling water,or water spurts back,or water level goes down............134 S-12 Oil pressure lamp lights up(drop in oil pressure).............................135 S-13 Oil level rises...............................................................136 S-14 Water temperature becomes too hight(overheating)..............................137 S-15 Abnormal noise is made........................................................138 S-16 Vibration is excessive........................................................139 TESTING AND ADJUSTING TOOL LIST........................................................140 TESTING AND ADJUSTING DATA.............................................................141 13 DISASSEMBLY AND ASSEMBLY................................................................142 DISASSENBLY............................................................................142 SPECIAL TOOL LIST..................................................................143 1.Starting motor assembly..........................................................144 2.Engine oil cooler................................................................144 3.Resetting to tool A1(overhaul stand).............................................144 4.Fan..............................................................................145 5.Engine mounts....................................................................145 6.Air cleaner,bracket assembly.....................................................145 7.Turbocharger,exhaust manifold assembly...........................................146 8.Corrosion resistor and piping,wiring.............................................146 9.Engine oil filter................................................................146 10.Lubrication valve...............................................................147 11.Fuel filter assembly............................................................147 12.Fuel injection pipes............................................................147 13.After cooler assembly...........................................................147 14.Fuel injection pump.............................................................148 15.Alternator assembly.............................................................148 16.Thermostat housing,water pump...................................................149 17.Fan pulley,drive assembly.......................................................149 18.Front support...................................................................149 19.Crankshaft pulley,vibration damper..............................................150 20.Air vent tube,spill pipe........................................................150 21.Head covers.....................................................................150 22.Nozzle holders..................................................................150 23.Rocker arms.....................................................................151 24.Crossheads......................................................................151 25.Push rods.......................................................................151 26.Rocker arm housings.............................................................151 27.Cylinder head assemblies........................................................152 28.Oil pan.........................................................................152 29.Flywheel........................................................................153 30.Rear seal.......................................................................153 31.Flywheel housing................................................................154 32.Front cover.....................................................................154 33.Fuel injection pump drive gear..................................................154 34.Cam follower covers.............................................................155 35.Cam followers...................................................................155 36.Camshaft........................................................................155 37.Oil pump........................................................................156 38.Idler gear......................................................................156 39.Oil suction pipe................................................................156 40.Piston and connecting rod assembly..............................................157 41.Crankshaft......................................................................158 42.Piston cooling nozzle...........................................................159 43.Cylinder liner..................................................................160 ASSEMBLY...............................................................................161 1.Cylinder liner...................................................................163 2.Piston cooling nozzle............................................................165 3.Crankshaft.......................................................................165 4.Piston and connecting rod assembly...............................................168 5.Oil suction pipe.................................................................173 6.Idler gear.......................................................................173 7.Oil pump.........................................................................173 8.Camshaft.........................................................................174 9.Can followers....................................................................174 10.Cam follower covers.............................................................174 11.Drive gear of fuel injection pump...............................................175 12.Fuel injection pump assembly....................................................176 13.Adjusting fuel injection timing.................................................177 14.Front cover.....................................................................178 15.Crankshaft pulley,vibration damper..............................................178 16.Flywheel housing................................................................178 17.Rear seal.......................................................................180 18.Flywheel........................................................................182 19.Oil pan.........................................................................184 20.Cylinder head assemblies........................................................184 21.Rocker arm housing..............................................................186 22.Push rods.......................................................................186 23.Crossheads......................................................................187 24.Rocker arms.....................................................................187 25.Adjusting valve clearance.......................................................188 26.Nozzle holders..................................................................188 27.Head covers.....................................................................189 28.Spill pipe,air vent tube........................................................189 29.Pulley,front support............................................................189 30.Drive sensor,tubes,bracket......................................................190 31.Water pump,thermostat housing...................................................190 32.Alternator assembly.............................................................191 33.Adjusting V-belts...............................................................191 34.Aftercooler assembly............................................................191 35.Fuel injection pump pipng.......................................................192 36.Lubrication valve...............................................................192 37.Engine oil filter...............................................................193 38.Corrosion resistor..............................................................193 39.Turbocharger,exhaust manifoid assembly..........................................193 40.Air cleaner.....................................................................194 41.Engine mounts...................................................................194 42.Fan.............................................................................195 43.Resetting engine in engine stand................................................195 44.Engine oil cooler assembly......................................................195 45.Starting motor assembly.........................................................195 Refilling with oil.............................................................195 14 MAINTENAANCE STANDARD...................................................................197 INTAKE AND EXHAUST SYSTEM..............................................................198 TURBOCHARGER.......................................................................198 ENGINE BODY............................................................................200 CYLINDER HEAD......................................................................200 VALVE AND VALVE GUIDE..............................................................201 ROCKER ARM SHAFT...................................................................203 CROSSHEAD..........................................................................204 CYLINDER BLOCK.....................................................................205 CYLINDER LINER.....................................................................207 CRANKSHAFT.........................................................................208 CAMASHAFT..........................................................................209 CAM FOLLOWER AND PUSH ROD..........................................................210 TIMING GEAR........................................................................211 PISTION,PISTON RING AND PISTON PIN.................................................213 CONNECTING ROD.....................................................................217 VIBRATION DAMPER...................................................................218 FLYWHEEL AND FLYWHEEL HOUSING......................................................219 COOLING SYSTEM.........................................................................220 WATER PUMP AND THERMOSTAT..........................................................220 OIL COOLER.........................................................................221 LUBRICATION SYSTEM.....................................................................222 OIL PUMP...........................................................................222 MAIN RELIEF VALVE..................................................................223 REGULATOR VALVE AND SAFETY VALVE...................................................224 ACCESSORY..............................................................................225 AIR COMPRESSOR.....................................................................225 15 REPAIR AND REPLACEMENT OF PARTS.........................................................226 REPLACING VALVE SEAT INSERTS...........................................................227 REPLACING NOZZLE HOLDER SLEEVE.........................................................231 REPLACING VALVE GUIDE..................................................................233 REPLACING CROSS HEAD GUIDE.............................................................233 GRINDING THE VALVE.....................................................................234 GRINDING THE FITTING FACE OF CYLINDER HEAD.............................................234 REPLACING CAM BUSING...................................................................235 REPLACING CAM GEAR.....................................................................237 REPLACING FLYWHEEL RING GEAR...........................................................237 PRESSURE TEST..........................................................................238 REPLACTING ENGINE REAR SEAL............................................................239 REPLACING CONNECTING ROD SMALL END BUSHING.............................................244 REPLACING MAIN BEARING CAP.............................................................245 GRINDING CRANKSHAFT....................................................................248 REPLACING WEAR SLEEVE..................................................................257
DESCRIPTION:
KOMATSU 6D125-2 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 18/12/24
