KOMATSU 6D125 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBE61500110) KOMATSU 6D125 – PDF DOWNLOAD

Description

KOMATSU 6D125 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBE61500110) KOMATSU 6D125

KOMATSU 6D125 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBE61500110) KOMATSU 6D125 – PDF DOWNLOAD:

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TABLE OF CONTENTS:

KOMATSU 6D125 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBE61500110) KOMATSU 6D125

COVER....................................................................................  1
CONTENTS.................................................................................  2
01 GENERAL............................................................................... 24
	GENERAL VIEW......................................................................... 25
	SPECIFICATIONS....................................................................... 27
	GENERAL ASSEMBLY DRAWING............................................................. 45
	ENGINE PERFORMANCE CURVE............................................................. 53
	WEIGHT TABLE......................................................................... 81
11 STRUCTURE AND FUNCTION................................................................ 85
	GENERAL STRUCTURE.................................................................... 86
	INTAKE AND EXHAUST SYSTEM............................................................ 88
		INTAKE AND EXHAUST SYSTEM........................................................ 88
		TURBOCHARGER..................................................................... 93
	ENGINE BODY.......................................................................... 96
		CYLINDER HEAD.................................................................... 96
		VALVE SYSTEM..................................................................... 98
		CYLINDER BLOCK...................................................................100
		MAIN CIRCULATION PART............................................................102
		TIMING GEAR......................................................................104
		FLYWHEEL AND FLYWHEEL HOUSING....................................................106
	LUBRICATION SYSTEM...................................................................110
		LUBRICATION SYSTEM CHART.........................................................110
		OIL PUMP.........................................................................111
		REGULATOR VALVE..................................................................113
		OIL FILTER.......................................................................114
		OIL COOLER.......................................................................116
	FUEL SYSTEM..........................................................................117
		FUEL SYSTEM CHART................................................................117
		FUEL INJECTION PUMP..............................................................118
		FUEL INJECTION NOZZLE............................................................122
		FUEL FILTER......................................................................123
		MAGNETIC SWITCH (FUEL CUT SOLENOID)..............................................124
	COOLING SYSTEM.......................................................................133
		COOLING SYSTEM CHART.............................................................133
		WATER PUMP.......................................................................134
		THERMOSTAT.......................................................................136
		CORROSION RESISTOR...............................................................137
	ELECTRICAL SYSTEM....................................................................138
		ALTERNATOR.......................................................................138
		STARTING MOTOR...................................................................143
		ELECTRICAL INTAKE AIR HEATER.....................................................145
	ACCESSORY............................................................................146
		AIR COMPRESSOR...................................................................146
		EXHAUST BRAKE....................................................................149
12 TESTING AND ADJUSTING.................................................................150
	ENGINE BODY..........................................................................151
		ADJUSTING VALVE CLEARANCE........................................................151
		MEASURING COMPRESSION PRESSURE...................................................152
	FUEL SYSTEM..........................................................................153
		CHECKING AND ADJUSTING FUEL INJECTOIN TIMING.....................................153
		TESTING AND ADJUSTING FUEL CUT SOLENOID..........................................155
		ADJUSTING ENGINE STOP MOTOR CABLE................................................156
		FUEL INJECTION PUMP CALIBRATION DATA.............................................158
	PERFORMANCE TEST.....................................................................243
		RUN-IN STANDARD..................................................................243
		PERFORMANCE TEST CRITERIA........................................................250
		TESTING AND ADJUSTING TOOL LIST..................................................264
		TESTING AND ADJUSTING DATA.......................................................265
	TROUBLESHOOTING......................................................................284
		POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................286
		METHOD OF USING TROUBLESHOOTING CHART............................................287
		S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................291
		S-2 ENGINE DOES NOT START........................................................292
			①ENGINE DOES NOT TURN........................................................292
			②ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)......293
			③EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....294
		S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).........................295
		S-4 ENGINE STOPS DURING OPERATIONS...............................................296
		S-5 ENGINE DOES NOT ROTATE SMOOTHLY..............................................297
		S-6 ENGINE LACKS OUTPUT (NO POWER)...............................................298
		S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION).................................299
		S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)........................300
		S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................301
		S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................302
		S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.....303
		S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)..........................304
		-13 OIL LEVEL RISES..............................................................305
		S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................306
		S-15 ABNORMAL NOISE IS MADE......................................................307
		S-16 VIBRATION IS EXCESSIVE......................................................308
13 DISASSEMBLY AND ASSEMBLY..............................................................309
	GENERAL..............................................................................310
		DISASSEMBLY......................................................................310
		ASSEMBLY.........................................................................326
	AIR COMPRESSOR.......................................................................353
		DISASSEMBLY......................................................................353
		ASSEMBLY.........................................................................355
	EXHAUST BRAKE........................................................................357
		DISASSEMBLY AND ASSEMBLY.........................................................357
14 MAINTENANCE STANDARD..................................................................360
	TURBOCHARGER.........................................................................361
	CYLINDER HEAD........................................................................364
	VALVE AND VALVE GUIDE................................................................365
	ROCKER ARM SHAFT.....................................................................367
	CROSSHEAD............................................................................368
	CYLINDER BLOCK.......................................................................369
	CYLINDER LINER.......................................................................371
	CRANKSHAFT...........................................................................372
	CAMSHAFT.............................................................................373
	CAM FOLLOWER AND PUSH ROD............................................................374
	PISTON, PISTON RING AND PISTON PIN...................................................376
	CONNECTING ROD.......................................................................382
	TIMING GEAR..........................................................................383
	FLYWHEEL AND FLYWHEEL HOUSING........................................................384
	VIBRATION DAMPER.....................................................................385
	WATER PUMP AND THERMOSTAT............................................................386
	OIL COOLER...........................................................................387
	OIL PUMP.............................................................................388
	MAIN RELIEF VALVE....................................................................389
	REGULATOR VALVE AND SAFETY VALVE.....................................................390
	AIR COMPRESSOR.......................................................................391
15 REPAIR AND REPLACEMENT OF PARTS.......................................................392
	REPLACING VALVE SEAT INSERTS.........................................................393
	REPLACING NOZZLE HOLDER SLEEVE.......................................................397
	REPLACING VALVE GUIDE................................................................399
	REPLACING CROSS HEAD GUIDE...........................................................399
	GRINDING THE VALVE...................................................................400
	REPLACING CAM BUSHING................................................................401
	REPLACING FLYWHEEL RING GEAR.........................................................403
	REPLACING CAM GEAR...................................................................403
	PRESSURE TEST........................................................................404

DESCRIPTION:

KOMATSU 6D125 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBE61500110) KOMATSU 6D125

ANUAL (SN:1890 & UP) KOMATSU PW100-3

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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.
• 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“ to “Causes” are also included in this section.
• DISASSEMBLY AND ASSEMBLY
  This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
• MAINTENANCE STANDARD
  This section gives the judgement standards when inspecting disassembled parts.

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.