Komatsu 6D125 Series Diesel Engine Shop Manual – SEBE61500110

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

File Format : PDF
Language : English
Total Pages : 402
Part Number : SEBE61500110

APPLICABLE MODELS :

Komatsu D50A-17
Komatsu D50P-17
Komatsu D50F-17
Komatsu D53A-17
Komatsu D53P-17
Komatsu D58E-1
Komatsu D58P-1
Komatsu D60A-8
Komatsu D60E-8
Komatsu D60P-8
Komatsu D60PL-8
Komatsu D60S-8

Komatsu D63E-1
Komatsu D65A-8
Komatsu D65E-8
Komatsu D65P-8
Komatsu D65S-8
Komatsu D65E-12
Komatsu D68E-1
Komatsu D68P-1
Komatsu D70LE-1

Komatsu GD600R-3
Komatsu GD650R-3
Komatsu GD605R-3
Komatsu GD655R-3
Komatsu GD605A-3 with 146HP engine
Komatsu GD605A-3 with 155HP engine
Komatsu GD613A-1
Komatsu GD623A-1
Komatsu GD622A-1

Komatsu GD625A-1
Komatsu GD625A-1C
Komatsu GD655A-3

Komatsu 6D125-11

Komatsu GD633A-1
Komatsu GD705R-3
Komatsu GD705R-4

Komatsu S6D125-1
Komatsu D60F-8
Komatsu D60F-8A
Komatsu D65EX-12
Komatsu D65P-12
Komatsu D65PX-12

TABLE OF CONTENTS :

COVER
CONTENTS
01 GENERAL
– GENERAL VIEW
– SPECIFICATIONS
– GENERAL ASSEMBLY DRAWING
– ENGINE PERFORMANCE CURVE
– WEIGHT TABLE
11 STRUCTURE AND FUNCTION
– GENERAL STRUCTURE
– INTAKE AND EXHAUST SYSTEM
– – INTAKE AND EXHAUST SYSTEM
– – TURBOCHARGER
– ENGINE BODY
– – CYLINDER HEAD
– – VALVE SYSTEM
– – CYLINDER BLOCK
– – MAIN CIRCULATION PART
– – TIMING GEAR
– – FLYWHEEL AND FLYWHEEL HOUSING
– LUBRICATION SYSTEM
– – LUBRICATION SYSTEM CHART
– – OIL PUMP
– – REGULATOR VALVE
– – OIL FILTER
– – OIL COOLER
– FUEL SYSTEM
– – FUEL SYSTEM CHART
– – FUEL INJECTION PUMP
– – FUEL INJECTION NOZZLE
– – FUEL FILTER
– – MAGNETIC SWITCH (FUEL CUT SOLENOID)
– COOLING SYSTEM
– – COOLING SYSTEM CHART
– – WATER PUMP
– – THERMOSTAT
– – CORROSION RESISTOR
– ELECTRICAL SYSTEM
– – ALTERNATOR
– – STARTING MOTOR
– – ELECTRICAL INTAKE AIR HEATER
– ACCESSORY
– – AIR COMPRESSOR
– – EXHAUST BRAKE
12 TESTING AND ADJUSTING
– ENGINE BODY
– – ADJUSTING VALVE CLEARANCE
– – MEASURING COMPRESSION PRESSURE
– FUEL SYSTEM
– – CHECKING AND ADJUSTING FUEL INJECTOIN TIMING
– – TESTING AND ADJUSTING FUEL CUT SOLENOID
– – ADJUSTING ENGINE STOP MOTOR CABLE
– – FUEL INJECTION PUMP CALIBRATION DATA
– PERFORMANCE TEST
– – RUN-IN STANDARD
– – PERFORMANCE TEST CRITERIA
– – TESTING AND ADJUSTING TOOL LIST
– – TESTING AND ADJUSTING DATA
– TROUBLESHOOTING
– – POINTS TO REMEMBER WHEN TROUBLESHOOTING
– – METHOD OF USING TROUBLESHOOTING CHART
– – S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
– – S-2 ENGINE DOES NOT START
– – – ①ENGINE DOES NOT TURN
– – – ②ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)
– – – ③EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
– – S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
– – S-4 ENGINE STOPS DURING OPERATIONS
– – S-5 ENGINE DOES NOT ROTATE SMOOTHLY
– – S-6 ENGINE LACKS OUTPUT (NO POWER)
– – S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
– – S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
– – S-9 OIL BECOMES CONTAMINATED QUICKLY
– – S-10 FUEL CONSUMPTION IS EXCESSIVE
– – S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
– – S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
– – -13 OIL LEVEL RISES
– – S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
– – S-15 ABNORMAL NOISE IS MADE
– – S-16 VIBRATION IS EXCESSIVE
13 DISASSEMBLY AND ASSEMBLY
– GENERAL
– – DISASSEMBLY
– – ASSEMBLY
– AIR COMPRESSOR
– – DISASSEMBLY
– – ASSEMBLY
– EXHAUST BRAKE
– – DISASSEMBLY AND ASSEMBLY
14 MAINTENANCE STANDARD
– TURBOCHARGER
– CYLINDER HEAD
– VALVE AND VALVE GUIDE
– ROCKER ARM SHAFT
– CROSSHEAD
– CYLINDER BLOCK
– CYLINDER LINER
– CRANKSHAFT
– CAMSHAFT
– CAM FOLLOWER AND PUSH ROD
– PISTON, PISTON RING AND PISTON PIN
– CONNECTING ROD
– TIMING GEAR
– FLYWHEEL AND FLYWHEEL HOUSING
– VIBRATION DAMPER
– WATER PUMP AND THERMOSTAT
– OIL COOLER
– OIL PUMP
– MAIN RELIEF VALVE
– REGULATOR VALVE AND SAFETY VALVE
– AIR COMPRESSOR
15 REPAIR AND REPLACEMENT OF PARTS
– REPLACING VALVE SEAT INSERTS
– REPLACING NOZZLE HOLDER SLEEVE
– REPLACING VALVE GUIDE
– REPLACING CROSS HEAD GUIDE
– GRINDING THE VALVE
– REPLACING CAM BUSHING
– REPLACING FLYWHEEL RING GEAR
– REPLACING CAM GEAR
– PRESSURE TEST