Komatsu Engine 6d125 1 Workshop Manuals 1
Komatsu Engine 6d125 1 Workshop Manuals 1
Komatsu Engine 6d125 1 Workshop Manuals 1
6Dl25 SERIES
DIESEL ENGINE
0 1995KOMAl’&U
All Rights Reserved
IO-95(01)05501
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No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-001
14 MAINTENANCE STANDARD . .. .. ... .. . ... .. ... .. .. . ... .. .... . .... ... 14-001
6D125 SERIES
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6D125SERlES
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SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A. IS used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21 When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
00-4
FOREWORD GENERAL
FOREWORD
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.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs, They are divided as follows: (a@@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: issued for each engine series
FILING METHOD
See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
A
Following examples show how to read the
Safety necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3
or other precautions for pre-
Caution serving standards are neces-
*
Item number (IO. Structure sary when performing the
and Function) ~ work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
Places that require special at-
Tightening
Unit number (I. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting)
‘T Consecutive page number for & I Coat
Places to be coated with ad-
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Oil, water must be added, and the ca-
Additional pages: Additional pages are indi- % pacity.
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
4) Do not sling a heavy load with ropes form-
Wire ropes
ing a wide hanging angle from the hook.
(Standard “Z” or “S” twist ropes
When hoisting a load with two or more
without galvanizing)
ropes, the force subjected to each rope
Rope diameter will increase with the hanging angles. The
Allowable load
table below shows the variation of allow-
mm KN tons able load KN (kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 KN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 KN (2000 kg) of total weight can
16 27.5 2.8 be suspended. This weight becomes 9.8
18 35.3 3.6 KN (1000 kg) when two ropes make a 120”
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Category <omatsu code Pat-t No. Q’ty Container Main applications, features
* Used to prevent rubber gaskets, rubber cushions,
LT-IA 790-129-9030 150 g Tube
and cork plugs from coming out
. Used in places requiring an immediately effec-
LT-10 790-129-9050
20 9 Plastic tive, strong adhesive. Used for plastics (except
1x2) container polyethylene, polypropylene, tetrafluoroethylene,
and vinyl chloride), rubber, metal, and non-metal.
* Features: Resistance to heat, chemicals
Plastic
LT-2 09940-00030 50 g container
- Used for anti-loosenina and sealant DurDoses for
Adhesive bolts and plugs. -
rdhesive * Used as adhesive or sealant for metal, glass, plastic
‘90-129-9060
Set of adhesive 1 Kg
LT-3 hardening Can
Ind hardengins
gent:
Igent)
500 g
Plastic * Used as sealant for machined holes
LT-4 790-I 29-9040 250 g
container
* Features: Resistance to heat, chemicals
Loctite 646-50 79A-129-91 IO 50 cc - - Used at joint portions subject to high tempera-
ture
- Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube Dackinas of Dower train case, etc.
* Features: Resistance to heat
* Used as sealant for flange surfaces and bolts at
high temperature locations, used to prevent sei-
LG-3 790-129-9070 1 Kg Can zure
- Used as sealant for heat resistant gasket for high
temperature locations such as engine precombustion
chamber, exhaust pipe
* Features: Resistance to water, oil
- Used as sealant for flange surface, thread
LG-4 790-I 29-9020 200 g Tube
* Also possible to use as sealant for flanges with
Gasket sealant large clearance
* Used as sealant for mating surfaces of final drive
case, transmission case
* Used as sealant for various threads, pipe joints,
Plastic flanges
LG-5 790-I 29-9080 1 Kg * Used as sealant for tapered plugs, elbows, nip-
container
ples of hydraulic piping
* Features: Silicon based, resistance to heat, cold
LG-6 09940-00011 250 g Tube * Used as sealant for flange surface, thread
* Used as sealant for oil pan, final drive case, etc.
- Features: Silicon based, quick hardening type
LG-7 09920-00150 150 g Tube - Used as sealant for flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
Rust preven - Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
squeaking)
tion lubricant
Molybdenum * Used to Drevent seizure or scuffina of the thread
disulphide Iu- LM-P 09940-00040 200 g Tube when press fitting or shrink fitting-
bricant * Used as lubricant for linkaqe, bearinqs, etc.
;YG350LI * General purpose type
SYG-400LI
Liiium grease G2-LI SYG-400LI-A Various Various
:YG-16OLI
;YGA-IGOCNLI
jSG2-400CA * Used for normal temperature, light load bearing
jYG2-350CA at places in contact with water or steam
Calcium grease G2-CA jYG2-400CA-P Various Various
jYG2-160CA
jYGA-IGCNCA
Molybdenum . Used for places with heavy load
400 g
disulphide SYG2-400M 3ellows type
lopercase
grease
00-8
FOREWORD STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given
in section of DISASSEMBLY AND ASSEMBLY.
1 Kam = 9.806 Nm
Thread diameter
of bolt
Width
across flats T SAD00481 SAD00482
mm mm Nm kgm
6 10 13.2k1.4 1.35kO.15
8 13 31.4k2.9 3.2kO.3
10 17 65.7k6.8 6.7kO.7
12 19 112k9.8 11.5+1.0
14 22 177+-19 18.Ok2.0
16 24 279*29 28.5*3
18 27 383139 3954
20 30 549k58 56f6
22 32 745f78 76f8
24 36 927+98 94.5+ 10
Ir This torque table does not apply to the bolts with which nylon packings or other
nonferrous metal washers are to be used, or which require tightening to otherwise
specified torque.
00-9
FOREWORD STANDARD TIGHTENING TORQUE
Thread diameter
of nut part
mm
\iNidth across flats
of nut part
mm
T Nm
Tightening torque
km
14 19 24.5f 4.9 2.5-10.5
18 24 49+ 19.6 5k2
22 27 78.5+ 19.6 8+2
24 32 137.3k29.4 14k3
30 36 176.5k29.4 18+3
33 41 196.1+49 2Ok5
36 46 245.2+ 49 25+5
42 55 294.2k 49 30+5
00-l0
FOREWORD ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal CatokzjD. Currerirating
number Number of Dia. of strandscross section Applicable circuit
strands (mm) (mm?
I
Prior-
ity
6
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point 0 gives the value when converting
from millimeters to inches. Therefore, 55 m-m = 2.165 inches.
0 1 2 3 4 5; 6 7 8 9
@- . .. .50
. . . . .. . . .. . .1.969
. . .. . . . . . . . . .2.008
. .. .. . . . . .. . ..2.047
. . . . . . . . .. .. . . .2.087
. . .. . .. . . . . . .2.126
. .. . . . . . . . . . lmi 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
00-l 2
FOREWORD CONVERSIONTABLE
Millimeters to inches
1 mm = 0.03937 in
1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 01827 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
I I I I I
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
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 03.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 25.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 47.71 149.91 152.12
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
00-13
FOREWORD CONVERSIONTABLE
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6:340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-14
FOREWORD CONVERSIONTABLE
kgm to ft. lb
1 kgm = 7.233 ft.lb
\“\ 0
0
1
7.2
2
14.5
3
21.7
4 5 6
43.4
7 8 9
65.1
0 28.9 36.2 50.6 57.9
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-l 5
Komatsu Engine 6d125 1 Workshop Manuals 1
Full download: http://manualplace.com/download/komatsu-engine-6d125-1-workshop-manuals-1/
FOREWORD CONVERSIONTABLE
kg/cm* to lb/in*
1 kg/cm* = 14.2233 lb/in2
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-l 6
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