Komatsu 6D125 Diesel Engine Service Repair Manual PDF [PDF]

Citation preview

SEBE61500109



6Dl25 SERIES DIESEL ENGINE



0 1995KOMAl’&U All Rights Reserved IO-95(01)05501



No. of page



01



GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



01-001



11



STRUCTURE



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .



11-001



12



TESTING AND ADJUSTING



13



DISASSEMBLY



14



MAINTENANCE



15



REPAIR AND REPLACEMENT



AND FUNCTION



. . . . . . . ..I................................



AND ASSEMBLY



STANDARD



12-001



. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .



13-001



. .. .. ... .. . ... .. ... .. .. . ... .. .... . .... ...



14-001



OF PARTS . . . . . . . . . . . . . . . . . . . .



15-001



6D125



SERIES



SAFETY



SAFETY



NOTICE



SAFETY SAFETY



NOTICE



IMPORTANT



SAFETY



Proper



service



and



service



and repair



are both



manual.



injury



important



recommended



to workers,



the symbol



situation



actions



techniques



A.



these



arises



to deal



safe



machine



and described



require



should



in operation



the



with



arise, first



carefully



and



BEFORE operating



1. Before



carrying



out any greasing



2. When



given



to the machine.



carrying



out



wear



safety



shoes



loose



work



clothes,



any



or repairs,



operation,



and helmet.



always



parts with . Always



or clothes



3. If welding trained,



safety



with



buttons



glasses



when



hitting



a hammer.



wear



ing parts



safety



with



glasses



a grinder,



repairs



are needed,



experienced



when



grind-



etc. always



welder



carrying



out welding



wear



welding



gloves,



shield,



cap and other



clothes



have a



carry



When



out



the



work,



apron, suited



al-



hand



for weld-



ing work.



only



ing. Never



out



workers,



any operation



always



ating



procedure



before



form



your fellow



workers



step of the operation. UNDER



all tools way



with



two



on the oper-



starting. before



REPAIR signs



in the operator’s



the correct



agree



Before



Always starting



starting



inany



work,



on the controls



compartment. in good



condition



to use them.



repair



workshop



parts. Always



in their



correct



area clean



to keep



places.



and make



is no dirt or oil on the floor.



in the areas smoke



PREPARATIONS 7. Before block



provided



while



for smok-



working.



FOR WORK



adding the



8. Before



oil



and



learn



or tracks



work,



If this



is not



from



falling.



to lock all the control ing signs



the



other chine.



the



ripper,



possible,



to the



insert



to prevent



the



the work



In addition,



be sure



and hang warn-



Never



jump



support



jacks



or



stands



and



oil from



the



steps



or



used to get on and off the ma-



Always when



blocks,



work.



all mud



places



steps



steps,



blade,



or assembling,



with



starting



impossible



and



prevent



equipment



levers



disassembling



10. Remove



repairs,



on them.



machine



before



to



lower



work



pin or use blocks



equipment



any



moving.



starting



ground.



making



on hard, level ground,



wheels from



or



or any other



safety



9. When



carrying



or more



5. Keep



Smoke



bucket



ways



hang



parts



keep the work



machine



work.



4. When



and



Always



in the



park the machine wear



and



Do not wear



missing. . Always



care-



safety,



and removed



sure that there



on the decals



are fixed



consider



a place



the tools



Manual



the machine.



read all the precautions which



dangerous.



Maintenance



in this



be followed



the situation.



6. Decide



are extremely



Operation



specially



precautions



always



keep tools Read



The



in this manual



the use of tools



IS used to mark safety symbols



or may possibly



PRECAUTIONS



Mistakes



operation.



purpose.



accompanying



If any dangerous



for



by Komatsu



of these



for the specific



The cautions



take the necessary



GENERAL



is extremely



and safe. Some



by Komatsu



To prevent fully.



repair



techniques



effective



designed



NOTICE



use the handrails, getting



on or off the to provide



or



machine.



machine.



to use the handrails,



use a stand



ladders



on or off the



If it is



ladders



or



safe footing.



00-3



SAFETY



SAFETY



PRECAUTIONS



DURING



19. Be sure to assemble



WORK



original 11. When or



removing



hydraulic



loosen them spurting



the oil filler cap, drain plug pressure



slowly



measuring



to prevent



the oil from



disconnecting



or removing



of the oil, water



remove



the



pressure



or air circuits, completely



from



first the



and



oil in the



the engine



circuits



is stopped,



are



hot



so be careful



for the oil and water



carrying



out any work



to cool



before



on the oil or water



circuits.



20. When sure



installing that



ful when circuits.



high pressure



they



are



the battery. the negative



installing Also,



Always



remove



(-1 terminal



the lead from



check that



use a hoist



vibrate



aligning



Check that the wire rope, chains and hooks



fingers



caught



lifting



ample



capacity.



Install



the lifting



equipment



Use a hoist to prevent



ting any other



23. When



equipment



which



has



or crane



and



the component



operate hit-



part. Do not work with



any



removing



covers which



pressure



or under



always



leave two



bolts in position



are under in-



sides. Slowly



release the pres-



pressure



from



a



sure, then slowly loosen the bolts to remove. removing



to break wiring 17. When



components,



or damage



removing



be careful



the wiring.



may cause electrical piping,



not



Damaged



fires.



stop the fuel or oil



from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor



Fuel or oil



can cause you to slip, or can



even start fires. 18. As a general



.rule, do not use gasoline



to



wash



parts. In particular,



use only the mini-



mum



of gasoline



washing



parts.



00-4



when



or rotate at



careful to check



correctly.



Be careful



not to get your



in a hole.



measuring



hydraulic



pressure,



tool is correctly



bled before taking



any measurements.



electrical



removing



tracks of track-type When



removing



rates suddenly,



ternal



16. When



violently



that the measuring



24. Take care when



from



15. When



on opposite



When



check assem-



at the correct



part still raised by the hoist or crane.



spring,



parts, always torques.



two holes, never insert your



or hand.



are free from damage.



parts



parts such as guards,



be particularly



fingers



use



tightening



protective



or parts which



22. When



care-



connecting



or installing



use the specified



high speed,



Damaged



so be extremely



installed.



or crane.



Always



is be-



hoses, make



not twisted.



that they are installed



first.



14. When raising heavy components,



places.



be sure



by contact



tubes for high pressure



21 When assembling installing



13. Before starting work, remove the leads from



slowly



parts with new parts.



hoses and wires,



that they will not be damaged



are correctly



not to get burned. Wait



installing



tubes are dangerous,



water



when



Replace any damaged . When



ing operated.



compo-



circuit. 12. The



all parts again in their



places.



with other parts when the machine



out.



Before nents



plugs,



NOTICE



or installing



the



machines.



the track, the track



sepa-



so never let anyone stand at



either end of the track.



GENERAL



FOREWORD



FOREWORD GENERAL This



shop



manual



serviceman repairs effect



has



been



an accurate



prepared



understanding



and make judgements. at every



This shop service



manual



mainly



STRUCTURE



AND



of the product



the necessary



into the each



the



quality



and by showing



of repairs



by



giving



the



him the correct



way to perform



the contents



of this manual



and use it to full



information



for operations



technical



the manual main



group



is divided



performed



into the following



in a



chapters;



these



not only



to give



of components.



FUNCTION



explains



an understanding



the structure



of the structure,



and function



of each component.



but also serves



as reference



It serves



material



for troubleshooting.



AND ADJUSTING section



explains



adjustments



checks



to be made



Troubleshooting DISASSEMBLY This



contains



divided



This section



This



improve



Make sure you understand



For ease of understanding,



are further



TESTING



to



opportunity.



workshop.



chapters



as an aid



charts



to



be



made



at completion correlating



before



and



of the checks



“Problems”



after



performing



repairs,



as well



as



and repairs.



to “Causes”



are also included



in this section.



AND ASSEMBLY



section



assembling



explains



the



order



each component,



MAINTENANCE



to be followed



as well



when



as precautions



removing, to be taken



installing, for these



disassembling



or



operations.



STANDARD



This section



gives



the judgement



standards



when



inspecting



disassembled



parts.



NOTICE The



specifications



time



and



with



the



without latest



contained any



advance



in this notice.



shop Use



manual the



are



subject



specifications



to



change



given



in the



at any book



date.



00-5



HOW TO READ THE SHOP MANUAL



FOREWORD



HOW TO READ THE SHOP MANUAL VOLUMES



REVISED



Shop manuals are issued as a guide to carrying out repairs, They are divided as follows:



When



Chassis volume: Issued for every machine model Engine volume: issued for each engine series



pages.



Electrical volume: Attachments volume:



I



Each issued as one volume to cover all models



These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION



AND



UPDATING



Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.



EDITION



a manual



(a@@....)



MARK is revised,



is recorded



an edition



on the



bottom



mark of the



REVISIONS Revised VISED



pages PAGES



are shown next



to the



in the LIST OF REpage.



CONTENTS



SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.



FILING METHOD See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number. Example 1 (Chassis volume):



Item



A



Safety



Special safety precautions are necessary when performing the work.



Caution



Special technical precautions or other precautions for preserving standards are necessary when performing the work.



Weight



Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.



10 -3 Item number (IO. Structure and Function) Consecutive page number for each item. Example



*



~



2 (Engine volume):



12 - 5



‘T



Additional cated



pages:



by a hyphen



page number.



Additional



IO-4 10-4-I 1O-4-2 _._+ IO-5



torque



(-1 and number



Places to be coated with adhesives and lubricants, etc.



Oil, water



Places where oil, water or fuel must be added, and the capacity.



after the I



12-203 12-203-I pages -C12_203_2 12-204



Places where oil or water must be drained, and quan-



:



i-



Places that require special attention for the tightening torque during assembly.



Coat



%



File as in the example.



Added



I



&



pages are indi-



Example:



00-6



Tightening



Unit number (I. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.



Remarks



Symbol



Drain



tity to be drained.



HOISTING



FOREWORD



HOISTING



INSTRUCTIONS



INSTRUCTIONS



HOISTING Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.



Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part 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: I)



Check for removal



the part to the relative 2) Check for existence ing interference



the



part caus-



part to be re-



WIRE ROPES adequate



weight



ropes



L-i



u



88%



79%



71%



u 41% SAD00479



of another



with



100%



u



parts.



moved.



1) Use



L_



of all bolts fastening



depending



of parts to be hoisted,



on the



referring



to



3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.



the table below: 4)



Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter mm



load



KN



tons



9.8



1.0



11.2



13.7



1.4



12.5



15.7



1.6



14



21.6



2.2



16



27.5



2.8



be suspended.



18



35.3



3.6



KN (1000 kg) when two ropes make a 120”



20



43.1



4.4



10



*



Allowable



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, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load KN (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 KN (1000 kg) vertically, at various hanging angles.



22.4



54.9



5.6



30



98.1



10.0



40



176.5



18.0



50



274.6



28.0



60



392.2



40.0



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 of the hook.



portion



When two ropes sling a load vertically, to 19.6 KN (2000



hanging



kg) of total weight



This weight



angle.



becomes



On the other



ropes are subjected



up can 9.8



hand, two



to an excessive



force



as large as 39.2 KN (4000 kg) if they sling a 19.6 KN (2000 kg) load at a lifting angle of 150”.



0 6



_



&!



~~~~



30 Lifting



60 angle



90 (degree)



120



150 SAD00480



00-7



COATING



FOREWORD



COATING



MATERIALS



The recommended



Category



coating