Komatsu 125, 125E, 6D125 Series Diesel Engine Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu 125, 125E, 6D125 Series Diesel Engine, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu 125, 125E, 6D125 Series Diesel Engine workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,525 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBE61500109 - 6D125 Series Diesel Engine Shop Manual.pdf
SEBE61500111 - 6D125 Series Diesel Engine Shop Manual.pdf
SEBM006410 - 125-2 Series Diesel Engine Shop Manual.pdf
SEBM024208 - 125-3 Series Diesel Engine Shop Manual.pdf
SEN00177-14 - 125E-5 Series Diesel Engine Shop Manual.pdf
SEN05624-02 - 125E-6 Series Diesel Engine Shop Manual.pdf
MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...26
APPLICABLE MACHINE...27
SPECIFICATIONS...28
GENERAL ASSEMBLY DRAWING...38
ENGINE PERFORMANCE CURVE...57
WEIGHT TABLE...75
11 STRUCTURE AND FUNCTION...76
GENERAL STRUCTURE...77
INTAKE AND EXHAUST SYSTEM...79
INTAKE AND EXHAUST SYSTEM...79
AIR CLEANER...95
TURBOCHARGER...96
AFTERCOOLER...99
ENGINE BODY...101
CYLINDER HEAD...101
CYLINDER BLOCK...103
MAIN CIRCULATION PART ...105
TIMING GEAR...107
VALVE SYSTEM...109
FLYWHEEL AND FLYWHEEL HOUSING...111
LUBRICATION SYSTEM...115
LUBRICATION SYSTEM CHART...115
OIL PUMP...117
REGULATOR VALVE...119
OIL FILTER...120
BYPASS FILTER...121
OIL COOLER...122
FUEL SYSTEM...123
FUEL SYSTEM CHART...123
FUEL INJECTION PUMP...124
FUEL 2-STAGE SET CONTROL MOTOR MOUNT...130
ENGINE STOP MOTOR,2-STAGE SET CONTROL MOTOR...131
MAGNETIC SWITCH AND FUEL SOLENOID...136
BOOST COMPENSATOR...139
FUEL INJECTION NOZZLE...140
FUEL FILTER...141
COOLING SYSTEM...142
COOLING SYSTEM CHART...142
WATER PUMP...143
THERMOSTAT...145
CORROSION RESISTOR...146
FAN DRIVE...147
ELECTRICAL SYSTEM...151
ALTERNATOR...151
STARTING MOTOR...156
ELECTRICAL INTAKE AIR HEATER...158
ACCESSORY...160
AIR COMPRESSOR...160
12 TESTING AND ADJUSTING...162
ADJUSTING ENGINE SPEED SENSOR...164
ENGINE BODY...165
ADJUSTING VALVE CLEARANCE...165
MEASURING COMPRESSION PRESSURE...166
FUEL SYSTEM...167
TESTING AND ADJUSTING FUEL INJECTION TIMING...167
TESTING AND ADJUSTING FUEL CUT SOLENOID...173
ADJUSTING ENGINE STOP MOTOR LEVER...174
FUEL INJECTION PUMP CALIBRATION DATA...176
PERFORMANCE TEST...204
RUN-IN STANDARD...204
PERFORMANCE TEST CRITERIA...208
TROUBLESHOOTING...216
POINTS TO REMEMBER WHEN TROUBLESHOOTING...218
METHOD OF USING TROUBLESHOOTING CHART...219
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...223
S-2 ENGINE DOES NOT START...224
(1) ENGINE DOES NOT TURN...224
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)...225
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...226
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...227
S-4 ENGINE STOPS DURING OPERATIONS...228
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...229
S-6 ENGINE LACKS OUTPUT (NO POWER)...230
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...231
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...232
S-9 OIL BECOMES CONTAMINATED QUICKLY...233
S-10 FUEL CONSUMPTION IS EXCESSIVE...234
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...235
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...236
S-13 OIL LEVEL RISES...237
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...238
S-15 ABNORMAL NOISE IS MADE...239
S-16 VIBRATION IS EXCESSIVE...240
TESTING AND ADJUSTING TOOL LIST...241
TESTING AND ADJUSTING DATA...242
13 DISASSEMBLY AND ASSEMBLY...254
DISASSEMBLY...254
SPECIAL TOOL LIST...255
1.STARTING MOTOR ASSEMBLY...256
2.ENGINE OIL COOLER...256
3.RESETTING TO TOOL A1 (OVERHAUL STAND)...256
4.FAN...257
5.ENGINE MOUNTS...257
6.AIR CLEANER,BRACKET ASSEMBLY...257
7.TURBOCHARGER,EXHAUST MANIFOLD ASSEMBLY...258
8.CORROSION RESISTOR AND PIPING,WIRING...258
9.ENGINE OIL FILTER...258
10.LUBRICATION VALVE...259
11.FUEL FILTER ASSEMBLY...259
12.FUEL INJECTION PIPES...259
13.AFTERCOOLER ASSEMBLY...259
14.FUEL INJECTION PUMP...260
15.ALTERNATOR ASSEMBLY...260
16.THERMOSTAT HOUSING,WATER PUMP...261
17.FAN PULLEY,DRIVE ASSEMBLY...261
18.FRONT SUPPORT ...261
19.CRANKSHAFT PULLEY,VIBRATION DAMPER...262
20.AIR VENT TUBE,SPILL PIPE...262
21.HEAD COVERS...262
22.NOZZLE HOLDERS...262
23.ROCKER ARMS...263
24.CROSSHEADS...263
25.PUSH RODS...263
26.ROCKER ARM HOUSINGS...263
27.CYLINDER HEAD ASSEMBLIES...264
28.OIL PAN...264
29.FLYWHEEL...265
30.REAR SEAL...265
31.FLYWHEEL HOUSING...266
32.FRONT COVER...266
33.FUEL INJECTION PUMP DRIVE GEAR...266
34.CAM FOLLOWER COVERS...267
35.CAM FOLLOWERS...267
36.CAMSHAFT...267
37.OIL PUMP...268
38.IDLER GEAR...268
39.OIL SUCTION PIPE...268
40.PISTON AND CONNECTING ROD ASSEMBLY...269
41.CRANKSHAFT...270
42.PISTON COOLING NOZZLE...271
43.CYLINDER LINER...272
ASSEMBLY...273
1.CYLINDER LINER...275
2.PISTON COOLING NOZZLE...277
3.CRANKSHAFT...277
4.PISTON AND CONNECTING ROD ASSEMBLY...280
5.OIL SUCTION PIPE...285
6.IDLER GEAR...285
7.OIL PUMP...285
8.CAMSHAFT...286
9.CAM FOLLOWERS...286
10.CAM FOLLOWER COVERS...286
11.DRIVE GEAR OF FUEL INJECTION PUMP...287
12.FUEL INJECTION PUMP ASSEMBLY...288
13.ADJUSTING FUEL INJECTION TIMING...289
14.FRONT COVER...290
15.CRANKSHAFT PULLEY,VIBRATION DAMPER...290
16.FLYWHEEL HOUSING...290
17.REAR SEAL...292
18.FLYWHEEL...294
19.OIL PAN...296
20.CYLINDER HEAD ASSEMBLIES...296
21.ROCKER ARM HOUSINGS...298
22.PUSH RODS...298
23.CROSSHEADS...299
24.ROCKER ARMS...299
25.ADJUSTING VALVE CLEARANCE...300
26.NOZZLE HOLDERS...300
27.HEAD COVERS...301
28.SPILL PIPE,AIR VENT TUBE...301
29.PULLEY,FRONT SUPPORT...301
30.DRIVE SENSOR,TUBES,BRACKET...302
31.WATER PUMP,THERMOSTAT HOUSING...302
32.ALTERNATOR ASSEMBLY...303
33.ADJUSTING V-BELTS...303
34.AFTERCOOLER ASSEMBLY...303
35.FUEL INJECTION PUMP PIPING...304
36.LUBRICATION VALVE...304
37.ENGINE OIL FILTER...305
38.CORROSION RESISTOR...305
39.TURBOCHARGER,EXHAUST MANIFOLD ASSEMBLY...305
40.AIR CLEANER...306
41.ENGINE MOUNTS...306
42.FAN...307
43.RESETTING ENGINE IN ENGINE STAND...307
44.ENGINE OIL COOLER ASSEMBLY...307
45.STARTING MOTOR ASSEMBLY...307
?REFILLING WITH OIL...307
14 MAINTENANCE STANDARD...308
TURBOCHARGER...309
CYLINDER HEAD...311
VALVE AND VALVE GUIDE...312
ROCKER ARM SHAFT...314
CROSSHEAD...315
CYLINDER BLOCK...316
CYLINDER LINER...318
CRANKSHAFT...319
CAMSHAFT...320
CAM FOLLOWER AND PUSH ROD...321
TIMING GEAR...322
PISTON,PISTON RING AN PISTON PIN...323
CONNECTING ROD...327
VIBRATION DAMPER...328
FLYWHEEL AND FLYWHEEL HOUSING...329
WATER PUMP AND THERMOSTAT...330
OIL COOLER...331
OIL PUMP...332
MAIN RELIEF VALVE...333
REGULATOR VALVE AND SAFETY VALVE...334
AIR COMPRESSOR...335
15 REPAIR AND REPLACEMENT OF PARTS...336
REPLACING VALVE SEAT INSERTS...337
REPLACING NOZZLE HOLDER SLEEVE...341
REPLACING VALVE GUIDE...343
REPLACING CROSS HEAD GUIDE...343
GRINDING THE VALVE...344
GRINDING OF FITTING FACE OF CYLINDER HEAD...344
REPLACING CAM BUSHING...345
REPLACING CAM GEAR...347
REPLACING FLYWHEEL RING GEAR...347
PRESSURE TEST...348
REPLACING ENGINE REAR SEAL...349
REPLACING CONNECTING ROD SMALL END BUSHING...354
REPLACING MAIN BEARING CAP...355
GRINDING CRANKSHAFT...357
REPLACING WEAR SLEEVE (WHEN EQUIPPED WITH SLEEVE)...366
