This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the Komatsu 125-2 Series Diesel Engine 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.
APPLICABLE MODELS :
Engine : 6D125-2;
D53A-17, D53P-17, D58E-1, D58P-1
D65E-12, D70LE-12
D85A-21, D85A-21B, D85A-21D, D85A-21S
D85P-21, D85C-21
D85E-SS-2, D85E-SS-2A
D87E-2, D87P-2, LW250-5, CS210-1,
FD250-2, FD400-2, EG220BS-2, DCA-220SSK
Engine: S6D125-2;
D60P-12, D65P-12, D65EX-12, D65PX-12
D75S-5
Engine: SA6D125-2;
PC400-6C, PC400LC-6
HD255-5
WA470-3, WA450-3 (USA)
BR500JG-1, FD, 430-2, EG300BS-5
DCA300BS-5, DCA-300SPK, J6D125E-G1-2
Engine: SAA6D125-2;
PC400-6, PC450-6, PC400AC-6
BR550JG-1, SAA6D125-P400
TABLE OF CONTENTS :
01 GENERAL
-- APPLICABLE MACHINE
-- SPECIFICATIONS
-- GENERAL ASSEMBLY DRAWING
-- ENGINE PERFORMANCE CURVE
-- WEIGHT TABLE
11 STRUCTURE AND FUNCTION
-- GENERAL STRUCTURE
-- INTAKE AND EXHAUST SYSTEM
-- ENGINE BODY
-- LUBRICATION SYSTEM
-- FUEL SYSTEM
-- COOLING SYSTEM
-- ELECTRICAL SYSTEM
-- ACCESSORY
12 TESTING AND ADJUSTING
-- ADJUSTING ENGINE SPEED SENSOR
-- ENGINE BODY
-- FUEL SYSTEM
-- PERFORMANCE TEST
-- TROUBLESHOOTING
-- TESTING AND ADJUSTING TOOL LIST
-- TESTING AND ADJUSTING DATA
13 DISASSEMBLY AND ASSEMBLY
-- DISASSEMBLY
-- 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
-- TIMING GEAR
-- PISTON,PISTON RING AN PISTON PIN
-- CONNECTING ROD
-- VIBRATION DAMPER
-- FLYWHEEL AND FLYWHEEL HOUSING
-- 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
-- GRINDING OF FITTING FACE OF CYLINDER HEAD
-- REPLACING CAM BUSHING
-- REPLACING CAM GEAR
-- REPLACING FLYWHEEL RING GEAR
-- PRESSURE TEST
-- REPLACING ENGINE REAR SEAL
-- REPLACING CONNECTING ROD SMALL END BUSHING
-- REPLACING MAIN BEARING CAP
-- GRINDING CRANKSHAFT
-- REPLACING WEAR SLEEVE (WHEN EQUIPPED WITH SLEEVE)
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM006410
Total Pages : 399
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Completly bookmarked and complete searcheble so you can easily find what you are looking for. This is the same Repair Service manual your local dealer will use when doing a repair. These are real files not scans. Complete Manuals in PDF format
This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.
Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.
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COVER
CONTENTS
SAFETY
FORWARD
01 GENERAL
APPLICABLE MACHINE
SPECIFICATIONS
GENERAL ASSEMBLY DRAWING
ENGINE PERFORMANCE CURVE
WEIGHT TABLE
11 STRUCTURE AND FUNCTION
GENERAL STRUCTURE
INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM
AIR CLEANER
TURBOCHARGER
AFTERCOOLER
ENGINE BODY
CYLINDER HEAD
CYLINDER BLOCK
MAIN CIRCULATION PART
TIMING GEAR
VALVE SYSTEM
FLYWHEEL AND FLYWHEEL HOUSING
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART
OIL PUMP
REGULATOR VALVE
OIL FILTER
BYPASS FILTER
OIL COOLER
FUEL SYSTEM
FUEL SYSTEM CHART
FUEL INJECTION PUMP
BOOST COMPENSATOR
FUEL INJECTION NOZZLE
FUEL FILTER
MAGNETIC SWITCH (FUEL CUT SOLENOID)
FUEL 2-STAGE SET CONTROL MOTOR MOUNT
ENGINE STOP MOTOR, 2-STAGE SET CONTROL MOTOR
COOLING SYSTEM
COOLING SYSTEM CHART
WATER PUMP
THERMOSTAT
CORROSION RESISTOR
FAN DRIVE
ELECTRICAL SYSTEM
ALTERNATOR
STARTING MOTOR
ELECTRICAL INTAKE AIR HEATER
ACCESSORY
AIR COMPRESSOR
12 TESTING AND ADJUSTING
ADJUSTING ENGINE SPEED SENSOR
ENGINE BODY
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
FUEL SYSTEM
CHECKING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL CUT SOLENOID
ADJUSTING ENGINE STOP MOTOR LEVER
FUEL INJECTION PUMP CALIBRATION DATA
PERFORMANCE TEST
RUN-IN STANDARD
PERFORMANCE TEST CRITERIA
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
(1) ENGINE DOES NOT TURN
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)
(3) EXHAUST 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 (HUNTING)
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)
S-13 OIL LEVEL RISES
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING DATA
13 DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
SPECIAL TOOL LIST
1. STARTING MOTOR ASSEMBLY
2. STARTING MOTOR ASSEMBLY
3. SETTING TO ENGINE OVERHAUL STAND
4. FAN
5. ENGINE MOUNTS
6. AIR CLEANER, BRACKET ASSEMBLY
7. TURBOCHARGER, EXHAUST MANIFOLD ASSEMBLY
8. CORROSION RESISTOR AND PIPING WIRING
9. ENGINE OIL FILTER
10. LUBRICATION VALVE
11. FUEL FILTER
12. FUEL INJECTION PIPES
13. AFTERCOOLER ASSEMBLY
14. FUEL INJECTION PUMP ASSEMBLY
15. ALTERNATOR ASSEMBLY
16. THERMOSTAT HOUSING, WATER PUMP
17. FAN PULLEY, DRIVE ASSEMBLY
18. FRONT SUPPORT
19. CRANKSHAFT PULLEY, VIBRATION DAMPER
20. AIR VENT TUBE, SPILL PIPE
21. HEAD COVERS
22. NOZZLE HOLDERS
23. ROCKER ARMS
24. CROSSHEADS
25. PUSH RODS
26. ROCKER ARM HOUSINGS
27. CYLINDER HEAD ASSEMBLIES
28. OIL PAN
29. FLYWHEEL
30. REAR SEAL
31. FLYWHEEL HOUSING
32. FRONT COVER
33. FUEL INJECTION PUMP DRIVE GEAR
34. CAM FOLLOWER COVERS
35. CAM FOLLOWERS
36. CAMSHAFT
37. OIL PUMP
38. IDLER GEAR
39. OIL SUCTION PIPE
40. PISTON, CONNECTING ROD ASSEMBLY
41. CRANKSHAFT
42. PISTON COOLING NOZZLE
43. CYLINDER LINER
ASSEMBLY
1. CYLINDER LINER
2. PISTON COOLING NOZZLE
3. CRANKSHAFT
4. PISTON AND CONNECTING ROD ASSEMBLY
5. OIL SUCTION PIPE
6. IDLER GEAR
7. OIL PUMP
8. CAMSHAFT
9. CAM FOLLOWERS
10. CAM FOLLOWERS COVERS
11. FUEL PUMP DRIVE GEAR
12. FUEL INJECTION PUMP ASSEMBLY
13. ADJUSTING FUEL INJECTION TIMING
14. FRONT COVER
15. CRANKSHAFT PULLEY, VIBRATION DAMPER
16. FLYWHEEL HOUSING
17. REAR SEAL
18. FLYWHEEL
19. OIL PAN
20. CYLINDER HEAD ASSEMBLIES
21. ROCKER ARM HOUSINGS
22. PUSH RODS
23. CROSSHEADS
24. ROCKER ARMS
25. ADJUSTING VALVE CLEARANCE
26. NOZZLE HOLDERS
27. HEAD COVERS
28. SPILL PIPE, AIR VENT TUBE
29. PULLEY, FRONT SUPPORT
30. DRIVE SENSOR, TUBES, BRACKET
31. THERMOSTAT HOUSING, WATER PUMP
32. ALTERNATOR ASSEMBLY
33. ADJUSTING V-BELTS
34. AFTERCOOLER ASSEMBLY
35. FUEL INJECTION PUMP PIPES
36. LUBRICATION VALVE
37. ENGINE OIL FILTER
38. CORROSION RESISTOR AND PIPING, WIRING
39. TURBOCHARGER, EXHAUST MANIFOLD ASSEMBLY
40. AIR CLEANER, BRACKET ASSEMBLY
41. ENGINE MOUNTS
42. FAN
43. MOVING TO ENGINE OVERHAUL STAND
44. ENGINE OIL COOLER ASSEMBLY
45. STARTING MOTOR ASSEMBLY
FILLING WITH OIL
14 MAINTENANCE STANDARD
INTAKE AND EXHAUST SYSTEM
TURBOCHARGER
ENGINE BODY
CYLINDER HEAD
VALVE AND VALVE GUIDE
ROCKER ARM SHAFT
CROSSHEAD
CYLINDER BLOCK
CYLINDER LINER
CRANKSHAFT
CAMSHAFT
CAM FOLLOWER AND PUSH ROD
TIMING GEAR
PISTON, PISTON RING AND PISTON PIN
CONNECTING ROD
VIBRATION DAMPER
FLYWHEEL AND FLYWHEEL HOUSING
COOLING SYSTEM
WATER PUMP AND THERMOSTAT
OIL COOLER
LUBRICATION SYSTEM
OIL PUMP
MAIN RELIEF VALVE
REGULATOR VALVE AND SAFETY VALVE
ACCESSORY
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
GRINDING OF FITTING FACE OF CYLINDER HEAD
REPLACING CAM BUSHING
REPLACING CAM GEAR
REPLACING FLYWHEEL RING GEAR
PRESSURE TEST
REPLACING ENGINE REAR SEAL
REPLACING CONNECTING ROD SMALL END BUSHING
REPLACING MAIN BEARING CAP
GRINDING CRANKSHAFT
REPLACING WEAR SLEEVE (WHEN EQUIPPED WITH SLEEVE)
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