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

Zitiervorschau

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