Komatsu 6D105 Series Diesel Engine Service Repair Manual

6D105-1 EG80-1
6D105-1 EG805-1
6D105-1 D40A P-3 (Engine No

10001-49999)
6D105-1 D40A P-3 (Engine No 50001-)
6D105-1 D41A P-3 (Engine No 10001-49999)
6D105-1 D41A P-3 (Engine No 50001-)
6D105-1 D41S Q-3 (Engine No 10001-49999)
6D105-1 D41S Q-3 (Engine No

50001-)
6D105-1 W70-2 W70-3

6D105-1 GD405A-1
6D105-1 PC150-1 PC150LC-1
6D105-1 PC200-1
6D105-1 PC200-2 PC200LC-2
6D105-1 W60 W60-2
6D105-1 WA200-1

S6D105-1E W90-2 W90-3
S6D105-1 WA300-1 WA320-1
S6D105-1B EG100-2
560105-1C EG100S-2
560105-1 EG125-1 EG125S-1
S6D105-B-1 PC200-3 PC200LC-3
S6D105-1 PC220-1
S6D105-1 PC220-2 PC220LC-2
S6D105-1 PC220-3 PC220LC-3
S6D105-1 GD500R-2 GD505A-2 GD505R-2

S6D105-1 LW160-1 (Engine No

50001 )
S6D105-1 LW160-1 LW200-1 LW200L-1
S6D105-1 EC170Z-1
S6D105-1 EC170ZS-1
S6D105-1 JV100A-1

S6D105-1 GD611A-1
S6D105-1 GD661A-1
S6D105-1 GD521A-1 GD521R-1 GD523A-1

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Manual Contents:

01 GENERAL
-GENERAL VIEW
-SPECIFICATIONS
-ASSEMBLY DRAWING
-WEIGHT TABLE
-PERFORMANCE CURVE
11 STRUCTURE AND FUNCTION
-GENERAL STRUCTURE
-INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM CHART
TURBOCHARGER
-ENGINE BODY
CYLINDER HEAD
MAIN CIRCULATION PART (1/3)
MAIN CIRCULATION PART (2/3)
MAIN CIRCULATION PART (3/3)
-LUBRICATING SYSTEM
LUBRICATING SYSTEM CHART
OIL PUMP
REGULATOR VALVE
OIL FILTER
OIL COOLER
-FUEL SYSTEM
FUEL SYSTEM CHART
FOR CONSTRUCTION EQUIPMENT
FOR GENERATOR
FUEL INJECTION PUMP
GOVERNOR
FEED PUMP
FUEL INJECTION NOZZLE
FUEL FILTER
FUEL CUT SOLENOID
-COOLING SYSTEM
COOLING SYSTEM CHART
WATER PUMP
THERMOSTAT
CORROSION RESISTOR
-ELECTRICAL SYSTEM
WIRING DIAGRAM
ALTERNATOR
STARTING MOTOR
SENSOR
-ACCESSORY
AIR COMPRESSOR
12 TESTING AND ADJUSTING
-GENERAL OF TESTING AND ADJUSTING
MEASURING ENGINE SPEED
CRANKING METHOD
-INTAKE AND EXHAUST SYSTEM
CHECKING INTAKE AND EXHAUST SYSTEM
ADJUSTING VALVE CLEARANCE
MEASURING EXHAUST COLOR (BOSCH TYPE)
-ENGINE BODY
MEASURING BLOW-BY
MEASURING COMPRESSION PRESSURE
CLEANING BREATHER ELEMENT
-LUBRICATING SYSTEM
CHECKING LUBRICATING SYSTEM
REPLACEMENT AND CLEANING OF LUBRICATING SYSTEM
MEASURING OIL CONSUMPTION
-FUEL SYSTEM
CHECKING FUEL SYSTEM
REPLACEMENT AND CLEANING OF COMPONENTS OF FUEL SYSTEM
CHECKING FUEL INJECTION PUMP
CHECKING AND ADJUSTMENT OF FUEL INJECTION NOZZLE
TESTING AND ADJUSTING FUEL INJECTION TIMING
ADJUSTING FUEL CUT SOLENOID (FOR WA300-1)
CALIBRATION DATA
-COOLING SYSTEM
CHECKING COOLING SYSTEM
REPLACEMENT AND CLEANING OF COMPONENTS OF COOLING SYSTEM
CHECKING THERMOSTAT FUNCTION
CHECKING AND ADJUSTMENT OF V-BELT TENSION AND REPLACEMENT OF V-BELT
-PERFORMANCE TEST
TESTING METHOD OF PERFORMANCE
RUN-IN CRITERIA
PERFORMANCE TEST CRITERIA
-TROUBLESHOOTING
TESTING AND ADJUSTING DATA
TESTING AND ADJUSTING TOOL LIST
METHOD OF READING TROUBLESHOOTING TABLE
TROUBLESHOOTING TABLE
1

STARTING DEFECTIVE OR BADNESS
2 ENGINE STOPPED DURING OPERATION
3 ENGINE RUNS ABNORMALLY
4 FUEL CONSUMPTION TOO HIGH
5 LACK OF POWER
6 EXHAUST GAS IS BLACK
7 EXHAUST GAS IS BLUE
8

OIL CONSUMPTION TOO HIGH
9 OIL LEVEL RISES
10 OL QUICKLY BECOMES DIRTY
11 ENGINE OIL PRESSURE GAUGE INDICATOR FLUCTUATES ABNORMALLY
12 LACK OF OIL PRESSURE
13 OIL IN COOLING SYSTEM
14

WATER TEMPERATURE DOES NOT RISE
15 WATER TEMPERATURE RISES EXCESSIVELY
16 TOO MUCH VIBRATION
17 ABNORMAL NOISE EMITTED
18 EXCESSIVE WEAR OF ENGINE PARTS
19 ENGINE DOES NOT START BECAUSE OF FAULT IN ELECTRICAL SYSTEM
20

BATTERY DOES NOT CHARGE
13 DISASSEMBLY AND ASSEMBLY
-GENERAL
DISASSEMBLY
ASSEMBLY
-DISASSEMBLY AND ASSEMBLY OF ACCESSORIES
TURBOCHARGER
OIL PUMP
WATER PUMP
14 MAINTENANCE STANDARD
-INTAKE AND EXHAUST SYSTEM
TURBOCHARGER
-ENGINE BODY
CYLINDER HEAD
VALVES AND VALVE GUIDES
ROCKER ARM SHAFT PUSH-ROD AND TAPPET
CYLINDER BLOCK
CYLINDER LINER
CRANKSHAFT
CAMSHAFT
TIMING GEAR
PISTON PISTON RING PISTON PIN
CONNECTING ROD
FLYWHEEL AND FLYWHEEL HOUSING
-LUBRICATING SYSTEM
OIL PUMP
-COOLING SYSTEM
WATER PUMP THERMOSTAT