Componentes de Motor

SEBM040401
Component of
engine
Applicable component
Turbocharger
Air compressor
Oil pump
EGR oil pump
Fuel injection pump
Fuel injection pump governor
Fuel supply pump (Common rail type)
Fuel pump
Water pump
© 2008
All Rights Reserved 00-1
Printed in Japan 02-08 (02) (11)
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions must be taken to these pages according to Q Page to be newly added Add
the list below.
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES

Revision Revision
Mark Pages Mark Pages
number number
q 00-1 (11)
q 00-2 (11)
q Turbocharger SEBM041000 (11)
q Air compressor SEBM041100 (11)
Oil pump SEBM040600
EGR oil pump SEBM040500
Fuel injection pump
PE(S) • A type SEBM002000
PE(S) • P type SEBM004300
KFE type SEBM012702
Fuel injection pump governor
RSV SEBM002100
RSUV(D) • Z SEBM004400
q Fuel supply pump
(Common rail type) SEBM024002 (11)
Water pump SEBM026200
Fuel pump SEBM026400
00-2 Component of engine

(11)
Foreword Safety notice
Safety notice 1 (Rev. 2007/03)
Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w eld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
Component of engine 00-3

3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot th a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When la r l y c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.

4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.

8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".

Foreword How to read the shop manual
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
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 main-
tenance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjust-
ments 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.
2. Revision and distribution

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

Foreword How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.

Foreword Explanation of terms for maintenance standard
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0

Foreword Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.

Foreword Handling of electric equipment and hydraulic component
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.

3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.

2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.

3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks

4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter from th e c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.

4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.

Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.

Foreword Handling of connectors newly used for engines
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 107 – 170, 12V140 engine
q 107E-1 q Various temperature sensors
q 114E-3 Example)
q 125E-5 Intake air temperature sensor in
q 140E-5 intake manifold: TIM
q 170E-5 Fuel temperature sensor: TFUEL
q 12V140E-3 Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
1. Slide lock type etc.
(FRAMATOME-3, FRAMATOME-2) Disconnect the connector by pulling lock
q 107 – 170, 12V140 engines (B) (on the wiring harness side) of connec-
q Various pressure sensors and NE tor (2) outward.
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.

3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.

Foreword How to read electric wire code
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene

2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.

3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –

Foreword Precautions when carrying out operation
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.

4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.

Foreword Method of disassembling and connecting push-pull type coupler
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.

Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-

Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-

Foreword Coating materials list
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.

Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention com-

prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.

Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)

Foreword Standard tightening torque table
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B

2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92

Foreword Conversion table
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

SEBM041000
Turbocharger
Turbocharger model
KTR100
KTR110
KTR130
KTR150
© 2008
Contents
00 Introduction ............................................................................................................ 00-011
01 General ....................................................................................................................... 01-001
11 Structure and function ................................................................................... 11-001
13 Disassembly and assembly ....................................................................... 13-001
14 Maintenance standard and inspection of parts......................... 14-001
00-002 Turbocharger
(11)
actions be taken to these pages according to the Q Page to be newly added Add
table below.
Pages having no marks are those previously revised

or made additions.

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
q 00-001 (11)
q 00-002 (11)
q 00-003 (11)
00-011
01-001
01-002
11-001
11-002
11-003
11-004
11-005
11-006
13-001
13-002
13-004 (1)
13-005 (1)
13-006 (1)
13-007 (1)
13-008 (1)
13-009 (1)
13-010 (1)
13-011 (1)
13-012 (1)
14-001
14-002
14-003
14-004
14-005
14-006
14-007
14-008
14-009
Turbocharger 00-003
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SEBM040600
Oil pump
© 2007
Printed in Japan 04-07 (02)
Contents
00-002 Oil pump

13 Disassembly and assembly
125E-5 Series
Disassembly ........................................... 13-002
Assembly ................................................ 13-002
140E-5 Series
Disassembly ........................................... 13-003
Assembly ................................................ 13-004
Oil pump 13-001

Disassembly and assembly 125E-5 Series
Disassembly and assembly Assembly

(Main valve)
125E-5 Series 1. Put spring (3) and valve (4) to body (1).
Disassembly
(Main valve)
1. Remove plug (2) from body (1).
2. Connect plug (2) to body (1).

a Coat plug (2) and thread of body (1) with ad-
hesive.
2 Plug (2) and thread of body (1):
2. Pull spring (3) and valve (4) out of body (1). Adhesive (Loctite#262)
3 Plug (2): 49 ± 7.8 Nm {5 ± 0.8 kgm}
(Inner parts)
This oil pump is supplied only as whole oil pump
assembly except above three parts.
So disassembly and assembly instruction is not
shown for inner parts.
13-002 Oil pump

Disassembly and assembly 4. Disassembly of main relief valve

1) Remove main relief valve plug (7) from body
(3).
140E-5 Series
Disassembly
1. Remove 4 pieces of cover mounting bolts (1)
and remove cover assembly (2) from body (3).
2) Remove spring (8) and valve (9) from body

(3).
2. Remove driven gear (4) from body (3).
3. Push shaft (5) of drive gear down with a press

and pull it from pump drive gear (6).
5. Disassembly of sub relief valve

1) Remove sub relief valve plug (10) from cover
assembly (2).
Oil pump 13-003

2) Remove spring (11) and valve (12) from Assembly

cover assembly (2). a Coat the both side of gear and sliding surface
of inner races with engine oil (SAE#30).
1. Assembly of main relief valve

a Replace bushing with new one, when there
are any damage inside of the bushing.
1) Install valve (9) and spring (8) to body (3).
2) Tighten the main relief valve plug (7) to body

(3).
3 Main relief valve pllug:
88.2 ± 9.8 Nm {9 ± 1 kgm}
13-004 Oil pump

2. Shrink fit pump drive gear (6) to shaft (5) of drive 2) Fit O-ring to plug (10) and coat cover and
gear. thread of plug with adhesive, then install the
a Shrink-fit temperature: 180 – 220°C plug (10) to cover (2).
a Fit the pump drive gear (6) until its surface is 2 Cover and thread of plug:
flush with the shaft (5) end of drive gear. Adhesive (Loctite#262)
3 Plug: 49 ± 7.8 Nm {5 ± 0.8 kgm}
3. Install drive gear (4) to body assembly (3).

5. Install cover (2) to body assembly (3).
3 Cover mounting bolt:
23.5 ± 4.7 Nm {2.4 ± 0.48 kgm}
4. Assembly of sub relief valve

1) Put spring (11) and valve (12) to cover
assembly (2).
Oil pump 13-005

SEBM040500
EGR oil pump
© 2007
Printed in Japan 04-07 (02)
Contents
00-002 EGR oil pump

125E-5 Series
Disassembly ........................................... 13-002
Assembly ................................................ 13-003
140E-5 Series
Disassembly ........................................... 13-004
Assembly ................................................ 13-005
170E-5 Series
Disassembly ........................................... 13-007
Assembly ................................................ 13-008
EGR oil pump 13-001

Disassembly and assembly 4. Disassembly of cover assembly

1) Remove relief valve plug (7) from cover
assembly (2).
125E-5 Series
k Spring force of relief valve spring is
Disassembly very strong, so pay attention when
1. Remove 3 pieces of cover mounting bolts (1) loosen plug (7) last 3 or 4 turn.
and remove cover assembly (2) from body
assembly (3).
2) Remove spring (8) and valve (9) from cover

assembly (2).
2. Remove driven gear (4) from case (3).

13-002 EGR oil pump

Assembly 2) Fit O-ring to plug (7) and install it to cover

a Coat the both side of gear and sliding surface (2).
of inner races with engine oil (SAE#30). 3 Plug: 88 ± 10 Nm {9 ± 1 kgm}
1. Shrink fit pump drive gear (6) to shaft (5) of drive

gear.
a Shrink-fit temperature: 180 – 220°C
a Fit the pump drive gear (6) until its surface is
flush with the shaft (5) end of drive gear.
3. Assemble driven gear (4) and O-ring to body (3).
2. Assembly of cover assembly

1) Put spring (8) and valve (9) to cover (2).
4. Assemble cover assemble (2) to body assembly

(3) with 3 pieces of mounting bolts (1).
3 Mounting bolt: 20 ± 2.0 Nm {2 ± 0.2 kgm}
EGR oil pump 13-003

Disassembly and assembly 4. Disassembly of sub relief valve

1) Remove sub relief valve plug (7) from body
assembly (3).
140E-5 Series
Disassembly
1. Remove 3 pieces of cover mounting bolts (1)
assembly (3).
2) Remove spring (8) and valve (9) from body

assembly (3).
2. Remove driven gear (4) from body assembly (3).

13-004 EGR oil pump

5. Disassembly of cover assembly Assembly

1) Remove main relief valve plug (10) from a Coat the both side of gear and sliding surface
cover assembly (2). of inner races with engine oil (SAE#30).
very strong, so pay attention when 1. Assembly of sub relief valve
loosen plug (7) last 3 or 4 turn. 1) Put valve (9) and spring (8) to body assem-
bly (3).
2) Remove spring (11) and valve (12) from

cover assembly (2). 2) Tighten sub plug (7) to body (3).
3 Plug: 24.5 ± 4.9 Nm {2.5 ± 0.5 kgm}
EGR oil pump 13-005

2. Shrink fit pump drive gear (6) to shaft (5) of drive 2) Fit O-ring to plug (10) and tighten it to cover
gear. (2).
a Shrink-fit temperature: 180 – 220°C 3 Plug: 88 ± 10 Nm {9 ± 1 kgm}
5. Assemble cover assemble (2) to body assembly

3. Install driven gear (4) to body (3). 3 Mounting bolt: 20 ± 2.0 Nm {2 ± 0.2 kgm}

1) Put spring (11) and valve (12) to cover (2).
13-006 EGR oil pump

Disassembly and assembly 4. Disassembly of cover assembly

1) Remove relief valve plug (7) from cover
assembly (2).
170E-5 Series
Disassembly very strong, so pay attention when
1. Remove 3 pieces of cover mounting bolts (1) loosen plug (7) last 3 or 4 turn.
assembly (3).
2) Remove spring (8) and valve (9) from cover

assembly (2).
2. Remove driven gear (4) from body assembly (3).

EGR oil pump 13-007

Assembly 2) Fit O-ring to plug (7) and install it to cover

a Coat the both side of gear and sliding surface (2).
of inner races with engine oil (SAE#30). 3 Plug: 88 ± 10 Nm {9 ± 1 kgm}
1. Shrink fit pump drive gear (6) to shaft (5) of drive

gear.
a Shrink-fit temperature: 180 – 220°C
3. Assemble driven gear (4) and O-ring (10), (11) to

body assembly.

1) Put valve (9) and spring (8) to cover (2).
4. Assemble cover assembly (2) to body assembly

3 Mounting bolt:
20 ± 2.0 Nm {2 ± 0.2 kgm}
13-008 EGR oil pump

SEBM024002
Fuel supply pump

(Common rail type)
Fuel supply pump model
DENSO CRI type
© 2008
Contents
14 Performance test ................................................................................................ 14-001
00-002 Fuel supply pump

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actions be taken to these pages according to the Q Page to be newly added Add
table below.
Pages having no marks are those previously revised

or made additions.

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
q 00-001 (11) Q 13-038 (11)
q 00-002 (11) Q 13-039 (11)
q 00-003 (11) Q 13-040 (11)
Q 13-041 (11)
q 13-001 (11) Q 13-042 (11)
q 13-002 (11) Q 13-043 (11)
q 13-003 (11)
q 13-004 (11) q 14-001 (11)
q 13-005 (11) q 14-002 (11)
q 13-006 (11) q 14-003 (11)
q 13-007 (11) q 14-004 (11)
q 13-008 (11) q 14-005 (11)
q 13-009 (11) q 14-006 (11)
q 13-010 (11) q 14-007 (11)
q 13-011 (11) q 14-008 (11)
q 13-012 (11) q 14-009 (11)
q 13-013 (11) q 14-010 (11)
q 13-014 (11) q 14-011 (11)
q 13-015 (11) q 14-012 (11)
q 13-016 (11) Q 14-013 (11)
q 13-017 (11) Q 14-014 (11)
q 13-018 (11) Q 14-015 (11)
q 13-019 (11) Q 14-016 (11)
q 13-020 (11) Q 14-017 (11)
q 13-021 (11) Q 14-018 (11)
q 13-022 (11)
q 13-023 (11)
q 13-024 (11)
q 13-025 (11)
Q 13-026 (11)
Q 13-027 (11)
Q 13-028 (11)
Q 13-029 (11)
Q 13-030 (11)
Q 13-031 (11)
Q 13-032 (11)
Q 13-033 (11)
Q 13-034 (11)
Q 13-035 (11)
Q 13-036 (11)
Q 13-037 (11)
Fuel supply pump 00-003

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Applicable engine: 6D125-3, 6D140-3

Special tools list ...................................... 13-002
Consumable parts list ............................. 13-003
Sketches of special tools ........................ 13-004
Disassembly and assembly of
fuel supply pump..................................... 13-006
Applicable engine: 6D125-5, 6D140-5, 6D170-5,

12V140-3
Special tools list ...................................... 13-021
Component part drawing ........................ 13-022
Disassembly and assembly of
fuel supply pump..................................... 13-030

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Disassembly and assembly Special tools list
Special tools list

Applicable pump part No.
Pump category No. Komatsu part No. Denso part No. Engine
1 6156-71-1110 094000-0380 6D125-3
2 6218-71-1110 094000-0341 6D140-3
a In the following explanation, the fuel supply pump specifications are indicated by the pump category Nos. in
the above table.
Pump category
Pump category
No. 1
No. 2
Q’ty
Symbol Part No. Part name Nature of work, remarks
1 799-609-1010 Puller, PCV 1 Q Q

2 799-609-1020 Mounting, PCV 1 Q Q
A Removal, installation of PCV assembly
3 Purchased Socket, B = 42 mm 1 Q Q
4 Purchased Deep socket, B = 22 mm 1 Q Q
1 799-609-1030 Extractor 1 Q Q
B 799-609-1040 Holding spanner 1 Q Removal, installation of upper spring seat
2
799-609-1050 Holding spanner 1 Q
C 799-609-1310 Pliers 1 Q Q Removal, installation of feed pump
1 799-609-1320 Puller 1 Q Q
2 799-609-1330 Hook set 1 Q Q Removal of bearing outer race
3 799-609-1060 Base (ø100) 1 Q Q
D 799-609-1070 Support (ø31) 1 Q
4 799-609-1080 Support (ø37) 1 Q Removal of bearing inner race
799-609-1090 Support (ø39) 1 Q
5 799-609-1110 Wear ring stopper 1 Q Q Installation of wear ring
1 799-609-1120 Handle 1 Q Q
2 799-609-1130 Adapter 1 Q Q
799-609-1140 Replacer (ø34) 1 Q
3
799-609-1150 Replacer (ø43) 1 Q
799-609-1160 Replacer (ø52) 1 Q
4
799-609-1170 Replacer (ø60) 1 Q
E 799-609-1180 Replacer (ø61) 1 Q Removal, installation of bearing
5
799-609-1190 Replacer (ø71) 1 Q
6 799-609-1210 Replacer (ø81) 1 Q Q
799-609-1220 Base housing (ø62) 1 Q
7
799-609-1230 Base housing (ø72) 1 Q
8 799-609-1260 Pipe (ø30) 1 Q Q
9 799-609-1270 Guide pin 1 Q Q
1 799-609-1240 Oil seal presser 1 Q Q
F Installation of oil seal
2 799-609-1250 Oil seal guide 1 Q Q
799-609-1340 Guide rail, nut (ø25) 1 Q
1
799-609-1440 Guide rail, nut (ø30) 1 Q
G Installation of camshaft
799-609-1450 Cam clearance measure (ø25) 1 Q
2
1 799-609-1280 Depth measure 1 Q Q
H Installation of G sensor
2 799-609-1290 Sensor measure 1 Q Q
1 Purchased Slide calipers 1 Q Q
2 Purchased Hexagon wrench 1 Q Q B = 3 mm, 5 mm
3 Purchased Tweezers 1 Q Q L = 100 mm, 150 mm
I
4 Purchased Torque wrench 1 Q Q Preset type
5 Purchased Dial gauge 1 Q Q Accuracy: 0.01 mm
6 Purchased Gasket sealant 1 Q Q LG-6

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Disassembly and assembly Consumable parts list
Consumable parts list
Pump category
Pump category
No. 1
No. 2
Q’ty
No. Part No. Part name Remarks
1 ND094086-0210 O-ring 1 Q Q
2 ND094086-0090 O-ring 2 Q Q
3 ND094137-0010 Gasket 2 Q Q
4 ND094086-0100 O-ring 6 Q Q
5 ND949150-3030 Seal 1 Q
6 ND949150-3200 Seal 1 Q
7 ND094086-0120 O-ring 1 Q
8 ND094086-0150 O-ring 1 Q
9 ND094095-0100 Shim 1 Q T = 0.05
10 ND094095-0130 Shim 1 Q T = 0.1
11 ND094095-0140 Shim 1 Q T = 0.2
12 ND094095-0150 Shim 1 Q T = 0.3
13 ND094095-0160 Shim 1 Q T = 0.5
14 ND094095-0330 Shim 1 Q T = 0.05
15 ND094095-0340 Shim 1 Q T = 0.1
16 ND094095-0350 Shim 1 Q T = 0.2
17 ND094095-0360 Shim 1 Q T = 0.3
18 ND094095-0370 Shim 1 Q T = 0.5
19 ND094086-0110 O-ring 1 Q
20 ND094086-0160 O-ring 1 Q
21 ND094086-0130 O-ring 1 Q
22 ND094086-0170 O-ring 1 Q
23 ND949140-6310 O-ring 1 Q Q
24 ND094096-0050 Shim 1 Q Q T = 0.15
25 ND094096-0060 Shim 1 Q Q T = 0.20
26 ND094096-0070 Shim 1 Q Q T = 0.25
27 ND094096-0080 Shim 1 Q Q T = 0.40
28 ND090222-0070 Washer 5 Q Q
29 ND090222-0120 Washer 2 Q Q
30 ND095331-0020 Stopper 2 Q Q
31 ND090207-0100 Ring 1 Q Q
32 ND094086-0200 O-ring 1 Q Q
33 ND094087-0050 Seal 1 Q Q
34 ND092125-0010 Gasket 1 Q Q
35 ND090222-0070 Washer 6 Q Q
36 ND094092-0010 Washer 4 Q Q
37 ND094093-0050 Washer 1 Q
38 ND094093-0060 Washer 1 Q
39 ND094093-0070 Washer 1 Q
40 ND094093-0080 Washer 1 Q
41 ND094093-0090 Washer 1 Q
42 ND094093-0100 Washer 1 Q
43 ND094093-0110 Washer 1 Q
44 ND094093-0120 Washer 1 Q
45 ND949018-0350 Washer 1 Q Q
46 ND949010-3020 Washer 1 Q Q

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Disassembly and assembly Sketches of special tools
Sketches of special tools

Bracket [1] (Dimensions drawing for mounting fuel supply pump)
Pump dimension table

Pump
category Pump part No. A B C D E F G H I J K L
No.
1 6156-71-1110 214.4 57 60.3 129.0 11.0 75 55 54 27 14.5 M12x1.75 15
2 6218-71-1110 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12

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For reference For reference

Bracket [1] on drive shaft side Bracket on feed pump side
Note) Manufacture the bracket according to the following mounting dimensions drawing and the dimensions of
the test stand in hand. When manufacturing it, consider that it will be used for the performance test of the
pump, too.
a The bracket parts are shown the drawing for reference.

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Disassembly and assembly Disassembly and assembly of fuel supply pump
Disassembly and assembly of 2) Tighten the bolts of tool A1 evenly to remove

element assembly (2).
fuel supply pump • Lift up the element assembly vertically so
that its housing will not be damaged.
Disassembly
1. Securing fuel supply pump
1) Hold bracket [1] with a vise.
(Manufacture bracket [1] in the field.)
3) Pull plunger (3) out of the housing, taking

care not to damage it.
2) Fix pump assembly (1) to bracket [1] with 4

bolts (M8 or M10).
3. Removal of PCV
1) Secure tool A2 with the vise and fix removed
element assembly (2) to tool A2.
Tool: A2 (PCV mounting) 799-609-1020
2. Removal of element assembly

1) Remove the mounting nut of element assem-
bly (2) and install tool A1.
Tool: A1 (PCV puller) 799-609-1010

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2) Remove PCV (4) with tool A3. 5) Remove the stopper, washer, spring, gasket,
• Use an extension bar about 500 mm and valve.
long. • Do not mix the parts of element assembly
PCV1 and element assembly PCV2.
4. Removal of upper spring seat

1) Fix tool B1 to housing (35).
Tool: B1 (Extractor) 799-609-1030
3) Remove stopper (5) with tweezers.

• Do not reuse stopper (5).
2) Install tool B2 to the drive shaft end.

Tool: B2 (Holding spanner)
799-609-1040 (Pump category No. 2)
3) Turn the shaft with tool B2 to bring the cam

of upper spring seat (34) of the cylinder to be
removed to the bottom dead center.
4) Loosen the vise and change the fixing angle

of tool A2, then remove valve holder (6) with
tool A4.

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4) Put the pin of tool B1 in the semicircular 5. Removal of feed pump

groove of upper spring seat (34). Pushing it 1) Remove pump cover (10) with a hexagon
in, turn the handle by 90 degrees and wrench (width across flats: 5 mm), then
remove upper spring seat (34). remove the O-ring.
a Do not push in the pin more than neces- • Drain the fuel remaining in the pump with
sity since it can cut the housing surface the priming pump.
under the seat.
2) Remove 4 mounting bolts (12) of side plate

5) Using tweezers [2], remove lower spring (11) (outer) with a hexagon wrench (width
seat and tappet (9). across flats: 3 mm).
6) Drain the oil from the pump. 3) Using tool C, remove side plate (11).
Tool: C (Pliers) 799-609-1310

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4) Remove casing (13). 2) Remove G sensor (18).

• When removing the G sensor, take care
5) Remove outer rotor (14). not to damage the shim and housing.
6) Remove inner rotor (15) and key (39).
7. Removal of camshaft
1) Remove mounting bolts (21) of bearing cover
7) Remove side plate (16) (inner). assembly (19) with a hexagon wrench (width
across flats: 5 mm).
6. Removal of feed pump and G sensor

1) Remove the mounting bolts and feed pump 2) Remove key (20).
housing (17) from housing (35).

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3) Hit the end of camshaft (22) on the feed 8. Removal of bearing outer race
pump side with a plastic hammer to remove 1) Set tools D1, D2, and D3 and place bearing
bearing cover assembly (19) from the hous- cover assembly (19) on tool D3.
ing. Tools: D1 (Bearing puller) 799-609-1320
D2 (Hook set) 799-609-1330
D3 (Base) 799-609-1060
2) Pull out bearing outer race (24) with a hand

press.
4) Pull out camshaft (22).
9. Removal of oil seal

Remove oil seal (30) with tools E3 and E1 and a
hand press.
Tools: E1 (Handle) 799-609-1120
E3 (Replacer) 799-609-1140
(Pump category No. 1)
799-609-1150

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10. Removal of wear ring 12. Removal of oil seal of feed pump case
1) Set shaft (22) to a vise. Using tools D1 and D2, pull out the oil seal with
a hand press.
2) Break wear ring (25) with a hammer. Tools: D1 (Bearing puller) 799-609-1320
D2 (Hook set) 799-609-1330
3) Pull wear ring (25) out of shaft (22).
13. Removal of bearing outer race of pump

11. Removal of bearing roller housing
Secure the camshaft with tool D4 and pull out Place the housing on tool E7 and assemble the
bearing rollers (26) (2 pieces, 1 each on both replacers of 2 types, handle, and adapter to
sides). make a jig. Remove the bearing outer race with
• Install thread protection nut [3] to the shaft that jig and a hand press.
end on the drive side. Tools: E1 (Handle) 799-609-1120
Tool: D4 (Support) 799-609-1070 E2 (Adapter) 799-609-1130
(Pump category No. 1) E4 (Replacer) 799-609-1160 (ø52)
(Pump category No. 1) 799-609-1170 (ø60)
(Pump category No. 2) E5 (Replacer) 799-609-1180 (ø61)
799-609-1190 (ø71)
E7 (Base) 799-609-1220 (ø62)
799-609-1230 (ø72)

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Assembly 2) Install camshaft clearance adjustment shim

a When installing each part, clean it in clear diesel (29).
fuel and take care that foreign matter will not en-
ter it.
Replace O-rings, gaskets and seales with new
ones.
a Prepare the consumable parts indicated in the
list.
1. Assembly of bearing outer race

1) Place bearing outer race (27) by using tool
E7, then remove tool E7.
2 Outside surface of outer race:
Gear oil (SAE90 or equivalent)
Tool: E7 (Base) 799-609-1220 (ø62)
799-609-1230 (ø72) 3) Fit the O-ring to camshaft housing (35) and
(Pump category No. 2) install feed pump housing (17).
3 Mounting bolt:
2) After removing tool E7, place tool E6 on 6.8 – 11.8 Nm {0.7 – 1.2 kgm}
bearing outer race (27) and press fit to the
end of retainer (28) with a hand press.
Tool: E6 (Replacer) 799-609-1210 (ø81)
3. Press fitting of bearing outer race

Assemble the replacers of 2 types, handle, and
adapter to make a press fitting jig. Press fit
2. Assembly of feed pump housing bearing outer race (27) on the feed pump side to
1) Set tool F2 to feed pump housing (17) and the feed pump housing end with the press fitting
insert the oil seal, then press fit with tool F1 jig and a hand press.
with a hand press. Tools: E1 (Handle) 799-609-1120
2 Oil seal lip surface: E2 (Adapter) 799-609-1130
Gear oil (SAE90 or equivalent) E4 (Replacer) 799-609-1160 (ø52)
Tool: F1 (Oil seal presser) 799-609-1240 (Pump category No. 1)
F2 (Oil seal guide) 799-609-1250 799-609-1170 (ø60)
E5 (Replacer) 799-609-1180 (ø61)
799-609-1190 (ø71)

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4. Installation of bearing roller 5. Installation of bearing outer race

1) Press fit bearing (26) on the drive side. 1) Press fit bearing outer race (24) to bearing
Tool: E8 cover (19).
Pipe (ø30): 799-609-1260 Tools: E1 (Handle) 790-609-1120
E2 (Adapter) 790-609-1130
• Do not receive the press fitting force with the E4 (Replacer) 790-609-1160 (ø52)
cam at part (a) but receive it with the shaft (Pump category No. 1)
end. 790-609-1170 (ø60)
2 Inside surface of bearing: (Pump category No. 2)
Gear oil (SAE90 or equivalent) E5 (Replacer) 790-609-1180 (ø61)
790-609-1190 (ø71)
2) Press fit bearing (26) on the feed pump side.

Tool: E8 Pipe (ø30): 799-609-1260
2 Inside surface of bearing:
2) Press fit oil seal (30) to the bearing cover
end.
2 Oil seal lip surface:
3) Using tool D5, set wear ring (25) in the

inserting position and press fit it with a press.
Tool: D5 (wear ring stopper) 799-609-1110

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6. Installation of PCV 7. Installation of delivery valve holder

1) Install new stopper (5) with tweezers. 1) Change the fixing direction of tool A2 and
replace gasket (36) with new one, then
install check valve (31) and washer (37A).
2) Install spring (32), washer (37B), and stop-
per (38).
3) Replace the O-ring with new one and apply
grease to it and the threads of delivery valve
holder (6), then assemble them temporarily.
2 O-ring: Grease (G2-LI)
2) Fit the new O-ring to element (4) and apply

grease to them.
3) Fix element (2) to tool A2 and install PCV (4)

to element (2).
3 PCV: 157 – 177 Nm {16 – 18 kgm}
• Using a limit-type torque wrench, tighten
the element to the specified torque with- 4) Using tool A4, install delivery valve holder
out stopping halfway. (6).
3 Delivery valve holder:
137 – 167 Nm {14 – 17 kgm}
• Use a limit-type torque wrench.

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5) Fit O-ring (40).
9. Measuring camshaft clearance

8. Installation of camshaft and bearing cover • Hit both ends of camshaft (22) lightly with a
1) Install camshaft (22) to pump housing (1), plastic hammer to fit the camshaft.
then install guide pin E9 and bearing cover
(19) and camshaft clearance adjustment
shim without fitting the O-ring.
Tool: E9 (Guide pin) 799-609-1270
• When installing the camshaft and bearing
cover, take care not to damage the oil
seal on the feed pump side and bearing
cover side.
1) Install guide rail G1 to the camshaft end and

measure the projection of the camshaft in
the axial direction.
If the projection is out of the standard range,
change the thickness of adjustment shim
(29) [See 2.2)].
Tools: G1 (Guide rail)
799-609-1340 (ø25)
2) Using a hand press, press fit bearing cover (Pump category No. 1)
(19) and secure it with the bolt. 799-609-1440 (ø30)
Tool: E8 (Pipe) 799-609-1260 (Pump category No. 2)
3 Mounting bolt of bearing cover (19): Standard projection:
9.8 – 11.8 Nm {1.0 – 1.2 kgm} 16.5 ± 0.3 mm (Pump category No. 1)
• Replace the washer with a new part 13.5 ± 0.3 mm (Pump category No. 2)
when installing the bolt.

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2) Install camshaft clearance measure G2 to

the camshaft and measure the clearance.
Standard clearance: 0.03 ± 0.03 mm
Tool: G2 (Camshaft clearance measure)
799-609-1450 (ø25)
799-609-1460 (ø30)
• If the clearance is out of the standard
range, change the thickness of adjust-
ment shim [See 8.1)].
If the clearance is in the standard range,
fit the O-ring to bearing cover (19) and
apply grease to them and install them.
Then, measure the clearance again. 2) Push in G sensor (18) firmly and read the
a If the clearance is "0" reduce the turning value of the dial gauge (L1).
torque of the camshaft to 0.6 Nm {0.06 a If the sensor is longer than the master
kgm} or below. pin, the dial gauge indicates a positive
value (L1) (the pointer moves clockwise).
Accordingly, select a thicker shim in this
case.
3) Install the dial gauge to tool H1 and press it

against attached master pin [4] firmly and set
the dial gauge to "0".
Tool: H1 (Depth measure) 799-609-1280
10. Installation of G sensor

1) Install a dial gauge to tool H2 and insert the
attached master pin.
Tool: H2 (Measure sensor) 799-609-1290
• Push master pin [1] into measure sensor
[2] firmly and set dial gauge [3] to "0".

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4) Insert tool H1 in the mounting hole of the G 5) Apply grease to the O-ring and install G sen-
sensor and read the value of the dial gauge sor (18) and selected shim together.
(L2). 2 O-ring: Grease (G2-LI)
• Calculate the thickness (t) of the air gap 3 Mounting bolt :
adjustment shim by the following expres- 4.4 – 8.34 Nm {0.45 – 0.85 kgm}
sion.
t = L1 + L2 (Pump category No. 1)
t = L1 + L2 + 0.4 (Pump category No. 2)
a If value (L2) is positive, the distance be-
tween the sensor fitting face and barrel is
less than the depth of the master pin
hole. Accordingly, select a thicker shim
in this case.
11. Installation of tappet

1) Insert tappet (9) in pump housing (35).
2) Insert lower spring seat (8).
3) Install plunger spring (7).
a There is a difference of 0.4 mm in length

between the master pins used for mea-
surement. Accordingly, if a shim having
thickness nearest to the calculated shim
thickness is selected, the air gap is set in
the standard range.
a Standard air gap:
+0.20
• 0.4 –0.05 mm (Pump category No. 1)
+0.15
• 0.8 –0.05 mm (Pump category No. 2)
• Shim size
Part No. Thickness (mm) 12. Installation of upper spring seat
ND094096-0050 0.15 1) Set upper spring seat (34) in the inserting
position and push it in with tool B1, then turn
ND094096-0060 0.20 the handle by 90 degrees.
ND094096-0070 0.25
ND094096-0080 0.40

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a When installing the upper spring seat, set the

cam at the bottom dead center.
• Install tool B2 to the drive shaft end and
turn the shaft to bring the cam to the bot-
tom dead center.
a Do not push in the upper spring seat with the
extractor too much, since it can cut the hous-
ing end.
B2 (Holding spanner)
799-609-1040
799-609-1050
14. Installation of feed pump
1) Install side plate (16) (inner) as follows.
• Install the plate with the wider groove fac-
ing down. (Pump category No. 2)
ing up. (Pump category No. 1)
13. Installation of element

1) Install plunger (3).
• Install plunger (3) so that its bottom will
be at the cut of lower spring seat (8).
2) Install the inner rotor.

Fit key (39) to camshaft (22) and install inner
rotor (15).
• Make sure that the inner rotor is inserted
smoothly.
2) Install element assembly (2), taking care not

to damage the plunger, then tighten the nuts
alternately.
3 Nut: 17.6 – 24.5 Nm {1.8 – 2.5 kgm}

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3) Install casing (13). 5) Install side plate (11) (outer) as follow.

• Since the hole is eccentric downward, in- • Plate face with wider groove (b) is at top
stall the casing as shown below. (Pump category No. 1)
Set the eccentric side up • Plate face with wider groove (b) is at bot-
(Pump category No. 1) tom (Pump category No. 2)
Set the eccentric side down • Install the plate with hole (a) on the left
(Pump category No. 2) side.
3 Screw:
1.96 – 2.94 Nm {0.2 – 0.3 kgm}
• Install inner rotor (15) and outer rotor (14)

with their ends having punch marks (a)
on this side. 6) Fit the O-ring to housing (17) and install
cover (10).
3 Mounting bolt:
5.88 – 9.8 Nm {0.6 – 1.0 kgm}
4) Install outer rotor (14).
15. Refilling with oil

Pour lubricating oil in the fuel supply pump to oil
filler (41).

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Tightening torque table
Tightening torque Tightening torque

No. Item No. Item
(Nm {kgm}) (Nm {kgm})
1 Piston 1.96 – 2.94 {0.2 – 0.3} 11 Bolt 9.8 – 11.8 {1.0 – 1.2}
2 Priming pump (M16) 39.0 – 58.8 {4.0 – 6.0} 12 Bolt 6.8 – 11.8 {0.7 – 1.2}
3 Screw 14.7 – 19.6 {1.5 – 2.0} 13 Bolt 5.88 – 9.8 {0.6 – 1.0}
4 Bolt 6.8 – 11.8 {0.7 – 1.2} 14 Bolt 4.4 – 8.3 {0.45 – 0.85}
5 Nut (With washer) 17.6 – 24.5 {1.8 – 2.5} 15 Screw (M10) 7.8 – 11.8 {0.8 – 1.2}
6 PCV 157.0 – 177.0 {16.0 – 18.0} 16 Screw 1.96 – 2.9 {0.2 – 0.3}
7 Holder 137.0 – 167.0 {14.0 – 17.0} 17 Plug (M16) 39.0 – 58.8 {4.0 – 6.0}
8 Bolt 15.7 – 23.5 {1.6 – 2.4} 18 Filter 1.98 – 3.92 {0.2 – 0.4}
Overflow valve 19 Plug (M10) 7.8 – 11.8 {0.8 – 1.2}
9 14.8 – 19.6 {1.5 – 2.0}
(Temporarily tightened) 20 Plug 29.5 – 39.2 {3.0 – 4.0}
Screw 21 Air breeder 4.9 – 6.9 {0.5 – 0.7}
10 7.9 – 12.7 {0.8 – 1.3}
(Temporarily tightened)

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Disassembly and assembly Special tools list
Special tools list

1 6251-71-1120 094000-0570 6D125-5
2 6261-71-1110 094000-0580 6D140-5
3 6245-71-1110 094000-0600 6D170-5
4 6219-71-1110 094000-0620 12V140-3 (Left bank)
5 6219-71-1120 094000-0630 12V140-3 (Right bank)
the above table.
Pump category
Pump category
No. 2 – 5
No. 1
Q’ty
Symbol Part No. Part name Nature of work, remarks
A 1 799-609-1010 Puller, PCV 1 Q Q Removal, installation of PCV assembly

1 799-609-1030 Extractor 1 Q Q
B 799-609-1040 Holding spanner 1 Q Removal, installation of upper spring seat
2
799-609-1050 Holding spanner 1 Q
C 799-609-1310 Pliers 1 Q Q Removal, installation of feed pump
1 799-609-1320 Puller 1 Q Q
2 799-609-1330 Hook set 1 Q Q Removal of bearing outer race
3 799-609-1060 Base (ø100) 1 Q Q
D 799-609-1070 Support (ø31) 1 Q
4 799-609-1080 Support (ø37) 1 Q Removal of bearing inner race
799-609-1090 Support (ø39) 1 Q
5 799-609-1110 Wear ring stopper 1 Q Q Installation of wear ring
1 799-609-1120 Handle 1 Q Q
2 799-609-1130 Adapter 1 Q Q
799-609-1140 Replacer (ø34) 1 Q
3
799-609-1150 Replacer (ø43) 1 Q
799-609-1160 Replacer (ø52) 1 Q
4
799-609-1170 Replacer (ø60) 1 Q
E 799-609-1180 Replacer (ø61) 1 Q Removal, installation of bearing
5
799-609-1190 Replacer (ø71) 1 Q
6 799-609-1210 Replacer (ø81) 1 Q Q
799-609-1220 Base housing (ø62) 1 Q
7
799-609-1230 Base housing (ø72) 1 Q
8 799-609-1260 Pipe (ø30) 1 Q Q
9 799-609-1270 Guide pin 1 Q Q
1 799-609-1240 Oil seal presser 1 Q Q
F Installation of oil seal
2 799-609-1250 Oil seal guide 1 Q Q
799-609-1340 Guide rail, nut (ø25) 1 Q
1
799-609-1440 Guide rail, nut (ø30) 1 Q
G Installation of camshaft
2
1 799-609-1280 Depth measure 1 Q Q
H Installation of G sensor
2 799-609-1290 Sensor measure 1 Q Q
1 Purchased Slide calipers 1 Q Q
2 Purchased Hexagon wrench 1 Q Q B = 3 mm, 5 mm
3 Purchased Tweezers 1 Q Q L = 100 mm, 150 mm
I
4 Purchased Torque wrench 1 Q Q Preset type
5 Purchased Dial gauge 1 Q Q Accuracy: 0.01 mm
6 Purchased Gasket sealant 1 Q Q LG-6

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Disassembly and assembly Component part drawing
Component part drawing

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Component parts list

(This parts list shows the part Nos. at the time when the manual is made. The part Nos. are subject to change.)
Engine model 6D125-5 6D140-5 6D170-5
No. Pump part No. 6251-71-1120 6261-71-1110 6245-71-1110
Part name Part No. Part No. Part No.
1 PCV element assembly ND094040-0270 ND094040-0280 ND094040-0280
2 O-ring ND094086-0090 ND094086-0090 ND094086-0090
3 Gasket ND094137-0010 ND094137-0010 ND094137-0010
4 Valve assembly ND094140-0040 ND094140-0040 ND094140-0040
5 O-ring ND094086-0100 ND094086-0100 ND094086-0100
6 Washer ND949013-5880 ND949013-5880 ND949013-5880
7 Nut ND92156-08081 ND92156-08081 ND92156-08081
8 Upper spring seat ND094162-0040 ND094162-0031 ND094162-0031
9 Plunger spring ND094164-0010 ND094164-0030 ND094164-0030
10 Lower spring seat ND094165-0021 ND094165-0031 ND094165-0031
11 Tappet assembly ND094170-0100 ND094170-0110 ND094170-0110
12 Camshaft ND094191-0161 ND094191-0451 ND094191-0540
13 Roller bearing ND949101-0230 ND949101-0250 ND949101-0250
14 Bearing cover ND094104-0100 ND094104-0160 ND094104-0160
15 Oil seal ND949150-3030 ND949150-3200 ND949150-3200
16 O-ring ND094086-0120 ND094086-0150 ND094086-0150
17 Shim, 0.05 mm ND094095-0100 ND094095-0330 ND094095-0330
18 Shim, 0.10 mm ND094095-0130 ND094095-0340 ND094095-0340
19 Shim, 0.20 mm ND094095-0140 ND094095-0350 ND094095-0350
20 Shim, 0.30 mm ND094095-0150 ND094095-0360 ND094095-0360
21 Shim, 0.50 mm ND094095-0160 ND094095-0370 ND094095-0370
22 Washer ND094092-0010 ND094092-0010 ND094092-0010
23 Bolt ND949044-3320 ND949044-3320 ND949044-3320
24 O-ring ND094086-0110 ND094086-0160 ND094086-0160
25 O-ring ND094086-0130 ND094086-0170 ND094086-0170
26 Shim, 0.40 mm ND094093-0050 ND094093-0090 ND094093-0090
27 Shim, 0.60 mm ND094093-0060 ND094093-0100 ND094093-0100
28 Shim, 0.80 mm ND094093-0070 ND094093-0110 ND094093-0110
29 Shim, 1.00 mm ND094093-0080 ND094093-0120 ND094093-0120
30 Sensor assembly ND949979-1300 ND949979-1300 ND949979-1300
31 O-ring ND949140-6310 ND949140-6310 ND949140-6310
32 Shim, 0.15 mm ND094096-0050 ND094096-0050 ND094096-0050
33 Shim, 0.20 mm ND094096-0060 ND094096-0060 ND094096-0060
34 Shim, 0.25 mm ND094096-0070 ND094096-0070 ND094096-0070
35 Shim, 0.40 mm ND094096-0080 ND094096-0080 ND094096-0080
36 Washer ND90200-06081 ND90200-06081 ND90200-06081
37 Bolt ND90107-06161 ND90107-06161 ND90107-06161
38 Overflow valve assembly ND090310-0500 ND090310-0500 ND090310-0500
39 Washer ND090222-0070 ND090222-0070 ND090222-0070
40 Screw ND949180-0310 ND949180-0310 ND949180-0310
41 Washer ND090222-0120 ND090222-0120 ND090222-0120
42 Screw ND949180-0060 ND949180-0060 ND949180-0060

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12V140-3 (L bank) 12V140-3 (R bank)

6219-71-1110 6219-71-1120 Q'ty Remarks
Part No. Part No.
ND094040-0280 ND094040-0280 2
ND094086-0090 ND094086-0090 2
ND094137-0010 ND094137-0010 2
ND094140-0040 ND094140-0040 2
ND094086-0100 ND094086-0100 4
ND949013-5880 ND949013-5880 4
ND92156-08081 ND92156-08081 4
ND094162-0031 ND094162-0031 2
ND094164-0030 ND094164-0030 2
ND094165-0031 ND094165-0031 2
ND094170-0110 ND094170-0110 2
ND094191-0451 ND094191-0570 1
ND949101-0250 ND949101-0250 2
ND094104-0160 ND094104-0160 1
ND949150-3200 ND949150-3200 1
ND094086-0150 ND094086-0150 1
ND094095-0330 ND094095-0330 —
ND094095-0340 ND094095-0340 —
ND094095-0350 ND094095-0350 —
ND094095-0360 ND094095-0360 —
ND094095-0370 ND094095-0370 —
ND094092-0010 ND094092-0010 4
ND949044-3320 ND949044-3320 4
ND094086-0160 ND094086-0160 1
ND094086-0170 ND094086-0170 1
ND094093-0090 ND094093-0090 —
ND094093-0100 ND094093-0100 —
ND094093-0110 ND094093-0110 —
ND094093-0120 ND094093-0120 —
ND949979-1300 ND949979-1300 1
ND949140-6310 ND949140-6310 1
ND094096-0050 ND094096-0050 —
ND094096-0060 ND094096-0060 —
ND094096-0070 ND094096-0070 —
ND094096-0080 ND094096-0080 —
ND90200-06081 ND90200-06081 1
ND90107-06161 ND90107-06161 1
ND090310-0500 ND090310-0500 1
ND090222-0070 ND090222-0070 5
ND949180-0310 ND949180-0310 1
ND090222-0120 ND090222-0120 2
ND949180-0060 ND949180-0060 1

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Engine model 6D125-5 6D140-5 6D170-5

No. Pump part No. 6251-71-1120 6261-71-1110 6245-71-1110
Part name Part No. Part No. Part No.
43 Washer ND949018-0350 ND949018-0350 ND949018-0350
44 Screw plug ND090317-0480 ND090317-0480 ND090317-0480
45 Ring ND090207-0100 ND090207-0100 ND090207-0100
46 Screw ND090244-0010 ND090244-0010 ND090244-0010
47 Washer ND949010-3020 ND949010-3020 ND949010-3020
48 O-ring ND094086-0210 ND094086-0210 ND094086-0210
49 Casing ND094231-0060 ND094231-0060 ND094231-0060
50 Pump sub assembly ND094230-0080 ND094230-0080 ND094230-0080
51 Plate ND094241-0040 ND094241-0040 ND094241-0040
52 Plate ND094244-0040 ND094244-0040 ND094244-0040
53 Cover ND094251-0050 ND094251-0050 ND094251-0050
54 Screw ND094082-0040 ND094082-0040 ND094082-0040
55 O-ring ND094086-0200 ND094086-0200 ND094086-0200
56 Oil seal ND094087-0050 ND094087-0050 ND094087-0050
57 Key ND094205-0060 ND094205-0060 ND094205-0060
58 Check valve spring ND092124-0010 ND092124-0010 ND092124-0010
59 Check valve ND092121-0011 ND092121-0011 ND092121-0011
60 Chamber plug ND092126-0010 ND092126-0010 ND092126-0010
61 Priming pump ND092130-0360 ND092130-0360 ND092130-0360
62 Gasket ND092125-0010 ND092125-0010 ND092125-0010
63 Screw plug ND090317-0060 ND090317-0060 ND090317-0060
64 Washer, 1 mm ND949018-1500 ND949018-1500 ND949018-1500
65 Bolt ND949044-3320 ND949044-3320 ND949044-3320
66 Washer ND090222-0070 ND090222-0070 ND090222-0070
67 Overflow valve ND090310-0490 ND090310-0490 ND090310-0490
68 Filter ND092220-0040 ND092220-0040 ND092220-0040
69 Screw ND092223-0042 ND092223-0042 ND092223-0042
70 Bolt ND949044-3320 ND949044-3320 ND949044-3320
71 Socket bolt ND096449-0070 ND096449-0070 ND096449-0070

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12V140-3 (L bank) 12V140-3 (R bank)

6219-71-1110 6219-71-1120 Q'ty Remarks
Part No. Part No.
ND949018-0350 ND949018-0350 1
ND090917-0480 ND090317-0480 1
ND090207-0100 ND090207-0100 1
ND090244-0010 ND090244-0010 1
ND949010-3020 ND949010-3020 1
ND094086-0210 ND094086-0210 1
ND094231-0060 ND094231-0060 1
ND094230-0080 ND094230-0080 1
ND094241-0040 ND094241-0040 1
ND094244-0040 ND094244-0040 1
ND094251-0050 ND094251-0050 1
ND094082-0040 ND094082-0040 4
ND094086-0200 ND094086-0200 1
ND094087-0050 ND094087-0050 1
ND094205-0060 ND094205-0060 1
ND092124-0010 ND092124-0010 2
ND092121-0011 ND092121-0011 2
ND092126-0010 ND092126-0010 1
— — 1
ND092125-0010 ND092125-0010 2
ND090317-0060 ND090317-0060 2
ND949018-1500 ND949018-1500 2
ND949044-3320 ND949044-3320 4
ND090222-0070 ND090222-0070 6
ND090310-0490 ND090310-0490 1
ND092220-0040 ND092220-0040 1
ND092223-0042 ND092223-0042 1
ND949044-3320 ND949044-3320 1
ND096449-0070 ND096449-0070 4

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Bracket [1] (Installation dimensional drawing of fuel supply pump)

Pump
No.
1 6251-71-1120 214.4 57 60.3 129.0 11.0 75 55 54 27 14.5 M12x1.75 15
2 6261-71-1110 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12
3 6245-71-1110 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12
4 6219-71-1110 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12
5 6219-71-1120 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12

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For reference For reference

Bracket [1] on drive shaft side Bracket on feed pump side
Note) Make a bracket according to this dimensional drawing and the dimensions of the existing test stand.
When making it, consider that it will be used for the pump performance test, too.
a For reference, the bracket parts are shown.

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Disassembly and assembly of 2) Tighten the bolts of tool A1 evenly to remove

element assembly (2).
fuel supply pump • Lift up the element assembly vertically so
that its housing will not be damaged.
Applicable engine:
6D125-5, 6D140-5, 6D170-5, 12V140-3
Disassembly
1. Securing fuel supply pump
1) Hold bracket [1] with a vise.
(Manufacture bracket [1] in the field.)
3) Pull plunger (3) out of the housing, taking

care not to damage it.
2) Fix pump assembly (1) to bracket [1] with 4

bolts (M8 or M10).
3. Removal of upper spring seat

1) Fix tool B1 to housing (35).
2. Removal of element assembly

1) Remove the mounting nut of element assem-
bly (2) and install tool A1.
Tool: A1 (PCV puller) 799-609-1010
2) Install tool B2 to the drive shaft end.

Tool: B2 (Holding spanner)
799-609-1040
(Pump category No. 2 – 5)
799-609-1050

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3) Turn the shaft with tool B2 to bring the cam 6) Drain the oil from the pump.
of upper spring seat (34) of the cylinder to be
removed to the bottom dead center.
4. Removal of feed pump

1) Remove pump cover (10) with a hexagon
4) Put the pin of tool B1 in the semicircular wrench (width across flats: 5 mm), then
groove of upper spring seat (34). Pushing it remove the O-ring.
in, turn the handle by 90 degrees and • Drain the fuel remaining in the pump with
remove upper spring seat (34). the priming pump.
a Do not push in the pin more than neces-
sity since it can cut the housing surface
under the seat.
2) Remove 4 mounting bolts (12) of side plate

(11) (outer) with a hexagon wrench (width
5) Using tweezers [2], remove lower spring
seat and tappet (9).

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3) Using tool C, remove side plate (11). 5. Removal of feed pump and G sensor
Tool: C (Pliers) 799-609-1310 1) Remove the mounting bolts and feed pump
housing (17) from housing (35).
4) Remove casing (13).

2) Remove G sensor (18).
5) Remove outer rotor (14). • When removing the G sensor, take care
not to damage the shim and housing.
6) Remove inner rotor (15) and key (39).
6. Removal of camshaft
7) Remove side plate (16) (inner). 1) Remove mounting bolts (21) of bearing cover
assembly (19) with a hexagon wrench (width

(11)
2) Remove key (20). 4) Pull out camshaft (22).
3) Hit the end of camshaft (22) on the feed 7. Removal of bearing outer race
pump side with a plastic hammer to remove 1) Set tools D1, D2, and D3 and place bearing
bearing cover assembly (19) from the hous- cover assembly (19) on tool D3.
ing. Tools: D1 (Bearing puller) 799-609-1320
D2 (Hook set) 799-609-1330
D3 (Base) 799-609-1060
2) Pull out bearing outer race (24) with a hand

press.

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8. Removal of oil seal

Remove oil seal (30) with tools E3 and E1 and a
hand press.
Tools: E1 (Handle) 799-609-1120
E3 (Replacer) 799-609-1140
799-609-1150
11. Removal of oil seal of feed pump case

Using tools D1 and D2, pull out the oil seal with
a hand press.
Tools: D1 (Bearing puller) 799-609-1320
D2 (Hook set) 799-609-1330
9. Removal of wear ring

1) Set shaft (22) to a vise.
2) Break wear ring (25) with a hammer.
3) Pull wear ring (25) out of shaft (22).
12. Removal of bearing outer race of pump

housing
Place the housing on tool E7 and assemble the
replacers of 2 types, handle, and adapter to
make a jig. Remove the bearing outer race with
that jig and a hand press.
Tools: E1 (Handle) 799-609-1120
E2 (Adapter) 799-609-1130
E4 (Replacer) 799-609-1160 (ø52)
10. Removal of bearing roller (Pump category No. 1)
Secure the camshaft with tool D4 and pull out 799-609-1170 (ø60)
bearing rollers (26) (2 pieces, 1 each on both (Pump category No. 2 – 5)
sides). E5 (Replacer) 799-609-1180 (ø61)
• Install thread protection nut [3] to the shaft (Pump category No. 1)
end on the drive side. 799-609-1190 (ø71)
Tool: D4 (Support) 799-609-1070 (Pump category No. 2 – 5)
(Pump category No. 1) E7 (Base) 799-609-1220 (ø62)
(Pump category No. 1) 799-609-1230 (ø72)
799-609-1090 (Pump category No. 2 – 5)

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Assembly
a When installing each part, clean it in clear diesel
fuel and take care that foreign matter will not en-
ter it.
Replace O-rings, gaskets and seales with new
ones.
1. Assembly of bearing outer race

1) Place bearing outer race (27) by using tool
E7, then remove tool E7.
Tool: E7 (Base) 799-609-1220 (ø62)
799-609-1230 (ø72)
2) After removing tool E7, place tool E6 on

bearing outer race (27) and press fit to the
end of retainer (28) with a hand press.
Tool: E6 (Replacer) 799-609-1210 (ø81)
2. Assembly of feed pump housing

1) Set tool F2 to feed pump housing (17) and
insert the oil seal, then press fit with tool F1
with a hand press.
Tool: F1 (Oil seal presser) 799-609-1240
F2 (Oil seal guide) 799-609-1250

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2) Install camshaft clearance adjustment shim

(29).
4. Installation of bearing roller

1) Press fit bearing (26) on the drive side.
3) Fit the O-ring to camshaft housing (35) and Tool: E8
install feed pump housing (17). Pipe (ø30): 799-609-1260
3 Mounting bolt:
• Do not receive the press fitting force with the
6.8 – 11.8 Nm {0.7 – 1.2 kgm} cam at part (a) but receive it with the shaft
end.
3. Press fitting of bearing outer race

Assemble the replacers of 2 types, handle, and
adapter to make a press fitting jig. Press fit
bearing outer race (27) on the feed pump side to 2) Press fit bearing (26) on the feed pump side.
the feed pump housing end with the press fitting Tool: E8 Pipe (ø30): 799-609-1260
jig and a hand press.
Tools: E1 (Handle) 799-609-1120 Gear oil (SAE90 or equivalent)
E2 (Adapter) 799-609-1130
E4 (Replacer) 799-609-1160 (ø52)
799-609-1170 (ø60)
E5 (Replacer) 799-609-1180 (ø61)
799-609-1190 (ø71)

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3) Using tool D5, set wear ring (25) in the

inserting position and press fit it with a press.
Tool: D5 (wear ring stopper) 799-609-1110
6. Installation of camshaft and bearing cover

1) Install camshaft (22) to pump housing (1),
then install guide pin E9 and bearing cover
5. Installation of bearing outer race (19) and camshaft clearance adjustment
1) Press fit bearing outer race (24) to bearing shim without fitting the O-ring.
cover (19). Tool: E9 (Guide pin) 799-609-1270
Tools: E1 (Handle) 790-609-1120 • When installing the camshaft and bearing
E2 (Adapter) 790-609-1130 cover, take care not to damage the oil
E4 (Replacer) 790-609-1160 (ø52) seal on the feed pump side and bearing
(Pump category No. 1) cover side.
790-609-1170 (ø60)
E5 (Replacer) 790-609-1180 (ø61)
790-609-1190 (ø71)
2) Using a hand press, press fit bearing cover

(19) and secure it with the bolt.
Tool: E8 (Pipe) 799-609-1260
3 Mounting bolt of bearing cover (19):
9.8 – 11.8 Nm {1.0 – 1.2 kgm}
• Replace the washer with a new part
when installing the bolt.
2) Press fit oil seal (30) to the bearing cover

end.

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7. Measuring camshaft clearance • If the clearance is out of the standard

• Hit both ends of camshaft (22) lightly with a range, change the thickness of adjust-
plastic hammer to fit the camshaft. ment shim [See 6.1)].
If the clearance is in the standard range,
fit the O-ring to bearing cover (19) and
apply grease to them and install them.
Then, measure the clearance again.
a If the clearance is "0" reduce the turning
torque of the camshaft to 0.6 Nm {0.06
kgm} or below.
1) Install guide rail G1 to the camshaft end and

measure the projection of the camshaft in
the axial direction.
If the projection is out of the standard range,
change the thickness of adjustment shim
(29) [See 2.2)].
Tools: G1 (Guide rail)
799-609-1340 (ø25)
799-609-1440 (ø30)
Standard projection:
16.5 ± 0.3 mm (Pump category No. 1)
13.5 ± 0.3 mm (Pump category No. 2 – 5)
8. Installation of G sensor
1) Install a dial gauge to tool H2 and insert the
attached master pin.
Tool: H2 (Measure sensor) 799-609-1290
• Push master pin [4] into measure sensor
[5] firmly and set dial gauge [6] to "0".
2) Install camshaft clearance measure G2 to

the camshaft and measure the clearance.
Standard clearance: 0.03 ± 0.03 mm
Tool: G2 (Camshaft clearance measure)
799-609-1450 (ø25)
799-609-1460 (ø30)

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2) Push in G sensor (18) firmly and read the

value of the dial gauge (L1).
a If the sensor is longer than the master
pin, the dial gauge indicates a positive
value (L1) (the pointer moves clockwise).
Accordingly, select a thicker shim in this
case.
a There is a difference of 0.4 mm in length

between the master pins used for mea-
surement. Accordingly, if a shim having
thickness nearest to the calculated shim
thickness is selected, the air gap is set in
the standard range.
a Standard air gap:
3) Install the dial gauge to tool H1 and press it
• 0.6 ± 0.1 mm
against attached master pin [7] firmly and set
• Shim size
the dial gauge to "0".
Tool: H1 (Depth measure) 799-609-1280 Part No. Thickness (mm)
ND094096-0050 0.15
ND094096-0060 0.20
ND094096-0070 0.25
ND094096-0080 0.40
5) Apply grease to the O-ring and install G sen-

sor (18) and selected shim together.
3 Mounting bolt :
4.4 – 8.34 Nm {0.45 – 0.85 kgm}
4) Insert tool H1 in the mounting hole of the G

sensor and read the value of the dial gauge
(L2).
• Calculate the thickness (t) of the air gap
adjustment shim by the following expres-
sion.
t = L1 + L2 + 0.2
a If value (L2) is positive, the distance be-
tween the sensor fitting face and barrel is
less than the depth of the master pin
hole. Accordingly, select a thicker shim
in this case.

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9. Installation of tappet
1) Insert tappet (9) in pump housing (35).
2) Insert lower spring seat (8).
3) Install plunger spring (7).
11. Installation of element

1) Install plunger (3).
• Install plunger (3) so that its bottom will
be at the cut of lower spring seat (8).
10. Installation of upper spring seat

1) Set upper spring seat (34) in the inserting
position and push it in with tool B1, then turn
the handle by 90 degrees.
2) Install element assembly (2), taking care not

to damage the plunger, then tighten the nuts
alternately.
3 Nut: 17.6 – 24.5 Nm {1.8 – 2.5 kgm}
a When installing the upper spring seat, set the

cam at the bottom dead center.
• Install tool B2 to the drive shaft end and
turn the shaft to bring the cam to the bot-
tom dead center.
a Do not push in the upper spring seat with the
extractor too much, since it can cut the hous-
ing end.
B2 (Holding spanner)
799-609-1040
799-609-1050
12. Installation of feed pump
1) Install side plate (16) (inner) as follow.
ing down. (Pump category No. 2 – 5)
ing up. (Pump category No. 1)

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• Install inner rotor (15) and outer rotor (14)

with their ends having punch marks (a)
on this side.
2) Install the inner rotor.

Fit key (39) to camshaft (22) and install inner
rotor (15).
• Make sure that the inner rotor is inserted 4) Install outer rotor (14).
smoothly.
5) Install side plate (11) (outer) as follows.

3) Install casing (13). • Plate face with wider groove (b) is at top
• Since the hole is eccentric downward, in- (Pump category No. 1)
stall the casing as shown below. • Plate face with wider groove (b) is at bot-
Set the eccentric side up tom (Pump category No. 2 – 5)
(Pump category No. 1) • Install the plate with hole (a) on the left
Set the eccentric side down side.
3 Screw:
1.96 – 2.94 Nm {0.2 – 0.3 kgm}

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6) Fit the O-ring to housing (17) and install

cover (10).
3 Mounting bolt:
5.88 – 9.8 Nm {0.6 – 1.0 kgm}
13. Refilling with oil

Pour lubricating oil in the fuel supply pump to oil
filler (41).

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Tightening torque table
Tightening torque Tightening torque

No. Item No. Item
(Nm {kgm}) (Nm {kgm})
1 Piston 1.96 – 2.94 {0.2 – 0.3} 10 Bolt 6.8 – 11.8 {0.7 – 1.2}
2 Priming pump (M16) 39.0 – 58.8 {4.0 – 6.0} 11 Bolt 5.88 – 9.8 {0.6 – 1.0}
3 Screw 14.7 – 19.6 {1.5 – 2.0} 12 Bolt 4.4 – 8.3 {0.45 – 0.85}
4 Bolt 6.8 – 11.8 {0.7 – 1.2} 13 Screw (M10) 7.8 – 11.8 {0.8 – 1.2}
5 Nut (With washer) 17.6 – 24.5 {1.8 – 2.5} 14 Screw 1.96 – 2.9 {0.2 – 0.3}
6 Bolt 15.7 – 23.5 {1.6 – 2.4} 15 Plug (M16) 39.0 – 58.8 {4.0 – 6.0}
Overflow valve 16 Filter 1.98 – 3.92 {0.2 – 0.4}
7 14.8 – 19.6 {1.5 – 2.0}
(Temporarily tightened) 17 Plug (M10) 7.8 – 11.8 {0.8 – 1.2}
8 Screw (Temporarily tightened) 7.9 – 12.7 {0.8 – 1.3} 18 Plug 29.5 – 39.2 {3.0 – 4.0}
9 Bolt 9.8 – 11.8 {1.0 – 1.2} 19 Air breeder 4.9 – 6.9 {0.5 – 0.7}

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14 Performance test
Applicable engine: 6D125-5, 6D140-5, 6D170-5,

12V140-3, 6D125-3, 6D140-3
Special tools list for performance test ..... 14-002
Performance test of fuel supply pump .... 14-007

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Performance test Special tools list for performance test
Special tools list for performance test

1 6251-71-1120 094000-0570 6D125-5
2 6261-71-1110 094000-0580 6D140-5
3 6245-71-1110 094000-0600 6D170-5
4 6219-71-1110 094000-0620 12V140-3 (Left bank)
5 6219-71-1120 094000-0630 12V140-3 (Right bank)
6 6156-71-1110 094000-0380 6D125-3
7 6218-71-1110 094000-0341 6D140-3
the above table.
Commonality
Komatsu part
Symbol Part name Q'ty Contents of work and remarks with 6D125-3,
No.
6D140-3
1 799-609-5130 Timer joint (Outside diameter: 25) 1 Q
2 799-609-5140 Timer joint (Outside diameter: 35) 1 Q
L Installation of coupling
3 799-609-5150 Coupling (Outside diameter: 25) 1 Q
4 799-609-5160 Coupling (Outside diameter: 35) 1 Q
1 799-609-5080 Tube (4 x 8 x L500, internal thread) 4 Q
M Piping for test
2 799-609-5090 Tube (4 x 8 x L900, internal thread) 2 Q
1 799-609-1040 1 Q
N Holding spanner Installation of coupling
2 799-609-1050 1 Q
1 799-609-5190 Pressure regulator 1 Q
P Measurement of discharge pressure
2 799-609-5210 Pressure gauge 1 Q
1 799-607-4060 Wiring harness 1 For checking G sensor
2 799-607-4070 Wiring harness 1 For measuring common rail pressure
Q 3 799-607-4080 Power unit 1
4 ND029600-580 G sensor 1 G sensor for test
5 Purchased Tester 1 —
R 799-609-5010 Suction hose 1 — Q
1 7872-10-910A Controller 1 — Q
S
2 799-607-4040 Wiring harness 1 — Q
T 799-609-5180 Fuel filter 1 — Q
Commercially
U
available
Measuring cylinder 1 Measurement of pump delivery Q
Extractor
1 799-609-5230
(For pump category No. 1, 6)
1 Q
V Removal of coupling
Extractor
2 799-609-5220
(For pump category No. 2 – 5, 7)
1 Q
Local procure-
1
ment part
Bracket 1 Fixing of drive shaft side Q
W
Local procure-
2
ment part
Bracket 1 Fixing of feed pump side Q

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Performance test Special tools list for performance test
Tool Q1 (799-607-4060) Tool Q2 (799-607-4070)
Tool Q3 (799-607-4080) Tool Q4 (ND029600-580)
Tool W1 (Local procurement part) Tool W2 (Local procurement part)
a Since the shape in this drawing depends on the shapes of the fuel filter and test bench, check the parts in
the site when making in the site.

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Performance test Sketches of special tools

Installation dimensional drawing of tool P1 (pressure regulator)
1. Fuel outlet (to test bench) Precautions

2. Pressure limiter 1. Do not give a strong impact to the pressure lim-
3. Pressure sensor iter or pressure sensor.
4. Fuel inlet (from fuel supply pump) 2. If the fuel supply pump is connected fuel outlet
(M14 x 1.5) port (1), the main unit may be broken because of
5. Hole for fixing pressure regulator high pressure.
(4 x M5, Depth: 10) 3. If the back pressure is high (1 MPa {10 kg/cm2}
or higher), the handle becomes heavy and the
life of the main unit is shortened.

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1 6251-71-1120 094000-0570 6D125-5
2 6261-71-1110 094000-0580 6D140-5
3 6245-71-1110 094000-0600 6D170-5
4 6219-71-1110 094000-0620 12V140-3 (Left bank)
5 6219-71-1120 094000-0630 12V140-3 (Right bank)
6 6156-71-1110 094000-0380 6D125-3
7 6218-71-1110 094000-0341 6D140-3
the above table.
Dimensional drawing of fuel supply pump (6261-71-1110)

Pump
No.
1, 6 6251-71-1120 214.4 57 60.3 129.0 11.0 75 55 54 27 14.5 M12x1.75 15
2, 7 6261-71-1110 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12
3 6245-71-1110 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12
4 6219-71-1110 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12
5 6219-71-1120 239.0 59 60.1 139.5 12.5 75 57 70 35 14.5 M12x1.75 12

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Locations of high-pressure pipe, overflow valve

and G sensor
Pump P/N: 6251-71-1120, 6261-71-1110,

6156-71-1110, 6218-71-1110
Symbol Name Position
A High pressure outlet Left side
B Over flow valve Right side
C G sensor Right side
Pump P/N: 6245-71-1110, 6219-71-1110

A High pressure outlet Right side
B Over flow valve Right side
C G sensor Right side
Pump P/N: 6219-71-1120

A High pressure outlet Left side
B Over flow valve Left side
C G sensor Left side

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Performance test Performance test of fuel supply pump
Performance test of fuel 4) Stick tape [2] to the oil inlet hole of the fuel
supply pump flange.
supply pump a Stick this tape to prevent oil from leaking
through the oil hole.
Applicable engine:
6D125-5, 6D140-5, 6D170-5,
12V140-3, 6D125-3, 6D140-3
1. Test bench setting
1) Install tool W1 (bracket) to the test bench
temporarily.
a Tool W1 (bracket) is a local procurement
part.
5) Remove plug (2) and check that there is

engine oil (10W30) in the crankcase.
2) Install tool L (timer joint) to the drive shaft of

the test bench.
Tool L (Timer joint):
L1: 799-609-5130 (Pump category No. 1)
L2: 799-609-5140 (Pump category No. 2 – 5)
6) Check that key (3) is installed securely to the

camshaft of fuel supply pump (1).
3) Install fuel supply pump (1) to tool W1

(bracket).
7) Using tool N (holding spanner), install tool

L3 or L4 (coupling) to fuel supply pump (1).
a Insert stopper [4] in the peripheral hole of
tool L3 or L4 (coupling) to lock and then
tighten the nut.

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Tool N (Holding spanner): 10) Securely tighten the mounting bolts of tool
N1: 799-609-1040 L3 or L4 (coupling) and those of tool W1
(Pump category No. 1) (bracket).
N2: 799-609-1050
Tool L3 or L4 (Coupling)
L3: 799-609-5150
L4: 799-609-5160
3 Coupling mounting nut:
127 – 147 Nm {13 – 15 kgm}
176 – 196 Nm {18 – 20 kgm}
11) Install tool W2 (bracket) to the bottom of the

pump.
a Tool W2 (bracket) is a local procurement
part.
a When replacing the fuel supply pump, re-

move tool L3 or L4 (coupling) with tool V
(extractor).
Tool V: 799-609-5230
Tool V: 799-609-5220
(Pump category No. 2 – 5) 2. Installation of pressure regulator
Using the mounting bolts (M5, 4 pieces), install
tool P1 (pressure regulator) to the test bench.
• Install tool P1 by actually positioning it on the
machine (See the inhalation dimensional
drawing of the pressure regulator).
8) Move fuel supply pump (1) to the drive shaft

side of the test bench and tighten the mount-
ing bolts of tool L3 or L4 (coupling) tempo-
rarily.
9) While rotating the camshaft of the fuel sup-

ply pump at a speed of 20 rpm or less, cen-
ter the coupling.

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3. Installation of fuel filter

1) Install fuel filter fixing bracket [4].
2) Install tool T (fuel filter).

a Fuel filter fixing bracket [4] is a local pro-
curement part.
5. Connection of high-pressure piping

1) Connect tool M (tube) between the fuel sup-
ply pump and pressure regulator.
a The figure shows an example of test on
the PCV1 side.
a The camshaft side is PCV1.
4. Connection of low-pressure piping
a Connect all the low-pressure pipes with joint 2) Connect tube [11] between the pressure reg-
bolts (M14). ulator and test bench.
3 Sleeve nut:
1) Connect hose [5] between the fuel filter and
fuel supply pump. 39.2 – 49.0 Nm {4 – 5 kgm}
2) Connect hose [6] between the fuel filter and

feed pump.
3) Connect tool R (suction hose) between the

test bench and feed pump.
4) Connect hose [8] between the test bench

and overflow valve.
6. Installation of pressure gauge

Install tool P2 (pressure gauge) to tool P1 (pres-
sure regulator).
5) Connect hose [9] between the test bench

and pressure limiter.
6) Connect hose [10] between the PCV valve

and test bench.

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7. Replacement of G sensor (Except 6D125-3, 8. Performance test

6D140-3) 1) Testing condition
a Applicable engines (A) and (B) use different • Fuel: Test oil (ISO 4113)
G sensors. • Fuel temperature:
A: 6D125-3, 6D140-3 40 – 45 °C (104 – 113 °F)
Part No. of G sensor for (A) ND094000-0580 • Lubricating oil: Engine oil (10W30)
B: 6D125-5, 6D140-5, 6D170-5, 12V140-3 • Set voltage of controller power supply:
Part No. of G sensor for (B) ND949979-1300 27.8 – 28.2 V
Accordingly, be sure to replace the G sensor a Check that the cam chamber of the fuel
with G sensor for (A) above before the test. supply pump is filled with lubricating oil
a Since the shim does not need to be adjusted, up to the specified level.
use it as it is. a Direction of fuel supply pump rotation:
Counterclockwise (6156-71-1110, 6251-
1) Preparation of G sensor 71-1120)
1] Remove G sensor (4) from the fuel sup- Clockwise (Except above)
ply pump.
2] Prepare tool Q4 (G sensor for test). 2) Check of priming pump
Tool Q4: ND029600-580 1] Drain the fuel from tool R (suction hose)
between the fuel tank and feed pump.
2) Installation of G sensor
1] Apply grease to the O-ring of tool Q4 (G
sensor for test).
2] Install tool Q4 (G sensor for test) to the
fuel supply pump.
3 Mounting bolt:
4.4 – 8.3 Nm {0.45 – 0.85 kgm}
2] Disconnect hose [6] between the fuel fil-

ter and feed pump from the fuel filter dis-
charge side.
3] Insert hose [6] in tool U (measuring cylin-
der) to receive the fuel.

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4] Operate priming pump (5) at a rate of 1

stroke/sec and check that the fuel is
sucked up in 55 strokes.
a Check while the fuel supply pump is
stopped.
4) Preparation before measurement of high

pressure delivery (Connection of electric wir-
ing harness)
The method of measuring pressure with the
pressure sensor installed to the pressure
3) Check of feed pump delivery regulator is explained below.
1] Drain the fuel from tool R (suction hose) 1] Connection of wiring harness to common
between the fuel tank and feed pump rail pressure sensor
securely again. • Connect tool Q2 (wiring harness) to
common rail pressure sensor [13] of
tool P1 (pressure regulator).
• Connect tool Q2 (wiring harness) to
tool Q3 (power unit).
• Connect tool Q2 (wiring harness) to
tester [14].
• Connect power supply wiring har-
ness [15] of tool Q3 (power unit) to a
wall outlet.
2] Disconnect hose [6] between the fuel fil-

ter and feed pump and connect hose
[12] between the feed pump and test
bench.
3] Set the fuel supply pump speed to 400
rpm and check that the delivery is at
least 2.4 l/min with the flow meter of the
test bench.

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2] Connection of wiring harness to PCV 5) Check before measurement of high pressure

valve and controller delivery
• Connect tool S2 (wiring harness) to G 1] Check that the piping and wiring are con-
sensor (4). nected normally.
• Connect tool S2 (wiring harness) to 2] Turn the power switch ON and check
PCV valve (7) and tool S1 (control- that the power supply voltage of tool S1
ler). (controller) is 27.8 – 28.2 V.
• Connect power supply wiring har- 3] Turn the pressure regulator valve of the
ness [16] of tool S1 (controller) to the pressure regulator to the left end.
DC power supply [18]. 4] Set the fuel supply pump speed to 200
rpm and check that no fuel is leaking.
5] Check that tool S1 (controller) indicates
"13" while the fuel supply pump cam-
shaft is rotating.
6) Measurement of high pressure delivery

a Measure the high pressure delivery and
enter the result in the "Performance test
check sheet" at the end of this section.
1] Set the fuel supply pump speed to the
following.
1,250 rpm (Pump category No. 1)
1,100 rpm (Pump category No. 2 – 5)
2] Turn the pressure regulator valve handle
of the pressure regulator to the right and
set the discharge pressure of the fuel
supply pump to 160 MPa {1,632 kg/cm2}.
a The relationship between the pres-
sure regulator pressure and pressure
sensor output voltage becomes as
shown below.
At 160 MPa {1,632 kg/cm2}:
3.0 – 3.2 V (Measured value)

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3] Using the flowmeter of the test bench, 7) Check of G sensor signal (Except 6D125-3,
measure the PCV1 delivery at this time. 6D140-3)
4] Turn the pressure regulator valve of the 1] Replace tool Q4 (G sensor for test)
pressure regulator to the left end and installed in the previous step with the
check that the pressure is "0". original G sensor (4).
5] Decrease the fuel supply pump speed Tool Q4: ND029600-580
gradually to "0". a Apply grease to the O-ring of G sen-
6] Exchange the high pressure fuel tube sor (4) when installing the G sensor.
and drain hose connected to PCV1 and 2 O-ring: Grease (G2-LI)
PCV2 and connect them again. 3 Mounting bolt:
a PCV1 is on the camshaft side. 4.4 – 8.3 Nm {0.45 – 0.85 kgm}
7] Similarly to the above, measure the
PCV2 delivery.
Standard values
• Measure PCV1 5 times and then
PCV2 5 times and check that the
measured values are in the following
range.
285 – 315 cc/200 rev.
400 – 460 cc/200 rev.
Reference: Check of indication of controller

1] Tool S1 (controller) indicates 787210910A
2 letters by 2 and then indicates "00".
2] While the fuel supply pump camshaft is
rotating,
• Tool S1 (controller) indicates "13".
a If "13" is indicated, the signal from the
G sensor is normal.
3] While tool S1 (controller) is indicating
"74" or "75",
• If "74" is indicated, the PCV1 circuit is
disconnected or shorted. In this
case, check tool S2 (wiring harness)
and connector.
• If "75" is indicated, the PCV2 circuit is
disconnected or shorted. In this
case, check tool S2 (wiring harness)
and connector.

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2] Connect tool Q1 (wiring harness) to G

sensor (4).
3] Connect tool Q1 (wiring harness) to tool
Q3 (power unit).
4] Connect tool Q1 (wiring harness) to cir-
cuit tester or oscilloscope [17].
a Procure circuit tester or oscilloscope
[17] locally.
5] Connect power supply wiring harness
[15] of tool Q3 (power unit) to a wall out-
let.
6] Set the fuel supply pump speed to 1,000
rpm.
7] Measure the sensor output frequency at
this time with circuit tester or oscillo-
scope [17].
Standard value (When fuel supply pump

speed is 1,000 rpm): 110 – 125 Hz

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Performance test check sheet (1)

Pump part No. Date of test
Pump serial No. Work No.
Tested by
1. Measurement conditions
Fuel: Test oil (ISO4113)
Fuel temperature: 40 – 45 °C {104 – 113 °F}
Lubricating oil: Engine oil (10W30)
Direction of pump rotation:
Counterclockwise as seen from drive shaft end (6156-71-1110)
Clockwise as seen from drive shaft end (6218-71-1110)
2. Performance test
Measured
Item Measurement conditions Standard value Judgment
value
a. Pump speed: 0 rpm
b. Drain the fuel from hose between the fuel
tank of the test bench and feed pump. • The measuring cylin-
1) Priming pump c. Disconnect the feed pump outlet hose and der must be filled with
prepare for receiving the fuel with a measur- fuel in 55 strokes of
ing cylinder. the pump.
d. Operate the priming pump at a rate of 1

stroke/sec.
a. Drain the fuel from hose between the fuel
tank of the test bench and feed pump.
b. Disconnect the feed pump outlet hose and
2) Feed pump • Min. 2.4 l/min
connect the hose between the feed pump
and test bench.
c. Pump speed: 400 rpm
Pump speed: 200 rpm • Fuel must not leak. —
a. Pump speed: 1,100 rpm 6156-71-1110: PCV1 PCV2 PCV1 PCV2
172.5 ± 15 cc/100 rev.
b. Operate the pressure regulator and adjust
the pump discharge pressure to 120 MPa 6218-71-1110:
{1,224 kg/cm2}. 240 ± 15 cc/100 rev.
3) High pressure • Dispersion of delivery

delivery of PCV1 and PCV2:
Max. 9 cc/100 rev.
3. Comment

(11)
Applicable engine: 6D125-5

Pump part No. 6251-71-1120 Date of test
Tested by
Direction of pump rotation: Counterclockwise as seen from drive shaft end
2. Performance test
Measured
value

stroke/sec.
and test bench.
a. Pump speed: 1,250 rpm • 285 – 315 cc/200 rev. PCV1 PCV2 PCV1 PCV2
b. Operate the pressure regulator and adjust • Dispersion of delivery
the pump discharge pressure to 160 MPa of PCV1 and PCV2:
{1,632 kg/cm2}. Max. 18 cc/200 rev.
3) High pressure
delivery
4) G sensor Pump speed: 1,000 rpm • 110 – 125 Hz
3. Comment

(11)
Applicable engine: 6D140-5, 6D170-5, 12V140-3

Pump part No. Date of test
Tested by
Direction of pump rotation: Clockwise as seen from drive shaft end
2. Performance test
Measured
value

stroke/sec.
and test bench.
a. Pump speed: 1,100 rpm • 400 – 460 cc/200 rev. PCV1 PCV2 PCV1 PCV2
b. Operate the pressure regulator and adjust • Dispersion of delivery
the pump discharge pressure to 160 MPa of PCV1 and PCV2:
{1,632 kg/cm2}. Max. 18 cc/200 rev.
3) High pressure
delivery
4) G sensor Pump speed: 1,000 rpm • 110 – 125 Hz
3. Comment

(11)

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SEBM040401

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Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

00-2 Component of engine

Safety notice 1 (Rev. 2007/03)

Important safety notice

1. General precautions 7) If welding repairs are needed, always

Component of engine 00-3

00-4 Component of engine

4. Precautions for sling work and making

Component of engine 00-5

00-6 Component of engine

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

Component of engine 00-7

How to read the shop manual 1

1. Composition of shop manual

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

2. Revision and distribution

00-8 Component of engine

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Component of engine 00-9

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

00-10 Component of engine

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Component of engine 00-11

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

00-12 Component of engine

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

Component of engine 00-13

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

00-14 Component of engine

Component of engine 00-15

00-16 Component of engine

4) Drying wiring harness

Component of engine 00-17

5. Points to remember when troubleshooting

00-18 Component of engine

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the