SEBM024002

Fuel supply pump

(Common rail type)

Fuel supply pump model

DENSO CRI type

© 2008
All Rights Reserved 00-001
Printed in Japan 02-08 (02) (11)
 Contents

13 Disassembly and assembly ....................................................................... 13-001

14 Performance test ................................................................................................ 14-001

00-002 Fuel supply pump

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Fuel supply pump 00-003

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 13 Disassembly and assembly

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
Sketches of special tools ........................ 13-028
Disassembly and assembly of
fuel supply pump..................................... 13-030

Fuel supply pump 13-001

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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
799-609-1460 Cam clearance measure (ø30) 1 Q
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

13-002 Fuel supply pump

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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

Fuel supply pump 13-003

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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

13-004 Fuel supply pump

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Disassembly and assembly Sketches of special tools

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.

Fuel supply pump 13-005

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

13-006 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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)
799-609-1050 (Pump category No. 1)

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.

Fuel supply pump 13-007

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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

13-008 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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).

Fuel supply pump 13-009

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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
(Pump category No. 2)

13-010 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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)
799-609-1080 (Pump category No. 1)
(Pump category No. 1) 799-609-1170 (ø60)
799-609-1090 (Pump category No. 2)
(Pump category No. 2) E5 (Replacer) 799-609-1180 (ø61)
(Pump category No. 1)
799-609-1190 (ø71)
(Pump category No. 2)
E7 (Base) 799-609-1220 (ø62)
(Pump category No. 1)
799-609-1230 (ø72)
(Pump category No. 2)

Fuel supply pump 13-011

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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)
(Pump category No. 1)
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)
(Pump category No. 2)
E5 (Replacer) 799-609-1180 (ø61)
(Pump category No. 1)
799-609-1190 (ø71)
(Pump category No. 2)

13-012 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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)
(Pump category No. 1)
790-609-1190 (ø71)
(Pump category No. 2)
2 Outside surface of outer race:
Gear oil (SAE90 or equivalent)

2) Press fit bearing (26) on the feed pump side.

Tool: E8 Pipe (ø30): 799-609-1260
2 Inside surface of bearing:
Gear oil (SAE90 or equivalent)
2) Press fit oil seal (30) to the bearing cover
end.
2 Oil seal lip surface:
Gear oil (SAE90 or equivalent)

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

Fuel supply pump 13-013

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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.
2 O-ring: Grease (G2-LI)

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.

13-014 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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.

Fuel supply pump 13-015

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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)
(Pump category No. 1)
799-609-1460 (ø30)
(Pump category No. 2)
• 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.
2 O-ring: Grease (G2-LI)
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".

13-016 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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

Fuel supply pump 13-017

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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.
Tool: B1 (Extractor) 799-609-1030
B2 (Holding spanner)
799-609-1040
(Pump category No. 1)
799-609-1050
(Pump category No. 2)
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)
• Install the plate with the wider groove fac-
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.
2 O-ring: Grease (G2-LI)
3 Nut: 17.6 – 24.5 Nm {1.8 – 2.5 kgm}

13-018 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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).

Fuel supply pump 13-019

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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)

13-020 Fuel supply pump

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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 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)
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. 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
799-609-1450 Cam clearance measure (ø25) 1 Q
2
799-609-1460 Cam clearance measure (ø30) 1 Q
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

Fuel supply pump 13-021

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Disassembly and assembly Component part drawing

Component part drawing

13-022 Fuel supply pump

(11)
Disassembly and assembly Component part drawing

Fuel supply pump 13-023

(11)
Disassembly and assembly Component part drawing

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

13-024 Fuel supply pump

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Disassembly and assembly Component part drawing

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

Fuel supply pump 13-025

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Disassembly and assembly Component part drawing

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

13-026 Fuel supply pump

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Disassembly and assembly Component part drawing

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

Fuel supply pump 13-027

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Disassembly and assembly Sketches of special tools

Sketches of special tools

Bracket [1] (Installation dimensional drawing of 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 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

13-028 Fuel supply pump

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Disassembly and assembly Sketches of special tools

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.

Fuel supply pump 13-029

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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.
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).
Tool: B1 (Extractor) 799-609-1030

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
(Pump category No. 1)

13-030 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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
across flats: 3 mm).
5) Using tweezers [2], remove lower spring
seat and tappet (9).

Fuel supply pump 13-031

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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
across flats: 5 mm).

13-032 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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.

Fuel supply pump 13-033

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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
(Pump category No. 1)
799-609-1150
(Pump category No. 2 – 5)

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)
799-609-1080 (Pump category No. 1)
(Pump category No. 1) 799-609-1230 (ø72)
799-609-1090 (Pump category No. 2 – 5)
(Pump category No. 2 – 5)

13-034 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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.
2 Outside surface of outer race:
Gear oil (SAE90 or equivalent)
Tool: E7 (Base) 799-609-1220 (ø62)
(Pump category No. 1)
799-609-1230 (ø72)
(Pump category No. 2 – 5)

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.
2 Oil seal lip surface:
Gear oil (SAE90 or equivalent)
Tool: F1 (Oil seal presser) 799-609-1240
F2 (Oil seal guide) 799-609-1250

Fuel supply pump 13-035

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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.
2 Inside surface of bearing:
Gear oil (SAE90 or equivalent)

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
2 Inside surface of bearing:
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)
(Pump category No. 1)
799-609-1170 (ø60)
(Pump category No. 2 – 5)
E5 (Replacer) 799-609-1180 (ø61)
(Pump category No. 1)
799-609-1190 (ø71)
(Pump category No. 2 – 5)

13-036 Fuel supply pump

(11)
Disassembly and assembly Disassembly and assembly of fuel supply pump

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)
(Pump category No. 2 – 5)
E5 (Replacer) 790-609-1180 (ø61)
(Pump category No. 1)
790-609-1190 (ø71)
(Pump category No. 2 – 5)
2 Outside surface of outer race:
Gear oil (SAE90 or equivalent)

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.
2 Oil seal lip surface:
Gear oil (SAE90 or equivalent)

Fuel supply pump 13-037

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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)
(Pump category No. 1)
799-609-1440 (ø30)
(Pump category No. 2 – 5)
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)
(Pump category No. 1)
799-609-1460 (ø30)
(Pump category No. 2 – 5)

13-038 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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.
2 O-ring: Grease (G2-LI)
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.

Fuel supply pump 13-039

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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.
2 O-ring: Grease (G2-LI)
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.
Tool: B1 (Extractor) 799-609-1030
B2 (Holding spanner)
799-609-1040
(Pump category No. 1)
799-609-1050
(Pump category No. 2 – 5)
12. Installation of feed pump
1) Install side plate (16) (inner) as follow.
• Install the plate with the wider groove fac-
ing down. (Pump category No. 2 – 5)
• Install the plate with the wider groove fac-
ing up. (Pump category No. 1)

13-040 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

• 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:
(Pump category No. 2 – 5)
1.96 – 2.94 Nm {0.2 – 0.3 kgm}

Fuel supply pump 13-041

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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).

13-042 Fuel supply pump

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Disassembly and assembly Disassembly and assembly of fuel supply pump

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}

Fuel supply pump 13-043

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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
Sketches of special tools ........................ 14-004
Performance test of fuel supply pump .... 14-007

Fuel supply pump 14-001

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Performance test Special tools list for performance test

Special tools list for performance test

Applicable pump part No.

Pump category No. Komatsu part No. Denso part No. Engine
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

a In the following explanation, the fuel supply pump specifications are indicated by the pump category Nos. in
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

14-002 Fuel supply pump

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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.

Fuel supply pump 14-003

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Performance test Sketches of special tools

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.

14-004 Fuel supply pump

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Performance test Sketches of special tools

Applicable pump part No.

Pump category No. Komatsu part No. Denso part No. Engine
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
a In the following explanation, the fuel supply pump specifications are indicated by the pump category Nos. in
the above table.

Dimensional drawing of fuel supply pump (6261-71-1110)

Pump dimension table

Pump
category Pump part No. A B C D E F G H I J K L
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

Fuel supply pump 14-005

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Performance test Sketches of special tools

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

Symbol Name Position
A High pressure outlet Right side
B Over flow valve Right side
C G sensor Right side

Pump P/N: 6219-71-1120

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

14-006 Fuel supply pump

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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.

Fuel supply pump 14-007

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Performance test Performance test of fuel supply pump

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
(Pump category No. 2 – 5)
Tool L3 or L4 (Coupling)
L3: 799-609-5150
(Pump category No. 1)
L4: 799-609-5160
(Pump category No. 2 – 5)
3 Coupling mounting nut:
127 – 147 Nm {13 – 15 kgm}
(Pump category No. 1)
176 – 196 Nm {18 – 20 kgm}
(Pump category No. 2 – 5)

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
(Pump category No. 1)
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.

14-008 Fuel supply pump

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Performance test Performance test of fuel supply pump

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.

Fuel supply pump 14-009

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Performance test Performance test of fuel supply pump

14-010 Fuel supply pump

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Performance test Performance test of fuel supply pump

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.
2 O-ring: Grease (G2-LI)
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.

Fuel supply pump 14-011

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Performance test Performance test of fuel supply pump

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.

14-012 Fuel supply pump

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Performance test Performance test of fuel supply pump

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)

Fuel supply pump 14-013

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Performance test Performance test of fuel supply pump

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.
(Pump category No. 1)
400 – 460 cc/200 rev.
(Pump category No. 2 – 5)

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.

14-014 Fuel supply pump

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Performance test Performance test of fuel supply pump

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

Fuel supply pump 14-015

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Performance test Performance test of fuel supply pump

Performance test check sheet (1)

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

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

14-016 Fuel supply pump

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Performance test Performance test of fuel supply pump

Performance test check sheet (2)

Applicable engine: 6D125-5

Pump part No. 6251-71-1120 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

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: 1,250 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

Fuel supply pump 14-017

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Performance test Performance test of fuel supply pump

Performance test check sheet (3)

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

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: Clockwise as seen from drive shaft end

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 • 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

14-018 Fuel supply pump

(11)