SEBE61500109

6Dl25 SERIES
DIESEL ENGINE

0 1995KOMAl’&U
All Rights Reserved
IO-95(01)05501
 No. of page

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-001

11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 11-001

12 TESTING AND ADJUSTING . . . . . . . ..I................................ 12-001

13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 13-001

14 MAINTENANCE STANDARD . .. .. ... .. . ... .. ... .. .. . ... .. .... . .... ... 14-001

15 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . 15-001

6D125 SERIES
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6D125 SERIES OOG2-3

SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is 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 A. IS used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.

2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for weld- ing signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21 When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.

14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.

16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.

18. As a general .rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.

00-4
FOREWORD GENERAL

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.

00-5
FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs, They are divided as follows: (a@@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: issued for each engine series

Electrical volume: Each issued as one

Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.

FILING METHOD
See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are

A
Following examples show how to read the
Safety necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3
or other precautions for pre-
Caution serving standards are neces-
*
Item number (IO. Structure sary when performing the
and Function) ~ work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
Places that require special at-
Tightening
Unit number (I. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting)
‘T Consecutive page number for & I Coat
Places to be coated with ad-
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Oil, water must be added, and the ca-
Additional pages: Additional pages are indi- % pacity.

cated by a hyphen (-1 and number after the

Places where oil or water
page number. File as in the example. : must be drained, and quan-
Example: I Drain tity to be drained.
i-
IO-4 12-203
10-4-I - 12-203-I
1O-4-2 _._+ Added pages -C12_203_2
IO-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &

. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made: L_ u L-i u u
I) Check for removal of all bolts fastening 100% 79% 71% 41%
88%
the part to the relative parts. SAD00479

2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
4) Do not sling a heavy load with ropes form-
Wire ropes
ing a wide hanging angle from the hook.
(Standard “Z” or “S” twist ropes
When hoisting a load with two or more
without galvanizing)
ropes, the force subjected to each rope
Rope diameter will increase with the hanging angles. The
Allowable load
table below shows the variation of allow-
mm KN tons able load KN (kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 KN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 KN (2000 kg) of total weight can
16 27.5 2.8 be suspended. This weight becomes 9.8
18 35.3 3.6 KN (1000 kg) when two ropes make a 120”

20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 KN (4000 kg) if they sling
30 98.1 10.0
a 19.6 KN (2000 kg) load at a lifting angle
40 176.5 18.0 of 150”.
0
50 274.6 28.0 6
60 392.2 40.0 _
&!

* The allowable load value is estimated to ~~~~

be one-sixth or one-seventh of the break-
ing strength of the rope used.

2) Sling wire ropes from the middle portion 30 60 90 120 150

of the hook. Lifting angle (degree) SAD00480

00-7
FOREWORD COATING MATERIALS

COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.

Category <omatsu code Pat-t No. Q’ty Container Main applications, features
* Used to prevent rubber gaskets, rubber cushions,
LT-IA 790-129-9030 150 g Tube
and cork plugs from coming out
. Used in places requiring an immediately effec-

LT-10 790-129-9050
20 9 Plastic tive, strong adhesive. Used for plastics (except
1x2) container polyethylene, polypropylene, tetrafluoroethylene,
and vinyl chloride), rubber, metal, and non-metal.
* Features: Resistance to heat, chemicals
Plastic
LT-2 09940-00030 50 g container
- Used for anti-loosenina and sealant DurDoses for
Adhesive bolts and plugs. -
rdhesive * Used as adhesive or sealant for metal, glass, plastic
‘90-129-9060
Set of adhesive 1 Kg
LT-3 hardening Can
Ind hardengins
gent:
Igent)
500 g
Plastic * Used as sealant for machined holes
LT-4 790-I 29-9040 250 g
container
* Features: Resistance to heat, chemicals
Loctite 646-50 79A-129-91 IO 50 cc - - Used at joint portions subject to high tempera-
ture
- Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube Dackinas of Dower train case, etc.
* Features: Resistance to heat
* Used as sealant for flange surfaces and bolts at
high temperature locations, used to prevent sei-
LG-3 790-129-9070 1 Kg Can zure
- Used as sealant for heat resistant gasket for high
temperature locations such as engine precombustion
chamber, exhaust pipe
* Features: Resistance to water, oil
- Used as sealant for flange surface, thread
LG-4 790-I 29-9020 200 g Tube
* Also possible to use as sealant for flanges with
Gasket sealant large clearance
* Used as sealant for mating surfaces of final drive
case, transmission case
* Used as sealant for various threads, pipe joints,
Plastic flanges
LG-5 790-I 29-9080 1 Kg * Used as sealant for tapered plugs, elbows, nip-
container
ples of hydraulic piping
* Features: Silicon based, resistance to heat, cold
LG-6 09940-00011 250 g Tube * Used as sealant for flange surface, thread
* Used as sealant for oil pan, final drive case, etc.
- Features: Silicon based, quick hardening type
LG-7 09920-00150 150 g Tube - Used as sealant for flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
Rust preven - Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
squeaking)
tion lubricant
Molybdenum * Used to Drevent seizure or scuffina of the thread
disulphide Iu- LM-P 09940-00040 200 g Tube when press fitting or shrink fitting-
bricant * Used as lubricant for linkaqe, bearinqs, etc.
;YG350LI * General purpose type
SYG-400LI
Liiium grease G2-LI SYG-400LI-A Various Various
:YG-16OLI
;YGA-IGOCNLI
jSG2-400CA * Used for normal temperature, light load bearing
jYG2-350CA at places in contact with water or steam
Calcium grease G2-CA jYG2-400CA-P Various Various
jYG2-160CA
jYGA-IGCNCA
Molybdenum . Used for places with heavy load
400 g
disulphide SYG2-400M 3ellows type
lopercase
grease

00-8
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given
in section of DISASSEMBLY AND ASSEMBLY.

1 Kam = 9.806 Nm

Thread diameter
of bolt
Width
across flats T SAD00481 SAD00482

mm mm Nm kgm

6 10 13.2k1.4 1.35kO.15
8 13 31.4k2.9 3.2kO.3
10 17 65.7k6.8 6.7kO.7
12 19 112k9.8 11.5+1.0
14 22 177+-19 18.Ok2.0

16 24 279*29 28.5*3
18 27 383139 3954
20 30 549k58 56f6
22 32 745f78 76f8
24 36 927+98 94.5+ 10

27 41 132Ok 140 135* 15

30 46 17201190 175*20
33 50 2210f240 225+25
36 55 2750+290 28Ok30
39 60 3280&340 335k 35

Ir This torque table does not apply to the bolts with which nylon packings or other
nonferrous metal washers are to be used, or which require tightening to otherwise
specified torque.

00-9
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Thread diameter Width

Tightening torque
of bolt across flats
mm mm Nm kgm

10 14 65.7 k 6.8 6.7kO.7

12 17 112k9.8 11.5&l
16 22 279+29 28.5+3

TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.

SAD00483

Thread diameter
of nut part
mm
\iNidth across flats
of nut part

mm
T Nm
Tightening torque

km
14 19 24.5f 4.9 2.5-10.5
18 24 49+ 19.6 5k2
22 27 78.5+ 19.6 8+2
24 32 137.3k29.4 14k3
30 36 176.5k29.4 18+3
33 41 196.1+49 2Ok5
36 46 245.2+ 49 25+5
42 55 294.2k 49 30+5

00-l0
FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire
Nominal CatokzjD. Currerirating
number Number of Dia. of strandscross section Applicable circuit
strands (mm) (mm?
I

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Startina

60 127 0.80 63.84 13.6 178 Startina

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Prior-
ity

6
FOREWORD CONVERSION TABLE

CONVERSION TABLE

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.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point 0 gives the value when converting
from millimeters to inches. Therefore, 55 m-m = 2.165 inches.

2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide 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 IO, 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 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
0

@- . .. .50
. . . . .. . . .. . .1.969
. . .. . . . . . . . . .2.008
. .. .. . . . . .. . ..2.047
. . . . . . . . .. .. . . .2.087
. . .. . .. . . . . . .2.126
. .. . . . . . . . . . lmi 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

00-l 2
FOREWORD CONVERSIONTABLE

Millimeters to inches
1 mm = 0.03937 in

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 01827 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

I I I I I

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 03.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 25.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 47.71 149.91 152.12

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

00-13
FOREWORD CONVERSIONTABLE

Liter to U.S. Gallon

I! = 0.2642 U.S. Gal

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

Liter to U.K. Gallon

I! = 0.21997 U.K. Gal

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 7.969 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

00-14
FOREWORD CONVERSIONTABLE

kgm to ft. lb
1 kgm = 7.233 ft.lb

\“\ 0

0
1

7.2
2

14.5
3

21.7
4 5 6

43.4
7 8 9

65.1
0 28.9 36.2 50.6 57.9

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

00-l 5
FOREWORD CONVERSIONTABLE

kg/cm* to lb/in*
1 kg/cm* = 14.2233 lb/in2

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 1010 1024 1038 1053 1067 1081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266

90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693

120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835

130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977

140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-l 6
FOREWORD CONVERSION TABLE

Temperature
Fahrenheit-Centigrade Conversion ;a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade 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 81 117.8

-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 46 118.4 28.3 63 181.4
-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 JO 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

00-17
 ENGINE
01 GENERAL

General view ....................... 01-002

Specifications ...................... 01-004
General assembly drawing .............. 01-010
Engine performance curve .............. 01-018
Weight table ....................... 01-040

6D125 SERIES Ol--01

GENERAL GENERAL VIEW

GENERAL VIEW

6D125-1 * The configulation may differ depending on the

product on which the engine is mounted.

1. fan pulley
2. Fuel filter
3. Oil filter
4. Adapter
5. Fuel injection pump
6. Automatic timer
7. Crankshaft pulley
8. Vibration damper
9. Dipstick

6150P001

10. Starting motor

11. Oil cooler
12. Alternator
13. Thermostat housing

6 I5OPOO2

0 l-002 6D125 SERIES

GENERAL GENERAL VIEW

S6D125-1

1. Fan pulley
2. Dipstick
3. Fuel filter
4. Adapter
5. Fuel injection pump
6. Oil filter
7. Crankshaft pulley
8. Vibration damper

6 I5OPOO3

9. Turbocharger
IO. Alternator
11. Thermostat housing
12. Oil cooler
13. Starting motor

13

6 I5OPOO4

6D125 SERIES 0 l-003

GENERAL SPECIFICATIONS

SPECIFICATIONS

Engine model 6DI25-1

D50A-I 7 D53A-17
Applicable machine D50F-17
D50P-I 7 D53P-17
Number of cylinder -
(mm) 6-125x 150
Bore x Stroke

Total piston displacement (cc) I 1,040

Firing order l-5-3-6-2-4

Overall length (mm) 1,533 1,532 1,440

Overall width (mm) 850 850 850

Overall height
(mm) 1,555 1,555 1,555
(excluding exhaust pipe)
Overall height - - -
(mm)
(including exhaust pipe)

Flywheel horsepower (HP/rpm) 120/1,750 13811,900 12411.900

Maximum torque (kgm/rpm) 65.511 ,I 00 66/I ,300 62.5/1,300

High idling speed (rpm) 1,875 - 1,975 2,050 - 2,150 2,050 - 2,150

Low idling speed (rpm) 650 - 700 650 - 700 600 - 650

c”,;ypurn fuel consumption (g,HPhj

155 155 156

Dry weight (kg) 1,090 1,090 970

Fuel pump Bosch PE - NB type

Governor Bosch RSV Centrifugal, all-speed type

Lubricating oil amount

(refill capacitv) (0

Coolant amount (engine only) (8)

Alternator 24V, 13A 24V, I3A 24V. I3A

Starting motor 24V, 7.5 kw 24V, 7.5 kw 24V. 7.5 kw

Battery 12V 150Ah x 2 I2V 150Ah x 2 12V 150Ah x 2

Turbocharger - - -

Air compressor - - -

Others - - -

01204 6Dl25 SERIES

GENERAL SPECIFICATIONS

6D125-1

D58E-1 D60P-8
D60A-8 D60E-8 D60S-8
D58P-1 D60PL-8

6-125x150

11,040

l-5-3-6-2-4

1,440 1,704 1,704 1,704 1,692

850 930 930 930 794

1,555 1,776 1,776 1,776 1,851

- - - - -

130/1,900 155/1,8;9 170/1,850 16511,850 160/1,750

64.8/1,300 78/1,100 81/1,100 7811,000 78/1,000

2,050 - 2,150 2,050 - 2,150 2,050 - 2,150 2,050 - 2,150 1,950 - 2,050

800 -850 600 - 630 600- 630 600- 630 600- 630

156 155 155 155 155

970 1,250 1,250 1,250 1,250

t
NIPPON DENS0
Bosch PE- NBtype
NB (EP9)type
RVS centrifugal,
Bosch RSV centrifugal,all-speed type
all-speed type

(Z, (;:I (ZE,

21 24 24 24 24

24V,13A 24V,13A 24V,13A 24V,13A 24V,13A

24V, 7.5 kW 24V,7.5 kW 24V, 7.5 kW 24V, 7.5 kW 24V,7.5 kW

12V,150Ahx2 12V,170Ahx2 12V,170Ahx2 12V,170Ah x2 12V,170Ah x 2

- - - - -

- - - - -

- - - - -

6D125SERIES
O’-k!05
GENERAL SPECIFICATIONS

Engine model 6D125-1

Applicable machine D63E-1 D65A-8 D65E-8

I I
Number of cylinder -
(mm) 6-125x150
Bore x Stroke

Total piston displacement (cc) 11,040

Firing order 1-5-3-6-2-4

Overall length (mm) 1,440 1,704 1,704

Overall width (mm) 850 930 930

Overall height
(mm) 555 1,776 1,776
(excluding exhaust pipe)
Overall height - - -
(including exhaust pipe) (mm)

Flywheel horsepower (HP/rpm) 14Of 1,900 155f 1,850 16511,850

Maximum torque (kgm/rpml 68/l ,300 7811 ,I 00 78/l ,000

High idling speed (rpm) 2,050 - 2,150 2,050 - 2,150 2,050 - 2,150

Low idling speed (rpm) 800 - 850 600 - 630 600 - 630

t$Amum fuel consumption (g,HPh)

156 155 155

I
Dry weight (kg) 970 1,250 1,250
I
NIPPON DENS0
Fuel pump Bosch PE - NB type
NB (EP9) type
Governor RSV centrifugal,
Bosch RSV centrifugal, all-speed type
all-speed tvpe
Lubricating oil amount
(refill capacity) (2)

Coolant amount (engine only) (Q) 21 24 24

Alternator 24V, 13A 24V, 13A 24V, 13A

Starting motor 24V, 7.5 kW 24V, 7.5 kW 24V, 7.5 kW

Battery 12V, 150Ah x 2 12V, 170Ah x 2 12V, 170Ah x 2

Turbocharger - - -

Air compressor - - -

Others - - -

01$06 6D125 SERIES

GENERAL SPECIFICATIONS

6D125-1

D68E-1
D65P-8 D65S-8 D65E-12 D70LE-1
D68P-1

6-125x150

11,040

l-5-3-6-2-4

1,704 1,692 1,482.7 1,704 1,704

930 794 906 930 930

1,776 1,851 1,565.7 1,776 1,776

- - - - -

1650,850 160/1,850 180/1,950 180/1,850 177.5/1,850

78/1,000 78/1,100 81.5/1,100 81.5/1,100 81.5/1,100

2,050 - 2,150 2,050 - 2,150 2,050 - 2,150 2,050 - 2,150 2,050 - 2,150

600- 630 600-630 800 - 850 600 - 630 600 - 630

155 155 161 155 155

1,250 1,250 1,150 1,165 1,250

Bosch PE-NBtype NIPPON DENS0 NB(EP9)type

Bosch RSV centrifugal,allspeed type RSV centrifugal,all-speed type

(&

24 24 21 24.5 24.5
I
24V,13A 24V,l3A 24V,13A 24V,l3A 24V,13A

24V, 7.5kW 24V, 7.5kW 24V,7.5kW 24V,7.5kW 24V,7.5kW

12V,170Ahx2 12V,170Ahx2 12V,l70Ah x2

- - -

- - -

-
I - I - - -

6D125SERlES
O’:O’
GENERAL SPECIFICATIONS

Engine model 6D125-1

GD600R-3 GD650R3
Applicable machine
GD605R3 GD655R3

Number of cylinder -
(mm) 6-125x150
Bore x Stroke

Total piston displacement (cc) 11,040

Firing order l-5-3-6-2-4

Overall length (mm) 1,549

T 1,549

Overall width (mm) 805 805

Overall height
(mm) 1,532 1,532
(excluding exhaust pipe)

Overall height - -
(mm)
(including exhaust pipe)

Flywheel horsepower (HP/rpm) 146/l ,800 165/I ,800

Maximum torque (kgm/rpm) 74/I ,I 00 78/I ,I 00

High idling speed (rpm) 2,000 - 2,100 2,000 - 2,100

Low idling speed (rpm) 650 - 700 650 - 700

Minimum fuel consumption

(g/HPh) 159 159
ratio

Dry weight (kg) 1,130 1,130

Fuel pump Bosch PE-NB type

Governor Bosch RSV centrifugal, all speed type

Lubricating oil amount

(Q)
(refill capacity)
19 (GD600R-3)
Coolant amount (engine only) (2) 24
24 (GD605R3)

Alternator 24V, 25A 24V, 25A

Starting motor 24V, 7.5 kW 24V, 7.5kW

Battery 12V, 150Ah x 2 12V, 150Ah x 2

Turbocharger -

Air compressor - -

Others - -

O’-go*
6D125 SERIES
GENERAL SPECIFICATION

6D125-1

GD605A-3 GD605A-3 GD613A-1

GD622A-1
with 146HP engine with 155HP engine GD623A-1

6-125x150

11,040

l-5-3-6-2-4

1,549 1,549 1,471 1,471

805 805 822 822

1.532 1,532 1,465 1,465

- - - -

146/I ,800 155/I ,800 15512,200 15512,200

74/1,100 77/1,100 67f 1,350 67/l ,350

2,000 - 2,100 2,000 - 2,100 2,350 - 2,450 2,350 - 2,450

650 - 700 650 - 700 650 - 700 650 - 700

159 163 153 153

I
1,130 1,130 1,050 1,050
I I

Bosch PE-NB type NIPPON DENS0

NB (EP9) type
Bosch RSV centrifugal,
Bosch RSV centrifugal, all speed type
all-speed type

24 24 19 19

24V, 25A 24V, 25A 24V, 25A 24V, 35A

24V, 7.5kW 24V, 7.5kW 24V, 7.5kW 24V, 7.5kW

12V, 150Ah x 2 12V, 150Ah x 2 12V, 140Ah x 2 12V. 140Ah x 2

- - - -

- - - -

- - - -

6D125 SERIES
O’-%iY8-’
GENERAL SPECIFICATION

Engine model 6D125-1

Applicable machine GD625A-1 GD625A-1 C GD655A-3

Number of cylinder -
6-125x150
Bore x Stroke (mm)

Total piston displacement (cc) 11,040

Firing order l-5-3-6-2-4

Overall length (mm) 1,471 1,471 1,549

Overall width (mm) 822 822 805

Overall height
(mm) 1,465 1,465 1,532
(excluding exhaust pipe)

Overall height - - -
(including exhaust pipe) (mm)

Flywheel horsepower (HP/rpm) 155j2.200 155/2,200 165f 1,800

Maximum torque (kgmirpm) 67/l ,350 67f 1,350 78/1,100

High idling speed (rpm) 2,350 - 2,450 2,350 - 2,450 2,000 - 2,100

Low idling speed (rpm) 650 - 700 650 - 700 650 - 700

Minimum fuel consumption

(g/HPh) 153
ratio

Dry weight (kg) 960 960

Fuel pump Bosch PE-NB type

Governor Bosch RSV centrifugal, all-speed type

Lubricating oil amount

(refill caoacitv) (Q)

Coolant amount (engine only) (Q)

Alternator 24V, 25A

Starting motor 24V, 7.5 kW

Battery 12V, 200Ah x 2 12V, 200Ah x 2 12V, 150Ah x 2

Turbocharger

Air compressor vlade by DIESEL KIKI Made by DIESEL KIF

Others - I -

O’-o8-2
6D125 SERIES
GENERAL SPECIFICATION

6D125-11

GD705R-3
GD633A-1
GD705R-4

6-125x150

11,040

l-5-3-6-2-4
T

1,471 1,563

822 881

1,465 1,507

- -

180/2,200 180/l ,850

6711,350 80/l .I 00

2,350 - 2,450 2,050 - 2,150

650 - 700 650 - 700

160 158

1,300 (R-3)
1,060
1,100 (R-4)

NIPPON DENS0 Bosch PE-P type

NB (EP9) type
Bosch RSV centrifugal I 13osch RSV centrifugal
all-speed type all-speed type

30
(Z, (26)
52 (R-3)
50
55 (R-4)
24V, 12A (R-3)
24V, 25A
24V, 25A (R-4)

24V, 7.5kW 24V, 7.5kW

12V, 150Ah x 2 (R-3)

12V, 140Ah x 2
12V, 140Ah x 2 (R-4)

- -

- Made by DIESEL KIKI

- -

6D125 SERIES
0’209
GENERAL SPECIFICATION

Engine model S6D125-1

D65EX-12
Applicable machine D60F-8 D60F-8A
I / D65P. PX-12

Number of cylinder -
(mm) 6-125x150
Bore x Stroke

Total piston displacement (cc) 11,040

Firing order l-5-3-6-2-4

Overall length (mm) 1,704 1,704 1,482.7

Overall width (mm) 930 930 906

Overall height
(mm) 1,963 1,963 1,544.7
(excluding exhaust pipe)

Overall height - -
(including exhaust pipe) (mm)

Flywheel horsepower (HP/rpm) 182f 1,850 21 g/2,000 190/l ,950

I
Maximum torque (kgmirpm) 85/1,100 92/I ,500 100/l ,200

High idling speed (rpm) 2,050 - 2,150 2,200 - 2,300 2,050 - 2,150

Low idling speed (rpm) 600 - 630 600 - 630 800 - 850

Minimum fuel consumption

(g/HPh) 150 150 155
ratio

Dry weight (kg) 1,275 1,275 1,200

NIPPON DENS0
Fuel pump Bosch PE-P type
NB (EP9) type
RSV centrifugal,
Governor Bosch RSV centrifugal, all-speed type
all-speed type
Lubricating oil amount
(refill capacity) (Q)
c:,

Coolant amount (engine only) 63 63 -

(Q)

Alternator 24V, 13A 24V, 13A 24V, 35A

Starting motor 24V, 7.5kW 24V, 7.5kW 24V, 7.5kW

Battery 12V, 200Ah x 2 12V, 200Ah x 2 12V, 140Ah x 2

GARRET-T CO. GARRETT CO. GARRETT CO.

Turbocharger
TV77-05 TV77-05 T04E

Air compressor - - -

Others - -

O’-ti9-’ 6D125 SERIES

GENERAL SPECIFICATIONS

S6D125-1

D75.S5 D75S-5 D83E-1

D75A-1 D85A-21
Serial No. 10001-23192 Serial No. 23193 and up D83P-1

6-125x150

11,040

l-5-3-6-2-4

1,603 1,603 1,704 1,451

900 900 930 876

1,445 1,445 1,365 1,926

- - - -

200/2,000 200/2,000 215/2,000 225/2,000

89f 1,300 88/l ,500 88/l ,500 89/l ,300 102/l ,400

2,150 - 2,250 2,150 - 2,250 2,150 - 2,250 ,200 - 2,300 2,150 - 2,250

600 - 630 550 - 650 550 - 650 600 - 630 650 - 700

161 150 150 150 152

1,195 1,145 1,145 1,190 1,400

NIPPON DENS0
Bosch PE-P type Bosch PE-P type
NB (EP9) type
osch RSV centrifugal,
Bosch RSV centrifugal, all-speed type Bosch RSV centrifugal, all-speed type
all-speed type

(Z, $1 ii:,

65 54.5 79

24V, 13A 24V, 13A 24V, 35A

24V, 7.5 kW (STD)

24V. 11 kW 24V, 7.5 kW 24V, 7.5 kW 24V, 7.5 kW
24V, 11 kW (OP)

12V, 200Ah x 2 12V170Ahx2 12V, 170Ah x 2 12V 200Ah x 2 12V, 170Ah x 2

GARRETT CO. GARREl-f CO. GARRETT CO. GARRETT CO. GARRETT CO.
TV77-05 TV77-05 T45 TV77 T45

Made by DIESEL KIKI - - -

- - - -
I -

6D125 SERIES 0 l-0$9-2

GENERAL SPECIFICATIONS

Engine model S6D125-1

D85E-21 (B) PC300-3 PC300-3

Applicable machine
D85P-21 Serial No. 10001-20727 Serial No. 20728-23688

Number of cylinder -
(mm) 6-125x150
Bore x Stroke

Total piston displacement (cc) 11,040

Firing order l-5-3-6-2-4

Overall length (mm) 1,451 1,723 1,723

Overall width (mm) 876 1,043 1,043

Overall height
(mm) 1,926 1,130 1,130
(excluding exhaust pipe)
Overall height - - -
(mm) 7
(including exhaust pipe)

Flywheel horsepower (HP/rpm) 22512,000 197/l ,550 197/l ,550

Maximum torque (kgm/rpm 102/l ,400 105/l ,200 105/l ,200

High idling speed (rpm) 2,150 - 2,250 1,675 - 1,725 1,675 - 1,725

Low idling speed (rpm) 650 - 700 625 - 675 725 - 745

c”,;pum fuel consumption (g,HPh)

152 154 148

Dry weight (kg) 1,400 1,050 1,050

I

Fuel pump Bosch PE-P type NIPPON DENS0 NB (EP9) type

osch RSV centrifugal,
Governor Bosch RSV centrifugal, all-speed type
all-speed type

Lubricating oil amount 32

(Q)
(refill capacity) (Z, (28)

Coolant amount (engine only) (Q) 79 52 52

Alternator 24V, 35A 24V, 25A 24V, 25A

Starting motor 24V, 7.5 kW 24V, 7.5 kW 24V, 7.5 kW

Battery 12V, 170Ah x 2 12V,150Ahx2 12V, 150Ah x 2

GARRETT CO. GARRElT CO. GARRETT CO.

Turbocharger
T45 T04B NV T04B NV

Air compressor - - -

Others - - -

0 l-0$9-3 6D125 SERIES

GENERAL SPECIFICATIONS

S6D125-1

PC300-3 PC3OOLC-3 PC400-3 PC400-3

PC36OLC3
Serial No. 23689 and up PC300NLC3 Serial No. 10001-23750 Serial No. 23751 and up

6- 125x150

11,040

l-5-3-6-2-4

1,723 1,723 1,723 1,723 1,723

1,043 1,043 1,043 1,043 1,043

1,130 1,130 1,130 1,130 1,130

- - - - -

19711,550 197f 1,550 202/ 1,550 266/2,000 26612,000

105/l ,200 105/l ,200 107.6/l ,200 11 O/l ,400 11 O/l ,400

1,675 - 1,725 1,675 - 1,725 1,650 - 1,750 2,150 - 2,250 2,150 - 2,250

725 - 745 625 - 675 650 - 700 650 - 700 650 - 700

148 145 148 152 152

1,090
1,050
I
1,050 1,050
I 1,090

NIPPON DENS0 NB (EP9) type Bosch PE-NB type Bosch PE-P type

osch RSV centrifugal,

Bosch RSV centrifugal, ail-speed type Bosch RSV centrifugal, all-speed type
all-speed type

(%,

52 52 52

24V, 25A 24V, 25A 24V, 25A 24V, 25A 24V, 25A

24V, 7.5 kW 24V, 7.5 kW 24V, 7.5 kW 24V, 7.5 kW 24V, 7.5 kW

12V, 150Ah x 2 12V, 150Ah x 2 12V, 150Ah x 2 12V. 150Ah x 2 12V, 150Ah x 2

GARRETT CO. GARRETT CO. GARRETT CO. GARRETT CO. GARRET CO.
T45 T04B NV T04B NV TV77-05 T45

- - - - -

- - - _

6D125 SERIES
O’-g9-4
GENERAL SPECIFICATIONS

Engine model S6D125-1

PC400-5
Applicable machine PC4OOLC-3 HD200D-3
I PC4OOLC-5 I
Number of cylinder -
(mm) 6-125~150
Bore x Stroke

Total piston displacement (cc) 11,040

Firing order l-5-3-6-2-4

Overall length (mm) 1,723 1,708 1,635

Overall width (mm) 1,043 1,010 813.5

Overall height
1,130 1,177 1,268.5
(excluding exhaust pipe) (mm)

Overall height - - -
(including exhaust pipe) (mm)

Flywheel horsepower (HP/rpm) 26612,000 276/2,000 276/2,100

Maximum torque (kgm/rpm 11 O/l ,400 115/l ,400 115/l ,400

High idling speed (rpm) 2,150 - 2,250 2,150 - 2,250 2,350 - 2,450

Low idling speed (rpm) 600 - 700 600 - 700 650 - 700

frJl:murn fuel consumption (g,HPh)

152 152 149

Dry weight (kg) 1,090 1,090 1,050

NIPPON DENS0
Fuel pump Bosch PE-P type Bosch PE-P type
NB (EP9) type
osch RSV centrifugal RSV centrifugal, ;osch RFD centrifugal,
Governor
all-speed type all-speed type nax. and min. speed type
Lubricating oil amount
(refill capacity) (Q)
(z:) (z;) (ZZ,

Coolant amount (engine only) (Q) 54.1 34 40

Alternator 24V, 25A 24U, 25A 24V, 35A

Starting motor 24V, 7.5 kW 24U, 7.5 kW 24V, 7.5 kW

Battery 12V, 150Ah x 2 12V, 150Ah x 2 12U, 150Ah x 2

GARRET-T CO. GARRETT CO. GARRET-T CO.

Turbocharger
n/77-05 T45 TV77-05

Air compressor - - Wade by DIESEL KIKI

Others - - -

0 l-009-5 6D125 SERIES

a
GENERAL SPECIFICATION

S6D125-1

GD705A-4
HD205-3 WA450-1 WA470-1 WF450T-1
Serial No. 10001-23598

6-125x150

11,040

l-5-3-6-2-4

1,620 1,452 1,452 1,480 1,556

813.5 900 900 869 877

1,234 1,501 1,501 1,532 1,703

- - - - -

29612,100 237/2,200 26012,200 23712,200 200/2,000

124/l ,400 105/l ,400 107/l ,400 105/I ,400 92/l ,300

2,350 - 2,450 2,350 - 2,450 2,350 - 2,450 2,400 - 2,450 2,150 - 2,250

700 - 750 700 - 750 700 - 750 700 - 750 775 - 800

149 148 148 148 152

1,100 1,040 1,040 1,060 1,175

I

Bosch PE-P type Bosch PE-P type

Bosch RFD centrifugal,

max.and minspeed type Bosch RSV centrifugal, all-speed type

40 66

24V, 35A 24V, 50A 24V, 50A 24V, 50A 24V, 35A

24V, 7.5kW 24V, 7.5kW 24V, 7.5kW 24V, 7.5kW 24V, 7.5kW

12V, 150Ah x 2 12V,170Ahx2 12V, 170Ah x 2 12V, 150Ah x 2 12V, 150Ah x 2

GARRETT CO. GARRETT CO. GARRETT CO. GARRETT CO. GARRETT CO.
TV77-05 n/77-05 TV77-05 T45 n/77-05
I I
Made by ZEXEL
Made by DIESEL KlKl Made by DIESEL KIKI Made by DIESEL KIKI Made by DIESEL KIKI
(DIESEL KIKI)

- - - - -

6D125 SERIES
O’-“z9-6
GENERAL SPECIFICATION

Engine S6D125-1

GD705A-4
Applicable machine EC260Z-1 EG200-3
jerial No. 23599 and up

Number of cylinder -
6-125x150
Bore x Stroke (mm)

Total piston displacement (cc) 11,040

Firing order l-5-3-6-2-4

Overall length (mm) 1,556 1,464 1,715

Overall width (mm) 877 850 834

Overall height
(mm) 1,703 1,229 1,571
(excluding exhaust pipe)

Overall height - -
(mm) 1,808
(including exhaust pipe)

229/l ,500 (50 Hz)

Flywheel horsepower (HP/rpm) 200/2,000 232/2,150
253/l ,800 (60 Hz)

Maximum torque 92/I ,300 96f 1,500 -

(kgmirpm)

Max. 1,560 (50 Hz)

High idling speed (rpm) 2,150 - 2,250 2,250 - 2,350
Max. 1,872 (60 Hz)

Low idling speed (rpm) 775 - 800 975 - 1,025 725 - 775

Minimum fuel consumption

(g/HPh) 152 149 150
ratio

Dry weight (kg) 1,175 1,050

NIPPON DENS0
Fuel pump Bosch PE-P type
NB (EP9) type
RSV centrifugal,
Governor Bosch RSV centrifugal, all-speed type
all-speed type
Lubricating oil amount
(refill capacity) (Q) (z:,

Coolant amount (engine only) (2) 19 60 46

I

Alternator 24V, 35 A 24V, 25 A 24V, 13A

Starting motor 24V, 7.5kW 24V, 7.5 kW 24V, 7.5 kW

Battery 12V, 150Ah x 2 12V. 150Ah x 2 12V, 140Ah x 2

GARRETT CO. GARRETT CO. GARRETT CO.

Turbocharger
T45 TV77-05 TV77-05

Air compressor Made by DIESEL KIKI - -

Others - - -
i

O’-029-7 6D125 SERIES

GENERAL SPECIFICATION

S6D125-1

HA250
EG220, 6, BS-1 EG220, B-2 EG220BS-2
HA270

6-125x150

11,040

l-5-3-6-2-4

1,725 1,725 1,725 1,455

850 800 850 756

1,472
1,295 1,472 1,129
1,345 (6, BS)

- - -

230/1,500 (50 Hz) 230/1,500 (50 Hz) 230/1,500 (50 Hz)

24012,200
255/l ,800 (60 Hz) 255/l ,800 (60 Hz) 255/l ,800 (60 Hz)

- - 98.8/1,400

Max. 1,560 (50 Hz) Max. 1,560 (50 Hz) Max. 1,560 (50 Hz)
2,550 - 2,650
Max. 1.872 (60 Hz) Max. 1,872 (60 Hz) Max. 1,872 (60 Hz)

700 - 800 725 - 775 725 - 775 650 - 700

153 (50 Hz) 153 (50 Hz) 153 (50 Hz)

155
154 (60 Hz) 154 (60 Hz) 154 (60 Hz)

1,050 1,050 1,050 1,025

Bosch PE-P type Bosch PE-P type

3osch RED centrifugal

Bosch RSV centrifugal, all-speed type
lax. and min. speed type

(ZZ,

45 42 43

24V, 13A
24V, 13A 24V, 25A 24V, 35A
24V, 25A (BS)

24V, 7.5kW 24V, 5.5kW 24V, 5.5kW 24V, 7.5kW

12V. 150Ah x 2 12V, 150Ah x 2 12V, 150Ah x 2 12V, 150Ah x 2

GARRETT CO. GARRETT CO. GARRETT CO. GARRETT CO.

TV77-05 T45 T45 TV77

- Made by ZEXEL
(DIESEL KIKI)

- - - with exhaust brake

(butterfly type)

6D125 SERIES
O’-Oi9-*
 GENERAL SPECIFICATION

Engine SAGDI 25-l

Applicable machine D135A-1 EG275, B, BS-1 EG275, B, BS-2

Number of cylinder -
(mm) 6-125x150
Bore x Stroke

Total piston displacement (cc) 11,040

Firing order l-5-3-6-2-4

-
Overall length (mm)
- 1,725 1,725

800
E Overall width (mm) 972
850 (BS)
.g
5 Overall height 1,472 1,295
(mm)
.-E (excluding exhaust pipe) 1,345 (B, BS) 1,472 (BS)
n
Overall height - -
(including exhaust pipe) (mm)
-
269/I ,500 (50 Hz) 269/1,500 (50 Hz)
Flywheel horsepower (HP/rpm) 27512,000
321 /I ,800 (60 Hz) 321/1,800 (60 Hz)

Maximum torque 128/1,400 - -

(kgmirpm)
8
$ Max. 1,560 (50 Hz) Max. 1,560 (50 Hz)
E High idling speed (rpm) 2,150 - 2,250
Max. 1,872 (60 Hz) Max. 1,872 (60 Hz)
b
‘t
Low idling speed (rpm) 650 - 700 700 - 800 700 - 800
B

Minimum fuel consumption 153 (50 Hz) 153 (50 Hz)

(g/HPh) 160
ratio 155 (60 Hz) 155 (60 Hz)
-
Dry weight (kg) 1,350 1,080 1,080

Fuel pump Bosch PE-P type

Governor Bosch RSV centrifugal, all-speed type

Lubricating oil amount

(refill capacity) (Q) (z:,

Coolant amount (engine only) (k) 90 46

ti (BS)
24V, 13A 24V, 13A
Alternator 24V, 35A
24V, 25A (BS) 24V, 25A (BS)

Starting motor 24V, 7.5kW 24V, 7.5kW 24V, 5.5 kW

Battery 12V, 170Ah x 2 12V,150Ahx2 12V, 150Ah x 2

GARRETT CO. GARRETT CO. GARRETT CO.

Turbocharger
TV77 TV77-05 TV77

Air compressor - - -

Others with after cooler with after cooler with after cooler

O’-%9-9 6D125 SERIES

 GENERAL GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWIN,G

6D125-1 LEFT SIDE VIEW (For D60A-8)

1596
c
J --

Direction
of wind
ti

1192
1247
1416

6 I5OFOO I

01-010 6D125 SERIES

GENERAL GENERAL ASSEMBLY DRAWING

6D125-1 RIGHT SIDE VIEW (For D60A-8)

Coolant
(to radiator)

Crankshaft center
IIIR lr7
/‘

6 I5OFOO2

6D125 SERIES 01-011

GENERAL GENERAL ASSEMBLY DRAWING

6D125-1 REAR VIEW (For D60A-8)

12-12x

6 I5OFOO4

01-012 6D125 SERIES

GENERAL GENERAL ASSEMBLY DRAWING

6D125-1 FRONT VIEW (For D60A-8)

Coolant (from
ete

6 l5OFOO3

6D125 SERIES
01-073
S6D125-1 LEFT SIDE VIEW (For D75S-5)

Direction of wind
+

” f------L
6 I5OFOO5

01-014 6D125 SERIES

 GENERAL GENERAL ASSEMBLY DRAWING

S6D125-1 RIGHT SIDE VIEW (For D75S-5)

Block heater
mounting position

7
‘=
3

5
E

6 I5OFOO6

6D125 SERIES 01-015

GENERAL GENERAL ASSEMBLY DRAWING

S6D125-1 FRONT VIEW (For D75S5)

6 I5OFOO7

01-016 6D125 SERIES

GENERAL GENERAL ASSEMBLY DRAWING

S6D125-1 REAR VIEW (For D75S-5)

Crankshaft
d
center

12X1.75

L 320
I
325

6 I5OFOO6

6D125 SERIES 01-017

GENERAL ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE

6D125-1 (For D50A-17, D50P-17)

Flywheel horsepower: 120HP/1,750 rpm
Maximum torque: 65.5 kgm/l,lOO rpm
Minimum fuel consumption ratio: 155 g/HPh

'80

70

'60

50 -c
y"
-40 -
J
30 F
P
-20

10

-0

,220 g
I
210 >

200 .o
5
190 ;
0
180 '"n

170 5
P
160 8
u
150 2

Engine speed (t-pm)

F615001001

01-018 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D50F-17)

Flywheel horsepower: 138HP/1,900 rpm
Maximum torque: 66 kgm/l,300 rpm
Minimum fuel, consumption ratio: 155 g/HPh

80

60

160 6
.,=

150 g

d
ru
140 2

1400 1600 1800 2000 2200

Engine speed (rpm)

6D125 SERIES 079

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D53A-17, D53P-17)

Flywheel horsepower: 124HP/1,900 rpm
Maximum torque: 62.5 kgm/1,300 rpm
Minimum fuel consumption ratio: 156 g/HPh

.- 70

- 60

-- 50

- 40

'- 30

- 20

- 220

- 210

60 - 200

- 190

- 180

- 170

- 160

- 150

0 600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

F615001002

01--$20 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

6D 125- 1 ( For D60A-8)

Flywheel horsepower: 155HP/1,850 rpm
Maximum torque: 78 kgm/l ,100 rpm
Minimum fuel consumption ratio: 155 g/HPh

80

70

60

180

80

60

600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

6D125 SERIES
GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D60E-8)

Flywheel horsepower: 170HP/1,850 rpm
Maximum torque: 81 kgm/l,lOO rpm
Minimum fuel consumption ratio: 155 g/HPh

- 80

70

- 60

,50 -c
m

-40 y
2
.30 F
g
- 20

10

'0

180

140

120

220 r
I"
210 2
60
200 .g
E
190
E
40
180 '"n
E
170 2
20 s
160 0
lu
150 2

0 600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

F615001004

01222 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D60P-8 and D60PL-8)

Flywheel horsepower: 165HP/1,850 rpm
Maximum torque: 78 kgm/l,OOO rpm
Minimum fuel consumption ratio: 155 g/HPh

80

70

60
-
50 ME
22
40 -
2
30 g
i-
20

10

160

80 220 g

210 $

60

/
20 Fuel consumption rati
-3

I
600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm) 615OFOl2

6D125 SERIES Ol-;23

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D60S-8)

Flywheel horsepower: 160HP/1,750 rpm
Maximum torque: 78 kgm/l,OOO rpm
Minimum fuel consumption ratio: 155 g/HPh

80

70

60

160

60

Fuel consumption ratio

600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

F615001005

01$24 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D65A-8)

Flywheel horsepower: 155HP/1,850 rpm
Maximum torque: 78 kgm/l,lOO rpm
Minimum fuel consumption ratio: 155 g/HPh

80

60

10

180 -.

160 -.

80 -.
220 g
I
210 2

200 .o_

Fdel consuhption iatio

0 600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (t-pm)

F615001003

6D125 SERIES
01225
GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D65E-8, D65P-8)

Flywheel horsepower: 165HP/1,850 rpm
Maximum torque: 78 kgm/l,OOO rpm
Minimum fuel consumption ratio: 155 g/H Ph

80

70

60

50 ECI)
Y
40
2
30 p
If
20

10

180 -.

80 -- 220 2
I
210 B

200 .g
190 E
s
180 'g
E
170 2
160 s
o

150 $

600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

F615001006

01226 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D65S-8)

Flywheel horsepower: 160HP/1,850 rpm
Maximum torque: 78 kgm/l,lOO t-pm
Minimum fuel consumption ratio: 155 g/HPh

10

200 0

180

160

220

210

60 -. 200

190

40 . 180

170

20 _ Fuel consumption ratio 160

150
I
0 600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed bm 1
F615001007

6D125 SERIES 01$27

GENERAL ENGINE PERFORMANCE CURVE

6D 125-1 (For D65E-12)

Flywheel horsepower: 180 HP/l ,950 rpm
Maximum torque: 81.5 kgm/l ,I 00 rpm
Minimum fuel consumption ratio: 161 g/HPh

80

I
0
600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

615OFO61

O’-fz7-’ 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For D7OLE-1)

Flywheel horsepower: 177.5 HP/l ,850 rpm
Maximum torque: 81.5 kgm/l ,I 00 rpm
Minimum fuel consumption ratio: 155 g/HPh

Toraue
-80

-70

.60
.50 -z
~
Y
-40
s
30 g
I-
20

.lO

-0

60 I

40

20
I

u 600 800 1000 1200 1400 1600 1800 2000

I I 2200

Engine speed (rpm)

6 I 5OFO66

60125 SERIES
O’ -“i7-2
GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For GD600R-3, GD605R-3, GD605A-3 with 146 HP engine)

Flywheel horsepower: 146HP/1,800 rpm
Maximum iorque: 74 kgm/l,lOO rpm
Minimum fuel consumption ratio: 159 g/HPh

- 80

70

- 60

50

40

30

20

10

'0

160

80 '220

210

60 200

190

180

170

160

'150

600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

F615001006

Ol-g28 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For GD605A-3 with 155HP engine)

Flywheel horsepower: 155HP/1,800 rpm
Maximum torque: 77 kgm/l,lOO rpm
Minimum fuel consumption ratio: 163 g/HPh

80

70

60

50 E,

160

80 Y
I \ I I I r

60

w
_ Fuel consumption ratio
\
20 -160
T
--150 I=

0 I I I \ I
600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

6D125 SERIES
O’-OZ8-’
GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For GD650R-3, GD655R-3, GD655A-3)

Flywheel horsepower: 165HP/1,800 rpm
Maximum torque: 78 kgm/l,lOO rpm
Minimum fuel consumption ratio: 159 g/HPh

80

70

60
E
50 m
Y
40 2
30 P
P
20

10

600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

6D125 SERIES 01229

GENERAL ENGINE PERFORMANCE CURVE

6D125-1 (For GD705R-3, GD705R-4)

Flywheel horsepower: 182HP/1,850 rpm
Maximum torque: 80 kgm/l ,100 rpm
Minimum fuel consumption ratio: 158 g/HPh

180

160

120

60

0 600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

F615001010

01-$30 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For D75S-5)

Flywheel horsepower: 200HP/2,000 rpm
Maximum torque: 88 kgm/l,500 rpm
Minimum fuel consumption ratio: 152 g/HPh

90

80

70

40 s
P
30 g

20

10

180

160

6
80 220 g
I
210 2

60 200 .c
E
190
6
40 180 '"a

170 5
E
20 160 8
._ Fuel consumption ratio-/-
5
c, I / 2
150
I
0 600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

F61500101I

6D125 SERIES 0931

GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For D60F-8)

Flywheel horsepower: 182HP/1,850 rpm
Maximum‘torque: 85 kgmil ,100 rpm
Minimum fuel consumption ratio: 150 g/HPh

200 -

180

160

140

60

40

\
20

0 1000 1200 1400 1600 1800 2000

Engine speed (rpm)

01232 6D126 SERIES

GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For D65EX-12, D65P, PX-12)

Flywheel horsepower: 190 HP/l,950 rpm
Maximum torque: 100 kgm/l,200 rpm
Minimum fuel consumption ratio: 155 g/HPh

100

--go
80

--70

--30

U
600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

615OFO62

6D125 SERIES
01-OZ2-'
GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For HA250, HA270)

Flywheel horsepower: 240 HP/2,200 rpm
Maximum’torque: 98.8 kgm/1,400 rpm
Minimum fuel consumption ratio: 155 g/HPh

150-

loo- -200
-190

-180

-170
\
50- -160
-150

0 , I
800 1000 1200 1400 1600 1800 2000 2200 2400

Engine speed (rpm)

6 I5OFO52

O’-“i2-2 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For GD705A-4)

Flywheel horsepower: 200HPl2,OOO rpm
Maximum torque: 92 kgm/l,300 rpm
Minimum fuel consumption ratio: 152 g/HPh

90

80

70

60

50

40

30

220 20

10

200 '0

180

160

140

120

100

80

60

40 180

170

20 Fuel consumption ratio -160 6

5
,150 2

600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

F615001012

6D125 SERIES 01-$33

GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For WA450-1)

Flywheel horsepower: 237HP/2,200 rpm
Maximum torque: 105 kgm/l,400 rpm
Minimum fuel consumption ratio: 148 g/HPh

'50

250

/- \

225

200

.220

-210

-200

-190

-180

.170

800 1000 1200 1400 1600 1800 2000 2200 2400

Engine speed (rpm) 6 I5OFO2 I

01-$34 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For WF450T-1)

Flywheel horsepower: 237 HP/2,200 rpm
Maximum torque: 105 kgm/1,400 rpm
Minimum fuel consumption ratio: 148 g/HPh

Engine speed (rpm)

615OFO63

6D125 SERIES
01-Oi4-'
GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For EG200-3)

Flywheel horsepower: 229HP/1,500 rpm (50 Hz)
253HP/1,800 rpm (60 Hz)
Minimum fuel consumption ratio: 150 g/HPh

200

150

300 100

275 50

150 0

225

175
50Hz 60Hz

150 / /

1?5-.

100 220

--210

75 200

--190

50 180

--I70

25 I 160
- A_ Fuel consu mption ratjo
--I50

L
1100 1200 1300 1400 !500 1600 1700 1800 1900

Engine speed (rpm) 6 I5OFO24

6D125 SERIES 0735

GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For EC260Z-1)

Flywheel horsepower: 232HP/2,150 rpm
Maximum torque: 96 kgm/l,500 rpm
Minimum fuel consumption ratio: 149 g/HPh

8!J

6’)

275

250 I

.- 210

-- 190

e-170

--150

800 1000 1200 1400 1600 1800 2000 2200 2400

Engine speed (rpm) 6 ISOFO23

01-$36 6D125 SERIES

GENERAL ENGINE PERFORMANCE CURVE

S6D 125-1 (For PC300-3 and PC3OOLC-3)

Flywheel horsepower: 197HP/1,550 rpm
Maximum torque: 105 kgm/l,ZOO rpm
Minimum fuel consumption ratio: 145 g/HPh

90

V
80

180

160

120 -180

100 170

80 160

60 150

40 140

20 130

0'
800 1000 1200 1400 1600 1800 2000

Engine speed (rPm)

6D125 SERIES Ol-$37

GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For PC400-3 and PC4OOLC-3)

Flywheel ,horsepower: 266 HP/2,000 rpm
Maximum torque: 110 kgm/l,400 rpm
Minimum fuel consumption ratio: 152 g/HPh

100

250

225

175

?y 150
a
5
0
125

220

75
-lTl--l 210

200
F
%

Ef
.;
190 i!?

50

25 Fuel consumption ratib

I 1
150 3
I I LL

600 800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)

01338 6D125SERIES
GENERAL ENGINE PERFORMANCE CURVE

S6D125-1 (For HD205-3)

Flywheel horsepower: 296 HP/2,100 rpm
Maximum torque: 124 kgm/l,400 rpm
Minimum fuel consumption ratio: 149 g/HPh

150

100 -z
m

Y
2
300 P
50
s

275 0

250

225.

125

100 180 g
I
2

75 170 g

5
'G

50 160 f

E
25 150 "
$
u

0
800 1000 1200 1400 1600 1800 2000 2200 2400

Engine speed (rpm)

6D125 SERIES Ol--39

 GENERAL WEIGHT TABLE

WEIGHT TABLE
A . .
This weight table is a guide for use when transporting or handling components.

No Item Components 6D1251 S6D125-1

-
GARRETT CO. TV??-05 17

1 Turbocharger GARRETT CO. T04B NV 7

-
2 r Cylinder head, valve, valve sprrng

Cylinder block, main bearing cap,

223:
16 x 6

Except D50F-17 223:

15

16x6

Except D60F-8, 8A
3 Cylinder block assembly
cylinder liner 264: HD205-3
275: D50F-17
- 280: D60F-8. 8A

19: Except D50F-17 19: Except D60F-8, 8A

4 Front cover
20: D50F-17 21: D60F-8, 8A

14: Except EC260Z-1, EG220BS

and D60F-8, 8A
5 Oil pan 14 20: EC260Z-1, EG220BS,
D85A-21
21: D60F-8, 8A

30: HD205-3
35: Except D50F-17 33: WA450-1
35: Except WA450-1
EC260Z-1, D60F-8, 8A
PC300-3, PC3OOLC3
6 Flywheel assembly Flywheel, ring gear PC400-3, PC4OOLC3
38: EC260Z-1
65: D50F-17 45: PC300-3, PC3OOLC3
PC400-3, PC4OOLC3
59: HD200D-3, D85A-21
75: D60F-8, 8A

24: EC260Z-1,
25: Exceot EC260Z-1,
25: Except D50F-17 WA450-1, D60F-8, 8A
PC300-3, PC3OOLC-3,
PC400-3, PC4OOLC-3
29: WA450-1
7 Flywheel housing
50: PC300-3, PC3OOLC-3
PC400-3, PC4OOLC3
57: HO200D-3
130: D50F-17 85: HD205-3
130: D60F-8, 8A
139: D85A-21

8 Crankshaft assembly Crankshaft, crankshaft gear 104 104

-
Camshaft, camshaft gear thrust 13: HD200D-3, HD205-3
9 Camshaft assembly 16
plate 16: Except HD200D,,205-3
Piston, connecting rod Piston, piston ring, piston pin
10 6.8 x 6 7.6 x 6
assemblv connectina rod
-

11 011 pump 5 5
-
23: HD200D-3, HD205-3
26: PC300-3, PC3OOLC3
12 Fuel injection pump 26
27: Except PC300-3,
I PC3OOLC-3

01-$40 6D125 SERIES

GENERAL WEIGHT TABLE

Unit:kg

SA6D125-1

17

16x6

19

15: EG275,B
20: EG275BS

56.6

41.6

104

16

7.6 x 6

27

6D125 SERIES
O’-g4’
GENERAL WEIGHT TABLE

No. Item Components 6D125-1 S6D125-1

13 Water pump 8.5 9.5

Without vacuum pump (24V. 13A) 7.5 7.5

14 Alternator With vacuum pump (24V, 25A) 11 11

24V, 35A _ 10.5

15 Starting motor 18 (STD), 20 (OP) 18

I
16 Air compressor 10 10
I I

0 l-042 6Dl25 SERIES

GENERAL WEIGHT TABLE

Unit: kg

SAGD125-1

9.5

7.6

18

6D125 SERIES
O’-243
 ENGINE
I1 STRUCTURE AND FUNCTION

GENERAL STRUCTURE .............. II-002

INTAKE AND EXHAUST SYSTEM

Intake and exhaust system ........... 1 I-004
Turbocharger ................... 1 I-008

ENGINE BODY
Cylinder head................ 1 I-010
Valve system ................. II-012
Cylinder block ............... 1 I-014
Main circulation part ........... 1 I-016
Timing gear ................. II-018
Flywheel and flywheel housing ..... II-020

LUBRICATION SYSTEM
Lubrication system chart ............ 1 l-025
Oil pump ...................... 1 I-026
Regulator valve .................. 11-028
Oil filter ....................... 1 l-029
Oil cooler ...................... 1 I-030

FUEL SYSTEM
Fuel system chart 1 l-031
Fuel injection pump . . . 1 I-032
Fuel injection nozzle . 1 I-036
Fuel filter . . . . 1 l-037
Magnetic switch (fuel cut solenoid) . 1 I-038

COOLING SYSTEM
Cooling system chart .. 1 I-039
Water pump ... .. 1 l-040
Thermostat . ......... .... 1 I-042
Corrosion resistor . . . II-043

ELECTRICAL SYSTEM
Alternator .................. 1 I-045
Starting motor ............... 1 l-048
Electrical intake air heater ........ 1 I-049

ACCESSORY
Air compressor . . . . _. _. . . . . . . . . 1 l-050
Exhaustbrake . . . . . . . 11-053

‘2O’
6D125 SERIES
STRUCTURE AND FUNCTION GENERAL STRUCTURE

GENERAL STRUCTURE

1. Cylinder block 10. Fuel injection nozzle 19. Main bearing cap
2. Cylinder liner 11. Cylinder head cover 20. Oil strainer
3. Piston 12. Camshaft 21. Crankshaft gear
4. Connecting rod 13. Ring gear 22. Front cover
5. Piston pin 14. Flywheel 23. Front seal
6. Intake valve 15. Rear seal 24. Crankshaft pulley
7. Crosshead 16. Flywheel housing 25. Vibration damper
8. Exhaust valve 17. Oil pan
9. Rocker arm shaft 18. Crankshaft

1 l-002 6D125 SERIES

STRUCTURE AND FUNCTION GENERAL STRUCTURE

615OFIOI

26. Cylinder head Engine: 6D125-1

27. Thermostat S6D125-1 (with turbocharger)
28. Rocker arm SA6D125-1 (with turbocharger
29. Push rod and after-cooler)
30. Cam follower Type: In-line, g-cylinders, water-
31. Connecting rod cap cooled, direct fuel injection,
32. Oil pump d-cycle diesel engine.

6D125 SERIES
’203
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

INTAKE AND EXHAUST SYSTEM

6D125-1 (For D60*65A,E,P-8)

615OFlO2

1. Dust cap 4. Air cleaner body

2. Outer element 5. Electrical intake air heater
3. Inner element 6. Evacuator valve

11-004 6D125 SERIES

STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

615OFlO3

7. Muffler A. Gas exhaust

8. Exhaust manifold (Front) a. Intake air pressure pick-up for

9. Exhaust manifold (Center) dust indicator

10. Exhaust manifold (Rear)

6D125 SERIES 11-005

STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

S6D125-1 (For D75S-5)

615OFlO4

1. Dust cap 4. Air cleaner body

2. Outer element 5. Electrical intake air heater
3. Inner element 6. Evacuator valve

1 l-006 6D125 SERIES

STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

615OFlO5

7. Air cleaner cover A. Air intake

8. Muffler 8. Gas exhaust
9. Turbocharger a. Intake air pressure pick-up for
10. Exhaust manifold (Front) dust indicator
11. Exhaust manifold (Center)
12. Exhaust manifold (Rear)

6D125 SERIES 11-007

 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

FTG AIR CLEANER (WA450-1, WA470-1)

Current type (FHG) FTG type

I---7 8

6137FOCS10

1. Inlet 4. Primary element 7. Dust pan

2. Outlet 5. Safety element 8. Diffusion vane (sleeve)
3. Guide vane 6. Vacuator 9. Body

ADVANTAGES STRUCTURE
l The diameter of the element is the same but l Air containing dust is sucked in from inlet (1) at
the outside diameter of the body is smaller. a tangent, and the dust is separated by the
The inlet is placed in the direction of connec- centrifugal force of guide vane (3). More than
tion, so ample centrifugal force can be ob- 99.9% of the remaining drist is removed by pri-
tained from a simple spiral guide vane, mary element (4), and the cleaned air then
without usng a diffusion vane. passes through safety element (5) and outlet
(2), and is sucked into the engine.
l There is no dust pan or diffusion vane, so the The dust and moisture that is separated by the
. structure is simple. guide vane (3) rotates around the inside wall of
body (9), and goes inside vacuator (6), where is
discharged automatically to the outside.

’ ’-07-’ 6D125 SERIES

STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

TURBOCHARGER

TV77

C
615OF106-1

1. Locknut 12. Turbine housing Turbocharger

2. Blower housing 13. Piston ring
GARRETT co.
3. Blower impeller 14. Turbine impeller Type T-,177

4. Thrust collar Overall length 275 mm

5. Back plate A. Air inlet
Overall width 264 mm
6. Thrust bearing B. Air outlet
7. Seal ring C. Gas inlet Overall height 264 mm
8. Center housing D. Gas outlet
Weight 17 kg
9. Retaining ring E. Oil inlet
10. Journal bearing F. Oil outlet Continuous speed 90,000 rpm
11. Shroud
Max. air supply 0.43 kglsec

Compression ratio 3.4

Applicable exhaust temp. Max. 7OO’C

I
Clockwise (see from
Direction of rotation the blower ride1

’ ’-zo8 6D125 SERIES

 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

T45

12 3 4 5 6 7 8 9 10 11 12

6150F150

1. Locknut 12. Turbine housing Turbocharger

2. Blower housing 13. Piston ring
GARRETT CO.
3. Blower impeller 14. Turbine impeller TvPe TAF,

4. Thrust collar
Overall length 27.5 mm
5. Back plate A. Air inlet
6. Seal ring B. Air outlet Overall width 284 mm

7. Thrust bearing C. Gas inlet

8. Center housing D. Gas outlet
9. Retaining ring E. Oil inlet
10. Journal bearing F. Oil outlet
11. Shroud
Applicable exhaust temp. 1 Max. 7OO’C

Clockwise (see from

Direction of rotation the blower side)

60125 SERIES
’ ’-OZ8-’
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

T04B, E

14FO36

1. Locknut 12. Turbine housing Turbocharger

2. Blower housing 13. Piston ring
3. Blower impeller 14. Turbine impeller
4. Thrust collar
5. Back plate A. Air inlet )
6. Thrust bearing B. Air outlet
7. Seal ring C. Gas inlet
I
8. Center housing D. Gas outlet T04B: 7 kg
Weight
9. Retaining ring E. Oil inlet T04E: 9 kg

10. Journal bearing F. Oil outlet Continuous speed 125,000 rpm

11. Shroud
Applicable exhaust temp. Max. 7OO’C

Clockwise (see from

Direction of rotation the blower side1

6D126 SERIES
’’-go9
STRUCTURE AND FUNCTION ENGINE BODY

ENGINE BODY
CYLINDER HEAD

a b

3 4
i

1. Cylinder head bolt 5. Valve spring

2. Nozzle holder 6. Intake valve
3. Cylinder head 7. Exhaust valve
4.. Cylinder head cover

1 l-g10 6D125 SERIES

STRUCTURE AND FUNCTION ENGINE BODY

CYLINDER HEAD
* Direct fuel injection
-4 valve
* Injection nozzle assembled in cylinder head
- Divided type
(1 cylinder head for 1 cylinder)

VALVE SEAT
- Press-fitted insert for intake and exhaust

CYLINDER HEAD COVER

- Floating type seal

VALVE ROTATOR
* Installed S6D125, SAGD125

6150Fl07A

8. Valve spring seat 14. Push rod

9. Valve cotter
10. Crosshead a Water temperature pick-up
11. Rocker arm b Outlet for heater
12. Valve guide C Outlet for corrosion resistor
13. Valve seat insert d Inlet for corrosion resistor

6D125 SERIES 11-011

8
STRUCTURE AND FUNCTION ENGINE BODY

VALVE SYSTEM

Ii 615OFI 13A

1. Rocker arm shaft 9. Crosshead 13. Valve rotator

2. Camshaft gear (No. of teeth: 44) 10. Upper valve spring seat (S6D125-1, SA6D125-1:
3. Camshaft 11. Intake valve Intake only)
4. Air compressor drive gear 12. Valve spring 14. Adjustment screw
(No. of teeth: 14) 13. Lower valve spring seat 15. Locknut
5. Cam roller 6D125-1: Intake and 16. Rocker arm
6. Cam roller pin exhaust 17. Push rod
7. Adjustment screw S6D125-l,SAGD125-1: 18. Cam follower
8. Locknut Exhaust only 19. Exhaust valve
20. Valve seal (Exhaust only)

11g2 6D125 SERIES

 615OFI 14A
a. Oil

CAMSHAFT
* Stamp forging
-Journal portion, cam portion:
Induction hardening
VALVE TIMING

Topdead center
List of part (related to valve) to be set in place

60125-I S6Dl25-l,SAGDl25-1

615041-5611
Crosshead 615041-5611 615041-5611 615041-5611
1615041-5710
6150414210
Valve 6150414120 6150414210 6150414120
%6150414230 I,,
6150414411
Valve spring 6150-414411 6150414411 6150414420 (Yellow)
(Color code) (Yellow) (Yellow) (Purple) X6150414450
(White)
aonom dead center
Spring seat
(Lower) 6150414430 6150414430 - 6150414430
615OF115

Valve rotator - - 6150414540

Valve guide 6150-11-1341 6150-I!-1351 6150-11-1341 6150-11-1351

Stem seal - 6140414540 - 6140414540

Parts marked f are applicable only to an engine equipped with a exhaust brake (side
and butterfly types).

6D125 SERIES
‘Y3
STRUCTURE AND FUNCTION ENGINE BODY

CYLINDER BLOCK

6 7 8 9 10

1. Cylinder block 7. Front cover

2. Cylinder liner 8. Main bearing cap bolt
3. Crevice seal 9. Main bearing cap
4. Liner seal (Ethylene propylene rubber) 10. Main bearing
5. Liner seal (Silicon rubber) 11. Thrust bearing
6. Front seal 12. Piston cooling nozzle (S6D125, SA6D125)

“-F4 6D125 SERIES

STRUCTURE AND FUNCTION ENGINE BODY

6150Fl09A

li

615OFlO8

CYLINDER BLOCK CYLINDER LINER

*Crankshaft: 7 bearings -Wet type
*Camshaft: 7 bearings *Treatment: Plateau honing finish
Tufftride treated (S6D125, SA6Dl25)
FRONT SEAL
*Single lip with dust seal LINER SEAL
* Top: Clevis seal
PISTON COOLING * Middle: O-ring (Ethylene propylene rubber)
*With piston cooling nozzle (S6D125, SAGD125) - Bottom: O-ring (Silicon rubber)

6D125 SERIES
’‘-F
STRUCTURE AND FUNCTION ENGINE BODY

MAIN CIRCULATION PART

1-A 2 3

1-A. Piston (S6D125, SAGDI 25) 7. Connecting rod

1-B. Piston (6D125, S6D125) 6. Crankshaft
2. Connecting rod bushing 9. Crankshaft gear
3. Piston pin 10. Connecting rod cap
4. Top ring 11. Connecting rod bearing
5. Second ring 12. Connecting rod cap bolt
6. Oil ring

* The above is a composite sectional drawing for

6D1251, S6D125-1 and SAGD125-1.

11-016 6D125 SERIES

03
STRUCTURE AND FUNCTION ENGINE BODY

615OFI IOA

PISTON RING

,
Top ring Second ring Oil ring

@J&E! @#j@#j$EE r
CRANKSHAFT: Stamp forging
Both faces keystone Keystone inner cut Hard chrome platin
6D125-1: Induction hardening on journal portion Barrel face Tapered face with coil expander
S(A)6D125-1 : Induction hardening on journal por- Hard chrome platinBt+rd chrome plating
I
tion and filet portion.

615OFI II
PISTON
Material CONNECTING ROD

S(A)6Dl25-1 (No.l-A): Ductile cast iron (FCD). Connecting rod lube oil holes
(S)6D125-1 (No.l-6): Aluminum alloy not provided: 6D125-1
provided: S6D125-1, SAGD125-1
Type: Elliptical taper profile thermal flow, Piston cooling from the connecting rod tip
MTCC combustion chamber not provided: 6D125-1, S6D125-1
(with aluminum alloy pistons)
provided: 6D125-1, SAGD125-1
(with FCD pistons)

6D125 SERIES
’ ‘-ki’
’
STRUCTURE AND FUNCTION ENGINE BODY

TIMING GEAR

Section F-F Section E-E

1. Cylinder block 7. Injection pump drive gear (No. of teeth: 44)

2. Water pump drive gear (No. of teeth: 22) 8. Timing gear cover
3. Main idler gear (No. of teeth: 57) 9. Camshaft gear (No. of teeth: 44)
4. Main idler gear (No. of teeth: 38) 10. Crankshaft gear (No. of teeth: 33)
5. Oil pump drive gear (No. of teeth: 21) 11. Crankshaft
6. Idler gear for oil pump (No. of teeth: 25)
A,B,C: Match marks for timing gears

11-018 6D125 SERIES

a
 ENGINE BODY
STRUCTURE AND FUNCTION

SectionD-D
11'
615OFI 12A

H-$19
6D125 SERIES
STRUCTURE AND FUNCTION ENGINE BODY

FLYWHEEL AND FLYWHEEL HOUSING

With PTO type (For D60*65A,E,P-8,11, HD200 - 205)

615OFI 16

“-tA20 6D125 SERIES

STRUCTURE AND FUNCTION ENGINE BODY

1. Ring gear
No. of teeth
137: D60 * 65A, P-8, 11
131: HD200 .205
2. Flywheel
3. Spacer
16 4. PTO drive gear (No. of teeth: 41)
5. Rear seal
6. Idler gear (No. of teeth: 52)
7. Idler shaft
8. PTO cover
9. PTO drive shaft
10. Bearing case
11. Roller bearing
,17 12. PTO drive gear (No. of teeth: 35)
13. PTO gear (No. of teeth: 57)
(Without PTO gear for HD200 * 205)
,18
14. Ball bearing
15. Bearing case
16. Cover
17. Bushing
18. Oil seal
19. Cover
20. Flywheel housing

Section A-A

615OFI 18

6D125 SERIES
’ ‘S2’
STRUCTURE AND FUNCTION ENGINE BODY

(D60 * 65A. P-8,11)

2 3 1. Bearing case
2. Ball bearing
\ I 3. Pump drive shaft
4. Pump drive gear (No. of teeth: 61)
5. Spacer
6. Ball bearing
7. Bearing case

a. PTO for steering pump

b. PTO for torque converter pump

Section B-B

(D60 * 65A, P-8,1 1, HD200 - 205)

9 10 11 12 13 8. Bearing case
9. Roller bearing
10. Pump drive shaft
11. Pump drive gear
(No. of teeth: 35)
,I4 12. Spacer
13. Ball bearing
14. Bearing case

C. PTO for work equipment pump

Section C-C
615OFI 17

60126 SERIES
’ ’-ii22
STRUCTURE AND FUNCTION ENGINE BODY

Without PTO type (For D75S5, PC300-3, PC3OOLC-3, PC400-3, PC4OOLC-3)

Section A -A
T- A
615OFI IS

1. Flywheel housing
No. of teeth
2. Ring gear Applicable
3. Flywheel machine Flywheel
Ring gear
inner gear

D75S5 137 131

I I
PC300-3
PC300 LC-3 -
148
PC400-3
PC400 LC-3

6D125 SERIES l l -g23

STRUCTURE AND FUNCTION LUBRICATION SYSTEM

LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART

6150Fl20A

1. Oil strainer 8. Safety valve 14. Intake and exhaust valve

2. Oil pump 9. Crankshaft 15. Fuel injection pump
3. Oil cooler 10. Camshaft 16. Turbocharger (S(A)GD125-I)
4. Oil filter 11. Piston 17. Timing gear
5. Main relief valve 12. Piston cooling nozzle (S(A)GDl25-1) 18. Adapter
6. Thermostat 13. Rocker arm
7. Regulator valve w: Cooling water

6D125 SERIES
’ ’-ii25
STRUCTURE AND FUNCTION LUBRICATION SYSTEM

OIL PUMP

6D125-1

1 2 3 4 5 6

12 11 10 9

1. Pump drive gear (No. of teeth: 21) 01 L PUMP

2. Bushing *Type: Gear type
3. Pump cover - Pump speed: Engine speed x 1.571
4. Drive gear
5. Pump body MAIN RELIEF VALVE
6. Drive shaft -Set pressure: 7+; kg/cm2
7. Main relief valve
8. Valve spring
9. Retainer
10. Driven shaft
11. Bushing
12. Driven gear

11:26 6D126 SERIES

STRUCTURE AND FUNCTION LUBRICATION SYSTEM

S6D125-1, SAGD125-1

07

-8

615OFl22

1. Pump drive gear (No. of teeth: 21) 01 L PUMP

2. Bushing * Type: Gear type
3. Pump cover - Pump speed: Engine speed x 1.571
4. Drive gear
5. Pump body MAIN RELIEF VALVE
6. Drive shaft
*Set pressure: 7+: kg/cm’
7. Main relief valve
8. Valve spring
9. Retainer
10. Driven shaft
11. Bushing
12. Driven gear

6D125 SERIES
’ 1-:27
STRUCTURE AND FUNCTION LUBRICATION SYSTEM

REGULATOR VALVE

Section A -A
\ \
G F E 6150F123A

REGULATORVALVE
1. Adapter 6. From oil filter
*n 1
2: Regulator valve C. To engine each part - Set pressure: 3 zz.i kg/cm’ (6~125-1)
D. To oil filter
- Set pressure: 3.75 i 0.15 kg/cm* (S6D125-1)
E. From oil pump
(SAGDI 25-l)
F. To oil pan
G. To piston cooling nozzle (S6D125-1)

l l -g28 6D125 SERIES

STRUCTURE AND FUNCTION LUBRICATION SYSTEM

OIL FILTER

6D125-1

-A

615OF431

1. Bracket OIL FILTER

2. Cartridge . Filtration area: 0.53 m2
3. Safety valve
SAFETY VALVE
A. Oil inlet - Set pressure: 2.0 f 02 kg/cm2
B. Oil outlet

6D125 SERIES 1 l-029

8
STRUCTURE AND FUNCTION LUBRICATION SYSTEM

S6D125-1, SAGD125-1

Remote mounting type Direct mounting type

B A

t t
-B

-A

615OFl24 6150F124-I

1. Bracket OIL FILTER

2. Safety valve * Filtration area: 0.64 m2
3. Cartridge
SAFETY VALVE
A Oil inlet * Set pressure: 2.0 f 0.2 kg/cm2
B Oil outlet

“Z30 6D125 SERIES

STRUCTURE AND FUNCTION LUBRICATION SYSTEM

OIL COOLER

\
a

Section A-A

6150F125A

1. Thermostat housing THERMOSTAT FUNCTION

2. Thermostat - Valve cracking temperature: 104 k 1.5”C
3. Cooler cover * Full opening temperature: l15°c
4. Cooler element * Full opening lift: Min. 8 mm (6Dl25-1, SSDl25-1)
6D125-1: 4 cores Min. 11 mm (SAGDI 25-l)
S6D125-1: 7 cores
SAGD125-1: 10 cores 01 L COOLER
* Effective area 6Dl25-1: 0.289 m*
a. Water drain port S6Dl25-1 : 0.504 m2
SAGDl25-1: 0.781 m2
B. Oil inlet
C. To engine each part

6D125 SERIES
’ ’-OiO-’
STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL SYSTEM
FUEL SYSTEM CHART

6150Fl26A

1. Fuel tank
2. Feed pump
3. Fuel injection pump
4. Fuel filter
5. Fuel injection nozzle
6. Governor

60125 SERIES ll-z31

STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL INJECTION PUMP

6D125-1 (For D60*65A,E,P-8)

16

17

6150Fl27A

1. Fuel injection pipe (No. 3) 9. Feed pump

2. Fuel injection pipe (No. 2) 10. Priming pump
3. Fuel injection pipe (No. 1) II. Fuel injection pump
4. Fuel injection,pump drive gear 12. Gauze filter
(No. of teeth: 44) 13. Oil tube (inlet)
5. Drive shaft 14. Oil tube (outlet)
6. Drive case 15. Fuel injection pipe (No. 4)
7. Tachometer pick-up 16. Fuel injection pipe (No. 5)
8. Coupling 17. Fuel injection pipe (No. 6)

1’-kh32 6D125 SERIES

STRUCTURE AND FUNCTION FUEL SYSTEM

6150F126A

a. Fuel inlet FUEL INJECTION PUMP

b. To fuel filter * Maker: NIPPON DENS0
c. From fuel filter +Type: Bosch PE-N 6
d. To fuel injection nozzle * Lubrication method: Forced lubrication with engine oil.
e. To oil pan (oil)
GOVERNOR
*Type: RSV Centrifugal, all-speed type.

6D125 SERIES
’’-:33
STRUCTURE AND FUNCTION FUEL SYSTEM

S6D125-1 (For D75S-5)

6150F129A

1. Fuel injection pipe (No. 3) 9.. Oil tube (inlet)

2. Fuel injection pipe (No. 2) 10. Feed pump
3. Fuel injection pipe (No. 1) 11. Fuel injection pump
4. Fuel injection pump drive gear 12. Oil tube (outlet)
(No. of teeth: 44) 13. Fuel injection pipe (No. 4)
5. Drive shaft 14. Fuel injection pipe (No. 5)
6. Drive case 15. Fuel injection pipe (No. 6)
8. Coupling

’ ’-:34 6D125 SERIES

STRUCTURE AND FUNCTION FUEL SYSTEM

a. Fuel inlet FUEL INJECT PUMP

b. To fuel filter * Maker: DIESEL KIKI NIPPON DENS0
c. From fuel filter ‘Type: Bosch PE-P NB (EP9)
d. To fuel injection nozzle * Lubrication method: Forced lubrication with engine oil
e. To oil pan (oil)
GOVERNOR
*Type: RSV Centrifugal, all-speed type

6D125 SERIES 1 l-035

8
STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL INJECTION NOZZLE

615OFl32

I J 615OFl3lB

1. Inlet connector FUEL INJECTION NOZZLE * Adjusting injection pressure:

2. Nozzle holder * Type Shim adjusting type
3. Nozzle spring 6D125-1, S6D125-1: Adjusting value (per shim thickness 0.1 mm)
4. Nozzle Made by NIPPON DENS0 6D125-1: Approx. 16 kg/cm2
5. Needle valve Multi-hole type. S6Dl25-1: Approx. 16 kg/cm2
S6D125-1, SAGD125-1: (For PC300-3
a. From injection pump Made by DIESEL KIKI Engine No. 23689 and up.)
b. Nozzle hole Multi-hole type S6D1251: Approx. 14 kg/cm’
C. To fuel tank - Injection pressure SAGD1211: Approx. 14 kg/cm2
6D125-1 : 225 kg/cm’ Adjusting shims (at intervals of 0.025 mm)
S6D125-1: 225 kg/cm2 6D125-1: 0.7 to 1.5 mm
(For PC300-3 Engine No. S6D125-1: 0.7 to 1.5 mm
23689 and up) (For PC300-3
S6D125-1: 250 kg/cm’ Engine No. 23689 and up.)
SAGD125-1: 250 kg/cm2 !%D125-1: 0.5 to 1.975 mm
SAGD125-1: 0.5 to 1.975 mm

’’-:36
6D125 SERIES
STRUCTURE AND FUNCTION
FUEL SYSTEM

FUEL FILTER

615OFl33

1. Air bleed plug FUEL FILTER

2. Bracket * Filtration area: 0.3 mz
3. Cartridge
4. Water drain plug
A. Fuel inlet
B. Fuel outlet

6D125 SERIES

’‘-ii3’
MAGNETIC SWITCH AND FUEL SOLENOID
MAGNETIC SWITCH
B contact (electricity flows in ordinary operations) method

1 2 3 4

615OFl34

1. Shaft 5. Stop lever

2. Case 6. Return spring
3. Piston 7. Solenoid
4. Coil 8. Fuel control lever

MAGNETIC SWITCH
Inner wiring Maker:
- NIKKO DENKI
* Type: Sealed
Cl : Pull-in coil * Rated voltage: DC24V
C2: Holding coil - Operating current: Maximum: 35A max.
Continuity: 0.5A max
- Stroke: 12 f 0.3 mm
- Weight: 3.3 kg
FUNCTION

,8
* Starting engine

When the starting key is turned on, the solenoid is

energized.
Solenoid shaft (1) is electrically attracted, pulling
injection pump stop lever (5) and fixing it in the
RUN position.

* Stopping engine

When the starting key is turned off, the solenoid is

de-energized.
Injection pump stop lever (5) is returned to STOP
position (non-injection position) by return spring (6).

* During operation, the amount of fuel injection is

controlled by fuel control lever (8).

- When installing the fuel solenoid, adjust clearance A

referring to TESTING AND ADJUSTING.
6162F151

l l--38 6D125 SERIES

STRUCTURE AND FUNCTION FUEL SYSTEM

A contact (electricity flows when stopped) method

615OFl91

FUNCTION FUEL SOLENOID

l When stopping the engine, the solenoid is . Maker: SYNCHROSTART
energized, the solenoid plunger is electri- . Type: Sealed
cally attracted, and the stop lever of the in- . Rated voltage: DC24 V
jection pump is moved by a rod to the stop l Operating current
(non-injection) position. As a result, the fuel Pull-in coil: 25 A max.
is cut off and the engine is brought to a Holding coil: 0.5 A max.
stop. Accordingly, this solenoid is used only l Stroke: 25.4 mm
when the engine is being stopped; it is in
free condition during ordinary operations.
. No electricity goes to the solenoid when the
engine is running. The solenoid has no mag-
netic force, so the shaft of the solenoid is
pulled back by the return spring.

6D125 SERIES 11-038-l

0
STRUCTURE AND FUNCTION FUEL SYSTEM

ENGINE STOP MOTOR

Shape of cable tip

Shape of cable tip

Section A-A
(threaded stopper type)‘

6 7

I / Made by AMP Co.,

Econoseal connector, 8P male
Stroke

2. Not used (filler plug added)

/ 1. Not used (filler plug added)
4. 8 (AV 0.85LR)
3. P, (AV0.85LY)

Not used (filler plug added)

’ / i. A (AV 0.85Ll
8. E (AV 0.858)

1. Motor assembly ENGINE STOP MOTOR

2. Cover * Maker: Jidosha Denki Kogyo Co. Ltd
3. Cable assembly - Rated voltage: DC24V
4. Cable clamp - Operating force: 15 kg min.
5. Coil spring * Stroke: 35:::: mm
6. Cable
- Weight: 1.2 kg
7. Screw
8. 6 reather
9. Bracket assembly
10. Cover assembly

’ ’-os8-2 6D125 SERIES

 FUEL SYSTEM
STRUCTURE AND FUNCTION

STRUCTURAL DRAWING (1)

1. Gear cover assembly

2. Slider assembly
3. Armature shaft
4. Contactor assembly
5. Roller
6. Worm wheel assembly
7. Motor assembly
8. Gear case assembly

1 l-08-3
6D125 SERIES
STRUCTURE AND FUNCTION FUEL SYSTEM

STRUCTURAL DRAWING (2)

1. Gear cover assembly

2. Motor assembly
3. Cable clamp
4. Cable assembly
5. Gear case assembly

1 l-088-4 6D125 SERIES

STRUCTURE AND FUNCTION FUEL SYSTEM

DESCRIPTION OF OPERATION AND CIRCUITS

1. Stop Condition (0’ or 360”)

, Battery

,i

The above drawing shows the stopped condition when a

closed circuit has been formed. The slider assembly is
stopped at the auto-stop position on the PI side.

2. When switch is turned (when starting the motor)

attery

k-i
1

When the switch is moved to the P2 side (starting switch starting the motor. The slider assembly starts to move in
ON), an electric current flows from the plus side the direction of the arrow at the same time as the roller
contact plate through the P2 auto-stop terminal and starts to move.
switch and into the armature shaft assembly, thereby

3. Turning Condition (90’ in the drawing)

atterv

II-4
1

Electric current continues to pass through the armature the rotation of the roller, the slider assembly also
assembly and the motor continues to turn. Because of continues to move in the direction of the arrow.

6D125 SERIES
’ ’-“i8-5
 STRUCTURE AND FUNCTION FUEL SYSTEM

4. When stopped (180°)

Battery
+-i

A closed circuit is formed when the Pz auto-stop motor comes to a sudden stop. The slider assembly also
terminal rides on the minus-side contactor plate, and the stops.

5. When switch is turned (when starting the motor)

Battery

+-i
27

When the switch is moved to the PI side (starting switch motor. The slider assembly starts to move in the direc-
OFF), an electric current flows from the pluscontactor tion of the arrow at the same time as the roller starts to
plate through the PI auto-stop terminal and switch and move.
into the armature shaft assembly, thereby starting the

6. Turning condition (270’ in the drawing)

Battery

27

nh A7

Electric current continues to pass through the armature of the arrow. Then the circuit returns to stop condition
shaft assembly -and the motor continues to turn. The 1.
slider assembly also continues to move in the direction

1 l-028-6 6D125 SERIES

STRUCTURE AND FUNCTION COOLING SYSTEM

COOLING SYSTEM
COOLING SYSTEM CHART

6150F135A

1. Radiator 8. Cylinder liner

2. Thermostat 9. Piston
3. Water pump 10. Cylinder block
4. Water temperature gauge 11. Oil cooler
5. Water manifold 12. Air compressor (GD705R-3, GD705A-4)
6. Corrosion resistor (if equipped)
7. Cylinder head A. Lubrication oil

60125 SERIES ll-$39

STRUCTURE AND FUNCTION COOLING SYSTEM

WATER PUMP

MOUNTING

6150Fl36A

1. Thermostat A. To radiator (coolant)

2. Housing cover B. From engine each part (coolant)
3. Corrosion resistor C. To engine each part thru oil cooler (coolant)
4. Thermostat housing D. From radiator (coolant)
5. Water pump E. From oil pump (oil)
6. Oil cooler F. To engine each part (oil)
a. Outlet for heater
b. Water temperature gauge pick-up
C. Coolant drain plug
CL Outlet for air bleed tube

1y40 6D125 SERIES

STRUCTURE AND FUNCTION COOLING SYSTEM

WATER PUMP

6150Fl37A

1. Water pump drive gear WATER PUMP

(No. of teeth: 22) -Type: Centrifugal gear drive.
2. Pump shaft * Pump speed: Engine speed x 1.5
3. Ball bearing
4. Pump body
5. Water seal
6. Impeller
7. Pump cover

A. From thermostat
B. From radiator
r
V. To engine each part

6D125 SERIES y41

STRUCTURE AND FUNCTION COOLING SYSTEM

THERMOSTAT

1. Housing cover THERMOSTAT

2. Thermostat - Valve cracking temperature: 74.5 - 78.5’C
3. Gasket * Full open temperature: 9o”c
4. Thermostat housing * Full open lift Min. 10 mm

A. To radiator
B. To corrosion resistor KXD1251, SAGD125-1)
C. From corrosion resistor (S6D125-1, SAGDI 25-l)

11-042 6D125 SERIES

@
STRUCTURE AND FUNCTION COOLING SYSTEM

CORROSION RESISTOR
(If equipped)

B- -A

15 615OF139

1. Head CORROSION RESISTOR

2. Cartridge - Filtration area: 0.5 m2
3. Element (Paper)
4. Element (Chemicals)
5. Spring

A. Water inlet
B. Water outlet

6D125 SERIES 1 l-$43

STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
ALTERNATOR
MOUNTING

615OFl42

. Pulley O.D.

Engine
Applicablemachine
model

GD600R-3,GD605A-3 214 120 182

1. Adjustment plate
2. Alternator D75S-5 300 95 182
3. Fan belt
4. Fan Pc300-3,Pc300Lc-3 .214 95 182

5. Fan pulley
PC400-3,PC4OOLC-3 228 95 182
6. Crankshaft pulley
GD705-4 214 120 182
a. Fan pulley O.D. S6D125-1
WA450-1 300 95 182
b. Alternator pulley O.D.
c. Crankshaft pulley O.D.
b200-3 1214 1 95 1,811

6D125 SERIES
’ ’-ii45
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

ALTERNATOR WITH REGULATOR

Alternator Regulator

E
__-~ ..__
inner wiring
6150Fl43

I. Regulator B, E, F, R: Terminals
2. Alternator
3. Alternator pulley

Pulley O.D.
Engine model Applicable machine Type Specification Weight (kg)
(mm)

D50A. P-17
D50F-17
D53A. P-17
D60A, E, P-8 Maker: NIKKO DENKI
6D125-1 24V, 13A 95 7.6
D60S8 Type: Sealed
D65A. E, P-8
D65S-8
GD705R-3, GD705R-4

D60F-8
D60F-8A
13A
D75S5
EG220, B-l
Maker: NIKKO DENKI
S6D125-1 24V - 95 7.6
WA450-1 Type : Sealed 25A
EG200-3
35A
EC2602-1
GD705A-4 50A
Maker: NIKKO DENKI
SAG01 25-1 EG275, B-l 24V, 13A 95 7.6
Type: Sealed

6D125 SERIES
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

ALTERNATOR REGULATOR (Opentype)

l-_-l : 3

I Alternator Regulator 1
Innerwiring

1. Regulator
l!-l Double groove pulley

6 I36FO24-2
2. Alternator

3. Alternator pulley B, E, F, R: Terminals

Pulley O.D.
Engine model Applicable machine Type Specification Weight (kg)
(mm)

PC300-3
PC300 LC-3
PC400-3
PC400 LC-3 Maker: NIKKO DENKI
24V, 25A 95 7.5
GD613A-1 Type: Opened
S6D125-1 GD623A-1
GD663A-1
EG220BS1

HD200D-3 Maker: NIKKO DENKI

24V, 35A 95 10.5
HD205-3 Type: Opened
Maker: NIKKO DENKI
SAGD1251 EG275BS-1 24V, 25A 95 7.5
Type : Opened

6D125 SERIES
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

ALTERNATOR WITH REGULATOR (Opentype)

62lOFI 16

Inner wiring

1. Alternator B, E, R: Terminals
2. Alternator pulley

Pulley O.D.
Engine model Applicable machine Tvw Specification
(mm)
Weight (kg)

Maker: NIKKO DENKI

6D125-1 GD625A-1 24V, 50A 95 13
Type: Opened
I

11 -Og6-2 6D125 SERIES

STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

ALTERNATOR WITH REGULATOR AND VACUUM PUMP

Regulator

Inner wiring
615OFl44

1. Vacuum pump a. Air inlet VACUUM PUMP

2. Regulator b. Oil inlet * Discharge volume: 110 cc/rev.
3. Alternator c. Air and oil outlet
4. Alternator pulley

6, E, R: Terminals

I Engine model Applicable machine Type Specification

Pulley 0. D.
(mm)
Weight (kg)

GD600.650 R-3
Maker: NIKKO DENKI
6D125-1 24V, 25A 120 11
GD605*655R-3 Type: Opened

GD605*655A-3

6D125 SERIES 1 l-047

STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

STARTING MOTOR
4 R

3
Jd s
\

Safety Starting
relay motor

#-e+;

Inner wiring
615OFl45

I. Pinion gear B, C, R, S: Terminals

2. Body
3. Magnetic switch
4. Connector

Number of
Engine model Applicable machine Type Specifications pinion teeth Weight kg)

Maker: NIKKO DENKI

Standard (All machine) 24V, 7.5 kw 12 18
Type: Sealed
6D125-1
Maker: SAWAFUJI DENKI 24v ,, kw
Option I 12 20
Type: Sealed

Maker: NIKKO DENKI

Standard (All machine) 24V, 7.5 kw 12 18
Type: Sealed
S6Dl25-1
Maker: SAWAFUJI DENKI 24v ,, kw
Opt&n , 12 20
Type: Sealed

Maker: NIKKO DENKI

SAGD 125-I Standard 24V, 7.5 kw 12 19
Type: Sealed

6D125 SERIES
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

Inner wiring

1. Magnetic switch B, R, S: Terminals

2. Pinion gear
3. Body

Engine model Applicable machine Type Specifications p~~i~n~~e$, Weight (kg)

Maker: SAWAFUJI DENKI 24v, , , kw

6D125-1 GD625A-1 ?2 20
Type: Sealed

6D125 SERIES l l-068-l

STRUCTURE AND FUNCTION ELECTRICAL SYSTEM

ELECTRICAL INTAKE AIR HEATER

RIBBON TYPE

1. Body
2. Heater coil

ELECTRICAL INTAKE AIR HEATER

* Rated voltage: DC24V
- Rated current: 11 IA

Inner wiring

615OFl46

6D125 SERIES 1 l-$49

STRUCTURE AND FUNCTION ACCESS0 RY

ACCESSORY
AIR COMPRESSOR
For GD705R-3, GD705A-4, GD705R-4

615OF140

1. Cylinder head 10. Bearing cover

2. Unloader valve 11. Piston pin
3. Piston ring
4. Piston a. Air intake
5. Cylinder block b. Air exhaust
6. Connecting rod c. Unloader
7. Crankcase d. Cooling water inlet
8. Crankshaft e. Cooling water outlet
9. Connecting rod cap f. Oil inlet

11 -po 6D125 SERIES

STRUCTURE AND FUNCTION ACCESSORY

615OF141

AIR COMPRESSOR UNLOADER VALVE

- Maker: DIESEL KIKI *Valve opening pressure: 6.3 kg/cm2
‘Type: Single cylinder, double acting *Valve shutting pressure: 5.4 kg/cm2
* Discharge volume: 340 cc/rev.
*Air pressure: 8.5 kg/cm’ (at full load)
-Weight: 11 kg

6D125 SERIES 1 l-051

STRUCTURE AND FUNCTION ACCESSORY

OUTLINE
The air compressor is installed between the engine
timing gear and fuel injection pump, and is driven
by the timing gear. It is connected directly to the
engine, so the air compressor always rotates when
the engine is rotating.

ACTION OF UNLOADER VALVE

1) The intake valve and delivery valve automati-
cally open and close according to the pressure
inside the cylinder. During the piston up-stroke,
the air inside the cylinder is compressed, the
intake valve is closed, and the delivery valve
opens to discharge the compressed air. On the Air intake port
down-stroke, the delivery vaive closes and the
intake valve opens to suck in air from the air
cleaner.
2) An air governor is installed to control the
amont of air inside the air tank. When the air
pressure inside the air tank reaches the speci- 6 I5OF320

fied pressure, the compressed air inside the When intake valve is actuated
tank passes through the air governor, and
pushes down the rod of the unloader valve to
keep the intake valve open. As a result, while
the unloader valve is being actuated, the intake
air is not compressed. Air pressure from air governor
3) If the air pressure inside the air tank goes be-
low the specified pressure of the air governor,
the rod of the unloader valve returns to its
original position. The intake valve then returns
to its normal operation, and starts to send com-
pressed air again.

Air intake port

G

615OF321

When intake valve is kept open

1 l-052 6D125 SERIES

a
STRUCTURE AND FUNCTION ACCESSORY

EXHAUST BRAKE
For H D200D-3, H D205-3

i f

1,l

F567D03005A

1. Pipe 8. Piston
2. Poppet 9. Piston packing
3. Valve housing 10. Retainer
4. Gate valve 11. Head cover
5. Guide bushing A. From solenoid valve
6. Cylinder B. Exhaust gas exist
7. Spring

OUTLINE
- Exhaust brake mounting between engine turbo-
charger and muffler works due to air pressure
from solenoid valve.
The exhaust brake throttles exhaust passage bet-
ween turbocharger and muffler, and reduces engine
speed.
The exhaust brake consists of valve mechanism and
air cylinder which operates a valve.

6D125 SERIES
’ ’-F3
 ENGINE BODY
Adjusting valve clearance . . . . . . . . . . . . 12-002
Measuring compression pressure . . . . . . 12-003

FUEL SYSTEM
Checking and adjusting
fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-004
Testing and adjusting fuel cut solenoid . . . 12-006
Adjusting engine stop motor cable . . . . . . . . 12-006-I
Fuel injection pump calibration data......... 12-007

PERFORMANCE TEST
Run-in standard .................. 12-021
Performance test criteria ............ 12-024
Testing and adjusting tool list ......... 12-030
Testing and adjusting data ........... 12-031

TROUBLESHOOTING . . . . . . . . . . . . . . . . 12-045

‘*go’
6D125 SERIES
TESTING AND ADJUSTING ENGINE BODY

ENGINE BODY
ADJUSTING VALVE CLEARANCE
ADJUSTMENT PROCEDURE

1. Remove the cylinder head cover.

2. Rotate the crankshaft in the normal direction. While

watching the movement of the intake valve of the No. 6
cylinder, bring the No. 1 cylinder into the top dead
center position of the compression stroke and align the
“1.6 TOP” mark on vibration damper (2) with pointer
(3).
* When the No. 1 cylinder comes near the top dead
center of the compression stroke, the No. 6 intake
valve will start to move (open).
* Valve arrangement chart
3. Adjust the valve clearance for valves marked 0 in the
valve arrangement chart.

=
4. Rotate the crankshaft in the normal direction by one
8
revolution and adjust the valve clearance for the re-
maining valves markedo.

* To adjust the valve clearance, loosen lock nut (8)

on adjustment screw (7). insert Feeler gauge A
corresponding to the specified clearance between
crosshead (6) and rocker arm (5). and adjust the
clearance with the adjustment screw until the
thickness gauge can slide lightely.

6 I5OF20 I

5. After the clearance is properly adjusted, tighten the lock

nut to secure the adjustment screw.

m Locknut: 720.5 kgm

* The engine firing order is l-5-3-6-2-4.

* Intake and exhaust valve clearances may be adjusted for
each cylinder in the firing order by rotating the crank-
shaft 120’ at a time in the normal direction.
* For details about valve clearance, see TESTING AND
ADJUSTING DATA.

12-002 6D125 SERIES

0
TESTING AND ADJUSTING ENGINE BODY

MEASURING COMPRESSION PRESSURE

MEASUREMENT PROCEDURE

A While measuring
not burn yourself
the compression
on the
pressure, take care
exhaust manifold or
muffler, and be careful not to get caught in any
revolving part of the engine.
* Measure the compression pressure while the engine
is warm.
(Oil temperature: 40 - 6O’C)

1. Adjust the valve clearance properly. For details, see

ADJUSTING VALVE CLEARANCE.

2. Remove spill tube (1) and disconnect fuel injection pipe

(2).

3. Remove nozzle holder assembly (3) for each cylinder.

* Remove the nozzle holder assembly by prying it
with two mounting bolts.
* Take care not to let any dirt or foreign matter get
into the cylinder.

4. Install adapter A to the nozzle holder mounting section

of the cylinder to be measured, and tighten the adapter
to the specified torque.

w Torque: 2.2 i 0.3 kgm

5. Connect compression gauge B to the adapter.

6. Place the fuel control lever in NO INJECTION position,

crank the engine with the starting motor, and read the
gauge when the pointer is stabilized.

A If you do not put the fuel control

INJECTION position, fuel will blow out.
lever in NO

* Most compression leakage can be prevented by

applying a small amount of oil to the mounting
section of the adapter.
* For the reference values of the compression pres-
sure, see TESTING AND ADJUSTING DATA.

6D125 SERIES
TESTING AND ADJUSTING FUEL SYSTEM

FUEL SYSTEM
CHECKING AND ADJUSTING FUEL
INJECTION TIMING
There are two methods for checking and adjusting the fuel
injection timing of an injection pump.
The “MATCH MARK ALIGNMENT” method, which is
used when the injection pump is installed to the original
engine and the pump is not being repaired.
The “DELIVERY VALVE” method, which is used when
a repaired or replaced injection pump is installed to the
engine.
When using the DELIVERY VALVE method, make
preparations to replace the delivery valve copper
gasket and O-ring with new parts.
Before inspecting and adjusting the fuel injection timing,
bring the No. 1 cylinder piston to the top dead center of
the compression stroke. For details, see 12 ADJUSTING
VALVE CLEARANCE.

CHECKING AND ADJUSTING BY THE MATCH

MARK ALIGNMENT METHOD
With No. 1 cylinder piston at TOP position, rotate
the crankshaft 30’ to 40’ in the reverse direction.

Align the injection timing stamp line on crankshaft

615OFlO52
damper (1) with pointer (2) by slowly rotating the
crankshaft in the normal direction.

Confirm that stamp line a on the injection pump is

aligned with stamp line b on the coupling.

* If the stamp lines are out of alignment, loosen nut

(3). align the stamp lines by shifting the coupling,
and tighten the nut.

QED Nut: 6.2 f 0.2 kgm

615OFlO53

CHECKING AND ADJUSTING BY THE DELIV-

ERY VALVE METHOD
1. Disconnect fuel injection pipe (4) for the No. 1 cylinder.

2. Remove delivery valve holder (5).

615OFlO54

’2-:04 6D125 SERIES

TESTING AND ADJUSTING FUEL SYSTEM

3. Remove spring (6) and delivery valve (7) from the

delivery valve holder, and reassemble the delivery valve
holder.

4. With No. 1 cylinder piston at TOP position, rotate

the crankshaft 30” to 40” in the reverse direction.

5. Place the fuel control lever in FULL position, slowly

rotate the crankshaft in the normal direction while
operating the priming pump, and observe the position
when the fuel stops flowing out of the delivery valve
holder.
615OFlO55

6. In the position where the outflow of fuel stops, check

the injection timing stamp line on the crankshaft damper
to see if it is aligned with the pointer.
* If the injection timing stamp line passed through the
pointer: The injection timing is late.
* If the injection timing stamp line did not reach the
pointer: The injection timing is advanced.

* If the inspection shows that the injection timing is out

of adjustment, adjust the fuel injection timing in the
following manner.

1) Rotate the crankshaft 30’ to 40’ in the reverse

direction, starting from TOP position in No. 1
cylinder.
2) Align the injection timing stamp line on damper (1)
with pointer (2) by slowly rotating the crankshaft
in the normal direction.
3) Loosen nut (3) on the injection pump mounting
flange slot, and rotate the flange on the pump side
little by little by operating the priming pump until
no fuel flows out of the delivery valve holder.
4) Tighten the nut on the injection pump mounting
flange slot.
1
k Recheck the injection timing to see if it is
properly adjusted.
5) Align match mark a with mark b and stamp the
15OFI
marks.

* After the checking and adjusting, be sure to reas-

semble the spring and the delivery valve.
* Always replace the delivery valve copper gasket and
O-rings with new parts.

615OFlO57

6D125 SERIES
’2-iio5
TESTING AND ADJUSTING FUEL SYSTEM

TESTING AND ADJUSTING FUEL

CUT SOLENOID
1. Adjust rod (2) so that there is clearance of 0.4 + 0.1 mm
between stop lever (4) and stopper (51, while pulling rod
(2) to the running direction.

2. Turn on the engine starting key and confirm that the

solenoid has a stroke of 12 mm and the clearance of
0.4 + 0.1 mm.

3. After turning on and off the key two or three times,

reconfirm that solenoid works smoothly and engine runs
or stops completely.
* If the solenoid does not work smoothly, solenoid
coil burns in the cause of excessive current or
flywheel horsepower downs in the cause of drop-
ping fuel injection volume.

61 SOF208-1
S6D125-1 (EG2201, SAGD125-1 (EG275)
A rod forms a link between the solenoid and injec- 1. Solenoid valve 4. Stop lever
tion pump. At this time, when the stop lever returns 2. Rod 5. Stopper
0.5 - 1.0 mm from the stop pin on the RUN side 3. Fuel injection pump
and the solenoid shaft is pushed by hand, the stop
lever of the pump will be set in a position in which
it has returned 0.5 - 1 .O mm from the stop pin.

Next, energize the solenoid and see if its movement

is smooth. Turn the starting switch ON and OFF
two to three times and confirm that the operation
condition does not change. If the operation is not
smooth, adjust the linkage and carefully observe
the movement.

Confirmation of Functions
After confirming that the operation is smooth, start
the engine and confirm that the rated output can be
obtained. Next, energize the solenoid and confirm
that the engine stops. (The engine should stop
within 10 sec.)

Failures caused by faulty adjustment of solenoid

. If the clearance between * Burning of the solenoid

the stop bolt and lever is core (when solenoid is
0 when the solenoid is only partially pulled)
energized * Breakage or scuffing
of the injection pump
governor (an undue
force will be applied
to the lever)
* When there is a large * Engine power will not
clearance between the be generated because
stop lever and RUN side of a decline in amount
bolt when the lever is free of fuel injection
(faultv Iinkaae)

‘*zo6 6D125SERIES
 TESTING AND ADJUSTING FUEL SYSTEM

ADJUSTING ENGINE STOP MOTOR CABLE

HD200D-3, HD205-3
When the cable is pulled and stop lever (4) of the fuel
injection pump is aligned with the STOP position, the
cable will be fastened to bracket (1) with clamp (3).
To give some play to the cable, remove the ball joint,
turn the ball joint one revolution in the opposite (exten-
sion) direction, then reinstall it to the stop lever of the
fuel injection pump.
(Note that it is also acceptable to install the ball joint
from the beginning after estimating how much play the
cable needs.) :; :\
i 3 62lOF21 I

1. Bracket
2. Wire
3. Clamp
4. Injection pump stop lever

6D125 SERIES
’2-o$6-’
TESTlNG AND ADJUSTING FUEL SYSTEM

WA450-1
1. Stop the engine. The engine stop motor has limit switches built
2. Install a ball joint to the injection pump stop in on both sides of the cable stroke.
lever, then temporarily fit the cable connecting Engine stop motor stroke: 35 mm
the wiper motor and injection pumps. Fuel injection pump stop lever stroke: 30 mm
3. Pull the injection pump stop lever by hand to When the engine is running, there is slack in
the NO INJECTION position, and temporarily fix the engine stop motor cable, and the RUN posi-
the cable to the bracket. tion is maintained by the action of a spring
When doing this, temporarily fit the cable to (this is frequently built into the fuel injection
the bracket using the holding nut with the stop pump.)
lever contacting the ENGINE STOP stopper. There is a loose spring inside the engine stop
* The engine stop motor is delivered with the motor, and this absorbs the tolerance of the
cable pulled (engine stopped). stop motor when the engine is stopped.
* The stop lever of the fuel injection pump is at However, if it is absorbed by the loose spring
the RUN position when the lever is free. (It is of the engine stop motor, force is applied to
pulled to the RUN position by a spring.) the injection pump, so depending on the model,
4. When the wiper motor is installed (engine this may be impossible.
stopped), adjust so that the clearance between With such models, if the clearance between the
the stop lever of the fuel injection pump and stop lever and STOP stopper is made 0 when
the STOP stopper is 0.5 - 2.5 mm. Carry out the engine is stopped, there is a risk that prob-
the adjustment with the nut holding the cable lems may occur with the injection pump.
to the bracket, or make fine adjustments by Problems caused by defective adjustment of the
changing the amount the ball joint is screwed engine stop motor cable.
in.
5. Tighten all bolts and nuts.
6. Turn the engine starting switch ON and OFF re- l When the clearance . Engine does not stop
peatedly, and check that the engine stop motor between the stop
and cable move smoothly. Then check the fol- lever and STOP
lowing points again. stopper is excessive
(1) When the engine is running, check visually with the engine stop
that there is slack in the engine stop motor motor cable pulled
cable, and that the stop lever of the fuel in-
jection pump is fully returned o the RUN l When the clearance . Fuel injection
position. between the stop amount drops,
(2) Check again that the clearance between the lever and the RUN causing loss of
stop lever and STOP stopper is 0.5 - 2.5 stopper is excessive engine output power
mm when the engine is stopped. at the free position

6D125 SERIES

’2-oz6-2
TESTING AND ADJUSTING FUEL SYSTEM

FUEL INJECTION PUMP CALIBRATION DATA

Engine model

D50F-17

D60E-8
D60P, PL-8
6D125-1

6D125 SERIES 12-007

@
TESTING AND ADJUSTING FUEL SYSTEM

Engine model Applicable machine Pump assembly No. Engine serialNo. Page

D65S-8 6150-71-1341 12-010-4

6150-71-1342 12-010-5

6150-71-1343 12-010-5

D65A-8 (forFrance) 6150-71-1411 12-012-3

6150-71-1412 12-012-3

D65E-12 6150-71-1170 12-012-4

D68E, P-l 6150-71-1490 12-012-5

6150-71-1491 12-012-5

PC300-3c 6150-71-1810 12-012-6

GD600R-3 6150-71-1511 12-013

I I
GD605R-3
6150-71-1513 1 12-013-I
I I

I 6150-71-1514 1 12-013-I
GD605A-3 6150-71-1581 12-014

6150-71-1583 12-014-I

6150-71-1584 12-014-I

GD650R-3 1 6150-71-1521 I / 12-015

GD655A-3
6D125-1 1 6150-71-1522 1 12-015-I
GD655R-3
6150-71-1523 12-015-I

6150-71-1524 12-015-I

16150-71-1590 1 12-015

16150-71-1592 I 1 12-015-I

16150-71-1593 I 1 12-015-I

1 GD613A-1 1 6150-71-1550 119761 - l 1 12-012-7

GD622A-1 .
6150-71-1551 - 26169 12-012-7
GD623A-1
6150-71-2720 26170- l 12-012-8

6150-71-2721 l andup 12-012-8

GD625A-1 6150-71-1570 12-014-2

6150-71-1571 12-014-3

GD625A-IC 6150-71-2710 12-014-4

6150-71-2711 12-014-4

GD663A-1 6150-71-1560 12-014-5

6150-71-1561 12-014-5
6150-71-1660 12-014-5

6150-71-1661 12-010-5

12-007-l 6D125 SERIES

0
TESTING AND ADJUSTING FUEL SYSTEM

Engine model Applicable machine Pump assembly No. Engine serial No. Page
GD705R-3 6150-71-1531 12-016
I I
GD705R-4
6150-71-1533 1 12-016-I
6150-71-1534 12-016-I

6150-71-1542 12-016-I

6150-71-1543 12-016-I

6D125-1

6D125 SERIES 12-007-2

@
TESTING AND ADJUSTING FUELSYSTEM

Engine model Applicable machine 1 Pump assembly No. 1 Engine serialNo. Page

D60F-8A 1 6151-71-1721 1 10001 -12582 1 12-017

6151-71-1722 12583- l 12-017

6151-71-1723 l and up 12-017

D60P-12 1 6151-71-1190 I 1 12-017-I

D65EX-12 6151-71-1180 12-017-2

D75S-5 6151-71-1731 10001 -12014 12-017-3

6151-71-1732 12015- l 12-017-4

6151-71-1733 . -23192 12-017-4

6151-71-1640 23193- l 12-017-5

6151-71-1641 l and up 12-017-5

D83E, P-l 6151-71-1621 26263- l 12-017-6

D85E, SS-1 6151-71-1622 l and up 12-017-6

D85A, P-21 6151-71-1770 12-017-7

I ,
D85E-21
6151-71-1771 / 12-017-7
PC300-3, PC3OOLC-3 6151-71-1210 13137 -23688 12-017-8
PC300NLC-3
PC36OLC-3

S6D125-1 PC300-3 6151-71-1230 12-017-8

(forSweden)

PC300-3, PC3OOLC-3 6151-71-1211 23689- l 12-017-9

PC300NLC-3
6151-71-1212 l andup 12-017-9
PC36OLC-3

PC300-3 6151-71-1250 12-017-9

(forcold weather)

PC300-3 6151-71-1231 12-017-10

(forSweden)
I / I

PC360-3 1 6151-71-1270 1 12-017-11

PC400-3 6151-71-1220 13444-26690 12-017-12
PC4OOLC-3

PC400-3 6151-71-1240 12-017-12

(forSweden)

PC400-3 6150-71-1260 12-017-12

(forcold weather)

PC400-3 6151-71-1221 26691 and up 12-017-13

PC4OOLC-3
6151-71-1222 12-017-13

12-007-3 6D125 SERIES

@
TESTING AND ADJUSTING FUEL SYSTEM

Engine model Applicable machine Pump assembly No. Engine serialNo. Page

PC400-3 6151-71-1241 12-017-13

(forSweden)
6151-71-1242 12-017-13

PC400-3 6151-71-1261 12-017-13

(forcold weather)

PC400-5, PC4OOLC-5 6151-73-1210 12-017-14

PC400-5 6151-73-1220 12-017-14

(forSweden)

PC400-5 6151-73-1230 12-017-14

(forcold weather)

PC400-5c 6151-73-1240 12-017-14

HD200D-3 6151-71-1362 19950-21454 12-017-15

6151-71-1363 21455- l 12-017-15

6151-71-1364 . and up 12-017-15

HD205-3 6151-71-1322 16790 -21668 12-017-16

6151-71-1323 21669- l 12-017-17

6151-71-1324 . and up 12-017-18

WA450-1 6151-71-1112 15805 -23903 12-017-19

S6D125-1 6151-71-1113 23904-26687 12-017-19

1 6151-71-1114 1 26688-and up 1 12-017-20

6151-73-1115 . -35041 12-017-21

6151-71-1116 35042 and up 12-017-21

WA450-IC 6151-71-1121 12-017-22

6151-71-1122 12-017-22

WA450-3 6151-71-1440 12-017-23

D65EX-12 6151-71-1180 12-017-24

D65P, PX-12

HA250, HA270 6151-71-2720 12-017-25

6D125 SERIES 12-007-4

@
TESTING AND ADJUSTING FUEL SYSTEM

Engine model Applicable machine Pump assembly No. Engine serialNo. Page

WA470-1 6151-71-1151 23333-26687 12-017-26

6151-71-1153 26688- l 12-017-26

6151-71-1154 9 andup 12-017-26

6151-71-1450 12-017-26

WA470-1 6151-71-1152 12-017-27

GD705A-4 6151-71-1511 12-017-28

6151-71-1513 12-017-28

6151-71-1531 12-017-28
I I

6151-71-1550 I 12-017-29
6151-71-1551 12-01J-29
EC260Z-1 6151-71-1821 12-017-30
1 6151-71-1822 I 1 12-017-31
6151-71-1823 12-017-31
EG200-3 6151-71-1930 12-017-32

6151-71-1931 12-018

6151-71-1932 12-018

S6D125-1

12-007-5 6D125 SERIES

8
TESTING AND ADJUSTING FUEL SYSTEM

Engine model 1Applicable machine / Pump assembly No. 1 Engine serial No. 1 Page

D135A-1 6152-71-1730 12-019

6152-71-1731 12-019

EP (Power unit) 6152-71-I 170 12-020

6152-71-1171 12-020

Alaska diesel 6152-71-1220 12-020-I

6152-71-1221 12-020-2

Big Bud (OEM use) 6152-71-1230 12-020-3

6152-71-1231 12-020-3

D85A 6152-71-1760 12-020-4

(for Indonesia)
6152-71-1761 12-020-4

SAGDI 25-l

6D125 SERIES 12-007-6

@
 injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
6D125-1 PE-6NB NIPPON DENS0 6150-71-l 111 (I 90000-9050). .0
Bzg$::;

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Specification for engine with fan (reference only)

Delivery valve
so High idling: rpm 1875 to 1975
retraction volume mm3

Low idling: rpm 650 to 700

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-0540) (DNI 2SDl2)

Nozzle holder part no. (093 100-0190) (EFB5 11 /SA)

In ectron pope mm 6x2~600 6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm” 175 175

Transfer pump pressure kg/cm” 1.6 1.6

specifications
Injection volume (cc/l OOOst) Injection volume(cc/l OOOst)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
pozion speed Basis Allowance Basis Allowance
between between
m (rpm) cylinder cylinder
Calibration ‘Each cyl. Each cyl.
basic point 9.4 875 74.5 71.5 to 77.5 max. 6.0 72.0 69.0 to 75.0 max. 6.0

l Rack positions B 10.5 550 94.5 * 91.5 to 97.5 max. 6.0 94.5 * 91.5 to97.5 max.6.0
B to E are the refer-
ence volume when C 9.2 325 26.0 * 24.0 to 28.0 max. 5.0 24.5 * 22.5 to 26.5 max. 5.0
adjustingthe injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

0 k$ K:: x
5 SEmm.-

Pump speed (rpm) r

12-007-7 Numbers In parentheses are pump manutacturer part numbers.

6D125 SERIES
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D50A, P-l 7 6D125-1 PE-6NB NIPPON DENS0 6150-71-1112 (190000-9052) 3
I 6150-71-1113 (190000-9053)

injection Timing

Unit Basis Allowance

Rotating direction Counterclockwise viewed

from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference on(y)
Injection interval 60” 59’30’ to 60’30’ Rated horsepower: HP/rpm 120/1750

Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 65.5/l 100

Delivery valve mm3
retraction volume 90 High idling: rpm 1875 to 1975

Low idling: rpm 650 to 700

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

Injectron pope
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm2 175

Transfer pump pressure kg/cm* 1.6

Specifications
injection volume (mm3/st) Injection volume (mm3/.st)
for manufacturer standard for service standard

Rack Maximum Maximum

Pump
Basis variance variance
y;sion ;pe;~I Allowance Basis Allowance
r between between
cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 9.6 875 75.5 75.5 72.5 to 78.5 max. 6.0

l Rack positions B to 8 10.8 550 87.5 * 87.5 * 84.5 to 90.5 max. 8.0
E are the reference
volume when ad- C 9.4 325 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

200\325 \ 550 \
245 400 *7z090501100

Pump speed (rpm)

12-008 Numbers in parentheses are pump manufacturer part numbers. 6D125 SERIES
0
Pump Assembly Number
6150-71-1210 (191000-4130)
6150-71-1211 (191000-4131) Applicable Machine 1 Applicable Engine

( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

D50A, P-18 6D125-I

e

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[HPl/ rpm) 91.2 [122.31/ 1,750
viewed from drive end
Injection order l-5-3-6-2-4

Injection interval 60” (59”30’ - 60”30’)

Plunger pre-stroke (mm)

Pump tester capacity
Delivery valve (mm3/st) 59 Motor 7.5 kW
retraction volume for Service standard
alibration Standard ( ): Pump manufacturer’s part No.

Service standard
indicates data
using calibration
test parts.
Manufacturer
standard is data
for factory test.

Rack positions
B to E are the ref-
erance volume

Governor performance

0 2 4 10 12 14 16
PUMP6
SPEED8WM~ x10’
TKEOOI 55

6D125 SERIES 12-008-l

0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D50F-17 6D125-1 PE-6NB NIPPON DENS0 6150-71-I 131 (190000-8862) . 2
6150-71-1132 (190000-8863) 0

Injection Timing

Specification for engine with fan (reference only)

Injection interval 60” 5930’ to 60’30’ Rated horsepower: HP/rpm 138/l 900

Plunger pre-stroke

Delivery valve
mm 4.7
I Maximum torque: kgm/rpm 66/I 300
I
mm3 so High idling:
retraction volume rpm 2050 to 2150

Low idling: rpm 625 to 675

Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SD12A)

Nozzle holder part no. 093100-0190 (EF8511/SA)

InjectIon tpe
(O/D x I/ B x length) mm 6x2~600

Test oil ASTM DS75 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm2 175

Transfer pump pressure kg/cm2 1.6

jpecifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
osition speed Basis Allowance variance Basis Allowance variance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 9.9 950 78.0 78.0 75.0 to 81 .O max. 6.0

1 Rack positions B to B 10.6 650 85.0 * 85.0 * 82.0 to 88.0 max. 6.0
E are the reference
volume when ad- C 9.4 325 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
) Marks * are aver-
age volumes. E * *

sovernor performance

Min. 14.0

Il.1 \

0 2001 3251 650 8009~~510501200

240 400

Pump speed (rpm)

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers.

12-gO9
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
PE-6NB NIPPON DENS0 6150-71-l 121 (I 90000-9060). 0

Injection Timing

Unit Basis Allowance

I
Counterclockwise viewed
Rotating direction
from drive end I
Specification for engine with fan (reference only)

Delivery valve
retraction volume mm3 I
I
I High idling: 2050 to 2150

Low idling: rpm 600 to 650

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-I 6001 (DNI 2SD 121

Nozzle holder part no. (093 100-27 IO) (EF85 11/9A)

In ectron pope
mm 6x2~600 6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm2 175 175

Transfer pump pressure kg/cm2 1.6 1.6

specifications
Injection volume W500st) Injection volumeW500st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (rpmj
cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 9.3 950 36.0 34.5 to 37.5 max. 3.0 35.5 34.0 to 37.0 max. 3.0

’ Rack positions B 10.1 650 39.0 * 37.5 to40.5 max. 3.0 39.0 * 37.5 to 40.5 max. 3.0
B to E are the refer-
ence volume when C 8.8 325 7.3 * 6.3 to 8.3 max. 2.5 7.5 * 6.5 to 8.5 max. 2.5
adjusting the injec-
tion volume. D * *
l Marks * are aver-
age volumes. E * *

sovernor,performance

Pump speed (rpmj

Numbers in parentheses are pump manufacturer part numbers.

SERIES
’*-E9-’
6D125
Pump Assembly Number
6150-71-1122 (190000-9062)
6150-71-1123 (190000-9063) Applicable Machine Applicable Engine

( 1: Manufacturer’s part No. Model 1 Serial No. Model Serial No.

D53A, P-17 1 I6D125-1 I

Injection Timing Engine Specification

Counterclockwise
Rotating direction
viewed from drive end
Injection order l-5-3-6-2-4

Injection interval 60” (59”30’ - 60”30’)

Plunger pre-stroke (mm) I

I
Pump tester capacity
Delivery valve (mm’/st) Motor 7.5 kW
retraction volume for Service standard
alibration Standard ( ): Pump manufacturer’s part No.

Governor performance

14

0 2 4 PUti SPdRPMI 10 12 14 16
x10?
TKE00156

6D125 SERIES 12-009-2

0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D58E-1 6D125-1 NB (EP9) NIPPON DENS0 6150-71-1220 (191000-5230) 1
D58P-1 6150-71-1221 (191000-5231) 0

Injection Timing

Specification for engine with fan (reference only)

Injection interval 60 5930’ to 60”30’ Rated horsepower: HP/t-pm 130/l 900

Plunger pre-stroke

Delivery valve
mm 3.0
I Maximum torque: kgm/rpm 64.8/l 300
I
mm3 59 High idling: 2050 to 2150
retraction volume rpm

Low idling: rpm 775 to 875

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511 l9A)

Injectjon pope
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

Specifications injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 10.4 950 79.0 79.0 76.0 to 82.0 max. 6.0

l Rack positions B to B 1I.2 650 94.0 * 94.0 * 91 .o to 97.0 max. 8.0

E are the reference
volume when ad- C 8.6 410 17.0 * 17.0 * 15.0 to 19.0 max. 510
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

tn
11.2
F 10.4

E 8.6

s
.-
f 7.9

%
d Max. 4.0

Pump speed (rpm)

Numbers in parentheses are pump manufacturer part numbers.

6D125 SERIES
12-% O-l
Pump Assembly Number
6150-71-1222 (191000-5232) Applicable Machine Applicable Engine

( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

D58E, P-l 6D125-1

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[HPl/ rpm) 92.5 [124.01/ 1,900
viewed from drive end
Injection order l-5-3-6-2-4

Injection interval 60” (59”30’ - 60”30’)

Plunger pre-stroke (mm)

Pump tester capacity
Delivery valve (mm”/st) 59 Motor 7.5 kW
retraction volume for Service standard
:alibration Standard ( ): Pump manufacturer’s part No.

Conditions Service standard Manufacturer standard

Service standard
indicates data Nozzle part no. (093400-0540)
using calibration
Nozzle holder part no. (093100-0190)
test parts.
Manufacturer Injection pipe
(O/D x I/D x length) mm 6 x 2 x 600
standard is data
for factory test.
Test oil ASTM D975 No.2 diesel fuel or equivalent

1Rack positions
B to E are the ref-
erance volume
when adjusting

volume.

Governor performance

2 4 6 a 10 12 14 16
PUMPSPEED(RPM1 x1 01
TKE00157

12-010-2 6D125 SERIES

0
Pump Assembly Number Applicable Machine Applicable Engine
6150-71-1460 (191000-4051)
6150-71-1461 (191000-4052) Model Serial No. Model Serial No.
( ): Manufacturer’s part No.
D58E-1 6D125-1 Up to 29456

D58P-1 6D125-1 up to 29471

Injection Timing Engine specification

Counterclockwise Rated horsepower HP/rpm
Rotating direction 130/l 900
viewed from drive end
lniection order l-5-3-6-2-4 Maximum torque kgm/rpm 64.311300

Calibration Standard

Conditions Service standard Manufacturer standard

* Service standard
Nozzle part no. (093400-0540)(ND-DN12SD12A) (093400-0540)(ND-DN12SDl2A;
indicates data
using calibration Nozzle holder part no. (093100-0190)(EF8511/9A) (093100-0190)(EF8511/9A)
test parts.
*Manufacture Injection ipe
(O/D x l/g x length) mm 6 x 2 x 600 6 x 2 x 600
standard is data
for factory test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175 175

Transfer pump pressure kg/cm’ 1.6 1.6

Injection volume Service standard (cc/500 St) Manufacturer standard (cc/ 500 st
Rack Pump
Rack
position speed Maximum Maximurr
point variance
(mm) b-pm) Basis Allowance ~~~~~ Basis Allowance between
cylinder cylinder
bRack positions Each cyl.
B to E are the refer- Basic point 9.5 950 36.75 Max. 3 36.75 Each “j.
35.25 to 38.25
ence volume when
adjusting the injec- B 10.4 650 (44.5) +(43.0 to 46.0) Max. 4 (44.5) *
tion volume.
* Marks * are aver- C (8.8) 410 10.5 * 9.5 to 11.5 Max. 2.5 10.5 -k
age volumes.
D * *

E * *

Governor performance 1 410 - 950 rpm)

Pump speed (rpmj SEBH4540-01

6D125 SERIES
’2-g
o-3
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
6D125-1 PE-6NB NIPPON DENS0 6150-71-1341 (l$OOOO-9100)...0

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm

Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 78/l 100

Delivery valve High idling: 2050 to 2150

90 rpm
retraction volume mm3

Low idling: rpm 600 to 630

Calibration Standard

Manufacturer standard Service standard

ionditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-0540) (DNI 2sDi 2)

Nozzle holder part no. (093 100-0190) (EF85 11/9A)

In ectron pope mm 6x2~600
6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm2 175 175

Transfer pump pressure kg/cm2 1.6 1.6

ipecifications
Injection volume W500st) Injection volumeW5OOst)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
yo$ion speed Basis Allowance Basis Allowance
between between
(rpm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 10.0 925 42.0 40.5 to 43.5 max. 4.0 42.0 40.5 to43.5 max.4.0

’ Rack positions B 11.5 550 63.3 t 61.8 to 64.8 max. 4.0 64.5 * 63.0 to 66.0 max.4.0
B to E are the refer-
ence volume when C 9.1 300 8.5 * 7.5 to 9.5 max. 2.5 9.0 * 8.0 to 10.0 max. 2.5
adjustingthe injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

jovernor
Min. 14.0

(12.01
(11.5)

0
8 800 % g$g
De Lo
Pump speed (rpm) -

Numoers In parenrneses are pump manuracrurer part numoers.

12-010-4 6D125 SERIES
8
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
b&8’, PL-8 6D1251 PE-6NB NIPPON DENS0 6150-71-1342 (190000-9102) . . 3
6150-71-1343 (190000-9103)
I

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Specification for engine with fan (reference only)

Low idling: rpm

Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

lnlectlon pipe
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm2 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack_ pun?p variance variance
fc;;lon speed Basis Allowance Basis Allowance
between between
(rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 10.4 925 86.0 86.0 83.0 to 89.0 max. 8.0

l Rack positions B to B Il.7 550 120.5 * 120.5 * 117.5 to 123.5 max. 8.0
E are the reference
volume when ad- C 9.5 300 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

0 100 300\400 550 750 92~~~0501200

350

Pump speed (rpm)

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers.

’ *-O: o-5
Machine Model injection Pump
Engine Model
Pump Type Manufacturer Pump Assembly Number
6D125-1 PE-6NB NIPPON DENS0 6150-71-I 321 (I 90000-9080). 0
&!:$:S,

Injection Timing

Unit Basis Allowance 1

Specification for engine with fan (reference only)

Plunger pre-stroke mm 4.7 I ~1

Delivery valve
mm3 90
retraction volume
I
Low idling: rpm 570 to 630 I
Calibration Standard

Conditions Unit Manufacturer standard Service standard

(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-0540) (DNI 2SD12)

Nozzle holder part no. (093100-0190) (EF85 1119A)

In ectron pope
mm 6x2~600 6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm” 175 175

Transfer pump pressure kg/cm2 1.6 1.6

Specifications
Injection volume (cci500st) Injection volume(cc/500st)
for manufacturer standard for service standard

Rack Pump Maximum Maximum

p,ososon speed variance variance
Basis Allowance Basis Allowance
between between
(mm)
cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 10.2 950 45.0 43.5 to 46.5 max. 4.0 44.5 43.0 to 46.0 max. 4.0

’ Rack positions B 11.8 550 67.5 * 66.0 to 69.0 max. 4.0 67.5 * 66.0 to 69.0 max. 4.0
B to E are the refer-
ence volume when C 9.3 300 11.0 * 10.0 to 12.0 max. 2.5 10.7 * 9.7 to 11.7 max. 2.5
adjusting the injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

Zovernor performance

12.3
11.8

^ 10.7
E 10.2
r 9.3

s
.-
c
$
a 6.5
Y
8
CT 4.5

0 00
s 8 $2

Pump speed (rpm)

.
Numbers In parentheses are pump manutacturer part numbers.

’2-oAo-6 6Dl25 SERIES

Pump Assembly Number

6150-71-l 322 (190000-9081, 9082)

6150-71-l 323 (190000-9083)

( ): Manufacturer’s part No.

Injection Pump
Pump Type Manufacturer
NB (EP-9) NIPPON DENS0 D65P, PL-1 1

Injection Timing Engine Specification

Counterclockwise viewed from
Rotating direction
drive end
Injection order l-5-3-6-2-4 .~

Injection interval 60” + 30’

Plunger pre-stroke mm 4.7 i 0.05

Pump tester capacity
Delivery valve Motor 7.5 KW
mm3/st 90 for Service standard
retraction volume

Calibration Standard

Conditions Service standard Manufacturer standard

Service standard
Nozzle part no. (093400-0540) (ND-DN 12SD12A)‘O93400-0540) (ND-DN 12SD12P
indicates data
using calibration Nozzle holder part no. (093100-0190) (EF8511/9A) (093100-0190) (EF8511/9A)
test parts.
Injection pipe
Manufacture 6 X 2 X 600 6 X 2 X 600
(O/D X I/D X length) mm
standard is data
for factory test. Test oil ASTM D975 No.2 diesel fuel or eouivalent
Oil temoerature
Nozzle opening pressure kg/cm* 175 175
Transfer pump pressure kg/cm2 1.6 1.6

njection volume
Rack Service standard (cc/ 500st) Manufacturer standard (cc/ 500~1
Puma,

Rack positions

tion volume.
Marks + are aver-
age volumes.

Governor oerformance 1300 - 925 mm)

I Ill 1, I, ,,,I I
0 100 300 550 750 1050 1200
350 400 925 950+10

Pump speed (rpm)

SEBH 4542-O

6D125 SERIES
’ *-; o-7
Pump Assembly Number
6150-71-1312 (190000-9072)
6150-71-1313 (190000-9073) Applicable Machine 1 Applicable Enqine

( ): Manufacturer’s part No. Model 1 Serial No. 1 Model 1 Serial No.

D60P-11 I 16D125-1 I

injection Timing Engine Specification

Counterclockwise
Rotating direction
viewed from drive end
Rated horsepower (kW[HPl / rpm) 1126.5 [169.61/ 1,850
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 799.24 [81.51/ 1,100

I
Injection interval 60’ (59”30’ - 60”30’)
High idling

ILow idlinq
(rpm)

(mm11
2,050 - 2,150

600 - 630 I
IPlunger pre-stroke (mm)
Pump tester capacity
Delivery valve (mm3/ St) Motor 7.5 kW
retraction volume for Service standard
alibration Standard ( ): Pump manufacturer’s part No.

II

Governor performance

14

0 2 4 6 8 10 12 14 16
PUMP SPEEDCRPM) x10'
TKE00158

o-8
’*-Od 6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D60S-8 6D125-1 PE-6NB NIPPON DENS0 6150-71-1331 (190000-9090). .O
B~$?:~
D65E-8

Injection Timing

Unit Basis Allowance

I
Counterclockwise viewed
Rotating direction
from drive end

injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60” 59”30’ to 60”30’

Plunger pre-stroke mm 4.7

Delivery valve
90
retraction volume mm3

Low idling: rpm

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-0540) (DNI 2SD12)

Nozzle holder part no. (093100-0190) (EF85 11 l9A)

In ectron pope mm 6x2~600
6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm* 175 175

Transfer pump pressure kg/cm2 1.6 1.6

specifications
Injection volume (cc/500st) Injection volumeW500st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (rpm) cylinder
cylinder
Calibration Each cyl. Each cyl.
basic point 10.5 875 47.0 45.5 to 48.5 max.4.0 46.5 45.0 to48.0 max.4.0

’ Rack positions B 11.8 550 65.8 * 64.3 to 67.3 max.4.0 66.3 * 64.8 to 67.8 max.4.0
B to E are the refer-
ence volume when C 9.9 300 19.0 * 18.0 to 20.0 max. 2.5 18.0 * 17.0 to 19.0 max. 2.5
adjustingthe injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

Pump speed (rpm)

Numbers In parentheses are pump manutaCturer part numbers.

6D125 SERIES 12-011
Pump Assembly Number
6150-71-1332 (190000-9092)
6150-7 1-l 333 (I 90000-9093) Applicable Machine Applicable Engine

( ): Manufacturer’s part No. Model ) Serial No. Model 1 Serial No.

D60S-8 1 ~ /6D125-1 1
D65A,P,E-8 ) I I

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[HPl / rpm) 121.36 [162.71/ 1,750
viewed from drive end ~~
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 798.7 [81.51/ 1,006

High idling (rpm) 1,950 - 2,050

Injection interval 60” (59”30’ - 60”30’)
~ Low idling (rpm) 600 - 630
Plunger pre-stroke (mm) 4.7
Pump tester capacity
90 Motor 7.5 kW
for Service standard
alibration Standard ( ): Pump manufacturer’s part No.

Conditions
Service standard
I Service standard
I
Manufacturer standard

indicates data Nozzle part no. (093400-0540)

using calibration
Nozzle holder part no. (093100-0190)
test parts.
Manufacturer Injection pipe
6 x 2 x 600
standard is data (O/D x I/D x length) mm
for factory test.
Test oil ASTM D975 No.2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure (MPa[kg/cm21) 17.16 [I751

I
Transfer pump pressure (kPa[kgicm’l) 156.91 Il.61

njection volume Service standard Manufacturer standard

Rack Pump
Rack
position speed Maximam Maximam
point Injection volume variance Injection volume variance
(mm) (rpm)
(cc/1000 St) between W1000 St) between
Rack positions cylinder (%) cylinder (%)
B to E are the ref-
erance volume A (Basic point) 10.5 875 85.5 - 91.5 9.0
when adjusting
B 12.1 500 131-137 6.0
the injection
volume. C 9.5 300 19-23 23.8
rl

Governor performance

6 8 IO 12 14 16
PUMP SPEED (RPM) x I 0’
TKE00159

‘*-(ii
‘-’ 6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number

I
D63E-1 6D125-1 NB (EP9) NIPPON DENS0 6150-71-1470 (191000-3481) . . 2
6150-71-1471 (191000-3482)

Injection Timing

Unit Basis Allowance

Rotating direction Counterclockwise viewed

from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60 59”30’ to 60’30 Rated horsepower: HP/rpm 140/l 900
1

I
Plunger pre-stroke mm 4.7
l I Maximum torque: kgm/rpm 68/l 300 I
Delivery valve
mm3 90 High idling: 2050 to 2150
retraction volume rpm

Low idling: rpm 800 to 850

Calibration Standard

Manufacturer standard Service standard

:onditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

Injectron pope
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm2 175

Transfer pump pressure kg/cm2 1.6

specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 10.1 950 82.5 82.5 79.5 to 85.5 max. 6.0

1 Rack positions B to B 1 I.0 650 103.0 * 103.0 * 100.0 to 106.0 max. 8.0
E are the reference
volume when ad- C 8.9 410 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
) Marks * are aver-
age volumes. E * *

Zovernor performance

Min. 14.0

11.3
11.0
10.1
F
E 8.9

s
.- 7.5
.5

::
cz

0 ZOO\ 400\ 650 \

240 410 g5:7:050

Pump speed (rpm)

 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D63E-1 6D125-1 NB (EP9) NIPPON DENS0 6150-71-I 270 (191000-6420) 1

Injection Timing

Unit Basis Allowance

Specification for engine with fan (reference only)

Rated horsepower: HP/rpm 140/l 900

I
Plunger pre-stroke mm 3.0
I Maximum torque: kgm/rpm 6811300
I
Delivery valve
mm3 59 High idling: 2050 to 2150
retraction volume rpm

Low idling: rpm 800 to 850

Calibration Standard
Manufacturer standard Service standard
londitions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SDl2A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

Injectron pope
mm 6 x 2 x 600
(O/D x I/D x length)

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance variance
r;si;ion speed Basis Allowance Basis Allowance
between between
(rpmj cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 10.2 950 73.0 73.0 70.0 to 76.0 max. 6.0

l Rack positions B to B 11.4 650 103.0 * 103.0 * 100.0 to 106.0 max. 8.0
E are the reference
volume when ad- C 8.8 410 16.0 * 16.0 * 14.0 to 16.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

0 100200 410\ 650 600 950&050

450

Pump speed (mm)

6D125 SERIES
Numbers in parentheses are pump manufacturer part numbers.
12-012-l
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D63E-1 6D125-1 NB (EP9) NIPPON DENS0 6150-71-1271 (191000-6421) . 1

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Specification for engine with fan (reference only)

Delivery valve
mm3 59 High idling: 2050 to 2150
retraction volume rpm

Low idling: rpm 800 to 850

Calibration Standard I

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

lnlectlon pope
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm2 175

Transfer pump pressure kg/cm2 1.6

Specifications
Injection volume (mm3/st) Injection volume (mm3/st)
for manufacturer standard for service standard

Rack Pump
Maximum Maximum
Basis variance variance
position speed Allowance Basis Allowance
between between
(mm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 10.4 950 77 74 - 80 max. 6

l Rack positions B to B 11.4 650 * 99 * 96 - 102 max. 8

E are the reference
volume when ad- C 8.8 410 * 16 * 14 - 18 max. 5
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

h
11.4
10.8
-c 10.4

E 8.8

s
.- 8.2
.-z

::
m Max.4.0
IT

11 I II I I Ill
0 100200 410\ 650 800 950\1050
450 975

Pump speed (rpm)

Numbers in parentheses are pump manufacturer part numbers.

’2-oi
2-2 6D125 SERIES
Pump Assembly Number
6150-71-1411 (190000-8882)
6150-71-1412 (190000-8883) Applicable Machine 1 Applicable Engine

( ): Manufacturer’s part No. Model Serial No. Model Serial No.

D65A-8 6D125-1

(for France)

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[HPl / rpm) 117.7 [157.8] / 1,750
viewed from drive end ~~
Injection order l-5-3-6-2-4 Maximum torque (Nmlkgml/ rpm) 764.9 [781/ 1,100

High idling (rpm) 1,900 - 2,000

Injection interval 60” (59”30’ - 60”30’)
~ Low idling (rpm) 600 - 630
Plunger pre-stroke (mm) 4.7
I
Pump tester capacity
Delivery valve (mm’/st) 90 Motor 7.5 kW
retraction volume for Service standard
slibration Standard ( ): Pump manufacturer’s part No.

standard is data
‘or factory test.

Rack positions
B to E are the ref-

Governor performance

16

14

0 2 4 6 6 10 12 14 16
PUMP SPEEDiRPMl x102
TKE00160

6D125 SERIES
Pump Assembly Number Applicable Machine Applicable Engine I
6150-71-1170 (191000-9780)
Model Serial No. Model Serial No.

( 1:Manufacturer’s part No. D65E-12 6D125-1

Injection Timing Engine specification

Counterclockwise Rated horsepower HP/rpm 180/l 950
Rotating direction
I viewed from drive end
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 81.5/1100

High idling rpm 2050 to 2150

Injection interval 60” + 30’
Low idling rpm 800 to 825
Plunger pre-stroke mm 4.7 f 0.05
Pump tester capacity
Delivery valve Motor 7.5 KW
retractinn vnl~rna~~~‘~~ 90 for Service standard

Calibration Standard

Conditions Service standard Manufacturer standard

Service standard
indicates data Nozzle part no. (093400-0540) (ND-DN12SD12A) (093400-0540) (ND-DN12SD12A)
using calibration Nozzle holder part no. (093100-0190) (EF8511/9A) (093100-0190) (EF8511/9A)
test pans
Injection pipe
(Nozzle, Nozzle mm 6 x 2 x 600 6 x 2 x 600
(O/D x I/D x length)
holder and injec-
tion pipe) Test oil ASTM D975 No. 2 diesel fuel or equivalent
Manufacture
standard is data Oil temperature “C 40 to 45
using factory test Nozzle opening pressure kg/cm2 175 175
parts
(For reference) Transfer pump pressure kg/cm2 1.6 1.6

Injection volume Service standard (cc/ 500st) Manufacturer standard (cc/ 500 stl
Rack Pump
Rack Maximum Maximum
position speed
point variance variance
(mm) (rpm) Basis Allowance between Basis Allowance between
cylinder cylinder
Rack positions Each cyl. 48 5 Each cyl.
B to E are the ref- Basic point 11.0 975 48.5 47.0 to 50.0 Max.4 .
erence volume
when adjusting B (8.9) 400 6.5 * 5.5 to 7.5 Max. 2.5 6.5 *
the injection vol-
ume. C * *
‘Marks* are aver- D * sr
age volumes.
E * *

Governor performance ( 400 - 975 rpm)

0 100200 /400\ 600 /so0 ,,@ooo\ 1200

350 450 550 750 975990+10 1050

Pump speed (rpm)

SEBH

2-4
’2-% 6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D68E-1 6D1251 NB (EP9) NIPPON DENS0 6150-71-1490 (191000-4061) . .. 2
D68P-1 6150-71-1491 (191000-4062)
I

injection Timing

Specification for engine with fan (reference only)

Injection interval 60” 59”30’ to 60’30’ Rated horsepower: HP/rpm 180/1850

Plunger pre-stroke mm 4.7 1 Maximum torque: kgm/rpm 81.5/l 100

Delivery valve
mm3 so High idling: 2050 to 2150
retraction volume I rpm

Low idling: rpm 600 to 630

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

Injectron pipe
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm2 175

Transfer pump pressure kg/cm* 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 10.8 925 99.0 99.0 96.0 to 102.0 max. 8.0

l Rack positions B to S 11.9 550 126.0 * 126.0 * 123.0 to 129.0 max. 8.0
E are the reference
volume when ad- C 9.5 300 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

12.9
11.9
11.3
10.8
-z
9.5
E

0'
.- 7.5
.Zm

I%

::
2

0
350 950

Pump speed (rpm)

_- __- -
6D125 SERIES Numbers in parentheses are pump manufacturer part numbers. 12-o 12-5
8
Pump Assembly Number
6150-71-1810 (191000-1801)
Applicable Machine Applicable Engine

1 1: Manufacturer’s part No. Model Serial No. Model Serial No.

PC300-3c 6D125-1
/

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kWIHPl/ rpm) 136.1 [182.41/ 1,900
viewed from drive end ~~
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml / rpm) 804.1 [821/ 1,200

High idling (nom) 2,050 - 2,150

Injection interval 60” (59”30’ - 60”30’)
~ Low idling (rpm) 600 - 700
Plunger pre-stroke (mm) 4.7
Pump tester capacity
Delivery valve (mm”/st) 90 Motor 7.5 kW
retraction volume for Service standard
talibration Standard ( ): Pump manufacturer’s part No.
I I
Conditions
Service standard
I Service standard
I
Manufacturer standard

indicates data Nozzle part no. (093400-0540)

using calibration Nozzle holder part no. (093100-0190)
test parts.
Manufacturer Injection pipe
(O/D x I/D x lenqth) mm 6 x 2 x 600
standard is data
for factory test.
Test oil ASTM D975 No.2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure (MPakdcm21) 1 17.16 11751 I

Transfer pump pressure (kPa[kg/cm’]) 156.91 [I.61

njection volume Service standard Manufacturer standard

Rack Pump
Rack
position speed Maximam Maximam
point Injection volume variance Injection volume variance
(mm) (rpm)
1Rack positions kc/1000 St) between (cc/1000 St) between
cylinder (%) cylinder (%I
B to E are the ref-
erance volume A (Basic point) 11.3 950 108- 114 7.2
when adjusting
B 12 600 129.5 - 135.5 6.0
the injection
volume. C 9.4 325 19-23 23.8
D
E

Governor performance

Rn+O. 7
-to. 3 R,

Beainnina of
rack DUII 975*10

PUM SPEED(RPM) x lo*

TKE00161

12-012-6 6D125 SERIES

0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
6D125-1 NB (EP9) NIPPON DENS0 6150-71-1550 (191000-2071) . . 3
%E?: 6150-71-1551 (191000-2702)
GD623A:l

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60 59’30’ to 60”30’ Rated horsepower: HP/rpm 155/2200

Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 67/I 350

Delivery valve
mm3 90
retraction volume High idling: rpm 2350 to 2450

Low idling: rpm 650 to 700

Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (ND-DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

InJectIon pipe
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance
variance
osition speed Basis Allowance Basis Allowance
between
between
Pmm) (rpm) cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 9.5 1100 78.0 78.0 75.0 to 81 .O max. 8.0

l Rack nositions B to B IO.6 675 90.0 * 90.0 * 87.0 to 93.0 max. 8.0
E are the reference
volume when ad- C 9.4 325 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

ITI

11.5
10.6
9.5
9.4

.-
C
7.3

B
a
Y

B Max .4.0
cc

Pump speed (rpm)

6D125 SERIES
Numbers in parentheses are pump manufacturer part numbers. 12-O 12-7
 Injection Pump
Machine Model Engine Model Manufacturer
Pump Type Pump Assembly Number
g3i-; 6D125-1 NB (EP9) NIPPON DENS0 6150-71-2720 (191000-5510) .0
6150-71-2721 (191000-5511)
GD623A-1

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
I

Injection interval 60 59’30’ to 60’30’ Rated horsepower: HP/rpm

Plunger pre-stroke mm 3.0 Maximum torque: kgm/rpm

Delivery valve mm3 59 High idling: 2350 to 2450
retraction volume rpm

Low idling: rpm 650 to 700

Calibration Standard
Manufacturer standard Service standard
fonditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

InjectIon pipe
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm2 1.6

ipecifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 10.3 1100 82.0 82.0 79.0 to 85.0 max. 6.0

* Rack positions B to B 1 I.0 675 91.0 * 91 .o * 88.0 to 94.0 max. 8.0

E are the reference
volume when ad- C 9.0 325 17.0 * 17.0 * 15.0 to 19.0 max. 5.0
justing the injection
volume. D * *
m Marks * are aver-
age volumes. E * *

Sovernor performance

11
0 100 325 400 675 900 1100\1200
1125

Pump speed (rpm)

Numbers in parentheses are pump manufacturer part numbers. 6D125 SERIES

’ 2-% 2-8
 Injection Pump
Machine Model Engine Model Manufacturer Pump Assembly Number
Pump Type

GD600R-3 6D125-1 PE-6NB NIPPON DENS0 6150-71-1511 (190000-9110~::::

GD605R-3 6150-71-1581 1

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

1Injection order 1-5-3-6-2-4 I Specification for engine with fan (reference only)

Injection interval 60” 59”3O’to 60”30’ Rated horsepower: HP/rpm 146/l 800 I
Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 74/l 100
I
Delivery valve High idling: 2000 to 2100
90 rpm
retraction volume mm3

Low idling: rpm 650 to 700

Calibration Standard

Manufacturer standard Service standard

mditions Unit (with calibration test parts)
(with nearly the same actual machine parts)

Nozzle part no. (093400-0540) (DNI 2SD12)

Nozzle holder part no. (093100-0190) (EF85 11/9A)

In ectron pope mm 6x2~600 6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm2 175 175

Transfer pump pressure kg/cm2 1.6 1.6

becifications
Injection volume (cc/500st) Injection volumeW500st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance variance
r;o$on speed Basis Allowance Basis Allowance
between between
(rpm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 9.9 900 40.0 38.5 to 41.5 max. 4.0 39.75 38.25 to 41.25 max. 4.0

Rack positions B 11.5 550 64.25 * 62.75 to 65.75 max. 4.0 64.25 * 62.75 to 65.75 max. 4.0
6 to E are the refer-
ence volume when C 8.8 350 7.25 * 6.25 to 8.25 max. 2.5 6.75 * 5.75 to 7.75 max. 2.5
adjustingthe injec-
tion volume. D * *
Marks * are aver-
age volumes. E * *

lvernor performance

Pump speed (rpm)

Pump Assembly Number
6150-71-1513 (190000-9113)
6150-71-1514 (190000-9114) Applicable Machine Applicable Engine

( ): Manufacturer’s part No. Model Serial No. Model Serial No.

GD600R-3 6D125-1

GD605R-3 6D125-1

Injection Timing Engine Specification

Rotating direction vie”,o,u,n:~~~~~~~nd
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 725.7 [74]/ 1,100
High idling (rpm) 2,000 - 2,100
Injection interval 60” (59”30’ - 60”30’)
I 1Low idling (rpm)l 650 -700 1
Plunger pre-stroke (mm) 1 #
I
Pump tester capacity
Delivery valve (mm’/st) Motor 7.5 kW
retraction volume for Service standard
Calibration Standard ( ): Pumo manufacturer’s Dart No.

(Conditions
. Service standard
I Service standard
I
Manufacturer standard

indicates data Nozzle part no. I ~093400-05401 I

using calibration
Nozzle holder oar-t no. I (093100-0190~ I
test parts.
. Manufacturer Injection pipe
(O/D x I/D x length) mm 6 x 2 x 600
standard is data
for factory test.
Test oil ASTM D975 No.2 diesel fuel or equivalent
Oil temperature ‘C 40 to 45

Nozzle opening pressure (MPa[kg/cm’]) 17.16 I1751

I
Transfer pump pressure (kPa[kg/cm’]) 156.91 [I.61

Injection volume Service standard Manufacturer standard

Rack Pump
Rack
position speed Maximam Maximam
point Injection volume variance variance
(mm) (rpm) Injection volume
(cc/1000 St) between (cc/l 000 St) between
. 1Rack positions cylinder (%) cylinder (%
B to E are the ref-
erance volume A (Basic point) 10.0 900 77-83 IO
when adjusting
B 11.3 550 110-116 7.0
the injection
volume. C 9.4 325 19-23 23.6
D

Governor performance

6-
z14

4-

*x5
of rack PuII)

PlJMi SPEED-(RPM) ilO’ -

TKE00162

’2-oA3-1 6D125 SERIES

 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
GD605A-3 6D125-1 PE-6NB NIPPON DENS0 6150-71-1581 (190000-9140)...1

Injection Timing

Unit Basis Allowance

I
Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60” 59”3O’to 60”30’ Rated horsepower: HP/rpm 146/ 1800

Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 74/l 100

Delivery valve
90 High idling: rpm 2000 to 2 100
retraction volume mm3

Low idling: rpm 650 to 700

Calibration Standard

Manufacturer standard Service standard

:onditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-0540) (DN12SD12)

Nozzle holder part no. (093 100-0190) (EF85 1 1/9A)

In ectlon pipe
mm 6x2~600 6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm2 175 175

Transfer pump pressure kg/cm2 1.6 1.6

ipecifications
Injection volume (cc/500st) Injection volumeW500st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (rpm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 9.9 900 40.0 38.5 to41.5 max.4.0 38.8 37.3 to 40.3 max. 4.0

’ Rack positions 8 11.2 550 56.8 * 55.3 to 58.3 max.4.0 56.0 * 54.5 to 57.5 max. 4.0
B to E are the refer-
ence volume when C 9.5 325 12.8 * 11.8 to 13.8 max. 2.5 11.3 * 10.3 to 12.3 max. 2.5
adjustingthe injec-
tion volume. D * sr
’ Marks * are aver-
age volumes. E * *

cs
x $$ ; HHZ 5
Pumpspeed (rpm) - -

Numbers in parentheses are pump manufacturer part numbers.

12-014 6D125 SERIES
Pump Assembly Number
6150-71-1583 (190000-9143)
6150-71-1584 (190000-9144) Applicable Machine Applicable Engine

( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

GD605A-3 6D125-1

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[HPl/ rpm) 110.3 [147.91/ 1,800
viewed from drive end
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 729.6 [74.41/ 1,100

High idling (rpm) 2,000 - 2,100

Injection interval 60” (59”30’ - 60”30’)
Low idling (rpm) 650 - 700
IPlunger pre-stroke (mm) 1 4.7 I
Pump tester capacity
Delivery valve (mm3/st) 90 Motor 7.5 kW
retraction volume for Service standard
alibration Standard ( ): Pump manufacturer’s part No.

Service standard
indicates data
using calibration
test parts.
Manufacturer
standard is data
for factory test.

Rack positions
B to E are the ref-
erance volume

Governor performance

14

0 2 4 6 6 10 12 14 I6
PUMP SPEED[RPMI x10'
TKEOOi62

6D125 SERIES
’*-24-’
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
GD625A-1 6D125-1 PE-6NB NIPPON DENS0 6150-71-1570 (191000-2721) 3

I ,

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60” 59’30’ to 60’30’ Rated horsepower: HP/rpm 155/2200

I Plunger pre-stroke mm 4.7

I Maximum torque: kgm/rpm 67/l 350
Delivery valve so
mm3 High idling: rpm 2350 to 2450
retraction volume

Low idling: rpm 650 to 700

Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

InJectIon Ipe
(O/D x I/ g x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance Allowance variance
osition speed Basis Allowance Basis
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 9.5 1100 78.0 78.0 75.0 to 81 .O max. 8.0

;acc~;~i;gs~~ B lo.6 675 90.0 * 90.0 * 87.0 to 93.0 max. 8.0

volume when ad- C 9.4 325 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

11.5
10.6
z 9.5
E 9.4

s
.- 7.3
.z

kz
Y
0 Max.4.0
n

0 100 325 400 675 ,100\1200 1350

1125

Pump speed (rpm)

1 Numbers in parentheses are pump manufacturer part numbers.

*-Od4-*
6D125 SERIES
 injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
GD625A-1 6D125-1 NB (EP9) NIPPON DENS0 6150-71-1571 (191000-2722)

I I

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60” 5930’ to 60”30’ 155/2200

Rated horsepower: HP/rpm

Plunger pre-stroke mm 4.7 Maximum torque: kgmlrpm 67/l 350

Delivery valve 90
mm3
retraction volume High idling: rpm 2350 to 2450
I
Low idling: rpm 650 to 700
Calibration Standard I

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (ND-DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

Inlectron pope
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 9.5 1100 78.0 78.0 75.0 to 81 .O max. 8.0

. Rack positions B to B 10.6 675 90.0 * 90.0 * 87.0 to 93.0 max. 8.0
E are the reference
volume when ad- C 9.4 325 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

11.5
10.6
-z
E
.E

s
.- 7.3
.%
$
a
Y
8 Max.4.0
cc

0
1125

Pump speed (rpm)

’*-z
Numbers in parentheses are pump manufacturer part numbers.
6D125 SERIES
4-3
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
GD625A-1 C 6D125-1 PE-6NB NIPPON DENS0 6150-71-2710 (191000-5420) ... 1
6150-71-2711 (191000-5421)

Injection Timing

Unit Basis Allowance

Rotating direction Counterclockwise viewed

from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60 5930’ to 60”30’ Rated horsepower: HP/rpm

Plunger pre-stroke mm 3.0 Maximum torque: kgm/rpm

Delivery valve
retraction volume mm3 59 High idling: rpm 2350 to 2450

Low idling: rpm 650 to 700

Calibration Standard

Conditions Unit Manufacturer standard Service standard

(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

Injectron rpe
(O/D x I/ g x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm2 175

Transfer pump pressure kg/cm2 1.6

jpecifications
Injection volume (mm3/st) Injection volume (mm3/st)
for manufacturer standard for service standard

Rack Pump Maximum Maximum

osition speed Basis variance variance
Allowance Basis Allowance
between between
Pmm) @pm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 10.3 1100 82.0 82.0 79.0 to 85.0 max. 6.0

b Rack positions B to B 11.0 675 91.0 * 91.0 * 88.0 to 94.0 max. 8.0
E are the reference
volume when ad- C 8.7 325 17.0 * 17.0 * 15.0 to 19.0 max. 5.0
justing the injection
volume. D * *
* Marks * are aver-
age volumes. E * *

Ziovernor performance

II II, I I II I
0 100 325 400 675 900 1100\1200
1125

Pump speed (rpm)

Numbers in parentheses are pump manufacturer part numbers.

’*-%i
4-4 6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
GD663A-1 6D125-1 NB (EP9) NIPPON DENS0 6150-71-1560 (191000-2711) . .. 2
6150-71-1561 (191000-2712)
6150-71-1660 (191000-3970)
6150-71-1661 (191000-3971)
Injection Timing

Unit Basis Allowance I

Rotating direction Counterclockwise viewed
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
I
Injection interval 60” 5930’ to 60”30 Rated horsepower: HP/rpm 180/2200

Plunger pre-stroke

Delivery valve
mm 4.7
I Maximum torque: kgm/rpm 67/l 350
I
mm3 90 High idling: 2350 to 2450
retraction volume rpm

Low idling: rpm 650 to 700

Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511 l9A)

Injectron pipe
(O/D x I/D x length) mm 6x2~600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm2 175

Transfer pump pressure kg/cm* 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 10.2 1100 90.0 90.0 87.0 to 93.0 max. 8.0

l Rack positions B to 8 10.6 675 90.0 * 90.0 * 87.0 to 93.0 max. 8.0
E are the reference
volume when ad- C 9.4 325 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

11.5
10.6
z 10.2
9.4
E

5
.-
.z 7.3

6.2
x

%
$ Max.4.0

0 100 325 400 675 llOO\ 1200 1350

1125

Pump speed (rpm)

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers.

’ 2-o;4-5
 Injection Pump
Machine Model Engine Model Pump Assembly Number
Pump Type Manufacturer I
GD650R-3 6D125-1 PE-6NB NIPPON DENS0 6150-71-1521 (190000-9120)...0
GD655A-3 6150-71-1590(190000-9160)...0
GD655R-3

Injection Timing

Unit Basis Allowance I

Counterclockwise viewed
Rotating direction from drive end

injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60” 59”3O’to 60”30’ Rated horsepower: HP/rpm 165/l 800
I
Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 78.3/l 100
I _
Delivery valve High idling: 2000 to 2 100
90 rpm I
retraction volume mm3

rpm 650 to 700 I

Calibration Standard

Manufacturer standard Service standard

ionditions Unit (with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-0540) (DNI 2SD12)

Nozzle holder part no. (093 100-0190) (EF85 11/9A)

In ection pope mm 6x2~600 6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent
.~
Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm2 175 175

Transfer pump pressure kg/cm2 1.6 1.6

ipecifications
Injection volume W500st) Injection volume(cc/5OOstj
for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance variance
y;osion speed Basis Allowance Basis Allowance
between between
(rpm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 10.5 900 45.75 44.25 to 47.25 max. 4.0 45.0 43.5 to 46.5 max. 4.0

’ Rack positions B 11.8 550 66.0 * 64.5 to 67.5 max. 4.0 66.0 + 64.5 to 67.5 max. 4.0
B to E are the refer-
ence volume when C 9.7 325 16.0 * 15.0 to 17.0 max. 2.5 17.5 * 16.5 to 18.5 max. 2.5
adjustingthe injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

Numbers In parentneses are pump manuracrurer part numoers.

6D125 SERIES 12-015
Pump Assembly Number
6150-71-1522 (190000-9122)
6150-71-1523 (190000-9123)
6150-71-1592 (190000-9163)
6150-71-I 593 (190000-9164) Applicable Machine Applicable Engine

( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

GD650R3 6D125-1

G D655A-3

GD655R-3

Injection Timing Engine Specification

Counterclockwise
Rotating direction
viewed from drive e
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 767.8 [78.3] / 1,100
High idling (w-n) 2,000 - 2,100
Injection interval 60” (59”30’ - 60”30’)

alibration Standard ( ): Pump manufacturer’s part No.

Conditions Service standard Manufacturer standard

Service standard
indicates data Nozzle part no. (093400-0540)
using calibration
Nozzle holder part no. (093100-0190)
test parts.
Manufacturer injection pipe
(O/D x I/D x lenqth) mm 6 x 2 x 600
standard is data I
for factory test.
Test oil ASTM D975 No.2 diesel fuel or equivalent
Oil temperature ‘C 40 to 45

Nozzle opening pressure (MPa[kg/cm2]) 17.16 [I751

Transfer pump pressure (kPa[kg/cm’]) 156.91 f1.61

njection volume Service standard Manufacturer standard

Rack Pump
Rack Maximam
position speed Maximam
point Injection volume variance Injection volume variance
(mm) (rpm)
(cc/1000 St) between (cc/1000 St] between
Rack positions cylinder (%] cylinder (%)
B to E are the ref-
erance volume A (Basic point] 10.5 900 86-92 9.0
when adjusting
B 11.6 550 115 - 121 6.8
the injection
volume. C 9.4 325 19-23 23.8

Governor performance

2 4 6 a 10 12 14 16
PUMP SPEED&PM) x10'
TKE00164

6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
GD705R-3 6D125-1 PE-6NB NIPPON DENS0 6150-71-I 531 (I 90000-9130). 0

Injection Timing

Specification for engine with fan (reference only)

Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 180/l 850
I
Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 80 /llOO
I
Delivery valve
90 High idling: rpm 2050 to 2150
retraction volume mm3

Low idling: rpm 650 to 700

Calibration Standard

Manufacturer standard Service standard

ionditions Unit
(with calibration test parts)
(with nearly the same actual machine parts)

Nozzle part no. (093400-0540) (DNI 2SD12)

Nozzle holder part no. (093 100-0190) (EF85 1 1/9A)

Injectron pipe mm 6x2~600
6 x 2 x 600
(O/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm2 175 175

Transfer pump pressure kg/cm2 1.6 1.6

ipecifications
Injection volume W500st) Injection volumekd5OOst)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (mm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 10.7 925 52.25 50.75 to 53.75 max. 4.0 51.0 49.5 to 52.5 max. 4.0

Rack positions B 11.2 550 69.75 * 68.25 to 71.25 max. 4.0 70.25 * 68.75 to 71.75 max. 4.0
B to E are the refer-
ence volume when C 8.6 350 6.75 * 5.75 to 7.75 max. 2.5 6.0 * 5.0 to 7.0 max. 2.5
adjusting the injec-
tion volume. D * *
Marks * are aver-
age volumes. E * *

iovernor performance

-ii 12.3
4 10.7
12

s 6.6
'L=
'Fi 6.6
zi 6

::
d

0
s 5:
z

Pump speed (rpm)

Numbers in parentheses are pump manufacturer part numbers.

12-016 6D125 SERIES
0
Pump Assembly Number
6150-71-1534 (190000-9134)
6150-71-I 542 (190000-8903)
6150-71-1543 (190000-8904) Applicable Machine Applicable Engine

( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

GD705R-3 6D125-1

GD705R-4

Injection Timing Engine Specification

Counterclockwise
Rotating direction
viewed from drive end Rated horsepower WMHPI / rpm) 136.1 [182.41/ 1,850
Injection order l-5-3-6-2-4 Maximum torque (NmIkgml/ rpm)

Injection interval 60” (59”30’ - 60”30’)

Plunger pre-stroke (mm)

Pump tester capacity
Delivery valve (mm’ist) 90 Motor 7.5 kW
retraction volume for Service standard
‘alibration Standard ( ): Puma manufacturer’s oar-t No.

Service standard
indicates data
using calibration
test parts.
Manufacturer
standard is data
for factory test.

1Rack positions
B to E are the ref-
erance volume
when adjusting
the injection
volume.

Governor performance

0 2 4 6 a 10 12 14 16
PUMP SPEED(RPMI x10'
TKE00165

6D125 SERIES
12-OA6-’
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D60F-8A S6D125-1 PE-6P DIESEL KIKI 6151-71-1721 (106692-4100) . 0
6151-71-1722 (106692-4102) . 1
6151-71-1723 (106692-4103)

Injection Timing

.~I
Specification for engine with fan (reference only)
Injection interval 60 5930’ to 60”30’
I Rated horsepower: HP/rpm 21 g/2000

Plunger pre-stroke mm 3.75 3.70 to 3.80 Maximum torque: kgm/rpm 92/1500

Delivery valve
retraction voIume
mm3 60 High idling: 2200 to 2300
rpm

Low idling: rpm 600 to 630

Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (105015-5370)

Nozzle holder part no. (105041-7030)

Injectron pope
(O/D x I/D x length) mm 6 x 2.2 x 710

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 43 to 47

Nozzle opening pressure kg/cm* 250

Transfer pump pressure kg/cm2 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
Basis Allowance variance variance
osition speed Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 7 1000 126.5 124.5 to 128.5 & 3

l Rack positions 8 to B 7.3 750 132.5 * 130.5 to 134.5 * 4 *

E are the reference
volumewhen ad- C 4 300 15 * 13.5 to 16.5 k 15 *
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

z
g

:
.- 7.1
f
7.0
x

%
4.0
d
3.2

0
9801000

Pump speed (rpm)

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers. 12-017
0
Pump Assembly Number
6150-71-1190 (191000-9800)
Applicable Machine Applicable Engine 1
( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

D60P-12 S6D125-1
Injection Pump
Pump Type Manufacturer

PE-6N B NIPPON DENS0

Injection Timing Engine Specification

Counterclockwise
Rotating direction
viewed from drive end
Rated horsepower
~~
(kWIHP1 / rpm) 139.7 [187.31/ 1,950

Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 980.7 [IO01 / 1,200
High idling (rpm) 2,050 - 2,150
Injection interval 60’ (59”30’ - 60”30’)
~ Low idling (rpm) 800 - 850
Plunger pre-stroke (mm) 4.7
Pump tester capacity
Delivery valve (mm’/st) 90 Motor 7.5 kW
retraction volume for Service standard
alibration Standard ( ): Pump manufacturer’s part No.

Conditions Service standard Manufacturer standard

Service standard
indicates data Nozzle part no. (093400-0540)
using calibration
Nozzle holder part no. (093100-0190)
test parts.
Manufacturer injection pipe
mm 6 x 2 x 600
standard is data (O/D x IKI x length)
for factory test.
Test oil ASTM D975 No.2 diesel fuel or equivalent

Oil temperature “C 40 to 45

1 Nozzle openina pressure (MPa[ka/cm*lj 1 17.16 11751 I

1Transfer pump pressure (kPa[kg/cm’l) 1 156.91 Il.61

njection volume Service standard Manufacturer standard

Rack Pump _
Rack Maximam Maximam
position speed
point Injection volume variance Injection volume variance
(mm) (mm)
W1000 St) between (cc/1000 St) between
1Rack positions cylinder (%) cylinder (%I
B to E are the ref-
erance volume A (Basic point) 11.0 975 Ill+3 7.2
when adjusting
B 11.8 500 134*3 6.0
the injection
volume. C 8.8 410 24~2 20.8
D
E

Governor performance

16-

14-

12-
-Z
$lO-
0
- S-
g
= Fi-
2
cc
4-

2- <

0 2 4 6 6 10 12 14 16
PUMPSPEED(RPM) XI 0’

‘*-z7-’
6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D65EX-12 S6D125-1 PE-6NB NIPPON DENS0 6151-71-1180 (191000-9790)

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm

I I I I
Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm

Delivery valve
90 High idling: rpm
retraction volume mm3
I I
I I
Low idling: rpm
Calibration Standard

Manufacturer standard Service standard

:onditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-I 600) (093400-0540) (DNI 2s~12)

Nozzle holder part no. (093100-2710) (093100-0190) (EF851 1/9A)

In ectron pope mm 6x2~600
6 x 2 x 600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm’ 175 175

Transfer pump pressure kg/cm’ 1.6 1.6

ipecifications
Injection volume (mm%) Injection volume (mmYst)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (rpm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point max. max.

’ Rack positions B * max. * max.

B to E are the refer-
ence volume when C * max. * max.
adjusting the injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

;overnor performance

*
2- o a 0 3
m-r
I
0 2 4 10 12 14 16
PUG SPEEDBRPM~ x 10'
TKE00167

Numbers in parentheses are pump manufacturer part numbers.

6D125 SERIES 12-017-2
0
 injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D75S-5 S6D125-1 PE-6P DIESEL KlKl 6151-71-1731 (106692-4090)...0

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 200/2000

Plunger pre-stroke mm 3.75 3.7 t0 3.8 Maximum torque: kgm/rpm 88/l 500

Delivery valve
60 High idling: rpm 2150 to 2250
retraction volume mm3

Low idling: rpm 550 to 650

Calibration Standard

Conditions Manufacturer standard Service standard

Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (I 05015-5370) ( )

Nozzle holder part no. (I 05041-7030) ( )
In ectron pope
mm 6x2.2x710
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47

Nozzle opening pressure kg/cm2 250

Transfer pump pressure kg/cm2 1.6

ipecifications
Injection volume W500st) Injection volumeW500st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (rpm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 7.0 1000 58.5 57.5 to 59.5 Z!I 1.76

’ Rack positions B 7.5 700 64.0 * 63.0 to 65.0 -r- 2.56 *

B to E are the refer-
ence volume when C 4.0 300 7.0 * 6.75 to 8.25 * 1.13 *
adjustingthe injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

Zovernor performance
Min. 14

t7

Numbers in parentheses are pump manufacturer part numbers.

6D125 SERIES

’*-ii7-3
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D75S-5 S6D125-1 PE-6P DIESEL KIKI 6151-71-1732 (106692-4092) . .. 2
6151-71-1733 (106692-4093)

Injection Timing

Unit Basis Allowance

I
Counterclockwise viewed
Rotating direction
from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

I Injection interval 60 59”30’

1 Rated horsepower: HP/rpm 200/2000
I
Plunger pre-stroke mm 3.75 3.7 to 3.8
I Maximum torque: kgm/rpm 8811500 I
Delivery valve
mm3 60
retraction volume High idling: rpm 2150 to 2250

Low idling: rpm 550 to 650

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (105015-5370) (105780-0000)

Nozzle holder part no. (105041-7030) (105780-2080)

Injection pipe
(O/D x I/D x length) mm 6 x 2.2 x 720 8 x 3 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm2 1.6 1.6

jpecifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (rpm) cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 7.5 1000 117 104.5 102.5 to 106.5 + 3

1 Rack positions B to B 8.0 700 128 * 115.9 * 113.9 to 117.9 * 4

E are the reference
volume when ad- c 4.5 300 15 * 11.7 * 10.2 to 13.2 * 15
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.07

300 700 920 \ 1100

1000

Pump speed (rpm)

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers. 12-o 17-4
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D75S-5 S6D125-1 NE (EP9) NIPPON DENS0 6151-71-1640 (191000-3360) . 2
6151-71-1641 (191000-3361)

Injection Timing

Specification for engine with fan (reference only)

Rated horsepower: HP/rpm 200/2000

Maximum torque: kgm/rpm 88/I 500

High idling: rpm 2150 to 2250

Low idling: rpm 550 to 650

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

In]ectlon Ipe
(O/D x l/g x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

specifications Injection volume (mm3/st) injection volume (mm3/st)

for manufacturer standard for service standard

Rack Maximum Maximum

Pump
osition speed Basis variance variance
Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 11.4 1000 114.0 114.0 112.0 to 116.0 max. 8.0

1 Rack positions B to B 12.0 750 130.5 * 130.5 * 127.5 to 133.5 max. 8.0
E are the reference
volume when ad- C 9.2 300 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

0 100 300350 750 900 /\11001200

10001025

Pump speed (rpm)

12-017-5 Numbers in parentheses are pump manufacturer part numbers. 6D125 SERIES
0
Pump Assembly Number
Applicable Machine Applicable Engine
6151-71-1621 (191000-5500)
6151-71-1622 (191000-5501) Model / Serial No. Model Serial No.
( ): Manufacturer’s part No.
I D83E, P-l 1 / S6D125-1 1 25851 and up
Injection Pump
Pump Tvpe Manufacturer D85E-SS-1

1 NB (EP9) / NIPPON DENS6 1

lniection Timina Engine Specification

Counterclockwise viewed from Rated horsepower HP/rpm 205/2000
Rotating direction
drive end
Injection order l-5-3-6-2-4 1 Maximum torque kgm/rpm/ 89/l 300

High idling rot-n 2200 to 2300

Injection interval 60° zb 30’
I I Low idling rot-n 600 to 630

Plunger pre-stroke mm 4.7 * 0.05

p,“,~$~~‘;v,,v~J$,me mm3/st 90 IPump tester capacity

for Service standard I
Motor 7.5 KW

Calibration Standard

Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test.

Rack positions
B to E are the refer-
ence volume when
adjusting the injec-
tion volume.
Marks * are aver-
age volumes.

Governor performance (300 - 1000 rpm)

350 1000 1025+2"

Pump speed (rpm)

SEBH 4608-01

6D125 SERIES 12-017-6

0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D85A. P-21 S6D125-1 PE-6P DIESEL KIKI 6151-71-1770 (106692-4691) . 2
D85E-21 (B) 6151-71-1771 (106692-4692)

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

injection interval 60 59’30’ to 60”30’ Rated horsepower: HP/rpm 225/2000

Plunger pre-stroke mm 3.75 3.7 to 3.8 Maximum torque: kgmlrpm 102/1400

Delivery valve
retraction volume
mm3 60 High idling: rpm 2150 to 2250

Low idling: rpm 650 to 700

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (105015-5370) (105780-0000)

Nozzle holder part no. (105041-7030) (105780-2080)

InjectIon Ipe
(O/D x I/ B x length) mm 6 x 2.2 x 70 8 x 3 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm2 1.6 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation
basic point 7.3 1000 125.7 cyl. to 127.7
Each 123.7 Each cyl.
122.3 120.3 to 124.3 + 3

l Rack positions B to B 8.4 700 150.7 * 148.7 to 152.7 148.0 * 146.0 to 150.0 * 4
E are the reference
volume when ad- C 4.0 325 15.0 * 13.5 to 16.5 13.4 * 11.9 to 14.9 * 15
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance Boost compensator performance

Minl4.0

-Z
a. 6
E
Z
E s
75 7. c
7. 3
0
r m
z L?
E
2 4. 0 ::
d 8. I
PI
2. 9
0
160= APPROX300
BOOST PRESSURE ImmHa)
0
700 1000
PUMPSPEED(RPM) TKEOOI 93
TKEOOl68

I z-u I /-I/ Numbers in parentheses are pump manufacturer part numbers. 6Dl25 SERIES
0
 6151-71-1230 (191000-1221) . .. 4

Injection Timing

I_:..f..l
Specification for engine with fan (reference only)

Injection interval 60 5930’ to 60”30’ Rated horsepower: HP/rpm 197/l 550 (200 PS)

Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 105/l 200

Delivery valve
mm3 so High idling: 1675 to 1725
retraction volume rpm

Low idling: wm 650 to 675

Calibration Standard
Manufacturer standard Service standard
tonditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

Injectron pope
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance
variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 12.2 775 133.0 133.0 130.0 to 136.0 max. 8.0

m Rack positions B to B 12.9 600 154.0 * 154.0 * 151 .O to 157.0 max. 8.0
E are the reference
volume when ad- C 9.4 325 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
B Marks * are aver-
age volumes. E * *

sovernor performance

Min. 14.0

Itt
12.2

-z
9.4
.k
8.6
0'
.-
C
::
a

5 4.7
a" Max.4.0

0 100 325 \ 600700/\850

400 775 800

Pump speed (rpm)

6D125 SERIES
Numbers in parentheses are pump manufacturer part numbers.
12-017-8
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
PC300-3 S6D125-1 NB (EP9) NIPPON DENS0 6151-71-1211 (191000-0062) .. 2
PC3OOLC-3
PEtOONLC-3 6151-71-1212 (191000-0063) . 0
PC36OLC-3 6151-71-1250
PC300-3 for cold weather

Injection Timing

Unit Basis Allowance I

Rotating direction Counterclockwise viewed
from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
I
Injection interval 60 5930 to 60’30’ 197/l 550
Rated horsepower: HP/rpm

Plunger pre-stroke mm 4.7

Delivery valve mm3 90

retraction volume

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

InjectIon pipe
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Rack Pump Maximum Maximum

osition speed Basis Allowance variance variance
Basis Allowance
between between
Pmm) (rpm)
cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 12.4 775 138.0 138.0 135.0 to 141 .O max. 8.0

l Rack positions B to B 13.1 600 154.0 * 154.0 * 151 .O to 157.0 max. 8.0
E are the reference
volume when ad- C 9.4 360 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

775 800

Rack position (mm)

Numbers in parentheses are pump manufacturer part numbers.

6D125 SERIES
 Injection Pump
~Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
PC300-3 S6D125-1 NB (EP9) NIPPON DENS0 6151-71-1231 (191000-1222) . .. 1
for Sweden

Injection Timing

Unit Basis Allowance

Rotating direction Counterclockwise viewed

from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60 5930’ to 60’30’ Rated horsepower: HP/rpm 197/l 550

Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 105/l 200

Delivery valve
mm3 90 1 High idling: 1675 to 1725
retraction volume rpm I
I Low idling: rpm 700 to 750 I
Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

Injectron pope
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm2 1.6

specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
p,az$ion speed Basis Allowance Basis Allowance
between between
(rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 12.2 775 133 131 - 135 8

1 Rack positions B to 8 12.9 600 * 154 * 151 - 157 8

E are the reference
volume when ad- c 12.9 325 * Min. 150 *
justing the injection
volume. D 9.4 325 * 21 * 19 - 23 5
) Marks * are aver-
age volumes. E * *

Zovernor performance

esinnina of rack
PuI I 800flOrPm

0 2 4 6 8 10 12 14 I6
PUMP SPEED (RPM) x1 0’
TKE00169

.
NUmtJerS In parentheses are pump rEInUtaCtUrer part numbers.
6D125 SERIES
’ *-OA7-’ O
Pump Assembly Number
6151-71-1270 (191000-5570) ... 1
Applicable Machine Applicable Engine

( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

PC360 S6D125-1

11

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[HPI / rpm)
viewed from drive end
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm)

High idling (rpm) 1,650 - 1,750

Injection interval 60” (59”30’ - 60”30’)
~ Low idling (rpm) 700 - 750
Plunger pre-stroke (mm) 4.7
~ Pump tester capacity
Deliven/ valve (mm”/st) 90 Motor 7.5 kW
,retraction volume for Service standard
alibration Standard

Rack positions
B to E are the ref-
erance volume
when adjusting

volume.

Governor performance

16-
214 13. 1

Leo 0 Loo
0 02 0 P-m
cc0 ,
0 2 4 6 a 10 12 14 16
PUMP SPEED (RPM) xl 0’
TKE00170

’2-ok7-1
’
6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
PC400, 4OOLC-3 S6D125-1 PE-6P DIESEL KIKI 6151-71-1220 (106692-4323) . . . 3
PC400-3 for Sweden 6151-71-1240 (106692-4441) . 1
PC400-3 for cold weather 6151-71-1260 (106692-4471) ... 1

Injection Timing

Unit Basis Allowance

Rotating direction Counterclockwise viewed

from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

~-7
I Injection interval 60 59’30’ to 60 30
I Rated horsepower: HP/rpm 266/2000 (270 PS)

Plunger pre-stroke mm 3.75 3.7 to 3.8 Maximum torque: kgm/rpm 11 o/1400

Delivery valve
mm3 60
retraction volume High idling: rpm 2150 to 2250

Low idling: rpm 600 to 700

Calibration Standard

Manufacturer standard Service standard

ionditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (105015-5370) (105780-0000)

Nozzle holder part no. (105041-7030) (105780-2080)

Injectron pipe
(O/D x I/D x length) mm 6x2.2x710 8 x 3 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm* 1.6 1.6

ipecifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Pump Maximum Maximum

Rack
Basis variance Basis Allowance variance
osition speed Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 9.7 1000 146.0 144.0 to 148.0 * 3 141.8 139.8 - 143.8 c 4.3

1 Rack positionsB to B 6.5 325 15.0 * 13.5 to 16.5 * 15 11 * 9.5 - 12.5 + 1.7
E are the reference
volume when ad- C * *
justing the injection
volume. D * *
Marks * are aver-
age volumes. E * *

iovernor performance

Min. 14.0-

-z
9.7
E 9.5

El
.-
C
g 6.5
cl
5.5
::
2

0 325 1000 1100

Pump speed (rpm)

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers.

12-017-12
@
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
PC400,4OOLC-3 S6D125-1 EP-6P NIPPON DENS0 6151-71-1221 (191000-5400) .. 1
PC400-3 for Sweden 6151-71-1222 (191000-5401)
PC400-3 for cold weather 6151-71-1241 (191000-5720) .0
6151-71-1242 (191000-5721) .. 1
6151-71-1261 .. . . . . . . . . . . . ... 1
Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60 5930 to 60”30’

Plunger pre-stroke mm 4.7

Delivery valve mm3 90

retraction volume

Low idling: rpm 650 to 700

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DN12SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

InjectIon rpe
(O/D x I/ B x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45

Nozzle opening pressure kg/cm* 175

Transfer pump pressure kg/cm* 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
position speed variance variance
Basis Allowance Basis Allowance
between between
(mm) (mm) cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 12.9 1000 143.0 143.0 140.0 to 146.0 max. 8.0

l Rack positions B to B 13.0 700 150.0 * 150.0 * 147.0 to 153.0 max. 8.0
E are the reference
volume when ad- c 10.1 325 21.0 * 21.0 * 19.0 to 23.0 max. 5.0
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

.U
400 ,020’

Pump speed (rpm)

Numbers in parentheses are pump manufacturer part numbers. 6D125 SERIES

’ *-Ok7-’ 3
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
PC400.4OOLC-5 S6D125-1 NB (EP9) NIPPON DENS0 6151-73-1210 (191000-7350) . 1
PC400-5 for Sweden
6151-73-1220 (191000-7903)
PC400-5 for cold weather
PC400-5c 6151-73-1230 (191000-9666) . . 1
6151-73-1240 (191000-9623) . 1
Injection Timing

Unit Basis Allowance

I
Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

I
Injection interval 60” 5930 to 60”30
I Rated horsepower: HP/rpm 276/2000

Plunger pre-stroke mm 4.7

I Maximum torque: kgm/rpm 115/1400
I
High idling: rpm 2150 to 2250

Low idling: rpm 600 to 700

Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 093400-0540 (DNI 2SD12A)

Nozzle holder part no. 093100-0190 (EF8511/9A)

InJectIon pipe
(O/D x I/D x length) mm 6 x 2 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 40 to 45

Nozzle opening pressure kg/cm2 175

Transfer pump pressure kg/cm2 1.6

specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump variance
variance Basis Allowance
osition speed Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 13.3 1000 154 154 151 to 157 max. 8.0

mRack positions 8 to B 9.4 325 15 * 15 * 13to 17 max. 5.0

E are the reference
volume when ad- C * *
justing the injection
volume. D * *
) Marks t are aver-
age volumes. E * *

3overnor performance

Min. 14.0

13::

z
9.4
r 9.0

5
.-
c
8 6.3
a

::
$ Max.4.0

II / '1.1
0 100200 325 550 1000\11001250
400 1020

Pump speed (rpm)

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers. 12-017-14
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
HD200D-3 S6D125-1 PE-6P DIESEL KIKI 6151-71-1362 (106692-4451) .. 0
6151-71-1363 (106692-4452) .. . 1
6151-71-1364 (106692-4910)

Injection Timing

Unit Basis Allowance

Specification for engine with fan (reference only)

Rated horsepower: HP/rpm 27612100

I
Plunger pre-stroke mm 3.75 3.7 to 3.8 Maximum torque: kgm/rpm 115/l 400

I High idling: rpm 2350 to 2450 I

Low idling: rpm 650 to 700
Calibration Standard I

Manufacturer standard Service standard

:onditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (105015-5370)

Nozzle holder part no. (105041-7030)

I t
(8% %l%ength) mm 6x2.2x710

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 43 to 47

Nozzle opening pressure kg/cm* 250

Transfer pump pressure kg/cm* 1.6

specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
osition speed variance variance
Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 8.6 1050 158.5 156.5 to 160.5 I!Z 3

p Rack Dositions B to B
--r- ~~~~~
9.0 700 172.0 * 170.0 to 174.0 * 4 *
E are the reference
volume when ad- c 4.0 325 15.0 * 13.5 to 16.5 +15 *
justing the injection
volume. D * *
8 Marks * are aver-
age volumes. E * *

sovernor performance

9. 0
a. 6

FMin5.5
Z
2 4. 0
G 3. 2
Z

I. 2

0
420 860 1175

PUMP SPEED (RPM)

TKE00171

Numbers in parentheses are pump manufacturer part numbers.

’*-07-’
5 6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
HD205-3 S6D125-1 PE-6P DIESEL KIKI 6151-71-1322 (106672-9301) 1

Injection Timing

Specification for engine with fan (reference only)

Injection interval 60 59’30’ to 60”30 Rated horsepower: HP/rpm 296/2100

Plunger pre-stroke mm 3.8 3.75 to 3.85 Maximum torque: kgm/rpm 12411400

Delivery valve
mm3 80 High idling: 2350 to 2450
retraction volume rpm

Low idling: rpm 750 to 800

Calibration Standard
Manufacturer standard Service standard
ionditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 6151-11-3121 (105015-5950)

Nozzle holder part no. 6151-11-3111 (105041-7040)

Injectron pope
(O/D x I/D x length) mm 6 x 2.2 x 720

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47

Nozzle opening pressure kg/cm* 250

Transfer pump pressure kg/cm* 1.6

specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance Allowance variance
osition speed Basis Allowance Basis
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 9.5 1050 148.2 146.2 to 150.2 + 3

b Rack positions B to B 10.2 700 168.5 * 166.5 to 170.5 * 4 *

E are the reference
volume when ad- C 4.0 375 15.0 * 13.5 to 16.5 * 15 *
justing the injection
volume. D * *
) Marks * are aver-
age volumes. E * *

Zovernor performance Boost compensator performance

BoostcomDe Stroke

Damper Spring Set

3. 5$ s

0. 5qa.a 0 5Of'0 v?_oo1

f60
I I I I I I I
0 375 420+,@ / (9001 \ 12oo*,s BOOST PRESSURE(mmHa)
(350) 740*30 1050:::
PUMP SPEED (RPM) TKE00172 TKE00173

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers.

’ 2-ok7-’ 6
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
HD205-3 S6D125-1 PE-6P DIESEL KIKI 6151-71-1323 (106672-9303) . .. 3

Injection Timing

I”l:.t..,..l
Specification for engine with fan (reference only)

Low id!ing: rpm 750 to 800 I

Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 6151-11-3121 (105015-5950) (105780-0000)

Nozzle holder part no. 6151-11-3111 (105041-7040) (105780-2080)

InJectron ipe
(O/D x I/ B x length) mm 6 x 2.2 x 720 8x3~600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm2 1.6 1.6

specifications
Injection volume (mm3/st) Injection volume (mm3/st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
osition speed variance variance
Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 9.7 1050 152.2 150.7 148.7 to 152.7 + 3

) Rack positions B to B 10.7 700 185.6 176.8 * 174.8 to 178.8 + 4

E are the reference
volume when ad- C 3.6 375 15 10.8 * 9.3 to 12.3 IL 15
justing the injection
volume. D * *
) Marks * are aver-
age volumes. E * *

sovernor performance Boost compensator performance

- BaostcomPe Stroke

(250l*so
BOOST PRESSURE (mmHal

(350) (660) 105o::I

PUMP SPEED(RPM) TKEOOI 74 TKEOOl75

Numbers in parentheses are pump manufacturer part numbers.

6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
HD205-3 S6D125-1 PE-6P DIESEL KIKI 6151-71-1324 (106672-9740)

Injection Timing

Specification for engine with fan (reference only)

Injection interval 60” 59’30’ to 60’30’ Rated horsepower: HP/rpm 296/2100

Plunger

Delivery valve
pre-stroke mm 3.8 3.75 to 3.85
I Maximum torque: kgm/rpm 124/1400
I
mm3 80 High idling: 2350 to 2450
retraction volume rpm

Low idling: rpm 750 to 800

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 6151-11-3121 (105015-5950) (105780-0000)

Nozzle holder part no. 6151-11-3111 (105041-7040) (105780-2080)

Injection pipe
(O/D x I/D x length) mm 6 x 2.2 x 720 8 x 3 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm2 1.6 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (rpm) cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 9.7 1050 152.2 146 144 - 148 f 3

l Rack positions 8 to B 10.8 700 185.6 * 175.3 * 173.3 - 177.3 * 4

E are the reference
volume when ad- C 3.6 375 15 * 13.3 * 11.8 - 14.8 + 15
justing the injection
volume. D * *
m Marks * are aver-
age volumes. E * *

Ziovernor performance Boost compensator performance

Boostcompe Stroke

(350) (660) 1050:::

PUMP SPEED RPM) TKE00176 TKE00177

12-017-l
Numbers in parentheses are pump manufacturer part numbers.
6D125 SERIES
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
WA450-1 S6D125-1 PE-6P DIESEL KIKI 6151-71-l 112 (106692-4402) 2
6151-71-1113 (106692-4591) . 2

injection Timing

Ic:::,..l
Specification for engine with fan (reference only)

Low idling: rpm 700 to 750

Calibration Standard I

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (105015-5370) (105780-0000)

Nozzle holder part no. (105041-7030) (105780-2080)

InjectIon pipe
(O/D x I/D x length) mm 6x2.2x710 8 x 3 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm* 1.6 1.6

specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cvlinder cylinder

Calibation
basic point 9.1 1100 130.5 Each cyl. 120.8 Each cyl.
118.8to 122.8 k 3

1 Rack positions 6 to B 6.5 350 15.0 12.3 f 10.8 to 13.8 i 15

E are the reference
volume when ad- C * *
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance

Min. 14.0

Pump speed (rpm)

12-017-19 Numbers in parentheses are pump manufacturer part numbers. 6D125 SERIES

0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
WA450-1 6D125-1 PE-6NB NIPPON DENS0 6151-71-1114 (191000-5280)

Injection Timing

pecification for engine with fan (reference only)

Injection interval 60” 59”3O’to 60”30’ Rated horsepower: HP/rpm 23712200

Plunger pre-stroke mm 4.7 Maximum torque: kgm/rpm 105/l400

Delivery valve
90 High idling: rpm 2350 - 2450
retraction volume mm3

Low idling: rpm 700 - 750

Calibration Standard

Conditions Manufacturer standard Service standard

Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-I 600) (093400-0540) (DNI 2SD12)

Nozzle holder part no. (093 100-27 10) (093100-0190) (EFB511 l9A)
In ectron pope
(d/D x I/D x length)
mm 6x2~600 6x2~600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm2 175 175

Transfer pump pressure kg/cm2 1.6 1.6

Specifications
Injection volume (mm%t) Injection volume (mm%t)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
yr$ion speed Basis Allowance Basis Allowance
between between
(rpm)
cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 11.6 1100 max. 117.5 114.5 - 120.5 max. 8

l Rack positions B 12.9 700 * max. 149.5 * 146.5 - 152.5 max. 8

8 to E are the refer-
ence volume when C 9.4 350 * max. 21 * 19 - 23 max. 5
adjusting the injec-
tion volume. D * *
l Marks * are aver-
age volumes. E * *

Sovernor performance

16

0 2 4 6 8 IO 12 14 16
PUMPSPEED(RPM) xl 0’ TKE00178

.. . . I
Numbers In parentneses are pump manuracturer part numoers.
6D125 SERIES
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
WA450-1 S6D125-1 PE-6P DIESEL KIKI 6151-71-1115 (106692-4820) 1
6151-71-1116 (106692-4822) 0

Injection Timing

Unit Basis Allowance

Rotating direction Counterclockwise viewed

from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60” 5930’ to 60’30’ 1 Rated horsepower: HP/rpm 23712200

Plunger pre-stroke mm 3.75 3.7 to 3.8 Maximum torque: kgm/rpm 105/l 400
Delivery valve
mm3 60
retraction volume High idling: rpm 2350 to 2450

Low idling: rpm 700 to 750

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 6151-I I-31 21 (105015-5950) (105780-0000)

Nozzle holder part no. 6151-11-3111 (105041-7040) (105780-2080)

InjectIon pipe
(O/D x I/D x length) mm 6 x 2 x 720 8 x 3 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm* 1.6 1.6

Specifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Rack Maximum Maximum

Pump
osition speed Basis Allowance variance variance
Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 9.1 1100 130.5 120.8 118.8 to 122.8, f 3

m Rack positions 8 to B 6.5 350 15.0 12.3 * 10.8 to 13.8 * 15

E are the reference
volume when ad- C * *
justing the injection
volume. D * *
m Marks * are aver-
age volumes. E * *

Zovernor performance

1075 1100

Pump speed (rpm)

12-017-21 Numbers in parentheses are pump manufacturer part numbers. 6D125 SERIES
0
m “m.mp r..naYmmmYm, m~“m~mY”.

6151-71-1115 (106692-4820) Applicable Machine Applicable Engine

6151-71-1116 (106692-4822)
6151-71-1121 (106692-4301) Model Serial No. Model Serial No.
6151-71-1122 (106692-4303)
( ): Manufacturer’s part No. WA450-1 S6D125-1

WF450T- 1A

Injection Timing Engine Specification

Counterclockwise Rated horsepower HP/rpm 237/2200
Rotating direction
viewed from drive end
lniection order l-5-3-6-2-4 1 Maximum torque kgm/rpml 105/1400 I
High idling rpm 2350 to 2450
Injection interval 60° & 30’
Low idling rpm 700 to 750

Plunger pre-stroke mm1 3.75 * 0.05

Delivery valve
L retraction volume
mm3/st 60 I Pump tester capacity
for Service standard
Motor 7.5 KW
I

Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test.

Rack positions
6 to E are the ref-
erence volume
when adjusting the
injection volume.
Marks + are aver-
age volumes.

Governor performance (350 - 1100 rpm)

1075i25 1100::8
Pump speed (rpm) SEBH4858

6D125 SERIES 12-017-22

0
Pump Assembly Number
6151-71-1440 (106692-9081)
Applicable Machine Applicable Engine

( ): Manufacturer’s part No. Model Serial No. Model Serial No.

WA450-3 S6D125-1
II

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[HPl / rpm) 193.4 [259.31/ 2,200
viewed from drive end ~~
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 1048.6 [IO71 / 1,400
High idling (rpm) 2,350 - 2,450
Injection interval 59”31’ - 60”30’
~ Low idling (rpm) 700 - 750
Plunger pre-stroke (mm) 3.75 + 0.05
~ Pump tester capacity
Delivery valve (mm3/stI 60 Motor 7.5 kW
retraction volume for Service standard
alibration Standard ( ): Pump manufacturer’s part No.

:onditions Service standard Manufacturer standard

Service standard
indicatesdata Nozzle part no. (105780-0000) 6151-11-3121 (105015-5950)
using calibration Nozzle holder part no. (105780-2080) 6151-11-3111 (105041-7040)
test parts.
Manufacturer Injection pipe
(O/D x I/D x length) mm 8x3~600 6 x 2.2 x 720
standard is data
for factory test.
Test oil I ASTM D975 No.2 diesel fuel or eauivalent

Oil temperature ‘C 43 to 47

Nozzle opening pressure (MPa[kg/cm’l) 17.16 [175] 24.52 12501

Transfer pump pressure (kPa[kg/cm21) 156.91 il.61 156.91 II.61
I I
njection volume Service standard Manufacturer standard
Rack Pump
Rack
position speed Maximam Maximam
point Injection volume variance Injection volume variance
(mm) @pm)
WI 000 St) between (cc/l 000 St) between
Rack positions cylinder (%) cylinder (%)
B to E are the ref-
erance volume A (Basic point) 10.1 1100 159*2 *3 150.4
when adjusting
the injection B 6.4 365 13* 1.5 f 15 15
volume. C 10.4 700 166.6 f 3 - 169.6
D
E

Governor performance

Rack Limit:13. 6’:“mm

‘E9. 4
9. 2’0.4
6. 5*0.1
6. 4

(10001 (1115)
PUMPSPEED(RPM) TKEOO179

’2-o&7-23 613125 SERIES

Pump Assembly Number
Applicable Machine Applicable Engine
6151-71-1180 (191000-9790)
I Model 1 Serial No. 1 Model 1 Serial No. 1
( ): Manufacturer’s part No.
D65EX-12 S6D125-1

D65P, PX-12

Injection Timing Engine specification

I
Counterclockwise
Rotating direction Rated horsepower HP/rpm 190/l 950
viewed from drive end
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 100/l 200

IInjection interval / 60” i 30’ I I High idling

1 Low idling
rpm 2050 to 2 150

800to 825 1
rpm I
Plunger pre-stroke mm 4.7 + 0.05
Pump tester capacity
Delivery valve Motor 7.5 KW
retraction vnlilme mm3bt 90 for Service standard

Calibration Standard

Conditions Service standard Manufacturer standard

1Service standard
indicates data Nozzle part no. (093400-0540) (ND-DNIZSDISA) (093400-0540) (ND-DN12SD12A)
using calibration Nozzle holder part no. (093100-0190) (EF8511/9A) (093100-0190) (EF8511/9A)
test parts
Injection pipe
(Nozzle, Nozzle mm 6 x 2 x 600 6 x 2 x 600
(O/D x I/D x length)
holder and injec-
tion pipe) Test oil ASTM D975 No. 2 diesel fuel or equivalent
1Manufacture
standard is data Oil temperature “C 40 to 45
using factory test Nozzle opening pressure kg/cm2 175 175
parts
(For reference) Transfer pump pressure kg/cm2 1.6 1.6

Injection volume Service standard (cc/ 500st) Manufacturer standard (cc/ 500 st)
Rack Pump
Rack Maximum Maximum
position speed
point variance variance
(mm) (rpm) Basis Allowance between Basis Allowance between
cylinder cylinder
Rack positions Each cyl. 55,5 Each cyl.
B to E are the ref- Basic Point 11.0 975 55.5 54.0 to 57.0 Max. 4
erence volume
when adjusting B 11.8 500 67.0 * 65.5 to 68.5 Max. 4 67.0 *
the injection vol-
ume. C (8.8) 410 12.0 * 11.0 to 13.0 Max.2.5 12.0 *
‘Marks+ are aver- D * *
age volumes.
E * *

Governor performance ( 410 - 975 rpm)

0 100 200 30040\\600 600 //006\1200

410 460 976 99OilO 1060

Pump speed (rpm)

SEBH

6D125 SERIES
’ 2-o;7-24
Pump Assembly
6151-71-2720
Number
(1066914031)
I Applicable Machine Applicable Engine I
Model Serial No. Model Serial No.
( 1: Manufacturer’s part No.
HA250 S6D125-1

I HA270 I

Injection Timing Engine specification

Counterclockwise
Rotating direction Rated horsepower HP/rpm 239.512.200
I viewed from drive end I
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 98.8/1,400

I High idling rpm 2,550 to 2,650

Injection interval 60” + 30’
I
I
I Low idling rpm 650 to 700
I
Plunger prestroke mm 3.75 + 0.05
Pump tester capacity
Motor 7.5 KW
P,e,~~~~~$~~ume mm3/st 60 for Service standard
J

Calibration Standard

:onditions Service standard Manufacturer standard

Service standard 6151-11-3121 (105015-5950)
Nozzle part no. (I 05780-0000)
indicates data
using calibration Nozzle holder part no. (I 05780-2080) 6151-11-3111 (105041-7040)
test parts.
Injection ipe
Manufacture 8 x 3 x 600 6 x 2.2 x 720
standard is data
(O/D x l/b x length) mm
for factory test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature OC 43 to 47

Nozzle opening pressure kg/cm2 175 250

Transfer pump pressure kg/cm2 1.6 1.6

njection volume Service standard (CC/ 500 St) Manufacturer standard (cc/500 stl
Rack Pump
Rack
position speed Maximum Maximum
point variance
(mm) (rpm) Basis Allowance rey$g?, Basis Allowance between
cylinder cylinder
Rack positions Each cyl.
Each cyl.
B to E are the refer- Basic point 7.5 63.35
ence volume when ’ loo t58.653 [ 57.65 to 59.651
adjusting the injec-
B 8.1 700 [71.701 *t71.7 to 72.71 73.00 *
tion volume.
A
Marks * are aver- C 325 L6.701 *[ 5.95 to 7.451 7.5 *
“496”“-
age volumes.
D * *

E * *

iovernor performance ( 325 - 1100 rpm) Boost compensator performance ( 65Orpm)

s (8.1)
e
::
b
Boost Compensator Stroke +G

:
Damper Spring

!
U (6.3)
I_
“oE B
$E 0 50f10 (200) f 50
Boost pressure (mmHg)

Automatic timer performance

I 3to.5
e
1. 5*03 t-4
b
5
2
350 940 1300~sa K
PUMPSPEED(RPM)
E Max 0.5
Line6:At boost Pressure 3OOmmHa or more w-
Line@:At boost Pressure OmmHe TKEOOl
80 I;E 7zI
$E 0 650 1050

Boost pressure (mmHg1 SEBH468’

’2-oh7-25 6D125 SERIES

 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
WA470-1 S6D125-1 PE-6P DIESEL KIKI 6151-71-1151 (106692-4750) . 0
6151-71-1153 (106692-4830) ... 1
6151-71-1154 (106692-4833) 1
6151-71-1450 (106692-4753) . 1

Injection Timing

Specification for engine with fan (reference only)

Injection interval 60 5930’ to 60’30’

Plunger pre-stroke mm 3.75 3.7 to 3.8

Delivery valve
mm3 60
retraction volume

Low idling: rpm 650 to 750

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. 6151-11-3121 (105015-5950) (105780-0000)

Nozzle holder part no. 6151-11-3111 (105041-7040) (105780-2080)

InJectIon pipe
(O/D x I/D x length) mm 6 x 2.2 x 720 8 x 3 x 600

Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm* 1.6 1.6

jpecifications
Injection volume (mm3/st) Injection volume (mm3/st)
for manufacturer standard for service standard

Rack Pump Maximum Maximum

osition speed Basis Allowance variance Basis variance
Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibation Each cyl. Each cyl.
basic point 10.2 1100 148.4 152.7 150.7 to 154.7 f 3

) Rack positions B to B 6.5 350 15.0 12.0 * 10.5 to 13.5 * 15

E are the reference
volume when ad- C * *
justing the injection
volume. D * *
B Marks * are aver-
age volumes. E * *

Zovernor performance

980 1200

Pump speed (rpm)

6D125 SERIES Numbers in parentheses are pump manufacturer part numbers.

12-O 17-26
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
S6D125-1 PE-6NB NIPPON DENS0 6151-71-1152 (191000-5390)

Injection Timing

Unit Basis Allowance

I
Counterclockwise viewed
Rotating direction
from drive end I
Specification for engine with fan (reference only)

, Plunger pre-stroke mm

Delivery valve
90 High idling: rpm 2350 - 2450
retraction volume mm3

Low idling: rpm 700 - 750

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (093400-l 600) (093400-0540) (DNI 2SD12)

Nozzle holder part no. (093100-2710) (093100-0190) (EF8511/9A)

In ectron pope
mm 6x2~600 6x2~600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 40 to 45 40 to 45

Nozzle opening pressure kg/cm’ 175 175

Transfer pump pressure kg/cm’ 1.6 1.6

specifications
Injection volume (mm%) Injection volume (mm%t)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (mm)
cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 12.1 1100 max. 125 122 - 128 max. 2 8

l Rack positions B 13.1 700 * max. 146 * 143- 149 max. 2 6

B to E are the refer-
ence volume when C 9.4 350 * max. 21 * 19 -23 max. * 5
adjusting the injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

;overnor performance

0 2 4 i0 12 14 16
x IO’ TKE00161

Numbers in parentheses are pump manufacturer part numbers.

6D125 SERIES
’ 2-ok7-27
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
GD705A-4 S6D125-1 PE-6P DIESEL KIKI 6151-71-1511 (106692-4070) . 0
6151-71-1513 (106692-4083)
6151-71-1531 (106692-4423)

Injection Timing

Unit Basis Allowance I

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 I Specification for engine with fan (reference only)

Rated horsepower: HP/rpm 200/2000

Maximum torque: kgm/rpm 92 /I300

High idling: rpm 2150 to 2250

Low idling: rpm 600 to 700

Calibration Standard

Conditions Unit Manufacturer standard Service standard

(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (I 05015-5370) ( 1

Nozzle holder part no. (I 05041-7030) ( 1
In ectron pope mm 6x2.2x710
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47

Nozzle opening pressure kg/cm2 250

Transfer pump pressure kg/cm2 1.6

ipecifications
Injection volume (cc/500stj Injection volumeW500st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
position speed Basis Allowance Basis Allowance
between between
(mm) (mm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 7.0 1000 58.5 57.5 to 59.5 * 1.76

Rack positions B 7.9 650 66.0 * 65.0 to 67.0 * 2.64 *

B to E are the refer-
ence volume when C 4.0 325 7.5 * 6.75 to 8.25 * 1.13 *
adjusting the injec-
tion volume. D * *
l Marks t are aver-
age volumes. E * *

Ziovernor performance
Min. 14

0 IX-J
2 s 38 z
Pump speed (rpm) - -

Numbers in parentheses are pump manufacturer part numbers.

6D125 SERIES
’*-O7-**
Pump Assembly Number
6151-71-1550 (191000-3340) . .. 1
6151-71-1551 (191000-3341) _.. 0 Aoolicable Machine 1 Aoolicable Enaine I

( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

G D705A-4 S6D125-1

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[WPl / rpm) 149.2 [2001/ 2,000
viewed from drive end l_
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 901.6 [921/ 1,300

High idling (rpm) 2,150 - 2,250

Injection interval 60 (59”30’ - 60”30’)
- Low idling (rpm) 600 - 700
Plunger pre-stroke (mm) 4.7
Pump tester capacity
Motor 7.5 kW
for Service standard
Calibration Standard ( ): Pumo manufacturer’s Dart No.

1Service standard
indicates data
using calibration
test parts.
‘Manufacturer
standard is data
for factory test.

Governor performance

0 z
me z a3

0 2 4 PUMP6 SPEED*(RPM) 10 12 14 16
x 1 o2 TKE00182

’2-ok7-29
6D125 SERIES
 Injection Pump
Machine Model Engine Model Manufacturer Pump Assembly Number
Pump Type

EC2602-1 S6D125-1 PEGP DIESEL KIKI 6151-71-1821 (106692-4260)...0

Injection Timing

Unit Basis Allowance

I
Counterclockwise viewed
Rotating direction
from drive end I
Specification for engine with fan (reference only)

Rated horsepower: HPlrpm 232/2150

I
Maximum torque: kgm/rpm 96 /1500
I
Delivery valve High idling: 2250 to 2350
60 rpm
retraction volume mm3 I I
Low idling: rpm 975 to 1025
I
Calibration Standard

Manufacturer standard Service standard

Zonditions Unit (with calibration test parts)
(with nearly the same actual machine parts)

Nozzle part no. (105015-5370) ( 1

Nozzle holder part no. (I 05041-7030) ( 1

In ection ipe mm 6x2.2x710
(d/D x II&)x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47

Nozzle opening pressure kg/cm’ 250

Transfer pump pressure kg/cm’ 1.6

specifications
Injection volume (cc/l OOOst) Injection volume(cc/ St)
for manufacturer standard for service standard

Maximum Maximun
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 7.4 1075 125.0 123.0 to 127.0 k3.75

’ Rack positions B 3.5 500 15.0 * 13.5 to 16.5 a2.25 *

B to E are the refer-
ence volume when C 8.1 1050 142.0 * 140.0 to 144.0 k5.68 *
adjusting the injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

Zovernor performance

Pump speed (rpm)

Numbers in parentheses are pump manufacturer part numbers

6D125 SERIES
’2-oA7-30
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
EC2602-1 S6D125-1 PEGP DIESEL KIKI 6151-71-1822 (106692-4263)
6151-71-1823 (106692-4264)

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 23212150

Plunger pre-stroke mm 3.75 3.7 t0 3.8 Maximum torque: kgm/rpm 96 I1500

Delivery valve
mm3 60 High idling: rpm 2250 to 2350
retraction volume

Low idling: rpm 975 to 1025

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (I 05015-5370) (105780-0000)

Nozzle holder part no. !I 05041-7030) (105780-2080)

In ectlon Ipe
mm 6x2.2x710 8 x 3 x 600
(d/D x l/$x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47 43 to 47

Nozzle opening pressure kg/cm” 250 175

Transfer pump pressure kg/cm’ 1.6 106

ipecifications
Injection volume (cc/l OOOst) Injection volume(cc/ St)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
y;$ion speed Basis Allowance Basis Allowance
between between
(rpm)
cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 7.0 1075 125.0 123.0 to 127.0 a3.75 120 118 - 122 + 3.6
-
’ Rack positions a 3.5 500 15.0 * 13.5 to 16.5 e2.25 13 * 11.5 - 14.5 * 1.2
8 to E are the refer-
ence volume when C 7.8 1050 142.0 * 140.0 to 144.0 -+5.68 137 * 135 - 139 t 5.5
adjusting the injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

governor performance

Minl4.0

Z
E
Z
; 1. 8
1. 0 \
2 Damper sprine
0
set :3. 5-1.,mm
a
DZ

;: 5

500 1075 1150

PUMPSPEED(RPM) TKEOOI 83

Numbers in parentheses are pump manufacturer part numbers.

12-017-31 6D125 SERIES
0
Machine Model Engine Model Pump Assembly Number
EG200-3 S6D125 PEGP DIESEL KIKI 6151-71-1930(106692-4130)... 1

Injection Timing

Unit Basis Allowance

Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
225/l 500 (50Hz)
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm
249/l 800 (60Hz)

Plunger pre-stroke mm 3.75 3.7 to 3.8 Maximum torque: kgm/rpm

Delivery valve Max. 1560 (50Hz)

60 High idling: rpm
retraction volume mm3 Max. 1872 (60Hz)

Low idling: rpm 950 to 1000

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with calibration test parts)
(with nearly the same actual machine parts)

Nozzle part no. (105015-5370) 1 1

Nozzle holder part no. (I 05041-7030) 1 )
In ectron ipe mm 6x2.2x710
(d/D x lIC?x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47

Nozzle opening pressure kg/cm2 250

Transfer pump pressure kg/cm2 1.6

ipecifications
Injection volume W500st) Injection volume(cc/500st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
r;o.s$ion speed Basis Allowance Basis Allowance
between between
(rpm) cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 10.9 900 93.5 92.5 to 94.5 k2.81

’ Rack positions B 10.5 750 87.5 * 86.5 to 88.5 r3.50 *

6 to E are the refer-
ence volume when C 6.3 375 7.5 * 6.8 to 8.3 k1.13 *
adjusting the injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

iovernor performance

min. 14

10.9
10.6

F
E
6
G
(mm1
B
:: 6.3
2 6.0

Numbers In parentheses are pump manufacturer part numbers,

6D125 SERIES 12-O 17-32
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
EG200-3 S6D125 PEGP DIESEL KIKI 6151-71-1931 (106692-4133)
6151-71-1932 (106692-4134)

Injection Timing

Unit Basis Allowance

1
Counterclockwise viewed
Rotating direction
from drive end

Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)

225/l 500 (50Hz)

Injection interval 60” 59”3O’to 60”30’ Rated horsepower: HP/rpm
249/l 800 (60Hz)

Plunger pre-stroke mm 3.75 3.7 to 3.8 Maximum torque: kgm/rpm

I
Delivery valve Max. 1560 (50Hz)
rnrn:j 60 High idling: rpm
retraction volume Max. 1872 (60Hz)

Low idling: rpm 950 to 1000

Calibration Standard

Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)

Nozzle part no. (105015-5370) (105780-0000)

Nozzle holder part no. (I 05041-70301 (105780-2080)

In ection pipe
mm 6x2.2x710 8 x 3 x 600
(d/D x I/D x length]
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature “C 43 to 47 43 to 47

Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm’ 1.6 1.6

ipecifications
Injection volume W500st) Injection volume(cc/500st)
for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
p;$ion speed Basis Allowance Basis Allowance
between between
(rpm)
cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 10.9 900 93.5 92.5 to 94.5 12.81 94.75

l Rack positions B 10.5 750 87.5 * 86.5 to 88.5 k3.50 86.4 * 85.4 - 87.4 -c 3.5
B to E are the refer-
ence volume when C 6.3 375 7.5 * 6.8 to 8.3 k1.13 6.5 * 5.75 - 7.25 f 1.0
adjusting the injec-
tion volume. D * *
’ Marks * are aver-
age volumes. E * *

jovernor performance

min 14

10.9
10.5

F
.E
s
‘Z
lmm)
P
2 6.3
$ 6.0

Numbers In parentheses are pump manufacturer part numbers.

12-018 6D125 SERIES
0
 Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D135A-1 SAGDI 25-1 PE-6P DIESEL KIKI 6152-71-1730 (106672-9602) . .. 2
I 6152-71-1731 (106672-9604)

Injection Timing

Unit Basis Allowance I

Specification for engine with fan (reference only)

Rated horsepower: HP/rpm 275/2000

-.. _
Plunger pre-stroke mm 3.8 3.75 to 3.85 Maximum torque: kgm/rpm 128/l 400
-..-
Delivery valve
mm3 80
retraction volume High idling: rpm 2150 to 2250
_- _
Low idling: rpm 650 to 700
Calibration Standard
Manufacturer standard Service standard
Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)
._
Nozzle part no. 6152-I I-3220 (105015-6770) (105780-0000)
_._.
Nozzle holder part no. 6152-11-3210 (105041-7080) (105780-2080)
__^
Infectron pope
(O/D x I/D x length) mm 6 x 2.2 x 720 8 x 3 x 600
_.
Test oil ASTM D975 No. 2 diesel fuel or equivalent

Oil temperature ‘C 43 to 47 43 to 47
..
Nozzle opening pressure kg/cm2 250 175

Transfer pump pressure kg/cm2 1.6 1.6

jpecifications Injection volume (mm3/st) Injection volume (mm3/st)

for manufacturer standard for service standard

Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder

Calibation Each cyl. Each cyl.

basic point 10.9 1000 158.6 145.8 143.8 to 147.8 + 3
-

b Rack positions B to 8 12.2 700 188.4 174.6 * 172.6 to 176.6 f 4

-
E are the reference
volume when ad- C 5.2 325 15.0 13.3 t 11.8 to 14.8 + 15
justing the injection
volume. D * *
l Marks * are aver-
age volumes. E * *

Governor performance Boost compensator performance

Z 12. 5
F E
E z
;
.-: z
.%
g z
CL 10. 9
::
%
2
d

0 90 380
BOOST PRESSURElmmHg)

0 325 600700 \
g7?O~~oo
TKE00184
Pump speed (rpm)

Numbers in parentheses are pump manufacturer part numbers.

6D125 SERIES
Pump Assembly Number

TV -1
6152-71-1170 (106671-4052)
6152-71-1171 (106671-4053) Applicable Machine Applicable Engine ~~~

( 1: Manufacturer’s part No. Model 1 Serial No. / Model 1 Serial No. 1

EP SA6D125-1

(Power unit)

Injection Timing Ermine Sbecification

Counterclockwise
Rotating direction Rated horsepower (kWjHP1 / rpm) 203 [272.11/ 2,100
viewed from drive end
Injection order l-5-3-6-2-4 Maximum torque (Nmjkgml/ rpm) -

59”31’ - 60”30’
High idling (pm) 2,150 - 2,250
Injection interval
I I
Low idling (rpm) 750 - 800
/Plunger pre-stroke (mm)
Delivery valve (mm31St) 80 Motor 7.5 kW
retraction volume
Calibration Standard ( ): Pump manufacturer’s part No.

Service standard
indicates data
using calibration
test parts.
Manufacturer
standard is data
for factory test.

Injection volume Injection volume

1Rack positions
B to E are the ref-

Governor performance Boost compensator performance

;i 3s 6
-2 =:
E
5 ?I

L
m (9.41
0. 7 z I.2to.6
2 E
z
zPI b543 2
2 0. 5
ORLESS
0 650 850 1050
BOOST PRESSURE(mmHa)
0
750 1050:::
PUMP SPEED (RPM) TKE00185 TKEOO186

12-020 6D125 SERIES

0
Pump Assembly Number
6152-71-1220 (106672-9520)
Applicable Machine I Applicable Engine I
( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

Alaska diesel SAGD1251

(OEM use) I I I I

Injection Timing Engine Specification

Counterclockwise
Rotating direction
viewed from drive end
Rated horsepower (kW[HPl / rpm) 328 [439.81/ 2,300
Injection order l-5-3-6-2-4

Injection interval
I 59”31’ - 60”30’
I
IPlunger pre-stroke (mm) 1 3.8 + 0.05 I
Pump tester capacity
Delivery valve hm’/st) 80 Motor 7.5 kW
retraction volume for Service standard
alibration Standard ( ): Puma manufacturer’s Dart No.

Service standard
ndicates data

standard is data
‘or factory test.

Rack positions
B to E are the ref-
erance volume

volume.

Governor performance

0 325 12 5Ots
1 150%
PUMP SPEEDCRPM) TKE00167

6D125 SERIES 12-020-l

0
Pump Assembly Number
6152-71-1221 (106672-9521)
Applicable Machine Applicable Engine

( 1: Manufacturer’s part No. Model Serial No. Model Serial No.

Alaska diesel SA6D125-1

(OEM use)

Injection Timing Engine Specification

Rotating direction

Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 1,490.6 [I521 / 1,400
High idling (rpm) 2,450 - 2,550
Injection interval 59”31’ - 60”30’
I 1Low idling W-d 650 - 700 1
Plunger pre-stroke (mm) 3.8 f 0.05

Delivery valve
retraction volume
(mm3/st) 80
I Pump tester capacity
I for Service standard
Motor 7.5 kW
I
Calibration Standard ( ): Pump manufacturer’s part No.

‘Service standard
indicates data
using calibration
test parts.
‘Manufacturer
standard is data
for factory test.

1Rack positions
B to E are the ref-
erance volume
when adjusting

Governor performance

1 150:::
PUMP SPEEDCRPM) TKE00188

12-020-2 6D125 SERIES

C3
Pump Assembly Number
6152-71-1230 (106671-4151) ... 2
6152-71-1231 (106671-4152) ... 0 Applicable Machine Applicable Engine

( ): Manufacturer’s part No. Model Serial No. Model Serial No.

Big Bud I 1SA6D125-1 I I

(OEM use) I I I I

Injection Timing Engine Specification

Counterclockwise
Rotating direction Rated horsepower (kW[HPI / rpm) 275.8 [369.81/ 2,200
viewed from drive end ~~
Injection order l-5-3-6-2-4 Maximum torque (Nm[kgml/ rpm) 1,372 [I401 / 1,400

High idling @r-n) 2,350 - 2,450

Injection interval 59”31’ - 60”30’
~ Low idling (rpm) 600 - 650
Plunger pre-stroke (mm) 3.8 2 0.05
Pump tester capacity
80 Motor 7.5 kW
for Service standard

alibration Standard ( ): Pump manufacturer's part No.

Service standard
indicatesdata
using calibration
test parts.
Manufacturer
standard is data
for factory test.

Rack positions
B to E are the ref-
erance volume
when adjusting
the injection

Governor performance Boost compensator performance

Boost PreSSure
:300mmHs(OR MORE)

2 11.0
oost Pressure:OmmHa 5
C
z
B

0
50*'0 200*ro
BOOST PRESSURE(mmHs)
0 325400f'o 1100%12OOS6
PUMP SPEED(RPM)
TKE00189 TKE00190

6D125 SERIES 12-020-3

0
Pump Assembly Number
6152-71-1760 (106672-9432) ... 2
6152-71-1761 (106672-9434) ... 1 Applicable Machine Applicable Engine

( ): Manufacturer’s part No. Model Serial No. Model Serial No.

I
SA6D125-1
( (for Indonesia)
I

Injection Timing Engine Specification

Rotating direction vie$-$~~~~~~~nd
Injection order l-5-3-6-2-4

Injection interval 59”31’ - 60”30’

Plunger pre-stroke (mm) 3.8 +: 0.05

- Pump tester capacity
Delivery valve hm3/st) 80 Motor 7.5 kW
retraction volume for Service standard
alibration Standard ( ): Pump manufacturer’s part No.

ionditions I Service standard I Manufacturer standard

Service standard
indicates data
using calibration
test parts.
Manufacturer
standard is data
for factory test.

Service standard Manufacturer standard

Rack positions
B to E are the ref-
erance volume
when adjusting

volume.

Governor performance Boost compensator performance

14
OR MORE

I I I
0 90 APPROX 300
BOOST PRESSURECmmHo)
0 325 (5601 625 800.101000:::
900:::
PUMP SPEEDMPM) TKE00191 TKE00192

6D125 SERIES
’2-oio-4
TESTING AND ADJUSTING PERFORMANCE TEST

PERFORMANCE TEST
RUN-IN STANDARD l
Load are given for the case of the dynamometer arm length is 716 mm.
This list shows the standard on condition that the fan is removed.

Order
Engine Applicable
Item
model machine
1 2 3 4 5 6
-
Running time min. 5 10 10 15 15 5

Enginespeed rpm 650- 700 880 1,100 1,380 1,590 1,750

D50A-17
D50P-17
Load kg 0 18 29 46 61 73.5

output HP 0 15.5 31 62 94 125

Running time min. 5 10 10 15 15 5

Enginespeed rpm 650- 700 950 1,200 1,500 1,750 1,900

D50F-17
Load kg 0 19 30.5 48.5 63 77

output HP 0 17.7 36 72 108.5 144

Running time min. 5 10 10 15 15 5

Enginespeed rpm 600 - 650 950 1,200 1,500 1,730 1,900

D53A-17
D53P-17
Load kg 0 18 28 45 59 72

output HP 0 16.5 33 66 100 132.4

Running time min. 4 8 2 2 9 35

Enginespeed rpm 800 -850 1,000 1,200 1,200 1,500 1,900

D58E-1
D58P-1
Load kg 0 20 36 63 80 70

output HP 0 19.7 42.6 74.5 118 131

6D125-1
Running time min. 5 10 10 15 15 5

Enginespeed rpm 600 - 630 950 1,200 1,500 1,700 1,850

D60A-8
Load kg 0 22 35 56 74 91

output HP 0 20.5 41 81.5 122 163

Running time min. 5 10 10 15 15 5

Enginespeed rpm 600 - 630 950 1,200 1,500 1,700 1,850

D60E-8
Load kg 0 23.5 37.5 60 79.5 97.5

output HP 0 22 43.5 83.5 130 174.5

Running time min. 5 10 10 15 15 5

Enginespeed rpm 600 - 630 950 1,200 1,500 1,700 1,850

D60P-8
D60PL-8
Load kg 0 23.5 37 59.5 78.5 96

output HP 0 22 43 86.5 129.5 172.5

Running time min. 5 10 IO 15 15 5

Enginespeed rpm 600 - 630 900 1,100 1,400 1,600 1,750

D60S8
Load kg 0 24 38.5 60.5 79.5 97

output HP 0 21 41 82.5 123.5 165

-

6D125 SERIES
’*-:*’
TESTING AND ADJUSTING PERFORMANCE TEST

* Load are given for the case of the dynamometer arm length is 716 mm
This list shows the standard on condition that the fan is removed.

Order
Engine Applicable
Item
model machine

-
’ I 2 I 3 4 5 6

Running time min. 4 a 2 2 9 35

Engine speed rpm 800 - 850 1,000 1,200 1,200 1,500 1,900
D63E-1
Load kg 0 20 36 63 84 80

output HP 0 19.7 42.6 74.5 124 150

-
Running time min. 5 10 15 15 5

Engine speed rpm 600 - 630 950 1,500 1,700 1,850

D65A-8
Load kg 0 22 56 74 91

output HP 0 20.5 81.5 122 163

Running time min. 5 10 10 15 15 5

Engine speed rpm 600 - 630 950 1,200 1,500 1,700 1,850
D65E-8
D65P-8
Load kg 0 22.3 37 59.5 78.5 96

output HP 0 22 43 86.5 129.5 172.5

Running time min. 5 10 10 15 15 5

Engine speed rpm 600 - 630 950 1,200 1,500 1,700 1,800
D65S-8
Load kg 0 22.5 36 57 75.5 92.5

output HP 0 21 41.5 83 124.5 166

6D125-1
Running time min. 4 8 2 2 9 35

Engine speed rpm 825 1,000 1,200 1,200 1,500 1,950

D65E-12
Load kg 0 20 35 60 90 100

output HP 0 19.7 41.4 71 133.1 192.3

-
Running time min. 4 8 2 2 9 35

Engine speed rpm 600 - 630 1,000 1,200 1,200 1,500 1,850
D68E-1
D68P-1
Load kg 0 25 45 80 110 100

output HP 0 24.7 53.2 94.6 162.7 182.4

Running time min. 4 8 2 2 9 35

Engine speed rpm 620 1,000 1,200 1,200 1,500 1,850

D70LE-1
Load kg 0 20 36 63 94 96

output HP 0 19.7 42.6 74.5 139 175.1

-
Running time min.

Engine speed rpm

Load kg

output HP
-

’*-:** 6D125 SERIES

TESTING AND ADJUSTING PERFORMANCE TEST

It Load are given for the case of the dynamometer arm length is 716 mm.
This list shows the standard on condition that the fan is removed.

-r
Order
Engine Applicable
Item
model machine
1 2 3 4 5 6
I
I--
I

Running time min. 5 10 10 15 I 15 5

GD600R3
GD605R3 900 1,150 1,450 1,600 1,800
GD605A-3
with 146 HP 105.5 104.4 98 91.5 86.1
engine
92 116.5 150.5

10 10 5

GD605A-3 Engine speed rpm 650 - 700 900 1,150 1,800

with 155 HP
engine Load kg 0 100 111 92

output HP 0 88.5 126 163.5

Running time min. 4 8 2 2 9 35

GD613A-1
GD622A-1 Engine speed rpm 650 - 700 1,000 1,200 1,200 1,500 2,200
GD623A-1
GD625A-1 Load 0 20 36 63 94 75
kg
GD625A-1 C
output HP 0 19.7 42.6 74.5 139 162.7

Running time min. 5 10 10 15 15 5

GD650R3 Engine speed rpm 650 - 700 900 1,150 1,450 1,650 1,800
GD655R-3
GD655A-3 Load kg 0 105.5 109.6 106.2 101.8 97.2

output HP 0 92 122 149.5 163 170

6D125-1
Running time min. 5 10 10 15 15 5

Engine speed rpm 650 - 700 1,100 1,390 1.740 2,000 2,200
GD663A-1
Load kg 0 21 33 52 68 83

output HP 0 22.7 45 59 134 180

Running time min. 5 10 10 15 15 5

Engine speed rpm 650 - 700 900 1,150 1,450 1,700 1,850
GD705R-3
GD705R-4
Load kg 0 117.9 110.7 112.2 107.1 104.9

output HP 0 104.5 125.5 160.5 179.5 191

Running time min.

Engine speed rpm

Load kg

output HP

Running time min.

Engine speed rpm

Load kg

output HP

6D125 SERIES
’2-oi2-1
TESTING AND ADJUSTING PERFORMANCE TEST

* Load are given for the case of the dynamometer arm length is 716 mm.
This list shows the standard on condition that the fan is removed.

Engine
model
Applicable
machine
Item
T Order

2 3 4 5 6
-
Running time min. 5 10 10 15 15 5

Enginespeed rpm 600-630 950 1,200 1,500 1,700 1,850

D60F-8
Load kg 0 13 26 52.5 79 105

output HP 0 23.7 27 95.5 144 191

Running time min. 5 10 10 15 15 5

Engine speed rpm 600 -630 1,000 1,300 1,600 1,800 2,000
D60F-8A
Load kg 0 14.5 29 58.5 87.5 116.5

output HP 0 28.6 57.2 115 173 230

Running time min. 4 8 2 2 9 35

Enginespeed rpm 825 1,000 1,200 1,200 1,400 1,950

D65EX-12
D65P,PX-12
Load kg 0 21 37 63 95 105

output HP 0 20.7 43.8 74.5 131.1 201.9

-
Running time min. 5 10 10 15 15 5

Enginespeed rpm 600 -630 1,000 1,260 1,580 1,820 2,000

D75A-1
Load kg 0 27.5 43.5 69 90 109

output HP 0 27 53.7 107.5 102 215

S6D125-1
Running time min. 5 10 10 15 15 5

Enginespeed rpm 550-650 1,000 1,260 1,580 1,820 2,000

D75S-5
Load kg 0 27.3 43.3 69.0 89.8 109

output HP 0 26.3 53 105.5 158.5 211.5

-
Running time min. 5 10 10 15 15 5

Enginespeed rpm 550 - 650 1,000 1,260 1,580 1,820 2,000

D83E-1
D83P-1
Load kg 0 27.5 43.5 69 90 112.8

output HP 0 27 53.7 107.5 102 222.4

-
Runnkg time min. 5 10 IO 15 15 5

D85A-21 Enginespeed rpm 650- 700 1,000 1,200 1,200 1,400 2,000
D85&21(B)
D85P-21 Load 0 20 60 90 145 120
kg

output HP 0 19.7 71 106.5 200 236.6

-
Running time min.

Enginespeed rpm

Load kg

output HP
-

6D125 SERIES
’2-g23
TESTING AND ADJUSTING PERFORMANCE TEST

* Load are given for the case of the dynamometer arm length is 716 mm.
This list shows the standard on condition that the fan is removed.

Order
Engine Applicable
Item
model machine
1 2 3 4 5 6
-
Running time min. 5 10 10 15 15 5

PC300-3 Engine speed rpm 630 - 670 1,000 1,200 1,200 1,400 1,550
PC3OOLG3
PC300NLC3 Load kg 0 20 52 a3 133 133

output HP 0 20 62 99 183 203

Running time min. 4 a 2 2 9 -

Engine speed 700 1,000 1,200 1,200 1,550 _

rpm
PC36OLC-3
Load 0 20 56 a7 140 -
kg

output HP 0 19.7 66.3 103 214 -

Running time min. 5 IO IO 15 15 5

Engine speed rpm 630 - 670 1,300 1,500 1,500 i ,800 2,000
PC400-3
PC4OOLC3
Load kg 0 20 53 a5 135 135

output HP 0 26 78 126 240 266

Running time min. 4 a 2 2 9 35

Engine speed rpm 600 - 700 1,000 1,200 1,200 1,400 2,000
PC400-5
PC4OOLG5
Load kg 0 22 61 95 147 145

output HP 0 21.7 72.2 112 203 286

S6D125-1 -
Running time min. 4 a 2 2 9 35

HA250 Engine speed rpm 650 1,000 1,200 1,200 1,400 2,200
HA270
Load kg 0 20 52 a3 143 115

output HP 0 20 62 100 200 253

Running time min. 4 a 2 2 9 35

Engine speed rpm 650 - 700 1,000 1,200 1,200 1,400 2,100
HD200D-3
HD205-3
Load kg 0 20 52 a3 143 133

output HP 0 19.7 61.5 98 197 275

Running time min. 4 a 2 2 9 35

WA450 Engine speed rpm 695 - 745 1,000 1,200 1,200 1,400 2,200
WF450T-1
Load kg 0 20 52 a3 143 115

output HP 0 19.7 61.5 98 197.5 249.5

-
Running time min. 4 a 2 2 9 35

Engine speed rpm 695 - 745 1,000 1,200 1,200 1,400 2,200
WA470-1
Load kg 0 20 52 a3 143 125

output HP 0 19.7 61.6 98 197 271

-

’2-o23-’ 6D125 SERIES

TESTING AND ADJUSTING PERFORMANCE TEST

. Load are given for the case of the dynamometer arm length is 716 mm.
This list shows the standard on condition that the fan is removed.

Order
Engine
model
2 3 4 5 6

min. 5 10 IO 15 15 5

rpm 650-700 1,000 1,300 1,600 1,800 2,000

kg 0 124.4 131.7 120 114.1 108.8

HP 0 120.5 166 186 199 211

Running time min. 5 IO 10 15 15 5

Enginespeed rpm 975 - 1,015 1,080 1,510 1,720 1,940 2,150

EC2602-1
Load kg 0 57 81 92 104 116

output
tHP 0 61.1 120 157 199 245.5
S6D125-1
Running time min. 5 IO IO I5 I5 5

Engine speed rpm 700 - 800 1,000 1,200 1,500 1,700 1,800
EGZOO-3
Load kg 0 37 61 98 129.5 163

output HP 0 36.4 72 145 217 289

Running time min. 4 8 2 2 9 35

EG220-1,2
EGZZOB-1,2 Enginespeed rpm 900- 1,000 1,000 1,200 1,200 1,400 1,800
EGZZOBS-1,2
Load kg 0 20 52 83 143 160
!!:::-by)
oljtput HP 0 19.7 61.5 98 197 284

Running time 8 '. 2 2 9 35

Enginespeed 1,000 1,200 1,200 1,400 2,000

D135A-1
Load 20 52 83 143 148

Outout 19.7 61.5 98 197 292

Running time 8 2 2 9 35
EG275-1.2
EG275&1,2 Enginespeed 1,000 1,200 1,200 1,400 1,800
EG275BS1.2
26 67 107 183 204
($~~.b,) Load
output HP/ 0 25.6 79 126.6 252.6 362
SA6DI25-1
Running time min.

Enginespeed rpm

Load kg

output HP

Running time min.

Enginespeed rpm

Load kg

output HP

6D125 SERIES
’2-%3-2
TESTING AND ADJUSTING PERFORMANCE TEST

PERFORMANCE TEST CRITERIA

Engine Applicable Specified value Enginespeed Dynamometer

Test item
model machine (fullyequipped) (rpmi (kg)

+wheel horsepower 120 HP/l,750 rpm 1,745 - 1,755 71.4 - 75.7

Maximum torque 65.5 kgm/l,lOO rpm 1,000 - 1,200 89.8 - 95.3

D50A-17
D50P-17 iigh idling speed 1,875 - 1,975 rpm 1,875 - 1,975 0

_ow idling speed 650- 700 rpm 650-700 0

Flywheel horsepower 138 HP/I,900 rpm 1,895 - 1,905 74.6 - 79.1

Maximum torque 66 kgm/l,300 rpm 1,200 - 1,400 90.9 - 96.5

D50F-17
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600- 650 rpm 600- 650 0

Flywheelhorsepower 124 HP/l,750 rpm 1,895 - 1,905 69.8 - 73.8

Maximum torque 62.5 kgm/I,300 rpm 1,200 - 1,400 86.9 - 91.9

D53A-17
D53P-17
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600-650rpm 600-650 0

Flywheel horsepower 130 HP/l,900 rpm 1,895 - 1,905 70.4 - 74.4

Maximum torque 64.8 kgm/1,300 rpm 1,200 - 1,400 87.5 - 92.6

D58E-1
D58P-1
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 800 -850 rpm 800- 850 0

61X25-1
Flywheel horsepower 155 HP/l,850 rpm 1,845 - 1,855 88.3 - 93.4

Maximum torque 78 kgm/l,lOO rpm 900 - 1,100 107.5 - 113.8

D60A-8
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600-650 rpm 600- 650 0

Flywheel horsepower 170 HP/l,850 rpm 1,845 - 1,855 94.9 - 99.7

Maximum torque 81 kgm/l,lOO rpm 1,000 - 1,200 110.3 - 115.8

D60E-8
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600- 630 rpm 600- 630 0

Flywheel horsepower 165 HP/l,850 rpm 1,845 - 1,855 93.8 - 99.1

Maximum torque 78 kgm/l,OOO rpm 900-1,100 110.2 - 115.6

D60P-8
D60PL-8
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600- 630 rpm 600-630 0

Flywheel horsepower 160 HP/l,750 rpm 1,745 - 1,755 94.2 - 99.8

Maximum torque 78 kgm/l,OOO rpm 900-1,100 110.6 - 116.1

D60S8
High idling speed 1,950- 2,050 rpm 1,950 - 2,050 0

Low idling speed 600- 630 rpm 600- 630 0

12-024 6D125 SERIES

0
 TESTING AND ADJUSTING PERFORMANCE TEST

* The values in the table are indicated at standard conditions (atmospheric temperature 25”C, atmospheric pressure 750 mmHg).
t The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from those of the spe-
cification.
* Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air compressor
(if installed) open.
* Dynamometer loads are given for the case of the arm length is 716 mm.
* Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAESO.
* Exhaust tern1 Per‘ature column t: Intake temperature -25X.

Coolant Lubrication oil Lubrication oil

output Torque Fuel consumption %haust temperature (“C)
temperature temperature pressure
(HP1 (kgm) (sec./200 cc) :t = Intake temp. -25°C)
m (“C) (kg/cm*)

121 - 128.5 - Min. 29.8 70 - 95 80- 115 2.5 - 5.0 Max. 650 + 3t

- 64.4 - 68.2 - 70 - 95 80- 115 - Max. 650 + 3t

0 0 _ 70 - 95 80 - 115 - -

0 0 - 70 - 95 Min. 80 Min. 1 .O -

139.8 - 148.1 _ Min. 26 70 - 95 go- 115 2.5 - 5.5 Max. 500 + 3t

- 65.1 - 69.1 - 70 - 95 go- 115 _ Max. 600 + 3t

0 0 _ 70 - 95 go- 115 - -

0 0 - 70 - 95 Min. 80 Min. 1.O

128.5 - 136 - Min. 28 70 - 95 80- 115 2.5 - 5.0 Max. 650 + 3t

- 62.2 - 65.8 - 70 - 95 80- 115 _ Max. 650 + 3t

0 0. _ 70 - 95 80- 115 - _

0 0 - 70 - 95 Min. 80 Min. 1 .O

131.8 - 139.3 - Min. 27.6 70 - 95 80-115 3.0 - 5.0 Max. 550 + 3t

- 62.7 - 66.3 - 70 - 95 80- 115 _ Max. 550 + 3t

0 0 _ 70 - 95 80- 115 _ -

0 0 _ 70 - 95 Min. 80 Min. 1 .O -

158.5 - 167.5 - Min. 22 70 - 95 go- 115 2.5 - 5.5 Max. 500 + 3t

- 77 - 81.5 - 70 - 95 go- 115 - Max. 600 + 3t

0 0 - 70 - 95 go- 115 _ _

0 0 - 70 - 95 Min. 80 Min. 1 .O -

169.5 - 179 - Min. 20 70 - 95 go- 115 2.5 - 5.5 Max. 500 + 3t

- 79 - 82.9 - 70 - 95 go- 115 _ Max. 600 + 3t

0 0 - 70 - 95 90-115 - -

0 0 - 70 - 95 Min. 80 Min. 1 .O

168 - 178 - Min. 20 70 - 95 go- 115 2.5 - 5.5 Max. 500 + 3t

- 78.9 - 82.8 - 70 - 95 go- 115 - Max. 600 + 3t

0 0 _ 70 - 95 go- 115 - -

0 0 - 70 - 95 Min. 80 Min. 1.O -

160 - 169.5 - Min. 22 70 - 95 90 - 115 2.5 - 5.5 Max. 500 + 3t

- 79.2 - 83.1 - 70 - 95 90 - 115 - Max. 600 + 3t

0 0 - 70 - 95 90 - 115 - -

0 0 - 70 - 95 Min. 80 Min. 1.O

6D125 SERIES 12-$25

TESTING AND ADJUSTING PERFORMANCE TEST

Engine Applicable Specified value Engine speed Dynamometer

Test item
model machine (fully equipped) (rpm) (kg)

Flywheel horsepower 140 HP/l ,900 rpm 1,895- 1,905 77.0 - 81.4

Maximum torque 68 kgm/l,300 rpm 1,200 - 1,400 94.3 - 99.8

D63E-1
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Lo& idling speed 800 - 850 rpm 800 - 850 0

Flywheel horsepower 155 HP/l ,850 rpm 1,845 - 1,855 88.3 - 93.4

Maximum torque 78 kgm/l ,I 00 rpm 1,000 - 1,200 107.5 - 113.8

D65A-8
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600 - 630 rpm 600 - 630 0

Flywheel horsepower 165 HP/l ,850 rpm 1,845 - 1,855 93.8 - 99.1

Maximum torque 78 kgm/l ,I 00 rpm 900 - 1,100 110.2 - 115.6

D65E-8
D65P-8
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600 - 630 rpm 600 - 630 0

Flywheel horsepower 160 HP/l ,850 rpm 1,845 - 1,855 89.9 - 95.2

Maximum torque 78 kgmll ,100 rpm 1,000 - 1,200 107.8 - 115.2

D65S8
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600 - 630 rpm 600 - 630 0

6D125-1
Flywheel horsepower 180 HP/I ,950 rpm 1,945 - 1,955 98.5 - 103.5

Maximum torque 81.5 kgm/l,lOO rpm 1,000 - 1,200 113.4-119.0

D65E-12
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 -

Low idling speed 800 - 850 rpm 800 - 850 -

Flywheel horsepower 180 HP/l,850 rpm 1,845 - 1,855 -

Maximum torque 81.5 kgm/l,lOO rpm 1,000 - 1,200 111.2 - 116.6

D68E-1
D68P-1
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600 - 630 rpm 600 - 630 0

Flywheel horsepower 177.5 HP/l ,850 rpm 1,845 - 1,855 97.1 - 102.4

Maximum torque 81.5 kgm/I,l00 rpm 1,000 - 1,200 110.3 - 115.7

D70LE-1
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed 600 - 630 rpm 600 - 630 0

Flywheel horsepower

Maximum torque

High idling speed

Low idling speed

’2-iz26 6D125 SERIES

 TESTING AND ADJUSTING PERFORMANCE TEST

* The values in the table are indicated at standard conditions (atmospheric temperature 25”C, atmospheric pressure 750 mmHg).
* The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from those of the specifi-
cation.
* Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air compressor
(if installed) open.
* Dynamometer loads are given for the case of the arm length is 716 mm
* Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAESO.
* Exhaust temperature column t: Intake temperature -25°C.
Coolant Exhaust
output Torque :uel consumption
temperature temperature temperature (‘C)
(HP) Uw-n) (sec./200 cc)
- (‘Cl (*intake temp. - 25°C)

144.2 - 152.6 - Min. 25.2 70 - 95 Max. 550 + 3t

- 67.5 - 71.5 - 70 - 95 Max. 550 + 3t

0 0 - 70 - 95 80- 115 _ -

0 0 70 - 95 Min. 1.5 Min. 1.5

158.5 - 167.5 - Min. 22 70 - 95 go- 115 2.5 - 5.5 Max. 500 + 3t

- 77 - 81.5 - 70 - 95 90-115 1 - Max. 600 + 3t

0 0 70 - 95 go- 115 -

0 0 - 70 - 95 Min. 80 Min. 1 .O -

166 - 178 - Min. 20 70 - 95 90 - 115 2.5 - 5.5 Max. 500 + 3t

- 78.9 - 82.8 70 - 95 90 - 115 - Max. 600 + 3t

0 0 70 - 95 90 - 115 _

0 0 70 - 95 Min. 80 Min. 1 .O -

161.5 - 171 - Min. 22 70 - 95 90-115 2.5 - 5.5 Max. 500 + 3t

- 77.2 - 82.5 70 - 95 90-115 - Max. 600 + 3t

0 0 70 - 95 go- 115 _

0 0 70 - 95 Min. 80 Min. 1 .O -

189.3- 199.2 - Min. 18.4 70 - 85 90 - 110 3.0 - 5.0 Max. 650 + 3t

_ 81.2 - 85.2 - 70 - 85 90 - 110 - Max. 650 + 3t

- _ - 70 - 85 90-110 _ -

_ - 70 - 85 Min. 80 Min. 1.5 -

184.3 - 193.8 _ Min. 19.5 70 - 95 90-115 3.0 - 5.0 Max. 550 + 3t

_ 79.6 - 83.5 _ 70 - 95 go- 115 - Max. 550 + 3t

0 0 _ 70 - 95 90 - 115 - -

0 0 - 70 - 95 Min. 80 Min. 1 .O

177.1 - 186.8 - Min. 20.0 70 - 95 80-110 3.0 - 5.0 Max. 560 + 3t

- 79.0- 82.9 _ 70 - 95 80-110 _ Max. 620 + 3t

0 0 - 70 - 95 80 - 110 - -

0 0 70 - 95 Min. 80 Min. 1 .O

6D125 SERIES
’2-:27
TESTING AND ADJUSTING PERFORMANCE TEST

Engine Applicable Specified value Engine speed Dynamometer

Test item
model machine (fully equipped) (rpm) (kg)

Flywheel horsepower 146 HP/l,800 rpm 1,795 - 1,805 84.2 - 89.2

GD600R3
GD605R3 Maximum torque 74.4 kgm/l ,100 rpm 1,000 - 1,200 101.8 - 108.0
GD605A-3
with 146 HP High idling speed 2,000 - 2,100 rpm 2,000 - 2,100 0
engine
Low idling speed 650 - 700 rpm 650 - 700 0

Flywheel horsepower 155 HP/l ,800 rpm 1,795 - 1,805 89 - 94.3

GD605A-3 Maximum torque 77 kgm/l ,I 00 rpm 1,000 - 1,200 107.5 - 114

with 155 HP
engine High idling speed 2,000 - 2,100 rpm 2,000 - 2,100 0

Low idling speed 650 - 700 rpm 650 - 700 0

Flywheel horsepower 155 HP/2,200 rpm 2,195 - 2,205 73.2 - 77.7

GD613A-1
GD622A-1 Maximum torque 67 kgm/1,350 rpm 1,250 - 1,450 92.3 - 97.9
GD623A-1
GD625A-1 High idling speed 2,350 - 2,450 rpm 2,350 - 2,450 0
GD625A-1 C
Low idling speed 650 - 700 rpm 650 - 700 0

Flywheel horsepower 165 HP/l,800 rpm 1,795 - 1,805 94.4 - 100.1

GD650R3 Maximum torque 78.3 kgm/l ,I 00 rpm 1,000 - 1,200 107.1 - 113.6
GD655R-3
GD655A-3 High idling speed 2,000 - 2,100 rpm 2,000 - 2,100 0

Low idling speed 650 - 700 rpm 650 - 700 0

6D125-1
Flywheel horsepower 180 HP/2,200 rpm 2,195 - 2,205 84.5 - 89.5

Maximum torque 67 kgm/1,350 rpm 1,250 - 1,450 92.3 - 97.9

GD663A-1
High idling speed 2,350 - 2,450 rpm 2,350 - 2,450 0

Low idling speed 650 - 700 rpm 650 - 700 0

Flywheel horsepower 180 HP/l,850 rpm 1,845 - 1,855 101.9 - 107.9

Maximum torque 80 kgm/l,lOO rpm 1,000 - 1,200 110.1 - 116.8

GD705R-3
GD705R-4 -
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150

Low idling speed 650 - 700 rpm 650 - 700 -

Flywheel horsepower

Maximum torque

High idling speed

Low idling speed

Flywheel horseposer

Maximum torque

High idling speed

Low idling speed

’2-%7-’ 6D125 SERIES

 TESTING AND ADJUSTING PERFORMANCE TEST

* The values in the table are indicated at standard conditions (atmospheric temperature 25”C, atmospheric pressure 750 mmHg).
* The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from those of the spe-
cification.
* Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air compressor
(if installed) open.
* Dynamometer loads are given for the case of the arm length is 716 mm.
* Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAEBO.
* Exhaust temperature column t: intake temoerature -25°C.

Coolant Lubrication oil Lubrication oil Exhaust

output Torque Fuel consumption
temperature temperature pressure temperature ("C)
(HP) (kgm) (sec./200 cc)
(‘C) K) (kg/cm2) (t-IntaketemD.- 25'CI

146 - 154.5 _ 24.0 - 25.5 70-95 90-115 2.5 - 5.5 Max. 500+ 3t

- 72.9 - 77.3 - 70-95 90-115 - Max.600+ 3t

0 0 - 70 -95 90-115 - -

0 0 - 70 - 95 Min.80 Min. 1.0 -

158 - 167.5 _ Min. 22.4 70-95 90-115 2.5 - 5.5 Max.500+ 3t

- 77 - 81.6 - 70-95 go-115 - Max.600+ 3t

0 0 - 70-95 90-115 _ -

0 0 - 70- 95 Min. 80 Min. 1 .O -

158.7- 168.5 - 20.6 - 23.2 70-95 80-110 3.0 - 5.0 Max.650+ 3t

- 66-70 70-95 80-110 _ Max.650+ 3t

0 0 - 80-110 - -

0 0 - - Min. 80 Min. 1.5

160 -174.5 - 21.3 - 22.5 70-95 90 -115 2.5 - 5.5 Max.500+ 3t

76.7 - 81.3 - 70-95 90-115 - Max.600+ 3t

0 0 _ 70-95 90-115 - _

0 0 - 70- 95 Min. 80 Min. 1.0 -

183.2-194 - 17.6- 19.3 70-95 80-110 3.0 - 5.0 'Max.650+ 3t

- 66-70 - 70-95 80-110 - Max.650+ 3t

0 0 - 80 -110 - -

0 0 - - Min. 80 Min. 1.5 -

186-196 - 18.0- 19.1 70-95 90-115 2.5 - 5.5 Max.500+ 3t

- 78.8 - 83.6 _ 70 -95 90-115 - Max.600 + 3t

0 0 - 70-95 90-115 _ -

0 0 - 70-95 Min.80 Min. 1.0

6D125 SERIES
’2-027-2
TESTING AND ADJUSTING PERFORMANCE TEST

Engine Applicable Specified value Engine speed Dynamometer

Test item
model machine (fully equipped) (rpm) (kg)

Flywheel horsepower 182 HP/l,850 rpm 1,845 - 1,855 101.7 - 107.7

Maximum torque 85 kgm/l ,100 rpm 1,000 - 1,200 116.8 - 124.0

D60F-8
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0

Low idling speed I 600 - 603 rpm 600 - 630 0

Flywheel horsepower 219 HPI2.000 rpm 1,995 - 2,005 113.2- 119.8

Maximum torque 92 kgm/1,500 rpm 1,400 - 1,600 127.7 - 135.5

D60F-8A
High idling speed 2,200 - 2,300 rpm 2,200 - 2,300 0

Low idling speed 600 - 640 rpm 600 - 630 0

Flywheel horsepower 190 HP/l ,950 rpm 1,945 - 1,955 104.7 - 110.7

Maximum torque 100 kgm/1,200 rpm 1,100 - 1,300 138.9 - 147.2

D65EX-12
D65P. PX-12 _
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150

Low idling speed 800 - 850 rpm 800 - 850 _

Flywheel horsepower 200 HP/2,000 rpm 1,995 - 2,005 107-113

Maximum torque 89 kgm/l,300 rpm 1,200 - 1,400 123.4 - 130.7

D75A-1
High idling speed 2,150 - 2,250 rpm 2,150 - 2,250 0

Low idling speed 600 - 630 rpm 600 - 630 0

S6D125-1
Flywheel horsepower 200 HP/2,000 rpm 1,995 - 2,005 106.0 - 112.0

Maximum torque 88 kgm/l,500 rpm 1,400 - 1,600 125.3 - 132.8

D75S5
High idling speed 2,150 - 2,250 rpm 2,150 - 2,250 0

Low idling speed 550 - 650 rpm 550 - 650 0

Flywheel horsepower 215 HP/2,000 rpm 1,995 - 2,005 111.9- 117.0

Maximum torque 89 kgm/l,300 rpm 1,200 - 1,400 123.8- 131.4

D83E-1
D83P-1
High idling speed 2,200 - 2,300 rpm 2,200 - 2,300 0

Low idling speed 600 - 630 rpm 600 - 630 0

Flywheel horsepower

Maximum torque

High idling speed

Low idling speed

Flywheel horseposer
I

6D125 SERIES
’*-ii**
 TESTING AND ADJUSTING PERFORMANCE TEST

* The values in the table are indicated at standard conditions (atmospheric temperature 25”C, atmospheric pressure 750 mmHg).
* The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from those of the spe-
cification.
* Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air compressor
(if installed) open.
* Dynamometer loads are given for the case of the arm length is 716 mm.
* Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAESO.
+ Exhaust temperature column t: Intake temperature -25°C.

Coolant Lubrication oil Lubrication oil Exhaust

output Torque =uelconsumption
temperature temperature pressure temperature (“C)
(HP) (k9m) (sec./200 cc)
(“C) (“Cl (kg/cm*) (@Intake temp. - 25°C)

195.5- 196.4 - 19-21 70-95 go- 115 2.5 - 5.5 Max. 500 + 3t

_ 83.6 - 88.8 - 70-95 90-115 - Max. 600 + 3t

0 0 - 70-95 go-115 - _

0 0 - 70-95 Min. 80 Min. 1 .O -

223.2 - 236.2 - 16 - 17.5 70- 95 go-115 2.5- 5.5 Max.500+ 3t

- 91.4 - 97.0 - 70-95 90-115 _ Max.600+ 3t

0 0 - 70-95 90 - 115 - -

0 0 - 70-95 Min. 80 Min. 1.0 -

201.2 - 213 - Min. 16.9 70-85 go- 110 3.0 - 5.0 Max.550+ 3t

- 99.4 - 105.4 _ 70-85 go- 110 - Max.630+ 3t

- - 70 - 85 go- 110 _ -

- - 70-85 Min. 80 Min. 1.5 -

211 - 222.8 - Min. 16.7 70- 95 95-115 3.0- 5.5 Max.550 + 3t

_ 88.4- 93.6 - 70- 95 95-115 - Max.600 + 3t

0 0 _ 70- 95 95-115 - -

0 0 - 70-95 Min.80 Min. 1.0

209-220.1 - 17.0- 18.3 70- 95 95-115 3.0- 5.0 Max.550+ 3t

89.7 - 95.1 - 70-95 95-115 - Max.600+ 3t

0 - - 70-95 95-115 - -

0 - 70-95 Min.80 Min. 1.0 -

220.7 - 230.7 - Min. 16.0 70- 80 90-115 3.0 - 5.0 Max. 650 + 3t

- 88.6 - 94.0 - 70- 80 90 -115 - Max. 650 + 3t

0 - _ 70- 80 90-115 - _

0 - - 70- 80 Min. 80 Min. 1 .O -

6D125 SERIES
’2-liL29
TESTING AND ADJUSTING PERFORMANCE TEST

Engine Applicable Specified value Engine speed Dynamometer

Test item
model machine (fully equipped) irpm) (kg)

Flywheel horsepower 225 HP/2,000 rpm 1,995 - 2,005 115.6 - 122.4

II85A-21 Maximum torque 102 kgm/l,400 rpm 1,300 - 1,500 140.5 - 149.1
385E-21 (B)
385P-21 High idling speed 2,150 - 2,250 rpm 2,150 - 2,250 0

Low idling speed 650 - 700 rpm 650 - 700 0

Flywheel horsepower 197 HP/l,550 rpm 1,545 - 1,555 130.0 - 137.7

PC300-3
PC3OOLG3 Maximum torque 105 kgm/l,200 rpm 1 ,I 00 - 1,300 145.0 - 153.9
PC300NLC3
(Serial No. 10001 High idling speed 1,675 - 1,725 rpm 1,675 - 1,725 0
- 20727)
Low idling speed 625 - 675 rpm 625 - 675 0

Flywheel horsepower 197 HP/l,550 rpm 1,545 - 1,555 130.0 - 137.7

PC300-3
PC3OOLG3 Maximum torque 105 kgm/l,200 rpm 1,I 00 - 1,300 145.0 - 153.9
PC300NLC-3
(Serial No. 20728 High idling speed 1,657 - 1,725 rpm 1,675 - 1,725 0
and up)
Low idling speed 725 - 745 rpm 725 - 745 0

Flywheel horsepower 202 HP/l,550 rpm 1,545 - 1,555 130.0 - 137.7

Maximum torque 108 kgm/l,200 rpm 1,100 - 1,300 144.9 - 153.9

PC36OLC-3
High idling speed 1,650 - 1,750 rpm 1,650 - 1,750 0

Low idling speed 650 - 670 rpm 650 - 670 0

S6D125-1
Flywheel horsepower 266 HP/2,000 rpm 1,995 - 2,005 137 - 145

Maximum torque 110 kgm/l,400 rpm 1,300 - 1,400 151.9 - 161.0

PC400-3
PC4OOLC3
High idling speed 2,150 - 2,250 rpm 2,150 - 2,250 0

Low idling speed 600 - 700 rpm 600 - 700 0

Flywheel horsepower 276 HP/2,000 rpm 1,995 - 2,005 142.5 - 150.5

Maximum torque 115 kgm/l,400 rpm 1,300 - 1,500 159.1 - 168.5

PC400-5
PC4OOLG5
High idling speed 2,150 - 2,250 rpm 2,150 - 2,250 0

Low idling speed 600 - 700 rpm 600 - 700 0

Flywheel horsepower 240 HP/2,200 rpm 2,195 - 2,205 114.6 - 118.0

Maximum torque 98.8 kgm/l,400 rpm 1,200 - 1,400 139.7 - 143.8

HA250
HA270
High idling speed 2,600 rpm 2,550 - 2,650 0

Low idling speed 650 rpm 650 - 700 0

Flywheel horseposer 276 HP/2,100 rpm 2,095 - 2,105 133.2 - 141.2

Maximum torque 115 kgm/l,400 rpm 1,300 - 1,500 157.4 - 167.2

HD200-3
High idling speed 2,350 - 2,450 rpm 2,350 - 2,450 0

Low idling speed 650 - 700 rpm 650 - 700 0

’2-oz9-1 6D125 SERIES

 TESTING AND ADJUSTING PERFORMANCE TEST

t The values in the table are indicated at standard conditions (atmospheric temperature 25”C, atmospheric pressure 750 mmHg).
* The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from those of the spe-
cification.
t Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air compressor
(if installed) open.
* Dynamometer loads are given for the case of the arm length is 716 mm.
* Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAEBO.
* Exhaust temperature column t: Intake temperature -25°C.

Coolant Lubrication
oil Lubrication
oil Exhaust
output Torque Fuel consumption
temperature temperature pressure temperature ("C)
(HP) (kgm) (sec./200cc)
("C) ('Cl (kg/cm2) (tylntaketemp.- 25°C)

228-241.4 _ Min. 15.3 70-95 95-115 3.0 - 5.0 Max.650 + 3t

- 100.6- 106.8 - 70-95 95-115 - Max.650 + 3t

0 0 _ 70-95 90-115 - _

0 0 - 70-95 Min.80 Min. 1.0 -

198.7- 210.5 _ 18.9- 20.5 70-95 95-115 2.7- 5.0 Max.550 + 3t

- 103.8- 110.2 - 70-95 95-115 - Max.650 + 3t

0 0 _ 70- 95 95-115 _ -

0 0 - 70-95 Min. a0 Min. 1.0

198.7- 210.5 - 18.9- 20.5 70-95 95-115 2.7- 5.0 Max.550+ 3t

_ 103.8- 110.2 _ 70-95 95-115 _ Max.650+ 3t

0 0' 70-95 95-115 -

0 0 70-95 Min. a0 Min. 1.0 -

198.7- 210.5 - Min. la.9 70-95 95-115 2.5- 5.5 Max.550+ 3t

- 103.8- 110.2 - 70- 95 95-115 - Max.650+ 3t

0 0 _ 70-95 95-115 - _

0 0 - 70-95 Min. a0 Min. 1.0 -

270 - 286 - 13.5- 14.3 70-95 95-115 3.0 - 5.0 Max.550 + 3t

- 108.7- 115.3 - 70-95 95-115 _ Max.650 + 3t

0 0 70-95 95-115 - -

0 0 70-95 Min. a0 Min. 1.0

281 - 296.8 _ Min. 13.1 70- 90 95-115 3.5 - 5.0 Max.550 + 3t

- 113.9- 120.7 - 70-90 95-115 - Max.650+ 3t

0 0 70-90 go-115 _ -

0 0 70-a9 Min. a0 Min. 1.0

248.5 - 255.9 - Min. 13.9 70--o go-115 3.5 - 5.0 Max.650+ 3t

- 100.0 - 103.0 - 70--o 90-115 - Max.650+ 3t

0 0 _ 70--o go-115 _ -

0 0 - 70--o Min. a0 Min. 1.5 -

275.8- 292.3 _ 13.0- 14.1 70-95 go-115 3.5 - 5.5 Max.650+ 3t

- 112.6- 119.7 17.4- la.8 70-95 90-115 - Max.650 + 3t

0 0 - - - - -

0 0 - Min. a0 Min. 1.0

6D125 SERIES
’2-o;9-2
TESTING AND ADJUSTING PERFORMANCE TEST

Engine Applicable Specified value Engine speed Dynamometer

Test item
model machine (fully equipped) irpm) (kg)
I
Flywheel horsepower 296 HP/2,100 rpm 2,095 - 2,105 142.4 - 151

Maximum torque 124 kgm/1,400 rpm 1,300 - 1,400 169.4 - 179.7

HD205-3
High idling speed 2,350 - 2,450 rpm 2,350 - 2,450 0

Low idling speed 700 - 750 rpm 700 - 750 0

Flywheel horsepower 237 HP/2,200 rpm 2,195 - 2,205 111.3- 117.8

Maximum torque 105 kgm/l,400 rpm 1,300 - 1,500 148.9 - 157.8

WA450-1
High idling speed 2,350 - 2,450 rpm 2,350 - 2,450 0

Low idling speed 700 - 750 rpm 700 - 750 0

Flywheel horsepower 260 HP/2,200 rpm 2,195 - 2,205 121.9 - 129.0

Maximum torque 107 kgm/l,400 rpm 1,300 - 1,500 151.7 - 160.6

WA470-1
High idling speed 2,350 - 2,450 rpm 2,350 - 2,450 0

Low idling speed 700 - 750 rpm 700 - 750 0

Flywheel horsepower 237 HP/2,200 rpm 2,195 - 2,205 111.3 - 117.8

Maximum torque 105 kgm/l,400 rpm 1,300 - 1,500 148.9 - 157.8

WF450T-1
High idling speed 2,400 - 2,450 rpm 2,400 - 2,450 0

Low idling speed 700 - 750 rpm 700 - 750 0

S6D125-1
Flywheel horsepower 200 HP/2,000 rpm 1,995 - 2,005 105.7 - 111.8

Maximum torque 92 kgm/l,300 rpm 1,200 - 1,400 127 - 134.6

GD705A-4
High idling speed 2,150 - 2,250 rpm 2,150 - 2,250 0

Low idling speed 775 - 800 rpm 775 - 800 0

Flywheel horsepower 232 HP/2,150 rpm 2,145 - 2,155 112.6- 119.1

Maximum torque 96 kgm/l,500 rpm 1,400 - 1,600 _

EC260Z-1
High idling speed 2,250 - 2,350 rpm 2,250 - 2,350 0

Low idling speed 975 - 1,025 rpm 975 - 1,025 0

Flywheel horsepower (50 Hz) 229 HP/l,500 rpm 1,495 - 1,505 153 - 162

(60 Hz) 253 HP/l,800 rpm 1,795 - 1,805 142 - 151

EG200-3
High idling (50 Hz) Max. 1,560 rpm Max. 1,560 0

(60 Hz) Max. 1,872 rpm Max. 1,872 0

Flywheel horsepower (50 Hz) 230 HP/l ,500 rpm 1,495 - 1,505 155.3 - 164.6
EG220-1, -2 (60 Hz) 255 HP/l,800 rpm 1,795 - 1,805 143.9 - 152.5
EG220B-l,-2
EG220BSI,-2 High idling speed (50 Hz) Max. 1,560 rpm Max. 1,560
(60 Hz) Max. 1,872 rpm Max. 1,872
Prime
Low idling speed 700 - 800 rpm 700 - 800

’2-oJ9-3 6D125 SERIES

 TESTING AND ADJUSTING PERFORMANCE TEST

* The values in the table are indicated at standard conditions (atmospheric temperature 2X, atmospheric pressure 750 mmHg).
* The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from those of the spe-
cification.
* Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air compressor
(if installed) open.
* Dynamometer loads are given for the case of the arm length is 716 mm.
* Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAE30.
* Exhaust temperature column t: Intake temoerature -25°C.

Coolant Lubrication oil Lubrication oil Exhaust

output Torque Fuel consumption
temperature temperature pressure temperature ('C)
(HP) (kgm) (sec./200 cc)
(‘(7 (“C) (kg/cm2) t-Intaketemp. - 25°C)

294.8 - 312.6 - 13.0- 14.1 70-95 90-115 3.5 - 5.5 Max.650 f3t

- 121.2 - 128.6 17.4- 18.8 70-95 90-115 - Max.650 + 3t

0 0 - - - -

0 0 - Min.80 Min. 1.0

241.4 - 255.6 - Min.14.5 70 - 90 80-110 3.0 - 5.0 Max. 550 + 3t

- 106.6- 113 - 70 - 90 80 -110 - Max. 630 + 3t

0 0 _ 70-90 80 -110 - -

0 0 - 70 - 90 Min. 80 Min. 1.5

264.3 - 279.9 - Min.13.0 70-90 90 - 110 3.0 - 5.0 Max. 600 + 3t

- 108.6 - 115.0 _ 70-90 90 - 110 _ Max.630 + 3t

0 0 - 70 - 90 90 - 110 -

0 0 _ 70 - 90 Min.80 Min. 1.5 -

241.4- 255.6 - Min.14.5 70 - 90 90-110 3.0 - 5.0 Max.550+ 3t

_ 106.6 - 113 70 - 90 90-110 - Max.630 + 3t

0 0 _ 70 - 90 90-110 _ _

0 0 - 70-90 Min. 80 Min. 1.5 -

208.4 - 220.5 _ 17.7- 18.5 70-95 90-115 3.0 - 5.0 Max. 550+ 3t

_ 91 .O - 96.4 _ 70-95 90-115 - Max.600+ 3t

0 0 - 70-95 90-115 - -

0 0 70-95 Min. 80 Min. 1.5

238.6 - 252.4 - 14.9- 16.5 70-95 90-115 2.5 - 5.5 Max.500+ 3t

_ 91 - 101 19.1- 21.1 70-95 90-115 - Max.600+ 3t

0 0 _ 70-95 90-115 _ _

0 0 - 70-95 Min.80 Min. 1.0 -

225.8 - 239.6 _ Min. 15.9 70-95 90-115 2.5 - 5.5 Max.600+ 3t

252.4- 268.2 - Min. 14.2 70-95 go-115 2.5 - 5.5 Max.600+ 3t

0 0 - - 90-115 -

0 0 - go-115 -

229.6- 243.4 - Min. 15.8 70-85 80-120 3.0 - 5.0 Max. 650+ 3t
255.3- 270 _ Min. 14.1 70 - 85 80-120 3.0 - 5.0 Max.650 + 3t
-
0 70-85 80-120 - _
0 _ 70 - 85 80-120 - -

0 70 - 85 Min. 80 Min. 1.5

6D125 SERIES
’2-029-4
TESTING AND ADJUSTING PERFORMANCE TEST

Engine Applicable Specified value Engine speed Dynamometer

Test item
model machine (fully equipped) irpm) (kg)
I
(50 Hz) 253 HP/l ,500rpm 1,495 - 1,505 168.7 - 179.3
Flywheel horsepower
EG220-1. -2 (60 Hz) 281 HP/l,800 rpm 1,795 - 1,805 157.8 - 166.6
EG220B-‘I, -2
EG220BS1, -2 High idling speed (50 Hz) Max. 1,575 rpm Max. 1,575 0
(60 Hz) Max. 1,890 rpm Max. 1,890 0
Stand-bv
Low idling speed 700 - 800 rpm 700 - 800 0
I
Flywheel horsepower 275 HP/2,000 rpm 1,995 - 2,005 143.8 - 152.2

Maximum torque 128 kg/l ,400 rpm 1,300 - 1,500 177.9 - 188.5
D135A-1
High idling speed 2,150 - 2,250 rpm 2,150 - 2,250 0

Low idling speed 650 - 700 rpm 650 - 700 0

(50 Hz) 269 HP/l,500 rpm 1,495 - 1,505 182 - 192.9

Flywheel horsepower
EG275-1, -2 (60 Hz) 321 HP/l,800 rpm 1,795 - 1,805 181.1 - 192
EG275B-1, -2
EG275BS-1, -2 High idling speed (50 Hz) Max. 1,560 rpm Max. 1,560 0
(60 Hz) Max. 1,872 rpm Max. 1.872 0
Prime
Low idling speed 700 - 800 rpm 700 - 800 0

Flywheel horsepower (50 Hz) 296 HP/l,500 rpm 1,495 - 1,505 198 - 216
EG275-1, -2 (60 Hz) 353 HP/l,800 rpm 1,795 - 1,805 198.3 - 210.6
EG275B-1, -2
SAGD125-1 EG275BS1, -2 (50 Hz) Max. 1,757 rpm Max. 1,575 0
High idling speed
(60 Hz) Max. 1,890 rpm Max. 1,890 0
Stand-bv
Low idling speed 700 - 700 rpm 700 - 800 0

’2-oi9-5 613125 SERIES

TESTING AND ADJUSTING PERFORMANCE TEST

The values in the table are indicated at standard conditions (atmospheric temperature 2X, atmospheric pressure 750 mmHg).
The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from those of the spe-
cification.
Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air compressor
(if installed) open.
Dynamometer loads are given for the case of the arm length is 716 mm.
Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
Lubrication oil used: CLASS-CD SAEBO.
Exhaust temperature column t: Intake temperature -25’C.
Coolant Lubrication oil Lubrication oil Exhaust
output Torque Fuel consumption
temperature temperature pressure temperature (“C)
(HP) (k9r-n) (sec.1200 cc)
(‘C) (“Cl (kg/cm2) (t-Intake temp. - 25°C)

249.5 - 265 _ Min. 14.4 70 - 85 80 - 120 3.0 - 5.0 Max. 700 + 3t

280 - 295.6 - Min. 12.7 70 - 85 80 - 120 3.0 - 5.0 Max. 700 + 3t

0 - 70 - 85 80 - 120 -
0 - 70 - 85 80 - 120 - -

0 - 70 - 85 Min. 80 Min. 1.5 -

283.6 - 300.1 Min. 12.3 70 - 95 go- 110 3.0 - 5.0 Max. 650 + 3t

- 127.4 - 135.0 _ 70 - 95 90 -110 - Max. 650 + 3t

0 0 - 70 - 95 go- 110 -

0 0 - 70 - 95 Min. 80 Min. 1.5 -

269 - 285.2 Min. 13.5 70 - 85 80 - 120 3.0 - 5.0 Max. 700 + 3t

321.4 - 340.7 Min. 11 .l 70 - 85 80 - 120 3.0 - 5.0 Max. 700 + 3t

0 _ 70 - 85 80 - 120 - -
0 - 70 - 85 80 - 120 _ -

0 70 - 85 Min. 80 Min. 1.5 -

292.8 - 319.4 Min. 11.9 70 - 85 80 - 120 3.0 - 5.0 Max. 700 + 3t

352.0 - 373.6 Min. 10.1 70 - 85 80 - 120 3.0 - 5.0 Max. 700 + 3t

- 70 - 85 80 - 120 - -
_ 70 - 85 80 - 120 - _

- 70 -85 Min. 80 Min. 1.5 -

6D125 SERIES
’2-029-6
TESTING AND ADJUSTING PERFORMANCE TEST

TESTING AND ADJUSTING TOOL LIST

No. Testing and measuring item Fault finding tool Part No. Remarks

Digital reading, pressure sensing type

1 Engine speed Multi-tachometer 799-203-8001
60 - 19,999 rpm

2 Battery S.G. 1,100 - 1,300

Battery coolant tester 795-500-I 001
Freezing temperature of cooling
3
water

Water temperature, oil temperature

4 air intake temperature, exhaust Digital temperature gauge
temperature

~~ $gine pressure measuring

7 Intake pressure, exhaust pressure

795-502-l 205 0 - 70 kg/cm2

795-502-I 360 Adaptor

11 Blow-by pressure Blow-by checker 799-201-1504 0 - 500 mm,0

12 Valve clearance Feeler gauge

Dirtiness 0 - 70% with standard color

13 Exhaust gas color Handy smoke tester

Provided with 0.1 and 0.2 water

14 Water and fuel content in oil Engine oil checker

15 Fuel injection pressure

Commercially
Nozzle tester 0 - 300 kg/cm*
availabale
16 Fuel injection nozzle spray condition

17 Coolant quality Water quality tester PH. nitrite ion concentration

18 Pressure valve performance

Radiator cap tester ;
19 Leakage in cooling water system

Anemometer
20 Radiator blockage (with speed) 799-202-2001 0 - 40 m/s
(Air speed gauge)

Cranking kit 795-61 O-l 000 DC24V with starting motor

21 Engine cranking
Barring tool 795-215-1600

Commercially
22 Electrical circuits Circuit tester Current, voltage, resistance
available

12-t&30 6D125 SERIES

TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

TESTING AND ADJUSTING DATA

Engine model 6D125-1

1
Applicable machine model
I D50A-17
D50P-17 I
D50F-17

Standard Permissible Standard Permissible

Item Condition, etc. Unit
value value value value

Engine speed High idling speed rpm 1,875 - 1,975 1,875 - 1,975 2,050 - 2,151 ,050 - 2,150

LOW idling speed rpm 650 - 700 650 - 700 650 - 700 650 - 700

o”c rpm Min. 100 - Min. 100 -

Necessary
starting speed - -
-20°C (with starting aid) rpm Min. 85 Min. 85

intake resistance At all speed mmH,O Max. 300 635 Max. 380 635

intake pressure At rated output mmHg - - -

Exhaust pressure
At rated output mmHg - - -
(Turbine inlet press.)
Exhaust temperature Max. 650 Max. 500 Max. 600
All speed (20°C) “C Max. 650
(Turbine inlet temp.)

Quick acceleration Max. 3.0 4.0 Max. 3.0 4.5

(Low idle -* high idle)
Bosch
Exhaust gas color At rated output scale

High idling Max. 1 .O 2.0 Max. 1 .O 2.0

Valve clearance lnta ke valve mm 0.33 - 0.33 -

(When engine is hot
or cold) Exhaust valve mm 0.71 0.71 -

oil temperature: 40 - 60°C kg/cm’ Min. 34 24 Min. 36 24

Compression pressure
(SAE 30)
(Engine speed) (rpm) (200 - 250) (200 - 250) (200 - 250) 200 - 250)

Blow-by pressure At rated output

mmH20 Max. 100 200 Max. 50. 100
:SAE30) (Water temp.: 70°C min.)

SAE30 oil kg/cm’ 3.0 - 5.0 2.1 2.5 - 5.0 2.5 - 5.0
At rated output

ZIil pressure
Oil temperature:
i,” Min. 1.3 0.7
80°C min.)
At low idling

120

1 .o

180

0.75 * 0.1

lo- 16

* The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

6D125 SERIES
’2-ki3’
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

Engine model 6D125-1

I

Applicable machine model

I D53A-17
D53P-17 I
D58E-1
D58P-1

Condition, etc.

High idling speed :

f
Low idling speed

O’C - Min. 100 -

-20°C (with starting aid)

Intake resistance At all speed

Intake pressure At rated output

Exhaust pressure
(Turbine inlet pressure) At rated output

Exhaust temperature Max. 650 Max. 650 Max. 650

All speed (2O’C)
(Turbine inlet temp.)
Quick acceleration - Max. 3.0 5.0
Exhaust gas color (Low idling - High idling)
At rated output
At high idling

Valve clearance Intake valve

(When engine is hot
or cold.) Exhaust valve

47 Compresion Oil temperature: 40 - 60°C

B pressure
(SAE30 oil) (Engine speed)
.-g
? Blow-by pressure At rated output
w mmH,O Max. 100
(SAE30 oil) (Water temperature: Min. 7o’C)

SAE30 oil
At rated output SAE,OW oil
E
(u Oil pressure
z (Oil temperature:
t
Min. 8o’C) SAE30 oil
At low idling
.-6 SAEl OW oil
z
All speed (oil in oil pan) 120 1 80- 110 1 120

At continuous rated output

Max. 0.5
(Ratio of fuel consumption)

E 1 Fuel injection pressure Nozzle tester

B.T.D.C

Opening pressure
(Differential pressure) kg/cm2

F 1 Fan speed At rated engine speed vm /

=
z
0 Fan belt tension
Deflects when pushed with a
mm 7.5
force of 6 kg

* The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.
% 26 + 1 (No. 29457 and up)

’2-:32 6D125 SERIES

TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

6D125-I

D60A-8

Standard Permissible Standard Permissible Standard Permissible Standard Permissible

value value value value value value value value

2,050 - 2,100 2,050 - 2,150 2,050 - 2,150 2,050- 2,150 2,050 - 2,150 2,050 - 2,150 1,950- 2,050 1,950- 2,050

600- 630 600 -630 600 - 630 600- 630 600- 630 600- 630 600 - 630 600- 630

Min. 100 Min. 100 _ Min. 100 _ Min. 100 -

Min. 85 Min. 85 - Min. 85 _ Min. 85 -

Max.300 635 Max.300 635 Max.300 635 Max.300 635

- - - - - - _ -

- - - - - - - -

Max.600 Max.650 Max.600 650 Max.600 650 Max.600 650

Max. 4.5 Max. 4.5 5.5 Max. 4.5 5.5 Max. 4.5 5.5

- _ _ - - - _
Max. 1.0 Max. 1.0 2.0 Max. 1.0 2.0 Max. 1.0 2.0

0.33 0.33 - 0.33 _ 0.33 _

0.71 0.71 _ 0.71 - 0.71 _

Min. 34 24 Min.34 24 Min. 34 24 Min. 34 24

(200- 250) (200- 250) (200 - 250) (200- 250) (200- 250) (200 - 250) (200- 250) (200 -250)

Max.100 Max.100 200 Max.100 200 Max. 100 200

2.5 - 5.5 2.5 - 5.5 2.5- 5.5 2.5 - 5.5 2.5- 5.5 2.5- 5.5 2.5 - 5.5 2.5- 5.5
- - - - - - - -

Min. 1.0 Min. 1.0 0.7 Min. 1.0 0.7 Min. 1.0 0.7
_ - - - - - -

80-110 80-110 120 80- 110 120 80-110 120

Max. 0.5 Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0

225:'; 225 i 10 180 225;'; 186 225:'; 186

22 * 1 22 * 1 22 * 1 22i.l 22 * 1 22 * 1 22 * 1

0.75 * 0.1 0.75 * 0.1 0.75 f 0.1 0.75 * 0.1 0.75 * 0.1 0.75 + 0.1 0.75 * I

13 lo-16 13 IO-16 13 lo-16 13 IO-16

6D125 SERIES
’2-ii33
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

Engine model

Applicable machine model

I D63E-1
6D125-1

D65A-8

Standard Permissible Standard Permissible

Item Condition, etc. Unit
value value value value

High idling speed rpm 2,050 - 2,15CI 2,050 - 2,150 2,050 - 2,150 2,050 - 2,150
Engine speed
Low idling speed rpm 800 - 850 800 - 850 600 - 630 600 - 630

O’C Min. 110 Min. 100 -

Necessary rpm
starting speed - -
-20X (with starting aid) rpm Min. 85 Min. 85

intake resistance At all speed mmH,O Max. 300 762 Max. 300 635

Intake pressure At rated output mmHg - - -

Exhaust pressure - - - -
At rated output mmHg
(Turbine inlet pressure)
Exhaust temperature
All speed (20°C) “C Max. 550 650 Max. 600 650
(Turbine inlet temp.)
Quick acceleration Max. 3.0 5.0 Max. 4.5 5.5
Exhaust gas color (Low idling - High idling) Bosch
At rated output scale Max. 1.0 2.0 - -
At high idling Max. 1.O 2.0 Max. 1.O 2.0

Valve clearance Intake valve mm 0.33 - 0.33 -

(When engine is hot
or cold.) Exhaust valve mm 0.71 - 0.71 -

Compresion Oil temperature: 40 - 60°C kg/cm2 Min. 34 24 Min. 34 24

pressure
(SAE30 oil) (Engine speed) (rpm) (200 - 250) (200 - 250) (200 - 250) (200 - 250)

Blow-by pressure At rated outout

mmH,O Max. 80 160 Max. 100 200
ISAE30 oil) (Water temperature: Min. 7o’C)

kg/cm2 3.0 - 5.0 2.1 2.5 - 5.5 2.5 - 5.5

At rated output ~$~~$bil - -
kg/cm2 2.5 - 4.5 1.8
Oil pressure
(Oil temperature:
Min. 80X) SAE30 oil kg/cm2 Min. 1.5 0.7 Min. 1 .O 0.7
At low idling - -
SAEl OW oil kg/cm2 Min. 1 .O 0.7

Oil temperature All speed (oil in oil pan) “C 80- 110 120 80-110 120

At continuous rated output

% Max. 0.5 1.0 Max. 0.5 1.0
(Ratio of fuel consumption)

Fuel injection pressure Nozzle tester kg/cm2 225:‘; 200 225:‘; 186

Fuel injection timing B.T.D.C degree 22 * 1 22 * 1 22* 1 22 * 1

Opening pressure
Radiator pressure valve kg/cm2 0.75 * 0.1 0.75 * 0.1 0.75 * 0.1 0.75 It 0:1
(Differential pressure)

Fan speed At rated engine speed rpm 1,682 - 1,772 1,682 - 1,772

Deflects when pushed with a

Fan belt tension mm 13 lo- 16 13 lo- 16
force of 6 kg

* The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

’2-$34 6D125 SERIES

TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

6D125-1

Standard
value
D65E-8
D65P-8

Permissible
value
rStandard
value
D65S8

Permissible
value
r
Standard
value
D65E-12

Permissible
value
D68E-1
D68P-1

2,050 - 2,150 2,050- 2,150 2,050- 2,150 2,050- 2,150 2,050- 2,150 2,050- 2,150

600-630 600 - 630 600- 630 600 -630 800-850 800-850

Min.100 - Min.100 - Min. 100 -

Min. 85 Min.85 - Min. 85

Max.300 762 Max.300 635 Max.300 762

_ - _ - - -

- - - - _ _

Max.550 650 Max.600 Max.650 Max.650 700

Max. 4.5 6.5 Max. 4.5 5.5 Max. 5.0 6.0

Max. 1.5 2.5 _ Max. 2.0 3.0

Max. 1.5 2.5 Max. 1.0 2.0 Max. 1.0 2.0

0.33 - 0.33 - 0.33 _ 0.33 -

0.71 0.71 0.71 - 0.71 -

Min. 34 24 Min. 34 24 Min. 34 24 Min. 34 24

(200- 250) (200 - 250) (200- 250) (200-250) (200 - 250) (200-250) (200 - 250) (200-250)

Max.80 Max.100 Max.50 100 Max.80 160

3.0 - 5.0 2.1 2.5 - 5.5 2.5 - 5.5 3.0 - 5.0 2.1 3.0 - 5.0 2.1

2.5 - 5.0 1.8 - - 2.5 - 4.5 1.8 2.5 - 5.0 1.8

Min. 1.5 0.7 Min. 1.0 0.7 1.5- 2.5 0.7 Min. 1.5 0.7

Min. 1.0 0.7 - - 1.0- 2.0 0.7 Min. 1.0 0.7

80-110 120 80-110 120 90-110 120 80-110 120

Max. 0.5 1.0 Max. 0.5 1 .o Max. 0.5 1.0 Max. 0.5 1.0

225;'; 200 225:'; 186 225:'; 186 225:'; 200

22 + 1 22 + 1 22 * 1 22* 1 22 * 1 22 + 1

0.75 It0.1 0.75 * 0.1 0.75 It0.1 0.75 * 0.1 0.9 f 0.15 0.9 * 0.15

1,440- 1,520 1,440- 1,520 1,605- 1,705 1,605- 1,705

13 lo-16 13 IO-16 10 8-12

6D125 SERIES
’2-ki35
 TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

I
Engine model 6D125-1

GD600R-3
Applicable machine model DTIOLE-1 GD605R-3
GD6 A-3
i- Standard Permissible Standard Permissible
Item Condition, etc. Unit
value value value value

High idling speed 2,050 - 2,150 - !,OOO- 2,100 2,000 - 2,100

rpm
Engine speed
Low idling speed 600 - 630 - 650 - 700 650 - 700
rpm

O’C rpm Min. 100 - Min. 100 -

Necessary
starting speed
-2o’C (with starting aid) rpm Min. 85 - Min. 85 -

Intake resistance At all speed mmH,O Max. 300 762 Max. 300 635

Intake pressure At rated output mmHg - - - -

Exhaust pressure - - - -
At rated output mmHg
(Turbine inlet pressure)
Exhaust temperature
All speed (20°C) ‘C Max. 620 Max. 700 Max. 600 Max. 650
(Turbine inlet temp.)
Quick acceleration
Max. 4.5 6.5 Max. 4.5 5.5
(Low idling - High idling)

Exhaust gas color At rated output

Bosch
Max. 4.5 5.5 - -
scale

At high idling Max. 2.5 3.5 Max. 1 .O 2.0

Intake valve mm 0.33 - 0.33 -

Valve clearance
(When engine is hot
or cold.) Exhaust valve mm 0.71 - 0.71 -

Oil temperature: 40 - 60°C kg/cm2 Min. 34 24 Min. 34 24

Compression pressure
(SAEBO oil)
(Engine speed) (rpm) (200 - 250) (200 - 250) (200 - 250) (200 - 250)

Blow-by pressure At rated output

nmH,O Max. 80 160 Max. 100 200
(SAE30 oil) (Water temperature: Min. 70°C)

SAE30 oil kg/cm2 3.0 - 5.0 2.1 2.5 - 5.5 2.5 - 5.5
At rated output
Oil pressure SAEIOW oil kg/cm2 2.5 - 4.5 1.8 - -
(Oil temperature:
Min. 80°C) SAE30 oil kg/cm2 Min. 1.5 0.7 Min. 1.O 0.7
At low idling
. SAEl OW oil kg/cm2 Min. 1.O 0.7 - -

Oil temperature All speed (oil in oil pan) “C 80- 110 120 80 - 110 120

At continuous rated output

Oil consumption ratio % Max. 0.5 1 .o Max. 0.5 1.0
(Ratio of fuel consumotion)

Fuel injection pressure Nozzle tester kg/cm2 225 :‘; 200 225 :‘; 186

Fuel injection timing B.T.D.C. degree 22 * IO 22 + 1 22 * 1 22 * 1

Opening pressure
Radiator pressure valve kg/cm2 0.7 * 0.10 0.7 * 0.1 0.75 f 0.1 0.75 * 0.1
(Differential oressure)

Fan speed At rated engine speed 1,360 - 1,440 -

rpm

Deflects when pushed with

Fan belt tension mm 13 lo- 16 13 lo- 16
a force of 6 kg

* The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

’2-o25-1 6D125 SERIES

TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

6D125-1

GD623A-l;GD663A-1 GD6
Standard Permissible Standard Permissible Standard Permissible
value value value value value value

2,350 - 2,450 2,000 - 2,100 2,000 - 2,100 2,050 - 2,150 2,050- 2,150

650 - 700 650 - 700 650 - 700 650-700 650 -700

Min. 100 - Min.100 - Min. 110 -

Min. 65 Min. 65 - Min.65 -

I - I
Max.300 762 Max.300 635 Max.300 635

- - - - - -

- - - - - -

Max.650 Max.700 Max.600 Max.650 Max.600 Max.650

Max.4.5 6.5 Max. 4.5 5.5 Max.4.5 5.5

Max. 3.0 4.0 - -

Max. 2.0 3.0 Max.1.0 2.0

0.33 - 0.33 -

0.71 - 0.71 -
I I
Min. 34 Min. 34 24

(200- 250) (200 -250) (200-250)

Max.60 160 Max.100 200

3.0 - 5.0 2.1 2.5 - 5.5 2.5 - 5.5 2.5 - 5.5 2.5- 5.5
2.5 - 4.5 1.8 - - -

Min.1.5 0.7 Min.l.O 0.7 Min. 1.0 0.7

Min.l.O 0.7 - _ - -

I
120 1 80-110 120

1.0

180

22 * 1

0.7 + 0.15 0.7 * 0.15 0.75 f 0.1

1,820- 1,914 -

10 a-12 13 lo-16 13

6D125 SERIES
’2-025-2
 TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

Engine model S6D125-1

Applicable machine model D60F08 D60F-8A

Classifi Permissible
Item Condition, etc. Unit
cation value

High idling speed rpm 2,200 - 2,300

8 Engine speed
6 Low idling speed rpm 600 - 630
E
b
Y 0°C rpm Min. 100 Min. 110 -
2 Necessary
starting speed
-20°C (with starting aid) rpm Min. 85 Min. 85 -

Intake resistance At all speed mmH,O Max. 300 635 Max. 300 635

Intake pressure At rated output mmHg - - - _

Exhaust pressure
At rated output mmHg - - _ -
(Turbine inlet pressure)
Exhaust temperature
All speed (2o’C) “C Max. 600 Max. 650 Max. 600 Max. 650
(Turbine inlet temp.)
Quick acceleration
Max. 4.5 5.5 Max. 4.5 5.5
(Low idling - High idling)

Exhaust gas color At rated output

Bosch - - - -
scale

At high idling Max. 1 .O 2.0 Max. 1 .O 2.0

(
Valve clearance Intake valve mm
(When engine is hot
or cold.) Exhaust valve mm

Oil temperature: 40 - 6o’C kg/cm2 22

Compression pressure
(SAE30 oil)
(Engine speed) @pm) (200 - 250)

Blow-by pressure At rated output

(SAE30 oil) (Water temperature: Min. 70°C)
mmH,O Max. 100 200 1 Max. 100 200

SAE30 oil kg/cm2 3.0 - 5.0 2.1 3.0 - 5.0 2.5 - 5.5
At rated output
Oil pressure SAEI OW oil kg/cm2 - - - -
(Oil temperature:
Min. 8o’C) SAE30 oil kg/cm2 Min. 1 .O 0.7 Min. 1.5 0.7
At low idling
SAEl OW oil kg/cm2 - - - -

Oil temperature All speed (oil in oil pan) ‘C 120

At continuous rated output

Oil consumption ratio % 1.0
(Ratio of fuel consumption)

Fuel injection pressure Nozzle tester kg/cm2 250 ;‘; 225 250 :‘; 225

Fuel injection timing B.T.D.C. degree 2611 / 26,l 1 2611 26 jz 1

Radiator pressure valve

Opening pressure
kg/cm2 -
(Differential pressure)

Fan speed At rated engine speed rpm 1,385 1,310 1,500 1,420

Deflects when pushed with

Fan belt tension
a force of 6 kg
mm 13 1 lo-16 1 13 10 - 16

* The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

’2-ii36 6D125 SERIES

TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

S6D125-1

D65EX-12
D75A-1
D65P, PX-12

Standard Permissible Standard Permissible Standard Permissible Standard Permissible

value value value value value value value value

2,050 - 2,150 2,050 - 2,150 2,150 - 2,250 2,150 - 2,250

800 - 850 800-850 600-630 600- 630

Min. 100 - Min. 100 -

Min.85 - Min.85 -

Max.300 762 Max.300 635

Min. 600 Max.480 Min.650 -

Min. 500 Max.400 Min. 700 -

Max.630 Max.700 Max.600 650

Max. 5.0 6.0 Max.4.5 6.5

Max. 1.5 2.5 Max. 1.5 2.5

Max. 1.0 2.0 Max. 1.0 2.0

0.9 * 0.15 0.9 It0.15 0.75 + 0.1 0.75 * 0.1

1,722- 1,828 1,722- 1,828 1,715- 1,805 1,715- 1,805

10 8-12 13 lo-16

6D125 SERIES
’2-ii37
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

Engine model S6D125-1

D83E-1
Applicable machine model D75S-5
D83P-1

Standard Permissible Standard Permissible

Item Condition, etc. Unit
value value value value

High idling speed rpm !,150 - 2,250 !,150 - 2,250 2,200 - 2,300 2,200 - 2,300
Engine speed
Low idling speed rpm 600 - 650 600 - 650 600 - 630 600 - 630

0°C rpm Min. 100 - Min. 100 _

Necessary
starting speed _
-20’C (with starting aid) rpm Min. 85 Min. 85

intake resistance At all speed mmH,O Max. 300 Max. 300 762

Intake pressure At rated output mmHg Min. 650 - Min. 550 350

Exhaust pressure -
At rated output mmHg Min. 700 Min. 500 300
(Turbine inlet pressure)
Exhaust temperature All speed (20°C) Max. 650 ’ 700
‘C Max. 600 Max. 650
(Turbine inlet temp.)
Quick acceleration Max. 4.5 6.5 Max. 4.5 6.5
Exhaust gas color (Low idling - High idling) Bosch
At rated output scale Max. 2.0 3.0 Max. 2.5 3.5
At high idling Max. 1 .O 2.0 Max. 2.0 3.0

Valve clearance Intake valve mm 0.33 - 0.33 _

(When engine is hot
or cold.) Exhaust valve mm 0.71 0.71 -

Compresion Oil temperature: 40 - 60°C kg/cm2 Min. 32 22 Min. 32 22

pressure
(SAE30 oil) (Engine speed) irpm) (200 - 250) (200 - 250) (200 - 250) (200 - 250)

Blow-by pressure At rated output

mmH,O Max. 150 Max. 150 300
(SAE30 oil) (Water temperature: Min. 70°C)

SAE30 oil kg/cm2 3.0 - 5.0 2.1 3.0 - 5.0 2.1

At rated output SAEl oW oil
kg/cm2 2.5 - 4.5 1.8 2.5 - 4.5 1.8
Oil pressure
(Oil temperature:
Min. 80X) SAE30 oil kg/cm? Min. 1.3 1.5 - 2.5 0.7
At low idling
SAElOW oil kg/cm? Min. 0.8 1 .o - 2.0 0.7

Oil temperature All speed (oil in oil pan) “C 80- 110 120

At continuous rated output

Oil consumption ratio % Max. 0.5 Max. 0.5 1.0
(Ratio of fuel consumotion)

E Fuel injection pressure Nozzle tester kg/cm* 250:‘: 205 250 ‘2; 225
‘0,
zt;
l?$- Fuel injection timing B.T.D.C degree 26 zt 1 26* 1 26 * 1 26 * 1

Opening pressure
Radiator pressure valve kg/cm2 0.75 * 0.1 0.75 * 0.1 0.75 f 0.1
(Differential oressure)

Fan speed At rated engine speed rpm 1,170 - 1,230 1,170 - 1,230 1,648 - 1,748 1,648 - 1,748

Deflects when pushed with a

Fan belt tension mm 10 - 16 IO- 16
force of 6 kg

* The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

6D125 SERIES
’2-:38
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

S6Dl25-1

PC300-3,PC300NLC-3 PC300-3,PC300NLC-3
D85A-21, D85P-21
PC3OOLC-3 PC3OOLC-3 PC36OLG3
D85E-21 (B)
No. 10001 - 20727)
(Serial (Serial
No. 20728 and up)
Standard Permissible Standard Permissible Standard 1 Permissible Standard Permissible
value value value value value value

2,150 - 2,250 2,150 - 2,250 1,675- 1,725 1,675- 1,725 1,650- 1,750 1,650- 1,750

650- 700 650- 700 625 - 675 625-675 725- 745 725 - 745 650- 700 650- 700

Min. 100 _ Min.100 - Min. 100 Min.100 -

Min. 85 - Min. 85 - Min. 85 - Min. 85 -

Max.300 635 Max.300 635 Max.300 635 Max.300 635

Min. 550 350 Min. 710 - Min. 710 - Min. 710

Min. 500 300 Min. 530 - Min. 530 Min. 530 -

Max.650 Max.650 Max.650 Max.650 Max.650 Max.650 Max.650 -

Max. 5.0 7.0 Max. 4.5 5.5 Max. 4.5 5.5 Max.4.5 5.5

Max. 2.0 3.0 Max. 1.5 2.5 Max.1.5 2.5 - _

Max. 1.0 2.0 Max. 1.0 2.0 Max. 1.0 2.0 Max. 1.0 2.0

0.33 _ 0.33 - 0.33 - 0.33 _

t
0.71 - 0.71 - 0.71 - 0.71 _

Min. 32 22 Min. 32 22 Min. 32 22 Min. 32 22

(200-250) (200- 250) (200-250) (200-250) (200- 250) (200- 250)

t
Max.150 I 300 Max.150 300 Max.150 300
-
t
1.9 2.7- 5.0 1.9 2.7 - 5.0 1.9
1.8 2.5- 4.5 1.8 2.5 - 5.5 1.8

0.7 Min. 1.2 0.7

0.7 Min. 1.0 0.7

120

1.0 Max. 0.5 1.0

I
205 250i10 200

24 k 1 I 24+1 1 20_+1 22 * 1

0.75 + 0.1 0.75 * 0.1 0.75 i 0.1 0.75 i 0.1

925- 975 925- 975 1,315 f 35 1,315* 35

13 lo-16 6.5 5 - 8.5 6.5 1 5-8.5

6D125 SERIES
’2-:39
 TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

Engine model S6D125-1

PC400-3 PC400-5
Applicable machine model
t PC4OOLC3 PC4OOLG5

Classifi Standard Permissible Standard Permissible

Condition, etc. Unit
cation value value value value

High idling speed rpm !,150 - 2,250 2,150 - 2,250 2,150 - 2,250 2,150 - 2,250
Engine speed
Low idling speed rpm 600 - 700 600 - 700 600 - 700 600 - 700

0°C Min. 100 - Min. 100 -

rpm
Necessary
starting speed
-2o’C (with starting aid) Min. 85 - Min. 85 -
rpm

Intake resistance At all speed nmH,O Max. 300 635 Max. 300 762

Intake pressure At rated output mmHg Min. 800 _ Min. 800 _

Exhaust pressure - -
At rated output mmHg Min. 600 Min. 600
(Turbine inlet pressure)
Exhaust temperature
All speed (209 “C Max. 650 Max. 650 Max. 650 700
(Turbine inlet temp.)
Quick acceleration
Max. 5.0 6.0 Max. 5.0 7.0
(Low idling - High idling)
Bosch -
Exhaust gas color At rated output Max. 1.5 Max. 1.5 2.5
scale

At high idling Max. 1.O 2.0 Max. 1.0 2.0

Intake valve mm 0.33 - 0.33 -

Valve clearance
(When engine is hot
or cold.) Exhaust valve mm 0.71 - 0.71 _

Oil temperature: 40 - 6o’C kg/cm2 Min. 32 22 Min. 32 22

Compression pressure
(SAE30 oil)
(Engine speed) @pm) (200 - 250) (200 - 250) (200 - 250) (200 - 250)

Blow-by pressure At rated output

nmH,O Max. 150 300 Max. 80 160
(SAE30 oil) (Water temperature: Min. 7o’C)

SAE30 oil kg/cm2 3.0 - 5.0 2.1 3.0 - 5.0 2.1

At rated output
Oil pressure SAEI OW oil kg/cm2 2.5 - 4.5 1.8 2.5 - 4.5 1.8
(Oil temperature:
Min. 8o’C) SAE30 oil kg/cm2 Min. 1.2 0.7 Min. 1.5 0.7
At low idling
SAEIOW oil kg/cm* Min. 1.0 0.7 Min. 1 .O 0.7

Oil temperature All speed (oil in oil pan) “C 80- 110 120 80- 110 120

At continuous rated output

Oil consumption ratio % Max. 0.5 1 .o Max. 0.5 1.0
(Ratio of fuel consumption)

Fuel injection pressure Nozzle tester kg/cm2 250 :‘; 205 250 z’s 205

Fuel injection timing B.T.D.C. degree 22 + 1 22 * 1 24 * 1 24 f 1

Opening pressure
Radiator pressure valve kg/cm2 0.75 i 0.1 0.75 * 0.1 0.5 f 0.1 0.5 f 0.1
(Differential oressure)

Fan speed At rated engine speed rpm 1,460 - 1,540 1,460 - 1,540 1,460 - 1,540 1,460 - 1,540

Deflects when pushed with

Fan belt tension mm 6.5 4.5 - 8.5 6.5 4.5 - 8.5
a force of 6 kg

* The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

’2-:40
6D125 SERIES
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

S6D125-1

HA250
HA270 I
I

Standard Permissible Standard Permissible Standard

value value value value value

2,550 - 2,650 2,550- 2,650

650 - 700 650-700

Min.100

Min. 85

Max.300 )jl
_

Max.650

Max. 6.0

Max. 1.5

Max. 1.0

0.33 -

0.71 -

Min. 32 22

(200 - 250) (200-250)

Max.100 160

3.0 - 5.0 2.1

2.5- 4.5 1.8

Min.1.5 0.7

Min.l.O 0.7

80-110 120

Max. 0.5 1.o

250:'; 205

20 + 1 20 + 1

0.5 f 0.1 0.5 zk0.1

2,160 - 2,240 _

13 lo-16

6D125 SERIES
’2-oio-1
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

S6D125-1

Standard
HD200D-3

Permissible
T Standard
HD205-3

Permissible
T Standard
WA450-1

Permissible
I
WA470-1

value value value value value value

2,350- 2,450 2,350 - 2,450 2,350 - 2,450 2,350- 2,450 2,350 - 2,450 2,350 - 2,450

650- 700 650- 700 700-750 700-750 700-750 700-750

Min.100 - Min.100 - Min. 100

Min. 85 - Min.85 Min. 85 -

Max.300 635 Max.300 635 Max.200 635 Max.300 762

Min.800 600 Min.800 600 Min. 600 550 Min.800 -

Min. 750 550 Min.750 550 Min. 550 Min. 750 -

Max.650 Max.650 Max.650 Max.650 Max.630 Max.630 700

Max. 7.0 8.0 Max. 4.5 5.5 Max. 5.0 5.5 Max. 6.0 8.0

Max. 2.0 3.0 Max. 2.0 3.0 - - Max. 2.5 3.5

Max. 2.0 2.5 Max. 2.0 2.5 Max. 1.0 2.0 Max.l.5 2.5

0.33 _ 0.33 - 0.33 0.33 -

0.71 - 0.71 - 0.71 0.71 -

Min. 32 22 Min. 32 22 Min. 32 22 Min. 32 22

(200- 250) (200- 250) (200 - 250) (200-250) (200- 250) (200-250) (200- 250) (200 - 250)

Max.100 200 Max.100 200 Max.150 300

3.0- 5.0 2.1 3.5 - 5.5 2.4 3.0 - 5.0 2.1

2.5- 4.5 1.8 - - - -

Min. 1.5 0.7 Min. 1.5 0.7 Min. 1.5 0.7

Min. 1.0 0.7 Min. 1.0 0.7 - -

80-110 120 80-110 120 80 -110 120

Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0

250:'; 205 25O:l; 205 250:'; 250:'; 225

24il 24 i 1 24 zk1 24k 1 24 + 1 24 zk1 24 f 1 24ztl

0.49 i 0.1 0.49 f 0.1 0.49 * 0.1 0.49 + 0.1 0.75 + 0.1 0.75 * 0.1 0.75 * 0.1 0.75 * 0.1

1,304- 1,384 - 1,344 * 40 1,344 * 40 1,320k 35 1,320+ 35 1,395- 1,465 1,395 - 1,465

10 8-12 10 8-12 10 7-13 10 7-13

6D125 SERIES 12-;4 1

 TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

Engine model S6Dl.z1

Applicable machine model

Standard
WF450T-1

Permissible
T Standard
GD705A-4

Permissible
Item Condition, etc. Unit
value value value value

High idling speed rpm 2,400 - 2,450 2,400 - 2,450 2,150 - 2,250 !,I 50 - 2,250
Engine speed
Low idling speed rpm 700 - 750 700 - 750 775 - 800 775 - 800

0°C vm Min. 100 - Min. 100 -

Necessary
starting speed
-20°C (with starting aid) rpm Min. 65 - Min. 65 -

Intake resistance At all speed mmH,O Max. 300 762 Max. 300 635

Intake pressure At rated output Min. 600 550 Min. 650 -

Exhaust pressure _ -
At rated output Min. 550 Min. 700
(Turbine inlet pressure)
Exhaust temperature
Max. 630 Max. 700 Max. 600 Max. 650
(Turbine inlet temp.)
Quick acceleration
Max. 5.5 7.5 Max. 3.0 5.5
(LOW idling - High idling)

Exhaust gas color Max. 2.5 3.5 _ -

Max. 1.0 2.0 Max. 1 .O 2.0

Intake valve mm 0.33 _ 0.33 _

Valve clearance
(When engine is hot
or cold.) Exhaust valve mm 0.71 - 0.71 -

Oil temperature: 40 - 6o’C kg/cm2 Min. 32 22 Min. 32 22

Compression pressure
(SAE30 oil)
(Engine speed) (rpm) (240 - 260) (240 - 260) (240 - 260) (240 - 260)

Blow-by pressure At rated output

Max. 60 160 Max. 150 200
(SAE30 oil) (Water temperature: Min. 70X) mmHzo
I
SAE30 oil kg/cm2 3.0 - 5.0 2.1 3.0 - 5.0 2.1
At rated output
Oil pressure SAEl OW oil kg/cm2 2.5 - 4.5 I .a _ -
(Oil temperature:
Min. 60°C) SAE30 oil kg/cm2 Min. 1.5 0.7 Min. 1.5 0.7
At low idling
SAEI OW oil kg/cm2 Min. 1 .O 0.7 - -

Oil temperature All speed (oil in oil pan) “C 80-110 120 80-110 120

Oil consumption ratio Max. 0.5 1 .o Max. 0.5 1.0

Fuel injection pressure 250:‘; 205 250:‘; 225

Fuel injection timing 24 zt 1 24 + 1 26 * 1 26 zt 1

Opening pressure 0.7 f 0.1 0.7 * 0.1 0.75 * 0.1 0.75 * 0.1
Radiator pressure valve kg/cm2
(Differential oressure)

Fan speed 1,720 - 1,600 1,720 - 1,600 1,950 - 2,050 1,950 - 2,050

Fan belt tension 10 a-12 13 lo- 16

* The values givenin the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

’2-ii42 6D125 SERIES

TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

S6D125-1

T
EG220-I,2
EC2607_-1 EG200-3 EG220B-1,2
EG220BSI,2
Standard Permissible Standard Permissible Standard Permissible Standard Permissible
value value value value value value value value
2 250 _ 2 350 Max.1,560
(50Hz) Max.1.575
(50Hz dax.1.560
(50Hz) Max.1.560(50
Hz)
2,250 - 2,350
(60Hz) Max.1.890
Max.1.872 (60Hz rlax.1,872
(60Hz) Max.1,872
(60Hz)

975 - 1,025 975-1,025 ) - 1 - 700 - 800 700-800

Min. 100 Min. 100 -

Min. 85 Min. 85 -

Max.300 Max.300 762

- - _ - Min.570(50Hz)

- - I - / - Min.740(60Hz)
Min.410(50Hz)
Min.590(60Hz)
-

Max.600 Max.650 Max.600 700

~-
Max.4.5 5.5 / Max.4.5 1 Moe
- - I _ I -

Max. 1.0

0.33

0.71 - / 0.71 ( -

Min. 32 22 Min. 32 22

(200- 250) (200 - 250) (200-250) (200- 250) (200 - 250) (200- 250)
! 1
I I I
Max.150 300 Max.80 160 Max.80 160

2.5- 5.5 2.1

2.5- 4.5(50Hz) 1.8
2.5 - 5.5 3.0 - 5.0 2.1
3.0- 5.0(60Hz)
_ - 2.5 - 4.5 i.a

Min. 1.0 0.7 Min.1.5 0.7

- - Min. 1.0 0.7 Min.l.O 0.7

80-110 120 1 80-110 ) 120

Max. 0.5

250:';

26k 1 - 1 22*1 1 -

0.75 * 0.1

1,620+ 40

10 7-13 13 IO-16

6D125 SERIES
’2-ii43
 TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

Engine model SAGDI 25-1

1 EG275-1,2
Applicable machine model D135A-1 EG275B-I,2
EG275BS1.2

Classifi- Standard Permissible Standard Permissible

Condition, etc. Unit
cation value value value value
lax. 1,560 (50 Hz) (ax. 1,560 (50 Hz)
High idling speed rpm 2,150 - 2,250 2,150 - 2,250
lax. 1,872 (60 Hz) flax. 1,872 (60 Hz)
Engine speed
Low idling speed rpm 650 - 700 650 - 700 700 - 800 700 - 800

0°C wm Min. 100 - Min. 100 -

Necessary
starting speed
-20°C (with starting aid) rpm
Min. 85 - Min. 85 -

Intake resistance At all speed mmH,O Max. 300 762 Max. 300 762

Min. 800 (50 Hz) -

Intake pressure At rated output mmHg Min. 750 600
nin. 1,020 (60 Hz)
Exhaust pressure Min. 530 (50 Hz) -
At rated output mmHg Min. 600 480
(Turbine inlet pressure) Min. 770 (60 Hz)
Exhaust temperature Max. 650 700 700
All speed (20°C) “C Max. 650
(Turbine inlet temo.1
Quick acceleration Max. 5.0 7.0 Max. 9.0 -
(Low idling - High idling)
I
Bosch
Exhaust gas color At rated output Max. 2.0 3.0 Max. 2.5 3.5
scale

At high idling Max. 1.5 2.5 Max. 2.0 3.0

Intake valve mm 0.33 - 0.33 -

Valve clearance
(When engine is hot
or cold.) Exhaust valve mm 0.71 _ 0.71

Oil temperature: 40 - 60°C kg/cm2 Min. 30 21 Min. 32 22

Compression pressure
(SAE30 oil)
(Engine speed) (rpmj (200 - 250) (200 - 250) (200 - 250) (200 - 250)

Blow-by pressure At rated output Max. 100 200 Max. 100

(SAE30 oil) (Water temperature: Min. 70°C) mmHzo
2.5 - 4.5 150Hz1 1.8
kg/cm2 3.0 - 5.0 2.1
At rated output SAE30 Oil 3.0 - 5.0 (60 Hz) 2.1
Oil pressure 2.0 - 4.0 (50 Hz) 1.4
SAEl OW oil kg/cm2 2.5 - 4.5 1.8
(Oil temperature: 1.5 - 4.5 (60 Hz) 1.8
Min. 8o’C) SAE30 oil kg/cm’ Min. 1.5 0.7 Min. 1.O 0.7
At low idling
SAEl OW oil kg/cm2 Min. 1 .O 0.7 Min. 1 .O 0.7

Oil temperature 80-110 120 80 - 110 120

Oil consumption ratio Max. 0.5 1 .o Max. 0.5 1 .o

Fuel injection pressure 250 :‘O

-r5 225 250 :‘; 205

Fuel injection timing 22 f 1 22 + 1 22 * 1 22 It 1

0.7 + 0.1 0.7 i 0.1

Radiator pressure valva 1.0 + 0.15 1 .o f 0.15
j.39 i 0.1 (BS 1.39 + 0.1 (BS)
1,365*34 (50 Hz’
Fan speed 1,072 - 1,138 1,072 - 1.13E
I,638+40 (60 Hz
Fan belt tension 10 8- 12 10 8- 12
a force of 6 kg

t The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.

’2-:44
6D125 SERIES
 TROUBLESHOOTING
Points to remember when troubleshooting . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 12-047
Method of using troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._.................................... 12-048

S-l Starting performance is poor (Starting always takes time) .............................................................. 12-052

s-2 Engine does not start

@ Engine does not turn .............................................................................................................. 12-053
0 Engine turns but no exhaust gas comes out (Fuel is not being injected) ..................................... 12-054
@ Exhaust gas comes out but engine does not start (Fuel is being injected) ................................... 12-055

s-3 Engine does not pick up smoothly (Follow-up is poor) .................................................................... 12-056

s-4 Engine stops during operations ..................................................................................................... 12-057

s-5 Engine does not rotate smoothly ................................................................................................... 12-058

S-6 Engine lacks output (no power) ..................................................................................................... 12-059

s-7 Exhaust gas is black (incomplete combustion) ................................................................................ 12-060

S-8 Oil consumption is excessive (or exhaust gas is blue) ..................................................................... 12-061

s-9 Oil becomes contaminated quickly ................................................................................................ 12-062

S-IO Fuel consumption is excessive ...................................................................................................... 12-063

S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 12-064

s-12 Oil pressure lamp lights up (drop in oil pressure) ........................................................................... 12-065

s-13 Oil level rises ............................................................................................................................... 12-066

s-14 Water temperature becomes too high (overheating) ....................................................................... 12-067

S-l 5 Abnormal noise is made ............................................................................................................... 12-068

S-16 Vibration is excessive ................................................................................................................... 12-069

6D125 SERIES
’2-:45
 TESTING AND ADJUSTING TROUBLESHOOTING

A When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit safety
pins, block the wheels, and apply the parking brake.

A When carrying out operations with two or more workers, always use signals, and do not allow any unau-
thorized person near the machine.

A When checking the water level, if the radiator cap is removed when the engine is hot, boiling water will
spurt out and may cause burns, so always wait for the engine to cool down before checking the water
level.

A Be extremely careful not to touch any hot parts.

A Be extremely careful not to get caught in the fan or any other rotating parts.

Y Y

‘! When
release
removing
the internal
the plugs
pressure
or caps
first.
from
Fit the
places
measuring
under hydraulic
tools securely
pressure,
before
water
carrying
pressure,
out any
or air pressure,
testing, adjust-
ing, or troubleshooting.

* When using the standard values table for judgement in testing, adjusting, or troubleshooting, it is necessary to
be careful of the following points.
1. The standard values for the new machines in the standard values table are values given as reference from the
standards for new machines and machines shipped from the factory. They should be used as values for esti-
mating wear during operation or as target values when carrying out repairs.
2. The failure judgement standard values in the standard value table are values using estimated values based on
the results of various tests and standard values for machines shipped from the factory. Use these values for ref-
erence together with the repair and operation history of the machine when judging failures.
3. Do not use this standard values table as a standard for judging claims.

’2-:46
6D125 SERIES
TESTING AND ADJUSTING TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs, and ensuring that the
failure does not occur again.
When carrying out troubleshooting, it is of course important to understand the structure and function. But to
carry out the troubleshooting effectively, a quick method is to carry out troubleshooting using the problems
mentioned by the operator as a guide in locating the cause
4. Confirming failure
1. Do not disassemble the machine simply be- Check the degree of the problem to judge for
cause there is a failure yourself if it is really a failure, or if there is some
If the machine is disassembled immediately just problem in the handling or operation of the ma-
because there is a fuilure: chine.
l Unrelated or unnecessary places are also dis- * When driving the machine and re-enacting
assembled the failure, be sure that the investigation or
. It becomes difficult to locate the cause of the measurement does not make the failure
failure worse.
This means that there is not only a waste of time
and money on replacement parts, oil, and grease, 5. Troubleshooting
but this action will also lose the confidence of the Narrow down the causes of the failure from the
user and operator. results of the questions and checks in the above
For this reason also, it is important to carry out Items 2 - 4, then follow the troubleshooting flow
troubleshooting based on full investigation before chart to locate the failure.
starting and troubleshooting following the correct * Basic procedure for troubleshooting
order. 1) Start from the simple places.
2) Start from the most probable places.
2. Questions to ask the user and operator 3) Investigate related parts also.
1) Are there any problems other than those al-
ready reported? 6. Basic action to remedy cause of failure
2) Did anything unusual happen before the fai- Even if the failure is repaired, if the root cause of
lure occurred? the failure is not repaired, the same failure will oc-
3) Did the failure occur suddenly, or had the cur again.
condition of the machine been poor before To prevent this, it is necessary to investigate why
the failure occurred? the failure occurred, and to remove the root
4) What were the conditions when the failure oc- cause of the failure.
curred?
5) Had any repairs been carried ot before the fai-
lure occurred?
6) Had any similar failure occurred before?

3. Checks before troubleshooting

1) Check the oil level.
2) Check for any external leakage of oil from the
piping and hydraulic equipment.
3) Check the travel of the control levers.
4) Other maintenance items can also be carried
out visually, so carry out any check that is
considered necessary.

6D125 SERIES 12-047

TESTING AND ADJUSTING TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three
sections: questions, check items, and troublesh-
ooting. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection
without using.troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.

[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in @ are
items’ that can be obtained from the user,
/ Causes /
depending on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @I that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].

(b)
(d

1! I /I (e) IO

6D125 SERIES
’*-g4*
TESTING AND ADJUSTING TROUBLESHOOTING

The basic method of using the troubleshooting chart is as

follows.
items listed for [Questions] and [Check items] that have a
relationship with the Cause items are marked with 0, and
of these, causes that have a high probability are marked
with 0.
Check each of the [Questions] and [Check items] in turn,
and marked the 0 or 0 in the chart for items where the
problem appeared. The vertical column (Causes) that has
the highest number of points is the most probable cause,
so start troubleshooting for that item to make final confir-
mation of the cause.
%I. For [Confirm recent repair history] in the [Ques-
tions] Section, ask the user, and mark the Cause

3
column with A to use as reference for locating
the cause of the failure. However, do not use this
when making calculations to narrow down the
causes.
%2. Use the A in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference. As a rule, do not
use it when calculating the points for locating the
cause, but it can be included if necessary to deter-
mine the order for troubleshooting.

Xl Confirm recent repair history

3%2 Degree of use Operated for long period A A A

6D125 SERIES
’2-iii49
TESTING AND ADJUSTING TROUBLESHOOTING

- Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weak-
er], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

S-7 Exhaust gas is black (incomplete combustion) in

’2-:50 6D125 SERIES

TESTING AND ADJUSTING TROUBLESHOOTING

Step 1

Clarify the relationship between the three symptoms

in the [Questions] and [Check items] section and
the five Cause items in the vertical column.

Three symptoms
A 1. A

Step 2

Add up the total of 0 and 0 marks where the hori-

zontal lines for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element: DO@
(2) Air leakage between turbocharger and
head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0

\7 Step 3

The calculations in Step 2 show that the closest

relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item marked
0. The Remedy is given as [Clean], so carry out
cleaning, and the exhaust gas color should return
to normal.

6D125 SERIES 12-p

TESTING AND ADJUSTING TROUBLESHOOTING

S-l Starting performance is poor (Starting always takes time)

General causes why starting performance is poor
. Defective electrical system
. Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel Legend
0~_: Possible causes (judging from Questions and check items)
(At ambient temperature of -10°C or below, use
: Most probable causes (judging from Questions and Check items)
ASTM D975 No. 1, and -10°C or above, use ASTM a : Possible causes due to length of use (used for a long period)

D975 No. 2 diesel fuel.) 0 : items to confirm the cause.

* Battery charging rate.

The specific gravity should exceed the value for the charging rate
of 70% in the above table.
In cold weather the specific gravity must exceed the value for the
charging rate of 75% in the above table.

I I I I I I.1

I I I I I I I I

’2-:52 6D125 SERIES

TESTING AND ADJUSTING TROUBLESHOOTING

S-2 Engine does not start

@ Engine does not turn

General causes why engine does not turn

* Internal parts of engine seized
* If internal parts of the engine are seized, carry
outtroubleshooting for “Engine stops during
operations”.
. Failure in power train
. Defective electrical system

Legend
0 : Possible causes liudaina from Questions and check items)
: Most probable caus& (judging from Questions and Check items1
a : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.

Confirm recent repair history

Degree of use Operated for long period a a

Condition of horn when starting Horn does not sound _ 0 0

switch is turned ON Horn sound level is low z

When starting switch is

turned to START, pinion

moves out, but

When starting switch is turned to ON, there is no clicking sound

Battery terminal is loose

When startlng switch IS turned to ON, linkage does not move

When batterv is checked. batterv electrolvte is found to be low

-

connect the cord, and carry out troubleshootIng at ON

‘Z
F
8
f
2
s
z

en ring gear IS jnspec e

6D125 SERIES
’2-:53
TESTING AND ADJUSTING TROUBLESHOOTING

0 Engine turns but no exhaust gas comes out

(Fuel is not being injected)

General causes why engine turns but no exhaust gas

comes out
. Supply of fuel impossible
. Supply of fuel is extremely small
. Improper selection of fuel (particularly in winter)

Standards for use of fuel

Ambient temperature

Type of fuel -22 -4 14 32 50 68 86 104 122°F

-30 -20 -10 0 10 20 30 40 50°C

Leaend
0 y Possible causes (judging from Cluestions and check items)
b:o : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)

Check injection pump directly 1.1 1 1 / 1 I j I j 1

I When

return
control rack is pushed, it is found to be heavy, or does not
a
I
Check feed pump directly

When fuel filter, strainer are inspected directly, they are found to be

-
cino”ed
-zz--

When feed pump strainer is inspected directly, it is found to be

clogged

When fuel cao is insoected directlv. it is found to be cloaaed 0

Does not move even when fuel cut solenoid linkage is disconnected 0

Does not move even when engine stop motor linkage is disconnected *

z z E L - $ g g
Remedy s s $ p
$ $ d

’2-Y4 6D125 SERIES

TESTING AND ADJUSTING TROUBLESHOOTING

0 Exhaust gas comes out but engine does not

start I causes I
(Fuel is being injected)

General causes why exhaust gas comes out but

engine does not start
. Lack of rotating force due to defective electri-
cal system
. Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel

Legend
0 : Possible causes (judging from Questions
and check items)
;l’ : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.

6D125 SERIES
TESTING AND ADJUSTING TROUBLESHOOTING

S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick up
smoothly
. Insufficient intake of air
I I
. Insufficient supply of fuel
. Improper condition of fuel injection
. improper fuel used

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)

There is hunting from engine (rotation is irregularJ

When exhaust manifold is touched immediately after starting engine,

rrr 0
temperature of some cylinders is low

Blow-by gas is excessive 2

When air element is inspected directly, it is found to be clogged 0

When fuel filter, strainer are inspected directly, they are found to be
0
clogged

When feed pump strainer is inspected directly, it is found to be clogged 0

01 Speed of some cylinders does not change when operating on reduced

.g
8
f
2
‘:
e
k
When valve clearance is checked directly, it 1s oun

When feed pump is operated, operation is too light or too heavy l

’2-:56
6D125 SERIES
TESTING AND ADJUSTING TROUBLESHOOTING

S-4 Engine stops during operations

General causes why engine stops during
operations
. Seized parts inside engine
. Insufficient supply of fuel
. Overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
. Failure in power train
* If the engine stops because of a failure in
the power train, carry out troubleshooting
for the chassis.

Legend
0 : Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)

Condition when engine

stopped

Try to turn by hand using

6D125 SERIES
TESTING AND ADJUSTING TROUBLESHOOTING

S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
* Air in fuel system
* Defective governor mechanism
* Defective engine throttle controller mechanism
(engine throttle controller type)
* If there is no hunting when the engine throttle
controller rod is disconnected, carry out trou-
bleshooting for the electrical system.

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)

Condition of hunting

2) No response, light, return is normal

C
Engine speed sometimes rises too high $ 0
t:
_F Engine is sometimes difficult to stop Q $
v
Seal on injection pump has come off Q Q

1 When sovernor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be improperly

adiusted 1 /*I I I I I I I I
When control rack is pushed, it is found to be heavy, or does not return 0

When fuel cap is inspected directly, it is found to be clogged 0 0

When feed pump strainer is inspected directly, it is found to be

a
clogged

When fuel filter, strainer are inspected directly, they are found to be

clogged

12-g58 6D125 SERIES

TESTING AND ADJUSTING TROUBLESHOOTING

S-6 Engine lacks output (no power)

General causes why engine lacks output
Insufficient intake of air
Insufficient supply of fuel
Improper condition of fuel injection
Improper fuel used
(if non-specified fuel is used, output drops)
Lack of output due to overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.

Legend
0 : Possible causes (judging from Questions and check items)
,.’ : Most probable causes (judging from Questions and Check items]
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.

Replacement of filters,has not been carried out according to operation

Color of exhaust gas

When air element is inspected directly, it is found to be clogged

When control rack is pushed, it is found to be heavy, or does not return

When valve clearance is checked directly, it is found to be

l
outside standard value

When lever is olaced at FULL oosition. it does not contact stoooer l

When feed pump is operated, operation is too light or too heavy 0

When fuel cap is inspected directly, it is found to be clogged 0

0 ; L z z z ;; .L
5 : E ‘rn 2 6
Remedy 8 = E 2 y g LI 5 $ 5 z 2
$$UQU$< $<c?U

6D125 SERIES
’2-:59
TESTING AND ADJUSTING TROUBLESHOOTING

S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel

Legend
0 : Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)

1 When turbocharaer is rotated bv hand. it is found to be heavv I.1 I I I I I I I I I I

‘Z
F
8
5
z
:
F When valve clearance is checked directly it is found to be outside
l
standard value

When muffler is removed, exhaust gas color returns to normal 0

When control rack is pushed, it is found to be heavy, or does nOtreturn l

’*-PO
6D125 SERIES
TESTING AND ADJUSTING TROUBLESHOOTING

S-8 Oil consumption is excessive (or exhaust gas is blue)

* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is excessive
. Abnormal combustion of oil
. External leakage of oil
. Wear of lubrication system

Legend
0 : Possible causes (judging from Questions and check items)
(judging from Questions and Check items)
gth of use (used for a long period)

When compression pressur

6D125 SERIES
TESTING AND ADJUSTING TROUBLESHOOTING

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper combustion
. Improper oil used
. Operation under excessive load

Legend
0 : Possible causes (judging from Questions and check items)
!.Z : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.

’2-Y2 6D125 SERIES

TESTING AND ADJUSTING TROUBLESHOOTING

S-l 0 Fuel consumption is excessive

General causes why fuel consumption is exces-
sive
. Leakage of fuel
. Improper condition of fuel injection
. Excessive injection of fuel

Legend
0 : Possible causes (judging from Questions and check items)
_: Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.

More than for other machines

Condition of fuel consumption

Exhaust gas color

I Enaine low idlina weed is hiah lol I I I I I I ‘$3I

6D125 SERIES
’2-F3
TESTING AND ADJUSTING TROUBLESHOOTING

S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system

Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
a : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
Confirm recent repair history

I 1 Oil level ^ II

f When hydraulic oil, torque converter, transmission oil is drained,

$4
0
water is found

’2-P4 6D125 SERIES

TESTING AND ADJUSTING TROUBLESHOOTING

S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubricating system
. Defective oil pressure control
* Improper oil used (improper viscosity)
1 Deterioration of oil due to overheating

* Standards for use of fuel

Selection of oil SAE number according
to ambient temperature
Type of oil
-22 -4 14 32 50 68 86 104 122°F
-30 -20 -10 0 10 20 30 40 5o’c

Legend
es (judging from Questions and check items)
uses (judging from Questions and Check items)
gth of use (used for a long period)

Condition when oil pressure

6D125 SERIES 12-065

0
TESTING AND ADJUSTING TROUBLESHOOTING

S-13 Oil level rises

* If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
. Water in oil (cloudy white)
* Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component

Legend
0 : Possible causes (judging from Questions and check items)
d : Most probable causes (judging from Questions and Check items)
a : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.

number of bubbl

Water pump breather hole is clogged with mud

When water pump breather hole is clean, water comes out

Oil level goes down in clutch, TORQFLOW transmission,

or damper chamber

Oil level goes down in hydraulic tank I I I I I I <<>

I I I I I I
Engine oil smells of diesel fuel

Fuel is added more frequently

1 Pressure-tiohtness test of oil cooler shows there is leakaae I.1 II I III1 III
Pressure-tightness test of cylinder head shows there is leakage 1 1.1 1 1 1 ) 1 I I j
When comoression oressure is measured. it is found to be low I I I.1 I I I I I I I
Removewater pump and check directly 1 I.1 I ( I 1 I j
Check rear seal directlv I I I I I.1 I I I I I
1 When pump auxiliary equipment is removed, seal is found to be broken 1 I I I I I.1 I I I I I
1 Remove head cover and check directlv I I I I I I I.1 I I I I
Remove injection pump and check directly 1 1.1 I j
There is imorooer contact of thermostat seat valve I I I I I I I I I.1 I
/ Remove oil pan and check directly
I I I I I I I I I I*l.I

’v4 6D125 SERIES

TESTING AND ADJUSTING TROUBLESHOOTING

S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes
too high
. Lack of cooling water (deformation, damage of
fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
. Rise in oil temperature of power train
* Carry out troubleshooting for chassis.

Legend
0 : Possible causes (judging from Questions and check items)
:b : Most probable causes (judging from Questions and Check items)
a : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.

F
$
: Water temperature gauge
6

/
/

C
5 Radiator shroud, inside of underguard are clogged with dirt or mud
I
When light bulb is held behind radiator, no light passes through
::

2 Water IS leaking because of cracks in hose or loose clamps 8

u
Belt tension is found to be slack Q

Power train oil level enters red range before engine water temperature 0

Temperature difference between top and bottom radiator tanks is

I.1 I I I I I I I I I I

Remove oil pan and check directly

6D125 SERIES 12-067

TESTING AND ADJUSTING TROUBLESHOOTING

S-l 5 Abnormal noise is made

t Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
* Abnormal combustion noise
. Air sucked in from intake system

Legend
Q : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)

must be added more frequently I I I I I I I I

Blue under light load

Metal particles are found in oil filter !‘J (3

Blow-by gas is excessive (3

Noise of interference is heard from around turbocharger 0

En_
qine oickup is poor and combustion is irregular I I I I0 I I I I I I I n I

When exhaust manifold is touched immediately after starting engine.

temperature of some cylinders is low

C Seal on injection pump has come off \:a

I
Abnormal nscise is loud when accelerating engine I I I lolwwolol I
Clanging sound is heard from around cylinder head

Leakage i
of 3ir between turbocharger and head, loose clamp I I I I I I I I I I ICI
Vibrating noise is heard from around muffler

r .ed. it is found to be low

I standard value
I

I -Remove cylinder head cover and check directly I I.1 I ILI

’2-F8 6D125 SERIES

TESTING AND ADJUSTING TROUBLESHOOTING

S-l 6 Vibration is excessive

+ If there is abnormal noise together with the
vibration, carry out troubleshooting for “Abnor-
mal noise is made”.
General causes why vibration is excessive
* Defective parts (abnormal wear, breakage)
- Improper alignment
. Abnormal combustion

Legend
0 : Possible causes (judging from Questions and check items)
,: : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
I / / I / I I I /
Confirm recent repair history

Degree of use Operated for long period A A A A

s Suddenly increased
I loI I lol
:
‘C
Condition of vibration
Grad&Iv increased lolololol I I I I

I Remove oil pan and check directly I.1 / I I I I I I1

Remove side cover and check directlv I I.1 I I I I I I
Check directly for worn support pilot. play I I I.1 I I I I I
Check directly for loose engine mounting bolts, broken cushion a

Check inside of output shaft (damper) directly l

When radial runout, face runout are measured, they are found to be
0
outside standard value I I I I I I I I I
Remove front cover and check directly I 1.1 I

Remove head cover and check directly 1 I.1

Injection pump test shows that injection amount is incorrect a
u 0) : .= .k ; ;;
z z
Remedy d P 4~ $ $ p g 55
E
drr$$du=$<

’*-lr9
6D125 SERIES
 ENGINE
13 DISASSEMBLY AND ASSEMBLY

GENERAL
Disassembly .. .. . . . . . . . . . 13-002
Assembly ... . . .. . . . . . . 13-018

AIR COMPRESSOR
Disassembly ......... .. ... . 13-044
Assem blv _. . .. .. ... 13-046

EXHAUST BRAKE
Disassembly and Assembly . . . 13-048

* The description of overall engine disassembly and assembly given in this section is
based on the S6D125-1 engine, assuming the use of an overhaul stand.
* The work procedure may differ slightly from that given here depending upon the ma-
chine in which the engine is mounted and also the particular stand used, however it is
fundamentally the same.
* Use the correct service tools when performing disassembly and assembly.

6D125 SERIES
’3-:o’
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

GENERAL DISASSEMBLY

7S6D125-1

13-002 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

44

J I

6 l5OF30 I

13-004 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

Special tools

Part number Part name I o’w

A 790-901-I 240 Adapter 1

B 790-501-2000 Engine overhaul stand 1

C ) 795-102-2102 ) Spring pusher I ’

D ) 795-100-1191 ( Piston ring tool I 1
E 795-220-l 000 Liner puller 1

Preparation work
1) Clean the engine by washing the mud and dirt off.
2) Drain the engine coolant and the engine oil.

_ : Engine oil: approx. 3011

3) Mount the engine assembly on a stable engine stand so

that it won’t fall down.

Engine assembly: approx. 1,175 kg

(The engine weight differs according to the
machine model.)

1. Air cleaner
I) Disconnect the connecting hose to the turbocharger.
2) Remove the mounting bolts, and lift off air cleaner
(2) together with bracket (I).

* The air cleaner and the bracket may be disconnect-

ed depending upon the machine models.

2. Turbocharger and exhaust manifold assembly

1) Remove turbocharger outlet tube (I) and inlet tube
(2).
2) Disconnect the intake connector connecting hose
from the turbocharger.
3) Suspend the turbocharger and exhaust manifold
assembly (3), and dismount them after removing 18
mounting bolts (4).

6Dl25 SERIES 13$05

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

3. Starting motor
Remove starting motor (1).

4. Body side oil cooler

1) Remove aeration pipe (1).
2) Remove 8 mounting bolts (2) and engine side oil
cooler (3).

5. Engine oil cooler

Remove 17 mounting bolts (I) and engine oil cooler (2).

6. Mounting the engine assembly on the engine overhaul

stand
1) Install adapter A to the mounting section of the
engine oil cooler.
2) Sling the engine assembly, align engine overhaul
stand B with the adapter, and secure the engine
assembly to the stand.

13-006 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

7. Oil filter
1) Disconnect hoses (1) and (2) between the oil fil-
ter and the adapter from the oil filter.
2) Remove 4 mounting bolts, and dismount engine
oil filter (3) together with the bracket.

8. Fuel filter
1) Disconnect hoses (4) and (5) between the fuel
filter and the injection pump from the injection
pump.
2) Remove 4 mounting bolts, and disconnect fuel
filter (6) together with the bracket.
615OFlO92

9. Fuel injection pipes

1) Remove clamps (1) and (2).
2) Remove 6 fuel injection pipes (3) and (4).

10. Intake manifold

1) Remove tube (I) between the intake manifold
and the air compressor.
2) Remove 24 mounting bolts (2) and intake man-
ifold (3).

11. Fuel injection pump

1) Disconnect overflow hose (1) at adapter end.
2) Remove lubrication tubes (2) and (3).
3) Remove 2 bolts (8) holding front laminated I 615OFlO93

coupling (9) and cross coupling (10).

4) Remove 4 mounting bolts (5) of fuel injection
pump.
5) Move fuel injection pump assembly (6) to rear
and remove. When doing this, leave flange
coupling (11) and front laminated coupling (3)
on drive shaft.
6) Remove bolt (4) connecting coupling and drive
shaft, then remove flange coupling (11) and
front laminated coupling (9).
7) Remove bracket (7).

’ 615OFlO94

6 ,
Rear
laminated Coupling

615OF328

8D125 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

12. Lubricating oil valve adapter

1) Remove lubricating oil valve adapter (1).
2) Disconnect the spill hose and remove fuel overflow
adapter (2).

13. Fan
Remove fan (I).

14. V-belts
1) Remove belt tension adjustment bolt (2).
2) Loosen alternator fastening bolt (3), and remove
V-belts (4) by pushing the alternator inward.

15. Alternator
1) Remove the fastening bolts for plate (1) and
alternator (4).
2) Remove fastening bolt (3) and alternator (4).
3) Remove bracket (5).

16. Fan pulley

1) Remove 4 mounting bolts and fan pulley (1).
2) Remove bracket (2) and 2 spacers (3).
3) Remove hanger (4) and spacer (5).

615OP317
, -

13--08 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

17. Water pump

1) Disconnect connecting hose (1) between the water
pump and the thermostat housing connector, and
shift the hose towards the connector.
2) Remove 3 mounting bolts (2) and water pump (3).

18. Crankshaft pulley * Vibration damper

Remove 6 mounting bolts (1) and crankshaft pulley -
vibration damper (2).

19. Front support

Remove front support (3).

20. Water manifold

1) Disconnect tube (1) between the air compressor and
the connector.
2) Remove 12 mounting bolts (2). 2 bolts (3), and
water manifold (4).

21. Spill pipes

Remove spill pipes (1)

6D125 SERIES 13-009

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

22. Cylinder head covers

Remove 24 mounting bolts (I) and each head cover (2).

23. Nozzle holders

Remove 12 mounting bolts (1) and each nozzle holder
(2).
* Give a number to each nozzle holder before re-
moving it and store all nozzle holders together in an
appropriate place to protect them from damage.

24. Rocker arms

Remove 12 mounting bolts (1) and each rocker arm (2).
* Before installing the rocker arms, loosen the lock
nut and then the adjustment screw by 2 to 3 turns
so that the push rod will not be subjected to undue
force.

25. Crossheads
Remove crossheads (1).

26. Push rods

Remove push rods (2).

13-010 6Dl25 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

27. Rocker arm housing

Remove 42 mounting bolts (1) and each rocker arm
housing (2).

28. Cylinder head assembly

1) Remove 42 mounting bolts (1) and each cylinder
head (2).
2) Remove each cylinder head gasket.

0 Disassemble the cylinder head assembly as follows.

i) Compress valve spring (3) using spring pusher C
and remove valve totters (4).
ii) Remove upper seat (5) and valve spring (3).

6t5W330 6E5OP33Li

iii) Remove seal (7) and lower seat (8).

iv) Set up the cylinder head upright and remove
valve (6).
* The seals are provided on the exhaust side
only.
* Mark the valves with tags to show the
place of installation and keep in a safe
place.

6D125 SERIES
13-:11
 DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

29. Oil pan

Remove oil pan (1).

30. Flywheel
1) Sling flywheel (1) using eye bolt @ (Thread dia.:
12 mm, Pitch: 1.75 mm).
2) Remove the mounting bolts and flywheel.

31. Flywheel housing

1) Sling flywheel housing (1).
2) Remove mounting bolts (2) and the housing.
* When removing the housing, take care not to
damage the oil seal.

32. Front cover

1) Remove tachometer drive assembly (1).
2) Remove front cover (2).
* When removing the front cover, take care not
to damage the oil seal.

13-012 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

33. Fuel injection pump drive gear

1) Remove nut (1) and washer (2).
* Loosen the nut while holding the gear with a
screwdriver.
2) Pull out fuel injection pump drive gear (3) using
puller 0.

6 I5OP338

“$+&*<,8:,
I ,*\\\\\,\,,~,\%,W
‘&&&W,%\
,_x
34. Air compressor
!‘*‘ %‘.‘
1) Remove air compressor tubes (1) and (2).
2) Remove dipstick guide (4).
3) Remove 4 mounting bolts (5) and air compressor
,:: L
(6).

35. Cam follower cover

Remove cam follower cover (1).

36. Cam follower

Remove 12 mounting bolts (1) and each cam follower
(2).

6D125 SERIES 13-013

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

37. Camshaft
1) Remove 2 mounting bolts (1).
2) Remove camshaft (2).
* When pulling out the camshaft, turn it slowly
to protect the cam bushing from damage.

38. Oil pump

Remove 4 mounting bolts (1) and oil pump (2).

\’ I
39. Idler gears *“,% d
1) Remove mounting bolt (3), plate (4), and oil pump ’ ,‘,
idler gear (5).
2) Remove shaft (6).
3) Remove mounting bolt (7), shaft (8), and main idler
gear (9).

40. Oil suction pipe

Detach bracket (1) and remove oil suction pipe (2).

41. Piston and connecting rod assembly

1) Check stamp numbers on connecting rod caps.
(Make sure the cap number coincides with the
cylinder number and also that the number is
stamped on the cam side) 6 I 5OP348
* If there is no stamp number, stamp the number
before the cap is removed.
2) Rotate the crankshaft so that the piston to be
removed is placed in bottom dead center.
3) Remove the carbon from the liner wall using a fine
sand paper.
* If necessary, measure the end play of the
connecting rod using dial gauge @ before
removing the piston and connecting rod as-
sembly.

13-014 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

4) Remove bolt (1) from the connecting rod cap.

5) Remove connecting rod cap (2) and the connecting
rod bearing as a unit by tapping the connecting rod
bolt with a plastic hammer.
* Take care not to damage the screw.

6) Push the piston and connecting rod assembly from

the oil pan side with a wooden stick. Hold piston
(3) in your hand and remove it from the cylinder
head side.
* Take care not to damage the piston cooling
nozzle. (S6D125-1, SA6D125-1)
* During removal, take care not to damage the
inner surface of the liner with the connecting
rod.

7) Remove the remaining piston and connecting rod

assemblies in the same manner.
* When storing the pistons and connecting rods,
take care not to damage sliding portions of the
piston and the bearing.
* Keep the connecting rods and caps together,
then store them with their corresponding
bearings in order to avoid confusion during
reassembly.

0 Disassemble the piston and connecting rod assembly as

follows.
i) Remove snap ring (4).
ii) Pull out piston pin (6) while holding connecting
rod (5) in your hand, and separate connecting
rod from piston (7).
6 I 5OP352
iii) Remove the snap ring on the opposite side.

iv) Remove piston rings (8) using piston ring tool

D.
* Store the piston, connecting rod, con-
necting rod bearings, piston rings, and
piston pin for every cylinder.

6 15OP353 6 15OP354

6D125 SERIES 13-015

@
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

42. Crankshaft
* If necessary, measure the crankshaft end play using
dial gauge @ before removing the crankshaft.

1) Remove mounting bolts (2) for main cap (1).

2) Insert a bolt into the hole on the main cap, and
remove the main cap by shaking it.

3) Since lower thrust bearing (3) is installed to main

cap No. 7, mark the installation position after
removing the cap.

4) Using nylon slings, lift off crankshaft (4).

* When lifting the crankshaft, take care not to
let it hit against the cylinder block.
* Store the crankshaft in an appropriate place so
that its sliding portions do not get damaged.

13-016 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

5) Remove upper thrust bearing (5).

6) Remove upper bearing (6).

* Put identification tags on the main caps, main

bearings, and thrust bearings or mark their in-
stallation positions with a felt-tip pen, segregate
them for each cap, and store them properly to
protect them from damage.

43. Piston cooling nozzle (S6D125-1, SA6Dl25-I)

Remove mounting bolts (I) and each piston cooling
nozzle (2).

44. Cylinder liner

* If necessary, measure the cylinder liner protrusion
using dial gauge @ before removing the cylinder
liners.

Pull out cylinder liners (I) using liner puller E.

6D125 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

GENERAL ASSEMBLY

c Cylinder
block

13-018 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

To C

To D

To E

To F

To G

To H

To I

To J

To K

26

- To L

6D125 SERIES 13-019

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

44
Turbocharger
and exhaust

45
I
1-1 Air cleaner 1

6 I5OF302

13-020 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

TIGHTENING BOLTS BY THE PLASTIC

RANGE TURNING ANGLE METHOD
l Special tools
Important bolts in the 125 Series engines are
tightened by the plastic range turning angle method. Part number Part name O’ty
In this method, special bolts are used. By being
tightened to the load (plastic range) at which they A 790-901-I 240 Adapter 1
begin to be permanently deformed, accurate and B 1 790-501-2000 1 Engine overhaul stand / 1
high tightening force can be obtained.
The most common method for tightening bolts is C 1 795-102-2102 / Spring pusher
the torque control method. In this method, how-
ever, it is difficult to accurately control the tighten-
ing force because of the coefficient of friction.
l The plastic range turning angle method is based on
the initial tightening torque and the turning angle.
H 795-502-I 121 Gauge 1

I 795-l 25-1360 Feeler gauge 1

f Kit range)

* Clean every part thoroughly and check the part

for dents, flaws, and blowholes. When assembling
Plastic range turning angle the parts, make sure that none of the oil and wa-
ter passages are blocked.

Preparation work
. Install adapter A to the cylinder block, then raise it
and place it on engine overhaul stand B.
Torque method
. Repair the cylinder block as follows before insert-
! (conventional method)
ing the cylinder
1) Remove
liners.
rust and scale from surfaces @ and
@ with sandpaper until the machined surface
is exposed.
Elongation of bolt 2) Polish portion @ with No. 60 sandpaper to
6 I5OF302- I make surface @ smooth.
Elongation exceeding the elastic range results in 3) Polish portions @ and @ with No. 60 sand-
permanent deformation. paper to make them smooth.
Bolts to be tightened by the plastic range turning If portion @ is square or burred, polish it with
angle method in the 125 Series engines. sandpaper or a scraper.
1) Cylinder head mounting bolts Finish this portion to an especially smooth
2) Main cap mounting bolts surface to protect the O-ring from damage.
3) Connecting rod cap mounting bolts 4) If the pitting in surface @ is so rough that it
4) Crank pulley mounting bolts (only in D60P, S-8 cannot be rapaired, replace the cylinder block.
machines)
In the plastic range turning angle method, the
permanent strain remains in bolts after they are
tightened. Therefore, the number of times that each
bolt can be reused is limited. Observe the following
precautions.
1) After tightening, put one punch mark on the
bolt. Do not reuse any bolt which has 5 or
more punch marks.
2) If a bolt has been tightened in excess of the
specified turning angle, loosen the bolt com-
pletely and retighten it. (In this case, put two
punch marks on the bolt.)
3) The tightening angle should be targeted at the
standard value plus or minus tolerance.

6D125 SERIES 13-021

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

5) If surface @ and portion @ are roughened

with pitting, finish them smooth.
6) Inspect the counterbore section and remove
any burrs. Chips and dirt on surface @ will
cause poor contact of the liner, which will
lead to water leakage or improper liner pro-
jection.
* Repair the counterbore section if there is
any drooping, corrosion, or pitting.

Q portion
6 I5OF304

1. Cylinder liner
* Replace the liner O-ring and clevis seal with
new parts just before assembling the liner.
. Method of installing liner O-rings and clevis
seal
1) Confirm that the cylinder liner O-ring
grooves and the circumference of the
liner are free from rust and pitting.
* If these surfaces are roughened with
pitting, replace the liner to remove
the cause of water leakage.
2) Coat liner O-rings and clevis seals with
6136F303
SAE No. 30 engine oil.
* The clevis seal and black O-ring will
become swollen and degraded be-
cause of oil. To prevent this, do not
leave these parts immersed in oil.
* Apply a little oil with a brush just be-

/
fore assembling the parts. Press it to the groove
3) After fitting the O-ring on the cylinder /
liner, check that it is not twisted. If it is

4)
twisted,
mm
O-ring.
To prevent
O.D.)
use

the
a smooth
to remove

clevis
the
bar
twist

seal from
(approx.
from

twisting,
the
10

I$
1
Chamfered side

6136FO29
continue to press the whole circumfer-
ence until it is installed properly in the
groove.
5) Install the liner O-ring and clevis seal as

Fi
shown in the diagram.
* Install the clevis seal with the cham-
fered side down.
Cylinder liner

Black (Ethylene propylene rubber)

6150F303A

6D125 SERIES
’3-h!22
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

2) Insert the cylinder liners

i) Coat the liner O-rings and cylinder block O-ring
grooves with SAE No. 30 engine oil, just before
assembling the liner.
ii) Insert the liner into the cylinder block with
mark A or B stamped on the liner top facing
the front, taking care not to damage the O-ring.
iii) Insert the liner by pushing with both hands and
all your weight.
* If the liner fails to go into the cylinder
block smoothly when pushed with your
weight, the O-ring may get damaged.
Confirm that there are no burrs on the
cylinder block.

iv) Press-fit cylinder liners (1) into the cylinder

block using liner driver F.
VI Measure the cylinder liner protrusion using dial
gauge @ after press-fitting the cylinder liner.
* Before measuring the liner protrusion,
press the liner with a plate to eliminate the
raising of the liner caused by the O-ring.
* Cy.linder liner protrusion:
0.07 - 0.15 mm

2. Piston cooling nozzle (S6D125, SA6D125-1)

Install each piston cooling nozzle (2) and tighten mount-
ing bolts (1).
* Before setting nozzles in place, put them side by
side and make sure that they are free from bends
and other defects.

6 I5OF304- I

* After the piston and connecting rod assembly is

installed, recheck the mounting position.

60125 SERIES 13-g23

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

3. Crankshaft
1) install upper main bearing (6) to the cylinder block
with the projected part of the bearing aligned with
the groove on the cylinder block.
* Before installing the bearing, see if any foreign
matter is adhering to the back of the bearing.
Coat the inner surface of the bearing with SAE
No. 30 engine oil.

2) Drive the roll pin until its protrusion reaches 1.5 to

1.9 mm from the end of the cylinder block, then
install upper side thrust bearing (5).
* Install the thrust bearing with the grooved
surface facing the crankshaft.

3) Lift crankshaft (4) using nylon slings. Place it in the

mounting position, taking care not to let it hit the
cylinder block.
* When replacing the crank gear, heat the new
gear in an electric furnace at 200°C for at least
30 minutes and shrink fit it.

Install lower main bearing (7) with the projected

part of the bearing aligned with the groove on the
main cap.
* Before installing the bearing, make sure that no
foreign matter is stuck on the back of the
bearing.
Drive the roll pin into the No. 7 cap until its pro-
trusion reaches 1.5 to 1.9 mm from the end of the
cap, and install thrust bearings (3) to both sides.
* Install the thrust bearings with the grooved side
facing the crankshaft.

13-024 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

6) Coat the crankshaft journal with SAE No. 30 engine

oil, confirm that the stamp No. on main cap (1)
coincides with the number on the cylinder block,
and install the main cap.
* Install the- main cap with the cast number
facing the engine front.
7) Coat the threads of the mounting bolts and the
washers for the main cap with SAE No. 30 engine
oil and secure the main cap by tightening the bolts.
8) Tighten main bearing cap mounting bolts (2) as
follows.
* Starting from the center to the outside, tighten
the bolts to the specified tightening torque as
follows.

m Main bearing cap mounting bolts

Unit: kgm

Order Target Range

1 st step 10 9-11

2nd step ) 20 ) 19.5 - 20.5

Mark the bolts and the cap with

a felt-tip pen, and turn the bolts
3rd step with following degrees.

I 9o" 90” - 120°

\
Mark the bolt and the cap

I
-/
,90” +30°
0

6 I5OF305

* After tightening the bolts, put one punch mark on

the head of each bolt. Do not reuse a bolt which has
5 punch marks. Replace it with a new one.
9) After tightening the bolts, confirm that the crank-
shaft rotates smoothly.
10) Measure the end play of the crankshaft using dial
gauge 0.
* End play: 0.14 - 0.315 mm

4. Piston and connecting rod assembly

1) Assemble the piston and connecting rod assembly as
follows.

i) install piston rings (7) to the piston using

piston ring tool D.

6 I5OP369

6D125 SERIES 13-g25

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

* Install each piston ring as shown in the

.
Piston rings
drawing.
* Install each piston ring to the piston with
the stamped surface facing upward.
* Remove the expander from the oil ring, fit Top ring
---..
the expander into the groove, then install Second ring _
the oil ring. Make sure that the expander Oil ring- -
fits snugly into the ring groove.

6 i 5OP370 6 I5OF306

ii) Connect the piston to the connecting rod.

* Align the cylinder No. on the piston top
with the stamp No. on the connecting rod,
and install piston (7) to connecting rod (5)
by inserting piston pin (6) with the num-
bers facing in the same direction.
iii) Secure the piston pin by fitting snap rings (4)
on both sides.

6150P37t

iv) Install the upper bearing to the connecting rod

with the projected part on the bearing aligned
with the notch on the rod. Cast number (fact it toward the front of the engine)
* Make sure the back of the bearing is free
from any foreign matter before installing
the bearing.

2) Rotate the crankshaft of the cylinder to be installed

to bring it to bottom dead center, and coat the
inner surface of the connecting rod bearing and the Cylinder No. (to be aligned with the cam side) Y
inner surface of the cylinder with SAE No. 30
engine oil.
6 I5OF307

3) Insert piston and connecting rod assembly (3) into

the cylinder with the cast number on the rod facing
the engine front (the stamp No. should be on the
camshaft side), and with the relative position of the
Piston ring openings arranged as shown in the
drawing.
Front
* For S6D1251
Take care not to damage the piston cooling
nozzle when inserting the piston and con-
netting rod assembly.

6 I50F306

13-026 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

4) Contract the piston r’ings using piston holder G, and

push the piston head into the cylinder with a
wooden stick.
* For S6D125-1
Take care not to damage the piston cooling
nozzle when inserting the piston. Make sure
also that the nozzle is located in the center of
the notched part on the piston.

Install the lower bearing to the connecting rod cap

with the projected part on the bearing aligned with
the notch on the cap, and install connecting rod cap
(2) in alignment with the stamped mark on the
connecting rod.
* Make sure the back of the bearing is free from
any foreign matter before installing it.
* Coat the sliding surface of the connecting rod
with SAE No. 30 engine oil.

Coat the threads and seating surface of connecting

rod bolts (1) with SAE No. 30 engine oil and
tighten them as follows.

w Connecting rod cap mounting bolts

Unit: kgm

Order Target Range

1 st step 10 9.5 - 10.5

Mark the bolts and the cap with

a felt-tip pen and turn the bolts
2nd step with following degrees.

9o” 9o” - 120°

* After tightening the bolts, put one punch mark on

the head of each bolt. Do not reuse a bolt which has
5 punch marks. Replace it with a new one.

7) After the piston and connecting rod assembly is

installed, make sure the crankshaft rotates smooth-
lY.

8) Measure the side clearance of the connecting rod

with dial gauge 0.
* Standard side clearance: 0.20 - 0.375 mm

6D125 SERIES 13-$27

 DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

9) Measure the protrusion of piston top from cylinder

block top face using gauge H.

5. Oil suction pipe

1) Fit an O-ring and install oil suction pipe (2).
2) Install bracket (1) to secure the pipe.

6. Idler gear
1) Align mark A on the crankshaft gear with mark A
on main idler gear (9), install shaft (8), and tighten
mounting bolt (7).

w Mounting bolt:
16.5 k 1.5 kgm (For M: 14 mm)
27.5 k 2.5 kgm (For M: 16 mm)
2) Drive in the pin and install shaft (6).

3) Install oil pump idler gear (5). fit plate (4), and
tighten mounting bolt (3).

Qjq Mounting bolt: 16.5 f 1.5 kgm

7. Oil pump
1) Fit O-ring and install oil pump (2).
2) Tighten 4 mounting bolts (1).

m Mounting bolt: 7 f 0.5 kgm

13-$28 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

8. Camshaft
1) Coat the camshaft journal with SAE No. 30 engine
oil.
2) Install camshaft (2) by aligning mark B on the
camshaft gear with mark B on the main idler gear.
3) Tighten mounting bolts (1).

m Plate mounting bolts: 6.75 + 0.75 kgm

* When installing the camshaft, turn it to prevent
damage to the cambushing.
* When replacing the cam gear, heat the gear in
an electric furnace at 200 - 24O’C for 30
minutes and shrink fit it.

9. Cam follower
Install cam follower (2) in alignment with the pin, and
tighten mounting bolts (1).

w Mounting bolts: 5.25 + 0.75 kgm

10. Cam follower cover

Fit an O-ring and install cam follower cover (I).

w Mounting bolt: 1.15 ?r 0.15 kgm

11. Air compressor

1) Fit an O-ring and install air compressor (6), and
tighten 4 bolts (5).
2) Install dipstick guide (4).
3) Fit gasket on both sides and install air compressor
tubes (3), (2), and (1).

6D125 SERIES
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

12. Fuel injection pump drive gear

1) Drive the drive shaft gear, and install fuel injection
pump drive gear (3) in alignment with mark C on
the cam shaft gear.
2) Fit washer (2) and tighten nut (1).
* Tighten the nut while holding the gear with a
screwdriver.

m Nut: 24.5 f 1.5 kgm

6 t 5OP379

* Make sure match marks on each drive gear and on the

idler gear are aligned with each other.

6 I5OF309

* Measure the backlash and the end play of each gear with
dial gauge 0.
0 Standard value of gear backlash

Position Range (mm)

C 0.139 - 0.427

0 Standard value of gear end play

~Position I Range (mm)

1 I 0.09 - 0.48

6150F310

13-030 613125 SERIES

8
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

13. Front cover

1) Press fit oil seal (3) into the cover using a push tool
(outside diameter: 120 mm).
* Insertion allowance (a) for oil seal: 11 +A mm

AI!IYY= Oil seal lip: G2-LI (Coat 50 to 80% of the

lip clearance)

2) Coat the mounting surface with liquid gasket and

install front cover (2).
* Take care not to damage the oil seal when
installina the cover.

&= Mounting surface: Liquid gasket (LG-7)

3) Fit an O-ring and install tachometer drive assembly
(1).
4) Measure the difference between the cylinder block
lower face and the front cover using dial gauge.
* Difference: 0 - 0.275 mm

14. Flywheel housing

1) Press fit oil seal (3) into the housing using a push
tool (outside diameter: 180 mm). 3
&& Oil seal lip: Engine oil

615OF312

* If the oil seal lip contact surface of the crank-

Front of engine Front of engine
shaft is worn (enough for your fingernail to -- Position of
catch: 0.1 mm or more), assemble a rear seal to
correct the wear (assemble it 3.5 mm to the
front of the engine from the lip position).

Single lip rear seal Double lip rear seal

615OF326 6 I5OF327

6D125 SERIES
13g3’
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

2) Coat mounting surface of cylinder block with re-

quid gasket.

& Mounting surface: Liquid gasket (LG-7)

3) Sling flywheel housing (I), install the housing to
cylinder block and tighten mounting bolts (2).
* Take care not to damage the oil seal when
installing the housing.

& Bolt thread and washer:

SAE No. 30 engine oil

13-%‘-’ 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

Tighten flywheel housing mounting bolts as

Tightening order
follows and in the order shown in the drawing.

B Flywheel housing mounting bolts

Unit: kgm

1st step 2nd step

615OF313

3) After flywheel housing is installed, measure the face

runout and radial runout using dial gauge 0.
* Radial runout: 0.20 mm max.
* Face runout: 0.20 mm max.

4) Measure the difference between the cylinder block

and the flywheel housing using dial gauge 0.
* Difference: 0 - 0.35 mm

15. Flywheel
1) Sling flywheel (I) with eye bolt @ (Thread dia.:
12 mm, Pitch: 1.75 mm), install the flywheel to the
crankshaft, and tighten the mounting bolts.

& Bolt threads and washers:

SAE No. 30 engine oil

’3-ii32 SD1 25 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

* Tighten the flywheel mounting bolts as follows

and in the order shown in the drawing.

w Flywheel mounting bolts

Unit: kgm

Order Target Range

1 st step 15 13 - 17

2nd step 1 29.5 1 27.5 - 31.5

2) After the flywheel is installed, measure the face

runout and radial runout using dial gauge 0.
* Face runout: 0.20 mm max.
* Radial runout: 0.15 mm max.

16. Oil pan

Fit a gasket and install oil pan (1).

17. Cylinder head assembly

1) Assemble the cylinder head assembly as follows.
i) Fit lower seat (8) and install seal (7).
* The seals are provided on the exhaust side
only.
ii) Coat the valve stems and the inner surface of
valve guides with SAE No. 30 engine oil and
install valve (6).

* The valve rotator is installed in S6D125, SA6D125

engine, instead of the lower seat.
* The free length of the valve springs are different
between 6D125 and S6D125, SAGDI 25.
* The engine equipped with the exhaust brake (slide
and butterfly type) is different in the exhaust valve
springs (New valve springs are coated with the white
paint).
* Exhaust valves in the engine equipped with the
exhaust brake (slide and butterfly type) is different
only in the valve stem length.
(Mark “5” is stamped in the spare area of each
valve.)

613125 SERIES
’ 3-:33
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

iii) Set the cylinder head upright, and install valve

spring (3) and upper seat (5).
iv) Contract the valve spring using spring pusher C,
and install valve totters (4).
t Tap the valve stem lightly with a plastic
hammer to make sure the totters are
securely installed in the valve stem groove.

615OP331 6 I SOP330

2) Make sure the mounting surface of cylinder head

and the inside of cylinders are free from dust and
foreign matter, and place cylinder head gasket (9) in
position.
* When installing the gasket, make sure the
grommet is not loose.

3) Install each cylinder head assembly (2) and tighten

mounting bolts (1).

a Coat the threads and lower side of the bolt

head before tightening the mounting bolts
with lubricant (LM-P).
* First screw in the mounting bolts two or three
revolutions by hand, then tighten the bolts as
follows.

QZ Cylinder head mounting bolts

Unit: kgm
-511
Order Target Range
NE
r 1 st step [ 10 ) 9-11

@ 1 2nd step 1 14

Mark the bolts and the cylinder

head with a felt-tip pen, and turn
the bolts with following degrees

Tightening order
I I

Put a mark on the bolt and cylinder head

* After tightening the bolts, put one punch mark on

the head of each bolt. Do not reuse a bolt which has
5 punch marks. Replace it with a new one.
615OF316

13834 60125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

18. Rocker arm housing

Fit gaskets and install rocker arm housings (2) to the
cylinder heads, then tighten 42 mounting bolts (1).

m Mounting bolts: 6.75 + 0.75 kgm

19. Push rod

Install push rods (2).
+ Make sure the push rods are securely positioned in
the cam follower lever holes.

20. Crosshead
Install crosshead (1).
* The exhaust crosshead in the engine equipped with
the exhaust brake (slide and butterfly type)
is different only in the pocket depth.
* Adjust the crosshead as follows.
i) Loosen the lock nut and the adjustment screw.
ii) Hold down the upper surface of the crosshead
lightly with a finger, and screw the adjustment
screw.
iii) After the adjustment screw comes into contact
with the valve stem, screw the adjustment screw
20 degrees.
iv) Tighten the lock nut in this position.

m Lock nut: 6.75 + 0.75 kgm

21. Rocker arm

Fit gaskets and install rocker arms (2). then tighten 12
mounting bolts (1).
* Make sure the ball portion of the adjustment screws
are securely placed in the socket portion of the push
rods before tightening the bolts.
* Clean oil holes on the bolts and tighten the bolts.

w Mounting bolt: 6.75 * 0.75 kgm

* Set a rocker arm shaft in place so that the portion
having a large hole (13 mm dia.) is on the lower side
and that having a blind ball plug is on the front side.

60125 SERIES 13-035

8
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

22. Adjustment of valve clearance

Adjust the valve clearance in the following procedure.
* Adjust the valve clearance to obtain the following
clearances between the crosshead and the rocker
arm.
* Valve clearances (when engine is cold)

Unit: mm

* With the engine cranking in firing order 1-5-3-6-

2-4, adjust the valve clearance for each cylinder.
1) Rotate the crankshaft in the normal direction.
While watching the movement of the valve,
align stamped line “1.6 TOP” on vibration
damper (1) with pointer (2).

2) Insert a Feeler gauge I between rocker arm (3)

and crosshead (4), and adjust the clearance with
adjustment screw (5) until the gauge can slide
lightly.

3) Tighten lock nut (8) to secure the adjustment

screw.

m Lock nut: 6.75 * 0.75 kgm

* Recheck the valve clearance after tighten-

ing the lock nut. Refer 12 ADJUSTING
VALVE CLEARANCE.

615OF317

23. Nozzle holder

* Make sure the inside of nozzle holder sleeve is free
from dust and foreign matter.
Fit O-rings and install nozzle holders (2) to the
cylinder head, then tighten mounting bolts (1).
* Tighten the nozzle holder mounting bolts equally to
achieve even tightening.

m Mounting bolt: 2.2 * 0.3 kgm

13-036 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

24. Cylinder head cover

Fit O-rings and install cylinder head covers (2). then
tighten 24 mounting bolts (1).
* Apply adhesive to the O-rings so that they can be
installed without causing twisting.

w Cylinder head cover mounting bolts:

1 f 0.1 kgm

25. Spill pipes

Fit gaskets on both sides and install spill pipes (1).

m Joint bolt: 1.25 * 0.25 kgm

26. Water manifold

1) Fit gaskets and install water manifold (4). then
tighten 12 bolts (2) and 2 bolts (3).
2) Fit gaskets on both sides, and connect tube (1)
between the air compressor and connector.

27. Front support

Install front support (3).

26. Crankshaft pulley and vibration damper

Install crankshaft pulley and vibration damper (2).
then tighten 6 mounting bolts (1).

m Mounting bolts: 28 f 3 kgm

(Thread dia.: 16 mm, Pitch:
1.5 mm)
18f2kgm
(Thread dia.: 14 mm, Pitch:
1.5 mm)

6D125 SERIES 13-g37

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

28-1. Crankshaft pulley (for D60P-8 and D60S-8)

1) Install crankshaft pulley.
2) Coat bolts with the engine oil, then tighten the
bolts as follows.

m Bolt@: 18f2kgm
Bolts 0:
1st step: 15 f 1 kgm
2nd step: 30 * 1 kgm
3rd step: Mark the bolts and the
pulley with a felt-tip pen,
and turn the bolts 90’ -
1 20°.
* Bolt 0: Thread dia.: 14 mm, Pitch: 1.5 mm 615OF316-I

Bolts@: Thread dia.: 16 mm, Pitch: 1.5 mm

13-g38 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

29. Wiiter pump

1) Fit O-ring and install water pump (3), then tighten 3
mounting bolts.

w Mounting bolts: 6.75 * 0.75 kgm

2) Connect hose (1) between the water pump and the
thermostat housing.

3) Install spacer (5) and hanger (4).

4) Install 2 spacers (3) and bracket (2).

30. Fan pulley

Install fan pulley (1) and tighten the 4 mounting bolts.

6 Z 5OP3 16

31. Alternator
1) Install bracket (5).
2) Set alternator (4) on the bracket, and loosely
tighten fastening bolt (3).
3) Install plate (1).

32. V-belts
1) Install V-belts (4) to the pulley grooves, and install
the belt tension adjustment bolt (2).
2) Adjust the belt tension by raising the alternator
with a bar until the belt deflects about 13 mm when
the center of the belt is depressed with a force of
6 kg then tighten bolts (3) and (2).
PC300-3, PC400-3
Standard belt tension: about 6 - 7 mm

33. Fan
Install fan (1).

6D125 SERIES
’3-:39
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

34. Lubricating oil valve adapter

1) Install adapter (2) for the fuel overflow, and con-
nect the spill hose.
2) Fit O-ring and install lubricating oil valve adapter
(1).

35. Fuel injection pump

1) Install bracket (7).
2) Drive in a key to the fuel injecion pump drive
shaft. Position fuel injection pump (6) with the
key seat on the pump coupling aligned with pin
section on the bracket.
3) Remove 2 coupling bolts (8) from fuel injection
pump, then install flange coupling (11) and front
laminated coupling (9) to engine drive shaft.
When doing this, do not tighten coupling con-
nection bolt (4). I
I ,(-jj 6,

4) Align coupling key groove with drive shaft key, l’- 615OFI 132
push in fuel injection pump assembly (6), align
with pin portion of bracket, and set in position.
5) Tighten 4 mounting bolts (5) of fuel injection
pump.
Rear
m Mounting bolt: 3.2 + 0.3 kgm (6D125) laminated CouDlina block
6.75 & 0.75 kgm (S6D125)
6.75 k 0.75 kgm (SAGD125)

6) Tighten 2 bolts (8) connecting coupling and

drive shaft.

m Coupling connecting bolt: 6.25 + 0.25 kgm

7) Tighten bolt (4) connecting pump coupling and

drive shaft. I 615OF328

m Mounting bolt: 9 ‘z,” kgm (6D125)

8 + 0.5 kgm (S6D125)
8 + 0.5 kgm (SAGD125)

’3-z40 6D125 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

8) Check the injection timing as follows.

i) Rotate the crankshaft in the normal direction
and align the injecion timing stamp line on
vibration damper (8) with pointer (9).
* If the stamp line on the injecion pump
coupling is invisible from the front, ro-
tate the crankshaft one more revolution.
ii) In the condition described in step i), confirm
that stamp line a on the injection pump side
is aligned with stamp line b on the coupling
side.
* If the stamp lines are out of alignment,
loosen nut (IO), turn the coupling until
one stamp line is aligned with the other,
and tighten the nut to the specified tor-
que.

w Nut: 6.2 f 0.2 kgm

* When the fuel injecion pump is repaired or
replaced, or if the stamp line is missing, ad-
just the injection timing by the delivery
valve method. See 12 CHECKING AND AD-
JUSTING FUEL INJECTION TIMING.

0
615OF31S

9) Fit gaskets to both sides and install lubrication

tubes (3) and (2).

w Joint bolt for tube (2): 2.5 ‘i.” kgm

Joint bolt for tube (3): 1.5 ‘t” kgm

10) Fit gaskets to both sides and connect overflow

hose (1).

-iiiisj- 615OFI 134

36. Intake manifold

1) Fit a gasket, install intake manifold (3), and
tighten 24 mounting bolts (2).
2) Install tube (I) between the intake manifold and
the air compressor.

’ 615OF1094

6D125 SERIES 13g41

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

37. Fuel injection pipe

Install fuel injection pipes (4) and (3), and secure the
pipes with clamps (2) and (1).

m Sleeve nut: 2.4 + 0.1 kgm

3
.4

I 615OFlO93

38. Fuel filter

1) Install fuel filter (6) and the bracket as a unit.
2) Fit gaskets to boh sides and install hoses (5)
and (4) between the filter and the pump.

39. Oil filter

1) Install engine oil filter (3) and the bracket as a
unit.
2) Connect hoses (2) and (I) between the filter and
the adapter.
* Install the hoses without twisting or inter-
ference.
615OFlO92/

40. Setting engine assembly on the engine stand

Sling the engine assembly, remove the connect-
ing bolts between adapter A and engine over-
haul stand B, to separate the engine assembly
from overhaul stand.
Set the engine assembly on the engine stand.
Remove adapter A.

I I

6lkOFlO91

41. Engine oil cooler

Fit a gasket and install engine oil cooler (3, then
tighten 17 bolts (1).

m Mounting bolt: 6.75 * 0.75 kgm

’ 615OFlOS( 1

13-g42 6D125 SERIES

 DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

42. Body side oil cooler

1) Fit a gasket and install body side oil cooler (3),
then tighten 8 bolts (2).
2) Install aeration pipe (1).

615OF108Z

43. Starting motor

Fit a gasket and install starting motor (1).

44. Turbocharger and exhaust manifold assembly

1) Sling turbocharger and exhaust manifold assem-
bly (3), fit gaskets, and tighten 18 mounting
bolts (4).
* Fit the gasket with the marked side facing
outward.

m Mounting bolt: 6.75 + 0.75 kgm

2) Assemble exhaust brake.
* To prevent any excessive force from being
brought to bear on the turbocharger when
assembling the exhaust brake, position it
first and then tighten all the bolts.
3) Fit gaskets and install turbocharger inlet tube (2)
and outlet tube (1).
4) Connect the intake connector hose to the turbo-
615OFlO87
charger.

45. Air cleaner

Install air cleaner (2) and bracket (1) as a unit, and
connect the hose to the turbocharger.

. Refilling with the engine oil

1) Make sure the engine drain plug is tightened.
2) Add engine oil through the oil filler to the speci-
fied level.

& Engine oil pan: about 26 Q

: 6t50P301

6D125 SERIES
’ 3-:43
DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR

DISASSEMBLY OF AIR COMPRESSOR

3 17

4
16
5
6
15

i i \
li 1'3 12

6150F140A

?O 21 ?2 ?3

‘///Ii \ I\\ 28 27
\\\
26 25 24
35 34 33 32 31 30 29
6150F322A

13-g44 6D125 SERIES

DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR

OVERALL ASSEMBLY FINE DIASSEMBLY.

1. Cylinder head 1. Piston, connecting rod
I) Remove 4 cylinder head mounting bolts (1). I) Remove snap ring (17), then pull out piston
2) Tap with a wooden hammer from under cylin- pin (16), and remove piston (8).
der head, and remove cylinder head (2). 2) Remove piston rings (7) from piston.
3) Remove gasket (3) inserted between cylinder
and cylinder head. 2. Unloader valve assembly
1) Remove unloader valve body (19) installed on
2. Cylinder, connecting rod, piston top of cylinder head.
1) Remove 4 cylinder mounting bolts (5), then 2) Remove snap ring (30) from inside unloader
remove cylinder (4) from crankcase (10). valve body (19), then take out washer (31),
2) Remove 2 bolts (6) holding big end of spring (22), and rod (20).
connecting rod.
3) Remove piston (8) and connecting rod (9) 3. Delivery valve assembly
from crankcase. I) Seat (26) is screwed in and installed to bot-
tom of cylinder head, and thread is caulked,
3. Bearing cover so remove caulking.
1) Remove 4 mounting bolts (14) of bearing 2) Remove seat (26), then remove guide (23),
cover installed to crankcase, then remove spring (27), valve plate (25), guide (29), and
cover (15) from crankcase together with oil gasket (28) from inside.
seal.
2) Remove oil seal from bearing cover (15). 4. Intake valve assembly
1) Guide (32) is screwed in to bottom of cylinder
4. Crankshaft head, and thread is caulked, so remove
1) Pull out crankshaft (12) in direction of mount- caulking.
ing surface of bearing cover (15) with 2 ball 2) Remove guide (32). then remove spring (33),
bearings (11) stil installed. valve plate (34), seat (35), and gasket (36) at
2) Using a press, remove ball bearings (11) from the same time.
crankshaft (12).

6D125 SERIES 13-g45

DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR

ASSEMBLY OF AIR COMPRESSOR

16-------

12

6150F140A

18 19 20 21 22 23

///i/i \ I\\ \\\

36 35 34 33 32 31 30 29 28 27 26 25 24
6150F322A

’3-$46 6D125 SERIES

 DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR

FINE ASSEMBLY OVREALL ASSEMBLY

1. Intake valve 1. Crankshaft
1) Assemble gasket (36), seat (35), valve plate 1) Press fit bearings (11) to both ends of crank-
(34), and spring (33) in turn to cylinder head shaft (12).
(I), then temporarily tighten guide (32). 2) Insert crankshaft (12) from installation side of
2) Check that valve plate and spring move bearing cover (15) of crankcase.
smoothly, then tighten guide (32) to the speci- 3) Press fit oil seal to bearing cover (15), and fit
fied torque. O-ring, then install to case and tighten bolts

w Guide: 10 kgm (14).

* If the guide is protruding from the bottom m Bolt: 2.5 kgm
surface of the cylinder head, it will inter-
fere with the piston, so check the 2. Cylinder, connecting rod, piston
condition. Insert connecting rod from top of crankcase,
3) Caulk guide at three places with a punch. then tighten cap (13) with bolts (6).

m Connecting rod bolt: 2.5 kgm

2. Delivery valve
* Check that the connecting rod match
1) Assemble guide (23), spring (27), valve plate
marks are aligned.
(25), gasket (28), guide (29), and gasket (24) in
Fit O-ring to cylinder mounting surface, then
turn to cylinder head (l), then temporarily
compress piston ring while inserting piston in-
tighten seat (26).
to cylinder (4), and tighten bolts (5).
2) Check that valve plate moves smoothly, then
tighten seat (26) to the specified torque. m Bolt: 3 kgm

m Seat: 15 kgm
3. Cylinder head
* If the seat is protruding from the bottom
1) Install gasket (3) to cylinder.
surface of the cylinder head, it will inter-
2) Install cylinder head (2), then tighten bolts (1)
fere with the piston, so check the
uniformly.
condition.
3) Caulk seat at three places with a punch. m Cylinder head bolt: 5 kgm

3. Unloader valve PERFORMANCE TEST AFTER ASSEMBLY

1) Fit O-ring (21) to rod (20), then asemble in After disassembling, inspecting, and assembling, car-
body (19). ry out an air-tightness test and performance test as
follows.
& O-ring: Grease (LM-G)
Air tighteness test
2) Install spring (22) and washer (31) to rod (20),
Apply an air pressure of 7 kg/cm2 at the same
then install snap ring (30).
time to the discharge port and unloader valve,
3) Install gasket (18), then assemble unloader
and measure the amount of leakage from the
valve assembly to cylinder head (I), and tigh-
intake port.
ten to the specified torque.
Standard for leakage: Max. 450 cc/min
m Unloader valve: 5 kgm Filling performance
* Push rod (20) with a screwdriver, and With a tank capacity of 30 litres, the time tak-
check that the valve moves. en to raise the tank pressure from 0 + 8 kg/
cm2 must be as follows.
4. Piston, connecting rod
1) Set piston (8) to connecting rod (9), then in- +
sert piston pin (16), and install snap ring (17).
2) Assemble piston rings (7) to piston (8).
t Install the top ring and second ring with
the stamped mark at the top, and make
sure that the end gaps are not aligned. Oil leaking up
Remove the pipe of the discharge port in the
cylinder head, and check the operation. Check
that there is no abnormal spray of oil from the
discharge port.

6D125 SERIES 13-247

DISASSEMBLY AND ASSEMBLY EXHAUST BRAKE

DISASSEMBLY AND ASSEMBLY OF EXHAUST BRAKE

13’ a

19/@
@
21’
Q
12’ @

II
0

22- m
------9

A8
@a
0

35---*
b
4oH 615OF319

6D125 SERIES
13-848
DISASSEMBLY AND ASSEMBLY EXHAUST BRAKE

1. Exchange O-ring (30) and poppet (23).

I) Remove bolt (41) after fixing body. 12) Install spring (25) into spring holder (8).
2) Exchange O-ring (30) and poppet (23). 13) Apply LOCK-TIGHT to surrounding groove of
piston (12).
& Poppet (23): Silicon grease
& Piston: Adhesive (LT-2)
m Bolt: 0.8 kgm

14) Place piston packing (21) on piston (12) and

2. Exchange liner (5). gate valve (2). gasket (18) and
place the burrless side of washer (19) to the
valve housing (1).
packing (21).
1) Remove socket head cap screw (39). (40) after
fixing valve housing (1). 15) Apply silicon grease lightly to the edge of
packing (21).
2) Remove valve housing (1).
3) Connect air piping to PT l/4 of poppet cover, & Packing: Silicon grease
raise air pressure to approx. 1 - 2 kg/cm*
and float T block (4). 16) Apply silicon grease to the region surround-
4) Remove gate valve (2), liner (5), and gasket ing retainer (14) and position two web wash-
(18) in order, and install replacement parts in ers (29) and taper washer (13).
regular order. & Retainer: Silicon grease
5) Remove air piping after reducing air pressure
to 0 kg/cm2.
17) Place sub-assembly of piston (12), packing
6) Install valve housing (I) and socket head cap (21) and washer (19) into piston rod (17),
screws (39) and (40). while pressing packing (21) with the tapered
& Cap screw: Antifriction compound portion of washer (13).
18) Push in sub-assembly of (13), (29), (14) and in-
m Cap screw: 3 kgm
stall them using two nuts (33).

3. Exchange cylinder tube (9). piston portions (12). w 1st nut: 2 kgm
(13). (14). (19). (21). (29) and spring (25). 2nd nut: 2 kgm
1) Fix valve housing (1).
2) Remove head cover (10) after removing nut 19) Remove fixing nut (32).
(34). 20) Install gasket (18) and liner (5).
3) Remove socket head cap screws (39) and (40) 21) Install gate valve (2) while pushing in retainer
fixing valve housing (1). (14).
4) Remove valve housing (1) after pushing re- 22) Install valve housing (1) and tighten socket
tainer (14). head cap screws (39) and (40).
5) Remove liner (5) and gasket (18). w Cap screw: 3 kgm
6) Fix hexagonal nut (32) holding T block (4). * Install head cover (10) and tighten nut (34).
7) Remove two hexagonal nuts (33) holding pis-
w Nut: 2.5 kgm
ton portion.
8) Remove retainer (14), wave washer (29), taper
washer (13), washer (19), and piston packing
(21).
9) After removing cylinder tube (9) and setting
piston (12) on vice, top piston rod (17) with
rubber mallet and remove piston (12).
JO) Remove spring (25).
11) Apply silicon grease to one side only of the
exchanged cylinder tube (9) to a surrounding
width of 40 mm, install the tube turning the
grease upwards, into spring holder (8).

&&z Cylinder tube: Silicon grease

6D125 SERIES
’3-;49
DISASSEMBLY AND ASSEMBLY EXHAUST BRAKE

4. Exchange guide busing (24) and insulating pack- 5. Exchange piston rod (17)
ings (27) and (28). 1) Remove rod (17) using similar method to item
1) Remove spring (25) using similar method to 4.
that of item 3. 2) Place T Block (4) and guide (42) onto ex-
2) Loosen nut (44) holding sleeve (43) after rem- changed rod (17).
oving (22), and remove (43) and (44) from rod 3) Tighten nut (32) so that the chamfered side of
(17). nut (32) faces guide (42).
3) Remove fixing nut (32) and draw out rod (17)
w Nut: 5.5 kgm
from base plate (3) and adapter plate (7).
4) Remove seal packing sub-assembly (15), relief
4) Calk the nut at three places using a punch to
spacer (6) and guide bushing (24) from plate
avoid loosening.
(3) in that order, and install the exchanged
5) After this, assemble using similar method to
parts in regular order.
item 4.
* Face the wider side of spacer (6) to pack-
ing sub-assembly (15) side.
6. Matters to be attended to before assembly
5) Fix plate (7) by vice and remove (8) and (24),
housing (1) when carrying out items 3,4. and 5.
while tapping bushing (24) slightly with bar (a
1) Install air piping to PT l/4 of poppet cover,
little smaller than hole diameter of plate) from
raise air pressure to approx. 1 - 2 kg/cm’,
the opposite hole of spring holder (8).
float T block (4) and remove gate valve (2).
* When (8) is difficult to remove, turn (8)
* When reducing air pressure to 0 kg/cm’,
using a pipe wrench then remove it.
position an approx. IO mm block so that T
* In this case, exchange (8) with new part.
block (4) does not contact base plate (3)
6) Make a hole ( 4 5 mm) in plate (7), then apply directly.
thread tightener and position packing (27) so 2) Then reduce air pressure to 0 kg/cm*.
that the hole of packing (27) is aligned with 3) Adjust by turning T block (4) so that the seat
the hole of plate (7). side of gate valve (2) for liner guide (42) is ap-
a Plate: Thread tightener (LT-2) proximately parallel with the longitudinal di-
7) Place bushing (24) in spring holder (8), then rection of base plate (3).
apply thread tightener to pilot portion of plate 4) If operation is smooth after carrying out the
(7) and align holes of packing (27) and spring operation of T block several times, float T
holder (8) to install spring holder (8). block (4) and remove block.
5) After this, assemble using similar method to
& Plate: Thread tightener (LT-2)
item 2.
8) Place insulating packing (28) into plate (7). * Silicon grease.
9) Adjust the pilot of plate (7) to align with base Pertinent brand: SHINETSU KAGAKU
plate (3), and install rod (17) from plate (3) (FG721A) or equivalent.
side. * Antifriction compound
10) Place nut (44) onto rod (17) so that the flat Pertinent brand: LC-G MORI court 1000 or
face of the nut meets sleeve (43). equivalent.
11) Adjust the distance from the rod (17) end to
sleeve (43) to approx. 27 mm, by use of nut
(44).
12) Fix sleeve (43) by vice and tighten the nut
(44).

w Nut: 2.5 kgm

13) Place collar (22) on sleeve (43) and apply
LOCK-TIGHT to 8 mm screw and 8 mm di-
ameter portions of rod (17).

& Screw, rod: Adhesive (LT-2)

14) After this, assemble using similar method to
item 3.

13--50 6D125 SERIES

 ENGINE
14 MAINTENANCE STANDARD

INTAKE AND EXHAUST SYSTEM

Turbocharger . . .. 14-002

ENGINE BODY
Cylinder head ................... 14-003
Valve and valve guide .............. 14-004
Rocker arm shaft ................. 14-006
Crosshead ...................... 14-007
Cylinder block .................. 14-008
Cylinder liner ................... 14-010
Crankshaft ..................... 14-011
Camshaft ...................... 14-012
Cam follower and push rod .......... 14-013
Piston, piston ring and piston pin ...... 14-014
Connecting rod .................. 14-018
Timing gear .................... 14-019
Flywheel and flywheel housing ........ 14-020
Vibration damper ............... 14-020-l

COOLING SYSTEM
Water pump and thermostat ... . . _ . . . 14-021
Oil cooler .. . . . . . . . 14-022

LUBRICATION SYSTEM
Oil pump . . ... ... .. . 14-023
Main relief valve .. . . . . . . . . . . 14-024
Regulator valve and safety valve . . . . . 14-025
ACCESSORY
Air compressor . . . . . . . . . 14-026

6Dl25 SERIES
’4-:o’
 MAINTENANCE STANDARD TURBOCHARGER

TU 3BOCHARGER
TV7 , 12

615OF401A

Unit: mm

NC Criteria Remedy

Standard Repair limit

1 Radial play of rotor
0.08 - 0.18 0.18
Reolace

2 End play of rotor 0.08 - 0.25 0.25

-

Target !kgm) Range (kgm)

Tightening torque of back
3
plate mounting bolt
1.25 1.15 - 1.38
-

Order Target (kgm) Range (kgm)

Retighten
1st step 1.8 1.6 - 2.0
A Tightening torque of V-band
locknut
2nd step 0 Loosen completely

3rd step 1.4 1.27 - 1.50

Standard Repair limit

5 Thickness of thrust bearing
2.315 2.29

Measuring point Standard Repair limit

Outside diameter of wheel shaft A 17.53 17.48

6
B 15.88 i 5.88

Bend of wheel shaft Repair limit: 0.010 (Total indicated runout)

Repair limit Replace

Standard
7 Inside diameter of back plate
17.47 17.49

Measuring point Standard Repair limit

8 Inside diameter of center housing C 20.90 20.93

D 24.97 24.97

’4-:02 6D125 SERIES

MAINTENANCE STANDARD TURBOCHARGER

T04B, E

9 J ?

b
I4F036A I4FO36- I I4FO36-2

Unit: mm

NO Item
I Criteria Remedy

Standard Repair limit

1 Radial play of rotor

0.075 - 0.150 0.180

2 End play of rotor 0.025 - 0.075 0.10

3 Thickness of thrust bearing 4.36 4.35

Measuring point Standard Repair limit

Outside diameter of wheel shaft A 17.34 17.25

4
B 10.16 10.15

Bend of wheel shaft Repair limit: 0.010 (Total indicated runout)

Standard Repair limit

5 Inside diameter of back plate

12.70 12.73
-

6 Depth of back plate 11.66 11.68

Measuring point Standard Repair limit

7 Inside diameter of center housing C 15.80 15.81

I D
I 18.03 I 18.08

Target (kgm) Range (kgm)

Tightening torque of turbine
8
housing bolt
2.0 1.8 - 2.2
- Retighten
Tightening torque of blower
9 1.3 1.15- 1.5
housing bolt I
Tightening torque of back
0.95 0.86 - 1.04
plate mounting bolt

6D125 SERIES
‘4-o:2
-’
 MAINTENANCE STANDARD TURBOCHARGER

T45 1 2

8 615OF425

8 615OF424 Unit: mm

No Item Criteria Remedy

Standard Repair limit

1 Radial play of rotor

0.12 - 0.17 0.17 Replace

2 End play of rotor 0.025 - 0.08 0.10

Target (kgm) Range (kgm)

Tightening torque of back
3
plate mounting bolt
1.13 1.04 - 1.21

Tightening torque of blower

4 1.05 0.92 - 1.15
housing bolt I I
__

Order Target (kgm) Range (kgm) Retighten

1 Ststep
Tightening torque of V-band
5
locknut

I 2nd step / 0 1 Loosen completely 1

I 3rd step
I
1 .4
I
1.28 - 1.50 I

Standard Repair limit

6 Thickness of thrust bearing

4.304 4.36

Measuring point Standard Repair limit

1

Outside diameter of wheel shaft A 17.48

17.526 I
B 12.996 12.90
Replace
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout)

Standard Repair limit

8 Inside diameter of back plate

17.475 17.49

Measuring point Standard Repair limit

9 Inside diameter of center housing C 20.181 20.188

D 20.904 20.930

14-002 -2 6D125 SERIES

8
 MAINTENANCE STANDARD CYLINDER HEAD

CYLINDER HEAD
? ?

0
8 0
0

cl i
0
0
/ \ 6 I SOF403
1 2 6 ISOF
Unit: mm

No. item Criteria Remedy

Standard Repair limit

Repair by
Distortion of cylinder head
1 grinding
mounting surface
0 - 0.06 0.09 or replace

Applicalbe model Standard

6D1251 1 S.T.D I 4.90 - 5.70

S.T.D 3.35 - 4.25

2 Protrusion of nozzle S6D125-1 D75S-5 (23193 and up) D85E.P-1 Replace sleeve
PC300-3 (23689 and up) HD205-3 4.90 - 5.70
GD705A-4 (23599 and up)

S.T.D. 4.90 - 5.70

SAGD125-1
D135A-1 3.35 - 4.25

Tightening torque of cylinder

Tighten bolts
head mounting bolts
3 in accordance
(Coat the thread areas with
with bolts No.
molybdenum disulfide or engine oil)
Retighten with
3rd step 90 90” - 120

0 - 7 6 - 7.5

Tightening torque of nozzle

4 2.2 * 0.3 kgm
holder mounting bolt
Retighten
Tightening torque of rocker
5 6.75 * 0.75 kgm
arm housing

6D125 SERIES
’4-:03
MAINTENANCE STANDARD VALVE AND VALVE GUIDE

VALVE AND VALVE GUIDE

6 I5OF404

Unit: mm

No. Item Criteria Remedy

\
Valve Standard Tolerance Repair limit

Intake 0 *0.10 0.63 Replace valve

1 Amount of valve sinking or valve seat

Exhaust 0 *0.10 0.70

14-go4 6D125 SERIES

 MAINTENANCE STANDARD VALVE AND VALVE GUIDE

Unit: mm

Nc Item Criteria Remedy

Valve Standard Repair limit

2 Thickness of valve lip Intake I 2.10 I 1.7 Replace

Exhaust I 1.50 I 1.2

-

Valve Standard Tolerance

Repair
3 Valve seat angle Intake 60’ *o”15,
or replace

Exhaust I 45O I *o” 15’

-
Valve Standard Tolerance

Intake -0.045
9
Outside diameter of valve stem -0.065

Exhaust
I
9
I -0.050
-0.070

+0.015
4 Before inserting 9
-0.005
Inside diameter of valve guide Replace

After inserting 9 to.01 0

Valve Standard Clearance limit

Clearance between valve

Intake 0.035 - 0.075 0.22 Replace
guide and valve stem

Exhaust 0.040 - 0.080 0.24

Bend of valve stem Repair limit: 0.02 (Total indicated runout for 100 mm) Replace

Standard Tolerance
5 Protrusion of valve guide Repair
20 *0.2

Engine Valve Color code Free length Repair limit

Free length of valve spring

S6D125-1 66.9 64.7

SAGDI 25-l Yellow
Exhaust
White 75.2 -
Replace
6 Color Installed Installed Repair
Engine Valve
code length load limit

Intake Yellow 56.0 30.0 f 27.0 kg

1.5 kg
6Dl251
Exhaust Yellow 56.0 30.0 + 27.0 kg
1.5 kg
Installed load of valve spring
49.5 40.0
2.0 +kc
Intake Purple 36.0 kg

S6D125-1 / Yellow 56.0

30.0 f
1.5 kg 27.0 kg
;A6D125-1
Exhaust
r
White 56.0 53.0 47.7 kg
2.6 kg

Squarence of valve spring Repair limit: 2’ (for both end)

6D125 SERIES
’4-:05
 MAINTENANCE STANDARD ROCKER ARM SHAFT

ROCKER ARM SHAFT

6 I50F405A

Unit: mm

No Item Criteria Remedy

Standard Tolerance
Replace
Outside diameter of rocker rocker arm
arm shaft -0.055 shaft
28.6
-0.065

Inside diameter of rocker arm +0.035 Replace

28.6
shaft hole -0.025 rocker arm
1

Standard Clearance limit

, Replace rocker
Clearance between rocker arm arm or rocker
and rocker arm shaft arm shaft
0.025 - 0.100 0.130

Bend of rocker arm shaft Replace rocker

Repair limit: 0.20 (Total indicated runout)
arm shaft
-

Tightening torque of rocker arm

2 6.75 * 0.75 kgm Retighten
adjustment nut

Valve Standard Tolerance

3 Valve clearance (at hot or cold) Intake 0.33 co.02 Adjust

Exhaust 0.71 kO.02

“-:06 6D125 SERIES

MAINTENANCE STANDARD CROSSHEAD

CROSSHEAD

6 ISOF406A

Unit: mm

No Item Criteria Remedy

I

Standard Tolerance Repair limit

1
Depth of crosshead stem
I +0.56
-0.46

Depth of crosshead stem +0.55

5.5 6.17
(For Ex. w/exhaust brake) -0.45
Replace

+0.075
Inside diameter of crosshead 11 11.18
+0.025
2

Outside diameter of crosshead guide 11 +0.010

10.95
I 0 I

3 Protrusion of crosshead guide 45.5 iO.25 IRepair

Tightening torque of crosshead

4 6:75 t 0.75 kgm Retighten
lock nut
I

6D125 SERIES 14-c&07

MAINTENANCE STANDARD CYLINDER BLOCK

CYLINDER BLOCK

6 I5OF407

6 ISOF

14-008 6D125 SERIES

 MAtNTENANCE STANDARD CYLINDER BLOCK

Unit: mm
-
No Item
-

Distortion of cylinder head

1 mounting surface

Inside diameter of main

bearing hole

Roundness of main bearing hole

-

3 Inside diameter of main bearing

5
-

7
-

Tightening torque of main

bearing cap
8
(Coat thread area with engine
oil)

Tightening torque of crankshaft

9
pulley mounting bolt

6D125 SERIES
’ 4-:09
 MAINTENANCE STANDARD CYLINDER LINER

CYLINDER LINER

=i-+
Detail P

Unit: mm
-
No item Criteria Remedy
-
1 Replace liner
Protrusion of cylinder liner Repair limit: 0.07 - 0.15
- or block

Standard Tolerance Repair limit

Inside diameter of cylinder liner

+0.040
125 125.20
0
2

Roundness of cylinder liner Repair limit: 0.08

Reolace liner

Cylindricity of cylinder liner Repair limit: 0.08

Standard Tolerance
Outside diameter of cylinder liner
3 (Counter bore)
153 kO.025

Interference between cylinder Standard: 0 - 0.113 Replace liner

liner and block (Counter bore) or block

Standard Tolerance
Outside diameter of cylinder liner
(Counter bore bottom) Replace liner
+0.090
145
+0.040
4

Standard Interference limit

Interference between cylinder liner Replace liner
and block (Counter bore bottom) or block
0.01 - 0.12 0.01

Standard Tolerance
Outside diameter of cylinder liner
Replace liner
(O-ring) +0.386
5 141 +0.361

Clearance between cylinder liner Replace liner

Standard: 0.014 - 0.079
and block (O-ring) or block
- A

“-:10 6D125 SERIES

MAINTENANCE STANDARD CRANKSHAFT

CRANKSHAFT

\
4
6150F410

Unit: mm

NO. Item Criteria Remedy

Standard Repair limit Repair by using

1
over size
End play
0.0140 - 0.315 thrust bearing
0.50
or replace
Standard Tolerance Repair limit

STD 110 109.88

0.25 U.S. 109.75 109.63

Outside diameter of main journal Repair
-0.050
0.50 U.S. 109.50 109.38 by using
-0.070
under size
0.75 U.S. 109.25 109.13 main bearing
2 or replace
1.00 U.S. 109.00 108.88

Standard Repair limit

Roundness of main journal
0 - 0.010 0.020

Standard Clearance limit

Clearance of main journal , Replace main
0.062 - 0.106 bearing
0.27

Standard Tolerance Repair limit

STD 80 79.86

0.25 U.S. 79.75 79.63 I

Outside diameter of crankpin
lournal

3
1.oo U.S. 79.00 78.88
I I I
Standard Repair limit
Roundness of crankpin journal
0-0.010 0.020

Standard Clearance limit Replace

Clearance of crankpin journal connecting
0.046 - 0.090 0.24 rod

Standard Repair limit Repair by using

4 under size
Bend of crankshaft
bearing or
0 - 0.090 0.20 replace

6D125 SERIES
MAINTENANCE STANDARD CAMSHAFT

CAMSHAFT

I-A

T 1

Section A-A

615OF41 I

Unit: mm

No. Criteria

:nd play

Outside diameter of camshaft

journal

Clearance of camshaft journal

0.080 - 0.180

Cam height

14-012 6D125 SERIES

MAINTENANCE STANDARD CAM FOLLOWER AND PUSH ROD

CAM FOLLOWER AND PUSH ROD

Engine serial No.
6D125-1: up to 21771
S(A)6D125-1: up to 21839

2 3
615OF412

Unit: mm

Outside diameter of cam

follower shaft

Outside diameter of cam roller

4 Radius of push rod ball end

12.7
-LO

5 Radius of push rod socket end 12.7

-:.20

6 Bend of push rod Repair limit: 0.50 (Total indicator reading)

Tightening torque of cam follower

7 5.25 + 0.75 kgm
housing mounting bolt

6D125 SERIES
14-i?3
MAINTENANCE STANDARD CAM FOLLOWER AND PUSHROD

Engine serial No.

6D125-1: 21772 and up
S(A)GD125-1: 21840 and up

615OF426

Unit: mm

Item Criteria Remedy

Standard Tolerance Repair limit

Outside diameter of cam
follower shaft -0.040
19.8 19.73
1 -0.050

Inside diameter of cam follower +0.020

19.8
shaft hole 0

2 Outside diameter of cam roller 32 -0.250 31.71

-0.280

-0.260
Inside diameter of cam roller 13 12.76
-0.285
3
Outside diameter of cam roller -0.365
pin 13 -0.375 12.62 Replace

Standard Tolerance

4 Radius of push rod ball end

0
12.7
-0.20

5 Radius of push rod socket end 12.7

-:.20

6 Bend of push rod Repair limit: 0.50 (Total indicator reading)

-

Tightening torque of cam follower

7 5.25 * 0.75 kgm
housing mounting bolt

6D125 SERIES
MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN

PISTON, PISTON RING AND PISTON PIN

6D125-1 (Aluminum alloy)

6150F414A

14-$14 6D125 SERIES

MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN

6D125-1 (Aluminum alloy)

Unit: mm
l-

No kern Criteria Remedy

Standard Tolerance Repair limit

Outside diameter of piston Replace

I
1
(Aluminum piston) -0.295 124.59
piston
125 -0.325 I

rJO. Measuring point Standard I Tolerance

-0.015
2 Top ring 2.4
I I -0.035
Replace
Thickness of piston ring
-0.010 piston ring
3 Second ring 2.4
I I -0.030

-0.010
4 Oil ring 4.0
I I -0.030

Judge using groove wear gauge

Replace
Width of piston ring groove piston

2 4 Oil ring 4.0 +0.025

+0.010
3
4 P40. Measuring point Standard Clearance limit

2 Top ring
Judge using groove wear gauge Replace
Clearance between piston
piston Or
ring and ring groove
3 Second ring piston ring

4 Oil ring 0.020 - 0.055 0.15

2 Top ring 0.37 - 0.52 2.0

I I
Replace
3 Second ring 0.33- 0.48(NO.- 464351 piston ring
Piston ring gap 0.50 - 0.62 (NO. 46436 and up) or cylinder
liner

4 Oil ring 0.28 - 0.43 1.0

Standard Tolerance
Replace
Outside diameter of piston pin
piston pin
48
-00.00S

Inside diameter of piston pin +0.012 Replace

5 48 +0.004
hole piston

Standard Clearance limit

Replace
Clearance between piston pin
piston or
and piston
0.004 - 0.018 0.030 piston pin

6D125 SERIES
14-F5
MAINTENANCE STANDARD PISTON. PISTON RING AND PISTON PIN

S6D125-1, SAGDI 25-1 (Ductile cast iron (FCD))

6150F415A

6D125 SERIES
14-P
 MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN

Unit: mm

No Item Criteria Remedy

Standard Tolerance Repair limit

Replace

I
1 Outside diameter of piston
-0.075 124.80 piston
125 -0.105
I

No. I Measuring point I Standard I Tolerance

2 Top ring 2.4 -0.015

-0.035

Thickness of piston ring Replace

3 Second ring 2.4 -0.010 piston ring
-0.030

4 Oil ring 4.0 -0.010

-0.030

Judge using groove wear gauge

Replace
Width of piston ring groove
piston

2 4 Oil ring 4.0 +0.040

+0.020
3
4 No. Measuring point Standard Clearance limit

Clearance between piston Judge using groove wear gauge Replace

ring and ring groove piston or
piston ring

4 Oil ring 0.03 - 0.07 0.15

2 Top ring 0.37 - 0.52 2.0

Replace
- 0.48 - piston ring
Piston ring gap 3 Second ring 0.33
0.50- 0.62,NO.
(No. 46435,
46436andup, 1.5 or cylinder
liner

4 Oil ring 0.28 - 0.43 1 .o

-
Standard Tolerance

Outside diameter of piston pin Replace

piston pin

Inside diameter of piston pin Replace

5 48
hole piston

Repair limit
Standard I
Clearance between piston pin Replace
and piston piston or
0.035 - 0.051 0.063 piston pin

6D125 SERIES 14-017

MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN

S6D125-1 (Aluminum alloy)

6150F414A

’4-g7-1 6D125 SERIES

MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN

Unit: mm
- -
No Item Criteria Remedy

Replace
1 Outside diameter of piston
piston

-
I

Replace
Thickness of piston ring
piston ring

Judge using groove wear gauge

Width of piston ring groove piston

2
3
4

Judge using groove wear gauge Replace

Clearance between piston
piston or
ring and ring groove
piston ring

Replace
0.33- 0.48 - piston ring
Piston ring gap 3 Second ring 0.50 - 0.62 (No.46436
INo. 46435)
and up) 1.5 or cylinder
liner

4 Oil ring 0.28 - 0.43 1.0

-
Standard Tolerance
Replace
Outside diameter of piston pin
piston pin
48 -Lo5

Inside diameter of piston pin 48 +0.012 Replace

5 +0.004
hole piston

Standard Clearance limit

Replace
Clearance between piston pin
piston or
and piston
0.004 - 0.018 0.530 piston pin

6D125 SERIES
’4-s7-2
 MAINTENANCE STANDARD TIMING GEAR

TIMING GEAR

2,4’

6150F413A

Unit: mm
-
No Criteria Remedy

idler gear 1Large)

Backlash of each gears Replace

0.155 - 0.440

0.130 - 0.405

0.080 - 0.390

Standard size

Clearance between main idler

1
gear bushing and shaft
Replace
wshing

Clearance between oil pump

2
idler gear and shaft
-

3 End play of main idler gear

Replace
:hrust
Jearing
4 End play of oil pump idler gear

6D125 SERIES 14219

 MAINTENANCE STANDARD FLYWHEEL AND FLYWHEEL HOUSING

FLYWHEEL AND FLYWHEEL HOUSING

I
6 5 615OF417

Unit: mm

No Item Criteria Remedy

1 Fase runout of flywheel housing Repair limit: 0.35

Radial runout of flywheel housing Repair limit: 0.30

Repair by
reassembling
3 Face runout of flywheel Repair limit: 0.20
-
4 Radial runout of flywheel Repair limit: 0.15

j
Tightening torque of flywheel
5
housing mounting bolt

Ml0 - 7 6 - 7.5
Retighten
Tightening order

1st step 15 13 - 17
Tightening torque of flywheel
mounting bolt
6
(Coat the bolt threads
with engine oil)
2nd step 29.5 27.5 - 31.5

14-$20 6D125 SERIES

MAINTENANCE STANDARD VIBRATION DAMPER

VIBRATION DAMPER

Unit: mm
-
NO. Item Criteria Remedy

1 Visual check Not appear any cracks on the rubber Part. Replace

Face runout of vibration damper

2 Repair limit: 0.80 Replace
(For D60P-17)

Radial runout of vibration damper

3 Repair limit: 0.80 Replace
(For D60P-17)
-
Bolt Target (kgm) Range (kgm)

Tightening torque of vibration Ml2 (Except D60P-17) 11.3 lo- 12.5

4 Retighten
damper mounting bolt

Ml4 (For D60P-17) 18 16-20

-

6D125 SERIES
’4-oio-1
MAINTENANCE STANDARD WATER PUMP AND THERMOSTAT

WATER PUMP AND THERMOSTAT

6 I5OF422 6 ISOF

Unit: mm

NO. Item Criteria Remedy

I
Tolerance
Standard Interference
Standard size
interference limit
Interference between impeller Shaft Hole Replace
and shaft impeller
+o.ozo -0.020 0.025 - -
15.9
+0.005 -0.050 0.070

Interference between drive gear +0.015 -0.025 0.025 -

20.0 Replace gear
and shaft 0 +0.055 0.070

Clearance between impeller

Standard: 0.30 - 1.10 (Include end play)
and body

Repair limit
4 Abrasion of seal ring in water seal A: 1.5 Replace

Min. 10 (Check after immersion in a hot water bath

Lift of thermostat valve
of 90°C for 4 or 5 minutes.)
5 Replace
Valve must be close fully when immersed in a hot water bath (71’C)
Opening and closing of valve
for 4 or 5 minutes after being immersed in a hot water bath (90°C)
in thermostat
to fully open the valve.

6D125 SERIES 14-$21

MAINTENANCE STANDARD OIL COOLER

OIL COOLER

6 I5OF42 I

Unit: mm

I I I
No. 1 Item Criteria I Remedy
I

1
Lift of thermostat valve
I 6D125
S6D125
I
Min. 8 (Check after immersion in a hot oil bath
of 115’C for 4 or 5 minutes.) I
- Replace
Valve must be close fully when immersed in a hot oil bath (104°C)
Opening and closing of valve
for 4 or 5 minutes after being immersed in a hot oil bath (115’C)
in thermostat
to fully open the valve.

14-$22 6D125 SERIES

 MAINTENANCE STANDARD OIL PUMP

OIL PUMP

i 615OF418

Unit: mm

No. Criteria Remedy

I I I I
Tolerance
Standard Standard Clearance
Engine
size Gear Body clearance limit
thickness depth
I
1 Axial clearance of pump gear
6D125-1 23 0 +0.065 0.03 -
-0.021 +0.040 0.09 0.10
Replace gear
S6D125-1 0 +0.065 0.03 -
SA6D125-1 47 0.10
-0.025 +O.WO 0.09
I I I
Tolerance
Standard _ Standard Clearance
size clearance limit
2 Radial clearance of pump gear Gear 0.0. Gear I.D.

51.4 -0.15
-0.21
1 +o.c6 0.03 -
0.13
0 0.10
I I I I
Tolerance Standard Clearance or
Standard
clearance or interference
size
Interference between pump Shaft Hole interference limit Replace
3
drive gear and drive shaft
+0.106 +0.065 0.023 - -
18
+0.088 +0.047 0.059

Clearance between drive shaft +0.106 10.173 0.040 - Replace

4 18 +0.088 bushing
and cover bushing +0.146 0.085
-
Interference between pump +0.106 +0.063 0.025 -
5 18 Replace
-
gear and drive shaft +0.088 +0.028 0.078 I
Clearance between drive shaft -0.006 +0.061 0.040 - Replace
18 -0.024 +0.034 bushing
and body bushing 0.085

Clearance between driven shaft +0.090 +0.129 0.012 -

7 18 Replace
and body +0.070 +0.102 0.059
1
Clearance between driven shaft +0.090 +0.147 0.032 - Replace
8 and gear bushing 18
+0.122 0.077 bushing
+0.070
-
Interference between driven shaft +0.090 +0.040 0.030 - -
9 18 Replace
and cover +0.070 +0.020 0.068
I

6D125SERIES
’4-ki23
MAINTENANCE STANDARD MAIN RELIEF VALVE

MAIN RELIEF VALVE

615OF416

Unit: mm

NO. Item I Criteria Remedy

-
Tolerance
Standard _ . Standard Clearance
size clearance limit
Shaft Hole
10 Clearance between valve and body

-0.040 +0.043 0.040 -

16 0.103
-0.060 0

Standard size Repair limit

Replace
Installed Installed Installed
Free length Free length
length load load
11 Relief valve spring

49.1 34.8 10.8 kg 9.8 kg

+1
12 Relief valve set pressure 7 o kg/cm2

6D125 SERIES
’4-:24
MAINTENANCE STANDARD REGULATOR VALVE AND SAFETY VALVE

REGULATOR VALVE AND SAFETY VALVE

S6D125-1, SAGD125-1

6 I50F420A

6D125-1

/ \
2 1
6150F4lSA

Unit: mm

NO kern Criteria Remedy

Tolerance
Standard Standard Clearance
size clearance limit
Valve Body
Clearance between regulator
1
valve and body
+0.15 +0.26 0.07 -
22
+0.12 +0.22 0.16
I I I

Standard size Repair limit

Regulator valve spring
Installed installed Installed
Free length Free length
length load load
Reolace
Outer
2 Remote 65.0 8.63 kg
spring
mounting 42.3
we Inner
56.3 4.248 kg
spring

Direct mounting type 106.2 75.5 11.02 kg

I
3 Regulator valve set pressure 6D125-1: 3.0;;:; kg/cm2 SA6D,
S6D125-1 25_, : 3.75 +0.15 kg/cm*
I I
4 Safety valve set pressure 2.0 + 0.2 kg/cm*

6D125 SERIES
MAINTENANCE STANDARD AIR COMPRESSOR

AIR COMPRESSOR

Unit: mm

No. Item Criteria Remedy

-
Standard clearance Repair limit

1 Piston ring gap 1st. 2nd ring 0.1 - 0.3 2.0

Oil ring 0.2 - 0.6 1.5

I I
Standard size Standard clearance Repair limit
Clearance between
2 piston ring and ring 1st. 2nd ring 3 0.015 - 0.050 0.15
groove
Oil ring 4 0.035 - 0.110 0.20 Repair or
replace
Clearance between piston and
3 85 0.090 - 0.150 0.25
cylinder

4
Clearance between
piston
piston pin and
I 0.006 - 0.026
I
Cleaiance between piston pin and
5 16 0.006 - 0.026 0.1
connecting rod small end
I I I

6
Clearance between
and crankpin
crankpin metal
I
35
I 0.034 - 0.075
I
0.15

6D125 SERIES
 ENGINE
REPAIR AND REPLACEMENT
I5 OF PARTS

Replacing valve seat inserts .. 15-002

Replacing nozzle holder sleeve 15-006
Replacing valve guide .. 15-008
Replacing cross head guide 15-008
Grinding the valve ... ... .. . 15-009
Replacing cam bushing .. . 15-010
Replacing flywheel ring gear 15-012
Replacing cam gear . 15-012
Pressure test ... . 15-013

6D125 SERIES
’so’
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE SEAT INSERTS

REPLACING VALVE SEAT INSERTS

Special tools

3 795-l 00-3720 Cutter (for 30”) 1

4 795-l 00-3730 Cutter (for 45”) 1

1. Pulling out the valve seat insert

A Before
to test it.
using the grinder, run it for a minute

l After replacing the grindstone, run the

grinder for three minutes to test it.

A Confirm that the grindstone is not damaged,

then install it to the shaft of the grinder
without applying excessive force.
Confirm that there is no play between the
grindstone and shaft.

A When using the grinder, wear safety

goggles.

l When using a valve seat puller to remove the valve

seat
1) Install grindstone @to grinder 0.
2) Align the groove of sleeve @ with holder 0,
then insert.
* Adjust the position of the grinder with set
6162F504
screw @I.

1SC402 6D125 SERIES

REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE SEAT INSERTS

3) Adjust the position of the grinder so that the

center of grindstone @ will be at the center of
seat insert (l), then tighten the set screw to
secure the grinder.
4) Rotate the grindstone and move slowly until it
contacts insert (1).

6162F505

5) Press the grindstone against the inside of the

insert, move it in a circular pattern, and make a
groove about 1 mm deep.

6) Push in the three claws (a) on puller head @ of

tool A by hand to insert it inside insert (1).

7) Tighten screw @ to press the three claws

against the groove on the inside surface of the
insert.
* When the claws contact the groove com-
pletely, stop tightening.

8) Place bridge @ over the puller head, then place

plates @ and 0 on the bridge.
Tighten nut @ to pull out the insert.

6162F506

l When welding a bar to the insert to remove the

seat insert
1) Weld bar (I) of radius approx. 4 10, that is
0.1 - 0.5 mm shorter than the inside diameter
to the inside diameter of insert (2).
* Be careful not to let the welding metal stick
to the head itself.

2) When the temperature of the weld goes down 1

to around room temperature, insert an old valve
(3) in the reverse direction, and tap the head of @I?)
the valve with a small hammer to knock out the 2
insert. 6127F205

* If the valve is hit too hard, the weld may

break.

6D125 SERIES
’so3
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE SEAT INSERTS

2. Press fitting the valve seat insert

l When not grinding and correcting the press fitting
surface for the valve seat insert
1) Using tool B, press fit standard valve seat insert
(2).
* Do not use a hammer to press fit.
* Press-fitting force for valve seat (intake,
exhaust sides): Approx. 1 ton

615OF431

2) Check the depth of the insert from the bottom

surface of the cylinder head.
Bottom surface of cylinder head
* Depth of the insert h (intake and exhaust
sides): 1.9 - 2.2 mm.

Insert

615OF432

Machining valve seat insert mounting hole to

oversize
1) Using tools Cl and Cp, grind the hole to a one
size larger oversize.
* Machine within a range of 1.0 mm oversize.
If it is more than 1.0 mm, replace the cylin-
der head.
Dimensions of insert and mounting hole

Insert Unit: mm

Valve O.D. (d) Height(h)

Intake 47.50 $::A;; 7.5 -;., 615OF433

S.T*D
46.5 CO.080 7.5 -;.,
Exhaust f0.070

Intake 47.75 :;:;;; 7.5 -“o.,

0.25 0. S -
Exhaust 46.75 ;;:;;; 7.5 -“o.,

Intake 48.0 +0.100

+0.090 7.62 -;,,
0.50 0 .s
Exhaust 47.0 Z:% 7.62 -“o,,

Intake 48.25 :p:;;; 7.75 -“o,,

0.75 0 *s
Exhaust 47.25 =;:;;; 7.75 -“o,,

Intake 48.5 :1:11: 7.88 -“o.,

1 .oo 0 .s 6162F502-1
Exhaust 47.5 CO.080
co.070
7.88 -“o,,

6D125 SERIES
15go4
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE SEAT INSERTS

Mounting hole for valve seat insert Unit mm

\ 1 Valve 1 D, 1 4 1 H
Intake 47.5 ;;:;:; 50.30 + 0.2 9.5 + 0.1
SeTaD -
Exhaust 46.5 zi:$ 49.30 + 0.2 9.5 * 0.1

Intake 47.75 ;;:;;; 50.55 * 0.2 9.5 * 0.1

0.25 0. S
Exhaust 46.75 $,$ 49.55 + 0.2 9.5 _+ 0.1
D2
Intake 48.0 ;;:;:; 50.80 k 0.2 9.62 k 0.1 -It
Bottom surface of
0.50 0. s cylinder head
Exhaust 47.0 ~~:~:~ 49.80 f 0.2 9.62 k 0.1
615OF434
Intake 48.25 ;;:;:; 51.05 + 0.2 9.75 k 0.1
0.75 0 -s
Exhaust 47.25 ~~:~:~50.05 f 0.2 9.75 k 0.1
intake 48.5 ;;:;;; 51.30 + 0.2 9.88 + 0.1 Intake valve side Exhaust valve
1 .oo 0 . s
Exhaust 47.5 z$i 50.30 + 0.2 9.88 + 0.1

* Inside surface roughness: 12.55 max.

* Mounting hole bottom roughness: 12.5s max.
+ Concentricity of valve guide hole and insert:
0.07 mm (T.1.R) max.

615OF435

4. Finishing insert seat surface

1) Using tools Cl, C3, and Cd, finish the insert seat
surface to the dimensions shown in the
diagram.
* When inserting the pilot into the valve
guide, select a pilot that will enter and leave
Pencil marks:
no clearance.
(Approx. 20 places)

2) Fit the seat surface using the compound.

615OF436
5. Final check
l Coat the seat surface thinly with minimum (red
lead), and insert a new valve into the valve Sinking of valve
guide. Put it lightly in contact with the valve
insert surface, and rotate lo”, then check the When using a
When using a
contact surface with the valve insert. Confirm master valve master valve
that the contact is uniform with no breaks. e of 0 + 0.1 Bottom surface of

l Another way is to mark the new valve with pen-

cil marks as shown in the diagram, insert into
the valve guide, bring into light contact with the
valve insert surface, and rotate 10”. Check that
the pencil marks are erased uniformly around
the whole circumference.
* If a vacuum tester is available, carry out an air-
tightness test to check. 615OF437

6D125 SERIES
REPAIR AND REPLACEMENT OF PARTS REPLACING NOZZLE HOLDER SLEEVE

REPLACING NOZZLE HOLDER SLEEVE

Special tools

1. Removing the sleeve

1) Insert push bar A inside the sleeve.
2) Using sleeve extraction tap 0, cut tap to about
25 mm depth from top face of sleeve.
Add oil while cutting.
* Sleeve extraction tap: M2.5, P = 1.5
3) Insert push bar B from the bottom of the head
6162F509
and tap with the hammer to remove the sleeve.
* Remove the sleeve material cleanly from
portion P of the cylinder head.

ViewP
615OF438

2. Press-fitting the sleeve

Insert sleeve (1) into the cylinder head, then using
sleeve driver C, tap lightly until the sleeve is com-
pletely in close contact with the seat surface.
* Before installing the sleeve, clean the sleeve and
seat.
* Apply adhesive to the seat around the sleeve.

& Adhesive: Loctite (No. 54)

6162F510

6D125 SERIES
’5-:06
 REPAIR AND REPLACEMENT OF PARTS REPLACING NOZZLE HOLDER SLEEVE

3. Roll-fitting the taper section of sleeve

Using roiling tool D, roll-fit the taper section of the
sleeve.
* Set the roll-fitting amount with stopper @ of
the expander.
* Install the expander to a radial drilling machine
or upright drilling machine to roll-fit with its own
weight.
+ Rotating speed: 200 to 300 rpm.

4. Roll-fitting press-fitting portion at top of sleeve

1) Using sleeve holder E, tighten the sleeve from
the bottom surface of the cylinder.

m Tightening torque for sleeve holder:

2 kgm
6162F513

2) Using sleeve expander F, carry out rolling to

caulk the press-fitting portion.
* Rotating speed: 450 rpm
* Inside diameter: 23.9 + 0.1 mm
* Amount of insertion of roller (h): 31 mm
* Adjust the inside diameter with stopper 0,
and fix the position.

3) After rolling, turn in the reverse direction and

remove the sleeve expander.

4) Remove the sleeve holder.

5) Roll the sleeve taper portion again.

615OF439
5. Spot-facing the inside seat of the sleeve
1) Using guide bushing G as the guide, spot-face
the seat with sleeve cutter H.
* When grinding the seat surface, insert the
nozzle holder, check that the protrusion is
within the standard value, and cut a little
more each time.
* Rotating speed: 500 to 600 rpm
* Protrusion of nozzle (S.T.D)
6D125: 4.9 - 5.7 mm
S6D125: 3.35 - 4.25 mm
SA6D125: 4.9 - 5.7 mm
2) Remove all the metal chips and dust from the
machined surface.

6. Checking the leakage from the seat

Carry out a water pressure or air pressure test to
check that there is no leakage from the sleeve seat
surface or upper press-fitting portion.
* When checking for leakage from the seat sur-
6162F514
face, install a used nozzle holder.

6D125 SERIES
 REPLACING VALVE GUIDE
REPAIR AND REPLACEMENT OF PARTS REPLACING CROSS HEAD GUIDE

REPLACING VALVE GUIDE

Special tools

I Part No. I Part Name I Q-Y

A 795-600-2550 Valve guide remover 1

B 795-600-2560 Valve guide driver 1

1. Removing the valve guide

Remove the valve guide with valve guide remover
615OF440
A.

2. Press-fitting the valve guide

1) Press-fit the valve guide until the tip of valve
guide driver B contacts the cylinder head.
2) Confirm that the protrusion of the valve guide is
within specification.
* Protrusion of valve guide: 20.0 + 0.2 mm

615OF441

REPLACING CROSS HEAD GUIDE

Special tools

1. Removing the cross head guide

. Using cross head guide puller A, pull out the cross
head guide.
1) As shown in the figure, hold the cross head
guide with coolet @ of the puller.
2) Tighten the collet with bolt @ to lock sleeve 0.
3) Rotate nut @ and pull out the cross head
guide.
4) Remove burns, fins, etc. from the mounting
place of the cross head guide and clean it.

2. Press-fitting the cross head guide

. Using cross head guide driver B, press fit the cross
head guide.
615FO19

’%08
6D125 SERIES
REPAIR AND REPLACEMENT OF PARTS GRINDING THE VALVE

GRINDING THE VALVE

Special tools

Part No. Part Name Q’ty

A - (Purchase) Valve refacer 1

Grinding the seat surface

Grind the seat surface with valve refacer A.
* Angle of valve seat (a): Intake valve: 60
Exhaust valve: 45”

Checking after grinding

Confirm that the thickness of the valve head, protru-
sion of the valve, and the contact surface of the
valve seat are within specification.
* Allowable thickness of valve head (h)
Intake valve: 1.7 mm
Exhaust valve: 1.2 mm
* Sinking distance of valve: 0 i 0.3

615OF442

6D125 SERIES
’so9
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM BUSHING

REPLACING CAM BUSHING

Special tools

I Part No. I Part Name I O’w

A 1 795-225-1200 1 Push tool I 1
11 I 795-225-l 310 1 Push bar I 1
/ 2 1 795-225-l 210 1 Push tool I 1
A I3 I 795-225-1220 I Collar I 1
I 4 I 795-225-1290 ( Guide I 1
/ 5 ) 795-103-0400 1 Grip
I ’

t Before replacing the cam bushing, remove the plug

from the rear of the cylinder block.

1. Pulling out No. 1,7 bushings

l Assemble push tool AZ, collar A3, and push bar AI
A3 A2 AI
of push tool A, then tap the push bar and remove
bushing (2) from cylinder block (1).

2. Pulling out No. 2,6 bushings

l Assemble push bar Al, push tool AZ, collar A3, and
guide & of push tool A, then tap the push bar and A3 A2 A4

remove bushing (3) from cylinder block (1).

6162F519

3. Pulling out No. 3.4,5 bushings

l Assemble push bar Al, push tool AZ, collar A3, and
guide A4 of push tool A, then tap the push bar and 4
remove bushing (4) from cylinder block (1).

6162F520

6D125 SERIES
15-i?o
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM BUSHING

l After pulling out the bushing, remove all burrs and

clean all dirt and dust from the bushing mounting
hole.

1. Press fitting No. 3,4, 5 bushings

l Assemble bushing (4) to tool A, then press fit the
bushing until the oil hole in cylinder block (1) is
aligned with the oil hole in the bushing.

6202FO17

2. Press fitting No. 2,6 bushings

l Assemble bushing (3) to tool A, then press fit the
bushing until the oil hole in cylinder block (1) is
aligned with the oil hole in the bushing.

6162F522

3. Press fitting No. 1.7 bushings

l Assemble bushing (2) to tool A, then press fit the
bushing until the oil hole in cylinder block (1) is
aligned with the oil hole in the bushing.

6202FO18

Using inside gauge 0, measure the inside diameter

of the bushing.
Check the clearance between the bushing and the
shaft, and if the clearance is not within the standard
range, or if the shaft does not pass through
smoothly, correct the inside diameter of the bushing
with a reamer.
l After correcting the inside diameter of the bush-
ing with a reamer, clean all chips from the oil
6202FO19
hole and oil groove.
Inside diameter of cam bushing: 60 ?t.070 mm
Clearance at camshaft journal: 0.080 - 0.180 mm

6D125 SERIES
5’ ’
 REPLACING FLYWHEEL RING GEAR
REPAIR AND REPLACEMENT OF PARTS REPLACING CAM GEAR

REPLACING FLYWHEEL
RING GEAR

A Take care not to let the flywheel fall.

1. Removing the ring gear

. Make a groove on the tooth bottom surface of the
ring gear with a grinder, then crack the gear with a
chisel.

A Take
details,
care
see
in handling
the discussion
the grinder
on safety
and
in
chisel.
the GEN-
For

ERAL section of this Shop Manual.

2. Press-fitting the ring gear

1) Check the fitting surface of the ring gear. If any
flaw is found, repair it with an oilstone.
2) Heat the ring gear at the specified temperature
for the specified time for shrinkage fitting.
* Heating temperature for ring gear: 200°C max.
Heating time: 30 minutes
3) With the chamferred side of ring gear facing the
flywhel, fit it until its side contacts the flywheel.

REPLACING CAM GEAR

* Heating temperature for cam gear: 220 to 240°C

Heating time: 30 minutes

15-g 2 6D125 SERIES

REPAIR AND REPLACEMENT OF PARTS PRESSURE TEST

PRESSURE TEST

l If the area round the head has been corrected, test as

follows.

Special tools

1. Water pressure test

1) Tighten the nozzle holder assembly to the speci-
fied torque.
2) Assemble tool A and tool 6, and connect a hose
to flange (1).
3) Apply water pressure (3.5 - 4.0 kg/cm2) for
approx. 10 minutes, and check for any leakage
from around the head.
* It is preferable to warm the whole cylinder head
and carry out the test with hot water (82 -
93°C).

2. Air pressure test

1) Tighten the nozzle holder assembly to the speci-
6202FO19
fied torque.
2) Connect the pump hose to flange (1).
3) Place the head in a water bath, apply air pres-
sure (3.0 - 3.5 kg/cm2) for approx. 30 seconds,
and check for any air leakage in the water.
+ If the above test shows that there are cracks
around the nozzle holder and plugs, replace the
cylinder head.

6D125 SERIES 15-($3

Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
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PFMRl 081696