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SEBM0086

DIESEL ENGINE



Contents

No. of page

01 General .......................................................................................................................... 01-1

11 Structure and function...................................................................................... 11-1

12 Testing and adjusting........................................................................................ 12-1

13 Disassembly and assembly .......................................................................... 13-1

14 Maintenance standard.........................................................................................14-1

15 Repair and replacement of parts.............................................................. 15-1



List of revised pages

The affected pages are indicated by the use of the

following marks. It is requested that necessary

actions be taken to these pages according to the

table below.

Pages having no marks are those previously revised

or made additions.


Mark Indication Action required

Q Page to be newly added Add

q Page to be replaced Replace

( ) Page to be deleted Discard

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revision Mark Page

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revision

q 00-1 (11) 01-2 (10) 01-32 (10) 11-17 (10) 11-50 (10)

00-2 (10) 01-3 (10) 01-33 (10) 11-18 (10) 11-51 (10)

q 00-2-1 (11) 01-4 (10) 01-34 (10) 11-19 (10) 11-52 (10)

q 00-2-2 (11) 01-5 (10) 01-35 (10) 11-20 (10) 11-53 (10)

q 00-2-3 (11) 01-6 (10) 01-36 (10) 11-21 (10) 11-54 (10)

00-3 01-7 (10) 01-37 (10) 11-22 (10) 11-55 (10)

00-4 01-8 (10) 01-38 (10) 11-24 (10) 11-56 (10)

00-5 01-9 (10) 01-39 (10) 11-25 (10) 11-57 (10)00-6 01-10 (10) 01-40 (10) 11-26 (10) 11-58 (10)

00-7 01-11 (10) 01-41 (10) 11-27 (10) 11-59 (10)

00-8 01-12 (10) 01-42 (10) 11-28 (10) 11-60 (10)

00-9 01-13 (10) 11-29 (10) 11-61 (10)

00-10 01-14 (10) 11-1 (10) 11-30 (10) 11-62 (10)

00-11 01-15 (10) 11-2 (10) 11-32 (10) 11-63 (10)

00-12 01-16 (10) 11-3 (10) 11-33 (10) 11-64 (10)

00-13 01-18 (10) 11-4 (10) 11-34 (10) 11-65 (10)

00-14 01-19 (10) 11-5 (10) 11-36 (10) 11-66 (10)

00-15 01-20 (10) 11-6 (10) 11-38 (10) 11-67 (10)

00-16 01-21 (10) 11-7 (10) 11-39 (10) 11-68 (10)

00-17 01-22 (10) 11-8 (10) 11-40 (10) 11-70 (10)

00-18 01-23 (10) 11-9 (10) 11-41 (10) 11-71 (10)

00-19 01-24 (10) 11-10 (10) 11-42 (10) 11-72 (10)

00-20 01-25 (10) 11-11 (10) 11-43 (10) 11-73 (10)

00-21 01-26 (10) 11-12 (10) 11-44 (10) 11-74 (10)

00-22 01-28 (10) 11-13 (10) 11-45 (10) 11-75 (10)

01-29 (10) 11-14 (10) 11-46 (10) 11-76 (10)

01-30 (10) 11-15 (10) 11-48 (10) 11-77 (10)

01-1 (10) 01-31 (10) 11-16 (10) 11-49 (10) 11-78 (10)




Mark Page Time of

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11-79 (10) 12-11 (10) 12-55 (10) 13-21 (2) 14-7 (10)

11-80 (10) 12-12 (10) 12-56 (10) 13-22 (2) 14-8 (10)

11-81 (10) 12-13 (10) 12-57 (10) 13-23 (4) 14-9 (10)

11-82 (10) 12-14 (10) 12-58 (10) 13-24 (4) 14-10 (10)

11-83 (10) 12-15 (10) 12-59 (10) 13-25 (4) 14-11 (10)

11-84 (10) 12-16 (10) 12-60 (10) 13-26 (2) 14-12 (10)

11-85 (10) 12-17 (10) 12-61 (10) 13-27 (4) 14-13 (10)

11-86 (10) 12-18 (10) 12-62 (10) 13-28 (4) 14-14 (10)

11-88 (10) 12-19 (10) 12-63 (10) 13-29 (4) 14-16 (10)

11-89 (10) 12-20 (10) 12-65 (10) 13-30 (2) 14-18 (10)

11-90 (10) 12-21 (10) 12-66 (10) 13-31 (2) 14-19 (10)

11-91 (10) 12-22 (10) 12-67 (10) 13-32 (2) 14-20 (10)

11-92 (10) 12-23 (10) 12-68 (10) 13-33 (2) 14-21 (10)

11-93 (10) 12-24 (10) 12-69 (10) 13-34 (2) 14-22 (10)

11-94 (10) 12-25 (10) 12-70 (10) 13-35 (2) 14-23 (10)

11-95 (10) 12-26 (10) 12-71 (10) 13-36 (4) 14-24 (10)

11-96 (10) 12-27 (10) 12-72 (10) 13-37 (4) 14-25 (10)

11-97 (10) 12-28 (10) 12-73 (10) 13-38 (2) 14-26 (10)

11-98 (10) 12-29 (10) 12-74 (10) 13-39 (2) 14-27 (10)

11-99 (10) 12-30 (10) 12-75 (10) 13-40 (2) 14-28 (10)

11-100 (10) 12-32 (10) 13-41 (2) 14-29 (10)

11-102 (10) 12-33 (10) 13-42 (2) 14-30 (10)

11-103 (10) 12-34 (10) 13-1 (2) 13-43 (2) 14-31 (10)

11-104 (10) 12-35 (10) 13-2 (2) 13-44 (2)

11-105 (10) 12-36 (10) 13-3 (2) 13-45 (2)

11-106 (10) 12-37 (10) 13-4 (2) 13-46 (2) 15-1 (10)

11-107 (10) 12-38 (10) 13-5 (2) 13-47 (2) 15-2 (10)

11-108 (10) 12-39 (10) 13-6 (2) 13-48 (2) 15-3 (10)

11-109 (10) 12-41 (10) 13-7 (2) 13-49 (2) 15-4 (10)

11-110 (10) 12-42 (10) 13-8 (2) 13-50 (2) 15-5 (10)

12-43 (10) 13-9 (2) 13-51 (2) 15-6 (10)

12-44 (10) 13-10 (2) 13-52 (2) 15-7 (10)

12-1 (10) 12-45 (10) 13-11 (2) 13-53 (2) 15-8 (10)

12-2 (10) 12-46 (10) 13-12 (2) 13-54 (2) 15-9 (10)

12-3 (10) 12-47 (10) 13-13 (2) 15-10 (10)

12-4 (10) 12-48 (10) 13-14 (2) 15-11 (10)

12-5 (10) 12-49 (10) 13-15 (2) 14-1 (10) 15-12 (10)

12-6 (10) 12-50 (10) 13-16 (2) q 14-2 (11) 15-13 (10)

12-7 (10) 12-51 (10) 13-17 (2) q 14-3 (11) 15-14 (10)

12-8 (10) 12-52 (10) 13-18 (4) q

14-4 (11) 15-15 (10)12-9 (10) 12-53 (10) 13-19 (2) q 14-5 (11) 15-16 (10)




Mark Page Time of

revision Mark Page

Time of

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revision Mark Page

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revision Mark Page

Time of

revision

15-18 (10)

15-19 (10)

15-20 (10)

15-21 (10)

15-22 (10)

15-23 (10)

15-24 (10)

15-25 (10)

15-26 (10)

15-27 (10)

15-28 (10)

15-29 (10)

15-31 (10)

15-31 (10)

15-32 (10)

15-33 (10)



Safety Safety notice

SafetySafety notice

General precautions

Mistakes in operation are extremely dangerous.

Read the Operation and Maintenance Manual care-

fully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read

all the precautions given on the decals which

are fixed to the machine.

2. When carrying out any operation, always wear

safety shoes and helmet. Do not wear loose

work clothes, or clothes with buttons missing.

• Always wear safety glasses when hitting

parts with a hammer.

• Always wear safety glasses when grinding

parts with a grinder, etc.

3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.

When carrying out welding work, always wear

welding gloves, apron, hand shield, cap and

other clothes suited for welding work.

4. When carrying out any operation with two or more workers, always agree on the operating

procedure before starting. Always inform your

fellow workers before starting any step of the

operation. Before starting work, hang UNDER

REPAIR signs on the controls in the operator's

compartment.

5. Keep all tools in good condition and learn the

correct way to use them.

6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools

and parts in their correct places. Always keep

the work area clean and make sure that there is

no dirt or oil on the floor. Smoke only in the

areas provided for smoking. Never smoke while

working.

Preparations for work

7. Before adding oil or making any repairs, park

the machine on hard, level ground, and block

the wheels or tracks to prevent the machine

from moving.

8. Before starting work, lower blade, ripper, bucket

or any other work equipment to the ground. If

this is not possible, insert the safety pin or use

blocks to prevent the work equipment from fall-

ing. In addition, be sure to lock all the control

levers and hang warning signs on them.

9. When disassembling or assembling, support the

machine with blocks, jacks or stands beforestarting work.

10. Remove all mud and oil from the steps or other

places used to get on and off the machine.

Always use the handrails, ladders or steps when

getting on or off the machine. Never jump on or

off the machine. If it is impossible to use the

handrails, ladders or steps, use a stand to pro-

vide safe footing.

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 symbolk is used to mark safety precautions in this manual. The

cautions accompanying these symbols should always be followed carefully. If any dangerous situa-

tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the

situation.



Safety Safety notice

Precautions during work

11. When removing the oil filler cap, drain plug or

hydraulic pressure measuring plugs, loosen

them slowly to prevent the oil from spurting out.

Before disconnecting or removing components

of the oil, water or air circuits, first remove thepressure completely from the circuit.

12. The water and oil in the circuits are hot when the

engine is stopped, so be careful not to get

burned.

Wait for the oil and water to cool before carrying

out any work on the oil or water circuits.

13. Before starting work, remove the leads from the

battery. Always remove the lead from the nega-

tive (–) terminal first.

14. When raising heavy components, use a hoist or

crane.

Check that the wire rope, chains and hooks are

free from damage.

Always use lifting equipment which has ample

capacity.

Install the lifting equipment at the correct places.

Use a hoist or crane and operate slowly to pre-

vent the component from hitting any other part.

Do not work with any part still raised by the hoist

or crane.

15. When removing covers which are under internalpressure or under pressure from a spring,

always leave two bolts in position on opposite

sides. Slowly release the pressure, 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 minimum of gas-

oline when washing electrical parts.

19. Be sure to assemble all parts again in their origi-

nal places.

Replace any damaged parts with new parts.

• When installing hoses and wires, be sure

that they will not be damaged by contact with

other parts when the machine is being

operated.

20. When installing high pressure hoses, make sure

that they are not twisted. Damaged tubes are

dangerous, so be extremely careful when install-

ing tubes for high pressure circuits. Also, check

that connecting parts are correctly installed.

21. When assembling or installing parts, always use

the specified tightening torques. When installing

protective parts such as guards, or parts which

vibrate violently or rotate at high speed, be par-

ticularly careful to check that they are installedcorrectly.

22. When aligning two holes, never insert your fin-

gers or hand. Be careful not to get your fingers

caught in a hole.

23. When measuring hydraulic pressure, check that

the measuring tool is correctly assembled

before taking any measurements.

24. Take care when removing or installing the tracks

of track-type machines.

When removing the track, the track separates

suddenly, so never let anyone stand at either

end of the track.



Foreword General

ForewordGeneral

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 judge-ments. 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 fur-

ther 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 under-

standing of the structure, but also serves as reference material for troubleshooting.

In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-

nance standards.

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” with “Causes” are also included in this section.

Disassembly and assembly

This section explains the procedures for removing, installing, disassembling and assembling each com-

ponent, as well as precautions for them.

Maintenance standard

This section gives the judgment standards for inspection of disassembled parts.

The contents of this section may be described in “Structure and function”.

Others

This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.

In addition, this section may give the specifications of attachments and options together.

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.



Foreword General

How to read the shop manual

Volumes

Shop manuals are issued as a guide to carrying out

repairs. They are divided as follows:

Chassis volume: Issued for every machine modelEngine volume: Issued for each engine series

These various volumes are designed to avoid dupli-

cating the same information. Therefore, to deal with

all repairs for any model , it is necessary that chas-

sis, engine, electrical and attachment volumes be

available.

Distribution and updating

Any additions, amendments or other changes will be

sent to KOMATSU distributors. Get the most up-to-

date information before you start any work.

Filing method

1. See the page number on the bottom of the page.

File the pages in correct order.

2. Following examples show how to read the page

number.

Example 1 (Chassis volume):

Example 2 (Engine volume):

3. Additional pages: Additional pages are indi-

cated by a hyphen (–) and number after the

page number. File as in the example.

Example:

Revised edition mark

When a manual is rev ised, an edi t ion mark

((1)(2)(3)....) is recorded on the bottom of the pages.

Revisions

Revised pages are shown in the List of revisedpages next to the Contents page.

Symbols

So that the shop manual can be of ample practical

use, important safety and quality portions are

marked with the following symbols.

Electrical volume:

Attachments volume:

Each issued as one

volume to cover all

models

10 - 3

Item number

(10. Structure and Function)

Consecutive page number for

each item.

12 - 5

Unit number (1. Engine)

Item number

(2. Testing and Adjusting)

Consecutive page number for

each item.

10-4

Added pages

20-203

10-4-1 12-203-1

10-4-2 12-203-2

Symbol Item Remarks

k Safety

Special safety precautions

are necessary whenperforming the work.

a Caution

Special technical

precautions or other

precautions for preserving

standards are necessary

when performing the work.

4 Weight

Weight of parts of systems.

Caution necessary when

selecting hoisting wire, or

when working posture is

important, etc.

3Tightening

torque

Places that require special

attention for the tightening

torque during assembly.

2 Coat

Places to be coated with

adhesives and lubricants,

etc.

5 Oil, water

Places where oil, water or

fuel must be added, and

the capacity.

6 Drain

Places where oil or water

must be drained, andquantity to be drained.



Foreword Hoisting instructions

Hoisting instructions

Hoisting

• If a part cannot be smoothly removed from the

machine by hoisting, the following checks should

be made:

1) Check for removal of all bolts fastening the

part to the relative parts.

2) Check for existence of another part causing

interference with the part to be removed.

Wire ropes

1) Use adequate ropes depending on the

weight of parts to be hoisted, referring to the

table below:

a The allowable load value is estimated to be

one-sixth or one-seventh of the breaking

strength of the rope used.

2) Sling wire ropes from the middle portion of

the hook.

Slinging near the edge of the hook may

cause the rope to slip off the hook during

hoisting, and a serious accident can result.Hooks have maximum strength at the mid-

dle portion.

3) Do not sling a heavy load with one rope

alone, but sling with two or more ropessymmetrically wound onto the load.

k Slinging with one rope may cause

turning of the load during hoisting,

untwisting of the rope, or slipping of the

rope from its original winding position on

the load, which can result in a dangerous

accident.

4) Do not sling a heavy load with ropes forming

a wide hanging angle from the hook.

When hoisting a load with two or more

ropes, the force subjected to each rope will

increase with the hanging angles. The table

below shows the variation of allowable load

kN {kg} when hoisting is made with two

ropes, each of which is allowed to sling up

to 9.8 kN {1000 kg} vertically, at various

hanging angles.

When two ropes sling a load vertically, up to

19.6 kN {2000 kg} of total weight can be

suspended. This weight becomes 9.8 kN

{1000 kg} when two ropes make a 120?

hanging angle. On the other hand, two

ropes are subjected to an excessive forceas large as 39.2 kN {4000 kg} if they sling a

19.6 kN {2000 kg} load at a lifting angle of

150°.

k Heavy parts (25 kg or more) must be lifted

with a hoist, etc. In the Disassembly andassembly section, every part weighing 25

kg or more is indicated clearly with the

symbol

Wire ropes

(Standard “Z” or “S” twist ropes

without galvanizing)

Rope diameter Allowable load

mm kN tons

10

11.5

12.5

14

16

18

20

22.4

30

40

50

60

9.8

13.7

15.7

21.6

27.5

35.3

43.1

54.9

98.1

176.5

274.6

392.2

1.0

1.4

1.6

2.2

2.8

3.6

4.4

5.6

10.0

18.0

28.0

40.0

4

SAD00479

41%71%79%88%100%



Foreword Method of disassembling, connecting push-pull type coupler

Method of disassembling, connecting push-pull type coupler

k Before carrying out the following work, release

the residual pressure from the hydraulic tank.

For details, see “Testing and adjusting”,

Releasing residual pressure from hydraulic tank.

k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out

when the hose is disconnected. Accordingly,

prepare an oil receiving container.

Disconnection

1) Release the residual pressure from the

hydraulic tank. For details, see “Testing and

adjusting”, Releasing residual pressure from

hydraulic tank.

2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)

a The adapter can be pushed in about 3.5 mm.

a Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it

clicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)

a Since some hydraulic oil flows out, prepare

an oil receiving container.

Connection

1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with each

other. (See Fig. 4)

a Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting

condition. (See Fig. 5)

a When the hose is pulled back, the rubber cap

portion moves toward the hose about 3.5mm. This does not indicate abnormality,

however.

Type 1



Foreword Method of disassembling, connecting push-pull type coupler

Type 2 Type 3

D i s a s s e m b l y

1) Hold the mouthpiece of the tightening portion

and push body (2) in straight unti l sl iding

prevention ring (1) contacts contact surface a of

the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever

(4) to the right (clockwise).

3) Hold in the condition in Steps 1) and 2), and pull

out whole body (2) to disconnect it.

1) Hold the mouthpiece of the tightening portion

and push body (2) in straight unti l sl iding

prevention ring (1) contacts contact surface a of

the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and push until

cover (3) contacts contact surface a of thehexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull

out whole body (2) to disconnect it.

C o n n e c t i o n

• Hold the mouthpiece of the tightening portion and

push body (2) in straight until sliding prevention

ring (1) contacts contact surface a of the

hexagonal portion at the male end to connect it.

• Hold the mouthpiece of the tightening portion and

push body (2) in straight until sliding prevention

ring (1) contacts contact surface a of the

hexagonal portion at the male end to connect it.



Foreword Coating materials

Coating materials

a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly

and assembly are listed below.

a For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q’ty Container Main applications, featuresr

Adhesives

LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets, rubber

cushions, and cock plug from coming out.

LT-1B 790-129-905020 g

(2 pcs.)Polyethylene

container

• Used in places requiring an immediatelyeffective, strong adhesive.Used for plastics (except polyethylene,polyprophylene, tetrafluoroethlene andvinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 gPolyethylene

container

• Features:Resistance to heat and chemicals

• Used for anti-loosening and sealant

purpose for bolts and plugs.

LT-3

790-129-9060(Set of adhesiveand hardening

agent)

Adhesive:1 kg

Hardeningagent:500 g

Can

• Used as adhesive or sealant for metal,glass and plastic.

LT-4 790-129-9040 250 gPolyethylene

container • Used as sealant for machined holes.

HoltzMH 705

790-126-9120 75 g Tube• Used as heat-resisting sealant for

repairing engine.

Three bond1735

790-129-9140 50 gPolyethylene

container

• Quick hardening type adhesive• Cure time: within 5 sec. to 3 min.• Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha201

790-129-9130 2 gPolyethylene

container

• Quick hardening type adhesive• Quick cure type

(max. strength after 30 minutes)• Used mainly for adhesion of rubbers,

plastics and metals.

Loctite648-50

79A-129-9110 50 ccPolyethylene

container

• Resistance to heat, chemicals• Used at joint portions subject to high

temperatures.

Gasketsealant

LG-1 790-129-9010 200 g Tube• Used as adhesive or sealant for gaskets

and packing of power train case, etc.

LG-5 790-129-9080 1 kg Can

• Used as sealant for various threads, pipe joints, flanges.

• Used as sealant for tapered plugs,

elbows, nipples of hydraulic piping.

LG-6 790-129-9020 200 g Tube

• Features: Silicon based, resistance toheat, cold

• Used as sealant for flange surface, tread.• Used as sealant for oil pan, final drive

case, etc.

LG-7 790-129-9070 1 g Tube

• Features: Silicon based, quick hardeningtype

• Used as sealant for flywheel housing,intake manifold, oil an, thermostathousing, etc.

Three bond1211

790-129-9090 100 g Tube• Used as heat-resisting sealant for

repairing engine.

Three bond1207B

419-15-18131 100 g Tube• Features: Silicone type, heat resistant,

vibration resistant, and impact resistantsealing material



Foreword Coating materials

Molybdenumdisulphide

lubricant

LM-G 09940-00051 60 g Can• Used as lubricant for sliding portion (to

prevent from squeaking).

LM-P 09940-00040 200 g Tube

• Used to prevent seizure or scuffling of the

thread when press fitting or shrink fitting.• Used as lubricant for linkage, bearings,etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

• General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

• Used for normal temperature, light loadbearing at places in contact with water orsteam.

Molybdenum

disulphidegreaseLM-G (G2-M)

SYG2-400MSYG2-400M-ASYGA-16CNM

400 g × 10400 g × 2016 kg

Bellows typeBellows typeCan

• Used for heavy load portion

Hyper WhiteGrease G2-TG0-T (*)*: For use in

cold district

SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)

400 g16 kg

Bellows typeCan

• Seizure resistance and heat resistancehigher than molybdenum disulfide grease

• Since this grease is white, it does notstand out against machine body.

Biogrease G2BG2-BT (*)*: For high

temperatureand large load

SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)

400 g16 kg

Bellows typeCan

• Since this grease is decomposed bybacteria in short period, it has less effectson microorganisms, animals, and plants.

Primer

SUNSTARPAINT PRIMER580 SUPER

417-926-3910

20 ml Glasscontainer

A d h e s i v e f o r c a b g l a s s

• Used as primer for cab side(Using limit: 4 months)

SUNSTARGLASS PRIMER580 SUPER

20 mlGlass

container

• Used as primer for glass side(Using limit: 4 months)

Adhesive

SUNSTARPENGUINESEAL 580SUPER “S” or“W”

320 mlPolyethylene

container

• “S” is used for high-temperatureseason (April - October) and “W” forlow-temperature season (November - April) as adhesive for glass.(Using limit: 4 months)

Sika Japan,Sikaflex 256HV

20Y-54-39850 310 mlPolyethylene

container • Used as adhesive for glass.

(Using limit: 6 months)

Caulkingmaterial

SUNSTAR

PENGUINESEAL No. 2505

417-926-3920 320 ml Polyethylenecontainer

• Used to seal joints of glass parts.

(Using limit: 4 months)

SEKISUISILICONESEALANT

20Y-54-55130 333 mlPolyethylene

container

• Used to seal front window.(Using limit: 6 months)

Category Komatsu code Part No. Q’ty Container Main applications, featuresr



Foreword Standard tightening torque

Standard tightening torque

Standard tightening torque table (when using torque wrench)

a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the

table below.

Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no

special instruction, tighten to the torque given inthe table below.

Thread diameter

of bolt

Width across

flats

Tightening torque

mm mm Nm kgm

6

8

10

12

14

10

13

17

19

22

11.8 – 14.7

27 – 34

59 – 74

98 – 123

153 – 190

1.2 – 1.5

2.8 – 3.5

6 – 7.5

10 – 12.5

15.5 – 19.5

16

18

2022

24

24

27

3032

36

235 – 285

320 – 400

455 – 565610 – 765

785 – 980

23.5 – 29.5

33 – 41

46.5 – 5862.5 – 78

80 – 100

27

30

33

36

39

41

46

50

55

60

1150 – 1440

1520 – 1910

1960 – 2450

2450 – 3040

2890 – 3630

118 – 147

155 – 195

200 – 250

250 – 310

295 – 370

Thread diameter

of bolt

Width across

flats

Tightening torque

mm mm Nm kgm

6

8

10

12

10

13

14

27

5.9 – 9.8

13.7 – 23.5

34.3 – 46.1

74.5 – 90.2

0.6 – 1.0

1.4 – 2.4

3.5 – 4.7

7.6 – 9.2

SAD00483

Sealing surface

Thread diameter Width across flats Tightening torque

mm mm Nm kgm

14

18

22

24

30

33

36

42

19

24

27

32

36

41

46

55

24.5 ± 4.9

49 ± 19.6

78.5 ± 19.6

137.3 ± 29.4

176.5 ± 29.4

196.1 ± 49

245.2 ± 49

294.2 ± 49

2.5 ± 0.5

5 ± 2

8 ± 2

14 ± 3

18 ± 3

20 ± 5

25 ± 5

30 ± 5




Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table

below.

Table of tightening torques for o-ring boss piping joints

a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Table of tightening torques for o-ring boss plugs

a Unless there are special instructions, tighten the O-ring boss plugs to the torque below.


mm mm Nm kgm

10

12

16

14

17

22

59 – 74

98 – 123

235 – 285

6 – 7.5

10 – 12.5

23.5 – 29.5

Norminal No.Thread diameter Width across flats Tightening torque

mm mm Nm kgm

02

03, 04

05, 06

10, 12

14

14

20

24

33

42

Varies depending

on type of

connector.

35 – 63 {3.5 – 6.5}

84 – 132 {8.5 – 13.5}

128 – 186 {13.0 – 19.0}

363 – 480 {37.0 – 49.0}

746 – 1010 {76.0 – 103}

44 {4.5}

103 {10.5}

157 {16.0}

422 {43.0}

883 {90.0}

Norminal No.


mm mm Nm kgm

08

10

12

14

16

18

20

24

30

33

36

4252

08

10

12

14

16

18

20

24

30

33

36

4252

14

17

19

22

24

27

30

32

32

—

36

——

5.88 – 8.82 {0.6 – 0.9}

9.8 – 12.74 {1.0 – 1.3}

14.7 – 19.6 {1.5 – 2.0}

19.6 – 24.5 {2.0 – 2.5}

24.5 – 34.3 {2.5 – 3.5}

34.3 – 44.1 {3.5 – 4.5}

44.1 – 53.9 {4.5 – 5.5}

58.8 – 78.4 {6.0 – 8.0}

93.1 – 122.5 {9.5 – 12.5}

107.8 – 147.0 {11.0 – 15.0}

127.4 – 176.4 {13.0 – 18.0}

181.3 – 240.1 {18.5 – 24.5}274.4 – 367.5 {28.0 – 37.5}

7.35 {0.75}

11.27 {1.15}

17.64 {1.8}

22.54 {2.3}

29.4 {3.0}

39.2 {4.0}

49.0 {5.0}

68.6 {7.0}

107.8 {11.0}

124.4 {13.0}

151.9 {15.5}

210.7 {21.5}323.4 {33.0}




Tightening torque for 102 engine series

1) Bolt and nuts

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

2) Eye joints

Use these torques for eye joints (unit: mm) of Cummins Engine.

3) Tapered screws

Use these torques for tapered screws (unit: inch) of Cummins Engine.

Tightening torque table for hoses (taper seal type and face seal type)

a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.

a Apply the following torque when the threads are coated (wet) with engine oil.

Thread diameter Tightening torque

mm Nm kgm

6

8

10

12

10 ± 2

24 ± 4

43 ± 6

77 ± 12

1.02 ± 0.20

2.45 ± 0.41

4.38 ± 0.61

7.85 ± 1.22


mm Nm kgm

6

8

1012

14

8 ± 2

10 ± 2

12 ± 224 ± 4

36 ± 5

0.81 ± 0.20

1.02 ± 0.20

1.22 ± 0.202.45 ± 0.41

3.67 ± 0.51


inch Nm kgm

1 / 16

1 / 8

1 / 4

3 / 8

1 / 2

3 / 4

1

3 ± 1

8 ± 2

12 ± 2

15 ± 2

24 ± 4

36 ± 5

60 ± 9

0.31 ± 0.10

0.81 ± 0.20

1.22 ± 0.20

1.53 ± 0.41

2.45 ± 0.41

3.67 ± 0.51

6.12 ± 0.92

Nominalsize ofhose

Widthacross flats

Tightening torque (Nm {kgm})Taper seal

typeFace seal type

Range TargetThread size

(mm)

Nominal thread size – Threads per inch,

Thread series

Root diameter(mm) (Reference)

02 19 34 – 63 {3.5 – 6.5} 44 {4.5} 149

– 18UNF 14.316

0322 54 – 93 {5.5 – 9.5} 74 {4.5} —

11 – 16UN 17.5

16

24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 — —

04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 113

– 16UN 20.716

05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4

06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 13

– 12UNF 30.316

(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 — —

(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —



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

Classification by color and code

Norminal

number

Copper wireCable O.D.

(mm)

Current rating

(A) Applicable circuitNumber of

strands

Dia. of

strands (mm2)

Cross section

(mm2)

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 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

PriorityCircuits

Charging Ground Starting Lighting Instrument Signal Other Classification

1 Primary

Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxiliary

Code WR — BW RW YR GW LW

Color White &

Red—

White &

Black

Red &

White

Rellow &

Red

Green &

White

Blue &

White

3Code WB — BY RB YB GR LR

Color White &

Black—

Black &

Yellow

Red &

Black

Yellow &

Black

Green &

Red

Blue &

Yellow

4

Code WL — BR RY YG GY LY

Color White &

Blue—

Black &

Red

Red &

Yellow

Yellow &

Green

Green &

Yellow

Blue &

Yellow

5

Code WG — — RG YL GB LB

Color White &

Green— —

Red &

Green

Yellow &

Blue

Green &

Black

Blue &

Black

6Code — — — RL YW GL —

Color Red & BlueYellow & Green &



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.

1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line

from (A).

2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down

from (B).

3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from

millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm.2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

3.543

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

3.583

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

3.622

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

3.661

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

3.701

0.197

0.591

0.984

1.378

1.772

(C)

2.559

2.953

3.346

3.740

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

3.780

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

3.819

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

3.858

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

3.898

2.165

(B)

(A)




Millimeters to Inches

1 mm = 0.03937 in

Kilogram to Pound

1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

3.543

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

3.583

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

3.622

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

3.661

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

3.701

0.197

0.591

0.984

1.378

1.772

2.165

2.559

2.953

3.346

3.740

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

3.780

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

3.819

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

3.858

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

3.898

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

22.05

44.09

66.14

88.18

110.23

132.28

154.32

176.37

198.42

2.20

24.25

46.30

68.34

90.39

112.44

134.48

156.53

178.57

200.62

4.41

26.46

48.50

70.55

92.59

114.64

136.69

158.73

180.78

202.83

6.61

28.66

50.71

72.75

94.80

116.85

138.89

160.94

182.98

205.03

8.82

30.86

51.91

74.96

97.00

119.05

141.10

163.14

185.19

207.24

11.02

33.07

55.12

77.16

99.21

121.25

143.30

165.35

187.39

209.44

13.23

35.27

57.32

79.37

101.41

123.46

145.51

167.55

189.60

211.64

15.43

37.48

59.53

81.57

103.62

125.66

147.71

169.76

191.80

213.85

17.64

39.68

61.73

83.78

105.82

127.87

149.91

171.96

194.01

216.05

19.84

41.89

63.93

85.98

108.03

130.07

152.12

174.17

196.21

218.26




Liter to U.S. Gallon

1l = 0.2642 U.S. Gal

Liter to U.K. Gallon

1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.642

5.283

7.925

10.567

13.209

15.850

18.492

21.134

23.775

0.264

2.906

5.548

8.189

10.831

13.473

16.115

18.756

21.398

24.040

0.528

3.170

5.812

8.454

11.095

13.737

16.379

19.020

21.662

24.304

0.793

3.434

6.076

8.718

11.359

14.001

16.643

19.285

21.926

24.568

1.057

3.698

6.340

8.982

11.624

14.265

16.907

19.549

22.190

24.832

1.321

3.963

6.604

9.246

11.888

14.529

17.171

19.813

22.455

25.096

1.585

4.227

6.869

9.510

12.152

14.795

17.435

20.077

22.719

25.361

1.849

4.491

7.133

9.774

12.416

15.058

17.700

20.341

22.983

25.625

2.113

4.755

7.397

10.039

12.680

15.322

17.964

20.605

23.247

25.889

2.378

5.019

7.661

10.303

12.944

15.586

18.228

20.870

23.511

26.153

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.200

4.399

6.599

8.799

10.998

13.198

15.398

17.598

19.797

0.220

2.420

4.619

6.819

9.019

11.281

13.418

15.618

17.818

20.017

0.440

2.640

4.839

7.039

9.239

11.438

13.638

15.838

18.037

20.237

0.660

2.860

5.059

7.259

9.459

11.658

13.858

16.058

18.257

20.457

0.880

3.080

5.279

7.479

9.679

11.878

14.078

16.278

18.477

20.677

1.100

3.300

5.499

7.969

9.899

12.098

14.298

16.498

18.697

20.897

1.320

3.520

5.719

7.919

10.119

12.318

14.518

16.718

18.917

21.117

1.540

3.740

5.939

8.139

10.339

12.528

14.738

16.938

19.137

21.337

1.760

3.950

6.159

8.359

10.559

12.758

14.958

17.158

19.357

21.557

1.980

4.179

6.379

8.579

10.778

12.978

15.178

17.378

19.577

21.777




kgm to ft. lb

1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180190

0

72.3

144.7

217.0

289.3

361.7

434.0

506.3

578.6

651.0

723.3

795.6

868.0

940.3

1012.6

1084.9

1157.3

1129.6

1301.91374.3

7.2

79.6

151.9

224.2

296.6

368.9

441.2

513.5

585.9

658.2

730.5

802.9

875.2

947.5

1019.9

1092.2

1164.5

1236.8

1309.21381.5

14.5

86.8

159.1

231.5

303.8

376.1

448.5

520.8

593.1

665.4

737.8

810.1

882.4

954.8

1027.1

1099.4

1171.7

1244.1

1316.41388.7

21.7

94.0

166.4

238.7

311.0

383.4

455.7

528.0

600.3

672.7

745.0

817.3

889.7

962.0

1034.3

1106.6

1179.0

1251.3

1323.61396.0

28.9

101.3

173.6

245.9

318.3

390.6

462.9

535.2

607.6

679.9

752.2

824.6

896.9

969.2

1041.5

1113.9

1186.2

1258.5

1330.91403.2

36.2

108.5

180.8

253.2

325.5

397.8

470.2

542.5

614.8

687.1

759.5

831.8

904.1

976.5

1048.8

1121.1

1193.4

1265.8

1338.11410.4

43.4

115.7

188.1

260.4

332.7

405.1

477.4

549.7

622.0

694.4

766.7

839.0

911.4

983.7

1056.0

1128.3

1200.7

1273.0

1345.31417.7

50.6

123.0

195.3

267.6

340.0

412.3

484.6

556.9

629.3

701.6

773.9

846.3

918.6

990.9

1063.2

1135.6

1207.9

1280.1

1352.61424.9

57.9

130.2

202.5

274.9

347.2

419.5

491.8

564.2

636.5

708.8

781.2

853.5

925.8

998.2

1070.5

1142.8

1215.1

1287.5

1359.81432.1

65.1

137.4

209.8

282.1

354.4

426.8

499.1

571.4

643.7

716.1

788.4

860.7

933.1

1005.4

1077.7

1150.0

1222.4

1294.7

1367.01439.4




kg/cm2 to lb/in2

1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180190

200

210

220

230

240

0

142.2

284.5

426.7

568.9

711.2

853.4

995.6

1138

1280

1422

1565

1707

1849

1991

2134

2276

2418

25602702

2845

2987

3129

3271

3414

14.2

156.5

298.7

440.9

583.2

725.4

867.6

1010

1152

1294

1437

1579

1721

1863

2005

2148

2290

2432

25742717

2859

3001

3143

3286

3428

28.4

170.7

312.9

455.1

597.4

739.6

881.8

1024

1166

1309

1451

1593

1735

1877

2020

2162

2304

2446

25892731

2873

3015

3158

3300

3442

42.7

184.9

327.1

469.4

611.6

753.8

896.1

1038

1181

1323

1465

1607

1749

1892

2034

2176

2318

2460

26032745

2887

3030

3172

3314

3456

56.9

199.1

341.4

483.6

625.8

768.1

910.3

1053

1195

1337

1479

1621

1764

1906

2048

2190

2333

2475

26172759

2901

3044

3186

3328

3470

71.1

213.4

355.6

497.8

640.1

782.3

924.5

1067

1209

1351

1493

1636

1778

1920

2062

2205

2347

2489

26312773

2916

3058

3200

3343

3485

85.3

227.6

369.8

512.0

654.3

796.5

938.7

1081

1223

1365

1508

1650

1792

1934

2077

2219

2361

2503

26462788

2930

3072

3214

3357

3499

99.6

241.8

384.0

526.3

668.5

810.7

953.0

1095

1237

1380

1522

1664

1806

1949

2091

2233

2375

2518

26602802

2944

3086

3229

3371

3513

113.8

256.0

398.3

540.5

682.7

825.0

967.2

1109

1252

1394

1536

1678

1821

1963

2105

2247

2389

2532

26742816

2958

3101

3243

3385

3527

128.0

270.2

412.5

554.7

696.9

839.2

981.4

1124

1266

1408

1550

1693

1835

1977

2119

2262

2404

2546

26882830

2973

3115

3257

3399

3542




Temperature

Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centi-

grade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-

umn 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

–37.2

–34.4

–31.7

–28.9

–28.3

–27.8

–27.2

–26.7

–26.1

–25.6

–25.0

–24.4

–23.9

–23.3

–22.8

–22.2

–21.7

–21.1

–20.6

–20.0

–19.4

–18.9

–18.3 –17.8

–17.2

–16.7

–16.1

–15.6

–15.0

–14.4

–13.9

–13.3 –12.8

12 2

–40

–35

–30

–25

–20

–19

–18

–17

–16

–15

–14

–13

–12

–11

–10

–9

–8

–7

–6

–5

–4

–3

–2

–10

1

2

3

4

5

6

7

89

10

–40.0

–31.0

–22.0

–13.0

–4.0

–2.2

–0.4

1.4

3.2

5.0

6.8

8.6

10.4

12.2

14.0

15.8

17.6

19.4

21.2

23.0

24.8

26.6

28.4

30.232.0

33.8

35.6

37.4

39.2

41.0

42.8

44.6

46.448.2

50 0

–11.7

–11.1

–10.6

–10.0

–9.4

–8.9

–8.3

–7.8

–7.2

–6.7

–6.1

–5.6

–5.0

–4.4

–3.9

–3.3

–2.8

–2.2

–1.7

–1.1

–0.6

0

0.6

1.11.7

2.2

2.8

3.3

3.9

4.4

5.0

5.6

6.16.7

7 2

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

3435

36

37

38

39

40

41

42

4344

45

51.8

53.6

55.4

57.2

59.0

60.8

62.6

64.4

66.2

68.0

69.8

71.6

73.4

75.2

77.0

78.8

80.6

82.4

84.2

86.0

87.8

89.6

91.4

93.295.0

96.8

98.6

100.4

102.2

104.0

105.8

107.6

109.4111.2

113 0

7.8

8.3

8.9

9.4

10.0

10.6

11.1

11.7

12.2

12.8

13.3

13.9

14.4

15.0

15.6

16.1

16.7

17.2

17.8

18.3

18.9

19.4

20.0

20.621.1

21.7

22.2

22.8

23.3

23.9

24.4

25.0

25.626.1

26 7

46

47

48

49

50

51

52

53

54

55

56

57

58

59

0

61

62

63

64

65

66

67

68

6970

71

72

73

74

75

76

77

7879

80

114.8

116.6

118.4

120.2

122.0

123.8

125.6

127.4

129.2

131.0

132.8

134.6

136.4

138.2

140.0

141.8

143.6

145.4

147.2

149.0

150.8

152.6

154.4

156.2158.0

159.8

161.6

163.4

165.2

167.0

168.8

170.6

172.4174.2

176 0

27.2

27.8

28.3

28.9

29.4

30.0

30.6

31.1

31.7

32.2

32.8

33.3

33.9

34.4

35.0

35.6

36.1

36.7

37.2

37.8

40.6

43.3

46.1

48.951.7

54.4

57.2

60.0

62.7

65.6

68.3

71.1

73.976.7

79 4

81

82

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99

100

105

110

115

120125

130

135

140

145

150

155

160

165170

175

117.8

179.6

181.4

183.2

185.0

186.8

188.6

190.4

192.2

194.0

195.8

197.6

199.4

201.2

203.0

204.8

206.6

208.4

210.2

212.0

221.0

230.0

239.0

248.0257.0

266.0

275.0

284.0

293.0

302.0

311.0

320.0

329.0338.0

347 0



Foreword Units

Units

In this manual, the measuring units are indicated with Internatinal System of units (SI).

As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:N {kg}

Nm {kgm}

MPa {kg/cm2}

kPa {mmH2O}

kPa {mmHg}

kW/rpm {HP/rpm}

g/kWh {g/HPh}



Applicable machine ........................................01- 2

Specifications .................................................01- 4

General assembly drawing.............................01- 12

Weight table ...................................................01-28

Engine performance curve.............................01-31

01 General



General Applicable machine

Applicable machine

a Serial No. shows for engine serial No.

Engine Serial No. Applicable machine

S6D140-2

GD825A-2 Motor grader

WA500-3 Wheel loader

SA6D140-2

D155A-2, D155A-3, D155AX-3, D155AX-5 Bulldozer

D155C-1 (–30°C spec.), D155C-1 (–50°C spec.), D355C-3,

D355C-3 (–30°C spec.), D355C-3 (–50°C spec.)Bulldozer

PC1600SP-1 Hydraulic excavator

DCA400SSK-2 DENYO Generator

DCA-400SSK MQ Generator

J6D140E-G1-2 TAIYO DENKI Generator

SAA6D140-2

PC750-6, PC800-6, PC1800-6 Hydraulic excavator

HD325-6, HD405-6 Dump truck

SDA6D140E-2

D275A-5 (–50°C spec.) Bulldozer



General Specifications

Specifications

Engine model S6D140-2

Applicable machine GD825A-2 WA500-3

Number of cylinder – Bore x Stroke mm 6 – 140 x 165

Total piston displacement l {cc} 15.2 {15,240}

Firing order 1 – 5 – 3 – 6 – 2 – 4

D i m

e n s i o n s

Overall length mm 1,593 1,787

Overall width mm 895 1,060

Overall height (excluding exhaust pipe) mm 2,060 1,670

Overall height (including exhaust pipe) mm — —

P e r f o r m a n c e

Flywheel horsepower kW {HP}/rpm 209 {280}/2,100 236 {316}/2,100

Maximum torque Nm {kgm}/rpm 1,230 {125}/1,400 1,370 {140}/1,400

High idling speed rpm 2,300 – 2,400 2,300 – 2,400

Low idling speed rpm 650 – 700 700 – 750

Minimum fuel consumption ratio g/kW•h {g/HP•h} 208 {155} 204 {152}

Dry weight kg 1,506 1,520

Fuel injection pump BOSCH PE-P (PS3S) type

Governor BOSCH RSV centrifugal

all speed control type

Lubricating oil amount (refill capacity) l 38 (34)

Coolant amount l (Engine side: 23)

Alternator 24 V, 50 A

Starting motor 24 V, 11 kW

Battery 12 V 200 Ah x 2 12 V 170 Ah x 2

Turboharger KOMATSU KTR110 type

Air compressor ZEXEL Recipro-

cation, 1-cylinder

type

—

Oth




S6D140-2




Engine model SA6D140-2

Applicable machineD155A-3,

D155AX-3

PC1600SP-1

(2 engines)



Firing order 1 – 5 – 3 – 6 – 2 – 4

D i m e n s i o n s


Overall width mm 1,040 1,185




Flywheel horsepower kW {HP}/rpm225 {302}/1,900

(Net)

316 {424}/1,800

(Net)

Maximum torque Nm {kgm}/rpm 1,430 {146}/1,300

(Net)

1,860 {190}/1,400





Fuel injection pump BOSCH PE-P

(PS7S) type

BOSCH PE-P

(PS7S) type

Governor BOSCH RSUV

centrifugal,

all speed type

BOSCH RSV

centrifugal,

all speed type

Lubricating oil amount (refill capacity) l 42 (37) 38 (34)

Coolant amount l (Engine only: 25) (Engine side: 25)


24 V, 50 A (opt)

24 V, 50 A

Starting motor 24 V, 11 kW 24 V, 7.5 kW


Turboharger KOMATSU KTR110 type

Air compressor

—

ZEXEL Recipro-

cation, 1-cylinder

type

Others With aftercooler




SA6D140-2

D155A-2 D155AX-5D155C-1

(–30°C spec.)

D155C-1

(–50°C spec.)D355C-3

D355C-3

(–30°C spec.)

6 – 140 x 165

15.2 {15,240}

1 – 5 – 3 – 6 – 2 – 4

1,566 1,498 1,614 1,614 1,577 1,577

1,136 1,040 1,193 1,193 1,265 1,265

1,824 1,740 1,824 1,824 1,843 1,843

— — — — — —

253 {339}/2,000

(Net)

232 {310}/1,900

(Net)

255 {342}/2,000

(Gross)

255 {342}/2,000

(Gross)

265 {355}/2,000

(Net)

265 {355}/2,000

(Net)

1,608 {164}/1,400

(Net)

1,610 {164}/1,250

(Net)

1,490 {152}/1,400

(Gross)

1,490 {152}/1,400

(Gross)

1,570 {160}/1,400

(Net)

1,570 {160}/1,400

(Net)

2,200 – 2,280 2,100 2,190 – 2,290 2,190 – 2,290 2,200 – 2,280 2,200 – 2,280

550 – 650 700 700 – 750 700 – 750700 – 750 (engine set)

575 – 675 (on board)

700 – 750 (engine set)

575 – 675 (on board)

206 {153} 205 {153} 205 {151} 205 {151} 203 {151} (Gross) 203 {151} (Gross)

1,750 1,560 1,790 1,790 1,850 1,850

BOSCH PE-P (PS7S) type

BOSCH RSV centrifugal,

all speed type

42 (37) 78 (34) 42 (37) 42 (37) 42 (37) 42 (37)

(Engine side: 25)23

(Engine only) (Engine side: 25) (Engine side: 25) (Engine side: 25) (Engine side: 25)

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

24 V, 11 kW 24 V, 11 kW 24 V, 11 kW x 2 24 V, 11 kW x 2 24 V, 11 kW x 1 24 V, 11 kW x 2

12 V 170 Ah x 2 12 V 170 Ah x 2 12 V 200 Ah x 2 12 V 200 Ah x 2 12 V 200 Ah x 2 12 V 200 Ah x 2

KOMATSU

KTR110 type

KOMATSU

KTR110 type

KOMATSU

KTR110 type

KOMATSU

KTR110 type

KOMATSU

KTR110 type

KOMATSU

KTR110 type

— — — — — —

With aftercooler With aftercooler With aftercooler With aftercooler With aftercooler With aftercooler





Applicable machineD355C-3

(–50°C spec.)

Number of cylinder – Bore x Stroke mm6 – 140 x 165

15.2 {15,240}

1 – 5 – 3 – 6 – 2 – 4

Total piston displacement l {cc}

Firing order

D i m e n s i o n s

Overall length mm 1,577

Overall width mm 1,265

Overall height (excluding exhaust pipe) mm 1,843

Overall height (including exhaust pipe) mm —


Flywheel horsepower kW {HP}/rpm 265 {355}/2,000

(Net)


(Net)

High idling speed rpm 2,200 – 2,280

Low idling speed rpm 700 – 750 (engine set)

575 – 675 (on board)

Minimum fuel consumption ratio g/kW•h {g/HP•h}203 {151} (Gross)

Dry weight kg 1,850

Fuel injection pump BOSCH PE-P (PS7S) type

Governor BOSCH RSV centrifugal,

all speed type

Lubricating oil amount (refill capacity) l 42 (37)

Coolant amount l (Engine side: 25)


Starting motor 24 V, 11 kW x 2

Battery 12 V 200 Ah x 2

Turboharger KOMATSU

KTR110 type

Air compressor —

Oth With ft l




SA6D140-2

DCA400SSK-2(DENYO generator)

DCA-400SSK(For MQ generator)

J6D140E-G1-2

6 – 140 x 165

15.2 {15,240}

1 – 5 – 3 – 6 – 2 – 4

1,874 1,874 1,874

957 957 957

1,598 1,598 1,634

— — —

310 {415}/1,500

(Net, 50 Hz)

357 {478}/1,800

(Net, 60 Hz)

357 {478}/1,800

(Net, 60 Hz)

271 {275}/1,500

(50 Hz)

299 {303}/1,800

(60 Hz)

— — —

Max. 1,570 (50 Hz)

Max. 1,880 (60 Hz)

Max. 1,890 (60 Hz) Max. 1,575 (50 Hz)

Max. 1,890 (60 Hz)

800 – 850

At rated

800 – 850

At rated

700 – 900

At rated

217 {162} (50 Hz)

231 {172} (60 Hz) 214 {160} (60 Hz)

209 {156} (50 Hz)

222 {166} (60 Hz)

1,450 1,450 1,750

BOSCH PE-P (PS7S) type

BOSCH RSUV centrifugal, all speed type

74 (67) 74 (67) 80 (73)

64 (Engine side: 27) 66(Engine only: 27)

24 V, 50 A 24 V, 50 A 24 V, 35 A (OPT)

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

12 V 200 Ah x 2 12 V 200 Ah x 2 12 V 200 Ah x 2

KOMATSU

KTR110 type

KOMATSU

KTR110 type

KOMATSU

KTR110 type

— — —

With ft l With ft l With ft l




Engine model SAA6D140-2

Applicable machinePC750-6,

PC800-6

HD325-6,

HD405-6



Firing order 1 – 5 – 3 – 6 – 2 – 4

D i m e n s i o n s


Overall width mm 1,185 1,202




Flywheel horsepower kW {HP}/rpm 331 {444}/1,800(Net)

379 {508}/2,000(Gross)

364 {488}/2,000

(Net)


(Net)

2,170 {221}/1,400

(Gross, Net)





Fuel injection pump BOSCH PE-P

(PS7S) type

BOSCH PE-P

(PS7S) type

Governor BOSCH RSUV

centrifugal, all

speed type

BOSCH RFD

Min. – max. speed

control type

Lubricating oil amount (refill capacity) l 38 (32) 41 (37)

Coolant amount l (Engine only: 25) (Engine only: 25.5)

Alternator 24 V, 50 A 24 V, 50 A

Starting motor 24 V, 7.5 kW

24 V, 11 kW (opt)

24 V, 11 kW


Turboharger KOMATSU

KTR110 type

KOMATSU

KTR110 type

Air compressor ZEXEL

Single cylinder,

reciprocation type

ZEXEL

Single cylinder,

reciprocation type

Others With air cooledaftercooler

With air cooledaftercooler and

retarder




SAA6D140-2 SDA6D140E-2

HD325-6

(High altitude spec.)

PC1800-6

(2 engines)

D275A-5

(–50°C spec.)

6 – 140 x 165

15.2 {15,240}

1 – 5 – 3 – 6 – 2 – 4

1,688 1,582 1,461

1,202 1,056

1,300 1,684 2,084

— — —

307 {411}/2,000 331 {444}/1,800(Net)

332 {446}/2,000(Gross)

1,750 {179}/1,400 2,100 {214}/1,350

(Net)

2,030 {207}/1,400

(Gross)

2,350 – 2,400 1,930 – 2,030 2,150 – 2,250

675 – 725 800 – 850 650 – 750

197 {147} 200 {149} 214 {160}

1,450 1,650 1,765

BOSCH PE-P

(PS7S) type

BOSCH PE-P

(PS7S) type

BOSCH PE-P

(PS7S) type

BOSCH RFD

Min. – max. speed

control type

BOSCH RSUV

centrifugal, all

speed type

BOSCH RSUV

centrifugal, all

speed type

41 (37) 38 (32) 62 (55)

(Engine only: 26) (Engine only: 25) (Engine only: 26)

24 V, 50 A 24 V, 50 A 24 V, 75 A

24 V, 11 kW 24 V, 7.5 kW 24 V, 11 kW x 2

12 V 170 Ah x 2 12 V 170 Ah x 2 12 V 170 Ah x 2

KOMATSU

KTR110 type

KOMATSU

KTR110 type

KOMATSU

KTR110 type

ZEXEL

Reciprocation,

single cylinder type

ZEXEL Reciprocation,

single cylinder type

(front engine only)

—

With air cooledaftercooler and

retarder

With air cooled

aftercooler With aftercooler



General General assembly drawing

General assembly drawing

SA6D140-2 left side view (For D155A-3, D155AX-3)a The specifications are subject to change according to modification, etc.




SA6D140-2 right side view (For D155A-3, D155AX-3)




SA6D140-2 front view (For D155A-3, D155AX-3)




SA6D140-2 rear view (For D155A-3, D155AX-3)




SA6D140-2 upper side view (For D155A-3, D155AX-3)




SAA6D140-2 left side view (For PC750-6, PC800-6)




SAA6D140-2 right side view (For PC750-6, PC800-6)




SAA6D140-2 front view (For PC750-6, PC800-6)




SAA6D140-2 rear view (For PC750-6, PC800-6)




SDA6D140E-2 left side view (For D275A-5, –50°C spec.)

a. Crankshaft center

b. Flywheel housing rear surface




SDA6D140E-2 front view (For D275A-5, –50°C spec.)

c. Crankshaft center

d. Cylinder liner center




SDA6D140E-2 rear view (For D275A-5, –50°C spec.)

c. Crankshaft center

d. Cylinder liner center




Dimension tablea These dimensions are reference values for use when installing to a test bench.

Engine Machine model

Dimensions for each part (mm)

A B C D E F G

SDA6D140E-2

D275A-5 (–50°C spec.) 1,461 1,056 2,084 — — — —



General Weight table

Weight table

a The specifications may be different depending on the type of machine.

Unit: kg

No. Item Components S6D140-2

1 Turbocharger Komatsu KTR110 23

2 Cylinder head assemblyCylinder head, valve, rocker arm,

valve spring19

3 Cylinder block assemblyCylinder block, bearing cap,

cylinder liner 400

4 Front cover 38

5 Oil pan 30

6 Flywheel assembly Flywheel, ring gear 60 (GD825A-2, WA500-3)

—

7 Flywheel housing55 (GD825A-2, WA500-3)

—

8 Crankshaft assembly Crankshaft, crankshaft gear 136

9 Camshaft assemblyCamshaft, camshaft gear, thrust

plate19

10 Piston and connectingrod assembly

Piston, piston ring, piston pin,connecting rod

10.7 x 6

11 Oil pump 5.5

12 Fuel injection pump 20

13 Water pump 17

14 Alternator 24 V, 35 A —

24 V, 50 A 10

15 Starting motor 24 V, 7.5 kW —

24 V, 11 kW 19.5

16 Air compressor 11

17 Aftercooler assembly —




Unit: kg

No. Item Components SA6D140-2



valve spring19


cylinder liner 400

4 Front cover 38

5 Oil pan 30

6 Flywheel assembly Flywheel, ring gear

60 (D155A-2,3, AX-3, AX-5)

54 (PC1600SP-1)

129 (DCA400SSK-2, J6D140E-G1-2 Generator)

7 Flywheel housing

55 (D155A-2,3, AX-3, AX-5)

52 (PC1600SP-1)

52 (DCA400SSK-2 Generator)



plate

19

10Piston and connecting

rod assembly

Piston, piston ring, piston pin,

connecting rod10.7 x 6

11 Oil pump 5.5

12 Fuel injection pump

21 (D155A-2,3, AX-3, AX-5)

23 (Generator)

13 Water pump 17

14 Alternator 24 V, 35 A, 25 A 8.0

24 V, 50 A 10

15 Starting motor 24 V, 7.5 kW 18

24 V, 11 kW 19.5


17 Aftercooler assembly 43




Unit: kg

No. Item Components SAA6D140-2 SDA6D140E-2



valve spring19


cylinder liner 400

4 Front cover 38

5 Oil pan 30

6 Flywheel assembly Flywheel, ring gear

55 (PC750-6, PC800-6)

51 (HD325-6/405-6)

7 Flywheel housing54 (PC750-6, PC800-6)

68 (HD325-6/405-6)



plate19

10Piston and connecting

rod assembly

Piston, piston ring, piston pin,

connecting rod10.7 x 6

11 Oil pump 5.5

12 Fuel injection pump 20

13 Water pump 17

14 Alternator 24 V, 35 A 8.0

24 V, 50 A 10

15 Starting motor 24 V, 7.5 kW 18

24 V, 11 kW 19.5


17 Air-cooled aftercooler

assembly

37 (PC750, 800-6)

35 (HD325-6/405-6)



General Engine performance curve

Engine performance curve

Engine Engine Serial No. Machine model Page

S6D140-2GD825A-2 01-32

WA500-3 01-33

SA6D140-2

D155A-3, D155AX-3 01-34

PC1600SP-1 01-35

D155A-2 01-36

D355C-3, D355C-3 (–30°C spec.),

D355C-3 (–50°C spec.)01-37

D155AX-5 01-38

D155C-1 (–30°C spec.),

D155C-1 (–50°C spec.)01-42

SAA6D140-2HD325-6, HD405-6 01-39

PC750-6, PC800-6, PC1800-6 01-40

SDA6D140E-2D275A-5 (–50°C spec.) 01-41




S6D140-2 for GD825A-2Net flywheel horsepower:209 kW {280 HP}/2,100 rpm

Net maximum torque: 1,250 Nm {128 kgm}/1,400 rpm




S6D140-2 for WA500-3Net flywheel horsepower:236 kW {316 HP}/2,100 rpm





SA6D140-2 for D155A-3, D155AX-3Net flywheel horsepower:225 kW {302 HP}/1,900 rpm





SA6D140-2 for PC1600SP-1Net flywheel horsepower:316 kW {424 HP}/1,800 rpm





SA6D140-2 for D155A-2Flywheel horsepower: 253 kW {339 HP}/2,000 rpm (Net)

Maximum torque: 1,608 Nm {164 kgm}/1,400 rpm (Net)




SA6D140-2 for D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.)Flywheel horsepower: 265 kW {355 HP}/2,000 rpm (Net)





SA6D140-2 for D155AX-5Flywheel horsepower: 232 kW {320 HP}/1,900 rpm (Net)





SAA6D140-2 for HD325-6, HD405-6Flywheel horsepower: 379 kW {508 HP}/2,000 rpm (Gross), 364 kW {488 HP}/2,000 rpm (Net)

Maximum torque: 2,170 Nm {221 kgm}/1,400 rpm (Gross, Net)




SAA6D140-2 for PC750-6, PC800-6, PC1800-6Flywheel horsepower: 331 kW {444 HP}/1,800 rpm

Maximum torque: 2,099 Nm {214 kgm}/1,350 rpm




SDA6D140E-2 [For D275A-5 (–50°C spec.)]Rated output: 332 kW {446 HP}/2,000 rpm (Gross)

Max. torque: 2,030 Nm {207 kgm}/1,400 rpm (Gross)




SA6D140-2 for D155C-1 (–30°C spec.), D155C-1 (–50°C spec.)Flywheel horsepower: 255 kW {342 HP}/2,000 rpm (Gross)

Maximum torque: 1,490 Nm {152 kgm}/1,400 rpm (Gross)



Intake and exhaust system

Intake and exhaust system.......................11- 2

Air cleaner ................................................ 11- 15

Turbocharger ............................................11- 18

Aftercooler ................................................ 11- 20

Engine body

Cylinder head ...........................................11- 24

Cylinder block...........................................11- 26

Main circulation system ............................ 11- 28

Vibration damper ......................................11- 30

Timing gear...............................................11- 32

Valve system.............................................11- 34

Flywheel and flywheel housing .................11- 36

Lubrication system

Lubrication system chart........................... 11- 38Oil pump ...................................................11- 40

Regulator valve and

piston cooling valve........................... 11- 41

Oil filter ..................................................... 11- 42

Oil cooler ..................................................11- 46

Fuel system

Fuel system chart .....................................11- 48

Fuel injection pump .................................. 11- 50

Feed pump ............................................... 11- 58

Fuel injection nozzle................................. 11- 59

Fuel filter...................................................11- 60

Engine stop motor ....................................11- 61

Cooling system

Cooling system chart................................ 11- 66

Water pump.............................................. 11- 70

Thermostat ............................................... 11- 76

Corrosion resistor ..................................... 11- 77Corrosion resistor mounting..................... 11- 78

Cooling fan drive ...................................... 11- 79

Accessory

Air compressor ......................................... 11- 88

Exhaust brake .......................................... 11- 91

Electrical system

Alternator.................................................. 11- 95

Starting motor ........................................... 11-102

Electrical intake air heater........................ 11-107

Front PTO mounting................................. 11-108Front PTO assembly ................................ 11-109

Front PTO drive gear assembly ............... 11-110

11 Structure and function



Structure and function Intake and exhaust system



S6D140-2 for WA500-3a The specifications are subject to change according to modification, etc.

1. Bracket A. Intake

2. Muffler B. Exhaust

3. Check valve

(to prevent exhaust gas from flowing back)

C. Dust (together with exhaust gas)

4. Electrical intake air heater (ribbon type)5. Air cleaner

6. Intake manifold

7. Intake connector

8. Exhaust manifold (Rear)

9. Exhaust manifold (Center)

10. Exhaust manifold (Front)

11. Elbow

12. Turbocharger




SA6D140-2 for D155A-3, D155AX-3 (Left side view)a The specifications are subject to change according to modification, etc.

1. Muffler A. Intake

2. Air cleaner B. Exhaust

3. Aftercooler assembly

4. Connector




SA6D140-2 for D155A-3, D155AX-3 (Intake system, front view)a The specifications are subject to change according to modification, etc.

1. Check valve

(To prevent exhaust gas from flowing back)

C. Dust (together with exhaust gas)

2. Tube

3. Band assembly (air cleaner)

4. Connector (Crossover)

5. Valve6. Connector

7. Electrical intake air heater

8. Tube (aftercooler – cylinder block)




SA6D140-2 for D155A-3, D155AX-3 (Exhaust system, rear view)a The specifications are subject to change according to modification, etc.

1. Dust indicator

2. O-ring

3. Connector

4. Tube (cylinder block – aftercooler)




SAA6D140-2 for PC750-6, PC800-6 (Left side view)a The specifications are subject to change according to modification, etc.

1. Connector (air-cooled aftercooler –

electrical intake air heater)

A. Intake

B. Exhaust

2. Electrical intake air heater (ribbon type) C. Dust (together with exhaust gas)

3. Connector (electrical intake air heater –

intake manifold)

4. Muffler 5. Check valve

(to prevent exhaust gas from flowing back)

6. Intake manifold

7. Air cleaner

8. Precleaner




SAA6D140-2 for PC750-6, PC800-6 (Right side view)a The specifications are subject to change according to modification, etc.

1. Sensor for dust indicator

2. Intake connector (air cleaner – turbocharger)

3. Turbocharger

4. Exhaust manifold (Front)

5. Exhaust manifold (Center)

6. Exhaust manifold (Rear)




SAA6D140-2 for PC750-6, PC800-6 (Front view)a The specifications are subject to change according to modification, etc.

A. Intake air (turbocharger – air cooled aftercooler)

B. Intake air

(air cooled aftercooler – electrical intake air heater)




SAA6D140-2 for PC750-6, PC800-6 (Rear view)a The specifications are subject to change according to modification, etc.




SAA6D140-2 for HD325-6 (Left side view)a The specifications are subject to change according to modification, etc.

1. Connector

(air-cooled aftercooler – electrical intake air heater)

2. Electrical intake air heater

3. Intake connector

(electrical intake air heater – intake manifold)

4. Intake manifold




SAA6D140-2 for HD325-6 (Right side view)a The specifications are subject to change according to modification, etc.

1. Exhaust brake (butterfly type) A. Intake

2. Turbocharger B. Exhaust

3. Exhaust connector C. Intake air (turbocharger – air-cooled aftercooler)

4. Exhaust manifold (front) D. Intake air

(air-cooled aftercooler – electrical intake air heater)5. Exhaust manifold (center)

6. Exhaust manifold (rear)




SAA6D140-2 for HD325-6 (Front view)

SAA6D140-2 for HD325-6 (Rear view)




Air cleaner

a The specifications may be different from the following figure, depending on the type of machine.

KOMA-CLONE type (Automatic discharge multicyclone type)

1. Hood A. Air inlet

2. Precleaner B. To turbocharger (Air)3. Air cleaner body C. To muffler (Dust)

4. Outer element

5. Inner element

Engine model Applicable

machine modelType

Dust discharging

method of precleaner

Number of

cleaner element

S6D140-2 GD825A-2, WA500-3

KOMA-CLONE,

Multicyclone

Automatic discharge

(Exhaust ejector)

Inner element: 1

Outer element: 1SA6D140-2 D155A-2,3, AX-3, AX-5

SAA6D140-2 PC750-6, PC800-6





FHG, FTG type (Cyclopack type)

FHG type FTG type

Advantages

FTG type

The diameter of the element is the same but the out-

side diameter of the body is smaller.

• The inlet is placed in the direction of connection,

so ample centrifugal force can be obtained from

a simple spiral guide vane, without using a diffu-

sion vane.

• The is no dust pan or diffusion vane, so the

structure is simple.

Structure

• Air containing dust is sucked in from inlet (1) at a

tangent, and the dust is separated by the centrif-

ugal force of guide vane (3). More than 99.9% of

the remaining dust is removed by primary ele-

ment (4), and the cleaned air then passes

through safety element (5) and outlet (2), and is

sucked into the engine.

The dust and moisture that is separated by

guide vane (3) rotates around the inside wall of

body (9), and goes inside vacuator (6), where is

discharged automatically to the outside.

1. Inlet 6. Vacuator

2. Outlet 7. Dust pan

3. Guide vane 8. Diffusion vane (sleeve)

4. Primary element 9. Body

5. Safety element 10. Element




ERB typea Details may differ according to the machine model.

1. Precleaner A. Intake air port2. Air cleaner casing B. To turbocharger (intake air port)

3. Outer element C. To muffler (dust)

4. Inner element

Engine Machine model TypeDust discharge method

for precleaner No. of elements

SDA6D140E-2D275A-5

(–50°C spec.)

Komaclone, multicyclone

type (ERB type)

Automatic discharge

(exhaust ejector)

Inner cylinder 1,

Outer cylinder 1




Turbocharger

KTR110

S6D140-2

SA6D140-2SAA6D140-2

1. Blower housing A. Intake inlet Turbocharger

2. V-band B. Intake outlet Type: KTR110

3. Defuser plate C. Exhaust inlet Overall length: 284 mm

4. Center housing D. Exhaust outlet Overall width: 305 mm

5. Shroud E. Oil inlet Overall height: 287 mm

6. Turbine housing F. Oil outlet Weight: 22.5 kg

7. Blower impeller G. Cooling water

8. Seal ring

9. Thrust metal

10. Metal

11. Seal ring12. Turbine impeller




KTR110 (Air-cooled type)

SDA6D140E-2 (D275A-5, –50°C spec.)

1. Blower housing A. Intake inlet Specifications

2. V-band B. Intake outlet Type: Komatsu KTR110L (air-cooled)

3. Diffuser plate C. Exhaust inlet Overall length: 308 mm

4. Center housing D. Exhaust outlet Overall width: 305 mm5. Shroud E. Oil inlet Overall height: 287 mm

6. Turbine housing F. Oil outlet Weight: 24 kg

7. Turbine impeller

8. Seal ring

9. Bearing

10. Thrust bearing

11. Seal ring

12. Blower impeller




Aftercooler

(Water-cooled type)

SA6D140-2 (For construction machinery, generator)


1. Aftercooler cover A. Intake air inlet

2. Aftercooler core B. Intake air outlet

3. Intake manifold C. Water inlet (from cylinder head)

D. Water outlet (to thermostat)




(Air-cooled type)

SAA6D140-2 for PC750-6, PC800-6a The specifications are subject to change according to modification, etc.

1. Tank a. Intake air port

(Turbocharger io Intake manifold)2. Side support

3. Tube

4. Fin




(Air-cooled type)

SAA6D140-2 for HD325-6a The specifications are subject to change according to modification, etc.

1. Tank a. Intake air port

(Turbocharger io Intake manifold)2. Side support

3. Tube

4. Fin



Structure and function Engine body

Engine body

Cylinder head


1. Rocker arm housing mounting bolt B. Intake

2. Cylinder head mounting bolt C. Exhaust

3. Air vent tube

4. Fuel spill pipe d. To fuel tank

5. Rocker arm housing e. To radiator

6. Cylinder head f. To rocker arm (Oil)

7. Rocker arm housing cover

8. Nozzle holder ass’y

9. Nozzle holder retainer

10. Nozzle connecter




Cylinder head

• Direct fuel injection type

• 4-valve

• Divided type (One cylinder head for one cylin-

der)

• Centralized cooling system of valve bridge and

nozzle • Cylinder head bolt: Plastic-area tightening

Valve seat insert

• Press-fitted insert for intake and exhaust

Rocker arm housing cover

• Floating type seal

Fuel injection nozzle

• Mount: Dry type (without sleeve)




Cylinder block

1. Front cover 7. Thrust metal

2. Cylinder block 8. Main metal

3. Cylinder liner 9. Main metal cap

4. Crevice seal 10. Main metal cap bolt

5. Liner O-ring 11. Front oil seal

6. Liner O-ring 12. Piston cooling nozzle




Cylinder block

• Crankshaft:7 bearings

• Camshaft: High cam type, 7 bearings

• Main cap mounting bolt: Plastic-area tightening

Front oil seal

• Single lip with dust seal (Lay-down seal)

Piston cooling

• With cooling nozzle

Cylinder liner

• Wet type

• Machining of inside wall: Plateau honing, tufftrid-

ing

Liner seal

• Top: Crevice seal

• Middle: O-ring (Ethylene propylene rubber)

• Bottom: O-ring (Silicon rubber)




Main circulation system


1. Piston (FCD piston) 8. Key (Crankshaft gear)

2. Piston pin 9. Crankshaft

3. Connecting rod, bushing 10. Crankshaft gear (No. of teeth: 36)

4. Top ring 11. Connecting rod metal

5. Second ring 12. Connecting rod cap

6. Oil ring 13. Connecting rod

7. Pin (Crankshaft pulley) 14. Connecting rod cap mounting bolt




Crankshaft

Stamp forging

Journal and filet portion: Induction hardening

Piston

Ductile cast iron (FCD piston)

Re-entrant piston

Connecting rod

Stamp forging

Cap bolt is of screw-in type and tightened by plastic-

area tightening and has lubricating oil hole.

Piston ringTop ring Second ring Oil ring

Both faces

keystone Barrel

face Hard chrome

plating

Both faces

keystone inner

cut Tapered face

Hard chrome

plating

M-shape steel

ring Hard chrome

plating with coil

expander




Vibration damper


1. Crankshaft pulley

2. Pin (Crankshaft pulley – vibration damper)

3. Vibration damper

4. Pin (Crankshaft – crankshaft pulley)




Timing gear


1. Water pump drive gear (No. of teeth: 23) 8. Fuel injection pump drive gear (No. of teeth: 48)

2. Sub idler gear (No. of teeth: 42) 9. PTO gear (Option) (No. of teeth: 22)

3. Main idler gear (Large) (No. of teeth: 60) 10. Crankshaft gear (No. of teeth: 36)

4. Main idler gear (Small) (No. of teeth: 40) 11. Oil pump drive gear (No. of teeth: 22)

5. Camshaft gear (No. of teeth: 48)

6. PTO gear (Option) (No. of teeth: 14) A, B, C: Match marks

7. Compressor drive gear (No. of teeth: 24)




Valve system

a The specifications are subject to change according to modification, etc.

1. Thrust plate 12. Rocker arm adjustment screw

2. Camshaft gear (No. of teeth: 48) 13. Crosshead adjustment screw

3. Camshaft 14. Locknut

4. Cam roller 15. Crosshead

5. Cam roller pin 16. Valve retainer

6. Cam follower shaft 17. Outer valve spring

7. Cam follower 18. Inner valve spring

8. Push rod 19. Exhaust valve

9. Rocker arm shaft 20. Valve guide

10. Rocker arm 21. Spring seat

11. Locknut 22. Intake valve




Camshaft

• Drawn steel bar (Turned)

• Journal and filet portion: Induction hardening

Valve timing




Flywheel and flywheel housing

Without PTO type


For marine engine: Eight flywheel mounting bolts

1. Ring gear (No. of teeth: 148)

2. Flywheel

3. Rear oil seal (Lay-down lip seal)

4. Flywheel housing



Structure and function Lubrication system

Lubrication system

Lubrication system chart


1. Oil pan 12. Piston cooling nozzle

2. Oil strainer 13. Piston

3. Oil pump 14. Camshaft

4. Main relief valve 15. Cam follower

5. Oil cooler 16. Rocker arm

6. Thermostat 17. Intake and exhaust valve

7. Regulator valve 18. Timing gears

8. Valve adapter 19. Turbocharger (S6D140, SA6D140, SAA6D140)

9. Oil filter 20. Fuel injection pump

10. Safety valve




Large capacity oil filter + bypass filter a The specifications may be different from the following figure, depending on the type of machine.

1. Oil pan 13. Piston

2. Oil strainer 14. Camshaft

3. Oil pump 15. Cam follower

4. Main relief valve 16. Rocker arm

5. Oil cooler 17. Intake and exhaust valve

6. Thermostat 18. Timing gears

7. Regulator valve 19. Turbocharger

8. Valve adapter 20. Fuel injection pump

9. Oil filter (full-flow filter x 2) 21. Bypass filter (Installed to depending on the model)

10. Safety valve

11. Crankshaft W: Cooling water

12. Piston cooling nozzle




Oil pump


Oil pump

• Type: Gear pump

• Pump speed: Engine speed x 1.64

Main relief valve

• Set pressure:

0.78 ± 0.05 MPa {8.0 ± 0.5 kg/cm2}

1. Pump cover

2. Drive gear

3. Pump body

4. Pump drive gear (No. of teeth: 22)

5. Valve spring

6. Main relief valve

7. Driven gear

A. Suction (From oil pan)

B. Discharge (To oil cooler)




Regulator valve and piston cooling valve


Regulator valve

• Valve opening pressure:

0.3 ± 0.02 MPa {3.2 ± 0.2 kg/cm2}

Piston cooling valve

• Valve opening pressure:

0.14 ± 0.02 MPa {1.4 ± 0.2 kg/cm2}

1. Valve body

2. Valve spring

3. Valve

a. From oil cooler

b. To oil filter

c. From oil filter

d. To main gallery

e. To piston cooling nozzle

f. To oil pan (drain)




Oil filter

S6D140-2

SA6D140-2

SAA6D140-2


Oil filter

• Filtration area: 0.84 m2

(Rated flow 160 l/min)

For construction machinery, generator

(Rated flow 240 l/min)

For marine engine

Safety valve

• Set pressure: 0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2}

1. Filter head

2. Safety valve

3. Cartridge

A. Oil inlet

B. Oil outlet




SDA6D140E-2 (D275A-5, –50°C spec.)a The shape may differ according to the machine model.

Oil filter

• Filtering area: 0.42 m2 (Full-flow)

Safety valve

• Cracking pressure:

245 ± 19 kPa {2.5 ± 0.2 kg/cm2}

1. Safety valve

2. Filter head

3. Cartridge

A. Oil inlet

B. Oil outlet




Large capacity oil filter a The specifications may be different from the following figure, depending on the type of machine.

Oil filter

• Filtration area:1.8 m2 (0.9 m2 x 2)

• Rated flow: 180 l/min.

Safety valve


1. Filter head

2. Safety valve

3. Filter connector

4. Cover

5. Alarm assembly

6. Cartridge

A. Oil inlet

B. Oil outlet




Large capacity oil filter + bypass filter a The specifications may be different from the following figure, depending on the type of machine.

Oil filter

• Filtration area:1.8 m2 (0.9 m2 x 2)

• Rated flow: 180 l/min.

Safety valve


Bypass filter

• Filtration area:1.4 m

2

• Rated flow: 7.5 l/min.

1. Filter head

2. Safety valve

3. Filter connector

4. Cover

5. Alarm assembly

6. Cartridge (Bypass filter)

7. Cartridge (Full-flow filter)

A. Oil inlet

B. Oil outlet




Oil cooler


Thermostat function • Valve cracking temperature: 85 ± 1.5°C

• Full opening temperature: 100°C

• Full opening lift: Min. 8 mm

Oil cooler

• Effective area: 6D140-2 : 0.822 m2

S6D140-2 : 0.822 m2

SA6D140-2 : 0.986 m2

SAA6D140-2 : 0.986 m2

SDA6D140E-2: 0.986 m2

1. Cooler cover 2. Cooler element

6D140-2 : 10 cores

S6D140-2 : 10 cores

SA6D140-2 : 12 cores

SAA6D140-2 : 12 cores

SDA6D140E-2: 12 cores

3. Thermostat

4. Spring

5. Thermostat cover

A. Oil inlet

B. Oil outlet

C. Cooling water



Structure and function Fuel system

Fuel system

Fuel system chart


1. Fuel tank

2. Gauze filter

3. Priming pump

4. Feed pump

5. Fuel filter

6. Fuel injection pump

7. Fuel injection nozzle

8. Over-flow valve





1. Fuel tank

2. Gauze filter

3. Priming pump

4. Feed pump

5. Fuel filter

6. Fuel injection pump

7. Fuel injection nozzle

8. Over-flow valve




Fuel injection pump

SA6D140-2 (D155A-3, D155AX-3, D155AX-5, D155C-1 (–30°C spec., –50°C spec.),

D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.))a The specifications are subject to change according to modification, etc.

1. Fuel injection pipe (No. 1) 9. Fuel injection pump drive shaft

2. Fuel injection pipe (No. 2) 10. Bearing box

3. Fuel injection pipe (No. 3) 11. Coupling

4. Fuel injection pipe (No. 4) 12. Oil inlet pipe

5. Fuel injection pipe (No. 5) 13. Feed pump

6. Fuel injection pipe (No. 6) 14. Fuel injection pump (With boost compensator)

7. Boost compensator tube 15. Oil outlet pipe

8. Fuel injection pump drive gear (No. of teeth 48)




Fuel injection pump

• Maker: BOSCH automotive system

• Type: Bosch PE-P

• Lubrication method:

Forced lubrication with engine oil

Governor

• Type: Made by BOSCH automotive system,

Bosch RSUV Centrifugal, all speed type

a: Fuel inlet

b: To fuel filter

c: From fuel filter

d: To fuel injection nozzle

e: Fuel return (Over-flow valve – Fuel tank)

f: Fuel spill (Nozzle – Fuel tank)

g: Engine oil (To fuel injection pump)

h: Engine oil (To engine oil pan)




SAA6D140-2 (PC750-6, PC800-6)a The specifications are subject to change according to modification, etc.

1. Fuel injection pipe (No. 1) 8. Fuel injection pump drive gear (No. of teeth 48)2. Fuel injection pipe (No. 2) 9. Fuel injection pump drive shaft




6. Fuel injection pipe (No. 6) 13. Fuel injection pump (With boost compensator)

7. Boost compensator tube 14. Oil outlet pipe




Fuel injection pump





Governor • Type: Bosch RSUV Centrifugal, all speed type

a: Fuel inlet

b: To fuel filter

c: From fuel filter

d: To fuel injection nozzle

e: Fuel return (Over-flow valve – Fuel tank)

f: Engine oil (To fuel injection pump)

g: Engine oil (To engine oil pan)




SAA6D140-2 (HD325-6)

1. Fuel injection pipe (No. 1) 9. Fuel injection pump drive shaft



4. Fuel injection pipe (No. 4) 12. Oil outlet pipe


6. Boost compensator tube 14. Oil inlet pipe

7. Fuel injection pipe (No. 6) 15. Fuel injection pump8. Fuel injection pump drive gear (No. of teeth 48)




Fuel injection pump





Governor


Bosch RFD Centrifugal, max. – min.

speed control type




Feed pump


Functions

• The feed pump sucks fuel from the fuel tank and

supplies (discharge) it through the fuel filter to

the injection pump.

• This feed pump also has the function to maintain

the discharge pressure (rate) at constant 0.1 –

0.2 MPa {1 – 2 kg/cm2} to set the fuel injection

rate of the injection pump (quantity of fuel

injected by each stroke) constant.

1. Cover

2. Priming pump

3. Spring

4. Check valve (intake)

5. Eyebolt

6. Plug

7. Piston spring

8. Piston

9. Push rod

10. Tappet

11. Check valve (exhaust)

A. Fuel inletB. Fuel outlet




Fuel injection nozzle


1. Fuel inlet connector Fuel injection nozzle

S6D140-2: Made by BOSCH automotive system

Diameter of nozzle hole 0.35 x 7 hole)

SA6D140-2: Made by BOSCH automotive system

(Diameter of nozzle hole 0.36 x 6 hole)

SAA6D140-2: Made by BOSCH automotive system

(Diameter of nozzle hole 0.36 x 6 hole)

• Type: Multi-hole type

• Injection pressure:24.5 MPa {250 kg/cm2}

• Adjusting INJECTION pressure:

Shim adjusting type

2. Nozzle holder

3. Adjustment shim

4. Spring

5. Seat

6. Spacer

7. Nozzle

8. Retaining cap

9. Nozzle needle

a. Fuel inlet (From injection pump)

b. Injection (To cylinder)

c. Fuel return (To fuel tank)




Fuel filter


Fuel filter

• Filtration area: 1.0 m2

1. Filter head

2. Air bleed plug

3. Cartridge

a. Fuel inlet

b. Fuel outlet




Engine stop motor

Engine stop motor

• Maker: Jidosha Denki Kogyo Co. Ltd

• Rated voltage: DC24V

• Operating force: 147 N {15 kg} min.

• Stroke: 35 mm • Weight: 1.2 kg

1. Motor assembly

2. Cover

3. Cable assembly

4. Cable clamp

5. Coil spring

6. Cable

7. Screw

8. Breather

9. Bracket assembly

10. Cover assembly

+1.0 –0.4




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




Structural drawing (2)

1. Gear cover assembly

2. Motor assembly

3. Cable clamp

4. Cable assembly

5. Gear case assembly




Description of operation and circuits1. Stop condition (0° or 360°)

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 P1 side.

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

When the switch is moved to the P2 side (starting switch ON), an electric current flows from the plus side

contact plate through the P2 auto-stop terminal and switch and into the armature shaft assembly, thereby

starting the motor. The slider assembly starts to move in the direction of the arrow at the same time as the

roller starts to move.

3. Turning condition (90° in the drawing)

Electric current continues to pass through the armature assembly and the motor continues to turn. Because

of the rotation of the roller, the slider assembly also continues to move in the direction of the arrow.



Structure and function Cooling system

Cooling system

Cooling system chart

For construction machinery, generator

1. Radiator

2. Thermostat3. Water-cooled aftercooler (SA6D140-2)

4. Oil cooler

5. Water pump

6. Air compressor

7. Cooling fan

8. Corrosion resistor

A. Oil inlet and outlet




SDA6D140E-2 (D275A-5, –50°C spec.)

1. Radiator

2. Radiator (small type)

3. Thermostat

4. Water-cooled aftercooler


6. Oil cooler

7. Water pump

8. Air compressor

9. Cooling fan

10. Corrosion resistor (for aftercooler)

11. Water pump (for aftercooler)

A. Oil inlet and outlet




For marine engine

1. Sea water aftercooler 10. Heat exchanger

2. Water level sensor 11. Marine gear oil cooler

3. Fresh water tank 12. Spare sea water pump

4. Thermostat 13. Sea water pump

5. Water-cooled exhaust manifold 14. Kingston cock

6. Water thermometer

7. Oil cooler A. Engine oil inlet, outlet8. Water pump B. Marine gear oil inlet, outlet

9. Water temperature rise alarm switch C. Air inlet, outlet




Water pump

Mounting

S6140-2

SA6D140-2SAA6D140-2 (PC750-6, PC800-6)

1. Oil cooler A. From radiator outlet (Cooling water)

From heat exchanger outlet (For marine engines)2. Thermostat housing

3. Water pump B. Via oil cooler to each portion of engine

(Cooling water)

C. To radiator inlet (Cooling water)

To heat exchanger (For marine engines)

D. From thermostat (Cooling water)E. From oil pump (Oil)

F. To each portion of engine (Oil)




SA6D140-2 (D155A-3, D155AX-3, D155AX-5, D155C-1 (–30°C spec., –50°C spec.),

D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.))

SDA6D140E-2 (D275A-5, –50°C spec.)


2. Thermostat housing B. Via oil cooler to each portion of engine

(Cooling water)3. Water pump

C. To radiator (Cooling water)

D. To oil cooler on machine (Cooling water)

E. From oil pump (Oil)

F. To each portion of engine (Oil)




SAA6D140-2 (HD325-6)a The specifications are subject to change according to modification, etc.


2. Thermostat housing B. Via oil cooler to each portion of engine

(Cooling water)3. Water pump

C. To radiator (Cooling water)

D. To oil cooler on machine (Cooling water)

E. From oil pump (Oil)F. To each portion of engine (Oil)




SDA6D140E-2 (D275A-5, –50°C spec.)

For aftercooler

1. Tube A. From water pump to aftercooler

2. Tube

3. Water pump




S6D140-2

SA6D140-2

SAA6D140-2

SDA6D140E-2 (D275A-5, –50°C spec.)

Water pump

• Type: Centrifugal, gear-driven

• Water pump speed : Engine speed x 1.56

• Flow capacity: 800 l/min.

• Total water head: 14 m

1. Alternator drive pulley

2. Oil seal

3. Ball bearing

4. Pump shaft

5. Water pump drive gear (No. of teeth: 23)

6. Pump body

7. Water seal

8. Impeller

9. Pump cover

a. From radiator

b. To oil cooler




For aftercooler

SDA6D140E-2 (D275A-5, –50°C spec.)

Water pump

• Type: Centrifugal, gear-driven

• Water pump speed :Engine speed x 1.26

• Flow capacity: 120 l/min.

• Total water head: 3 m

1. Pump shaft

2. Water pump drive gear (No. of teeth: 19)

3. Spacer

4. Seal ring

5. Ball bearing

6. Spacer

7. Ball bearing

8. Gasket

9. Impeller

10. Water seal

11. Plate

a. From radiator b. To aftercooler




Thermostat

a The specifications may be different from the following figure, depending on the type of machine model.

Thermostat

• Valve opening temperature:

76.5 ± 2°C (For construction machine and

generator)

82 ± 2°C (For marine engines)

• Fully opening temperature: 90°C

• Lift and fully opening position:10 mm min.

1. Cylinder block

2. Thermostat housing

3. Thermostat

A. To radiator To heat exchanger

(For marine engines)

B. To water pump

To Brake cooler (HD325)

To oil cooler on machine body

(D155A-3, D155AX-3)




Corrosion resistor


Corrosion resistor

• Filtration area:

6D140-2: 0.13 m2

SA6D140, S6D140-2: 0.13 m

2

SAA6D140, SA6D140-2: 0.373 m2

• Quantity of corrosion preventive agent:

6D140-2: 400 g

SA6D140, S6D140-2: 400 g

SAA6D140, SA6D140-2: 1,000 g

1. Head

2. Cartridge

3. Element

4. Inhibitor (Solid corrosion preventive agent)

5. Spring

6. Stop valve

a. Water inlet

b. Water outlet




Corrosion resistor mounting


1. Bracket

2. Hose (return from corrosion resistor)3. Valve

4. Corrosion resistor cartridge

5. Hose (to corrosion resistor)




Cooling fan drive

Tension pulley mount

S6D140-2 for WA500-3a The specifications may be different from the following figure, depending on the type of machine.

1. Fan pulley

2. Tension pulley (Outside diameter: 120mm)

3. Crank pulley (Outside diameter: 164 mm)

4. Fan belt




Tension pulley mount

SA6D140-2 for D155A-3, D155AX-3, D155AX-5a The specifications may be different from the following figure, depending on the type of machine.

Fan pulley1. Fan pulley

2. Tension pulley


4. Fan belt

Outside

diameter

(mm)

Applicable machine

295 D155A-3, D155AX-3, D155AX-5

316 D155A-3, D155AX-3 (Scraper spec.)




Tension pulley

SA6D140-2 (D155A-3, D155AX-3, D155AX-5)a The specifications may be different from the following figure, depending on the type of machine.

1. Bracket

2. Spacer

3. Ball bearing

4. Tension pulley (Outside diameter: 118 mm)

5. Oil seal

6. Inner race

7. Needle bearing

8. Coil spring

9. Tension shaft




SAA6D140-2 (PC750-6, PC800-6)a The specifications may be different from the following figure, depending on the type of machine.

Pulley outside diameter

Unit: mm

1. Fan pulley

2. Fan belt

3. Crank pulley

4. Tension pulley

5. Tension shaft

6. Tension spring

Model Fan pulleyCrank

pulley

Tension

pulley

PC750-6

PC800-6280 164 118




Tension pulley

SAA6D140-2 (PC750-6, PC800-6)a The specifications may be different from the following figure, depending on the type of machine.

1. Tension shaft

2. Roller bearing

3. Tension bracket

4. Oil seal


6. Ball bearing

7. Spacer

8. Stopper




SAA6D140-2 for HD325-6, HD405-6a The specifications may be different from the following figure, depending on the type of machine.

Fan pulley1. Tension pulley (Outside diameter: 118 mm)

2. Fan pulley

3. Fan mount case

4. Fan belt


a. Wind direction

Outside diameter (mm) Applicable machine

275 HD325-6, HD405-6




Tension pulley


1. Bracket

2. Spacer

3. Ball bearing


5. Bearing

6. Coil spring

7. Tension shaft




Fan mount case


1. Fan pulley hub

2. Ball bearing

3. Shaft4. Case



Structure and function Accessory

Accessory

Air compressor

(Installed depending on the model)

1. Crankshaft a. Air intake

2. Crankcase b. Air exhaust3. Connecting rod c. Unloader

4. Cylinder d. Oil inlet

5. Piston e. Cooling water inlet or outlet

6. Piston ring f. Cooling water outlet or inlet

7. Piston pin

8. Bearing cover

9. Cylinder head

10. Unloader valve




Air compressor

• Maker: ZEXEL

• Type: Single cylinder, reciprocated

type

• Discharge volume:340 cc/rev.

• Air pressure: 834 kPa {8.5 kg/cm2}

(at full load)

• Weight: 11 kg

Unloader valve

• Valve opening pressure: 618 kPa {6.3 kg/cm2}

• Valve shutting pressure: 530 kPa {5.4 kg/cm2}




Air compressor mountinga The specifications may be different from the following figure, depending on the type of machine.

1. Air compressor

2. PTO case

3. Compressor drive gear (No. of teeth: 24)

a. From intake manifold (air)

b. Exhaust (air)

c. From air governor to unloader (air)

d. From cylinder block (cooling water)

e. To cylinder block (cooling water)

f. From cylinder block (oil inlet)




Exhaust brake

Slide valve typea The specifications are subject to change according to modification, etc.

Outline

An exhaust brake is installed between the turbo-

charger and muffler, and works due to the air pres-

sure from the solenoid valve, reducing engine speed

by throttling the exhaust passage of the muffler from

the turbocharger. The exhaust brake consists of a

valve mechanism and an air cylinder which controls

the valve.

1. Valve housing

2. Gate valve

3. Guide bushing

4. Cylinder

5. Spring

6. Spring

7. Piston

8. Retainer

9. Release valve

10. Packing

11. Packing

12. Exhaust pressure adjustment bolt

13. Breather




Butterfly valve typea The specifications are subject to change according to modification, etc.

1. Air cylinder 9. Valve

2. Stopper bolt (fully open) 10. Spindle

3. Stopper bolt (fully close) 11. Bushing

4. Lever 12. Valve body

5. Yoke 13. Cover

6. Insulator

7. Bushing a: From exhaust brake valve

8. Spindle




Solenoid valve for exhaust brakea The specifications may be different from the following figure, depending on the type of machine.

1. Connector A. From air tank

2. Case B. To exhaust brake

3. Core C. Exhaust outlet

4. Coil assembly

5. Spring

6. Plunger

7. Spring

8. Valve

9. Rod

10. Body




Operation1. When the exhaust brake switch is turned off

If the switch is turned off, solenoid (1) of the

exhaust brake valve is deenergized.

Under this condition, ports A and B of the

exhaust brake are closed, but ports B and C are

open. Accordingly, air in cylinder (5) of the but-

terfly valve returns through port B to port C, then

discharged in the atmosphere, and butterfly

valve (7) fully opens the path from the turbo-

charger to the muffler.

2. When the exhaust brake switch is turned on

If the switch is turned on, solenoid (1) of the

exhaust brake valve is energized, and plunger

(3) and valve (4) move in the direction of to

close ports B and C and open ports A and B. As

the result, air from the dry tank flows in port B,

then to cylinder (5) of the butterfly valve.Then, the cylinder is extracted to move lever (6)

in the direction of , and butterfly valve (7) fully

closes the path from the turbocharger to the

muffler. Accordingly, the engine speed drops

and the downhill travel speed of the machine is

limited.

While the accelerator pedal is pressed, the

exhaust brake limit switch operates so that the

engine brake will not be applied even if the

switch is turned on.



Structure and function Electrical system

Electrical system

Alternator

Mountinga The specifications may be different from the following figure, depending on the type of machine.

1. Alternator a. Alternator pulley (Pulley O.D. 85 mm)

2. Adjust rod b. Alternator drive pulley (Pulley O.D. 132 mm)

3. Nut (2 pieces)

4. Plate

5. Cover

6. V-belt (2 pieces)

7. Spacer




Alternator with built-in regulator (Open type 35A)a The shape may differ according to the machine model.

1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Primary energized resistance

3. Terminal B 6B. Regulator

4. Terminal R 6C. Field coil

5. Terminal E

Engine model Applicable machine

modelType Specification

Pulley O.D.

(mm)

Weight

(kg)Pulley type

S6D140-2 WA500-3Maker: NIKKO DENKI

Type: Opened (Brushless) 24 V, 35 A 85 9.5 I

SA6D140-2 D155A-3, AX-3, AX-5Maker: NIKKO DENKI

Type: Opened (Brushless)24 V, 35 A 85 9.5 I




Alternator with built-in regulator (Open type)a The shape may differ according to the machine model.

1. Alternator 5. Terminals B

2. Alternator pulley 6. Internal electric circuit diagram

3. Terminal R 6A. Field coil

4. Terminal E 6B. Regulator



Pulley O.D.

(mm)

Weight

(kg)

S6D140-2Maker: NIKKO DENKI

Type: Opened (Brushless)24 V, 35 A 85 9.5

SA6D140-2D155A-3, AX-3, D355C-3,

D355C-3 (–30°C spec.)

Maker: NIKKO DENK


SAA6D140-2

Maker: NIKKO DENKI


Maker: NIKKO DENKI

Type: Opened (Brushless)

24 V, 30 A 85 9.5






2. Alternator pulley 6A. Alternator


4. Terminal E

5. Terminal R



Pulley O.D.

(mm)

Weight

(kg)Pulley type

S6D140-2 GD825A-2Maker: SAWAFUJI DENKI

Type: Opened (Brushless)24 V, 50 A 85 12 II

SA6D140-2D155A-3, AX-3, AX-5 (if

equipped)

Maker: SAWAFUJI DENKI


SAA6D140-2PC750-6, PC800-6

HD325-6, HD405-6








2. Alternator pulley 6A. Primary energized resistance


4. Terminal R 6C. Field coil

5. Terminal E



Pulley O.D.

(mm)

Weight

(kg)Pulley type

SA6D140-2

D155C-1 (–30°C spec.)

D155C-1 (–50°C spec.)

D355C-3

D355C-3 (–30°C spec.)

D355C-3 (–50°C spec.)

Maker: NIKKO DENKI

Type: Opened (Brushless)24 V, 50 A 85 11.0 I






2. Alternator pulley 5A. Alternator


4. Terminal R

Engine Machine model Type SpecificationOutside diameter

of pulley (mm)

Weight

(kg)

SDA6D140E-2 D275A-5 (–50°C spec.)Sawafuji Denki

Open type (brushless)24 V, 75 A 85 12.5




Starting motor

For 7.5 kWa The shape may differ according to the machine model.

1. Pinion gear 8. External wiring diagram (3-pin connector type)

2. Starting motor assembly 8A. Safety relay portion

3. Magnetic switch 8B. Starting motor portion

4. Safety relay

5. Terminal B S. To starting switch terminal C

6. Terminal C R. To alternator terminal R

7. External wiring diagram (2-pin connector type) E. To ground

7A. Safety relay portion

7B. Starting motor portion






Pulley O.D.

(mm)

Weight

(kg)

Connector

type

S6D140-2

Maker: NIKKO DENKI

Type: Closed

(drip-proof, oil proof)

24 V, 7.5 kW 12 18

SA6D140-2

Maker: NIKKO DENKI

Type: Closed


24 V, 7.5 kW 12 18 B

SAA6D140-2 PC750-6, PC800-6

Maker: NIKKO DENKI

Type: Closed


24 V, 7.5 kW 12 18 C




For 11 kWa The shape may differ according to the machine model.

1. Starting motor assembly 9. External wiring diagram (3-pin connector type)

2. Magnetic switch 9A. Control unit

3. Safety relay 10. External wiring diagram (without safety relay)

4. Pinion gear

5. Terminal B S. To starting switch terminal C

6. Terminal C R. To alternator terminal R

7. Connector E. To ground

8. External wiring diagram (2-pin connector type)

8A. Control unit






Number of

pinion

teeth

Weight

(kg)

Connector

type

S6D140-2GD825A-2 Maker: SAWAFUJI DENKI

Type: Closed


24 V, 11 kW 11 20 B

WA500-3 24 V, 11 kW 11 20 C

SA6D140-2

D155A-2,3, AX-3, AX-5

(X type connector)


Type: Closed


24 V, 11 kW 11 20 C

D155C-1 (–30°C spec.)

D155C-1 (–50°C spec.)

D355C-3

D355C-3 (–30°C spec.)

D355C-3 (–50°C spec.)

24 V, 11 kW 11 20 C

SAA6D140-2HD325-6, HD405-6 Maker: SAWAFUJI DENKI

Type: Closed


24 V, 11 kW 11 20 C




For 11 kWa The shape may differ according to the machine model.

1. Pinion gear 7. External wiring diagram (2-pin connector type)

2. Starting motor assembly 7A. Safety relay portion

3. Magnetic switch 7B. Starting motor portion

4. Terminal B

5. Terminal C S. To starting switch terminal C

6. Safety relay R. To alternator terminal RE. To ground

Engine Machine model Type Specification

No. of

pinion

teeth

Weight

(kg)

Connector

type

SDA6D140E-2 D275A-5 (–50°C spec.)Nikko Denki

Waterproof, oilproof type24 V, 11 kW 12 18 B




Electrical intake air heater

S6D140-2a The specifications may be different from the following figure, depending on the type of machine.

Electrical intake air heater

• Rated voltage: DC22 V

• Rated current: 175 A

SA6D140-2

SDA6D140E-2 (D275A-5, –50°C spec.)

Electrical intake air heater • Rated voltage: DC11 V

• Rated current: 86 A

1. Heater body

2. Heater coil

1. Heater body2. Heater coil

3 Terminal




Front PTO mounting


1. Front PTO

2. O-ring

3. Front PTO drive gear assembly




Front PTO assembly


1. Shaft

2. Pulley

3. Oil seal

4. Bearing (2 pieces)

5. Housing

6. O-ring

7. Gear (No. of teeth: 14)

8. Snap ring

9. Sleeve




Front PTO drive gear assembly


1. Gear (No of teeth: 24) 7. Gasket

2. Snap ring 8. O-ring

3. Pin 9. Bearing (2 pieces)

4. Plate 10. Housing

5. Bolt 11. Shaft

6. Flange



Mounting (adjusting) method of

engine speed sensor............................... 12- 2

Engine body

Adjusting valve clearance......................... 12- 3Measuring compression pressure ............ 12- 4

Fuel system

Testing and adjusting fuel

injection timing.................................. 12- 5

Adjusting fuel injection pressure............... 12- 6

Procedure for adjusting engine

stop motor cable ............................... 12- 7

Cooling system

Checking and adjusting fan belt tension... 12- 9

Fuel injection pump calibration data .............. 12- 10

Performance test ........................................... 12- 26

Run-in standard........................................ 12- 26

Performance test criteria ..........................12- 32

Troubleshooting ............................................. 12- 41

Points to remember when

troubleshooting .......................................12- 43

Method of using troubleshooting charts......... 12- 44

Testing and adjusting tool list......................... 12- 67

Testing and adjusting data ............................. 12- 68

12 Testing and adjusting



Testing and adjusting Mounting (adjusting) method of engine speed sensor

Mounting (adjusting) methodof engine speed sensor

Adjustment of gap between speed sensor and

pin on periphery of flywheel

• The following is the removing and mounting pro-cedure of the engine speed sensor.

1. Turn the crankshaft forward to match pin (1)

driven in the periphery of the flywheel.

2. At this position, tighten speed sensor (2) until it

touches pin (1) of the flywheel, then loosen it by

one turn.

a Gap at this time: 1.0 – 1.2 mm

3. Tighten lock nut (3).

a After adjusting, confirm that the enginecranks smoothly.

Adjustment of gap between speed sensor and

contact surface of ring gear

• The following is the removing and mounting pro-cedure of the engine speed sensor.

1. Tighten sensor (1) until its tip touches ring gear

(2).

2. After sensor (1) touches gear (2), loosen it by

1/2 – 2/3 turns.

a Gap at this time: 0.75 – 1.00 mm

3. Tighten lock nut (3).

a Arrange the sensor wires carefully so that an

excessive force will not be applied to them.

a Take care to keep the sensor tip free from

metallic chips dust, dirt etc.

a The specifications may be different from the

following figure, depending on the machine

model.



Testing and adjusting Engine body

Engine body

Adjusting valve clearance

1. Remove the rocker arm housing 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 cylin-

der into the top dead center position of the com-

pression stroke and align the "1.6 TOP" mark on

vibration damper (1) with pointer (2).

a 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).

3. Adjust the valve clearance for valves marked q

in the valve arrangement chart.

4. Rotate the crankshaft in the normal direction by

one revolution and adjust the valve clearance

for the remaining valves marked Q.

a To adjust the valve clearance, loosen lock

nut (5) on adjustment screw (4), insert the

feeler gauge corresponding to the specified

clearance between crosshead (6) and rocker

arm (7), and adjust the clearance with the

adjustment screw until the thickness gauge

can slide lightly.

5. After the clearance is properly adjusted, tighten

the lock nut to secure the adjustment screw.

3 Lock nut: 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}

a The engine firing order is 1 – 5 – 3 – 6 – 2 – 4.

a Intake and exhaust valve clearances may be

adjusted for each cylinder in the firing order

by rotating the crankshaft 120° at a time in

the normal direction.



Testing and adjusting Engine body

Measuring compressionpressure

Measurement procedurek While measuring the compression pressure,

take care not burn yourself on the exhaustmanifold or muffler, and be careful not to get

caught in any revolving part of the engine.

a Measure the compression pressure while the

engine is warm.

(Oil temperature: 40 – 60°C)

1. Adjust the valve clearance properly. For details,

see ADJUSTING VALVE CLEARANCE.

2. Disconnect fuel injection tube (1).

a When the No. 1 cylinder comes near the top

dead center of the compression stroke, theNo. 6 intake valve will start to move (open).

3. Remove inlet connector (2) and nozzle holder

assembly (3) for each cylinder.

4. Install adapter (4) to the nozzle holder mounting

section of the cylinder to be measured, and

tighten the adapter with retainer (5) to the speci-

fied torque:

3 Torque: 66.7 ± 7.3 Nm {6.8 ± 0.75 kgm}

5. Connect compression gauge A 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.

k If you do not put the fuel control lever in NO

INJECTION position, fuel will blow out.

a Most compression leakage can be

prevented by applying a small amount of oil

to the mounting section of the adapter.

a For the reference values of the compression

pressure, see TESTING AND ADJUSTING

DATA.



Testing and adjusting Fuel system

Fuel system

Testing and adjusting fuelinjection timing

• Inspection of fuel injection timing

1. Turn the engine to match stamped line (1) (1-6

TOP) of the damper to pointer (2).

2. Pull out snap pin (3) of the injection timing fixing

pin, and remove nut (4).

3. Pushing pin (5) against the engine, turn the

crankshaft in reverse and insert pin (5) in gear

(6).

4. In this condition, confirm that stamped line "a"

on the injection pump is matched to stampedline "b" on the coupling side.

a If the engine is started or turned forcedly in

this condition, the end of pin (5) will be

broken and caught in the gear, and that can

cause a serious accident.

• Adjustment of fuel injection timing

1. If the stamped line of the fuel injection timing is

found to be deviated, as the result of inspection,

adjust it according to the following procedure.

1) Loosen bolt (7) and shift the coupling to

match the stamped line, then tighten thebolt.

3 Bolt:

58.8 – 62.8 Nm {6.0 – 6.4 kgm}

• Releasing fixing pin

1) Pull pin (5) out of gear (6).

a Pin (5) can be pulled out easily if it is

turned.

a Pull out pin (5) until is stops.

2) Tighten nut (4).

3 Nut:

26.9 – 33.9 Nm {2.74 – 3.46 kgm}

a The nut can be tightened securely if a

flat-head screwdriver is set in the slit of

pin (5) to lock it.

3) Insert snap pin (3) to lock nut (4) and pin (5).

4) Turn on the engine and confirm that it runs

smoothly.




Adjusting fuel injectionpressure

1. Remove retaining cap (8).

2. Confirm thickness of adjustment shim (3).

3. Insert correct shim (3) in response to the adjust-

ment value of injection pressure.

4. Tighten retaining cap (8), then confirm the fuel

injection pressure.

3 Retaining cap:

58.8 – 68.6 Nm {6 – 7 kgm}

Data for shims used for adjusting injection pressure

6D140-2, S6D140-2, SA6D140-2, SAA6D140-2

Maker BOSCH automotive system

Cracking pressure (MPa {kg/cm2}) 24.5 {250 }

Change in cracking pressure for 0.025 mm

thickness of shim (MPa {kg/cm2})0.34 {3.5}

Thickness of adjustment shim (mm) 0.5 – 1.975 (For each 0.025 mm)

Thickness (mm) Part No. Thickness (mm) Part No.

Shim thickness and maker part number

0.50 150530–4000 0.525 150530–4100

0.55 150530–4200 0.575 150530–4300

0.60 150530–4400 0.625 150530–4500

0.65 150530–4600 0.675 150530–4700

0.70 150530-4800 0.725 150530–4900

0.75 150530–5000 0.775 150530–5100

0.80 150530–5200 0.825 150530–5300

0.85 150530–5400 0.875 150530–5500

0.90 150530–5600 0.925 150530–5700

0.95 150530–5800 0.975 150530–5900

1.00 150530–6000 1.025 150530–6100

1.05 150530–6200 1.075 150530–6300

1.10 150530–6400 1.125 150530–6500

1.15 150530–6600 1.175 150530–6700

1.20 150530–6800 1.225 150530–6900

O O O O

1.95 150530–9800 1.975 150530–9900

+1.3+0.5

+13+5




Procedure for adjustingengine stop motor cable

S6D140-2 for GD825A-2, WA500-31. Temporarily attach the ball joint connected to the

injection pump to the cable of the engine stopmotor.

2. Pull injection pump stop lever (2) to the ENGINE

STOP (fuel non-injection) position, temporarily

attach the ball joint to the stop lever, then fix

cable (4) to bracket (3).

a The engine stop motor cable is housed in the

pulled condition.

a When the lever is free, the stop lever is in the

OPERATING position (built-in spring).

3. When the engine is stopped (at time of installa-tion), clearance a between stop lever (2) of the

injection pump and lever stopper (1) should be

0.5 – 1.5 mm. Adjustment is made according to

the depth that the ball joint is screwed in.

4. After adjusting the clearance between the stop-

per and lever, tighten each bolt and nut.

5. Turn the engine starting switch ON and OFF a

few times to confirm that the engine stop motor

actuated smoothly. Be especially sure to confirm

that there is a clearance between the stop lever

and stopper when the engine is stopped.a The engine stop motor has built-in limit

switches on both sides of the cable stroke.

a When the engine is running, there is some

slack in the engine stop motor cable. A

spring built into the injection pump actuates

to hold the opening position.

• Engine stop motor stroke: 35 mm

• Injection pump stop lever stroke: 30 mm

1. Lever stopper

2. Fuel injection pump stop lever

3. Bracket

4. Cable

5. Joint




SAA6D140-2 for HD325-6, HD405-61. Temporarily attach the ball joint connected to the

injection pump to the cable of the engine stop

motor.

2. Pull injection pump stop lever (1) to the ENGINE

STOP (fuel non-injection) position, temporarily

attach the ball joint to the stop lever, then fix

cable (3) to bracket (2).

a The engine stop motor cable is housed in the

pulled condition.

a When the lever is free, the stop lever is in the

OPERATING position (built-in spring).

3. When the engine is stopped (at time of installa-

tion), clearance a between stop lever (1) of the

injection pump and the lever stopper (built-in to

pump) should be 0.5 – 1.5 mm. Check clear-

ance by movement of cable due to stopper isbuilt into pump housing. Adjustment is made

according to the depth that the ball joint is

screwed in.

4. After adjusting the clearance between the stop-

per and lever, tighten each bolt and nut.

5. Turn the engine starting switch ON and OFF a

few times to confirm that the engine stop motor

actuated smoothly. Be especially sure to confirm

that there is a clearance between the stop lever

and stopper when the engine is stopped.a The engine stop motor has built-in limit

switches on both sides of the cable stroke.

a When the engine is running, there is some

slack in the engine stop motor cable. A

spring built into the injection pump actuates

to hold the opening position.

• Engine stop motor stroke: 35 mm

• Injection pump stop lever stroke: 30 mm

1. Stop lever

2. Bracket

3. Cable

4. Ball Joint



Testing and adjusting Cooling system

Cooling system

Checking and adjusting fan belt tension

Unit: mm

1. Adjustment nut

2. Washer

3. Tension spring

4. Adjustment bolt

5. Tension pulley

A. Protrusion of adjustment bolt

Engine model

Applicable

machine Dimension A

SAA6D140-2PC750-6

PC800-644 ± 3



Testing and adjusting Fuel injection pump calibration data

Fuel injection pump calibration data

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

S6D140-2

6211-72-1310 WA500-3 12-11

6211-72-1470 GD825A-2 12-16

SA6D140-2

6212-72-1120 D155A-3, D155AX-3 12-12

6211-72-1140 D155AX-5 12-23

6211-72-1150 D155A-2 12-18

6211-72-1160 D355C-3, D355C-3 (–30°C spec.),

D355C-3 (–50°C spec.) 12-19

6211-72-1170 D155AX-5 12-24

6211-72-1180 D155C-1 (–30°C spec.)

D155C-1 (–50°C spec.) 12-25

6212-72-1430 PC1600SP-1 12-17

6212-72-1830 J6D140E-G1-2 (with electronic governor)

(TAIYO DENKI generator) 12-21

6212-72-1840 J6D140E-G1-2 (with mechanical governor)

(TAIYO DENKI generator) 12-22

6212-72-1860 DCA400SSK-2 (DENYO generator) 12-13

6212-72-1860 DCA-400SSK (For MQ generator) 12-20

SAA6D140-2

6212-72-1250HD325-6 (with mechanical governor)

12-14HD405-6 (with mechanical governor)

6212-72-1421 PC750-6, PC800-6, PC1800-6 12-15



Testing and adjusting Performance test

Performance test

Run-in standard

a The table gives the standard values for machines without fan.

a The loads for the dynamometer are at an arm's length of 716 mm.

Engine

model

Applicable

machineItem

Order

1 2 3 4 5 6

S6D140-2

GD825A-2

Running time min. 2 8 2 3 5

Engine speed rpm 650 1,300 1,650 1,900 2,100

LoadN

{kg}

0

{0}

343

{35}

686

{70}

1,030

{105}

1,373

{140}

Flywheel

horsepower

kW

{HP}

0

{0}

33.9

{45.4}

85.4

{114.4}

147.2

{197.2}

216.4

{289.9}

WA500-3


Engine speed rpm 725 1,000 1,200 1,500 2,100

LoadN

{kg}

0

{0}

392

{40}

785

{80}

1,177

{120}

1,569

{160}

Flywheel

horsepower

kW

{HP}

0

{0}

29.4

{39.4}

70.7

{94.7}

132.5

{177.5}

247.3

{331.3}

Running time min.

Engine speed rpm

LoadN

{kg}

Flywheel

horsepower

kW

{HP}

Running time min.

Engine speed rpm

LoadN

{kg}

Flywheel

horsepower

kW

{HP}

Running time min.

Engine speed rpm

LoadN

{kg}

Flywheel

horsepower

kW

{HP}






Engine

model

Applicable

machineItem

Order

1 2 3 4 5 6

SA6D140-2

D155A-3

D155AX-3


Engine speed rpm 700 1,100 1,450 1,710 1,900

LoadN

{kg}

0

{0}

432

{44}

863

{88}

1,285

{131}

1,716

{175}

Flywheel

horsepower

kW

{HP}

0

{0}

35.6

{47.7}

93.9

{128.5}

164.9

{220.9}

244.7

{327.8}

PC1600SP-1


Engine speed rpm 750 1,000 1,200 1,500 1,800

LoadN

{kg}

0

{0}

618

{63}

1,226

{125}

1,844

{188}

2,452

{250}

Flywheel

horsepower

kW

{HP}

0

{0}

46.4

{62.1}

110.4

{147.9}

207.6

{278.1}

331.2

{443.7}

DCA400SSK-2

(DENYO

generator)


Engine speed rpm 800 1,000 1,200 1,500 1,800

LoadN

{kg}

0

{0}

539

{55}

1,844

{188}

2,157

{220}

2,707

{276}

Flywheel

horsepower

kW

{HP}

0

{0}

40.5

{54.2}

166.3

{222.8}

242.9

{325.4}

365.8

{490.0}

D155A-2


Engine speed rpm 550 – 650 1,000 1,200 1,500 2,000

LoadN

{kg}

0

{0}

353

{36}

883

{90}

1,410

{144}

1,770

{180}

Flywheel

horsepower

kW

{HP}

0

{0}

26

{35}

79

{106}

159

{213}

265

{355}

D355C-3


Engine speed rpm 700 – 750 1,000 1,200 1,500 2,000

LoadN

{kg}

0

{0}

373

{38}

932

{95}

1,490

{152}

1,860

{190}

Flywheel

horsepower

kW

{HP}

0

{0}

28

{37}

84

{112}

168

{225}

279

{375}






Engine

model

Applicable

machineItem

Order

1 2 3 4 5 6

SA6D140-2

DCA-400SSK

(MQ

generator)


Engine speed rpm 800 1,000 1,200 1,500 1,800

LoadN

{kg}

0

{0}

540

{55}

1,840

{188}

2,160

{220}

2,700

{276}

Flywheel

horsepower

kW

{HP}

0

{0}

40

{54}

166

{223}

243

{325}

366

{490}

J6D140E-GI-2

(TAIYO DENKI

generator)


Engine speed rpm 800 1,000 1,200 1,500 1,800

LoadN

{kg}

0

{0}

470

{48}

1,180

{120}

1,880

{192}

2,350

{240}

Flywheel

horsepower

kW

{HP}

0

{0}

35

{48}

106

{146}

212

{292}

318

{438}

D155AX-5


Engine speed rpm 700 1,000 1,200 1,500 1,900

Load

N

{kg}

0

{0}

353

{36}

883

{90}

1,410

{144}

1,770

{180}

Flywheel

horsepower

kW

{HP}

0

{0}

26

{36}

79

{109}

159

{219}

252

{347}

D155C-1

(–30°C spec.)


Engine speed rpm 725 1,000 1,200 1,500 2,000

LoadN

{kg}

0

{0}

667

{68}

1,670

{170}

2,670

{272}

3,330

{340}

Flywheel

horsepower

kW

{HP}

0

{0}

50

{67}

150

{201}

300

{402}

500

{670}

D155C-1

(–50°C spec.)


Engine speed rpm 725 1,000 1,200 1,500 2,000

LoadN

{kg}

0

{0}

667

{68}

1,670

{170}

2,670

{272}

3,330

{340}

Flywheel

horsepower

kW

{HP}

0

{0}

50

{67}

150

{201}

300

{402}

500

{670}






Engine

model

Applicable

machineItem

Order

1 2 3 4 5 6

SA6D140-2

D355C-3

(–30°C spec.)


Engine speed rpm 700 – 750 1,000 1,200 1,500 2,000

LoadN

{kg}

0

{0}

373

{38}

932

{95}

1,490

{152}

1,860

{190}

Flywheel

horsepower

kW

{HP}

0

{0}

28

{37}

84

{112}

168

{225}

279

{375}

D355C-3

(–50°C spec.)


Engine speed rpm 700 – 750 1,000 1,200 1,500 2,000

LoadN

{kg}

0

{0}

373

{38}

932

{95}

1,490

{152}

1,860

{190}

Flywheel

horsepower

kW

{HP}

0

{0}

28

{37}

84

{112}

168

{225}

279

{375}

SAA6D140-2

HD325-6

HD405-6


Engine speed rpm 800 1,300 1,650 1,900 2,100

Load

N

{kg}

0

{0}

588

{60}

1,177

{120}

1,765

{180}

2,354

{240}

Flywheel

horsepower

kW

{HP}

0

{0}

57.4

{76.9}

145.7

{195.2}

251.7

{337.2}

370.9

{496.9}

HD325-6

(High altitude

spec.)


Engine speed rpm 725 1,000 1,200 1,500 2,000

LoadN

{kg}

0

{0}

490

{50}

1,030

{105}

1,569

{160}

1,961

{200}

Flywheel

horsepower

kW

{HP}

0

{0}

36.8

{49.3}

92.7

{124.2}

176.6

{236.6}

294.4

{394.4}

PC750-6

PC800-6

PC1800-6


Engine speed rpm 825 1,000 1,200 1,500 1,800

LoadN

{kg}

0

{0}

588

{60}

1,275

{130}

2,060

{210}

2,550

{260}

Flywheel

horsepower

kW

{HP}

0

{0}

44

{60}

115

{156}

232

{315}

344

{463}






Engine

model

Applicable

machineItem

Order

1 2 3 4 5 6

SDA6D140E-2D275A-5

(–50°C spec.)


Engine speed rpm 700 1,000 1,200 1,500 2,000

LoadN

{kg}

0

{0}

441

{45}

1,110

{113}

1,770

{180}

2,220

{226}

Flywheel

horsepower

kW

{HP}

0

{0}

33

{45}

100

{136}

199

{270}

332

{452}




Performance test criteria

a The table gives the standard values using the JIS compensator factor.

a The values in the table are the standard values for machines with the muffler installed, air cleaner installed,

alternator under no load, and air compressor open (if installed).

aThe loads for the dynamometer are at an arm's length of 716 mm.


machineTest item Specified value

Engine speed

(rpm)

Dynamometer load

(N {kg})

S6D140-2

GD825A-2

Flywheel

horsepower

209.0 kW/2,100 rpm

{280.0 HP/2,100 rpm}2,095 – 2,105

1,360 – 1,440

{139 – 147}

Maximum

torque

1,255 Nm/1,400 rpm

{128 kgm/1,400 rpm}1,300 – 1,500

1,730 – 1,840

{177 – 187}

High idling

speed2,300 – 2,400 rpm 2,300 – 2,400 —

Low idling

speed600 – 650 rpm 600 – 650 —

WA500-3

Flywheelhorsepower

235.5 kW/2,100 rpm{315.5 HP/2,100 rpm}

2,095 – 2,105 1,520 – 1,610{155 – 164}

Maximum

torque

1,373 Nm/1,400 rpm

{140 kgm/1,400 rpm}1,350 – 1,450

1,890 – 2,010

{193 – 205}

High idling

speed2,300 – 2,400 rpm 2,300 – 2,400 —

Low idling

speed700 – 750 rpm 700 – 750 —

Flywheel

horsepower

Maximum

torque

High idlingspeed

Low idling

speed

Flywheel

horsepower

Maximum

torque

High idling

speed

Low idling

speed

Flywheelhorsepower

Maximum

torque

High idling

speed

Low idling

speed

Flywheel

horsepower

Maximum

torque

High idlingspeed

Low idling




a For fuel, use ASTM D975 No. 1 or No. 2.

aFor lubricant, use SAE15W-40 or SAE30 oil.

Flywheel

horsepower

(kW{HP})

Torque

(Nm{kgm})

Fuel

consumption

(sec/200cc)

Coolant

temperature

(°C)

Lubrication oil

temperature

(°C)

Lubrication

oil pressure

(kPa {kg/cm2})

Exhaust

temperature

(°C)

214.5 – 227.1

{287.4 – 304.2}— Min. 17.3 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}

Max. 650

Max. 650

1,242 – 1,316

{126.6 – 134.2}70 – 90 90 – 110 —

— 70 – 90 90 – 110 — —

— 70 – 90 Min. 80 Min. 120 {1.2} —

238.9 – 253.6{320.1 – 339.8}

— Min. 15.7 70 – 90 90 – 110 340 – 490{3.5 – 5.0}

Max. 650

1,352 – 1,439

{137.9 – 146.7}70 – 90 90 – 110 — Max. 650

— 70 – 90 90 – 110 — —

— 70 – 90 Min. 80 Min. 118 {1.2} —









machine Test item Specified value Engine speed (rpm)Dynamometer load

(N {kg})

SA6D140-2

D155A-3

D155AX-3

Flywheel

horsepower

225.2 kW/1,900 rpm

{301.7 HP/1,900 rpm}1,895 – 1,905

1,671 – 1,773

{170.4 – 180.8}

Maximum

torque

1,432 Nm/1,300 rpm

{146 kgm/1,300 rpm}1,250 – 1,350

2,002 – 2,124

{204.1 – 216.6}

High idling

speed2,050 – 2,150 rpm 2,050 – 2,150 —

Low idling

speed700 – 725 rpm 700 – 725 —

PC1600SP-1

Flywheel

horsepower

316.5 kW/1,800 rpm

{424.0 HP/1,800 rpm}1,795 – 1,805

2,378 – 2,525

{242.5 – 257.5}

Maximumtorque

1,863 Nm/1,400 rpm{190 kgm/1,400 rpm}

1,300 – 1,500 2,606 – 2,764{265.7 – 281.8}

High idling

speed1,930 – 2,030 rpm 1,930 – 2,030 —

Low idling

speed725 – 775 rpm 725 – 775 —

DCA400SSK-2

(DENYO

generator)

Flywheel

horsepower

309.9 kW/1,500 rpm (50Hz)

{415.1 HP/1,500 rpm} (50Hz)1,495 – 1,505 (50Hz)

2,714 – 2,883 (50Hz)

{276.7 – 294.0} (50Hz)

357.0 kW/1,800 rpm (60Hz)

{478.2 HP/1,800 rpm} (60Hz)1,795 – 1,805 (60Hz)

2,621 – 2,783 (60Hz)

{267.3 – 283.8} (60Hz)

Maximum

torque— —

High idlingspeed Max. 1,568 rpm (50Hz)Max. 1,881 rpm (60Hz) Max. 1,568 (50Hz)Max. 1,881 (60Hz) —

Low idling

speed800 – 850 rpm 800 – 850 —

D155A-2

Flywheel

horsepower

253 kW/2,000 rpm

{339 HP/2,000 rpm}1,995 – 2,005

1,730 – 1,820

{176 – 186}

Maximum

torque

1,608 Nm/1,400 rpm

{164 kgm/1,400 rpm}1,300 – 1,500

2,230 – 2,350

{227 – 240}

High idling

speed2,200 – 2,280 rpm 2,200 – 2,280 —

Low idling

speed550 – 650 rpm 550 – 650 —

D355C-3

Flywheel

horsepower

265 kW/2,000 rpm

{355 HP/2,000 rpm} 1,995 – 2,0051,790 – 1,900

{183 – 194}

Maximum

torque

1,570 Nm/1,400 rpm

{160 kgm/1,400 rpm}1,300 – 1,500

2,180 – 2,300

{222 – 235}

High idling

speed2,200 – 2,280 rpm 2,200 – 2,280 —

Low idling

speed700 – 750 rpm 700 – 750 —

DCA-400SSK

(MQ generator)

Flywheel

horsepower 357 kW/1,800 rpm (60 Hz)

{478 HP/1,800 rpm} (60 Hz)1,795 – 1,805 (60 Hz)

2,620 – 2,780 (60 Hz)

{267 – 284} (60 Hz)

Maximum

torque— — —

High idling

speed Max. 1,890 rpm (60 Hz) Max. 1,890 (60 Hz) —

Low idling800 – 850 rpm 800 – 850 —





a For lubricant, use SAE15W-40 or SAE30 oil.

Flywheel

horsepower(kW{HP})

Torque

(Nm{kgm})

Fuel

consumption(sec/200cc)

Coolant

temperature(°C)

Lubrication oil

temperature(°C)

Lubrication

oil pressure(kPa {kg/cm2})

Exhaust

temperature(°C)

238.2 – 252.9

{319.1 – 338.8}Min. 16.8 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

1,433 – 1,521

{146.1 – 155.1}70 – 90 90 – 110 — Max. 650

— 70 – 90 90 – 110 — —

— 70 – 90 Min. 80 Min. 118 {1.2} —

321.3 – 341.1

{430.4 – 457.0}— Min. 12.3 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

1,865 – 1,979{190.2 – 201.8}

— 70 – 90 90 – 110 — Max. 650

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 Min. 80 Min. 120 {1.2} —

305.4 – 324.6 (50Hz)

{409.2 – 434.8} (50Hz)

Min. 13.0 (50Hz)

Min. 10.6 (60 Hz)70 – 90 90 – 110

290 – 490 (50Hz)

{3.0 – 5.0} (50Hz)Max. 650

354.0 – 376.1 (60Hz)

{474.3 – 503.8} (60Hz)70 – 90 90 – 110

290 – 490 (60Hz)

{3.0 – 5.0} (60Hz)Max. 650

— — —

— — 70 – 90 90 – 110 —

— — 70 – 90 Min. 80 Min. 180 {1.8} —

258 – 274

{346 – 368}— — 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

—1,590 – 1,690

{162 – 172}— 70 – 90 90 – 110 — Max. 680

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 80 – 110 Min. 120 {1.2} —

269 – 285{361 – 382} — — 70 – 90 90 – 110 340 – 490{3.5 – 5.0} Max. 650

—1,560 – 1,650

{159 – 168}— 70 – 90 90 – 110 — Max. 680

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 80 – 110 Min. 120 {1.2} —

354 – 376 (60 Hz)

{474 – 504} (60 Hz)— Min. 10.6 (60 Hz) 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

— — — — — — —

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 90 – 110 Min 180 {1 8} —










(N {kg})

SA6D140-2

J6D140E-G1-2

(TAIYO DENKI

generator)

Flywheel

horsepower 271 kW/1,500 rpm (Net, 50Hz)

374 HP/1,500 rpm (Net, 50Hz)1,495 – 1,505 (50 Hz)

2,430 – 2,580

{248 – 263}

299 kW/1,800 rpm (Net, 60Hz)

412 HP/1,800 rpm (Net, 60Hz)1,795 – 1,805 (60 Hz)

2,290 – 2,420

{233 – 247}

High idling

speed

Max. 1,575 rpm (50 Hz)

Max. 1,890 rpm (60 Hz)

Max. 1,575 (50 Hz)

Max. 1,890 (60 Hz)—

Low idling

speed700 – 725 rpm 700 – 900 —

D155AX-5

Flywheel

horsepower

232 kW/1,900 rpm (Net)

{320 HP/1,900 rpm} (Net)1,895 – 1,905

1,730 – 1,820

{176 – 186}

Maximumtorque

1,610 Nm/1,250 rpm (Net){164 kgm/ 1,250 rpm} (Net)

1,150 – 1,350 2,250 – 2,380{229 – 243}

High idling

speed2,050 – 2,150 rpm 2,050 – 2,150 —

Low idling

speed675 – 725 rpm 675 – 725 —

D155C-1

(–30°C spec.)

Flywheel

horsepower

225 kW/2,000 rpm (Gross)

{342 HP/2,000 rpm} (Gross)1,995 – 2,005

1,650 – 1,750

{168.5 – 178.5}

Maximum

torque

1,490 Nm/1,400 rpm (Gross)

{152 kgm/1,400 rpm} (Gross)1,300 – 1,500

2,020 – 2,150

{206 – 219}

High idling

speed2,190 – 2,290 rpm 2,190 – 2,290 —

Low idlingspeed 700 – 750 rpm 700 – 750 —

D155C-1

(–50°C spec.)

Flywheel

horsepower

225 kW/2,000 rpm (Gross)

{342 HP/2,000 rpm} (Gross)1,995 – 2,005

1,650 – 1,750

{168.5 – 178.5}

Maximum

torque

1,490 Nm/1,400 rpm (Gross)

{152 kgm/1,400 rpm} (Gross)1,300 – 1,500

2,020 – 2,150

{206 – 219}

High idling

speed2,190 – 2,290 rpm 2,190 – 2,290 —

Low idling

speed700 – 750 rpm 700 – 750 —

D355C-3

(–30°C spec.)

Flywheel

horsepower

265 kW/2,000 rpm (Net)

{355 HP/2,000 rpm} (Net)1,995 – 2,005

1,790 – 1,900

{183 – 194}

Maximum

torque

1,570 Nm/1,400 rpm (Net)

{160 kgm/1,400 rpm} (Net) 1,300 – 1,5002,180 – 2,300

{222 – 235}

High idling

speed2,200 – 2,280 rpm 2,200 – 2,280 —

Low idling

speed700 – 750 rpm 700 – 750 —

D355C-3

(–50°C spec.)

Flywheel

horsepower

265 kW/2,000 rpm (Net)

{355 HP/2,000 rpm} (Net)1,995 – 2,005

1,790 – 1,900

{183 – 194}

Maximum

torque

1,570 Nm/1,400 rpm (Net)

{160 kgm/1,400 rpm} (Net)1,300 – 1,500

2,180 – 2,300

{222 – 235}

High idling

speed2,200 – 2,280 rpm 2,200 – 2,280 —

Low idling

speed 700 – 750 rpm 700 – 750 —






Flywheel

horsepower(kW{HP})

Torque

(Nm{kgm})

Fuel


Coolant

temperature(°C)

Lubrication oil

temperature(°C)

Lubrication


Exhaust

temperature(°C)

273.6 – 289.8 (Gross, 50 Hz)

{337.3 – 399.6} (Gross, 50 Hz)— Min. (50 Hz) 70 – 90 90 – 110

290 – 490

{3.0 – 5.0}Max. 650

308.9 – 326.6 (Gross, 60 Hz)

{425.9 – 450.4} (Gross, 60 Hz)— Min. (60 Hz) 70 – 90 90 – 110

290 – 490

{3.0 – 5.0}Max. 650

— — 70 – 90 90 – 110 — —

— — 70 – 90 80 – 110 Min. 120 {1.2} —

245 – 260 (Gross)

{328 – 348} (Gross)— — 70 – 90 90 – 110

343 – 490

{3.5 – 5.0}Max. 650

— 1,608 – 1,706 (Gross){164 – 174} (Gross)

— 70 – 90 90 – 110 — Max. 650

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 80 – 110 Min. 120 {1.2} —

248 – 262 (Gross)

{332 – 352} (Gross)— — 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

—1,447 – 1,535 (Gross)

{147.5 – 156.5} (Gross)— 70 – 90 90 – 110 — Max. 650

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 80 – 110 Min. 180 {1.8} —

248 – 262 (Gross)

{332 – 352} (Gross)— — 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

—1,447 – 1,535 (Gross)

{147.5 – 156.5} (Gross)— 70 – 90 90 – 110 — Max. 650

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 80 – 110 Min. 180 {1.8} —

269 – 285 (Gross)

{361 – 382} (Gross)— — 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

— 1,560 – 1,650 (Gross){159 – 168} (Gross) — 70 – 90 90 – 110 — Max. 680

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 80 – 110 Min. 120 {1.2} —

269 – 285 (Gross)

{361 – 382} (Gross)— — 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

—1,560 – 1,650 (Gross)

{159 – 168} (Gross)— 70 – 90 90 – 110 — Max. 680

— — — 70 – 90 90 – 110 — —

— — — 70 – 90 80 – 110 Min. 120 {1.2} —










(N {kg})

SAA6D140-2

HD325-6

HD405-6

Flywheel

horsepower

379.0 kW/2,000 rpm

{507.8 HP/2,000 rpm}1,995 – 2,005

2,398 – 2,545

{244.5 – 259.5}

Maximum

torque

2,167 Nm/1,350 rpm

{214 kgm/1,350 rpm}1,300 – 1,500

2,902 – 3,083

{296.0 – 314.4}

High idling

speed2,300 – 2,450 rpm 2,300 – 2,400 —

Low idling

speed675 – 775 rpm 675 – 775 —

HD325-6

(High altitude

spec.)

Flywheel

horsepower

306.9 kW/2,000 rpm

{411.2 HP/2,000 rpm}1,995 – 2,005

1,930 – 2,053

{196.8 – 209.3}

Maximumtorque

1,755 Nm/1,400 rpm{179 kgm/1,400 rpm}

1,300 – 1,500 2,351 – 2,487{239.7 – 253.6}

High idling

speed2,350 – 2,450 rpm 2,350 – 2,450 2,350 – 2,450

Low idling

speed675 – 775 rpm 675 – 775 675 – 775

PC750-6

PC800-6

PC1800-6

Flywheel

horsepower

331.2 kW/1,800 rpm

{443.7 HP/1,800 rpm}1,795 – 1,805

2,378 – 2,525

{242.5 – 257.5}

Maximum

torque

2,099 Nm/1,350 rpm

{214 kgm/1,350 rpm}1,250 – 1,450

1,508 – 1,601

{153.8 – 163.3}

High idling

speed1,930 – 2,030 rpm —

Low idlingspeed 800 – 850 rpm —

SDA6D140E-2

D275A-5

(–50°C spec.)

Flywheel

horsepower

332 kW/2,000 rpm

{446 HP/2,000 rpm}1,995 – 2,005

2,177 – 2,305

{222 – 235}

Maximum

torque

2,030 Nm/1,400 rpm

{207 kgm/1,400 rpm}1,300 – 1,500 Min. 2,834 {289}

High idling

speed 2,150 – 2,250 rpm 2,150 – 2,250 —

Low idling

speed650 – 750 rpm 650 – 750 —

Flywheel

horsepower

Maximum

torque

High idling

speed

Low idling

speed

Flywheel

horsepower

Maximum

torque

High idling

speed

Low idling

speed






Flywheel

horsepower(kW{HP})

Torque

(Nm{kgm})

Fuel


Coolant

temperature(°C)

Lubrication oil

temperature(°C)

Lubrication


Exhaust

temperature(°C)

359.9 – 381.7

{482.2 – 511.7}Min. 11.2 70 – 95 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

2,079 – 2,208

{212.0 – 225.2}— 70 – 95 90 – 110 — —

— — 70 – 80 90 – 110 — —

— — 70 – 80 Min. 80 Min. 118 {1.2} —

289.6 – 308.0

{388.0 – 412.6}— Min. 13.5 70 – 85 90 – 110

343 – 490

{3.5 – 5.0}650

1,683 – 1,781{171.6 – 181.6}

70 – 85 90 – 110 — 700

— 70 – 85 90 – 110 — —

— 70 – 85 90 – 110 Min. 147 {1.5} —

321.3 – 341.1

{430.4 – 457.0}— Min. 12.3 70 – 95 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

—2,036 – 2,161

{207.6 – 220.4}70 – 95 90 – 110 — —

— — 70 – 90 90 – 110 — —

— — 70 – 90 80 – 110 Min. 118 {1.2} —

325 – 345

{436 – 463}— Min. 11.8 70 – 90 90 – 110

340 – 490

{3.5 – 5.0}Max. 650

Min. 2,030 {207} — 70 – 90 90 – 110340 – 490

{3.5 – 5.0}—

— — 70 – 90 90 – 110340 – 490

{3.5 – 5.0}—

— — 70 – 90 80 – 110 Min. 118 {1.2} —



Points to remember when troubleshooting.................................................................................................. 12- 43

Method of using troubleshooting charts ......................................................................................................12- 44

S-1 Starting performance is poor (starting always takes time) ................................................................ 12- 48

S-2 Engine does not start ........................................................................................................................ 12- 49

S-3 Engine does not pick up smoothly (follow-up is poor).......................................................................12- 52

S-4 Engine stops during operations ........................................................................................................ 12- 53

S-5 Engine does not rotate smoothly (hunting) ....................................................................................... 12- 54

S-6 Engine lacks output (no power) ........................................................................................................ 12- 55

S-7 Exhaust smoke is black (incomplete combustion) ............................................................................12- 56

S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................................. 12- 57

S-9 Oil becomes contaminated quickly ................................................................................................... 12- 58

S-10 Fuel consumption is excessive ......................................................................................................... 12- 59

S-11 Oil is in cooling water, or water spurts back, or water level goes down............................................ 12- 60

S-12 Oil pressure caution lamp lights up (drop in oil pressure)................................................................. 12- 61

S-13 Oil level rises (water, fuel in oil) ........................................................................................................12- 62

S-14 Water temperature becomes too high (overheating) ........................................................................12- 63

S-15 Abnormal noise is made .................................................................................................................... 12- 64

S-16 Vibration is excessive ....................................................................................................................... 12- 65

Testing and adjusting tool list ...................................................................................................................... 12- 67

Testing and adjusting data .......................................................................................................................... 12- 68

Troubleshooting



Troubleshooting

k 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.

k When carrying out operations with two or more workers, always use signals, and do not allow any

unauthorized person near the machine.

k 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.

k Be extremely careful not to touch any hot parts.

k Be extremely careful not to get caught in the fan or any other rotating parts.

k When removing the plugs or caps from places under hydraulic pressure, water pressure, or air pressure,

release the internal pressure first. Fit the measuring tools securely before carrying out any testing, adjusting,

or troubleshooting.

a 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 estimating wear during operation or as target values when carrying out repairs.

2. The failure judgement standard values in the standard values 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 reference 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.



Troubleshooting Points to remember when 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 men-tioned by the operator as a guide in locating the cause.

1. Do not disassemble the machine simply

because there is a failure

If the machine is disassembled immediately just

because there is a failure:

• Unrelated or unnecessary places are also

disassembled

• It becomes difficult to locate the cause of the

failure

This means that there is not only a waste of time

and money on replacement parts, oil, and

grease, but this action will also lose the confi-dence of the user and operator.

For this reason also, it is important to carry out

troubleshooting based on full investigation

before starting and troubleshooting following

before the correct order.

2. Questions to ask the user and operator

1) Are there any problems other than those

already reported?

2) Did anything unusual happen before the

failure occurred?

3) Did the failure occur suddenly, or had thecondition of the machine been poor before

the failure occurred?

4) What were the conditions when the failure

occurred?

5) Had any repairs been carried out before the

failure occurred?

6) Had any similar failure occurred before?

3. Check 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.

4. Confirming failure

Check the degree of the problem to judge for

yourself if it is really a failure, or if there is some

problem in the handling or operation of the

machine.

a When driving the machine and re-enacting

the failure, be sure that the investigation or

measurement does not make the failure

worse.

5. TroubleshootingNarrow down the cause of the failure from the

results of the questions and checks in the above

Items 2 – 4, then follow the troubleshooting flow

charts to locate the failure.

a Basic procedure for troubleshooting

1) Start from the simple places.

2) Start from the most probable places.

3) Investigate related parts also.

6. Basic action to remedy cause of failure

Even if the failure is repaired, if the root cause of

the failure is not repaired, the same failure willoccur again.

To prevent this, it is necessary to investigate

why the failure occurred, and to remove the root

cause of the failure.



Troubleshooting Method of using troubleshooting charts

Method of using troubleshooting charts

This troubleshooting chart is divided into three sec-

tions: questions, check items, and troubleshoot-

ing. The questions and check items are used to

pinpoint high probability causes that can be locatedfrom the failure symptoms or simple inspeciton with-

out using troubleshooting tools.

Next, troubleshooting tools or direct inspection are

used to check the high probability causes to make

final confirmation.

[Questions]

Sections [A] + [B] in the chart on the right corre-

sponds to the items where answers can be obtained

from the user. The items in [B] are items that can be

obtained from the user, depending on the user's

level.

[Check items]The serviceman carries out simple inspection to nar-

row down the causes. The items under [C] in the

chart on the right correspond to this.

The serviceman narrows down the causes from

information [A] that he has obtained from the user

and the results of [C] that he has obtained from his

own inspection.

[Troubleshooting]

Troubleshooting is carried out in the order of proba-

bility, starting with the causes that have been

marked as having the highest probability from infor-

mation gained from [Questions] and [Checkitems].

Causes

Q u e s t i o

n s

C h e c k i t e m s

T r o u b l e -

s h o o t i n g

(1) (2)

[A]

[B]

[C]

(3)

(a)

(b)

(c)

(d)

(e)

i

ii

iii




S e i z e d

t u r b o c h a r g e r , i n t e r f e r e n c e

C l o g g e d

a i r c l e a n e r e l e m e n t

W o r n

p i s t o n r i n g ,

c y l i n d e r

C l o g g e d ,

s e i z e d f u e l i n j e c t i o n

n o z z l e

I m p r o p e r f u e l i n j e c t i o n

t i m i n g

D e f e c t i v e

f u e l i n j e c t i o n p u m

p ( e x c e s s i v e

f u e l i n j e

c t i o n )

Causes

Confirm recent repair history

Degree of use Operated for long period

*1

*2

e as c met o o us ng t e trou es oot ng c art

is as follows.

Items listed for [Questions] and [Check items] that

have a relationship with the Cause items are marked

with Q, and of these, causes that have a high proba-

bility are marked with w.Check each of the [Questions] and [Check items]

in turn, and marked the Q or w 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 confirmation of the cause.

*1. For [Confirm recent repair history] in

the [Questions] Section, ask the user,

and mark the Cause column with E to

use as reference for locating the cause

of the failure. However, do not use this

when making calculations to narrowdown the causes.

*2. Use the E in the Cause column as ref-

erence 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

locat ing the cause, but i t can be

included if necessary to determine the

order for 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

weaker], 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)

General causes why exhaust gas is black

• Insufficient intake of air

• Improper condition of fuel injection

• Excessive injection of fuel



Troubleshooting S-1

S-1 Starting performance is poor (starting always takes time)

a Check that the monitor panel does not display any abnormality in the

governor control system.

General causes why exhaust smoke comes out but engine takes time to start

• Defective electrical system• Insufficient supply of fuel


• Improper selection of fuel

(At ambient temperature of 10°C or below, use ASTM D975 No. 1)

a Battery charging rate

• The specific gravity should exceed the value for the

charging rate of 70% in the above table.

• In cold areas the specific gravity must exceed the value

for the charging rate of 75% in the above table.

Charging rate

Ambient

temperature

100 % 90 % 80 % 75 % 70 %

20°C 1.28 1.26 1.24 1.23 1.22

0°C 1.29 1.27 1.25 1.24 1.23

–10°C 1.30 1.28 1.26 1.25 1.24



Troubleshooting S-2

S-2 Engine does not start

ng ne oes not turn

General causes why engine does not turn

• Internal parts of engine seized

a If internal parts of the engine are seized,

carry out troubleshooting for "Engine stops

during operations".

• Failure in power train

• Defective electrical system



Troubleshooting S-2

(2) Engine turns but no exhaust smoke comes

out (fuel is not being injected)

enera causes w y eng ne turns ut no ex aust

smoke comes out

• Supply of fuel impossible

• Supply of fuel is extremely small• Improper selection of fuel (particularly in winter)

a Standards for use of fuel



Troubleshooting S-2

(3) Exhaust smoke comes out but engine does

not start

(Fuel is being injected)

a General causes why exhaust smoke comes out

but engine does not start

• Lack of rotating force due to defective electricalsystem

• Insufficient supply of fuel


• Improper selection of fuel and oil



Troubleshooting S-3

S-3 Engine does not pick up smoothly (follow-up is poor)

a ec t at t e mon tor pane oes not sp ay

any abnormality in the governor control system.

General causes why engine does not pick up

smoothly




• Improper fuel used



Troubleshooting S-4

S-4 Engine stops during operations

enera causes w y eng ne stops ur ng operat ons

• Seized parts inside engine


• Overheating

a If there is overheating and insufficient out-

put, carry out troubleshooting for overheat-

ing.

• Failure in power train

a If the engine stops because of a failure in

the power train, carry out troubleshooting for

the chassis.



Troubleshooting S-5

S-5 Engine does not rotate smoothly (hunting)

enera causes w y eng ne oes not rotate

smoothly

• Air in fuel system

• Defective governor mechanism

• Defective electric governor mechanism

a If hunting does not occur when the rod

between the governor motor and the injec-

tion pump is disconnected, troubleshoot by

using the electrical system troubleshooting

(E mode).



Troubleshooting S-6

S-6 Engine lacks output (no power)

enera causes w y eng ne ac s output




• Improper fuel used

(if non-specified fuel is used, output drops)

• Lack of output due to overheating

a If there is overheating and insufficient out-

put, carry out troubleshooting for overheat-

ing.



Troubleshooting S-7

S-7 Exhaust smoke is black (incomplete combustion)

enera causes w y ex aust smo e s ac






Troubleshooting S-8

S-8 Oil consumption is excessive (or exhaust smoke is blue)

a 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



Troubleshooting S-9

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 fuel

• Improper oil used

• Operation under excessive load



Troubleshooting S-10

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive

• Leakage of fuel






S-11 Oil is in cooling water, or water spurts back, or water level goes down

enera causes w y o s n coo ng water

• Internal leakage in lubrication system

• Internal leakage in cooling system




S-12 Oil pressure caution 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)

• Deterioration of oil due to overheating

a Standards for engine oil selection




S-13 Oil level rises (water, fuel in oil)

a 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

• Fuel in oil (diluted, and smells of diesel fuel)

• Entry of oil from other component




S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes

too high

• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency

• Defective cooling circulation system

• Power train oil temperature rises excessively

a Carry out troubleshooting for chassis.




S-15 Abnormal noise is made

a 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

• Air sucked in from intake system




S-16 Vibration is excessive

a 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



Troubleshooting Testing and adjusting tool list

Testing and adjusting tool list

No. Testing and measuring item Part No. Fault finding tool Remarks

1 Engine speed 799-203-8000 Multi-tachometer Digital reading: L: 60 – 2,000 rpm

H: 60 – 20,000 rpm

2 Battery S.G.

795-500-1001 Battery coolant tester

1.100 – 1.300

3Freezing temperature of

cooling water –5 – –50ºC

4

Water temperature,

oil temperature,

air intake temperature,

exhaust temperature

799-101-6000Digital temperature

gauge – 50 – 1,200°C

790-500-1300Thermistor temperature

gauge

0 – 200°C

0 – 1,000ºC

5 Lubrication oil pressure

799-203-2002Engine pressure

measuring kit

0 – 1 MPa {0 – 10 kg/cm2}

6 Fuel pressure 0 – 2 MPa {0 – 20 kg/cm2}

7Intake pressure,

exhaust pressure0 – 200 MPa {0 – 1,500 mmHg}

8 Blow-by pressure 0 – 9.8 kPa {0 – 1,000 mmH2O}

9 Intake resistance –9.8 – 0 kPa {–1,000 – 0 mmH2O}

10 Compression pressure

795-502-1205 Compression gauge 0 – 0.69 MPa {0 – 70 kg/cm2}

• 795-502-1510 • Adapter

11 Blow-by pressure 799-201-1504 Blow-by checker 0 – 4.9 kPa {0 – 500 mmH2O}

12 Valve clearance 795-125-1210 Feeler gauge 0.43, 0.80 mm

13 Exhaust gas color 799-201-9000 Handy smoke checker Dirtiness 0 – 70% with standard color

(Dirtiness % × 1/10 Bosch scale)

14 Water and fuel content in oil 799-201-6000 Engine oil checker Provided with 0.1 and 0.2 water content

standard sample

15 Fuel injection pressureCommercially

availableNozzle tester 0 – 29.4 MPa {0 – 300 kg/cm2}

16Fuel injection nozzle spray

condition

17 Coolant quality 799-202-7001 Water quality tester PH, nitrite ion concentration

18 Pressure valve function

799-202-9001 Radiator cap tester 0 – 0.2 MPa {0 – 2 kg/cm2}

19 Leakage in cooling system

20 Electrical circuitCommercially

availableTester Current, Voltage, Resistance

21Diagnosis of engine controller

t799-606-9100 Governor checker



Troubleshooting Testing and adjusting data

Testing and adjusting data

a This STANDARD VALUE TABLE does not give the standard value for adjusting the engine output.

Do not use the values in this table to change the setting for fuel injection pump.

Engine model S6D140-2

Applicable machine model GD825A-2 WA500-3

Cate-

goryItem Measurement conditions Unit

Standard

value

Permissible

value

Standard

value

Permissible

value


Engine speedHigh idling speed rpm 2,300 – 2,400 2,300 – 2,400 2,300 – 2,400 2,300 – 2,400

Low idling speed rpm 650 – 700 650 – 700 700 – 750 700 – 750

Necessary starting speed0ºC (without starting aid) rpm Min. 110 — Min. 110 —

–20ºC (with starting aid) rpm Min. 85 — Min. 85 —

I n t a k e , e x h a u s t s y s t e m

Intake resistance At all speedkPa

{mmH2O}

Max. 2.94

{Max. 300}

7.50

{762}

Max. 2.94

{Max. 300}

7.50

{762}

Boost pressure At rated flywheel horsepower kPa

{mmHg}

Min.70.6

{Min. 530}

56.0

{420}

Min. 85.4

{Min. 640}

68.0

{510}

Exhaust pressure

(Turbine inlet press.) At rated flywheel horsepower

kPa

{mmHg}

Min. 61.3

{Min. 460}

49.3

{370}

Min. 72.0

{Min. 540}

57.3

{430}

Exhaust temperature

(Turbine inlet temp.) All speed (20ºC) ºC 700 700 650 700

Exhaust gas color

Quick acceleration

(Low idle o high idle)Bosch

index

Max. 6.0 8.0 Max. 6.0 8.0

At rated flywheel horsepower Max. 1.5 2.5 Max. 1.0 2.5

High idling speed Max. 1.0 2.0 Max. 1.0 2.0

Valve clearance

(When engine is hot or cold)

Intake valve mm 0.43 — 0.43 —

Exhaust valve mm 0.80 — 0.80 —

E n g i n e

p r o p e r

Compression pressure(SAE30 or SAE 15W-40)

Oil temperature: 40 – 60ºC(Engine speed: 200 – 250 rpm)

MPa{kg/cm2}

Min. 3.82{Min. 39}

2.65{27}

Min. 3.82{Min. 39}

2.65{27}

Blow-by pressure

(SAE30 or SAE 15W-40)

At rated flywheel horsepower

(Water temp: Min. 70ºC)

kPa

{mmH2O}

Max. 0.98

{Max. 100}

1.96

{200}

Max. 1.47

{Max. 150}

2.94

{300}

L u b r i c a t i o n s y s t e m Oil pressure

(Oil temperature:

Min. 80ºC)


SAE30 or SAE15W-40 oil

kPa

{kg/cm2}

340 – 490

{3.5 – 5.0}

206

{2.1}

340 – 490

{3.5 – 5.0}

206

{2.1}

SAE 10W oilkPa

{kg/cm2}

290 – 441

{3.0 – 4.5}

177

{1.8}

290 – 441

{3.0 – 4.5}

177

{1.8}

At low idling


kPa

{kg/cm2}

Min. 118

{Min. 1.2}

69

{0.7}

Min. 118

{Min. 1.2}

69

{0.7}

SAE 10W oilkPa

{kg/cm2}

Min. 98

{Min. 1.0}

69

{0.7}

Min. 98

{Min. 1.0}

69

{0.7}

Oil temperature All speed (Oil in oil pan) ºC 90 – 110 120 90 – 110 120

Oil consumption ratio At continuous rated horsepower

(Ratio to fuel consumption)% Max. 0.5 1.0 Max. 0.5 1.0

F u e l Fuel injection pressure Nozzle tester

MPa

{kg/cm2}

25.0 – 25.8

{255 – 263}

20.2

{206}

25.0 – 25.8

{255 – 263}

20.2

{206}

Fuel injection timing B.T.D.C. degree 15 – 17 15 – 17 15 – 17 15 – 17

C o o l i n g

Radiator pressure valveOpening pressure

(Differential pressure)

MPa

{kg/cm2}— — — —

Fan speed At rated engine speed rpm 1,640 – 1,720 1,640 – 1,720 1,106 – 1,174 1,106 – 1,174

Fan belt tensionDeflects when pushed with a

force of 59 N {6 kg}mm 8 – 12 8 – 12

13 – 15 *1

17 – 19 *2

13 – 15 *1

17 – 19 *2




S6D140-2

Standard

value

Permissible

value

Standard

value

Permissible

value

Standard

value

Permissible

value

Standard

value

Permissible

value





Do not use the values in this table to change the setting for fuel injection pump


Applicable machine model D155A-2 D155A-3, D155AX-3

Cate-gory

Item Measurement conditions Unit Standardvalue

Permissiblevalue

Standardvalue

Permissiblevalue






I n t a k e , e x h a u s t s y s t e m


{mmH2O}

Max. 2.94

{Max. 300}

7.50

{762}

Max. 2.94

{Max. 300}

7.50

{762}


{mmHg}

Max. 85.4

{Min. 640}

68.0

{510}

Exhaust pressure(Turbine inlet press.) At rated flywheel horsepower kPa{mmHg} Min. 74.7{Min. 560} 60.0{450}

Exhaust temperature

(Turbine inlet temp.) All speed (20ºC) ºC Max. 650 700 Max. 680 700

Exhaust gas color

Quick acceleration


index

Max.6.0 8.0 Max. 6.0 8.0



Valve clearance




E n g i n

e

p r o p e

rCompression pressure


Oil temperature: 40 – 60ºC

(Engine speed: 200 – 250 rpm)

MPa

{kg/cm

2

}

Min. 3.80

{Min. 39}

2.65

{27}

Min. 3.82

{Min. 39}

2.65

{27}Blow-by pressure




kPa

{mmH2O}

Max. 0.98

{Max. 100}

1.96

{200}

Max. 0.98

{Max. 100}

1.96

{200}


(Oil temperature:

Min. 80ºC)



kPa

{kg/cm2}

340 – 490

{3.5 – 5.0}

205

{2.1}

340 – 490

{3.5 – 5.0}

206

{2.1}

SAE 10W oilkPa

{kg/cm2}

290 – 440

{3.0 – 4.5}

176

{1.8}

290 – 441

{3.0 – 4.5}

177

{1.8}

At low idling


kPa

{kg/cm2}

Min. 118

{Min. 1.2}

78

{0.8}

Min. 118

{Min. 1.2}

69

{0.7}

SAE 10W oilkPa

{kg/cm2}

Min. 98

{Min. 1.0}

68

{0.7}

Min. 98

{Min. 1.0}

69

{0.7}




F u e l

Fuel injection pressure Nozzle tester MPa

{kg/cm2}

25.0 – 25.8

{255 – 263}

20.2

{206}

24.0 – 25.8

{245 – 263}

20.2

{206}

Fuel injection timing B.T.D.C. degree 14.5 – 15.5 — 26 – 28 26 – 28

C o o l i n g



kPa

{kg/cm2}— — — —

Fan speed At rated engine speed rpm 1,165 – 1,235 1,165 – 1,235 1,255 – 1,335 1,255 – 1,335


force of 59 N {6 kg}mm Auto-tensioner — Auto-tensioner Auto-tensioner




SA6D140-2

D155AX-5 D355C-3 PC1600SP-1DCA400SSK-2

(DENYO generator)

Standardvalue

Permissiblevalue

Standard value

Permissiblevalue

Standardvalue

Permissiblevalue

Standardvalue

Permissiblevalue

2,050 – 2,150 2,050 – 2,150 2,200 – 2,280 2,200 – 2,280 1,930 – 2,030 1,930 – 2,030Max. 1,568 50Hz

Max. 1,881 60Hz

Max. 1,568 50Hz

Max. 1,881 60Hz

700 – 725 700 – 725 700 – 750 700 – 750 725 – 775 725 – 775 800 – 850 800 – 850

Min. 110 — Min. 110 — Min. 110 — Min. 110 —

Min. 85 — Min. 85 — Min. 85 — Min. 85 —

Max. 2.94

{Max. 300}

7.47

{762}

Max. 2.94

{Max. 300}

7.47

{762}

Max. 2.94

{Max. 300}

7.50

{762}

Max. 2.94

{Max. 300}

7.50

{762}

Min. 85

{Min. 640}

66.5

{500}

Min. 160

{Min. 1,200}

128

{960}

Min. 117.4

{Min. 880}

93.4

{700}

Min. 160

{Min. 1,200}

128

{960}

Min. 74{Min. 560} 59.9{450} Min. 120{Min. 900} 96.0{720} Min. 102.7{Min.770} 82.7{620} Min. 120{Min. 900} 96.0{720}

Max. 650 700 Max. 650 700 700 700 650 700

Max. 6.0 8.0 Max. 6.0 8.0 Max. 6.0 8.0 — —

Max. 1.0 2.5 Max. 1.0 2.5 Max. 2.0 3.5 1.5 2.5

Max. 1.0 2.0 Max. 1.0 2.0 Max. 2.0 3.0 1.0 2.0

0.43 — 0.43 — 0.43 — 0.43 —

0.80 — 0.80 — 0.80 — 0.80 —

Min. 3.8

{Min. 39}

2.7

{27}

Min. 3.80

{Min. 39}

2.7

{27}

Min. 3.82

{Min. 39}

2.65

{27}

Min. 3.82

{Min. 39}

2.65

{27}Max. 0.98

{Max. 100}

1.96

{200}

Max. 0.98

{Max. 100}

1.96

{200}

Max. 1.96

{Max. 200}

3.92

{400}

Max. 1.96

{Max. 200}

3.92

{400}

340 – 490

{3.5 – 5.0}

210

{2.1}

340 – 490

{3.5 – 5.0}

210

{2.1}

340 – 490

{3.5 – 5.0}

177

{1.8}

275 – 441

{2.8 – 4.5}

192

{2.0}

290 – 440

{3.0 – 4.5}

176

{1.8}

290 – 440

{3.0 – 4.5}

176

{1.8}

290 – 441

{3.0 – 4.5}

137

{1.4}

226 – 392

{2.3 – 4.0}

157

{1.6}

Min. 118

{Min. 1.2}

78

{0.8}

Min. 118

{Min. 1.2}

78

{0.8}

Min. 118

{Min. 1.2}

69

{0.7}

Min. 177

{Min. 1.8}

69

{0.7}

Min. 98

{Min. 1.0}

68

{0.7}

Min. 98

{Min. 1.0}

68

{0.7}

Min. 98

{Min. 1.0}

69

{0.7}

Min. 98

{Min. 1.0}

69

{0.7}

90 – 110 120 90 – 110 120 90 – 110 120 110 120

Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0

24.8 – 25.5

{253 – 260}

20.2

{206}

25.0 – 25.8

{255 – 263}

20.2

{206}

24.8 – 25.5

{253 – 260}

20.2

{206}

25.0 – 25.8

{255 – 263}

20.2

{206}

14 – 16 — 18.5 – 19.5 — 18 – 20 18 – 2014.5 – 15.5 50Hz

16.5 – 17.5 60Hz

14.5 – 15.5 50Hz

16.5 – 17.5 60Hz

— — — — —59 – 78

{0.6 – 0.8}—

1,390 – 1,470 — 970 – 1,030 970 – 1,030 1,025 – 1,085 1,025 – 1,0851,106 – 1,174 50Hz1,327 – 1,409 60Hz

1,106 – 1,174 50Hz1,327 – 1,409 60Hz

Auto-tensioner Auto-tensioner — Auto-tensioner Auto-tensioner 8 – 12 8 – 12





Do not use the values in this table to change the setting for fuel injection pump


Applicable machine modelDCA-400SSK

(MQ generator)

J6D140E-G1-2

(TAIYO DENKI generator)

Cate-gory


Permissiblevalue

Standardvalue

Permissiblevalue


Engine speedHigh idling speed rpm Max. 1,890 60Hz Max. 1,890 60Hz

Max. 1,575 50HzMax. 1,890 60Hz

Max. 1,575 50HzMax. 1,890 60Hz

Low idling speed rpm 800 – 850 700 – 900 700 – 900



I n t a k e , e x h a u s t s y s t e

m


{mmH2O}

Max. 2.94

{Max. 300}

7.47

{762}

Max. 2.94

{Max. 300}

7.47

{762}


{mmHg}— —

Max. 160

{Min. 1,200}

128

{960}

Exhaust pressure

(Turbine inlet press.) At rated flywheel horsepower kPa

{mmHg} — —Min. 120

{Min. 900}

96

{720}

Exhaust temperature


Exhaust gas color

Quick acceleration


index

— — — —



Valve clearance




E n g i n e

p r o p e r

Compression pressure




MPa

{kg/cm2}

Min. 3.80

{Min. 39}

2.7

{27}

Min. 3.82

{Min. 39}

2.7

{27}

Blow-by pressure




kPa

{mmH2O}

Max. 1.96

{Max. 200}

3.92

{400}

Max. 1.96

{Max. 200}

3.92

{400}


(Oil temperature:

Min. 80ºC)



kPa

{kg/cm2}

294 – 490

{3.0 – 5.0}

210

{2.1}

294 – 490

{3.0 – 5.0}

210

{2.1}

SAE 10W oilkPa

{kg/cm2}

245 – 440

{2.5 – 4.5}

176

{1.8}

245 – 440

{2.5 – 4.5}

176

{1.8}

At low idling


kPa

{kg/cm2}

Min. 118

{Min. 1.2}

78

{0.8}

Min. 118

{Min. 1.2}

78

{0.8}

SAE 10W oilkPa

{kg/cm2}

Min. 98

{Min. 1.0}

68

{0.7}

Min. 98

{Min. 1.0}

68

{0.7}




F u e l


{kg/cm2}

25.0 – 25.8

{255 – 263}

20.2

{206}

25.0 – 25.8

{255 – 263}

20.2

{206}

Fuel injection timing B.T.D.C. degree 16.5 – 17.5 —16 – 18 50Hz

17 – 19 60Hz

16 – 18 50Hz

17 – 19 60Hz

C o o l i n g



kPa

{kg/cm2}— —

Fan speed At rated engine speed rpm1,330 – 1,410

(60 Hz)

1,330 – 1,410

(60 Hz)1,220 – 1,300 50Hz1,465 – 1,555 60Hz

1,220 – 1,300 50Hz1,465 – 1,555 60Hz


force of 60 N {6 kg}mm 8 – 12 14 – 18 8 – 12 8 – 12




SA6D140-2

D155C-1 (–30°C spec.) D155C-1 (–50°C spec.) D355C-3 (–30°C spec.) D355C-3 (–50°C spec.)

Standardvalue

Permissiblevalue

Standard value

Permissiblevalue

Standard value

Permissiblevalue

Standard value

Permissiblevalue

2,190 – 2,290 2,190 – 2,290 2,190 – 2,290 2,190 – 2,290 2,200 – 2,280 2,200 – 2,280 2,200 – 2,280 2,200 – 2,280

700 – 750 700 – 750 700 – 750 700 – 750 700 – 750 700 – 750 700 – 750 700 – 750

Min. 110 — Min. 110 — Min. 110 — Min. 110 —

Min. 85 — Min. 85 — Min. 85 — Min. 85 —

Max. 2.94

{Max. 300}

7.47

{762}

Max. 2.94

{Max. 300}

7.47

{762}

Max. 2.94

{Max. 300}

7.47

{762}

Max. 2.94

{Max. 300}

7.47

{762}

Min. 99

{Min. 740}

83

{620}

Min. 99

{Min. 740}

83

{620}

Min. 160

{Min. 1,200}

128

{960}

Min. 160

{Min. 1,200}

128

{960}

Min. 84

{Min. 630}

71

{530}

Min. 84

{Min. 630}

71

{530}

Min. 120

{Min. 900}

96.0

{720}

Min. 120

{Min. 900}

96.0

{720}

Max. 600 700 Max. 600 700 Max. 650 700 Max. 650 700

Max. 6.0 7.0 Max. 6.0 7.0 Max. 6.0 8.0 Max. 6.0 8.0

Max. 1.0 2.5 Max. 1.0 2.5 Max. 1.0 2.5 Max. 1.0 2.5

Max. 1.0 2.0 Max. 1.0 2.0 Max. 1.0 2.0 Max. 1.0 2.0

0.43 — 0.43 — 0.43 — 0.43 —

0.80 — 0.80 — 0.80 — 0.80 —

Min. 3.80

{Min. 39}

2.7

{27}

Min. 3.80

{Min. 39}

2.7

{27}

Min. 3.80

{Min. 39}

2.7

{27}

Min. 3.80

{Min. 39}

2.7

{27}

Max. 0.98

{Max. 100}

1.96

{200}

Max. 0.98

{Max. 100}

1.96

{200}

Max. 0.98

{Max. 100}

1.96

{200}

Max. 0.98

{Max. 100}

1.96

{200}

340 – 490

{3.5 – 5.0}

210

{2.1}

340 – 490

{3.5 – 5.0}

210

{2.1}

340 – 490

{3.5 – 5.0}

210

{2.1}

340 – 490

{3.5 – 5.0}

210

{2.1}

290 – 440

{3.0 – 4.5}

176

{1.8}

290 – 440

{3.0 – 4.5}

176

{1.8}

290 – 440

{3.0 – 4.5}

176

{1.8}

290 – 440

{3.0 – 4.5}

176

{1.8}

Min. 118

{Min. 1.2}

78

{0.8}

Min. 118

{Min. 1.2}

78

{0.8}

Min. 118

{Min. 1.2}

78

{0.8}

Min. 118

{Min. 1.2}

78

{0.8}

Min. 98

{Min. 1.0}

68

{0.7}

Min. 98

{Min. 1.0}

68

{0.7}

Min. 98

{Min. 1.0}

68

{0.7}

Min. 98

{Min. 1.0}

68

{0.7}

80 – 110 120 80 – 110 120 90 – 110 120 90 – 110 120

Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0

24.8 – 25.5

{253 – 260}

20.2

{206}

24.8 – 25.5

{253 – 260}

20.2

{206}

25.0 – 25.8

{255 – 263}

20.2

{206}

25.0 – 25.8

{255 – 263}

20.2

{206}

18 – 20 — 18 – 20 — 18.5 – 19.5 — 18.5 – 19.5 —

— — — — — — — —

— — — — 970 – 1,030 970 – 1,030 970 – 1,030 970 – 1,030

— — — — Auto-tensioner — Auto-tensioner —





Do not use the values in this table to change the setting for fuel injection pump.

*: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)

Engine model SAA6D140-2

Applicable machine model PC750-6, PC800-6 HD325-6, HD405-6

Cate-gory


Permissiblevalue

Standardvalue

Permissiblevalue






I n t a k e , e x h a u s t s y s

t e m


{mmH2O}

Max. 2.94

{Max. 300}

7.47

{762}

Max. 2.9

{Max. 300}

7.47

{762}

Boost pressure At rated outputkPa

{mmHg}

Exhaust pressure

(Turbine inlet press.)

At rated outputkPa

{mmHg}

Exhaust temperature


Exhaust gas color

Quick acceleration


index

Max.6.0 7.0 Max. 6.0 7.0

At rated output Max. 1.0 2.0 Max. 1.0 2.0

High idling Max. 1.0 2.0 Max. 1.0 2.0

Valve clearance




E n g i n e

b o

d y

Compression pressure




MPa

{kg/cm2}

Min. 3.82

{Min. 39}

2.65

{27}

Min. 3.82

{Min. 39}

2.65

{27}

Blow-by pressure


At rated output

(Water temp: 70ºC min.)

kPa

{mmH2O}

Max. 1.96

{Max. 200}

3.92

{400}

Max. 1.96

{Max. 200}

3.92

{400}


(Oil temperature:

80ºC min.)

At rated output


kPa

{kg/cm2}

340 – 490

{3.5 – 5.0}

210

{2.1}

340 – 490

{3.5 – 5.0}

210

{2.1}

SAE 10W oilkPa

{kg/cm2}

290 – 440

{3.0 – 4.5}

180

{1.8}

290 – 440

{3.0 – 4.5}

180

{1.8}

At low idling


kPa

{kg/cm2}

Min. 118

{Min. 1.2}

69

{0.7}

Min. 118

{Min. 1.2}

78

{0.8}

SAE 10W oilkPa

{kg/cm2}

Min. 98

{Min. 1.0}

69

{0.7}

Min. 98

{Min. 1.0}

69

{0.7}


Oil consumption ratio At continuous rated output(Ratio to fuel consumption)

% Max. 0.5 1.0 Max. 0.5 1.0

F u e l

s y s t e m


{kg/cm2}

24.8 – 25.5

{253 – 260}

20.2

{206}

24.8 – 25.5

{253 – 260}

20.2

{206}

Fuel injection timing B.T.D.C. degree 18.5 – 19.5 18.5 – 19.5 19.5 – 20.5 19.5 – 20.5

C o o l i n g

s y s t e m



kPa

{kg/cm2}— — — —

Fan speed At rated engine speed rpm 1,018 – 1,082 1,018 – 1,082


force of 58.8 N {6 kg}mm

(Autotensioner)

——

(Autotensioner)

——




SAA6D140-2 SDA6D140E-2

HD325-6 (High altitude spec.)

Standardvalue

Permissiblevalue

Standard value

Permissiblevalue

Standardvalue

Permissiblevalue

Standardvalue

Permissiblevalue

2,350 – 2,450 2,350 – 2,450 2,150 – 2,250 —

675 – 775 675 – 775 650 – 750 —

Min. 110 — Min. 110 —

Min. 85 — Min. 85 —

Max. 2.94

{Max. 300}

7.50

{762}

Max. 2.94

{Max. 300}

7.50

{762}

Min. 97.4

{Min. 730}

77.3

{580}

Min. 118.6

{Min. 890}

98.6

{740}

Min. 97.4

{Min. 730}

77.3

{580}

Min. 113.3

{Min. 850}

94.7

{710}

Max. 700 700 Max. 650 700

Max. 5.0 7.0 Max. 6.0 7.0

Max. 1.5 2.5 Max. 1.0 2.0

Max. 1.0 2.0 Max. 1.0 2.0

0.43 — 0.43 —

0.80 — 0.80 —

Min. 3.82

{Min. 39}

2.65

{27}

Min. 3.14

{Min. 32}

2.16

{22}

Max. 1.96

{Max. 200}

3.92

{400}

Max. 1.47

{Max. 150}

2.94

{300}

343 – 490

{3.5 – 5.0}

245

{2.5}

290 – 490

{3.0 – 5.0}

200

{2.0}

294 – 441

{3.0 – 4.5}

206

{2.1}

250 – 440

{2.5 – 4.5}

180

{1.8}

Min. 147

{Min. 1.5}

69

{0.7}

Min. 100

{Min. 1.0}

70

{0.7}

Min. 98

{Min. 1.0}

69

{0.7}

Min. 100

{Min. 1.0}

70

{0.7}

90 – 110 120 80 – 110 120

Max. 0.5 1.0 Max. 0.5 1.0

25.0 – 25.8

{255 – 263}

20.2

{206}

25.0 – 25.8

{255 – 263}

20.2

{206}

19.5 – 20.5 19.5 – 20.5 18.5 – 19.5 18.5 – 19.5

— — — —

1,018 – 1,082 1,018 – 1,082 — —

Auto-tensioner Auto-tensioner — —



13

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

Air cleaner muffler

......................................

13-2

Starting motor ................................................

13-2

Turbocharger drain tube ...............................

13-3

Setting engine in engine overhaul stand ... 13-3

Corrosion resistor, air compressor

suction tube

..............................................

13-3

Bracket.. ...........................................................

13-3

Connector.. ......................................................

13-4

Tension pulley assembly.. .............................

13-4

Fan pulley assembly ......................................

13-4

g

Alternator assembly pulley.. .......................

13-4

Dipstick guide, air compressor .....................

13-5

:

Fuel hose.. .......................................................

13-5

Turbocharger ..................................................

13-5

Exhaust manifold ...........................................

13-5

After-cooler assembly

Intake manifold assembly). ....................

13-5

Fuel injection tube .........................................

13-5

Fuel injection pump assembly..

................... .13-6

Tube, bracket, PTO case ................................

13-6

Fuel filter fuel filter bracket

........................

13-6

Oil filter oil regulator

...................................

13-6

Oil pan

............................................................. 13-7

Suction pipe, under frame ............................

13-7

Flywheel ..........................................................

13-7

Rear seal

.........................................................

13-7

Flywheel housing ...........................................

13-8

Air vent tube, spill pipe, rocker arm

housing cover ........................................

13- 8

Nozzle holder, inlet connector ....................

13- 9

Rocker arm.. .................................................. 13- 9

Push rod.. ......................................................

13-10

Crosshead

.....................................................

13-10

Rocker arm housing.. ...................................

13-10

Cylinder head assembly ..............................

13-10

Vibration damper crankshaft pulley

assembly .................................................

13-l 1

Front support.. ..............................................

13-11

Thermostat housing .....................................

13-11

Water pump assembly ................................

13-11

Oil cooler assembly .....................................

13-11

Cam follower ................................................

13-12

Gear case cover.. ..........................................

13-12

Injection pump drive gear.. .........................

13-12

Camshaft .......................................................

13-12

Oil pump assembly, oil pump

idler gear ................................................

13-13

Main idler gear, injection pump

drive shaft

...............................................

13-13

Piston cooling nozzle ...................................

13-13

Piston and connecting rod assembly

......... 13-13

Crankshaft .....................................................

13-15

Cylinder liner

................................................

13-16



ASSEMBLY AND DISASSEMBLY

GENERAL DISASSEMBLY

Special tools

Part No. Part Name

Q’ty

A 790 901 1260 Adapter

1

B

790 501 2001 Engine overhaul stand 1

C 795 102 2102 Spring pusher

1

Preparatory work

Clean off all mud and dirt.

Drain cooling water and engine oil.

:

- Engine oil: Approx. 37 L?

Prepare a stable engine stand which will prevent

the engine from falling over, then put the engine

securely in the stand.

A

kg

Engine assembly: Approx. 1550 kg

The weight of the engine differs accord-

ing to the model of machine on which it

is mounted.)

I

I

CLl E 133

1. Air cleaner muffler

I) Disconnect hose I) between air cleaner and

muffler and hose 2) between air cleaner and

turbocharger, then remove band 3) then

remove air cleaner 4).

Ir When removing turbocharger connection,

cover the openings to prevent dirt or dust

from entering the turbocharger.

2) Remove valve 51, muffler mounting bolts

6) and band 7), then remove muffler 8).

3) Remove exhaust connector 9).

Sr When removing the turbocharger con-

nection, cover the openings to prevent dirt

or dust from entering the turbocharger.

2. Starting motor

Remove mounting bolts I), then remove starting

motor 2).

13 2

0



ASSEMBLY AND DISASSEMBLY GENERAL DISASSEMBLY

3. Turbocharger drain tube

Remove turbocharger drain tube (I).

4. Setting engine in engine overhaul stand

1) install adapter A on engine.

2) Sling engine assembly, align tool A with

engine overhaul stand B, and install engine

assembly.

6

kg

Engine assembly: Approx. 1500 kg

5. Corrosion resistor, air compressor suction tube

I

2

3)

4)

Remove hoses (I) and (2).

Remove corrosion resistor (3).

Remove tubes (4) and (5).

Remove tubes from air compressor. (If

equipped).

6. Bracket

Remove mounting bolts, then remove brackets

(I) and (2).

CEE 137

COEOO 38

CDE 139

13-3

0




GENERAL DISASSEMBLY

7. Connector

1) Remove clamp I), then remove turbocharger

lubrication tube 2).

2) Remove mounting bolts 31, then remove

connector 4) and electrical intake air heaters

5).

8. Tension pulley assembly

1

2

3)

Loosen tension pulley assembly mounting

nuts I).

Loosen adjustment bolt 2), move tension

pulley toward inside, then remove V-belts

3).

Remove mounting bolts 41, then remove

tension pulley assembly 5).

9. Fan pulley assembly

Remove mounting bolts I), then remove fan

pulley assembly 2).

10. Alternator assembly pulley

I) Loosen mounting bolts I), 2) and 3).

2) Loosen 2 adjustment nuts 41, then remove

2 alternator belts 5).

3) Remove mounting bolts I), 2) and 3), then

remove alternator assembly 6) and

adjustment rod 7).

4) Remove bracket 8).

5) Remove mounting

pulley IO).

bolts 9) and remove

CEE 143

CEE 144




GENERAL DISASSEMBLY

11. Dipstick guide, air compressor

1) Remove dipstick guide I).

2) Remove lubrication tube 21, then remove

air compressor 3). If equipped.)

3) Remove air compressor mounting plate 4).

If equipped.)

12. Fuel hose

Remove fuel hoses 5).

13. Turbocharger

1) Disconnect turbocharger lubrication inlet

tube.

2) Remove mounting bolts I), then remove

turbocharger 2).

14. Exhaust manifold

Remove mounting bolts I), then remove exhaust

manifold 2).

15. After-cooler assembly Intake manifold

assembly)

1) Remove clamps I).

2) Sling after-cooler assembly 21, remove

mounting bolts 3). then lift off after-cooler

assembly.

16. Fuel injection tube

Remove fuel injection tubes 4).




GENERAL DISASSEMBLY

17.

18.

19

20.

Fuel injection pump assembly

1) Remove lubrication tubes 1) and 2).

2) Remove lubrication tubes 3) and 4).

3) Remove 2 bolts 7) securing cross coupling

6) and front laminated coupling 5).

4) Remove 4 mounting bolts 8), then remove

fuel injection pump assembly 9).

+ When doing this, leave flange coupling

IO) and front laminated coupling 5) on

the drive shaft.

5) Remove connecting bolts I I) of coupling

and drive shaft, then remove flange coupling

IO) and front laminated coupling 5).

Tube, bracket, PTO case

1) Remove turbocharger lubrication tube 1).

2) Remove fuel injection pump bracket 2).

3) Remove PTO case 3).

Fuel filter fuel filter bracket

Remove fuel filter I) and fuel filter bracket 2).

Oil filter oil regulator

Remove oil filter 3) and oil regulator 4).

CEE 15

13 6

0




GENERAL DISASSEMBLY

21. Oil pan

1) Remove wiring connector (I) from bracket.

2) Disconnect drain hose (2).

3) Remove oil pan (3).

22. Suction pipe, under frame

1) Remove bracket (I), then remove suction

pipe (2).

23. Flywheel

Using eye bolt @ (Dia. = 12 mm, Pitch = 1.75

mm), sling flywheel (I), then remove.

I

kg

Flywheel: 60 kg

24. Rear seal

Remove rear seal (I) as follows.

2 CEE 154




GENERAL DISASSEMBLY

25.

26.

Removal of standard seal

Hook tip of tool L to metal ring of seal I),

then use impact force of slide hammer to

remove seal.

* Before removing the seal, knock it in

slightly to release the contact between

the seal and the housing. This will make

it easier to remove the seal.

Removal of seal with sleeve

I) Hook tip of tool L to metal ring of seal

I), then use impact force of slide

hammer to remove seal.

* Before removing the seal, knock it in

slightly to release the contact

between the seal and the housing.

This will make it easier to remove

the seal.

2) Use a hammer and chisel to cut sleeve

2) to remove it.

* Be extremely careful not to damage

the crankshaft when cutting the seal.

* If any metal particles are formed, be

sure to remove them all completely.

Flywheel housing

Remove mounting bolts I), sling flywheel

housing 2), then remove.

LL?l

g

Flywheel housing: 55 kg

Air vent tube, spill pipe, rocker arm housing

cover

1) Remove air vent tube 1).

2) Remove spill pipe 2).

3) Remove rocker arm housing covers 3).

oo

Sl i de hammer

DWE00211

Standard seal

Fl ywheel

hausi ns

Metal r i ns

Cr ankshaf t

DWEOOZI Z

Seal wth sl v

Fl ywheel

housi ng

Cr ankshaf t

2

DWE00213

CDE00158



AS

SEM

BLY

AN

D

DISA

SS E

MBL Y

GE

NER

AL

DISA

SS E

MBL

Y

27

. No

zzle

ho

lder,

in l

et c

onne

ctor

I)

Lo o

sen

lo

cknu

t

I),

the

n

remo

ve

inl

et

conn

ecto

r

2).

2)

Re

mov

e

mou n

ting

b

olts 3) , then rem ove

ho l

der

4).

3)

Fully

sc

rew

bolt

@

Dia

. =

10

mm,

Pi

tch

=

1.

5 m

m),

th

en

rem

ov e

n

ozzl

e

hold

er

a

ssem

bly

5

) us i

ng

bar

etc.

* When removing noz zle holder assembly,

cle

an

arou

nd

noz z

le ho

lder

an d

be

care

ful

not

to e

nter

fore

ign

mate

rial

insi

de s

leev

e.

*

C

heck

tha

t th

ere

is

gask

et

6)

fitted

to

the

tip

of t

he n

ozzl

e h

older

.

28 .

R

ock e

r ar

m

CEE

159

Re

mov

e m

ou n

ting

bo l

ts 1

) an

d 2

), th

en r

em o

ve

r

ocker arm 3).

*

L

oos e

n lo

ck

nuts

4)

of

adjus

tm e

nt

scre

ws,

then

loo

sen

each

ad

justm

en t

sc

rew

5)

2 -

3

tu

rns

to

avoi

d e

xces

sive

p

ress

ure

be

ing

brou

ght

to

be

ar o

n t

he

push

ro

ds

wh e

n

in

stal

ling

the

roc

ker

arm.

_..

~

,_

--- --

-..,

,_‘._

2

.5

1

016

1




GENERAL DISASSEMBLY

29

Push rod

Remove push rod I).

30. Crosshead

Remove crosshead 2).

31. Rocker arm housing

Remove mounting bolts, then remove rocker arm

housing 3).

32. Cylinder head assembly

1) Remove mounting bolts I), then remove

cylinder head assembly 2).

2) Remove each cylinder head gasket.

Disassemble cylinder head assembly as

follows,

i)

Using spring pusher C, compress valve

spring and remove cotter I).

ii)

Remove upper vale seat 2), outer valve

spring 3), and inner valve spring 4).

iii) Remove lower valve seat 5).

iv) Lift up cylinder head and remove valves

6).

CEE0016r

CEEOO 65

CEE00166

I

I

I

6

CEE00167

13 10

0




GENERAL DISASSEMBLY

33. Vibration damper crankshaft pulley assembly

Remove mounting bolts I), then remove

vibration damper, crankshaft pulley assembly 2).

34. Front support

Remove front support 3).

35. Thermostat housing

1) Remove ring I), then remove tube 2) up.

2) Remove mounting bolts 3), then remove

thermostat housing 4).

36. Water pump assembly

Remove tube I), then remove water pump

assembly 2).

* The mounting bolts for the water pump are

also used to tighten the gear case cover.

37. Oil cooler assembly

Remove oil cooler assembly I).

I

CEE00170

1 CEE00171




GENERAL DISASSEMBLY

38. Cam follower

Remove cover, then remove mounting bolts I)

and cam follower 2).

* Each of twelve mounting bolts I) has its

own oil holes so pass wire through the holes

and keep the bolts in a safe place to prevent

them from being lost.

39 Gear case cover

Remove gear case cover I).

40.

41.

Camshaft

Align mounting bolts 3) with camshaft gear hole

and remove mounting bolts then remove

camshaft 4).

* When removing the camshaft, rotate the

camshaft to prevent damage to the cam

bushing.

Injection pump drive gear

Remove mounting nut I), then remove injection

pump drive gear 2).

CEE00176

13 12

0




GENERAL DISASSEMBLY

42. Oil pump assembly, oil pump idler gear

1) Remove oil pump assembly I).

2) Remove oil pump idler gear 2).

43. Main idler gear, injection pump drive shaft

1) Remove mounting bolt I), then remove

main idler gear 2).

2) Remove mounting bolts 31, remove thrust

plate 4) and injection pump drive shaft 5).


Remove mounting bolt I), then remove piston

cooling nozzle 2).

45. Piston and connecting rod assembly

1

2

3)

Check number on connecting rod cap.

* Check that the cap number and the

cylinder number match, and that the

number is stamped at the cam end.

Ir If there is no number, stamp a number

before removing.

Rotate crankshaft so that piston to be

removed is at bottom dead center.

Using fine sandpaper, remove carbon at top

of liner.

* If necessary, measure the end play of

the connecting rod with dial gauge @I

before removing the connecting rod

assembly.

CEE 18

CEEOO I 31




GENERAL DISASSEMBLY

4)

5)

6)

7)

0

Remove bolts I) of connecting rod cap.

Tap cap with plastic hammer and remove

connecting rod cap 2) together with

connecting rod bearing.

* Be careful not to damage the threads of

the connecting rod bolts.

Using wooden bar, push piston and

connecting rod from oil pan side. Support

piston 6) at cylinder head side and remove.

* When removing, be careful not to

damage the inside surface of the liner

with the corners of the connecting rod.

Remove remaining pistons and connecting

rods in the same way.

Ir Keep the pistons and connecting rods in

a safe place and be careful not to damage

the sliding surface of the piston or the

bearing.

* Keep the connecting rod and cap

assembled to prevent mistakes when

assembling, and keep together with the

bearing.

Disassemble piston and connecting rod

assembly as follows.

i

ii)

iii)

iv)

Remove snap ring 3).

Hold connecting rod 4) by hand, and

tap out piston pin 5). Disconnect piston

assembly 6) and connecting rod.

Remove snap ring on opposite side.

Using piston ring tool D, remove piston

rings 7).

* Keep piston, connecting rod, bearing,

piston rings and piston pin in sets

according to cylinder number.

3 CEE00184

7

CEE00185

13 14

0




GENERAL DISASSEMBLY

46. Crankshaft

1

2

2

;;

0

3)

4)

If necessary, measure the end play of the

crankshaft with dial gauge @ before

removing the crankshaft.

Remove mounting bolts 2) of main bearing

cap I).

Insert bolts 2) in holes in main bearing cap,

then remove main bearing cap while shaking

the cap with the inserted bolts.

The lower thrust bearings 3) are assembled

on both sides of the No. 7 main bearing cap,

so after removing, mark the position for

assembly.

Using a wire, remove crankshaft 4).

r55

g

Crankshaft: 140 kg

* When slinging the crankshaft, be careful

not to let it hit or damage the cylinder

block.

Ir

Keep the crankshaft in a safe place, and

be careful not to damage the machined

surfaces.

-

CEE 186




GENERAL DISASSEMBLY

5) Remove upper thrust bearings 5).

6) Remove upper main bearing 6).

* Mark the positions for assembly of the

main bearing caps, main bearings and

thrust bearings with tags or felt pen.

Keep in sets according to the cap

number. Keep them in a safe place and

be careful not to damage them.

47. Cylinder liner

* If necessary, measure the protrusion of the

cylinder liner with dial gauge H before

removing the liner.

Using liner puller E, remove cylinder liner 1).

CEEOO 9



GENERAL ASSEMBLY

Tightening bolts by the plastic range

turning angle method ........................... 13-18

Drawing

of special tool

...............................

13-19

Preparatory work

.......................................... 13-20

Cylinder liner

................................................ 13-21

Crankshaft

..................................................... 13-23

Piston and connecting rod assembly

......... 13-26

Piston cooling

nozzle ................................... 13-28

Main idler gear, fuel injection pump

drive shaft ...............................................

13-29

Oil pump idler gear, oil pump

assembly

................................................. 13-30

Camshaft

....................................................... 13-30

Fuel injection

pump drive

gear ..................

13-30

Fuel injection pump drive shaft oil seal

... 13-31

Gear case cover ............................................ 13-32

Breather..

....................................................... 13-32

Front seal

......................................................

13-33

Cam follower

................................................ 13-34

Oil cooler assembly

..................................... 13-34

Water pump

assembly ................................ 13-35

Thermostat housing

.....................................

13-35

Front support

................................................

13-35

Vibration damper, crankshaft pulley

assembly..

............................................... 13-35

Cylinder

head assembly

..............................

13-36

Crosshead

.....................................................

13-38

Rocker arm housing

..................................... 13-38

Push rod

........................................................

13-38

Rocker arm

....................................................

13-39

Adjusting

valve clearance

...........................

13-39

Nozzler holder,

inlet connector.. .................

13-40

Rocker arm housing cover, spill pipe,

air vent tube

...........................................

13-41

Flywheel

housing .........................................

13-41

Rear seal

.......................................................

13-42

Flywheel

........................................................

13-45

Suction pipe .................................................. 13-46

Oil pan ...........................................................

13-46

Oil filter

assembly, oil regulator..

..............

.13-46

Fuel filter assembly fuel filter bracket..

.. 13-46

PTO case

tube, bracket.. ..............................

13-47

Fuel injection

pump assembly.. ..................

13-47

Adjusting

fuel injection pump ....................

13-48

Fuel injection tube

.......................................

13-50

After-cooler assembly Intake manifold

assembly) ............................................... 13-50

Exhaust

manifold .........................................

13-50

Turbocharger

................................................ 13-51

Fuel hose .......................................................

13-51

Dipstick

guide, air compressor

.................. .13-51

Alternator

assembly, pulley ........................

13-51

Fan pulley

assembly ....................................

13-52

Tension

pulley assembly.. ...........................

13-52

Intake connector

........................................... 13-52

Muffler bracket, air cleaner bracket

..........

.13-52

Corrosion resistor

......................................... 13-53

Resetting

engine in engine stand..

............. 13-53

Turbocharger

drain tube .............................

13-53

Starting motor ..............................................

13-53

Air cleaner,

muffler.. ....................................

13-54

Refilling with oil

...........................................

13-54

13-17

0




GENERAL ASSEMBLY

TIGHTENING BOLTS BY THE PLASTIC RANGE

TURNING ANGLE METHOD

0

0

*

0

*

Important bolts in the 140 Series engines are

tightened by the plastic range turning angle

method. In this method, special bolts are used.

By

being tightened to the load (plastic range) at

which they begin to be permanently deformed,

accurate and high tightening force can be

obtained.

The most common method for tightening bolts

is the torque control method.

In this method,

however, it is difficult to accurately control the

tightening force because of the coefficient of

friction.

The plastic range turning angle method is based

on the initial tightening torque and the turning

angle.

Elongation exceeding the elastic range results

in permanent deformation.

Bolts to be tightened by the plastic range turning

angle method in the 140 Series engines.

I) Cylinder head mounting bolts

2) Main cap mounting bolts

3) Connecting rod cap mounting bolts

4) Flywheel mounting bolts

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

followina orecautions.

I

2)

3)

Befoie tightening, measure the free length

of bolt and check that bolt length exceeds

tolerance limit or not. Do not reuse any bolt

which has exceeded the tolerance limit.

Before tightening, measure the free length


tolerance limit or not.

If a bolt has been tightened in excess of the

specified turning angle, loosen the bolt and

measure the free length of bolt again.

The tightening angle should be targeted at

the standard value plus or minus tolerance.

Special tools

Part

No Part Name

a’tv

A 790-901-1260

Adapter

1

B 790-501-2001

Engine overhaul

stand

1

c 795-102-2102

Spring pusher

1

D 795-100-I 191 Piston ring tool 1

F 795-230-5472 Liner driver 1

t

Wlastic

range)

Plastic range turning

angle

(conventional method)

Elongation of bolt

Part No.

Part Name Q’ty

J

1 790-331-I 110

1

Wrench

I I

I

K 1 795T-473-1110 1 Push tool

1

795-521-1110

Push tool

1

M

01050-31640

Bolt

3

1

795-931-1210

Sleeve jig

1

2

795-931-1220

Sleeve jig

1

N

3

01050-31645

Bolt

3

4

01050-31625

Bolt

3

Clean

all parts, and check for dents, scores or

casting defects. Check that all the oil and water

passages are clear.

13i’*




GENERAL ASSEMBLY

Drawing of special tool

Push tool K

Note Komatsu has no responsibility for special tool made by this drawing.

1

A

I

\

L

N

mnd

G

fl

om

_______-_-.

- ----------.--.-

g6

-=t

;s

‘a

I

t

’

/

/

‘L

ep’

2 Cl

CDE00261

/ 795T 473 1110 n

13 19

0




GENERAL ASSEMBLY

Preparatory work

Install adapter A on cylinder block, set cylinder

block on engine overhaul stand B.

Prepare the cylinder block before inserting the

cylinder liner as follows.

1

2

3

4

5

Using sandpaper, remove rust and scale

from faces @ and @ until machined surface

can be seen.

Using No. 60 sandpaper, polish portions @

and @ to give a smooth finish. If there is a

sharp corner formed or any burrs on portion

8, remove with a scraper or sandpaper. Be

particularly careful to finish this surface

smoothly to prevent damage to the O-ring.

If there is pitting on face @ and it cannot be

repaired, replace cylinder block.

If there is pitting on face @ or portion 0,

polish to give a smooth finish.

Inspect counterbore and remove all burrs.

Remove all chips and dirt from face @J. Such

dirt will cause defective sealing of the liner,

leakage of water, or defective protrusion of

the liner.

Ir If there is any damage, corrosion or

pitting in the counterbore; repair it.

Q

CEE 51

13-20

0




GENERAL ASSEMBLY

Cylinder liner

Before assembling, carry out selection of

clearance between liner and piston referring to

MAINTENANCE STANDARD.

Replace the liner O-ring and crevice seal with

new parts just before assembling the liner.

Method of installing liner O-rings and crevice

seal

1) Check the cylinder liner O-ring groove and

outside circumference of the liner to confirm

that there is no rust or pitting.

If the surface is rough and pitted, it may

cause leakage of water, so replace the

liner.

2) Coat the mating surface of the cylinder block

and cylinder liner counterbore with silicon-

based gasket sealant LG-6).

Use a cloth to wipe off all the dirt or oil

from the cylinder block counterbore and

liner flange contact surface.

Width of gasket sealant LG-6):

m2-3mm

Make an overlap of 6 r 6 mm at the

beginning and end when coating with

gasket sealant LG-6.

If the parts are left for a long time after

coating them with gasket sealant, the

surface will start to become hard, so

complete assembly to the block within

50 minutes.

block

DWE00214

TOP surface of block

Matins portion

coat the corner of the deck)

DWEOOIBB

DWE00189

+=I

Cylin

P

er liner

Crevice seal

Black Ethylene propylene rubber)

O-ring

Black Ethylene propylene rubber)

O-ring

Orange Silicon rubber)

w

I

DEE 9




GENERAL ASSEMBLY

3)

*

*

4)

5)

+

Coat the liner O-ring and cylinder block O-

ring grooves with rubber lubricant RF-l.

RF-l: Daido Kagaku Kogyo

If RF-1 is not available, coat liner O-rings

and crevice seals with clean SAE30 engine

oil.

Oil causes the crevice seal and O-ring to

swell and deteriorate, so do not leave them

soaking in oil.

Use a brush and coat them with a small

amount of oil immediately before assembly.

After installing the liner O-ring, check for

twisting. If any twisting is found, use a

smooth bar approx. 0 10 mm) to remove

the twisting.

To prevent the crevice seal from twisting

when it is installed, press it around the whole

circumference so that it fits into the seal

groove.

Assemble the crevice seal with the

chamfered side facing down.

Method of inserting cylinder liner

I

2)

3)

Set the stamped mark “A” or “B” on the top

of the liner facing to the front, then insert

the liner into the cylinder block taking care

not to damage the O-ring.

Use your weight and push the liner in with

both hands.

* If the liner does not go in smoothly when

you apply your weight, there is danger

that the O-ring may be damaged, so

check the cylinder block for burrs or

flashes.

Using tool F, press fit cylinder liner 1) into

the cylinder block.

CEE00201

Press i t to the grove

K

Chamfered side

DEE00089




GENERAL ASSEMBLY

4) After press fitting cylinder liner, use tool H

to measure protrusion of cylinder liner.

*

*

*

When measuring the protrusion of the

cylinder liner, clamp the liner with a plate

to prevent it from being pushed up by

the O-ring.

Protrusion of cylinder liner: 0.08 - 0.18

mm

If any gasket sealant is squeezed out from

the mating portion of the cylinder block

and cylinder liner on to the top of the

cylinder block, wipe it off.

5) In addition, to prevent gasket sealant from

being squeezed out from between the block

and liner when the head is tightened, fit a

used head gasket after inserting the liner

and tighten the cylinder head temporarily.

When tightening, use the tightening torque

shown below and the order of tightening

shown on the right.

m Temporary tightening torque for

cylinder head:

137 - 157 Nm (14 - 16 kgml

CDE00204

6) Remove the cylinder head, and wipe off the

gasket sealant that has been squeezed out

from the counterbore.

j, If gasket sealant sticks to the grommet

in the head gasket, the grommet will be

deformed, so always carry out Steps 5)

and 6) to remove all the gasket sealant.

2. Crankshaft

1) Align protrusion of upper main bearing (6)

with notch in cylinder block, and install in

cylinder block.

* Check that there is no dirt or dust stuck

to the rear face of the bearing. Coat the

inside face of the bearing with engine

oil (SAE 30) before assembling.

A

Do not coat with oil to back face of metal.

* Upper metal: with oil hole.

If the grommet is deformed into a heart shape and

covers the water hole

th

coolant may leak

Grommet

Water hole

DWE002 I5

6,




GENERAL ASSEMBLY

7)

8)

9)

Before tightening main cap mounting bolt

(21, make sure as follows.

i

ii)

*

Measure the free length a of all bolts

and check that bolt length exceeds toler-

ance limit or not. Do not reuse any bolt





Tolerance limit of bolt free length:

Max. 159.8 mm.

If the bolt length a exceeds tolerance

limit, do not reuse.

Coat washer and threads of mounting bolts

of main bearing cap with engine oil (SAE 30).

Screw in bolts (1) to fit main bearing cap

completely.

Tighten mounting bolts (2) of main bearing

cap as follows.

* When tightening the mounting bolts of

the main bearing cap, start in the middle

and work to the outside. Then tighten all

the mounting bolts again to the next step.

w Mounting bolt of main bearing cap

1st step:

108 - 128 Nm {II - 13

kgml

2nd step:

211 - 221 Nm 121.5 - 22.5 kgm1

3rd step: I)

2

When using tool J.

Turn the bolt further 90 - 120

degrees with tool J.

When not using tool J.

Mark the bolts and the cap

with a felt-tip pen, and turn

the bolts further 90 - 120

degrees.

10) After tightening bolts, rotate crankshaft and

check that it rotates smoothly.

11) Measure end play of crankshaft with dial

gauge 0.

* End play: 0.140 - 0.315 mm

DWE00275

Put a make on the

bolt and cao




GENERAL ASSEMBLY

3. Piston and connecting rod assembly

* Before assembling, carry out selection of

clearance between liner and piston referring to

MAINTENANCE STANDARD.

Assemble piston and connecting rod assembly

as follows.

I

2

3)

4)

5)

Using piston ring tool D, install piston rings

(7) on piston.

Ir Assemble the rings as shown in the

diagram.

* Install the piston rings with the stamped

mark facing up.

Sr When fitting the oil ring, remove the

expander and fit the piston, then fit the

oil ring. When doing this, check that the

expander is fitted completely inside the

ring groove.

Set piston and connecting rod.

Sr Match cylinder number on piston head

with number stamped on connecting rod,

and set numbers facing in the correct

direction. Then insert piston pin (5) and

assemble piston (6) to connecting rod

(4).

Install snap rings (3) on both sides to secure

piston pin.

Align protrusion of upper bearing of

connecting rod with notch in connecting rod

and install bearing.

* Check that there is no dirt or dust stuck

to the rear face of the bearing when

installing.

Set crankshaft to bottom dead center in

cylinder to be assembled, then coat inside

surface of connecting rod bearing and inside

surface of cylinder with engine oil (SAE 30).

CEE00165

DWE00192

3

CEE00164

Cast number

al i gn on camshai

t s i de)

13-26




GENERAL ASSEMBLY

6)

7)

8)

9)

Set cast number on connecting rod facing

front of engine (number is on camshaft side),

align end gaps of piston rings as shown in

diagram, and insert piston and connecting

rod assembly (8).

Using piston holder G, compress piston rings

and push in piston head with wooden bar.

Before tightening connecting rod bolt, make

sure as follows.

i)

ii)

+









Max. 95.0 mm.

If the bolt length exceeds tolerance


Align protrusion of lower bearing with notch

in connecting rod cap and assemble. Align

connecting rod cap (2) with mark on

connecting rod and install.

+

Check that there is not dirt or dust stuck

to the rear face of the bearing when

installing.

* Coat the sliding surface of the connect-

ing rod cap with engine oil (SAE 30).

CEE 212

CEE 213

\

P

~

DWE 275




GENERAL ASSEMBLY

IO

111

Coat bolt threads and bolt seat with engine

oil (SAE 30). Tighten mounting bolt (I) of

connecting rod as follows.

m Mounting bolt of connecting rod

1st step: 123 - 132 Nm {12.5 - 13.5 kgm1

2nd step: I)

When using tool J.

Turn the bolt further 90 - 120

degrees with tool J.

When not using tool J.

Mark the bolts and the cap

with a felt-tip pen and turn the

bolts further 90 - 120 degrees.

2)

* Make a punch mark on the bolt head

each time the bolts are used. If there are

already five marks on the bolt head, re-

place with new bolts.

After installing piston and connecting rod

assembly, rotate crankshaft and check that it

rotates smoothly. There must be no catch-

ing or other abnormality.

12) Measure side clearance of connecting rod

with dial gauge 0.

* Side clearance: 0.100 - 0.274 mm


Fit piston cooling nozzle (2) and install mounting

bolts (I).

jr Check that the tip of each nozzle is directed

at the center of each piston shaker hole.

Put mark on bolt and

connectino rod cap

I

DWE 216

CEE 181

13-28

0




GENERAL ASSEMBLY

5. Main idler gear, fuel injection pump drive shaft

I

21

3)

4)

Coat fuel injection pump drive shaft (5) with

engine oil (SAE 30) and install.

Install thrust plate (41, then install mounting

bolts (3).

Install shaft (6) to main idler gear (21, then fit

washer (7) on inside.

Align “A” mark on crankshaft gear with “A”

mark on main idler gear (21, then tighten

mounting bolts (11.

m Idler mounting bolt:

1st step: 265 - 343 Nm I27 - 35 kgml

2nd step:

Mark the bolts and the side seat

of idler gear shaft with a felt-tip

pen and turn the bolts further 90

- 120 degrees.

* Make a punch mark on the bolt head

each time the bolts are used.

If there are already five marks on the

bolt head, replace with new bolts.

I

2 CEE00216

Put mark on side seat

of idler gear and bolt

I

DWE00217

Put one punch

mark

DEEM 100




GENERAL ASSEMBLY

6.

7.

8.

Oil

1)

2)

pump idler gear, oil pump assembly

Install oil pump idler gear (2).

Fit O-ring and install oil pump assembly (I).

w Oil pump idler mounting bolt:

377.6 - 426.6 Nm (38.5 - 43.5 kgm1

m Oil pump mounting bolt:

98 - 123 Nm I10 - 12.5 kgm1

Camshaft

Coat camshaft journal surfaces with engine oil

(SAE 30). Align “B” mark of camshaft gear with

“B” mark of main idler gear, then tighten

mounting bolts (3) of camshaft (4).

m Mounting bolt of plate:

98 - 123 Nm {IO - 12.5 kgml

Ir When installing the camshaft, rotate the

camshaft to prevent damage to the cam

bushing.

*

If the camshaft gear has been replaced, heat

the camshaft gear in an electric furnace at

220 - 240°C for 30 minutes, then shrink fit

the gear.

Fuel injection pump drive gear

Fit key to shaft, align “C” mark of main idler

gear ‘with “C” mark of drive gear, then fit drive

gear (2) and tighten nut (I).

m Nut: 226 - 255 Nm (23 - 26 kgml

* Check that the match marks of each drive

gear and idler gear are aligned.

I

I I

CFFOO176

_

I

c---G?/

B

m

CDE 217




GENERAL ASSEMBLY

*

Measure backlash and end play of each gear

using dial gauge 0.

* Standard backlash for each gear

Position Range (mm)

A 0.141 -

0.425

B 0.129 -

0.391

C 0.129 -

0.391

D 0.141 -

0.426

E 0.095 -

0.346

F 0.080 -

0.417

G 0.118 -

0.369

I-i OP) 0.118 -

0.369

1 tow 0.025 -

0.486

Sr Standard end play for each gear

Position Range (mm)

1 0.140 -

0.315

2 0.100 -

0.250

3 0.050 -

0.170

4 0.050 -

0.170

5 0.070 -

0.200

6 0.030 -

0.088

9. Fuel injection pump drive shaft oil seal

Before assembling the seal, check that there

is no damage, burrs, flashes, or rust on the

housing and sliding surface of the lip.

When assembling the seal, do not coat the

shaft, and the space between the sleeve and

seal lip with oil or grease. If there is any oil

or grease on the shaft, wipe it off completely.

Handle the seal and sleeve as an assembly.

Never separate them.

CEE00218

1

I

-I

2 G1

B

%6

4

D

3c

5

IF

A

H

I

---l

1

CDEOOLI S

Assembl y gui de

0 ast i c tubal

Large i nsi de

di amet er end

Smal l nsi de

di amet er end

DWE00218

13-31

0




GENERAL ASSEMBLY

1) Put large inside diameter end of plastic inner

tube I) in contact with end of shaft 2).

Sr Be particularly careful not to mistake the

direction when assembling.

CDE00221

2) Hold metal ring of seal 3) with both hands,

push evenly, and use sudden pushing force

to push in.

3) After pushing in seal, remove plastic inner

tube 1).

* Be particularly careful not to damage the

seal lip when removing the inner tube.

CDE00222

4) Using tool K, press fit oil seal 3) until seal

contacts to housing 4).

10

Gear case cover

Fit gasket, install gear case cover I).

* When installing the gear case cover, remove

the service meter gear box. After installing

gear case cover, install service meter gear

box.

11. Breather

1) Fit O-ring, install breather 3).

w Mounting bolt:

24.5 - 29.4 Nm I2.5 - 3.0 kgm}

2) Install hose 4) and tube 5), then secure

with clamps.

c

’

CDE00223

CDE00175




GENERAL ASSEMBLY

12. Front seal

‘7

Assemble front seal I) as follows.

Assemble guide

:

K4

co

2)

3)

4)



housing, sliding surface of the lip and the

corner of the end face of the crankshaft.

When assembling the seal, do not coat the

shaft or seal lip with oil or grease. If there is

any oil or grease on the shaft, wipe it off

completely.

Do not remove the plastic tube inside the

standard seal provided as a spare part until

immediately before assembling the seal.

Put large inside diameter end of plastic inner

tube 2) in contact with end of crankshaft

3).

Ir Be particularly careful not to mistake the


Hold metal ring of seal I) with both hands,


to push in.

After pushing in seal, remove plastic inner

tube 2).

* Be particularly careful not to damage the


Tighten bolts of tool M uniformly until end

face of tool M contacts ends face of

crankshaft 3) to press fit seal I).

j, When press fitting the seal, be extremely

careful not to damage the lip at the PTO

end when setting the tool.

* After press fitting the seal, remove the

red sealant layer from the outside

circumference.

Small inside

diameter end

Large inside

diameter end

DWEOOZI 9

CDE 232

13 33

0



ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY

13. Cam follower

1) Align cam follower 2) with dowel pin, then

tighten mounting bolts 1).

w Mounting bolt:

44.1 - 58.8 Nm I4.5 - 6.0 kgm}

2) Fit O-ring and install cover.

w Mounting bolt:

9.8 - 12.7 Nm 1.0 - 1.3 kgm}

Ir The mounting bolts for the cam follower

are fitted with lubrication holes, so check

that the holes are clear.

14. Oil cooler assembly

Fit gasket and install oil cooler assembly I).

* When installing therm0 valve, confirm the

protrusion amount of spring. Fit spring again

when exceeding standard value.

Protrusion amount of spring a: 24 mm

CEE 233




GENERAL ASSEMBLY

15.

16.

:

g

17.

Water pump assembly

1) Fit O-ring and install water pump assembly

2).

*

The mounting bolts of the water pump

are used to tighten the gear case.

2) Fit gasket and install tube I).

Thermostat housing

I

2)

3)

Fit O-ring to tube 21, then install to

thermostat housing 4).

Fit gasket and install thermostat housing 4)

with mounting bolts 3).

Move tube 2) down and install ring I).

Front support

Install front support 3).

Ir For trunnion type, fill 20 cc of grease G2-LI)

to groove on mounting face of support 3),

then install.

1‘ 1 CEE00171

CEE00170

18. Vibration damper, Crankshaft pulley assembly

Install vibration damper, crankshaft pulley

assembly 21, then tighten with mounting bolt

I).

w Mounting bolt:

245 - 308.7 Nm I25 - 31.5 kgm}




GENERAL ASSEMBLY

19. Cylinder head assembly

I

Assemble cylinder head assembly as follows.

2

3)

i

ii)

iii)

iv)

Coat valve stem and inside surface of

valve guide with engine oil (SAE 30) then

assemble valve (6).

Raise cylinder head and assemble lower

valve seat (5).

Install inner valve spring (4) and outer

valve spring (31, then assemble upper

valve seat (2).

Using spring pusher C, compress valve

spring and install valve cotter (I).

+ Tap the valve stem with a plastic

hammer to check that the cotter is

completely fitted in the groove of the

valve stem.

Check that the mounting surfaces of the

cylinder head and cylinder block are clean

and that there is no dirt or foreign matter

inside the cylinder. Set cylinder head gasket

(9) in position.

* When installing the gasket, check that

the grommets are correctly in place.

Before tightening

sur

as follows.

i)

ii)

*

cylinder head bolt, make









Max. 166.3 mm.

If the bolt length a exceeds tolerance


CEE001651

CEE00164

I

CEE00166

CEE00234

OWE00275




GENERAL ASSEMBLY

4) Install cylinder head assembly (21, then

tighten mounting bolts (I).

Mounting bolt:

Antifriction compound (LM-PI

m Mounting bolt:

1st step:

I37 - 157

Nm I14 - 16 kgm)

2nd step:

211 - 221

Nm (21.5 - 22.5 kgm1

3rd step: I)

2)

*

When using tool J

Tighten bolts further 90 - 120

degrees in tightening order 0

to @ with tool J.

When not using tool J

Mark the bolt and head with a

felt-tip pen, turn bolt further

90 - 120 degree in tightening

order @ to 8.

Tighten bolt @ by tightening

torque 58.8 -

74.5 Nm (6.0 -

7.6 kgm) after tightening bolts

@ to 8.

DAD00043

I

CEE00 235

Put mark on cylinder

head and bolt

DWE00220



ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY

20. Crosshead

Install crosshead I 1.

* Adjust crosshead as follows.

i)

ii)

iii)

iv)

Loosen locknut, and loosen adjustment

screw.

Hold top of crosshead lightly and tighten

adjustment screw.

Tighten adjustment screw until it contacts

valve stem, then tighten a further 20”.

Tighten locknut to hold in position.

m Locknut:

53 - 64.7 Nm 5.4 - 6.6 kgm}

21.

22.

Push rod

Install push rods 1).

Ir Check that the push rod is properly fitted in

the cam follower.

Rocker arm housing

Fit gasket and install

w Mounting bolt:

rocker arm housing

I).

58.8 - 73.5 Nm 16.0 - 7.5 kgm}

CEE 237




GENERAL ASSEMBLY

23.

Rocker arm

install rocker arm 3) and tighten with mounting

bolts 2) and I).

* Check that the ball of the adjustment screw

is properly fitted into the socket of the push

rod. Then tighten bolts.

w Mounting bolt:

93 - 103 Nm I9.5 - 10.5 kgm1

24. Adjusting valve clearance

Adjust valve clearance as follows.

* Adjust the clearance between the crosshead

and rocker arm to the following values.

Sr Valve clearance When engine is hot or cold.)

Unit: mm

Intake valve 1 Exhaust valve

0.41 - 0.45

0.78 - 0.82

* Crank the engine and follow the firing order

to adjust the valve clearance of each cylinder.

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

1

2

3)

Rotate the crankshaft in the normal

direction to align pointer 2) with the 1.6

TOP mark on vibration damper I 1. When

rotating, check the movement of the

valves.

To adjust, insert feeler gauge I between

rocker arm 3) and crosshead 4) and turn

adjustment screw 5) until clearance is a

sliding fit.

Tighten locknut 6) to hold adjustment

screw in position.

m Lock nut:

53 - 64.7 Nm j5.4 - 6.6 kgml

Ir After tightening the

the clearance again.

lock nut, check

-..

---------

\J-.._..

----

-..-.

XL

CDE00240

I

5 6

3




GENERAL ASSEMBLY

25. Nozzle holder, inlet connector

*

1

Check that there is no dirt or dust inside the

nozzle holder sleeve.

Fit O-ring (71, and coat with engine oil

(SAE 30).

* Check that there is no damage to the O-

ring.

2

3)

Install gasket (6) to nozzle holder.

Align nozzle holder (5) with mounting hole

of inlet connector and insert nozzle holder.

4)

5)

insert inlet connector (2) in rocker arm

housing and tighten partially.

Fit holder (41, then fit ball washer to

mounting bolt (3) and tighten mounting bolt.

w Holder mounting bolt:

58.8 - 73.5 Nm IS.0 - 7.5 kgm}

* Install one end of the holder to the rocker

arm housing, lay on

tighten with the bolt.

the bolt head and

6)

Tighten inlet connector

locknut (1).

w inlet connector:

(2), then tighten

34.3 - 39.2 Nm 13.5 - 4.0

kgm}

w Locknut:

29.4 - 34.3 Nm (3.0 - 3.5

kgm}

7)

Install air compressor pipe bracket.

CEE 243

CEE 159

13-40

0




GENERAL ASSEMBLY

2) After installing the flywheel housing,

measure the radial runout and face runout

using dial gauge 0.

* Radial runout: Max. 0.30 mm

Ir Face runout: Max. 0.30 mm

28. Rear seal

* Check condition of wear of shaft, then select

standard seal or seal with sleeve for Teflon

seal lay-down lip seal) and assemble seal.

The condition of wear of the shaft can be

judged from the degree of luster touch with

the flat of your finger to check that the depth

of wear is less than 10 pm). If there are no

scratches, assemble a standard seal. In all

other cases, assemble a seal with sleeve.

Procedure for assembling standard seal

Before assembling the seal, check that there is

no damage, burrs, f lashes, or rust on the

housing, sliding surface of the lip and the corner

of the end face of the crankshaft.

When assembling the seal, do not coat the shaft

or seal lip with oil or grease. If there is any oil or

grease on the shaft, wipe it off completely.

Do not remove the plastic tube inside the

standard seal provided as a spare part until

immediately before assembling the seal.

Put large inside diameter end of plastic inner

tube 3) in contact with end of crankshaft 4).

* Be particularly careful not to mistake the


Lip at

Large inside

Small inside

diameter end

diameter end

DEE 1 5

CEP00535




GENERAL ASSEMBLY

2) Hold metal ring of seal (I) with both hands,


to push in.

3) After pushing in seal, remove plastic inner

tube (3).

+ Be particularly careful not to damage the


4)

Tighten bolts uniformly until end face of tool

Nl contacts ends face of crankshaft (4) to

press fit seal (1).

j, Firstly tighten tool Nl with bolt N3

(45 mm) until tool contacts end face of

crankshaft, then tighten with bolt N4

(25 mm).

j, When press fitting the seal, be extremely

careful not to damage the lip at the PTO

end when setting the tool.

Ir After press fitting the seal, remove the


circumference.

Procedure for assembling seal with sleeve

*



housing, sliding surface of the lip and the

corner of the end face of the crankshaft.

* When assembling the seal, do not coat the

shaft, and the space between the sleeve and

seal lip with oil or grease. If there is any oil

or grease on the shaft, wipe it off completely.

*

Handle the seal and sleeve as an assembly.

Never separate them.

CFFOO414

Li e at crankshaf t end

DWE 221

I) Set sleeve/seal (2) to tool N2.

Surface of sleeve inner tube:

Gasket sealant (LG-7)

~ DWE 222




GENERAL ASSEMBLY

2)

3)

4)

Put sleeve of seal in contact with end face of

crankshaft, tighten 3 bolts uniformly until

end face of tool N2 contacts ends face of

crankshaft (4) to press fit sleeve/seal (2).

Remove tool N2 and replace with tool Nl.

Tighten 3 bolts uniformly until end face of

tool Nl contacts ends face of crankshaft (4)

to press fit sleeve/seal (2).

* Firstly tighten tool Nl with bolt N3

(45 mm) until tool contacts end face of

crankshaft, then tighten with bolt N4

(25 mm).

* After press fitting the seal, remove the


circumference.

45mm

25mm

N

45mm

N4

25mm

CEE 251

’3 44




GENERAL ASSEMBLY

29. Flywheel

1) Using eye bolt @ (Dia. = 12 mm, Pitch = 1.75

mm), sling flywheel (I), install the flywheel

to the crankshaft, and tighten the mounting

bolt.

Coat the threads of the bolts and the

seat face, with engine oil SAE No. 30

before tightening the bolts.

kg

Flywheel: 60 kg

* Tighten mounting bolts as follows.

w Flywheel mounting bolt

1st step:

112.7 - 122.5 Nm 111.5 - 12.5 kgm1

2nd step: I)

2)

When using tool J

Tighten bolts further 90 - 120

degrees in tightening order @

to @ with tool J.

When not using tool J

Mark the bolt and head with a

felt-tip pen, turn bolt further

90 - 120 degree in tightening

order @ to 8.

CEE00156

ightening order

For construction

machine and generator

For marine engine

DKEOOI I

* Make a punch mark on the bolt head each

time the bolts are used.

* If there are already five marks on the bolt

head, replace with new bolts.

Put mark on flywheel

and bolt

DWE00223

Put one punch

mark

DEE 1




GENERAL ASSEMBLY

Ir After installing the flywheel, measure the

face runout and radial runout using dial

gauge 0.

* Face runout: Max. 0.30 mm

f Radial runout: Max. 0.30 mm

30. Suction pipe

Fit O-ring, then fit suction pipe 2) and install

bracket I) to the under frame.

31. Oil pan

1) Fit gasket and install oil pan 3).

2) Install drain hose 2).

m Hose clamp:

3.9 - 4.9 Nm jO.4 - 0.5 kgm}

3) Install wiring connector I) to bracket.

32.

33.

Oil filter assembly, oil regulator

1) Fit O-ring and install oil regulator 4).

2) Fit O-ring and install oil filter assembly 3).

Fuel filter assembly fuel filter bracket

1) Fit O-ring and install fuel filter bracket 2).

2) Install fuel filter assembly I).

3 2

CEE 154

13 46

0




GENERAL ASSEMBLY

34. PTO case tube, bracket

1

2)

3)

Install fuel injection pump bracket 2).

Install turbocharger lubrication inlet tube I).

w Turbocharger lubrication inlet tube

Bracket side of tube):

24.5 - 58.8 Nm 2.5 - 6 kgm1

Fit O-ring and install PTO case 3).

w Mounting bolt:

107.8 - 122.5 Nm 11.0 - 12.5 kgm}

35. Fuel iniection pump assembly

1

2)

3)

Knock key’ l3).into drive shaft 12) of fuel

injection pump.

Remove 2 coupling bolts 7) of fuel injection

pump, then remove flange coupling IO) and

front laminated coupling 5).

Install flange coupling IO) and front

laminated coupling 5) to fuel injection pump

drive shaft 12).

_j, Do not tighten mounting bolt 11).

w Mounting bolt 14)

D155AX-3 LW500-1):

58.8 - 63.7 Nm IS.0 - 6.5 kgm}

HD325 with electronic governor

KP21)):

147 - 166.6 Nm {I5 - 17 kgm}

Except above):

83.3 - 93.1 Nm 18.5 - 9.5 kgm1

-

\ 1-1 CEE00152

I

II

CEE00254

13-47

0




GENERAL ASSEMBLY

36.

4)

5)

6)

7)

8)

Align coupling key groove with drive shaft

key, push in fuel injection pump assembly

9), align with pin portion of bracket, and set

in position.

Tighten 4 mounting bolts 8) of fuel injection

pump.

Tighten connecting bolts 11) of coupling IO)

and drive shaft 12).

w Mounting bolt I I)

HD325 with electronic governor

KP-21)): 206 - 255 Nm I21 - 23 kgm1

Except above):

83.3 - 93.1 Nm I8.5 - 9.5 kgm}

Install lubrication tubes 3) and 4).

Install fuel hoses I) and 2).

Adjusting fuel injection pump

Under the following conditions, it is possible to

increase the setting precision of the crankshaft

angle.

* If pin 19) is still in the condition set when

shipped from the factory if front cover 22)

and flange 23) have not been removed):

I) Pull out pin 24). then remove nut 15).

2) Rotate the crankshaft in the normal direction,

and align pointer 17) with the fuel injection

line 16” position) on damper 16).

* When doing this, check that line 18) on

the coupling block is near the line on the

pump housing. If it cannot be seen, rotate

the crankshaft one more turn.

CEE 255

CDE 256




GENERAL ASSEMBLY

3) Rotate crankshaft and push lock pin 19)

towards engine so that pin 19) enters hole

in fuel injection pump drive gear 20).

* When lock pin 19) is fully inserted in

the hole in gear 20), the dimension from

the tip of lock pin 19) to housing 23) is

approx. 6 mm.

4) In this position, check position of line 18)

on coupling block and line 21) on pump

housing.

A Never try to crank the engine by force

when the pin is inserted.

5) If the lines in Step 4) are not correct, adjust

as follows.

i)

ii)

iii)

Loosen bolt I 1) and flange coupling

bolts and nuts 14) at two places.

Rotate coupling block 22) and align line

21) on fuel injection pump housing with

line 18) on coupling block completely.

Tighten bolt 11) and flange coupling

bolts and nuts 14) again.

Mounting bolt, nut 14):

D155AX-3, LW500- 1)

58.8 - 63.7 Nm I6.0 - 6.5 kgm}

HD325 Electronic governor

specification KP-21))

147 - 166.6 Nm I15 - 17 kgm1

Other models)

83.3 - 93.1 Nm I8.5 - 9.5 kgm}

Mounting bolt I 1):

HD325 Electronic governor

specification KP-21))

206 - 225 Nm I21 - 23 kgm}

Other models)

83.3 - 93.1 Nm 8.5 - 9.5 kgm}

6) Pull lock pin 19) out from hole in gear 20).

or If pin 19) is stiff, tighten nut 15) before

pulling the pin out.

Ir Pull the pin out completely to a point

where it does not move.

CEE 258

7) Tighten nut 15).

8) Install pin 24).

13 49

0




GENERAL ASSEMBLY

37.

Fuel injection tube

Install fuel injection tube 4).

m Sleeve nut Fuel injection pump end)

22.5 - 24.5 Nm l2.3 - 2.5 kgm1

38.

After-cooler assembly Intake manifold

assembly)

1) Fit gasket, sling after-cooler assembly 2) and

tighten mounting bolts 3).

Ir Tighten bolts in order shown in diagram

at right.

m Mounting bolt:

58.8 - 73.5 Nm 6 - 7.5 kgm1

2) Install clamp 1) of fuel injection tube.

39.

Exhaust manifold

Fit gasket and install exhaust manifold 2), then

tighten with mounting bolts I).

Ir Firstly tighten mounting bolts in order @ to

@ shown in diagram, then tighten other

bolts.

m Mounting bolt:

58.8 - 73.5 Nm {6 - 7.5 kgm1

I

CEW00552

I

CEE00259

13 50

0




GENERAL ASSEMBLY

40.

Turbocharger

Fit gasket and install turbocharger 2) with

mounting bolts I).

m Mounting bolt and nut:

44.1 - 49.0 Nm i4.5 - 5.0 kgml

41.

Fuel hose

Fit gasket on both sides and install fuel hose 5).

42. Dipstick guide, air compressor

1

2

3)

Fit e-ring and install air compressor

mounting plate 4). If equipped.)

Fit O-ring and install air compressor 31, then

install lubrication tube 2). If equipped.)

Install dipstick guide 1).

:

6

43

Alternator assembly, pulley

I

2

3)

4)

5)

6)

7)

Install pulley IO) and tighten with mounting

bolt 9).

Install alternator assembly 6) with bolt 1).

* Temporarily tighten bolt I).

Install bracket 8).

Install adjustment rod 7) with bolts 2) and

3).

or Temporarily tighten bolts 2) and 3).

+ Loosen 2 adjustment nuts 4).

Install alternator belts 5).

Adjust belt tension with adjustment nuts 4)

that deflection is 13 - 16 mm when pushed

with a force 98 N {IO kg}.

Tighten bolts I), 2) and 3).

CDE00145




GENERAL ASSEMBLY

44.

45.

46.

47.

Fan pulley assembly

Install fan pulley assembly then secure with bolts

I).

Tension pulley assembly

1

2)

3)

Install tension pulley assembly 5) with

mounting bolts 4).

Set fan belt 3) on groove of pulley.

Adjust fan belt tension with tightening

adjustment bolt 2) and move tension pulley

toward outside that deflection is 13 - 15 mm

new belt) or 17 - 19 mm when tension

adjustment) when push a force 98 N {IO kg}

at middle of fan belt 3), then tighten locknut

I). Machine without auto-tension)

Intake connector

1

2

Fit gasket to electrical intake air heater 5)

and intake connector 41, then install with

mounting bolts 3).

Install turbocharger lubrication inlet tube 21,

and secure with clamp I).

Muffler bracket, air cleaner bracket

Install muffler bracket 2) and air cleaner bracket

I).

CEE 144

I

CDE 139




GENERAL ASSEMBLY


1) Install air compressor tubes. if equipped)

2) install tubes 4) and 5).

3) Install corrosion resistor assembly 3).

4) Install hoses 2) and 1).

49. Resetting engine in engine stand

1

2

3)

Sling engine assembly, remove bolts

connecting tool A and tool B to disconnect

engine assembly.

Set engine assembly on engine stand or

block.

Remove tool A.

50

51.

Turbocharger drain tube

Fit gasket and install turbocharger drain tube

1).

Starting motor

Fit gasket and install starting motor 2) wit

mounting bolts 1).

CDE 138




GENERAL ASSEMBLY

52. Air cleaner, muffler

1)

2)

3)

4)

5)

*

Install exhaust connector 9).

Fit gasket and install muffler 8) with

mounting bolts 6), then secure with band

7).

Fit gasket and install valves 5).

Install air cleaner 4) and install hose 2)

between air cleaner and turbocharger and

hose I) between air cleaner and muffler,

then tighten mounting bolt of band 3).

w Band mounting bolt:

9.8 - 11.76 Nm Il.0 - 1.2 kgm}

For the Komaclone type air cleaner, install

precleaner 11) to air cleaner body 10).

Tighten until clearance a is 0.

53. Refilling with oil

I) Check that engine drain plug is tightened.

2) Add engine oil through oil filler to the

specified level.

Q

Engine oil pan: Approx. 37 L?

‘2

11

+

6 c

IO

CEE 26




Turbocharger............................................ 14- 2

Engine body

Cylinder head ........................................... 14- 6Valve, valve guide ....................................14- 8

Rocker arm and shaft ...............................14- 10

Crosshead and guide ...............................14- 11

Cylinder block........................................... 14- 12

Cylinder liner ............................................ 14- 13

Crankshaft................................................ 14- 14

Camshaft .................................................. 14- 15

Cam follower and push rod ...................... 14- 16

Timing gear .............................................. 14- 18

Piston ....................................................... 14- 20

Connecting rod......................................... 14- 22

Flywheel and flywheel housing.................14- 23

Lubrication system

Oil pump................................................... 14- 24

Regulator valve, piston cooling valve

and safety valve................................ 14- 26

Oil cooler ..................................................14- 27

Cooling system

Water pump.............................................. 14- 28

Thermostat ............................................... 14- 31

14 Maintenance standard



Maintenance standard Intake and exhaust system


Turbocharger

KTR110

S6D140-2

SA6D140-2

SAA6D140-2




Unit: mm

No. Check item Criteria Remedy

1 End play (Play in axial direction)

Standard Repair limit Replace parts

related to

thrust0.08 – 0.13 0.18

2 Radial play (Play in radial direction) 0.25 – 0.44 0.60

Replace parts

related to

bearing

3Outside diameter or journal bearing.

Inner diameter of center housing.

Standard

size

Tolerance Repair limit

Replace

Shaft Hole Shaft Hole

25 –0.050 –0.067

+0.021+0.021

24.92 25.03

4

Inner diameter of journal bearing.

Outside diameter of wheel shaft17

–0.032

–0.043

+0.009

–0.00316.95 17.04

Curvature of wheel shaft Repair limit: 0.010 (total deflection of indicator)

5 Thickness of thrust bearing

Standard

size


Width Groove Width Groove

5 –0.08

–0.10

+0.02

+0.024.86 5.04

6Thickness

of seal ring

Standard

size


Turbine

side

Ring 2.3 –0.08

–0.102.15

Groove 2.3 –0.01

–0.022.35

Blower

side

Ring 2 –0.08

–0.101.85

Groove

1 Ring 2 –0.03

–0.042.05

2 Ring 4 –0.11

–0.124.05

7Clearance between blower housing

and impellerClearance limit: (Min.) 0.20

Replace parts

related to

b i




KTR110L

SDA6D140E-2 (D275A-5, –50°C spec.)




Unit: mm


1 End play (Play in axial direction)

Standard Repair limit Replace parts

related to

thrust0.08 – 0.13 0.18

2 Radial play (Play in radial direction) 0.25 – 0.44 0.60

Replace parts

related to

bearing

3Outside diameter or journal bearing.

Inner diameter of center housing.

Standard

size


Replace

Shaft Hole Shaft Hole

25 –0.050 –0.067

+0.021+0.021

24.92 25.03

4

Inner diameter of journal bearing.

Outside diameter of wheel shaft17

–0.032

–0.043

+0.009

–0.00316.95 17.04

Curvature of wheel shaft Repair limit: 0.010 (total deflection of indicator)

5 Thickness of thrust bearing

Standard

size


Width Groove Width Groove

5 –0.08

–0.10

+0.02

+0.024.86 5.04

6Thickness

of seal ring

Standard

size


Turbine

side

Ring 2.3 –0.08

–0.102.15

Groove 2.3 –0.01

–0.022.35

Blower

side

Ring 2 –0.08

–0.101.85

Groove

1 Ring 2 –0.03

–0.042.05

2 Ring 4 –0.11

–0.124.05

7Clearance between blower housing

and impellerClearance limit: (Min.) 0.20

Replace parts

related to

b i



Maintenance standard Engine body

Engine body

Cylinder head




Unit: mm


1Distortion of cylinder head

mounting surface

Standard Repair limit Repair by

grinding or

replace0 – 0.06 0.09

2 Protrusion of nozzle

Engine Standard

Replace

nozzle or

cylinder head

6D140-2 4.8 – 5.6

S6D140-2, SA6D140-2,

SAA6D140-24.8 – 5.6

3

Tightening torque of cylinder

head mounting bolt (Coat the

thread areas with molybde-

num disulfide or engine oil)

Bolt No. Order Target

(Nm {kgm})

Range

(Nm {kgm})

Tighten in

sequence as

indicated

above

(1) – (6)

1st step 147 {15}137 – 157

{14 – 16}

2nd step 216 {22}211 – 221

{21.5 – 22.5}

3rd stepRetighten with

90 °90° – 120°

(7) — 68.6 {7}58.8 – 73.6

{6 – 7.5}

4Tightening torque of nozzle

holder mounting bolt

Target (Nm {kgm}) Range (Nm {kgm})

Retighten

66.7 {6.8} 58.8 – 73.6 {6 – 7.5}

5Tightening torque of fuel inlet

connector 37.3 {3.8} 34.3 – 40.2 {3.5 – 4.1}

6Tightening torque of

connector pipe locknut39.2 {4} 34.3 – 44.1 {3.5 – 4.5}

7Tightening torque of cylinder

head cover mounting bolt4.9 {0.5} 3.9 – 5.9 {0.4 – 0.6}




Valve, valve guide




Unit: mm

Note 1: Valve springs marked with *1 have a regular pitch.

Note 2: Valve springs marked with *2 have an irregular pitch


1 Amount of valve sinking

Valve Standard size Tolerance Repair limit

Replace valve

or valve seatIntake valve 0 ±0.10 0.70

Exhaust valve 0 ±0.10 0.70

2 Thickness of valve lip

Valve Standard size Repair limit

Replace valveIntake valve 2.4 1.9

Exhaust valve 2.15 1.75

3 Valve seat angle

Valve Standard size ToleranceRepair or

replace valve

and valve seat

Intake valve 30° ±0°15'

Exhaust valve 45° ±0°15'

4

Outside diameter of valve

stem

Intake valve 10 –0.045

–0.060Replace valve

Exhaust valve 10 –0.075

–0.090

Inside diameter of valve guide

Before inserting 10+0.019

+0.001 Replace valve

guide After inserting 10 +0.019 –0.020

Clearance between valve

guide and valve stem

Valve Standard clearance Clearance limit

Replace valve

or valve guideIntake valve 0.029 – 0.084 0.22

Exhaust valve 0.065 – 0.100 0.24

Bend of valve stem Repair limit: 0.02 (Total indicated runout, for 100) Replace valve

5 Protrusion of valve guideStandard size Tolerance

Repair 23 ±0.2

6

Free length of valve spring

Spring Standard size Repair limit

Replace valve

spring

Large *1 82.2 *2 81.7 —

Small *1 65.5 *2 72.0 —

Installed load of valve spring

SpringInstalled

length

Standard installed

load (N {kg})

Installed load limit

(N {kg})

Large 51.0*1

474±23.5

{48.4±2.4}

*2

424.3±21.6

{43.3±2.2}

*1

450.8

{46.0}

*2

377.3

{38.5}

Small 43.6*1

231.3±11.8

{23.6±1.2}

*2

215.6±10.8

{22.0±1.1}

*1

207.8

{21.2}

*2

192.1

{19.6}

Squarence of valve spring Repair limit: 2° (for both end)




Rocker arm and shaft

Unit: mm


1

Outside diameter of rocker

arm shaft

Standard size Tolerance Replace

rocker arm

shaft32.0 ±0.0065

Inside diameter of rocker arm

bushing32.0

+0.087

+0.035

Replace

rocker arm

Clearance between rocker

arm shaft and rocker arm

bushing

Standard clearance Clearance limit Replace

rocker arm or

rocker arm

shaft0.0285 – 0.0935 0.13

2Valve clearance


Valve Standard size Tolerance

AdjustIntake 0.43 ±0.02

Exhaust 0.80 ±0.02

3Tightening torque of rocker

arm adjustment screw locknut

Target (Nm {kgm}) Range (Nm {kgm})

Retighten58.8 53.0 – 64.7 {5.4 – 6.6}




Crosshead and guide

Unit: mm


1 Depth of crosshead stem

Standard size Tolerance Repair limit

Replace

3+0.3

+0.33.41

2

Inside diameter of crosshead 11±0.06

±0.0211.17

Outside diameter of

crosshead guide11

+0.011

+0.01110.95

3 Protrusion of crosshead guide 49.0 ±0.25 — Repair




Cylinder block

Unit: mm


1Distortion of cylinder head

mounting surface

Standard size Repair limit Repair by

grinding or

replace0 – 0.09 0.135

2

Inside diameter of main

bearing hole

Standard size ToleranceReplace main

bearing cap127+0.018

–0.006

Thickness of main bearing 3.5 –0.010

–0.010 Replace mainbearingRoundness of main bearing

holeRepair limit: 0.005

3Inside diameter of main

bearing

Standard size Tolerance Repair limitReplace main

bearing120+0.038

–0.006120.15

4Inside diameter of camshaft

bushing hole69

+0.030

+0.030—

Repair or

replace

cylinder block

5Inside diameter of camshaft

bushing65

+0.040

+0.03065.15

Replace cam-

shaft bushing

6Difference of face between

cylinder block and front cover Repair limit: 0.14

Repair by

reassembling

7

Tightening torque of main

bearing cap bolt

(Coat thread area with engine

oil)

Order Target (Nm{kgm}) Range (Nm{kgm})

Retighten

1st step 117.7 {12}107.9 – 127.5

{11 – 13}

2nd step 215.7 {22}210.8 – 220.7

{21.5 – 22.5}

3rd step Retighten with 90° 90 – 120°

8

Tightening torque of oil pan

mounting bolt and under frame

mounting bolt

Target (Nm {kgm}) Range (Nm{kgm})

66.7 {6.8} 58.8 – 73.6 {6 – 7.5}

9Tightening torque of crank

ll ti b lt274.6 {28} 245.2 – 308.9 {25 – 31.5}




Cylinder liner

Unit: mm


1 Protrusion of cylinder liner Permissible range: 0.07 – 0.15

Replace cylin-

der liner or

cylinder block

2

Inside diameter of cylinder

liner

Rank Standard size Tolerance Repair limit

Replace

cylinder

liner

S 140+0.020

+0.020140.12

L 140 +0.040+0.021

140.14

Roundness of cylinder liner Repair limit: 0.08

Cylindricity of cylinder liner Repair limit: 0.08

3

Outside diameter of cylinder

liner (Counter bore)

Standard size Tolerance

170.2 –0.10

–0.10

Clearance between cylinder

liner and block (Counter bore)Standard: 0 – 0.163

Replace cylin-

der liner or

cylinder block

4


liner (Counter bore bottom)

Standard size Tolerance Replacecylinder

liner 161.2+0.090

+0.050

Interference between

cylinder liner and block

(Counter bore bottom)

Standard interference Interference limit Replace cylin-

der liner or

cylinder block,

or repair 0.02 – 0.12 0.02

5


liner (O-ring)


cylinder

liner 158 –0.024

–0.049

Clearance between cylinder

liner and block (O-ring)Standard: 0.024 – 0.089

Replace cylin-der liner or

cylinder block




Crankshaft

Unit: mm


1 End play

Standard size Repair limitRepair by

using over

size thrust

bearing or

replace0.140 – 0.315 0.50

2

Outside diameter of main

journal


Repair by

using over

size bearing or

replace

STD 120.00

–0.050

–0.068

119.88

0.25 U.S. 119.75 119.63

0.50 U.S. 119.50 119.38

0.75 U.S. 119.25 119.13

1.00 U.S. 119.00 118.88

Roundness of main journalStandard size Repair limit

0 – 0.010 0.020

Clearance of main journalStandard clearance Clearance limit Replace main

bearing0.044 – 0.106 0.27

3

Outside diameter of crank pin

journal


Repair by

using under

size bearing or

replace

STD 90.00

–0.050

–0.068

89.88

0.25 U.S. 89.75 89.63

0.50 U.S. 89.50 89.38

0.75 U.S. 89.25 89.13

1.00 U.S. 89.00 88.88

Roundness of crank pin

journal

Standard size Repair limit

0 – 0.010 0.020

Clearance of crank pin journal


connecting rod

bearing0.042 – 0.110 0.24

4

Straightness of all main

journals

Standard size Repair limitRepair by

using under

size bearing or

replace

0 – 0.150 0.20

Straightness of two main journals

0 – 0.050 0.10




Camshaft

Unit: mm


1 End playStandard size Repair limit Replace

thrust plate0.1 – 0.25 0.36

2

Outside diameter of camshaft

journal

Standard size ToleranceReplace

camshaft65 –0.016

–0.036

Clearance of camshaft journalStandard clearance Clearance limit Replace

camshaft

bushing0.016 – 0.096 0.15

3 Bend of camshaft Repair limit: 0.03 (Total indicated runout)

Replace

camshaft4 Cam height

Cam Standard size Tolerance Repair limit

Intake 55.48 ±0.1 55.08

Exhaust 55.75 ±0.1 55.35




Cam follower and push rod

Unit: mm


1

Outside diameter of cam

follower shaft


Replace

22 –0.021

–0.03421.92

Inside diameter of cam

follower shaft hole22

+0.021

+0.02122.07

2 Outside diameter of cam roller 31.7+0.05

+0.0231.50

3

Inside diameter of cam roller 12.7+0.038

+0.01312.78

Outside diameter of cam roller

pin12.63 ±0.006 12.56

4 Radius of push rod ball end

Standard size Tolerance

12.7 –0.20

–0.20

5Radius of push rod socket

end

13.4 –0.20

–0.206 Bend of push rod Repair limit: 0.3 (Total indicated runout)




Timing gear




Unit: mm


— Backlash of each gears

Measuring

pointGears

Standard

size

Repair

limit

Replace

ACrankshaft gear and main idler

gear (Large)

0.141 –

0.425

0.6

BMain idler gear (Small) and

injection pump drive gear

0.129 –

0.391

CMain idler gear (Small) and

camshaft gear

0.129 –

0.391

aMain idler gear (Large) and sub

idler gear

0.141 –

0.426

bSub idler gear and oil pump drive

gear

0.080 –

0.417

c Sub idler gear and water pumpdrive gear

0.095 –0.346

dCamshaft gear and air

compressor drive gear

0.118 –

0.369

eInjection pump drive gear and

PTO gear (Lower)

0.118 –

0.369

f Compressor drive gear and PTO

gear (Upper)

0.025 –

0.486

1

Clearance between main idler

gear bushing and shaft

EngineStandard

size

Tolerance Standard

clearance

Clearance

limit

Replace

bushing

Shaft Hole

S6D140 47.6+0.014

+0.001

+0.085

+0.030

0.016 –

0.084 0.20

SA6D140 56 –0.016

–0.029

+0.055

+0.055

0.016 –

0.0840.20

2Clearance between sub idler

gear bushing and shaft

S6D140 47.6+0.014

+0.001

+0.085

+0.030

0.016 –

0.0840.20

SA6D140 56 –0.016

–0.029

+0.055

+0.055

0.016 –

0.0840.20

3 End play of main idler gear Standard size Repair limit

Replace

thrust

bearing

0.05 – 0.17 0.4

4 End play of sub idler gear 0.05 – 0.17 0.4

5End play of injection pump

drive gear 0.07 – 0.20 0.4




Piston




Unit: mm


1 Outside diameter of piston

Rank Standard size Tolerance Repair limit

Replace

piston

S 140 –0.070

–0.085139.81

L 140 –0.055

–0.070

2|

4

Thickness of piston ring

No. Measuring point Standard size Tolerance

Replace

piston ring

2 Top ring 2.4 –0.015 –0.035

3 Second ring 2.41 –0.010

–0.035

4 Oil ring 4 –0.010

–0.030

Width of piston ring groove

2 Top ringJudge using groove wear gauge

Replace

piston

3 Second ring

4 Oil ring 4+0.040

+0.020

Clearance between piston ring

and ring groove

No. Measuring point Standard clearance Clearance limit

Replace

piston or

piston ring

2 Top ringJudge using groove wear gauge

3 Second ring

4 Oil ring 0.02 – 0.06 0.14

Piston ring gap

2 Top ring

0.42 – 0.57

(Tension

16.5 – 23.5 N

{1.68 – 2.40 kg})

2.0

Replace

piston ring or

cylinder liner

3 Second ring

0.65 – 0.80

(Tension

16.2 – 24.2 N

{1.65 – 2.47 kg})

1.5

4 Oil ring

0.37 – 0.52

(Tension

55.9 – 75.5 N

{5.7 – 7.7 kg})

1.0

5

Outside diameter of piston pin


piston pin52 –0.006

–0.006

Inside diameter of piston pin

hole52

+0.045

+0.035

Replace

piston

Clearance between piston pin

and piston


piston orpiston pin0.035 – 0.051 0.10




Connecting rod

Unit: mm

a Note: The connecting rod bolt can be re-used up to a maximum of 5 times. Each time the bolt is re-used,


1

Inside diameter of bushing at

connecting rod small end

(Treat with reamer after press

fitting bushing)

Standard size Tolerance Repair limit Replace bushing

(New part is sup-

plied as a semi-

finished part)52

+0.049

+0.03052.09

Clearance between bushing at

connecting rod small end and

piston pin


bushing or

piston pin0.030 – 0.055 0.11

2Inside diameter of bushing hole

at connecting rod small end


connecting

rod57.4+0.030

+0.030

3Inside diameter of bearing at

connecting rod big end

Standard size Tolerance Repair limitReplace

bearing90+0.042

–0.00890.15

4

Inside diameter of bearing hole

at connecting rod big end

(a Measure after tightening

connecting rod cap bolt

with specified torque)


connecting

rod95+0.026

–0.004

Thickness of connecting rod

bearing

Standard size Tolerance Repair limitReplace

bearing2.5+0.002

–0.008

—

5Parallelism and twist of

connecting rod

ItemStandard

size

Repair

limit Replace

connecting

rodParallelism 0 – 0.20 0.25

Twist 0 – 0.30 0.35

6

Tightening torque of connect-

ing rod cap mounting bolt

(Coat bolt threads and nut

seats with engine oil)

Standard size Target (Nm{kgm}) Repair (Nm{kgm})

Retighten1st step 127.5 {13}117.7 – 132.4

{12.5 – 13.5}

2nd step Retighten with 90° 90 – 120°

— Weight of connecting rod

Permissible range:

Variation between weights on the machine max. 154 g Replace




Flywheel and flywheel housing

Unit: mm


1Face runout of flywheel

housingRepair limit: 0.35

Repair 2Radial runout of flywheel

housingRepair limit: 0.30

3 Face runout of flywheel Repair limit: 0.20

4 Radial runout of flywheel Repair limit: 0.15

5

Tightening torque of flywheel

housing mounting bolts

(Coat thread areas with engine

oil)

Order Tightening order Target(Nm {kgm}) Range(Nm {kgm})

Retighten

1st step191.2

{19.5}147.1 – 235.4

{15 – 24}

2nd step274.6

{28.0}245.2 – 308.9

{25 – 31.5}

6

Tightening torque of flywheel

mounting bolts

(Coat thread areas with engine

oil)

Order Target

(Nm {kgm})

Range

(Nm {kgm})

1st step117.7

{12}112.8 – 122.6

{11.5 – 12.5}

2nd stepRetighten

with 90°90° – 120°



Maintenance standard Lubrication system

Lubrication system

Oil pump




Unit: mm


1 Axial clearance of pump gear

Standard

size

ToleranceStandard

clearance

Clearance

limit

Replace

Gear

thickness

Housing

depth

45 –0.025

–0.025

+0.067

+0.040

0.03 –

0.0880.10

2 Radial clearance of pump gear

Standardsize

Tolerance

Standardclearance

ClearancelimitGear

O.D.

Housing

I.D.

51.4 –0.15

–0.21

+0.06

+0.06

0.033 –

0.100.13

3Clearance between drive shaft

and pump body bushing

Standard

size

Tolerance Standard

clearance

Clearance

limit

Replace

bushing

Shaft Hole

18+0.106

+0.088

+0.173

+0.146

0.040 –

0.085

4Clearance between driven

shaft and driven gear bushing18

+0.090

+0.070

+0.147

+0.127

0.032 –

0.077

5Clearance between driven

shaft and body18

+0.090

+0.070

+0.129

+0.102

0.012 –

0.059

6Clearance between relief

valve and pump cover 16

–0.040

–0.060

+0.043

+0.043

0.040 –

0.103

7Interference between drive

shaft and oil pump drive gear

Standard

size

Tolerance Standard

interference

Interference

limit

Replace

Shaft Hole

18+0.106

+0.088

+0.065

+0.047

0.023 –

0.059—


gear and drive shaft18

+0.106

+0.088

+0.063

+0.028

0.025 –

0.078—

9Interference between driveshaft bushing and pump cover

21+0.090+0.065

+0.021+0.021

0.044 –0.090

—

10Interference between driven

shaft bushing and driven gear 21

+0.090

+0.065

+0.035

+0.035

0.030 –

0.090—

11Interference between driven

shaft and pump cover 18

+0.090

+0.070

+0.040

+0.022

0.030 –

0.068—

12 Main relief valve spring


ReplaceFree length

Installed

length

Installed

loadFree length

Installed

load

49.1 32.0126.4 N

{12.9 kg}

113.7 N

{11.6 kg}

13 Main relief valve set pressure Standard: 0.8 ± 0.05 MPa {8.0 ± 0.5 kg/cm2} Replace




Regulator valve, piston cooling valve and safety valve

Unit: mm


1Clearance between regulator

valve and body

Standard

size

Tolerance Standard

clearance

Clearance

limit Replace valve

or body

Shaft Hole

22+0.15

+0.12

+0.28

+0.220.07 – 0.16 —

2 Regulator valve spring


Replace springFree length

Installed

length

Installed

load (N{kg})Free length

Installed

load (N{kg})

83 7916.1

{1.64}—

15.1

{1.54}

3 Regulator valve set pressure 0.3 ± 0.02 MPa {3.2 ± 0.2 kg/cm

2

} Replace4 Safety valve set pressure 0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2}




Oil cooler

Unit: mm

a The figure in ( ) indicates the thermostat for fully open temperature 116°C.a There are two types of thermostat for the oil cooler (fully open temperature: 100°C and 116°C). For the

marine engine only the fully open temperature 100°C is applicable; for other models, either type can be used.


1

Lift of thermostat to fully open

position

Min 8 mm (soak in oil bath at 100°C (116°C) for 4 to 5 minutes to

check)

Replace

Opening/closing of thermostat

Valve must fully close when valve is soaked in oil bath for fully

open 100°C (116°C) and then soaked in oil bath for fully closed

85°C (110°C) for 4 to 5 minutes.



Maintenance standard Cooling system

Cooling system

Water pump

6D140-2

S6D140-2SA6D140-2

Unit: mm


1Interference between

impeller and shaft

Standard sizeTolerance Standard

interference

Replace

Shaft Hole

15.9 +0.018+0.005

–0.020 –0.050

0.025 – 0.068


gear and shaft25

+0.015

+0.002

–0.023

–0.0530.025 – 0.068

3Interference between pulley

flange and shaft25

+0.015

+0.002

–0.023

–0.0530.025 – 0.068

4Clearance between impeller

and bodyStandard clearance: 0.30 – 1.0 (Including end play)

5 Abrasion of seal ring in water

seal

Repair limit

A: 1.5




S6D140-2

SA6D140-2

SDA6D140E-2 (D275A-5, –50°C spec.)

Unit: mm



impeller and shaft

Standard sizeTolerance Standard

interference

Replace

Shaft Hole

16 –0.082 –0.095

–0.020 –0.150

0.025 – 0.068


gear and shaft28

+0.015

+0.002

–0.023

–0.0530.025 – 0.068

3Interference between pulley

flange and shaft25

+0.015

+0.002

–0.021

–0.0410.025 – 0.056




seal

Repair limit

A: 1.5




For aftercooler

SDA6D140E-2 (D275A-5, –50°C spec.)

Unit: mm



impeller and shaft

Standard size

Tolerance Standard

interference

Replace

Shaft Hole

15.9+0.018

+0.005

–0.020

–0.0500.025 – 0.068


gear and shaft20

+0.015

+0.002

–0.023

–0.0530.025 – 0.068




seal

Repair limit

A: 1.5




Thermostat

Unit: mm


1

Lift of thermostat to fully open

positionMin. 10 mm (soak in oil bath at 90°C for 4 to 5 minutes to check)

ReplaceOpening/closing of thermostat

Valve must fully close when valve is soaked in oil bath for fullyopen (90°C) and then soaked in oil bath for fully closed (71°C) for

4 to 5 minutes



Table of special tools .....................................15- 2

Cylinder head

Grinding of fitting face of cylinder head.... 15- 3

Replacing valve seat insert ......................15- 4Pressure test ............................................ 15- 9

Replacing valve guide ..............................15- 10

Replacing crosshead guide......................15- 11

Grinding valve .......................................... 15- 12

Cylinder block

Replacing cam bushing............................15- 13

Replacing crankshaft gear........................ 15- 16

Replacing cam gear ................................. 15- 17

Replacing flywheel ring gear ....................15- 18

Replacing connecting rod small

end bushing ......................................15- 19

Cylinder block parts .......................................15- 20

Testing and inspecting cylinder block ............15- 21

Correcting cylinder block top surface,

counterbore............................................. 15- 24

Replacing main bearing cap .......................... 15- 32

15 Repair and replacement of parts



Repair and replacement of parts Table of special tools

Table of special tools

Operation Symbol Part No. Part Name Q'ty Remarks

Checking inside diameter of

main bearing mounting hole JCommercially

available Alignment bar

Grinding counterbore K

1 79A-513-1710 Basic machine 1

2 79A-513-1780 Guide plate 1

3 79A-513-1820 Cutter plate 1

4 79A-513-1860 Cutter 1

5 79A-513-1940 Cutter set gauge 1

6 79A-513-1950 Micrometer 1

7 79A-513-1960 Driver plate 1

8 79A-513-2090 Driver shaft 1

9 79A-513-2110 Driver handle 1

10 79A-513-2120 Service package 1

11 79A-513-2130 Case 1

12 79A-513-2140 Basic machine 1

13 79A-513-2160 Cutter plate 1

14 79A-513-2230 Cutter 1

15 79A-513-2240 Remover pin 1

16 79A-513-2250 Case 1

17 79A-513-2260 Service package 118 79A-513-2270 Compound 1 Loctite

19 79A-513-2280 Primer 1 Loctite

20 79A-513-2320 Bushing 12



Repair and replacement of parts Cylinder head

Cylinder head

Grinding of fitting face ofcylinder head

1. Grinding

1) Remove the valve seat insert. See the

section of replacement of the valve seat

insert.

2) Remove the strain and corrosion of the

cylinder head by grinding them within the

allowable limit of the cylinder head height H,

then stamp the letter "R" on the left side of

the cylinder head.

a Cylinder head height H

Basic height: 105 ± 0.05 mm

a Limit after grinding: 104.65 mm

a Grinding height/time: 0.10 – 0.15 mma Roughness of ground surface: 6 S max.

a Change of cross level: 0.05 mm max.

a Grinding limit: 0.3 mm

a Height difference among cylinder heads

of each engine: 0.15 max.

3) Fit an oversize insert one rank larger. See

the section of replacing valve seat insert.

2. Check after grinding

Confirm that the sinking distance of the valve is

within the standard range. Grind for adjustment,

if necessary.a Standard sinking distance of valve:

0 ± 0.1 mm




Replacing valve seat insert

Special tools

1. Removal of valve seat insert

k When using a grinder to carry out this work, carryout a test run for one minute before starting the

operation to check that there is no abnormality.

• If the grindstone has been replaced, carry

out the test run 3 minutes.

k Check that there is no damage to the grindstone,

fit it to the grinder spindle so that there is play,

and wear safety glasses when using the grinder.

• When removing with a valve seat puller

1) Install grindstone to grinder .

2) Align the groove of sleeve with holder ,and insert.

a Adjust the position of the grinder with set

screw .

No. Part No. Part Name Q'ty

A 795-100-4800 Puller (valve seat) 1

B

1 790-101-5001 Push tool (KIT) 1

2 790-101-5081• Plate

(for intake valve)1

3 790-101-5071• Plate

(for exhaust valve)1

C

1

795-100-3003 Seat cutter (KIT) 1

795-100-3100 • Body ass'y 1

795-100-3200 • Micrometer 1

795-100-3300 • Gauge 1

795-100-3400 • Tool head 1

795-100-3601 • Head support 1

2 795-100-3710• Cutter (for oversize

machining)1

3 795-100-3720 • Cutter (for 30°) 1

4795-100-3730 • Cutter (for 45°) 1

795-100-4210 • Pilot (10.000 mm) 1

5

795-100-4220 • Pilot (10.010 mm) 1

795-100-4230 • Pilot (10.020 mm) 1

795-100-4240 • Pilot (10.030 mm) 1

HEE00081




3) Adjust the position of the grinder so that the

center of grindstone is at the center of

seat insert (1), then tighten the set screw to

fix the grinder in place.

4) Rotate the grindstone and move it slowly

until it contacts insert (1).

5) Press the grindstone lightly against the

inside face of the insert and make a groove

around the whole circumference of the

inside face of the insert.

a Depth of groove: Approx. 1 mm

6) Push the three claws (a) of puller head of

tool A inwards by hand, and fit into insert

(1).

7) Tighten screw to push the three claws

into the groove on the inside face of the

insert.

a When the claws are completely in

contact with the groove, stop tightening.

8) Insert bridge on the outside of the puller

head, set plates and on top of the

bridge, and tighten nut to pull out the

insert.

• When welding a bar to the insert to remove

1) Weld bar (1) (diameter: approx. 10 ø) of a

diameter 0.1 – 0.5 mm smaller than the

inside diameter of the insert to insert (2).

a Be careful not to deposit any of the

welding metal on the head itself.

2) When the temperature of the weld has

dropped to around room temperature, insert

a used valve (3) in the opposite direction,

and hit the face of the valve with a smallhammer to remove the insert.

a Be careful not to hit too hard, as any

excessive shock may cause the weld to

break off.




2. Press fitting valve seat insert

• When not grinding and correcting press-fit-

ting surface of valve seat insert

1) Using tools B1 and B2, or tools B1 and B3,

press fit standard valve seat insert (2) with a

press.

a Do not use a hammer to press fit.a Press-fitting force for valve seat insert

Intake side : Approx. 14.7 kN {1.5 ton}

Exhaust side: Approx. 14.7 kN {1.5 ton}

2) Check the insertion depth (h) of the insert

from the bottom surface of the cylinder

head.

a Insertion depth (h) of insert

Intake side : 2.2 mm

Exhaust side: 2.4 mm




3. Oversize machining of mounting hole for

valve seat insert

1) Using tools C1 and C2, grind the hole to the

one level larger oversize.

a Machine within an oversize range of 1.0

mm. If it is more than 1.0 mm, replace

the cylinder head.

• Method of machining insert and mounting hole

a Roughness of inside surface: Within 6.3 S

a Roughness at bottom of mounting hole:

Within 12.5 S

a Concentricity with valve guide inside surface:

Within 0.03 mm (TIR)

Insert ValveInsert Insert mounting hole

d h D1 D2 H

STDIntake 55.0 8.8 55.0 58.00 ± 0.2 11

Exhaust 52.0 8.6 52.0 55.00 ± 0.2 11

0.25 O.S.Intake 55.25 8.8 55.25 58.25 ± 0.2 11

Exhaust 52.25 8.6 52.25 55.25 ± 0.2 11

0.50 O.S.Intake 55.5 8.92 55.5 58.50 ± 0.2 11.12

Exhaust 52.5 8.72 52.5 55.50 ± 0.2 11.12

0.75 O.S

Intake 55.75 9.05 55.75 58.75 ± 0.2 11.25

Exhaust 52.75 8.85 52.75 55.75 ± 0.2 11.25

1.00 O.SIntake 56.0 9.18 56.0 59.00 ± 0.2 11.38

Exhaust 53.0 8.98 53.0 56.00 ± 0.2 11.38

+0.100+0.090

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.080+0.070

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.100+0.090

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.080+0.070

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.100+0.090

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.080+0.070

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.100+0.090

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.080+0.070

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.100+0.090

–0.1 –0.1

+0.019+0

–0.1 –0.1

+0.080+0.070

–0.1 –0.1

+0.019+0

–0.1 –0.1




4. Finishing insert seat surface

1) Using tools C1, and C3, and C4, finish the

surface of the insert seat to the dimensions

shown in the diagram below.

a When selecting a pilot C5 to insert into

the valve guide, choose one that gives

no clearance.• Intake valve

• Exhaust valve

2) Rub the seat surface with compound.

Width of finished face of exhaust valveinsert and width of contact with valve

5. Finish inspection

• Coat the seat surface of the new valve thinly

with red lead (minimum), insert it in the valve

guide, push lightly against the valve insert

surface, and rotate 10°. Check the valve

insert contact surface, and confirm that the

contact is uniform without any breaks.

• Or

Make marks with a pencil on the seat sur-

face of the new valve as shown in the dia-

gram below, insert it in the valve guide, push

lightly against the valve insert surface, and

rotate 10°. Check that the pencil marks have

been erased uniformly around the whole cir-

Unit’ mm

Unit: mm

Part No. 6210-11-1320 (S.T.D)

6210-19-1320 (0.25 O.S)

6210-18-1320 (0.50 O.S)

6210-17-1320 (0.75 O.S)

6210-16-1320 (1.00 O.S)

6210-11-1321 (S.T.D)

6210-19-1321 (0.25 O.S)

6210-18-1321 (0.50 O.S)

6210-17-1321 (0.75 O.S)

6210-16-1321 (1.00 O.S)

Width of finished surface A: 47.1 B: 1.5 A: 45.7 B: 2.5

Width of contact with valve

(when using master valve)C: 1.5 ± 0.2 C: 2.5 ± 0.2




Pressure test

• When corrections have been made around the

cylinder head, test the pressure as follows.

Special tools

1. Water pressure test

1) Assemble tool A and tool B, and connect

the hose to flange (1).

2) Apply water pressure (0.34 – 0.39 MPa {3.5

– 4.0 kg/cm 2}) for approx. 10 minutes, and

check that there is no leakage from around

the cylinder head.

a When carrying out this test, heat the whole

cylinder head and carry out the test with hot

water (80 – 95°C).

2. Air pressure test

1) Connect the compressor hose to flange (1).

2) Put the head in the container of water, apply

air pressure (0.29 – 0.34 MPa {3.0 – 3.5 kg/

cm2}) for approx. 30 seconds, and check

that there is no leakage in the water.

a If the above test shows any cracks around the

plate plugs, replace the cylinder head.


A 790-553-1600 Coolant tester kit 1

B 79A-471-1050 Pump assembly 1




Replacing valve guide

Special tools

1. Removal of valve guide

Using valve guide remover A, remove the valve

guide.

2. Press fitting valve guide

1) Press fit the valve guide until the tip of valve

guide driver B contacts the cylinder head.2) Measure the protrusion of the valve guide

and check that it is within the standard

range.

a Valve guide protrusion

Tolerance: 23 ± 0.2 mm


A 795-100-1520 Valve guide remover 1

B 795-130-1710 Valve guide driver 1




Replacing crosshead guide

Special tools

1. Removal of crosshead guide

Using crosshead guide puller A, remove the

crosshead guide.

1) As shown in the diagram, grip crosshead

guide with collet of puller.

2) Tighten collet with bolt , and lock sleeve

.

3) Turn nut , and pull out crosshead guide.

4) Remove any burrs or flashes from thecrosshead guide mount.

2. Press fitting crosshead guide

Using tool B, insert the crosshead guide in the

cylinder head, and use a copper bar or plastic

hammer to press fit until the protrusion is within

the permitted tolerance.

a Protrusion of crosshead guide

Tolerance: 49 ± 0.5 mm


A 795-140-6410 Crosshead guide puller 1

B 795-130-1310 Crosshead guide driver 1



Repair and replacement of parts Cylinder block

Cylinder block

Replacing cam bushing

Special tools

a When replacing the cam bushing, first remove

the blind plug at the rear of the cylinder block.

1. Removal of No. 1, 7 bushings

As shown in the diagram, assemble push tool

A2, collar A3, and push bar A1 of push tools A,

then hit the push bar to knock bushing (2) out

from cylinder block (1).

2. Removal of No. 2, 6 bushings

Assemble push bar A1, push tool A2, collar A3,

and guide A4 of push tool A, then hit the push

bar to knock bushing (3) out from cylinder block

(1).

3. Removal of No. 3, 4, 5 bushings

Assemble push bar A1, push tool A2, collar A3,

and guide A4 of push tool A, then hit the push

bar to knock bushing (4) out from cylinder block

(1).


A 795-213-1200 Push tool 1

A

1 795-213-1250 Push bar 1

2 795-213-1210 Push tool 1

3 795-213-1240 Collar 1

4 795-213-1230 Guide 1

5 792-103-0400 Grip 1




• Using inside gauge , measure the inside

diameter of the bushing.

• Check the clearance between the bushing and

shaft, and if the clearance is not within the spec-

ified range, or the shaft does not move smoothly,

correct the inside diameter of the bushing with a

reamer.

• When the inside diameter of the bushing has

been corrected with a reamer, clean all the

metal particles from the oil hole and oil

groove.

a Inside diameter of cam bushing: ø65 mm

a Clearance of camshaft journal: 0.016 – 0.096 mm

+0.06 –0




Replacing crankshaft gear

Special tools

1. Removal of Gear

Make a scratch in the surface at the root of the

teeth with a grinder, then assemble pullers

and , and turn the nut to remove the gear.

a If the gear cannot be removed in this way,

make a scratch in the surface at the root of

the teeth with a grinder, then heat the gear

with a burner and knock the gear out with a

copper rod.

a Be careful not to damage the shaft.

2. Press fitting gear

1) Check the gear mounting surface, key

groove, and flange surface, and if there are

any scratches, correct them wi th an

oilstone.

2) Knock a new key into the key groove of the

shaft.

3) Heat the gear for the specified time at thespecified shrink-fitting temperature.

a Crankshaft gear shrink-fitting temperature:

200°C

Heating time: Min. 30 minutes

4) Put the timing mark on the outside, then use

a hitting tool to press fit until the side face of

the gear is in close contact with the shaft

flange.

a Knock in quickly before the gear becomes

cool.


790-101-2800 Bearing puller 1790-101-2300 Push puller 1




Replacing cam gear

1. Removal of gear

Set the camshaft assembly on the press stand,

then push the camshaft to remove the gear.

kWhen setting the camshaft assembly on thepress stand, be careful not to get caught your

fingers between the press stand and the gear.

2. Press fitting gear

1) Check the gear mounting surface, key

groove, and flange surface, and if there are

any scratches, correct them with an oilstone.

2) Knock a new key into the key groove of the

shaft.

3) Assemble the thrust plate.

4) Heat the gear for the specified time at the

specified shrink-fitting temperature.a Crankshaft gear shrink-fitting temperature:

220 – 240°C


5) Put the timing mark on the outside, then use

a hitting tool to press fit until the side face of

the gear is in close contact with the shaft

flange.

a Knock in quickly before the gear becomes

cool.




Replacing flywheel ring gear

k Be careful not to let the flywheel fall and injure

you.

1. Removal of ring gear Make a scratch in the surface at the root of the

teeth with a grinder, then split with a chisel to

remove.

k Be careful when handling the grinder and

chisel.

2. Press fitting ring gear

1) Check the ring gear mounting surface, and if

there are any scratches, correct them with

an oilstone.

2) Heat the ring gear for the specified time atthe specified shrink-fitting temperature.

a Ring gear shrink-fitting temperature:

Max. 200°C


3) Set the chamfered face of the ring gear

facing the flywheel, and press fit until the

side face of the gear is in close contact with

the flywheel.




Replacing connecting rodsmall end bushing

Special tools

1. Removal of connecting rod bushing

1) Set the connecting rod to tool B3.

2) Using tool B1, remove the connecting rod

bushing with press.

a After removing the bushing, remove any

burrs or flashes, and clean the mounting

hole of the bushing.

2. Press fitting connecting rod bushing

1) Set connecting rod to tool B3.

2) Assemble connecting rod bushing in tool

B1, set tool B2 in position, then secure with

tool B4 so that it does not move.

a Align the oil hole of the connecting rod

bushing with the oil hole of the connecting

rod.

3) Push tool B1 with press, and press fit the

connecting rod bushing.

• The bushing is supplied as a semi-finished prod-uct, so the inside diameter is too small and the

piston pin will not go in.

Af ter press fi tt ing the bush ing, machine the

inside diameter of the bushing with a reamer or

honing machine in accordance with the mainte-

nance standard.

a After machining, clean all the metal particles

from the oil hole and oil groove.

No. Part No. Part Name Q'tyA 795-240-6400 Push tool (KIT) 1

B

1 795-240-6410 Push tool 1

2 795-240-6420 Push tool 1

3 795-240-6430 Block 1

4 01530-03912 Nut 1



Repair and replacement of parts Cylinder block parts

Cylinder block parts

1. Cylinder liner

2. Clevis seal

3. Cylinder liner O-ring

4. Cylinder block

5. Main bearing cap

6. Main bearing cap bolt

7. Camshaft bushing



Repair and replacement of parts Testing and inspecting cylinder block

Testing and inspecting cylinder block

Unit: mm

Sym-

bolInspection item Judgement standards Remedy

A. CracksCheck for cracks (external color check)

Cylinder head bolt hole portion, etc.Replace

B.Correction of contact at

packing portionReplace

C.Clearance from

cylinder liner

Replace cylinder

liner or cylinder

block

D.Inside diameter of

camshaft bushing

• Inside diameter

• Clearance from camshaft bearingReplace bushing

E. Protrusion of liner

Replace cylinder

liner or correct

cylinder block

F.

Depth of counterbore

and corrosion of

bottom surface

• Check for corrosion

Repair by

machining,

add shim

G.

Distortion, wear of

cylinder head mounting

surface

Repair by

machining

Check for water leakage caused by corrosion

Standard

size

Standard valueStandard

clearanceInside diameter of

cylinder block

Outside diameter

of cylinder block

158.00158.00 –

158.04

157.946 –

157.976

0.024 –

0.094

Standard size Standard value Standard limit

69 69.000 – 69.025 69.10

Standard clearance Clearance limit

0.016 – 0.096 0.15

Permissible range: 0.07 – 0.15

Standard size Standard value

11 11.00 – 11.05


Overall top surface of block: Max. 0.09

For one cylinder: Max. 0.05

0.135

0.100




H.

Inside diameter of main

bearing mounting hole

Replace

I.Fitting of main bearing

cap and cylinder block

J.

Inside diameter of

counterbore, outside

diameter of cylinder

liner flange

• Cylinder liner

Replace cylinder

liner

• Cylinder block

Correct cylinder

block sleeve

Unit: mm

Sym-

bolInspection item Judgement standards Remedy

• Tighten main bear-ing cap bolt tospecified torque

• Measure mainbearing cap matingsurface within up-and-down range of10°

Standard size Standard value Standard limit

127 127.000 – 127.025 —

Coaxiality of whole unit Max. 0.020

Coaxiality between neighboring holes Max. 0.013

Journal Standard fitting Clearance limit

No.1 – 7Interference

0.002 – 0.060—

Standard

size

Standard

value

Repair

limit

Top

step170.2

170.10 –

170.20—

Bottom

step161.2

161.25 –

161.29—

Standard

size

Standard

value

Repair

limit

Top

step170.2

170.200 –

170.263—

Bottom

step161.2

161.197 –

161.230—




Method of checking inside diameter of main

bearing mounting hole using alignment bar

• When checking the inside diameter of the main

bearing mounting hole using an alignment bar,

do as follows.

Tool J (alignment bar)

1. Set the cylinder block on a stand with the main

bearing cap mount at the top.

2. Coat the inside surface of the main bearing hole

of the cylinder block with engine oil.

a Remove the main bearing cap.

3. Set tool J (alignment bar) in the main bearing

hole of the cylinder block.

4. Install the main bearing cap, then tighten the

mounting bolts to the specified torque.

5. Check that tool J moves smoothly.

n t: mm

Standard dimension

Diameter 127

Roundness 0.005

Straightness 0.010

Length Min. 1,150



Repair and replacement of parts Correcting cylinder block top surface, counterbore

Correcting cylinder block top surface, counterbore

Flow for correction procedure

a When removing, installing, disassembling, or assembling the engine, see the DISASSEMBLY AND

ASSEMBLY section for details of the procedure.

a If the judgement for Item 9 is NO, go to (A). If the answer is NO again, go on to (B).




Grinding

• If there is strain or corrosion of the top surface of

the cylinder block, grind the top surface.

• If there are blackened portions on the cylinder

liner contact surface of the counterbore (particu-

larly in the front-to-rear direction), or there is

speckled wear, and these portions extend over more than half of the contact surface, or if grind-

ing has been carried out on the top surface, cor-

rect the counterbore.

1. Grinding top surface of cylinder block

1) Measure the wear and strain of the top

surface of the cylinder block, and if it is over

the repair limit, grind the top surface of the

cylinder block within the repair limit for

height d of the cylinder block.

a Guideline for grinding top surface of

cylinder block• When wear and corrosion on top

surface of cylinder block are the

same shape as the mark left by the

head gasket

• When wear amount a is more than

0.15 mm

Table 1

a When grinding with grindstone (reference)

Grindstone speed : 1650 – 1950 m/min

Table speed : 15 – 30 m/min

Amount of grinding

for one pass : 0.025 mm

Cross feed for one pass : 1 – 2 mmGrindstone : A461V

Grinding fluid : Water soluble

grinding fluid

Fig.1

Fig. 2

n t: mm

Standard

dimension

Repair

limit

Flatness of cylinder block(for one cylinder)

0.05 0.10

Height of cylinder block d 430.5 ± 0.04 430.0

Roughness of top surface of

cylinder blockWithin 12.5 S




2. Grinding counterbore

• After grinding the top surface of the cylinder

block, measure the depth of the ounterbore.

If necessary, correct the counterbore depth f

within the repair limit.

a Guideline for correcting counterbore

• If it is not within the standard dimension.• If there are blackened portions on the

cylinder liner contact surface of the

counterbore (particularly in the front-to-

rear direction), or there is speckled wear,

and these portions extend over more

than half of the contact surface.

• After correcting, if the counterbore depth

is within 14.05 – 15.525 mm, combine

with shims and adjust so that the

cylinder liner protrusion is 0.07 – 0.15

mm.

Table 2

• For the machining amount for counterbore depth

f, decide an amount that will bring protrusion e

of the cylinder liner within the standard value.

• When grinding within the repair limit in cases

where the counterbore depth f exceeds the stan-

dard dimension, set the machining amount so

that one shim can be used for each cylinder as

shown in the table below.

Table 3 [Reference]

Adjustment shims for counterbore depth

Unit: mm

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Part No. T tWeight

(kg)Remarks

6210-29-2260 1.50 0.025 0.023

6210-29-2250 0.80 0.025 0.012

6210-29-2240 0.50 0.025 0.008

6210-29-2230 0.26 0.025 0.004

6210-29-2220 0.20 0.020 0.003

6210-29-2210 0.16 0.016 0.002

Unit: mm

Standard

dimensionRepair limit

Counterbore depth f 11 12.525

Cylinder liner protrusion e — 0.07 – 0.15

Roughness of counterbore Within 12.5 S

Machined shape

In accordance with diagram

on right (detail diagram for

portion b)

+0.05+0




• Use tool K when grinding the counterbore.

Fig. 7

Fig. 8

Fig. 9




3. Checking and distinguishing after grinding

and correcting

• After grinding and correcting, check for

scratches on the flat surface around the

water and oil holes in the cylinder block top

surface.

• Remove all burrs and flashes completely.• After grinding the top surface, if the cylinder

block height d exceeds the standard

dimension (430.5 ± 0.04 mm), but is within

the repair limit (430.46 – 430.10 mm),

always use an oversize head gasket.

Table 4

Unit: mm

a To distinguish, the letters [OS] are stamped on

the plate.

• After correcting, stamp the top surface of the

cylinder block (rear of left bank) according to the

nature of the correction as shown in the table

below.

Table 5

(Size of letters: 5 – 10 mm)

Fig. 10

Fig. 11

Head gasket Part No. Plate thickness

S.T.D. 6210-17-1813 2.0

Oversize 6210-19-1813 2.4

Oversize head

gasketShim Stamp

P a r t s

u s e d

f o r c o r r e c t i o n — — Not needed

Q — OS

— Q SH

Q Q WS




4. Procedure for coating cylinder block top sur-

face deck with gasket sealant

• When pulling out the cylinder liner and press fit-

ting it again, coat the cylinder block top surface

deck (the cylinder liner flange contact surface of

the cylinder block) with gasket sealant (LG-6) as

follows.Use the same procedure when using a shim for

the deck.

1) Use a cloth to wipe off all the dirt and oil

from the cylinder block top surface deck and

cylinder liner flange contact surface.

2) Coat the position marked in the diagram

with LG-6.

• Diameter of line of gasket sealant:

2 – 3 mm

• Overlap of beginning and end of sealant:

6 ± 6 mm

a When using shims for deck

• After coating the bottom of the shim

thinly with LG-6, install it to the deck

portion of the cylinder block.

• Next, coat with LG-6 in the same

way as when not using shims.

3) Press fit the liner in the cylinder block.When doing this, coat the cylinder block

contact surface of the seal and O-ring with a

small amount of engine oil (SAE30) immedi-

ately before press fitting the liner.

a Do not coat with engine oil until

immediately before press fitting the

cylinder liner.

4) After setting the cylinder liner in the cylinder block, assemble a used head gasket and

temporarily tighten the cylinder head.

When doing this, tighten in the tightening

order shown in the diagram on the right.

3 Tightening torque:

147 ± 10 Nm {15 ± 1 kgm}

Fig. 12

Fig. 13

Fig. 14

Fig. 15




5) Loosen the cylinder head mounting bolts,

remove the cylinder head, then wipe off the

excess gasket sealant that has come out

from the counterbore.

a The gasket sealant that comes out may

cause deformation of the head gasket

grommet, so always carry out Steps 4)and 5) without fail.

a After carrying out Steps 4) and 5), use a

new head gasket to install the cylinder

head.

5. Standard for rebuilding cylinder liner O-ring

portion of cylinder block

• If the bushing of the cylinder liner O-ring of

the cylinder block has been corrected, make

the finishing dimensions as follows.

a Concentricity of in relation to standard :

Max. 0.05 mm

Table 6

Unit: mm

Fig. 16

Fig. 17

Fig. 18

No. Finishing dimensions

ø167

ø161.45 ± 0.25

ø160.67 ± 0.064

176 ± 0.25

184.94 ± 0.18

ø158

ø159.03 (Gauge diameter)

+0.040+0



Repair and replacement of parts Replacing main bearing cap

Replacing main bearing cap

• When replacing the main bearing cap, machine

the semi-finish product to the following dimen-

sions, then install.

Correction parts

1. Machining inside diameter of main bearing

cap

1) Remove the cylinder liner.

2) Install the replacement main bearing cap tothe cyl inder block, and t ighten to the

specified torque.

2 Main bearing cap mounting bolt:

Coat seat face of threaded

portion with engine oil

3 Main bearing cap mounting bolt:

Unit: Nm {kgm}

a Align the cylinder block and main

bearing cap notch.

3) Set a cylinder block mounting jig on the

table of a horizontal boring machine, fit the

cylinder liner mounting hole of the cylinder

block to the standard line on the jig, and

install the cylinder block.

4) Of the main bearing caps to be used again,take the one with the longest pitch and put a

dia l gauge in contact wi th the ins ide

diameter at two places to align the center of

the boring machine arbor.

Part No. Part Name

6215-29-1210 Main bearing caps other than No. 4, 7

6215-29-1230 No. 4 main bearing cap

6215-29-1250 No. 7 main bearing cap

Order Target Range

1st step 118 {12}108 – 128

{11 – 13}

2nd step 216 {22} 211 – 221{21.5 – 22.5}

3rd stepTighten a further

90°90°+30°

+0



Repair and replacement of parts Replacing main bearing cap

5) Check the machined inside diameter of

bearing cap (1) and grind a little at a time.

a Grind until the bit touches the inside

surface of cylinder block (2).

a Inside diameter of main bearing cap

i) Machining dimension

Tolerance: 127 mm

ii) Inside diameter of cap when main

bearing cap is tightened to specified

torque after machining

Tolerance: 127 mm

(Up-down range of 10° at mating

surface of main bearing cap)

a Finishing roughness: Within 10 S

a Do not grind the inside face of the

cylinder block.

2. Machining width of main bearing cap

(Only when machining No. 7 main bearing

cap)

1) Insert cast iron bushing , then pass arbor

through.

2) Install facing bit to the arbor.

3) Grind cap (1) until the bit touches the

cylinder block face.

4) Grind the opposite side in the same way.

a Roughness of thrust bearing mounting

surface: Within 12.5 S

a Do not grind the cylinder block.

a Width of main bearing cap

Tolerance: 43.970 – 44.000 mm

+0.025+0

+0.025 –0.010



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