SM 140-2 PDF

SEBM008608
DIESEL ENGINE
© 2003 1
All Rights Reserved
00-1
Printed in Japan 07-03(01) (8)
CONTENTS
No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 01-l
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 Mark Indication Action required
be taken to these pages according to the table below.
○ Page to be newly added Add
‡ Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGE
Time of Time of Time of Time of Time of

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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
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
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make 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.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• 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 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 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,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ 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.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
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 hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ 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)
★ 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)
★ 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)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ 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
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
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
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
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.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters 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.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade 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 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
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}
00-22
01 GENERAL
Applicable machine..................................... 01-1-1

Specifications ................................................ 01- 2
General assembly drawing ......................... 01- 4
Weight table ................................................. 01-14
Engine performance curve .......................... 01-17
621202
01-1
3
6
GENERAL APPLICABLE MACHINE
APPLICABLE MACHINE
fl Serial No. shows for engine serial No.
Engine Serial No. Applicable machine
GD825A-2 Motor grader
S6D140-2 WA500-3 Wheel loader
D155A-2, D155A-3, D155AX-3, D155AX-5 Bulldozer
D155C-1A (–30°C spec.), D355C-3 Bulldozer
PC1600SP-1 Hydraulic excavator
SA6D140-2 DCA400SSK-2 DENYO Generator
DCA-400SSK MQ Generator
J6D140E-G1-2 TAIYO DENKI Generator
621202
PC750-6, PC800-6, PC1800-6 Hydraulic excavator
HD325-6, HD405-6 Dump truck
SAA6D140-2
D275A-5 (–50°C spec.) Bulldozer
SDA6D140E-2
01-1-1
01-1-2
6
(8)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Engine model S6D140-2
Applicable machine GD825A-2 WA500-3
Number of cylinder — Bore × Stroke mm 6 — 140 × 165
Total piston displacement ¬ {cc} 15.2 {15,240}
Firing order 1–5–3–6–2–4
Overall length mm 1,593 1,787

Dimensions
Overall width mm 895 1,060
Overall height mm 2,060 1,670

(excluding exhaust pipe)
Overall height
mm — —
(including exhaust pipe)
Flywheel horsepower kW {HP}/rpm 209 {280}/2,100 236 {316}/2,100

Performance
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
621202
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 ZEXEL PE-P (PS3S) type
ZEXEL RSV centrifugal

Governor
all speed control type
Lubricating oil amount 38

¬
(refill capacity) (34)
Coolant amount ¬ (Engine side: 23)
Alternator 24V, 50A
Starting motor 24V, 11kW
Battery 12V 200Ah × 2 12V 170Ah × 2
Turboharger KOMATSU KTR110 type
Air compressor ZEXEL Reciprocation, —

1-cylinder type
Others — —
01-2
3
6
S6D140-2
621202
01-2-1
01-1
3
3
Engine model SA6D140-2

D155A-3, PC1600SP-1
Applicable machine D155AX-3 (2 engines)

Dimensions
Overall width mm 1,040 1,185

Overall height mm — —
Flywheel horsepower kW {HP}/rpm 225 {302}/1,900 316 {424}/1,800

(Net) (Net)

Performance
(Net)
621202
Fuel injection pump BOSCH PE-P (PS7S) type BOSCH PE-P (PS7S) type
BOSCH RSUV centrifugal, BOSCH RSV centrifugal,
Governor all speed type all speed type
Lubricating oil amount ¬ 42 38

(refill capacity) (37) (34)
Coolant amount ¬ (Engine only: 25) (Engine side: 25)
Alternator 24V, 35A 24V, 50A

24V, 50A (opt)
Starting motor 24V, 11kW 24V, 7.5kW
Battery 12V 170Ah × 2 12V 170Ah × 2
Turbocharger KOMATSU KTR110 type
Air compressor — ZEXEL Reciprocation,

1-cylinder type
Others With aftercooler
01-2-2
01-2
36
SA6D140-2
D155C-1A
D355C-3 D155A-2 D155AX-5 (–30°C spec.)
6 — 140 × 165
15.2 {15,240}
1–5–3–6–2–4
1,577 1,566 1,498 1,614
1,265 1,136 1,040 1,193
1,843 1,824 1,740 1,824
— — — —
265 {355}/2,000 253 {339}/2,000 232 {310}/1,900 255 {342}/2,000

(Net) (Net) (Net) (Gross)
1,570 {160}/1,400 1,608 {164}/1,400 1,610 {164}/1,250 1,490 {152}/1,400

(Net) (Net) (Net) (Gross)
2,200 – 2,280 2,200 – 2,280 2,100 2,190 – 2,290

621202
700 – 750 (engine set) 550 – 650 700 700 – 750

575 – 675 (on board)
203 {151} (Gross) 206 {153} 205 {153} 205 {151}
1,850 1,750 1,560 1,790
BOSCH PE-P (PS7S) type
BOSCH RSV centrifugal,

all speed type
42 42 78 42
(37) (37) (34) (37)
(Engine side: 25) (Engine side: 25) 23 (Engine side: 25)

(Engine only)
24V, 50A 24V, 35A 24V, 35A 24V, 50A
24V, 11kW x 2 24V, 11kW 24V, 11kW 24V, 11kW x 2
12V 200Ah x 2 12V 170Ah × 2 12V 170Ah x 2 12V 200Ah x 2
KOMATSU KOMATSU KOMATSU KOMATSU

KTR110 type KTR110 type KTR110 type KTR110 type
— — — —
With aftercooler With aftercooler With aftercooler With aftercooler
01-3
5
(8)
Applicable machine
Number of cylinder — Bore × Stroke mm
Total piston displacement ¬ {cc}
Firing order
Overall length mm
Dimensions
Overall width mm
Overall height mm
Overall height
mm
Flywheel horsepower kW {HP}/rpm

Performance
Maximum torque Nm {kgm}/rpm
High idling speed rpm
621202
Low idling speed rpm
Minimum fuel consumption ratio g/kW•h{g/HP•h}
Dry weight kg
Fuel injection pump
Governor
Lubricating oil amount

¬
(refill capacity)
Coolant amount ¬
Alternator
Starting motor
Battery
Turbocharger
Air compressor
Others
01-2
01-3-1
36
SA6D140-2
DCA400SSK-2 DCA-400SSK
(DENYO generator) (For MQ generator) J6D140E-G1-2
6 — 140 × 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}/1,500 271 {275}/1,500

(Net, 50Hz) (50Hz)
357 {478}/1,800 357 {478}/1,800 299 {303}/1,800
(Net, 60Hz) (Net, 60Hz) (60Hz)
— — —
Max. 1,570 (50Hz) Max. 1,890 (60Hz) Max. 1,575 (50Hz)
621202
Max. 1,880 (60Hz) Max. 1,890 (60Hz)

800 – 850 800 – 850 700 – 900
At rated At rated At rated
217 {162} (50Hz) 209 {156} (50Hz)
231 {172} (60Hz) 214 {160} (60Hz) 222 {166} (60Hz)
1,450 1,450 1,750
BOSCH PE-P (PS7S) type

BOSCH RSUV centrifugal,
all speed type
74 74 80
(67) (67) (73)
64 (Engine side: 27) (Engine66

only: 27)
24V, 50A 24V, 50A 24V, 35A (OPT)
24V, 7.5kW 24V, 7.5kW 24V, 7.5kW
12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2
KOMATSU KOMATSU KOMATSU

KTR110 type KTR110 type KTR110 type
— — —
With aftercooler With aftercooler With aftercooler
01-3-2
01-3
3
6
Engine model SAA6D140-2
Applicable machine PC750-6, PC800-6 HD325-6, HD405-6

Dimensions
Overall width mm 1,185 1,202

Overall height
mm — —
Flywheel horsepower kW {HP}/rpm 331 {444}/1,800 379 {508}/2,000 (Gross)

(Net) 364 {488}/2,000 (Net)
Performance

(Net) (Gross, Net)
621202
Fuel injection pump BOSCH PE-P (PS7S) type BOSCH PE-P (PS7S) type
BOSCH RSUV centrifugal, BOSCH RFD Min. –

Governor
all speed type max. speed control type
Lubricating oil amount 38 41

¬
(refill capacity) (32) (37)
Coolant amount ¬ (Engine only: 25) (Engine only: 25.5)
Alternator 24V, 50A 24V, 50A
24V, 7.5kW
Starting motor 24V, 11kW
24V, 11kW (opt)
Battery 12V 170Ah × 2 12V 170Ah × 2
Turbocharger KOMATSU KTR110 type KOMATSU KTR110 type

ZEXEL ZEXEL
Air compressor Single cylinder, Single cylinder,
reciprocation type reciprocation type
With air cooled
Others With air cooled aftercooler and
aftercooler retarder
01-4
01-3-3
3
6
SAA6D140-2 SDA6D140E-2
HD325-6 PC1800-6 D275A-5
(High altitude spec.) (2 engines) (–50°C spec.)
6 — 140 × 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}/1,800 332 {446}/2,000

(Net) (Gross)
1,750 {179}/1,400 2,100 {214}/1,350 2,030 {207}/1,400
(Net) (Gross)
2,350 – 2,400 1,930 – 2,030 2,150 – 2,250
621202
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. – BOSCH RSUV centrifugal, BOSCH RSUV centrifugal,

max. speed control type all speed type all speed type
41 38 62
(37) (32) (55)
(Engine only: 26) (Engine only: 25) (Engine only: 26)
24V, 50A 24V, 50A 24V, 75A
24V, 11kW 24V, 7.5kW 24V, 11kW × 2
12V 170Ah × 2 12V 170Ah × 2 12V 170Ah × 2
KOMATSU KTR110 type KOMATSU KTR110 type KOMATSU KTR110L type

ZEXEL ZEXEL —
Reciprocation, Reciprocation,
single cylinder type single cylinder type
(front engine only)
With air cooled With aftercooler
aftercooler and With air cooled
retarder aftercooler
* : At rated flywheel horsepower
01-3-4
01-5
3
7
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING * The specifications are subject to

change according to modification, etc.
SAGD140-2 LEFT SIDE VIEW (For D155A-3, D155AX-31
SDE00391
01-4
SAGD140-2 RIGHT SIDE VIEW (For D155A-3, D155AX-3)
SDE00392
01-5
SA6D140-2 FRONT VIEW (For D155A-3, D155AX-3)
SDE00393
01-6
SAGD140-2 REAR VIEW (For D155A-3, D155AX-3)
SDE00394
01-7
SAGD140-2 UPPER SIDE VIEW (For D155A-3, D155AX-3)
SDE00395
01-8
SAAGD140-2 LEFT SIDE VIEW (For PC750-6, PCSOO-6)
SDE00396
01-10
SAAGD140-2 RIGHT SIDE VIEW (For PC750-6, PCSOO-6)
L. /
SDE00397
01-7 1
SAAGD140-2 FRONT VIEW (For PC750-6, PCSOO-6)
c
c
r-
SDE00398
01-12
SAAGD140-2 REAR VIEW (For PC750-6, PCSOO-6)
v SDE00399
01-13
SDA6D140E-2 LEFT SIDE VIEW (For D275A-5, –50°C spec.)
621202
a. Crankshaft center
b. Flywheel housing rear surface
01-13-1
7
SDA6D140E-2 RIGHT SIDE VIEW (For D275A-5, –50°C spec.)

621202
a. Crankshaft center
b. Flywheel housing rear surface
01-13-2
7
SDA6D140E-2 FRONT VIEW (For D275A-5, –50°C spec.)
621202
c. Crankshaft center
d. Cylinder liner center
01-13-3
7
SDA6D140E-2 REAR VIEW (For D275A-5, –50°C spec.)

621202
c. Crankshaft center
d. Cylinder liner center
01-13-4
7
DIMENSION TABLE fl These dimensions are reference values for use

when installing to a test bench.
Dimensions for each part (mm)

Engine Machine model
A B C D E F G
D275A-5 (–50°C spec.) 1,461 1,056 2,084 — — — —
SDA6D140E-2
621202
01-13-5
7
GENERAL WEIGHT TABLE
WEIGHT TABLE
* The specifications may be different depending on the type of machine.
Unit: kg
No. Item Components S6D140-2
1 1 Turbocharger Komatsu KTRI 10

I 23
I
Cylinder head, valve, rocker arm,

2 Cylinder head assembly 19
valve spring I
Cylinder block, bearing cap,
3 Cylinder block assembly 400
cvlinder liner I I
4 Front cover 38
5 Oil pan 30
6o(GD825A-2,
WA5003)
6 Flywheel assembly Flywheel, ring gear
-
55(GD825A-2, WA50031
7 Flywheel housing -
8 Crankshaft assembly Crankshaft, crankshaft gear 136

:
9 Camshaft assembly Camshaft, camshaft gear, thrust plate 19 $
Piston and connecting Piston, piston ring, piston pin,

10 10.7 x 6
rod assem blv connecting rod
11 Oil pump 5.5
12 Fuel injection pump 20
13 Water pump 17
14 Alternator 24U, 35A -

24U. 50A 10
15 Starting motor 24U, 7.5 kW -
24U, 11 kW 19.5
16 Air compressor 11
17 Aftercooler assembly -
01-14
0
Unit: kg
No. Item Components SA6D140-2
1 Turbocharger Komatsu KTR110 23

2 Cylinder head assembly valve spring 19

3 Cylinder block assembly cylinder liner 400
4 Front cover 38
5 Oil pan 30
60 (D155A-2,3, AX-3, AX-5)
6 Flywheel assembly Flywheel, ring gear 54 (PC1600SP-1)

129 (DCA400SSK-2, J6D140E-G1-2 Generator)
55 (D155A-2,3, AX-3, AX-5)

7 Flywheel housing 52 (PC1600SP-1)
621202
52 (DCA400SSK-2 Generator)
9 Camshaft assembly Camshaft, camshaft gear, thrust plate 19

10 rod assembly connecting rod 10.7 × 6
11 Oil pump 5.5
21 (D155A-2,3, AX-3, AX-5)

12 Fuel injection pump 23 (Generator)
13 Water pump 17
24V, 35A, 25A 8.0

14 Alternator
24V, 50A 10
24V, 7.5 kW 18
15 Starting motor
24V, 11 kW 19.5
17 Aftercooler assembly 43
01-15
3
6
Unit: kg
No. Item Components SAA6D140-2 SDA6D140E-2
1 Turbocharger Komatsu KTR110 23

2 Cylinder head assembly valve spring 19

3 Cylinder block assembly cylinder liner 400
4 Front cover 38
5 Oil pan 30
55 (PC750-6, PC800-6)
6 Flywheel assembly Flywheel, ring gear
51 (HD325-6/405-6)
54 (PC750-6, PC800-6)
7 Flywheel housing
68 (HD325-6/405-6)
621202
9 Camshaft assembly Camshaft, camshaft gear, thrust plate 19

10 rod assembly connecting rod 10.7 × 6
11 Oil pump 5.5
12 Fuel injection pump 20
13 Water pump 17
24V, 35A 8
14 Alternator
24V, 50A 10
24V, 7.5 kW 18
15 Starting motor
24V, 11 kW 19.5
Air-cooled 37 (PC750, 800-6)

17 aftercooler assembly 35 (HD325-6/405-6)
01-16
7
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE
Engine Engine Serial No. Machine model Page

GD825A-2 01-17
S6D140-2
WA500-3 01-18
D155A-3, D155AX-3 01-19

PC1600SP-1 01-20
D155A-2 01-21
SA6D140-2
D355C-3 01-22
D155AX-5 01-22-1
D155C-1A (–30°C spec.) 01-26
HD325-6, HD405-6 01-23

SAA6D140-2
PC750-6, PC800-6, PC1800-6 01-24
D275A-5 (–50°C spec.) 01-25

SDA6D140E-2
621202
01-17
(8)
S6D140-2 for GD825A-2

Net flywheel horsepower: 209 kW {280 HP}/2,100 rpm
Net maximum torque: 1,250 Nm {128 kgm}/1,400 rpm
621202
01-17-1
7
S6D140-2 for WA500-3

Net flywheel horsepower: 236 kW (316 HPI/2,100 rpm
Net maximum torque: 1,370 Nm {I 40 kgm)/1,400 rpm
900 g
rs
L
60 600 :
a B
r Y
330-
240-
300-
300
210-
270-
270
240- 180- 240
ZIO- 210
150-
1
.z 180- 180
2
IZO-
150- 150
IZO- 90- 120
go- 90
60-
60- 60
30-
30- 30
o- o- n 2
.’ 600 800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rpm) SDE00959
01-18
a
SAGD140-2 for D155A-3, D155AX-3

Net flywheel horsepower: 225 kW (302 HPI/l,900 rpm
Net maximum torque: 1,432 Nm {I 46 kgm~/l,300 rpm
E
s s
150 -1500
120 -1200
go -900 QJ
3
0
L
60 -600 :
270
240
60
” \.
600 600 1000 1200 1400 1600 1600 2000 2200
Engine speed (rpm) SDE00960
01-19
0
SAGD140-2 for PC16OOSP-1

Net flywheel horsepower: 316 kW I424 HP)/1,800 rpm
Net maximum torque: 1,863 Nm (190 kgm}/l,400 rpm
200
150
100
I I I I I I I I Ill 0
3
% Y 2
350-
450- 450
\
400- 3cJO- 400 /
350- 350
250-
300- 300 /
zoo-
250- 250
200- 150- 200

/ I
150- 150
IOO-
loo- 100
50-
50- 50
o- o- 0 ::
600 600 1000 1200 1400 1600 1600 2000 2200
Engine speed (rpm) SrlE00961
01-20
0
SA6D140-2 for D155A-2

Flywheel horsepower: 253 kW (339 HPY2,OOO rpm (Net)
Maximum torque: 1,608 Nm (164 kgmY1,400 rpm (Net)
s I
180 1,800
120 1,200 ;
n
L
90 900 If
Q
1
360 270 60 600
330 300
240
300 3
210
270
240 180
2lCI-
150
t-
120
l-
I- 90
90I-
60
60
30
30
0 0
600 800 1.000 1.200 1.400 1,600 1,800
Ena i ne speed (rpm) SWE01337
01-21
0
SA6D140-2 for D355C-3

Flywheel horsepower: 265 kW (355 HPV2,OOO rpm (Net)
Maximum torque: 1,570 Nm 1160 kgmV1,400 rpm (Net)
200 2.000
t
150 1,500 z
CT
:
100 1.000 +
I
50 500
0 t0
p. P cn
r A 0.
400- 300-
350-
250-
: 300-
0
0
; 250- 200-
0
r
- 200- 150-
al
aa
AZ
'. 150-
LL IOO-
IOO-
50-
50-
o- o-
0 ,\
600 800 1.000 1.200 1,400 1.600 1.800 2.000 2.200
Ena i ne speed (rpm) SWE01346
01-22
0
SA6D140-2 for D155AX-5

Flywheel horsepower: 232 kW {320 HP}/1,900 rpm (Net)
Maximum torque: 1,610 Nm {164 kgm}/1,250 rpm (Net)
621202
01-22-1
6
SAAGD140-2 for HD325-6, HD4056

Flywheel horsepower: 379 kW (508 HPY2,OOO rpm (Gross), 364 kW 1488 HPY2,OOO rpm (Net)
Maximum torque: 2,170 Nm (221 kgm}/l,400 rpm (Gross, Net)
s
- 2,500
- 2.000
(u
=I
- 1,500 z
0
I-
- 1.000
7 500
-0
550-
400-
500- 500
350-
450- 450
L
g 400- 300- 400
0
P
z 350- 350
250-
z 300- 300
: 250- 200-
250
r
P
.z 200- 150-
LL
150-
IOO-
loo-
50-
50-
o- o-
” ” 400 600 800 1.000 1.200 1.400 1.600 1.800 2.000 2,200 2.400 2.600
En9 i ne speed (rpm) SWE01096
01-23
0
SAAGD 140-Z for PC750-6, PC800-6, PC1 800-6

Flywheel horsepower: 331 kW 1444 HPY1,800 rpm
Maximum torque: 2,099 Nm (214 kgm}/1,350 rpm
2
-2500
-2000
-1500 2
D
I
-1000 :
-500
a 3
xz 3
450- -0
350
450-
400- 300
350- 350
250
300- 300
ZJ 200
: 250- 250
:
200- 150
150-
100
too-
50
50-
0- 0 04) ’ I I I I I
600 600 1000 1200 1400 1600 1600 2000 2200
Eneine speed (rpm) SDE00963
01-24
0
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)
621202
01-25
7
SA6D140-2 for D155C-1A

Flywheel horsepower: 255 kW {342 HP}/2,000 rpm (Gross)
Maximum torque: 1,490 Nm {152 kgm}/1,400 rpm (Gross)
621202
01-26
(8)
11 STRUCTURE AND FUNCTION
INTAKE AND EXHAUST SYSTEM FUEL SYSTEM

Intake and exhaust system ................... 11- 2 Fuel system chart .................................. 11-44
Air cleaner .............................................. 11-15 Fuel injection pump ............................... 11-46
Turbocharger .......................................... 11-17 Feed pump ............................................. 11-52
Aftercooler .............................................. 11-18 Fuel injection nozzle .............................. 11-53
Fuel filter ................................................. 11-54
ENGINE BODY Engine stop motor ................................. 11-55
Cylinder head ......................................... 11-22
Cylinder block ........................................ 11-24 COOLING SYSTEM
Main circulation system ........................ 11-26 Cooling system chart ............................ 11-60
Vibration damper ................................... 11-28 Water pump ........................................... 11-62
Timing gear ............................................ 11-30 Thermostat ............................................. 11-66
621202
Valve system .......................................... 11-32 Corrosion resistor .................................. 11-67

Flywheel and flywheel housing ...........11-34 Cooling fan drive ................................... 11-69
LUBRICATION SYSTEM ACCESSORY

Lubrication system chart ...................... 11-36 Air compressor ...................................... 11-76
Oil pump ................................................. 11-38 Exhaust brake ......................................... 11-79
Regulator valve and piston
cooling valve .................................. 11-39 ELECTRICAL SYSTEM
Oil filter ................................................... 11-40 Alternator ................................................ 11-83
Oil cooler ................................................ 11-43 Starting motor ........................................ 11-88
Electrical intake air heater .................... 11-89
11-1
(8)
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM

* The specifications are subject to change
INTAKE AND EXHAUST SYSTEM according to modification, etc.
S6D140-2 for WA500-3
1. Bracket A. Intake
2. Muffler B. Exhaust
3. Check valve (to prevent exhaust gas from C. Dust (together with exhaust gas)
flowing back)
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
1l-2
a
I
I
i,
SDE00965
11-3
0
SA6D140-2 for D155A-3, D155AX-3 * The specifications are subject to change

(Left side view) according to modification, etc.
! SDE00407
1. Muffler A. Intake
2. Air cleaner B. Exhaust
3. Aftercooler assembly
4. Connector
11-4
SAGD140-2 for D155A-3, D155AX-3 f The specifications are subject to change

(Right side view) according to modification, etc.
I
SDE00408
1. O-ring 6. Connector
2. Air cleaner connector 7. Exhaust manifold (Front)
3. Precleaner 8. Drain tube
4. Turbocharger 9. Exhaust manifold (Center)
5. Seal ring IO. Exhaust manifold (Rear)
11-5
SA6D140-2 for D155A-3, D155AX-3 * The specifications are subject to change

(Intake system, front view) according to modification, etc.
SDE00409
1. Check valve (To prevent exhaust gas from C. Dust (together with exhaust gas)
flowing back)
2. Tube
3. Band assembly (air cleaner)
4. Connector (Crossover)
5. Valve
6. Connector
7. Electrical intake air heater (ribbon type)
8. Tube (aftercooler - cylinder block)
11-6
SAGD 140-2 for D 155A-3, D 155AX-3 * The specifications are subject to change
(Exhaust system, rear view) according to modification, etc.
4 SDE00410
1. Dust indicator
2. O-ring
3. Connector
4. Tube (cylinder block - aftercooler)
11-7
SAAGD140-2 for PC750-6, PC800-6 * The specifications are subject to change

SDE00411
1. Connector (air-cooled aftercooler - electrical A. Intake

intake air heater) B. Exhaust
2. Electrical intake air heater (ribbon type) C. Dust (together with exhaust gas)
3. Connector (electrical intake air heater - in-
take manifold)
4. Muffler
5. Check valve (to prevent exhaust gas from
flowing back)
6. Intake manifold
7. Air cleaner
8. Precleaner
11-8

4
SDE00412
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)
11-9
SAAGD 140-2 for PC750-6, PCSOO-6 * The specifications are subject to change
(Front view) according to modification, etc.
A. Intake air (turbocharger - air cooled

aftercooler)
B. Intake air (air cooled aftercooler -
electrical intake air heater)
11-10

(Rear view) according to modification, etc.
SDE00414
11-11
SAA6D140-2 for HD325-6 * The specifications are subject to change

SDE00415
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
11-12
SAAGD140-2 for HD325-6 Ir The specifications are subject to change

SDE00416
1. Exhaust brake (butterfly type) A. Intake

2. Turbocharger B. Exhaust
3. Exhaust connector C. Intake air (turbocharger - air-cooled
4. Exhaust manifold (front) aftercooler)
5. Exhaust manifold (center) D. Intake air (air-cooled aftercooler - electri-
6. Exhaust manifold (rear) cal intake air heater)
1 l-13
SAAGD140-2 for HD325-6

(Front view)
SDE00417
SAA6D140-2 for HD325-6

(Rear view)
SDE00418
1 I-14
AIR CLEANER fl The specifications may be different from the following

figure, depending on the type of machine.
KOMA-CLONE TYPE (AUTOMATIC DISCHARGE MULTICYCLONE TYPE)

621202
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
Applicable Dust discharging Number of

Engine model machine model Type method of precleaner cleaner element
S6D140-2 GD825A-2, WA500-3
KOMA-CLONE, Automatic discharge Inner element: 1
SA6D140-2 D155A-2,3, AX-3, AX-5
Multicyclone (Exhaust ejector) Outer element: 1
SAA6D140-2 PC750-6, PC800-6
11-15
3
6
AIR CLEANER * The specifications may be different from the following

figure, depending on the type of machine.
FHG, FTG TYPE (CYCLOPACK TYPE)
FHG type FTG type
I
SEE00420
1. Inlet 5. Safety element 9. Body

2. Outlet 6. Vacuator 10. Element
3. Guide vane 7. Dust pan
4. Primary element 8. Diffusion vane (sleeve)
ADVANTAGES STRUCTURE
mG tVpe . Air containing dust is sucked in from inlet
. The diameter of the element is the same but the (I) at a tangent, and the dust is separated
outside diameter of the body is smaller. by the centrifugal force of guide vane (3).
The inlet is placed in the direction of connec- More than 99.9% of the remaining dust is
tion, so ample centrifugal force can be obtained removed by primary element (41, and the
from a simple spiral guide vane, without using cleaned air then passes through safety
a diffusion vane. element (5) and outlet (21, ad is sucked
into the engine.
l The is no dust pan or diffusion vane, so the The dust and moisture that is separated
structure is simple. by guide vane (3) rotates around the in-
side wall of body (91, and goes inside
vacuator (61, where is discharged auto-
matically to the outside.
11-16
ERB TYPE fl Details may differ according to the machine

model.
621202
1. Precleaner A. Intake air port

2. Air cleaner casing B. To turbocharger (intake air port)
3. Outer element C. To muffler (dust)
4. Inner element
Dust discharge
Engine Machine model Type No. of elements
method for precleaner
Komaclone, multicyclone Automatic discharge Inner cylinder 1,
SDA6D140E-2 D275A-5 (–50°C spec.)
type (ERB type) (exhaust ejector) Outer cylinder 1
11-16-1
7
TURBOCHARGER
KTR110
S6D140-2
SA6D140-2
SAA6D140-2
621202
1. Blower housing 11. Seal ring TURBOCHARGER

2. V-band 12. Turbine impeller Type: KTR110
3. Defuser plate Overall length: 284 mm
4. Center housing A. Intake inlet Overall width: 305 mm
5. Shroud B. Intake outlet Overall height: 287 mm
6. Turbine housing C. Exhaust inlet Weight: 22.5 kg
7. Blower impeller D. Exhaust outlet
8. Seal ring E. Oil inlet
9. Thrust metal F. Oil outlet
10. Metal G. Cooling water
11-17
7
KTR110 (AIR-COOLED TYPE)

SDA6D140E-2 (D275A-5, –50°C spec.)
621202
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 mm
5. 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
11-17-1
7
AFTERCOOLER (Water-cooled type) Ir The specifications may be different

from the following figure, depending
on the type of machine.
SA6D140-2 (For construction machinery, generator)
;I
SDE00422
s:
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)
11-18
AFTERCOOLER (Air-cooled type) * The specifications are subject to change

according to modification, etc.
SAAGD140-2 for PC750-6, PC800-6
A-
L 4/I’
@
,’
I’
a
4 A-A
SDE00423
1. Tank a. Intake air port

2. Side support (Turbocharger ++ Intake manifold)
3. Tube
4. Fin
11-19
AFTERCOOLER (Air-cooled type) * The specifications are subject to change

SAAGD140-2 for HD325-6
A-
4 A-A
SEE00424
l. Tank a. Intake air port

2. Side support (Turbocharger tf Intake manifold)
3. Tube
4. Fin
11-20
ENGINE BODY
* The specifications may be different from

ENGINE BODY the following figure, depending on the
type of machine.
CYLINDER HEAD
u II /
I LJ!
? SDE00427
6. Cylinder head B. Intake

1. Rocker arm housing mounting bolt
7. Rocker arm housing cover C. Exhaust
2. Cylinder head mounting bolt
3. Air vent tube 8. Nozzle holder ass’y
9. Nozzle holder retainer d. To fuel tank
4. Fuel spill pipe
10. Nozzle connecter e. To radiator
5. Rocker arm housing
f. To rocker arm (Oil)
11-22
STRUCTURE AND FUNCTION ENGINE BODY
CYLINDER HEAD
. Direct fuel injection type
. 4-valve
. Divided type (One cylinder head for one cyl-
inder)
. 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

l
Floating type seal
FUEL INJECTION NOZZLE

. Mount: Dry type (without sleeve)
A-A
SDE00428
11-23
CYLINDER BLOCK
1 2 3
1’1 IO 9 8 7 SEE00429
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 1 I, Front oil seal
6. Liner O-ring 12. Piston cooling nozzle
11-24
-
SEE00430
CYLINDER BLOCK CYLINDER LINER

. Crankshaft: 7 bearings l Wet type
l Camshaft: High cam type, 7 bearings . Machining of inside wall: Plateau honing,
. Main cap mounting bolt: Plastic-area tight- tufftriding
ening
LINER SEAL
FRONT OIL SEAL . Top: Crevice seal
l Single lip with dust seal (Lay-down seal) . Middle: O-ring (Ethylene propylene rubber)
. Bottom: O-ring (Silicon rubber)
PISTON COOLING
. With cooling nozzle
11-25
MAIN CIRCULATION SYSTEM + The specifications may be different from

the following figure, depending on the
type of machine.
9 IO II 12 13 I4 SDE00431
1. Piston (FCD piston) 8. Key (Crankshaft gear)

2. Piston pin 9. Crankshaft
3. Connecting rod, bushing IO. 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
11-26
I
SDE00432
CRANKSHAFI-
l Stamp forging
. Journal and filet portion: Induction harden-
ing PISTON RING
Top ring Second ring Oil ring

PISTON
. Ductile cast iron (FCD piston)
Re-entrant piston
SDE00547 SDE00548
CONNECTING ROD SDE00549
l Stamp forging
Both faces keystone Both faces keystone M-shape steel ring
Cap bolt is of screw-in type and tightened
Barrel face inner cut Hard chrome plating
by plastic-area tightening and has lubricat- Hard chrome plating Tapered face with coil expander
Hard chrome plating
ing oil hole.
11-27
VIBRATION DAMPER * The specifications may be different from

type of machine.
SDE00433
1. Crankshaft pulley
2. Pin (Crankshaft pulley - vibration damper)
3. Vibration damper
4. Pin (Crankshaft - crankshaft pulley)
1l-28
TIMING GEAR * The specifications may be different from

type of machine.
E-E SEE00434
1. Water pump drive gear (No. of teeth: 23) 7. Compressor drive gear (No. of teeth: 24)
2. Sub idler gear (No. of teeth: 42) 8. Fuel injectionpump drive gear
3. Main idler gear (Large) (No. of teeth: 60) (No. of teeth: 48)
4. Main idler gear (Small) (No. of teeth: 40) 9. PTO gear (OPTION) (No. of teeth: 22)
5. Camshaft gear (No. of teeth: 48) IO. Crankshaft gear (No. of teeth: 36)
6. PTO gear (OPTION) (No. of teeth: 14) 11. Oil pump drive gear (No. of teeth: 22)
A, B, C: Match marks
11-30
D-D
F-F
SEE00435
11-31
j, The specifications are subject to change

VALVE SYSTEM
3 SEE00656
1. Thrust plate 12. Rocker arm adjustment screw

2. Camshaft gear (No. of teeth: 48) 13. Crosshead adjustment screw
3. Camshaft 14. Lock nut
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. Lock nut 22. Intake valve
11-32
I
12 1
I
II
I
IO I
9 I8
8 I!
20
7 21
-!
6
1__ __
1 ]
I I SEE00437
CAMSHAFT VALVE TIMING

. Drawn steel bar (Turned)
. Journal and filet portion:
VALVE TIMING
Induction hardening TOP dead center
Intake - Exhaust
valve open valve close
11-33
FLYWHEEL AND FLYWHEEL HOUSING

Without PTO type * The specifications may be different from
type of machine.
j b
A-A
SEE00438
1. Ring gear (No. of teeth: 148)

2. Flywheel
3. Rear oil seal (Lay-down lip seal)
4. Flywheel housing
For marine engine:

Eight flywheel mounting bolts
11-34
STRUCTURE AND FUNCTION LUBRICATION SYSTEM
LUBRICATION SYSTEM * The specifications may be different from

type of machine.
LUBRICATION SYSTEM CHART
SEE00439
1. Oil pan 9. Oil filter 17. Intake and exhaust valve

2. Oil strainer 10. Safety valve 18. Timing gears
3. Oil pump 11. Crankshaft 19. Turbocharger
4. Main relief valve 12. Piston cooling nozzle (S6D140, SAGDI 40, SAAGDI 40)
5. Oil cooler 13. Piston 20. Fuel injection pump
6. Thermostat 14. Camshaft
7. Regulator valve 15. Cam follower W: Cooling water
8. Valve adapter 16. Rocker arm
11-36
LARGE CAPACITY OIL FILTER + BYPASS FILTER * The specifications may be different from
type of machine.
SEE00440
1. Oil pan 9. Oil filter (full-flow filter x 2) 17. Intake and exhaust valve
2. Oil strainer 10. Safety valve 18. Timing gears
3. Oil pump 11. Crankshaft 19. Turbocharger
4. Main relief valve 12. Piston cooling nozzle 20. Fuel injection pump
5. Oil cooler 13. Piston 21. Bypass filter (Installed to de-
6. Thermostat 14. Camshaft pending on the model)
7. Regulator valve 15. Cam follower
8. Valve adapter 16. Rocker arm W: Cooling water
11-37
Sr The specifications are subject to change

OIL PUMP according to modification, etc.
SEE00441
1. Pump cover OIL PUMP

2. Drive gear l Type: Gear pump
. Pump speed: Engine speed x 1.64
3. Pump body
4. Pump drive gear (No. of teeth: 22)
5. Valve spring MAIN RELIEF VALVE
. Set pressure:
6. Main relief valve
7. Driven gear 0.78 f 0.05 MPa I8.0 f 0.5 kg/cm*)
A. Suction (From oil pan)

B. Discharge (To oil cooler)
11-38
REGULATOR VALVE AND PISTON COOLING VALVE

Ir The specifications are subject to change
3’ e b
A-A
SEE00442
1. Valve body a. From oil cooler REGULATOR VALVE

2. Valve spring b. To oil filter . Valve opening pressure:
3. Valve c. From oil filter 0.3 r 0.02 MPa 13.2 - 0.2 kg/cm*}
d. To main gallery
e. To piston cooling nozzle PISTON COOLING VALVE
f. To oil pan (drain) . Valve opening pressure
0.14 + 0.02 MPa (1.4 + 0.2 kg/cm*)
1 l-39
OIL FILTER fl The specifications may be different from

S6D140-2 type of machine.
SA6D140-2
SAA6D140-2
621202
1. Filter head OIL FILTER

2. Safety valve • Filtration area: 0.84 m2
3. Cartridge (Rated flow 160 ¬/min)
For construction machinery, generator
A. Oil inlet (Rated flow 240 ¬/min)
B. Oil outlet For marine engine
SAFETY VALVE
• Set pressure:
0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2}
11-40
7
SDA6D140E-2 (D275A-5, –50°C spec.) fl The shape may differ according to the machine
model.
621202
1. Safety valve Specifications

2. Filter head
3. Cartridge Oil filter
• Filtering area: 0.42 m2 (Full-flow)
A. Oil inlet Safety valve
B. Oil outlet • Cracking pressure:
245 ± 19 kPa {2.5 ± 0.2 kg/cm2}
11-40-1
7
Sr The specifications may be different from

LARGE CAPACITY OIL FILTER type of machine.
I 2 3

2. Safety valve l Filtration area: 1.8 m2 (0.9 m2 x 2)
3. Filter connector l Rated flow: 180 e/min.
4. Cover
5. Alarm assembly SAFETY VALUE
6. Cartridge . Set pressure: 0.2 f 0.02 MPa
12.0 a 0.2 kg/cm21
A. Oil inlet
B. Oil outlet
SEE00445
11-41
LARGE CAPACITY OIL FILTER + BYPASS FILTER

* The specifications may be different from the
following figure, depending on the type of
3 4
machine.
SEE00446
/3

2. Safety valve . Filtrationarea: 1.8 m2 (0.9 m2 x 2)
3. Filter connector . Rated flow: 180 Urnin.
4. Cover
5. Alarm assembly SAFETY VALVE
6. Cartridge (Bypass filter) l Set pressure: 0.2 + 0.02 MPa
7. Cartridge (Full-flow filter) {2.0 + 0.2 kg/cm*}
A. Oil inlet BYPASS FILTER

B. Oil outlet . Filtration area: 1.4 m2
. Rated flow: 7.5 Urnin.
iEE00445
H-42
OIL COOLER fl The specifications are subject to change

621202
1. Cooler cover THERMOSTAT FUNCTION

2. Cooler element • Valve cracking temperature: 85 ± 1.5°C
6D140-2 : 10 cores • Full opening temperature: 100°C
S6D140-2 : 10 cores • Full opening lift: Min. 8 mm
SA6D140-2 : 12 cores
SAA6D140-2 : 12 cores OIL COOLER
SDA6D140E-2 : 12 cores • Effective area: 6D140-2 : 0.822 m2
3. Thermostat S6D140-2 : 0.822 m2
4. Spring SA6D140-2 : 0.986 m2
5. Thermostat cover SAA6D140-2 : 0.986 m2
SDA6D140E-2 : 0.986 m2
A. Oil inlet
B. Oil outlet
C. Cooling water
11-43
7
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM * The specifications may be different from

type of machine.
FUEi 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
11-44
Ir The specifications may be different from

type of machine.
1//////11/1/,,
11//1,11111,,111,1,,,
11111,11,1/,,111//,,,
11//1/,11,,,/,,,,,,,,
1///11/1/1/,,,1/,//,,
4 3 2
SEE00450
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
11-45
FUEL INJECTION PUMP fl The specifications are subject to change

SA6D140-2 (D155A-3, D155AX-3, D155AX-5, D155C-1A (–30°C spec.))
621202
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
7. Boost compensator tube (With boost compensator)
8. Fuel injection pump drive gear 15. Oil outlet pipe
(No. of teeth 48)
11-46
(8)
SDE00452
a: Fuel inlet FUEL INJECTION PUMP

b: To fuel filter . Maker: ZEXEL
c: From fuel filter . Type: Bosch PE-P
d: To fuel injection nozzle . Lubrication method:
e: Fuel return (Over-flow valve - Fuel tank) Forced lubrication with engine oil
f: Fuel spill (Nozzle - Fuel tank)
g: Engine oil (To fuel injection pump) GOVERNOR
h: Engine oil (To engine oil pan) . Type: Made by ZEXEL, bosch RSUV
Centrifugal, all speed type
11-47
SAA6D140-2 (PC750-6, PC800-6) fl The specifications are subject to change

621202

6. Fuel injection pipe (No. 6) (With boost compensator)
7. Boost compensator tube 14. Oil outlet pipe
8. Fuel injection pump drive gear
(No. of teeth 48)
11-48
7
hi________.
SOE00454
a: Fuel inlet FUEL INJECTION PUMP

b: To fuel filter . Maker: ZEXEL
c: From fuel filter l Type: Bosch PE-P
d: To fuel injection nozzle . Lubrication method:
e: Fuel return (Over-flow valve - Fuel tank) Forced lubrication with engine oil
f: Engine oil (To fuel injection pump)
g: Engine oil (To engine oil pan) GOVERNOR
l Type: Bosch RSUV Centrifugal, all speed
type
11-49
SAA6D140-2 (HD325-6)
i
8 12 13 I4 I5 SDE00455

4. Fuel injection pipe (No. 4) 12. Oil outlet pipe
6. Boost compensator tube 14. Oil inlet pipe
(No. of teeth 48)
1 l-50
SDE00456
FUEL INJECTION PUMP GOVERNOR

. Maker: ZEXEL . Type: Made by ZEXEL, Bosch RFD
l Type: Bosch PE-P Centrifugal, max. - min. speed
. Lubrication method: control type
Forced lubrication with engine oil
11-51
SDA6D140E-2 (D275A-5, –50°C spec.) fl The specifications are subject to change

621202

2. Fuel injection pipe (No. 2) (With boost compensator)
7. Boost compensator tube 15. Fuel injection pump drive gear
8. Oil inlet pipe (No. of teeth: 48)
9. Oil outlet pipe
11-51-1
7
621202
FUEL INJECTION PUMP GOVERNOR

• Maker: ZEXEL • Type: Made by ZEXEL, Bosch RFD
• Type: Bosch PE-P Centrifugal, max. – min. speed
• Lubrication method: control type
Forced lubrication with engine oil
11-51-2
7
FEED PUMP Ir The specifications may be different from

type of machine.
SEE00457
1. Cover A. Fuel inlet Functions

2. Priming pump B. Fuel outlet l The feed pump sucks fuel from the fuel tank
3. Spring and supplies (discharge) it through the fuel
4. Check valve (intake) filter to the injection pump.
5. Eyebolt . This feed pump also has the function to
6. Plug maintain the discharge pressure (rate) at
7. Piston spring constant 0.1 - 0.2 MPa {I - 2 kg/cm21 to set
8. Piston the fuel injection rate of the injection pump
9. Push rod (quantity of fuel injected by each stroke) con-
10. Tappet stant.
11. Check valve (exhaust)
11-52
FUEL INJECTION NOZZLE * The specifications may be different from

type of machine.
SEE00458
1. Fuel inlet connector FUEL INJECTION NOZZLE

2. Nozzle holder S6D140-2: Made by ZEXEL
3. Adjustment shim Diameter of nozzle hole 0.35 x 7 hole)
4. Spring SAGD140-2: Made by ZEXEL
5. Seat (Diameter of nozzle hole 0.36 x 6 hole)
6. Spacer SAAGD140-2: Made by ZEXEL
7. Nozzle (Diameter of nozzle hole 0.36 x 6 hole)
8. Retaining cap
9. Nozzle needle l Type: Multi-hole type
. Injection pressure: 24.5 MPa I250 kg/cm*)
a. Fuel inlet . Adjusting INJECTION pressure:
(From injection pump) Shim adjusting type
b. Injection (To cylinder)
c. Fuel return (To fuel tank)
11-53
0
FUEL FILTER * The specifications may be different from

type of machine.
a b
SEE00
1. Filter head FUEL FILTER

2. Air bleed plug
. Filtration area: 1.0 m2
3. Cartridge
a. Fuel inlet
b. Fuel outlet
11-54
0
ENGINE STOP MOTOR
Shape of cable ti
7 (non-threaded sto
Stroke
Shape of cable tip
7 (threaded stopper type) 7
Stroke
Made by AMP Co. I

Econoseal connect or.
/’ 8P male
2. Not used(filler plug added)
1. Not usedtfiller plug added)
4. B (AV 0. 85LR)
3. PI (AV 0. 85LY)
/ (filler plug added)

3. Pz (AV 0. 85LW)
8. E (AVO. 85B)
9 IO SEE00657
1. Motor assembly ENGINE STOP MOTOR

2. Cover . Maker: Jidosha Denki Kogyo Co. Ltd
3. Cable assembly . Rated voltage: DC24V
4. Cable clamp . Operating force: 147 N (15 kg) min.
5. Coil spring . Stroke: 35::: mm
8. Cable . Weight: 1.2 kg
7. Screw
8. Breather
9. Bracket assembly
IO. Cover assembly
11-55
STRUCTURAL DRAWING (1)
0
SEE00461
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
11-56
STRUCTURAL DRAWING (2)
SEE00462
1. Gear cover assembly

2. Motor assembly
3. Cable clamp
4. Cable assembly
5. Gear case assembly
11-57
DESCRIPTION OF OPERATION AND CIRCUITS

1. Stop Condition (0” or 360”)
\
contact plate I P2, I
on DIUS side E,
I I 1
Auto-stop position on PI side Auto-stoD Dosition an P side

* Valve ih- SbEOO656
The above drawing shows the stopped condi- The slider assembly is stopped at the auto-stop
tion when a closed circuit has been formed. position on the P1 side.
2. When switch is turned (when starting the

motor)
A,
Battery
6,
PI, < I++
- 37
P2, I
E,
SDE00659
When the switch is moved to the P2 side (start- shaft assembly, thereby starting the motor. The
ing switch ON), an electric current flows from slider assembly starts to move in the direction
the plus side contact plate through the P2 auto- of the arrow at the same time as the roller starts
stop terminal and switch and into the armature to move.
3. Turning Condition (90° in the drawing)
ii& 7h
SDE00660
Electric current continues to pass through the slider assembly also continues to move in the
armature assembly and the motor continues to direction of the arrow.
turn. Because of the rotation of the roller, the
11-58
4. When stopped (180”)
tterv
I-l
27
SDE00661
A closed circuit is formed when the PZ auto-stop and the motor comes to a sudden stop. The
terminal rides on the minus-side contactor plate, slider assembly also stops.
5. When switch is turned (when starting the

motor)
SDE00662
When the switch is moved to the PI side (start- shaft assembly, thereby starting the motor. The
ing switch OFF), an electric current flows from slider assembly starts to move in the direction
the plus contactor plate through the PI auto- of the arrow at the same time as the roller starts
stop terminal and switch and into the armature to move.
6. Turning Condition (270” in the drawing)
SDE00663
Electric current continues to pass through the arma- direction of the arrow. Then the circuit returns
ture shaft assembly and the motor continues to turn. to stop condition 1.
The slider assembly also continues to move in the
11-59
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM CHART
FOR CONSTRUCTION MACHINERY, GENERATOR
621202
1. Radiator
2. Thermostat
3. 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
11-60
7
SDA6D140E-2 (D275A-5, –50°C spec.)

621202
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
11-61
7
FOR MARINE ENGINE
621202
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, outlet
8. Water pump B. Marine gear oil inlet, outlet
9. Water temperature rise alarm switch C. Air inlet, outlet
11-61-1
7
WATER PUMP
MOUNTING
S6140-2
SA6D140-2
SAAGD 140-2 (PC750-6, PCSOO-6)
3 SDE00471
1. Oil cooler A. From radiator outlet (Cooling water)

2. Thermostat housing From heat exchanger outlet
3. Water pump (For marine engines)
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)
11-62
SA6D140-2 (D155A-3, D155AX-3, D155AX-5, D155C-1A (–30°C spec.))

SDA6D140E-2 (D275A-5, –50°C spec.)
621202

2. Thermostat housing B. Via oil cooler to each portion of engine
3. Water pump (Cooling water)
C. To radiator (Cooling water)
D. To oil cooler on machine (Cooling water)
11-63
(8)
SAAGD140-2 (HD325-6) + The specifications are subject to change

r-
i
3 SDE00473

2. Thermostat housing B. Via oil cooler to each portion of engine
3. Water pump (Cooling water)
C. To radiator (Cooling water)
D. To oil cooler on machine (Cooling water)
11-64
SDA6D140E-2 (D275A-5, –50°C spec.)

FOR AFTERCOOLER
621202
1. Tube A. From water pump to aftercooler

2. Tube
3. Water pump
11-64-1
7
S6D140-2
SA6D140-2
SAA6D140-2
SDA6D140E-2 (D275A-5, –50°C spec.)
621202
1. Alternator drive pulley WATER PUMP

2. Oil seal • Type: Centrifugal, gear-driven
3. Ball bearing • Water pump speed : Engine speed × 1.56
4. Pump shaft • Flow capacity: 800 ¬/min.
5. Water pump drive gear • Total water head: 14 m
(No. of teeth: 23)
6. Pump body
7. Water seal
8. Impeller
9. Pump cover
a. From radiator
b. To oil cooler
11-65
7
FOR AFTERCOOLER
SDA6D140E-2 (D275A-5, –50°C spec.)
621202
1. Pump shaft WATER PUMP
2. Water pump drive gear • Type: Centrifugal, gear-driven
(No. of teeth: 19) • Water pump speed : Engine speed × 1.26
3. Spacer • Flow capacity: 120 ¬/min.
4. Seal ring • Total water head: 3 m
5. Ball bearing
6. Spacer
7. Ball bearing
8. Gasket
9. Impeller
10. Water seal
11. Plate
a. From radiator
b. To aftercooler
11-65-1
7
j, The specifications may be different from

type of machine model.
0 SEE00475
1. Cylinder block THERMOSTAT

2. Thermostat housing . Valve opening temperature:
3. Thermostat 76.5 + 2°C (For construction machine
and generator)
A. To radiator 82 + 2°C (For marine engines)
To heat exchanger (For marine engines) . Fully opening temperature: 90°C
B. To water pump . Lift and fully opening position: 10 mm min.
To Brake cooler (HD325)
To oil cooler on machine body
(D155A-3, D155AX-3)
11-66
CORROSION RESISTOR * The specifications may be different from

type of machine.
SEE00476
1. Head CORROSION RESISTOR

2. Cartridge . Filtration area:
3. Element 6D140-2: 0.13 m2
4. Inhibitor (Solid corrosion preventive agent) SAGDI 40, S6D140-2: 0.13 m2
5. Spring SAAGD140, SAGD140-2: 0.373 m*
6. Stop valve . Quantity of corrosion preventive agent:
6D140-2: 400 g
a. Water inlet SAGDI 40, S6D140-2: 400 g
b. Water outlet SAAGDI 40, SAGD140-2: 1,000 g
11-67
CORROSION RESISTOR MOUNTING

type of machine.
__
r-.-
I
___
--‘I.
-1
fr
r._-
-_.-
-L
_._-
i=
i
Ip SEE00477
1. Bracket
2. Hose (return from corrosion resistor)
3. Valve
4. Corrosion resistor cartridge
5. Hose (to corrosion resistor)
11-68
COOLING FAN DRIVE fl The specifications may be different from

TENSION PULLEY MOUNT type of machine.
S6D140-2 for WA500-3

621202
1. Fan pulley
2. Tension pulley (Outside diameter: 120mm)
3. Crank pulley (Outside diameter: 164 mm)
4. Fan belt
11-69
31
TENSION PULLEY MOUNT fl The specifications may be different from

SA6D140-2 for D155A-3, D155AX-3, D155AX-5 type of machine.
621202
1. Fan pulley FAN PULLEY

2. Tension pulley Outside
3. Crank pulley (Outside diameter: 200 mm) diameter Applicable machine
4. Fan belt (mm)
295 D155A-3, D155AX-3, D155AX-5
D155A-3, D155AX-3
316
(Scraper spec.)
11-69-1
6
TENSION PULLEY * The specifications may be different from

SA6D140-2 (D155A-3, D155AX-3) type of machine.
9. d i ‘5 SDE00479
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
11-70
SAAGD140-2 (PC750-6, PCSOO-6) * The specifications may be different from

type of machine.
1
I
SDE00480
Pulley outside diameter

Unit: mm
1. Fan pulley Fan Crank Tension
Model pulley pulley
2. Fan belt pulley
3. Crank pulley PC750-6, PC800-6 280 164 118
4. Tension pulley
5. Tension shaft
6. Tension spring
11-71
TENSION PULLEY + The specifications may be different from

SAAGD 140-2 (PC750-6, PCSOO-6) type of machine.
7 6 SDE00481
1. Tension shaft
2. Roller bear,ing
3. Tension bracket
4. Oil seal
6. Ball bearing
7. Spacer
8. Stopper
11-72
SAAGD140-2 for HD325-6, HD405-6 Ir The specifications may be different from

type of machine.
5’ SDE00482
1. Tension pulley (Outside diameter: 118 mm) Fan pulley

2. Fan pulley
Outside diameter
3. Fan mount case Applicable machine
(mm)
4. Fan belt
275 HD325-6, HD405-6
5. Crank pulley (Outside diameter: 164 mm)
a. Wind direction
11-73
0
TENSION PULLEY j, The specifications may be different from

SAAGD140-2 for HD325-6, HD405-6 type of machine.
7 5
SEE00483
A-A
1. Bracket
2. Spacer
3. Ball bearing
5. Bearing
6. Coil spring
7. Tension shaft
11-74
0
FAN MOUNT CASE Sr The specifications may be different from

SAAGD140-2 for HD325-6, HD405-6 type of machine.
SEE00484
1. Fan pulley hub

2. Ball bearing
3. Shaft
4. Case
11-75
0
STRUCTURE AND FUNCTION ACCESSORY
ACCESSORY
AIR COMPRESSOR
(Installed depending on the model)
SEE00485
1. Crankshaft a. Air intake

2. Crankcase b. Air exhaust
3. 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
11-76
I 1
SEE00466
AIR COMPRESSOR UNLOADER VALVE

. Maker: ZEXEL . Valve opening pressure: 618 kPal6.3 kg/cm21
. Type: Single cylinder, . Valve shutting pressure: 530 kPaI5.4 kg/cm21
reciprocated type
. Discharge volume: 340 cc/rev.
. Air pressure: 834 kPa (8.5 kg/cm21
(at full load)
l Weight: 11 kg
11-77
0
AIR COMPRESSOR MOUNTING Ir The specifications may be different from

type of machine.
1. Air compressor
2. PTO case
3. Compressor drive gear
(No. of teeth: 24) SDE00467
a. From intake manifold (air)

b. Exhaust (air) Intake manifold
c. From air governor to unloader (air)
Air
d. From cylinder block (cooling water)
e. To cylinder block (cooling water) Air Air
f. From cylinder block (oil inlet) - compressor aovernor
I
g. To cylinder block (oil outlet) Air tank
1 Oil Air
SDE00655
11-78
EXHAUST BRAKE Jr The specifications are subject to change

SLIDE VALVE TYPE
SEE00488
1. Valve housing 8. Retainer

2. Gate valve 9. Release valve
3. Guide bushing 10. Packing
4. Cylinder 11. Packing
5. Spring 12. Exhaust pressure adjustment bolt
6. Spring 13. Breather
7. Piston
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.
11-79
EXHAUST BRAKE * The specifications are subject to change

BUTTERFLY VALVE TYPE
1. Air cylinder 9. Valve

2. Stopper bolt (fully open) IO. 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
11-80
SOLENOID VALVE FOR EXHAUST BRAKE

type of machine.
-
m I
li
C
B
7’ B/
SEE00490
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
11-81
EXHAUST BRAKE
Operation
1. 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 butterfly valve returns through port B to
port C, then discharged in the atmosphere,
and butterfly valve (7) fully opens the path
from the turbocharger to the muffler.
To
4
muffler
- Ia”K
SEE00664
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 t
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 4, and butterfly valve
(7) fully closes the path from the turbo-
charger to the muffler. Accordingly, the en-
gine 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 From dry tank
the engine brake will not be applied even if To muffler
SEE00665
the switch is turned on.
11-82
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ELECTRICAL SYSTEM It The specifications may be different from

type of machine.
ALTERNATOR
MOUNTING
c__ -I_______._-___
SOE00493
1. Alternator a. Alternator pulley (Pulley O.D. 85 mm)

2. Adjust rod b. Alternator drive ~ullev (Pulley O.D. 132 mm)
3. Nut (2 pieces)
4. Plate
5. Cover
6. V-belt (2 pieces)
7. Spacer
H-83
ALTERNATOR WITH BUILT-IN REGULATOR fl The shape may differ according to the
(OPEN TYPE 35A) machine model.
621202
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
Applicable Pulley O.D. Weight Pulley

Engine model Type Specification
machine model (mm) (kg) type
Maker: NIKKO DENKI
S6D140-2 WA500-3 Type: Opened 24V, 35A 85 9.5 I
(Brushless)
Maker: NIKKO DENKI
SA6D140-2 D155A-3, AX-3, AX-5 Type: Opened 24V, 35A 85 9.5 I
(Brushless)
11-84
(8)
(OPEN TYPE) machine model.
621202
1. Alternator 5. Terminals B
2. Alternator pulley 6. Internal electric circuit diagram
3. Terminal R 6A. Field coil
4. Terminal E 6B. Regulator
Applicable Pulley O.D. Weight

machine model (mm) (kg)
Maker: NIKKO DENKI
S6D140-2 24V, 35A 85 9.5
Type: Opened (Brushless)
Maker: NIKKO DENKI

SA6D140-2 D155A-3, AX-3 24V, 35A 85 9.5
Maker: NIKKO DENKI
24V, 25A 85 8.5
SAA6D140-2
Maker: NIKKO DENKI
24V, 30A 85 9.5
11-85
7
1. Alternator 6. Internal electric circuit diagram 621202

2. Alternator pulley 6A. Alternator
4. Terminal E
5. Terminal R

Maker: SAWAFUJI DENKI
S6D140-2 GD825A-2 Type: Opened 24V, 50A 85 12 II
(Brushless)
D155A-3, AX-3, AX-5
SA6D140-2 Type: Opened 24V, 50A 85 12 II
(if equipped)
(Brushless)
PC750-6, PC800-6
SAA6D140-2 Type: Opened 24V, 50A 85 12 II
HD325-6, HD405-6
(Brushless)
11-86
(8)
621202
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Primary energized resistance
4. Terminal R 6C. Field coil
5. Terminal E

Maker: NIKKO DENKI
SA6D140-2 D155C-1A (–30°C spec.) Type: Opened 24V, 50A 85 11.0 I
(Brushless)
11-87
(8)
1. Alternator 621202
5. Internal electric circuit diagram
2. Alternator pulley 5A. Alternator
4. Terminal R
Outside diameter Weight

Engine Machine model Type Specification
of pulley (mm) (kg)
Sawafuji Denki
SDA6D140E-2 D275A-5 (–50°C spec.) 24V, 75A 85 12.5
Open type (brushless)
11-87-1
(8)
STARTING MOTOR fl The shape may differ according to the

machine model.
FOR 7.5 kW
621202
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
11-88
(8)
621202
Applicable Pulley O.D. Weight Connector

machine model (mm) (kg) Type
Maker: NIKKO DENKI
S6D140-2 Type: Closed 24V, 7.5kW 12 18
(drip-proof, oil proof)
Maker: NIKKO DENKI
SA6D140-2 Type: Closed 24V, 7.5kW 12 18 B
Maker: NIKKO DENKI
SAA6D140-2 PC750-6, PC800-6 Type: Closed 24V, 7.5kW 12 18 C
11-88-1
(8)
FOR 11 kW fl The shape may differ according to the

machine model.
621202
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
11-88-2
(8)
621202
Engine model Applicable Type Specification Number of Weight Connector

machine model pinion teeth (kg) type
GD825A-2 Type: Closed 24V, 11kW 11 20 B
S6D140-2 (drip-proof, oil proof)
WA500-3 Maker: SAWAFUJI DENKI
Type: Closed 24V, 11kW 11 20 C
D155A-2,3, AX-3, AX-5
(X type connector)
SA6D140-2 Maker: SAWAFUJI DENKI
D155C-1A (–30°C spec.) Type: Closed 24V, 11kW 11 20 C
HD325-6, HD405-6 Maker: SAWAFUJI DENKI 24V, 11kW 11 20 C

SAA6D140-2 Type: Closed
11-88-3
(8)
FOR 11 kW fl The shape may differ according to the

machine model.
621202
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 R
E. To ground
No. of Weight Connector

Engine Machine model Type Specification
pinion teeth (kg) type
Nikko Denki
SDA6D140E-2 D275A-5 (–50°C spec.) Waterproof, 24V, 11kW 12 18 B
oilproof type
11-88-4
(8)
ELECTRICAL INTAKE AIR HEATER

fl The specifications may be different from
S6D140-2 the following figure, depending on the
type of machine.
1. Heater body
2. Heater coil

• Rated voltage: DC22V
• Rated current: 175A
621202
SA6D140-2
SDA6D140E-2 (D275A-5, –50°C spec.)
1. Heater body
2. Heater coil
3. Terminal

• Rated voltage: DC11V
• Rated current: 86A
11-89
7
FRONT PTO MOUNTING f The specifications may be different from

type of machine.
__- -
-__
i,
1r
I
lI
-__i i.
-__-.
/
i
SDE00501
I. Front PTO
2. O-ring
3. Front PTO drive gear assembly
11-90
FRQNT PTO ASSEMBLY * The specifications may be different from

type of machine.
A-A SEE00502
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
11-91
FRONT PTO DRIVE GEAR ASSEMBLY

type of machine.
1
/
I /”
1’ /”
/’
/”
A-A SDE00503
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
1l-92
1% TESTING AND ADJUSTING
Adjusting engine speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 2
ENGINE BODY
Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 3
Measuring compression pressure . . . . . . . . . . . . . . . 12- 4
FUEL SYSTEM
Testing and adjusting fuel
injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4-1
Adjusting fuel injection pressure . . . . . . . . . . . . . . . . . 12- 5
Procedure for adjusting engine
stop motor cable ._..............._.................. 12- 6
Fuel injection pump
calibration data . . . . . . . . . . ..__......................... 12- 7
COOLING SYSTEM
Checking and adjusting
fan belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6-2
PERFORMANCE TEST
Run-in standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Performance test criteria . . .._.......................... 12-14
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
TESTING AND ADJUSTING TOOL LIST . . . . . . . . . . . . . 12-45
TESTING AND ADJUSTING DATA . . . . . . . . . . . . . . . . . . . . . 12-46
12-1
0
TESTING AND ADJUSTING TESTING AND ADJUSTING
Sr The specifications may be different from

MOUNTING (ADJUSTING) the following figure, .depending on the
machine model.
METHOD OF ENGINE
SPEED SENSOR
Adjustment of gap between speed sensor

and pin on periphery of flywheel
. The following is the removing and mount-
ing procedure of the engine speed sensor.
1. Turn the crankshaft forward to match pin (1)

driven in the periphery of the flywheel.
I TDE00254
2. At this position, tighten speed sensor (2)
until it touches pin (1) of the flywheel, then
loosen it by one turn.
Ir Gap at this time: 1.0 - 1.2 mm
3. Tighten lock nut (3).

* After adjusting, confirm that the engine
cranks smoothly.
Adjustment of gap between speed sensor

and contact surface of ring gear
l The following is the removing and mount-
ing procedure 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

TDE00255
by II2 - 213 turns.
Jr Gap at this time: 0.75 - 1.00 mm
3. Tighten lock nut (3).

* Arrange the sensor wires carefully so
that an excessive force will not be ap-
plied to them.
* Take care to keep the sensor tip free
from metallic chips dust, dirt etc.
Clearance
TDE00257 TEE00351
12-2
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 cylinder
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).
fl 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 ‡

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 ‡.
621202
fl 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}
fl The engine firing order is 1 – 5 – 3 – 6 – 2 – 4.
fl Intake and exhaust valve clearances may be ad-
justed for each cylinder in the firing order by
rotating the crankshaft 120° at a time in the nor-
mal direction.
12-3
7
MEASURING COMPRESSION
PRESSURE
MEASUREMENT PROCEDURE
A While measuring the compression pressure,

take care not burn yourself on the exhaust
manifold or muffler, and be careful not to
get caught in any revolving part of the en-
gine.
-k 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 (I 1.

* 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. 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:
m Torque: 66.7 2 7.3 Nm 16.8 f 0.75 kgml
5. Connect compression gauge A to the adapter.
6. Place the fuel control lever in NO INJECTION

position, crank the engine with the starting mo-
tor, and read the gauge when the pointer is
stabilized.
A If you do not put the fuel control lever in NO
INJECTION position, fuel will blow out.
Ir Most compression leakage can be prevented
by applying a small amount of oil to the
mounting section of the adapter.
* For the reference values of the compression
pressure, see TESTING AND ADJUSTING
DATA.
12-4
TESTING AND ADJUSTING FUEL SYSTEM
TESTING AND ADJUSTING

FUEL INJECTION TIMING
. Inspection of fuel injection timing
1. Turn the engine to match stamped line (I) (I-6
TOP) of the damper to pointer (2).
2. Pull out snap pin (3) of the injection timing fix-

ing pin, and remove nut (4).
3. Pushing pin (5) against the engine, turn the

crankshaft in reverse and insert pin (5) in gear
(6). TEE00258
4. In this condition, confirm that stamped line “a”

on the injection pump is matched to stamped Pin
line “b” on the coupling side.
* If the engine is started or turned forcedly in
this condition, the end of pin (5) will be bro-
ken and caught in the gear, and that can
cause a serious accident.
l 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.
: TEH00092 BEH00013
z 1)
(D Loosen bolt (7) and shift the coupling to
match the stamped line, then tighten the bolt.
w Bolt: 58.8 - 62.8 Nm I6.0 - 6.4 kgm1
b a
. Releasing fixing pin
1) Pull pin (5) out of gear (6).
* Pin (5) can be pulled out easily if it is
turned.
* Pull out pin (5) until is stops.
2) Tighten nut (4).

w Nut: 26.9 - 33.9 Nm (2.74 - 3.46 kgm1
* The nut can be tightened securely if a
flat-head screwdriver is set in the slit of I TEE00576
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.
BEH00015
12-4- 1
a
ADJUSTING FUEL INJECTION PRESSURE
1. Remove retaining cap (8).
2. Confirm thickness of adjustment shim (3).
3. insert correct shim (3) in response to the

adjustment value of injection pressure.
4. Tighten retaining cap (81, then confirm the

fuel injection pressure.
w Retaining cap:
58.8 - 68.6 Nm 16 - 7 kgm1
B
TEE00270
Data for shims used for adjusting injection pressure
I 6D140-2, S6D140-2, SAGDI 40-2, SAAGDI 40-2
ZEXEL
Cracking pressure (MPa {kg/cm*}) 24.5 $2 {250:‘$

Change in cracking pressure for 0.025
mm thickness of shim (MPa {kg/cm*}) 0.34 (3.51
Thickness of adjustment shim (mm) 0.5 - 1.975 (For each 0.025 mm)
Thickness Thickness
Part No. Part No.
(mm) (mm)
0.50 150530-4000 0.525 150530-4100
0.55 150530-4200 0.575 150530-4300
I 0.60 I 150530-4400 I 0.625 I 150530-4500
I 0.65 1 150530-4600 1 0.675 1 150530-4700
I 0.70 1 150530-4800 1 0.725 1 150530-4900
0.75 150530-5000 0.775 150530-5100
0.80 150530-5200 0.825 150530-5300
I--~~0.85 ~0530-5400 1 0.875 1 150530-5500
Shim thickness and maker part 0.90 150530-5600 0.925 150530-5700
number 0.95 150530-5800 0.975 150530-5900
1.oo 150530-6000 1.025 1505306100
1.05 150530-6200 1.075 1505306300
1.10 150530-6400 1.125 1505306500
I 1.15 1 150530-6600 1 1.175 I 1505306700
I 1.20 1 1505306800 1 1.225 I 1505306900
.L 1 1 1
1.95 150530-9800 1.975 150530-9900
12-5
PROCEDURE FOR ADJUSTING

ENGINE STOP MOTOR CABLE
S6D140-2 for GD825A-2, WA500-3
1. Temporarily attach the ball joint connected to

the injection pump to the cable of the engine
stop motor.
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).
* The engine stop motor cable is housed in
the pulled condition.
Ir When the lever is free, the stop lever is in
the OPERATING position (built-in spring).
When the engine is stopped (at time of installa-

tion), clearance a between stop lever (2) of the
injection pump and lever stopper (I) should be
1 2 3 4
0.5 - 1.5 mm. Adjustment is made according to
TEE00577
the depth that the ball joint is screwed in.
After adjusting the clearance between the stop-

per and lever, tighten each bolt and nut. 1. Lever stopper
2. Fuel injection pump stop lever
3. Bracket 2
Turn the engine starting switch ON and OFF a
few times to confirm that the engine stop motor 4. Cable :
actuated smoothly. Be especially sure to con- 5. Joint
firm that there is a clearance between the stop
lever and stopper when the engine is stopped.
* The engine stop motor has built-in limit
switches on both sides of the cable stroke.
* 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
12-6
0
PROCEDURE FOR ADJUSTING

ENGINE STOP MOTOR CABLE
SAAGD 140-2 for HD325-6, HD405-6
1. Temporarily attach the ball joint connected to Engine stop

the injection pump to the cable of the engine Normal use
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).
+ The engine stop motor cable is housed in
the pulled condition.
* 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 (I) of the
injection pump and the lever stopper (built-in to
pump) should be 0.5 - 1.5 mm. Check clearance
by movement of cable due to stopper is built
into pump housing. Adjustment is made accord-
ing 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. TOE00578
5. Turn the engine starting switch ON and OFF a

few times to confirm that the engine stop motor 1. Stop lever
actuated smoothly. Be especially sure to con- 2. Bracket
firm that there is a clearance between the stop 3. Cable
lever and stopper when the engine is stopped. 4. Ball Joint
* The engine stop motor has built-in limit
switches on both sides of the cable stroke.
* 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
12-6- 1
0
TESTING AND ADJUSTING COOLING SYSTEM
COOLING SYSTEM
CHECKING AND ADJUSTING FAN
BELT TENSION
2 1. Adjustment nut
2. Washer
1 3. Tension spring
4. Adjustment bolt
5. Tension pulley
3
A. Protrusion of adjustment bolt
i-
l__,-’
Unit: mm
Engine model Applicable machine Dimension A
PC750-6
SAAGDI 40-2 44 z!z3
PC800-6 I
12-6-2
0
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP CALIBRATION DATA

Engine model Pump assembly No. Engine serial No. Applicable machine Page
6211-72-1310 WA500-3 12-8
6211-72-1470 GD825A-2 12-11-2
S6D140-2
6212-72-1120 D155A-3, D155AX-3 12-9

6211-72-1140 D155AX-5 12-11-9
6211-72-1150 D155A-2 12-11-4
621202
6211-72-1160 D355C-3 12-11-5

6211-72-1170 D155AX-5 12-11-10
6211-72-1180 D155C-1A (–30°C spec.) 12-11-11
SA6D140-2
6212-72-1430 PC1600SP-1 12-11-3
6212-72-1830 J6D140E-G1-2 (with electronic governor) 12-11-7
(TAIYO DENKI generator)
6212-72-1840 J6D140E-G1-2 (with mechanical governor) 12-11-8
(TAIYO DENKI generator)
6212-72-1860 DCA400SSK-2 (DENYO generator) 12-10
6212-72-1860 DCA-400SSK (For MQ generator) 12-11-6
HD325-6 (with mechanical
governor)
6212-72-1250 HD405-6 (with mechanical
12-11
governor)
6212-72-1421 PC750-6, PC800-6, PC1800-6 12-11-1
SAA6D140-2
12-7
(8)
TESTlNG AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
Injection Pump Assembly Number I Applicable Machine Applicable Engine I

6211-72-1310 (106675-4400) rl 1 Serial No. 1 S6Dz; 1 Serial No. 1
( 1: Injection pump manufacturer’s part No.
Injection Injection pump
Pump Type Manufacturer
PE-P (PSTIS) ZEXEL
Injection Pump Specification
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 246{33OY2,100(Gross)
injection order l-5-3-6-2-4 Maximum torque (Nm {kgmI/ rpm) 1,390~1421/1,490

(Gross)
IHigh idling speed (rpm) 1 2,300 - 2,400 I

* Low idling speed (rpm) 700 - 750
I
’Delivery valve (mm3/st) Pump tester capacity
Motor 7.5 kW
for Service standard I I
I
~nditions
rjection volume
6 to E are the
reference volume
Marks* are
average volumes.
Governor PerformanceCurve # Adjusting the injection pump at 360(rpm) is as follows: adjust injection volume and
variance of injection pump without governor to adapt to the values in the chart
above at the rack position on 7.6(mm), and after coupling with the governor, check
Min. 14. O- if the rack position is 7.0(mm), and checking of injection volume or variance is not
lIack ’ imit necessary to be checked at rack position on 7.0(mm).
D
-G B A
e R,(l0.7),
t&36. 5-39. 5 (mm’/st)
:
._ R,+3. 0
._
I
i ;:;;:;;.
:
=
0 360 1,080-1.090 \
1.150-1.200
Pump speed (rvm)
TWE00830
12-8
0
Injection Pump Assembly Number Applicable Machine Applicable Engine

6212-72-1120 (106671-9440) Model Serial No. Model Serial No.
( ): Injection pump manufacturer’s part No. D155A-3 SA6D140-2
Injection Injection pump D155AX-3
PE-P (PS7S) ZEXEL
Injection Pump Specification Engine Specification

Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 246{329}/1,900 (Gross)
Injection order 1–5–3–6–2–4 Maximum torque (Nm {kgm}/ rpm) 1,480{151}/1,300 (Gross)
Injection interval 59°30’ – 60°30’ High idling speed (rpm) 2,050 – 2,150
Plunger pre-stroke (mm) 3.85 – 3.95 Low idling speed (rpm) 700 – 725
Delivery valve (mm3/st) Pump tester capacity

retraction volume 100 Motor 7.5 kW
for Service standard
Calibration Standard ( ): Injection pump manufacturer’s part number

Service standard Manufacturer standard
Conditions Nozzle & nozzle holder part No. (105780-8140) 6211-12-3500 (105111-4650)
‡ Service standard Nozzle part No. (105780-0000) 6211-12-3520 (105025-0880)
indicates data Nozzle holder part No. (105780-2080) 6211-12-3210 (105041-7150)
using calibration Injection pipe (mm) 8 x 3 x 600 6 x 2.2 x 630
test parts. (Outside dia. x inside dia. x length)
‡ Manufacturer Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard is data
Oil temperature (°C) 40 – 45
for the engine on
the machine. Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 24.5 {250}
621202
Transfer pump pressure (kPa{kg/cm2}) 157 {1.60} 157 {1.60}

Service standard (cc/1000 st.) Manufacturer standard (cc/1000 st.)
Injection volume Rack Pump
Rack Maximum Maximum
point position speed Injection Injection
‡ Rack positions (mm) (rpm) variance variance
volume between cylinder volume between cylinder
B to E are the
reference volume A
when adjusting 10.10 950 141.5 – 145.5 max. 8.6 195.5
(Basic point)
the injection
volume. B 10.55 650 176.5 – 182.5 – 229.0
‡ Marks fl are C approx. 6.9 360 7.0 – 10.0 max. 2.6 20.0
average volumes. D – 100 210.0 – 230.0 – 225.0
E
Governor Performance Curve Boost Compensator Performance Curve
12-9
3
6

): Injection pump manufacturer’s part NO. DENY0 generator SA6D140-2
DCA400SSK-2
m
Injection Pump Specification Engine Specification (Without fan)
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) ~~~$f~*~~~ ‘i$oz l i:
Injection order l-5-3-6-2-4 Maximum torque (Nm IkgmY rpm) -

Max. 1,570 (50 Hz)
Injection interval 59”30’ - 60”30 High idling speed (rpm) Max. 1,880 (60 Hz)
Plunger pre-stroke (mm) 3.85 - 3.95 Low idling speed (rpm) 800 - 850
Deliven/ valve (mm3/st) Pump tester capacity

120 Motor 7.5 kW
retraction volume for Service standard
dll”rau”,I aLdll”QI” \ ,. III,T~~I”,I pu,,,p IIICII,.UI~“L”,r, e p”.r llYlll”Il

!onditions Nozzle & nozzle holder part No. 6212-12-3300 (105111-4750)
6. strndard Nozzle part No. 6212-12-3320 (105025-1250)
indicates data Nozzle holder part No. 6212-12-3212 (105041-7122)
using calibration Injection pipe (mm) 6 x 2.2 x 630
Manufacturer Test oil ASTM 0975 No. 2 diesel fuel or equivalent
standard is data 40 - 45
Oil temperature (“C)
for factory test.
NozzleopeningpressurejMPa{kg/cm?j 24.5 (250)
Transfer pump pressure(kPaRg/cm9) 157 {I.601
Service standard (cc/l000 St.1 Manufacturer standard (cc/l000 St.)

ejection volume Rack Pump
point position speed Injection
Injection variance variance
Rack positions (mm) (mm) volume between cylinder volume between cylinder
B to E are the
reference volume A
when adjusting 13.2 900 *311.0 - 321.0 max. 19.0
(Basic point)
the injection
B 12.4 750 k298.0 - 310.0
volume.
Marks * are C 7.1 405 k18.5 - 21.5 max. 6.0
average volumes. D 15.0 900 *391.0 - 403.0
E Rack limt 100 k436.0 - 455.0
Governor Performance Curve
Min.- max. speed control euec. All speed.idlino set
P=47. 5-50. 5 Cm ma/s t .)
0 405
895-905 Pumpsueed (ram)
Pump speed (rpm) TWE00699
12-10
0

( 1:Injection pump manufacturer’s part No. HD325-6 1 SAAGD140-2 1
Injection Injection pump HD405-6
Puma Tvoe Manufacturer
PE-P (PS7S) ZEXEL
Injection Pump Specification Enaine Soecification Wiihout fan)
1Rotating direction I Clockwise I Flywheel horsepower (kW (HP}) / rpm) 1379I508Y2,OOO(Gross11

Ilniection order 1 l-5-3-6-2-4 1 Maximum torque (Nm (kgmY rpm) 1 2,170(221}/1,400(Gross)I
High idling speed (rpm) 2,350 - 2,450
Low idling speed (rpm) 700 - 750
Pump tester capacity

Motor 7.5 kW
mlihratinn Stan&A 1: lniection oumo manufacturer’s oart number
Service standard
indicates data
Manufacturer
standard is data
ljaction volume
B to E are the
reference volume
Marks t are
average volumes.
Governor Pwformance Curve Boost Compensator Performance Curve
Rack limit :ll. 9-12. 1 (mm)

Dumper sprins set
Boost comuensator stroke

:2.7-2.9 (mm)
E
- a. 7-9.
L Min.7.5 ' RI (11.3)
.- z
.-
Z
6. .- RI-O. 9
P
z
a 5. 4-6. m
u
a RI-~. a
A?
4. 7 z
e
4. o-4i6 0 26. 7-33. 3 Apornx.77.3
(200-2501 (Aoprox. 5801
I I 50.6-64.0
0 225, 420\ /\\ (380-4801
(250)365 (430) Min.1.020 1.200
435 1,075 Boost Pressure (kPa(mmHe))
Pump speed (rprn)

TWE00831
12-11
'0

6212-72-1421 (106682-9421)
Model Serial No. Model Serial No.
f212-7211 420 (106682-9420)
): InJection pump manufacturer’s part No. PC750-6 SAAGDI 40-2
Injection injection pump PC800-6
Puma Tvoe Manufacturer PC1800-6
(2 engines)
PE-P (PS7S) ZEXEL
Injection Pump Specification Enaine SDecification (Without fan)
Maximum torque (Nm {kgmI/ rpm) 2,160{220~/1,350 (Gross)

Low idling speed (rpm) 800 - 850
I
retraction volume Motor 7.5 kW
for Service standard I I
I \- Ininrtinn
Fondiions
Service standard
indicates data
Manufacturer
standard is data
+&ion volume
B to E are the
reference volume
Marks * are
average volumes.
18. O-21.0
Rack limit
- Boost compensator stroke

:l. 9-2. 1 (mm)
-z
_E 12.8
z
3 9. 9
.-
P
.x 6. 9
6. 7
s
Boost pressure (kPa(mmHel)

415 / 965-1.020
920-930
Pump weed (rpm)
TWE00632
12-11-1
0

621 I-72-1470 (106675-4421) Model Serial No. Model Serial No.
): Injection pump manufacturer’s part No. GD825A-2 S6D140-2
lniection Puma Soecification Engine Specification

Rotating direction Clockwise
Injection order l-5-3-6-2-4
Injection interval 59”30’ - 60”30
Plunger pre-stroke (mm) 3.85 - 3.95
Delivery valve (mm3/st)

100
alibration Standard ( ): lniection pump manufacturer’s part number

Eondiiions
I Service standard
indicates data
using calibration
teat parts.
I Manufacturer
standard is data
for factory test.
Jection volume
Rack positions
B to E are the between cylinder between cylinder
reference volume
when adjusting
the injection
volume.
Marks * are
average volumes.
Governor Performance Curve # Adjusting the injection pump at 325(rpm) is as follows: adjust injection volume and
variance of injection pump without governor to adapt to the values in the chart
above at the rack position on 7.l(mm), and after coupling with the governor, check
Min. 14. 0 if the rack position is 6.8(mm), checking of injection volume or variance is not
Rack limit necessan/ to be checked at rack position on 6.8(mmL
0 325 (1.0751 1,175

I.085
Pumpspeed (r Pm)
TWEOOB33
12-11-2
0

): Injectionpump manufacturer’s part No. PC16OOSP-1 SAGDI 40-2
/I
l-5-3-6-2-4 Maximum torque (Nm {kgmI/ rpm) 1,910~1951/1,400

(Gross)
Injection interval 59"30'- 60"30 High idling speed 1rpn-r) 1,930 - 2,030
Plunger pre-stroke (mm) 3.25 - 3.35 Low idling speed (rpm) 725-775
Delivery valve (mm%t) Pump tester capacity

alibration Standard ( ): lniection pump manufacturer’s part number

~nditions Nozzle & nozzle holder part No. (105780-8130) 6212-12-3200 (105111-4680)
Nozzle part No. (105780-0050) (105025-0940)
1servicestandard
using calibration Injectionpipe (mm) 8x 4x600 6 x 2.2 x 630
I Manufacturer Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard isdata - .__. ._ ._
Oil temperature ('CJ 40 - 45
for factory test.
Nozzle opening pressure (MPaIkg/cm% 17.2 {I751 24.5 12501
Transferpump pressure(kPa{kg/cti) 157 {I.601 157 {I.601
/ Service standard (cc/1000 St.) 1Manufacturer standard WI000 St.)

ijection volume
Rack positions
8to E are the
referencevolume
when adjusting (BasicApaint) 12.2 895-905 *308.0-318.0 +.3 *274.0
the injection
0 approx. 7.6 375 *11.0 - 14.0 * 15 *35.0
volume.
Marks t are C 12.2 700 k281.0 - 297.0 k296.0
average volumes. D rack limit 100 k440.0 - 460.0 *475.0
I
E I
Boost compensator stroke :2. 6-2.8 (mm)
4
2 _---c---
12.
6 9.
Boost Dressure (kPa(mmHs1)

0
400 970-980 965-1.015
Pump speed (rpm) ME00696
12-11-3
0

6211-72-1150 (106675-4640) D155M_;el ~ Serial No. ~ ,,,:;fei 1 Serial No. 1
1 ): Injection pump manufacturer’s part No.
Pump Tvpe Manufacturer
I PE-P (PS7S) ZEXEL

I
lniectionPump Specification Engine Specification
Flywheel horsepower (kW IHPI) / rpm) 266{3571/2,000(Gross)
IMaximum torque (Nm {kgmI/ rpm)] 1.6401167~~

Plunger pre-stroke (mm) 3.25 - 3.35 I Low idling speed (rpm) 550 - 650
I
120 Motor 7.5 kW
I Ininrtinn
bnditlons
Bewvicestandard
indicates data
Manufacturer
standard is data
+sction volume
Boost compensator stroke

:1.1-l. 3 (mm)
~120-160) (265-3651
Boost pressure (kPa{mmHel 1
Pump speed (rpm)

TWEOOB34
12-11-4
0
Injection Pump Assembly Number Applicable Machine I Awlicable

.. Engine -
6211-72-l 160
Model
( ): Injection pump manufacturer’s part No. SAGDI 40-2
PE-P (PS3S) ZEXEL
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 277{371}/2,OOO(Gross)
Injection order l-5-3-6-2-4 Maximum torque (Nm {kgmI/ rpm) 1,603.4I163.5I/1,400

(Gross)
Injection interval 59”30’ - 60”30 High idling speed (rpm) 2,200 - 2,280
(rpm) 1 700 - 750
Motor 7.5 kW
\ ,. ,.,, ““.s_., C”...F *.._.._.__._._. _ --.- ..-...--.

:ondiions Nozzle & nozzle holder part No. (105780-8140) 6211-12-3600 (105111-4890)
(105780-0000) 6211-12-3620 (1050212290)
) Servicestandard - Nozzle part No.
D Manufacturer Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard is data ’ Oil temperature 40 - 45
(“C)
for factory test.
Nozzle opening pressure (MPa{kg/cm% 17.2 {I751 24.5 (2501
Transfer pump pressure (kPaWcm2)) 157 {I.601 157 (1.60)
Service standard (cc/1000 St.) Manufacturer standard (cc/1000 St.1

njection volume Rack Pump
I Rack positions variance variance
(mm) (mm) volume volume
8 to E are the between cylinder between cylinder
reference volume A
when adjusting 11.5 1,000 174.5 - 178.5 *3 222
(Basic point)
the injection
B 11.5 700 200 - 206 248
volume.
bMarks t are C 6.9 360 21.5 - 24.5 + 15 23.0
average volumes. D 21.5 - 24.5
E 100 160 - 180 200
Boost comoensator stroke:O. 85-l. 05 (mm)
?
E (1 1. 5) (RI)
:,
._
.-
a
:
* (R,) -0. 95,
z
@z
0 15. 3-20. 7 3 I. 3-44.7
(115-1551 (235-335)
Boost Pressure (kPa(mmHsl)
12-11-5
0

1: Injection pump manufacturer’s part No. For MQ generator SAGDI 40-2
DCA-400SSK

I
~Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 365#891/1,800 (Gross,60Hz)
l-5-3-6-2-4 Maximum torque (Nm IkgmY rpm) -

Injection order
Injection interval 59”30’ - 60”30 High idling speed (rpm) Max. 1,890 (60 Hz)
Plunger pm-stroke (mm) 3.85 - 3.95 ILow idling speed (rpm) 1 800 I

120 Motor 7.5 kW
PllYlQUVll G&QII”III” \ ,. ,,,I ““.,“I, CY...p., . ..“..“.1”.“._. ” C’.. ..“...I_.

:ondiiions Nozzle & nozzle holder part No. 6212-12-3300 (105111-4750)
Nozzle part No. 6212-12-3320 (105025-1250)
I Service standard
indicates data Nozzle holder part No. 6212-12-3212 (105041-7122)
using calibration Injection pipe (mm) 6 x 2.2 x 630
test parts. (Outsidedia.x insidedia.x length)
I Manufacturer Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard is data ’ Oil temperature 40 - 45
(“C)
for factory test.
Nozzle opening pressure (MPa{kg/cm% 24.5 (250)
Transfer pump pressure (kPa(kg/cm3) 157 (1.60)
Service standard (cc/1000 St.1 Manufacturer standard (cc/l000 St.1

ijection volume Rack Pump
position speed Injection
point Injection variance variance
Rack positions (mm) (rpm) volume between cylinder volume between cylinder
B to E are the
reference volume A
when adjusting 13.2 900 311 - 321 max. 19.0
(Basic point)
the injection 298 - 310
B 12.4 750
volume.
Marks * are C Approx. 7.1 405 18.5 - 21.5 max. 6.0
average volumes. D 15.0 900 391 - 403
E Rack limt 100 435 - 455
Governor Performance Curve
Min.- max. speed control soec. All speed.idlino set
(1=41.5-50.5 (mm’/st.)
0 405
895-905 Pump speed (rpm)
12-11-6
0

( ): Injection pump manufacturer’s part No. J6D140E-G1-2 SA6D140-2
Injection Injection pump (with electronic
Pump Type Manufacturer governor
TAIYO DENKI
PE-P (PS7S) ZEXEL generator)

282{383}/1,500(Gross 50Hz)
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 318{432}/1,800(Gross 60Hz)
Injection order 1–5–3–6–2–4 Maximum torque (Nm {kgm}/ rpm)
High idling speed (rpm) Max. 1,575 (50 Hz)

Injection interval 59°30’ – 60°30’ Max. 1,890 (60 Hz)


standard is data
for factory test.
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 24.5 {250}
621202
‡ Rack positions voltage speed Injection Injection
point variance variance
B to E are the refer- (V) (rpm) volume volume
between cylinder between cylinder
ence volume when
adjusting the
injection Rated 900 fl265 – 275 ±3
volume. point
‡ Marks fl are
average Low
volumes. idling 400 fl18.5 – 21.5 ± 15
point
Governor performance curve

There is no Governor performance curve because of the mounting fuel injection pump with electronic governor.
12-11-7
6

( ): Injection pump manufacturer’s part No. J6D140E-G1-2 SA6D140-2
Injection Injection pump (with mechanical
Pump Type Manufacturer governor
TAIYO DENKI
PE-P (PS7S) ZEXEL generator)

282{383}/1,500(Gross 50Hz)
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 318{432}/1,800(Gross 60Hz)
Injection order 1–5–3–6–2–4 Maximum torque (Nm {kgm}/ rpm)

Max. 1,575 (50 Hz)
Injection interval 59°30’ – 60°30’ High idling speed (rpm) Max. 1,890 (60 Hz)


standard is data
for factory test.
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 24.5 {250}
621202

B to E are the
reference volume A
when adjusting 900 fl265 – 275 ±3
(Basic point)
the injection
volume. B 750 fl275 – 285 –
‡ Marks fl are C 400 fl18.5 – 21.5 ±15
average volumes. D 900 fl295 – 305 –
E 100 fl435 – 455 –
12-11-8
6

( ): Injection pump manufacturer’s part No. D155AX-5 SA6D140-2
PE-P (PS3S) ZEXEL



standard is data
for the engine on
621202
B to E are the
reference volume A
when adjusting 10.7 950 fl148.5 – 152.5 ±3 fl203
(Basic point)
the injection
volume. B 11.45 625 fl196 – 202 – fl250
‡ Marks fl are C approx. 7.1 350 fl21.5 – 24.5 ±15 fl23
average volumes. D
E – 100 fl155 – 175 – fl195
12-11-9
7

( ): Injection pump manufacturer’s part No. D155AX-5 SA6D140-2
PE-P (PS3S) ZEXEL



standard is data
for the engine on
621202

B to E are the
reference volume A
when adjusting 10.7 900 fl154 – 158 ±3 fl207
(Basic point)
the injection
volume. B 11.45 625 fl196 – 202 – fl250
‡ Marks fl are C approx. 7.1 350 fl8.5 – 11.5 ±15 fl23
average volumes. D
E – 100 fl170 – 190 – fl195
12-11-10
7

( ): Injection pump manufacturer’s part No. D155C-1A SA6D140-2
Injection Injection pump (–30°C spec.)
BOSCH
PE-P (T-27) automotive
system



standard is data
for the engine on
621202
B to E are the
reference volume A
when adjusting 11.1 1,000 206 ± 2 ±3
(Basic point)
the injection
volume. B 11.1 700 (survey) ±3 –
‡ Marks fl are C 6.9 360 23 ±1.5 ±15
average volumes. E – 100 200 ± 10 –
12-11-11
(8)
TESTING AND ADJUSTING PERFORMANCE TEST
PERFORMANCE TEST
RUN-IN STANDARD * The table gives the standard values for machines without fan.
* The loads for the dynamometer are at an arm’s length of 716 mm.
Engine Applicable Item Order

model machine 1 3 4 5 6
-
Running time nin. 2 8 2 3 5
Engine speed rpm 650 1,300 1,650 1,900 2,100
3 D825A-2 Load N 0 343 686 1,030 1,373

{kg) 10) I351 I701 (105) {I401
Flywheel kW 0 33.9 85.4 147.2 216.4

horsepower HiPI IO) (45.41 (I 14.41 {I 97.2) (289.9)
S6D140-2
Running time nin. 2 8 2 3 5
Engine speed rpm 725 1,000 1,200 1,500 2,100
NA500-3 Load N 0 392 785 1,177 1,569

{kg1 10) I401 I801 (1201 I1601
Flywheel kW 0 29.4 70.7 132.5 247.3

horsepower K-IF’1 (01 (39.41 l94.7) (177.5) (331.3)
Running time nin.
Engine speed rpm
Load N
{kg)
Flywheel kW
horsepower U-LPI
Running time min.
Engine speed rpm
Load N
(kg1
Flywheel kW
horsepower U-IPI
Running time min.
Engine speed rpm
Load N
(kg)
Flywheel kW
horsepower (HP1
-
12-12
0
fl The table gives the standard values for machines without fan.
fl The loads for the dynamometer are at an arm’s length of 716 mm.

model machine 1 2 3 4 5 6
Running time min. 2 8 7 10 3
Engine speed rpm 700 1,100 1,450 1,710 1,900

D155A-3
Load N 0 432 863 1,285 1,716
D155AX-3 {kg} {0} {44} {88} {131} {175}
Flywheel kW 0 35.6 93.9 164.9 244.7

horsepower {HP} {0} {47.7} {128.5} {220.9} {327.8}
Engine speed rpm 750 1,000 1,200 1,500 1,800
PC1600SP-1 Load N 0 618 1,226 1,844 2,452

{kg} {0} {63} {125} {188} {250}
Flywheel kW 0 46.4 110.4 207.6 331.2

horsepower {HP} {0} {62.1} {147.9} {278.1} {443.7}
621202
Engine speed rpm 800 1,000 1,200 1,500 1,800

DCA400SSK-2
SA6D140-2 (DENYO Load N 0 539 1,844 2,157 2,707
generator) {kg} {0} {55} {188} {220} {276}
Flywheel kW 0 40.5 166.3 242.9 365.8

horsepower {HP} {0} {54.2} {222.8} {325.4} {490.0}
Engine speed rpm 550 – 650 1,000 1,200 1,500 2,000
D155A-2 Load N 0 353 883 1,410 1,770

{kg} {0} {36} {90} {144} {180}
Flywheel kW 0 26 79 159 265

horsepower {HP} {0} {35} {106} {213} {355}
Engine speed rpm 700 – 750 1,000 1,200 1,500 2,000
D355C-3 Load N 0 373 932 1,490 1,860

{kg} {0} {38} {95} {152} {190}
Flywheel kW 0 28 84 168 279

horsepower {HP} {0} {37} {112} {225} {375}
12-13
3
6

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

DCA-400SSK
(MQ Load N 0 540 1,840 2,160 2,700
generator) {kg} {0} {55} {188} {220} {276}
Flywheel kW 0 40 166 243 366

horsepower {HP} {0} {54} {223} {325} {490}
Engine speed rpm 800 1,000 1,200 1,500 1,800

J6D140E-GI-2
(TAIYO DENKI Load N 0 470 1,180 1,880 2,350
generator) {kg} {0} {48} {120} {192} {240}
Flywheel kW 0 35 106 212 318

horsepower {HP} {0} {48} {146} {292} {438}
621202
Engine speed rpm 700 1,000 1,200 1,500 1,900

SA6D140-2
D155AX-5 Load N 0 353 883 1,410 1,770
{kg} {0} {36} {90} {144} {180}
Flywheel kW 0 26 79 159 252

horsepower {HP} {0} {36} {109} {219} {347}
12-13-1
6

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

HD325-6
Load N 0 588 1,177 1,765 2,354
HD405-6 {kg} {0} {60} {120} {180} {240}
Flywheel kW 0 57.4 145.7 251.7 370.9

horsepower {HP} {0} {76.9} {195.2} {337.2} {496.9}
Engine speed rpm 725 1,000 1,200 1,500 2,000
SAA6D140-2 HD325-6 Load N 0 490 1,030 1,569 1,961

(High altitude spec.) {kg} {0} {50} {105} {160} {200}
Flywheel kW 0 36.8 92.7 176.6 294.4

horsepower {HP} {0} {49.3} {124.2} {236.6} {394.4}
621202
PC750-6 Engine speed rpm 825 1,000 1,200 1,500 1,800
PC800-6 Load N 0 588 1,275 2,060 2,550

{kg} {0} {60} {130} {210} {260}
PC1800-6
Flywheel kW 0 44 115 232 344
horsepower {HP} {0} {60} {156} {315} {463}
Engine speed rpm 700 1,000 1,200 1,500 2,000
D275A-5 Load N 0 441 1,110 1,770 2,220

(–50°C spec.) {kg} {0} {45} {113} {180} {226}
Flywheel kW 0 33 100 199 332

horsepower {HP} {0} {45} {136} {270} {452}
SDA6D140E-2
12-13-2
7
TEST CRITERIA
* The table gives the standard values using the JIS compensator
factor.
* 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).
* The loads for the dynamometer are at an arm’s length of 716 mm.
Engine Applicable Test item Specified value Engine speed Dynamometer

model machine Load
(rpm) (NIkgI)
Flywheel horsepower 209.0 kWl2,lOO rpm 2,095 - 2,105 1,360 - 1,440

1280.0 HP/2,100 rpm) (139 - 1471
Maximum torque 1,255 Nm/1,400 rpm 1,300 - 1,500 1,730 - 1,840
3D825A-2 (128 kgm/l,400 rpm) (177 - 187)
High idling speed 2,300 - 2,400 rpm 2,300 - 2,400 -
Low idling speed 600 - 650 rpm 600 - 650 -

S6D140-2
Flywheel horsepower 235.5 kW/2,100 rpm 2,095 - 2,105 1,520 - 1,610
1315.5 HP/2,100 rpm1 (155 - 1641
Maximum torque 1,373 Nm/1,400 rpm 1,350 - 1,450 1,890 - 2,010
NA500-3 040 kgm/1,400 rpm1 1193 - 2051
High idling speed 2,300 - 2,400 rpm 2,300 - 2,400 -
Low idling speed 700 - 750 rpm 700 - 750 -
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
12-14
0
* For fuel, use ASTM D975 No. 1 or No. 2.

* For lubricant, use SAE15W-40 or SAEBO oil.
Flywheel Torque Fuel Coolant .ubricationoil Lubrication Exhaust

horsepower consumption emperature temperature oil pressure emperature
(kW{HPI) (NmIkgmI) (sed200cc) (“C) VC) (kPaIkg/cmZI) (“C)
214.5 - 227.1 - Min. 17.3 70 - 90 go- 110 340 - 490 Max. 650
1287.4 - 304.2) 13.5 - 5.01 Max. 650
1,242 - 1,316 70 - 90 go- 110 -
126.6 - 134.21
- 70 - 90 go- 110 - -
- 70 - 90 Min. 80 Min. 120{1.2} -
238.9 - 253.6 - Min. 15.7 70 - 90 go- 110 340 - 490 Max. 650
1320.1 - 339.81 (3.5 - 5.01
1,352 - 1,439 70 - 90 go- 110 - Max. 650
137.9 - 146.71
- 70 - 90 90 - 110 - -
- 70 - 90 Min. 80 Min. 118{1.2} -
12-15
0
fl The table gives the standard values using the JIS compensator
factor.
fl The values in the table are the standard values for machines with
model machine Load
(rpm) (N{kg})
Flywheel horsepower 225.2 kW/1,900 rpm 1,895 – 1,905 1,671 – 1,773

{301.7 HP/1,900 rpm} {170.4 – 180.8}
D155A-3 Maximum torque 1,432 Nm/1,300 rpm 1,250 – 1,350 2,002 – 2,124
{146 kgm/1,300 rpm} {204.1 – 216.6}
D155AX-3 High idling speed 2,050 – 2,150 rpm 2,050 – 2,150 —
Low idling speed 700 – 725 rpm 700 – 725 —

{424.0 HP/1,800 rpm} {242.5 – 257.5}
Maximum torque 1,863 Nm/1,400 rpm 1,300 – 1,500 2,606 – 2,764
PC1600SP-1 {190 kgm/1,400 rpm} {265.7 – 281.8}
High idling speed 1,930 – 2,030 rpm 1,930 – 2,030 —
621202
Flywheel horsepower 309.9 kW/1,500 rpm 50Hz 1,495 – 1,505 50Hz 2,714 – 2,883 50Hz
{415.1 HP/1,500 rpm} 50Hz {276.7 – 294.0} 50Hz
357.0 kW/1,800 rpm 60Hz 1,795 – 1,805 60Hz 2,621 – 2,783 60Hz
DCA400SSK-2 {478.2 HP/1,800 rpm} 60Hz {267.3 – 283.8} 60Hz
SA6D140-2 (DENYO Maximum torque — —
generator)
High idling speed Max. 1,568 rpm 50Hz Max. 1,568 50Hz —
Max. 1,881 rpm 60Hz Max. 1,881 60Hz
Flywheel horsepower 253 kW/2,000 rpm 1,995 – 2,005 1,730 – 1,820

{339 HP/2,000 rpm} {176 – 186}
D155A-2 {164 kgm/1,400 rpm} {227 – 240}

{355 HP/2,000 rpm} {183 – 194}
D355C-3 {160 kgm/1,400 rpm} {222 – 235}
Flywheel horsepowe 357 kW/1,800 rpm (60 Hz) 1,795 – 1,805 (60 Hz) 2,620 – 2,780 (60 Hz)
{478 HP/1,800 rpm} (60 Hz) {267 – 284} (60 Hz)
DCA-400SSK Maximum torque — — —
(MQ
generator) High idling speed Max. 1,890 rpm (60 Hz) Max. 1,890 (60 Hz) —
12-16
3
6
* For fuel, use ASTM D975 No. 1 or No. 2.

* For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel Torque Fuel Coolant Lubricationoi Lubrication Exhaust

horsepower consumption temperature temperature oil pressure temperature
(kWIHP1) (Nm{kgmII (sed200cc) 1°C) (“C) (kPa(kg/cm2)) I”C)
238.2 - 252.9 Min. 16.8 70 - 90 90 - 110 340 - 490 Max. 650

j319.1 - 338.8) (3.5 - 5.0)
1,433 - 1,521 70 - 90 90 - 110 - Max. 650
c146.1 - 155.1)
- 70 - 90 90 - 110 - -
- 70 - 90 Min. 80 Min. 118{1.21 -
321.3 - 341.1 - Min. 12.3 70 - 90 90 - 110 340 - 490 Max. 650

1430.4 - 457.0) l3.5 - 5.0)
1,865 - 1,979 70 - 90 go- 110 - Max. 650
L190.2 - 201.8)
- - - 70 - 90 90 - 110 - -
- - - 70 - 90 Min. 80 Min. 12Of1.21 -
% 305.4 - 324.6 5OHz Min. 13.0 50Hz 70 - 90 90 - 110 290 - 490 50Hz Max. 650
cv
F (409.2 - 434.8) 5OHz Min. 10.6 6OH2 :3.0 - 5.0) 50Hz
s: 354.0 - 376.1 6OHz 70 - 90 90 - 110 290 - 490 6OHz Max. 650
1474.3 - 503.8) 60Hz :3.0 - 5.01 60Hz
- -
- - 70 - 90 90 - 110 -
- - 70 - 90 Min. 80 Min. 18OU.81 -
258 - 274 - - 70 - 90 go- 110 340 - 490 Max. 650

(346 - 368) 13.5 - 5.0)
- 1,590 - 1,690 70 - 90 90 - 110 - Max. 680
(162 - 172)
- - - 70 - 90 90 - 110 - -
- - - 70 - 90 80 - 110 Min. 120{1.2) -
269 - 285 - - 70 - 90 90 - 110 340 - 490 Max. 650

(361 - 382) (3.5 - 5.01 .
- 1,560 - 1,650 70 - 90 90 - 110 - Max. 680
{159 - 1681
- - - 70 - 90 90 - 110 - -
- - - 70 - 90 80 - 110 Min. 120{1.2) -
354 - 376 (60 Hz) - Min. 10.6 160 Hz) 70 - 90 90 - 110 340 - 490 Max. 650
1474 - 504) (60 Hz) 13.5 - 5.01
- - - - - - -
- - 70 - 90 90 - 110 -
- - - 70 - 90 90 - 110 Min. 18Of1.81 -
12-17
0
factor.
model machine Load
(rpm) (N{kg})
Flywheel horsepower 271 kW/1,500 rpm (Net, 50 Hz) 1,495 – 1,505 (50 Hz) 2,430 – 2,580
374 HP/1,500 rpm (Net, 50 Hz) {248 – 263}
J6D140E-G1-2 299 kW/1,800 rpm (Net, 60 Hz) 1,795 – 1,805 (60 Hz) 2,290 – 2,420
(TAIYO DENKI 412 HP/1,800 rpm (Net, 60 Hz) {233 – 247}
generator) High idling speed MAX. 1,575 rpm (50 Hz) MAX. 1,575 (50 Hz) —
MAX. 1,890 rpm (60 Hz) MAX. 1,890 (60 Hz)
SA6D140-2
Flywheel horsepower 232 kW/1,900 rpm (Net) 1,895 – 1,905 1,730 – 1,820
{320 HP/1,900 rpm} (Net) {176 – 186}
Maximum torque 1,610 Nm/1,250 rpm (Net) 1,150 – 1,350 2,250 – 2,380
D155AX-5 {164 kgm/1,250 rpm} (Net) {229 – 243}
621202
Flywheel horsepower 255 kW/2,000 rpm (Gross) 1,995 – 2,005 1,650 – 1,750
{342 HP/2,000 rpm} (Gross) {168.5 – 178.5}
Maximum torque 1,490 Nm/1,400 rpm (Gross) 1,300 – 1,500 2,020 – 2,150
D155C-1A
{152 kgm/1,400 rpm} (Gross) {206 – 219}
(–30°C spec.)
High idling speed 2,190 – 2,290 rpm 2,190 – 2,290 ––
Low idling speed 700 – 750 rpm 700 – 750 ––
12-18
(8)
fl For fuel, use ASTM D975 No. 1 or No. 2.

fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel Torque Fuel Coolant Lubrication oil Lubrication Exhaust
(kW{HP}) (Nm{kgm}) (sec/200cc) (°C) (°C) (kPa{kg/cm2}) (°C)
273.6 – 289.8 (Gross, 50Hz) — Min. (50 Hz) 70 – 90 90 – 110 290 – 490 Max. 650
{337.3 – 399.6} (Gross, 50Hz) {3.0 – 5.0}
308.9 – 326.6 (Gross, 60Hz) — Min. (60 Hz) 70 – 90 90 – 110 290 – 490 Max. 650
{425.9 – 450.4} (Gross, 60Hz) {3.0 – 5.0}
— — 70 –90 90 – 110 — —
— — 70 – 90 80 – 110 Min. 120 {1.2} —
245 – 260 (Gross) — — 70 – 90 90 – 110 343 – 490 Max. 650

{328 – 348} (Gross) {3.5 – 5.0}
— 1,608 – 1,706 (Gross) — 70 – 90 90 – 110 — Max. 650
{164 – 174} (Gross)
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 120 {1.2} —

621202
248 – 262 (Gross) — — 70 – 90 90 – 110 340 – 490 Max. 650

{332 – 352} (Gross) {3.5 – 5.0}
— 1,447 – 1,535 (Gross) — 70 – 90 90 – 110 — Max. 650
{147.5 – 156.5} (Gross)
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 180 {1.8} —
12-18-1
(8)
factor.
model machine Load
(rpm) (N{kg})

{507.8 HP/2,000 rpm} {244.5 – 259.5}
HD325-6 Maximum torque 2,167 Nm/1,350 rpm 1,300 – 1,500 2,902 – 3,083
{214 kgm/1,350 rpm} {296.0 – 314.4}
HD405-6 High idling speed 2,300 – 2,450 rpm 2,300 – 2,400 —

{411.2 HP/2,000 rpm} {196.8 – 209.3}
SAA6D140-2 HD325-6 {179 kgm/1,400 rpm} {239.7 – 253.6}
(High altitude spec.) High idling speed 2,350 – 2,450 rpm 2,350 – 2,450 2,350 – 2,450
Low idling speed 675 – 775 rpm 675 – 775 675 – 775
621202
PC750-6 {443.7 HP/1,800 rpm} {242.5 – 257.5}
PC800-6 {214 kgm/1,350 rpm} {153.8 – 163.3}
High idling speed 1,930 – 2,030 rpm —
PC1800-6
Low idling speed 800 – 850 rpm —

{446 HP/2,000 rpm} {222 – 235}
Maximum torque 2,030 Nm/1,400 rpm 1,300 – 1,500 Min. 2,834 {289}
D275A-5 {207 kgm/1,400 rpm}
(–50°C spec.) High idling speed 2,150 – 2,250 rpm 2,150 – 2,250 —
Flywheel horsepower
Maximum torque
SDA6D140E-2
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
12-18-2
7
fl For fuel, use ASTM D975 No. 1 or No. 2.

fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel Torque Fuel Coolant Lubrication oil Lubrication Exhaust
(kW{HP}) (Nm{kgm}) (sec/200cc) (°C) (°C) (kPa{kg/cm2}) (°C)
359.9 – 381.7 Min. 11.2 70 – 95 90 – 110 340 – 490 Max. 650

{482.2 – 511.7} {3.5 – 5.0}
2,079 – 2,208 — 70 – 95 90 – 110 — —
{212.0 – 225.2}
— — 70 – 80 90 – 110 — —
— — 70 – 80 Min. 80 Min. 118{1.2} —
289.6 – 308.0 — Min. 13.5 70 – 85 90 – 110 343 – 490 650

{388.0 – 412.6} {3.5 – 5.0}
1,683 – 1,781 70 – 85 90 – 110 — 700
{171.6 – 181.6}
— 70 – 85 90 – 110 — —
— 70 – 85 90 – 110 Min. 147{1.5} —

621202
321.3 – 341.1 — Min. 12.3 70 – 95 90 – 110 340 – 490 Max. 650

{430.4 – 457.0} {3.5 – 5.0}
— 2,036 – 2,161 70 – 95 90 – 110 — —
{207.6 – 220.4}
— — 70 – 90 90 – 110 — —
— — 70 – 90 80 – 110 Min. 118{1.2} —
325 – 345 — Min. 11.8 70 – 90 90 – 110 340 – 490 Max. 650

{436 – 463} {3.5 – 5.0}
Min. 2,030 {207} — 70 – 90 90 – 110 340 – 490 —
{3.5 – 5.0}
— — 70 – 90 90 – 110 340 – 490 —
{3.5 – 5.0}
— — 70 – 90 80 – 110 Min. 118{1.2} —
12-18-3
7
TROUBLESHOOTING
Points to remember when troubleshooting .......................................................................................... 12-21
Method of using troubleshooting charts ............................................................................................... 12-22
s- 1 Starting performance is poor (starting always takes time) .................................................... 12-26
s- 2 Engine does not start ................................................................................................................. 12-27
(1) Engine does not turn ............................................................................................................ 12-27

(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ................ 12-28
(3) Exhaust smoke comes out, but engine does not start (fuel is being injected) ............. 12-29
s- 3 Engine does not pick up smoothly ........................................................................................... 12-30
s- 4 Engine stops during operations ................................................................................................ 12-31
s- 5 Engine does not rotate smoothly (hunting) ............................................................................. 12-32
S- 6 Engine lacks output (no power). ...................... .:.. ...................................................................... 12-33
s- 7 Exhaust gas is black ................................................................................................................... 12-34
S- 8 Oil consumption is excessive, or exhaust gas is blue ............................................................ 12-35
s- 9 Oil becomes contaminated quickly ........................................................................................... 12-36
S-IO Fuel consumption is excessive .................................................................................................. 12-37
2 S-l 1 Oil is in cooling water ................................................................................................................ 12-38

& s-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................... 12-39
(0
s-13 Oil level rises (water, fuel in oil) ............................................................................................... 12-40
s-14 Water temperature becomes too high (overheating) .............................................................. 12-41
s-15 Abnormal noise is made ............................................................................................................ 12-42
S-16 Vibration is excessive ................................................................................................................. 12-43
12-19
TESTING AND ADJUSTING TROUBLESHOOTING
A When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit
safety pins, block the wheels, and apply the parking brake.
A When carrying out operations with two or more workers, always use signals, and do not allow any
unauthorized person near the machine.
A When checking the water level, if the radiator cap is removed when the engine is hot, boiling water
will spurt out and may cause burns, so always wait for the engine to cool down before checking
the water level.
A Be extremely careful not to touch any hot parts.
A Be extremely careful not to get caught in the fan or any other rotating parts.
A 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.
* 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.
1Z-20
TESTING AND ADJUSTING TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs, and
ensuring that the failure does not occur again.
When carrying out troubleshooting, it is of course important to understand the structure and function.
But to carry out the troubleshooting effectively, a quick method is to carry out troubleshooting using
the problems mentioned by the operator as a guide in locating the cause.
Do not disassemble the machine simply 4. Confirming failure

because there is a failure Check the degree of the problem to judge
If the machine is disassembled immediately for yourself if it is really a failure, or if there
just because there is a failure: is some problem in the handling or opera-
l Unrelated or unnecessary places are also tion of the machine.
disassembled * When driving the machine and re-enact-
l It becomes difficult to locate the cause ing the failure, be sure that the investi-
of the failure gation or measurement does not make
This means that there is not only a waste of the failure worse.
time and money on replacement parts, oil,
and grease, but this action will also lose the 5. Troubleshooting
confidence of the user and operator. Narrow down the cause of the failure from
For this reason also, it is important to carry the results of the questions and checks in
out troubleshooting based on full investiga- the above Items 2 - 4, then follow the trou-
tion before starting and troubleshooting fol- bleshooting flow charts to locate the failure.
lowing before the correct order. * Basic procedure for troubleshooting
I) Start from the simple places.
Questions to ask the user and operator 2) Start from the most probable places.
1) Are there any problems otherthan those 3) Investigate related parts also.
already reported?
2) Did anything unusual happen before the 6. Basic action to remedy cause of failure
failure occurred? Even if the failure is repaired, if the root
3) Did the failure occur suddenly, or had cause of the failure is not repaired, the same
the condition of the machine been poor failure will occur again.
before the failure occurred? To prevent this, it is necessary to investigate
4) What were the conditions when the fail- why the failure occurred, and to remove the
ure occurred? root cause of the failure.
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 car-
ried out visually, so carry out any check
that is considered necessary.
12-21
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from 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 @ + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user’s level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
12-22
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items1 that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with Q.
Check each of the [Questions] and [Check items1 in
turn, and marked the 0 or Q 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.
‘%I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with a to use as reference
4 for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
,%2. Use the D in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
:
12-23
. 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 iniection of fuel
12-24
9 Five causes
Clarify the relationship between the three

Step 1
symptoms in the [Questions] and [Check items1

section and the five Cause items in the vertical
column.
Three symptoms
t ’ ’
JI
Add up the total of Oand Omarks where the
SteD 2
horizontal lines for the three symptoms and the

vertical columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculation in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
12-25
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)

fl 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
• Insufficient intake of air
• Improper selection of fuel
(At ambient temperature of 10˚C or below, use
ASTM D975 No. 1)
fl Battery charging rate Causes
Charging rate
)
Ambient tem-
100% 90% 80% 75% 70%
in fuiping r stuck
perature
20°C 1.28 1.26 1.24 1.23 1.22
ap
nk c
0°C 1.29 1.27 1.25 1.24 1.23
e
her in fuel k, plung
at
ater
Defeged fee l filter, elemen alve se
–10°C 1.30 1.28 1.26 1.25 1.24
el ta
Lea ctive in ection ozzle ttery
ir he
p
• The specific gravity should exceed the value
c
air b ging, a mp (ra
Defective el d pump trainer t
v
n d ba
Defective al ulator ntake a
Defective re ctrical straine
for the charging rate of 70% in the above table.
Clogged fuecleaner valve,

Clogged air ntact o linder
hole
pu g
in
e
• In cold areas the specific gravity must ex-
r
a
i
r
y
i
s
i
ceed the value for the charging rate of 75%
t
ator
Defective in deterio
Clogctive co ring, c
Defe ve in tion
Clog e, clo tion

reat
in the above table.
tern
c
g
e
e
g
e
j
j
Defe piston
j
e or
Legend
: Possible causes (judging from Questions and check items)
ged
v
kag
i
i
: Most probable causes (judging from Questions and Check items)
t
c
c
n
Defe
Wor
: Possible causes due to length of use (used for a long period)

: Items to confirm the cause
621202
Confirm recent repair history
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

Engine oil must be added more frequently
Replacement of filters has not been carried out according to Operation Manual
Dust indicator is red
Non-specified fuel is being used
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Blow-by gas is excessive
Check items
Match marks on fuel injection pump are out of alignment

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pipe sleeve
nut is loosened
2) Little fuel comes out even when fuel filter air bleed
plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When compression pressure is measured, it is found to be low
When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Troubleshooting
Heater mount does not become warm

Is voltage 26 – 30V between alternator terminal Yes
B and terminal E with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When control rack is pushed, it is found to be heavy or does
not return (when blind cover at rear of pump is removed, it
can be seen that plunger control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12-26
6
TROUBLESHOOTING s-2
S-2 Engine does not start

(I) Engine does not turn
General causes why engine does not turn

. Internal parts of engine seized
* If internal parts of the engine are seized,
carry out troubleshooting for “Engine
stops during operations”.
Causes
. Failure in power train
. Defective electrical system
Legend
0 : Possible causes (judging from Questions and check items)
When starting switch is

turned to START, pinion
moves out, but
OFF, connect the cord, and carry out troubleshooting at ON

1) When terminal B and terminal C of starting switch are
connected, engine starts .-9
2) When terminal B and terminal C of starting motor are 2
connected, engine starts $
3) When terminal B and terminal C of safety relay are 5
connected, engine starts P
4) When terminal of safety switch and terminal B of ‘g
_?
starting motor are connected, engine starts
1
5) There is no 24V voltage between battery relay terminal o
band terminal E z
&
When ring gear is inspected directly, tooth surface is found g
0
to be chipped z
Does not move even when fuel cut solenoid linkage is disconnected
Does not move even when engine stop motor linkage is disconnected
12-27
TROUBLESHOOTING s-2
(21 Engine turns but no exhaust smoke comes

out (fuel is not being injected)
General causes why engine turns but no ex-

haust smoke comes out
l Supply of fuel impossible
l Supply of fuel is extremely small
. Improper selection of fuel (particularly in win-
ter)
* Standards for use of fuel
Ambient temprature
Tape of fuel -22 -4 -El 32 50 68 86 104°F
-30 -20 0 10 20 30 4OT
Legena
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
I Rust and water are found when fuel tank is drained I I I lnlnl I
Check injection pump directly 1.1 1 ) 1 1 1 I 1 ) 1
When control rack is pushed, it is found to be heavy, or does not return l
Check feed pump directly
When feed pump strainer is inspected directlv, it is found to be
Does not move even when fuel cut solenoid linkaae is d
12-28
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does

not start
(Fuel is being injected)
fl General causes why exhaust smoke comes

out but engine does not start Causes
• Lack of rotating force due to defective elec-
.)
r, etc
trical system
)
tuck
• Insufficient supply of fuel
ck, p ker leve
ap
er s
in fu e spray
nk c
lung
defe tem
roc
• Improper selection of fuel and oil
el ta
Clog e, clogg iorated r heate
ctiv
sys
pum (valve,
ery
iner
batt
fuel
p (ra
trica lement
r
i
filte linder l
dete ntake a
lean straine
er
m
ole
zle,
n
Wor ve injec lve syste
ir in
a i
r fue ather h
r
noz
er e
r, st
a
, cy
li
p
ed
ing,
tion
pum
tion
va
ring
l us
re
Defe , broken
Defe ve elec
njec
air b
feed
air c
fuel
ton
e or
Legend
i
rope
ged
ged
ged
ged
ged
ctiv
n pi
ctive
kag
cti
cti
Clog
Clog
Clog
Defe
Clog
Defe
Imp
Lea
: Items to confirm the cause.
Suddenly failed to start
When engine is cranked, abnormal noise is heard from around head
Questions

621202
Replacement of filters has not been carried out according

to Operation Manual
Rust and water are found when fuel tank is drained
Preheating indicator lamp does not light up
Starting motor cranks engine slowly
Mud is stuck to fuel tank cap
When fuel lever is placed at FULL position, it does not contact stopper
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pipe
Check items
sleeve nut is loosened

2) No fuel comes out even when fuel filter air bleed
plug is loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or does not return
Troubleshooting
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
12-29
6
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly (follow-up is poor)

Causes
Ir Check that the monitor panel does not display any

abnormality in the governor control system.
General causes why engine does not pick up smoothly’
. insufficient supply of fuel
. Improper fuel used
Legend
th of use fused for a long period)
to Operation Manual
z Non-specified fuel is being used
.P
z Engine oil must be added more frequently
2
CI Rust and water are found when fuel tank is drained
Noise of interference is heard from around turbocharger
/ Engine pick-up suddenly became poor
Color of exhaust gas
but speed suddenly drops when load is applied
3 When turbocharger is rotated by hand, it is found to be heavy 0

51
2 Whenvalve clearanceis checkeddirectly, it is found to be outside standardvalue 0
<
When fuel cap is inspected directly, it is found to be clogged 0
When feed pump is operated, operation is too light or too heavy 0
I
12-30
TROUBLESHOOTING s-4
S-4 Engine stops during operations

General causes why engine stops during opera-
tions
l Seized parts inside engine
. Insufficient supply of fuel
l Overheating
* If there is overheating and insufficient out- Causes
put, carry out troubleshooting for over-
heating.
. Failure in power train
* If the engine stops because of a failure in

the power train, carry out troubleshoot-
ing for the chassis.
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
n : Possible causes due to length of use fused for a long period)
Condition when
engine stopped
Fuel gauge lamp lights up I lo,1 I I I I I I

__. ._ . in_ fntilnd
F~lnl tank __. _ tn
._ he
__ emntv
_...r., II II II II II II 101
I
_
I
I I I I I I
Replacement of filters has not been carried out according to
00
operation manual
Non-specified fuel is being used 00 0
When feed pump is operated, there is no response or it i 0
Mud is stuck to fuel tank cap Q
_..I..._._..._,__._._r_.. .._...._.._....__._..
__...._.._._..__r_._.__ v
Does not turn at all 00

Try to turn by
Turns in opposite direction 0
hand using
Moves amount of backlash 00 E
barring tool 3
Shaft does not turn 0 o
I I I I I I I Ifi
>
Rust and water are found when fuel is drained I I I I I I wo .I
I I I I lolol I I I D
I I
Metal particles are found when oil is drained loI
12-31
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
Causes
smoothly
• Air in fuel system
zzle
p
• Defective governor mechanism
o
pum
on n
• Defective electric governor mechanism
feed
jecti
fl If hunting does not occur when the rod
nd in
and
ap
between the governor motor and the in-
nk c
mp a
tank
jection pump is disconnected, trouble-
el ta
rack
shoot by using the electrical system trou-
d pu
or
uel
rnor
vern
in fu
bleshooting (E mode).
en f
e
trol
e
er
f
ove
w
o
n
er
twe
con
rain
twee
g
o lo
hole
rain
of g
t of
t be
n of
p st
is to
it be
r, st
her
men
rcui
ion
pum
ratio
circu
reat
eed
filte
erat
just
in ci
Legend
e
g sp
air b
feed
air in
fuel
e op
e op
e ad
, air
el
of fu
idlin
ged
ged
ged
ctiv
ctiv
ctiv
ged
ged,
Defe
Defe
Defe
Clog
Clog
Clog
Lack
Clog
Low
Clog
Occurs at a certain speed range
Occurs at low idling
Condition of hunting
Questions
Occurs even when speed is raised
621202
Occurs on slopes
Fuel tank is found to be empty
to Operation Manual
Rust, water are found when fuel tank is drained
When feed pump is operated,
1) No response, light, return is quick
Check items
2) No response, light, return is normal

Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
improperly adjusted
Troubleshooting
When control rack is pushed, it is found to be heavy, or

does not return
When feed pump strainer is inspected directly, it is found to
be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
12-32
6
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

General causes why engine lacks output
. Insufficient supply of fuel
. Improper fuel used
(if non-specified fuel is used, output drops)
. Lack of output due to overheating
* If there is overheating and insufficient output,
carry out troubleshooting for overheating.
Power was lost

Gradually
I
.g Engine oil must be added more frequently I I loI I I I I I I I I 1
I Replacement of filters has not been carried out according
0 00
4 to Operation Manual
Non-specified fuel is being used 0000
/l Dust indicator is red 101 I I I I
Y8”U.R

Blue under ~grr~ ww w
/
Noise of interference is heard from around turbocharger 0
Blow-bv oas is excessive I I
12-33
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(incomplete combustion) Causes
ea d
d)
)
tion
General causes why exhaust smoke is black
eize
der h
njec
er s
ray
at
cylin
e se
• Improper condition of fuel injection
e sp
lung
ve i
r a nd
valv
• Excessive injection of fuel
essi
e
ctiv
ck, p
renc
er
a rg e
d
defe
(exc
r lin
e an
p (ra
ent
erfe
b o ch
g
r
e
inde
lem
zle,
mp
valv
imin
ranc
, int
pum
fl
n tur
f
z
u
er e
, cyl
n no
p
rger
m
clea
on t
t of
w ee
ion
ion
d
lean
ring
ntac
ctio
e
cha
ecti
ject
ject
lve
r b et
g
Legend
g
air c
urbo
inje
o
ston
r inj
r va
e co
e in
e in
of ai
l
d, c
rope
rope
ged
ged
ctiv
ctiv
ctiv
n pi
ed t
she
age
Clog
Clog
Defe
Defe
Defe
Wor
Seiz
Leak
Imp
Imp
Cru

Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Suddenly
Power was lost
Gradually
621202
Engine pickup is poor and combustion is irregular
Check items
Match marks on fuel injection pump are out of alignment

Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and cylinder head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
Troubleshooting

When check is made using delivery method, injection timing is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be outside standard value
When muffler is removed, exhaust color returns to normal
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
12-34
6
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

Ir Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-
sive
. Abnormal combustion of oil
. External leakage of oil
. Wear of lubrication system
Causes
Legend
0 : Most probable causes (judgingfrom Questions and Check items)
n : Possible causes due to length of use fused for a long period)
Amount of blow-by gas
found to be dirty with oil
When compression pressure is measured, it is found to be low l l

When breather element is inspected, it is found to be clogged with dirty oil I I.1 I I I I I I I I I
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with oil 1 10

I I I I I I I I I I I I I I
12-35
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
Causes
end
bine
r tur
tube
se
er
r ho
r lin
arge
ain
athe
inde
r dr
och
ide
lack
, bre
e
arge
e gu
turb
, cyl
valv
is b
r
ther
oole
ring
valv
och
ilter
t
fety
al a
oke
Legend
brea
oil c
turb
oil f
ston
e se
e sa
lve,
t sm
n va
ged
ged
ged
ged
ctiv
ctiv
n pi
aus
Clog
Clog
Clog
Clog
Defe
Defe
W or
W or
Exh
621202
Questions

Non-specified oil is being used

Black
Excessive
Carry out troubleshooting for “Exhaust smoke is black”.
Amount of blow-by gas

None
Check items
Oil filter caution lamp stays on even when oil pressure rises
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly

When breather element is inspected directly, hose is broken
or is found to be clogged with dirty oil
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
12-36
6
TROUBLESHOOTING S-IO
S-IO Fuel consumption is excessive

General causes why fuel consumption is exces-
sive
. Leakage of fuel
. Excessive injection of fuel
I Causes I
Possible causes ljud from Questions and check items

from Questions and Ch
Condition of fuel
Injection pump measurement shows that injection amount is excessive
.-F When control rack is pushed, it is found to be heavy, or does not return
i;
2 When check is made using delivery method, injection timing
1 is found to be incorrect
o
: Remove head cover and inspect directly
;
Remove feed pump and inspect directly
1 When engine speed is measured, low idling speed is found to be high
Remedy
12-37
TROUBLESHOOTING S-l 1
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
Legend
n : Possible causes due to length of use (used for a long period)
12-38
TROUBLESHOOTING s-12
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
* Standards for engine oil selection
r
1 Type of oil
Diesel fuel
Legend
0 : Most probable causes (judgingfrom Questions and Check items)
n : Possible causes due to length of use (used for a long period)
Degree of use of machine Operated for long period aa n

g Replacement of filters has not been carried out according
.o
;; 0
to Operation Manual
S
u Caution lamp lights up 0 0
Condition when oil
pressure lamp lights up
1 When oil filter is inspected directly, it is found to be clogged 1l 1l 1 1

Remove oil pan and inspect directly aa
.-F Oil pump rotation is heavy, there is play

5
_z! There is catching of relief valve or regulator valve, spring or
I
E valve guide is broken
z When oil level sensor is replaced, oil pressure sensor lamp goes out
;
When oil pressure is measured, it is found to be within
1 standard value I I I I
12-39
TROUBLESHOOTING S-13
S-13 Oil level rises (water, fuel in oil)

fl If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises Causes
• Water in oil
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
g
ittin
seal
pe)
by p
e ty
ive
ade
ang
fect
les m
, de
p (fl
hole
pum
t
, ho
aske
ver
on
ace
i
d co
ring
port
e
ther
surf
n
-ring
ad g
leev
ctio
k
bloc
-
brea
hea
al
O
seat
seal
e
er s
re, O
inje
p se
d, h
ner
side
der
hold
mp
stat
rear
side
pum
er li
r co
hea
cylin
r pu
o
i
rt in
lind
oole
zzle
ged
erm
der
fuel
ain
Legend
side
wat
e no
d cy
cylin
ama
e pa
em
e th
: Possible causes (judging from Questions and check items) oil c
e of
ks in
ged
age
ctiv
ctiv
ctiv
ctiv
n, d
ken
ken
kag
Dam
Defe
Clog
Defe
Defe
Defe
Crac
Wor
Bro
Bro
Lea

Questions

When engine is first started, drops of water come from muffler
621202
Exhaust smoke is white
There is oil in radiator cooling water
Leave radiator cap open. When engine is run at idling, an
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
Check items
When water pump breather hole is cleaned, water comes out

Oil level goes down in clutch, TORQFLOW transmission or
damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel must be added more frequently
Pressure-tightness test of oil cooler shows there is leakage

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Remove water pump and inspect directly

Remove rear seal and inspect directly
When main pump is removed, seal is found to be damaged
Remove head cover and inspect directly
Remove injection pump and inspect directly
Defective contact of thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
12-40
6
TROUBLESHOOTING s-14
S-14 Water temperature becomes too high (overheating)

Causes
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
* Carry out troubleshooting for chassis.
Legend
th of use (used for a long period)
Remove oil pan and inspect directly
12-41
S-15 Abnormal noise is made Causes

fl Judge if the noise is an internal noise or an
d
)
etc.
he a
external noise.
ion)
ver,
General causes why abnormal noise is made
der
osit
d)
cylin
• Abnormality due to defective parts
er le
n)
of p
eize
ctio
r
• Abnormal combustion
line
rock
a nd
er s
out
inje
ce
• Air sucked in from intake system
der
aran
lung
r
ard
e
e
ive
v
ylin
ha r g
(val
renc
n ce
g bo
e cle
c es s
ck, p
zzle
g, c
rboc
em
e
terfe
idin
lash
r
v alv
a
n no
n rin
erfe
p (e
r
s ys t
(
u
(div
ump
lt in
k
t
, int
ing
t of
ctio
pum
bac
isto
e en
lve
n be
u sh
fler
me n
p
rger
inje
of p
etw
ain
c va
ion
ion
muf
b
n, fa
ar tr
c ha
just
air b
zed
e ar
zed
ject
ject
am i
Legend
side
urbo
d fa
, sei
e ad
r ge
ve w
, se i
e in
e in
d yn
e of
ct in
rm e
rope
ged
ctiv
ctiv
ctiv
ed t
s i ng
essi
k en
kag
Defo
Clog
Defe
D efe
Defe
Defe
S e iz
Imp
M is
L ea
Exc
Bro

Questions
Gradually occurred
Condition of abnormal noise
Suddenly occurred
621202
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Clanging sound is heard from around cylinder head
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

When turbocharger is rotated by hand, it is found to be heavy
Remove gear cover and inspect directly
Troubleshooting

Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
12-42
6
S-16 Vibration is excessive

fl If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment Causes
• Abnormal combustion
)
etc.
ver,
er le
train
n
n)
shio
rock
ctio
we r
per)
n cu
inje
ve,
d po
dam
(val
roke
sive
ring
e an
aft (
tem
xces
s, b
bea
ngin
h
t sh
s
bolt
klas
ain
p (e
s y
utpu
e
d, m
ting
bac
pum
v
een
l
ic va
de o
g ro
oun
ain
etw
ing
lot
ion
nam
ar tr
rt pi
em
ctin
ush
insi
nt b
ject
Legend
ppo
r ge
e dy
nne
mb
ngin
n me
e in
part
n co
n su
rope
n ca
ctiv
ctiv
se e
alig
ken
Defe
Defe
W or
W or
W or
Imp
Loo
M is
Bro
621202

Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black
Remove oil pan and inspect directly

Remove side cover and inspect directly
Troubleshooting
Check directly for worn support pilot, play

Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
When radial runout, face runout are measured, they are
found to be outside standard value
Remove front cover and inspect directly
Remove head cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
12-43
6
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING TOOL LIST

No. Fault finding tool 1 Remarks
Digital reading:
1 Multi-tachometer L: 60 - 2,000 rpm
H: 60 - 20,000 rom
2 Battery S.G.
795-500-1001 Battery coolant tester
Freezing temperature of
3
cooling water
Water temperature, oil Digital temperature -50 - 1,200”C

799-101-6000
temperature, air intake gauge
4 temperature, exhaust tem-
Thermistor tempera- 0 - 200°C
perature 790-500-l 300
ture gauge 0 - 1,ooo”c
5 Lubrication oil pressure
6 Fuel pressure
Engine pressure
7 measuring kit
9 -9.8 - 0 kPa Cl,000 - 0 mmHnO1
z
&
Compression gauge 0 - 0.69 MPa 10 - 70 kg/cm21
(0 10
l Adapter
11 Blow-by pressure 799-201-1504 Blow-by checker 0 - 4.9 kPa IO - 500 mmHzO1
12 Valve clearance 795-125-1210
]
13
(Dirtiness % x l/IO 6 Bosch scale)
Provided with 0.1 and 0.2
14 Engine oil checker
water content standard sample
15
Nozzle tester o - 29.4 MPa (0 - 300 kg/cm21
16
1
Water quality tester PH. nitrite ion concentration
18
Radiator cap tester 0 - 0.2 MPa IO - 2 kg/cm21
Commercially
20 Electrical circuit Tester Current, Voltage, Resistance
available
Diagnosis of engine control-
21 799-606-9100 Governor checker
ler system 1
12-45
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA
TESTING AND ADJUSTING DATA

Engine model S6D140-2
Applicable machine model GD825A-2 WA500-3

Cate- Standard Permissible Standard Permissible
gory Item Measurement conditions Unit
value value value value
Engine speed High idling speed rpm 2,300 – 2,400 2,300 – 2,400 2,300 – 2,400 2,300 – 2,400
Performance
Low idling speed rpm 650 – 700 650 – 700 700 – 750 700 – 750
Necessary starting 0°C (without starting aid) rpm Min. 110 — Min. 110 —
speed
–20°C (with starting aid) rpm Min. 85 — Min. 85 —
Intake resistance At all speed kPa Max. 2.94 7.50 Max. 2.94 7.50
{mmH2O} {Max. 300} {762} {Max. 300} {762}
Boost pressure At rated flywheel kPa Min. 70.6 56.0 Min. 85.4 68.0
horsepower {mmHg} {Min. 530} {420} {Min. 640} {510}
Intake, exhaust system
Exhaust pressure At rated flywheel kPa Min. 61.3 49.3 Min. 72.0 57.3
(Turbine inlet press.) horsepower {mmHg} {Min. 460} {370} {Min. 540} {430}
Exhaust temperature
(Turbine inlet temp.) All speed (20°C) °C 700 700 650 700
Quick acceleration Max. 6.0 8.0 Max. 6.0 8.0

(Low idle → high idle) Bosch
Exhaust gas color At rated flywheel index Max. 1.5 2.5 Max. 1.0 2.5
horsepower
High idling speed Max. 1.0 2.0 Max. 1.0 2.0
Valve clearance Intake valve mm 0.43 — 0.43 —

(When engine is
hot or cold) Exhaust valve mm 0.80 — 0.80 —
621202
Compression Oil temperature: MPa Min. 3.82 2.65 Min. 3.82 2.65
Engine proper
pressure 40 – 60°C {kg/cm2} {Min. 39} {27} {Min. 39} {27}

(SAE30 or SAE 15W-40)
(Engine speed: 200 – 250 rpm)
Blow-by pressure At rated flywheel horsepower kPa Max. 0.98 1.96 Max. 1.47 2.94
(SAE30 or SAE 15W-40) (Water temp: Min. 70°C) {mmH2O} {Max. 100} {200} {Max. 150} {300}
At rated flywheel horsepower

SAE30 or SAE15W-40 oil kPa 340 – 490 206 340 – 490 206
{kg/cm2} {3.5 – 5.0} {2.1} {3.5 – 5.0} {2.1}
SAE 10W oil kPa 290 – 441 177 290 – 441 177
Lubrication system
Oil pressure {kg/cm2} {3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8}

(Oil temperature: At low idling
Min. 80°C) SAE30 or SAE15W-40 oil kPa Min. 118 69 Min. 118 69
{kg/cm2} {Min. 1.2} {0.7} {Min. 1.2} {0.7}
SAE 10W oil kPa Min. 98 69 Min. 98 69
{kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}
Oil temperature All speed (Oil in oil pan) °C 90 – 110 120 90 – 110 120
Oil consumption At continuous rated

ratio horsepower % Max. 0.5 1.0 Max. 0.5 1.0
(Ratio to fuel consumption)
Fuel injection Nozzle tester MPa 25.0 – 25.8 20.2 25.0 – 25.8 20.2
Fuel
pressure {kg/cm2} {255 – 263} {206} {255 – 263} {206}
Fuel injection timing B.T.D.C. degree 15 – 17 15 – 17 15 – 17 15 – 17
Radiator pressure Opening pressure kPa — — — —

valve (Differential pressure) {kg/cm2}
Cooling
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 tension Deflects when pushed mm 8 –12 8 –12 13 –15 *1 13 –15 *1
with a force of 59N{6kg} 17 –19 *2 17 –19 *2
fl 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.
*1: When belt is new. *2: When adjusting
12-46
6
S6D140-2
Standard Permissible Standard Permissible Standard Permissible Standard Permissible

value value value value value value value value
621202
12-47
6
Applicable machine model D155A-2 D155A-3, D155AX-3

Engine speed High idling speed rpm 2,200 – 2,280 2,200 – 2,280 2,050 – 2,150 2,050 – 2,150
Performance
speed
{mmH2O} {Max. 300} {762} {Max. 300} {762}
Boost pressure At rated flywheel kPa Min. 85.4 68.0
horsepower {mmHg} {Min. 640} {510}
Exhaust pressure At rated flywheel kPa Min. 74.7 60.0

(Turbine inlet press.) horsepower {mmHg} {Min. 560} {450}
Exhaust temperature
(Turbine inlet temp.) All speed (20°C) °C Max. 650 700 Max. 680 700

horsepower

(When engine is
621202
Engine proper


{kg/cm2} {3.5 – 5.0} {2.1} {3.5 – 5.0} {2.1}
SAE 10W oil kPa 290 – 440 176 290 – 441 177
Lubrication system

{kg/cm2} {Min. 1.2} {0.8} {Min. 1.2} {0.7}
{kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}

Fuel
pressure {kg/cm2} {255 – 263} {206} {245 – 263} {206}
Fuel injection timing B.T.D.C. degree 14.5 – 15.5 — 26 – 28 26 – 28
Radiator pressure Opening pressure kPa — — — —

Cooling
Fan speed At rated engine speed rpm 1,165 – 1,235 1,165 – 1,235 1,255 – 1,335 1,255 – 1,335
Fan belt tension Deflects when pushed mm Auto-tensinoer — Auto-tensinoer Auto-tensinoer

with a force of 59N{6kg}
*: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0m).
12-48
6
SA6D140-2
D155AX-5 D355C-3 PC1600SP-1 DCA400SSK-2

(DENYO generator)
2,050 – 2,150 2,050 – 2,150 2,200 – 2,280 2,200 – 2,280 1,930 – 2,030 1,930 – 2,030 Max. 1,568 50Hz Max. 1,568 50Hz
Max. 1,881 60Hz 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 7.47 Max. 2.94 7.47 Max. 2.94 7.50 Max. 2.94 7.50
{Max. 300} {762} {Max. 300} {762} {Max. 300} {762} {Max. 300} {762}
Min. 85 66.5 Min. 160 128 Min. 117.4 93.4 Min. 160 128
{Min. 640} {500} {Min. 1,200} {960} {Min. 880} {700} {Min. 1,200} {960}
Min. 74 59.9 Min. 120 96.0 Min. 102.7 82.7 Min. 120 96.0
{Min. 560} {450} {Min. 900} {720} {Min. 770} {620} {Min. 900} {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 —

621202
Min. 3.8 2.7 Min. 3.80 2.7 Min. 3.82 2.65 Min. 3.82 2.65
{Min. 39} {27} {Min. 39} {27} {Min. 39} {27} {Min. 39} {27}
Max. 0.98 1.96 Max. 0.98 1.96 Max. 1.96 3.92 Max. 1.96 3.92
{Max. 100} {200} {Max. 100} {200} {Max. 200} {400} {Max. 200} {400}
340 – 490 210 340 – 490 210 340 – 490 177 275 – 441 192
{3.5 – 5.0} {2.1} {3.5 – 5.0} {2.1} {3.5 – 5.0} {1.8} {2.8 – 4.5} {2.0}
290 – 440 176 290 – 440 176 290 – 441 137 226 – 392 157
{3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8} {3.0 – 4.5} {1.4} {2.3 – 4.0} {1.6}
Min. 118 78 Min. 118 78 Min. 118 69 Min. 177 69

{Min. 1.2} {0.8} {Min. 1.2} {0.8} {Min. 1.2} {0.7} {Min. 1.8} {0.7}
Min. 98 68 Min. 98 68 Min. 98 69 Min. 98 69
{Min. 1.0} {0.7} {Min. 1.0} {0.7} {Min. 1.0} {0.7} {Min. 1.0} {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 20.2 25.0 – 25.8 20.2 24.8 – 25.5 20.2 25.0 – 25.8 20.2
{253 – 260} {206} {255 – 263} {206} {253 – 260} {206} {255 – 263} {206}
14.5 – 15.5 50Hz 14.5 – 15.5 50Hz
14 – 16 — 18.5 – 19.5 — 18 – 20 18 – 20 16.5 – 17.5 60Hz 16.5 – 17.5 60Hz
— — — — — 59 – 78 —
{0.6 – 0.8}
1,106 – 1,174 50Hz 1,106 – 1,174 50Hz
1,390 – 1,470 — 970 – 1,030 970 – 1,030 1,025 – 1,085 1,025 – 1,085 1,327 – 1,409 60Hz 1,327 – 1,409 60Hz
Auto-tensinoer Auto-tensinoer — Auto-tensinoer Auto-tensinoer 8 –12 8 –12
12-49
(8)
Applicable machine model DCA-400SSK J6D140E-G1-2

(MQ generator) (TAIYO DENKI generator)
Engine speed High idling speed rpm Max. 1,890 60Hz Max. 1,890 60Hz Max. 1,575 50Hz Max. 1,575 50Hz
Performance
Max. 1,890 60Hz Max. 1,890 60Hz

Low idling speed rpm 800 – 850 700 – 900 700 – 900
speed
{mmH2O} {Max. 300} {762} {Max. 300} {762}
Boost pressure At rated flywheel kPa — — Min. 160 128
horsepower {mmHg} {Min. 1,200} {960}
Exhaust pressure At rated flywheel kPa — — Min. 120 96

(Turbine inlet press.) horsepower {mmHg} {Min. 900} {720}
Exhaust temperature
Quick acceleration — — — —
horsepower
(When engine is
Exhaust valve mm 0.80 —
621202
hot or cold) 0.80 —
Engine proper

{kg/cm2} {3.0 – 5.0} {2.1} {3.0 – 5.0} {2.1}
SAE 10W oil kPa 245 – 440 176 245 – 440 176
Lubrication system

{kg/cm2} {Min. 1.2} {0.8} {Min. 1.2} {0.8}
{kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}

Fuel
pressure {kg/cm2} {255 – 263} {206} {255 – 263} {206}

B.T.D.C. degree 16.5 – 17.5 — 16 – 18 50Hz 16 – 18 50Hz
Fuel injection timing 17 – 19 60Hz 17 – 19 60Hz
Radiator pressure Opening pressure kPa — —
Cooling
Fan speed At rated engine speed rpm 1,330 – 1,410 (60 Hz) 1,330 – 1,410 (60 Hz) 1,220 – 1,300 50Hz 1,220 – 1,300 50Hz
1,465 – 1,555 60Hz 1,465 – 1,555 60Hz
Fan belt tension Deflects when pushed mm 8 – 12 14 – 18 8 –12 8 –12
with a force of 60N{6kg}
12-50
(8)
SA6D140-2
D155C-1A (–30°C spec.)

2,190 – 2,290 2,190 – 2,290
700 – 750 700 – 750

Min. 110 —
Min. 85 —
Max. 2.94 7.47

{Max. 300} {762}
Min. 99 83
{Min. 740} {620}
Min. 84 71
{Min. 630} {530}
Max. 600 700

Max. 6.0 7.0
Max. 1.0 2.5
Max. 1.0 2.0
0.43 —
621202
0.80 —
Min. 3.8 2.7

{Min. 39} {27}
Max. 0.98 1.96

{Max. 100} {200}
340 – 490 210

{3.5 – 5.0} {2.1}
290 – 440 176
{3.0 – 4.5} {1.8}
Min. 118 78
{Min. 1.2} {0.8}
Min. 98 68
{Min. 1.0} {0.7}
80 – 110 120
Max. 0.5 1.0
24.8 – 25.5 20.2

{253 – 260} {206}
18 – 20 ––
–– ––
––
––
–– ––
12-51
(8)
Engine model SAA6D140-2
Applicable machine model PC750-6, PC800-6 HD325-6, HD405-6

Classi- Standard Permissible Standard Permissible
fication Item Condition, etc. Unit
High idling speed rpm 1,930 – 2,030 1,930 – 2,030 2,350 – 2,450 2,350 – 2,450
Engine speed
Performance
0°C rpm Min. 110 — Min. 110 —

Necessary starting (without starting aid)
speed –20°C rpm Min. 85 — Min. 85 —
(with starting aid)
Intake resistance kPa Max. 2.9 7.47 Max. 2.9 7.47
At all speed {mmH2O} {Max. 300} {762} {Max. 300} {762}
kPa
Boost pressure At rated output {mmHg}
Intake and exhaust system
Exhaust pressure kPa

(Turbine inlet press.) At rated output {mmHg}
Exhaust temperature

(Low idle → high idle)
Exhaust gas color Bosch
At rated output index Max. 1.0 2.0 Max. 1.0 2.0
High idling Max. 1.0 2.0 Max. 1.0 2.0
621202
(When engine is
Oil temperature: MPa
Engine body
Compression Min. 3.82{39} 2.65{27} Min. 3.82{39} 2.65{27}

pressure 40 – 60°C {kg/cm2}
(SAE30 or SAE 15W-40) (Engine speed: 200 – 250 rpm)
kPa Max. 1.96 3.92 Max. 1.96 3.92
Blow-by pressure At rated output
{mmH2O} {Max. 200} {400} {Max. 200} {400}
(SAE30 or SAE 15W-40) (Water temp: 70°C min)
At rated output kPa
2
SAE30 or SAE15W-40 oil {kg/cm } 340–490{3.5–5.0} 210{2.1} 340–490{3.5–5.0} 210{2.1}
SAE 10W oil kPa 290–440{3.0–4.5} 180{1.8} 290–440{3.0–4.5} 180{1.8}
Lubrication system
Oil pressure 2{kg/cm }

(Oil temperature: kPa
At low idling Min. 118{1.2} 69{0.7} Min. 118{1.2} 78{0.8}
80°C min) 2
SAE30 or SAE15W-40 oil {kg/cm }
SAE 10W oil kPa Min. 98{1.0} 69{0.7} Min. 98{1.0} 69{0.7}
2{kg/cm }
All speed
Oil temperature °C 80 – 110 120 80 – 110 120
(Oil in oil pan)
At continuous rated
Oil consumption output Max. 0.5 1.0 Max. 0.5 1.0
ratio %
system
MPa 24.8 – 25.5 20.2 24.8 – 25.5 20.2

Fuel injection pressure Nozzle tester
Fuel
{kg/cm2} {253 – 260} {206} {253 – 260} {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
Radiator pressure Opening pressure kPa
(Differential pressure) {kg/cm2} — — — —
valve
Cooling
system
Fan speed At rated engine speed rpm 1,018 – 1,082 1,018 – 1,082
Deflects when pushed (Autotensioner) — (Autotensioner) —
Fan belt tension with a force of 58.8N {6kg} mm — —
12-52
6
SAA6D140-2 SDA6D140E-2
HD325-6 (High altitude spec.)

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 7.50 Max. 2.94 7.50

{Max. 300} {762} {Max. 300} {762}
Min. 97.4 77.3 Min. 118.6 98.6
{Min. 730} {580} {Min. 890} {740}
Min. 97.4 77.3 Min. 113.3 94.7
{Min. 730} {580} {Min. 850} {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

621202
0.43 — 0.43 —
0.80 — 0.80 —
Min. 3.82{39} 2.65{27} Min. 3.14{32} 2.16{22}
Max. 1.96 3.92 Max. 1.47 2.94

{Max. 200} {400} {Max. 150} {300}
343 – 490 245 290 – 490 200

{3.5 – 5.0} {2.5} {3.0 – 5.0} {2.0}
294 – 441 206 250 – 440 180
{3.0 – 4.5} {2.1} {2.5 – 4.5} {1.8}
Min. 147 69 Min. 100 70
{Min. 1.5} {0.7} {Min. 1.0} {0.7}
Min. 98 69 Min. 100 70
{Min. 1.0} {0.7} {Min. 1.0} {0.7}
90 – 110 120 80 – 110 120
Max. 0.5 1.0 Max. 0.5 1.0
25.0 – 25.8 20.2 25.0 – 25.8 20.2

{255 – 263} {206} {255 – 263} {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-tensinoer Auto-tensinoer — —
12-53
7
13 DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
Air cleaner muffler ......................................
l 13-2 Air vent tube, spill pipe, rocker arm
Starting motor ................................................ 13-2 housing cover ........................................ 13- 8
Turbocharger drain tube ............................... 13-3 Nozzle holder, inlet connector .................... 13- 9
Setting engine in engine overhaul stand ... 13-3 Rocker arm.. .................................................. 13- 9
Corrosion resistor, air compressor Push rod.. ...................................................... 13-10
suction tube .............................................. 13-3 Crosshead ..................................................... 13-10
Bracket.. ........................................................... 13-3 Rocker arm housing.. ................................... 13-10
Connector.. ...................................................... 13-4 Cylinder head assembly .............................. 13-10
Tension pulley assembly.. ............................. 13-4 Vibration damper l crankshaft pulley
Fan pulley assembly ...................................... 13-4 assembly ................................................. 13-l 1
Alternator assembly l pulley.. ....................... 13-4 Front support.. .............................................. 13-11
g Dipstick guide, air compressor ..................... 13-5 Thermostat housing ..................................... 13-11
: Fuel hose.. ....................................................... 13-5 Water pump assembly ................................ 13-11
Turbocharger .................................................. 13-5 Oil cooler assembly ..................................... 13-11
Exhaust manifold ........................................... 13-5 Cam follower ................................................ 13-12
After-cooler assembly Gear case cover.. .......................................... 13-12
(Intake manifold assembly). .................... 13-5 Injection pump drive gear.. ......................... 13-12
Fuel injection tube ......................................... 13-5 Camshaft ....................................................... 13-12
Fuel injection pump assembly.. ................... .13-6 Oil pump assembly, oil pump
Tube, bracket, PTO case ................................ 13-6 idler gear ................................................ 13-13
Fuel filter fuel filter bracket ........................
l 13-6 Main idler gear, injection pump
Oil filter oil regulator ...................................
l 13-6 drive shaft ............................................... 13-13
Oil pan ............................................................. 13-7 Piston cooling nozzle ................................... 13-13
Suction pipe, under frame ............................ 13-7 Piston and connecting rod assembly ......... 13-13
Flywheel .......................................................... 13-7 Crankshaft ..................................................... 13-15
Rear seal ......................................................... 13-7 Cylinder liner ................................................ 13-16
Flywheel housing ........................................... 13-8
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
l Clean off all mud and dirt.
l Drain cooling water and engine oil.
- : Engine oil: Approx. 37 L?
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 I I
CLlE00133
is mounted.)
1. Air cleaner muffler

l
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
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
CEE00137
5. Corrosion resistor, air compressor suction tube

I) Remove hoses (I) and (2).
2) Remove corrosion resistor (3).
3) Remove tubes (4) and (5).
4) Remove tubes from air compressor. (If
equipped).
COEOOl38
6. Bracket
Remove mounting bolts, then remove brackets
(I) and (2).
CDE00139
13-3
0
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) Loosen tension pulley assembly mounting
nuts (I).
2) Loosen adjustment bolt (2), move tension
pulley toward inside, then remove V-belts
(3).
3) Remove mounting bolts (41, then remove
tension pulley assembly (5).
CEE00143
9. Fan pulley assembly

Remove mounting bolts (I), then remove fan
pulley assembly (2).
CEE00144
10. Alternator assembly l 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 bolts (9) and remove
pulley (IO).
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).
17. 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).
CEE0015
18. Tube, bracket, PTO case

1) Remove turbocharger lubrication tube (1).
2) Remove fuel injection pump bracket (2).
3) Remove PTO case (3).
19. Fuel filter fuel filter bracket

l
Remove fuel filter (I) and fuel filter bracket (2).
20. Oil filter

l oil regulator
Remove oil filter (3) and oil regulator (4).
-
-
13-6
0
21. Oil pan

1) Remove wiring connector (I) from bracket.
2) Disconnect drain hose (2).
3) Remove oil pan (3).
3 2 CEE00154
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.
l Removal of standard seal Too I

Hook tip of tool L to metal ring of seal (I),
then use impact force of slide hammer to
remove seal. Slide hammer
* 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.
DWE00211
l Removal of seal with sleeve

Standard seal Seal with sleeve
I) Hook tip of tool L to metal ring of seal
(I), then use impact force of slide Flywheel Flywheel
hausins housing
hammer to remove seal. I Metal rins
* 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. Cr.ankshaft Crankshaft
2
* Be extremely careful not to damage DWEOOZIZ DWE00213
the crankshaft when cutting the seal.
* If any metal particles are formed, be
sure to remove them all completely.
25. Flywheel housing

Remove mounting bolts (I), sling flywheel
housing (2), then remove.
kg
LL?l Flywheel housing: 55 kg
26. 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).
CDE00158
27. Nozzle holder, inlet connector

I) Loosen locknut (I), then remove inlet
connector (2).
2) Remove mounting bolts (3), then remove
holder (4).
CEE00159
3) Fully screw bolt @ (Dia. = 10 mm, Pitch =

1.5 mm), then remove nozzle holder
assembly (5) using bar etc.
* When removing nozzle holder assembly,
clean around nozzle holder and be careful
not to enter foreign material inside sleeve.
* Check that there is gasket (6) fitted to
the tip of the nozzle holder.
28. Rocker arm _..~ ,_------.., ,_‘._

Remove mounting bolts (1) and (2), then remove
rocker arm (3).
* Loosen lock nuts (4) of adjustment screws,
then loosen each adjustment screw (5) 2 - 3
turns to avoid excessive pressure being
brought to bear on the push rods when
installing the rocker arm. 2
.5
10161
29. Push rod

Remove push rod (I).
30. Crosshead
Remove crosshead (2).

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.
l 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).
CEE0016r CEEOOl65
iii) Remove lower valve seat (5).

iv) Lift up cylinder head and remove valves
(6).
I
I
I
CEE00166 6 CEE00167
13-10
0
33. Vibration damper l 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).
CEE00170
I
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.
-1 CEE00171
37. Oil cooler assembly

Remove oil cooler assembly (I).
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. Injection pump drive gear

Remove mounting nut (I), then remove injection
pump drive gear (2).
CEE00176
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.
13-12
0
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).
44. Piston cooling nozzle

Remove mounting bolt (I), then remove piston
cooling nozzle (2).
CEE00180
45. Piston and connecting rod assembly
1) 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.
2) Rotate crankshaft so that piston to be
removed is at bottom dead center.
3) 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 CEEOOlI31
assembly.
4) Remove bolts (I) of connecting rod cap.

5) 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.
6) 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.
7) 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.
0 Disassemble piston and connecting rod

assembly as follows.
i) Remove snap ring (3).
ii) Hold connecting rod (4) by hand, and
tap out piston pin (5). Disconnect piston
assembly (6) and connecting rod.
iii) Remove snap ring on opposite side.
3 CEE00184
iv) Using piston ring tool D, remove piston

rings (7).
* Keep piston, connecting rod, bearing, 7
piston rings and piston pin in sets
according to cylinder number.
CEE00185
13-14
0
46. Crankshaft
If necessary, measure the end play of the
crankshaft with dial gauge @ before
removing the crankshaft.
-
CEE00186
1) Remove mounting bolts (2) of main bearing

cap (I).
2) Insert bolts (2) in holes in main bearing cap,
then remove main bearing cap while shaking
the cap with the inserted bolts.
2
;;
0
3) 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.
4) Using a wire, remove crankshaft (4).
r55kg 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.
5) Remove upper thrust bearings (5).
CEEOOl90
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).

GENERAL ASSEMBLY
Tightening bolts by the plastic range Nozzler holder, inlet connector.. ................. 13-40
turning angle method ........................... 13-18 Rocker arm housing cover, spill pipe,
Drawing of special tool ............................... 13-19 air vent tube ........................................... 13-41
Preparatory work .......................................... 13-20 Flywheel housing ......................................... 13-41
Cylinder liner ................................................ 13-21 Rear seal ....................................................... 13-42
Crankshaft ..................................................... 13-23 Flywheel ........................................................ 13-45
Piston and connecting rod assembly ......... 13-26 Suction pipe .................................................. 13-46
Piston cooling nozzle ................................... 13-28 Oil pan ........................................................... 13-46
Main idler gear, fuel injection pump Oil filter assembly, oil regulator.. .............. .13-46
drive shaft ............................................... 13-29 Fuel filter assembly l fuel filter bracket.. .. 13-46
Oil pump idler gear, oil pump PTO case tube, bracket.. .............................. 13-47
assembly ................................................. 13-30 Fuel injection pump assembly.. .................. 13-47
Camshaft ....................................................... 13-30 Adjusting fuel injection pump .................... 13-48
Fuel injection pump drive gear .................. 13-30 Fuel injection tube ....................................... 13-50
Fuel injection pump drive shaft oil seal ... 13-31 After-cooler assembly (Intake manifold
Gear case cover ............................................ 13-32 assembly) ............................................... 13-50
Breather.. ....................................................... 13-32 Exhaust manifold ......................................... 13-50
Front seal ...................................................... 13-33 Turbocharger ................................................ 13-51
Cam follower ................................................ 13-34 Fuel hose ....................................................... 13-51
Oil cooler assembly ..................................... 13-34 Dipstick guide, air compressor .................. .13-51
Water pump assembly ................................ 13-35 Alternator assembly, pulley ........................ 13-51
Thermostat housing ..................................... 13-35 Fan pulley assembly .................................... 13-52
Front support ................................................ 13-35 Tension pulley assembly.. ........................... 13-52
Vibration damper, crankshaft pulley Intake connector ........................................... 13-52
assembly.. ............................................... 13-35 Muffler bracket, air cleaner bracket .......... .13-52
Cylinder head assembly .............................. 13-36 Corrosion resistor ......................................... 13-53
Crosshead ..................................................... 13-38 Resetting engine in engine stand.. ............. 13-53
Rocker arm housing ..................................... 13-38 Turbocharger drain tube ............................. 13-53
Push rod ........................................................ 13-38 Starting motor .............................................. 13-53
Rocker arm .................................................... 13-39 Air cleaner, muffler.. .................................... 13-54
Adjusting valve clearance ........................... 13-39 Refilling with oil ........................................... 13-54
13-17
0
ASSEMBLY AND DISASSEMBLY GENERAL ASSEMBLY
TIGHTENING BOLTS BY THE PLASTIC RANGE

TURNING ANGLE METHOD
0 Important bolts in the 140 Series engines are
tightened by the plastic range turning angle
method. In this method, special bolts are used. t
By being tightened to the load (plastic range) at Wlastic range)
which they begin to be permanently deformed,
accurate and high tightening force can be
obtained.
The most common method for tightening bolts Plasticrange turning angle
is the torque control method. In this method,
however, it is difficult to accurately control the
tightening force because of the coefficient of
friction. (conventional method)
0 The plastic range turning angle method is based
on the initial tightening torque and the turning
angle.
* Elongation exceeding the elastic range results Elongation of bolt
in permanent deformation.
0 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) 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.
2) If a bolt has been tightened in excess of the
specified turning angle, loosen the bolt and
measure the free length of bolt again.
3) The tightening angle should be targeted at
the standard value plus or minus tolerance.
Part No. Part Name Q’ty
Special tools J 1 790-331-I 110 1 Wrench

I
I I
Part No. Part Name a’tv

K 1 795T-473-1110 1 Push tool I 1
A 790-901-1260 Adapter 1 795-521-1110 Push tool 1

M
B 790-501-2001 Engine overhaul stand 01050-31640 Bolt 3
1
c 795-102-2102 Spring pusher 1 1 795-931-1210 Sleeve jig 1
D 795-100-I 191 Piston ring tool 1 2 795-931-1220 Sleeve jig 1

N
F 795-230-5472 Liner driver 1 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’*
Drawing of special tool
Push tool K
Note) Komatsu has no responsibility for special tool made by this drawing.
1 \
A I
mnd G
omfl _______-_-. & - ----------.--.-
-=t
g6 ‘a
;s
I
t ’ / /
‘L
ep’
2 Cl
CDE00261
/ 795T-473-1110 n
13-19
0
Preparatory work
l Install adapter A on cylinder block, set cylinder
block on engine overhaul stand B.
l Prepare the cylinder block before inserting the

cylinder liner as follows.
1) Using sandpaper, remove rust and scale
from faces @ and @ until machined surface
can be seen.
2) 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
Q
smoothly to prevent damage to the O-ring. CEE00051
3) If there is pitting on face @ and it cannot be

repaired, replace cylinder block.
4) If there is pitting on face @ or portion 0,

polish to give a smooth finish.
5) 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.
13-20
0
Cylinder liner
Before assembling, carry out selection of
clearance between liner and piston referring to block
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.
l If the surface is rough and pitted, it may DWE00214
cause leakage of water, so replace the
liner.
TOP surface of block
2) Coat the mating surface of the cylinder block
Matins portion
and cylinder liner counterbore with silicon-
based gasket sealant (LG-6).
l Use a cloth to wipe off all the dirt or oil

from the cylinder block counterbore and
liner flange contact surface.
l Width of gasket sealant (LG-6):

m2-3mm (coat the corner of the deck)
DWEOOIBB
l Make an overlap of 6 r 6 mm at the
beginning and end when coating with
gasket sealant LG-6.
l 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.
I DWE00189
Cylin er liner
+=I P Crevice seal
Black (Ethylene propylene rubber)
O-ring
Black (Ethylene propylene rubber)
O-ring
Orange (Silicon rubber)
w
I DEE00090
3) 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.
4) 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.
5) 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. CEE00201
l Method of inserting cylinder liner

Press it to the grove
I) Set the stamped mark “A” or “B” on the top
K
of the liner facing to the front, then insert
the liner into the cylinder block taking care
not to damage the O-ring.
2) Use your weight and push the liner in with

both hands.
* If the liner does not go in smoothly when
h Chamfered side
you apply your weight, there is danger

that the O-ring may be damaged, so
i
check the cylinder block for burrs or DEE00089
flashes.
3) Using tool F, press fit cylinder liner (1) into

the cylinder block.
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 If the grommet is deformed into a heart shape and
covers the water hole. the coolant may leak.
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.
Grommet Water hole

DWE002 I5
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
6,
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.
2) Knock in roll pin so that it protrudes 2.7 -

3.4 mm from block, then install upper thrust
bearings (5).
j, Install the thrust bearings with the groove
on the crankshaft.
CEEOOlQO
3) Using a wire, sling crankshaft (4) and set in

position on cylinder block. When installing
the crankshaft, be careful not to let it hit or
damage the cylinder block.
* If the crankshaft gear has been replaced,
heat the crankshaft gear in an electric
furnace at 200°C for 30 minutes, then
shrink fit.
4) Align protrusion of lower main bearing with

notch in main bearing cap and install
bearing.
to the rear face of the bearing when
installing.
5) Knock in roll pin so that it protrudes 2.7 -

3.4 mm from cap, then assemble thrust
bearings (3) on both sides of No. 7 main
cap.
* Install the thrust bearings with the groove
on the crankshaft side.
6) Coat journal surfaces of crankshaft with

engine oil (SAE#30). Check that the number
on main bearing cap (2) matches the cylinder
block number, and install main bearing cap.
* Install the main bearing cap with the part
number casting mark facing the front of
the engine.
7) Before tightening main cap mounting bolt

(21, make sure as follows.
i) Measure the free length a of all bolts
and check that bolt length exceeds toler-
ance limit or not. Do not reuse any bolt
ii) Tolerance limit of bolt free length:
Max. 159.8 mm.
* If the bolt length a exceeds tolerance DWE00275
limit, do not reuse.
8) 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.
9) 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) When using tool J.
Turn the bolt further 90 - 120
degrees with tool J. Put a make on the
2) When not using tool J. bolt and cao
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
3. Piston and connecting rod assembly

* Before assembling, carry out selection of
clearance between liner and piston referring to
MAINTENANCE STANDARD.
l Assemble piston and connecting rod assembly

as follows.
I) Using piston ring tool D, install piston rings
(7) on piston.
CEE00165
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.
DWE00192
2) 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).
3) Install snap rings (3) on both sides to secure
piston pin.
3 CEE00164
4) Align protrusion of upper bearing of

Cast number
connecting rod with notch in connecting rod
and install bearing.
installing.
5) 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).
(align on camshai t side)
13-26
6) 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).
CEE00212
7) Using piston holder G, compress piston rings

and push in piston head with wooden bar.
CEE00213
8) Before tightening connecting rod bolt, make
P\
sure as follows.
i) Measure the free length a of all bolts \
ii) Tolerance limit of bolt free length: ~ a
Max. 95.0 mm.
+ If the bolt length a exceeds tolerance DWE00275
9) 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
installing.
* Coat the sliding surface of the connect-
ing rod cap with engine oil (SAE#30).
IO) 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.
2) When not using tool J.
Mark the bolts and the cap
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 Put mark on bolt and
already five marks on the bolt head, re- connectino rod cap
place with new bolts.
111After installing piston and connecting rod

assembly, rotate crankshaft and check that it
rotates smoothly. There must be no catch-
ing or other abnormality.
I DWE00216
12) Measure side clearance of connecting rod

with dial gauge 0.
* Side clearance: 0.100 - 0.274 mm
CEE00181
4. Piston cooling nozzle

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.
13-28
0
5. Main idler gear, fuel injection pump drive shaft

I) Coat fuel injection pump drive shaft (5) with
engine oil (SAE#30) and install.
21 Install thrust plate (41, then install mounting
bolts (3).
3) Install shaft (6) to main idler gear (21, then fit

washer (7) on inside.
4) 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.
I 2 CEE00216
* Make a punch mark on the bolt head

each time the bolts are used.
Put mark on side seat
of idler gear and bolt
l If there are already five marks on the

bolt head, replace with new bolts.
I DWE00217
Put one punch mark
DEEM)100
6. Oil pump idler gear, oil pump assembly

1) Install oil pump idler gear (2).
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:
I-
98 - 123 Nm I10 - 12.5 kgm1
II
7. 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.
CFFOO176
_
Fit key to shaft, align “C” mark of main idler
gear ‘with “C” mark of drive gear, then fit drive
I c---G?/
m
gear (2) and tighten nut (I).
m Nut: 226 - 255 Nm (23 - 26 kgml
B
* Check that the match marks of each drive
C
gear and idler gear are aligned.
I
CDE00217
* 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 CEE00218
F 0.080 - 0.417
G 0.118 - 0.369
1 I
I-i (OP) 0.118 - 0.369
-I
%6!3
1 tow 0.025 - 0.486
2 G1
B
Sr Standard end play for each gear
D A 3c
E 5
Position Range (mm) 4
H
1 0.140 - 0.315 IF I
2 0.100 - 0.250 ---l 1

CDEOOLIS
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 Assembly guide
(0 I astic tubal
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.
Large inside Small- inside
diameter end diameter end
DWE00218
13-31
0
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.
I I 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.
I I CDE00222
4) Using tool K, press fit oil seal (3) until seal

contacts to housing (4).
I ’ CDE00223
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 CDE00175
with clamps.
‘7
12. Front seal
Assemble front seal (I) as follows. Assemble guide
Before assembling the seal, check that there
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. Small inside Large inside
Do not remove the plastic tube inside the diameter end diameter end
standard seal provided as a spare part until DWEOOZI 9
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
:
K4
co
2) Hold metal ring of seal (I) with both hands,

to push in.

tube (2).
* Be particularly careful not to damage the
4) 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.
CDE00232
13-33
0
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
CEE00233
15. 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).
-1‘1 CEE00171
16. Thermostat housing

I) Fit O-ring to tube (21, then install to
thermostat housing (4).
2) Fit gasket and install thermostat housing (4)
with mounting bolts (3).
3) Move tube (2) down and install ring (I).
: CEE00170
17. 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.
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}
19. Cylinder head assembly

I) Assemble cylinder head assembly as follows.
i) Coat valve stem and inside surface of
valve guide with engine oil (SAE#30) then
assemble valve (6).
ii) Raise cylinder head and assemble lower
valve seat (5).
I CEE00166
iii) Install inner valve spring (4) and outer

valve spring (31, then assemble upper
valve seat (2).
iv) 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.
CEE001651 CEE00164
2) 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.
CEE00234
3) Before tightening cylinder head bolt, make

sure as follows.
i) Measure the free length a of all bolts
ii) Tolerance limit of bolt free length:
Max. 166.3 mm.
a
* If the bolt length a exceeds tolerance
OWE00275
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) When using tool J
Tighten bolts further 90 - 120
degrees in tightening order 0
to @ with tool J.
2) 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. DAD00043
* Tighten bolt @ by tightening

torque 58.8 - 74.5 Nm (6.0 -
7.6 kgm) after tightening bolts
@ to 8.
I CEE00.235
Put mark on cylinder

head and bolt
DWE00220
20. Crosshead
Install crosshead (I 1.
* Adjust crosshead as follows.
i) Loosen locknut, and loosen adjustment
screw.
ii) Hold top of crosshead lightly and tighten
adjustment screw.
iii) Tighten adjustment screw until it contacts
valve stem, then tighten a further 20”.
iv) Tighten locknut to hold in position.
m Locknut:
53 - 64.7 Nm (5.4 - 6.6 kgm}

Fit gasket and install rocker arm housing (I).
w Mounting bolt:
58.8 - 73.5 Nm 16.0 - 7.5 kgm}
CEE00237
22. Push rod

Install push rods (1).
Ir Check that the push rod is properly fitted in
the cam follower.
23. Rocker arm -.. --------- ----

install rocker arm (3) and tighten with mounting
bolts (2) and (I).
-..-.
\J-.._.. XL
* 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
- CDE00240
I
* Crank the engine and follow the firing order

5 6 3
to adjust the valve clearance of each cylinder.
Firing order: 1 - 5 - 3 - 6 - 2 - 4
1) 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.
2) To adjust, insert feeler gauge I between

rocker arm (3) and crosshead (4) and turn
adjustment screw (5) until clearance is a
sliding fit.
3) 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 lock nut, check

the clearance again.
25. Nozzle holder, inlet connector

* Check that there is no dirt or dust inside the
nozzle holder sleeve.
1) Fit O-ring (71, and coat with engine oil
(SAE#30).
* Check that there is no damage to the O-
ring.
2) Install gasket (6) to nozzle holder.
3) Align nozzle holder (5) with mounting hole
of inlet connector and insert nozzle holder.
CEE00243
4) insert inlet connector (2) in rocker arm

housing and tighten partially.
5) 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 the bolt head and
tighten with the bolt.
6) Tighten inlet connector (2), then tighten CEE00159

locknut (1).
w inlet connector:
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.
13-40
0
26. Rocker arm housing cover, spill pipe, air vent

tube
1) Fit O-ring and install rocker arm housing
cover (3).
w Mounting bolts:
14.7 - 34.3 Nm Il.5 - 3.5 kgml
2) Fit gasket on both sides and install spill pipe

(2).
w Joint bolt:
7.8 - 9.8 Nm IO.8 - 1.0 kgml
2
CDE00158
3) Fit gasket on both sides and install air vent
tube (I).
w Joint bolt:
9.8 - 12.7 Nm Il.0 - 1.3 kgm}
27. Flywheel housing

1) Sling flywheel housing (2), coat mounting
surface with gasket sealant, then install on
cylinder block and tighten bolts (I).
* When installing the housing, be careful
not to damage the oil seal.
& Contact surface:
Gasket sealant ILG-7)
& Coat the bolt threads and seat face
with engine oil (SAE#30) before
tightening.
j, Tighten the mounting bolts of the

flywheel housing in the order shown in
the diagram and to the following torques.
* When 1st step tightening, tighten

mounting bolts (I), (41, (2) and (9) by
two steps.
w Flywheel housing mounting bolt
1st step: 147 - 235 Nm I15 - 24 kgm1 -0
2nd step: 245 - 309 Nm I25 - 31.5 kgm} G-D
1st step 2nd step
13-41
0
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, flashes, or rust on the
housing, sliding surface of the lip and the corner
of the end face of the crankshaft. Lip at
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 Large inside Small inside
immediately before assembling the seal. diameter end diameter end
DEE00105
Put large inside diameter end of plastic inner

tube (3) in contact with end of crankshaft (4).
* Be particularly careful not to mistake the
4
CEP00535
2) Hold metal ring of seal (I) with both hands,

to push in.

tube (3).
+ Be particularly careful not to damage the
CFFOO414
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.
l Procedure for assembling seal with sleeve

* Before assembling the seal, check that there
housing, sliding surface of the lip and the Lie at crankshaft end
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.
DWE00221
I) Set sleeve/seal (2) to tool N2.

& Surface of sleeve inner tube:
Gasket sealant (LG-7)
~ DWE00222
2) 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
(45mm)
crankshaft (4) to press fit sleeve/seal (2).
(25mml
3) Remove tool N2 and replace with tool Nl.
4) Tighten 3 bolts uniformly until end face of

tool Nl contacts ends face of crankshaft (4) N3 (45mm)
to press fit sleeve/seal (2). N4 (25mm)
* 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. CEE00251
’3&44
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
CEE00156
* Tighten mounting bolts as follows. Tightening order

w Flywheel mounting bolt
1st step: 112.7 - 122.5 Nm 111.5 - 12.5 kgm1
2nd step: I) When using tool J
Tighten bolts further 90 - 120
degrees in tightening order @
to @ with tool J.
2) When not using tool J
Mark the bolt and head with a
felt-tip pen, turn bolt further
90 - 120 degree in tightening For construction For marine engine
order @ to 8. machine and generator
DKEOOII!
* Make a punch mark on the bolt head each

time the bolts are used. Put mark on flywheel
* If there are already five marks on the bolt and bolt
head, replace with new bolts.
I DWE00223
Put one punch mark
DEE00100
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.
3 2 CEE00154
32. Oil filter assembly, oil regulator

1) Fit O-ring and install oil regulator (4).
2) Fit O-ring and install oil filter assembly (3).
33. Fuel filter assembly l fuel filter bracket

1) Fit O-ring and install fuel filter bracket (2).
2) Install fuel filter assembly (I).
13-46
0
34. PTO case tube, bracket

1) Install fuel injection pump bracket (2).
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
3) Fit O-ring and install PTO case (3).

w Mounting bolt:
107.8 - 122.5 Nm (11.0 - 12.5 kgm}
-
"\ 1-1 CEE00152
35. Fuel iniection pump assembly

1) Knock key’(l3).into drive shaft (12) of fuel
injection pump.
2) Remove 2 coupling bolts (7) of fuel injection

pump, then remove flange coupling (IO) and
front laminated coupling (5).
3) Install flange coupling (IO) and front

laminated coupling (5) to fuel injection pump
drive shaft (12).
_j, Do not tighten mounting bolt (11). I II CEE00254
w Mounting bolt (14)

(D155AX-3 LW500-1):
l
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
13-47
0
4) 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.
5) Tighten 4 mounting bolts (8) of fuel injection

pump.
6) 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}
7) Install lubrication tubes (3) and (4).
8) Install fuel hoses (I) and (2).
36. 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).
CEE00255
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.
CDE00256
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) Loosen bolt (I 1) and flange coupling
bolts and nuts (14) at two places.
ii) Rotate coupling block (22) and align line
(21) on fuel injection pump housing with
line (18) on coupling block completely.
iii) 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} CEE00258
(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.
7) Tighten nut (15).
8) Install pin (24).
13-49
0
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.
I CEW00552
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 CEE00259
13-50
0
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) Fit e-ring and install air compressor
mounting plate (4). (If equipped.)
2) Fit O-ring and install air compressor (31, then
install lubrication tube (2). (If equipped.)
3) Install dipstick guide (1).
:
6
43 Alternator assembly, pulley

I) Install pulley (IO) and tighten with mounting
bolt (9).
2) Install alternator assembly (6) with bolt (1).
* Temporarily tighten bolt (I).
3) Install bracket (8).
4) Install adjustment rod (7) with bolts (2) and
(3).
or Temporarily tighten bolts (2) and (3).
+ Loosen 2 adjustment nuts (4).
5) Install alternator belts (5).
6) Adjust belt tension with adjustment nuts (4) CDE00145
that deflection is 13 - 16 mm when pushed

with a force 98 N {IO kg}.
7) Tighten bolts (I), (2) and (3).
44. Fan pulley assembly

Install fan pulley assembly then secure with bolts
(I).
CEE00144
45. Tension pulley assembly I
1) Install tension pulley assembly (5) with

mounting bolts (4).
2) Set fan belt (3) on groove of pulley.
3) 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)
46. Intake connector

1) Fit gasket to electrical intake air heater (5)
and intake connector (41, then install with
mounting bolts (3).
2) Install turbocharger lubrication inlet tube (21,
and secure with clamp (I).
47. Muffler bracket, air cleaner bracket

Install muffler bracket (2) and air cleaner bracket
(I).
CDE00139

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).
CDE00138
49. Resetting engine in engine stand

1) Sling engine assembly, remove bolts
connecting tool A and tool B to disconnect
engine assembly.
2) Set engine assembly on engine stand or
block.
3) Remove tool A.
50 Turbocharger drain tube

Fit gasket and install turbocharger drain tube
(1).
51. Starting motor

Fit gasket and install starting motor (2) with
mounting bolts (1).
52. Air cleaner, muffler

1) Install exhaust connector (9).
2) Fit gasket and install muffler (8) with
mounting bolts (6), then secure with band
(7).
3) Fit gasket and install valves (5).
4) 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}
‘2
c
5) For the Komaclone type air cleaner, install
precleaner (11) to air cleaner body (10).
* Tighten until clearance a is 0. Z 11
6
+
IO
Z
CEE00260
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?

14 MAINTENANCE STANDARD

Turbocharger .......................................... 14- 2
ENGINE BODY
Cylinder head ....................................... 14- 4
Valve and valve guide ......................... 14- 6
Rocker arm shaft .................................. 14- 8
Crosshead ............................................. 14- 9
Cylinder block ...................................... 14-10
Cylinder liner ........................................ 14-11
Crankshaft ............................................. 14-12
Camshaft ............................................... 14-13
621202
Cam follower and push rod................ 14-14

Timing gear .......................................... 14-16
Piston ................................................... 14-18
Connecting rod .................................... 14-20
Flywheel and flywheel housing ......... 14-21
LUBRICATION SYSTEM
Oil pump ............................................... 14-22
Regulator valve, piston cooling
valve and safety valve ................... 14-24
Oil cooler ............................................... 14-25
COOLING SYSTEM
Water pump .......................................... 14-26
Thermostat ............................................ 14-30
14-1
14-1
7
MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM

TURBOCHARGER
KTR110
S6D140-2
SA6D140-2
SAA6D140-2
621202
14-2
14-2
7
Unit: mm
621202
No. Check item Criteria Remedy
Standard Repair limit

1 End play Replace
parts
0.08 to 0.13 0.18
Replace
2 Radial play 0.25 to 0.44 0.60 parts
Tolerance Repair limit

Standard
Outside diameter or journal size
3 bearing. Shaft Hole Shaft Hole
Inner diameter of center housing.
–0.050 +0.021
25 –0.067 +0 24.92 25.03
Inner diameter of journal bearing. –0.032 +0.009

Outside diameter of wheel shaft. 17 –0.043 – 0.003 16.95 17.04
4
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout)
Replace
Standard
size
5 Thickness of thrust bearing Shaft Hole Shaft Hole
–0.08 +0.02
5 –0.11 +0 4.86 5.04
Turbine –0.08 –0.03

2.3 –0.10 –0.04 2.15 2.35
side
6 Thickness of seal ring
Blower –0.08 –0.03
2 –0.10 –0.04 1.85 2.05
side
Clearance between blower housing Replace
7 and impeller Tolerance (min.): 0.20 parts
14-3
14-3
7
KTR110L
SDA6D140E-2 (D275A-5, –50°C spec.)
621202
14-3-1
7
Unit: mm

621202
Standard Repair limit Replace

parts
1 End play (Play in axial direction) related to
0.08 – 0.13 0.18 thrust
Replace
0.25 – 0.44 0.60 parts
2 Radial play (Play in radial direction)
related to
bearing

Standard
Outside diameter or journal size
3 bearing. Shaft Hole Shaft Hole
Inner diameter of center housing
–0.050 +0.021
25 –0.067 +0 24.92 25.03
Inner diameter of journal bearing. –0.032 +0.009

Outside diameter of wheel shaft 17 –0.043 – 0.003 16.95 17.04
4
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout)
Replace
Standard
size
5 Thickness of thrust bearing Shaft Hole Shaft Hole
–0.08 +0.02
5 –0.11 +0 4.86 5.04
Turbine –0.08 –0.03

2.3 –0.10 –0.04 2.15 2.35
side
6 Thickness of seal ring
Blower –0.08 –0.03
2 –0.10 –0.04 1.85 2.05
side
Clearance between blower housing Replace
7 and impeller Tolerance (min.): 0.20 parts
14-3-2
7
MAINTENANCE STANDARD ENGINE BODY
ENGINE BODY
CYLINDER HEAD
s
1
Check item
2
Criteria
SEE00505 Unit:
Remedy
mm
I
Standard Repair limit Repair by Kl
Distortion of cylinder head (D
1 grinding
mounting surface
or replace
0 - 0.06 0.09
-
Engine Standard
Replace
nozzle or
2 Protrusion of nozzle 6D140-2 4.8 - 5.6 cylinder
head
S6D140-2, SAGD140-2,
SAAGDI 40-2 4.8 - 5.6
Target Range
Bolt No. Order
(Nm {kgm}) (Nm {kgml)
Tightening torque of cylinder head

mounting bolt (Coat the thread
3 areas with molybdenum disulfide or
engine oil)
Retighten with
3rd step 90” - 120”
90”
0 - 68.6 17) 58.8 - - 73.6

16 7.5)
Target (Nm {kgm}) Range (Nm {kgm))

4 Tightening torque of nozzle holder
mounting bolt
66.7 16.8) 58.8 - 73.6 {6 - 7.5)
Tightening torque of fuel inlet

5 connector 37.3 I3.8) 34.3 - 40.2 13.5 - 4.1) Retighten
-
Tightening torque of connector pipe
6 locknut 39.2 (4) 34.3 - 44.1 13.5 - 4.5}
Tightening torque of cylinder head

cover mounting bolt 4.9 to.51 3.9 - 5.9 {0.4 - 0.61
14-4
VALVE, VALVE GUIDE
14-6
0
Unit: mm
NC). Check item Criteria Remedy

-
Replace
1 Amount of valve sinking 1 valve or
valve seat
Replace
2 Thickness of valve lip ~ valve
Repair or
replace
3 r/alve seat angle valve and
valve seat
Intake valve 10 -0.045

-0.060 Replace
3utside diameter of valve stem
10 -0.075 valve
Exhaust valve
-0.090
+0.019
Before inserting 10 Replace
+O.OOl
nside diameter of valve guide valve
+0.019 guide
After inserting IO
-0.020
4
Replace
valve or
Clearance between valve guide and
valve
lalve stem
guide
Replace
3end of valve stem Repair limit: 0.02 (Total indicated runout, for 100) valve
I
Standard size Tolerance

5 ‘rotrusion of valve guide Repair
23 kO.2
-
Spring Standard size Repair limit
?ee length of valve spring Large / *’ 82.2 / lz 81.7 1 -

I
Small *I 65.5 *2 72.0 - Replace
valve
Installed Standard installed Installed load limit spring
6 Spring
length load (N {kg}) (N (kg})
Squarence of valve spring I Repair limit: 2” (for both end)

-
Note 1: Valve springs marked with *I have a regular pitch.

Note 2: Valve springs marked with *2 have an irregular pitch.
14-7
0
ROCKER ARM AND SHAFT
!I
-
-
I -d
I?
=I
II I
L!L
II I
SEE00507
Unit: mm
No.
Outside diameter of rocker arm

shaft
Clearance between rocker arm shaft

and rocker arm bushing
Valve clearance
2 (When engine is hot or cold)
14-8
0
CROSSHEAD AND GUIDE
SEE00508
Unit: mm
Standard size Tolerance Repair limit

Depth of crosshead stem
+0.3
3 0 3.41
Replace
+0.06
Inside diameter of crosshead 11 11.17
+0.02
Outside diameter of crosshead +O.Oll

guide 11 10.95
I
I
II 0 I I
I I
3 Protrusion of crosshead guide 49.0 +0.25 1 - 1 Repair

II II I I
14-9
CYLINDER BLOCK
SEE00509
-
No
Standard size
Distortion of cylinder head mount-
1
ing surface
Standard size
Inside diameter of main bearing
hole
2
Thickness of main bearing
3 Inside diameter of main bearing
6
-
Tightening torque of main bearing

7 cap bolt (Coat thread area with
engine oil)
Tightening torque of oil pan

8 mounting bolt and under frame
mounting bolt
14-10
CYLINDER LINER
i-4 P
SEE00510
Unit: mm
Replace cylinder
1 Protrusion of cylinder liner Permissible range: 0.07 - 0.15 liner or cylinder
block
2 -
5
(
inside diameter of cylinder liner
Replace
Roundness of cylinder liner Repair limit: 0.08 cylinder
liner
Cylindricity of cylinder liner Repair limit: 0.08

Outside diameter of cylinder liner
(Counter bore) 0
3 170.2 -0.10
Clearance between cylinder liner Replace cylinder

Standard: 0 - 0.163 liner or cylinder
and block (Counter bore) I block
Standard size Tolerance Replace

Outside diameter of cylinder liner
cylinder
(Counter bore bottom)
+0.090 liner
161.2
+0.050
4
Replace
Interference between cylinder liner Standard interference Interference limit cylinder liner
and block (Counter bore bottom) or cylinder
block, or
0.02 - 0.12 0.02
repair

Outside diameter of cylinder liner cylinder
(O-ring) -0.024 liner
5 158 -0.049
Replace cylinder
Clearance between cylinder liner
Standard: 0.024 - 0.089 liner or cylinder
and block (O-ring) I block
14-11
CRANKSHAFT
I 3 2 4
SEE0051 1 Unit: mm
-
NO Check item Criteria Remedy
Repair by
Standard size Repair limit using over
1 End play size thrust
0.140 - 0.315 0.50

-
STD 120.00 119.88
0.25 U.S. 119.75 119.63

Outside diameter of main journal
Repair by
0.50 U.S. 119.50 -0.050 119.38 using over
-0.068
size
oearing or
0.75 U.S. 119.25 119.13
Feolace
2
1.00 U.S. 119.00 118.88
Standard size Repair limit

Roundness of main journal
0 - 0.010 0.020
I I
Standard clearance Clearance limit IReplace
Clearance of main journal Imain
I
Ibearing
-
I 0.044 - 0.106 I 0.27
/ STD 1 Staa”,“b”, size 1 Tolerance Repair limit
89.88
89.63
Dutside diameter of crank pin
iournal IRepair by
89.38 IJsing
Imder size
Isearing or
0.75 U.S. 89.25 89.13
I.eplace
3
1.00 U.S. 89.00 88.88

qoundness of crank pin journal
0 - 0.010 0.020
3eplace
Standard clearance Clearance limit
:onnecting
Clearance of crank pin journal
,od
0.042 - 0.110 0.24 learing
Stanadard size Repair limit F Repair by

Straightness of all main journals - 1 lsing
4 0 - 0.150 0.20 mder size
-i Iearing or
straightness of two main journals 0 - 0.050 0.10 r eplace
-
14-12
CAMSHAFT
1
T \ l--A
2
\ 3
=4A-A SEE00512
Unit: mm
Standard size Repair limit Replace

1 End play thrust
plate
0.1 - 0.25 0.36

Outside diameter of Replace
camshaft journal camshaft
-0.016
65
-0.036
2
Standard clearance Clearance limit Replace
Clearance of camshaft journal camshaft
bushing
0.016 - 0.096 0.15
3 Bend of camshaft Repair limit: 0.03 (Total indicated runout)
Cam Standard size Tolerance Repair limit

Replace
camshaft
4 Cam height
Intake 55.48 *O.l 55.08
Exhaust 55.75 -co. 1 55.35
14-13
CAM FOLLOWER AND PUSH ROD
I SEE00513
- Unit: mm

Outside diameter of cam follower
1
shaft -0.021
22 -0.034 21.92
Inside diameter of cam follower +0.021

shaft hole 22 22.07
0
-
2 Outside diameter of cam roller
I
I
31.7
I
I
+0.05
+0.02
31.50
+0.038
Inside diameter of cam roller 12.7 12.78
I I +0.013
3 Replace
Outside diameter of cam roller pin 12.63 20.006 12.56

-
I I I

4 Radius of push rod ball end
0
12.7 -0.20
0
5 Radius of push rod socket end 13.4 -0.20
6 Bend of push rod Repair limit: 0.3 (Total indicated runout)
14-14
TIMING GEAR
0
0
\
3:,t
A
A-A SEE00514
14-16
Unit: mm
-
No Check item Criteria Remedy
hneasuring Standard
Gears Repair limit
point size
Crankshaft gear and main

A 0.141 - 0.425
idler gear (Large)
Main idler gear (Small) and

B 0.129 - 0.391
injection pump drive gear
Main idler gear (Small) and o,,2g _ o,3g,

C
camshaft gear
Main idler gear (Large) and

a 0.141 - 0.426
sub idler gear
I3acklash of each gears
0.6 Replace
Sub idler gear and water

C 0.095 - 0.346
pump drive gear
Camshaft gear and air

d 0.118 - 0.369
compressor drive gear
Injection pump drive gear

e 0.118 - 0.369
and PTO gear (Lower)
-
Compressor drive gear and o,025 _ o.486
f
PTO gear (Upper)
-
I
Clearance
limit
Clearance between main idler gear

1 bushing and shaft
0.20
Replace
< bushing
-
0.20
Clearance between sub idler gear
2
bushing and shaft
‘ 0.20
-
3 End play of main idler gear

0.05 - 0.17 0.4
Replace
- thrust
0.05 - 0.17 0.4 bearing
4 End play of sub idler gear
-
End play of injection pump drive 0.4
5 0.07 - 0.20
gear
- -
14-17
PISTON
14-18
Unit: mm
-
I Rank
I Standard size Tolerance Repair limit
Replace
1 Outside diameter of piston piston
;I 139.81
No. Measuring point Standard size Tolerance
-0.015
2 Top ring 2.4 -0.035
Replace
Thickness of piston ring
-0.010 piston ring
3 Second ring 2.41 -0.035
-0.010
4 Oil ring 4 -0.030
Judge using groove wear gauge

Replace
Width of piston ring groove piston
+0.040
4 Oil ring 4 +0.020
I No. 1 Measuring point Standard clearance Clearance limit
2 Top ring Replace

Clearance between piston ring and _ piston or
Judge using groove wear gauge
ring groove piston ring
3 Second ring
4 Oil ring 0.02 - 0.06 0.14
0.42 - 0.57
2 Top ring (Tension 16.5 - 23.5N 2.0
(1.68 - 2.40kgH Replace
0.65 - 0.80 piston ring
Piston ring gap 3 Second ring (Tension 16.2 - 24.2N 1.5 or cylinder
(1.65 - 2.47kgH
liner
0.37 - 0.52
4 Oil ring (Tension 55.9 - 75.5N 1.0
(5.7 - 7.7kg))

Replace
Outside diameter of piston pin piston pin
52 l.006
+0.045 Replace
5 Inside diameter of piston pin hole 52
I +0.035 piston
Clearance limit Replace

Clearance between piston pin and piston or
piston piston pin
0.10
14-19
CONNECTING ROD
4 SEE00516
Unit: mm
Replace
Inside diameter of bushing at Standard size Tolerance Repair limit bushing
connecting rod small end (New pan is
(Treat with reamer after press +0.049 supplied as a
52 52.09 semi-finished
fitting bushing) +0.030 pan)
1
I
Clearance between bushing at Standard clearance Clearance limit Replace
connecting rod small end and bushing or
piston pin piston pin
0.030 - 0.055 0.11

Inside diameter of bushing hole at
connecting
connecting rod small end
+0.030 rod
57.4
0

Inside diameter of bearing at Replace
connecting rod big end +0.042 bearing
so -0.008 90.15
Inside diameter of bearing hole at

connecting rod big end Standard size Tolerance Replace
(* Measure after tightening connecting
connecting rod cap bolt with +0.026 rod
95
specified torque) -0.004
4

Thickness of connecting rod Replace
bearing bearing
+0.002
2.5 -
-0.008
-
Parallelism and twist of connecting

5 rod
rod
Twist Parallelism
SEE00672 Twist 0 - 0.30 0.35
Standard size Target (NmIkgmI) Repair (Nmfkgm))

Tightening torque of connecting rod I I
cap mounting bolt
I
117.7 - 132.4
6 (Coat bolt threads and nut seats 1st step 127.5 {13} Retighten
i12.5 - 13.5)
with engine oil)
2nd step Retighten with SO” so - 1200
Permissible range:
- Weight of connecting rod Replace
Variation between weights on the machine max. 154 g
* Note: The connecting rod bolt can be re-used up to a maximum of 5 times. Each time the bolt is
re-used, make a punch mark on the bolt head.
14-20
FLYWHEEL AND FLYWHEEL HOUSING
A-A
SEE00518
Unit: mm
No.
I Check item
I
Criteria
I
Remedy
1 Face runout of flywheel housing Repair limit: 0.35
2 Radial runout of flywheel housing Repair limit: 0.30

Repair
I I
31 Face runout of flywheel
I
Repair limit: 0.20
I
4 Radial runout of flywheel Repair limit: 0.15

I I I
Target Range
Order Tightening order (NmIkgmI) (NmIkgm})
Tightening torque of flywheel 191.2 147.1 - 235.4
@-+@+@+@+@+@
5 housing mounting bolts l19.5) {I5 - 24)
1st step @+@+O+@+@+@
(Coat thread areas with engine oil)
@-@-@+@+@ 274.6 245.2 - 308.9
2nd step @-+@+@+@+@ 128.01 {25 - 31.5)
Retighten
Target Range
,,Bx-ro,> Order
(NmIkgm}) (Nm{kgm))
Tightening torque of flywheel 9_-.-b- 117.7 112.8 - 122.6
6 mounting bolts 1st step
112) III.5 - 12.5)
(Coat thread areas with engine oil)
“o;._o
i /’ Retighten with
2nd step 90” - 120”
SDE00519 90”
14-21
MAINTENANCE STANDARD LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PUMP
SEE00520
14-22
Unit: mm

I
1 Axial clearance of pump gear
-
45 0 +0.067 0.03 0.10
-0.025 +0.040 0.088
Replace
Standard
size hi %aarZZ “eEi~ce
2 Radial clearance of pump gear
-
51.4 -0.15 +0.06 0.033 0.13
-0.21 0 0.10
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between drive shaft and Shaft Hole
pump body bushing
+0.106 +0.173 0.040 -
18
+0.088 +O. 146 0.085 Replace
bushing
Clearance between driven shaft +0.090 +o. 147 0.032 -
18
and driven gear bushing +0.070 +0.127 0.077
Clearance between driven shaft 18 +0.090 +0.129 0.012 -

and body +0.070 +0.102 0.059
Clearance between relief valve and -0.040 +0.043 0.040 -

6
pump cover 16 -0.060 0 0.103
Interference between drive shaft

7
and oil pump drive gear
I 18
+0.106
+0.088
+0.065
+0.047
0.023 -
0.059 - I
Interference between drive gear +0.106 +0.063 0.025 -
8 18 Replace
and drive shaft I +0.088 +0.028 0.078 -
Interference between drive shaft +0.090 +0.021 0.044 -

9 21
bushing and pump cover +0.065 0 0.090 -
Interference between driven shaft +0.090 +0.035 0.030 -

10 21
bushing and driven gear +0.065 0 0.090 -
Interference between driven shaft +0.090 +0.040 0.030 -

11 18 +0.070 +0.022 0.068 -
and pump cover
Free Installed Installed Free Installed Replace

12 Main relief valve spring
length length load length load
126.4 N 113.7 N
49.1 32.0
112.9 kg} {Il.6 kg}
13 Main relief valve set pressure Standard: 0.8 + 0.05 MPa 18.0 * 0.5 kg/cm*} Replace
14-23
RE GULATOR VALVE, PISTON COOLING VALVE

An D SAFETY VALVE
SEE00521
Unit: mm
Standard
Clearance between regulator valve size
1 Replace
_II...-
and body valve or
body
I
I
Free Installed Installed load Free Installed load Replace

2 Regulator valve spring length length (NIkgH length (N{kgH spring
16.1 15.1
a3 79 -
Il.641 Il.541
3 Regulator valve set pressure 0.3 t 0.02 MPa {3.2 + 0.2 kg/cm*}
Replace
4 Safety valve set pressure 0.2 f 0.02 MPa {2.0 = 0.2 kg/cm2}
14-24
OIL COOLER
SDE00522
Unit: mm
Lift of thermostat to fully open Min 8 mm (soak in oil bath at 100°C (116°C) for 4 to 5 minutes to
position check)
1 Replace
Valve must fully close when valve is soaked in oil bath for fully
Opening/closing of thermostat open 100°C (116°C) and then soaked in oil bath for fully closed
85°C (110°C) for 4 to 5 minutes.
Ir The figure in ( ) indicates the thermostat for fully open temperature 116°C.
+ There are two types of thermostat for the oil cooler (fully open temperature: IOO’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.
14-25
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
WATER PUMP
6D140-2
S6D140-2
SA6D140-2
SEE00523
Unit: mm
-
NC Check item Criteria Remedy
Tolerance
Standard Standard
size interference
1 Interference between impeller and Shaft Hole
shaft
-
Interference between drive gear
2 and shaft
-
Interference between pulley flange Reolace
3 and shaft
-
Clearance between impeller and
4 Standard clearance: 0.30 - 1.0 (Including end play)
body
-
Repair limit
5 Abrasion of seal ring in water seal A: 1.5
SEE00524
14-26
S6D140-2
SA6D140-2
SDA6D140E-2 (D275A-5, –50°C spec.)
621202
Unit: mm
Standard Tolerance
Standard
size interference
shaft
–0.082 –0.020 0.025 –
16 –0.095 –0.150 0.068
Interference between drive gear +0.015 –0.023 0.025 –
2 and shaft 28 +0.002 –0.053 0.068
Interference between pulley flange +0.015 –0.021 0.025 – Replace
3 and shaft 25 +0.002 –0.041 0.056
4 body Standard clearance: 0.6 – 0.9 (Including end play)
5 Abrasion of seal ring in water seal Repair limit

A: 1.5
14-27
7
FOR AFTERCOOLER
SDA6D140E-2 (D275A-5, –50°C spec.)
621202
Unit: mm
Standard Tolerance
Standard
size interference
shaft
+0.018 –0.020 0.025 –
15.9 +0.005 –0.050 0.068
Interference between drive gear +0.015 –0.023 0.025 –
2 and shaft 20 +0.002 –0.053 0.068
Replace
3 body Standard clearance: 0.3 – 1.1 (Including end play)
4 Abrasion of seal ring in water seal Repair limit

A: 1.5
14-28
7
THERMOSTAT
621202
Unit: mm
Lift of thermostat to fully open

position Min 10 mm (soak in oil bath at 90°C for 4 to 5 minutes to check)
1 Replace
Valve must fully close when valve is soaked in oil bath for fully
Opening/closing of thermostat open (90°C) and then soaked in oil bath for fully closed (71°C) for 4
to 5 minutes.
14-30
7
15 REPAIR AND REPLACEMENT OF PARTS
TABLE OF SPECIAL TOOLS ...................... 15-1-1
CYLINDER HEAD
Grinding of fitting face of
cylinder head ..................................... 15- 2
Replacing valve seat insert ................... 15- 3
Pressure test ........................................... 15- 8
Replacing valve guide ........................... 15- 9
Replacing crosshead guide ................... 15-10
Grinding valve ........................................ 15-11
CYLINDER BLOCK
621202
Replacing cam bushing ......................... 15-12

Replacing crankshaft gear .................... 15-15
Replacing cam gear ............................... 15-16
Replacing flywheel ring gear ................ 15-17
Replacing connecting rod small
end bushing ....................................... 15-18
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
15-1
6
REPAIR AND REPLACEMENT OF PARTS TABLE OF SPECIAL TOOLS
TABLE OF SPECIAL TOOLS
Operation Symbol Part No. Part Name Q’ty Remarks
Checking inside
Commercially
diameter of main J Alignment bar
available
bearing mounting hole
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

Grinding counterbore K
11 79A-513-2130 Case 1
12 79A-513-2140 Basic machine 1
13 79A-513-2160 Cutter plate 1
621501
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 1
18 79A-513-2270 Compound 1 Loctite
19 79A-513-2280 Primer 1 Loctite
20 79A-513-2320 Bushing 12
15-1-1
6
REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD
GRINDING OF FllTlNG FACE OF CYLINDER HEAD

1. Grinding
I) Remove the valve seat insert. See the sec-
tion of replacement of the valve seat insert.
2) Remove the strain and corrosion of the cyl-
inder head by grinding them within the al-
lowable limit of the cylinder head height H,
then stamp the letter “R” on the left side of
the cylinder head.
li Cylinder head height H
Basic height: 105 + 0.05 mm
* Limit after grinding: 104.65 mm
* Grinding height/time: 0.10 - 0.15 mm HEE00080
* Roughness of ground surface: 6 S max.

* Change of cross level: 0.05 mm max.
* Grinding limit: 0.3 mm
Sr 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.
Ir Standard sinking distance of valve:
0 + 0.1 mm
15-2
REPLACING VALVE SEAT INSERT

Special tools
No. 1 Part No. 1 Part Name IMY
A 1 795-100-4800 1Puller (valve seat) I ’
-
1 1 790-101-5001 1Push tool (KIT) I 1
E 2 1 790-101-5081 I Plate (for intake
l valve) I I
3 790-101-5071 l Plate (for exhaust valve) 1

-
795-100-3003 Seat cutter (KIT) 1
Tl:~ Body ass’y I 1

I 795-100-3200 I l Micrometer I I
1 1795-100-3300 1 l Gauge
795-100-3400 l Tool head
795-100-3601 l Head support

C
l Cutter (for oversize
2 795-100-3710 1
machining
3 795-100-3720 l Cutter (for 30”) 1
4 795-100-3730 l Cutter (for 45”) 1
1795-100-4210 1 Pilot
l (10.000 mm) I 1
!J 795-100-4220 l Pilot (10.010 mm) 1
T; 5
(D 795-100-4230 l Pilot (10.020 mm) 1
1 795-100-4240 1l Pilot (10.030 mm) I 1
1. Removal of valve seat insert
a When using a grinder to carry out this work,

carry out a test run for one minute before start-
ing the operation to check that there is no ab-
normality.
. If the grindstone has been replaced, carry
out the test run 3 minutes.
a Check that there is no damage to the grind-

stone, fit it to the grinder spindle so that there is
play, and wear safety glasses when using the
grinder.
l When removing with a valve seat puller

1) Install grindstone @ to grinder 0.
2) Align the groove of sleeve @ with holder 0,
and insert.
Ir Adjust the position of the grinder with
set screw 0.
15-3
3) Adjust the position of the grinder so that the

center of grindstone @ is at the center of
seat insert (I), then tighten the set screw to
fix the grinder in place.
4) Rotate the grindstone and move it slowly
until it contacts insert (I).
5) Press the grindstone lightly against the in-
side face of the insert and make a groove
around the whole circumference of the in-
side face of the insert.
* Depth of groove: Approx. 1 mm
HEE00082
6) Push the three claws (a) of puller head @ of

tool A inwards by hand, and fit into insert
(I).
7) Tighten screw @ to push the three claws
into the groove on the inside face of the
insert.
* When the claws are completely in con-
tact with the groove, stop tightening.
8) insert bridge @I on the outside of the puller
head, set plates @Cand @I on top of the
bridge, and tighten nut @ to pull out the
insert.
HEE00083
l When welding a bar to the insert to remove

1) Weld bar (I) (diameter: approx. 10 o) of a
diameter 0.1 - 0.5 mm smaller than the in-
side diameter of the insert to insert (2).
Ir Be careful not to deposit any of the weld-
ing metal on the head itself.
2) When the temperature of the weld has
dropped to around room temperature, in-
sert a used valve (3) in the opposite direc-
tion, and hit the face of the valve with a
small hammer to remove the insert.
* Be careful not to hit too hard, as any
excessive shock may cause the weld to I HEE00084
break off.
15-4
2. Press fitting valve seat insert

Press
l When not grinding and correcting press-fitting
surface of valve seat insert
1) Using tools Bl and B2, or tools Bl and B3,
61s 82
press fit standard valve seat insert (2) with a Bl. 83
press.
Ir Do not use a hammer to press fit.
* Press-fitting force for valve seat insert
Intake side: Approx. 14.7 kN {I .5 ton}
Exhaust side: Approx. 14.7 kN (1.5 ton}
HEE00231
2) Check the insertion depth (h) of the insert

from the bottom surface of the cylinder head.
Bottom surface of cylinder head
* Insertion depth (h) of insert
Intake side: 2.2 mm
Exhaust side: 2.4 mm
insert
I HEE00232 1
15-5
3. Oversize machining of mounting hole for valve

seat insert
I) Using tools Cl and Cz, grind the hole to the
one level larger oversize.
* Machine within an oversize range of 1.0
mm. If it is more than 1.0 mm, replace
the cylinder head.
HEE00087
l Method of machining insert and mounting hole
Inset-t Insert mounting hole

Insert Valve
d h DI D2 H
Intake 55.0 :;:;; 8.8 J.1 55.0 +P’S 58.00 f 0.2 11 ’

-0.1
STD
Exhaust 52.0 :;:;; 8.6 1.1 52.0 +prs 55.00 + 0.2 11 O
4.1
Intake 55.25:;:;: 8.8 :.I 55.25’p” 58.25 + 0.2 11 ’

-0.1
0.25 O.S.
Exhaust 52.25:;:;; 8.6 :.I 52.25’p” 55.25 + 0.2 11 ’
-0.1
Intake 55.5 :;:$J 8.92 & 55.5 +;.o’s 58.50 + 0.2 11.12&
0.50 O.S.
Exhaust 52.5 :;:z 8.72 j, 52.5 +tors 55.50 + 0.2 11.12:,
Intake 55.75:;:;;; 9.05 :,, 55.75+:.0’s 58.75 A 0.2 11.25 &

0: 75 0.s
Exhaust 52.75:;:;; 8.85 l,, 52.75+;.“’ 55.75 + 0.2 11.25&
Intake 56.0 :;:;;; 9.18& 56.0 +;.“’ 59.00 + 0.2 11.38 ;.,
1.00 0.s
Exhaust 53.0 :;:;; 8.98 l., 53.0 +y 56.00 i 0.2 11.38 ;.,
Insert Insert mountins hole
Bottom surface of
cylinder head
HEE00.733
* Roughness of inside surface: Within 6.3s

Ir Roughness at bottom of mounting hole:
Within 12.5 S
Jr Concentricity with valve guide inside surface:
Within 0.03 mm (TIR)
15-6
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.
fl When selecting a pilot C5 to insert into
the valve guide, choose one that gives
no clearance.
• Intake valve
• Exhaust valve
621202
2) Rub the seat surface with compound.
Width of finished face of exhaust valve

insert and width of contact with valve Unit: mm
Part No. 6210-11-1320 (S.T.D) 6210-11-1321 (S.T.D)
6210-19-1320 (0.25 O.S) 6210-19-1321 (0.25 O.S)
6210-18-1320 (0.50 O.S) 6210-18-1321 (0.50 O.S)
6210-17-1320 (0.75 O.S) 6210-17-1321 (0.75 O.S)
6210-16-1320 (1.00 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 C: 1.5 ± 0.2 C: 2.5 ± 0.2
using master valve)
5. Finish inspection
• Coat the seat surface of the new valve thinly
Unit: mm
with red lead (minimum), insert it in the valve
guide, push lightly against the valve insert
surface, and rotate 10°. Check the valve in-
sert 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-
cumference.
15-7
6
PRESSURE TEST
‡ When corrections have been made around the
cylinder head, test the pressure as follows.
Special tools
No. Part No. Part Name Q’ty
A 790-553-1600 Coolant tester kit 1
B 79A-471-1050 Pump assembly 1
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/cm2}) for approx. 10 minutes, and
check that there is no leakage from around
the cylinder head.
fl When carrying out this test, heat the whole
cylinder head and carry out the test with hot
water (80 – 95°C).
621202
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.
fl If the above test shows any cracks around the

plate plugs, replace the cylinder head.
15-8
6
REPLACING VALVE GUIDE

Special tools
No. Part No. Part Name Qw
A 795-100-1520 Valve guide remover 1
B 795-130-1710 Valve guide driver II
1. Removal of valve guide

Using valve guide remover A, remove the valve
guide.
2. Press fitting valve guide

I) 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.
* Valve guide protrusion
Tolerance: 23 ? 0.2 mm
15-9
REPLACING CROSSHEAD GUIDE

Special tools
No. ( Part No. Part Name 1Q’ty
A 795-140-6410 Crosshead guide puller 1
B 795-130-1310 Crosshead guide driver 1
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 0, and lock sleeve
0.
3) Turn nut 0, and pull out crosshead guide.
4) Remove any burrs or flashes from the
crosshead guide mount.
!ad
HEE00238
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.
* Protrusion of crosshead guide
Tolerance: 49 -c 0.5 mm
15-10
REPAIR AND REPLACEMENT OF- PARTS CYLINDER HEAD
GRINDING VALVE
Special tool
No. Part No. Part Name Q’ty
A Commercially available Valve refacer 1
1. Grinding seat face

Grind the seat surface with valve refacer A.
* Valve seat angle Intake valve: 30”
Exhaust valve: 45”
2. Checking after grinding

Measure the thickness of the valve head, pro-
trusion of the valve and the contact of the valve HEE00098
seat face to check that they are within the stand-

ard range.
j, Thickness of valve head
Intake valve: 2.4 mm
Exhaust valve: 2 mm
* Insertion depth of valve
Standard: 0 + 0.1 mm
j, Contact width of valve
Standard Intake valve: 4.33 mm
Exhaust valve: 3.47 mm
15-11
REPAIR AND REPLACEMENT OF PARTS CYLINDER BLOCK
REPLACING CAM BUSHING

Special tools
No. 1 Part No. Part Name 1O’ty
A 1 795-213-1200 1 Push tool
( 4 1 795-213-1230 I Guide
5 792-l 03-0400 Grip 1
* 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
AZ, collar AS, and push bar AI of push tools A,
then hit the push bar to knock bushing (2) out
from cylinder block (I).
HEE00099
2. Removal of No. 2, 6 bushings

Assemble push bar AI, push tool AZ, collar AS,
and guide A4 of push tool A, then hit the push
bar to knock bushing (3) out from cylinder block
(I).
3. Removal of No. 3, 4, 5 bushings

. Assemble push bar Al, push tool AZ, collar AS,
and guide A4 of push tool A, then hit the push
bar to knock bushing (4) out from cylinder block A3 A2 Al A4
4
(1).
1’ HEEOOlOl
15-12
. After removing the bushing, remove any burrs

or dirt, and clean the mounting hole of the bush-
ing.
* Cam bushing assembly drawing
b I ock
rn hole
HEE00239
1. Press fitting No. 3, 4,5 bushings

Assemble bushing (4) to tool A, and press fit the
bushing until the oil hole of cylinder clock (I)
matches the oil hole of the bushing.
I ” HEE00103
2
5
2. Press fitting No. 2, 6 bushings
Assemble bushing (3) to tool A, and press fit the
I HEE00104
3. Press fitting No. 1, 7 bushings

. Assemble bushing (2) to tool A, and press fit the
HEE00105
. Using inside gauge 0, measure the inside di-

ameter of the bushing.
l Check the clearance between the bushing and
shaft, and if the clearance is not within the speci-
fied range, or the shaft does not move smoothly,
correct the inside diameter of the bushing with
a reamer.
l 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.
* Inside diameter of cam bushing: @65y mm HEE00106
* Clearance of camshaft journal: 0.016 - 0.096 mm
15-14
REPLACING CRANKSHAFT GEAR

Special tools
No. 1 Part No. Part Name IQW
@ 790-101-2800 Bearing puller
@ 790-101-2300 Push puller
1. Removal of Gear
Make a scratch in the surface at the root of the
teeth with a grinder, then assemble pullers 0
and 0, and turn the nut to remove the gear.
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.
Be careful not to damage the shaft.
!z
HEE00240
Kl
(D
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) Heat the gear for the specified time at the
specified shrink-fitting temperature.
* Crankshaft gear shrink-fitting temperature:
200°C
Heating time: Min. 30 minutes
HEE00108
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.
Ir Knock in quickly before the gear becomes
cool.
15-15
1. Removal of gear
Set the camshaft assembly on the press stand,
then push the camshaft to remove the gear.
a When setting the camshaft assembly on the

press stand, be careful not to get caught your
fingers between the press stand and the gear.
HEEOO
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.
Ir 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.
* Knock in quickly before the gear becomes
cool.
15-16
REPLACING FLYWHEEL RING GEAR

g 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.
A 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 at
the specified shrink-fitting temperature.
* Ring gear shrink-fitting temperature:
Max. 200°C
3) Set the chamfered face of the ring gear fac-
ing the flywheel, and press fit until the side
face of the gear is in close contact with the
flywheel.
15-17
REPLACING CONNECTING ROD SMALL END BUSHING

Special tools
No. Part No. Part Name o’tv
A 795-240-6400 Push tool (KIT) 1
4 01530-03912 Nut 1
1. Removal of connecting rod bushing

1) Set the connecting rod to tool B3.
2) Using tool BI, remove the connecting rod +
bushing with press.
Ir After removing the bushing, remove any
burrs or flashes, and clean the mounting
hole of the bushing. Connecting
rod bushing
Connecting
rod
HEE0024 1
2. Press fitting connecting rod bushing

1) Set connecting rod to tool 83.
2) Assemble connecting rod bushing in tool
BI, set tool BZ in position, then secure with
tool B4 so that it does not move.
* Align the oil hole of the connecting rod bush-
ing with the oil hole of the connecting rod. Connecting
rod bushins
3) Push tool Bl with press, and press fit the
connecting rod bushing.
Connecting
l The bushing is supplied as a semi-finished prod-
rod
uct, so the inside diameter is too small and the
piston pin will not go in.
After press fitting the bushing, machine the in- B3
side diameter of the bushing with a reamer or
/
honing machine in accordance with the mainte- /!225 HEE00242
nance standard.
Ir After machining, clean all the metal parti-
cles from the oil hole and oil groove.
15-18
REPAIR AND REPLACEMENT OF PARTS CYLINDER BLOCK PARTS
CYLINDER BLOCK PARTS
621202
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
15-20
6
REPAIR AND REPLACEMENT OF PARTS TESTING AND INSPECTING CYLINDER BLOCK
TESTING AND INSPECTING CYLINDER BLOCK

Unit: mm
Symbol Inspection item Judgement standards Remedy

Check for cracks (external color check)
A. Cracks Replace
Cylinder head bolt hole portion, etc.
Check for water leakage caused by corrosion

Correction of contact at
B. Replace
packing portion
Standard value
Standard Standard
size Inside diameter of Outside diameter clearance
cylinder block of cylinder block Replace
Clearance from cylinder 158.00 – 157.946 – 0.024 – cylinder liner
C. 158.00 158.04 157.976 0.094
liner or cylinder
block
• Inside diameter
621202
Standard size Standard value Standard limit

69 69.000 – 69.025 69.10
Inside diameter of Replace
D. bushing
camshaft bushing
• Clearance from camshaft bearing
Standard clearance Clearance limit

0.016 – 0.096 0.15
Permissible range: 0.07 – 0.15 Replace

cylinder liner
E. Protrusion of liner
or correct
cylinder block
Depth of counterbore Standard size Standard value Repair by

F. and corrosion of 11 11.00 – 11.05
machining,
bottom surface add shim
• Check for corrosion

Distortion, wear of
G. cylinder head Overall top surface of block: Max. 0.09 0.135 Repair by
For one cylinder: Max. 0.05 0.100 machining
mounting surface
15-21
6
Unit: mm
Symbol Inspection item Judgement standards Remedy
Standard size Standard value Standard limit
127 127.000 – 127.025 —
Inside diameter of main

bearing mounting hole Coaxiality of whole unit Max. 0.020
• Tighten main Coaxiality between neighboring holes Max. 0.013
bearing cap bolt to
specified torque
H.
• Measure main
bearing cap
mating surface
within up-and-
down range of 10°
Replace
Journal Standard fitting Clearance limit

No.1 – 7 Interference —
0.002 – 0.060
621202
Fitting of main bearing
I.
cap and cylinder block
• Cylinder liner
Standard Standard Repair
size value limit
Top 170.2
170.10 – —
Replace
step 170.20 cylinder liner
Bottom 161.25 –
161.2 161.29 —
step
Inside diameter of
counterbore, outside
J.
diameter of cylinder
liner flange
• Cylinder block
Standard Standard Repair
size value limit
Correct
Top 170.200 –
cylinder block
170.2 —
step 170.263 sleeve
Bottom 161.197 –
161.2 161.230 —
step
15-22
6
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)
Unit: mm
Standard dimension
Diameter 127 –0.014
–0.039
Roundness 0.005
Straightness 0.010
Length Min. 1,150
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.
fl 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.
621202
5. Check that tool J moves smoothly.
15-23
6
CORRECTING CYLINDER BLOCK TOP SURFACE,
REPAIR AND REPLACEMENT OF PARTS COUNTERBORE

COUNTERBORE
Flow for correction procedure
(a ≥ 0.15mm) 3 4 5 6
Measure dimension Is dimension d of
YES Remove cylinder d of cylinder block, cylinder block
Machine top face
and determine within standard
liner machining amount.
of cylinder block value?
[See Fig. 2, Table 1] [See Table 1]
• Before
measuring, wash
and remove all
carbon and scale.
• Set so that
machining
amount is within
repair limit for
dimension d.
621202
18
1 2 • Measure depth f of
Is it necessary to counterbore
Disassemble grind top surface of YES • Determine amount for
engine cylinder block? maching according to
[See Fig. 1] relationship with cylinder
liner protrusion e.
• Leave cylinder • If wear a of top [See Fig. 5, Table 2]
liner installed face of cylinder • Determine amount
• Keep used head block is more of machining so
gasket for later than 0.15 mm, it that cylinder liner
Within
use is necessary to Standard value 16 17 protrusion e is
grind top face. within standard
Has any fretting value.
YES Remove cylinder occurred in • If grinding goes
liner counterbore? beyond standard
[See Fig. 3] size but is still
• If more than half within repair limit,
of cylinder liner set machining
(a < 0.15mm) 15 amount so that
contact surface
Is protrusion e of (particularly in one shim shown in
cylinder liner within [Fig. 7] is used for
front-to-rear
NO standard value? each cylinder.
direction) of
[See Fig. 4, Table 2]
counterbore is
worn, it is
necessary to NO
correct by
Outside grinding
Standard value
NO
fl When removing, installing, disassembling, or assembling the engine, see the DISASSEMBLY AND
ASSEMBLY section for details of the procedure.
fl If the judgement for Item 9 is NO, go to A. If the answer is NO again, go on to B.
15-24
6
Within 10
Standard value
1 Remove
cylinder liner
again and coat
counterbore 11
with gasket Punch
YES sealant LG-6. distinguishing mark
on cylinder block.
2 Install cylinder [See Fig. 11, Table
liner O-ring, 5]
Within
Standard value 7 8 9 then press fit
• When using an
cylinder liner.
Is protrusion e of oversized head
Prepare standard Press fit cylinder [See Fig. 12, 13,
YES cylinder liner within gasket and shim,
head gasket. liner standard value?
14]
always punch a
[See Table 4] [See Table 2] distinguishing
mark at the
• When using
Within
specified
shim, see Fig. 6,
NO repair limit 13 position.
7, Table 3.
Prepare oversize
NO
head gasket (to
prevent interference
between piston and
cylinder head)
[See Table 4]
Below repair
limit 14
Replace cylinder
NO block 12
621202
B
Within Assemble engine
YES Standard value
A
Within
19 20 NO repair limit 21
Is depth f of
Set insertion
Machine counterbore within
shim.
counterbore standard value?
[See Table 2] [See Table 3]
Below repair
limit 22
Replace cylinder
NO block
15-25
6
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,
correct the counterbore.
1. Grinding top surface of cylinder block Fig. 1

1) Measure the wear and strain of the top sur-
face 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.
fl Guideline for grinding top surface of cyl-
inder block
• When wear and corrosion on top
surface of cylinder block are the same
shape as the mark left by the head
621202
gasket
• When wear amount a is more than
0.15 mm
Fig. 2
Table 1
Unit: mm
Standard Repair
dimension limit
Flatness of cylinder block
0.05 0.10
(for one cylinder)
Height of cylinder block d 430.5 ± 0.04 430.0
Roughness of top surface
Within 12.5 S
of cylinder block
fl 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 mm
Grindstone : A461V
Grinding fluid : Water soluble
grinding fluid
15-26
6
Fig. 3
2. Grinding counterbore
• After grinding the top surface of the cylinder
block, measure the depth of the counterbore.
If necessary, correct the counterbore depth f
within the repair limit.
fl Guideline for correcting counterbore
• If it is not within the standard dimen-
sion.
• 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. Fig. 4
• After correcting, if the counterbore depth
is within 14.05 – 15.525 mm, combine
with shims and adjust so that the cylin-
der liner protrusion is 0.07 – 0.15 mm.
Table 2
Unit: mm
Standard Repair
dimension limit
Counterbore depth f 11+0.05 12.525
621202
Cylinder liner protrusion e — 0.07 – 0.15

Roughness of counterbore Within 12.5 S
In accordance with diagram Fig. 5
Machined shape on right (detail diagram for
portion b)
• 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 stand-
ard 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. 6
Part No. T t Weight (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
15-27
6
Fig. 7
Fig. 8
• Use tool K when grinding the counterbore.
621202
Fig. 9
15-28
6
Fig. 10
3. Checking and distinguishing after grinding and
correcting
• After grinding and correcting, check for
scratches on the flat surface around the wa-
ter 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 dimen-
sion (430.5 ± 0.04 mm), but is within the re-
pair limit (430.46 – 430.10 mm), always use
an oversize head gasket.
Table 4 Fig. 11
Unit: mm
Head gasket Part No. Plate thickness
S.T.D. 6210-17-1813 2.0
Oversize 6210-19-1813 2.4
fl 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
621202
the nature of the correction as shown in the

table below.
Table 5
Oversize head gasket Shim Stamp
Parts used for
— — Not needed
correction
fi — OS
— fi SH
fi fi WS
(Size of letters: 5 – 10 mm)
15-29
7
Fig. 12
4. Procedure for coating cylinder block top surface
deck with gasket sealant
• When pulling out the cylinder liner and press
fitting it again, coat the cylinder block top
surface deck (the cylinder liner flange con-
tact surface of the cylinder block) with gas-
ket sealant (LG-6) as follows.
Use the same procedure when using a shim
for the deck.
Fig. 13
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 seal-
ant: 6 ± 6 mm
621202
fl 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. Fig. 14
• 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 con-
tact surface of the seal and O-ring with a
small amount of engine oil (SAE30) immedi-
ately before press fitting the liner.
fl Do not coat with engine oil until imme-
diately before press fitting the cylinder
liner.
Fig. 15
4) After setting the cylinder liner in the cylin-
der 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}
15-30
6
Fig. 16
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.
fl The gasket sealant that comes out may
cause deformation of the head gasket
grommet, so always carry out Steps 4)
and 5) without fail.
fl After carrying out Steps 4) and 5), use a
new head gasket to install the cylinder
head.
Fig. 17
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.
fl Concentricity of 6 in relation to standard
A: Max. 0.05 mm
Table 6
621202
Unit: mm
No. Finishing dimensions
1 ø167
Fig. 18
2 ø161.45 ± 0.25
3 ø160.67 ± 0.064
4 176 ± 0.25
5 184.94 ± 0.18
+0.040
6 ø158 0
7 ø159.03 (Gauge diameter)
15-31
6
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
Part No. Part Name
Main bearing caps other than
6215-29-1210
No. 4, 7
6215-29-1230 No. 4 main bearing cap
6215-29-1250 No. 7 main bearing cap
1. Machining inside diameter of main bearing cap

1) Remove the cylinder liner.
2) Install the replacement main bearing cap to
the cylinder block, and tighten to the speci-
fied 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}
621202
Order Target Range
108 – 128
1st step 118 {12}
{11 – 13}
211 – 221
2nd step 216 {22}
{21.5 – 22.5}
3rd step Tighten a further 90° 90° +30°
0
fl Align the cylinder block and main bear-

ing cap notch.
3) Set a cylinder block mounting jig on the ta-
ble 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 dial gauge in contact with the inside diam-
eter at two places to align the center of the
boring machine arbor.
15-32
6
REPAIR AND REPLACEMENT OF PARTS REPLACING MAIN BEARING CAP
5) Check the machined inside diameter of bear-

ing cap (1) and grind a little at a time.
fl Grind until the bit touches the inside
surface of cylinder block (2).
fl Inside diameter of main bearing cap
1 Machining dimension
+0.025
Tolerance: 127 0 mm
2 Inside diameter of cap when main
bearing cap is tightened to specified
torque after machining
Tolerance: 127 +0.025
– 0.010 mm
(Up-down range of 10° at mating

surface of main bearing cap)
fl Finishing roughness: Within 10 S
fl Do not grind the inside face of the cylin-
der block.
2. Machining width of main bearing cap

(Only when machining No. 7 main bearing cap)
1) Insert cast iron bushing 1, then pass arbor
2 through.
2) Install facing bit 3 to the arbor.
3) Grind cap (1) until the bit touches the cylin-
der block face.
621202
4) Grind the opposite side in the same way.

fl Roughness of thrust bearing mounting sur-
face: Within 12.5 S
fl Do not grind the cylinder block.
fl Width of main bearing cap
Tolerance: 43.970 – 44.000 mm
15-33
6
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications 1 PROPOSAL FOR MANUAL REVlslON 1
Fax No. (847) 970-4186 I I
FOR INTERNAL USE ONLY -- No. PMR

I
P 1 NAME OF COMPANY: 1 LOCATION:
PHONE NO:
DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
\ttach photo or sketch.

f more space is needed, use another sheet.
FOR INTERNAL USE ONLY

:ORRECTIVE ACTION:
PFMRl 081696

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SEBM008608

11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 13-1

14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

15 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . 15-1

The affected pages are indicated by the use of the

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of

o 00- 2-3 (8) o 01- 3 (8) 01-22 (5) 11-19 11-49

Time of Time of Time of Time of Time of

11-68 12- 5 12-27 13-13 (2) 13-53 (2)

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

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

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

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

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

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

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

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

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque