Sebe62120112 D140 1

SEBE62120112
DIESEL ENGINE
© 2005 1 00-1
All Rights Reserved (12)
Printed in Japan 02-05 (01)
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.
ﬁ 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

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
‡ 00-1 (12) 01-003-3 (10) 01-023 (7) 11-010-2 (8) 11-033 (3)
00-2 (8) 01-003-4 (10) 01-024 (7) 11-011 (2) 11-033-1 (3)
‡ 00-2-1 (12) 01-003-5 (10) 01-025 (7) 11-012 11-033-2 (3)
‡ 00-2-2 (12) 01-003-6 (10) 01-026 (7) 11-013 (4) 11-033-3 (3)
‡ 00-2-3 (12) 01-003-7 (10) 01-027 (7) 11-014 11-033-4 (3)
00-3 01-003-8 (10) 01-028 (10) 11-015 (8) 11-033-5 (3)
00-4 01-003-9 (11) 01-029 (10) 11-016 (1) 11-034 (4)
00-5 01-003-10 (11) 01-030 (10) 11-017 (1) 11-035 (8)
00-6 01-004 01-031 (10) 11-018 (4) 11-035-1 (8)
00-7 01-005 01-032 (10) 11-019 (4) 11-036
00-8 01-006 11-020 (8) 11-037
00-9 01-007 11-020-1 (8) 11-038 (1)
00-10 01-008 (1) 11-001 (10) 11-021 11-038-2 (6)
00-11 01-009 (1) 11-002 11-022 (4) 11-039 (10)
00-12 01-010 (1) 11-003 (1) 11-023 11-039-1 (10)
00-13 01-011 (1) 11-004 (1) 11-024 (8) 11-040 (10)
00-14 01-012 (2) 11-005 11-024-1 (8) 11-041 (2)
00-15 01-013 (2) 11-006 (8) 11-024-2 (8) 11-042 (6)
00-16 01-014 (2) 11-006-1 (8) 11-025 (8) 11-043 (10)
00-17 01-015 (2) 11-007 (8) 11-027 (5) 11-044 (5)
00-18 01-016 (7) 11-007-1 (8) 11-028 (5) 11-045 (10)
00-19 01-016-1 (8) 11-007-2 (8) 11-029 (1)
01-017 (7) 11-008 (8) 11-029-1 (1)
01-018 (7) 11-008-1 (8) 11-029-2 (1) 12-001 (10)
01-001 (10) 01-019 (7) 11-008-2 (8) 11-030 (5) 12-002 (6)
01-002 (1) 01-020 (7) 11-009 (8) 11-030-1 (10) 12-003
01-003-1 (10) 01-021 (7) 11-010 (8) 11-031 12-004 (7)
01-003-2 (10) 01-022 (7) 11-010-1 (8) 11-032 (3) 12-005 (8)
6D140-1 SERIES 00-2-1

(12)

12-006 (6) 12-021-22 (10) 12-022-26 (10) 13-009-1 (7) 13-046

12-007 (8) 12-021-23 (9) 12-022-27 (10) 13-010 13-047 (8)
12-007-1 (7) 12-021-24 (9) 12-022-28 (11) 13-011 (1) 13-048 (3)
12-007-2 (8) 12-021-25 (9) 12-022-29 (11) 13-012 13-049 (3)
12-008-1 (7) 12-021-26 (9) 12-023 (6) 13-013 13-050 (3)
12-008-2 (2) 12-021-27 (10) 12-024 (6) 13-014 13-051 (3)
12-009 (9) 12-021-28 (9) 12-025 (6) 13-015 13-052 (3)
12-010 (10) 12-021-29 (9) 12-026 (6) 13-016 13-053 (3)
12-011 (9) 12-021-30 (9) 12-027 (6) 13-017 13-054 (3)
12-012 (11) 12-021-31 (9) 12-028 (6) 13-018 13-055 (3)
12-013 (10) 12-021-32 (9) 12-029 (6) 13-019 13-056 (5)
12-014 (9) 12-021-33 (9) 12-030 (6) 13-020 13-057 (5)
12-015 (9) 12-021-34 (9) 12-031 (6) 13-021 13-058 (5)
12-016 (10) 12-021-35 (9) 12-032 (6) 13-022 13-059 (5)
12-017 (10) 12-021-36 (9) 12-033 (6) 13-022-1 (8)
12-018 (9) 12-021-37 (9) 12-034 (6) 13-022-2 (8)
12-019 (9) 12-022 (9) 12-035 (6) 13-023 (8) 14-001 (8)
12-020 (9) 12-022-1 (9) 12-036 (6) 13-024 (8) ‡ 14-002 (12)
12-021 (9) 12-022-2 (9) 12-037 (6) 13-025 (8) ‡ 14-002-1 (12)
12-021-1 (9) 12-022-3 (10) 12-038 (6) 13-026 (4) 14-003 (4)
12-021-2 (9) 12-022-4 (9) 12-039 (6) 13-027 14-004 (10)
12-021-3 (9) 12-022-5 (9) 12-040 (6) 13-028 14-005 (8)
12-021-4 (9) 12-022-6 (11) 12-041 (6) 13-029 (1) 14-006 (4)
12-021-5 (9) 12-022-7 (11) 12-042 (6) 13-030 (9) 14-007 (1)
12-021-6 (9) 12-022-8 (10) 12-043 (6) 13-031 (4) 14-008 (10)
12-021-7 (9) 12-022-9 (10) 12-044 (6) 13-032 (4) 14-009 (3)
12-021-8 (9) 12-022-10 (11) 12-045 (6) 13-033 (5) 14-010 (8)
12-021-9 (9) 12-022-12 (10) 12-046 (6) 13-034 14-011 (4)
12-021-10 (9) 12-022-13 (10) 12-047 (6) 13-035 (4) 14-012 (4)
12-021-11 (9) 12-022-14 (10) 13-036 (4) 14-013 (8)
12-021-12 (9) 12-022-15 (10) 13-037 (3) 14-014
12-021-13 (9) 12-022-16 (11) 13-001 (5) 13-038 (10) 14-015 (2)
12-021-14 (9) 12-022-17 (11) 13-002 13-039 (4) 14-016 (1)
12-021-15 (9) 12-022-18 (10) 13-003 13-040 (10) 14-017 (4)
12-021-16 (9) 12-022-20 (10) 13-004 13-041 (4) 14-018 (4)
12-021-17 (9) 12-022-21 (10) 13-005 13-042 (7) 14-020
12-021-18 (9) 12-022-22 (10) 13-006 13-043 (7) 14-021 (1)
12-021-19 (9) 12-022-23 (10) 13-007 (1) 13-043-1 (7) 14-022 (1)
12-021-20 (10) 12-022-24 (10) 13-008 (10) 13-044 (10) 14-022-1 (8)
12-021-21 (10) 12-022-25 (10) 13-009 (7) 13-045 14-023 (8)
00-2-2 6D140-1 SERIES

(12)

14-024 (8)
14-025 (8)
15-001 (8)
15-001-1 (8)
15-002 (6)
15-003 (6)
15-004 (6)
15-005 (8)
15-006 (8)
15-007 (6)
15-008 (6)
15-009 (8)
15-010 (8)
15-011 (6)
15-012 (6)
15-013 (6)
15-014 (8)
15-015 (6)
15-016 (8)
6D140-1 SERIES 00-2-3

(12)
ENGINE
01 GENERAL
Genral view ....................... 01-002

Specifications ..................... .01-003-l
General assembly drawing .............. 01-004
Engine performance curve .............. 01-016
Weight table ....................... 01-032
6D140-1 SERIES Ol$Ol

GENERAL GENERAL VIEW
GENERAL VIEW
S6D140-1
1. Fan pulley
2. Breather
3. Electrical intake air heater
4. Oil filler
5. Crankshaft pulley
6. Vibration damper
7. Dipstick
8. Fuel injection pump
9. Fuel filter
10. Oil filter
i i i i i 1’0
621OPOOl
11. Turbocharger
12. Oil cooler
13. Alternator
14. Thermostat housing
15. Starting motor
16. Under frame
17. Oil pan
621 OPO02
6D140-1 SERIES
GENERAL SPECIFICATIONS
SPECIFICATIONS
Engine model S6D140-1
D155A-3
Applicable machine D 135A-2 WA500-1
I D155AX-3 I
Number of cylinder - mm 6 - 140 x 165

Bore x Stroke
Total piston displacement e {cc) 15.24 {I 5,240)
Firing order l-5-3-6-2-4
Overall length mm 1,552 1,499 1,880
Overall width mm 1,110 1,041 1,060
Overall height mm 1.939 1,740 1,670

(excluding exhaust pipe)
Overall height mm -
(including exhaust pipe)
Flywheel horsepower kW/rpm 20512,000 228/l ,900 217/2,100

WP/rpm~ {275/2,000} {306/l ,900} I291/2,100~
Maximum torque Nm/rpm 1,236/1,400 1,432/1,300 1,226/1,400

fkgm/rpmI I126/1,400} 1146/l ,300) {125/l ,400}
High idling speed rpm 2,150 - 2,250 2,100 + 50 2,300 - 2,400
Low idling speed rpm 650 - 700 700 - 725 700 - 750
Minimum fuel consumption g/kWh 211 (157) 212 1158) 201 11501
ratio Ig/HPhI
Dry weight kg 1,575 1,550 1,453
Fuel pump Bosch PE-P type
Governor Bosch RSV centrifugal, all speed type
Lubricating oil amount 42 42 40

(refill capacity) (38) (37) (32)
Coolant amount 90 97 80
Alternator 24 V, 35 A 24 V, 35 A 24 V, 50 A
Starting motor 24V, 11 kW 24 V, 11 kW 24 V, 11 kW
Battery 12 V 170 Ah x 2 12 V 170 Ah x 2 12 V 170 Ah x 2
Turbocharger Komatsu KTRI 10 Komatsu KTRllO Komatsu KTRI IO

i
Air compressor - - Made by ZEXEL
i
Others
1 I -
01-003-l 6D140-1 SERIES

@
S6D140-1
HD325-5 (C SPEC.) WS16S-3 WS23-2 GD825A-1 EG300B-5
6 - 140 x 165
15.24 115,240)
l-5-3-6-2-4
1,762 1,701 1,700 1,593 1,874
1,179 1,045 1,045 895 957
1,298 1,262 1,262 2,060 1,521
- - - -
24811,500 (50 Hz)

302/2,100 302/2,100 302/2,100 213/2,100 {332/1,500} (50 Hz)
(405/2,100} {405/2,100} {405/2,100} {285/2,100) 284/1,800 (60 Hz)
{381/1,800} (60 Hz)
1,554/l ,400 1,579/l ,400 1,579/1,400 1,255/1,400 -

1158.5/l ,400) (161/1,400} I161/1,400) {128/1,400}
1,560 max. (50 Hz)

2,300 - 2,400 2,300 - 2,400 2,300 - 2,400 2,300 - 2,400
1,872 max. (60 Hz)
750 - 800 750 - 800 750 - 800 650 - 700 800 - 850
196 (1461 196 I1461 196 {I461 198 11481 198 (1481
(at rated output)
1,350 1,350 1,350 1,360 1,420
Bosch PE-P type Bosch PE-P type Bosch PE-P type
Bosch RFD centrifugal, Bosch RSV centrifugal, Bosch RSUV centrifugal,

max. and min. speed type all speed type all speed type
38 40 35 40 38
(30) (29) (30) (36) (32)
125 115 115 78.5 58
24 V, 50 A 24 V, 35 A 24 V, 35 A 24 V, 50 A 24 V, 25 A
24 V, 11 kW 24 V, 7.5 kW 24 V, 7.5 kW 24 V, 7.5 kW 24 V, 7.5 kW
12 V 170 Ah x 2 12 V 170 Ah x 2 12V 200Ahx2 12V 200Ahx2 12V 200Ahx2
Komatsu KTRI 10 Komatsu KTRl IO Komatsu KTRIIO Komatsu KTRI 10 Komatsu KTRI IO
Made by ZEXEL -
Made by ZEXEL Made by ZEXEL Made by ZEXEL
(Front Engine only)
- - -
L
6D140-1 SERIES 01-003-2

@
GC380 GS360-2 (Engine

Applicable machine EG300BS-5
(GC380F) No. up to 12024)
Number of cylinder - mm 6-140x165

Bore x Stroke
Total piston displacement e {cc1 15.24 {I 5,240)
Firing order _ l-5-3-6-2-4
Overall width mm 957 977 880
Overall height mm 1,521 1,248 1,678

Overall height mm - - -
241/1,500 (50 Hz)

Flywheel horsepower kW/rpm {323/1,5001(50 Hz) 28012,000 265/2,000
IHP/rpmI 276/1,800 (60 Hz) {375/2,000} {355/2,000)
{370/1,8001(60 Hz)
Maximum torque Nm/rpm - 1,502/1,500 1,432/l ,500

fkgm/rpmI 1153.2/1,500} {146/1,500}
1,560 max. (50 Hz)

High idling speed rpm 2,230 - 2,330 2,200 - 2,300
1,872 max. (60 Hz)
Minimum fuel consumption g/kWh 198 {148} 205 (1531 205 {153}
ratio Ig/HPhI (at rated output)
r-
Dry weight kg 1,420 1,320 1,320
Fuel pump Bosch PE-P type
Governor Bosch RSV centrifugal, all speed type
Lubricating oil amount 38 36 38

(refill capacity)
e
(32) (33) (32)
Coolant amount e 64 45 60
Starting motor 24 V, 7.5 kW 24 V, 7.5 kW 24 V, 7.5 kW
Battery 12V 200Ahx2 12 V 170 Ah x 2 12 V 170 Ah x 2
Turbocharger Komatsu KTRIIO Komatsu KTRI 10 Komatsu KTRIIO
Air compressor - - -
Others -
I
01-003-3 6D140-1 SERIES
@
*I: Engine No. 12025 and up
S6D140-1
GS360-2 (* 1)
CS360-2 WFGOOT- 1
CS360SD-2
6- 140 x 165
15.24 {I 5,240}
l-5-3-6-2-4
1,606 1,617
950 1,060
1,684 1,337
26512,000 250/2,100
{355/2,000) {335/2,100}
1,432/l ,500 1,422/l ,400

1146/1,500} ~145/1,4001
2,200 - 2,300 2,300 - 2,400
800 - 850 700 - 750
202 I1531 212 I1581
1,320 1,500
Bosch PE-P type
Bosch RSV centrifugal,

all speed type
38 40
(32) (34)
60 94
24 V, 35 A 24 V, 50 A
24 V, 7.5 kW 24 V, 11 kW
12 V 170 Ah x 2 12 V 170 Ah x 2
Komatsu KTRI 10 Komatsu KTRI 10
Made by ZEXEL
- l-cylinder, reciprocated
type
- -
6D140-1 SERIES 01-003-4

@
Engine
Applicable
model
machine I H D325-6
SAGD140-1
PC650-3
PC650-5
PC710-5
PC1600-1
Number of cylinder - mm 6- 140 x 165

Bore x Stroke
Total piston displacement e {cc1 15.24 {I 5,240)
Overall width mm 1,179 1,185 1,185
Overall height mm 1,277 1,684 1,684

Overall height mm -
Flywheel horsepower kW/rpm *379/2,100 306/l ,800 30611,800

IHP/rpmI *{508/2,100} I410/1,800} {410/1,800}
Maximum torque Nm/rpm *2,069/l ,500 1,804/1,400 1,804/l ,400

fkgm/rpmI *I21 l/l ,500) {184/1,400} {I 84/l ,400)
High idling speed rpm 2,400 - 2,500 1,930 - 2,030 1,930 - 2,030
Minimum fuel consumption g/kWh 197 {I471 199 1149) 199 (1491
ratio In/HPhI
I
Dry weight kg 1,450 1,475 1,475
‘JIPPON DENS0 NE (EPll) NIPPON DENS0 NE (EPll)

Fuel pump tvpe
NIPPON DENS0 R811H NIPPON DENS0 RSUV centrifugal,
3
TI
Governor centrifugal, max. and min.
speed type L
all-so eed tvoe
.
Iingine No. 10001 - 1862: Engine No. 10001 - 17791
Lubricating oil amount 42 38 (33.5) 38 (33.5)
e IEngine No. 18624 and ur , Engine No. 17792 and up
(refill capacity) (37)
48 (43) 48 (43)
Coolant amount e 156 147 147
Starting motor 24V, 11 kW 24 V, 7.5 kW 24 V, 7.5 kW
Battery 12 V 170 Ah x 2 12 V 170 Ah x 2 12 V 170 Ah x 2
Turbocharger Komatsu KTRI 10 Komatsu KTRIIO Komatsu KTRI 10
Air compressor Made by ZEXEL Made by ZEXEL Made by ZEXEL

-cylinder, reciprocated typ e
Others With after-cooler With after-cooler With after-cooler
*: Performance with gross
01-003-5 6D140-1 SERIES

@
SAGD140-1
EG400B-2 EG400BS-2
HD325-5 (STD.) WS23S-2 EG400B-2L
OEM for generator OEM for generator
6 - 140 x 165
15.24 115,240)
l-5-3-6-2-4
1,762 1,700 1,878 1,874 1,878
1,179 1,045 1,000 957 1,000
1,304 (Engine No. - 11428)

1,298 (Engine No.11429 and "1 1,277 1,521 1,521 1,628
311/1,500 (50 Hz) 314/1,500 (50 Hz)

351/2,100 340/2,100 {417/1,500) (50 Hz) I421/1,500} (50 Hz) 307/l ,500 (50Hz)
{470/2,100} {456/2,100} 357/1,800 (60 Hz) 362/1,800 (60 Hz)
~411/1,5001 (50 Hz)
{478/1,8001 (60 Hz) {485/1,800) (60 Hz)
1,922/l ,400 1,844/l ,400 - - -

I196/1,400} 1188/l ,400)
1,560 max. (50 Hz) 1,560 max. (50 Hz)

2,350 - 2,450 2,300 - 2,400 1,575 max. (50 Hz)
1,890 max. (60 Hz) 1,890 max. (60 Hz)
750-800 (Engme NO.- 10581)
700-750 (EngineNo.10582 and us 680 - 720 800 - 850 800 - 850 800 - 850
189 {I411 189 I1411 196 {I461 196 (1461 196 1146)
(at rated output) (at rated output) (at rated output)
1,400 1,380 1,450 1,450 1,450
NIPPON DENS0 NE (EPll) Bosch PE-P (PS7S)

we
NIPPON DENS0 NE (EPII) type
type
NIPPON DENS0 R811H
centrifugal, max. and min. RSUV centrifugal,
NIPPON DENS0 RSUV centrifugal, all-speed type
speed L all speed type
38 35 38 38 38
(30) (30) (32) (32) (32)
125 150 58 64 58
24 V, 50 A 24 V, 50 A 24 V, 25 A 24 V, 25 A 24 V, 25 A
24V, 11 kW 24 V, 11 kW 24 V, 7.5 kW 24 V, 7.5 kW 24 V, 7.5 kW
12 V 170 Ah x 2 12 V 170 Ah x 2 12V 200Ahx2 12V 200Ahx2 12V 200Ahx2
Komatsu KTRI IO Komatsu KTRI 10 Komatsu KTRllO Komatsu KTRI IO Komatsu KTRllO
Made by ZEXEL Made by ZEXEL - - -
With after-cooler With after-cooler With after-cooler With after-cooler With after-cooler
6D140-1 SERIES 01-003-6

@
Engine model SAGD140-1
Number
Total
Applicable
of cylinder -
machine
Bore x Stroke
piston displacement
Firing order
mm
e {cc1
I GC380F-2
OEM for 200 kW
GENERATOR
6- 140 x 165
15.24 {15,240}
l-5-3-6-2-4
-
Overall length mm 1,638 1,711
: Overall width mm 1,019 1,041

.g
2
Overall height mm 1,280 1,603
.-E (excluding exhaust pipe)
n
Overall height mm -
-
274/1,500 (50 Hz)
Flywheel horsepower kW/rpm 36412,000 I367/1,500} (50 Hz)
304/1,800 (60 Hz)
{HP/rpml {488/2,000)
{408/1,800) (60 Hz)
Maximum torque Nm/rpm 2,010/1,400 -

2
5 Ikgm/rpmI {205/l ,400}
E
z Max. 1,575 (50 Hz)
High idling speed rpm 2,200 - 2,300
‘t Max. 1,890 (60 Hz)
d
Low idling speed rpm 850 - 900 800 - 850
Minimum fuel consumption g/kWh 215 11601 209 11541 (50 Hz)
ratio {g/HPhI 212 {I561 (60 Hz)
-
Dry weight kg 1,560 1,400 (Engine only)
IIPPON DENS0 NE (EPll

Fuel pump type Bosch PE-P (PS7S)
NIPPON DENS0 R811H
Governor :entrifugal, max. and min Electronic control
speed type
Lubricating oil amount 42 74

Q
(refill capacity) (37) (71)
Coolant amount Q 73 (Engine only 23) 27 (Engine only)
Alternator 24 V, 75 A
Starting motor 24 V, 11 kW 24 V, 11 kW
Battery 12 V 170 Ah x 2 12V 200Ahx2
Turbocharger Komatsu KTRIIO Komatsu KTRllO
Air compressor ZEXEL l-cylinder,

reciprocated type
Others With after-cooler With after-cooler
01-003-7 6D140-1 SERIES

@
Engine model SAGDl40-1
g-pole GENERATOR OEM for g-pole

Applicable machine
f (50 Hz) GENERATOR (60 Hz)
Number of cylinder - mm 6-140x165

Bore x Stroke
Total piston displacement e {cc) 15.24 (15,240)
Overall length mm 1,878
Overall width mm 1,060
Overall height mm 1,597

Overall height mm -
Flywheel horsepower
Prime kW/rpm 191/1,000 227/I ,200
0-lP/rpmI {256/l ,000) {304/l ,200I
Standby kW/rpm 210/1,000 250/I ,200
IHP/rpml {282/l ,OOOI {334/l ,200)
Maximum torque Nm/rpm -

fkgm/rpmI
High idling speed

Prime rpm Max. 1,045 Max. 1,254
Standby rpm Max. 1,050 Max. 1,260
Low idling speed rpm 750 - 850 750 - 850
Minimum fuel consumption g/kWh 208 I1551 208 {I551

ratio (Prime) {g/HPhI
Dry weight kg 1,450
Fuel pump Bosch PE-P (PS7S) type
Governor Bosch RSUV, mechanical, all-speed type
Lubricating oil amount

(refill capacity)
e
Coolant amount e 66 (Engine only 27)
Alternator -
Starting motor 24 V, 7.5 kW
Battery 12 V 200Ah.x 2
Turbocharger SCHWITZER S3A
Air compressor
Others With after-cooler
6D140-1 SERIES 01-003-8

@
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
S6D140-1 LEFT SIDE VIEW (For WA500-1)
1146.5
Crankshaft
_
center
I-
cq
tz
m
1 50.8 ‘k;;”
850.8
612OFOOl
0 l-004 6D140-1 SERIES

GENERAL
S6D140-1 RIGHT SIDE VIEW (For WA500-1)
Crankshatt center
# I
1772.2
612OFOO3
6D140-1 SERIES
0 l-005
S6D140-1 FRONT VIEW (For WA500-1)
407.5
472.5 _ _
407.5
472.5 I 612OFOO4
0 l-006 6D140-1 SERIES

S6D140-1 REAR VIEW (For WASOO-1)
Distance for
replacement
of element 470
12 x pitch 1.75, depth 21 - 2
‘dia. 12 x pitch 1.75, depth 21 - 12 points
612OFOO2
6D140-1 SERIES 0 l-007

SAGD140-1 LEFT SIDE VIEW (For HD325-5)
F621201100
01 -go8 60140-l SERIES

SAGD140-1 RIGHT SIDE VIEW (For HD325-5)
Coolant
(To radiator)
Water
temperature
sensor 16 x 1.5
Outlet for heater
F621201101
6D140-1 SERIES Ol-gO9

SAGD140-1 FRONT VIEW (For HD325-5)
1198.8
r.“‘z_,
_A-\
f
Coolant
(From radiator)
F621201102
Ol-go 6D140-1 SERIES

SAGD140-1 REAR VIEW (For HD325-5)
I
Coolant
(To chassis
brake cooler)
‘12-l 0x1.5 Depth 20
x?;-8-12x1 .75 Depth 21
F621201103
6D140-1 SERIES
o’F1
SADGD140-1 LEFT SIDE VIEW (For PC650-3)
4-10x1.5
Depth 18 I
T
'10X1.5
lth 18
Inki
‘4
6”
(D
Oilpressure
Inkshaft center
i
t
,Rotatsonsensor
u
850.5
1366.5
L
1572.5
01-F2 6D140-1 SERIES

GENERAL
SAGD140-1 RIGHT SIDE VIEW (For PC650-3)
Water temp.
\
PT112
\
Engine hook
~__
\
7
(7
mo
o!
ISI
Crankshaft center ,_-’
2-14H8 Iw
Depth 15 /
I \
‘63.5
280.5
--
1206 -__1
6D140-1 SERIES
01-F3
SAGD140-1 FRONT VIEW (For PC650-3)
/
9
J
Ii
Crankshaft center
L4
L
376.1 507.3
01g14 6D140-1 SERIES

SAGD140-1 REAR VIEW (For PC650-3)
12 - 12 x 1.75 Depth
27
1 285.8 ’ (_ 285.8 _!
6D140-1 SERIES
O’-P
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE

S6D140-1 for D135A-2
Flywheel horsepower: 279 HP/2,000 rpm
Maximum torque: 126 kgm/l,400 rpm
Minimum fuel consumption ratio: 157 g/HPh
300
250
200
150
100
600 800 1000 1200 1400 1600 1800 2000 2200
Engine speed (ipm)
62 I OF034
O’P 6D140-1 SERIES

S6D140-1 for D155A-3, D155AX-3

Flywheel horsepower: 306 HP/l ,900 rpm
Maximum torque: 146 kgm/1,300 rpm
180
150
120
-z
90 f
z
b
360 60 I-
330 30
270
240
180
120
90
60
.
\ Fuel consumption ratio /
30 -
T
140
O- I=
600 800 1000 1200 1400 1600 1800 2000 2200
Engine speed (rpm) 621OFO40
6D140-1 SERIES
O’-%
&’
S6D140-1 for WA500-1

275
250
225
125
100 180
75
50 160
25 150
0
800 1000 i 200 1400 1600 1800 2000 2200 2400
Engine speed (rpm)
612OFOO5
6D140-1 SERIES
OY7
S6D140-1 for WS16S-3, WS23-2

180
160
140
120
100
80
60
40
20
450
400
350
300
ii
I
5
a 250
2
200 200
190
150 180
170
100 160
150
50 140
130
0
800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rpm)

62lOFOl2
Ol-$18 6D140-1 SERIES

S6D140-1 for GD825A-1

250
c 200
I1
s
cl
S
0
150
50
--160
--150
0
800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine speed (rpm)
F621201104
6D140-1 SERIES
0'SY9
S6D140-1 for EG300B-5

Flywheel horsepower: 332 HP/l ,500 rpm (50 Hz)
381 HP/l,800 rpm (60 Hz)
Fuel consumption ratio: 148 g/HPh (at rated output) (50 Hz)
148 g/HPh (at rated output) (60 Hz)
-’ 220
150 --
-. 200
-. 190
loo--
. . 180
-. 170
-. 160
-150
Engine speed (rpm) 62 I OF027
Ol-g20 6D140-1 SERIES

S6D140-1 for EG300BS-5

Flywheel horsepower: 323 HP/l,500 rpm (50 Hz)
370 HP/l,800 rpm (60 Hz)
Fuel consumption ratio: 148 g/HPh (at rated output) (50 Hz)
148 g/HPh (at rated output) (60 Hz)
250---
-220
-200
-190
-180
-170
-160
- -150
0 i
1200 1300 1400 1500 1600 1700 1800 1900 2000
Engine speed (rpm) 62 I OF026
6D140-1 SERIES 01g21

SAGDI 40-I for PC650-3, PC650-5, PC1 600-I

Flywheel horsepower: 410 HP/l ,800 rpm
200
180
160
140
120 -z
m
300
z
I
sa 250
Engine speed (rpm)

621OFO13
0 l-.22 6D140-1 SERIES

SAGDI 40-I for HD325-5

200
175
150
g
125 9
100 ,;
b
75 i-
50
25
z
%
180 $
170 .g
Y
160 E
0
800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rpm)
F621201105
6D140-1 SERIES 01$23

v
SAGD140-1 for WS23S-2

-180
160
- 140
120
- 20
-0
&I 300
I
‘;
5 250
0
- 180
- 140
800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rpm)
6D140-1 SERIES
0 1X$24
SAGDI 40-I for EG400B-2

478 HP/l ,800 rpm (60 Hz)
Fuel consumption ratio: 146 g/HPh (at rated output)
210 -
200
190
180
170
160
150
Engine speed (rpm)

62 I OF030
6D140-1 SERIES
o’$25
SAGD140-1 for EG400BS-2

Flywheel horsepower: 421 HP/l,500 rpm (50 Hz)
485 HP/l,800 rpm (60 Hz)
Fuel consumption ratio: 146 g/HPh (at rated output)
550-y
500~-
450
400
350
ic
E.
2
2n 300~-
250 -.
2cQ-
150
loo--
50
0 1200 1300 1400 1500 1600 1700 1800 1900 2000
Engine speed (rpm)

62 I OF03 I
Ol-$26 6D140-1 SERIES

SAGDI 40-I for EG400B-2L

500
450-
400
350
300
250
200
,210
150 200
190
100 180
170
50 160
150
0
1000 1100 1200 1300 1400 1500 1600 1700 1800
Enginespeed (rpm)
F621201120
6D140-1 SERIES
o’227
SA6D140-1 for HD325-6

Flywheel horsepower: 379 kW I508 HPY2,lOO rpm
Maximum torque: 2,069 Nm (211 kgmY2,lOO rpm
E
z 2
250 -2500
-2000
- 1500
- 1000
-500
3
k Y
550 0 -0
!OO
1
500
350
450
400 300
2 350
LI 250
$ 300
2oc I-
250
200 15( )-
15c
lO( )-
IOC
5( I-
5c
( t3-
800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Ens i ne speed (r Pm) SWE00978
01-028 6D140-1 SERIES

@
SAGD140-1 for GC380F-2

Flywheel horsepower: 364 kW {488 HP}/2,000 rpm
Maximum torque: 2,010 Nm 1205 kgm}/1,400 rpm
E
9
200
150
100
50
600 1000 1200 1400 1600 1600 2000 2200 2400
Ens i ne speed (r pm) SWE00979
6D140-1 SERIES 01-029

@
S6D140-1 for WFGOOT-1

Flywheel horsepower: 250 kW I335 HPV2,lOO rpm
Maximum torque: 1,422 Nm (145 kgmYl,400 rpm
E
,” :
200 -2000
150 -1500 g
cr
I-
100 1000 ,”
t
50 500
I
0 LO
a 3
I Y
400- 300- 400
350- 350
250-
300- 300
200-
; 250- 250
(1
: 200- 150- 200
150- 150
loo-
IOO- 100
50-
\
50- 50
o- o- n
1
!!
.I
600 600 1000 1200 1400 1600 1600 2000 2200 2400
Engine speed (rpm) SWE00980
01-030 6D140-1 SERIES

@
S6D140-1 for GS360-2, CS360-2

Flywheel horsepower: 265 kW 1355 HPY2,OOO rpm
Maximum torque: 1,432 Nm 1146 kgmV1,500 rpm
E
:
I
z
200 2000
150 -1500 2
D
L
100 -1000 :
50 -500
0 -0
I
\
600 800 1000 1200 1400 1600 1800 2000 2200 2400
Ens ine speed (rpm) SWE00981
6D140-1 SERIES 01-031

@
GENERAL WEIGHT TABLE
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
Unit: kg
No. item Components S6Dl40-1 SAGD140-1
1 Turbocharger Komatsu KTR-110 22 22
2 Cylinder head assembly Cylinder head, valve, valve spring 18.3 18.3
Cylinder block, cylinder liner, main

3 Cylinder block assembly 340 340
bearing cap, bearing
4 Front cover 37 37
5 Oil pan 30 30
51: WS23, WS16S-3 51: HD325, WS23S
55: WA500, GD825A 55: PC650, PC710

6 Flywheel assembly Flywheel, ring gear D155A-3, D155AX-3
WFGOOT, GS360-2
CS360-2
60: WA500, GD825A 54: PC650, PC710
D155A-3, D155AX-3
WFBOOT, GS360-2
7 Flywheel housing CS360-2
68: WS23, WS16S-3 68: HD325, WS23S
8 Crankshaft asssembly Crankshaft, crankshaft gear I 132 I 132
9 Camshaft assembly Camshaft, camshaft gear 19 19
Piston and connecting Piston, piston ring, piston pin, connecting

10 10.5 10.5
rod assembly rod, connecting rod cap, bearing
11 Oil pump 5.5 5.5
21: HD325, WS23S

12 Fuel injection pump 20
31: PC650, PC710
13 1 Water pump I I 12 I 17
I I I
24 V. 35 A 9.5 9.5
14 Alternator ‘)” \I rrl 1. I “0 I ..n
L4 v, 3” H IL IL
15 Startinn mr\+r\r I - 24 V, 7.5 kW 18 18

,L”,Y lll”L”l
24 V, 11 kW 20 20
I I
16 Air compressor 15 15
17 After-cooler assembly 43
01-032 6D140-1 SERIES

@
ENGINE
I1 STRUCTURE AND FUNCTION
GENERAL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-002 FUEL SYSTEM

Fuel system chart ........................................ 1 I-027
INTAKE AND EXHAUST SYSTEM Fuel injection pump.. ................................... 1 I-028
Intake and exhaust system ......................... 1 I-004 Fuel injection nozzle.. .................................. 1 l-030
Air cleaner .................................................... 1 I-006 Boost compensator device ...................... 11-030-I
Turbocharger.. .............................................. 1 I-007 Fuel filter.. ..................................................... 1 I-031
After-cooler ................................................ 1 l-007-2 Fuel solenoid.. .............................................. 1 l-032
Engine stop motor.. .................................. 1 l-033-1
ENGINE BODY
Cylinder head ............................................... 1 I-008 COOLING SYSTEM
Valve system ................................................ 1 l-010 Cooling system chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-034
Cylinder block .............................................. 1 I-012 Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-035
Main circulation system .............................. 1 I-014 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-036
Timing gear .................................................. II-016 Corrosion resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-038
Flywheel and flywheel housing ................. 1 I-018
ELECTRICAL SYSTEM
LUBRICATION SYSTEM Alternator mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-038-2
Lubrication system chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-020 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 l-039
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-021 Starting motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-040
Regulator valve and piston cooling Electrical intake air heater . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-041
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-022
Oil filter .._._.._................................................. 1 I-024 ACCESSORY
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 I-025 Air compressor ............................................ 1 I-042
Exhaust brake.. ............................................. 1 l-044
Exhaust brake butterfly valve.. ................... 1 l-045
6D140-1 SERIES 11-001

@
STRUCTURE AND FUNCTION GENERAL STRUCTURE
- GENERAL STRUCTURE
S6D140-1
IF101
1. Fan pulley 9. Camshaft 17. Connecting rod

2. Cylinder block 10. Camfollower 18. Oil strainer
3. Cylinder liner 11. Crankshaft pulley 19. Oil pan
4. Exhaust valve 12. Vibration damper 20. Crankshaft
5. Piston 13. Front cover 21. Main bearing cap
6. Rocker arm housing 14. Under frame 22. Flywheel
7. Rocker arm housing cover 15. Crankshaft gear 23. Flywheel housing
8. Intake valve 16. Connecting rod cap 24. Turbocharger
1 l-002 6D140-1 SERIES

STRUCTURE AND FUNCTION GENERAL STRUCTURE
621OFlOl
25. Exhaust manifold Engine: S6D140-1 (with turbocharger)

26. Cylinder head SAGD140-1 (with turbocharger and after-cooler)
27. Oil cooler
28. Oil pump
29. Intake connector pipe Type: In-line, B-cylinder, water-cooled, direct fuel injection,
30. Electrical intake air heater 4-cycle diesel engine
31. Intake manifold
32. Push rod
33. Dipstick
6D140-1 SERIES 1 l-003

0
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM

S6D140-1
621OF102
1. Bracket 11. Elbow

2. Muffler 12. Turbocharger
3. Check valve
4. Electrical intake air heater A. Intake
5. Air cleaner B. Exhaust
6. Intake manifold C. Dust (together with exhaust gas)
7. Intake connector
8. Exhaust manifold (Rear)
9. Exhaust manifold (Center)
10. Exhaust manifold (Front)
1 l-004 6D140-1 SERIES

0
621OF103
6D140-1 SERIES 1 l-005

AIR CLEANER
KOMA-CLONE TYPE (AUTOMATIC DISCHARGE MULTICYCLONE TYPE)
S6D140-1
621OF104
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
6D140-1 SERIES
’’-go6
FHG, FTG TYPE (CYCLOPACK TYPE)
FHG type FTG type
6137FOO9.10
1. Inlet 4. Primary element 7. Dust pan

2. Outlet 5. Safety element 8. Diffusion vane (sleeve)
3. Guide vane 6. Vacuator 9. Body
ADVANTAGES STRUCTURE
l The diameter of the element is the same but l Air containing dust is sucked in from inlet (1) at
the outside diameter of the body is smaller. a tangent, and the dust is separated by the
The inlet is placed in the direction of connec- centrifugal force of guide vane (3). More than
tion, so ample centrifugal force can be ob- 99.9% of the remaining drxst is removed by pri-
tained from a simple spiral guide vane, mary element (4). and the cleaned air then
without usng a diffusion vane. passes through safety element (5) and outlet
(2), and is sucked into the engine.
l There is no dust pan or diffusion vane, so the The dust and moisture that is separated by the
structure is simple. guide vane (3) rotates around the inside wall of
body (9), and goes inside vacuator (6), where is
discharged automatically to the outside.
6D140-1 SERIES
’ ’-F-l
TURBOCHARGER
KTRllO
Engine No. 10001 - 19016
rn
L__ -- __ __A
II
C
10 11 12 6210F105A
1. Blower housing 11. Seal ring TURBOCHARGER

2. V-band 12. Turbine impeller
Type: KTRIIO
3. Plate
Overall length: 290 mm
4. Center housing A. Intake inlet
Overall width: 305 mm
5. Shroud B. Intake outlet
Overall height: 267 mm
6. Turbine housing C. Exhaust inlet
Weight: 19 kg
7. Blower impeller D. Exhaust outlet
Maximum allowable rotation: 94,000 rpm
8. Seal ring E. Oil inlet
Maximum charging: 46 kg/min.
9. Thrust bearing F. Oil outlet
Maximum allowable temperature (inlet): 750°C max.
IO. Journal bearing
Direction of rotation (view from blower side): Right
Lubrication method: Forced librication with
engine oil
’’-go7
6D140-1 SERIES
Engine No. 19017 and up
62lOFl34
1. Blower housing 11. Seal ring TURBOCHARGER

2. V-band 12. Turbine impeller Type: KTRIIO
3. 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 bearing F. Oil outlet
10. Journal bearing
’ ’-O!i7-’ 6D140-1 SERIES

AFTER-COOLER
SAGD140-1
D-
L : . .
01 lo
F621201106
1. After-cooler cover A. Intake air inlet (from turbocharger)

2. After-cooler core B. Intake air outlet (to cylinder head)
3. Intake manifold C. Water inlet (from cylinder block)
D. Water outlet (to thermostat)
6D140-1 SERIES
’’-Oki7-*
STRUCTURE AND FUNCTION ENGINE BODY
ENGINE BODY
CYLINDER HEAD
Engine No. 10001 - 14583
f u
F621201011
1. Rocker arm housing mounting 6. Cylinder head B. Intake

bolt 7. Rocker arm housing cover C. Exhaust
2. Cylinder head mounting bolt 8. Fuel injection nozzle
3. Air vent tube 9. Nozzle mounting bracket d. To fuel tank (Fuel)
4. Fuel spill pipe 10. Fuel inlet connector e. To radiator (Air)
5. Rocker arm housing f. To rocker arm (Oil)
To8 6D140-1 SERIES

View Z
Section A-A
F621201011
CYLINDER HEAD VALVE SEAT INSERT

. Divided type (One cylinder head for one cylinder) . Press-fitted insert for intake and exhaust
. 4-valve
. Direct fuel injection type ROCKER ARM HOUSING COVER
. Injection nozzle and fuel inlet connector assembled - Floating type seal
in rocker arm housing and cylinder head
FUEL INJECTION NOZZLE
- Mount: Dry type (without sleeve)
6D140-1 SERIES
’ ’-Og8-’
5 6 7
621OF142
1. Rocker arm housing mounting 6. Cylinder head B. Intake

bolt 7. Rocker arm housing cover C. Exhaust
2. Cylinder head mounting bolt 8. Fuel injection nozzle
3. Air vent tube 9. Nozzle mounting bracket d. To fuel tank (Fuel)
4. Fuel spill pipe 10. Fuel inlet connector e. To radiator (Air)
5. Rocker arm housing f. To rocker arm (Oil)
’’-z8-2
6D140-1 SERIES
View Z
Section A-A
F621201011
CYLINDER HEAD VALVE SEAT INSERT

. Divided type (One cylinder head for one cylinder) . Press-fitted insert for intake and exhaust
. 4-valve
. Direct fuel injection type ROCKER ARM HOUSING COVER
. Injection nozzle and fuel inlet connector assembled * Floating type seal
in rocker arm housing and cylinder head
* Mount: Dry type (without sleeve)
6D140-1 SERIES
VALVE SYSTEM
Engine No. 10001 - 19603
F621201012
1. Thrust plate 8. Push rod 15. Crosshead

2. Camshaft gear 9. Rocker arm shaft 16. Upper spring seat
3. Camshaft 10. Rocker arm 17. Outer valve spring
4. Cam roller 11. Lock nut 18. Inner valve spring
5. Cam roller pin 12. Rocker arm adjustment screw 19. Exhaust valve
6. Cam follower shaft 13. Crosshead adjustment screw 20. Valve guide
7. Cam follower 14. Lock nut 21. Lower spring seat
22. Intake valve
’ ‘-iYO 6D140-1 SERIES

11 ii
10
9 17
18
8 ::
21
7
6
r
Exhaust side 1 I make side
F621201013
CAMSHAFT VALVE TIMING

. Stamp forging
. Journal and cam portion: Top dead center
Induction hardening
Intake valve open Exhaust valve close
Exhaust valve open
Intake valve close
6210F.107
6D140-1 SERIES
621OF143
1. Thrust plate 8. Push rod 15. Crosshead

2. Camshaft gear 9. Rocker arm shaft 16. Upper spring seat
3. Camshaft 10. Rocker arm 17. Outer valve spring
4. Cam roller 11. Lock nut 18. Inner valve spring
5. Cam roller pin 12. Rocker arm adjustment screw 19. Exhaust valve
6. Cam follower shaft 13. Crosshead adjustment screw 20. Valve guide
7. Cam follower 14. Lock nut 21. Lower spring seat
22. Intake valve
’ ’-%o-2 6D140-1 SERIES

1 I
1 15
1 16
17
18
:90
21
i..,
I Exhaust side
7
Intake side
F621201013
CAMSHAFT VALVE TIMING

. Stamp forging
. Journal and cam portion: Top dead center
Induction hardening
Intake valve open Exhaust valve close
255”
Exhaust valve open
Intake valve close
621OF107
6D140-1 SERIES
“-F
CYLINDER BLOCK
1‘1 i
F621201015
1. Front cover 7. Thrust bearing

2. Cylinder block 8. Main bearing
3. Cylinder liner 9. Main bearing cap
4. Crevice seal 10. Main bearing cap mounting bolt
5. Liner seal 11. Front oil seal
6. Liner seal 12. Piston cooling nozzle
1 l-012 6D140-1 SERIES

F621201015
CYLINDER BLOCK CYLINDER LINER-

. Crankshaft: 7 bearings . Wet type
. Camshaft: 7 bearings
LINER SEAL
FRONT OIL SEAL . Top: Crevice seal (Ethylene propylene rubber)
- Single lip with dust seal . Middle: O-ring (Ethylene propylene rubber)
. Bottom: O-ring (Silicon rubber)
PISTON COOLING
. With cooling nozzle
6D140-1 SERIES u-g13

MAIN CIRCULATION SYSTEM
F621201016
1. Piston 8. Vibration damper

2. Piston pin 9. Crankshaft
3. Connecting rod, bushing 10. Crankshaft gear
4. Top ring 11. Connecting rod bearing
5. Second ring 12. Connecting rod cap
6. Oil ring 13. Connecting rod
7. Crankshaft pulley 14. Connecting rod cap mounting bolt
11-014 60140-l SERIES

PISTON RING
Engine No. 10001 - 18538

F621201017
Top ring Second ring Oil ring
Both faces key- Keystone inner cut M-shapesteel ring

stone Tapered face Hard chrome plat-
Barrel face Hard chrome ing with coil
Hard chrome plating expander
plating
CRANKSHAFT
. Stamp forging
. Journal and filet portion:
Top ring Second ring Oil ring
Induction hardening
PISTON
. Ductile cast iron
CJ
CONNECTING ROD
. Stamp forging Both faces keystone Keystone inner cut M-shape steel ring
Barrel face Tapered face Hard chrome plat-
Hard chrome Hard chrome ing with coil
plating plating expander
6D140-1 SERIES
“P
TIMING GEAR
I
11 2 3 4 I
Section E-E
F621201018
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 injection pump drive gear (No. of teeth: 48)
3. Main idler gear (Large) (No. of teeth: 60) 9. PTOgear (OPTION) (No. of teeth: 22)
4. Main idler gear (Small) (No. of teeth: 40) 10. Crankshaft gear (No. of teeth: 36)
5. Camshaft gear (No. of teeth: 48) 11. Oil pump drive gear (No. of teeth: 22)
6. PTO gear (OPTION) (No. of teeth: 14)
A, B, C: Match marks
‘Y 6D146-1 SERIES
Section D-D
1 2
Section F-F
F621201018
6D140-1 SERIES
“-F7
FLYWHEEL AND FLYWHEEL HOUSING

Without PTO type
Section A-A
F621201019
1. Ring gear (No. of teeth: 148)

2. Flywheel
3. Rear oil seal
4. Flywheel housing
6D140-1 SERIES
’ ‘-r*
With PTO type
6
4
8
2
Section A-A
Section B-B
1. Rear oil seal
2. Flywheel housing
3. Idler gear (No. of teeth: 43)
4. Ball bearing
5. PTO drive gear (No. of teeth: 43)
6. Ball bearing
7. Ring gear (No. of teeth: 138)
8. Flywheel
9. Steering pump drive gear (No. of teeth: 46)
6D140-1 SERIES 11-019

@
LUBRICATION SYSTEM
STRUCTURE AND FUNCTION
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART
16
F621201020A
I. Oil pan 8. Valve adapter 15. Cam follower

2. Oil strainer 9. Oil filter 16. Rocker arm
3. Oil pump 10. Safety valve 17. Intake and exhaust valve
4. Main relief valve 11. Crankshaft 18. Timing gears
5. Oil cooler 12. Piston cooling nozzle 19. Turbocharger
6. Thermostat 13. Piston 20. Fuel injection pump
7. Regulator valve 14. Camshaft
W: Cooling water
6D140-1 SERIES
’ ’-kh20
STRUCTURE AND FUNCTION LUBRICATION SYSTEM
LARGE CAPACITY OIL FILTER + BYPASS FILTER
6210F14.4
1. Oil pan 8. Valve adapter 15. Cam follower

2. Oil strainer 9. Oil filter 16. Rocker arm
3. Oil pump (full-flow filter x 2) 17. Intake and exhaust valve
4. Main relief valve 10. Safety valve 18. Timing gears
5. Oil cooler 11. Crankshaft 19. Turbocharger
6. Thermostat 12. Piston cooling nozzle 20. Fuel injection pump
7. Regulator valve 13. Piston 21. Bypass filter
14. Camshaft
W: Cooling water
6D140-1 SERIES
’ ’-OiO-’
OiL PUMP
B-
F621201021
1. Pump cover OIL PUMP

2. Drive gear
3. Pump body
4. Pump drive gear (No. of teeth: 22)
5. Valve spring
6. Main relief valve
7. Driven gear
A. Suction (From oil pan)

B. Discharge (To oil cooler)
F621201022
. Type: Gear pump
Pump speed: Engine speed x 1.64
MAIN RELIEF VALVE

. Set pressure: 8.0 f 0.5 kg/cm’
6D140-1 SERIES 11-021

REGULATOR VALVE AND PISTON COOLING VALVE
Section A -A
F621201023A
1. Valve body a. From oil cooler

2. Valve spring b. To oil filter
3. Valve C. From oil filter
d. To main gallery
e. To piston cooling nozzle
f. To oil pan (drain)
REGULATOR VALVE
. Valve opening pressure: 3.2kO.2 kg/cm’
PISTON COOLING VALVE

. Valve opening pressure: 1.4kO.2 kg/cm2
F62120 11024
’ ’-ii** 6D140-1 SERIES

FUNCTION
The regulator valve keeps the oil pressure in the
main gallery at the proper value.
The oil pressure in the main gallery and piston
cooling gallery is controlled by the one spool built
into the regulator valve.
The drain port is split into two parts to handle
any sharp rise in the oil pressure which may occur
if the engine is mistakenly caused to overrun.
The regulator valve spool is activated by the oil
pressure in the main gallery, but the pressure oil
is relieved before the filter so that the quantity of
oil flowing through the filter is small, thus reducing
Oil filter
the load imposed on the oil pump. -
At low speeds, the quantity of oil in the piston
cooling gallery is somewhat reduced through the
regulator valve, thus the oil pressure in the main
gallery is maintained at the specified value.
OPERATION
. At a normal engine speed:
When the oil pressure in the main gallery reaches
the specified pressure (regulator valve cracking
pressure) As the engine speed increases after the To main
engine has been started, the spool will be pushed up
by the pilot pressure from the main gallery, allow-
ing the oil to be relieved through the smaller hole To piston COOiing nOZZk W
before entering the oil filter.
F621201025
Oil filter
-
. When the engine overruns:

When the engine overruns, the oil pressure in the
main gallery sharply increases, causing the spool
to be forced up further, which in turn causes a
lot of oil to be relieved through the larger hole.
Thus, the oil pressure in the main gallery is main-
tained at the specified level.
To main
To piston cooling nozzle W
F621201026
6D140-1 SERIES 1 l-023

OIL FILTER
F621201027
1. Filter bracket SAFETY VALVE OIL FILTER

2. Safety valve . Set pressure: 2.0 f 0.2 kg/cm2
3. Cartridge
A. Oil inlet
B. Oil outlet
F621201028
. Filtration area: 0.84 m2
’ ’-:24 6D140-1 SERIES

LUBRICATION SYSTEM
LARGE CAPACITY OIL FILTER
3 1 2
5
621OF145
1. Filter head OIL FILTER

Filtration area: 1.8 m2 (0.9 m2 x 2)
2. Safety valve
3. Filter connector Rated flow: 180 Urnin.
4. Cover
SAFETY VALVE
5. Alarm assembly . Set pressure: 2.0 k 0.2 kg/cm*
6. Cartridge
A. Oil inlet
EL Oil outlet
62 I5FO93
60140-I SERIES
LARGE CAPACITY OIL FILTER + BYPASS FILTER
621OF146
1. Filter head OIL FILTER (full-flow filter)

2. Safety valve . Filtration area: 1.8 m2 (0.9 m* x 2)
3. Filter connector * Raied flow: 180 Q/min.
4. Cover
5. Alarm assembly SAFETY VALVE (full-flow filter)
6. Cartridge (Bypass filter) . Set pressure: 2.0 * 0.2 kg/cm2
7. Cartridge (Full-flow filter)
BYPASS FILTER
* Filtration area: 1.4 m2
A. Oil inlet
* Rated flow: 7.5 Q/min.
B. Oil outlet
62 I SF093
’’-%4-2 6D140-1 SERIES

OIL COOLER
F621201029
1. Cooler cover OIL COOLER

2. Cooler element
S6D140-1: 10 cores
SAGD140-1: 12 cores
3. Thermostat
4. Spring
5. Thermostat cover
A. Oil inlet (From oil pump)

B. Oil outlet (To regulator valve)
C. Cooling water
THERMOSTAT FUNCTION
. Valve cracking temperature: 85 k 1.5”C
. Full opening temperature: 100°C F621 201030
. Full opening lift: Min. 8 mm . Effective area: S6D140-1: 0.822 m*
SAGD140-1: 0.986 m”
6D140-1 SERIES 11-025

0
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM CHART
F621201031A
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
6D140-1 SERIES
’’-:27
FUEL INJECTION PUMP
S6D140-1 (WASOO-1, GD825A-1)
/ /
..2
11 12 13 14 15 16 17
621OF108B
1. Fuel injection pipe (No. 1) 10. Fuel iniection pump drive shaft
2. Fuel injection pipe (No. 2) 11. Bearing box
3. Fuel injection pipe (NO. 3) 12. Coupling
4. Fuel injection pipe (No. 4) 13. Feed pump
5. Fuel injection pipe (No. 5) 14. Fuel injection pump
6. Fuel injection pipe (No. 6) 15. Gauze filter
7. Air bleeder plug 16. Oil tube (outlet)
8. Oil tube (inlet) 17. Fuel filter
9. Fuel injection pump drive gear (No. of teeth 48)
1 l-028 6D140-1 SERIES

0
612OF109
FUEL INJECTION PUMP GOVERNOR

. Maker: DIESEL KlKl . Type: Bosch RSV Centrifugal, all speed type
. Type: Bosch PE-P
. Lubrication method: Forced lubrication
with engine oil
6D140-1 SERIES 11 f.f.29

SAGD140-1 (HD325-5)
F621201107
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) 1 1. Coupling
4. Fuel injection pipe (No. 4) 12. Feed pump
5. Fuel injection pipe (No. 5) 13. Fuel injection pump
6. Fuel injection pipe (No. 6) 14. Oil tube (outlet)
7. Boost compensator tube 15. Oil tube (inlet)
8. Fuel injection pump drive gear (No. of teeth 48)
ll-$f9-1 60140-l SERIES

F621201108
FUEL INJECTION PUMP GOVERNOR

. Maker: NIPPON DENS0 . Type: Bosch Centrifugal, max. and min. speed
. Type: Bosch PE-NE control type
- Lubriczition method: Forced lubrication
with engine oil
60140-I SERIES 1 l-029-2

F621201033
1. Fuel inlet connector a. Fuel inlet (From injection pump) FUEL INJECTION NOZZLE
2. Noozle holder b. Injection (To cylinder)
3. Adjustment shim C. Fuel return (To fuel tank)
4. Spring
5. Seat
6. Spacer
7. Nozzle
8. Retaining cap
9. Needle valve
S6D140-1: Made by DIESEL KlKl

(Diameter of nozzle hole 0.35 x 7 hole)
SAGD140-1: Made by DIESEL KIKI -
F621201034
Made by NIPPON DENS0
. Maker: DIESEL KIKI (S6D140-1)
(Diameter of nozzle hole 0.36 x 6 hole)
NIPPON DENS0 (SAGD140-1)
. Type: Multi-hole type
. Injection pressure: 250 kg/cm’
. Adjusting injection pressure:
Shim adjusting type
1 l-030 6D140-1 SERIES

0
BOOST COMPENSATOR DEVICE
1 2 3 4 5 6
16\
12 11 10
611F109
1. Governor spring 10. Idling sub spring A. Air supply pressure

2. Floating lever 11. Torque control spring (boost pressure)
3. Guide lever 12. Full load stopper B. Fuel increase direction
4. Tension lever 13. Camshaft
5. Push rod 14. Flyweight
6. Boost compensator spring 15. Swivel lever
7. Adjustment screw 16. Control rack
8. Diaphragm 17. Start spring
9. Boost compensator lever
6D140-1 SERIES l l -030- 1

@
FUEL FILTER
1. Filter bracket a. Fuel inlet (From feed pump) FUEL FILTER

2. Air bleed plug b. Fuel outlet (To injection pump)
3. Cartridge !&y. ’ -- , .:.
! i! !_
F621201036
. Filtration area: 1 .O m2
6D140-1 SERIES 11-031

FUEL SOLENOID
B contact (electricity flows in ordinary operations) method
615OFl34
1. Shaft 5. Stop lever

2. Case 6. Return spring
3. Piston 7. Solenoid
4. Coil 8. Fuel control lever
FUEL SOLENOID
Inner wiring
- Maker: NIKKO DENKI
- Type: Sealed
Cl : Pull-in coil - Rated voltage: DC24V
C2: Holding coil * Operating current: Maximum: 35A max.
Continuity: 0.5A max.
* Stroke: 12 * 0.3 mm
* Weight: 3.3 kg
FUNCTION
Starting engine
When the starting key is turned on, the solenoid is

energized.
Solenoid shaft (1) is electrically attracted, pulling
injection pump stop lever (5) and fixing it in the
RUN position.
Stopping engine
When the starting key is turned off, the solenoid is

de-energized.
Injection pump stop lever (5) is returned to STOP
position (non-injection position) by return spring (6).
During operation, the amount of fuel injection is

controlled by fuel control lever (8).
When installing the fuel solenoid, adjust clearance A

referring to TESTING AND ADJUSTING.
6162F151
1$32 6D146-1 SERIES

w
A contact (electricity flows when stopped) method
02FO82
Before pull-in After pull-in
Pull-in co11 Pull-ill coil 1. Case

2. Coil
aa
3. Return spring
Holding coil Holding coil 4. Plunger
Inner wiring
02FO8 I
FUNCTION
When stopping the engine,. the solenoid is energized, the FUEL SOLENOID
solenoid plunger is electrically attracted, and the stop - Maker: NIPPON DENS0
lever of the injection pump is moved by a rod to the * Type: Sealed
stop (non-injection) position. As a result, the fuel is cut * Rated voltage: DC24V
off and the engine is brought to a stop. Accordingly, - Operating current
this solenoid is used only when the engine is being Pull-in coil: 20A max.
stopped; it is in free condition during ordinary opera- Holding coil : 5A max.
tions. * Stroke: 27 mm
F621201038
6D140-1 SERIES
‘1:33
ENGINE STOP MOTOR
Shape of cable tip

-(non-threaded stopper type)-
Shape of cable tip

Section A-A
(threaded stopper type)
‘^h;:::
j
6 7
Made by AMP Co.,
\ i/ Econoseal connecfor. 8P male
ot used (filler plug added)
Not used (filler plug added)
4. B (AV 0.85LR)
3. P, (AV 0.85LY)
Not used (filler plug added)

A (AV 0.85L)
5. Pz (AV 0.85L E (AV 0.85B)
8 9 10
1. Motor assembly ENGINE STOP MOTOR

2. Cover * Maker: Jidosha Denki Kogyo Co. Ltd
3. Cable assembly - Rated voltage: DC24V
4. Cable clamp - Operating force: 15 kg min.
5. Coil spring * Stroke: 35fA.t mm
6. Cable
- Weight: 1.2 kg
7. Screw
8. Breather
9. Bracket assembly
10. Cover assembly
’ ’-z3-’
6D140-1 SERIES
FUEL SYSTEM
STRUCTURAL DRAWING (1)
1. Gear cover assembly

2. Slider assembly
3. Armature shaft
4. Contactor assembly
5. Roller
6. Worm wheel assembly
7. Motor assembly
8. Gear case assembly
6D140-1 SERIES
’’-if3-*
STRUCTURAL DRAWING (2)
1. Gear cover assembly

2. Motor assembly
3. Cable clamp
4. Cable assembly
5. Gear case assembly
’ ’-023-3 6D140-1 SERIES

DESCRIPTION OF OPERATION AND CIRCUITS

1. Stop Condition (0” or 360’)
position on PI side Auto-stop position P2 side
The above drawing shows the stopped condition when a

closed circuit has been formed. The slider assembly is
stopped at the auto-stop position on the PI side.
2. When switch is turned (when starting the motor)
affery
k-i
Yfl7
When the switch is moved to the Pz side (starting switch starting the motor. The slider assembly starts to move in
ON), an electric current flows from the plus side the direction of the arrow at the same time as the roller
contact plate through the P2 auto-stop terminal and starts to move.
switch and into the armature shaft assembly, thereby
3. Turning Condition (90’ in the drawing)
Electric current continues to pass through the armature the rotation of the roller, the slider assembly also
assembly and the motor continues to turn. Becausr nf continues to move in the direction of the arrow.
6D140-1 SERIES
’ ’-z3-4
4. When stopped (180’)
Battery
+-I
777
A closed circuit is formed when the Pz auto-stop motor comes to a sudden stop. The slider assembly also
terminal rides on the minus-side contactor plate, and the stops..
5. When switch is turned (when starting the motor)
Battery
+-i
When the switch is moved to the PI side (starting switch motor. The slider assembly starts to move in the direc-
OFF), an electric current flows from the plus contactor tion of the arrow at the same time as the roller starts to
plate through the PI auto-stop terminal and switch and move.
into the armature shaft assembly, thereby starting the
6. Turning condition (270’ in the drawing)
Electric current continues to pass through the armature of the arrow. Then the circuit returns to stop condition
shaft assembly and the motor continues to turn. The 1.
slider assembly also continues to move in the direction
’ ’-023-5
6D140-1 SERIES
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM CHART
d
d
62lOFI 12
1. Radiator 6. Oil cooler

2. Thermostat 7. Corrosion resistor
3. After-cooler (SAGD 140-I ) 8. Cooling fan
4. Air compressor (if equipped)
5. Water pump A. Lubrication oil
1 l-034 6D140-1 SERIES

@
WATER PUMP
S6D140-1
a
I
b-
F621201 042
1. Alternator drive Pulley a. Water inlet (From thermostat) WATER PUMP

2. Oil seal b. Water inlet (From radiator) . Water pump speed = Engine speed x 1.56
3. Ball bearing c. Water outlet (To oil cooler) . Flow capacity: 400 Illmin.
4. Pump shaft
5. Water pump drive gear
(No. of teeth: 23)
6. Pump body
7. Water seal
8. Impeller
9. Pump cover
F621201043
6D140-1 SERIES 1 l-035

@
SA6D140-1
F621201109
1. Alternator drive pulley a. Water inlet (From radiator) WATER PUMP

2. Oil seal b. Water outlet (To oil cooler) . Water pump speed = Engine speed x 1.56
3. Ball bearing - Flow capacity: 800 Q/min.
4. Pump shaft 660 !Z/min. (PC650-3)
5. Water pump drive gear
(No. of teeth: 23)
6. Pump body
7. Water seal
8. Impeller
9. Pump cover
11-035-l 6D140-1 SERIES

8
COOLING SYSTEM
THERIMOSTAT
F621201044
1. Wax case THERMOSTAT

2. Valve . Opening temperature: 76.5 + 2°C
3. Spring . Full opening temperature: %f’c
4. Thermostat case - Valve lift: 10 f 0.5 mm
F621201045
1 l-036 6D140-1 SERIES

FUNCTION
. The thermostat keeps the engine cooling water at
the proper temperature by automatically controll-
ing the amount of cooling water flowing to the
radiator. The thermostat opens or closes depending
on the temperature of the cooling water.
. A wax case (the heat sensing element) is set in the
thermostat. The thermostat opens or closes depend-
ing on the amount of swelling of the wax.
OPERATION
. When the cooling water temperature is low:
Most of the cooling water entering from the water
manifold flows to the water pump.
mcylinder block
To water pump F621201046

2. Thermostat
3. Cylinder block
4. Piston
5. Wax case
6. Wax
. When the cooling water temperature is high:

As the cooling water temperature goes up, the wax
in the wax case expands to push the case upward.
Thereby, the amount of water flowing to the
water pump and the radiator is restricted, keeping
the water at the proper temperature. ram cylinder block
(Water manifold)
F621201047
6D140-1 SERIES
1 l-037
CORROSION RESISTOR
S6D140-1
\ n
Section A-A
F621201048
1. Bracket a. Water inlet CORROSION RESISTOR

2. Cartridge b. Water outlet
3. Element (Paper)
4. Element (Chemicals)
5. Spring
6. Valve
F621201 049
. Filtration area:
S6D140-1: 0.13 m2
SAGD140-1: 0.373 m2
’ ’-ti3* 6D140-1 SERIES

STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ALTERNATOR MOUNTING
1. Alternator
2. Adjusting plate
3. Alternator drive pulley
4. Alternator bracket
a. Alternator pulley (Pulley 0.0. 85 mm)

b. Alternator drive pulley (Pulley O.D. 132 mm)
11-028-2 6D140-1 SERIES

ALTERNATOR
621OF116
1. Alternator ALTERNATOR
2. Alternator pulley
B, E, F, N, R: Terminals
F621201051
Engine model Applicable machine model Pulley O.D.

Type Specification Weight (kg)
(mm)
Maker: SAWAFUJI
S6D140-1 GDB25A-1 24U, 50A 85 12
Type: Opened
HD325-5, HD325-6
Maker: SAWAFUJI
SAGDI 40-I PC650-3, PC650-5, 24V, 50A 85 12
PC1 600-1, WS23S-2 Type: Opened
6D140-1 SERIES 11-039

@
Inner wiring
6150Fl47A
ALTERNATOR
1. Alternator
B, E, R, F: Terminals
051
Engine model Applicable machine model Pulley O.D.

Type Specification Weight (kg)
(mm)
D135A-2
S6D140-1 Maker: NIKKO DENKI
;$;;_;I 24V, 35A 85 9.5
Type: Opened
D155A, AX-3
11-039-l 6D140-1 SERIES

@
STARTING MOTOR
F621201052
STARTING MOTOR
View Z
1. Safety relay
2. Connector
3. Magnetic switch
4. Pinion gear
5. Starting motor
B, C, E, R, S: Terminals
‘1201053
Number of
Engine model Applicable machine model Type Specification Pinion teeth Weight (kg)
GD825A-1 (S.T.D) Maker: NIKKO DENKI

24V, 7.5 kW 12 18
WS23-2 Type: Sealed
S6D140-1 D135A-2 11
Maker: SAWAFUJI
24V, 11 kW 20
WA500-1 Type: Sealed
D155A. AX-3 (X type connector) 12
GD825A-1 (If equipped)
PC650-3
PC650-5, PC7 1 O-5 Maker: NIKKO DENKI
24V, 7.5 kW 12 18
PC1600-1 Type: Sealed
SAGDI 40-I
HD325-5, HD325-6 Maker: SAWAFUJI
WS23S-2 24V, 11 kW 12 20
Type: Sealed
11-040 6D140-1 SERIES

@
ELECTRICAL INTAKE AIR HEATER
S6D140-1
1. Heater body
2. Heater coil
3. Terminal

. Rated voltage: DC22V
. Rated current: 175A
lIlI!l
Wiring
22v
diagram
615OF146
SAGD140-1
1. Heater body
2. Heater coil
3. Terminal

. Rated voltage: DC1 1 V
. Rated current: 86A
Wiring diagram F621201054A F621201055
6D140-1 SERIES
’ ‘-g4’
STRUCTURE AND FUNCTION ACCESSORY
ACCESSORY
AIR COMPRESSOR
F621201110
1. Cylinder head a. Air intake

2. Unloader valve b. Air exhaust
3. Piston ring c. Unloader
4. Piston d. Oil inlet
5. Cylinder e. Cooling water inlet or outlet
6. Connecting rod f. Cooling water outlet or inlet
7. Crankcase
8. Crankshaft
9. Bearing cover
10. Piston pin
11-042 6D140-1 SERIES

0
STRUCTURE AND FUNCTION ACCESSORY
L
\ c b
a-
F621201111
AIR COMPRESSOR UNLOADER VALVE

lMaker: ZEXEL lValve opening pressure: 618 kPa l6.3 kg/cm21
lType: Single cylinder, reciprocated type lValve shutting pressure: 530 kPa 15.4 kg/cm?
l Discharge volume: 340 cc/rev.
lAir pressure: 834 kPa {8.5 kg/cm*} (at full load)
lWeight: 11 kg
6D140-1 SERIES 11-043

@
ACCESSORY STRUCTURE AND FUNCTION
EXHAUST BRAKE
SLIDE VALVE TYPE
6215FO85
1. Valve housing 7. Piston

2. Gate valve 8. Retainer
3. Guide bushing 9. Release valve
4. Cylinder 10. Packing
5. Spring 11. Packing
6. Spring 12. Breather
Outline
An exhaust brake is installed between the turbocharger and
muffler, and works due to the air pressure 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.
6D140-1 SERIES
11 -g44
ACCESSORY STRUCTURE AND FUNCTION
EXHAUST BRAKE BUTTERFLY VALVE
22XF458
1. Plate 6. Spindle 11. Yoke
2. Bushing 7. Bushing 12. Lever
3. Spindle 8. Air cylinder 13. Stopper (Fully close position)
4. Valve 9. Insulator
6. Valve body 10. Stopper (Fully open position)
Outline
Butterfly valve is installed between turbocharger and
muffler and actuates by air pressure from exhaust brake
valve. The butterfly valve is throttled exhaust passage
between turbocharger and muffler, engine speed is
decreased. The butterfly valve is consisted of valve
mechanism and air cylinder which actuated to valve.
6D140-1 SERIES 11-045

@
ENGINE
12 TESTING AND ADJUSTING
ENGINE BODY
Adjusting valve clearance . .. .... 12-002
Measuring compression pressure . . . . . . . 12-003
FUEL SYSTEM
Checking and adjusting
fuel injection timing . . . . . . . . . . 12-004
Adjusting fuel injection pressure . . . . . . . 12-006
Adjusting fuel cut solenoid . . . . . . . . . . . 12-007
COOLING SYSTEM
Checking and adjusting V-belt tension . . 12-008-I
FUEL INJECTION PUMP

CALIBRATION DATA .... . . . . . . . . 12-010
PERFORMANCE TEST
Run-in standard ................. 12-022-8
Performance test criteria ........... 12422-12
Testing and adjusting tool list ....... 12-022-18
Testing and adjusting data .......... 12-022-20
TROUBLESHOOTING ....... ... . . . 12-023

Points to remember
when troubleshooting .... . . . . . . 12-025
Method of using troubleshooting chart . . . 12-026
Troubleshooting table . . . . . . . . . . 12-030
6D140-1 SERIES 12-001

@
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 compression stroke and align the
“1.6 TOP” mark on vibration damper (1) with pointer
(2).
* 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 l in the + Valve arrangement chart
valve arrangement chart.
8=
Cylinder No. 1 2 3 4 5 6
4. Rotate the crankshaft in the normal direction by one
Exhaust valve l 0 0 0 l 0
revolution and adjust the valve clearance for the re-
maining valves marked 0. Intake valve l l o l o o
* 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 lightely.
* Valve clearance (When engine is cold)
Unit: mm
Intake valve Exhaust valve
At 20°C 0.43 0.80
F621201056
5. After the clearance is properly adjusted, tighten the lock

nut to secure the adjustment screw.
w Lock nut: 6.0 + 0.6 kgm
* The engine firing order is 1 - 5 - 3 - 6 -.2 - 4.

* Intake and exhaust valve clearances may be adjusted for
each cylinder in the firing order by rotating the crank-
shaft 120” at a time in the normal direction.
’2-:02 6D140-1 SERIES

MEASURING COMPRESSION PRESSURE
MEASUREMENT PROCEDURE
A While measuring
not burn yourself
the compression
on the
pressure, take care
exhaust manifold or
muffler, and be careful not to get caught in any
revolving part of the engine.
* Measure the compression pressure while the engine
is warm.
(Oil temperature: 40 - 6O’C)
1. Adjust the valve clearance properly. For details, see

ADJUSTING VALVE CLEARANCE.
2. Disconnect fuel injection tube (1).
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 specified torque:
m Torque: 6.8 + 0.75 kgm
5. Connect compression gauge A to the adapter.
6. Place the fuel control lever in NO INJECTION position,

crank the engine with the starting motor, and read the
gauge when the pointer is stabilized.
A If you do not put the fuel control

INJECTION position, fuel will blow out.
lever in NO
* Most compression leakage can be prevented by

applying a small amount of oil to the mounting
section of the adapter.
* For the reference values of the compression pres-
sure, see TESTING AND ADJUSTING DATA.
6D140-1 SERIES 12-003

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

MARK ALIGNMENT METHOD
1. With No. 1 cylinder piston at top position, rotate the
crankshaft 30’ to 40’ in the reverse direction.
2. Align the injection timing stamp line on vibration

damper (1) with pointer (2) by slowly rotating the
crankshaft in the normal direction.
3. Confirm that stamp line a on the injection pump is

aligned with stamp line b on the coupling.
* If the stamp lines are out of alignment, loosen nut

(3), align the stamp lines by shifting the coupling,
and tighten the nut.
m Nut: 6.2 + 0.2 kgm
CHECKING AND ADJUSTING BY THE DELIV-

ERY VALVE METHOD
1. Disconnect fuel injection tube (4) for the No. 1 cylinder.
2. Remove delivery valve holder (5).
6D140-1 SERIES
’2-$04
Remove spring (6) and delivery valve (7) from the

delivery valve holder, and reassemble the delivery valve
holder.
With No. 1 cylinder piston at TOP position, rotate the

crankshaft 30” to 40” in the reverse direction.
Place the fuel control lever in FULL position, slowly

rotate the crankshaft in the normal direction while
operating the priming pump, and observe the position
when the fuel stops flowing out of the delivery valve
holder.
423F302
In the position where the outflow of fuel stops, check

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

of adjustment, adjust the fuel injection timing in the
following manner.
1) Rotate the crankshaft 30’ to 40” in the reverse

direction, starting from TOP position in No. 1
cylinder.
2) Align the injection timing stamp line on damper (1)
with pointer (2) by slowly rotating the crankshaft
in the normal direction.
3) Loosen nut (3) on the injection pump mounting
flange slot, and rotate the flange on the pump side
little by little by operating the priming pump until
no fuel flows out of the delivery valve holder.
4) Tighten the nut on the injection pump mounting
flange slot.
* Recheck the injection timing to see if it is
properly adjusted.
5) If match marks a and b are not aligned, stamp
new one.
After the checking and adjusting, be sure to reassemble

the spring and the delivery valve.
Always replace the delivery valve copper gasket and
O-rings with new parts.
6D140-1 SERIES
ADJUSTING FUEL INJECTION PRESSURE
Remove retaining cap (8).
Confirm thickness of adjustment shim (3).
Insert correct shim (3) in response to the adjustment

value of injection pressure.
Tighten retaining cap (8), then confirm the fuel injec-

tion pressure.
m Retaining cap: 6.5 f 0.5 kgm
F621iO 1033A
Data for shims used for adjusting injection pressure
S6D140-1 SA6D140-1
Maker DIESEL KIKI NIPPON DENS0
Crackingpressure(kg/cm2) 250:': 250:':

I I
Shimthicknessand maker
part number
1.15 150530-6600 1.175 150530-6700 1.35 093175-1150 1.375 093175-1630
1.20 150530-6800 1.225 150530-6900 1.40 093175-1160 1.425 093175-1640
1.45 093175-1170 1.475 093175-1650

1 1 1 1
1.50 093175-1180
1.95 150530-9800 1.975 150530-9900
12-006 6D140-1 SERIES

8
ADJUSTING FUEL CUT SOLENOID

S6D140-1 (WA500-1, Engine No. 10001 - 11032),
SAGDI 40-I (EG400B-2L)
If the solenoid does not work smoothly, solenoid coil burns in
the cause of excessive current or flywheel horsepower
downs in the cause of dropping fuel injection volume.
Carry out the clearance check between stopper and lever,
the check of solenoid stroke, and the adjustment of rod
length as showing the following method.
After pulling rod (5) to solenoid side by hand so that

stop-lever works while solenoid operates, adjust the
length of rod (5) to become clearance A between stop-
lever (4) and stopper (7) of fuel injection pump.
A: WA500-1 (0.4 + 0.1 mm), EG400B-2L (1.25 k 0.25 mm)
After turning on electricity to solenoid, check and adjust

correctly the solenoid stroke and clearance A between
stop-lever (4) and fuel injection pump stopper (7).
After turning on and off the starting key two or three

times, confirm that solenoid works smoothly and engine
runs or stops completely.
-r
Lock the adjusting nut.
Failures caused by faulty adjustment of solenoid
If the clearance between - Burning of the solenoid

the stop bolt and lever is core (when solenoid is
0 when the solenoid is only partially pulled)
energized - Breakage or scuffing
of the injection pump
62lOFI I I
1 (faulty linkage)
6D140-1 SERIES 12-007

0
SA6D140-B-1 (EG380BS1)
A contact (electricity flows when stopped) type
A rod forms a link between the solenoid and injec-
tion pump. At this time, when the stop lever returns
1 - 1.5 mm from the stop pin on the RUN side and
the solenoid shaft is pushed by hand, the stop lever
of the pump will be set in a position in which it has
returned 1.5 - 2.0 mm from the stop pin.
Next, energize the solenoid and see if its movement

is smooth. Turn the starting switch ON and OFF
two to three times and confirm that the operation
condition does not change. If the operation is not
smooth, adjust the linkage and carefully observe
the movement.
Confirmation of Functions
After confirming that the operation is smooth, start
the engine and confirm that the rated output can be
obtained. Next, energize the solenoid and confirm
that the engine stops. (The engine should stop
within 10 sec.)
Failures caused by faulty adjustment of solenoid
- Burning of the solenoid

core (when solenoid is
only partially pulled)
- Breakaae or scuffina
of the injection pump
governor (an undue
force will be applied
to the lever)
f Engine power will not

be generated because
of a decline in amount
of fuel injection
6D140-1 SERIES
’2-z7-1
S6D140-1 (WA500-1 Engine No. 11033 and up,

and WS23-2)
SAGDI 40-I (WS23S-2)
PROCEDURE FOR ADJUSTING THE ENGINE STOP
MOTOR CABLE (with lever stopper type)
1. Temporarily attach the ball joint connected to the in-
jection pump to the cable of the engine stop motor.
2. Pull the injection pump stop lever (2) to the ENGINE

STOP (fuel non-injection) position, temporarily attach
the ball joint to the stop lever, then fix the cable (4) to
the bracket (3).
* 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 installation),

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

lever, tighten each bolt and nut.
6210F24.8
1. Lever stopper
5. Turn the engine strating switch ON and OFF a few times
2. Fuel injection pump stop lever
to confirm that the engine stop.motor actuated smooth-
3. Bracket
ly. Be especially sure to confirm that there is a clearance
4. Cable
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 posi-
tion.
l Engine stop motor stroke: 35 mm
a Injection pump stop lever stroke: 30 mm
SAGD140-1 (HD325-5)
PROCEDURE FOR ADJUSTING THE ENGINE STOP

MOTOR CABLE (without lever stopper type)
When the cable is fully pulled, wire (2) is fixed to bracket
(1) with clamp (3) so that the cable is aligned with the
intermediate position of the non-injection zone of stop lever
(4).
The error in each section is adjusted with the oblong hole in
the bracket.
621OF21 I
1. Bracket
2. Cable
3. Clamp
4. Fuel injection pump stop lever
6D140-1 SERIES
’ 2-oz7-2
TESTING AND ADJUSTING COOLING SYSTEM
COOLING SYSTEM
8-12mm
CHECKING AND ADJUSTING
V-BELT TENSION Tn
Approx. 6
CHECKING AND ADJUSTING FAN BELT
TENSION
(S6D140-1)
1. Checking the fan belt tension.

To check the fan belt tension, push the belt at the
mid-point between the fan and tension pulleys with a
force of approx. 6 kg and measure the distance that F621201057
the belt sags.
2. Adjusting the fan belt tension.

1) Loosen tension pulley mounting nut (1).
2) Adjust the belt tension while tightening adjustment
bolt (2).
At the proper tension, fix the pulleys by tightening
tension pulley mounting nut (1).
(SAGD140-1)
Unit: mm
Engine model Applicable machIne Dimension A
PC650-3
SAGD140.1 55 * 4
PC650-5
1. Adjustment nut
2. Washer
3. Tension spring
4. Adjustment bolt
5. Tension pulley
A. Protrusion of adjustment bolt
6D140-1 SERIES
TESTING AND ADJUSTING COOLING SYSTEM
CHECKING AND ADJUSTING ALTERNATOR

BELT TENSION
1. Checking alternator belt tension.
Push the belt (3) at mid-point between the alternator
6 kg
and water pump pulley with a force of approx. 6 kg and
measure the distance that the belt sags.
F621201058
2. Adjusting alternator belt tension.

1) Loosen alternator mounting bolts (1) and adjustment
bolt (2).
2) Shift the alternator upward with a pipe and tighten
adjustment bolt (2) while checking the velt tension.
Then tighten alternator mounting bolt (1) to the
proper belt tension.
12-O&)8-2 6D140-1 SERIES

TESTING AND ADJUSTING FUELSYSTEM
FUEL INJECTION PUMP CALIBRATION DATA
Engine model Pump assembly No. Engine serialNo. Applicablemachine Page

6211-71-1110 D135A-2 12-013
1 6211-71-1120 1 1 D155A-3, D155AX-3 1 12-014

I I I
6211-71-1311 WA500-1 12-015

1 6211-71-1312 I 1 WA500-1 1 12-016
6211-71-1313 WA500-1 12-017
6211-71-1314 WA500-1 12-017
6211-71-1320 GD825A-1 12-018

6211-71-1321 GD825A-1 12-019
6211-71-1322 GD825A-1 12-019
6211-71-1330 GD825A-1 Extreme cold area 12-020

1 6211-71-1331 I GD825A-1 Extreme cold area 1 12-020
6211-71-1350 WA500-1C 12-021

1 6211-71-1351 I l WA500-1C I 12-021-l
S6D140-1 6211-71-1352 WA500-IC 12-021-I
I I I
6211-71-1362 HA350, HD325-5C 12-021-2
6211-71-1381 10001-12024 GS360-2 12-021-3
6211-71-1391 GC380-1 12-021-4
1 6211-71-1420 I l WS23-2 (front) 1 12-021-5

6211-71-1421 WS23-2 (front) 12-021-5
6211-71-1430 WS23-2 (rear) 12-021-6
6211-71-1431 WS23-2 (rear) 12-021-6
6211-71-1451 10001 -0 HD325-5C 12-021-7
6211-71-1470 GD825 12-021-8

I I I
6211-71-1480 GS360-2 12-021-9
6D140-1 SERIES 12-009

@a
6212-71-1311 GC380F-2 12-021-20
6212-71-1330 OEM for generator 12-021-21
6212-71-1340 OEM for g-pole generator 12-021-22
6212-71-1410 PC650-3 12-021-23
6212-71-1411 PC650-3 12-021-24
6212-71-1420 PC650-3, PC1600-1 12-021-25
6212-71-1421 PC650-3, PC1600-1 12-021-25
12-010 6D140-1 SERIES

@
Engine model Pump assembly No. Engine serial No. Applicable machine Page
6212-71-1423 PC650-3, PC1600-1 12-021-26
6212-71-1424 PC650-3, PC1600-1 12-021-26
1 6212-71-1430 I 1 PC650-5, PC710-5 1 12-021-27

6212-71-1431 PC650-5, PC710-5 12-021-27
6212-71-1432 PC650-5, PC710-5 12-021-27
6212-71-1511 EPSA6D140 12-021-28
6212-71-1512 EPSA6D140 12-021-28
6212-71-1520 OEM 12-021-29
1 6212-71-1530 I l DCA400SPK 1 12-021-30
6212-71-1540 Power unit 12-021-31
6212-71-1560 OEM for generator 12-021-32
SAGD140-1 1 6212-71-1611 I 1 OEM for generator 1 12-021-33

1 6212-71-1612 I 1 OEM for generator 1 12-021-33
1 6212-71-1692 I l EG400-2 1 12-021-34

6212-71-1693 EG400-2 12-021-34
6D140-1 SERIES 12-011

@
Injection Pump Assembly Number Applicable Machine Applicable Engine
6211-71-l 110 (106692-4881)
Model Serial No. Model Serial No.
( 1:Injection pump manufacturer’s part No. D135A-2 10301 and up S6D140-1 10001 and up
Injection Injection Pump
Pump Type Manufacturer
PE-6P ZEXEL
Injection Pump Specification Engine Specification (Without fan)
Delivery valve (mm3/st) Pump tester capacity

retraction volume 60 Motor 7.5 kW
for service standard
:alibration Standard ( 1: Injectionpump manufacturer’s part number

Service standard Manufacturer standard
Conditions Nozzle & nozzle holder part No. (105780-8140) 6211-11-3100 (105111-4111)
Nozzle part No. ( 105780-0000) 6211-11-3120 (105015-6390)
) Service standard
indicates data
using calibration
test parts.
I Manufacturer
standard is data
for factory test.
ijection volume
Rack positions
B to E are the
reference volume
when adjusting
the injection
volume.
Marks * are
average volumes.
Governor performance (325 - 1000 rpm)
0 325 75Oi30 \1100*25

1000::
lOOK&
Pump speed (rpm)
6D140-1 SERIES n-013

@
Pump Assembly Number Applicable Machine Applicable Engine
6211-71-1120
( 1: Manufacturer’s part No.
D155A, AX-3 60001 and up S60140-1
Injection Timing Engine specification
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 306/I ,900
Maximum torque kgm/rpm 149/I ,300
High idling rpm 2,050 to 2,150
Low idling rpm 700 to 725
Delivery valve
r&rartinn vnlllmP mm3/st 60 I Pump tester capacity
for Service standard I
Motor 7.5 KW
I
Calibration Standard
Conditions Service standard Manufacturer standard

Service standard
Nozzle part no. (1057800000) 621 l-l I-3520 (105015-9790)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6212-I I-321 2 (105041-7122)
test parts.
Injection ipe
Manufacture 8x3~600 6 x 2.2 x 630
(O/D x I/g x length) mm
standard is data
for factory test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature “C 43 to 47
Nozzle opening pressure kg/cm* 175 250
Transfer pump pressure kg/cm* 1.6 1.6
Injection volume Service standard (cc/ 100 st) Manufacturer standard (cc/ 100 st:
Rack Pump
Rack
position speed Maximum Maximum
point variance
(mm) (rpm) Basis Allowance ~er$$, Basis Allowance between
cylinder cylinder
Rack positions Each cyl. 1g o Each cyl.
B to E are the refer- Basic point 12.1 950
ence volume when 1g.55 19.35 to 19.75 * 3 .
adjusting the injec- Approx.
B 13.3 600 21.6 * 21.4t021.8 - 23.6 t
tion volume.
Marks * are aver- C 5.5 340 1.7 * 1.55 to 1.85 f 15 1.7 *
age volumes.
D 16.9 100 30.0 * 30.0 to 32.0 30.0 *
E * *
Sovernor performance (100 - 950 rpm)
Idling sub spring set
overnor spring set (final adjustment)
R,(13.3)
R,(lZ.l)
--C
E &+3.0
E
._
C
0” =44.5*1.5mm3/st
P
y RS(5.5)
n FL(5.5)
o’t++++!k
340 630 i 30 950:;:

Pump speed (rpm) 621 OF249
6D140-1 SERIES
Injection Pump
Machine Model Engine Model Pump Assembly Number
WA500-1 S6D140-1 PE-6P DIESEL KIKI 6211-71-1311 (106672-9181)....2

302 HP S/N 10001 and up
injection Timing
Unit Basis Allowance
Counterclockwise viewed
Rotating direction
from drive end
Injection order l-5-3-6-2-4 lpecification for engine with fan (reference only)
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HP/rpm 30212 100
I
Plunger pre-stroke mm 4.3 4.25 to 4.35 Maximum torque: kgm/rpm 126.5/l 400
I I
Delivery valve High idling: 2300 to 2400
60 rpm I
retraction volume mm3
Low idling: rpm 700to 750

I
Manufacturer standard Service standard

Conditions Unit
(with nearly the same actual machine parts) (with calibration test parts)
Nozzle part no. (105780-0000 1 (105780-0000)
Nozzle holder part no. (I 05780-2080) (105780-2080)

I t mm
8% %%?%ngth) 8 x 3 x 600 8 x 3 x 600
Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature “C 40 to 45 40 to 45
Nozzle opening pressure kg/cm2 175 175

Transfer pump pressure kg/cm2 1.6 1.6
Specifications
Injection volume (cc/500st) Injection volumekd St)
for manufacturer standard for service standard
Maximum Maximum
Rack Pump
variance variance
osition spPeme;r Basis Allowance Basis Allowance
between between
Pmm) r
cylinder cylinder
Calibration Each cyl. Each cyl.
basic point 8.3 1050 66.95 65.95 to 67.95 +1.5
l Rack positions 8 3.5 365 5.75 * 5.00 to 6.50 *7.5 *

B to E are the refer-
ence volume when C * *
adjustingthe injec-
tion volume. D * *
l Marks * are aver-
age volumes. E * *
Eiovernor performance
14
orInOre
SEBH450E
6D140-1 SERIES
‘*-:15
Injection Pump Assembly Number
6211-71-1312
( 1:Injection pump manufacturer’s part No.

Injection Injection Pump
I PE-6P
I ZEXEL I
Injection Pump Specification Engine Specification (Without fan)

Clockwise viewed
Rotating direction Flywheel horsepower (kW {HP}) / rpm) 217/2,100 {291/2,100}
from drive end
Injection order l-5-3-6-2-4 Maximum torque (Nm {kgmI/ rpm) 1,226/1,400 {125/1,400}
Injection interval 59”30’ - 60”30’ High idling speed (rpm) 2,300 - 2,400
Plunger pre-stroke (mm) 4.25 - 4.35 Low idling speed (rpm) 700 - 750

retraction volume 60
Motor 7.5 kW
alibration Standard
:onditions
Service standard
indicates data
using calibration
standard is data
ejection volume
between cylinder between cylinder
Governor performance curve
Pumpspeed (rpml
1Z-016 6D140-1 SERIES

@
Injection Pump Assembly Number
6211-71-1313 (106692-4710) (106692-4712) Applicable Machine Applicable Engine
6211-71-1314 (106692-4891)
1: Injection pump manufacturer’s part No. WA500-1 S6D140-1
lniection Pump. Specification

. Enaine Soecification (Without fan)
Clockwise viewed
Rotating direction
from drive end
Injection order l-5-3-6-2-4
Injection interval 59”30’ - 60”30’
Plunger pre-stroke (mm) 4.25 - 4.35
Delivery valve (mm3/st)

retraction volume
alibration Standard ( 1: Injection pump manufacturer’s part number

:onditions Nozzle & nozzle holder part No. (105780-8140) 6211-11-3100 (105111-4111)
t Nozzle part No. (105780-0000) 6211-11-3120 (105015-6390)
Service standard
indicates data Nozzle holder part No. (105780-2080) 6211-11-3110 (105041-7051)
using calibration Injection pipe (mm) 8 x 3 x 600 6 x 2 x 630
test parts. (Outside dia. x inside dia. x length)
Manufacturer Test oil ASTM D975 No. 2 diesel fuel or eauivalent
standard is data
Oil temperature (“C) 43 to 47
for factory test.
Nozzle opening pressure (MPa{kg/cm*)) 17.2 {I751 24.5 I2501
Transfer pump pressure (kPaIkg/cm2}) 157 11.6) 157 Il.61
Service standard (cc/1000 St.) Manufacturer standard (cc/1000 St.1

ejection volume Rack Pump
Rack Maximum Maximum
point position speed
Injection variance Injection variance
Rack positions (mm) (rpm) volume between cylinder volume between cylinder
B to E are the
reference volume A
when adjusting Basic point) 8.2 1,050 152.2 - 156.2 Max. 9.2 168.2
the injection
B 3.8 365 10 - 13 Max. 3.5 17
volume.
Marks * are
average volumes.
Governor performance curve
h
14
or more
105068 hol3o,
Pump speed frpm)
6D140-1 SERIES 12-017

@
Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
GD825A-1 S6D140 PE-6P DIESEL KIKI 621 l-71-1320 (106672-9310). ..O
285 HP S/N 10278 and up
Injection Timing
Rotating direction Counterclockwise viewed

from drive end
1 Injection order l-5-3-6-2-4 I Specification for engine with fan (reference only)
Rated horsepower: HPlrpm 28512 100

I
Maximum torque: kgm/rpm 128/1400
I
High idling: rpm 2300 to 2400 I
I
Conditions Manufacturer standard Service standard

Unit
Nozzle part no. (105780-0000) (105780-0000)
Nozzle holder part no. (105780-2080) (105780-2080)

In ection pipe
mm 8 x 3 x 600 8 x 3 x 600
(d/D x I/D x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent ASTM D975 No. 2 d,$,$$a#or

Specifications
Injection volume (cc/ 500st) Injection volume(cc/ st)
l [ 1 : Reference data for manufacturer standard for service standard
Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm)
cylinder cylinder
Calibration Each cyl.
basic point IS.31 1050 80 Ea7”9h
cyLto81 I&2.4]
l Rack positions B L3.51 325 6.5 * 5.75 to 7.25 kO.325 *

6 to E are the refer-
ence volume when C * *
adjusting the injec-
tion volume. D * *
* Marks * are aver-
age volumes. E * *
Pump speed kpml SEBH451:
‘%r8 6D140-1 SERIES

Pump Assembly Number
6211-71-1321 (106692-4771) Applicable Machine Applicable Engine
6211-71-1322 (106692-4772)
GD825A-1 S6D140-1
Injection Timing
Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm)
from drive end
Injection order I- 5 - 3 - 6 - 2 - 4 Maximum torque (NmIkgmI / rpm)
Injection interval 60” f 30’
Plunger pre-stroke (mm) 3.75 f 0.05

___ Pump tester capacity
Delivery valve b-nm3/st) 60 Motor 7.5 kW
retraction volume for Service standard
Calibration Standard ( ): Pump manufacturer’s part No.
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
Injection volume Injection volume

‘Rackpositions
B to E are the ref-
erance volume
Governor performance
z
z (7.6)
.-
2 (6.6)
_
: 4.1
u (3.8)
(920)*so1050:::
Pump speed (ram)
TKE00213
6D140-1 SERIES
‘*-z9
Pump Assembly
621 l-71-1330
Number
(106672-9333)
I Applicable Machine , Applicable Engine I
6211-71-1331 (106672-9334) Model Serial No. Model Serial No.
injection Timing Engine specification
Rotating direction Clockwise viewed from drive end
IPump tester capacity

for Service standard I
Motor 7.5 KW
I

- Servicestandard
Nozzle part no. (I 05780-0000) 6211-11-3120 (105015-6390)
indicates data
using calibration Nozzle holder part no. (I05780-2080) 6211-11-3110 (105041-7051)
test parts.
Injection ipe
- Manufacture (O/D x i/g x length) mm 8x3~600 6x2.2x630
standard is data
Oil temperature OC 43 to 47
Injection volume Service standard kc/ 1 OOst) Manufacturer standard (cc/ IOOst
Rack Pump
Rack
point
(mm) bm) Basis Allowance zerE$, Basis Allowance
variance
between
cylinder cylinder
BRack positions
B to E are the refer- Basic point 8.5 1050 13.72 E;;h;;;o 13_g2 kO.4116 16.0 Each “‘-
ence volume when
adjusting the injec- A~3qr60x.
B 335 1.30 * 0.80 to 1.80 kO.195 1.3 *
tion volume.
- Marks * are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 335 - I 050 rpm)
0 335 700 920t50 1175f25

105o:g
Pump speed (rpm)
SEBH4645-0’
6D140-1 SERIES
I Applicable Machine I Applicable Engine I
621 I-71-1350 (106672-9142)
( ): Manufacturer’s part No.
WA500-IC S6D140-1
Delivery valve
retraction volume mm3/st
I
60 1 I Pump tester capacity

for Service standard
Motor 7.5 KW

- Servicestandard
Nozzle part no. 621 l-l I-3220 ( 105015-6390)
indicates data (I 05780-0000)
usingcalibration Nozzle holder part no. (105780-2080) 6211-11-3110 (105041-7050)
fesf parts.
Injection ipe
* Manufacture (O/D x I$ x length) mm 8x3~600 6 x 2 x 630
standard is data
for factory tesf. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Injection volume Service standard (cc/ 100 st) Manufacturer standard (cc/ 100 st
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance TJ$$‘E”, Basis Allowance between
cylinder cylinder
pRack positions 13 3g Each cyl. Each cyl.
B to E are the refer- Basic point 8.3 1050 . 13 19 to 13 59 kO.4017 15.55
ence volume when
adjusting the injec- “““jqx,.
8 365 1.15 * 1.0 to 1.3 20.1725 1.7 *
tion volume.
* Marks * are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 365 - 1050 rpm)
Pump speed (rpm)

SEBH4630
6D140-1 SERIES
’*-:*’
6211-71-1352 (106692-4900)
Model 1 Serial No. 1 Model 1 Serial No.
yzgqegq
WA500- 1C S6D140-1
Injection Timing Engine Specification

Clockwise viewed
Rotating direction Rated horsepower (kW{HP) / rpm) 217 {291)/2,100
from drive end
Injection order I- 5 - 3 - 6 - 2 - 4 Maximum torque (Nm{kgm} / rpm) 1225{125)/1,400
Injection interval 60” k 30’

High idling (rpm) 2350250
- Low idling (rpm) 700+05O

- Pump tester capacity
~~~~!y~Jaume(mm3/st) 60 Motor 7.5 kW
Service standard
for factory test.
when adjusting
105028 (10801
Pump speed (rpmj
12-021-l 6D140-1 SERIES
@
6211-71-1362 (106672-9810)

Clockwise viewed
Rotating direction Rated horsepower (kW{HP) / rpm) 303.0 {4061/ 2,100 (gross)
from drive end
injection order Maximum torque (Nm(kgmI / rpm) 1568 {1601/ 1,400 (gross)
High idling (rpm) 2310 f 60

Injection interval 60’ + 30’
~ Low idling (rpm) 650250
I
Delivery valve
r&mtiinn w-41 wfw
(mm’lst) 60
Pump tester capacity
for Service standard I Motor 7.5 kW
I
lService standard
indicates data
using calibration
l Rack positions
B to E are the ref-
erance volume
(21. 31 (mmHa1
kpa
Boost Pressure
TKEOOZI 5
Pump speed (rum)
TKE00214
6D140-1 SERIES 12-021-2

c3

Clockwise viewed
Rotating direction Rated horsepower (kW{HP) / rpm) 264.8 (355)/2,000
from drive end kp
Injection order l-5-3-6-2-4 Maximumtorque(Nm{kgmI/rpm) 1430.8 {I 46) / 1,500
High idling (rpm) 2250 + 50

Injection interval 60” + 30’
~ Low idling (rpm) 650+:’
Plunger pre-stroke (mm) 3.75 f 0.05 ,
60 Motor 7.5 kW
Calibration Standard ( ): Pump manufacturer’s pat-t No.
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
Rack positions
B to E are the ref-
erance volume
0 325 (950)fso 1125’=

750 1000:::
PumQ speed (YQrn)
TKE00216
12-02’-3 6D140-1 SERIES

GC380-1 S6D140-1
Injection Timing Enaine Soecification

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 279.5 {374.51/2,000
from drive end
Injection order l-5-3-6-2-4 Maximum torque (NmIknmI / rpm) 1501.4U53.2~1 1.500
Low idling (rpm) 800+i"

Motor 7.5 kW
Calibration Standard ( 1:Pump manufacturer’s part No.
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.

Rack positions
B to E are the ref-
: C
w
I:: 3
\
0 / 4!io= 1 140*x5
400 1000:::
Pump speed (rprn)
TKE00217
6D140-1 SERIES
‘2-02’-4
6211-71-1420 (106672-9401)
6211-71-1421 (106672-9402) Model 1 Serial No. Model 1 Serial No.
( j: Manufacturer’s part No. 1 S6D140-1 (
WS23-2 I
(For front engine)
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 40012 100 I
Plunger pre-stroke mm 3.75 f 0.05

Motor 7.5 KW
mm3/st 60 for Service standard

Service standard
Nozzle part no. ( 105780-0050) 621 l-l I-3320 (105015-6920)
indicates data
using calibration Nozzle holder part no. ( 105780-2090) 6211-II-3110(105041-7051)
test parts.
Injection ipe
Manufacture 8 x 3 x 600 6 x 2.2 x 630
(O/D x i/g x length) mm
standard is data
for factory test. Test oil ASTM 0975 No. 2 diesel fuel or equivalent
Injection volume Service standard kc/ 100 St) Manufacturer standard (cc/ 100~1
Rack Pump
Rack
position speed Maximum Maximun
point variance
(mm) bPm) Basis Allowance Terr,EE Basis Allowance between
cylinder cylinder
Rack positions Each cyl. Each cyl.
6 to E are the refer- BSSjo point 26.74 26.54 to 26.94 kO.8022 21.2
ence volume when 14.0 1050
adjusting the injec- Approx.
B 375 2.06 * 1.91 to 2.21 kO.309 1.7 *
tion volume. 6.4
8Marks * are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 375 - 1050 rpm) Boost compensator performance (400 rpm)
@ Strokeof bQonc~mPe”sater
14 or mere
I
A
--._---.
P
E
.-:
C
0”
a
Y
0 300*50
a:
Boost pressure (mmHg)
Line @ : At boost pressure400 mmHg or mere

Line @: At boost pressure0 mmHg
Pump speed (rpm) SEBH4616-0
‘2-o:1-5
6D140-1 SERIES
Pump Assembly Number Applicable Machine , Applicable Engine
6211-71-1430 (106672-9411)
( ): Manufacturer’s part No. WS23-2 S6D140-1
(For rear engine)
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm I 400/2100 I
Injection order l-5-3-6-2-4 1 Maximum torque kgm/rpm 1 159/1400 I

High idling rpm 2300 to 2400
Injection interval 60’ * 30
Plunger pre-stroke mm 4.3 f 0.05

Delivery valve Motor 7.5 KW
60 for Service standard I I

Service standard (105780-0050) 621 l-l I-3320 (105015-6920)
Nozzle part no.
indicates data
usingcalibration Nozzle holder part no. (105780-2090) 6211-ll-3110(105041-7051)
test parts.
Injection ipe 6 x 2.2 x 630
Manufacture 8 x 3 x 600
(Cl/D x l/g x length) mm
standard is data
Injection volume Service standard (cc/ IOOst) Manufacturer standard (cc/ 100~1
Rack Pump
Rack
point variance
(mm) (vm) Basis Allowance yJs$ Basis Allowance between
cylinder cylinder
Rack positions Each cyl. Each cyl.
B to E are the refer- Basic point 14.0 1050 26.74 26.54 to26.94 kO.8022 21.2
ence volume when
adjusting the injec- B AP~.T. 375 2.06 * 1.91 to 2.21 iO.309 1.7 *
tion volume.
Marks * are aver- C * *
age volumes.
D * *
E * *
Governor performance (375 - 1050 rpm) Boost compensator performance (400 rpm)
Stroke of boost c~rn~ensat~r
-e
1 14.9
--__---.
5
._
P C
0”
.-5 P
C :: 13.0
0”
a d ITT
Y I I I
P 50+20 3oot50
[r
Line @ : At boost pressure 400 mmHgor more

Line @: At boost picture 0 mmHg
Pump speed (rprn) SEBH4617-0
6D140-1 SERIES
Applicable Machine bpplicable Engine
6211-71-1451 (191000-5932)
( ): Manufacturer’s part No. HD325-5C S6D140-1 _.
( 1
Rotating direction 1Clockwise viewed from drive end 1 1Rated horsepower HP/rpm 1 399/2100 I
Injection interval 60° + 30

I I I
Plunaer
“-
ore-stroke
r ~~
mm1 3.65 I : I 1
I
Delivery valv Motor 7.5 KW
120 for Service standard
retractlon vo eume mm3/st
1Service standard
indicates data
using calibration
test parts.
1Manufacture
standard is data
for factory test.
1Rack positions
B to E are the
ence volume when

tion volume.
1Marks * are aver-
age volumes.
Governor performance (360 - 1050 rpm) Boost compensator performance (600 rpm)
11.7 e
z
S
z I
g 5
5 6.2 2
‘J
.- 8
B 6.5 z
0. 5.9 8 0 5Of25 250f25
-8 in
B 4.0
Boostpressure(mmHg)
2.5
II.1 I.IIII l l \
100 225360 I- 600700 10501 1300
500fiO 1135.F 200
Line @ : At boost pressure 400 mmHg or more
Pump speed (rpm) Line 0 : At boost pressure 0 mmHg
SEBH4822
12-02’-7 6D140-1 SERIES

GD825 S6D140
Ei

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 222.5 {298.3)/2,100 (gross)
from drive end ~~
Injection order 1- 5- 3 - 6 - 2 - 4 Maximum torque (Nm{kgmI / rpm) 1273 {29.8)/1,400 (gross)
High idling (rpm) 2350 2 50

Injection interval 60’ f 30’
Low idling (rpm) 650 +g”
Plunger pre-stroke (mm) 3.75 + 0.05
~ Pump tester capacity
Delivery valve (mm’/ st) 60 Motor 7.5 kW
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory teat.
Injection vo,lume Injection volume

Rack positions
B to E are the ref-
No set load of adapte spring
0 335 700 92O’SO 117w

1050:::
Pump speed (rum1
TKE00218
6D140-1 SERIES
‘2-oi’-8
GS360-2 S6D140 12025 and up
Injection Timing Enaine Specification

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm)
from drive end
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgmI / rpm)
Injection interval 60’ -c 30’

I I
IPlunger pre-stroke (mm) ( 4.3 ” 0.05 I
Delivery valve
~retractionvolume(mm”‘st’j 6o I Pump tester capacity
Motor 7.5 kW
I
~Service standard Nozzle part no. (105780-0000) 6211-11-3220 (105015-6390)

indicates data Nozzle holder part no. (105780-2080) 6211-11-3110 (105041-7051)
using calibration
test parts. Injection pipe
8 x 3 x 600 6x2.2x630
~Manufacturer (O/D x I/D x length) mm
standard is data
Test oil ASTM D975 No.2 diesel fuel or equivalent
for factory test.
I Oil temperature ‘C I 40 to 45
Nozzle opening pressure (MPa{kg/cm?) 17.2 {175} 24.52 I2501
Transfer pump pressure fkPa(kglcm2)) 156.91 Il.61 156.91 11.6)
Injection volume Service standard Manufacturer standard

Rack Pump
Rack Maximam Maximam
position speed
point Injection volume variance Injection volume variance
(mm) (rpm) WI 000 St) between (cc/1000 st) between
) Rack positions cylinder (%) cylinder (%
0 to E are the ref-
erance volume A (Basic point) 10.2 1000 193 -c 2 *3 200
when_adjusting -
R 10.7 750 205 = 2 220
;z;;rtton
C 3.2 400 9+ 1.5 + 15 13
D
14
or lore
h f- No set load of
adac-te spring
Pump speed (rpm)
TKE00219
12-oi1-9
6D140-1 SERIES
6211-71-1622 (106672-9660) Applicable Machine 1 Applicable Engine
Model Serial No. Model I Serial ~No.
OEM for generator S6D140
Injection Timing Enaine SDecification

Clockwise viewed
Rotating direction Rated horsepower (kW{HP} / rpm)
from drive end
High idling (rpt?l) Max.15M)(50Hz),Max.l872(60Hz)

Injection interval 60” -c 30’
Low idling (rpm) 800 +05’
IDelivery valve
r&rxtinn vnllmw
(mm3/sd 60
Calibration Standard ( 1: Pump manufacturer’s part No.
Service standard
ndicates data
Jsing calibration
Wanufacturer
itandard is data
B to E are the ref-

erance volume
I 8’: Rack Iimit:13.6'~'mm
C
-Z
A
= 12.3
z
.-
.-
::
: 5.6
z 5.2
=
0 400 900':
Pump speed (rpm)
TKE00220
6D140-1 SERIES 12-021-10

8
EG300L-5 S6D140
mi

Clockwise viewed
Rotating direction Rated horsepower (kW{HP} / rpm) 274.3 ~367.8111500 (gross)
from drive end
Injection order l-5-3-6-2-4 317 I426.0}/ 1,800 (gross)
High idling ( QX-fl) Max. 1575 (5OHz). Max. 1890 6OHzl

~ Low idling (rpm) 800 +05’
60 Motor 7.5 kW
Calibration Standard ( ): Pump maqufacturer’s part No.
1Service standard
indicates data
using calibration
1Manufacturer
standard is data
for factory test.
Injection volume injection volume

) Rack positions
B to E are the ref-
erance volume
Rack limitil3. 6’:“mm
spring set
0 400 500’20 9007

Pump speed (rDmJ
TKE00221
12-o:‘-” 6D140-1 SERIES

EG300BS-5 S6D140

Clockwise viewed
Rotating direction Rated horsepower (kWIHP1 / rpm) 242.7 {352.8/1,500 (gross)
from drive end
Injection order l-5-3-6-2-4 280.2 {375.71/ 1,800 (gross)
High idling (rpm) Max. 1560 WJHz),Max. 1872 (6OHz)

D$;~Y~vV$mebnm3/st) 60 Motor 7.5 kW
‘Service standard
indicates data
standard is data
forfactorytest.
Injectionvolume Injection volume

I Rack positions
B to E are the ref-
Rack limit:l3.6'!*mm
3. 0
0 400 (500)*0 900':"

Pump speed (rprn)
TKE00222
6D140-1 SERIES
12-02’-12
I I I
I
I
PE-6P II ZEXEL I
I I I I I I
Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 242.7 {352.8/1,500 (gross)
from drive end
Injection order l-5-3-6-2-4 280.2 (375.7) / 1,800 (gross)
Injection interval High idling (rpm) Max.1560(50Hz),Max.l812(60Hz)

60” f 30’
I
Delivery valve (mm3/st) 60 Motor 7.5 kW
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
1Rack positions
B to E are the ref-
Rack Iimit:l3.5'~'mm
0 400 (530)*~*750*s 900:s

Pump speed (rpm)
TKE0022.3
12-oi’-13 6D140-1 SERIES

S6D140-1

Clockwise viewed
Rotating direction Rated horsepower (kW(HP) / rpm)
from drive end

~~~&!YJ~ume(mm3/stI 60 Motor 7.5 kW
Cionditions Service standard Manufacturer standard

. Service standard Nozzle part no. (105780-0050) 6215-1 l-3220 (105015-8070)
indicates data
Nozzle holder part no. (105780-2090) 6212-11-3211 (105041-7120)
using calibration
test parts. Injection pipe
(O/D x I/D x length) mm 8x4~600 6x2.2x630
. Manufacturer
standard is data
Test oil ASTM D975 No.2 diesel fuel or equivalent
for factory test.
I Oil temperature ‘C I 40 to 45
Nozzle opening pressure (MPaIkg/cm?) 17.2 {175} 24.5 f2501
1 Transfer pump pressure (kPa{kg/cm?) 1 156.91 {I .6} 156.91 (I.61
IInjection volume Service standard Manufacturer standard

Rack Pump -
Rack Maximam Maximam
position speed
point Injection volume variance Injection volume variance
(mm) (rpm) between between
Rack positions (cc/1000 St) (cc/1000 St)
cylinder (%) dinder (%
B to E are the ref-
erance volume A (Basic 8.9 1050 145.5 * 4 *3 162
whenpdjusting
me mjecnon
B point)/1 8.9 1
j 700
__ 1
1 149+4
.-- - 169.5 I
\,r\ll I-P
.“I”III”.
C I 5.1 I 4m-l
.__
I lf?+l!i
._ - .._ t 15 20
D - I 100 I 200 f 10 - 210
F I I I
z
.-
_
.-
8.1
:
_
400 / (I 175)
1050:::
Pump speed (rprn)
TKE00224
6D140-1 SERIES
Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
HD325-5 SA6D140 PE-6NE NIPPON DENS0 6212-71-1210(191000-1090)....0
487 HP S/N 10185 and up
injection Timing
Clockwise viewed
Rotating direction from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60” 59”30’ to 60”30’ Rated horsepower: HPirpm 48712100
Plunger pre-stroke mm 3.65 3.60 to 3.70 Maximum torque: kgm/rpm 196/l 400
Delivery valve 120 2350 to 2450

mm3 High idling: rpm
retraction volume

Manufacturer standard Service standard

Conditions Unit
Nozzle part no. 093400-l 800 093400-I 800

Nozzle holder part no. 093100-095 1 093100-0951
In ection ipe
mm 6x2.2x630 6 x 2.2 x 630
(d/D x l/$x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent ASTM D975 No. 2 $.$a$~;or
Transfer pump pressure kg/cm2 2.0 2.0 .
Specifications
Injection volume (cc/ 1 OOst) Injection volume(cc/ St)
l [ I : Referencedata for manufacturer standard for service standard
Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm]
cylinder cylinder
Calibration Each cyl. Each cyl
basic point 13.7 700 28 27.5 to 28.5 2.8 or less
l Rack positions B 13.7 1050 26 t 25.5 to 26.5 2.6 or less *

B to E are the refer-
ence volume when C 5.9 385 2 t 1.8to 2.2 0.1 or less *
;%:%ehe ‘“‘ec- D l13.71 700 28 * 27.5 to 28.5 *

l Marks * are aver-
age volumes. E [13.7] 1050 24 Sr 25.5 to 26.5 *
Governor performance Boost compensator performance (600 rpm)
18 ! 1.
Rack hmiter set 13.7 + 0.75 t 0.25
” 2 4 6 a 10 F40 12
+x7
Pumpspeed(mm) 6
SEBH451 E
6D140-1 SERIES
12-oZ’-‘5
6212-71-1211 (191000-1090) I Applicable Machine Applicable Engine
6212-71-1212 (191000-1091)
6212-71-1213 (191000-1092) I Model Serial No. Model 1 Serial No.
6212-71-1214 (191000-1093)
H D325-5 SAGD140-1 10582 and up
1 ): Manufacturer’s part No.
r I I I
Manufacturer
Clockwise viewed from drive end Rated horsepower HP/rpm 46312 100
l-5-3-6-2-4 Maximum torque kgm/rpm 196/1400
High idling rpm 2350 to 2450
Plunger prestroke mm 3.65kO.05


- Service standard
Nozzle part no. (093400-I 800) (093400-1800)
indicates data
using calibration Nozzle holder part no. (093 100-0951) (093100-0951)
test parts.
- Manufacture Injection ipe
(D/D x I/g x length) mm 6 x 2.2 x 600 6x2.2x600
standard is data
Transfer pump pressure kg/cm’ 2.0 2.0
Injection volume Service standard (cc/ 100 st) Manufacturer standard (cc/ 1 OOst
Rack Pump
Rack
point variance
(mm) (rPm) Basis Allowance rerEzz Basis Allowance between
cylinder cylinder
* Rack positions 28 o Each cyl. Each cyl.
B to E are the refer- Basic point 13.7 700 . Max. 1.0 28.0
ence volume when 27.5 to 28.5
adjusting the injec- B 13.7 1050 26.0 t 25.5 to 26.5 Max. 1.0 26.0 t
tion volume.
* Marks * are aver- C 5.9 360 2.0 * 1.8 to 2.2 Max. 0.5 2.0 *
age volumes.
D * *
E * *
Limit sleeve set
-E
.E
d 3.5
P
::
s
I
E
E
0
t; 0 5OQ5 250+25
8
m Boost pressure (mmHg)
0 2 4 6 a IO 12 14
Pump speed (YPml x10'
TKE00225
SEBH4614-02
6D140-1 SERIES
‘2-o:‘-‘6
6212-71-1220 (191000-1360)
6212-71-1222 (191000-1362)
WS23S-2 3001 and up SAGD140-1 10428 and up
Clockwise viewed from drive end
,
Plunger pre-stroke mm 3.65kO.05
Del ivery valve Motor 7.5 KW

Service standard (093400-1800)
Nozzle part no. (093400-I 800)
indicates data
using calibration Nozzle holder part no. (093 100-0951) (093 100-0951)
test parts.
Injection ipe
t Manufacture (D/D x l/g x length) mm 6 x 2.2 x 650 6 x 2.2 x 650
standard is data
Injection volume Service standard (cc/ 1 OOst) Manufacturer standard (cc/ 1OOst
Rack Pump
Rack
point variance
(mm) hm) Basis Allowance ~e~~‘$ Basis Allowance
between
cylinder cylinder
Rack positions
point 24 4 Each cyl. Each cyl.
B to E are the refer- Basic 13.0 1050 . 23.9 to 24.9
Max. 1.0 24.4
ence volume when
adjusting the injec- B 13.2 700 27.2 * 26.7 to 27.7 Max. 1.0 27.2 *
tion volume.
Marks * are aver- C (6.0) 350 2.0 * 1.8 to 2.2 Max. 0.5 2.0 t
age volumes.
D * *
E * *
1
q777
200 400 600
Start up 150+25
356r&o ‘O” 105/o;;;&
Pump speed (rpm)
SEBH4536-01
6D140-1 SERIES
‘2-oi’-‘7
6212-71-1242 (191000-8112)
HD325 SAGDI 40- 1

Clockwise viewed
Rotating direction Rated horsepower (kWIHPI/ rpm) 363.3 {487.11/2,100 (gross)
from drive end
Injection order 1- 5- 3 - 6 - 2 - 4 Maximum torque (NmIkgm) / rpm) 1921{196~/ 1,400 (gross)
High idling (rpm) 2400+50

Injection interval 60” +. 30’
~ Low idling (rpm) 775 + 25
Plunger pre-stroke (mm) 3.25 +. 0.05
Delivery valve (mm’/st) 120 Motor 7.5 kW
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
B to E are the ref-
Governor performance Boost compensator performance
; 4
2 0 100 200 300 IllHOl
(toal
0 0 IO 20 30 40
2 4 6 6 10 12 14
Boost PresSUre
Pump speed (rpm) x10'
TKE00226 TKE00227
60140-I SERIES
12-oP8
6212-71-1251 (191000-9571)
Model Serial No. Model 1 Serial No.
H D325-6 SAGDI 40-I

Clockwise viewed
Rotating direction Rated horsepower (kW{HP} / rpm) 379 {507.81/ 2,100 (gross)
from drive end ~~
Injection order 1- 5- 3 - 6 - 2 - 4 Maximum torque (Nm{kgmI / rpm) 2140 {210)/ 1,500 (gross)
High idling (rpm) 24.50+50

- Low idling (rpm) 800*25
~i~~,Va$ume(mm’/st) 120 Motor 7.5 kW
Calibration Standard ( ): Pump manufacturer’s Dart No.
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
Injection volume
B to E are the ref-
Rr Ill)
Rw
(mm) 16-
I6
15. 3 .
15 -
2 14
14 -
= I.2
z
.- IO
._
PI lO_- ;; 5; lo
2 " " z
I
0 ? 400 I1nHtl
2 4 6 B IO 12 14 I6
NP (rpm) x I 0’ ItPa)
Boost Pressure
TKE00229
TKE00228
‘2-o$‘-‘9 6D140-1 SERIES

6212-71-1311 (106682-9192)
1: Injection pump manufacturer’s part No. GC380F-2 SAGDI 40-I
,njection Pump Specification Engine Specification (Without fan)
Rotating direction Counterclockwise Flywheel horsepower (kW {HP}) / rpm) 375/2,000 {503/2,000)
Injection order l-5-3-6-2-4 Maximum torque (Nm {kgm}/ rpm) 2,040/1,400 {208/1,4001
Injection interval 59”30’ - 60”30’ High idling speed (rpm) 2,200 - 2,300
Plunger pre-stroke (mm) 2.95 - 3.05 Low idling speed (rpm) 850 - 900
Delivery valve (mm%) Pump tester capacity

alibration Stan ldard ( 1: Injection pump manufacturer’s part number

) Service standard
indicates data
using calibration
test parts.
) Manufacturer
standard is data
for factory test.
1 Service standard (cc/1000 St.) 1Manufacturer standard (cc1000 St.1

njection volume
I Rack positions
B to E are the
reference volume A
when adjusting (Basic point) 14.4 1000 349 - 355 Max. 77.7 280
the injection
B Approx. 7.8 435 23 - 26 Max. 1.8 24
volume.
I Marks t are C 15.4 700 376 - 386 327
average volumes. D 100 325 - 345 340
E
Rack limit
r Boost compensator stroke:3. OfO. I (mm)
E
14. 4 E 15. 4
IO. a
7. a
12. 4
7. a /II
0 13.3f6.7 40. 0+2. 7
~100+501 (300+20)
Boost Pressure (kPa(mmHs I 1

77oi40 1000::~
Pump speed (r pm) TWE00595
6D140-1 SERIES 12-021-20

@
6212-71-1330 (106682-9330)
1: Injection pump manufacturer’s part No. OEM for generator SAAGD140-1
njection Pump Specification Engine Specification (Without fan)

Clockwise viewed Rated horsepower (kW {HP}) / rpm) 356 I477.2V1.500 (50 Hz:
Rotating direction
from drive end
Injection order ) l-5-3-6-2-4 449 {610}/1,800 (60 Hz)
Max. 1560 (50 Hz)
Injection interval 59”30’ - 60”30’ High idling speed (rpm)
I Max. 1872 (60 Hz)
Plunger pre-stroke (mm) Low idling speed (rpm) 800
Delivery valve (mm3/st)

retraction volume
I Pump tester capacity
for service standard I
Motor 7.5 kW
Conditions
I Service standard
indicates data
I Manufacturer
standard is data
ijection volume
B to E are the between cylinder between cylinder

reference volume
when adjusting
Marks * are
average volumes.
ack I imi t :14. 3’:‘mm
Idling sub sorina set-l.P-ismm

-z
E
14. 9
.-z
-
.- 13.8
:: 12. 7
P 1. 2
-II
cz
6. 7
0
900
Pump speed (r pm) TN00400
12-021-21 60140-l SERIES

@
6212-71-1410 (106682-4330)
SA6D140-1 10420 and up
PC650-3
Injection order 1-5-3-6-2-4
Injection interval 60’ * 30’
Plunger prestroke mm 3.85 + 0.05


- Servicestandard
Nozzle part no. (105780-0050) 6212-1 I-3230 (105015-6720)
indicates data
using calibration Nozzle holder part no. (105780-2090) 6212-I l-3210 (105041-7070)
test parts.
Injection ipe
* Manufacture (O/D x I/g x length) mm 8 x 3 x 600 6 x 2.2 x 630
standard is data
Injection volume Service standard (cc/ 100 St) Manufacturer standard (cc/ 1 OOst
Rack Pump
Rack
point variance
(mm) b-pm) Basis Allowance rey$EE Basis Allowance between
cylinder cylinder
* Rack positions Each cyl. Each cyl.
B to E are the refer- Basic point 13.0 900 29.9 kO.897 24.8
adjusting the injec- B APPro;li 350 2.0 +I.95 to 2.15 10.3 2.0 *
tion volume.
bMarks * are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 350 - 900 rpmj
l,L,
I
0 / \
350 80035 \ 990*25
875+25 g00:;$
Pump speed (rpm)
SEBH4522-0:
‘2-E1-23 6D140-1 SERIES

PC650-3 SAGDI 40-I
Engine Specification
Rated horsepower (kW{HP) / rpm) 301.6 {404} / 1,800

Maximum torque (NmIkgmI / rpm) 1803.2 {I841 / 1,400
High idling (rpm) 198Ok50
I I
Low idling (rpm) 700225
Plunger pre-stroke (mm) 3.65 1?:0.05
Delivery valve (mm’lst) 120 Motor 7.5 kW
Service standard
indicates data
using calibration
test parts.
Manufacturer
standard is data
for factory test.
I Rack positions
B to E are the ref-
erance volume
Rcak Iimit;14':'mm
0 350 800"' a 7 5-s 9 go*,'

900:;:
Pump speed (rpml
TKE00234
6D140-1 SERIES 12-021-24

6212-71-1420 (191000-3950)
PC650-3 SA6D140-1 10420 and up
PC1 600-I SAGD140-1 11397 and up
Plunger prestroke mm 3.65 * 0.05

Motor 7.5 KW
~$t~~J~~ume mm3/st 120 for Service standard

- Service standard Nozzle part no. (093400-l 800) (093400-l 800)
indicates data
using calibration Nozzle holder part no. (093100-0951) (093100-0951)
test parts.
- Manufacture
Injection ipe
(O/D x l/g x length) mm 6 x 2.2 x 650 6 x 2.2 x 650
standard is data
Nozzle opening pressure kg/cm’ 250 250
Injection volume Service standard (CC/ 100 st) Manufacturer standard (cc/ 100 sl
Rack Pump
Rack
point variance
(mm) (rpm) Basis Allowance Ter$EL Basis Allowance between
cylinder cylinder
- Rack positions 243 Each cyl. Each cyl.
B to E are the refer- Basic point 13.2 900 max. 1 24.3
adjusting the injec- B 13.4 700 26.3 * 25.8 to 26.8 max. 1 26.3 t
tion volume.
- Matks * are aver- C L7.51 350 5.0 * 4.8to 52 max. 1 5.0 *
age volumes.
D * *
E * *
Pump speed (rpm)

SEBH4590-01
’*-Oil
-25 6D140-1 SERIES
6212-71-1424 (191000-7723)
PC650-3 SAGDI 40-I

-1 PC1600-1 I 1SAGD140-1 1 I
lniection Timina Engine Specification

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 316.3 I4041/ 1,800 (gross)
from drive end
Injection order l-5-3-6-2-4 Maximum torque (NmIkgmI / rpm) 1793.6~188.8~/1,4OO(gross)
Injection interval
I 60” f 30’
I
High idling
Low idling
(rpm)
@pm)
1980 f 50
700225
IPlunger pre-stroke (mm) 3.65 f 0.05 I
Delivery valve (mm3/st) 120
retraction volume
~Service standard
indicates data
using calibration
standard is data
for factory test.
I Rack positions
6 to E are the ref-
erance volume
when adjusting
8 IO 12 14 16
Pump speed (r pm)
TKE00235
6D140-1 SERIES
’2-o21
-26
6212-71-1430 (191000-9520)
I Applicable Machine Applicable Engine I
6212-71-1431 (191000-9521) I Model 1 Serial No. 1 Model ) Serial No. 1
6212-71-1432 (191000-9522)
( ): Manufacturer’s part No. PC650-5 20001 and up SAGDI 40-I
PC710-5 20001 and up SAGDI 40-I

Clockwise
Rotating direction
viewed from drive end
Maximum torque NmIkgmlhpm 1,004/1,400 {184/1,400}
Injection order 1-5-3-6-2-4
Injection interval 60’ * 30’
Plunger pre-stroke mm 3.65 + 0.05


Service standard
Nozzle part no. (093400-2220) (093400-2220)
indicates data
using calibrarion Nozzle holder part no. (093100-4090) (093100-4090)
test parts.
Manufacture x l/g ipe
Injection
(O/D x length) mm 8 x 3 x 600 8 x 3 x 600
stendard is data
Nozzle opening pressure kg/cm’ 175 175

Injection volume
Rack Pump Service standard (cc/ 100 St) Manufacturer standard (cc/ 100 st
Rack
point variance
(mm) (rPm) Basis Allowance ggf’, Basis Allowance between
cylinder cylinder
Rack
6 to Epositions
are the refer- Basic point 13.3 900 37 2 Each cyl. 1.2 37.2 Each cyl.
ence volume when
. 36.7 to 37.7 max.
tion volume. B 13.6 700 38.1 t 37.6 to 38.6 max. 1.2 38.1 t
Marks * are aver- C l7.11 350 4.8 * 4.6 to 5.0 max. 1 4.8 t
age volumes.
D * *
E * *
L
0 2 4 6 8 10 12 14 16 18
Pump speed (rpm)

621OF252
12-021-27 6D140-1 SERIES
@
6212-71-1511 (191000-0762) ADDlicable Machine 1 ADDlicable Enaine
6212-71-1512 (191000-0763)
Model 1 Serial No. 1 Model 1 Serial No.
EPSAGDI 40 1 1SAGDI 40-I 7

Clockwise viewed
Rotating direction Rated horsepower (kW{HP) / rpm)
from drive end
Plunger pre-stroke (mm) 3.65 - 0.05

~~~~!YYv~ume(mm3/st) 120 Motor 7.5 kW
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.

. (cc/1000St)
B to E are the ref-
erance volume
16
0 2 4 6 0 10 12
Pump speed (rpm)
TKE00236
6D140-1 SERIES
-28
’2-o;’
6212-71-1520 (106682-9110)
Applicable Machine Applicable Engine
1
( OEfodel 1 Serial No. 1sA6;p4doel 1 Serial No. 1

Clockwise viewed
Rotating direction
from drive end
Injection order l-5-3-6-2-4 Maximum torque (Nm{kgm) / rpm) 2039.8 {208)/ 1,400

Calibration Standard ( 1: Pump manufacturer’s part No.
‘Service standard
indicates data
using calibration
Manufacturer
standard is data
1Rack positions
B to E are the ref-
erance volume
Idling sub spring set
Governor spring set
0 350 500 900::: 1000*:r

Pump speed (rpml
TKE00237.
’*-Oil
-29 6D140-1 SERIES
DCA400SPK SAGDI 40-I

Ei

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) . . ,
fromdriveend .j
Injection interval 60” k 30’

_____ Pump tester capacity
D$;;!YYv~ume(mm3/st) 120 Motor 7.5 kW
Calibration Standard ( ): Pump manufacturer’s pat-t No.
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
)Rack positions
B to E are the ref-
erance volume
when adjusting
Rack limii:15.5'~"mm
b spring set
r spring set
280
Pump speed (rpm)
TKE00239
(480) 900ts
Pump speed (rpml
TKE00238
6D140-1 SERIES
-30
’*-Oz’
yq%F&q Power unit SAGDI 40-I

Clockwise viewed
Rotating direction Rated horsepower (kW{HP} / rpm)
from drive end
ti
Plunger pre-stroke (mm) 3.65 +: 0.05

Delivery valve (mm3/atI .I 20 Motor 7.5 kW
_retraction volume for Service standard
~Service standard
indicates data
using calibration
~Manufacturer
standard is data
for factory test.
) Rack positions
B to E are the ref-
Rack sensor slope adjustment standard
Rack sensor
Rt=ll*lmm
Rz-R,=W@mm
3. I
z
f 2.2
-bA
0 R,t-5) R,C-1I)
Rack position (mm1
TKE00240
’2-o;’
-3’ 6D140-1 SERIES
I Model 1 Serial No. 1 Model 1 Serial No.

OEM for generator SAGDI 40
Engine Specification
Rated horsepower (kW{HPI / rpm)
I
Injection interval
I
60” +. 30’
I
Plunger pre-stroke (mm)
Delivery valve
retraction volume
(mm’/.st)
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
1Rack positions
Bto E are the ref-
erance volume
when adjusting
Rack limit; [R,+O.81':"mm
:: R,(6.81
2 R.6.21
[RI-~.415o.r
0
(480)
Pump speed (rpm)
TKE00241
6D140-1 SERIES
’2-oi’
-32
6212-71-1612 (191000-0013)
OEM for generator 1SAGD140-1 1
injection Timing Engine Specification

Clockwise viewed
Rotating direction Rated horsepower (kWIHPI/ rpm) 289.8(388.5)/ 1,500
from drive end
Injection order l-5-3-6-2-4 331.7 {444.7)/ 1,800
High idling (mm) Max15606OW Max18726OHz)

_ Low idling (rpm) 825225
DeliveT valve (mm’/st) 120 Motor 7.5 kW
1Service standard
indicates data
using calibration
standard is data
for factory test.
I Rack positions
B to E are the ref-
erance volume
425 935
Pump speed (rpm)
TKE00242
’*-Oi’
-33 6D140-1 SERIES
6212-71-1693 (191000-2983)
EG400-2 SAGD140-1
E

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 309.6 {415.11/ 1,500
from drive end
Injection order l-5-3-6-2-4 375.8 1503.9) / 1,800
High idling (rpm) Max1560(50l-U Max.l872(60l-&

- Low idling (rpm) 825 + 25
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
Pump speed (rpml

TKE00243
6D140-1 SERIES
-34
’2-o;’
6212-71-1751 (191000-5272)
6212-71-1753(191000-9881)
OEM for Alaska SAGDI 40-I

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 441.3 691.61/2,100 (gross)
from drive end
Injection order 1 - 5 - 3 - 6 - 2 - 4
Plunger pre-stroke (mm) 3.0 r 0.05

~~~~!YY~~ume(mm3/st~ 120 Motor 7.5 kW
Calibration Standard ( 1:Puma manufacturer’s oat-t No.
‘Service standard
indicates data
using calibration
‘Manufacturer
standard is data
for factory teat.
I Rack positions
8 to E are the ref-
erance volume
14-
0 2 4 6 8 10 12 14 I6
TKE00244
’2-o2
-35 6D140-1 SERIES
6212-71-1762 (191000-6982)
EG350 SAGD140-1

Clockwise viewed
Rotating direction Rated horsepower (kW{HP) / rpm) 289.8 (388.5) 1 1,500
from drive end
Injection order l-5-3-6-2-4 331.7 (444.7) / 1,800
High idling (rpm) Maxl%OEOW Max1872(6OM)

~ Low idling (nom) 825 + 25
‘Service standard
indicates data
using calibration
‘Manufacturer
standard is data
for factory test.

I Rack positions
B to E are the ref-
20
14
;i
E
12
:
.-
_ 1c
.-
:
P a
: 6
w
0 2 4 6 a IO 12 14
Pump speed (rvml x10' TKE00245
6D140-1 SERIES
’2-o$’
-36
6212-71-1780 (191000-7660)
6212-71-1781 (191000-7661)
I Applicable Machine Applicable Engine
I Model 1 Serial No. 1 Model 1 Serial No. 1

EG350B SAGDI 40-I

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 335.4 {449.6}! 1,500
from drive end
Injection order l-5-3-6-2-4 381.7 {511.7}/ 1,800
High idling (rpm) Max.1575Wl-U Max1890(60M)
Injection interval 60’ k 30’
- Low idling (rpm) 825 -c25
Delivery valve (mm3/stl 120 Motor 7.5 kW
,retraction volume for Service standard
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
1Rack positions
B to E are the ref-
erance volume
0 2 4 6 8 IO 12 14
Pump speed (rpm) x10’ TKEO0246
‘2-%1-37 6D140-1 SERIES

6212-71-1790 (191000-7670) I Applicable Machine I Applicable Engine I
6212-71-1791 (191000-7671)
I Model ) Serial No. ) Model 1 Serial No. I
I EG400-2 I 1 SAGD140-1 1 I
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm %1 z% I%!;~
Injection order l-5-3-6-2-4 Maximum torque kgm/rpm
High idling rpm z::: 1;; [%!:I

Injection interval 60° f 30
Plunger pre-stroke mm 3.65
Delrvery valve mm3/st 120 Motor 7.5 KW
retractron volume for Service standard

* Service standard
Nozzle part no. (093400-l 800) 6212-l l-31 20 (093400-l 800)
indicates data
using calibration Nozzle holder part no. (093100-0951) (093100-0951)
test parts.
Injection pipe
) Manufacture
(O/D X I/D X length) mm 6 X 2.2 X 650 6X2.2X650
standard is data
for factory test. Test oil ASTM D975 No.2 diesel fuel’ or equivalent
1 Rack positions
B to E are the
ence volume when

tion volume.
1Marks j, are aver-
age volumes.
17.6
16.5 I
,Auto low idlingcharacteristic
--
406 -i+
50
Pumpspeed(rp
SEBH4823
’*-hi** 6D140-1 SERIES

Applicable Machine Applicable Engine
6212-71-1860
( ): Manufacturer’s part No. EG400B2L SAGD140-1 17320 and up
Rotating direction Clockwise viewed from drive end Rated horsepower HP/rpm 1 41 I /I ,500 (50 Hz)
Maximum torque kgm/rpm -

High idling rpm 1,575

Injection interval I 60” f 30’
I
Plunger pre-stroke mm 3.85
Dellvery valve mms/st 120 Motor 7.5 KW
retractron volume for Service standard I
1 Service standard
indicates data
using calibration
test parts.
1Rack positions
6 to E are the
Ingsub spring set 5.3 -o,:
1 T,‘,
0 4001750*5 9oozt.5
(490)
Pump speed &pm)
SEBH482
6D140-1 SERIES
’*-Oi*-’
EG350B, A SAGD140-1

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 335.4 (449.61/1,500 (gross)
from drive end
Injection order l-5-3-6-2-4 381.7 (511.7)/1,800 (gross)
High idling (rpm) -

Low idling (rpm) -
Plunger ore-stroke (mm) 3.5 + 0.05
Delivery valve (mm3/stI 120 Motor 7.5 kW
:ondiiions Service standard Manufacturer standard

Nozzle part no. (105780-0050) 6215-1 I-3220 (105015-8070)
Service standard
indicates data (105780-2090) 6212-11-3211 (105041-7120)
Nozzle holder part no.
using calibration
test parts. Injection_pipe
.) mm 8x4~1000 6x2.2x630
Marhfacturer lengtn
standard is data
ASTM D975 No.2 diesel fuel or equivalent
for factory test.
B to E are the ref-

erance volume
when adjusting
volume.
Rack limit;14 1’1 ‘mm
400 (480) 750'S 900*5

Puma speed (rprn)
TKE00247
’*-tz*-* 6D140-1 SERIES

injection Pump Assembly Number
6212-71-1881 (106682-4740) Applicable Machine I Applicable Engine I
6212-71-1882 (106682-4741)
1: Injection pump manufacturer’s part No. OEM for 200 kW SAGD140-1
generator
njection Timing Engine Specification

Clockwise viewed Rated horsepower (kW {HP}) / rpm) 281.7 (377.6V1,500 (gross)
Rotating direction
from drive end
Injection order l-5-3-6-2-4 317.7{426.0)/1,800
(gross)
injection interval 59”30’ - 60”30’ 1 High idling speed (rpm) I

Plunger pre-stroke (mm) 3.45 - 3.55 1 Low idling speed (rpm) I 800 - 850 I
alibration Standard ( 1: Injection pump manufacturer’s part number

Conditions Nozzle & nozzle holder part No.
Nozzle part No. (105780-0050) 6215-11-3220 (105015-8070)
I Service standard
indicates data Nozzle holder part No. (105780-2090) 6212-11-3211 (105041-7120)
using calibration Injection pipe (mm) 8 x 4 x 1,000 6 x 2.2 x 630
test parts. (Outside dia. x inside dia. x length)
I Manufacturer Test oil ASTM D975 No. 2 diesel fuel or equivalent
standard is data
Oil temperature (“C) 40 to 45
for factory test.
Nozzle opening pressure (MPa{kg/cm21) 17.2 1175) 24.5 {250}
njection volume
I Rack positions
B to E are the
reference volume
when adjusting
I Marks t are
average volumes.
Rack I imit :13. 6’:‘mm
set
2. 6
1. 5
I. 2
: 8 sub
PDle set
&mm
:: ;
g*o,
0 400 (480) 750’S 900:s

Pump speed (rpm)
Pump speed (ram)
TWE00594
TKE00248
6D140-1 SERIES 12-022-3

@
6M 132A-2 SAGDI 32-1

-1

Clockwise viewed
Rotating direction Rated horsepower (kW{HPI / rpm) 435 {485.1}/ 2,100
from drive end_
Injection order I- 5 - 3 - 6 - 2 - 4 Maximum torque (Nm{kgmI / rpm) -
High idling (rpm) 2300 2 50

~ Low idling (rpm) 575 2 2.5
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
I Rack positions
B to E are the ref-
erance volume
when adjusting
Boost compensator performance
15-
,4 14.0
13
I I
20 40 (kpa)
Q
I
0 100 200 300 (mmHo)
04mo
LnC"Io Y) Boost Press"le
-z--m
--- - TKE00250
0 2 4 6 8 10 12 14
Pump sDeed Irum) TKE00249
12-022-4 6D140-1 SERIES
@
6212-75-1340 (092000-1441) Applicable Machine I Applicable Engine
6M 140A-2 SAGDI 40-I

Clockwise viewed
Rotating direction Rated horsepower (kW{HP) / rpm) 476{637.9}/2,100
from drive end
Injection order 1- 5- 3 - 6 - 2 - 4 Maximum torque (Nm{kgm) / rpm) -
High idling (rpm) 23OO-c50

~ Low idling (rpm) 575225
~~;~~~v~ume(mm3/st) 120 Motor 7.5 kW
Service standard
for factory test.
I Rack positions
B to E are the ref-
Boost compensator performance
Boost PreSSUre
TKE00252
Pump speed (rprn) TKE00251
6D140-1 SERIES
'2-oz2-5
TESTING AND ADJUSTING PERFORMANCE TEST
PERFORMANCE TEST t Load are given for the case of the dynamometer
arm length is 716 mm.
RUN-IN STANDARD t This list shows the standard on condition that the
fan is removed.
Engine
model
Applicable
machine
1
Running
Item
time min.
1
2
2
8
3
7
Order
10
5
3
--
6
Engine speed rpm 700 1,300 1,650 1,900 2,100

WA500-1
Load N {kg} 0 353 136) 696 {71) 1,049 {107) 1,392 {I 42:
output kW{HP) 0 35.1 {47) 87.3 {I 17) 151.4 {203) 222.3 {298]
Running time min. 2 8 7 10 3
Engine speed rpm 750 - 800 1,300 1,650 1,900 2,100

HD325-5
(C SPEC)
Load N {kg1 0 481 (49) 961 198) 1,432 {I 46) 1,912 1195)
output kW{HP) 0 63.7 161.7 277.4 409.5
Engine speed rpm 775 1,300 1,650 1,900 2,100

WS16.S3
WS23-2 Load 0 481 (49) 961 (98) 1,432 {I461
N {kg} 1,912 (195)
output kW (HP1 0 47.5 164) 120.9 (162) 206.6 I2771 305.9 (410)
Engine speed rpm 700 1,300 1,650 1,900 2,100

GD825A-1
Load N {kg} 0 343 (35) 686 (70) 1,030 1105) 1,373 (140)
output kW{HP) 0 34.3 I461 86.5 (116) 149.2 {200) 219.3 (294)
S6D140-1
Engine speed rpm 800 - 850 1,150 1,400 1,650 1,800

EG300B-5
Load N {kg} 0 579 (59) 1,157 (118) 1,726 1176) 2,138 I2181
Output kW{HP) 0 50.7 {68) 123.1 {165} 216.3 (290) 292.4 (392)
Engine speed rpm 800 - 850 1,150 1,400 1,650 1,800

EG300BS5
Load N {kg1 0 579 {59) 1,157 1118) 1,726 (176) 2,079 {212}
Dutput kW(HPI 0 50.7 I681 123.1 {I651 216.3 {290) 285 (382)
qunning time min. 2 8 7 10 3
Engine speed rpm 650 - 700 1,250 1,600 1,800 2,000

D135A-2
_oad N {kg) 0 363 {37} 735 {75) 1,098 {I 12) 1,461 (149)
Dutput kW{HP) 0 14.0 (45.6) 38.3 (118.3) 48.3 1198.8) 219.2 (293.8)
3unning time min. 2 8 7 10 3
D155A-3 :ngine speed rpm 700 1,100 1,450 1,710 1,900

D155AX-3
Load N {kg} 0 431 {44) 863 (88) 1,285 (131) 1,716 1175:
output kWIHP) 0 36.1 {48.4: 35.2 l127.6 167.1 (224) 248.0 (332.E
12-022-8 6D140-1 SERIES

@
* Load are given for the case of the dynamometer arm

length is 716 mm.
* This list shows the standard on condition that the fan
is removed.
Order
Engine Applicable
item
model machine
1 2 3 4 5 6
Engine speed rpm 900-950 1,250 1,600 1,800 2,000

GC380
GC380F
Load N {kg} 0 451 (46) 912 193) 1,373 1140) 1,814 {I851
output kW {HP 0 42.7 157.2) 109.7 (146.9 185.5(248.51272.3 (364.8,
GS360-2 Engine speed rpm 650 - 700 1,250 1,600 1,800 2,000
S6D140-1 CS360-2
CS360SD-2 Load N Ikgl 0 451 {46} 912 193) 1,373 {140) 1,814 {I851
output kW {HP: 0 42.7 157.2) I09.7 (146.9: 185.51248.51272.3 (364.8,
Engine speed rpm 700-750 1,300 1,650 1,900 2,100

WF600T-1
Load N {kg} 0 422 143) 834 1851 1,255 {I281 1,667 {I 70)
output kW {HP: 0 41.1 I55.1) II

33.3 1138.5 179 (240) 263 1352)

PC650-3
Engine speed rpm 700 1,150 1,400 1,650 1,800
PC650-5
PC7 I o-5
Load N {kg} 0 588 160) 1,177 11201 1,765 1180) 2,354 1240)
PC1600-1
output kW {HP; 0 51.5 (691 1125.3 1168) 221.6 {297) 322.3 {423}
HD325-5 Engine speed rpm 750-800 1,300 1,650 1,900 2,100

(STD.)
Load N {kg1 0 569 I581 11,128 (115) 1,697 I1731 2,256 I2301
output kW {HP; 0 56.0 (75) 1141.7 1190) 245.4 1329) 360.3 14831
Engine speed rpm 700 1,300 1,650 1,900 2,100

SA6D140-1 WS23S-2
Load N {kg} 0 539 I551 1,079 {I 10) 1,618 {I651 2,157 {220}
output kW {HP) 0 53.7 172) 120.9 062) 234.2 1314) 344.7 I4621
Running time min. 2 8 7 IO 3

EG400B-2
Engine speed rpm 800- 850 1,150 1,400 1,650 1,800
EG400BS-2
OEM for
Load N {kg1 0 735 I751 1,471 {150) 2,206 {225} 2,707 1276)
generator
output kW (HP) 0 64.2 {86) 156.7 I2101 276.6 {371) 348.4 1467)
Running time min. 2 8 7 IO 3
Engine speed rpm 800- 850 1,000 1,200 1,400 1,500

EG400B-2L
Load N {kg} 0 735 {75} 981 {IOO) 1,471 {150} 2,716 {277)
output kW {HP) 0 55.2 174) 38.0 {I 18) 154.4 {207} 305.1 I4091
6D140-1 SERIES 12-022-9

@
t Load are given for the case of the dynamometer arm

length is 716 mm.
t This list shows the standard on condition that the fan
is removed.
Order
Engine Applicable -.-
Item
model machine
1 2 3 4 5 6
Running 2 8 7 10 3
Engine speed rpm 800 1,300 1,650 1,900 2,100

-lD325-6
Load N {kg) 0 588 1601 1,177 I1201 1,765 {180} 2,354 1240)
output kW {HP 0 57.4 {76.9} 145.5 1195) 241.7 {324} 355.1 {476)
SA6D140-1
Engine speed rpm 850 1,000 1,200 1,500 2,000

;C38OF-2
Load N {kg} 0 569 {58} 1,422 {145} 2,275 (232) !,452 (250)
output kW (HP: 0 42.7 (57.2) 28.1 (171.6) !56.1 (343.1) 368 {493}
Engine speed rpm 800 1,000 1,200 1,500 1,500

)EM for
SAA6D140-1
3enerator
Load N (kg1 0 883 {90) 1,765 {180) t.684.8 (270) 3,530 (360)
output kW {HP: 0 66.2 I88.7) 59.0 (213.0) !98.1 (399.3) 197.4(532.4:
Running time min.
Engine speed rpm
Load N {kg}
Dutput kW (HP:
qunning time min.
Engine speed rpm
Load N (kg}
3utput kW {HP:
qunning time min.
ingine speed rpm
_oad N {kg}
Dutput kW (HP]
qunning time min.
ingine speed rpm
_oad N {kg}
Dutput kW {HP]
qunning time min.
:ngine speed rpm
_oad N {kg}
Dutput kW (HP]
12-022-10 6D140-1 SERIES

03
PERFORANCE TEST CRITERIA
xl: This shows the performance and basic speed on the engine as an individual part. When the control lever of the fuel
injection pump is at the free position, the speed is 650+a5 rpm.
Adjust the low idling speed at the control linkage end after mounting on the machine.
Engine 4pplicablN Engine speed Dynamometer

Test item Specified value
model machine @pm) load N {kg1
Flywheel horsepower 225 kW/1,900 rpm 1,895 - 1,905 1,671 - 1,773

1302 HP/l,900 rpm} 1170.4 - 180.8)
D155A-3 Maximum torque 1,432 Nm/1,300 rpm 1,200 - 1,300 2,001 - 2,124
D155AX-3 {I46 kgm/1,300 rpm) f204.1 - 216.6}
High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 0
Low-idling speed 700 - 725 rpm xl 700- 725 0

I335 HP/2,100 rpm} I164.8 - 174.2}
Maximum torque 1,422 Nm /1,400 rpm 1,300 - 1,500 1,959 - 2,079

rRIF600T-1 {I45 kgm/1,400 rpm} 1199.8 - 212)
High idling speed 2,300 - 2,400 2,300 - 2,400 0
Low idling speed 700 - 750 rpm 700 - 750 0

I375 HP/2,000 rpm) t185.2 - 197.0}
Maximum torque 1,502 Nm/1,500 rpm 1,450 - 1,550 2,074 - 2,200

S6D140-1 SC380 I153.2 kgm/1,500 rpm} c211.5 - 224.3}

1355 HP/2,000 rpm} 1181.6 - 192.4)
38360-2
Engine Maximum torque 1,432 Nm/1,500 rpm 1,400 - 1,500 1,979 - 2,097
serial No. II46 kgm/1,500 rpm} 1201.8 - 213.8)
Jp t0
12024)

3S360-2
{355 HP/2,000 rpm) U83.6 - 194.4)
Engine
serial No. Maximum torque 1,432 Nm/1,500 rpm 1,400 - 1,500 1,995 - 2,111
12025 and {I46 kgm/1,500 rpm) 1203.4 - 215.3}
JP)
:S360-2 High idling speed 2,200 - 2,300 rpm 2,200 - 2,300 0
:S360SD-2 Low idling speed 800 - 850 rpm 800 - 850 0

I404 HP/l,800 rpm} l232.1 - 245.7)
‘C650-3
‘C650-5 Maximum torque 1,804 Nm/1,400 rpm 1,300 - 1,500 2,511 - 2,662
SAGD140-1 {I84 kgm/1,400 rpm} I256 - 271.4)
‘C710-5
‘C1600-1
12-022- 12 6D140-1 SERIES

@
The values in the table are indicated at standard conditions (atmospheric temperature 25"C, atmospheric
pressure 750 mmHg).
The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from
those of the specification.
Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling;
and air compressor (if installed) open.
Dynamometer loads are given for the case of the arm length is 716 mm.
Fuel used: ASTM D975 No. 1 or No.2 diesel fuel.
Lubrication oil used: CLASS-CD SAE30.
Coolant Lubrication oil

output Torque Gel consumption Lubrication oil Exhaust
temperature pressure
kW {HP} Nm {kgm} (sec./300cc) 1°C) emperature ("C kPa {kg/cm21 t emperature ("C)
238.2 - 252.9 Min. 16.8 70 -80 go- 110 343- 490 Max.600
1319.1 - 338.8) {3.5- 5.01
1,433 - 1,521 70 -80 90 - 110

{146.1 - 155.1
0 0 70 -80 90 - 110
0 0 70-80 Min. 90 Min. 118 Il.21
254.7 - 269.4 Min. 15.6 70-80 go- 110 294 - 490 Max.600
f341.1 - 360.91 I3.0- 5.0)
1,402 - 1,489 70-80 90 - 110 Max.600

{I43 - 151.8)
0 0 70-80 go- 110
0 0 70-80 Min. 90 Min. 98 {I.01
272.6 - 290.0 Min. 14.0 70-95 go- 110 294- 343 Max.650
1365.2 - 388.51 I3.0- 3.5)
1,485 - 1,575 70-95 90 - 110 Max.650

{151.4 - 160.6:
294-343
0 0 70 - 80 go- 110
13.0- 3.5)
0 0 70-80 Min. 80 Min. 98 {l.O)
267.3 - 283.2 Min. 15.3 70-80 go- 120 294 - 490 Max.650
t358.1 - 379.4) 13.0- 5.0)
1,417 - 1,501 70-80 go- 120 Max.650

U44.5 - 153.1:
0 0 70-80 90-120
0 0 70-80 Min. 80 Min. 118 cl.21
270.3 - 286.2 Min. 15.1 70-95 90 - 110 294 - 490 Max.700

{362.1 - 383.4) (3.0- 5.01
1,428 - 1,512 70-95 go- 110 Max.700

{145.6 - 154.2:
0 0 70-80 go- 110
0 0 70-80 Min. 80 Min. 98 cl.01
307.4 - 325.6 Min. 13.9 70-95 90 - 110 245 - 490 Max.700

t411.9 - 436.2) {2.5- 5.0)
1.798 - 1,905 70-95 go- 110 Max.700

(183.3 - 194.31
0 0 70 -80 go- 110
0 0 70-80 Min. 80 Min. 118 (1.2)
6D140-1 SERIES 12-022-13

@
*: HD325-6 performance indicates as gross.
Engine Engine speed Dynamometer

model Test item Specified value
(rpm) load N {kg}

1463 HP/2,100 rpm} I228.3 - 242.4)
HD325-5 Maximum torque 1,942 Nm/1,400 rpm 1,300 - 1,500 2,684 - 2,818
(STD.) {I96 kgm/1,400 rpm} 1273.7 - 287.4)

750 - 800 rpm 750 - 800
0
700 - 750 rpm 700 - 750
{450 HP/2,100 rpm} 1218.5 - 232)
Maximum torque 1,844 Nm/1,400 rpm 1,300 - 1,500 2,604 - 2,765
\
VVS23S-2 {I88 kgm/1,400 rpm} C265.5 - 282)
Flywheel horsepower (50 Hz) 307 kW/1,500 rpm 1,495 - 1,505 2,7 14 - 2,883
(50 Hz) 411 HP/l,500 rpm} l276.7 - 294.0}
(60 Hz) 352 kW/1,800 rpm 1,795 - 1,805 2,621 - 2,783
IEG400B-2 (60 Hz) 1471 HP/l,800 rpm} t267.3 - 283.8)
IDEM for High idling speed (50 Hz) Max. 1,560 rpm Max. 1,560 0
Igenertor
(60 Hz) Max. 1,890 rpm Max. 1,890

SAGD140-’ I -
Flywheel horsepower (50 Hz) 310 kW/1,500 rpm 1,495 - 1,505 2,7 f 4 - 2,883
(50 Hz) 1415 HP/l,500 rpm) I276.7 - 294.0)
(60 Hz) 357 kW/1,800 rpm 1,795 - 1,805 2,621 - 2,783
I:G400BS-2 (60 Hz) 1478 HP/l,800 rpm} 1267.3 - 283.8}
t3EM for
,generator High idling speed (50 Hz) Max. 1,560 rpm Max. 1,560 0
(60 Hz) Max. 1,890 rpm Max. 1,890
Flywheel horsepower (50 Hz) 303 kW/1,500 rpm 1,495 - 1,505 2.7 14 - 2,883
I405 HP/l,500 rpm) 1276.7 - 294.0)
IIG400B-2L
High idling speed Max. 1,575 rpm Max. 1,757 0
Flywheel horsepower *379 kW/2,100 rpm 2,095 - 2,105 2,335 - 2,474

*{508 HP/2,100 rpm) 1238.1 - 252.3)
Maximum torque “2,069 Nm/1,500 rpm 1,450 - 1,550 2,804 - 2,975

tiD325-6 *{211 kgm/1,500 rpm) 1285.9 - 303.4)
High idling speed *2,400 - 2,500 rpm 2,400 - 2,500 0
Low idling speed ‘775 - 825 rpm 775 - 825 0
12-022-14 6D140-1 SERIES

@
* The values in the table are indicated at standard conditions (atmospheric temperature 25"C, atmospheric
pressure 750 mmHg).
* The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from
those of the specification.
$i Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling;
and air compressor (if installed) open.
Sr Dynamometer loads are given for the case of the arm length is 716 mm.
* Fuel used: ASTM D975 No. 1 or No.2 diesel fuel.
+ Lubrication oil used: CLASS-CD SAE30.
Coolant Lubrication oil

output Torque :uelconsumptio Lubrication oil Exhaust
temperature pressure
kW {HP} Nm {kgm} (sec./300cc) ("C) amperature 1°C kPa {kg/cm21 :emperature ("C)
352.8 - 375.2 Min. 'il.6 70-95 90-110 294- 490 Max. 650
,{472.7- 502.7) (3.0- 5.0)
1,922 - 2,018 70-95 90-110 Max.650
(196 - 205.8)
0 0 70 - 80 go- 110
0 0 70-80 Min. 80 Min. 118 (I.21
337.7 - 358.6 Min. 11.9 70-95 go- 110 294- 490 Max.700
1452.4 - 480.4) {3.0- 5.01
1,864 - 1,980 70-95 90-110 Max.700

190.1 - 201.9:
0 0 70-80 go- 110
0 0 70-80 Min. 80 Min. 98 Il.01
305.4 - 324.6 Min. 13.8 70-80 80- 90 196- 392 Max. 700
1409.2 - 434.8} I2.0- 4.0)
354.1 - 375.9 go- 110 245 - 441
c474.4 - 503.6) (2.5- 4.5}
0 0 70-80 80-90
go- 110
0 0 70 - 80 Min. 80 Min. 118 Il.21
305.4 - 324.6 Min. 13.8 70-80 80 -90 196 - 392 Max.700

I409.2 - 434.8) (2.0- 4.0)
354.1 - 375.9 go- 110 245-441
t474.4 - 503.61 (2.5- 4.5)
0 0 70-80 80-90
go- 110
0 0 70-80 Min. 80 Min. 118 (1.2)
301 -320 Min. 13.8 70-80 80- 90 196 - 392 Max.700

l403.3 - 428.7) c2.0- 4.01
0 0 0 70-80 80 - 90
0 0 0 70-80 Min. 80 Min. 118 (1.2)
368- 390 Min. 10.6 70 -80 go- 110 245- 441 Max.700
1493 - 522.6) (2.5- 4.5)
2,007 - 2,131 70-80 90 - 110 Max.700

204.7 - 217.3:
70- 80 90 - 110 _
70-80 Min. 80 Min. 118 (I.21
6D140-1 SERIES 12-022-l 5

@
TESTING AND ADJUSTING TOOL LIST
NO. Testing and measuring item Fault finding tool Part No. Remarks
1 Engine speed Multi-tachometer 799-2038000 Digital reading: 60 - 20,000 rpm
2 Battery S.G.
Battery coolant tester
Freezing temperature of cooling
3
water
Water temperature, oil temperature,

4
air intake temperature
Thermistor temperature
gauge
5 Exhaust temperature
0 - 20 kg/cm’
Intake pressure, exhaust pressure
Dirtiness 0 - 70% with standard color

(Dirtiness % x l/l 0% Bosch scale)
Provided with 0.1 and 0.2 water

Water and fuel content in oil
Fuel injection pressure Nozzle tester

16 Fuel Injection nozzle spray condition
I I
17 Coolant quality Water quality tester 799-202-7001 PH. nitrite ion concentration
Pressure valve function

18 Radiator cap tester 799-202-9001 0 - 2 kg/cm’
Leakage in cooling system
Anemometer
19 Radiator blockage (wind speed) 799-202-2001 1 - 40 m/s
(Air speed gauge)
20 Engine cranking Cranking kit 795-610-1000
Commercially
21 Electrical circuit Tester Current, Voltage, Resistance
available
12-022-l 8 6D140-1 SERIES

@
TESTING AND ADJUSTING DATA

I
Applicable machine model Dl35A-2 T WA500-1
Classifi Standard Permissible Standard Permissible

Item Condition, etc. Unit
cation value value value value
High idling speed rpm 2,200 f 50 $150 - 2,250 2,350 + 50 2,300 - 2,400
Engine speed
Low idling speed rpm 65O+s; 650 - 700 700+5; 700 - 750
O’C rpm Min. 110 - Min. 110 _

Necessary
starting speed _
-20°C (with starting aid) rpm Min. 85 Min. 85
Intake resistance At all speed mmH,O Max. 300 762 Max. 300 762
Intake pressure At rated output mmHg Min. 750 600 Min. 750 600
Exhaust pressure
At rated output mmHg Min. 600 480 Min. 540 440
(Turbine inlet pressure)
Exhaust temperature All speed
“C Max. 650 700 Max. 650 700
(Turbine inlet temp.) (intake air temp.: 20°C)
Quick acceleration Max. 6.5 8.5 Max. 4.0 6.0
Exhaust gas color (Low idling - High idling) Bosch
At rated output scale Max. 2.5 3.5 Max. 2.0 3.0
At high idling Max. 1 .O 2.0 Max. 1.5 2.5
Valve clearance Intake valve mm 0.43 _ 0.43

(When engine is hot
or cold.) Exhaust valve mm 0.80 _ 0.80
Compresion Oil temperature: 40 - 6o’C kg/cm2 Min. 32 22 Min. 32 22

pressure
(SAE30 oil) (Engine speed) (rpm) (200 - 250) (200 - 250) (200 - 250) (200 - 250)
Blow-by pressure At rated output

mmH,O Max. 100 200 Max. 100
(SAE30 oil) Water temperature: Min. 70°C
SAE30 oil kg/cm2 3.0 - 5.0 2.1 3.0 - 5.0 2.1

At rated output SAEIOW oil
kg/cm2 2.5 - 4.5 1.8 2.5 - 4.5 1.8
Oil pressure
(Oil temperature:
Min. 80X) SAE30 oil kg/cm2 Min. 1.2 0.7 Min. 1.2 0.7
At low idling
SAEIOW oil kg/cm2 Min. 1.O 0.7 Min. 1.0 0.7
Oil temperature All speed (oil in oil pan) “C 80- 110 120 80 - 110 120
At continuous rated output

Oil consumption ratio
(Ratio of fuel consumption)
% Max. 0.5 1.o 0.5 1.0
Fuel injection pressure Nozzle tester kg/cm2 250 ;‘; 225 250 ;‘; 225
Fuel injection timing B.T.D.C degree 27 zt 1 27 + 1 27 k 1 27 f 1
Opening pressure
Radiator pressure valve kg/cm2 1 .o * 0.15 _ 0.70 * 0.1 0.70 * 0.1
(Differential pressure)
Fan speed At rated engine speed rpm 1,184 * 35 1,184 + 35 1,050 * 30 11,020 - 1,080
Deflects when pushed with a -

Fan belt tension mm Autotension 6 4-8
force of 6 ko
* The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.
1Z-022-20 6D140-1 SERIES

@
S6D140-1
EG300B-5
HD325-5 (C SPEC.) WS16S-3,WS23-2 GD825A-1
I EG300BS5
I
Standard Permissible Standard Permissible Standard Permissible Standard Permissible
value value value value value value value value
Vlax.
1,560(50Hz)
2,350i 50 2,300- 2,400 2,350 + 50
klax.
1,872(60Hz)
775 +25 750- 800 750+5; 800-850
Min.110 - _
Min. 85 - -
Max.300 762 Max.300 762 Max.300 762 m 762
- - - Min. 897 (50 Hz) -

Min. 1,150 920 Min. 300
Min. 927 (60 Hz)
- _ -
Max.700 700 700
Max. 6.0 8.0 10.0
Max. 2.0 3.0 _

Max. 2.0 3.0 2.5
0.43 _ _
0.80 - -
Min. 32 22 Min. 32 22 Min. 32 22 Min. 32 22
(200- 250) (200- 250) (200- 250) (200- 250) (200- 250) (200- 250) (200- 250) (200 - 250)
Max.100 200 Max.100 200 Max.100 200 Max.200 400
3.0- 5.1 2.1 3.0 - 5.1 2.1 2.5 - 5.0 1.8

- _ 2.5 - 4.5 1.8 - -
Min. 1.2 0.7 Min. 1.2 0.7 Min. 1.2 0.7

_ - Min. 1.0 0.7 - _
80-110 120 80- 110 120 80-110 120
0.5 1.0 0.5 1.0 0.5 1.0 0.5 1.0

I
250:'; I 225 250:'; 225 250:'; 225 250:'; 225

I I I I
27il 27 k 1 27 i_1 27 f 1 27+ 1 27k 1
I I I I
0.49 * 0.1 0.49 * 0.1 0.50 f 0.1 0.50 + 0.1 0.7 * 0.15 0.7 f 0.15
LWt:,9, 11,220 - 1.280

1,250f 30 1,220- 1,280 1,766k 45 1,721- 1,811 1,125*50(50Hz)
1,370f40(60Hz1
,125i50(50Hz)
,370*40(60Hz)
Autotension 1 - 1 7 1 5-9 1 10 8-12
6D140-1 SERIES 12-022-2 1

6D
Engine S6Dl40-1
Applicable machine model

T D155A-3
WF600T-1
D155AX-3
i- Standard Permissible Standard Permissible
1
/ value value value value
High idling speed rpm 2,050 - 2,15( 12 1,050 - 2,151 2,300 - 2,401 3 2!,300 - 2,400
Engine speed
Low idling speed rpm 700 - 725 700 - 725 700 - 750 700 - 750
0°C rpm Min. 110 Min. 110

Necessary
starting speed
kPa Max. 2.94 7.47 Max. 2.94 7.47
Intake resistance At all speed
ImmH,O {Max. 300) (762) (Max. 300) {7621
kPa Min. 82.6 65.8
Intake pressure At rated output
(mmHd (Min. 640) 15101
Exhaust pressure kPa Min. 72.3 58.1
At rated output
(Turbine inlet pressure) {mmHgI {Min. 560) I4501

“C Max. 680 700 Max. 650
Quick acceleration
Max. 6.0 8.0 Max. 5.0 7.0
(Low idling _j High idling)
Bosch
Exhaust gas color At rated output scale Max. 1.5 2.5 Max. 2.0 3.0
At high idling Max. 1.0 2.0 Max. 1.0 2.0
Intake valve mm 0.43 0.43

Valve clearance
(When engine is hot
or cold) Exhaust valve mm 0.80 0.80
MPa Min. 3.1 2.2 Min. 3.1 2.2

Oil temperature: 40 - 60°C
Compression pressure :kg/cm? {Min. 32) (221 {Min. 32) 122)
lSAE30 oil)
(Engine speed) (rpm) (200 - 250) (200 - 250)
Blow-by pressure At rated output kPa Max. 0.98 1.96 Max. 0.98 1.96
ISAESO oil) water temperature: Min. 70°C mmH20) {Min. 100) {200) {Min. 100) c-a01
kPa 294 - 490 206 294 - 490 206
SAE30 oil
kg/cm*) (3.0 - 5.0) (2.11 13.0 - 5.0) l2.11
At rated output
kPa 245 - 441 177 245 - 441 177
SAEIOW oil
3il pressure kg/cm? (2.5 - 4.5) 11.81 (2.5 - 4.5) (I.81
roil temperature:
kPa Min. 118 68.6 Min. 98 68.6
Min. 80°C) SAE30 oil
At low idling kg/cm21 {Min. 1.2) IO.71 {Min. 1.0) (0.71
kPa Min. 98 68.6 Min. 78.5
SAEIOW oil
lkg/cm? {Min. 1.0) (0.7) {Min. O.S}
Oil temperature All speed (oil in oil pan) “C 80 - 110 120 80- 110

Oil consumption ratio % Max. 0.5 1.0 Max. 0.5
(Ratio for fuel consumption)
MPa 24.0 - 25.8 20.2 24.0 - 25.5 20.2
(kg/cm2 (245 - 263) {206) (245 - 2601 (2061
Fuel injection timing B.T.D.C. degree 26 - 28 26 - 28 26 - 28 26 - 28
Radiator pressure Opening pressure kPa 88.3 88.3 58.8 - 78.5 58.8 - 78.5
valve (Differential pressure) [kg/cm2 10.9) {0.91 CO.6 - 0.8) IO.6 - 0.8)
Fan speed At rated engine speed rpm 1,198 - 1,27: ,198 - 1,27: 1,163 - 1,23! ,163 - 1,235
Deflects when pushed with

Fan belt tension mm Autotension
a force of 6 kg
Sr The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
12-022-22 6D140-1 SERIES

@
*l:Engine No.12065and up
S6D140-1
T T
GS360-2 *l
GC380 GS360-2
CS360-2
GC380F (IEngine serialNo. up to 12024 .I
cs3 SD-2
Standard Permissible Standard Permissible Standard Permissible Standard Permissible

value value value value value value value value
2,230 - 2,330 2,230 - 2,330 2,200 - 2,300 2,200 - 2,300 2,200 - 2,300 2,200 - 2,300
800- 850 800- 850 650- 700 650 -700 800 - 850 800 - 850
Min. 110 Min. 110 Min. 110
Min. 85 Min. 85 Min. 85

Max. 2.94 7.47 Max. 2.94 7.47 Max. 2.94 7.47
{Max. 300) {7621 {Max. 300) I7621 {Max. 300) 17621
Min. 146 117 Min. 146 117

{Min. 1,130} I9051 {Min. 1,130} I9051
Min. 116 92.9 Min. 116 92.9
{Min. 900) I7201 {Min. 900) 17201
Max.650 700 Max. 650 700 Max. 650 700
Max. 5.0 7.0 Max. 5.0 7.0 Max. 5.0 7.0
Max. 2.0 3.0 Max. 2.0 3.0 Max. 2.0 3.0
Max. 1.5 2.5 Max. 1.5 2.5 Max. 1.5 2.5
0.43 0.43 0.43
0.80 0.80 0.80
Min. 3.1 2.2 Min. 3.1 2.2 Min. 3.1 2.2

{Min. 32) 122) {Min. 321 {22) {Min. 32) I221
(200 -250) (200 -250) (200 - 250) (200-250) (200 -250) (200-250)
Max. 0.98 1.96 Max. 0.98 1.96 Max. 0.98 1.96
{Max. 100) I2001 {Max. 100) 12001 {Max. 1001 {Max.200}
294-343 206 294 - 490 206 294 - 490 206
(3.0- 3.51 12.1) 13.0- 5.0) 12.1) f3.0- 5.0) 12.1)
245- 343 177 245- 441 177 245- 441 177
12.5- 3.5) (I.81 (2.5- 4.51 11.8) (2.5- 4.5) Il.81
Min. 118 68.6 Min. 118 68.6 Min. 118 68.6
{Min. 1.2) CO.7) {Min. 1.2) 10.71 {Min. 1.2) (0.71
Min. 98 68.6 Min. 98 68.6 Min. 98 68.6
(Min. 1.0) (0.7) {Min. 1.01 (0.71 {Min. l.O} iO.7)
80- 110 120 80 - 110 80- 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
24.0 - 25.5 20.2 24.0 - 25.5 20.2 24.0 - 25.5 20.2

I245 - 260) {206) (245 -2601 12061 {245 - 260) (2061
26-28 26-28 26-28 26-28 26-28 26-28
58.8 - 78.5 58.8 - 78.5 63.7 - 83.4 63.7 - 83.4 63.7 - 83.4 63.7 - 83.4
IO.6- 0.8) fO.6- 0.8) LO.65- 0.851 (0.65- 0.851 (0.65 - 0.85) LO.65- 0.85}
1,580 - 1,660 I.580- 1,660 ,580 - 1,660 ,580 - 1,660 1,580 - 1,660 ,580 - 1,660
6 4-8 6 4-8 6 4-8
6D140-1 SERIES 12-022-23

@a
Engine SA6D140-1
PC650-3, PC650-5,
Applicable machine model HD325-5 (STD.)
PC710-5, PC1600-1
Classifi Standard Permissible Standard Permissible

cation value value value value
High idling speed rpm 1,930 - 1,98C 1,930 - 2,030 !,350 - 2,45( ,350 - 2,450
Engine speed
‘75?25(-10581
Low idling speed rpm 750 - 800 750 - 800 25+25(10582-
0°C rpm Min. 110 Min. 110

Necessary
starting speed
kPa Max. 2.94 7.47 Max. 2.94 7.47
{mmH,O} {Max. 300) (762) {Max. 3001 (7621
kPa Min. 141 114 Min. 126 94.8
Intake pressure At rated output
ImmHg) {Min. l,lOO} 1880) {Min. 980) 1735)
Exhaust pressure kPa Min. 110 87.7 Min. 106 79.4
(Turbine inlet pressure) At rated Output ImmHg) (Min. 850) I6801 {Min. 820} (615)

“C Max. 700 Max. 700 Max. 650
Quick acceleration
Max. 6.0 8.0 Max. 6.0 8.0
(Low idling --f High idling)
Bosch
Exhaust gas color At rated output scale Max. 2.0 3.0 Max. 2.0 3.0
1At hiah idlina 1 1 Max. 2.0 3.0 Max. 2.0 3.0
Intake valve 0.43 0.43

Valve clearance
(When engine is hot
or cold) Exhaust valve 0.80 0.80
MPa Min. 2.8 2.0 Min. 2.8 2.0

Compression pressure Oil temperature: 40 - 60°C
(kg/cmz) {Min. 29) (20) {Min. 29) {201
(SAE30 oil)
(Engine speed) (rpm) (200 - 250) (200 - 250) (200 - 250) (200 - 250)
Blow-by pressure At rated output kPa Max. 1.96
+ 3.92 Max. 1.96 3.92
(SAE30 oil) Water temperature: Min. 70°C ImmH,OI (Max. 2001 (4001 {Max. 200) (400)
kPa 245 - 490 177 294 - 490 206
SAE30 oil
{kg/cm? {2.5 - 5.0) 0.81 (3.0 - 5.0) t2.11
At rated output
137 245 - 441 177
SAElOW oil ik;,ymzj ;29; I5”9;
Oil pressure Il.41 {2.5 - 4.5) Il.81
(Oil temperature:
kPa Min. 118 68.6 Min. 118 68.6
Min. 80°C) SAE30 oil
At low idling {kg/cm? {Min. 1.2) IO.71 {Min. 1.2) (0.7)
68.6 Min. 98 68.6
SAElOW oil IkJ,pm21 $;z,’ 1980,
10.7) {Min. 1.0) (0.7)
Oil temperature All speed (oil in oil pan) 1 “C 1 80- 110 120 80 - 110

Oil consumption ratio (Ratio for fuel consumption) % Max. 0.5 1.0 Max. 0.5
MPa 24.0 - 25.5 22.1 24.0 - 25.5 22.1

{kg/cm? I245 - 260) 12251 {245 -260) (2251
28 + 1 IPC650 28 + 1(PC650
Eng. No.-198841 Eng. No.-198841
Fuel injection timing B.T.D.C. degree 26 + 1(PC650 26 t 1 (PC650 27-29 27 - 29
Eng. No. 19885- Eng. No. 19885-
25 + 1 (PC1600) 25 2 1 (PC16001
Radiator pressure Opening pressure kPa 63.7 - 83.4 63.7 - 83.4 38.2 - 57.9 38.2 - 57.9
valve (Differential pressure) {ko/cm*> (0.65 - 0.851 IO.65 - 0.851 IO.39 - 0.59; (0.39- 0.59)
Fan speed At rated engine speed rpm 975 - 1,025 1,220 - 1,281 1,220- 1,280
I I
Deflects when pushed with mm
Fan belt tension See page 12-008-I Autotensior
a force of 6 kg
* The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
1 Z-022-24 6D140-1 SERIES

039
SA6D140-1
EG400B-2
WS23S-2 EG400BS-2
OEM for Generator
Standard Permissible Standard

EG400B-2L
Permissible
1 Standard
GC380F-2
Permissible
value value value value value value
lax.1,560(50Hz) Max. 1,560(50Hz
lax.1,575(50Hz/ lax.1,575(50Hz 2,200 - 2,300 2,200 - 2,300
lax.1,872(60Hz) Max. 1,872(60Hz
800-850 1 800-850 800 - 850 800- 850 850 -900 850 - 900
Min. 110 Min. 110 Min. 110
g&--p Min. 85
Max. 3.72
{Max. 380)
7.47
{762)
Min. 85
Max. 2.94
{Max. 3001
7.47
{762)
Min. 129 103 Min. 135 108

{Min. 1,000) 18001 {I,0501 I8401
Min. 107 86.5 Min. 116 92.9
{Min. 830) I6701 {Min. 900) I7201
Max.650 700 Max.700 Max.700 Max.700 Max.700 Max.700 700
Max. 6.0 8.0 Max. 8.0 10.0 Max. 8.0 10.0 Max. 6.0 8.0
Max. 2.0 3.0 Max. 2.0 3.0 Max. 1.5 2.5 Max. 2.0 3.0
Max. 2.0 3.0 Max.,'." ~ 2; Max. 1.0 2.0 Maxx;." / 2:
0.43 I - 0.43
0.80 I - 0.80 0.80 0.80

I -
Min. 2.9 2.0 Min. 2.9 2.0
{Min. 29) 1201 {Min. 29) I201
(200 -250) (200 -250) (200 - 250) (200 -250) (200-250) (200 -250)
Max. 1.96 3.92 Max. 1.96 3.92
{Max.200) I4001 IMax.200} {4001
295- 490 177 245 - 490 177
I2.1) {2.5- 5.0) il.81 12.5 - 5.0) U.8)
295- 441 177 196- 441 137 196- 441 137
12.5 - 4.5) U.8) f2.0 - 4.5) U.4) {2.0- 4.5) U.4)
Min. 118 68.6 Min. 118 68.6 Min. 118 68.6
{Min. 1.2) iO.71 {Min. 1.2) fO.7) {Min. 1.21 lO.7)
Min. 98 68.6 Min. 98 68.6
{Min. 1.0) 10.7) {Min. l.O} 10.71
80- 110 120 80- 110 120
z&--p& Max. 0.5
24.0 - 25.5
{245 -260)
1.0
22.1
I2251
Max. 0.5
24.0 - 25.5
1245 -260)
1.0
20.2
(2061
,;I;:,
V222,k:;:,'," 1 1.220 I 1,280
23-25
53.9 - 83.4
IO.55 - 0.85}
23-25
53.9 - 83.4
IO.55 - 0.85)
,140*30(50Hz) 1,140+30(50Hz)
23-25
53.9 - 83.4
:0.55- 0.85)
140?30(50 Hz)
23-25
53.9 - 83.4
(0.55- 0.85)
,140+30(50Hz)
25-27
58.8 - 78.5
IO.6- 0.8)
1,118; 1,178
I
/
25-
58.8 - 78.5
IO.6- 0.8)
l,lly I ;78
27
,370?40(60Hz) 1,370*40(60Hz1
10 8 - 12 10 8-12
6D140-1 SERIES 12-022-25

63
Engine
T SAGD140-1
OEM for
Applicable machine model H D325-6
200 kW Generator
Standard ‘ermissible Standard Permissible

Item Measurement conditions Unit
value value value value
lax.l,575(50Hz lax.l,575(50Hzl
High idling speed vm 2,400 - 2,50( ,400 - 2,50(
lax.l,890(60Hz lax.l,890(60Hz)
Engine speed
0°C (without starting aid) rpm Min. 110 Min. 110

Necessary
starting speed
20°C (with starting aid) wm Min. 85 Min. 85
kPa Max. 2.94 7.47 Max. 2.94 7.46
nmH,Ol {Max. 300) (762) {Max. 300) (762)
kPa 132 106
Boost pressure At rated flywheel horsepower
mmHg1 (1,020) I8201
Exhaust pressure kPa Min. 125 101
At rated flywheel horsepower
:Turbine inlet pressure) mmHg) {Min. 970) 1780)

“C Max. 700 700 Max. 600
:Turbine inlet temp.) (intake air temp.: 20°C)
Quick acceleration
5.0 7.0
[Low idling + High idling)
Bosch
!xhaust gas color At rated flywheel horsepower index 2.0 3.0 Max. 1.0 2.0
High idling speed 1.0 2.0 Max. 0.5 1.5

r/alve clearance
When engine is hot
3r cold) Exhaust valve mm 0.80 0.80
MPa Min. 2.8 2.0 Min. 2.8 2.0

Dil temperature: 40 - 60°C
Zompression pressure (g/cm? {Min. 29) I201 {Min. 29) (20)
(SAE30 or SAEl5W-40)
(Engine speed) (rpm) 200 - 250 200 - 250 200 - 250 200 - 250
Blow-by pressure At rated flywheel horsepower kPa 1.96 3.92 Max.1.96 3.92
(SAE30 or SAEl5W-40) Water temperature: Min. 70°C mmH?O 1200) {400) {Max. 200) 1400)
At rated flywheel horsepower kPa 245 - 441 177 265 - 441 186
SAE30 or SAE15W-40 oil kg/cm2 (2.5 - 4.5) U.8) 12.7 - 4.5} 11.9)
kPa 245 - 343 177 216 - 392
SAElOW oil
Oil pressure kg/cm2 12.5 - 3.5) Il.81 (2.2 - 4.0)
(Oil temperature:
At low idling kPa Min. 118 68.6 Min. 177 127
Min. 80°C)
SAE30 or SAEl5W-40 oil kg/cm2 {Min. 1.2) (0.7) {Min. l.S} l1.3)
kPa Min. 98 68.6 Min. 98 68.6
SAEIOW oil
kg/cm? {Min. 1.0) (0.7) {Min. l.O} fO.7)
Oil temperature All speed (oil in oil pan) “C 80 - 110 120 80 - 110 120
At continuous rated horsepowe r

Oil consumption ratio % Max. 0.5 1.0 Max. 0.5 1.0
(Ratio to fuel consumption)
MPa 24.0 - 25.5 20.2 25.0 - 25.8 20.2
kg/cm2 (245 - 260) I2061 (255 - 263) {206)
Fuel injection timing B.T.D.C. degree 25 - 27 25 - 27 21 -23 21 -23
Radiator pressure Opening pressure MPa 48.1 48.1 - 50.0 48.1 - 50.0
valve (Differential pressure) kg/cm2 (0.49) :0.49 - 0.51: (0.49 - 0.51)
Fan speed At rated engine speed rpm 1,212 - 1,281 ,212 - 1.28:
Deflects when pushed with

Fan belt tension mm Autotension
a force of 60 N 16 kg}
12-022-26 6D140-1 SERIES

@
Engine SAGD140-1
i-
Applicable machine model
f B-Pole
Standard
OEM for
Generator
Permissible
(50 Hz)
l- 6-Pole
Standard
OEM for
Generator (60 Hz)
‘ermissible
Item Measurement conditions Unit
I value value value value
High idling speed (Prime) rpm Max. 1,045 Max. 1,045 Max. 1,254 Max. 1,254
(Standby1 Max. 1,050 Max. 1,050 Max. 1,260 Max. 1,260
Engine speed
0°C (without starting aid) rpm Min. 110 Min. 110

Necessary
starting speed
20°C (with starting aid) rpm Min. 85 Min. 85
kPa Max. 2.94 7.47 Max. 2.94 7.46
Intake resistance At all speed {Max. 300)
mmH,O: (Max. 300) (7621 1762)
kPa Min. 116 Min. 135
Boost pressure At rated flywheel horsepower
ImmHgl {Min. 900) (Min. 1,050)
Exhaust pressure kPa
(Turbine inlet pressure) At rated flywheel horsepower (mmHg)
Exhaust temperature All speed 700 Max. 700

“C Max. 700
Quick acceleration
(Low idling + High idling)
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 1.0 2.0 Max. 1.0
High idling speed Max. 0.5 1.5 Max. 0.5

Valve clearance
(When engine is hot
or cold) Exhaust valve mm 0.80 0.80
MPa Min. 2.8 2.0 Min. 2.8

Compression pressure Oil temperature: 40 - 60°C {Min. 29) {Min. 29)
:kg/cm2) 120)
(SAE30 or SAE15W-40)
(Engine speed) (rpm) 200 - 250 200 - 250 200 - 250 200 - 250
Blow-by pressure At rated flywheel horsepower kPa 1.96 3.92 Max. 1.96 3.92
(SAE30 or SAE15W-40) Water temperature: Min. 70°C mmH>OI {200) 14001 {Max. 200) I4001
At rated flywheel horsepower kPa 245 - 392 177 245 - 392 177
SAE30 or SAE15W-40 oil kg/cm?: I2.5 - 4.0) (1.8) 12.5 - 4.01 11.8)
kPa _
SAElOW oil
kg/cm21
Oil pressure Min. 147 68.6 Min. 147
At low idling kPa
(Oil temperature: kg/cm? {Min. 1.5) {Min. 1.5)
SAE30 or SAE15W-40 oil fO.71
Min. 80°C)
kPa
SAEIOW oil
kg/cm’:
Oil temperature All speed (oil in oil pan) “C 80- 110 120 80- 110
At continuous rated horsepower

Oil consumption ratio % Max. 0.5 1.0 Max. 0.5
(Ratio to fuel consumption)
MPa 24.0 - 25.5 20.2 24.0 - 25.5 20.2
Fuel injection pressure Nozzle tester (2061
kg/cm? {245 - 260) (2061 I245 - 260)
Fuel injection timing B.T.D.C. degree 12- 14 12 - 14 12 - 14
Radiator pressure Opening pressure MPa 58.8 - 78.5 58.8 - 78.5 58.8 - 78.5 58.8 - 78.5
valve (Differential pressure) kg/cm? lo.6 - 0.81 (0.6 - 0.8) IO.6 - 0.8) IO.6 - 0.8)
Fan speed At rated engine speed rpm 815 - 865 815 - 865 978 - 1,038 378 - 1,038
Deflects when pushed with mm 8- 12 8- 12

Fan belt tension 8- 12 8- 12
a force of 60 N 16 kg)
6D140-1 SERIES 12-022-27

@
TROUBLESHOOTING
Points to remember when troubleshooting ......... ....................................................................................... 12-025
Method of using troubleshooting chart ...................................................................................................... 12-026
S-l Starting performance is poor (Starting always takes time) .............................................................. 12-030
s-2 Engine does not start

@ Engine does not turn .............................................................................................................. 12-031
@ Engine turns but no exhaust gas comes out (Fuel is not being injected) ..................................... 12-032
@ Exhaust gas comes out but engine does not start (Fuel is being injected) ................................... 12-033
s-3 Engine does not pick up smoothly (Follow-up is poor) .................................................................... 12-034
s-4 Engine stops during operations ..................................................................................................... 12-035
s-5 Engine does not rotate smoothly (hunting) .................................................................................... 12-036
S-6 Engine lacks output (no power) ..................................................................................................... 12-037
s-7 Exhaust gas is black (incomplete combustion) ................................................................................ 12-038
S-8 Oil consumption is excessive (or exhaust gas is blue) ..................................................................... 12-039
s-9 Oil becomes contaminated quickly ................................................................................................ 12-040
S-IO Fuel consumption is excessive ...................................................................................................... 12-041
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 12-042
S-l 2 Oil pressure lamp lights up (drop in oil pressure) ........................................................................... 12-043
S-l 3 Oil level rises ........................................... .................................................................................... 12-044
s-14 Water temperature becomes too high (overheating) ....................................................................... 12-045
S-l 5 Abnormal noise is made .................................... ........................................................................... 12-046
S-16 1 Vibration is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-047
6D140-1 SERIES 12-;23

TESTING AND ADJUSTING TROUBLESHOOTING
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.
When carrying out operations with two or more workers, always use signals, and do not allow any unau-
thorized person near the machine.
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.
Be extremely careful not to touch any hot parts.
Be extremely careful not to get caught in the fan or any other rotating parts.
*fi Wh en 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, adjust-
ing, or troubleshooting.
When using the standard values table for judgement in testing, adjusting, or troubleshooting, it is necessary to
be careful of the following points.
The standard values for the new machines in the standard values table are values given as reference from the
standards for new machines and machines shipped from the factory. They should be used as values for esti-
mating wear during operation or as target values when carrying out repairs.
The failure judgement standard values in the standard value table are values using estimated values based on
the results of various tests and standard values for machines shipped from the factory. Use these values for ref-
erence together with the repair and operation history of the machine when judging failures.
Do not use this standard values table as a standard for judging claims.
12-824 6D140-1 SERIES

POINTS TO REMEMBER WHEN TROUBLESHOOTING
Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs, and ensuring that the
failure does not occur again.
When carrying out troubleshooting, it is of course important to understand the structure and function. But to
carry out the troubleshooting effectively, a quick method is to carry out troubleshooting using the problems
mentioned by the operator as a guide in locating the cause.
4. Confirming failure
1. Do not disassemble the machine simply be- Check the degree of the problem to judge for
cause there is a failure yourself if it is really a failure, or if there is some
If the machine is disassembled immediately just problem in the handling or operation of the ma-
because there is a fuilure: chine.
l Unrelated or unnecessary places are also dis- * When driving the machine and re-enacting
assembled the failure, be sure that the investigation or
. It becomes difficult to locate the cause of the measurement does not make the failure
failure worse.
This means that there is not only a waste of time
and money on replacement parts, oil, and grease, 5. Troubleshooting
but this action will also lose the confidence of the Narrow down the causes of the failure from the
user and operator. results of the questions and checks in the above
For this reason also, it is important to carry out Items 2 - 4, then follow the troubleshooting flow
troubleshooting based on full investigation before chart to locate the failure.
starting and troubleshooting following the correct * Basic procedure for troubleshooting
order. 1) Start from the simple places.
2) Start from the most probable places.
2. Questions to ask the user and operator 3) Investigate related parts also.
1) Are there any problems other than those al-
ready reported? 6. Basic action to remedy cause of failure
2) Did anything unusual happen before the fai- Even if the failure is repaired, if the root cause of
lure occurred? the failure is not repaired, the same failure will oc-
3) Did the failure occur suddenly, or had the cur again.
condition of the machine been poor before To prevent this, it is necessary to investigate why
the failure occurred? the failure occurred, and to remove the root
4) What were the conditions when the failure oc- cause of the failure.
curred?
5) Had any repairs been carried ot before the fai-
lure occurred?
6) Had any similar failure occurred before?
3. Checks before troubleshooting

1) Check the oil level.
2) Check for any external leakage of oil from the
piping and hydraulic equipment.
3) Check the travel of the control levers.
4) Other maintenance items can also be carried
out visually, so carry out any check that is
considered necessary.
6D140-1 SERIES 12-;25

METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three
sections: questions, check items, and troublesh-
ooting. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection
without using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @I + @ in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in @J are
items that can be obtained from the user,
depending on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
proubleshooting]
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].
’2-$26 6D140-1 SERIES

The basic method of using the troubleshooting chart is as

follows.
Items listed for [Questions] and [Check items] that have a
relationship with the Cause items are marked with 0, and
of these, causes that have a high probability are marked
with 0.
Check each of the [Questions] and [Check items] in turn,
and marked the 0 or 0 in the chart for items where the
problem appeared. The vertical column (Causes) that has
the highest number of points is the most probable cause,
so start troubleshooting for that item to make final confir-
mation of the cause.
%l. For [Confirm recent repair history] in the [Ques-
I
tions] Section, ask the user, and mark the Cause
column with A to use as reference for locating
r the
when
cause
making
of the failure.
calculations
However,
to
do
narrow
not
down
use this
the
causes.
%2. Use the A in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference. As a rule, do not
use it when calculating the points for locating the
cause, but it can be included if necessary to deter-
mine the order for troubleshooting.
1 Sl 1 Confirm recent repair history

7%2 Degreeof use Operated for long period A A A
I I I I 1 1 /
6D140-1 SERIES
’ 2:g27
- Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weak-
er], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
12428 6D140-1 SERIES

Five causes
Step 1
Clarify the relationship between the three symptoms

in the [Questions] and [Check items] section and
the five Cause items in the vertical column.
7-r-r
Three symptoms
Step 2
Add up the total of 0 and 0 marks where the hori-

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

relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item marked
0. The Remedy is given as [Clean], so carry out
cleaning, and the exhaust gas color should return
to normal.
6D140-1 SERIES 12-829

TROUBLESHOOTING TABLE
S-l Starting performance is poor (Starting always takes time)
General causes why starting performance is poor
* Defective electrical system
* Insufficient supply of fuel
* Insufficient intake of air
- Improper selection of fuel Legend
(At ambient temperature of -10°C or below, use 0 7 Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
ASTM D975 No. 1, and -10°C or above, use ASTM A : Possible causes due to length of use (used for a long period)
D975 No. 2 diesel fuel.) 0 : Items to confirm the cause.
* Battery charging rate.
A______.
I I
ZO'C I 1.28 I 1.26 I 1.24 I 173 I 199
O’C 1.29 1.27 1.25 1.24 1.23
-10°C I 1.30 I 1.28 I

I
1.26
--
I
I
7 25
..--
I
I
, 34
‘.-’ ,,,“.~,$,Z,Pl~
. The specific gravity should exceed the value for the charging rate
of 70% in the above table.
In cold weather the specific gravity must exceed the value for the
charging rate of 75% in the above table.
Engme 011 mm, be added more frequently
Replacement of flIterr has no, been cawed ou, accordmg ,o
bYhen compressmn pressure 15 measured, it IS found ,o be low

1.1.1 I Tii I I/ I/ I; ; I; I; I,
I
When aw elemen, IB tnspected directly. it IS found to be clogged .
I I I / I I I I
When
fuel filter. straner are mtpected dnrectly. fhey are found 10
0 0
be clogged
I
When feed pump stmmer IS inspected dlrectlv. I, IS found to be clomed I_~ ~,
I I I.1 I I I I I I I I
Heater mountdoes no, become warm ! ! ! ! ! !.! ! ! ! ! ! I !
Voltage IS 26 - 3OV between al,erna,~r ,ermma, B and IYes I I I I I Ial I I I I I I
termmal E va,h engme a, low ldiing NO
Either specific grawy of elecfroly,e or voltage of banery 1s low
Speed of some cylinders does no, change when operating on reduced
cvlmders
When check 16 made “sing delivery method. ,“jec,m ,,mmg 1s found
0
10 be mcorrec,
When con,m rack !I pushed. it 1s found 10 be heavy or does no, refurn
lwhen blind plug a, rear of ,mmp is removed. 11can be seen that l

~lunaer conrrol sleeve does no, move,
When fuel cap IS inspected dlrecdy. it II found 10 be clogged .
e
Remedy %
d
12-830 6D140-1 SERIES

S-2 Engine does not start

0 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
I I
operations”.
. Failure in power train
. Defective electrical system
Legend
0 : Possible causes (judging from Cluestions and check items)
_ : Most probable causes (judging from Questions and Check items)
a : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
Conflrm recent repa1r.histor-f

F Degree of use Operated for long period a a
.g
: Condition of horn when starting Horn does not sound Q 0 0
5 switch is turned ON Horn sound level is low a2
When starting swtch is
turned to START, pinion
moves out. but
1) When terminal B and terminal C of starting switch are connected,
6D140-1 SERIES
’2-831
0 Engine turns but no exhaust gas comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust gas

comes out
* Supply of fuel impossible
- Supply of fuel is extremely small
* Improper selection of fuel (particularly in winter)
Standards for use of fuel
Ambient temperature I
Type offuel -22 _4 14 32
50 68 86 104 122’F
-30 -20 -10 0 10 20 30 40 50°C
Diesel fuel
..I.A..
i....I.l......l
.,.........,.,.,.,....
:AsTM
............D975
..........NO.
......1g
0::
I
Legend
0 : Possible causes (judging from Questions and check items)
G : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
I i , I
Confirm recent repair history
Degree of use Operated for long period A A A
Exhaust gas suddenly stops coming out (when starting again) 0 0 Q
I 1 Replacement of filters has not been carried out accordina to ooeration /
When engine is cranked with starting motor,
Check injection pump directly 1.1 1 1 [ 1 1 I I 1 I

When control rack is pushed, it is found to be heavy, or does not
.
I return
Check feed pump directlv I I I.1 I I I I I I I
When fuel filter, strainer are inspected directly, they are found to be
clogged
loI I I II
When feed pump strainer is inspected directly, it is found to be
clogged I I I
12-832 6D140-1 SERIES

0 Exhaust gas comes out but engine does not

start
(Fuel is being injected)
General causes why exhaust gas comes out but

engine does not start
. Lack of rotating force due to defective electri-
cal system
. Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel
Legend
0 : Possible causes liudaina from Questions and check items)
g) : Most probable c.&& (judging from Questions and Check items)
Starting motor cranks engine slowlv Q
Mud is stuck to fuel tank cap 0
When fuel lever IS placed at FULL position, it does not contact stopper 0
When engine is cranked with starting motor,
1) Linle fuel comes out even when Injection pump Sleeve nut is 0
6D140-1 SERIES 12-833

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

General causes why engine does not pick up smoothly
. Insufficient intake of air
. Improper condition of fuel injection
* Improper fuel used
Legend
; : Most probable causes (judging from Questions and Check items)
Replacement of filters has not been cawed out according to operation
manual
Non-specified fuel is being used I-

:
1 Engine oil must be added more frequently
I Engrne pick-up suddenly became poor
1 Black
High idling speed under no load IS normal, but speed suddenly drops
,L 1:
0
when load is applied
There IS hunting from engine (rotation is irreaular) 0 I 0 0

When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Blow-by gas is excessive
12-834 6D140-1 SERIES

S-4 Engine stops during operations

General causes why engine stops during operations
. Seized parts inside engine
. Overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
. Failure in power train
* If the engine stops because of a failure in
the power train, carry out troubleshooting
for the chassis.
Legend
: Most probable causes (judging from Questions and Check items)
1 Confirm recent repair history
Condition when engine
stopped
6D140-1 SERIES 12-g35

S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly
. Air in fuel system
- Defective governor mechanism
- Defective electric governor machanism (electric
governor type)
* If there is no hunting when the electric governor
rod is disconnected, carry out troubleshooting
for the electrical system.
Legend
Q : Most probable causes (judging from Questions and Check items)
(Occurs at certain speed range 0
Condition of hunting Occurs even when speed is

0 0 u 0
raised
Occurs on slopes Q
Fuel tank is found to be empty 0
Replacement of filters has not been carried out according to
Q 0
operation manual
I clogged
0
I
12-836 6D140-1 SERIES

S-6 Engine lacks output (no power)

General causes why engine lacks output
Insufficient intake of air
Insufficient supply of fuel
improper condition of fuel injection
Improper fuel used
(if non-specified fuel is used, output drops)
Lack of output due to overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
legend
II II I I II I I I I
Confirm recent reDair historv II I I I III1 I II
5 Replacement of filters has not been carried out according to operation

5 ’ ’ ’ ’
manual
Non-specified fuel is being used
Dust indicator is red
Black
IQI
Color of exhaust gas
/
Blue under light load
I I I I I I I I I I
Noise of interference is heard from around turbocharger D
when load is applied

C
%
,”
”
Clawing sound is heard from around cvlinder head I I I I I I I IQI I I I I

High idling speed of engine is low
position, it does not contact stopper
6D140-1 SERIES
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
- Insufficient intake of air
* Improper condition of fuel injection
. Excessive injection of fuel
Color of exhaust gas
When valve clearance is checked directly it is found to be outside

l
standard value
When muffler is removed, exhaust gas color returns to normal l

When control rack is pushed, it is found to be heavy, or does not return l
z c 8 8 z 6 ;; z .: z :
m s x 9 _m
Remedy $ 2 0 0 s L$ g $
aaag$,, $ P
P ” ( Cc nr
12-g38 6D140-1 SERIES

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

* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is excessive
. Abnormal combustion of oil
. External leakage of oil
. Wear of lubrication system
uestions and check items)

rom Questions and Check items)
use (used for a long period)
1 Oil consumption suddenly increased
1 Enqine oil must be added more freouentlv
Engine oil becomes contaminated quickly
Exhaust gas is blue under light load
Area around engine IS dtrty with oil
There is 011 in engine cooling water
When exhaust pipe is removed, inside is found to be dirty with oil
When intake manifold is removed, dust is found inside l

When intake manifold is removed, inside is found to be dirty with oil 0
gyj .* .= .& .: z 8 8 .* .r .r
Remedy z $ y5 g
~ g
m g x
g
“Z~.x~
g c& &,
al D 0
~~uccecc~~,~ebe
6D140-1 SERIES 12-t&39

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
* Clogging of lubrication passage
. improper combustion
. Improper oil used
. Operation under excessive load
Legend
Q : Most probable causes (judging from Questions and Check items)
1 Confirm recent repair history
Amount of blow-by gas
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
with dirty oil, or hose is broken
Excessive play of turbocharger shaft 0 a

When safety valve is directly inspected, spring is found to be catching
.h
or broken
8 : 2
6
Remedy $ 2 : 2 2 -
dU$Z
12-840 6D140-1 SERIES

S-l 0 Fuel consumption is excessive

General causes why fuel consumption is excessive
. Leakage of fuel
. Improper condition of fuel injection
. Excessive injection of fuel
/ I
Legend
: Most probable causes (judging from Ouestions and Check items)
l : Items to confirm the cause.
CondIllon of fuel consumption
In’ection pump test shows that injection amount is excessive
6D140-1 SERIES 12-841

S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
* internal leakage in lubrication system
. Internal leakage in cooling system
Legend
$ : Most probable causes (judging from Questions and Check items)
Pressure-tightness test of oil cooler shows there is leakage
Pressure-tightness test of cylinder head shows there is leakage
Remove cylinder head and check directly
’*-g4* 6D140-1 SERIES

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

General causes why oil pressure lamp lights up
* Leakage, clogging, wear of lubricating system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
* Standards for engine oil selection
Type of oil
I Selection of oil SAE number
to ambient temperature
according
I
-22 -4 14 32 50 68 86 104 122’F
-30 -20 -10 0 10 20 30 40 50°C
Legend
O : Possible causes (judging from Questions and check items)
l : Items to confirm the cause.
I Degree of use Operated for long period lalal I I la/ I I I I I I I

I t:
,” / Replacement of filters has not been carried out according to I 0,
I I I I I I I I I I I I I
: operation manual
56 Caution lamp lights up 0
Non-spectfled fuel has been used 0 0
Lights up at low idling D 0

/
I /I Condition when oil pressure 1 Lights up at low, high idling 1 6,)1icli 0, /
There is catching of relief valve or regulator valve, spring or
6D140-1 SERIES 12-843

S-13 Oil level rises

* If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
* Water in oil (cloudy white)
. Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
Legend
D : Most probable causes (judging from Questions and Check items)
I Confirm recent repair history
12-g44 6D140-1 SERIES

S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes
too high
. Lack of cooling water (deformation, damage of
fan)
* Drop in heat dissipation efficiency
. Defective cooling circulation system
. Rise in oil temperature of power train
* Carry out troubleshooting for chassis.
Legend
Condition of overheatin
Water temperature gauge
1
I Temperature difference between top and bottom radiator tanks is
l
excessive
I
.E
Temperaturedifference between top and bonom radiator tanks is P
0 2
slight 0
,+,3* ‘ills* nnrt ie inenor,~A ,h. Pnll iF fn,,nrl tn hr r,o”nPfi a i
6D140-1 SERIES
’2-845
S-l 5 Abnormal noise is made

* Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
* Abnormality due to defective parts
. Abnormal combustion noise
. Air sucked in from intake system
Legend
8 : Most probable causes (judging from Questions and Check items)
E Condition of abnormal noise

.g Suddenly occutred ” 0 /”
t
Non-specified fuel is being used 0 0
5
Enaine oil must be added more freauentlv Q 1
Leakage of air between turbocharger and head, loose clamp 0
Vibrating noise is heard from around muffler (d
12-p 6D140-1 SERIES

S-l 6 Vibration is excessive

* If there is abnormal noise together with the
vibration, carry out troubleshooting for “Abnor-
mal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)
- Improper alignment
. Abnormal combustion
Legend
: Possible cau e to length of use (used for a long period)
Condition of vibration
1 Remove oil oan and check directlv IO I I I I I I I I I

1 Remove side cover and check directly I I.1 I I I I I I I
Remove head cover and check directly 0
Injection pump test shows that injection amount is incorrect 0
z saq $ .r .r p ;i
Remedy % : z m x g Es
% @ a a
ddgEE==8a
6D140-1 SERIES 12-847

ENGINE
13 DISASSEMBLY AND ASSEMBLY
GENERAL
Disassembly . .. . 13-002
Assembly . . 13-020
TURBOCHARGER
Disassembly ....... ....... . . . 13-048
Assembly . ...... ...... . . . 13-052
EXHAUST BRAKE
Disassembly and Assembly .... . . . . 13-056
* This Chapter deals with procedures both for general disassembly and assembly
putting emphasis on SAGD140-1 engine in case overhaul stand is used.
* When machine serial numbers and/or engine bases are different, or when engine
without after cooler is handled, some of procedures mentioned here may differ in
detailed part, but the essentials of the procedures are the same.
6D140-1 SERIES 13-go1

DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY
5
Corrosion
GENERAL DISASSEMBLY resistor
pressor
suction tube
Tension
pulley ass’y
Setting
SA6D140 engine in Fan pulley
Engine engine over- ass’v
haul stand
10
-Alternator
Kpulley
11
*Diostick 1
guide
*Air corn-
pressor
13-002 6D140-1 SERIES

32
To A
33
Vibration
I damper. - To B
crankshaft
pulley ass’y
To C
t To D
c To F
c To G
To H
To I
To J
6D140-1 SERIES 13-003

34
B 43
*Main idler
gear
C . Injection
pump drive
IIshaft
42
*Oil pump
ass’y
46
Crankshaft
F621201059
13-004 6D140-1 SERIES

Special tools
C 1 795-l 02-2102 1 Spring pusher I 1

D ) 795-100-l 190 1 Piston ring tool I ’
E 1 795-236-1000 1 Liner puller I 1
H 795-502-l 121 Gauge 1
Preparatory work
. Clean off all mud and dirt.
. Drain cooling water and engine oil.
_ : Engine oil: Approx. 30!?

. Prepare a stable engine stand which will prevent the
engine from falling over, then put the engine securely
in the stand.
Engine assembly: Approx. 1420 kg

(The weight of the engine differs according to
the model of machine on which it is mounted.)
1. Air cleaner, muffler

1) Remove hose connecting to turbocharger, then
remove tube and lift off air cleaner (1).
2) Remove connecting bolts (2) of exhaust connector,
remove band (3) and then remove muffler (4).
3) Remove exhaust connector (5).
* When removing the turbocharger connection,
cover the openings to prevent dirt or dust
from entering the turbocharger.
2. Starting motor
Remove mounting bolts (11, then remove starting
motor (2).
6D140-1 SERIES
3. Turbocharger drain tube

Remove turbocharger drain tube (1).
4. Setting engine in engine overhaul stand

1) install adapter A on engine.
2) Sling engine assembly, align the adapter with
engine overhaul stand B, and install engineassembly.
5. Corrosion resistor, air compressor suction tube

I) Remove tubes (11, (2) and (3).
2) Remove corrosion resistor (4).
3) Remove air compressor suction tube (5).
6. Bracket
Remove mounting bolts, then remove brackets (1) and
(2).
13-006 6D140-1 SERIES

7. Connector
1) Remove clamp (l), then remove turbocharger
lubrication tube (2).
2) Remove mounting bolts (3), then remove connector
(4) and electrical intake air heaters (5).
8. Tension pulley assembly

1) Loosen tension pulley assembly mounting nuts
(1).
2) Loosen adjustment bolt (21, move tension pulley
toward inside, then remove V-belts (3).
3) Remove mounting bolts (4). then remove tension
pulley assembly (5).
9. Fan pulley assembly

Remove mounting bolts (11, then remove fan pulley
assembly (2).
P621201017

1) Remove adjustment bolt (I) for belt tension, then
loosen alternator fastening bolt (2) and push down
alternator to remove V-belts (7).
2) Remove plate (3).
3) Remove fastening bolt (2). then remove alternator
(4).
4) Remove mounting bolts (5). then remove pulley (6).
6D146-1 SERIES
11. Dipstick guide, air compressor

1) Remove dipstick guide (I).
2) Remove lubrication tube (2), then remove air
compressor (3).
3) Remove air compressor mounting plate (4).
12. Fuel hose

Remove fuel hoses (5).
13. Turbocharger
Remove mounting bolts (l), then remove turbocharger
(2).
14. Exhaust manifold

Remove mounting bolts (I), then remove exhaust
manifold (2).
* SA6D140 engine for HD326 is employed 6 pieces
type exhaust manifold since engine No. 20626
and up.
15. After-cooler assembly

1) Remove clamps (1).
2) Sling after-cooler assembly (2), remove mounting
bolts (3), then lift off after-cooler assembly.
16. Fuel injection tube

Remove fuel injection tubes (4).
13-008 6D140-1 SERIES

69
GENERAL DISASSEMBLY
DISASSEMBLY AND ASSEMBLY
17. Fuel injection pump assembly

1) Remove lubrication tubes (1) and (2).
2) Remove 2 bolts (6) securing cross coupling (10) and
front laminated coupling (7).
3) Remove 4 mounting bolts (4) of fuel injection pump.
4) Move fuel injection pump assembly (5) to rear, and
remove.
* When doing this, leave flange coupling (9) and
front laminated coupling (7) on the drive shaft.
5) Remove connecting bolts (3) of coupling and drive
shaft, then remove flange coupling (9) and front
laminated coupling (7). P6-21201023
i 621OF30!
______.______
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

Remove fuel filter (1).
20. Oil filter

Remove oil filter (2).
21. Bracket, cover

1) Remove fuel filter bracket (4) together with oil
filler (3).
2) Remove oil filter bracket (5) and cover (6).
60140-I SERIES
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY
22. Oil pan

Remove oil pan (1).
’3-o$9-1 6D140-1 SERIES

GENERAL DISASSEMBLY
DISASSEMBLY AND ASSEMBLY
24. Flywheel
Using eye bolt @ (Dia. = 12 mm, Pitch = 1.75 mm),
sling flywheel (l), then remove.
Flywheel: 55 kg
25. Flywheel housing

Remove mounting bolts (l), sling flywheel housing (2),
then remove.
ez kg Flywheel housing: 42 kg
P62 I
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).
60140-I SERIES
13-010
27. Nozzle holder, inlet connector

1) Remove compressor pipe bracket (1).
2) Loosen locknut (2), then remove inlet connector
(3).
3) Remove mounting bolts (4) and bracket, using

bolt @ (Dia. = 10 mm, Pitch = 1.51, remove nozzle
holder (5).
t Mark each nozzle holder with a number before
removing. Keep the nozzle holders in a safe place
and be careful not to damage them.
* Check that there is a gasket fitted to the tip of
the nozzle holder.
28. Rocker arm

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

Remove push rod (1).
30. Crosshead
Remove crosshead (2).
31. Rocker arm housing

Remove mounting bolts, then remove rocker arm
housing (3).
6D140-1 SERIES 13-$11

J
32. Cylinder head assembly

1) Remove mounting bolts (1). then remove cylinder
head assembly (2).
2) Remove each cylinder head gasket.
. Disassemble cylinder head assembly as follows.

i) Using spring pusher C, compress valve spring
and remove cotter (1).
ii) Remove upper valve seat (2). outer valve spring
(3), inner valve spring (4).
iii) Remove lower valve seat (5).

iv) Lift up cylinder head and remove valves (6).
33. Vibration damper * crankshaft pulley assembly

Remove mounting bolts (I), then remove vibration
damper, crankshaft pulley assembly (2).
34. Front support

Remove front support (3).
13-012 6D140-1 SERIES


1) Remove ring (l), then move tube (2) up.
2) Remove mounting bolts (3), then remove thermostat
housing (4).
P62120fO44
36. Water pump assembly

Remove tube (I), then remove water pump assembly
(2).
t The mounting bolts for the water pump are also
used to tighten the gear case cover.
37. Oil cooler assembly

Remove oil cooler assembly (1).
38. Cam follower

Remove cover, then remove mounting bolts (1) and cam -
follower (2).
* d
Each of twelve mounting bolts (1) 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.
6D140-1 SERIES 13-013

39. Gear case cover

Remove gear case cover (1).
P6212011049
40. Injection pump drive gear

Remove mounting nut (I), then remove injection pump
drive gear (2).
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.
P621201050
42. Oil pump assembly, sub idler gear

1) Remove oil pump assembly (1).
2) Remove sub idler gear (2).
43. Main idler gear, injection pump drive shaft

1) Remove mounting bolt (l), then remove main
idler gear (2).
2) Remove mounting bolts (3), remove thrust plate
(4) and injection pump drive shaft (5).
13-014 6D140-1 SERIES

44. Piston cooling nozzle

Remove mounting bolt (l), then remove piston cooling
nozzle (2).
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. 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 @ before
removing the connecting rod assembly.
4) Remove bolts (I) of connecting rod cap.

5) Tap cap with plastic hammer and remove connect-
ing rod cap (2) together with connectingrod 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.
t 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.
* 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.
6D140-1 SERIES 13-015

iv) Using piston ring tool D, remove piston rings

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

2) Insert bolts (2) in holes in main bearing cap, then
remove main bearing cap while shaking the cap
with the inserted bolts.
13-016 6D140-1 SE RI ES
3) The lower thrust bearings (3) are assembled on both

sides of the No. 7 main bearing cap, so after remov-
ing, mark the position for assembly.
4) Using a wire, remove crankshaft (4).
& kg Crankshaft: 132 kg

* When slinging the crankshaft, be careful not to
let it hit or damage the cylinder block.
* Keep the crankshaft in a safe place, and be
careful not to damage the machined surfaces.
5) Remove upper thrust bearings (5).
6) Remove upper main bearing (6).
* Mark the positions for assembly of the main bearing

caps, main bearings and thrust bearings with tags or
felt pen. Keep in sets according to the cap number.
Keep them in a safe place and be careful not to
damage them.
6D140-1 SERIES
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).
13-018 6D140-1 SERIES

GENERAL ASSEMBLY
.
nlIdler gear
for oil
pump
6
*Oil pump
3ass’v
Camshaft
7
,_,_,
“‘_“’
L I gear Fuel injec-
13-020 6D140-1 SERIES

DISASSEMBLY AND ASSEMBLY GENERAL ASSEMLBY
- To C
- To D
To E
11
C To G
15
Vibration
e To K
31
To L
20 21
To M
To N
\ - To0
6D140-1 SERIES 13-021

35 36
Nt
F621201060
13-022 6D140-1 SERIES

TIGHTENING BOLTS BY THE PLASTIC

RANGE TURNING ANGLE METHOD
Important bolts in the 140 Series engines are
tightened by the plastic range turning angle method.
In this method, special bolts are used. By being
tightened to the load (plastic range) at which they
(plastic range)
begin to be permanently deformed, accurate and
high tightening force can be obtained.
The most common method for tightening bolts is
the torque control method. In this method, how-
B Plastic range turning angle
ever, it is difficult to accurately control the tighten- 5 method
ing force because of the coefficient of friction.
5
The plastic range turning angle method is based on 2
the initial tightening torque and the turning angle.
Elongation exceeding the elastic range results in
Torque method
permanent deformation.
(conventional method)
Bolts to be tightened by the plastic range turning
angle method in the 140 Series engines.
1) Cylinder head mounting bolts
2) Main cap mounting bolts I /
3) Connecting rod cap mounting bolts Elongation of bolt

4) Flywheel mounting bolts. 6 I5OF302- I
In the plastic range turning angle method, the

permanent strain remains in bolts after they are
tightened. Therefore, the number of times that each
bolt can be reused is limited. Observe the following
precautions.
1) After tightening, put one punch mark on the
bolt. Do not reuse any bolt which has 5 or
more punch marks.
2) If a bolt has been tightened in excess of the
specified turning angle, loosen the bolt com-
pletely and retighten it. (In this case, put two
punch marks on the bolt.)
3) The tightening angle should be targeted at the
standard value plus or minus tolerance.
6D140-1 SERIES
,’3-iz2-1
Special tools
Part No. Part Name IQ%

A 1 790-901-1260 1 Adapter -TY
F 795-230-5472 Liner driver 1
G 795-236-1500 Piston holder 1
H 1 795-502-1121 1 Gauge I
I 1 795-125-1210 I Feeler gauge I 1
* Clean all parts, and check for dents, scores or casting

defects. Coat the machined surfaces of all parts with
engine oil before installing. Check that all the oil and
water passages are clear.
Preparatory work
. Install adapter A on cylinder block, set cylinder block
on engine overhaul stand B.
0 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. 60sandpaper. polish portions @ and @

to give a smooth finish. If there is a sharp corner
formed or any burrs on portion 8, remove with a
scraper or sandpaper. Be particularly careful to
finish this surface smoothly to prevent damage to
the O-ring.
0 portion
3) If there is pitting on face @I and it cannot be 6 I5OF304
repaired, replace cylinder block.
4) If there is pitting on face @ or portion @, polish

to give a smooth finish.
5) Inspect counterbore and remove all burrs. Remove

all chips and dirt from face 0. Such dirt will cause
defective sealing of the liner, leakage of water, or
defective protrusion of the liner.
* If there is any damage, corrosion or pitting in
the counterbore, repair it.
’3-o22-2 6D140-1 SERIES

1. Cylinder liner
* Replace the liner O-ring and crevice seal with new
parts just before assembling the liner.
. Method of installing liner O-rings and crevice seal
1) Check the cylinder liner O-ring groove and outside
circumference of the liner to confirm that there is
no rust or pitting.
. If the surface is rough and pitted, it may cause
leakage of water, so replace the liner.
6136F303
2) Coat the mating surface of the cylinder block and

cylinder liner counterbore with silicon-based gas-
Top surface of block
ket sealant (LG-6).
. Use a cloth to wipe off all the dirt or oil from

the cylinder block counterbore and liner flange liner
contact surface.
l Width of gasket sealant (LG-6): 4 2 - 3 mm
l Make an overlap of 6 k 6 mm at the beginning

and end when coating with gasket sealant
LG-6. Position to coat with gasket sealant
(coat the corner of the deck)
62 I OF304
* 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 of the
head within 50 minutes. Overlap: 6 f 6 mm
I I-
62 I OF305
62 I OF306
ti Cylinder liner
Black (Ethylene propylene rubber)
Black (Ethylene propylene rubber)
Orange (Silicon rubber)
6150F303A
6D140-1 SERIES
’3-i23
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 cre-
vice seals with clean SAE 30 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.
$10 mm) to remove the twisting.
5) To prevent the crevice seal from twisting when it Press it to the groove
/
is installed, press it around the whole circum-
*
ference
Assemble
facing down.
so that it fits into the seal groove.
the crevice seal with the chamfered side I$

1
Chamfered side
6136FO29
. Method of inserting cylinder liner

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

hands.
f If the liner does not go in smoothly when you
apply your weight, there is danger that the
O-ring may be damaged, so check the cylinder
block for burrs or flashes.
3) Using tool F, press fit cylinder liner (1) into the cy-
linder block.
’3-z24 6D140-1 SERIES

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: 0.07 - 0.15 mm
* If any gasket sealant is squeezed out from the

mating portion of the cylinder block and cylin-
der liner on to the top of the cylinder block,
wipe it off.
5) In addition, to prevent gasket sealant from being Order for temporary tightening cylinder head
squeezed out from between the block and liner mounting bolts
when the head is tightened, fit a used head gasket
after inserting the liner and tighten the cylinder
Y
0
head temporarily.
6
When tightening, use the tightening torque shown ?
below and the order of tightening shown on the
02
right.
m Temporary tightening torque for cylinder 3

‘00
I
head: 14 - 16 kgm
6) Remove the cylinder head, and wipe off the gasket 62 I OF307
sealant that has been squeezed out from the
\
counterbore. If the grommet is deformed into a heart shape and
covers the water hole, the coolant mav leak.
* If gasket sealant sticks to the grommet in the
9P
head gasket, the grommet will be deformed,
so always carry out Steps 5) and 6) to remove
all the gasket sealant.
Grommet \
Water hole
62 I OF306
6D140-1 SERIES
2) Knock in roll pin so that it protrudes 2.7 - 3.4 mm

from block, then install upper thrust bearings (5).
* Install the thrust bearings with the groove on
the outside.
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.
* Check that there is no dirt or dust stuck to
the rear face of the bearing when installing.
5) Knock in roll pin so that is 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.

* 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) Coat washer and threads of mounting bolts of main

bearing cap with engine oil. Screw in bolts (1) to
fit main bearing cap completely.
13-026 6D140-1 SERIES

@I
8) Tighten mounting bolts (1) 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.
m Mounting bolt of main bearing cap

Unit: kgm
Order Target Range
1 st step 12 11 - 13
2nd step 22 21.5 - 22.5
Mark the bolts and the cap with

Make mark with punch
a felt-tip pen, and turn the bolts
3rd step with following degrees.
90” go”-120”
Mark the bolt and the cap
* Make a punch mark on the bolt head each time

615OF305
hi F621201061
the bolts are used. If there are already five

marks on the bolt head, replace with new
bolts.
9) After tightening bolts, rotate crankshaft and check

that it rotates smoothly.
IO) Measure end play of crankshaft with dial gauge 0.

* End play: 0.14 - 0.315 mm
3. Pison and connecting rod assembly

1). Assemble piston and connecting rod assembly as
follows.
i) Using piston ring tool D, install piston rings
(7) on piston.
P62!201059
6D140-1 SERIES 13-027

* Assemble the rings as shown in the diagram.

* Install the piston rings with the stamped
mark facing up.
+ When fitting the oil ring, remove the Top ring
expander and fit the piston, then fit

the oil ring. When doing this, check that Second ring
the expander is fitted completely inside

the ring groove. Oil ring
F621201062
ii) Set piston and connecting rod.

t 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).
iii) Install snap rings (3) on both sides to secure
piston pin.
iv] Align protrusion of upper main bearing of

connecting rod with notch in connecting rod Cast number
(faces front of e
and install bearing.
* Check that there is no dirt or dust stuck
to the rear face of the bearing when
installing.
2) 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.
Cylinder No. (align on camshaft side)
F621201063
3) 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).
F621201064
13-028 6D140-1 SERIES

4) Using piston holder G, compress piston rings and

push in piston head with wooden bar.
8621201073
5) Align protrusion of lower main bearing with notch

in connecting rod cap and assemble. Align connect-
ing rod cap (2) with mark on connecting rod and
install.
* Check that there is no dirt or dust stuck to the
rear face of the bearing when installing.
* Coat the sliding surface of the connecting rod
cap with engine oil.
6) Coat bolt threads and bolt seat with engine oil

(SAESO). Tighten mounting bolt (1) of connecting
rod as follows.
QBZ Mounting bolt of connecting rod
Unit: kgm
Order I Target I Range
1st step 13 12.5 - 13.5
Mark the bolts and the cap with

a felt-tip pen and turn the bolts
2nd step
1with f;~~wingd~reee~ _ ,200
* Make a punch mark on the bolt head each time

marks on the bolt head, replace with new bolts.
7) After installing piston and connecting rod assembly,
rotate crankshaft and check that it rotatessmoothl;.
There must be no catching or other abnormality.
8) Measure side clearance of connecting rod with

dial gauge 0.
* Side clearance: 0.100 - 0.274 mm
6D140-1 SERIES
’3-:29
4. Piston cooling nozzle

Fit piston cooling nozzle (2) and install mounting bolts
(I).
* Check that the tip of each nozzle is directed at the
center of each piston shaker hole.
5. Main idler gear, fuel injection pump drive shaft

1) Coat fuel injection pump drive shaft (5) with engine
oil and install.
2) Install thrust plate (4), then install mounting bolts
(3).
3) Install shaft (6) to main idler gear (2). then fit

washer (7) on inside.
4) Align “A” mark on crankshaft gear with “A”
mark on main idler gear (2), then tighten mounting
bolts (1).
m Idler mounting bolt:

Engine No.
up to 10368 32.5 + 2.5 kgm
10369 and up 41 .O ? 2.5 kgm
6. Sub idler gear, oil pump assembly

1) Install sub idler gear (2).
2) Fit O-ring and install oil pump assembly (1).
m Sub idler mounting bolt:

Engine No.
up to 10368 32.5 f 2.5 kgm
10369 and up 41 .O + 2.5 kgm
w Oil pump mounting bolt: 11.25 * 1.25 kgm
6D140-1 SERIES
’3-:30
7. Camshaft
Coat camshaft journal surfaces with engine oil. 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: 11.25 ? 1.25 kgm
* 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 - 24O’C
for 30 minutes, then shrink fit the gear.
8. Fuel injection pump drive gear

Fit key to shaft, align “C” mark of main idler gear
with “C” mark of drive gear, then fit drive gear (2)
and tighten nut (1).
w Nut: 17.5 * 2.5 kgm
* Check that the match marks of each drive gear

and idler gear are aligned.
065
6D140-1 SERIES
13if3’
t Measure backlash and end play of each gear using

a dial gauge 0.
* Standard backlash for each gear
Position Range hlm~
A 0.141 - 0.425
6 0.129 - 0.391
c 0.129 - 0.391
D 0.141 - 0.426
E 0.095 - 0.346
F 0.080 - 0.417
G 0.118 - 0.369
H 0.118 - 0.369
* Standard end play for each gear
Position Range (mm)
1 0.14- 0.315
2 0.10 - 0.25
3 0.05 - 0.17
4 0.05 - 0.17
5 0.07 - 0.20
6 0.03 - 0.088
1201066
9. Gear case cover

1) Using push tool (outside diameter: 120 mm),
press fit oil seal (2) to cover.
* Press-fitting interference ‘a’ of oil seal:
2
5.0 +’ mm
0
6 Lip of oil seal (50 - 80% of space):

Grease (G2-LI)
+ When installing the gear case cover, remove the
service meter gear box.
13-032 6D140-1 SERIES

@
When the sheet gasket is in use:

2) The sheet gasket is stuck on the gear case cover
and dried up.
3) Install gear case cover (1).

* When installing the cover, be careful not to
damage the oil seal.
P62 t 20 B049
4) Install service meter gear box.
10. Cam follower

1) Align cam follower (2) with dowel pin, then tighten
mounting bolts (1).
w Mounting bolt: 5.2 t 0.8 kgm

2) Fit O-ring and install cover.
m Mounting bolt: 1 .I 5 + 0.15 kgm

* The mounting bolts for the cam follower are
fitted with lubrication holes, so check that
the holes are clear.
11. Oil cooler assembly

Fit gasket and install oil cooler assembly (1).
* When installing servo valve, confirm the overhang
amount of spring. Fix spring again when
exceeding standard value.
Overhang amount of spring a: 24 mm
12. Water pump assembly

1) Fit O-ring and install water pump assembly (1).
* The mounting bolts of the water pump are
used to tighten the gear case.
2) Fit gasket and install tube (2).
6D140-1 SERIES

1) Fit O-ring to tube (Z), 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 (1).
P62!20(044
14. Front support

install front support (3).
15. Vibration damper, Crankshaft pulley assembly

Install vibration damper, crankshaft pulley assembly
(2), then tighten with mounting bolt (1).
m Mounting bolt: 28.5 f 3.0 kgm
16. Cylinder head assembly

1) Assemble cylinder head assembly as follows.
i) Coat valve stem and inside surface of valve
guide with engine oil, then assemble valve (6).
ii) Raise cylinder head and assemble lower valve
seat (5).
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 (1).
* Tap the valve stem with a plastic hammer
to check that the cotter is completely
fitted in the groove of the valve stem.
13-034 6D140-1 SERIES

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.
3) Install cylinder head assembly (2), then tighten

mounting bolts (1).
&Coat threads of mounting bolts and under

part of bolt head with antifriction compound
(LM-P) or engine oil.
t Tighten the mounting bolts 2 - 3 turns by
hand, then tighten as follows.
w Cylinder head mounting bolt:

Unit: kgm
Tightening order
Mark the bolts and the cylinder

head with a felt-tip pen, and
turn the bolts with following
degrees.
Put a mark on the

and cylinder head
+30°
0
Make mark with punch
I I
F621201067
t Make a punch mark on the bolt head each time

marks on the bolt head, replace with new bolts.
F621201061
6D140-1 SERIES 13-035

@
17. Crosshead
Install crosshead (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.
w Locknut: 6.0 + 0.6 kgm
18. Rocker arm housing

Fit gasket and install rocker arm housing (1).
m Mounting bolt:
(10M bolt) 6.75 f 0.75 kgm
(12M bolt) 11.25 + 1.25 kgm
19. Push rod

Install push rods (1).
* Check that the push rod is properly fitted in the
cam follower.
20. Rocker arm

1) Install rocker arm (3) and tighten with mounting
bolts (2).
* Check that the ball of the adjustment screw is
properly fitted into the socket of the push rod.
w Mounting bolt: 10.0 * 0.5 kgm
2) Install turbocharger lubrication tube bracket (1).
13-036 6D140-1 SERIES

@
21. Adjusting valve clearance

Adjust valve clearance as follows.
* Adjust the clearance between the crosshead and
rocker arm to the following values.
* Valve clearance (When engine is hot or cold.)
Unit: mm
* Crank the engine and follow the firing order to

adjust the valve clearance of each cylinder.
Firing order: 1- 5 - 3 - 6 - 2 - 4
1) Rotate the crankshaft in the normal direction
to align pointer (2) with the 1.6 TOP mark on
vibration damper (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.
w Locknut: 6.0 * 0.6 kgm F621201068

* After tightening the lock nut, check the
clearance again.
6D140-1 SERIES 13-g37

22. Nozzle holder, inlet connector

* Check that there is no dirt or dust inside the nozzle
holder sleeve.
1) Fit O-ring (8). and coat with engine oil.
* Check that there is no damage to the O-ring.
2) Install gasket (7) to nozzle holder.
3) Align nozzle holder (6) with mounting hole of
inlet connector and insert nozzle holder.
4) Insert inlet connector (3) in rocker arm housing
and tighten partially.
5) Fit holder (5), then fit ball washer to mounting
bolt (4) and tighten mounting bolt.
* Install one end of the holder to the rocker F621201069
arm housing, lay on the bolt head and tighten
with the bolt.
6) Tiahten inlet connector (3). then tiahten locknut
(2).
m Holder mounting bolt:
58.8 - 73.5 Nm (6.0 - 7.5 kgm}
Inlet connector:
34.3 - 39.2 Nm (3.5 - 4.0 kgm)
Locknut: 29.4 - 34.3 Nm (3.0 - 3.5 kgm)
7) Install air compressor pipe bracket (1).
23. Rocker arm housing cover, spill pipe, air vent tube
1) Fit O-ring and install rocker arm housing cover (3).
2) Fit gaskets on both sides and install spill pipe (2).
3) Fit gaskets on both sides and install air vent tube
(1).
13-038 6D140-1 SERIES

@
24. Flywheel housing

1) Using push tool (outside diameter: 180 mm), press
fit oil seal (3) on housing.
& Coat lip surface of oil seal (50 - 80% of 3

lip space) with grease (G2-LI).
F621201070
2) Sling flywheel housing (l), coat mounting surface

with gasket sealant, then install on cylinder block
and tighten bolts (2).
* When installing the housing, be careful not to
damage the oil seal.
& Contact surface: Gasket sealant (LG-7)
& Coat the bolt threads and seat face with

engine oil before tightening.
* Tighten the mounting bolts of the flywheel housing

Tightening order
in the order shown in the diagram and to the follow-
ing torques.
m Flywheel housing mounting bolt

Unit: kgm
Order Target Range
1st step 19 15-24
2nd step 28 25 - 31.5
1st step 2nd step
615OF313
3) After installing the flywheel housing, measure the

radial runout face runout and using dial gauge 0.
* Radial runout: Max. 0.30 mm
* Face runout: Max. 0.30 mm
6D140-1 SERIES
25. Flywheel
1) Using eye bolt @ (Dia. = 12 mm, Pitch = 1.75).
sling flywheel (l), install the flywheel to the crank-
shaft, 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.
2) Tighten mounting bolts as follows. 1 Tightening order

m Flywheel mounting bolt
Unit: kgm
Order Target I Range
Mark the bolts and the flywheel
the bolts with following degress.
For construction For marine engine

machine and generator
“YE00l15
Make mark on flywheel
and bolt
* Make a punch mark on the bolt head each time the

bolts are used. If there are already five marks on
the bolt head, replace with new bolts.
3) After installing the flywheel, measure the face

runout and radial runout using dial gauge 0.
* Face runout: Max. 0.30 mm
* Radial runout: Max. 0.30 mm
13-040 6D140-1 SERIES

@
When the under frame is provided:

Flywheel housing side
26. Under frame, suction pipe of under frame
1) Assemble packing (5) to rear face of under frame.
/
F621201071
2) Coat groove on top face of underframe with gasket

sealant.
& Groove of underframe:

Gasket sealant (LG-7)
* Be careful not to get the gasket sealant on the Front
protruding part of the packing.
4-
3) Install under frame (3) to cylinder block and fly-
wheel housing, and tighten mounting bolt partially
at 4 places at front and rear.
* Assemble with wavy end facing front of engine.
t Be careful not to let the packing protrude
from the packing groove or slip out of position.
F621201072
4) Tighten bolts on both cylinder block and flywheel
housing sides.

5) Fit O-ring, then fit suction pipe (2) and install
bracket (1) to the under frame.
When the under frame is not provided:
bracket (1) to the cylinder block.
27. Oil pan

Fit gasket and install oil pan (1).
6D140-1 SE RI ES
28. Bracket, cover

1) Fit O-ring and install cover (6).
2) Fit O-ring and install valve adapter (5).
3) Fit O-ring and install fuel filter bracket (4) together
with fuel filler (3).
29. &I filter assembly

Fit O-ring and install oil filter assembly (2).
30. Fuel filter assembly

Install fuel filter assembly (1).
31. PTO case tube, bracket

1) Fit O-ring and install PTO case (3).
2) install fuel injection pump bracket (2).
m Bracket mounting bolt: 11.7 f. 0.8 kgm
3) Install turbocharger lubrication tube (1).
32. Fuel injection pump assembly

1) Knock key into drive shaft of fuel injection pump.
2) Install 2 coupling bolts (6) of fuel injection pump,
then install flange coupling (9) and front laminated
coupling (7) to engine drive shaft.
* When doing this, do not tighten coupling con-
necting bolts (3).
’3-:42
6D140-‘I SERIES
3) Align coupling key groove with drive shaft key,

push in fuel injection pump assembly (5), align with
pin portion of bracket, and set in position.
4) Tighten 4 mounting bolts (4) of fuel injection pump.
Mounting bolt: 6.7 f 0.8 kgm
5) Tighten connecting bolts (3) of coupling and drive

shaft.
- Coupling connecting bolt: 7.95 * 0.65 kgm
! \
3 621OF309
6) Adjust fuel injection timing as follows.

i) Rotate crankshaft in normal direction and
align pointer (7) with injection timing line on
vibration damper (6).
* When doing this, if the line on the timer
side is not at the front, rotate one more
turn.
ii) Check that line a on injection pump side is

aligned with line b on coupling side.
t If the lines are not aligned, loosen nut
(8) and move the coupling to align the
lines, then tighten the nut to the specified
tightening torque.
w Nut: 6.2 f 0.2 kgm

* After repairing or replacing the fuel injection
pump, or if there is no line, adjust the injec-
tion timing by the delivery valve method.
For details, see 12 TESTING AND ADJUST-
ING FUEL INJECTION TIMING. 0 0
615OF318
7) Fit gaskets on both sides and install lubrication

tubes (2) and (1).
w Joint bolt: 2 f 0.2 kgm
P621201088
6D140-1 SERIES 13-043

0
6D140-1 SERIES
’3-o23-1
35. Exhaust manifold

Fit gasket and install exhaust manifold (2). then tighten
with mounting bolts (1).
t SA6D140 engine for HD325-6 is employed 6 pieces
type exhaust manifold since engine No. 20626
and up.
36. Turbocharger
Fit gasket and tighten turbocharger (2) with mounting
bolts (1).
B Mounting bolt and nut:
. For PC650, HD325, WS23S 5-6kgm

. Except above machines 6.5 - 7.5 kgm
& Coat the threads of the bolts and the seat face,
with antifriction compound (LM-P) before
thightening the bolts.
37. Fuel hose

Fit gaskets on both sides and install fuel hose (5).
38. Dipstick guide, air compressor

1) Fit O-ring and install air compressor mounting
plate (4).
2) Fit O-ring and install air compressor (3), then install
lubrication tube (2).
3) Install dipstick guide (1).

1) Install pulley (6) and tighten with mounting bolt (5).
2) Set alternator (4) on bracket, tighten fastening
bolt (2) partially, then temporarily install plate.
3) Fit V-belts (7) in grooves of pulley and install
adjustment bolt (1) for belt tension.
4) Using bar or pipe, raise alternator. When belt
tension is correct, tighten bolts (2) and (1).
t The belt should deflect about 15 mm when
pushed with a finger pressure of 6 kg at a point
midway between the pulleys.
13-044 6D140-1 SERIES

69
40. Fan pulley assembly

Install fan pulley assembly (2) and tighten with bolts
(I).
P621204Oi7
41. Tension pulley assembly

1) Install tension pulley assembly (5) and tighten
with bolts (4).
2) Fit V-belt (3) in groove of pulley.
3) Screw in adjustment bolt (2) and move tension
pulley to outside. When belt tension is correct,
tighten tension locknut (1).
* The belt should deflect about 8 - 12 mm
when pushed with a finger pressure of 6 kg at
a point midway between the pulleys.
42. Connector
1) Fit gaskets and install electrical intake air heater
(5) and connector (4), then tighten mounting
bolts (3).
2) Install turbocharger lubrication tube (21, then
secure with clamp (1).
43. Bracket
Tighten brackets (2) and (1) with mounting bolts.
6D140-1 SERIES
44. Corrosion resistor, air compressor suction tube

1) Install corrosion resistor assembly (4).
2) Install tubes (31, (2) and (1).
3) Install air compressor suction tube (5).
45. Resetting engine in engine stand

1) Sling engine assembly, remove bolts connecting
adapter A and engine overhaul stand B to disconnect
engine assembly.
2) Set engine assembly on engine stand.
3) Remove adapter.
47. Starting motor

Fit gasket and install starting motor (2) with mounting
bolts (1).
13-046 6D140-1 SERIES

48. Air cleaner, muffler

1) Raise air cleaner (1) and install. Then fit hose
connecting to turbocharger, connect air compressor
suction tube and secure with band.
2) Install exhaust connector (5).
3) Fit gasket and install muffler (4) with mounting
bolts (2), then secure with band (3).
4) For the Komaclone type air cleaner, install pre-

cleaner (6) to air cleaner body (7).
* Tighten until clearance a is 0.
621OF310
Refilling with oil

1) Check that engine drain plug is tightened.
2) Add engine oil through oil filler to the specified
level.
Q Engine oil pan: Approx. 3OQ

+ Check the oil level after mounting the engine
on the machine, and add oil to the specified
level.
6D140-1 SERIES
13if47
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
DISASSEMBLY OF TURBOCHARGER
Before disassembling the turbocharger, clean its outside
surface and apply match marks to ensure that the blower
housing and turbine housing are reassembled in their
original positions.
Replace the entire rotor ass’y, if the dynamic balance

check on the rotor ass’y is impracticable.
Before disassembling the turbocharger assembly, measure

the radial clearance in the following manner and keep the
measurement on record.
1) Depress the front end of the rotor in the radial
direction with a finger.
2) Measure the clearance between the blower impeller
and the housing by using filler gauge 0.
Blower housing
1) Remove the nut and V-band clamp (1).
2) Remove blower housing (2).
* When removing the blower housing, take care
not to damage the blower impeller.
P6’B 6201002
2. Turbine housing
1) Straighten the lock washer, remove mounting’bolts
(3). and then remove lock plate (4).
P6162OJ 003
2) Remove turbine housing (5).

* Take care not to damage the turbine impellers
when removing the turbine housing.
P616203004
13ii4* 6D140-1 SERIES

* Before removing the blower impellers, measure the end

play and the radial play of the rotor ass’y in the following
manner and keep the measurements on record.
1) Measurement of the end play (A play in the axial
direction)
i) Set dial gauge @ in position.
ii) Read the dial gauge indicator when the rotor
ass’y is moved in the axial direction.
2) Measurement of the radial play (A play in the radial

direction)
ass’y is moved in the radial direction.
3. Blower impellers
1) Clamp the end of the turbine rotor in a vice.
* Securely clamp the turbine rotor in the vice SO
as to prevent it from overturning or from falling.

2) Loosen and remove nut (6).
3) Extract the blower impellers from the turbine rotor
in the following manner.
i) Immerse the rotor ass’y in the oil that is heated
at 140 to 160°C for 5 to 20 minutes.
ii) Extract blower impellers (7) from the turbine

rotor.
* When exjracting the blower impeller, take
care not to apply an excessive force to the
impeller.
-.,,
P6’f6201008
6D140-1 SERIES
’3-:49
4. Back plate (Diffuser plate)

1) Straighten the lock washer and remove bolt (8).
2) Remove turbine rotor from the back plate (9).
5. Flinger
1) Pull out flinger (10) from the back plate.
2) Remove seal ring (11) from the flinger.
6. Thrust bearing
Remove thrust bearing (12).
7. Thrust collar
Remove thrust collar (13).
8. Center housing
Remove turbine rotor from the center housing (14).
* Take care not to damage the journal bearing.
9. Journal bearing
Remove journal bearing (15).
P6352Of014
6D146-1 SERIES
13F0
10. Shield
Remove shield (16) from the turbine rotor.
P6162010T5
11. Turbine rotor

Remove two seal rings (18) from turbine rotor (17).
6D140-1 SERIES
’3-$5’
ASSEMBLY OF TURBOCHARGER
l Before assembling parts, wash and clean the parts, allow
them to dry by air blow, and apply engine oil to the
sliding parts.
0 Remove burrs completely from the parts. (Pay attention
to seal ring grooves, in particular.)
* When reassembling the rotor ass’y after the dynamic
balance check has been made, be sure to align all the
match marks stamped on the component parts.
1. Turbine rotor
1) Clamp the end of the turbine rotor in a vice.
* Securely clamp the rotor to prevent it from
P616201016
overturning or from failing.
2) Fit seal rings (18) into turbine rotor (17).
* Apply a coat of engine oil to the side of seal
,,,
rings and install the seal rings in such a way that
the gap of each ring is positioned at 180’ apart
from that of the neighboring ring.
2. Shield
Install shield (16) into the turbine rotor.
P666201015
3. Journal bearing.
Install journal bearing (15).
* Apply sufficient amount of engine oil to the inside,
outside, and both sides of the journal bearing prior
to the installation.
P6162O‘FO14
4. Center housing
Install center housing (14) on the turbine rotor.
* When installing the center housing, take care to
prevent the seal ring from slipping out.
5. Thrust collar
1) Install thrust collar (13).
* Make sure that the thrust collar is free from
foreign matter on both sides, apply engine oil
to both sides of the collar, and install the collar
with the match mark aligning with the mating
mark.
P61620‘8013
2) Drive a dowel pin in the center housing.
6D140-1 SERIES
’3:52
6. Thrust bearing
Install thrust bearing (12) with the dowel pin fitted in
position.
* Before installing the thrust bearing, apply engine oil
to both sides of the oil hole.
7. Flinger
Fit seal ring (11) into flinger (10).
* Apply engine oil to the sides of the seal ring.
8. Back plate (Diffuser plate)

1) Fit an O-ring to the center housing.
* Apply some grease (G2-LI) to the O-ring.
2) Install flinger into the back plate (9).
* Let the gap of the seal ring on the flinger direct
to the oil filler port on the center housing.
3) Install the turbine rotor onto the back plate.
4) Tighten bolts (8) and bend the lock washer.
N Mounting bolt: 3.2 + 0.2 kgm
9. Blower impellers
1) install blower impellers onto the turbine rotor in
the following manner.
i) Immerse blower impellers (7) in the oil that is
heated at 140’ to 1 60°C for 5 to 20 minutes.
ii) Install the blower impellers onto the turbine
rotor, aligning the match mark.
::,
* Apply engine oil to the inner face of the ?
blower impeller and install the impeller :.,
,,
without using an excessive force.
008
2) Tighten nut (6).

* When tightening the nut, take care not to allow
any of match marks to be out of alignment.
w, Nut: 2.9 * 0.3 kgm
6D14.61 SERIES
* Measure the end play and the radial play of the rotor
ass’y in the following manner.
1) Measurement of the end play (A play in the axial
direction)
ass’y is moved in the axial direction.
* Standard value: 0.08 to 0.13 mm
2) Measurement of the radial play (A play in the radial

direction)
ass’y is moved in the radial direction.
* Standard value: 0.25 to 0.43 mm
10. Turbine housing

1) Install the turbine housing (5) into the center
housing and the rotor ass’y.
P6f6201004
2) Install lock plate (4), tighten mounting bolt (3), and

bend the lock washer.
6 Mounting bolt: Antifriction compound

disulfide (LM-P)
P616201003
13:54 6D140-1 SERIES

11. Blower housing

1) Install blower housing (2) aligning it with the center
housing and the rotor ass’y.
* Apply a thin coat of grease (G2-LI) to theflange
section and install it with care not to damage
the blower impeller.
2) Tighten V-band clamp (1).
B Clamp nut: 0.9 +O.l kgm
P61;6201002
* Measure the clearance in the radial direction in

the following manner.
1) Depress the end of the rotor in the radial
direction with a finger.
2) Measure the clearance between the blower
impeller and the housing by using filler
gauge 0.
Standard value: 0.20 mm (Min. clearance)
* After completing the assembly, rotate the rotor

ass’y while depressing it lightly and make sure
P616201001
that the rotor can be rotated smoothly without
binding.
6D140-1 SERIES 13-055

0
EXHAUST BRAKE
1. Disconnect air line from quick release valve. Re-
move bolts holding brake housing to base plate.
Remove cylinder and gate assembly from housing.
2. Remove nuts and bolts holding cylinder shell to

cylinder adapter. Remove cylinder shell.
3. Remove waste gate and brake gasket by pushing

down on base cap assembly and pushing up on
waste gate.
4. Dismantle cylinder parts by holding waste gate

and removing lock nut securing piston. E
’3-:56 6D140-1 SERIES

5. Remove bushing from base cap bore.

6. Thoroughly clean all components with a mild
solvent. Discard any parts which show signs of
damage or wear. All parts in the repair kit must
be used in reassembly.
7. Use arbour press to install bushing in base cap

bore. Insert piston rod and waste gate assembly.
8. Place washers, packing and spring on piston rod.
9. Mount cylinder adapter, spring retainer and small

spring to base cap assembly. If unit has been as-
sembled correctly, piston rod should slide freely.
6D140-1 SERIES
10. Install large spring.
11. Assemble piston, packing cup and seal retainer to

piston rod. Install lock nut and torque to IO/12
ft. Ibs. (14/16 ntn-m) while holding waste gate.
12. Apply a liberal amount of medium consistency

silicone type lubricant (Dow Corning 33 or equi-
valent) to internal sufaces of cylinder and to the
cavity between the packing cup and the seal re-
tainer.
13. Place waste gate seal in waste gate so that ears on

seal match cavities in waste gate. Seal must be on
the same side as breather port in cylinder adapter.
14. Install brake gasket over waste gate.
15. With cylinder’s breather port facing away from

you, mount brake gate to piston rod so that brake
gate is facing waste gate seal.
16. Reassemble cylinder shell to cylinder adapter.
17. Insert cylinder and gate assembly into brake body
with engine side of brake gate facing engine.
18. Measure supply pressure to the brake to verify that
it is at least 85 PSI (587,7 kPa).
19. Tighten all exhaust fasteners and mountings. See
Exhaust Brake Reference Bulletin for torque
specifications. Replace any worn or damaged
mounting components.
20. Road test the reassembled exhaust brake as des-
cribed in the Adjustment, Road Test and Trou-
bleshoting Bulletin.
’3-:58
6D140-1 SERIES
w Exhaust brake tightening torque:

3/8” capscrews: 15/22 ft.-tbs. (30/30 ntn-m)
l/2” capscrew (gate adj.) : 3Oh5 ft.-lbs. (42/47 ntn-m)
5/16” locknut (piston): lo/12 ft.-lbs. (14/16 ntn-m)
l/2” capscrew (gate adj.): 30/35 ft.-lbs. (42/47 ntn-m)
5/16” locknut (piston): lo/12 ft.-lbs. (14/16 ntn-m)
ADJUSTMENT,ROAD TESTING AND TROUBLESHOOTING

WM770 AND WM780 SERIES EXHAUST BRAKE
The adjustment and road test sequence in this bulletin is mandatory after an exhaust brake is installed. Refer to the Exhaust Brake
Reference Bulletin or consult engine manufacturer for specifications on maximum back pressure and engine speed for specific
engine models. Before beginning the adjustment and road test sequence, warm your engine to its normal operating temperature.
l/S” N.P.T.
A. ADJUSTMENT EXHAUST BRAKE

1. Idle Speed: Compare engine’s idle speeds with exhaust TROUBLESHOOTING
brake “applied” and “released”. Idle speed should drop
25.50 RPM’ when the exhaust brake is applied. To de-
crease the drop in idle speed, tighten the adjustment screw.
Loosen the screw to increase the drop in idle speed. COMPLAINT
*May be less for some engine models.
2. Microswitch: CAUTION: NEVER MANUALLY OPER- EXHAUST FUMES IN CA6
ATE THE THROTTLE MICROSWITCH. IF EXHAUST INTERMITTENT OPERATION 1
BRAKE ISAPPLIEDWHILE ENGINE ISBEING FUELED,
DAMAGE MAY RESULT. To check microswitch opera-
tion, manually open the throttle to full fuel position and
release. Microswitch must actuate immediately when the
throttle reaches the idle position. BRAKE SLOW TO OPERATE
3. Leakage: With the exhaust brake “applied” and the en- CAUSE BRAKE WON’TOPERATE 1 / / / /
gine decelerating, check system for leaks. Leakage must
be corrected before road testing brake.
B. ROAD TEST
1. Gage Installation: Remove the pipe plug from brake’s
test port. Install gage kit P/N 117774 so that gage will
be easily visible during road test.
2. Select a slope for the road test where the engine can reach
maximum allowable RPM for extended periods. Change
gears to maintain maximum engine speed during exhaust
braking. The back pressure level indicated on the 117774
gage must not exceed the maximum back pressure speci- PLUGGED CYLINDER VENT ( /XIX] ]
fied by the engine manufacturer. If the pressure level is DAMAGED BRAKE CYLINDER xxx x x x
too high, tighten the gate adjustment screw and repeat DAMAGED CYLINDER SEAL x x
the road test. If pressure level is too low:
WORN SHAFT SEAL X
a. Check system’for leakage.
LEAKY GASKET X X
b. Check brake’s air supply.
C. Check engine’s exhaust valve springsforcorrect loading. BURRED ‘7” BAR 1 1x1 1 1 1
Some engine manufacturers specifyvalvespringrequire- LOOSE MOUNTING BOLTS ( /XIX
ments when exhaust brakes are installed. Refer to PLUGGED QUICK RELEASE VALVE x x xx
Special Engine Manufacturer’s Recommendations in
CARSON IN BRAKE BODY xx x
Reference Bulletin or consult manufacturer.
INCORRECT GATE ADJUSTMENT x x
C. TROUBLESHOOTING
1. First, establish whether it is safe to continue using engine
and/or exhaust brake. If the engine is malfunctioning,
don’t use the exhaust brake until engine problems are
corrected.
2. Investigate simple solutions first, Refer to the chart on
the right for assistance.
6D140-1 SERIES 13-g59

ENGINE
14 MAINTENANCE STANDARD

Turbocharger . . . . . . . . . . . . . . . . . . . 14-002
ENGINE BODY
Cylinder head ................... 14-003
Valve, valve spring and valve guide ..... 14-004
Rocker arm and shaft .............. 14-006
Crosshead and guide ............... 14-007
Cylinder block .................. 14-008
Cylinder liner ................... 14-009
Crankshaft ..................... 14-010
Camshaft ...................... 14-011
Cam follower and push rod .......... 14-012
Connecting rod .................. 14-013
Piston, piston ring and piston pin ...... 14-014
Timing gear .................... 14-016
Flywheel and flywheel housing ........ 14-018
LUBRICATION SYSTEM
Oil pump and main relief valve ........ 14-020
Regulator valve and safety valve ....... 14-022
Oil cooler ...................... 14-022-I
COOLING SYSTEM
Water pump . . . . . . . . . . . . . . . . . . . . 14-023
Thermostat ... .............. . 14-025
6D140-1 SERIES
1420’
MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM

TURBOCHAGER
KTR110
14-002 6D140-1 SERIES

(12)
MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit Replace

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

Standard
size
3 Outside diameter or journal 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
Curvature of wheel shaft Repair limit: 0.010 (Total deflection of indicator)

Standard
size Replace
5 Thickness of thrust bearing Width Groove Width Groove
–0.08 +0.02
5 –0.10 +0 4.86 5.04
Standard
size
Ring
Turbine –0.08
end 2.3 –0.10 2.15
Groove –0.01
2.3 –0.02 2.35
6 Thickness of
seal ring –0.08
Ring 2 1.85
–0.10
Blower –0.03
1 Ring 2 2.05
end –0.04
Groove
2 Ring –0.11
4 –0.12 4.05
Replace
Clearance between blower housing parts
7 Clearance limit: (Min.) 0.20
and impeller related to
bearing
6D140-1 SERIES 14-002-1

(12)
MAINTENANCE STANDARD ENGINE BODY
ENGINE BODY
CYLINDER HEAD
Tightening order of cylinder head mounting bolt
5 6
F621201073A
Unit: mm
Check item Criteria F.t..nedy
Standard Repair limit

Repair by
Distortion of cylinder head
1 grinding or
mounting surface
0 - 0.06 0.09 replace
Engine Standard
Replace
S6D140-1 4.8 - 5.6
nozzle or
cylinder head
2 Protrusion of nozzle
SAGD140-1 4.65 - 5.65
Bolt No. Order Target (kgm) Range fkgm)
1st step 15 14- 16

Tightening torque of cylinder head Tighten in
mounting bolt (Coat the thread sequence as
3 areas with molybdenum disulfide O-8 2nd step 22 21.5 - 22.5
indicated
or engine oil) above.
Retighten with
3rd step 9o” 90” - 1 2o”
0 - 7 6- 7.5
Tightening torque of nozzle holder

4 mounting bolt 6.8 r 0.7 kgm
-
Tightening torque of fuel inlet
5 3.8 r 0.3 kgm
connector
Retighten
Tightening torque of connector 4.0 r 0.5 kgm
6
pipe locknut
Tightening torque of cylinder head

7 cover mounting bolt 0.5 + 0.1 kgm
6D140-1 SERIES
’ 4-:03
MAINTENANCE STANDARD
ENGINE BODY
VALVE, VALVE SPRING AND VALVE GUIDE
I- SEE0091 7
14-004 6D140-1 SERIES

@
Unit: mm
No Check item Criteria Remedy
Valve Standard size Tolerance Repair limit
Intake valve 0 * 0.10 0.70 Replace valve

1 4mount of valve sinking
or valve seat
2 Thickness of valve lip Replace valve
Exhaust valve 2.15 1.75
Valve Standard size Tolerance
Repair or
Intake valve 60 It o”15’
3 Valve seat angle replace valve
and valve seat
Exhaust valve I 45” I * 0’15
-0.045
Intake valve 10
-0.060
Outside diameter of valve stem Replace valve
Exhaust valve
I 10
I -0.075
-0.090
+0.019
Before inserting 10
+0.001
Replace valve
Inside diameter of valve guide
guide
+0.019
After inserting 10
-0.020
4
I Valve Standard clearance Clearance limit
Clearance between valve guide and Intake valve 0.029 - 0.084 0.22 Replace valve
valve stem or valve guide
Exhaust valve 0.065 - 0.100 0.24
Replace valve
5 Protrusion of valve guide Repair
Free length of valve spring
Replace valve
6
spring
Installed load of valve spring
Squarence of valve spring
Note 1: Valve springs marked with %l have a regular pitch.

Note 2: Valve springs marked with %2 have an irregular pitch.
6D140-1 SERIES
’4-:05
ROCKER ARM AND SHAFT
F621201075B
Unit: mm
Standard size Tolerance

Outside diameter of rocker Replace rocker
arm shaft arm shaft
32.0 f 0.0065
Inside diameter of rocker +0.087 Replace rocker

1 32.0
arm bushing +0.035 arm
Standard clearance Clearance limit

Clearance between rocker arm Replace rocker
shaft and rocker arm bushing arm or rocker
0.0285 - 0.0935 0.13 arm shaft
Valve Standard size Tolerance
Valve clearance Intake 0.43 * 0.02

2 Adjust
(When engine is hot or cold)
Exhaust 0.80 r 0.02
Tightening torque of rocker

wm adjustment screw locknut 6.0 + 0.6 kgm
6D140-1 SERIES
CROSSHEAD AND GUIDE
F621201076B
Unit: mm
1 Depth of crosshead stem

I Standard size
I
I
3 +0.3 3.41
0
Replace
+0.06
Inside diameter of crosshead 11 11.17
+0.02
2 I
Outside diameter of crosshead +0.011
11 10.95
guide 0
3 Protrusion of crosshead guide 49.0 * 0.25 - I Repair

I I I I
Tightening torque of crosshead 6 i 0.6 kgm

4
locknut
6D140-1 SERIES 14-007

0
CYLINDER BLOCK
6 8
F621201077
Unit: mm
Standard size Repair limit

Distortion of cylinder head Repair by
1 grinding or
mounting surface
0 - 0.09 0.135 replace

Inside diameter of main bearing Replace main
hole +0.018 bearing cap
127
-9.006
2
Thickness of main bearing 3.5
-Lo10
Replace main
bearing
Roundness of main bearing hole Repair limit: 0.005
Standard size Tolerance Repair limit

Inside diameter of main Replace main
3
I I
bearing i9.038 bearing
120 120.15
-0.006 I I
Repair or
Inside diameter of camshaft i9.030 -
4 69 replace
bushing hole 0
I I I cylinder block
Inside diameter of camshaft +0.040 Replace cam-

5 65 65.15
bushing I I 0 I I shaft bushing
I
Difference of face between cylinder Repair by
6 Repair limit: 0.14
block and front cover reassembling
,-
Order Target (kgm ) Range (kgm)
Tightening torque of main bearing 1st step 12 II- 13

7 cap bolt (Coat thread area with
engine oil) 2nd step 22 21.5 - 22.5
Retighten
-
I 3rd step Retighten with 90” 1 90 - 120°
I
Tightening torque of oil pan
8 mounting bolt and under frame 6.75 i 0.75 kgm
mounting bolt I
14-008 6D140-1 SERIES
a3
CYLINDER LINER
Detail P
F621201078
Unit: mm
NO Check item Criteria Remedy
Replace
Protrusion of cylinder liner Permissible range: 0.07 - 0.15 cylinder liner or
cylinder block
Inside diameter of cylinder liner

+0.04 1
140 140.22
+0.021
Replace
2
cylinder liner
Roundness of cylinder liner Repair limit: 0.08
Cylindricity of cylinder liner Repair limit: 0.08

I I
-
Outside diameter of cylinder
liner (Counter bore)
170.2
3 -o”.lO
Replace
Clearance between cylinder Standard: 0 - 0.163 cylinder liner or
liner and block (Counter bore) cylinder block

Outside diameter of cylinder Replace
liner (Counter bore bottom) +o ,090 cylinder liner
161.2
+0.050
4
Standard interference Interference limit
Replace
Interference.between cylinder liner cylinder liner
and block (Counter bore bottom) or cylinder block
0.02 - 0.12 0.02

Outside diameter of cylinder liner Replace
(O-ring) -0.024 cylinder liner
158
5 -0.049
Replace
Clearance between cylinder
Standard: 0.024 - 0.089 cylinder liner or
liner and block (O-ring)
cylinder block
6D140-1 SERIES
CRANKSHAFT
1 2
F621201079
Unit: mm
Check item Criteria Remedy
Standard size Repair limit Repair by

using over size
1 End play
thrust bearing
0.140- 0.315 0.50 or replace
-
STD 120.00 119.88
0.25 U.S. 119.75 119.63

Outside diameter of main journal
0.50 U.S. 119.50 -0.068
-0.050 119.38 Repair by
using over size
0.75 U.S. 119.25 119.13 bearing
or replace
2
1 .oo U.S. 119.00 118.88

Roundness of main journal
0 - 0.010 0.020

Clearance of main journal Replace main
bearing
0.044 - 0.106 0.27

I I I
STD 90.00 89.88

I
I I I I
Outside diameter of crank pin 0.25 U.S. 89.75 89.63
journal
0.50 U.S. 89.50 -0.050 89.38 Repair by.
-0.068 using under size
bearing or
0.75 U.S. 89.25 89.13 replace
3
1 .oo U.S. 89 .OO 88.88

Roundness of crank pin journal
0 - 0.010 0.020
Standard clearance Clearance limit Replace

Clearance of crank pin journal connecting
0.042 - 0.110 0.24 rod bearing

Straightness of all main journals Repair by
0 - 0.150 0.20 using under size
4 bearing or
I replace
Straightness of two main journals 0 - 0.050 0.10
14-ii10 6D140-1 SERIES

CAMSHAFT
i 1
cIl---4
Section A - A
F621201080
Unit: mm
-

1 End play Replace
thrust plate
0.1 - 0.25 0.36
-
Standard size
Outside diameter of camshaft journal Replace

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

camshaft
4 Cam height I Intake I 55.48 + 0.1 I 55.08
I Exhaust I 55.75 f 0.1 I 55.35
6D140-1 SERIES
’4-:1
’
CAM FOLLOWER AND PUSH ROD
3 1
F621201081
Unit: mm
Standard size Tolerance I Repair limit

Outside diameter of cam
follower shaft
-0.021
22 21.96
1 -0.034
Inside diameter of cam +0.021

22 22.04
follower shaft hole 0
-
+0.05
2 Outside diameter of cam roller 31.7 31.50
i9.02
+0.038
Inside diameter of cam roller 12.7 12.78
+0.013
3 Replace
Outside diameter of cam 12.56
12.63 + 0.006
roller pin
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)
Tightening torque of cam

7 1.15 +‘0.15 kgm
follower housing mounting bolt
14-:12 6D14@1 SERIES

CONNECTING ROD
2 6
fAr==4
F621201082
i Unit: mm
No.
Clearance between bushing at

connecting rod small end
and piston pin
2 connecting rod
Inside diameter of bearing at

3
connecting rod big end
Thickness of connecting rod bearing
Parallelism and twist of

5
connecting rod
Tightening torque of connecting

rod cap mounting bolt
6 (Coat bolt threads and nut
seats with engine oil)
-
-
* Note: The connecting rod bolt can be reused up to a maximum of 5 times. Each time the bolt is re-used,
make a punch mark on the bolt head.
6D140-1 SERIES
PISTON, PISTON RING AND PISTON PIN
Section A-A
F621201083
14-014 6D140-1 SERIES

Unit: mm
-
NI Check item
I Criteria Remedy
-
1 Outside diameter of piston Replace piston

-0.070
140 139.8 1
-0.085
-
No. 1 Measuring point Standard size I Tolerance I
Top ring 2.4 -0.015
-0.035
Replace
Thickness of piston ring
Second ring 2.41 -0.010 piston ring
-0.035
4 Oil ring
I
4
I -0.010
-0.030
I
Judge using groove wear gauge

Replace
Width of piston ring groove piston
2
1 4 Oil ring 4 ( jjq
4 I I
No. Measuring point Standard clearance Clearance limit
2 Top ring
Replace
Clearance between piston Judge using groove wear gauge piston or
ring and ring groove
piston ring
4 Oil ring 0.02 - 0.06 0.14

..a,
2 Top ring 0.42 - 0.57 2.0
Replace pis
Piston ring gap 3 Second ring 0.42 - 0.57 1.5 piston ring or
cylinder liner
4 Oil ring 0.37 - 0.52 1 .o
-
Replace
Outside diameter of piston pin
0 piston pin
52
-0.006
Inside diameter of piston pin

5
hole
Clearance between piston pin

and piston
6D140-1 SERIES
TIMING GEAR
2 --.p-.-
1'
[
\ L-L
./ --\ \
4 3 .5
Section E - E
F621201064
14-g16 6D140-1 SERIES

NO Check item Criteria Remedy

-
Measuring
Gears Standard size Repair limi
Dnint
Crankshaft gear and main

A
idler gear (Large)
10.,4, -0.425 1
Main idler gear (Small) and

B 0.129 - 0.391
injection pump drive gear
Main idler gear (Small) and

C 0.129 - 0.391
camshaft gear
Main idler gear (Large) and

a 0.141 - 0.426
sub idler gear
I I
I I
- Backlash of each gears b

Sub idler gear and oil pump
o.OBo - 0.417 0.6 Replace
drive gear
Sub idler gear and water

C /0.095-0.3461
pump drive gear
Camshaft gear and air

d 0.118 - 0.369
compressor drive gear
Injection pump drive gear

e
and PTO gear (Lower)
10.118-0.369 1
Compressor drive gear

f 0.025 - 0.486
and PTO gear (Upper)
Clearance between main idler

1
aear bushing and shaft
qeplace
xrshing
-
Celarance between sub idler

2
lear bushing and shaft
‘O”,6Rd up 1 50 1 2:;;: 1 +:.055 10.01;.;64 I 0.20
Standard size I Repair limit
3 End play of main idler gear

0.05 - 0.17 0.4
I
qeplace
:hrust bearing
4 End play of sub idler gear 0.05 - 0.17 0.4
I
-
End play of injection pump

5 drive gear 0.07 - 0.20 0.4
I
-
6D140-1 SERIES
14-F7
FLYWHEEL AND FLYWHEEL HOUSING
J
-I
\ Section A - A
I
6 F621201085A
A-l
Unit: mm

I
1 Face runout of flywheel housing Repair limit: 0.2
2 Radial runout of flywheel housing Repair limit: 0.2
- Repair
3 Face runout of flywheel Repair limit: Diameter of measuring points x 0.0005
4 Radial runout of flywheel Repair limit: 0.13
Order I Tightening order 1 Target(km) 1 Ranga (kgttt) 1

Tightening torque of flywheel
housing mounting bolts
izb@0-~0-0
lststep @@+o-~~@ 19.5 15-24
5 (Coat thread areas with
engine oil)
G@-G+@+o
2nd step @+-@-Q+@ 28.0 25- 31.5
Order Target (kgm) Range (kgm) Retighten

I
Tightening torque ot flywheel
mounting bolts
6
(Coat thread areas with
engine oil)
14-018 6D140-1 SERIES

@
MAINTENANCE STANDARD LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PUMP AND MAIN RELIEF VALVE
F621201086
14-020 6D140-1 SERIES

Unit: mm
NO Check item Crieteria Remedy

I
1 Axial clearance of pump gear
- Replace
2 Radial clearance of pump gear
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between drive Shaft Hole
3
shaft and pump body bushing
18 +0.106 +0.173 0.040 -
+0.088 +0.146 0.085
Replace
4
Clearance between driven shaft 18 +0.090 +0.147 0.032 - bushing
and driven gear bushing +0.070 +0.122 0.077
Clearance between driven shaft

5
and body
Clearance between relief valve 16 -0.040 +0.043 0.040 -

6 -0.060 0 0.103
and pump cover
Standard Tolerance Standard Interference

size interference limit
Interference between drive shaft Shaft Hole
7
and oil pump drive gear
+0.106 +0.065 0.023 - -
18
+0.088 io.047 0.059
I
-
8
9
Interference between drive gear
and drive shaft
Interference between drive shaft

+I Replace
bushing and pump cover
10
Interference between driven shaft 21 to.090 +0.035 0.030 - -
bushing and driven gear +0.065 0 0.090
11
Interference between driven shaft 18 +0.090 +0.040 0.030 - -
and pump cover +0.070 +0.022 0.068
Installed Installed Installed

Free length Free length
li Main relief valve spring length load load
Repiace
I I
49.1 32.0 12.9 kg 11.6 kg
I
1: Main relief valve set pressure . Standard: 8.0 i 0.5 kg/cm2 Replace
6D140-1 SERIES 14-02 1

a
REGULATOR VALVE AND SAFETY VALVE
F621201087A F621201088
Unit: mm
No. Check item
~
Clearance between regulator
1
valve and body
+0.15 +0.28 0.07 -
22
+0.12 +0.22 0.16 I
I I I I I
Installed Installed Installed

Free length Free length Replace
Regulator valve spring length load load
2 spring
83 79 1.64 kg 1.54 kg
I I
-
3 Regulator valve set pressure 3.2 + 0.2 kg/cm2
Replace
4 Safety valve sat pressure ?.O + 0.2 kg/cm2
14-g22 6D140-1 SERIES

OIL COOLER
62lOF401
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 check]
position
1 Replace
Valve must fully close when valve is soaked in oil bath for fully open 100°C
Opening/closing of thermostat (116X) and then soaked in oil bath for fully closed 85’C (IIO’C) for 4 to 5
minutes.
t 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: 100°C and 116°C). For the marine
engine only the fully open temperature 100°C is applicable; for other models, either type can be used.
6D140-1 SERIES
’ 4-(%2-1
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
WATER PUMP
S6D140-1 (WA500-1, GD825A-1)
Unit: mm
-
No. Check item Criteria
1 Remedy
Standard Standard
size * interference
1 Interference between impeller and
shaft
15.9
I +0.018
+0.005
I
-0.020
-0.050
0.025 -
0.068
2
Interference between drive gear and
25
+0.015 -0.023 0.025 -
shaft +0.002 -0.053 0.068
I I
Interference between pulley flange +0.015 -0.023 0.025 -
3 25
and shaft +0.002 -0.053 0.068
I I :
4 Clearance between impeller and body Standard clearance: 0.30 - 1.0 (Including end play)
Repair limit
5 Abrasion seal ring in water seal A: 1.5
6D140-1 SERIES
’4-:23
S6D140-1 (WS23-2, D155A, AX-3)

SAGD140-1 (HD325-5)
F621201112
Unit: mm
No. Check item Remedy
Standard
size -1 inZ%Ze
1 Interference between impeller and
shaft
16 -0.082 I -0.120 I 0.025 -
-0.095 -0.150 0.068
Interference between drive gear and +0.015 -0.023 0.025 -

28
shaft +0.002 -0.053 0.068
I I I
Interference between pulley flange +0.015 -0.021 0.023 - Reolace
25
and shaft +0.002 -0.041 0.056
I I I
Clearance between impeller and body Standard clearance: 0.6 - 0.9 (Including end play)
--+-l--A
Repair limit
5 Abrasion seal ring in water seal A: 1.5
’4-:24 6D140-1 SERIES

THERMOSTAT
62 I OF403
Unit: mm

I
Lift of thermostat to fully open
Min. 10 mm (soak in oil bath at 9o’C for 4 to 5 minutes to check)
position I
1 I Reolace
Valve must fully close when valve is soaked in oil bath for fully open (90°C)
Opening/closing of thermostat
and then soaked in oil bath for fully closed (71°C) for 4 to 5 minutes. I
- i
6D140-1 SERIES 14-025

0
CYLINDER HEAD
Grinding cylinder head mounting face ... 1El-001-1
Replacing valve seat insert ......... . 15-002
Replacing crosshead guide ......... . 15-007
Replacing valve guide ............. . 15-008
Grinding valve .................. . 15-009
Pressure test ................... . 15-010
CYLINDER BLOCK
Replacing cam bushing ............ . 15-011
Replacing crankshaft gear.......... . 15-013
Replacing cam gear. .............. . 15-014
Replacing flywheel ring gear ........ . 15-015
Replacing connecting rod small
end bushing ................. . 15-016
6D140-1 SERIES 15301

REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD
GRINDING CYLINDER HEAD MOUNTING FACE
1. Grinding
1) Remove valve seat insert.
For details, see REPLACING VALVE SEAT INSERT.
2) Grind cylinder head to remove deformation or
rust. Do not exceed repair limit of cylinder head
height H; stamp [R] on left side of cylinder head.
Standard dimension for height of cylinder
head H: 105 f 0.05 mm
Repair limit after grinding: 104.65 mm
Amount to remove per grinding:
62 I OF303
0.10 - 0.15 mm
Surface roughness of grinding surface:
Within 6s
Flatness (deformation): Within 0.05 mm
Grinding limit: 0.3 mm
Difference in head height per unit: Within 0.15
3) Press fit one size larger oversize valve seat insert.
For details, see REPLACING VALVE SEAT INSERT.
2. Checking after completion of grinding

Check that sinking of valve is within standard value.
Carry out adjustment and modification if necessary.
* Sinking of valve Standard: 0 f. 0.1 mm
15-oP1 6D140-1 SERIES

REPLACING VALVE SEAT INSERT

Special tools
No. 1 Part No. 1 Part Name latv
A 795-l 00-4800 Puller (valve seat) 1
1 790-l 01-5001 Push tool (KIT) 1
2 790-I 01-5081 - Plate (for intake valve) 1
3 790-I 01-5071 + Plate (for exhaust valve) 1
795-l 00-3003 Seat cutter (KIT) 1
795-l 00-3100 . Body ass’y 1
795-l 00-3200 * Micrometer 1

1
795-l 00-3300 - Gauge 1
795-l 00-3400 - Tool head 1
795-l 00-3601 * Head support 1

I I I
- Cutter (for oversize
2 795-l 00-3710 1
machining)
I I I
3 795-l 00-3720 - Cutter (for 30”) 1
4 1 795-100-3730 1 * Cutter (for 45”) I 1
1. Removal of valve seat insert
A When
out a test
using a grinder
run for
to carry
one minute
out
before
this work,
starting
carry
the op-
eration to check that there is no abnormality.
l If the grindstone has been replaced, carry out
the test run for 3 minutes.
A Check
it to
that
the
there
grinder
is no damage
spindle so that
to the grindstone,
there is play,
fit
and
wear safety glasses when using the grinder.
l When removing with a valve seat puller

1) Install grindstone @ to grinder‘@.
2) Align the groove of the sleeve @ with holder
0, and insert.
* Adjust the position of the grinder with set
screw 0.
15.02 6D140-1 SERIES

3) Adjust the position of the grinder so that the

center of grindstone @ is at the center of seat
insert (l), then tighten the set screw to fix the
grinder in place.
4) Rotate the grindstone and move it slowly until it
contacts insert (1).
5) Press the grindstone lightly against the inside
face of the insert and make a groove around
the whole circumference of the inside face of
the insert.
* Depth of groove: Approx. 1 mm
6162F505
6) Push the three claws (a) of puller head @ of

tool A inwards by hand, and fit into insert (1).
7) Tighten screw @ to push the three claws into
the groove on the inside face of the insert.
* When the claws are completely in contact
with the groove, stop tightening.
8) Insert bridge @ on the outside of the puller
head, set plates @ and 0 on top of the bridge,
and tighten nut 0 to pull out the insert.
6162F506
l When welding a bar to the insert to remove

1) Weld bar (1) (diameter: approx. 10 4) of a
diameter 0.1 - 0.5 mm smaller than the inside
diameter of the insert to insert (2).
* Be careful not to deposit any of the welding
metal on the head itself.
0 E’
2) When the temperature of the weld has dropped
-
to around room temperature, insert a used valve 1
(3) in the opposite direction, and hit the face of
the valve with a small hammer to remove the T
insert. 2
* Be careful not to hit too hard, as any exces- 6127F205
sive shock may cause the weld to break off.
6D140-1 SERIES 1x403

2. Press fitting valve seat insert

l When not grinding and correcting press-fitting sur-
face of valve seat insert
1) Using tools B, and B,, or tools B, and B,, press
. B,, B, Or 4, B,
fit standard valve seat insert (2) with a press.
* Do not use a hammer to press fit.
* Press-fitting force for valve seat insert
Intake side: Approx. 1.5 ton
Exhaust side: Approx. 1.5 ton
615OF431
2) Check the insertion depth (h) of the insert from

the bottom surface of the cylinder head.
Bottom surface of cvlinder head
* Insertion depth (h) of insert’
intake side: 2.2 mm
Exhaust side: 2.4 mm
Insert
615OF432
15go4 6D140-1 SERIES

3. Oversize machining of mounting hole for valve seat

insert
1) Using tools C, and C,, 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.
F6 I64099
l Method of machining insert and mounting hole

Unit: mm
Insert Insert mounting hole

Insert Valve
d h D, D, H
Intake 55.0 ;I;;; 8.8 -8, 55.0 +:.Olg 58.00 f 0.2 11 4.1
S.T.D
1 Exhaust 1 52.0 t@i 1 8.6 -8, 1 52.0 +g”lg 1 55.00 f 0.2 1 11 _;., 1
Intake 55.25 :;;;!j; 8.8 -;., 55.25 +;.org 58.25 + 0.2 11 A.1
0.25 0.S
Exhaust 52.25 $;:;;; 8.6 -;., 52.25 +;.Olg 55.25 f 0.2 11 -1.1
Intake 55.5 $!+;I; 8.92 -;,, 55.5 +g”lg 58.50 f 0.2 11.12 -8,
0.50 OS
Exhaust 52.5 f0.080
+0.070 8.72 -;,, 52 . 5 +0.019
0 55.50 + 0.2 11.12 _;,,
Intake 55.75 $$!$ 9.05 -8, 55.75 +y9 58.75 f 0.2 11.25 _;,,
0.75 0,s I I I
Exhaust 52.75 ;;:;;; 8.85 -;,, 52.75 +g”lg 55.75 + 0.2 11.25 _&
Intake 56.0 $;:$$j 9.18 -;., 56.0 +%O” 59.00 * 0.2 11.38 _&
1 .oo 0.s
Exhaust 53.0 $$$g 8.98 _;., 53.0 +yg 56.00 + 0.2 11.38 _;,,
Insert Insert mounting hole
* Roughness of inside surface: Within 6.3s ’ B&tom

surface of
* Roughness at bottom of mounting hole: Within 12.5s cylinder head
* Concentricity with valve guide inside surface:
615OF434
Within 0.03 mm (TI!?)
6D140-1 SERIES 15-go5

4. Finishing insert seat surface

1) Using tools C,, and C,, and C,, finish the surface
of the insert seat to the dimensions shown in
the diagram below.,
* When selecting a pilot C, to insert into the
valve guide, choose one that gives no clear-
ance.
l Intake valve
Unit: mm
3.3
(Width of finishing surface)
v F6 I64099
6 I 5OF435
l Exhaust valve
(Width of finishing surface)

Pencil marks
(about 20 places)
6 I6OF435
2) Rub the seat surface with compound.

615OF436
Width of finished face of exhaust valve insert and width

of contact with valve
6210-11-1320 (S.T.D) 6210-11-1321 (S.T.D)
Part No. 6210-19-1320 (0.25 0.S) 6210-19-1321 (0.25 OS)
621 O-18-1320 (0.50 0.S) 6210-18-1321 (0.50 0.S)
6210-17-1320 (0.75 0.S) 6210-17-1321 (0.75 0.S)
621 O-l 6-1320 (1 .OO0.S) 621 O-l 6-1321 (1 .OO0.S)
V&ir.$rrf finished A: 47.1 B: 1.5 A: 45.7 B: 2.5
Width of contact
with valve (when c: 1.5 * 0.2 C: 2.5 * 0.2
using master valve)
5. Finish inspection
Unit: mm
l Coat the seat surface of the new valve thinly
with red lead (minimum), insert it in the valve When using master When using master
guide, push lightly against the valve insert valve valve
0 f 0.1 Bottom surface 0 * 0.1 Bottom surface
surface, and rotate 10”. Check the valve insert
of cylinder head of cylinder head
contact surface, and confirm that the contact is
uniform without any breaks.
l Or
Make marks with a pencil on the seat surface of
the new valve as shown in the diagram below,
insert it in the valve guide, push lightly against +a4
the valve insert surface, and rotate lo”. Check +$fl Intake side Exhaust side
that the pencil marks have been erased 615OF437
uniformly around the whole circumference.
15;06 6D140-1 SERIES

REPLACING CROSSHEAD GUIDE

Special tools
No. 1 Part No. I Part Name I CiG

A 795-l 40-6410 Crosshead guide puller 1
B 795-l 30-I 310 Crosshead guide driver 1
1. Removal of crosshead guide

. Using crosshead guide puller A, remove the cross-
head 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 cross-
head guide mount.
615FO19
2. Press fitting crosshead guide

l Using tool B, insert the crosshead guide in the cy-
linder head, and use a copper bar or plastic ham-
mer to press fit until the protrusion is within the
permitted tolerance.
* Protrusion of crosshead guide
Tolerance: 49 + 0.5 mm
6D140-1 SERIES 15-807

REPLACING VALVE GUIDE

Special tools
No. Part No. Part Name o’tv
A 795-l 00-l 520 Valve guide remover 1
B 795-l 30-l 710 Valve guide driver 1
1. Removal of valve guide

l Using valve guide remover A, remove the valve
guide.
2. Press fittng valve guide

1) Press fit the valve guide until the tip of valve
guide driver B contacts the cylinder head.
2) Measure the protrusion of the valve guide and
check that it is within the standard range.
* Valve guide protrusion Tolerance: 23 + 0.2 mm
6D140-1 SERIES
’5-zo8
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 F6164107

. Measure the thickness of the valve head, protrusion
of the valve and the contact of the valve seat face
to check that they are within the standard range.
* Thickness of valve head Intake valve: 2.4 mm
Exhaust valve: 2 mm
* Insertion depth of valve Standard: 0 f 0.1 mm
+ Contact width of valve
Standard Intake valve: 4.33 mm
Exhaust valve: 3.47 mm
6D140-1 SERIES
To9
PRESSURE TEST
l When corrections have been made around the head,
test the pressure as follows.
Special tools
No. 1 Part No. I Part Name Q-Y
790-553-I 600 1 Coolant tester kit I 1

B 1 79A-471-1050 1 Pump assembly I 1
1. Water pressure test

Assemble tool A and tool B, and connect the
hose to flange (1).
Apply water pressure (3.5 - 4.0 kg/cm2) for ap-
prox. 10 minutes, and check that there is no
leakage from around the head.
When carrying out this test, heat the whole cy-
linder head and carry out the test with hot
water (82 - 93°C).
F6164106
2. Air pressure test

1) Connect the compressor hose to flange (1).
2) Put the head in the container of water, apply air
pressure (3.0 - 3.5 kg/cm*) for approx. 30
seconds, and check that there is no leakage in
the water.
* If the above test shows any cracks arond the plate

plugs, replace the cylinder head.
6D140-1 SERIES
15210
REPAIR AND REPLACEMENT OF PARTS CYLINDER BLOCK
REPLACING CAM BUSHING

Special tools
No. Part No. Part Name Q’tv
A 795-213-l 200 Push tool 1
1 1 1 795-213-1250 1 Push bar I 1

1 2 1 795-213-1210 1 Push tool I 1
A 13 I 795-213-1240 I Collar I 1
I 4 I 795-213-1230 I Guide I 1
I 5 I 792-193-9490 I Grip I 1
When replacing the cam bushing, first remove the

blind plug at the rear of the cylinder block.
Removal of No. 1,7 bushings

As shown in the diagram, assemble push tool A,, A3 A2 AI
collar A,, and push bar A, of push tools A, then hit

the push bar to knock bushing (2) out from cylinder
block (1).
2. Removal of No. 2,6 bushings

l Assemble push bar A,, push tool A,, collar A,, and
guide A, 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 A3 A2

. Assemble push bar A,, push tool A,, collar A,, and 4
guide A,, of push tool A, then hit the push bar to
knock bushing (4) out from cylinder block (1). 1
6162F520
6D140-1 SERIES 15-g 1

. After removing the bushing, remove any burrs or

dirt, and clean the mounting hole of the bushing.
* Cam bushing assembly drawing
Oil hole
i 7”
PNotch
6 I27F242
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 block (1)
matches the oil hole of the bushing.
6202FOll
3
2. Press fitting No. 2,6 bushings
bushing until the oil hole of cylinder block (1) 1 c
matches the oil hole of the bushing.
4
6162F522
3. Press fitting No. 1,7 bushings 2

bushing until the oil hole of cylinder block (1)
matches the oil hole of the bushing. 4
1
6202FO18
. Using inside gauge 0, measure the inside diameter

of the bushing.
. Check the clearance between the bushing and shaft,
and if the clearance is not within the specified
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 cam bushing: qi 65 ?fo6
* Clearance of camshaft journal: 0.016 - 0.096 6202FO19
6D140-1 SERIES
15-ti’2
REPLACING CRANKSHAFT GEAR

Special tools
No. Part No. Part Name Q’tv
0 790-I Ol-2800 Bearig puller 1
0 790-I 01-2300 Push puller 1
1. Removal of gear Nut

l Make a scratch in the surface at the root of the
teeth with a grinder, then assemble pullers @ 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.
62 I OF503
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 spec-
ified shrink-fitting temperature.
* Crankshaft gear shrink-fitting temperature: 2Oo’C
Heating time: Min. 30 minutes
4) Put the timing mark on the outside, then use a
hitting tool to press fit until the side face of the
62 I OF504
gear is in close contact with the shaft flange.
t Knock in quickly before the gear becomes
cool.
6D140-1 SERIES
15-813
REPLACING CAM GEAR

1. Removal of gear
Set the camshaft assembly on the press stand, then
push the camshaft to remove the gear.
A When
stand,
setting
be careful
the camshaft
not to get
assembly
caught your
on the
fingers
press
be-
tween the press stand and the gear.
2. Press fitting gear

1) Check the gear mounting surface, key groove,
and flange surface, and if there are any
scratches, correct them with an oilstone.
2) Knock a new key into the key groove of the
shaft.
3) Assemble the thrust plate.
4) Heat the gear for the specified time at the spec-
ified shrink-fitting temperature.
* 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:
t Knock in quickly before the gear becomes
cool.
15814 6D140-1 SERIES

REPLACING FLYWHEEL RING GEAR
A 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

Check the ring gear mounting surface, and if
there are any scratches, correct them with an
oilstone.
Heat the ring gear for the specified time at the
specified shrink-fitting temperature.
Ring gear shrink-fitting temperature: Max. 200°C
Set the chamfered face of the ring gear facing
the flywheel, and press fit until the side face of
the gear is in close contact with the flywheel.
6D140-1 SERIES
‘%Y
REPLACING CONNECTING ROD SMALL BUSHING

Special tools
No. 1 Part No. I Part Name ) cty

,
A 1 795-240-5400 1 Push tool (KIT) 7
1 1 1 795-240-5410 1 Push tool I 1

2 795-240-6420 Push tool 1
B
3 795-240-5430 Block 1
14 1 01530-03912 1 Nut I 1
1. Removal of connecting rod bushing

1) Set the connecting rod to tool B,.
2) Using tool B,, remove the connecting rod bush-
ing with press.
* After removing the bushing, remove any burrs
or flashes, and clean the mounting hole of the
bushing.
62 I OF506
2. Press fitting connecting rod bushing

1) Set connecting rod to tool B,.
2) Assemble connecting rod bushing in tool B,, set
tool B, in position, then secure with tool B, so
that it does not move.
t Align the oil hole of the connecting rod bushing
with the oil hole of the connecting rod.
3) Push tool B, with press, and press fit the con-
necting rod bushing.
l The bushing is supplied as a semi-finished product, so

the inside diameter is too small and the piston pin will
not go in.
After press fitting the bushing, machine the inside
diameter of the bushing with a reamer or honing
machine in accordance with the maintenance
standard.
62 I OF507
* After machining, clean all the metal particles
from the oil hole and oil groove.
6D140-1 SERIES
15-i?6
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

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

CORRECTIVE ACTION:
PFMRl 081696

Sebe62120112 D140 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sebe62120112 D140 1

Uploaded by

Copyright:

Available Formats

SEBE62120112

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

6D140-1 SERIES 00-2-1

Time of Time of Time of Time of Time of

12-006 (6) 12-021-22 (10) 12-022-26 (10) 13-009-1 (7) 13-046

00-2-2 6D140-1 SERIES

Time of Time of Time of Time of Time of

6D140-1 SERIES 00-2-3

Genral view ....................... 01-002

6D140-1 SERIES Ol$Ol

Engine model S6D140-1

Number of cylinder - mm 6 - 140 x 165

Total piston displacement e {cc) 15.24 {I 5,240)

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

Overall length mm 1,552 1,499 1,880

Overall width mm 1,110 1,041 1,060

Overall height mm 1.939 1,740 1,670

Flywheel horsepower kW/rpm 20512,000 228/l ,900 217/2,100

Maximum torque Nm/rpm 1,236/1,400 1,432/1,300 1,226/1,400

High idling speed rpm 2,150 - 2,250 2,100 + 50 2,300 - 2,400

Dry weight kg 1,575 1,550 1,453

Fuel pump Bosch PE-P type

Governor Bosch RSV centrifugal, all speed type

Lubricating oil amount 42 42 40

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

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

Turbocharger Komatsu KTRI 10 Komatsu KTRllO Komatsu KTRI IO

01-003-l 6D140-1 SERIES

HD325-5 (C SPEC.) WS16S-3 WS23-2 GD825A-1 EG300B-5

1,762 1,701 1,700 1,593 1,874

1,179 1,045 1,045 895 957

1,298 1,262 1,262 2,060 1,521

24811,500 (50 Hz)

1,554/l ,400 1,579/l ,400 1,579/1,400 1,255/1,400 -

1,560 max. (50 Hz)

1,350 1,350 1,350 1,360 1,420

Bosch PE-P type Bosch PE-P type Bosch PE-P type

Bosch RFD centrifugal, Bosch RSV centrifugal, Bosch RSUV centrifugal,

125 115 115 78.5 58

24 V, 11 kW 24 V, 7.5 kW 24 V, 7.5 kW 24 V, 7.5 kW 24 V, 7.5 kW

12 V 170 Ah x 2 12 V 170 Ah x 2 12V 200Ahx2 12V 200Ahx2 12V 200Ahx2

6D140-1 SERIES 01-003-2

Engine model S6D140-1

GC380 GS360-2 (Engine

Number of cylinder - mm 6-140x165

Total piston displacement e {cc1 15.24 {I 5,240)

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

Overall length mm 1,874 1,735 1,596

Overall width mm 957 977 880

Overall height mm 1,521 1,248 1,678

241/1,500 (50 Hz)

Maximum torque Nm/rpm - 1,502/1,500 1,432/l ,500

1,560 max. (50 Hz)

Fuel pump Bosch PE-P type

Governor Bosch RSV centrifugal, all speed type

Lubricating oil amount 38 36 38

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

Battery 12V 200Ahx2 12 V 170 Ah x 2 12 V 170 Ah x 2