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14[~~ SM-{Sl6095L-BE2 DIESEL ENGINE
6D95L/S6D95L-1
DIESEL ENGINE
·. · KOMATSU FORKLIFT
'
6095L/S6095L-1
DIESEL ENGINE
ENGINE MODEL APPLICABLE MACHINE MODEL

6095(,-1 F035Z/40Z-4
F035/40/45-4
F033S/35S/40S/45S-4
F035/40/45-5E
F035Z/40Z-5
F035/40/45-5
F050E/60E/70E-5
F050/60/70-5
F050E/60E/70E-6
F050/60/70-6
$023/25-3
S6095L-1 F060H/70H/80H-5
6095L/S6095L-1 00-1
CONTENTS
No. of page
01 GENERAL ............................................................................................................. 01-1
10 INSPECTION AND MAINTENANCE.................................................................. 10-1
20 DISASSEMBLY AND ASSEMBLY ...................................................................... 20-1
30 STRUCTURE AND FUNCTION........................................................................... 30-1
40 TESTING AND ADJUSTING.............................................................................. 40-1
50 INSPECTION STANDARD................................................................................... 50-1
60 REPAIR AND REPLACEMENT............................................................................ 60-1
70 TROUBLESHOOTING.......................................................................................... 70-1
00-2 6095L/S6D95L-1
ENGINE
01 GENERAL
GENERAL VIEW ..................................................... 01-2

SPECIFICATIONS •••••••.••...........••••.•••............•.•..•..• 01-4
ENGINE PERFORMANCE CURVE ..•......••.......••.•••. 01-6
WEIGHTTABLE •••••••••.•...•..•••••••.....•......•....••••........• 01-B
6D95L/S6D95L-1 01-1
GENERAL GENERAL VIEW
GENERAL VIEW
6D95L-1 (with in-line type pump)
6D95L-1 (with distributor type pump)
01-2 6D95LIS6D95L-1
GENERAL GENERAL VIEW
S6D95L-1 (with distributor type pump)
6D95L/S6D95L-1 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
6D95L-1 6D95L-1
Engine model
(with in-line type pump) (with distributor type pump)
FD35Z/40Z-4, FD35/40/45-4 FD35Z/40Z-4, FD35/40/45-4
Applicable machine model FD33S/35S/40S/45S-4
FD33S/35S/40S/45S-4 FD35/40/45-5E, SD23/25-3
Number of cylinder- Bare x Stroke (mm) 6-95x115 6- 95 X 115

Total piston displacement (cm 3) 4,890 4,890
Firing order 1-5-3-6-2-4 1-5-3-6-2-4
Overall length (mm) 986 986

(in) (38.8) (38.8)
"'c:0
·;;; Overall width (mm) 637 637
c:
"E (in) (25.1) (25.1)
i5 Overall height (mm) 809 809
(Excluding exhaust pipe) (in) (31.9) (31.9)
Flywheel horsepower (HP/rpm) 82/2,150 82/2,150

Maximum torque (kgm/rpm) 28/1,500 28/1,500
""c:
(ft • lb/rpm) (203/1 ,500) (203/1 ,500)
"'
E
0 High idling speed (rpm) 2,350 ±50 2,350 ±50
'1:
"
"- Law idling speed (rpm) 700 ± 25 700 ± 25
Minimum fuel consumption ratio (g/HPh) 160 160
Dry weight (kg) 370 360
Fuel pump Basch type PES"A Basch type VE

Governor Basch RSV centrifugal, Mechanical all-speed type
all-speed type
Lubricating oil capacity I21 11 11
[gal (us)] [2.9] [2.9]
Coolant capacity I 2) 7.5 8.5
[gal (us)] [2.0] [2.2]
Alternator 24V, 15A 24V, 15A

Starting motor (Refer to page 30-51) 24 V, 4.5 kW 24 V, 4.5 kW (2.8 kW)
Battery 12V, 70Ahx2 12 V, 70 Ah x 2
Turbocharger - -
Air compressor - -
Others - -
01-4 6D95L/S6D95L-1
GENERAL SPECIFICATIONS
6D95L-1 6D95L-1 6D95L-1 S6D95L-1

(with distributor type pump) (with distributor type pump), (with distributor type pump) (with distributor type pump)
FD35Z/40Z-5 FD50E/60E/70E-5 FD50/60/70-5 FD50/60/70-6 FD60H/70H/80H-5
FD35/40/45-5 FD50E/60E/70E-6
6-95x115 6-95x115 6-95x115 6-95x115

4,890 4,890 4,890 4,890
1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
983 986 986 986

(38.7) (38.8) (38.8) (38.8)
627 586 586 586
(24.7) (23.1) (23.1) (23.1)
875 876 876 876
(34.4) (34.5) (34.5) (34.5)
85/2,150 82/2,150 90/2,250 95/2,250 110/2,000
28/1,500 28/1,500 30/1,500 32/1,500 41.5/1,500
(203/1 ,500) (203/1 ,500) (217/1 ,500) (231/1 ,500) (300/1 ,500)
2,350 ~~~ 2,350 ±50 2,500 ±50 2,500 ±50 2,200 ±50
700 ± 25 700 ± 25 700 ± 25 700 ± 25 700 ± 25
160 160 160 160 160
345 360 360 425
Bosch type VE Bos.ch type VE Bosch type VE Bosch type VE

Mechanical all-speed type Mechanical all-speed type Mechanical all-speed type Mechanical all-speed type
(Bosch PES-A: Option)
13 11 11 12.5
[3.4] [2.9] [2.9] [3.3]
10 16 16 18
[2.6] [4.2] [4.2] [4.8]
24 V, 25 A 24V, 15A 24V, 15A 24V, 15A

24 V, 4.5 kW 24 V, 4.5 kW 24 V, 4.5 kW 24 V, 4.5 kW (2.8 kW)
12 V, 70 Ah x 2 12 V, 70 Ah X 2 12V, 70Ahx2 12 V, 70 Ah x 2
- - - GARRETT31
- - - -
- - - -
6095L/S6D95L-1 01-5
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE

6D95L·1
FD35Z/40Z-4, FD35/40/45·4 · )
( FD33S/35S/40S/45S-4, FD35/40/45-5E 40
FD50E/60E/70E-5, FD50E/60E/70E-6, 5023/25-3
Flywheel horsepower:
Maximum torque:
82 HP/2,150 rpm
28 kgm/1 ,500 rpm
- Tor!ue
\
30
20
E
"'•"'
0
EO
10
Minimum fuel consumption ratio: 160 g/HPh
\ 0 "'
100
90
~
80
I/
;;::
:E.
70
60
,, v
au~
""
c. 50
0 /
40
/
30
20
10
0
BOO 1000 1200140016001800 2000 2200 2400
Engine speed (rpm)
6D95L-1
FD35Z/40Z-5 )
( FD35/40/45-5
40
Flywheel horsepower: 85 HP/2,150 rpm

Tor~ue ao E
g
Maximum torque: 28 kgm/1 ,500 rpm 20 •
0
Minimum fuel consumption ratio: 160 g/HPh 1\ 10 ~
EO
\ 0
100
90
80 I/'
70
v
;;::
:E. 60 ,,q,, v
~
""
c. 50
0 /
40
30
/
20
10
0
BOO 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rpm)
01-6 6D95LIS6095L-1
GENERAL ENGINE PERFORMANCE CURVE
6D95L-1
(FDS0/60/70-5) . .
40
Flywheel horsepower: 90 HP/2,250 rpm Tor~ue
30 E
Maximum torque: 30 kgm/1,500 rpm r- C>
Minimum fuel consumption ratio: 160 g/HPh

/ 1\ 20
'!
•
\ ",-
10 {!.
\ 0
6D95L-1
100
(FD50/60/70·6)
90
Flywheel horsepower: 95 HP/2,250 rpm /
80 /
Maximum torque: 32 kgm/1,500 rpm
~y
Minimum fuel consumption ratio: 160 g/HPh 70 ~,Q
0::
;; 60 /
~
~
~
5 50
/
0
40
/
30 /
20
10
0
800 1000 1200 1400 16001800 2000 2200 2400
Engine speed (rpm)
S6D95L-1
(FD60H/70H/80H-5)
Torqu~
40
Flywheel horsepower: 110 HP/2,000 rpm
/
v 3o E
Maximum torque: 41.5 kgm/1,500 rpm
\ g
Minimum fuel consumption ratio: 160 g/HPh 20
,-~
1 10 ~
100
v 0
/
90
80 so/
70
"/
0::
;; 60
5
~
5
50 I
0
40
j
30
v
20
10
0
BOO 100012001400 16001800 2000 2200 2400
Engine speed (rpm)
6095L/S6095L-1 01•7
GENERAL WEIGHT TABLE
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
Unit: kg (lb)
.
No. Item Components 6D95L-1 S6D95L-1
1 Turbocharger - 7.0 (15.4)
2 Cylinder head assembly Cylinderhead, valve, valve spring 41 (90) 41 (90)
Cylinder block, main bearing cap, 105 (232) 105 (232)

3 Cylinder block assembly cylinder liner
9.8 (22)
4 Timing gear case 9.0(20): FD50(E) - 70(E) 9.0 (20)
5 Oil pan 3.1 (6.8) 3.1 (6.8)
6 Flywheel assembly Flywheel, ring gear 17 (37) 17 (37)
7 Flywheel housing 20 (44) 35 (77)
8 Crankshaft assembly Crankshaft, crankshaft gear 36.5 (80) 36.5 (80)
9 Camshaft assembly Camshaft, camshaft gear thrust plate 8.5 (18.7) 8.5 (18.7)
Piston and connecting rod Piston, piston ring, piston pin,

2.1 (4.6) 2.1 (4.6)
10 assembly connecting rod
11 Oil pump 0.5 (1.1) 0.5 (1.1)
13.5 (30)
(for in-line type pump)
12 Fuel injection pump 5.5 (12.1)
5.5 (12.1)
(for distributor type pump)
13 Water pump 7.3 (16.1) 7.3 (16.1)
7.8 (17.2)
(for 24 V, 25 A type) 4.0 (8.8)
14 Alternator 4.0 (8.8) (24 V, 15 A type)
(for 24 V, 15 A type)
8.5 (18.7)
(for 24 V, 4.5 kW type) 6.8 (15)
15 Starting motor (24 V, 2.8 kW)
6.8 (15)
(for 24 V, 2.8 kW type)
01-8 6D95L/S6D95L-1
ENGINE
XO INSPECTION AND MAINTENANCE
INSPECTION AND MAINTENANCE
1. Proper selection of fuel

and lubricants .......................................... 10- 2
2. Fuel filter ......................................................... 10- 3
3. Fan belt tension ............................................. 10- 3
4. Cylinder head mounting bolt ........................ 1o- 4
5. Valve clearance adjustment .......................... 10- 5
6. Injection timing ............................................... 10- 6
7. Engine compression measuring ................... 10-11
8. Engine oil pressure measuring .................... 1 0-11
6095L/S6D95L-1 10-1
INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE
INSPECTION AND MAINTENANCE

1. PROPER SELECTION OF FUEL AND LUBRICANTS
KIND OF ATMOSPHERIC TEMPERATURE

RESERVOIR 14 32 50 68 B6"F
FLUID
-10 0 10 20 30"C
Engine oil pan
Engine oil
:ik:S#iii*"j((.mi'~~i!~3t!SAE 10 - D ~>~f,iifr·P:lf:Gi~~-o~,,:·,~.,·:; . ~
TORQFLOW
transmission case ' AESW·CDO I
~i:%\":· · -~C< :.XM 1SAE 901. W•?:~?S;q :1"£1&~:
Differential case Gear oil
~SAE 80%7 I
Hydraulic tank ~ngine oil '* <f~::?~tlr,S:liJf.~:&mt:r;~JSAE 10 f;if'~~#'%t'r~''B'HJf;i~;v1ntJ:A:t-··
I
Fuel tank !ff Diesel fuel
Brake fluid reservoir

Brake fluid
Clutch fluid reservoir
Grease . NLGI No.2
Coolant Soft water
*. Do not use diesel fuel mixed with kerosene for the diesel engine.
Figures in parenthesis shows oil refill quantity.
NOTE:
1. SAE numbers give to engine oil should be selected according to atmospheric temperature.
2. As for engine oil used in engine oil pan, use SAE 10W oil when the temperature at the time of engine
start-up is below aoc, even if the atmospheric temperature in daytime is expected to rise to 1aoc or more.
3. If any engine oil of API service class CC is to be used instead of class CD engine oil, the frequency of oil
change must be doubled.
Engine oil
* When adding engine oil, do not let the oil over-
flow from the filler port.
Fuel filter
Always remove the dipstick and add the speci-
fied amount of oil.
For details of the replacement interval for the

oil and oil filter, and details of the method for
checking the oil level, see the Operation & Mainten-
ance Manual.
10-2 6D95US6D95L-1
2. FUEL FILTER
For details of the replacement interval for the
fuel filter, and details of the method for re-
placement for the fuel filter, see the Operation
& Maintenance Manual.
Air bleeding
Loosen plug (1 ), and move knob (2) up and
down until no more bubbles come out.
Then, tighten plug (1 ).
'<;~~;;':~-- Sensor plug
3. FAN BELT TENSION

Check the amount the fan belt deflects when
pushed with a force of 6 kg at a point midway
between the fan pulley and the alternator pul-
ley.
Adjumstment
1) Loosen mounting bolt of alternator pulley
and belt tension adjustment bolt (1 ). .. ~
2) Using a bar, raise alt~rnator and adjust fan I
belt tension. Tighten adjustment bolt (1 ),
then tighten mounting bolt. )
6D95L/S6D95l-1 10-3
4.. CYLINDER HEAD MOUNTING BOLT

~ Cylinder head mounting bolt Tight8ning order of cylinder head mounting bolt
(Coat bolt threads and washers with molybde-
num disulphide)
Front
(@ @@J @(?) ~ @I@J €® @)
Rear
@ @ ® 0 ® ® 18
There are two methods of tightening the head LiD @ ® 0 @ @
bolts. Intake side 6206F401
1) Tightening by plastic turning angle
(See the figure bolt.)
~ Cylinder head mounting bolt
Order Target
Unit: kgm (ft · lb), deg.
Range
·~
~
For tightening by plastic
1st step 7 6-8 turning angle bolts
(51) (43- 58)
2nd step 11 10.5-11.5

(80) (76- 83)
3rd step 90" 90"- 120" Make mark with punch
* The cylinder head mounting bolt may be reused

Make mark on flywheel and bolt
five times. 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.
2) Tightening by torque
(See the figure bolt.) F621201067A F621201061
Unit: kgm (ft · lb)

Order Target Range
-$-~
1st step 8
(58)
7-9
(51- 65) LD
For tightening by torque bolts
12 11 - 13
2nd step (87) (80- 94)
3rd step 15 14.5-15.5

(109) (105-112)
10-4 6D95L/S6D95L-1
5. VALVE CLEARANCE ADJUSTMENT

Warm and cold mm (in)
IN 0.35 (0.0138)
EX 0.50 (0.0197)
1) Rotate the crankshaft in the normal direc-

tion to align pointer (2) on the gear case
cover with the 1.6 TOP mark on crankshaft
pulley 11 ). When the begin to open, No.1
cylinder is in compression T.D.C.
2) When No.1 cylinder is at compression Rocker arm Rocker
T.D.C., adjust the valve marked e. Then ro- adjustment screw arm shaft Valve clearance
tate the crankshaft 360" in the normal direc-
tion, and adjust the valves marked o.
* Valve arrangement chart Push rod
Cylinder No. 1 2 3 4 5 6 t
= Intake valve • • 0 • 0 0
Exhaust valve • 0 • 0 • 0
4.5 ± 0.5 kgm

~Locknut 33 ±4ft. lb
44 ± 5 Nm 6206F404
3) After adjusting No. 1 cylinder at compress-

ion top dead center, it is also possible to
turn the crankshaft 120" each time and ad-
just the _valve clearance of each cylinder ac-
cording to the firing order.
* Firing order: 1 - 5 - 3 - 6 - 2 - 4
* After tightening the locknut, check the clear-
ance again.
6D95L/S6D95L-1 10-5
6. INJECTION TIMING
There are two types of injection pump: the dis-
tributor type and the in-line type. The method
for testing and adjusting is different for each
type.
FOR DISTRIBUTOR TYPE INJECTION PUMP

There are two methods for checking and adjust-
ing 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 "MEASURING DEVICE" method, which
is used when a repaired or replaced injec-
tion pump is installed to the engine.
* Before inspecting and adjusting the fuel

injection timing, bring the No. 1 cylinder
piston to the top dead center (T.D.C.) of the
compression stroke, refer to VALVE CLEAR-
ANCE ADJUSTMENT section.
MATCH MARK ALIGNMENT method
1. Check that line a on the injection pump and

line b on the timing gear case are aligned.
* If the lines are not aligned, loosen nut (7),
move the injection pump to align the lines,
then tighten the bolt.
MEASURING DEVICE method
Adjust so that the camlift ,of .the injection pump

comes to attain the specified value when the No. 1
cylinder is set to compressionT.D.C. ~osition.
1. Set No. 1 cylinder at the. compression T.D.C.
position. Then rotate the cn:mkshaft 25" to 30" in
the reverse direction from the compression
T.D.C. position.
(The plunger of injection pump should be set to
B.D.C. position.)
2. Remove the distributor head bolt from the in-
jection pump.
bolt
10-6 6D95L/S6D95L-1
3. Set the dial gauge to the plunger stroke

measure (ND95095-10173*). and then fit to the
pump.
* Check that the stylus end of plunger stroke
measure contacts the plunger head.
4. Set the dial gauge pointer to 0. In this case, by
rotating the crankshaft clockwise/counterclock-
wise a little, check that the pointer is steady at
0.
5. Rotating the crankshaft in the normal direction. ND95095-10173 *

Take the reading of the dial gauge indication
when the V-groove of crank pulley matches the
pointer. (Compression T.D.C.)
0.97 - 1.03 mm
Standard value
(0.038- 0.041 in)
The gauge reading, ±0.03 mm (0.001 in) is equival-

ent to ±0.5" fuel injection timing.
* The crankshaft should be rotated in the normal

direction (clockwise looking from front) without
fail.
*: Following tools are also available

ND95095-1 0172
ND95095-1 0171
ND95095-1 0170
ND95904-51260
z
* The groove of the crankshaft pulley
which is aligned with the pointer dif-
fers according to the engine model.
Pointer Refer to the value for TESTING AND
Crank pulley
ADJUSTING DATA table in TESTING
AND ADJUSTING chapter.
Detail z Groove Pattern A Pattern B
c BTDC 16" BTDC 10"
D BTDC 14" BTDC B"
E BTDC 12" BTDC 6"
Groove F: Compression T.D.C. position
6D95L/S6D95L-1
6. Adjustment of fuel injection timing

I
A,1·.,)~0 ,~
CD Unless the reading of dial gauge is within
'
the standard value, adjust the fuel injection
timing by rotating the injection pump body.
.. ~,
... Rotate the body to this direction,
® Tighten the pump mounting bolt.
® Remove the plunger stroke measure (STI). if v~:iu·.·.·.·
is ~~~uer
than the st(a~d.
and then fit the distributor head bolt to
there. b
~~(
·~-a
'
··. l\1.
* The copper washer of the distributor head \h\1\\ ~Rotate the body to this dir.ection,
bolt should be replaced with a new one. value is higher than the standard.
® Stamp a match mark. ~I//~
FOR IN-LINE TYPE INJECTION PUMP
\ 1~7
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 in-
stalled 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.
* Before inspecting and adjusting the fuel

injection timing, bring the No. 1 cylinder piston
to the top dead center (T.D.C.) of the com-
pression stroke, refer to VALVE CLEARANCE
ADJUSTMENT section.
MATCH MARK ALIGNMENT method
1. Assemble the injection pump, injection pump

holder, and drive gear.
2. Set the No. 1 cylinder piston to the compress-

ion top dead center.
When aligning the. line on the crankshaft pulley
11T or 1.4T, 1.6T) and the pointer, match mark
C can be seen at the tip of the idler gear tooth.
If line C cannot be seen, rotate the crankshaft
one more turn.
6140F107
(View from flywheel side)
10-8 6D95L/S6D95L-1
3. Remove cover (1) from the injection pump.
4. Install the injection pump to the engine with the

injection pump holder and drive gear as one
unit.
When doing this, insert a pin 1¢4 - 4.5, length:
80 mm) through the hole in portion (a) of the
front gear cover to align the hole in the drive
gear.
5. After installing, check that the pin is straight.

Check that there is no misalignment between
the hole in the injection pump holder and the
mounting hole of the front gear cover, and that
there is no problem inserting the bolt.
6. If the position is misaligned, repeat the proce-

dure again from Step 4.
7. After tightening the bolts, check that the lines

on the injection pump, injection pump holder,
and front plate are aligned.
DELIVERY VALVE method

• Except for injection pumps with a stepped lead
plunger
1. Disconnect fuel injection tube (1 I of No. 1 cylin-

der.
2. Remove delivery valve holder (2).

2
3. Take out spring (3) and delivery valve (4), then
install the delivery valve holder again.
4. Place the fuel control lever at the FULL posi-

tion, then rotate the crankshaft slowly in the
counterclockwise direction while operating the
priming pump, and stop at the point where the
fuel stops flowing from the delivery valve
holder.
6150P210A
6D95L/S6D95L-1
5. Check that pointer (6) is aligned with the injec-

tion timing line on crankshaft pulley (5) at the
point where the fuel stops flowing.
* If it is after the injection timing line: Injection timing lines
·injection. timing is delayed
* If it is before the injection timing line:
5
injection timing is advanced
* · If the result of the inspection shows that the in- 6

jection timing is wrong, adjust the fuel injection
timing as follows.
* After testing and adjusting, do not forget to in- ~op dead center line
stall the spring and delivery valve again.
1) Rotate the No. 1 cylinder 30 - 40" in the

clockwise direction from the TOP position. Injection timing lines
2) Rotate the crankshaft slowly in the counter- 1/--/.'.J---;~RrliE The lowest line of the
three Jines: 12~
clockwise direction and align pointer (6) ac- (for 6D95L-1l
curately with the injection timing line on The center of the 3
lines: 14"
crankshaft pulley (5). (for S6D95L-1)
':~ The injection timing differs according to the

model on which the injection pump is mounted,
3) Loosen nut (7) in the oblong hole of the so refer to the value for TESTING AND AD-
mounting flange of the fuel injection pump, JUSTING DATA table in TESTING AND ADJUST-
or loosen the bolt in the oblong hole ofthe ING chapter.
coupling, then mov~ the pump. flange a
little at a time while. operating the priming
· pump, and stop at the point where the fuel
stops. flowing . from the delivery valve
holder.
4) Tighten the nut in the oblong hole of the

mounting flange of the fuel injection pump
or tighten the bolt in the oblong hole of the
coupling.
*Check the fuel injection timing again to
confirm that the injection timing is cor-
rect.
5) Make match marks.
10-10 6D95L/S6D95L-1
7. ENGINE COMPRESSION MEASURING
A While measuring the compression pressure, .

take care not burn yourself on the exhaust
manifold or muffler, and be careful not to get
caught in any revolving part of the engine.
* Measure the compression pressure while the
engine is warm.
(Oil temperature 40- 60"C)
1. Adjust the valve clearance properly.
2. Remove spill pipe and disconnect fuel injec-
tion tube.
3. Remove wiring of fuel cut-off solenoid
valve.
4. Remove nozzle holder assembly for each
cylinder.
* Remove the nozzle holder assembly by
prying it with the spill pipe mounting
bolt.
* Take care not to let any dirt or foreign
matter get into the cylinder.
5. Install adapter to the nozzle holder mount-
ing section of the cylinder to be measured,
and tighten the adapter to the specified tor-
que.
~ Torque: 4.5 ± 0.5 kgm

(33 ±4ft. Ib)
6. Connect compression gauge to the adapter.

* Most compression leakage can be
prevented by applying a small amount
of oil to the mounting section of the
adapter.
7. Crank the enine with the starting motor,
and read the gauge when the pointer is
stabilized.
8. ENGINE OIL PRESSURE MEASURING
A When measuring the oil pressure, be careful

not to get caught in rotating parts.
A Always remove or install plugs or oil pressure
gauges with the engine stopped.
• Remove oil pressure sensor and install gauge .
Measure the oil pressure while engine is warm.

* (Oil temperature: Min. SO"C)
Start the engine, and measure the oil pressure.
6D95L/S6D95L-1 10-11
ENGINE
ZO DISASSEMBLY AND ASSEMBLY
DISASSEMBLY .....•.•.......••....•• 20- 2

ASSEMBLY . . . . • . . . . • . . • . . . .. . • . • . • . . 20-18
* The work procedure may differ slightly from that given here depending upon the machine in which the
engine is mounted and also the particular stand used, however it is fundamentally the same.
* Use the correct service tools when performing disassembly and assembly.
6095L/S6D95L-1 20-1
DISASSEMBLY AND ASSEMBLY DISASSEMBLY
DISASSEMBLY
6D95L/S6D95L-1
795-102-2102
11
25
23~
f
:~
FD60H/70H/BOH-5(S6D95L-1)
e 6095L-1 (New engine type)
FD35Z/40Z-4
26
SD23/25-3(6D95l-1) ~ FD35/40/45-4
(j FD33S/35S/40S/45S-4
0 FD35/40/45-5E
~ F035Z/40Z-5
FD35/40/45-5
FD35/40/45-4(01d e::
FD35Z/40Z-4 {Old en ine
I type)
F033S/35S/40S/45S-: l~dtyepnel_
gmetype)
FD50E/60E/70E-5
FD50/60/70-5
____] 6206F4 1 1
6D95L/S6D95L-1 20-3
6D95L-1 (New engine type)

FD35Z/40Z-4
FD35/40/45-4
FD33S/35S/40S/45S-4
FD35/40/45-5E
FD35Z/40Z-5
FD35/40/45-5 20
FD50E/60E/70E-5
FDS0/60/70-5
21
Except FD50E/60E/70E
I Piston
nng tool
FD35Z/40Z-4(01d engine type)

F035/40/45-4 (Old engine type)
FD33S/35S/40S/45S-4 {Old engine type)
21
20-4 6D95LIS6D95L-1
DISASSEMBLy AND ASSEMBLV DISASSEMBLV
18
S6095L·1
FD60H/70H/BOH·5
6D95L/S6D95L·1 20-5
With in-line type fuel pump
With distributor type fuel pump
Detail A
20-6 6D95L/S6D95L-1
Special tool
No. Part No. Part name Q'ty
A 790·501-5000 Engine repair stand 1

A1 790-901·1250 Bracket 1
B 795·1 02·21 02 Spring pusher 1
c 795·100·4710 Valve guide remover 1
D 795·240·2801 Flange puller . 1
E 795·1 00·2800 Piston ring tool 1
• Prepartory work
1) Remove all dirt and mud from around the engine.
2) Remove drain plug and drain oil from engine .
•
...:.,.. Engine oil: Approx. 10.5 ~
[2.8 gal Ius)]
3) Prepare a stable stand which will prevent the engine

from falling over, then put the engine securely in
the stand.
~ Engine assembly: Approx. 410 kg (900 lbs)

!The weight of the engine differs according
to the model of machine on which it is
mounted.)
1·. Starting motor

Remove starting motor 11 ).
2. Setting engine onto repair stand·

1) Install bracket A1 to engine assembly 11 ).
2) Install engine assembly 11) onto engine repair
stand A using bracket A1.
6D95L/S6095L-1 20-7
3. Alternator
1I Loosen mounting bolts of adjustment plate 11 ), and
mounting bolt and nut of alternator.
2) Move alternator towards cylinder block, and remove
belt 121.
A Be careful not to catch your fingers or

damage the alternator when moving the
alternator towards the cylinder block.
3) Remove alternator 13).
4. Oil cooler (S6D95L)

Remove oil cooler 11 ).
5. Exhaust manifold
Remove exhaust manifold 11 ).
6. Water pump
Pull out pilot portion, then remove water pump 11 ).
20-8 6D95L/S6D95L·1
7. Fuel filter
1 ) Disconnect hose I1 l between pump and filter at
pump end.
2) Disconnect hose (2) between pump and filter at
pump end.
3) Remove fuel filter (3).
8. Fuel injection pipe

1) Remove clamp (1 ).
2) Remove sleeve nut, then remove fuel injection
pipe (2).
9. Spill tube
Remove spill tube (1 ).
* When removing the nozzle holder, the inserted part
is easier to pull out if the spill tube is removed after
the nozzle holder is removed.
10. Fuel injection pump

1) Remove oil supply tube (1 ).
2) Remove fuel injection pump holder bolt (2).
3) Remove gear and nut (3), then remove fuel injection
pump (4).
* There is one bolt installed from the fuel injec-
tion pump side, so do not forget to remove it.
* To prevent dirt or dust from entering, fit caps
or use tape to cover the oil and fuel inlet and
outlet ports.
6D95L/S6D95L·1 20-9
11. Intake manifold

Remove intake manifold (1).
12. Nozzle holder

1) Remove nozzle holder (1).
* When removing the nozzle holder, clean around
the nozzle holder and fit a blind plug to prevent
dust or dirt from entering.
* Be careful not to damage the tip of the nozzle
holder when removing.
* Mark the nozzle holders with tags showing the
cylinder No. and keep in a safe place. If there
is no abnormality in the nozzle holder, install
in the same position when assembling.
13. Cylinder head cover

Remove cylinder head cover (1).
14. Rocker arm assembly

Remove rocker arm assembly (1).
* When removing the rocker arm, loosen the locknut
and turn the adjustment screw back 2 to 3 turns.
20- 10 6D95L/S6D95L-1
15. Push rods

Remove push rods (1) from cylinder head.
* Mark the push rods with tags to show the places of
installation and keep in a·safe place. If there is no
abnormality in the push rod, install in the same
position when assembling.
16. Cylinder head assembly

1) Remove mounting bolts of cylinder head assembly.
2) Fit lifiting tool in mount on cylinder head, then lift
off cylinder head assembly (1) with crane.
* Lay cardboard on the floor to protect the
bottom face of the cylinder head from damage.
• Disassemble the cylinder head assembly as follows.

i) Using spring pusher 8, compress valve spring,
then remove valve cotter (2).
iii Loosen spring, and remove spring seat (3)

and valve spring (4).
iii) Raise cylinder head and remove valve (5).
* Mark the valves with tags to show the place
iv)
of installation and keep in a safe place.
Using remover C, remove valve guide (6). l
5
6206F301
6095L/S6095L-1 20-11
17. Flywheel
Remove mounting bolts, then remove flywheel (1 ).
A The pilot is short, so the flywheel may come off
suddenly.
18. Flywheel housing

1) Remove flywheel housing (1 ).
2) Remove rear oil seal (2).
19. Vibration damper

Remove vibration damper (1 ).
20. Crankshaft pulley

1) Remove plate (1 ).
2) Set flange puller D in position, then pull out crank-
shaft pulley (2).
* The tapered collar is press fitted, so hit the bolt
portion of the flange puller with a hammer to
remove it.
20-12 6D95L/S6D95L-1
21. Gear case cover

1) Remove gear case cover (1 ).
2) Remove front oil seal (2).
22. Oil pan

Remove oil pan (1 ).
23. Oil pump

Remove oil pump (1 ).
6D95L/S6D95L-1 20-13
24. Idler gear

1) Remove bolts (1 ), then remove plate (2).
2) Remove gear (3).
25. Camshaft assembly (Cam gear shrink-fitted type)

1) Turn over cylinder block, so that cylinder head
mounting face is facing down.
2) Engine No. 10001 - 10036
Remove mounting bolts (1) through casting
hole in gear, then remove thrust plate (2).
Engine No. 10037 and up
Remove mounting bolts (1) through casting
hole in gear.
3) Engine No. 10001 - 10036
Remove camshaft assembly (3).
Engine No. 10037 and up
Remove camshaft assembly (3) together with
thrust plate (2).
* When removing, rotate the camshaft lightly
and be careful not to damage the bushing.
25-1. Camshaft assembly (Cam gear bolted type)

1) Turn over cylinder block so that cylinder head
mounting face is facing down.
2) Remove housing mounting bolts through hole in
cam gear, then remove camshaft assembly.
* Rotate the camshaft lightly to prevent damage
to the bushing when removing.
26. Oil suction pipe

Remove oil suction pipe (1 ).
20-14 6D95L/S6D95L-1
27. Piston, connecting rod assembly

1) Checking connecting rod cap number.
i) Turn over cylinder block, and set with cylinders
horizontal.
iii Check that the number stamped on connecting
rod cap matches cylinder number.
* If there is no number stamped on the
connecting rod cap, stamp a number at the
camshaft end.
21 Removing carbon
Using fine sandpaper, remove carbon at top of
cylinder.
* Be careful not to damage the inside of the
cylinder.
* If necessary, measure the end play of the
connecting rod with a dial gauge before remov-
ing the piston and connecting rod assembly.
31 Connecting rod cap
iI Rotate the crankshaft to set the piston at
bottom dead center.
ii) Remove Tnounting bolts of connecting rod
cap (11.
iii) Tap cap with plastic hammer and remove
connecting rod cap together with bearing.
* Be careful not to damage the thread of
the mounting bolts.
4) Piston, connecting rod assembly

Push a wooden bar or hammer handle through from
oil pan side. Support piston at cylinder head end,
then push bar in further from oil pan side to remove
piston and connecting rod assembly (21.
6206P332
• Disassemble piston and connecting rod assembly

as follows.
il Using pliers CD, remove snap ring (31 on one
side.
ii) Remove piston pin (4), and separate connecting
rod (51 and piston (61.
* If the pin does not come out, soak in hot
water.
iii) Remove snap ring on other side in the same
way.
6D95L/S6D95L-1 20-15
iv) Using piston ring tool E, remove piston ring (7)

from piston.
v) Using push tool ®, remove bushing (8) of

connecting rod.
* Keep the pistons, connecting rods, bearings,
piston rings, piston pins, and bushings in
sets for each cylinder number.
28. Main bearing cap

1) Measuring end play
i) Turn over cylinder block, so that oil pan is
facing up.
ii) Measure end play of crankshaft using dial
gauge CD.
* The end play measurement is necessary for
judging wear of the thrust bearing and
abnormal wear of the crankshaft, so
measure before removing the crankshaft.
2) Remove mounting bolts (1) of main bearing cap.

3) Insert mounting bolt in bolt hole in cap, then
lever cap, or tap with plastic hammer on left and
right and remove main bearing cap (3) together
with lower main bearing (2).
20-16 6D95L/S6D95L-1
* Thrust bearings (4) are assembled on both

sides of cap (3) at the flywheel end, so
after removing, mark to show the place
of installation.
29. Crankshaft
1) Remove crankshaft (1 ).
* Be careful not to hit the crankshaft against
the cylinder block and damage the sliding
surface.
2) Remove upper main bearing (2).

* Mark the main bearing and thrust bearing with
tags to show the place of installation, and
keep in a safe place in sets for each cap number.
30. Tappet
Remove tappet (1 ).
6D95L/S6D95L-1 20-17
DISASSEMBLY AND ASSEMBLY ASSEMBLY
4.5 ± 0.5 kgm

ASSEMBLY Oil 33±4ft·lb ~~
44 ± 5 Nm M~"u,
21 @ ® ~~~0.,~
2.5 ± 0.5 kgm

18±4ft·lb
25 ± 5 Nm I
J
~"I
I
6
~~I
0
w
~~"I
I@
~~0
0
20 Feeler
795-125-1370
gauge
Valve clearance mm (in)

IN EX
0.35 0.5
(0.0138) (0.0197)
Unit: mm (In)
Gaora
Cronkahaft ooar and Idler ooar 11.14-0.28

(0.0055- 11.0110)
,_, Com onor ond Idler gonr 11.15-0.311

(0.0059- 0.0116)
lnjnc1ion pump gear and Idler gnor 0.13-0.34

(0.11051- 0.0134)
,_, Cam !IDDr nnd oil pump gonr

11.13-0.35
(0.0051- 11.0130)
,_, Cam gear and PTO gear o.tJ- o.:m

(0.0051 - 0.01421
PTO Idle goor and I'TO goor 0.13-0.27

(0.0051- 0.111101
G·G Cam guor and PTO goar O.l!i- 0.30

(11.0059- 0.0110)
FD35Z/40Z~4 (Old engine type)

FD35/40/45-4 (Old engine type)
FD33S/35S/40S/45S-4(Did engine type)
___j 6206F411
20-18 6D95LIS6D95L-1
6D95L-1 (New engine type) 3.1 ± 1.1 kgm

FD35Z/40Z-4 22 ± 8 ft·lb
FD35/40/45-4 30±11 Nm
FD33S/35S/40S/45S-4
FD35/40/45-5E
FD35Z/40Z-5
FD35/40/45-5
FD50E/60E/70E-5
FD50/60/70-5
Except FD50E/60E/70E
FD60H/70H/80H-5(S6095l-1)
SD23/25-3(6D95l-1) 10
Push 795-100-1591 L Piston
ring tool
0 Ditfere•nce height
Max. 0.15 mm (0.0059 in)
* 0
11.25 ± 1.25 kgm
81 ±9ft ·lb
5---~ ~ _ Piston 795-213-1800
~holder
110±12Nm ~o$l ~~-L______
End play
0.03- 0.09 mm "'\)"'
(0.0012- 0.0035 in) I
/
* "').)
~~~ ~"6.35 mm
{0.0051 - 0.0138 in) "
3 "\\),1_<'1..<1'"'-
J. ~ mm lin)
f\ ______ Side clearance
Y!l 0.20 - 0.40
! (0.008 - 0.01 6)
4~ Put a mark the front cap
Main bearing cap

}
Unit: kg (lb • fti[Nm]
~~
Order Target Range
11.5 11-12 After tightening, stamp
f(' head.,:~::nch.
1st step {831 {80- 87) mark the tightening time
{1131 [108 1181
2nd step 0 Laosen completely
13.5 3 14
Jrd step (98) (94 -101)
1132] [127- 137}
Connecting rod Unit: kg (lb • fti[Nm]
Order Target Range

4.0 4.0- 4.2
1st step {29) (29- 30)
[39] [39-41[
End play Mark bolt head and cap seat
with felt pen, then tighten to
0.03 - 0.09 mm 2nd step followng angle.
(0.0012 - 0.0035 in)
90'
I 90" -120"
6D95L/S6D95L-1 20-19
LG-7
Run out mm (in)

Face Max. 0.35 (0.01 38)
Aadlal Max. 0.30 (0.01 1 B)

20
4.5 ± 1.5 kgm

LG-7 33 ± 11 ft. lb
44±15Nm
11
12
LG-7
12
LG-1
(Surface) /
Difference in mounting I
Surface/mm (in) ~~
·. tf
'v
Max. 0.15(0.0059) ~
11
i
1.5 ± 0.4 kgm
11±3ft•lb
~
/
~ ----43±7ft·lb
6.0±1.0kgm
59±10Nm
15 ± 4 Nm
Tightening order of cylinder head mounting bolt
00 CDV ®§I 13:® ®)

( @ @:€1
Front Rear
@ @ ® 8 @ I@ @
@ @ ® 0 @ ®
6- . kgm
43- 54ft. lb Intake side
59-74Nm
• Tightening by torque
Unit: kgm(lb · ft)(Nm]
Order Target Range
Dial gauge 1st step 8 (58) 7 - 9 (51 - 65) [69- 88]
2nd step 12 (87) 11- 13(80- 94) [108- 127]
3rd step 15(109) 14.5- 15.5 (105- 112) [142- 152]
• Tightening by plastic turning angle Unit· kgm(lb. ft)[Nm]
Order Target Range
1st step 7 (51) 6-8 (43- 58) [59-78]

2nd step 11 (80) 10.5- 11.5(76- 83) [103- 113]
3rd step 90" so~- 120c
20-20 6D95L/S6D95L-1
DISASSEMBLY AND ASSEMBLy ASSEMBLY
24
·Sleeve nuts
Nozzle holders 2.3 ± 0.2 kgm
4.5 ± 0.5 kgm 17 ± 1.5 ft·lb
33 ± 4ft. lb 23 ± 2 Nm
44± 5 Nm
S6095l-1
FD60H/70H/BOH-S 22
Detail A
6D95LIS6D95L-1 20-21
Special tool
No. Part No. Part name Q'ty

A 790-501-5000 Engine repair stand 1
A1 790-901-1250 Bracket 1
B 795-1 02-21 02 Spring pusher 1
E 795·1 00·2800 Piston ring tool 1
F 795-213-1800 Piston holder 1
G 795-1 00-4 720 Pusnto6T 1
(Valve guide)
H 795·1 00-1591 Push tool 1
(Front oil seal)
J 795-100-5201 Push tool 1
(Rear oil seal)
K 795·125·1370 Feeler gauge 1
1. Setting in engine repair stand

1) Install bracket A1 to engine repair stand A.
2) Set cylinder block in engine repair stand A.
2. Tappet
1 I Turn over cylinder block so that cylinder head side
is at bottom.
2) Coat with engine oil and assemble tappet (1 ).
3. Crankshaft
1 I Align protrusion of upper main bearing (21 with
notch in cylinder block, then assemble to cylinder
block.
* Check that there is no dirt or dust stuck to the
rear face of the bearing. Coat the inside face of
the bearing with engine oil (SAE30) before
assembling.
* When the crankshaft gear has been re-
placed, insert the crankshaft gear in an
electric furnace and heat to 230 - 250"C for
at least 30 minutes, then shrink fit the gear.
• :6206P342i
20-22 6D95LIS6D95L-1
2) Install upper thrust bearing.

3) Raise crankshaft (1 ), and assemble to mounting
position.
* Be Careful not to hit the crankshaft against the
cylinder block.
4. Main bearing cap

1) Align protrusion in lower bearing (2) with notch
in cap, then install main bearing cap.
* Check that there is no dirt or dust stuck to the
rear face of the bearing. Coat the inside face of
the bearing with engine oil (SAE30) before
assembling.
2) Check that number stamped on main bearing cap
is the same as number on cylinder block.
3) Align lower thrust bearing (4) with dowel pin, then
install in main bearing cap (3).
* There is one upper thrust bearing but two
lower thrust bearings. Be careful not to mistake
these bearings.
* Install each thrust bearing with the oil groove
(portion "a") on the outside,
4) Set casting number facing front, and install main

bearing cap (3).
* Be careful not to let the thrust bearings slip
out of place.
6D95L/S6D95L-1 20-23
5) Tighten mounting bolts of main bearing cap as

follows.
* Coat the bolt thread and seat face with engine
oil.
* When tightening the mounting bolts of the
main bearing cap, start in the middle and work
to the outside. Tighten to the following torque.
~ Mounting bolt of main bearing cap
Unit: kgm (lb · ft)

Order target Range
1st step 11.5 (83) 11 - 12 (80- 83)
2nd step 0 Loosen completely
3rd step 13.5 (98) 13- 14 (94- 101)
* After tightening the mounting bolts, check

that the crankshaft rotates smoothly.
6) Measuring end play of crankshaft

Put probe of dial gauge CD in contact with end face
of crankshaft. Read movement of gauge when
crankshaft is moved forward and backward.
* Permissible range of end play:
0.13-0.35 mm
(0.0051 - 0.01 38 in)
5. Piston, connecting rod assembly

1) Assemble piston and connecting rod assembly as
follows.
i) Set piston ring with stamped mark at end gap
facing up, then use piston ring tool E to assem-
ble piston rings (7) on piston (6).
* Be careful not to damage the piston or
break the piston rings.
* Fit expander (1 0) in the groove on the
inside diameter of oil ring (9) before
installing. Check that the expander is
completely fitted into the ring groove.
* The end gap of the ring should be at 180°
to the join of the coil in the expander.
6206P345·
20-24 6D95L/S6D95L-1
iii Using pliers (1), assemble snap ring on one side

in snap ring groove of piston.
6206P346
iii) Using push tool ®. press fit bushing (B)

on connecting rod.
iv) Set arrow on head of piston facing in same

direction as casting number on connecting rod.
Insert piston pin (4), and assemble connecting
rod (5) and piston (6).
* If it is difficult to insert the piston pin,
put the piston in hot water to expand the
diameter of the pin hole, then insert
the pin.
v) Assemble other snap ring on other side of
piston.
* After assembling the snap rings, check
that the connecting rod moves smoothly
forward and backward.
vi) Align the protrusion in the upper bearing of
the connecting rod with the notch in the
connecting rod, then install.
6D95L/S6D95L·1 20-25
2) Turn over cylinder block so that crankshaft is

vertical.
3) Set end gaps of piston rings as shown in diagram. Oil ring Size mark (S or Ll
4) Set crankshaft·pin at bottom dead center.
* Coat the inside face of the cylinder, the piston
rings and the surface of the connecting rod -~.
bearing with engine oil. ~ -+-FFiF-"F.il- Over size mark
Second ring
6206F302
5) Align direction of F (Front) mark on side face of

piston to face front of engine. Using piston holder
F, insert piston and connecting rod assembly (2)
from cylinder head end.
6) When piston rings are inserted inside cylinder, push
in head of piston with hand or wooden bar. In
addition, pull big end of connecting rod to align
with crankshaft pin.
7) Align protrusion of lower bearing with notch in
cap, then assemble to bearing cap.
8) Set with stamped mark at camshaft end, then install

connecting rod cap (1).
* Coat the connecting rod bearing with engine
oil.
* Check that the stamped number on the connect·
ing rod cap is the same as the number of the
cylinder.
20-26 6D95LIS6D95L-1
9) Tighten mounting bolts of connecting rod cap as

follows. Put a mark on the bolt cap
* Coat the connecting rod bolt thread and .seat
face with engine oil.
~ Mounting bolt of connecting rod
Unit: kgm (lb · ft) After tightening, stamp

mark the tightening time
Order Target Range on bolt head by punch
1st step
2nd step
4.0 (29) 4.0 - 4.2 (29 - 30)
Mark bolt head and cap seat with felt

pen, then tighten to following angle.
f¥ 6206F303
90° 90°- 120°
* The connecting rod bolts may be reused five

times. Make a punch ma~k on the bolt head
each time the bolts are used. if there are already
five marks on the bolt head, replace with new
bolts.
* After assembling the connecting rods, check
that crankshaft rotates smoothly.
1 0) Measuring side clearance of connecting rod cap.

i) Turn over cylinder block so that oil pan faces
up.
ii) Using dial gauge @,measure side clearance of
connecting rod cap.
* Permissible range of side clearance:
0.20 - 0.40 mm
(0.008 - 0.016 in)
6. Camshaft assembly (Cam gear shrink-fitted type)

1) Insert camshaft assembly (3) into cylinder block.
*
Rotate the camshaft lightly when inserting to
avoid damaging the bushing.
* When inserting the camshaft assembly, insert
thrust plate (2) from the side to install.
2) Tighten mounting bolts (1) of thrust plate through

casting hole of gear to secure camshaft assembly.
~ Mounting bolt of thrust plate:

1.9 ± 0.5 kgm
(14±41b·ft)
6D95L/S6D95L-1 20-27
3) Measuring end play of camshaft

Put probe of dial gauge CD irr contact with end face
of camshaft. Read movement of gauge when cam-
shaft is moved.
0.15-0.35 mm
(0.059- 0.0138 in)
6-1 Camshaft assembly (Bolted type)

1) Insert the camshaft assembly into the cylinder
block.
* Rotate the camshaft lightly when inserting_ it
to prevent damage to the bushing.
2) Using the sleeve inserted in the block as a pilot,
install the housing.
Press fit the gear so that the sleeve, bearing,
and gear are in contact as shown in the diag-
ram. r?"@j&f!lP
3) Insert the mounting bolt through the casting
hole in the gear, and tighten the housing to the 18-20 kgm /End play
block assembly. (Tighten temporarily) 130-145 ft ·lb 0.15-0.35 mm
180- 200 Nm (0.0057 - 0.014 in)
Secure the camshaft assembly.
""'
4) Mesh the cam gear with the PTO gear and idler
gear.
Tighten the cam gear mounting bolts.
~ Mounting bolt: 18- 20 kgm
(130- 145lb. It)
7. Idler gear
1) Align match marks of gear, and install idler gear (3).
* March marks
Crankshaft gear 141 and idler gear: "A"
Idler gear and cam gear (5): "B"
2) Install plate (2).

3) Tighten lock bolt (1) of idler gear shaft.
~ Lock bolt: 11.25 ± 1.25 kgm
(81 ± 9 lb • It)
4) Measuring backlash
Using dial gauge CD. measure backlash of gears.
* Standard backlash
Crankshaft gear and idler gear:
0.14- 0.28 mm
(0.0055 - 0.0110 in)
Idler gear and cam gear:
0.15-0.30 mm
(0.0059 - 0.0118 in)
Measure end play of idler gear in same way as
measuring end play of camshaft.
0.03 - 0.09 mm
(0.0012- 0.0035 in)
20-28 6D95L/S6D95L-1
B. Oil pump
1 I Install driven gear (1 I of oil pump.
2) Install cover (2) and drive gear (3) of oil pump ..
3) Measuring backlash
Measure backlash of oil pump gear in same way as
measuring backlash of idler gear.
* Standard backlash:
Cam gear and ail pump gear:
0.13-0.35 mm
(0.0051 - 0.0138 in)
Measure end play of oil pump gear in same way as
measuring end play of camshaft.
0.02- 0.07 mm
(0.0008 - 0.0028 in)

1) Turn over cylinder block so that cylinder head is
at top.
2) Fit D-ring, align match marks with idler gear, and
install fuel injection pump (1 ).
3) Fit gasket and install oil supply tube.
6D95L/S6D95L-1 20-29
* Measuring backlash of gears

Using dial gauge, measure backlash of each gear.
• Standard backlash
With front PTO (6D95L-1) Without front PTO

(New engine type) FD60H/70H/BOH·5IS6D95l-1)
FD35Z/40Z-4 SD23/25·3 (6095L-1)
FD35/40/45-4
FD33S/35S/40S/45S·4
FD35/40/45·5E
FD35Z/40Z-5
FD35/40/45·5
FD50E/60E/70E·5
FD50/60/70·5
- - - ' 6206F411
With front PTO (6D95L-1)

FD35Z/40ZM4(0ld engine type}
FD35/40/45-4 {Old engine type)
FD33S/35S/40S/45S-4 (Old engine type)
Unit· mm (in)
Position Gears Range
0.14-0.28
A Crankshaft gear and idler gear
10.0055 - 0.011 0)
0.15-0.30
B Cam gear and idler gear
10.0059- 0.011 B)
Injection pump gear and idler 0.13-0.34
c gear 10.0051 - 0.0134)
0.13-0.35
D Cam gear and oil pump gear
10.0051 - 0.013B)
0.13-0.36
E Cam gear and PTO gear
10.0051 - 0.0142)
0.13-0.27
F PTO idle gear and PTO gear
10.0051 - 0.0111
0.15-0,30
G Cam gear and PTO gear
10.0059 - 0.011 B)
20-30 6D95L/S6D95L-1
10. Gear case cover

1) Using push tool H, install front oil seal (1).
2) After press fitting front seal, fill 40- 60% of space

at seal lip with grease.
~ Front seal: Lithium grease
3) Coat mounting surface on cylinder block side with

gasket sealant.
~. Mounting surface: Gasket sealant (LG-7)
4) Install gear case cover assembly (2).
5) Measuring difference in height of mounting surface

Measure distance in height between surface for
mounting oil pan on cylinder block and gear case
cover.
* Permissible difference in height of oil pan
mounting surface: Max. 0.15 mm
(0.0059 in)
11. Flywheel housing

1) Using push tool J (outside diameter: 120 mml.
install rear oil seal (2) on flywheel housing (1).
~ Outside circumference of rear seal;
Gasket sealant ( LG-1)
2) After press fitting rear seal, fill 40- 60% of space at

seal lip with grease.
~ Rear seal: Grease (G2-LI)
3) Coat mounting surface of flywheel housing with

gasket sealant.
~ Mounting surface: Gasket sealant (LG-7)
4) Align with dowel pin (3), and install flywheel

housing (1).
* When fitting the seal lip to the outside diameter
of the crankshaft flange, be careful not to
apply force to the seal lip surface.
~ Mounting bolt: 6.0- 7.5 kgm
(43- 54 lb. ft)
6D95L/S6D95L-1 20-31
5) Measuring difference in height of mounting surface

Measure distance in height between surface for
mounting oil pan on cylinder block and flywheel
housing.
* Permissible difference in height of flywheel
housing mounting surface: Max. 0.15 mm
(0.0059 in)
6) Measure radial and face runout of flywheel housing

with dial gauge ®.
* Radial runout: Max. 0.30 mm (0.0118 in)
Face runout: Max. 0.35 mm (0.0138 in)
12. Flywheel
1) Install flywheel (1 ).
~ Mounting bolt: 19.5 ± 0.5 kgm
(141 ±41b·ft)
2) Measure radial and face runout of flywheel with

dial gauge.
* Radial runout: Max. 0.15 mm (0.0059 in)
* Face runout: Max. 0.20 mm (0.0079 in)
13. Oil suction pipe

Fit O·ring and install oil suction pipe (1), then secure
with bracket.
20-32 6D95LIS6D95L-1
14. Oil pan (Without under plate)

Coat mounting face with gasket sealant, then install
oil pan (1 ).
~ Mounting face: Gasket sealant (LG-7)
(11 ± 3 lb • It)
~ Drain plug: 6.0 ± 1.0 kgm
(43 ± 7 lb . It)
14-1. Oil pan (With under plate)

1) Coat under plate mounting face with gasket
sealant, then install cylinder block.
2) Coat mounting face with gasket sealant, then
install oil pan.
~ Mounting face: Gasket sealant (LG-7)
(11 ± 3 lb . It)
~ Drain plug: 6.0 ± 1.0 kgm
(43 ± 7 lb . It)
15. Crankshaft pulley

1) Insert tapered collar, then install crankshaft pulley
(2).
2) Fit plate (1 ), then tighten mounting bolts.
(275 ± 22 lb . It)
16. Vibration damper

Install vibration damper (1).
(22 ±Bib· It)
17. Cylinder head assembly

1) Assemble cylinder head assembly as follows.
i) Using push tool G, install valve guide (6) in
cylinder head (1 ).
6095l/S6D95l-1 20-33
ii) Coat stems of intake and exhaust valves and 2

inside face of valve guide with engine oil.
iii) Install valve (5).
iv) Assemble valve spring (4) and spring seat (3).
l
5
-----4
l ~ ~~r--- --------6
-"--,, 6206F301
v) Using spring pusher B, compress valve spring,

and fit valve cotter (2) in valve stem groove.
* After releasing the valve spring, tap the top
of the valVe stem with a plastic hammer
to check that the cotter is completely
fitted.
* Remove all carbon and dirt from the contact

surface of the cylinder block and cylinder head.
Remove all burrs and damage, and clean out all
dirt from inside the cylinder block.
2) Install cylinder head gasket.
* Fit the gasket with the TOP mark facing up.
3) Raise cylinder head (1) then using 4 head bolts
as guide, install cylinder head to cylinder block.
4) Tighten mounting bolts of cylinder head as fol- Tightening order of cylinder head mounting bolt
lows.
* Coat the thread of the mounting bolts with -®11 CDV ®§! €® ® )
( @J @:€1
engine oil. Front Rear
There are two methods of tightening the @ @ ® 0 ® ® @I
head bolts.
@ @ ® 0 @ ®
Intake side 6206F401
1I Tightening by plastic turning angle (See the
figure bolt).
6204·13·1610 (Part No.)
•-rn
20-34 6D95L/S6D95L-1
~ Cylinder head mounting bolt m: After tightening, make a punch mark on the
Unit: kgm (lb · ft) bolt head to indicate the number of times the
bolt has been tightened. The bolt can be used
Order Target Range a maximum of five times. Always replace any
1st step 7 (51) 6-8 (43- 58) bolt that already has five punch marks.
Make mark with punch m
2nd step 11 (80) 10.5 - 11.5 (76 - 83)
Make mark on cylinder head
3rd step 90' 90'- 120' and bolt
2) Tightening by torque
(See the figure bolt)
Unit: kgm (lb · ft)
F621201067A F621201061
Order Target Range
1st step 8 (58) 7-9 (51- 65)
2nd step 12 (87) 11 -13 (80 -101)
3rd step 15 (109) 14.5-15.5 (105- 112)
6142·11-1611 (Part No.)
-~
~
18. Push rods
Insert push rods (1) in tappet guides.
* The same part is used for the intake and exhaust
push rods.
* If there is no abnormality in the push rod, install
in the same po_sition as before disassembly.
19. Rocker arm assembly
1) Install rocker arm assembly (1).
2) Check that ball of adjustment screw is fitted properly
into socket of push rod, then tighten the nuts and
bolts uniformly.
(18 ± 4 lb . ft)
* If the valve spring tension pushes against the
rocker arm, loosen the locknut and turn the
adjustment screw back 2 to 3 turns to prevent
strain on the push rod.
20. Adjusting valve clearance
• Adjust clearance between valve and rocker arm as
follows.
* Valve clearance (hot or cold)
Unit: mm (in)
Intake valve Exhaust valve
0.35 (0.0138) 0.50 (0.0197)
1) Rotate the crankshaft in the normal direction to
align pointer (b) on the gear case cover with the 1.6
TOP mark (a) on crankshaft pulley (1). When
rotating, check the movement of the valves of No.6
cylinder.
6D95L/S6D95L-1 20-35
2) When No. 1 cylinder is at compression top dead

center, adjust the valves marked e. Then rotate
the crankshaft jn the normal direction, and when
No. 6 cylinder is at compression top dead center,
adjust the valves marked 0.
Valve arrangement chart
Cylinder No. 1 2 3 4 5 6
Intake valve
• • 0
• 0 0
Exhaust valve
• 0
• 0
• 0
* To adjust, insert feeler gauge H between ro"cker

arm and valve stem and turn adjustment screw
until clearance is a sliding fit. Then tighten
locknut to hold adjustment screw in position.
~ Locknut: 4.5 ± 0.5 kgm

(33 ± 41b ·ft)
* After adjusting No. 1 cylinder at compression top

dead center, it is also possible to turn the crankshaft
120° each time and adjust the valVe clearance of
each cylinder according to the firing order.
Firing order: 1 - 5 - 3 - 6 - 2 - 4
21. Cylinder head cover

Fit O·ring and install cylinder head cover (1).
22. Nozzle holder

Fit gasket and install nozzle holder (1).
(33 ± 4 lb . ft)
* When remove the nozzle holder, replace the seat
gasket with new one.
* Insert the spill tube before installing the nozzle
holder.
20-36 6095L/S6095L-1
23. Spill tube

Install spill tube 11 ).
24. Fuel injection pipe

* Before installing the fuel injection pipe, blow
compressed air through it.
1) Install fuel injection pipe 12), then temporarily
tighten sleeve nuts at both ends.
2) Align fuel injection pipes, then tighten clamps 11 ).
3) Fully tighten sleeve nuts of injection pipes.
~ Sleeve nut: 2.3 ± 0.2 kgm
117 ± 1.51b. ft)
25. Intake manifold

Coat mounting surface with gasket sealant, then install
intake manifold 11 ).
~ Mounting surface: Gasket sealant ILG·7)
130 ± 4 lb . ft)
26. Fuel filter

1) ~nstall fuel filter 13) to bracket.
2) Fit gaskets to both faces of joints of fuel hoses
12) and 11 ), then connect with joint bolts.
~ Joint bolt: 2.3 ± 0.2 kgm
117 ± 1.51b. ft)
6D95L/S6D95L-1 20-37
27. Water pump

Fit gasket and install water pump (1 ).
~ Both faces of gasket: Gasket sealant (LG-1 )
28. Exhaust manifold

Fit gasket and install exhaust manifold (1 ).
(33 ± 11 lb. ft)
29. Oil cooler (S6D95L)

Coat mounting surface with gasket sealant, then install
oil cooler (1 ).
~. Mounting surface: Gasket sealant (LG-7)
* Be careful not to get gasket sealant on the mounting

surface of the filter.
(9 ± 41b. ft)
30. Alternator
1) Install alternator (3).
2) Fit belt (2), then temporarily tighten adjustment
plate (1 ).
20-38 6D95L/S6D95L-1
3) Insert a bar or pipe between alternator and cy- Approx. 8 mm /Fan pulley
linder block, and raise alternator to outside to Alternator pulley
adjust fan belt tension.
A Be careful not to get your fingers caught.
* The belt should deflect approx. 8 mm when

pushed with a finger pressure of 6 kg at a
point midway between the alternator pulley
and the fan pulley. After adjusting the belt
tension, tighten the bolt fully. \
Crankshaft pulley
6140F301
31. Lowering engine

Sling engine assembly (1), disconnect engine from
bracket A1 and engine repair stand A, then lower engine
on to a stable stand.
32. Starting motor

Install starting motor (1 ).
• Refilling with oil

1) Tighten drain plug.
2) Add engine oil through oil filler to the specified
level.
W Engine oil: Approx. 11 £

[2.9 gal (us)]
6D95L/S6D95L-1 20-39
ENGINE
30 STRUCTURE AND FUNCTION
GENERAL STRUCTURE ................. 30- 2

INTAKE AND EXHAUST SYSTEM
Turbocharger ...........••••.•..... 30- 6
ENGINE BODY
Cylinder head ......•••............. 30- 8
Valve system ............•...•..... 30-12
Cylinder block ....•................. 30-14
Main circulation system ..•............ 30-16
Timing gear ..•.................... 30-18
Flywheel and flywheel housing ......... 30-24
LUBRICATION SYSTEM
Lubrication system chart ..........•... 30-26
Oil pump .......•.•.••............ 30-27
Oil filter •...........•............. 30-28
Oil cooler ...........•............. 30-2g
FUEL SYSTEM
Fuel system chart ................... 30-30
Fuel injection pump .................. 30-32
Fuel injection nozzle .....•........... 30-36
Fuel filter ......................... 30-37
COOLING SYSTEM
Cooling system chart ................. 30-39
Water pump ..••................... 30-41
Oil cooler ......................... 30-43
Thermostat and fan drive ............. 30-44
ELECTRICAL SYSTEM
Starting and charging circuit ........... 30-47
Alternator ......................... 30-48
Starting motor ..................... 30-50
Electrical intake air heater ............. 30-52
Fuel cut solenoid .. .. . .. .. .. .. .. .. .. .. .. .. 30-53
6D95LIS6D95L-1 30-1
STRUCTURE AND FUNCTION GENERAL STRUCTURE
GENERAL STRUCTURE
6D95L-1
6206F101A
1. Fan 11. Piston 21. Cylinder block

2. Camshaft gear 12. Intake valve 22. Push rod
3. Front cover 13. Exhaust valve 23. Flywheel housing
4. Connecting rod bushing 14. Valve guide 24. Flywheel
5. Piston pin 15. Thermostat 25. Tappet
6. Oil ring 16. Valve spring 26. Camshaft bushing
7. Second ring 17. Cylinder head cover 27. Rear oil seal
8. Top ring 18. Rocker arm shaft 28. Main bearing
9. Water pump 19. Rocker arm bracket 29. Ring gear
10. Fan pulley 20. Cylinder head 30. Thrust bearing
30-2 6D95LIS6D95L-1
6206FI02
31. Camshaft 41. Dipstick Engine: 6D95L-1

32. Oil pan 42. Oil cooler (Option) Type: In-line, 6-cylinders, water-cooled, direct
33. Connecting rod 43. Exhaust manifold fuel injection, 4-cycle diesel engine.
34. Connecting rod cap 44. Filler cap
35. Crankshaft 45. Rocker arm
36. Crankshaft gear 46. Fuel injection nozzle
37. Front oil seal 47. Electrical intake air heater
38. Crankshaft pulley (Ribbon type)
39. Vibration damper 48. Intake manifold
40. Oil filter 49. Fuel injection pump
(Distributor type is STD spec.)
50. Starting motor
51. Oil strainer
6D95L/S6D95L-1 30-3
S6D95L-1
6207F101A
1. Thermostat 11. Cylinder head cover 21. Main bearing cap

2. Valve spring 12. Cylinder head 22. Main bearing cap bolt
·3. Valve guide 13. Tappet 23. Crankshaft gear
4. Intake valve 14. Flywheel housing 24. Front oil seal
5. Piston 15. Ring gear 25. Crankshaft
6. Exhaust valve 16. Flywheel 26. Connecting rod cap
7. Valve seat insert 17. Camshaft 27. Connecting rod bearing
8. Top ring 18. Rear seal 28. Crankshaft pulley
9. Second ring 19. Main bearing 29. Vibration damper
10. Oil ring 20. Thrust beaiing 30. Camshaft gear
30-4 6095L/S6D95L·1
6207F102A
31. Connecting rod 41. Fuel injection nozzle Engine: S6D95L-1

32. Piston pin 42. Electrical intake air heater Type: In-line, 6-cylinder,
33. Water pump 43. Intake manifold water-cooled, direct
34. Cylinder block 44. Fuel injection pump fuel injection, 4-cycle
35. Fan pulley 45. Starting motor diesel engine with
36. Fan 46. Oil strainer turbocharger.
37. Turbocharger 47. Oil filter
38. Oil filler cap 48. Dipstick
39. Rocker arm .49. Oil cooler
40. Intake connector pipe 50. Exhaust manifold
6D95L/S6D95L-1 30-5
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM

TURBOCHARGER
T-31 2 3 4 5 6 7 8 9
A c:::> c:::> D
10 11 12 13 14
c 6207F1 10A
1. Piston ring A. Ambient air inlet TURBOCHARGER
2. Back plate B. Compressed air outlet
Model GARRETT CO.
3. ThrUst bearing C. Exhaust gas inlet T-31
4. Seal ring D. Exhaust gas outlet
Overall length 211 mm
5. Retainer E. Lubricating oil inlet (8.31 in)
6. Center housing F. Lubricating oil outlet 189 mm
7. Journal bearing Overall width
(7.44 in)
8. Piston ring 159 mm
Overall height
9. Shroud (6.26 in)
10. Lock nut Weight 7 kg
11. Blower impeller (15.4 lb)
12. Blower housing Continuous
rotating speed 150,000 rpm
13. Turbine housing
14. Turbine impeller (Wheel shaft) Max. air supply 15.6 kg/min.
Compression
2.8
ratio
Applicable
exhaust temp. Max. 700°C
Direction Clockwise (see
of rotation from blower side)
30-6 6095L/S6D95L-1
STRUCTURE AND FUNCTION ENGINE BODY
ENGINE BODY
CYLINDER HEAD
6D95L-1
1. Cylinder head 6. Valve seat insert

2. Cylinder head cover 7. Cylinder head mounting bolt
3. Oil filler cap 8. Bracket
4. Valve guide 9. Nozzle holder
5. Blow-by suction pipe 10. Fuel injection nozzle
30-8 6D95L/S6D95L-1
Section A-A
6206FIOS
CYLINDER HEAD VALVE SEAT INSERT

Direct fuel injection type Press-fitted insert
One-piece type for exhaust
2-valve for one cylinder
Injection nozzle assembled
in cylinder head CYLINDER HEAD COVER
Floating type seal
6095L/S6095L-1 30-9
S6D95L-1
A---\
4 5 6
1. Cylinder head 6. Valve seat insert

2. Cylinder head cover 7. Nozzle holder mounting bolt
3. Oil filler cap 8. Nozzle holder
4. Valve guide 9. Seat gasket
5. Cylinder head mounting bolt
30-10 6D95LIS6D95L-1
Section A- A
6207F112
CYLINDER HEAD VALVE SEAT INSERT

Direct fuel injection type Press-fitted insert
One-piece type
2 valve for one cylinder CYLINDER HEAD COVER
Injection nozzle assembled in cylinder head R oati ng type seal
6D95L/S6D95L-1 30-11
VALVE SYSTEM
1. Spring seat 12. Rocker arm spring

2. Valve spring 13. Rocker arm bracket
3. Intake valve 1ll. Rocker arm shaft
4. Exhaust valve 15. Adjustment screw
5. Push rod 16. Lock nut
6. Tappet 17. Rocker arm
7. Camshaft 18. Housing
B. Thrust plate 19. Roller bearing
9. Camshaft gear 20. Pin
10. Valve cotter 21. Key
11. Valve seal (Intake and Exhaust) 22. Plate
30-12 6D95L/S6D95L-1
VALVE TIMING
c:" '>:...
Top dead center
Intake open 9° 12a Exhaust close
Intake close ~2.c:0_"1---..--

VALVE LIFT Bottom dead center
15 Intake valve: 9.6 mm
Exhaust valve: 10.6 mm 6206F114A
16
Cam gear bolt tightening type
17
Cam gear shrink fitting-bolt tightening type
6206FI13
CAMSHAFT
Induction hardening for
cam and journal portion.
6095L/S6D95L-1 30-13
CYLINDER BLOCK
1--D
Section A-A
SectionB-8
6206F106B
1. Cylinder block a. Piston cooling oil jet

2. Camshaft bushing (Cam gear shrink fitting type) (S6D95L-1)
Camshaft sleeve (Bolt on cam gear)
3. Main bearing cap bolt
4. Main bearing cap
5. Oil pump drive shaft bushing
6. Oil pump driven shaft
30-14 6D95L/S6D95L-1
j--B f--A
3
I--A
Section D-D
Front
Section C-C
Rear
6206F107A
CYLINDER BLOCK
Crankshaft: 7 bearings
Camshaft: 4 bearings
CYLINDER
Linerless
Inner treatment: Honing treatment
6D95L/S6D95L-1 30-15
MAIN CIRCULATION SYSTEM
6206F110·1
1. Crankshaft 14. Main bearing cap

2. Crankshaft gear (No. of teeth: 24) 15. Connecting rod cap bolt
3. Main bearing 16. Main bearing cap bolt
4. Connecting rod bearing 17. Thrust bearing
5. Connecting rod 18. Camshaft bushing
6. Cylinder block
7. Piston a. Offset
8. Connecting rod bushing b. Steel strut
9. Piston pin c. Trochoidal
10. Top ring d. Reentrant (FD35/40/45-5, FD35Z/40Z-5)
11. Second ring e. Ringtrage (S6D95L-1)
12. Oil ring f. Piston cooling oil jet (S6D95L-1)
13. Connecting rod cap g. Lubrication hole (S6D95L-1)
30-16 6D95L/S6D95L-1
g Section A-A
c
18
A A
Section A-A
6206F108A
PISTON RING
CRANKSHAFT
Stamp forging Engine Top ring Second ring Oil ring
PISTON
Reentrant combustion chamber for direct fuel injec-
tion (FD35/40/45-5, FD35Z/40Z-5)
~;:\::;~?,::;[ 3@
6D95L
Trochoidal combustion chamber Flat barrel Flat inner cut M~shape steel
-1
face, tappered face, ring,
Offset (1.0 mm between pin hole center and piston Hard chrome Parkerizing Hard chrome
center) plating treatment plating with coil
Auto-thermatic expander
(Control thermal expansion by steel strut which is
build in piston to achieve a smaller clearance be-
tween piston and cylinder)
('~''"''br--
,;;~zt%-,':':;_5:
3@
S6D95L
Two sizes of pistons (S-mark and L-mark) are avail- -1 Keystone Flat inner cut M-shape steel
barrel face, tappered face, ring,
able. Hard chrome Parkerizlng Hard chrome
(Depending on the dimensions of the piston outside plating treatment plating with coil
expander
diameter.)
For detail, see 50. INSPECTION STANDARD.
6D95L/S6D95L-1 30-17
TIMING GEAR
6D95L-1 FD35Z/40Z-4 (Old engine type)
FD35/40/45-4 (Old engine type)
FD33S/35S/40S/45S-4 (Old engine type)
WITH FRONT PTO TYPE (Helical gear)
~---1
.~-~ :
1 2 3 4
Section D- D
1. PTO gear (No. of teeth: 21) 8. Front cover

2. Idler gear (No. of teeth: 33) 9. Front cover
3. Camshaft gear (No. of teeth: _48) 10. Crankshaft
4. Idler gear (N'o. of teeth: 48) 11. Crankshaft pulley
5. Injection pump drive gear (No. of teeth: 48) 12. Timing gear case
6. Crankshaft geijr (No. of teeth: 24) 13. Front seal
7. Oil pump drive gear (No. of teeth: 21) A,B,C: Gear match mark
30-18 6D95L/S6D95L-1
B 5
13
12
Section E- E
FRONT SEAL
Single lip with dust seal
6095L/S6D95L-1 30-19

FD35Z/40Z-4 FD35Z/40Z-5 FD50E/60E/70E-6
FD35/40/45-4 FD35/40/45-5 FD50/60/70-6
FD33S/35S/40S/45S-4 FD50E/60E/70E-5
FD35/ 40/ 45-5E FD50/60/70-5
WITH FRONT PTO TYPE (Helical gear)
Cam-gear bolt tightening type
Cam-gear shrink fitting type 12 3 8 9 5
Section E-E
2 3 4 5 6
J--D
r--j f--D
30-20 6D95L/S6D95L-1
Cam~gear shrink fitting type Cam-gear bolt tightening type
1'"tt---2
Section D -D SectionF-F
1. PTO gear (No. of teeth: 24t 8. Roller bearing

2. Oil pump drive gear (No. of teeth: 21) 9. Idler gear shaft
3. Camshaft gear (No. of teeth: 48) 10. Front seal
4. Crankshaft gear (No. of teeth: 24) 11. Housing
5. Idler gear (No. of teeth: 48) 12. Roller bearing
6. Injection pump drive gear (No. of teeth: 48)
7. PTO gearshaft A, B, C: Match marks for timing gear
FRONT SEAL
6D95L/S6D95L-1 30-21
6095L·1 (5023/25-3)
S6095L-1 (FD60H/70H/80H-5)
WITHOUT FRONT PTO TYPE (Helical gear)
l,_.
:
Section E-E
8
2 3
r-D
1. Oil pump drive gear (No. of teeth: 21) 6. Thrust plate

2. Camshaft gear (No. of teeth: 48) 7. Idler gear shaft
3. Crankshaft gear (No. of teeth: 24) 8. Idler gear bushing
4. Idler gear (No. ofteeth: 48) 9. Front seal
5. Injection pump drive gear (No. of teeth: 48) A, B,C: Match marks for timing gears
30-22 6D95L/S6D95L·1
7
1
Section D-0 SectionF-F
FRONT SEAL
6095l/S6095l-1 30-23
FLYWHEEL AND FLYWHEEL HOUSING

WITHOUT PTO TYPE
1. Flywheel housing REAR OIL SEAL

2. Starting motor Dry type: Single lip with dust seal
3. Crankshaft Wet type: Double lip
4. Rear oil seal
5. Flywheel
6. Ring gear (No. of teeth: 119)
No. of teeth
Engine No. 1 0020 - 19026: 130
19027- 127
30-24 6D95L/S6D95L-1
6206FII5
6D95L/S6095L-1 30-25
STRUCTURE AND FUNCTION LUBRICATION SYSTEM
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART
I
In-line type
injection pump- -7l 14
11
15
56D95L-1
1. Oil strainer 6. Safety valve 11. Rocker arm

2. Oil pump 7. Crankshaft 12. Timing gear
3. Oil cooler (S6D95L-1) B. Camshaft 13. Fuel injection pump (in-!Jne type)
4. Oil filter 9. Piston 14. Turbocharger (S6D95L-1)
5. Regulator valve 10. Intake and exhaust valve 15. Piston cooling (S6D95L-1)
W: Cooling water
30-26 6D95LIS6095L-1
OIL PUMP
2 3
A-I
I
'
4
5 B)'
6
j 7
=r
Section A-A 8/-
A--j
8 9
Section B-8 6206F117
1. Bushing OIL PUMP

2. Drive gear (No. of teeth: 7) Type: Geartype
3. Pump cover Pump speed: Engine speed x 1.143
4. Oil pump drive gear (No. of teeth: 21)
5. Drive shaft REGULATOR VALVE
6. Driven shaft Set pressure: 6.0 ± 0.5 kg/em'
7. Driven gear (No. ofteeth: 7) (85 ± 7 psi)
8. Regulator valve [6 ± 0.5 bar]
9. Valve spring
6D95L/S6D95L-1 30-27
OIL FILTER
IL
1. Safety valve OIL FILTER

2. Cartridge Filtration area: 0.20 m2
(2.2 ft 2 )
S,L\FETY VALVE
Set pressure: 2.0 ,::6:gkg/cm 2
(29 ~~~psi)
[2 :!:~ bar]
30-28 6D95L/S6D95L-1
OIL COOLER
S6D95L-1
A--I
Section 8-B
Section A-A
6206F1198
1. Cooler element OIL COOLER

2. Cooler cover Type: Multiple plate type
3. Water drain plug Effective area: 0.273 m 2
(2.945 ft 2 )
c. Oil inlet
D. Oil outlet
E. Cooling water inlet
F. Cooling water outlet
6D95L/S6095L-1 30-29
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM CHART
WITH DISTRIBUTOR TYPE PUMP
1. Fuel tank 5. Fuel injection nozzle

2. Fuel filter 6. Joint bolt with overflow valve
3. Fuel injection pump 7. Hand priming pump
4. Fuel cut solenoid B. Water sedimentary sensor
30-30 6D95L/S6D95L-1
WITH IN-LINE TYPE PUMP
I I I I I
F614601036
1. Fuel tank
2. Water separator (Option)
3. Feed pump
4. Fuel filter
6. Fuel injection nozzle
6D95L/S6D95L-1 30-31
FUEL INJECTION PUMP

DISTRIBUTOR TYPE
13
1. Pump holder 7. Fuel injection pipe (No. 1)

2. Fuel injection pump drive gear B. Fuel injection pipe (No. 2)
(No. of teeth: 48) 9. Fuel injection pipe (No.3)
3. Drive shaft 10. Fuel injection pipe (No.4)
4. Fuel injection pump 11. Fuel injection pipe (No. 51
5. Fuel pipe 12. Fuel injection pipe (No.6)
6. Fuel filter 13. Spill tube
30-32 6095US6D95L-1
ViewZ
A. Fuel inlet (from fuel tank) FUEL INJECTION PUMP

B. To fuel tank Maker: DIESEL KIKI
C. To fuel injection pump Type: Bosch type VE
D. To fuel filter Lubrication method: Forced lubrication with fuel
E. To fuel injection nozzle
GOVERNOR
Type: Centrifugal, all-speed type
6D95L/S6D95L-1 30-33
WITH IN-LINE TYPE PUMP
1. Lubrication tube 8. Fuel injection pipe (No. 1)

2. Tachometer pick~up 9. Fuel injection pipe (No. 2)
3. Drive shaft 10. Fuel injection pipe (No. 3)
4. Injection pump drive gear (No. of teeth: 48) 11. Fuel injection pipe (No.4)
5. Feed pump 12. Fuel injection pipe (No. 5)
6. Fuel injection pump 13. Fuel injection pipe (No. 6)
7. Fuel filter 14. Governor
30-34 6D95L/S6D95L-1
View Z
6206F121A
A. Fuel inlet (from fuel tank) FUEL INJ.ECTION PUMP

B. To fuel filter Maker: DIESEL KIKI
C. From fuel filter Type: Bosch PES-A type
D. To fuel injection nozzle Lubrication method: Forced lubrication with engine oil.
E. To fuel tank
F. From oil pump (oil) GOVERNOR
Maker: DIESEL KIKI
Type: Bosch RSV Centrifugal, all-speed type.
6D95L/S6D95L-1 30-35
FUEL INJECTION NOZZLE
~
1
9
3
4
6204F124
6204F123
1. Outlet connector FUEL INJECTION NOZZLE

2. Nozzle holder Maker: DIESEL KIKI
3. Shim Type: Multi-hole type
4. Nozzle spring Injection pressure: 200 kg/em'
5. Spacer (2845 psi)
6. Seat [196 bar]
7. Nozzle body
8. Retaining cap 225 kg/em' (FD35Z/40Z-5 )
9. Needle valve (3200 psi) FD35/40/45-5
[221 bar]
A. Fuel inlet (from injection pump)
B. Fuel injection (to cylinder) * Adjustment of injection pressure:
c. Fuel return (to fuel tank) By shim (about 15kg/cm 2 /0.1 mm)
30-36 6095US6D95L-1
FUEL FILTER
WITH DISTRIBUTOR TYPE INJECTION PUMP
A-
0 0
0 0
B A Section A-A
1. Air bleed plug FUEL FILTER

2. Bracket Filtration area: 0.15 m 2
2'. Bracket with hand priming pump (1.61 ft 2 )
3. Cartridge
A. Fuel inlet (from feed pump)

B. Fuel outlet (to injection pump)
6D95L/S6D95L-1 30-37
WITH IN-LINE TYPE INJECTION PUMP
0
,{1
' I
1 I
I
I
I
I
I
I
0
r+~
B A
6206FI25
1. Air drain plug FUEL FILTER

2. Bracket Filtration area: 0.093 m 2
3. Cartridge (1.00 ft')
A. Fuel inlet (from feed pump)

B. Fuel outlet (to injection pump)
30-38 6D95L/S6095L-1
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM CHART
6D95L-1
1. Radiator
2. Thermostat
3. Water temperature gauge
4. Water pump
5. Water manifold
6. Cylinder head
7. Piston
8. Cylinder block
6D95L/S6095L-1 30-39
S6D95L-1
F614601037
1. Radiator 7. Cylinder head

2. Thermostat 8. Piston
3. Water pump 9. Cylinder block
4. Water temperature gauge 10. Oil cooler
5. Water manifold
6. Corrosion resistor (Option) A. Lubrication oil
30-40 6D95LIS6D95L-1
WATER PUMP
• WITH SEPARATE TYPE WATER SEAL * The shape may differ according to the machine model.
(Old type)
Ring assembled to Seat assembled to

water pump body impeller
2
D
3
1
'--
t'o d
4
' I
8 Detail P
I
5
6206F127·1
1. Pump cover
2. Impeller
3. Water seal
4. Pump body
5. Boss
6. Drive shaft
A. Water inlet port (from radiator)

B. Water inlet port (from thermostat)
C. Water outlet port (to engine)
D. Water outlet port (to radiator)
6D95LIS6D95L-1 30-41
• UNITIZED SEAL WITH ONE PIECE WATER SEAL

(New type)
Ring
0
2
1 J
p
Portion where shape of
impeller has been changed
6206F127-2
1. Pump cover Water pump

2. Impeller Type: Centrifugal type (V-belt drive)
3. Water seal
4. Pump body
5. Boss
6. Drive shaft
A. Water inlet port (from radiator)

B. Water inlet port (from thermostat)
C. Water outlet port (to engine)
D. Water outlet port (to radiator)
30-42 6D95L/S6D95L-1
OIL COOLER
S6D95L
A---1
Section B-8
Section A-A
6206F119B
1. Cooler element OIL COOLER

2. Cooler cover Type: Multiple plate type
3. Water drain plug Effective area: 0.273 m 2
(2.94 ft 2 )
C. Oil inlet
0. Oil outlet
E. Cooling water inlet
F. Cooling water outlet
6095L/S6D95L-1 30-43
THERMOSTAT AND FAN DRIVE
Wind==:>
c
d
@j
ViewZ
1. Fan 7. Crankshaft pulley a. To radiator

2. Fan belt 8. Crankshaft b. From engine each part
3. Water pump 9. Thermostat case cover c. Outlet for heater
4. Fan spacer 10. Thermostat d. Outlet for water temperature gauge
5. Fan pulley 11. Thermostat case e. Thermosensor mounting position
6. Vibration damper 12. Alternator
30-44 6D95LIS6D95L-1
THERMOSTAT A. To radiator
Function 8. From cylinder block
Valve cracking temperature: 74.5- 77.5°C C. To water pump
Full open temperature: 90°C
a, Water pump·
Full open lih: 8 mm (0.31 in)
side clearance
b. Radiator-side
clearance
F614601035
6D95L/S6095L·1 30-45
STRUCTURE AND FUNCTION ELECTRICAL SYTEM
ELECTRICAL SYSTEM
STARTING AND CHARGING CIRUIT
Alternator with
regulator
Heater signal
mBrake accumulator
caution lamp Hour meter Charge lamp
Heater
relay
Starting
switch
Starting motor
m Accumulator oil
pressure switch
Battery
m Truck with power brake only
6095L/S6095L-1 30-47
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ALTERNATOR
R
s
R R
8
Regulator
~ ~ ~S~Gt4~~tt~~~
Q E
E
n
" r, , Eo---f
A, C type 8 type
Pulley
Engine model Type Specification Weight kg (lb) Diagram
Stage O.D. mm (in)
Maker: NIKKO
24 V, 25A 1 95 (3.7) 7.8 (17.2) . A
Type: opened
6D95L
Maker: NIKKO
24V,15A 1 77 (3.0) 4.0 (8.8) B
Type: opened
Maker: NIKKO
S6D95L 24 V,15A 1 77 (3.0) 4.0 (8.8) B
Type: opened
30-48 6D95LIS6D95L-1
WITH VACUUM PUMP
R
8
Regulator
SG ,6-
~ c..:~
E
nlT T lT
A, C type
Pulley
Engine model Type Specification Weight kg (lb) Diagram
Stage O.D. mm (in)
Maker: NIKKO
6D95L
Type: opened
24 V, 25 A 1 95(3.7) 11 (24) c
6095l/S6D95l-1 30-49
STARTING MOTOR
A type
Terminal C
Starting switch {MS)
...1..
T
-'- '
l
Inner wiring
Btype
2 3
Terminal C Terminal B
{M4)
Safety relay Starting motor
s /~]
1 R ''
'' 6206FB32
~-t
1. Pinion gear
2. Magnetic switch
3. Starting motor (body) Inner wiring
30-50 6095L/S6095L-1
Engine
Specification Pinion gear Weight
Type Applicable machine model Type No. of teeth kg (lb)
model
FD35Z/40Z-4
NIPPON DENSO, 24 V, 4.5 kW
6D95L-1 A FD35/40/45-4 Drop-proof 11 8.5 (19)
(with in-line FD33S/35S/4DS/45S-4
type pump)
B SD23/25-3 NIKKO, Drop-proof 24 V, 2.8 kW 11 6.8 (15)
FD35Z/40Z-4
FD35/40/45-4
FD33S/35S/4DS/45S-4
FD35/40/45-5E
FD35Z/40Z-5
FD35/40/45-5
NIPPON DENSO, 24 v, 4.5 kw· 8.5 (19)
A Drop-proof 11
SD23/25-3
6D95L-1 FD50E/60E/70E-5
(with FD50/60/70-5
distributor
type pump) FD50E/6DE/70E-6
FD50/60/70-6
FD35Z/4DZ-4
FD35/40/45-4
FD33S/35S/4DS/45S-4
8 SD23/25-3 NIKKO, Drop-proof 24 V, 2.8 kW 11 6.8 (15)
FD50E/60E/7DE-5
FD50/60/70-5
S6D95L-1 NIPPON DENSO, 24 V, 4.5 kW 8.5 (19)

A FD60H/70H/80H-5. Drop-proof 11
(with
distributor
type pump) 8 FD60H/70H/80H-5 NIKKO, Drop-proof 24 V, 2.8 kW 11 6.8 (15)
6D95L/S6D95L-1 30-51
ELECTRICAL INTAKE AIR HEATER

RIBBON TYPE
1. Heater coil
2. Housing
Specification
Rated voltage: DC24V
Rated current: 110Ah
-I"
IT 1-
ll!,!l[
@ 0~
Wiring diagram
6136F025
30-52 6D95L/S6D95L-1
FUEL CUT SOLENOID

SOLENOID
B .contact (electricity flows in ordinary operation) method
1 2 3
1. Plunger 6. Solenoid
2. Coil 7. Fuel control lever Inner wiring
6206F607
3. Moving contactor C1: Pull· in coil
4. Stop lever C2: Holding coil
5. Return spring
SOLENOID
Type: Nikko Oenki
Rated voltage: DC24 V
Actuatiitg current:
* The diagram may be slightly different from the
Momentary max.: 40A
Continuous: Max. 2A
actual part.
Stroke: 20 ± 0.3 mm (0.787 ± 0.012 in)
Weight: 3.3 kg (7.3 Ib)
When starting the engine, electricity passes through
the solenoid, so plunger (2) of the solenoid is
7
actuated. This extends return spring (5) installed
to stop lever (4) of the fuel injection pump. (The
spring may be built into the injection pump.) The
spring is pu\1ed to the running position and is held
in position.
4
When stopping the engine, turn the key switch to
the STOP position and the flow of electricity to the
solenoid stops. The magnetic force of the solenoid
is lost, so the force of the return spring moves the ( 5
stop lever of the fuel pump to the ENGINE STOP
(NO INJECTION) position. At the same time, the .I
6
plunger of the solenoid is also pulled back, and the
engine is stopped.
When operating, the amount of fuel injected is
controlled by fuel control lever (7).
When installing the fuel solenoid valve, ·adjust
clearance A.
B 6162F151
6095L/S6D95L-1 30-53
ADJUSTMENT OF FUEL SOLENOID LINK
1. Maximum value of yoke

1) Stop the engine, and move the stop lever fully
to the STOP (NO INJECTION) position. (The
solenoid shaft is returned.)
2) Adjust the maximum value of the solenoid
yoke with the rod.
Max. value of yoke (A): Approx. 78 mm
(3.07 in)
2. Adjusting clearance between stop lever and stopper

1) Push the solenoid shaft in fully by hand
towards the solenoid.
2) Adjust the clearance between the stop lever and
injection pump FULL stopper to the specified
value with the rod.
Specified value for clearance (B):
0.4 ± 0.1 mm
(0.016 ± 0.004)
* When clearance is,O: An excessive current
will flow to the solenoid and burn the
solenoid coil out, so it will not work.
* When clearance is more than 2 mm: There
will be a drop in the amount of fuel inject-
ed, and the engine will not be able to
produce the rated output.
3. Checking continuity
Pass electricity through the solenoid, and make final
adjUstments to obtain the specified value for the
clearance between the stop lever and injection pump
FULL stopper.
4. Checking operation
Start and stop the engine 2 or 3 times in succession,
and check that the solenoid is actuated normally
and that the engine stops smoothly.
30-54 6095L/S6D95L-1
ENGINE
40 TESTING AND AD~USTING
Testing and adjusting data ................................ 40- 2

Fuel injection pump calibration data ................ 40- 6
Standard volume of fuel injection .................... 40- 8
Adjustment of governor ..................................... 40-1 0
PERFORMANCE TEST ......................................... 40-13

Run-in standard ................................................... 40-13
Performance test criteria ................................... 40-14
Testing and adjusting tool list .......................... 40-16
6095L/S6D95L-1 40-1
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA
TESTING AND ADJUSTING DATA
6095L-1 6D95L-1
Engine model
(with in-line type pump) (with distributor type pump)
FD35Z/40Z-4 FD35/40/45-4 FD35Zl40Z-4 FDJS/40145-4
Applicable machine model FDJJS/355/405/455-4
FD33S/35S/40S/45S-4 F035/40!45·5E 5023/25-3
Classifi- Standard Permissible Standard Permissible
Item Condition, etc. Unit
cation value value value value
m High idling speed (un-load) rpm 2350 ±50 2350 ±50 2350 ±50 2350 ±50
u Engine speed
c
m Low idling speed (un-load) rpm 700 ± 25 700 ± 25 700 ± 25 700 ± 25
E
5 o·c rpm Min. 150 - Min. 150 -
't: Necessary
m
"- starting speed - -
-2o~c {with starting aid) rpm Min. 100 Min. 100
Intake resistance At rated output mmH 20 Max. 380 762 Max. 380 762
E
Intake pressure At rated output mmHg - - - -
*••
>
t;
0
Exhaust pressure At rated output
All speed
mmHg Min. 75 Min. 75 Min. 75 Min. 75
~
X
Exhaust temperature
(intake air temp.: 20"C)
·c Max. 650 700 Max. 650 700
•
"C Quick acceleration 4.0 6,0 Max. 4.0 6,0
c Bosch
• Exhaust gas color
~•
l"
At high idling
scale
2.5 3.5 Max. 2.5 3.5
-" Intake valve mm 0.35 0.35
Valve clearance
(When engine is cold.)
(in)
mm
(0.0138)
0.50
-- (0.0138)
0.50
--
Exhaust valve (in) (0.0197) - (0.0197) -
> kg/cm 2 Min. 30 20 Min. 30 20
"C
0 Compression pressure Oil temperature: 40 - 60"C
D (psi) (Min. 430) (280) (Min. 430) (280)
(SAE30) (Engine speed:320-360rpm)
m [bar) [Min. 291 [20) )Min. 291 )20)
c
'C> Blow-by pressure At rated output
c mmH 20 Max. 50 100 Max. 50 100
UJ (SAE30) Water temp.: Min. 60"C
kfcm
psi)
2
3.5- 7.5 2.5 3,5-7.0 2.5
E Oil pressure At high idling (50- 110) (36) (50- 100) (36)
[bar) [3.4- 7.4] [2.5) [3.4- 6.9] [2.5)
*
•>
0
0
(oil temperature:
Min. 80"C, SAE30I At low idling
kfcm
gsi)
I ar)
2
Min. 1.0
(Min. 14)
[Min. 0.98)
0.7
(10)
[0.67)
Min. 1.0
(Min. 141
[Min. 0.98)
0.7
(10)
[0.67]
"'•u 011 temperature All speed (oil in oil pan) ·c 90-110 120 90- 110 120
:§
0
~
At continuous rated output
Oil consumption ratio % Max. 0.5 1.0 Max. 0.5 1.0
(Ratio to fuel consumption)
E kg/cm 2 200 t 1 ~ 168 200 ! 1 ~ 168

Fuel injection pressure Nozzle tester (psi) (2845 t 2 ~8l (2390) (2845 t 2 }3l (2390)
..*•
>
0
~ Fuel injection timing B.T.D.C.
[bar]
degree
[196 t 1 ~]
14 ± 1
[165)
14 ± 1
[196 t'~l
12 ± 1
[165)
12 ± 1
Coolant temperature All speed ·c 70-80 100 70-80 100

Valve opening temperature ·c 74.5 77.5 74.5 77.5 74.5 77.5 74.5 77.5
Thermostat function Full-opening temperature "C 90 - 90 -
Full-opening lift mm - 8 - 8
E kg/cm 2 0.9 0.9 0.9 0,9
Radiator pressure valve Opening pressure
s function
(psi) (3.0) (3.0) (3.0) (3.0)
•> (Differential pressure)
[bar) • [0.9) [0.9) [0.9] [0.9)
•
0>
£ Fan speed At rated engine speed rpm 1818±55 1818 ±55 1818±55 1818±55
0
0
u Fan belt tension
Deflects when pushed with mm 8 6- 10 8 6- 10
(Alternator to fan
a force of 6 kg (in) (0.3) (0.2- 0.4) (0,3) (0.2- 0.4)
pulley)
Fuel mixing in oil Ignition point "C Min. 270 180 - -
Water mixing in oil % - 0.2 - -

Note: The values g1ven 1n the Testmg 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.
40-2 6D95L/S6D95L-1
6D95L-1
(with distributor type pump)
FD35Z/40Z-5 5023/25-3
FD35/40/45-5
Standard Permissible Standard Permissible
value value value value
2350 :::~g 2350 ±50 2350 ±50 2350 ±50
700 ± 25 700 ± 25 700 ± 25 700 ± 25

Min. 150 - Min. 150 -
Min. 100 - Min. 100 -
Max. 380 762 Max. 380 762
- - - -
Min. 75 Min. 75 Min. 75 Min. 75
Max. 650 700 Max. 650 700

Max. 4.0 6.0 Max. 4.0 6.0
Max. 2.5 3.5 Max. 2.5 3.5

0.35 0.35
(0.0138)
0.50
-
--
(0.0138)
0.50
--
(0.0197) (0.0197) -
Min. 30 20 Min. 30 20
(Min. 430) (280) (Min. 430) (280)
[Min. 29] [20] [Min. 29] [20]
Max. 100 200 Max. 100 200
3.5 7.0 2.5 3.5 7.0 2.5
(50- 100) (36) (50 -100) (36)
[3.4- 6.9] [2.5] [3.4- 6.9] [2.5]
Min. 1.0 0.7 Min. 1.0 0.7
(Min.14) (10) (Min.14) (10)
[Min. 0.98] [0.67] [Min. 0.98] [0.67]
90-110 120 90-110 120
Max. 0.5 1.0 Max. 0.5 1.0
225 +tS 188 200 +15 168

(3200 !•lg) (2670) (2845 !•lg) (2390)
[220 t 1 1i [184] [19Bt1 iJ [165]
6±1 6± 1 12 ± 1 12 ± 1
70-80 100 70-80 100
74.5-77.5 74.5-77.5 74.5-77.5 74.5-77.5

90 - 90 -
- 8 (0.3) - 8
0,9 0.9 0.9 0.9
(13) (13) (3.0) (3.0)
[0.9] [0.9] [0.9] [0.9]
1818±55 1818±55 1818±55 1818±55
8 6-10 8 6-10
(0.3) (0.2- 0.4) (0.3) (0.2- 0.4)
- - - -
- - - -
6D95L/S6D95L-1 40-3
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA,
6D95L-1 6D95L-1
Engine model (with distributor type pump)
FD50/60/70-5 FD50E/60E/70E-5
Applicable machine model
FD50/60/70-6 FD50E/60E/70E-6
Classifi- Standard Permissible Standard Permissible
Item Condition, etc. Unit
cation value value value value
High idling speed rpm 2500 ±50 2500 ±50 2350 ±50 2350 ±50
•uc Engine speed
•E Low Idling speed rpm 700 ± 25 700 ± 25 700 ± 25 700 ± 25
~ Necessary
o·c rpm Min. 150 - Min. 150 -
•
a. starting speed -20gC (with starting aid) rpm Min. 100 - Min. 100 -
Intake resistance At rated output mmH 2D Max. 500 762 Max. 500 762
E
Intake pressure At rated output mmHg - - - -
*•
,
>
•
;;;
Exhaust pressure At rated output mmHg Min. 75 Min. 75 Min. 75 Min.-75
0
All speed
~
X
Exhaust temperature
(intake air temp.: 20~C)
·c Max. 650 700 ,
Max. 650 700
• Quick acceleration Max. 5.5 7,5 Max. 4.0 6,0
"•c Exhaust gas color Bosch
scale
~
m At high idling Max, 3.0 4.0 Max. 3.0 4.0
l' mm 0.35 0,35
E Intake valve
Valve clearance
(When engine Is cold.)
(in)
mm
(0,0138)
0.50
-- (0,0138)
0,50
--
Exhaust valve (in) (0,0197) - (0,0197) -
> kg/cm 2 Min. 30 21 Min.·3o 21
"
0 Compression pressure Oil temperature: 40 - 60~C
(psi) (Min. 430) (300) (Min. 430) (300)
"'cm (SAE30) (Engine speed:320-360rpm)
lbarl IMin, 291 [21] [Min. 29] [211
,a,
c Blow~by pressure At rated output
w mmH 2 0 Max. 50 100 Max. 50 100
(SAE30) Water temp.: Min. 60"C
2
kytcm 3.5-7.5 2,5 3.5-7.0 2.5
E Oil pressure At high Idling gsi) (50-110) (36) (50- 100) (36)
I ar] [3.4- 7.41 [2,5] [3.4- 6.9] [2.5]
*•
>
c
0
(oil temperature:
Min. ao~c, SAE3Dl At low idling
k~/cm
psi)
[bar]
2
Min. 1.0
(Min. 14)
IMin. 0,98]
0.7
(1 D)
[0.67]
Min. 1.0
(Min. 14)
[Min. 0.98]
0,7
(10)
[0.67]
"•u Oil temperature All speed (oil in oil pan) ·c BO- 110 . 120 80-110 120
:§
0
~
At continuous rated output
Oil consumption ratio % Max. 0.5 1,0 Max. 0.5 1.0
(Ratio to fuel consumption)
E kg/cm 2 200 :t 1 ~ 168 200 :t 1 ~ 168

Fuel injection pressure Nozzle tester (psi) (2845 t 2 ~g) (2390) (2845 ! 2 ~81 (2390)
•*
[196 t 1 ~] [196 t 1 ~]
•> [bar] [1 65] [165]
0
B.T,D,C, Type 5:12 ± 1 Type 5:12 ± 1
~ Fuel injection timing degree 12 ± 1 12 ± 1
Type 6: B ± 1 Type 6: 8 ± 1
Coolant temperature All speed ·c 70-80 100 70-80 100

Valve opening temperature ·c 82 ±.2 82 ± 2 82 ± 2 82 ± 2
Thermostat function Full~opening temperature •c 95 - 95 -
Full~opening lift mm - 8 - 8
E kg/cm 2 0.9 0.9 0,9 0.9

Opening pressure
Radiator pressure valve (psi) (3.0) (3,0) (3.0) (3.0)
*•"'
£
0
>
Fan speed
(Differential pressure)
At rated engine speed

(bar]
rpm
[0,91
2465 ± 60
[0,91
2465 ± 60
[0.91
1827 ± 55
[0,9]
1827±55
0
u Fan belt tension
Deflects when pushed with mm 8 6- 10 8 6- 10
(Alternator to fan
a force of 6 kg (in) (0.3) (0,2- 0,4) (0,3) (0,2- 0.4)
pulley)
Fuel mixing in oil Ignition point ·c Min. 270 180 - -

Water mixing in-oil % - 0,2 - -
Note: The values given in the Testtng and Adjustmg 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.
40-4 6D95L/S6D95L-1
S6D95L·1
FD60H/70H/80H-5
Standard Permissible
value value
2200 ±50 2200 ±50
700 ± 25 700 ± 25
Min. 150 -
Min. 100 -
Max. 500 762
Min. 280 Min. 280
Min. 380 Min. 380
Max. 650 700

Max. 8.0 8.0
Max. 3.5 4.5

0.35
(0.0138)
0.50
--
(0.0197) -
Min. 28 20
(Min. 400) (280)
[Min. 271 [20]
Max. 50 100
3.5 7.0 2.5
(50 -100) (36)
[3.4- 6.91 [2.5]
Max. 1.0 0.7
(Max. 14) (10)
[Max. 0.9B]_ [0.6J)_
80-110 120
Max. 0.5 1.0
200 t 1 ~ 168
(2845 t 2 ~8J (2390)
[196 t 1 ~] [165]
14 ± 1 14 ± 1
70-80 100
82± 2 82 ± 2
95 -
- 8(0.3)
0.9 0.9
(13) (13)
[0.9] [0.9]
1870 ±50 1870 ±50
8 6- 10
(0.3) (0.2- 0.4)
- -
- -
6D95L/S6D95L-1 40-5
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP CALIBRATION DATA

FUEL INJECTION PUMP
6D95L (with distributor type pump)

Item Engine 6D95L (with in-line type pump)
(without FD35Z/40Z-5, FD35/40/45-5)
Maker DIESEL KIKI DIESEL KIKJ
Type Bosch PES-A, PE-A Bosch VE
Rotating direction Clockwise viewed from drive end Clockwise viewed from drive end
Injection order 1-5-3-6-2-4 1-5-3-6-2-4
Plunger pre-stroke 3.6 ± 0.05 mm (0.14 ± 0.020 in) -
SERVICE STANDARD
m Without FD50/60/70-6,
FD35Z/40Z-4 and FD35/40/45-4
Engine 6D95L 6D95L with distributor tvoe oumol
Item (with in-line type pump) m FD50/60/70-6
Nozzle holder Part No. 105780-2080 105780-2080 105780-2150
Injection nozzle Part No. 105780-0000 105780-0000 105780-0060
* Injection pressure kg/em' f~si)

ar]
175 f2490)
172]
150 f2130)
147]
133 f1890)
130]
Injection pipe J.D. x O.D. x length Onl 2x6x600
(0.08 X 0.2 X 23.6)
2x6x840 2x6x450
(0.08 X 0.2 X 33.1) (0.08 X 0.2 X 17.7)
Transfer pump pressure kg/em' f~si)
ar] 1.6 f~% 0.2 f~:~l
MANUFACTURER STANDARD
Engine 6D95L 6D95L

Item (with in-line type pump) (with distributor type pump)
Nozzle holder Part No. 6207-11-311 0 105048-3060
Injection nozzle Part No. 6207-11-3130 105017-0140
* Injection pressure kg/em' (~si)

[ ar]
200 f2845)
196]
200 f2845)
196]
Injection pipe 1.6 X 6 X 594 1.8 X 6 X 642
J.D. x O.D. x length Onl (0.06 X 0.2 X 23.4) (0,06 X 0.2 X 25.3)
Transfer pump pressure kg/cm 2 f~si)
ar] 1.6 Wci1 0.2 f~:~l
* The values given for the injection pressure for the condition on the test bench, so they differ from condi-
tion of engine mounted on the truck.
40-6 6D95L/S6D95L-1
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP
Item Engine 6D95L (with distributor type pump) S6095L

(FD35Z/40Z-5, FD35/40/45-5) (with distributor-tYpe pump)
Maker DIESEL KIKI DIESEL KIKI
Type Bosch VE Bosch VE
Rotating direction Clockwise viewed from drive end Clockwise viewed from drive end
Injection order 1-5-3-6-2-4 1-5-3-6-2-4
Plunger pre-stroke - -
SERVICE STANDARD
Engine 6095L S6D95L

Item (with distributor type pump) (with distributor type pump)
Nozzle holder Part No. 1 05780-2080 1 05780-20BO
Injection nozzle Part No. 1 05780-0000 1 05780-0000
* Injection pressure kg/em' ~~si)

ar]
150 12130)
147] 150 12130)
147]
Injection pipe 1.0. x O.D. x length frn) 2x6x840 2x6x840
(0.08 X 0.2 X 33.1 I (0.08 X 0.2 X 33.1 I
Transfer pump pressure kg/em' ~~si)
ar] 0.21g:~l 0.21g:~l
MANUFACTURER STANDARD
Engine 6095L S6095L

Item (with distributor type pump) (with distributor type pump)
Nozzle holder Part No. 1 05048-3300 1 05048-3300
Injection nozzle Part No. 1 05017-0970 1 05017-0970
* Injection pressure kg/em' ~~si)

ar]
225 13200)
221] 200 12845)
196]
Injection pipe 1.0. x 0.0. x length frn) 1.8 X 6 X 642 1.8x6x642
(0.07 X 0.2 X 25.3) (0.06 X 0,2 X 25.3)
Transfer pump pressure kg/em' wsi)
ar] 0.21g:~l 0.21g:~l
* The values given for the injection pressure for the condition on the test bench, so they differ from condi-
tion of engine mounted on the truck.
6D95L/S6D95L-1 40-7
TESTING AND ADJUSTING STANDARD VOLUME OF FUEL INJECTION
STANDARD VOLUME OF FUEL INJECTION
Applicable Type of Rack position Pump speed Injection volume

Max. variation
Engine
machine injection pump (mm) (rpm) (mm'/st) bet. cyl.
(mm 3 /stl
FD35Z/40Z-4 In-line type

9.7 (BASIS) 1,075 Average: 31 ±1 ± 2.5 (%)
FD35/40/45-4 (6206-71-1 130)
8.7 350 Average: 10.5 ±1 ± 1.5 (%)
6D95L-1
FD33S/35S/ In-line type
9.5 (BASIS) 950 Average: 29.5 ±1 ± 2.5 (%)
40S/45S-4 (6206-71-1110)
8.7 350 Average: 1 0.5 ±1 ± 1.5 (%)
500 Average: 44.6 ± 2.5

750 Average: 45.6 ±1 3
(Full load)
FD33S/35S/ Distributor type
1,075 Average: 38.1 ± 2.5
40S/45S-4 (6206-71-1160)
100 Average: min. 85
(Idling) 350 Average: 9.4 ±2 2

(High speed
control) 1,150 Average: 17.5 ±3 4.5
500 Average: 42.8 ± 2.5

750 Average: 43.3 ±1 3
(Full load)
FD33S/35S/ Distributor type
950 Average: 35.9 ± 2.5
40S/45S-4 (6206-71-1161)
100 Average: 60- 90

(High speed
500 Average: 44.6 ± 2.5

6D95L'1
FD33S/35S/ 750 Average: 45.6 ±1 3
40S/45S-4 (Full load)
FD35Z/40Z-4 Distributor type 1,075 Average: 38.1 ± 2.5
FD35/40/45-4 (6206-71-1170)
FD35/40/45-5E (6206-71-1171)
FD50E/60E/ (6206-71-1172) 100 Average: 60- 90
70E-5
SD23/25-3 (Idling) 350 Average: 12.2 ±2 2
(High speed
500 Average: 44.6 ± 2.5

750 Average: 45.6 ±1 3
(Full load)
1,075 Average: 38.1 ± 2.5
100 Average: 60- 90
FD50E/60E/ Distributor type
70E-6 (6206-71-1 173)
(High speed
control) 1.150 Average: 17.5 ±3 4.5
150 Average: max. 20

(Stop)
40-8 6D95l!S6D95L-1
TESTING AND ADJUSTING STANDARD VOLUME OF FUEL INJECTION
Max. variation
Applicable Type of Rack position Pump speed Injection volume
Engine
machine injection pump (mm) (rpm) (mm 3 /st) (~et. 3cy~)
mm /st
500 Average: 45.1 ± 2.5
750 Average: 46.3 ± 1 3

(Full load)
Distributor type 1,125 Average: 40.7 ± 2.5
(6206-71-1190)
FD50/60/70-5 (6206-71-1191)
(6206-71-1192) 100 Average: min. 85
(Idling) 350 Average: 12.2 ± 2 2

(High speed
1,225 Average: 10.9 ± 3 4.5
control)
500 Average: 44.8 ± 2.5
750 Average: 43.6 ± 1 3

(Full load)
1,125 Average: 44.4 ± 2.5
Distributor type 100 Average: 66.8 ± 5

FD50/60/70-6 With timer
(6206-73-1192) (Idling) 350 Average: 10.8 ± 2 2
6D95L-1
(High speed 1,225 Average: 12.2 ± 3
control) 4.5

(Stop)
500 Average: 54± 2.5
750 Average: 54.2 ± 1 . 3

(Full load)
1,075 Average: 50.3 ± 2.5
Distributor type 100 Average: 70 ± 15
FD35Z/40Z-5 With timer
FD35/40/45-5 (6206-73-1171)
(6206-73-1172) ; (Idling) 350 Average: 13.4 ± 2 2
(High speed 1,150 Average: 23.1 ± 3 4.5
control)
125 Average: max. 5
[ ]: for [150] [max. 20]
(Stop)
6206-73-1172 350
[200] Average: ?r
max.1 51
500 Average: 61.8 ± 2.5
750 Average: 65.6 ± 1 3

Distributor type (Full load)
(6207-71-1110) 1,000 Average: 66.2 ± 2.5
FD60H/70H/
S6D95L·1 80H-5 (6207-71-1111)
(6207-71-1112) 100 Average: min. 80
(6207-71-1113)
(idling) 350 Average: 12.2 ± 2 2
(High speed Average: 12.0 ± 3 4.5
control) 1,100
6D95L/S6D95L·1 40-9
TESTING AND ADJUSTING ADJUSTMENT OF GOVERNOR
ADJUSTMENT OF GOVERNOR
6D95L-1 In-line type 6D95L-1 Distributor type
FD35Z/4DZ-4, FD35/40/45-4 FD33S/35S/40S/45S-4
(6206-71-1 130) (6206-71-1160)
Min.B 5 -
Adjustment range 350- 1075 rpm
Rack cap:
Approx. 13
"!
I -0 0
+I
I +I
¢
~
-
....... 0
E
s
II. 7
9. 7
8.7
~
\ "
.3
.9
~
\
.•
c
0
·~ 6.0
1\
~
0
0.
u
a:•
1\ 1\_ 17 .4
\
9.4
0
350
I~
(860( 1175±20
0
100
I"
350 500 750 1075 I
400 1075'~~ 400-480 1150
Pump speed (rpm)
750
Pump speed (rpm)
6D95L-1 In-line type 6D95L-1 Distributor type

FD33S/35S/4DS/45S-4 FD33S/35S/4DS/45S-4
(6206-71-111 0) (6206-71-1161)
Adjustment range 350 - 950 rpm 60-9 o -

Rack cap· Approx 13
--., Idling spring set: 350 -950
tf
;;-- 43.0
E 11.7 --, E 42. ~
sc 9.5
'\ I .§ /
~
~
\/
' 0
N ·~ 35.7
•0 8.7
+0
0 •0
0. \
\ +•
"'~
~
•
u
a:
6.0 '
'
'I
"l
0
":
..•
.~
0
\
15. 4
I
I 12. 2
'I \
0 350 400
''L
(900( 1050 ± 20
0
100 350
\
500 750 950
\
750 950 =~g 400-480 1025
Pump speed (rpm I
Pump speed (rpm)
40-10 6D95L/S6D95L-1
6D95L-1 Distributor type 6D95L-1 Distributor type

FD35Z/40Z-4, FD35/40/45-4 FD35Z/40Z-5, FD35/40/45-5
SD23/25-3, FD33S/35S/40S/45S-4 (6206-73-1171. 6206-73-1 172)
(6206-71-1170, 6206-71-1171) .l1 E TIMER CHARACTERISTIC
FD50E/60E/70E-6 e E The dimension of figures
ti -;a in parenthesis is degree.
(6206-71-1 173) 1: 12ll'!r--'-----::....::.:.:::.:.;.--
70 ± 15
ll
'0.
"• "m
..
/I
-~
-I\
60 -90 E
F
" ~
'"
Pump speed (rpm)
53,9
·45.3
/ \ ~
iii
;;-
E
.s
...
53.7
50 .0
'
---
44.3
37.9 /
"'•
0
""'
1:'
.•>
17.4
•
D 23 .0
13. 4
1\
12.2
0
I'
350 500
1\
1075""·
0
100 350
f\
500 750 1075
I
400-480 1150
100 750 11 50
/400-480. Pump speed (rpm)
Pump speed (rpm I
6D95L-1 Distributor type 6D95L-1 Distributor type

FDS0/60/70-5 FDS0/60/70-6
(6206-71-1190, 1191, 1192) (6206-73-1292)
TIMER CHARACTERISTIC
The dimension of figures
in parenthesis is degree.
M'Ln. 85 r-
66.8 ± 5 ~ ~
Pump speed {rpm)
1
·46
44.8
. 40.5 /
-
--.........
" ----
1\
12.2
10.8 -
-
0
1\
350 500 1125
1do 7~0 122 5 1225

400-480
Pump speed (rpm) Pump speed (rpm)
6D95L/S6D95L-1 40-11
S6095L-1 Distributor type

FD60H/70H/BOH-5
(6207-71-1110)
Min. 80 -
65,8
\
-
.!!!
66,2
61.4
""
/ v
1
.E.
~
0
m
~
0'
~
.m
.2:
0
12.2
11.9
-......
360 sao: 1000
:L /
400-480
760 110
Pump speed (rpm)
40-12 6D95L/S6D95L-1
TESTING AND ADJUSTING PERFORMANCE TEST
PERFORMANCE TEST
RUN-IN STANDARD • Load are given for the case 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
Running time min. 2 10 2 2 10

FD35Z/40Z-4
FD35/40/454
FD335/355/ Engine speed •pm 700 1,070 1,500 1,820 2,150
405/455-4 kg 1g 26
0 33 37
5023/25-3 Load (lbs) (57) (73)
(O) (42) (82)
FD30/40/45-5E
Output HP 0 20 40 60 80
Engine speed •pm 700 1,070 1,500 1,820 2,150

FD35Z/40Z-5
FD35/40/45-5 kg 0 1g 26 33 37
Load (42) (82)
(lbs) (0) (57) (73)
Output HP 0 20 40 60 80
6D95L-1
FD50E/60E 1,500 1,820
Engine speed •pm 700 1,070 2,150
70E-5
FD50E/60E kg 0 1g 26 33 37
70E-6 Load (lbs) (O) (42) (57) (73) (82)
Output HP 0 20 40 60 80

FD50/60/ Engine speed •Pm 700 1,000 1,200 1,600 2,250
70-5
kg 0 10 20 40 40
FDS0/60/ Load (0) (88) (88)
(lbs) (22) (44)
70-6
Output HP 0 10 24 64 88
Engine speed •Pm 700 1,000 1,200 1,600 2,000

S6095L-1 FD60H/70H/
80H-5 kg 0 10 20 40 55
Load (88)
(lbs) (0) (22) (44) (121)
Output HP 0 10 24 64 110
6D95L/S6095L-1 40-13
PERFORMANCE TEST CRITERIA
Engine Applicable Specified value Engine speed Dynamometer

Test item
model machine (fully equipped) (rpm) (kg) [lbs]
Flywheel horsepower 82 HP /2,150 rpm 36.5- 38.8

2,150±50
[80.5 - 85.6]
FD35Z/40Z-4 28 kgm/1 ,500 rpm 38.0-40.8

Maximum torque 1,500 ± 100
FD35/40/45-4 (203 lbft/1,500 rpm) [83.8 - 89.9]
FD335/355/
405/455-4
High idling speed 2,350 ± 50 rpm 2,300 ±50 0 [OJ
FD35/40/45-5E
5023/25-3
Low idling speed 700 ± 25 rpm 700 ± 25 0 [OJ
35.6-41.1
Flywheel horsepower 85 HP/2,150 rpm 2,150 :::~~
[78.5 - 90.6J
36.6-42.1
FD35Z/40Z-5
Maximum torque 28 kgm/1 ,500 rpm 1,500 ± 100
[80.7- 92.3J
FD35/40/45-5
High idling speed 2,350 :!:~5 rpm 2,350 :!:~5 0 [0]
Low idling speed 700 ± 25 rpm 700 ± 25 0 [0]

6D95L-1
Flywheel horsepower 82 HP /2,150 rpm 2,150±50 36.6- 41.1
[80.7- 90.6]
FD50E/60E 36.6-42.1
Maximum torque 28 kgm/1 ,500 rpm 1,500 ± 100
70E-5 [80. 7 - 92.8]
FD50E/60E
70E-6
High idling speed 2,350 ± 50 rpm 2,350 ±50 0 [0]
Low idling speed 700 ± 25 rpm 700 ± 25 0 [OJ
38.7- 42.6
Flywheel horsepower 90 HP /2,250 rpm 2,250 - 2,300
[85.3 - 93.9]
*95 HP/2,250 rpm
39.4-44.9
Maximum torque 30 kgm/1 ,500 rpm 1,400-1,600
FD50/60/70·5 [86.9 - 99.0]
*32 kgm/1 ,500 rpm
FDS0/60/70-6"'
High idling speed 2,500 ± 50 rpm 2,450 - 2,550 0 [OJ
Low idling speed 700 ± 25 rpm 700 ± 25 0 [0]
51.5- 56.5
Flywheel horsepower 110 _,g HP/2,000 rpm 2,000 +!'ig [114-125]
52.9- 58.5
Maximum torque 41.5 -~ kgm/1,500 rpm 1,500 ± 100
FD60H/70H [117-129J
56D95L-1
80H·5
High idling speed 2,200 ± 50 rpm 2,150 - 2,250 0 [OJ
Low idling spe.ed 700 ± 25 rpm 700 ± 25 0 [OJ

.
40-14 6D95L/S6D95L-1
* The values given for the output and torque are with the fan removed, so they differ from those of the specificaion.
* Values are standardized under the following conditions: Air cleaner installed; alternator idling; and air compressor
(if installed) open.
* Dynamometers are given for the case of the arm length is 716 mm (28.2 in).
* Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
* Lubrication oil used: CLASS-CD SAE30.
Torque Fuel consumption

Coolant Lubrication oil Lubrication oil Exhaust
Output IHP) temperature temperature pressure (kg/cm 2) temperature ("C)
(kgmJ[Ibft] (sec./1 00 cc)
('CJ ('CJ [psi] (bar) t-lntake temp. - 20"C
3.0 5.5
78.5- 83.5 - Min. 20.7 70-80 80-110 [4.3- 85] Max. 650
(2.9- 5.4)
27.2- 29.2
-
[197- 211] - 70-80 eo- 110 - Max. 650
0 0 - 70-80 80- 110 - -

Min.1.0
0 0 - 70-80 Min. 80 [Min. 14.2]
(Min. 0.981
-
76.5- 88.5 - Min. 19.6 70-80 80-110 3.0-7.0 Max. 650
26.2-30.2
-
[190- 218]
- 70-80 80-110 - Max. 650
- - - 70-80 80-110 - -
Min. 1.0
- - - 70-80 Min. eo [Min. 14.2]
(Min. 0.981
-
3.5 6.0
78.5- 83.5 - Min. 20.7 70-80 80-110 [49.7 - 85.3] Max. 650
(3.4- 5.91
26.2-30.2 -
- (190-218]
70-80 80-110 - Max. 650
0 0 - 70-80 80- 110 - -
Min. 1.0
0 0 - 70-80 Min, 80 [Min. 14.2] -
(Min. 0.98)
5.0 6.0
87-96 - Min. 18.3 70-80 90-110 [71.1 - 85.3] Max. 650
(4.9- 5.9)
- 28.2- 32.2 - 70-80 -

[204- 233] 90-110 Max. 650
0 0 - - 90-110 - -
Min. 1.0
0 0 - - Mln. 80 [Min. 14.2] -
(Min. 0.98)
3,6-6.0
103- 113 - Min. 16.0 70-80 90- 110 [51.2 - 85.3] Max. 650
(3.5- 5.9)
- 37.9-41.9
[274- 303] - 70-80 90- 110 - Max. 650
0 0 - - 90- 110 - -
Min. 1.0
0 0 - - Min. 80 [Min. 14.2]
(Min. 0.98)
-
6D95L/S6D95L-1 40-15
TESTING AND ADJUSTING TOOL LIST
No. Testing and measuring item Fault finding tool Part No. Remarks
1 Engine speed Multi-tachometer 799-203-8001 Digital reading: 60 - 20,000 rpm
2 Battery S.G. 1.100- 1.300

Battery coolant tester 795-500-1 001
3 Freezing temperature of -5- -50"C
cooling water
4 Water temperature, oil tempe-

rature, air intake temperature
Digital temperature gauge 799-101-1500 -99.9 - 1299'C
5 Exhaust temperature
10- 142 psi)

6 Lubrication oil pressure o - 10 kg/em' [0- 10 bar]
(0 - 285 psi)
7 Fuel pressure 0 - 20 kg/em' 10- 20 bar]
Intake pressure, exhaust Engine pressure

8 measuring kit 799-203-2002 0 - 1,500 mmHg
pressure
9 Blow-by pressure 0 - 1,000 mmH,O
10 Intake resistance -1,000 - 0 mmH,O
Compression pressure
0 - 70 kg/em' (0- 1000 psi)
11 Compression gauge, hose 795-502-1205 [0- 69 bar]
12 Blow-by pressure Blow-by checker 799-201-1504 0-500 mmH 20
Feeler gauge 795-114-1370 IN/EX 0.35/0.50 mm !COLD)

13 Valve clearance (0.0138/0.0197 inl
799-201-9000 Dirtiness 0 - 70% with standard color

14 Exhaust gas color Handy smoke checker (Dirtiness % x 1/10 = Bosch scale)
799-201-6000 Provided with 0.1 and 0.2 water
15 Water and fuel contnet in oil Engine oil checker content standard sample
Fuel injection pressure Commercially
16 Fuel J~jection nozzle spray Nozzle tester 0 - 300 kg/cm'IO - 4270 psi!
available [0- 294 bar]
17 Coolant quality Water quality tester 799-202-7001 PH, nitrite ion concentration
Pressure valve function 799-202-9001 10-30 psi)
18 Leakage in cooling system Radiator cap tester 0 - 2 kg/em' [0- 2.0 bar]
19 Radiator blockage (wind speed) Anemometer

(Air speed gauge) 799-202-2001 1-40m/s
Tester Commercially Current, Voltage, Resistance

20 Electrical circuit available
.
40-16 6D95L/S6D95L-1
ENGINE
50 INSPECTION STANDARD
Turbocharger ....................................................... 50- 2

Cylinder head· ....................................................... 50- 3
Valve and valve guide ....................................... 50- 4
Rocker arm shaft, push rod and tappet .......... 50- 5
Cylinder block ..................................................... 50- 6
Crankshaft ............................................ 50- 8
Piston, piston ring and piston pin .................... 50-10
Connecting rod ................................................... 50-12
Timing gear ......................................................... 50-14
Camshaft .............................................................. 50-16
Flywheel and flywheel housing ........................ 50-17
Oil pump .............................................................. 50-18
Regulator valve ................................................... 50-19
Water pump and thermostat ............................. 50-20
6D95L/S6D95L-1 50" 1
INSPECTION STANDARD TURBOCHARGER
TURBOCHARGER (S6D95U
1 4
6207F402
7 3 8
6207F401
Unit' mm (in)
No. Check item Criteria Remedy
Standard size Repair limit

1 Radial play of rotor
0.075 - 0.150 0.18
(0.0030 - 0.0059) (0.0071)
0.025 - 0.075 0.10

2 End play of rotor
(0.0010 - 0.0030) (0.0039)

3 Thickness of thrust bearing
4.36 4.35
(0.172) (0.1711
Measuring point Standard size Repair limit

Replace
Outside diameter of wheel shaft A 17.340 (0.68271 17.25 10.6791 I
4 8 10.155 (0.3998) 10.1 5 (0.3996)
Repair limit:
Bend of wheel shaft ?0~~g041 (Total indicator reading)

5 l nside diameter of back plate
12.70 12.73
(0.5000) (0.5012)
Measuring point Standard size Repair limit
6 Inside diameter of center housing c 1 5.80 (0.6220) 15.81 (0.6224)
D 18.03 (0.7098) 18.08(0.7118)
Tightening torque of blower 1.3 ± 0.2 kgm

7
housing mounting bolt (9 ± 1.5 lbft)
Retighten
Tightening torque of turbine 2.0 ± 0.2 kgm
8
housing mounting bolt (15 ± 1.51bft)
50-2 6D95L/S6D95L-1
INSPECTION STANDARD CYLINDER HEAD
CYLINDER HEAD 3 5
Tightening order of cylinder head mounting bolt
(®@@ 80 tml@@ 13® ®)

Front Rear
@ @ ® 0 @ ® @I
@J @I ® 0 @ ®
Intake side
6206F401A
Unit: mm (in)
Standard Repair limit

Distortion of cylinder head
1 Repair by
mounting surface 0- 0.05 0.30
grinding or
(0- 0.02) (0.012)
replace
3.12 ± 0.28 2.7-3.5 Replace

2 Protrusions of nozzles
(0.123- 0.011) (0.106- 0.138) nozzle gasket
Tightening by plastic Order Target (kgm} Range (kgm)

turning angle
1st step 7 (51) 6-8 (43- 58)
Tightening torque of cylinder head
mounting bolts
2nd step 11 (80) 10.5- 11.5 (76- 83)
(Coat bolt threads and washers
3 with molybdenum disulphide) 3rd step 90" 90"- 120"
1st step 8 (58) 7-9 (51- 65)

Retighten
Tightening by torque 2nd step 12 (87) 11-13(80-94)
3rd step 15 (109) 14.5-15.5 (105- 112)
Tightening torque of nozzle

4 4.5 ± 0.5 kgm (33 ± 4 lbft)
holder mounting bolt
Tightening torque of head

5 0.9 ± 0.1 kgm (6.6 ± 0. 7)
cover mounting bolt
6D95L/S6D95L-1 50-3
INSPECTION STANDARD VALVE AND VALVE GUIDE
VALVE AND VALVE GUIDE

4
2
IN
6206F402 6206F403
Unit: mm (in)

1 Amount of valve sinking
0 ± 0.18 Replace valve
1.00 (0.039)
(0 ± 0.0071) or valve seat

2 Thickness of valve head
1.40-1.60 Replace valve
1.00 (0.039)
(0.0551 - 0.0630)
Standard Tolerance Repair limit

3 Valve seat angle Judge condition of Repair or
45' ± 15' contact surface by replace valve
vacuum test and valve seat
Tolerance
Standard size Standard Clearance
clearance limit
Shaft Hole
Clearance between valve guide 0.035
+0.020
0.035
4 8 (-0.0014) 0.070 0.20
and valve stem Intake (+0.0008) Replace
(0.3150) -0.050 (0.0014- (0.0079)
0
(-0.0020) 0.0028) valve,
-0.050 +0.020 0.050 valve guide
8 (-0.0020) 0.080 0,20 or both
Exhaust -0.060
(+0.0008) (0,0020-
(0.3150) 0 (0.0079)
[-0.0024) 0.0031)
Free Installed Installed Free Installed

Valve spring length length load length load
5 15.6 ± 1.5 kg 13.0 kg
56(2.2) 40.5 (1.6) 55(2.2) Replace
(34 ± 31b) (291b)
Squareness of valve spring Repair limit: 1.85°
·Standard Tolerance
6 Protrusion of valve. guide
14.5 (0.5709) ± 0.2 (±0.0079) Repair
50-4 6D95LIS6D95L-1
INSPECTION STANDARD ROCKER ARM SHAFT, PUSH ROD AND TAPPET
ROCKER ARM SHAFT, PUSH ROD AND TAPPET
2 3
6206F405
6206F404
Unit: mm (In)
No. Check item Criteria .Remedy
Standard Tolerance
Outside diameter of rocker arm
shaft a Replace rocker
19 10.75) -a.a2a l-0.0008) arm shaft
Inside diameter of rocker arm +a.a30 I+O.Oa12) Replace

shaft hole 19 10.75) +a.a1 a l+o.oaa41 rocker arm
1
Standard clearance Clearance limit
Clearance between rocker arm
and rocker arm shaft Replace rocker
a.a1 a - a.o5a a.12la.a047) arm or rocker
la.Oa04 - a.002a) arm shaft
Bend of rocker arm shaft

Repair limit:
?o~g0791 (Total indicator reading) Replace rocker
arm shaft
2 Bend of push rod

Repair limit:
?o~g11 Bl (Total indicator reading) Replace
push rod
Valve Standard Tolerance
3 Valve clearance (at cold) Intake 0.35 10.0138) ±a.a2 l±a.0008)

Adjust
Exhaust a.5a la.a197) ±a.a2 l±a.aOOB)
Standard Tolerance
Outside diameter of tappet
-O.D151-0.0a06) Replace
1610.63) -0.030 l-0.012) tappet
1610.63) +0.020 1+0.0008) Replace

Inside diameter of tappet hole
0 cylinder block
4
Standard clearance Clearance l'lmit
Clearance between tappet and
tappet hole a.Q15 - 0.050 0.12 Replace tappet
10.0006 - 0.0020) 10.00471 or cylinder
block
Tightening torque of adjustment 4.5 ± 0.5 kgm

5 Retighten
nut of rocker arm 133 ± 41bft)
6D95L/S6D95L-1 50-5
INSPECTION STANDARD CYLINDER BLOCK
CYLINDER BLOCK
~~
J 1 0
0
~
0
1
J:, :!!
- 1 1/~
Dfd
.'--
fp
~ r \"'\ I
6206F407
4 6206F406
Unit: mm (in)
No. Check Item Criteria Remedy
Piston size Standard size Tolerance Repair limit Repair by

using over
STD 96.00 (3.740) 95.15(3.746) size piston,
Inside diameter of cylinder replace
+0.020 (+0.0008) cylinder block
0.25 D.S. 95.25 (3.750) 95.40 (3.756) or insert
0
1 cylinder liner
0.50 o.s. 95.50 (3.760) 95.65 (3.766)
Roundness of cylinder Repair limit: 0.02 {0,0008)
Cylindridty of cylinder Repair llmlt: 0.02 (0,0008)
50-6 6D95LIS6D95L-1
INSPECTION STANDARD CYLINDER BLOCK
Unit: mm (in)
There are both S-size and L-size pistons for each size of piston
in the 95 series of engines. Select the size of pistons according to
the followings.
0 When using the Standard (STD) piston,
use the size of pistons indicated by the stamped mark (S or L)
on the top surface of the cylinder block.
0 When using the Over Size (O,S.) piston,
measure inside diameter of cylinder at points 40 mm, 100 mm
and 160 mm from the cylinder block top face.
Then select S-size or L-size piston according to the smallest
of the three inside diameters.
When changing
the piston size,
Piston Standard Cylinder Inside diameter Selected correct the
1 Selection of pistons size size [Range] stamped mark
piston size
(S or Ll on the
95.25 +g. 011 (3.7500 ~. 0004) cylinder block
0.25 95.25
[95250 -95261
(3.7500 - 3.7504
J S-size
piston
top face
o.s. (3.75001 +0.011 ~ +{),0004)

95.25 +0.022 3.7500 ~.0009 L-size
[95,261 - 95.272
(3.7504- 3.7509
J piston
95.50 +g. 011 (3.7598 ~.Ooo 4 ) S-size

0.50 95.50
[95.500 - 95.511
(3.7598 -3.76031
J piston
o.s. (3.75981 +0.011 ~ +{).0004)
95.50 +0.022 3.7598 +{).0008 L-size
[95.511 -95.522
(3.7603- 3.7507!
J piston

Distortion of cylinder head Repair by
2 mounting surface graiding
0-0.08 (0- 0.0031) 0.15 (0.0591
Standard Tolerance
Inside diameter of main bearing
hole +O.D19 (+0.00071
74 (2.91 -0.005 (:-lJ,00021 Repair or
3 rePlace
Roundness of main bearing hole Repair limit: 0.005 (0.00021 cylinder block
Straighteness of main
bearing holes Repair limit: 0.010 (0.00041
Standard size Tolerance Repair limit

70.00 70.20
STD (2.7561 (2.7641
69.75 69.95
0.25 u.s. 12.7461 (2.7541 Replace
4 Inside diameter of main bearing +0.103
69.50 (+0.0041 I 69.70 main bearing
0.50 u.s. (2.7361 +0.053 (2.7441
(+{).0021 I
69.25 69.45
0.75 u.s. (2.7261 (2.7341
69.00 69.20
1.00 u.s. (2.7171 (2.7241
Standard Tolerance Rapair or

5 Inside diameter of cam bushing
replace
hole +0.030 (+0.001 21
53.5 (2. 10631 cylinder block
0
Standard Tolerance Repair limit

6 Inside diameter of cam
bushing +0.020 (+{).00081 Replace
50.5 (1.9881 -0.050 (-0.00201 50.60 (1.9921
Order Target Range

Tightening torque of main bearing 11 -12kgm
cap mounting bolts 1st step 1 1.5 kgm (83 lbftl (80 - 87 lbftl
7
(Coat bolt threads and washers 2nd step 0 Loosen completely
with engine oil)
13 14 kgm Retighten
3rd step 13.5 kgm (98lbftl (94.0- 101 lbftl
6D95L/S6D95L-1 50-7
INSPECTION STANDARD CRANKSHAFT
CRANKSHAFT
6095L-1 4
6206F408
Unit: mm lin)

Repair by
1 End play using over size
0.130-0.350 0.40 (0.0157)
(0.0051 - 0.0138) thrust bearing
or replace
70.00 69.86
STD (2.756) (2.750)
69.76 69.61
0.25 u.s. (2.746) (2.741)
Outside diamter of main
journal 69.50 +0.015 1+0.0006) 69.36 Repair by
0.50 u.s. 12.736) 0 12.731) using under
size bearing
69.25 69.11 or replace
0.75 u.s. (2.726) 12.721)
69.00 68.86
2 1.00 u.s. 12.717) 12.711)
.
Repair limit: 0.020
Roundness of main journal (0.0008)
.

Clearance of main journal
0.043 - 0.1 03 0.25 (0.0098) Replace main
(0.0017- 0.0041) bearing
57.00 56.91
STD (2.244) 12.241)
56.75 56.66
0.25 u.s. (2.234) 12.231)
Outside diameter of crankpin
journal 66.50 +0.015 (+0.0006) 56.41 Repair by
0.50 u.s. 12.2241 0 12.221) using under
size bearing
0.75 u.s. 12.215) 12.211)
3
56.00 55.91
1.00 u.s. (2.205) 12.201)
Repair limit: 0.020

Roundness of crankpin journal (0.0008)
.
Clearance of crankpin journal Replace

0.029 - 0.089
0.22 (0.0087) connecting
(0.0011 - 0.0035)
rod bearing
Repair by
using under
?0~5035. (Total indicator reading}
1
4 Bend of crankshaft Repair limit:
size bearing
or replace
50-8 6D95L/S6D95L-1
INSPECTION STANDARD .CRANKSHAFT
S6095L-1
1 3 2 4
I
1
6206F408
Unit: mm (in)
Standard Repair limit )£:1

Repair by
1 End play uSing over size
0.130-0.350 0.40 (0.0157)
10.0051 - 0.0138) thrust bearing
or replace
70.00 69.86
STD ;!!2
Outside diamter of main (2.756) (2.750)
0.25 u.s. (2.746) 0 (2.741) using under
size bearing
0.50 u.s. (2.736) (2.731)
2
Repair limit: 0.020
Roundness of main journal (0.0008)

Clearance of main journal
0.043 - 0.1 03 0.25 (0.0098) Replace main
(0.0017- 0.0041) bearing
Standard size Toleran!=e Repair limit
STD 57.00 56.91

Outside diameter of crankpin (2.244) (2.241) l!!2
0.25 u.s. (2.234) 0 (2.231) using under
size bearing
56.50 56.41
3
0.50 u.s. (2.224) (2.221)
or replace
'
Repair limit: 0.020
Roundness of crankpin journal
(0.0008)

Clearance of crankpin journal Replace
0.029 - 0.089 0.22 (0.0087) connecting
(0.011 - 0.0035) rod bearing
Repair by m2
using under
4 Bend of crankshaft Repair limit: fo~50351 (Total indicator reading) size bearing
or real ace
...:::1: It 1s 1mposs1ble to repair usmg overs1ze ... m2: It 1s 1m possible to repair usmg undersize
for the tufftriding crankshaft. for the tufftriding crankshaft.
6D95L/S6D95L-1 50-9
INSPECTION STANDARD PISTON, PISTON RING AND PISTON PIN
PISTON, PISTON RING AND PISTON PIN

6D95l-1 4 3 2
Cs
6206F413
Unit· mm (in)
Standard
Size mark Tolerance Repair limit
size
95.00 -0.045 94.85
STD (-0.00181
(3.740) L (3.734)
1 Outside diameter of piston -0,060
95.25 l-0.00241 95.10
0.25 o.s. (3.750) -0.060 (3.744) Replace piston
(-0.00241
0.50 o.s. 95.50 s -0.075 95.35
(3.760) (-0.00301 (3.754)
No.
Measuring Standard clearance Clearance limit
point
2
0.30- 0.45
2 Top ring
(0.012- 0.018) 2.0 (0.079)
3 Piston ring gap

Second 0.30- 0.45 2.0 (0.079)
3 ring (0.01 2 - 0.01 B) Replace
4
0.25-0.40
4 Oil ring (0.0098 - 0.01 6) 1.5 (0.059)
Tolerance
Measuring Standard Standard Clearance
No.
point size clearance limit
5 Ring Piston
-0.01 +0.07 0.06
2 l-0.00041 (+0.0028) 0.10 0.15
Clearance between piston ring 5 Top ring (0.0787) -0.03 +0.05 (0.0024- (0.0059)
6
groove and piston ring (-0.00121 (+0.0020) 0,0039)
-0.01 +u.U'I 0.03
(-0.0004) (+0.0016) 0.07 0.20 Replace
Second 2
6 (0.0787) -0.03 +0.02 (0.0012- (0.0079) piston ring
7 ring
{-0.0012) {+0.0008} 0.0028) or piston
-0.01 +0.04 0,03
4 l-0.00041 (+0.0016) 0.07 0.15
7 Oil ring (0.1575) -0.03 +0.02 (0.0012- (0.0059)
I 0,0012) (+0.0008} 0.0028)
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between piston Shaft Hole
8
and piston pin
0 +0.010 0.005- Replace
30 [+0.000~) 0.015 0.05
-0.005 piston or
(1.1811) +0.005 b".0002- (0.0020)
(-0.0002) (+0.0002) .0006) piston pin
50-10 6D95L/S6D95L-1
INSPECTION STANDARD PISTON, PISTON RING AND PISTON PIN
S6D95L-1
4 3 2
6
_j2smm
B
6206F413
Unit· mm (in)
Standard
size
Size mark Tolerance Repair limit
95.00 -0.045 94.85

STD l-0.0018)
13.740) L 13.734)
1 Outside diameter of piston -0.060
95.25 l-0.0024) 95.10
0.25 o.s. 13.750) -0.060 13.744) Replace piston
l-0.0024)
0.50 o.s. 95.50 s -0.075 95.35
13.760) (-0.0030) 13.754)
Measuring
No. Standard clearance Clearance limit
point
2
0.30- 0.45
2 Tap ring 10.012- 0.018) 2.0 10.079)
3 Piston ring gap

Second 0.30- 0.45
3 10.012- 0.018) 2.0 10.079) Aelllace
ring
4
0.25- 0.40
4 Oil ring 1.5 10.059)
10.0098- 0.016)
Tolerance
Measuring Standard Standard Clearance
No.
- point size clearance limit
5 Ring Piston
-0.01
2 (-0.0004)
Clearance between piston ring 5 Top ring Judge using wear gauge
6 10.0787) -0.03
groove and piston ring l-0.0012)
-0.01 +0'~- 0.03
Replace
Second 2 l-0.0004) 1+0.0016) 0.07 0.20
6 -0.03 +0.02 (0,0012- 10.0079) piston ring
7 ring 10.0787)
l-0.00121 1+0.0008) 0,0028) or piuon
0.01 +0.04 0.03
4 (-0.0004) (+0.0016) 0.07 0.15
7 Oil ring 10.1575) -0.03 +0.02 (0.0012- 10.0059)
l-0.0012) (+0.0008) 0,0028)
Tolerance
Clearance between piston Shaft Hole
B and piston pin
0 +0.010 0.005 Replace
30 1+0.0004) O.D15 0.05
-0.005 10.0020) piston or
11.1811) 1-0.0002) +0.005 &0.0002-
1+0.0002) .0006) piston pin
6D95L/S6D95L-1 50-11
INSPECTION STANDARD CONNECTING ROD
CONNECTING ROD
6206F414
Unit: mm lin)
No, Check item Criteria Remedy
Tolerance
Clearance between connecting rod Shaft Hole
1 bushing and p'1ston pin
0 +0.033 0.020
30 (+0.0013) 0.039 0.10 Replace
11.1811) -0.006 +0.020 (0.0008- bushing
l-0.0002) 10.0040)
{+0.0008) 0.0015)
Standard Tolerance
Inside diameter of connecting
2 rod bushing hole +0.025 1+0.001 0) Replace
33 11.3) connecting rod
0
57.00 57.20
STO (2.244) (2.252)
56.75 56.95
Inside diameter of connecting
0.25 u.s. (2.234) +0.095 (2.242)
3 Replace
'tad bearing 56.50 1+0.0037) 56.70
0.50 u.s. (2.224) +0.045 12.232)
connecting
(+0.0018) rod bearing
56.25 56.45
0.75 u.s. (2.215) (2.222)
56.00 56.20
0.10 u.s. (2.205) (2.213)
Standard Tolerance
4 Inside i::liameter of connecting
rod bearing hole +0.025 (+O.Q010)
61 (2.4)
0
Bend Repair limit
5
Be.nd and twist of connecting
cod
'"'"!!t
Order
: 167 .
Bend
Twist
Target
0.25
(0.0098)
0.35
(0.0138)
Range
Replace
Connecting rod
Tightening torque of connecting

rod cap mounting bolts 4.0-4.2 kgm
6 (Coat bolt threads and washers 1st step 4 kgm (29 lbft)
(29 - 30 lbft)
with engine oil)
2nd step Retighten with 90° 90° - 120°
50-12 6D95LIS6D95L-1
INSPECTION STANDARD TIMING GEAR
TIMING GEAR
WITHOUT FRONT PTO WITH FRONT PTO
6D95L-1 (5023/25-3) 6D95L-1 FD35Z/40Z-4 (Old engine type)
S6D95L-1 (FD60H/70H/BOH-5) FD35/40/45-4 (Old engine type)
FD33S/35S/40S/45S-4
(Old engine type)
_ __j 6206F41 I
WITH FRONT PTO

FD35Z/40Z-4
FD35/40/45-4
FD33S/35S/40S/45S-4
FD35/40/45-5E 2
FD35Z/40Z-5
FD35/40/45-5
FD50E/60E/70E-5
FD50/60/70-5
6206F412
50-14 6D95L/S6D95L-1
INSPECTION STANDARD TIMING GEAR
Unit: mm (In)
Measuring Gears Standard Repair limit

point
- Camshaft gear and 0.13-0.35

oil pump gear 10.0051 - 0.0138)
Camshaft gear and 0.15-0.30

- PTO gear 10.0059 - 0.0118)
Crankshaft gear and idler gear 0.14-0.28

A 10.0055- 0.0110)
8 Cam gear and idler gear 0.15-0.30 Replace

- Backlash of each gears 10.0059- 0.0118) 0.40 bushing or
(Helical gear) 10.0157) gear
Injection pump gear and idler 0.13-0.34
c gear 10.0051- 0.0134)
D Cam gear and oil pump gear 0.13-0.35

10.0051 -0.0138)
E Cam gear and PTO gear 0.13-0.36

10.0051 - 0.0142)
F PTO idle gear and PTO gear· 0.13-0.27

10.0051 - 0.011)
0.15-0.30
G Cam gear and PTO gear 10.0059- 0.0118)
Tolerance
Clearance between idler gear Shaft Hole
1 bushing and shaft
Replace bushi~~
0 +0.035 0.015
45 (+0.0014) 0.055 0.10
-0.015 +0.015 (0,0006-
11.77171 1-0.0006) 10.0039) or gear assembl y
{+0.0006) 0.00221
2 End play of idler gear Replace

0.08-0.14 0.20 thrust
10.0031 - 0.0055) 10.0079)
plate
m: The bushing
that is sup-
plied is a
semi-finished
part
6D95L/S6D95L-1 50-15
INSPECTION STANDARD CAMSHAFT
CAMSHAFT
1 2 3 4
Section A-A
6206F409
Unit: mm (in)
1 End play Replace

D. 150 - 0.350 0.50 (0.01 97) thrust
(0.0059- 0.0138) bearing
Tolerance
Clearance between camshaft Shaft Hole
2
and bushing -0.080 +0.020 0.030
50.5 (-0.0031) (+0.0008) 0.130 0.25 Replace
(1 .9882) -0.110 -0.050 (0.0012- (0.0098) bushing
l-0.0043} (-0.0020) 0.00511
3 Bend of camshaft
Repair limit:
fo~50121 (Total indicator reading)
Cam Standard size Tolerance Repair limit
4 Cam height Intake 42.7 (1.68) 42.2 (1.66)

±0.10 Replace
(±0.0039) camshaft
Exhaust 43.4 (1.71) 42.9 (1.69)
50-16 6D95L/S6D95L-1
INSPECTION STANDARD FLYWHEEL AND FLYWHEEL HOUSING
FLYWHEEL AND FLYWHEEL HOUSING
6206F415
6206F416
Unit· mm lin}
1 Face runout of flywheel housing

Repair limit: 0.35
(0.01381
2 Radial runout of flywheel housing Repair limit: 0,30

(0.01181
Repair by
reassembling
3 Face runout of flywheel Repair limit: 0.20
(0.00791
4 Radial runout of flywheel Repair limit: 0.15

(0.00591
Order Target Range

Tightening torque of flywheel '0'
5
mounting bolts
0@)0
I (© i 1st step
11 kgm
(80 lbftl
10-12kgm
(72- 87
!Coat bolt threads and washers •0·~0 lbft)
with engine oil) •, 0 19.5 kgm 19-20 kgm
2nd step (141 lbftl (137- 145 Retighten
lbftl
Tightening torque of flywheel 7 ± 0.5 kgm

6 (51 ± 4 Jbft)
housing mounting bolts
6D95L/S6D95L-1 50-17
INSPECTION STANDARD OIL PUMP
OIL PUMP 6 g 5 4 3
6206F417
Unit: mm (in)
Tolerance Standard Clearance

Standard
Engine clearance limit
size (End play)
Gear width Body depth (End play)
0 +0.070 0.030
1 Axial clearance of pump gear 16 -O.D15 (+0.0028) 0.085 0.10
6095L-1 (0.63) -0.030 (0.0012- (0.0039)
(-0.0006) (-0.0012} 0.0033)
0 +0.070 0.030
21 (+0.0028) 0.085 0.10
S6095L-1 (0,83) -0.015 -0.030 (0,0012-
l-0.0006) (0.0039)
l-0.0012) 0.0033) Replace
gear
Tolerance
Gear width Body I. D.
2 Radial clearance of pump gear
+0.115 +0.245 0.045
38 (+0.0045) (+0.0096) 0,090 0.13
(1.4961) +0.065 +0.205 {0.002- (0.0051)
1+0.0026) 1+0.0081) 0.0035)
Tolerance Standard
Standard Clearance
size
clearance or
interference limit
Interference between pump drive Shaft Hole
3
gear and drive shaft -0.025 0.065 0.025
13 l-0.00101.. l-0.00261 0.060 - Replace
(0.51) -0.040 -0.085 10.0010-
l-0.0016) (-0.0033) 0,0024)
0.025 +0.020 0.025
Clearance between drive 13 l-0.0010) 0.060 Replace
4 10.51) (+0.00081
shaft and cover -0.040 {0.0010- bushing
{-0.0016) 0 0,0024)
-0.025 -0.065 0.025
Interference between pump 13 {-0.0010) (-0.00261 0.060 - Replace
5 -0.040 -0.085 (0.0010-
gear and drive shaft (0.51)
{-0.0016) (-0.0033) 0.0024)
-0.025 0.025
Clearance between drive shaft 13 +0.060 Replace
(-0.00101 {+0.0024) 0.075
6 (0.51) -0.040 (0.0010-
and bushing 0 bushing
I 0.00161 0.0030}
+0.064 +0.020 0.019
Clearance between driven 16 {+0.0025) 0.064 Replace
7 shaft and cylinder block (0.63) +0.046
{+0.0008)
0• {0.0007- - cylinder block
1+0.00181 0.0025)
0.110 0.065 0.025
Clearance between driven 13 {-0.0043) {-0.0026} o.o6o· Replace
8 (0.51) -0.125 -0.085 (0.0010-
shaft and gear shaft or gear
l-0.00491 {-0.0033} 0.0024)
+0.085 0.035
16 +0.020
Interference between drive shaft {+0.0033)
(+0.0008)
0.085
- Replace
9 (0.63) +o~oao . {0.0014-
bushing hole and cylinder block 0 cylinder block
1+0.0023) 0.0033)
50-18 6D95LIS6D95L-1
INSPECTION STANDARD REGULATOR VALVE
REGULATOR VALVE
3 2
6206F418
Unit· mm lin)
Tolerance
Standard
size Standard clearance
Shaft Hole
1 Clearance between valve and body
-0.050 +0.020
11 (-0.00201 (+0.0008) 0.030 - 0.095
(0.431 -0.075 -0.020 (0.0012- 0.00371
l-0.00301 l-0.0008)
Replace
Installed Installed Installed

Free length Free length
2 Regulator valve spring length load load
33.1 27.8 2.44 kg 26.5 2.3 kg

11.301 (1.091 (6.381bl (1.04) (5.071bl
{85 ± 7 psl) Repair or

3 Regulator valve set pressure 6.0 i 0.5 kg/em 1
(6 ± 0,5 bar! replace spring
6D95LIS6D95L-1 50-19
INSPECTION STANDARD WATER PUMP AND TERMOSTAT
WATER PUMP AND THERMOSTAT
6206F419
Unit: mm (in)
1 Clearance of '1mpeller body Standard clearance: 0.30- 1.00

(0.01 18- 0.0394)
Tolerance
Standard Standard Interference
size interference limit
Interference between shaft and Shaft Hole
2
fan pulley boss
+0.020 -0.045 0.~:,~
15.9 (+0,0008) (-0.0018) 0,080
(0.6260) +0.005 -0.065 (0.0020-
(+0.00021 (-0.0026) 0.0031)
-0.025 0.012-
Interference between shaft and 35 0 (-0.0010) 0.050
3 -0.013 (0.0005-
body (1.38) (-0.0005) -0.050
(-0.0020) 0.0020)
0 0.043 0.030 Replace
Jnterfernece between shaft and 12 {-0.0017) 0.070
4 (0.472) -0.013 -0.070 {0.0012-
impeller (-0.0005) (-0.0028) 0.0028)
5 Bend of shaft Repair limit: 0.1 (Face runout at face A)

(0.0039)
6
Abrasion of seal ring in water
seal
A -Repair limit A: 0
Valve opening temperature: 76 ± 1.5cC

7 Thermostat Full-opening temperature: 90°C
Full-opening lift: Min. 8 (Min. 0.3150)
50-20 6D95l/S6D95L-1
ENGINE
60 REPAIR AND REPLACEMENT
CYLINDER HEAD SECTION

Grinding cylinder head mounting
face .......................................................... 60- 2
Replacing valve seat insert ........................... 60- 3
Replacing valve guide .................................... 60- 7
Grinding valve ............................................... 60- 8
Replacement of connecting rod
small end bushing .................................. 60- 8
CYLINDER BLOCK SECTION
Replacing camshaft bushing ......................... 60- 9
Replacing crankshaft gear ............................ 60-11
Replacing cam gear ...................................... 60-11
Replacing flywheel ring gear ........................ 60-11
Pressure test .................................................. 60-12
Cylinder liner .._............................................... 60-13
Manufacturing of cylinder block
bore part ................................................. 60-14
Grinding crankshaft ........................................ 60-15
6095L/S6D95L-1 60-1
REPAIR AND REPLACEMENT CYLINDER HEAD SECTION
GRINDING CYLINDER HEAD

MOUNTING FACE
1. GRINDING
Grind the cylinder head with a surface grind-
ing machine to remove deformation or rust.
Do not exceed the repair limit of cylinder
head height IH).
* Repair limit of cylinder head height H: H
90 °
- 0.2 mm c
* Tolerance limits after grinding: 6202F010
89.5 mm
* Amount to remove per grinding:

0.10-0.15 mm
* Surface roughness of grinding surface:

Within 65
* Flatness (deformation):
Within 0.05 mm
* Grinding limit: 0.3 mm

* Difference in head height per unit:
Within 0.15 mm
2. CHECKING AFTER GRINDING

• Check that the insertion depth of the valve
and the protrusion of nozzle are within the
standard value.
* Insertion depth of valve: 0 ± 0.18 mm
60-2 6D95LIS6D95L-1
REPLACING VALVE SEAT INSERT

Special tools required
No. Part No. Part Name Q'ty

795-100-3003 Seat cutter (kit) 1
Correction limit: 0 - 0.5 mm
795-100·3100 Body ass'y 1
795-1 00·3200 Micrometer 1
795-100-3300 Gauge 1
795-100-3400 Tool head 1
A 795-100-3601 Head support 1
795-1 00·371 0 Cutter 1
795-100-3730 Cutter 1
795-100-4730 Pilot 1 I
8
c
D
795-100-4740
795-100-4750
795-1 00·4800
795-100·2810
795-100-2820
Pilot
Pilot
Puller (valve seat)
Push tool
Push tool
1
1
1
1
1
8i \ 6202F011
* When correcting the valve seat insert and

not replacing it, use tool A and finish at a
range within 0.5 mm ofthe insert seat face.
* Insertion depth after machining:
0 ± 0.18 mm
1. REMOVING VALVE SEAT INSERT
A When using a grinder to carry out this

work, carry out a test run for one minute
before starting the operation to check that
there is no abnormality.
• If the grindstone has been replaced,
carry out the test run for 3 minutes.
A Check that there is no damage to the

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

1) Install grindstone ® to grinder CD.
2) Align the groove of sleeve ® with
holder ® and insert.
*
Adjust the position of the grinder 6162F504
with set screw @ .
6D95L/S6D95L-1 60-3
3) Adjust the position of the grinder so

that the center of grindstone ® is at
the center of seat insert (1). then
tighten the set screw to fix the grinder
in place.
4) Rotate the grindstone and move it
slowly until it contacts insert (1).
1
6162F505
5) Press the grindstone lightly against the

inside face of the insert and make a
groove around the whole circumfer-
ence of the inside face of the insert.
* Depth of groove: Approx. 1 mm
6) Push the three claws (a) of puller head

® of tool B inwards by hand, and fit
into insert (1).
12
7) Tighten screw ® to push the three
claws into the groove on the inside 10
face of the insert.
* When the claws are completely in
contact with the groove, stop tight-
ening.
8) Insert bridge ® on the outside of the
puller head, set plates @) and (j])
on top of the bridge, and tighten nut
@ to pull out the insert.
a
6162F506
60-4 6D95LIS6D95L-1
• When welding a bar to the insert to remove

1) Weld bar (1) (diameter: approx. 111 10) of 3
a diameter 0.1 - 0.5 mm smaller than
the inside diameter of the insert to insert
(2).
* Be careful not to get any of the weld-
ing metal on the head itself.
2) When the temperature of the weld has
dropped to around room temperature,
6127F205
insert a used valve (3) in the opposite
direction, and hit the face of the valve
with a small hammer to remove the
insert. Intake valve
* Be careful not to hit too hard, as any (Direct Injection) um.mm
't•
excessive shock will cause the weld Insert Insert mounting hole
to break off. Insert
saar Height Height Chamfer Chamfer
Diameter (d 1) Diameter (d1)
{h,) lhtl {ell (c,)
2. MACHINING MOUNTING HOLE FOR VALVE p4soa+o.too 0 p45.00 +~.020 10.70+~- 2 2.2 -~.2
S.T.D. . +0.090 8.50_0.1 2.0 -~.2
SEAT INSERT
*When no valve seat insert is used, and 0.25
o.s p4szs to. too
. +0.090 8.50_~.1 p45.25 +~·
020
10.70+~- 2 0
2.2 -0.2
0
2.0 -0.2
the seat face is damaged or worn, follow
the same procedure and use tool A to
0.50
o.s p45.50 !~:~~~ 8.62_~.1 945.50 +~.020 10.82+~- 2 2.2 -Kz 0
2.0 -0.2
grind, then press fit the insert.

1) Using tool A, grind the hole to the over-
size one level up. Exhaust valve
*
Machine within an oversize range of
(Direct injection) um:mm
.,
0.5 mm. If it is more than 0.5 mm,
Insert Insert mountlhg hole
replace the cylinder head. Insert
seal Height Height
Diameter {d 1 ) Diameter {d 1 ) Chamfer
(h,) (h,) (c,)
• Method of machining insert and mount-
ing hole S.T.D ; 39 00 +0.080
. +0.070
0
6.50 -0.1 pJe.oo +g.ozo 8.70 +g.z 0
3.0 -0.2
0.25 o.s p 39 .25 +0.080

+0.070
0
6.50 -0.1 p 39.25 +g.ozo 8.70 +g- 2 3.0 -8.2
h2 Max. 0.5 0.50 o.s p 39.50 ~8:8~8 6.62 -0.1 0 pJe.so +g.ozo a.a2 +g.z J.O -8.2
Insert
d2
l~
lhl Intake valve
d!
!J
Exhaust valve
6202F012
* Roughness of inside surface:

Within 6.3 S
* Roughness at bottom of mounting
hole: Within 12.5 S
* Concentricity with valve guide inside
surface: Within 0.05 mm (TIR)
6D95L/S6D95L-1 60-."'
3. PRESS FITTING VALVE SEAT INSERT

1) Using tool C or tool D, press fit insert
(2) of a size that matches the oversize
of the mounting hole.
* Used the inside diameter of valve guide
C orO
(4) as a guide, and press fit, taking care

that the insert is not fitted at an angle.
* To check that insert bottom face (C) is
2
completely sealed, tap with a hammer
and listen to the change in sound, or c
judge from the springing back ofthe push
tool.
2) Check the insertion depth of the insert 4 615F004
from the mounting surface of the cylin-
der head.
* Insertion depth of insert Standard:
2.2 +g.a mm (Direct injection)
4. FINISHING INSERT SEAT SURFACE

1) Using tool A, finishing the surface of the
insert seat to the dimension shown in 6202F013
the diagram below.
* When selecting a pilot to insert into the
valve guide, choose one that gives no
clearance.
. 00 (Gauge diameter) 35. 00 (Gauge
Intake valve Exhaust valve
No. Direct injection type engine
a 3.0 ± 0.1 mm
b 3.0 ± 0.1 mm
60-6 6D95L/S6D95L-1
REPLACING VALVE GUIDE

No. Part No. Part Name Q'ty A B

A 795-100-4710 Valve guide remover 1
B 795-100-4720 Valve guide driver 1
1. REMOVING VALVE GUIDE

Insert tool A from the top surface of the cylin-
der head, put it in contact with the valve
guide, then hit with a hammer to remove.
2. PRESS FITTING VALVE GUIDE

1) Press fit the valve guide until the top of
tool B contacts the cylinder head.
* After press fitting, insert the valve, and
if the valve does not enter smoothly,
machine the hole with a reamer
( ¢8 +g.o15 mm).
2) Measure the protrusion of the valve

guide and check that it is within the stan-
dard range.
* Valve guide protrusion
Tolerance: 14.5 ± 0.2 mm
6095L/S6D95L-1 60-7
GRINDING VALVE
No. Part No. Part Name O'ty
A - Valve refacer 1
(Commercially available)
1. GRINDING SEAT FACE

After using tool A to adjust the valve seat
angle, grind the seat face.
*For the angle of the valve seat, check the
Maintenance Standard Table
(Ref. page 60-6).
2. CHECKING AFTER GRINDING

• Measure the thickness of valve head, inser-
tion depth of the valve and the contact of
the valve seat face to check that they are
within the standard range.
*Thickness of valve head:
1.40- 1.60 mm
*Insertion depth of valve: 0 ± 0.18 mm
* Contact width of valve seat

Standard Intake valve: 2.0 mm
Exhaust valve: 2.0 mm
REPLACEMENT OF CONNECTING ROD SMALL END BUSHING

With bushing installed, take two measurements at sao to each other, of the small end bore using
an inside micrometer. If the difference between the measured bore and pin diameter exceeds the
limit, replace either or both the connecting rod bushing and piston pin.
1. Removal of bushing
1) Remove bushing using a pushing tool
2) Remove fins or burrs, and clean the bushing hole
2. Press fitting of bushing
1) Press fit bushing with its guide hole positioned upward so that bushing is clinched in its
upP.er half. (Only applicabe to naturally aspirated engines)
2) At this stage, piston pin will not fit as the bushing is still only semi-finished. The bushing
bore must be reamed or machined with a honing machine.
* When reamed or honed, ensure that machining chips are completely removed and the portion
is thoroughly cleaned.
* Use group wear gauge for evaluation.
60-8 6D95L/S6D95L-1
REPAIR AND REPLACEMENT CYLINDER BLOCK SECTION
REPLACING CAMSHAFT BUSHING

No. Part No. Part Name O'ty
A 795-215-1101 Push tool 1

1 795-215-1110 Push bar 1
2 795-215-1120 Push tool 1
A
3 795-215-1140 Collar 1
4 795-215-1150 Guide 1
1. REMOVING FRONT AND REAR BUSHINGS

• As shown in the diagram, assemble push
tool (2), collar (3), and push bar (1) of push
tool A, then hit the push bar to knock
bushing (6) out from cylinder block (5).
2. REMOVING CENTER BUSHING

• Assemble push bar (1). push tool (2), collar
(3), and guide (4) of push tool A, then hit
the push bar to knock bushing (6) out from
cylinder block (5).
6202F016
• After removing the bushing, remove any * CAM BUSHING ASSEMBLY DRAWING
burrs or dirt from the mounting hole of the
bushing. Oil hole
Bushing
Cylinder block
Notch Oil return hole
6127F242
6D95L/S6D95L-1 60-9
3. PRESS FITTING CENTER BUSHING

Assemble bushing (6) to tool A, and press
fit the bushing until the oil hole of cylinder
block (5) matches the oil hole of the bush-
ing. 1
I
6202FD17
4. PRESS FITTING FRONT AND REAR BUSH-

INGS
Assemble bushing (6) to tool A, and press
fit the bushing until the oil hole of cylinder
block (5) matches the oil hole of the bush- 3 6 2 1
.~~
ing. I I+
6202F01B
5. AFTER PRESS FITTING BUSHING

• Using inside gauge CD, 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 rej3mer.
• When correcting the inside diameter of
the bushing with a reamer, clean all chips
from the oil hole and oil groove.
6202F019
* Inside diameter cam bushing:
"50 •5 + 0·030 mm
'f' -0.040
* Clearance of camshaft journal:

0.030 - 0.130 mm
60-10 6D95L/S6D95L-1
REPLACING CRANKSHAFT 4) In order to push in the inner race of the

GEAR bearing with the tip at the inside of the
cam gear that is to be press fitted to the
1. REMOVAL OF GEAR camshaft, push the outside shoulder of
Remove the gear with a gear puller. the gear with a press at approx. 5 tons.
After cooling to the ambient temper-
2. PRESS FITTING GEAR ature, push with a press at approx. 5
1) Check the gear mounting surface, key tons to press fit securely.
Pushing position of press
groove, and flange surface, and if there
are any scratches, correct them with an
oil stone.
2) Knock the key into the key groove of the
shaft.
3) Heat the gear for the specified time at
the specified shrink-fitting temperature.
* Crankshaft gearshrink-fitting temperature: Camshaft support
portion
230- 250°C
Heating time: 30 minutes 5) Insert the plate on the bolt, coat with LT-2,
4) Put the timing mark on the outside, then then tighten twice to the following tighte-
use a hitting tool to press fit until the ning torque.
side face of the gear is in close c.ontact Tightening torque of bolt: 10- 12.5 kgm
with the shaft flange. After press fitting the gear, tighten the
* Knock in quickly before the gear be- bolt completely within 2 minutes, and be
comes cool. careful not to let the temperature of the
gear drop.
REPLACING CAM GEAR
REPLACING FLYWHEEL RING
1. WHEN SECURING BY SHRINK FITTING GEAR
* Replace the cam gear in the same way as
. the crankshaft gear. A Be careful not to let the flywheel fall and
* Cam gear shrink fitting temperature: Injure you.
250- 270°C
Heating time: 30 minutes 1. REMOVAL OF RING GEAR
1) Prepare a support for the flywheel, and
2. WHEN SECURING BY BOTH SHRINK FIT- set on the support with the ring gear
TING AND TIGHTENING BY BOLT surface facing down.
1) Assemble the bearing to the camshaft, 2) Heat the area around the ring gear with
then press fit. a torch lamp, then hit it with a hammer
Putth inner race of the bearing in contact to remove it.
with the shoulder of the No. 1 journal.
2) Knock the key (6206-41-1380) into the 2. PRESS FITTING RING GEAR
camshaft. When doing this, check that th 1) Check the ring gear mounting surface,
key is sunk below the tip of the camshaft. and if there are any scratches, correct
(See the diagram on the right.) them with an oil stone.
2) Heat the ring gear for the specified time
at the specified shrink-fitting temperature.
* Ring gear shrink-fitting temperature:
Max. 200°C
Heating time: 45 minutes
3) Set chamfered face of the ring gear fac-
Camshaft ing the flywheel, and press fit until the
3) Heat the cam gear for approx. 35 minutes side face of the gear is in close contact
at 220 - 240"C in a furnace. with the flywheel.
6D95L/S6D95L-1 60-11
PRESSURE TEST
• When corrections have been made around

the head, test the pressure as follows.
No. Part No. Part Name Q"ty
A 790·513·4200 Coolant tester kit 1
B 79A·471-1050 Pump assembly 1
1. WATER PRESSURE TEST

1) Tighten the nozzle holder assembly to the
specified torque.
2) Assemble tool A and tool 8, and connect
the hose to flange (1 ).
3) Apply water pressure (2.5- 6.0 kg/em')
for approx. 10 minutes, and check that
there is no leakage from around the head.
* When carrying out this test, heat the
whole cylinder head and carry out the
test with hot water (82 - 93°C).
2. AIR PRESSURE TEST

1) Tighten the nozzle holder assembly to the
specified torque.
2) Connect the compressor hose to flange 6202F020
(1 ).
3) Put the head in the container of water,
apply air pressure (2.0 kg/em') for ap-
prox. 30 seconds, and check that there is
no leakage in the water.
60-12 6D95L/S6D95L-1
CYLINDER LINER (FOR REPAIR ONLV)
r"
30mm
40mm
80mm
F614601010
CYLINDER LINER
• The 95 series engine uses linerless cylin-
ders. When boring cylinder to recondition
them, use only the specified replacement
liners.
• Selection of liners
Two sizes (A and B) of replacement cylin-
der liners are available.
Choose the size of liner to match the inside
diameter of the cylinders after machining.
Outside diameter of cylinder liner Unit: mm

Measuring point [Remark]
Part Liner
Machined dimen-
number mark
® @ © sian of cylinder
A 98 +0.020 98 +0.025 98 +0.025 98 +0.0125

6207-21-211 0
(Small) +0.005 -0.010 -0.020 0
6207-21-2120 8 98 +0.035 98 +0.040 98 +0.040 98 +0.0250

(Large) +0.020 +0.005 +0.005 +0.0125
6D95L/S6D95L-1 60-13
MANUFACTURING OF CYLINDER BLOCK BORE PART
HONING TREATMENT
Measure the diameter ln two directions at this point

as shown in the diagram below.
Select the liner according to the average diameter.
~ 1o4 tHj
R Coaxiality 0.050 A
-"'
u
0
:c ~ ______M .1....._--j
c
~
M
"C
.5
-
>u
0
w
u
m
0.030/100 c
"t: Out of
"~
R54 0.015
roundness
E
0
t: Cylindricity 0.012 Radius method
0
.c
0 Note: Benchmark C is center of clank shaft
f-
If the diameter is within 0.005 mm at a point

15 mm from the top surface and 20 mm from
the bottom surface, it is permissible even if
there is a drooping edge framed by the honing.
w~
u
"'
m-'<
"t: u
"~.c
_g Stamped letter Diameter
1--(
E ~
O-c
t: ~ ¢98 +0.0125
0
.c >
u
= A
0
o-
f- 0 ¢98 +0.0250
B
+0.0125
Right side face
00
N
0
I 0 01
''
~
"
Stamp A orB {6 places) Erase stamp mark S or L

Detail of portion R Fig.2
6206F904 6206F904-1
60-14 6D95L/S6D95L-1
GRINDING CRANKSHAFT
APPLICABLE CRANKSHAFT
After correction by grinding or rebuilding, only induction hardened crankshafts can use an
undersize bearing. This action cannot be carried out with tufftride treated crankshafts. (Note 1)
The two types of crankshaft can be distinguished by storing them according to the serial num-
ber of the engine on which they are used (Note 2). However, use the method given below to
distinguish the actual parts and to avoid mistake in judgement.
(New( (Old(
Induction hardened part (Correction by grinding Tufftride treated part (Correction by grinding
possible( not possible)
Part No. 6207-31-3320 Part No. 6207-31-3410
The charge symbol ( !!JJ) on The charge symbol ( 1!:!1) on

the opposite side of arm #5
the opposite side of arm #5 is in Roman alphabet
is in Japanese katakana (6 cylinders only)
(6 cylinders only)
The counterweight and arm

~
have the black skin from forging
Part No. 6207-31-3310
{stamped on rear face)
The counterweight and arm are

a grey color from the tufftride treatment
Part No. 6204-31-3410
(stamped on rear face)
Note 1: With tufftride, the hardening depth is shallow, so if grinding is carried out on the surface, the
hardened layer will be lost, and it will be impossible to guarantee the strength or resistance to
wear.
Note 2: When the surface treatmentfor the crankshaft was changed, the part number was not changed,
but as shown above, the crankshaft pin bearing was changed at the same time.
6D95L/S6D95L-1 60-15
ENGINE
70 TROUBLESHOOTING
Method of using troubleshooting chart . . . . . . . 70-4

Points to remember when troubleshooting . . . . 70-8
6095L/S6D95L-1 70-1
TROUBLESHOOTING
Method of using troubleshooting chart ...................................................................................................... 70- 4
Points to remember when troubleshooting ................................................................................................ 70- 8
S-1 Starting performance is poor (Starting always takes time) 70- 9
S-2 Engine does not start

(j) Engine does not turn .............................................................................•................................ 70-11
® Engine turns but no exhaust gas comes out (Fuel is not being injected) ..................................... 70-12
® Exhaust gas comes out but engine does not start (Fuel is being injected) ................................... 70-14
S-3 Engine does not pick up smoothly (Follow-up is poor) ...........•..............................•................•........ 70-16
S-4 Engine stops during operations ..................................................................................................... 70-18
S-5 Engine does not rotate smoothly ......... : ................................................................•........................ 70-20
S-6 Engine lacks output (no power) .....................................................................•..............•...........•.... 70-22
S-7 Exhaust gas is black (incomplete combustion) ..........................................•.............•....................... 70-24
S-8 Oil consumption is excessive {or exhaust gas is blue) ..................................................................... 70-26
S-9 Oil becomes contaminated quickly ................................................•..............................•.•.............. 70-27
S-10 Fuel consumption is excessive ...................................................................................................... 70-28
S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 70-30
S-12 Oil pressure lamp lights up (drop in oil pressure) ........................................................................... 70-31
S-13 Oil level rises ............................................................................................................................... 70-32
S-14 Water temperature becomes too high (overheating) ............•.......................................................... 70-33
S-15 Abnormal noise is made ...............................•............................................................................... 70-34
S-16 Vibration is excessive ................................................................................................................... 70-36
6D95L/S6D95L-1 70-3
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
METHOD OF USING TROUBLESHOOTING CHART
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection
without using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections ® +® in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in ® are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under © in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information ® that he has obtained from the
user and the results of © that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
(a) ©•
•c0
® ...• (b) ©
•
~
(c) ©
d
(d) 0
lei 0
~
u
~
u
•
•
'"'
• c
::c~
, 0
ii
•
0 0
-~
t-•
ill
•
70-4 6D95L/S6095L-1
The basic method of using the troubleshooting chart is as fol-

lows.
Items listed for [Questions] and [Check items] that have a rela-
tionship with the Cause items are marked with 0, and of these,
causes that have a high probability are marked with Ill.
Check each of the [Questions] and [Check items] in turn, and
marked the 0 or © 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 troublesh-
ooting for that item to make final confirmation of the cause.
*1. For (Confirm recent repair history) in the [Ques-

tions] Section, ask the user, and mark the Cause
column with D. to use as reference for locating
the cause of the failure. However, do not use this
when making calculations to narrow down the
causes.
~~2. Use the l:::. 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 Confirm recent repair history

'--------+ l!!2 Degree of use Operated for long period
Precautions when carrying out troubleshooting
A When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit safety
pins, block the wheels, and apply the parking brake.
A When carrying out operations with two or more workers, always use signals, and do not allow any unau-
thorized person near the machine.
A When checking the water level, if the radiator cap is removed when the ~ngne is hot, boiling water will
spurt out and may cause burns, so always wait for the engine to cool down before checking the water
level.
A Be extremely careful not to touch any hot parts.
A Be extremely careful not to get caught in the fan or any other rotating parts.
"'A"
+ When removing the plugs or caps from places under hydraulic pressure, water pressure, or air pressure,
release the internal pressure first. Fit the measuring tools securely before carrying out any testing, adjusting,
or troubleshooting.
Method of using testing, adjusting, and troubleshooting values table

*When using the standard values table for judgment in testing, adjusting, or tourbleshooting, it is necessary
to be careful of the following points.
1. The standard values for the new machines in the staQdard values table are values given as reference from
the standards for the new machine and machine shipped from the factory. They should be used as values
for estimating wear during operation or as target values when carrying out repairs.
2. The failure judgment 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 reference toghther with the repair and operation history of the machine when judging failures.
3. Doo not use this standard values able as a standard for judging claims.
6D95L/S6D95L-1 70-5
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.
70-6 6D95LIS6D95L-1
Five causes I
Step 1
Clarify the relationship between the three symptoms
in the [Questions] and [Check items] section and
the five Cause items in the vertical column.
~ }
Three symptoms J
Step 2
Add up the total of 0 and I) marks where the hori-
zontal lines for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element: 1)00
(2) Air leakage between turbocharger and
head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculations in Step 2 show that the deepest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item marked
e. The Remedy is given as [Clean], so carry out
cleaning, and the exhaust gas color should return
to normal.
6D95LIS6D95L-1 70-7
TROUBLESHOOTING POINT TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs to ensure 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.
1. Do not disassemble the machine simply 4. Confirming failure

because there is a failure Check the degree of the problem to judge for
If the machine is disassembled immediately yourself if it is really a failure, or if there is
just because there is a fuilure: some problem in the handling or operation of
Unrelated or unnecessary places are also the machine.
disassembled * When driving the machine and re-enacting
It becomes difficult to locate the cause of the failure, be sure that the investigation or
the failure measurement does not make the failure
This means that there is not only a waste of worse.
time and money on replacement parts, oil, and
grease, but this action will also lose the confid- 5. Troubleshooting
ence of the user and operator. Narrow down the causes of the failure from
For this reason also, it is importa'nt to carry out the results of the inspection and check in
troubleshooting based on full investigation before Items 2 - 4, then follow the troubleshooting
starting and troubleshooting following the correct flow chart to locate the failure.
order. * Basic procedure for troubleshooting
1) Start from the simple places.
2. Questions to ask the user and operator 2) Start from the most probable places.
1) Are there any problems other than those 3) Investigate related parts also.
already reported?
2) Did anything unusual happen before the failure 6. Basic action to remedy cause of failure
occurred? Even if the failure is repaired, if the root
3) Did the failure occur suddenly, or had the cause of the failure is not repaired, the same
condition of the machine been poor before the failure will occur again.
failure occurred? To prevent this, it is necessary to investigate
4) What were the conditions when the failure why the failure occurred, and to remove the
occurred? root cause of the failure.
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) Check the spool stroke of the control valve.
5) Other maintenance items can also be carried
out visually, so carry out any check that is
considered necessary.
70-8 6D95LJS6D95L-1
TROUBLESHOOTING 5·1
S·1 Starting performance is poor (Starting always takes time) (with distributor type pump)
General causes why starting performance is poor
Defective electrical system
Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
(At ambient temperature of -10"C or below, use
ASTM 0975 No.1, and -1 or above, use ASTM o·c
0975 No. 2 diesel fuel.) I Causes I
* Charging rate of battery. /Starting aid
Ambient ~ate 100% 90% 80% 75%• 70%

temperature
2 o·c 1.28 1.26 1.24 1.23 1.22
o·c 1.29 1.27 1.25 1.24 1.23
lO"C 1.30 1.28 1.26 1.25 1.24
The specific gravity should be for the charging rate of 70% or more in
the abov e table.
Jn cold weather the specific gravity must be for the charging rate of at
least 75% in the above table.
Confirm recent repair history

Degree of use Operated far long period
Gradually became worse
Easo of stoning
Starts when warm
Indicator lamp does not light up
Englna oil must be added more frequently
Repla~:ement of filters has not been carried out accQtding tQ
Qperatlon manual
Oust Indicator is red
Non·speclfled fuel has been used
Battery charge lamp Is ON
Starting motor tranks engine slowly
f-iwo,c,':,",:C,'i,':'""c,:,cm::,::,C:,C',c"c'>!,:'.,c,:C,c,,:',:C,':mcmo,c,o,,c,c,,c,c,o.,.:"c,c,:":":":,:,:,,c,:,o.-r-+-+--+-+--+-+--+-+--+-f-"-+-f---+-f---+-1
/
1
temperature ol some tyllnders Is low
Engine does nQt pick up smoothly, and cQmbustlon Is irregular
BIQw·by gas Is excessive
Match marks on fuallnjectJQn pump are out Qf alignment
e
-~
Mud Is stuck to fuel tank cap
When engine Is cranked with starting motor,
11 Llnle fuel comas out even when Injection pump sleeve nul is
loQsened
21 Little fuel comas out evan when fuel filler air bleed plug is
loQsened
Leakage from fuel piping
Thera Is hunting from engine [rotation is Irregular]
When cQmpresslon pressure is measured, It is found to be low

••
When air elementlslnspectad dlrectly,lt is found to ba tlogged
Whan fual filter, stralnar are inspettad directly, they are found to
•
be clogged • •
When feed pump strainer Is inspe~:ted dlrettly, itls found to be ~:logged
•
Heater mount does not betome warm
•
Glow plug does not be~:ome warm
• •
;
~
0 Voltage Is 26 30V (13,5 -15V: 12V series) between
alternator terminal 8 and terminal E with engine at
y,.
•
~
0
0 Jaw Idling No
•
~
Eithar spetlf!t gravlly of alettrolyte or voltage of battery Is low
Speed of some tylind!!rS does notthange when operating on raduted
•
~ tyllnders •
When thetk Is made using measuring device method, ln]ettlon
timing Is found to be lntorrect •
When blind plug at rear of pump Is removed, It can be
sean that plunger control sleeve does not move •
When fuel tap Is inspected direttly, it Is found to be ~:logged
.. ~ ~
0
•
!Remedy !
~
-~
~
0
~
: 0
:
" " "~ ~" ~
~
i
~
I "Ii i '
~ ~ ~ ~
-~
~ ~
6D95L/S6D95L·1 70-9
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time) (with in-line type pump)
General causes why starting performance is poor
(At ambient temperature of -10"C or below, use
ASTM 0975 No.1, and -1 O"C or above, use ASTM
0975 No. 2 diesel fuel.) I Causes I
* Charging rate of battery. Starling a!d
Ambient ~rate 100% 90% 80% 75% 70%

temperature
2 o·c 1.28 1.26 1.24 1.23 1.22
o·c 1.29 1.27 1.25 1.24 1.23
lO"C 1.30 1.28 1.26 1.25 1.24
The spec !fie gravity should be for the charging rate of 70% or more in
the abov a table.
In cold weather the specific gravity must be for the charging rate of at
least 75% In the above table.

Degree of use Operated for long period A A A A
Graduallv became worse G 0 0 0 0
Ease of starling
Starts when warm : :~
. .
Indicator lamp do11s not light up '•" 0
Enginl! oil must b!! add!!d morl! frl!quantly .
Replacement of filters has not bl!en carried out according to
operation manual
.. .. 0 0
Oust Indicator is red

Non-specified fuel has been used
' 0 0 0 0
Banary charge lamp Is ON . "
I 5
~When
1
=.''o"o"c'cmc='"''o'"'"''o"
eJChaust manlfold
1 1
0~o='"c'c"c'c'oo'•""''---cccc--c--c-c----c----t--t--t--t--t--tc_t--t--t--t--""-t--t--t--t--t~
is touched immediately altar starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion Is irregular
Blow-by gas Is BJCCesslve
0 0
:
t.
Match marks on fuel Injection pump are out of alignment c

Mud Is stuck to fuel tank cap 0
.
6
11 Little fuel comas out even when iniection pump sleeve nut is
loosened
2) Little fuel comes out evan when fuel filter air bleed plug is
.·
loosened
leakage from fuel piping 0
There Is hunting from angina )rotation is irregular) 0 0 0
When compression pressure is measured. it Is found to be low

••
When air element Is inspected directly, it is found to be clogged
When fuel filter, strainer arl! Inspected direclly, the'{ are found to
•
be clogged • •
When feed pump sttlliner is inspected directlv. it is found to be clogged
•
Heater mount does not become warm
•
Glow plug does not become warm
••
0
-~
Voltage Is 26 30V j13.5 -15V; 12V series) between
alternator terminal 8 ;md tllrmlnal E with angina at I y,.
•
~
low idliilO No
•
~
Either specific gravity of electrolyte or voltage of battery is low
Speed of some cylinders does not change when operating on reduced
•
~ cylinders •
When check is made using delivery method, injection timing is found
to be incorrect •
When control rack is pushed, it is found lo be he~vy or does not return
lwhen blind plug at rear of pump is removed. It can be seen lhat
plunger conlrol sleeve does not move!
•
. . ! . . ... . •
When fuel cap Is inspectl!d d!rectly.lt is found lobe clogged
'Remedy i" ! u a u: 1i £" 1i 1i £" 1i 1i' l

~ ~
c c
~ ~ ~ ~ ~ ~ 1i
~
·i;
~
~
:
u
70-10 6095L/S6D95L-1
TROUBLESHOOTING S-2
S-2 Engine does not start

CD Engine does not turn
General causes why engine does not turn

Internal parts of engine seized
* If internal parts ofthe engine are seized, carry
out troubleshooting for "Engine stops during
operations".
I Causes
I
Failure in power train
I'!
~
ti ~
"
0
£
-
,g ff
~
.•e !Pc
" • " "-
•
~
...
~
~
0
•" J' .;;••
!f
• f
..
f" ""' ~
!; "' ·"
., ., ..g •... •" •ff •"
.s I;
~
iJ!
~
" 0
~ 0
~
.::' 0
£ ~
.{E
.. ,g" ••- ... c c- .."" •g • "

0
0
~ £ I'!
0 I'!
·€" ff ~
!P !P :§ a;
~
'[
~
• ·€"" "'•
J!! JJ ~ J!!
I; iJ! • • •
.J J ! ! :5• ! .J"' !l'
~ J !
...•" ,§..." ...•" ,E ...•" ...•" ,§..." ...•" ,§..." ,§..." ,§..."
~

" " " " "
•c Degree of use Operated for long period
~ Condition of horn when starting Horn does not sound 0
" "
,• 0 0
a switch is turned ON Horn sound level is low 0
Rotating speed is slow ©
When starting switch Is Makes grating noise @ ~'}
1/
turned to START, pinion
moves out, but
Soon disengages again
Makes rattling noise and
0 0
"
0
does not turn
E When starting switch is turned to START, pinion does not move out © 0 0
~ When starting switch is turned to ON, there is no clicking sound
~
0 ©
u
•
~
Battery terminal is loose ©
u
·;
~
When starting switch is turned to ON, linkage does not move 0·

When battery is checked, battery electrolyte is found to be low .,e 0
" '£?
~
c
Specific gravity of electrolyte, voltage of battery Is low •t
• •
For the following condi!Jons 1)- 5), turn the starting switch OFF,
connect the cord, and carry out troubleshooting at ON
"
a
1) When terminal 8 and terminal C of starting switch are connected,
m
c
:~ •
engine starts •
~
c
2) When ternimal 8 and terminal C of starting motor are connected,
engine starts
..•
·~
~
•
50 3) When terminal 8 and terminal C of safety relay are connected,
~
•
,•
engine starts
.E
~
.E
0
•
".=
0
4) When terminal of safety switch and terminal 8 of starting motor 0
•
are connected, engine starts
5) There is no 24V voltage between terminal band terminal E of
"",•
battery relay
g
50
•
When ring gear is inspected directly, tooth surface Is found to be
chipped
~
u•
•
Does not move even when fuel cut solenoid linkage is disconnected
•
Does not move even when engine stop motor linkage is disconnected
•u B •u •u •u •u ~
•• ~ ~
Remedy - c.• c.•• " c.•• c.•• c.• c.••
0
"
.2. c.• c.
•
"'• "' •
• • • ~
"' "' "' "' "' "' "' "'
6D95L/S6095L-1 70-11
TROUBLESHOOTING S-2

® 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
Type of fuel
-20 -10 0 10 20 30"C
I Causes
I
Diesel fuel
~TI ""
D9< Nc 2!· '·
~~
~
~
~
•
-'!!
.,- g• -8 -'!!
•
~
•
_, 0
0 -0
~
J;
0
s
l
-"
l §" §.s•' §.s
•'
...
.s;" •
,t ", "•" ,.• • " '"•-0

~
.
" .g ./!! -'!! §" !!"
. "'"'. "'
0 ~
0
-8 " ~ if: " "
-• ./!!"• ,.-'!!• J;•
0
:ff l!!
-
0
.g( :;
.s" ?1 e
~
. .
rG a rJf a
'b'
.:!!" .!J! ~
1:" :::
"• "• ~Is.
...0
"
• iJ iJ §
" 8- "'
I ~
"'
~
0
~
Cll <ll
Confirm recent history

Degree of use I Operated for long period 6 6 6
Exhaust gas suddenly (when starting again) stops coming out {)! ©-
.c
0
Replacement of filters has not been carried out according to operation "' 0 Q>
"ti manual
•0 Fuel tank is found to be empty Q
0
There is leakage from fuel piping tJ
Mud is stuck to fuel tank cap
/ When fuel filter Is drained, fuel does not come out "
•E When engine is cranked with starting motor, "
-~
11 injection pump coupling does not rotate "
~
0 21 ~~ic~ob'~rt~~~~a~~.u~l~~a~r ';,~'::;~~~!~~~~~~~~::.cncd. I} 0 0 0
~
• 31 No fuel spurts out even when injection pipe sleeve nut is loosened
u
Rust and water are found when fuel is drained
" " " 0 0
Check injection pump directly

•
After removing blind cover at rear of pump, plunger control
sleeve does not move when Inspected •
•
~
.= Check feed pump directly
0
0 When fuel filter, strainer are inspected directly, they are found to be
~
••
:0
0
clogged • •
When feed pump strainer is inspected directly, it is found to be
~ clogged •
When fuel cap is inspected directly, it is found to be clogged
•
Remedy
•" • •
~
• • •
c c .,
"'
.
c. c.• c. 0•• 0•• ., "•c. ~
0 0
•
•
•
c.
•
0
"' "' "' "' "' "'
70-12 6095L/S6095L-1
TROUBLESHOOTING S-2
(with in-line type pump)

® 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 I Causes

I
Type of fuel
••
- !0 -10 0 10 30'C
.ASTi I U97! iNc~ b'

Diesel fuel
-~
•
I]~ >.
,.~ .,cll:
-
Ill
.,
• "" §
;; ~·
u ..., 0
~
i .,l.g .,l g·" g·" ....,'""' •s .i 8

~
~ ;;,
.,ff
~
• •
" .s•• •"•
~
.,"• •-· .•• • ff" -o

~
0
0 0
0
u
:ff"'"' "'
,gc
& .,l
~
~
0 !;"
u ~
.,• " " •g>

0
:8 ·!! ~ ;;;
·"
u
e " "• ;;;
·" J • ;"•"' •""' "' • "•"' 1"' J .,e-•-"'
,.
·!!:
c ,. u
-o
~
0 u
~
l c'l"' J'J a !"' • tJ iJ ~ c'l"'
.~
~
u "'
0: "'
PI ./!!u
~
.§
Confirm recent history

Degree of use I Operated for long period " "
Exhaust gas suddenly {when starting again] stops coming out 0 ()
"
.
c
0
Replacement of filters has not been carried out according to operation
IE; {j
-~ manual
,• Fuel tank is found to be empty 't.\'
0
There is leakage from fuel piping a,
Mud is stuck to fuel tank cap <;
When starting switch is turned ON, linkage does not move <;
/
1}1
When fuel filter is drained, fuel does not come out p

When engine is cranked with starting motor,
E 11 injection pump coupling does not rotate
<;
.~
~
u 21 No fuel comes out even when fuel filter air bleed plug Is loosened <; 0 0 0
~• 31 No fuel spurts out even when injection pipe sleeve nut is loosened <; p
u
Rust and water are found when fuel is drained " 0 0
Check injection pump directly

When control rack is pushed, it is found to be heavy or does not
•
return •
~
.E
Check feed pump directly
When fuel filter, strainer are inspected directly, they are found to be
•
0
0
iii clogged • •
:a,• When feed pump strainer is inspected directly, It is found to be
0
clogged •
"' When fuel cap is inspected directly, it is found to be clogged
•
Does not move even when fuel cut solenoid linkage is disconnected
•
Does not move even when engine stop motor linkage Is disconnected
• •u •u c c
••
Remedy
~ • c.• •• ••
c. c.
• • • u u
'C
'C
<(
•• •• ".,••
0. 0.
u
• •
u
c.
8
• c.•
"' "' "' "' "' "' "' "'
6D95L/S6095L-1 70-13
TROUBLESHOOTING 5-2
(with distributor type pump) I Causes

I
® Exhaust gas comes out but engine does not /Starting aid/
start
(Fuel is being injected)
General causes why exhaust gas comes out but
.,_g•.
engine does not start
Lack of rotating force due to defective electri-
cal system
J

Degree of use I Operated for long period
Suddenly failed to start
When engine is cranked, abnormal noise is heard from around head 0
Engine oil must be added more frequently
•c
.2 Non-specified fuel has been used 0 0
~, Replacement of filters has not been carried out according to operation
0
manual
Rust Is found when fuel is drained
Dust Indicator is red
Indicator lamp does not light up
V
Starting motor cranks engine slowly
Mud is stuck to fuel tank cap 0
~VV~hce~ncf~uceclcle=v=e=r~l:,cp~l:,,~.~d~e7t~F~U;L~L-p:o:,c.,~tl=o=n-.~,,cd~o=•=•=n=o=t~oo:n:,:,:,:,:,:,o:p:p:,:,c-t--i-o~+--ir--t---+--+---t--ir--t---+--+---t"~---l
1) Little fuel comes out even when Injection pump sleeve nut is
•E loosened
,j!
~ 2) Fuel does not flow even when overflow valve Is loosened 0
u
•
~
u There Is leakage from fuel piping
When exhaust manifold Is touched Immediately after starting engine,
temperature of some cylinder is low
When fuel filter Is drained, no fuel comes out
Remove head cover and check directly

After removing blind cover at rear of pump control sleeve does not
•
move when Inspected •
When compression pressure is measured, it Is found to be low
•
clogged • •
When feed pump strainer Is Inspected directly, It is found to be clogged
•
When air element is Inspected directly, It is found to be clogged
•
Heater mount does not become warm
•
Glow plug mount does not become warm ••
Either specific gravity of electrolyte or voltage of battery is low
•
When feed pump is operated, there is no response or pump is heavy
•
cylinders - •
•
.• .•
When fuel cap Is inspected directly, It Is found to be clogged
•u •u ~ c c ~ ~
~
Remedy • c.• •• ••
-5_ c. • c. c.
c.
.l' • • u u •
"' "' "' "' "'
70-14 6D95LIS6095L-1
TROUBLESHOOTING S-2
-
(with in line type pump)
@Exhaust gas comes out but engine does not I Causes
I
start /Starting aid/
s ~§I
(Fuel is being injected)
,.• ••
General causes why exhaust gas comes out but >• -"•
'"~
engine does not start .§"'
Lack of rotating force due to defective electri- e •!1"'
•. "'• >.
I'!
cal system
_g-"
• l ;"' J .,
c £ Iii
Insufficient supply of fuel .2
Q. 0
g
_,• • fi"' s•
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Improper selection of fuel • f -S
£ ~
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Q.

Degree of use [ Operated for long period
Suddenly failed to start (} f;}
"' "' "' "'
When engine is cranked, abnormal noise Is heard from around head
.
c
0
0
0
©
0
ti
,• Replacement of filters has not been carried out according to operation
a manual
0 {» [y
Rust Is found when fuel Is drained 'tJ (~
Dust indicator is red (,j
Indicator lamp does not light up 0' {;,
I
Starting motor cranks engine slowly 19'
Mud is stuck to fuel tank cap 0
When fuel lever is placed at FULL position, It do&s not contact stopper 0
1) little fuel comes out even when Injection pump sleeve nut is ·:;l
loosened
E:
£ 2) Little fuel comes out even when fuel filter air bleed plug is
Q (!l 0
~ loosened
•
~
u There is leakage from fuel piping ,')
When exhaust manifold Is touched immediately after starting engine,

'0
temperature of some cylinder is low
When fuel filter is drained, no fuel comes out
"'
•
When control rack Is pushed, it is found to be heavy or does not return
•
When compression pressure is measured, It is found to be low
•
clogged • •
~
c
·g
When feed pump strainer is inspected directly, it is found to be clogged
•
0 When air element Is Inspected directly, it is found to be dogged
•
•
~
• Heater mount does not become warm

,•
:0
0
Glow plug mount does not become warm
••
"' Either specific gravity of electrolyte or voltage of battery is low
•
When feed pump Is operated, there Is no response or pump is heavy
•
cylinders •
When fuel cap is inspected directly, it is found to be clogged
•u u• u• c c c •u ~
•
• 0.• •• •• •• a 0.• 0.• 0.• ••a ••c ••c -
~
Remedy -"
a 0.
• • • u u u "'• • • • "'• u u
•
"' "' "' "' "' "'
6095L/S6D95L-1 70-15
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor) (with in-line type pump)
General causes why engine does not pick up
smoothly
Insufficient supply of fuel I Causes 7
Improper condition of fuel injection
Use of improper fuel

manual
Rust and water are found when fuel is drained 0 0
Noise of interference is heard from around turbocharger 0
/
~:~:_:_~:~:_;_:_:_~_: _,~:~:~:d_:_"_'~y~b-'_' _m •_p_o_o_,_J.:~:~:~ :~:_"_d_'_'_n_o_"'
__ __
'o_'_d______ 4-o=-e--+--4-:~,4---t-o-+~:~.4-_J~o--t-o-+~o~
Clanging sound is heard from around cylinder head ©l
Mud Is stuck to fuel tank cap 0
There is leakage from fuel piping @
•E High Idling speed under no load is normal, but speed suddenly drops
0 0 0
~ when load is applied
~
u There Is hunting from engine (rotation is irregular) 0 0 0 0
•
~
u When exhaust manifold is touched immediately after starting engine,
0 0
temperature of some cylinders is low
Blow·by gas Is excessive
When air element is Inspected directly, it is found to be clogged

•
clogged •
When feed pump strainer is Inspected directly, It is found to be clogged
•
cylinders •
When control rack Is pushed, It Is found to be heavy or does not return
•
When compression pressure Is measured, It is found to be low
• •
When turbocharger Is rotated by hand, it Is found to be heavy
When valve clearance is checked directly, it is found to be outside
•
standard value •
When fuel cap is inspected directly, It Is found to be clogged
•
When feed pump Is operated, operation Is too light or too heavy
c c c
•
:ll •• •
0•
Remedy
0 0
70-16 6D95L/S6D95L-1
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor) (with distributor type pump)
General causes why engine does not pick up
smoot hi y
Insufficient intake of air I Causes I
~
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Iii-
!' I'!
.,. •
~
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0
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0 0
P!
~
.%
•.
./!' !'
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./!'
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0
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~
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0 0. ~
fj 1;;: 0. ~ ~ .g" •
0
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0 0
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~
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0
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·"• .2
iii • " -~ .s
·!!!
1
0 iii 0
.&
0
0
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./!' .2
.•
.~
j I
121 :,:::
alf 8~ Ji i Ji·• ! a"' ~./!' J "' 0

Replacement of filters has not been carried out according to operation "' "' "' "' "'
© © ©
. manual
Non-specified fuel has bean used © ©
c
0
"t;
0•
0
" 0
a Rust and water are found when fuel Is drained 0 ©
Dust Indicator is red ©
Noise of Interference Is heard from around turbocharger ©
Engine pick-up suddenly became poor 0 © 0 0
I Blue under light load Q
1/
Color of exhaust gas
l Black 0
Clanging sound Is heard from around cylinder head
<0
" "' "
There is leakage from fuel piping
"
•E High Idling speed under no load is normal, but speed suddenly drops
"
© 0
.~
~
u
when load is applied
There Is hunting from engine (rotation Is Irregular) 0
"
© 0 0
•
~
u When exhaust manifold is touched Immediately after starting engine,
<:J 0
temperature ~f some cylinders Is low
Blow-by gas Is excessive <:J
When air element is inspected directly, It is found to be clogged

•
clogged •
When feed pump strainer Is Inspected directly, It Is found to be clogged
•
~
c
:g
0
cylinders •
~
•
:c•0
When bllnd plug at rear or pump Is removed, It can ba seen that
plunger control sleeve does not move •
~
When compression pressure is measured, it is found to be low
• •
When turbocharger Is rotated by hand, it is found to be heavy
When valve clearance Is checked directly, It is found to be outside
•
standard value •
When fuel cap is inspected directly, It is found to be clogged
•
. ••••
When feed pump Is operated, operation Is too light or too heavy
~ •u
• D.~ D.• ~ ••
c c c ~ c
• • • " •
u• u• u-" •
Remedy ~
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D.
• • • u •
~
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~
6D95L/S6D95L-1 70-17
TROUBLESHOOTING S-4
S-4 Engine stops during operations {with distributor type pump)

General causes why engine stops during
operations
Seized parts inside engine
Insufficient supply of fuel I Causes
I
Overheating
If there is overheating and insufficient
* output, carry out troubleshooting for over-
heating.
Failure in power train E
If the engine stops because of a failure in ,.•
* the power train, carry out troubleshooting e<> , ~
g>
.!!!
.!!!
.
~
for the chassis.
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Degree of use Operated for long period
Abnormal noise was heard
" "
© .p tl· © 'i~J \> 0 0 {:<~
and engine stops suddenly
Condition when engine EnQine overheated and stopped i[J 0 0
.c
.0
stopped Engine stopped slowly
There was hunting and engine
0
(;'·
0
0
0
0 0
;;; stopped
,•
a Fuel gauge lamp lights up 9
Fuel tank Is found to be empty (j
Replacement of filters has not been carried out according to

,} (_)
operation manual
Non·speclfied fuel has been used 0 0 0 0
When feed pump Is operated, there Is no response or It is heavy 0 0 ·":,
I•E
Mud is stuck to fuel tank cap
Engine turns, but stops when transmission control lever Is
operated
Try to turn by hand using bar

Does not turn at all
Turns in opposite direction
n !!;:,;
{)>
"''
('!
~
~ ring tool Moves amount of backlash p (>
u
• Shaft does not turn rti
m
~
u ,E
Metal particles are found when oil Is drained 0 (!;,,,
0
0
t!
0 ..•••
0
>
Remove oil pan and check directly

•• ~
u

• .E
~
When gear train is inspected, It does not turn

• .5
E
~
.§
Turns when pump auxiliary equipment is removed
When fuel filter, strainer are inspected directly, they are found
• 0
;\;
:c,•
0
0
;\;
to be clogged • g
m When feed pump strainer is Inspected directly, it is found 5
:c,
!!
to be clogged • 0
j;'
•
Check feed pump directly
• u
When blind plug nt renr of pump is removnd, lt cnn be sean that

p[ungsr control sleeve does not move. •
~ • • •u •~ •~ c c , ••
m
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Remedy • 0.~ 0.~ 0.• 0.
0. 0.
'0
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m [j m u m
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70-18 6D95L/S6D95L-1
S-4 Engine stops during operations (with in-line type pump)

General causes why engine stops during
operations
Seized parts inside engine
Insufficient supply of fuel I Causes
I
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
,
•..,s•
~ .:;•
2"'"
the power train, carry out troubleshooting e i!'
} >. .!'! .£!
"' "' "
•. ·"""
for the chassis. e
• .,. .:; "
0
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Abnormal noise was heard "' "'
© 0 0 c:::'
and engine stops suddenly
D '()) 0- 0
"
Condition when engine En~ine overheated and stopped <D 0 0
.
e
0
stopped Engine stopped slowly
There was hunting and engine
~"'J'
Q
0
0
0
0 0
"
•0
a Fuel gauge lamp lights up
Fuel tank is found to be empty
stopped
(';1
©
Q ()
operation manual
Non·specified fuel has been used 0 0 0 0
When feed pump Is operated, there is no response or It is heavy 0 0 tJ
I
•E
Engine turns, but stops when transmission control lever is
operated
Try to turn by hand using bar

Does not turn at all
Turns in opposite direction
tJ i:·>
6>
0
tJ
~
~ ring tool Moves amount of backlash © Q
u
• Shaft does not turn •E
~
u "' "
Metal particles are found when oil is drained a ©
Q
0
0
0 .
0
>
'li
•u
•• ~

• .5
~
When gear train is Inspected, It does not turn

• ~
~
.5
Turns when pump auxlllary equ-Ipment is removed
When fuel filter, strainer are inspected directly, they are found
• 0
"
m
:c0
0
0 to be clogged • g
"
:c•
0
When feed pump strainer Is Inspected directly, it Is found
to be clogged •
5
0
r•
I! Check feed pump directly
• u
When control rack is pushed, It Is found to be heavy or
does not return •
m
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• • • " •m •m • '·"'•0. • g -
u ~ c e ~ c
Remedy • •
""'m ""'• "'• ""'• ""'m ""'• "<t [j [j ""'• "'• [l "'•
" "
6095L/S6095L-1 70-19
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (with distributor type pump)
General causes why engine does not rotate
smoothly (hunting)
Air in fuel system
Defective governor mechanism
Defective electrically controlled throttle
mechanism
(electrically controlled throttle type)
* If there is no hunting when the electrically
controlled throttle rod is disconnected, carry
out troubleshooting for the electrical sys- I Causes I
tem.
0.
g
, cff
0.
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c
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[f• J • , .. • .. ., ., ..
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I}
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"' "'• if
& (j"" cJ1: cIf
~
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~ ~ • rJ
Occurs at fixed speed range <~.""". ·~ 0 0
"' "'
Occurs at low idling 0 (} 0 0 0 0
Condition of hunting Occurs even when speed Is
0 0 0 0
•c raised
·~ Occurs on slopes <0
,•
a Fuel tank Is found to be empty 0
0
operation manual "
Rust Is found when fuel is drained 0 0
0
/
Leakage from fuel piping 0
When feed pump is operated,
g e_,
11 No response, light, return is quick
ti 21 No response, light, return is normal ')
.~
~ Engine speed sometimes rises too high -::]) ti
•"
£
u Sometimes Is difficult to stop engine Q 0
Seal on injection pump has come off ©· ©
When governor lever Is moved it is found to be stiff

When injection pump is tested, governor is found to be improperly
• •
~
c
adjusted •
~
£
0
Whan blind plug at rear of pump Is removed, It can be seen that
plunger control sleeve does not move. •
:c•• When fuel cap is inspected directly, it is found to be clogged
• •
"0 When feed pump strainer is Inspected directly, it is found to be
"' clogged •
•
clogged
. •, •" •"
.2.
Remedy ~
~
~
c c
• •
u• u• •
.• ~
••
~ •
• u•
c
" ""' ""' ""' " "' "'
70-20 6095L/S6D95L-1
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (with in-line type pump)
General causes why engine does not rotate
smoothly (hunting)
Air in fuel system
Defective governor mechanism
Defective electrically controlled throttle
mechanism
(electrically controlled throttle type)
*
If there is no hunting when the electrically
controlled throttle rod is disconnected, carry
out troubleshooting for the electrical sys-
tern.
I Causes
I

Degree of use Operated fer long period
Occurs at fhced speed range (j) 'Q\ 0 0
Occurs at low idling 0 0 0 0 0
Condition of hunting Occurs even when speed is
0 0 0 0
raised
Occurs on slopes
Fuel tank is found to be empty
operation manual
Rust is found when fuel is drained 0 0
/•
~L~e7''='~g7e~f~c7o~m~f~"=e~l~p·='"='"~g~-c------------------------------~--t--1--~--t--+--1---~o-+~o-1--~
When feed pump is operated,
@ 9>
1) No response, light, return is quick
E 2) No response, light, return Is normal
•
.:
Engine speed sometimes rises too high
Sometimes Is difficult to stop engine
Seal on injection pump has come off
When governor lever Is moved it is found to be stiff

When injection pump is tested, governor Is found to be improperly
• •
adjusted •
When control rack is pushed, it is found to be heavy or does not return
•
When fuel cap is Inspected directly, it is found to be clogged
When feed pump strainer Is inspected directly, it is found to be
• •
clogged •
When fuel filler, strainer are inspected directly, they are found to be
•
.•
clogged
•• •• • ••• 0••
c c c
Remedy ~ ~
u u ~ ~
6D95L/S6095L-1 70-21
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power) (with in-line type pump)
Genera I caus es why engine Ia c ks au tput
Insufficient intake of air I Causes
I
(if non-specified fuel is used, output drops)
Lack of output due to overheating
* If there is overheating and insufficient
z
I!!
~
[
output, carry out troubleshooting for over-
heating. If !f
I/
ill •• :§
"'
-
0
!f
""' • 1
-
~ ~
""'
~
s•
--
./!! !f
E;
• f! f! .s• ~ .§"'
•"' •-·"' :f •ff •
E
"•
.~
·i
f!
;· •. f!"' .s"' ~• .~
.•
f" •I!!
.~ ff ~
J "•
.0
-
~• [!> " -· f
• • .g .g " "' u ,§ ~
~ ~
~
0
"'"
"'•" f'fi ,8 " "& "•" .?u .g" !f1 "iii'! ~ ,.Jff~ iiiI!
u
.•
~
"' if ~
0 ~
i1
fil" •" E" "• "
•
:? ~ ,• -
•"' "• " g ./!!""' E;•"' fil• •"
"' - "'
fj Jt ~
·~
a~I
u aI·~ Cl} ! q • £! "' fj cJ&
Suddenly
" Gl
" " " "
.c
0
Power was lost
Engine ell must be added more frequently

Gradually . 0
,,
0 0 0 0 0
...,• Replacement of filters has not been carried out according to operation
g-, {il 0
a manual
Non-specified fuel has been used © <0 ,~, iQJ
Dust Indicator is red . 6•

I
I
Black {)J ©
f Blue under light load
Noise of Interference is heard from around turbocharger
"
Blow-by gas is excessive
" 0
Engine pickup Is poor and combustion is irregular 0 0
High Idling speed under no load is normal, but speed suddenly drops
" 0
E• © © 0
when load Is applied
~
~
u When exhaust manifold is touched immediately after starting engine,
~
u
• temperature of some cylinders Is low " 0
There is hunting from engine (rotation is Irregular) 0 0 0 0

High Idling speed of engine is low 0
"
Leakage from fuel piping " "
When air element is Inspected directly, It is found to be clogged
•
When trubocharger Is rotated by hand, it Is found to be heavy
•
When fuel filter, strainer are Inspected directly, they are found
• •
to be clogged •
•
~
.,•
-" When feed pump strainer is Inspected directly, It is found to be clogged
0
0 Speed of some cylinders does not change when operating on reduced
:c, cylinders •
,g When control rack is pushed, It is found to be heavy or does not return
•
When valve clearance is checked directly, it is found to be
outside standard value •
When lever is placed at FULL position, It does not contact stopper
•
When feed pump is operated, operation Is too light or too heavy
•
•
c ~ •
• c.• c•• c••
u
.. ••• ., •• •.,
u u
• c
Remedy •l3• c.
• • l3 13 "'•
"' "'
~
"'
.. "'•
c. 'C' c. 'C'
•
~
"'
•
• 13•
70-22 6D95LIS6D95L-1
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power) (with distributor type pum;.p-=-)------::---------,
General causes why engine lacks output f Causes f
lif 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.

Suddenly
Power was lost
Gradually 0 0 0 0 0 0
•cc Engine oil must be added more frequently
:g
a•
manual
I Black
I Color of exhaust gas
~~c-~e7-;---c-c~~~~-c~_LI~B~Iu=e~un~d="='~'~'g~h=t~le=e=dc_____4---~c4-o~.4---~-+--+--1--4---f--1--4--1
Noise of interference Is heard from around turbocharger
Blow·by gas is excessive
tl'
Engine pickup is poor and combustion is irregular 0 0 0

High idling speed under no load is normal, but speed suddenly drops
•
E 0
when load Is applled
.~
~
u
When exhaust manifold is touched immediately after starting engine,
• temperature of same cylinders is low
ti
There is hunting from engine (rotation is irregular) 0 0 0 0
Clanging sound is heard from around cylinder head
High Idling speed of engine Is law 0
Leakage from fuel piping
When air element Is inspected directly, It is found to be clogged

•
When trubocharger is rotated by hand, It is found to be heavy
•
When compression pressure is measured, it Is found to be law
When fuel filter, strainer are lnspe~ted directly, they are found
• •
to be clogged •
When feed pump strainer is inspected directly, It Is found to be clogged
•
cylinders •
When blind plug at rear of pump Is removed, it can ba sean that
When valve clearance Is checked directly, It Is found to be
outside standard value •
When lever Is placed at FULL position, it does not contact stopper
•
When feed pump Is operated, operation is too light or too heavy
•
•
Remedy
c
:g
u
.1• ~,
u •
••
~ •
• u•
c
"'
6095L/S6095L-1 70-23
TROUBLESHOOTING S-7
S-7 Exhaust gas is black (incomplete combustion) (with distributor type pump)
General causes why exhaust gas is black
· Insufficient intake of air
Excessive injection of fuel I Causes I
}
l

Suddenly became black <> 0 0
.0
Color of exhaust gas Gradually became black
Blue under light load
<> 0 0
.iii0
,• Engine all must be added more frequently
a Suddenly I) 0 0 0
Power was lost
I Gradually 0 0 0 0
Non-specified fuel has been used 0 0
I
Noise of interference is heard from around turbocharger
~"c"-'-'-'c"-d_r,_,_toc'--c''-'c'cd-cc--------------------------------------1---t-©c•-r~~-+---t---r--t--1---t---r--+--1
Blow-by gas is excessive ,.,
Engine pickup is poor and combustion Is Irregular 0 0 0 0 0
When exhaust manifold is touched Immediately after starting engine,
0
•E temperature of some cylinders Is low
.~ Match marks on fuel injection pump are out of allgnment
~
u
~
u
• Seal on injection pump has come off
Exhaust noise Is abnormal 0 0
Muffler Is crushed
Leakage of air between trubocharger and head, loose clamp
When turbocharger Is rotated by hand, ills found to be heavy

•
When air cleaner Is Inspected directly, It Is found to be clogged
•
Speed of some cy!lnders does not change when operating on reduced
• •
cylinders •
When check Is made using measuring device method, Injection
timing Is found to be Incorrect. •
Injection pump test shows that Injection amount is Incorrect
•
When valve clearance Is checked directly It Is found to be outside
standard value •
When muffler is removed, exhaust gas color returns to normal
•
When blind plug at rear of pump Is removed, It can be seen that
•u c •u •u ~ ~
Remedy -5. u-"• • • • •
C.ii
"'• ""'• ""'• • •
"' "'
70-24 6095LIS6095l-1
TROUBLESHOOTING S-7
S-7 Exhaust gas is black (incomplete combustion) (with in-fine type pump)
General causes why exha~st.gas is black
· Improper condition of fuel injection
Excessive injection of fuel
I Causes
I
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-
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0
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-
r1 rJ& i ! " afl "' "'• 0
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Suddenly became black ,;;;, " " 0" " 0
©·
~
•c
Color of exhaust gas Gradually became black
Blue under light load ., 0 0
,• Engine oil must be added more frequently ©

0 j Suddenly © 0 0 0
Power was lost
I Gradually 0 0 0 0
Non-specified fuel has been used 0 0
Noise of Interference Is heard from around turbocharger Q)
I Dust indicator is red

Blow-by gas Is excessive
Engine pickup Is poor and combustion is Irregular
When exhaust manifold is touched Immediately after starting engine,
0
0
,
n 0 0 0 0
© 0
•
.~ Match marks on fuel Injection pump are out of alignment 0
~
u Seal on Injection pump has come off ©I
•
~
u Clanging sound Is heard from around cylinder head 0
Exhaust noise is abnormal 0 0 ©
Muffler is crushed 0
Leakage of air between trubocharger and head, loose clamp ©
When turbocharger is rotated by hand, it Is found to be heavy

•
When air cleaner is Inspected directly, It Is found to be clogged
•
When compression pressure is measured, it is found !O be low
• •
.5
0
m cylinders •
.,.
0 When check is made using delivery method, injection timing is found
to be incorrect •
•
",
~
Injection pump test shows that Injection amount Is incorrect
When valve clearance Is checked directly it Is found to be outside
•
standard value •
When muffler is removed, exhaust gas color returns to normal
•
When control rack Is pushed, It is found to be heavy or does not return
•u •u
•
~ c , , ••u ·"• ~ ••u
Remedy c. u•• "'• c.•• ~ """
c. • c. c. ~
"' "'
~
• • "' • •
"' "' "' "' "' "' "' "' "'
6D95L/S6D95L-1 70-25
TROUBLESHOOTING S·B
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
I Causes I
/d
,.•
J2 ~~ ;;;
• • Ill
••
u
- s "'- 0•
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0
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u
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c
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•
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c • £ 0!; g g c
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c ••Ill
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l if #~J if
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Degree of use J Operated for long period 6 6 6 6
•c Oil consumption suddenly increased {) 0
~ Engine oil must be added more frequently 0
•,
d
©
Engine oil becomes contaminated quickly 0 © 0
Exhaust gas Is blue under llght load {) 0
I •E
.~
~
Amount of blow-by gas
Area around engine Is dirty with ell

There is oil in engine cooling water
I
I
Abnormally excessive
None
When exhaust pipe is removed, inside is found to be dirty with oil

.f) (':;J
©
'~ til
" ·~
tt
0
0 0
0
u
•
~
u
Inside of turbocharger intake pipe is dirty with oil (J
Oil level in clutch or TORQFLOW transmission damper chamber rises ©

Clamps for intake system are loose
"
When compression pressure is measured, it is found to be low
••
~
When breather element is inspected, it is found to be clogged with
dirty oil •
.£
,.•
0 There is external leakage of oil from engine
••••
0
Pressure-tightness test of oil cooler shows there is leakage
•
"t!,
Excessive play of turbocharger shaft
••
Check rear seal directly
•
When Intake manifold Is removed, dust is found inside
•
When intake manifold Is removed, Inside is found to be dirty with oil
•
Remedy
•u •u c ••
• c.• ••
c. • •
·;;; ·' •
• •
~ •
• c.•u c.• c.~ ••
• •
~
•
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•
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~ ~ ~ ~
..
~ ~
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~
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"' "' "'

~
70-26 6095L/S6D95L-1
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
Intake of exhaust gas due to internal wear
Clogging of lubrication passage
Improper combustion
Use of improper oil
Operation under excessive load
I Causes I
~ l
#1
.g"
.f
.
c
0
Degree of use ! Operated for long period
"i;; Engine all must be added more frequently
a• Non-specified fuel has been used 0
V
Blue under light load
c---------------------------+-"~'~''~'C--c-----c------~-4L-~-4C=~-4C=~~e-~0=4
Abnormally excessive Q 0 0 0
Amount of blow-by gas
E None fJ
!.1! ~~O~~II~fl=ll~e~c~'~'~"~tl;o;n=l;a~m~p~~'~la;v~•=o=n=~·~v~e~n=w~h=e~n=~o~lltp~c~e~';'~"~"~=d;'~';'=========~~:=t=~=~~O~·t=:=t==t===t==~=O~~ ~
J-,WC'Ch_e_n_o_lcl_ficllc•c'c''cc'"c'"P-•_cct•cdc,cmcc•c"c'"P~'~rtcl~clc•c'c'c'c'c'-o-"~"cd-,,----,----if-0=--l--f-Co'--l-0=-1-c-!-+-+-l .!!!
u When exhaust pipe is removed, Inside is found to be dirty with oil © ~
Engine oil temperature rises quickly © •
.c
~~~~====~~~~~~~~~
When compression pressure Is measured, It Is found to be low e e o
fovv7Chc,cncbc,c,c,:,hc,0,cc,,c,crn"ecnctclc,c,cnc,c,c,c,,=,cd
0 d~Jccecc:,c,vc,~itCCJ,ctcoc"c"cd~toOCb e"cclocc9 c,cdc.-1-=-t-.--r--t-=-t--+---r--t---l
0 0
9 ~
with dirty oil, or hose Is broken g
~~--7.7.~~c---~~-c-c~~~-cc-~--~------+-~-l~i--+--+-~-l~~
When oil filter is inspected directly, It is round to be clogged e :3
r:VV
70hce_n_oclcl-,-o-o71e-,c,-,~,nc,-P-,-,c,-,dc-doi,-,-,ctlcy-,71t7Jc,cfco-,-ncdctcocbce--cclo gcg_e_dc-------+---t---r--t---+o•~---+--+---1
0
1i
Turbocharger drain tube Is clogged • ~
5
Excessive play of turbocharger shaft e o
When safety valve is directly Inspected, spring is found to be catching e a~
or broken
•u c •u •u c c 8 •u
Remedy • •• c.• c.• •• •• c.• • -
c.
• 13 • • u u • "•
"' "' "' "' "'
6D95L/S6D95L·1 70-27
TROUBLESHOOTING S-10
5·1 0 Fuel consumption is excessive (with distributor type pump)

General causes why fuel consumption is exces-
sive
Leakage of fuel
I Causes
I
?
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?
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1
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0.
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0.
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0 0 0
0. 0 0. ~ 0 0
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0
0
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I" J:

" " " "
~

. More than for other machines
" " "
0
0 ·P 0
"i; of same model
Condition of fuel consumption
•= Gradually increased 0 0
0
v
Suddenly Increased 0 0
Black © 0 0 0
Exhaust gas color
White 0
Seal on injection pump has come off ©
There is Irregular combustion •!J
;: When exhaust manifold Is touched immediately after starting engine,
{I 0
~ temperature of some cylinders Is low
~
u Match mark on Injection pump Is misaligned ©
~
u
•
There Is external leakage of fuel from engine ©
Engine oil level rises and smells of diesel fuel 0 ., ©
Engine low idling speed Is high 0 {I
Injection pump test shows that Injection amount Is Incorrect

•
~
0
cylinders •
·~
0
~
When blind plug at rear of pump Is removed, It can be seen that
••
:c
=
0
,::
When check Is made using measuring device method, Injection
timing Is found to be Incorrect. •
•
Remove feed pump and check directly
•
When engine speed Is measured, low idling speed is found to be high
•u ~
•
= ••• ••• •• 'C=
~ .: ~ ~
Remedy =
'C
• c.•
c.'C ~ ~ ~
• •
" "' "' " "' "' "' "
70-28 6D95L/S6D95L-1
5-10 Fuel consumption is excessive {with in-line type pump)

General causes why fuel consumption is exces-
sive
Leakage of fuel
I Caus'es
I
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0
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0 0 0
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c
0
More than for other machines
of same model
()-
"' "'
0
"'
't; Condition of fuel consumption
,• Gradually Increased 0 0
a
Suddenly Increased 0 0
I
Black © 0 0 0
Exhaust gas color
White 0
Seal on injection pump has come off {)
.
There Is Irregular combustion '(;;'
E
• When exhaust manifold is touched Immediately after starting engine,
0
.~
~
u
temperature of some cylinders Is low
Match mark on Injection pump Is misaligned
"
u
•
~
There Is external leakage of fuel from engine
"
Engine oil level rises and smells of diesel fuel 0
"
Engine low Idling speed is high 0
("
" <D·
Injection pump test shows that injection amount Is incorrect

•
~
cylinders •
c
·g
0
When control rack is pushed, It is found to be heavy or does not return
When check Is made using delivery method, injection timing is found
•
•
~
•
,• to be incorrect
"~ Remove head cover and check directly
•
Remove feed pump and check directly
•
When engine speed Is measured, low Idling speed is found to be high
•
Remedy
, ••u •~
"
~ c. c.
• • " ••• ••• • ", 0
~
~ ~
. ~
~
" "' "' " "' "' "' "
6D95L/S6D95L-1 70-29
S-11 Oil is in cooling water, or water spurts back, or water level goes down
Generl causes why oil is in cooling water
Internal leakage in lubrication system
· Internal leakage in cooling system
." Confirm recent repair history

.2 "' "'
a"
Suddenly increased 0 0 0
,• Increase In oil level
Gradually increased 0 0
Hard water is being used as cooling water 0 0
Engine oil level has risen, allis cloudy white 0 0
•E Excessive air bubbles Inside radiator, spurts back
"
.~
~
Hydraulic oil, torque converter transmission a ills cloudy white
" ©
©
~ •" When hydraulic oil, torque converter transmission oil is drained,
©
u
water comes out
.'"'" Pressure-tightness test of oil cooler shows there is leakage

• •
::C'<= Pressure-tightness test of cylinder head shows there is leakage
•
0
0
"~
t- •
0
0 Remove cylinder head and check directly
•
••
Remedy
• • •
~
.
...•"• ...••" "•
~
• • •
... ... ...
•" •" •"
~• • •
~ ~
~
"'
70-30 6D95L/S6D95l-1
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
Use of improper oil (improper viscosity)
Deterioration of oil due to overheating
* Standards for engine oil selection
Selection of oil SAE number according
to ambient temperature
Type of oil
-30 -20 -10 0 10 20 30 40 50°C
II
Engine oil I I I Causes I
SAEj P\I'M!Jqi:)
I \ $AE1iiW'liO¢P< ,.
0
!'!
a
.s"'
.s
0
.?
.,"• .s• -~"' b
:§" 15 •0
•
• .s• .0I!!
0
0
• .;: •0" ~"
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;;; ~
£ .s "'" .s• " s!J"" I
-" 1:! ~
t "'
2 .g .s•' .: g" ,, ,,.s _, :& ti•" !J ~ .s"'
0 ~
~
0
0 ~ ~
0 0
" ~"' I!! 2 "'"' "'" ;;;

~
"'"' ••-! "ff ,,."' ~

e 0
0
." ,• ,• o; •
0 0 0
."'
0 0
! f ;, ;, :ff s i ,.
~
• E f:"• f:• .:
l:"
.0 0
0 0 0 0 0
cJ ~ a a .; ~ .s" q"'• q"'• •• q"'• ~ ~ "' "'

~

Replacement of filters has not been carried out according to "' "' "'
•0
0 r~
operation manual
~
• Caution lamp lights up 0 0
0" Non-specified fuel has been used © 0
Lights up at low idling 0
"
I
0 0 0
Condition when oil pressure
lamp lights up
Lights up at low, high Idling
Lights up on sloes
Q
" ©
"'
Sometimes lights up
" © 0 0
There Is clogging, leakage from hydraulic piping (external) "'
•E Oil level sensor lamp lights up
"'
~
When oil level In oll pan is checked, it is found to be low
©
"
~
~•" Metal particles are found when oil is drained 0

"'
u
Metal particles are stuck to aU filter element 0 0
Oil is cloudy white or smells of diesel oil 0
When oil filler Is inspected directly, it Is found to be clogged

•• a
·g"
~
c
••• ..
0
~.·
·g
0
Oil pump rotation Is heavy, there is play
There is catching of relief valve, regulator valve, spring,
• ~]
,.
iii
:c• valve guide is broken •• _,
e~
'5!!
" 0=
0
"'
When all level sensor is replaced, oil pressure sensor lamp goes out
• ~p
When oil pressure Is measured, it Is found to be within standard value

• . . •
• :O:i:;
u-
•• •• •• •• •• 'ii•"
0
c c c
"" " "'• • ••" -
0 0
Remedy ~
~
~ • ~
u u u u • • <( 'D 'D 'ii 'ii
"' "'
<(
"'
<(
"'
6D95L/S6D95L-1 70-31
S-13 Oil level rises

* If there is oil in the coating water, carry out
troubleshooting for "Oil is in cooling water".
Water in oil (cloudy white)
Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component
I Causes I

•c
0
Degree of use j Operated for long period A A A A A
·~ There Is on In radiator cooling water 0 0 0 0
0
,•
Exhaust gas Is white 0 0 0
1 i1
When engine Is first started, drops of water come from muffler
Leave radiator cap open. When engine Is run at Idling, an abnormal
number of bubbles appear, or water spurts back
Water pump breather hole Is clogged with mud
When water pump breather hole is clean, water comes out
0
0
0
0
~ Oil level goes down ·In clutch, TOROFLOW transmission,

~ 0
u or damper ~:ham bar
•
~
u Oil level goes down in hydraulic tank 0
Engine ell smells of diesel fuel 0 0 0
Fuel is added more frequently 0 0 0
Pressure-tightness test of all cooler shows there Is leakage

•
Pressure-tightness test of cylinder head shows there Is leakage
•
When compression pressure Is measured, It is found to be low
•
~
c
E0
Remove water pump and check directly
•
Check rear seal directly
•
•
~
• When pump auxiliary equipment Is removed, seal is found to be broken

:a,•
~
•
Remove Injection pump and check directly
•
There Is Improper contact of thermostat seat valve
•
••
Remedy
~
:a
~
• • •
•u
• :a• :a•
•u
•
:a •
. .
•u
•
:a
~
•
•u .=• •u• •u
•
:a~
:a :a
• • • •
~ •
"' "' "' "'• "' "'• "' "' "' "' "'
70-32 6095L/S6095L-1
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes
too high
Lack of cooling water (deformation, damage of
f an )
Drop in heat dissipation efficiency I Causes
I
Defective in cooling circulation system
Rise in oil temperature of power train
Carry out troubleshooting for chassis.
*
c •
t., "' J
>.
f}•!J' >. fl •I!!
0 !:: :§ £• f
- .,
s
:§
• "' - . • "
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0
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u !::
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b
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f 0 .II
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u I!!
b !'t • Ill ::
i • ~i ./!! • u .II Iii' .s;

~
f:5
£ .,•
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c
0•
•
0• .s; ~
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rJ 8 l CJ
"'
Degree of use Operated for long period 6 6 6 6
Suddenly overheated 0 0 0
.
c
Condition of overheating
Always tends to overheat
Rises quickly
" " 0
0
0
0
"a,• Water temperature gauge Does not go down from

"
red range "
Radiator water level sensor Jlghts up
Fan belt whines under sudden load
"
"
/
Cloudy whlte ellis floating on cooling water
Cooling water flows out from overflow hose
"
Excessive air bubbles Inside radiator, water spurts back
"
Engine oil level has risen, oH Is cloudy white 0
"
There Is play when fan pulley Is rotated
"
•E Radiator shroud, Inside of underguard are clogged with dirt or mud "
.~
When light bulb is held behind radiator, no llght passes through
" "
~
u
• Water Is leaking because of cracks in hose or loose clamps
"
~
u
Belt tension Is found to be slack
"
Power train oil level enters red range before engine water temperature
"
"
Temperature difference between top and bottom radlator·tanks Is
excessive • .
Temperature difference between top and bottom radiator tanks 1iim
slight • ~
u
E
~
c
When water filler port ls Inspected, the core Is found to be clogged
When a function test Is carried out on the thermostat, It does not open
• .E!
~
c
0
~
• even at the cracking temperature • E0

~
:c,• •
When water temperature Is measured, it is found to be normal
• :c,•
~ When aU cooler is inspected directly, It Is found to be clogged
When measurement Is made with radiator cap taster, set pressure Is
• g
s
found to be low • 0
~
When compression pressure Is measured, It Is found to be low
• u
m
Remove aU pan and check directly

~ .. •u •u . •u •u •u ~
•
• • • ~
• • •
c. c. c. • "• c.• c.• c.• -
~
Remedy ~ ~ ~
• • • •
~
• <(
"'
"' "' "' "' "' "' "' "' "'
6D95L/S6D95L-1 70-33
S·15 Abnormal noise is made (with distributor type pump)

* 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
I Causes I
Air sucked in from intake system
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ill
I
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u
8 !f
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<'
""
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e
0
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0
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u • •
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e
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u
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tf
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0
e 0
0
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0
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fu •<' I.;;"' u f e .E!< 2'
.;; 0
0
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.;; • 1 1 g ~ e
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E" " • • 151 " .E!" .$! • ~ .J: .E!

i ••• ~ (j ~"' C'l C'l l J .§" ill C'l
~
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.
c
0
Degree of use
Condition of abnormal noise

Operated for long period
Gradually occurred
Suddenly occurred
A
0
0 0
0
0
~
,• Non-specified fuel has been used 0 0
a
Engine all must be added more frequently .
Color or exhaust gas
LBlue under light load ,::_
I Black 0 0
1/
•"
Metal particles are found In oil filter
Blow-by gas is excessive
Noise of interference is heard from around turbocharger "
•.
Engine pickup Is poor and combustion is irregular

\() 0
•E temperature of some cylinders is low
o1! Seal on injection pump has come off c
~
0 0 0 0 0 0
~
•" Abnormal noise Is loud when accelerating engine
u Clanging sound is heard from around cylinder head .tf
''
Leakage of air between turbocharger and head, loose clamp "~
Vibrating noise Is heard from around muffler c

•
When trubocharger is rotated by hand, it Is found to be heavy
•
Remove gear cover and check directly
Speed of some cylinders does not change when operating on
• •
.s"' reduced cylinders •
00
",•
When blind plug at rear of pump is removed, It can be seen that
:0 Injection pump test shows that injection amount Is incorrect
•
~ Fan is deformed, or belt is loose
When valve clearance is checkE!d directly, it is found to be outside
•
standard value •
Remove cylinder head cover and check directly
•
When muffler is removed, abnormal noise disappers
Remedy c.
u•
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•
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70-34 6D95L/S6D95L-1
S-15 Abnormal noise is made (with in-fine type pump)

* 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 I Causes I
."
0
Degree of use
Condition of abnormal noise

Operated for long period
Gradually occurred
Suddenly occurred
6
0
0 0
0
0
·~
•
0 Non· specified fuel has been used 0 0
a -
Engine oil must be added more frequently ''-'
Blue under light load ' '""'
Color or exhaust gas
I Black 0 0
1/
''d
Metal particles are found in oil filter c, '
Blow-by gas is excessive !;:
Noise of interference is heard from around turbocharger -9

Engine pi~kup is poor and combustion is irregular ,::;,

,:)) 0
•
.~ Seal on injection pump has come off <W>
~
0
Abnormal noise is loud when accelerating engine 0 0 0 0 0 0
•
~
u Clanging sound is heard from around cylinder head :g ild·
leakage of air between turbocharger and head, loose clamp ,;;_.
VIbrating noise is heard from around muffler Q
When compression pressure is measured, It Is found to be low

•
When trubocharger is rotated by hand, it is found to be heavy
•
Remove gear cover and check directly
Speed of some cylinders does not change when operating on
• •
~
·g" reduced cylinders •

~
0 When control rack is pushed, it is found to be heavy or does not return
•
••
:;;
Injection pump test shows that Injection amount is incorrect
•
0
,g Fan is deformed, or belt Is loose
When valve clearance is checked directly, It Is found to be outside
•
standard value •
Remove cylinder head cover and check directly
•
When muffler Is removed, abnormal noise dlsappers
••
Remedy
• • ~ • ~
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" " " " " "
6D95L/S6D95L-1 70-35
S-16 Vibration is excessive {with distributor type pump)

* 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
I Causes
I
e .s
f • f
.~
• ·~
~
~
0
2 -2
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0
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0
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Degree of use Operated for long period A A A
•0 Suddenly Increased 0 0
"••
0
Condition of vibration
Gradually Increased 0 0 0
0 Non·speclfled fuel has been used 0
I
Metal particles are found In all filter
Metal particles are found when oll Is drained
"
Oil pressure is low at low Idling
"
0
E Vibration occurs at mid·range speed 0 0
.~
~
0
Vibration follows engine speed 0 0 0 0 0
~• Exhaust gas Is black 0
u
Seal on Injection pump has come off ""
Remove ell pan and check directly
•
Check directly for worn support pilot, play
•
"'c
'g
Check directly for loose engine mounting bolts, broken cushion
•
0
~
••
Check inside of output shaft (damper) directly
When radial runout, face runout are measured, they are found to be
•
,
:;;
0 outside standard •
"' Remove front cover and check directly
•
•
Injection pump test shows that Injection amount Is Incorrect
•
_,• 0.•• 0.•• 0.•~ ·=• " • ,
• "
0 0 0 0
Remedy ~ ~ • 'C
• • • • •
~ 0.
"'• "' "' "' "' "' "' "'
70-36 6D95US6D95L-1
S-16 Vibration is excessive (with in-line type pump)

* 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
{ Causes 7
e .s 2
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•c
0 Suddenly Increased
" " " " 0 0
;;: Condition of vibration
,• Gradually increased 0 0 0 0
0 Non-specified fuel has been used 0 0
I/
Metal particles are found In oil filter 0 0
Metal particles are found when oil is drained 0
011 pressure Is low at low idling
"
0 0
E Vibration occurs at mid-range speed 0 0
.~
~
u Vibration follows engine speed 0 0 0 0 0
•
~
u Exhaust gas is black 0 0
Seal on injection pump has come off
"
Remove all pan and check dlrectly
•
Remove side cover and check directly
•
Check directly for worn support pilot, play
•
"'
.5 Check directly for loose engine mounting bolts, broken cushion
•
~
00
••
Check Inside of output shaft (damper) directly
When radial runout, face runout are measured, they are found to be
•
:0
~"
outside standard •
Remove front cover and check directly
•
•
. . •.
Injection pump test shows that Injection amount is Incorrect
•u •u • •u ~ •u u
Remedy • c.• c.• c.• c.•
c. • ·"-
c. ~ ~
• • • • • • • • <i ~
"' "' "' "' "' "' "' "'
6D95L/S6D95L-1 70-37

Komatsu Forklift 6D95L de SM S6D95LBE2 Ocr

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Komatsu Forklift 6D95L de SM S6D95LBE2 Ocr

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10101270 9 3 061

ENGINE MODEL APPLICABLE MACHINE MODEL

01 GENERAL ............................................................................................................. 01-1

10 INSPECTION AND MAINTENANCE.................................................................. 10-1

20 DISASSEMBLY AND ASSEMBLY ...................................................................... 20-1

30 STRUCTURE AND FUNCTION........................................................................... 30-1

40 TESTING AND ADJUSTING.............................................................................. 40-1

50 INSPECTION STANDARD................................................................................... 50-1

60 REPAIR AND REPLACEMENT............................................................................ 60-1

GENERAL VIEW ..................................................... 01-2

6D95L-1 (with distributor type pump)

S6D95L-1 (with distributor type pump)

Number of cylinder- Bare x Stroke (mm) 6-95x115 6- 95 X 115

Overall length (mm) 986 986

Flywheel horsepower (HP/rpm) 82/2,150 82/2,150

Dry weight (kg) 370 360

Fuel pump Basch type PES"A Basch type VE

[gal (us)] [2.9] [2.9]

Coolant capacity I 2) 7.5 8.5

[gal (us)] [2.0] [2.2]

Alternator 24V, 15A 24V, 15A

6D95L-1 6D95L-1 6D95L-1 S6D95L-1

6-95x115 6-95x115 6-95x115 6-95x115

983 986 986 986

345 360 360 425

Bosch type VE Bos.ch type VE Bosch type VE Bosch type VE

[3.4] [2.9] [2.9] [3.3]

[2.6] [4.2] [4.2] [4.8]

24 V, 25 A 24V, 15A 24V, 15A 24V, 15A

ENGINE PERFORMANCE CURVE

Engine speed (rpm)

Flywheel horsepower: 85 HP/2,150 rpm

Engine speed (rpm)

Minimum fuel consumption ratio: 160 g/HPh

1 Turbocharger - 7.0 (15.4)

2 Cylinder head assembly Cylinderhead, valve, valve spring 41 (90) 41 (90)

Cylinder block, main bearing cap, 105 (232) 105 (232)

5 Oil pan 3.1 (6.8) 3.1 (6.8)

6 Flywheel assembly Flywheel, ring gear 17 (37) 17 (37)

7 Flywheel housing 20 (44) 35 (77)

8 Crankshaft assembly Crankshaft, crankshaft gear 36.5 (80) 36.5 (80)

Piston and connecting rod Piston, piston ring, piston pin,

11 Oil pump 0.5 (1.1) 0.5 (1.1)

13 Water pump 7.3 (16.1) 7.3 (16.1)

INSPECTION AND MAINTENANCE

1. Proper selection of fuel

INSPECTION AND MAINTENANCE

KIND OF ATMOSPHERIC TEMPERATURE

Engine oil pan

Brake fluid reservoir

Grease . NLGI No.2

Coolant Soft water

For details of the replacement interval for the

'<;~~;;':~-- Sensor plug

3. FAN BELT TENSION

4.. CYLINDER HEAD MOUNTING BOLT

~ Cylinder head mounting bolt

2nd step 11 10.5-11.5

3rd step 90" 90"- 120" Make mark with punch

* The cylinder head mounting bolt may be reused

~ Cylinder head mounting bolt

Unit: kgm (ft · lb)

3rd step 15 14.5-15.5