Komatsu D140-2 Series

SEBM008603
Shop
Manual
6D14o=e SERIES
DIESEL ENGINES
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
December 1997 Cowriaht 1997 Komatsu America International Comoanv

00&l
CONTENTS
No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 01-l
11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12 TESTING AND ADJUSTING .. .. .. .. . ... . ... .. .. .. . ... .. .... ..... ..... 12-1
13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 13-1
14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
15 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . 15-1

LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requestedthatnecessaryactions Mark Indication Action required
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0
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

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

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

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

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

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: ((iJ@@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one
Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
2. Following examples
page number.
show how to read the
Example 1 (Chassis volume):

a Safety necessary
the work.
when performing
Special technical precautions

10 -3
Item number (IO. Structure

* Caution
or other precautions for pre-
serving standards are neces-
sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Example 2 (Engine volume): fh kg Weight lecting hoisting wire, or when

working posture is important,
etc.
Places that require special at-

‘ightenin! 3
Unit number (I. Engine) tention for the tightening
torque
Item number (2. Testing and torque during assembly.
Adjusting) Places to be coated with ad-

Consecutive page number for Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
31, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the

Places where oil or water
page number. File as in the example. must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
1o-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. sADoo479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rooe
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
WIRE ROPES untwisting of the rope, or slipping of
the rope from its original winding
I) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter T Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN {2000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 {IO00 kg) when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg) if they sling
30 98.1 10.0
a 19.6 kN (2000 kg) load at a lifting angle
40 176.5 18.0 of 150”.
0
50 274.6 28.0
8
60 392.2 40.0 D
fl/! tll:,
16.7 0
Jr The allowable load value is estimated to ~~~
(I 400)
be one-sixth or one-seventh of the break- &, *
ing strength of the rope used. Es
2) Sling wire ropes from the middle portion

30 60 90 120 150
of the hook. Lifting mole (deoreel SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
* The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
* For coating materials not listed below, use the equivalent of products shown in this list.
Category :omatsu code Part No. Q’W Container Main applications, features
l Used to prevent rubber gaskets, rubber

LT-IA 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
l Used in places requiring an immediately

effective, strong adhesive. Used for plas-
LT-1 B 20 9
(2 pes.)
p”“““e! tics (except polyethylene,
tetrafluoroethlene
her,
* Features:
metal and
polyprophylene,
and vinyl chloride) rub-
non-metal.
Resistance
’
to heat and chemi-
LT-2
and sealant pur-
l Used as adhesive or sealant for metal, glass

and plastic.
LT-3 Can
Adhesives
LT-4 l Used as sealant for machined holes,
Holtz l Used as heat-resisting sealant for repair-

790-126-9120~ 75 g I Tube I ing engine.
MH 705
l Quick hardening type adhesive

Three bond Polyethylene l Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container l Used mainly for adhesion of metals, rub-
bers, plastics and woods.
I l
l
Quick hardening type adhesive
Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylene
790-129-9130 29 utes)
201 container
l Used mainly for adhesion of rubbers, plas-
tics and metals.
l Features: Resistance to heat, chemicals

Loctite Polyethylene
79A-129-9110 50 cc l Used at joint portions subject to high tem-
648-50 container
peratures.
l Used as adhesive or sealant for gaskets

LG-1 790-129-9010~ 200 g 1 Tube /
and packing of power train case, etc.
Features: Resistance to heat

Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant LG-3 790-129-9070 to prevent seizure.
1 kg
Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category Komatsu code Part No. O’ty Container Main applications, features
I I
l Features: Resistance to water, oil
l Used as sealant for flange surface, thread.
LG-4 200 g Tube l Also possible to use as sealant for flanges
790-129-9020
with large clearance.
l Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
l Used as sealant for various threads, pipe

Polyethylene joints, flanges.
LG-5 790-129-9080 Used as sealant for tapered plugs, elbows,
container l
nipples of hydraulic piping.
l Features: Silicon based, resistance to heat,

Gasket
sealant LG-6 0994040011 Tube Used as sealant for flange surface , tread .
~0 Ild
Used as sealant for oil pan, final drive case,
l
l Features: Silicon based, quick hardening

type
LG-7 09920-00150 150 g Tube Used as sealant for flywheel housing, in-
---I
l
take manifold, oil an, thermostat housing,

etc.
Three bond l Used as heat-resisting sealant for repairing

790-129-9090 100 g Tube engine.
1211
Used as lubricant for sliding portion (to pre-

l
LM-G
Molybde- 1 ogg40-ooo51 1 6o g 1 Can 1 vent from squeaking).
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
l General purpose type
G2-LI p$tL/ Various Various
l Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GZ-CA SYGS-4OOCA-A Various Various
SYG2-16OCA
SYGA-16OCNCA
Molybdenum 400 g l Used for places with heavy load

disulphide SYG2-400M (IO per Belows type
lubricant case)
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across flats
mm mm Nm bm
6 10 13.2f 1.4 1.35kO.15

8 13 31+3 3.2f0.3
10 17 6657 6.7f0.7
12 19 113flO 11.5fl
14 22 177+19 18f2
16 24 279+30 28.5&3
18 382f39 39t4
:i 549k59 56+6
Ii 32 745+83 76k8.5
24 36 927+103 94.5? 10.5
27 41 1320+140 135k15
30 46 1720+190 175f20
33 50 221Ortr240 225+25
36 55 275Ok290 28Ok30
39 60 3290f340 335+35
Thread diameter Width

of bolt across flats
mm mm Nm bm
6 10 7.85f 1.95 0.8f0.2
8 13 18.6k 4.9 1.9f0.5
10 14 40.2f 5.9 4.1f0.6
12 27 82.35k7.85 8.4f0.8
TIGHTENING TORQUE OF HOSE NUTS

Use these toraues for hose nuts.
Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kam
02 14 19 24.5? 4.9 2.5k0.5
18 24 49k19.6 5+2
89 22 27 78.5f19.6 8k2
05 24 32 137.3f29.4 14k3
06 30 36 176.5k29.4 18+3
10 33 41 196.lf49 20f5
12 36 46 245.2+ 49 25+5
14 42 55 294.2f 49 30f5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
mm mm Nm bm
10 14 65.7f 6.8 6.7? 0.7

12 17 112f9.8 11.5fl
16 22 279f29 28.5f3
00-l 0
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Nominal No.
mm mm Nm kgm
02 14 34.3k4.9 3.5kO.5
03,04 20 Varies depending on 93.1k9.8 9.5+1
05,06 24 type of connector. 142.1f19.6 14.5k2
10.12 33 421.4f58.8 43f6
14 42 877.1f 132.3 89.5k13.5
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Nominal No.
Thread diameter Width across flat Tighteni ns3 torque
mm mm Nm kgm
08 8 14 7.35+ 1.47 0.75f0.15
10 10 17 11.27+ 1.47 1.15+0.15
12 12 19 17.64f 1.96 1.8f0.2
14 14 22 22.54k1.96 2.3f 0.2
16 16 24 29.4k4.9 3f0.5
18 18 27 39.21k4.9 4kO.5
20 20 30 49+4.9 5f0.5
24 24 32 68.6f9.8 7fl
30 30 32 107.8+ 14.7 llf 1.5
33 33 - 127.4k19.6 13f2
36 36 36 151.9k24.5 15.5f2.5
42 42 - 210.7f29.4 21.5&3
52 52 - 323.4? 44.1 33* 4.5
-
TIGHTENING TORQUES OF FLARE NUT

Thread diameter 1 Width across flat 1 Tiahtenina toraue

mm mm Nm bm
14 19 24.5f4.9 2.5kO.5
18 24 49k 19.6 5f2
22 27 78.5+ 19.6 8+2
24 32 137.3k29.4 14f3
30 36 176.5k29.4 18f3
33 41 196.1k49 2055
36 46 245.2?49 25k5
42 55 294.2f49 30f5
00-l 1
TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

Use these torques for metric bolts and nuts of 102 Series Engine.
Thread diameter Tightening torque

mm Nm kgm
6 10 + 2 1.02 k 0.20
8 24 f 4 2.45 k 0.41
10 43 + 6 4.38 I!I
0.61
12 77 + 12 7.85 f 1.22
TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

Use these torques for metric eye joints of 102 Series Engine.

mm Nm kgm
6 8f2 0.81 f 0.20
8 10*2 1.02 ?I0.20
10 12 f2 1.22 f 0.20
12 24 f 4 2.45 f 0.41
14 36 f 5 3.67 f 0.51
TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)

Use these torques for inches tapered screws of 102 Series Engine.

inches Nm kgm
1 / 16 3*1 0.31 f 0.10
118 8f2 0.81 f 0.20
l/4 12f2 1.22 f 0.20
318 15f2 1.53 f 0.41
l/2 24 f 4 2.45 Y!I
0.41
314 36 f 5 3.67 IL0.51
1 60 + 9 6.12 f 0.92
00-l 2
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Ca;kzjD. Curreykrating
N;tJaFzsof Dia. T;s$nds Cro;;E$tion Applicable circuit
11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 I 26 I 0.32 I 2.09 I 3.1 I 20 I Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Ground 1 Starting 1 Lighting 1 Instrument 1 Signal 1 Other
Black I Black I Red I Yellow Green I Blue
- 1 BW 1 RW 1 YR 1 GW 1 LW
- IBlack & White1 Red & White (Yellow & Red IGreen & WhitelBlue & White
- 1 BY 1 RB 1 YB 1 GR 1 LR
- IBlack & Yellowl Red & Black (Yellow & BlacklGreen & Red I Blue & Red
- 1 BR 1 RY 1 YG 1 GY 1 LY
- I Black & Red IRed & Yellow Ivellow & Greenb reen & Yellow
_I Blue & Yellow
Code WG - - RG YL GB LB
5
Color White & Greer - - Red & Green Yellow & Blue Green & Black Blue & Black
Code - - - RL YW GL -
6
Color - - - Red & Blue Yellow&White Green & Blue -
00-13
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @I.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply2.165 inches by 10 (move the decimal
point one place to the right)to returnto the originalvalue.This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5; 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197; 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591: 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984: 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378; 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772; 1.811 1.850 1.890 1.929
0 i
. . .. .............1.969
...50 .......... ...2.008
..............2.047
..............2.087
...............
2.126
.......... . 12.1651 2.205 2.244 2.283 2.323
@- 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
60
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-14
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
- - -
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
\
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-l 5
Liter to U.S. Gallon

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

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

It = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-16
kgm to ft. lb
1 kgm = 7.233 ft. Ib
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-17
kg/cm* to lb/in*
1kg/cm2 = 14.2233 lb/in*
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 !I62 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 !731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-18
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 332°F
“C “F “C “F “C “F “C “F
-40.4 -46 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 61 117.8

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

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

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 166 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-l 9
01 GENERAL
Specifications.. ...................................... ........ Ol- 2

General assembly drawing ......................... Ol- 4
Weight table ................................................ 01-14
Engine performance curve.. ...................... 01-17
01-l
GENERAL SPECIFICATIONS
SPECIFICATIONS
Engine model S6D140-2
Applicable machine GD825A-2 WA500-3
Number of cylinder - Bore x Stroke mm 6 - 140 x 165
Total piston displacement e {cc1 15.2 {15,240)
Firing order l-5-3-6-2-4
Overall length mm 1,593 1,787
Overall width mm 895 1,060
Overall height mm 2,060 1,670

(excluding exhaust pipe)
Overall height
mm
(including exhaust pipe)
Flywheel horsepower kW/rpm 209/2,100 236/2,100

IHPN-pm {280/2,100} {316/2,100}
Maximum torque Nm/rpm 1,230/l ,400 1,370/l ,400

(kgmYrpm {I 25/l ,400} {I 40/l ,400I
High idling speed rpm 2,300 - 2,400 2,300 - 2,400
Low idling speed rpm 650 - 700 700 - 750
Minimum fuel consumption ratio I/kW*h{g/HP*h; 208 {155} 204 (152)
Dry weight kg 1,506 1,520
Fuel injection pump ZEXEL PE-P (PS3S) type
ZEXEL RSV centrifugal

Governor
all speed control type
Lubricating oil amount 38

(refill capacity)
e
(34)
Coolant amount e (Engine side: 23)
Alternator 24V, 50A
Starting motor 24V, IlkW
Battery 12V 200Ah x 2 12V 170Ah x 2
Turboharger KOMATSU KTRI IO type
Air compressor ‘EXEL Reciprocation, -

l-cylinder type
Others - -
01-2
0
S6D140-2
01-2-l
0
Engine model SAGDI 40-2

D155A-3, PC16OOSP-1
Applicable machine f D155AX-3 (2 engines)
Number of cylinder - Bore x Stroke mm 6 - 140 x 165
Total piston displacement e {cc> 15.2 {I 5,240)
Overall width mm 1,040 1,185

Overall height mm -
Flywheel horsepower kW/rpm 225/1,90O(Net) 316/1,800 (Net)

+lPI/rpm {302/19001 (Net) {424/1,800) (Net)
Maximum torque Nm/rpm 1,430/1,300(Net) 1,860/l ,400

{kgmYrpm 1146/1,3001 (Net) {I 90/l ,400)
:
High idling speed 2,050 - 2,150 1,930 - 2,030 (v
rpm
5
Minimum fuel consumption ratio Ej/kWah{g/HP*h} 214 (1601 207 (154)
Dry weight kg 1,555 1,670
Fuel injection pump IOSCH PE-P (PS7S)type BOSCH PE-P(PS7S)type
lOSCHRSUVcentrifugal BOSCH RSV centrifugal,

Governor all speed type all speed type
Lubricating oil amount e

(refill capacity)
Coolant amount e (Engine only: 27) (Engine side: 27)

24U, 35A
Alternator 24V, 50A
24U, 50A (opt)
Starting motor 24V, IlkW 24V, 7.5kW
Battery 12V 170Ah x 2 12V 170Ah x 2
Turbocharger KOMATSU KTRI 10 type
Air compressor - ZEXEL Reciprocation,

l-cylinder type
Others With aftercooler
01-2-2
0
SAGDI 40-Z
DENY0 generator
DCA400SSK-2
6 - 140 x 165
15.2 {15,240}
l-5-3-6-2-4
1,870
957
1,521
310/1,500(Net, 50ti2
{415/1,5001
(Net, 50Hi
357/1,800(Net, 6OH2
I478/1,8001
(Net, 60Hi
Max. 1,570 (50H2

Max. 1,880 (6OH2
800 - 850
“217 {I621 (50Hz

“231 {I721 (60Hz
1,450
BOSCH PE-P (PS7S) type
BOSCH RSV centrifugal,

all speed type
&
64
24V, 25A
24V, 7.5kW
12V 200Ah x 2
KOMATSU
KTRI 10 type
With aftercooler
* : At rated flywheel horsepower
01-3
0
Engine model SAAGDI 40-2
Applicable machine f PC750-6, PC800-6 1 HD325-6, HD405-6
Number of cylinder - Bore x Stroke mm 6-140x 165
Total piston displacement Q {cc1 15.2 {I 5,240)
Overall width mm 1,185 1,202

Overall height
mm -
Flywheel horsepower kW/rpm 331/1,800 (Net) 179/2,000{508/2,000)

(Gross)
#iPYrpm {444/l ,800) (Net) 364/2,000(488/2,000)
(Net)
Maximum torque N m/rpm 2,100/1,350 (Net) !,170/1,400 (Gross, Net)

{kgmI/rpm {214/1,3501 (Net) 221/1,4001 (Gross, Net)
High idling speed rpm 1,930 - 2,030 2,350 - 2,450
Minimum fuel consumption ratio $kW*h{g/HP*hl 200 (1491 200 (1491
Dry weight 1,670 1,450
Fuel injection pump BOSCH PE-P (PS7S) type BOSCH PE-P (PS7S) type
BOSCH RSUV centrifugal, BOSCH RFD Min. -

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

Q
(refill capacity) (32) (37)
Coolant amount Q (Engine only: 25.5) (Engine only: 25.5)
Alternator 24U, 50A 24U, 50A
24U, 7.5kW
Starting motor 24U, IlkW
24U, 11 kW (opt)
Battery 12U 170Ah x 2 12U 170Ah x 2
Turbocharger KOMATSU KTRI 10 type KOMATSUKTRI10 type
ZEXEL ZEXEL
Air compressor Single cylinder, Single cylinder,
reciprocation type reciprocation type
With air cooled
With air cooled
Others aftercooler and
aftercooler
retarder
01-3-l
0
SAAGD 140-2
HD325-6
(High altitude spec.)
6- 140 x 165
15.2 {15,240)
l-5-3-6-2-4
1,688
1,202
1,300
307/2,000
~411/2,0001
1,750/l ,400
~179/1,4001
2,350 - 2,400
675 - 725
197 I1471
-
1,450
BOSCH PE-P (PS7S) type
BOSCH RFD
Min. - max. speed control type
41
(37)
(Engine only: 26)
24V, 50A
24V, IlkW
l2V 170Ah x 2 1
KOMATSU
KTRIIOtype
ZEXEL
Reciprocation,
single cylinder type
With air cooled
aftercooler and
retarder
01-3-2
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING * The specifications are subject to

change according to modification, etc.
SAGD140-2 LEFT SIDE VIEW (For D155A-3, D155AX-31
SDE00391
01-4
SAGD140-2 RIGHT SIDE VIEW (For D155A-3, D155AX-3)
SDE00392
01-5
SA6D140-2 FRONT VIEW (For D155A-3, D155AX-3)
SDE00393
01-6
SAGD140-2 REAR VIEW (For D155A-3, D155AX-3)
SDE00394
01-7
SAGD140-2 UPPER SIDE VIEW (For D155A-3, D155AX-3)
SDE00395
01-8
SAAGD140-2 LEFT SIDE VIEW (For PC750-6, PCSOO-6)
SDE00396
01-10
SAAGD140-2 RIGHT SIDE VIEW (For PC750-6, PCSOO-6)
L. /
SDE00397
01-7 1
SAAGD140-2 FRONT VIEW (For PC750-6, PCSOO-6)
c
c
r-
SDE00398
01-12
SAAGD140-2 REAR VIEW (For PC750-6, PCSOO-6)
v SDE00399
01-13
GENERAL WEIGHT TABLE
WEIGHT TABLE
Ir The specifications may be different depending on the type of machine.
Unit: kg
Components S6D140-2
1 Turbocharger Komatsu KTRIIO 22
Cylinder head, valve, rocker arm,

2 Cylinder head assembly 18.3
valve spring
Cylinder block, bearing cap,

3 Cylinder block assembly 340
cylinder liner
4 Front cover 37
5 Oil pan 30
55(GD825A-2,
WA500-3)
6 Flywheel assembly Flywheel, ring gear
-
60(GD825A-2,
WA500-3)
7 Flywheel housing
-
8 Crankshaft assembly Crankshaft, crankshaft gear 132
9 Camshaft assembly Camshaft, camshaft gear, thrust plate 19
Piston and connecting Piston, piston ring, piston pin,

10 rod assembly connecting rod 10.5 x 6
11 Oil pump 5.5
12 Fuel injection pump 20
13 Water pump
14 Alternator 24U, 35A 9.5

24U, 50A 12
15 Starting motor 24U, 7.5 kW 18
24U, 11 kW 20
16 Air compressor 15
I I I
17 Aftercooler assembly -
01-14
0
GENERAL WEIGHT TABLE
Unit: kg
No. Item Components SAGDI 40-2

I
1 Turbocharger Komatsu KTRI 10 23
I I
Cylinder head, valve, rocker arm,
2 Cylinder head assembly 18.3
valve spring I
Cylinder block, bearing cap,
3 Cylinder block assembly 340
cylinder liner I I
4 Front cover 38
5 Oil pan 30
60 (D155A, AX-31
55 (PC16OOSP-1)
6 Flywheel assembly Flywheel, ring gear
129 (Generator)
55 (D155A, AX-31
7 Flywheel housing 54 (PC16OOSP-I)
52 (Generator)
8 Crankshaft assembly Crankshaft, crankshaft gear 132
g Ic amshaft assembly Camshaft, camshaft gear, thrust plate
11 Oil pump 5.5
21 (D155A, AX-3)
12 Fuel injection pump 23 (Generator)
13 Water pump 17
24U, 35A, 25AI 8.5

14 Alternator
24U, 50A 12
24U, 7.5 kW 18
15 Starting motor
24U, 11 kW 20
16 1 Air compressor 15
I I I
17 Aftercooler assembly 43
01-15
0
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE

S6D140-2 for GD825A-2
Net flywheel horsepower: 209 kW (280 HPI/2,100 rpm
Net maximum torque: 1,250 Nm I128 kgmI/1,400 rpm
E
2 25
150 -1500
120 -1200
90 -900 $
IJ
L
60 -600 :
30 300
;
330 t0
0
24c
300
210
270
240 180
210
150
xl
: 180
z
120
150
120 90
90
60
60
30
0
Y " 600 800 1000 1200 1400 1600 1800 2000 2200 2400
Engine speed (rpm) SOE00956
01-17
0
S6D140-2 for WA500-3

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

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

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

/ I
150- 150
IOO-
loo- 100
50-
50- 50
o- o- 0 ::
600 600 1000 1200 1400 1600 1600 2000 2200
Engine speed (rpm) SrlE00961
01-20
0
SAAGD140-2 for HD325-6, HD405-6

Flywheel horsepower: 379 kW (508 HP}/2,000 rpm (Gross), 364 kW (488 HPY2,OOO rpm (Net)
Maximum torque: 2,170 Nm 1221 kgmI/1,400 rpm (Gross, Net)
E
z I
250 2,500
200 -2.000
a,
3
150 -1.500 z
0
+
100 -1~000
50 500
0 t 0
& 3
Y
550-
400
500-
350
450- 450
L
$ 400- 300 400
0
a
g 350- 350
I- 250
Jz 300- 300
: 250- 200
250
L
3
-x 200- 150
u_
100
50
J OJ-+
400 600 800 1,000 1.200 1,400 1.600 1,800 2,000 2.200 2,400 2,600
Ens i ne speed (rprn) SWE01096
01-21
0
SAAGDI 40-2 for PC750-6, PC800-6

Flywheel horsepower: 331 kW I444 HPI/1,800 rpm
Maximum torque: 2,099 Nm (214 kgmY1,350 rpm
E
9 e
250 -2500
200 -2000
150 1500 ;
100
50
1 1000
500
:
u
I
a 3
I Y
450 0 t 0
350
450
450
400 300
400
350 350
250
300
3 200
: 250 250
z
200 150 200
150
100
IOC
50
50
C 0 0
600 800 1000 1200 1400 1600 1800 2000 2200
Ens i ne speed (rpm) SDE00963
01-22
0
II STRUCTURE AND FUNCTION
INTAKE AND EXHAUST SYSTEM FUEL SYSTEM

Intake and exhaust system ................... 1 I- 2 Fuel system chart .................................. 1 l-44
Air cleaner .............................................. 11-15 Fuel injection pump.. ............................. 1 l-46
Turbocharger.. ........................................ 11-17 Feed pump ............................................. 1 l-52
Aftercooler .............................................. 1 I-1 8 Fuel injection nozzle .............................. 1 l-53
Fuel filter.. ............................................... 1 l-54
ENGINE BODY Engine stop motor.. ............................... 1 l-55
Cylinder head ......................................... 1 l-22
Cylinder block ........................................ 1 l-24 COOLING SYSTEM
Main circulation system ....................... .I l-26 Cooling system chart ............................ 1 I-60
Vibration damper ................................... 11-28 Water pump ........................................... 1 l-62
Timing gear ............................................ II-30 Thermostat ............................................. 1 l-66
Valve system .......................................... 11-32 Corrosion resistor .................................. 1 l-67
:
Flywheel and flywheel housing .......... .I l-34 Cooling fan drive ................................... 11-69
Z
(0
LUBRICATION SYSTEM ACCESSORY
Lubrication system chart ...................... 1 l-36 Air compressor . . . . . . . .. . .. . . . . . .. . . . . . . . . . . .. . . . . .. . 1 l-76
Oil pump.. ............................................... 1 l-38 Exhaust brake .. . . . . . . .. .. . . . . . . . . .. . .. . . . . . . .. . . . . .. . . 1 l-79
Regulator valve and piston
cooling valve .................................. 1 l-39 ELECTRICAL SYSTEM
Oil filter ................................................... 1 I-40 Alternator.. .............................................. 1 l-83
Oil cooler ................................................ 11-43 Starting motor.. ...................................... 1 l-87
Electrical intake air heater ................... .I l-89
11-l
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM

* The specifications are subject to change
INTAKE AND EXHAUST SYSTEM according to modification, etc.
S6D140-2 for WA500-3
1. Bracket A. Intake
2. Muffler B. Exhaust
3. Check valve (to prevent exhaust gas from C. Dust (together with exhaust gas)
flowing back)
4. Electrical intake air heater (ribbon type)
5. Air cleaner
6. Intake manifold
7. Intake connector
8. Exhaust manifold (Rear)
9. Exhaust manifold (Center)
10. Exhaust manifold (Front)
11. Elbow
12. Turbocharger
1l-2
a
I
I
i,
SDE00965
11-3
0
SA6D140-2 for D155A-3, D155AX-3 * The specifications are subject to change

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

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

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

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

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

4
SDE00412
1. Sensor for dust indicator

2. Intake connector (air cleaner -turbocharger)
3. Turbocharger
4. Exhaust manifold (Front)
5. Exhaust manifold (Center)
6. Exhaust manifold (Rear)
11-9
SAAGD 140-2 for PC750-6, PCSOO-6 * The specifications are subject to change
(Front view) according to modification, etc.
A. Intake air (turbocharger - air cooled

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

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

SDE00415
1. Connector (air-cooled aftercooler - electrical

intake air heater)
2. Electrical intake air heater
3. Intake connector (electrical intake air heater
- intake manifold)
4. Intake manifold
11-12
SAAGD140-2 for HD325-6 Ir The specifications are subject to change

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

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

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

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

figure, depending on the type of machine.
KOMA-CLONE TYPE (AUTOMATIC DISCHARGE MULTICYCLONE TYPE)
SEE00419
1. Hood A. Air inlet

2. Precleaner B. To turbocharger (Air)
3. Air cleaner body C. To muffler (Dust)
4. Outer element
5. Inner element
Applicable Dust discharging Number of

Engine model Type
machine model method of precleaner cleaner element
KOMA-CLONE, Automatic discharge Inner element: 1

tii Multicyclone (Exhaust ejector) Outer element: 1
11-15
0
AIR CLEANER * The specifications may be different from the following

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

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

2. V-band 12. Turbine impeller Type: KTRI 10
3. Defuser plate Overall length: 284 mm
4. Center housing A. Intake inlet Overall width: 305 mm
5. Shroud B. Intake outlet Overall height: 287 mm
6. Turbine housing C. Exhaust inlet Weight: 22.5 kg
7. Blower impeller D. Exhaust outlet
8. Seal ring E. Oil inlet
9. Thrust metal F. Oil outlet
IO. Metal G. Cooling water
11-17
0
AFTERCOOLER (Water-cooled type) Ir The specifications may be different

from the following figure, depending
on the type of machine.
SA6D140-2 (For construction machinery, generator)
;I
SDE00422
s:
1. Aftercooler cover A. Intake air inlet

2. Aftercooler core B. Intake air outlet
3. Intake manifold C. Water inlet (from cylinder head)
D. Water outlet (to thermostat)
11-18
AFTERCOOLER (Air-cooled type) * The specifications are subject to change

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

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

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

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

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

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

. Press-fitted insert for intake and exhaust
ROCKER ARM HOUSING COVER

l
Floating type seal
FUEL INJECTION NOZZLE

. Mount: Dry type (without sleeve)
A-A
SDE00428
11-23
CYLINDER BLOCK
1 2 3
1’1 IO 9 8 7 SEE00429
1. Front cover 7. Thrust metal

2. Cylinder block 8. Main metal
3. Cylinder liner 9. Main metal cap
4. Crevice seal 10. Main metal cap bolt
5. Liner O-ring 1 I, Front oil seal
6. Liner O-ring 12. Piston cooling nozzle
11-24
-
SEE00430
CYLINDER BLOCK CYLINDER LINER

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

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

2. Piston pin 9. Crankshaft
3. Connecting rod, bushing IO. Crankshaft gear (No. of teeth: 36)
4. Top ring 11. Connecting rod metal
5. Second ring 12. Connecting rod cap
6. Oil ring 13. Connecting rod
7. Pin (Crankshaft pulley) 14. Connecting rod cap mounting bolt
11-26
I
SDE00432
CRANKSHAFI-
l Stamp forging
. Journal and filet portion: Induction harden-
ing PISTON RING
Top ring Second ring Oil ring

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

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

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

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

2. Camshaft gear (No. of teeth: 48) 13. Crosshead adjustment screw
3. Camshaft 14. Lock nut
4. Cam roller 15. Crosshead
5. Cam roller pin 16. Valve retainer
6. Cam follower shaft 17. Outer valve spring
7. Cam follower 18. Inner valve spring
8. Push rod 19. Exhaust valve
9. Rocker arm shaft 20. Valve guide
10. Rocker arm 21. Spring seat
11. Lock nut 22. Intake valve
11-32
I
12 1
I
II
I
IO I
9 I8
8 I!
20
7 21
-!
6
1__ __
1 ]
I I SEE00437
CAMSHAFT VALVE TIMING

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

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

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

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

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

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

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

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

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

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

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

type of machine.
SEE00443
1. Filter head OIL FILTER

2. Safety valve . Filtration area: 0.84 m2
3. Cartridge (Rated flow 160 elmin)
For construction machinery, generator
A. Oil inlet (Rated flow 240 Urnin)
B. Oil outlet For marine engine
SAFETY VALUE
. Set pressure:
0.2 f 0.02 MPa (2.0 + 0.2 kg/cm2)
11-40
Sr The specifications may be different from

LARGE CAPACITY OIL FILTER type of machine.
I 2 3

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

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

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

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

v
” 0 0 0 0
SDE00448
1. Cooler cover THERMOSTAT FUNCTION

2. Cooler element . Valve cracking temperature: 85 + 1.5”C
6D140-2 : 10 cores . Full opening temperature: 1oo”c
S6D140-2 : 10 cores . Full opening lift: Min. 8 mm
SAGD140-2 : 12 cores
SAAGDI 40-2 : 12 cores OIL COOLER
3. Thermostat . Effective area: 6D140-2 : 0.822 m*
4. Spring S6D140-2 : 0.822 m*
5. Thermostat cover SAGD140-2 : 0.986 m*
SAAGD140-2 : 0.986 m*
A. Oil inlet
B. Oil outlet
C. Cooling water
11-43
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM * The specifications may be different from

type of machine.
FUEi SYSTEM CHART
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Fuel injection pump
7. Fuel injection nozzle
8. Over-flow valve
11-44
Ir The specifications may be different from

type of machine.
1//////11/1/,,
11//1,11111,,111,1,,,
11111,11,1/,,111//,,,
11//1/,11,,,/,,,,,,,,
1///11/1/1/,,,1/,//,,
4 3 2
SEE00450
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Fuel injection pump
7. Fuel injection nozzle
8. Over-flow valve
11-45
FUEL INJECTION PUMP * The specifications are subject to change

SA6D140 -2 (D155A-3, D155AX-3)
SDE00451
1. Fuel injection pipe (No. I) 9. Fuel injection pump drive shaft

2. Fuel injection pipe (No. 2) 10. Bearing box
3. Fuel injection pipe (No. 3) 11. Coupling
4. Fuel injection pipe (No. 4) 12. Oil inlet pipe
5. Fuel injection pipe (No. 5) 13. Feed pump
6. Fuel injection pipe (No. 6) 14. Fuel injection pump
7. Boost compensator tube (With boost compensator)
8. Fuel injection pump drive gear 15. Oil outlet pipe
(No. of teeth 48)
11-46
SDE00452
a: Fuel inlet FUEL INJECTION PUMP

b: To fuel filter . Maker: ZEXEL
c: From fuel filter . Type: Bosch PE-P
d: To fuel injection nozzle . Lubrication method:
e: Fuel return (Over-flow valve - Fuel tank) Forced lubrication with engine oil
f: Fuel spill (Nozzle - Fuel tank)
g: Engine oil (To fuel injection pump) GOVERNOR
h: Engine oil (To engine oil pan) . Type: Made by ZEXEL, bosch RSUV
Centrifugal, all speed type
11-47
SAAGD 140-2 (PC750-6, PCSOO-6) Ir The specifications are subject to change

a SDE00453
1. Fuel injection pipe (No. 1) 9. Fuel injection pump drive shaft

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

b: To fuel filter . Maker: ZEXEL
c: From fuel filter l Type: Bosch PE-P
d: To fuel injection nozzle . Lubrication method:
e: Fuel return (Over-flow valve - Fuel tank) Forced lubrication with engine oil
f: Engine oil (To fuel injection pump)
g: Engine oil (To engine oil pan) GOVERNOR
l Type: Bosch RSUV Centrifugal, all speed
type
11-49
SAA6D140-2 (HD325-6)
i
8 12 13 I4 I5 SDE00455
1. Fuel injection pipe (No. 1) 9. Fuel injection pump drive shaft

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

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

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

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

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

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

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

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

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

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

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

2. Slider assembly
3. Armature shaft
4. Contactor assembly
5. Roller
6. Worm wheel assembly
7. Motor assembly
8. Gear case assembly
11-56
STRUCTURAL DRAWING (2)
SEE00462
1. Gear cover assembly

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

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

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

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

motor)
SDE00662
When the switch is moved to the PI side (start- shaft assembly, thereby starting the motor. The
ing switch OFF), an electric current flows from slider assembly starts to move in the direction
the plus contactor plate through the PI auto- of the arrow at the same time as the roller starts
stop terminal and switch and into the armature to move.
6. Turning Condition (270” in the drawing)
SDE00663
Electric current continues to pass through the arma- direction of the arrow. Then the circuit returns
ture shaft assembly and the motor continues to turn. to stop condition 1.
The slider assembly also continues to move in the
11-59
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM CHART
For construction machinery, generator
4 5 SEE00469
1. Radiator
2. Thermostat
3. Water-cooled aftercooler (SAGDI 40-2)
4. Air compressor
5. Water pump
6. Oil cooler
7. Corrosion resistor
8. Cooling fan
A. Oil inlet and outlet
11-60
For marine engine
i SEE00470
1. Sea water aftercooler 10. Heat exchanger

2. Water level sensor 11. Marine gear oil cooler
3. Fresh water tank 12. Spare sea water pump
4. Thermostat 13. Sea water pump
5. Water-cooled exhaust manifold 14. Kingston cock
6. Water thermometer
7. Oil cooler A. Engine oil inlet, outlet
8. Water pump B. Marine gear oil inlet, outlet
9. Water temperature rise alarm switch C. Air inlet, outlet
11-61
WATER PUMP
MOUNTING
S6140-2
SA6D140-2
SAAGD 140-2 (PC750-6, PCSOO-6)
3 SDE00471
1. Oil cooler A. From radiator outlet (Cooling water)

2. Thermostat housing From heat exchanger outlet
3. Water pump (For marine engines)
B. Via oil cooler to each portion of engine
(Cooling water)
C. To radiator inlet (Cooling water)
To heat exchanger (For marine engines)
D. From thermostat (Cooling water)
E. From oil pump (Oil)
F. To each portion of engine (Oil)
11-62
SA6D140-2 (D155A-3, D155AX-3)
I
i___
i3
SDE00472

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

r-
i
3 SDE00473

2. Thermostat housing B. Via oil cooler to each portion of engine
3. Water pump (Cooling water)
C. To radiator (Cooling water)
D. To oil cooler on machine (Cooling water)
11-64
S6D140-2
SA6D140-2
SAAGD 140-2
SEE00474
1. Alternator drive pulley WATER PUMP

2. Oil seal l Type: Centrifugal, gear-driven
3. Ball bearing l Water pump speed : Engine speed x 1.56
4. Pump shaft . Flow capacity: 800 Urnin.
5. Water pump drive gear l Total water head: 14 m
(No. of teeth: 23)
6. Pump body
7. Water seal
8. Impeller
9. Pump cover
a. From radiator
b. To oil cooler
11-65
j, The specifications may be different from

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

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

type of machine.
SEE00476
1. Head CORROSION RESISTOR

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

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

TENSION PULLEY MOUNT type of machine.
S6D140-2 for WA500-3
conditioner
IVYIOPT)
4 3 2 SDE00966
1. Fan pulley
2. Tension pulley (Outside diameter: 120mm)
3. Crank pulley (Outside diameter: 164 mm)
4. Fan belt
11-69
0
TENSION PULLEY MOUNT * The specifications may be different from

SA6D140-2 for D155A-3, D155AX-3 type of machine.
l___--’ SDE00478
1. Fan pulley FAN PULLEY

2. Tension pulley
3. Crank pulley (Outside diameter: 200 mm) )
4. Fan belt
D155A-3, D155AX-3
314
(Scraper spec.)
11-69-1
0
TENSION PULLEY * The specifications may be different from

SA6D140-2 (D155A-3, D155AX-3) type of machine.
9. d i ‘5 SDE00479
1. Bracket
2. Spacer
3. Ball bearing
4. Tension pulley (Outside diameter: 118 mm)
5. Oil seal
6. Inner race
7. Needle bearing
8. Coil spring
9. Tension shaft
11-70
SAAGD140-2 (PC750-6, PCSOO-6) * The specifications may be different from

type of machine.
1
I
SDE00480
Pulley outside diameter

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

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

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

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

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

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

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

2. Crankcase b. Air exhaust
3. Connecting rod c. Unloader
4. Cylinder d. Oil inlet
5. Piston e. Cooling water inlet or outlet
6. Piston ring f. Cooling water outlet or inlet
7. Piston pin
8. Bearing cover
9. Cylinder head
10. Unloader valve
11-76
I 1
SEE00466
AIR COMPRESSOR UNLOADER VALVE

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

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

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

SLIDE VALVE TYPE
SEE00488
1. Valve housing 8. Retainer

2. Gate valve 9. Release valve
3. Guide bushing 10. Packing
4. Cylinder 11. Packing
5. Spring 12. Exhaust pressure adjustment bolt
6. Spring 13. Breather
7. Piston
Outline
An exhaust brake is installed between the turbo-
charger and muffler, and works due to the air pres-
sure from the solenoid valve, reducing engine speed
by throttling the exhaust passage of the muffler
from the turbocharger. The exhaust brake consists
of a valve mechanism and an air cylinder which
controls the valve.
11-79
EXHAUST BRAKE * The specifications are subject to change

BUTTERFLY VALVE TYPE
1. Air cylinder 9. Valve

2. Stopper bolt (fully open) IO. Spindle
3. Stopper bolt (fully close) 11. Bushing
4. Lever 12. Valve body
5. Yoke 13. Cover
6. Insulator
7. Bushing a: From exhaust brake valve
8. Spindle
11-80
SOLENOID VALVE FOR EXHAUST BRAKE

type of machine.
-
m I
li
C
B
7’ B/
SEE00490
1. Connector A. From air tank

2. Case B. To exhaust brake
3. Core C. Exhaust outlet
4. Coil assembly
5. Spring
6. Plunger
7. Spring
8. Valve
9. Rod
10. Body
11-81
EXHAUST BRAKE
Operation
1. When the exhaust brake switch is turned
Off
If the switch is turned off, solenoid (1) of the
exhaust brake valve is deenergized.
Under this condition, ports A and B of the
exhaust brake are closed, but ports B and C
are open. Accordingly, air in cylinder (5) of
the butterfly valve returns through port B to
port C, then discharged in the atmosphere,
and butterfly valve (7) fully opens the path
from the turbocharger to the muffler.
To
4
muffler
- Ia”K
SEE00664
2. When the exhaust brake switch is turned

on
If the switch is turned on, solenoid (1) of the
exhaust brake valve is energized, and plunger
(3) and valve (4) move in the direction of t
to close ports B and C and open ports A and
B. As the result, air from the dry tank flows
in port B, then to cylinder (5) of the butterfly
valve.
Then, the cylinder is extracted to move lever
(6) in the direction of 4, and butterfly valve
(7) fully closes the path from the turbo-
charger to the muffler. Accordingly, the en-
gine speed drops and the downhill travel
speed of the machine is limited.
While the accelerator pedal is pressed, the
exhaust brake limit switch operates so that From dry tank
the engine brake will not be applied even if To muffler
SEE00665
the switch is turned on.
11-82
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ELECTRICAL SYSTEM It The specifications may be different from

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

2. Adjust rod b. Alternator drive ~ullev (Pulley O.D. 132 mm)
3. Nut (2 pieces)
4. Plate
5. Cover
6. V-belt (2 pieces)
7. Spacer
H-83
Alternator with built-in regulator (Open type) rt The specifications may be different from
type of machine.
Internal connection diagram
SDE00666
1. Alternator B, E, R, F: Terminals
2. Alternator pulley
Applicable Pulley O.D. Weight Pulley

Engine model Type Specification
machine model (mm) (kg) type
Maker: NIKKO DENKI
S6D140-2 WA500-3 Type: Opened 24V, 35A 85 9.5 I
(Brushless)
Maker: NIKKO DENKI
SAGD 140-2 D155A-3, AX-3 Type: Opened 24V, 25A 85 8.5 I
(Brushless)
11-84
0
Alternator with built-in regulator (Open type) * The specifications may be different from
type of machine.
---1 I--
Reeu I ator
7
Internal connecti on diaer ‘am SEE00667
1. Alternator B, E, R, F: Terminals
Applicable Pulley O.D. Weight

machine model (mm) (kg)
Maker: NIKKO DENKI
6D140-2 24V, 35A 85 9.5
Type: Opened (Brushless)
S6D140-2 Maker: NIKKO DENKI

D155A-3, AX-3 24V, 35A 85 9.5
SAGD 140-2 Type: Opened (Brushless)
Maker: NIKKO DENKI

24V, 25A 85 8.5
SAGD 140-2
Maker: NIKKO DENKI
24V, 30A 85 9.5
11-85
Alternator with built-in regulator (Open type) + The specifications may be different from
type of machine.
- II
.-__-__-__-__-__-__-_-----
Internal connection
Reeulator
diagram
E
*I SDE00668
1. Alternator B, E, F, N, R: Terminals
Applicable Pulley O.D. Weight Pulley

machine model (mm) (kg) type
Maker: SAWAFUJIDENKI
S6D140-2 G D825A-2 Type: Opened 24V. 50A 85 12 II
(Brushless)
SAGDI 40-2 D155A-3, AX-3 (opt) Type: Opened 24V. 50A 85 12 II
(Brushless)
PC750-6, PC800-6
SAAGDI 40-2 Type: Opened 24V, 50A 85 12 II
HD325-6, HD405-6
(Brushless)
11-86
0
STARTING MOTOR (7.5 kW) -Ir The specifications may be different from
type of machine.
Connector specification
(X-type connector)
~ <2. R terminal I
I. S terminal
2P connector (male)
2. R terminal’ '1.S terminal
2P drip-proof connector (male)
I. S terminal
a=@snn III
h
3. E terminal 2. R terminal
3P drip-proof connector (male1
1. Pinion gear
2. Starting body 2. R terminal’ I. s\ terminal
3. Engage switch 2P connector (male)

4. Connector Outer connection diagram
SEE00669
B, C, R, S, E: Terminals
Applicable Pulley O.D. Weight Connector

machine model (mm) (kg) specification
6D140-2
Maker: NIKKO DENKI

Type: Closed 24V, 7.5kW 12 18
(drip-proof, oil proof)
S6D140-2
Maker: NIKKO DENKI

Type: Closed 24V, 7.5kW 12 18
(drip-proof, oil proof)
PC750-6, PC800-6 24V, 7.5kW 12 18 IV
SAAGDI 40-2
11-87
STARTING MOTOR (11 kW) * The specifications may be different from

3 type of machine.
\
Connector specitication
2 R terminal
I
I. S terminal
2P connector (male)
rf-:
-c
.: ”
II
E .;
2”
2. R terminal I s terminal
-2 2P connector (male)
-r
-00
2+
: 3. Safety relay COUPI er
I 3P circuit 1. s terminal
<
~=+slIl~ III
A
3. E terminal- 2. -R terminal
2P connector (male)
: 2. Safety relay coup ler

Z 2P circuit
Iv
3. E terminal 2. R terminal
2P connector (male)
1. Circuit without safety relay
Internal connection diagram SEE00670
Engine model Applicable Type Specification Pulley O.D. Weight Connector

machine model (mm) (kg) specification
GD825A-2 Type: Closed 24V, 11 kW 11 20 II
S6D140-2 (drip-proof, oil proof)
12 20 IV
HD325-6, HD405-6
SAAGD140-2
---.
ELECTRICAL INTAKE AIR HEATER

S6D140-2 the following figure, depending on the
type of machine.
1. Heater body
2. Heater coil

. Rated voltage: DC22V
. Rated current: 175A
Internal
connection diagram
SEE00671
SAGD140-2
1. Heater body
2. Heater coil
3. Terminal

. Rated voltage: DCIIV
. Rated current: 86A
SEE00500
11-89
FRONT PTO MOUNTING f The specifications may be different from

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

type of machine.
A-A SEE00502
1. Shaft
2. Pulley
3. Oil seal
4. Bearing (2 pieces)
5. Housing
6. O-ring
7 Gear (No. of teeth: 14)
8. Snap ring
9. Sleeve
11-91
FRONT PTO DRIVE GEAR ASSEMBLY

type of machine.
1
/
I /”
1’ /”
/’
/”
A-A SDE00503
1. Gear (No of teeth: 24) 7. Gasket

2. Snap ring 8. O-ring
3. Pin 9. Bearing (2 pieces)
4. Plate 10. Housing
5. Bolt 11. Shaft
6. Flange
1l-92
1% TESTING AND ADJUSTING
Adjusting engine speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 2
ENGINE BODY
Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 3
Measuring compression pressure . . . . . . . . . . . . . . . 12- 4
FUEL SYSTEM
Testing and adjusting fuel
injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4-1
Adjusting fuel injection pressure . . . . . . . . . . . . . . . . . 12- 5
Procedure for adjusting engine
stop motor cable ._..............._.................. 12- 6
Fuel injection pump
calibration data . . . . . . . . . . ..__......................... 12- 7
COOLING SYSTEM
Checking and adjusting
fan belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6-2
PERFORMANCE TEST
Run-in standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Performance test criteria . . .._.......................... 12-14
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
TESTING AND ADJUSTING TOOL LIST . . . . . . . . . . . . . 12-45
TESTING AND ADJUSTING DATA . . . . . . . . . . . . . . . . . . . . . 12-46
12-1
0
TESTING AND ADJUSTING TESTING AND ADJUSTING
Sr The specifications may be different from

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

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

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

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

and contact surface of ring gear
l The following is the removing and mount-
ing procedure of the engine speed sensor.
1. Tighten sensor (1) until its tip touches ring

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

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

* Arrange the sensor wires carefully so
that an excessive force will not be ap-
plied to them.
* Take care to keep the sensor tip free
from metallic chips dust, dirt etc.
Clearance
TDE00257 TEE00351
12-2
TESTING AND ADJUSTING ENGINE BODY
ENGINE BODY
ADJUSTING VALVE CLEARANCE
1. Remove the rocker arm housing cover.
2. Rotate the crankshaft in the normal direction.

While watching the movement of the intake valve
of the No. 6 cylinder, bring the No. 1 cylinder
into the top dead center position of the com-
pression stroke and align the “1.6 TOP” mark
on vibration damper (I) with pointer (2).
* When the No. 1 cylinder comes near the top
TEE00258
dead center of the compression stroke, the
No. 6 intake valve will start to move (open).
3. Adjust the valve clearance for valves marked l Valve arrausement diagram
in the valve arrangement chart.
4. Rotate the crankshaft in the normal direction by

one revolution and adjust the valve clearance
for the remaining valves marked .
TDE00352
Sr To adjust the valve clearance, loosen lock

nut (5) on adjustment screw (4), insert the
feeler gauge corresponding to the specified
clearance between crosshead (6) and rocker
arm (71, and adjust the clearance with the
adjustment screw until the thickness gauge
can slide lightly.
5. After the clearance is properly adjusted, tighten

the lock nut to secure the adjustment screw.
w Lock nut: 58.8 2 5.9 Nm (6.0 d 0.6 kgm}
* The engine firing order is 1 - 5 - 3 - 6 - 2 - 4.
* Intake and exhaust valve clearances may be ad-
justed for each cylinder in the firing order by
rotating the crankshaft 120” at a time in the nor-
mal direction.
12-3
MEASURING COMPRESSION
PRESSURE
MEASUREMENT PROCEDURE
A While measuring the compression pressure,

take care not burn yourself on the exhaust
manifold or muffler, and be careful not to
get caught in any revolving part of the en-
gine.
-k Measure the compression pressure while the
engine is warm.
(Oil temperature: 40 - 60°C)
1. Adjust the valve clearance properly. For details,

see ADJUSTING VALVE CLEARANCE.
2. Disconnect fuel injection tube (I 1.

* When the No. 1 cylinder comes near the top
dead center of the compression stroke, the
No. 6 intake valve will start to move (open).
3. Remove inlet connector (2) and nozzle holder

assembly (3) for each cylinder.
4. Install adapter (4) to the nozzle holder mounting

section of the cylinder to be measured, and
tighten the adapter with retainer (5) to the speci-
fied torque:
m Torque: 66.7 2 7.3 Nm 16.8 f 0.75 kgml
5. Connect compression gauge A to the adapter.
6. Place the fuel control lever in NO INJECTION

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

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

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

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

on the injection pump is matched to stamped Pin
line “b” on the coupling side.
* If the engine is started or turned forcedly in
this condition, the end of pin (5) will be bro-
ken and caught in the gear, and that can
cause a serious accident.
l Adjustment of fuel injection timing

1. If the stamped line of the fuel injection timing is
found to be deviated, as the result of inspection,
adjust it according to the following procedure.
: TEH00092 BEH00013
z 1)
(D Loosen bolt (7) and shift the coupling to
match the stamped line, then tighten the bolt.
w Bolt: 58.8 - 62.8 Nm I6.0 - 6.4 kgm1
b a
. Releasing fixing pin
1) Pull pin (5) out of gear (6).
* Pin (5) can be pulled out easily if it is
turned.
* Pull out pin (5) until is stops.
2) Tighten nut (4).

w Nut: 26.9 - 33.9 Nm (2.74 - 3.46 kgm1
* The nut can be tightened securely if a
flat-head screwdriver is set in the slit of I TEE00576
pin (5) to lock it.
3) Insert snap pin (3) to lock nut (4) and pin (5).
4) Turn on the engine and confirm that it runs

smoothly.
BEH00015
12-4- 1
a
ADJUSTING FUEL INJECTION PRESSURE
1. Remove retaining cap (8).
2. Confirm thickness of adjustment shim (3).
3. insert correct shim (3) in response to the

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

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

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

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

the injection pump to the cable of the engine
stop motor.
2. Pull injection pump stop lever (2) to the ENGINE

STOP (fuel non-injection) position, temporarily
attach the ball joint to the stop lever, then fix
cable (4) to bracket (3).
* The engine stop motor cable is housed in
the pulled condition.
Ir When the lever is free, the stop lever is in
the OPERATING position (built-in spring).
When the engine is stopped (at time of installa-

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

per and lever, tighten each bolt and nut. 1. Lever stopper
2. Fuel injection pump stop lever
3. Bracket 2
Turn the engine starting switch ON and OFF a
few times to confirm that the engine stop motor 4. Cable :
actuated smoothly. Be especially sure to con- 5. Joint
firm that there is a clearance between the stop
lever and stopper when the engine is stopped.
* The engine stop motor has built-in limit
switches on both sides of the cable stroke.
* When the engine is running, there is some
slack in the engine stop motor cable. A spring
built into the injection pump actuates to hold
the opening position.
. Engine stop motor stroke: 35 mm
. Injection pump stop lever stroke: 30 mm
12-6
0
PROCEDURE FOR ADJUSTING

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

the injection pump to the cable of the engine Normal use
stop motor.
2. Pull injection pump stop lever (1) to the ENGINE

STOP (fuel non-injection) position, temporarily
attach the ball joint to the stop lever, then fix
cable (3) to bracket (2).
+ The engine stop motor cable is housed in
the pulled condition.
* When the lever is free, the stop lever is in
the OPERATING position (built-in spring).
3. When the engine is stopped (at time of installa-

tion), clearance a between stop lever (I) of the
injection pump and the lever stopper (built-in to
pump) should be 0.5 - 1.5 mm. Check clearance
by movement of cable due to stopper is built
into pump housing. Adjustment is made accord-
ing to the depth that the ball joint is screwed in.
4. After adjusting the clearance between the stop-

per and lever, tighten each bolt and nut. TOE00578
5. Turn the engine starting switch ON and OFF a

few times to confirm that the engine stop motor 1. Stop lever
actuated smoothly. Be especially sure to con- 2. Bracket
firm that there is a clearance between the stop 3. Cable
lever and stopper when the engine is stopped. 4. Ball Joint
* The engine stop motor has built-in limit
switches on both sides of the cable stroke.
* When the engine is running, there is some
slack in the engine stop motor cable. A spring
built into the injection pump actuates to hold
the opening position.
. Engine stop motor stroke: 35 mm
. Injection pump stop lever stroke: 30 mm
12-6- 1
0
TESTING AND ADJUSTING COOLING SYSTEM
COOLING SYSTEM
CHECKING AND ADJUSTING FAN
BELT TENSION
2 1. Adjustment nut
2. Washer
1 3. Tension spring
4. Adjustment bolt
5. Tension pulley
3
A. Protrusion of adjustment bolt
i-
l__,-’
Unit: mm
Engine model Applicable machine Dimension A
PC750-6
SAAGDI 40-2 44 z!z3
PC800-6 I
12-6-2
0
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP CALIBRATION DATA
Engine model Pump assembly No. Engine serialNo. Applicable machine Page
6211-72-1310 WA500-3 12-8
6211-72-1470 GD825A-2 12-11-2
S6D140-2
6212-72-1120 D155A-3, D155AX-3 12-9
6212-72-1860 DENY0 generator

DCA400SSK-2 12-10
6212-72-1430 PC16OOSP-1 12-11-3
SAGD140-2
6212-72-1420 PC750-6, PC800-6 12-11-1

HD325-6 (with mechanical
6212-72-1250 governor)
12-11
HD405-6 (with mechanical
aovernorl
SAAGD140-2
12-7
0
Injection Pump Assembly Number Applicable Machine Applicable Engine

621 I-72-1310 (106675-4400) Serial No. Model Serial No.
Model
): Injection pump manufacturer’s part No. WA500-3 S6D140-2
njection Pump Specification Engine Specification
Delivery valve (mm3/st) Pump tester capacity

retraction volume Motor 7.5 kW
for Service standard
1 Inbrtinn
:onditions
I Service standard
indicates data
) Manufacturer
standard is data
for the engine on
the machine.
ijection volume
B to E are the
reference volume
when adjusting
volume.
Marks * are
average volumes.
Governor Performance Curve # Adjusting the injection pump at 360frpm) is as follows: adjust injection volume and
variance of injection pump without governor to adapt to the values in the chart
above at the rack position on 7.6(mm), and after coupling with the governor, check
if the rack position is 7.0(mm), and checking of injection volume or variance is not
necessary to be checked at rack position on 7.0fmm).
Min. 14. 0
E
E
10. 7
z IO. l-10.3
._ 10 0
.-
:
0
6. 9-8. I
7. 0
:
C.z
1,085 1,095
Pump speed (rprn) TWE00697
12-8
0

6212-72-1120 (106671-9440) Model / Serial No. Model 1 Serial No.
( ): Injection pump manufacturer’s part No. D155A-3 SAGDI 40-2
Injection Injection pump D155AX-3
Pump Type Manufacturer
PE-P (PS7S) ZEXEL
Injection Pump Specification Engine Specification

Flywheel horsepower (kW {HP}) / rpm) 246{3291/1,900 (Gross)
(Nm {kgmI/ rpm) 1,480~151~/1,300 (Gross)
Delivery
retraction
valve
volume
(mm3/st)
II Pump tester capacity
Motor 7.5 kW
nlihratinn _Standarri 1 Ininrtinn
Conditions
Service standard
indicates data
using calibration
Manufacturer
standard is data
for the engine on
the machine.
ejection volume
B to E are the between cylinder between cylinder

reference volume
Marks t are
average volumes.
Governor Performance Curve Boost Compensator Performance Curve
Boost compensator stroke:O. 85-l 05 (mm)
-2
E 1055
C
.z
.-
P
9. 60
0
Cz
1 /
0 18.6-24 0 34.6-48.0
(140-1801 1250-3701
Boost Pressure (kPa{mmHsl)
720 965 990
Pump speed Cram) TWE00698
12-9
0

6212-72-I 860 (106682-9590)
Model 1 Serial No. Model / Serial No.
( ): Injection pump manufacturer’s part No. DENY0 generator SAGDI 40-2
injection Injection pump DCA400SSK-2
PE-P (PS7S) ZEXEL
Injection Pump Specification Engine Specification (Without fan)
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) ~,!~$$“~$~~ ‘E:?i> ii !:i
Injection order l-5-3-6-2-4 Maximum torque (Nm Ikgml/ rpm) -
Max. 1,570 (50 Hz)

Injection interval 59”30’ - 60”30’ High idling speed (rpm) Max. 1,880 (60 Hz)
Plunger pre-stroke (mm) 3.85 - 3.95 Low idling speed (rpm) 800 - 850

retraction volume 120 Motor 7.5 kW
onditions
Service standard
indicates data
Manufacturer
standard is data
for factory test.
jection volume
B to E are the
reference volume
Governor Performance Curve
Min.- max.speed control s~ec. All speed.idlina set
Q=47.5-50.5 (mm3/s t .)
0 405
895-905 Pump sueed (rem)
Pump speed (rpm) TWE00699
12-10
0

6212-72-1250 (1016682-9391)
Model 1 Serial No. 1 Model 1 Serial No.
( ): Injection pump manufacturer’s part No. HD325-6 SAAGDI 40-2
Injection Injection pump HD405-6
Pump Type Manlufacturer
PE-P (PS7S) ZEXEL
Injection Pump Specification Engine Specification (Without fan)

Rotating direction Clockwise 1 Flywheel horsepower (kW {HP}) / rpm) 1379I508K?OOO (Gross)l
Injection order l-5-3-6-2-4 1 Maximum torque (Nm {kgmI/ rpm) 1 2,170{221)/1,400 (Gross) 1
1Injection interval1 1 59”30’ - 60’30’ 1 1 High idling speed (rpm) 1 2,350 - 2,450 I
Plunger pre-stroke (mim) 3.25 - 3.35 Low idling speed (rpm) 700 - 750
Delivery valve (mm3/‘st) Pump tester capacity

Conditions
b Service standard
indicates data
D Manufacturer
standard is data
for factory test.
njection volume
I Rack positions
B to E are the
reference volume
Rack limitIll. 9-12. I (mm)

ost comDensator siroke:Z. 7-2. 9 (mm)
Dumper spring set:5. 5-5.7 (mm)
: 11.3
0 26. 3-33. 3 Approx. 78. 0

(200-2501 (Approx. 5901
Boost Pressure (kPa{mmHgi)
225-275 365 Min. 1.020 I.075
12-11
0

6212-72-I 420 (106682-9420) Model Serial No. Model Serial No.
( ): Injection pump manufacturer’s part No. PC750-6 SAAGDl40-2
Injection Injection pump PC800-6
Pump Tvpe Manufacturer
PE-P (PS7S) ZEXEL

I
lniection Puma SDecification Enaine SDecification (Without fan)
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 353{4731/1,800 (Gross)
I
Injection order 1 l-5-3-6-2-4 Maximum torque (Nm IkgmY rpm) 2,160{220}/1,350 (Gross)
Injection interval 59”30’ - 60”30’ High idling speed (rpm) 1 1,930 - 2,030
I
Plunger pre-stroke (mm) 3.25 - 3.35 i Low idling speed (rpm) I 800 - 850 I
f ). Ininctinn mnnllfactllrer’s nart number
:onditions
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
ijection volume
B to E are the
reference volume
when adjusting
Marks * are
average volumes.
18. O-21. 0 Rack limit
-Boost comeensator stroke:l. 9-2. 1 (mm)
12. a I C A
_-_-_-_-_-_-__-_-_*_-_*-
-z \
E E 12.8
r
._z .z
.- .-
_ vi
: 6. 9 0
n
r 6.7 ; 10.8
2 CL
-PI 9.9 XZL
0 25. 3-38. 7 65. 3-70. 7
(190-2901 1490-5301
Boost pressure (kPa{mmHg))

0 415 / 965-1,020
Min. 910
Puma speed irom) TWE00700
12-11-1
0

621 I-72-1470 (106675-4421)
Model 1 Serial No. Model / Serial No.
( ): Injection pump manufacturer’s part No. iy.1.12 1 , S6D140-2 ~
Injection Injection pump
PE-P (PS3S) ZEXEL

I
Injection Pump Specification Ensine Specification
Rotating direction Clockwise Flywheel horsepower (kW {HP)) / rpm) 221{296}/2,100 (Gross)
Injection order l-5-3-6-2-4 Maximum torque (Nm {kgm}/ rpm) / 1,280{130}/1,400 (Gross)
1Injection interval / 59”30’ - 60”30’ 1 High idling speed (rpm) / 2,300 - 2,400
Plunger pre-stroke (mm) Low idling speed (rpm) 650 - 700
I Delivery valve
retraction volume
(mm3/st)
IIPump tester capacity
for Service standard I
Motor 7.5 kW
nlihratinn _Standard Inbrtinn
onditions
Service standard
indicates data
using calibration
Manufacturer
standard is data
for factory test.
jection volume
B to E are the
reference volume
when adjusting
volume.
Marks * are
average volumes. D 1rack limit 1 100 / * 175.0 - 195.0 * 195.0
E
Governor Performance Curve # Adjusting the injection pump at 325(rpm) is as follows: adjust injection volume and
variance of injection pump without governor to adapt to the values in the chart
above at the rack position on 7.l(mm), and after coupling with the governor, check
if the rack position is 6.B(mm), checking of injection volume or variance is not
Min. 14. 0 Rack I imit necessary to be checked at rack position on 6.B(mm).
0 325 1.075’/ 1.175

I.085
12-11-2
0

6212-72-1430 (106682-9571)
Model 1 Serial No. Model 1 Serial No.
( ): Injection pump manufacturer’s part No. PC16OOSP-1 SAGD 140-2
injection Injection pump
PumD TvDe Manufacturer
PE-P (PS7S) ZEXEL

I
Injection Pump Specification Engine Specification
Rotating direction Clockwise 1 Flywheel horsepower (kW {HP}) / rpm) 1 331{444)/1,800 (Gross) 1
Injection order l-5-3-6-2-4 1 Maximum torque (Nm IkgmY rpm) 1 1,910I195~/1,400 iGross j
Injection interval 59”30’ - 60”30’ i High idling speed (rpm) / 1,930 - 2,030
Plunger pre-stroke (mm) 3.25 - 3.35 ILow idling speed (rpm)] 725 - 775 I
Delivery valve (mm3/st)
retraction volume 120
I Pump tester capacity
for Service standard I
Motor 7.5 kW
alibration Standard ( ): Injection pump manufacturer’s part number

Service standard Manufacturer standard
Conditions Nozzle & nozzle holder part No. (105780-8130) 6212-12-3200 (105111-4680)
Nozzle part No. (I 05780-0050) ( 105025-0940)
I Service standard
indicates data Nozzle holder part No. (105780-2090) 6212-11-3212 (105041-7122)
using calibration Injection pipe (mm) 8 x 4 x 600 6 x 2.2 x 630
test parts. (Outside dia. x inside dia. x length)
I Manufacturer Test oil ASTM D975 No. 2 diesel fuel or eauivalent
standard is data
Oil temoerature (“C) I 40 - 45
for factory test.
Nozzle opening pressure (MPa{kg/cm21) 17.2 {I751 24.5 1250)
Transfer pump pressure (kPaIkg/cmZ}) 157 U.60) 157 {I.601
I I I Service standard (cc/1000 St.1 Manufacturer standard (cc/1000 St.)

njection volume Rack Pump
Rack Maximum Maximum
point position speed
Injection variance Injection variance
Rack positions (mm) (rpm) volume between cylinder volume between cylinder
B to E are the
reference volume A
when adjusting Basic point) 12.2 895 - 905 k308.0 - 318.0 max. 18.8 k274.0 I
the injection
B approx. 7.6 375 t11.0 - 14.0 max. 3.8 *35.0
volume.
Marks * are C 12.2 700 Sr281 .O - 297.0 k296.0
average volumes. D rack limit 100 k440.0 - 460.0 *475.0
E
Boost comPensator strokey2. 6-2. 8 (mm)
____ * ____
-Z
5 12.2
.-Z
.-
::
P
&!?I
U 9. 5
2
0 16. O-29. 4 64. O-69. 4

~120-2201 (480-5201
Boost Pressure (kPaimmHo1)
400 970-980 965-1.015
12-11-3
0
TESTING AND ADJUSTING PERFORMANCE TEST
PERFORMANCE TEST
RUN-IN STANDARD * The table gives the standard values for machines without fan.
* The loads for the dynamometer are at an arm’s length of 716 mm.
Engine Applicable Item Order

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

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

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

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

horsepower K-IF’1 (01 (39.41 l94.7) (177.5) (331.3)
Running time nin.
Engine speed rpm
Load N
{kg)
Flywheel kW
horsepower U-LPI
Running time min.
Engine speed rpm
Load N
(kg1
Flywheel kW
horsepower U-IPI
Running time min.
Engine speed rpm
Load N
(kg)
Flywheel kW
horsepower (HP1
-
12-12
0
t The table gives the standard values for machines without fan.
T
Engine
model
Applicable
machine T Item
-
1 2 3
Order
4 5 6
Running time min 2 8 7 10 3
Engine speed rpn 700 1,100 1,450 1,710 1,900

D155A-3
Load N 0 432 863 1,285 1,716
D155AX-3 {kg1 IO1 I441 I881 I1311 I1751
Flywheel kW 0 35.6 93.9 164.9 244.7

horsepower {HP: 101 (47.7) (128.5) (220.91 (327.81
Engine speed rpn- 750 1,000 1,200 1,500 1,800
SAGDI 40-2 PC16OOSP-1 Load N 0 618 1,226 1,844 2,452

{kg1 {OI (631 I1251 1188) 12501
Flywheel kW 0 46.4 110.4 207.6 331.2

horsepower 0-t? {OI (62.1) {I 47.91 (278.1) 1443.71
Engine speed rpm 800 1,000 1,200 1,500 1,800

DENY0
Load N 0 539 1,844 2,157, 2,707
DCA400SSK-2 {kg) 101 I551 (1881 (2201 12761
Flywheel kW 0 40.5 166.3 242.9 365.8

horsepower {HP1 101 (54.21 (222.8) (325.4) 1490.01
Running time min
Engine speed rpm
Load N
{kg}
Flywheel kW
horsepower U-II’1
?unning time min.
Engine speed rpm
_oad N
{kg}
-lywheel kW
iorsepower :HPI
-
12-13
0
* The table gives the standard values for machines without fan.
Engine
model
Applicable
machine T Item
- 1 2 3
Order
4 5 6
Running time min. 2 8 7 IO 3
Engine speed rpm 725 1,300 1,650 1,900 2,000

iD325-6
Load N 0 588 1,177 1,765 2,354
iD405-6 {kg1 (0) I601 I1201 U801 12401
Flywheel kW 0 57.4 145.7 251.7 370.9

horsepower U-IPI {OI (76.9) {I 95.2) (337.2) (496.9)
Running time min. 2 8 2 3 5
Engine speed rpm 725 1,000 1,200 1,500 2,000
SAAGD 140-:2 iD325-6 Load N 0 490 1,030 1,569 1,961

Highaltitudespec {kg} IO1 1501 I1051 I1601 I2001
Flywheel kW 0 36.8 92.7 176.6 294.4

horsepower (HP1 (01 149.3) l124.21 (236.6) (394.4)
Running time min. 2 8 7 IO 3
Engine speed rpm 825 1,150 1,400 1,650 1,800

X750-6
Load N 0 588 1,177 1,765 2,354
X800-6 {kg1 101 (601 I1201 11801 (2401
Flywheel kW 0 50.8 123.6 218.6 318.0

horsepower (HP1 101 (68.0) {I 65.6) (292.8) (430.01
Running time min.
Engine speed rpm
Load N
{kg}
Flywheel kW
horsepower U-tRI
Running time min.
Engine speed w-n
Load N
{kg}
Flywheel kW
horsepower (HP1
-
12-13-1
0
PERFORMANCE TEST CRITERIA

The table gives the standard values using the JIS compensator
factor.
The values in the table are the standard values for machines with
the muffler installed, air cleaner installed, alternator under no
load, and air compressor open (if installed).
The loads for the dynamometer are at an arm’s length of 716 mm.
Engine Applicable Test item Specified value Engine speed Dynamometer

model machine Load
(rpm) (N{kgI)
Flywheel horsepower 209.0 kW/2,100 rpm 2,095 - 2,105 1,359 - 1,443

(280.0 HP/2,100 rpm1 1138.6 - 147.1)
Maximum torque 1,255 Nm/1,400 rpm 1,300 - 1,500 1,734 - 1,838
;D825A-2 1128 kgm/1,400 rpm1 I176.8 - 187.41
High idling speed 2,300 - 2,400 rpm 2,300 - 2,400 -
Low idling speed 600 - 700 rpm 600 - 700 -

S6D140-2
(315.5 HP/2,100 rpm1 1154.6 - 164.1)
VA500-3 1140 kgm/1,400 rpml I192.6 - 204.9)
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
12-14
0
+ For fuel, use ASTM D975 No. 1 or No. 2.

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

horsepower consumption temperaturt temperature oil pressure :emperature
(kWIHP1) (kWIkgm1) (sed200cc) (“C) (“C) (kPaIks/cm*I) (“C)
214.5 - 227.1 - Min. 17.3 70 - 80 90 - 110 294 - 490 700

(287.4 - 304.21 13.0 - 5.01
1,242 - 1,316 70 - 80 go- 110 -
1126.6 - 134.21
- 70 - 80 go- 110
- 70 - 80 90-110 Min. 118{1.2}
238.9 - 253.6 - Min. 15.7 70 - 80 go- 110 294 - 490 650

I320.1 - 339.81 l3.0 - 5.01
1,352 - 1,439 70 - 80 go- 110
U37.9 - 146.7)
70 - 80 go- 110
70 - 80 go- 110 Min. 118I1.2) -
12-15
0
* The table gives the standard values using the JIS compensator
factor.
* The values in the table are the standard values for machines with
* The loads for the dynamometer are at an arm‘s length of 716 mm.

model machine Load
(rpm) (Nfkg))

1301.7 HP/l,900 rpm} {170.4 - 180.81
)I 55A-3 Maximum torque 1,432 Nm/1,300 rpm 1,250 - 1,350 2,002 - 2,124
II46 kgm/1,300 rpm1 I204.1 - 216.61
)155AX-3 High idling speed 2,050 - 2,150 rpm 2,050 - 2,150 -

1424.0 HP/l,800 rpm1 i242.5 - 257.51
SAGD140-2 'C16OOSP-1 {I90 kgm/1,400 rpm1 (265.7 - 281.81
Flywheel horsepower 309.9 kW/1,500 rpm 50Hz ,495- 1,50550Hz 2,714- 2,883 50Hz
415.1 HP/l,500 rpm} 50H2 276.7- 294.0)50Hz
357.0 kW/1,800 rpm 60Hz ,795- 1,80560Hz 2,621- 2,78360Hz
IENYO 478.2 HP/l,800 mm1 6OH2 :267.3
- 283.8)60Hz
Maximum torque - -
)CA400SSK-2
High idling speed Max. 1,568 rpm 50Hz Max.1,568 50Hz -
Max. 1,881 rpm 60Hz Max. 1,881 60Hz
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed

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

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

horsepower consumption :emperature temperature oil pressure ,emperature
(kWIHP1) (kW{kgmI) (sec/200cc) (“Cl K) (kPa{ks/cm2N (“C)
238.2 - 252.9 Min. 16.8 70 - 80 go- 110 343 - 490 Max. 600
1319.1 - 338.8) 13.5 - 5.01
1,433 - 1,521 70 - 80 go- 110 - -
:146.1 - 155.1
- 70 - 80 go- 110 - -
- 70 - 80 Min. 80 Min. 118{1.2} -
321.3 - 341.1 - Min. 12.3 70 - 90 90 - 110 245 - 490 700

1430.4 - 457.01 (2.5 - 5.01
1,865 - 1,979 - 70 - 90 go- 110 - 700
190.2 - 201.8:
- - 70 - 90 go- 110 - -
- - - 70 - 90 90 - 110 Min. 118{1.2} -
2 305.4 - 324.6 50Hz Win. 13.0 50Hz 70 - 85 go- 110 275 - 343 50Hj 650
54 1409.2-434.81 50Hz Vlin. 10.6 60Hz :2.8 - 3.5} 50H;
5 354.0 - 376.1 60Hz 70 - 85 90 - 110 343 - 441 60Hi 650
I474.3 - 503.8} 60H; :3.5 - 4.51 60H;
- - -
- - 70 - 85 90 - 110 -
- - 70 - 85 go- 110 Min. 177{1.8} -
12-17
0
The table gives the standard values using the JIS compensator
factor.
The values in the table are the standard values for machines with
The loads for the dynamometer are at an arm’s length of 716 mm.

model machine Load
(rpm) (N{kgI)

1507.8 HP/2,000 rpm) 1244.5 - 259.51
HD325-6 Maximum torque 2,167 Nm/1,350 rpm 1,300 - 1,500 2,902 - 3,083
{214 kgm/1,350 rpml (296.0 - 314.4)
H D405-6 High idling speed 2,300 - 2,450 rpm 2,300 - 2,400 -

(411.2 HP/2,000 rpm1 1196.8 - 209.31
.---- Maximum torque 1,755 Nm/1,400 rpm 1,300 - 1,500 2,351 - 2,487
SAAGD140-2 HD325-6 1179 kgm/1,400 rpml (239.7 - 253.6)
(High altitude spec High idling speed 2,350 - 2,450 rpm 2,350 - 2,450 2,350 - 2,450
Low idling speed 675 - 775 rpm 675 - 775 675 - 775

1443.7 HP/l,800 rpm) 1242.5 - 257.5)
/ PC750-6 Maximum torque 2,099 Nm/1,350 rpm 1,250 - 1,450 1,508 - 1,601
I214 kgm/1,350 rpm) 1153.8 - 163.31
I PC800-6 High idling speed 1,930 - 2,030 rpm -
Low idling speed 800 - 850 rpm -
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
Flywheel horsepower
Maximum torque
High idling speed
Low idling speed
12-18
0
t For fuel, use ASTM D975 No. 1 or No. 2.

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

horsepower consumption 1temperature temperature oil pressure :emperature
(kWIHP1) (kW{kgmH (sed200cc) YC) (“C) (kPa{kg/cm2H (“C)
359.9 - 381.7 Min. 11.2 70 - 95 go- 110 245 - 343 Max. 700
1482.2 - 511.71 12.5 - 3.5)
2,079 - 2,208 70 - 95 go- 110
:212.0 - 225.2
- 70 - 80 go- 110
70 - 80 Min. 80 Min. 118{1.2} -
289.6 - 308.0 Min. 13.5 70 - 85 go- 110 343 - 490 650

{388.0 - 412.6} i3.5 - 5.01
1,683 - 1,781 70 - 85 90 - 110 - 700
:171.6 - 181.6
- 70 - 85 go- 110
- 70 - 85 go- 110 Min. 147I1.5) -
321.3 - 341.1 Min. 12.3 70 - 95 go- 110 245 - 343 Max. 700
I430.4 - 457.0) 12.5 - 3.5)
2,036 - 2,161 70 - 95 go- 110 - -
207.6 - 220.4:
70 - 95 go- 110 -
70 - 95 Min. 80 Min. 118I1.21 -
12-18-1
0
TROUBLESHOOTING
Points to remember when troubleshooting .......................................................................................... 12-21
Method of using troubleshooting charts ............................................................................................... 12-22
s- 1 Starting performance is poor (starting always takes time) .................................................... 12-26
s- 2 Engine does not start ................................................................................................................. 12-27
(1) Engine does not turn ............................................................................................................ 12-27

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

& s-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................... 12-39
(0
s-13 Oil level rises (water, fuel in oil) ............................................................................................... 12-40
s-14 Water temperature becomes too high (overheating) .............................................................. 12-41
s-15 Abnormal noise is made ............................................................................................................ 12-42
S-16 Vibration is excessive ................................................................................................................. 12-43
12-19
TESTING AND ADJUSTING TROUBLESHOOTING
A When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit
safety pins, block the wheels, and apply the parking brake.
A When carrying out operations with two or more workers, always use signals, and do not allow any
unauthorized person near the machine.
A When checking the water level, if the radiator cap is removed when the engine is hot, boiling water
will spurt out and may cause burns, so always wait for the engine to cool down before checking
the water level.
A Be extremely careful not to touch any hot parts.
A Be extremely careful not to get caught in the fan or any other rotating parts.
A When removing the plugs or caps from places under hydraulic pressure, water pressure, or air
pressure, release the internal pressure first. Fit the measuring tools securely before carrying out
any testing, adjusting, or troubleshooting.
* When using the standard values table for judgement in testing, adjusting, or troubleshooting, it is
necessary to be careful of the following points.
1. The standard values for the new machines in the standard values table are values given as
reference from the standards for new machines and machines shipped from the factory. They
should be used as values for estimating wear during operation or as target values when carrying
out repairs.
2. The failure judgement standard values in the standard values table are values using estimated
values based on the results of various tests and standard values for machines shipped from the
factory. Use these values for reference together with the repair and operation history of the
machine when judging failures.
3. Do not use this standard values table as a standard for judging claims.
1Z-20
TESTING AND ADJUSTING TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs, and
ensuring that the failure does not occur again.
When carrying out troubleshooting, it is of course important to understand the structure and function.
But to carry out the troubleshooting effectively, a quick method is to carry out troubleshooting using
the problems mentioned by the operator as a guide in locating the cause.
Do not disassemble the machine simply 4. Confirming failure

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

1) Check the oil level. -
2) Check for any external leakage of oil from
the piping and hydraulic equipment.
3) Check the travel of the control levers.
4) Other maintenance items can also be car-
ried out visually, so carry out any check
that is considered necessary.
12-21
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

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

is as follows.
Items listed for [Questions] and [Check items1 that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with Q.
Check each of the [Questions] and [Check items1 in
turn, and marked the 0 or Q in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
‘%I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with a to use as reference
4 for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
,%2. Use the D in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
:
12-23
. Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
s-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive iniection of fuel
12-24
9 Five causes
Clarify the relationship between the three

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

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

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

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

Check that the monitor panel does not display any
abnormality in the governor control system.
General causes why exhaust smoke comes out but
engine takes time to start
. Defective electrical system
. Insufficient supply of fuel
. Improper selection of fuel
(At ambient temperature of 10°C or below, use
ASTM D975 No. 1)
Battery charging rate
. The specific gravity should exceed the value

for the charging rate of 70% in the above table.
. In cold areas the specific gravity must ex-
ceed the value for the charging rate of 75%
in the above table.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : items to confirm the cause
Degree of use of machine 1Operated for long period I IA

I I II Ease of starting
Gradually became v
E.--r.. . ..L^_ ..^_ -
llacementof filters has not been carried out according to Operation Manual
2) Little fuel comes out even when fuel filter air bleed
plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When compression pressure is measured, it is found to be low
When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
1 1 When feed pump strainer is inspected directly. it is found to be cloggad
Heater mount does not become warm
Is voltage 26 - 30V between alternator terminal Yes
Band terminal E with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When control rack is pushed, it is found to be heavy or does
not return (when blind cover at rear of pump is removed, it l
can be seen that plunger control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged 0
E- I_)oIlrn za
~Occc00XX:5mmr
Remedy$g;;z-,-,-,-,-,.z-,t z
EOUUUSLZBB988G
12-26
TROUBLESHOOTING s-2
S-2 Engine does not start

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

. Internal parts of engine seized
* If internal parts of the engine are seized,
carry out troubleshooting for “Engine
stops during operations”.
Causes
. Failure in power train
. Defective electrical system
Legend
When starting switch is

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

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

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

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

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

out but engine does not start Causes
. Lack of rotating force due to defective elec-
trical system
. Improper selection of fuel and oil
0 : Possible causes
0 : Most probable M
: Possible causes
Degree of use of machine Operated for long period

Suddenly failed to start
When enaine is cranked. abnormal noise is heard from around
Engine oil must be added more frequently
Non-specified fuel is being used
s has not been carried out according
I) Little fuel comes out even when injection pump
e
starting engine, temperature of some cylinders is low I I I I I I I I I I I I
When fuel filter is drained, no fuel comes out I 10
12-29
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly (follow-up is poor)

Causes
Ir Check that the monitor panel does not display any

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

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

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

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

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

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

General causes why engine does not rotate
smoothly
. Air in fuel system
. Defective governor mechanism
. Defective electric governor mechanism
Ir If hunting does not occur when the rod
between the governor motor and the in-
jection pump is disconnected, trouble-
shoot by using the electrical system trou-
bleshooting (E mode).
Legend
a: Possible causes due to length of use fused for a long period)
l
-
: Items to confirm the cause.
1 Confirm recent repair history
Degree of use of machine Operated for long period
Occurs at a certain speed range
Occurs even when speed is raised
Replacement of filters has not been carried out according
/
11
Rust, water are found when fuel tank is drained
1) No response, light, return is quick

!
.=
%
0)
6
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
.-P When control rack is pushed, it is found to be heavy, or

5
r” does not return
f When fuel cap is inspected directly, it is found to be clogged
=
z When feed pump strainer is inspected directly, it is found to
;
be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
-
Remedy
12-32
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

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

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

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

(incomplete combustion)
General causes why exhaust smoke is black

. Excessive injection of fuel
--- L-b
0 0 0
Color of exhaust gas 0 0 0
0
0
0 0 0
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
” starting engine, temperature of some cylinders is low
Whenvalve clearanceis checkeddirectly it is found to be outsidestandardvalue 1 i i a

When muffler is removed, exhaust color returns to normal 0
When control rack is pushed, it is found to be heavy, or does not return
12-34
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

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

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

I I I I I I I I I I I I I I
12-35
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper fuel
. Improper oil used
l Operation under excessive load
Legend
0 : MOS probable causes (judgingfrom Questionsand Check items)
n : Possible causes due to length of use (used for a long period)
I I Confirm recent repair history
Amount of blow-by gas
12-36
TROUBLESHOOTING S-IO
S-IO Fuel consumption is excessive

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

from Questions and Ch
Condition of fuel
When exhaust manifold is touched immediately after
Injection pump measurement shows that injection amount is excessive
Speed does not change when operation of certain cylinders is stopped
.-F When control rack is pushed, it is found to be heavy, or does not return
i;
2 When check is made using delivery method, injection timing
1 is found to be incorrect
o
: Remove head cover and inspect directly
;
Remove feed pump and inspect directly
1 When engine speed is measured, low idling speed is found to be high
Remedy
12-37
TROUBLESHOOTING S-l 1
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
Legend
12-38
TROUBLESHOOTING s-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubricating system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
* Standards for engine oil selection
r
1 Type of oil
Diesel fuel
Legend
Confirm recent repair history
Degree of use of machine Operated for long period aa n

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

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

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

* If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
Causes
General causes why oil level rises
l Water in oil
. Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
ging from Questions and check items)

(judgingfrom Questionsand Check items)
to length of use (used for a long period)
12-40
S-14 Water temperature becomes too high (overheating)

Causes
General causes why water temperature becomes too
high
. Lack of cooling air (deformation, damage of fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
. Power train oil temperature rises excessively
* Carry out troubleshooting for chassis.
Legend
th of use (used for a long period)
When compression pressure is measured, it is found to be low
Remove oil pan and inspect directly
12-41
S-15 Abnormal noise is made

Causes
* Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion
. Air sucked in from intake system
Legend
0 : Most probablecauses (judgingfrom Questionsand Check items)
A: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
12-42
TROUBLESHOOTING S-16
S-16 Vibration is excessive

* If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)
. Improper alignment Causes
l Abnormal combustion
Legena
.
A : Possible causes due to lenath of use (used for a long period)
Degree of use of machine Operated for long period Annal 1 , ,

Es
2 Suddenly increased lo1 I Ic
lz Condition of vibration
? Gradually increased oooc
u
Non-soecified oil is beino used 00
Metal particles are found when oil is drained 10,101 I

Oil pressure is low at low idling IOIOI I
Vibration occurs at mid-range speed 00
Vibration follows engine speed oooc, ,

Exhaust smoke is black 00
Seal on injection pump has come off 0
found to be outside standard value
Remove front cover and inspect directly
Remove head cover and inspect directly
Injection pump test shows that injection amount is incorrect
12-43
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING TOOL LIST

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

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

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

Standard IPermissible Standard Permissible
Item Measurement conditions Unit
value value value value
Engine speed High idling speed rpm 2,300 - 2,400 ’2,300 - 2,40(1 :2,300 - 2,400 2,300 - 2,400
Low idling speed rpm 650 - 700 650 - 700 700 - 750 700 - 750
Necessary starting 0°C (without starting aid) rpm Min. 110 Min. 110 -
speed
-20°C (with starting aid) rpm Min. 85 Min. 85
Intake resistance At all speed kPa Max. 2.94 Max. 2.94

1;;;. ;;y
Boost pressure At rated flywheel IrnIZO)
horsepower (mkmp;gI {f&r:. ;;$
Exhaust pressure At rated flywheel
(Turbine inlet press.) horsepower ImmHgI {Min. 5601
Exhaust temperature
(Turbine inlet temp.) All speed (20°C) “C 700 650
Quick acceleration Max. 4.0 6.0 Max. 4.5 6.5

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

(When engine is
hot or cold) Exhaust valve mm 0.80 - 0.80 -
Compression Oil temperature: MPa Min. 3.82 2.65 Min. 3.82 2.65
2
pressure 40 - 60°C (kg/cm*} {Min. 391 1271 (Min. 391 1271 5
(SAE30or SAE 15W-40)
(Engine speed) (rpm) 200 - 250 200 - 250
Blow-by pressure At rated flywheel horsepower kPa Max. 0.98 1.96 Max. 1.47 2.94
(SAESO or SAE 15W-40) (Water temp: Min. 70°C) :mmHzO) (Max. 1001 I2001 {Max. 1501 {3001
At rated flywheel horsepower
SAE30 or SAE15W-40 oil kPa 294 - 490 206 294 - 490 206
Ikg/cm*} y4; 15&l (2.1) yi; I ik9’ (2.11
SAE IOW oil kPa 177 177
Oil pressure [kg/cm*} (2.5 - 4.51 (1.8) (2.5 - 4.51 0.8)
(Oil temperature: At low idling
Min. 80°C) SAE30 or SAE15W-40 oil kPa Min. 118 Min. 118
(kg/cm*} {Min. 1.2) (1; I..’
SAE IOW oil kPa Min. 98
(kg/cm*} (Min. 1.0) {Min: 1.0)
Oil temperature All speed (Oil in oil pan) “C go- 110 120 go- 110 120
Oil consumption At continuous rated

ratio horsepower % Max. 0.5 1.0 Max. 0.5 1.0
(Ratio to fuel consumption)
Fuel injection Nozzle tester MPa 25.0 - 25.8 20.2 25.0 - 25.8 20.2
pressure [kg/cm*} (255 - 2631 {2061 (255 - 2631 I2061
Fuel injection timing B.T.D.C. degree 15.5 - 16.5 15.5 - 16.5 15.5 - 16.5 15.5 - 16.5
Radiator pressure Opening pressure MPa - - - -

valve (Differential pressure) [kg/cm*}
Fan speed At rated engine speed rpm 1,640- 1,720 1,640- 1,7201 11,106- 1,174 1,106- 1,174
Fan belt tension Deflects when pushed mm 8 -12 8 -12 13-15 *1 13-15 “I
with a force of 60NI6kgI
L 17-19 *2 17-19 “2
Ir This STANDARD VALUE TABLE does not give the standard value for adjusting the engine output.
Do not use the values in this table to change the setting for fuel injection pump.
*I: When belt is new. *2: When adjusting
12-46
0
Engine model SAGDI 40-2
Applicable machine model D155A-3, D155AX3

T PC16OOSP-1
I‘ermissible Standard Permissible

iiE-1 Item Measurement conditions Unit 1 “til”,“,’ value value value
p: 1Engine speed High idling speed f-pm 2,050 - 2,15C1 ;!,050 - 2,15c 1,930 - 2,030 1,930 - 2,030
Low idling speed rpm 700 - 725 700 - 725 725 - 775 725 - 775
0°C (without starting aid1 rpm Min. 110 - Min. 110 -
-20°C (with starting aid] rpm Min. 85 - Min. 85 -
Intake resistance At all speed kPa Max. 2.94 7.50 Max. 2.94 7.50
{m~;azO) Wl;;. 30~006 (Max. 3001
Boost pressure At rated flywheel (Z Min. 117.4 0
horsepower {mk-nW {h$/. ;$+I (5l2 (Min. 880)
Exhaust pressure At rated flywheel Min. 102.7 Zo:
(Turbine inlet press.) horsepower {mmHg} {Min.. 5601 (4501 (Min. 770} (6201
Exhaust temperature
(Turbine inlet temp.) All speed (20°C) “C Max. 680 700 700 700
Quick acceleration Max. 6.0 8.0 2.0 4.0

(Low idle + high idle) Bosch
Exhaust gas color At rated flywheel index Max. 1.5 2.5 2.0 3.0
horsepower
High idling speed Max. 1.0 2.0 2.0 3.0
Intake valve mm 0.43 - 0.43 -
Exhaust valve mm 0.80 - 0.80 -
Oil temperature: MPa Min. 3.82 2.65 Min. 3.82 2.65

40 - 60°C (kg/cm21 (Min. 391 (271 (Min. 391 (271
(Engine speed) (rpm) 1 200 - 250 200 - 250
At rated flywheel horsepower kPa Max. 0.98 1.96 Max. 1.96 3.92
(SAE30 or SAE 15W-40) (Water temp: Min. 70°C (mmHn0: (Max. 100) I2001 (Max. 200) (4001

SAE30 or SAE15W-40 oil kPa 294 - 490 206 245 - 490 177
(kg/cm*1 y; 1 50; (2.1) (2.5 - 5.01 (I.81
SAE IOW oil kPa 177 196 - 441 137
(kg/cm*1 (2.5 - 4.5) (I.81 (2.0 - 4.51 (I.41
At low idling
SAEBO or SAE15W-40 oil kPa Min. 118 Min. 118
(kg/cm*1 (Min. I.21 (rv$. I..’ (&
(kg/cm*1 (Min. I.01 (Min: l.O} (:.;I
All speed (Oil in oil pan) 80- 110 90: 110 120

horsepower % Max. 0.5 Max. 0.5 1.0
Nozzle tester MPa 24.0 - 25.8 20.2 25.0 - 25.8 20.2

(kg/cm*1 (245 - 263) (2061 (255 - 263) (2061
B.T.D.C. degree 11.5 - 12.5 11.5 - 12.5 18-20 18- 20
Radiator pressure Opening pressure MPa - -

m valve (Differential pressure) (kg/cm*)
c
5 Fan speed At rated engine speed vm 1,256 - 1,334 1,256 - 1,334 1,022 - 1,086 1,022 - 1,086
s
Fan belt tension Deflects when pushed mm Auto-tensinoer \uto-tensinoer 4utotensinoer Auto-tensinoer
ilvith a force of 60N(6kg}
* This STANDARD VALUE TABLE does not give the standard value for adjusting the engine output.
12-47
0
Engine model I SAGD140-2
Applicable machine model DENY0 DCA4OOSSK-2
I‘ermissible
Item Measurement conditions 1 Unit 1 s~~l:‘,~d
value
Engine speed High idling speed Max. 1,56850H2: hAax.1,568 50H
Max. 1,8816OH2: hAax. 1,881 60H
Low idling speed 800 - 850 800 - 850
Necessary starting 0°C (without starting aid) rpm Min. 110 -

speed
-20°C (with starting aid) Min. 85 -
rpm
Intake resistance At all speed kPa Max. 2.94 7.50

{m;p;OI (“,T;. ;;@&I (7621
Boost pressure At rated flywheel 128
horsepower imkmp;gI Wl$~~I~2;01
Exhaust pressure At rated flywheel Z?
(Turbine inlet press.) horsepower ImmHg) {Min. 9001 I72.0)
Exhaust temperature
Quick acceleration - -
(Low idle + high idle) Bosch
Exhaust gas color At rated flywheel index 1.5 2.5
horsepower
High idling speed 1.0 2.0
Valve clearance Intake valve mm 0.43 -

(When engine is
hot or cold) Exhaust valve mm 0.80 -
Compression 2.65
pressure I271
(SAE30 or SAE 15W-40)
(Engine speed) 200 - 250
Blow-by pressure At rated flywheel horsepower kPa Max. 1.96 3.92

ISAESO or SAE 15W-40) (Water temp: Min. 70°C) I(mmH20) I (Max. 200} (4001
192
{kg/;a”2’ (2.8 - 4.51 (2.01
SAE IOW oil 226 - 392 157
Oil pressure {kg/cm21 (2.3 - 4.0) 11.SI
Min. 80°C) SAE30 or SAE15W-40 oil kPa Min. 177
{kg/cm21 {Min. 1.8)
{kg/cm21 {Min. I.01
Oil temperature All speed (Oil in oil pan) “C 110 120

ratio horsepower % Max. 0.5 1.0
[Ratio to fuel consumption)
Fuel injection Nozzle tester MPa 25.0 - 25.8 20.2

pressure {kg/cm21 (255 - 2631 (2061
B.T.D.C. degree 14.5 - 15.5 50th: 14.5 - 15.5 50th
Gel injection timing
16.5 - 17.5 6OH2: 16.5 - 17.5 6OH2
Radiator pressure 3pening pressure MPa 59 - 78 -
ilalve IDifferential pressure) {kg/cm*] (0.6 - 0.8)
1,106-1,174
5OH2 1,106-1,174
5OH2
-an speed 4t rated engine speed rpm 1.327
- 1.409
6OH2 1,327
-1.40960Hz
-an belt tension Deflects when pushed 1 mm 1 8-12 8-12
Nith a force of 60N{6kaI
12-48
0
I
Applicable machine model PC750-6, PC800-6 T HD325-6, HD405-6
Classi- Standard Permissible Standard ‘ermissible

Item Condition, etc. Unit
fication value value value value
High idling speed wm 1,980*50 1,980+50 2,400*50 2,400+50
Engine speed
Low idling speed rpm 800 +; 800 +05’ 725250 725+50
Min. 110 - -
0°C wm Min. 110
(without starting aid
Necessary starting
speed rpm Min. 85 - Min. 85 -
-20°C
(with starting aid)
kPa Max. 2.9 7.47 Max. 2.9 7.47
Intake resistance At all speed
mmHzO} {Max. 3001 17621 {Max. 3001 I7621
kPa
Boost pressure At rated output
mmHg1
Exhaust pressure
kPa
(Turbine inlet press.) At rated output
mml-lg}
Exhaust temperature
All speed (20°C) “C Max. 700 700 Max. 700 700
(Turbine inlet temp.)
Quick acceleration Max. 6.0 7.0 Max. 6.0 7.0

(Low idle + high idle
Exhaust gas color Bosch
At rated output Max. 1.0 2.0 Max. 1.0 2.0
index
High idling Max. 1.0 2.0 Max. 1.0 2.0
Valve clearance Intake valve mm 0.43 - 0.43

(When engine is
hot or cold) Exhaust valve mm 0.80 - 0.80
Oil temperature: MPa

$ Compression
40 - 60°C kg/cm21
8 pressure Min. 3.82I391 2.651271 Min. 3.82991 2.65{27)
(SAE30 or SAE 15W-40: (Engine speed*) (rpm)
.-I
P
w
Blow-by pressure At rated output
kPa Max. 1.96 3.92 Max. 1.96 3.92
mmHzO1 {Max. 200) I4001 {Max. 2001 f400)
(SAE30 or SAE 15W-401 (Water temp: 70°C minj
At rated output kPa

SAE30 or SAE15W-40 oil :kg/cm2} 255-35712.5-3.51 176U.8) !55-35712.5-3.5) 176{1.8)
SAE IOW oil kPa 137I1.4)
196-357{2.0-3.51 196-35712.0-3.5) 13711.4)
Oil pressure kg/cm*}
(Oil temperature: kPa
At low idling Min. 118I1.2) 6910.7)
80°C min) Min. 118{1.2) 6910.7)
SAESO or SAE15W-40 oil kg/cm*}
SAE IOW oil kPa Min. 98Il.O) 6910.7) Min. 98{1.0) 6910.7)
kg/cm21
All speed
Oil temperature “C 80- 110 120 80- 110 120
(Oil in oil pan)
4t continuous rated
Oil consumption
zlutput % Max. 0.5 1.0 Max. 0.5 1.0
ratio
IRatioto fuel consumption
MPa
Fuel injection pressure Nozzle tester !4.52 :::; 1250:; 20.2{206) 14.52:::;: 1250::‘: 20.2{206)
kg/cm?
Fuel injection timing B.T.D.C. degree 1920.5 19TO.5 20~0.5 20r0.5
Radiator pressure 3pening pressure kPa
- -
valve :differeGtial pressure) kg/cm*}
Fan speed 4t rated engine speed vm 1,050?32 I,050532

Ieflects when pushed Autotensioner) _ Autotensioner)
Fan belt tension with a force of 58.8N16kol mm - -
* The values given in the Testing and Adjusting Data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.
* Engine speed: 200 - 250 rpm
12-49
0
Applicable machine model iD325-6 (High altitude spec.1
Standard I‘ermissible
Item Measurement conditions Unit
value value
Engine speed High idling speed rpm 2,350 - 2,450 2,350 - 2,45C
Low idling speed mm 675 - 775 675 - 775
Necessary starting 0°C (without starting aid wm Min. 110 -

speed
-20°C (with starting aid, rpm Min. 85 -
Intake resistance At all speed kPa Max. 2.94 7.50

{Max. 3001 I7621
Boost pressure* At rated flywheel (mG:01 Min. 97.4 77.3
horsepower Imkmp;gI Wii;. ;;y
Exhaust pressure* At rated flywheel :57803
(Turbine inlet press.) horsepower ImmHg) {Min.. 7301 (5801
Exhaust temperature
Quick acceleration 5.0 7.0

(Low idle 3 high idle) Bosch
Exhaust gas color At rated flywheel index 1.5 2.5
horsepower
High idling speed 1.0 2.0
Valve clearance Intake valve mm 0.43 -

(When engine is
hot or cold) Exhaust valve mm 0.80 -
Compression y;IJs6;~rature: MPa Min. 3.82 2.65

0
pressure {kg/cm*1 {Min. 391 (271
(SAE30 or SAE 15W-40)
(Engine speed) (rpm) 200 - 250
L
Blow-by pressure At rated flywheel horsepower kPa Max. 1.96 3.92

(SAE30 or SAE 15W-40) (Water temp: Min. 70°C (mmH20) {Max. 200) I4001

SAESO or SAE15W-40 oil kPa 343 - 490 245
‘kg//+ (3.5 - 5.01 (2.5)
SAE IOW oil 294 - 441 206
Oil pressure (kg/cm*1 13.0 - 4.5) I2.11
Min. 80°C) SAEBO or SAE15W-40 oil kPa Min. 147
‘kg/;,m21 {Min. 1.5)
SAE IOW oil Min. 98
(kg/cm21 (Min. 1.0)
Oil temperature All speed (Oil in oil pan) “C 90 - 110 120

ratio horsepower % Max. 0.5 1.0
Fuel injection Nozzle tester MPa 25.0 - 25.8 20.2

pressure (kg/cm*) (255 - 263) I2061
Fuel injection timing B.T.D.C. degree 19.5 - 20.5 19.5 - 20.5
Radiator pressure Opening pressure MPa - -

valve (Differential pressure) (kg/cm*)
Fan speed At rated engine speed wm 1,018 - 1,082 1,018 - 1,082)
Fan belt tension Deflects when pushed mm 4uto-tensinoer 4uto-tensinoe r

with a force of 60N{6kgI
*: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: Om).
12-50
0
13 DISASSEMBLY AND ASSEMBLY
GENERAL DISASSEMBLY
Air cleaner muffler ......................................
l 13-2 Air vent tube, spill pipe, rocker arm
Starting motor ................................................ 13-2 housing cover ........................................ 13- 8
Turbocharger drain tube ............................... 13-3 Nozzle holder, inlet connector .................... 13- 9
Setting engine in engine overhaul stand ... 13-3 Rocker arm.. .................................................. 13- 9
Corrosion resistor, air compressor Push rod.. ...................................................... 13-10
suction tube .............................................. 13-3 Crosshead ..................................................... 13-10
Bracket.. ........................................................... 13-3 Rocker arm housing.. ................................... 13-10
Connector.. ...................................................... 13-4 Cylinder head assembly .............................. 13-10
Tension pulley assembly.. ............................. 13-4 Vibration damper l crankshaft pulley
Fan pulley assembly ...................................... 13-4 assembly ................................................. 13-l 1
Alternator assembly l pulley.. ....................... 13-4 Front support.. .............................................. 13-11
g Dipstick guide, air compressor ..................... 13-5 Thermostat housing ..................................... 13-11
: Fuel hose.. ....................................................... 13-5 Water pump assembly ................................ 13-11
Turbocharger .................................................. 13-5 Oil cooler assembly ..................................... 13-11
Exhaust manifold ........................................... 13-5 Cam follower ................................................ 13-12
After-cooler assembly Gear case cover.. .......................................... 13-12
(Intake manifold assembly). .................... 13-5 Injection pump drive gear.. ......................... 13-12
Fuel injection tube ......................................... 13-5 Camshaft ....................................................... 13-12
Fuel injection pump assembly.. ................... .13-6 Oil pump assembly, oil pump
Tube, bracket, PTO case ................................ 13-6 idler gear ................................................ 13-13
Fuel filter fuel filter bracket ........................
l 13-6 Main idler gear, injection pump
Oil filter oil regulator ...................................
l 13-6 drive shaft ............................................... 13-13
Oil pan ............................................................. 13-7 Piston cooling nozzle ................................... 13-13
Suction pipe, under frame ............................ 13-7 Piston and connecting rod assembly ......... 13-13
Flywheel .......................................................... 13-7 Crankshaft ..................................................... 13-15
Rear seal ......................................................... 13-7 Cylinder liner ................................................ 13-16
Flywheel housing ........................................... 13-8
ASSEMBLY AND DISASSEMBLY GENERAL DISASSEMBLY
Special tools
Part No. Part Name Q’ty
A 790-901-1260 Adapter 1
B 790-501-2001 Engine overhaul stand 1
C 795-102-2102 Spring pusher 1
Preparatory work
l Clean off all mud and dirt.
l Drain cooling water and engine oil.
- : Engine oil: Approx. 37 L?
l Prepare a stable engine stand which will prevent

the engine from falling over, then put the engine
securely in the stand.
A kg Engine assembly: Approx. 1550 kg

(The weight of the engine differs accord-
ing to the model of machine on which it I I
CLlE00133
is mounted.)
1. Air cleaner muffler

l
I) Disconnect hose (I) between air cleaner and

muffler and hose (2) between air cleaner and
turbocharger, then remove band (3) then
remove air cleaner (4).
Ir When removing turbocharger connection,
cover the openings to prevent dirt or dust
from entering the turbocharger.
2) Remove valve (51, muffler mounting bolts
(6) and band (7), then remove muffler (8).
3) Remove exhaust connector (9).
Sr When removing the turbocharger con-
nection, cover the openings to prevent dirt
or dust from entering the turbocharger.
2. Starting motor
Remove mounting bolts (I), then remove starting
motor (2).
13-2
0
3. Turbocharger drain tube

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

1) install adapter A on engine.
2) Sling engine assembly, align tool A with
engine overhaul stand B, and install engine
assembly.
6%kg Engine assembly: Approx. 1500 kg
CEE00137
5. Corrosion resistor, air compressor suction tube

I) Remove hoses (I) and (2).
2) Remove corrosion resistor (3).
3) Remove tubes (4) and (5).
4) Remove tubes from air compressor. (If
equipped).
COEOOl38
6. Bracket
Remove mounting bolts, then remove brackets
(I) and (2).
CDE00139
13-3
0
7. Connector
1) Remove clamp (I), then remove turbocharger
lubrication tube (2).
2) Remove mounting bolts (31, then remove
connector (4) and electrical intake air heaters
(5).
8. Tension pulley assembly

1) Loosen tension pulley assembly mounting
nuts (I).
2) Loosen adjustment bolt (2), move tension
pulley toward inside, then remove V-belts
(3).
3) Remove mounting bolts (41, then remove
tension pulley assembly (5).
CEE00143
9. Fan pulley assembly

Remove mounting bolts (I), then remove fan
pulley assembly (2).
CEE00144
10. Alternator assembly l pulley

I) Loosen mounting bolts (I), (2) and (3).
2) Loosen 2 adjustment nuts (41, then remove
2 alternator belts (5).
3) Remove mounting bolts (I), (2) and (3), then
remove alternator assembly (6) and
adjustment rod (7).
4) Remove bracket (8).
5) Remove mounting bolts (9) and remove
pulley (IO).
11. Dipstick guide, air compressor

1) Remove dipstick guide (I).
2) Remove lubrication tube (21, then remove
air compressor (3). (If equipped.)
3) Remove air compressor mounting plate (4).
(If equipped.)
12. Fuel hose

Remove fuel hoses (5).
13. Turbocharger
1) Disconnect turbocharger lubrication inlet
tube.
2) Remove mounting bolts (I), then remove
turbocharger (2).
14. Exhaust manifold

Remove mounting bolts (I), then remove exhaust
manifold (2).
15. After-cooler assembly (Intake manifold

assembly)
1) Remove clamps (I).
2) Sling after-cooler assembly (21, remove
mounting bolts (3). then lift off after-cooler
assembly.
16. Fuel injection tube

Remove fuel injection tubes (4).
17. Fuel injection pump assembly

1) Remove lubrication tubes (1) and (2).
2) Remove lubrication tubes (3) and (4).
3) Remove 2 bolts (7) securing cross coupling
(6) and front laminated coupling (5).
4) Remove 4 mounting bolts (8), then remove
fuel injection pump assembly (9).
+ When doing this, leave flange coupling
(IO) and front laminated coupling (5) on
the drive shaft.
5) Remove connecting bolts (I I) of coupling
and drive shaft, then remove flange coupling
(IO) and front laminated coupling (5).
CEE0015
18. Tube, bracket, PTO case

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

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

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

1) Remove wiring connector (I) from bracket.
2) Disconnect drain hose (2).
3) Remove oil pan (3).
3 2 CEE00154
22. Suction pipe, under frame

1) Remove bracket (I), then remove suction
pipe (2).
23. Flywheel
Using eye bolt @ (Dia. = 12 mm, Pitch = 1.75
mm), sling flywheel (I), then remove.
&I kg Flywheel: 60 kg
24. Rear seal

Remove rear seal (I) as follows.
l Removal of standard seal Too I

Hook tip of tool L to metal ring of seal (I),
then use impact force of slide hammer to
remove seal. Slide hammer
* Before removing the seal, knock it in

slightly to release the contact between
the seal and the housing. This will make
it easier to remove the seal.
DWE00211
l Removal of seal with sleeve

Standard seal Seal with sleeve
I) Hook tip of tool L to metal ring of seal
(I), then use impact force of slide Flywheel Flywheel
hausins housing
hammer to remove seal. I Metal rins
* Before removing the seal, knock it in
slightly to release the contact
between the seal and the housing.
This will make it easier to remove
the seal.
2) Use a hammer and chisel to cut sleeve
(2) to remove it. Cr.ankshaft Crankshaft
2
* Be extremely careful not to damage DWEOOZIZ DWE00213
the crankshaft when cutting the seal.
* If any metal particles are formed, be
sure to remove them all completely.
25. Flywheel housing

Remove mounting bolts (I), sling flywheel
housing (2), then remove.
kg
LL?l Flywheel housing: 55 kg
26. Air vent tube, spill pipe, rocker arm housing

cover
1) Remove air vent tube (1).
2) Remove spill pipe (2).
3) Remove rocker arm housing covers (3).
CDE00158
27. Nozzle holder, inlet connector

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

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

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

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

Remove mounting bolts, then remove rocker arm
housing (3).
32. Cylinder head assembly

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

follows,
i) Using spring pusher C, compress valve
spring and remove cotter (I).
ii) Remove upper vale seat (2), outer valve
spring (3), and inner valve spring (4).
CEE0016r CEEOOl65
iii) Remove lower valve seat (5).

iv) Lift up cylinder head and remove valves
(6).
I
I
I
CEE00166 6 CEE00167
13-10
0
33. Vibration damper l crankshaft pulley assembly

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

Remove front support (3).
35. Thermostat housing

1) Remove ring (I), then remove tube (2) up.
2) Remove mounting bolts (3), then remove
thermostat housing (4).
CEE00170
I
36. Water pump assembly

Remove tube (I), then remove water pump
assembly (2).
* The mounting bolts for the water pump are
also used to tighten the gear case cover.
-1 CEE00171
37. Oil cooler assembly

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

Remove cover, then remove mounting bolts (I)
and cam follower (2).
* Each of twelve mounting bolts (I) has its
own oil holes so pass wire through the holes
and keep the bolts in a safe place to prevent
them from being lost.
39. Gear case cover

Remove gear case cover (I).
40. Injection pump drive gear

Remove mounting nut (I), then remove injection
pump drive gear (2).
CEE00176
41. Camshaft
Align mounting bolts (3) with camshaft gear hole
and remove mounting bolts then remove
camshaft (4).
* When removing the camshaft, rotate the
camshaft to prevent damage to the cam
bushing.
13-12
0
42. Oil pump assembly, oil pump idler gear

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

1) Remove mounting bolt (I), then remove
main idler gear (2).
2) Remove mounting bolts (31, remove thrust
plate (4) and injection pump drive shaft (5).
44. Piston cooling nozzle

Remove mounting bolt (I), then remove piston
cooling nozzle (2).
CEE00180
45. Piston and connecting rod assembly
1) Check number on connecting rod cap.
* Check that the cap number and the
cylinder number match, and that the
number is stamped at the cam end.
Ir If there is no number, stamp a number
before removing.
2) Rotate crankshaft so that piston to be
removed is at bottom dead center.
3) Using fine sandpaper, remove carbon at top
of liner.
* If necessary, measure the end play of
the connecting rod with dial gauge @I
before removing the connecting rod CEEOOlI31
assembly.
4) Remove bolts (I) of connecting rod cap.

5) Tap cap with plastic hammer and remove
connecting rod cap (2) together with
connecting rod bearing.
* Be careful not to damage the threads of
the connecting rod bolts.
6) Using wooden bar, push piston and

connecting rod from oil pan side. Support
piston (6) at cylinder head side and remove.
* When removing, be careful not to
damage the inside surface of the liner
with the corners of the connecting rod.
7) Remove remaining pistons and connecting
rods in the same way.
Ir Keep the pistons and connecting rods in
a safe place and be careful not to damage
the sliding surface of the piston or the
bearing.
* Keep the connecting rod and cap
assembled to prevent mistakes when
assembling, and keep together with the
bearing.
0 Disassemble piston and connecting rod

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

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

cap (I).
2) Insert bolts (2) in holes in main bearing cap,
then remove main bearing cap while shaking
the cap with the inserted bolts.
2
;;
0
3) The lower thrust bearings (3) are assembled

on both sides of the No. 7 main bearing cap,
so after removing, mark the position for
assembly.
4) Using a wire, remove crankshaft (4).
r55kg Crankshaft: 140 kg

* When slinging the crankshaft, be careful
not to let it hit or damage the cylinder
block.
Ir Keep the crankshaft in a safe place, and
be careful not to damage the machined
surfaces.
5) Remove upper thrust bearings (5).
CEEOOl90
6) Remove upper main bearing (6).

* Mark the positions for assembly of the
main bearing caps, main bearings and
thrust bearings with tags or felt pen.
Keep in sets according to the cap
number. Keep them in a safe place and
be careful not to damage them.
47. Cylinder liner

* If necessary, measure the protrusion of the
cylinder liner with dial gauge H before
removing the liner.
Using liner puller E, remove cylinder liner (1).

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

TURNING ANGLE METHOD
Important bolts in the 140 Series engines are
tightened by the plastic range turning angle
method. In this method, special bolts are used.
By being tightened to the load (plastic range) at
which they begin to be permanently deformed,
accurate and high tightening force can be
obtained.
The most common method for tightening bolts
is the torque control method. In this method,
however, it is difficult to accurately control the
tightening force because of the coefficient of
friction.
The plastic range turning angle method is based
on the initial tightening torque and the turning
angle.
Elongation exceeding the elastic range results Elongation of bolt
in permanent deformation. DEE00088
Bolts to be tightened by the plastic range turning

angle method in the 140 Series engines.
I) Cylinder head mounting bolts
2) Main cap mounting bolts
3) Connecting rod cap mounting bolts
4) Flywheel mounting bolts
In the plastic range turning angle method, the
permanent strain remains in bolts after they are
tightened. Therefore, the number of times that
each bolt can be reused is limited. Observe the
following precautions.
1) AfteFtightening, put one punch mark on the
bolt. Do not reuse any bolt which has 5 or
more punch marks.
2) If a bolt has been tightened in excess of the
specified turning angle, loosen the bolt
completely and retightened it. (In this case,
put two punch marks on the bolt.)
3) The tightening angle should be targeted at
the standard value plus or minus tolerance.
Special tools
1 Part No. 1 Pat-t Name I Q’tv Part No. 1 Part Name 1 Q’ty
A 790-901-1260 Adapter 1 J 790-331-I 110 Wrench 1
B 790-501-2001 Engine overhaul stand 1 K 795T-473-1110 Push tool 1
c 795-102-2102 Spring pusher 1 795-521-1110 Push tool 1
M
D 795-100-I 191 Piston ring tool 1 01050-31640 Bolt 3
F 795-230-5472 Liner driver 1 1 795-931-1210 Sleeve jig 1
G 795-236-l 500 Piston holder 1 2 795-931-1220 Sleeve jig 1
N
._
H 795-502-I 121 Gauge 1 3 01050-31645 Bolt 3
I 795-125-1210 Feeler gauge 1 4 01050-31625 Bolt 3
Ir Clean all parts, and check for dents, scores or

casting defects. Check that all the oil and water
passages are clear.
Drawing of special tool
Push tool K
Note) Komatsu has no responsibility for special tool made by this drawing.
1 \
A I
mnd G
omfl _______-_-. & - ----------.--.-
-=t
g6 ‘a
;s
I
t ’ / /
‘L
ep’
2 Cl
CDE00261
/ 795T-473-1110 n
13-19
0
Preparatory work
l Install adapter A on cylinder block, set cylinder
block on engine overhaul stand B.
l Prepare the cylinder block before inserting the

cylinder liner as follows.
1) Using sandpaper, remove rust and scale
from faces @ and @ until machined surface
can be seen.
2) Using No. 60 sandpaper, polish portions @

and @ to give a smooth finish. If there is a
sharp corner formed or any burrs on portion
8, remove with a scraper or sandpaper. Be
particularly careful to finish this surface
Q
smoothly to prevent damage to the O-ring. CEE00051
3) If there is pitting on face @ and it cannot be

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

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

Remove all chips and dirt from face @J. Such
dirt will cause defective sealing of the liner,
leakage of water, or defective protrusion of
the liner.
Ir If there is any damage, corrosion or
pitting in the counterbore; repair it.
13-20
0
Cylinder liner
Before assembling, carry out selection of
clearance between liner and piston referring to block
MAINTENANCE STANDARD.
Replace the liner O-ring and crevice seal with
new parts just before assembling the liner.
Method of installing liner O-rings and crevice
seal
1) Check the cylinder liner O-ring groove and
outside circumference of the liner to confirm
that there is no rust or pitting.
l If the surface is rough and pitted, it may DWE00214
cause leakage of water, so replace the
liner.
TOP surface of block
2) Coat the mating surface of the cylinder block
Matins portion
and cylinder liner counterbore with silicon-
based gasket sealant (LG-6).
l Use a cloth to wipe off all the dirt or oil

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

m2-3mm (coat the corner of the deck)
DWEOOIBB
l Make an overlap of 6 r 6 mm at the
beginning and end when coating with
gasket sealant LG-6.
l If the parts are left for a long time after

coating them with gasket sealant, the
surface will start to become hard, so
complete assembly to the block within
50 minutes.
I DWE00189
Cylin er liner
+=I P Crevice seal
Black (Ethylene propylene rubber)
O-ring
Black (Ethylene propylene rubber)
O-ring
Orange (Silicon rubber)
w
I DEE00090
3) Coat the liner O-ring and cylinder block O-

ring grooves with rubber lubricant RF-l.
* RF-l: Daido Kagaku Kogyo

If RF-1 is not available, coat liner O-rings
and crevice seals with clean SAE30 engine
oil.
* Oil causes the crevice seal and O-ring to

swell and deteriorate, so do not leave them
soaking in oil.
Use a brush and coat them with a small
amount of oil immediately before assembly.
4) After installing the liner O-ring, check for

twisting. If any twisting is found, use a
smooth bar (approx. 0 10 mm) to remove
the twisting.
5) To prevent the crevice seal from twisting

when it is installed, press it around the whole
circumference so that it fits into the seal
groove.
+ Assemble the crevice seal with the

chamfered side facing down. CEE00201
l Method of inserting cylinder liner

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

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

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

the cylinder block.
4) After press fitting cylinder liner, use tool H

to measure protrusion of cylinder liner.
* When measuring the protrusion of the
cylinder liner, clamp the liner with a plate
to prevent it from being pushed up by
the O-ring.
Protrusion of cylinder liner: 0.08 - 0.18

mm
* If any gasket sealant is squeezed out from

the mating portion of the cylinder block
and cylinder liner on to the top of the
cylinder block, wipe it off.
5) In addition, to prevent gasket sealant from

being squeezed out from between the block
and liner when the head is tightened, fit a
used head gasket after inserting the liner
and tighten the cylinder head temporarily. 02
When tightening, use the tightening torque
shown below and the order of tightening
shown on the right.
w Temporary tightening torque for __h_
cylinder head:
137 - 157 Nm {I4 - 16 kgml CDE00204
6) Remove the cylinder head, and wipe off the

gasket sealant that has been squeezed out If the srommet is deformed into a heart shape and
covers the water hole-the coolant may leak.
from the counterbore.
Ir If gasket sealant sticks to the grommet
in the head gasket, the grommet will be \
deformed, so always carry out Steps 5)
and 6) to remove all the gasket sealant.
B
Grommet Water hole
DWE00215
2. Crankshaft
1) Align protrusion of upper main bearing (6)
with notch in cylinder block, and install in
cylinder block.
* Check that there is no dirt or dust stuck
to the rear face of the bearing. Coat the
inside face of the bearing with engine
oil (SAE#30) before assembling.
13-23
0
2) Knock in roll pin so that it protrudes 2.7 -

3.4 mm from block, then install upper thrust
bearings (5).
* Install the thrust bearings with the groove
on the crankshaft.
CEE00190
3) Using a wire, sling crankshaft (4) and set in

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

notch in main bearing cap and install
bearing. EE00189

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

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

engine oil (SAE#30). Check that the number
on main bearing cap (2) matches the cylinder
block number, and install main bearing cap.
Sr Install the main bearing cap with the part
number casting mark facing the front of
the engine.
7) Coat washer and threads of mounting bolts

of main bearing cap with engine oil (SAE#30).
Screw in bolts (1) to fit main bearing cap
completely.
8) Tighten mounting bolts (2) of main bearing

cap as follows.
* When tightening the mounting bolts of
the main bearing cap, start in the middle
and work to the outside. Then tighten all
the mounting bolts again to the next step.
w Mounting bolt of main bearing cap
1st step: 108 - 128 Nm 111 - 13 kgm)
2nd step: 211 - 221 Nm 121.5 - 22.5 kgm}
3rd step: 1) When using tool J.
Turn the bolt further 90 - 120
degrees with tool J. CDE00207
2) When not using tool J.
Mark the bolts and the cap
with a felt-tip pen, and turn
the bolts further 90 - 120
degrees. Put a make on the
bolt and cap
DDE00094
* Make a punch mark on the bolt head

each time the bolts are used. If there are
already five marks on the bolt head,
replace with new bolts.
Put one punch mark
9) After tightening bolts, rotate crankshaft and
check that it rotates smoothly.
I DEE00 100
IO) Measure end play of crankshaft with dial

gauge 6J.
* End play: 0.140 - 0.315 mm
L-P-u
CEE00186
3. Piston and connecting rod assembly

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

as follows.
I) Using piston ring tool D, install piston rings
(7) on piston.
CEE00165
Ir Assemble the rings as shown in the

diagram.
* Install the piston rings with the stamped
mark facing up.
Sr When fitting the oil ring, remove the
expander and fit the piston, then fit the
oil ring. When doing this, check that the
expander is fitted completely inside the
ring groove.
DWE00192
2) Set piston and connecting rod.

Sr Match cylinder number on piston head
with number stamped on connecting rod,
and set numbers facing in the correct
direction. Then insert piston pin (5) and
assemble piston (6) to connecting rod
(4).
3) Install snap rings (3) on both sides to secure
piston pin.
3 CEE00164
4) Align protrusion of upper bearing of

Cast number
connecting rod with notch in connecting rod
and install bearing.
installing.
5) Set crankshaft to bottom dead center in
cylinder to be assembled, then coat inside
surface of connecting rod bearing and inside
surface of cylinder with engine oil (SAE#30).
(align on camshai t side)
13-26
6) Set cast number on connecting rod facing

front of engine (number is on camshaft side),
align end gaps of piston rings as shown in
diagram, and insert piston and connecting
rod assembly (8).
DEE00098 I CEE00212
7) Using piston holder G, compress piston rings

and push in piston head with wooden bar.
CEE00213
Align protrusion of lower bearing with notch

in connecting rod cap and assemble. Align
connecting rod cap (2) with mark on
connecting rod and install.
j, Check that there is not dirt or dust stuck
installing.
* Coat the sliding surface of the connecting
rod cap with engine oil (SAE#SO).
9) Coat bolt threads and bolt seat with engine

oil (SAEWO). Tighten mounting bolt (I) of
connecting rod as follows.
w Mounting bolt of connecting rod
1st step: 123 - 132 Nm I12.5 - 13.5 kgm}
2nd step: 1) When using tool J.
Turn the bolt further 90 - 120
degrees with tool J.
2) When not using tool J.
Mark the bolts and the cap
with a felt-tip pen and turn the
bolts further 90 - 120 degrees. CEE00214
13-27
0

each time the bolts are used. If there are
Put ma rk on bolt and
already five marks on the bolt head, tins rod cap
replace with new bolts.
IO) After installing piston and connecting rod

assembly, rotate crankshaft and check that it
rotates smoothly. There must be no catching
or other abnormality.
DWE00216
Put one punch mark
DEE00100
11) Measure side clearance of connecting rod

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

Fit piston cooling nozzle (2) and install mounting
bolts (I).
* Check that the tip of each nozzle is directed
at the center of each piston shaker hole.
13-28
0
5. Main idler gear, fuel injection pump drive shaft

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

washer (7) on inside.
4) Align “A” mark on crankshaft gear with “A”
mark on main idler gear (21, then tighten
mounting bolts (1).
m Idler mounting bolt:
1st step: 265 - 343 Nm (27 - 35 kgm}
2nd step: Mark the bolts and the side seat
of idler gear shaft with a felt-tip
pen and turn the bolts further 90
- 120 degrees.
I 2 CEE00216
Sr Make a punch mark on the bolt head

each time the bolts are used.
l If there are already five marks on the

bolt head, replace with new bolts. Put one punch mark
DEE00100
Put mark on side seat

of idler sear and bolt
DWE00217
6. Oil pump idler gear, oil pump assembly

1) Install oil pump idler gear (2).
2) Fit O-ring and install oil pump assembly (I).
w Oil pump idler mounting bolt:
377.6 - 426.6 Nm (38.5 - 43.5 kgm1
m Oil pump mounting bolt:
I-
98 - 123 Nm I10 - 12.5 kgm1
II
7. Camshaft
Coat camshaft journal surfaces with engine oil
(SAE#30). Align “B” mark of camshaft gear with
“B” mark of main idler gear, then tighten
mounting bolts (3) of camshaft (4).
m Mounting bolt of plate:
98 - 123 Nm {IO - 12.5 kgml
Ir When installing the camshaft, rotate the
camshaft to prevent damage to the cam
bushing.
* If the camshaft gear has been replaced, heat
the camshaft gear in an electric furnace at
220 - 240°C for 30 minutes, then shrink fit
the gear.
CFFOO176
_
Fit key to shaft, align “C” mark of main idler
gear ‘with “C” mark of drive gear, then fit drive
I c---G?/
m
gear (2) and tighten nut (I).
m Nut: 226 - 255 Nm (23 - 26 kgml
B
* Check that the match marks of each drive
C
gear and idler gear are aligned.
I
CDE00217
* Measure backlash and end play of each gear

using dial gauge 0.
* Standard backlash for each gear
Position Range (mm)
A 0.141 - 0.425
B 0.129 - 0.391
C 0.129 - 0.391
D 0.141 - 0.426
E 0.095 - 0.346 CEE00218
F 0.080 - 0.417
G 0.118 - 0.369
1 I
I-i (OP) 0.118 - 0.369
-I
%6!3
1 tow 0.025 - 0.486
2 G1
B
Sr Standard end play for each gear
D A 3c
E 5
Position Range (mm) 4
H
1 0.140 - 0.315 IF I
2 0.100 - 0.250 ---l 1

CDEOOLIS
3 0.050 - 0.170
4 0.050 - 0.170
5 0.070 - 0.200
6 0.030 - 0.088
9. Fuel injection pump drive shaft oil seal

Before assembling the seal, check that there Assembly guide
(0 I astic tubal
is no damage, burrs, flashes, or rust on the
housing and sliding surface of the lip.
When assembling the seal, do not coat the
shaft, and the space between the sleeve and
seal lip with oil or grease. If there is any oil
or grease on the shaft, wipe it off completely.
Handle the seal and sleeve as an assembly.
Never separate them.
Large inside Small- inside
diameter end diameter end
DWE00218
13-31
0
1) Put large inside diameter end of plastic inner

tube (I) in contact with end of shaft (2).
Sr Be particularly careful not to mistake the
direction when assembling.
I I CDE00221
2) Hold metal ring of seal (3) with both hands,

push evenly, and use sudden pushing force
to push in.
3) After pushing in seal, remove plastic inner

tube (1).
* Be particularly careful not to damage the
seal lip when removing the inner tube.
I I CDE00222
4) Using tool K, press fit oil seal (3) until seal

contacts to housing (4).
I ’ CDE00223
10. Gear case cover

Fit gasket, install gear case cover (I).
* When installing the gear case cover, remove
the service meter gear box. After installing
gear case cover, install service meter gear
box.
11. Breather
1) Fit O-ring, install breather (3).
w Mounting bolt:
24.5 - 29.4 Nm I2.5 - 3.0 kgm}
2) Install hose (4) and tube (5), then secure CDE00175
with clamps.
‘7
12. Front seal
Assemble front seal (I) as follows. Assemble guide
Before assembling the seal, check that there
housing, sliding surface of the lip and the
corner of the end face of the crankshaft.
When assembling the seal, do not coat the
shaft or seal lip with oil or grease. If there is
any oil or grease on the shaft, wipe it off
completely. Small inside Large inside
Do not remove the plastic tube inside the diameter end diameter end
standard seal provided as a spare part until DWEOOZI 9
immediately before assembling the seal.
Put large inside diameter end of plastic inner

tube (2) in contact with end of crankshaft
(3).
Ir Be particularly careful not to mistake the
:
K4
co
2) Hold metal ring of seal (I) with both hands,

to push in.

tube (2).
* Be particularly careful not to damage the
4) Tighten bolts of tool M uniformly until end

face of tool M contacts ends face of
crankshaft (3) to press fit seal (I).
j, When press fitting the seal, be extremely
careful not to damage the lip at the PTO
end when setting the tool.
* After press fitting the seal, remove the
red sealant layer from the outside
circumference.
CDE00232
13-33
0
13. Cam follower

1) Align cam follower (2) with dowel pin, then
tighten mounting bolts (1).
w Mounting bolt:
44.1 - 58.8 Nm I4.5 - 6.0 kgm}
2) Fit O-ring and install cover.

w Mounting bolt:
9.8 - 12.7 Nm (1.0 - 1.3 kgm}
Ir The mounting bolts for the cam follower

are fitted with lubrication holes, so check
that the holes are clear.
14. Oil cooler assembly

Fit gasket and install oil cooler assembly (I).
* When installing therm0 valve, confirm the
protrusion amount of spring. Fit spring again
when exceeding standard value.
Protrusion amount of spring a: 24 mm
CEE00233
15. Water pump assembly

1) Fit O-ring and install water pump assembly
(2).
* The mounting bolts of the water pump
are used to tighten the gear case.
2) Fit gasket and install tube (I).
-1‘1 CEE00171
16. Thermostat housing

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

Install front support (3).
Ir For trunnion type, fill 20 cc of grease (G2-LI)
to groove on mounting face of support (3),
then install.
18. Vibration damper, Crankshaft pulley assembly

Install vibration damper, crankshaft pulley
assembly (21, then tighten with mounting bolt
(I).
w Mounting bolt:
245 - 308.7 Nm I25 - 31.5 kgm}
19. Cylinder head assembly

I) Assemble cylinder head assembly as follows.
i) Coat valve stem and inside surface of
valve guide with engine oil (SAE#30) then
assemble valve (6).
ii) Raise cylinder head and assemble lower
valve seat (5).
i CEE00167 CEE00166
iii) Install inner valve spring (4) and outer

valve spring (3), then assemble upper
valve seat (2).
iv) Using spring pusher C, compress valve
spring and install valve cotter (1).
Sr Tap the valve stem with a plastic
hammer to check that the cotter is
completely fitted in the groove of the
valve stem.
CEE00165 CEE00164
2) Check that the mounting surfaces of the

cylinder head and cylinder block are clean
and that there is no dirt or foreign matter
inside the cylinder. Set cylinder head gasket
(9) in position.
* When installing the gasket, check that
the grommets are correctly in place.
CEE00234
3) Install cylinder head assembly (2), then

tighten mounting bolts (I).
& Mounting bolt:
Antifriction compound (LM-P)
13-36
0
w Mounting bolt:
1st step: 137 - 157 Nm {I4 - 16 kgm}
2nd step: 211 - 221 Nm (21.5 - 22.5 kgm1
3rd step: 1) When using tool J
Tighten bolts further 90 - 120
degrees in tightening order @
to @ with tool J.
2) When not using tool J
Mark the bolt and head with a
felt-tip pen, turn bolt further
90 - 120 degree in tightening
order @ to @. DAD00043
* Tighten bolt 0 by tightening

torque 58.8 - 74.5 Nm I6.0 -
7.6 kgm1 after tightening bolts
@ to @.

each time the bolts are used.
Ir If there are already five marks on the
bolt head, replace with new bolts.
CEE00235
Put one
DEE00100
Put mark on cylinder

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

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

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

install rocker arm (3) and tighten with mounting
bolts (2) and (I).
-..-.
\J-.._.. XL
* Check that the ball of the adjustment screw
is properly fitted into the socket of the push
rod. Then tighten bolts.
w Mounting bolt:
93 - 103 Nm I9.5 - 10.5 kgm1
24. Adjusting valve clearance

Adjust valve clearance as follows.
* Adjust the clearance between the crosshead
and rocker arm to the following values.
Sr Valve clearance (When engine is hot or cold.)
Unit: mm
Intake valve 1 Exhaust valve
0.41 - 0.45 0.78 - 0.82
- CDE00240
I
* Crank the engine and follow the firing order

5 6 3
to adjust the valve clearance of each cylinder.
Firing order: 1 - 5 - 3 - 6 - 2 - 4
1) Rotate the crankshaft in the normal
direction to align pointer (2) with the 1.6
TOP mark on vibration damper (I 1. When
rotating, check the movement of the
valves.
2) To adjust, insert feeler gauge I between

rocker arm (3) and crosshead (4) and turn
adjustment screw (5) until clearance is a
sliding fit.
3) Tighten locknut (6) to hold adjustment

screw in position.
m Lock nut:
53 - 64.7 Nm j5.4 - 6.6 kgml
Ir After tightening the lock nut, check

the clearance again.
25. Nozzle holder, inlet connector

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

housing and tighten partially.
5) Fit holder (41, then fit ball washer to
mounting bolt (3) and tighten mounting bolt.
w Holder mounting bolt:
58.8 - 73.5 Nm IS.0 - 7.5 kgm}
* Install one end of the holder to the rocker

arm housing, lay on the bolt head and
tighten with the bolt.
6) Tighten inlet connector (2), then tighten CEE00159

locknut (1).
w inlet connector:
34.3 - 39.2 Nm 13.5 - 4.0 kgm}
w Locknut:
29.4 - 34.3 Nm (3.0 - 3.5 kgm}
7) Install air compressor pipe bracket.
13-40
0
26. Rocker arm housing cover, spill pipe, air vent

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

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

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

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

mounting bolts (I), (41, (2) and (9) by
two steps.
w Flywheel housing mounting bolt
1st step: 147 - 235 Nm I15 - 24 kgm1 -0
2nd step: 245 - 309 Nm I25 - 31.5 kgm} G-D
1st step 2nd step
13-41
0
2) After installing the flywheel housing,

measure the radial runout and face runout
using dial gauge 0.
* Radial runout: Max. 0.30 mm
Ir Face runout: Max. 0.30 mm
28. Rear seal

* Check condition of wear of shaft, then select
standard seal or seal with sleeve for Teflon
seal (lay-down lip seal) and assemble seal.
The condition of wear of the shaft can be
judged from the degree of luster (touch with
the flat of your finger to check that the depth
of wear is less than 10 pm). If there are no
scratches, assemble a standard seal. In all
other cases, assemble a seal with sleeve.
Procedure for assembling standard seal

Before assembling the seal, check that there is
no damage, burrs, flashes, or rust on the
housing, sliding surface of the lip and the corner
of the end face of the crankshaft. Lip at
When assembling the seal, do not coat the shaft
or seal lip with oil or grease. If there is any oil or
grease on the shaft, wipe it off completely.
Do not remove the plastic tube inside the
standard seal provided as a spare part until Large inside Small inside
immediately before assembling the seal. diameter end diameter end
DEE00105
Put large inside diameter end of plastic inner

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

to push in.

tube (3).
+ Be particularly careful not to damage the
CFFOO414
4) Tighten bolts uniformly until end face of tool

Nl contacts ends face of crankshaft (4) to
press fit seal (1).
j, Firstly tighten tool Nl with bolt N3
(45 mm) until tool contacts end face of
crankshaft, then tighten with bolt N4
(25 mm).
j, When press fitting the seal, be extremely
careful not to damage the lip at the PTO
end when setting the tool.
Ir After press fitting the seal, remove the
circumference.
l Procedure for assembling seal with sleeve

* Before assembling the seal, check that there
housing, sliding surface of the lip and the Lie at crankshaft end
corner of the end face of the crankshaft.

* When assembling the seal, do not coat the
shaft, and the space between the sleeve and
seal lip with oil or grease. If there is any oil
or grease on the shaft, wipe it off completely.
* Handle the seal and sleeve as an assembly.
Never separate them.
DWE00221
I) Set sleeve/seal (2) to tool N2.

& Surface of sleeve inner tube:
Gasket sealant (LG-7)
~ DWE00222
2) Put sleeve of seal in contact with end face of

crankshaft, tighten 3 bolts uniformly until
end face of tool N2 contacts ends face of
(45mm)
crankshaft (4) to press fit sleeve/seal (2).
(25mml
3) Remove tool N2 and replace with tool Nl.
4) Tighten 3 bolts uniformly until end face of

tool Nl contacts ends face of crankshaft (4) N3 (45mm)
to press fit sleeve/seal (2). N4 (25mm)
* Firstly tighten tool Nl with bolt N3
(45 mm) until tool contacts end face of
crankshaft, then tighten with bolt N4
(25 mm).
* After press fitting the seal, remove the
circumference. CEE00251
’3&44
29. Flywheel
1) Using eye bolt @ (Dia. = 12 mm, Pitch = 1.75
mm), sling flywheel (I), install the flywheel
to the crankshaft, and tighten the mounting
bolt.
& Coat the threads of the bolts and the
seat face, with engine oil SAE No. 30
before tightening the bolts.
& kg Flywheel: 60 kg
CEE00156
* Tighten mounting bolts as follows. Tightening order

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

time the bolts are used. Put mark on flywheel
* If there are already five marks on the bolt and bolt
head, replace with new bolts.
I DWE00223
Put one punch mark
DEE00100
Ir After installing the flywheel, measure the

face runout and radial runout using dial
gauge 0.
* Face runout: Max. 0.30 mm
f Radial runout: Max. 0.30 mm
30. Suction pipe

Fit O-ring, then fit suction pipe (2) and install
bracket (I) to the under frame.
31. Oil pan

1) Fit gasket and install oil pan (3).
2) Install drain hose (2).
m Hose clamp:
3.9 - 4.9 Nm jO.4 - 0.5 kgm}
3) Install wiring connector (I) to bracket.
3 2 CEE00154
32. Oil filter assembly, oil regulator

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

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

1) Install fuel injection pump bracket (2).
2) Install turbocharger lubrication inlet tube (I).

w Turbocharger lubrication inlet tube
(Bracket side of tube):
24.5 - 58.8 Nm (2.5 - 6 kgm1
3) Fit O-ring and install PTO case (3).

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

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

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

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

(D155AX-3 LW500-1):
l
58.8 - 63.7 Nm IS.0 - 6.5 kgm}

(HD325 with electronic governor
KP21)):
147 - 166.6 Nm {I5 - 17 kgm}
(Except above):
83.3 - 93.1 Nm 18.5 - 9.5 kgm1
13-47
0
4) Align coupling key groove with drive shaft

key, push in fuel injection pump assembly
(9), align with pin portion of bracket, and set
in position.
5) Tighten 4 mounting bolts (8) of fuel injection

pump.
6) Tighten connecting bolts (11) of coupling (IO)

and drive shaft (12).
w Mounting bolt (I I)
(HD325 with electronic governor
(KP-21)): 206 - 255 Nm I21 - 23 kgm1
(Except above):
83.3 - 93.1 Nm I8.5 - 9.5 kgm}
7) Install lubrication tubes (3) and (4).
8) Install fuel hoses (I) and (2).
36. Adjusting fuel injection pump

Under the following conditions, it is possible to
increase the setting precision of the crankshaft
angle.
* If pin (19) is still in the condition set when
shipped from the factory (if front cover (22)
and flange (23) have not been removed):
I) Pull out pin (24). then remove nut (15).
CEE00255
2) Rotate the crankshaft in the normal direction,

and align pointer (17) with the fuel injection
line (16” position) on damper (16).
* When doing this, check that line (18) on
the coupling block is near the line on the
pump housing. If it cannot be seen, rotate
the crankshaft one more turn.
CDE00256
3) Rotate crankshaft and push lock pin (19)

towards engine so that pin (19) enters hole
in fuel injection pump drive gear (20).
* When lock pin (19) is fully inserted in
the hole in gear (20), the dimension from
the tip of lock pin (19) to housing (23) is
approx. 6 mm.
4) In this position, check position of line (18)

on coupling block and line (21) on pump
housing.
A Never try to crank the engine by force
when the pin is inserted.
5) If the lines in Step 4) are not correct, adjust

as follows.
i) Loosen bolt (I 1) and flange coupling
bolts and nuts (14) at two places.
ii) Rotate coupling block (22) and align line
(21) on fuel injection pump housing with
line (18) on coupling block completely.
iii) Tighten bolt (11) and flange coupling
bolts and nuts (14) again.
Mounting bolt, nut (14):
(D155AX-3, LW500- 1)
58.8 - 63.7 Nm I6.0 - 6.5 kgm} CEE00258
(HD325 Electronic governor
specification (KP-21))
147 - 166.6 Nm I15 - 17 kgm1
(Other models)
83.3 - 93.1 Nm I8.5 - 9.5 kgm}
Mounting bolt (I 1):
(HD325 Electronic governor
specification (KP-21))
206 - 225 Nm I21 - 23 kgm}
(Other models)
83.3 - 93.1 Nm (8.5 - 9.5 kgm}
6) Pull lock pin (19) out from hole in gear (20).

or If pin (19) is stiff, tighten nut (15) before
pulling the pin out.
Ir Pull the pin out completely to a point
where it does not move.
7) Tighten nut (15).
8) Install pin (24).
13-49
0
37. Fuel injection tube

Install fuel injection tube (4).
m Sleeve nut (Fuel injection pump end)
22.5 - 24.5 Nm l2.3 - 2.5 kgm1
38. After-cooler assembly (Intake manifold

assembly)
1) Fit gasket, sling after-cooler assembly (2) and
tighten mounting bolts (3).
Ir Tighten bolts in order shown in diagram
at right.
m Mounting bolt:
58.8 - 73.5 Nm (6 - 7.5 kgm1
2) Install clamp (1) of fuel injection tube.
I CEW00552
39. Exhaust manifold

Fit gasket and install exhaust manifold (2), then
tighten with mounting bolts (I).
Ir Firstly tighten mounting bolts in order @ to

@ shown in diagram, then tighten other
bolts.
m Mounting bolt:
58.8 - 73.5 Nm {6 - 7.5 kgm1
I CEE00259
13-50
0
40. Turbocharger
Fit gasket and install turbocharger (2) with
mounting bolts (I).
m Mounting bolt and nut:
44.1 - 49.0 Nm i4.5 - 5.0 kgml
41. Fuel hose

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

1) Fit e-ring and install air compressor
mounting plate (4). (If equipped.)
2) Fit O-ring and install air compressor (31, then
install lubrication tube (2). (If equipped.)
3) Install dipstick guide (1).
:
6
43 Alternator assembly, pulley

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

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

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

mounting bolts (4).
2) Set fan belt (3) on groove of pulley.
3) Adjust fan belt tension with tightening
adjustment bolt (2) and move tension pulley
toward outside that deflection is 13 - 15 mm
(new belt) or 17 - 19 mm (when tension
adjustment) when push a force 98 N {IO kg}
at middle of fan belt (3), then tighten locknut
(I). (Machine without auto-tension)
46. Intake connector

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

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

1) Install air compressor tubes. (if equipped)
2) install tubes (4) and (5).
3) Install corrosion resistor assembly (3).
4) Install hoses (2) and (1).
CDE00138
49. Resetting engine in engine stand

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

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

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

1) Install exhaust connector (9).
2) Fit gasket and install muffler (8) with
mounting bolts (6), then secure with band
(7).
3) Fit gasket and install valves (5).
4) Install air cleaner (4) and install hose (2)

between air cleaner and turbocharger and
hose (I) between air cleaner and muffler,
then tighten mounting bolt of band (3).
w Band mounting bolt:
9.8 - 11.76 Nm Il.0 - 1.2 kgm}
‘2
c
5) For the Komaclone type air cleaner, install
precleaner (11) to air cleaner body (10).
* Tighten until clearance a is 0. Z 11
6
+
IO
Z
CEE00260
53. Refilling with oil

I) Check that engine drain plug is tightened.
2) Add engine oil through oil filler to the
specified level.
Q Engine oil pan: Approx. 37 L?

14 MAINTENANCE STANDARD

Turbocharger . .. . . . . . .. . . .. . . . . . .. . . . . . .. . .. . . . . .. . . . . . 14- 2
ENGINE BODY
Cylinder head ....................................... 14- 4
Valve and valve guide.. ....................... 14- 6
Rocker arm shaft.. ................................ 14- 8
Crosshead ............................................. 14- 9
Cylinder block ...................................... 14-10
Cylinder liner.. ...................................... 14-11
Crankshaft.. ........................................... 14-12
Camshaft.. ............................................. 14-13
Cam follower and push rod.. .............. 14-14
Timing gear.. ........................................ 14-16
Piston ................................................... 14-18
Connecting rod .................................... 14-20
Flywheel and flywheel housing ......... 14-21
LUBRICATION SYSTEM
Oil pump . . . . . . .. . . . . . .. . . .. . . . . .. . . . . . . .. . . . . . .. .. . . . . . 14-22
Regulator valve, piston cooling
valve and safety valve . .. .._............. 14-24
Oil cooler . . .. . .. . . . . . .. . . . . . . .. .. . . . . . . .. . . . . . .. . . . . . .. . 14-25
COOLING SYSTEM
Water pump . . .. .. . . . . . . .. . . . . . . .. .. . . . . . . .. . . . . . .. . . . 14-26
Thermostat . . .. .. . . . . . . .. . . . . . .. . .. . . . . . . .. . . . . . .. . . . . . 14-28
14-1
MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM

TURBOCHARGER
KTRllO
*0.98Nm
*O.lkPml
SDE00504
14-2
MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM
Unit: mm
& No Check item

(D -
1 End play
-
2 Radial play 0.25 to 0.44 0.60
I Replace
parts
Outside diameter or journal

3 bearing. Inner diameter of center
housing.
Inner diameter of journal bearing. -0.032 +0.009

Outside diameter of wheel shaft. 17 -0.043 -0.003 16.95 17.04
4
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout)
Replace
Tolerance Repair limit

Standard
size
5 Thickness of thrust bearing Shaft Hole Shaft Hole
5 -0.08 +0.02 4.86 5.04

-0.11 0
-0.08 -0.03
2.3 -0.10 -0.04 2.15 2.35
6
2 -0.10
-0.08 -0.04
-0.03 1.85 2.05 I
Clearance between
and impeller
blower housing
Tolerance: (min.) 0.20
I Replace
parts
14-3
MAINTENANCE STANDARD ENGINE BODY
ENGINE BODY
CYLINDER HEAD
s
1
Check item
2
Criteria
SEE00505 Unit:
Remedy
mm
I
Standard Repair limit Repair by Kl
Distortion of cylinder head (D
1 grinding
mounting surface
or replace
0 - 0.06 0.09
-
Engine Standard
Replace
nozzle or
2 Protrusion of nozzle 6D140-2 4.8 - 5.6 cylinder
head
S6D140-2, SAGD140-2,
SAAGDI 40-2 4.8 - 5.6
Target Range
Bolt No. Order
(Nm {kgm}) (Nm {kgml)
Tightening torque of cylinder head

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

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

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

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

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

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

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

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

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

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

Note 2: Valve springs marked with *2 have an irregular pitch.
14-7
0
ROCKER ARM AND SHAFT
SEE00507
Unit: mm
NO Check item Criteria Remedy
Standard size Tolerance Replace

Outside diameter of rocker arm rocker
shaft arm shaft
32.0 kO.0065
Inside diameter of rocker arm +0.087 Replace

1 bushing 32.0 +0.035 rocker arm
Clearance limit Replace

Clearance between rocker arm shaft Standard clearance
rocker arm
and rocker arm bushing
or rocker
0.0285 - 0.0935 0.13 arm shaft
-
Valve clearance
I Valve Standard size
I
Tolerance
2 0.43 kO.02 Adjust

(When engine is hot or cold) Intake
Exhaust 0.080 kO.02

-
I I
Target (Nm {kgm)) Range (Nm {kgm})
Tightening torque of rocker arm
3 adjustment screw locknut
58.8 161 53.0 - 64.7 I5.4 - 6.6)
14-8
CROSSHEAD AND GUIDE
SEE00508
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit

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

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

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

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

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

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

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

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

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

-
STD 120.00 119.88
0.25 U.S. 119.75 119.63

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

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

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

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

1 End play thrust
plate
0.1 - 0.25 0.36

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

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

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

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

-
I I I

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

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

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

C
camshaft gear
Main idler gear (Large) and

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

C 0.095 - 0.346
pump drive gear
Camshaft gear and air

d 0.118 - 0.369
compressor drive gear
Injection pump drive gear

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2 Regulator valve spring length length (NIkgH length (N{kgH spring
16.1 15.1
a3 79 -
Il.641 Il.541
3 Regulator valve set pressure 0.3 t 0.02 MPa {3.2 + 0.2 kg/cm*}
Replace
4 Safety valve set pressure 0.2 f 0.02 MPa {2.0 = 0.2 kg/cm2}
14-24
OIL COOLER
SDE00522
Unit: mm
Lift of thermostat to fully open Min 8 mm (soak in oil bath at 100°C (116°C) for 4 to 5 minutes to
position check)
1 Replace
Valve must fully close when valve is soaked in oil bath for fully
Opening/closing of thermostat open 100°C (116°C) and then soaked in oil bath for fully closed
85°C (110°C) for 4 to 5 minutes.
Ir The figure in ( ) indicates the thermostat for fully open temperature 116°C.
+ There are two types of thermostat for the oil cooler (fully open temperature: IOO’C and 116°C). For
the marine engine only the fully open temperature 100°C is applicable; for other models, either
type can be used.
14-25
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
WATER PUMP
6D140-2
S6D140-2
SA6D140-2
SEE00523
Unit: mm
-
NC Check item Criteria Remedy
Tolerance
Standard Standard
size interference
1 Interference between impeller and Shaft Hole
shaft
-
Interference between drive gear
2 and shaft
-
Interference between pulley flange Reolace
3 and shaft
-
Clearance between impeller and
4 Standard clearance: 0.30 - 1.0 (Including end play)
body
-
Repair limit
5 Abrasion of seal ring in water seal A: 1.5
SEE00524
14-26
S6D140-2
SAGD140-2
SEE00525
Unit: mm

-
1 Interference between impeller and

shaft
-0.082 -0.020 0.025 -
16 -0.095 -0.150 0.068
-
Interference between drive gear +0.015 -0.023 0.025 -
2 and shaft 28 +0.002 -0.053 0.068
3 I Interference
and shaft
between
pulley flange I 25
+0.015
+0.002
-0.021
-0.041
0.025 -
0.056
Replace
Clearance between impeller and

4 Standard clearance: 0.6 - 0.9 (Including end play)
bodv
-
5 Abrasion of seal ring in water seal Repair limit

A: 1.5
SEE00524
14-27
THERMOSTAT
SEE00527
Unit: mm
Lift of thermostat to fully open

position Min 10 mm (soak in oil bath at 90°C for 4 to 5 minutes to check)
1 Replace
Valve must fully close when valve is soaked in oil bath for fully
Opening/closing of thermostat open (90°C) and then soaked in oil bath for fully closed (71°C) for 4
to 5 minutes.
14-28
15 REPAIR AND REPLACEMENT OF PARTS
CYLINDER HEAD
Grinding of fitting face of
cylinder head . . . . . . . .. . . . .. . . .. . . .. . .. . . . . .._..... 15- 2
Replacing valve seat insert . .. . .. . . . . . .. . . . . .. 15- 3
Pressure test . . . . .. . . .. .. . .. . . . .. . . .. . . .. .. . . . . . . .. . . . . . 15- 8
Replacing valve guide . . . . . . . .. . . . . . .. . .. . . . . .. .. 15- 9
Replacing crosshead guide . .. . . . . .. . . . . .. . . . . 15-10
Grinding valve . . . . . .. . . . . . .. . . . .. . .. . .. .. . . . .. . . . . .. .. 15-1 1
CYLINDER BLOCK
Replacing cam bushing.. ....................... 15-12
Replacing crankshaft gear .................... 15-15
Replacing cam gear.. ............................. 15-16
Replacing flywheel ring gear.. .............. 15-17
Replacing connecting rod small
end bushing ....................................... 15-18
15-l
0
REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD
GRINDING OF FllTlNG FACE OF CYLINDER HEAD

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

* Change of cross level: 0.05 mm max.
* Grinding limit: 0.3 mm
Sr Height difference among cylinder heads
of each engine: 0.15 max.
3) Fit an oversize insert one rank larger. See
the section of replacing valve seat insert.
2. Check after grinding

Confirm that the sinking distance of the valve is
within the standard range. Grind for adjustment,
if necessary.
Ir Standard sinking distance of valve:
0 + 0.1 mm
15-2
REPLACING VALVE SEAT INSERT

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Ir Roughness at bottom of mounting hole:
Within 12.5 S
Jr Concentricity with valve guide inside surface:
Within 0.03 mm (TIR)
15-6
4. Finishing insert seat surface

1) Using tools Cl, and C3, and C4, finish the
surface of the insert seat to the dimensions
shown in the diagram below.
* When selecting a pilot C5 to insert into
the valve guide, choose one that gives
no clearance.
. Intake valve
52.7iO.l I
HEE00087
. Exhaust valve
Pencil marks
(about 20 Places)
HEE00234
5 2) Rub the seat surface with compound.
Width of finished face of exhaust valve

insert and width of contact with valve
7 6210-11-1320(ST.D) 1 6210-11-1321(STD)
6210-19-1320(0.250.S) 6210-19-1321(0.250.S)
6210-18-1320(0.500.S) 6210-18-1321(0.500.S)
6210-17-1320(0.750.S) 6210-17-1321(0.750.S)
6210-16-1320(I.000.S) 6210-16-1321(1.000.S)
Width of finished
A: 47.1 B: 1.5 A: 45.7 B: 2.5
surface
Width of contact
with valve (when C:1.5+0.2 C: 2.5* 0.2
using master valve)
5. Finish inspection
l Coat the seat sutface of the new valve thinly
with red lead (minimum), insert it in the valve
guide, push lightly against the valve insert
surface, and rotate 10”. Check the valve in- When usina When using
sert contact surface, and confirm that the master valve master valve
contact is uniform without any breaks. ad d

l Or
Make marks with a pencil on the seat sur-
face of the new valve as shown in the dia-
gram below, insert it in the valve guide, push
lightly against the valve insert surface, and
rotate 10”. Check that the pencil marks have Intake side
been erased uniformly around the whole cir- HEE0023i
cumference.
15-7
REPLACING VALVE GUIDE

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

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

I) Press fit the valve guide until the tip of valve
guide driver B contacts the cylinder head.
2) Measure the protrusion of the valve guide
and check that it is within the standard range.
* Valve guide protrusion
Tolerance: 23 ? 0.2 mm
15-9
REPLACING CROSSHEAD GUIDE

Special tools
No. ( Part No. Part Name 1Q’ty
A 795-140-6410 Crosshead guide puller 1
B 795-130-1310 Crosshead guide driver 1
1. Removal of crosshead guide

Using crosshead guide puller A, remove the
crosshead guide.
1) As shown in the diagram, grip crosshead
guide with collet @ of puller.
2) Tighten collet with bolt 0, and lock sleeve
0.
3) Turn nut 0, and pull out crosshead guide.
4) Remove any burrs or flashes from the
crosshead guide mount.
!ad
HEE00238
2. Press fitting crosshead guide

Using tool B, insert the crosshead guide in the
cylinder head, and use a copper bar or plastic
hammer to press fit until the protrusion is within
the permitted tolerance.
* Protrusion of crosshead guide
Tolerance: 49 -c 0.5 mm
15-10
REPAIR AND REPLACEMENT OF- PARTS CYLINDER HEAD
GRINDING VALVE
Special tool
No. Part No. Part Name Q’ty
A Commercially available Valve refacer 1
1. Grinding seat face

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

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

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

Special tools
No. 1 Part No. Part Name 1O’ty
A 1 795-213-1200 1 Push tool
( 4 1 795-213-1230 I Guide
5 792-l 03-0400 Grip 1
* When replacing the cam bushing, first remove

the blind plug at the rear of the cylinder block.
1. Removal of No. 1, 7 bushings

As shown in the diagram, assemble push tool
AZ, collar AS, and push bar AI of push tools A,
then hit the push bar to knock bushing (2) out
from cylinder block (I).
HEE00099
2. Removal of No. 2, 6 bushings

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

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

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

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

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

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

Special tools
No. 1 Part No. Part Name IQW
@ 790-101-2800 Bearing puller
@ 790-101-2300 Push puller
1. Removal of Gear
Make a scratch in the surface at the root of the
teeth with a grinder, then assemble pullers 0
and 0, and turn the nut to remove the gear.
If the gear cannot be removed in this way,
make a scratch in the surface at the root of
the teeth with a grinder, then heat the gear
with a burner and knock the gear out with a
copper rod.
Be careful not to damage the shaft.
!z
HEE00240
Kl
(D
2. Press fitting gear

1) Check the gear mounting surface, key
groove, and flange surface, and if there are
any scratches, correct them with an oilstone.
2) Knock a new key into the key groove of the
shaft.
3) Heat the gear for the specified time at the
specified shrink-fitting temperature.
* Crankshaft gear shrink-fitting temperature:
200°C
Heating time: Min. 30 minutes
HEE00108
4) Put the timing mark on the outside, then
use a hitting tool to press fit until the side
face of the gear is in close contact with the
shaft flange.
Ir Knock in quickly before the gear becomes
cool.
15-15
1. Removal of gear
Set the camshaft assembly on the press stand,
then push the camshaft to remove the gear.
a When setting the camshaft assembly on the

press stand, be careful not to get caught your
fingers between the press stand and the gear.
HEEOO
2. Press fitting gear

1) Check the gear mounting surface, key
groove, and flange surface, and if there are
any scratches, correct them with an oilstone.
2) Knock a new key into the key groove of the
shaft.
3) Assemble the thrust plate.
4) Heat the gear for the specified time at the
specified shrink-fitting temperature.
Ir Crankshaft gear shrink-fitting
temperature: 220 - 240°C
5) Put the timing mark on the outside, then use
a hitting tool to press fit until the side face
of the gear is in close contact with the shaft
flange.
* Knock in quickly before the gear becomes
cool.
15-16
REPLACING FLYWHEEL RING GEAR

g Be careful not to let the flywheel fall and injure
you.
1. Removal of ring gear

Make a scratch in the surface at the root of the
teeth with a grinder, then split with a chisel to
remove.
A Be careful when handling the grinder and

chisel.
2. Press fitting ring gear

1) Check the ring gear mounting surface, and if
there are any scratches, correct them with
an oilstone.
2) Heat the ring gear for the specified time at
the specified shrink-fitting temperature.
* Ring gear shrink-fitting temperature:
Max. 200°C
3) Set the chamfered face of the ring gear fac-
ing the flywheel, and press fit until the side
face of the gear is in close contact with the
flywheel.
15-17
REPLACING CONNECTING ROD SMALL END BUSHING

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

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

1) Set connecting rod to tool 83.
2) Assemble connecting rod bushing in tool
BI, set tool BZ in position, then secure with
tool B4 so that it does not move.
* Align the oil hole of the connecting rod bush-
ing with the oil hole of the connecting rod. Connecting
rod bushins
3) Push tool Bl with press, and press fit the
connecting rod bushing.
Connecting
l The bushing is supplied as a semi-finished prod-
rod
uct, so the inside diameter is too small and the
piston pin will not go in.
After press fitting the bushing, machine the in- B3
side diameter of the bushing with a reamer or
/
honing machine in accordance with the mainte- /!225 HEE00242
nance standard.
Ir After machining, clean all the metal parti-
cles from the oil hole and oil groove.
15-18
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications 1 PROPOSAL FOR MANUAL REVlslON 1
Fax No. (847) 970-4186 I I
FOR INTERNAL USE ONLY -- No. PMR

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

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

:ORRECTIVE ACTION:
PFMRl 081696

Komatsu D140-2 Series

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SEBM008603

December 1997 Cowriaht 1997 Komatsu America International Comoanv

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

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

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

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

The affected pages are indicated by the use of the

0 Pageto be replaced Replace

Page to bedeleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time o Time oi Time of Time o Time of

0 oo- 1 (tjl 0 Ol- 3-l II- 7 11-38 11-66

00- 6 01-10 11-14 11-45 11-72

00-13 01-17 11-22 11-52 11-79

00-14 01-18 11-23 11-53 0 II-80

00-15 01-19 11-24 11-54 0 11-81

00-16 01-20 11-25 11-55 11-82

00-17 0 01-21 11-26 11-56 11-83

0 Ol- 2 @ ll- 3 11-33 11-62 11-89

0 Ol- 3 @ II- 6 11-37 11-65 11-92

Time of Time 01 Time of Time of Time of

12-1 @ 12-33 13-21 14- 6 15-17

12- 2 12-34 13-22 0 14- 7 15-18

12- 3 12-35 13-23 14- 8

12- 4 12-36 13-24 14- 9

12- 4-l @ 12-37 13-25 14-10

12- 5 12-38 13-26 14-11

12-6 @ 12-39 13-27 14-12

12- 6-l 0 12-40 13-28 14-13

0 12- 6-2 @ 12-41 13-29 14-14

0 12-7 @ 12-42 13-30 14-16

0 12-8 @ 12-43 13-31 14-17

0 12-9 @ 12-44 13-32 14-18

0 12-10 @ 12-45 13-33 14-19

0 12-11 @ 12-46 13-34 14-20

0 12-11-l @ 12-47 13-35 14-21

0 12-11-2 @ 12-48 13-36 14-22

0 12-11-3 @ 12-49 13-37 14-23

12-12 @ 12-50 13-38 14-24

12-13 @ 13-39 14-25

12-13-1 @ 13-40 14-26

12-14 @ 13. 1 13-41 14-27

12-15 @ 13- 2 13-42 14-28

12-16 @ 13- 3 13-43

12-17 @ 13- 4 13-44

12-18 @ 13- 5 13-45 15- 1

12-18-1 @ 13- 6 13-46 15- 2

12-19 13- 7 13-47 15- 3

12-20 13- 8 13-48 15- 4

12-21 13- 9 13-49 15- 5

12-22 13-10 13-50 15- 6

12-23 13-11 13-51 15- 7

12-24 13-12 13-52 15- 8

12-25 13-13 13-53 15- 9

12-26 13-14 13-54 15-10

12-27 13-15 15-11

12-28 13-16 15-12

12-29 13-17 14- 1 15-13

12-30 13-18 14- 2 15-14

12-31 13-19 14- 3 15-15

12-32 13-20 14- 4 15-16

IMPORTANT SAFETY NOTICE