GD 825 A - 2 ENGINE SYSTEM TRAINING II - 01 - 17

GENERAL STRUCTURE
S6D140-1

1. Fan pulley 9. Camshaft 17. Connecting rod

2. Cylinder block 10. Cam follower 18. Oil strainer
3. Cylinder liner 11. Crankshaft pulley 19. Oil pan
4. Exhaust valve 12. Vibration damper 20. Crankshaft
5. Piston 13. Front cover 21. Main bearing cap
6. Rocker arm housing 14. Under frame 22. Flywheel
7. Rocker arm housing cover 15. Crankshaft gear 23. Flywheel housing
8. Intake valve

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 02 - 17

25. Exhaust manifold Engine : S6D140-1 (with turbocharger)

26. Cylinder head SA6D140-1 (with turbocharger and after -cooler )
27. Oil cooler
28. Oil pump
29. Intake connector pipe Type : In-line, 6-cylinder, water-cooled, direct fuel injection ,
4-cycle diesel engine
30. Electrical intake air heater
31. Intake manifold
32. Push rod
33. Dipstick

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PT Pamapersada Nusantara
 GD 825 A - 2
VALVE SYSTEM
Engine No. 10001 - 19603
1. Thrust plate
2. Camshaft gear
3. Camshaft
4. Cam roller
5. Cam roller pin
6. Cam follower shaft
7. Cam follower
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ENGINE SYSTEM TRAINING II - 03 - 17
8. Push rod 15. Cross head
9. Rocker arm shaft 16. Upper spring seat
10. Rocker arm 17. Outer valve spring
11. Lock nut 18. Inner valve spring
12. Rocker arm adjustment screw 19. Exhaust valve
13. Cross head adjustment screw 20. Valve guide
14. Lock nut 21. Lower spring seat
22. Intake valve
 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 04 - 17

CAMSHAFT
• Stamp forging
• Journal and cam portion:
Induction hardening

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 05 - 17

MAIN CIRCULATION SYSTEM

1. Piston 8. Vibration damper

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

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 06 - 17

PISTON RANGE
Engine No . 10001 - 18536
Top ring Second ring Oil ring

CRANKSHAFT
• Stamp forging Both faces keystone Keystone inner cut M-shape steel ring
• Journal and filet portion: Tapered face Hard chrome
Barrel face plating with coil
Induction hardening
Hard chrome plating Hard chrome plating expander
PISTON
• Ductile cast iron
Engine No . 18537 and up
CONNECTING ROD
• Stamp forging
Top ring Second ring Oil ring

Both faces keystone Keystone inner cut M-shape steel ring

Tapered face Hard chrome
Barrel face plating with coil
Hard chrome plating Hard chrome plating expander

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 07 - 17

TIMING GEAR

1. Water pump drive gear (No. of teeth : 23) 7. Compressor drive gear (No. of teeth : 24)
2. Sub idler gear (No. of teeth : 42) 8. Fuel injection pump drive gear (No. of teeth : 46)
3. Main idler gear (Large) (No. of teeth : 60) 9. PTO gear (OPTION) (No. of teeth : 22)
4. Main idler gear (Small) (No. of teeth : 40) 10. Crankshaft gear (No. of teeth : 36)
5. Camshaft gear (No. of teeth : 48) 11. Oil pump drive gear (No. of teeth : 22)
6. PTO gear (OPTION) (No. of teeth : 14)
A, B, C: Match marks

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 08 - 17

LUBRICATION SYSTEM CHART

1. Oil pan 8. Valve adapter 15. Cam follower

2. Oil strainer 9. Oil filter 16. Rocker arm
3. Oil pump 10. Safety valve 17. Intake and exhaust valve
4. Main relief valve 11. Crankshaft 18. Timing gears
5. Oil cooler 12. Piston cooling nozzle 19. Turbocharger
6. Thermostat 13. Piston 20. Fuel injection pump
7. Regulator valve 14. Camshaft
W:Cooling water

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 09 - 17

LARGE CAPACITY OIL FILTER + BY PASS FILTER

1. Oil pan 8. Valve adapter 15. Cam follower

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

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 10 - 17

FUEL SYSTEM CHART

1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Fuel injection pump
7. Fuel injection nozzle
8. Over-flow valve

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 11 - 17

FUEL INJECTION PUMP

1. Fuel injection pipe (No. 1 ) 10. Fuel injection pump drive shaft
2. Fuel injection pipe (No. 2) 11. Bearing box -
3. Fuel injection pipe (No. 3) 12. Coupling
4. Fuel injection pipe (No. 4) 13. Feed pump
5. Fuel injection pipe (No. 5) 14. Fuel injection pump
6. Fuel injection pipe (No. 6) 15. Gauze filter
7. Air bleeder plug 16. Oil tube (outlet)
8. Oil tube (inlet) 17. Fuel filter
9. Fuel injection pump drive gear (No. of teeth 48)

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 12 - 17

FUEL INJECTION NOZZLE

1. Fuel inlet connector

2. Nozzle holder
3. Adjustment shim.
4. Spring
5. Seat
6. Spacer
7. Nozzle
8. Retaining cap
9. Needle valve

FUEL INJECTION NOZZLE

a. Fuel inlet (From injection pump)

b. Injection (To cylinder)
c. Fuel return (To fuel tank) • Maker : DIESEL KIKI ( S6D140-1 )
NIPPO DENSO ( SA6D140-1 )
S6D140-1: Made by DIESEL KIKI • Type : Multi-hole nozzle
(Diameter of nozzle hole 0.35 x 7 hole)
• Injection pressure : 250 kg/cm ²
SA6D140-1: Made by DIESEL KIKI • Adjusting injection pressure :
Made by NIPPON DENSO
(Diameter of nozzle hole 0.36 x 6 hole) Shim adjusting type.

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 13 - 17

COOLING SYSTEM CHART

1.Radiator 6.Oil cooler

2.Thermostat 7.Corrosion resistor
3.After-cooler (SA6D140-1) 8.Cooling fan
4.Air compressor (if equipped)
5.Water pump A.Lubrication

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 14 - 17

MEASURING BLOW - BY
PRESSURE

 Measure the blow by pressure under the following

conditions.
Temperature of cooling water:
Within operating range
Temperature of hydraulic oil: 45 - 55°C
1. Set tool E4 and E, to blow by hose (1).
2. Use tool E3 to connect tool E, and E2.
3. Run the engine at the rated output and measure the
blow by pressure as follows.
 Blow by varies greatly according to the condition
of the engine. Therefore, if the blow by value is
considered abnormal, check for problems con
nected with defective blow by, such as excessive
oil consumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
 When taking measurements, be careful
not to touch any hot parts or rotating parts.
1) Before starting measurements,. set the work
equipment to the following posture.
A:  When setting the work equipment in
position, be careful not to let the blade
hit the tire.
B: For the draw bar shift, take the center
position as the standard position.
C: Shift the blade fully to the right.
D: Rotate the circle to give a propulsion angle
of 50°.
E: Raise the blade fully on both the left and
right sides.
2) Pull right blade lift lever (1) back, and hold it at
the end of its stroke.
 Raise the right end of the blade, and relieve
the circuit.
3) In the condition in Step 2), operate blade left
shift lever (2) and circle left rotation lever (3) at
the same time to the front to move the work
equipment.
 Use the blade left shift lever and the circle
left rotation lever to set the oil discharge
amount to the maximum .

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 15 - 17

MEASURING COMPRESSION
PRESSURE

 When measuring the compression pressure,

be careful not to touch the exhaust manifold
or muffler, or to get caught in rotation parts.

1. Adjust valve clearance.

 For details, see TESTING AND
ADJUSTING VALVE CLEARANCE.

2. Warm up engine (oil temperature 40 - 60°C).

3. Remove nozzle holder assembly.

4. Install tool Dz to the nozzle holder mount,

then connect pressure gauge D,.

5. Set engine tachometer in position.

6. Disconnect connector (2) of stop motor (1),

set to the NO INJECTION position, then crank
the engine and measure the. compression
pressure.

 Measure the compression pressure at the

point where the pressure gauge indicator
remains steady.

 When measuring the compression pressure,

measure the engine speed to confirm that it
is within the specified range

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 16 - 17

TESTING AND ADJUSTING

VALVE CLEARANCE

 Adjust clearance between rocker lever and top

of cross head to following value.

Intake valve (at 20°C) Exhaust valve (at 20°C)

0.43 mm 0.80 mm

1. Remove cylinder head cover (1).

2. Rotate the crankshaft in the normal direction to

align pointer (2) with the 1.6 TOP mark of
crankshaft pulley. When rotating, check the
movement of the intake valve of No. 1 cylinder
and No. 6 cylinder.
Set with No. 1 cylinder at compression top dead
center.

3. When No. 1 cylinder is at compression top dead

center, adjust the valves marked . Then rotate
the crankshaft one turn in the normal direction,
set No. 6 cylinder to compression top dead center,
and adjust the valves marked O.

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 GD 825 A - 2 ENGINE SYSTEM TRAINING II - 17 - 17

4. To adjust, insert tool F between rocker lever (3)

and cross head (4) and turn adjustment screw (5)
until clearance is a sliding fit.

Tighten lock nut (6) to hold adjustment screw in

position.

Lock nut: 58.8 t 5.9 Nm (6.0 t 0.6 kgm)

5. Then rotate the crankshaft in the normal direction

by one turn and adjust the valve clearance for the
remaining valves marked o.

 After adjusting No. 1 cylinder at compression

top dead center, it is also possible to turn the
crankshaft 120° each time and adjust the valve
clearance of each cylinder according to the
firing order.

• Firing order: 1 - 5 - 3 - 6 - 2 - 4

  After tightening the lock nut, check the

clearance again.

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