SAA6D140E-2 Series.pdf
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SEBM008611
DIESEL ENGINE
© 2005 All Rights Reserved Printed in Japan 02-05 (01)
00-1 (11)
Contents No. of page
01 General ..........................................................................................................................
01-1
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 ..............................................................
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6D140-2 SERIES
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Safety
Safety notice
Safety Safety notice Important safety notice Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
General precautions Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. Preparations for work 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
Safety
Precautions during work 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
Safety notice
19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. Testing and adjusting This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. Disassembly and assembly This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. Maintenance standard This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”. Others This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
Notice The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
Foreword
General
How to read the shop manual Volumes Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Attachments volume:
Each issued as one volume to cover all models
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. Distribution and updating Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work. Filing method 1. See the page number on the bottom of the page. File the pages in correct order.
Revised edition mark W he n a m a nu a l i s r e v i s ed , an ed i t io n ma r k ((1)(2)(3)....) is recorded on the bottom of the pages. Revisions Revised pages are shown in the List of revised pages next to the Contents page. Symbols So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols. Symbol
Item
Remarks
k
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
4
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
Places that require special attention for the tightening torque during assembly.
2
Coat
Places to be coated with adhesives and lubricants, etc.
5
Oil, water
Places where oil, water or fuel must be added, and the capacity.
6
Drain
Places where oil or water must be drained, and quantity to be drained.
a
2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (–) and number after the page number. File as in the example. Example: 10-4 10-4-1 10-4-2 10-5
00-6
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20-203 12-203-1 12-203-2 12-204
Foreword
Hoisting instructions
Hoisting instructions Hoisting k
•
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the Disassembly and assembly section, every part weighing 25 kg or more is indicated clearly with the symbol 4
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k
Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
a The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120? hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
00-7
Foreword
Method of disassembling, connecting push-pull type coupler
Method of disassembling, connecting push-pull type coupler k
k
Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see “Testing and adjusting”, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see “Testing and adjusting”, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
Foreword
Method of disassembling, connecting push-pull type coupler
Type 2
Type 3
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1)
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2)
Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2)
Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3)
Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3)
Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
•
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Disassembly
1)
00-9
Foreword
Coating materials
Coating materials a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list. Category
Komatsu code
Part No.
Q’ty
Container
Main applications, featuresr
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
• Used in places requiring an immediately effective, strong adhesive. Polyethylene Used for plastics (except polyethylene, container polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and nonmetal. • Features: Polyethylene Resistance to heat and chemicals container • Used for anti-loosening and sealant purpose for bolts and plugs.
LT-2
09940-00030
50 g
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
LT-4
790-129-9040
250 g
Holtz MH 705
790-126-9120
75 g
Three bond 1735
790-129-9140
50 g
• Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. container • Used mainly for adhesion of metals, rubbers, plastics and woods. Polyethylene container
Adhesives
Can
Polyethylene • Used as sealant for machined holes. container Tube
• Used as heat-resisting sealant for repairing engine.
• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.
Aron-alpha 201
790-129-9130
2g
Loctite 648-50
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
Tube
• Used as adhesive or sealant for gaskets and packing of power train case, etc.
LG-5
790-129-9080
1 kg
Can
• Used as sealant for various threads, pipe joints, flanges. • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Tube
• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc.
LG-6
790-129-9020
200 g
• Resistance to heat, chemicals Polyethylene • Used at joint portions subject to high container temperatures.
Gasket sealant
00-10
• Used as adhesive or sealant for metal, glass and plastic.
LG-7
790-129-9070
1g
Tube
• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
Three bond 1211
790-129-9090
100 g
Tube
• Used as heat-resisting sealant for repairing engine.
Three bond 1207B
419-15-18131
100 g
Tube
• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case
Foreword
Molybdenum disulphide lubricant
Grease
Primer
Adhesive
Caulking material
Komatsu code
Part No.
Q’ty
Container
LM-G
09940-00051
60 g
Can
• Used as lubricant for sliding portion (to prevent from squeaking).
Tube
• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.
LM-P
09940-00040
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
200 g
• General purpose type Various
Various
Various
Various
Molybdenum disulphide grease LM-G (G2-M)
SYG2-400M SYG2-400M-A SYGA-16CNM
Hyper White Grease G2-T G0-T (*) *: For use in cold district
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
400 g 16 kg
Biogrease G2B G2-BT (*) *: For high temperature and large load
SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
400 g 16 kg
Bellows type Can
SUNSTAR PAINT PRIMER 580 SUPER
20 ml
Glass container
SUNSTAR GLASS PRIMER 580 SUPER
20 ml
Glass container
417-926-3910
SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”
Main applications, featuresr
400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can
• Used for normal temperature, light load bearing at places in contact with water or steam.
• Used for heavy load portion
• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body.
320 ml
Polyethylene container
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants.
• Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months) Adhesive for cab glass
Category
Coating materials
• “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months)
00-11
Foreword
Standard tightening torque
Standard tightening torque Standard tightening torque table (when using torque wrench) a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12 14
10 13 17 19 22
11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190
1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5
16 18 20 22 24
24 27 30 32 36
235 – 285 320 – 400 455 – 565 610 – 765 785 – 980
23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100
27 30 33 36 39
41 46 50 55 60
1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630
118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
Tightening torque
Sealing surface
Table of tightening torques for flared nuts a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. SAD00483
Thread diameter
Width across flats
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
00-12
Tightening torque
Foreword
Standard tightening torque
Table of tightening torques for flared nuts a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter
Width across flats
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
59 – 74 98 – 123 235 – 285
6 – 7.5 10 – 12.5 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Norminal No. 02 03, 04 05, 06 10, 12 14
Thread diameter
Width across flats
mm
mm
14 20 24 33 42
Varies depending on type of connector.
Tightening torque Nm
kgm
35 – 63 {3.5 – 6.5} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 363 – 480 {37.0 – 49.0} 746 – 1010 {76.0 – 103}
44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
Table of tightening torques for o-ring boss plugs a Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Norminal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter
Width across flats
Tightening torque
mm
mm
Nm
kgm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 — 36 — —
5.88 – 8.82 {0.6 – 0.9} 9.8 – 12.74 {1.0 – 1.3} 14.7 – 19.6 {1.5 – 2.0} 19.6 – 24.5 {2.0 – 2.5} 24.5 – 34.3 {2.5 – 3.5} 34.3 – 44.1 {3.5 – 4.5} 44.1 – 53.9 {4.5 – 5.5} 58.8 – 78.4 {6.0 – 8.0} 93.1 – 122.5 {9.5 – 12.5} 107.8 – 147.0 {11.0 – 15.0} 127.4 – 176.4 {13.0 – 18.0} 181.3 – 240.1 {18.5 – 24.5} 274.4 – 367.5 {28.0 – 37.5}
7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
Foreword
Standard tightening torque
Tightening torque for 102 engine series 1) Bolt and nuts Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
6 8 10 12
10 ± 2 24 ± 4 43 ± 6 77 ± 12
1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22
2) Eye joints Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
6 8 10 12 14
8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
3) Tapered screws Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
kgm
1 / 16 1/8 1/4 3/8 1/2 3/4 1
3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9
0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.41 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type) a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm})
Taper seal type
Face seal type
Nominal size of hose
Width across flats
02
19
34 – 63 {3.5 – 6.5}
44 {4.5}
22
54 – 93 {5.5 – 9.5}
74 {4.5}
24
59 – 98 {6.0 – 10.0}
78 {8.0}
18
04
27
84 – 132 {8.5 – 13.5}
103 {10.5}
22
05
32
128 – 186 {13.0 – 19.0}
157 {16.0}
24
06
36
177 – 245 {18.0 – 25.0}
216 {22.0}
30
(10)
41
177 – 245 {18.0 – 25.0}
216 {22.0}
33
—
—
(12)
46
197 – 294 {20.0 – 30.0}
245 {25.0}
36
—
—
(14)
55
246 – 343 {25.0 – 35.0}
294 {30.0}
42
—
—
Range
Target
03
00-14
Nominal thread size Root diameter Thread size – Threads per inch, (mm) (Reference) (mm) Thread series 9 14 – 18UNF 14.3 16 11 — – 16UN 17.5 16
1
1
—
—
13 – 16UN 16
20.7
1 – 14UNS
25.4
3 – 12UNF 16
30.3
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 Norminal number
Copper wire Number of strands
Dia. of Cross section strands (mm2) (mm2)
Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.85
11
0.32
0.88
2.4
12
Starting, lighting, signal etc.
2
26
0.32
2.09
3.1
20
Lighting, signal etc.
5
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Classification by color and code Priority
1
Circuits
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
Color
White & Red
—
White & Black
Red & White
Rellow & Red
Green & White
Blue & White
Code
WB
—
BY
RB
YB
GR
LR
Color
White & Black
—
Black & Yellow
Red & Black
Yellow & Black
Green & Red
Blue & Yellow
Code
WL
—
BR
RY
YG
GY
LY
Color
White & Blue
—
Black & Red
Red & Yellow
Yellow & Green
Green & Yellow
Blue & Yellow
Code
WG
—
—
RG
YL
GB
LB
Color
White & Green
—
—
Red & Green
Yellow & Blue
Green & Black
Blue & Black
Code
—
—
—
RL
YW
GL
—
Color
—
—
—
Red & Blue
Yellow & White
Green & Blue
—
Classification Primary
2
3
4
Auxiliary
5
6
00-15
Foreword
Conversion table
Conversion table Method of using the conversion table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in 0
(A)
00-16
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
2.205
2.244
2.283
2.323
50
1.969
2.008
2.047
2.087
2.126
(C) 2.165
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
Foreword
Conversion table
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
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
0
0
00-17
Foreword
Conversion table
Liter to U.S. Gallon 0
1l = 0.2642 U.S. Gal 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 0
1l = 0.21997 U.K. Gal 1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
Foreword
Conversion table
kgm to ft. lb 1 kgm = 7.233 ft. lb 0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
Foreword
Conversion table
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2 0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
Foreword
Conversion table
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature 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 = 33.8°F °C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
Foreword
Units
Units In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
}.
01 General
Applicable machine ........................................01- 2 Specifications .................................................01- 4 General assembly drawing.............................01- 12 Weight table ...................................................01- 28 Engine performance curve .............................01- 31
6D140-2 SERIES
01-1 (10)
General
Applicable machine
Applicable machine a Serial No. shows for engine serial No. Engine
S6D140-2
Serial No.
Applicable machine GD825A-2
Motor grader
WA500-3
Wheel loader
D155A-2, D155A-3, D155AX-3, D155AX-5
Bulldozer
D155C-1 (–30°C spec.), D155C-1 (–50°C spec.), D355C-3, Bulldozer D355C-3 (–30°C spec.), D355C-3 (–50°C spec.) SA6D140-2
PC1600SP-1
Hydraulic excavator
DCA400SSK-2
DENYO Generator
DCA-400SSK
MQ Generator
J6D140E-G1-2
TAIYO DENKI Generator
PC750-6, PC800-6, PC1800-6
Hydraulic excavator
HD325-6, HD405-6
Dump truck
D275A-5 (–50°C spec.)
Bulldozer
SAA6D140-2
SDA6D140E-2
01-2 (10)
6D140-2 SERIES
General
Specifications
Specifications Engine model
S6D140-2
Applicable machine Number of cylinder – Bore x Stroke Total piston displacement
GD825A-2 mm
6 – 140 x 165
l {cc}
15.2 {15,240}
Dimensions
Firing order
1–5–3–6–2–4
Overall length
mm
1,593
1,787
Overall width
mm
895
1,060
Overall height (excluding exhaust pipe)
mm
2,060
1,670
Overall height (including exhaust pipe)
mm
—
—
kW {HP}/rpm
209 {280}/2,100
236 {316}/2,100
Maximum torque
Nm {kgm}/rpm
1,230 {125}/1,400
1,370 {140}/1,400
High idling speed
rpm
2,300 – 2,400
2,300 – 2,400
Low idling speed
rpm
650 – 700
700 – 750
g/kW•h {g/HP•h}
208 {155}
204 {152}
kg
1,506
1,520
Flywheel horsepower
Performance
WA500-3
Minimum fuel consumption ratio Dry weight Fuel injection pump
BOSCH PE-P (PS3S) type BOSCH RSV centrifugal all speed control type
Governor Lubricating oil amount (refill capacity)
l
38 (34)
Coolant amount
l
(Engine side: 23)
Alternator
24 V, 50 A
Starting motor Battery Turboharger Air compressor
Others
01-4 (10)
24 V, 11 kW 12 V 200 Ah x 2
12 V 170 Ah x 2
KOMATSU KTR110 type ZEXEL Reciprocation, 1-cylinder type
—
—
—
6D140-2 SERIES
General
Specifications
S6D140-2
6D140-2 SERIES
01-5 (10)
General
Specifications
Engine model
SA6D140-2 D155A-3, D155AX-3
Applicable machine Number of cylinder – Bore x Stroke Total piston displacement
PC1600SP-1 (2 engines)
mm
6 – 140 x 165
l {cc}
15.2 {15,240}
Firing order
1–5–3–6–2–4 mm
1,498
1,938
Overall width
mm
1,040
1,185
Overall height (excluding exhaust pipe)
mm
1,740
1,722
Overall height (including exhaust pipe)
mm
—
—
Flywheel horsepower
kW {HP}/rpm
225 {302}/1,900 (Net)
316 {424}/1,800 (Net)
Maximum torque
Nm {kgm}/rpm
1,430 {146}/1,300 (Net)
1,860 {190}/1,400
High idling speed
rpm
2,050 – 2,150
1,930 – 2,030
Low idling speed
rpm
700 – 725
725 – 775
g/kW•h {g/HP•h}
214 {160}
207 {154}
kg
1,550
1,670
Fuel injection pump
BOSCH PE-P (PS7S) type
BOSCH PE-P (PS7S) type
Governor
BOSCH RSUV centrifugal, all speed type
BOSCH RSV centrifugal, all speed type
Performance
Dimensions
Overall length
Minimum fuel consumption ratio Dry weight
Lubricating oil amount (refill capacity)
l
42 (37)
38 (34)
Coolant amount
l
(Engine only: 25)
(Engine side: 25)
24 V, 35 A 24 V, 50 A (opt)
24 V, 50 A
24 V, 11 kW
24 V, 7.5 kW
12 V 200 Ah x 2
12 V 170 Ah x 2
Alternator
Starting motor Battery Turboharger
KOMATSU KTR110 type
Air compressor —
Others
01-6 (10)
ZEXEL Reciprocation, 1-cylinder type With aftercooler
6D140-2 SERIES
General
Specifications
SA6D140-2 D155A-2
D155AX-5
D155C-1 (–30°C spec.)
D155C-1 (–50°C spec.)
D355C-3
D355C-3 (–30°C spec.)
6 – 140 x 165 15.2 {15,240} 1–5–3–6–2–4
1,566
1,498
1,614
1,614
1,577
1,577
1,136
1,040
1,193
1,193
1,265
1,265
1,824
1,740
1,824
1,824
1,843
1,843
—
—
—
—
—
—
253 {339}/2,000 (Net)
232 {310}/1,900 (Net)
255 {342}/2,000 (Gross)
255 {342}/2,000 (Gross)
265 {355}/2,000 (Net)
265 {355}/2,000 (Net)
1,608 {164}/1,400 (Net)
1,610 {164}/1,250 (Net)
1,490 {152}/1,400 (Gross)
1,490 {152}/1,400 (Gross)
1,570 {160}/1,400 (Net)
1,570 {160}/1,400 (Net)
2,200 – 2,280
2,100
2,190 – 2,290
2,190 – 2,290
2,200 – 2,280
2,200 – 2,280
550 – 650
700
700 – 750
700 – 750
206 {153}
205 {153}
205 {151}
205 {151}
203 {151} (Gross)
203 {151} (Gross)
1,750
1,560
1,790
1,790
1,850
1,850
700 – 750 (engine set) 700 – 750 (engine set) 575 – 675 (on board) 575 – 675 (on board)
BOSCH PE-P (PS7S) type BOSCH RSV centrifugal, all speed type
42 (37)
78 (34)
42 (37)
42 (37)
42 (37)
42 (37)
(Engine side: 25)
23 (Engine only)
(Engine side: 25)
(Engine side: 25)
(Engine side: 25)
(Engine side: 25)
24 V, 35 A
24 V, 35 A
24 V, 50 A
24 V, 50 A
24 V, 50 A
24 V, 50 A
24 V, 11 kW
24 V, 11 kW
24 V, 11 kW x 2
24 V, 11 kW x 2
24 V, 11 kW x 1
24 V, 11 kW x 2
12 V 170 Ah x 2
12 V 170 Ah x 2
12 V 200 Ah x 2
12 V 200 Ah x 2
12 V 200 Ah x 2
12 V 200 Ah x 2
KOMATSU KTR110 type
KOMATSU KTR110 type
KOMATSU KTR110 type
KOMATSU KTR110 type
KOMATSU KTR110 type
KOMATSU KTR110 type
—
—
—
—
—
—
With aftercooler
With aftercooler
With aftercooler
With aftercooler
With aftercooler
With aftercooler
6D140-2 SERIES
01-7 (10)
General
Specifications
Engine model
SA6D140-2 D355C-3 (–50°C spec.)
Applicable machine Number of cylinder – Bore x Stroke Total piston displacement
mm l {cc}
6 – 140 x 165 15.2 {15,240} 1–5–3–6–2–4
Dimensions
Firing order Overall length
mm
1,577
Overall width
mm
1,265
Overall height (excluding exhaust pipe)
mm
1,843
Overall height (including exhaust pipe)
mm
—
kW {HP}/rpm
265 {355}/2,000 (Net)
Maximum torque
Nm {kgm}/rpm
1,570 {160}/1,400 (Net)
High idling speed
rpm
2,200 – 2,280
Low idling speed
rpm
700 – 750 (engine set) 575 – 675 (on board)
Performance
Flywheel horsepower
Minimum fuel consumption ratio Dry weight
g/kW•h {g/HP•h} kg
Fuel injection pump
203 {151} (Gross) 1,850 BOSCH PE-P (PS7S) type
Governor
BOSCH RSV centrifugal, all speed type
Lubricating oil amount (refill capacity)
l
42 (37)
Coolant amount
l
(Engine side: 25)
Alternator
24 V, 50 A
Starting motor
24 V, 11 kW x 2
Battery
12 V 200 Ah x 2
Turboharger
Air compressor
Others
01-8 (10)
KOMATSU KTR110 type —
With aftercooler
6D140-2 SERIES
General
Specifications
SA6D140-2 DCA400SSK-2
DCA-400SSK
(DENYO generator)
(For MQ generator)
J6D140E-G1-2 6 – 140 x 165 15.2 {15,240} 1–5–3–6–2–4
1,874
1,874
1,874
957
957
957
1,598
1,598
1,634
—
—
—
310 {415}/1,500 (Net, 50 Hz) 357 {478}/1,800 (Net, 60 Hz)
357 {478}/1,800 (Net, 60 Hz)
271 {275}/1,500 (50 Hz) 299 {303}/1,800 (60 Hz)
—
—
—
Max. 1,570 (50 Hz) Max. 1,880 (60 Hz)
Max. 1,890 (60 Hz)
Max. 1,575 (50 Hz) Max. 1,890 (60 Hz)
800 – 850 At rated
800 – 850 At rated
700 – 900 At rated
217 {162} (50 Hz) 231 {172} (60 Hz)
214 {160} (60 Hz)
209 {156} (50 Hz) 222 {166} (60 Hz)
1,450
1,450
1,750
BOSCH PE-P (PS7S) type BOSCH RSUV centrifugal, all speed type 74 (67)
74 (67)
80 (73)
64
(Engine side: 27)
66 (Engine only: 27)
24 V, 50 A
24 V, 50 A
24 V, 35 A (OPT)
24 V, 7.5 kW
24 V, 7.5 kW
24 V, 7.5 kW
12 V 200 Ah x 2
12 V 200 Ah x 2
12 V 200 Ah x 2
KOMATSU KTR110 type
KOMATSU KTR110 type
KOMATSU KTR110 type
—
—
—
With aftercooler
With aftercooler
With aftercooler
6D140-2 SERIES
01-9 (10)
General
Specifications
Engine model
SAA6D140-2 PC750-6, PC800-6
Applicable machine Number of cylinder – Bore x Stroke Total piston displacement
HD325-6, HD405-6
mm
6 – 140 x 165
l {cc}
15.2 {15,240}
Firing order
1–5–3–6–2–4 mm
1,938
1,688
Overall width
mm
1,185
1,202
Overall height (excluding exhaust pipe)
mm
1,722
1,300
Overall height (including exhaust pipe)
mm
—
—
kW {HP}/rpm
331 {444}/1,800 (Net)
379 {508}/2,000 (Gross) 364 {488}/2,000 (Net)
Maximum torque
Nm {kgm}/rpm
2,100 {214}/1,350 (Net)
2,170 {221}/1,400 (Gross, Net)
High idling speed
rpm
1,930 – 2,030
2,350 – 2,450
Low idling speed
rpm
800 – 850
700 – 750
g/kW•h {g/HP•h}
200 {149}
200 {149}
kg
1,670
1,450
Fuel injection pump
BOSCH PE-P (PS7S) type
BOSCH PE-P (PS7S) type
Governor
BOSCH RSUV centrifugal, all speed type
BOSCH RFD Min. – max. speed control type
Dimensions
Overall length
Performance
Flywheel horsepower
Minimum fuel consumption ratio Dry weight
Lubricating oil amount (refill capacity)
l
38 (32)
41 (37)
Coolant amount
l
(Engine only: 25)
(Engine only: 25.5)
24 V, 50 A
24 V, 50 A
Starting motor
24 V, 7.5 kW 24 V, 11 kW (opt)
24 V, 11 kW
Battery
12 V 170 Ah x 2
12 V 170 Ah x 2
KOMATSU KTR110 type
KOMATSU KTR110 type
ZEXEL Single cylinder, reciprocation type
ZEXEL Single cylinder, reciprocation type
With air cooled aftercooler
With air cooled aftercooler and retarder
Alternator
Turboharger Air compressor
Others
01-10 (10)
6D140-2 SERIES
General
Specifications
SAA6D140-2 HD325-6 (High altitude spec.)
SDA6D140E-2
PC1800-6 (2 engines)
D275A-5 (–50°C spec.) 6 – 140 x 165 15.2 {15,240} 1–5–3–6–2–4
1,688
1,582
1,202
1,461 1,056
1,300
1,684
2,084
—
—
—
307 {411}/2,000
331 {444}/1,800 (Net)
332 {446}/2,000 (Gross)
1,750 {179}/1,400
2,100 {214}/1,350 (Net)
2,030 {207}/1,400 (Gross)
2,350 – 2,400
1,930 – 2,030
2,150 – 2,250
675 – 725
800 – 850
650 – 750
197 {147}
200 {149}
214 {160}
1,450
1,650
1,765
BOSCH PE-P (PS7S) type
BOSCH PE-P (PS7S) type
BOSCH PE-P (PS7S) type
BOSCH RFD Min. – max. speed control type
BOSCH RSUV centrifugal, all speed type
BOSCH RSUV centrifugal, all speed type
41 (37)
38 (32)
62 (55)
(Engine only: 26)
(Engine only: 25)
(Engine only: 26)
24 V, 50 A
24 V, 50 A
24 V, 75 A
24 V, 11 kW
24 V, 7.5 kW
24 V, 11 kW x 2
12 V 170 Ah x 2
12 V 170 Ah x 2
12 V 170 Ah x 2
KOMATSU KTR110 type
KOMATSU KTR110 type
KOMATSU KTR110 type
ZEXEL ZEXEL Reciprocation, single cylinder type Reciprocation, (front engine only) single cylinder type With air cooled aftercooler and retarder
6D140-2 SERIES
With air cooled aftercooler
—
With aftercooler
01-11 (10)
General
General assembly drawing
General assembly drawing SA6D140-2 left side view (For D155A-3, D155AX-3) a The specifications are subject to change according to modification, etc.
01-12 (10)
6D140-2 SERIES
General
General assembly drawing
SA6D140-2 right side view (For D155A-3, D155AX-3)
6D140-2 SERIES
01-13 (10)
General
General assembly drawing
SA6D140-2 front view (For D155A-3, D155AX-3)
01-14 (10)
6D140-2 SERIES
General
General assembly drawing
SA6D140-2 rear view (For D155A-3, D155AX-3)
6D140-2 SERIES
01-15 (10)
General
General assembly drawing
SA6D140-2 upper side view (For D155A-3, D155AX-3)
01-16 (10)
6D140-2 SERIES
General
General assembly drawing
SAA6D140-2 left side view (For PC750-6, PC800-6)
01-18 (10)
6D140-2 SERIES
General
General assembly drawing
SAA6D140-2 right side view (For PC750-6, PC800-6)
6D140-2 SERIES
01-19 (10)
General
General assembly drawing
SAA6D140-2 front view (For PC750-6, PC800-6)
01-20 (10)
6D140-2 SERIES
General
General assembly drawing
SAA6D140-2 rear view (For PC750-6, PC800-6)
6D140-2 SERIES
01-21 (10)
General
General assembly drawing
SDA6D140E-2 left side view (For D275A-5, –50°C spec.)
a. Crankshaft center b. Flywheel housing rear surface
01-22 (10)
6D140-2 SERIES
General
General assembly drawing
SDA6D140E-2 right side view (For D275A-5, –50°C spec.)
a. Crankshaft center b. Flywheel housing rear surface
6D140-2 SERIES
01-23 (10)
General
General assembly drawing
SDA6D140E-2 front view (For D275A-5, –50°C spec.)
c. Crankshaft center d. Cylinder liner center
01-24 (10)
6D140-2 SERIES
General
General assembly drawing
SDA6D140E-2 rear view (For D275A-5, –50°C spec.)
c. Crankshaft center d. Cylinder liner center
6D140-2 SERIES
01-25 (10)
General
General assembly drawing
Dimension table a These dimensions are reference values for use when installing to a test bench. Dimensions for each part (mm) Engine
Machine model
D275A-5 (–50°C spec.)
A
B
C
D
E
F
G
1,461
1,056
2,084
—
—
—
—
SDA6D140E-2
01-26 (10)
6D140-2 SERIES
General
Weight table
Weight table a The specifications may be different depending on the type of machine.
Unit: kg No.
Item
Components
S6D140-2
1
Turbocharger
Komatsu KTR110
23
2
Cylinder head assembly
Cylinder head, valve, rocker arm, valve spring
19
3
Cylinder block assembly
Cylinder block, bearing cap, cylinder liner
400
4
Front cover
38
5
Oil pan
30
6
Flywheel assembly
7
Flywheel housing
8
Crankshaft assembly
Crankshaft, crankshaft gear
136
9
Camshaft assembly
Camshaft, camshaft gear, thrust plate
19
10
Piston and connecting rod assembly
Piston, piston ring, piston pin, connecting rod
11
Oil pump
5.5
12
Fuel injection pump
20
13
Water pump
17
14
Alternator
15
Starting motor
16
Air compressor
11
17
Aftercooler assembly
—
01-28 (10)
60 (GD825A-2, WA500-3)
Flywheel, ring gear
— 55 (GD825A-2, WA500-3) —
10.7 x 6
24 V, 35 A
—
24 V, 50 A
10
24 V, 7.5 kW
—
24 V, 11 kW
19.5
6D140-2 SERIES
General
Weight table
Unit: kg No.
Item
Components
SA6D140-2
1
Turbocharger
Komatsu KTR110
23
2
Cylinder head assembly
Cylinder head, valve, rocker arm, valve spring
19
3
Cylinder block assembly
Cylinder block, bearing cap, cylinder liner
400
4
Front cover
38
5
Oil pan
30 60 (D155A-2,3, AX-3, AX-5)
6
Flywheel assembly
Flywheel, ring gear
54 (PC1600SP-1) 129 (DCA400SSK-2, J6D140E-G1-2 Generator)
55 (D155A-2,3, AX-3, AX-5) 7
Flywheel housing
52 (PC1600SP-1) 52 (DCA400SSK-2 Generator)
8
Crankshaft assembly
Crankshaft, crankshaft gear
136
9
Camshaft assembly
Camshaft, camshaft gear, thrust plate
19
10
Piston and connecting rod assembly
Piston, piston ring, piston pin, connecting rod
11
Oil pump
10.7 x 6 5.5 21 (D155A-2,3, AX-3, AX-5)
12
Fuel injection pump
13
Water pump
14
Alternator
15
Starting motor
16
Air compressor
11
17
Aftercooler assembly
43
6D140-2 SERIES
23 (Generator)
17 24 V, 35 A, 25 A
8.0
24 V, 50 A
10
24 V, 7.5 kW
18
24 V, 11 kW
19.5
01-29 (10)
General
Weight table
Unit: kg No.
Item
Components
SAA6D140-2
1
Turbocharger
Komatsu KTR110
23
2
Cylinder head assembly
Cylinder head, valve, rocker arm, valve spring
19
3
Cylinder block assembly
Cylinder block, bearing cap, cylinder liner
400
4
Front cover
38
5
Oil pan
30
6
Flywheel assembly
7
Flywheel housing
8
Crankshaft assembly
Crankshaft, crankshaft gear
136
9
Camshaft assembly
Camshaft, camshaft gear, thrust plate
19
10
Piston and connecting rod assembly
Piston, piston ring, piston pin, connecting rod
11
Oil pump
5.5
12
Fuel injection pump
20
13
Water pump
17
14
Alternator
15
Starting motor
16
Air compressor
17
Air-cooled aftercooler assembly
01-30 (10)
Flywheel, ring gear
SDA6D140E-2
55 (PC750-6, PC800-6) 51 (HD325-6/405-6) 54 (PC750-6, PC800-6) 68 (HD325-6/405-6)
10.7 x 6
24 V, 35 A
8.0
24 V, 50 A
10
24 V, 7.5 kW
18
24 V, 11 kW
19.5 11 37 (PC750, 800-6) 35 (HD325-6/405-6)
6D140-2 SERIES
General
Engine performance curve
Engine performance curve Engine S6D140-2
SA6D140-2
SAA6D140-2
SDA6D140E-2
6D140-2 SERIES
Engine Serial No.
Machine model
Page
GD825A-2
01-32
WA500-3
01-33
D155A-3, D155AX-3
01-34
PC1600SP-1
01-35
D155A-2
01-36
D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.)
01-37
D155AX-5
01-38
D155C-1 (–30°C spec.), D155C-1 (–50°C spec.)
01-42
HD325-6, HD405-6
01-39
PC750-6, PC800-6, PC1800-6
01-40
D275A-5 (–50°C spec.)
01-41
01-31 (10)
General
Engine performance curve
S6D140-2 for GD825A-2 Net flywheel horsepower: 209 kW {280 HP}/2,100 rpm Net maximum torque: 1,250 Nm {128 kgm}/1,400 rpm
01-32 (10)
6D140-2 SERIES
General
Engine performance curve
S6D140-2 for WA500-3 Net flywheel horsepower: 236 kW {316 HP}/2,100 rpm Net maximum torque: 1,370 Nm {140 kgm}/1,400 rpm
6D140-2 SERIES
01-33 (10)
General
Engine performance curve
SA6D140-2 for D155A-3, D155AX-3 Net flywheel horsepower: 225 kW {302 HP}/1,900 rpm Net maximum torque: 1,432 Nm {146 kgm}/1,300 rpm
01-34 (10)
6D140-2 SERIES
General
Engine performance curve
SA6D140-2 for PC1600SP-1 Net flywheel horsepower: 316 kW {424 HP}/1,800 rpm Net maximum torque: 1,863 Nm {190 kgm}/1,400 rpm
6D140-2 SERIES
01-35 (10)
General
Engine performance curve
SA6D140-2 for D155A-2 Flywheel horsepower: 253 kW {339 HP}/2,000 rpm (Net) Maximum torque: 1,608 Nm {164 kgm}/1,400 rpm (Net)
01-36 (10)
6D140-2 SERIES
General
Engine performance curve
SA6D140-2 for D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.) Flywheel horsepower: 265 kW {355 HP}/2,000 rpm (Net) Maximum torque: 1,570 Nm {160 kgm}/1,400 rpm (Net)
6D140-2 SERIES
01-37 (10)
General
Engine performance curve
SA6D140-2 for D155AX-5 Flywheel horsepower: 232 kW {320 HP}/1,900 rpm (Net) Maximum torque: 1,610 Nm {164 kgm}/1,250 rpm (Net)
01-38 (10)
6D140-2 SERIES
General
Engine performance curve
SAA6D140-2 for HD325-6, HD405-6 Flywheel horsepower: 379 kW {508 HP}/2,000 rpm (Gross), 364 kW {488 HP}/2,000 rpm (Net) Maximum torque: 2,170 Nm {221 kgm}/1,400 rpm (Gross, Net)
6D140-2 SERIES
01-39 (10)
General
Engine performance curve
SAA6D140-2 for PC750-6, PC800-6, PC1800-6 Flywheel horsepower: 331 kW {444 HP}/1,800 rpm Maximum torque: 2,099 Nm {214 kgm}/1,350 rpm
01-40 (10)
6D140-2 SERIES
General
Engine performance curve
SDA6D140E-2 [For D275A-5 (–50°C spec.)] Rated output: 332 kW {446 HP}/2,000 rpm (Gross) Max. torque: 2,030 Nm {207 kgm}/1,400 rpm (Gross)
6D140-2 SERIES
01-41 (10)
General
Engine performance curve
SA6D140-2 for D155C-1 (–30°C spec.), D155C-1 (–50°C spec.) Flywheel horsepower: 255 kW {342 HP}/2,000 rpm (Gross) Maximum torque: 1,490 Nm {152 kgm}/1,400 rpm (Gross)
01-42 (10)
6D140-2 SERIES
11 Structure and function
Intake and exhaust system Intake and exhaust system ....................... 11- 2 Air cleaner ................................................ 11- 15 Turbocharger ............................................ 11- 18 Aftercooler ................................................ 11- 20 Engine body Cylinder head ........................................... 11Cylinder block ........................................... 11Main circulation system ............................ 11Vibration damper ...................................... 11Timing gear............................................... 11Valve system............................................. 11Flywheel and flywheel housing ................. 11-
24 26 28 30 32 34 36
Lubrication system Lubrication system chart........................... 11Oil pump ................................................... 11Regulator valve and piston cooling valve........................... 11Oil filter ..................................................... 11Oil cooler .................................................. 11-
41 42 46
Fuel system Fuel system chart ..................................... 11Fuel injection pump .................................. 11Feed pump ............................................... 11Fuel injection nozzle ................................. 11Fuel filter ................................................... 11Engine stop motor .................................... 11-
48 50 58 59 60 61
6D140-2 SERIES
38 40
Cooling system Cooling system chart................................ 11Water pump.............................................. 11Thermostat ............................................... 11Corrosion resistor ..................................... 11Corrosion resistor mounting ..................... 11Cooling fan drive ...................................... 11-
66 70 76 77 78 79
Accessory Air compressor ......................................... 11- 88 Exhaust brake .......................................... 11- 91 Electrical system Alternator.................................................. 11- 95 Starting motor ........................................... 11-102 Electrical intake air heater ........................ 11-107 Front PTO mounting................................. 11-108 Front PTO assembly ................................ 11-109 Front PTO drive gear assembly ............... 11- 110
11-1 (10)
Structure and function
Intake and exhaust system
Intake and exhaust system Intake and exhaust system S6D140-2 for WA500-3 a The specifications are subject to change according to modification, etc.
1. Bracket 2. Muffler 3. Check valve (to prevent exhaust gas from 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
11-2 (10)
A. Intake B. Exhaust C. Dust (together with exhaust gas)
6D140-2 SERIES
Structure and function
6D140-2 SERIES
Intake and exhaust system
11-3 (10)
Structure and function
Intake and exhaust system
SA6D140-2 for D155A-3, D155AX-3 (Left side view) a The specifications are subject to change according to modification, etc.
1. 2. 3. 4.
Muffler Air cleaner Aftercooler assembly Connector
11-4 (10)
A. Intake B. Exhaust
6D140-2 SERIES
Structure and function
Intake and exhaust system
SA6D140-2 for D155A-3, D155AX-3 (Right side view) a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5.
O-ring Air cleaner connector Precleaner Turbocharger Seal ring
6D140-2 SERIES
6. 7. 8. 9. 10.
Connector Exhaust manifold (Front) Drain tube Exhaust manifold (Center) Exhaust manifold (Rear)
11-5 (10)
Structure and function
Intake and exhaust system
SA6D140-2 for D155A-3, D155AX-3 (Intake system, front view) a The specifications are subject to change according to modification, etc.
1. Check valve (To prevent exhaust gas from flowing back) 2. Tube 3. Band assembly (air cleaner) 4. Connector (Crossover) 5. Valve 6. Connector 7. Electrical intake air heater 8. Tube (aftercooler – cylinder block)
11-6 (10)
C. Dust (together with exhaust gas)
6D140-2 SERIES
Structure and function
Intake and exhaust system
SA6D140-2 for D155A-3, D155AX-3 (Exhaust system, rear view) a The specifications are subject to change according to modification, etc.
1. 2. 3. 4.
Dust indicator O-ring Connector Tube (cylinder block – aftercooler)
6D140-2 SERIES
11-7 (10)
Structure and function
Intake and exhaust system
SAA6D140-2 for PC750-6, PC800-6 (Left side view) a The specifications are subject to change according to modification, etc.
1. Connector (air-cooled aftercooler – electrical intake air heater) 2. Electrical intake air heater (ribbon type) 3. Connector (electrical intake air heater – intake manifold) 4. Muffler 5. Check valve (to prevent exhaust gas from flowing back) 6. Intake manifold 7. Air cleaner 8. Precleaner
11-8 (10)
A. Intake B. Exhaust C. Dust (together with exhaust gas)
6D140-2 SERIES
Structure and function
Intake and exhaust system
SAA6D140-2 for PC750-6, PC800-6 (Right side view) a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6.
Sensor for dust indicator Intake connector (air cleaner – turbocharger) Turbocharger Exhaust manifold (Front) Exhaust manifold (Center) Exhaust manifold (Rear)
6D140-2 SERIES
11-9 (10)
Structure and function
Intake and exhaust system
SAA6D140-2 for PC750-6, PC800-6 (Front view) a The specifications are subject to change according to modification, etc.
A. Intake air (turbocharger – air cooled aftercooler) B. Intake air (air cooled aftercooler – electrical intake air heater)
11-10 (10)
6D140-2 SERIES
Structure and function
Intake and exhaust system
SAA6D140-2 for PC750-6, PC800-6 (Rear view) a The specifications are subject to change according to modification, etc.
6D140-2 SERIES
11-11 (10)
Structure and function
Intake and exhaust system
SAA6D140-2 for HD325-6 (Left side view) a The specifications are subject to change according to modification, etc.
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 (10)
6D140-2 SERIES
Structure and function
Intake and exhaust system
SAA6D140-2 for HD325-6 (Right side view) a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6.
Exhaust brake (butterfly type) Turbocharger Exhaust connector Exhaust manifold (front) Exhaust manifold (center) Exhaust manifold (rear)
6D140-2 SERIES
A. B. C. D.
Intake Exhaust Intake air (turbocharger – air-cooled aftercooler) Intake air (air-cooled aftercooler – electrical intake air heater)
11-13 (10)
Structure and function
Intake and exhaust system
SAA6D140-2 for HD325-6 (Front view)
SAA6D140-2 for HD325-6 (Rear view)
11-14 (10)
6D140-2 SERIES
Structure and function
Intake and exhaust system
Air cleaner a The specifications may be different from the following figure, depending on the type of machine.
KOMA-CLONE type (Automatic discharge multicyclone type)
1. 2. 3. 4. 5.
Hood Precleaner Air cleaner body Outer element Inner element
Engine model S6D140-2 SA6D140-2 SAA6D140-2
6D140-2 SERIES
A. Air inlet B. To turbocharger (Air) C. To muffler (Dust)
Applicable machine model
Type
Dust discharging method of precleaner
Number of cleaner element
KOMA-CLONE, Multicyclone
Automatic discharge (Exhaust ejector)
Inner element: 1 Outer element: 1
GD825A-2, WA500-3 D155A-2,3, AX-3, AX-5 PC750-6, PC800-6
11-15 (10)
Structure and function
Intake and exhaust system
a The specifications may be different from the following figure, depending on the type of machine.
FHG, FTG type (Cyclopack type) FHG type
1. 2. 3. 4. 5.
Inlet Outlet Guide vane Primary element Safety element
Advantages FTG type The diameter of the element is the same but the outside diameter of the body is smaller. • The inlet is placed in the direction of connection, so ample centrifugal force can be obtained from a simple spiral guide vane, without using a diffusion vane. • The is no dust pan or diffusion vane, so the structure is simple.
11-16 (10)
FTG type
6. 7. 8. 9. 10.
Vacuator Dust pan Diffusion vane (sleeve) Body Element
Structure • Air containing dust is sucked in from inlet (1) at a tangent, and the dust is separated by the centrifugal force of guide vane (3). More than 99.9% of the remaining dust is removed by primary element (4), and the cleaned air then passes through safety element (5) and outlet (2), and is sucked into the engine. The dust and moisture that is separated by guide vane (3) rotates around the inside wall of body (9), and goes inside vacuator (6), where is discharged automatically to the outside.
6D140-2 SERIES
Structure and function
Intake and exhaust system
ERB type a Details may differ according to the machine model.
1. 2. 3. 4.
Precleaner Air cleaner casing Outer element Inner element
Engine SDA6D140E-2
6D140-2 SERIES
A. Intake air port B. To turbocharger (intake air port) C. To muffler (dust)
Machine model
Type
Dust discharge method for precleaner
No. of elements
D275A-5 (–50°C spec.)
Komaclone, multicyclone type (ERB type)
Automatic discharge (exhaust ejector)
Inner cylinder 1, Outer cylinder 1
11-17 (10)
Structure and function
Intake and exhaust system
Turbocharger KTR110 S6D140-2 SA6D140-2 SAA6D140-2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Blower housing V-band Defuser plate Center housing Shroud Turbine housing Blower impeller Seal ring Thrust metal Metal Seal ring Turbine impeller
11-18 (10)
A. B. C. D. E. F. G.
Intake inlet Intake outlet Exhaust inlet Exhaust outlet Oil inlet Oil outlet Cooling water
Turbocharger Type: Overall length: Overall width: Overall height: Weight:
KTR110 284 mm 305 mm 287 mm 22.5 kg
6D140-2 SERIES
Structure and function
Intake and exhaust system
KTR110 (Air-cooled type) SDA6D140E-2 (D275A-5, –50°C spec.)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Blower housing V-band Diffuser plate Center housing Shroud Turbine housing Turbine impeller Seal ring Bearing Thrust bearing Seal ring Blower impeller
6D140-2 SERIES
A. B. C. D. E. F.
Intake inlet Intake outlet Exhaust inlet Exhaust outlet Oil inlet Oil outlet
Specifications Type: Komatsu KTR110L (air-cooled) Overall length: 308 mm Overall width: 305 mm Overall height: 287 mm Weight: 24 kg
11-19 (10)
Structure and function
Intake and exhaust system
Aftercooler (Water-cooled type) SA6D140-2 (For construction machinery, generator) a The specifications may be different from the following figure, depending on the type of machine.
1. Aftercooler cover 2. Aftercooler core 3. Intake manifold
11-20 (10)
A. B. C. D.
Intake air inlet Intake air outlet Water inlet (from cylinder head) Water outlet (to thermostat)
6D140-2 SERIES
Structure and function
Intake and exhaust system
(Air-cooled type) SAA6D140-2 for PC750-6, PC800-6 a The specifications are subject to change according to modification, etc.
1. 2. 3. 4.
Tank Side support Tube Fin
6D140-2 SERIES
a. Intake air port (Turbocharger io Intake manifold)
11-21 (10)
Structure and function
Intake and exhaust system
(Air-cooled type) SAA6D140-2 for HD325-6 a The specifications are subject to change according to modification, etc.
1. 2. 3. 4.
Tank Side support Tube Fin
11-22 (10)
a. Intake air port (Turbocharger io Intake manifold)
6D140-2 SERIES
Structure and function
Engine body
Engine body Cylinder head a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Rocker arm housing mounting bolt Cylinder head mounting bolt Air vent tube Fuel spill pipe Rocker arm housing Cylinder head Rocker arm housing cover Nozzle holder ass’y Nozzle holder retainer Nozzle connecter
11-24 (10)
B. Intake C. Exhaust d. To fuel tank e. To radiator f. To rocker arm (Oil)
6D140-2 SERIES
Structure and function
Engine body
Cylinder head • Direct fuel injection type • 4-valve • Divided type (One cylinder head for one cylinder) • 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 • Floating type seal Fuel injection nozzle • Mount: Dry type (without sleeve)
6D140-2 SERIES
11-25 (10)
Structure and function
Engine body
Cylinder block
1. 2. 3. 4. 5. 6.
Front cover Cylinder block Cylinder liner Crevice seal Liner O-ring Liner O-ring
11-26 (10)
7. 8. 9. 10. 11. 12.
Thrust metal Main metal Main metal cap Main metal cap bolt Front oil seal Piston cooling nozzle
6D140-2 SERIES
Structure and function
Engine body
Cylinder block • Crankshaft: 7 bearings • Camshaft: High cam type, 7 bearings • Main cap mounting bolt: Plastic-area tightening
Cylinder liner • Wet type • Machining of inside wall: Plateau honing, tufftriding
Front oil seal • Single lip with dust seal (Lay-down seal)
Liner seal • Top: Crevice seal • Middle: O-ring (Ethylene propylene rubber) • Bottom: O-ring (Silicon rubber)
Piston cooling • With cooling nozzle
6D140-2 SERIES
11-27 (10)
Structure and function
Engine body
Main circulation system a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7.
Piston (FCD piston) Piston pin Connecting rod, bushing Top ring Second ring Oil ring Pin (Crankshaft pulley)
11-28 (10)
8. 9. 10. 11. 12. 13. 14.
Key (Crankshaft gear) Crankshaft Crankshaft gear (No. of teeth: 36) Connecting rod metal Connecting rod cap Connecting rod Connecting rod cap mounting bolt
6D140-2 SERIES
Structure and function
Crankshaft Stamp forging Journal and filet portion: Induction hardening Piston Ductile cast iron (FCD piston) Re-entrant piston Connecting rod Stamp forging Cap bolt is of screw-in type and tightened by plasticarea tightening and has lubricating oil hole.
6D140-2 SERIES
Engine body
Piston ring Top ring
Both faces keystone Barrel face Hard chrome plating
Second ring
Both faces keystone inner cut Tapered face Hard chrome plating
Oil ring
M-shape steel ring Hard chrome plating with coil expander
11-29 (10)
Structure and function
Engine body
Vibration damper a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4.
Crankshaft pulley Pin (Crankshaft pulley – vibration damper) Vibration damper Pin (Crankshaft – crankshaft pulley)
11-30 (10)
6D140-2 SERIES
Structure and function
Engine body
Timing gear a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7.
Water pump drive gear Sub idler gear Main idler gear (Large) Main idler gear (Small) Camshaft gear PTO gear (Option) Compressor drive gear
11-32 (10)
(No. of teeth: 23) (No. of teeth: 42) (No. of teeth: 60) (No. of teeth: 40) (No. of teeth: 48) (No. of teeth: 14) (No. of teeth: 24)
8. 9. 10. 11.
Fuel injection pump drive gear PTO gear (Option) Crankshaft gear Oil pump drive gear
(No. of teeth: 48) (No. of teeth: 22) (No. of teeth: 36) (No. of teeth: 22)
A, B, C: Match marks
6D140-2 SERIES
Structure and function
6D140-2 SERIES
Engine body
11-33 (10)
Structure and function
Engine body
Valve system a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Thrust plate Camshaft gear (No. of teeth: 48) Camshaft Cam roller Cam roller pin Cam follower shaft Cam follower Push rod Rocker arm shaft Rocker arm Locknut
11-34 (10)
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Rocker arm adjustment screw Crosshead adjustment screw Locknut Crosshead Valve retainer Outer valve spring Inner valve spring Exhaust valve Valve guide Spring seat Intake valve
6D140-2 SERIES
Structure and function
Camshaft • Drawn steel bar (Turned) • Journal and filet portion: Induction hardening
6D140-2 SERIES
Engine body
Valve timing
11-35 (10)
Structure and function
Engine body
Flywheel and flywheel housing Without PTO type a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4.
Ring gear (No. of teeth: 148) Flywheel Rear oil seal (Lay-down lip seal) Flywheel housing
For marine engine: Eight flywheel mounting bolts
11-36 (10)
6D140-2 SERIES
Structure and function
Lubrication system
Lubrication system Lubrication system chart a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Oil pan Oil strainer Oil pump Main relief valve Oil cooler Thermostat Regulator valve Valve adapter Oil filter Safety valve Crankshaft
11-38 (10)
12. 13. 14. 15. 16. 17. 18. 19. 20.
Piston cooling nozzle Piston Camshaft Cam follower Rocker arm Intake and exhaust valve Timing gears Turbocharger (S6D140, SA6D140, SAA6D140) Fuel injection pump
W: Cooling water
6D140-2 SERIES
Structure and function
Lubrication system
Large capacity oil filter + bypass filter a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Oil pan Oil strainer Oil pump Main relief valve Oil cooler Thermostat Regulator valve Valve adapter Oil filter (full-flow filter x 2) Safety valve Crankshaft Piston cooling nozzle
6D140-2 SERIES
13. 14. 15. 16. 17. 18. 19. 20. 21.
Piston Camshaft Cam follower Rocker arm Intake and exhaust valve Timing gears Turbocharger Fuel injection pump Bypass filter (Installed to depending on the model)
W: Cooling water
11-39 (10)
Structure and function
Lubrication system
Oil pump a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6. 7.
Pump cover Drive gear Pump body Pump drive gear (No. of teeth: 22) Valve spring Main relief valve Driven gear
Oil pump • Type: Gear pump • Pump speed: Engine speed x 1.64 Main relief valve • Set pressure: 0.78 ± 0.05 MPa {8.0 ± 0.5 kg/cm2}
A. Suction (From oil pan) B. Discharge (To oil cooler)
11-40 (10)
6D140-2 SERIES
Structure and function
Lubrication system
Regulator valve and piston cooling valve a The specifications are subject to change according to modification, etc.
1. Valve body 2. Valve spring 3. Valve
Regulator valve • Valve opening pressure: 0.3 ± 0.02 MPa {3.2 ± 0.2 kg/cm2}
a. b. c. d. e. f.
Piston cooling valve • Valve opening pressure: 0.14 ± 0.02 MPa {1.4 ± 0.2 kg/cm2}
From oil cooler To oil filter From oil filter To main gallery To piston cooling nozzle To oil pan (drain)
6D140-2 SERIES
11-41 (10)
Structure and function
Lubrication system
Oil filter S6D140-2 SA6D140-2 SAA6D140-2 a The specifications may be different from the following figure, depending on the type of machine.
1. Filter head 2. Safety valve 3. Cartridge A. Oil inlet B. Oil outlet
Oil filter • Filtration area: 0.84 m2 (Rated flow 160 l/min) For construction machinery, generator (Rated flow 240 l/min) For marine engine Safety valve • Set pressure: 0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2}
11-42 (10)
6D140-2 SERIES
Structure and function
Lubrication system
SDA6D140E-2 (D275A-5, –50°C spec.) a The shape may differ according to the machine model.
1. Safety valve 2. Filter head 3. Cartridge A. Oil inlet B. Oil outlet
6D140-2 SERIES
Oil filter • Filtering area: 0.42 m2 (Full-flow) Safety valve • Cracking pressure: 245 ± 19 kPa {2.5 ± 0.2 kg/cm2}
11-43 (10)
Structure and function
Lubrication system
Large capacity oil filter a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6.
Filter head Safety valve Filter connector Cover Alarm assembly Cartridge
A. Oil inlet B. Oil outlet Oil filter • Filtration area:1.8 m2 (0.9 m2 x 2) • Rated flow: 180 l/min. Safety valve • Set pressure: 0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2}
11-44 (10)
6D140-2 SERIES
Structure and function
Lubrication system
Large capacity oil filter + bypass filter a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7.
Filter head Safety valve Filter connector Cover Alarm assembly Cartridge (Bypass filter) Cartridge (Full-flow filter)
A. Oil inlet B. Oil outlet Oil filter • Filtration area:1.8 m2 (0.9 m2 x 2) • Rated flow: 180 l/min. Safety valve • Set pressure: 0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2} Bypass filter • Filtration area:1.4 m2 • Rated flow: 7.5 l/min.
6D140-2 SERIES
11-45 (10)
Structure and function
Lubrication system
Oil cooler a The specifications are subject to change according to modification, etc.
1. Cooler cover 2. Cooler element 6D140-2 : 10 cores S6D140-2 : 10 cores SA6D140-2 : 12 cores SAA6D140-2 : 12 cores SDA6D140E-2: 12 cores 3. Thermostat 4. Spring 5. Thermostat cover
Thermostat function • Valve cracking temperature: • Full opening temperature: • Full opening lift:
85 ± 1.5°C 100°C Min. 8 mm
Oil cooler • Effective area: 6D140-2 : 0.822 m2 S6D140-2 : 0.822 m2 SA6D140-2 : 0.986 m2 SAA6D140-2 : 0.986 m2 SDA6D140E-2: 0.986 m2
A. Oil inlet B. Oil outlet C. Cooling water
11-46 (10)
6D140-2 SERIES
Structure and function
Fuel system
Fuel system Fuel system chart a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8.
Fuel tank Gauze filter Priming pump Feed pump Fuel filter Fuel injection pump Fuel injection nozzle Over-flow valve
11-48 (10)
6D140-2 SERIES
Structure and function
Fuel system
a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8.
Fuel tank Gauze filter Priming pump Feed pump Fuel filter Fuel injection pump Fuel injection nozzle Over-flow valve
6D140-2 SERIES
11-49 (10)
Structure and function
Fuel system
Fuel injection pump SA6D140-2 (D155A-3, D155AX-3, D155AX-5, D155C-1 (–30°C spec., –50°C spec.), D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.)) a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6. 7. 8.
Fuel injection pipe (No. 1) Fuel injection pipe (No. 2) Fuel injection pipe (No. 3) Fuel injection pipe (No. 4) Fuel injection pipe (No. 5) Fuel injection pipe (No. 6) Boost compensator tube Fuel injection pump drive gear (No. of teeth 48)
11-50 (10)
9. 10. 11. 12. 13. 14. 15.
Fuel injection pump drive shaft Bearing box Coupling Oil inlet pipe Feed pump Fuel injection pump (With boost compensator) Oil outlet pipe
6D140-2 SERIES
Structure and function
a: Fuel inlet b: To fuel filter c: From fuel filter d: To fuel injection nozzle e: Fuel return (Over-flow valve – Fuel tank) f: Fuel spill (Nozzle – Fuel tank) g: Engine oil (To fuel injection pump) h: Engine oil (To engine oil pan)
6D140-2 SERIES
Fuel system
Fuel injection pump • Maker: BOSCH automotive system • Type: Bosch PE-P • Lubrication method: Forced lubrication with engine oil Governor • Type: Made by BOSCH automotive system, Bosch RSUV Centrifugal, all speed type
11-51 (10)
Structure and function
Fuel system
SAA6D140-2 (PC750-6, PC800-6) a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6. 7.
Fuel injection pipe (No. 1) Fuel injection pipe (No. 2) Fuel injection pipe (No. 3) Fuel injection pipe (No. 4) Fuel injection pipe (No. 5) Fuel injection pipe (No. 6) Boost compensator tube
11-52 (10)
8. 9. 10. 11. 12. 13. 14.
Fuel injection pump drive gear (No. of teeth 48) Fuel injection pump drive shaft Bearing box Coupling Feed pump Fuel injection pump (With boost compensator) Oil outlet pipe
6D140-2 SERIES
Structure and function
a: b: c: d: e: f: g:
Fuel inlet To fuel filter From fuel filter To fuel injection nozzle Fuel return (Over-flow valve – Fuel tank) Engine oil (To fuel injection pump) Engine oil (To engine oil pan)
6D140-2 SERIES
Fuel system
Fuel injection pump • Maker: BOSCH automotive system • Type: Bosch PE-P • Lubrication method: Forced lubrication with engine oil Governor • Type: Bosch RSUV Centrifugal, all speed type
11-53 (10)
Structure and function
Fuel system
SAA6D140-2 (HD325-6)
1. 2. 3. 4. 5. 6. 7. 8.
Fuel injection pipe (No. 1) Fuel injection pipe (No. 2) Fuel injection pipe (No. 3) Fuel injection pipe (No. 4) Fuel injection pipe (No. 5) Boost compensator tube Fuel injection pipe (No. 6) Fuel injection pump drive gear (No. of teeth 48)
11-54 (10)
9. 10. 11. 12. 13. 14. 15.
Fuel injection pump drive shaft Bearing box Coupling Oil outlet pipe Feed pump Oil inlet pipe Fuel injection pump
6D140-2 SERIES
Structure and function
Fuel injection pump • Maker: BOSCH automotive system • Type: Bosch PE-P • Lubrication method: Forced lubrication with engine oil
6D140-2 SERIES
Fuel system
Governor • Type: Made by BOSCH automotive system, Bosch RFD Centrifugal, max. – min. speed control type
11-55 (10)
Structure and function
Fuel system
SDA6D140E-2 (D275A-5, –50°C spec.) a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6. 7. 8.
Fuel injection pipe (No. 1) Fuel injection pipe (No. 2) Fuel injection pipe (No. 3) Fuel injection pipe (No. 4) Fuel injection pipe (No. 5) Fuel injection pipe (No. 6) Boost compensator tube Oil inlet pipe
11-56 (10)
9. 10. 11. 12. 13. 14. 15.
Oil outlet pipe Fuel injection pump (With boost compensator) Feed pump Coupling Bearing box Fuel injection pump drive shaft Fuel injection pump drive gear (No. of teeth: 48)
6D140-2 SERIES
Structure and function
Fuel injection pump • Maker: BOSCH automotive system • Type: Bosch PE-P • Lubrication method: Forced lubrication with engine oil
6D140-2 SERIES
Fuel system
Governor • Type: Made by BOSCH automotive system, Bosch RFD Centrifugal, max. – min. speed control type
11-57 (10)
Structure and function
Fuel system
Feed pump a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Cover Priming pump Spring Check valve (intake) Eyebolt Plug Piston spring Piston Push rod Tappet Check valve (exhaust)
Functions • The feed pump sucks fuel from the fuel tank and supplies (discharge) it through the fuel filter to the injection pump. • This feed pump also has the function to maintain the discharge pressure (rate) at constant 0.1 – 0.2 MPa {1 – 2 kg/cm2} to set the fuel injection rate of the injection pump (quantity of fuel injected by each stroke) constant.
A. Fuel inlet B. Fuel outlet
11-58 (10)
6D140-2 SERIES
Structure and function
Fuel system
Fuel injection nozzle a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Fuel inlet connector Nozzle holder Adjustment shim Spring Seat Spacer Nozzle Retaining cap Nozzle needle
a. Fuel inlet (From injection pump) b. Injection (To cylinder) c. Fuel return (To fuel tank)
6D140-2 SERIES
Fuel injection nozzle S6D140-2: Made by BOSCH automotive system Diameter of nozzle hole 0.35 x 7 hole) SA6D140-2: Made by BOSCH automotive system (Diameter of nozzle hole 0.36 x 6 hole) SAA6D140-2: Made by BOSCH automotive system (Diameter of nozzle hole 0.36 x 6 hole) • • •
Type: Multi-hole type Injection pressure:24.5 MPa {250 kg/cm2} Adjusting INJECTION pressure: Shim adjusting type
11-59 (10)
Structure and function
Fuel system
Fuel filter a The specifications may be different from the following figure, depending on the type of machine.
1. Filter head 2. Air bleed plug 3. Cartridge
Fuel filter • Filtration area: 1.0 m2
a. Fuel inlet b. Fuel outlet
11-60 (10)
6D140-2 SERIES
Structure and function
Fuel system
Engine stop motor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Motor assembly Cover Cable assembly Cable clamp Coil spring Cable Screw Breather Bracket assembly Cover assembly
6D140-2 SERIES
Engine stop motor • Maker: Jidosha Denki Kogyo Co. Ltd • Rated voltage: DC24V • Operating force: 147 N {15 kg} min. • •
Stroke: Weight:
35 +1.0 mm –0.4 1.2 kg
11-61 (10)
Structure and function
Fuel system
Structural drawing (1)
1. 2. 3. 4. 5. 6. 7. 8.
Gear cover assembly Slider assembly Armature shaft Contactor assembly Roller Worm wheel assembly Motor assembly Gear case assembly
11-62 (10)
6D140-2 SERIES
Structure and function
Fuel system
Structural drawing (2)
1. 2. 3. 4. 5.
Gear cover assembly Motor assembly Cable clamp Cable assembly Gear case assembly
6D140-2 SERIES
11-63 (10)
Structure and function
Fuel system
Description of operation and circuits 1. Stop condition (0° or 360°)
The above drawing shows the stopped condition when a closed circuit has been formed. The slider assembly is stopped at the auto-stop position on the P1 side. 2. When switch is turned (When starting the motor)
When the switch is moved to the P2 side (starting switch ON), an electric current flows from the plus side contact plate through the P2 auto-stop terminal and switch and into the armature shaft assembly, thereby starting the motor. The slider assembly starts to move in the direction of the arrow at the same time as the roller starts to move. 3. Turning condition (90° in the drawing)
Electric current continues to pass through the armature assembly and the motor continues to turn. Because of the rotation of the roller, the slider assembly also continues to move in the direction of the arrow.
11-64 (10)
6D140-2 SERIES
Structure and function
Fuel system
4. When stopped (180°)
A closed circuit is formed when the P2 auto-stop terminal rides on the minus-side contactor plate, and the motor comes to a sudden stop. The slider assembly also stops. 5. When switch is turned (When starting the motor)
When the switch is moved to the P1 side (starting switch OFF), an electric current flows from the plus contactor plate through the P1 auto-stop terminal and switch and into the armature shaft assembly, thereby starting the motor. The slider assembly starts to move in the direction of the arrow at the same time as the roller starts to move. 6. Turning condition (270° in the drawing)
Electric current continues to pass through the armature shaft assembly and the motor continues to turn. The slider assembly also continues to move in the direction of the arrow. Then the circuit returns to stop condition 1.
6D140-2 SERIES
11-65 (10)
Structure and function
Cooling system
Cooling system Cooling system chart For construction machinery, generator
1. 2. 3. 4. 5. 6. 7. 8.
Radiator Thermostat Water-cooled aftercooler (SA6D140-2) Oil cooler Water pump Air compressor Cooling fan Corrosion resistor
A. Oil inlet and outlet
11-66 (10)
6D140-2 SERIES
Structure and function
Cooling system
SDA6D140E-2 (D275A-5, –50°C spec.)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Radiator Radiator (small type) Thermostat Water-cooled aftercooler Corrosion resistor Oil cooler Water pump Air compressor Cooling fan Corrosion resistor (for aftercooler) Water pump (for aftercooler)
A. Oil inlet and outlet
6D140-2 SERIES
11-67 (10)
Structure and function
Cooling system
For marine engine
1. 2. 3. 4. 5. 6. 7. 8. 9.
Sea water aftercooler Water level sensor Fresh water tank Thermostat Water-cooled exhaust manifold Water thermometer Oil cooler Water pump Water temperature rise alarm switch
11-68 (10)
10. 11. 12. 13. 14.
Heat exchanger Marine gear oil cooler Spare sea water pump Sea water pump Kingston cock
A. Engine oil inlet, outlet B. Marine gear oil inlet, outlet C. Air inlet, outlet
6D140-2 SERIES
Structure and function
Cooling system
Water pump Mounting S6140-2 SA6D140-2 SAA6D140-2 (PC750-6, PC800-6)
1. Oil cooler 2. Thermostat housing 3. Water pump
11-70 (10)
A. From radiator outlet (Cooling water) From heat exchanger outlet (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)
6D140-2 SERIES
Structure and function
Cooling system
SA6D140-2
(D155A-3, D155AX-3, D155AX-5, D155C-1 (–30°C spec., –50°C spec.), D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.)) SDA6D140E-2 (D275A-5, –50°C spec.)
1. Oil cooler 2. Thermostat housing 3. Water pump
6D140-2 SERIES
A. From radiator outlet (Cooling water) B. Via oil cooler to each portion of engine (Cooling water) C. To radiator (Cooling water) D. To oil cooler on machine (Cooling water) E. From oil pump (Oil) F. To each portion of engine (Oil)
11-71 (10)
Structure and function
Cooling system
SAA6D140-2 (HD325-6) a The specifications are subject to change according to modification, etc.
1. Oil cooler 2. Thermostat housing 3. Water pump
11-72 (10)
A. From radiator outlet (Cooling water) B. Via oil cooler to each portion of engine (Cooling water) C. To radiator (Cooling water) D. To oil cooler on machine (Cooling water) E. From oil pump (Oil) F. To each portion of engine (Oil)
6D140-2 SERIES
Structure and function
Cooling system
SDA6D140E-2 (D275A-5, –50°C spec.) For aftercooler
1. Tube 2. Tube 3. Water pump
6D140-2 SERIES
A. From water pump to aftercooler
11-73 (10)
Structure and function
Cooling system
S6D140-2 SA6D140-2 SAA6D140-2 SDA6D140E-2 (D275A-5, –50°C spec.)
1. 2. 3. 4. 5. 6. 7. 8. 9.
Alternator drive pulley Oil seal Ball bearing Pump shaft Water pump drive gear (No. of teeth: 23) Pump body Water seal Impeller Pump cover
Water pump • Type: • Water pump speed : • Flow capacity: • Total water head:
Centrifugal, gear-driven Engine speed x 1.56 800 l/min. 14 m
a. From radiator b. To oil cooler
11-74 (10)
6D140-2 SERIES
Structure and function
Cooling system
For aftercooler SDA6D140E-2 (D275A-5, –50°C spec.)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Pump shaft Water pump drive gear (No. of teeth: 19) Spacer Seal ring Ball bearing Spacer Ball bearing Gasket Impeller Water seal Plate
Water pump • Type: Centrifugal, gear-driven • Water pump speed :Engine speed x 1.26 • Flow capacity: 120 l/min. • Total water head: 3 m
a. From radiator b. To aftercooler
6D140-2 SERIES
11-75 (10)
Structure and function
Cooling system
Thermostat a The specifications may be different from the following figure, depending on the type of machine model.
1. Cylinder block 2. Thermostat housing 3. Thermostat A. To radiator To heat exchanger (For marine engines) B. To water pump To Brake cooler (HD325) To oil cooler on machine body (D155A-3, D155AX-3)
11-76 (10)
Thermostat • Valve opening temperature: 76.5 ± 2°C (For construction machine and generator) 82 ± 2°C (For marine engines) • Fully opening temperature: 90°C • Lift and fully opening position:10 mm min.
6D140-2 SERIES
Structure and function
Cooling system
Corrosion resistor a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6.
Head Cartridge Element Inhibitor (Solid corrosion preventive agent) Spring Stop valve
a. Water inlet b. Water outlet
6D140-2 SERIES
Corrosion resistor • Filtration area: 6D140-2: 0.13 m2 SA6D140, S6D140-2: 0.13 m2 SAA6D140, SA6D140-2: 0.373 m2 • Quantity of corrosion preventive agent: 6D140-2: 400 g SA6D140, S6D140-2: 400 g SAA6D140, SA6D140-2: 1,000 g
11-77 (10)
Structure and function
Cooling system
Corrosion resistor mounting a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5.
Bracket Hose (return from corrosion resistor) Valve Corrosion resistor cartridge Hose (to corrosion resistor)
11-78 (10)
6D140-2 SERIES
Structure and function
Cooling system
Cooling fan drive Tension pulley mount S6D140-2 for WA500-3 a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4.
Fan pulley Tension pulley (Outside diameter: 120mm) Crank pulley (Outside diameter: 164 mm) Fan belt
6D140-2 SERIES
11-79 (10)
Structure and function
Cooling system
Tension pulley mount SA6D140-2 for D155A-3, D155AX-3, D155AX-5 a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4.
Fan pulley Tension pulley Crank pulley (Outside diameter: 200 mm) Fan belt
11-80 (10)
Fan pulley Outside diameter (mm)
Applicable machine
295
D155A-3, D155AX-3, D155AX-5
316
D155A-3, D155AX-3 (Scraper spec.)
6D140-2 SERIES
Structure and function
Cooling system
Tension pulley SA6D140-2 (D155A-3, D155AX-3, D155AX-5) a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Bracket Spacer Ball bearing Tension pulley (Outside diameter: 118 mm) Oil seal Inner race Needle bearing Coil spring Tension shaft
6D140-2 SERIES
11-81 (10)
Structure and function
Cooling system
SAA6D140-2 (PC750-6, PC800-6) a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6.
Fan pulley Fan belt Crank pulley Tension pulley Tension shaft Tension spring
11-82 (10)
Pulley outside diameter Unit: mm Model PC750-6 PC800-6
Fan pulley
Crank pulley
Tension pulley
280
164
118
6D140-2 SERIES
Structure and function
Cooling system
Tension pulley SAA6D140-2 (PC750-6, PC800-6) a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8.
Tension shaft Roller bearing Tension bracket Oil seal Tension pulley (Outside diameter: 118 mm) Ball bearing Spacer Stopper
6D140-2 SERIES
11-83 (10)
Structure and function
Cooling system
SAA6D140-2 for HD325-6, HD405-6 a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5.
Tension pulley (Outside diameter: 118 mm) Fan pulley Fan mount case Fan belt Crank pulley (Outside diameter: 164 mm)
Fan pulley Outside diameter (mm)
Applicable machine
275
HD325-6, HD405-6
a. Wind direction
11-84 (10)
6D140-2 SERIES
Structure and function
Cooling system
Tension pulley SAA6D140-2 for HD325-6, HD405-6 a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7.
Bracket Spacer Ball bearing Tension pulley (Outside diameter: 118 mm) Bearing Coil spring Tension shaft
6D140-2 SERIES
11-85 (10)
Structure and function
Cooling system
Fan mount case SAA6D140-2 for HD325-6, HD405-6 a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4.
Fan pulley hub Ball bearing Shaft Case
11-86 (10)
6D140-2 SERIES
Structure and function
Accessory
Accessory Air compressor (Installed depending on the model)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Crankshaft Crankcase Connecting rod Cylinder Piston Piston ring Piston pin Bearing cover Cylinder head Unloader valve
11-88 (10)
a. b. c. d. e. f.
Air intake Air exhaust Unloader Oil inlet Cooling water inlet or outlet Cooling water outlet or inlet
6D140-2 SERIES
Structure and function
Air compressor • Maker: • Type: • • •
ZEXEL Single cylinder, reciprocated type Discharge volume: 340 cc/rev. Air pressure: 834 kPa {8.5 kg/cm2} (at full load) Weight: 11 kg
6D140-2 SERIES
Accessory
Unloader valve • Valve opening pressure: 618 kPa {6.3 kg/cm2} • Valve shutting pressure: 530 kPa {5.4 kg/cm2}
11-89 (10)
Structure and function
Accessory
Air compressor mounting a The specifications may be different from the following figure, depending on the type of machine.
1. Air compressor 2. PTO case 3. Compressor drive gear (No. of teeth: 24) a. b. c. d. e. f. g.
From intake manifold (air) Exhaust (air) From air governor to unloader (air) From cylinder block (cooling water) To cylinder block (cooling water) From cylinder block (oil inlet) To cylinder block (oil outlet)
11-90 (10)
6D140-2 SERIES
Structure and function
Accessory
Exhaust brake Slide valve type a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Valve housing Gate valve Guide bushing Cylinder Spring Spring Piston Retainer Release valve Packing Packing Exhaust pressure adjustment bolt Breather
6D140-2 SERIES
Outline An exhaust brake is installed between the turbocharger and muffler, and works due to the air pressure from the solenoid valve, reducing engine speed by throttling the exhaust passage of the muffler from the turbocharger. The exhaust brake consists of a valve mechanism and an air cylinder which controls the valve.
11-91 (10)
Structure and function
Accessory
Butterfly valve type a The specifications are subject to change according to modification, etc.
1. 2. 3. 4. 5. 6. 7. 8.
Air cylinder Stopper bolt (fully open) Stopper bolt (fully close) Lever Yoke Insulator Bushing Spindle
11-92 (10)
9. 10. 11. 12. 13.
Valve Spindle Bushing Valve body Cover
a: From exhaust brake valve
6D140-2 SERIES
Structure and function
Accessory
Solenoid valve for exhaust brake a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Connector Case Core Coil assembly Spring Plunger Spring Valve Rod Body
6D140-2 SERIES
A. From air tank B. To exhaust brake C. Exhaust outlet
11-93 (10)
Structure and function
Accessory
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.
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 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 , and butterfly valve (7) fully closes the path from the turbocharger to the muffler. Accordingly, the engine 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 the engine brake will not be applied even if the switch is turned on.
11-94 (10)
6D140-2 SERIES
Structure and function
Electrical system
Electrical system Alternator Mounting a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7.
Alternator Adjust rod Nut (2 pieces) Plate Cover V-belt (2 pieces) Spacer
6D140-2 SERIES
a. Alternator pulley (Pulley O.D. 85 mm) b. Alternator drive pulley (Pulley O.D. 132 mm)
11-95 (10)
Structure and function
Electrical system
Alternator with built-in regulator (Open type 35A) a The shape may differ according to the machine model.
1. 2. 3. 4. 5.
Alternator Alternator pulley Terminal B Terminal R Terminal E
6. Internal electric circuit diagram 6A. Primary energized resistance 6B. Regulator 6C. Field coil
Engine model
Applicable machine model
Type
Specification
Pulley O.D. (mm)
Weight (kg)
Pulley type
S6D140-2
WA500-3
Maker: NIKKO DENKI Type: Opened (Brushless)
24 V, 35 A
85
9.5
I
SA6D140-2
D155A-3, AX-3, AX-5
Maker: NIKKO DENKI Type: Opened (Brushless)
24 V, 35 A
85
9.5
I
11-96 (10)
6D140-2 SERIES
Structure and function
Electrical system
Alternator with built-in regulator (Open type) a The shape may differ according to the machine model.
1. 2. 3. 4.
Alternator Alternator pulley Terminal R Terminal E
Engine model
Applicable machine model
Specification
Pulley O.D. (mm)
Weight (kg)
Maker: NIKKO DENKI Type: Opened (Brushless)
24 V, 35 A
85
9.5
D155A-3, AX-3, D355C-3, Maker: NIKKO DENK D355C-3 (–30°C spec.) Type: Opened (Brushless)
24 V, 35 A
85
9.5
Maker: NIKKO DENKI Type: Opened (Brushless)
24 V, 25 A
85
8.5
Maker: NIKKO DENKI Type: Opened (Brushless)
24 V, 30 A
85
9.5
S6D140-2 SA6D140-2
5. Terminals B 6. Internal electric circuit diagram 6A. Field coil 6B. Regulator
SAA6D140-2
6D140-2 SERIES
Type
11-97 (10)
Structure and function
Electrical system
Alternator with built-in regulator (Open type 50A) a The shape may differ according to the machine model.
1. 2. 3. 4. 5.
Alternator Alternator pulley Terminal B Terminal E Terminal R
Engine model S6D140-2 SA6D140-2 SAA6D140-2
11-98 (10)
6. Internal electric circuit diagram 6A. Alternator 6B. Regulator
Applicable machine model
Type
Specification
Pulley O.D. (mm)
Weight (kg)
Pulley type
GD825A-2
Maker: SAWAFUJI DENKI Type: Opened (Brushless)
24 V, 50 A
85
12
II
D155A-3, AX-3, AX-5 (if Maker: SAWAFUJI DENKI equipped) Type: Opened (Brushless)
24 V, 50 A
85
12
II
24 V, 50 A
85
12
II
PC750-6, PC800-6 HD325-6, HD405-6
Maker: SAWAFUJI DENKI Type: Opened (Brushless)
6D140-2 SERIES
Structure and function
Electrical system
Alternator with built-in regulator (Open type 50A) a The shape may differ according to the machine model.
1. 2. 3. 4. 5.
Alternator Alternator pulley Terminal B Terminal R Terminal E
Engine model
SA6D140-2
Applicable machine model
6. Internal electric circuit diagram 6A. Primary energized resistance 6B. Regulator 6C. Field coil
Type
D155C-1 (–30°C spec.) D155C-1 (–50°C spec.) Maker: NIKKO DENKI D355C-3 Type: Opened (Brushless) D355C-3 (–30°C spec.) D355C-3 (–50°C spec.)
6D140-2 SERIES
Specification
Pulley O.D. (mm)
Weight (kg)
Pulley type
24 V, 50 A
85
11.0
I
11-99 (10)
Structure and function
Electrical system
Alternator with built-in regulator (Open type 75A) a The shape may differ according to the machine model.
1. 2. 3. 4.
Alternator Alternator pulley Terminal B Terminal R
Engine
Machine model
SDA6D140E-2 D275A-5 (–50°C spec.)
11-100 (10)
5. Internal electric circuit diagram 5A. Alternator 5B. Regulator
Type
Specification
Outside diameter of pulley (mm)
Weight (kg)
Sawafuji Denki Open type (brushless)
24 V, 75 A
85
12.5
6D140-2 SERIES
Structure and function
Electrical system
Starting motor For 7.5 kW a The shape may differ according to the machine model.
1. 2. 3. 4. 5. 6. 7.
Pinion gear Starting motor assembly Magnetic switch Safety relay Terminal B Terminal C External wiring diagram (2-pin connector type) 7A. Safety relay portion 7B. Starting motor portion
11-102 (10)
8. External wiring diagram (3-pin connector type) 8A. Safety relay portion 8B. Starting motor portion S. To starting switch terminal C R. To alternator terminal R E. To ground
6D140-2 SERIES
Structure and function
Engine model
Applicable machine model
Electrical system
Type
Specification
Pulley O.D. (mm)
Weight (kg)
Connector type
S6D140-2
Maker: NIKKO DENKI Type: Closed 24 V, 7.5 kW (drip-proof, oil proof)
12
18
SA6D140-2
Maker: NIKKO DENKI Type: Closed 24 V, 7.5 kW (drip-proof, oil proof)
12
18
B
Maker: NIKKO DENKI Type: Closed 24 V, 7.5 kW (drip-proof, oil proof)
12
18
C
SAA6D140-2
PC750-6, PC800-6
6D140-2 SERIES
11-103 (10)
Structure and function
Electrical system
For 11 kW a The shape may differ according to the machine model.
1. 2. 3. 4. 5. 6. 7. 8.
Starting motor assembly Magnetic switch Safety relay Pinion gear Terminal B Terminal C Connector External wiring diagram (2-pin connector type) 8A. Control unit
11-104 (10)
9. External wiring diagram (3-pin connector type) 9A. Control unit 10. External wiring diagram (without safety relay) S. To starting switch terminal C R. To alternator terminal R E. To ground
6D140-2 SERIES
Structure and function
Engine model
Number of pinion teeth
Weight (kg)
Connector type
Maker: SAWAFUJI DENKI 24 V, 11 kW Type: Closed (drip-proof, oil proof) 24 V, 11 kW
11
20
B
11
20
C
24 V, 11 kW
11
20
C
D155C-1 (–30°C spec.) Maker: SAWAFUJI DENKI D155C-1 (–50°C spec.) Type: Closed (drip-proof, oil proof) 24 V, 11 kW D355C-3 D355C-3 (–30°C spec.) D355C-3 (–50°C spec.)
11
20
C
11
20
C
Applicable machine model GD825A-2
S6D140-2
WA500-3 D155A-2,3, AX-3, AX-5 (X type connector)
SA6D140-2
Electrical system
HD325-6, HD405-6 SAA6D140-2
6D140-2 SERIES
Type
Specification
Maker: SAWAFUJI DENKI 24 V, 11 kW Type: Closed (drip-proof, oil proof)
11-105 (10)
Structure and function
Electrical system
For 11 kW a The shape may differ according to the machine model.
1. 2. 3. 4. 5. 6.
Pinion gear Starting motor assembly Magnetic switch Terminal B Terminal C Safety relay
Engine
Machine model
SDA6D140E-2 D275A-5 (–50°C spec.)
11-106 (10)
7. External wiring diagram (2-pin connector type) 7A. Safety relay portion 7B. Starting motor portion S. To starting switch terminal C R. To alternator terminal R E. To ground
Type Nikko Denki Waterproof, oilproof type
Specification
No. of pinion teeth
Weight (kg)
Connector type
24 V, 11 kW
12
18
B
6D140-2 SERIES
Structure and function
Electrical system
Electrical intake air heater S6D140-2 a The specifications may be different from the following figure, depending on the type of machine.
1. Heater body 2. Heater coil
Electrical intake air heater • Rated voltage: DC22 V • Rated current: 175 A
SA6D140-2 SDA6D140E-2 (D275A-5, –50°C spec.)
1. Heater body 2. Heater coil 3. Terminal
6D140-2 SERIES
Electrical intake air heater • Rated voltage: DC11 V • Rated current: 86 A
11-107 (10)
Structure and function
Electrical system
Front PTO mounting a The specifications may be different from the following figure, depending on the type of machine.
1. Front PTO 2. O-ring 3. Front PTO drive gear assembly
11-108 (10)
6D140-2 SERIES
Structure and function
Electrical system
Front PTO assembly a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Shaft Pulley Oil seal Bearing (2 pieces) Housing O-ring Gear (No. of teeth: 14) Snap ring Sleeve
6D140-2 SERIES
11-109 (10)
Structure and function
Electrical system
Front PTO drive gear assembly a The specifications may be different from the following figure, depending on the type of machine.
1. 2. 3. 4. 5. 6.
Gear (No of teeth: 24) Snap ring Pin Plate Bolt Flange
11-110 (10)
7. 8. 9. 10. 11.
Gasket O-ring Bearing (2 pieces) Housing Shaft
6D140-2 SERIES
12 Testing and adjusting
Mounting (adjusting) method of engine speed sensor............................... 12-
2
Engine body Adjusting valve clearance......................... 12Measuring compression pressure ............ 12-
3 4
Fuel system Testing and adjusting fuel injection timing .................................. 12Adjusting fuel injection pressure............... 12Procedure for adjusting engine stop motor cable ............................... 12Cooling system Checking and adjusting fan belt tension... 12-
5 6 7 9
Fuel injection pump calibration data .............. 12- 10 Performance test ........................................... 12- 26 Run-in standard........................................ 12- 26 Performance test criteria .......................... 12- 32 Troubleshooting ............................................. 12- 41 Points to remember when troubleshooting ....................................... 12- 43 Method of using troubleshooting charts......... 12- 44 Testing and adjusting tool list......................... 12- 67 Testing and adjusting data ............................. 12- 68
6D140-2 SERIES
12-1 (10)
Testing and adjusting
Mounting (adjusting) method of engine speed sensor
Mounting (adjusting) method of engine speed sensor
a The specifications may be different from the following figure, depending on the machine model.
Adjustment of gap between speed sensor and pin on periphery of flywheel • The following is the removing and mounting procedure of the engine speed sensor. 1. Turn the crankshaft forward to match pin (1) driven in the periphery of the flywheel. 2. At this position, tighten speed sensor (2) until it touches pin (1) of the flywheel, then loosen it by one turn. a Gap at this time: 1.0 – 1.2 mm 3. Tighten lock nut (3). a After adjusting, confirm that the engine cranks smoothly.
Adjustment of gap between speed sensor and contact surface of ring gear • The following is the removing and mounting 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 by 1/2 – 2/3 turns. a Gap at this time: 0.75 – 1.00 mm 3. Tighten lock nut (3). a Arrange the sensor wires carefully so that an excessive force will not be applied to them. a Take care to keep the sensor tip free from metallic chips dust, dirt etc.
12-2 (10)
6D140-2 SERIES
Testing and adjusting
Engine body
Engine body Adjusting valve clearance 1. Remove the rocker arm housing cover. 2. Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of the No. 6 cylinder, bring the No. 1 cylinder into the top dead center position of the compression stroke and align the "1.6 TOP" mark on vibration damper (1) with pointer (2). a When the No. 1 cylinder comes near the top dead center of the compression stroke, the No. 6 intake valve will start to move (open). 3. Adjust the valve clearance for valves marked q 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 Q.
a To adjust the valve clearance, loosen lock nut (5) on adjustment screw (4), insert the feeler gauge corresponding to the specified clearance between crosshead (6) and rocker arm (7), and adjust the clearance with the adjustment screw until the thickness gauge can slide lightly.
5. After the clearance is properly adjusted, tighten the lock nut to secure the adjustment screw. 3 Lock nut: 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm} a The engine firing order is 1 – 5 – 3 – 6 – 2 – 4. a Intake and exhaust valve clearances may be adjusted for each cylinder in the firing order by rotating the crankshaft 120° at a time in the normal direction.
6D140-2 SERIES
12-3 (10)
Testing and adjusting
Engine body
Measuring compression pressure Measurement procedure k
While measuring the compression pressure, take care not burn yourself on the exhaust manifold or muffler, and be careful not to get caught in any revolving part of the engine. a 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 (1). a 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 specified torque: 3 Torque: 66.7 ± 7.3 Nm {6.8 ± 0.75 kgm} 5. Connect compression gauge A to the adapter. 6. Place the fuel control lever in NO INJECTION position, crank the engine with the starting motor, and read the gauge when the pointer is stabilized. k If you do not put the fuel control lever in NO INJECTION position, fuel will blow out. a Most compression leakage can be prevented by applying a small amount of oil to the mounting section of the adapter. a For the reference values of the compression pressure, see TESTING AND ADJUSTING DATA.
12-4 (10)
6D140-2 SERIES
Testing and adjusting
Fuel system
Fuel system Testing and adjusting fuel injection timing • Inspection of fuel injection timing 1. Turn the engine to match stamped line (1) (1-6 TOP) of the damper to pointer (2). 2. Pull out snap pin (3) of the injection timing fixing pin, and remove nut (4). 3. Pushing pin (5) against the engine, turn the crankshaft in reverse and insert pin (5) in gear (6). 4. In this condition, confirm that stamped line "a" on the injection pump is matched to stamped line "b" on the coupling side. a If the engine is started or turned forcedly in this condition, the end of pin (5) will be broken and caught in the gear, and that can cause a serious accident. • 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. 1) Loosen bolt (7) and shift the coupling to match the stamped line, then tighten the bolt. 3 Bolt: 58.8 – 62.8 Nm {6.0 – 6.4 kgm} •
Releasing fixing pin 1) Pull pin (5) out of gear (6). a Pin (5) can be pulled out easily if it is turned. a Pull out pin (5) until is stops. 2) Tighten nut (4). 3 Nut: 26.9 – 33.9 Nm {2.74 – 3.46 kgm} a The nut can be tightened securely if a flat-head screwdriver is set in the slit of 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.
6D140-2 SERIES
12-5 (10)
Testing and adjusting
Fuel system
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 (8), then confirm the fuel injection pressure. 3 Retaining cap: 58.8 – 68.6 Nm {6 – 7 kgm}
Data for shims used for adjusting injection pressure 6D140-2, S6D140-2, SA6D140-2, SAA6D140-2 Maker
BOSCH automotive system 24.5 +1.3 {250 +13 }
Cracking pressure (MPa {kg/cm2})
+0.5
Change in cracking pressure for 0.025 mm thickness of shim (MPa {kg/cm2})
0.34 {3.5}
Thickness of adjustment shim (mm)
Shim thickness and maker part number
12-6 (10)
+5
0.5 – 1.975 (For each 0.025 mm) Thickness (mm)
Part No.
Thickness (mm)
Part No.
0.50
150530–4000
0.525
150530–4100
0.55
150530–4200
0.575
150530–4300
0.60
150530–4400
0.625
150530–4500
0.65
150530–4600
0.675
150530–4700
0.70
150530-4800
0.725
150530–4900
0.75
150530–5000
0.775
150530–5100
0.80
150530–5200
0.825
150530–5300
0.85
150530–5400
0.875
150530–5500
0.90
150530–5600
0.925
150530–5700
0.95
150530–5800
0.975
150530–5900
1.00
150530–6000
1.025
150530–6100
1.05
150530–6200
1.075
150530–6300
1.10
150530–6400
1.125
150530–6500
1.15
150530–6600
1.175
150530–6700
1.20
150530–6800
1.225
150530–6900
O
O
O
O
1.95
150530–9800
1.975
150530–9900
6D140-2 SERIES
Testing and adjusting
Fuel system
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). a The engine stop motor cable is housed in the pulled condition. a When the lever is free, the stop lever is in the OPERATING position (built-in spring). 3. When the engine is stopped (at time of installation), clearance a between stop lever (2) of the injection pump and lever stopper (1) should be 0.5 – 1.5 mm. Adjustment is made according to the depth that the ball joint is screwed in. 4. After adjusting the clearance between the stopper and lever, tighten each bolt and nut. 5. Turn the engine starting switch ON and OFF a few times to confirm that the engine stop motor actuated smoothly. Be especially sure to confirm that there is a clearance between the stop lever and stopper when the engine is stopped. a The engine stop motor has built-in limit switches on both sides of the cable stroke. a 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
6D140-2 SERIES
1. 2. 3. 4. 5.
Lever stopper Fuel injection pump stop lever Bracket Cable Joint
12-7 (10)
Testing and adjusting
Fuel system
SAA6D140-2 for HD325-6, HD405-6 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 (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). a The engine stop motor cable is housed in the pulled condition. a When the lever is free, the stop lever is in the OPERATING position (built-in spring). 3. When the engine is stopped (at time of installation), clearance a between stop lever (1) 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 according to the depth that the ball joint is screwed in. 4. After adjusting the clearance between the stopper and lever, tighten each bolt and nut. 5. Turn the engine starting switch ON and OFF a few times to confirm that the engine stop motor actuated smoothly. Be especially sure to confirm that there is a clearance between the stop lever and stopper when the engine is stopped. a The engine stop motor has built-in limit switches on both sides of the cable stroke. a 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
12-8 (10)
1. 2. 3. 4.
Stop lever Bracket Cable Ball Joint
6D140-2 SERIES
Testing and adjusting
Cooling system
Cooling system Checking and adjusting fan belt tension
1. 2. 3. 4. 5.
Adjustment nut Washer Tension spring Adjustment bolt Tension pulley
A. Protrusion of adjustment bolt
Unit: mm Engine model
Applicable machine
Dimension A
SAA6D140-2
PC750-6 PC800-6
44 ± 3
6D140-2 SERIES
12-9 (10)
Testing and adjusting
Fuel injection pump calibration data
Fuel injection pump calibration data Engine model
Pump assembly No.
Engine serial No.
Applicable machine
Page
6211-72-1310
WA500-3
12-11
6211-72-1470
GD825A-2
12-16
6212-72-1120
D155A-3, D155AX-3
12-12
6211-72-1140
D155AX-5
12-23
6211-72-1150
D155A-2
12-18
6211-72-1160
D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.)
12-19
6211-72-1170
D155AX-5
12-24
6211-72-1180
D155C-1 (–30°C spec.) D155C-1 (–50°C spec.)
12-25
6212-72-1430
PC1600SP-1
12-17
6212-72-1830
J6D140E-G1-2 (with electronic governor) (TAIYO DENKI generator)
12-21
6212-72-1840
J6D140E-G1-2 (with mechanical governor) (TAIYO DENKI generator)
12-22
6212-72-1860
DCA400SSK-2 (DENYO generator)
12-13
6212-72-1860
DCA-400SSK (For MQ generator)
12-20
S6D140-2
SA6D140-2
6212-72-1250 6212-72-1421
HD325-6 (with mechanical governor) HD405-6 (with mechanical governor) PC750-6, PC800-6, PC1800-6
12-14 12-15
SAA6D140-2
12-10 (10)
6D140-2 SERIES
Testing and adjusting
6D140-2 SERIES
Fuel injection pump calibration data
12-11 (10)
Testing and adjusting
12-12 (10)
Fuel injection pump calibration data
6D140-2 SERIES
Testing and adjusting
6D140-2 SERIES
Fuel injection pump calibration data
12-13 (10)
Testing and adjusting
12-14 (10)
Fuel injection pump calibration data
6D140-2 SERIES
Testing and adjusting
6D140-2 SERIES
Fuel injection pump calibration data
12-15 (10)
Testing and adjusting
12-16 (10)
Fuel injection pump calibration data
6D140-2 SERIES
Testing and adjusting
6D140-2 SERIES
Fuel injection pump calibration data
12-17 (10)
Testing and adjusting
12-18 (10)
Fuel injection pump calibration data
6D140-2 SERIES
Testing and adjusting
6D140-2 SERIES
Fuel injection pump calibration data
12-19 (10)
Testing and adjusting
12-20 (10)
Fuel injection pump calibration data
6D140-2 SERIES
Testing and adjusting
6D140-2 SERIES
Fuel injection pump calibration data
12-21 (10)
Testing and adjusting
12-22 (10)
Fuel injection pump calibration data
6D140-2 SERIES
Testing and adjusting
6D140-2 SERIES
Fuel injection pump calibration data
12-23 (10)
Testing and adjusting
12-24 (10)
Fuel injection pump calibration data
6D140-2 SERIES
Testing and adjusting
6D140-2 SERIES
Fuel injection pump calibration data
12-25 (10)
Testing and adjusting
Performance test
Performance test Run-in standard a The table gives the standard values for machines without fan. a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine
(10)
2
3
4
5
min.
2
8
2
3
5
Engine speed
rpm
650
1,300
1,650
1,900
2,100
Load
N {kg}
0 {0}
343 {35}
686 {70}
1,030 {105}
1,373 {140}
Flywheel horsepower
kW {HP}
0 {0}
33.9 {45.4}
85.4 {114.4}
147.2 {197.2}
216.4 {289.9}
Running time
min.
2
8
2
3
5
Engine speed
rpm
725
1,000
1,200
1,500
2,100
Load
N {kg}
0 {0}
392 {40}
785 {80}
1,177 {120}
1,569 {160}
Flywheel horsepower
kW {HP}
0 {0}
29.4 {39.4}
70.7 {94.7}
132.5 {177.5}
247.3 {331.3}
Running time
min.
Engine speed
rpm
Load
N {kg}
Flywheel horsepower
kW {HP}
Running time
min.
Engine speed
rpm
Load
N {kg}
Flywheel horsepower
kW {HP}
Running time
min.
Engine speed
rpm
Load
N {kg}
Flywheel horsepower
kW {HP}
WA500-3
12-26
1
Running time
GD825A-2
S6D140-2
Order
Item
6
6D140-2 SERIES
Testing and adjusting
Performance test
a The table gives the standard values for machines without fan. a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine
Running time
min.
1
2
3
4
5
2
8
7
10
3
D155A-3
Engine speed rpm
700
1,100
1,450
1,710
1,900
D155AX-3
Load
N {kg}
0 {0}
432 {44}
863 {88}
1,285 {131}
1,716 {175}
Flywheel horsepower
kW {HP}
0 {0}
35.6 {47.7}
93.9 {128.5}
164.9 {220.9}
244.7 {327.8}
Running time
min.
2
8
2
3
5
Engine speed rpm
750
1,000
1,200
1,500
1,800
Load
N {kg}
0 {0}
618 {63}
1,226 {125}
1,844 {188}
2,452 {250}
Flywheel horsepower
kW {HP}
0 {0}
46.4 {62.1}
110.4 {147.9}
207.6 {278.1}
331.2 {443.7}
Running time
min.
2
8
2
3
5
800
1,000
1,200
1,500
1,800
0 {0}
539 {55}
1,844 {188}
2,157 {220}
2,707 {276}
PC1600SP-1
SA6D140-2
Order
Item
DCA400SSK-2 Engine speed rpm (DENYO N generator) Load {kg} Flywheel horsepower
kW {HP}
0 {0}
40.5 {54.2}
166.3 {222.8}
242.9 {325.4}
365.8 {490.0}
Running time
min.
2
8
2
3
5
1,000
1,200
1,500
2,000
Engine speed rpm 550 – 650 D155A-2 Load
N {kg}
0 {0}
353 {36}
883 {90}
1,410 {144}
1,770 {180}
Flywheel horsepower
kW {HP}
0 {0}
26 {35}
79 {106}
159 {213}
265 {355}
Running time
min.
2
8
2
3
5
1,000
1,200
1,500
2,000
Engine speed rpm 700 – 750 D355C-3
6D140-2 SERIES
Load
N {kg}
0 {0}
373 {38}
932 {95}
1,490 {152}
1,860 {190}
Flywheel horsepower
kW {HP}
0 {0}
28 {37}
84 {112}
168 {225}
279 {375}
6
12-27 (10)
Testing and adjusting
Performance test
a The table gives the standard values for machines without fan. a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine
1
2
3
4
5
2
8
2
3
5
Engine speed rpm
800
1,000
1,200
1,500
1,800
Load
N {kg}
0 {0}
540 {55}
1,840 {188}
2,160 {220}
2,700 {276}
Flywheel horsepower
kW {HP}
0 {0}
40 {54}
166 {223}
243 {325}
366 {490}
Running time
min.
2
8
2
3
5
800
1,000
1,200
1,500
1,800
0 {0}
470 {48}
1,180 {120}
1,880 {192}
2,350 {240}
Running time DCA-400SSK (MQ generator)
Order
Item min.
J6D140E-GI-2 Engine speed rpm (TAIYO DENKI N generator) Load {kg}
SA6D140-2
D155C-1 (–50°C spec.)
(10)
kW {HP}
0 {0}
35 {48}
106 {146}
212 {292}
318 {438}
Running time
min.
2
8
2
3
5
Engine speed rpm
700
1,000
1,200
1,500
1,900
Load
N {kg}
0 {0}
353 {36}
883 {90}
1,410 {144}
1,770 {180}
Flywheel horsepower
kW {HP}
0 {0}
26 {36}
79 {109}
159 {219}
252 {347}
Running time
min.
2
8
2
3
5
Engine speed rpm
725
1,000
1,200
1,500
2,000
Load
N {kg}
0 {0}
667 {68}
1,670 {170}
2,670 {272}
3,330 {340}
Flywheel horsepower
kW {HP}
0 {0}
50 {67}
150 {201}
300 {402}
500 {670}
Running time
min.
2
8
2
3
5
Engine speed rpm
725
1,000
1,200
1,500
2,000
Load
N {kg}
0 {0}
667 {68}
1,670 {170}
2,670 {272}
3,330 {340}
Flywheel horsepower
kW {HP}
0 {0}
50 {67}
150 {201}
300 {402}
500 {670}
D155AX-5
D155C-1 (–30°C spec.)
12-28
Flywheel horsepower
6
6D140-2 SERIES
Testing and adjusting
Performance test
a The table gives the standard values for machines without fan. a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine
1
2
3
4
5
2
8
2
3
5
1,000
1,200
1,500
2,000
Running time
min.
Engine speed
rpm 700 – 750
Load
N {kg}
0 {0}
373 {38}
932 {95}
1,490 {152}
1,860 {190}
Flywheel horsepower
kW {HP}
0 {0}
28 {37}
84 {112}
168 {225}
279 {375}
Running time
min.
2
8
2
3
5
Engine speed
rpm 700 – 750
1,000
1,200
1,500
2,000
Load
N {kg}
0 {0}
373 {38}
932 {95}
1,490 {152}
1,860 {190}
Flywheel horsepower
kW {HP}
0 {0}
28 {37}
84 {112}
168 {225}
279 {375}
Running time
min.
2
8
2
3
5
HD325-6
Engine speed
rpm
800
1,300
1,650
1,900
2,100
HD405-6
Load
N {kg}
0 {0}
588 {60}
1,177 {120}
1,765 {180}
2,354 {240}
Flywheel horsepower
kW {HP}
0 {0}
57.4 {76.9}
145.7 {195.2}
251.7 {337.2}
370.9 {496.9}
Running time
min.
2
8
2
3
5
Engine speed
rpm
725
1,000
1,200
1,500
2,000
Load
N {kg}
0 {0}
490 {50}
1,030 {105}
1,569 {160}
1,961 {200}
Flywheel horsepower
kW {HP}
0 {0}
36.8 {49.3}
92.7 {124.2}
176.6 {236.6}
294.4 {394.4}
Running time
min.
2
8
2
3
5
Engine speed
rpm
825
1,000
1,200
1,500
1,800
Load
N {kg}
0 {0}
588 {60}
1,275 {130}
2,060 {210}
2,550 {260}
Flywheel horsepower
kW {HP}
0 {0}
44 {60}
115 {156}
232 {315}
344 {463}
D355C-3 (–30°C spec.)
SA6D140-2
D355C-3 (–50°C spec.)
SAA6D140-2
Order
Item
HD325-6 (High altitude spec.)
PC750-6 PC800-6 PC1800-6
6D140-2 SERIES
6
12-29 (10)
Testing and adjusting
Performance test
a The table gives the standard values for machines without fan. a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
SDA6D140E-2
12-30 (10)
Applicable machine
D275A-5 (–50°C spec.)
Order
Item
1
2
3
4
5
Running time
min.
2
8
2
3
5
Engine speed
rpm
700
1,000
1,200
1,500
2,000
Load
N {kg}
0 {0}
441 {45}
1,110 {113}
1,770 {180}
2,220 {226}
Flywheel horsepower
kW {HP}
0 {0}
33 {45}
100 {136}
199 {270}
332 {452}
6
6D140-2 SERIES
Testing and adjusting
Performance test
Performance test criteria a The table gives the standard values using the JIS compensator factor. a 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). a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine
GD825A-2
S6D140-2
WA500-3
Specified value
Engine speed (rpm)
Dynamometer load (N {kg})
Flywheel horsepower
209.0 kW/2,100 rpm {280.0 HP/2,100 rpm}
2,095 – 2,105
1,360 – 1,440 {139 – 147}
Maximum torque
1,255 Nm/1,400 rpm {128 kgm/1,400 rpm}
1,300 – 1,500
1,730 – 1,840 {177 – 187}
2,300 – 2,400 rpm
2,300 – 2,400
—
600 – 650 rpm
600 – 650
—
Test item
High idling speed Low idling speed Flywheel horsepower Maximum torque
235.5 kW/2,100 rpm {315.5 HP/2,100 rpm} 1,373 Nm/1,400 rpm {140 kgm/1,400 rpm}
2,095 – 2,105 1,350 – 1,450
1,520 – 1,610 {155 – 164} 1,890 – 2,010 {193 – 205}
High idling speed
2,300 – 2,400 rpm
2,300 – 2,400
—
Low idling speed
700 – 750 rpm
700 – 750
—
Flywheel horsepower Maximum torque High idling speed Low idling speed Flywheel horsepower Maximum torque High idling speed Low idling speed Flywheel horsepower Maximum torque High idling speed Low idling speed Flywheel horsepower Maximum torque High idling speed Low idling speed
12-32 (10)
6D140-2 SERIES
Testing and adjusting
Performance test
a For fuel, use ASTM D975 No. 1 or No. 2. a For lubricant, use SAE15W-40 or SAE30 oil. Flywheel horsepower (kW{HP})
Torque (Nm{kgm})
Fuel consumption (sec/200cc)
214.5 – 227.1 {287.4 – 304.2}
—
Min. 17.3
238.9 – 253.6 {320.1 – 339.8}
6D140-2 SERIES
Lubrication Coolant Lubrication oil Exhaust oil pressure temperature temperature temperature (°C) (°C) (°C) (kPa {kg/cm2}) 340 – 490 Max. 650 70 – 90 90 – 110 {3.5 – 5.0} Max. 650
1,242 – 1,316 {126.6 – 134.2}
70 – 90
90 – 110
—
—
70 – 90
90 – 110
—
—
—
70 – 90
Min. 80
Min. 120 {1.2}
—
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
1,352 – 1,439 {137.9 – 146.7}
70 – 90
90 – 110
—
Max. 650
—
70 – 90
90 – 110
—
—
—
70 – 90
Min. 80
Min. 118 {1.2}
—
—
Min. 15.7
12-33 (10)
Testing and adjusting
Performance test
a The table gives the standard values using the JIS compensator factor. a 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). a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine
D155A-3 D155AX-3
PC1600SP-1
Test item
D355C-3
High idling speed
2,050 – 2,150 rpm
2,050 – 2,150
—
Low idling speed
700 – 725 rpm
700 – 725
—
Flywheel horsepower Maximum torque High idling speed Low idling speed
1,250 – 1,350
1,795 – 1,805 1,300 – 1,500
1,671 – 1,773 {170.4 – 180.8} 2,002 – 2,124 {204.1 – 216.6}
2,378 – 2,525 {242.5 – 257.5} 2,606 – 2,764 {265.7 – 281.8}
1,930 – 2,030 rpm
1,930 – 2,030
—
725 – 775 rpm
725 – 775
—
2,714 – 2,883 (50Hz) 309.9 kW/1,500 rpm (50Hz) 1,495 – 1,505 (50Hz) {276.7 – 294.0} (50Hz) {415.1 HP/1,500 rpm} (50Hz) 2,621 – 2,783 (60Hz) 357.0 kW/1,800 rpm (60Hz) 1,795 – 1,805 (60Hz) {267.3 – 283.8} (60Hz) {478.2 HP/1,800 rpm} (60Hz) —
—
Max. 1,568 (50Hz) Max. 1,881 (60Hz)
—
800 – 850 rpm
800 – 850
—
253 kW/2,000 rpm {339 HP/2,000 rpm}
1,995 – 2,005
1,730 – 1,820 {176 – 186}
Maximum torque
1,608 Nm/1,400 rpm {164 kgm/1,400 rpm}
1,300 – 1,500
2,230 – 2,350 {227 – 240}
High idling speed
2,200 – 2,280 rpm
2,200 – 2,280
—
550 – 650 rpm
550 – 650
—
Low idling speed Flywheel horsepower Maximum torque High idling speed
Flywheel horsepower Maximum DCA-400SSK torque (MQ generator) High idling speed Low idling speed
(10)
316.5 kW/1,800 rpm {424.0 HP/1,800 rpm} 1,863 Nm/1,400 rpm {190 kgm/1,400 rpm}
1,895 – 1,905
Max. 1,568 rpm (50Hz) Max. 1,881 rpm (60Hz)
Low idling speed
12-34
Dynamometer load (N {kg})
225.2 kW/1,900 rpm {301.7 HP/1,900 rpm} 1,432 Nm/1,300 rpm {146 kgm/1,300 rpm}
DCA400SSK-2 Maximum (DENYO torque generator) High idling speed Low idling speed Flywheel horsepower D155A-2
Engine speed (rpm)
Flywheel horsepower Maximum torque
Flywheel horsepower
SA6D140-2
Specified value
265 kW/2,000 rpm {355 HP/2,000 rpm} 1,570 Nm/1,400 rpm {160 kgm/1,400 rpm}
1,995 – 2,005 1,300 – 1,500
1,790 – 1,900 {183 – 194} 2,180 – 2,300 {222 – 235}
2,200 – 2,280 rpm
2,200 – 2,280
—
700 – 750 rpm
700 – 750
—
357 kW/1,800 rpm (60 Hz) {478 HP/1,800 rpm} (60 Hz)
1,795 – 1,805 (60 Hz)
2,620 – 2,780 (60 Hz) {267 – 284} (60 Hz)
—
—
—
Max. 1,890 rpm (60 Hz)
Max. 1,890 (60 Hz)
—
800 – 850 rpm
800 – 850
—
6D140-2 SERIES
Testing and adjusting
Performance test
a For fuel, use ASTM D975 No. 1 or No. 2. a For lubricant, use SAE15W-40 or SAE30 oil. Flywheel horsepower (kW{HP})
Torque (Nm{kgm})
238.2 – 252.9 {319.1 – 338.8}
Fuel consumption (sec/200cc)
Lubrication Coolant Lubrication oil Exhaust oil pressure temperature temperature temperature (°C) (°C) (°C) (kPa {kg/cm2}) 70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
1,433 – 1,521 {146.1 – 155.1}
70 – 90
90 – 110
—
Max. 650
—
70 – 90
90 – 110
—
—
—
70 – 90
Min. 80
Min. 118 {1.2}
—
Min. 16.8
—
Min. 12.3
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
1,865 – 1,979 {190.2 – 201.8}
—
70 – 90
90 – 110
—
Max. 650
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
Min. 80
Min. 120 {1.2}
—
Min. 13.0 (50Hz) Min. 10.6 (60 Hz)
70 – 90
90 – 110
70 – 90
90 – 110
321.3 – 341.1 {430.4 – 457.0}
305.4 – 324.6 (50Hz) {409.2 – 434.8} (50Hz) 354.0 – 376.1 (60Hz) {474.3 – 503.8} (60Hz)
290 – 490 (50Hz) {3.0 – 5.0} (50Hz) 290 – 490 (60Hz) {3.0 – 5.0} (60Hz)
Max. 650 Max. 650
—
—
—
—
70 – 90
90 – 110
—
—
70 – 90
Min. 80
Min. 180 {1.8}
—
258 – 274 {346 – 368}
—
—
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
—
1,590 – 1,690 {162 – 172}
—
70 – 90
90 – 110
—
Max. 680
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
80 – 110
Min. 120 {1.2}
—
269 – 285 {361 – 382}
—
—
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
—
1,560 – 1,650 {159 – 168}
—
70 – 90
90 – 110
—
Max. 680
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
80 – 110
Min. 120 {1.2}
—
354 – 376 (60 Hz) {474 – 504} (60 Hz)
—
Min. 10.6 (60 Hz)
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
—
—
—
—
—
—
—
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
90 – 110
Min. 180 {1.8}
—
6D140-2 SERIES
— —
12-35 (10)
Testing and adjusting
Performance test
a The table gives the standard values using the JIS compensator factor. a 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). a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine
Test item Flywheel horsepower
J6D140E-G1-2 (TAIYO DENKI High idling generator) speed Low idling speed
D155AX-5
D155C-1 (–30°C spec.)
SA6D140-2
D155C-1 (–50°C spec.)
D355C-3 (–30°C spec.)
D355C-3 (–50°C spec.)
12-36 (10)
Specified value
Engine speed (rpm)
271 kW/1,500 rpm (Net, 50Hz) 1,495 – 1,505 (50 Hz) 374 HP/1,500 rpm (Net, 50Hz) 299 kW/1,800 rpm (Net, 60Hz) 1,795 – 1,805 (60 Hz) 412 HP/1,800 rpm (Net, 60Hz)
Dynamometer load (N {kg}) 2,430 – 2,580 {248 – 263} 2,290 – 2,420 {233 – 247}
Max. 1,575 rpm (50 Hz) Max. 1,890 rpm (60 Hz)
Max. 1,575 (50 Hz) Max. 1,890 (60 Hz)
—
700 – 725 rpm
700 – 900
—
Flywheel horsepower Maximum torque High idling speed Low idling speed
232 kW/1,900 rpm (Net) {320 HP/1,900 rpm} (Net) 1,610 Nm/1,250 rpm (Net) {164 kgm/ 1,250 rpm} (Net)
1,895 – 1,905 1,150 – 1,350
1,730 – 1,820 {176 – 186} 2,250 – 2,380 {229 – 243}
2,050 – 2,150 rpm
2,050 – 2,150
—
675 – 725 rpm
675 – 725
—
Flywheel horsepower
225 kW/2,000 rpm (Gross) {342 HP/2,000 rpm} (Gross)
1,995 – 2,005
1,650 – 1,750 {168.5 – 178.5}
Maximum torque
1,490 Nm/1,400 rpm (Gross) {152 kgm/1,400 rpm} (Gross)
1,300 – 1,500
2,020 – 2,150 {206 – 219}
2,190 – 2,290 rpm
2,190 – 2,290
—
700 – 750 rpm
700 – 750
—
High idling speed Low idling speed Flywheel horsepower Maximum torque
225 kW/2,000 rpm (Gross) {342 HP/2,000 rpm} (Gross) 1,490 Nm/1,400 rpm (Gross) {152 kgm/1,400 rpm} (Gross)
1,995 – 2,005 1,300 – 1,500
1,650 – 1,750 {168.5 – 178.5} 2,020 – 2,150 {206 – 219}
High idling speed
2,190 – 2,290 rpm
2,190 – 2,290
—
Low idling speed
700 – 750 rpm
700 – 750
—
Flywheel horsepower Maximum torque High idling speed Low idling speed
265 kW/2,000 rpm (Net) {355 HP/2,000 rpm} (Net) 1,570 Nm/1,400 rpm (Net) {160 kgm/1,400 rpm} (Net)
1,995 – 2,005 1,300 – 1,500
1,790 – 1,900 {183 – 194} 2,180 – 2,300 {222 – 235}
2,200 – 2,280 rpm
2,200 – 2,280
—
700 – 750 rpm
700 – 750
—
Flywheel horsepower
265 kW/2,000 rpm (Net) {355 HP/2,000 rpm} (Net)
1,995 – 2,005
1,790 – 1,900 {183 – 194}
Maximum torque High idling speed Low idling speed
1,570 Nm/1,400 rpm (Net) {160 kgm/1,400 rpm} (Net)
1,300 – 1,500
2,180 – 2,300 {222 – 235}
2,200 – 2,280 rpm
2,200 – 2,280
—
700 – 750 rpm
700 – 750
—
6D140-2 SERIES
Testing and adjusting
Performance test
a For fuel, use ASTM D975 No. 1 or No. 2. a For lubricant, use SAE15W-40 or SAE30 oil. Lubrication Coolant Lubrication oil Exhaust oil pressure temperature temperature temperature (°C) (°C) (°C) (kPa {kg/cm2})
Flywheel horsepower (kW{HP})
Torque (Nm{kgm})
Fuel consumption (sec/200cc)
273.6 – 289.8 (Gross, 50 Hz) {337.3 – 399.6} (Gross, 50 Hz)
—
Min. (50 Hz)
70 – 90
90 – 110
308.9 – 326.6 (Gross, 60 Hz) {425.9 – 450.4} (Gross, 60 Hz)
—
Min. (60 Hz)
70 – 90
90 – 110
—
—
70 – 90
90 – 110
—
—
—
—
70 – 90
80 – 110
Min. 120 {1.2}
—
245 – 260 (Gross) {328 – 348} (Gross)
—
—
70 – 90
90 – 110
343 – 490 {3.5 – 5.0}
Max. 650
—
1,608 – 1,706 (Gross) {164 – 174} (Gross)
—
70 – 90
90 – 110
—
Max. 650
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
80 – 110
Min. 120 {1.2}
—
248 – 262 (Gross) {332 – 352} (Gross)
—
—
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
—
1,447 – 1,535 (Gross) {147.5 – 156.5} (Gross)
—
70 – 90
90 – 110
—
Max. 650
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
80 – 110
Min. 180 {1.8}
—
248 – 262 (Gross) {332 – 352} (Gross)
—
—
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
—
1,447 – 1,535 (Gross) {147.5 – 156.5} (Gross)
—
70 – 90
90 – 110
—
Max. 650
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
80 – 110
Min. 180 {1.8}
—
269 – 285 (Gross) {361 – 382} (Gross)
—
—
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
—
1,560 – 1,650 (Gross) {159 – 168} (Gross)
—
70 – 90
90 – 110
—
Max. 680
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
80 – 110
Min. 120 {1.2}
—
269 – 285 (Gross) {361 – 382} (Gross)
—
—
70 – 90
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
—
1,560 – 1,650 (Gross) {159 – 168} (Gross)
—
70 – 90
90 – 110
—
Max. 680
—
—
—
70 – 90
90 – 110
—
—
—
—
—
70 – 90
80 – 110
Min. 120 {1.2}
—
6D140-2 SERIES
290 – 490 {3.0 – 5.0} 290 – 490 {3.0 – 5.0}
Max. 650 Max. 650
12-37 (10)
Testing and adjusting
Performance test
a The table gives the standard values using the JIS compensator factor. a 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). a The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine
HD325-6 HD405-6
SAA6D140-2
HD325-6 (High altitude spec.)
PC750-6 PC800-6 PC1800-6
D275A-5 (–50°C spec.)
SDA6D140E-2
Test item
Specified value
Engine speed (rpm)
Dynamometer load (N {kg})
Flywheel horsepower Maximum torque
379.0 kW/2,000 rpm {507.8 HP/2,000 rpm} 2,167 Nm/1,350 rpm {214 kgm/1,350 rpm}
High idling speed
2,300 – 2,450 rpm
2,300 – 2,400
—
Low idling speed
675 – 775 rpm
675 – 775
—
Flywheel horsepower Maximum torque High idling speed Low idling speed
306.9 kW/2,000 rpm {411.2 HP/2,000 rpm} 1,755 Nm/1,400 rpm {179 kgm/1,400 rpm}
1,995 – 2,005 1,300 – 1,500
1,995 – 2,005 1,300 – 1,500
2,398 – 2,545 {244.5 – 259.5} 2,902 – 3,083 {296.0 – 314.4}
1,930 – 2,053 {196.8 – 209.3} 2,351 – 2,487 {239.7 – 253.6}
2,350 – 2,450 rpm
2,350 – 2,450
2,350 – 2,450
675 – 775 rpm
675 – 775
675 – 775
Flywheel horsepower
331.2 kW/1,800 rpm {443.7 HP/1,800 rpm}
1,795 – 1,805
2,378 – 2,525 {242.5 – 257.5}
Maximum torque
2,099 Nm/1,350 rpm {214 kgm/1,350 rpm}
1,250 – 1,450
1,508 – 1,601 {153.8 – 163.3}
High idling speed Low idling speed Flywheel horsepower Maximum torque
1,930 – 2,030 rpm
—
800 – 850 rpm
—
332 kW/2,000 rpm {446 HP/2,000 rpm} 2,030 Nm/1,400 rpm {207 kgm/1,400 rpm}
1,995 – 2,005
2,177 – 2,305 {222 – 235}
1,300 – 1,500
Min. 2,834 {289}
High idling speed
2,150 – 2,250 rpm
2,150 – 2,250
—
Low idling speed
650 – 750 rpm
650 – 750
—
Flywheel horsepower Maximum torque High idling speed Low idling speed Flywheel horsepower Maximum torque High idling speed Low idling speed
12-38 (10)
6D140-2 SERIES
Testing and adjusting
Performance test
a For fuel, use ASTM D975 No. 1 or No. 2. a For lubricant, use SAE15W-40 or SAE30 oil. Flywheel horsepower (kW{HP})
Torque (Nm{kgm})
359.9 – 381.7 {482.2 – 511.7}
289.6 – 308.0 {388.0 – 412.6}
Fuel consumption (sec/200cc)
Lubrication Coolant Lubrication oil Exhaust oil pressure temperature temperature temperature (°C) (°C) (°C) (kPa {kg/cm2})
Min. 11.2
70 – 95
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
2,079 – 2,208 {212.0 – 225.2}
—
70 – 95
90 – 110
—
—
—
—
70 – 80
90 – 110
—
—
—
—
70 – 80
Min. 80
Min. 118 {1.2}
—
—
Min. 13.5
70 – 85
90 – 110
343 – 490 {3.5 – 5.0}
650
1,683 – 1,781 {171.6 – 181.6}
70 – 85
90 – 110
—
700
—
70 – 85
90 – 110
—
—
—
70 – 85
90 – 110
Min. 147 {1.5}
—
70 – 95
90 – 110
340 – 490 {3.5 – 5.0}
Max. 650
321.3 – 341.1 {430.4 – 457.0}
—
—
2,036 – 2,161 {207.6 – 220.4}
70 – 95
90 – 110
—
—
—
—
70 – 90
90 – 110
—
—
—
—
70 – 90
80 – 110
Min. 118 {1.2}
—
325 – 345 {436 – 463}
—
Min. 11.8
70 – 90
90 – 110
Min. 2,030 {207}
—
70 – 90
90 – 110
—
—
70 – 90
90 – 110
—
—
70 – 90
80 – 110
6D140-2 SERIES
Min. 12.3
340 – 490 {3.5 – 5.0} 340 – 490 {3.5 – 5.0} 340 – 490 {3.5 – 5.0} Min. 118 {1.2}
Max. 650 — — —
12-39 (10)
Troubleshooting Points to remember when troubleshooting.................................................................................................. 12- 43 Method of using troubleshooting charts ...................................................................................................... 12- 44 S-1
Starting performance is poor (starting always takes time) ................................................................ 12- 48
S-2
Engine does not start ........................................................................................................................ 12- 49
S-3
Engine does not pick up smoothly (follow-up is poor)....................................................................... 12- 52
S-4
Engine stops during operations ........................................................................................................ 12- 53
S-5
Engine does not rotate smoothly (hunting) ....................................................................................... 12- 54
S-6
Engine lacks output (no power) ........................................................................................................ 12- 55
S-7
Exhaust smoke is black (incomplete combustion) ............................................................................ 12- 56
S-8
Oil consumption is excessive (or exhaust smoke is blue)................................................................. 12- 57
S-9
Oil becomes contaminated quickly ................................................................................................... 12- 58
S-10 Fuel consumption is excessive ......................................................................................................... 12- 59 S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 12- 60 S-12 Oil pressure caution lamp lights up (drop in oil pressure)................................................................. 12- 61 S-13 Oil level rises (water, fuel in oil) ........................................................................................................ 12- 62 S-14 Water temperature becomes too high (overheating) ........................................................................ 12- 63 S-15 Abnormal noise is made .................................................................................................................... 12- 64 S-16 Vibration is excessive ....................................................................................................................... 12- 65 Testing and adjusting tool list ...................................................................................................................... 12- 67 Testing and adjusting data .......................................................................................................................... 12- 68
6D140-2 SERIES
12-41 (10)
Troubleshooting k k k k k k
When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit safety pins, block the wheels, and apply the parking brake. When carrying out operations with two or more workers, always use signals, and do not allow any unauthorized person near the machine. When checking the water level, if the radiator cap is removed when the engine is hot, boiling water will spurt out and may cause burns, so always wait for the engine to cool down before checking the water level. Be extremely careful not to touch any hot parts. Be extremely careful not to get caught in the fan or any other rotating parts. 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.
a 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.
12-42 (10)
6D140-2 SERIES
Troubleshooting
Points to remember when 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. 1. Do not disassemble the machine simply because there is a failure If the machine is disassembled immediately just because there is a failure: • Unrelated or unnecessary places are also disassembled • It becomes difficult to locate the cause of the failure This means that there is not only a waste of time and money on replacement parts, oil, and grease, but this action will also lose the confidence of the user and operator. For this reason also, it is important to carry out troubleshooting based on full investigation before starting and troubleshooting following before the correct order. 2. Questions to ask the user and operator 1) Are there any problems other than those already reported? 2) Did anything unusual happen before the failure occurred? 3) Did the failure occur suddenly, or had the condition of the machine been poor before the failure occurred? 4) What were the conditions when the failure occurred? 5) Had any repairs been carried out before the failure occurred? 6) Had any similar failure occurred before?
4. Confirming failure Check the degree of the problem to judge for yourself if it is really a failure, or if there is some problem in the handling or operation of the machine. a When driving the machine and re-enacting the failure, be sure that the investigation or measurement does not make the failure worse. 5. Troubleshooting Narrow down the cause of the failure from the results of the questions and checks in the above Items 2 – 4, then follow the troubleshooting flow charts to locate the failure. a Basic procedure for troubleshooting 1) Start from the simple places. 2) Start from the most probable places. 3) Investigate related parts also. 6. Basic action to remedy cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, it is necessary to investigate why the failure occurred, and to remove the root cause of the failure.
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 carried out visually, so carry out any check that is considered necessary.
6D140-2 SERIES
12-43 (10)
Troubleshooting
Method of using troubleshooting charts
Method of using troubleshooting charts This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections [A] + [B] in the chart on the right corresponds to the items where answers can be obtained from the user. The items in [B] are items that can be obtained from the user, depending on the user's level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under [C] in the chart on the right correspond to this. The serviceman narrows down the causes from information [A] that he has obtained from the user and the results of [C] 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].
Causes
[A]
Questions
(1) (2) (3)
(a) (b) (c) (d)
[B]
[C]
Check items
(e)
Troubleshooting
i
12-44 (10)
ii iii
6D140-2 SERIES
Method of using troubleshooting charts
e fu el in jectio n)
Causes
Seiz
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with Q, and of these, causes that have a high probability are marked with w. Check each of the [Questions] and [Check items] in turn, and marked the Q or w 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. *1. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with E to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. *2. Use the E in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.
ed t urbo char Clog ger, ged inter air c fere lean Wor nce er e n pis leme ton n r t in Clog g, cy ged linde , seiz r ed f Imp uel in rope jectio r fue l inje n no Defe ction zzle ctive timin fuel g injec tion pum p (e xces siv
Troubleshooting
6D140-2 SERIES
*1
Confirm recent repair history
*2
Degree of use
Operated for long period
12-45 (10)
Troubleshooting
•
Method of using troubleshooting charts
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
12-46 (10)
Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel
6D140-2 SERIES
Troubleshooting
Method of using troubleshooting charts
6D140-2 SERIES
12-47 (10)
Troubleshooting
S-1
S-1 Starting performance is poor (starting always takes time) a Check that the monitor panel does not display any abnormality in the governor control system. General causes why exhaust smoke comes out but engine takes time to start • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel (At ambient temperature of 10°C or below, use ASTM D975 No. 1) a Battery charging rate Charging rate Ambient temperature
• •
100 %
90 %
80 %
75 %
70 %
20°C
1.28
1.26
1.24
1.23
1.22
0°C
1.29
1.27
1.25
1.24
1.23
–10°C
1.30
1.28
1.26
1.25
1.24
The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.
12-48 (10)
6D140-2 SERIES
Troubleshooting
S-2
S-2 Engine does not start (1) Engine does not turn General causes why engine does not turn • Internal parts of engine seized a If internal parts of the engine are seized, carry out troubleshooting for "Engine stops during operations". • Failure in power train • Defective electrical system
6D140-2 SERIES
12-49 (10)
Troubleshooting
S-2
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) General causes why engine turns but no exhaust smoke comes out • Supply of fuel impossible • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter) a Standards for use of fuel
12-50 (10)
6D140-2 SERIES
Troubleshooting
S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) a General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel and oil
6D140-2 SERIES
12-51 (10)
Troubleshooting
S-3
S-3 Engine does not pick up smoothly (follow-up is poor) a 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 intake of air • Insufficient supply of fuel • Improper condition of fuel injection • Improper fuel used
12-52 (10)
6D140-2 SERIES
Troubleshooting
S-4
S-4 Engine stops during operations General causes why engine stops during operations • Seized parts inside engine • Insufficient supply of fuel • Overheating a If there is overheating and insufficient output, carry out troubleshooting for overheating. • Failure in power train a If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.
6D140-2 SERIES
12-53 (10)
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 a If hunting does not occur when the rod between the governor motor and the injection pump is disconnected, troubleshoot by using the electrical system troubleshooting (E mode).
12-54 (10)
6D140-2 SERIES
Troubleshooting
S-6
S-6 Engine lacks output (no power) General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Improper condition of fuel injection • Improper fuel used (if non-specified fuel is used, output drops) • Lack of output due to overheating a If there is overheating and insufficient output, carry out troubleshooting for overheating.
6D140-2 SERIES
12-55 (10)
Troubleshooting
S-7
S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel
12-56 (10)
6D140-2 SERIES
Troubleshooting
S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue) a Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling) General causes why oil consumption is excessive • Abnormal combustion of oil • External leakage of oil • Wear of lubrication system
6D140-2 SERIES
12-57 (10)
Troubleshooting
S-9
S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly • Intake of exhaust gas due to internal wear • Clogging of lubrication passage • Improper fuel • Improper oil used • Operation under excessive load
12-58 (10)
6D140-2 SERIES
Troubleshooting
S-10
S-10 Fuel consumption is excessive General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection • Excessive injection of fuel
6D140-2 SERIES
12-59 (10)
Troubleshooting
S-11
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
12-60 (10)
6D140-2 SERIES
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 a Standards for engine oil selection
6D140-2 SERIES
12-61 (10)
Troubleshooting
S-13
S-13 Oil level rises (water, fuel in oil) a If there is oil in the cooling water, carry out troubleshooting for "Oil is in cooling water". General causes why oil level rises • Water in oil • Fuel in oil (diluted, and smells of diesel fuel) • Entry of oil from other component
12-62 (10)
6D140-2 SERIES
Troubleshooting
S-14
S-14 Water temperature becomes too high (overheating) 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 a Carry out troubleshooting for chassis.
6D140-2 SERIES
12-63 (10)
Troubleshooting
S-15
S-15 Abnormal noise is made a 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
12-64 (10)
6D140-2 SERIES
Troubleshooting
S-16
S-16 Vibration is excessive a If there is abnormal noise together with the vibration, carry out troubleshooting for "Abnormal noise is made". General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment • Abnormal combustion
6D140-2 SERIES
12-65 (10)
Troubleshooting
Testing and adjusting tool list
Testing and adjusting tool list No. Testing and measuring item 1
Engine speed
2
Battery S.G.
3
Freezing temperature of cooling water
4
Water temperature, oil temperature, air intake temperature, exhaust temperature
Part No. 799-203-8000
Fault finding tool Multi-tachometer
Remarks Digital reading: L: 60 – 2,000 rpm H: 60 – 20,000 rpm 1.100 – 1.300
795-500-1001
Battery coolant tester –5 – –50ºC
799-101-6000
Digital temperature gauge
790-500-1300
Thermistor temperature 0 – 200°C gauge 0 – 1,000ºC
– 50 – 1,200°C
5
Lubrication oil pressure
0 – 1 MPa {0 – 10 kg/cm2}
6
Fuel pressure
0 – 2 MPa {0 – 20 kg/cm2}
7
Intake pressure, exhaust pressure
8
Blow-by pressure
0 – 9.8 kPa {0 – 1,000 mmH2O}
9
Intake resistance
–9.8 – 0 kPa {–1,000 – 0 mmH2O}
799-203-2002
795-502-1205 10
Engine pressure measuring kit
Compression gauge
0 – 200 MPa {0 – 1,500 mmHg}
0 – 0.69 MPa {0 – 70 kg/cm2}
Compression pressure • 795-502-1510 • Adapter
11
Blow-by pressure
799-201-1504
Blow-by checker
0 – 4.9 kPa {0 – 500 mmH2O}
12
Valve clearance
795-125-1210
Feeler gauge
0.43, 0.80 mm
13
Exhaust gas color
799-201-9000
Handy smoke checker
Dirtiness 0 – 70% with standard color (Dirtiness % × 1/10 Bosch scale)
14
Water and fuel content in oil
799-201-6000
Engine oil checker
Provided with 0.1 and 0.2 water content standard sample
15
Fuel injection pressure
Nozzle tester
0 – 29.4 MPa {0 – 300 kg/cm2}
16
Fuel injection nozzle spray condition
Commercially available
17
Coolant quality
799-202-7001
Water quality tester
PH, nitrite ion concentration
18
Pressure valve function 799-202-9001
Radiator cap tester
0 – 0.2 MPa {0 – 2 kg/cm2}
Current, Voltage, Resistance
19
Leakage in cooling system
20
Electrical circuit
Commercially available
Tester
21
Diagnosis of engine controller system
799-606-9100
Governor checker
6D140-2 SERIES
12-67 (10)
Troubleshooting
Testing and adjusting data
Testing and adjusting data Engine model
S6D140-2
Applicable machine model
Intake, exhaust system
Performance
Category
Item Engine speed
Necessary starting speed
Measurement conditions High idling speed
GD825A-2 Unit rpm
Engine proper Lubrication system
Standard value
Permissible value
2,300 – 2,400 2,300 – 2,400 2,300 – 2,400 2,300 – 2,400
rpm
650 – 700
650 – 700
700 – 750
700 – 750
0ºC (without starting aid)
rpm
Min. 110
—
Min. 110
—
–20ºC (with starting aid)
rpm
Min. 85
—
Min. 85
—
kPa {mmH2O}
Max. 2.94 {Max. 300}
7.50 {762}
Max. 2.94 {Max. 300}
7.50 {762}
Intake resistance
At all speed
Boost pressure
At rated flywheel horsepower
kPa {mmHg}
Min.70.6 {Min. 530}
56.0 {420}
Min. 85.4 {Min. 640}
68.0 {510}
Exhaust pressure (Turbine inlet press.)
At rated flywheel horsepower
kPa {mmHg}
Min. 61.3 {Min. 460}
49.3 {370}
Min. 72.0 {Min. 540}
57.3 {430}
Exhaust temperature (Turbine inlet temp.)
All speed (20ºC)
ºC
700
700
650
700
Max. 6.0
8.0
Max. 6.0
8.0
Max. 1.5
2.5
Max. 1.0
2.5
Max. 1.0
2.0
Max. 1.0
2.0
mm
0.43
—
0.43
—
mm
0.80
—
0.80
—
MPa {kg/cm2}
Min. 3.82 {Min. 39}
2.65 {27}
Min. 3.82 {Min. 39}
2.65 {27}
Blow-by pressure At rated flywheel horsepower (SAE30 or SAE 15W-40) (Water temp: Min. 70ºC)
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
Max. 1.47 {Max. 150}
2.94 {300}
At rated flywheel horsepower SAE30 or SAE15W-40 oil
kPa {kg/cm2}
340 – 490 {3.5 – 5.0}
206 {2.1}
340 – 490 {3.5 – 5.0}
206 {2.1}
kPa {kg/cm2}
290 – 441 {3.0 – 4.5}
177 {1.8}
290 – 441 {3.0 – 4.5}
177 {1.8}
kPa {kg/cm2}
Min. 118 {Min. 1.2}
69 {0.7}
Min. 118 {Min. 1.2}
69 {0.7}
kPa {kg/cm2}
Min. 98 {Min. 1.0}
69 {0.7}
Min. 98 {Min. 1.0}
69 {0.7}
Quick acceleration (Low idle o high idle) Exhaust gas color
At rated flywheel horsepower
Intake valve Valve clearance (When engine is hot or cold) Exhaust valve
Fuel
Permissible value
Low idling speed
Bosch index
High idling speed
Cooling
Standard value
WA500-3
Compression pressure Oil temperature: 40 – 60ºC (SAE30 or SAE 15W-40) (Engine speed: 200 – 250 rpm)
Oil pressure (Oil temperature: Min. 80ºC)
SAE 10W oil At low idling SAE30 or SAE15W-40 oil SAE 10W oil
Oil temperature
All speed (Oil in oil pan)
ºC
90 – 110
120
90 – 110
120
Oil consumption ratio
At continuous rated horsepower (Ratio to fuel consumption)
%
Max. 0.5
1.0
Max. 0.5
1.0
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
25.0 – 25.8 {255 – 263}
20.2 {206}
25.0 – 25.8 {255 – 263}
20.2 {206}
Fuel injection timing
B.T.D.C.
degree
15 – 17
15 – 17
15 – 17
15 – 17
Radiator pressure valve
Opening pressure (Differential pressure)
MPa {kg/cm2}
—
—
—
—
Fan speed
At rated engine speed
rpm
Fan belt tension
Deflects when pushed with a force of 59 N {6 kg}
mm
1,640 – 1,720 1,640 – 1,720 1,106 – 1,174 1,106 – 1,174 8 – 12
8 – 12
13 – 15 *1 17 – 19 *2
13 – 15 *1 17 – 19 *2
a This STANDARD VALUE TABLE does not give the standard value for adjusting the engine output. Do not use the values in this table to change the setting for fuel injection pump. *1: When belt is new. *2: When adjusting
12-68 (10)
6D140-2 SERIES
Troubleshooting
Testing and adjusting data
S6D140-2
Standard value
Permissible value
6D140-2 SERIES
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
12-69 (10)
Troubleshooting
Testing and adjusting data
Engine model
SA6D140-2
Applicable machine model
Intake, exhaust system
Performance
Category
Item
Engine speed
Necessary starting speed
Measurement conditions
D155A-2 Unit
Engine proper
Permissible value
Low idling speed
rpm
550 – 650
550 – 650
700 – 725
700 – 725
0ºC (without starting aid)
rpm
Min. 110
—
Min. 110
—
–20ºC (with starting aid)
rpm
Min. 85
—
Min. 85
—
2,200 – 2,280 2,200 – 2,280 2,050 – 2,150 2,050 – 2,150
kPa {mmH2O}
Max. 2.94 {Max. 300}
7.50 {762}
Max. 2.94 {Max. 300}
7.50 {762}
Intake resistance
At all speed
Boost pressure
At rated flywheel horsepower
kPa {mmHg}
Max. 85.4 {Min. 640}
68.0 {510}
Exhaust pressure (Turbine inlet press.)
At rated flywheel horsepower
kPa {mmHg}
Min. 74.7 {Min. 560}
60.0 {450}
Exhaust temperature (Turbine inlet temp.)
All speed (20ºC)
Max. 650
700
Max. 680
700
Max.6.0
8.0
Max. 6.0
8.0
Max. 1.0
2.5
Max. 1.0
2.5
Max. 1.0
2.0
Max. 1.0
2.0
mm
0.43
—
0.43
—
mm
0.80
—
0.80
—
Compression pressure Oil temperature: 40 – 60ºC (SAE30 or SAE 15W-40) (Engine speed: 200 – 250 rpm)
MPa {kg/cm2}
Min. 3.80 {Min. 39}
2.65 {27}
Min. 3.82 {Min. 39}
2.65 {27}
Blow-by pressure At rated flywheel horsepower (SAE30 or SAE 15W-40) (Water temp: Min. 70ºC)
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
Max. 0.98 {Max. 100}
1.96 {200}
kPa {kg/cm2}
340 – 490 {3.5 – 5.0}
205 {2.1}
340 – 490 {3.5 – 5.0}
206 {2.1}
kPa {kg/cm2}
290 – 440 {3.0 – 4.5}
176 {1.8}
290 – 441 {3.0 – 4.5}
177 {1.8}
kPa {kg/cm2}
Min. 118 {Min. 1.2}
78 {0.8}
Min. 118 {Min. 1.2}
69 {0.7}
kPa {kg/cm2}
Min. 98 {Min. 1.0}
68 {0.7}
Min. 98 {Min. 1.0}
69 {0.7}
Quick acceleration (Low idle o high idle) Exhaust gas color
At rated flywheel horsepower
At rated flywheel horsepower SAE30 or SAE15W-40 oil Lubrication system
Standard value
rpm
Intake valve Valve clearance (When engine is hot or cold) Exhaust valve
Fuel
Permissible value
High idling speed
ºC
Bosch index
High idling speed
Cooling
Standard value
D155A-3, D155AX-3
Oil pressure (Oil temperature: Min. 80ºC)
SAE 10W oil At low idling SAE30 or SAE15W-40 oil SAE 10W oil
Oil temperature
All speed (Oil in oil pan)
ºC
90 – 110
120
80 – 110
120
Oil consumption ratio
At continuous rated horsepower (Ratio to fuel consumption)
%
Max. 0.5
1.0
Max. 0.5
1.0
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
25.0 – 25.8 {255 – 263}
20.2 {206}
24.0 – 25.8 {245 – 263}
20.2 {206}
Fuel injection timing
B.T.D.C.
degree
14.5 – 15.5
—
26 – 28
26 – 28
Radiator pressure valve
Opening pressure (Differential pressure)
kPa {kg/cm2}
—
—
—
—
Fan speed
At rated engine speed
rpm
1,165 – 1,235 1,165 – 1,235 1,255 – 1,335 1,255 – 1,335
Fan belt tension
Deflects when pushed with a force of 59 N {6 kg}
mm
Auto-tensioner
—
Auto-tensioner Auto-tensioner
a 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. *: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)
12-70 (10)
6D140-2 SERIES
Troubleshooting
Testing and adjusting data
SA6D140-2 D155AX-5
D355C-3
DCA400SSK-2 (DENYO generator)
PC1600SP-1
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
2,050 – 2,150
2,050 – 2,150
2,200 – 2,280
2,200 – 2,280
1,930 – 2,030
1,930 – 2,030
700 – 725
700 – 725
700 – 750
700 – 750
725 – 775
725 – 775
800 – 850
800 – 850
Min. 110
—
Min. 110
—
Min. 110
—
Min. 110
—
Min. 85
—
Min. 85
—
Min. 85
—
Min. 85
—
Max. 2.94 {Max. 300}
7.47 {762}
Max. 2.94 {Max. 300}
7.47 {762}
Max. 2.94 {Max. 300}
7.50 {762}
Max. 2.94 {Max. 300}
7.50 {762}
Min. 85 {Min. 640}
66.5 {500}
Min. 160 {Min. 1,200}
128 {960}
Min. 117.4 {Min. 880}
93.4 {700}
Min. 160 {Min. 1,200}
128 {960}
Min. 74 {Min. 560}
59.9 {450}
Min. 120 {Min. 900}
96.0 {720}
Min. 102.7 {Min.770}
82.7 {620}
Min. 120 {Min. 900}
96.0 {720}
Max. 650
700
Max. 650
700
700
700
650
700
Max. 6.0
8.0
Max. 6.0
8.0
Max. 6.0
8.0
—
—
Max. 1.0
2.5
Max. 1.0
2.5
Max. 2.0
3.5
1.5
2.5
Max. 1.0
2.0
Max. 1.0
2.0
Max. 2.0
3.0
1.0
2.0
0.43
—
0.43
—
0.43
—
0.43
—
0.80
—
0.80
—
0.80
—
0.80
—
Min. 3.8 {Min. 39}
2.7 {27}
Min. 3.80 {Min. 39}
2.7 {27}
Min. 3.82 {Min. 39}
2.65 {27}
Min. 3.82 {Min. 39}
2.65 {27}
Max. 0.98 {Max. 100}
1.96 {200}
Max. 0.98 {Max. 100}
1.96 {200}
Max. 1.96 {Max. 200}
3.92 {400}
Max. 1.96 {Max. 200}
3.92 {400}
340 – 490 {3.5 – 5.0}
210 {2.1}
340 – 490 {3.5 – 5.0}
210 {2.1}
340 – 490 {3.5 – 5.0}
177 {1.8}
275 – 441 {2.8 – 4.5}
192 {2.0}
290 – 440 {3.0 – 4.5}
176 {1.8}
290 – 440 {3.0 – 4.5}
176 {1.8}
290 – 441 {3.0 – 4.5}
137 {1.4}
226 – 392 {2.3 – 4.0}
157 {1.6}
Min. 118 {Min. 1.2}
78 {0.8}
Min. 118 {Min. 1.2}
78 {0.8}
Min. 118 {Min. 1.2}
69 {0.7}
Min. 177 {Min. 1.8}
69 {0.7}
Min. 98 {Min. 1.0}
68 {0.7}
Min. 98 {Min. 1.0}
68 {0.7}
Min. 98 {Min. 1.0}
69 {0.7}
Min. 98 {Min. 1.0}
69 {0.7}
90 – 110
120
90 – 110
120
90 – 110
120
110
120
Max. 0.5
1.0
Max. 0.5
1.0
Max. 0.5
1.0
Max. 0.5
1.0
24.8 – 25.5 {253 – 260}
20.2 {206}
25.0 – 25.8 {255 – 263}
20.2 {206}
24.8 – 25.5 {253 – 260}
20.2 {206}
25.0 – 25.8 {255 – 263}
20.2 {206}
14 – 16
—
18.5 – 19.5
—
18 – 20
18 – 20
—
—
—
—
970 – 1,030
970 – 1,030
1,025 – 1,085
1,025 – 1,085
Auto-tensioner
—
Auto-tensioner
Auto-tensioner
— 1,390 – 1,470 Auto-tensioner
6D140-2 SERIES
—
Standard value
Permissible value
Max. 1,568 50Hz Max. 1,568 50Hz Max. 1,881 60Hz Max. 1,881 60Hz
14.5 – 15.5 50Hz 14.5 – 15.5 50Hz 16.5 – 17.5 60Hz 16.5 – 17.5 60Hz
59 – 78 {0.6 – 0.8}
—
1,106 – 1,174 50Hz 1,106 – 1,174 50Hz 1,327 – 1,409 60Hz 1,327 – 1,409 60Hz
8 – 12
8 – 12
12-71 (10)
Troubleshooting
Testing and adjusting data
Engine model
SA6D140-2 DCA-400SSK (MQ generator)
Applicable machine model
Intake, exhaust system
Performance
Category
Item
Engine speed
Necessary starting speed
Measurement conditions
Unit
Engine proper
Permissible value
Max. 1,575 50Hz Max. 1,575 50Hz Max. 1,890 60Hz Max. 1,890 60Hz
Low idling speed
rpm
800 – 850
0ºC (without starting aid)
rpm
Min. 110
–20ºC (with starting aid)
rpm
Min. 85
—
Min. 85
—
kPa {mmH2O}
Max. 2.94 {Max. 300}
7.47 {762}
Max. 2.94 {Max. 300}
7.47 {762}
Max. 1,890 60Hz Max. 1,890 60Hz
—
700 – 900
700 – 900
Min. 110
—
Intake resistance
At all speed
Boost pressure
At rated flywheel horsepower
kPa {mmHg}
—
—
Max. 160 {Min. 1,200}
128 {960}
Exhaust pressure (Turbine inlet press.)
At rated flywheel horsepower
kPa {mmHg}
—
—
Min. 120 {Min. 900}
96 {720}
Exhaust temperature (Turbine inlet temp.)
All speed (20ºC)
ºC
Max. 650
700
Max. 650
700
—
—
—
—
Max. 1.5
2.5
Max. 1.5
2.5
Max. 1.0
2.0
Max. 1.0
2.0
mm
0.43
—
0.43
—
mm
0.80
—
0.80
—
Min. 3.80 {Min. 39}
2.7 {27}
Min. 3.82 {Min. 39}
2.7 {27}
kPa {mmH2O}
Max. 1.96 {Max. 200}
3.92 {400}
Max. 1.96 {Max. 200}
3.92 {400}
kPa {kg/cm2}
294 – 490 {3.0 – 5.0}
210 {2.1}
294 – 490 {3.0 – 5.0}
210 {2.1}
kPa {kg/cm2}
245 – 440 {2.5 – 4.5}
176 {1.8}
245 – 440 {2.5 – 4.5}
176 {1.8}
kPa {kg/cm2}
Min. 118 {Min. 1.2}
78 {0.8}
Min. 118 {Min. 1.2}
78 {0.8}
kPa {kg/cm2}
Min. 98 {Min. 1.0}
68 {0.7}
Min. 98 {Min. 1.0}
68 {0.7}
Quick acceleration (Low idle o high idle) Exhaust gas color
At rated flywheel horsepower
Bosch index
Compression pressure Oil temperature: 40 – 60ºC MPa (SAE30 or SAE 15W-40) (Engine speed: 200 – 250 rpm) {kg/cm2} Blow-by pressure At rated flywheel horsepower (SAE30 or SAE 15W-40) (Water temp: Min. 70ºC) At rated flywheel horsepower SAE30 or SAE15W-40 oil
Lubrication system
Standard value
rpm
Intake valve Valve clearance (When engine is hot or cold) Exhaust valve
Fuel
Permissible value
High idling speed
High idling speed
Cooling
Standard value
J6D140E-G1-2 (TAIYO DENKI generator)
Oil pressure (Oil temperature: Min. 80ºC)
SAE 10W oil At low idling SAE30 or SAE15W-40 oil SAE 10W oil
Oil temperature
All speed (Oil in oil pan)
ºC
90 – 110
120
90 – 110
120
Oil consumption ratio
At continuous rated horsepower (Ratio to fuel consumption)
%
Max. 0.5
1.0
Max. 0.5
1.0
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
25.0 – 25.8 {255 – 263}
20.2 {206}
25.0 – 25.8 {255 – 263}
20.2 {206}
Fuel injection timing
B.T.D.C.
degree
16.5 – 17.5
—
16 – 18 50Hz 17 – 19 60Hz
16 – 18 50Hz 17 – 19 60Hz
Radiator pressure valve
Opening pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated engine speed
rpm
1,330 – 1,410 (60 Hz)
Fan belt tension
Deflects when pushed with a force of 60 N {6 kg}
mm
8 – 12
1,330 – 1,410 1,220 – 1,300 50Hz 1,220 – 1,300 50Hz 1,465 – 1,555 60Hz 1,465 – 1,555 60Hz (60 Hz) 14 – 18
8 – 12
8 – 12
a 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. *: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)
12-72 (10)
6D140-2 SERIES
Troubleshooting
Testing and adjusting data
SA6D140-2 D155C-1 (–30°C spec.)
D155C-1 (–50°C spec.)
D355C-3 (–30°C spec.)
D355C-3 (–50°C spec.)
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
2,190 – 2,290
2,190 – 2,290
2,190 – 2,290
2,190 – 2,290
2,200 – 2,280
2,200 – 2,280
2,200 – 2,280
2,200 – 2,280
700 – 750
700 – 750
700 – 750
700 – 750
700 – 750
700 – 750
700 – 750
700 – 750
Min. 110
—
Min. 110
—
Min. 110
—
Min. 110
—
Min. 85
—
Min. 85
—
Min. 85
—
Min. 85
—
Max. 2.94 {Max. 300}
7.47 {762}
Max. 2.94 {Max. 300}
7.47 {762}
Max. 2.94 {Max. 300}
7.47 {762}
Max. 2.94 {Max. 300}
7.47 {762}
Min. 99 {Min. 740}
83 {620}
Min. 99 {Min. 740}
83 {620}
Min. 160 {Min. 1,200}
128 {960}
Min. 160 {Min. 1,200}
128 {960}
Min. 84 {Min. 630}
71 {530}
Min. 84 {Min. 630}
71 {530}
Min. 120 {Min. 900}
96.0 {720}
Min. 120 {Min. 900}
96.0 {720}
Max. 600
700
Max. 600
700
Max. 650
700
Max. 650
700
Max. 6.0
7.0
Max. 6.0
7.0
Max. 6.0
8.0
Max. 6.0
8.0
Max. 1.0
2.5
Max. 1.0
2.5
Max. 1.0
2.5
Max. 1.0
2.5
Max. 1.0
2.0
Max. 1.0
2.0
Max. 1.0
2.0
Max. 1.0
2.0
0.43
—
0.43
—
0.43
—
0.43
—
0.80
—
0.80
—
0.80
—
0.80
—
Min. 3.80 {Min. 39}
2.7 {27}
Min. 3.80 {Min. 39}
2.7 {27}
Min. 3.80 {Min. 39}
2.7 {27}
Min. 3.80 {Min. 39}
2.7 {27}
Max. 0.98 {Max. 100}
1.96 {200}
Max. 0.98 {Max. 100}
1.96 {200}
Max. 0.98 {Max. 100}
1.96 {200}
Max. 0.98 {Max. 100}
1.96 {200}
340 – 490 {3.5 – 5.0}
210 {2.1}
340 – 490 {3.5 – 5.0}
210 {2.1}
340 – 490 {3.5 – 5.0}
210 {2.1}
340 – 490 {3.5 – 5.0}
210 {2.1}
290 – 440 {3.0 – 4.5}
176 {1.8}
290 – 440 {3.0 – 4.5}
176 {1.8}
290 – 440 {3.0 – 4.5}
176 {1.8}
290 – 440 {3.0 – 4.5}
176 {1.8}
Min. 118 {Min. 1.2}
78 {0.8}
Min. 118 {Min. 1.2}
78 {0.8}
Min. 118 {Min. 1.2}
78 {0.8}
Min. 118 {Min. 1.2}
78 {0.8}
Min. 98 {Min. 1.0}
68 {0.7}
Min. 98 {Min. 1.0}
68 {0.7}
Min. 98 {Min. 1.0}
68 {0.7}
Min. 98 {Min. 1.0}
68 {0.7}
80 – 110
120
80 – 110
120
90 – 110
120
90 – 110
120
Max. 0.5
1.0
Max. 0.5
1.0
Max. 0.5
1.0
Max. 0.5
1.0
24.8 – 25.5 {253 – 260}
20.2 {206}
24.8 – 25.5 {253 – 260}
20.2 {206}
25.0 – 25.8 {255 – 263}
20.2 {206}
25.0 – 25.8 {255 – 263}
20.2 {206}
18 – 20
—
18 – 20
—
18.5 – 19.5
—
18.5 – 19.5
—
—
—
—
—
—
—
—
—
—
—
—
—
970 – 1,030
970 – 1,030
970 – 1,030
970 – 1,030
—
—
—
—
Auto-tensioner
—
Auto-tensioner
—
6D140-2 SERIES
12-73 (10)
Troubleshooting
Testing and adjusting data
Engine model
SAA6D140-2
Applicable machine model
Intake, exhaust system
Performance
Category
Item Engine speed
Necessary starting speed
Measurement conditions
PC750-6, PC800-6 Unit
rpm
775 – 825
775 – 825
675 – 775
675 – 775
0ºC (without starting aid)
rpm
Min. 110
—
Min. 110
—
–20ºC (with starting aid)
rpm
Min. 85
—
Min. 85
—
kPa {mmH2O}
Max. 2.94 {Max. 300}
7.47 {762}
Max. 2.9 {Max. 300}
7.47 {762}
Max. 650
700
Max. 700
700
Max.6.0
7.0
Max. 6.0
7.0
At all speed
Boost pressure
At rated output
kPa {mmHg}
Exhaust pressure (Turbine inlet press.)
At rated output
kPa {mmHg}
Exhaust temperature (Turbine inlet temp.)
All speed (20ºC) Quick acceleration (Low idle o high idle) At rated output
ºC
Bosch index
Engine body
1,930 – 2,030 1,930 – 2,030 2,350 – 2,450 2,350 – 2,450
Max. 1.0
2.0
Max. 1.0
2.0
Max. 1.0
2.0
Max. 1.0
2.0
mm
0.43
—
0.43
—
mm
0.80
—
0.80
—
Compression pressure Oil temperature: 40 – 60ºC (SAE30 or SAE 15W-40) (Engine speed: 200 – 250 rpm)
MPa {kg/cm2}
Min. 3.82 {Min. 39}
2.65 {27}
Min. 3.82 {Min. 39}
2.65 {27}
Blow-by pressure At rated output (SAE30 or SAE 15W-40) (Water temp: 70ºC min.)
kPa {mmH2O}
Max. 1.96 {Max. 200}
3.92 {400}
Max. 1.96 {Max. 200}
3.92 {400}
kPa {kg/cm2}
340 – 490 {3.5 – 5.0}
210 {2.1}
340 – 490 {3.5 – 5.0}
210 {2.1}
kPa {kg/cm2}
290 – 440 {3.0 – 4.5}
180 {1.8}
290 – 440 {3.0 – 4.5}
180 {1.8}
kPa {kg/cm2}
Min. 118 {Min. 1.2}
69 {0.7}
Min. 118 {Min. 1.2}
78 {0.8}
kPa {kg/cm2}
Min. 98 {Min. 1.0}
69 {0.7}
Min. 98 {Min. 1.0}
69 {0.7}
At rated output SAE30 or SAE15W-40 oil Lubrication system
Permissible value
Low idling speed
Intake valve Valve clearance (When engine is hot or cold) Exhaust valve
Fuel system
Standard value
rpm
High idling
Cooling system
Permissible value
High idling speed
Intake resistance
Exhaust gas color
Standard value
HD325-6, HD405-6
Oil pressure (Oil temperature: 80ºC min.)
SAE 10W oil At low idling SAE30 or SAE15W-40 oil SAE 10W oil
Oil temperature
All speed (Oil in oil pan)
ºC
80 – 110
120
80 – 110
120
Oil consumption ratio
At continuous rated output (Ratio to fuel consumption)
%
Max. 0.5
1.0
Max. 0.5
1.0
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
24.8 – 25.5 {253 – 260}
20.2 {206}
24.8 – 25.5 {253 – 260}
20.2 {206}
Fuel injection timing
B.T.D.C.
degree
18.5 – 19.5
18.5 – 19.5
19.5 – 20.5
19.5 – 20.5
Radiator pressure valve
Opening pressure (Differential pressure)
kPa {kg/cm2}
—
—
—
—
Fan speed
At rated engine speed
rpm
Fan belt tension
Deflects when pushed with a force of 58.8 N {6 kg}
mm
1,018 – 1,082 1,018 – 1,082 (Autotensioner)
—
—
(Autotensioner)
—
—
a 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. *: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)
12-74 (10)
6D140-2 SERIES
Troubleshooting
Testing and adjusting data
SAA6D140-2
SDA6D140E-2
HD325-6 (High altitude spec.) Standard value
Permissible value
2,350 – 2,450
Standard value
Permissible value
2,350 – 2,450
2,150 – 2,250
—
675 – 775
675 – 775
650 – 750
—
Min. 110
—
Min. 110
—
Min. 85
—
Min. 85
—
Max. 2.94 {Max. 300}
7.50 {762}
Max. 2.94 {Max. 300}
7.50 {762}
Min. 97.4 {Min. 730}
77.3 {580}
Min. 118.6 {Min. 890}
98.6 {740}
Min. 97.4 {Min. 730}
77.3 {580}
Min. 113.3 {Min. 850}
94.7 {710}
Max. 700
700
Max. 650
700
Max. 5.0
7.0
Max. 6.0
7.0
Max. 1.5
2.5
Max. 1.0
2.0
Max. 1.0
2.0
Max. 1.0
2.0
0.43
—
0.43
—
0.80
—
0.80
—
Min. 3.82 {Min. 39}
2.65 {27}
Min. 3.14 {Min. 32}
2.16 {22}
Max. 1.96 {Max. 200}
3.92 {400}
Max. 1.47 {Max. 150}
2.94 {300}
343 – 490 {3.5 – 5.0}
245 {2.5}
290 – 490 {3.0 – 5.0}
200 {2.0}
294 – 441 {3.0 – 4.5}
206 {2.1}
250 – 440 {2.5 – 4.5}
180 {1.8}
Min. 147 {Min. 1.5}
69 {0.7}
Min. 100 {Min. 1.0}
70 {0.7}
Min. 98 {Min. 1.0}
69 {0.7}
Min. 100 {Min. 1.0}
70 {0.7}
90 – 110
120
80 – 110
120
Max. 0.5
1.0
Max. 0.5
1.0
25.0 – 25.8 {255 – 263}
20.2 {206}
25.0 – 25.8 {255 – 263}
20.2 {206}
19.5 – 20.5
19.5 – 20.5
18.5 – 19.5
18.5 – 19.5
—
—
—
—
1,018 – 1,082
1,018 – 1,082
—
—
Auto-tensioner
Auto-tensioner
—
—
6D140-2 SERIES
Standard value
Permissible value
Standard value
Permissible value
12-75 (10)
13
DISASSEMBLY
AND ASSEMBLY
GENERAL DISASSEMBLY 13-2 Air cleaner muffler ...................................... Starting motor ................................................ 13-2 Turbocharger drain tube ............................... 13-3 Setting engine in engine overhaul stand ... 13-3 Corrosion resistor, air compressor 13-3 suction tube .............................................. Bracket.. ........................................................... 13-3 Connector.. ...................................................... 13-4 Tension pulley assembly.. ............................. 13-4 Fan pulley assembly ...................................... 13-4 Alternator assembly pulley.. ....................... 13-4 Dipstick guide, air compressor ..................... 13-5 Fuel hose.. ....................................................... 13-5 Turbocharger .................................................. 13-5 Exhaust manifold ........................................... 13-5 After-cooler assembly (Intake manifold assembly). .................... 13-5 Fuel injection tube ......................................... 13-5 Fuel injection pump assembly.. ................... .13-6 Tube, bracket, PTO case ................................ 13-6 Fuel filter fuel filter bracket ........................ 13-6 Oil filter oil regulator ................................... 13-6 13-7 Oil pan ............................................................. Suction pipe, under frame ............................ 13-7 Flywheel .......................................................... 13-7 Rear seal ......................................................... 13-7 Flywheel housing ........................................... 13-8 l
l
g :
l
l
Air vent tube, spill pipe, rocker arm housing cover ........................................ Nozzle holder, inlet connector .................... Rocker arm.. .................................................. Push rod.. ...................................................... Crosshead ..................................................... Rocker arm housing.. ................................... Cylinder head assembly .............................. Vibration damper crankshaft pulley assembly ................................................. Front support.. .............................................. Thermostat housing ..................................... Water pump assembly ................................ Oil cooler assembly ..................................... Cam follower ................................................ Gear case cover.. .......................................... Injection pump drive gear.. ......................... Camshaft ....................................................... Oil pump assembly, oil pump idler gear ................................................ Main idler gear, injection pump drive shaft ............................................... Piston cooling nozzle ................................... Piston and connecting rod assembly ......... Crankshaft ..................................................... Cylinder liner ................................................
13- 8 13- 9 13- 9 13-10 13-10 13-10 13-10
l
13-l 1 13-11 13-11 13-11 13-11 13-12 13-12 13-12 13-12 13-13 13-13 13-13 13-13 13-15 13-16
ASSEMBLY
Special
AND
DISASSEMBLY
GENERAL
tools Part No.
Part Name
A
790-901-1260
Adapter
B
790-501-2001
Engine overhaul
C
795-102-2102
Spring pusher
l
:
Engine
oil: Approx.
Q’ty 1
Preparatory work l Clean off all mud and dirt. l Drain cooling water and engine -
DISASSEMBLY
stand
1 1
oil.
37 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 according to the model of machine on which it is mounted.)
1.
Air cleaner muffler 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 connection, cover the openings to prevent dirt or dust from entering the turbocharger.
2.
Starting motor Remove mounting motor (2).
l
13-2 0
bolts (I), then remove starting
I
I
CLlE00133
ASSEMBLY
AND
DISASSEMBLY
GENERAL
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.
DISASSEMBLY
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). tubes from air compressor. (If 4) Remove equipped).
COEOOl38
6.
Bracket Remove mounting (I) and (2).
bolts, then remove
brackets
CDE00139
13-3 0
ASSEMBLY
7.
AND
DISASSEMBLY
GENERAL
DISASSEMBLY
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 tension pulley assembly (5).
remove
CEE00143
9.
Fan pulley assembly Remove mounting bolts pulley assembly (2).
(I),
then
remove
fan
CEE00144
10. Alternator assembly 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). bolts (9) and remove 5) Remove mounting pulley (IO). l
ASSEMBLY
AND
GENERAL
DISASSEMBLY
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 tube. 2) Remove mounting bolts turbocharger (2).
14. Exhaust manifold Remove mounting manifold (2).
lubrication (I),
then
inlet remove
bolts (I), then remove exhaust
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).
DISASSEMBLY
ASSEMBLY
AND
GENERAL
DISASSEMBLY
DISASSEMBLY
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).
fuel filter bracket 19. Fuel filter Remove fuel filter (I) and fuel filter bracket (2). l
oil regulator 20. Oil filter Remove oil filter (3) and oil regulator l
(4).
-
13-6 0
ASSEMBLY
21. Oil 1) 2) 3)
AND
GENERAL
DISASSEMBLY
DISASSEMBLY
pan Remove wiring connector (I) from bracket. Disconnect drain hose (2). Remove oil pan (3).
3
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.
2
CEE00154
ASSEMBLY
l
AND
DISASSEMBLY
GENERAL
Removal of standard seal Hook tip of tool L to metal ring of seal (I), then use impact force of slide hammer to remove seal. * 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.
DISASSEMBLY
Too I
Slide hammer
DWE00211
l
Removal of seal with sleeve I) Hook tip of tool L to metal ring of seal (I), then use impact force of slide hammer to remove seal. * 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. * Be extremely careful not to damage 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 housing (2), then remove.
(I),
Flywheel
55 kg
kg LL?l
housing:
sling
Standard Flywheel hausins
I
seal
Seal
Metal rins
with
sleeve
Flywheel housing
Cr.ankshaft DWEOOZIZ
Crankshaft
2
DWE00213
flywheel
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
ASSEMBLY
AND
DISASSEMBLY
GENERAL
DISASSEMBLY
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
ASSEMBLY
AND
GENERAL
DISASSEMBLY
DISASSEMBLY
29. Push rod Remove push rod (I). 30. Crosshead Remove crosshead
(2).
31. Rocker arm housing Remove mounting bolts, then remove rocker arm housing (3).
32. Cylinder head assembly 1) Remove mounting bolts (I), then cylinder head assembly (2). 2) Remove each cylinder head gasket.
l
remove
Disassemble cylinder head assembly as follows, Using spring pusher C, compress valve i) spring and remove cotter (I). ii) Remove upper vale seat (2), outer valve spring (3), and inner valve spring (4).
CEEOOl65
CEE0016r
iii) Remove lower valve seat (5). iv) Lift up cylinder head and remove
valves
(6).
I I
I CEE00166
13-10 0
6
CEE00167
ASSEMBLY
AND
GENERAL
DISASSEMBLY
DISASSEMBLY
33. Vibration damper crankshaft pulley assembly Remove mounting bolts (I), then remove vibration damper, crankshaft pulley assembly (2). l
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
37. Oil cooler assembly Remove oil cooler assembly
(I).
CEE00171
ASSEMBLY
AND
DISASSEMBLY
GENERAL
DISASSEMBLY
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
ASSEMBLY
AND
GENERAL
DISASSEMBLY
DISASSEMBLY
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 cooling nozzle (2).
piston
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. so that piston to be 2) Rotate crankshaft 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 assembly.
CEEOOlI31
ASSEMBLY
AND DISASSEMBLY
4) 5)
Remove bolts (I) of connecting rod cap. 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. 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.
7)
0
GENERAL
DISASSEMBLY
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. CEE00184
3
iv) Using piston ring tool D, remove piston rings (7). * Keep piston, connecting rod, bearing, piston rings and piston pin in sets according to cylinder number.
7
CEE00185
13-14 0
ASSEMBLY AND DISASSEMBLY
GENERAL DISASSEMBLY
46. Crankshaft If necessary, measure the end play of the crankshaft with dial gauge @ before removing the crankshaft.
-
1) Remove mounting bolts (2) of main bearing cap (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).
Crankshaft: 140 kg r55kg * 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.
CEE00186
ASSEMBLY
5)
AND
Remove
DISASSEMBLY
GENERAL
upper thrust bearings
DISASSEMBLY
(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 turning angle method ........................... Drawing of special tool ............................... Preparatory work .......................................... Cylinder liner ................................................ Crankshaft ..................................................... Piston and connecting rod assembly ......... Piston cooling nozzle ................................... Main idler gear, fuel injection pump drive shaft ............................................... Oil pump idler gear, oil pump assembly ................................................. Camshaft ....................................................... Fuel injection pump drive gear .................. Fuel injection pump drive shaft oil seal ... Gear case cover ............................................ Breather.. ....................................................... Front seal ...................................................... Cam follower ................................................ Oil cooler assembly ..................................... Water pump assembly ................................ Thermostat housing ..................................... Front support ................................................ Vibration damper, crankshaft pulley assembly.. ............................................... Cylinder head assembly .............................. Crosshead ..................................................... Rocker arm housing ..................................... Push rod ........................................................ Rocker arm .................................................... Adjusting valve clearance ...........................
13-18 13-19 13-20 13-21 13-23 13-26 13-28 13-29 13-30 13-30 13-30 13-31 13-32 13-32 13-33 13-34 13-34 13-35 13-35 13-35 13-35 13-36 13-38 13-38 13-38 13-39 13-39
Nozzler holder, inlet connector.. ................. 13-40 Rocker arm housing cover, spill pipe, air vent tube ........................................... 13-41 Flywheel housing ......................................... 13-41 Rear seal ....................................................... 13-42 Flywheel ........................................................ 13-45 Suction pipe .................................................. 13-46 13-46 Oil pan ........................................................... Oil filter assembly, oil regulator.. .............. .13-46 Fuel filter assembly fuel filter bracket.. .. 13-46 PTO case tube, bracket.. .............................. 13-47 Fuel injection pump assembly.. .................. 13-47 Adjusting fuel injection pump .................... 13-48 Fuel injection tube ....................................... 13-50 After-cooler assembly (Intake manifold 13-50 assembly) ............................................... Exhaust manifold ......................................... 13-50 ................................................ 13-51 Turbocharger 13-51 Fuel hose ....................................................... Dipstick guide, air compressor .................. .13-51 Alternator assembly, pulley ........................ 13-51 Fan pulley assembly .................................... 13-52 Tension pulley assembly.. ........................... 13-52 13-52 Intake connector ........................................... Muffler bracket, air cleaner bracket .......... .13-52 13-53 Corrosion resistor ......................................... Resetting engine in engine stand.. ............. 13-53 Turbocharger drain tube ............................. 13-53 13-53 Starting motor .............................................. Air cleaner, muffler.. .................................... 13-54 Refilling with oil ........................................... 13-54 l
13-17 0
ASSEMBLY
AND DISASSEMBLY
GENERAL ASSEMBLY
TIGHTENING BOLTS BY THE PLASTIC RANGE TURNING ANGLE METHOD Important bolts in the 140 Series engines 0
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
t Wlastic range)
obtained. The most
common
is the torque however, tightening friction.
for tightening bolts method. In this method,
method
control
it is difficult to accurately control force because of the coefficient
Plastic range turning angle
the of (conventional
The plastic range turning angle method is based on the initial tightening torque and the turning angle. Elongation exceeding the elastic range results
0
*
in permanent
Elongation
deformation.
method)
of bolt
Bolts to be tightened by the plastic range turning angle method in the 140 Series engines.
0
I) 2) 3)
Cylinder head mounting bolts Main cap mounting bolts Connecting rod cap mounting
4)
Flywheel
mounting
bolts
bolts
In the plastic range turning angle method, the permanent strain remains in bolts after they are
*
tightened. Therefore, the number of times that each bolt can be reused is limited. Observe the followina orecautions. measure the free length I) Befoie tightening, of bolt and check that bolt length exceeds tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. 2) If a bolt has been tightened in excess of the specified turning angle, loosen the bolt and measure the free length of bolt again. angle should be targeted at 3) The tightening the standard
value
plus or minus
tolerance.
Special tools Part
A
No.
790-901-1260
Part Name Adapter
a’tv 1
B
790-501-2001
Engine overhaul stand
1
c
795-102-2102
Spring pusher
1
D
795-100-I 191
Piston ring tool
1
F
795-230-5472
Liner driver
1
Part Name
Part No.
J
1
K
1 795T-473-1110 1 Push tool
I
I
I
I
1
795-521-1110
Push tool
1
01050-31640
Bolt
3
1
795-931-1210
Sleeve jig
1
2
795-931-1220
Sleeve jig
1
3
01050-31645
Bolt
3
4
01050-31625
Bolt
3
M
N
790-331-I 110 1 Wrench
Q’ty
Clean all parts, and check for dents, scores or casting defects. Check that all the oil and water passages are clear.
13i’*
ASSEMBLY
Drawing
AND DISASSEMBLY
GENERAL
ASSEMBLY
of special tool
Push tool K Note)
Komatsu
has no responsibility
for special tool made by this drawing.
1
I
A
\
L
N
G
mnd
_______-_-.
omfl g6
& -=t
----------.--.-
‘a
;s
I t
/
’
/
‘L
ep’
2
Cl CDE00261
/ 795T-473-1110
n
13-19 0
ASSEMBLY
AND
DISASSEMBLY
GENERAL
ASSEMBLY
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. remove rust and scale 1) Using sandpaper, 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 smoothly to prevent damage to the O-ring.
3)
If there is pitting on face @ and it cannot be repaired, replace cylinder block.
4)
If there is pitting on face @ or portion polish to give a smooth finish.
5)
Inspect counterbore and remove all burrs. Remove all chips and dirt from face @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
0,
Q
CEE00051
GENERAL ASSEMBLY
ASSEMBLY AND DISASSEMBLY
Cylinder liner Before assembling, carry out selection of clearance between liner and piston referring to 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. If the surface is rough and pitted, it may l cause leakage of water, so replace the liner.
block
DWE00214
TOP surface
2)
of
block
Coat the mating surface of the cylinder block and cylinder liner counterbore with siliconbased 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
Matins
portion
of
deck)
the
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 +=I
er liner P
I
Crevice seal Black (Ethylene
propylene
rubber)
O-ring Black (Ethylene
propylene
rubber)
O-ring Orange
rubber)
(Silicon
w DEE00090
ASSEMBLY
l
AND
DISASSEMBLY
GENERAL
3)
Coat the liner O-ring and cylinder ring grooves with rubber lubricant
*
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 chamfered
the crevice seal side facing down.
block ORF-l.
with
the CEE00201
Method of inserting cylinder liner I) Set the stamped mark “A” or “B” on the top of the liner facing to the front, then insert the liner into the cylinder block taking care not to damage the O-ring. 2)
3)
Use your weight and push the liner in with both hands. * If the liner does not go in smoothly when you apply your weight, there is danger that the O-ring may be damaged, so check the cylinder block for burrs or flashes. Using tool F, press fit cylinder the cylinder block.
ASSEMBLY
liner (1) into
Press it to the grove
K h i
Chamfered
side
DEE00089
GENERAL ASSEMBLY
ASSEMBLY AND DISASSEMBLY
4)
5)
6)
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.
In addition, to prevent gasket sealant from being squeezed out from between the block and liner when the head is tightened, fit a used head gasket after inserting the liner and tighten the cylinder head temporarily. When tightening, use the tightening torque shown below and the order of tightening shown on the right. m Temporary tightening torque for cylinder head: 137 - 157 Nm (14 - 16 kgml
Remove the cylinder head, and wipe off the gasket sealant that has been squeezed out from the counterbore. j, If gasket sealant sticks to the grommet in the head gasket, the grommet will be deformed, so always carry out Steps 5) and 6) to remove all the gasket sealant.
CDE00204
If the covers
grommet is deformed the water hole. the
Grommet
into a heart shape coolant may leak.
Water
and
hole DWE002 I5
2.
Crankshaft 1) Align protrusion of upper main bearing (6) with notch in cylinder block, and install in cylinder block. * Check that there is no dirt or dust stuck to the rear face of the bearing. Coat the inside face of the bearing with engine oil (SAE#30) before assembling.
A *
Do not coat with oil to back face of metal. Upper metal: with oil hole.
6,
ASSEMBLY AND DISASSEMBLY
2)
GENERAL ASSEMBLY
Knock in roll pin so that it protrudes 2.7 3.4 mm from block, then install upper thrust bearings (5). j, Install the thrust bearings with the groove on the crankshaft.
CEEOOlQO
3)
Using a wire, sling crankshaft (4) and set in position on cylinder block. When installing the crankshaft, be careful not to let it hit or damage the cylinder block. * If the crankshaft gear has been replaced, heat the crankshaft gear in an electric furnace at 200°C for 30 minutes, then shrink fit.
4)
Align protrusion of lower main bearing with notch in main bearing cap and install bearing. * Check that there is no dirt or dust stuck to the rear face of the bearing when installing.
5)
Knock in roll pin so that it protrudes 2.7 3.4 mm from cap, then assemble thrust bearings (3) on both sides of No. 7 main cap. * Install the thrust bearings with the groove on the crankshaft side.
6)
Coat journal surfaces of crankshaft with engine oil (SAE#30). Check that the number on main bearing cap (2) matches the cylinder block number, and install main bearing cap. * Install the main bearing cap with the part number casting mark facing the front of the engine.
GENERAL ASSEMBLY
ASSEMBLY AND DISASSEMBLY
7)
Before tightening main cap mounting bolt (21, make sure as follows. i) Measure the free length a of all bolts and check that bolt length exceeds tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. ii) Tolerance limit of bolt free length: Max. 159.8 mm. * If the bolt length a exceeds tolerance limit, do not reuse.
8)
Coat washer and threads of mounting bolts of main bearing cap with engine oil (SAE#30). Screw in bolts (1) to fit main bearing cap completely.
9)
Tighten mounting bolts (2) of main bearing cap as follows. * When tightening the mounting bolts of the main bearing cap, start in the middle and work to the outside. Then tighten all the mounting bolts again to the next step. w Mounting bolt of main bearing cap 108 - 128 Nm {II - 13 kgml 1st step: 2nd step: 211 - 221 Nm 121.5 - 22.5 kgm1 3rd step: I) When using tool J. Turn the bolt further 90 - 120 degrees with tool J. 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.
10) After tightening bolts, rotate crankshaft and check that it rotates smoothly. 11) Measure end play of crankshaft with dial gauge 0. * End play: 0.140 - 0.315 mm
DWE00275
Put a make on the bolt and cao
ASSEMBLY
AND
DISASSEMBLY
GENERAL
3. *
Piston and connecting rod assembly Before assembling, carry out selection clearance between liner and piston referring MAINTENANCE STANDARD.
l
Assemble piston and connecting rod assembly as follows. I) Using piston ring tool D, install piston rings (7) on piston.
ASSEMBLY
of to
CEE00165
Ir * Sr
Assemble the rings as shown in the diagram. Install the piston rings with the stamped mark facing up. When fitting the oil ring, remove the 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 Sr
3)
rod. 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). Install snap rings (3) on both sides to secure piston pin.
3
4)
5)
Align protrusion of upper bearing of connecting rod with notch in connecting rod and install bearing. * Check that there is no dirt or dust stuck to the rear face of the bearing when installing. 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).
Cast
CEE00164
number
(align
13-26
on camshai t side)
ASSEMBLY AND DISASSEMBLY
6)
GENERAL ASSEMBLY
Set cast number on connecting rod facing front of engine (number is on camshaft side), align end gaps of piston rings as shown in diagram, and insert piston and connecting rod assembly (8).
CEE00212
7)
Using piston holder G, compress piston rings and push in piston head with wooden bar.
CEE00213
8)
9)
Before tightening connecting rod bolt, make sure as follows. i) Measure the free length a of all bolts and check that bolt length exceeds tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. ii) Tolerance limit of bolt free length: Max. 95.0 mm. + If the bolt length a exceeds tolerance limit, do not reuse. Align protrusion of lower bearing with notch in connecting rod cap and assemble. Align connecting rod cap (2) with mark on connecting rod and install. + Check that there is not dirt or dust stuck to the rear face of the bearing when installing. * Coat the sliding surface of the connecting rod cap with engine oil (SAE#30).
P\
\
~
a DWE00275
GENERAL ASSEMBLY
ASSEMBLY AND DISASSEMBLY
IO) Coat bolt threads and bolt seat with engine oil (SAE#30). Tighten mounting bolt (I) of connecting rod as follows. m Mounting bolt of connecting rod 1st step: 123 - 132 Nm {12.5 - 13.5 kgm1 2nd step: I) When using tool J. Turn the bolt further 90 - 120 degrees with tool J. 2) When not using tool J. Mark the bolts and the cap with a felt-tip pen and turn the bolts further 90 - 120 degrees.
*
Make a punch mark on the bolt head each time the bolts are used. If there are already five marks on the bolt head, replace with new bolts.
Put mark on bolt and connectino rod cap
111After installing piston and connecting rod assembly, rotate crankshaft and check that it rotates smoothly. There must be no catching or other abnormality.
I 12) Measure side clearance of connecting with dial gauge 0. * Side clearance: 0.100 - 0.274 mm
DWE00216
rod
CEE00181
4.
Piston cooling nozzle Fit piston cooling nozzle (2) and install mounting bolts (I). jr Check that the tip of each nozzle is directed at the center of each piston shaker hole.
13-28 0
ASSEMBLY
5.
AND DISASSEMBLY
GENERAL ASSEMBLY
Main idler gear, fuel injection pump drive shaft I) Coat fuel injection pump drive shaft (5) with engine oil (SAE#30) and install. 21 Install thrust plate (41, then install mounting bolts (3).
3) 4)
Install shaft (6) to main idler gear (21, then fit washer (7) on inside. Align “A” mark on crankshaft gear with “A” mark on main idler gear (21, then tighten mounting bolts (11. m Idler mounting bolt: 1st step: 265 - 343 Nm I27 - 35 kgml 2nd step: Mark the bolts and the side seat of idler gear shaft with a felt-tip pen and turn the bolts further 90 - 120 degrees.
I *
Make a punch mark on the bolt each time the bolts are used.
2
head Put mark on side of
l
CEE00216
idler
gear
and
seat bolt
If there are already five marks on the bolt head, replace with new bolts.
I
DWE00217
Put one punch mark
DEEM)100
ASSEMBLY
6.
AND DISASSEMBLY
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: 98 - 123 Nm I10 - 12.5 kgm1
GENERAL
ASSEMBLY
I-
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
8.
Fuel injection pump drive gear Fit key to shaft, align “C” mark of main idler gear ‘with “C” mark of drive gear, then fit drive gear (2) and tighten nut (I). m Nut: 226 - 255 Nm (23 - 26 kgml
_
I c---G?/
m B
*
Check that the match marks of each drive gear and idler gear are aligned.
C
I
CDE00217
ASSEMBLY
*
AND
DISASSEMBLY
GENERAL
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
F
0.080 - 0.417
G
0.118 - 0.369
(OP)
0.118 - 0.369
I-i
1 tow
Sr
Standard
0.025 - 0.486
end play for each gear
CEE00218
1
-I
Range (mm)
1
0.140 - 0.315
2
0.100 - 0.250
3
0.050 - 0.170
4
0.050 - 0.170
5
0.070 - 0.200
6
0.030 - 0.088
Fuel injection pump drive shaft oil seal Before assembling the seal, check that there 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.
I
%6!3 E
Position
9.
ASSEMBLY
4
IF
---l
2 G1
B
D A 3c
5
H
I
1
CDEOOLIS
Assembly guide (0 I astic tubal
Large inside diameter end
Small- inside diameter end DWE00218
13-31 0
ASSEMBLY
1)
AND
GENERAL
DISASSEMBLY
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
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
4)
ASSEMBLY
I
CDE00221
CDE00222
Using tool K, press fit oil seal (3) until seal contacts to housing (4).
c 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 with clamps.
CDE00175
ASSEMBLY
AND DISASSEMBLY
12. Front seal Assemble front seal (I) as follows. 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. 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 immediately before assembling the seal.
GENERAL
ASSEMBLY
‘7
Assemble
Small diameter
inside end
guide
Large diameter
inside end DWEOOZI
9
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 direction when assembling.
:
K4 co 2)
Hold metal ring of seal (I) with both hands, push evenly, and use sudden pushing force to push in.
3)
After pushing in seal, remove plastic inner tube (2). * Be particularly careful not to damage the seal lip when removing the inner tube.
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
ASSEMBLY
AND
DISASSEMBLY
GENERAL
ASSEMBLY
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
ASSEMBLY
AND
GENERAL
DISASSEMBLY
15. Water pump assembly 1) Fit O-ring and install water
pump
ASSEMBLY
assembly
(2). * The mounting 2)
bolts of the water pump are used to tighten the gear case. Fit gasket and install tube (I).
-1‘1
housing 16. Thermostat to tube I) Fit O-ring thermostat housing 2) Fit gasket and install with mounting bolts 3) Move tube (2) down
(21, then install (4). thermostat housing (3). and install ring (I).
CEE00171
to (4)
:
CEE00170
g 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}
GENERAL ASSEMBLY
ASSEMBLY AND DISASSEMBLY
19. Cylinder head assembly I) Assemble cylinder head assembly as follows. i) Coat valve stem and inside surface of valve guide with engine oil (SAE#30) then assemble valve (6). ii) Raise cylinder head and assemble lower valve seat (5).
I
CEE00166
iii) Install inner valve spring (4) and outer valve spring (31, then assemble upper valve seat (2). iv) Using spring pusher C, compress valve spring and install valve cotter (I). + Tap the valve stem with a plastic hammer to check that the cotter is completely fitted in the groove of the valve stem.
CEE00164
CEE001651
2) Check that the mounting
surfaces of the cylinder head and cylinder block are clean and that there is no dirt or foreign matter inside the cylinder. Set cylinder head gasket (9) in position. * When installing the gasket, check that the grommets are correctly in place.
CEE00234
3)
Before tightening cylinder head bolt, make sure as follows. i) Measure the free length a of all bolts and check that bolt length exceeds tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. ii) Tolerance limit of bolt free length: Max. 166.3 mm. * If the bolt length a exceeds tolerance limit, do not reuse.
a OWE00275
GENERAL ASSEMBLY
ASSEMBLY AND DISASSEMBLY
4)
Install cylinder head assembly (21, then tighten mounting bolts (I). & Mounting bolt: Antifriction compound (LM-PI
m Mounting bolt: 1st step: I37 - 157 Nm I14 - 16 kgm) 2nd step: 211 - 221 Nm (21.5 - 22.5 kgm1 3rd step: I) When using tool J Tighten bolts further 90 - 120 degrees in tightening order 0 to @ with tool J. 2) When not using tool J Mark the bolt and head with a felt-tip pen, turn bolt further 90 - 120 degree in tightening order @ to 8. * Tighten bolt @ by tightening torque 58.8 - 74.5 Nm (6.0 7.6 kgm) after tightening bolts @ to 8.
DAD00043
I
CEE00.235
Put mark on cylinder head and bolt
DWE00220
ASSEMBLY
AND
DISASSEMBLY
GENERAL
ASSEMBLY
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}
21. Rocker arm housing 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 the cam follower.
fitted in
ASSEMBLY
GENERAL
AND DISASSEMBLY
ASSEMBLY
--------- ----..-. \J-.._.. XL -..
23. Rocker arm install rocker arm (3) and tighten with mounting bolts (2) and (I). * 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 0.41 - 0.45
1
Exhaust
valve
0.78 - 0.82
-
I
*
Crank the engine and follow the firing order to adjust the valve clearance of each cylinder. Firing order: 1 - 5 - 3 - 6 - 2 - 4 in the normal 1) Rotate the crankshaft 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.
5
6
CDE00240
3
ASSEMBLY
AND DISASSEMBLY
GENERAL
ASSEMBLY
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 Oring. 2) Install gasket (6) to nozzle holder. 3) Align nozzle holder (5) with mounting hole of inlet connector and insert nozzle holder. CEE00243
4) 5)
insert inlet connector (2) in rocker arm housing and tighten partially. 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 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
13-40 0
pipe bracket.
CEE00159
ASSEMBLY
AND
GENERAL
DISASSEMBLY
ASSEMBLY
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
3)
Joint bolt: 7.8 - 9.8 Nm IO.8 - 1.0 kgml
2
CDE00158
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 2nd step: 245 - 309 Nm I25 - 31.5 kgm}
-0 1st step
2nd step
G-D
13-41 0
ASSEMBLY
2)
AND
DISASSEMBLY
GENERAL
ASSEMBLY
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. 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 immediately before assembling the seal.
Lip at
Large inside diameter end
Small inside 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 direction when assembling.
4 CEP00535
ASSEMBLY
AND
DISASSEMBLY
GENERAL
2)
Hold metal ring of seal (I) with both hands, push evenly, and use sudden pushing force to push in.
3)
After pushing in seal, remove plastic inner tube (3). + Be particularly careful not to damage the seal lip when removing the inner tube.
ASSEMBLY
CFFOO414
4)
l
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 red sealant layer from the outside circumference.
Procedure for assembling seal with sleeve * 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. * 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.
Lie
at
crankshaft
end
DWE00221
I)
Set sleeve/seal (2) to tool N2. & Surface of sleeve inner tube: Gasket sealant
(LG-7)
~
DWE00222
ASSEMBLY
2)
AND
DISASSEMBLY
GENERAL
ASSEMBLY
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 crankshaft (4) to press fit sleeve/seal (2).
3)
Remove
4)
Tighten 3 bolts uniformly until end face of tool Nl contacts ends face of crankshaft (4) to press fit sleeve/seal (2). * 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 red sealant layer from the outside circumference.
’3&44
(45mm) (25mml
tool N2 and replace with tool Nl.
N3 N4
(45mm) (25mm)
CEE00251
ASSEMBLY
AND
GENERAL
DISASSEMBLY
ASSEMBLY
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
*
* *
Tightening order
Tighten mounting bolts as follows. 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 order @ to 8.
For construction machine and generator
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 and
For marine
engine DKEOOII!
mark on flywheel bolt
I
DWE00223
Put one punch mark
DEE00100
GENERAL ASSEMBLY
ASSEMBLY AND DISASSEMBLY
Ir
After installing the flywheel, measure face runout and radial runout using gauge 0. Max. 0.30 mm * Face runout: f Radial runout: Max. 0.30 mm
the dial
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
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).
fuel filter bracket 33. Fuel filter assembly 1) Fit O-ring and install fuel filter bracket (2). 2) Install fuel filter assembly (I). l
13-46 0
2
CEE00154
ASSEMBLY
AND
GENERAL
DISASSEMBLY
34. PTO case tube, bracket 1) Install fuel injection
pump
ASSEMBLY
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 drive shaft (12) of fuel 1) Knock key’(l3).into 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). w Mounting bolt (14) (D155AX-3 LW500-1): 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
I
II
CEE00254
l
13-47 0
ASSEMBLY
AND
GENERAL
DISASSEMBLY
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
ASSEMBLY
bolts (8) of fuel injection
pump. 6)
Tighten connecting bolts (11) of coupling and drive shaft (12). w
(IO)
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
ASSEMBLY
AND
DISASSEMBLY
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. Loosen bolt (I 1) and flange coupling i) 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. bolt (11) and flange coupling iii) Tighten bolts and nuts (14) again. Mounting bolt, nut (14): (D155AX-3, LW500- 1) 58.8 - 63.7 Nm I6.0 - 6.5 kgm} (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
8)
Install pin (24).
GENERAL
ASSEMBLY
CEE00258
nut (15).
13-49 0
ASSEMBLY
AND
GENERAL
DISASSEMBLY
ASSEMBLY
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 assembly (Intake manifold 38. After-cooler 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.
39. Exhaust manifold Fit gasket and install exhaust manifold tighten with mounting bolts (I).
Ir
13-50 0
I
CEW00552
I
CEE00259
(2), then
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
ASSEMBLY
AND
GENERAL
DISASSEMBLY
ASSEMBLY
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 and install air compressor 1) Fit e-ring 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
2) 3) 4)
5) 6)
7)
with mounting
bolt (9). Install alternator assembly (6) with bolt (1). * Temporarily tighten bolt (I). Install bracket (8). Install adjustment rod (7) with bolts (2) and (3). or Temporarily tighten bolts (2) and (3). + Loosen 2 adjustment nuts (4). Install alternator belts (5). Adjust belt tension with adjustment nuts (4) that deflection is 13 - 16 mm when pushed with a force 98 N {IO kg}. Tighten bolts (I), (2) and (3).
CDE00145
ASSEMBLY
AND
DISASSEMBLY
GENERAL
ASSEMBLY
44. Fan pulley assembly Install fan pulley assembly then secure with bolts (I).
CEE00144
45. Tension pulley assembly (5) with 1) Install tension pulley assembly mounting bolts (4). 2) Set fan belt (3) on groove of pulley. fan belt tension with tightening 3) Adjust 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)
I
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
ASSEMBLY AND DISASSEMBLY
GENERAL ASSEMBLY
48. Corrosion resistor 1) Install air compressor 2) 3) 4)
tubes. (if equipped) install tubes (4) and (5). Install corrosion resistor assembly (3). Install hoses (2) and (1).
CDE00138
49. Resetting engine in engine stand assembly, remove bolts 1) Sling engine 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 mounting bolts (1).
starting
motor
(2) with
ASSEMBLY
AND
DISASSEMBLY
GENERAL
ASSEMBLY
52. Air cleaner, muffler 1) Install exhaust connector (9). and install muffler (8) with 2) Fit gasket mounting bolts (6), then secure with band 3)
4)
(7). Fit gasket and install valves
(5).
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
5) *
For the Komaclone type air cleaner, install precleaner (11) to air cleaner body (10). Tighten until clearance a is 0.
Z
6
11
+
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?
c
a IO
Z
CEE00260
14 Maintenance standard
Intake and exhaust system Turbocharger ............................................ 14-
2
Engine body Cylinder head ........................................... 14Valve, valve guide .................................... 14Rocker arm and shaft ............................... 14Crosshead and guide ............................... 14Cylinder block........................................... 14Cylinder liner ............................................ 14Crankshaft ................................................ 14Camshaft .................................................. 14Cam follower and push rod ...................... 14Timing gear .............................................. 14Piston ....................................................... 14Connecting rod ......................................... 14Flywheel and flywheel housing................. 14-
6 8 10 11 12 13 14 15 16 18 20 22 23
Lubrication system Oil pump ................................................... 14- 24 Regulator valve, piston cooling valve and safety valve................................ 14- 26 Oil cooler .................................................. 14- 27 Cooling system Water pump.............................................. 14- 28 Thermostat ............................................... 14- 31
6D140-2 SERIES
14-1 (10)
Maintenance standard
Intake and exhaust system
Intake and exhaust system Turbocharger KTR110 S6D140-2 SA6D140-2 SAA6D140-2
14-2 (11)
6D140-2 SERIES
Maintenance standard
Intake and exhaust system
Unit: mm No.
Check item
Criteria
1
End play (Play in axial direction)
2
Radial play (Play in radial direction)
3
4
Outside diameter or journal bearing. Inner diameter of center housing.
Inner diameter of journal bearing. Outside diameter of wheel shaft
Standard
Repair limit
0.08 – 0.13
0.18
0.25 – 0.44
0.60
Standard size
Thickness of seal ring
Shaft
Hole
25
–0.050 –0.067
+0.021 +0.021
24.92
25.03
17
–0.032 –0.043
+0.009 –0.003
16.95
17.04
Standard size
7
Repair limit
Width
Groove
Width
Groove
–0.08 –0.10
+0.02 +0.02
4.86
5.04 Replace
Tolerance
Repair limit
Ring
2.3
–0.08 –0.10
2.15
Groove
2.3
–0.01 –0.02
2.35
2
–0.08 –0.10
1.85
1 Ring
2
–0.03 –0.04
2.05
2 Ring
4
–0.11 –0.12
4.05
Groove
Clearance between blower housing and impeller
6D140-2 SERIES
Tolerance
Standard size
Ring Blower side
Repair limit
Hole
5
6
Replace parts related to bearing
Repair limit: 0.010 (total deflection of indicator)
Thickness of thrust bearing
Turbine side
Tolerance
Replace parts related to thrust
Shaft
Curvature of wheel shaft
5
Remedy
Clearance limit: (Min.) 0.20
Replace parts related to bearing
14-3 (11)
Maintenance standard
Intake and exhaust system
KTR110L SDA6D140E-2 (D275A-5, –50°C spec.)
14-4 (11)
6D140-2 SERIES
Maintenance standard
Intake and exhaust system
Unit: mm No.
Check item
Criteria
1
End play (Play in axial direction)
2
Radial play (Play in radial direction)
3
4
Outside diameter or journal bearing. Inner diameter of center housing.
Inner diameter of journal bearing. Outside diameter of wheel shaft
Standard
Repair limit
0.08 – 0.13
0.18
0.25 – 0.44
0.60
Standard size
Thickness of seal ring
Shaft
Hole
25
–0.050 –0.067
+0.021 +0.021
24.92
25.03
17
–0.032 –0.043
+0.009 –0.003
16.95
17.04
Standard size
7
Repair limit
Width
Groove
Width
Groove
–0.08 –0.10
+0.02 +0.02
4.86
5.04 Replace
Tolerance
Repair limit
Ring
2.3
–0.08 –0.10
2.15
Groove
2.3
–0.01 –0.02
2.35
2
–0.08 –0.10
1.85
1 Ring
2
–0.03 –0.04
2.05
2 Ring
4
–0.11 –0.12
4.05
Groove
Clearance between blower housing and impeller
6D140-2 SERIES
Tolerance
Standard size
Ring Blower side
Repair limit
Hole
5
6
Replace parts related to bearing
Repair limit: 0.010 (total deflection of indicator)
Thickness of thrust bearing
Turbine side
Tolerance
Replace parts related to thrust
Shaft
Curvature of wheel shaft
5
Remedy
Clearance limit: (Min.) 0.20
Replace parts related to bearing
14-5 (11)
Maintenance standard
Engine body
Engine body Cylinder head
14-6 (10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm No.
1
2
Check item
Criteria Standard
Repair limit
0 – 0.06
0.09
Engine
Standard
6D140-2
4.8 – 5.6
S6D140-2, SA6D140-2, SAA6D140-2
4.8 – 5.6
Distortion of cylinder head mounting surface
Protrusion of nozzle
Order
Target (Nm {kgm})
Range (Nm {kgm})
1st step
147 {15}
137 – 157 {14 – 16}
2nd step
216 {22}
211 – 221 {21.5 – 22.5}
3rd step
Retighten with 90 °
90° – 120°
—
68.6 {7}
58.8 – 73.6 {6 – 7.5}
Bolt No.
3
Tightening torque of cylinder head mounting bolt (Coat the thread areas with molybdenum disulfide or engine oil)
Remedy
(1) – (6)
(7)
Target (Nm {kgm})
Range (Nm {kgm})
66.7 {6.8}
58.8 – 73.6 {6 – 7.5}
37.3 {3.8}
34.3 – 40.2 {3.5 – 4.1}
4
Tightening torque of nozzle holder mounting bolt
5
Tightening torque of fuel inlet connector
6
Tightening torque of connector pipe locknut
39.2 {4}
34.3 – 44.1 {3.5 – 4.5}
7
Tightening torque of cylinder head cover mounting bolt
4.9 {0.5}
3.9 – 5.9 {0.4 – 0.6}
6D140-2 SERIES
Repair by grinding or replace Replace nozzle or cylinder head
Tighten in sequence as indicated above
Retighten
14-7 (10)
Maintenance standard
Engine body
Valve, valve guide
14-8 (10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm No.
1
2
3
Check item
Amount of valve sinking
Thickness of valve lip
Valve seat angle
Outside diameter of valve stem
4
Criteria Valve
Standard size
Tolerance
Repair limit
Intake valve
0
±0.10
0.70
Exhaust valve
0
±0.10
0.70
Valve
Standard size
Repair limit
Intake valve
2.4
1.9
Exhaust valve
2.15
1.75
Valve
Standard size
Tolerance
Intake valve
30°
±0°15'
Exhaust valve
45°
±0°15'
Intake valve
10
–0.045 –0.060
Exhaust valve
10
–0.075 –0.090
Before inserting
10
+0.019 +0.001
After inserting
10
+0.019 –0.020
Valve
Standard clearance
Clearance limit
Intake valve
0.029 – 0.084
0.22
Exhaust valve
0.065 – 0.100
0.24
Inside diameter of valve guide
Clearance between valve guide and valve stem Bend of valve stem 5
Remedy
Standard size
Tolerance
23
±0.2
Spring Free length of valve spring
Standard size * 81.7
—
Small
*1 65.5
*2 72.0
—
Installed length
6
Squarence of valve spring
Large
51.0
Small
43.6
2
Standard installed load (N {kg}) *2
*1
*1
*2
*1
231.3±11.8 215.6±10.8 {23.6±1.2} {22.0±1.1}
Replace valve guide
Replace valve or valve guide Replace valve
Installed load limit (N {kg})
*1
474±23.5 424.3±21.6 {48.4±2.4} {43.3±2.2}
Replace valve
Repair limit
* 82.2 1
Repair or replace valve and valve seat
Repair
Large
Spring
Installed load of valve spring
Replace valve
Repair limit: 0.02 (Total indicated runout, for 100)
Protrusion of valve guide
Replace valve or valve seat
450.8 {46.0} 207.8 {21.2}
*2
*2
377.3 {38.5}
Replace valve spring
192.1 {19.6}
Repair limit: 2° (for both end)
Note 1: Valve springs marked with *1 have a regular pitch. Note 2: Valve springs marked with *2 have an irregular pitch.
6D140-2 SERIES
14-9 (10)
Maintenance standard
Engine body
Rocker arm and shaft
Unit: mm No.
Check item Outside diameter of rocker arm shaft
1
3
Valve clearance (When engine is hot or cold) Tightening torque of rocker arm adjustment screw locknut
14-10 (10)
Remedy
Standard size
Tolerance
32.0
±0.0065
Replace rocker arm shaft
32.0
+0.087 +0.035
Replace rocker arm
Standard clearance
Clearance limit
0.0285 – 0.0935
0.13
Inside diameter of rocker arm bushing Clearance between rocker arm shaft and rocker arm bushing
2
Criteria
Valve
Standard size
Tolerance
Intake
0.43
±0.02
Exhaust
0.80
±0.02
Target (Nm {kgm})
Range (Nm {kgm})
58.8
53.0 – 64.7 {5.4 – 6.6}
Replace rocker arm or rocker arm shaft
Adjust
Retighten
6D140-2 SERIES
Maintenance standard
Engine body
Crosshead and guide
Unit: mm No.
1
2
3
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
3
+0.3 +0.3
3.41
Inside diameter of crosshead
11
±0.06 ±0.02
11.17
Outside diameter of crosshead guide
11
+0.011 +0.011
10.95
49.0
±0.25
—
Depth of crosshead stem
Protrusion of crosshead guide
6D140-2 SERIES
Replace
Repair
14-11 (10)
Maintenance standard
Engine body
Cylinder block
Unit: mm No.
1
Check item Distortion of cylinder head mounting surface Inside diameter of main bearing hole
2
Criteria
Remedy
Standard size
Repair limit
0 – 0.09
0.135
Standard size
Tolerance
127
+0.018 –0.006
3.5
–0.010 –0.010
Thickness of main bearing Roundness of main bearing hole
Repair by grinding or replace Replace main bearing cap
Replace main bearing
Repair limit: 0.005 Standard size
Tolerance
Repair limit
120
+0.038 –0.006
120.15
Inside diameter of camshaft bushing hole
69
+0.030 +0.030
—
Repair or replace cylinder block
5
Inside diameter of camshaft bushing
65
+0.040 +0.030
65.15
Replace camshaft bushing
6
Difference of face between cylinder block and front cover
3
Inside diameter of main bearing
4
7
Tightening torque of main bearing cap bolt (Coat thread area with engine oil)
8
Tightening torque of oil pan mounting bolt and under frame mounting bolt
9
Tightening torque of crank pulley mounting bolt
14-12 (10)
Replace main bearing
Repair by reassembling
Repair limit: 0.14 Order
Target (Nm{kgm})
Range (Nm{kgm})
1st step
117.7 {12}
107.9 – 127.5 {11 – 13}
2nd step
215.7 {22}
210.8 – 220.7 {21.5 – 22.5}
3rd step
Retighten with 90°
90 – 120°
Target (Nm {kgm})
Range (Nm{kgm})
66.7 {6.8}
58.8 – 73.6 {6 – 7.5}
274.6 {28}
245.2 – 308.9 {25 – 31.5}
Retighten
6D140-2 SERIES
Maintenance standard
Engine body
Cylinder liner
Unit: mm No.
1
Check item
Protrusion of cylinder liner
Inside diameter of cylinder liner 2
Criteria
Remedy
Permissible range: 0.07 – 0.15
Replace cylinder liner or cylinder block
Rank
Standard size
Tolerance
Repair limit
S
140
+0.020 +0.020
140.12
L
140
+0.040 +0.021
140.14
Roundness of cylinder liner
Repair limit: 0.08
Cylindricity of cylinder liner
Repair limit: 0.08
Outside diameter of cylinder liner (Counter bore)
Standard size
Tolerance
170.2
–0.10 –0.10
3 Clearance between cylinder liner and block (Counter bore) Outside diameter of cylinder liner (Counter bore bottom) 4 Interference between cylinder liner and block (Counter bore bottom)
Outside diameter of cylinder liner (O-ring) 5 Clearance between cylinder liner and block (O-ring)
6D140-2 SERIES
Replace cylinder liner or cylinder block
Standard: 0 – 0.163 Standard size
Tolerance
161.2
+0.090 +0.050
Standard interference
Interference limit
0.02 – 0.12
0.02
Standard size
Tolerance
158
–0.024 –0.049 Standard: 0.024 – 0.089
Replace cylinder liner
Replace cylinder liner Replace cylinder liner or cylinder block, or repair Replace cylinder liner Replace cylinder liner or cylinder block
14-13 (10)
Maintenance standard
Engine body
Crankshaft
Unit: mm No.
1
Check item
Criteria Standard size
Repair limit
0.140 – 0.315
0.50
Outside diameter of main journal 2
Roundness of main journal
Clearance of main journal
STD
120.00
0.25 U.S.
119.75
Outside diameter of crank pin journal 3 Roundness of crank pin journal Clearance of crank pin journal Straightness of all main journals Straightness of two main journals
14-14
Tolerance
Repair limit 119.88 119.63
–0.050 –0.068
0.50 U.S.
119.50
0.75 U.S.
119.25
119.13
1.00 U.S.
119.00
118.88 Repair limit
0 – 0.010
0.020
Standard clearance
Clearance limit
0.044 – 0.106
0.27
STD
90.00
0.25 U.S.
89.75
Repair by using over size bearing or replace
119.38
Standard size
Standard size
(10)
Repair by using over size thrust bearing or replace
End play
Standard size
4
Remedy
Tolerance
Replace main bearing
Repair limit 89.88 89.63
–0.050 –0.068
0.50 U.S.
89.50
89.38
0.75 U.S.
89.25
89.13
1.00 U.S.
89.00
88.88
Standard size
Repair limit
0 – 0.010
0.020
Standard clearance
Clearance limit
0.042 – 0.110
0.24
Standard size
Repair limit
0 – 0.150
0.20
0 – 0.050
0.10
Repair by using under size bearing or replace
Replace connecting rod bearing Repair by using under size bearing or replace
6D140-2 SERIES
Maintenance standard
Engine body
Camshaft
Unit: mm No. 1
Check item End play
Outside diameter of camshaft journal
Criteria
Remedy
Standard size
Repair limit
0.1 – 0.25
0.36
Standard size
Tolerance
65
–0.016 –0.036
Standard clearance
Clearance limit
0.016 – 0.096
0.15
2 Clearance of camshaft journal 3
4
Bend of camshaft
Cam height
6D140-2 SERIES
Replace thrust plate Replace camshaft Replace camshaft bushing
Repair limit: 0.03 (Total indicated runout) Cam
Standard size
Tolerance
Repair limit
Intake
55.48
±0.1
55.08
Exhaust
55.75
±0.1
55.35
Replace camshaft
14-15 (10)
Maintenance standard
Engine body
Cam follower and push rod
Unit: mm No.
1
Check item
3
Remedy
Standard size
Tolerance
Repair limit
22
–0.021 –0.034
21.92
22
+0.021 +0.021
22.07
Outside diameter of cam roller
31.7
+0.05 +0.02
31.50
Inside diameter of cam roller
12.7
+0.038 +0.013
12.78
Outside diameter of cam roller pin
12.63
±0.006
12.56
Outside diameter of cam follower shaft Inside diameter of cam follower shaft hole
2
Criteria
Standard size
Tolerance
12.7
–0.20 –0.20 –0.20 –0.20
4
Radius of push rod ball end
5
Radius of push rod socket end
13.4
6
Bend of push rod
Repair limit: 0.3 (Total indicated runout)
14-16 (10)
Replace
6D140-2 SERIES
Maintenance standard
Engine body
Timing gear
14-18 (10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm No.
Check item
Criteria Measuring point
—
1
2
3
Clearance between sub idler gear bushing and shaft
End play of main idler gear
Standard size
Gears
A
Crankshaft gear and main idler gear (Large)
0.141 – 0.425
B
Main idler gear (Small) and injection pump drive gear
0.129 – 0.391
C
Main idler gear (Small) and camshaft gear
0.129 – 0.391
a
Main idler gear (Large) and sub idler gear
0.141 – 0.426
b
Sub idler gear and oil pump drive gear
0.080 – 0.417
c
Sub idler gear and water pump drive gear
0.095 – 0.346
d
Camshaft gear and air compressor drive gear
0.118 – 0.369
e
Injection pump drive gear and PTO gear (Lower)
0.118 – 0.369
f
Compressor drive gear and PTO gear (Upper)
0.025 – 0.486
Backlash of each gears
Clearance between main idler gear bushing and shaft
Remedy
Engine
Standard size
S6D140
Tolerance
Replace 0.6
Standard Clearance clearance limit
Shaft
Hole
47.6
+0.014 +0.001
+0.085 +0.030
0.016 – 0.084
0.20
SA6D140
56
–0.016 –0.029
+0.055 +0.055
0.016 – 0.084
0.20
S6D140
47.6
+0.014 +0.001
+0.085 +0.030
0.016 – 0.084
0.20
SA6D140
56
–0.016 –0.029
+0.055 +0.055
0.016 – 0.084
0.20
Standard size
Repair limit
0.05 – 0.17
0.4
4
End play of sub idler gear
0.05 – 0.17
0.4
5
End play of injection pump drive gear
0.07 – 0.20
0.4
6D140-2 SERIES
Repair limit
Replace bushing
Replace thrust bearing
14-19 (10)
Maintenance standard
Engine body
Piston
14-20 (10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm No.
1
Check item
Outside diameter of piston
Thickness of piston ring
Width of piston ring groove
2 | 4
Clearance between piston ring and ring groove
Criteria Rank
Standard size
Tolerance
S
140
–0.070 –0.085
5
Inside diameter of piston pin hole Clearance between piston pin and piston
6D140-2 SERIES
139.81
140
–0.055 –0.070
No.
Measuring point
Standard size
Tolerance
2
Top ring
2.4
–0.015 –0.035
3
Second ring
2.41
–0.010 –0.035
4
Oil ring
4
–0.010 –0.030
2
Top ring
3
Second ring
4
Oil ring
4
+0.040 +0.020
No.
Measuring point
Standard clearance
Clearance limit
2
Top ring
3
Second ring
4
Oil ring
0.02 – 0.06
0.14
Top ring
0.42 – 0.57 (Tension 16.5 – 23.5 N {1.68 – 2.40 kg})
2.0
Second ring
0.65 – 0.80 (Tension 16.2 – 24.2 N {1.65 – 2.47 kg})
1.5
Oil ring
0.37 – 0.52 (Tension 55.9 – 75.5 N {5.7 – 7.7 kg})
1.0
3
4
Outside diameter of piston pin
Repair limit
L
2
Piston ring gap
Remedy
Judge using groove wear gauge
Judge using groove wear gauge
Standard size
Tolerance
52
–0.006 –0.006
52
+0.045 +0.035
Standard clearance
Clearance limit
0.035 – 0.051
0.10
Replace piston
Replace piston ring
Replace piston
Replace piston or piston ring
Replace piston ring or cylinder liner
Replace piston pin Replace piston Replace piston or piston pin
14-21 (10)
Maintenance standard
Engine body
Connecting rod
Unit: mm No.
1
Check item Inside diameter of bushing at connecting rod small end (Treat with reamer after press fitting bushing) Clearance between bushing at connecting rod small end and piston pin
2
Inside diameter of bushing hole at connecting rod small end
3
Inside diameter of bearing at connecting rod big end
4
Inside diameter of bearing hole at connecting rod big end (a Measure after tightening connecting rod cap bolt with specified torque) Thickness of connecting rod bearing
Criteria Standard size
Tolerance
Repair limit
52
+0.049 +0.030
52.09
Standard clearance
Clearance limit
0.030 – 0.055
0.11
Standard size
Tolerance
57.4
+0.030 +0.030 Repair limit
90
+0.042 –0.008
90.15 Tolerance
95
+0.026 –0.004 Tolerance
Repair limit
2.5
+0.002 –0.008
—
Parallelism 0 – 0.20 Twist
6
—
Weight of connecting rod
Standard size
0 – 0.30
Replace bearing
Replace connecting rod
Standard size
Parallelism and twist of connecting rod
Tightening torque of connecting rod cap mounting bolt (Coat bolt threads and nut seats with engine oil)
Replace connecting rod
Tolerance
Standard size
Replace bushing (New part is supplied as a semifinished part) Replace bushing or piston pin
Standard size
Item 5
Remedy
Replace bearing
Repair limit 0.25 0.35
Standard size
Target (Nm{kgm})
Repair (Nm{kgm})
1st step
127.5 {13}
117.7 – 132.4 {12.5 – 13.5}
2nd step
Retighten with 90°
90 – 120°
Permissible range: Variation between weights on the machine max. 154 g
Replace connecting rod
Retighten
Replace
a 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.
14-22 (10)
6D140-2 SERIES
Maintenance standard
Engine body
Flywheel and flywheel housing
Unit: mm No.
Check item
Criteria
Remedy
1
Face runout of flywheel housing
Repair limit: 0.35
2
Radial runout of flywheel housing
Repair limit: 0.30
3
Face runout of flywheel
Repair limit: 0.20
4
Radial runout of flywheel
Repair limit: 0.15 Order
5
Tightening torque of flywheel housing mounting bolts (Coat thread areas with engine oil)
Tightening order
6
6D140-2 SERIES
Target Range (Nm {kgm}) (Nm {kgm})
1st step
191.2 {19.5}
147.1 – 235.4 {15 – 24}
2nd step
274.6 {28.0}
245.2 – 308.9 {25 – 31.5}
Order Tightening torque of flywheel mounting bolts (Coat thread areas with engine oil)
Repair
Retighten
Target Range (Nm {kgm}) (Nm {kgm})
1st step
117.7 {12}
112.8 – 122.6 {11.5 – 12.5}
2nd step
Retighten with 90°
90° – 120°
14-23 (10)
Maintenance standard
Lubrication system
Lubrication system Oil pump
14-24 (10)
6D140-2 SERIES
Maintenance standard
Lubrication system
Unit: mm No.
1
Check item
Axial clearance of pump gear
Criteria Tolerance
Standard size 45
2
Radial clearance of pump gear
Clearance between drive shaft and pump body bushing
Housing depth
–0.025 –0.025
+0.067 +0.040
Tolerance
Standard size 51.4
3
Gear thickness
Gear O.D.
Housing I.D.
–0.15 –0.21
+0.06 +0.06
Tolerance
Standard size
Remedy Standard clearance 0.03 – 0.088
0.033 – 0.10
0.13
Standard clearance
Clearance limit
18
+0.106 +0.088
+0.173 +0.146
0.040 – 0.085
4
Clearance between driven shaft and driven gear bushing
18
+0.090 +0.070
+0.147 +0.127
0.032 – 0.077
5
Clearance between driven shaft and body
18
+0.090 +0.070
+0.129 +0.102
0.012 – 0.059
6
Clearance between relief valve and pump cover
16
–0.040 –0.060
+0.043 +0.043
0.040 – 0.103
7
Interference between drive shaft and oil pump drive gear
Replace Clearance limit
Hole
Tolerance
0.10
Standard clearance
Shaft
Standard size
Clearance limit
Replace bushing
Standard Interference interference limit
Shaft
Hole
18
+0.106 +0.088
+0.065 +0.047
0.023 – 0.059
—
18
+0.106 +0.088
+0.063 +0.028
0.025 – 0.078
—
+0.021 +0.021
0.044 – 0.090
—
8
Interference between drive gear and drive shaft
9
Interference between drive shaft bushing and pump cover
21
+0.090 +0.065
10
Interference between driven shaft bushing and driven gear
21
+0.090 +0.065
+0.035 +0.035
0.030 – 0.090
—
11
Interference between driven shaft and pump cover
18
+0.090 +0.070
+0.040 +0.022
0.030 – 0.068
—
Standard size 12
13
Main relief valve spring
Main relief valve set pressure
6D140-2 SERIES
Replace
Repair limit
Free length
Installed length
Installed load
49.1
32.0
126.4 N {12.9 kg}
Free length
Standard: 0.8 ± 0.05 MPa {8.0 ± 0.5 kg/cm2}
Installed load
Replace
113.7 N {11.6 kg} Replace
14-25 (10)
Maintenance standard
Lubrication system
Regulator valve, piston cooling valve and safety valve
Unit: mm No.
1
Check item
Clearance between regulator valve and body
Criteria Standard size 22
Tolerance Shaft
Hole
+0.15 +0.12
+0.28 +0.22
Remedy Standard clearance 0.07 – 0.16
Standard size 2
Regulator valve spring
Free length
Installed length
83
79
Repair limit Installed Installed Free length load (N{kg}) load (N{kg}) Replace spring 16.1 {1.64}
—
3
Regulator valve set pressure
0.3 ± 0.02 MPa {3.2 ± 0.2 kg/cm2}
4
Safety valve set pressure
0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2}
14-26 (10)
Clearance limit Replace valve or body —
15.1 {1.54} Replace
6D140-2 SERIES
Maintenance standard
Lubrication system
Oil cooler
Unit: mm No.
Check item Lift of thermostat to fully open position
1
Criteria
Remedy
Min 8 mm (soak in oil bath at 100°C (116°C) for 4 to 5 minutes to check)
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.
Replace
a The figure in ( ) indicates the thermostat for fully open temperature 116°C. a There are two types of thermostat for the oil cooler (fully open temperature: 100°C and 116°C). For the marine engine only the fully open temperature 100°C is applicable; for other models, either type can be used.
6D140-2 SERIES
14-27 (10)
Maintenance standard
Cooling system
Cooling system Water pump 6D140-2 S6D140-2 SA6D140-2
Unit: mm No.
1
Check item
Interference between impeller and shaft
Criteria Standard size
Remedy
Tolerance
Standard interference
Shaft
Hole
15.9
+0.018 +0.005
–0.020 –0.050
0.025 – 0.068
2
Interference between drive gear and shaft
25
+0.015 +0.002
–0.023 –0.053
0.025 – 0.068
3
Interference between pulley flange and shaft
25
+0.015 +0.002
–0.023 –0.053
0.025 – 0.068
4
Clearance between impeller and body
5
Abrasion of seal ring in water seal
14-28 (10)
Replace
Standard clearance: 0.30 – 1.0 (Including end play)
Repair limit A: 1.5
6D140-2 SERIES
Maintenance standard
Cooling system
S6D140-2 SA6D140-2 SDA6D140E-2 (D275A-5, –50°C spec.)
Unit: mm No.
1
Check item
Interference between impeller and shaft
Criteria Standard size
Remedy
Tolerance
Standard interference
Shaft
Hole
16
–0.082 –0.095
–0.020 –0.150
0.025 – 0.068
2
Interference between drive gear and shaft
28
+0.015 +0.002
–0.023 –0.053
0.025 – 0.068
3
Interference between pulley flange and shaft
25
+0.015 +0.002
–0.021 –0.041
0.025 – 0.056
4
Clearance between impeller and body
5
Abrasion of seal ring in water seal
6D140-2 SERIES
Replace
Standard clearance: 0.6 – 0.9 (Including end play)
Repair limit A: 1.5
14-29 (10)
Maintenance standard
Cooling system
For aftercooler SDA6D140E-2 (D275A-5, –50°C spec.)
Unit: mm No.
1
Check item
Interference between impeller and shaft
2
Interference between drive gear and shaft
3
Clearance between impeller and body
4
Abrasion of seal ring in water seal
14-30 (10)
Criteria Standard size
Remedy
Tolerance
Standard interference
Shaft
Hole
15.9
+0.018 +0.005
–0.020 –0.050
0.025 – 0.068
20
+0.015 +0.002
–0.023 –0.053
0.025 – 0.068
Standard clearance: 0.3 – 1.1 (Including end play)
Replace
Repair limit A: 1.5
6D140-2 SERIES
Maintenance standard
Cooling system
Thermostat
Unit: mm No.
Check item Lift of thermostat to fully open position
1
Criteria Min. 10 mm (soak in oil bath at 90°C for 4 to 5 minutes to check)
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.
6D140-2 SERIES
Remedy
Replace
14-31 (10)
15 Repair and replacement of parts
Table of special tools ..................................... 15-
2
Cylinder head Grinding of fitting face of cylinder head .... 15- 3 Replacing valve seat insert ...................... 15- 4 Pressure test ............................................ 15- 9 Replacing valve guide .............................. 15- 10 Replacing crosshead guide ...................... 15- 11 Grinding valve .......................................... 15- 12 Cylinder block Replacing cam bushing ............................ 15Replacing crankshaft gear........................ 15Replacing cam gear ................................. 15Replacing flywheel ring gear .................... 15Replacing connecting rod small end bushing ...................................... 15-
13 16 17 18 19
Cylinder block parts ....................................... 15- 20 Testing and inspecting cylinder block ............ 15- 21 Correcting cylinder block top surface, counterbore ............................................. 15- 24 Replacing main bearing cap .......................... 15- 32
6D140-2 SERIES
15-1 (10)
Repair and replacement of parts
Table of special tools
Table of special tools Operation
Symbol
Checking inside diameter of main bearing mounting hole
Grinding counterbore
15-2 (10)
Part Name
Q'ty
Remarks
Commercially available
Alignment bar
1
79A-513-1710
Basic machine
1
2
79A-513-1780
Guide plate
1
3
79A-513-1820
Cutter plate
1
4
79A-513-1860
Cutter
1
5
79A-513-1940
Cutter set gauge
1
6
79A-513-1950
Micrometer
1
7
79A-513-1960
Driver plate
1
8
79A-513-2090
Driver shaft
1
9
79A-513-2110
Driver handle
1
10
79A-513-2120
Service package
1
11
79A-513-2130
Case
1
12
79A-513-2140
Basic machine
1
13
79A-513-2160
Cutter plate
1
14
79A-513-2230
Cutter
1
15
79A-513-2240
Remover pin
1
16
79A-513-2250
Case
1
17
79A-513-2260
Service package
1
18
79A-513-2270
Compound
1
Loctite
19
79A-513-2280
Primer
1
Loctite
20
79A-513-2320
Bushing
12
J
K
Part No.
6D140-2 SERIES
Repair and replacement of parts
Cylinder head
Cylinder head Grinding of fitting face of cylinder head 1. Grinding 1) Remove the valve seat insert. See the section of replacement of the valve seat insert. 2) Remove the strain and corrosion of the cylinder head by grinding them within the allowable limit of the cylinder head height H, then stamp the letter "R" on the left side of the cylinder head. a Cylinder head height H Basic height: 105 ± 0.05 mm a Limit after grinding: 104.65 mm a Grinding height/time: 0.10 – 0.15 mm a Roughness of ground surface: 6 S max. a Change of cross level: 0.05 mm max. a Grinding limit: 0.3 mm a 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. a Standard sinking distance of valve: 0 ± 0.1 mm
6D140-2 SERIES
15-3 (10)
Repair and replacement of parts
Cylinder head
Replacing valve seat insert Special tools No.
Part No.
A
795-100-4800
Puller (valve seat)
1
790-101-5001
Push tool (KIT)
1
2
790-101-5081
• Plate (for intake valve)
1
3
790-101-5071
• Plate (for exhaust valve)
1
795-100-3003
Seat cutter (KIT)
1
795-100-3100
• Body ass'y
1
795-100-3200
• Micrometer
1
795-100-3300
• Gauge
1
795-100-3400
• Tool head
1
795-100-3601
• Head support
1
2
795-100-3710
• Cutter (for oversize machining)
1
3
795-100-3720
• Cutter (for 30°)
1
795-100-3730
• Cutter (for 45°)
1
795-100-4210
• Pilot (10.000 mm)
1
795-100-4220
• Pilot (10.010 mm)
1
795-100-4230
• Pilot (10.020 mm)
1
795-100-4240
• Pilot (10.030 mm)
1
1 B
1
C
4
5
Part Name
Q'ty
1. Removal of valve seat insert k When using a grinder to carry out this work, carry out a test run for one minute before starting the operation to check that there is no abnormality. • If the grindstone has been replaced, carry out the test run 3 minutes. k
•
Check that there is no damage to the grindstone, fit it to the grinder spindle so that there is play, and wear safety glasses when using the grinder. When removing with a valve seat puller 1) Install grindstone to grinder . 2) Align the groove of sleeve with holder , and insert. a Adjust the position of the grinder with set screw .
HEE00081
15-4 (10)
6D140-2 SERIES
Repair and replacement of parts
Cylinder head
3) Adjust the position of the grinder so that the center of grindstone is at the center of seat insert (1), then tighten the set screw to fix the grinder in place. 4) Rotate the grindstone and move it slowly until it contacts insert (1). 5) Press the grindstone lightly against the inside face of the insert and make a groove around the whole circumference of the inside face of the insert. a Depth of groove: Approx. 1 mm
6) Push the three claws (a) of puller head of tool A inwards by hand, and fit into insert (1). 7) Tighten screw to push the three claws into the groove on the inside face of the insert. a When the claws are completely in contact with the groove, stop tightening. 8) Insert bridge on the outside of the puller head, set plates and on top of the bridge, and tighten nut to pull out the insert.
•
When welding a bar to the insert to remove 1) Weld bar (1) (diameter: approx. 10 ø) of a diameter 0.1 – 0.5 mm smaller than the inside diameter of the insert to insert (2). a Be careful not to deposit any of the welding metal on the head itself. 2) When the temperature of the weld has dropped to around room temperature, insert a used valve (3) in the opposite direction, and hit the face of the valve with a small hammer to remove the insert. a Be careful not to hit too hard, as any excessive shock may cause the weld to break off.
6D140-2 SERIES
15-5 (10)
Repair and replacement of parts
Cylinder head
2. Press fitting valve seat insert • When not grinding and correcting press-fitting surface of valve seat insert 1) Using tools B1 and B2, or tools B1 and B3, press fit standard valve seat insert (2) with a press. a Do not use a hammer to press fit. a Press-fitting force for valve seat insert Intake side : Approx. 14.7 kN {1.5 ton} Exhaust side: Approx. 14.7 kN {1.5 ton}
2) Check the insertion depth (h) of the insert from the bottom surface of the cylinder head. a Insertion depth (h) of insert Intake side : 2.2 mm Exhaust side: 2.4 mm
15-6 (10)
6D140-2 SERIES
Repair and replacement of parts
Cylinder head
3. Oversize machining of mounting hole for valve seat insert 1) Using tools C1 and C2, grind the hole to the one level larger oversize. a Machine within an oversize range of 1.0 mm. If it is more than 1.0 mm, replace the cylinder head.
•
Method of machining insert and mounting hole Insert
Valve
Insert
Insert mounting hole
d
h
D1
D2
H
Intake
55.0 +0.100 +0.090
–0.1 8.8 –0.1
55.0 +0.019 +0
58.00 ± 0.2
–0.1 11 –0.1
Exhaust
52.0 +0.080 +0.070
–0.1 8.6 –0.1
52.0 +0.019 +0
55.00 ± 0.2
–0.1 11 –0.1
Intake
55.25 +0.100 +0.090
–0.1 8.8 –0.1
55.25 +0.019 +0
58.25 ± 0.2
–0.1 11 –0.1
Exhaust
52.25 +0.080 +0.070
–0.1 8.6 –0.1
52.25 +0.019 +0
55.25 ± 0.2
–0.1 11 –0.1
Intake
55.5 +0.100 +0.090
–0.1 8.92 –0.1
55.5 +0.019 +0
58.50 ± 0.2
–0.1 11.12 –0.1
Exhaust
52.5 +0.080 +0.070
–0.1 8.72 –0.1
52.5 +0.019 +0
55.50 ± 0.2
–0.1 11.12 –0.1
Intake
55.75 +0.100 +0.090
–0.1 9.05 –0.1
55.75 +0.019 +0
58.75 ± 0.2
–0.1 11.25 –0.1
Exhaust
52.75 +0.080 +0.070
–0.1 8.85 –0.1
52.75 +0.019 +0
55.75 ± 0.2
–0.1 11.25 –0.1
Intake
56.0 +0.100 +0.090
–0.1 9.18 –0.1
56.0 +0.019 +0
59.00 ± 0.2
–0.1 11.38 –0.1
Exhaust
53.0 +0.080 +0.070
–0.1 8.98 –0.1
53.0 +0.019 +0
56.00 ± 0.2
–0.1 11.38 –0.1
STD
0.25 O.S.
0.50 O.S.
0.75 O.S
1.00 O.S
a Roughness of inside surface: Within 6.3 S a Roughness at bottom of mounting hole: Within 12.5 S a Concentricity with valve guide inside surface: Within 0.03 mm (TIR)
6D140-2 SERIES
15-7 (10)
Repair and replacement of parts
Cylinder head
4. Finishing insert seat surface 1) Using tools C1, and C3, and C4, finish the surface of the insert seat to the dimensions shown in the diagram below. a When selecting a pilot C5 to insert into the valve guide, choose one that gives no clearance. • Intake valve
•
Exhaust valve
2) Rub the seat surface with compound. Width of finished face of exhaust valve insert and width of contact with valve Unit: mm Part No. 6210-11-1320 (S.T.D) 6210-19-1320 (0.25 O.S) 6210-18-1320 (0.50 O.S) 6210-17-1320 (0.75 O.S) 6210-16-1320 (1.00 O.S) Width of finished surface
A: 47.1
B: 1.5
Width of contact with valve C: 1.5 ± 0.2 (when using master valve)
5. Finish inspection • Coat the seat surface 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 insert contact surface, and confirm that the contact is uniform without any breaks. • Or Make marks with a pencil on the seat surface of the new valve as shown in the diagram below, insert it in the valve guide, push lightly against the valve insert surface, and rotate 10°. Check that the pencil marks have been erased uniformly around the whole circumference.
15-8 (10)
6210-11-1321 (S.T.D) 6210-19-1321 (0.25 O.S) 6210-18-1321 (0.50 O.S) 6210-17-1321 (0.75 O.S) 6210-16-1321 (1.00 O.S) A: 45.7
B: 2.5
C: 2.5 ± 0.2
Unit’ mm
6D140-2 SERIES
Repair and replacement of parts
Cylinder head
Pressure test •
When corrections have been made around the cylinder head, test the pressure as follows.
Special tools No.
Part No.
A
790-553-1600
Part Name
B
79A-471-1050 Pump assembly
Coolant tester kit
Q'ty 1 1
1. Water pressure test 1) Assemble tool A and tool B, and connect the hose to flange (1). 2) Apply water pressure (0.34 – 0.39 MPa {3.5 – 4.0 kg/cm2}) for approx. 10 minutes, and check that there is no leakage from around the cylinder head. a When carrying out this test, heat the whole cylinder head and carry out the test with hot water (80 – 95°C).
2. Air pressure test 1) Connect the compressor hose to flange (1). 2) Put the head in the container of water, apply air pressure (0.29 – 0.34 MPa {3.0 – 3.5 kg/ cm 2 }) for approx. 30 seconds, and check that there is no leakage in the water. a If the above test shows any cracks around the plate plugs, replace the cylinder head.
6D140-2 SERIES
15-9 (10)
Repair and replacement of parts
Cylinder head
Replacing valve guide Special tools No.
Part No.
A
795-100-1520
Valve guide remover
Part Name
Q'ty 1
B
795-130-1710
Valve guide driver
1
1. Removal of valve guide Using valve guide remover A, remove the valve guide.
2. Press fitting valve guide 1) Press fit the valve guide until the tip of valve guide driver B contacts the cylinder head. 2) Measure the protrusion of the valve guide and check that it is within the standard range. a Valve guide protrusion Tolerance: 23 ± 0.2 mm
15-10 (10)
6D140-2 SERIES
Repair and replacement of parts
Cylinder head
Replacing crosshead guide Special tools No.
Part No.
Part Name
Q'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 , and lock sleeve . 3) Turn nut , and pull out crosshead guide. 4) Remove any burrs or flashes from the crosshead guide mount. 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. a Protrusion of crosshead guide Tolerance: 49 ± 0.5 mm
6D140-2 SERIES
15-11 (10)
Repair and replacement of parts
Cylinder head
Grinding valve Special tool No.
Part No.
A
Commercially available
Part Name Valve refacer
Q'ty 1
1. Grinding seat face Grind the seat surface with valve refacer A. a Valve seat angle Intake valve: 30° Exhaust valve: 45° 2. Checking after grinding Measure the thickness of the valve head, protrusion of the valve and the contact of the valve seat face to check that they are within the standard range. a Thickness of valve head Intake valve: 2.4 mm Exhaust valve: 2 mm a Insertion depth of valve Standard: 0 ± 0.1 mm a Contact width of valve Standard Intake valve: 4.33 mm Exhaust valve: 3.47 mm
15-12 (10)
6D140-2 SERIES
Repair and replacement of parts
Cylinder block
Cylinder block Replacing cam bushing Special tools No.
Part No.
A
795-213-1200
Push tool
1
1
795-213-1250
Push bar
1
2
795-213-1210
Push tool
1
3
795-213-1240
Collar
1
4
795-213-1230
Guide
1
5
792-103-0400
Grip
1
A
Part Name
Q'ty
a 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 A2, collar A3, and push bar A1 of push tools A, then hit the push bar to knock bushing (2) out from cylinder block (1).
2. Removal of No. 2, 6 bushings Assemble push bar A1, push tool A2, collar A3, and guide A4 of push tool A, then hit the push bar to knock bushing (3) out from cylinder block (1).
3. Removal of No. 3, 4, 5 bushings Assemble push bar A1, push tool A2, collar A3, and guide A4 of push tool A, then hit the push bar to knock bushing (4) out from cylinder block (1).
6D140-2 SERIES
15-13 (10)
Repair and replacement of parts
•
Cylinder block
After removing the bushing, remove any burrs or dirt, and clean the mounting hole of the bushing.
a Cam bushing assembly drawing
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 (1) matches the oil hole of the bushing.
2. Press fitting No. 2, 6 bushings Assemble bushing (3) to tool A, and press fit the bushing until the oil hole of cylinder clock (1) matches the oil hole of the bushing.
3. Press fitting No. 1, 7 bushings • Assemble bushing (2) to tool A, and press fit the bushing until the oil hole of cylinder clock (1) matches the oil hole of the bushing.
15-14 (10)
6D140-2 SERIES
Repair and replacement of parts
Cylinder block
•
Using inside gauge , measure the inside diameter of the bushing. • Check the clearance between the bushing and shaft, and if the clearance is not within the specified range, or the shaft does not move smoothly, correct the inside diameter of the bushing with a reamer. • 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. a Inside diameter of cam bushing: ø65 +0.06 mm –0 a Clearance of camshaft journal: 0.016 – 0.096 mm
6D140-2 SERIES
15-15 (10)
Repair and replacement of parts
Cylinder block
Replacing crankshaft gear Special tools No.
Part No.
Part Name
Q'ty
790-101-2800
Bearing puller
1
790-101-2300
Push puller
1
1. Removal of Gear Make a scratch in the surface at the root of the teeth with a grinder, then assemble pullers and , and turn the nut to remove the gear. a 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. a Be careful not to damage the shaft.
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. a Crankshaft gear shrink-fitting temperature: 200°C Heating time: Min. 30 minutes 4) Put the timing mark on the outside, then use a hitting tool to press fit until the side face of the gear is in close contact with the shaft flange. a Knock in quickly before the gear becomes cool.
15-16 (10)
6D140-2 SERIES
Repair and replacement of parts
Cylinder block
Replacing cam gear 1. Removal of gear Set the camshaft assembly on the press stand, then push the camshaft to remove the gear. k When setting the camshaft assembly on the press stand, be careful not to get caught your fingers between the press stand and the gear. 2. Press fitting gear 1) Check the gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock a new key into the key groove of the shaft. 3) Assemble the thrust plate. 4) Heat the gear for the specified time at the specified shrink-fitting temperature. a Crankshaft gear shrink-fitting temperature: 220 – 240°C Heating time: Min. 30 minutes 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. a Knock in quickly before the gear becomes cool.
6D140-2 SERIES
15-17 (10)
Repair and replacement of parts
Cylinder block
Replacing flywheel ring gear k
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. k
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. a Ring gear shrink-fitting temperature: Max. 200°C Heating time: Min. 50 minutes 3) Set the chamfered face of the ring gear facing the flywheel, and press fit until the side face of the gear is in close contact with the flywheel.
15-18 (10)
6D140-2 SERIES
Repair and replacement of parts
Cylinder block
Replacing connecting rod small end bushing Special tools No.
Part No.
A
795-240-6400
Push tool (KIT)
1
1
795-240-6410
Push tool
1
2
795-240-6420
Push tool
1
3
795-240-6430
Block
1
4
01530-03912
Nut
1
B
Part Name
Q'ty
1. Removal of connecting rod bushing 1) Set the connecting rod to tool B3. 2) Using tool B1, remove the connecting rod bushing with press. a After removing the bushing, remove any burrs or flashes, and clean the mounting hole of the bushing.
2. Press fitting connecting rod bushing 1) Set connecting rod to tool B3. 2) Assemble connecting rod bushing in tool B1, set tool B2 in position, then secure with tool B4 so that it does not move. a Align the oil hole of the connecting rod bushing with the oil hole of the connecting rod. 3) Push tool B1 with press, and press fit the connecting rod bushing. •
The bushing is supplied as a semi-finished product, so the inside diameter is too small and the piston pin will not go in. After press fitting the bushing, machine the inside diameter of the bushing with a reamer or honing machine in accordance with the maintenance standard. a After machining, clean all the metal particles from the oil hole and oil groove.
6D140-2 SERIES
15-19 (10)
Repair and replacement of parts
Cylinder block parts
Cylinder block parts
1. 2. 3. 4. 5. 6. 7.
Cylinder liner Clevis seal Cylinder liner O-ring Cylinder block Main bearing cap Main bearing cap bolt Camshaft bushing
15-20 (10)
6D140-2 SERIES
Repair and replacement of parts
Testing and inspecting cylinder block
Testing and inspecting cylinder block Unit: mm Symbol
Inspection item
A.
Cracks
B.
Correction of contact at packing portion
Judgement standards Check for cracks (external color check) Cylinder head bolt hole portion, etc.
Replace
Check for water leakage caused by corrosion
Standard size
C.
Remedy
Clearance from cylinder liner
Standard value Inside diameter of Outside diameter cylinder block of cylinder block 158.00 – 158.04
158.00
157.946 – 157.976
Replace
Standard clearance 0.024 – 0.094
Replace cylinder liner or cylinder block
• Inside diameter
D.
Inside diameter of camshaft bushing
Standard size
Standard value
Standard limit
69
69.000 – 69.025
69.10 Replace bushing
• Clearance from camshaft bearing Standard clearance
Clearance limit
0.016 – 0.096
0.15
Permissible range: 0.07 – 0.15 E.
Protrusion of liner
F.
Depth of counterbore and corrosion of bottom surface
Standard size
Standard value
11
11.00 – 11.05
Replace cylinder liner or correct cylinder block
Repair by machining, add shim
• Check for corrosion
G.
Distortion, wear of cylinder head mounting surface
6D140-2 SERIES
Tolerance Overall top surface of block: Max. 0.09 For one cylinder: Max. 0.05
Repair limit 0.135 0.100
Repair by machining
15-21 (10)
Repair and replacement of parts
Testing and inspecting cylinder block
Unit: mm Symbol
Inspection item
Inside diameter of main bearing mounting hole • Tighten main bearing cap bolt to specified torque • Measure main bearing cap mating surface within upand-down range of 10°
H.
Judgement standards
Remedy
Standard size
Standard value
Standard limit
127
127.000 – 127.025
—
Coaxiality of whole unit
Max. 0.020
Coaxiality between neighboring holes
Max. 0.013
Replace
I.
Journal
Standard fitting
Clearance limit
No.1 – 7
Interference 0.002 – 0.060
—
Fitting of main bearing cap and cylinder block
• Cylinder liner
J.
Inside diameter of counterbore, outside diameter of cylinder liner flange
15-22 (10)
Standard size
Standard value
Repair limit
Top step
170.2
170.10 – 170.20
—
Bottom step
161.2
161.25 – 161.29
—
Standard size
Standard value
Repair limit
Top step
170.2
170.200 – 170.263
—
Bottom step
161.2
161.197 – 161.230
—
Replace cylinder liner
• Cylinder block Correct cylinder block sleeve
6D140-2 SERIES
Repair and replacement of parts
Testing and inspecting cylinder block
Method of checking inside diameter of main bearing mounting hole using alignment bar •
When checking the inside diameter of the main bearing mounting hole using an alignment bar, do as follows. Tool J (alignment bar) Unit: mm Standard dimension Diameter
127
Roundness
0.005
Straightness
0.010
Length
Min. 1,150
1. Set the cylinder block on a stand with the main bearing cap mount at the top. 2. Coat the inside surface of the main bearing hole of the cylinder block with engine oil. a Remove the main bearing cap. 3. Set tool J (alignment bar) in the main bearing hole of the cylinder block. 4. Install the main bearing cap, then tighten the mounting bolts to the specified torque. 5. Check that tool J moves smoothly.
6D140-2 SERIES
15-23 (10)
Repair and replacement of parts
Correcting cylinder block top surface, counterbore
Correcting cylinder block top surface, counterbore Flow for correction procedure
a When removing, installing, disassembling, or assembling the engine, see the DISASSEMBLY AND ASSEMBLY section for details of the procedure. a If the judgement for Item 9 is NO, go to (A). If the answer is NO again, go on to (B).
15-24 (10)
6D140-2 SERIES
Repair and replacement of parts
6D140-2 SERIES
Correcting cylinder block top surface, counterbore
15-25 (10)
Repair and replacement of parts
Correcting cylinder block top surface, counterbore
Grinding • If there is strain or corrosion of the top surface of the cylinder block, grind the top surface. • If there are blackened portions on the cylinder liner contact surface of the counterbore (particularly in the front-to-rear direction), or there is speckled wear, and these portions extend over more than half of the contact surface, or if grinding has been carried out on the top surface, correct the counterbore. 1. Grinding top surface of cylinder block 1) Measure the wear and strain of the top surface of the cylinder block, and if it is over the repair limit, grind the top surface of the cylinder block within the repair limit for height d of the cylinder block. a Guideline for grinding top surface of cylinder block • When wear and corrosion on top surface of cylinder block are the same shape as the mark left by the head gasket • When wear amount a is more than 0.15 mm
Fig. 2
Table 1
Unit: mm Standard dimension
Repair limit
Flatness of cylinder block (for one cylinder)
0.05
0.10
Height of cylinder block d
430.5 ± 0.04
430.0
Roughness of top surface of cylinder block
Fig.1
Within 12.5 S
a When grinding with grindstone (reference) Grindstone speed : 1650 – 1950 m/min Table speed : 15 – 30 m/min Amount of grinding for one pass : 0.025 mm Cross feed for one pass : 1 – 2 mm Grindstone : A461V Grinding fluid : Water soluble grinding fluid
15-26 (10)
6D140-2 SERIES
Repair and replacement of parts
Correcting cylinder block top surface, counterbore
2. Grinding counterbore • After grinding the top surface of the cylinder block, measure the depth of the ounterbore. If necessary, correct the counterbore depth f within the repair limit. a Guideline for correcting counterbore • If it is not within the standard dimension. • If there are blackened portions on the cylinder liner contact surface of the counterbore (particularly in the front-torear direction), or there is speckled wear, and these portions extend over more than half of the contact surface. • After correcting, if the counterbore depth is within 14.05 – 15.525 mm, combine with shims and adjust so that the cylinder liner protrusion is 0.07 – 0.15 mm. Table 2 Standard dimension
Repair limit
11 +0.05 +0
12.525
—
0.07 – 0.15
Cylinder liner protrusion e Roughness of counterbore
Within 12.5 S In accordance with diagram on right (detail diagram for portion b)
Machined shape
•
Fig. 4
Unit: mm
Counterbore depth f
•
Fig. 3
Fig. 5
For the machining amount for counterbore depth f, decide an amount that will bring protrusion e of the cylinder liner within the standard value. When grinding within the repair limit in cases where the counterbore depth f exceeds the standard dimension, set the machining amount so that one shim can be used for each cylinder as shown in the table below.
Table 3 [Reference] Adjustment shims for counterbore depth Unit: mm Part No.
T
t
Weight (kg)
6210-29-2260
1.50
0.025
0.023
6210-29-2250
0.80
0.025
0.012
6210-29-2240
0.50
0.025
0.008
6210-29-2230
0.26
0.025
0.004
6210-29-2220
0.20
0.020
0.003
6210-29-2210
0.16
0.016
0.002
6D140-2 SERIES
Fig. 6
Remarks
15-27 (10)
Repair and replacement of parts
Correcting cylinder block top surface, counterbore
Fig. 7
•
Use tool K when grinding the counterbore.
Fig. 8
Fig. 9
15-28 (10)
6D140-2 SERIES
Repair and replacement of parts
Correcting cylinder block top surface, counterbore
3. Checking and distinguishing after grinding and correcting • After grinding and correcting, check for scratches on the flat surface around the water and oil holes in the cylinder block top surface. • Remove all burrs and flashes completely. • After grinding the top surface, if the cylinder bloc k height d ex ceeds the s tandard dimension (430.5 ± 0.04 mm), but is within the repair limit (430.46 – 430.10 mm), always use an oversize head gasket.
Fig. 10
Table 4 Unit: mm Head gasket
Part No.
Plate thickness
S.T.D.
6210-17-1813
2.0
Oversize
6210-19-1813
2.4
Fig. 11
a To distinguish, the letters [OS] are stamped on the plate. • After correcting, stamp the top surface of the cylinder block (rear of left bank) according to the nature of the correction as shown in the table below.
Parts used for correction
Table 5 Oversize head gasket
Shim
Stamp
—
—
Not needed
Q
—
OS
—
Q
SH
Q
Q
WS
(Size of letters: 5 – 10 mm)
6D140-2 SERIES
15-29 (10)
Repair and replacement of parts
Correcting cylinder block top surface, counterbore
4. Procedure for coating cylinder block top surface deck with gasket sealant • When pulling out the cylinder liner and press fitting it again, coat the cylinder block top surface deck (the cylinder liner flange contact surface of the cylinder block) with gasket sealant (LG-6) as follows. Use the same procedure when using a shim for the deck.
Fig. 12
1) Use a cloth to wipe off all the dirt and oil from the cylinder block top surface deck and cylinder liner flange contact surface. 2) Coat the position marked in the diagram with LG-6. • Diameter of line of gasket sealant: 2 – 3 mm • Overlap of beginning and end of sealant: 6 ± 6 mm
Fig. 13
a When using shims for deck • After coating the bottom of the shim thinly with LG-6, install it to the deck portion of the cylinder block. • Next, coat with LG-6 in the same way as when not using shims. 3) Press fit the liner in the cylinder block. When doing this, coat the cylinder block contact surface of the seal and O-ring with a small amount of engine oil (SAE30) immediately before press fitting the liner. a Do not coat with engine oil until immediately before press fitting the cylinder liner.
4) After setting the cylinder liner in the cylinder block, assemble a used head gasket and temporarily tighten the cylinder head. When doing this, tighten in the tightening order shown in the diagram on the right. 3 Tightening torque: 147 ± 10 Nm {15 ± 1 kgm}
15-30 (10)
Fig. 14
Fig. 15
6D140-2 SERIES
Repair and replacement of parts
Correcting cylinder block top surface, counterbore
5) Loosen the cylinder head mounting bolts, remove the cylinder head, then wipe off the excess gasket sealant that has come out from the counterbore. a The gasket sealant that comes out may cause deformation of the head gasket grommet, so always carry out Steps 4) and 5) without fail. a After carrying out Steps 4) and 5), use a new head gasket to install the cylinder head.
Fig. 16
5. Standard for rebuilding cylinder liner O-ring portion of cylinder block • If the bushing of the cylinder liner O-ring of the cylinder block has been corrected, make the finishing dimensions as follows. a Concentricity of in relation to standard : Max. 0.05 mm
Fig. 17
Table 6 Unit: mm No.
Finishing dimensions ø167 ø161.45 ± 0.25
Fig. 18
ø160.67 ± 0.064 176 ± 0.25 184.94 ± 0.18 ø158 +0.040 +0 ø159.03 (Gauge diameter)
6D140-2 SERIES
15-31 (10)
Repair and replacement of parts
Replacing main bearing cap
Replacing main bearing cap •
When replacing the main bearing cap, machine the semi-finish product to the following dimensions, then install.
Correction parts Part No.
Part Name
6215-29-1210
Main bearing caps other than No. 4, 7
6215-29-1230
No. 4 main bearing cap
6215-29-1250
No. 7 main bearing cap
1. Machining inside diameter of main bearing cap 1) Remove the cylinder liner. 2) Install the replacement main bearing cap to the c ylinder block, and tighten to the specified torque. 2 Main bearing cap mounting bolt: Coat seat face of threaded portion with engine oil 3 Main bearing cap mounting bolt: Unit: Nm {kgm} Order
Target
Range
1st step
118 {12}
108 – 128 {11 – 13}
2nd step
216 {22}
211 – 221 {21.5 – 22.5}
3rd step
Tighten a further 90°
90° +30° +0
a Align the cylinder block and main bearing cap notch. 3) Set a cylinder block mounting jig on the table of a horizontal boring machine, fit the cylinder liner mounting hole of the cylinder block to the standard line on the jig, and install the cylinder block. 4) Of the main bearing caps to be used again, take the one with the longest pitch and put a d ia l ga ug e i n c o ntac t w it h t he i n s id e diameter at two places to align the center of the boring machine arbor.
15-32 (10)
6D140-2 SERIES
Repair and replacement of parts
Replacing main bearing cap
5) Check the machined inside diameter of bearing cap (1) and grind a little at a time. a Grind until the bit touches the inside surface of cylinder block (2). a Inside diameter of main bearing cap i) Machining dimension Tolerance: 127 +0.025 mm +0 ii) Inside diameter of cap when main bearing cap is tightened to specified torque after machining Tolerance: 127 +0.025 –0.010 mm (Up-down range of 10° at mating surface of main bearing cap) a Finishing roughness: Within 10 S a Do not grind the inside face of the cylinder block. 2. Machining width of main bearing cap (Only when machining No. 7 main bearing cap) 1) Insert cast iron bushing , then pass arbor through. 2) Install facing bit to the arbor. 3) Grind cap (1) until the bit touches the cylinder block face. 4) Grind the opposite side in the same way. a Roughness of thrust bearing mounting surface: Within 12.5 S a Do not grind the cylinder block. a Width of main bearing cap Tolerance: 43.970 – 44.000 mm
6D140-2 SERIES
15-33 (10)
Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. 1 Attn: Technical Publications Fax No. (847) 970-4186 I
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