SAA6D140E-2 Series PDF

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
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.
Weight
Weight of parts of systems.

Caution necessary when
selecting hoisting wire, or
when working posture is
important, etc.
Tightening
torque
Places that require special

attention for the tightening
torque during assembly.
Coat
Places to be coated with

adhesives and lubricants,
etc.
Oil, water
Places where oil, water or

fuel must be added, and
the capacity.
Drain
Places where oil or water

must be drained, and
quantity to be drained.
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
Added pages
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

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
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.
Qty
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.
Qty
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
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.
Used as adhesive for glass.
Used to seal joints of glass parts.
Used to seal front window.
00-11
Foreword
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
52
82
14 3
18 3
20 5
25 5
30 5
00-12
Tightening torque
Foreword
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
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
82
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
31
82
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
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.
26
0.32
2.09
3.1
20
Lighting, signal etc.
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
Circuits
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
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
Auxiliary
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
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
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
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
Foreword
Conversion table
Liter to U.S. Gallon

0
1l = 0.2642 U.S. Gal

1
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
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
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
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.
1C = 33.8F
C
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 (30C spec.), D155C-1 (50C spec.), D355C-3,

Bulldozer
D355C-3 (30C spec.), D355C-3 (50C 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 (50C 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
153624
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/kWh {g/HPh}
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)
38 (34)
Coolant amount
(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
PC1600SP-1
(2 engines)
mm
6 140 x 165
l {cc}
15.2 {15,240}
Firing order
153624
mm
1,498
1,938
Overall width
mm
1,040
1,185
mm
1,740
1,722
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/kWh {g/HPh}
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

Dry weight
42 (37)
38 (34)
Coolant amount
(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
(30C spec.)
D155C-1
(50C spec.)
D355C-3
D355C-3
(30C spec.)
6 140 x 165
15.2 {15,240}
153624
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 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
(50C spec.)
Applicable machine
mm
l {cc}
6 140 x 165
15.2 {15,240}
153624
Dimensions
Firing order
Overall length
mm
1,577
Overall width
mm
1,265
mm
1,843
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

Dry weight
g/kWh {g/HPh}
kg
Fuel injection pump
203 {151} (Gross)

1,850
Governor
BOSCH RSV centrifugal,

all speed type
42 (37)
Coolant amount
(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}
153624
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 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
HD325-6,
HD405-6
mm
6 140 x 165
l {cc}
15.2 {15,240}
Firing order
153624
mm
1,938
1,688
Overall width
mm
1,185
1,202
mm
1,722
1,300
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/kWh {g/HPh}
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

Dry weight
38 (32)
41 (37)
Coolant amount
(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
(50C spec.)
6 140 x 165
15.2 {15,240}
153624
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

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
SA6D140-2 right side view (For D155A-3, D155AX-3)
6D140-2 SERIES
01-13
(10)
General
SA6D140-2 front view (For D155A-3, D155AX-3)
01-14
(10)
6D140-2 SERIES
General
SA6D140-2 rear view (For D155A-3, D155AX-3)
6D140-2 SERIES
01-15
(10)
General
SA6D140-2 upper side view (For D155A-3, D155AX-3)
01-16
(10)
6D140-2 SERIES
General
SAA6D140-2 left side view (For PC750-6, PC800-6)
01-18
(10)
6D140-2 SERIES
General
SAA6D140-2 right side view (For PC750-6, PC800-6)
6D140-2 SERIES
01-19
(10)
General
SAA6D140-2 front view (For PC750-6, PC800-6)
01-20
(10)
6D140-2 SERIES
General
SAA6D140-2 rear view (For PC750-6, PC800-6)
6D140-2 SERIES
01-21
(10)
General
SDA6D140E-2 left side view (For D275A-5, 50C spec.)
a. Crankshaft center
b. Flywheel housing rear surface
01-22
(10)
6D140-2 SERIES
General
SDA6D140E-2 right side view (For D275A-5, 50C spec.)
a. Crankshaft center
b. Flywheel housing rear surface
6D140-2 SERIES
01-23
(10)
General
SDA6D140E-2 front view (For D275A-5, 50C spec.)
c. Crankshaft center
d. Cylinder liner center
01-24
(10)
6D140-2 SERIES
General
SDA6D140E-2 rear view (For D275A-5, 50C spec.)
c. Crankshaft center
d. Cylinder liner center
6D140-2 SERIES
01-25
(10)
General
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 (50C spec.)
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
Turbocharger
Komatsu KTR110
23
Cylinder head assembly
Cylinder head, valve, rocker arm,

valve spring
19
Cylinder block assembly
Cylinder block, bearing cap,

cylinder liner
400
Front cover
38
Oil pan
30
Flywheel assembly
Flywheel housing
Crankshaft assembly
Crankshaft, crankshaft gear
136
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
Turbocharger
Komatsu KTR110
23

valve spring
19

cylinder liner
400
Front cover
38
Oil pan
30
60 (D155A-2,3, AX-3, AX-5)
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)
Crankshaft assembly
136
Camshaft assembly

plate
19
10

rod assembly

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
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
Turbocharger
Komatsu KTR110
23

valve spring
19

cylinder liner
400
Front cover
38
Oil pan
30
Flywheel assembly
Flywheel housing
Crankshaft assembly
136
Camshaft assembly

plate
19
10

rod assembly

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
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 (30C spec.),

D355C-3 (50C spec.)
01-37
D155AX-5
01-38
D155C-1 (30C spec.),

D155C-1 (50C spec.)
01-42
HD325-6, HD405-6
01-39
PC750-6, PC800-6, PC1800-6
01-40
D275A-5 (50C spec.)
01-41
01-31
(10)
General
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
S6D140-2 for WA500-3

Net maximum torque:
1,370 Nm {140 kgm}/1,400 rpm
6D140-2 SERIES
01-33
(10)
General
SA6D140-2 for D155A-3, D155AX-3

Net maximum torque:
1,432 Nm {146 kgm}/1,300 rpm
01-34
(10)
6D140-2 SERIES
General
SA6D140-2 for PC1600SP-1

Net maximum torque:
1,863 Nm {190 kgm}/1,400 rpm
6D140-2 SERIES
01-35
(10)
General
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
SA6D140-2 for D355C-3, D355C-3 (30C spec.), D355C-3 (50C spec.)

Maximum torque:
1,570 Nm {160 kgm}/1,400 rpm (Net)
6D140-2 SERIES
01-37
(10)
General
SA6D140-2 for D155AX-5

Maximum torque:
1,610 Nm {164 kgm}/1,250 rpm (Net)
01-38
(10)
6D140-2 SERIES
General
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
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
SDA6D140E-2 [For D275A-5 (50C 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
SA6D140-2 for D155C-1 (30C spec.), D155C-1 (50C 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)

S6D140-2 for WA500-3
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
6D140-2 SERIES
11-3
(10)
SA6D140-2 for D155A-3, D155AX-3 (Left side view)

1.
2.
3.
4.
Muffler
Air cleaner
Connector
11-4
(10)
A. Intake
B. Exhaust
6D140-2 SERIES
SA6D140-2 for D155A-3, D155AX-3 (Right side view)

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)
SA6D140-2 for D155A-3, D155AX-3 (Intake system, front view)

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)
6D140-2 SERIES
SA6D140-2 for D155A-3, D155AX-3 (Exhaust system, rear view)

1.
2.
3.
4.
Dust indicator
O-ring
Connector
Tube (cylinder block aftercooler)
6D140-2 SERIES
11-7
(10)
SAA6D140-2 for PC750-6, PC800-6 (Left side view)

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
6D140-2 SERIES
SAA6D140-2 for PC750-6, PC800-6 (Right side view)

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)
SAA6D140-2 for PC750-6, PC800-6 (Front view)

A. Intake air (turbocharger air cooled aftercooler)

B. Intake air
(air cooled aftercooler electrical intake air heater)
11-10
(10)
6D140-2 SERIES
SAA6D140-2 for PC750-6, PC800-6 (Rear view)

6D140-2 SERIES
11-11
(10)
SAA6D140-2 for HD325-6 (Left side view)

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
SAA6D140-2 for HD325-6 (Right side view)

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)
SAA6D140-2 for HD325-6 (Front view)
SAA6D140-2 for HD325-6 (Rear view)
11-14
(10)
6D140-2 SERIES
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)
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
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
(50C spec.)
Komaclone, multicyclone
type (ERB type)
Automatic discharge
(exhaust ejector)
Inner cylinder 1,
Outer cylinder 1
11-17
(10)
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
KTR110 (Air-cooled type)

SDA6D140E-2 (D275A-5, 50C 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)
Aftercooler
(Water-cooled type)
SA6D140-2 (For construction machinery, generator)
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
(Air-cooled type)
SAA6D140-2 for PC750-6, PC800-6
1.
2.
3.
4.
Tank
Side support
Tube
Fin
6D140-2 SERIES
a. Intake air port

(Turbocharger io Intake manifold)
11-21
(10)
(Air-cooled type)
SAA6D140-2 for HD325-6
1.
2.
3.
4.
Tank
Side support
Tube
Fin
11-22
(10)
a. Intake air port

(Turbocharger io Intake manifold)
6D140-2 SERIES
Engine body
Engine body
Cylinder head
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 assy
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
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)
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
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)
Engine body
Main circulation system

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
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)
Engine body
Vibration damper
1.
2.
3.
4.
Crankshaft pulley
Pin (Crankshaft pulley vibration damper)
Vibration damper
Pin (Crankshaft crankshaft pulley)
11-30
(10)
6D140-2 SERIES
Engine body
Timing gear
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
6D140-2 SERIES
Engine body
11-33
(10)
Engine body
Valve system
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
Camshaft
Drawn steel bar (Turned)
Journal and filet portion: Induction hardening
6D140-2 SERIES
Engine body
Valve timing
11-35
(10)
Engine body
Flywheel and flywheel housing

Without PTO type
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
Lubrication system
Lubrication system
Lubrication system chart
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
Camshaft
Cam follower
Rocker arm
Intake and exhaust valve
Timing gears
Turbocharger (S6D140, SA6D140, SAA6D140)
Fuel injection pump
W: Cooling water
6D140-2 SERIES
Lubrication system
Large capacity oil filter + bypass filter

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
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)
Lubrication system
Oil pump
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
Lubrication system
Regulator valve and piston cooling valve

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)
Lubrication system
Oil filter
S6D140-2
SA6D140-2
SAA6D140-2
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
Lubrication system
SDA6D140E-2 (D275A-5, 50C 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)
Lubrication system
Large capacity oil filter

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
11-44
(10)
6D140-2 SERIES
Lubrication system
Large capacity oil filter + bypass filter

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
Bypass filter
Filtration area:1.4 m2
Rated flow: 7.5 l/min.
6D140-2 SERIES
11-45
(10)
Lubrication system
Oil cooler
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 1.5C
100C
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
Fuel system
Fuel system
Fuel system chart
1.
2.
3.
4.
5.
6.
7.
8.
Fuel tank
Gauze filter
Priming pump
Feed pump
Fuel filter
Fuel injection pump
Over-flow valve
11-48
(10)
6D140-2 SERIES
Fuel system
1.
2.
3.
4.
5.
6.
7.
8.
Fuel tank
Gauze filter
Priming pump
Feed pump
Fuel filter
Fuel injection pump
Over-flow valve
6D140-2 SERIES
11-49
(10)
Fuel system
Fuel injection pump

SA6D140-2 (D155A-3, D155AX-3, D155AX-5, D155C-1 (30C spec., 50C spec.),
D355C-3, D355C-3 (30C spec.), D355C-3 (50C spec.))
1.
2.
3.
4.
5.
6.
7.
8.
Fuel injection pipe (No. 1)

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
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)
Fuel system
SAA6D140-2 (PC750-6, PC800-6)

1.
2.
3.
4.
5.
6.
7.

11-52
(10)
8.
9.
10.
11.
12.
13.
14.

Bearing box
Coupling
Feed pump
Oil outlet pipe
6D140-2 SERIES
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

Type: Bosch PE-P
Lubrication method:
Governor
Type: Bosch RSUV Centrifugal, all speed type
11-53
(10)
Fuel system
SAA6D140-2 (HD325-6)
1.
2.
3.
4.
5.
6.
7.
8.

11-54
(10)
9.
10.
11.
12.
13.
14.
15.

Bearing box
Coupling
Oil outlet pipe
Feed pump
Oil inlet pipe
Fuel injection pump
6D140-2 SERIES
Fuel injection pump

Type: Bosch PE-P
Lubrication method:
6D140-2 SERIES
Fuel system
Governor
Bosch RFD Centrifugal, max. min.
speed control type
11-55
(10)
Fuel system
SDA6D140E-2 (D275A-5, 50C spec.)

1.
2.
3.
4.
5.
6.
7.
8.

Oil inlet pipe
11-56
(10)
9.
10.
11.
12.
13.
14.
15.
Oil outlet pipe

Feed pump
Coupling
Bearing box
Fuel injection pump drive gear (No. of teeth: 48)
6D140-2 SERIES
Fuel injection pump

Type: Bosch PE-P
Lubrication method:
6D140-2 SERIES
Fuel system
Governor
Bosch RFD Centrifugal, max. min.
speed control type
11-57
(10)
Fuel system
Feed pump
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
Fuel system

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

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)
Fuel system
Fuel filter
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
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)
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
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)
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
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)
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
Cooling system
SDA6D140E-2 (D275A-5, 50C 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)
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
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
Cooling system
SA6D140-2
(D155A-3, D155AX-3, D155AX-5, D155C-1 (30C spec., 50C spec.),

D355C-3, D355C-3 (30C spec.), D355C-3 (50C spec.))
SDA6D140E-2 (D275A-5, 50C spec.)
1. Oil cooler
3. Water pump
6D140-2 SERIES

(Cooling water)
C. To radiator (Cooling water)
D. To oil cooler on machine (Cooling water)
11-71
(10)
Cooling system
SAA6D140-2 (HD325-6)
1. Oil cooler
3. Water pump
11-72
(10)

(Cooling water)
C. To radiator (Cooling water)
D. To oil cooler on machine (Cooling water)
6D140-2 SERIES
Cooling system
SDA6D140E-2 (D275A-5, 50C spec.)

For aftercooler
1. Tube
2. Tube
3. Water pump
6D140-2 SERIES
A. From water pump to aftercooler
11-73
(10)
Cooling system
S6D140-2
SA6D140-2
SAA6D140-2
SDA6D140E-2 (D275A-5, 50C 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
Cooling system
For aftercooler
SDA6D140E-2 (D275A-5, 50C 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)
Cooling system
Thermostat
a The specifications may be different from the following figure, depending on the type of machine model.
1. Cylinder block
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 2C (For construction machine and
generator)
82 2C (For marine engines)
Fully opening temperature: 90C
Lift and fully opening position:10 mm min.
6D140-2 SERIES
Cooling system
Corrosion resistor
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)
Cooling system
Corrosion resistor mounting

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
Cooling system
Cooling fan drive

Tension pulley mount
S6D140-2 for WA500-3
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)
Cooling system
Tension pulley mount

SA6D140-2 for D155A-3, D155AX-3, D155AX-5
1.
2.
3.
4.
Fan pulley
Tension pulley
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
Cooling system
Tension pulley
SA6D140-2 (D155A-3, D155AX-3, D155AX-5)
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)
Cooling system
SAA6D140-2 (PC750-6, PC800-6)

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
Cooling system
Tension pulley
SAA6D140-2 (PC750-6, PC800-6)
1.
2.
3.
4.
5.
6.
7.
8.
Tension shaft
Roller bearing
Tension bracket
Oil seal
Ball bearing
Spacer
Stopper
6D140-2 SERIES
11-83
(10)
Cooling system
SAA6D140-2 for HD325-6, HD405-6

1.
2.
3.
4.
5.

Fan pulley
Fan mount case
Fan belt
Fan pulley
Outside diameter (mm)
Applicable machine
275
HD325-6, HD405-6
a. Wind direction
11-84
(10)
6D140-2 SERIES
Cooling system
Tension pulley
SAA6D140-2 for HD325-6, HD405-6
1.
2.
3.
4.
5.
6.
7.
Bracket
Spacer
Ball bearing
Bearing
Coil spring
Tension shaft
6D140-2 SERIES
11-85
(10)
Cooling system
Fan mount case

SAA6D140-2 for HD325-6, HD405-6
1.
2.
3.
4.
Fan pulley hub

Ball bearing
Shaft
Case
11-86
(10)
6D140-2 SERIES
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
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)
Accessory
Air compressor mounting

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
Accessory
Exhaust brake
Slide valve type
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)
Accessory
Butterfly valve type

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
Accessory
Solenoid valve for exhaust brake

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)
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
Electrical system
Electrical system
Alternator
Mounting
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)
Electrical system
Alternator with built-in regulator (Open type 35A)

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
SA6D140-2
D155A-3, AX-3, AX-5
Maker: NIKKO DENKI

24 V, 35 A
85
9.5
11-96
(10)
6D140-2 SERIES
Electrical system
Alternator with built-in regulator (Open type)

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

24 V, 35 A
85
9.5
D155A-3, AX-3, D355C-3, Maker: NIKKO DENK

D355C-3 (30C spec.) Type: Opened (Brushless)
24 V, 35 A
85
9.5
Maker: NIKKO DENKI

24 V, 25 A
85
8.5
Maker: NIKKO DENKI

24 V, 30 A
85
9.5
S6D140-2
SA6D140-2
5. Terminals B
6A. Field coil
6B. Regulator
SAA6D140-2
6D140-2 SERIES
Type
11-97
(10)
Electrical system

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)

6A. Alternator
6B. Regulator
Applicable machine
model
Type
Specification
Pulley O.D.
(mm)
Weight
(kg)
Pulley type
GD825A-2
Maker: SAWAFUJI DENKI

24 V, 50 A
85
12
II
D155A-3, AX-3, AX-5 (if Maker: SAWAFUJI DENKI

equipped)
24 V, 50 A
85
12
II
24 V, 50 A
85
12
II
PC750-6, PC800-6
HD325-6, HD405-6

6D140-2 SERIES
Electrical system

1.
2.
3.
4.
5.
Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E
Engine model
SA6D140-2
Applicable machine
model

6A. Primary energized resistance
6B. Regulator
6C. Field coil
Type
D155C-1 (30C spec.)

D155C-1 (50C spec.)
Maker: NIKKO DENKI
D355C-3
D355C-3 (30C spec.)
D355C-3 (50C spec.)
6D140-2 SERIES
Specification
Pulley O.D.
(mm)
Weight
(kg)
Pulley type
24 V, 50 A
85
11.0
11-99
(10)
Electrical system

1.
2.
3.
4.
Alternator
Alternator pulley
Terminal B
Terminal R
Engine
Machine model
SDA6D140E-2 D275A-5 (50C spec.)
11-100
(10)

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
Electrical system
Starting motor
For 7.5 kW
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)

S. To starting switch terminal C
R. To alternator terminal R
E. To ground
6D140-2 SERIES
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
12
18
Maker: NIKKO DENKI

Type: Closed
24 V, 7.5 kW
12
18
SAA6D140-2
PC750-6, PC800-6
6D140-2 SERIES
11-103
(10)
Electrical system
For 11 kW
1.
2.
3.
4.
5.
6.
7.
8.

Magnetic switch
Safety relay
Pinion gear
Terminal B
Terminal C
Connector
External wiring diagram (2-pin connector type)
8A. Control unit
11-104
(10)

9A. Control unit
10. External wiring diagram (without safety relay)
E. To ground
6D140-2 SERIES
Engine model
Number of
pinion
teeth
Weight
(kg)
Connector
type

24 V, 11 kW
Type: Closed
(drip-proof, oil proof) 24 V, 11 kW
11
20
11
20
24 V, 11 kW
11
20
D155C-1 (30C spec.) Maker: SAWAFUJI DENKI

D155C-1 (50C spec.) Type: Closed
(drip-proof, oil proof) 24 V, 11 kW
D355C-3
D355C-3 (30C spec.)
D355C-3 (50C spec.)
11
20
11
20
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

24 V, 11 kW
Type: Closed
11-105
(10)
Electrical system
For 11 kW
1.
2.
3.
4.
5.
6.
Pinion gear
Magnetic switch
Terminal B
Terminal C
Safety relay
Engine
Machine model
SDA6D140E-2 D275A-5 (50C spec.)
11-106
(10)

E. To ground
Type
Nikko Denki
Waterproof, oilproof type
Specification
No. of
pinion
teeth
Weight
(kg)
Connector
type
24 V, 11 kW
12
18
6D140-2 SERIES
Electrical system
Electrical intake air heater

S6D140-2
1. Heater body
2. Heater coil

Rated voltage: DC22 V
Rated current: 175 A
SA6D140-2
SDA6D140E-2 (D275A-5, 50C spec.)
1. Heater body
2. Heater coil
3. Terminal
6D140-2 SERIES

Rated voltage: DC11 V
Rated current: 86 A
11-107
(10)
Electrical system
Front PTO mounting

1. Front PTO
2. O-ring
3. Front PTO drive gear assembly
11-108
(10)
6D140-2 SERIES
Electrical system
Front PTO assembly

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)
Electrical system
Front PTO drive gear assembly

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-
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)
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
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)
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 60C)
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
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)
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
1505304000
0.525
1505304100
0.55
1505304200
0.575
1505304300
0.60
1505304400
0.625
1505304500
0.65
1505304600
0.675
1505304700
0.70
150530-4800
0.725
1505304900
0.75
1505305000
0.775
1505305100
0.80
1505305200
0.825
1505305300
0.85
1505305400
0.875
1505305500
0.90
1505305600
0.925
1505305700
0.95
1505305800
0.975
1505305900
1.00
1505306000
1.025
1505306100
1.05
1505306200
1.075
1505306300
1.10
1505306400
1.125
1505306500
1.15
1505306600
1.175
1505306700
1.20
1505306800
1.225
1505306900
1.95
1505309800
1.975
1505309900
6D140-2 SERIES
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)
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
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)
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 (30C spec.),

D355C-3 (50C spec.)
12-19
6211-72-1170
D155AX-5
12-24
6211-72-1180
D155C-1 (30C spec.)

D155C-1 (50C 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)

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
6D140-2 SERIES
12-11
(10)
12-12
(10)
6D140-2 SERIES
6D140-2 SERIES
12-13
(10)
12-14
(10)
6D140-2 SERIES
6D140-2 SERIES
12-15
(10)
12-16
(10)
6D140-2 SERIES
6D140-2 SERIES
12-17
(10)
12-18
(10)
6D140-2 SERIES
6D140-2 SERIES
12-19
(10)
12-20
(10)
6D140-2 SERIES
6D140-2 SERIES
12-21
(10)
12-22
(10)
6D140-2 SERIES
6D140-2 SERIES
12-23
(10)
12-24
(10)
6D140-2 SERIES
6D140-2 SERIES
12-25
(10)
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)
min.
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.
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
Running time
GD825A-2
S6D140-2
Order
Item
6D140-2 SERIES
Performance test
Engine
model
Applicable
machine
Running time
min.
10
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.
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.
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.
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.
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}
12-27
(10)
Performance test
Engine
model
Applicable
machine
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.
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
(50C spec.)
(10)
kW
{HP}
0
{0}
35
{48}
106
{146}
212
{292}
318
{438}
Running time
min.
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.
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.
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
(30C spec.)
12-28
Flywheel
horsepower
6D140-2 SERIES
Performance test
Engine
model
Applicable
machine
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.
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.
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.
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.
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
(30C spec.)
SA6D140-2
D355C-3
(50C spec.)
SAA6D140-2
Order
Item
HD325-6
(High altitude
spec.)
PC750-6
PC800-6
PC1800-6
6D140-2 SERIES
12-29
(10)
Performance test
Engine
model
SDA6D140E-2
12-30
(10)
Applicable
machine
D275A-5
(50C spec.)
Order
Item
Running time
min.
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}
6D140-2 SERIES
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).
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
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)
Performance test
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
Performance test

Flywheel
horsepower
(kW{HP})
Torque
(Nm{kgm})
238.2 252.9
{319.1 338.8}
Fuel
consumption
(sec/200cc)
Lubrication
Exhaust
oil pressure
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)
Performance test
Engine model
Applicable
machine
Test item
Flywheel
horsepower
J6D140E-G1-2
(TAIYO DENKI
High idling
generator)
speed
Low idling
speed
D155AX-5
D155C-1
(30C spec.)
SA6D140-2
D155C-1
(50C spec.)
D355C-3
(30C spec.)
D355C-3
(50C 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
Performance test

Lubrication
Exhaust
oil pressure
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)
Performance test
Engine model
Applicable
machine
HD325-6
HD405-6
SAA6D140-2
HD325-6
(High altitude
spec.)
PC750-6
PC800-6
PC1800-6
D275A-5
(50C 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
Performance test

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
Exhaust
oil pressure
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

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
12-44
(10)
ii
iii
6D140-2 SERIES
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
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
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
Improper selection of fuel
(At ambient temperature of 10C or below, use ASTM D975 No. 1)
a Battery charging rate
Charging rate
Ambient
temperature
100 %
90 %
80 %
75 %
70 %
20C
1.28
1.26
1.24
1.23
1.22
0C
1.29
1.27
1.25
1.24
1.23
10C
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
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
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
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
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
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
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
Battery S.G.
Freezing temperature of
cooling water
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 50C
799-101-6000
Digital temperature
gauge
790-500-1300
Thermistor temperature 0 200C

gauge
0 1,000C
50 1,200C
Lubrication oil pressure
0 1 MPa {0 10 kg/cm2}
Fuel pressure
0 2 MPa {0 20 kg/cm2}
Intake pressure,
exhaust pressure
Blow-by pressure
0 9.8 kPa {0 1,000 mmH2O}
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

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
0C (without starting aid)
rpm
Min. 110
Min. 110
20C (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.)
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 (20C)
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
(SAE30 or SAE 15W-40) (Water temp: Min. 70C)
kPa
{mmH2O}
Max. 0.98
{Max. 100}
1.96
{200}
Max. 1.47
{Max. 150}
2.94
{300}

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
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
Oil temperature: 40 60C
(SAE30 or SAE 15W-40) (Engine speed: 200 250 rpm)
Oil pressure
(Oil temperature:
Min. 80C)
SAE 10W oil

At low idling
SAE 10W oil
Oil temperature
All speed (Oil in oil pan)
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
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
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
Engine model
SA6D140-2
Performance
Category
Item
Engine speed
D155A-2
Unit
Engine
proper
Permissible
value
Low idling speed
rpm
550 650
550 650
700 725
700 725
rpm
Min. 110
Min. 110
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
kPa
{mmHg}
Max. 85.4
{Min. 640}
68.0
{510}
Exhaust pressure
kPa
{mmHg}
Min. 74.7
{Min. 560}
60.0
{450}
Exhaust temperature
All speed (20C)
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
MPa
{kg/cm2}
Min. 3.80
{Min. 39}
2.65
{27}
Min. 3.82
{Min. 39}
2.65
{27}
Blow-by pressure
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
Exhaust gas color

Lubrication system
Standard
value
rpm
Intake valve
Valve clearance
Fuel
Permissible
value
High idling speed
Bosch
index
High idling speed
Cooling
Standard
value
D155A-3, D155AX-3
Oil pressure
(Oil temperature:
Min. 80C)
SAE 10W oil

At low idling
SAE 10W oil
Oil temperature
90 110
120
80 110
120

Max. 0.5
1.0
Max. 0.5
1.0
Nozzle tester
MPa
{kg/cm2}
25.0 25.8
{255 263}
20.2
{206}
24.0 25.8
{245 263}
20.2
{206}
B.T.D.C.
degree
14.5 15.5
26 28
26 28
Opening pressure
kPa
{kg/cm2}
Fan speed
rpm
1,165 1,235 1,165 1,235 1,255 1,335 1,255 1,335
Fan belt tension

mm
Auto-tensioner
Auto-tensioner Auto-tensioner
*: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)
12-70
(10)
6D140-2 SERIES
Troubleshooting
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
Engine model
SA6D140-2
DCA-400SSK
(MQ generator)
Performance
Category
Item
Engine speed
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
rpm
Min. 110
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
kPa
{mmHg}
Max. 160
{Min. 1,200}
128
{960}
Exhaust pressure
kPa
{mmHg}
Min. 120
{Min. 900}
96
{720}
Exhaust temperature
All speed (20C)
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
Exhaust gas color
Bosch
index
MPa
(SAE30 or SAE 15W-40) (Engine speed: 200 250 rpm) {kg/cm2}
Blow-by pressure
Lubrication system
Standard
value
rpm
Intake valve
Valve clearance
Fuel
Permissible
value
High idling speed
High idling speed
Cooling
Standard
value
J6D140E-G1-2
Oil pressure
(Oil temperature:
Min. 80C)
SAE 10W oil

At low idling
SAE 10W oil
Oil temperature
90 110
120
90 110
120

Max. 0.5
1.0
Max. 0.5
1.0
Nozzle tester
MPa
{kg/cm2}
25.0 25.8
{255 263}
20.2
{206}
25.0 25.8
{255 263}
20.2
{206}
B.T.D.C.
degree
16.5 17.5
16 18 50Hz
17 19 60Hz
16 18 50Hz
17 19 60Hz
Opening pressure
kPa
{kg/cm2}
Fan speed
rpm
1,330 1,410
(60 Hz)
Fan belt tension

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
12-72
(10)
6D140-2 SERIES
Troubleshooting
SA6D140-2
D155C-1 (30C spec.)
D155C-1 (50C spec.)
D355C-3 (30C spec.)
D355C-3 (50C 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
Engine model
SAA6D140-2
Performance
Category
Item
Engine speed
PC750-6, PC800-6
Unit
rpm
775 825
775 825
675 775
675 775
rpm
Min. 110
Min. 110
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
At rated output
kPa
{mmHg}
Exhaust temperature
All speed (20C)

Quick acceleration
At rated output
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
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: 70C 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
Lubrication system
Permissible
value
Low idling speed
Intake valve
Valve clearance
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:
80C min.)
SAE 10W oil

At low idling
SAE 10W oil
Oil temperature
80 110
120
80 110
120
At continuous rated output

Max. 0.5
1.0
Max. 0.5
1.0
Nozzle tester
MPa
{kg/cm2}
24.8 25.5
{253 260}
20.2
{206}
24.8 25.5
{253 260}
20.2
{206}
B.T.D.C.
degree
18.5 19.5
18.5 19.5
19.5 20.5
19.5 20.5
Opening pressure
kPa
{kg/cm2}
Fan speed
rpm
Fan belt tension

force of 58.8 N {6 kg}
mm
1,018 1,082 1,018 1,082

(Autotensioner)
(Autotensioner)
12-74
(10)
6D140-2 SERIES
Troubleshooting
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
g
:
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
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
790-901-1260
Adapter
790-501-2001
Engine overhaul
795-102-2102
Spring pusher
Engine
oil: Approx.
Qty
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).
13-2
0
bolts (I), then remove starting
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).
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.
CEE00154
ASSEMBLY
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
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
seal
Seal
Metal rins
with
sleeve
Flywheel
housing
Cr.ankshaft
DWEOOZIZ
Crankshaft
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.
_..~
,_------..,
,_._
.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.
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
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
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)
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
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.
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
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
in permanent
Elongation
deformation.
method)
of bolt
Bolts to be tightened by the plastic range turning

angle method in the 140 Series engines.
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
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
No.
790-901-1260
Part Name
Adapter
atv
1
790-501-2001
Engine overhaul stand
795-102-2102
Spring pusher
795-100-I 191
Piston ring tool
795-230-5472
Liner driver
Part Name
Part No.
1 795T-473-1110 1 Push tool
795-521-1110
Push tool
01050-31640
Bolt
795-931-1210
Sleeve jig
795-931-1220
Sleeve jig
01050-31645
Bolt
01050-31625
Bolt
790-331-I 110 1 Wrench
Qty
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.
mnd
_______-_-.
omfl
g6
& -=t
----------.--.-
;s
I
t
ep
Cl
CDE00261
/ 795T-473-1110
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.
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,
CEE00051
GENERAL ASSEMBLY
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.
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.
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.
DWE00189
Cylin
+=I
er liner
P
Crevice seal
Black (Ethylene
propylene
rubber)
O-ring
Black (Ethylene
propylene
rubber)
O-ring
Orange
rubber)
(Silicon
w
DEE00090
ASSEMBLY
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
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,
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 200C for 30 minutes, then
shrink fit.
4)
Align protrusion of lower main bearing with

notch in main bearing cap and install
bearing.
*
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
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
Before tightening, measure the free length
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.
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.
4)
5)
Align
protrusion
of upper
bearing
of
connecting rod with notch in connecting rod
and install bearing.
*
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)
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.
Max. 95.0 mm.
+ If the bolt length a exceeds tolerance
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
installing.
*
Coat the sliding surface of the connecting rod cap with engine oil (SAE#30).
P\
a
DWE00275
GENERAL ASSEMBLY
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.

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.
head
Put mark on side
of
CEE00216
idler
gear
and
seat
bolt
If there are already five marks on the

bolt head, replace with new bolts.
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 - 240C 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.
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)
0.141 - 0.425
0.129 - 0.391
0.129 - 0.391
0.141 - 0.426
0.095 - 0.346
0.080 - 0.417
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
-I
Range (mm)
0.140 - 0.315
0.100 - 0.250
0.050 - 0.170
0.050 - 0.170
0.070 - 0.200
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.
%6!3
E
Position
9.
ASSEMBLY
IF
---l
2 G1
D A 3c
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.
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.
4)
ASSEMBLY
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.
housing, sliding surface of the lip and the
corner of the end face of the crankshaft.
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
Assemble
Small
diameter
inside
end
guide
Large
diameter
inside
end
DWEOOZI

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

to push in.
3)

tube (2).
*
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).
-11
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
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).
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.
Max. 166.3 mm.
*
If the bolt length a exceeds tolerance
a
OWE00275
GENERAL ASSEMBLY
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
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
Exhaust
valve
0.78 - 0.82
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.
CDE00240
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
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

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

to push in.
3)

tube (3).
+
ASSEMBLY
CFFOO414
4)
Tighten bolts uniformly until end face of tool

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

*
housing, sliding surface of the lip and the
corner of the end face of the crankshaft.
*
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
DWE00223
Put one punch mark
DEE00100
GENERAL ASSEMBLY
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.
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
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
II
CEE00254
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
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
CEW00552
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)
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
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}
5)
*
For the Komaclone

type air cleaner, install
precleaner (11) to air cleaner body (10).
Tighten until clearance a is 0.
11
53. Refilling with oil

I) Check that engine drain plug is tightened.
2) Add engine
oil through
oil filler to the
specified level.
Engine
oil pan: Approx.
37 L?
a
IO
CEE00260
14 Maintenance standard

Turbocharger ............................................ 14-
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)

Turbocharger
KTR110
S6D140-2
SA6D140-2
SAA6D140-2
14-2
(11)
6D140-2 SERIES
Unit: mm
No.
Check item
Criteria
End play (Play in axial direction)
Radial play (Play in radial direction)
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
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
0.08
0.10
1.85
1 Ring
0.03
0.04
2.05
2 Ring
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
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
Remedy
Clearance limit: (Min.) 0.20
Replace parts
related to
bearing
14-3
(11)
KTR110L
SDA6D140E-2 (D275A-5, 50C spec.)
14-4
(11)
6D140-2 SERIES
Unit: mm
No.
Check item
Criteria
End play (Play in axial direction)
Radial play (Play in radial direction)
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
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
0.08
0.10
1.85
1 Ring
0.03
0.04
2.05
2 Ring
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
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
Remedy
Clearance limit: (Min.) 0.20
Replace parts
related to
bearing
14-5
(11)
Engine body
Engine body
Cylinder head
14-6
(10)
6D140-2 SERIES
Engine body
Unit: mm
No.
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.
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}
Tightening torque of nozzle

holder mounting bolt
Tightening torque of fuel inlet

connector
Tightening torque of
connector pipe locknut
39.2 {4}
34.3 44.1 {3.5 4.5}
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)
Engine body
Valve, valve guide
14-8
(10)
6D140-2 SERIES
Engine body
Unit: mm
No.
Check item
Amount of valve sinking
Thickness of valve lip
Valve seat angle
Outside diameter of valve

stem
Criteria
Valve
Standard size
Tolerance
Repair limit
Intake valve
0.10
0.70
Exhaust valve
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
015'
Exhaust valve
45
015'
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
Squarence of valve spring
Large
51.0
Small
43.6
Standard installed
load (N {kg})
*2
*1
*1
*2
*1
231.311.8 215.610.8
{23.61.2} {22.01.1}
Replace valve
guide
Replace valve
or valve guide
Replace valve
Installed load limit

(N {kg})
*1
47423.5 424.321.6
{48.42.4} {43.32.2}
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)
Engine body
Rocker arm and shaft
Unit: mm
No.
Check item
Outside diameter of rocker
arm shaft
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
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
Engine body
Crosshead and guide
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
+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)
Engine body
Cylinder block
Unit: mm
No.
Check item
Distortion of cylinder head
mounting surface
Inside diameter of main
bearing hole
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
Inside diameter of camshaft

bushing
65
+0.040
+0.030
65.15
Replace camshaft bushing
Difference of face between

cylinder block and front cover

bearing
Tightening torque of main

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

mounting bolt and under frame
mounting bolt
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
Engine body
Cylinder liner
Unit: mm
No.
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
140
+0.020
+0.020
140.12
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)
liner (Counter bore bottom)
4
Interference between
cylinder liner and block
(Counter bore bottom)

liner (O-ring)
5
Clearance between cylinder
liner and block (O-ring)
6D140-2 SERIES

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
cylinder block,
or repair
Replace
cylinder
liner
cylinder block
14-13
(10)
Engine body
Crankshaft
Unit: mm
No.
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
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
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
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)
Engine body
Cam follower and push rod
Unit: mm
No.
Check item
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
Criteria
Standard size
Tolerance
12.7
0.20
0.20
0.20
0.20
Radius of push rod ball end
Radius of push rod socket

end
13.4
Bend of push rod
Repair limit: 0.3 (Total indicated runout)
14-16
(10)
Replace
6D140-2 SERIES
Engine body
Timing gear
14-18
(10)
6D140-2 SERIES
Engine body
Unit: mm
No.
Check item
Criteria
Measuring
point
Clearance between sub idler

gear bushing and shaft
End play of main idler gear
Standard
size
Gears
Crankshaft gear and main idler

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

injection pump drive gear
0.129
0.391
Main idler gear (Small) and

camshaft gear
0.129
0.391
Main idler gear (Large) and sub

idler gear
0.141
0.426
Sub idler gear and oil pump drive

gear
0.080
0.417
Sub idler gear and water pump

drive gear
0.095
0.346
Camshaft gear and air

compressor drive gear
0.118
0.369
Injection pump drive gear and

PTO gear (Lower)
0.118
0.369
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
End play of sub idler gear
0.05 0.17
0.4
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)
Engine body
Piston
14-20
(10)
6D140-2 SERIES
Engine body
Unit: mm
No.
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
140
0.070
0.085
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
Top ring
2.4
0.015
0.035
Second ring
2.41
0.010
0.035
Oil ring
0.010
0.030
Top ring
Second ring
Oil ring
+0.040
+0.020
No.
Measuring point
Standard clearance
Clearance limit
Top ring
Second ring
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
Outside diameter of piston pin
Repair limit
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)
Engine body
Connecting rod
Unit: mm
No.
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
Inside diameter of bushing hole

at connecting rod small end
Inside diameter of bearing at

connecting rod big end
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
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
Engine body
Flywheel and flywheel housing
Unit: mm
No.
Check item
Criteria
Remedy
Face runout of flywheel

housing
Repair limit: 0.35
Radial runout of flywheel

housing
Repair limit: 0.30
Face runout of flywheel
Repair limit: 0.20
Radial runout of flywheel
Repair limit: 0.15

Order
Tightening torque of flywheel

housing mounting bolts
(Coat thread areas with engine
oil)
Tightening order
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)
Lubrication system
Lubrication system
Oil pump
14-24
(10)
6D140-2 SERIES
Lubrication system
Unit: mm
No.
Check item
Axial clearance of pump gear
Criteria
Tolerance
Standard
size
45
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
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
Clearance between driven

shaft and driven gear bushing
18
+0.090
+0.070
+0.147
+0.127
0.032
0.077
Clearance between driven

shaft and body
18
+0.090
+0.070
+0.129
+0.102
0.012
0.059
Clearance between relief

valve and pump cover
16
0.040
0.060
+0.043
+0.043
0.040
0.103
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

gear and drive shaft

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)
Lubrication system
Regulator valve, piston cooling valve and safety valve
Unit: mm
No.
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}
Regulator valve set pressure
0.3 0.02 MPa {3.2 0.2 kg/cm2}
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
Lubrication system
Oil cooler
Unit: mm
No.
Check item
Lift of thermostat to fully open
position
Criteria
Remedy
Min 8 mm (soak in oil bath at 100C (116C) 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 100C (116C) and then soaked in oil bath for fully closed
85C (110C) for 4 to 5 minutes.
Replace
a The figure in ( ) indicates the thermostat for fully open temperature 116C.
a There are two types of thermostat for the oil cooler (fully open temperature: 100C and 116C). For the
marine engine only the fully open temperature 100C is applicable; for other models, either type can be used.
6D140-2 SERIES
14-27
(10)
Cooling system
Cooling system
Water pump
6D140-2
S6D140-2
SA6D140-2
Unit: mm
No.
Check item
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

gear and shaft
25
+0.015
+0.002
0.023
0.053
0.025 0.068
Interference between pulley

flange and shaft
25
+0.015
+0.002
0.023
0.053
0.025 0.068
Clearance between impeller

and body
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
Cooling system
S6D140-2
SA6D140-2
SDA6D140E-2 (D275A-5, 50C spec.)
Unit: mm
No.
Check item
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

gear and shaft
28
+0.015
+0.002
0.023
0.053
0.025 0.068
Interference between pulley

flange and shaft
25
+0.015
+0.002
0.021
0.041
0.025 0.056

and body

seal
6D140-2 SERIES
Replace
Repair limit
A: 1.5
14-29
(10)
Cooling system
For aftercooler
SDA6D140E-2 (D275A-5, 50C spec.)
Unit: mm
No.
Check item
impeller and shaft

gear and shaft

and body

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
Replace
Repair limit
A: 1.5
6D140-2 SERIES
Cooling system
Thermostat
Unit: mm
No.
Check item
Lift of thermostat to fully open
position
Criteria
Min. 10 mm (soak in oil bath at 90C 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 (90C) and then soaked in oil bath for fully closed (71C) for
4 to 5 minutes.
6D140-2 SERIES
Remedy
Replace
14-31
(10)
15 Repair and replacement of parts
Table of special tools ..................................... 15-
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
79A-513-1710
Basic machine
79A-513-1780
Guide plate
79A-513-1820
Cutter plate
79A-513-1860
Cutter
79A-513-1940
Cutter set gauge
79A-513-1950
Micrometer
79A-513-1960
Driver plate
79A-513-2090
Driver shaft
79A-513-2110
Driver handle
10
79A-513-2120
Service package
11
79A-513-2130
Case
12
79A-513-2140
Basic machine
13
79A-513-2160
Cutter plate
14
79A-513-2230
Cutter
15
79A-513-2240
Remover pin
16
79A-513-2250
Case
17
79A-513-2260
Service package
18
79A-513-2270
Compound
Loctite
19
79A-513-2280
Primer
Loctite
20
79A-513-2320
Bushing
12
Part No.
6D140-2 SERIES
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)
Cylinder head
Replacing valve seat insert

Special tools
No.
Part No.
795-100-4800
Puller (valve seat)
790-101-5001
Push tool (KIT)
790-101-5081
Plate
(for intake valve)
790-101-5071
Plate
(for exhaust valve)
795-100-3003
Seat cutter (KIT)
795-100-3100
Body ass'y
795-100-3200
Micrometer
795-100-3300
Gauge
795-100-3400
Tool head
795-100-3601
Head support
795-100-3710
Cutter (for oversize

machining)
795-100-3720
Cutter (for 30)
795-100-3730
Cutter (for 45)
795-100-4210
Pilot (10.000 mm)
795-100-4220
Pilot (10.010 mm)
795-100-4230
Pilot (10.020 mm)
795-100-4240
Pilot (10.030 mm)
1
B
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
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 ) 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)
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
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
D1
D2
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)
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
Cylinder head
Pressure test
When corrections have been made around the

cylinder head, test the pressure as follows.
Special tools
No.
Part No.
790-553-1600
Part Name
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 95C).
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)
Cylinder head
Replacing valve guide

Special tools
No.
Part No.
795-100-1520
Valve guide remover
Part Name
Q'ty
1
795-130-1710
Valve guide driver
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
Cylinder head
Replacing crosshead guide

Special tools
No.
Part No.
Part Name
Q'ty
795-140-6410
Crosshead guide puller
795-130-1310
Crosshead guide driver
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)
Cylinder head
Grinding valve
Special tool
No.
Part No.
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
Cylinder block
Cylinder block
Replacing cam bushing
Special tools
No.
Part No.
795-213-1200
Push tool
795-213-1250
Push bar
795-213-1210
Push tool
795-213-1240
Collar
795-213-1230
Guide
792-103-0400
Grip
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)
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
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: 65 +0.06
mm
0
a Clearance of camshaft journal: 0.016 0.096 mm
6D140-2 SERIES
15-15
(10)
Cylinder block
Replacing crankshaft gear

Special tools
No.
Part No.
Part Name
Q'ty
790-101-2800
Bearing puller
790-101-2300
Push puller
1. Removal of Gear
Make a scratch in the surface at the root of the
teeth with a grinder, then assemble pullers
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:
200C
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
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 240C
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)
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. 200C
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
Cylinder block
Replacing connecting rod

small end bushing
Special tools
No.
Part No.
795-240-6400
Push tool (KIT)
795-240-6410
Push tool
795-240-6420
Push tool
795-240-6430
Block
01530-03912
Nut
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)
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
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)
Unit: mm
Symbol
Inspection item

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
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)
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
6D140-2 SERIES
15-25
(10)
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
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.
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)
Fig. 7
Use tool K when grinding the counterbore.
Fig. 8
Fig. 9
15-28
(10)
6D140-2 SERIES
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
OS
SH
WS
(Size of letters: 5 10 mm)
6D140-2 SERIES
15-29
(10)
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
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
167
161.45 0.25
Fig. 18
160.67 0.064
176 0.25
184.94 0.18
158 +0.040
+0
159.03 (Gauge diameter)
6D140-2 SERIES
15-31
(10)
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
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
PROPOSAL
FOR MANUAL
REVlslON
1
I
FOR INTERNAL USE ONLY -- No. PMR

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

f more space is needed, use another sheet.
FOR INTERNAL USE ONLY
:ORRECTIVE ACTION:
PFMRl 081696

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SEBM008611

11 Structure and function ......................................................................................

12 Testing and adjusting ........................................................................................

13 Disassembly and assembly ..........................................................................

List of revised pages

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are those previously revised

List of revised pages

List of revised pages

List of revised pages

6. Decide a place in the repair workshop to keep

Precautions during work

19. Be sure to assemble all parts again in their original places.

Structure and function

How to read the shop manual

Each issued as one

Revised edition mark

Special safety precautions

Weight of parts of systems.

Places that require special

Places to be coated with

Places where oil, water or

Places where oil or water

2. Following examples show how to read the page

Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

Slinging near the edge of the hook may

3) Do not sling a heavy load with one rope

Slinging with one rope may cause

a The allowable load value is estimated to be

2) Sling wire ropes from the middle portion of

4) Do not sling a heavy load with ropes forming

Method of disassembling, connecting push-pull type coupler

Method of disassembling, connecting push-pull type coupler

Before carrying out the following work, release

Method of disassembling, connecting push-pull type coupler

Hold the mouthpiece of the tightening portion

Hold the mouthpiece of the tightening portion

Hold in the condition in Step 1), and turn lever

Hold in the condition in Step 1), and push until

Hold in the condition in Steps 1) and 2), and pull

Hold in the condition in Steps 1) and 2), and pull

Hold the mouthpiece of the tightening portion and

Hold the mouthpiece of the tightening portion and

Main applications, featuresr

Used to prevent rubber gaskets, rubber

Used in places requiring an immediately

Quick hardening type adhesive

Polyethylene Used as sealant for machined holes.

Used as heat-resisting sealant for

Quick hardening type adhesive

Used as adhesive or sealant for gaskets

Used as sealant for various threads, pipe

Features: Silicon based, resistance to

Resistance to heat, chemicals

Used as adhesive or sealant for metal,

Features: Silicon based, quick hardening

Used as heat-resisting sealant for

Features: Silicone type, heat resistant,

Used as lubricant for sliding portion (to

Used to prevent seizure or scuffling of the