DIESEL ENGINE
2005
All Rights Reserved
Printed in Japan 02-05 (01)
00-1
(11)
Contents
No. of page
01 General ..........................................................................................................................
01-1
11-1
12-1
13-1
14 Maintenance standard.........................................................................................14-1
15 Repair and replacement of parts ..............................................................
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00-2-3
(11)
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.
00-3
Safety
00-4
Safety notice
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.
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
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.
Item
Remarks
Safety
Caution
Special technical
precautions or other
precautions for preserving
standards are necessary
when performing the work.
Weight
Tightening
torque
Coat
Oil, water
Drain
00-6
Added pages
20-203
12-203-1
12-203-2
12-204
Foreword
Hoisting instructions
Hoisting instructions
Hoisting
k
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
100%
88%
79%
71%
41%
SAD00479
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
00-7
Foreword
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
1)
2)
2)
3)
3)
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
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pcs.)
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
Adhesives
Can
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9080
1 kg
Can
Tube
LG-6
790-129-9020
200 g
Gasket
sealant
00-10
LG-7
790-129-9070
1g
Tube
Three bond
1211
790-129-9090
100 g
Tube
Three bond
1207B
419-15-18131
100 g
Tube
Foreword
Molybdenum
disulphide
lubricant
Grease
Primer
Adhesive
Caulking
material
Komatsu code
Part No.
Qty
Container
LM-G
09940-00051
60 g
Can
Tube
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
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
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
Category
Coating materials
00-11
Foreword
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
Thread diameter
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
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
Thread diameter
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}
Thread diameter
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
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
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
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
103 {10.5}
22
05
32
157 {16.0}
24
06
36
216 {22.0}
30
(10)
41
216 {22.0}
33
(12)
46
245 {25.0}
36
(14)
55
294 {30.0}
42
Range
Target
03
00-14
16UN
17.5
16
13
16UN
16
20.7
1 14UNS
25.4
3
12UNF
16
30.3
Foreword
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
26
0.32
2.09
3.1
20
65
0.32
5.23
4.6
37
15
84
0.45
13.36
7.0
59
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
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
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
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
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
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
Bulldozer
PC1600SP-1
Hydraulic excavator
DCA400SSK-2
DENYO Generator
DCA-400SSK
MQ Generator
J6D140E-G1-2
Hydraulic excavator
HD325-6, HD405-6
Dump truck
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
mm
2,060
1,670
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
rpm
2,300 2,400
2,300 2,400
rpm
650 700
700 750
g/kWh {g/HPh}
208 {155}
204 {152}
kg
1,506
1,520
Flywheel horsepower
Performance
WA500-3
Governor
Lubricating oil amount (refill capacity)
38 (34)
Coolant amount
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
6D140-2 SERIES
General
Specifications
S6D140-2
6D140-2 SERIES
01-5
(10)
General
Specifications
Engine model
SA6D140-2
D155A-3,
D155AX-3
Applicable machine
Number of cylinder Bore x Stroke
Total piston displacement
PC1600SP-1
(2 engines)
mm
6 140 x 165
l {cc}
15.2 {15,240}
Firing order
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
rpm
2,050 2,150
1,930 2,030
rpm
700 725
725 775
g/kWh {g/HPh}
214 {160}
207 {154}
kg
1,550
1,670
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
42 (37)
38 (34)
Coolant amount
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
Air compressor
Others
01-6
(10)
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}
1,750
1,560
1,790
1,790
1,850
1,850
42 (37)
78 (34)
42 (37)
42 (37)
42 (37)
42 (37)
23
(Engine only)
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
Number of cylinder Bore x Stroke
Total piston displacement
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)
rpm
2,200 2,280
rpm
Performance
Flywheel horsepower
g/kWh {g/HPh}
kg
Governor
42 (37)
Coolant amount
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)
800 850
At rated
800 850
At rated
700 900
At rated
1,450
1,450
1,750
74 (67)
80 (73)
64
66
(Engine only: 27)
24 V, 50 A
24 V, 50 A
24 V, 35 A (OPT)
24 V, 7.5 kW
24 V, 7.5 kW
24 V, 7.5 kW
12 V 200 Ah x 2
12 V 200 Ah x 2
12 V 200 Ah x 2
KOMATSU
KTR110 type
KOMATSU
KTR110 type
KOMATSU
KTR110 type
With aftercooler
With aftercooler
With aftercooler
6D140-2 SERIES
01-9
(10)
General
Specifications
Engine model
SAA6D140-2
PC750-6,
PC800-6
Applicable machine
Number of cylinder Bore x Stroke
Total piston displacement
HD325-6,
HD405-6
mm
6 140 x 165
l {cc}
15.2 {15,240}
Firing order
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)
rpm
1,930 2,030
2,350 2,450
rpm
800 850
700 750
g/kWh {g/HPh}
200 {149}
200 {149}
kg
1,670
1,450
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
38 (32)
41 (37)
Coolant amount
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
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)
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 aftercooler
01-11
(10)
General
01-12
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-13
(10)
General
01-14
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-15
(10)
General
01-16
(10)
6D140-2 SERIES
General
01-18
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-19
(10)
General
01-20
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-21
(10)
General
a. Crankshaft center
b. Flywheel housing rear surface
01-22
(10)
6D140-2 SERIES
General
a. Crankshaft center
b. Flywheel housing rear surface
6D140-2 SERIES
01-23
(10)
General
c. Crankshaft center
d. Cylinder liner center
01-24
(10)
6D140-2 SERIES
General
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
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
19
400
Front cover
38
Oil pan
30
Flywheel assembly
Flywheel housing
Crankshaft assembly
136
Camshaft assembly
19
10
11
Oil pump
5.5
12
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)
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
19
400
Front cover
38
Oil pan
30
60 (D155A-2,3, AX-3, AX-5)
Flywheel assembly
54 (PC1600SP-1)
129 (DCA400SSK-2, J6D140E-G1-2 Generator)
Flywheel housing
52 (PC1600SP-1)
52 (DCA400SSK-2 Generator)
Crankshaft assembly
136
Camshaft assembly
19
10
11
Oil pump
10.7 x 6
5.5
21 (D155A-2,3, AX-3, AX-5)
12
13
Water pump
14
Alternator
15
Starting motor
16
Air compressor
11
17
Aftercooler assembly
43
6D140-2 SERIES
23 (Generator)
17
24 V, 35 A, 25 A
8.0
24 V, 50 A
10
24 V, 7.5 kW
18
24 V, 11 kW
19.5
01-29
(10)
General
Weight table
Unit: kg
No.
Item
Components
SAA6D140-2
Turbocharger
Komatsu KTR110
23
19
400
Front cover
38
Oil pan
30
Flywheel assembly
Flywheel housing
Crankshaft assembly
136
Camshaft assembly
19
10
11
Oil pump
5.5
12
20
13
Water pump
17
14
Alternator
15
Starting motor
16
Air compressor
17
Air-cooled aftercooler
assembly
01-30
(10)
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
SA6D140-2
SAA6D140-2
SDA6D140E-2
6D140-2 SERIES
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
01-37
D155AX-5
01-38
01-42
HD325-6, HD405-6
01-39
01-40
01-41
01-31
(10)
General
01-32
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-33
(10)
General
01-34
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-35
(10)
General
01-36
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-37
(10)
General
01-38
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-39
(10)
General
01-40
(10)
6D140-2 SERIES
General
6D140-2 SERIES
01-41
(10)
General
01-42
(10)
6D140-2 SERIES
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)
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)
1.
2.
3.
4.
Muffler
Air cleaner
Aftercooler assembly
Connector
11-4
(10)
A. Intake
B. Exhaust
6D140-2 SERIES
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)
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
1.
2.
3.
4.
Dust indicator
O-ring
Connector
Tube (cylinder block aftercooler)
6D140-2 SERIES
11-7
(10)
11-8
(10)
A. Intake
B. Exhaust
C. Dust (together with exhaust gas)
6D140-2 SERIES
1.
2.
3.
4.
5.
6.
6D140-2 SERIES
11-9
(10)
11-10
(10)
6D140-2 SERIES
6D140-2 SERIES
11-11
(10)
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
1.
2.
3.
4.
5.
6.
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)
11-14
(10)
6D140-2 SERIES
Air cleaner
a The specifications may be different from the following figure, depending on the type of machine.
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)
a The specifications may be different from the following figure, depending on the type of machine.
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
Machine model
Type
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
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)
a The specifications may be different from the following figure, depending on the type of machine.
1. Aftercooler cover
2. Aftercooler core
3. Intake manifold
11-20
(10)
A.
B.
C.
D.
6D140-2 SERIES
(Air-cooled type)
SAA6D140-2 for PC750-6, PC800-6
a The specifications are subject to change according to modification, etc.
1.
2.
3.
4.
Tank
Side support
Tube
Fin
6D140-2 SERIES
11-21
(10)
(Air-cooled type)
SAA6D140-2 for HD325-6
a The specifications are subject to change according to modification, etc.
1.
2.
3.
4.
Tank
Side support
Tube
Fin
11-22
(10)
6D140-2 SERIES
Engine body
Engine body
Cylinder head
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
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
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
1.
2.
3.
4.
5.
6.
7.
11-28
(10)
8.
9.
10.
11.
12.
13.
14.
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
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
Crankshaft pulley
Pin (Crankshaft pulley vibration damper)
Vibration damper
Pin (Crankshaft crankshaft pulley)
11-30
(10)
6D140-2 SERIES
Engine body
Timing gear
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
11-32
(10)
8.
9.
10.
11.
A, B, C: Match marks
6D140-2 SERIES
6D140-2 SERIES
Engine body
11-33
(10)
Engine body
Valve system
a The specifications are subject to change according to modification, etc.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Thrust plate
Camshaft gear (No. of teeth: 48)
Camshaft
Cam roller
Cam roller pin
Cam follower shaft
Cam follower
Push rod
Rocker arm shaft
Rocker arm
Locknut
11-34
(10)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
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
1.
2.
3.
4.
11-36
(10)
6D140-2 SERIES
Lubrication system
Lubrication system
Lubrication system chart
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Oil pan
Oil strainer
Oil pump
Main relief valve
Oil cooler
Thermostat
Regulator valve
Valve adapter
Oil filter
Safety valve
Crankshaft
11-38
(10)
12.
13.
14.
15.
16.
17.
18.
19.
20.
W: Cooling water
6D140-2 SERIES
Lubrication system
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Oil pan
Oil strainer
Oil pump
Main relief valve
Oil cooler
Thermostat
Regulator valve
Valve adapter
Oil filter (full-flow filter x 2)
Safety valve
Crankshaft
Piston cooling nozzle
6D140-2 SERIES
13.
14.
15.
16.
17.
18.
19.
20.
21.
Piston
Camshaft
Cam follower
Rocker arm
Intake and exhaust valve
Timing gears
Turbocharger
Fuel injection pump
Bypass filter (Installed to depending on the model)
W: Cooling water
11-39
(10)
Lubrication system
Oil pump
a The specifications are subject to change according to modification, etc.
1.
2.
3.
4.
5.
6.
7.
Pump cover
Drive gear
Pump body
Pump drive gear (No. of teeth: 22)
Valve spring
Main relief valve
Driven gear
Oil pump
Type:
Gear pump
Pump speed: Engine speed x 1.64
Main relief valve
Set pressure:
0.78 0.05 MPa {8.0 0.5 kg/cm2}
11-40
(10)
6D140-2 SERIES
Lubrication system
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.
6D140-2 SERIES
11-41
(10)
Lubrication system
Oil filter
S6D140-2
SA6D140-2
SAA6D140-2
a The specifications may be different from the following figure, depending on the type of machine.
1. Filter head
2. Safety valve
3. Cartridge
A. Oil inlet
B. Oil outlet
Oil filter
Filtration area: 0.84 m2
(Rated flow 160 l/min)
For construction machinery, generator
(Rated flow 240 l/min)
For marine engine
Safety valve
Set pressure: 0.2 0.02 MPa {2.0 0.2 kg/cm2}
11-42
(10)
6D140-2 SERIES
Lubrication system
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
1.
2.
3.
4.
5.
6.
Filter head
Safety valve
Filter connector
Cover
Alarm assembly
Cartridge
A. Oil inlet
B. Oil outlet
Oil filter
Filtration area:1.8 m2 (0.9 m2 x 2)
Rated flow: 180 l/min.
Safety valve
Set pressure: 0.2 0.02 MPa {2.0 0.2 kg/cm2}
11-44
(10)
6D140-2 SERIES
Lubrication system
1.
2.
3.
4.
5.
6.
7.
Filter head
Safety valve
Filter connector
Cover
Alarm assembly
Cartridge (Bypass filter)
Cartridge (Full-flow filter)
A. Oil inlet
B. Oil outlet
Oil filter
Filtration area:1.8 m2 (0.9 m2 x 2)
Rated flow: 180 l/min.
Safety valve
Set pressure: 0.2 0.02 MPa {2.0 0.2 kg/cm2}
Bypass filter
Filtration area:1.4 m2
Rated flow: 7.5 l/min.
6D140-2 SERIES
11-45
(10)
Lubrication system
Oil cooler
a The specifications are subject to change according to modification, etc.
1. Cooler cover
2. Cooler element
6D140-2
: 10 cores
S6D140-2
: 10 cores
SA6D140-2 : 12 cores
SAA6D140-2 : 12 cores
SDA6D140E-2: 12 cores
3. Thermostat
4. Spring
5. Thermostat cover
Thermostat function
Valve cracking temperature:
Full opening temperature:
Full opening lift:
85 1.5C
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
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
8.
Fuel tank
Gauze filter
Priming pump
Feed pump
Fuel filter
Fuel injection pump
Fuel injection nozzle
Over-flow valve
11-48
(10)
6D140-2 SERIES
Fuel system
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
8.
Fuel tank
Gauze filter
Priming pump
Feed pump
Fuel filter
Fuel injection pump
Fuel injection nozzle
Over-flow valve
6D140-2 SERIES
11-49
(10)
Fuel system
1.
2.
3.
4.
5.
6.
7.
8.
11-50
(10)
9.
10.
11.
12.
13.
14.
15.
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
11-51
(10)
Fuel system
1.
2.
3.
4.
5.
6.
7.
11-52
(10)
8.
9.
10.
11.
12.
13.
14.
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
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.
6D140-2 SERIES
6D140-2 SERIES
Fuel system
Governor
Type: Made by BOSCH automotive system,
Bosch RFD Centrifugal, max. min.
speed control type
11-55
(10)
Fuel system
1.
2.
3.
4.
5.
6.
7.
8.
11-56
(10)
9.
10.
11.
12.
13.
14.
15.
6D140-2 SERIES
6D140-2 SERIES
Fuel system
Governor
Type: Made by BOSCH automotive system,
Bosch RFD Centrifugal, max. min.
speed control type
11-57
(10)
Fuel system
Feed pump
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Cover
Priming pump
Spring
Check valve (intake)
Eyebolt
Plug
Piston spring
Piston
Push rod
Tappet
Check valve (exhaust)
Functions
The feed pump sucks fuel from the fuel tank and
supplies (discharge) it through the fuel filter to
the injection pump.
This feed pump also has the function to maintain
the discharge pressure (rate) at constant 0.1
0.2 MPa {1 2 kg/cm2} to set the fuel injection
rate of the injection pump (quantity of fuel
injected by each stroke) constant.
A. Fuel inlet
B. Fuel outlet
11-58
(10)
6D140-2 SERIES
Fuel system
1.
2.
3.
4.
5.
6.
7.
8.
9.
6D140-2 SERIES
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
a The specifications may be different from the following figure, depending on the type of machine.
1. Filter head
2. Air bleed plug
3. Cartridge
Fuel filter
Filtration area: 1.0 m2
a. Fuel inlet
b. Fuel outlet
11-60
(10)
6D140-2 SERIES
Fuel system
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
Stroke:
Weight:
35 +1.0
mm
0.4
1.2 kg
11-61
(10)
Fuel system
1.
2.
3.
4.
5.
6.
7.
8.
11-62
(10)
6D140-2 SERIES
Fuel system
1.
2.
3.
4.
5.
6D140-2 SERIES
11-63
(10)
Fuel system
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
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
11-66
(10)
6D140-2 SERIES
Cooling system
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)
6D140-2 SERIES
11-67
(10)
Cooling system
1.
2.
3.
4.
5.
6.
7.
8.
9.
11-68
(10)
10.
11.
12.
13.
14.
Heat exchanger
Marine gear oil cooler
Spare sea water pump
Sea water pump
Kingston cock
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)
6D140-2 SERIES
Cooling system
SA6D140-2
1. Oil cooler
2. Thermostat housing
3. Water pump
6D140-2 SERIES
11-71
(10)
Cooling system
SAA6D140-2 (HD325-6)
a The specifications are subject to change according to modification, etc.
1. Oil cooler
2. Thermostat housing
3. Water pump
11-72
(10)
6D140-2 SERIES
Cooling system
1. Tube
2. Tube
3. Water pump
6D140-2 SERIES
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.
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
2. Thermostat housing
3. Thermostat
A. To radiator To heat exchanger
(For marine engines)
B. To water pump
To Brake cooler (HD325)
To oil cooler on machine body
(D155A-3, D155AX-3)
11-76
(10)
Thermostat
Valve opening temperature:
76.5 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
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
Head
Cartridge
Element
Inhibitor (Solid corrosion preventive agent)
Spring
Stop valve
a. Water inlet
b. Water outlet
6D140-2 SERIES
Corrosion resistor
Filtration area:
6D140-2:
0.13 m2
SA6D140, S6D140-2:
0.13 m2
SAA6D140, SA6D140-2: 0.373 m2
Quantity of corrosion preventive agent:
6D140-2:
400 g
SA6D140, S6D140-2:
400 g
SAA6D140, SA6D140-2: 1,000 g
11-77
(10)
Cooling system
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
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
1.
2.
3.
4.
Fan pulley
Tension pulley
Crank pulley (Outside diameter: 200 mm)
Fan belt
11-80
(10)
Fan pulley
Outside
diameter
(mm)
Applicable machine
295
316
6D140-2 SERIES
Cooling system
Tension pulley
SA6D140-2 (D155A-3, D155AX-3, D155AX-5)
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Bracket
Spacer
Ball bearing
Tension pulley (Outside diameter: 118 mm)
Oil seal
Inner race
Needle bearing
Coil spring
Tension shaft
6D140-2 SERIES
11-81
(10)
Cooling system
1.
2.
3.
4.
5.
6.
Fan pulley
Fan belt
Crank pulley
Tension pulley
Tension shaft
Tension spring
11-82
(10)
Fan pulley
Crank
pulley
Tension
pulley
280
164
118
6D140-2 SERIES
Cooling system
Tension pulley
SAA6D140-2 (PC750-6, PC800-6)
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
8.
Tension shaft
Roller bearing
Tension bracket
Oil seal
Tension pulley (Outside diameter: 118 mm)
Ball bearing
Spacer
Stopper
6D140-2 SERIES
11-83
(10)
Cooling system
1.
2.
3.
4.
5.
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
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
Bracket
Spacer
Ball bearing
Tension pulley (Outside diameter: 118 mm)
Bearing
Coil spring
Tension shaft
6D140-2 SERIES
11-85
(10)
Cooling system
1.
2.
3.
4.
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
1. Air compressor
2. PTO case
3. Compressor drive gear (No. of teeth: 24)
a.
b.
c.
d.
e.
f.
g.
11-90
(10)
6D140-2 SERIES
Accessory
Exhaust brake
Slide valve type
a The specifications are subject to change according to modification, etc.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Valve housing
Gate valve
Guide bushing
Cylinder
Spring
Spring
Piston
Retainer
Release valve
Packing
Packing
Exhaust pressure adjustment bolt
Breather
6D140-2 SERIES
Outline
An exhaust brake is installed between the turbocharger and muffler, and works due to the air pressure from the solenoid valve, reducing engine speed
by throttling the exhaust passage of the muffler from
the turbocharger. The exhaust brake consists of a
valve mechanism and an air cylinder which controls
the valve.
11-91
(10)
Accessory
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
6D140-2 SERIES
Accessory
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Connector
Case
Core
Coil assembly
Spring
Plunger
Spring
Valve
Rod
Body
6D140-2 SERIES
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.
11-94
(10)
6D140-2 SERIES
Electrical system
Electrical system
Alternator
Mounting
a The specifications may be different from the following figure, depending on the type of machine.
1.
2.
3.
4.
5.
6.
7.
Alternator
Adjust rod
Nut (2 pieces)
Plate
Cover
V-belt (2 pieces)
Spacer
6D140-2 SERIES
11-95
(10)
Electrical system
1.
2.
3.
4.
5.
Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E
Engine model
Applicable machine
model
Type
Specification
Pulley O.D.
(mm)
Weight
(kg)
Pulley type
S6D140-2
WA500-3
24 V, 35 A
85
9.5
SA6D140-2
24 V, 35 A
85
9.5
11-96
(10)
6D140-2 SERIES
Electrical system
1.
2.
3.
4.
Alternator
Alternator pulley
Terminal R
Terminal E
Engine model
Applicable machine
model
Specification
Pulley O.D.
(mm)
Weight
(kg)
24 V, 35 A
85
9.5
24 V, 35 A
85
9.5
24 V, 25 A
85
8.5
24 V, 30 A
85
9.5
S6D140-2
SA6D140-2
5. Terminals B
6. Internal electric circuit diagram
6A. Field coil
6B. Regulator
SAA6D140-2
6D140-2 SERIES
Type
11-97
(10)
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)
Applicable machine
model
Type
Specification
Pulley O.D.
(mm)
Weight
(kg)
Pulley type
GD825A-2
24 V, 50 A
85
12
II
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
Type
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
11-100
(10)
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
a The shape may differ according to the machine model.
1.
2.
3.
4.
5.
6.
7.
Pinion gear
Starting motor assembly
Magnetic switch
Safety relay
Terminal B
Terminal C
External wiring diagram (2-pin connector type)
7A. Safety relay portion
7B. Starting motor portion
11-102
(10)
6D140-2 SERIES
Engine model
Applicable machine
model
Electrical system
Type
Specification
Pulley O.D.
(mm)
Weight
(kg)
Connector
type
S6D140-2
12
18
SA6D140-2
12
18
12
18
SAA6D140-2
PC750-6, PC800-6
6D140-2 SERIES
11-103
(10)
Electrical system
For 11 kW
a The shape may differ according to the machine model.
1.
2.
3.
4.
5.
6.
7.
8.
11-104
(10)
6D140-2 SERIES
Engine model
Number of
pinion
teeth
Weight
(kg)
Connector
type
11
20
11
20
24 V, 11 kW
11
20
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
11-105
(10)
Electrical system
For 11 kW
a The shape may differ according to the machine model.
1.
2.
3.
4.
5.
6.
Pinion gear
Starting motor assembly
Magnetic switch
Terminal B
Terminal C
Safety relay
Engine
Machine model
11-106
(10)
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
1. Heater body
2. Heater coil
SA6D140-2
SDA6D140E-2 (D275A-5, 50C spec.)
1. Heater body
2. Heater coil
3. Terminal
6D140-2 SERIES
11-107
(10)
Electrical system
1. Front PTO
2. O-ring
3. Front PTO drive gear assembly
11-108
(10)
6D140-2 SERIES
Electrical system
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
1.
2.
3.
4.
5.
6.
11-110
(10)
7.
8.
9.
10.
11.
Gasket
O-ring
Bearing (2 pieces)
Housing
Shaft
6D140-2 SERIES
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
6D140-2 SERIES
12-1
(10)
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.
6D140-2 SERIES
12-3
(10)
Engine body
Measuring compression
pressure
Measurement procedure
k
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}
6D140-2 SERIES
12-5
(10)
Fuel system
+0.5
0.34 {3.5}
12-6
(10)
+5
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
6D140-2 SERIES
1.
2.
3.
4.
5.
Lever stopper
Fuel injection pump stop lever
Bracket
Cable
Joint
12-7
(10)
Fuel system
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
Unit: mm
Engine model
Applicable
machine
Dimension A
SAA6D140-2
PC750-6
PC800-6
44 3
6D140-2 SERIES
12-9
(10)
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
12-19
6211-72-1170
D155AX-5
12-24
6211-72-1180
12-25
6212-72-1430
PC1600SP-1
12-17
6212-72-1830
12-21
6212-72-1840
12-22
6212-72-1860
12-13
6212-72-1860
12-20
S6D140-2
SA6D140-2
6212-72-1250
6212-72-1421
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
a The table gives the standard values for machines without fan.
a The loads for the dynamometer are at an arm's length of 716 mm.
Engine
model
Applicable
machine
Running time
min.
10
D155A-3
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.
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
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
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
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
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
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.
SA6D140-2
D155C-1
(50C spec.)
(10)
kW
{HP}
0
{0}
35
{48}
106
{146}
212
{292}
318
{438}
Running time
min.
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.
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.
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
a The table gives the standard values for machines without fan.
a The loads for the dynamometer are at an arm's length of 716 mm.
Engine
model
Applicable
machine
1,000
1,200
1,500
2,000
Running time
min.
Engine speed
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
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
a The table gives the standard values for machines without fan.
a The loads for the dynamometer are at an arm's length of 716 mm.
Engine
model
SDA6D140E-2
12-30
(10)
Applicable
machine
D275A-5
(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
Applicable
machine
GD825A-2
S6D140-2
WA500-3
Specified value
Engine speed
(rpm)
Dynamometer load
(N {kg})
Flywheel
horsepower
2,095 2,105
1,360 1,440
{139 147}
Maximum
torque
1,300 1,500
1,730 1,840
{177 187}
2,300 2,400
600 650
Test item
High idling
speed
Low idling
speed
Flywheel
horsepower
Maximum
torque
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
Low idling
speed
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
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
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. 15.7
12-33
(10)
Performance test
a The table gives the standard values using the JIS compensator factor.
a The values in the table are the standard values for machines with the muffler installed, air cleaner installed,
alternator under no load, and air compressor open (if installed).
a The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable
machine
D155A-3
D155AX-3
PC1600SP-1
Test item
D355C-3
High idling
speed
2,050 2,150
Low idling
speed
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
725 775
800 850
1,995 2,005
1,730 1,820
{176 186}
Maximum
torque
1,300 1,500
2,230 2,350
{227 240}
High idling
speed
2,200 2,280
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)
1,895 1,905
Low idling
speed
12-34
Dynamometer load
(N {kg})
DCA400SSK-2
Maximum
(DENYO
torque
generator)
High idling
speed
Low idling
speed
Flywheel
horsepower
D155A-2
Flywheel
horsepower
Maximum
torque
Flywheel
horsepower
SA6D140-2
Specified value
1,995 2,005
1,300 1,500
1,790 1,900
{183 194}
2,180 2,300
{222 235}
2,200 2,280
700 750
800 850
6D140-2 SERIES
Performance test
Torque
(Nm{kgm})
238.2 252.9
{319.1 338.8}
Fuel
consumption
(sec/200cc)
Lubrication
Coolant Lubrication oil
Exhaust
oil pressure
temperature temperature
temperature
(C)
(C)
(C)
(kPa {kg/cm2})
70 90
90 110
340 490
{3.5 5.0}
Max. 650
1,433 1,521
{146.1 155.1}
70 90
90 110
Max. 650
70 90
90 110
70 90
Min. 80
Min. 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
70 90
90 110
70 90
90 110
321.3 341.1
{430.4 457.0}
Max. 650
Max. 650
70 90
90 110
70 90
Min. 80
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
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
70 90
90 110
340 490
{3.5 5.0}
Max. 650
70 90
90 110
70 90
90 110
6D140-2 SERIES
12-35
(10)
Performance test
a The table gives the standard values using the JIS compensator factor.
a The values in the table are the standard values for machines with the muffler installed, air cleaner installed,
alternator under no load, and air compressor open (if installed).
a The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable
machine
Test item
Flywheel
horsepower
J6D140E-G1-2
(TAIYO DENKI
High idling
generator)
speed
Low idling
speed
D155AX-5
D155C-1
(30C spec.)
SA6D140-2
D155C-1
(50C spec.)
D355C-3
(30C spec.)
D355C-3
(50C spec.)
12-36
(10)
Specified value
Dynamometer load
(N {kg})
2,430 2,580
{248 263}
2,290 2,420
{233 247}
700 900
Flywheel
horsepower
Maximum
torque
High idling
speed
Low idling
speed
1,895 1,905
1,150 1,350
1,730 1,820
{176 186}
2,250 2,380
{229 243}
2,050 2,150
675 725
Flywheel
horsepower
1,995 2,005
1,650 1,750
{168.5 178.5}
Maximum
torque
1,300 1,500
2,020 2,150
{206 219}
2,190 2,290
700 750
High idling
speed
Low idling
speed
Flywheel
horsepower
Maximum
torque
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
Low idling
speed
700 750
Flywheel
horsepower
Maximum
torque
High idling
speed
Low idling
speed
1,995 2,005
1,300 1,500
1,790 1,900
{183 194}
2,180 2,300
{222 235}
2,200 2,280
700 750
Flywheel
horsepower
1,995 2,005
1,790 1,900
{183 194}
Maximum
torque
High idling
speed
Low idling
speed
1,300 1,500
2,180 2,300
{222 235}
2,200 2,280
700 750
6D140-2 SERIES
Performance test
Flywheel
horsepower
(kW{HP})
Torque
(Nm{kgm})
Fuel
consumption
(sec/200cc)
70 90
90 110
70 90
90 110
70 90
90 110
70 90
80 110
70 90
90 110
343 490
{3.5 5.0}
Max. 650
70 90
90 110
Max. 650
70 90
90 110
70 90
80 110
70 90
90 110
340 490
{3.5 5.0}
Max. 650
70 90
90 110
Max. 650
70 90
90 110
70 90
80 110
70 90
90 110
340 490
{3.5 5.0}
Max. 650
70 90
90 110
Max. 650
70 90
90 110
70 90
80 110
70 90
90 110
340 490
{3.5 5.0}
Max. 650
70 90
90 110
Max. 680
70 90
90 110
70 90
80 110
70 90
90 110
340 490
{3.5 5.0}
Max. 650
70 90
90 110
Max. 680
70 90
90 110
70 90
80 110
6D140-2 SERIES
290 490
{3.0 5.0}
290 490
{3.0 5.0}
Max. 650
Max. 650
12-37
(10)
Performance test
a The table gives the standard values using the JIS compensator factor.
a The values in the table are the standard values for machines with the muffler installed, air cleaner installed,
alternator under no load, and air compressor open (if installed).
a The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable
machine
HD325-6
HD405-6
SAA6D140-2
HD325-6
(High altitude
spec.)
PC750-6
PC800-6
PC1800-6
D275A-5
(50C spec.)
SDA6D140E-2
Test item
Specified value
Dynamometer load
(N {kg})
Flywheel
horsepower
Maximum
torque
High idling
speed
2,300 2,400
Low idling
speed
675 775
Flywheel
horsepower
Maximum
torque
High idling
speed
Low idling
speed
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
2,350 2,450
675 775
675 775
Flywheel
horsepower
1,795 1,805
2,378 2,525
{242.5 257.5}
Maximum
torque
1,250 1,450
1,508 1,601
{153.8 163.3}
High idling
speed
Low idling
speed
Flywheel
horsepower
Maximum
torque
1,995 2,005
2,177 2,305
{222 235}
1,300 1,500
High idling
speed
2,150 2,250
Low idling
speed
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
Torque
(Nm{kgm})
359.9 381.7
{482.2 511.7}
289.6 308.0
{388.0 412.6}
Fuel
consumption
(sec/200cc)
Lubrication
Coolant Lubrication oil
Exhaust
oil pressure
temperature temperature
temperature
(C)
(C)
(C)
(kPa {kg/cm2})
Min. 11.2
70 95
90 110
340 490
{3.5 5.0}
Max. 650
2,079 2,208
{212.0 225.2}
70 95
90 110
70 80
90 110
70 80
Min. 80
Min. 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
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
325 345
{436 463}
Min. 11.8
70 90
90 110
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
S-2
S-3
S-4
S-5
S-6
S-7
S-8
S-9
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
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.
6D140-2 SERIES
12-43
(10)
Troubleshooting
Causes
[A]
Questions
(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
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
*2
Degree of use
12-45
(10)
Troubleshooting
12-46
(10)
6D140-2 SERIES
Troubleshooting
6D140-2 SERIES
12-47
(10)
Troubleshooting
S-1
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
12-48
(10)
6D140-2 SERIES
Troubleshooting
S-2
6D140-2 SERIES
12-49
(10)
Troubleshooting
S-2
12-50
(10)
6D140-2 SERIES
Troubleshooting
S-2
6D140-2 SERIES
12-51
(10)
Troubleshooting
S-3
12-52
(10)
6D140-2 SERIES
Troubleshooting
S-4
6D140-2 SERIES
12-53
(10)
Troubleshooting
S-5
12-54
(10)
6D140-2 SERIES
Troubleshooting
S-6
6D140-2 SERIES
12-55
(10)
Troubleshooting
S-7
12-56
(10)
6D140-2 SERIES
Troubleshooting
S-8
6D140-2 SERIES
12-57
(10)
Troubleshooting
S-9
12-58
(10)
6D140-2 SERIES
Troubleshooting
S-10
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
6D140-2 SERIES
12-61
(10)
Troubleshooting
S-13
12-62
(10)
6D140-2 SERIES
Troubleshooting
S-14
6D140-2 SERIES
12-63
(10)
Troubleshooting
S-15
12-64
(10)
6D140-2 SERIES
Troubleshooting
S-16
6D140-2 SERIES
12-65
(10)
Troubleshooting
Engine speed
Battery S.G.
Freezing temperature of
cooling water
Water temperature,
oil temperature,
air intake temperature,
exhaust temperature
Part No.
799-203-8000
Remarks
Digital reading: L: 60 2,000 rpm
H: 60 20,000 rpm
1.100 1.300
795-500-1001
799-101-6000
Digital temperature
gauge
790-500-1300
50 1,200C
0 1 MPa {0 10 kg/cm2}
Fuel pressure
0 2 MPa {0 20 kg/cm2}
Intake pressure,
exhaust pressure
Blow-by pressure
Intake resistance
799-203-2002
795-502-1205
10
Engine pressure
measuring kit
Compression gauge
Compression pressure
795-502-1510 Adapter
11
Blow-by pressure
799-201-1504
Blow-by checker
12
Valve clearance
795-125-1210
Feeler gauge
0.43, 0.80 mm
13
799-201-9000
14
799-201-6000
15
Nozzle tester
16
Commercially
available
17
Coolant quality
799-202-7001
18
19
20
Electrical circuit
Commercially
available
Tester
21
799-606-9100
Governor checker
6D140-2 SERIES
12-67
(10)
Troubleshooting
S6D140-2
Performance
Category
Item
Engine speed
Measurement conditions
High idling speed
GD825A-2
Unit
rpm
Engine
proper
Lubrication system
Standard
value
Permissible
value
rpm
650 700
650 700
700 750
700 750
rpm
Min. 110
Min. 110
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
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.)
700
700
650
700
Max. 6.0
8.0
Max. 6.0
8.0
Max. 1.5
2.5
Max. 1.0
2.5
Max. 1.0
2.0
Max. 1.0
2.0
mm
0.43
0.43
mm
0.80
0.80
MPa
{kg/cm2}
Min. 3.82
{Min. 39}
2.65
{27}
Min. 3.82
{Min. 39}
2.65
{27}
Blow-by pressure
At rated flywheel horsepower
(SAE30 or SAE 15W-40) (Water temp: Min. 70C)
kPa
{mmH2O}
Max. 0.98
{Max. 100}
1.96
{200}
Max. 1.47
{Max. 150}
2.94
{300}
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
Bosch
index
Cooling
Standard
value
WA500-3
Compression pressure
Oil temperature: 40 60C
(SAE30 or SAE 15W-40) (Engine speed: 200 250 rpm)
Oil pressure
(Oil temperature:
Min. 80C)
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
15 17
15 17
15 17
15 17
Opening pressure
(Differential pressure)
MPa
{kg/cm2}
Fan speed
rpm
mm
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
Measurement conditions
D155A-2
Unit
Engine
proper
Permissible
value
rpm
550 650
550 650
700 725
700 725
rpm
Min. 110
Min. 110
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
kPa
{mmHg}
Max. 85.4
{Min. 640}
68.0
{510}
Exhaust pressure
(Turbine inlet press.)
kPa
{mmHg}
Min. 74.7
{Min. 560}
60.0
{450}
Exhaust temperature
(Turbine inlet temp.)
Max. 650
700
Max. 680
700
Max.6.0
8.0
Max. 6.0
8.0
Max. 1.0
2.5
Max. 1.0
2.5
Max. 1.0
2.0
Max. 1.0
2.0
mm
0.43
0.43
mm
0.80
0.80
Compression pressure
Oil temperature: 40 60C
(SAE30 or SAE 15W-40) (Engine speed: 200 250 rpm)
MPa
{kg/cm2}
Min. 3.80
{Min. 39}
2.65
{27}
Min. 3.82
{Min. 39}
2.65
{27}
Blow-by pressure
At rated flywheel horsepower
(SAE30 or SAE 15W-40) (Water temp: Min. 70C)
kPa
{mmH2O}
Max. 0.98
{Max. 100}
1.96
{200}
Max. 0.98
{Max. 100}
1.96
{200}
kPa
{kg/cm2}
340 490
{3.5 5.0}
205
{2.1}
340 490
{3.5 5.0}
206
{2.1}
kPa
{kg/cm2}
290 440
{3.0 4.5}
176
{1.8}
290 441
{3.0 4.5}
177
{1.8}
kPa
{kg/cm2}
Min. 118
{Min. 1.2}
78
{0.8}
Min. 118
{Min. 1.2}
69
{0.7}
kPa
{kg/cm2}
Min. 98
{Min. 1.0}
68
{0.7}
Min. 98
{Min. 1.0}
69
{0.7}
Quick acceleration
(Low idle o high idle)
Exhaust gas color
Standard
value
rpm
Intake valve
Valve clearance
(When engine is hot or cold) Exhaust valve
Fuel
Permissible
value
Bosch
index
Cooling
Standard
value
D155A-3, D155AX-3
Oil pressure
(Oil temperature:
Min. 80C)
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
(Differential pressure)
kPa
{kg/cm2}
Fan speed
rpm
mm
Auto-tensioner
Auto-tensioner Auto-tensioner
a This STANDARD VALUE TABLE does not give the standard value for adjusting the engine output.
Do not use the values in this table to change the setting for fuel injection pump.
*: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)
12-70
(10)
6D140-2 SERIES
Troubleshooting
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
59 78
{0.6 0.8}
8 12
8 12
12-71
(10)
Troubleshooting
Engine model
SA6D140-2
DCA-400SSK
(MQ generator)
Performance
Category
Item
Engine speed
Measurement conditions
Unit
Engine
proper
Permissible
value
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}
700 900
700 900
Min. 110
Intake resistance
At all speed
Boost pressure
kPa
{mmHg}
Max. 160
{Min. 1,200}
128
{960}
Exhaust pressure
(Turbine inlet press.)
kPa
{mmHg}
Min. 120
{Min. 900}
96
{720}
Exhaust temperature
(Turbine inlet temp.)
Max. 650
700
Max. 650
700
Max. 1.5
2.5
Max. 1.5
2.5
Max. 1.0
2.0
Max. 1.0
2.0
mm
0.43
0.43
mm
0.80
0.80
Min. 3.80
{Min. 39}
2.7
{27}
Min. 3.82
{Min. 39}
2.7
{27}
kPa
{mmH2O}
Max. 1.96
{Max. 200}
3.92
{400}
Max. 1.96
{Max. 200}
3.92
{400}
kPa
{kg/cm2}
294 490
{3.0 5.0}
210
{2.1}
294 490
{3.0 5.0}
210
{2.1}
kPa
{kg/cm2}
245 440
{2.5 4.5}
176
{1.8}
245 440
{2.5 4.5}
176
{1.8}
kPa
{kg/cm2}
Min. 118
{Min. 1.2}
78
{0.8}
Min. 118
{Min. 1.2}
78
{0.8}
kPa
{kg/cm2}
Min. 98
{Min. 1.0}
68
{0.7}
Min. 98
{Min. 1.0}
68
{0.7}
Quick acceleration
(Low idle o high idle)
Exhaust gas color
Bosch
index
Compression pressure
Oil temperature: 40 60C
MPa
(SAE30 or SAE 15W-40) (Engine speed: 200 250 rpm) {kg/cm2}
Blow-by pressure
At rated flywheel horsepower
(SAE30 or SAE 15W-40) (Water temp: Min. 70C)
At rated flywheel horsepower
SAE30 or SAE15W-40 oil
Lubrication system
Standard
value
rpm
Intake valve
Valve clearance
(When engine is hot or cold) Exhaust valve
Fuel
Permissible
value
Cooling
Standard
value
J6D140E-G1-2
(TAIYO DENKI generator)
Oil pressure
(Oil temperature:
Min. 80C)
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
(Differential pressure)
kPa
{kg/cm2}
Fan speed
rpm
1,330 1,410
(60 Hz)
mm
8 12
8 12
8 12
a This STANDARD VALUE TABLE does not give the standard value for adjusting the engine output.
Do not use the values in this table to change the setting for fuel injection pump.
*: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)
12-72
(10)
6D140-2 SERIES
Troubleshooting
SA6D140-2
D155C-1 (30C 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
Measurement conditions
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
(Turbine inlet press.)
At rated output
kPa
{mmHg}
Exhaust temperature
(Turbine inlet temp.)
Bosch
index
Engine
body
Max. 1.0
2.0
Max. 1.0
2.0
Max. 1.0
2.0
Max. 1.0
2.0
mm
0.43
0.43
mm
0.80
0.80
Compression pressure
Oil temperature: 40 60C
(SAE30 or SAE 15W-40) (Engine speed: 200 250 rpm)
MPa
{kg/cm2}
Min. 3.82
{Min. 39}
2.65
{27}
Min. 3.82
{Min. 39}
2.65
{27}
Blow-by pressure
At rated output
(SAE30 or SAE 15W-40) (Water temp: 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
SAE30 or SAE15W-40 oil
Lubrication system
Permissible
value
Intake valve
Valve clearance
(When engine is hot or cold) Exhaust valve
Fuel
system
Standard
value
rpm
High idling
Cooling
system
Permissible
value
Intake resistance
Standard
value
HD325-6, HD405-6
Oil pressure
(Oil temperature:
80C min.)
Oil temperature
80 110
120
80 110
120
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
(Differential pressure)
kPa
{kg/cm2}
Fan speed
rpm
mm
(Autotensioner)
a This STANDARD VALUE TABLE does not give the standard value for adjusting the engine output.
Do not use the values in this table to change the setting for fuel injection pump.
*: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)
12-74
(10)
6D140-2 SERIES
Troubleshooting
SAA6D140-2
SDA6D140E-2
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
:
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?
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
CLlE00133
ASSEMBLY
AND
DISASSEMBLY
GENERAL
3.
Turbocharger
drain tube
Remove turbocharger
drain tube (I).
4.
Engine assembly:
Approx.
DISASSEMBLY
1500 kg
CEE00137
5.
COEOOl38
6.
Bracket
Remove mounting
(I) and (2).
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.
(3).
Remove mounting
bolts (41, then
tension pulley assembly (5).
remove
CEE00143
9.
(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
13. Turbocharger
1) Disconnect
turbocharger
tube.
2) Remove mounting
bolts
turbocharger
(2).
lubrication
(I),
then
inlet
remove
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
CEE0015
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).
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
CEE00154
ASSEMBLY
AND
DISASSEMBLY
GENERAL
DISASSEMBLY
Too I
Slide hammer
DWE00211
(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
CDE00158
ASSEMBLY
AND
DISASSEMBLY
GENERAL
DISASSEMBLY
CEE00159
3)
_..~
,_------..,
,_._
.5
10161
ASSEMBLY
AND
GENERAL
DISASSEMBLY
DISASSEMBLY
(2).
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
valves
(6).
I
I
I
CEE00166
13-10
0
CEE00167
ASSEMBLY
AND
GENERAL
DISASSEMBLY
DISASSEMBLY
(3).
35. Thermostat
housing
1) Remove ring (I), then remove tube (2) up.
2) Remove mounting
bolts (3), then remove
thermostat
housing (4).
CEE00170
-1
(I).
CEE00171
ASSEMBLY
AND
DISASSEMBLY
GENERAL
DISASSEMBLY
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
piston
CEE00180
CEEOOlI31
ASSEMBLY
AND DISASSEMBLY
4)
5)
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
CEE00185
13-14
0
GENERAL DISASSEMBLY
46. Crankshaft
If necessary, measure the end play of the
crankshaft
with
dial gauge
@ before
removing the crankshaft.
2
;;
0
3)
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
DISASSEMBLY
(5).
CEEOOl90
6)
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
13-17
0
ASSEMBLY
AND DISASSEMBLY
GENERAL ASSEMBLY
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
the
of
(conventional
in permanent
Elongation
deformation.
method)
of bolt
I)
2)
3)
4)
Flywheel
mounting
bolts
bolts
value
plus or minus
tolerance.
Special tools
Part
No.
790-901-1260
Part Name
Adapter
atv
1
790-501-2001
795-102-2102
Spring pusher
795-100-I 191
795-230-5472
Liner driver
Part Name
Part No.
795-521-1110
Push tool
01050-31640
Bolt
795-931-1210
Sleeve jig
795-931-1220
Sleeve jig
01050-31645
Bolt
01050-31625
Bolt
Qty
13i*
ASSEMBLY
Drawing
AND DISASSEMBLY
GENERAL
ASSEMBLY
of special tool
Push tool K
Note)
Komatsu
has no responsibility
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.
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)
4)
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
Width
of gasket sealant
(LG-6):
m2-3mm
(coat
the
corner
Matins
portion
of
deck)
the
DWEOOIBB
l
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)
4)
5)
Assemble
chamfered
the
crevice
seal
side facing down.
block ORF-l.
with
the
CEE00201
3)
ASSEMBLY
K
h
i
Chamfered
side
DEE00089
GENERAL ASSEMBLY
4)
5)
6)
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
*
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)
4)
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)
GENERAL ASSEMBLY
7)
8)
9)
DWE00275
ASSEMBLY
AND
DISASSEMBLY
GENERAL
3.
*
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
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.
*
Check that there is no dirt or dust stuck
to the rear face of the bearing when
installing.
Set crankshaft
to bottom
dead center in
cylinder to be assembled,
then coat inside
surface of connecting rod bearing and inside
surface of cylinder with engine oil (SAE#30).
Cast
CEE00164
number
(align
13-26
on camshai t side)
6)
GENERAL ASSEMBLY
CEE00212
7)
CEE00213
8)
9)
P\
a
DWE00275
GENERAL ASSEMBLY
I
12) Measure side clearance of connecting
with dial gauge 0.
*
Side clearance: 0.100 - 0.274 mm
DWE00216
rod
CEE00181
4.
13-28
0
ASSEMBLY
5.
AND DISASSEMBLY
GENERAL ASSEMBLY
3)
4)
I
*
head
Put mark on side
of
CEE00216
idler
gear
and
seat
bolt
DWE00217
DEEM)100
ASSEMBLY
6.
AND DISASSEMBLY
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.
I c---G?/
m
B
CDE00217
ASSEMBLY
AND
DISASSEMBLY
GENERAL
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
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
%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
2)
3)
4)
ASSEMBLY
CDE00221
CDE00222
c
I
CDE00223
CDE00175
ASSEMBLY
AND DISASSEMBLY
GENERAL
ASSEMBLY
Assemble
Small
diameter
inside
end
guide
Large
diameter
inside
end
DWEOOZI
K4
co
2)
3)
4)
CDE00232
13-33
0
ASSEMBLY
AND
DISASSEMBLY
GENERAL
ASSEMBLY
CEE00233
ASSEMBLY
AND
GENERAL
DISASSEMBLY
pump
ASSEMBLY
assembly
(2).
* The mounting
2)
-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.
Mounting
bolt:
245 - 308.7 Nm I25 - 31.5 kgm}
GENERAL ASSEMBLY
CEE00166
CEE00164
CEE001651
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)
a
OWE00275
GENERAL ASSEMBLY
4)
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
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}
CEE00237
fitted in
ASSEMBLY
GENERAL
AND DISASSEMBLY
ASSEMBLY
--------- ----..-.
\J-.._.. XL
-..
Exhaust
valve
0.78 - 0.82
After tightening
the lock nut, check
the clearance again.
CDE00240
ASSEMBLY
AND DISASSEMBLY
GENERAL
ASSEMBLY
4)
5)
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)
13-40
0
pipe bracket.
CEE00159
ASSEMBLY
AND
GENERAL
DISASSEMBLY
ASSEMBLY
3)
Joint bolt:
7.8 - 9.8 Nm IO.8 - 1.0 kgml
CDE00158
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
Lip at
Large inside
diameter end
Small inside
diameter end
DEE00105
4
CEP00535
ASSEMBLY
AND
DISASSEMBLY
GENERAL
2)
3)
ASSEMBLY
CFFOO414
4)
Lie
at
crankshaft
end
DWE00221
I)
(LG-7)
DWE00222
ASSEMBLY
2)
AND
DISASSEMBLY
GENERAL
ASSEMBLY
3)
Remove
4)
3&44
(45mm)
(25mml
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
For construction
machine and generator
Put
and
For marine
engine
DKEOOII!
mark on flywheel
bolt
DWE00223
DEE00100
GENERAL ASSEMBLY
Ir
the
dial
(3).
13-46
0
CEE00154
ASSEMBLY
AND
GENERAL
DISASSEMBLY
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)
"\
1-1
CEE00152
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)
5)
Tighten
4 mounting
ASSEMBLY
pump.
6)
(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
8)
CEE00255
2)
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)
5)
6)
7)
Tighten
8)
GENERAL
ASSEMBLY
CEE00258
nut (15).
13-49
0
ASSEMBLY
AND
GENERAL
DISASSEMBLY
ASSEMBLY
Install clamp
tube.
Ir
13-50
0
CEW00552
CEE00259
(2), then
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
:
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
CEE00144
bracket
(I).
CDE00139
GENERAL ASSEMBLY
CDE00138
50 Turbocharger
drain tube
Fit gasket and install turbocharger
drain
tube
(1).
starting
motor
(2) with
ASSEMBLY
AND
DISASSEMBLY
GENERAL
ASSEMBLY
4)
(7).
Fit gasket and install valves
(5).
5)
*
11
Engine
37 L?
a
IO
CEE00260
14 Maintenance standard
Engine body
Cylinder head ........................................... 14Valve, valve guide .................................... 14Rocker arm and shaft ............................... 14Crosshead and guide ............................... 14Cylinder block........................................... 14Cylinder liner ............................................ 14Crankshaft ................................................ 14Camshaft .................................................. 14Cam follower and push rod ...................... 14Timing gear .............................................. 14Piston ....................................................... 14Connecting rod ......................................... 14Flywheel and flywheel housing................. 14-
6
8
10
11
12
13
14
15
16
18
20
22
23
Lubrication system
Oil pump ................................................... 14- 24
Regulator valve, piston cooling valve
and safety valve................................ 14- 26
Oil cooler .................................................. 14- 27
Cooling system
Water pump.............................................. 14- 28
Thermostat ............................................... 14- 31
6D140-2 SERIES
14-1
(10)
Maintenance standard
14-2
(11)
6D140-2 SERIES
Maintenance standard
Unit: mm
No.
Check item
Criteria
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
6D140-2 SERIES
Tolerance
Standard
size
Ring
Blower
side
Repair limit
Hole
Replace parts
related to
bearing
Turbine
side
Tolerance
Replace parts
related to
thrust
Shaft
Remedy
Replace parts
related to
bearing
14-3
(11)
Maintenance standard
KTR110L
SDA6D140E-2 (D275A-5, 50C spec.)
14-4
(11)
6D140-2 SERIES
Maintenance standard
Unit: mm
No.
Check item
Criteria
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
6D140-2 SERIES
Tolerance
Standard
size
Ring
Blower
side
Repair limit
Hole
Replace parts
related to
bearing
Turbine
side
Tolerance
Replace parts
related to
thrust
Shaft
Remedy
Replace parts
related to
bearing
14-5
(11)
Maintenance standard
Engine body
Engine body
Cylinder head
14-6
(10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm
No.
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
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.
Remedy
(1) (6)
(7)
66.7 {6.8}
37.3 {3.8}
Tightening torque of
connector pipe locknut
39.2 {4}
4.9 {0.5}
6D140-2 SERIES
Repair by
grinding or
replace
Replace
nozzle or
cylinder head
Tighten in
sequence as
indicated
above
Retighten
14-7
(10)
Maintenance standard
Engine body
14-8
(10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm
No.
Check item
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
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
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
*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
Replace valve
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}
6D140-2 SERIES
14-9
(10)
Maintenance standard
Engine body
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
Criteria
Valve
Standard size
Tolerance
Intake
0.43
0.02
Exhaust
0.80
0.02
58.8
Replace
rocker arm or
rocker arm
shaft
Adjust
Retighten
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
+0.3
+0.3
3.41
11
0.06
0.02
11.17
Outside diameter of
crosshead guide
11
+0.011
+0.011
10.95
49.0
0.25
6D140-2 SERIES
Replace
Repair
14-11
(10)
Maintenance standard
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
Repair by
grinding or
replace
Replace main
bearing cap
Replace main
bearing
Tolerance
Repair limit
120
+0.038
0.006
120.15
69
+0.030
+0.030
Repair or
replace
cylinder block
65
+0.040
+0.030
65.15
14-12
(10)
Replace main
bearing
Repair by
reassembling
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
Range (Nm{kgm})
66.7 {6.8}
274.6 {28}
Retighten
6D140-2 SERIES
Maintenance standard
Engine body
Cylinder liner
Unit: mm
No.
Check item
Criteria
Remedy
Rank
Standard size
Tolerance
Repair limit
140
+0.020
+0.020
140.12
140
+0.040
+0.021
140.14
Standard size
Tolerance
170.2
0.10
0.10
3
Clearance between cylinder
liner and block (Counter bore)
Outside diameter of cylinder
liner (Counter bore bottom)
4
Interference between
cylinder liner and block
(Counter bore bottom)
6D140-2 SERIES
Standard: 0 0.163
Standard size
Tolerance
161.2
+0.090
+0.050
Standard interference
Interference limit
0.02 0.12
0.02
Standard size
Tolerance
158
0.024
0.049
Standard: 0.024 0.089
Replace
cylinder
liner
Replace
cylinder
liner
Replace cylinder liner or
cylinder block,
or repair
Replace
cylinder
liner
Replace cylinder liner or
cylinder block
14-13
(10)
Maintenance standard
Engine body
Crankshaft
Unit: mm
No.
Check item
Criteria
Standard size
Repair limit
0.140 0.315
0.50
STD
120.00
0.25 U.S.
119.75
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
Maintenance standard
Engine body
Camshaft
Unit: mm
No.
1
Check item
End play
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
Standard size
Tolerance
Repair limit
Intake
55.48
0.1
55.08
Exhaust
55.75
0.1
55.35
Replace
camshaft
14-15
(10)
Maintenance standard
Engine body
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
31.7
+0.05
+0.02
31.50
12.7
+0.038
+0.013
12.78
12.63
0.006
12.56
Criteria
Standard size
Tolerance
12.7
0.20
0.20
0.20
0.20
13.4
14-16
(10)
Replace
6D140-2 SERIES
Maintenance standard
Engine body
Timing gear
14-18
(10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm
No.
Check item
Criteria
Measuring
point
Standard
size
Gears
0.141
0.425
0.129
0.391
0.129
0.391
0.141
0.426
0.080
0.417
0.095
0.346
0.118
0.369
0.118
0.369
0.025
0.486
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
0.05 0.17
0.4
0.07 0.20
0.4
6D140-2 SERIES
Repair
limit
Replace
bushing
Replace
thrust
bearing
14-19
(10)
Maintenance standard
Engine body
Piston
14-20
(10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm
No.
Check item
2
|
4
Criteria
Rank
Standard size
Tolerance
140
0.070
0.085
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
Repair limit
Remedy
Standard size
Tolerance
52
0.006
0.006
52
+0.045
+0.035
Standard clearance
Clearance limit
0.035 0.051
0.10
Replace
piston
Replace
piston ring
Replace
piston
Replace
piston or
piston ring
Replace
piston ring or
cylinder liner
Replace
piston pin
Replace
piston
Replace
piston or
piston pin
14-21
(10)
Maintenance standard
Engine body
Connecting rod
Unit: mm
No.
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
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
Standard
size
0 0.30
Replace
bearing
Replace
connecting
rod
Standard size
Replace
connecting
rod
Tolerance
Standard size
Replace bushing
(New part is supplied as a semifinished part)
Replace
bushing or
piston pin
Standard size
Item
5
Remedy
Replace
bearing
Repair
limit
0.25
0.35
Standard size
Target (Nm{kgm})
Repair (Nm{kgm})
1st step
127.5 {13}
117.7 132.4
{12.5 13.5}
2nd step
Retighten with 90
90 120
Permissible range:
Variation between weights on the machine max. 154 g
Replace
connecting
rod
Retighten
Replace
a Note: The connecting rod bolt can be re-used up to a maximum of 5 times. Each time the bolt is re-used,
make a punch mark on the bolt head.
14-22
(10)
6D140-2 SERIES
Maintenance standard
Engine body
Unit: mm
No.
Check item
Criteria
Remedy
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)
Maintenance standard
Lubrication system
Lubrication system
Oil pump
14-24
(10)
6D140-2 SERIES
Maintenance standard
Lubrication system
Unit: mm
No.
Check item
Criteria
Tolerance
Standard
size
45
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
18
+0.090
+0.070
+0.147
+0.127
0.032
0.077
18
+0.090
+0.070
+0.129
+0.102
0.012
0.059
16
0.040
0.060
+0.043
+0.043
0.040
0.103
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
21
+0.090
+0.065
10
21
+0.090
+0.065
+0.035
+0.035
0.030
0.090
11
18
+0.090
+0.070
+0.040
+0.022
0.030
0.068
Standard size
12
13
6D140-2 SERIES
Replace
Repair limit
Free length
Installed
length
Installed
load
49.1
32.0
126.4 N
{12.9 kg}
Free length
Installed
load
Replace
113.7 N
{11.6 kg}
Replace
14-25
(10)
Maintenance standard
Lubrication system
Unit: mm
No.
Check item
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
Free length
Installed
length
83
79
Repair limit
Installed
Installed
Free length
load (N{kg})
load (N{kg}) Replace spring
16.1
{1.64}
14-26
(10)
Clearance
limit
Replace valve
or body
15.1
{1.54}
Replace
6D140-2 SERIES
Maintenance standard
Lubrication system
Oil cooler
Unit: mm
No.
Check item
Lift of thermostat to fully open
position
Criteria
Remedy
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)
Maintenance standard
Cooling system
Cooling system
Water pump
6D140-2
S6D140-2
SA6D140-2
Unit: mm
No.
Check item
Interference between
impeller and shaft
Criteria
Standard size
Remedy
Tolerance
Standard
interference
Shaft
Hole
15.9
+0.018
+0.005
0.020
0.050
0.025 0.068
25
+0.015
+0.002
0.023
0.053
0.025 0.068
25
+0.015
+0.002
0.023
0.053
0.025 0.068
14-28
(10)
Replace
Repair limit
A: 1.5
6D140-2 SERIES
Maintenance standard
Cooling system
S6D140-2
SA6D140-2
SDA6D140E-2 (D275A-5, 50C spec.)
Unit: mm
No.
Check item
Interference between
impeller and shaft
Criteria
Standard size
Remedy
Tolerance
Standard
interference
Shaft
Hole
16
0.082
0.095
0.020
0.150
0.025 0.068
28
+0.015
+0.002
0.023
0.053
0.025 0.068
25
+0.015
+0.002
0.021
0.041
0.025 0.056
6D140-2 SERIES
Replace
Repair limit
A: 1.5
14-29
(10)
Maintenance standard
Cooling system
For aftercooler
SDA6D140E-2 (D275A-5, 50C spec.)
Unit: mm
No.
Check item
Interference between
impeller and shaft
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
Maintenance standard
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)
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
6D140-2 SERIES
15-1
(10)
Symbol
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
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
Part No.
795-100-4800
790-101-5001
790-101-5081
Plate
(for intake valve)
790-101-5071
Plate
(for exhaust valve)
795-100-3003
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
795-100-3720
795-100-3730
795-100-4210
795-100-4220
795-100-4230
795-100-4240
1
B
Part Name
Q'ty
HEE00081
15-4
(10)
6D140-2 SERIES
Cylinder head
6D140-2 SERIES
15-5
(10)
Cylinder head
15-6
(10)
6D140-2 SERIES
Cylinder head
Valve
Insert
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
6D140-2 SERIES
15-7
(10)
Cylinder head
Exhaust valve
A: 47.1
B: 1.5
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
Special tools
No.
Part No.
790-553-1600
Part Name
Q'ty
1
1
6D140-2 SERIES
15-9
(10)
Cylinder head
Part No.
795-100-1520
Part Name
Q'ty
1
795-130-1710
15-10
(10)
6D140-2 SERIES
Cylinder head
Part No.
Part Name
Q'ty
795-140-6410
795-130-1310
6D140-2 SERIES
15-11
(10)
Cylinder head
Grinding valve
Special tool
No.
Part No.
Commercially
available
Part Name
Valve refacer
Q'ty
1
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
6D140-2 SERIES
15-13
(10)
Cylinder block
15-14
(10)
6D140-2 SERIES
Cylinder block
6D140-2 SERIES
15-15
(10)
Cylinder block
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.
15-16
(10)
6D140-2 SERIES
Cylinder block
6D140-2 SERIES
15-17
(10)
Cylinder block
15-18
(10)
6D140-2 SERIES
Cylinder block
Part No.
795-240-6400
795-240-6410
Push tool
795-240-6420
Push tool
795-240-6430
Block
01530-03912
Nut
Part Name
Q'ty
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)
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
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
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 limit
0.016 0.096
0.15
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
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
H.
Judgement standards
Remedy
Standard size
Standard value
Standard limit
127
127.000 127.025
Max. 0.020
Max. 0.013
Replace
I.
Journal
Standard fitting
Clearance limit
No.1 7
Interference
0.002 0.060
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
127
Roundness
0.005
Straightness
0.010
Length
Min. 1,150
6D140-2 SERIES
15-23
(10)
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
0.05
0.10
430.5 0.04
430.0
Fig.1
Within 12.5 S
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
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
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
Fig. 8
Fig. 9
15-28
(10)
6D140-2 SERIES
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
Parts used
for correction
Table 5
Oversize head
gasket
Shim
Stamp
Not needed
OS
SH
WS
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
Fig. 13
15-30
(10)
Fig. 14
Fig. 15
6D140-2 SERIES
Fig. 16
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)
Correction parts
Part No.
Part Name
6215-29-1210
6215-29-1230
6215-29-1250
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
15-32
(10)
6D140-2 SERIES
6D140-2 SERIES
15-33
(10)
PROPOSAL
FOR MANUAL
REVlslON
1
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:
PFMRl 081696