6D140-2

SEBM008610
DIESEL ENGINE
© 2004
All Rights Reserved 00-1
Printed in Japan 06-04 (01) (10)
Contents
No. of page
01 General .......................................................................................................................... 01-1
11 Structure and function ...................................................................................... 11-1
12 Testing and adjusting ........................................................................................ 12-1
13 Disassembly and assembly .......................................................................... 13-1
14 Maintenance standard.........................................................................................14-1
15 Repair and replacement of parts .............................................................. 15-1
00-2 6D140-2 SERIES

(10)
List of revised pages
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (10) (01-1-1) (01-17-1) q 11-1 (10) q 11-27 (10)

q 00-2 (10) q 01-2 (10) q 01-18 (10) q 11-2 (10) q 11-28 (10)
q 00-2-1 (10) (01-2-1) q 01-19 (10) q 11-3 (10) Q 11-29 (10)
q 00-2-2 (10) (01-2-2) q 01-20 (10) q 11-4 (10) q 11-30 (10)
q 00-2-3 (10) q 01-3 (10) q 01-21 (10) q 11-5 (10) (11-31)
q 00-3 (01-3-1) q 01-22 (10) q 11-6 (10) q 11-32 (10)
q 00-4 (01-3-2) (01-22-1) q 11-7 (10) q 11-33 (10)
q 00-5 (01-3-3) q 01-23 (10) q 11-8 (10) q 11-34 (10)
q 00-6 (01-3-4) q 01-24 (10) q 11-9 (10) q 11-36 (10)
q 00-7 q 01-4 (10) q 01-25 (10) q 11-10 (10) (11-37)
q 00-8 q 01-5 (10) q 01-26 (10) q 11-11 (10) q 11-38 (10)
q 00-9 q 01-6 (10) Q 01-28 (10) q 11-12 (10) q 11-39 (10)
q 00-10 q 01-7 (10) Q 01-29 (10) q 11-13 (10) q 11-40 (10)
q 00-11 q 01-8 (10) Q 01-30 (10) q 11-14 (10) (11-40-1)
q 00-12 Q 01-9 (10) Q 01-31 (10) q 11-15 (10) q 11-41 (10)
q 00-13 q 01-10 (10) Q 01-32 (10) q 11-16 (10) q 11-42 (10)
q 00-14 q 01-11 (10) Q 01-33 (10) (11-16-1) q 11-43 (10)
q 00-15 q 01-12 (10) Q 01-34 (10) q 11-17 (10) q 11-44 (10)
q 00-16 q 01-13 (10) Q 01-35 (10) (11-17-1) q 11-45 (10)
q 00-17 (01-13-1) Q 01-36 (10) q 11-18 (10) q 11-46 (10)
q 00-18 (01-13-2) Q 01-37 (10) q 11-19 (10) (11-47)
q 00-19 (01-13-3) Q 01-38 (10) q 11-20 (10) q 11-48 (10)
q 00-20 (01-13-4) Q 01-39 (10) Q 11-21 (10) q 11-49 (10)
q 00-21 (01-13-5) Q 01-40 (10) q 11-22 (10) q 11-50 (10)
q 00-22 q 01-14 (10) Q 01-41 (10) (11-23) q 11-51 (10)
q 01-15 (10) Q 01-42 (10) q 11-24 (10) (11-51-1)
q 01-16 (10) q 11-25 (10) (11-51-2)
q 01-1 (10) (01-17) q 11-26 (10) q 11-52 (10)
6D140-2 SERIES 00-2-1

(10)

q 11-53 (10) (11-88-2) (12-11-3) (12-40) 13-6 (2)
q 11-54 (10) (11-88-3) (12-11-4) q 12-41 (10) 13-7 (2)
q 11-55 (10) (11-88-4) (12-11-5) q 12-42 (10) 13-8 (2)
q 11-56 (10) q 11-89 (10) (12-11-6) q 12-43 (10) 13-9 (2)
q 11-57 (10) q 11-90 (10) (12-11-7) Q 12-44 (10) 13-10 (2)
q 11-58 (10) q 11-91 (10) (12-11-8) q 12-45 (10) 13-11 (2)
q 11-59 (10) q 11-92 (10) (12-11-9) q 12-46 (10) 13-12 (2)
q 11-60 (10) Q 11-93 (10) (12-11-10) q 12-47 (10) 13-13 (2)
q 11-61 (10) Q 11-94 (10) (12-11-11) q 12-48 (10) 13-14 (2)
(11-61-1) Q 11-95 (10) q 12-12 (10) q 12-49 (10) 13-15 (2)
q 11-62 (10) Q 11-96 (10) q 12-13 (10) q 12-50 (10) 13-16 (2)
q 11-63 (10) Q 11-97 (10) (12-13-1) q 12-51 (10) 13-17 (2)
q 11-64 (10) Q 11-98 (10) (12-13-2) q 12-52 (10) 13-18 (4)
(11-64-1) Q 11-99 (10) q 12-14 (10) q 12-53 (10) 13-19 (2)
q 11-65 (10) Q 11-100 (10) q 12-15 (10) Q 12-54 (10) 13-20 (2)
(11-65-1) Q 11-102 (10) q 12-16 (10) Q 12-55 (10) 13-21 (2)
q 11-66 (10) Q 11-103 (10) q 12-17 (10) Q 12-56 (10) 13-22 (2)
q 11-67 (10) Q 11-104 (10) q 12-18 (10) Q 12-57 (10) 13-23 (4)
q 11-68 (10) Q 11-105 (10) (12-18-1) Q 12-58 (10) 13-24 (4)
(11-69) Q 11-106 (10) (12-18-2) Q 12-59 (10) 13-25 (4)
(11-69-1) Q 11-107 (10) (12-18-3) Q 12-60 (10) 13-26 (2)
q 11-70 (10) Q 11-108 (10) q 12-19 (10) Q 12-61 (10) 13-27 (4)
q 11-71 (10) Q 11-109 (10) q 12-20 (10) Q 12-62 (10) 13-28 (4)
q 11-72 (10) Q 11-110 (10) q 12-21 (10) Q 12-63 (10) 13-29 (4)
q 11-73 (10) q 12-22 (10) Q 12-65 (10) 13-30 (2)
q 11-74 (10) q 12-23 (10) Q 12-66 (10) 13-31 (2)
q 11-75 (10) q 12-1 (10) q 12-24 (10) Q 12-67 (10) 13-32 (2)
q 11-76 (10) q 12-2 (10) q 12-25 (10) Q 12-68 (10) 13-33 (2)
q 11-77 (10) q 12-3 (10) q 12-26 (10) Q 12-69 (10) 13-34 (2)
q 11-78 (10) q 12-4 (10) q 12-27 (10) Q 12-70 (10) 13-35 (2)
q 11-79 (10) (12-4-1) q 12-28 (10) Q 12-71 (10) 13-36 (4)
q 11-80 (10) q 12-5 (10) q 12-29 (10) Q 12-72 (10) 13-37 (4)
q 11-81 (10) q 12-6 (10) q 12-30 (10) Q 12-73 (10) 13-38 (2)
q 11-82 (10) (12-6-1) (12-31) Q 12-74 (10) 13-39 (2)
q 11-83 (10) (12-6-2) q 12-32 (10) Q 12-75 (10) 13-40 (2)
q 11-84 (10) q 12-7 (10) q 12-33 (10) 13-41 (2)
q 11-85 (10) q 12-8 (10) q 12-34 (10) 13-42 (2)
q 11-86 (10) q 12-9 (10) q 12-35 (10) 13-1 (2) 13-43 (2)
(11-87) q 12-10 (10) q 12-36 (10) 13-2 (2) 13-44 (2)
(11-87-1) q 12-11 (10) q 12-37 (10) 13-3 (2) 13-45 (2)
q 11-88 (10) (12-11-1) q 12-38 (10) 13-4 (2) 13-46 (2)
(11-88-1) (12-11-2) q 12-39 (10) 13-5 (2) 13-47 (2)
00-2-2 6D140-2 SERIES

(10)

13-48 (2) q 15-1 (10)
13-49 (2) (15-1-1)
13-50 (2) q 15-2 (10)
13-51 (2) q 15-3 (10)
13-52 (2) q 15-4 (10)
13-53 (2) q 15-5 (10)
13-54 (2) q 15-6 (10)
q 15-7 (10)
q 15-8 (10)
q 14-1 (10) q 15-9 (10)
q 14-2 (10) q 15-10 (10)
q 14-3 (10) q 15-11 (10)
(14-3-1) q 15-12 (10)
(14-3-2) q 15-13 (10)
q 14-4 (10) q 15-14 (10)
Q 14-5 (10) q 15-15 (10)
q 14-6 (10) q 15-16 (10)
q 14-7 (10) q 15-17 (10)
q 14-8 (10) q 15-18 (10)
q 14-9 (10) Q 15-19 (10)
q 14-10 (10) q 15-20 (10)
q 14-11 (10) q 15-21 (10)
q 14-12 (10) q 15-22 (10)
q 14-13 (10) q 15-23 (10)
q 14-14 (10) q 15-24 (10)
q 14-16 (10) q 15-25 (10)
(14-17) q 15-26 (10)
q 14-18 (10) q 15-27 (10)
q 14-19 (10) q 15-28 (10)
q 14-20 (10) q 15-29 (10)
q 14-21 (10) q 15-30 (10)
q 14-22 (10) q 15-31 (10)
q 14-23 (10) q 15-32 (10)
q 14-24 (10) q 15-33 (10)
q 14-25 (10)
q 14-26 (10)
q 14-27 (10)
q 14-28 (10)
Q 14-29 (10)
q 14-30 (10)
Q 14-31 (10)
6D140-2 SERIES 00-2-3

(10)
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 situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.
General precautions
6. Decide a place in the repair workshop to keep
Mistakes in operation are extremely dangerous. tools and removed parts. Always keep the tools
Read the Operation and Maintenance Manual care- and parts in their correct places. Always keep
fully BEFORE operating the machine. the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the
1. Before carrying out any greasing or repairs, read areas provided for smoking. Never smoke while
all the precautions given on the decals which working.
are fixed to the machine.
Preparations for work
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose 7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing. the machine on hard, level ground, and block
• Always wear safety glasses when hitting the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Always wear safety glasses when grinding
parts with a grinder, etc. 8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work.
9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's Always use the handrails, ladders or steps when
compartment. getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
Safety Safety notice
Precautions during work 19. Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or
Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen
• When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out.
that they will not be damaged by contact with
Before disconnecting or removing components
other parts when the machine is being
of the oil, water or air circuits, first remove the
operated.
pressure completely from the circuit.
20. When installing high pressure hoses, make sure
12. The water and oil in the circuits are hot when the
that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get
dangerous, so be extremely careful when install-
burned.
ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carrying
that connecting parts are correctly installed.
out any work on the oil or water circuits.
21. When assembling or installing parts, always use
13. Before starting work, remove the leads from the
the specified tightening torques. When installing
battery. Always remove the lead from the nega-
protective parts such as guards, or parts which
tive (–) terminal first.
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installed
14. When raising heavy components, use a hoist or
correctly.
crane.
Check that the wire rope, chains and hooks are
22. When aligning two holes, never insert your fin-
free from damage.
gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample
caught in a hole.
capacity.
Install the lifting equipment at the correct places.
23. When measuring hydraulic pressure, check that
Use a hoist or crane and operate slowly to pre-
the measuring tool is correctly assembled
vent the component from hitting any other part.
before taking any measurements.
Do not work with any part still raised by the hoist
or crane.
24. Take care when removing or installing the tracks
of track-type machines.
15. When removing covers which are under internal
When removing the track, the track separates
pressure or under pressure from a spring,
suddenly, so never let anyone stand at either
always leave two bolts in position on opposite
end of the track.
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16. When removing components, be careful not to

break or damage the wiring. Damaged wiring
may cause electrical fires.
17. When removing piping, stop the fuel or oil from

spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of gas-
oline when washing electrical parts.
00-4
Foreword General
Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. 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 fur-
ther divided into the each main group of components.
Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
Testing and adjusting

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
Foreword General
How to read the shop manual Revised edition mark

W he n a m a nu a l i s r e v i s ed , an ed i t io n ma r k
Volumes ((1)(2)(3)....) is recorded on the bottom of the pages.
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Revisions
Chassis volume: Issued for every machine model Revised pages are shown in the List of revised
Engine volume: Issued for each engine series pages next to the Contents page.
Each issued as one
Electrical volume:
volume to cover all
Attachments volume: Symbols
models
So that the shop manual can be of ample practical
use, important safety and quality portions are
These various volumes are designed to avoid dupli- marked with the following symbols.
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
Symbol Item Remarks
sis, engine, electrical and attachment volumes be
available. Special safety precautions
k Safety are necessary when
performing the work.
Distribution and updating Special technical
Any additions, amendments or other changes will be precautions or other
sent to KOMATSU distributors. Get the most up-to- a Caution precautions for preserving
date information before you start any work. standards are necessary
when performing the work.
Filing method Weight of parts of systems.
1. See the page number on the bottom of the page. Caution necessary when
4
File the pages in correct order. Weight selecting hoisting wire, or
when working posture is
2. Following examples show how to read the page
important, etc.
number.
Places that require special
3
Example 1 (Chassis volume): Tightening
attention for the tightening
torque
10 - 3 torque during assembly.
Places to be coated with
2
Item number Coat adhesives and lubricants,
(10. Structure and Function) etc.
Consecutive page number for
Places where oil, water or
5
each item.
Oil, water fuel must be added, and
Example 2 (Engine volume): the capacity.
12 - 5 Places where oil or water
6
Drain must be drained, and
Unit number (1. Engine) quantity to be drained.
Item number
(2. Testing and Adjusting)
Consecutive page number for
each item.
3. Additional pages: Additional pages are indi-

cated by a hyphen (–) and number after the
page number. File as in the example.
Example:
10-4 20-203
10-4-1 Added pages 12-203-1
10-4-2 12-203-2
10-5 12-204
00-6
Foreword Hoisting instructions
Hoisting instructions
Hoisting
Slinging near the edge of the hook may
k
cause the rope to slip off the hook during
Heavy parts (25 kg or more) must be lifted
hoisting, and a serious accident can result.
with a hoist, etc. In the Disassembly and
Hooks have maximum strength at the mid-
assembly section, every part weighing 25
dle portion.
kg or more is indicated clearly with the
symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
1) Check for removal of all bolts fastening the
part to the relative parts. 100% 88% 79% 71% 41%
2) Check for existence of another part causing SAD00479
interference with the part to be removed. 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
Wire ropes symmetrically wound onto the load.
k
1) Use adequate ropes depending on the
Slinging with one rope may cause
weight of parts to be hoisted, referring to the
turning of the load during hoisting,
table below:
untwisting of the rope, or slipping of the
Wire ropes rope from its original winding position on
(Standard “Z” or “S” twist ropes the load, which can result in a dangerous
without galvanizing) accident.
Rope diameter Allowable load
mm kN tons 4) Do not sling a heavy load with ropes forming
10 9.8 1.0 a wide hanging angle from the hook.
11.5 13.7 1.4 When hoisting a load with two or more
12.5 15.7 1.6 ropes, the force subjected to each rope will
14 21.6 2.2 increase with the hanging angles. The table
16 27.5 2.8 below shows the variation of allowable load
18 35.3 3.6 kN {kg} when hoisting is made with two
20 43.1 4.4 ropes, each of which is allowed to sling up
22.4 54.9 5.6
to 9.8 kN {1000 kg} vertically, at various
30 98.1 10.0
hanging angles.
40 176.5 18.0
50 274.6 28.0 When two ropes sling a load vertically, up to
60 392.2 40.0 19.6 kN {2000 kg} of total weight can be
suspended. This weight becomes 9.8 kN
a The allowable load value is estimated to be {1000 kg} when two ropes make a 120?
one-sixth or one-seventh of the breaking hanging angle. On the other hand, two
strength of the rope used. ropes are subjected to an excessive force
as large as 39.2 kN {4000 kg} if they sling a
2) Sling wire ropes from the middle portion of 19.6 kN {2000 kg} load at a lifting angle of
the hook. 150°.
00-7
Foreword Method of disassembling, connecting push-pull type coupler
Method of disassembling, connecting push-pull type coupler

k Before carrying out the following work, release Type 1
the residual pressure from the hydraulic tank.
For details, see “Testing and adjusting”,
Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the
hydraulic tank. For details, see “Testing and
adjusting”, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
a The adapter can be pushed in about 3.5 mm.
a Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
a Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
a When the hose is pulled back, the rubber cap
portion moves toward the hose about 3.5
mm. This does not indicate abnormality,
however.
00-8
Foreword Method of disassembling, connecting push-pull type coupler
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding and push body (2) in straight until sliding
prevention ring (1) contacts contact surface a of prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever 2) Hold in the condition in Step 1), and push until
(4) to the right (clockwise). cover (3) contacts contact surface a of the
hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and pull 3) Hold in the condition in Steps 1) and 2), and pull
out whole body (2) to disconnect it. out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion and • Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the ring (1) contacts contact surface a of the
hexagonal portion at the male end to connect it. hexagonal portion at the male end to connect it.
Connection
00-9
Foreword Coating materials
Coating materials
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, featuresr
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel housing,
intake manifold, oil an, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
Foreword Coating materials
Category Komatsu code Part No. Q’ty Container Main applications, featuresr
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER 417-926-3910
Adhesive for cab glass
SUNSTAR • “S” is used for high-temperature

PENGUINE season (April - October) and “W” for
Polyethylene
SEAL 580 320 ml low-temperature season (November -
container
Adhesive SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
Caulking SEAL No. 2505
material SEKISUI • Used to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
container
SEALANT
00-11
Foreword Standard tightening torque
Standard tightening torque

Standard tightening torque table (when using torque wrench)
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table
below.

mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints

a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
Table of tightening torques for o-ring boss plugs

a Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
Tightening torque for 102 engine series

1) Bolt and nuts
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) Tapered screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 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.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
Nominal type
Width
size of Nominal thread size
across flats Thread size Root diameter
hose Range Target – Threads per inch,
(mm) (mm) (Reference)
Thread series
9
02 19 34 – 63 {3.5 – 6.5} 44 {4.5} 14 – 18UNF 14.3
16
11
22 54 – 93 {5.5 – 9.5} 74 {4.5} — – 16UN 17.5
16
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 — —
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 1 – 16UN 20.7
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 – 12UNF 30.3
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 — —
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —
00-14
Foreword Electric wire code
Electric wire code

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
Classification by thickness
Copper wire
Norminal Cable O.D. Current rating
Number of Dia. of Cross section Applicable circuit
number (mm) (A)
strands strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Classification by color and code

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
White & White & Red & Rellow & Green & Blue &
Color —
Red Black White Red White White
Code WB — BY RB YB GR LR
3
White & Black & Red & Yellow & Green & Blue &
Color —
Black Yellow Black Black Red Yellow
Code WL — BR RY YG GY LY
4 Auxiliary
White & Black & Red & Yellow & Green & Blue &
Color —
Blue Red Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5
White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6
Yellow & Green &
Color — — — Red & Blue —
White Blue
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.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 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
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
Foreword Units
Units
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 General
Applicable machine ........................................01- 2

Specifications .................................................01- 4
General assembly drawing.............................01- 12
Weight table ...................................................01- 28
Engine performance curve .............................01- 31
6D140-2 SERIES 01-1

(10)
General Applicable machine
Applicable machine
a Serial No. shows for engine serial No.
Engine Serial No. Applicable machine
GD825A-2 Motor grader

S6D140-2 WA500-3 Wheel loader
D155A-2, D155A-3, D155AX-3, D155AX-5 Bulldozer

D155C-1 (–30°C spec.), D155C-1 (–50°C spec.), D355C-3,
Bulldozer
D355C-3 (–30°C spec.), D355C-3 (–50°C spec.)
PC1600SP-1 Hydraulic excavator
SA6D140-2
DCA400SSK-2 DENYO Generator
DCA-400SSK MQ Generator
J6D140E-G1-2 TAIYO DENKI Generator
PC750-6, PC800-6, PC1800-6 Hydraulic excavator

HD325-6, HD405-6 Dump truck
SAA6D140-2
D275A-5 (–50°C spec.) Bulldozer
SDA6D140E-2
01-2 6D140-2 SERIES

(10)
General Specifications
Specifications
Engine model S6D140-2
Applicable machine GD825A-2 WA500-3
Number of cylinder – Bore x Stroke mm 6 – 140 x 165
Total piston displacement l {cc} 15.2 {15,240}
Firing order 1–5–3–6–2–4
Overall length mm 1,593 1,787

Dimensions
Overall width mm 895 1,060
Overall height (excluding exhaust pipe) mm 2,060 1,670
Overall height (including exhaust pipe) mm — —
Flywheel horsepower 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

Performance
High idling speed rpm 2,300 – 2,400 2,300 – 2,400
Low idling speed rpm 650 – 700 700 – 750
Minimum fuel consumption ratio g/kW•h {g/HP•h} 208 {155} 204 {152}
Dry weight kg 1,506 1,520
Fuel injection pump BOSCH PE-P (PS3S) type
BOSCH RSV centrifugal

Governor
all speed control type
Lubricating oil amount (refill capacity) l 38 (34)
Coolant amount l (Engine side: 23)
Alternator 24 V, 50 A
Starting motor 24 V, 11 kW
Battery 12 V 200 Ah x 2 12 V 170 Ah x 2
Turboharger KOMATSU KTR110 type
Air compressor ZEXEL Recipro-

cation, 1-cylinder —
type
Others — —
01-4 6D140-2 SERIES

(10)
S6D140-2
6D140-2 SERIES 01-5

(10)
Engine model SA6D140-2
D155A-3, PC1600SP-1
Applicable machine
D155AX-3 (2 engines)

Dimensions
Overall width mm 1,040 1,185
225 {302}/1,900 316 {424}/1,800

Flywheel horsepower kW {HP}/rpm
(Net) (Net)
(Net)
Performance
Fuel injection pump BOSCH PE-P BOSCH PE-P

(PS7S) type (PS7S) type
Governor BOSCH RSUV BOSCH RSV
centrifugal, centrifugal,
all speed type all speed type
Lubricating oil amount (refill capacity) l 42 (37) 38 (34)
Coolant amount l (Engine only: 25) (Engine side: 25)
Alternator 24 V, 35 A 24 V, 50 A
24 V, 50 A (opt)
Starting motor 24 V, 11 kW 24 V, 7.5 kW
Turboharger KOMATSU KTR110 type
Air compressor ZEXEL Recipro-

— cation, 1-cylinder
type
Others With aftercooler
01-6 6D140-2 SERIES

(10)
SA6D140-2
D155C-1 D155C-1 D355C-3

D155A-2 D155AX-5 D355C-3
(–30°C spec.) (–50°C spec.) (–30°C spec.)
6 – 140 x 165
15.2 {15,240}
1–5–3–6–2–4
1,566 1,498 1,614 1,614 1,577 1,577
1,136 1,040 1,193 1,193 1,265 1,265
1,824 1,740 1,824 1,824 1,843 1,843
— — — — — —
253 {339}/2,000 232 {310}/1,900 255 {342}/2,000 255 {342}/2,000 265 {355}/2,000 265 {355}/2,000
(Net) (Net) (Gross) (Gross) (Net) (Net)
1,608 {164}/1,400 1,610 {164}/1,250 1,490 {152}/1,400 1,490 {152}/1,400 1,570 {160}/1,400 1,570 {160}/1,400
(Net) (Net) (Gross) (Gross) (Net) (Net)
2,200 – 2,280 2,100 2,190 – 2,290 2,190 – 2,290 2,200 – 2,280 2,200 – 2,280
700 – 750 (engine set) 700 – 750 (engine set)

550 – 650 700 700 – 750 700 – 750
575 – 675 (on board) 575 – 675 (on board)
206 {153} 205 {153} 205 {151} 205 {151} 203 {151} (Gross) 203 {151} (Gross)
1,750 1,560 1,790 1,790 1,850 1,850
BOSCH PE-P (PS7S) type
BOSCH RSV centrifugal,

all speed type
42 (37) 78 (34) 42 (37) 42 (37) 42 (37) 42 (37)
23
(Engine side: 25) (Engine side: 25) (Engine side: 25) (Engine side: 25) (Engine side: 25)
(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 KOMATSU KOMATSU KOMATSU KOMATSU KOMATSU

KTR110 type KTR110 type KTR110 type KTR110 type KTR110 type KTR110 type
— — — — — —
With aftercooler With aftercooler With aftercooler With aftercooler With aftercooler With aftercooler
6D140-2 SERIES 01-7

(10)
D355C-3
Applicable machine
(–50°C spec.)
Number of cylinder – Bore x Stroke mm

6 – 140 x 165
1–5–3–6–2–4
Firing order
Overall length mm 1,577

Dimensions
Overall width mm 1,265
Overall height (excluding exhaust pipe) mm 1,843
Overall height (including exhaust pipe) mm —
Flywheel horsepower kW {HP}/rpm 265 {355}/2,000

(Net)
Maximum torque Nm {kgm}/rpm 1,570 {160}/1,400

Performance
(Net)
High idling speed rpm 2,200 – 2,280
Low idling speed rpm 700 – 750 (engine set)

575 – 675 (on board)
Minimum fuel consumption ratio g/kW•h {g/HP•h}

203 {151} (Gross)
Dry weight kg 1,850
Fuel injection pump BOSCH PE-P (PS7S) type
Governor BOSCH RSV centrifugal,

all speed type
Lubricating oil amount (refill capacity) l 42 (37)
Coolant amount l (Engine side: 25)
24 V, 50 A
Alternator
Starting motor 24 V, 11 kW x 2
Battery 12 V 200 Ah x 2
Turboharger KOMATSU
KTR110 type
Air compressor —
Others With aftercooler
01-8 6D140-2 SERIES

(10)
SA6D140-2
DCA400SSK-2 DCA-400SSK
J6D140E-G1-2
(DENYO generator) (For MQ generator)
6 – 140 x 165
15.2 {15,240}
1–5–3–6–2–4
1,874 1,874 1,874
957 957 957
1,598 1,598 1,634
— — —
310 {415}/1,500 271 {275}/1,500

(Net, 50 Hz) (50 Hz)
357 {478}/1,800 357 {478}/1,800 299 {303}/1,800
(Net, 60 Hz) (Net, 60 Hz) (60 Hz)
— — —
Max. 1,570 (50 Hz) Max. 1,890 (60 Hz) Max. 1,575 (50 Hz)
Max. 1,880 (60 Hz) Max. 1,890 (60 Hz)
800 – 850 800 – 850 700 – 900

At rated At rated At rated
217 {162} (50 Hz) 209 {156} (50 Hz)
231 {172} (60 Hz) 214 {160} (60 Hz) 222 {166} (60 Hz)
1,450 1,450 1,750
BOSCH PE-P (PS7S) type
BOSCH RSUV centrifugal, all speed type
74 (67) 74 (67) 80 (73)
66
64 (Engine side: 27)
(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 KOMATSU KOMATSU

KTR110 type KTR110 type KTR110 type
— — —
With aftercooler With aftercooler With aftercooler
6D140-2 SERIES 01-9

(10)
Engine model SAA6D140-2
PC750-6, HD325-6,
Applicable machine
PC800-6 HD405-6

Dimensions
Overall width mm 1,185 1,202
Flywheel horsepower kW {HP}/rpm 331 {444}/1,800 379 {508}/2,000

(Net) (Gross)
364 {488}/2,000
(Net)
Performance
(Net) (Gross, Net)
Fuel injection pump BOSCH PE-P BOSCH PE-P

(PS7S) type (PS7S) type
Governor BOSCH RSUV BOSCH RFD
centrifugal, all Min. – max. speed
speed type control type
Lubricating oil amount (refill capacity) l 38 (32) 41 (37)
Coolant amount l (Engine only: 25) (Engine only: 25.5)
Alternator 24 V, 50 A 24 V, 50 A
24 V, 7.5 kW 24 V, 11 kW
Starting motor
24 V, 11 kW (opt)
KOMATSU KOMATSU
Turboharger
KTR110 type KTR110 type
Air compressor ZEXEL ZEXEL
Single cylinder, Single cylinder,
reciprocation type reciprocation type
Others With air cooled With air cooled
aftercooler aftercooler and
retarder
01-10 6D140-2 SERIES

(10)
SAA6D140-2 SDA6D140E-2
HD325-6 PC1800-6 D275A-5

(High altitude spec.) (2 engines) (–50°C spec.)
6 – 140 x 165
15.2 {15,240}
1–5–3–6–2–4
1,688 1,582 1,461
1,202 1,056
1,300 1,684 2,084
— — —
307 {411}/2,000 331 {444}/1,800 332 {446}/2,000

(Net) (Gross)
1,750 {179}/1,400 2,100 {214}/1,350 2,030 {207}/1,400

(Net) (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 BOSCH PE-P BOSCH PE-P

(PS7S) type (PS7S) type (PS7S) type
BOSCH RFD BOSCH RSUV BOSCH RSUV
Min. – max. speed centrifugal, all centrifugal, all
control type speed type speed type
41 (37) 38 (32) 62 (55)
(Engine only: 26) (Engine only: 25) (Engine only: 26)
24 V, 50 A 24 V, 50 A 24 V, 75 A
24 V, 11 kW 24 V, 7.5 kW 24 V, 11 kW x 2
12 V 170 Ah x 2 12 V 170 Ah x 2 12 V 170 Ah x 2
KOMATSU KOMATSU KOMATSU

KTR110 type KTR110 type KTR110 type
ZEXEL ZEXEL Reciprocation,
Reciprocation, single cylinder type —
single cylinder type (front engine only)
With air cooled

With air cooled
aftercooler and With aftercooler
aftercooler
retarder
6D140-2 SERIES 01-11

(10)
General General assembly drawing
General assembly drawing

SA6D140-2 left side view (For D155A-3, D155AX-3)
a The specifications are subject to change according to modification, etc.
01-12 6D140-2 SERIES

(10)
SA6D140-2 right side view (For D155A-3, D155AX-3)
6D140-2 SERIES 01-13

(10)
SA6D140-2 front view (For D155A-3, D155AX-3)
01-14 6D140-2 SERIES

(10)
SA6D140-2 rear view (For D155A-3, D155AX-3)
6D140-2 SERIES 01-15

(10)
SA6D140-2 upper side view (For D155A-3, D155AX-3)
01-16 6D140-2 SERIES

(10)
SAA6D140-2 left side view (For PC750-6, PC800-6)
01-18 6D140-2 SERIES

(10)
SAA6D140-2 right side view (For PC750-6, PC800-6)
6D140-2 SERIES 01-19

(10)
SAA6D140-2 front view (For PC750-6, PC800-6)
01-20 6D140-2 SERIES

(10)
SAA6D140-2 rear view (For PC750-6, PC800-6)
6D140-2 SERIES 01-21

(10)
SDA6D140E-2 left side view (For D275A-5, –50°C spec.)
a. Crankshaft center
b. Flywheel housing rear surface
01-22 6D140-2 SERIES

(10)
SDA6D140E-2 right side view (For D275A-5, –50°C spec.)
a. Crankshaft center
b. Flywheel housing rear surface
6D140-2 SERIES 01-23

(10)
SDA6D140E-2 front view (For D275A-5, –50°C spec.)
c. Crankshaft center
d. Cylinder liner center
01-24 6D140-2 SERIES

(10)
SDA6D140E-2 rear view (For D275A-5, –50°C spec.)
c. Crankshaft center
d. Cylinder liner center
6D140-2 SERIES 01-25

(10)
Dimension table
a These dimensions are reference values for use when installing to a test bench.
Dimensions for each part (mm)

Engine Machine model
A B C D E F G
D275A-5 (–50°C spec.) 1,461 1,056 2,084 — — — —
SDA6D140E-2
01-26 6D140-2 SERIES

(10)
General Weight table
Weight table
a The specifications may be different depending on the type of machine.
Unit: kg
No. Item Components S6D140-2
1 Turbocharger Komatsu KTR110 23
Cylinder head, valve, rocker arm,

2 Cylinder head assembly 19
valve spring
Cylinder block, bearing cap,
3 Cylinder block assembly 400
cylinder liner
4 Front cover 38
5 Oil pan 30
60 (GD825A-2, WA500-3)
6 Flywheel assembly Flywheel, ring gear
—
55 (GD825A-2, WA500-3)
7 Flywheel housing
—
8 Crankshaft assembly Crankshaft, crankshaft gear 136
Camshaft, camshaft gear, thrust

9 Camshaft assembly 19
plate
Piston and connecting Piston, piston ring, piston pin,
10 10.7 x 6
rod assembly connecting rod
11 Oil pump 5.5
12 Fuel injection pump 20
13 Water pump 17
24 V, 35 A —
14 Alternator
24 V, 50 A 10
24 V, 7.5 kW —
15 Starting motor
24 V, 11 kW 19.5
16 Air compressor 11
17 Aftercooler assembly —
01-28 6D140-2 SERIES

(10)
Unit: kg
No. Item Components SA6D140-2

valve spring
cylinder liner
4 Front cover 38
5 Oil pan 30
60 (D155A-2,3, AX-3, AX-5)

54 (PC1600SP-1)
129 (DCA400SSK-2, J6D140E-G1-2 Generator)
55 (D155A-2,3, AX-3, AX-5)

7 Flywheel housing 52 (PC1600SP-1)
52 (DCA400SSK-2 Generator)

plate
10 10.7 x 6
11 Oil pump 5.5
21 (D155A-2,3, AX-3, AX-5)

12 Fuel injection pump 23 (Generator)
13 Water pump 17
24 V, 35 A, 25 A 8.0
14 Alternator
24 V, 50 A 10
24 V, 7.5 kW 18
15 Starting motor
24 V, 11 kW 19.5
17 Aftercooler assembly 43
6D140-2 SERIES 01-29

(10)
Unit: kg
No. Item Components SAA6D140-2 SDA6D140E-2

valve spring
cylinder liner
4 Front cover 38
5 Oil pan 30
55 (PC750-6, PC800-6)
51 (HD325-6/405-6)
54 (PC750-6, PC800-6)
7 Flywheel housing
68 (HD325-6/405-6)

plate
10 10.7 x 6
11 Oil pump 5.5
12 Fuel injection pump 20
13 Water pump 17
24 V, 35 A 8.0
14 Alternator
24 V, 50 A 10
24 V, 7.5 kW 18
15 Starting motor
24 V, 11 kW 19.5
Air-cooled aftercooler 37 (PC750, 800-6)

17
assembly 35 (HD325-6/405-6)
01-30 6D140-2 SERIES

(10)
General Engine performance curve
Engine performance curve
Engine Engine Serial No. Machine model Page
GD825A-2 01-32
S6D140-2
WA500-3 01-33
D155A-3, D155AX-3 01-34
PC1600SP-1 01-35
D155A-2 01-36
SA6D140-2 D355C-3, D355C-3 (–30°C spec.),

01-37
D355C-3 (–50°C spec.)
D155AX-5 01-38
D155C-1 (–30°C spec.),
01-42
D155C-1 (–50°C spec.)
HD325-6, HD405-6 01-39
SAA6D140-2
PC750-6, PC800-6, PC1800-6 01-40
D275A-5 (–50°C spec.) 01-41
SDA6D140E-2
6D140-2 SERIES 01-31

(10)
S6D140-2 for GD825A-2

Net flywheel horsepower: 209 kW {280 HP}/2,100 rpm
Net maximum torque: 1,250 Nm {128 kgm}/1,400 rpm
01-32 6D140-2 SERIES

(10)
S6D140-2 for WA500-3

6D140-2 SERIES 01-33

(10)
SA6D140-2 for D155A-3, D155AX-3

01-34 6D140-2 SERIES

(10)
SA6D140-2 for PC1600SP-1

6D140-2 SERIES 01-35

(10)
SA6D140-2 for D155A-2

Flywheel horsepower: 253 kW {339 HP}/2,000 rpm (Net)
Maximum torque: 1,608 Nm {164 kgm}/1,400 rpm (Net)
01-36 6D140-2 SERIES

(10)
SA6D140-2 for D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.)

6D140-2 SERIES 01-37

(10)
SA6D140-2 for D155AX-5

01-38 6D140-2 SERIES

(10)
SAA6D140-2 for HD325-6, HD405-6

Flywheel horsepower: 379 kW {508 HP}/2,000 rpm (Gross), 364 kW {488 HP}/2,000 rpm (Net)
Maximum torque: 2,170 Nm {221 kgm}/1,400 rpm (Gross, Net)
6D140-2 SERIES 01-39

(10)
SAA6D140-2 for PC750-6, PC800-6, PC1800-6

Flywheel horsepower: 331 kW {444 HP}/1,800 rpm
Maximum torque: 2,099 Nm {214 kgm}/1,350 rpm
01-40 6D140-2 SERIES

(10)
SDA6D140E-2 [For D275A-5 (–50°C spec.)]

Rated output: 332 kW {446 HP}/2,000 rpm (Gross)
Max. torque: 2,030 Nm {207 kgm}/1,400 rpm (Gross)
6D140-2 SERIES 01-41

(10)
SA6D140-2 for D155C-1 (–30°C spec.), D155C-1 (–50°C spec.)

Flywheel horsepower: 255 kW {342 HP}/2,000 rpm (Gross)
Maximum torque: 1,490 Nm {152 kgm}/1,400 rpm (Gross)
01-42 6D140-2 SERIES

(10)
11 Structure and function
Intake and exhaust system Cooling system

Intake and exhaust system ....................... 11- 2 Cooling system chart................................ 11- 66
Air cleaner ................................................ 11- 15 Water pump.............................................. 11- 70
Turbocharger ............................................ 11- 18 Thermostat ............................................... 11- 76
Aftercooler ................................................ 11- 20 Corrosion resistor ..................................... 11- 77
Corrosion resistor mounting ..................... 11- 78
Engine body Cooling fan drive ...................................... 11- 79
Cylinder head ........................................... 11- 24
Cylinder block ........................................... 11- 26 Accessory
Main circulation system ............................ 11- 28 Air compressor ......................................... 11- 88
Vibration damper ...................................... 11- 30 Exhaust brake .......................................... 11- 91
Timing gear............................................... 11- 32
Valve system............................................. 11- 34 Electrical system
Flywheel and flywheel housing ................. 11- 36 Alternator.................................................. 11- 95
Starting motor ........................................... 11-102
Lubrication system Electrical intake air heater ........................ 11-107
Lubrication system chart........................... 11- 38 Front PTO mounting................................. 11-108
Oil pump ................................................... 11- 40 Front PTO assembly ................................ 11-109
Regulator valve and Front PTO drive gear assembly ............... 11- 110
piston cooling valve........................... 11- 41
Oil filter ..................................................... 11- 42
Oil cooler .................................................. 11- 46
Fuel system
Fuel system chart ..................................... 11- 48
Fuel injection pump .................................. 11- 50
Feed pump ............................................... 11- 58
Fuel injection nozzle ................................. 11- 59
Fuel filter ................................................... 11- 60
Engine stop motor .................................... 11- 61
6D140-2 SERIES 11-1

(10)
Structure and function Intake and exhaust system
Intake and exhaust system

S6D140-2 for WA500-3
1. Bracket A. Intake
2. Muffler B. Exhaust
3. Check valve C. Dust (together with exhaust gas)
(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 6D140-2 SERIES

(10)
6D140-2 SERIES 11-3

(10)
SA6D140-2 for D155A-3, D155AX-3 (Left side view)

1. Muffler A. Intake
2. Air cleaner B. Exhaust
3. Aftercooler assembly
4. Connector
11-4 6D140-2 SERIES

(10)
SA6D140-2 for D155A-3, D155AX-3 (Right side view)

1. O-ring 6. Connector
2. Air cleaner connector 7. Exhaust manifold (Front)
3. Precleaner 8. Drain tube
4. Turbocharger 9. Exhaust manifold (Center)
5. Seal ring 10. Exhaust manifold (Rear)
6D140-2 SERIES 11-5

(10)
SA6D140-2 for D155A-3, D155AX-3 (Intake system, front view)

1. Check valve C. Dust (together with exhaust gas)

(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 6D140-2 SERIES

(10)
SA6D140-2 for D155A-3, D155AX-3 (Exhaust system, rear view)

1. Dust indicator
2. O-ring
3. Connector
4. Tube (cylinder block – aftercooler)
6D140-2 SERIES 11-7

(10)
SAA6D140-2 for PC750-6, PC800-6 (Left side view)

11-8 6D140-2 SERIES

(10)
SAA6D140-2 for PC750-6, PC800-6 (Right side view)

1. Sensor for dust indicator

2. Intake connector (air cleaner – turbocharger)
3. Turbocharger
4. Exhaust manifold (Front)
5. Exhaust manifold (Center)
6. Exhaust manifold (Rear)
6D140-2 SERIES 11-9

(10)
SAA6D140-2 for PC750-6, PC800-6 (Front view)

A. Intake air (turbocharger – air cooled aftercooler)

B. Intake air
(air cooled aftercooler – electrical intake air heater)
11-10 6D140-2 SERIES

(10)
SAA6D140-2 for PC750-6, PC800-6 (Rear view)

6D140-2 SERIES 11-11

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

1. Connector
(air-cooled aftercooler – electrical intake air heater)
2. Electrical intake air heater
3. Intake connector
(electrical intake air heater – intake manifold)
4. Intake manifold
11-12 6D140-2 SERIES

(10)
SAA6D140-2 for HD325-6 (Right side view)

1. Exhaust brake (butterfly type) A. Intake

2. Turbocharger B. Exhaust
3. Exhaust connector C. Intake air (turbocharger – air-cooled aftercooler)
4. Exhaust manifold (front) D. Intake air
5. Exhaust manifold (center) (air-cooled aftercooler – electrical intake air heater)
6. Exhaust manifold (rear)
6D140-2 SERIES 11-13

(10)
SAA6D140-2 for HD325-6 (Front view)
SAA6D140-2 for HD325-6 (Rear view)
11-14 6D140-2 SERIES

(10)
Air cleaner
a The specifications may be different from the following figure, depending on the type of machine.
KOMA-CLONE type (Automatic discharge multicyclone type)
1. Hood A. Air inlet

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

Engine model Type
machine model method of precleaner cleaner element
S6D140-2 GD825A-2, WA500-3
KOMA-CLONE, Automatic discharge Inner element: 1
SA6D140-2 D155A-2,3, AX-3, AX-5
Multicyclone (Exhaust ejector) Outer element: 1
SAA6D140-2 PC750-6, PC800-6
6D140-2 SERIES 11-15

(10)
FHG, FTG type (Cyclopack type)
FHG type FTG type
1. Inlet 6. Vacuator
2. Outlet 7. Dust pan
3. Guide vane 8. Diffusion vane (sleeve)
4. Primary element 9. Body
5. Safety element 10. Element
Advantages Structure
FTG type • Air containing dust is sucked in from inlet (1) at a
The diameter of the element is the same but the out- tangent, and the dust is separated by the centrif-
side diameter of the body is smaller. ugal force of guide vane (3). More than 99.9% of
• The inlet is placed in the direction of connection, the remaining dust is removed by primary ele-
so ample centrifugal force can be obtained from ment (4), and the cleaned air then passes
a simple spiral guide vane, without using a diffu- through safety element (5) and outlet (2), and is
sion vane. sucked into the engine.
• The is no dust pan or diffusion vane, so the The dust and moisture that is separated by
structure is simple. guide vane (3) rotates around the inside wall of
body (9), and goes inside vacuator (6), where is
discharged automatically to the outside.
11-16 6D140-2 SERIES

(10)
ERB type
a Details may differ according to the machine model.
1. Precleaner A. Intake air port

2. Air cleaner casing B. To turbocharger (intake air port)
3. Outer element C. To muffler (dust)
4. Inner element
Dust discharge method

Engine Machine model Type No. of elements
for precleaner
D275A-5 Komaclone, multicyclone Automatic discharge Inner cylinder 1,
SDA6D140E-2
(–50°C spec.) type (ERB type) (exhaust ejector) Outer cylinder 1
6D140-2 SERIES 11-17

(10)
Turbocharger
KTR110
S6D140-2
SA6D140-2
SAA6D140-2
1. Blower housing A. Intake inlet Turbocharger

2. V-band B. Intake outlet Type: KTR110
3. Defuser plate C. Exhaust inlet Overall length: 284 mm
4. Center housing D. Exhaust outlet Overall width: 305 mm
5. Shroud E. Oil inlet Overall height: 287 mm
6. Turbine housing F. Oil outlet Weight: 22.5 kg
7. Blower impeller G. Cooling water
8. Seal ring
9. Thrust metal
10. Metal
11. Seal ring
12. Turbine impeller
11-18 6D140-2 SERIES

(10)
KTR110 (Air-cooled type)

SDA6D140E-2 (D275A-5, –50°C spec.)
1. Blower housing A. Intake inlet Specifications

2. V-band B. Intake outlet Type: Komatsu KTR110L (air-cooled)
3. Diffuser plate C. Exhaust inlet Overall length: 308 mm
4. Center housing D. Exhaust outlet Overall width: 305 mm
5. Shroud E. Oil inlet Overall height: 287 mm
6. Turbine housing F. Oil outlet Weight: 24 kg
7. Turbine impeller
8. Seal ring
9. Bearing
10. Thrust bearing
11. Seal ring
12. Blower impeller
6D140-2 SERIES 11-19

(10)
Aftercooler
(Water-cooled type)
SA6D140-2 (For construction machinery, generator)

1. Aftercooler cover A. Intake air inlet

2. Aftercooler core B. Intake air outlet
3. Intake manifold C. Water inlet (from cylinder head)
D. Water outlet (to thermostat)
11-20 6D140-2 SERIES

(10)
(Air-cooled type)
SAA6D140-2 for PC750-6, PC800-6

1. Tank a. Intake air port

2. Side support (Turbocharger io Intake manifold)
3. Tube
4. Fin
6D140-2 SERIES 11-21

(10)
(Air-cooled type)
SAA6D140-2 for HD325-6

1. Tank a. Intake air port

2. Side support (Turbocharger io Intake manifold)
3. Tube
4. Fin
11-22 6D140-2 SERIES

(10)
Structure and function Engine body
Engine body
Cylinder head
1. Rocker arm housing mounting bolt B. Intake

2. Cylinder head mounting bolt C. Exhaust
3. Air vent tube
4. Fuel spill pipe d. To fuel tank
5. Rocker arm housing e. To radiator
6. Cylinder head f. To rocker arm (Oil)
7. Rocker arm housing cover
8. Nozzle holder ass’y
9. Nozzle holder retainer
10. Nozzle connecter
11-24 6D140-2 SERIES

(10)
Cylinder head
• Direct fuel injection type
• 4-valve
• Divided type (One cylinder head for one cylin-
der)
• 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)
Cylinder block
1. Front cover 7. Thrust metal

2. Cylinder block 8. Main metal
3. Cylinder liner 9. Main metal cap
4. Crevice seal 10. Main metal cap bolt
5. Liner O-ring 11. Front oil seal
6. Liner O-ring 12. Piston cooling nozzle
11-26 6D140-2 SERIES

(10)
Cylinder block Cylinder liner

• Crankshaft: 7 bearings • Wet type
• Camshaft: High cam type, 7 bearings • Machining of inside wall: Plateau honing, tufftrid-
• Main cap mounting bolt: Plastic-area tightening ing
Front oil seal Liner seal

• Single lip with dust seal (Lay-down seal) • Top: Crevice seal
• Middle: O-ring (Ethylene propylene rubber)
Piston cooling • Bottom: O-ring (Silicon rubber)
• With cooling nozzle
6D140-2 SERIES 11-27

(10)
Main circulation system

1. Piston (FCD piston) 8. Key (Crankshaft gear)

2. Piston pin 9. Crankshaft
3. Connecting rod, bushing 10. Crankshaft gear (No. of teeth: 36)
4. Top ring 11. Connecting rod metal
5. Second ring 12. Connecting rod cap
6. Oil ring 13. Connecting rod
7. Pin (Crankshaft pulley) 14. Connecting rod cap mounting bolt
11-28 6D140-2 SERIES

(10)
Crankshaft Piston ring

Stamp forging
Top ring Second ring Oil ring
Journal and filet portion: Induction hardening
Piston
Ductile cast iron (FCD piston)
Re-entrant piston
Both faces Both faces M-shape steel
Connecting rod keystone Barrel keystone inner ring Hard chrome
face Hard chrome cut Tapered face plating with coil
Stamp forging
plating Hard chrome expander
Cap bolt is of screw-in type and tightened by plastic-
plating
area tightening and has lubricating oil hole.
6D140-2 SERIES 11-29

(10)
Vibration damper
1. Crankshaft pulley
2. Pin (Crankshaft pulley – vibration damper)
3. Vibration damper
4. Pin (Crankshaft – crankshaft pulley)
11-30 6D140-2 SERIES

(10)
Timing gear
1. Water pump drive gear (No. of teeth: 23) 8. Fuel injection pump drive gear (No. of teeth: 48)
2. Sub idler gear (No. of teeth: 42) 9. PTO gear (Option) (No. of teeth: 22)
3. Main idler gear (Large) (No. of teeth: 60) 10. Crankshaft gear (No. of teeth: 36)
4. Main idler gear (Small) (No. of teeth: 40) 11. Oil pump drive gear (No. of teeth: 22)
5. Camshaft gear (No. of teeth: 48)
6. PTO gear (Option) (No. of teeth: 14) A, B, C: Match marks
7. Compressor drive gear (No. of teeth: 24)
11-32 6D140-2 SERIES

(10)
6D140-2 SERIES 11-33

(10)
Valve system
1. Thrust plate 12. Rocker arm adjustment screw

2. Camshaft gear (No. of teeth: 48) 13. Crosshead adjustment screw
3. Camshaft 14. Locknut
4. Cam roller 15. Crosshead
5. Cam roller pin 16. Valve retainer
6. Cam follower shaft 17. Outer valve spring
7. Cam follower 18. Inner valve spring
8. Push rod 19. Exhaust valve
9. Rocker arm shaft 20. Valve guide
10. Rocker arm 21. Spring seat
11. Locknut 22. Intake valve
11-34 6D140-2 SERIES

(10)
Camshaft Valve timing

• Drawn steel bar (Turned)
• Journal and filet portion: Induction hardening
6D140-2 SERIES 11-35

(10)
Flywheel and flywheel housing

Without PTO type
1. Ring gear (No. of teeth: 148)

2. Flywheel
3. Rear oil seal (Lay-down lip seal)
4. Flywheel housing
For marine engine: Eight flywheel mounting bolts
11-36 6D140-2 SERIES

(10)
Structure and function Lubrication system
Lubrication system
Lubrication system chart
1. Oil pan 12. Piston cooling nozzle

2. Oil strainer 13. Piston
3. Oil pump 14. Camshaft
4. Main relief valve 15. Cam follower
5. Oil cooler 16. Rocker arm
6. Thermostat 17. Intake and exhaust valve
7. Regulator valve 18. Timing gears
8. Valve adapter 19. Turbocharger (S6D140, SA6D140, SAA6D140)
9. Oil filter 20. Fuel injection pump
10. Safety valve
11. Crankshaft W: Cooling water
11-38 6D140-2 SERIES

(10)
Large capacity oil filter + bypass filter

1. Oil pan 13. Piston

2. Oil strainer 14. Camshaft
3. Oil pump 15. Cam follower
4. Main relief valve 16. Rocker arm
5. Oil cooler 17. Intake and exhaust valve
6. Thermostat 18. Timing gears
7. Regulator valve 19. Turbocharger
8. Valve adapter 20. Fuel injection pump
9. Oil filter (full-flow filter x 2) 21. Bypass filter (Installed to depending on the model)
10. Safety valve
11. Crankshaft W: Cooling water
12. Piston cooling nozzle
6D140-2 SERIES 11-39

(10)
Oil pump
1. Pump cover Oil pump

2. Drive gear • Type: Gear pump
3. Pump body • Pump speed: Engine speed x 1.64
4. Pump drive gear (No. of teeth: 22)
5. Valve spring Main relief valve
6. Main relief valve • Set pressure:
7. Driven gear 0.78 ± 0.05 MPa {8.0 ± 0.5 kg/cm2}
A. Suction (From oil pan)

B. Discharge (To oil cooler)
11-40 6D140-2 SERIES

(10)
Regulator valve and piston cooling valve

1. Valve body Regulator valve

2. Valve spring • Valve opening pressure:
3. Valve 0.3 ± 0.02 MPa {3.2 ± 0.2 kg/cm2}
a. From oil cooler Piston cooling valve

b. To oil filter • Valve opening pressure:
c. From oil filter 0.14 ± 0.02 MPa {1.4 ± 0.2 kg/cm2}
d. To main gallery
e. To piston cooling nozzle
f. To oil pan (drain)
6D140-2 SERIES 11-41

(10)
Oil filter
S6D140-2
SA6D140-2
SAA6D140-2
1. Filter head Oil filter

2. Safety valve • Filtration area: 0.84 m2
3. Cartridge (Rated flow 160 l/min)
For construction machinery, generator
A. Oil inlet (Rated flow 240 l/min)
B. Oil outlet For marine engine
Safety valve
• Set pressure: 0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2}
11-42 6D140-2 SERIES

(10)
SDA6D140E-2 (D275A-5, –50°C spec.)

a The shape may differ according to the machine model.
1. Safety valve Oil filter

2. Filter head • Filtering area: 0.42 m2 (Full-flow)
3. Cartridge Safety valve
• Cracking pressure:
A. Oil inlet 245 ± 19 kPa {2.5 ± 0.2 kg/cm2}
B. Oil outlet
6D140-2 SERIES 11-43

(10)
Large capacity oil filter

1. Filter head
2. Safety valve
3. Filter connector
4. Cover
5. Alarm assembly
6. Cartridge
A. Oil inlet
B. Oil outlet
Oil filter
• Filtration area:1.8 m2 (0.9 m2 x 2)
• Rated flow: 180 l/min.
Safety valve
11-44 6D140-2 SERIES

(10)
Large capacity oil filter + bypass filter

1. Filter head
2. Safety valve
3. Filter connector
4. Cover
5. Alarm assembly
6. Cartridge (Bypass filter)
7. Cartridge (Full-flow filter)
A. Oil inlet
B. Oil outlet
Oil filter
• Filtration area:1.8 m2 (0.9 m2 x 2)
• Rated flow: 180 l/min.
Safety valve
Bypass filter
• Filtration area:1.4 m2
• Rated flow: 7.5 l/min.
6D140-2 SERIES 11-45

(10)
Oil cooler
1. Cooler cover Thermostat function

2. Cooler element • Valve cracking temperature: 85 ± 1.5°C
6D140-2 : 10 cores • Full opening temperature: 100°C
S6D140-2 : 10 cores • Full opening lift: Min. 8 mm
SA6D140-2 : 12 cores
SAA6D140-2 : 12 cores Oil cooler
SDA6D140E-2: 12 cores • Effective area: 6D140-2 : 0.822 m2
3. Thermostat S6D140-2 : 0.822 m2
4. Spring SA6D140-2 : 0.986 m2
5. Thermostat cover SAA6D140-2 : 0.986 m2
SDA6D140E-2: 0.986 m2
A. Oil inlet
B. Oil outlet
C. Cooling water
11-46 6D140-2 SERIES

(10)
Structure and function Fuel system
Fuel system
Fuel system chart
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Fuel injection pump
7. Fuel injection nozzle
8. Over-flow valve
11-48 6D140-2 SERIES

(10)
1. Fuel tank
2. Gauze filter
3. Priming pump
4. Feed pump
5. Fuel filter
6. Fuel injection pump
7. Fuel injection nozzle
8. Over-flow valve
6D140-2 SERIES 11-49

(10)
Fuel injection pump

SA6D140-2 (D155A-3, D155AX-3, D155AX-5, D155C-1 (–30°C spec., –50°C spec.),
D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.))
1. Fuel injection pipe (No. 1) 9. Fuel injection pump drive shaft

2. Fuel injection pipe (No. 2) 10. Bearing box
3. Fuel injection pipe (No. 3) 11. Coupling
4. Fuel injection pipe (No. 4) 12. Oil inlet pipe
5. Fuel injection pipe (No. 5) 13. Feed pump
6. Fuel injection pipe (No. 6) 14. Fuel injection pump (With boost compensator)
7. Boost compensator tube 15. Oil outlet pipe
8. Fuel injection pump drive gear (No. of teeth 48)
11-50 6D140-2 SERIES

(10)
a: Fuel inlet Fuel injection pump

b: To fuel filter • Maker: BOSCH automotive system
c: From fuel filter • Type: Bosch PE-P
d: To fuel injection nozzle • Lubrication method:
e: Fuel return (Over-flow valve – Fuel tank) Forced lubrication with engine oil
f: Fuel spill (Nozzle – Fuel tank)
g: Engine oil (To fuel injection pump) Governor
h: Engine oil (To engine oil pan) • Type: Made by BOSCH automotive system,
Bosch RSUV Centrifugal, all speed type
6D140-2 SERIES 11-51

(10)
SAA6D140-2 (PC750-6, PC800-6)

1. Fuel injection pipe (No. 1) 8. Fuel injection pump drive gear (No. of teeth 48)
7. Boost compensator tube 14. Oil outlet pipe
11-52 6D140-2 SERIES

(10)
a: Fuel inlet Fuel injection pump

b: To fuel filter • Maker: BOSCH automotive system
c: From fuel filter • Type: Bosch PE-P
d: To fuel injection nozzle • Lubrication method:
e: Fuel return (Over-flow valve – Fuel tank) Forced lubrication with engine oil
f: Engine oil (To fuel injection pump)
g: Engine oil (To engine oil pan) Governor
• Type: Bosch RSUV Centrifugal, all speed type
6D140-2 SERIES 11-53

(10)
SAA6D140-2 (HD325-6)

4. Fuel injection pipe (No. 4) 12. Oil outlet pipe
6. Boost compensator tube 14. Oil inlet pipe
7. Fuel injection pipe (No. 6) 15. Fuel injection pump
8. Fuel injection pump drive gear (No. of teeth 48)
11-54 6D140-2 SERIES

(10)
Fuel injection pump Governor

• Maker: BOSCH automotive system • Type: Made by BOSCH automotive system,
• Type: Bosch PE-P Bosch RFD Centrifugal, max. – min.
• Lubrication method: speed control type
Forced lubrication with engine oil
6D140-2 SERIES 11-55

(10)
SDA6D140E-2 (D275A-5, –50°C spec.)

1. Fuel injection pipe (No. 1) 9. Oil outlet pipe

7. Boost compensator tube 15. Fuel injection pump drive gear (No. of teeth: 48)
8. Oil inlet pipe
11-56 6D140-2 SERIES

(10)
Fuel injection pump Governor

• Maker: BOSCH automotive system • Type: Made by BOSCH automotive system,
• Type: Bosch PE-P Bosch RFD Centrifugal, max. – min.
• Lubrication method: speed control type
Forced lubrication with engine oil
6D140-2 SERIES 11-57

(10)
Feed pump
1. Cover Functions
2. Priming pump • The feed pump sucks fuel from the fuel tank and
3. Spring supplies (discharge) it through the fuel filter to
4. Check valve (intake) the injection pump.
5. Eyebolt • This feed pump also has the function to maintain
6. Plug the discharge pressure (rate) at constant 0.1 –
7. Piston spring 0.2 MPa {1 – 2 kg/cm2} to set the fuel injection
8. Piston rate of the injection pump (quantity of fuel
9. Push rod injected by each stroke) constant.
10. Tappet
11. Check valve (exhaust)
A. Fuel inlet
B. Fuel outlet
11-58 6D140-2 SERIES

(10)
Fuel injection nozzle

1. Fuel inlet connector Fuel injection nozzle

2. Nozzle holder S6D140-2: Made by BOSCH automotive system
3. Adjustment shim Diameter of nozzle hole 0.35 x 7 hole)
4. Spring SA6D140-2: Made by BOSCH automotive system
5. Seat (Diameter of nozzle hole 0.36 x 6 hole)
6. Spacer SAA6D140-2: Made by BOSCH automotive system
7. Nozzle (Diameter of nozzle hole 0.36 x 6 hole)
8. Retaining cap
9. Nozzle needle • Type: Multi-hole type
• Injection pressure:24.5 MPa {250 kg/cm2}
a. Fuel inlet (From injection pump) • Adjusting INJECTION pressure:
b. Injection (To cylinder) Shim adjusting type
c. Fuel return (To fuel tank)
6D140-2 SERIES 11-59

(10)
Fuel filter
1. Filter head Fuel filter

2. Air bleed plug • Filtration area: 1.0 m2
3. Cartridge
a. Fuel inlet
b. Fuel outlet
11-60 6D140-2 SERIES

(10)
Engine stop motor
1. Motor assembly Engine stop motor

2. Cover • Maker: Jidosha Denki Kogyo Co. Ltd
3. Cable assembly • Rated voltage: DC24V
4. Cable clamp • Operating force: 147 N {15 kg} min.
5. Coil spring • Stroke: 35 +1.0 mm
6. Cable –0.4
• Weight: 1.2 kg
7. Screw
8. Breather
9. Bracket assembly
10. Cover assembly
6D140-2 SERIES 11-61

(10)
Structural drawing (1)
1. Gear cover assembly

2. Slider assembly
3. Armature shaft
4. Contactor assembly
5. Roller
6. Worm wheel assembly
7. Motor assembly
8. Gear case assembly
11-62 6D140-2 SERIES

(10)
Structural drawing (2)
1. Gear cover assembly

2. Motor assembly
3. Cable clamp
4. Cable assembly
5. Gear case assembly
6D140-2 SERIES 11-63

(10)
Description of operation and circuits

1. Stop condition (0° or 360°)
The above drawing shows the stopped condition when a closed circuit has been formed.
The slider assembly is stopped at the auto-stop position on the P1 side.
2. When switch is turned (When starting the motor)
When the switch is moved to the P2 side (starting switch ON), an electric current flows from the plus side
contact plate through the P2 auto-stop terminal and switch and into the armature shaft assembly, thereby
starting the motor. The slider assembly starts to move in the direction of the arrow at the same time as the
roller starts to move.
3. Turning condition (90° in the drawing)
Electric current continues to pass through the armature assembly and the motor continues to turn. Because
of the rotation of the roller, the slider assembly also continues to move in the direction of the arrow.
11-64 6D140-2 SERIES

(10)
4. When stopped (180°)
A closed circuit is formed when the P2 auto-stop terminal rides on the minus-side contactor plate, and the
motor comes to a sudden stop. The slider assembly also stops.
5. When switch is turned (When starting the motor)
When the switch is moved to the P1 side (starting switch OFF), an electric current flows from the plus con-
tactor 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 condi-
tion 1.
6D140-2 SERIES 11-65

(10)
Structure and function Cooling system
Cooling system
Cooling system chart
For construction machinery, generator
1. Radiator
2. Thermostat
3. Water-cooled aftercooler (SA6D140-2)
4. Oil cooler
5. Water pump
6. Air compressor
7. Cooling fan
8. Corrosion resistor
A. Oil inlet and outlet
11-66 6D140-2 SERIES

(10)
SDA6D140E-2 (D275A-5, –50°C spec.)
1. Radiator
2. Radiator (small type)
3. Thermostat
4. Water-cooled aftercooler
5. Corrosion resistor
6. Oil cooler
7. Water pump
8. Air compressor
9. Cooling fan
10. Corrosion resistor (for aftercooler)
11. Water pump (for aftercooler)
A. Oil inlet and outlet
6D140-2 SERIES 11-67

(10)
For marine engine
1. Sea water aftercooler 10. Heat exchanger

2. Water level sensor 11. Marine gear oil cooler
3. Fresh water tank 12. Spare sea water pump
4. Thermostat 13. Sea water pump
5. Water-cooled exhaust manifold 14. Kingston cock
6. Water thermometer
7. Oil cooler A. Engine oil inlet, outlet
8. Water pump B. Marine gear oil inlet, outlet
9. Water temperature rise alarm switch C. Air inlet, outlet
11-68 6D140-2 SERIES

(10)
Water pump
Mounting
S6140-2
SA6D140-2
SAA6D140-2 (PC750-6, PC800-6)
1. Oil cooler A. From radiator outlet (Cooling water)

2. Thermostat housing From heat exchanger outlet (For marine engines)
3. Water pump B. Via oil cooler to each portion of engine
(Cooling water)
C. To radiator inlet (Cooling water)
To heat exchanger (For marine engines)
D. From thermostat (Cooling water)
E. From oil pump (Oil)
F. To each portion of engine (Oil)
11-70 6D140-2 SERIES

(10)
SA6D140-2 (D155A-3, D155AX-3, D155AX-5, D155C-1 (–30°C spec., –50°C spec.),

D355C-3, D355C-3 (–30°C spec.), D355C-3 (–50°C spec.))
SDA6D140E-2 (D275A-5, –50°C spec.)

2. Thermostat housing B. Via oil cooler to each portion of engine
3. Water pump (Cooling water)
C. To radiator (Cooling water)
D. To oil cooler on machine (Cooling water)
6D140-2 SERIES 11-71

(10)
SAA6D140-2 (HD325-6)

2. Thermostat housing B. Via oil cooler to each portion of engine
3. Water pump (Cooling water)
C. To radiator (Cooling water)
D. To oil cooler on machine (Cooling water)
11-72 6D140-2 SERIES

(10)
SDA6D140E-2 (D275A-5, –50°C spec.)

For aftercooler
1. Tube A. From water pump to aftercooler

2. Tube
3. Water pump
6D140-2 SERIES 11-73

(10)
S6D140-2
SA6D140-2
SAA6D140-2
SDA6D140E-2 (D275A-5, –50°C spec.)
1. Alternator drive pulley Water pump

2. Oil seal • Type: Centrifugal, gear-driven
3. Ball bearing • Water pump speed : Engine speed x 1.56
4. Pump shaft • Flow capacity: 800 l/min.
5. Water pump drive gear (No. of teeth: 23) • Total water head: 14 m
6. Pump body
7. Water seal
8. Impeller
9. Pump cover
a. From radiator
b. To oil cooler
11-74 6D140-2 SERIES

(10)
For aftercooler
SDA6D140E-2 (D275A-5, –50°C spec.)
1. Pump shaft Water pump

2. Water pump drive gear (No. of teeth: 19) • Type: Centrifugal, gear-driven
3. Spacer • Water pump speed :Engine speed x 1.26
4. Seal ring • Flow capacity: 120 l/min.
5. Ball bearing • Total water head: 3 m
6. Spacer
7. Ball bearing
8. Gasket
9. Impeller
10. Water seal
11. Plate
a. From radiator
b. To aftercooler
6D140-2 SERIES 11-75

(10)
Thermostat
a The specifications may be different from the following figure, depending on the type of machine model.
1. Cylinder block Thermostat

2. Thermostat housing • Valve opening temperature:
3. Thermostat 76.5 ± 2°C (For construction machine and
generator)
A. To radiator To heat exchanger 82 ± 2°C (For marine engines)
(For marine engines) • Fully opening temperature: 90°C
B. To water pump • Lift and fully opening position:10 mm min.
To Brake cooler (HD325)
To oil cooler on machine body
(D155A-3, D155AX-3)
11-76 6D140-2 SERIES

(10)
Corrosion resistor
1. Head Corrosion resistor

2. Cartridge • Filtration area:
3. Element 6D140-2: 0.13 m2
4. Inhibitor (Solid corrosion preventive agent) SA6D140, S6D140-2: 0.13 m2
5. Spring SAA6D140, SA6D140-2: 0.373 m2
6. Stop valve • Quantity of corrosion preventive agent:
6D140-2: 400 g
a. Water inlet SA6D140, S6D140-2: 400 g
b. Water outlet SAA6D140, SA6D140-2: 1,000 g
6D140-2 SERIES 11-77

(10)
Corrosion resistor mounting

1. Bracket
2. Hose (return from corrosion resistor)
3. Valve
4. Corrosion resistor cartridge
5. Hose (to corrosion resistor)
11-78 6D140-2 SERIES

(10)
Cooling fan drive

Tension pulley mount
S6D140-2 for WA500-3
1. Fan pulley
2. Tension pulley (Outside diameter: 120mm)
3. Crank pulley (Outside diameter: 164 mm)
4. Fan belt
6D140-2 SERIES 11-79

(10)
Tension pulley mount

SA6D140-2 for D155A-3, D155AX-3, D155AX-5
1. Fan pulley Fan pulley

2. Tension pulley
Outside
diameter Applicable machine
4. Fan belt (mm)
295 D155A-3, D155AX-3, D155AX-5
316 D155A-3, D155AX-3 (Scraper spec.)
11-80 6D140-2 SERIES

(10)
Tension pulley
SA6D140-2 (D155A-3, D155AX-3, D155AX-5)
1. Bracket
2. Spacer
3. Ball bearing
4. Tension pulley (Outside diameter: 118 mm)
5. Oil seal
6. Inner race
7. Needle bearing
8. Coil spring
9. Tension shaft
6D140-2 SERIES 11-81

(10)
SAA6D140-2 (PC750-6, PC800-6)

1. Fan pulley Pulley outside diameter

2. Fan belt Unit: mm
3. Crank pulley
Crank Tension
4. Tension pulley Model Fan pulley
pulley pulley
5. Tension shaft
6. Tension spring PC750-6
280 164 118
PC800-6
11-82 6D140-2 SERIES

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

(10)
SAA6D140-2 for HD325-6, HD405-6

1. Tension pulley (Outside diameter: 118 mm) Fan pulley

2. Fan pulley
Outside diameter (mm) Applicable machine
3. Fan mount case
4. Fan belt 275 HD325-6, HD405-6
a. Wind direction
11-84 6D140-2 SERIES

(10)
Tension pulley
SAA6D140-2 for HD325-6, HD405-6
1. Bracket
2. Spacer
3. Ball bearing
5. Bearing
6. Coil spring
7. Tension shaft
6D140-2 SERIES 11-85

(10)
Fan mount case

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

2. Ball bearing
3. Shaft
4. Case
11-86 6D140-2 SERIES

(10)
Structure and function Accessory
Accessory
Air compressor
(Installed depending on the model)
1. Crankshaft a. Air intake

2. Crankcase b. Air exhaust
3. Connecting rod c. Unloader
4. Cylinder d. Oil inlet
5. Piston e. Cooling water inlet or outlet
6. Piston ring f. Cooling water outlet or inlet
7. Piston pin
8. Bearing cover
9. Cylinder head
10. Unloader valve
11-88 6D140-2 SERIES

(10)
Air compressor Unloader valve

• Maker: ZEXEL • Valve opening pressure: 618 kPa {6.3 kg/cm2}
• Type: Single cylinder, reciprocated • Valve shutting pressure: 530 kPa {5.4 kg/cm2}
type
• Discharge volume: 340 cc/rev.
• Air pressure: 834 kPa {8.5 kg/cm2}
(at full load)
• Weight: 11 kg
6D140-2 SERIES 11-89

(10)
Air compressor mounting

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

b. Exhaust (air)
c. From air governor to unloader (air)
d. From cylinder block (cooling water)
e. To cylinder block (cooling water)
f. From cylinder block (oil inlet)
g. To cylinder block (oil outlet)
11-90 6D140-2 SERIES

(10)
Exhaust brake
Slide valve type
1. Valve housing Outline

2. Gate valve An exhaust brake is installed between the turbo-
3. Guide bushing charger and muffler, and works due to the air pres-
4. Cylinder sure from the solenoid valve, reducing engine speed
5. Spring by throttling the exhaust passage of the muffler from
6. Spring the turbocharger. The exhaust brake consists of a
7. Piston valve mechanism and an air cylinder which controls
8. Retainer the valve.
9. Release valve
10. Packing
11. Packing
12. Exhaust pressure adjustment bolt
13. Breather
6D140-2 SERIES 11-91

(10)
Butterfly valve type

1. Air cylinder 9. Valve

2. Stopper bolt (fully open) 10. Spindle
3. Stopper bolt (fully close) 11. Bushing
4. Lever 12. Valve body
5. Yoke 13. Cover
6. Insulator
7. Bushing a: From exhaust brake valve
8. Spindle
11-92 6D140-2 SERIES

(10)
Solenoid valve for exhaust brake

1. Connector A. From air tank

2. Case B. To exhaust brake
3. Core C. Exhaust outlet
4. Coil assembly
5. Spring
6. Plunger
7. Spring
8. Valve
9. Rod
10. Body
6D140-2 SERIES 11-93

(10)
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 but-
terfly valve returns through port B to port C, then
discharged in the atmosphere, and butterfly
valve (7) fully opens the path from the turbo-
charger to the muffler.
2. When the exhaust brake switch is turned on

If the switch is turned on, solenoid (1) of the
exhaust brake valve is energized, and plunger
(3) and valve (4) move in the direction of to
close ports B and C and open ports A and B. As
the result, air from the dry tank flows in port B,
then to cylinder (5) of the butterfly valve.
Then, the cylinder is extracted to move lever (6)
in the direction of , and butterfly valve (7) fully
closes the path from the turbocharger to the
muffler. Accordingly, the engine speed drops
and the downhill travel speed of the machine is
limited.
While the accelerator pedal is pressed, the
exhaust brake limit switch operates so that the
engine brake will not be applied even if the
switch is turned on.
11-94 6D140-2 SERIES

(10)
Structure and function Electrical system
Electrical system
Alternator
Mounting
1. Alternator a. Alternator pulley (Pulley O.D. 85 mm)

2. Adjust rod b. Alternator drive pulley (Pulley O.D. 132 mm)
3. Nut (2 pieces)
4. Plate
5. Cover
6. V-belt (2 pieces)
7. Spacer
6D140-2 SERIES 11-95

(10)
Alternator with built-in regulator (Open type 35A)

1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Primary energized resistance
3. Terminal B 6B. Regulator
4. Terminal R 6C. Field coil
5. Terminal E
Applicable machine Pulley O.D. Weight

Engine model Type Specification Pulley type
model (mm) (kg)
Maker: NIKKO DENKI
S6D140-2 WA500-3 24 V, 35 A 85 9.5 I
Type: Opened (Brushless)
Maker: NIKKO DENKI
SA6D140-2 D155A-3, AX-3, AX-5 24 V, 35 A 85 9.5 I
11-96 6D140-2 SERIES

(10)
Alternator with built-in regulator (Open type)

1. Alternator 5. Terminals B
2. Alternator pulley 6. Internal electric circuit diagram
3. Terminal R 6A. Field coil
4. Terminal E 6B. Regulator

Engine model Type Specification
model (mm) (kg)
Maker: NIKKO DENKI
S6D140-2 24 V, 35 A 85 9.5
D155A-3, AX-3, D355C-3, Maker: NIKKO DENK
SA6D140-2 24 V, 35 A 85 9.5
D355C-3 (–30°C spec.) Type: Opened (Brushless)
Maker: NIKKO DENKI
24 V, 25 A 85 8.5
SAA6D140-2
Maker: NIKKO DENKI
24 V, 30 A 85 9.5
6D140-2 SERIES 11-97

(10)


2. Alternator pulley 6A. Alternator
4. Terminal E
5. Terminal R

model (mm) (kg)
Maker: SAWAFUJI DENKI
S6D140-2 GD825A-2 24 V, 50 A 85 12 II
D155A-3, AX-3, AX-5 (if Maker: SAWAFUJI DENKI
SA6D140-2 24 V, 50 A 85 12 II
equipped) Type: Opened (Brushless)
PC750-6, PC800-6 Maker: SAWAFUJI DENKI
SAA6D140-2 24 V, 50 A 85 12 II
HD325-6, HD405-6 Type: Opened (Brushless)
11-98 6D140-2 SERIES

(10)


2. Alternator pulley 6A. Primary energized resistance
4. Terminal R 6C. Field coil
5. Terminal E

model (mm) (kg)
D155C-1 (–30°C spec.)
D155C-1 (–50°C spec.)
Maker: NIKKO DENKI
SA6D140-2 D355C-3 24 V, 50 A 85 11.0 I
D355C-3 (–30°C spec.)
D355C-3 (–50°C spec.)
6D140-2 SERIES 11-99

(10)


2. Alternator pulley 5A. Alternator
4. Terminal R
Outside diameter Weight

Engine Machine model Type Specification
of pulley (mm) (kg)
Sawafuji Denki
SDA6D140E-2 D275A-5 (–50°C spec.) 24 V, 75 A 85 12.5
Open type (brushless)
11-100 6D140-2 SERIES

(10)
Starting motor
For 7.5 kW
1. Pinion gear 8. External wiring diagram (3-pin connector type)

2. Starting motor assembly 8A. Safety relay portion
3. Magnetic switch 8B. Starting motor portion
4. Safety relay
5. Terminal B S. To starting switch terminal C
6. Terminal C R. To alternator terminal R
7. External wiring diagram (2-pin connector type) E. To ground
7A. Safety relay portion
7B. Starting motor portion
11-102 6D140-2 SERIES

(10)
Applicable machine Pulley O.D. Weight Connector

Engine model Type Specification
model (mm) (kg) type
Maker: NIKKO DENKI
S6D140-2 Type: Closed 24 V, 7.5 kW 12 18
(drip-proof, oil proof)
Maker: NIKKO DENKI
SA6D140-2 Type: Closed 24 V, 7.5 kW 12 18 B
Maker: NIKKO DENKI
SAA6D140-2 PC750-6, PC800-6 Type: Closed 24 V, 7.5 kW 12 18 C
6D140-2 SERIES 11-103

(10)
For 11 kW
1. Starting motor assembly 9. External wiring diagram (3-pin connector type)

2. Magnetic switch 9A. Control unit
3. Safety relay 10. External wiring diagram (without safety relay)
4. Pinion gear
5. Terminal B S. To starting switch terminal C
6. Terminal C R. To alternator terminal R
7. Connector E. To ground
8. External wiring diagram (2-pin connector type)
8A. Control unit
11-104 6D140-2 SERIES

(10)
Number of
Applicable machine Weight Connector
Engine model Type Specification pinion
model (kg) type
teeth
GD825A-2 Maker: SAWAFUJI DENKI 24 V, 11 kW 11 20 B

S6D140-2 Type: Closed
WA500-3 (drip-proof, oil proof) 24 V, 11 kW 11 20 C
D155A-2,3, AX-3, AX-5

24 V, 11 kW 11 20 C
(X type connector)
D155C-1 (–30°C spec.) Maker: SAWAFUJI DENKI
SA6D140-2 D155C-1 (–50°C spec.) Type: Closed
D355C-3 (drip-proof, oil proof) 24 V, 11 kW 11 20 C
D355C-3 (–30°C spec.)
D355C-3 (–50°C spec.)
HD325-6, HD405-6 Maker: SAWAFUJI DENKI 24 V, 11 kW 11 20 C

SAA6D140-2 Type: Closed
6D140-2 SERIES 11-105

(10)
For 11 kW
1. Pinion gear 7. External wiring diagram (2-pin connector type)

2. Starting motor assembly 7A. Safety relay portion
3. Magnetic switch 7B. Starting motor portion
4. Terminal B
5. Terminal C S. To starting switch terminal C
6. Safety relay R. To alternator terminal R
E. To ground
No. of
Weight Connector
Engine Machine model Type Specification pinion
(kg) type
teeth
Nikko Denki
SDA6D140E-2 D275A-5 (–50°C spec.) 24 V, 11 kW 12 18 B
Waterproof, oilproof type
11-106 6D140-2 SERIES

(10)
Electrical intake air heater

S6D140-2
1. Heater body Electrical intake air heater

2. Heater coil • Rated voltage: DC22 V
• Rated current: 175 A
SA6D140-2
SDA6D140E-2 (D275A-5, –50°C spec.)
1. Heater body Electrical intake air heater

2. Heater coil • Rated voltage: DC11 V
3. Terminal • Rated current: 86 A
6D140-2 SERIES 11-107

(10)
Front PTO mounting

1. Front PTO
2. O-ring
3. Front PTO drive gear assembly
11-108 6D140-2 SERIES

(10)
Front PTO assembly

1. Shaft
2. Pulley
3. Oil seal
4. Bearing (2 pieces)
5. Housing
6. O-ring
7. Gear (No. of teeth: 14)
8. Snap ring
9. Sleeve
6D140-2 SERIES 11-109

(10)
Front PTO drive gear assembly

1. Gear (No of teeth: 24) 7. Gasket

2. Snap ring 8. O-ring
3. Pin 9. Bearing (2 pieces)
4. Plate 10. Housing
5. Bolt 11. Shaft
6. Flange
11-110 6D140-2 SERIES

(10)
12 Testing and adjusting
Mounting (adjusting) method of

engine speed sensor............................... 12- 2
Engine body
Adjusting valve clearance......................... 12- 3
Measuring compression pressure ............ 12- 4
Fuel system
Testing and adjusting fuel
injection timing .................................. 12- 5
Adjusting fuel injection pressure............... 12- 6
Procedure for adjusting engine
stop motor cable ............................... 12- 7
Cooling system
Checking and adjusting fan belt tension... 12- 9
Fuel injection pump calibration data .............. 12- 10
Performance test ........................................... 12- 26

Run-in standard........................................ 12- 26
Performance test criteria .......................... 12- 32
Troubleshooting ............................................. 12- 41
Points to remember when

troubleshooting ....................................... 12- 43
Method of using troubleshooting charts......... 12- 44
Testing and adjusting tool list......................... 12- 67
Testing and adjusting data ............................. 12- 68
6D140-2 SERIES 12-1

(10)
Testing and adjusting Mounting (adjusting) method of engine speed sensor
Mounting (adjusting) method a The specifications may be different from the

following figure, depending on the machine
of engine speed sensor model.
Adjustment of gap between speed sensor and

pin on periphery of flywheel
• The following is the removing and mounting pro-
cedure of the engine speed sensor.
1. Turn the crankshaft forward to match pin (1)

driven in the periphery of the flywheel.
2. At this position, tighten speed sensor (2) until it

touches pin (1) of the flywheel, then loosen it by
one turn.
a Gap at this time: 1.0 – 1.2 mm
3. Tighten lock nut (3).

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

contact surface of ring gear
• The following is the removing and mounting pro-
cedure of the engine speed sensor.
1. Tighten sensor (1) until its tip touches ring gear

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

1/2 – 2/3 turns.
a Gap at this time: 0.75 – 1.00 mm
3. Tighten lock nut (3).

a Arrange the sensor wires carefully so that an
excessive force will not be applied to them.
a Take care to keep the sensor tip free from
metallic chips dust, dirt etc.
12-2 6D140-2 SERIES

(10)
Testing and adjusting Engine body
Engine body
Adjusting valve clearance
1. Remove the rocker arm housing cover.
2. Rotate the crankshaft in the normal direction.

While watching the movement of the intake
valve of the No. 6 cylinder, bring the No. 1 cylin-
der into the top dead center position of the com-
pression stroke and align the "1.6 TOP" mark on
vibration damper (1) with pointer (2).
a When the No. 1 cylinder comes near the top
dead center of the compression stroke, the
No. 6 intake valve will start to move (open).
3. Adjust the valve clearance for valves marked q

in the valve arrangement chart.
4. Rotate the crankshaft in the normal direction by

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

nut (5) on adjustment screw (4), insert the
feeler gauge corresponding to the specified
clearance between crosshead (6) and rocker
arm (7), and adjust the clearance with the
adjustment screw until the thickness gauge
can slide lightly.
5. After the clearance is properly adjusted, tighten
3 Lock nut: 58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}

the lock nut to secure the adjustment screw.
a The engine firing order is 1 – 5 – 3 – 6 – 2 – 4.

a Intake and exhaust valve clearances may be
adjusted for each cylinder in the firing order
by rotating the crankshaft 120° at a time in
the normal direction.
6D140-2 SERIES 12-3

(10)
Testing and adjusting Engine body
Measuring compression
pressure
Measurement procedure
k While measuring the compression pressure,
take care not burn yourself on the exhaust
manifold or muffler, and be careful not to get
caught in any revolving part of the engine.
a Measure the compression pressure while the
engine is warm.
(Oil temperature: 40 – 60°C)
1. Adjust the valve clearance properly. For details,

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

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

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

section of the cylinder to be measured, and
tighten the adapter with retainer (5) to the speci-
3 Torque: 66.7 ± 7.3 Nm {6.8 ± 0.75 kgm}

fied torque:
5. Connect compression gauge A to the adapter.
6. Place the fuel control lever in NO INJECTION

position, crank the engine with the starting
motor, and read the gauge when the pointer is
stabilized.
k If you do not put the fuel control lever in NO
INJECTION position, fuel will blow out.
a Most compression leakage can be
prevented by applying a small amount of oil
to the mounting section of the adapter.
a For the reference values of the compression
pressure, see TESTING AND ADJUSTING
DATA.
12-4 6D140-2 SERIES

(10)
Testing and adjusting Fuel system
Fuel system
Testing and adjusting fuel
injection timing
• Inspection of fuel injection timing
1. Turn the engine to match stamped line (1) (1-6
TOP) of the damper to pointer (2).
2. Pull out snap pin (3) of the injection timing fixing

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

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

on the injection pump is matched to stamped
line "b" on the coupling side.
a If the engine is started or turned forcedly in
this condition, the end of pin (5) will be
broken and caught in the gear, and that can
cause a serious accident.
• Adjustment of fuel injection timing

1. If the stamped line of the fuel injection timing is
found to be deviated, as the result of inspection,
adjust it according to the following procedure.
1) Loosen bolt (7) and shift the coupling to
match the stamped line, then tighten the
3 Bolt:
bolt.
58.8 – 62.8 Nm {6.0 – 6.4 kgm}
• Releasing fixing pin

1) Pull pin (5) out of gear (6).
a Pin (5) can be pulled out easily if it is
turned.
a Pull out pin (5) until is stops.
3 Nut:
2) Tighten nut (4).
26.9 – 33.9 Nm {2.74 – 3.46 kgm}

a The nut can be tightened securely if a
flat-head screwdriver is set in the slit of
pin (5) to lock it.
3) Insert snap pin (3) to lock nut (4) and pin (5).
4) Turn on the engine and confirm that it runs
smoothly.
6D140-2 SERIES 12-5

(10)
Adjusting fuel injection

pressure
1. Remove retaining cap (8).
2. Confirm thickness of adjustment shim (3).
3. Insert correct shim (3) in response to the adjust-

ment value of injection pressure.
4. Tighten retaining cap (8), then confirm the fuel
3 Retaining cap:
injection pressure.
58.8 – 68.6 Nm {6 – 7 kgm}
Data for shims used for adjusting injection pressure
6D140-2, S6D140-2, SA6D140-2, SAA6D140-2

Maker BOSCH automotive system
Cracking pressure (MPa {kg/cm2}) 24.5 +1.3 {250 +13 }

+0.5 +5
Change in cracking pressure for 0.025 mm
0.34 {3.5}
thickness of shim (MPa {kg/cm2})
Thickness of adjustment shim (mm) 0.5 – 1.975 (For each 0.025 mm)
Thickness (mm) Part No. Thickness (mm) Part No.
0.50 150530–4000 0.525 150530–4100
0.55 150530–4200 0.575 150530–4300
0.60 150530–4400 0.625 150530–4500
0.65 150530–4600 0.675 150530–4700
0.70 150530-4800 0.725 150530–4900
0.75 150530–5000 0.775 150530–5100
0.80 150530–5200 0.825 150530–5300
0.85 150530–5400 0.875 150530–5500
Shim thickness and maker part number 0.90 150530–5600 0.925 150530–5700
0.95 150530–5800 0.975 150530–5900
1.00 150530–6000 1.025 150530–6100
1.05 150530–6200 1.075 150530–6300
1.10 150530–6400 1.125 150530–6500
1.15 150530–6600 1.175 150530–6700
1.20 150530–6800 1.225 150530–6900
O O O O
1.95 150530–9800 1.975 150530–9900
12-6 6D140-2 SERIES

(10)
Procedure for adjusting

engine stop motor cable
S6D140-2 for GD825A-2, WA500-3
1. Temporarily attach the ball joint connected to the
injection pump to the cable of the engine stop
motor.
2. Pull injection pump stop lever (2) to the ENGINE

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

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

1. Lever stopper
per and lever, tighten each bolt and nut.
2. Fuel injection pump stop lever
3. Bracket
5. Turn the engine starting switch ON and OFF a
4. Cable
few times to confirm that the engine stop motor
5. Joint
actuated smoothly. Be especially sure to confirm
that there is a clearance between the stop lever
and stopper when the engine is stopped.
a The engine stop motor has built-in limit
switches on both sides of the cable stroke.
a When the engine is running, there is some
slack in the engine stop motor cable. A
spring built into the injection pump actuates
to hold the opening position.
• Engine stop motor stroke: 35 mm
• Injection pump stop lever stroke: 30 mm
6D140-2 SERIES 12-7

(10)
SAA6D140-2 for HD325-6, HD405-6

1. Temporarily attach the ball joint connected to the
injection pump to the cable of the engine stop
motor.
2. Pull injection pump stop lever (1) to the ENGINE

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

tion), clearance a between stop lever (1) of the
injection pump and the lever stopper (built-in to
pump) should be 0.5 – 1.5 mm. Check clear-
ance by movement of cable due to stopper is
built into pump housing. Adjustment is made
according to the depth that the ball joint is
screwed in.
4. After adjusting the clearance between the stop-

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

few times to confirm that the engine stop motor
1. Stop lever
actuated smoothly. Be especially sure to confirm
2. Bracket
that there is a clearance between the stop lever
3. Cable
and stopper when the engine is stopped.
4. Ball Joint
a The engine stop motor has built-in limit
switches on both sides of the cable stroke.
a When the engine is running, there is some
slack in the engine stop motor cable. A
spring built into the injection pump actuates
to hold the opening position.
• Engine stop motor stroke: 35 mm
• Injection pump stop lever stroke: 30 mm
12-8 6D140-2 SERIES

(10)
Testing and adjusting Cooling system
Cooling system
Checking and adjusting fan belt tension
1. Adjustment nut
2. Washer
3. Tension spring
4. Adjustment bolt
5. Tension pulley
A. Protrusion of adjustment bolt
Unit: mm
Applicable
Engine model Dimension A
machine
PC750-6
SAA6D140-2 44 ± 3
PC800-6
6D140-2 SERIES 12-9

(10)
Testing and adjusting Fuel injection pump calibration data
Fuel injection pump calibration data
Engine model Pump assembly No. Engine serial No. Applicable machine Page
6211-72-1310 WA500-3 12-11

6211-72-1470 GD825A-2 12-16
S6D140-2
6212-72-1120 D155A-3, D155AX-3 12-12

6211-72-1140 D155AX-5 12-23
6211-72-1150 D155A-2 12-18
D355C-3, D355C-3 (–30°C spec.),
6211-72-1160 12-19
D355C-3 (–50°C spec.)
6211-72-1170 D155AX-5 12-24
D155C-1 (–30°C spec.)
6211-72-1180 12-25
SA6D140-2 D155C-1 (–50°C spec.)
6212-72-1430 PC1600SP-1 12-17
J6D140E-G1-2 (with electronic governor)
6212-72-1830 12-21
(TAIYO DENKI generator)
J6D140E-G1-2 (with mechanical governor)
6212-72-1840 12-22
(TAIYO DENKI generator)
6212-72-1860 DCA400SSK-2 (DENYO generator) 12-13
6212-72-1860 DCA-400SSK (For MQ generator) 12-20
HD325-6 (with mechanical governor)
6212-72-1250 12-14
HD405-6 (with mechanical governor)
6212-72-1421 PC750-6, PC800-6, PC1800-6 12-15
SAA6D140-2
12-10 6D140-2 SERIES

(10)
6D140-2 SERIES 12-11

(10)
12-12 6D140-2 SERIES

(10)
6D140-2 SERIES 12-13

(10)
12-14 6D140-2 SERIES

(10)
6D140-2 SERIES 12-15

(10)
12-16 6D140-2 SERIES

(10)
6D140-2 SERIES 12-17

(10)
12-18 6D140-2 SERIES

(10)
6D140-2 SERIES 12-19

(10)
12-20 6D140-2 SERIES

(10)
6D140-2 SERIES 12-21

(10)
12-22 6D140-2 SERIES

(10)
6D140-2 SERIES 12-23

(10)
12-24 6D140-2 SERIES

(10)
6D140-2 SERIES 12-25

(10)
Testing and adjusting Performance test
Performance test
Run-in standard
a The table gives the standard values for machines without fan.
a The loads for the dynamometer are at an arm's length of 716 mm.
Engine Applicable Order

Item
model machine 1 2 3 4 5 6
Running time min. 2 8 2 3 5
Engine speed rpm 650 1,300 1,650 1,900 2,100

GD825A-2
N 0 343 686 1,030 1,373
Load
{kg} {0} {35} {70} {105} {140}
Flywheel kW 0 33.9 85.4 147.2 216.4
horsepower {HP} {0} {45.4} {114.4} {197.2} {289.9}
S6D140-2
Engine speed rpm 725 1,000 1,200 1,500 2,100

WA500-3
N 0 392 785 1,177 1,569
Load
{kg} {0} {40} {80} {120} {160}
Flywheel kW 0 29.4 70.7 132.5 247.3
horsepower {HP} {0} {39.4} {94.7} {177.5} {331.3}
Running time min.
Engine speed rpm
N
Load
{kg}
Flywheel kW
horsepower {HP}
Running time min.
Engine speed rpm
N
Load
{kg}
Flywheel kW
horsepower {HP}
Running time min.
Engine speed rpm
N
Load
{kg}
Flywheel kW
horsepower {HP}
12-26 6D140-2 SERIES

(10)

Item
D155A-3 Engine speed rpm 700 1,100 1,450 1,710 1,900
D155AX-3 N 0 432 863 1,285 1,716

Load
{kg} {0} {44} {88} {131} {175}
Flywheel kW 0 35.6 93.9 164.9 244.7
horsepower {HP} {0} {47.7} {128.5} {220.9} {327.8}
Engine speed rpm 750 1,000 1,200 1,500 1,800

PC1600SP-1
N 0 618 1,226 1,844 2,452
Load
{kg} {0} {63} {125} {188} {250}
Flywheel kW 0 46.4 110.4 207.6 331.2
horsepower {HP} {0} {62.1} {147.9} {278.1} {443.7}
DCA400SSK-2 Engine speed rpm 800 1,000 1,200 1,500 1,800

SA6D140-2 (DENYO
generator) N 0 539 1,844 2,157 2,707
Load
{kg} {0} {55} {188} {220} {276}
Flywheel kW 0 40.5 166.3 242.9 365.8
horsepower {HP} {0} {54.2} {222.8} {325.4} {490.0}
Engine speed rpm 550 – 650 1,000 1,200 1,500 2,000

D155A-2
N 0 353 883 1,410 1,770
Load
{kg} {0} {36} {90} {144} {180}
Flywheel kW 0 26 79 159 265
horsepower {HP} {0} {35} {106} {213} {355}
Engine speed rpm 700 – 750 1,000 1,200 1,500 2,000

D355C-3
N 0 373 932 1,490 1,860
Load
{kg} {0} {38} {95} {152} {190}
Flywheel kW 0 28 84 168 279
horsepower {HP} {0} {37} {112} {225} {375}
6D140-2 SERIES 12-27

(10)

Item
DCA-400SSK Engine speed rpm 800 1,000 1,200 1,500 1,800

(MQ
generator) N 0 540 1,840 2,160 2,700
Load
{kg} {0} {55} {188} {220} {276}
Flywheel kW 0 40 166 243 366
horsepower {HP} {0} {54} {223} {325} {490}
J6D140E-GI-2 Engine speed rpm 800 1,000 1,200 1,500 1,800

(TAIYO DENKI
generator) N 0 470 1,180 1,880 2,350
Load
{kg} {0} {48} {120} {192} {240}
Flywheel kW 0 35 106 212 318
horsepower {HP} {0} {48} {146} {292} {438}
Engine speed rpm 700 1,000 1,200 1,500 1,900

SA6D140-2 D155AX-5
N 0 353 883 1,410 1,770
Load
{kg} {0} {36} {90} {144} {180}
Flywheel kW 0 26 79 159 252
horsepower {HP} {0} {36} {109} {219} {347}
Engine speed rpm 725 1,000 1,200 1,500 2,000

D155C-1
(–30°C spec.) N 0 667 1,670 2,670 3,330
Load
{kg} {0} {68} {170} {272} {340}
Flywheel kW 0 50 150 300 500
horsepower {HP} {0} {67} {201} {402} {670}
Engine speed rpm 725 1,000 1,200 1,500 2,000

D155C-1
(–50°C spec.) N 0 667 1,670 2,670 3,330
Load
{kg} {0} {68} {170} {272} {340}
Flywheel kW 0 50 150 300 500
horsepower {HP} {0} {67} {201} {402} {670}
12-28 6D140-2 SERIES

(10)

Item
Engine speed rpm 700 – 750 1,000 1,200 1,500 2,000

D355C-3
(–30°C spec.) N 0 373 932 1,490 1,860
Load
{kg} {0} {38} {95} {152} {190}
Flywheel kW 0 28 84 168 279
horsepower {HP} {0} {37} {112} {225} {375}
SA6D140-2
Engine speed rpm 700 – 750 1,000 1,200 1,500 2,000

D355C-3
(–50°C spec.) N 0 373 932 1,490 1,860
Load
{kg} {0} {38} {95} {152} {190}
Flywheel kW 0 28 84 168 279
horsepower {HP} {0} {37} {112} {225} {375}
HD325-6 Engine speed rpm 800 1,300 1,650 1,900 2,100
HD405-6 N 0 588 1,177 1,765 2,354

Load
{kg} {0} {60} {120} {180} {240}
Flywheel kW 0 57.4 145.7 251.7 370.9
horsepower {HP} {0} {76.9} {195.2} {337.2} {496.9}
HD325-6 Engine speed rpm 725 1,000 1,200 1,500 2,000

SAA6D140-2 (High altitude
spec.) N 0 490 1,030 1,569 1,961
Load
{kg} {0} {50} {105} {160} {200}
Flywheel kW 0 36.8 92.7 176.6 294.4
horsepower {HP} {0} {49.3} {124.2} {236.6} {394.4}
PC750-6
Engine speed rpm 825 1,000 1,200 1,500 1,800
PC800-6
N 0 588 1,275 2,060 2,550
Load
PC1800-6 {kg} {0} {60} {130} {210} {260}
Flywheel kW 0 44 115 232 344
horsepower {HP} {0} {60} {156} {315} {463}
6D140-2 SERIES 12-29

(10)

Item
Engine speed rpm 700 1,000 1,200 1,500 2,000

D275A-5
SDA6D140E-2
(–50°C spec.) N 0 441 1,110 1,770 2,220
Load
{kg} {0} {45} {113} {180} {226}
Flywheel kW 0 33 100 199 332
horsepower {HP} {0} {45} {136} {270} {452}
12-30 6D140-2 SERIES

(10)
Performance test criteria

a The table gives the standard values using the JIS compensator factor.
a The values in the table are the standard values for machines with the muffler installed, air cleaner installed,
alternator under no load, and air compressor open (if installed).
Applicable Engine speed Dynamometer load

Engine model Test item Specified value
machine (rpm) (N {kg})
Flywheel 209.0 kW/2,100 rpm 1,360 – 1,440

2,095 – 2,105
horsepower {280.0 HP/2,100 rpm} {139 – 147}
Maximum 1,255 Nm/1,400 rpm 1,730 – 1,840
1,300 – 1,500
torque {128 kgm/1,400 rpm} {177 – 187}
GD825A-2
High idling
2,300 – 2,400 rpm 2,300 – 2,400 —
speed
Low idling
600 – 650 rpm 600 – 650 —
speed
S6D140-2
Flywheel 235.5 kW/2,100 rpm 1,520 – 1,610
2,095 – 2,105
horsepower {315.5 HP/2,100 rpm} {155 – 164}
Maximum 1,373 Nm/1,400 rpm 1,890 – 2,010
1,350 – 1,450
torque {140 kgm/1,400 rpm} {193 – 205}
WA500-3
High idling
2,300 – 2,400 rpm 2,300 – 2,400 —
speed
Low idling
700 – 750 rpm 700 – 750 —
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
Flywheel
horsepower
Maximum
torque
High idling
speed
Low idling
speed
12-32 6D140-2 SERIES

(10)
a For fuel, use ASTM D975 No. 1 or No. 2.

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

Torque
horsepower consumption temperature temperature oil pressure temperature
(Nm{kgm})
(kW{HP}) (sec/200cc) (°C) (°C) (kPa {kg/cm2}) (°C)
214.5 – 227.1 340 – 490 Max. 650
— Min. 17.3 70 – 90 90 – 110
{287.4 – 304.2} {3.5 – 5.0} Max. 650
1,242 – 1,316
70 – 90 90 – 110 —
{126.6 – 134.2}
— 70 – 90 90 – 110 — —
— 70 – 90 Min. 80 Min. 120 {1.2} —
238.9 – 253.6 340 – 490

— Min. 15.7 70 – 90 90 – 110 Max. 650
{320.1 – 339.8} {3.5 – 5.0}
1,352 – 1,439
70 – 90 90 – 110 — Max. 650
{137.9 – 146.7}
— 70 – 90 90 – 110 — —
— 70 – 90 Min. 80 Min. 118 {1.2} —
6D140-2 SERIES 12-33

(10)
Applicable Dynamometer load

Engine model Test item Specified value Engine speed (rpm)
machine (N {kg})
Flywheel 225.2 kW/1,900 rpm 1,671 – 1,773

1,895 – 1,905
horsepower {301.7 HP/1,900 rpm} {170.4 – 180.8}
Maximum 1,432 Nm/1,300 rpm 2,002 – 2,124
D155A-3 1,250 – 1,350
torque {146 kgm/1,300 rpm} {204.1 – 216.6}
D155AX-3 High idling
2,050 – 2,150 rpm 2,050 – 2,150 —
speed
Low idling
700 – 725 rpm 700 – 725 —
speed
Flywheel 316.5 kW/1,800 rpm 2,378 – 2,525
1,795 – 1,805
Maximum 1,863 Nm/1,400 rpm 2,606 – 2,764
1,300 – 1,500
torque {190 kgm/1,400 rpm} {265.7 – 281.8}
PC1600SP-1
High idling
1,930 – 2,030 rpm 1,930 – 2,030 —
speed
Low idling
725 – 775 rpm 725 – 775 —
speed
Flywheel 309.9 kW/1,500 rpm (50Hz) 2,714 – 2,883 (50Hz)
1,495 – 1,505 (50Hz)
horsepower {415.1 HP/1,500 rpm} (50Hz) {276.7 – 294.0} (50Hz)
357.0 kW/1,800 rpm (60Hz) 2,621 – 2,783 (60Hz)
1,795 – 1,805 (60Hz)
{478.2 HP/1,800 rpm} (60Hz) {267.3 – 283.8} (60Hz)
DCA400SSK-2
Maximum
(DENYO — —
torque
generator)
High idling Max. 1,568 rpm (50Hz) Max. 1,568 (50Hz)
—
speed Max. 1,881 rpm (60Hz) Max. 1,881 (60Hz)
Low idling
SA6D140-2 800 – 850 rpm 800 – 850 —
speed
Flywheel 253 kW/2,000 rpm 1,730 – 1,820
1,995 – 2,005
horsepower {339 HP/2,000 rpm} {176 – 186}
Maximum 1,608 Nm/1,400 rpm 2,230 – 2,350
1,300 – 1,500
torque {164 kgm/1,400 rpm} {227 – 240}
D155A-2
High idling
2,200 – 2,280 rpm 2,200 – 2,280 —
speed
Low idling
550 – 650 rpm 550 – 650 —
speed
Flywheel 265 kW/2,000 rpm 1,790 – 1,900
1,995 – 2,005
Maximum 1,570 Nm/1,400 rpm 2,180 – 2,300
1,300 – 1,500
torque {160 kgm/1,400 rpm} {222 – 235}
D355C-3
High idling
2,200 – 2,280 rpm 2,200 – 2,280 —
speed
Low idling
700 – 750 rpm 700 – 750 —
speed
Flywheel 357 kW/1,800 rpm (60 Hz) 2,620 – 2,780 (60 Hz)
1,795 – 1,805 (60 Hz)
horsepower {478 HP/1,800 rpm} (60 Hz) {267 – 284} (60 Hz)
Maximum
— — —
DCA-400SSK torque
(MQ generator) High idling
Max. 1,890 rpm (60 Hz) Max. 1,890 (60 Hz) —
speed
Low idling
800 – 850 rpm 800 – 850 —
speed
12-34 6D140-2 SERIES

(10)


Torque
(Nm{kgm})
238.2 – 252.9 340 – 490
Min. 16.8 70 – 90 90 – 110 Max. 650
{319.1 – 338.8} {3.5 – 5.0}
1,433 – 1,521
70 – 90 90 – 110 — Max. 650
{146.1 – 155.1}
— 70 – 90 90 – 110 — —
— 70 – 90 Min. 80 Min. 118 {1.2} —
321.3 – 341.1 340 – 490

— Min. 12.3 70 – 90 90 – 110 Max. 650
{430.4 – 457.0} {3.5 – 5.0}
1,865 – 1,979
— 70 – 90 90 – 110 — Max. 650
{190.2 – 201.8}
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 Min. 80 Min. 120 {1.2} —
305.4 – 324.6 (50Hz) Min. 13.0 (50Hz) 290 – 490 (50Hz)

70 – 90 90 – 110 Max. 650
{409.2 – 434.8} (50Hz) Min. 10.6 (60 Hz) {3.0 – 5.0} (50Hz)
354.0 – 376.1 (60Hz) 290 – 490 (60Hz)
70 – 90 90 – 110 Max. 650
{474.3 – 503.8} (60Hz) {3.0 – 5.0} (60Hz)
— — —
— — 70 – 90 90 – 110 —
— — 70 – 90 Min. 80 Min. 180 {1.8} —
258 – 274 340 – 490

— — 70 – 90 90 – 110 Max. 650
{346 – 368} {3.5 – 5.0}
1,590 – 1,690
— — 70 – 90 90 – 110 — Max. 680
{162 – 172}
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 120 {1.2} —
269 – 285 340 – 490

— — 70 – 90 90 – 110 Max. 650
{361 – 382} {3.5 – 5.0}
1,560 – 1,650
— — 70 – 90 90 – 110 — Max. 680
{159 – 168}
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 120 {1.2} —
354 – 376 (60 Hz) 340 – 490

— Min. 10.6 (60 Hz) 70 – 90 90 – 110 Max. 650
{474 – 504} (60 Hz) {3.5 – 5.0}
— — — — — — —
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 90 – 110 Min. 180 {1.8} —
6D140-2 SERIES 12-35

(10)

machine (N {kg})
Flywheel 271 kW/1,500 rpm (Net, 50Hz) 2,430 – 2,580

1,495 – 1,505 (50 Hz)
horsepower 374 HP/1,500 rpm (Net, 50Hz) {248 – 263}
299 kW/1,800 rpm (Net, 60Hz) 2,290 – 2,420
J6D140E-G1-2 1,795 – 1,805 (60 Hz)
412 HP/1,800 rpm (Net, 60Hz) {233 – 247}
(TAIYO DENKI
generator) High idling Max. 1,575 rpm (50 Hz) Max. 1,575 (50 Hz)
—
speed Max. 1,890 rpm (60 Hz) Max. 1,890 (60 Hz)
Low idling
700 – 725 rpm 700 – 900 —
speed
Flywheel 232 kW/1,900 rpm (Net) 1,730 – 1,820
1,895 – 1,905
horsepower {320 HP/1,900 rpm} (Net) {176 – 186}
Maximum 1,610 Nm/1,250 rpm (Net) 2,250 – 2,380
1,150 – 1,350
torque {164 kgm/ 1,250 rpm} (Net) {229 – 243}
D155AX-5
High idling
2,050 – 2,150 rpm 2,050 – 2,150 —
speed
Low idling
675 – 725 rpm 675 – 725 —
speed
Flywheel 225 kW/2,000 rpm (Gross) 1,650 – 1,750
1,995 – 2,005
horsepower {342 HP/2,000 rpm} (Gross) {168.5 – 178.5}
Maximum 1,490 Nm/1,400 rpm (Gross) 2,020 – 2,150
1,300 – 1,500
D155C-1 torque {152 kgm/1,400 rpm} (Gross) {206 – 219}
(–30°C spec.) High idling
2,190 – 2,290 rpm 2,190 – 2,290 —
speed
Low idling
700 – 750 rpm 700 – 750 —
speed
SA6D140-2
Flywheel 225 kW/2,000 rpm (Gross) 1,650 – 1,750
1,995 – 2,005
horsepower {342 HP/2,000 rpm} (Gross) {168.5 – 178.5}
Maximum 1,490 Nm/1,400 rpm (Gross) 2,020 – 2,150
1,300 – 1,500
D155C-1 torque {152 kgm/1,400 rpm} (Gross) {206 – 219}
2,190 – 2,290 rpm 2,190 – 2,290 —
speed
Low idling
700 – 750 rpm 700 – 750 —
speed
1,995 – 2,005
1,300 – 1,500
D355C-3 torque {160 kgm/1,400 rpm} (Net) {222 – 235}
2,200 – 2,280 rpm 2,200 – 2,280 —
speed
Low idling
700 – 750 rpm 700 – 750 —
speed
1,995 – 2,005
1,300 – 1,500
D355C-3 torque {160 kgm/1,400 rpm} (Net) {222 – 235}
2,200 – 2,280 rpm 2,200 – 2,280 —
speed
Low idling
700 – 750 rpm 700 – 750 —
speed
12-36 6D140-2 SERIES

(10)


Torque
(Nm{kgm})
273.6 – 289.8 (Gross, 50 Hz) 290 – 490
— Min. (50 Hz) 70 – 90 90 – 110 Max. 650
{337.3 – 399.6} (Gross, 50 Hz) {3.0 – 5.0}
308.9 – 326.6 (Gross, 60 Hz) 290 – 490
— Min. (60 Hz) 70 – 90 90 – 110 Max. 650
{425.9 – 450.4} (Gross, 60 Hz) {3.0 – 5.0}
— — 70 – 90 90 – 110 — —
— — 70 – 90 80 – 110 Min. 120 {1.2} —
245 – 260 (Gross) 343 – 490

— — 70 – 90 90 – 110 Max. 650
{328 – 348} (Gross) {3.5 – 5.0}
1,608 – 1,706 (Gross)
— — 70 – 90 90 – 110 — Max. 650
{164 – 174} (Gross)
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 120 {1.2} —
248 – 262 (Gross) 340 – 490

— — 70 – 90 90 – 110 Max. 650
{332 – 352} (Gross) {3.5 – 5.0}
1,447 – 1,535 (Gross)
— — 70 – 90 90 – 110 — Max. 650
{147.5 – 156.5} (Gross)
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 180 {1.8} —
248 – 262 (Gross) 340 – 490

— — 70 – 90 90 – 110 Max. 650
{332 – 352} (Gross) {3.5 – 5.0}
1,447 – 1,535 (Gross)
— — 70 – 90 90 – 110 — Max. 650
{147.5 – 156.5} (Gross)
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 180 {1.8} —
269 – 285 (Gross) 340 – 490

— — 70 – 90 90 – 110 Max. 650
{361 – 382} (Gross) {3.5 – 5.0}
1,560 – 1,650 (Gross)
— — 70 – 90 90 – 110 — Max. 680
{159 – 168} (Gross)
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 120 {1.2} —
269 – 285 (Gross) 340 – 490

— — 70 – 90 90 – 110 Max. 650
{361 – 382} (Gross) {3.5 – 5.0}
1,560 – 1,650 (Gross)
— — 70 – 90 90 – 110 — Max. 680
{159 – 168} (Gross)
— — — 70 – 90 90 – 110 — —
— — — 70 – 90 80 – 110 Min. 120 {1.2} —
6D140-2 SERIES 12-37

(10)

machine (N {kg})
Flywheel 379.0 kW/2,000 rpm 2,398 – 2,545

1,995 – 2,005
Maximum 2,167 Nm/1,350 rpm 2,902 – 3,083
HD325-6 1,300 – 1,500
torque {214 kgm/1,350 rpm} {296.0 – 314.4}
HD405-6 High idling
2,300 – 2,450 rpm 2,300 – 2,400 —
speed
Low idling
675 – 775 rpm 675 – 775 —
speed
Flywheel 306.9 kW/2,000 rpm 1,930 – 2,053
1,995 – 2,005
Maximum 1,755 Nm/1,400 rpm 2,351 – 2,487
HD325-6 1,300 – 1,500
torque {179 kgm/1,400 rpm} {239.7 – 253.6}
SAA6D140-2 (High altitude
spec.) High idling
2,350 – 2,450 rpm 2,350 – 2,450 2,350 – 2,450
speed
Low idling
675 – 775 rpm 675 – 775 675 – 775
speed
Flywheel 331.2 kW/1,800 rpm 2,378 – 2,525
1,795 – 1,805
PC750-6 Maximum 2,099 Nm/1,350 rpm 1,508 – 1,601
1,250 – 1,450
torque {214 kgm/1,350 rpm} {153.8 – 163.3}
PC800-6
High idling
1,930 – 2,030 rpm —
PC1800-6 speed
Low idling
800 – 850 rpm —
speed
Flywheel 332 kW/2,000 rpm 2,177 – 2,305
1,995 – 2,005
Maximum 2,030 Nm/1,400 rpm
1,300 – 1,500 Min. 2,834 {289}
D275A-5 torque {207 kgm/1,400 rpm}
2,150 – 2,250 rpm 2,150 – 2,250 —
speed
Low idling
650 – 750 rpm 650 – 750 —
speed
Flywheel
horsepower
Maximum
torque
SDA6D140E-2
High idling
speed
Low idling
speed
Flywheel
horsepower
Maximum
torque
High idling
speed
Low idling
speed
12-38 6D140-2 SERIES

(10)


Torque
(Nm{kgm})
359.9 – 381.7 340 – 490
Min. 11.2 70 – 95 90 – 110 Max. 650
{482.2 – 511.7} {3.5 – 5.0}
2,079 – 2,208
— 70 – 95 90 – 110 — —
{212.0 – 225.2}
— — 70 – 80 90 – 110 — —
— — 70 – 80 Min. 80 Min. 118 {1.2} —
289.6 – 308.0 343 – 490

— Min. 13.5 70 – 85 90 – 110 650
{388.0 – 412.6} {3.5 – 5.0}
1,683 – 1,781
70 – 85 90 – 110 — 700
{171.6 – 181.6}
— 70 – 85 90 – 110 — —
— 70 – 85 90 – 110 Min. 147 {1.5} —
321.3 – 341.1 340 – 490

— Min. 12.3 70 – 95 90 – 110 Max. 650
{430.4 – 457.0} {3.5 – 5.0}
2,036 – 2,161
— 70 – 95 90 – 110 — —
{207.6 – 220.4}
— — 70 – 90 90 – 110 — —
— — 70 – 90 80 – 110 Min. 118 {1.2} —
325 – 345 340 – 490

— Min. 11.8 70 – 90 90 – 110 Max. 650
{436 – 463} {3.5 – 5.0}
340 – 490
Min. 2,030 {207} — 70 – 90 90 – 110 —
{3.5 – 5.0}
340 – 490
— — 70 – 90 90 – 110 —
{3.5 – 5.0}
— — 70 – 90 80 – 110 Min. 118 {1.2} —
6D140-2 SERIES 12-39

(10)
Troubleshooting
Points to remember when troubleshooting.................................................................................................. 12- 43

Method of using troubleshooting charts ...................................................................................................... 12- 44
S-1 Starting performance is poor (starting always takes time) ................................................................ 12- 48
S-2 Engine does not start ........................................................................................................................ 12- 49
S-3 Engine does not pick up smoothly (follow-up is poor)....................................................................... 12- 52
S-4 Engine stops during operations ........................................................................................................ 12- 53
S-5 Engine does not rotate smoothly (hunting) ....................................................................................... 12- 54
S-6 Engine lacks output (no power) ........................................................................................................ 12- 55
S-7 Exhaust smoke is black (incomplete combustion) ............................................................................ 12- 56
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................................. 12- 57
S-9 Oil becomes contaminated quickly ................................................................................................... 12- 58
S-10 Fuel consumption is excessive ......................................................................................................... 12- 59
S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 12- 60
S-12 Oil pressure caution lamp lights up (drop in oil pressure)................................................................. 12- 61
S-13 Oil level rises (water, fuel in oil) ........................................................................................................ 12- 62
S-14 Water temperature becomes too high (overheating) ........................................................................ 12- 63
S-15 Abnormal noise is made .................................................................................................................... 12- 64
S-16 Vibration is excessive ....................................................................................................................... 12- 65
Testing and adjusting tool list ...................................................................................................................... 12- 67
Testing and adjusting data .......................................................................................................................... 12- 68
6D140-2 SERIES 12-41

(10)
Troubleshooting
k 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.
k When carrying out operations with two or more workers, always use signals, and do not allow any
unauthorized person near the machine.
k 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.
k Be extremely careful not to touch any hot parts.
k Be extremely careful not to get caught in the fan or any other rotating parts.
k 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 6D140-2 SERIES

(10)
Troubleshooting Points to remember when troubleshooting
Points to remember when troubleshooting

Troubleshooting means locating the basic cause of the failure, and carrying out swift repairs, and ensuring that
the failure does not occur again.
When carrying out troubleshooting, it is of course important to understand the structure and function. But to
carry out the troubleshooting effectively, a quick method is to carry out troubleshooting using the problems men-
tioned by the operator as a guide in locating the cause.
1. Do not disassemble the machine simply 4. Confirming failure

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

1) Check the oil level.
2) Check for any external leakage of oil from
the piping and hydraulic equipment.
3) Check the travel of the control levers.
4) Other maintenance items can also be
carried out visually, so carry out any check
that is considered necessary.
6D140-2 SERIES 12-43

(10)
Troubleshooting Method of using troubleshooting charts
Method of using troubleshooting charts

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in [B] are items that can be
obtained from the user, depending on the user's
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under [C] in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting] Causes
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].
(1) (2) (3)
(a)
Questions
[A] (b)
(c)
(d)
[B]
(e)
Check items
[C]
i
shooting
Trouble-
ii
iii
12-44 6D140-2 SERIES

(10)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
*1. For [Confirm recent repair history] in
the [Questions] Section, ask the user,
and mark the Cause column with E to Causes
use as reference for locating the cause
n)
of the failure. However, do not use this
jectio
when making calculations to narrow
el in
down the causes.
e fu
*2. Use the E in the Cause column as ref-
siv
erence for [Degree of use (Operated
zzle
xces
nce
for long period)] in the [Questions]
n no
p (e
fere
section as reference. As a rule, do not
g
t
jectio
n
timin
pum
leme
inter
r
use it when calculating the points for
linde
uel in
tion
ction
er e
locating the cause, but it can be
ger,
g, cy
injec
lean
ed f
l inje
included if necessary to determine the
char
in
, seiz
fuel
r
air c
order for troubleshooting.
r fue
urbo
ton
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
*1 Confirm recent repair history
*2 Degree of use Operated for long period
6D140-2 SERIES 12-45

(10)
• Example of troubleshooting when exhaust gas is black

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

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
12-46 6D140-2 SERIES

(10)
6D140-2 SERIES 12-47

(10)
Troubleshooting S-1
S-1 Starting performance is poor (starting always takes time)
a Check that the monitor panel does not display any abnormality in the
governor control system.
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of 10°C or below, use ASTM D975 No. 1)
a Battery charging rate
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
temperature
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
–10°C 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the value for the

charging rate of 70% in the above table.
• In cold areas the specific gravity must exceed the value
for the charging rate of 75% in the above table.
12-48 6D140-2 SERIES

(10)
Troubleshooting S-2
S-2 Engine does not start
6D140-2 SERIES 12-49

(10)
Troubleshooting S-2
(2) Engine turns but no exhaust smoke comes

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

smoke comes out
• Supply of fuel impossible
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
a Standards for use of fuel
12-50 6D140-2 SERIES

(10)
Troubleshooting S-2
(3) Exhaust smoke comes out but engine does

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

but engine does not start
• Lack of rotating force due to defective electrical
system
• Improper selection of fuel and oil
6D140-2 SERIES 12-51

(10)
Troubleshooting S-3
S-3 Engine does not pick up smoothly (follow-up is poor)
a Check that the monitor panel does not display

any abnormality in the governor control system.
General causes why engine does not pick up
smoothly
• Improper fuel used
12-52 6D140-2 SERIES

(10)
Troubleshooting S-4
S-4 Engine stops during operations
General causes why engine stops during operations

• Seized parts inside engine
• Overheating
a If there is overheating and insufficient out-
put, carry out troubleshooting for overheat-
ing.
• Failure in power train
a If the engine stops because of a failure in
the power train, carry out troubleshooting for
the chassis.
6D140-2 SERIES 12-53

(10)
Troubleshooting S-5
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate

smoothly
• Air in fuel system
• Defective governor mechanism
• Defective electric governor mechanism
a If hunting does not occur when the rod
between the governor motor and the injec-
tion pump is disconnected, troubleshoot by
using the electrical system troubleshooting
(E mode).
12-54 6D140-2 SERIES

(10)
Troubleshooting S-6
S-6 Engine lacks output (no power)
General causes why engine lacks output

• Improper fuel used
(if non-specified fuel is used, output drops)
• Lack of output due to overheating
a If there is overheating and insufficient out-
put, carry out troubleshooting for overheat-
ing.
6D140-2 SERIES 12-55

(10)
Troubleshooting S-7
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

12-56 6D140-2 SERIES

(10)
Troubleshooting S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
a Do not run the engine at idling for more than 20

minutes continuously. (Both low and high idling)
General causes why oil consumption is excessive
• Abnormal combustion of oil
• External leakage of oil
• Wear of lubrication system
6D140-2 SERIES 12-57

(10)
Troubleshooting S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

• Intake of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
12-58 6D140-2 SERIES

(10)
Troubleshooting S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

• Leakage of fuel
6D140-2 SERIES 12-59

(10)
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 6D140-2 SERIES

(10)
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure lamp lights up

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection
6D140-2 SERIES 12-61

(10)
S-13 Oil level rises (water, fuel in oil)
a If there is oil in the cooling water, carry out

troubleshooting for "Oil is in cooling water".
General causes why oil level rises
• Water in oil
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
12-62 6D140-2 SERIES

(10)
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes

too high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Power train oil temperature rises excessively
a Carry out troubleshooting for chassis.
6D140-2 SERIES 12-63

(10)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an

external noise.
General causes why abnormal noise is made
• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
12-64 6D140-2 SERIES

(10)
S-16 Vibration is excessive
a If there is abnormal noise together with the

vibration, carry out troubleshooting for "Abnor-
mal noise is made".
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment
• Abnormal combustion
6D140-2 SERIES 12-65

(10)
Troubleshooting Testing and adjusting tool list
Testing and adjusting tool list
No. Testing and measuring item Part No. Fault finding tool Remarks
Digital reading: L: 60 – 2,000 rpm

1 Engine speed 799-203-8000 Multi-tachometer
H: 60 – 20,000 rpm
2 Battery S.G. 1.100 – 1.300

795-500-1001 Battery coolant tester
Freezing temperature of
3 –5 – –50ºC
cooling water
Water temperature, Digital temperature

799-101-6000 – 50 – 1,200°C
oil temperature, gauge
4
air intake temperature, Thermistor temperature 0 – 200°C
exhaust temperature 790-500-1300
gauge 0 – 1,000ºC
5 Lubrication oil pressure 0 – 1 MPa {0 – 10 kg/cm2}
6 Fuel pressure 0 – 2 MPa {0 – 20 kg/cm2}
Intake pressure, Engine pressure

7 799-203-2002 0 – 200 MPa {0 – 1,500 mmHg}
exhaust pressure measuring kit
8 Blow-by pressure 0 – 9.8 kPa {0 – 1,000 mmH2O}
9 Intake resistance –9.8 – 0 kPa {–1,000 – 0 mmH2O}
795-502-1205 Compression gauge 0 – 0.69 MPa {0 – 70 kg/cm2}

10 Compression pressure
• 795-502-1510 • Adapter
11 Blow-by pressure 799-201-1504 Blow-by checker 0 – 4.9 kPa {0 – 500 mmH2O}
12 Valve clearance 795-125-1210 Feeler gauge 0.43, 0.80 mm
Dirtiness 0 – 70% with standard color

13 Exhaust gas color 799-201-9000 Handy smoke checker
(Dirtiness % × 1/10 Bosch scale)
Provided with 0.1 and 0.2 water content
14 Water and fuel content in oil 799-201-6000 Engine oil checker
standard sample
15 Fuel injection pressure

Commercially
Nozzle tester 0 – 29.4 MPa {0 – 300 kg/cm2}
Fuel injection nozzle spray available
16
condition
17 Coolant quality 799-202-7001 Water quality tester PH, nitrite ion concentration
18 Pressure valve function

799-202-9001 Radiator cap tester 0 – 0.2 MPa {0 – 2 kg/cm2}
19 Leakage in cooling system
Commercially
20 Electrical circuit Tester Current, Voltage, Resistance
available
Diagnosis of engine controller
21 799-606-9100 Governor checker
system
6D140-2 SERIES 12-67

(10)
Troubleshooting Testing and adjusting data
Testing and adjusting data
Engine model S6D140-2
Applicable machine model GD825A-2 WA500-3
Cate- Standard Permissible Standard Permissible

Item Measurement conditions Unit
gory value value value value
High idling speed rpm 2,300 – 2,400 2,300 – 2,400 2,300 – 2,400 2,300 – 2,400
Performance
Engine speed
Low idling speed rpm 650 – 700 650 – 700 700 – 750 700 – 750
0ºC (without starting aid) rpm Min. 110 — Min. 110 —
Necessary starting speed
–20ºC (with starting aid) rpm Min. 85 — Min. 85 —
kPa Max. 2.94 7.50 Max. 2.94 7.50
Intake resistance At all speed
{mmH2O} {Max. 300} {762} {Max. 300} {762}
kPa Min.70.6 56.0 Min. 85.4 68.0
Boost pressure At rated flywheel horsepower
{mmHg} {Min. 530} {420} {Min. 640} {510}
Exhaust pressure kPa Min. 61.3 49.3 Min. 72.0 57.3
Intake, exhaust system
At rated flywheel horsepower

(Turbine inlet press.) {mmHg} {Min. 460} {370} {Min. 540} {430}
Exhaust temperature
All speed (20ºC) ºC 700 700 650 700
(Turbine inlet temp.)
Quick acceleration
Max. 6.0 8.0 Max. 6.0 8.0
(Low idle o high idle)
Bosch
Exhaust gas color
At rated flywheel horsepower index Max. 1.5 2.5 Max. 1.0 2.5
High idling speed Max. 1.0 2.0 Max. 1.0 2.0
Valve clearance Intake valve mm 0.43 — 0.43 —

(When engine is hot or cold) Exhaust valve mm 0.80 — 0.80 —
Compression pressure Oil temperature: 40 – 60ºC MPa Min. 3.82 2.65 Min. 3.82 2.65
(SAE30 or SAE 15W-40) (Engine speed: 200 – 250 rpm) {kg/cm2} {Min. 39} {27} {Min. 39} {27}
Engine
proper
Blow-by pressure At rated flywheel horsepower kPa Max. 0.98 1.96 Max. 1.47 2.94
(SAE30 or SAE 15W-40) (Water temp: Min. 70ºC) {mmH2O} {Max. 100} {200} {Max. 150} {300}
At rated flywheel horsepower kPa 340 – 490 206 340 – 490 206
SAE30 or SAE15W-40 oil {kg/cm2} {3.5 – 5.0} {2.1} {3.5 – 5.0} {2.1}
kPa 290 – 441 177 290 – 441 177
Oil pressure SAE 10W oil
{kg/cm2} {3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8}
Lubrication system
(Oil temperature:
Min. 80ºC) At low idling kPa Min. 118 69 Min. 118 69
SAE30 or SAE15W-40 oil {kg/cm2} {Min. 1.2} {0.7} {Min. 1.2} {0.7}
kPa Min. 98 69 Min. 98 69
SAE 10W oil
{kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}
Oil temperature All speed (Oil in oil pan) ºC 90 – 110 120 90 – 110 120
At continuous rated horsepower
Oil consumption ratio % Max. 0.5 1.0 Max. 0.5 1.0
(Ratio to fuel consumption)
MPa 25.0 – 25.8 20.2 25.0 – 25.8 20.2
Fuel injection pressure Nozzle tester
{kg/cm2}
Fuel
{255 – 263} {206} {255 – 263} {206}

Fuel injection timing B.T.D.C. degree 15 – 17 15 – 17 15 – 17 15 – 17
Opening pressure MPa
Radiator pressure valve — — — —
(Differential pressure) {kg/cm2}
Cooling
Fan speed At rated engine speed rpm 1,640 – 1,720 1,640 – 1,720 1,106 – 1,174 1,106 – 1,174
Deflects when pushed with a 13 – 15 *1 13 – 15 *1
Fan belt tension mm 8 – 12 8 – 12
force of 59 N {6 kg} 17 – 19 *2 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 6D140-2 SERIES

(10)
S6D140-2
Standard Permissible Standard Permissible Standard Permissible Standard Permissible

value value value value value value value value
6D140-2 SERIES 12-69

(10)
Applicable machine model D155A-2 D155A-3, D155AX-3

Performance
Engine speed
kPa Max. 2.94 7.50 Max. 2.94 7.50
{mmH2O} {Max. 300} {762} {Max. 300} {762}
kPa Max. 85.4 68.0
Boost pressure At rated flywheel horsepower
{mmHg} {Min. 640} {510}
Exhaust pressure kPa Min. 74.7 60.0
At rated flywheel horsepower

(Turbine inlet press.) {mmHg} {Min. 560} {450}
Exhaust temperature
All speed (20ºC) ºC Max. 650 700 Max. 680 700
Quick acceleration
Max.6.0 8.0 Max. 6.0 8.0
Bosch
Exhaust gas color

Engine
proper
kPa 290 – 440 176 290 – 441 177
{kg/cm2} {3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8}
Lubrication system
(Oil temperature:
kPa Min. 98 68 Min. 98 69
SAE 10W oil
{kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}
MPa 25.0 – 25.8 20.2 24.0 – 25.8 20.2
{kg/cm2} {255 – 263} {206} {245 – 263} {206}
Fuel
Fuel injection timing B.T.D.C. degree 14.5 – 15.5 — 26 – 28 26 – 28
Opening pressure kPa

Cooling
Fan speed At rated engine speed rpm 1,165 – 1,235 1,165 – 1,235 1,255 – 1,335 1,255 – 1,335
Deflects when pushed with a

Fan belt tension mm Auto-tensioner — Auto-tensioner Auto-tensioner
force of 59 N {6 kg}
*: Figures of boost pressure and exhaust pressure is indicated at sea level (altitude: 0 m)
12-70 6D140-2 SERIES

(10)
SA6D140-2
DCA400SSK-2
D155AX-5 D355C-3 PC1600SP-1
(DENYO generator)
Max. 1,568 50Hz Max. 1,568 50Hz
2,050 – 2,150 2,050 – 2,150 2,200 – 2,280 2,200 – 2,280 1,930 – 2,030 1,930 – 2,030
Max. 1,881 60Hz Max. 1,881 60Hz
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 7.47 Max. 2.94 7.47 Max. 2.94 7.50 Max. 2.94 7.50
{Max. 300} {762} {Max. 300} {762} {Max. 300} {762} {Max. 300} {762}
Min. 85 66.5 Min. 160 128 Min. 117.4 93.4 Min. 160 128
{Min. 640} {500} {Min. 1,200} {960} {Min. 880} {700} {Min. 1,200} {960}
Min. 74 59.9 Min. 120 96.0 Min. 102.7 82.7 Min. 120 96.0
{Min. 560} {450} {Min. 900} {720} {Min.770} {620} {Min. 900} {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 2.7 Min. 3.80 2.7 Min. 3.82 2.65 Min. 3.82 2.65
{Min. 39} {27} {Min. 39} {27} {Min. 39} {27} {Min. 39} {27}
Max. 0.98 1.96 Max. 0.98 1.96 Max. 1.96 3.92 Max. 1.96 3.92
{Max. 100} {200} {Max. 100} {200} {Max. 200} {400} {Max. 200} {400}
340 – 490 210 340 – 490 210 340 – 490 177 275 – 441 192
{3.5 – 5.0} {2.1} {3.5 – 5.0} {2.1} {3.5 – 5.0} {1.8} {2.8 – 4.5} {2.0}
290 – 440 176 290 – 440 176 290 – 441 137 226 – 392 157
{3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8} {3.0 – 4.5} {1.4} {2.3 – 4.0} {1.6}
Min. 118 78 Min. 118 78 Min. 118 69 Min. 177 69
{Min. 1.2} {0.8} {Min. 1.2} {0.8} {Min. 1.2} {0.7} {Min. 1.8} {0.7}
Min. 98 68 Min. 98 68 Min. 98 69 Min. 98 69
{Min. 1.0} {0.7} {Min. 1.0} {0.7} {Min. 1.0} {0.7} {Min. 1.0} {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 20.2 25.0 – 25.8 20.2 24.8 – 25.5 20.2 25.0 – 25.8 20.2
{253 – 260} {206} {255 – 263} {206} {253 – 260} {206} {255 – 263} {206}
14.5 – 15.5 50Hz 14.5 – 15.5 50Hz
14 – 16 — 18.5 – 19.5 — 18 – 20 18 – 20
16.5 – 17.5 60Hz 16.5 – 17.5 60Hz
59 – 78
— — — — — —
{0.6 – 0.8}
1,106 – 1,174 50Hz 1,106 – 1,174 50Hz
1,390 – 1,470 — 970 – 1,030 970 – 1,030 1,025 – 1,085 1,025 – 1,085 1,327 – 1,409 60Hz 1,327 – 1,409 60Hz
Auto-tensioner Auto-tensioner — Auto-tensioner Auto-tensioner 8 – 12 8 – 12
6D140-2 SERIES 12-71

(10)
DCA-400SSK J6D140E-G1-2
Applicable machine model
(MQ generator) (TAIYO DENKI generator)
Max. 1,575 50Hz Max. 1,575 50Hz
High idling speed rpm Max. 1,890 60Hz Max. 1,890 60Hz
Max. 1,890 60Hz Max. 1,890 60Hz
Performance
Engine speed
Low idling speed rpm 800 – 850 700 – 900 700 – 900
kPa Max. 2.94 7.47 Max. 2.94 7.47
{mmH2O} {Max. 300} {762} {Max. 300} {762}
kPa Max. 160 128
Boost pressure At rated flywheel horsepower — —
{mmHg} {Min. 1,200} {960}
Exhaust pressure kPa Min. 120 96
At rated flywheel horsepower — —

(Turbine inlet press.) {mmHg} {Min. 900} {720}
Exhaust temperature
Quick acceleration
— — — —
Bosch
Exhaust gas color

Engine
proper
kPa 245 – 440 176 245 – 440 176
{kg/cm2} {2.5 – 4.5} {1.8} {2.5 – 4.5} {1.8}
Lubrication system
(Oil temperature:
kPa Min. 98 68 Min. 98 68
SAE 10W oil
{kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}
MPa 25.0 – 25.8 20.2 25.0 – 25.8 20.2
{kg/cm2} {255 – 263} {206} {255 – 263} {206}
Fuel
16 – 18 50Hz 16 – 18 50Hz
Fuel injection timing B.T.D.C. degree 16.5 – 17.5 —
17 – 19 60Hz 17 – 19 60Hz
Radiator pressure valve — —
Cooling
1,330 – 1,410 1,330 – 1,410 1,220 – 1,300 50Hz 1,220 – 1,300 50Hz
Fan speed At rated engine speed rpm 1,465 – 1,555 60Hz 1,465 – 1,555 60Hz
(60 Hz) (60 Hz)
Deflects when pushed with a
Fan belt tension mm 8 – 12 14 – 18 8 – 12 8 – 12
force of 60 N {6 kg}
12-72 6D140-2 SERIES

(10)
SA6D140-2
D155C-1 (–30°C spec.) D155C-1 (–50°C spec.) D355C-3 (–30°C spec.) D355C-3 (–50°C spec.)

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 7.47 Max. 2.94 7.47 Max. 2.94 7.47 Max. 2.94 7.47
{Max. 300} {762} {Max. 300} {762} {Max. 300} {762} {Max. 300} {762}
Min. 99 83 Min. 99 83 Min. 160 128 Min. 160 128
{Min. 740} {620} {Min. 740} {620} {Min. 1,200} {960} {Min. 1,200} {960}
Min. 84 71 Min. 84 71 Min. 120 96.0 Min. 120 96.0
{Min. 630} {530} {Min. 630} {530} {Min. 900} {720} {Min. 900} {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 2.7 Min. 3.80 2.7 Min. 3.80 2.7 Min. 3.80 2.7
{Min. 39} {27} {Min. 39} {27} {Min. 39} {27} {Min. 39} {27}
Max. 0.98 1.96 Max. 0.98 1.96 Max. 0.98 1.96 Max. 0.98 1.96
{Max. 100} {200} {Max. 100} {200} {Max. 100} {200} {Max. 100} {200}
340 – 490 210 340 – 490 210 340 – 490 210 340 – 490 210
{3.5 – 5.0} {2.1} {3.5 – 5.0} {2.1} {3.5 – 5.0} {2.1} {3.5 – 5.0} {2.1}
290 – 440 176 290 – 440 176 290 – 440 176 290 – 440 176
{3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8}
Min. 118 78 Min. 118 78 Min. 118 78 Min. 118 78
{Min. 1.2} {0.8} {Min. 1.2} {0.8} {Min. 1.2} {0.8} {Min. 1.2} {0.8}
Min. 98 68 Min. 98 68 Min. 98 68 Min. 98 68
{Min. 1.0} {0.7} {Min. 1.0} {0.7} {Min. 1.0} {0.7} {Min. 1.0} {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 20.2 24.8 – 25.5 20.2 25.0 – 25.8 20.2 25.0 – 25.8 20.2
{253 – 260} {206} {253 – 260} {206} {255 – 263} {206} {255 – 263} {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)
Engine model SAA6D140-2
Applicable machine model PC750-6, PC800-6 HD325-6, HD405-6

Performance
Engine speed
kPa Max. 2.94 7.47 Max. 2.9 7.47
{mmH2O} {Max. 300} {762} {Max. 300} {762}
kPa
Boost pressure At rated output
{mmHg}
Exhaust pressure kPa
At rated output
(Turbine inlet press.) {mmHg}
Exhaust temperature
Quick acceleration
Max.6.0 7.0 Max. 6.0 7.0
Bosch
Exhaust gas color
At rated output index Max. 1.0 2.0 Max. 1.0 2.0
High idling Max. 1.0 2.0 Max. 1.0 2.0

Engine
body
Blow-by pressure At rated output kPa Max. 1.96 3.92 Max. 1.96 3.92
(SAE30 or SAE 15W-40) (Water temp: 70ºC min.) {mmH2O} {Max. 200} {400} {Max. 200} {400}
At rated output kPa 340 – 490 210 340 – 490 210
kPa 290 – 440 180 290 – 440 180
{kg/cm2} {3.0 – 4.5} {1.8} {3.0 – 4.5} {1.8}
Lubrication system
(Oil temperature:
80ºC min.) At low idling kPa Min. 118 69 Min. 118 78
kPa Min. 98 69 Min. 98 69
SAE 10W oil
{kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}
At continuous rated output
MPa 24.8 – 25.5 20.2 24.8 – 25.5 20.2
{kg/cm2}
system
{253 – 260} {206} {253 – 260} {206}

Fuel
Fuel injection timing B.T.D.C. degree 18.5 – 19.5 18.5 – 19.5 19.5 – 20.5 19.5 – 20.5

Cooling
system
Fan speed At rated engine speed rpm 1,018 – 1,082 1,018 – 1,082
Deflects when pushed with a (Autotensioner) (Autotensioner)
Fan belt tension mm — —
force of 58.8 N {6 kg} — —
12-74 6D140-2 SERIES

(10)
SAA6D140-2 SDA6D140E-2
HD325-6 (High altitude spec.)

2,350 – 2,450 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 7.50 Max. 2.94 7.50
{Max. 300} {762} {Max. 300} {762}
Min. 97.4 77.3 Min. 118.6 98.6
{Min. 730} {580} {Min. 890} {740}
Min. 97.4 77.3 Min. 113.3 94.7
{Min. 730} {580} {Min. 850} {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 2.65 Min. 3.14 2.16
{Min. 39} {27} {Min. 32} {22}
Max. 1.96 3.92 Max. 1.47 2.94
{Max. 200} {400} {Max. 150} {300}
343 – 490 245 290 – 490 200
{3.5 – 5.0} {2.5} {3.0 – 5.0} {2.0}
294 – 441 206 250 – 440 180
{3.0 – 4.5} {2.1} {2.5 – 4.5} {1.8}
Min. 147 69 Min. 100 70
{Min. 1.5} {0.7} {Min. 1.0} {0.7}
Min. 98 69 Min. 100 70
{Min. 1.0} {0.7} {Min. 1.0} {0.7}
90 – 110 120 80 – 110 120
Max. 0.5 1.0 Max. 0.5 1.0
25.0 – 25.8 20.2 25.0 – 25.8 20.2

{255 – 263} {206} {255 – 263} {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 12-75

(10)
14 Maintenance standard

Turbocharger ............................................ 14- 2
Engine body
Cylinder head ........................................... 14- 6
Valve, valve guide .................................... 14- 8
Rocker arm and shaft ............................... 14- 10
Crosshead and guide ............................... 14- 11
Cylinder block........................................... 14- 12
Cylinder liner ............................................ 14- 13
Crankshaft ................................................ 14- 14
Camshaft .................................................. 14- 15
Cam follower and push rod ...................... 14- 16
Timing gear .............................................. 14- 18
Piston ....................................................... 14- 20
Connecting rod ......................................... 14- 22
Flywheel and flywheel housing................. 14- 23
Lubrication system
Oil pump ................................................... 14- 24
Regulator valve, piston cooling valve
and safety valve................................ 14- 26
Oil cooler .................................................. 14- 27
Cooling system
Water pump.............................................. 14- 28
Thermostat ............................................... 14- 31
6D140-2 SERIES 14-1

(10)
Maintenance standard Intake and exhaust system

Turbocharger
KTR110
S6D140-2
SA6D140-2
SAA6D140-2
14-2 6D140-2 SERIES

(10)
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit Replace

1 End play
0.08 – 0.13 0.18 parts
Replace
2 Radial play 0.25 – 0.44 0.60
parts
Standard Tolerance Repair limit

Outside diameter or journal
bearing. size Shaft Hole Shaft Hole
3
Inner diameter of center
–0.050 +0.021
housing. 25 24.92 25.03
–0.067 +0.021
Inner diameter of journal
bearing. –0.032 +0.009
17 16.95 17.04
4 Outside diameter of wheel –0.043 –0.003
shaft.
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout) Replace
size Shaft Hole Shaft Hole
5 Thickness of thrust bearing
–0.08 +0.02
5 4.86 5.04
–0.11 +0.02
Turbine –0.08 –0.03
2.3 2.15 2.35
Thickness of side –0.10 –0.04
6
seal ring Blower –0.08 –0.03
2 1.85 2.05
side –0.10 –0.04
Clearance between blower Replace
7 Tolerance (min.): 0.20
housing and impeller parts
6D140-2 SERIES 14-3

(10)
KTR110L
SDA6D140E-2 (D275A-5, –50°C spec.)
14-4 6D140-2 SERIES

(10)
Unit: mm
Standard Repair limit Replace parts

End play
1 related to
(Play in axial direction) 0.08 – 0.13 0.18 thrust
Replace parts
Radial play
2 0.25 – 0.44 0.60 related to
(Play in radial direction)
bearing

Outside diameter or journal
bearing. size Shaft Hole Shaft Hole
3
Inner diameter of center
–0.050 +0.021
housing. 25 24.92 25.03
–0.067 +0.021
Inner diameter of journal
bearing. –0.032 +0.009
17 16.95 17.04
4 Outside diameter of wheel –0.043 –0.003
shaft
Bend of wheel shaft Repair limit: 0.010 (Total indicated runout) Replace
size Shaft Hole Shaft Hole
5 Thickness of thrust bearing
–0.08 +0.02
5 4.86 5.04
–0.11 +0.02
Turbine –0.08 –0.03
2.3 2.15 2.35
Thickness of side –0.10 –0.04
6
seal ring Blower –0.08 –0.03
2 1.85 2.05
side –0.10 –0.04
Clearance between blower Replace
7 Tolerance (min.): 0.20
housing and impeller parts
6D140-2 SERIES 14-5

(10)
Maintenance standard Engine body
Engine body
Cylinder head
14-6 6D140-2 SERIES

(10)
Unit: mm
Standard Repair limit Repair by

Distortion of cylinder head
1 grinding or
mounting surface 0 – 0.06 0.09 replace
Engine Standard
Replace
6D140-2 4.8 – 5.6
2 Protrusion of nozzle nozzle or
S6D140-2, SA6D140-2, cylinder head
4.8 – 5.6
SAA6D140-2
Target Range
Bolt No. Order
(Nm {kgm}) (Nm {kgm})
137 – 157
1st step 147 {15}
{14 – 16}
Tightening torque of cylinder Tighten in
head mounting bolt (Coat the 211 – 221 sequence as
3 (1) – (6) 2nd step 216 {22}
thread areas with molybde- {21.5 – 22.5} indicated
num disulfide or engine oil) above
Retighten with
3rd step 90° – 120°
90 °
58.8 – 73.6
(7) — 68.6 {7}
{6 – 7.5}
Tightening torque of nozzle Target (Nm {kgm}) Range (Nm {kgm})

4
holder mounting bolt 66.7 {6.8} 58.8 – 73.6 {6 – 7.5}
Tightening torque of fuel inlet
5 37.3 {3.8} 34.3 – 40.2 {3.5 – 4.1}
connector
Retighten
Tightening torque of
6 39.2 {4} 34.3 – 44.1 {3.5 – 4.5}
connector pipe locknut
Tightening torque of cylinder
7 4.9 {0.5} 3.9 – 5.9 {0.4 – 0.6}
head cover mounting bolt
6D140-2 SERIES 14-7

(10)
Valve, valve guide
14-8 6D140-2 SERIES

(10)
Unit: mm
Valve Standard size Tolerance Repair limit

Replace valve
1 Amount of valve sinking Intake valve 0 ±0.10 0.70
or valve seat
Exhaust valve 0 ±0.10 0.70
Valve Standard size Repair limit
2 Thickness of valve lip Intake valve 2.4 1.9 Replace valve
Exhaust valve 2.15 1.75
Valve Standard size Tolerance
Repair or
3 Valve seat angle Intake valve 30° ±0°15' replace valve
and valve seat
Exhaust valve 45° ±0°15'
–0.045
Intake valve 10
Outside diameter of valve –0.060
Replace valve
stem –0.075
Exhaust valve 10
–0.090
+0.019
Before inserting 10
+0.001 Replace valve
Inside diameter of valve guide
4 +0.019 guide
After inserting 10
–0.020
Valve Standard clearance Clearance limit
Clearance between valve Replace valve
Intake valve 0.029 – 0.084 0.22
guide and valve stem or valve guide
Exhaust valve 0.065 – 0.100 0.24
Bend of valve stem Repair limit: 0.02 (Total indicated runout, for 100) Replace valve
Standard size Tolerance
5 Protrusion of valve guide Repair
23 ±0.2
Spring Standard size Repair limit
Free length of valve spring Large * 82.2
1
* 81.7
2
—
Small *1 65.5 *2 72.0 —
Installed Standard installed Installed load limit
Spring
length load (N {kg}) (N {kg})
Replace valve
6
*1 *2 *1 *2 spring
Large 51.0 474±23.5 424.3±21.6 450.8 377.3
Installed load of valve spring
{48.4±2.4} {43.3±2.2} {46.0} {38.5}
*1 *2 *1 *2
Small 43.6 231.3±11.8 215.6±10.8 207.8 192.1
{23.6±1.2} {22.0±1.1} {21.2} {19.6}
Squarence of valve spring Repair limit: 2° (for both end)
Note 1: Valve springs marked with *1 have a regular pitch.

Note 2: Valve springs marked with *2 have an irregular pitch.
6D140-2 SERIES 14-9

(10)
Rocker arm and shaft
Unit: mm
Standard size Tolerance Replace

Outside diameter of rocker
rocker arm
arm shaft 32.0 ±0.0065 shaft
Inside diameter of rocker arm +0.087 Replace
32.0
1 bushing +0.035 rocker arm
Standard clearance Clearance limit Replace

Clearance between rocker
rocker arm or
arm shaft and rocker arm
rocker arm
bushing 0.0285 – 0.0935 0.13 shaft
Valve Standard size Tolerance
Valve clearance
2 Intake 0.43 ±0.02 Adjust
(When engine is hot or cold)
Exhaust 0.80 ±0.02
Tightening torque of rocker Target (Nm {kgm}) Range (Nm {kgm})

3 Retighten
arm adjustment screw locknut 58.8 53.0 – 64.7 {5.4 – 6.6}
14-10 6D140-2 SERIES

(10)
Crosshead and guide
Unit: mm
Standard size Tolerance Repair limit

1 Depth of crosshead stem +0.3
3 3.41
+0.3
±0.06 Replace
Inside diameter of crosshead 11 11.17
±0.02
2
Outside diameter of +0.011
11 10.95
crosshead guide +0.011
3 Protrusion of crosshead guide 49.0 ±0.25 — Repair
6D140-2 SERIES 14-11

(10)
Cylinder block
Unit: mm
Standard size Repair limit Repair by

Distortion of cylinder head
1 grinding or
mounting surface 0 – 0.09 0.135 replace
Inside diameter of main Replace main
bearing hole +0.018 bearing cap
127
–0.006
2 –0.010
Thickness of main bearing 3.5
–0.010 Replace main
Roundness of main bearing bearing
Repair limit: 0.005
hole
Inside diameter of main Replace main
3 +0.038
bearing 120 120.15 bearing
–0.006
Repair or
Inside diameter of camshaft +0.030
4 69 — replace
bushing hole +0.030
cylinder block
Inside diameter of camshaft +0.040 Replace cam-
5 65 65.15
bushing +0.030 shaft bushing
Difference of face between Repair by
6 Repair limit: 0.14
cylinder block and front cover reassembling
Order Target (Nm{kgm}) Range (Nm{kgm})
Tightening torque of main 107.9 – 127.5

1st step 117.7 {12}
bearing cap bolt {11 – 13}
7
(Coat thread area with engine 210.8 – 220.7
oil) 2nd step 215.7 {22}
{21.5 – 22.5}
3rd step Retighten with 90° 90 – 120° Retighten
Tightening torque of oil pan Target (Nm {kgm}) Range (Nm{kgm})

8 mounting bolt and under frame
mounting bolt 66.7 {6.8} 58.8 – 73.6 {6 – 7.5}
Tightening torque of crank

9 274.6 {28} 245.2 – 308.9 {25 – 31.5}
pulley mounting bolt
14-12 6D140-2 SERIES

(10)
Cylinder liner
Unit: mm
Replace cylin-
1 Protrusion of cylinder liner Permissible range: 0.07 – 0.15 der liner or
cylinder block
Rank Standard size Tolerance Repair limit
+0.020
Inside diameter of cylinder S 140 140.12
+0.020
liner
2 +0.040
L 140 140.14
+0.021 Replace
cylinder
Roundness of cylinder liner Repair limit: 0.08
liner
Cylindricity of cylinder liner Repair limit: 0.08
Outside diameter of cylinder
liner (Counter bore) –0.10
170.2
–0.10
3
Replace cylin-
Clearance between cylinder
Standard: 0 – 0.163 der liner or
liner and block (Counter bore)
cylinder block
+0.090 cylinder
liner (Counter bore bottom) 161.2
+0.050 liner
4
Standard interference Interference limit Replace cylin-
Interference between
der liner or
cylinder liner and block
cylinder block,
(Counter bore bottom) 0.02 – 0.12 0.02 or repair

cylinder
liner (O-ring) –0.024
158 liner
5 –0.049
Replace cylin-
Clearance between cylinder
Standard: 0.024 – 0.089 der liner or
liner and block (O-ring)
cylinder block
6D140-2 SERIES 14-13

(10)
Crankshaft
Unit: mm
Repair by
Standard size Repair limit using over
1 End play size thrust
0.140 – 0.315 0.50 bearing or
replace
STD 120.00 119.88
Outside diameter of main 0.25 U.S. 119.75 119.63

–0.050 Repair by
journal 0.50 U.S. 119.50 119.38
–0.068 using over
0.75 U.S. 119.25 119.13 size bearing or
2 replace
1.00 U.S. 119.00 118.88
Standard size Repair limit
Roundness of main journal
0 – 0.010 0.020
Standard clearance Clearance limit Replace main
Clearance of main journal
0.044 – 0.106 0.27 bearing

STD 90.00 89.88
Outside diameter of crank pin 0.25 U.S. 89.75 89.63

–0.050 Repair by
journal 0.50 U.S. 89.50 89.38
–0.068 using under
0.75 U.S. 89.25 89.13 size bearing or
3 replace
1.00 U.S. 89.00 88.88
Roundness of crank pin Standard size Repair limit

journal 0 – 0.010 0.020
Clearance of crank pin journal connecting rod
0.042 – 0.110 0.24 bearing
Straightness of all main Standard size Repair limit

Repair by
journals 0 – 0.150 0.20 using under
4
size bearing or
Straightness of two main
0 – 0.050 0.10 replace
journals
14-14 6D140-2 SERIES

(10)
Camshaft
Unit: mm
Standard size Repair limit Replace

1 End play
0.1 – 0.25 0.36 thrust plate

Outside diameter of camshaft Replace
journal –0.016 camshaft
65
–0.036
2
Clearance of camshaft journal camshaft
0.016 – 0.096 0.15 bushing
3 Bend of camshaft Repair limit: 0.03 (Total indicated runout)
Cam Standard size Tolerance Repair limit Replace
4 Cam height Intake 55.48 ±0.1 55.08 camshaft
Exhaust 55.75 ±0.1 55.35
6D140-2 SERIES 14-15

(10)
Cam follower and push rod
Unit: mm

Outside diameter of cam
follower shaft –0.021
22 21.92
1 –0.034
Inside diameter of cam +0.021
22 22.07
follower shaft hole +0.021
+0.05
2 Outside diameter of cam roller 31.7 31.50
+0.02
+0.038
Inside diameter of cam roller 12.7 12.78
+0.013 Replace
3
Outside diameter of cam roller
12.63 ±0.006 12.56
pin
4 Radius of push rod ball end –0.20
12.7
–0.20
Radius of push rod socket –0.20
5 13.4
end –0.20
6 Bend of push rod Repair limit: 0.3 (Total indicated runout)
14-16 6D140-2 SERIES

(10)
Timing gear
14-18 6D140-2 SERIES

(10)
Unit: mm
Measuring Standard Repair

Gears
point size limit
Crankshaft gear and main idler 0.141 –
A
gear (Large) 0.425
Main idler gear (Small) and 0.129 –
B
injection pump drive gear 0.391
Main idler gear (Small) and 0.129 –
C
camshaft gear 0.391
Main idler gear (Large) and sub 0.141 –
a
idler gear 0.426
— Backlash of each gears Replace
Sub idler gear and oil pump drive 0.080 –
b 0.6
gear 0.417
Sub idler gear and water pump 0.095 –
c
drive gear 0.346
Camshaft gear and air 0.118 –
d
compressor drive gear 0.369
Injection pump drive gear and 0.118 –
e
PTO gear (Lower) 0.369
Compressor drive gear and PTO 0.025 –
f
gear (Upper) 0.486
Standard Tolerance Standard Clearance

Engine
size Shaft Hole clearance limit
Clearance between main idler +0.014 +0.085 0.016 –
1 S6D140 47.6 0.20
gear bushing and shaft +0.001 +0.030 0.084
–0.016 +0.055 0.016 – Replace
SA6D140 56 0.20 bushing
–0.029 +0.055 0.084
+0.014 +0.085 0.016 –
S6D140 47.6 0.20
Clearance between sub idler +0.001 +0.030 0.084
2
gear bushing and shaft –0.016 +0.055 0.016 –
SA6D140 56 0.20
–0.029 +0.055 0.084
3 End play of main idler gear
0.05 – 0.17 0.4 Replace
4 End play of sub idler gear 0.05 – 0.17 0.4 thrust
bearing
End play of injection pump
5 0.07 – 0.20 0.4
drive gear
6D140-2 SERIES 14-19

(10)
Piston
14-20 6D140-2 SERIES

(10)
Unit: mm
Rank Standard size Tolerance Repair limit

–0.070
S 140 Replace
1 Outside diameter of piston –0.085
139.81 piston
–0.055
L 140
–0.070
No. Measuring point Standard size Tolerance
–0.015
2 Top ring 2.4
–0.035
Replace
Thickness of piston ring –0.010
3 Second ring 2.41 piston ring
–0.035
–0.010
4 Oil ring 4
–0.030
2 Top ring
Judge using groove wear gauge
3 Second ring Replace
Width of piston ring groove
piston
+0.040
4 Oil ring 4
+0.020
No. Measuring point Standard clearance Clearance limit
2
| 2 Top ring Replace
Clearance between piston ring
Judge using groove wear gauge piston or
4 and ring groove 3 Second ring piston ring
4 Oil ring 0.02 – 0.06 0.14
0.42 – 0.57
(Tension
2 Top ring 2.0
16.5 – 23.5 N
{1.68 – 2.40 kg})
0.65 – 0.80
Replace
(Tension
Piston ring gap 3 Second ring 1.5 piston ring or
16.2 – 24.2 N
cylinder liner
{1.65 – 2.47 kg})
0.37 – 0.52
(Tension
4 Oil ring 1.0
55.9 – 75.5 N
{5.7 – 7.7 kg})
Replace
Outside diameter of piston pin –0.006
52 piston pin
–0.006
5 Inside diameter of piston pin +0.045 Replace

52
hole +0.035 piston

Clearance between piston pin
piston or
and piston 0.035 – 0.051 0.10 piston pin
6D140-2 SERIES 14-21

(10)
Connecting rod
Unit: mm
Inside diameter of bushing at Standard size Tolerance Repair limit Replace bushing
connecting rod small end (New part is sup-
(Treat with reamer after press +0.049 plied as a semi-
52 52.09
fitting bushing) +0.030 finished part)
1
Clearance between bushing at Standard clearance Clearance limit Replace
connecting rod small end and bushing or
piston pin 0.030 – 0.055 0.11 piston pin
Inside diameter of bushing hole
2 +0.030 connecting
at connecting rod small end 57.4
+0.030 rod

Inside diameter of bearing at Replace
3 +0.042
connecting rod big end 90 90.15 bearing
–0.008
Inside diameter of bearing hole
at connecting rod big end Standard size Tolerance Replace
(a Measure after tightening connecting
connecting rod cap bolt +0.026 rod
95
4 with specified torque) –0.004

Thickness of connecting rod Replace
bearing +0.002 bearing
2.5 —
–0.008
Standard Repair
Item
size limit Replace
Parallelism and twist of
5 connecting
connecting rod Parallelism 0 – 0.20 0.25
rod
Twist 0 – 0.30 0.35
Standard size Target (Nm{kgm}) Repair (Nm{kgm})
Tightening torque of connect-
ing rod cap mounting bolt 117.7 – 132.4
6 1st step 127.5 {13} Retighten
(Coat bolt threads and nut {12.5 – 13.5}
seats with engine oil)
2nd step Retighten with 90° 90 – 120°
Permissible range:
— Weight of connecting rod Replace
Variation between weights on the machine max. 154 g
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 6D140-2 SERIES

(10)
Flywheel and flywheel housing
Unit: mm
Face runout of flywheel

1 Repair limit: 0.35
housing
Radial runout of flywheel
2 Repair limit: 0.30 Repair
housing
3 Face runout of flywheel Repair limit: 0.20
4 Radial runout of flywheel Repair limit: 0.15
Target Range
Order Tightening order
Tightening torque of flywheel
housing mounting bolts 191.2 147.1 – 235.4
5 1st step
(Coat thread areas with engine {19.5} {15 – 24}
oil)
274.6 245.2 – 308.9
2nd step
{28.0} {25 – 31.5}
Retighten
Target Range
Order
Tightening torque of flywheel
mounting bolts 117.7 112.8 – 122.6
6 1st step
(Coat thread areas with engine {12} {11.5 – 12.5}
oil)
Retighten
2nd step 90° – 120°
with 90°
6D140-2 SERIES 14-23

(10)
Maintenance standard Lubrication system
Lubrication system
Oil pump
14-24 6D140-2 SERIES

(10)
Unit: mm
Tolerance
Standard Standard Clearance
size Gear Housing clearance limit
1 Axial clearance of pump gear thickness depth
–0.025 +0.067 0.03 –
45 0.10
–0.025 +0.040 0.088
Replace
Tolerance
Standard Standard Clearance
size Gear Housing clearance limit
2 Radial clearance of pump gear O.D. I.D.
–0.15 +0.06 0.033 –
51.4 0.13
–0.21 +0.06 0.10

Clearance between drive shaft size Shaft Hole clearance limit
3
and pump body bushing
+0.106 +0.173 0.040 –
18
+0.088 +0.146 0.085
Clearance between driven +0.090 +0.147 0.032 – Replace
4 18 bushing
shaft and driven gear bushing +0.070 +0.127 0.077
Clearance between driven +0.090 +0.129 0.012 –
5 18
shaft and body +0.070 +0.102 0.059
Clearance between relief –0.040 +0.043 0.040 –
6 16
valve and pump cover –0.060 +0.043 0.103
Standard Tolerance Standard Interference

Interference between drive size Shaft Hole interference limit
7
shaft and oil pump drive gear
+0.106 +0.065 0.023 –
18 —
+0.088 +0.047 0.059
Interference between drive +0.106 +0.063 0.025 –
8 18 —
gear and drive shaft +0.088 +0.028 0.078
Replace
Interference between drive +0.090 +0.021 0.044 –
9 21 —
shaft bushing and pump cover +0.065 +0.021 0.090
Interference between driven +0.090 +0.035 0.030 –
10 21 —
shaft bushing and driven gear +0.065 +0.035 0.090
Interference between driven +0.090 +0.040 0.030 –
11 18 —
shaft and pump cover +0.070 +0.022 0.068
Installed Installed Installed
Free length Free length
12 Main relief valve spring length load load Replace
126.4 N 113.7 N
49.1 32.0
{12.9 kg} {11.6 kg}
13 Main relief valve set pressure Standard: 0.8 ± 0.05 MPa {8.0 ± 0.5 kg/cm2} Replace
6D140-2 SERIES 14-25

(10)
Regulator valve, piston cooling valve and safety valve
Unit: mm

Clearance between regulator size Shaft Hole clearance limit Replace valve
1
valve and body or body
+0.15 +0.28
22 0.07 – 0.16 —
+0.12 +0.22
Installed Installed Installed
Free length Free length
2 Regulator valve spring length load (N{kg}) load (N{kg}) Replace spring
16.1 15.1
83 79 —
{1.64} {1.54}
3 Regulator valve set pressure 0.3 ± 0.02 MPa {3.2 ± 0.2 kg/cm2}
Replace
4 Safety valve set pressure 0.2 ± 0.02 MPa {2.0 ± 0.2 kg/cm2}
14-26 6D140-2 SERIES

(10)
Oil cooler
Unit: mm
Lift of thermostat to fully open Min 8 mm (soak in oil bath at 100°C (116°C) for 4 to 5 minutes to
position check)
1 Valve must fully close when valve is soaked in oil bath for fully Replace
Opening/closing of thermostat open 100°C (116°C) and then soaked in oil bath for fully closed
85°C (110°C) for 4 to 5 minutes.
a The figure in ( ) indicates the thermostat for fully open temperature 116°C.
a There are two types of thermostat for the oil cooler (fully open temperature: 100°C and 116°C). For the
marine engine only the fully open temperature 100°C is applicable; for other models, either type can be used.
6D140-2 SERIES 14-27

(10)
Maintenance standard Cooling system
Cooling system
Water pump
6D140-2
S6D140-2
SA6D140-2
Unit: mm
Tolerance Standard
Standard size
Interference between Shaft Hole interference
1
impeller and shaft
+0.018 –0.020
15.9 0.025 – 0.068
+0.005 –0.050
Interference between drive +0.015 –0.023
2 25 0.025 – 0.068
gear and shaft +0.002 –0.053
Interference between pulley +0.015 –0.023
3 25 0.025 – 0.068
flange and shaft +0.002 –0.053 Replace
Clearance between impeller
4 Standard clearance: 0.30 – 1.0 (Including end play)
and body
Abrasion of seal ring in water Repair limit

5
seal A: 1.5
14-28 6D140-2 SERIES

(10)
S6D140-2
SA6D140-2
SDA6D140E-2 (D275A-5, –50°C spec.)
Unit: mm
Tolerance Standard
Standard size
1
impeller and shaft
–0.082 –0.020
16 0.025 – 0.068
–0.095 –0.150
2 28 0.025 – 0.068
Interference between pulley +0.015 –0.021
3 25 0.025 – 0.056
flange and shaft +0.002 –0.041 Replace
Clearance between impeller
and body

5
seal A: 1.5
6D140-2 SERIES 14-29

(10)
For aftercooler
SDA6D140E-2 (D275A-5, –50°C spec.)
Unit: mm
Tolerance Standard
Standard size
1
impeller and shaft
+0.018 –0.020
15.9 0.025 – 0.068
+0.005 –0.050
2 20 0.025 – 0.068
Clearance between impeller Replace
and body

4
seal A: 1.5
14-30 6D140-2 SERIES

(10)
Thermostat
Unit: mm
Lift of thermostat to fully open

Min. 10 mm (soak in oil bath at 90°C for 4 to 5 minutes to check)
position
1 Valve must fully close when valve is soaked in oil bath for fully Replace
Opening/closing of thermostat open (90°C) and then soaked in oil bath for fully closed (71°C) for
4 to 5 minutes.
6D140-2 SERIES 14-31

(10)
15 Repair and replacement of parts
Table of special tools ..................................... 15- 2
Cylinder head
Grinding of fitting face of cylinder head .... 15- 3
Replacing valve seat insert ...................... 15- 4
Pressure test ............................................ 15- 9
Replacing valve guide .............................. 15- 10
Replacing crosshead guide ...................... 15- 11
Grinding valve .......................................... 15- 12
Cylinder block
Replacing cam bushing ............................ 15- 13
Replacing crankshaft gear........................ 15- 16
Replacing cam gear ................................. 15- 17
Replacing flywheel ring gear .................... 15- 18
Replacing connecting rod small
end bushing ...................................... 15- 19
Cylinder block parts ....................................... 15- 20
Testing and inspecting cylinder block ............ 15- 21
Correcting cylinder block top surface,

counterbore ............................................. 15- 24
Replacing main bearing cap .......................... 15- 32
6D140-2 SERIES 15-1

(10)
Repair and replacement of parts Table of special tools
Table of special tools
Operation Symbol Part No. Part Name Q'ty Remarks
Checking inside diameter of Commercially

J Alignment bar
main bearing mounting hole available
1 79A-513-1710 Basic machine 1
2 79A-513-1780 Guide plate 1
3 79A-513-1820 Cutter plate 1
4 79A-513-1860 Cutter 1
5 79A-513-1940 Cutter set gauge 1
6 79A-513-1950 Micrometer 1
7 79A-513-1960 Driver plate 1
8 79A-513-2090 Driver shaft 1
9 79A-513-2110 Driver handle 1
10 79A-513-2120 Service package 1
Grinding counterbore K
11 79A-513-2130 Case 1
12 79A-513-2140 Basic machine 1
13 79A-513-2160 Cutter plate 1
14 79A-513-2230 Cutter 1
15 79A-513-2240 Remover pin 1
16 79A-513-2250 Case 1
17 79A-513-2260 Service package 1
18 79A-513-2270 Compound 1 Loctite
19 79A-513-2280 Primer 1 Loctite
20 79A-513-2320 Bushing 12
15-2 6D140-2 SERIES

(10)
Repair and replacement of parts Cylinder head
Cylinder head
Grinding of fitting face of
cylinder head
1. Grinding
1) Remove the valve seat insert. See the
section of replacement of the valve seat
insert.
2) Remove the strain and corrosion of the
cylinder head by grinding them within the
allowable limit of the cylinder head height H,
then stamp the letter "R" on the left side of
the cylinder head.
a Cylinder head height H
Basic height: 105 ± 0.05 mm
a Limit after grinding: 104.65 mm
a Grinding height/time: 0.10 – 0.15 mm
a Roughness of ground surface: 6 S max.
a Change of cross level: 0.05 mm max.
a Grinding limit: 0.3 mm
a Height difference among cylinder heads
of each engine: 0.15 max.
3) Fit an oversize insert one rank larger. See
the section of replacing valve seat insert.
2. Check after grinding

Confirm that the sinking distance of the valve is
within the standard range. Grind for adjustment,
if necessary.
a Standard sinking distance of valve:
0 ± 0.1 mm
6D140-2 SERIES 15-3

(10)
Replacing valve seat insert

Special tools
No. Part No. Part Name Q'ty

A 795-100-4800 Puller (valve seat) 1
1 790-101-5001 Push tool (KIT) 1
• Plate
B 2 790-101-5081 (for intake valve) 1
3 790-101-5071 • Plate 1
(for exhaust valve)
795-100-3003 Seat cutter (KIT) 1
795-100-3100 • Body ass'y 1
795-100-3200 • Micrometer 1
1
795-100-3300 • Gauge 1
795-100-3400 • Tool head 1
795-100-3601 • Head support 1
• Cutter (for oversize
C 2 795-100-3710 machining) 1
3 795-100-3720 • Cutter (for 30°) 1

795-100-3730 • Cutter (for 45°) 1
4
795-100-4210 • Pilot (10.000 mm) 1
795-100-4220 • Pilot (10.010 mm) 1
5 795-100-4230 • Pilot (10.020 mm) 1
795-100-4240 • Pilot (10.030 mm) 1
1. Removal of valve seat insert

k When using a grinder to carry out this work, carry
out a test run for one minute before starting the
operation to check that there is no abnormality.
• If the grindstone has been replaced, carry
out the test run 3 minutes.
k Check that there is no damage to the grindstone,

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

1) Install grindstone to grinder .
2) Align the groove of sleeve with holder ,
and insert.
a Adjust the position of the grinder with set
screw .
HEE00081
15-4 6D140-2 SERIES

(10)
3) Adjust the position of the grinder so that the

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

tool A inwards by hand, and fit into insert
(1).
7) Tighten screw to push the three claws
into the groove on the inside face of the
insert.
a When the claws are completely in
contact with the groove, stop tightening.
8) Insert bridge on the outside of the puller
head, set plates and on top of the
bridge, and tighten nut to pull out the
insert.
• When welding a bar to the insert to remove

1) Weld bar (1) (diameter: approx. 10 ø) of a
diameter 0.1 – 0.5 mm smaller than the
inside diameter of the insert to insert (2).
a Be careful not to deposit any of the
welding metal on the head itself.
2) When the temperature of the weld has
dropped to around room temperature, insert
a used valve (3) in the opposite direction,
and hit the face of the valve with a small
hammer to remove the insert.
a Be careful not to hit too hard, as any
excessive shock may cause the weld to
break off.
6D140-2 SERIES 15-5

(10)
2. Press fitting valve seat insert

• When not grinding and correcting press-fit-
ting surface of valve seat insert
1) Using tools B1 and B2, or tools B1 and B3,
press fit standard valve seat insert (2) with a
press.
a Do not use a hammer to press fit.
a Press-fitting force for valve seat insert
Intake side : Approx. 14.7 kN {1.5 ton}
Exhaust side: Approx. 14.7 kN {1.5 ton}
2) Check the insertion depth (h) of the insert

from the bottom surface of the cylinder
head.
a Insertion depth (h) of insert
Intake side : 2.2 mm
Exhaust side: 2.4 mm
15-6 6D140-2 SERIES

(10)
3. Oversize machining of mounting hole for

valve seat insert
1) Using tools C1 and C2, grind the hole to the
one level larger oversize.
a Machine within an oversize range of 1.0
mm. If it is more than 1.0 mm, replace
the cylinder head.
• Method of machining insert and mounting hole
Insert Insert mounting hole

Insert Valve
d h D1 D2 H
Intake 55.0 +0.100

+0.090 8.8 –0.1
–0.1 55.0 +0.019
+0
58.00 ± 0.2 11 –0.1
–0.1
STD
Exhaust 52.0 +0.080
+0.070 8.6 –0.1
–0.1 52.0 +0.019
+0
55.00 ± 0.2 11 –0.1
–0.1
Intake 55.25 +0.100

+0.090 8.8 –0.1
–0.1 55.25 +0.019
+0
58.25 ± 0.2 11 –0.1
–0.1
0.25 O.S.
Exhaust 52.25 +0.080
+0.070 8.6 –0.1
–0.1 52.25 +0.019
+0
55.25 ± 0.2 11 –0.1
–0.1
Intake 55.5 +0.100

+0.090 8.92 –0.1
–0.1 55.5 +0.019
+0
58.50 ± 0.2 11.12 –0.1
–0.1
0.50 O.S.
Exhaust 52.5 +0.080
+0.070 8.72 –0.1
–0.1 52.5 +0.019
+0
55.50 ± 0.2 11.12 –0.1
–0.1
Intake 55.75 +0.100

+0.090 9.05 –0.1
–0.1 55.75 +0.019
+0
58.75 ± 0.2 11.25 –0.1
–0.1
0.75 O.S
Exhaust 52.75 +0.080
+0.070 8.85 –0.1
–0.1 52.75 +0.019
+0
55.75 ± 0.2 11.25 –0.1
–0.1
Intake 56.0 +0.100

+0.090 9.18 –0.1
–0.1 56.0 +0.019
+0
59.00 ± 0.2 11.38 –0.1
–0.1
1.00 O.S
Exhaust 53.0 +0.080
+0.070 8.98 –0.1
–0.1 53.0 +0.019
+0
56.00 ± 0.2 11.38 –0.1
–0.1
a Roughness of inside surface: Within 6.3 S

a Roughness at bottom of mounting hole:
Within 12.5 S
a Concentricity with valve guide inside surface:
Within 0.03 mm (TIR)
6D140-2 SERIES 15-7

(10)
4. Finishing insert seat surface

1) Using tools C1, and C3, and C4, finish the
surface of the insert seat to the dimensions
shown in the diagram below.
a When selecting a pilot C5 to insert into
the valve guide, choose one that gives
no clearance.
• Intake valve
• Exhaust valve
2) Rub the seat surface with compound.
Width of finished face of exhaust valve

insert and width of contact with valve
Unit: mm
Part No. 6210-11-1320 (S.T.D) 6210-11-1321 (S.T.D)
6210-19-1320 (0.25 O.S) 6210-19-1321 (0.25 O.S)
6210-18-1320 (0.50 O.S) 6210-18-1321 (0.50 O.S)
6210-17-1320 (0.75 O.S) 6210-17-1321 (0.75 O.S)
6210-16-1320 (1.00 O.S) 6210-16-1321 (1.00 O.S)
Width of finished surface A: 47.1 B: 1.5 A: 45.7 B: 2.5
Width of contact with valve
C: 1.5 ± 0.2 C: 2.5 ± 0.2
(when using master valve)
5. Finish inspection Unit’ mm

• 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 sur-
face of the new valve as shown in the dia-
gram below, insert it in the valve guide, push
lightly against the valve insert surface, and
rotate 10°. Check that the pencil marks have
been erased uniformly around the whole cir-
cumference.
15-8 6D140-2 SERIES

(10)
Pressure test
• When corrections have been made around the
cylinder head, test the pressure as follows.
Special tools

A 790-553-1600 Coolant tester kit 1
B 79A-471-1050 Pump assembly 1
1. Water pressure test

1) Assemble tool A and tool B, and connect
the hose to flange (1).
2) Apply water pressure (0.34 – 0.39 MPa {3.5
– 4.0 kg/cm2}) for approx. 10 minutes, and
check that there is no leakage from around
the cylinder head.
a When carrying out this test, heat the whole
cylinder head and carry out the test with hot
water (80 – 95°C).
2. Air pressure test

1) Connect the compressor hose to flange (1).
2) Put the head in the container of water, apply
air pressure (0.29 – 0.34 MPa {3.0 – 3.5 kg/
cm 2 }) for approx. 30 seconds, and check
that there is no leakage in the water.
a If the above test shows any cracks around the

plate plugs, replace the cylinder head.
6D140-2 SERIES 15-9

(10)
Replacing valve guide

Special tools

A 795-100-1520 Valve guide remover 1
B 795-130-1710 Valve guide driver 1
1. Removal of valve guide

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

1) Press fit the valve guide until the tip of valve
guide driver B contacts the cylinder head.
2) Measure the protrusion of the valve guide
and check that it is within the standard
range.
a Valve guide protrusion
Tolerance: 23 ± 0.2 mm
15-10 6D140-2 SERIES

(10)
Replacing crosshead guide

Special tools

A 795-140-6410 Crosshead guide puller 1
B 795-130-1310 Crosshead guide driver 1
1. Removal of crosshead guide

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

Using tool B, insert the crosshead guide in the
cylinder head, and use a copper bar or plastic
hammer to press fit until the protrusion is within
the permitted tolerance.
a Protrusion of crosshead guide
Tolerance: 49 ± 0.5 mm
6D140-2 SERIES 15-11

(10)
Grinding valve
Special tool

Commercially
A Valve refacer 1
available
1. Grinding seat face

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

Measure the thickness of the valve head, protru-
sion of the valve and the contact of the valve
seat face to check that they are within the stan-
dard range.
a Thickness of valve head
Intake valve: 2.4 mm
Exhaust valve: 2 mm
a Insertion depth of valve
Standard: 0 ± 0.1 mm
a Contact width of valve
Standard Intake valve: 4.33 mm
Exhaust valve: 3.47 mm
15-12 6D140-2 SERIES

(10)
Repair and replacement of parts Cylinder block
Cylinder block
Replacing cam bushing
Special tools

A 795-213-1200 Push tool 1
1 795-213-1250 Push bar 1
2 795-213-1210 Push tool 1
A 3 795-213-1240 Collar 1
4 795-213-1230 Guide 1
5 792-103-0400 Grip 1
a When replacing the cam bushing, first remove

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

As shown in the diagram, assemble push tool
A2, collar A3, and push bar A1 of push tools A,
then hit the push bar to knock bushing (2) out
from cylinder block (1).
2. Removal of No. 2, 6 bushings

Assemble push bar A1, push tool A2, collar A3,
and guide A4 of push tool A, then hit the push
bar to knock bushing (3) out from cylinder block
(1).
3. Removal of No. 3, 4, 5 bushings

Assemble push bar A1, push tool A2, collar A3,
and guide A4 of push tool A, then hit the push
bar to knock bushing (4) out from cylinder block
(1).
6D140-2 SERIES 15-13

(10)
• After removing the bushing, remove any burrs or

dirt, and clean the mounting hole of the bushing.
a Cam bushing assembly drawing
1. Press fitting No. 3, 4, 5 bushings

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

Assemble bushing (3) to tool A, and press fit the
bushing until the oil hole of cylinder clock (1)
matches the oil hole of the bushing.
3. Press fitting No. 1, 7 bushings

• Assemble bushing (2) to tool A, and press fit
the bushing until the oil hole of cylinder clock
(1) matches the oil hole of the bushing.
15-14 6D140-2 SERIES

(10)
• Using inside gauge , measure the inside

diameter of the bushing.
• Check the clearance between the bushing and
shaft, and if the clearance is not within the spec-
ified range, or the shaft does not move smoothly,
correct the inside diameter of the bushing with a
reamer.
• When the inside diameter of the bushing has
been corrected with a reamer, clean all the
metal particles from the oil hole and oil
groove.
a Inside diameter of cam bushing: ø65 +0.06
–0 mm
a Clearance of camshaft journal: 0.016 – 0.096 mm
6D140-2 SERIES 15-15

(10)
Replacing crankshaft gear

Special tools

790-101-2800 Bearing puller 1
790-101-2300 Push puller 1
1. Removal of Gear
Make a scratch in the surface at the root of the
teeth with a grinder, then assemble pullers
and , and turn the nut to remove the gear.
a If the gear cannot be removed in this way,
make a scratch in the surface at the root of
the teeth with a grinder, then heat the gear
with a burner and knock the gear out with a
copper rod.
a Be careful not to damage the shaft.
2. Press fitting gear

1) Check the gear mounting surface, key
groove, and flange surface, and if there are
any scratches, correct them with an
oilstone.
2) Knock a new key into the key groove of the
shaft.
3) Heat the gear for the specified time at the
specified shrink-fitting temperature.
a Crankshaft gear shrink-fitting temperature:
200°C
Heating time: Min. 30 minutes
4) Put the timing mark on the outside, then use
a hitting tool to press fit until the side face of
the gear is in close contact with the shaft
flange.
a Knock in quickly before the gear becomes
cool.
15-16 6D140-2 SERIES

(10)
Replacing cam gear

1. Removal of gear
Set the camshaft assembly on the press stand,
then push the camshaft to remove the gear.
k When setting the camshaft assembly on the
press stand, be careful not to get caught your
fingers between the press stand and the gear.
2. Press fitting gear

1) Check the gear mounting surface, key
groove, and flange surface, and if there are
any scratches, correct them with an oilstone.
2) Knock a new key into the key groove of the
shaft.
3) Assemble the thrust plate.
4) Heat the gear for the specified time at the
specified shrink-fitting temperature.
a Crankshaft gear shrink-fitting temperature:
220 – 240°C
5) Put the timing mark on the outside, then use
a hitting tool to press fit until the side face of
the gear is in close contact with the shaft
flange.
a Knock in quickly before the gear becomes
cool.
6D140-2 SERIES 15-17

(10)
Replacing flywheel ring gear

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

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

chisel.
2. Press fitting ring gear

1) Check the ring gear mounting surface, and if
there are any scratches, correct them with
an oilstone.
2) Heat the ring gear for the specified time at
the specified shrink-fitting temperature.
a Ring gear shrink-fitting temperature:
Max. 200°C
3) Set the chamfered face of the ring gear
facing the flywheel, and press fit until the
side face of the gear is in close contact with
the flywheel.
15-18 6D140-2 SERIES

(10)
Replacing connecting rod

small end bushing
Special tools

A 795-240-6400 Push tool (KIT) 1
1 795-240-6410 Push tool 1
2 795-240-6420 Push tool 1
B
3 795-240-6430 Block 1
4 01530-03912 Nut 1
1. Removal of connecting rod bushing

1) Set the connecting rod to tool B3.
2) Using tool B1, remove the connecting rod
bushing with press.
a After removing the bushing, remove any
burrs or flashes, and clean the mounting
hole of the bushing.
2. Press fitting connecting rod bushing

1) Set connecting rod to tool B3.
2) Assemble connecting rod bushing in tool
B1, set tool B2 in position, then secure with
tool B4 so that it does not move.
a Align the oil hole of the connecting rod
bushing with the oil hole of the connecting
rod.
3) Push tool B1 with press, and press fit the
connecting rod bushing.
• The bushing is supplied as a semi-finished prod-

uct, 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 mainte-
nance standard.
a After machining, clean all the metal particles
from the oil hole and oil groove.
6D140-2 SERIES 15-19

(10)
Repair and replacement of parts Cylinder block parts
Cylinder block parts
1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing cap
6. Main bearing cap bolt
7. Camshaft bushing
15-20 6D140-2 SERIES

(10)
Repair and replacement of parts Testing and inspecting cylinder block
Testing and inspecting cylinder block

Unit: mm
Sym-
Inspection item Judgement standards Remedy
bol
Check for cracks (external color check)
A. Cracks Replace
Cylinder head bolt hole portion, etc.
Correction of contact at
B. Check for water leakage caused by corrosion Replace
packing portion
Standard value
Standard Standard
size Inside diameter of Outside diameter clearance
cylinder block of cylinder block
158.00 – 157.946 – 0.024 – Replace cylinder
Clearance from 158.00
C. 158.04 157.976 0.094 liner or cylinder
cylinder liner
block
• Inside diameter
Standard size Standard value Standard limit
69 69.000 – 69.025 69.10
Inside diameter of
D. Replace bushing
camshaft bushing • Clearance from camshaft bearing
Standard clearance Clearance limit
0.016 – 0.096 0.15
Permissible range: 0.07 – 0.15 Replace cylinder

E. Protrusion of liner liner or correct
cylinder block
Depth of counterbore Standard size Standard value Repair by

F. and corrosion of 11 11.00 – 11.05 machining,
bottom surface add shim
• Check for corrosion
Distortion, wear of Tolerance Repair limit

Repair by
G. cylinder head mounting Overall top surface of block: Max. 0.09 0.135
machining
surface For one cylinder: Max. 0.05 0.100
6D140-2 SERIES 15-21

(10)
Unit: mm
Sym-
Inspection item Judgement standards Remedy
bol
Standard size Standard value Standard limit

127 127.000 – 127.025 —
Inside diameter of main

Coaxiality of whole unit Max. 0.020
bearing mounting hole
Coaxiality between neighboring holes Max. 0.013
• Tighten main bear-
ing cap bolt to
H. specified torque
• Measure main
bearing cap mating
surface within up-
and-down range of
10°
Replace
Journal Standard fitting Clearance limit

Interference
No.1 – 7 —
0.002 – 0.060
Fitting of main bearing

I.
cap and cylinder block
• Cylinder liner
Standard Standard Repair
size value limit
Top 170.10 –
Replace cylinder
170.2 — liner
step 170.20
Bottom 161.25 –
Inside diameter of 161.2 —
step 161.29
counterbore, outside
J.
diameter of cylinder • Cylinder block
liner flange
Standard Standard Repair
size value limit
Top 170.200 –
Correct cylinder
170.2 — block sleeve
step 170.263
Bottom 161.197 –
161.2 —
step 161.230
15-22 6D140-2 SERIES

(10)
Method of checking inside diameter of main

bearing mounting hole using alignment bar
• When checking the inside diameter of the main

bearing mounting hole using an alignment bar,
do as follows.
Tool J (alignment bar)
Unit: mm
Standard dimension
Diameter 127
Roundness 0.005
Straightness 0.010
Length Min. 1,150
1. Set the cylinder block on a stand with the main

bearing cap mount at the top.
2. Coat the inside surface of the main bearing hole

of the cylinder block with engine oil.
a Remove the main bearing cap.
3. Set tool J (alignment bar) in the main bearing

hole of the cylinder block.
4. Install the main bearing cap, then tighten the

mounting bolts to the specified torque.
5. Check that tool J moves smoothly.
6D140-2 SERIES 15-23

(10)
Repair and replacement of parts Correcting cylinder block top surface, counterbore
Correcting cylinder block top surface, counterbore

Flow for correction procedure
a When removing, installing, disassembling, or assembling the engine, see the DISASSEMBLY AND
ASSEMBLY section for details of the procedure.
a If the judgement for Item 9 is NO, go to (A). If the answer is NO again, go on to (B).
15-24 6D140-2 SERIES

(10)
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 (particu-
larly 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 grind-
ing has been carried out on the top surface, cor-
rect the counterbore.
1. Grinding top surface of cylinder block Fig.1

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 Repair
dimension limit
Flatness of cylinder block
0.05 0.10
(for one cylinder)
Height of cylinder block d 430.5 ± 0.04 430.0
Roughness of top surface of
Within 12.5 S
cylinder block
a When grinding with grindstone (reference)

Grindstone speed : 1650 – 1950 m/min
Table speed : 15 – 30 m/min
Amount of grinding
for one pass : 0.025 mm
Cross feed for one pass : 1 – 2 mm
Grindstone : A461V
Grinding fluid : Water soluble
grinding fluid
15-26 6D140-2 SERIES

(10)
2. Grinding counterbore Fig. 3

• 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-to-
rear 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 Fig. 4
with shims and adjust so that the
cylinder liner protrusion is 0.07 – 0.15
mm.
Table 2
Unit: mm
Standard
Repair limit
dimension
Counterbore depth f 11 +0.05

+0
12.525
Cylinder liner protrusion e — 0.07 – 0.15

Roughness of counterbore Within 12.5 S
In accordance with diagram Fig. 5
Machined shape on right (detail diagram for
portion b)
• For the machining amount for counterbore depth

f, decide an amount that will bring protrusion e
of the cylinder liner within the standard value.
• When grinding within the repair limit in cases
where the counterbore depth f exceeds the stan-
dard dimension, set the machining amount so
that one shim can be used for each cylinder as
shown in the table below.
Table 3 [Reference]
Adjustment shims for counterbore depth
Unit: mm Fig. 6
Weight
Part No. T t Remarks
(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 15-27

(10)
Fig. 7
• Use tool K when grinding the counterbore. Fig. 8
Fig. 9
15-28 6D140-2 SERIES

(10)
3. Checking and distinguishing after grinding Fig. 10

and correcting
• After grinding and correcting, check for
scratches on the flat surface around the
water and oil holes in the cylinder block top
surface.
• Remove all burrs and flashes completely.
• After grinding the top surface, if the cylinder
bloc k height d ex ceeds the s tandard
dimension (430.5 ± 0.04 mm), but is within
the repair limit (430.46 – 430.10 mm),
always use an oversize head gasket.
Table 4
Unit: mm Fig. 11
Head gasket Part No. Plate thickness
S.T.D. 6210-17-1813 2.0
Oversize 6210-19-1813 2.4
a To distinguish, the letters [OS] are stamped on

the plate.
• After correcting, stamp the top surface of the
cylinder block (rear of left bank) according to the
nature of the correction as shown in the table
below.
Table 5
Oversize head
Shim Stamp
gasket
— — Not needed
for correction
Parts used
Q — OS
— Q SH
Q Q WS
(Size of letters: 5 – 10 mm)
6D140-2 SERIES 15-29

(10)
4. Procedure for coating cylinder block top sur- Fig. 12

face deck with gasket sealant
• When pulling out the cylinder liner and press fit-
ting 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.
1) Use a cloth to wipe off all the dirt and oil Fig. 13
from the cylinder block top surface deck and
cylinder liner flange contact surface.
2) Coat the position marked in the diagram
with LG-6.
• Diameter of line of gasket sealant:
2 – 3 mm
• Overlap of beginning and end of sealant:
6 ± 6 mm
a When using shims for deck

• After coating the bottom of the shim
thinly with LG-6, install it to the deck
portion of the cylinder block.
• Next, coat with LG-6 in the same Fig. 14
way as when not using shims.
3) Press fit the liner in the cylinder block.
When doing this, coat the cylinder block
contact surface of the seal and O-ring with a
small amount of engine oil (SAE30) immedi-
ately before press fitting the liner.
a Do not coat with engine oil until
immediately before press fitting the
cylinder liner.
4) After setting the cylinder liner in the cylinder Fig. 15

block, assemble a used head gasket and
temporarily tighten the cylinder head.
When doing this, tighten in the tightening
3 Tightening torque:
order shown in the diagram on the right.
147 ± 10 Nm {15 ± 1 kgm}
15-30 6D140-2 SERIES

(10)
5) Loosen the cylinder head mounting bolts, Fig. 16

remove the cylinder head, then wipe off the
excess gasket sealant that has come out
from the counterbore.
a The gasket sealant that comes out may
cause deformation of the head gasket
grommet, so always carry out Steps 4)
and 5) without fail.
a After carrying out Steps 4) and 5), use a
new head gasket to install the cylinder
head.
5. Standard for rebuilding cylinder liner O-ring Fig. 17

portion of cylinder block
• If the bushing of the cylinder liner O-ring of
the cylinder block has been corrected, make
the finishing dimensions as follows.
a Concentricity of in relation to standard :
Max. 0.05 mm
Table 6
Unit: mm
No. Finishing dimensions
ø167
ø161.45 ± 0.25
Fig. 18
ø160.67 ± 0.064
176 ± 0.25
184.94 ± 0.18
ø158 +0.040
+0
ø159.03 (Gauge diameter)
6D140-2 SERIES 15-31

(10)
Repair and replacement of parts Replacing main bearing cap
Replacing main bearing cap

• When replacing the main bearing cap, machine
the semi-finish product to the following dimen-
sions, then install.
Correction parts
Part No. Part Name
6215-29-1210 Main bearing caps other than No. 4, 7
6215-29-1230 No. 4 main bearing cap
6215-29-1250 No. 7 main bearing cap
1. Machining inside diameter of main bearing

cap
1) Remove the cylinder liner.
2) Install the replacement main bearing cap to
the c ylinder block, and tighten to the
2 Main bearing cap mounting bolt:

specified torque.
Coat seat face of threaded
3 Main bearing cap mounting bolt:

portion with engine oil
Unit: Nm {kgm}
Order Target Range
108 – 128
1st step 118 {12}
{11 – 13}
211 – 221
2nd step 216 {22}
{21.5 – 22.5}
Tighten a further
3rd step
90° 90° +30°
+0
a Align the cylinder block and main

bearing cap notch.
3) Set a cylinder block mounting jig on the
table of a horizontal boring machine, fit the
cylinder liner mounting hole of the cylinder
block to the standard line on the jig, and
install the cylinder block.
4) Of the main bearing caps to be used again,
take the one with the longest pitch and put a
d ia l ga ug e i n c o ntac t w it h t he i n s id e
diameter at two places to align the center of
the boring machine arbor.
15-32 6D140-2 SERIES

(10)
Repair and replacement of parts Replacing main bearing cap
5) Check the machined inside diameter of

bearing cap (1) and grind a little at a time.
a Grind until the bit touches the inside
surface of cylinder block (2).
a Inside diameter of main bearing cap
i) Machining dimension
Tolerance: 127 +0.025
+0 mm
ii) Inside diameter of cap when main
bearing cap is tightened to specified
torque after machining
Tolerance: 127 +0.025
–0.010 mm
(Up-down range of 10° at mating
surface of main bearing cap)
a Finishing roughness: Within 10 S
a Do not grind the inside face of the
cylinder block.
2. Machining width of main bearing cap

(Only when machining No. 7 main bearing
cap)
1) Insert cast iron bushing , then pass arbor
through.
2) Install facing bit to the arbor.
3) Grind cap (1) until the bit touches the
cylinder block face.
4) Grind the opposite side in the same way.
a Roughness of thrust bearing mounting
surface: Within 12.5 S
a Do not grind the cylinder block.
a Width of main bearing cap
Tolerance: 43.970 – 44.000 mm
6D140-2 SERIES 15-33

(10)

6D140-2

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

6D140-2

Uploaded by

Copyright:

Available Formats

SEBM008610

11 Structure and function ...................................................................................... 11-1

12 Testing and adjusting ........................................................................................ 12-1

13 Disassembly and assembly .......................................................................... 13-1

15 Repair and replacement of parts .............................................................. 15-1

00-2 6D140-2 SERIES

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

List of revised pages

Time of Time of Time of Time of Time of

q 00-1 (10) (01-1-1) (01-17-1) q 11-1 (10) q 11-27 (10)

6D140-2 SERIES 00-2-1

Time of Time of Time of Time of Time of

00-2-2 6D140-2 SERIES

Time of Time of Time of Time of Time of

6D140-2 SERIES 00-2-3

Important safety notice

16. When removing components, be careful not to

17. When removing piping, stop the fuel or oil from

18. As a general rule, do not use gasoline to wash

Structure and function

Testing and adjusting

Disassembly and assembly

How to read the shop manual Revised edition mark

3. Additional pages: Additional pages are indi-

• If a part cannot be smoothly removed from the

Method of disassembling, connecting push-pull type coupler

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

SUNSTAR • “S” is used for high-temperature

Standard tightening torque

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for o-ring boss piping joints

Thread diameter Width across flats Tightening torque

Table of tightening torques for o-ring boss plugs

Thread diameter Width across flats Tightening torque

Tightening torque for 102 engine series

(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —

(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —

Electric wire code

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Classification by color and code

Millimeters to inches (B)

Liter to U.S. Gallon

Liter to U.K. Gallon