Manual: Diesel Engine

SEBM006904
Shop
Manual
DIESEL ENGINE
This material is proprietary

to Komatsu America International Company andis not to be reproduced, used, or
disclosed exceptin accordance with written authorization from Komatsu America International Company.
it is possible and practicalto do so. We reserve the right to make

It is our policy to improve our products whenever
changes or add improvements at any time without incurring any obligationto install such changes on products sold
previously.
Due to this continuous programof research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributot'for information on the latest revision.
January 2001 Copyright 2001 Komatsu

DataKom Publishing Corporation
The affeced pages are indicated by the use of the
following
marks. It is requested
necessary
thatactions Indication
required
Action
must be takento these pages according to the list below.
Page
replaced
be
to Replace
Page to be deleted
Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES
Mark page Revision Mark page Revision ~ ~ page

r k Revision dark page Revision dark page Revision
number number number number number
0 00-1 11-6 ' 0 11-39 0 12-33 13-24

0 00-1-1 11-7 0 11-40 0 0 12-34 13-25 0
0 00-1-2 11-8 0 11-45 0 12-35 13-26 0
00-2 0 11-9 0 11-45-1 0 12-36 13-27
00-3 0 11-10 0 11-46 0 12-37 13-28
00-4 0 11-11 0 11-46-1 @ 12-38 13-29
00-5 0 11-11-1 @ 0 11-47 0 12-39 13-30 0
hl 00-6 0 11-11-2 0 0 11-48 @ 12-40 13-31
z
hl
00-7 11-12 0 11-49 0 12-41 13-32
hl
(D
00-8 11-13 0 11-50 0 12-42 14-1
00-9 11-14 0 12-1 0 12-43 14-2
0 00-10 11-15 12-2 12-44 14-3
0 00-11 11-16 12-3 8 12-46 14-4 @
00-12 0 11-17 0 12-4 0 12-47 14-5 @
00-1 3 11-18 12-5 0 12-48 14-6
00-1 4 11-19 12-6 13-1 14-7
00-15 1 1-20 12-7 13-2 14-8
00-1 6 0 11-21 @ O 12-9 O 13-3 14-9
00-1 7 1 1-22 12-10 13-4 14-10
00-18 1 1-23 0 12-13 @ 13-5 14-1 1
00-1 9 1 1-24 0 12-14 @ 13-6 14-1 2
00-20 11-25 0 0 12-15 @ 13-7 14-13 0
00-21 1 1-26 0 12-16 @ 13-8 14-1 4
00-22 1 1-27 12-17 0 13-9 14-1 5
0 01-1 1 1-29 12-18 0 13-10 14-16 0
0 01-1-1 11-30 0 12-18-2 0 13-1 1 14-1 7
0 01-2 11-31 @ 12-18-3 0 13-12 14-18 0
0 01-2-1 11-32 0 12-19 0 13-1 3 15-1 0
01-3 11-33 12-20 13-1 4 15-2
01-4 11-34 12-22 13-14-1 15-3 0
01 -5 0 11-34-1 0 12-23 13-15 15-4
01-6 11-35 12-24 13-1 6 15-5
01-7 O 11-35-1 @ 12-25 13-17 15-6
0 01-8 0 11-35-2 0 0 12-26 0 13-18 15-7
0 01-9 O 11-35-3 0 0 12-27 0 13-1 9 15-8
11-1 O 11-35-4 0 0 12-28 @ 13-19-1 15-9
11-2 O 11-35-5 0 12-29 0 13-20 15-10
11-3 11-36 0 12-30 0 13-21 15-1 1
11-4 11-37 0 0 12-31 @ 13-22 15-12
11-5 11-38 0 12-32 0 13-23 15-13
00-1-1
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622 102
CONTENTS
No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-l
11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 11-l
12 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . ..m......................... 14-1
Fz
;;
15 REPAIR AND REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 2
00-2
a
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 A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed carefully.
If any dangerous situation arises or may possibly arise, first consider safety, and take the
necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, glasses, to lock all the control levers and hang warn-
cap and other clothes suited for welding ing signs on them.
work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
IO. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits,’ first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, 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 mini-
mum of gasoline when washing electrical
parts.
00-4
F O R EW OR D GENERAL
F O R EWOR D
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and
maintenance standards.
TESTING AND ADJUSTING

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

This section explains the procedures for removing, installing, disassembling and assembling
each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
F O R EW OR D HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (123....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume: } Each issued as one
volume to cover all
models
REVISIONS
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
2. Following examples show how to read the Special safety precautions are
page number. ¤ Safety necessary when performing
the work.
Example 1 (Chassis volume):
Special technical precautions
10 - 3
or other precautions for pre-
Item number (10. Structure

fl Caution serving standards are neces-
sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Example 2 (Engine volume):

4 Weight lecting hoisting wire, or when
working posture is important,
etc.
12 - 5
Tightening Places that require special at-
Unit number (1. Engine) 3 tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for 2 Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
5 Oil, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-) and number after the
Places where oil or water
page number. File as in the example. 6 Drain must be drained, and quan-
Example: tity to be drained.
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
F O R EW OR D HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
 Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
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 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
¤ Slinging with one rope may cause
turning of the load during hoisting,
WIRE ROPES untwisting of the rope, or slipping of
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-
(Standard "Z" or "S" twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN {1000 kg} vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2 to 19.6 kN {2000 kg} of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 {1000 kg} when two ropes make a 120°
20 43.1 4.4 hanging angle. On the other hand, two
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN {4000 kg} if they sling
30 98.1 10.0
a 19.6 kN {2000 kg} load at a lifting angle
40 176.5 18.0 of 150°.
50 274.6 28.0 °
60 392.2 40.0
fl The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
2) Sling wire ropes from the middle portion

of the hook.
00-7
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

fl There are 2 types of push-pull type coupler. The method of disassembling and connecting is differ-
ent, so see the table below when disassembling and connecting the coupler.
Type 1 Type 2
1) Hold the mouthpiece of the tightening por- 1) Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end. end.
2) Hold in the condition in Step 1), and push 2) Hold in the condition in Step 1), and turn
until cover (3) contacts contact surface a of lever (4) to the right (clockwise).
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
00-8
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 1 Type 2
• Hold the mouthpiece of the tightening por- • Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end to connect it. end to connect it.
Connection
00-9
F O R EW OR D COATING MATERIALS
COATING MATERIALS
¡ The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
¡ 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, features
• 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. Used for plas-
790–129–9050 20 g Polyethylene
LT–1B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
• Features: Resistance to heat and chemi-

Polyethylene cals
LT–2 09940–00030 50 g
container • Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT–3 sive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT–4 790–129–9040 250 g
container
Holtz • Used as heat-resisting sealant for repair-
790–126–9120 75 g Tube
MH 705 ing 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, rub-
bers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylene
790–129–9130 2g utes)
201 container
• Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals

Loctite Polyethylene • Used at joint portions subject to high tem-
648-50 79A–129–9110 50 cc
container peratures.
• 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

Polyethylene joints, flanges.
LG-5 790–129–9080 1 kg
container • Used as sealant for tapered plugs, elbows,
Gasket nipples of hydraulic piping.
sealant
• 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 case,
etc.
00-10
F O R EW OR D COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
• Features: Silicon based, quick hardening

type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing, in-
Gasket take manifold, oil an, thermostat housing,
sealant etc.
Three bond • Used as heat-resisting sealant for repairing

790–129–9090 100 g Tube engine.
1211
• Used as lubricant for sliding portion (to pre-

Molybde- LM-G 09940-00051 60 g Can vent from squeaking).
num
disulphide • Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
• 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
• Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease SYG2-350CA steam.
G2-CA SYG2-400CA-A Various Various
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
F O R EW OR D STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 13.2 ± 1.4 1.35 ± 0.15
8 13 31 ± 3 3.2 ± 0.3
10 17 66 ± 7 6.7 ± 0.7
12 19 113 ± 10 11.5 ± 1
14 22 177 ± 19 18 ± 2
16 24 279 ± 30 28.5 ± 3
18 27 382 ± 39 39 ± 4
20 30 549 ± 59 56 ± 6
22 32 745 ± 83 76 ± 8.5
24 36 927 ± 103 94.5 ± 10.5
27 41 1320 ± 140 135 ± 15
30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3290 ± 340 335 ± 35
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

fl 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 flat 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 SPLIT FLANGE BOLTS

fl In the case of split flange bolts for which there is no special instruction, tighten to the torque
given in the table below.

mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Nominal No.
mm mm Nm kgm
02 14 34.3 ± 4.9 3.5 ± 0.5
03, 04 20 Varies depending on 93.1 ± 9.8 9.5 ± 1
05, 06 24 type of connector. 142.1 ± 19.6 14.5 ± 2
10, 12 33 421.4 ± 58.8 43 ± 6
14 42 877.1 ± 132.3 89.5 ± 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

Nominal No.
mm mm Nm kgm
08 8 14 7.35 ± 1.47 0.75 ± 0.15
10 10 17 11.27 ± 1.47 1.15 ± 0.15
12 12 19 17.64 ± 1.96 1.8 ± 0.2
14 14 22 22.54 ± 1.96 2.3 ± 0.2
16 16 24 29.4 ± 4.9 3 ± 0.5
18 18 27 39.2 ± 4.9 4 ± 0.5
20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7± 1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 — 127.4 ± 19.6 13 ± 2
36 36 36 151.9 ± 24.5 15.5 ± 2.5
42 42 — 210.7 ± 29.4 21.5 ± 3
52 52 — 323.4 ± 44.1 33 ± 4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (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
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (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
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (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
00-14
F O R EW OR D 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
Nominal Cable O.D. Current rating
number Number of Dia. of strands Cross section (mm) (A) Applicable circuit
strands (mm) (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
Prior- Charging Ground Starting Lighting Instrument Signal Other
ity Classi-
fication
Pri- Code W B B R Y G L
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — Black & White Red & White Yellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red
Auxi- Code WL — BR RY YG GY LY
4 liary
Color White & Blue — Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
F O R EW OR D CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal
line from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line
down from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
..........................................
1 mm = 0.03937 in
0 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
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A ...........................................................................................
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

1¶ = 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

1¶ = 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 Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –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 60 140.0 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
F O R EW OR D 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 .................................... 01-1-I

Specifications ................................................. 01-2
General assembly drawing ........................... 0 1 - 3
Engine performance curve.. .......................... 0 1 - 7
Weight table ................................................... 01-9
01-l
0
APPLICABLE MACHINE
Engine I Engine
Serial No. I Applicable machine
EG150BS-5 Generator
S6D108-2 DCA150SSK MQ generator
DCA180SPKE DENY0 generator
DCA180SSK MQ generator
SA6D108-2
I
PC300-6, PC340-6,PC360-6,PC380-6 Hydraulic
excavator (v
2
hl
hl
CDI 10R-1 Crawler carrier (D
SAA6D 108-2
01-1 -1
0
SPECIFICATIONS
Engine model S6D108-2 SA6D108-2

~~
E G I 5OBS-5 DCA150SSK DCA180SPKE

Applicable machine
(generator) (MQ generator) (DENY0 generator)
6-108x130
Total piston displacement 7.15(7,150}
Firing order 1-5-3-6-2-4
3verall length mm 1,407 1,407 1,507
Overall width mm 840 840 827
3verall height (excluding exhaust pipe) mm 1,200 1,200 1,227
3verall height (including exhaust pipe) mm - -

Flywheel horsepower kW{HP}/rpn 113{1511/1,500 135{1 80~/1,800 13611 85)/1,500
(Net,50Hz) (Net,GOHz) (Net,50Hz)
13411 80}/1,800 162{220)/1,800
(Net,GOHz) (Net,GOHz)
Maximum torque Nm{kgm}/rpr
High idling speed rPm Max.I,570(50Hz) Max.I,570(50Hz)

Max.I,880(60Hz) Max.I,880(60Hz) (v
700 - 800 700 - 800 700 - 800

2
Low idling speed hl
hl
Fuel consumption ratio at Fuel consumption ratio at (D
eted flywheel horsepowerreted flywheel horsepowe,
Minimum fuel g/kW*h 217{160)(50Hz) 1 * 218{160)(50Hz)

consumption ratio {g/HP.h) 231{170)(60Hz) 1 * 231{172)(60Hz) 231{170)(60Hz)
Dry weight I kg
790 790 835
Fuel injectionpump BOSCH PES-AD type BOSCH PES-AD type DENS0 NB(EP-9) type
Governor RSV centrifugal , RSV centrifugal , RSV centrifugal ,

all speed type all speed type all speed type
31 31 31
Lubricating oil amount (refill Capacity) Q
(28) (28) (28)
Coolant amount I Q (engine only : 13) (engine only : 13)

32
(engine only : 13)
Alternator 24V.25A 24V.25A 24V.35A
Starting motor 24V,7.5kW 24V,7.5kW 24V,7.5kW
Battery 12V 120Ahx2 12V 120Ahx2 12V 170Ahx2
Turbocharger ;CHWlTZER S2B type SCHWITZER S2B typ SCHWITZER S2B type
Air compressor
Others I With aftercooler

* : When bypass filter is installed.
* 1 : Fuel consumption ratio at ratedflywheel horsepower.
01-2
0
Engine model SAGD108-2 SAAGDI 08-2
Applicable machine
No. of cylinder - Bore x Stroke mm 6-108~130

Total piston displacement e {Cd 7.15f7,150}
Firina order 1-5-3-6-2-4
~~ ~
Overall length 1,507 1,594 1,594
Overall width 827 947 947
Overall height (excluding exhaust pipe) 1,227 1,197 1,197
Overall height (including exhaust pipe) - - -

~~
Flywheel horsepower 162{2 17)/1,800

(Net,GOHz)
Maximum torque ~97{91.5}/1,500(Net 1,020{104}/1,600(Net)
High idling speed Max. 1,890(60Hz) 2,200 - 2,300 2,300 2 50
Low idling speed 700 - 800 700 - 750 1,000+25

Fuel consumption ratioat
eted flywheel horsepower
Minimum fuel
consumption ratio 231{172}(60Hz) 205{151} 218{162)
Dry weight 835 I 780 I 760
Fuel injection pump DENS0 NB(EP-9)type
Governor RSV centrifugal ,all speed type
31 31 *32 31
Lubricating oil amount (refill capacity)
(28) (28) *(29) (28)
32 12
Coolant amount (engine only : 13) (engine only : 12) (engine only)
Alternator 24V,25A24V,35A 24V,35A
Starting motor 24V,7.5kW 24V,7.5kW 24V, I l k W
Battery 12V 150Ahx2 12V 170Ahx2 12V 170Ahx2
Turbocharger SCHWITZER S2B type SCHWITZER S2B type SCHWITZER S2BG type
Air compressor
Others With aftercooler With air cooled With air cooled

aftercooler aftercooler
* :When bypass filter is installed.
* 1 :Fuel consumption ratio at ratedflywheel horsepower.
01-2-1
0
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
View from left side
SAAGD108-2 (PC300-6,PC340-6,PC350-6,PC380-6)
Direction of wind
of crankshaft
- -
SKEO0076
View from right side
SAAGD108-2 (PC300-S,PC340-S,PC350-6,PC380-6)
Direction of wind
+
Water temperature
Center of cran
--
01-4
0
View from front
SAA6D108-2 (PC300-6,PC340-6,PC350-6,PC380-6)
7
Center of crankshaft
z
400 6 400
1
SKEO0078
01-5
0
View from rear
SAAGDI 08-2 (PC300-6,PC340-6,PC350-6,PC380-6)
946.75
-I-
-E
6
r
r
haf t
SKE00079
01-6
0
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE
Flywheel horsepower : 172.8kW (231.7HP) / 2,050rpm

Max. torque : 897Nm (91.5kgm) / 1,500rpm
E
r” z
100 IO00
.80 800
al
3
.60 600 z
0
c
-40 400
-20 200
a
IT 2
1 -0 0
250-
!50
200- 200
_ 150- 150
3 /
P
;:
/ I
IOO- 100
I
50 50
0 OLL
600 a00 IO00 1200 1400 1600 1800 2000 2200 2400
Ena ine soeed (ram)
SDE00957
01-7
0
Flywheel horsepower
m 0 m 0 m ru
0 0 0 0 0 0 0 HP
I I I I I I
- - ru
cn 0 m 0
0 0 0 0 0 kW
Ln m 4 (I
, W - -
0 0 0 0 0 0 - kem
0
m m 4 (I
, (D -
0 0 0 0 0
0 0 0 0 0 0 Z Nm
0 0
Torque
622102
WEIGHT TABLE
A T h i s weighttable is aguidefor use when transportingorhandlingcomponents. Unit : kg
Engine
No. Item Main component
S6D108-2 SA6D108-2 SAA6D108-2
1 Turbocharger Schwitzer S2B 7.0 7.0 7.0
Schwitzer S2BG - 10.0 10.0
2 Aftercooler assembly (air-cooled) - - 17.3
Intake manifold 14.2
Cylinder head assembly 3 Cylinder head, valve, valve spring 63.0
4 Cylinderblock assembly Cylinder block, main cap,

I 1 87
01-9
0
II STRUCTURE AND FUNCTION
GENERAL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 1 I- 2 FUEL SYSTEM

Fuel system chart . . . . . . . . . . . .. . . . .. .. . . . . .. . . . . . . . . . . 1 l-29
INTAKE AND EXHAUST SYSTEM Fuel injection pump . . . . .. . . . . .. . . . . . . . .. . .._....... 1 I-30
After cooler . . .. . . . . . . . . ..__.............................. 1 I- 4 Speed control level angle . . .. . .. .. . . . . .. . . . . . . . 11-31
Air-cooled aftercooler mount . . . . .. . . . . .._... 1 I- 5 Boost compensator device .. .. . . . . .. . . . . . . . . . . 1 l-32
Air cleaner . .. . . .. . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . .. . . II- 9 Fuel injection nozzle . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 11-33
Electoronic dust indicator .. . . . . . . . . .. . . . . . . . . . . 1 I- 10 Fuel filter . .. . . . .. . . .. .. . . . . .. .. . .. . . . . . . .. .. . . .. . . . . . .. . . . . 11-34
Turbocharger _.......................................... 1 I- 11 Fuel injection pump drive case . . . . .. . . . . . .. 1 l-35
ENGINE BODY COOLING SYSTEM

Cylinder head . .. . .. . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . 11-12 Cooling system chart.. ............................ 11-36
Cylinder block . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . .. .. . . 11-14 Water pump.. ........................................... 1 l-38
Main revolving system . . . . . . . . .. . . . . .. . . .. . . . .. . . 1 I- 16 Thermostat .............................................. II- 40
Timing gear . . .. . . . .. . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 1 I- 18
Valve mechanism . . . . . . .. . . . . . . .. . .. . . . .. . . . . . . . . . . . . 1 I-20 ELECTRICAL SYSTEM
g
Flywheel and flywheel housing . .. . .. .._.._. 1 l-22 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . .. . . . . .._........ 11-45
;;
Alernator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..___....... 1 l-46
2
LUBRICATION SYSTEM Starting motor . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . . . . . . . . 1 l-47
Lubrication system chart . . . . . . . .. . . .. . . . . . . . . . . . 11-24 Oil pressure switch . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . 11-48
Oil pump . . . . . . . . .._....................................... 1 l-25 Relay switch . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .._._ 1 l-48
Oil filter . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . .. . . . . 11-26 Glow plug .. . . . . . . . . .._................................... 1 l-49
Oil cooler . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . .. . . . . . . .. . .. . . . . .. 11-27
+ The illustration given in STRUCTURE AND

FUNCTION are representative illustration.
Depending on the machine model, the ac-
tual component may be different from the
illustration.
1 l-l
0
STRUCTURE AND FUNCTION GENERAL STRUCTURE
GENERAL STRUCTURE
SAAGD 108-2 (PC300-6,PC350-6)
1 2 3 4 5 6 7 8 9
32
16
29 28 27 26 25 24 23 22 21 20 19 18
1. Fan 12. Flywheel housing 23. Oil pan

2. Cylinder liner 13. Tappet 24. Connecting rod cap
3. Valve seat insert 14. Camshaft 25. Connecting rod bearing
4. Valve guide 15. Cam bushing 26. Oil pump drive gear
5. Valve (exhaust) 16. Ring gear 27. Crankshaft gear
6. Rocker arm shaft 17. Flywheel 28. Front seal
7. Valve (intake) 18. Rear seal 29. Crankshaft pulley
8. Cylinder head cover 19. Crankshaft 30. Front cover
9. Breather 20. Thrust bearing 31. Connecting rod
10. Cylinder head 21. Main bearing cap 32. Piston pin
11. Cylinder block 22. Main bearing
11-2
a
STRUCTURE AND FUNCTION GENERAL STRUCTURE
SAAGD108-2 (PC300-6,PC350-6)
36
38
42
SKEOOOSZ
33. Oil filler 39. Second ring Engine

34. Rocker arm 40. Starting motor l Model: SAAGD108-2
35. Turbocharger 41. Oil ring lType:In-line, 6 cylinder, water cooled
36. Dipstick 42. Oil pump Direct injection type
37. Piston 43. Fuel filter With aftercooler
38. Top ring 4-cycle diesel engine
11-3
0
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
INTAKE AND EXHAUST SYSTEM
AFTERCOOLER (AIR-COOLED)
SAAGDI 08-2 (PC300-6,PC350-6)
B A
1 I
_____---
El Cl
1 3 4
2 1
1. Tank A: From turbocharger

2. Side support B: To intake manifold
3. Tube
4. Fin
1 l-4
a
AIR-COOLED AFTERCOOLER MOUNT
SAA6D108-2 (PC300-6,PC350-6)
A-
SKEOOOFA
1. Turbocharger A: From turbocharger

2. Air-cooled aftercooler B: To intake manifold
3. Air connector
1 l-5
a
(Intake SYSTEM)
S6D108-2 (EG150BS-5)
SKE00918
l.lntake manifold cover A:To Intake manifold

2.lntake manifold
11-6
0
SAAGD108-2 (PC300-6,PC350-6)
__-
--
?ik
-1 3.
$3
_-__-
SKE00085
1. Intake manifold B: To intake manifold

2. Air connector
3. Cover
11-7
0
(Exhaust SYSTEM)
SAAGDI 08-2 (PC300-6,PC350-6)
SiiE00086
1. Muffler A: To air-cooled aftercooler

2. Exhaust pipe (turbocharger - muffler)
3. Turbocharger
4. Exhaust manifold
1 l-8
0
AIR CLEANER
FHG Type FTG Type
I
SXEOl670
1. Inlet 4. Primary element 7. Dust pan

2. Outlet 5. Safety element 8. Diffusion vane (sleeve)
3. Guide vane 6. Vacuator valve 9. Body
Features
The diameter of the elements is the same, from the air by the centrifugal separation
and the outside dimension of the body is effect of vane (3). The air then passes
small. through primary element (41, and as a re-
The inlet is in the direction of the connec- sult, more than 99.9% o f t h e d u s t is re-
tion, so there is no need for a guide vane. moved. The clean air then passes through
It is possible to provide ample centrifugal safety element (5) and outlet (21 and is
force with a simple spiral guide vane. sucked into the engine.
There is no dust pan or guide vane, so the The dust and water separated out by vane
structure is simple. (3) circulates around the inside wall of the
Structure body, is thrown into vacuator valve (61, and
Air containing dust is sucked in tangentially is then automatically discharged to the out-
through inlet ( I ) , and the dust is separated side.
11-9
@I
. .
I-
(B
ai
rn
0
z -
m N N
N
z- 0 m D
N
622102
622102
-"
rn
X
5
al
C
2 vr
0 m
m
z2 <
m
(D
a
a
Y
SCHWITZER SPBG (WITH WESTGATE VALVE)
Westgate valve
1. Valve Set pressure of actuator:

2. Actuator 140kPa I1,040mmHgl
3. Hose
11-1 1-1
@
Operation of turbocharger with waste gate
valve
The purpose of the waste gate valve is to prev-
ent anexcessive increase of the engine output
caused
over-supercharging
by by the
turboch- To From a i r
muffler c Ieaner
arger compressor.
To i n t a k e
manifold
Valve (1) of the waste gate valve is installed

to
Fromexhaust
If the outlet
the exhaust pass before the turbine. manifold SXEO1668
pressure of the compressor rises and pres-
the
sure at actuator(2) of the waste gate valveex-
ceeds the set level, valve (1) of the waste gate
valve opens.
S e tP r e s s u r eo fa c t u a t o r
Time
SXEOI 6 6 9
If valve (1) opens, a part of the exhaust

gas bypasses the turbine. Accordingly, To From a i r
muffler cleaner
the turbinespeed does not rise and the
supercharging pressure of the compre- To i n t a k e
manifold
ssor is kept below the set level.
1’
Fromexhaust
manifold SXEO1660
11-1 1-2
@I
ENGINE BODY
ENGINE BODY
CYLINDER HEAD
622~01004
1. Cylinder head mounting bolt 11. Fuel injection nozzle

2. Nozzle holder 12. Oil filler cap
3. Rocker arm assembly 13. Valve cotter
4. Cylinder head 14. Valve spring
5. Cylinder head gasket 15. Valve spring seat
6. Head cover 16. Intake valve
7. Valve guide 17. Push rod
8. Exhaust valve
9. Valve seat insert
10. Nozzle holder packing
11-12
STRUCTURE AND FUNCTION ENGINE BODY
10
11
, I
1
KS100008 KS100009
Cross section of exhaust valve (No. 1 cylinder) Cross section of intake valve (No. 1 cylinder)
Cylinder head
Direct injection type, 2 valve, injection nozzle
assembled, integrated type
Valve seat
Valve seat insert press fitted for both intake and
exhaust valves
Fuel injection nozzle

l Type: Diesel Kiki, Multiple hole nozzle
: Nippon Denso, Multiple hole nozzle
. Injection pressure (Cracking pressure):
Differs according to machine model
See values in STANDARD VALUE TABLE.
. Pressure adjustment: Shim adjustment type
11-13
CYLINDER BLOCK
622FO1061
1. Cylinder block
2. Cylinder liner
3. Main bearing cap bolt
4. Main bearing cap
5. Cam bushing
11-14
622FO1062
Cylinder block
l Crankshaft: 7 bearings
l Camshaft: 4 bearings
Front seal
. With dust seal, double lip
Cylinder liner
. Dry type
11-15
MAIN REVOLVING SYSTEM
(RE-ENTRANT COMBUSTION CHAMBER)
1. Piston 8. Oil pump drive gear (No. of teeth: 58)

2. Top ring 9. Crankshaft gear (No. of teeth: 34)
3. Second ring 10. Connecting rod bearing
4. Oil ring 11. Crankshaft
5. Snap ring 12. Main bearing (upper)
6. Piston pin 13. Main bearing (lower)
7. Connecting rod 14. Thrust bearing
11-16
-
SKE00089
Piston ring
Top ring Second ring Oil ring

Keystone Keystone With coil
barrel facefor taper facefor expander
both faces, both faces,
PISTON hard chrome hard chrome
Aluminiumalloy(shakercoolinggalley) plating plating, inner
Conical taper profile, thermal flow type cut
Re-entrantcombustionchamber
Pin offset (1.1 mm)
Front seal SEE00631 SUE01 168
1
I
3
SEE00633
Single lip type with dust seal
Rear seal (Lay-down lip seal type) Seals
Single lip type : EG150BS-5
Single lip Lay-down seal lip
Doublelip typePC300-6,PC350-6
Connecting rod bolt
Screw-intype
Piston cooling: Provided
Crankshaft
Closeddieforging
High induction hardening of journal and fil-
let SLEOOOSO I SLE00091
11-17
@
TIMING GEAR
4 6 5
B-B
/
3 \
0
622FO1065
11-18
I __
J A-A
622FO1066
1. Timing gear case

2. Fuel injection pump gear (68 teeth)
3. Idler gear (51 teeth)
4. Oil pump gear (41 teeth)
5. Crankshaft gear (34 teeth)
6. Oil pump drive gear (58 teeth)
7. Camshaft gear (68 teeth)
8. PTO gear (34 teeth)
A,B,C: Match mark for timing gears
11-19
VALVE MECHANISM
3
T! \ i 2
1. Rocker arm shaft 7. Valve seat (upper)

2. Camshaft 8. Stem seal
3. Cam gear (No. of teeth: 68) 9. Valve spring
4. Thrust plate 10. Valve
5. Stem cap 11. Push rod
6. Valve cotter
1 l-20
622102
0,
h.
0
C
v)
3
0
0
0
W
w
ENGINE BODY
FLYWHEEL AND FLYWHEEL HOUSING
622FO1069
1. Flywheel housing
2. Flywheel mounting bolt
3. Ring gear (148 teeth)
4. Rear seal
5. Flywheel
11-22
\3
A-A
/ \
3 5
622FO1072
11-23
STRUCTURE AND FUNCTION LUBRICATION SYSTEM
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART 1. Oil strainer
2. Oil pump
3. Oil cooler
4. Oil Filter
5. Regulator valve
6. Safety valve
7. Oil cooler safety valve
8. Crankshaft
9. Camshaft
IO. Piston
11. Piston cooling nozzle
12. Rocker arm
13. Intake / exhaust valve
14. Turbocharger
15. Fuel injection pump
16. Timing gear
W. Cooling watr
11
622FO1073
LUBRICATION SYSTEM
1. Structere of Lubricating system l The oil discharged from the pump is
l The lubricating system consists mainly of cleaned fully through the oil filter (full-flow
the oil strainer, oil pump, oil pump type). Thus, the oil is distributed to vari-
regulater, oil cooler, oil filter and safety ous lubrication points in the engine.
valve to lubricate various engine parts. The oil is cooled, through heat exchanger
2. Circulation of lubricating oil with the engine cooling water at pipes in
l The lube oil flows from the oil pan to the the oil bracket or in the oil cooler.
oil pump through the oil strainer where
relatively large particles of dust, dirt, or,
foreign matter is removed from the oil.
The oil pump is driven by the gear in the
crankshaft cluster to suck in and charge
out the oil under pressure.
11-24
OIL PUMP
8
9
10
1. Oil pump body Oil pump

2. Pump drive gear (No. of teeth: 41) Type: Gear pump
3. Pump cover Rotating speed: Engine speed x 1.415
4. Drive gear (No. of teeth: 9)
5. Drive shaft Regulator valve
6. Driven gear (No. of teeth: 9) Cracking pressure :
7. Driven shaft S6D108-2(EG150BS-5)
8. Regulator valve : 784-883kPa (8.0 - 9.0 kg/cm?
9. Valve spring SAAGDl08-2(PC300-6,PC350-6)
10. Valve retainer : 931-1,030kPa (9.5 - 10.5 kg/cm?
A. From oil strainer

B. From oil pump
C. To engine
D. To oil pan
1 l-25
a
OIL FILTER (BUILT IN SAFETY VALVE)
l Suspended type
6136FO17C
1. Filter bracket
2. Cartridge
3. Safety valve
A. From oil pump

B. To engine
a: Oil pressure pickup port

Oil pressure switch device
Safety valve
Actuation pressure: 0.2+ 0.02 MPa (2 _+0.2 kg/cm*)
Oil filter
Filtering area: 0.53 m*
11-26
OIL COOLER
C--i +-B
r f
A A
l+B D
1 2 3 4 5
A-A
622FO1016
1. Valve case Oil cooler by-pass valve

2. Valve spring
3. By-pass valve Actuating pressure: 0.4f0.02MPa (4f0.2kg/cm2)
4. Cooler cover
5. Cooler element
D. From oil pump

a. Water drain port
Structure and function

l The oil cooler consists of element and cover.
The oil flowing through the cooler element
with the cooling fin is cooled properly by
the engine cooling water flowing outside
the element.
11-27
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM CHART c
2
!2
1. Fuel tank
2. Feed pump
3. Fuel filter
5. Fuel injection nozzle
6. Over-flow valve
KS100027
GENERAL DESCRIPTION
1. Structure of fuel system 2) Fuel entering the injection pump is pressur-

. The fuel system consists mainly of the fuel ized by the pump plunger to that required
tank, feed pump, fuel filter, fuel injection for injection and injected into each cylinder
pump, fuel injection nozzles and governor through the injection nozzle in the quantity
(built as one unit with the fuel injection required, meeting the injection timing for
pump). the cylinder.
2. Circulation of fuel
1) Fuel is delivered from the fuel tank to the
injection pump through the fuel filter by the
feed pump driven by the fuel injection pump
cam. During the course from the tank to the
injection pump, the fuel is cleaned of rough
dirt through the gauge filter at the inlet to
the feed pump. Then, complete dust removal
and water separation from the oil are ac-
complished through the filter.
11-29
FUEL INJECTION PUMP (WITH MECHANICAL GOVERNOR)

(WITH BOOST COMPENSATOR DEVICE)
SAAGDI 08-2 (PC300-6,PC350-6)
SLE00096
1. Fuel injection pipe (No. 6) 8. Injection pump gear a: From fuel tank
2. Fuel injection pipe (No. 5) 9. Ball bearing b: To fuel filter
3. Fuel injection pipe (No. 4) 10. Speed pickup shaft c: To fuel injection pump
4. Fuel injection pipe (No. 3) 11. Drive shaft d: To injection nozzle
5. Fuel hose 12. Fuel injection pump f: From cylinder block
6. Fuel injection pipe (No. 2) 13. Air pipe g: To fuel injection pump
7. Fuel injection pipe (No. I) 14. Fuel filter (boost pressure)
1 l-30
0
SPEEDCONTROL LEVER ANGLE

SAA6D108-2(PC300-6,PC350-6)
SLE00097 SLE00098
SMOKE LIMITER Fuel injection pump

Type: Nippon Denso NB(EP-9)
Lubrication method: Forced lubrication using en-
Pump housing
gine oil
Governor
Type: Bosch RSV centrifugal type
All-speed governor
Fuel injection timing: Differs according to machine

model
See values in STANDARD VALUE TABLE.
Smoke limiter End surface of
pump housing
SWEOI 095
11-31
0
BOOST COMPENSATOR DEVICE
SAA6D108-2 (PC300-6,PC350-6)
16
.7
I \
12 11
611F109
1. Governor spring 10. Idling sub spring A. Air supply pressure (boost pressure)
2. Floating lever 11. Angleich spring B. Fuel increase direction
3. Guide lever 12. Full load stopper
4. Tension lever 13. Camshaft
5. Push rod 14. Flyweight
6. Boost compensator spring 15. Swivel lever
7. Adjustment screw 16. Control rack
8. Diaphragm 17. Start spring
9. Boost compensator lever
1 l-32
FUEL INJECTION NOZZLE
KS100030
1. Nozzle spring
2. Nozzle holder
3. Push rod
4. Retaining cap
5. Nozzle body
6. Nozzle
A. From fuel injection pump

B. To cylinder (injection)
C. To fuel tank
11-33
FUEL FILTER
=
=
-
-
-
t
-
1. Bracket FUEL FILTER

2. Cartridge . Filtration area : 0.5m2
A. From feed pump

B. To injection pump
11-34
FUEL CUT SOLENOID

A contact （electricity flows when stopped）method
622102
FUNCTION
1. Return spring ・ When stopping the engine, the solenoid
2. Plunger is energized,the solenoid plunger (2) is
electrically attracted, and the stop lever
of the injection pump is moved by a rod
to the stop (non-injection) position. As a
result, the fuel is cut off and the engine
is brought to a stop. Accordingly, this
solenoid is used only when the engine is
being stopped; it is in free condition dur-
ing ordinary operations.
・ No electricity goes to the solenoid when
the engine is running. The solenoid has
no magnetic force, so the shaft of the
solenoid is pulled back by the return
spring (1)
11-34-1
4
FUEL INJECTION PUMP DRIVE CASE
5 4 2 1
KS100032
1. Snap ring
2. Ball bearing
3. Drive shaft
4. Ball bearing
5. Case
1 l-35
ENGINE STOP MOTOR
Shape o f c a b l et i p
7( n o n - t h r e a d e ds t o p p e rt y p e )
Shape o f c a b l e t i p A- A
7( t h r e a d e ds t o p p e rt y p e ) 7
Stroke
Made b y AMP Co. I
E c o n o s e aclo n n e c t or,
\ 2. Not used (f i I l e r p l u g added)
1. N o tu s e d( f i l l e r p l u g added)
4. B (AV 0. 85LR)
'I'
,3. PI (AV 0. 85LY)
.6' N out s e d
( f i l l e r PIUOadded)
' 0. 85LW) 7. A(AVO. 85U
8. E (AVO. 85B)
Y 10 SEE00667
ENGINE STOP MOTOR

1. Motor assembly Maker : Jidosha DenkiKogyo Co. Ltd
2. Cover Rated voltage : DC24V
3. Cable assembly Operatingforce : Min.I47N{15kg)
4. Cable clamp Stroke : 35:; mm
5. Coil spring Weight : 1.2kg
6. Cable
7. Screw
8. Breather
9. Bracket assembly
10. Cover assembly
1 1-35-1
@
STRUCTURAL DRAWING (11
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
1 1-35-2
@
622102
DESCRIPTION OF OPERATION AND CIRCUITS
1. Stop Condition (0’ or 360”)
The above drawing shows the stopped condi- The slider assembly is stopped at the auto-stop
tion when a closed circuit has been formed. position on thePI side.
2. When switch is turned (when starting the

motor)
When the switch is moved thePZside (starting shaft assembly, thereby starting the motor. The
switch ON), an electric current flows from the slider assembly starts to move in the direction
plus side contact plate through the Pz auto- of the arrow at the same time as the roller starts
stop terminal and switch and into the armature t o move.
3. Turning Condition (90’ in the drawing)
A,
Br.
“‘“’;;1,
Bat t e r v
5
P’E
-.
,
S w i t c h A-
Electriccurrentcontinuestopassthroughthesliderassemblyalsocontinuestomovein
armatureassemblyandthemotorcontinuestothedirectionofthearrow.
turn. Because of the rotation of the roller, the
1 1-35-4
@
4. Whenstopped (180")
A closed circuit is formed when thePZauto-stop and the motor comes to a sudden stop. The
terminal rides on the minus-side contactorplate, slider assembly also stops.
5. When switch is turned (when starting the

motor)
cu
cu
cu
(D
E: ..
SDE00662
When the switch is moved to thePI side (start- shaft assembly, thereby starting the motor.The
ing switch OFF), an electric current flows from slider assembly starts to move in the direction
the plus contactor plate through the PI auto- of the arrow at the same time as the roller starts
stop terminal and switch and into the armature t o move.
6. Turning condition (270" in the drawing)
-
A nlr SDE00663
Electric current continues t o pass through the arma- direction of the arrow.Then the circuit returns
ture shaft assembly and the motor continues to turn. to stop condition 1.
The slider assembly also continues to move in the
1 1-35-5
@
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM, CHART
S6D108-2(EG150BS-5)
Outlet control thermostat
622FO1063
1. Radiator A. From oil pump (oil)

2. Thermostat
3. Water pump
4. Water temperature gauge
5. Corrosion resistor (Optional)
6. Cylinder head
7. Cylinder liner
8. Piston
9. Cylinder block
10. Oil cooler
11-36
0
SAAGD108-2 (PC300-6,PC350-6)
Inlet control thermostat
SLE00099
1. Radiator A. From oil pump (oil)

2. Thermostat
3. Water pump
4. Water temperature gauge
5. Corrosion resistor (Optional)
6. Cylinder head
7. Cylinder liner
8. Piston
9. Cylinder block
10. Oil cooler
1 l-37
0
WATER PUMP
1. Nut
S6D108-2 (EG150BS-5)
2. Pulley
3. Pump shaft
4. Spacer
5. Water seal
6. Pump body
7. Impeller
8. Snap ring
9. Pump cover
A. To engine
-A
6138FO21-1
1 l-38
0
SAAGD108-2 (PC300-6,PC350-6)
SKEOOlOO
1. Pump shaft
2. Pulley
3. Bearing
4. Pump body
5. Water seal
6. Impeller
7. Snap ring
8. Pump cover
Outside diameter
Engine Machine model of pulley
(mm)
PC300-6
SAAGDI 08-2 120
PC350-6
1 l-39
(2
THERMOSTAT
INLET CONTROL THERMOSTAT SAAGD108-2 (PC300 -6,PC350-6)
1. Thermostat
2. Thermostat housing
a: Radiator
b: Bypass (from cylinder head)
c: Water pump
Thermostat
Cracking temperature: 69-73°C
Full open temperature: 85°C
Fully open lift: IO mm
SKEOOlOl
Outlet control thermostat S6D108-2 (EG150BS-5)

1 .
I
1. Connector
2. Thermostat
3. Gasket
4. Thermostat housing
a: To radiator
b: To water pump
c: From radiator
Thermostat
Cracking temperature: 74.5-
78.5%
Full open temperature: 90°C
Fully open lift: 10 mm
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
WIRING DIAGRAM
SAA6D108-2 (PC300-6,PC350-6)
Relay switch
Glow plug
Ammeter
Battery relay 1 I
+.-. Battery
P ‘I’
.-.
Starting switch key positions

Starting switch connections
START
return
Automatic return
622FO1085
11-45
Cc
ALTERNATOR MOUNTING
SAAGD108-2 (PC300-6,PC350-61
SKE00920
I. Adjustment bracket
2. Bracket
3. Adjustment Bolt
4. Lock nut
5. Alternator
11-45-1
Cc
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
ALTERNATOR
with built-in regulator (open type)
S6D108-2 (EG150BS-5)
2 1 1
\ -
6206F856
1. Alternator pulley
2. Alternator
Internal wiring diagram

6206F857
Engine 1 Machine model I Type 1Specification 1 Weight 1 Pulley O.D.
S6D108-2 1 EG150BS-5 INikko Denki, open type] 24V. 25A I 6.5kg 1 95 mm
11-46
0
with built-in regulator (open type)
SAAGD108-2(PC300-6, PC350-6)
1 2
\ n I
N
2
N
N
!I i
co
-+R
i 1
j
j
1 1
i
I
*E
I
SXEOl663
1. Alternator
2. Alternator pulley
3. B terminal
4. R terminal
5. Internal connection diagram
5A. Field coil
5B. Initial excitation resistance
5C. Regulator
Pulley
No. of Outside Weight
Engine Machine model TY Pe Specification
pulley grooves diameter (kg)
(mm)
PC300-6
SAA6D108-2 PC350-6 Nikko Denki, open type 24V, 35A 75 V-ribbed
8.0
CDI 10R-1
1 1-46-1
@
STARTING MOTOR
7.5kW
2 1
Alternator -
Controller
internal wiring diagram
KS100003
1. Starting motor
2. Starting motor pinion
B, R, S : Terminals
Engine Machine model TY Pe

No-Of
Weight pinion
Specifications
teeth
S6D108-2 EG150BS-5 Sawafuji Denki,sealed type
24v, 7.5kw ,4.5kg 12
SAA6D108-2 PC300-6,PC350-6 (Waterproof, oilproof)
1 1-47
@
IlkW
Type A
3
\
Type B
2. R 1. s
Type C
4 2 1 1, .s
6
r---- E
1 3. E 2. R
R
3 Type D
hl
0
3. E 2. R
L I SXEOl6 4
hl
(0
1. Pinion gear
2. Body
3. Magnetic switch
4. Connector
5. Internal wiring diagram (2 pin type)
6. Internal wiring diagram (3 pin type)
S. To starting key
R. To R terminal of alternator
E. Ground
No of onnector
Engine Machine model TY Pe Specifications pinion teeth Weight vpe
I
Sawafuji Denki,sealed type 24V, 11 kW 12 20kg

S6D108-2
(Waterproof, oilproof)
Sawafuji Denki,sealed type 24V, 11 kW 12 20kg

SA6D108-2
Sawafuji Denki,sealed type 24V, 11 kW 12 20kg D

SAA6D108-2
1 1-48
0
622102
1
N
0
z
..
0
h
A A
0 in
622102
12 TESTING AND ADJUSTING

Adjusting valve clearance ...................... 12- 3
ENGINE BODY
Measuring compression pressure .........12- 4
FUEL SYSTEM
Testing and adjusting
fuel injection timing ............................ 12- 5
Procedure for adjusting
fuel cut solenoid linkage.................... 12- 9
Procedure for adjusting
engine stop motor cable.................... 12-10
PERFORMANCE TEST
Running in standard ................................ 12-13
Performance test criteria ........................ 12-14
FUEL INJECTION PUMP

CALIBRATION DATA ........................... 12-16
TROUBLESHOOTING ................................... 12-19
TOOLS FOR TESTING, ADJUSTING,

AND TROUBLESHOOTING ................. 12-44
TESTING AND ADJUSTING DATA ............ 12-46
12-1
0
When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground,
fit safety pins, block the wheels, and apply the parking brake.
When carrying out operations with two or more workers, always use signals, and do not allow
any unauthorized person near the machine.
When checking the water level, if the radiator cap is removed when the engine is hot, boiling
water will spurt out and may cause burns, so always wait for the engine to cool down before
checking the water level.
Be extremely careful not to touch any hot parts,
Be extremely careful not to get caught in the fan or any other rotating parts.
When removing the plugs or caps from places under hydraulic pressure, water pressure, or air
pressure, release the internal pressure first. Fit the measuring tools securely before carrying out
any testing, adjusting, or troubleshooting.
* When using the standard values table for judgement in testing , or troubleshooting, it is neces-
sary 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 machones 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 value 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.
12-2
TESTING AND ADJUSTING INTAKE AND EXHAUST SYSTEM
--

ADJUSTING VALVE CLEARANCE
Method of adjusting valve clearance
1. Remove cylinder head cover (1).
2. Rotate the crankshaft in normal direction to

align pointer (4) with the 1.6 TOP mark on
crankshaft pulley (3). When rotating, check
the movement of the intake valve of No. 6
cylinder.
3. Adjust the clearance of the valves marked

l in the valve arrangement table below.
4. Next, rotate the crankshaft one turn in the

normal direction and adjust the valve clear-
ance of the remaining valves marked ,‘_.
+ To adjust the valve clearance, loosen
locknut (8) of adjustment screw (71, then
insert feeler gauge 3 of the specified
thickness between valve stem (6) and
rocker arm (51, and adjust with the ad-
justment screw to a tight fit.
2
;;
2
5. Tighten the locknut to keep the adjustment
screw in position.
VALVE ARRANGEMENT DIAGRAM
B Locknut : 44.1 f 4.9Nm

(4.5 ? 0.5 kgm)
* Firing order : l-5-3-6-2-4

* It is also possible to turn the crankshaft 120”
each time and adjust the intake and exhaust
valve clearance of each cylinder according
to the firing order.
* For details of the valve clearance, see TEST-
ING AND ADJUSTING,
Standard Value Table. I TVP01432
TKE00051
12-3
@
TESTING AND ADJUSTING ENGINE BODY
ENGINE BODY
MEASURING COMPRESSION
PRESSURE
Method of measuring compression pressure
g When measuring the compression pressure,

be careful not to touch the exhaust mani-
fold or muffler, or to get caught in rotating
parts.
* Measure the compression pressure with

the engine warmed up. (Oil temperature
: 40 - 60°C)
1. Adjust the valve clearance.
j, For details, see ADJUSTING VALVE

CLEARANCE.
2. Remove the spill pipe, then disconnect the

fuel injection tube.
3. Remove the nozzle holder assembly from

each cylinder.
j, Be careful not to let any dirt or dust get
inside.
* When removing the nozzle holder as-
sembly, replace the seat gasket.
4. Install the adapter (I) into the nozzle holder

mount of the cylinder to be measured, and
tighten to the specified torque.
m Adapter : 4.41 f 4.9 Nm
(4.5 f 0.5 kgm)
5. Connect compression gauge A to the

adapter.
6. Place the fuel control level in the NO INJEC-

TION position. Crank the engine with the
starting motor and measure the compres-
sion pressure at the point where the gauge
indicator remains steady.
A If the fuel control lever is not placed at

the NOINJECTION position, fuel will
spurt out.
* If the adapter mount is coated with a

small amount of oil, it will help to pre-
vent leakage.
* For details of the standard values for
the compression pressure, see TESTING
AND ADJUSTING, Standard Value Ta-
ble.
12-4
TESTING AND ADJUSTING FUEL SYSTEM
FUEL SYSTEM
TESTING AND ADJUSTING FUEL
INJECTION TIMING
The following methods are used for testing and
adjusting the fuel injection timing of the injec-
tion pump.
. If the injection pump has not been repaired

and it is reassembled to the same engine,
use the match mark method.
. If the injection pump has been repaired or

replaced, use the delivery valve method
when assembling the pump.
j, With the delivery valve method, it is nec-

essary to replace the delivery valve cop-
per gasket O-ring with a new part, so
prepare a new part before starting the
operation.
j, Set the No.1 cylinder at the compres-

sion top dead center befor carrying out
testing and adjusting.
For details, see ADJUSTING VALVE
CLEARANCE.
g TESTING AND ADJUSTING INJECTION TIMING

;; BY MATCH MARK METHOD
2 1. Rotate the crankshaft 30 - 40” in the reverse
direction from the No.1 cylinder TOP posi-
tion.
2. Rotate it slowly in the normal direction, and

align pointer (2) with the fuel injection tim-
ing line on crankshaft pulley (I).
3. Check that line a on the injection pump and

line b on the injection pump drive case are
aligned.
+ if the lines are not aligned, loosen nut

(3) in the oblong hole and pump mount- KS100172
ing nut (41, then move the fuel injection
pump to align the line, and tighten the
nut.
w Nut : 66.2 + 7.4 Nm

(6.75 2 f 0.75 kgm)
TESTING AND ADJUSTING BY DELIVERY

VALVE METHOD
1. Disconnect fuel injection tube (5) from the
No.1 cylinder.
2. Remove delivery valve holder (7). I I’ II ’ KS100173
12-5
3. Take out spring (8) and delivery valve (9)

from inside the delivery valve holder, then
assemble the delivery valve holder again.
4. Set the fuel control lever at the FULL posi-

tion, then operate the priming pump and
rotate the crankshaft slowly in the normal
direction.
Check the point where the fuel stops flow-
ing from the delivery valve holder.
5. Check that the injection timing line of the

crankshaft pulley (I) and the pointer (2) are
aligned at the point where the fuel stops
flowing.
* BEYOND injection timing line : Timing

RETARTED
* BEFOR injection timing line : Timing AD-
VANCED
* if the test shows that the injection tim-

ing is incorrect, adjust the fuel injection
timing as follows.
* After testing and adjusting, do not for- I KS100236

get to reassemble the spring and deliv-
ery valve.
I) Rotate the crankshaft 30 - 40” in the re-

verse direction from the No.1 cylinder
TOP position.
2) Rotate it slowly in the normal direction,

and align pointer (2) with the fuel injec-
tion timing line on crankshaft pulley (1).
Injection
flange
3) Loosen nut (3) in the oblong hole in the
mounting flange of the fuel injection Injection
pump, and pump mounting bolt (41, then TKE00052
operate the priming pump and rotate
the pump flange a little at a time. Stop
at the point where the fuel stops flow-
ing from the delivery valve holder.
4) Tighten the nut in the oblong hole in

the mounting flange of the fuel injection
pump, and the pump mounting bolt.
* Check the injection timing again to con-

firm that the timing is correct.
5) Make match mark (a) and (b).

KS100238
12-6
6. Remove delivery valve holder (7), assem-

ble delivery valve (9) and spring (8), then
install delivery valve holder (7) again.
Delivery valve holder : 88.3 f 9.8 Nm
(9 + 1 kgm)
* Always replace the delivery valve cop-

per gasket O-ring with a new part.
7. Connect fuel injection tube (5).

m Sleeve nut : 22.1 f 2.4 Nm
(2.25 f 0.25 kgm) KS100174 /
I II ’ KS100173
12-7
PROCEDURE FOR ADJUSTING
FUEL CUT SOLENOID LINKAGE
1. Stop the engine and connect solenoid (1) and
fuel injection pump (3) by rod(2) temporarily.
2. Adjust the length of the so

rod
that theclearance
a between stop lever(4)and stopper (5) on the
stop side willbe 0.5-1.0 mm when the rod
is
pulled fully by hand toward the solenoid.
3. Turn ON the solenoid and adjust the rod finally

so that clearance a between the stop lever(4)
and stopper (5) on the stop side will
l.Omm.
be0.5 -
2-3 times andcheck
4. Start and stop the engine
that the solenoid operates smoothly.If the
solenoid does not operate smoothly, adjustit
with the linkage. (Stop the engine within 10
seconds.) TWE00930
hl
z
hl
hl
(D 1. Solenoid valve
2. Rod
4. Stop lever
5. Fuel injection pump stopper
* Faults causedby wrong adjustment of solenoid
Condition Fault
on, if the
When the solenoid is turned An excessive current flows in the solenoid to burn the
clearance between the stop lever and solenoid coil.
stopper on the stop side "0"
is Fuel injection pump governor is broken or scuffed.
(An excessive force is appliedto thelever.)
free, if the
When the solenoid is Fuel injection rate lowers and the engine output does
clearance between the stop lever and not increase.
is "large"
stopper on the full side
12-9
0
PROCEDURE FOR ADJUSTING
ENGINE STOP MOTOR CABLE
1. Temporarily install ball joint (3) t o cable (2)

of engine stop motor(1) (tighten fully, then
turn back approx. 1/2 turns), then install a
ball joint to the stop lever of the fuel injec-
(v
tion pump.
9
(v
(v
co 2. Pullinjectionpumpstoplever (4) byhand
to the ENGINE STOP (NO INJECTION) posi-
tion, and temporarily fix the cable to the
bracket.
When doing this, put stop lever (4) in con-
tact with ENGINE STOP stopper (51,and tem-
porarily fit the cable to the bracket using
the holding nut.
* Engine stop motor (1) is delivered with
cable (2) pulled (engine stop position).
* Stop lever (4)of the fuel injection pump
is at the RUN position when the lever is
free. (It is pulled to theRUN position by
a spring.)
3. Adjust so that clearance a between stop le-

ver (4) of the fuel injection pump andSTOP
stopper (5)is 1 - 2 mm.
Carry out the adjustment with nut ( 6 ) hold-
ing the cable to the bracket, or make fine
adjustments by changing the amount that
ball joint (3) is screwed in.
12-10
PERFORMANCE TEST
j, The table gives the standard valuesfor machines without fan
RUNNING IN STANDARD except for machines with aircooledaftercooler.
* The loads for the dynamometer are at an arm's lengthof 716
mm.
Engine
model
Applicable
model
!unning
me
Item
min.
t 1 2
10
~~
3
Order
2
4
3
5 6
EG150BS-5 ingine speed 1,000 1,200 1,600

rPm
(generator)
.oad N W 98 { I 01 245 (251 637 (65)
$wheel 7.4 {9.9) !2.1{29.6) 16.5{102.5}
lorsepower :W {HP}
S6D108-2
?unning min. 2 10 2 3
ime
DCA150SSK 750 2 50 1,000 1,200 1,600
ingine speed rPm
(MQ
generator) .oad N(kg1 0 IO) 100 1101 250 {251 640 {651
:lywheel 7.4 (9.8) 22{29.5} 76{103}
lorsepower :W {HP} 0 101
:Ime
3CA180SPKE 1,000 1,200 1,600
ingine speec rPm 750
(DENY0
generator) -oad NRg1 0 {01 98 (10) 250 {25) 640 (65)
'lywheel 76.4{104}
lorsepower cW {HPJ 0 (01 7.3110.01 22.1{30.01
SA6D1 08-2
:Ime
DCA180SSK 750 k 50 1,200 1,600
ingine speec rPm 1,000
(MQ
generator) -oad N{kg) 0 101 100 (1
0) 250 (251 640 (65)
-1ywheel 7.4 {9.8) ZZ(29.51 761103)
lorsepower cW {HP] 0 101
PC300-6 :Ime
PC340-6 3gine speec rPm 700 1,000 1,200 1,600
PC350-6 Load 0 {01 98 { I 01 245{251 637 {65)
N(kg1
PC380-6 -1ywheel
7orseoower <W {HPI 0 101 7.4 (9.91 22.1{29.6) 76.5{102.5}
SAA6D108-2
Running min. 2 10 2 3
time
CDI 10R-1 Engine speec rPm 650 f 25 1,000 1,20a 1,600
Load NW1 0 {01 100 (10) 250 (251 640 I651

Flywheel 22{29.5] 7611031
horseoower kW {HP: 0 101 7.4 19.81
Running min.
time
Engine speec rPm
Load N{kg)
Flywheel
horsepower kW {HP:
Running min.
time
Engine speec rPm
Load N{kg)
Flywheel
-
horseDower kW {HP
12-13
0
PERFORMANCE TEST CRITERIA
* The table gives the standard values after applying the JIS correction coefficient.
* The flywheel horsepower and torque in the table are the standard for when the fan is removed, so
they are different from the specification value. However, for thePC300,350-6 only, the value is for
when a fan is installed.
* The table gives the standard values for machines with the muffler and air cleaner installed, the
alternator under no load and the air compressor released (when installed).
* The dynamometer load is for an arm length of 716 mm.
Machine Specification value Engine Speed lynamometer Load

Engine Test item
model (fully equipped) (rpm) (N {kg})
Flywheel horsepower 113kW~151HP}/1,500rpm(Net,50Hz)1,495 - 1,505(50Hz 1,000 - 1,060(50Hz)
(102 - 108K50HZ)
1,000 - I,070(60Hz)
134kWI180HP~/1,800rpm(Net,6OHz~1,795 - 1,805(60Hz (102 - 109)(60Hz)
generator
EG150BS-5 Maximum torque
Low. idling speed 700 - 800rpm 700 - 800

S6D 108-2 (1,000 - 1,070}(60Hz)
Flywheel horsepower 135kWI180HPl/l,800rpm(Net,6OHz)1,795 - l,805(60Hz
(102- 109)(60Hz)
For MQ
Maximum torque
generator
EG150SSK High. idling speed
Low. idling speed I 750+5orpm I 7502 50
Flywheel horsepower 136kW{185HP}/1,500rpm(Net,50Hz) 1,495 - 1,505(50H; 1,200 - 1,270(50Hz)
(122 - 130}(50Hz)
1,200 - 1,270(60Hz)
1,795 - 1,805(60Hz
162kW~220HP~/l,800rpm(Net,60Hz) (122 - 130H60HZ)
DENY0 Maximum torque
generator
High. idling speed Max.l,57Orpm(50Hz) Max.I,570(50Hz)
DCA180SPKE Max.l,88Orpm(60Hz) Max.I,880(60Hz)
SA6D108-2 1,200 - 1,270(60HZ)
Flywheel horsepower 162kW~2171/1,800r~m(Net,60Hz)1,795 - 1,805(60Hz
{I22 - 130)(60Hz)
For MQ
generator Maximum torque
DCAl8OSSK High. idling speed Max.l,89Orpm(60Hz) Max.I,890(60Hz:
Low. idling speed 750? 50rpm 750 ? 50
Flywheel horsepower 173kW{232HP1/2,050rpm(Net) 2,045 - 2,055 1,060 - 1,120
{108- 115)
PC300-6 1,200 - 1,290
PC340-6 Maximum torque 897Nm(91.5kgmY1,500rprn(Net) 1,400 - 1,600 (122 - 132)
PC350-6 High. idling speed 2,250 - 2,350rpm 2,250 - 2,350
PC380-6
SAA6D108-2
Flywheel horsepower 1,230 - 1,310
(126- 134)
CD110R-1 Maximum torque Min.1,420(1451
High. idling speed 2,300f50rpm 2,3002 50
Low. idling speed O
,I OO+ 25rpm 1,000 * 25
12-14
0
* For fuel use ASTM D975 No.1 or No.2
-k For lubricant, use SAE15W-40 OR SAE30 oil
* The SAA6D108-2 engine for the PC300,350-6 is equipped with an air-cooled aftercooler. The air-
cooled aftercooler is installed to the chassis a t the front of the radiator. When carrying out an
output performance test of the engine as an individual part, install the radiator and air-cooled
aftercooler t o a stand to give a same condition as when they are mounted on the machine, and
operate with the fan. When doing this, the standard temperature a t the outlet port of the air-
cooled aftercooler is 50 - 55°C.
:oolant temperature Lubrication oil

Flywheel Lubricationoil
Torque Fuel consumption
temperature pressure
khaust temperature
horsepower
(kW fHP1) (Nm Ikgml) (sec/200cc) ("C) ("C) [kPa Ikg/cm*l) PC)
112 - 119(50Hz) 70 - 85 80 - 110 230 - 460 Max.670
(152 - 162K50Hz) (2.3 - 4.7)
136 - 144(60Hz)
(184 - 196)(60Hz)
70 - 85 80 - 110 230 - 460

(2.3 - 4.7)
70 - 85 80 - 110 Min.150(1.5}
136- 143(60Hz) 70-90(60Hz) 80-1 O(60Hz)
1 290 - 460(60HZ)
(182 - 192)(60Hz) (3.0 - 4.7)(60Hz)
(Gross)
70 - 90 80 - 110 290 - 460(60Hz)

(3.0 - 4.7)(60Hz)
70 - 90 80 - 110 Min.150 (1.5 1
135 - 153(50Hz) 80 - 110 230 - 460
(183 - 195)(50Hz) 70 - 85 (2.3 - 4.7)
162 - 172(60Hz)
(220 - 234}(60HZ)
70 - 85 80 - 110 230 - 460

(2.3 - 4.7)
70 - 85 80 - 110 Min.150 (1.5 )
162 - 172(60Hz) Min.14.8(60Hz) 70 - 90 80 - 110 290 - 460(60Hz)
(217 - 231)(60HZ) (3.0 - 4.7}(60Hz)
(Gloss)
70 - 90 70 - 110 290 - 460(60Hz)

(3.0 - 4.7H60Hz)
70 - 90 70 - 110 Min.150 I1.5 1
~~
172-183 Min.15.7 71 -85 80 - 120 370 - 590 Max.600

{231-246) {3.8 - 6.0)
884-949 71 - 85 80 - 120 Max.650
{go. 1-96.8)
71 -85 80 - 120
71 - 85 Min.80 Min.120 (1.2 )
Min.13.7 70 -90 90 -110 290 - 490 Max.650
{3.0 - 5.0)
70 -90 90 -110 290 - 490 Max.650
(3.0 - 5.0)
70 -90 90 -1 10 290 - 490
{3.0 - 5.0)
70 -90 90 -110 Min.120 (1.2)
12-15
0
FUEL INJECTION PUMP CALIBRATION DATA
Engine model Engine

Pump assembly No.
serial No. Applicable machine Page
EG150BS-5
6221-73-1950 12-17
(generator)
S6D108-2
DCAI 50SSK
6221-73-1950 12-18
(MQ generator)
DCA180SPKE -
(DENY0 generator)
SA6D1 08-2
DCA180SSK
6221-73-1950 12-18-2
(MQ generator)
PC300-6,PC340-6
6222-73-1110 12-18-3
PC350-6,PC380-6
SAA6D108-2
CDI 10R-1 -
6222-73-1330
(With smoke limitta)
12-16
0
TESTING AND ADJUSTING CALIBRATION DATA
Injection pump Assembly Number

Applicable Machine Applicable Engine
6221-73-1950 (101609-3210) I r
Injection Pump Specification Engine Specification

-Flywheel horsepower llSil55}/1,500 !Gross.MHz
(kW{HP)/rpm) 140{187)/1,800 iGross.BOHz
Maximum torque
. (Nm{kgmYrpml
Max.l,570(50H )
High idling speed (rpm) Max.l,880(60H:
Low idling speed (rpm) 700 -800
Delivery valve Pump tester capacity
retraction volume(mm3’st) I for Service stand
Motor : 7.5 kW
Calibration Standard ( ) : Injection pump manufacturer’s part number
1
CConditions I Service standard Manufacturer standard
. Service standard Nozzle & Nozzle holder pat-f no. 6221-13-3500
indicates data
Nozzle part no.
using calibration
test parts. Nozzle holder part no.
. Manufacture Injection pipe
(mm) 6 X 2 X 600
standard is data IO/D X I/D X length)
for factory test Test oil ASTM D975 No.2 diesel fuel or equivalent
parts.
Oil temperature I”C) / 40 - 45
Nozzle opening pressure (MPa{kg/cm% 1 23.0 (235)
1Transfer pump pressure (KPa(kg/cm’H 1 157 (1.6)
IInjection volume Service standard (cc/lOOOst) Manufacturer standard (cc/lOOOstl
Rack Rack Pump
point position speed Max.variance Max.variance
Injection Injection
(mm1 (rpm) between between
Rack positions volume volume
cylinder cylinder
B to E are the ref- -
A
ernce volume 10.2 900 * 125- 127 f2
(Basic point)
when adjusting the-
B 10.9 900 * 148- 152
injection volume.
C approx.6.4 375 * 9.8- 12.2 f10
Marks * are aver- D 10.2 750
age volumes. -
E 100 * 200 -220 -
Governor perfomance
Min. 14. 0
E R,(10.9)
- R, (IO. 2)
:
._
O--16.8-13.2
IdllnQ sub SPrino

:R,-0. 3 (mm)
Pump speed (ram) TWEO0879
12-17
0
Injection pump Assembly Number Applicable Machine Applicable Engine

6221-73-1950 (101609-3210)
Model Serial No. Model Serial No.
( ): Injection pump manufacture’s part number.
For MQ S6D108-2
generator
DCA150SSK

Flywheel horsepower
Rotating direction Clockwise 140~187~/1,800 (Gross60Hz~
.(kW{HPI/rpm)
Maximum torque
1 Injection order 1 l-5-3-6-2-4 I iNm(kgml/rpm) ,
1Injection interval 59’30’ &60”30’ I 1High idling speed (rpm) I Max.l,890(6OHz,Gross) I
Plunger pre-stroke 3.55 k-3.65 Low idling speed (rpm) 700 -800
retraction volurne’mm”stl
70
for Service stand
Motor : 7.5 kW
Calibration Standard ( ) : lniection DumD manufacturer’s Dart number

:onditions I Service standard Manufacturer standard
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test
Rack positions
B to E are the ref-
ernce volume
when adjusting the
injection volume.
C approx.6.4 375 + 9.8 - 12.2 +10
Marks * are aver- D
age volumes.
E
Governor petfomance Boost compensator petfomance
Min. 18. 0
-z 16. 0
E 14. a
z 13. 2 2 13.2
.-
._
- IO.4
:: 2 12.1
D
z
= 9.7
2 :: II.0
D: -P I3
:I /
0 16. 7
i 1251
Boastpressure (kPa (mmHs1 )
Puma speed (rim) TWE00694

pump Assembly Number

6222-73-1950
I 1: Injection pump manufacture’s part number.
lniection I Pump I
generator
DCA180SSK
Injection Pump Specification Engine Soecification

Rotating direction Clockwise jehorsepower (kW{HPYrpm) 1162~2171/1,800~Gross.60Hz)
1
Maximum torque -
Injection order l-5-3-6-2-4
iNm{kgmYrpm)
Injection interval 59” 30’ - 60” 30’
I High idling (rpm) 1,890(Gross.60Hz)
Plunger pre-stroke (mm) 3.55 - 3.65 Low idling (rpm) 700-800

100 Motor 7.5 kW
retraction volume(mm”st) for Service stand
Calibration Standard ( 1 :Injection pump manufacturer’s part number
Service standard
indicates data
using calibration
test parts.
Manufacture
standard is data
for factory test
Injection volume Injection volume

Rack positions
I3 to E are the ref-
ernce volume
when adjusting the
injection volume. 0
C
Marks * are aver- D
age volumes.
E
Boost compensator perfomance
Governor perfomance
12-18-2
0
CALIBRATION DATA TESTING AND
pump Assembly Number

6222-73-1110 :092000-1171)
I Applicable Machine I Applicable Em
( ): Injection pump manufacture’s part number.

Rotating direction Clockwise 178{2381/2,05O(Net)
Injection order l-5-3-6-2-4
1injection interval I 59O 30’ - 60” 30’ 1

1 Plunger pre-stroke Imm) 1 3.55 - 3.65 I Low idling (rpm) 900 -950
1retraction 100 Motor 7.5 kW
volume(mm’/st’l I for Service stand
Conditions
Calibration Standard ( ) : lniection DumD manufacturer’s Dart number
1 ?ervicest&dard [ Manufacturer standard
Service standard Nozzle & Nozzle holder Dart no. 1 1 6222-l 3-3300(093500 - 60601
indicates data
Nozzle holder part no. (093400 - 5690) 6222-13-3320(093400 - 6430)
using calibration
test parts. Nozzle part no. IO931 00 - 4240) (093100 - 6060)
Manufacture Injection pipe
Imm) 6 X 2 X 600 6 X 2 X 678
standard is data (O/D X I/D X length)
for factory test Test oil I ASTM D975 No.2 diesel fuel or eauivalent
parts.
I Oil temoerature VU I 40 - 45
Nozzle opening pressure lMPa{kgkm’l) 17.16 U75) 25.99-26.97 {265-275)
Transfer pump pressure (KPa{kg/cm’)) 157 (1.6) -
njection volume Service standard lcc/lOOOst) Manufacturer standard (cc/lOOOst

Rack Rack Pump
point position speed Max.variance Max.variance
(mm) (rpm) Injection volume between Injection volume between
Rack positions cylinder cylinder
B to E are the ref- 1 /
ernce volume (BasicHpoiV~l 12.8 1 1,025 1 * 150-162 / Max.9 1 - I -
when adjusting the- - -
injection volume.
B 9.7 1 350 1 * 16-20 1 Max.5 1 I
Wit h smoke limiter
Marks t are aver- 10
1;r.O I, ,nn
I”” , *x ,*c
I ,a- ‘35
I (lever : full, boost : 0)
age volumes.
I
I
, ,-I n
IL.++
I ,nn
I””
I
,
* m-*cl
I
O~_OE (lever : idle, boost : 0)
I
Governor perfomance Boost compensator perfomance
Min. 18. 0
I 6. 0
14.
13.
IO.
9.
0 16. 1
11251
Boost pressure (kPa[mmHe))
Pun0 sDeed (ram) TWE00694
12- 18-3
0
TROUBLESHOOTING
Points to remember when troubleshooting ......................................................................................... 12-20
Method of using troubleshooting chart ................................................................................................ 12-21

s- 1 Starting performance is poor (Starting always takes time). .................................................... 12-26
s- 2 Engine dose not start

(I) Engine dose not turn ............................................................................................................... 12-27
(2) Engine turns but no exhaust gas comes out (Fuel is being injected) .............................. 12-28
(3) Exhaust gas comes out but engine dose not start (fuel is being injected). .................... .12-29
s- 3 Engine dose not pick up smoothly (follow-up is poor). ........................................................... 12-30
s- 4 Engine stops during operations .................................................................................................. 12-31
s- 5 Engine dose not rotate smoothly (hunting). .............................................................................. 12-32
s- 6 Engine lacks output (no power) .................................................................................................. 12-33
s- 7 Exhaust gas is black (incomplete combustion). ....................................................................... 12-34
S- 8 Oil consumption is excessive (or exhaust gas is blue). ........................................................... 12-35
s- 9 Oil becomes contaminated quickly ............................................................................................. 12-36

2 s-10 Fuel consumption is excessive.. .................................................................................................. 12-37
;;
z S-l 1 Oil is in cooling water, or water spurts back, or water level goes done.. ............................. 12-38
s-12 Oil pressure lamp lights up (drop in oil pressure) ................................................................... 12-39
s-13 Oil level rises .................................................................................................................................. 12-40
s-14 Water temperature becomes too high (overheating) ............................................................... 12-41
s-15 Abnormal noise is made .............................................................................................................. 12-42
S-16 Vibration is excessive ................................................................................................................... 12-43
12-19
cc
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 currying out troubleshooting, it is of course important to understand the structure and func-
tion. But to carry out the troubleshooting effectively, a quick method is to carry out troubleshooting
using the problems mentioned by the operator as a guide in the cause.
1. Do not diassemble the machine simply be- 4. Confirming failure

cause there is a failure Check the degree of the problem to judge
if the machine is diassembled immediately for yourself if it is really a failure, or if there
just because there is a failure: is some problem in the handing or opera-
. Unrelated or unnecessary places are also tion of the machine.
disassembled j, When driving the machine and re-enact-
. It becomes difficult to locate the cause ing the failure, be sure that the investi-
of the failure gation or measurement does not make
This means that there is not only a waste of the failure worse.
time and money on replacement parts, oil
and grease, but this action will also lose the 5. Troubleshooting
confidence of the user and operator. Narrow down the causes of the failure from
For this reason also, it is important to carry the results of the questions and checks in
out troubleshooting based on full investiga- the above items 2 - 4, then follow the trou-
tion before starting and troubleshooting fol- bleshooting flow chart to locate the failure.
lowing the correct order. * Basic procedure for troubleshooting
I) Start from the simple places.
2. Question 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 any thing unusual happen before 6. Basic action to remedy cause of failure
the failure occurred ? Even if the failure is repaired, if the root
3) Did the failure occur suddenly, or had cause of the failure is not repaired, the same
the condition of the machine been poor failure will occur again.
befor the failure occurred ? To prevent this, it is necessary to investi-
4) What were the conditions when the fail- gate why the failure occurred, and to re-
ure occurred ? move the root cause of the failure.
5) Had any repairs been carried out before
the failure occurred ?
6) Had any similar failure occurred before
?
3. Checks before troubleshooting

I) Check the level.
2) Check for any external leakage of oil
from the piping and hydraulic equip-
ment.
3) Check the travel of the control levers.
4) Other maintenance item can also be car-
ried out visually, so carry out any check
that is considered necessary.
1Z-20
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three
sections: questions, check items, and trouble-
shooting. The questions and check items are
used to pinpoint high probability causes that
can be located from the failure symptoms or
simple inspection without using troubleshoot-
ing tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Section @+@ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user’s level.
[Check items1
The serviceman carries out simple inspection
to narrow down the caues. The items under @
in the chart on the right correspond to this.
The serviceman narrows down the cause from
information @ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
z (a) 0
.o Q
(b)
5
3 (c) 43
4-l” (d) 01
J. I/ I (e) 0
12-22
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items1 that
have a relationship with the Cause items are marked
with 0, and of these, Cause that have a high probavility
are marked with 63.
Check eack of the [Questions] and [Check items1 in
turn, and marked the 0 or @ in 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.
/%I. For [Confirm recent repair history] in the [Ques-
tion] Section, ask the user, and mark the Cause
column with LI to use as reference for locating
-+ the cause of the failure. However, do not use
this when making calculations to narrow down
the cause.
1932. Use the LI in the Cause column as reference
for [Degree of use (Operated for long period)]
in the [Questions] section as reference. As a
rule, do not use it When calculating the points
for locating the cause, but it can be included if
necessary to deter mine the order for trouble-
8 shooting.
;; Xl Confirm recent repair history
z
~2 Degree of use Operated for long period nna
12-23
. 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
lInsufficient intake of air
lImproper condition of fuel injection
lExcessive injection of fuel
Legend
: Possible causes (judging from Questions and check items)
0: Most probable causes (judging from Questions and check items) $4
A : Possible causes due to length of use (used for a long period) I .;
Color of exhaust gas .,

‘Z Blue under light load I
g Engine oil must be added more frequently
2 Power was lost
Seal on injection pump has come off
12-24
Five causes
the [Questions] and [Check items] section and the five

Cause items in the vertical column.
Three symptoms
A A A
7
Y Step 2
Add up the of 0 and @ marks where the horizontal
lines for the three symptoms and the vertical columns
for the causes intersect.
(1) Clogged air cleaner element : @O@
(2) Air leakage between turbochargar and
head : 00
(3) Clogged, seized injection nozzle : 0
(4) Defective contact of valve, valve seat : 0
(5) Worn piston ring, cylinder : 0
1
I I
Step 3
The calculations in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting area
and carry out the troubleshooting item marked 0. The
Remedy is given as [Clean], so carry out cleaning, and
the exhaust gas color should return to normal.
12-25
S-1 Startingperformance is poor
(Starting always takes time)
Legend
General causes why starting performance is poor o : Possible causes(judging from
Defective electrical system Questions and check items)
8 : Most probable causes (judging
Insufficient supply of fuel from Questions and checkitems)
Insufficient
airintake
of due
A :causes
Possible use of
to length
(used for a long period)
Improper selection of fuel : items to confirm the cause
(At ambient temperature of- 10°C or below, use ASTM D975
No. 1, and - 10°C or above, use ASTM D975 No. 2 diesel fuel.)
j, Batterychargingrate.
value for the charging rate of 70% in the

above table.
In cold weather the specific gravity must
exceed the value for the charging rate of
75% in the above table.
1 2-26
0
S-2 Engine does not start
(1) Engine does not turn
I Causes I
General causes why engine dose not turn
Internal parts of engine seized
j , If internal parts of the engine are
seized, carry out troubleshooting for
"Engine stops during operations".
Failure in power train
Defective electrical system
Legend
0 : Possible causes (judging from Questions and check items)
Q: Most probablecauses (judging from Questions and check items)
A : Possible causes due t o length of use (used for a long period)
/
: Items to confirm thecause
Confirm recent repair history
In
s Degree of use Operated for long period
0
Conditin of horn when starting
U I
Rotating speed is slow
'I
ln
c
Makes ratting noise anddoes
not turn
When starting switch is turned

t o START, pinion does not
moveout
0
aY
&
U I
When starting switch is turned to ON, there is noclicking sound
Battery terminal is loose
When batteryis checked, battery electolyte is foundto be low
ISpecific gravity ofelectrolyte, voltage of battery is low
-
Forthe following conditions1) 51, turn thestarting switch
OFF, connect the cord, and carry out troubleshootingat ON
1) When terminalB and terminal C of starting switch

are
conneced, engine starts
P,
.E
4-
2) When terminal B and terminal C of starting motor are
0 conneced, engine starts
0
r
-
0
3)When terminalB and terminal C ofsafety relay are
conneced, engine starts
3
2
+ 4) When terminal of safety switch and terminal B of
starting motorare conneced, engine starts
5) There is no24V voltage between battery relay terminal

B and terminal E
When ringgear inspected directly, tooth surface is found to

be chipped
Remedy
12-27
0
(2) Engine turns but no exhaust gas comes out
(Fuel is not being injected)
is Mud stucktank
t o fuel cap I I 1 1 - 1 I
When fuelfilteris drained, fuel does notcomeout I I I I I I
When engine is cranked with startig motor,
1) Injection pump couplingdoes not rotate 14IIII
2)No fuel comes out even when fuel filter air bleed plugQ
I I I lo/o/
1
is loosened
is
3) No fuel spurts out even when injection pipesleeve
nut loosened
Rust and water are found
when
fuel is drained
l@IQl@II I
I I I lolol
directlyCheck
pumpinjection I . I I I I I I I I
return
When control rack is pushed, it is found to be
not
Check feed
directly
pump
heavy, or does
II 1lo/1 .- 1 I I I T I
I-3 When fuel filter, strainer are inspected directly, they are
found t o be clogged I I I 1. I I I.
clogged
When feed pump strainer is inspected directly, it is found to
be
When fuel cap is inspected directly, it is
found t o be clogged
II II II II 11. 1 I II II
12-28
0
(3) Exhaust gas comes out but engine does
not start I Causes I
(Fuel is being injected)
General causes why exhaust gas comes out but

engine does not start
Lack of rotating force due to defective electrical
system
Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
Legend
o : Possible causes (judging fromQuestions and check items)
Q : Most probablecauses (judging fromQuestions and check items)
A : Possible causes due t o length of use (used for a long period) /
the confirmrns to cause IC
Degree of use I Operatedlong
for
period
to Suddenlyfailed start 0
Engine oil must be added more frequently
Non-specified fuel has been used
Replacement of filters has not been carried out according t o
ooeration manual
Rust is found when fuel drained
is
Whe engine is cranked, abnormal noise heard from around cylinder head Q
Dust indicator is red
Indicator lamp does not light up
Starting motorcranks engine slowly
Mud isstuck t o fuel tank cap
When fuel control lever is placed at FULL position, it does
not contact stopper
When engine is cranked with startingmotor,
1) Little fuelcomes out even when injection pipesleeve
nut isloosened
___ ~~~
2) Little fuelcomes out even when fuel filter air bleed

plug isloosened
There is leakeoe from fuel oioina
Whenexhaustmanifoldistouchedimmediatelyafter
starting engine, temperture
When fuel filter is
of some cylinder islow
drained, no fuelcomes out
I
12-29
0
S-3 Engine does not pick up smoothly (Follow-up is poor)
When fuel filter, strainer are inspected directly, they are

found t o be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Speed of some cylinders does not change when operating
on reduced cylinders
When control rack is pushed, it is found to
be heavy, or does
not
.~ ~ I I II I I I I I I I I ,I
When compression pressure is measured, it is found to be 0 0
When turbocharger is rotated by hand, it is found to be heavy 0

I
When valve clearance is checked directly, it is found to be
outside standard value
I I I I I I I I I 1 1 I
When
tank
fuel cap is inspected directly, found
it to
is be 0
When
pump
feed
is operated, too
operation
or
light
is heavy 0
c c C.k 8 8 8 z c.k
a 8
m
Remedy fV V
fO a~ $$ $$ $$ g< zV Q E
$ $
12-30
0
0
LE-2 1
l 1 - 1 1 1 1 1 1 1 1 1 1 1 1
Q 0 0 I I h e a q s! a! JO asuodsal ou s! aJaql'paleJad0 s! dwnd paal uaqM
I I I I I l l h l l l l l l l aq
Aldwa oa puno) s! yuea land
sasne3
/ I
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate
smoothly
Air in fuel system I Causes
Defective governor mechanism
Defective engine throttle controller mecha-
nism
(engine throttle controller type)
.k If t h e r ei sn oh u n t i n gw h e nt h e
enginethrottlecontrollerrodis
disconnected, carry out troubleshoot-
ing for the electrical system.
Legend
Degree of use periodOperated

long for aa
Occursatcertain speed range Q Q Q 0
Occurs at low idling 0 Q 0 0 0 0
Condition of hunting Occurs even when
speed
is
0
raised
I Occurs on slopes I I I I I Q I I I I I
Replacement of filters has not been carried out according
t o operation manual I I I I I IQIQI I I
Fuel
tofound
tank is be empty I I I I I @ l I I I I
isRust
found
fuel
whenis drained I I I I I lolo1 I I
Leakage from fuel piping
When feed pump isoperated,
1) No response, light, return isquick
2)No response, light, return is normal
Engine speed sometimes rises too high
Engine is sometimes difficult
t o stop
Seal on injection pumphas come off
When fuel filter, strainer are inspected directly, they are

found to be clogged
e
E E :.Q hX Z=
+ - +
m m m- * I
Remedy .z .z .2 .%
% % % % %5+aWG
12-32
0
622102
Questions
. ....PL
Troubleshooting Check items
A-
ss
0,
(D
5
L
i
ro
a
Replace
8
Replace 0
Replace
Adjust
I Causes I
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
Legend
0 : Possible causes (judging from Questions and check items)
Q: Most probablecauses (judging from Questions and check items)
A : Possible causes due t o length ofuse (used for a long period)
: Items to confirm thecause
Color of exhaust gas
abnormal is Exhaust noise 0 0 Q

Muffler iscrushed Q
Leakage ofair between turbocharger and cylinder head, loose clamp Q
When turbochager is rotated by hand, it is found tobe heavy

When air cleaner is inspecteddirectly, it is found to be clogged e
When compression pressure is measured, it is found to be low
I .g-
c
8
Speed of some cylinderdoes not change when operating on
reduced cylinder
When check is made using deliverymethod, injection timing

e
e
is found to be incorrect
-g Injection pump test shows that injection amount
incorrect
is
$
e
+ When valve clearance is checked directly, it is found t o be
When muffler isremoved, exhaust gas color returns to noma1
When control rack is pushed, it is found to

be heavy, or does
not return
12-34
0
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust gas is blue)

* 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
lExternal leakage of oil
lWear of lubrication system Causes
I I I I I I I I I I
Legend
: Possible causes (judging from Questions and check items)
@: Most probable causes (judging from Questions and check items)
A : Possible causes due to length of use (used for a long period1
l : Items to confirm the cause
Confirm recent repair history III III I I I I I I I I
When exhaust pipe is removed, inside is found to be dirty with oil
Inside of turbocharger intake pipe is dirty with oil Q

Oil level clutch or TORQFLOWtransmission damper chamber rises 0
Clamps for intake system are loose 0
When intake manifold is removed, inside is found to be dirty

with oil I I I I I I
12-35
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contami-
nated quickly
lIntake of exhaust gas due to internal wear
lClogging of lubrication passage
lImproper combustion
lImproper oil used
lOperation under excessive load
.y
I
I
Q
0 YPossible causes (judging from Questions and check items) i
Q: Most probable causes (judging from Questions and check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause
2 Degree of use Operated for long period n n L
.g
g Engine oil must be added more frequently Q
a Non-specified is being used 0
Blue under light load 0

’ Color of exhaust gas
/ Black
/ s
6
Abnomally excessive 0 0 0 0
Amount of blow-by
gas Black Q
f
Y
Y
Oil filter caution lamp stays on even when oil pressuer rises 0 ;
hz 2
When oil filter is inspected, metal particles arefound 0 00 J
6 When exhaust pipe is removed, inside is found to be dirty with oil
.!
Engine oil temperature rises quickly
12-36
TROUBLESHOOTING
S-IO Fuel consumption is excessive

General causes why fuel consumption is ex-
cessive
l Leakage of fuel
l Improper condition of fuel injection I Causes I
l Excessive injection of fuel
Legs:nd
0:F om Questions and check items)
@:F ing from Questions and check items)
th of use (used for a long period)
Degree of use 1Operated for long period
More than for other machines of

@ 0
Condition of fuel same model
consumption Gradually increased 0 0
1Suddenly increased I I I I lolol I

/ Black I@lOl 101 I 0
Exhaust gas color
White 0
Seal on injection pump has come off IQI I I I I I I

There is irregular combustiom I 181 I I I I I
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinder is low
Match mark on injection pump is misaligned

I I
8
OlI I I I
Q
There is external of fuel from engine Q
Engine oil level rises and smells of diesel fuel 0 QQ
Engine low idling speed is high 0 Q
I Injection pump test shows that injection amount is excessive
Speed of some cylinders does not change when operating

on reduced cylinders
When control rack is pushed, it is found to be heavy, or does

not return
When check is made using delivery method, injection timing

is found to be incorrect
)l I
m
.I I I I II
I I I I
Remove head cover and check directly
Remove feed pump and check directly
When engine speed is measured, low idling speed is found

to be high
12-37
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
Legend
Pressure-tightness test oil cooler shows there is leakage 0 0

0,
46 Pressure-tightnesstest oil cylinder head shows there is leakage 0
''
30
0 0 Remove cylinder head and check directly
Remove oil Dan and check directlv

0
12-38
0
S-12 Oil pressure 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
12-39
@
S-13 Oil level rises
* 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 (cloudy white)
Fuel in oil (diluted, and smells of diesel
fuel)
Entry of oil from other component
I Causes I
12-40
0
1
asneo a y l wqjuoo 01 sua11 :
(po!Jad6uol e Joj pasn)asn $0 q16ualo1 anpsasneo alq!ssod : v
(swaa! ysayo pue suo!$sangwoJj 6u!6pn!) sasneo alqeqoJd 1soyy :Q
(sua$! yoaqo pue suo!lsang woJj 6u!6pn!) sasneo alq!ssod : o
pua6a1
I
S-15 Abnormal noise is made Causes i
(u
0
When compression pressure is measured, it is found to be low 0
When turbocharger is rotated by hand, it is found to be heavy 0
Remove gear cover and check directly 0 0
0 Speed of some cylinders does not change when operating

e
60 on reduced cylinders
2
[I)
When control rack is pushed, it is found to be heavyor not return 0
2 is incorrect
Injection pump test shows that injection amount 0
a
3
g Fan is deformed, or belt isloose
k
When valve clearance is checked directly, it is found to be
I I I I I I
Remove cylinder
head cover and check directly
I
I I I I I
I I I I I
When muffler isremoved, annomal noisedisappers
12-42
0
TROUBLESHOOTING S-16
S-16 Vibration is excessive

*
If there is abnormal noise together with
the vibration, carry out troubleshooting
for “Abnormal noise is made”.
General causes why vibration is excessive
lDefective parts (abnormal wear, breakage)
lImproper alignment
lAbnormal combustion
I Causes 7
Leoend
C :Possible causes (judging from Questions and check items)
Q: Most probable causes (judging from Questions and check items)
:
A Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause
Degree of use Operated for long period iAiA[AiAi 1 1 1 1

Suddenly increased
Condition of
vibration Gradually increased
) Non-specified fuel has been used l,:‘Ic‘l I I I I I 1 I

’ Metal particles are found in oil filter
Metal panicles are found when oil is drained
Oil pressure is low at low idling
Vibration occurs at mid-range speed
Vibration follows engine speed
1 Exhaust gas is black I I I I I I I I@lOl

Seal on injection pump has come off
Remove oil pan and check directly
Remove side cover and check directlv
I InJectIon pump test shows that injection amount is incorrect

I I I I I I I I
12-43
0
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
No. / Check item Part Number Remarks
Digital display L : 60 - 2,OOOrpm

799-203-8000
H : 60 - 19,999rpm
799-203-8901
6210-81-4111
‘I
1Specific gravity of 1
e-1 Battery, coolant tester
3 I temperature I
790-500-1300 0 - 2oo”c, 0 - 1 ,OOO”C
Exhaust temperature Digital temperature gauge 799-101-6000 -50 - 1,200”C
0 - 1.0 MPa
5 Lubricant pressure
(0 - 10 kg/cm’)
0 - 2.0 MPa
6 Fuel pressure
I (0 - 20 kg/cm’)
Intake, exhaust
7 Engine pressure test kit 799-203-2002 0 - 1,500mmHg
pressures
2
8 Blow-by pressure 0 - 1,OOOmmHzO ;r;
hl
9 Intake resistance -1,000 - OmmH20
,O Compression Compression gauge 795-502-1205 0 - 6.9 MPa

pressure . Adapter 790-472-1370 (0 - 70 kg/cm*)
11 Blow-by. pressure Blow-by checker 799-201-1504 0 - 500mmHsO
Commercially
12 Valve clearance Feeler gauge
available
Discoloration 0 - 70% (With standard color)

13 Exhaust color Handy smoke tester 799-201-9000
(Discoloration %xl/lO*Bosch index)
Water content O.l%, 0.2% standard

14 Water, fuel in oil Engine oil checker 799-201-6000
sample
Fuel injection pressure Commercially 0 - 29.4 MPa

15 Nozzle tester
Nozzle stray condition available (0 - 300 kg/cm21
16 Quality of coolant Water tester 799-202-7001 PH. nitrous acid ion density
0 - 0.2 MPa
799-202-9001
(0 - 2 kg/cm21
799-202-200 1 1 - 40m/s
Engine with DC24V starting motor

19 Engine cranking Cranking kit 795-610-1000
Current, voltaae. resistance
Commercially
20 Electric circuit Tester Current, voltage, resistance \ .
available
12-44
TESTING AND ADJUSTINGDATA TROUBLESHOOTING
TESTING AND ADJUSTING DATA
Engine S6D108-2
generator For MQ generator

Machine Model
EG150SSK
EG150BS - 5
Cate Measurement Standard I‘ermissible Standard ‘ermissible

Item Unit
son conditions value value value value
Max.1.570150Hr) 1,570(50Hz1
8 High idling speed vm Mar.1.880160Hzl 1,880(6OHz3 lax.1.890 (60Hz) 1,890(60Hr!
: Engine speed
E
Low idling speed rpm 700 - 800 700 - 800 700 - 800 700 - 800
b 0°C (without starting aid1
‘t Necessary rpm Min. 130 130 Min. 130 100
!
$ starting speed -20°C (with starting aid) vm Min. 100 100 Min. 100
Intake resistance At all speed kP Min. 2.94 7.50 Max. 3.00 7.50
{mm&O) {Min. 300) 17621 {Max. 300) (7621
Boost pressure At rated flywheel horsepower kPa Min. 160 128

{mmHgl {Min. 1,200) {9601
Exhaust pressure At rated flywheel horsepower kPa Min. 160 128
(turbine inlet pressure !) {Min. 1,200) 19601
Exhaust temperature All speed (2OT) im;Hgl Max.650 700 Max.670 700
(turbine inlet port)
Quick acceleration EBosch inder t

(Low idle-High idle)
Exhaust gas color At rated output Max. 1.5 2.5 Max. 1.5 2.5
At high idling Max. 1.0 2.0 Max. 1.0 2.0
Valve clearance Intake valve mm 0.34 0.34

(When engine is hot or colt Exhaust valve mm 0.66 0.66
Compression pressun Oil temperature: 40 - 60°C MPa Min. 2.9 Min. 2.9
(SAE30 or SAE 15W - 40 Ikg/cm? {Min. 30) {Min. 30)
s1
(Engine speed) (mm) L
(250 - 300) (250 - 300)
Blow-by pressure At rated flywheel horsepower kPa Max. 1.5 2.9 Max. 2.0 I 3.9
(SAE30 or SAE 15W - 40 (water temp : Min. 70°C) (mmH201 {Max. 150) {300) {Max. 200) {400)
At rated flywheel horsepower
SAE30 or SAElSW - 4Ooil kPa 250 - 460 180 290 - 460 160
Oil pressure ‘kg/;:? 12.5 - 4.7) (I.81 13.0 - 4.71
(oil temperature : Min. 80°C SAE 1OW oil 200-410 140 245 - 410 ViY
{kg/cm21 {2.0 - 4.2) (I.41 {2.5 - 4.2) 11.51
At Low idling
SAEBO or SAE15W - 4Ooil kPa Min.120 Min.150
,kg&*I {Min.?.21 {70!7, (Min.l.5) &
SAElOW oil Min. 100 Min. 100
{kg/cm’) {Min.1 .O} r& fMin.l.0) g7,
All speed
Oil temperature “C 80- 110 120 80- 110 120
(oil in oil pan)
At continuous rated horsepow
Oil consumption ratio, % Max. 0.6 1.0 Max. 0.5 1.0
(Ratio to fuel consumption)
Fuel injection MPa 27 - 28 22 23.5 - 24.5 19.7

Nozzle tester
pressure {kg/cm’1 1270 - 280) 12201 1240 - 250) 11961
Fuel injection timing B.T.D.C 14.25 - 15.75 12.25 - 13.75 12.25-13.75
I
Radiator pressure Opening pressure kPa 40 - 60 40 - 60
valve (Differential pressure) Ikg/cm’l iO.4 - 0.6) IO.4 - 0.6) I -
Fan speed At rated engine speed wm 1,540 - 1,630 1,540 - 1,631 ‘“““.‘.“” \
I
Deflects when pushed
Fan belt tension
with a force of 60 N (6 kg1 mm 8 6-10
* This STANDARD VALUE TABLE does not give the standard values for adjusting the engine output.
Do not use the values in this table to change the setting for the fuel injection pump.
12-46
0
SA6D108-2
-
DCA180SPKE DCAl8OSSK
(DENYO generator) (MQ generator)
- ~
Standard Permissible
value value - value value
w ax.1,890(60Hz 1,890(6OHd
- 700 - 800 700 - 800

Min. 130 Min. 130 130
Min. 100 - Min. 100 100
Min. 3.92 Min. 3.92 7.47
-IMin. 4001 (762)
- 50Hz 60Hz
k!in 120 Min.l6( 93 133
(h (700) ~1.000~
n 47 87
m M i n . 8 5 0 1 (350) I (6501 a
700
Max.650
-
2.5 1.5
- I -
Max. Max. 1.5 2.5
Max. 1.0 Max. 1.0 2.0
-
0.34
- 0.66
Min. 2.9 Min. 2.9 2.4
{Min.
(241
30) {Min. 30) I (24)
(250 - 300) - (250 - 300)
Max. 2.0 Max. 1.96 3.92
- {400} (Max. 200)
290 - 460 220 290 - 460 160
(3.0 - 4.71 (2.2) (3.0 - 4.71 (2.01
250 - 410 220 250 - 410 147
(2.5 - 4.2) {2.2) (2.5 - 4.21 (1 .5}
Min.150
(Min.l.5)
Min. 100
(Min.l.0)
50 78 Min.150
(0.5)
50
(0.5)
{Min.l.5}
Min. 100
IMin.l.0)
II {(I3
{0.71
II
- I I I I
80- 110
-
80-110 I 120 I
Max. 0.5
-
M a x . 0.5 I 1.0 I
I270 - 2801
27-28 I (2201
22
-
26.4 - 27.5
- 280)
21.5
(2201 (270
10.25 - 11.74 - 10.25 - 11.75

-
I ,304 -1,385 1,304 -1,385

-- (60Hz) (60Hz)
8 I 6-10 8 10 - 14
* This STANDARD VALUE TABLE doesnot give the standard valuesfor adjusting the engine output.
I
Do not use the values in this table to change the settingfor the fuel injection pump.
( * 1) Both betweenthe fan pulley and alternator, and between
the fan pulley and water pump.
12-47
@
Engine SAA6D108-2
I
Machine Model
Measurement Unit I
PC300-6, PC340-6
Standard 'errnissibk
T CDI 10R-1
Item value
conditions value
!,200 - 23M
Engine speed
Necessary
High idling speed
Low idling speed
DOC (without starting aid)
rp&
rprn I 900 2,300700 - 750
2,200 --950
Min. 130 130
1,000f25
Min. 130
1,000 f 25
100
starting speed -20°C(with starting aid) 100 Min. 100 100
Intake resistance At all speed 7.50
(7621
Boost pressure 4t rated flywheel horsepower 120
kPa - 146 88 - 108 147 - 173 133
{rnmHg) {900 - 1,100~ 300 - 1,Ioa (1,160 - 1,300} { I,0001
Exhaust pressure At rated flywheel horsepower kPa 93 - 113 93 - 113 120 - 147 107
(turbine inlet pressure {rnmHg} (700 - 850) (700 - 850) (900 - 1,100) {SOO)
Exhaust temperature All speed (2OOC) "C Max.650 700 700
Max.650
(turbine inletport)
Quick acceleration Sosch index
Max. 5.5 7.5 Max.
7.5 5.5
(Low i d l e t l i g h idle)
Exhaust gas color At ratedoutput Max. 2.0 3.0 2.0
Max. 3.0
At high idling Max. 1.0 2.0 2.01.0
Max.
Valve clearance Intake valve 0.34
(When engine is hot or cold Exhaust valve 0.66
Compression pressurc Oil temperature: 40 - 6OoC 2.5 Min. 2.9
(SAEBO or SAE 15W 40 - (25) {Min. 30) I241
(Enginespeed:250-300rpm
.m
Blow-by pressure At rated flywheel horsepower Max. 1.5 Max. 1.5
(SAEBO or SAE 15W - 40 (water temp : Min. 70°C)
At rated flywheel horsepower
SAEBO or SAE15W - 4Ooil 290 - 490 210
Oil pressure {3.0 - 5.01
(2.11
(oil temperature : Min. 80°C SAE 1OW oil 250 - 440 180
{2.5 - 4.5)
{1.81
At Low idling
SAE30 or SAE15W - moil Min.120 Min.120 80
(Min.l.2) (0.8)
SAElOW oil Min. 70 Min.
70100
10.71
{Min.l.O}
All speed
Oil temperature 90- 110 120 90- 110
(oil in oilpan)
At continuous rated honepowel
Oil consumption ratic % Max. 0.5 1.o Max. 0.5
(Ratio to fuel consumption)
Fuel injection MPa 27 - 28 21 26 - 27

Nozzle tester
Dressure {kg/cm21 (270 - 2801 (2 101
Fuel injection timing B.T.D.C degree 16.25 - 17.75
Radiator pressure Opening pressure kPa 40 - 60 40 - 60

valve (Differential Dressure) {kg/cm21 W.4 - 0.6) {0.4 - 0.6)
~~
Fan speed At rated engine speed rpm 1,490 - 1,580 1,490- 1,58(
Fan belt tension Deflects when pushed

with a force of 60 N (6 kg) (*1)3-5
Jr This STANDARD VALUE TABLE does

not give the standard valuesfor adjusting the engine output.
Do not use the values in thistable to change the settingfor the fuel injection pump.
( * 1) Both between the fan pulley and alternator, and betweenthe fan pulley and water pump.
12-48
@
13 DISASSEMBLY AND ASSEMBLY
Overall disassembly .................................... 13- 2

Overall assembly ........................................ .13-14
+ The description of overall engine disassembly and assembly given in this section is based on the
SAGD108-2 engine, assuming the use of an overhaul stand.
* The work procedure may differ slightly from that given here depending upon the machine in
which the engine is mounted, engine accessories and also the particular stand used, however it is
fundamentally the same.
* Use the correct service tools when performing disassembly and assembly.
13-1
DISASSEMBLY AND ASSEMBLY OVERALL DISASSEMBLY
OVERALL DISASSEMBLY
Special tools
Part No. I Part Name Q’ty
A ) - /English stand I 1
790-501-2000 English overhaul stand 1
B
790-345-1070 Bracket 1
C 795-102-2101 Spring washer 1
D 795-100-2800 Piston ring tool 1
E 1790-472-2000 ILiner puller I 1
Preparatory work
. Clean of all mud and dirt.
. Drain cooling water and engine oil.
:
w Engine oil : Approx.221 (S6D108)
: Approx.25 $ (SAGDIOS)
. Prepare a stable engine stand A so that the
engine will not overturn,and set the engine
securely on the stand.
&I kg Engine assembly:Approx.700kg(S6DlO8~

:Approx.770kg(SA6DlOS)
(Differs according to machine)
1. Oil dipstick guide

Remove dipstick guide(l).
2. Remove starting motor

Remove starting motor(lA).
3. Turbocharger,exhaust manifold assembly KS100055
1) Disconnect turbocharger inlet tube(2)

and outlet tube(3).
2) Disconnect intermediate connecter(4)
between turbocharger and aftercooler.
(SAGDI 08)
2A) Disconnect intermediate connecter(4)
from intake manifold.(SGDlOS)
3) Remove turbocharger(5) and exhaust
manifold assembly(6).
4. Setting engine in engine overhaul stand
Install engine on engine overhaul stand.
& kg Engine assembly:Approx.700kg

(Differs according to machine)
13-2
4-l .Air compressor

1) Disconnect water tubes (l),(2) and drain
hose (3).
2) Disconnect oil tube (4).
622FO1089
3) Remove air compressor assembly (5).

4) Remove drive case assembly (6).
4-2.Engine stop motor(if equipped)

1) Remove rod end (I 1 of engine stop motor
cable from stop lever (2) of fuel injection
pump.
2) Remove cable from bracket (3).
3) Remove engine stop motor (4).
k!dJ 622FOlOSl
5. Fuel filter
Disconnect fuel filter inlet hose (I) and
outlet hose (2) at fuel injection pump end,
then remove fuel filter (3).
6. Corrosion resistor(if equipped)

Disconnect water hose (4) and corrosion
resistor (5).
7. Fuel injection pipe

Remove fuel injection pipe (I ).
* Remove sleeve nuts at nozzle holder side
using tool 0.
KS100058
8. Intake manifold(SGD108, SAAGD108)

Using eyebolts @ (Dia. = 8mm, Pitch = 1.25).
Sling intake manifold assembly (3).
* Intake manifold assembly is separatable,
however, there is no need to disassemble
unless trouble occurred in this portion.
DKE00117
8-l.Aftercooler, intake manifold (SA6D108)

1) Disconnect aftercooler inlet tube (I).
2) Disconnect aftercooler outlet tube (2).

3) Using eyebolt 0 (8mm, Pitch = l-25),
sling inlet manifold assembly (3).
13-4
0
4) Remove cover (4), then remove

aftercooler (5). 4 5
KS100117
9. Thermostat
1) Remove connector (I 1.
2) Remove thermostat (2).
KS100063

Remove fuel injection pump (3).
* Loosen these two nuts from pump rear
using socket wrench, universal joint 0
and extensions @ and 0.
. Extension @ : 300mm
. Extension @ : IOOmm
KS100118
11. Oil filter

Remove oil filter (I) together with bracket.
I I \i I KSlOOO&l
13-5
12.Oil cooler
1) Remove oil cooler tube (I).
2) Remove oil cooler (2).
13. Tension pulley

Remove tension pulley (I).
14. Fan belt,water pump belts

1) Loosen mounting bolt of alternator,
3 4
move alternator to inside, and remove
fan belt (2).
2) Remove water pump belt (3).
1
622FO1093
15. Alternator
Remove alternator (4).
4
16. Fan pulley drive assembly
Remove fan pulley drive assembly (5).
* Insert tool from peeping holes and
loosen mounting bolts. 3 2
17. Water pump

Remove water pump (I).
13-6
18. Vibration damper

Remove vibration damper(l).
19. Crankshaft pulley

Remove crankshaft pulley(2).
20. Lead
Remove lead (IL
KS100119
21. Glow plug

Remove glow plug (IL
22. Spill hose

Remove spill hose (2).
23. Nozzle holder

Remove nozzle holder (I).
24. Cylinder head cover

Remove cylinder head cover (2).
25. Rocker arm assembly

I) Loosen lock nut of adjustment screw,
then loosen each adjustment screw 2 to
3 turns.
* Loosen the adjustment screw at this
step to avoid excessive pressure
being brought to the push rods when
installing the rocker arm assembly.
2) Remove rocker arm assembly (I).
26. Push rods

Remove push rods (I).
27. Cylinder head

1) Remove mounting bolts of cylinder head.
2) Remove cylinder head (I).
E?lkg Cylinder head assembly:63kg

3) Remove cylinder head gasket.
. Disassemble cy1inde.r head assembly as

follows.
1) Using spring pusher C, compress valve
spring and remove valve cotter (I).
13-8
2) Slowly release spring tension and

remove spring guide (2), valve spring
(3).
3) Lift up cylinder head (5) and remove

valves (6).
28. Oil pan

Remove oil pan (I).
* Be careful not to deform or damage the
oil pan when removing, as this will cause
oil leakage.
29. Suction tube

Remove suction tube (I).
30. Gear case cover

Remove gear case cover (1).
31. Drive gear for oil pump

Remove drive gear for oil pump (I).
32. Camshaft
1) Remove thrust plate (I).
2) Remove camshaft (2).
33. Oil pump

Remove oil pump (I).
34. Idler gear

Remove idler gear (2).
13-10
35. Idler shaft

Remove idler shaft (I).
36. Drive gear for fuel injection pump

Remove drive gear (2 )for injection pump.
37. Front plate

Remove front plate (3).
38. Flywheel
Remove flywheel (I 1.
&I kg Flywheel: 31.3kg

(Differs according to the machine)
“yqq/
KS100081
39.Flywheel housing
Remove flywheel housing (I).
kg
EL?l Flywheel housing: 46.5kg
(Differs according to the machine)
40. Piston,connecting rod assembly

* To avoid damage when removing the
piston, remove carbon sludge from the
upper inside surface of the liner with
fine emery paper.
1) Rotate crankshaft so that piston to be KS100082
removed comes to bottom dead center.

2) Remove connecting rod cap (I).
3) Using wooden bar, push piston and
connecting rod from oil pan side.
Support piston (2) at cylinder head side
and remove.
* When removing, be careful not to
damage the inside surface of the liner
with the corners of the connecting rod.
4) Remove remaining pistons and connect-
ing rods in the same way.
* Keep the pistons and connection rods in
a safe place and be careful not to damage
the sliding surface of the piston or the KS100064
bearing.
* Disassemble piston and connecting rod as

follows.
1) Using plier (a), remove snap spring (4).
2) Hold connecting rod (5) by hand, and
tap out piston pin (6) from the opposite
side.
3) Disconnect piston assembly and
connecting rod.
4) Remove snap ring in the opposite side.
KS100216 KS100124
5) Using piston ring tool D, remove rings

in turn,starting with top ring (5).
* Keep piston, connecting rod,
bearing, piston rings and piston pin
in sets according to cylinder number.
KS100217
41. Crankshaft
. Turn over engine so that crankshaft side
is at top.
I) Remove main bearing caps (I).
* The lower thrust bearings are
assembled on both sides of the No.7
main bearing cap, so after removing,
mark the position for assembly.
2) Using a nylon sling, remove crankshaft

(2).
* When raising the crankshaft, be
careful not to damage by letting it
hit the cylinder block.
+ Keep the crankshaft in a safe place,
and be careful not to damage the
sliding surface.
13-12
3) Remove upper thrust bearings (3) for

crankshaft side.
4) Remove upper bearings (4).

* Mark the positions for assembly of
the main bearing cap, main bearing
and thrust bearing with a tag or felt
pen. Keep in sets according to the
cap number. Keep them in a safe
place and be careful not to damage
them.
42. Tappets
Remove tappets (1).
43. Cylinder liner sleeve

. Before removing the cylinder liner sleeve
n I
if necessary using a dial gauge @_I,
measure the protrusion of the liner
sleeve.
. Using liner puller E, remove cylinder
liner sleeve (I).
13-13
DISASSEMBLY AND ASSEMBLY OVERALL ASSEMBLY
OVERALL ASSEMBLY
TIGHTENING BOLTS BY THE PLASTIC RANGE Before tightening, measure the free length of
TURNING ANGLE METHOD bolt and check that bolt length exceeds
Important bolts in the 140 Series engines are tolerance limit or not.
tightened by the plastic range turning angle
method. In this method, special bolts are 2) If a bolt has been tightened in excess of the
used. By being tightened to the load (plastic specified turning angle, loosen the bolt and
range) at which they begin to be permanently measure the free length of bolt again.
deformed, accurate and high tightening force
can be obtained. 3) The tightening angle should be targeted at
The most common method for tightening the standard value plus or minus tolerance.
bolts is the torque control method. In this
method, however, it is difficult to accurately * Clean every part thoroughly and check the
control the tightening force because of the part for dents, flaws, and bloholes. When
coefficient of friction. assembling the parts, make syre that none of
The plastic range turning angle method is the oil and water passages are blocked.
based on the initial tightening torque and the
turning angle. Preparation .wark
Install adapter to the cylinder block, then reise
it and place it on engine overhaul stand.
(p\estic range) Repair the cylinder block as follows before

inserting the cylider liners.
1) Remove rest and scale from sufaces @
and @ with sandpaper until the machined
Plasticrange turning angle surface is exposed. 2
I5
Polish portion 8 with No. 240 sandpaper z
to make surface @ smooth.
(conventional method)
Polish portion a and @ with No. 240
sandpaper to make them smooth.
II I I
If portion @ is square or burred, polish
it with sandpaper or a scraper.
Elongation of bolt
DEE00088 Finsh this portion to an especially
smooth surface to protect the O-ring
* Elongation exceeding the elastic range results frorm damege.
in permanent deformation.
Bolts to be tightened by the plastic range If the pitting in suface @I is so rough that it
turning angle method in the 140 Series cannot be repaired, replace the cylinder
engines. block.
1) Cylinder head mounting bolts
2) Main cap mounting bolts
3) Connecting rod cap mounting bolts
4) Flywheel mounting bolts
In the plastic range turning angle method,
the permanent strain remains in bolts after
they are tightened. Therefore, the number of
times that each bolt can be reused is limited.
Observe the following precautions.
1) Before tightening, measure the free length of
bolt and check that bolt length exceeds
tolerance limit or not. Do not reuse any bolt
which has exceeded the tolerance limit.
13-14
0
Special tools
Part No. Pat-t Name O’ty
A - Engine stand 1
790-501-2000 Engine overhaul stand 1

B
790-345-1070 Bracket 1
C 1795-215-1711 [Liner driver I 1
G - Push tool for rear seal (A) 1
H - Push tool for rear seal (6) 1
Preparatory work
Install adapter plate on cylinder block, raise
and set on engine overhaul stand B.
1. Cylinder liner sleeve

* When cylinder liners are disassembled,
follow the next procedure.
* For each cylinder, check that the mark
of the cylinder liner and the stamped
mark (S or M,L) on the top face of right (A)
side of the cylinder block are correctly
coincide.
Liner I.11or III

1 1 mark
* Clean the press-fit surface of the cylinder

liner and cylinder block thoroughly.
(Completely remove the rust preventive
oil from the liner) Left and Right side of
* Coat the press-fit surface of the cylinder cylinder block with Liner
liner and cylinder block thinly with S.M or S, M L
engine oil (EO-30).
13-14-l
0
I) Set cylinder liner (I) on cylinder block.

+ Set cylinder liner (I) with its mark facing
to the front of the engine.
2) Using tool C, press fit liner in block.

* Press-fit slowly for the first 10 - 20 mm
stroke and make sure that the liner is
not inclined.
j, If the liner is inclined, there is a danger
that it will crack. Use a pulling tool to
remove it and press-fit from the
beginning again.
* If there is any dust or dirt on the press-
fit surface of the liner or the bottom
surface of the liner flange, the liner will
be deformed or the protrusion will not
be even. Never try to install the liner by
putting a wooden block on top of the
liner and hammering the liner into the
block.
3) Measure protrusion of cylinder liner

After press-fiting the cylinder liner, measure
the amount that the cylinder liner protrudes.
* Protrusion of cylinder liner : 0.50 to
0.13mm
4) Measure inside diameter of cylinder liner

After press-fitting the cylinder liner, measure
the inside diameter of the cylinder liner and
check that it is within the standard value.
Inside diameter; 0108+~.~~~~

2. Tappets
1) Turn over engine so that crankshaft side
is at top.
2) Assemble tappets (I).
* Check that tappets move up and
down smoothly.
B.Crankshaft
I) Align lug of upper main bearings (4) with
slot in cylinder block, and install.
* After installing the bearing, coat the
sliding surface with engine oil.
2) Install upper thrust bearing (3) for

crankshaft side.
* Check that the protrusion of the roll
pin is 1.5 to 1.9 mm.
* Install the thrust bearings with the
grooved face to the outside.
* Coat the sliding surface of the thrust
bearings with engine oil.
3) Using a nylon sling, raise crankshaft (2)

and set in position in cylinder block.
* When installing the crankshaft, be
careful not to damage by letting it
hit the cylinder block.
13-16
4) Align lug of lower main bearing (5) with

slot in main bearing cap and install
bearing in cap.
5) Assemble lower thrust bearings (6) on
both sides of No.7 main cap bearing.
* Check that the protrusion of the roil
pin is 1.5 to 1.9mm.
* Install the thrust bearing with the
grooved face to the outside.
6) Assemble main bearing cap (I).
* Coat the sliding surface of the
bearing with engine oil before
installing.
* Match bearing No. and block No, and
install the main bearing cap with the
raising letter “F” facing the front of
the engine.
7) Before tightening main cap mounting
bolt make sure as follows.
i) Measure the free length a of all bolts
and check that bolt length exceeds
tolerance limit or not. Do not reuse
any bolt which has exceeded the
tolerance limit.
Before tighening, measure the free
length of bolt and check that bolt
length exceededs tolerance limit or
not.
ii) Tolerance limit of bolt free length :
Max. 68.9mm
Ir If the bolt length a exceeds
tolerance limit, do not reuse.
w Main bearing cap

Unit :
‘(
3rd After marking bolts and by felt
ITurn over bolt 90”-120”
1 DWE00275
* After tightening the bolts, check that

the crankshaft rotates smoothly.
Put mark on the
bolt and cap
I DDE00094
8) Measure end play of crankshaft.

After tightening the main bearing cap,
measure the end play of the crankshaft.
+ End play of the crankshaft: 0.14 to
0.315mm
4. Piston connecting rod assembly

* Assemble piston rod and connecting rod
assembly as follows.
1) Install expander @ on piston (4).
2) Using tool D, install oil ring (7).

* Install the piston ring with the
stamped mark at the opening facing
UP.
* When fitting the oil ring, check that
the expander is fitted completely
inside the oil ring.
* Position the expander and oil ring
as shown in the diagram.
13-18
cc
3) Install compression ring (5). a

4) Set “FRONT” mark on piston head and
raised number on connecting rod facing
to the same direction. Insert piston pin
(3) and assemble connecting rod (2) with
piston pin
If the piston pin will not go in easily,
warm the piston in hot water before
installing.
Match the cylinder numbers on the
piston and the connecting rod. ‘b
a : Join of coil
Use an electric pen to mark the
b : End gap i
cylinder number on the connecting
rod.
5) Install snap ring (1) in both sides.
Raise up cylinder block putting flywheel

housing underside.
* Set the crankshaft pin at the bottom dead
center in the cylinder where the piston
and connecting rod assembly is to be
installed.
* Assemble the upper bearing with the
connecting rod aligning the bearing lug
2 with the slot in the connecting rod.
z * Caot the inside surface of the cylinder,
E: the surface of the piston rings and
connecting rod bearing surface with
engine oil (EO-30).
1) Align openings of piston rings as shown
in diagram.
2) Insert piston and connecting rod
assembly (2) from cylinder head side as
, far as piston ring position.
* Assemble the piston with the raised
mark “FRONT” facing the front of
the engine.
3) Using piston holder F, compress piston
rings and push piston head with a
wooden bar. Then pull big end of
connecting rod and fit on crankshaft pin.
4) Align slot in connecting rod cap with
lug in lower bearing of connecting rod Top ring
and assemble bearing.

5) Match cylinder number stamped on
connecting rod cap with cylinder number
stamped on connecting rod.
Install connecting rod cap (1) so that
stamped number is for cam side.
Ir Coat connecting rod cap bearing with 2nd ring
engine oil. Opening position
Aligning positions of
position ring opaning
II
6) Before tightening connecting rod bolt,

make sure as follows.
i) Measure the free length a of all bolts
and check that bolt length exceeds
tolerance limit or not. Donot reuse any
bolt which has exceeded the tolerance
limit.
Before tighening, measure the free
length of bolt and check that bolt
length exceededs tolerance limit or
not.
ii) Tolerance limit of bolt free length :
Max. 68.lmm
Ir If the bolt length a exceeds
tolerance limit, do not reuse.
B Connecting rod cap bolt
1st step 1Target 73.6Nm (7.5kgm)

1[Range 71.6 - 75.5Nm (7.3 - 7.7 kgm)]
2nd step After marking the bolts and cap by felt
1pen, turn over the bolt more 90” - 120”.
+ After tightening the bolt, check that

the crankshaft rotates smoothly.
There must be no abnormality.
DWE00275
Put a mark on the

bolt and cao
13-19-1
0
7) Measure side clearance of connecting

rod cap. After installing the piston and
connecting rod assembly, measure the
side clearance between the cap and the
side face of the crankshaft.
H Side clearance of cap: 0.16 to 0.33
mm.
5. Flywheel housing
1) Using push tool @ (0.D.150 mm), press
fit rear seal in housing.
Note 1: If there is any wear on the lip
contract surface (over 0.1 mm deep
enough for fingernails to scratch) or if it
is worn as mirror surface, move the rear
seal about 3 mm toward engine rear
when assembling.
Note 2: When double lip seal is installed.
I KS100148
Replaced new seal

using new crankshaft
(Refer to note1
Distance from
crankshaft end
KS100150
KS100228
2) Align dowel pin holes and install

flywheel housing (I 1.
6 Coat lip surface of rear sael with
grease (G2-LI). (about 3 cc)
& Coat front surface of housing with
gasket paste (LG-7)
w Flywheel housing mounting bolt:
98.1 - 122.6Nm (IO - 12.5 kgml
* Measure face and radial runout of
flywheel housing.
Face runout: within 0.35 mm
Radial runout: within 0.3 mm
13-20
6. Flywheel
1) Install flywheel (I) on crankshaft.
2) Tighten flywheel mounting bolts as
follows.
* Coat the threads of the bolts,the seat
face,and the washers with engine oil
(E030-CD).
+ Tighten the bolts in the order given
in the diagram, and to the following
tightening torgues.
w Flywheel mounting bolt:
Unit : Nm(kgm) I KSlOOOBl
Order Target I Range

1st step 88.3 (9) 58.8 - 117.7 (6 - 12)
2nd step 186.3 (19) 176.5 - 196.1 (18 - 20)
3) Measure face runout and radial runout

of flywheel.
l After installing the flywheel, measure
the face runout and radial runout.
+ Repair limit of face runout: 0.2 mm
+ Repair limit of radial runout: 0.15 mm
6-l.Engine speed sensor (when equipped)

Screw in until speed sensor 3 contacts ring
gear, then turn back l-1/6 turns to make
clearance a and lock in position.
m Locknut: 49.0 - 68.6 Nm (5 - 7 kgm)
Coat the thread portion with hydraulic
sealant.
I OWE00276
7. Front plate
Install the front plate (3).
8. Drive gear for fuel injection pump with drive

case assembly
Install drive gear (2) for fuel injection pump
with drive case assembly.
m Nut:156.9 - 176.5 Nm (16 - 18 kgm)
9. Idler shaft
Install idler shaft (1).
13-21
0
10. Idler gear

Install idler gear (2).
m Gear mounting: 137.3 - 176.5 Nm
(14 - 18 kgm)
11. Oil pump

Install oil pump (1).
12. Camshaft
I) Assemble camshaft(2).
* Be careful not to damage the cam
bushings when installing.
+ Push camshaft center softly. Must
not knock the gear with hammer.
2) Install thrust plate(l).
13. Drive gear of oil pump

Install drive gear (I) of oil pump.
* Check that the match marks of all drive

gears and idler gears are correctly
aligned.
* Measure the backlash and play of each
gear.
a) Backlash
Position Gears Range (mm)

A Crankshaft gear and idler gear 0.085 - 0.307
B Injection pump gear and idler gear 0.054 - 0.380
C 1Cameshaft gear and idler gear 1 0.075 - 0.359
D IOil pump gear and idler gear 1 0.102 - 0.332 6136F30
13-22
b) End play
+ End play of camshaft :0.15 to 0.35 mm
* End play of idler gear :0.08 to 0.14 mm
14. Gear case cover

I) Using push tool @ (0.D.90 mm), press-
fit oil seal (2) in case.
2) Fit gasket and install gear case cover

(I).
& Coat lip surface of front seal with
grease tG2-LI), (about 2 cc).
15. Crankshaft pulley

Install crankshaft pulley (2).
m Mounting bolt: 421.7 - 480.5 Nm
(43 - 49 kgm)
16. Vibration damper

Install vibration damper (I).
w Mounting bolt: 58.8 - 73.6 Nm
(6 -7.5 kgm)
13-23
17. Suction tube

Install suction tube (I).
18. Oil pan

Cut gasket so that it is flush with cylinder
block, front cover and flywheel housing
lower face. Install oil pan (IA).
19. Cylinder head

Assemble cylinder head as follows.
j, If the valve guide has been removed,
use push tool D to install valve guide
(7).
1) Install valve (6).

Sr Coat the stem of the valve with engine
oil (E030-CD).
2) Install valve spring (3) and valve spring
guide (2).
3) Using valve pusher E, compress valve

spring and fit valve cotter (Ijon valve
stem.
+ Remove tool E and tap the valve
stem with a plastic hammer to check
that the cotter is completely fitted.
13-24
It Check that the respective mounting

surface of the cylinder head and cylinder
block are clean and that there is no dirt
or foreign material inside the cylinder.
1) Fit cylinder head gasket.
install cylinder head assembly (1) on the
cylinder block.
2) Coat thread of mounting bolts and

washer seats with antifriction compound
or engine oil.Tighten mounting bolts in TlGHENlffi ORDER OF
order shown in diagram to the following CYLINDER HEAD BOLT
tightening torques.
& Mounting bolts: Antifriction CENTER
compound (LM-PI
w cylinder head :
Unit : Nm(kgm)
Order Target Range
1st step 98.1 (10) 88.3 - 107.9 (9 - 11)
Put mark on cylinder
2nd step 147.1 (15) 142.2-152.0 (14.5 - 15.5) head and boll
3rd step more 90” turn 90” - 120
* After tightening the bolts put one mark

on the bolt head with the pointer. If the
number of marks exceeds 5, replace with
the new bolt.
I
6
--!--
DWE00220
20. Push rods

Assemble push rod (1).
t Check that the push rod is properly fitted
into the tappet.
KS100072
DlSASShMBLY AND ASSEMBLY OVERALL ASSEMBLY
21. Rocker arm assembly

1) Position rocker arm assembly (I).
Ir Check that the ball end of the ad-
justment screw is properly fitted into
the socket of the push rod.
+ If the spring is pushing the rocker
arm, loosen the adjustment screw.
2) Tighten mounting bolts.
3) When the rocker arm shaft is disassem-
bled, assemble it putting the V grooves
of the shaft underside.
4) Adjust valve clearance as follows.

+ Adjust the clearance between valve
and rocker arm as folloes(cold).
intake valve : 0.34 mm
Exhaust valve : 0.66 mm
* Firing order: 1 - 5 - 3 - 6 - 2 - 4
a) Rotate the crankshaft in the normal
direction to align pointer (4) with the
“1.6TOP” mark on the crankshaft
pulley (3). When rotating, check the
motion of the valves.
* When No.1 cylinder is at com-
pression top dead center, adjust
the valves marked 0.
* When No.6 cylinder is at com-
VALVE ARRANGEMENT DIAGRAM
pression top dead center, adjust
the valves marked 0.
TVP01432
b) To adjust clearance, insert feeler gauge

F between rocker arm (5) and valve stem
(6)and turn adjustment screw (7) to the
degree that the gauge moves narrowly.
13-26
0
c) Tighten lock nut (8) to hold adjustment

screw in position. 5 7. 8
w Lock nut: 39.2 - 49.0 Nm (4 - 5 kgm)
* After tightening the lock nut, check the 6
clearance again.
22. Cylinder head cover

Fit O-ring and install cylinder head cover
(2).
a Head cover mounting bolt: 0.8 - 1.0
kgm
23. Nozzle holder
* Check that there is no dirt or damage
inside the holder sleeve or on the contact
surface of the nozzle holder. Install
nozzle holder (I) in cylinder head.
w Mounting bolt:39.2 - 49.0 Nm
(4.0 - 5.0 kgm) KS100070
24. Spill pipe

Install spill pipe (2).
25. Glow plug

Install glow plug (I).
26. Lead
Install lead (1).
w Nut:1 - 2 Nm (0.1 - 0.2 kgm)
KS100119
13-27
27.Water pump
Fit gasket and install water pump (1).
KS100067
28. Fanpulley drive assembly

Install fan pully drive assembly (5).
m Mounting nut:2157 - 255.0 Nm
(22 - 26 kgm)
29. Alternator
Temporarily install alternator (4).
30. Fan belt and water pump belt.

1) Install water pump belt (3).
2) Install fan belt (2).
3) Adjust fan belt tension as follows. I KS100066
a) Raise alternator to outside and tem-

porarily tighten alternator mounting
bolt and plate mounting bolt to the
degree that belt has no loosening. a
Fan pulley
b) After adjusting tension, tighten bolts
Alternator
fully. pulley
c) After adjusting tension, check the
amount of belt deflection when
pushed by 58.8 N (6 kg) of thumb
finger force at a point midway
between pulley and alternator pulley.
* Standard slack (a): 3 mm ADJUSTMENT OF FAN
BELT TENSION
31. Tension pulley Crankihaft pulley
1) Install tension pulley (1).
2) Adjust water pump belt tension as
follows.
a) Watching belt tension, turn the Way pump pulley
adjusting screw inside. Temporarily
tighten lock nut to the degree that
belt has no loosening.
pulley
b) After adjusting tension, tighten bolts
fully.
c) After adjusting tension, check the
amount of deflection when pushed
by 58.8 N (6 kg) of thumb finger force
at a point midway between fan
pulley and water pump pulley. OF WATEI
* Standard slack lb): 3 mm PUMP BELT TENSION
13-28
32. Oil cooler

1) Fit gasket and install oil cooler (2).
2) Fit O-ring and install oil cooler inlet tube
(I).
33. Oil filter

Fit O-ring and install oil filter (I) together
with bracket.
KS100064

Install fuel injection pump (I) to the drive
case.
* When installing the injection pump, align a
line (a) of the injection pump flange and
line (b) of the injection pump drive case.
KS100232
H Tighten these two nuts from pump rear

using socket wrench, universal joint 0,
and extensions @ and 0.
l Extension 0: 300 mm
l Extension 0: 100 mm
w Nut: 58.5 - 73.6 Nm (6 - 7.5 kgm)
KS100233
13-29
35. Thermostat
1) Fit gasket and install thermostat (2).
2) Install connector (I).
KS100063
36. Intake manifold (S6D108, SAA6D108)

1) Usining eyebolts 0 (Thread dia. = 8 mm,
Pitch = 1.25 mm), sling intake manifold
(3).
2) Fit gasket and install intake manifold (3).
(1.5 - 3.5 kgm)
I DKE00117
36-l.Aftercooler,intake manifold (SAGD108)

I) Fit gasket and assemble aftercooler (5)
to intake manifold.
2) Install cover (4).
3) Using eyebolts 0 (Thread dia. = 8 mm,

Pitch = 1.25 mm), sling intake manifold.
4) Fit gasket and install intake manifold(3).
(1.5 - 3.5 kgm)
5) Fit O-ring and install aftercooler outlet
tube (2).
13-30
a
* Coat the O-ring and O-ring groove with

soapy water or vegetable oil. O-rings
Never use mineral oil (engine oil) as this
will cause swelling and deterioration.
622FO1096
6) Fit O-ring and install aftercooler inlet

tube (I).
37. Fuel injection pipe

Install fuel injection pipe (1).
* Using tool 0, install sleeve nut for nozzle
holder.
w Sleeve nut: 19.6 - 24.5 Nm
(2.0 - 2.5 kgm)
(flat width 17 mm)
w Injection pump side sleeve nut:
19.6 - 34.3 Nm (2.5 - 3.5 kgm)
KS100058 KS100059
38. Corrosion resistor (if equipped)

Install corrosion resistor (5) and connect
hose (4).
‘39. Fuel filter

I) Install fuel filter (3).
2) Connect fuel filter inlet hose (1).
3) Connect fuel outlet hose (2).
40. Resetting engine in engine stand
,
KS100057
13-31
41.Turbocharger and exhaust manifold assembly

1) Install turbocharger(5) and exhaust
manifold assembly.
2) Connect intermediate connecter(4)
between turbocharger and aftercooler.
3) Connect inlet tube(2) and outlet tube(3)
between turbocharger and cylinder
block.
42.Starting motor
lnstal starting motor(lA).
43.Oil dipstick guide

Install oil dipstick guide(l).
KS100055
13-32
14 MAINTENANCE STANDARD

Turbocharger . . .. . . . . . . .. . .. . . . . . . . . .. . . . .. . . . . . . .. . . . . 14- 2
ENGINE BODY
Cylinder head.. ....................................... 14- 3
Valve and valve guide ......................... 14- 4
Rocker arm, push rod and tappet.. .... 14- 6
Cylinder liner.. ........................................ 14- 7
Cylinder block ....................................... .14- 8
Crankshaft.. ............................................. 14-10
Camshaft.. ............................................... 14-1 1
Piston, piston ring and piston pin ...... 14-12
Connecting rod ...................................... 14-13
Timing gear.. .......................................... 14-14
Flywheel and flywheel housing.. ........ 14-15
LUBRICATION SYSTEM
Oil pump ................................................. 14-16
Regulator valve.. ................................... .14-17
Safety valve.. .......................................... 14-17
COOLING SYSTEM
Water pump and thermostat . . . . . . .. .. . .. . . 14-18
14-1
MAINTENANCE STANDARD TURBOCHARGER
TURBOCHARGER
S2B (SPITZER)
-
I I I
SKE00103’
Unit:mm
Check item Criteria Remedy
Standard size Repair limit

Play of rotor in radial
0.400 - 0.565 0.840 2

z
2 Play of rotor in axial E:
0.051 - 0.090 0.142 Correct or replace
direction
3 Thickness of thrust
4.35 4.30
bearing
i
Position Standard size Repair limit
3utside
A 10.152 10.130
Outside diameter, jiameter
4 curvature of wheel
B 17.32 17.25
shaft
Curvature Repair limit: 0.0076 (total runout of indicator)

5 !nside diameter of
Insert Replace
12.71 12.71
Position Standard size Repair limit
Inside diameter of
6 C 15.80 15.82
center housing
D 18.06 18.06
Tightening torque of 29.4- 44.1Nm

7 turbocharger (3.0 - 4.5 kgm)
mounting bolt (stud)
14-Z
MAINTENANCE STANDARD CYLINDER HEAD
CYLINDER HEAD
.3
KS100207
i i
KS100094
Unit:mm
-
No Check item Criteria Remedy
-
Distortion of cylinder Standard size Repair limit
Correct by grinding
1 lead mounting
0 - 0.09 0.12 or replace
surface
Engine No Standard
Replace nozzle or
2 ‘rotrusion of nozzle
10001- 3.1 2 + 0.39 gasket
1
Tightening torque of Coat with molvbdenum disulphide
:ylinder head
mounting bolt
3 (Coat thread with
molybdenum (14.5
142.2
88.3 --- 107.9
15.5
15 .ONm
kgm)
Nm any
new bolt
bolt. has 5 punch
disulphide.) marks, replace with
(g-Ilk m)
(Plastic range turnir 9
2nd pass 147.1Nm (15kgm)
angle tightening
method) 3rd pass 105” 90"-120" I
Tightening torque of Target Range
4 nozzle holder Tighten
44.1 Nm (4.5 kgm) 39.2 - 49 Nm (4 - 5 kgm)
mounting bolt
14-3
MAINTENANCE STANDARD VALVE AND VALVE GUIDE
VALVE AND VALVE GUIDE
Cylinder head
r face
14-4
0
MAINTENANCE STANDARD VALVE AND VALVE GUIDE
- Unit : mm
NC Check item Criteria Remedy

-
Valve Standard size
Replace
1 Sinking of valve valve or
Intake, exhaust valves 1.12
valve seat
i
Valve Standard size Repair limit
Thickness of
Intake valve 2.0 1.7
2 Replace
valve lip
valve
Exhaust valve 1.50 1.2
I I
Angle of
I Intakevalve 1 Exhaust valve Repair or
3 replace valve
valve seat Standard
I or valve seat
Valve 1 Standard size 1 Tolerance
-0.030
O.D. of valve Intake valve 9
-0.045 Replace
stem
-0.060 valve
Exhaust valve 9
-0.075
I. D. of valve +0.025 Replace valve
Intake, exhaust valves 9
guide I I -0.010 ouide
4
Valves IStandard clearrancel Clearance limit
Clearance Replace valve
Intake valve 0.040 - 0.070 0.22
between valve or
guide and stem valve guide
Exhaust valve 0.070 - 0,100 0.25
Curvature of
Repair limit : 0.02 (total variation of indicator, per IOOmm) Replace
- valve stem
Height of valve Standard Tolerance
5 guide when Repair
14 + 0.2
- knocked in I
Standard size Reoair limit
Free length of
valve spring 62.69
I
Standard load
61.2
Repair limit Replace valve

Installed length
6 Installed length of
254 k12.8N 227.5N spring
valve spring 51.1
(25.76 + 1.3ka) (23.2ka)
Out-of straight of
Repair limit 2”(at both ends)
- valve spring
14-5
0
MAINTENANCE STANDARD ROCKER ARM, PUSH ROD AND TAPPET
ROCKER ARM, PUSH ROD AND TAPPET
KS100098
Unit:mm
-
- I I

D.D. of rocker arm I n Replace rocker
”
arm shaft
-0.020
Standard clearance Clearance limit
I.D. of rocker arm Replace rocker
+ 0.030
1 shaft hole 19 arm
+ 0.010
Clearrance between Standard clearance Clearance limit Replace rocker
rocker arm shaft and arm or rocker arm
0.010 - 0.050 0.13
rocker arm shaft hole shaft
Curvature of rocker Replace rocker
Repair limit : 0.20 (total variation of indicator)
arm shaft arm shaft
2 Curvature of push rod Repair limit : 0.30 (total variation of indicator) Replace push rod
rightening torque or Target Range

oke nut for rocker 39.2 - 49.0 Nm Tighten
3
3rm adjustment 44.1 Nm (4.5kgm)
screw (4 -5 kgm)
Valve Standard 1 Tolerance
I
4 dalve clearance
)I fO.02 Adjust
Iwhen cold)
Standard size Tolerance

3.D. of tappet - 0.020 Replace tappet
18
- 0.038
+ 0.018 Replace cylinder
5 I.D. of tappet hole 18
0 head
Clearance between Standard clearance Clearance limit
Replace tappet or
tappet and tappet
0.020 - 0.056 0.20 cylinder head
hole
14-6
MAINTENANCE STANDARD CYLINDER LINER
CYLINDER LINER
40mm
1
KS100209
Unit:mm
tz
No. Check item Criteria Remedy
Protrusion of Replace cylinder linn-

1 Permissible range : 0.05 - 0.13
cylinder liner er or cylinder block
Standard size Tolerance Repair limit
Inside diameter of
+ 0.032
cylinder liner 108 108.20
n
2 Roundness of
Repair limit : 0.15
cylinder liner Replace cylinder
Cylinder of cylinder linner
Repair limit : 0.08
liner
Outside diameter of Standard size Tolerance
cylinder liner 0
120
3 (Counter bore) -0.08
Clearance between
cylinder block and Replace cylinder
Standard clearance : 0.10 - 0.28
cylinder liner liner or cylinder block
(Counter bore)
Interference between Standard Tolerance Standard
Mark
cylinder liner and cy- size Liner O.D. Block I.D. interference
Replace cylinder liner
linder block + 0.029 + 0.012
S or cylinder block
4 (The average value + 0.017 + 0.006
(Selection of size)
in the front-rear and + 0.042 + 0.024 0.005 -
111.4 M (Assemble a part of
left-right dirsctions + 0.029 + 0.012 0.030
the same mark)
at a point 40mm -t 0.053 + 0.030
L
from the top surface) + 0.042 + 0.04
14-7
MAINTENANCE STANDARD CYLINDER BLOCK
CYLINDER BLOCK
\ for PC300
/5
7 ,
L
8
/
6
\ 10
KS100210
KS100211
14-8
MAINTENANCE STANDARD CYLINDER BLOCK
Unit:mm
Distortion of cylinder Standard size Repair limit

Repair by grinding
1 head mounting
0 - 0.080 0.12 or replace
surface
Inside diameter of Standard size Tolerance
main bearing + 0.022
101
mountina hole I I 0
Straightness of main
Replace main
2 bearing mountig Repair limit : 0.010
bearing cap
hole
Roundness of main
bearing mounting Repair limit : 0.005
hole
Inside diameter of Replace main
3 + 0.050
main bearing 95 95.15 bearing
+ 0.006
Inside diameter of Standard size Tolerance
4 bushing mounting + 0.030 Replair or replace
62
hole I 0
Inside diameter of Replace camshaft
5 + 0.088
camshaft bushing 59 59.3 bearing
+ 0.009
2 Difference between
;J 6
cylinder block lower
Repair limit : 0.13
H face and flywheel
housing
Difference between Repair by
7 cylinder block lower Repair limit : 0.11 reassembling
face and front cover
Difference between
Plate protrusion : 0.04
8 cylinder block lower Repair limit
Plate inset : 0.22
face and front olate
Tightening torque of I Order I Tarnet I Ranae
main bearing cap 1st step 78.5 Nm 68.6 - 88.3 N m
mounting bolt
(8 kgm) (7 - 9 kgm)
(Coat bolt thread
9 2nd step 156.9 Nm 152.0 - 161.8 Nm
with engine oil)
(Tightening using (16 kgm) (15.5 - 16.5 kgm)
plastic range turning
3rd step 105” 90” - 120”
angle) 1 Tighten
Tightening torque of
18.6 Nm 13.7 - 23.5 Nm
oil pan mounting
(1.9 kgm) (1.4 - 2.4 kgm)
bolt
451 Nm 421.4 - 480.2 Nm
11 crankshaft pulley
(46 kgm) (43 - 49 kgm)
mountina bolt
14-9
MAINTENANCE STANDARD CRANKSHAFT
KS100103
No.
z
eanng ;;
of
3 I 1.00 u.s I 69.00 1

t-z%-i
I 68.87
Correct
I under size
or replace
Repair limit : 0.020
Standard Clearance limit

Clearance at crank Replace connecting
pin journal 0.040 0.28 rod bearing
Correct under-size
4 Bend of crankshaft Repair limit : 0.2 (total variation of indicator)
or replace
14-10
MAINTENANCE STANDARD CAMSHAFT
CAMSHAFT
KS100212
Unit:mm

1 End play Replace thrust plate
0.15-0.35 0.50
Standard size Tolerance

O.D. of camshaft
- 0.03 Replace
journal 59
- 0.06
2
Standard clearance Clearance limit
Clearance at
Replace bushing
camshaft journal 0.039 - 0.148 0.28
3 Curvature of
Repair limit : 0.03 (total variation of indicator)
camshaft
Cam Standard size Tolerance Repair limit
Intake 50.76235 + 0.10 50.26 Replace
4 Cam height
Exhaust 49.87052 + 0.10 49.37
14-11
MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN
PISTON, PISTON RING AND PISTON PIN
Unit:mm

-
I I
Outside diameter of
1 Replace piston
piston 107.830 + 0.015
Thickness of piston
groove
Replace piston or
piston ring and Judge using groove wear gauge
piston ring groove
Piston ring gap
Replace piston pin
Replace piston pin
Standard weight Remissible range

6 Weight of piston
I 1,350 g f 139
14-12
CONNECTING ROD
6136F046
Unit:mm
Check item Criteria Remedy

I.D. of bushing at Standard size Tolerance
small end of
45
+ 0.041 Replace bushing
connectina rod + 0.025
1
Clearance between Standard clearance Clearance limit
bushing and piston Replace bushing or
pin at small endof 0.025 - 0.048 0.10 piston rod
connecting rod
I.D. of bushing Standard size Tolerance
mounting hole at Replace connecting
2 small endof + 0.025 rod
49
connecting rod I
0 I
I.D. of bearing atbig Standard

size I Tolerance ReDair limit
end of connecting
3 rod (crank Din I + 0.035 I
- journal)
I.D. of bearing
mounting hole atbig
4 end of connecting I I
- rod Measure after tightening connecting rod cap to specified torque. Replace
connecting
Curvature and twist Bend repairlimit a : 0.25 rod
5
of connecting rod Twist repair limit b : 0.35
SWEOl623 Dimension c : 205
Tightening torque of Order Target Range
connecting rod cap 1 st 73.6 Nm(7.5 kgn) 71.6- 75.5 Nm
6 mounting bolt
7
Coat bolt threads
and nut seats with
engine oil
Weight of
I 2nd 10.5"
Repair limit : 2,437

(7.3 - 7.7 kgn)
90"- 120"
* 70 (g)
Tighten
Replace
- connecting rod
14-13
(9
MAINTENANCE STANDARD TIMING GEAR
TIMING GEAR
.._..-..- .._..- .._.._..

-.._..-..-..-..-.A...:
6136FO44
Unit:mm
No.
-
Crank gear and idler gear 0.062 - 0.213

A
Replace bushing
2 Gear back lash
C
O.D. of idler gear
Replace bushing
idler gear bushing
Idler gear end play Replace thrust plate
14-14
MAINTENANCE STANDARD FLYWHEEL AND FLYWHEEL HOUSING
FLYWHEEL AND FLYWHEEL HOUSING
2
1
z KS100108
K4 Unit:mm
sf - I
NC Check item Criteria Remedy
-
Face runout of
1 Repair limit : 0.35
flywheel housing Correct and
-
Radial runout of reassemble
flywheel housing
-
Tightening torque of Target Range
3 flywheel housing Tighten
107.9Nm (Ilkgm) 98.1 - 122.6Nm (IO - 12.5kgm)
- mounting bolts
Face runout of
flywheel Correct and
-
Radial runout of reassemble
- flywheel
flywheel mounting
bolts
6 176.5 - 196.1Nm
Coat thread, seat
and washer with
i: engine oil. 1
Installation position
for rear seal
7 Double lip oil seal
Single lip oil seal 23
14-15
MAINTENANCE STANDARD OIL PUMP
LUBRICATION SYSTEM
OIL PUMP t--%3
5
6
9
7
SKEOO 106
Unit:mm
Tolerance Standard Clearance
Axial clearance of
1
pump gear
Radial clearance of
2
pump gear
3 pump drive gear and

drive shaft
5
-
7
-
8
-
9
- -t driven shaft and cover
14-16
a
MAINTENANCE STANDARD REGULATOR VALVE, SAFETY VALVE
REGULATOR VALVE SAFETY VALVE
KS100110 KS100111
Unit:mm
No. Check item I Criteria I Remedy
Tolerance Standard
Standard size
, Clearance between Shaft Hole clearance
Replace
valve and body - 0.040 -I- 0.043
18 0.040 - 0.103
- 0.060 0
l Free length
Standard size : 44.9
2 Regulator valve l Installed load
Replace
spring Installed length Standard load Repair limit
I I
I 38.97 155.9 N (15.9 kg) 273.6 N (27.9 kg)
5 Operating pressure 1.0 2 0.05 MPa (IO.0 + 0.5 kg/cm’) Adjust

of regulator valve
6 Operating pressure
0.2 + 0.02 MPa (2 f 0.2 kg/cm’) Replace cartridge
of relief valve
14-17
COOLING SYSTEM
WATER PUMP AND THERMOSTAT
4\ w /3
W (v
SKE00107 SKE00108
z
(v
(v
- Unit:mm (D
No, Check item Criteria Remedy
Interference between
Standardsize I Shaft O.D. I Impeller I.D.
I interference
Standard
3eplace (usualy re-
1
impeller and shaft
12
0
- 0.013
- 0'030
- 0.055
I dace impeller, shaft
0.017 - 0.055 3.D. rarely changes)
Clearance between
2 Standard clearance: 0.3 - 1.3
- body and impeller
Abrasion of seal ring
3 A dimension repair limit : 0
in water seal -e.-.)-. Replace
F14035
Total variation of indicator, measure by

4 Curvature of shaft Repair limit : 0.1 mm face run-out at point 40 mm fromcenter
of pulley
- ~
Full open lift of Permissible Inspect afterimmersion for 4 - 5

Min.6
thermostat range minites in water at 85"
I
5 Replace
Opening and closing Valve shoud befully closed afterimmersion for 4 - 5 min in
of thermostat water from fullyopen (85")to fully closed (71")
14-18
@
15 REPAIR AND REPLACEMENT
OF PARTS
Repairing mounting face of cylinder

head by grinding . . . . . . . . . . . . . . . . . . . . . . 15-2
Replacing valve seat insert . . . . . . . . . . . . . . . . 15-3
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Replacing valve guide . . . . . . . . . . . . . . . . . . . . 15-8
Grinding the valve . . . . . . . . . . . . . . . . . . . . . . . 15-9
Replacing cam bushing . . . . . . . . . . . . . . . . . . 15-10
Replacing crank gear . . . . . . . . . . . . . . . . . . . 15-12
Replacing cam gear . . . . . . . . . . . . . . . . . . . . 15-12
Replacing flywheel ring gear . . . . . . . . . . . . . . 15-13
Replacing main bearing cap . . . . . . . . . . . . . . 15-14
Grinding crankshaft . . . . . . . . . . . . . . . . . . . . . 15-15
Replacing engine rear seal . . . . . . . . . . . . . . . 15-20
Replacing connecting rod small
small end bushing . . . . . . . . . . . . . . . . . . . 15-23
15-1
REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD
REPAIRING MOUNTING FACE OF

CYLINDER HEAD BY GRINDING
1. Grinding
1) Remove the valve seat inserts. For
details, see REPLACING VALVE SEAT
INSERTS.
2) When grinding within the repair limit
for cylinder head height (H) to remove
deformation of corrosion from the
cylinder head, stamp an (R) mark on the
left side face of the cylinder head.
j, Repair limit of cylinder head height
6136F501
(HI : 99.5mm
(Standard size 99.8 - 100.2 mm)
* Amount to remove per grinding :
0.10 to 0.15 mm
-k Surface roughness of grinding

surface : Within 6s
j, Flatness (deformation):
0.05mm max.
* Grinding limit : 0.3mm
3) Press-fit the valve seat inserts. For
details, see REPLACING VALVE SEAT
INSERTS.
2. Check after grinding

Check the amount of sinking of the valve to
confirm that it is within the standard value.
Carry out further modification and
adjustment if necessary.
+ Standard sinking of valve:
1.12 + 0.18 mm
j, Allowable protrusion of nozzle :
2.73 to 3.51mm
15-2
REPAIR AND REPLACEMENT OF PARTS VALVE SEAT INSERT
REPLACING VALVE SEAT INSERTS

Special tools
Part No. Part Name O’tv
F-T---795-100-4800 Puller (Valve seat) I 1

B 1790-471-I 150 1Push tool (for intake valve) I 1
-
C j 790-470-I 160 1Push tool (for exhaust valve) I1
795-100-3003 Seat cutter (kit) 1
795-100-3100 Body assembly 1
795-100-3200 Micrometer 1
1
795-100-3300 Gauge 1
795-100-3400 Tool head 1
795-100-3601 Head support 1
D 2 795-100-3710 Cutter 1
-
3 795-100-3720 Cutter (for 30”) 1
I 4 I795-loo-3730 ICutter (for 45”) I1
I-IIIyyIIIIII1.III.
795-100-4110
795-100-4130
Pilot (9.00 mm)
Pilot (9.02 mm)
795-100-4140 Pilot (9.03 mm)
1. Pulling out the valve seat insert

1
AL Before using the grinder, run it for a
minute to test it.
. After replacing the grindstone, run

the grinder for three minutes to test
it.
A Confirm that the grindstone is not dam-

aged, then install it to the shaft of the
grinder without applying excessive force.
Confirm that there is no play between 6162F504
the grindstone and shaft.
AWhen using the grinder, wear safety

goggles.
. When using a valve seat puller to remove

the valve seat
1) Install grindstone @ to grinder 0.
2) Align the groove of sleeve @with holder
0, then insert.
* Adjust the position of the grinder
with set screw 0.
15-3
a
REPAIR AND REPLACEMENT OF PARTS VALVE SEAT INSERT
3) Adjust the position of the grinder so that

the center of grindstone @ will be at the
center of seat insert (I), then tighten the set
screw to secure the grinder.
4) Rotate the grindstone and move slowly un-
til it contacts insert (I).
6162F505
5) Press the grindstone against the inside of

the insert, move it in a circular pattern, and
make a groove about 1 mm deep.
61 Push in the three claws (a) on puller head

8 of tool A by hand to insert it inside insert
(I).
7) Tighten screw @ to press the three claws

against the groove on the inside surface of
the insert.
* When the claws contact the groove com-
pletely, stop tightening.
8) Place bridge @ over the puller head, then

place plates @ and @I on the bridge.
Tighten nut @ to pull out the insert
. When welding a bar to the insert to remove

the seat insert
I) Weld bar (I) of radius approx. pr 10, that
is 0.1 - 0.5mm shorter than the inside
diameter to the inside diameter of insert
(2).
+C Be careful not to let the welding
metal stick to. the head itself.
2) when the temperature of the weld goes

down to around room temperature, in-
sert an old valve (3) in the reverse direc-
tion, and tap the head of the valve with
a small hammer to knock out the insert.
Sr if the valve is hit too hard, the weld
may break. 6127F206
15-4
REPLACING MAIN BEARING CAP
* When replacingthemainbearing cap, ma-
chine the semi-finished product as follows,
9 Main bearing cap mounting bolt: Unit:Nm(kgm)
Range Target Order
then install.
1st step r?: 9.8(+ 1)
1. Machining inside diameter of main bearing
step 2nd r?: 4.9(+0.5)
cap
liner.
cylinder
the
Remove step 3rd
Install the replacement main bearingcap
to the cylinder block, and tighten to the
specified torque.
j , Alignthecylinderblockandthe
notch in the cap.
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 block.
Of the main bearing caps to be used
again, take the one with the longest pitch
and put a dial gauge in contact with the
inside diameter at two places to align
the center of the boring machine arbor.
5) Check the machined inside diameter of

bearing cap (1) and grind a little at a
time.
* Grind until the bit touches the in-
side surface of cylinder block (2).
* Inside diameter of main bearing cap
i-0.022
Tolerance:
0101 mm
J, Finishing roughness: Within 12.5 S
J, Do not grind the inside face of the
cylinder block.
‘1 6127F223
2. Machining width of main bearing cap

Insert-cast iron bushing (61, then pass
arbor (7) through.
Install facing bit ( 8 ) to the arbor.
Grind cap (9) until the bit touches the
cylinder block face.
Grind the opposite side in the same way.
Width of main bearing cap Tolerance:
35 - 8.025 mm
Roughness of thrust bearing mounting
surface: Within 12.5 S
Do not grind the cylinder block.
15-14
@
REPLACING CONNECTING ROD SMALL END BUSHING
Special tools
Part No. Part Name
B
1
3 1795-233-1230Block I
1
4 795-233-1240Nut 1
1. Removal of connecting rod bushing

1) Set the connecting rod(2)on tool B4.
2) Using tools B1 a n d B3, remove the
connecting rod bushing(l), with a press.
* After removing the bushing, remove any
burrs or dirt, and clean the mounting
hole of the bushing.
hl
zN
hl
419
2. Press fitting connecting rod bushing
1) Set the connecting rod on tool B3.
2) Assemble the connecting rod bushing(l),
t o t o o l BI, then set tool B2 and secure
with tool B4 so that it dose not move.
* Align the connecting rod bushing oil hole
and the connecting rod oil hole.
3) Push tool B1 with a press and press fit
the connecting rod bushing ( I ) .
The bushing is a semi-finished product, and
the insude diameter is small, so the piston
pin will not.
After press fitting the bushing, machine the
inside diameter of the bushing with a reamer
or honing machine in accordance with the
MAINTENANCE STANDARD.
-k Aftermachining,removeallthemetal
particles from the oilhole and oil groove.
15-23
@
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

Manual: Diesel Engine

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Manual: Diesel Engine

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it is possible and practicalto do so. We reserve the right to make

January 2001 Copyright 2001 Komatsu

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Mark page Revision Mark page Revision ~ ~ page

0 00-1 11-6 ' 0 11-39 0 12-33 13-24

11 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 11-l

12 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

14 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . ..m......................... 14-1

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

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

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

Item number (10. Structure

Example 2 (Engine volume):

• If a part cannot be smoothly removed from

ﬂ The allowable load value is estimated to

2) Sling wire ropes from the middle portion

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

• Used to prevent rubber gaskets, rubber

• Features: Resistance to heat and chemi-

790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

• Quick hardening type adhesive

• Quick hardening type adhesive

• Features: Resistance to heat, chemicals

• Used as adhesive or sealant for gaskets

• Used as sealant for various threads, pipe

• Features: Silicon based, quick hardening

Three bond • Used as heat-resisting sealant for repairing

• Used as lubricant for sliding portion (to pre-

SYG2-400LI • General purpose type

• Used for normal temperature, light load

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Thread diameter Width

Thread diameter Width

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Thread diameter Tightening torque

ELECTRIC WIRE CODE

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)

Minimum fuel g/kWh 217{160)(50Hz) 1 218{160)(50Hz)