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SEBE6120A04

(2
C5:

7A

J \

KOMATSU ENGINE

155-4 SERIES

Printed in Japan 0 0 -1
02-90(01)05881

from the library of Barrington Diesel Club


LIST OF REVISED PAGES LIST OF REVISED PAGES

The affected pages are indicated by the use o f the


follow ing marks. It is requested th at necessary actions be Mark Indication Action required
taken to these pages according to the table below.

O Page to be newly added Add

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Pages having no marks are those previously revised or


made additions.

LIST OF REVISED PAGES


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00-2 155-4 SERIES

from the library of Barrington Diesel Club


LIST OF REVISED PAGES LIST OF REVISED PAGES

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• 11-408 £ 11-613 • 12-708 £ 13-023 13-204 £

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© 11-409-2 £ • 12-905 £ 13-107-2 £ 13-214

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155-4 SERIES 00 2-1


-

(3)
from the library of Barrington Diesel Club
LIST OF REVISED PAGES LIST OF REVISED PAGES

Time of Time of Time of Time of .. . D Time of


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14-005 (D 14-046 CD 15-039 ®


14-006 15-040 D
14-007 15-041 D
14-008 15-001 • 15-042 ®

14-009 D 15-003 CD 15-043 D


14-010 <D 15-004 CD 15-044 D
14-011 D 15-005 CD 15-045 D
14-012 (D 15-006 CD 15-046 D
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• 14-015 ■® 15-009 CD 15-049

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00 2-2
- 155-4 SERIES

from the library of Barrington Diesel Club


CONTENTS
N o . o f page

0 1 G E N E R A L .............................................................. 01-001

11 S T R U C T U R E AND F U N C T IO N

GENERAL STRUCTURE............................................................................ 11 -004


INTAKE AND EXHAUST SYSTEM.................................................................. 11-102
ENGINE............................................................................................................... 11-201
LUBRICATION SYSTEM .................................................................................. 11 -302
FUEL SYSTEM.................................................................................................. 11-401
COOLING SYSTEM........................................................................................... 11-502
ACCESSORY...................................................................................................... 11-602

1 2 T E S T IN G AND A D J U S T IN G

FUEL SYSTEM.................................................................................................. 12-402


PERFORMANCE T E S T ................ 12-701
TESTING AND ADJUSTING TOOL LIST....................................................... 12-901
TESTING AND ADJUSTING, TROUBLESHOOTING CRITERIA..................... 12-902

1 3 D IS A S S E M B L Y AND ASSEM BLY

OVERALL DISASSEMBLY................................................................................ 13-004


OVERALL ASSEMBLY ...................................................................................... 13-102
DISASSEMBLY AND ASSEMBLY OF ASSEMBLY PART............................ 13-202

1 4 M A IN T E N A N C E STANDARD

INTAKE AND EXHAUST SYSTEM.................................................................. 14-004


ENGINE............................................................................................................... 14-008
LUBRICATION SYSTEM ................................................ 14-030
COOLING SYSTEM..................... 14-036
ACCESSORY........................................................................................... 14-037

1 5 R E P A IR AND REPLACEM ENT 15-001

155-4 SERIES 0 0 - 2 -3
( ?)

from the library of Barrington Diesel Club


A IM PO R TA N T SAFETY NOTICE

Proper service and repair is extremely im portant fo r the safe operation o f your machine.
The service and repair techniques recommended by Komatsu and described in this
manual are both effective and safe m ethods o f operation. Some o f these operations re­
quire the use o f tools specially designed by Komatsu fo r the purpose.

To prevent injury to workers, the symbols Aand ^ are used to mark safety pre­
cautions in this manual. The cautions accompanying these symbols should always be
follow ed carefully. If any dangerous situation arises or may possibly arise, first consider
safety, and take the necessary actions to deal w ith the situation.

A SAFETY
GENERAL PRECAUTIONS 6. Decide a place in the repair w orkshop to
keep tools and removed parts. Alw ays keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual A lways keep the w ork area clean and make
carefully BEFORE operating the machine. sure th a t there is no d irt or oil on the floor.
Smoke only in the areas provided fo r
1. Before carrying out any greasing or repairs,
smoking. Never smoke while working.
read all the precautions given on the
decals which are fixed to the machine.
2. W hen carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes w ith buttons 7. 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 w ith a hammer. machine fro m moving.
• A lw a ys w ear sa fe ty glasses when
8. Before starting work, lower blade, ripper,
grinding parts w ith a grinder, etc.
bucket or any other w ork equipm ent 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 w ork
work. W hen carrying out welding work, equipm ent from falling. In addition, be sure
always wear welding gloves, apron, glasses, to lock all the control levers and hang
cap and other clothes suited fo r welding warning signs on them.
work. 9. W hen disassembling or assembling, sup­
port the machine w ith blocks, jacks or
4. When carrying out any operation w ith tw o
stands before starting work.
or more workers, always agree on the op ­
erating procedure before starting. Always 10. Remove all mud and oil from the steps or
inform your fellow workers before starting other places used to get on and o ff the
any step o f the operation. Before starting machine. Always use the handrails, ladders
work, hang UNDER REPAIR signs on the or steps when getting on or o ff the
machine. Never jum p on or o ff the machine.
controls in the operator's compartm ent.
If it is impossible to use the handrails,
5. Keep all tools in good condition and learn ladders or steps, use a stand to provide safe
the correct way to use them. footing.

0 0 -3
from the library of Barrington Diesel Club
ELECTRIC W IRE CODE

ELECTR IC W IRE CODE


In th e w irin g d iagram s, various colors and sym bols are em plo yed to indicate th e th ickn ess o f w ires.
T his w ire co d e tab le w iil help you understand W IR IN G D IA G R A M S .
Exam ple: 5 W B indicates a cable having a nom inal n u m b e r 5 and w h ite coating w ith black stripe.

CLASSIFICATION BY THICKNESS

Copper wire
Nominal Cable O.D. Current rating
number Number Applicable circuit
Dia. of strands Cross section (mm) (A)
strands (mm) (mm-)

0 .8 5 11 0 .3 2 0 .8 8 2.4 12 Starting, lighting, signal etc.

2 26 0.3 2 2.0 9 3.1 20 Lighting, signal etc.

5 65 0 .3 2 5 .2 3 4.6 37 Charging and signal

15 84 0 .4 5 13 .3 6 7.0 59 Starting (Glow plug)

40 85 0 .8 0 4 2 .7 3 1 1.4 135 Starting

60 127 0 .8 0 6 3 .8 4 13.6 178 Starting

100 217 0 .8 0 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Circuits
Prior­
Classn1' ^ Charging Ground Starting Lighting Instrument Signal Other
ity
fication

Code W B B R Y G L
Pri­
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 W hite & Black - Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red
Auxi­
liary
Code WL - BR RY YG GY LY
4
Color White & Blue - Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow

Code WG - - RG YL (GB) (LB)


5
Color W hite & Green - _ Red & Green Yellow & Blue (Green & Black) (Blue & Black)

Code - - - RL YW (GL)
0
Color - - - Red & Blue Yellow & White (Green & Blue) -

00-10
from the library of Barrington Diesel Club
ENGINE

01 GENERAL

155-4 SERIES 01-001


from the library of Barrington Diesel Club
GENERAL
GENERAL VIEW ................................................................... 01-004

SP EC IFIC A TIO N S................................................................... 01-102

GENERAL ASSEMBLY D R A W IN G .................................... 01-202


WEIGHT T A B L E .......................................................... 01-302

PERFORMANCE C U R V E S ................................................... 01-401

155-4 SERIES 0 1 -0 0 3
<D
from the library of Barrington Diesel Club
GENERAL VIEW GENERAL

G E N E R A L VIE W

S4D155-4

1. Tension pulley
2. Tension spring
3. Accessory drive pulley
4. Front support
5. Air cleaner
6. Fuel injection pipe
7. Cam shaft lubrication pipe
8. Fuel filter
9. Fuilflow filter
10. O ilfille r
11. Fuel injection pump

12. Exhaust manifold


13. Generator
14. Starting motor
15. Oil cooler
16. Water pump

6 I2 7 P 0 0 2

0 1 -0 0 4 155-4 SERIES
<D

from the library of Barrington Diesel Club


GENERAL GENERAL VIEW

S6D155-4 (WITH STARTING MOTOR)


ENGINE SERIAL No. 10011 ~ 1999S

1. Tension pulley
2. Tension spring
3. Accessory drive pulley
4. Front support
5. Air cleaner
6 . Thermostat
7. Fuel pipe
8 . Cam lubricating pipe
9. Fuel filter
10. Fullflow filter
11. O ilfille r
12. Fuel injection pump

6 I2 7 P 0 0 3

Exhaust manifold
Generator
Starting motor
Oil cooler
Water pump

6 I2 7 P 0 0 4

155-4 SERIES 0 -0 0 5
(D

from the library of Barrington Diesel Club


GENERAL VIEW GENERAL

S6D155-4 (WITH 2G84 STARTING ENGINE)


ENGINE SERIAL No. 10011 ~ 19999 (OPTION)

6 . Air cleaner
7. Fullflow filter
8. Fuel filter
9. O ilfille r
10. Fuel injection pump
11. Fuel injection pipe

6 I2 7 P 0 0 6

01-006 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL GENERAL VIEW

S6D155-4 (WITH STARTING MOTOR)


ENGINE SERIAL No. 20000 - 24804

1. Fuel filter
2. Fuel injection pipe
3. Air cleaner
4. Oil filter
5. Oil filler

6. Fuel injection pump


7. Piston cooling nozzle

6 I2 7 P 0 0 7 A

8. By-pass filter
9. Corrosion resistor
10. Exhaust manifold
11. Generator
12. Tension pulley
13. Tension spring
14. Accesory drive pulley

15. Front support


16. Water pump

17. Oil cooler


18. Starting motor

6 I2 7 P 0 0 8 A

155-4 SERIES 0 1 -0 0 7
CD
from the library of Barrington Diesel Club
GENERAL VIEW GENERAL

S6D155-4 (D150, 155A-1)


ENGINE SERIAL No. 24805 and up
1. Fuel filter
2. Air cleaner

3. Front support
4. Oil level gauge
5. Fuel injection pump

6. Piston cooling nozzle

7. Oil filler

8 . Oil filter

3 4
6 I2 7 P 0 0 9

9. Starting motor
10. By-pass filter
11. Corrosion resistor
12. Turbocharger
13. Muffler
14. Thermostat housing

15. Alternator
16. Tension pulley
17. Accessory drive pully
18. Vibration damper

6 I2 7 P 0 I 2

01-008 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL GENERAL VIEW

S6D155G-4

1. Alternator
2. Fuel filter
3. Air cleaner
4. Piston cooling nozzle

5. Front support
6. Oil level gauge
7. Fuel injection pump

8 . Oil filler
9. Oil filter

6 i 27P0S 3

10. Turbocharger
11. Thermostat housing
12. Fan
13. Starting motor
14. By-pass filter
15. Corrosion resistor

16. Water pump


17. Accessory drive pulley
18. Tension pulley
19. Vibration damper

13 14 15 16 17 18 19 6 I2 7 P 0 I 4

155-4 SERIES 0 1 -0 0 9
CD
from the library of Barrington Diesel Club
GENERAL VIEW GENERAL

SA6D155-4

1. Front support

4 5 6 2. Tension pulley
3. Alternator

4. Breather
5. Fuel filter

6. Air cleaner
7. After-cooler

8. Flywheel housing

9. Oil filter
10. O ilfille r

11. Fuel injection pump

12. Vibration damper

13. Accessory drive pulley

6 I2 7 P 0 I 5

14. Turbocharger

15. Thermostat housing

16. Tension pulley

17. Starting motor

18. By-pass filter

19. Corrosion resistor

2 0 . Alternator
2 1 . Water pump
2 2 . Accessory drive pulley
23. Vibration damper

17 18 19 20 21 22
6 1 27P 0I 6

01-010 155-4 SERIES

from the library of Barrington Diesel Club


SPECIFICATIONS GENERAL

S P E C IF IC A T IO N S

Engine modei S4D155-4

Machine D80A-17 D85A-17 D95S-1

Number of cylinders — Bore x Stroke (mm) 4 - 155 x 170

Totbl piston displacement (cc) 12,840

Firing order 1- 2 - 4 - 3

Overall length (Fan to Rear support) (mm) 1,426 1,426 1,456

c
o Overall with (mm) 1,110 1,110 1,125
C/5
a>
E Overall height (Excluding exhaust pipe) (mm) - - 1,910
Q
Overall height (Including exhaust pipe) (mm) 2,570 2,530 3,305

Flywheel horsepower (HP/rpm) 2 10/1,850 240/1,850

0) Maximum torque (kg.m/rpm) 9 8/1,200 112/ 1,200


o
c
CO
E No-load maximum engine speed (rpm) 2,050 ± 50 2,050 ± 50
o
03
CL No-load minimum engine speed (rpm) 600 t 50 600 ± 50

Minimum fuel consumption ratio (g/HP.h) 180 180

Dry weight (kg) 2,050

Fuel pump BOSCH PES-PD type

Governor BOSCH RSUV centrifugal all speed governor

52 (*47) Engine Serial No.


Lubricating oil amount (refill capacity) (2) 52 (47) ~ 50278
64 (*47) Engine Serial No.
50279 ~

Coolant aount (2 ) 84 79

Alternator 2 4 V , 20A (Generator)

Starting motor 24 V, 11 kW

Battery 12V 200Ah x 2

Turbocharger K TR130

Air compressor -

A fter cooler -

* Change the oil every 250 hours service.


Add another 122 for by-pass filter every 500 hours service.

01-102 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL SPECIFICATIONS

S6D155-4

D150A-1 (Engine D150A-1 D155A-1 (Engine D155A-1 (Engine D155A-1


Serial No. 1 0 0 1 1 -1 9 9 9 9 ) (Engine Serial No. 20000—) Serial No. 1 0 0 1 1 -1 2 2 9 7 ) Serial No. 1 2 2 9 8 -1 9 9 9 9 ) (Engine Serial No. 20 0 00 —)

6 - 155 x 170

19,260

1 — 5 — 3 —6 —2 —4

1,893 1,880

1,190 1,190

1,931

2,933 2,914

300/2,000 300/2,000 300/2,000 32 0 /2 ,0 0 0 3 2 0 /2 ,0 0 0

134/1,400 134/1,400 134/1,400 144/1,400 1 44/1,400

2,230 ± 50 2,230 ± 50 2,230 ± 50 2,230 ± 50 2,230 ± 50

600 ± 50 600 ± 50 600 ± 50 6 00 ± 50 6 0 0 ± 50

185 180 185 185 180

2,490 2,600 2,490 2,580

BOSCH PES-PD type

BOSCH RSUV centrifugal all speed governor

77 (*57) 77 (*5 7 )
Engine Serial No. ~2 48 0 4 Engine Serial No. ~ 2 4 8 0 4
63 ( 56) 75 (*55) 75 (*5 5 )
Engine Serial No. 24805 — Engine Serial No. 24805 ~

120

24V, 20A (Generator) 24 V , 20A (Generator)


24 V, 20 A (Generator) No. -2 0 8 0 4 24 V , 20A (Generator) No. - 2 0 8 0 4
24V, 35A No. 2 0 8 0 5 - 2 4 V , 35A No. 2 0 8 0 5 -
24 V, 11 kW 2 4V , 11 kW 24 V, 11 kw 24 V , 11 kW

12V 200Ah x 2 12V 200Ah x 2 12V 2 00Ah x 2 12 V 200Ah x 2

KTR130

155-4 SERIES 01-103


from the library of Barrington Diesel Club
SPECIFICATION GENERAL

Engine modei S6D155-4

Machine D155S-1 D155S-1 D155W-1


(Eng. No. 15182 - 19999) (Eng. No. 20001 and up) (Eng. No. 20001 - 24804)

Number of cylinders — Bore x Stroke (mm) 6 - 155 x 170

Total piston displacement (cc) 19,260

Firing order

00
in

CO

CM

*3* :
I

i ;
Overall length (mm) 1,890 1,890 1,864
tn
c
o Overall width (mm) 1,190 1,190 1,180
'55
a)
E Overall height (Excluding exhaust pipe) (mm) 1,930 1,930 1,839
b
Overall height (Including exhaust pipe) (mm) 3,135 3,198 -

Flywheel horsepower (HP/rpm) 350/2,000 270/2,000

a)
o
Maximum torque (kgm/rpm) 160/1,400 120/1,400
c
<0
E No-load maximum engine speed (rpm) 2,240 ± 40 2,240 ± 40
o
<o
CL No-load minimum engine speed (rpm) 600 ± 50 600 ± 50

Minimum fuel consumption ratio (g/HPh) 175 180

Dry weight (kg) 2,490 2,575

Fuel pump BOSCH PES-PD type

Governor BOSCH RSUV centrifugal all speed governor

Lubricating oil amount 63 77 80


W
(Refill capacity) (56) (*57) (*60)

Coolant amount (2) 160

Alternator 24V, 32A (Generator) 24V, 20A 24V, 20A

Starting motor 24V, 11 kW 24V, 11kW 24V, 11kW

Battery 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2

Turbocharger KTR130

Air compressor -

After cooler '

* Change the oil every 250 hours service.


Add another 12£for by-pass filter every 500 hours service.

0 1 -1 0 4 155-4 SERIES
< s>

from the library of Barrington Diesel Club


GENERAL SPECIFICATION

S6D155-4
D155C-1 D155C-1
D155W-1 D155C-1 D155C-1 (Eng. No. 20001 - 24804) (Eng. No. 24805 and up)
(Eng. No. 24805 and up) (Eng. No. 20001 - 24804) (Eng. No. 24805 and up) (With starting Eng. 2K68) (With starting Eng. 2K68)

6 - 155 x 170

19,260

1 —5 —3 —6 —2 —4

1,864 1,880 1,998

1,180 1,190 1,190

1,839 - -

- 2,894 2,894

270/2,000 320/2,000 320/2,000

120/1,400 144/1,400 144/1,400

2,240 ± 40 2,240 ± 40 2,240 ± 40

600 ± 50 600 ± 50 600 ± 50

180 180 180

2,575 2,580 2,700

BOSCH PES-PD type

BOSCH RSUV centrifugal all speed governor

78 83 75 83 75
(*58) (47) (47) (47) (47)

160

24V, 35A 24V, 35A 24V, 50A 24V, 50A


24V,20A 24V, 50A 24V, 50A

24V, 11 kW 24V, 11 kW 24V, 11 kW - -

12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2

KTR130

155-4 SERIES 01-105

from the library of Barrington Diesel Club


SPECIFICATION GENERAL

Engine model S6D155-4

D155A-2 mcCKA-l D ‘?fi6 A -1


Machine (Eng. No. 10101 - 11708)
(Eng. Serial No. 52707 and up) (wifn starting Eng. 2G84) (Eng. No. 1 1 7 0 9 -2 0 3 37 )

Number of cylinders — Bore x Stroke (mm) 6 - 155 x 170

Total piston displacement (cc) 19,260

Firing order 1 — 5 — 3 — 6 —2 —4

Overall length (mm) 1,880 1,998 1,880


Cfl
c Overall width
o (mm) 1,190 1,280 1,280
'to
c
CD
E Overall height (Excluding exhaust pipe) (mm) 1,931 —

o
Overall height (Including exhaust pipe) (mm) 2,914 2,852 2.844

Flywheel horsepower (HP/rpm) 320/2,000 410/2,000 410/2,000

CD Maximum torque (kgm/rpm) 144/1,400 163/1,400 163/1,400


O
CO
£ No-load maximum engine speed (rpm) 2,240 ± 40 2,240 ± 40 2,240 ± 40
o
CD
CL No-load minimum engine speed (rpm) 600 ± 50 600 ± 50 600 ± 50

Minimum fuel consumption ratio (g/HPh) 180 180 180

Dry weight (kg) 2,580 2,670 2,520

Fuel pump BOSCH PES-PD type

Governor BOSCH RSUV centrifugal all speed governor

Lubricating oil amount 75 63 63


(Refill capacity) (55) (56) (56)

Coolant amount (8) 160 170

Alternator 24V, 35A 24V, 20A (Generator) 24V, 20A (Generator)

Starting motor 24V, 11 kW - 24V, 11 kW

Battery 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2

Turbocharger KTR130 RH1521

Air compressor -

After cooler -

* Change the oil every 250 hours service.


Add another 12£for by-pass filter every 500 hours service.

01-106 155-4 SERIES


0
from the library of Barrington Diesel Club
GENERAL SPECIFICATION

S6D155-4 S6D155G-4

D3R<5r-3 D355C-3 D355C-3


D355C-3 (Eng. No. 20001 - 24804)
EG300-1
(Eng. No. 24805 and up)
(Eng. No. 20001 - 24804) (Eng. No. 24805 and up) (with starting Eng. 2K68) (With starting Eng. 2K68) (Eng. No. 20001 - 26849)

6 - 155 x 170

19,260

1 — 5 —3 —6 —2 —4

1,880 1,998 2,020

1,265 1,265 1,080

- - 1,660

3,155 3,155 -

300/1,500 (50 Hz)


360/2,000 360/2,000
363/1,800 (60 Hz)

150/1,400 150/1,400 -

Max. 1,560 (50 Hz)


2,240 ± 40 2,240 ± 40
Max. 1,872 (60 Hz)

600 ± 50 600 ± 50 -

185
180 180
(at flywheel horsepower)

2,580 2,700 2,600

BOSCH PES-PD type

BOSCH RSUV centrifugal all speed governor

83 75 83 75 77
(47) (47) (47) (47) (*57)

180 85

24V, 35A 24V, 35A


24V, 50A 24V, 50A 24V, 20A
24V, 50A 24V, 50A
24V, 11 kw 24V, 11 kw 24V, 11 kw

12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2

KTR130

155-4 SERIES 01-107


from the library of Barrington Diesel Club
SPECIFICATION GENERAL

Engine modei S6D155G-4 SA6D155-4

EG300-2 D355A-3 (—50°C Spec.)


Machine D355A-3
(Eng. No. 26849 and up) (with starting Eng. 2K68)

Number of cylinders — Bore x Stroke (mm) 6 - 155 x 170

Total piston displacement (cc) 19,260

to

CO

CO

CM
Firing order

I
Overall length (mm) 2,260 1,890 1,972
CO
c
o Overall width (mm) 1,080 1,265 1,265
CO

03
E Overall height (Excluding exhaust pipe) (mm) - 3,178 3,178
b
Overall height (Including exhaust pipe) (mm) 1,720 - -

365/1,500 (50 Hz) 410/2,000


Flywheel horsepower (HP/rpm) 410/2,090
426/1,800 (60 Hz)

03
Maximum torque (kgm/rpm) - 176/1,400 176/1,400
c
CO Max. 1,560 (50 Hz)
E No-load maximum engine speed (rpm) 2,240 ± 40 2,240 ± 40
Max. 1,872 (60 Hz)
o
CU
CL No-load minimum engine speed (rpm) - 600 ± 50 600 ± 50

190 175
Minimum fuel consumption ratio (g/HPh) 175
(at flywheel horsepower)

Dry weight (kg) 2,500 2,700 2,856

Fuel pump BOSCH PES-PD type BOSCH PES-P type

BOSCH RSUV centrifugal


Governor BOSCH RSUV centrifugal all speed governor
all speed governor

77 (*57)
Lubricating oil amount 75 Engine Serial No. — 25899 75
m
(Refill capacity) (*55) 75 (*55) (*55)
Engine Serial No. 25900 —

Coolant amount (fi) 83 180 185

24V, 20A (Generator)


Alternator 24V,20A 24V, 50A
(Engine Serial No. — 25899)
24V, 35A (No. 25900 - ) 24V, 2 kW
Starting motor 24V, 11 kW
24V, 11kW (For starting engine)

Battery 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2

Turbocharger KTR130 KTR130 KTR130

Air compressor - - -

After cooler - Standard Standard

* Change the oil every 250 hours service.


Add another 12£for by-pass filter every 500 hours service.

01-108 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL SPECIFICATION

2G84-8 2K68 28K


SA6D155-4
(Gasoline Engine) (Gasoline Engine) (Gasoline Engine)
D355A-3 (High altitude, 4,000 m
spec, with starting Eng. 2K68)
D355A-5 S6D155-4 S6D155-4 S6D155-4
(Eng. No. 51811 and up) (Eng No. 50816 and up) Starting engine Starting engine Starting engine

6 - 1 5 5 x 170 2 - 84 x 100 2 - 68 x 59.5 2 - 68 x 59.5

19,260 1,108 432 432

1 - 5 - 3 -- 6 - 2 - 4 1- 2 1- 2 1 -2

1,972 1,890 1,263 1,153 514

1,265 1,265 415 388 356

3,178 3,178 645 718 500

320/2,000 410/2,000 18/2,500 25/5,000 25/5,000

137/1,400 176/1,400 6/1,800 3.5/5,000 3.5/5,000

2,240 ± 50 2,240 ± 40 - - -

600 ± 50 600 ± 50 1,250 ± 50 2,200 ± 200 -

175 175 - - -

2,856 2,700 220 156 55

BOSCH PES-P type (Carburetor) (Carburetor) (Carburetor)


BOSCH RSUV Centrifugal all
Centrifugal Centrifugal
centrifugal all speed governor speed governor

75 77 2.6 0.7 Oil mixed in


(*55) (*57) (2.5) (0.6) fuel type

185 180 7.4 1.0 Air cooling type

24V, 50A 24V, 35A - - -

24V, 2kW
24V, 11 kW - 24V, 2 kW 24V, 2 kW
(For starting engine)

12V 200Ah x 2 12V 200Ah x 2 - - -

KTR130 KTR130 - - -

Standard Standard - - —

155-4 SERIES 01-109


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DRAWING GENERAL

G E N E R A L A S S E M B L Y DRAW ING

S4D155-4 (D95S-1)

500
472

6 127FOOI

01-202 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL GENERAL ASSEMBLY DRAWING

S4D155-4 (D95S-1)

1414

6 I2 7 F 0 0 2

155-4 SERIES 01-203


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DRAWING GENERAL

S4D155-4 (D95S-1)

6 I2 7 F 0 0 3

01-204 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL GENERAL ASSEMBLY DRAWING

S4D155-4 (D95S-1)

6 I2 7 F 0 0 4

155-4 SERIES 01-205

from the library of Barrington Diesel Club


GENERAL ASSEMBLY DRAWING GENERAL

S6D155-4 (D150, 155A-1)

6 I2 7 F 0 0 5

01-206 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL GENERAL ASSEMBLY DRAWING

S6D155-4 (D150, 155A-1)

6 I2 7 F 0 0 6

155-4 SERIES 01-207


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DRAWING GENERAL

S6D155-4 (D150, 155A-1)

2933

6 127F007

01-208 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL GENERAL ASSEMBLY DRAWING

S6D155-4 (D150, 155A-1)

1 2 -12 X 1.75
( D155A)

12 -12 X 1.7
(D150A)

6 127F0 08

155-4 SERIES 01-209


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DRAWING GENERAL

SA6D155-4 (D355A-3)

6 127F009

01-210 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL GENERAL ASSEMBLY DRAWING

SA6D155-4 (D355A-3)

6 127F0IO

155-4 SERIES 01-211


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DRAWING GENERAL

SA6D155-4 (D355A-3)

6 127F01 I

01-212 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL GENERAL ASSEMBLY DRAWING

SA6D155-4 (D355A-3)

6 127F0I 2

155-4 SERIES 01-213


from the library of Barrington Diesel Club
WEIGHT TABLE GENERAL

W E IG H T T A B L E
Unit: kg

No. Item S6D155-4 SA6D155-4


Major component S4D155-4
S6D155G-4 SA6D155G-4

KTR130 30 30 30
1 Turbocharger
RH1521 - 50 -

2 After cooler - - 25

Cylinder head, Valve


3 Cylinder head ass'y 85 x 2 85x2 85 x 3
Valve spring
Cylinder block, cylinder liner.
4 Cylinder block ass'y 455 680 680
Main cap

5 Timing gear case 50 50 50

Welding type 60 65 65
6 Oil pan
Pressed type - 55 55

7 Crankshaft ass'y Crankshaft, Crank gear 170 245 245

Camshaft, Cam gear


8 Camshaft ass'y 20 25 25
Thrust plate
Piston, Piston pin,
9 Piston connecting rod ass'y 15x4 15x6 15x6
Connecting rod

10 Flywheel ass'y 95 (D150A)


Flywheel, Ring gear 85 85
85

11 Flywheel housing ass'y 170 170 170

Balancer shaft, Balancer gear


12 Balancer shaft ass'y 20 x 2 - -
Thrust plate

13 Oil pump 20 20 20

14 Fuel injectioin pump 30 35 35

25
15 Water pump 25 30
30

16 Starting motor 50 50 50

800W 10 10 10

17 Alternator 1kW - 20 20

1.2 kW - 12 —

18 Air compressor - 40 -

01-302 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL ENGINE PERFORMANCE CURVE

ENGINE P E R F O R M A N C E C U R V E

S4D155-4 (D80, 85A-17)


Rated horse power : 2 1 0 H P /1 ,8 5 0 rp m
Maxim um torque : 9 8 kg m /1,20 0rp m
Minim um fuel consumption ratio : 180g/H P*h

120

Torque
100

250 80

Torque (kg.m)
60

40

20

200 0
Output (HP)

150

220
Fuel consumption ratio (g/HP*h)

100

210

200

190
Fuel consumption ratio
180

170

800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm)


6 I2 7 F 0 I 3

155-4 SERIES 01-401


from the library of Barrington Diesel Club
ENGINE PERFORMANCE CURVE GENERAL

S4D155-4 (D95S-1)

Rated horse power : 2 4 0 H P /1 ,8 5 0 rpm


M axim um torque : 1 12kg m /1,200rpm
M inim um fuel consumption ratio : 180g/H P*h

Torque (kg.m)
Fuel consumption ratio (g/HP*h)

01-402 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL ENGINE PERFORMANCE CURVE

S6D155-4 (D155A-1, Engine Serial No. 10011 ~ 19999)


(D155A-1, Engine Serial No. 10011 ~ 12297, C unit engine)

Rated horse power : 3 0 0 H P /2 ,0 0 0 rp m


M axim um torque : 1 3 4k g m /1 ,4 00 rp m
M inim um fuel consumption ratio : 185g /H P *h

Torque (kg.m)
Fuel consumption ratio (g/HP*h)

Engine speed (rpm) q |27F0 !5

155-4 SERIES 01-403


from the library of Barrington Diesel Club
ENGINE PERFORMANCE CURVE GENERAL

S6D155-4 (D150A-1, Engine Serial No. 20000 and up)

Rated horse power 3 0 0 H P /2 ,0 0 0 rp m


M axim um torque 13 4 k g m /1,400rpm
M inim um fuel consumption ratio 180g/H P*h

160

140

120

Torque (kg.m)
100

80

60

40

20

230
Fuel consumption ratio (g/HP*h)

Q. 220
3
o
210
200

190

180

Engine speed (rpm) 6 I2 7 F 0 I 6

01-404 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL ENGINE PERFORMANCE CURVE

S6D155-4 (D155A-1 Engine Serial No. 12298 ~ 19999)

Rated horse power : 3 2 0 H P /2 ,0 0 0 rp m


Maxim um torque : 1 4 4k g m /1 ,4 00 rp m
M inim um fuel consumption ratio : 185g /H P *h

Torque (kg.m)
Fuel consumption ratio (g/HP*h)

Engine speed (rpm)


6 I2 7 F 0 I 7

155-4 SERIES 0 1 -4 0 5
(2)
from the library of Barrington Diesel Club
ENGINE PERFORMANCE CURVE GENERAL

S6D155-4 (D155A-1 Engine Serial No. 20000 and up)

Rated horse power : 3 2 0 H P /2 ,0 0 0 rp m


M axim um torque : 14 4kg m /1,400rp m
M inim um fuel consumption ratio : 180g/H P*h

w
o
I-

Engine speed (rpm)


6 I2 7 F 0 1 8

01-406 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL ENGINE PERFORMANCE CURVE

S6D155-4 (D155S-1)

Flywheel horsepower : 3 5 0 H P /2 ,0 0 0 rp m
M axim um torque : 1 6 0k g m /1 ,4 00 rp m
M inim um fuel consumption ratio : 175g /H P *h

Torque (kgm)
Fuel consumption ratio (g/HP*h)

800 1000 1200 1400 1600 1800 2000 2200

Engine speed (rpm) 6 I2 7 F 0 I 9

155-4 SERIES 01-407


from the library of Barrington Diesel Club
ENGINE PERFORMANCE CURVE GENERAL

S6D155-4C (D355A-1)

Flywheel horsepower : 4 1 0 H P /2 ,0 0 0 rp m
M axim um torque : 163k g m /1 ,4 00 rp m
M inim u m fuel consumption ratio : 180g/H P*h

Torque (kgm)
Fuel consumption ratio (g/HP*h)

Engine speed (rpm) 6 127F020

01-408 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL ENGINE PERFORMANCE CURVE

S6D 155*4 (EG300-1)

Rated horse power : 300HP/1,500rpm (50Hz)


: 363HP/1,800rpm (60Hz)
Fuel consumption ratio : 185g/HP*h (at flywheel horsepower)

Engine speed (rpm) 6 I2 7 F 0 2 I A

155-4 SERIES 01-409


from the library of Barrington Diesel Club
ENGINE PERFORMANCE CURVE GENERAL

S6D155G-4 (EG300-2)

Rated horse power 3 6 5 H P /1 ,5 0 0 rp m (50 H z)


4 2 6 H P /1 ,8 0 0 rp m (60H z)
Fuel consumption ratio 190g /H P *h (at flyw heel horsepower)

Torque (kg.m)
Fuel consumption ratio (g/HP*h)

1100 1200 1300 1400 1500 1600 1700 1800 1900

Engine speed (rpm)


6 I2 7 F 0 2 2 A

01-410 155-4 SERIES

from the library of Barrington Diesel Club


GENERAL ENGINE PERFORMANCE CURVE

SA6D155-4A (D355A-3)

Rated horse power : 4 1 0 H P /2 ,0 0 0 rp m


Maxim um torque : 176k g m /1 ,4 00 rp m
M inim um fuel consumption ratio : 175g/H P*h

Torque (kg.m)
Fuel consumption ratio (g/HP*h)

Engine speed (rpm) e I 27F023

155-4 SERIES 01-411


from the library of Barrington Diesel Club
Engine Serial No. 10011 and up
ENGINE

11 STRUCTURE
AND FUNCTION

155-4 SERIES 11-001


from the library of Barrington Diesel Club
STRUCTURE AND FUNCTION
GENERAL S T R U C TU R E .................... 11-004 FUEL SYSTEM

INTAKE AND EXHAUST SYSTEM FUEL SYSTEM C H A R T ............................ 11-401

INTAKE AND EXHAUST U N IT ............. 11-102 FUEL P IP IN G ................................................. 11-403

TURBOCHARGER......................................... 11-106 FUEL INJECTION PUMP ......................... 11-406

AFTER C O O L E R ......................................... 11-108 FUEL INJECTION PUMP D R IV E 11-410

ENGINE NOZZLE ......................................................... 11-411

CYLINDER HEAD ....................................... 11-201 FUEL F IL T E R .............................................. 11-412

ROCKER A R M .............................................. 11-203

VALVE ........................................................... 11-204 COOLING SYSTEM

CYLINDER BLOCK .................................... 11-208 COOLING SYSTEM C H A R T ..................... 11-502

MAIN REVOLVING .................................... 11-212 WATER P U M P ............................................ 11-505-1

TIM ING G E A R .............................................. 11-216 T H E R M O S T A T .............................................. 11-508

BALANCER S H A F T .................................... 11-218 CORROSION R E S IS T O R ............................ 11-509

P • T • O ........................................................... 11-219 ACCESSORY

LUBRICATION SYSTEM ALTERNATOR • ■ ......................................... 11-602


LUBRICATION SYSTEM C H A R T 11-302 D Y N A M O ........................................................ 11-603
OIL P U M P ...................................................... 11-306 STARTING M O T O R .................................... 11-604
FULLFLOW F IL T E R .................................... 11-308 STARTING E N G IN E .................................... 11-606
BY-PASS OIL F IL T E R ................................. 11-313 AIR COMPRESSOR....................................... 11-612
OIL COOLER ................................................. 11-314 ENGINE STARTING A I D S ............................... 11-617
TORQUE CONVERTER OIL COOLER . . . 11-316

155-4 SERIES 11-003


from the library of Barrington Diesel Club
GENERAL STRUCTURE STRUCTURE AND FUNCTION

GENERAL STRUCTURE

S4D155-4

1. Cylinder head 9. Push rod 17. Connecting rod gear


2 . Thermostat 10. Turbocharger 18. Crankshaft
3. Intake valve 11. Tappet 19. Cylinder liner
4. Rocker arm housing 12. Camshaft 20. Connecting rod
5. Exhaust valve 13. Flywheel housing 21. Oil pan
6. Exhaust muffler 14. Flywheel 22. Strainer
7. Rocker housing cover ^ 15. Ring gear 23. Oil pump
8. Compression release lever 4 ^ * N 16. Rear seal 24. Front seal

11-004 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION GENERAL STRUCTURE

36 43 6 I2 7 F 0 2 5

25. Indicator plate 33. Cylinder liner 41. Oil filler


26. Piston pin 34. Starting motor 42. Piston cooling nozzle
27. Accesory drive pulley 35. Oil cooler 43. Left balancer shaft
28. V belt 36. Right balancer shaft
29. Tension pulley 37. Air cleaner
30. Breather 38. Fuel filter
31. Rocker arm 39. Fuel injection pump
32. Injection nozzle 40. Oil level gauge

155-4 SERIES 11-005


from the library of Barrington Diesel Club
GENERAL STRUCTURE STRUCTURE AND FUNCTION

S6D155-4

1 2 3 4 5 6 7 8 9 10 11 12 13 14
\ \ / i i i \

18 19 20 21 22 23 24 25 26 27

6 I2 7 F 0 2 6

1. Fan 11. Rocker arm shaft


2. V belt 12. Camshaft
3. Thermostat 13. Tappet
4. Cylinder head 14. Push rod
5. Injection nozzle 15. Rocker arm housing
6. Cylinder head cover 16. Cylinder block
7. Breather 17. Rear seal
8. Piston pin 18. Vibration damper
9. Intake valve 19. Front seal
10. Exhaust valve 20. Oil strainer

11-006 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION GENERAL STRUCTURE

6 127F027

21. Oil pump 31. Oil cooler


22. Connecting rod cap 32. Starting motor
23. Oil pan 33. Oil level gauge
24. Main metal cap 34. Fuel injection pump
25. Cran kshaft 35. Oil filler
26. Ring gear 36. Piston cooling nozzle
27. Flywheel 37. Connecting rod
28. Air cleaner
29. Cylinder liner
30. Piston

155-4 SERIES 11-007


from the library of Barrington Diesel Club
INTAKE AND EXHAUST SYSTEM STRUCTURE AND FUNCTION

IN T A K E AND E X H A U S T S Y S T E M

S4D155-4

1. Turbocharger
2. Air cleaner
3. Intake manifold

Air cleaner
Centrifugal type
with paper element

Dust indicator
Perceive vacuum: 635mmAq

6 I27F028

1. Exhaust pipe
2. Muffler
3. Turbocharger
4. Exhaust manifold

6 1 2 7F029

11-102 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

S6D155-4

1. Turbocharger
2. Air cleaner
3. Intake manifold

A ir cleaner
Centrifugal type
with paper element

Dust indicator
Perceive vacuum: 635mmAq

1. Exhaust pipe
2. Muffler
3. Turbocharger
4. Exhaust manifold

6 1 2 7F0 3I

155-4 SERIES 11-103


from the library of Barrington Diesel Club
INTAKE AND EXHAUST SYSTEM STRUCTURE AND FUNCTION

S6D155-4 (EG300-1)

1. Turbocharger
2. A ir cleaner
3. Intake manifold

Air cleaner
Centrifugal type
with paper element

Dust indicator
Perceive vacuum: 635mmAq

1. Exhaust pipe
2. Muffler
3. Turbocharger
4. Exhaust manifold

11-104 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM

SA6D155-4

1. Turbocharger
2. Air cleaner
3. A fter cooler

A ir cleaner
Centrifugal type
with paper element

Dust indicator
Perceive vacuum: 635mm Aq

Dust indicator has been changed


to electric type from engine serial
No. 3 7 5 1 3 and up.

1. Exhaust pipe
2. Muffler
3. Turbocharger
4. Exhaust manifold
5. Rain cap

Rain cap has been equipped fro m


engine serial No. 3 7 5 1 3 and up.

6 I2 7 F 0 3 5 A

155-4 SERIES 11-105


0)
from the library of Barrington Diesel Club
TURBOCHARGER STRUCTURE AND FUNCTION

TURBOCHARG ER

RH 1521 (ISHIKAWAJIMA)

6 127F036A

1. Seal ring turbine side 11. Seal ring, blower side 21 . Sleeve
2. Rotor shaft 12. Thrust metal 22. Snap ring
3. Center housing 13. Back plate 23. Turbine housing
4. Spacer 14. Thrust collar A Intake inlet
5. Diffuser 15. Sleeve B Intake outlet
6 . A ir bent housing 16. Floating seal C Exhaust inlet
7. Blower housing 17. Turbine nozzle plate D Exhaust outlet
8. Blower impeller 18. Nozzle E Lubricating oil inlet
9. Lock nut 19. Shelter plate F Lubricating oil outlet
10. Oil slinger 2 0 . Sealed plate

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION TURBOCHARGER

KTR 130 (KOMATSU)

w m iF

6 I27F037

1. Blower housing 11. Insert Specification of turbocharger


2. Blower impeller 12. Thrust bearing Type: Exhaust gas turbine turbocharger
3. Clamp Length x width x height: 325 x 295 x 344
4. Bearing housing A. From oil filter Weight (kg): 30
5. Journal bearing B. To oil pan drain Continuous rotation (rpm): 70,000
6 . Clamp C. A ir inlet Maximum charging (kg/min): 31.8
7. Shield D. Air outlet Appropriate temperature (inlet, °C): 750 max.
8 . Turbine impeller E. Exhaust inlet Direction of rotation: Right
9. Turbine housing F. Exhaust outlet Lubrication method: Force lubrication with engine oil
10. Slinger
/p° ....
A- f,.
s b

)
155-4 SERIES J 1-107
from the library of Barrington Diesel Club
AFTER COOLER STRUCTURE AND FUNCTION

A F T E R COOLER

SA6D155-4

E3_
ga h J l h J1 a m Ii a J I m a
IW
|Wb (ton

d> i)

, ______
Uh © ©) c® © © @)

© )v® y|©
f@ ] 1 1) ® b

o> <o <py - '( o oV—

6 I27F038

1. Cover plate
2. Cover
3. Cover plate
4. Body

A. From water pump


B. To water manifold

11-108 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

ENGINE BODY
C Y LIN D E R HEAD

S4D155-4
A

1. Cylinder head
2. Rocker arm housing
3. Rocker arm housing cover
4. Breather
5. Nozzle holder sleeve
6 . Crosshead guide
7. Valve guide

A. Oil line (to rocker shaft)

155-4 SERIES 11-201


(4)
from the library of Barrington Diesel Club
ENGINE STRUCTURE AND FUNCTION

1. Cylinder head
2. Rocker arm housing
3. Rocker arm housing cover
4. Nozzle holder sleeve
5. Cross head guide
6. Valve guide

A. Oil line (to rocker shaft)

11-202 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

ROCKER A R M

5 6 10

6 I27F04I

1. Compression release shaft 11. Lock nut


2. Rocker arm shaft 12. Adjusting screw
3. Rocker arm exhaust valve lever
4. Rocker arm intake valve lever
5. Spring
6. Bushing
7. Collar
8 . Spill pipe connector
9. Fuel injection connector
10. Compression release lever

155-4 SERIES 11-203


from the library of Barrington Diesel Club
ENGINE STRUCTURE AND FUNCTION

V A L V E S Y S TE M

S4D155-4

10
6 I27F042

1. Push rod 11. Tappet


2. Valve spring 12. Rocker arm lever
3. Compressionrelease shaft 13. Cross head
4. Adjusting screw 14. Valve spring
5. Lock nut 15. Valve spring seat
6. Rocker arm shaft
7. Camshaft gear
8. Camshaft
9. Intake valve
10. Exhaust valve

11-204 155-4 SERIES


<D
from the library of Barrington Diesel Club
STRUCTURE AND FUNCTION ENGINE

V A L V E T IM IN G

Upper dead point

section view
(No. 4 cylinder)

6 I27F044

Intake valve
section view
(No. 4 cylinder) 6 I 27F043

Valve clearance

Engine serial No. 1 0 2 8 7 -5 0 1 5 6 50157-

Ex. valve 0.3 0.4

In. valve 0.3 0.6

155-4 SERIES 11-205


from the library of Barrington Diesel Club
ENGINE STRUCTURE AND FUNCTION

S6D155-4, SA6D155-4

1 2 3 4 5 6

1. Push rod 11. Tappet


2. Valve spring 12. Rocker arm lever
3. Compression release shaft 13. Cross head
4. Adjusting screw 14. Valve spring
5. Lock nut 15. Valve spring seat
6. Rocker arm shaft
7. Cam shaft gear
8. Camshaft
9. Intake valve
10. Exhaust valve

11-206 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

(No. 4 cylinder)

section view
(No. 4 cylinder)
6 I27F047

V A L V E T IM IN G Valve clearance

Engine Intake valve Exhaust valve


Upper dead point
Intake open ^20° Exhaust close S6D 155-4
0.3 0.3
No. 1 0 0 1 1 -1 1 7 4 5

S6D155-4
0.4 0.6
No. 11 7 4 6 -

* \ \ 260° SA6D155-4 0.4 0.6

260 \
------ / / f ' Exhaust open
ntake close -'C

---------
Lower dead point

155-4 SERIES 11-207


from the library of Barrington Diesel Club
ENGINE STRUCTURE AND FUNCTION

C Y L IN D E R BLOCK

S4D155-4

6 127F048

1. Front cover 11. Oil pan


2. Lubrication nozzle 12. Main metal
3. Cylinder block 13. Thrust metal
4. Idler shaft 14. Cam bushing
5. Cylinder liner 15. Piston cooling nozzle
6 . Crevice seal 16. Oil level gauge
7. O-ring 17. Oil filler
8 . O-ring 18. Balancer bushing
9. Front seal 19. Main metal bolt
10. Drain plug 20. Main metal cap

11-208 155-4 SERIES


(D
from the library of Barrington Diesel Club
STRUCTURE AND FUNCTION ENGINE

14

Cylinder block
Crankshaft : 5 metals
Camshaft : 5 metals
Balancer shaft : 5 metals

Cylinder liner
Wet type liner
Crevice seal, O-ring x 2

155-4 SERIES 11-209


from the library of Barrington Diesel Club
ENGINE STRUCTURE AND FUNCTION

S 6D 155-4, S A 6D 155-4

1 2 3 4 6 7 8

6 I2 7 F 0 5 0

1. Front cover 11. Main metal


2. Lubrication nozzle 12. Thrust metal
3. Cylinder block 13. Cam bushing
4. Idler shaft 14. Piston cooling nozzle
5. Cylinder liner 15. Oil level gauge
6. Crevice seal 16. Oil filler
7. O-ring 17. Drain plug
8. O-ring 18. Main metal bolt
9. Front seal 19. Main metal cap
10. Oil pan

11-210 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

13

Cylinder block
Crankshaft : 7 metals
Camshaft : 7 metals

Cylinder liner
Wet type liner
Crevice seal, O-ring x 2

155-4 SERIES 11-211


from the library of Barrington Diesel Club
ENGINE STRUCTURE AND FUNCTION

M A IN R E V O L V IN G

S 4D 155-4

6 I 27 F 05 2 A

11-212 155-4 SERIES


(D

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

1. Piston
2. Piston pin
3. Connecting rod
4. Bushing
5. Top ring
6. 2nd ring
7. Oil ring
8. Upper metal
9. Flywheel
10. Nylock bolt
11. Indicator plate
12. Crankshaft gear (number of teeth: 36)
13. Lower metal
14. Connecting rod cap
15. Connecting rod cap bolt
16. Crankshaft
17. Crank gear (number of teeth: 44)
18. Ring gear (number of teeth: 140)

PISTON RING
Top ring

Crankshaft
Stamp forging
Induction hardening on journal portion
Front seal
Double lip oil seal
Rear seal
Double

155-4 SERIES 11-213


from the library of Barrington Diesel Club
ENGINE STRUCTURE AND FUNCTION

S 6D 155-4, SA6D 155-4

1 2 3 4 5 6 7

10 11 12 13
6 I27F054

1. Piston 11. Flange


2. Piston pin 12. Crankshaft gear (number of teeth: 36)
3. Connecting rod 13. Lower metal
4. Bushing 14. Connecting rod cap
5. Top ring 15. Connecting rod cap mount bolt
6. 2nd ring 16. Crankshaft
7. Oil ring 17. Flywheel
8. Upper metal 18. PTO drive gear (number of teeth: 44)
9. Nylock bolt 19. Ring gear (number of teeth: 140)
10. Vibration damper

11-214 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

17

6 I27F055A

Crankshaft
Stamp forging
Induction hardening journal portion
Front seal
Double lip oil seal
Rear seal
Double lip oil seal (for bulldozer)
Single lip oil seal (for generators)

155-4 SERIES 11-215


(D

from the library of Barrington Diesel Club


ENGINE STRUCTURE AND FUNCTION

T IM IN G GEAR

S 4D 155-4

1 2 3

1. Main idler gear (big) (number of teeth 84) 11. Water pump drive gear (number of teeth 23)
2. Main idler gear (small) (number of teeth 63) 12. Accessory drive gear (number of teeth 43)
3. Camshaft drive gear (number of teeth 54) 13. Alternator drive gear (number of teeth 22)
4. Fuel injection pump drive gear (number of teeth 54)
5. Balancer idler gear (number of teeth 48)
6. Left balancer drive gear (number of teeth 18)
7. Crankshaft gear (number of teeth 36)
8 . Oil pump drive gear (number of teeth 27)
9. Idler gear (number of teeth 37)
10. Right balancer drive gear (number of teeth 18)

11-216 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

S 6D155-4, S A 6D 155-4

6127F058A

1. Main idler gear (big) (number of teeth 84)


2. Main idler gear (small) (number of teeth 63)
3. Camshaft drive gear (number of teeth 54)
4. Fuel injection pump drive gear (number of teeth 54)
5. Crankshaft drive gear (number of teeth 36)
6. Idler gear (number of teeth 37)
7. Oil pump drive gear (number of teeth 27)
8 . Water pump drive gear (number of teeth 23)
9. Accessory drive gear (number of teeth 43)
10. Alternator drive gear (number of teeth 22)

155-4 SERIES 11-217

from the library of Barrington Diesel Club


ENGINE STRUCTURE AND FUNCTION

B A LA N C E R S H A F T

S4D 155-4

— f t —

R.H.

6 I 27 F 0 5 9

1. Right balancer drive gear (number of teeth 18) Balancer shaft


2. Right balancer shaft Number of bearing : 5
3. Left balancer drive gear(number of teeth 18) Journal face High frequency hardening
4. Left balancer shaft Revolving speed Engine speed x 2.0

11-218 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

P.T.O

S4D155-4

6 I27F060

1. P -T -0 gear (number of teeth 51)


2. P -T - 0 gearshaft
3. P ‘ T - 0 cover
4. Flywheel housing
5. Idler gear (number of teeth 43)
6 . Rear seal

155-4 SERIES 11-219


from the library of Barrington Diesel Club
ENGINE STRUCTURE AND FUNCTION

S6D155-4 (D150, 155A-1)

1. PTO gear (number of teeth 51)


2. PTO gear shaft
3. PTO cover
4. Flywheel housing
5. Idler gear (number of teeth 43)
6. Rear seal

11-220 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ENGINE

S A6D 155-4

6 I27F062

1. PTO gear (number of teeth 51)


2. PTO gear
3. PTO cover
4. Flywheel housing
5. Idler gear (number of teeth 43)
6. Rear seal

155-4 SERIES 11-221


from the library of Barrington Diesel Club
LUBRICATION SYSTEM STRUCTURE AND FUNCTION

LUBLICATION SYSTEM
L U B L IC A T IO N S Y S T E M C H A R T

S 4D 155-4

Oil pan
Scavenging oil pump
Oil pump
Main relief valve
Oil cooler by-pass valve
By-pass filter
Oil cooler
Regulator valve
FullfloW filter
Safety valve
Piston cooling valve
Fuel injection pump
Balancer shaft
Main gallery
Crankshaft
Rocker arm
Camshaft
Piston cooling nozzle
Gear lubrication nozzle
Timing gear
Turbocharger
Oil pressure gauge
Cooling water

6 I2 7 F 0 6 3 B

11-302 155-4 SERIES


<D
from the library of Barrington Diesel Club
STRUCTURE AND FUNCTION LUBRICATION SYSTEM

S6D155-4 (Engine Serial No. 10011 ~ 19999)

1. Oil pan

2. Scavenging oil pump


3. Oil pump
4. Main relief valve
5. Oil cooler by-pass valve
6. Oil coolr
7. Oil filter

8. Safety valve
9. Regulator valve
10. Piston cooling valve

11. Main gallery


12. Fuel injection pump
13. Crankshaft
14. Piston cooling nozzle

15. Timing gear


16. Gear lubrication nozzle

17. Rocker arm

18. Camshaft
19. Turbocharger

20. Oil pressure gauge


W. Cooling water

6 I2 7 F 0 6 3 -I

155-4 SERIES 11-303


from the library of Barrington Diesel Club
LUBRICATION SYSTEM STRUCTURE AND FUNCTION

S6D155-4 (Engine Serial No. 20000 and up)


SA6D155-4

6 127F064B

11-304 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION LUBRICATION SYSTEM

1. Oil pan
2. Scavenging pump (Excluding generator)

3. Oil pump
4. Main relief valve

5. Oil cooler by-pass valve

6 . By-pass filter

7. Oil cooler
8. Regulator valve

9. Fullflow filter

10. Safety valve

11. Piston cooling vaive


12. Fuel injection pipe

13. Main gallery

14. Crankshaft
15. Piston cooling nozzle

16. Timing gear


17. Gear lubrication nozzle

18. Rocker arm

19. Camshaft
20. Turbocharger
21. Oil pressure gauge

W. Cooling water

155-4 SERIES 11-305


from the library of Barrington Diesel Club
LUBRICATION SYSTEM STRUCTURE AND FUNCTION

O IL P U M P

Serial No. 2 6 4 7 3 -

6 7 8 6127F065A

1. Drive gear (number of teeth 27)


2. Oil pump body
3. Drive shaft (with gear) (number of teeth 12)
4. Cover
5. Scavenging pump drive gear (number of teeth 12)
6. Driven gear (number of teeth 12)
7. Driven shaft
8 . Scavenging pump driven gear (number of teeth 12)

11-306 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION LUBRICATION SYSTEM

MAIN RELIEF VALVE

1. Retainer
2. Valve case
3. Valve spring, outer
4. Valve spring, inner
5. Main relief valve
6 . Oil pump body

A. From oil pump


B. To oil filter
C. To oil pan

Operating pressure: 8.5±0.5kg/cm 2

6 I27F066A

PISTON COOLING VALVE OIL COOLER BY-PASS VALVE


S4D155-4
S6D155-4 (Engine Serial No. 10011 ~ 19999)

6 5 4 3 2 1
6 I27F068

1. Snap ring A. From oil pump 1. Plug A. From oil pump


2. Retainer B. To piston cooling 2. Shim B. To oil cooler
3. Valve spring C. To oil filter
3. Spring
4. Valve body Operating pressure: 4.5±0.2kg/cm 3
4. Valve body
5. Valve S4D 155-4 Operating pressure
S 6D 155-4 5. Spring seat 4±0.5kg/cm 2
(Engine No. 1 0 0 1 1 -1 9 9 9 9 ) 6. Valve

155-4 SERIES 11-307


(2 )
from the library of Barrington Diesel Club
L U B R IC A T IO N S Y S T E M S T R U C T U R E A N D F U N C T IO N

FULL FLOW OIL FILTER

S TA N D IN G TYPE
S 4D 155-4
S6D155-4 (Engine Serial No. 10011 ~ 19999)

6127F069A

1. Filter cover F ilte r element Filteration area


2. Filter case S 4D 155-4 : 0.56m 2 x 2
3. Through bolt S 6 D 155-4 : 0.56m 2 x 3
4. Element
5. Bracket

-308 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION LUBRICATION SYSTEM

REGULATOR VALVE
S4D155-4
1. Filter bracket
S6D155-4 (Engine Serial No. 1 0 0 1 1 - 19999) 2 . Regulator valve
3. Regulator spring
1 2 3 4. Plug

A. From oil filter


B. To oil pan

Operating pressure
S4D155-4 : 3.75±0.25kg/cm 2
S6D155-4: 3 .45 ± 0.25 kg/cm2

SAFETY VALVE
S4D155-4 S6D155-4 (Engine Serial No. 10011 — 19999)

1. Filter bracket Operating pressure 1. Filter bracket Operating pressure


2. Safety valve (Balance pressure) 2. Safety valve (Balance pressure)
3. Valve spring 2 ±0 .2 kg/cm2 3. Valve spring 2±0 .2 kg/cm2
4. Plug 4. Plug
5. Caution lamp terminal nut 5. Caution lamp terminal nut

From oil filter A. From oil filter


To oil main gallery B. To oil main gallery

155-4 SERIES 11-309


from the library of Barrington Diesel Club
LUBRICATION SYSTEM STRUCTURE AND FUNCTION

HANGING TYPE
S6D155-4 {Engine Serial No. 20000 ~ 24804)
SA6D155-4 (Engine Serial No. 20338 ~ 25899)

6127F073A

1. Center bolt A. Oil inlet


2. Filter cover B. Oil outlet
3. Retainer
4. Filter case Filter
5. Element Filteration area
6. Lower seat

11-310 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION LUBRICATION SYSTEM

CARTRIDGE TYPE
S6D155-4 (Engine Serial No. 24805 and up)
SA6D155-4 (Engine Serial No. 25900 and up)

6127F074A

1. Filter cover Filter


2. Element ass'y Filteration area : 0.84m 2 x 2

A. Oil inlet
B. Oil outlet

155-4 SERIES 11-311

from the library of Barrington Diesel Club


LUBRICATION SYSTEM STRUCTURE AND FUNCTION

REGULATOR VALVE
S6D155-4 (Engine Serial No. 20000 and up)
SA6D155-4
A
♦ 1. Plug
2. Valve spring
3. Regulator valve
4. Filter bracket

A. From filter
B. To main gallery
C. To oil pan

Operating pressure
4.05±0.25kg/cm 2

SAFETY VALVE
S6D155-4 (Engine Serial No. 20000 and up)
SA6D155-4

1. Plug
2. Valve spring
3. Safety valve
4. Filter bracket
5. Caution terminal

A. From oil cooler


B. To oil filter
C. To main gallery

Operating pressure (Balance pressure):


2 ± 0.2 kg/cm2

PISTON COOLING VALVE


S6D155-4 (Engine Serial No. 20000 and up)
SA6D155-4
1. Plug
2. Valve spring
3. Piston cooling valve

A. To piston cooling gallery


B. From oil filter

Operating pressure
2.75 ± 0.25kg/cm 2
S6D1 55-4 No. 20000 ~ 22650
S A 6D 155-4 No. 20338 ~ 22992
1.6 ± 0.2 kg/cm2
S6D155-4 No. 22651 and up
♦ S A 6D 155-4 No. 22993 and up
A 6 I2 7 F 0 7 7

11-312 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION LUBRICATION SYSTEM

B Y -P A S S O IL F IL T E R S 4 D 155-4 50279 ~
S 6 D 1 5 5 -4 1 6 15 8 ~ 16165
I S A 6 D 155-4 20001

1 2 3 4

1. Cover plug A. Oil inlet


2. Filter cover B. Oil outlet
3. Upper support
4. Hold down spring
5. Cover coupling
6 . Filter shell
7. Filter cartridge
8 . Drain plug
9. Orifice plug

155-4 SERIES 11-313


from the library of Barrington Diesel Club
LUBRICATION SYSTEM STRUCTURE AND FUNCTION

O IL COOLER

S 4D 155-4

CO

Section A —A 6 127F078

1. Cooler cover Oil cooler


2. Cooler element Radiation area: 0.078m 2
3. From water pump

B. From torque converter oil cooler

11-314 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION LUBRICATION SYSTEM

S6D155-4, SA6D155-4

B 6 I2 7 F 0 7 9

1. Oil cooler cover


2. Oil cooler element

A. Water (from chassis oil cooler)


B. Oil (to oil filter)
C. Oil (from oil pump)

155-4 SERIES 11-315


<3 >

from the library of Barrington Diesel Club


LUBRICATION SYSTEM STRUCTURE AND FUNCTION

TO RQ UE C O N V E R TE R O IL CO O LER

S 4D 155-4

1. Cooler housing
2. Cooler element

A. From water pump


B. To engine oil cooler

11-316 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL SYSTEM
F U E L S Y S T E M C H AR T

S4D155-4

A- ......... n

'■♦I'WY.'.V.V
+4.

V... >

6 I2 7 F 0 8 2

1. Fuel tank
2. Fuel filter
3. Fuel injection pump
4. Feed pump
5. Nozzle

155-4 SERIES 11-401


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

S 6D 155-4, S A 6D 155-4

6 I27F083A

1. Fuel tank 5. Feedpump


2. Strainer 6 . Nozzle
3. Fuel filter
4. Fuel injection pump

11-402 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

F U E L PIPING

S4D155-4

1. Automatic timer A. From fuel tank


2. Fuel injection pump drive gear B. To fuel tank
3. Service meter
4. Fuel injection pump
5. Fuel filter
6 . Coupling
7. Housing
8 . Shaft

155-4 SERIES 11-403


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

S 6D 155-4

1 2

6 I27F085

1. Automatic timer A. From fuel tank


2. Fuel injection pump drive gear B. To fuel tank
3. Service meter
4. Fuel injection pump
5. Fuel filter
6. Coupling
7. Housing
8 . Shaft

11-404 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

SA6D155-4
IT T

1. Automatic timer A. From fuel tank


2. Fuel injection pump drive gear B. To fuel tank
3. Service meter
Fuel injection pump ★ Electric service meter has been changed fro m engine
4.
5. Fuel filter serial No. 3 7 5 1 3 and up.

6 . Coupling
7. Housing
8 . Shaft

155-4 SERIES 11-405


CD
from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

F U E L IN JEC TIO N P U M P

PUMP

6 127F088

Fuel injection pum p


• Type: Made by DIESEL KIKI
Lubrication method: Forced lubrication with engine oil

11-406 155-4 SERIES


@
from the library of Barrington Diesel Club
STRUCTURE AND FUNCTION FUEL SYSTEM

1. Straight pin
2. Flange sleeve
3. Pump housing
4. Plunger spring
5. Lower spring seat
6 . Control rack
7. Rack guide screw
8 . Plunger seat
9. Camshaft
10. Delivery valve holder
11. Delivery valve stopper
12. Delivery valve spring
13. Delivery valve
14. Adjust shim
15. Plunger^.
16. Plunger barrel
17. Guide pin
18. Control pinion
19. Tappet

20. Cover
21. Center metal

22. Cover

1. Outline
Refer to Fig. in which the injection pump is shown in a Each individual pumping element is built in the form
transverse cutaway view w ith one o f the plunger pum p of a block assembly. The plunger, delivery valve, spring,
elements exposed fo r identification o f parts. etc., are retained w ith in the flange sleeve by the
The subject injection pump is o f Type PES-PD, which delivery-valve holder. These parts constitute the block
has been developed specially for direct-injection diesel assembly.
engines. Many new features are adopted in this pump The barrel is positioned by means o f a straight pin
design, including stronger structural parts for allowing a located at the middle peripheral portion o f the flange
much higher injection pressure to be generated, provi­ sleeve, and the guide groove provided in the to p end o f
sions for minim izing internal leakage of oil and for the barrel. The block assembly, constructed as above,
perm itting high-speed operation, and a cam profile is secured in place by stud bolts, nuts and washers,
characterized by a tangential uphill curve and an which hold down the flange (o f the flange sleeve) to the
eccentric downhill curve. to p o f the pump housing.
The cover plate hitherto used on pumps o f Types Shims are used between the flange and the pump
PE-A, -B and -Z is eliminated on this Type PES-PD housing. Changing the shim thickness changes the
injection pump, so th at the pump body is a to tally- position o f the plunger relative to the inlet port provided
enclosing housing. in the barrel. In other words, vertical positional adjust­
m ent o f the block assembly is to be effected by means
o f the shims.

155-4 SERIES 11-407


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

The block assembly in place can be angularly reposi­ The mechanism fo r varying the injection quantity is
tioned, relative to the pum p housing, by turning the practically the same in design as those in Types PE-A, -B
flange sleeve. Turning the block affects the injection and -Z injection pumps hitherto used, except for the
tim ing. Thus, the relationship between the plunger and manner o f meshing the control rack teeth w ith gear
th e inlet port is determined by the angular and vertical teeth. As shown in Fig. the bottom end o f the plunger
positions o f the block assembly in the housing. has a sector pinion gear, which is an integral part o f the
The pressure-feed lubrication mentioned previously plunger. The teeth o f this sector gear are directly
refers to the tappets. Pressurized lubricating oil is led engaged w ith the control rack. Because of this design
into the pump housing from the engine lubricating feature, the control rack is located at a lower elevation
system. An oil orifice opens o u t into the bore in which as compared to its position in the pumps o f Types PE-A,
the tappet reciprocates in sliding contact. The oil is -B and -Z.
forced through the orifice into this sliding clearance
around the tappet. The camshaft and the moving parts in
the governor are lubricated w ith this oil. A return line is
provided to return the oil back to the engine lubricating
system.
In order to m inim ize leakage o f fuel oil along the
plunger, each barrel is provided w ith an angular groove
in its bore, and an oilw ay is machined o ut through the
w all o f the barrel to comm unicate the angular groove to
the fuel oil suction chamber. This oilw ay is slanted.
The flange sleeve has an O-ring on its periphery.
This ring seals the fit o f the sleeve in the housing to
prevent fuel oil from leaking fro m the suction chamber
in to the camshaft chamber.
A new type gasket is used in the delivery valve section.
It is a semi-metal gasket, m ainly phosphor bronze in
m aterial. An O-ring is fitte d to the holder to seal the
fit o f the holder in the sleeve. There are other O-rings
and gaskets in the plunger block assembly, presenting
tight joints fo r prevention of leakage o f low- and
high-pressure fuel oil.

In this Type PES-PD injection pump, the plunger


block assembly and the tappet assembly can be removed
by taking them o ut o f the housing top. The camshaft
remains behind and is to be taken o ut through the end
o f the pum p housing.
There are no plugs in the housing bottom , as in the older
models. The pump housing is an oil-tight enclosure by
itself.

11-407-1 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

2. Individual pumping elem ent


The individual pumping elements, the num ber of The effective stroke o f the plunger is the vertical length
which corresponds to th at o f cylinders in the engine, are of the land. In Fig. turning the plunger counter­
identical in construction, each consisting essentially o f a clockwise increases the effective stroke.
plunger block assembly and a tappet assembly. Fig. shows the effect o f moving the control rack. W ith
The plunger is a constant-stroke reciprocating member, the control rack moved to the left, the effective stroke
actuated by the camshaft through the tappet. The is the longest: plunger in this position gives the
q uantity o f fuel oil is varied by varying the angular m axim um injection q uantity. W ith the rack moved to
position o f this constant-stroke plunger in the barrel. In the right, the effective stroke is very short, so th at little
other words, turning the plunger changes its effective or no injection takes place.
stroke.
Note the shape of the plunger head fo r perm itting the
injection quantity to vary, in Fig. wherein tw o plunger
positions are indicated. Plunger head is so recessed and
grooved as to provide tw o identical lands opposite to
each other in perfect sym m etry. The barrel has tw o inlet
ports, one for each land o f the plunger. The trailing edge
of the land is slanted helically.

Plunder head Beginning o f End of


in je c tio n in je c tio n

During its upward stroke, the plunger head land closes


the port, thereby trapping the fuel oil ahead o f the
plunger. As the plunger moves forw ard, the trapped oil
becomes pressurized and forces itself out through the
delivery valve, and when the trailing helical edge meets
the port, the vertical groove in the head communicates
the oil-filled space ahead o f the plunger to the suction
chamber through the recess and port. This communica­
tion bleeds the pressure o ff to cause the delivery valve to
seat.

155-4 SERIES 11 -407-2


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

Beginning of Injection End of injection End of suction


injection (beginning of (valve seated)
suction)

A t any angular position of the plunger, the beginning o f


injection corresponds to the m om ent when a rising
plunger covers up the inlet port com pletely; and the end
o f injection corresponds to the m om ent when the helical
edge o f the land begins to uncover the port.
The delivery valve is a spring-loaded check valve whose
seating member is an integral com bination of a disc,
re lie f collar and guide. In Fig. fo u r positions o f the
delivery valve are shown. A t the end of injection, when
the valve disc moves down tow ard the seat, the relief
collar plugs the bore. As the disc seats, the collar goes
into the bore. By this movement o f the collar, a volume
o f oil corresponding to the collar displacement becomes
draw n o u t of the injection pipe to prevent the nozzle
fro m “ dribbling". This action o f the delivery valve is
referred to as "retracting action" and the am ount o f oil
so sucked out is called the "retraction volum e".

11-407-3 155-4 SERIES

from the library of Barrington Diesel Club


FUEL SYSTEM STRUCTURE AND FUNCTION

GOVERNER

13 12 6 I2 7 F 0 8 9

1. Control lever 7. Guide lever 13. Guide bushing


2. Control rack 8. Floating lever 14. Fly weight
3. Start spring 9. Idling sub spring 15. Driving gear
4. Swivel lever 10. Angreich spring 16. Driven gear shaft
5. Governer spring 11. Full load stopper 17. Camshaft
6 . Tension lever 12. Shifter

Governer
Type Bosch RSUV centrifugal all-speed type

11-408 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

1. Outline
Combined w ith the injection pum p is a Type R S U V The tension lever too hangs dow n. Its to p end is pivoted
mechanical governor o f all-speed type, designed to at the same poin t fro m which the guide lever hangs
perm it the speed control range and ratios to be readily dow n. The governor spring is hooked to the tension lever
varied fo r adjustment. So th at the governor w ill respond on one end and to the swivel lever on the other. The
sharply to engine speed even in the lowest zone o f the swivel lever, pivoted at a fixed p oin t o f the housing, is
range, the flyweights are driven faster than the injection- capable of rocking movement as actuated by the
pump camshaft through a single-stage step-up gearing governor control lever. The high end o f angular range o f
b u ilt in the governor housing, a feature desirable fo r the swivel lever is lim ited by the maximum-speed
engines powering construction machines. stopper positioned to bear against the control lever.
The governor construction w ill be described in reference The idling spring is carried in the b otto m section o f the
to Fig. showing the R SU V-PD governor in a cross- tension lever and is so located as to meet the end face o f
sectional view. the shifter.
The single-stage speed increase is accomplished w ith a The idling subspring is carried in the governor housing
drive pinion m ounted on the end of injection-pum p and so positioned as to elastically yield to the backward
camshaft and a driven gear splined to the gear shaft, motion of the tension lever.
which is journaled in the support bolted to the governor The torque spring, hooked to a screw held by the hous­
housing. The tw o flyweights are pivotally mounted on ing and to the back o f the tension lever at a point
this shaft to push on the guide bush. slightly above the idling spring pull on this lever.
The flyweights and guide bush are associated w ith each The full-load stopper limits the m axim um injection
other in such a w ay as to translate rotating speed into q uantity by bearing against the bottom end of the
linear movement o f the shifter. The shifter is carried by tension lever when this lever is pulled in all the w ay by
the guide bush w ith a bearing in between. The guide the governor spring.
bush is capable o f running w ith the flyweights. As the
flyweights spread out or expand on rising speed, the
bush pushes the shifter to swing out the pendant guide
lever.
The guide lever has its to p end pinned rotatably to the
top section of the housing and its b otto m end is
similarly connected w ith the shifter.
The floating lever has its b otto m end rotatably pinned to
a fixed anchor point, and its to p end is linked to the
control rack and urged toward the rack by the start
spring. An intermediate point o f this lever is pinned to
the guide lever.

155-4 SERIES 11-408-1


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

2. RSUV-governor operating principles


1) E N G IN E S T A R T IN G The foregoing conditions are illustrated in Fig. in
Pushing the governor control lever all the w ay until which it w ill be noted th at there is some clearance
it meets m axim um speed stopper will turn the between shifter and tension lever. This clearance
swivel lever likewise to stretch the governor spring corresponds to an extra injection quantity the pump
fu lly. would deliver during starting.
Consequently, this spring keeps the tension lever As the engine fires up upon cranking and begins to
pulled w ith full force to bear against full-load run steadily, flyweights w ill spread out. The push on
stopper. shifter, due to the centrifugal force developed by
A t this tim e, flyweights are fu lly contracted because flyweights, is strong enough to move back the flo at­
the engine is n ot yet running: the floating lever, ing lever against the force o f its start spring: the
w ith its start spring, keeps the control rack pushed shifter w ill move out to meet the tension lever,
all the way in to " S T A R T ” position. It is the start thereby taking up the clearance mentioned above
spring that pulls the floating lever, and hence the (to elim inate th at extra injection quantity).
guide lever, to urge the shifter and guide bush
tow ard the rollers o f flyweights.

Start spring

11-408-2 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

2) E N G IN E ID L IN G The thrust o f shifter is counteracted by idling


Soon after the engine fires up, the operator w ill pull sub-spring through tension lever: Floating lever
his fuel control lever to make the governor control keeps control rack pulled o u t to the position
lever come to the position indicated. Thereupon, " ID L IN G " . This position gives an injection quantity
the governor begins to control engine speed. necessary fo r proper idling speed.
W ith the control lever in " ID L IN G " position, Should the engine speed drop fo r some reason,
governor spring is in com pletely relaxed state, so shifter w ould move inward, allowing the floating
that tension lever is in free floating condition. lever to push the control rack inward to increase the
injection quantity.

3) F U L L -L O A D R U N N IN G
Pushing the control lever to m axim um speed stopper Under the condition shown, the centrifugal force w ill
w ill stretch the governor spring fu lly and pull tension be counteracted mostly by the governor spring through
lever up against full-load stopper. The tension lever, in the tension lever, and the governor w ill m aintain the
turn, pushes on shifter, marking the floating lever push speed determ ined by the load on the engine.
in control rack.

Fuli-load Control lever

155-4 SERIES 11-408-3


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

4) N O -L O A D M A X IM U M SPEED R U N N IN G
W ith the control lever kept in the position shown, and spring but also by the idling subspring. This engine
w ith the engine carrying full load, assume th at the load speed, lim ited by the balance between flyweights and
decreases gradually. First, flyweights w ill expand springs, is the m axim um no-load speed, which is the
fu rth er, and shifter w ill push o ut the tension lever, highest speed the engine is perm itted to run up to.
pulling the control rack o u t to decrease the injection It is an essential function of the governor to lim it the
q uantity. speed to the m axim um no-load level when the load is
W hen the load has dropped to zero, the outw ard thrust reduced to zero (while the control lever is kept pushed
o f shifter w ill be counteracted not only by the governor all the w ay).

No-load (idling)

5 ) S T O P P IN G
Pulling the control lever all the w ay to “ S T O P " position means o f the protrusion provided on the swivel lever.
w ill remove the pull (by the governor spring) on tension As a result, the control rack is pulled out fu lly to its
lever and, at the same tim e, cause the swivel lever to non-injection position, thereby stopping the engine.
push o u t the guide lever, and hence the tension lever, by

11-408-4 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

3. Torque spring
The engine in a fast-cruising m otor car is carrying a The torque spring is exactly the means o f lowering the
partial load. The engine in a construction machine in full-load o u tp u t level fo r the purpose stated above. It
operation works in highly loaded condition. Moreover a accomplishes this lowering by acting on (pulling on the
construction machine is liable to meet a sudden rise in back o f) the tension lever.
load. In Fig. when the tension lever moves to th e position
If an engine in fu lly loaded condition should be addi­ indicated as "torque spring starts to ac t", you have
tionally loaded suddenly, it would stall almost instantly: reached the full-load condition o f the engine. If an
the operator has no tim e to shift the transmission dow n­ additional load is encountered by the engine right then,
ward to increase the o utp ut torque to cope w ith the the engine w ill take up this load rather slowly (because
additional load. o f the pull exerted by the torque spring on the tension
How can such engine stalling be avoided? One o f the lever), so th at the operator w ill have a sufficient tim e fo r
ways is to lower the full-load o u tp u t lever o f the engine shifting the transmission to increase o utp ut torque. The
from the highest o utp ut level the engine is actually operator can usually tell the need fo r shifting from the
capable of, so th at, when you are operating the engine in exhaust noise.
full-load condition, there w ill be some marginal (or
extra) capacity that you can utilize.

4. Idling springs

This spring is otherwise called "angleich" or "adapto r"


spring. Its purpose is to m o d ify the speed characteristic
o f injection quantity to suit this characteristic to the
engine requirement.
The requirem ent arises fro m the inherent properties o f
internal-combustion engines and m ulti-elem ent injec­
tion pumps: namely, (1) air intake efficiency falls as
engine speed rises, and (2) injection q u antity increases as
speed rises, fo r a given position of the control rack.
In Fig. the solid-line curve A-B represents the
injection-quantity requirement o f the engine. The dot-
line curve A '-B represents the speed characteristic o f an
injection pump set to meet the required injection
q u a n tity B at speed N2.
Engine speed

155-4 SERIES 11-408-5


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

It is im p ortan t to bear in m ind th at by "injection- The idling spring modifies the inherent speed charac­
q u a n tity requirem ent" is m eant the am ount o f fuel oil teristic o f the pum p to provide a new characteristic
th e engine needs to develop fu ll power at each speed curve closely matching solid-line curve A-B. Row this is
w ith in its range. A n injection pum p w ith a such a fuel accomplished w ill be explained by referring to tw o
setting (represented by dot-line curve A '-B ) meets the illustrations, Figs.
requirem ent only at speed N2.

11-408-6 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

In Fig. the tension lever is pulled by the governor spring


to bear against the full-load stopper. The engine is
running slowly. The control rack is pushed in farther
then it would be if there were no idling spring. In other
words, the engine, now running slowly, is enabled to
carry a greater load (or, to say the same thing, to
develop greater pow er). It must be recalled here th at an
engine in low-speed condition can burn more fuel fo r
each cycle.
As the engine picks up speed, the shifter pushes the
idling spring and moves toward the right to pull o ut the
control rack, thereby reducing the injection quantity.
In Fig. the shifter has moved to come in direct contact
w ith the tension lever. It has moved through the stroke
o f "angleich” . The engine is running at a higher speed
(corresponding to N 2) and is carrying a full load which is
less than the low-speed full load considered above.

5. Governor performance curve


The graph of Fig. shown the relation o f control rack • Line B-C indicates that the start spring is being
displacement w ith engine speed. The solid line between stretched by the increasing centrifugal force.
" I ” and “ A " stands for full-load operation, w ith the • Line C-D means the oversupply o f fuel due to the
governor control lever pushed all the way to the presence of idling spring in the tension lever.
maximum speed stopper. • Line D-E means that the idling spring is being
Line A-B represents the fuel oversupply due to start compressed.
spring during engine starting. • Line E-F indicates the condition o f full-load setting,
w ith the shifter d irectly bearing against the tension
lever.
• Line F-G represents the action o f torque spring. A t
" G " , the power being developed is equal to 85% full
G load approxim ately. This is the point at which the
engine in a construction machine is operated.
• Point " H " is referred to as the no-load m axim um
speed point.
• Line H-l represents the jo in t action o f governor
spring and idling subspring.
The dot-dash line between "J " and " M " stands fo r
idling operation, w ith the governor control lever held in
idling position. Point " L " is the normal idling position
o f the control rack: should the speed fall fro m this
point, the start spring acts to move (push in) the control
rack in the direction o f increasing injection quantity.
Control rack position

155-4 SERIES 11-408-7


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

FEED PUMP

6 I27 F09 0

1. Eye bolt 7. Filter Two pumping elements constitute the feed pump:
2. Spring 8. Housing one is a piston pum p w ith tw o check valves, and the
3. Cover 9. Spring other is a hand-operated prim ing pump. The term "feed
4. Priming pump p um p" w ill be used to mean the piston pump, unless
5. Tappet otherwise noted.
6. Case The feed pum p is actuated by a cam formed on the
injection pum p camshaft. This cam actuates the plunger
tw ice fo r each rotation o f camshaft, a feature different
from the feed pumps hitherto used.
The priming pump is fo r "p rim ing " the injection pump
in starting up a cold engine. It may be operated to purge
o u t trapped air, if any, in the circuit between the feed
pum p and the suction chamber o f the injection pump,
w ith the fuel oil filte r included.

11-409 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

A B C

How the feed pum p operates will be explained in The foregoing cycle o f piston movements takes place
reference to Fig. in which the pum p is shown twice fo r each rotation o f the cam, and repeats itself as
schematically in three positions: (A) recirculating, (B) long as the pressure in the discharge line is not high
discharging-drawing, and (C) idling. enough to overcome the force o f piston spring. When
In position (A ), the cam pushes the piston down to force pressure gets built up on the discharge side, it w ill hold
the oil in the inner chamber out through the delivery the piston back as shown in (C).
check valve into the outer chamber. Some o f the oil goes In position (C), the push rod may follow the cam but
into the discharge line. During this movement o f the does not actuate the piston. This is an idling condition
piston, the suction check valve remains closed, o f the feed pump and w ill persist until the pressure on
in position (B), the piston moves back under the force the discharge side falls.
o f the spring, thereby forcing the oil out o f the outer
chamber into the discharge line and drawing oil into the
inner chamber through the suction check valve.

155-4 SERIES 11-409-1


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

AUTO TIMER
Timer spring

0 .02~ 0 . 1 m m

Fuel oil sprayed into the combustion chamber w ill start 1. Timer construction
to burn after some delay. This lapse o f tim e is called the Fig. shows an exploded view o f the tim er.
"ign itio n delay". The delay remains relatively constant The flyw eigh t holder has tw o pins, each fittin g into a
in length fo r a range o f engine speeds. hole provided in each flyw eight, fo r holding the two
O ur interest is prim arily in the m om ent when the fuel flyweights in pivoted fashion.
becomes ignited, fo r developm ent o f power begins w ith The driving flange has tw o studs, and each flyweight
the ignition. When the engine is running fast, the fuel oil has a curved face. W ith the driving flange combined with
must be sprayed in earlier so th a t ignition w ill occure at the flyw eigh t holder carrying the flyweights, each stud
the right m om ent expressed in terms o f crank angle. extends into the corresponding flyw eight and bears
The autom atic tim er provided in the path o f drive to against the curved face, there being a spring for urging
the injection-pum p camshaft is a means o f autom atically the stud to the curved face. In other words, the spring is
varying the m om ent o f fuel injection (injection tim ing) seated on the flyw eigh t by its one end and on the stud
in accordance to engine speed. by its other end.
The tim e r is m ounted w ith in the engine gear case and The threaded hub portion o f the flyw eight extends
lubricated w ith the same oil th at lubricates the tim ing through the driving flange, and the driving flange is
and other gears. axially retrained by the n ut run onto the threaded hub.
Between this n ut and the driving flange are the plate
bearing, shims, washer and lock plate.

11-409-2 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

The driving flange, before it is bolted to the driving gear,


is in an axially floating condition. The am ount o f its
axial play is determined by the thickness o f the shim.
The standard play is from 0 .0 2 to 0.1 mm. Shims o f
differen t thicknesses are available fo r use in play
adjustment.

2. Timer operation
How the tim er performs its function (of autom atically
Stud
advancing the injection tim ing) w ill be explained in
reference to Fig. Curved face
In the view on the right, the tim er is a standstill so th at
the coil spring keeps the flyw eigh t in contracted state.
Note that pin " A ” and flyw eight are engaged together
and belong to the driven side (flyw eight holder). When
the flyw eight expands, it pivots on pin " A " . Stud "B "
belongs to the driving side (flange).
F ly weight
Fly weight holder pin

In the view on the right, the tim e is running w ith the


maximum speed. In this condition, the flyw eight
expands, pushing on the stud " B " by its curved face to co « '» 'e5Se , i v ?
compress the coil spring fu lly. N ote th at, by this
compression, the pin " A " has been angularly displaced
from its the previous position. It w ill be seen th a t the
driven side (flyw eight holder) has been twisted forw ard
(in the direction of rotation) by an angular interval
corresponding to the displacement of pin "A ". In
technical language, we say th at the driven side has been
advanced in phase relationship.
For easier understanding, assume th at the driving side is
the engine crankshaft and the driven side is the injec­
tion pump camshaft. W ith an angle o f advance "a " in
the tim er, the pum p camshaft is ahead, in phase
relationship, o f the engine crankshaft, so th at each fuel
injection takes place earlier than when the angle of
advance is less than "a ".

155-4 SERIES 11-409-3


from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

F U E L IN JE C TIO N P U M P D R IVE

4 5 6

6 I27 F 09 I

1. Fuel injection pump drive shaft Type


2. Housing Flange type
3. Gear
4. Pinion gear
5. Bushing
6 . Service meter housing
7. Service meter drive shaft
8. Drive gear

11-410 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

FU EL IN JE C T IO N N O ZZLE

Fuel injection nozzle


Type: Made by DIESEL KIKI Multi-hole type

Fuel injection pressure


Unit: kg/cm2

Engine Serial No. Pressure

10011 —14256 175


S4D 155-4
14257- 220

1 0 0 1 1 -1 4 2 5 6 175
S6D 155-4
14257- 220

S A 6 D 155-4 20001- 220

1. Joint bolt 5. Nozzle nut


2. Inlet connector 6. Nozzle
3. Push rod 7. Spring
4. Nozzle holder body A. Inlet port

11-411
<3>
155-4 SERIES

from the library of Barrington Diesel Club


FUEL SYSTEM STRUCTURE AND FUNCTION

1. Injection nozzle
The nozzle consists o f a nozzle body and a needle valve. When valve is closed
In the present engine, m ulti-hole type injection nozzles
having a total of 8 orifices are used. Each orifice is
0 .3 2 mm in diameter. These orifices are so oriented as to
fo rm an angle o f spray o f 150 degrees.
Fuel oil is sprayed directly into the combustion chamber
at a m om ent best suited fo r complete fuel combustion.
The satisfactory engine performance depends largely on
the good atom ization o f fuel oil in the spray, the sharp
geometrical pattern o f the spray, and the accurate tim ing
and duration of fuel injection.
When valve is opened

2. Nozzle holder
It is the nozzle holder th at secures the injection nozzle
to the cylinder head. The holder has internal oil passages
fo r adm itting the high-pressure fuel oil to the injection
nozzle and to return leak-off oil to the return pipe. It
contains the nozzle spring and push rod for loading upon
the needle valve.
The nozzle is held to the inner end o f the holder by
means o f the nozzle nut. The high-pressure fuel oil
forces the needle valve upward against the force o f the
spring and sprays o ut through the orifices in the tip
section. The pressure at which the needle valve unseats is
determ ined by the spring preload. This preload can be
adjusted by the screw provided in the top or outer end
o f the holder.

11-411-1 155-4 SERIES


CD
from the library of Barrington Diesel Club
FUEL SYSTEM STRUCTURE AND FUNCTION

F U E L F IL T E R

CENTER BOLT TYPE

1. Filter bracket Filter


2. Center bolt Filtration area
3. Fuel filter
4. Filter case
5. Drain cock

A. Fuel inlet
B. Fuel outlet

11-412 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION FUEL SYSTEM

CARTRIDGE TYPE

1. Filter bracket Filter


2. Cartridge ass'y Filtration area: 0.5m 2 x 2
3. Drain cock

A. Fuel inlet
B. Fuel outlet

155-4 SERIES 11-413


from the library of Barrington Diesel Club
COOLING SYSTEM STRUCTURE AND FUNCTION

COOLING SYSTEM
COOLING S Y S T E M C H A R T

S4D155-4

Engine Serial No. C D


50279 and up

6 127F095A

1. Water manifold 9. Cylinder block


2 . Thermostat 10. Nozzle
3. Radiator
4. Fan
5. Water pump A. From oil pupm (oil)
6. Engine oil cooler B. To each part of engine (oil)
7. Torque converter oil cooler C. From pump of chassis' side (oil)
8. Corrosion resistor D. To torque converter (oil)

11-502 155-4 SERIES


(D
from the library of Barrington Diesel Club
STRUCTURE AND FUNCTION COOLING SYSTEM

S6D155-4

D150A, D150A,S, EG300


Engine Serial No.
20000 and up
Except oil cooler 6 I2 7 F 0 9 6 A
of generator

1. Water manifold 9. Cylinder block


2. Thermostat 10. Cylinder liner
3. Radiator
4. Fan A. From oil pump (oil)
5. Water pump B. To each part of engine (oil)
6 . Engine oil cooler C. From pump of chssis' side (oil)
7. Torque converter oil cooler D. To torque converter (oil)
8 . Corrosion resistor

155-4 SERIES 11-503


from the library of Barrington Diesel Club
COOLING SYSTEM STRUCTURE AND FUNCTION

1. Water manifold 9. Cylinder block


2. Thermostat 10. Cylinder liner
3. Radiator 11. A fter cooler
4. Fan
5. Water pump A. From oil pump (oil)
6 . Engine oil coloer B. To each part of engine (iol)
7. Torque converter cooler C. From pupm of chassis' side (oil)
8 . Corrosion resitor D. To torque converter (oil)

11-504 155-4 SERIES

from the library of Barrington Diesel Club


COOLING SYSTEM STRUCTURE AND FUNCTION

W ATER PUM P

S4D155-4, S6D155-4 (D150-155A, S, EG300)

1. Cover

2. Impeller

3. Floating seal

4. Water seal

5. Water pump body


6. Drive gear (number of teeth 23)

7. Bearing housing

8. Pump shaft

9. V-ring

A. From radiator
B. From thermostat
C. To oil cooler

11-505-1 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION COOLING SYSTEM

WATER PUMP SEAL


S4D155-4 (Engine Serial No. 10287 ~ 50060) S4D155-4 (Engine Serial No. 50248 and up)
S6D155-4 (Engine Serial No. 10011 ~ 13161) S6D155-4 (Engine Serial No. 15268 and up)

6 I2 7 F 0 9 7 -5

S4D155-4 (Engine Serial No. 50061 ~ 50132) 2. Impeller


S6D155-4 (Engine Serial No. 13162 ~ 13959) 3. Floating seal

4. Water pump seal

5. Water pump body

8. Pump shaft

9. V-ring

10. Retainer

6 I2 7 F 0 9 7 -3

S4D155-4 (Engine Serial No. 50133 ~ 50247)


S6D155-4 (Engine Serial No. 13960 ~ 15267)

6 I2 7 F 0 9 7 -4

155-4 SERIES 11-505-2


from the library of Barrington Diesel Club
COOLING SYSTEM STRUCTURE AND FUNCTION

S6D155-4 (D355A-1)
SA6D155-4

1. Inlet connection
2. Impeller
3. Floating seal
4. Water seal
5. Water pump body
6. Drive gear
(number of teeth 23)
7. Bearing housing
8. Pump shaft
9. V-ring

A. From radiator
B. From thermostat
C. To oil cooler

11-506 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION COOLING SYSTEM

WATER PUMP SEAL


S6D155-4 (Engine Serial No. 10011 ~ 10100)

2. Impeller

3. Floating seal
4. Water seal

5. Water pump body

8. Pump shaft

9. V-ring

6 I2 7 F 0 9 9 - I

S6D155-4 (Engine Serial No. 10101 - 15313)

2 3 4 5 8
6 I2 7 F IO O A

S6D155-4 (Engine Serial No. 15314 and up)


SA6D155-4 (Engine Serial No. 20338 and up)

155-4 SERIES 11-507


from the library of Barrington Diesel Club
COOLING SYSTEM STRUCTURE AND FUNCTION

THERM O STAT

1. Seal
2. V-notch

A. From engine
B. To water pump
C. To radiator

Operation
Cool (full close) Warm (full open)

Function
Opening temperature : 7 4.5 ~ 78.5°C
Full opening temperature : 90°C
Valve, lift : Minimum 10 mm

11-508 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION COOLING SYSTEM

CORROSION R E S IS TO R

1 A

1. Filter bracket Corrosion resistor


2. Plate Filteration area: 0.373m 2 x 1 (S4D155-4)
3. Element 0 .373m 2 x 2 (S6D155-4, SA6D155-4)
4. Case
5. Set spring

A. From oil cooler


B. To water pump

155-4 SERIES 11-509


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

ALTERNATOR

6 I2 7 F 1 0 6 A

1. Alternator
2. Pulley

B, E, F, N: each terminal

11-602
(3)
155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

A LTER N A TO R

m r\

Alternator Regulator

F6120A001

1. Alternator B,E,F,R: Terminals


2. Alternator pulley

Pulley O.D. W eig h t


Applicable machine Type Specification
(mm) (kg)

D155A-1 M aker: NIKKO DENKI


24V, 35A 84.4 10
D355C-3 Type: O pened

155-4 SERIES 11-602-1


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

A L T E R N A T O R W ITH R EG U LA TO R

6210F116A

1. Alternator B,E,F,L,R: Terminals


2. Alternator pulley

Pulley O.D. W eig h t


A pplicable m achine Type Specification
(mm) (kg)

M aker: S A W A FU JI
D355C-3 24V, 50A 84.4 12
T yp e: O pened

11-602-2 155-4 SERIES


@
from the library of Barrington Diesel Club
STRUCTURE AND FUNCTION ACCESSORY

DYNAMO

1 2

6 I2 7 F I 0 7

1. Dynamo ass'y
2. Pinion gear (number of teeth 22)

155-4 SERIES 11-603


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

S T A R T IN G M O T O R

6 I2 7 F I 0 8

1. Starting motor pinion


2. Starting motor ass'y

A. Gear case oil filler


B. Center bearing oil filler
C. Rear cover oil filler

11-604 155-4 SERIES

from the library of Barrington Diesel Club


ACCESSORY STRUCTURE AND FUNCTION

S T A R T IN G M O T O R

F6120A002

1. Starting motor pinion


2. Starting motor ass'y

W eig h t
Applicable m achine Type S pecification
(kg)

D155-1 Maker: SAWAFUJI 24V, 11kW 21.2

155-4 SERIES 11-604-1


<D
from the library of Barrington Diesel Club
STARTING ENGINE

155-4 SERIES 11-605

from the library of Barrington Diesel Club


ACCESSORY STRUCTURE AND FUNCTION

S T A R T IN G ENGINE (2G84)

STRUCTURE

7 8 9

25 24 23 22 21

1. Cylinder block 9. Water pipe 17. Crankshaft gear


2 . Tappet 10. Magnet drive shaft 18. Side race
3. Tappet guide 11. Idler shaft 19. Thrust metal
4. Adjusting screw 12. Idler gear 20. Main metal
5. Valve spring 13. Camshaft gear 21. Main metal cap
6. Valve 14. Starting crankshaft 22. Piston
7. Cylinder head 15. Coupling 23. Connecting rod
8 . Spark plug 16. Timing gear case 24. Connecting rod cap

11-606 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

LUBRICATION SYSTEM

25. Camshaft 33. Regulator valve


26. Crankshaft 34. Strainer
27. Oil pan 35. Oil pump
28. Rear cover
29. Bushing
30. Flywheel
31. Governor
32. Oil pressure gauge

155-4 SERIES 11-607


<D
from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

POWER TRAIN

11-608 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

1. Rod 23. Clutch case


2 . Cover 24. Cover
3. Ball bearing 25. Nut
4. Clutch shaft gear 26. Ball bearing
5. Oil seal 27. Spacer
6 . Cover 28. Pinion shaft gear
7. Brake lining 29. Pinion shaft
8 . Clutch lever 30. Spacer
9. Clutch fork shaft 31. Ball bearing
10. Pinion shaft lever 32. Oil seal
11. Clutch fork 33. Spring
12. Oil cup 34. Pinion
13. Shifter 35. Return rod
14. Clutch cam 36. Weight holder
15. Clutch cam link 37. Weight lock
16. Sleeve 38. Weight
17. Clutch shaft 39. Spring
18. Return spring rod 40. Adjustment screw
19. Adjustment ring 41. Pinion lever
20. Driven plate 42. Shaft
2 1 . Pressure plate 43. Lever
22. Drive plate

155-4 SERIES 11-609


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

2G84 OIL PUMP

1. Camshaft
2. Pump drive gear
3. Pump case
4. Drive gear
5. Idler gear
6 . Oil pan
7. Strainer

5 6 7
6 127P0I I

11-610 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

WATER PUMP

1. Impeller
2. Water seal

3. Pump shfat

4. Felt

5. Pump case

6. Pump drive gear

155-4 SERIES 11-611

from the library of Barrington Diesel Club


ACCESSORY STRUCTURE AND FUNCTION

AIR C O M P R E S S O R

for D155W (TU-FL0600)

CJOm m

6 I 2 7 F I 10

1. Air filter ass'y 9. Cylinder block


2. Cylinder head 10. Rear end cover
3. Discharge valve spring 11. Connecting rod cap
4. Discharge valve cap 12. Cran kcase cover
5. Unloader spring saddle 13. Crankshaft
6. Inlet valve spring 14. Bearing insert
7. Unloader piston 15. Spline
8 . Governor ass'y 16. Crankcase

11-612 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

A. Lubrication oil exit


18. Wide ring B. Cooling water exit
19. Narrow ring C. Cooling water inlet
20. Narrow ring D. Exhaust port
21. Lock wire E. Reservoir port
22. Piston F. Lubrication oil inlet

155-4 SERIES 11-613


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

D155W-1
' (DIESEL KIKi)
D155AR-1

1. Inlet valve seat 11. Bushing

2. Unloader valve body 12. Connecting rod

3. Unloader valve spring 13. Support

4. Unloader valve cap 14. Thrust washer

5. Head cover 15. Crankshaft

6. Inlet valve 16. Coupring gear

7. Inlet valve spring 17. Piston pin

8. Outlet valve 18. Crank case

9. Outlet valve spring 19. Oil ring

10. Piston 2 0 . 2nd ring

11-614 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

2 1 . Top ring A ir compressor


22. Cylinder head • Num ber of cylinders — Bore x Stroke:
23. Outlet valve seat • Rated rotation speed (Engine flywheel
A. Air inlet
2 ,0 5 0 rpm
• Discharging amount: 297£/m in .
B. Air outlet

C. Coolant inlet

D. Coolant outlet
t From oil pump (oil)
F. To compressor (oil)

G. To air governor

155-4 SERIES 11-615


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

AIR GOVERNOR (For air compressor)

6 I 2 7 F I I I -3

1. Governor cover A ir governor


2. Upper spring seat • Operating pressure
3. Governor spring Unloading pressure: 8 .3 8 .8 kg/

4. Adjustment screw Loading pressure: 6 .9 7 .3 kg/

5. Lower spring seat

6. Spring guide

7. Spring seat

8. Piston

9. Exhaust stem

10. Governor body

11. Exhaust stem spring

12. Valve spring

11-616 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

ENGINE S T A R T IN G AIDS

OUTLINE OF A STARTING AID

• A diesel engine is equipped w ith a starting aid fo r


easy starting in cold weather, etc., because fuel is
fired and burnt by compression tem perature in the
diesel engine.

Starting aids fo r direct fuel injection type engines

• In the direct fuel injection type engines, it is


d iffic u lt to install glow plugs in the combustion
chamber fro m the standpoint o f construction and
fuel injection conditions.
• For this reason, w ith starting aids fo r direct fuei
injection type engines, firing and burning of fuel is
facilitated by spraying fuel into the intake m anifold
to burn fuel mist in the intake air and w arm up the
combustion chamber interior by this combustion
tem perature.
• In the starting aids described above fo r direct fuel
injection type engines, the follow ing fo u r types are
used in Komatsu engines depending on the methods
of supplying fuel into the intake m anifold.
1) Priming pump type
A hand operated pump is provided to aid
1. Fuel nozzle
fuel supply in starting up engine.
2. Heater 2) Therm ostat type
3. Intake manifold Fuel is supplied by a head between a start­
4. Cylinder head ing aid fuel tank and fuel nozzles.

5. Intake valve 3) APS typ e (autom atic priming system)


Supply of the starting aid fuel is autom atically
6. Injection nozzle
controlled depending on the engine revolutions.
A. Combustion chamber

C. Water jacket

155-4 SERIES 11-617


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

PRIMING PUMP TYPE 4D 155-4


6D155-4 (D150A Engine Serial No. 14257 and up)
(D155A Engine Serial No. 12298 and up)
(D155S Engine Serial No. 15128 and up)
(D355A Engine Serial No. 14050 - 20337)
★ Engine Serial No. 10011 — 11709: 2G84 starting engine
SA6D155-4 (Engine Serial No. 20338 - 22201)
1. Fuel tank
2. Feed pump
3. Fuel filter
4. Fuel valve
5. Priming pump

6. Nozzle (Preheater nozzle)


7. Heater plug
8 . Preheater switch
9. Heater signal
10. Starting switch

11. Battery

12. Knob
13. Piston rod

14. Nut
15. Barrel

16. Spring
17. Pin
18. Priming pump body
19. Check valve (at inlet)
20. Check valve (at outlet)

A. Intake air

B. To injection nozzle

C. From feed pump

D. To heater nozzle

Function o f a prim ing pum p type starting aid


• Fuel is delivered from a feed pum p to a fuel filte r • Fuel delivered from the pum p is sprayed tfrom
by operating engine. This fuel line is connected to a nozzle into the intake m anifold.
prim ing pum p inlet piping at the filte r o u tlet port. • Fuel delivered from the pum p is prevented from
• If the priming pum p knob (12 ) is turned counter­ flow ing backward by a check valve on the outlet
clockwise, spring rod (13) w ill be pushed o ut by side.
spring (1 6 ) together w ith the knob, causing fuel to • On the other hand, heater plug (7) is electrically
be sucked into the pum p simultaneously. heated to a red-hot state by turning on the pre­
• If the knob is pushed in by hand, the piston rod will heater switch, causing fuel mists sprayed o ut of
also be pushed in, causing check valve (1 9 ) on the nozzles to burn. Then, the combustion chamber is
suction side to close. A t the same tim e, check valve warm ed up by the burning fuel entering each
(20) on the o utlet side w ill open, causing fuel to be cylinder, facilitating the starting up o f engine.
delivered.
• Pressure o f fuel delivered is varied by hand operat­ • Except in case o f starting up the engine, the priming
ing the pum p. pum p knob should be kept in a locked condition
and the preheater switch kept o ff.

11-618 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

THERMOSTART TYPE STARTING AID 6D 155-4


(D150A Engine Serial No. 10011 - 14256)
(D155A Engine Serial No. 10016 - 12297)
(D355A Engine Serial No. 1 1 7 1 0 - 14049)
★ Engine Serial No. 1011 — 11709: 2G84 starting engine
6
1. Fuel tank
2. Feed pump
3. Fuel filter
4. Thermostart tank
5. Thermostart
6 . Resistor
7. Thermostart switch
8. Heater signal
9. Starting switch

10. Battery
11. Shield

12. Igniter

13. Heater coil


14. Valve stem

15. Ball valve

16. Nozzle body

17. Terminal

A. Intake air
B. To injection nozzle

C. From thermostart tank

1514 13 6 I 2 7 F I 68

Function of a therm ostart type starting aid


1) Fuel presses a ball valve (1 5 ) under the head burnt in the intake m anifold. The burnt fuel enter­
between therm ostart tank (4) and therm ostart (5). ing each cylinder warms up the combustion
2) If the therm ostart switch is turned on, heater coil chamber, easing the starting up of engine.
(13) w ill be in a red-hot state and the coiled portion
o f nozzle body (16) w ill be heated. Thereby, valve ★ Where this starting oil need not be used, the therm o­
stem (14) integrated w ith the valve body w ill be start switch should be kept off.
moved to the right. ★ Before actuating the starting aid, open a cock fo r
3) As soon as the valve body is moved, the ball valve the therm ostart tan k to prevent fuel from becoming
(15) under the pressure o f fuel w ill open, allowing unable to flo w o u t due to internal negative pressure.
fuel to flo w out. Be careful not to leave the cock open. Otherwise,
4) Fuel flowing o u t o f the ball valve is fired by igniter fuel would overflow the starting aid.
(12 ), while being evaporated by the coil heater, and

155-4 SERIES 11-619


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

APS (Automatic Priming System) • S6D155-4 (Optional)


SA6D155-4 (Engine Serial No. 20338 — 22201: Optional)
(Engine Serial No. 22202 and up: Standard)

1. Fuel tank
2. Feed pump
3. Fuel filter
4. Fuel valve

5. Bracket
6. Nozze (electromagnetic nozzle)

7. Glow plug
8 . Control box
9. Engine speed sensor

10. Gearbox
11. Service meter

12. Relay switch


13. Water temperature sensor

14. Water manifold


15. Resistor

16. Heater signal


17. Preheater switch
18. Starting switch

19. Ammeter

20. Battery

A. Intake air

B. To injection nozzle
6 I 2 7 F I 69

F un ktio n o f APS
• When engine is in operation, fuel is delivered from • In the control box, the received engine speed signal
feed pum p (2) to a fuel filte r (3). This fuel line is is am plified and converted to the signal controlling
connected to APS fuel passage at the filte r outlet the fuel supply, which is transm itted to the electro­
port. magnetic nozzle (6 ). Then, the fuel quantity to be
• The APS fuel line consists o f fuel valve (4 ), bracket sprayed is autom atically controlled, corresponding
(5) fo r dividing the fuel passage and nozzle (6) to the engine speed.
m aking an autom atic control o f the fuel q u antity to • In order to prevent APS from continuing actuation
be sprayed by electric signal. W hile engine is in after the engine is started up, a water temperature
operation, the APS fuel line is under the delivery sensor (13 ) is provided in APS to autom atically shut
pressure o f fuel fro m the feed pum p. o ff an APS switch, by transm itting the electric
• In the APS electric circuit, an engine speed sensor signal thereto as soon as the engine cooling water
(9) fo r sensing and transm itting engine speeds is tem perature reaches a predeterm ined level (55 °C ).
provided in the service meter section. This sensor • When APS is not in use, be sure to keep the pre­
sends the electric signal o f engine speed (rpm's) to heater switch (17) o ff and fuel valve (4) closed.
control box (8) when the engine is brought in
operation.

11-620 155-4 SERIES

from the library of Barrington Diesel Club


STRUCTURE AND FUNCTION ACCESSORY

• S6D155-4 (Optional)
SA6D155-4 (Engine Serial No. 26691 — 35760: Standard)

6 I IF I3 9 A

1. Fuel tank 11. Battery relay A: Intake air


2. Feed pump 12. Relay switch B. To injection nozzle
3. Fuel valve 13. Water temprature sensor

4. Fuel filter 14. Water manifold


5. Bracket 15. Resistor
6. Electromagnetic nozzle (S6D1 55-4: One) 16. Heater signal
(SA6D155-4: Two) 17. Heater switch

7. Glow plug (S6D155-4: Two pieces) 18. Starting switch


(SA6D155-4: Two pieces) 19. Ammeter
8 . Control box 20. Battery
9. Starting motor
10. Safety relay

155-4 SERIES 11-621


from the library of Barrington Diesel Club
ACCESSORY STRUCTURE AND FUNCTION

S6D155-4 {D150A Engine No.


(D155A Engine No.
(D155S Engine No.
SA6D155-4 (Engine Serial No. 35761 and up)

6 I 27F094- I

1. Heater switch 9. Water manifold


2. Heater signal 10. Glow plug
3. Starting switch 11. Nozzle

4. Ammeter 12. Fuel valve

5. Fuse box 13. Glow plug

6. Safety relay 14. Nozzle


7. APS controller unit 15. Fuel filter

8. Fuse (5A)

11-622 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING
P R E P A R A T IO N ................................................................................ 12-402
A D J U S T IN G F U E L IN J E C T IO N T IM IN G ................. 12-405
P E R F O R M A N C E T E S T O N F E E D PUM P .............................. 12-407
F U E L IN J E C T IO N PUMP T E S T IN G S P E C IF IC A T IO N .. 12-408
E N G IN E P E R F O R M A N C E T E S T ............................................... 12-702
S T A R T IN G E N G IN E P E R F O R M A N C E T E S T ..................... 12-708
T E S T IN G A N D A D J U S T IN G T O O L L I S T .............................. 12-901
T E S T IN G A N D A D J U S T IN G ,
T R O U B L E S H O O T IN G C R IT E R IA ................................. 12-902

★ This section describes only specifications concerning Fuel injection pum p test and Engine perfor­
mance test. Therefore, please refer to SHOP M A N U A L "T E S T IN G M E T H O D " (S E B H 11 00).

Before perform ing inspection, adjustment or faultfinding, park the machine on level ground and
check the safety pin and chock.
When performing jo in t w ork, make appropriate signals and allow only authorized personnel near the
machine.
/ f \ When checking the w ater level, allow the engine to cool down before removing the radiator cap to
prevent the risk of being scalded by hot w ater which may spurt out if the engine is hot.
Take great care to avoid getting caught in rotating parts such as the fan, etc.

155-4 SERIES 12-003


(D
from the library of Barrington Diesel Club
PREPARATION TESTING AND ADJUSTING

PREPARATION

PRECAUTIONS
It is necessary to run in the engine before the engine
perform ance is tested.
Test the engine to find possible faults in assembling
procedures, and make the final adjustment to obtain the
best possible perform ance from the engine.

PRECAUTIONS WHEN OPERATING THE ENGINE


INDEPENDENTLY
★ If the engine is operated independently on a bench 16 + 0.5
w ith a double lip seal fitte d , the lubricating condi­
tions w ill d iffe r fro m actual running conditions,
resulting in possible damage to the seal lip.
★ It is in applicable to the generator engine w ith
single lip rear seal.

1. When running in the engine or subjecting it to a


bench test, use the rear seal shown in the
Clutch side
diagram at right on all models for the duration
o f testing.
S 4 D 155-4, S 6 D 1 5 5 -4 \ 6 I 2 7 F I 20
S A 6 D 155-4 '

A fte r .completing running-in or bench testing,


f it the correct rear seal.
1) S 4 D 15 5-4 (D 95S )
S 6 D 155-4 (D 1 5 0 A , D 1 5 5 A , D 3 5 5 A )

Torque converter
side or Clutch side

6 I2 7 F I2 I

2) S 6 D 15 5-4 (D 1 55 W )

Torque converter
side

6 127FI 22
★ Precautions when fittin g rear seal
1) A new rear seal is coated w ith grease. In the 2) Be careful n ot to damage the rear seal when
event th at it becomes soiled, however, w ipe it fittin g it.
clean w ith a cloth and coat it w ith about 1.2 to 3) Rear seals fo r am phibious bulldozers are not
1.6 cc o f G2-L1 (lith iu m grease). interchangeable w ith those for conventional
bulldozers.

12-402 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING PREPARATION

CHECK THE FOLLOWING POINTS PRIOR TO INSTALLING THE ENGINE ON THE


OPERATION: DYNAMOMETER STAND
• Engine parts and set-bolts fo r tightness Place the engine on the dynam om eter stand, and secure
• V -belt for proper tension the disk to the flyw heel w ith more than six bolts (012,
• Engine oil and cooling w ater fo r proper level P = 1.7 5 ). Tighten the engine set-bolts, when the posi­
• Dynam om eter parts fo r lubrication tion o f the stand is adjusted in all directions, th at is,
• Fuel injection interval upward and dow nw ard, right and left, and forw ard and
backward and the stand is secured in place in parallel
• Fan should be dismounted w ith the dynam om eter. The eccentricity o f the flanges
• To start the engine, turn the fuel lever to the non­ on the engine dynam om eter sides must be w ith in 0 .1 3
injection position under decompression and actuate mm , m axim um reading on the dial indicator, when
the starter to let the engine idle fo r about 20 flexible joints are used.
seconds. Then check as follows: Make sure dynam om eter equilibrium and dynam o­
1) Remove the oil o utlet pipe o f the turbocharger meter and dynamograph zero indication can be obtain­
to make sure oil is flowing out o f the pipe. ed.
2) Make sure the pointer o f the oil pressure gauge
swings in normal condition. TUBING AND WIRING
Note: Never run the starting m otor longer than • Run cooling pipes.
20 seconds. • Run fuel pipes, and feed fuel to the fuel filte r.
• Run wires to the tw o sets of battery to connect the
CHECK THE FOLLOWINGS DURING starting switch and starting m otor therm ostat.
OPERATION • Connect the exhaust pipe. Reduce its influence on
Lubricant: the air feed tem perature o f a minim um .
• The oil level must be between the markings " L " and • M ount the control lever.
" H " on the oil level gauge.
• The oil pressure must be w ith in 1.5 to 4 .5 kg /cm 2 CONNECTING THE METERS
• Check oil fo r water. • Engine Tachometer

Coolant: • Fuel Consumption Measuring Instrument


• Replenish coolant as required, even after starting M ount the three-way valve and burette between the
the engine to keep the cooling system filled w ith the engine and fuel tank in such a manner as illustrated
coolant, and bleed the cooling system. below. (Measuring accuracy: 1%)
• The coolant tem perature must fall w ith in the range
of 75 to 9 0 °C .
Fuel tank
Color of exhaust
Check for leakage of water, oil and compressed gas.
Check for unusual sound.
Check for loose clamping parts.
Check for abnormal flow-by.

Checks after running-in


• Check the oil o f the oil filte r. Wash foreign m atter
away if any. Replace oil, if it is too d irty. If there is
any metal grit in oil, check the cause or source.
• Recheck the valves fo r proper clearance. • A ir Feed Therm om eter

155-4 SERIES 12-403


from the library of Barrington Diesel Club
PREPARATION TESTING AND ADJUSTING

• Cooling Water Thermometer • Dangled type

from the library of Barrington Diesel Club


TESTING AND ADJUSTING ADJUSTING FUEL INJECTION TIM IN G

A D JU S TIN G FUEL IN JEC TIO N TIM IN G

ADJUSTING THE FUEL INJECTION TIM ING

Turn the crankshaft in the direction o f rotation to • F it the injection pump to the drive shaft housing so
set the No. 1 cylinder piston to T D C on the th at the match marks draw n on both parts before
compression stroke. disassembly come into alignment w ith each other.
Align the pointer w ith the 1.4 T o p mark on the
indicator fo r a 4-cylinder engine.
Align the pointer w ith the 1.6 T o p m ark on the
damper fo r a 6-cylinder engine.
Check for proper setting o f the compression T D C
fo r the No. 1 cylinder by confirm ing th at neither
the intake nor exhaust rocker arms o f the No. 1
cylinder are in contact w ith th eir respective valve
stems. (Since neither the intake nor exhaust valves
close or open when the crankshaft rotates in the
vicinity o f the T D C on the compression stroke o f
the No. 1 cylinder piston, the rocker arms o f the
No. 1 cylinder do not come in contact w ith the
valve stems and, therefore, remain stopped. Mean­
while, the rocker arms o f the No. 4 cylinder for • When the injection pum p has been replaced or when
4-cylinder engines and the rocker arm o f the No. 6 the injection tim ing before disassembly is unknow n,
cylinder fo r 6-cylinder engines move up and dow n.) tem porarily tighten the injection pum p mounting
Position the No. 1 cylinder o f the injection pum p at bolts (to allow the pum p to move right and left),
T D C . Insert the pump gear into the coupling so th at and adjust the injection tim ing according to the
the gear meshes w ith splines in the coupling. follow ing procedure.

INJECTION TIM ING ADJUSTMENT PROCEDURE


Injection timing:
33° BTDC /S 4 D 1 5 5 -4
'S 6 D 155-4 No. 10011 ~ 19 99 9)

38 ° B T D C /S 6 D 1 5 5 -4 No. 20001 and u p )


\S A 6 D 155-4

1. Turn the crankshaft in the direction o f rotation to


set the No. 1 cylinder piston to the T D C on the
compression stroke; align the pointer w ith the 1.4
Top mark on the indicator fo r a 4-cylinder engine
and align the pointer w ith the 1.6 Top m ark on the
damper fo r a 6-cylinder engine.
Relative marks on the 6-cylinder engine damper are
shown below.

155-4 SERIES 12-405


from the library of Barrington Diesel Club
ADJUSTING FUEL INJECTION TIM ING TESTING AND ADJUSTING

2. Remove the No. 1 cylinder delivery valve holder of 7. Turn back the crankshaft until the No. 1 cylin­
the injection pump. Pull the delivery valve and der piston is positioned to about 50° BTDC on
spring o ut o f the holder and reinstall the holder. the com pression stroke. W ith the priming pum p
3. Loosen the injection pipe sleeve nuts fo r the other operating, turn the crankshaft gradually in the
cylinders. direction of rotation until the No. 1 cylinder d e­
4. Pull the fuel control lever fu lly and lock it at that livery valve holder stops spilling fuel. A t that
position. position of the crankshaft, confirm that the
5. W ith the priming pum p operating to continue feed­ pointer is in alignm ent w ith the injection timing
ing the fuel, shift the injection pum p right and left stam p line on the indicator fo r a 4-cylinder en­
u ntil it is located at a position where the No. 1 gine and on the d am p er for a 6-cylinder engine.
cylinder delivery valve holder stops spilling fuel. If such an alignment is not obtained, repeat steps 5
To adjust, move the injection pum p gradually to 7 until the proper alignment can be obtained.
tow ard the engine. When it goes beyond the 8. Install the delivery valve and spring to their original
position where the fuel stops spilling, return the positions and tighten the holder.
injection pump. (Do not operate the priming pump j ESED Delivery valve holder: 11.5 + 0 . 5 kgm
or move the injection pum p hastily. Otherwise, fuel
may spurt out.)
• A fte r installing the injection pump, refill it w ith
about 1C o f oil.
• To facilitate cranking of the engine to adjust the
fuel injection timing of an engine mounted on a
machine, a bar ring tool is available. When using the
bar ring tool, release the compression from the
engine cylinders, remove the flywheel housing
P.T.O . cover from the engine, p ut the bar ring tool
into the splined hole o f the P.T.O . drive shaft, and
crank the engine w ith the bar ring tool and a large
ratchet handle.
Barring tool part num ber:
S 4 D 155-4, S 6 D 155-4
(excluding engines fo r D 3 55 ): 79 5-1 00-1 21 0
S 6 D 155-4, S A 6 D 155-4 (for D 355):
6. Retighten the injection pump mounting bolts 7 9 5 -1 00-1 37 0
(pum p housing and bracket).
• T o facilitate moving the injection pump mounted
on the machine, a special handle is available.
Handle for adjusting injection pum p part num ­
ber: 795-100-1710

12-406 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING PERFORMANCE TEST ON FEED PUMP

PERFORMANCE TE S T ON FEED PUMP

OIL-TIGHTNESS TEST DISCAHRGE PERFORMANCE TEST


Make sure the prim ing pump handle is secured tight in Operate the feed pum p under the same conditions as for
place. Plug the discharge opening. A pply 2 kg/cm 2 the function lift test, to check the following items:
compressed air to the pump inlet, the immerse the pump 1. Open the discharge valve. Run the feed pum p at
in a pool o f clean diesel fuel oil or kerosene. Bubbles will 1000 rpm. The pum p should deliver at a rate of
develop: catch the bubbles w ith a measuring cylinder, as 1700 cc/m inute, 1.5 kg/cm 2 .
shown. 2. Run the pump at 60 0 rpm, w ith the discharge side
Bubbles should be smaller than grain size, and the closed. The pump should develop at least 3 kg/cm 2
am ount o f air collected in the cylinder should not be of discharge pressure.
greater than 10 cc fo r 1 m inute. If leakage o f compres­
sed air is greater than this, replace the oil seal. INJECTION NOZZLE
There must not be any leakage from the connections o f Clean the injection nozzle to be test. Also clean the
the nipple, piston chamber plug and priming pump. A nozzle tester. Make absolutely sure th at the diesel fuel
leaky connection needs repair. oil to be used in testing the nozzle is perfectly clean.
1. W ith the nozzle-holder adjusting screw loosened,
install the nozzle in the tester, and blow oil out
Q i l ib r < i U ' d c y l i n d e r twice or thrice to purge the oil passage w ith in the
nozzle.
2. Pump the tester lever at a rate o f 6 0 stroke/m inute.
While reading the gauge, run in the adjusting screw
until the gauge indicates the specified pressure of
175 kg/cm 2 .
3. A fte r obtaining the specification pressure, tighten
the cap nut to lock the adjusting screw. Check to
see if this tightening has disturbed the setting. The
gauge pointer might vacillate: if it does, read the
mean value.
4. Check the spray pattern. A geometrically sym m etri­
cal pattern, w ith uniform atom ization from each
orifice, should be available. There should be no
break nor steps nor thin portions in the pattern.
5. Inspect the seating faces o f needle valve and nozzle
body. Remove score marks, if any, on the face by
lapping w ith the use o f a proper lapping compound.
If the seat face is damaged beyond repair, replace
SUCTION LIFT TEST the nozzle body and needle valve as a set. (Replace­
Install the feed pump on the injection pump, and ment o f one injection-nozzle necessitates replace­
connect a pipe (8 mm in I.D . and 2 m in length) to the ment o f all the outer nozzles for the pum p.)
feed pump inlet. Have the priming pump handle screws
in all the way. Operate the pump to lift diesel fuel oil in
a vessel one meter below the feed pump, in the fo llo w ­
Adjusting tools for type PD pump
ing manner:
1. Operate the priming pump at a rate o f 60 stroke/ Part Name Part No.
minute. The pum p should start discharging at 20th
Fixing stand 5 7 8 1 -0 1 7
stroke or, at least, at 30 th stroke.
Central rack measuring device 5 7 8 2 -6 0 2
2. Run the injection pump at 150 rpm. The feed pump
Governor adjusting device 5 7 8 2 -6 0 3
should start discharging w ith in 30 seconds o f opera­
Plunger stroke measuring device 5 7 8 2 -4 1 9
tion. (Cam lift: 6 mm)

155-4 SERIES 12-407


from the library of Barrington Diesel Club
FUEL INJECTION PUMP TABLE TESTING AND ADJUSTING

FU E L IN JE C T IO N PUM P TA B LE
1. INDEX
M achine Engine Pum p A ssem bly Applicable Engine
Specification
M odel M odel N u m b er Serial N um ber
D80A-17
S 4D 155-4 6125-71-1014
D85A-17
6125-71-1023 10287 - 50293
D95S-1 S4D 155-4
6125-71-1024 50294 -

6127-71-1004 1 0 0 1 4 - 10066

6127-71-1010 10067 - 10511

6127-71-1011 1 0 5 1 2 - 10703

6127-71-1012 1 0 7 0 4 - 11033

6127-71-1013 1 1 0 3 4 - 11769
D150A-1 S 6D 155-4
6127-71-1014 1 0 0 1 4 - 14256

6127-71-1015 14257 - 19999

6127-71-1016 2000 - 35626

6127-71-1017 2000- •

6127-71-1018 2000 -

6127-71-1004 1 0 0 1 4 - 10066

6127-71-1010 10067 - 10511

6127-71-1011 10512 - 10703

6127-71-1012 1 0 7 0 4 - 11033

6127-71-1013 1 1 0 3 4 - 11769
S6D 155-4
6127-71-1014 1 0 0 1 4 - 12297

6127-71-1030 1 2 2 9 8 - 19999

6127-71-1031 2000 - 35646


D155A-1
D155C-1
6127-71-1032 2000- •

6127-71-1033 2000 -

6127-71-1050 12298 - 19999

S 6D 155-4 Cold w e a th e r 6127-71-1051 2000 - 35646

6127-71-1052 2000-

6127-71-1080 24805 - 40560

S6D 155-4 Noise suppression 6127-71-1081 24805- •

6127-71-1082 24805 -

6127-71-1090

D155AR-1 S6D 155-4 6127-71-1091

6127-71-1092

6127-72-1002 2 2 1 4 4 -2 7 0 0 2
D155W -1 S6D 155-4
6127-72-1003 22144-

12-408 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING FUEL INJECTION PUMP TABLE

Machine Engine Pum p A ssem bly Applicable Engine


Specification
Model M odel N u m b er Serial N u m b er

6127-71-1150

D155A-2 S6D 155-4 6127-71-1151

6127-71-1152

6128-71-1002 10011 - 10112

6128-71-1010 1 0 1 1 3 - 10691

6128-71-1011 10692- •

D355A-1 S6D 155-4 6128-71-1012 • - 11293

6128-71-1013 11294 - 11709

6128-71-1014 11710 - 20337

6128-71-1030 10011 - 20337

6128-71-1060 2000- •
S6D 155-4
6128-71-1061 2000- •
D355C-3
6128-71-1070 2000- •
S 6D 155-4 Cold w e a th e r
6128-71-1071 2000 -

69902-0-0111 22146 - 28769

EG300-1 S 6D 155-4 6127-71-1300 28770- •

6127-71-1301 28770 -

EG300-2 S 6D 155-4 6127-71-1302

6128-71-1031 20338 - 23556

6128-71-1032 23557 - 26690

S A 6D 155-4 6128-71-1033 26691 - •

6128-71-1034 20338- • •

6128-71-1035 20338 -
High altitude, 4000 m
S A 6 D 155-4 6128-71-1170
cold weather
6128-71-1051 20338 - 23556
D355A-3
6128-71-1052 23557 - 26690
S A 6D 155-4 Cold w e a th e r
6128-71-1053 26691 - 35799

6128-71-1054 20338 -

6128-71-1081

6128-71-1082 26691 - •
S A 6D 155-4 Noise suppression
6128-71-1083 26691 - • •

6128-71-1084 26691 -

6128-71-1120 50816- •
D355A-5 S A 6D 155-4
6128-71-1121 50816-

155-4 SERIES 12-409


from the library of Barrington Diesel Club
ENGINE PERFORMANCE TEST_____________________ TESTING AND ADJUSTING

E N G IN E P ERFO R M A N CE T E S T
1. RUN IN STANDARD
W hen the engine is overhauled or repaired, it is necessary to run in the engine under the following condition,
since th e sliding surface o f such com ponents as the piston, cylinder liner, bearing, etc. are not adequately fitted,
disenabling sm ooth operation to be obtained.

Engine Application Check point 1 2 3 4 5 6 7 8

Time min 5 15 5 5 20 10

Speed rpm 625 ± 25 1,000 1,200 1,200 1,500 1,850

D80A-17 Load (716 mm) kg 0 26 50 83 100 120

D85A-17 (895 mm) kg 0 21 40 66.4 80 96

(1,023 mm) kg 0 18 35 58.1 70 84

Output HP 0 26 60 99.6 150 222


S4D155-4
Time min 5 15 5 5 20 10

Speed rpm 625 ± 25 1,000 1,200 1,200 1,500 1,850

Load (716 mm) kg 0 31 63 83 120 135


D95S-1 - -
(895 mm) kg 0 25 50 66.4 96 108

(1,023 mm) kg 0 22 44 58.1 84 94.5

Output HP 0 31 76 99.6 180 250

Time min 5 15 5 5 20 10

D150A-1 Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

D155A-1 Load (716 mm) kg 0 30 60 110 160 190

(Engine (895 mm) kg 0 24 48 88 128 152


serial No.
up to 12297 (1,023 mm) kg 0 21 42 77 112 133

Output HP 0 30 72 132 240 285

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500


D155A-1
Load (716 mm) kg 0 30 60 110 160 190
(Engine
S6D155-4 - -
serial No.
(895 mm) kg 0 24 48 88 128 152
12298 and
up)
(1,023 mm) kg 0 21 42 77 112 133

Output HP 0 30 72 132 240 285

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

Load (716 mm) kg 0 30 60 110 160 200


D155S-1 - -
(895 mm) kg 0 24 48 88 128 160

(1,023 mm) kg 0 21 42 77 112 140

Output HP 0 30 72 132 240 300

★ W h e n operating the engine independently, exchange double lip rear seal fo r single lip rear seal.
A fte r operation, exchange single lip rear seal fo r double lip rear seal. (Double lip rear engine).

12-702 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING ENGINE PERFORMANCE TEST

Load T im e (M inute)

Low -speed rotation No load 20


Rated rotation 1 /4 15
Rated rotation 2 /4 15
Rated rotation 3 /4 15
Rated rotation 4 /4 10

Engine Application Check point 1 2 3 4 5 6 7 8

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,500 1,800 2,000

Load (716 mm) kg 0 30 60 72 106 143


D155W-1 — —
(895 mm) kg 0 24 48 57.6 84.8 114.4

(1,023 mm) kg 0 21 42 50.4 74.2 100

Output HP 0 30 72 108 191 286

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

Load (716 mm) kg 0 30 60 110 160 190


D155C-1 — —
(895 mm) kg 0 24 48 88 128 152

(1,023 mm) kg 0 21 42 77 112 133

Output HP 0 30 72 132 240 285

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

Load (716 mm) kg 0 30 60 110 160 190


S6D155-4 D155A-2 — -
(895 mm) kg 0 24 48 88 128 152

(1,023 mm) kg 0 21 42 77 112 133

Output HP 0 30 72 132 240 285

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

Load (716 mm) kg 0 30 60 110 160 220


D355A-1 — —
(895 mm) kg 0 24 48 88 128 176

(1,023 mm) kg 0 21 42 77 112 154

Output HP 0 30 72 132 240 330

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

Load (716 mm) kg 0 30 60 110 160 210


D355C-3 — —
(895 mm) kg 0 24 48 88 128 168

(1,023 mm) kg 0 21 42 77 112 147

Output HP 0 30 72 132 240 315

155-4 SERIES 12-703


(D
from the library of Barrington Diesel Club
ENGINE PERFORMANCE TEST TESTING AND ADJUSTING

Load Tim e (M inute)

Low -speed rotation No load 20


Rated rotation 1 /4 15
Rated rotation 2 /4 15
Rated rotation 3 /4 15
Rated rotation 4 /4 10

Engine Application Check point 1 2 3 4 5 6 7 8

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 900 1,100 1,400 1,600 1,800

Load (716 mm) kg 0 30 60 106 159 211


EG300-1 - -
(895 mm) kg 0 24 48 84.8 127.2 168.8

(1,023 mm) kg 0 21 42 74.2 111.3 147.7

Output HP 0 27 66 148 254 380


S6D155G-4
Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 900 1,100 1,400 1,600 1,800

Load (716 mm) kg 0 30 60 120 180 239


EG300-2 - -
(895 mm) kg 0 24 48 96 144 191.2

(1,023 mm) kg 0 21 42 84 126 167.3

Output HP 0 27 66 168 288 430

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

Load (716 mm) kg 0 50 100 150 180 250


D355A-3 - -
(895 mm) kg 0 40 80 120 144 200

(1,023 mm) kg 0 35 70 105 126 175

Output HP 0 50 120 180 270 375

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

Load (716 mm) kg 0 50 100 150 180 250


D355A-3
SA6D155-4 - - ■
(—50°C spec.)
(895 mm) kg 0 40 80 120 144 200

(1,023 mm) HP 0 35 70 105 126 175

Output HP 0 50 120 180 270 375

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

D355A-3 Load (716 mm) kg 0 50 100 150 180 190


High altitude, - -
4000 m spec.) (895 mm) kg 0 40 80 120 144 152

(1,023 mm) kg 0 35 70 105 126 133

Output HP 0 50 120 180 270 285

★ W h e n operating the engine independently, exchange double lip rear seal for single lip rear seal.
A fte r operation, exchange single lip rear seal fo r double lip rear seal. (Double lip rear engine).

12-704 155-4 SERIES


(D
from the library of Barrington Diesel Club
TESTING AND ADJUSTING ENGINE PERFORMANCE TEST

Engine Application Check point 1 2 3 4 5 6 7 8

Time min 5 15 5 5 20 10

Speed rpm 600 ± 50 1,000 1,200 1,200 1,500 1,500

Load (716 mm) kg 0 50 100 150 180 250


SA6D155-4 D355A-5 — -
(895 mm) kg 0 40 80 120 144 200

(1,023 mm) kg 0 35 70 105 126 175

Output HP 0 50 120 180 270 375

155-4 SERIES 12-705


from the library of Barrington Diesel Club
ENGINE PERFORMANCE TEST TESTING AND ADJUSTING

2. PERFORMANCE TEST STANDARD


Dynamometer (kg)
Appli­ Specified value Engine speed
Engine Check point
cation (fully equipped) (rpm) Arm length Arm length Arm length
716 mm 895 mm 1,023 mm

Flywheel horsepower 210 HP/1,850 rpm 1,850 ± 5 120.6 - 127.7 96.5 - 102.1 84.4 - 89.4

r-'
Max. torque 98 kgm/1,200 rpm 1,200 ± 100 139.7 - 148.0 111.8 - 118.4 9 7 . 8 - 103.6
< <
00 00 0
Q Q High idling speed 2,100 rpm max. 2,050 ± 50 0 0

in Low idling speed 450 — 650 rpm 625 ± 25 0 0 0


in
5 Flywheel horsepower 240 HP/1,850 rpm 1,850 ± 5 136.7 - 144.5 109.3 - 115.6 95.7 - 101.2
CO

Max. torque 112 kgm /1,200 rpm 1,200 ± 100 160.5 - 170.0 1 2 8 .4 - 136.0 112.3 - 118.9
cd
O)
Q High idling speed 2,100 rpm max. 2,050 ± 50 0 0 0

Low idling speed 450 — 650 rpm 625 ± 25 0 0 0

o Flywheel horsepower 300 HP/2,000 rpm 2,000 ± 5 158.5 - 168.0 126.8 - 134.4 111.0 - 117.6
00
t—
< Max. torque 134 kgm/1,400 rpm 1,400 ± 100 190.8 - 202.2 152.6 - 161.8 133.5 - 141.5
tn * o
in
5 £
CO o High idling speed 0 0 0
co 2 Q 2,280 rpm max. 2,230 ± 50
O
z Low idling speed 450 — 650 rpm 625 ± 25 0 0 0

Cl Flywheel horsepower 300 HP/2,000 rpm 2,000 ± 5 164.0 - 173.0 131.2 - 138.4 114.8 - 121.1

? c Max. torque 134 kgm/1,400 rpm 1,400 ± 100 192.7 203.9 154.2 - 163.1 134.9 - 142.7
LO <0 <
J Z 00 m
O CM
CO
CO r-
5 High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0
O
z Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

r- Flywheel horsepower 300 HP/2,000 rpm 2,000 ± 5 158.5 - 168.0 126.8 - 134.4 111.0 - 117.6
o>
CM
CM
^ r-
in i Max. torque 134 kgm/1,400 rpm 1,400 ± 100 190.8 - 202.2 1 5 2 .6 - 161.8 133.5 - 141.5
in 1 <
in
Q tr
CD
C/)
O
2
5 High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0

o
z Low idling speed 450 — 650 rpm 600 ± 50 0 0 0

co Flywheel horsepower 320 HP/2,000 rpm 2,000 ± 5 170.5 ± 180.3 136.3 - 144.1 1 1 9 .4 - 126.1
LD
CM

i—
in | Max. torque 144 kgm/1,400 rpm 1,400 ± 100 205.2 - 217.3 164.1 - 173.9 1 4 3 .6 - 152.1.
in 1 <

q cn in
co ^ 5 High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0
co
o
Z Low idling speed 450 — 650 rpm 600 ± 50 0 0 0

Q. Flywheel horsepower 320 HP/2,000 rpm 2,000 ± 5 174.0 - 183.6 139.2 - 146.9 1 2 1 .8 -1 2 8 .5
3
14257 and
S6D155-4

< Max. torque 144 kgm/1,400 rpm 1,400 ± 100 206.7 218.7 1 6 5 .4 - 175.0 1 4 4 .7 - 153.1
m
in
5 High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0
i.

z Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

★ Values in table are standard values corrected by jis.


★ The values given for the shaft h orsep o w er and to rq ue are w ith the fan rem o ved, so th at differ fro m those of
the specification.
★ Values are standardized u nd er the follow ing conditions: A ir cleaner installed; alternator idling; and air com ­
pressor (if installed) open.

12-706 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING ENGINE PERFORMANCE TEST

Coolant Lubrication Lubrication Exhaust


Axial torque Fuel consumption
Axial output (HP) temperature oil temperature oil pressure temperature
(kgm) ratio (sec./500 cc)
rc) CC) (kg/cm2) rc>

223.8 - 236.3 - 23.0 min. (300 cc) 7 0 -9 0 8 0 -9 5 3 .5 -4 .5 Max. 650 + 3t

- 1 6 5 .0 - 174.6 29.0 min. (300 cc) 7 0 -9 0 8 0 -9 5 3.5 - 4.5 Max. 650 + 3t

0 0 - 7 0 -9 0 8 0 -9 5 3.5 - 4.5 -

0 0 - 7 0 -9 0 80 min. 1.5 min. -

253.0 - 267.4 - 20.0 min. (300 cc) 7 0 -9 0 8 0 -9 5 3.5 - 4.5 Max. 650 + 3t

- 122.5 - 130.0 24.0 min. (300cc) 7 0 -9 0 8 0 -9 5 3.5 - 4.5 Max. 650 + 3t

0 0 - 7 0 -9 0 8 0 -9 5 3.5 - 4.5 -

0 0 - 70 - 90 80 min. 1.5 min. -

317.0 - 336.0 - 25.7 min. 7 0 -9 0 80 - 95 3.5 - 4.5 Max. 650 + 3t

- 166.6 - 176.6 31.3 min. 7 0 -9 0 8 0 -9 5 3 .5 -4 .5 Max. 650 + 3t

0 0 - 7 0 -9 0 8 0 -9 5 3.5 - 4.5 -

0 0 - 70 - 90 80 min. 1.5 min. -

328.0 - 346.0 - 25.2 min. 7 0 -9 5 8 0 -1 0 0 3.5 - 4.5 Max. 650 + 3t

- 166.8 - 176.6 31.0 min. 7 0 -9 5 8 0 -1 0 0 3.5 - 4.5 Max. 650 + 3t

0 0 - 7 0 -9 5 80 - 100 3.5 - 4.5 -

0 0 - 7 0 -9 5 80min. 1.5 min. -

317.0 - 336.0 - 25.7 min. 70 - 90 80 - 95 3 .5 -4 .5 Max. 650 + 3t

- - 31.3 min. 70 - 90 80 - 95 3.5 - 4.5 Max. 650 + 3t

0 0 - 70 - 90 80 - 95 3.5 - 4.5 -

0 0 - 70 - 90 80 min. 1.5 min. -

341.1 - 360.5 - 23.5 min. 70 - 95 80 - 100 3.5 - 4.5 Max. 650 + 3t

- - 28.4 min. 7 0 -9 5 80 - 100 3.5 - 4.5 Max. 650 + 3t

0 0 - 7 0 -9 5 80 - 100 3.5 - 4.5 -

0 0 - 7 0 -9 5 80 min. 1.5 min. -

348.0 - 367.2 - 23.5 min. 7 0 -9 5 8 0 -1 0 0 3.5 - 4.5 Max. 650 + 3t

- 183.8 - 194.4 28.9 min. 70 - 95 80 - 100 3.5 - 4.5 Max. 650 + 3t

0 0 - 70 - 95 8 0 -1 0 0 3.5 - 4.5 -

0 0 - 7 0 -9 5 80 min. 1.5 min. -

★ Fuel used: A S T M D975 No. 1 or No.2 diesel fuel


★ Lubricating oil used: CLASS-CD SAE30
★ M ark "t" of exhaust tem perature: t = intake air tem p eratu re X°C —20°C.

155-4 SERIES 12-707


<D

from the library of Barrington Diesel Club


ENGINE PERFORMANCE TEST TESTING AND ADJUSTING

Dynamometer (kg)
Appli­ Specified value Engine speed
Engine Check point
cation (fully equipped) (rpm) Arm length Arm length Arm length
716 mm 895 mm 1,023 mm

Flywheel horsepower 350 HP/2,000 rpm 2,000 ± 5 1 9 0 .0 -2 0 0 .0 152.0 - 160.0 1 3 3 .0 - 140.0

Max. torque 160 kgm/1,400 rpm 1,400 ± 100 230.5 - 244.0 184.3 - 194.0 1 6 1 .4 - 170.8
CO
in
5 High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0

Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

Flywheel horsepower 270 HP/2,000 rpm 2,000 ± 5 142.7 - 150.9 114.2 - 120.7 9 9 .9 - 105.6

Max. torque 120 kgm/1,400 rpm 1,400 ± 100 171.1 - 181.6 1 4 0 .9 - 145.3 123.3 - 127.1
in
Q High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0

in Low idling speed 550 — 650 rpm 625 ± 25 0 0 0


in
Q
CO Flywheel horsepower 320 HP/2,000 rpm 2,000 ± 5 170.5 - 180.3 136.3 - 144.1 119.4 - 126.1
W

6 Max. torque 144 kg/1,400 rpm 1,400 ± 100 205.7 - 217.3 164.1 - 173.9 143.6 - 152.1
in
5 High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0
Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

Flywheel horsepower 320 HP/2,000 rpm 2,000 ± 5 1 6 9 .0 - 178.5 135.2 - 142.8 118.3 - 125.0

CM
Max. torque 144 kgm/1,400 rpm 1,400 ± 100 205.5 - 219.6 164.4 - 175.7 1 4 3 .9 - 153.7
<
in
5 High idling speed 2,280 rpm max. 2,240 ± 40 0 0 0

Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

CD
Flywheel horsepower 410 HP/2,000 rpm 2,000 ± 5 2 1 5 .0 -2 2 7 .9 172.0 - 182.3 150.5 - 159.5
O
i-
ln i <
Max. torque 163 kgm/1,400 rpm 1,400 ± 100 232.7 - 246.6 186.2 - 197.3 162.9 - 172.6
5 o* r in
CO
cn Q High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0
« o

o
z Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

a Flywheel horsepower 410 HP/2,000 rpm 2,000 ± 5 216.4 ± 228.7 173.1 - 183.0 151.5 - 160.1
3
. 14050 and
S6D155-4

Max. torque 163 kgm/1,400 rpm 1,400 ± 100 233.0 - 246.7 186.4 - 197.3 163.1 - 172.6
<
in
in
CO
Q High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0
o
z Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

Flywheel horsepower 360 HP/2,000 rpm 2,000 ± 5 1 8 8 .0 - 198.5 1 5 0 .4 - 158.8 1 3 1 .6 -1 3 9 .0

CO
in Max. torque 150 kgm/1,400 rpm 1,400 ± 100 2 1 6 - 229.1 1 7 2 .8 - 183.3 151.2 - 160.4
in 6
Q
in
CO
CO
O High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0
c/)

Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

★ V alues in tab le are standard values corrected by jis.


★ T he values given fo r the shaft h orsep o w er and to rq u e are w ith the fan rem o ved, so th at differ from those of
the specification.
★ Values are standardized u nd er the follow ing conditions: A ir cleaner installed; alternator idling; and air com ­
pressor (if installed) open.

12-708 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING ENGINE PERFORMANCE TEST

Coolant Lubrication Lubrication Exhaust


Axial torque Fuel consumption
Axial output (HP) temperature oil temperature oil pressure temperature
(kgm) ratio (sec./500 cc)
CC) CC) (kg/cm2) CC)

380.0 - 401.0 - 22.3 min. 7 0 -9 0 8 0 -1 0 0 3.5 - 4.5 Max. 650 + 3t

- 1 6 5 .0 - 174.6 27.4 min. 70 - 90 8 0 -1 0 0 3.5 - 4.5 Max. 650 + 3t

0 0 - 7 0 -9 0 8 0 -1 0 0 3.5 - 4.5 -

0 0 - 7 0 -9 0 80 min. 1.5 min. ..

2 8 5 .5 - 301.7 - 22.5 min. 7 0 -9 5 7 5 -1 0 0 3.5 - 4.5 Max. 650 + 3t

- 122.5 - 130.0 28.9 min. 7 0 -9 5 75 - 100 3 . 5 - 4.5 Max. 650 + 3t

0 0 - Measuring 7 5 -1 0 0 3.5 - 4.5 -

0 0 - Measuring 80 min. 2.0 min. -

341.1 - 360.5 - 23.5 min. 7 0 -9 5 7 5 - 100 3.5 - 4.5 Max. 650 + 3t

- 146.9 - 155.5 28.4 min. 7 0 -9 5 7 5 -1 0 0 3.5 - 4.5 Max. 650 + 3t

0 0 - Measuring 7 5 - 100 3.5 - 4.5 -

0 0 - Measuring 80 min. 2.0 min. -

338 - 357 - 23.5 min. 7 0 -9 5 9 0 - 100 3.5 - 4.5 Max. 650 + 3t

- 1 4 7 .2 - 155.8 - 7 0 -9 5 9 0 -1 0 0 3.5 - 4.5 650 + 3 (tmax.)

0 0 - 7 0 -9 5 9 0 - 100 3.5 - 4.5 -

0 0 - 7 0 -9 5 9 0 - 100 1.5 min. -

430.0 - 455.8 - 19.6 min. 7 0 -9 0 8 0 -9 5 3.5 - 4.5 Max. 650 + 3t

- 166.6 - 176.6 25.8 min. 7 0 -9 0 80 - 95 3.5 - 4.5 Max. 650 + 3t

0 0 - 7 0 -9 0 8 0 -9 5 3.5 - 4.5 -

0 0 - 7 0 -9 0 80 min. 1.5 min. -

432.7 - 457.3 - 19.6 min. 70 - 95 8 0 - 100 3.5 - 4.5 Max. 650 + 3t

- 1 6 6 .8 - 176.6 26.1 min. 7 0 -9 5 8 0 -1 0 0 3.5 - 4.5 Max. 650 + 3t

0 0 - 7 0 -9 5 8 0 - 100 3.5 - 4.5 -

0 0 - 7 0 -9 5 80 min. 1.5 min. -

376 - 397 - 22 min. 7 0 -9 5 7 5 - 100 3.5 - 4.5 Max. 650 + 3t

- 1 5 5 - 164 27.8 min. 7 0 -9 5 7 5 -1 0 0 3.5 - 4.5 Max. 650 + 3t

0 0 - Measuring 7 5 - 100 3.5 - 4.5 -

0 0 - Measuring 80 min. 2.0 min. -

★ Fuel used: A S T M D975 No. 1 or No.2 diesel fuel


★ Lubricating oil used: CLASS-CD SAE30
★ M ark "t" of exhaust tem perature: t = intake air tem perature X°C —20°C.

155-4 SERIES 12-709


CD
from the library of Barrington Diesel Club
ENGINE PERFORMANCE TEST TESTING AND ADJUSTING

Dynamometer (kg)
Appli­ Specified value Engine speed
Engine Check point
cation (fully equipped) (rpm) Arm length Arm length Arm length
716 mm 895 mm 1,023 mm

Flywheel horsepower (50 Hz) 300 HP/1,500 rpm 1,500 ± 5 209.0 - 212.0 167.2 - 169.6 146.3 - 148.4

o (60 Hz) 363 HP/1,800 rpm 1,800 ± 5 211.1 - 213.8 1 6 8 .9 -1 7 1 .0 1 4 7 .8 - 149.7


o
CO
o
LU High idling speed (50 Hz) 1,560 rpm max. 1,560 max. 0 0 0
S6D155G-4

(60 Hz) 1,872 rpm max. 1,872 max. 0 0 0

Flywheel horsepower (50 Hz) 365 HP/1,500 rpm 1,500 ± 5 242.0 - 256.7 193.6 - 205.4 1 6 9 .4 - 179.7

Csl
O (60 Hz) 426 HP/1,800 rpm 1,800 ± 5 238.3 - 252.8 1 9 0 .6 -2 0 2 .2 166.8 - 177.0
O
CO
(D
LU High idling speed (50 Hz) 1,560 rpm max. 1,560 max. 0 0 0

(60 Hz) 1,872 rpm 1,872 max. 0 0 0

Flywheel horsepower 410 HP/2,000 rpm 2,000 ± 5 220.4 - 232.7 176.3 - 186.2 154.3 - 162.9
CO
< Max. torque 176 kgm/1,400 rpm 1,400 ± 100 256.7 - 271.5 205.4 - 217.2 179.7 - 199.0
LO
LO
CO
a High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0

Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

Flywheel horsepower 410 HP/2,000 rpm 2,000 ± 5 220.4 - 232.7 176.3 - 186.2 154.3 - 162.9
-o
co £
• a Max. torque 176 kgm/1,400 rpm 1,400 ± 100 256.7 - 271.5 2 0 5 .4 - 217.2 179.7 - 199.0
< <0
LO , \
to
CO o
Q LO High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0
x
SA6D155-4

Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

Flywheel horsepower 320 HP/2,000 rpm 2,000 ± 5 1 7 5 .0 - 184.0


4000 m spec.)
(High altitude,
D355A-3

Max. torque 137 kgm/1,400 rpm 1,400 ± 100 1 9 8 .4 - 209.9 - -

High idling speed 2,280 rpm max. 2,230 ± 50 0

Low idling speed 550 — 650 rpm 600 ± 50 0

Flywheel horsepower 410 HP/2,000 rpm 2,000 ± 5 220.4 - 232.7 176.3 - 186.2 154.3 - 162.9
in
< Max. torque 176 kgm/1,400 rpm 1,400 ± 100 256.7 - 271.5 2 0 5 .4 - 217.2 1 7 9 .7 - 190.0
LO
LO
m
Q High idling speed 2,280 rpm max. 2,230 ± 50 0 0 0

Low idling speed 550 — 650 rpm 600 ± 50 0 0 0

★ Values in table are standard values corrected by jis.


★ T h e values given fo r the shaft h orsep o w er and to rq ue are w ith the fan rem o ved , so th at differ from those of
the specification.
★ Values are standardized u nd er the follow ing conditions: A ir cleaner installed; alternator idling; and air com ­
pressor (if installed) open.

12-710 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING ENGINE PERFORMANCE TEST

Coolant Lubrication Lubrication Exhaust


Axial torque Fuel consumption
Axial output (HP) temperature oil temperature oil pressure temperature
(kgm) ratio (sec./500 cc)
rc> CC) (kg/cm2) CC)

313.5 - 318.0 - 27.7 min. 7 0 -9 5 8 0 -1 0 0 2.5 - 3.5 Max. 650 + 3t

380.0 - 384.8 - 22.9 min. 7 0 -9 5 8 0 - 100 3.0 - 4.0 Max. 650 + 3t

0 0 - 7 0 -9 5 8 0 - 100 - -

0 0 - 7 0 -9 5 80 min. - -

363.0 - 385.0 - 23.4 min. 7 0 -9 5 8 0 -1 0 0 2.5 - 3.5 Max. 650 + 3t

429.0 - 455.0 - 19.8 min. 7 0 -9 5 8 0 - 100 3.0 - 4.0 Max. 650 + 3t

0 0 - 70 - 95 80 - 100 - -

0 0 - 7 0 -9 5 80 min. - -

440.8 - 465.4 - 19.0 min. 7 0 -9 5 8 0 - 100 3.5 - 4.5 Max. 650 + 3t

- 183.8 - 194.4 25.3 min. 7 0 -9 5 8 0 - 100 3.5 - 4.5 Max. 650 + 3t

0 0 - 70 - 95 8 0 - 100 3.5 - 4.5 -

0 0 - 70 - 95 80 min. 1.5 min. -

440.8 - 465.4 - 19.0 min. 7 0 -9 5 8 0 -1 0 0 3 .5 -4 .5 Max. 650 + 3t

- 183.8 - 194.4 25.3 min. 70 - 95 8 0 - 100 3.5 - 4.5 Max. 650 + 3t

0 0 - 70 - 95 80 - 100 3.5 - 4.5 -

0 0 - 7 0 -9 5 80 min. 1.5 min. -

350 - 369 - 21.6 min. 7 0 -9 5 80 - 100 2 . 5 - 3.5 Max. 650 + 3t

- 142.1 - 150.3 - 7 0 -9 5 80 - 100 3.0 - 4.0 Max. 650 + 3t

0 0 - 7 0 -9 5 8 0 - 100 3.5 - 4.5 -

0 0 - 7 0 -9 5 80 min. 1.5 min. -

440.8 - 465.4 - 19.0 min. 70 - 95 80 - 100 3.5 - 4.5 Max. 650 + 3t

- 183.8 - 194.4 25.3 min. 7 0 -9 5 80 - 100 3.5 - 4.5 Max. 650 + 3t

0 0 - 7 0 -9 5 8 0 - 100 3.5 - 4.5

0 0 - 70 - 95 80 min. 1.5 min.

★ Fuel used: A S T M D975 No. 1 or No.2 diesel fuel


★ Lubricating oil used: CLASS-CD SAE30
★ M ark "t" of exhaust tem perature: t = intake air tem p e ra tu re X°C —20°C.

155-4 SERIES 12-711


(4)
from the library of Barrington Diesel Club
STARTING ENGINE (2G84) PERFORMANCE TEST TESTING AND ADJUSTING

STARTING ENGINE (2G84) PERFORMANCE TEST

R U N N IN G -IN M A K E T H E F O L L O W IN G A D J U S T M E N T A F T E R
Running-in Standards O P E R A T IO N .
• The running-in standards are as follows, when the Governor adjustment
main components such as the piston, piston rings, Set the adjusting screw to the position selected before
and bearings are replaced. disassembling, if the governor was in normal condition.
1. Turn the adjusting screw counterclockwise to
Load Time (Minute) reduce spring tension to zero, and bring the

Low-speed rotation No load governor lever all the way to the side of the
20
Rated rotation 1/4 15 adjusting screw. (The governor weight will then be
Rated rotation 2/4 15 com pletely closed.)
Rated rotation 3/4 15 Then bring the road all the way to the side o f the
Rated rotation 4 /4 10
adjusting screw (thereby opening the th ro ttle valve
to its full w id th ), and adjust the length of the rod
• T he running-in standards are as follow s, when the by turning the ball jo in t. Finally, bring the ball joint
main components are not replaced. to the ball position on the end o f the governor lever
to connect them .
Load Time (Minute) 2. Turn the adjusting screw clockwise to provide
tension for the spring, and adjust the dynamometer
Low-speed rotation No load 60 load and adjusting screw so th at an output of 18 HP
may be obtained at a rotational speed of 2500 rpm.
Then reduce the load under the same condition, and
STEFS T O BE T A K E N B E F O R E O P E R A T IO N measure the rotational speed, when the engine is at
Prior to starting the engine, fill the oil pan and sumps no load. If the rotational speed exceeds a
w ith oil as specified, and prepare a separate w ater tank permissible lim it of 30 0 0 rpm despite another
so th at cooling w ater may circulate. Check the oil gauge adjustment, either shift the spring from one fitting
fo r oil pressure im m ediately after starting the engine. position to another (3 fittin g positions provided)
Do not accelerate its speed before it is adequately or replace the governor spring.
warmed up. Turn the adjusting screw in either direction
till an oil pressure of 3 to 4 kg/cm 2 can be obtained at a Carburetor idle adjustment
rotational speed of 2 6 0 0 rpm. Use the carburetor under the same condition as prior to
disassembling, if it was in normal condition.
C H E C K T H E F O L L O W IN G D U R IN G O P E R A T IO N 1. Give one or one and a half turns to the idle adjust­
1. Make sure the oil pressure is w ith in the range o f 3 to ing screw after it is tightened up, and turn the
4 k g /c m 2. th ro ttle adjusting screw clockwise to start the
2. Check the cooling w ater for abnormal tem perature engine w ith the th ro ttle valve slightly opened.
rise. 2. Slow ly turn back the th ro ttle adjusting screw till
3. Check the exhaust fo r abnormal color. the engine rotation becomes decreased and unstable.
4. Check the cooling w ater, lubricant, and combustion Then slowly turn back the idle adjusting screw till
gas fo r leaks. the engine rotation becomes stable and increases.
5. Check the bolts and nuts fo r tightness. Again turn back the th ro ttle adjusting screw till a
rotational speed o f 6 5 0 rpm is obtained.

12-712 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING STARTING ENGINE (2G84) PERFORMANCE TEST

Test of output adjustment and performance


Make the following tests, if necessary, to confirm the
specified engine performance after running-in.

1. Load test

Rotational Speed rpm

Make a connection to the dynam om eter, and fix the


throttle valve, when the dynam om eter load and
throttle value are adjusted till values o f 18 H P /2 5 0 0
rpm and 6 kg m /1 7 0 0 rpm are obtained at full load.
Then adjust the dynam om eter load w ith the th ro ttle
valve fixed to compare the shaft output, shaft
torque, and rate o f fuel consumption w ith the
curves plotted in the graph shown above.
When the load test is completed, reduce the load to
zero after the m axim um rotational speed is obtained
at full load. Then measure the m axim um rotational
speed at no load to determine the governor per­
formance.
2. No load and Low-speed test
The engine is in normal condition, if its rotational
speed is stable at 6 5 0 rpm at no load. Carburetor
idling must be again adjusted, if the engine speed is
not stable under the condition mentioned above.

155-4 SERIES 12-713


from the library of Barrington Diesel Club
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST

T E S TIN G AND A D JU S TIN G TO O L L IS T

No. Inspection and measuring item Faultfinding tool Part No. Remarks

Digital reading, pressure sensing


1 Engine speed Tachometer 799-202-5000
type 250 to 5000rpm

2 Battery S.G.
1 . 1 0 0 - 1.300
Battery coolant test 795-500-1000
Freezing temperature of ture of —5 ° C ----- 50° C
3
cooling water
Water temperature, oil temperature,
4 0 - 200° C
air intake temperature
Thermistor temperature gauge 790-500-1300
5 Exhaust temperature 0 ~ 1,000°C

6 Lubricating oil pressure 0 ~ 10 kg/cm2

7 Fuel pressure 0 ~ 20 kg/cm2

Intake pressure,
8 Exhaust pressure Engine pressure measuring kit 799-203-2002 0 — 1,500 mmHg

9 Blowby pressure 0 ~ 1,000 m m Hj O

10 Air intake resistance —1,000~0m m H 2O (negative pressure

11 Compression pressure Compression gauge 795-502-1203 0 ~ 70 kg/cm2

12 Blowby pressure Blowby checker 795-201-1502 0 — 500 mm Hj O

795-125-1310 0.3, 0.5 mm


13 Valve clearance Feeler gauge
795-125-1320 0.4, 0.6 mm

Handy smoke checker Dirtiness 0 ~ 70%


14 Exhaust color 799-201-9000
(Dirtiness % x 1/10 % Bosch scale)

Engine oil checker Provided with 0.1 and 0.2% water


15 Water and fuel content in oil 799-201-6000
content standard samples

16 Fuel injection pressure


Commercially
Nozzle tester 0 ~ 300 kg/cm2
available
17 Fuel injection nozzle spray condition

18 Cooling water quality Water quality tester 799-202-7001 pH, nitrite ion concentration

19 Pressure valve performance


Radiator cap tester 799-202-9000 0 ~ 2 kg/cm2
20 Leakage in cooling water system

21 Radiator blockage (air speed) Anemometer 799-202-2001 0 — 40 m/s

Cranking kit 799-610-1000 DC24V

22 Engine cranking 795-100-1210 for D95, D150, D155


Barring tool
795-100-1370 for D355

Commercially
23 Electrical circuits Tester Current, voltage, resistance
available

155-4 SERIES 12-901


from the library of Barrington Diesel Club
TESTING AND ADJUSTING DATA TESTING AND ADJUSTING

T EST IN G AND A D JU S T IN G DATA


Engine model S4D155-4

Machine Serial No. D80, 85A-17 D95S-1

Classifi­
Item Condition, etc. Unit Standard Tolerance Standard Tolerance
cation

Rated speed 1,850 1,850 1,850 1,850


o
c Engine speed Max. idling speed 2,050 ± 50 2,050 ± 50 2,050 ± 50 2,050 ± 50
CO
E
Min. idling speed rpm 625 ± 25 625 ± 25 625 ± 25 625 ± 25
o
i_
0) OX 150 min. — 150 min. —
Q_ Necessary
starting speed
— 20°C (with starting aid) 100 min. 100 min.

Intake resistance At rated horsepower mmH20 380 max. 762 380 max. 762

Air charging pressure At rated horsepower mmHg - 670 - 850 -


E
03 Exhausting pressure
+-» At rated horsepower mmHg - 600 - 720 -
CO
CO
+-< Exhaust temperature All speeds (20X) X 650 max. 680 650 max. 680
CO
D
CO Quick acceleration 9.0 max. 9.0 max. 9.0 max. 9.0 max.
.c
X Exhaust color Bosch scale
CO
High idling 4.0 max. 4.0 max. 4.0 max. 4.0 max.
T3
C
CO 0.3 0.3
CO (No. - 50156) (No. - 50156)
Valve clearance Intake valve —
CO 0.4 0.4
_c (No. 50157 - ) (No. 50157 - )
mm

Warm (cold) Exhaust valve


(No.
0.3
- 50156)
0.4
: (No.
0.3
- 50156)
0.6
(No. 50157 - ) (No. 50157 - )
Oil temperature 4 0 X — 60X kg/cm2 24 min. 24 min. 24 min. 24min.
CO
Compression
.E > pressure
03 "O (Engine speed) (rpm) (1 8 0 -2 1 0 ) (1 8 0 -2 1 0 ) (1 8 0 -2 1 0 ) (1 8 0 -2 1 0 )
LU -Q High idling at 6CX or
Blow-by pressure mmH20 150 max. 300 150 max. 300
above of oil temperature
3.5 - 4.5 2.5 3.5 - 4.5 2.5
Oil pressure High idling
c (3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1)
(SAE30, 80°C kg/cm2
o 1.5 min. 0.7 1.5 min. 0.7
’■*-> or above) Low idling
CO C (1.0 min.) (0.7) (1.0 min.) (0.7)
O c
•- 03 All speeds
-Q co Oil temperature X 8 0 -1 0 0 120 80 - 100 120
=3 > (Oil in oil pan)
— 1 CO
Continuous rated output
Oil consumption % 0.5 max. 1.0 max. 0.5 max. 1.0 max.
(Ratio to fuel consumption)
175 175
Fuel injection (No. - 50156) (No. - 50156)
system


Nozzle tester kg/cm2 -
pressure 220 220
Fuel

(N o .50157 - ) (No. 50157 - )


Fuel injection timing B.T.D.C. Degree 33 33

All speeds
Coolant temperature 7 0 -9 0 100 7 0 -9 0 100
(at engine outlet)

Valve cracking temperature X 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5
E
(13
to Thermostat function Full open temperature 90 - 90 -
CO
03 Full open lift mm - 10 max. - 10 max.

Radiator pressure Opening pressure


O kg/cm2 0.75 - 0.75 -
O valve (Differential pressure)

Fan speed At rated engine speed rpm - 1,480 ± 2 0 -

Protrusion of adjusting
Fan belt tension mm See attached sheet
screw

★ Engine oil pressure with ( ): For SAE10W

12-902 155-4 SERIES


(3)
from the library of Barrington Diesel Club
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

S6D155-4

D155A-1 D150A-1 D155A-1 D155A-1


(Engine Serial No. 10011 - 14280) (Engine Serial No. 14281 and up) (Engine Serial No. 10011 - 12297) (Engine Serial No. 12298 — 14256)

Standard Tolerance Standard Tolerance Standard Tolerance Standard Tolerance

2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000

2,230 ± 50 2,230 ± 50 2,230 + 50 2,230 ± 50 2,230 ± 50 2,230 ± 50 2,230 ± 50 2,230 ± 50

600 ± 50 600 ± 50 600 ± 50 600 ± 50 600 ± 50 600 ± 50 600 ± 50 600 ± 50

150 min. - 150 min. - 150 min. - 150 min. -

100 min. - 100 min. - 100 min. - 100 min. -

380 max. 762 380 max. 762 380 max. 762 380 max. 762

550 - 700 - 550 - 700 - 550 - 700 - 650 - 800 -

500 - 600 700 500 - 600 - 500 - 600 - 500 - 600 -

650 max. 700 650 max. 700 650 max. 700 650 max. 700

7.0 max. 7.0 max. 7.0 max. 7.0 max. 7.0 max. 7.0 max. 7.0 max. 7.0 max.

3.5 max. 3.5 max. 3.5 max. 3.5 max. 3.5 max. 3.5 max. 3.5 max. 3.5 max.

0.3 (No. - 11745) 0.3 (No. - 11745)


- 0.4 - - 0.4 -
0.4 (No. 11746 - ) 0.4 (No. 11746 - )

0.3 (No. - 11745) 0.3 (No. - 11745)


- 0 .6 - - 0 .6 -
0.6 (No. 11746 - ) 0.6 (No. 11746 - )

27 min. 27 min.
(No. - 14256) (No. - 14256) 24 min. 24 min. 27 min. 27 min. 27 min. 27 min.
24 min. 24 min.
(No. 14257 -) (No. 14257 -)
(1 8 0 -2 1 0 ) 0 80 - 210) (1 8 0 -2 1 0 ) (1 8 0 -2 1 0 ) (180 - 210) (1 8 0 -2 1 0 ) (180 - 210) ( 1 8 0 -2 1 0 )

200 max. 400 200 max. 400 200 max. 400 200 max. 400

3.5 - 4.5 2.5 3.5 - 4.5 2.5 3.5 - 4.5 2.5 3.5 - 4.5 2.5
(3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1)
1.5 min. 0.7 1.5 min. 0.7 1.5 min. 0.7 1.5 min. 0.7
(1.0 min.) (0.7) (1.0 min.) (0.7) (1.0 min.) (0.7) (1.0 min.) (0.7)

8 0 - 100 120 80 - 100 120 8 0 - 100 120 8 0 -1 0 0 120

0.5 max. 1.0 max. 0.5 max. 1.0 max. 0.5 max. 1.0 max. 0.5 max. 1.0 max.

175 - 200 175 175 - 175 -

37 (No. 10011 - 33 (No. 14257 -


14256) 19999) 33 (No. 12298-
33 (No. 14257 - - 40 (No. 20001 - - 37 - 19999) -
19999) 20597)
38 (No. 20598 - )

7 0 -9 0 100 7 0 -9 0 100 7 0 -9 0 100 7 0 -9 0 100

74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5

90 - 90 - 90 - 90 -

- 10 min. - 10 min. - 10 min. - 10 min.

0.75 - 0.75 - 0.75 - 0.75 -

- - - -

See attached sheet

155-4 SERIES 12-903


CD
from the library of Barrington Diesel Club
TESTING AND ADJUSTING DATA TESTING AND ADJUSTING

Engine model S6D155-4

D155A-1
Machine Serial No. D155S-1
(Engine Serial No. 14257 —)
Classifi­
Item Condition, etc. Unit Standard Tolerance Standard Tolerance
cation

Rated speed 2,000 2,000 2,000 2,000


CD
o Engine speed Max. idling speed 2,050 ± 50 2,050 ± 50 2,050 ± 50 2,050 ± 50
c
E
k- Min. idling speed rpm 600 ± 50 600 ± 50 600 ± 50 600 ± 50
M—
V-
O 0°C 150 min. 150 min.
Q_ Necessary
starting speed _ —
—20°C (with starting aid) 100 min. 100 min.

Intake resistance At rated horsepower mmH20 380 max. 762 380 max. 762

Air charging pressure At rated horsepower mmHg 650 - 800 - 780 - 880 -
E
CD
(/3 Exhausting pressure At rated horsepower mmHg 500 - 600 - 750 - 850 -
>
w
■*-> Exhaust temperature All speeds (20°C) °C 650 max. 700 650 max. 700
cn
CD
SZ Quick acceleration 9.0 max. 9.0 max. 9.0 max. 9.0 max.
X
CD
Exhaust color Bosch scale
"O High idling 4.0 max. 4.0 max. 4.0 max. 4.0 max.
CD
CD
Valve clearance Intake valve 0.4 - 0.4 -
CD
_C
mm

Warm (cold) Exhaust valve 0.6 0.6 -

Oil temperature 40°C — 60°C kg/cm2 24 min. 24 min. 24 min. 24min.


CD
Compression
.E >• pressure
03 "0 (Engine speed) (rpm) (180 - 210) (180 - 210) (1 8 0 -2 1 0 ) (1 8 0 -2 1 0 )
UJ -Q High idling at 60°C or
Blow-by pressure mmH20 200 max. 400 200 max. 300
above of oil temperature
3.5 - 4.5 2.5 3.5 - 4.5 2.5
Oil pressure High idling
(3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1)
(SAE30, 80°C kg/cm2
ubrication

1.5 min. 0.7 1.5 min. 0.7


or above) Low idling
(1.0 min.) (0.7) (1.0 min.) (0.7)
ystem

All speeds
Oil temperature °C 80 - 100 120 80 - 100 120
(Oil in oil pan)
—I CO
Continuous rated output
Oil consumption % 0.5 max. 1.0 max. 0.5 max. 1.0 max.
(Ratio to fuel consumption)

22° + 15° 220™


Fuel injection
system

Nozzle tester kg/cm2 33 (No. 1 2 2 9 8 - 200 33 (No. 15182 — 200


pressure 19999) 19999)
Fuel

40 (No. 20000 - 40 (No. 20000 -


20764) 20764)
Fuel injection timing B.T.D.C. Degree 38 (No. 20765 -) 38 (No. 20765 -)

All speeds
Coolant temperature 7 9 -9 0 100 7 0 -9 0 100
(at engine outlet)

Valve cracking temperature *C 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5
E
CD
Thermostat function Full open temperature 90 - 90 -
tfl
C/3
Full open lift mm - 10 min. - 10 min.
03
Radiator pressure Opening pressure
O kg/cm2 0.75 - 0.75 -
o valve (Differential pressure)
(J
Fan speed At rated engine speed rpm 1,350 ± 40 - 1,480 ± 4 5 -

Protrusion of adjusting
Fan belt tension mm See attached sheet
screw

★ Engine oil pressure with ( ): For SAE10W

12-904 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

S6D155-4

D355A-1
D155W-1 D155C-1 D155A-2
(Engine Serial No. 10011 — 14049)

Standard Tolerance Standard Tolerance Standard Tolerance Standard Tolerance

2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000

2,050 ± 50 2,050 ± 50 2,240 ± 40 2,240 ± 40 2,240 ± 40 2,240 ± 40 2,050 ± 50 2,050 ± 50

600 ± 50 600 ± 50 600 ± 50 600 ± 50 600 ± 50 600 ± 50 600 ± 50 600 ± 50

150 min. - 150 min. - 150 min. - 150 min. -

100 min. - 100 min. - 100 min. - 100 min. -

380 max. 762 380 max. 762 380 max. 762 380 max. 762

550 - - 650 min. - 650 min. - 800 - 900 -

550 - 650 - 500 min. - 500 min. - 800 - 900 -

650 max. 700 650 max. 700 650 max. 700 650 max. 700

9.0 max. 9.5 max. 6.0 max. 8.0 6.0 max. 8.0 6.5 max. 6.5 max.

4.0 max. 4.0 max. 2.5 max. 3.5 2.5 max. 3.5 2.0 max. 2.0 max

0.3 (No. - 11745)


0.4 - 0.4 - 0.4 - -
0.4 (No. 11746 - )

0.3 (No. - 11745)


0.6 - 0.6 - 0.6 - -
0.6 (No. 11746 - )

24 min. 24 min. 24 min. 14 24 min. 17 24 min. 24 min.

(180 - 210) (180 - 210) (180 - 210) (1 8 0 -2 1 0 ) (180 -- 210) (180 - 210) (180 - 210) ( 1 8 0 -2 1 0 )

150 max. 300 200 max. 400 200 max. 400 200 max. 400

3.5 - 5.5 2.5 3.5 - 4.5 2.5 3.5 - 4.5 2.5 3.5 - 4.5 2.5
(3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1)
1.5 min. 0.7 1.5 min. 0.7 1.5 min. 0.7 1.5 min. 0.7
(1.0 min.) (0.7) (1.0 min.) (0.7) (1.0 min.) (0.7) (1.0 min.) (0.7)

80 - 100 120 80 - 100 120 80 - 100 120 80 - 100 120

0.5 max. 1.0 max. 0.5 max. 1.0 max. 0.5 max. 1.0 max. 0.5 max. 1.0 max.

220 + 1 ° 200 220 + 1 ° 200 220 + 1 ° 200 175 + 10 160


+5 +5 +5 +5

38 - 38 - 38 - 37 -

7 0 -9 0 100 70 - 90 100 70 - 90 100 7 0 -9 5 100

74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5

90 - 90 - 90 - 90 -

- 10 min. - 10 min. - 10 min. - 10 min.

0.75 - 0.75 - 0.75 - 0.75 -

1,575 ± 45 (No. 10011 - 13716)


1,649 ± 50 - 1,350 ± 40 - 1,350 ± 40 -
1,085 ± 30 (No. 1 3 7 1 7 -)

See attached sheet

155-4 SERIES 12-905


<D
from the library of Barrington Diesel Club
TESTING AND ADJUSTING DATA TESTING AND ADJUSTING

Engine model S6D155-4

Machine Serial No. D355A-1


D355C-3
(Engine Serial No. 14050 —)
Classifi­
Item Condition, etc. Unit Standard Tolerance Standard Tolerance
cation

Rated speed 2,000 2,000 2,000 2,000


03
o
c Engine speed Max. idling speed 2,050 ± 50 2,050 ± 50 2,240 ± 40 2,240 ± 40
CO
E Min. idling speed
k_ rpm 600 ± 50 600 ± 50 600 ± 50 600 ± 50
o
k_
03
CL Necessary
starting speed
0°C

—20T (with starting aid)


150 min.

100 min.
— 150 min.

100 min. :
Intake resistance At rated horsepower mmHjO 380 max. 762 380 max. 762

Air charging pressure At rated horsepower mmHg 800 - 900 - 725 min. -
£
0)
C/3
Exhausting pressure At rated horsepower mmHg 800 - 900 - 700 min. -
C/3
Exhaust temperature All speeds (20°C) “C 650 max. 700 650 max. 700
CO
D
co Quick acceleration 6.5 max. 6.5 max. 6.5 max. 8.5
-C
X Exhaust color Bosch scale
03
High idling 2.0 max. 2.0 max. 2.5 max. 3.5
T3
C
CO
03 —
-X Valve clearance Intake valve 0.4 0.4 -

4->
_c mm

Warm (cold) Exhaust valve 0.6 - 0.6 -

Oil temperature 40°C — 60°C kg/cm2 24 min. 24 min. 24 min. 17


03
Compression
.E >- pressure
03 TJ
(Engine speed) (rpm) (180 - 210) ( 1 8 0 -2 1 0 ) (180 - 210) (180 - 210)
LU -Q High idling at 60°C or
Blow-by pressure mmH20 200 max. 400 200 max. 400
above of oil temperature
3.5 - 4.5 2.5 3.5 - 4.5 2.5
Oil pressure High idling
(3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1)
C (SAE30, 80°C kg/cm2
o 1.5 min. 0.7 1.5 min. 0.7
or above) Low idling
(1.0 min.) (0.7) (1.0 min.) (0.7)
o E
•- <u All speeds
-Q to Oil temperature °C 8 0 - 100 120 80 - 100 120
(Oil in oil pan)
3 >-
— 1 CO
Continuous rated output
Oil consumption % 0.5 max. 1.0 max. 0.5 max. 1.0
(Ratio to fuel consumption)

Fuel injection 175 (N o-14245)


system

160
Nozzle tester kg/cm2 220 + 1° 200
pressure 220 (No.14246—) 200 -rb
Fuel

37 (No. - 14245)
Fuel injection timing B.T.D.C. Degree 38
34 (No. 14246—)
All speeds
Coolant temperature 7 0 -9 5 100 7 0 -9 0 100
(at engine outlet)

Valve cracking temperature °C 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5
E
+V-> Thermostat function Full open temperature 90 - 90 -
CO
>.
CO
03 Full open lift mm - 10 min. - 10 min.

O Radiator pressure Opening pressure


kg/cm2 0.75 - 0.75 -
O valve (Differential pressure)
o

Fan speed At rated engine speed rpm 1,085 ± 30 - 1,180 ± 35

Protrusion of adjusting
Fan belt tension mm See attached sheet
screw

★ Engine oil pressure with ( ): For SAE10W

12-906 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

S6D155G-4 SA6D155-4

D355A-3
EG300-1 EG300-2 D355A-3
(—506C spec)

Standard Tolerance Standard Tolerance Standard Tolerance Standard Tolerance

1,560 max. (50 Hz) 1,560 max. (50 Hz) 1,560 max. (50 Hz) 1,560 max. (50 Hz) 2,000 2,000 2,000 2,000

1,872 max. (60 Hz) 1,872 max. (60 Hz) 1,872 max. (60 Hz) 1,872 max. (60 Hz) 2,240 ± 40 2,240 ± 40 2,240 ± 40 2,240 ± 40

- - - - 600 ± 50 600 ± 50 600 ± 50 600 ± 50

150 min. - 150 min. - 150 min. - 150 min. -

100 min. - 100 min. - 100 min. - 100 min. -

380 max. 635 380 max. 762 380 max. 762 380 max. 762

750 - 850 - - - 9 0 0 - 1,150 - - -

580 - 680 - - - 1,000 - 1,150 - - -

650 max. 700 680 max. 700 680 max. 700 680 max. 700

6.5 max. 6.5 max. 6.5 max. 6.5 max. 6.5 max. 6.5 max. 6.5 max. 6.5 max.

2.0 max. 2.0 max. 2.0 max. 2.0 max. 2.0 max. 2.0 max. 2.0 max. 2.0 m

0.4 - 0.4 - 0.4 - 0.4 -

0.6 - 0.6 - 0.6 - 0.6 -

24 min. 17 min. 24 min. 17 min. 22 min. 16 min. 22 min. 16 min.

(1 8 0 -2 1 0 ) (180 - 210) (180 - 210) (1 8 0 -2 1 0 ) ( 1 8 0 - 210) (1 8 0 -2 1 0 ) (1 8 0 -2 1 0 ) (180 - 210)

150 max. 300 200 max. 400 200 max. 400 200 max. 400

3.0 - 4.5 2.1 3.0 - 4.5 2.1 3.5 - 4.5 2.5 3.5 - 4.5 2.5
(2.5 - 4.0) (1.8) (2.5 - 4.0) (1.8) (3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1)
1.5 min. 0.7 1.5 min. 0.7 1.5 min. 0.7 1.5 min. 0.7
(1.0 min.) (0.7) (1.0 min.) (0.7) (1.0 min.) (0.7) (1.0 min.) (0.7)

8 0 - 100 120 8 0 - 110 120 8 0 - 100 120 8 0 -1 2 0 120

0.5 max. 1.0 max. 0.5 max. 1.0 mx. 0.5 max. 1.0 max. 0.5 max. 1.0 max.

220 + ; ° 200 200 2 2 0 1 1 ° 200 220 t j ° 200


~rb

38 - 38 - 38 - 38 -

7 0 -9 0 100 7 0 -9 0 100 7 0 -9 0 100 7 0 -9 0 100

74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5

90 - 90 - 90 - 90 -

- 10 min. - 10 min. - 10 min. - 10 min.

0.75 - 0.75 - 0.75 - 0.75 -

1,440 ± 40 - 1,140 ± 4 0 - 1,100 ± 35 - 1,100 ± 35 -

See attached sheet

155-4 SERIES 12-907


(D
from the library of Barrington Diesel Club
TESTING AND ADJUSTING DATA TESTING AND ADJUSTING

Engine model SA6D155-4

D355A-3
Machine Serial No. D355A-5
(High altitude, 4000 m spec.)
Classifi­
Item Condition, etc. Unit Standard Tolerance Standard Tolerance
cation

Rated speed 2,000 2,000 2,000 2,000


<D
o Engine speed Max. idling speed 2,240 ± 40 2,240 ± 40 2,240 ± 40 2,240 ± 40
c
E Min. idling speed rpm 600 ± 50 600 ± 50 600 ± 50 600 ± 50
Ho—
0°C 150 min. 150 min. —
0) Necessary
Q-
starting speed _
—20°C (with starting aid) 100 min. 100 min.

Intake resistance At rated horsepower mmHjO 380 max. 762 380 max. 762

Air charging pressure At rated horsepower mmHg - - 9 0 0 - 1,150 -


E
CD
to Exhausting pressure At rated horsepower mmHg - - 1,000 - 1,150 -
>-
C/J
■*->
CO Exhaust temperature All speeds (20°C) °C 680 max. 700 680 max. 700
CO
S I Quick acceleration 6.5 max. 8.5 6.5 max. 6.5 max.
X Exhaust color Bosch scale
CD
"O High idling 2.5 max. 3.5 2.0 max. 2.0 max.
CO
0}
Valve clearance Intake valve 0.4 - 0.4 -
CO
_c
mm

Warm (cold) Exhaust valve 0.6 - 0.6 -

Oil temperature 40°C — 60°C kg/cm2 22 min. 16 min. 22 min. 16 min.


CD Compression
.E >- pressure
CD"O (Engine speed) (rpm) (180 - 210) (1 8 0 -2 1 0 ) (1 8 0 -2 1 0 ) (180 - 210)
LU -Q High idling at 60°C or
Blow-by pressure mmH20 200 max. 400 200 max. 400
above of oil temperature
3 .5 -4 .5 2.5 3.5 - 4.5 2.5
Oil pressure High idling
C (3.0 - 4.0) (2.1) (3.0 - 4.0) (2.1)
(SAE30, 80°C kg/cm2
o 1.5 min. 0.7 1.5 min. 0.7
or above) Low idling
CO C (1.0 min.) (0.7) (1.0 min.) (0.7)
o <
■- ED
Ail speeds
-Q to Oil temperature °C 80 - 100 120 80 - 100 120
(Oil in oil pan)
3 >>
_1 CO
Continuous rated output
Oil consumption % 0.5 max. 1.0 max. 0.5 max. 1.0 max.
(Ratio to fuel consumption)

Fuel injection
system

Nozzle tester kg/cm2 200 200


pressure 220 t l ° 220 t s °
Fuel

Fuel injection timing B.T.D.C. Degree 38 38

All speeds
Coolant temperature 70 - 90 100 7 0 -9 0 100
(at engine outlet)

Valve cracking temperature °C 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5 74.5 - 78.5
E
4C
—D
' Thermostat function Full open temperature 90 - 90 -
CO

CO
O) Full open lift mm - 10 min. - 10 min.

o Radiator pressure Opening pressure


O kg/cm2 0.75 - 0.75 -
valve (Differential pressure)
U
Fan speed At rated engine speed rpm 1,100 ± 35 - 1,100 ± 35 -

Protrusion of adjusting
Fan belt tension mm See attached sheet
screw

★ Engine oil pressure with ( ): For SAE10W

12-908 155-4 SERIES

from the library of Barrington Diesel Club


TESTING AND ADJUSTING TESTING AND ADJUSTING DATA

FAN BELT TENSION

Engine model Application Engine serial No. Protrusion A (mm)

D80A-17
95 ± 5
D85A-17

S4D155-4
10277 - 50432 95 ± 5
D95S-1
50433 and up 80 + 5

10014 - 10277 91 ± 5

10278 - 24804 96 ± 5
D150A-1
24805 - 24973 121 + 5

24974 and up 85 ± 5

10016 - 10337 91 ± 5

10338 - 24804 96 ± 5 1. Adjustment nut

D155A-1 2. Lock nut


24805 - 25817 121 ± 5
D155C-1 3. Tension spring
25818 - 28423 110 9 4. Tension pulley
—b
5. Washer
28424 and up 85 ± 5
6. Protrusion of adjustment screw
S6D155-4 15182 - 25199 121 ± 5
D155S-1
25200 and up
11 ° - 5

2 2 1 4 4 - 25817 95 ± 5
D155W-1
25818 and up 80 ± 5

20001 - 51355 50 ± 5
D355C-3
51356 and up 30 ± 5

D155A-2 52707 and up 85 ± 5

10011 - 10427 91 ± 5

D355A-1 1 0 4 2 8 - 11274 96 ± 5

11275 - 20337 71 ± 5

20338 - 26062 54 ± 5

26063 - 26690 40 ± 5
D355A-3
SA6D155-4 26691 - 29842 50 ± 5

29843 and up 25 ± 5

D355A-5 50816 and up 25 ± 5

155-4 SERIES 12-909


from the library of Barrington Diesel Club
Engine Serial No. 10011 and up
E N G IN E
DISASSEMBLY
» AND ASSEMBLY

155-4 SERIES 13-001


from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY
OVERALL DISASSEMBLY ................................................. 13-004

OVERALL ASSEMBLY ........................................................ 13-102

DISASSEMBLY AND ASSEMBLY OF


ASSEMBLY PART

W A T E R PUMP ................................................................ 13-202

TURBOCHARGER ................................................................ 13-205

K T R 100, 130 .................................................................... 13-205

R H 1 5 2 1 ............................................................................... 13-213

S T A R T IN G E N G IN E ( 2 G 8 4 ) ............................................... 13-218

F U E L IN J E C T IO N P U M P ..................................................... 13-225

★ The description o f overall engine disassembly and assembly


given in this section is based on the D155A -1 engine, assuming
the use o f an overhaul stand.
★ The w ork procedure may d iffer slightly from th at given here
depending upon the machine in which the engine is m ounted
and also the particular stand used, however it is fundam entally
the same.
★ Use the correct service tools when performing disassembly and
assembly.
★ Refer to the Service Tool Guide for details of the various types
of service tools and method o f using them .

155-4 SERIES 13-003

from the library of Barrington Diesel Club


GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

G E N E R A L D IS A S S E M B L Y O F E N G IN E A S S E M B L Y

By-pass
filter 13
Filter Engine
bracket oil cooler

Corrosion
resistor

Starting
motor

Alternator
Alternator
drive shaft 14
155 series Engine
engine Ass'y repair
(D155A-1) stand set
Water
pump

Intake
connector

Turbo­
9 charger
Turbo- 12 I
charger
lubrication
tube______ Exhaust
manifold
10
Muffler

Idle gear

30
P.T.O and
Steering flywheel
From A Flywheel
pump gear housing

29
Rear seal

13-004 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

15
Water to B
manifold

16 17

18
Breather to D
tube

to E

23

to L

19 20

22
Dipstick
pipe

to A

155-4 SERIES 13-005


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

from B

from C

41

47

from G Idle gear

from H
38
Injection
pump
drive ass'y

from I

from J

from K

from L

13-006 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

155-4 SERIES 13-007


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

S P E C IA L T O O L S

Part No. Part name A B C D E F G


Engine repair stand, main
790-501-2000 1
unit
790-901-1150 Engine repair stand bracket 1

790-101-3500 Gear puller 1

795-102-2201 Flange puller 1

795-100-1181 Timer remover 1

795-102-2101 Spring pusher 1

795-225-1600 Piston ring tool 1

795-102-1100 Liner puller 1

Preparation w ork
• Set engine ass'y(1) on engine stand (T).

D ism ount engine-related parts.


1) Dism ount accelerator rod (2) together w ith
bracket (3).
2) Dism ount compression release rod (4).
3) Disconnect tube (5) of the intake air heater and
tube (6) of the engine oil pressure gauge.

4) Disconnect w iring (7) and (8) fro m the alternator


and starting m otor, respectively.

13-008 155-4 SERIES


<D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

5) Remove radiator outlet w ater hose (9) fro m the


connecting part of the w ater pump.
6) Disconnect service meter cable (10 ).
7) Remove wire harnesses (1 1 ), (1 2 ) and (1 3 ).

6 I2 7 P 0 2 5

1. Bypass filte r
1) Disconnect inlet hose (1) of the bypass filte r at the
engine oil cooler side, then disconnect the o utlet
hose at the cylinder block side.
2) Remove bypass filte r m ounting bands (2) and (3),
then dismount bypass filte r (4).

2. Corrosion resistor
1) Disconnect inlet hose (5) o f the corrosion resistor
at the w ater pump side, then disconnect o utlet
hose (6) at the cylinder block side.
2) Remove the bracket connecting bolts of corrosion
resistor (7), then dismount the corrosion resistor.

155-4 SERIES 13-009


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

4. Starting motor
1) Remove bracket (1).
★ Note that the tw o mounting bolts fo r the
bracket on the starting m otor side are fine
bolts.
2) Remove the mounting bolts o f the starting m otor
and lift out starting m otor (2).
Starting m otor: 5 0 kg

5. Alternator
1) Remove V -b elt cover (1).

2) Remove adjusting bolts (2), then loosen support


bolts (3), push alternator (4) to the engine side
and remove V -b elt (5).
3) Remove support bolts (3) and dism ount alternator
(4).

6. Alternator drived shaft


1) Remove mounting bolts of bracket (1) and the
gear case, then dismount alternator drive shaft (2).
2) Remove bracket (1).

Drive shaft: 2 5 kg

13-010 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

7. Water pump
1) Disconnect bypass tube (1) fro m the connecting
part o f the therm ostat and w ater pum p, respec­
tively, then remove the tube.
2) Remove the gear case m ounting nuts, then dis­
m ount w ater pum p (2).

W ater pump: 2 0 kg

9. Turbocharger lubricating tube


Disconnect turbocharger lubricating inlet tube (1) from
the turbocharger connecting part, then remove outlet
tube (2).

155-4 SERIES 13-011


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

2) L ift up m uffler (2), turbocharger (3) and exhaust


m anifold (4), then remove the mounting bolts
o f the exhaust m anifold and remove (2 ), (3) and
(4) as an assembly.
M uffler, turbocharger, exhaust manifold:
121 kg

13-012 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

15. Water manifold


Dismount w ater m anifold (1).

16. Fuel filter


1) Disconnect fuel filte r inlet hose (1) and outlet
hose (2) from the connecting part of the injection
pump.

2) Dismount fuel filte r (3) together w ith bracket (4).

17. Intake manifold


Dismount intake manifold (1).

18. Breather tube


Loosen hose clamp (3) of breather tube (2), then
remove tube clamp (4) and disconnect the tube.

19. Lubricating pipe


Remove clamp (1) and take out lubricating pipe (2).

20. Oilfiller
Remove oil filler (3).

155-4 SERIES 13-013


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

21. Injection pipe


1) Remove the six cam lubricating tubes (1) and also
remove the nipples at the cylinder block side.
* Note th a t the nipples fitte d w ith nozzles are
for lubricating the cam (bottom side, total
12 ).
2) Disconnect injection pipe (2) from the connecting
part of the rocker housing and injection pump.

22. Oil level gauge guide


R em ove oil level gauge guide (1).

23. Injection pump


Remove mounting bolts (2) and (3), then dismount
injection pump ass'y (4) together w ith bracket (5).
★ Check th at there are match marks on the m ount­
ing part. If there are none, mark them on the
m ounting part.

Injection pum p ass'y: 3 5 kg

6 I2 7 P 0 4 5

13-014 155-4 SERIES


(D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

27. Idle gear

28. Steering pum p gear


1) Remove bolt (2) from the hole in idle gear (1),
then dism ount the idle gear.
2) Push up lock plate (3) and remove the m ounting
bolt, then extract steering pum p gear (4) using
extraction bolts (10 m m , P = 1.5).
3) Extract the bearing cage from the rear.

4) Disassembling idle gear ass'y


i) Push up lock plate (5) and remove bearing
retainer (6) and shim (7).

ii) L ift up gear (8) and extract it together w ith


bearing (9).

iii) Dism ount bearing (11) from shaft (1 0 ).

6 I2 7 P 0 5 I 6 I2 7 P 0 5 2

155-4 SERIES 13-015


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

29. Rear seal


Push up lock plate (1) and remove the mounting bolt,
then extract rear seal (2) using extraction bolts (10
m m , P = 1.5).

I2 7 P 0 5 3 ,

30. P.T.O. and flywheel housing ass'y


1) F it sling bolts 0 (14 m m , P = 1.75) and 0 (16
m m , P = 2 .0 ) to the P.T.O . and flyw heel housing
and tem porarily suspend it.
2) Remove m ounting bolts (1) and (2) from the
flyw heel housing and dismount P .T.O . and fly ­
wheel housing (3).

0kg0 P .T.O . and flyw heel housing: 2 9 4 kg

I2 7 P 0 5 4

31. Tension pulley


1) Loosen adjusting n ut (2) o f tension spring (1),
then remove bracket (3) and spring (1).

Because tension pulley (4) w ill fall dow n,


be careful n o t to get hands caught.

2) Dism ount tension pulley (4).

13-016 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

32. Accessory pulley ass'y


1) When removing accessory pulley (1) fro m the drive
shaft ass'y, first remove m ounting bolts (2).
2) If it is necessary to finely disassemble the acces­
sory pulley, do so according to the follow ing
procedure, removing pulley (1) first.

i) Push up the lock washer and remove n ut (3).

ii) E xtract pulley (1) using puller B.

iii) Remove mounting bolts (2) and dism ount


drive shaft (4).

33. Damper
Push up lock plate (1), then remove the m ounting bolt
and damper (2).

34 . F ront support
Remove fro n t support (1).

155-4 SERIES 13-017


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

35. Damper flange


1) Remove bolt (1) and then dism ount holder (2).

2) F it bolt (1), then install puller C and remove


damper flange (3).

36. Gear case cover


Remove the crankshaft key, then suspend gear case
cover (1), remove m ounting bolts (2) and (3) and
remove the cover.

Gear case cover: 7 1 k g

37. Timer
1) Remove nut (1) and take out the shaft key.

13-018 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

2) Install remover D, then tighten it up and remove


tim er (2).
★ If the tim er does not come away when the
remover is tightened up, apply a slight shock
to the head of the remover by striking it
lightly w ith a hammer or other suitable
instrument.

38. Injection pum p drive ass'y


Remove the mounting bolts and dism ount injection
pum p drive ass'y (1).

155-4 SERIES 13-019


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

41. Spill pipe


Remove spill pipes (1) and (2).

42. Fuel pipe


Remove fuel pipe (3).

43. Rocker housing


1) Dism ount rocker housings (1 ), (2) and (3).
1 4 2 5 3
★ Take care n o t to lose joints (4) and (5) o f the
compression release shaft.

2) Disassembling rocker housing


i) Compression release shaft
When extracting compression release shaft (6),
first remove the stopper b olt from part (7).
ii) Rocker arm
• Remove left and right blind plugs (8).
• Remove stopper bolt (9).
• E xtract rocker arm shaft (1 0 ), then
remove rocker arm (1 1 ), spring (12) and
collar (1 3 ).

13-020 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

44. Push rod, crosshead and tappet


1) Remove pushrod (1) and crosshead (2). 3\

2) Extract tappet (3).

45. Cylinder head


1) Remove cylinder head mounting bolts (1 ), then fit
sling bolts ® (12 mm, P = 1.75) and lift out
cylinder head (2).

2) Disassembling cylinder head


i) Using valve spring pusher E, compress the
valve spring, then remove valve co tter (3).

ii) Release the compression from the spring, then


remove spring guide (4 ), valve spring (5) and
valve spring seat (6).
iii) Push up the cylinder head, then remove intake
valve (7) and exhaust valve (8).
★ Arrange each valve by marking the
mounting position.

155-4 SERIES 13-021


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

47. Idler gear


1) Push up lock plate (1) and remove the mounting
bolt, then remove holder (2) and dism ount main
idle gear ass'y (3).
2) Push up lock plate (4) and remove the mounting
bolt, then remove holder (5) and dism ount pump
idle gear (6).

48. Timing gear case


F it sling bolts 0 (14 m m , P = 1.75) to tim ing gear
case (1) and lift it up, then remove mounting bolts (2)
and the tw o m ounting bolts connecting the gear case to
the oil pan, and dism ount the gear case.

13-022 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMLBY GENERAL DISASSEMBLY

50. Oil strainer


Remove oil strainer (1).

51. Piping
Remove oil pum p pipings (2) and (3).

52. Oil pump


Remove oil pum p (4).

Oil pump: 2 0 kg

53. Piston cooling


Removing the six piston cooling nozzles (1

54. Gear lubricating nozzle


Remove gear lubricating nozzle (1).

55. Idle gear shaft


1) Push up lock washer (2) and remove the mounting
bolt, then dismount idle gear shaft (3) of the
pump.
2) Push up lock washer (4) and remove the mounting
bolt, then dismount the main idle gear shaft (5)
using tool (T).

012x2

155-4 SERIES 13-023


from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

5 6 . Piston and connecting rod ass'y


1) Check the No. embossed on the cap of the
connecting rod.
(Check that the cap No. and cylinder No. agree
w ith each other and th at the embossed mark is on
the cam side.)
★ If there is no mark, emboss a mark before
dismounting the cap.
2) Rotate the clutch shaft so th at the piston to be
remove falls to the B.D.C. position.
3) Remove carbon deposits from the upper wall of
the liner using fine sandpaper, etc.
4) Remove nut (2) of connecting rod cap (1).
5) Remove connecting rod cap (1) together w ith the
connecting rod bearing w hile tapping it lightly
w ith a plastic hammer to prevent damaging the
thread o f the connecting rod bolt.
6) Extract the piston and connecting rod ass'y from
the oil pan side using a wooden rod or the like.
During this operation, support the piston at the
cylinder head side to prevent damaging the inside
o f the cylinder liner.
★ Tem porarily f it the connecting rod and cap
together and place it alongside the bearing so
as to ensure that these parts are assembled
together correctly.

7) Disassembling piston and connecting rod ass'y


i) Remove the snap ring.
ii) Hold connecting rod (3) in the hand, then
extract piston pin (4) and disconnect the
connecting rod and piston fro m each other.
iii) Retain the other piston pin and remove the
snap ring.

iv) Using piston ring tool F, remove piston ring


(5).
★ Arrange the piston, connecting rod,
bearing, piston ring and piston pin of
each cylinder No. together.

6 I2 7 P 0 9 I

13-024 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY

57. Crankshaft
★ Before loosening the main cap, measure the end
play o f the crankshaft.
1) Remove m ounting b olt (2) of main bearing cap
( 1).
2) Insert the bolt into the cap hole, then dism ount
main bearing cap (1) together w ith the lower
bearing while rocking the cap.
★ There are fo ur bearings fitte d to both ends of
N o. 5 cap. A fte r removing them , m ark the
respective mounting positions.
3) L ift up crankshaft (3) using a nylon sling.

fncg~~"j Crankshaft: 2 4 2 kg

4) Dism ount upper main bearing (4).


★ M ark the mounting position of the upper
main bearing and arrange it so th at there is no
risk of it being fitted incorrectly.

5 9. Cylinder liner
★ Before removing the cylinder liner, measure the
liner protrusion. Set liner puller G, then remove
cylinder liner (1).

155-4 SERIES 13-025


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

G E N E R A L A S S E M B L Y OF ENGINE A S S E M B L Y
5

13-102 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

16

22

to L

to M

155-4 SERIES 13- 103


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

from A

from B

from C

36
from D

from E

from G

30 33

from F

42 43

from H

44
Water
from
manifold

from J

from K

37
Dip stick
from L pipe

39 40

13-104 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

155-4 SERIES 13-105


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

S P E C IA L T O O L S

Part No. Part name A E F H 1 J K L N O P Q S T U V w X Y z 1B

7 9 0 -5 0 1 -2 0 0 0 Engine repair stand body 1

7 9 0 -9 0 1 -1 1 5 0 Engine repair stand bracket 1

795-1 02-2 10 1 Spring pusher 1

7 9 5 -2 2 5 -1 6 0 0 Piston ring tool 1

7 9 5-100-1361 Hunger 1

7 9 5 -2 2 5 -1 3 0 0 Push tool 1

7 9 5 -1 0 0 -2 7 8 0 Plate 1

79 0-101-5821 Grip 1

7 9 5 -1 0 0 -2 6 0 0 Push tool kit 1

7 9 5 -2 2 5 -1 5 1 0 Liner driver y 1

7 9 5 -1 0 0 -1 2 8 0 Sleeve driver 1

79 5-1 00-1 29 1 Sleeve driver 1

79 0-101-5221 Grip 1

7 9 5-1 00-1 47 1 Piston holder v 1

7 9 0 -1 0 1 -5 0 8 0 Plate 1

79 5 -1 0 2 -2 4 0 2 Push tool 1

790-101-5221 Grip 1 1

7 9 5 -1 0 2 -2 3 0 2 Push tool 1

7 9 0-101-5021 Grip 1 1

7 9 5 -1 0 0 -1 1 6 3 T im er installer 1

79 5-1 00-1 13 1 Push tool 1

7 9 5 -1 0 0 -1 1 2 0 Seal guide 1

7 9 5 -5 2 5 -1 3 1 0 Push tool 1

795-1 01-5 02 1 G rip 1

7 9 5 -1 02-1 82 1 Seal driver 1

79 5-1 01-8 22 1 G rip 1

79 5-5 02-1 12 1 Holder 1

7 9 5 -1 2 5 -1 3 2 0 Feller gauge y 1

13-106 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

Preparation work
• Wash cylinder block (1), then raise it using suspension
tool H and m ount it on engine repair stand A.

• If it is necessary to replace the camshaft, do so


according to the follow ing procedure.
1) Remove the blind plug (flyw heel side) from the
camshaft hole.
2) Using bushing extraction tool I, successively
remove outer bushings ( 1 ) from both sides.

3) Using bushing press-fit tool I, successively press-fit


bushings ( 1) from the center.
★ During the above operation, ensure that
lubricating hole (2 ) of the bushing comes into
line w ith lubricating hole (3) of the cylinder
block.

4) Apply liquid gasket (LG -1) to the periphery of the


blind plug o f the camshaft hole, then drive on the
blind plug using tool J.

• When the blind plug of the formed hole in the water


manifold o f the cylinder block has been removed apply
liquid gasket (L G -1) to the periphery of the blind plug,
then drive on the blind plug using tool K.

155-4 SERIES 13-107


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

1. Cylinder liner
• For the engines using O-rings for all three liner
seal rings, replace the liners with ones of the clevis seal
type.
• For the engines with clevis seal type liners, the diameter
of the liner head flange determine the combination of
cylinder block, cylinder liners, cylinder head and gasket.
Do not confuse the replacement parts.

Combination of parts:

—-~ ^ L .in e r Flange dia. 183.50


Part n a m e ^ ^ 185.50

Cylinder block 6127-21-1116 From 6127-21-1117

Cylinder liner 6128-21-2212 From 6128-21-2214

Cylinder head Up to 6127-11-1112 From 6127-11-1113

Cylinder head
Up to 6127-11-1814 From 6127-11-1815
gasket

• Be sure to replace the liner O-rings whenever the liner is


removed.
• Install the O-rings and the clevis seal as illustrated below.

★ Method of installing liner O-rings and clevis seals


1) Confirm that the O-ring grooves in the liner are not
rough because of rust or pitting.
(If rough, there is a possibility of water leakage.
Replace the liner.)
2) Apply SAE30 engine oil to the seal rings and ring
grooves.
3) When installing the clevis seal, press its periphery so
that the seal fits in the upper portion of the groove
to prevent corrosion.

13-107-1 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

★ Repairing the cylinder block before installing cylinder


liners
1) Remove rust and scale from surfaces (A) and (B) Counterbore Portion Q
until the machined face is exposed.
2) Burnish portions (R) and (r) with #60 sandpaper
until they are round and smooth. If there are
sharp edges, chamfer the edges with a scraper or
hand grinder.
Then, burnish with sandpaper. Very smooth finish­
ing is required to prevent damage to the O-ring.
3) If surface B is rough because of pitting, replace the
cylinder block.
4) If surfaces (A) and (R) and portion (r) are rough
because of pitting, refinish them until smooth or
apply chamfering. Take care not to exceed the
allowable limit shown in the figure at right.
5) Check the counterbore and remove burrs, if any. 6 1 2 7F I 2 6 - 5
Completely remove chips and dust from surface (C)
to prevent water leakage because of poor contact of
liner.
Item 4) should be performed satisfactorily to eliminate
the possibility of damage to the O-ring during installa­
tion of the liners.
If the cylinder block has been corroded or damaged
beyond repair, replace the cylinder block.

Method of installing the cylinder liner


1) Apply SAE30 engine oil to the iiner O-rings and the H: 249.75 ~ 250.05m m
H': Within 250.90m m
cylinder block O-rina-qrooygs: ' \?©r-e
h: Within 1mm
★ Position each liner so that its top mark faces the
Remove sharp edges. 6 ,Z J F I26- 6
front of the engine.
2) Carefully insert'the liner until resistance is felt, taking
care not to damage the O-rings. Then, gradually apply
your weight to the liner. If smooth insertion of the liner
does not continue, the O-rings may be caught on the
cylinder block. Do not insert the liner with force as it
may damage the O-rings. Instead, repair the cylinder
block.

155-4 SERIES 13-107-2


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

4) A fte r press-fitting the cylinder liner, measure the


am ount of protrusion using dial gauge ® . If the
O-ring pushes up the liner, fit plate (2) to clamp
the liner before taking measurements.
Standard values:
Cylinder liner protrusion: 0.1 to 0.16m m
Difference in projection between cylinders:
0 .0 5 m m max.

2. Crankshaft
1) When replacing the rear sleeve, fro n t sleeve and
gear o f the crankshaft, do so according to the
follow ing procedure.
i) G rind a groove into fro n t sleeve (1 ), then
apply a chisel to this groove and knock o ff the
sleeve by tapping the chisel w ith a hammer.

ii) Extract gear (2) using a gear puller.

iii) Grind a groove into rear sleeve (3), then apply


a chisel to this groove and knock o ff the
sleeve by tapping the chisel w ith a hammer.

iv) Drive on gear (2) using tool N.

13-108 155-4 SERIES


©
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

6I27PI03

vi) Sh rink-fit rear sleeve (3) and drive it on using


tool O.
★ S h rink-fit temperature: 2 3 0 to 2 5 0 °C for
15 minutes

2) Align the projection o f upper metal (4) w ith the


notch in the cylinder block and install cylinder
block (5), then apply engine oil (E 0 3 0 -C D ) to the
inside surface o f the metal.
★ A fte r installing the upper metal, check th a t oil
holes (6 ) of the cylinder block and metal
are in line w ith each other.

3) Raise crankshaft (7) using a nylon sling, then


install it in such a way that it does not strike the
cylinder block.

155-4 SERIES 13-109


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

4) Fit upper thrust metal (8) to the No. 5 shaft


bearing with the oil groove facing outwards.
5) Align the projection of the lower bearing with the
notch on cap (9) of the main metal, then fit the
bearings together.
6 ) Apply engine oil (EO30-CD) to the journal face of
the crankshaft, then align the embossed mark on
the cylinder block and install the bearing cap on
/ /t h e cylinder block.
/ 7) Apply engine oil (E030-C D )to the threaded part
of mounting bolts/ (10) and washers of the main
metal cap, then screw in the bolts alternately to
fit the cap completely.
★ Because the lower thrust metal fits inside
the No. 5 main metal cap, install the cap so
that the oil groove is facing outwards.
8 ) Tighten up bolts (10) in the following sequence.
★ Tighten up the bolts sequentially from the
center outwards, then gradually apply the
final torque in the following steps.
kgm~i Main metal cap mounting bolts

kg.m

Sequence Target Range

1st pass 33 3 0 -3 2

2nd pass 61 6 0 -6 2
Slacken off
3rd pass 0
completely.

4th pass 15.5 1 5 -1 6

5th pass 29 2 8 -3 0

6 th pass 52 5 0 -5 4

7th pass 74 7 0 -7 8

9) After tightening up the bolts, measure the rotating


torque of the crank.
Standard value: 2.8 kg.m max.

13-110
<D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

10) Check the crankshaft end play with dial gauge ® . ME


★ End play: 0.140 ~ 0.285 mm

3. Piston and connecting rod assembly


1) Assembling the piston and connecting rod
i) Install the piston rings on the piston using pis­
ton ring tool F.
★ When it is necessary to replace an old three-ring
or four-ring type piston, replace ail pistons in
the engine with new three-ring type pistons.
Replace the cylinder liners at the same time.

6 I2 7 P I I I

★ Install piston rings (1) as illustrated at right.


★ Install the TOP, 2nd and oil .cointeal rings
with the white-paint marking "R " side up.
★ Separate ring gaps from each other by
120° .
★ Be careful not to confuse the TOP ring
(keystone) with the 2nd ring (inner cut).

Be careful to avoid damaging the piston


or rings.
Fit the oil ring after first extracting the
expander and fitting it in the piston.
During this operation, check that the
expander is properly seated in the ring
groove.
The relative positions of the expander
and ring are as shown in the diagram at
right.
a: Coil joint part
b: Teflon tube
c: Gap

155-4 SERIES 13-111

from the library of Barrington Diesel Club


GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

ii) Put the piston and connecting rod together.


• Position the part number stamp inside the
piston and the part number embossed on
the connecting rod on the same side. After
making sure that the number stamped on
the piston and connecting rod together.
★ When the piston is replaced or when
the piston lacks the piston No. stamp,
stamp the cylinder No. on the piston
at the position shown in the figure.

★ If there is any difficulty in installing piston


6 1z ip i12
pin (3), immerse the piston in hot water.

iii) Fit snap ring (4) to fix the piston pin in


position.

2) Align the projection of the upper bearing of the


connecting rod with the notch on the connecting
rod, then install the bearing on the connecting rod.
3) Fit a reamer bolt in the connecting rod.
4) After making sure that all ring gaps are positioned
properly, set the assembly in the piston holder "P".
5) Put the crankshaft of the cylinder to be fitted in
the B.D.C. position, then apply engine oil
(EO30-CD) to the bearing face of the connecting
rod and the inside of the cylinder.
6) Orient the connecting rod so that the embossed
characters face towards the front of the engine (so
that the stamped mark faces the cam side) then
insert connecting rod ass'y from the head side.
7) Insert the piston ring part into the cylinder liner,
then push it home with a wooden rod or the like.
8) Align the projecting part of the lower bearing with
the notch on the connecting rod cap and install
the bearing on the connecting rod cap. Sub­
sequently, mount connecting rod cap (6) onto the 6 I 2 7 F I 28
connecting rod after aligning the respective
stamped marks.

13-112 155-4 SERIES


(D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

C O N N E C T IO N R O D CAP
• Put the connecting rod cap w ith the cylinder i u u u u u lu a u liv e a y a n i a i

num ber appearing on the same side as the rod stopper.

connecting rod (that is, the side o f the cam.) Stopper surface
• The follow ing caution must be taken, when
driving the connecting rod b olt into the rod.

★ E N G IN E NOS. 1 1 0 5 8 A N D UP
(H A R D W A S H E R S )
• Coat the washers fo r the threads of the bolts
and nuts w ith engine oil, CLASS-C D S A E 30.
• When tightening the bolts, make sure th at the
chamfered portion of the bolt head is in
contact w ith the connecting rod stopper in
the direction o f tightening.

9) Apply engine oil (E O IO -C D )to the threaded part


of the bolts and also the underside o f the nuts,
then tighten up the nuts in the follow ing manner
after bringing the underside of the b olt heads into
intimate contact w ith the shoulder of the connect­
ing rod.
EED Connecting rod cap

kgm

Sequence Target Range

1st pass 21 2 0 -2 2

2nd pass 41.5 4 0 -4 3


Slacken off
3rd pass 0
completely.
4th pass 8 7- 9

5th pass 21 2 0 -2 2

6th pass 28.5 2 7 -3 0

7th pass 41.5 4 0 -4 3

10) Measure the end play of the connecting rod using


dial gauge (T ).

Standard value: 0.2 to 0 .3 7 mm


★ If the connecting rod does not move, remove
the cap and check for incorrect assembly,
burrs or foreign matter.

155-4 SERIES 13-113


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

4. Gear lubricating nozzle


Install gear lubricating nozzle (1), noting the position
o f the hole.
★ The hole position, must be 3 0 ° le ft under.
5. Idle gear shaft
1) Install shaft o f the main idle gear w ith the UP
mark facing upwards, then lock the m ounting bolt
w ith lock washer (4).
2) Install shaft (3) of the pump idle gear and lock the
mounting bolt w ith lock washer ( 2 ).

6. Timing gear case


1) When replacing the bushing of the accessory drive
gear shaft, use tool Q.
2) If blind plug (1) is removed, apply liquid gasket
(L G -1) to the periphery of the plug and install it
using tool K.

3) A p p ly liquid gasket (L G -1) to the face of timing


gear case (2 ) which is in contact w ith the cylinder
block, then fit a gasket and grommet, raise the
timing gear case and install it on the cylinder
block.
^ 2 3 Tim ing gear case mounting bolts: 27
kgm

13-114 155-4 SERIES


@
from the library of Barrington Diesel Club
GENERAL DISASSEMBLY DISASSEMBLY AND ASSEMBLY

7. Oil pump
M ount oil pum p (4). 1
Q Kg™l Oil pum p mounting bolts: 6.0 ± 0.5 kgm

8. Piping
1) Connect up oil cooler outlet tube (3) to the cy­
linder block and fix it in position using clam p.
★ Fit an O-ring at the point w h e re the tubes fit
into each other. Also, insert gaskets at the
m ounting flange face of the oil pum p and
cylinder block, respectively.
2) Fit a gasket to the end face of the flange of
scavenging pum p inlet tube (2), then fit the
flange to the oil pum p and fix the inlet tube in
position using clamp.
★ W hen installing oil pum p outlet tube (5), fit
all bolts first, then tighten bolt as follow s.
i) Tighten oil pum p end flan ge m ounting
bolt.
Bolt: 5.5 ± 2 kgm
ii) Tighten oil cooler relief valve (6 ) m ount­
ing bolt.
fcg™i Bolt: 5.5 ± 2 kgm.
iii) Tighten oil cooler relief valve end stopper
mounting bolt.
I Bolt: 1.25 + 0.25 kgm.

9. Oil strainer
Fit a gasket to the flange end face of oil strainer (1)
then fit the strainer to the oil pum p.

155-4 SERIES 13-114-1


from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

10. Idle gear


1) When replacing the bushing o f main idle gear (1),
drive in the new bushing using tool S.
2) When replacing the bushing o f pum p idle gear (2),
drive in the new bushing using tool T.

6 I27PI 20 6127PI 2 I

3) Align the match mark of main idle gear (1) w ith


that of crank gear (3) and m ount the main idle
gear on the shaft. Then, install holder (4) and lock
the mounting b olt using lock plate (5).
4) Align the match mark of pum p idle gear (2) w ith
that of crank gear (3) and m ount the pump idle
gear on the shaft. Then install holder ( 6 ) and lock
the mounting bolt using lock plate (7).

11. Piston cooling


F it O-rings to the six piston cooling nozzles (1) and
m ount the nozzles on the cylinder block.
★ Use O-rings made o f silicone rubber (Brick-red).

12. Injection pump drive ass'y


F it an O-ring and grommet to injection pum p drive
ass'y ( 1) and m ount the ass'y on the tim ing gear case.

155-4 SERIES 13-115


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

13. Camshaft
A p p ly oil (E O 30 -C D ) to camshaft (1 ), then insert the
camshaft fro m the tim ing gear case side, align the
m ounting b olt holes and fit the mounting bolts from
gear holes ( 2 ).
★ Align the match marks of idle gear (3) and
camshaft gear ( 1 ).
C\ I Camshaft: 3 .7 ± 0 .6 kg.m

14. Tim er
1) F it the key into the injection drive shaft and
install tim er ( 1 ) after aligning the match mark of
the gear w ith the key groove.

2) Install special tool U and tighten up the tim er


m ounting nut.
Tim er mounting nut: 1 7 ± 2 k g .m

3) Measure the backlash and end play of each gear


using dial gauge (T).

Unit: mm

Item End play Backlash

1 Cam gear 0 .1 0 -0 .2 5 0 .1 4 -0 .3 2
Fuel injection pump drive
2 0 .0 3 -0 .1 7 0 .1 2 -0 .3 3
gear

3 Crank gear 0 .1 4 -0 .2 7 -

4 Oil pump idle gear 0 .0 3 -0 .1 7 0 .0 8 -0 .2 8

5 Oil pump gear 0 .0 4 -0 .1 0 0 .0 5 -0 .2 9

6 Accessory gear 0 .0 9 -0 .3 1

13-116©
155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

15. Gear case cover


1) Check th a t the match marks o f the various gears
are correctly aligned and th a t the gears are all
tightened up.
2) When replacing the fro n t seal, drive in new fro n t
seal (1) using tool V .

X T V , F ro nt seal lip surface: G2-LI^ about 5 cc

1 ,

3) Set seal guide W on crankshaft (2).

1
/
4) F it a gasket to gear case cover (3 ), apply grease
(G2-L1) to the grip face of the fro n t seal, raise the
cover and m ount it on the tim ing gear case.

(£ ;5E3 Gear case mounting bolt: 2 7 .5 ± 4 kg.m

1
16. F ro n t support '
A pply grease (G2-L1) to the grease groove of the
mounting part o f fro n t support ( 1), then grasp both
ends of the fro n t support and m ount it on the trunnion
part of the gear case cover.
★ To set the position o f the fro n t support fo r the on-
the machine condition, adjust the clearance between
the support and gear case cover to the values shown
below.
S 4 D 155-4: 0.5 ~ 3.6 mm
S 6 D 155-4: 0 .5 ~ 3.7 mm
(D 1 5 0 ,1 5 5 )
S 6 D 155-4: 0 .5 ~ 4 .3 mm
(D 355)
S A 6 D 155-4: 0.5 ~ 4 .3 mm

155-4 SERIES 13-117


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

17 . Dam per flange


1) F it the key on the crankshaft, then m ount damper
flange ( 1 ) on the crankshaft after aligning the key
groove of the flange w ith the key on the crank­
shaft.
2) M ount holder (2) using mounting bolts (3).
kgm i Holder mounting bolts: 16 ± 1 kg.m

★ Indicator plate (S 4 D 155-4)


Position the No.1 cylinder piston at T D C on the com ­
pression stroke and align the 1.4 T O P mark on the
indicator plate w ith the pointer.

18. Dam per


M o u n t damper (1) and lock the mounting bolts using
lock plate ( 2 ).
★ Position the No.1 cylinder piston at T D C on the
compression stroke and align the 1.6 TO P mark on
the dam per w ith the pointer.
★ A fte r installation, check the dam per fo r face runout
and radial runout.
Damper face runout and radial runout:
W ithin 0 .2 5 mm
C£ kgm i Dam per m ounting bolts: 1 1 ± 1 k g .m

19. Accessory pulley ass'y


1) When replacing the bushing o f cover (1 ), drive in
the new bushing using tool X .

6 I 2 7 P I 34

2) A p p ly engine oil (E 0 1 0 -C D ) to the inside surface


o f the bushing, then f it the thrust washer to shaft
(2 ) and install cover ( 1 ).
3) F it an O-ring to drive shaft ass'y (3 ), then engage
the gear w ith the gear case cover and install the
gear.
★ O rient the thrust washer so th a t its oil groove
is facing the gear side.
Drive shaft ass'y m ounting bolts:
3 .7 ± 0 .6 kg.m

13-118 155-4 SERIES


(D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

4) F it the thrust washer to shaft (2) then install the


key.
★ O rient the thrust washer so th at its oil groove
is facing the pulley.
5) Install accessory pulley (4 ), then align the dowel
position o f the plate w ith pulley, tighten up nut
(5) and press-fit the pulley.
6) Remove n ut (5) and f it a lock washer, then
re-tighten the n ut and lock it w ith the lock washer.
★ If the lock washer is fitte d im m ediately after
press-fitting the pulley, there is a ris k *o f
damaging it.
C
£ N ut: 6 2 ± 7 kg.m

20. Tension pulley


1) install tension pulley ( 1 ).
2) F it bracket (2).
3) Connect tension spring (3) to the pulley side, then
tighten up adjusting n u t (4) on the bracket side.
★ Adjust the belt tension after fittin g the V -b elt.

21. P.T.O. and flywheel housing ass'y


1) F it a gasket to the cylinder block mounting face of
flyw heel housing (1), then f it sling bolts © (14
m m , P = 1.7 5) and ( 2) (16 m m , P = 2 .0 ) to P.T.O .
and flyw heel housing ass'y ( 1 ), raise the assembly
and then m ount it on the cylinder block.
★ Do not apply an adhesive on a gasket
Tighten up the flyw heel housing m o u nt­
ing bolts in the follow ing sequence:

Unit: kg.m

Sequence Target Range

1st pass 38 3 6 -4 0
Slacken off
2nd pass 0
completely.

3rd pass 42 4 0 -4 4

★ A p p ly engine oil (E 0 3 0 -C D ) to the bolts and


washers.

2) Check the flyw heel housing fo r face runout and


radial runout.
Face runout: 0 .3 5 m m or less
Radial runout: 0 .3 0 m m o r less
3) Check the step at the bottom o f cylinder block and
flywheel housing m ounting surfaces.
★ Step: 0.0 7 mm or less

155-4 SERIES 13-119


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

6 I 2 7 P I 39

3) F it an O-ring to rear seal cage (1 ), then m ount to


flyw heel housing ( 2 ) and lock the mounting bolts
w ith lock plates (3).
★ Be careful not to damage on the seal lip surface,
★ Bend lock plates securely.

23. Steering pump gear


1) F it an O-ring to the flyw heel m ounting face of
bearing cage ( 1), then m ount it to flywheel
housing ( 2 ) from the cylinder block side.

2) Install steering pum p gear (3) on the drive shaft,


then lock the m ounting bolts w ith lock plates (4).
★ Bend lock plates securely.

13-120<D
155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

24. Idler gear


1) Assembling idler gear ass'y
i) M o un t bearing (1 1 ) on shaft (1 0 ).
ii) F it a snap ring on gear ( 8 ), then install the
gear on the shaft.

6 I2 7 P 0 5 2 6 I2 7 P I 4 3

6 I2 7 P 0 5 I

iv) F it shim (7) and bearing retainer (6 ), then


tighten up the m ounting b o lt and lock it w ith
a lock plate.
6
★ Confirm it turns sm oothly. If it is not
smooth adjust shim.
★ Bend lock plate securely.

6 I2 7 P 0 5 0

2) F it idler gear ass'y ( 1) onto the flyw heel housing,


then tighten up b olt (5) from gear hole (2).
★ Backlash o f idler: 0 .1 5 ± 0 .5 2 mm
★ A fte r engine test, dism ount flyw heel to f it idler
gear.

4
I 27P049 I

155-4 SERIES 13-121


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

25. Flywheel
1) F it sling bolts © (12 m m , P = 1.75) to flyw heel
( 1), then raise the flyw heel and m ount it on the
flyw heel housing after engaging the respective
gears, and lock the mounting bolts w ith lock plates
( 2 ).
Flywheel m ounting bolt: 6 3 ± 2 kg.m

2) Using dial gauge (2), measure the radial and face


runout of flyw heel ( 1) and flyw heel housing (2 ).
Standard values:
Radial runout: 0 .1 5 mm max.
Face runout: 0 .2 0 mm max.

26 . O il pan
1) Before installing the oil pan, measure the d iffe r­
ence in height between the mounting face o f the
oil pan and tim ing gear case ( 1 ), gear case cover
(2 ), flyw heel housing (3) and cylinder block (4),
respectively using depth gauge (D .
★ Repair lim it: 0 .1 5 mm

2) A p p ly liquid gasket (L G -1 ) to oil pan (5 ), then f it


a gasket to the oil pan, raise it and m ount it on the
cylinder block.
Oil pan tightening bolt: 6 .5 ± 1 kg.m

★ Note th a t the oil pan m ounting bolts are o f


tw o d iffe re n t lengths, 3 0 mm (11 bolts) and
3 5 m m (measured fro m head bottom face).
Oil pan drain plug: 15.5 ± 2 . 5 kg.m
Oil drain plug: 6.5 ± 1 . 5 kg.m

13-122 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

27. Cylinder head ass'y


1) Assembling cylinder head ass'y
i) F it the nozzle holder ass'y, then measure the
am ount o f protrusion o f the tip o f the nozzle
using holder Z and dial gauge © .
Nozzle protrusion A : 2 .9 to 3 .6 mm

ii) A p p ly engine oil (E 0 3 0 -C D ) to the intake and


exhaust valve stems and the inside surface of
the guides, then install intake valves (7) and
exhaust valves ( 8 ).
iii) Push up the cylinder head, then f it valve
spring seat (4 ), valve spring (5) and spring
guide ( 6 ) successively.
★ F it valve spring so th a t the small pitches
side is undermost.
iv) Using valve spring pusher E, compress the
valve spring and f it valve cotter (3) into the
valve stem.
★ A fte r releasing the compression fro m the
valve spring, lightly tap the valve stem
w ith a plastic hammer to ensure th at the
cotter is com pletely fitte d .

2) Ensure th a t there is no d irt or foreign m atter on


the cylinder head mounting face o f cylinder block
(9) or inside the cylinder, then install retainer (10)
and f it gasket ( 11 ) and grommet.
★ F it the gasket so that the embossed side is
uppermost.

155-4 SERIES 13-123


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

3) F it sling bolts (D (12 mm, P = 1.75) to cylinder


head ass'y ( 12 ), then lift up the assembly and
m ount it on the cylinder block.
★ A p p ly engine oil (E 0 1 0 -C D ) to the threads of
the mounting bolts and also the washers.

C£ k9^~i Cylinder head mounting bolts


: Tighten up in the sequence (1) to (10)
indicated in the diagram.

U nit: kg.m

Sequence, Target Range

1st pass 29 25.5-32.5

2nd pass 44 4 0.5 -4 7.5

3rd pass 55 5 3 .5 -56 .5

Nozzle holder
★ Tighten them taking a balance m utually.
Mounting bolt: 3 .2 5 ± 0 .2 5 kg.m.

2 8 . Tappet, push rod and crosshead


1) A p p ly engine oil (E 0 1 0 -C D ) to tappets (1 ), then
m ount the tappets on cylinder head ( 2 ) and insert
push rod (3).

2) Install crosshead (4) and adjust it according to the


procedure below.
i) Loosen lock nut (5) and return adjusting
screw ( 6 ).
ii) Using the fingers, lightly hold down the
surface which comes into contact w ith the
rocker arm of crosshead (4), then support the
crosshead w ith the valve stems on the push
rod side in contact w ith it.
iii) Screw in adjusting screw ( 6 ) until the cross­
head comes into contact w ith the valve stems
on the other side, then screw in the screw by a
fu rth er 2 0 ° (3 0 ° if the crosshead or guide is
not new ).
iv) Tighten up lock n u t (5).
u % w 6 I 2.~7p T sa \
i Lock nut: 4 .0 ± 0 .4 kg.m

13-124 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

29. Rocker housing


1) M ounting rocker housing
i) Rocker arm

12
11 ® A®

6 I 2.7F I 34

• Install rocker arm (1 1 ), spring (12) and


collar (13) w hile inserting rocker arm
shaft ( 10 ).
★ O rient the stopper b olt hole of the
shaft so that it is facing upwards and
align it w ith the stopper bolt hole of
the housing.
• F it stopper bolt (9).
• F it blind plug ( 8 ) using driving tool K.
★ A pply liquid gasket (L G -1 ) to the
periphery of the plug.
Compression release shaft
Insert compression release shaft (6 ) and fit the
stopper bolt.

2) F it gaskets to rocker housings (1), (2) and (3),


then m ount the rocker housings on the cylinder
1 4 2 5 3
heads w hile fittin g joints (4) and (5) o f the
compression release shaft.

155-4 SERIES 13-125


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

3) A djust the valve clearance according to the fo llo w ­


ing procedure.
★ Ignition sequence:
S 4D 155-4: 1 - 2 - 4 - 3
S 6 D 1 55-4 . -| _ 5 _ 3 _ 6 — 2 — 4
S A 6 D 155-4
★ Valve clearance (in w arm atmosphere):
S 4 D 15 5-4 Engine serial N o .1 0 2 8 7 ~ 5 0 1 5 6
S 6D 15 5-4 Engine serial N o .10011 ~ 11 74 5
Intake valve 0 .3 mm
Exhaust valve 0 .3 mm
S 4D 15 5-4 Engine serial N o .5 0 1 5 7 and up
S 6 D 155-4 Engine serial No. 1 1 7 4 6 and up
S A 6 D 155-4 Intake valve 0 .4 mm
Exhaust valve 0 .6 mm
i) Align the embossed line around the periphery
of the damper (fro n t end o f crankshaft) w ith
the pointer.
ii) Check th at there is a clearance between rocker
lever (17) and compression release shaft (14 ).
iii) Screw in adjusting screw (1 5 ) until feeler
gauge I B moves sluggishly.
iv) Tighten up lock n ut (1 6 ).
Lock nut: 6 .9 ± 1 .0 kg.m
v) Repeat steps i) to iv) fo r each cylinder.
vi) Rotate compression release shaft (14) and
ensure th a t the intake push rod rises up.

3 0 . Fuel pipe
Install fuel pipe (3).
Fuel pipe sleeve nut: 4 .2 5 ± 0 .2 5 kg.m
★ Tighten the pipe o f nozzle side then tighten it's
rocker arm side.
• If there is no abnorm ality, install the pipe on the
same cylinder.

3 1 . Spill pipe
F it gaskets and jo in t bolts to spill pipes (2) and (1),
then m ount the spill pipes on the rocker housing and
f it the clamp bolts.
Spill pipe jo in t bolts: 2 ± 0 .5 kg.m

32. Rocker housing cover


A p p ly liquid gasket (L G -1 ) to the m ounting faces of
rocker housing covers (1 ), (2) and (3 ), then f it gaskets
and install the covers on the rocker housing.
C fcami Rocker housing cover m ounting bolts:
3 .2 5 ± 0 .2 5 kg.m

13-126
(D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

33. Turbocharger lubricating tube


Connect turbocharger lubricating tube (1) to the
cylinder block and fix it w ith a clamp.

34. Filter bracket


F it a gasket and O-ring to the cylinder block mounting
face of filte r bracket ( 1), then m ount the filte r bracket
on the cylinder block.

35. Full-flow filter


F it an O-ring to the top part o f filte r bracket (1) and
m ount full flo w filter ( 2 ) on the bracket.

36. Injection pump


1) F it coupling (5) to injection pum p drive (2).

2) F it an O-ring to injection pum p ass'y (4), then


align the spline of coupling (5) w ith injection
pump drive (2) and m ount the drive. Sub­
sequently, clamp bracket (3) to the cylinder block.
★ When clamping the pump, align the match
marks on the drive case and the pum p w ith
each other.

37. Oil level gauge guide


F it a gasket to the flange end face o f oil level gauge
guide ( 1), then install the oil pan.

155-4 SERIES 13-127


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

38. Injection pipe


1) Wrap sealing tape around the nipple of cam
lubricating pipe ( 1 ) and m ount the pipe on the
cylinder block.
★ N ote th at the nipples fitted w ith nozzles are
cam lubricating (total of 12 nipples on lower
side) nipples.

2) Install injection pipe (2) on the rocker housing and


injection pump.
C^~kssn Injection pipe sleeve nut: 2.4±0.1 kg.m

3) Install cam lubricating pipes (1) (six pipes) on the


cylinder block.
C£"kgm i Cam lubricating pipe sleeve nut:
2 .4 ± 0.1 kg.m

4) Install lubricating pipe (3) on the cylinder block


and injection pump.

39. Oil filler


F it a gasket to the flange end face o f oil filler (3) and
install the oil filler on the cylinder block.

40. Lubricating pipe


Install lubricating pipe (2) on the injection pum p and
the oil filler flange, and fix it in position using clamp
1
( ).

41. Breather tube


Connect breather tube (2) to breather (5 ), then tighten
up hose clamp (3) and install tube clamp (4).

42. Intake manifold


F it a gasket to intake m anifold (1) and m ount the
intake m anifold in the cylinder head.
kg^n Intake m anifold m ounting bolts:
6 .5 ± 1 kg.m

13-128 155-4 SERIES


<D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

43. Fuel filter


1) Install fuel filte r (3) together w ith bracket (4) on
the intake m anifold.

2) Connect up fuel filte r inlet hose (1) and outlet


hose ( 2 ) to the injection pump.

44. Water m anifold


★ When the therm ostat fo r the S 4 D 155-4 engine has
been removed, reinstall, it so th a t the V-notch in the
flange faces upward (to provide an air vent).
1) F it a gasket and seal ring to the w ater m anifold
mounting face on the cylinder head.

2) M ount w ater m anifold (1) on the cylinder head.


£ S W ater manifold mounting bolts:
6 .0 ± 0 .5 kg.m
★ When replacing the therm ostat seal, press-fit a new
seal w ith push tool (P/N 7 9 5 -1 0 0 -1 1 1 0 ).

45. Setting engine on engine stand


L ift up engine ass'y (1), remove the connecting bolts
securing it to engine repair stand A , then remove
engine ass'y ( 1 ) from the engine repair stand and set it
on the engine stand.

4 6. Engine oil cooler


1) F it tw o grommets and a gasket to engine oil cooler
( 1), then m ount the cooler on the cylinder block.
M ounting bolt: 6 .5 ± 1 kg.m

2) F it a gasket to the flange end face o f corrosion


resistor return valve (2 ) and install the return valve
on the cylinder block.

155-4 SERIES 13-129


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

47. Exhaust manifold


© 1i O M ounting bolt: 11 ± 1.5 kg.m

★ F it the ring to prevent a gas escape.

48. Turbocharger

49. Muffler
1) L ift up m uffler (1 ), turbocharger (2) and exhaust
m anifold (3) as a single assembly, then insert a
gasket between the cylinder head and the exhaust
m anifold and m o u nt the assembly on the cylinder
head. Subsequently, lock the m ounting bolts w ith
lock plates (4).
★ Use 125 m m bolts (six bolts) to clamp the
heat shield (5) and 110 mm bolts (twelve
bolts) fo r the other parts of the exhaust
manifold.
★ Confirm th a t the step between the exhaust
m anifold center and m u ffler m ounting bracket
does not exceed 0.1 m m . If the step is too
large, adjust the m u ffler m ounting bracket posi­
tion w ith shims.
2) Install m uffler drain tube ( 6 ) and clamp it using a
clamp.

50. Turbocharger lubricating tube


1) F it a gasket to the flange end face o f turbocharger
lubricating inlet hose ( 1) and connect the hose to
the turbocharger.

2) F it an O-ring to the cylinder block connecting side


o f outlet tube (2 ), then f i t a gasket to the end face
o f the turbocharger connecting flange and install
the outlet tube.
★ Make sure th a t every pipe is free from twisting
caused by im m oderate force.

51. Intake connector


F it an O-ring to the turbocharger insertion part of
intake connector (1 ), apply grease (G 2 -L I) to the
intake connector then insert the intake connector and
tighten up the b o lt securing it to the intake m anifold
(2).
★ Be careful n ot to bite into the O-ring when
inserting the intake connector.

13-130 155-4 SERIES


CD
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

52. Water pump


1) F it an O-ring to w ater pump (2), apply grease
(G 2 -L 1 ) to the w ater pump, then set it on the gear
case and secure it by means of a nut.

2) F it a gasket to both flange faces o f bypass tube


( 1 ), then install the tube on the w ater pum p and
thermostat.

53. Alternator drive shaft


1) Install bracket (1).

2) Set alternator drive shaft (2) on the gear case, then


tighten up the m ounting bolts securing the drive
shaft case to the gear case and bracket ( 1 ).

54. Alternator
1) Set alternator (4) at the mounting position and
mount it using support bolts (3).
2) F it adjusting b olt (2), then install V -b elt (5)
between the alternator pulley and the drive
pulley.
3) Tighten up adjusting b olt (2) so th at the V -b elt
deflects by about 15 mm when pressed mid-way
between the alternator pulley and the drive pulley,
then tighten up support b olt (3).

155-4 SERIES 13-131


from the library of Barrington Diesel Club
GENERAL ASSEMBLY DISASSEMBLY AND ASSEMBLY

55. Starting motor


1) F it an O-ring to starting m o to r (2), then lift up the
starting m otor and m ount it on the flyw heel
housing.
1 E I Starting m o to r m ounting bolt:
2 7 .5 ± 4 kg.m
^ kgm 1 Bracket m ounting bolt
Block side: 11 ± 1.5 kg.m
Starting m o to r side: 6 ± 1.5 kg.m
2) Install bracket (1).
★ If there is a clearance between bracket and
starting m otor, f it the shim.
★ Note th a t the bracket mounting bolts on the
starting m o to r side are fine thread bolts.

56. Filter bracket


Install filte r bracket (1).

57. Corrosion resistor


1) M o un t corrosion resistor (1) on filte r bracket (2).
2) Connect up the w ater pum p by-pass tube to
corrosion resistor inlet hose (3 ), then f it clamp (4).
3) Connect o utlet hose (5) to cylinder block return
valve ( 6 ).

58. Bypass filter


1) M o un t by-pass filte r (7) on filte r bracket (2) using
m ounting bands ( 8 ) and (9).

2) Connect up the by-pass filte r o u tlet hose to the


cylinder block, and connect in let hose ( 10 ) to the
engine oil cooler.

13-132 155-4 SERIES


<D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY

Upon completion of the above w ork, m ount the


following engine related parts.

1) Install wire harnesses (1 1 ), (1 2 ) and (13) using


clamps.
2) Install service meter cable (10 ).
★ F ix the interm ediate clamp to the rocker
housing cover using the cover m ounting bolts.
3) F it a gasket to the flange end face o f radiator
o utlet w ater pipe (9), then connect the water pipe
to the inlet connector of the w ater pump.

4) Connect w iring (7) from the alternator to the


appropriate terminals.
★ Connect the alternator wires as follows:
W hite and red wire (th ick) to B term inal
W hite wire to F terminal
W hite and red wire (th in ) to N term inal
Black and red wire to E term inal
5) Connect w iring ( 8 ) from the starting m otor to the
appropriate terminals.

6) Install intake air heater tube (5) and engine oil


pressure gauge tube (6 ).
7) Connect intake air heater wiring (14) and oil filte r
caution lamp wiring (15).
8) Install compression release rod (4).
9) M ount accelerator rod (2) together w ith bracket
(3).
10) When removing the heater for priming pum p and
the glow plug for APS, after installing them ,
perform wiring.
Take care of not tightening term inal nuts.
© 3ED Term inal nut: 0.125 ± 0.025 kgm

11: Install the V-belt.


Because o f the radiator-m ount type fan, install the
V-belt according to the follow ing procedure after
mounting the engine on the machine.
© Loosen double-nuts (1) and (2) to release the
load appling to tension spring (3).
(2) Push down tension pulley (4) until it comes into
contact w ith the stopper. Install the V -belt.
★ Replace the set o f belts.
(3) Tighten nut (1) until the specified protrusion
" A " o f the adjustment screw is obtained.
★ Protrusion o f adjustment screw:
See the table o f Values fo r Inspection,
Adjustm ent and Troubleshooting.
© Tighten nut (2) and lock it.

155-4 SERIES 13-133


from the library of Barrington Diesel Club
WATER PUMP DISASSEMBLY AND ASSEMBLY

D IS A S S E M B L Y O F W A T E R P U M P

6
Water
seal

1. Cover
• S 4 D 155-4
S 6 D 155-4 (D 15 0A ,D 1 5 5 A ,S -1)

2. Inlet connection
• S 6 D 1 5 5 -4 (D 3 5 5 A -1 )

3. Impeller and floating seat


• S 4 D 155-4
S 6 D 155-1
( D 15 5 A ,D 15 5 A ,S -1 )
(D 3 5 5 A -1 : Engine serial N o .1 0 0 1 1 ~ 10 10 0)
Using extraction taps (8 m m , P = 1 .2 5 ), extract
the im peller and floating seat by means o f a puller.
• S 6 D 155-4
(D 3 5 5 A -1 : Engine serial N o .101 01 and up)
S A 6 D 1 5 5 -4 (Engine serial N o .2 0 3 3 8 and up)
Remove the lock nut, then, using extraction taps
(8 m m , P = 1 .2 5 ), extract the im peller and floating
seat by means o f a puller.

4. Shaft ass'y
W hen extracting the shaft ass'y, be careful n ot to
damage the oil seal and w ater seal.

5. Oil seal
A fte r disassembling the w ater pum p ass'y, replace it
w ith a new one.

6. Water seal
A fte r disassembling the w ater seal, replace it w ith a
new one.

13-202 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY WATER PUMP

A S S E M B LY OF W ATER PU M P

1. Oil seal Impeller


Check the orientation of the seal to ensure th at it • Inspect the floating seat (ceramic seat) fitte d to
insert correctly. the impeller. If it n o t scratched or split and the
im peller itself can be reused, wash the shaft
face o f the seal and press-fit the im peller in
such a w ay th at the rear face of the impeller
comes into contact w ith the end face o f the
shaft.
If no facilities are available to replace the
ceramic seat, replace the entire im peller ass'y.

Method replacing floating seat


1) S 4 D 155-4 (Engine serial No. 10287 ~ 50 1 3 2 )
S 6 D 155-4 ( D 15 0 A ,D 1 5 5 A,S-1
Engine serial N o .1 0 1 1 ~ 13 95 9)
★ Ensure th at d irt and cutting chips do not i) Make a check mark (depression or groove)
adhere to the vicinity of the lip. on the counter bore (seat m ounting hole)
★ Handle the lip carefully to ensure th at it does o f the impeller.
not become damaged. ii) Heat the impeller and maintain it at a
/jA g Oil seal: G 2-L I (60% o f internal tem perature o f about 3 1 5 °C fo r one hour,
capacity) then extract the seat using pliers.
iii) Scrape out the adhesive fro m the counter
Water seal bore. During this operation, be careful not
Wash the part of the body to which the seal is to be to damage the inside surface o f the counter
press-fit, then lightly apply Three Bond No. 2 bore.
(non-drying liquid packing) to the outer periphery iv) Check the inside diameter of the counter
of the outer cylinder o f the seal and press-fit the bore. The inside diam eter shall be w ith in
seal. the range 2 6 .4 7 to 2 6 .5 7 m m and the
★ When press-fitting the seal, thoroughly wipe o ff perpendicularity shall be w ithin 0 .0 7 mm.
oil and d irt from the carbon seal face using v) Wash the impeller w ith a trichloro-ethylene
m ethyle-ethyle-ketone, then apply a small and dry it w ith compressed air.
quantity o f good q uality silicon oil. Because a strong water-resistant adhesive is
★ When replacing the water seal, replace the used inside the counter bore, dry it
floating seat as well. thoroughly to prevent adhesion o f oil and
d irt, etc.
Shaft ass'y
Shaft mounting lock nut: 2 0 .2 ± 3 kg.m

155-4 SERIES 13-203


from the library of Barrington Diesel Club
WATER PUMP DISASSEMBLY AND ASSEMBLY

vi) A p p ly Film Bonding to the counter bore. ii) F it the seat assembly to the impeller.
During this operation, be careful not to soil ★ Push in the assembly w ith force,
the Film Bonding w ith d irt, oil, hum id ity, taking care not to cause the seat to rise
fingerprints or dust. Do not use film or fall.
bonding which is more than six months Falling o f seat: 0.1 mm or less
old.
vii) Remove the backing strip from the Film Rubber ring
Bonding.
viii) Place a floating seat on the counter bore to
which the check mark has been applied,
Ceramic (No.10011 ~ 15313)
. then rotate the seat and coat its entire
Refractory metal
periphery w ith adhesive.
(No.15314 and up)
ix) Place a 6.8 kg w eight on the floating seat
and bond the floating seat to the counter
bore by leaving it for 6 5 minutes in an
oven at a tem perature o f 174 to 179°C .
—L. i l l 6 I27F I 36- I
Select the tem perature and tim e carefully
in order to ensure complete bonding.
Exposed edges of film w ill change color iii) Wipe the sealing surface of the seat w ith a
from yello w to rust brown. cloth soaked in m ethyl ethyl ketone to
2) S 4D 15 5-4 (Engine serial N o .5 0 1 3 3 and up) remove oil, grease and dust.
S 6 D 155-4 ( D 15 0A - 1, D 15 5 A ,S -1 4) Clean the tapered surfaces. F it the tapered sur­
Engine serial N o .5 0 1 3 3 and up) face o f the im peller to th at o f the shaft.
i) Lightly apply w ater soluble lubricant (toi­ 5) Tighten the nut.
let soap, etc.) to the inside surface o f the ★ A p p ly light taps to the periphery o f the
rubber o f the seat ass'y. impeller w ith a m allet and confirm th at the
ii) F it the seat ass'y onto the shaft in such a tightening torque does not decrease.
way th a t the carbon face o f the pum p seal Im peller lock nut; 7 .7 5 ± 0 .2 5 kg.m
comes into contact w ith the abrasive face 6) Bend the tongue on the lockplate.
of the ceramic o f the seat ass'y.
iii) Press-fit the impeller. 5. Cover

6. inlet connection
In order to prevent w ater leakage, apply Three Bond
No. 4 to the threaded part o f the stud body, then
screw in the stud.
★ A fte r assembling the inlet connection, p ut the gear
into manual, then rotate it to check th at it turns
sm oothly.

3) S 6 D 155-4
(D 3 5 5 -1 )
(Engine serial N o .10011 ~ 19 9 9 9 )
S A 6 D 1 5 5 -4 (Engine serial N o .2 0 3 3 8 and up)
i) A p p ly a th in coat o f w ater soluble lubri­
cant (such as to ile t soap) to the periphery
of the rubber o f the seat assembly.

13-204 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY TURBOCHARGER

D IS A S S E M B L Y OF TU RB O CHARG ER (K T R 100,130)

• Before disassembling the turbocharger, clean its outside


surface. In order to ensure th at the blow er housing,
turbine housing, center housing and clamp are re­
assembled in their original positions, apply match
marks w ith a sign pen or the like before disassembling
the turbocharger.

1. Housing
1) Remove clamps (1) and (2) which support the
housing.
2) Remove turbine housing (3).
★ Remove the housing carefully so as not to
damage the impeller.
3) Remove blower housing (4).

2. Blower impeller
1) Clamp the end o f the turbine rotor in a vice, then
remove nylon-lined nut (5) which clamps the
blower.
2) The blower impeller and shaft are shrink fit.
Extract them according to the follow ing proce­
dure.
i) Heat up blower impeller ( 6 ) for 10 minutes in
oil maintained at a tem perature of 140 to
160°C .
ii) Extract blow er impeller ( 6 ) from the shaft
while it is still hot, taking care n ot to apply
excessive force.

Insert
1) Open out the bent washers underneath the m ount­
ing bolts at the insert, and remove the mounting
bolts.

2) Screw tw o bolts alternately into the extraction


taps o f insert (7) and remove the insert.

6 I2 7 P I 6 4 i

155-4 SERIES 13-205


from the library of Barrington Diesel Club
TURBOCHARGER DISASSEMBLY AND ASSEMBLY

4. Cover
E xtract cover ( 8 ).

5 Collar
Extract collar (9).

6I2 7 P I66

6. Thrust bearing
E xtract thrust bearing (10 ).

6 I27PI67

7. Spacer and thrust collar


E xtract spacer and thrust collar (11 ).

6 I 2 7 P I 68

13-206 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY TURBOCHARGER

11. Slinger
1) Remove slinger (17) which is fitted on insert (16). 18
t
2) Remove O-ring (18) which is fitte d on insert (16 ).

6I27PI72

155-4 SERIES 13-207


from the library of Barrington Diesel Club
TURBOCHARGER DISASSEMBLY AND ASSEMBLY

13-208 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY TURBOCHARGER

A S S E M B L Y OF TU RB O CHARG ER ( k t r i o o , 130)

1. Shield
1) M ount turbine shaft (2 0 ) in a vice.

2) Install shield (1 4 ).
i) Because there is a risk of the shield becoming
warped or dented, m ount it on the rotor
turbine after aligning it w ith the center
housing.
ii) A p p ly grease to those parts of the turbine
shaft on which the collar, spacer and slinger
are to be installed (in order to maintain 6 I2 7 P I7 4
concentricity).

Seal ring
A pply a small am ount of oil (E O -10W ) to the side face
of seal ring (1 5 ), then install the seal ring in such a way
th at the gap clearance in the seal ring is on the oil filler
side.

Journal bearing
1)' T ilt and insert center housing (1 2 ) w ith the sealing
ring gap facing forward.
2) Place center housing (12 ) on a horizontal surface, 13 12
then properly fit the seal ring.
3) Apply oil (EO -10W ) to journal bearing (13 ) and fit
center housing ( 12 ).
4) Move the center housing up and down about 3 to
5 mm, tw o or three times, in order to straighten
out any twists in the seal ring.

6 I 2 7 P I 75

4. Spacer
Align the match mark on the shaft w ith the match
marks on the collar and spacer ( 11 ), then f it the spacer.
★ Keep foreign m atter out of the various gaps
(close-fitting) between the blow er im peller, slinger,
spacer and thrust collar.

6 I 2 7 P I 68

155-4 SERIES 13-209


from the library of Barrington Diesel Club
TURBOCHARGER DISASSEMBLY AND ASSEMBLY

5. Thrust bearing
M o u n t thrust bearing (10).
• A p p ly oil to both of the surfaces w ith which the
thrust collar comes into contact.
• Make sure that the collar and spacer do n ot move.

6. Cover
1) Align the match mark on the shaft w ith the match
mark on collar (8 ), then install the cover and
collar.
2) A p p ly Three Bond No. 4 at the points on the
cover corresponding to the locations o f the extrac­
tion bolt holes.

7. Slinger
1) Insert a seal ring into slinger (17) and f it the
slinger into the insert (16).
★ Ensure th at the gap in the seal ring is on the
oil filler side of the center housing. Align the
match mark on the shaft w ith the match mark
on the slinger, and also ensure th at the collar
and spacer do n ot move.
2) F it O-ring (18) on insert (16).

3) A p p ly Three Bond No. 4 to both faces of the lock


washer.
4) B olt the thrust bearing, cover and insert together.
★ During the above operation, be careful to
avoid moving the center housing in order to
ensure th at the match marks do not get out of
line.
*9™I Bolt: 1 .2 5 ± 0 .2 5 kg.m

5) Bend the lock washer.

13-210 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY TURBOCHARGER

8. Blower impeller
The blower impeller and shaft are shrink fit. F it them
together according to the following procedure.
1) Heat up the blower impeller in oil maintained at a
tem perature o f 140 to 16 0°C (for no more than
10 minutes).
2) Align the match mark on the blower im peller w ith
the match mark on the shaft, then install the
impeller on the shaft.
K T R 1 0 0 lock nut: 4 .2 5 ± 0 .2 5 kg.m
K T R 130 lock nut: 8.5 ± 0 .5 kg.m
★ When clamping the blower im peller, be careful
6 I 27P I 77
that the match marks do n ot get out of line.
★ Assemble the thrust collar, spacer, slinger and
blower impeller so that their respective match
marks are in line w ith each other.
If these match marks get out of line, the shaft w ill
bend, causing an imbalance. This in turn w ill result
in rotor vibration and noise as well as bearing
seizure.

Inspection
1) A fter assembling the rotor ass'y, insert the center
housing in a vice and check the am ount o f play,
i) Play in axial direction
K T R 100: 0 .0 6 to 0 .1 1 m m
K TR 130: 0 .0 8 to 0 .1 3 mm

2 7 P I 78

ii) Play in radial direction


K T R 1 0 0 : 0 .1 9 4 to 0 .4 0 4 mm
K T R 130: 0 .2 4 7 to 0 .4 3 3 mm

155-4 SERIES 13-211


from the library of Barrington Diesel Club
TURBOCHARGER DISASSEMBLY AND ASSEMBLY

10. Housing
1) Carefully install blower housing (4) and turbine
housing (3) in such a way th at the impeller is not
damaged.
XEEs A p p ly liquid gasket LG-3 to the mating
faces of turbine housing (3) and b low er
housing (4).
XEEs W h en installing the turbine housing, ap­
ply liquid gasket LG-3 to the m ounting
flange face on the center housing side.

6I27PI8CH

11. Clam p
Install clamps ( 1) and ( 2 ).
K9m i Bolt: 0 .9 5 ± 0 .0 5 kg.m

6 I 2 7 P I 621

12. R o to r inspection
1) Turn the rotor w ith the fingers and ensure th at the
impeller rotates sm oothly. Also, push the rotor
backward and forw ard and left and right while
turning it and ensure that the impeller does not
strike the housing.
2) Measure the clearance between the blower housing
and the blower impeller using a thickness gauge.
K T R 1 0 0 : 0 .1 5 mm min.
K T R 1 3 0 : 0 .2 0 mm min.

13-212 155-4 SERIES


@
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY TURBOCHARGER

D IS A S S E M B L Y O F TURBOCHARG ER (RH1521)

★ The angles at which the turbine housing, center 5. Oil slinger


housing and blower housing are assembled will
depend upon the way in which the turbocharger is 6. Thrust metal and collar
mounted on the engine. Accordingly, before dis­ Extract the thrust metal and collar w ith o u t damag­
assembling the turbocharger, be sure to apply ing them .
match marks on the respective parts using a sign pen
or the like. 7. Diffuser

1. Blower housing 8. Turbine housing


Dism ount the blower housing. Loosen the connecting bolts, then grasp the rotor
shaft in one hand and the center housing in the
2. Lock nut other, and disconnect them in the upward direction.
Clamp the end of the rotor shaft in a vice, then During this operation, be careful n ot to strike the
remove the lock nut. rotor shaft.

3. Blower impeller 9. Turbine nozzle plate


Grasp the impeller vanes, then carefully extract the
impeller while rotating it.

4. Air vent housing


Loosen the mounting bolts of the air vent housing,
then carefully extract the air vent housing in the
upward direction w hile rotating it. Because the oil
slinger will come away w ith the air vent housing, the
stinger w ill become twisted and the seal ring w ill
break if the housing is tilted. Consequently, extract
the housing horizontally.
A fte r dismounting the housing, disconnect the
slinger.

155-4 SERIES 13-213


from the library of Barrington Diesel Club
TURBOCHARGER DISASSEMBLY AND ASSEMBLY

10. Nozzle ★ Seal ring


The nozzle and turbine nozzle plate are shrink fit. If the rings on both the turbine and blower sides
Accordingly, place a piece of wood against the end wear significantly and have large clearances, replace
of the nozzle from the gas o utlet side, then lightly them using pliers, being careful not to damage the
tap the wood and remove the nozzle. The respective grooves.
positions of the spring pin and claw are predeter­
mined.

11. Rotor ass'y


Stand up the center housing and extract the rotor
ass'y in the horizontal direction. Because the flo a t­
ing metal w ill come away w ith the rotor ass'y, take
out the rotor shaft first in order to prevent
damaging the bearing. The shield plate is fixed by
means of a snap ring.

12. Shield plate


Remove the snap ring and take out the shield plate.

13. Floating metal

★ Sleeve
Because the sleeve is shrink fit, place a piece of
wood against the end of the sleeve and lightly tap it
to extract the sleeve.

6 I 2 7 F I 37

13-214 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY TURBOCHARGER

A S S E M B L Y OF TURBOCHARG ER (RH1521)

4 5

1. Floating metal 4. Thrust collar and thrust bearing


Align the notch of the oil hole of the thrust bearing
2. Shield plate w ith the oil hole of the spacer and the oil o utlet
flange hole of the center housing, then assemble the
3. Rotor ass'y thrust bearing, spacer and housing.
Arrange the seal ring so th at it is concentric w ith the (£ kgmi Bolt: 0 .8 kg.m
shaft. This w ill ensure th at it accurately enters the
specified position from the taper part o f the center 5. Air vent housing
housing when it is pressed onto the center housing. Before m ounting the air vent housing, install the oil
If the seal ring is not concentric w ith the shaft, it slinger on the housing. During this operation, be
w ill become twisted and may become damaged. careful to keep the seal ring concentric. Align the
Align the centers o f the tw o seal rings and arrange dowel hole and spring pin, then insert the spring pin
them so that the respective gaps are 18 0° apart. into the dowel hole.
It is recommended th at the O-ring is replaced
during each overhaul.
Rotor shaft
6. Blower impeller

7. Lock nut
Fix the rotor shaft and clamp the lock n ut o f the
blow er impeller.
There is a notch in the impeller boss. It has been
form ed in order to balance the rotor. Accordingly,
do not try and file it down.
££"kgm i Lock nut: 4 kg.m

155-4 SERIES 13-215


from the library of Barrington Diesel Club
TURBOCHARGER DISASSEMBLY AND ASSEMBLY

8. Blower housing 2) Radial play


Kg'" I Mounting bolts: 1.3 kg.m Before installing the blower housing, measure
the radial clearance at the boss on the shaft
9. Turbine housing end, at the blower side.
Because the turbine housing operates at red heat, it The clearance fo r the assembly should be 0.43
employs stainless steel nuts and bolts. Be careful not to 0.67 mm.
to m ix ordinary nuts and bolts w ith them.
Assemble the follow ing components after applying
thread seizure prevention paint to the threaded
parts thereof.
Painting point
• M ounting nuts for connecting exhaust pipe and
turbine housing
• M ounting nuts for connecting turbine housing
and center housing

10. Inspection
A fte r com pletely assembling the turbocharger,
gently rotate the rotating part w ith the fingers and
also push it backward and forw ard and left and right
while rotating it in order to ensure th at it does not
Next, install the blower housing, then push the
strike any other parts. Subsequently measure the
rotor in the radial direction w ith the tip of the
am ount of play of the rotating part.
finger and measure the clearance between the
1) Total end play
blower impeller and the blower housing using a
Move the rotor in the axial direction and
thickness gauge.
measure the clearance using a dial gauge. The
The clearance for the assembly should be 0.10
clearance fo r a new assembly should be 0 .0 5 to
to 0 .1 5 mm. if it is less than 0.0 5 mm, check
0 .0 9 mm. If the measured clearance becomes
the dimensions of the shaft bearing. As opposed
greater than 0 .1 9 mm, check the dimensions of
to the case where an ordinary fla t bearing is
the components related to the thrust bearing
used, there are clearances between the rotor
and replace any worn parts.
and the floating bearing and also between the
rotor and sleeve. Consequently, the overall
clearance appears larger than in the case where
a conventional shaft bearing is em ployed. Be
sure to measure the clearances and to indicate
them as numerical values.

6I2 7 P I82

13-216 155-4 SERIES

from the library of Barrington Diesel Club


STARTING ENGINE DISASSEMBLY AND ASSEMBLY

D IS A S S E M B L Y OF S T A R T IN G ENGINE ( 2 G 8 4 )

4 10

from A

from B

from C

from D

6 I 2 7 F I 39

13-218 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY STARTING ENGINE

★ Magnet
Dismount the magnet after making a match mark on
the flange.

★ Piston and connecting rod


Remove carbon from the top o f the cylinder liner.
Extract the piston pin after heating up the piston in
hot oil.

★ Camshaft
Extract the camshaft after removing the thrust plate
mounting bolt from the camshaft gear hole.

155-4 SERIES 13-219


from the library of Barrington Diesel Club
STARTING ENGINE DISASSEMBLY AND ASSEMBLY

A S S E M B L Y O F S T A R T IN G ENGINE ( 2 G 8 4 )

12

Oil pump
★ i s
* Camshaft

Tappet

Tappet
cover

Intake, ex­ Carburator


Valve haust
manifold air cleaner

2G84 Cylinder
Starting head
engine
Piston
connecting
rod
10 17
Connecting ...„ Flywheel to A
rod cap rear cover

Crankshaft Oil pan 20


Main metal Timing
to B
cap gear case

13
Timing
gear

14
Magnet
drive shaft

15
Hydraulic
adjusting
valve

18 19

from A Starting
Power line
motor

21

from B Magnet

6 I2 7 FI3 9 -I

13-220 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY STARTING ENGINE

★ Tappet ★ Main metal cap


• Adjusting valve clearance Cap m ounting bolts: 10 kg.m
Put the cylinder to be measured at the T .D .C .
position at the end of the compression stroke, • A fte r tightening up the mounting bolts, check
then adjust the clearance between the adjusting th a t the crankshaft rotates freely, and measure
screw and the end face of the valve to the the play in the axial direction.
specified dimension.
Clearance: 0 .3 mm ★ Connecting rod cap
The above value is applicable to a warm engine. kyn | Cap m ounting bolt: 5 kg.m
Accordingly, readjust the clearance after run­
ning in the engine. ★ Camshaft
Before mounting the oil pum p, measure the play in
★ Valve the axial direction.
Press-fit the valve using a press, until the stepped
part of the valve guide comes into contact w ith the ★ Piston and connecting rod
cylinder block. Using special tools, fit the piston rings in such a way
that the relative gap. positions are as shown in the
diagram below.

Spark plug center

6 I2 7 FI4 I
★ Cylinder head
Kgm i Bolt: 10 kg.m
• Tighten up the bolts according to the following • A p p ly engine oil to the inside surface of the
sequence: connecting rod metal, the piston ring part and
also to the outside surface of the piston. N ext,
using a piston ring compressor, press on the
rings w hile contracting them .

★ Timing gear
F it the gears after aligning the respective match
marks.

155-4 SERIES 13-221


from the library of Barrington Diesel Club
STARTING ENGINE DISASSEMBLY AND ASSEMBLY

★ Pow ertrain Gap between contact points


• Adjusting clutch Loosen the adjusting screw, then move the arm until
A fte r mounting the transmission, if the clutch the m axim um gap becomes 0.3 to 0.4 mm.
does not respond positively when the clutch
lever is pulled to the operating position, insert
the hand through the inspection w indow of the
clutch chamber, pull the knob and adjust the
clutch response by turning the adjusting ring.
A fte r adjustment is completed, insert the ad­
justing pin in the nearest adjusting pin hole in
the pressure plate to stop the adjusting ring
from turning. When the adjusting ring is turned
clockwise the clutch response will become hard,
while turning it counterclockwise will result in
a soft response.

Ignition tim ing


Remove the rear cover of the magnet, then place a
0.3 mm feeler gauge between the contact points and
slowly rotate the engine until the feeler gauge is just
able to be w ithdraw n (ignition timing = instant at
which points open). If the indication on the
graduated scale of the flyw heel at this point in time
is outside the range 5 to 10° past the compression
T .D .C . position, loosen the magnet mounting bolt
and rotate the magnet proper until the indication
is w ithin the range 5 to 10° past the compression
T .D .C . position.
• Turning the magnet clockwise will cause the
ignition tim ing to advance, while turning coun­
terclockwise will cause the timing to be re­
★ Magnet tarded.
Remove the clutch case cover and put No. 1 piston The ignition tim ing can also be adjusted by
in the compression T .D .C . position. removing the rear cover and turning the base
Leaving the ignition cable connected, clamp the plate of the interrupter.
magnet in a vice, then rotate the rotor shaft, lower • If the above procedure is carried out, the
the claw of the impulse and m ount the magnet at ignition tim ing during operation of the machine
the position where a spark appears between the w ill be 25° before the compression T.D .C .
ignition cable on the rear cover side and the vice position.
(position where No. 1 cylinder points open).
★ Pinion — disengagement engine speed
A fte r mounting the magnet, adjust the gap between
S tart the engine by meshing the pinion w ith the
the contact points and also the ignition tim ing.
engine flyw heel ring gear. Check to see that the
pinion backs out o f mesh at an engine speed of
4 0 0 to 4 5 0 rpm.
• T o adjust, turn the adjustment screw'in or out.
★ If the high pinion — disengagement engine speed
cannot be corrected w ith the adjustment screw, cut
o ff one or tw o coils o f spring and readjust the
adjustment screw.

13-222 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY STARTING ENGINE

D IS A SSEM B LY O F 2G84 POW ER TR A IN

6 I2 7 FI4 I- I

★ Measure gear backlash before disassembly. Clutch shaft assembly


Remove the m ounting bolts o f the oil seal retainer.
★ Cover Put a soft metal driver against the end face o f the
If there is any d iffic u lty , weld jack bolts to the clutch shaft and drive the assembly o u t tow ard the
cover and pull out the cover by force. engine side.
When pulling the shaft o u t o f the assembly, support
★ Brake lining the gear to prevent it from falling and take care n ot
Be careful not to let oil get on the lining or facing to damage the oil seal lip.
surface.
Pinion shaft assembly
Put a soft metal driver against the end face o f the
shaft and drive the assembly out tow ard the pinion
side.

155-4 SERIES 13-223


@
from the library of Barrington Diesel Club
STARTING ENGINE DISASSEMBLY AND ASSEMBLY

A S S E M B L Y OF 2 G 8 4 POW ER TRAIN

• Weight
From C holder
• Weight 6 I 2 7 F I 4 I -2

Pinion shaft
Pinion
Weight holder
Weight lock
With the lock washer in place, temporarily assemble
the weight lock. Indicate the position at which the
pinion shaft and weight lock are in alignment.
ii) Temporarily assemble the pinion and weight holder
so that the stopper bolt holes are in alignment.
in Install the pinion so that, when the weight holder is
installed, the weight is caught on the arc of the
weight lock.
iv) Install the return spring and return rod. Lock the
weight lock.
v) Install the weight holder and weight. Check the
weight for proper function.

★ Cover
Install the cover without fail.

13-224 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

DISASSEM BLY OF FUEL IN JEC TIO N PUM P

DISASSEMBLY OF PUMP BODY

4 5 6 7

6 I2 7 FI3 5 - I

Special tools

Part num ber Part name Q 'ty

A 1 5 7 9 2 0 -7 1 2 0 Extractor 1

B 15 7 9 1 5 -0 1 0 0 Socket wrench 1

C 1 5 7 8 1 4 -4 5 0 0 Z-coupling 1

D 15 7 9 1 6 -4 8 2 0 Special spanner 1

E 1 5 7 9 2 6 -5 3 2 0 Extractor 1

F 15 7 9 2 3 -5 1 2 0 Extractor 1

G 10 5 7 9 2 -0 0 2 0 Extractor 1

H 15 7 9 2 0 -5 6 0 0 Bracket 1

1 15 7 9 2 0 -5 7 2 0 Extractor 1

J 15 79 25 -7 12 0 Extractor 1

K 1 5 7 9 2 5 -0 3 2 0 Extractor 1

155-4 SERIES 13-225


from the library of Barrington Diesel Club
FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY

1. Tim ing gear


Remove tim ing gear using extractor A.

2. Feed pump

3. O verflow pipe

4. Governor cover assembly


1) Using a screwdriver, remove seven bolts holding
governor cover.
2) Tap governor cover w ith plastic hamm er to move
slightly. Using a screwdriver, push dow n plate hold­
ing link, then remove link fro m control rack.
3) Using narrow-nosed pliers, remove start spring from
spring eye.

5. Flyw eight assembly


1) Using socket wrench B, remove round n ut holding
flyw eight.
★ When doing this, install Z-coupling C and use
special spanner D to prevent the camshaft from
rotating.

2) Screw extractor E into flyw eigh t holder, and


remove flyw eigh t assembly fro m driven gear.

13-226
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

6. Driven gear
Remove three bolts holding bearing cover. Screw extrac­
to r F into driven gear, and remove driven gear and bear­
ing cover.

7. Drive gear
1) Using special wrench D, remove n ut holding drive
gear.

2) Screw extractor E into drive gear, and remove drive


gear from camshaft.

8. Bearing

9. Upper cover

10. Control rack cap, rack guide screw

11. Plunger block assembly


1) Using rack stopper, hold control rack 1 mm below
end face o f pump.

155-4 SERIES 13-227


from the library of Barrington Diesel Club
FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY

Rotate the camshaft slowly to set each cam at


bottom dead center before starting to remove any
part.
2) Loosen m ounting nut slightly, then remove shim
to prevent damage to O-ring.
3)
4)
Loosen m ounting nuts slowly in turn to remove.
Remove washer.
“C l !
5) Using extractor G, remove plunger block assembly
from pum p housing.
★ Remove the O-ring vertically to prevent it fro m
being damaged.
6) Remove rack stopper.
6 I 2 7 P 1 60 -9

12. Control rack

13. Tappet
Remove tappet.
★ When removing the tappet from the to p o f the
pump, be careful not to drop the plunger seat which
is fitted to the tappet.

14. Bearing cover

15. Center bearing


Using hole wrench, remove tw o screw lugs o f center

• ir t k
bearing.

16. Camshaft
1) Remove tw o set screws of center bearing, then using
bracket H and extractor I, remove bearing cover.
2) Using wooden hamm er, tap tip o f camshaft from
governor side, and remove camshaft together w ith
center bearing.
3) Using extractor J, remove bearing from camshaft.

17. Governor housing


1) Loosen eight set screws, then remove governor
housing.
2) Using extracto r K, remove outer race o f bearing.

13-228 155-4 SERIES


CD
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

DISASSEMBLY OF GOVERNOR COVER ASSEMBLY

Special tool

Part number Part name Q 'ty

L 10 57 92 -0 02 0 Extractor 1

1. Full load stopper

2. Torque spring double nut

3. Closing cover assembly


1) Remove lock nut o f full load stopper nut.
2) Remove four mounting bolts of closing cover.
3) Remove lock nut o f torque spring, then remove
closing cover.

Angleich spring assembly


Using special wrench L, remove angleich spring
assembly.

6 127P16 0 - I I

155-4 SERIES 13-229


from the library of Barrington Diesel Club
FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY

5. Tension lever
1) Remove tension lever pin (supporting tension lever
and guide lever) from governor cover.
2) Hold tension lever w ith fingertips and remove from
top of governor cover together w ith governor spring.

6. Guide lever

7. Control lever

8. Swivel lever
1) Remove snap ring on inside o f governor cover.
2) Remove bushing from governor cover, then remove
swivel lever.

9. Full load stopper bolt

10. idling sub spring

* Clean all parts after disassembly and keep in a safe place.


Be particularly careful when handling precision parts
such as plungers and delivery valves. Put to soak in a dish
containing clean diesel oil.

13-230 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

DISASSEMBLY OF AUTOMATIC TIMER

1. Ready the tim er fo r disassembly by m ounting it on the


vise, as follows:
1) Clamp the base in the vise, and install guide boot.
2) M ount the auto tim er, adm itting base pins into
holes o f flyweights.

2. Bend the tongues o f lock washer, and remove nut.

5. Lay the disassembled parts out in an orderly manner


on the table. oooooo

155-4 SERIES 13-231


from the library of Barrington Diesel Club
FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY

DISASSEMBLY OF FEED PUMP

1. Removing three nuts securing the feed pump to


injection-pum p housing allows the feed pump to be
detached as a unit.

2. Remove dust cover enclosing the priming pum p section


o f the feed pump.

3. Loosen the knurled screw on the b otto m o f filte r, and


take o ff the filter.

T h e follow ing three steps 4, 5 and 6 are to be carried out


w ith the feed pum p secured to the pum p housing.

4. Remove priming pum p, and take o u t valve spring and


check valve.

13-232 155-4 SERIES


(D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

5. Remove plug screw on the discharge side, and take o ut


valve spring and check valve.

6. Using a 32 mm wrench, remove plug and take o u t piston


spring and piston. Then, take o ut the push rod.

Snap ring has its one end fitted into the small hole in the
body. Remove snap ring by prising its opposite end.

8. Remove tappet and tappet spring. Be careful not to drop


tappet guide.

155-4 SERIES 13-233


from the library of Barrington Diesel Club
FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY

9. Break the tappet assembly into its parts by taking out


tappet guide and drawing o ff roller pin.

10. Lay the disassembled parts in an orderly manner on the


table.

O O BBC

13-234 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

DISASSEMBLY OF INJECTION NOZZLE AND


NOZZLE HOLDER

1. Remove the cap nut, as follows:


1) Clamp the nozzle holder in the vise, bringing the
nozzle tip to the top side. Loosen cap nut and inlet
connector, and take them o ff the holder.

2. Loosen nozzle nut, and separate nozzle from holder.

3. Lay the disassembled parts in an orderly manner on the

155-4 SERIES 13-235


from the library of Barrington Diesel Club
FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY

A SS EM B LY OF FUEL IN JEC TIO N PUMP

ASSEMBLY OF PUMP BODY

6 I27FI 35-3

Special tools

Part number Part name Q 'ty

M 1 5 4 3 5 0 -6 8 0 0 Craft paper 1

N 1 5 7 8 2 8 -7 2 0 0 Plate, measuring 1

0 1 5 7 8 2 0 -4 1 4 0 Measuring device 1

P 1 5 7 9 1 4 -0 5 0 0 Socket wrench 1

13-236 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

1. Governor housing 3. Center bearing set screw


Using adhesive and craft paper M , stick governor
housing to pump, then tighten seven set screws. 4. Bearing cover

2. Camshaft, center bearing 5. Tappet


1) F it center bearing in close contact w ith Hold tappet vertically and install in pum p housing.
camshaft, then assemble in pump housing from ★ Make sure th a t the guide pin o f the tappet is at
drive side. Fix center bearing in position w ith the center of the back face o f the pum p
tw o set screws. (w indow side o f tappet body on control rack
2) Install measuring plate N on tapered part on side).
drive side of camshaft. Using shims, center cam
by adjusting dimension "a " from end face of 6. Control rack
pump housing to end face o f measuring plate. Using nozzle and rack stopper, fix control rack at
★ Dimension "a ” : 13.5 ± 0 . 5 mm center o f pum p housing.
★ Shims fo r centering cam
7. Plunger block assembly
1) Hold plunger block assembly vertically and
install in pump housing.
★ Align the line on the flange o f the flange
Thickness sleeve w ith the line on the top face o f the
Part No.
(mm)
pump housing.
1343003-0000 1.2
★ To assemble the plunger correctly, hold the
1343003-0100 1.5
control rack in the center position and
1343003-0200 1.8
align the pinion guide groove of the
1343003-0300 2.0
plunger w ith the guide pin o f the tappet.
If they are not aligned and the plunger is
forced in, the pin w ill be bent or broken.
2) Before assembling, measure clearance " a " w ith
a feeler gauge. Choose a plunger seat to adjust
3) Tighten bearing cover. the clearance.
4) Using adjusting shims, adjust axial play o f cam­ ★ Clearance " a ” : 0 . 1 — 0. 16 mm
shaft.
★ Axial play o f camshaft: 0 .0 2 — 0 .0 6 mm
★ Adjusting shims Lower spring seat Plunger

Thickness
Part No.
(mm) Tappet
134314-0000 0.10
134314-0100 0.12
134314-0200 0.14 Plunger seat
134314-0300 0.16
134314-0400 0.18
134314-0500 0.30 6 I27 FI 35-5
134314-0600 0.50

155-4 SERIES 13-237


from the library of Barrington Diesel Club
FUEL INJECTION PUMP DISASSEMBLY AND ASSEMBLY

ASSEMBLY OF PLUNGER BLOCK ASSEMBLY

★ Plunger seat

Thickness
Part No.
(mm)
134140-0000 3.70
134140-0100 3.75
134140-0200 3.80
134140-0300 3.85
134140-0400 3.90
6 I 2 7 F I 35-6
134140-0500 3.95
134140-0600 4.00

3) Assemble washer on to p o f sleeve flange. 1. Plunger assembly


4) Set cam at bottom dead center, then tighten Position sleeve flange and plunger assembly with
nuts. straight pin, then secure w ith snap ring.
★ When tightening the nuts, insert adjusting
shims on the right or left between the 2. Delivery valve assembly
sleeve flange and pum p housing, and ★ Always replace the delivery valve gasket.
tighten the nuts unifo rm ly in turn.
3. O-ring, spring
Lock nut: 4 .2 5 ± 0.2 5 kgm
Coat tw o O-rings on outside of sleeve plunger w ith
★ Assemble the adjusting shims after the
grease. Then assemble plunger, lower spring seat and
O-ring is inserted inside the housing.
plunger spring correctly.
★ Always use new O-rings.
8. Rack guide screw, rack cap

4. Delivery valve assembly


9. Upper cover
Tighten w ith socket wrench P.
kgm i Upper cover: 0 .4 5 ± 0.0 5 kgm
k9m i Delivery valve holder

10. Drive gear

»<9™i Drive gear: 5.5 ± 0.5 kgm Order Tightening torque (kgm)

1st tim e 11 - 12
11. Bearing, driven gear
2nd tim e 0
3rd time 11-12
12. Bearing cover
4th tim e 0
5th time 11-12
13. Flyw eight assembly

iE ] Flyweight assembly: 6.5 ± 0.5 kgm


★ Always use new O-rings and assemble from the
14. Governor cover assembly to p o f the holder.

13-238 155-4 SERIES

from the library of Barrington Diesel Club


DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

ASSEMBLY OF GOVERNOR COVER ASSEMBLY

★ The governor has a very close relationship w ith 4. Tension lever


engine performance, so when assembling, be careful
to clean every part properly. Check also th at each 5. Idling spring
lever, link or w eight moves sm oothly w ith o u t
catching. 6. Torque spring

1. Full load stopper bolt 7. Closing cover assembly

Swivel lever 8. Control lever


1) Insert shaft o f swivel lever in governor cover.
2) Insert bushing in governor cover, then fit snap 9. Idling sub spring
ring.

3. Guide lever
A fte r installing the related parts, set the flyw eight
at maximum lift. Then use adjusting shims to adjust
dimension " b " from the end face of the governor
housing to the shifter.
★ Dimension "b ": 2 9 .4 ± 0.2 mm
★ Be careful not to damage the chrome plating at
the tip o f the shifter.
★ Adjsting shim

Thickness
Part No.
(mm)
029311-0010 0.2
029311-0180 0.3
029311-0190 0.4
029311-0210 0.1

155-4 SERIES 13-239


from the library of Barrington Diesel Club
BMP 5 M M L
1 5 5 -4
SERIES
Engine Serial No. 10011 and up
E N G IN E

14 MAINTENANCE
STANDARD

155-4 SERIES 14-001


from the library of Barrington Diesel Club
MAINTENANCE STANDARD
IN T A K E A N D E X H A U S T SYSTEM

TU R B O C H A R G E R ........................................................................................... 14-004

ENG IN E

C Y L IN D E R H EA D ........................................................................................... 14-008

V A L V E , V A L V E G U ID E ................................................................................ 14-010

CROSSHEAD, CROSSHEAD G U ID E .......................................................... 14-011

ROCKER HOUSING ........................................................................................ 14-012

TAPPET, PUSH ROD ..................................................................................... 14-013

C Y L IN D E R BLOCK ........................................................................................ 14-014

C Y L IN D E R L IN E R ........................................................................................... 14-018

C R A N K S H A F T ................................................................................................... 14-020

C A M S H A F T ......................................................................................................... 14-022

B ALANCER S H A F T ........................................................................................ 14-023

T IM IN G G E A R ................................................................................................... 14-024

PISTON, PISTON RIN G A N D PISTON PIN ............................................... 14-026

C O N N E C TIN G ROD ...................................................................................... 14-028

LU B R IC A T IO N SYSTEM

O IL PUMP ........................................................................................................... 14-030

R E L IE F V A L V E , R EG ULA TO R V A L V E A N D
S A F E TY V A L V E ..................................................................................... 14-032

PISTON C O O LING V A L V E ,
O IL COOLER BY-PASS V A L V E .......................................................... 14-034

COOLING SYSTEM

W ATER PUMP ................................................................................................... 14-036

ACCESSORY

S TA R TIN G E NG IN E ( 2 G 8 4 ) .......................................................................... 14-037

A IR C O M P R E S S O R ........................................................................................... 14-042

155-4 S E R IE S 14-003
(D
from the library of Barrington Diesel Club
TURBOCHARGER MAINTENANCE STANDARD

TURBO CHARG ER

KTR130

6 127F142A

14-004 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD TURBOCHARGER

Unit: mm

No. Check item Criteria Remedy

Standard Repair limit


Replace
1 End play parts
0 .0 8 -0 .1 3 0.18

Replace
2 Radial play 0 .2 5 -0 .4 3 0.60
parts

Tolerance Repair limit


Standard
Outer diameter of journal bearing Shaft Hole Shaft Hole
3 Inner diameter of center housing
-0.0 6 0 +0.020
30 29.89 30.04
-0.0 8 0 0

Inner diameter of journal bearing -0.0 3 0 +0.015


4 20 19.95 20.05
Outside diameter of turbine shaft -0 .0 4 5 0
Replace

Tolerance Repair limit


Standard
Width Groove Width Groove
5 Thickness of thrust bearing

-0 .0 8 +0.02
6 5.86 6.04
-0.11 0

-0 .0 8 -0 .0 3
6 Thickness of sealring 3 2.85 3.05
-0.1 0 -0 .0 4

Clearance between blower Replace


7 Tolerance: (min.) 0.20
housing and impeller parts
%
Tightening torque of blower
8 8.5 ±0.5 kg.m
impeller locknut

Tightening torque of insert 1.25±0.25kg.m Tighten


9 bolt

Tightening torque of V band 0.95±0.05kg.m


10
lock nut

155-4 SERIES 14-005


from the library of Barrington Diesel Club
TURBOCHARGER MAINTENANCE STANDARD

RH1521

Unit: mm

No. Check item Criteria Remedy

Standard Repair limit


Replace
1 End play
parts
0 .0 5 -0 .0 9 0.19

Replace
2 Radial play 0 .1 0 -0 .1 5 0.05
parts

14-006 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD TURBOCHARGER

Unit: mm

No. Check item Criteria Remedy

Standard Repair limit


O .D .o f
3
journal
26.0 25.95

Rotor
shaft Impeller
4 side 3.13 3.28
Turbine side
ring groove
5 Shaft side 3.08 3.15

Blower side
6 3.05 3.25
ring groove

7 Width of thrust collar 5.00 455

8 O.D 26.06 26.11 Replace


Dimension of floating
metal
9 I.D 35.03 34.96

10 Sleeve I.D 35.15 35.23

11 Thrust metal width 7.93 7.88

Dimension of thrust collar


12 8.00 8.07
and groove

13 Turbine side 3.00 2.90


Seal ring width

14 Blower side 3.00 2.90

Standard Repair limit


Journal and floating metal
15
clearance
0 .0 4 -0 .0 8 0.16

Floating metal and sleeve


16 0 .1 0 -0 .1 4 0.27
clearance

Thrust metal and thrust


17 0 .0 5 -0 .0 9 0.19 Replace
groove clearance

Impeller
o
in
0
00

18 0 .2 5 -0 .3 8
1

side
Turbine side seal ring and
groove clearance
19 Shaft side 0 .1 0 -0 .1 3 0 .2 5 -0 .3 8

Blower side seal ring and


20 0 .0 7 -0 .1 0 0 .2 5 -0 .3 8
groove clearance

Tightening torque of thrust


21 0.8 kg.m
metal tightening bolt

Tightening torque of blower


22 impeller tightening bolt 4.0kg.m Retighten

Tightening torque of blower


23 1,3kg.m
housing mounting bolt

155-4 SERIES 14-007


from the library of Barrington Diesel Club
CYLINDER HEAD MAINTENANCE STANDARD

C Y L IN D E R HEAD

14-008 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD CYLINDER HEAD

Unit: mm

No. Check item Criteria Remedy

Tolerance Repair limit


1 Strain of cylinder head
0.06 max. 0.1 Replace

Standard Repair lim it


2 Protrusion of nozzle
2 .9 ~ 3 .6 3.8

Refer to the section


3 Nozzle injection pressure TE S TIN G A N D ADJUSTING ; T R O U B LE SHO O TING C R IT E R IA Adjust

Nozzle holder mounting bolt


4 3.25±0.25kg/cm *
tightening torque

Injection nozzle inlet tighten­


5 4.25±0.25kg.m
ing torque

Injection nozzle outlet tighten­


6 1 .75±0.25kg.m Retighten
ing torque

7 Outlet pipe tightening torque 1.75±0.25kg.m

8 Inlet pipe tightening torque 4.25±0.25kg.m

Sequence Target value (kg.m) Range (kg.m)

1st 29 2 5 .5 -3 2 .5

Cylinder head bolt


9 2nd 44 4 0 .5 -4 7 .5 Retighten
tightening torque

3rd 55 5 3 .5 -5 6 .5

155-4 SERIES 14-009


from the library of Barrington Diesel Club
V A LV E , VA LVE GUIDE MAINTENANCE STANDARD

Unit: mm

No. Check item Criteria Remedy

Standard Repair limit


Replace valve
1 Protrusion of valve (IN. EX.) or valve
seat
3 .1 5 -3 .4 1 1.6

Repair or
2 Valve head wear Repair lim it: 0.15
replace

Standard Tolerance Repair limit

3 Thickness of valve head Intake valve 2 ±0.05 1 Replace

Exhaust valve 2 ±0.15 1

Standard Tolerance Repair limit

4 Valve seat angle Intake valve 30°

Exhaust valve 45° —

Standard Tolerance Repair limit


Replace
Valve stem O.D
- 0 .0 6 0
5 11 10.85
-0.0 8 0

■K).020
Valve guide I.D 11 11.17
-0 .0 1 0

6 Protrusion of valve guide 20 ±0.50


-- --------

Standard Repair lim it

Installed Installed Installed


Valve close Free length Free length
length load load

Valve
spring 88 66 40±2kg — 36.5 kg Replace
7

Valve open 88 51.9 72±3.6kg — 65.5 kg

Squareness of valve spring Repair limit: 20 max.

14-010 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD CROSSHEAD, CROSSHEAD GUIDE

CROSSHEAD, C R O SSH EA D GUIDE

No. Check item Criteria Remedy

Standard Tolerance Repair limit


1 Depth of crosshead stem
3 ±0.10 3.5

+0.07
2 Crosshead guide !.D. 12 12.13
+0.02

+0.01 Replace
3 Crosshead guide O.D. 12 11.95
0

Protrusion of crosshead
4 53 ±0.2 -
guide

Standard clearannce Clearance limit


Clearance between crosshead
5 guide and crosshead
0 .0 1 -0 .0 7 0.18

Engine serial No. Intake valve Exhaust valve

1 0 0 1 1 -5 0 1 5 6 0.3 0.3
S4D155-4
50157- 0.4 0.6

6 Valve clearance (warm) 1 0 0 1 1 -1 1 7 4 5 0.3 0.3 Adjust

S6D155-4

11 7 4 6 - 0.4 0.6

SA6D155-4 20338- 0.4 0.6

Tightening torque of cross­


7 4.0±0.6kg.m Tighten
head locknut

155-4 SERIES 14-011


(?)
from the library of Barrington Diesel Club
ROCKER HOUSING MAINTENANCE STANDARD

ROCKER HOUSING

1
2 3 4

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Repair limit


clearance
Compression release lever
1
shaft O.D
+0.050
28 0 .1 1 0 -0 .2 1 4 -
0

-0 .0 1 5 Replace
2 Rocker lever shaft O.D 32.4 0 .0 2 5 -0 .1 2 5 32.28
-0 .0 3 5

Rocker lever shaft +0.090


3 32.4 0 .0 2 5 -0 .1 2 5 32.52
bushing I.D +0.010

Clearance between rocker


4 housing and compression 32.4 0 .0 1 3 -0 .0 6 6 -
release shaft

Standard Tolerance Repair limit


Width of compression release Repair or
5
lever joint replace
+0.05
8 -
0

14-012 155-4 SERIES


(D
from the library of Barrington Diesel Club
MAINTENANCE STANDARD TAPPET, PUSH ROD

T A P P E T , PUSH ROD

6 I 2 7 F I 49

Unit: mm

No. Check item Criteria Remedy

Standard clearance Valve lift


Valve lift of compression
1 Adjust
release
1 .9 8 -3 .9 2 0 .5 0 5 -2 .7 5 5

Standard Tolerance Repair limit


Tappet O.D
-0 .0 2 5
46 45.90
-0 .0 5 0

Inner diameter of +0.040


2 tappet guide 46 46.13 Replace
0

Standard Clearance lim it


Tappet guide and tappet
clearance
0 .0 2 5 -0 .0 9 0 -

Tightening torque of
3 6.9±1 .Okg.m Retighten
locknut

155-4 SERIES 14-013


from the library of Barrington Diesel Club
CYLIN D ER BLOCK MAINTENANCE STANDARD

C Y L IN D E R BLOCK

S4D155-4

Unit: mm

No. Check item Criteria Remedy

6; w —^- Tolerance
Serial Standard Clearance
Standard
number clearance limit
Block Liner
o o
CO 00

Clearance between cylinder 10 2 8 7 ~ 40.08


1 176 0 .0 5 ~ 0 .1 6 - Replace
block and liner 50040 4-0.02

50041~ - 0 .0 3 4-0.08 -
176 0 .1 0 ~ 0 .1 8
-0 .1 0 40.02

Standard Tolerance Repair lim it


2 Main metal hole I.D
40.025
132 132.05
0

3 0 Repair or
Thickness of main metal 3.5 3.44
-0 .0 1 5 replace

40.050
4 Main metal I.D 125 125.12
0

14-014 155-4 SERIES


(2 )
from the library of Barrington Diesel Club
MAINTENANCE STANDARD CYLINDER BLOCK

Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit


Clearance between main metal
4 and crankshaft journal
0 .0 5 0 -0 .1 3 0 0.35

Standard interference Interference limit


Cap and cylinder block
5 interference
0 .1 0 0 -0 .1 6 0 0.05

Standard Tolerance Repair limit


Balancer bushing
6
mounting hole I.D +0.030
71 -
0

+0.110
7 Balancer bushing I.D 66 66.18
+0.040

+0.030
8 Cam bushing mounting hole I.D 64 64.03 *
0

Camshaft bushing I.D 61 +0.070 61.10 Repair or


0 replace

Standard clearance Clearance limit


9
Clearance between camshaft
and journal
0 .0 8 0 -0 .1 8 0 0.24

Standard Tolerance Clearance limit


10 Counter bore lower, I.D
178.5 0 .1 0 -0 .2 6

Interference
Engine Serial No. Tolerance Tolerance limit

11 Counter bore, I.D 1 0 0 1 1 -5 0 0 4 0 183.5 - 0 .0 1 -0 .1 1

50041- 185.5 - -0 .1 0 0 -0 .2 4 4

Tolerance Repair limit

12 Strain of cylinder head face


0.09 0.15

Variation of each counter Repair lim it: 0.03 Machining


13 bore depth

Sequence Target value (kg.m) Range (kg.m)

1st 31 3 0 -3 2

2nd 61 6 0 -6 2

Tightening torque of main 0 Loosen Retighten


14 3rd
metal cap
4th 15.5 1 5 -1 6

5th 29 2 8 -3 0

6th 52 5 0 -5 4
O

00

7th 74
I

155-4 SERIES 14-015


from the library of Barrington Diesel Club
CYLINDER BLOCK MAINTENANCE STANDARD

S6D155-4, S A 6 D 155-4

Unit: mm

No. Check item Criteria Remedy

Tolerance
Serial No. Standard Clearance
Standard
clearance limit
Block Liner

Clearance between cylinder S 6D 155-4 Replace


do
0 0
CO 0 0

+0.08
1 I

1 block and liner 1001 I ' ­ 176 0 .0 5 -0 .1 6 -


+0.02
l l 703
S6D 155-4
CO

+ 0.08
o o
o
I I

11704- 176 0 .0 5 -0 .1 8 -
+0.02
o

S A 6D 155-4

14-016 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD CYLINDER BLOCK
Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Repair limit


2 Main metal mounting hole I.D
-HD.025
132 132.05
0

3 0
Main metal thickness 3.5 -0 .0 6
-0 .0 5 0

+0.050
Main metal I.D 125 125.12
0

4 Standard clearance Clearance limit


Clearance between main metal
and crankshaft journal
0 .0 5 0 -0 .1 3 0 0.35

Standard interference Interference lim it


Cap and cylinder block
5 interference
0 .1 0 0 -0 .1 6 0 0.05

Standard Tolerance Repair limit

6 Cam bushing mounting hole I.D


64 +0.030
64.03
0

+0.070 Repair or
Cam shaft bushing I.D 61 61.10 replace
0

7 Standard clearance Clearance limit


Clearance between camshaft
journal and bushing
0 .0 8 0 -0 .1 8 0 0.24

Standard Tolerance Clearance limit


8 Counter bore lower I.D
178.5 - 0 .1 0 -0 .2 6

Interference
Engine Serial No. Standard Tolerance
limit

+0.17
9 Counter bore I.D 1 0 0 1 1 -1 2 4 2 8 183.5 0 .0 1 -0 .1 1
+0.12

+0.17
12429- 185.5 +0.12 -0 .1 0 0 ~ 0 .2 4 4

Tolerance Repair lim it


Cylinderhead mounting face
10 distortion
0.09 0.15

Variation of counter bore Repair limit: 0.03 Machining


11 depth

Order Target (kg.m) Range (kg.m)

1st 31 3 0 -3 2

2nd 61 6 0 -6 2

Main metal cap tightening Loosen Retighten


12 3rd 0
torque
4th 15.5 1 5 -1 6
00
CM

CO
0

5th 29
1

6th 52 5 0 -5 4

7th 74 7 0 -7 8

155-4 SERIES 14-017


(D
from the library of Barrington Diesel Club
CYLINDER LINER MAINTENANCE STANDARD

C Y L IN D E R LIN E R

Detail P

6127F152B

Unit: mm

No. Check item Criteria Remedy

Permissible range: 0.10—0.16


1 Protrusion of cylinder liner Replace
Difference among cylinders: 0.05 max.

Engine Serial No. Standard Tolerance Repair limit

S4D1 55-4 No. -5 0 4 7 2


+0.040
S6D155-4 No. - 2 7 1 2 8 155 155.54
S A 6D 15 6 4 No. -2 6 6 9 0 0

2 Cylinder liner I.D S6D155-4 No. 5 0 4 7 3 -


+0.060
S6D155-4 No. 2 7 1 2 9 - 155 155.26
+0.020
S A 6D 155-4 No. 2 6 6 9 1 -

Roundness Repair limit: 0.06


Replace
Cylindricity Repair limit: 0.06

Engine Serial No. Standard Tolerance

S4D155-4 No. 1 0 2 8 7 - 50040


Cylinder liner O.D S 6 D 1 5 5 4 No. 1 0 0 1 1 -2 7 1 2 8 183.5 -
(Counter bore part)
S4D155-4 No. 5 0 0 4 1 -
S6D1 55-4 No. 2 7 1 2 9 - 185.5 -
SA6D155-4
o
Engine Serial No. Standard Interference
interference limit

Cylinder liner and S 4D 155-4 No. 1 0 2 8 7 -5 0 0 4 0


0 .0 1 -0 .1 1 0.01 Replace
block interference S 6D 155-4 No. 1 0 0 1 1 -2 7 1 2 8
(Counter bore part)
S4D 155-4 No. 5 0 0 4 1 -
S6D 155-4 No. 2 7 1 2 9 - 0 .1 0 0 -0 .2 4 4
S A 6D 155-4

Standard Tolerance
Cylinder liner O.D
(Counter bore lower part) Replace
178.5
4

Clearance between cylinder


liner and block Standard clearance: 0.1 0 —0.21 Replace
(Counter bore lower part)

14-018 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD CYLINDER LINER

Unit: mm

No. Check item Criteria Remedy

Serial No. Standard Tolerance

S4D155-4 N o .- 5 0 0 0 0 - 0 .0 3
176
S6D155-4 N o .- 1 1 7 0 3 - 0 .0 8
Cylinder liner O.D S4D155-4 No. 50001 - 50472
5 (O-ring part) - 0 .0 3 Replace
S6D155-4 No. 1 1 7 0 4 - 27128 176
- 0 .1 3
SA6D155-4 N o .- 2 6 6 9 0
S4D155-4 No. 5 0 4 7 3 -
- 0 .0 3
S6D155-4 No. 2 7 1 2 9 - 176
- 0 .1 0
SA 6D 155-4 No. 26691 -

155-4 SERIES 14-019


from the library of Barrington Diesel Club
CRANKSHAFT MAINTENANCE STANDARD

CRANKSHAFT

S4D155-4

6 I27FI53A

S6D155-4
SA6D155-4

6 I 2 7 F I 54

14-020 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD CRANKSHAFT

Unit: mm

No. Check item Criteria Remedy

Size Standard Tolerance Repair limit

S.T.D 125.00 -0 .0 6 0
-0 .0 8 0 124.70

0.25US - 0 .0 6 0
124.75 124.45
- 0 .0 8 0

1 Main journal O.D 0.50US 124.50 -0 .0 6 0


124.20
-0 .0 8 0

0.75US 124.25 -0 .0 6 0
123.95
-0 .0 8 0

- 0 .0 6 0
1.00 US 124.00 123.70 Repair or
- 0 .0 8 0
replace

-0 .0 5 0
S.T.D 102.00 101.75
-0.0 8 0

-0.0 5 0
0.25US 101.75 101.50
-0.0 8 0

-0.0 5 0
2 Crank pin journal O.D 0.50US 101.50 101.25
-0.080

-0.0 5 0
0.75US 101.25 101.00
-0.0 8 0

-0.0 5 0
1 .OOUS 101.00 100.75
-0.0 8 0

Standard Repair limit


3 Journal roundness Replace
0.010 max. 0.015

Tolerance Repair limit


4 End play Replace
0 .1 4 0 -0 .2 8 5 0.64

Standard Tolerance Repair limit


5 Main metal thickness
0
3.5 -0.0 6
-0 .0 1 5
Replace
6 Rear flange O.D 170 ±0.020

Rear flange sleeve O.D after


7 180 ±0.030
assembled

Standard Tolerance Standard interference


8 Rear flange sleeve, I.D
-0 .2 5 0
170 0 .2 3 -0 .3 0
- 0.280
Replace
Tolerance Repair limit
9 Bend of crankshaft
(by indicator)
0 - 0 .0 9 0.10

10 Tightening torque 16±1 kg.m Retighten

155-4 SERIES 14-021


d>
from the library of Barrington Diesel Club
CAMSHAFT MAINTENANCE STANDARD

CAM SH A FT

S4D155-4

4 3 2 1

6 I 2 7 F I 55

S6D155-4
SA6D155-4

6 I 2 7 F I 56

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Repair limit


1 Repair or
Cam height
replace
+0.055
51.3 50.5
+0.045

-0 .0 8 0
2 Journal O.D 61.0 60.86
-0 .1 1 0
Replace
0
3 Thrust plate thickness 7 6.8 5
-0 .0 5

Standard Repair limit


Replace
4 Camshaft end play thrust
plate
0 .1 -0 .2 5 0.4

5 Bend of camshaft Repair lim it: 0.20 (by indicator) Replace

14-022 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD BALANCER SHAFT

BA LA N C ER S H A F T (S4D155 4)

a
Balancer shaft (R .H .)

2
Forward

6I27FI57A

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Repair
Standard
clearance limit
Clearance between Shaft Hole Replace
1
balancer shaft bushing bushing
-0.0 3 0 +0.110
66 0 .0 7 0 -0 .1 7 0 0.3
-0.060 +0.040

Standard Repair limit


Replace
2 End play of balancer shaft thrust
plate
0 .1 3 -0 .2 5 0.5

Tolerance Repair limit


3 Bend of balancer shaft Replace
(by indicator)
0.06 0.1

155-4 SERIES 14-023


from the library of Barrington Diesel Club
T IM IN G GEAR MAINTENANCE STANDARD

T IM IN G GEAR

14-024 155-4 SERIES


(D
from the library of Barrington Diesel Club
MAINTENANCE STANDARD TIM IN G GEAR

„ Unit: mm

No. Check item Criteria Remedy

Repair
Position Measuring point Standard
limit

Main idler gear (small) and camgear 0 .1 4 -0 .3 2


Main idler gear (small) and
0 .1 2 -0 .3 3
injection pump gear______
Main idler gear and balancer idler gear
0 .1 2 -0 .3 3
(S4D155-4)
Main idler gear and crank gear (S4D155-4) 0 .0 5 -0 .2 5

Oil pump idler gear and crank gear 0 .0 8 -0 .2 8

Gear backlash Right balancer idle gear and 0.5 Replace


0 .0 9 -0 .2 8
right balancer gear (S4D155-4)
Main idler gear (large) and
0 .0 9 -0 .3 1
accessory drive gear

Accessory drive gear and dinamo gear 0 .0 8 -0 .2 6

Accessory drive gear and water pump gear 0 .0 7 -0 .2 6

Oil pump idler gear and oil pump gear 0 .0 5 -0 .2 9

Main idler gear (large) crank gear 0 .1 2 -0 .2 9

Tolerance
Standard Repair
Standard
clearance limit
Clearance between main idler Shaft Hole
gear bushing and shaft
-0 .0 3 0 +0.070
60 0 .0 3 0 -0 .1 2 0 0.25
-0 .0 5 0 0

Clearance between idler gear - 0 .0 2 5 +0.065 Replace


40 0 .0 2 5 -0 .1 0 5 0.20
bushing and shaft -0 .0 4 0 0 bushing

Clearance between idler gear -0 .0 2 5 +0.065


40 0 .0 2 5 -0 .1 0 5 0.20
bushing and shaft - 0 .0 4 0 0

10 Front support mounting hole 160


-0.015
-0.050
+0.040
0
0 .0 1 5 -0 .0 9 5 1.0

Standard Repair limit

11 End play of main idler gear


0 .0 3 -0 .1 7 0.30

Replace
12 End play of idle gear (S4D155-4) 0 .0 6 -0 .1 9 0.30 thrust
bearing

13 End play of idle gear (S4D155-4) 0 .0 6 -0 .1 9 0.30

Difference of timing gear case and Repair or


14 Tolerance. 0.07 max.
cylinder block lower step replace

155-4 SERIES 14-025


from the library of Barrington Diesel Club
PISTON_______________________ MAINTENANCE STANDARD

P ISTO N , PISTO N RING AND PISTO N PIN


2-3

4-

Engine Serial No. S4D155-4 10287 - 59472


S6D155-4 1 1 0 5 8 -2 7 1 2 8
SA6D155-4 2 0 3 3 8 -2 6 6 9 0

No Item Criteria Remedy

Damage of piston Check piston for damage by dye-penetrant test

S4D155-4 10287 - 50040 S4D155-4 50041 - 50472


S6D155-4A 1 1 0 5 8 - 14256 -4 1 6 0 ± 1 0 S6D155-4A 14257 - 27128
Piston weight (g) 4074 ± 10
(for 4 rings) S6D155-4B 11238 - 12297 S6D155-4C 11274 -
SA6D155-4 2 0 3 3 8 -2 6 6 9 0 4 0 2 0 + 10 S6D155-4D 12298 - 27128

Outer diameter of Engine Basic dimension Tolerance Service limit


piston
Right angle to boss: - 0.200
S4D155-4 154.66
Basic 155 -0 .2 4 0
dimension -0 .3 3 0
S6D 155-4 Boss direction 155 154.53
-0 .4 7 0
Right angle to boss: - 0.220
155.66
9.7 155 - 0 .2 4 0
SA 6D 155-4
Boss direction 155 - 0 .3 5 0
154.53
- 0 .3 7 0
Tolerance
Measuring Permissible
Basic dimension
point clearance
Ring groove Ring thickness
Check them with a piston groove
Top ring Keystone
wear gauge.
Piston ring grooves
2nd ring 3.5
+0.05 -0.01
No. 1 oil ring 0.3
+0.03 -0.03

No. 2 oil ring

Measuring point Standard gap Permissible gap

Top ring
3. Piston ring gap
2nd ring 0.45 - 0.65 3.5

Oil ring

Basic dimension Tolerance Service limit


Inner diameter of
piston pin hole 0
60 60.03
- 0 .0 1 5
Outer diameter of -0.010
piston pin _____ 60 59.97
-0.015

14-026 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD PISTON

Engine Serial No. S 4D 15 5-4 5 9 4 7 3 and up


S 6 D 155-4 2 7 1 2 9 and up
S A 6 D 1 55-4 26691 and up

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Repair limit


Piston O.D
(65mm from bottom and 20° C) -0.275
90 to boss 1 55 154.65
-0.305

Tolerance
Measuring Clearance
Standard
point Ring limit
Ring groove
Thickness
Piston ring groove TOP ring
Keystone Check with gauge t = 0.5 0.15
2nd ring

Oil ring 4.8


+0.05 - 0.01 0.3
+0.03 -0.03

Measuring point Standard clearance Clearance limit

TOP ring
Piston ring gap Replace
2nd ring 0 .4 5 -0 .6 5 3.5

Oil ring

Standard Tolerance Repair limit

Piston pin boss I.D (20°C)


60 ±0.005 60.03

Piston pin O.D 60


- 0.010 59.97
-0 .0 1 5

Engine model Tolerance (g)

S4D155-4, S6D155-4 4,310 ± 10


Piston weight

SA 6D 155-4 4,285 ± 10

155-4 SERIES 14-027


from the library of Barrington Diesel Club
CONNECTING ROD MAINTENANCE STANDARD

C O N N EC TIN G ROD

6 I 2 7 F I 59

14-028 155-4 SERIES


(D
from the library of Barrington Diesel Club
MAINTENANCE STANDARD CONNECTING ROD

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Repair
Standard
clearance limit
Shaft Hole
Clearance between connecting
rod bushing and piston pin
-0.010 +0.050
60 0 .0 4 0 -0 .0 6 5 0.095
-0 .0 1 5 +0.030

Standard Tolerance

Connecting rod big end I.D


109 +0.020
0

Standard Repair limit


Clearance between connecting
rod big end I.D and
crankshaft journal 0 .0 5 0 -0 .1 3 0 0.35

Size Standard Tolerance Repair limit


0
S.T.D 3.500 3.45 Replace
-0.015
0
0.125US 3.625 3.55
-0.015
Metal thickness
0
0.250US 3.750 3.70
-0 .0 1 5
0
0.375US 3.875 3.80
-0 .0 1 5
0
0.500US 4.000 3.95
-0 .0 1 5

Repair limit of bend : 0.10

Bend or twist
Repair limit of twist : 0.25

Connecting rod weight 9 .1 74±25g

Order Target (kg.m) Range (kg.m)

1st 21 2 0 -2 2

2nd 41.5 4 0 -4 3

Connecting rod cap Loosen


3rd Retighten
tightening torque
4th 7 -9

5th 21 2 0 -2 2

6th 28.5 2 7 -3 0

7th 41.5 4 0 -4 3

155-4 SERIES 14-029


from the library of Barrington Diesel Club
O IL PUMP MAINTENANCE STANDARD

O IL P U M P

14-030 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD O IL PUMP

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Repair
Standard
clearance limit
Shaft Hole
Clearance between drive
1
shaft and bushing -0.0 2 0 +0.040
28 0 .0 4 0 -0 .0 7 5 -
-0 .0 3 5 +0.020

Clearance between driven


-0.0 2 0 +0.035
2 shaft and driven gear 24 0 .0 30 ~ 0 .0 7 0 -
-0.0 3 5 +0.010
bushing

Clearance between gear -0.1 7 0 +0.050


3 65.22 0 .1 7 0 -0 .0 5 0 - Replace
O.D and body clearance -0.2 0 0 0

Main pump gear and body -0.0 7 0 +0.035


4 65 0 .0 7 0 -0 .1 2 5 -
end play -0 .0 9 0 0

Scavenging pump gear and body -0.1 1 0 +0.070


5 60 0 .1 5 0 -0 .2 0 0 -
end play -0.130 +0.040

Mounting bolt 6.5±1 .Okg.m Retighten


6 tightening torque

155-4 SERIES 14-031


from the library of Barrington Diesel Club
RELIEF VA LVE, REGULATOR VA LVE AND SAFETY VALVE MAINTENANCE STANDARD

R E L IE F V A L V E , REG U LA TO R V A L V E AND S A F E T Y V A L V E

R E L IE F V A L V E S A F E TY V A L V E
(S 4 D 155-4)

2 1 8

R EG U LA TO R V A L V E S A F E TY V A L V E
S 4 D 155-4 S 6D 15 5-4 (Engine serial No. 10011 ~ 19999)
S 6 D 1 5 5 -4 (Engine serial No. 10011 ~ 19999)

6 I27FI62A 6 I27FI 63-2

R E G U LA TO R V A L V E S A F E TY V A L V E
S 6 D 155-4 (Engine serial No. 2 0 0 0 0 and up) S 6D 15 5-4 (Engine serial No. 2 0 0 0 0 and up)
S A 6 D 155-4 S A 6 D 155-4

6 127FI 6 3 - 3

14-032 155-4 SERIES


@
from the library of Barrington Diesel Club
MAINTENANCE STANDARD RELIEF V A LVE , REGULATOR VA LVE AND SAFETY VA LVE

Unit: mm

No. Item Criteria Remedy

Standard Repair limit

Free length Installed length Preload Free length Preload


1 Relief valve spring, inner

70 56.3 14.73 kg 63 14.0 kg

2 Relief valve spring, outer 81 56.3 25.44 kg 73 24.0 kg

3 Regulator valve spring 92.5 64 14.1 kg - - Replace

4 Regulator valve spring 92.5 64 14.1 kg - -

5 Safety valve spring 62 51 6.43 kg - 6.17 kg

6 Safety valve spring 62 51 6.43 kg - 6.17 kg

7 Safety valve spring 81 51 6.43 kg - 6.17 kg

8 Relief valve working pressure Standard: 8.5 ± 0.5 kg/cm2

Regulator valve working pressure Standard- 3.75 ± 0.25 kg/cm2 (S4D155-4)


9 standard. 3.45 ± 0 .75 kg/cm2 (S6D155-4)

10 Regulator valve working pressure Standrad: 4.05 ± 0.25 kg/cm2


Adjust shim
or replace
Safety valve working pressure spring
11 Standard: 2 ± 0.2 kg/cm2
(Differential pressure)

Safety valve working pressure


12 Standard: 2 ± 0.2 kg/cm2
(Differential pressure)

Safety valve working pressure


13 Standard: 2 ± 0,2 kg/cm2
(Differential pressure)

Target value (kg.m) Range (kg.m)


14
I Valve plug tightening torque Retighten
18 22 20 ~ 24

155-4 SERIES 14-033


from the library of Barrington Diesel Club
PISTON COOLING VA LVE, OIL COOLER BY-PASS VA LVE MAINTENANCE STANDARD

P ISTO N COOLING V A L V E . O IL CO O LER B Y -P A S S V A L V E

PISTON COOLING VALVE OIL COOLER BY-PASS VALVE


S 4 D 155-4
S 6 D 1 5 5 -4 (Engine serial No. 10011 ~ 19999)

8 4 11
6 I27FI 63-7

PISTON COOLING VALVE


S 6 D 155-4 (Engine serial No. 2 0 0 0 0 ~ 2 2 6 5 0 )
S A 6 D 155-4 (Engine serial No. 2 0 3 3 8 ~ 2 2 9 9 2 )

9 2 6

6 I27 FI 63-5

PISTON COOLING VALVE


S 6 D 155-4 (Engine serial No. 22651 and up)
S A 6 D 1 5 5 -4 (Engine serial No. 2 2 9 9 3 and up)

10 3 7

14-034 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD PISTON COOLING VA LVE, OIL COOLER BY-PASS VALVE

Unit: mm

No. Check item Criteria Remedy

Standard Repair limit

Free length Installed length Installed load Free length Installed load
1 Piston cooling valve spring

85.3 62.8 20.4 kg 76.5 19.5 kg

Replace
2 Piston cooling valve spring 92.5 64 14.1 kg - -

3 Piston cooling valve spring 158 123 8.6 kg - -

4 Oil cooler by-pass valve spring 72.9 50.0 12.0 kg 65.6 11.5 kg

5 Piston cooling valve hydraulic oil Standard: 4.5 ± 0.2 kg/cm2

Piston cooling valve


6 Standard: 2.75 ± 0.25 kg/cm2
working pressure
Replace
Piston cooling valve
7 Standard: 1.6 ± 0.2 kg/cm2
working pressure

Oil cooler by-pass valve


8 Standard? 4 ± 0.5 kg/cm2
working pressure

Target value (kg.m) Range (kg.m)


9
I Valve plug tightening torque Retighten
11 22 20 ~ 24

155-4 SERIES 14-035


from the library of Barrington Diesel Club
WATER PUMP MAINTENANCE STANDARD

W A TE R P U M P

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Standard interference
Interference of Shaft Hole
1 Replace
shaft and impeller
+0.070 +0.030
15.85 0.025 ~ 0.075
+0.055 0

Standard clearance Clearance limit


Clearance between
2 Replace
impeller and connection
0.62 ~ 1.70 -

Target value (kg.m) Range (kg.m)


Impeller lock nut
3
tightening torque
CO
in

7.75
I

Retighten

Bearing lock nut tightening


4 20 17 ~ 23
torque

14-036 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD STARTING ENGINE

STA R TIN G ENG INE (2 G 8 4 )


(1) Cylinder head
Unit: mm

No. Check item Criteria Remedy

Tolerance Repair limit

Strain of mounting surface Repair by


1
grinding or
0 -0 .0 5 0.10 replace

(2) Valve and valve guide


Unit: mm

No. Check item Criteria Remedy

Standard Repair limit

1 Protrusion of valve Replace


1.6 0.6

Standard clearance Repair limit


Replace
Clearance between valve either or
2 Intake valve 0 .0 3 0 --0.065 0.15
and valve guide both valve
and guide '
Exhaust valve 0 .0 4 5 --0.085 0.15

Standard size Repair limit

3 Valve spring Free length Installed length Preload Free length Preload Replace

38 - - 50 14.2 kg

(3) Cylinder block


Unit: mm

No. Check item Criteria Remedy

Tolerance Repair limit


Repair by
Strain of cylinder head grinding or
1
mounting surface replace
0 -0 .0 5 0.10

Standard size Tolerance Repair limit

STD 84.14 84.44

2 Cylinder bore 0.25 OS 84.39 84.69


+0.025
0 Rebore to
0.50 OS 84.64 84.94 oversize or
replace
0.75 OS 84.89 85.19

Standard size Standard clearance Repair limit


Replace
Clearance between tappet either or both
3
and tappet guide tappet and
16.0 0 .0 1 5 - 0.055 0.15 tappet guide

155-4 SERIES 14-037


from the library of Barrington Diesel Club
STARTING ENGINE MAINTENANCE STANDARD

(4) Crankshaft
Unit: mm

No. Check item Criteria Remedy

Standard Repair limit

1 End play Replace


0 .0 5 0 -0 .1 4 5 0.40

Standard size Tolerance Repair limit

STD 55 54.75

0.25 US 54.50

2 Main journal O.D 0.50 US 54.25


-
0.75 US 54.00

1.00 US 53.75
Repair or
1.50 US 53.25 replace

STD 54 53.75

0.25 US 53.50

3 Pin journal O.D 0.50 US - 53.25

0.75 US 53.00

1.00 US 52.75

Standard clearance Clearance limit


Clearance between main
4 Replace
journal and main metal
0 .0 3 0 -0 .1 0 0 0.25

Clearance between pin journal


5 0.020 0.25 Replace
and connecting rod metal

(5) Camshaft
Unit: mm

No. Check item Criteria Remedy

Standard size Standard clearance Clearance limit


Clearance between cam
1 Replace
journal and cam bushing
48.0 0 .0 2 5 - 0.085 0.15

2 End play of camshaft -- --------- 0 .1 0 - 0.20 0.40 Replace

Tolerance Repair limit


3 Bend of camshaft Replace
0 -0 .0 5 0.10

14-038 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD STARTING ENGINE

(6) Piston, piston rings and piston pin


Unit: mm

No. Check item Criteria Remedy

Standard size Standard clearance Clearance limit


Clearance between Replace
1
piston and cylinder piston
83.9 0 .0 2 5 - 0.275 -

Standard weight Tolerance

2 Weight of piston Replace


410 g ±10 g

Standard clearance Clearance limit

Clearance between piston ring Compression ring 0 .0 4 - 0.08 0.2


3 Replace
groove and new piston ring piston 4

Oil control ring 0 .0 2 - 0.06

Standard gap Clearance limit


Piston ring gap Replace
4
(inside cylinder)
0.1 - 0 . 3 1.2

Standard size Standard clearance Clearance limit


Replace
5 Piston to piston pin clearance piston or
0 .0 1 0 - 0.045 0.05 piston pin
25.15

(7) Clutch
Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


Replace
1 Thickness of drive plate lining lining
4.0 3.2

Standard size Standard clearance Clearance limit


Clearance between cam link Replace pin
2
and pin
8.0 0 .1 1 - 0.20 0.40

Clearance between clutch Replace


3 38.0 0 .2 8 - 0.50 0.80
shaft and sleeve sleeve

Replace
Clearance between sleeve sleeve or
4 8.0 0 .0 7 - 0.15 0.30
and shifter groove shifter

Clearance between clutch shaft Replace


5 and flywheel bushing 22.0 0 .0 2 0 - 0.070 0.20
bushing

155-4 SERIES 14-039


from the library of Barrington Diesel Club
STARTING ENGINE MAINTENANCE STANDARD

(8) Gear box


Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit

1 Backlash between gears


0 .1 3 -0 .2 2 0.60
Replace

Clearance between gear


2 0 .0 6 -0 .1 7 0.40
and shaft spline

(9) Starting pinion


Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit


Backlash between pinion Replace
1
and ring gear pinion
0 .1 4 -0 .2 4 1.0

Replace
Clearance between pinion
2 0 .0 5 -0 .1 0 0.20 pinion or
and shaft spline
shaft

Clearance between pinion Replace


3 0 .0 0 5 -0 .0 6 0 0 .1 0 '
guide lever and bushing bushing

14-040 155-4 SERIES

from the library of Barrington Diesel Club


A IR COMPRESSOR MAINTENANCE STANDARD

AIR C O M P R E S S O R (Nippon a i r b r a k e )

1 11

14-042 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD A IR COMPRESSOR

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Repair limit


1 Piston O.D
0 -
69.812
-0 .0 1 5

Standard
Check
Standard Repair limit
point
Ring Piston

Clearance between piston -


2 No. 1 3 .1 2 5 -3 .1 5 0 3 .2 0 0 -3 .2 2 5 0 .0 5 -0 .1 0
ring groove and piston ring o
o
in
0
o
No. 2 2 .3 5 0 -2 .3 7 5 2 .4 2 5 -2 .4 5 0 -
1

Check point Standard clearance Clearance limit Replace

3 Piston ring gap No. 1 0 .1 3 -0 .3 8 -

No. 2 0 .1 3 -0 .3 8 -

Standard Clearance limit


Clearance between piston pin
4
and piston
0 -0 .0 0 5 -

Clearance between piston -


5 0.038 max
and bushing

Clearance between connecting


6 0 .0 0 5 -0 .0 5 0 -
rod metal and journal

Repair or
7 Crankshaft journal roundness Maximum roundness: 0.0075
replace

Standard clearance Clearance limit

8 Crankshaft end play Replace


0 .1 8 0 -0 .9 5 0 -

Clearance between unloader


9 1.47 - Replace
piston and inlet valve

Connecting rod cap bolt 124 + 9 kg.cm


10 tightening torque
Retighten
Cylinder head bolt
11 125 ± 5 kg.cm
tightening torque

155-4 SERIES 14-043


(D
from the library of Barrington Diesel Club
A IR COMPRESSOR MAINTENANCE STANDARD

A IR C O M P R E S S O R

14-044 155-4 SERIES

from the library of Barrington Diesel Club


MAINTENANCE STANDARD A IR COMPRESSOR

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Repair limit

1 Cylinder I.D Replace


+0.08 crank case
92 -
+0.10

Tolerance
Standard Clearance
Standard
clearance limit
Clearance between Shaft Hole
2 Replace
piston and piston pin
+0.488
17 +0.465 0.010 ~ 0.028 -
+0.475

Clearance between +0.570 +0.663 Replace


3 47 0.042 - 0.113 -
crankshaft and bushing +0.550 +0.612 bushing

Tolerance
Standard Clearance
Standard
interference limit
Shaft Hole Repair or
Crank case and bushing
4 replace
interference
crank case
+0.019 -0 .1 2 9
51 0 .1 0 5 -0 .3 0 5 -
+0.006 -0 .0 8 6

Tolerance
Standard Clearance
Standard
clearance limit
Clearance between crankshaft Shaft Hole
5 Replace
and connecting rod
+0.162 +0.213
49 0.051 - 0.089 -
+0.136 +0.215

Clearance between +0.570 +0.612


6 47 0.042 - 0.089 - Replace
crankshaft and support +0.550 +0.638

Tolerance
Standard Interference
Standard
interference limit
Crankshaft and coupling Shaft Hole
7 Replace
gear interference
+0.489 +0.425
25 0.051 - 0.089 -
+0.476 +0.400

Standard (kg.m) Limit (kg.m)


Cylinder head mounting Retighten
8 bolt tightening torque
3 2 - 3 .5

155-4 SERIES 14-045


®
from the library of Barrington Diesel Club
TO R Q U E S P E C IF IC A T IO N S FOR N U T S AND B O L T S

Nuts and bolts should be tightened to torque values shown below.

Unit: kg.m
Nominal bolt

Width across
flats (mm)
dia. (mm)

k j Q j

Desired value Allowable range

6 10 1.35 1 .2 -1 .5

8 13 3.2 2.8—3.5

10 17 6.7 6 -7 .5

12 19 11.5 10 - 1 2 .5

14 22 18 16 - 2 0 .0

16 24 28.5 25 - 3 1 .5

18 27 39 35 - 4 3 .5

20 30 56 50 - 6 2 .0

22 32 76 6 7 .5 -8 4 .5

24 36 94.5 84 -1 0 5

27 41 135 120 -1 5 0

30 46 175 155 -1 9 5

33 50 225 200 -2 5 0

36 55 280 250 -3 1 0

39 60 335 295 -3 7 0

★ The above table indicates the cases where a torque wrench is employed.

14-046 155-4 SERIES

from the library of Barrington Diesel Club


Engine Serial No. 10011 and up
ENGINE
REPAIR AND
REPLACEMENT

155-4 SERIES 15-001


from the library of Barrington Diesel Club
REPAIR AND REPLACEMENT
CYLINDER HEAD SECTION ................................................ 1 5 -0 0 4
CYLINDER BLOCK SECTION ............................................ 1 5 -0 1 9
PRESS FITTING OF BUSHING .......................................... 1 5 -0 4 6
REPLACING SHRINK-FITTED GEAR .............................. 1 5 -0 4 9
OTHERS ................................................................................ 1 5 -0 5 0

155-4 SERIES 15-003


from the library of Barrington Diesel Club
CYLIN D ER HEAD SECTION REPAIR A N D REPLACEMENT

CYLINDER HEAD SECTION


1. LO CA TIO NS PRO HIBITED FOR
REPAIRING OF CRACKS IN
C Y LIN D E R HEAD
If th e re are any cracks in th e fo llo w in g places, do n ot 2. Repair by w e ld in g
repair. R eplace th e cylinder head. ★ Welding requires specialist knowledge and skill,
1) Inside co m b u stio n c h a m b e r so it should be carried out by an experienced
2) In ta ke or ex h a u st p o rt worker.
3) M a c h in e d m o u n t fa c e A. Repairing by arc w e ld in g
4) M o u n tin g bolt boss area 1) To avoid making blow holes or cracks when
5) N o zzle holder sleeve m o u n t welding, use a furnace or burner to preheat
★ R eplace th e cylin der head if th e crack is the base material of the cylinder head.
m o re th an 2 0 m m long. ★ Preheating temperature for base mate­
rial: 1 50 — 2 00 °C
2. REPAIRING CRACKS IN C YLIN D ER 2) Let the arc play shortly on the bottom of the
HEAD V-groove and weld with the minimum of
★ If th e re is any crac k in th e cylin der head, ch eck weaving.
th e location and size o f th e crack. If it is possible ★ Length of one bead: 15 — 20 mm
to repair,use th e fo llo w in g m e th o d s. ★ After making each bead, peen lightly
remove any bead wave, then remove
1. P ro cedu re b efo re w e ld in g the sludge with a wire brush.
1) C lean th e place to be w e ld e d , and re m o v e all ★ For the next welding, spread the welding
m o istu re and grease. heat so that all of the base material is
2) C arry o u t a co lor c h ec k to co n firm th e co n d i­ the same temperature, then start
tion o f th e crack. welding.
3) T o p rev en t th e c rac k fro m b eco m in g longer,
drill a hole ( $ 3 to (f>5 m m ) a t a poin t 5 to 1 0
W e ld in g rod (arc w e ld in g )
m m fro m th e end o f th e crack.
4) U sing a grinder, grind a V -g ro o v e to rem o ve
Welding rod Welding
th e crack co m p lete ly . Manufacturer Diameter current
(Nickel core)
(mm) (A)
★ A p p ly th e g rin d er lightly to avoid any
c h an g e in th e p ro p e rties o f th e base Kobe Seiko CIA-1 3.2 80 - 130
m aterial caused by th e h e a t pro du ced
Nittetsu Yosetsubo S C - IN 3.2 100 - 140
w h e n grinding.
★ G ro o v e angle: 6 0 ° — 9 0 ° Tokushu Denkyoku SN 3.0 - 3.2 7 0 - 100
★ Radius o f g ro o v e b o tto m : 2 — 3 m m

B. R epairing by p o w d e r w e ld in g
Use oxy-acetylene gas, shoot powder (nickel
Groove angle 60° — 90° powder alloy) with a powder welder, and weld
with the procedure for using a torch.

W e ld in g com pound (p o w d e r w e ld in g )

Manufacturer Welding compound Remarks

Nickel powder alloy


Nihon Yutek
N o .10224

3. C hecking a fte r w e ld in g
A fter completion of welding, cool in air. When
the base material is cool, carry out a color check
and water pressure or air pressure test to confirm
that there are no cracks.

15-004 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR A N D REPLACEMENT CYLINDER HEAD SECTION

3. G R IN D IN G C YLIN D ER HEAD 4. REPAIRING OR REPLACING VALVE


M O U N T IN G FACE SEAT
★ Grind cylinder head to remove deformation
or rust. Do not exceed repair limit of cylinder
Special tools
head height (h).
★ Repair lim it of cylinder head height: Part number Part name Q 'ty
1 5 4 .0 mm
A 7 9 5 -1 0 0 -3 0 0 2 Valve seat cutter 1
★ Amount to rem ove per grinding:
0 .1 0 — 0 .1 5 mm B 7 9 5 -6 0 0 -1 3 1 0 Seat push tool (intake) 1
★ Surface roughness of grinding surface: B 7 9 5 -6 0 0 -1 3 2 0 Seat push tool (exhaust) 1
W ith in 6S
★ Flatness (deformation): W ith in 0 .0 6 mm C 7 9 5 -1 2 5 -1 4 0 0 Caulking tool 1
★ Grinding lim it: 0.3 mm
★ D ifference in head height per unit:
★ If the damage or wear is small, do not replace the
W ith in 0 .1 5
valve seat but repair the seat surface.
When repairing the valve seat, see the diagram
below.

• Intake valve

1. M ach in ing
T h e re are tw o typ es o f cylinder head: one ty p e has a
p re s s -fitte d valve seat; th e o th e r has no valve seat.
1) R em o ve valve seat.
For details, see REPLA C IN G OR G RINDING
VALVE SEAT.
2) M achin e w ith a milling m a ch in e or su rface
grinder.
★ A m o u n t to re m o ve per grinding: • Exhaust valve
0 . 1 0 — 0.1 5 m m
★ Finish so th a t su rface roughness and
flatn ess (d efo rm a tio n ) are w ith in th e
stand ard value.
3) Press fit n ext oversize valve seat.
For details, see REPLA C IN G V A L V E S E A T .

2. C hecking a fte r grinding


1) C heck th a t protrusion d ep th o f valve and
protrusion of n ozzle are w ith in stand ard
value.
★ Protrusion o f v a lv e
S tan dard: 3 .1 5 — 3.41 m m
★ Protrusion o f n ozzle
A llo w e d range: 2.9 — 3 .6 m m

2) If protrusion o f nozzle is n o t w ith in standard


value, replace nozzle holder sleeve.

155-4 SERIES 15-005


from the library of Barrington Diesel Club
CYLIN D ER HEAD SECTION REPAIR A N D REPLACEMENT

C. W elding bar to v alve seat to rem ove


★ If the damage or wear of the valve seat is large, 1) Clean valve seat to remove all oil and water.
and the contact is bad, replace the valve seat as 2) W eld plate (1) to inside of valve seat as
follows. shown in Figure. Plate (1) should be about
10 mm thick and 0.1 to 0.5 mm smaller in
1. C h a m ferin g v a lv e s e a t diameter than the inside diameter of the
A. U sing s eat e x tra c to r valve seat.
Set depth with collar of extractor and fit correctly ★ Be careful not to let any welding material
into valve seat. Pull slide hammer up vertically to stick to the cylinder head itself.
remove valve seat. When firing the arc, avoid using the
S e a t e x tra c to r P a rt N o. S T - 1 1 3 3 (C um m ins matching face of the cylinder head. Use
P a rt No.) the inside face of the intake or exhaust
port.
★ Insert plate (1) inside valve seat (2) and
weld so that it is level with the mounting
surface.
3) W ait for welded part to cool to near room
temperature. Then insert old valve (3) in
reverse direction. Tap valve cup with
hammer to remove valve seat.
★ Be careful not to hit the valve too hard.
The welded part may break off.

2 1 3

B. W h e n using boring m a c h in e
Drill out with vertical boring machine.

6 I2 7 F 2 0 4

\
615F002

15-006 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT CYLINDER HEAD SECTION

2. M ach in ing m ounting hole of v a lv e seat


(oversize)
1) Remove burrs and dirt from mounting hole.
Measure inside diameter and decide dimen­
sions of oversize. (Use next size up.)
2) Cut mounting hole with valve seat cutter A.
★ Use the valve guide to prevent the cutter
from slipping off center.
★ When doing this, measure the inside
diameter of the valve guide. If it is more
than the repair limit + 0 .0 2 mm, replace
the valve guide.
★ For details of the machining procedure,
see the operating instructions for the
cutter. 67 I0 P 2 0 I
3) If the caulked part of the seat is damaged,
first remove a layer of within 0.3 mm. Next,
choose an oversize of hole diameter d 'x (the
next size up from the outsize diameter d x of
the damaged part. Machine as shown in the
diagram.
★ If the damaged part remains even when
the valve seat insertion hole in the cylin­
der head has been machined 1.00 mm,
replace the cylinder head.
★ Use the same oversize dimension for all of
the cylinders.
4) After machining, check the inside diameter
and depth of the machined hole, the concen­
tricity with the inside diameter of the valve
guide and the squareness of the inside face
and bottom of the machined part. They
must all be within the following standards.
Standard va lu e s :
Roughness o f inside su rface:
W ith in 6 .3 S
Roughness a t b o tto m o f m ounting
hole: W ith in 1 2 .5 S
C o n c e n tric ity w ith v a lv e guide
inside su rface: 0 .0 3 m m (TIR)
Squareness o f v a lv e guide
and b o tto m : 0 .0 4 m m (TIR)

155-4 SERIES 15-007


from the library of Barrington Diesel Club
C YLIN D ER HEAD SECTION REPAIR A N D REPLACEMENT

• D im ension s o f valve se at and m o u ntin g hole

6 I2 7 F 2 0 5

• In ta k e valve • E xhaust valve


U n it: mm U nit: mm

Insert Insert mounting hole Insert Insert mounting hole


Stamp on Old! l ip Oil
insert insert
Diameter ( d i ) Height ( h i ) Diameter (ch) Height (h2 ) Diameter ( d i ) Height ( h i ) Diameter (d2 ) Height (h2 )

R7 nn+0.10
S.T.D. 6 0 .0 0 + 9 0 2 0 5 7 .0 0 ^ - 020 9 OO^9-39
600C r a 9 0 0 -S .1 0 9" t S : “ STD- +0.08 9 0 0 -0 .1 0 • +0.10

5 , 25+0.020
0.25 O.S 6 0 -25t a J s e o ^ s 4^ 020 9 .0 0 ^ o 0.25 O.S 57 25+ 9 '^9 9" J ! . 1 0 9 00+9 '39
9 0 0 -S .1 0 +0.08 9 UU 0.10

c n i: n + 0 '1 0 57 SO*9 '^9 6 7 . 5 0 « 020 9 i 2+6-30


0.50 O.S 6 0 .5 0 49-929 9 1 2 +0 10 0.50 O.S 0 0 +0.08 9-12-0 .1 0
60-50+o.08 9 j , 2 - 0 .1 0 ^ " h O.IO

-,K+0.10 6 o .75+ 0 .°20 9 .2 5 ^ 0 0.75 O.S 57 75+ 9 '^9 9 25+0'30


0.7 5 O.S 6 0 .7 5 +q os +0.08 9-29—0.10 5 7 . 7 5 ^ 020 a ^ D+0.10
9 ‘2 9 —0.10

1.00 O.S R1 nn+0.10 6 1 .0049-929


cq nn+0-10 5 8 . 0 0 ^ 020 9 38+9'39
9-38t o i o 100 O.S +0.08 9 -38_o io 9 -3b+0.10
+0.08 9 3 8 -0 .1 0

3. Press fittin g v a lv e s e a t < 3


1) Using push tool B, press fit valve seat (2).
★ The valve seat should correspond in size
to the diameter (oversize) of the mount­
ing hole.
★ Use valve guide (4) as a guide to make
sure that the valve seat is press fitted
straight.
★ Press fit until the valve seat is in close
contact at the bottom (C). Judge if it is
in close contact by the feel of the push
615F004
tool and the sound of the hammer.
2) Check insertion depth of valve seat.
★ If the amount of insertion is not correct,
knock in again, or press fit a new valve
seat.
★ In s ertio n d epth o f v a lv e s e a t:
0 .1 0 — 0 .4 0 m m

4. C aulkin g c irc u m fe re n c e o f v a lv e s e a t
Using caulking tool C, caulk circumference of valve
seat.
★ Certain parts are prohibited from being caulked.
★ If the valve seat is caulked too strongly, the cylin­
der head may be cracked. 615P007

15-008 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AN D REPLACEMENT CYLINDER HEAD SECTION

5. Lapping seat surface


1) Using valve seat cutter A, lap seat surface to
dimensions in diagram on the right.
★ Use the valve guide to prevent the cutter
from slipping o ff center.
★ Choose a pilot which can be inserted in
valve guide without leaving any gap.
★ For details of the machining procedure,
see the operating instructions for the
cutter. 6 I2 7 F 2 0 6
★ Seat angle (a), seat contact width (f)
and the concentricity of the inside
diameter of the seat must be within the
following values.
★ Seat angle Intake: 3 0°
Exhaust: 4 5 °
★ Contact w idth Intake: 1.8 mm
Exhaust: 1.7 mm
★ C oncentricity of valve guide
and valv e seat: 0 .0 5 mm (TIR)
★ Roughness of seat surface: 615F005
W ith in 3.2S

2) Lap seat face with compound.


• Coat the contact surface of the valve with a
mixture of oil and rough abrasive compound,
then lap the valve and seat together.
• When the roughness of the valve seat sur­
face has been removed, wipe off the com­
pound. Then coat again with a fine com­
pound. Lap the surfaces together until they
fit perfectly.

6. Final inspection
1) Check that protrusion or insertion depth of
valve is within standard value for new valve.
2) Check that contact width of valve is within
standard value.
★ Standard protrusion of valve
(new part): 3 .1 5 — 3 .4 1 m m
★ Standard contact w idth
Intake: 1.8 — 2 .0 mm
Exhaust: 1.7 — 2 .0 mm

155-4 SERIES 15-009


from the library of Barrington Diesel Club
C YLIN D ER HEAD SECTION REPAIR A N D REPLACEMENT

5. REPLACING NOZZLE HOLDER


SLEEVE

Special tools

Part number Part name Q 'ty

A 7 9 5 -6 0 0 -1 1 8 0 Push bar 1

B 7 9 5 -6 0 0 -1 1 9 0 Push bar 1

C 7 9 5 -6 0 0 -1 1 1 1 Bead cutter 1

D 7 9 5 -6 0 0 -1 1 2 0 Sleeve driver 1

E 7 9 5 -6 0 0 -1 1 3 0 Sleeve punch 1

F 7 9 5 -6 0 0 -1 3 0 0 Sleeve holder 1

G 7 9 5 -6 0 0 -1 1 4 0 Punch bushing 1

H 7 9 5 -6 0 0 -1 1 50 Sleeve expander 1

I 7 9 5 -6 0 0 -1 1 6 0 Sleeve cutter 1

J 7 9 5 -6 0 0 -1 1 7 0 Guide bushing 1

★ When replacing the nozzle holder sleeve (if the


protrusion of the nozzle is not within the stan­
dard value, or there is leakage of water from the
sleeve seat face), replace as follows.

1. Removing sleeve
1) Insert push bar A inside sleeve (1).
2) Using sleeve extraction tap ® , cut tap to
about 25 mm from top face of sleeve. Add
oil while cutting.

x . x Pitch: 1.5 mm
★ Extraction tap: . x, , , -
Length: 3 0 mm

3) Insert push bar A from bottom of head, and


tap with hammer to remove sleeve.
★ Be careful not to damage the cylinder head.
4) Clean sleeve seat face to remove all dirt, oil
and grease.

615F009

15-010 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR A N D REPLACEMENT CYLINDER HEAD SECTION

2. M ach in in g g ro ove in s le e v e s e a t fa c e
If the groove in the seat face is damaged, ma­
chine the groove using bead cutter C.

C onditions:
★ C u ttin g speed: M a x . 5 0 rpm
if C u ttin g am o u nt: M a x . 0 .2 5 m m

★ For details of machining dimensions, see the


diagram on the right.

★ After cutting, remove all chips, dust, oil and


grease.

6 I2 7 F 2 0 8

3. Press fittin g s le e v e
Using sleeve driver D, tap until sleeve (1) reaches
seat face.
★ Do not put adhesive on the seat face.

6 I2 7 F 2 0 9

155-4 SERIES 15-011


from the library of Barrington Diesel Club
C YLIN D ER HEAD SECTION REPAIR A N D REPLACEMENT

4. Caulking sleeve seat face


1) Put sleeve holder F in cylinder head, then
tighten nut (D to put sleeve holder F in close
contact with seat face.
®35E3 Sleeve holder: 2 kgm
2) Fit punch bushing G and insert sleeve punch

3) Place support(3)under cylinder head to allow


bolt of sleeve holder to move out.
★ Make the space for bolt as narrow as
possible.
4) Drop 3 0 kg. weight (4) from a height of 3 0 0
mm on to the top of the sleeve punch E.
★ Drop the weight once only.
★ Weight: Copper bar (0 1 0 0 x 5 0 0 mm
[approx. 3 0 kg.])
5) Remove sleeve punch E and punch bushing
G.

6 I2 7 F 2 1 0

5. Caulking upper part of sleeve


Install sleeve expander I on a radial drilling ma­
chine or upright drilling machine, and caulk upper
part of sleeve.
1) Check bolt (2) of sleeve holder F is not loose.
Tighten if loose.
®ZHEZl Sleeve holder: 2 kgm
2) Raise sleeve expander I, and inset roller (5)
inside sleeve.
3) Push casing in to expand roller (5) and put in
close contact with sleeve.
4) Using sleeve expander, roll clockwise to
caulk sleeve.
★ Rotation speed: 4 5 0 rpm
★ inside diam eter: 2 9
+ 0.20
★ Roller insertion (h): 3 2 mm
★ A djust inside diam eter w ith stopper
(4) and set in position.
5) Remove sleeve holder F.

15-012 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR A N D REPLACEMENT CYLINDER HEAD SECTION

6. C uttin g s e a t inside s le e v e
1) Using guide bushing J as a guide, cut seat
with sleeve cutter I.
★ When cutting the seat, insert the nozzle
holder, and cut the seat gradually while
checking the protrusion of the nozzle.
★ R o tatio n speed: 7 0 0 rpm
★ Protrusion o f n o z z le :
S tan dard: 2 .9 — 3 .6 m m
2) Completely remove all chips and metal dust
from machined surface.

7. C hecking fo r le a k a g e fro m s e a t s u rfa c e


After sealant dries (hardens), check for leakage
from seat surface using water pressure or air
pressure test.

6 I2 7 F 2 I 2

155-4 SERIES 15-013


from the library of Barrington Diesel Club
CYLIN D ER HEAD SECTION REPAIR A N D REPLACEMENT

6. REPAIRING WATER LEAKAGE FROM


PLUG
★ If there is any water leakage from the plug, repair
with Roy.
★ If the plug is corroded, or deformed and leaking,
replace the plug.

C O R R E C T IN G B E A D IN G OF ROY O N PLUG
1) Clean part to be corrected with a cleaning
solvent.
★ If there is any paint stuck to that part
and it cannot be removed with the sol­
vent, remove it with a wire brush. Then
clean the part to be corrected.
2) Mix the Three Roy thoroughly.
★ Mix the main agent and the hardener in a
ratio of 10 : 1.
★ Use the Three Roy within 4 0 minutes
after mixing.
3) Fill area (a) around body (1) and plug (2) with
Three Roy as shown in diagram on the right.
★ H ardening tim e : A p p ro x . 24 hours
(18 - 2 0 °C )
★ The Three Roy will not harden at tem ­
peratures below 5°C, so heat with a
drier at 8 0 to 10 0 °C for 3 0 minutes to 1
hour.
★ Be careful not to apply any vibration
until the Roy has hardened.

R E P L A C IN G PLUG
1) Set grip and plate of push tool in position.
2) Put plate in contact with plug, then tap
center.
3) Hit around plug at edge of plate as when
caulking. (Flat plug)
4) Tap center of plug again.

Part numbers for push tool kit

Applicable Applicable
Part No. Part name Plug O.D. Part No. Part name Plug O.D.
plug plug
790-101-5821 Grip - - 795-100-2710 Plate 07046-13520 0 35

795-100-2620 Plate 07046-11216 012 795-100-2720 Plate 07046-14020 040

795-100-2630 Plate 07046-11516 015 795-100-2730 Plate 07046-14520 045

795-100-2650 Plate 07046-12016 020 795-100-2740 Plate 07046-15020 050

795-100-2660 Plate 07046-12220 0 22 795-100-2750 Plate 07046-15520 055

795-100-2670 Plate 07046-12520 025 795-100-2760 Plate 07046-16020 060

795-100-2690 Plate 07046-13020 030 795-100-2790 Case - -

15-014 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT CYLINDER HEAD SECTION

Replacing plug in cylinder head


Method for replacing plate plug w ith U-plug.
★ The cylinder head plug has been changed from a ★ Replace plugs as follows.
plate plug to an U-shaped plug for the following
serial numbers. Plate plug -* U-plug
S 6 D 15 5-4: Engine No. 3 2 2 3 6 and up
07046-13020 6710-11-1431
S A 6 D 1 5 5-4: Engine No. 3 2 6 9 4 and up (0A = 30.000 - 30.085) (0A = 31.800 - 3 1 .8 7 5 )
e If the plate plug leaks water and is replaced with
07046-12520 6710-11-1421
an U-plug, use the following method. (<t>A = 25.000 - 25.085) (0 A = 25.450 - 25.525)
1) Remove plate plug.
2) Machine plug hole with reamer as shown in Machining
diagram. depth
10— 12 Adhesive compound
★ Remove burrs from plug hole. Locktite No. 6 0 1 1
★ Clean inside of cylinder head thoroughly
to remove all metal chips.
3) Coat mounting hole of U-plug with adhesive
compound (Locktite No. 6 01 ).
4) Using a plug driver (see figure on right),
knock in U-plug.
Plate plug Cut with end mill, etc. U-plug
★ Be careful not to bend the plug.
r - . 'i "TWt,' CjM 6 127F255
5) Using water pressure test (4 kg/cm 2), check
Dimensions of plug driver (mm)
that there is no leakage.
0. 1
Op
roj
Replacing rocker arm housing plug -O-L
110
8 1h 6 I2 7 F 2 5 6
Special tool
Part No. 0D 0d h
Part number Part name Q ty
, —6710+ + -1431 31.6 28.8 6
A 7 9 5 -1 0 0 -1 3 2 0 Plug driver 1 n r j r - i c T , - ) Y ^ -d
^ 0710-1 M 4 2 T 25.2 22.4 5
A 7 9 5 -1 0 0 -1 3 2 1 Plug driver

Applicable engines (Serial No.)

Engine 795-100-1320 795-100-1321

S4D155-4 10287 - 50198 50199 and up

S6D155-4 (D150A) 10011 - 20598 20599 and up

SA6D155-4 - 20338 and up

• Put the plug driver in contact with the plug and


tap with a hammer.

6 127P202

155-4 SERIES 15-015


from the library of Barrington Diesel Club
C YLIN D ER HEAD SECTION REPAIR A N D REPLACEMENT

7. REPLACING VA LVE G UIDE

Special tools

Part number Part name Q 'ty

A 7 9 5 -1 0 0 -2 1 0 0 Valve guide remover 1

B 7 9 5 -1 0 0 -1 2 4 0 Valve guide driver 1

1. Removing valv e guide


1) Put valve guide remover A in contact with
valve guide at bottom of cylinder head. Then
tap with hammer to remove valve guide.
2) Remove burrs from valve guide hole, then
clean hole.

6127P203

2. Press fittin g valv e guide


1) Insert valve guide in cylinder head, then set
valve guide driver B in position.
2) Press fit valve guide until tip of valve guide
driver B contacts cylinder head.
3) Measure protrusion of valve guide and check
that it is within standard range.
★ V a lv e guide protrusion
Tolerance: 2 0 ± 0 .5 0 mm

6 I2 7 P 2 0 4

3. Reaming inside diam eter


If the supplied valve guide is semi-machined,
finish inside diameter d by reaming.
★ Valve guide inside diameter: See shop
manual for each series
★ Do not ream the inside diameter of any
valve guide which has had any surface
treatment such as tuftriding.

615F018

15-016 155-4 SERIES


(D
from the library of Barrington Diesel Club
REPAIR AND REPLACEMENT CYLINDER HEAD SECTION

8. REPLACING CROSSHEAD G UIDE

Special tools

Part number Part name Q 'ty

A 7 9 5 -1 0 0 -1 3 4 0 Crosshead guide driver 1

B 7 9 5 -1 3 0 -3 3 0 0 Crosshead guide puller 1

1. Removing crosshead guide


Using crosshead guide puller B, remove cross­
head guide.
1) Hold crosshead guide with collet (5) of puller
as shown in diagram.
2 ) Tighten bolt © .
★ The crosshead guide is tightened by
collet (D.
Turn nut (3) and remove crosshead guide.
Remove burrs from crosshead guide hole,
then clean hole.

1. Nut
2. Sleeve
3. Nut
4. Bearing
5. Collet
6. Block

2. Press fitting crosshead guide


1) Insert crosshead guide in cylinder head, then
set crosshead guide driver A in position.
2) Press fit crosshead guide until tip of cross­
head guide puller B contacts cylinder head.
3) Measure protrusion of crosshead guide and
check that it is within standard range.
★ Crosshead guide protrusion
Tolerance: 5 3 ± 0 .2 0 mm

155-4 SERIES 15-017


from the library of Barrington Diesel Club
C YLIN D ER HEAD SECTION REPAIR A N D REPLACEMENT

9. CORRECTING VA LVE

Special tool

Part number Part name Q 'ty

A Commercially Valve refacter 1


available

★ If there are any dents or damage to the seat face


of the valve, grind the surface as follows. Do not
grind the valve head beyond the repair limit for
the thickness.

1. G rinding s e a t fa c e
Grind seat face aligning the valve seat angle with
valve rafacer A.
★ V a lv e s e a t an gle In ta k e v a lv e : 3 0 °
E x h a u s t v a lv e : 4 5 °

2. C hecking a fte r grinding


1) Measure thickness of valve head, to check
that it is within the standard range.
★ If it is impossible to correct the dents or
damage without going beyond the
repair limit for the thickness, replace the
valve.
★ Thickness of valve head
Repair limit: 1.0 mm
2) Assemble valve in cylinder head, then check
that insertion depth (or protrusion) is within
standard value.
★ Protrusion of valve Repair limit: 1.6 mm
★ If the insertion depth (or protrusion) is
not within the standard value, replace
the valve.
3) Check that contact width of valve is within
standard value.
★ Contact width of valve
Standard Intake valve: 1.8 — 2.0
mm
Exhaust valve: 1.7 — 2.0
mm

15-018 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR A ND REPLACEMENT CYLINDER BLOCK SECTION

CYLINDER BLOCK SECTION

1. LO CATIO NS PROHIBITED FOR 2. REPAIRING CRACKS IN C Y LIN D E R


REPAIRING OF CRACKS IN BLOCK
CYLINDER HEAD ★ If there is any crack in the cylinder block, check
If th ere are any cracks in th e fo llo w in g places, do the location and size of the crack. If it is possible
not repair. R eplace th e cylin der block. to repair, use the following methods.
1) Places requiring stren g th ★ Carry out a color check before repairing to con­
• C ylin der head m o u n t firm the condition of the crack.
• Boss fo r cylin der head m o u ntin g bolts
• P re s s -fittin g area fo r cylin der liner 1. If c ra c k is sm all.
• M a in bearing m o u n t 1) Remove crack with drill.
• M ain bearing cap m o u n t, b olt boss area ★ Carry out a color check to confirm that
• P re s s -fittin g area fo r ca m bushing the crack has been completely removed.
• P re s s -fittin g area fo r b alan cer bushing 2) Make tap.
2) Places w ith co m p lex structure 3) Coat blind plug with screw seal (Locktite)
• Oil line boss and screw in.
• O -rin g insertion area
• W a ll o f w a te r ja c k e t w h e re th e re is risk 2. If c ra c k is large.
o f oil and w e a r mixing Follow the procedure for repairing the cylinder
• R eplace th e cylin der head if th e crac k is head.
m o re th an 2 0 m m long.
3. C hecks a fte r co rre c tin g c rack
★ Carry out a color check and water pressure
check to confirm that there is no leakage.
e Carry out a test run and check that there is no
leakage or oozing from the repaired point,
e Make a note of the location of the repair for
reference for future repairs.

155-4 SERIES 15-019


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

3. CORRECTING TOP FACE OF


C Y LIN D E R BLOCK
Grind top face of cylinder block to remove distor­
tion or corrosion. Do not grind beyond repair limit
of cylinder block height (h).
★ H e ig h t o f c y lin d e r blo ck:
R epair lim it: 4 9 4 .8 0 m m

1. Grinding
Machine with a milling machine or surface
grinder.
★ Amount to remove at each grinding:
0 .0 3 — 0 .0 8 mm
★ Finish so that the surface roughness and flat­
ness (deformation) are within the standard
value.
★ S u rfa c e roughness o f m ach in ed
su rfa c e : W ith in 6 .3 S
★ F latn ess (d istortio n ) stan d ard :
W ith in 0 .0 9 m m
★ W h e n grinding w ith an o ils to n e
★ O ils to n e speed: 1 6 5 0 — 1 9 5 0 m /m in .
★ T a b le speed: 1 5 — 3 0 m /m in . 6 I2 7 F 2 I 3
★ A m o u n t to re m o v e a t e ach g rin d in g :
0 .0 2 5 m m
★ C ro ssfeed fo r each grinding:
1 — 2 mm
★ O ilsto n e : A 4 6 IV
★ Grinding liquid: W a te r so lu b le

2. C hecking a fte r grinding


• Insert cylinder liner.
• Measure protrusion of cylinder liner and correct
counterbore if protrusion is not within permitted
range.
★ Protrusion o f c y lin d e r lin er
P e rm itte d range: 0 .1 0 — 0 .1 6 m m
V a ria tio n b e tw e e n c y lin d e rs :
W ith in 0 .0 5 m m
★ For details, see CORRECTING
CYLINDER BLOCK COUNTERBORE.

15-020 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT CYLINDER BLOCK SECTION

4. CORRECTING C Y LIN D E R BLOCK


COUNTERBORE
★ When machining the top face of the cylinder
block, if there is any damage or burr in the coun­
terbore, or the protrusion of the liner is not
within the standard value, repair the cylinder
block counterbore with a counterbore tool.

Special tools

Part number Part name Q 'ty

A 7 9 5 -2 2 5 -2 0 0 0 Counterbore tool 1

B 7 9 5 -2 2 5 -2 4 0 0 Counterbore gauge 1

Cylinder block Cylinder block


Engine Dimension D Engine Dimension d (mm)
part number part number
6124-21-1113 181 6124-21-1113 too c 0.02
18 3 .5 _ 0 07
S6D155-4 S4D155-4
6124-21-1114 and up 184 6124-21-1114 and up 1 at; a-J0.02
185,5- 0 .0 7
1QO c -0 .0 2
S6D155-4 6127-21-1113 to 1116 181 S6D155-4 6127-21-1113 to 1116 18 3 .5 _ 0 07
„ c -0 .0 2
SA 6D 155-4 6127-21-1117 and up 184 SA 6D 155-4 6127-21-1117 and up 1 8 5.5_0 07

155-4 SERIES 15-021


from the library of Barrington Diesel Club
CYLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

Presetting cutter
1) Set cutter in cutter plate (2).
★ Set the cutter so that the tip of the
cutter does not protrude beyond the out­
side diameter of the cutter plate.
★ Be careful not to set the cutter with the
edge facing in the wrong direction.

6127P207

2) Set cutter setting gauge (Qj) on cutter plate.


Set so that the inside diameter of the cutter
plate contacts the dowel pin of the gauge,
and the outside diameter of the cutter plate
contacts the probe of the gauge.
3) In this position, set scale of cutter setting
gauge to "0"
4) Following step 2), set so that probe of dial
gauge contacts tip of cutter.

6 I2 7 P 2 0 8

5) Screw in adjustment screw (Q) installed at


rear of cutter until scale of dial gauge
reaches "0".

6 I2 7 P 2 0 9

6) Tighten cutter clamp bolt © at rear of


cutter plate.
7) Put dial gauge in contact with tip of cutter
and check that dial gauge reading is "0".

6 I2 7 P 2 1 0

15-022 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT CYLINDER BLOCK SECTION

2. A ssem b lin g c o u n te rb o re to o l
1) Clean fitting of counterbore tool A and
cutter plate (2), then coat with oil.
2) Rotate shaft so that key (D of shaft and
groove of counterbore tool are at 180 °
angle.
3) Align key of shaft and groove of cutter plate,
then insert cutter plate.

6 I2 7 P 2 I I

4) Insert flat washer @ , then tighten set bolt


of cutter plate.

3. A ctio n b e fo re m achining
1) Clean top face of cylinder block, inside of
counterbore and pilot bore, and remove all
carbon and scale.
2) Polish top face of cylinder block with oil­
stone and remove all burrs and scratches.
★ Be particularly careful with the counter­
bore mount.
3) Polish counterbore area with sandpaper, and
remove all burrs and scratches.
★ Sandpaper: No. 8 0 — No. 100
★ This face is the datum plane for machin­
ing, so polish carefully.

155-4 SERIES 15-023


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

In s ta llin g co u n te rb o re tool
1) Loosen cutter plate holding screw (5) and
pull up handle (8) until tool holder (2) is held
by counterbore tool ( D .
★ Move the handle to the left and right
when pulling up to align groove (a) of the
tool with projection (b) of the cutter
plate.
2) Tighten cutter plate holding screw with
cutter plate to hold cutter plate in base.
★ By doing this, the cutter plate is fixed in
position, and the cutter is protected.
3) Align cutter plate with liner mounting hole in
cylinder block, and mount counterbore tool
on top face of cylinder block.
★ Be careful not to damage pilot bore.
★ Use a cloth to clean the surface of the
tool in contact with the cylinder block.
4) Using mounting bolt hole (for mounting
cylinder head on block), base tighten set
screw (7) of counterbore tool by hand, and
fix in position.
★ If the set screw is tightened too much, it
may be impossible to set the cutter plate
in position.
5) Grip handle (D, lift up slightly and release
cutter plate holding screw (5).
6) Lower cutter plate slowly into counterbore.
7) Insert large diameter side of cutter plate into
counterbore, and bring tool into contact with
shoulder of counterbore.
★ Insert the tool slowly to prevent the tool
from damaging the counterbore.

8) Tighten base set screw (7) more.

15-024 155-4 SERIES


<D
from the library of Barrington Diesel Club
REPAIR AND REPLACEM ENT CYLINDER BLOCK SECTION

6 I2 7 P 2 I 6

2) Check that there is no dirt or damage in the


counterbore gauge mounting holes.
3) Insert counterbore gauge B in holes (4
places) for measuring depth of counterbore
tool, and read measurement.
4) Measure depth at four places, and take aver­
age value.
★ Machine the difference between the
measured dimension (average value)
and the finished dimension (14.5m m ).

6. C utting
1) Prepare feeler gauge of same thickness as
amount to cut from counterbore.
2) Insert the feeler gauge between depth set
collar (4) and guide collar (3) of counterbore
tool.
★ Check that there is no dirt between the
guide collar and the set screw © .
3) Tighten depth set screw until feeler gauge is
a sliding fit.
4) Insert feeler gauge at several places around
circumference of guide collar to check that
clearance is the same.
★ If the clearance is not the same, repeat
from step 3).
★ Step 4) sets the amount of cutting of
the counterbore depth.
5) Tighten depth set screw © to fix depth set
collar © securely in position.
★ Tighten with the feeler gauge still
installed.

155-4 SERIES 15-025


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

6) Remove feeler gauge.


7) Turn handle (8) clockwise, then cut
counterbore.
★ Do not turn the handle counterclockwise.
This will damage the cutter.
8) After cuttingresistance is reduced, turn
handle three more turns.
9) Check visually that there is no clearance be­
tween guide collar (3) and depth set collar

10) Measure depth of counterbore with counter­


bore gauge B, and check that it is within the
standard dimension for machining.
★ For details, see DEPTH OF
COUNTERBORE.
★ Standard dimension for counterbore
dePth: 14 io:o5>m

11) Loosen cutter plate holding screw (§), and


raise handle (8) until cutter plate (2) is held in
base of counterbore tool.
★ Tighten cutter plate holding screw (5)
and check that the cutter plate is fixed in
position.
12) Loosen base set screw of counterbore tool
and cut next cylinder in the same way.
★ When machining the other cylinder, there is
no need to adjust the amount of cut again.
Machining can be performed with the coun­
terbore tool at the same setting.
However, check carefully that the counter­
bore depth is within the standard dimension.
★ After using the tool, coat the gap between
depth set collar (4) and guide collar (3) with
grease to prevent rust.
★ When storing the tools, take action to pro­
tect the machining datum plane and gauges
from rust.
★ Do not sharpen the tool in a place not
equipped with grinding facilities.

6 I2 7 P 2 2 0

15-026 155-4 SERIES


d>
from the library of Barrington Diesel Club
REPAIR A N D REPLACEMENT CYLINDER BLOCK SECTION

7. A ctio n a fte r c u ttin g


1) S e t c h a m fe rin g to ol (0) on c o u n te rb o re,
and tu rn tw o or th re e tim e s to c h a m fe r th e
edge.
2) Polish e d g e and shoulder o f co u n te rb o re
w ith sa n d p ap er to re m o ve burrs.
3) Polish to p fa c e o f cylin der blo ck w ith o il­
stone to re m o v e burrs.

6 I2 7 P 2 2 I

155-4 SERIES 15-027


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

5. CORRECTING SLEEVE OF C Y LIN D E R


BLOCK LINER O -RING

S p e c ia l to o ls

P art num ber P art n am e Q 't y

A 7 9 5 -2 2 5 -3 0 0 0 Boring c u tte r to ol 1

B 7 9 5 -2 2 5 -2 5 0 0 Slip push to ol 1

★ D im e n s io n o f sleeve a fte r co rrectin g

Pilot bore B Reference surface A

★ C o rre c tio n sleeve p a rt no.: 6 1 2 7 - 2 9 - 1 1 2 0

15-028 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT _____________________________________________ CYLINDER BLOCK SECTION

1. S e ttin g boring b it
1) S ettin g b it fo r co rrec tin g bore
i) S e t to ol set g au g e on m aster, th en set
scale o f dial g au g e to " 0 " .
ii) S e t to ol set g au g e on b it h old er (2), th en
s c re w in a d ju s tm e n t n ut o f EZ set (Q)
until dial g au g e scale is a t " 0 " .
★ For rough cu ttin g , se t th e scale o f
th e dial g au g e to — 0 .2 5 m m .
2) S ettin g b it fo r co rrectin g c h a m fe r
i) S e t to ol set g au g e on b it h old er (2).
ii) S c re w in a d ju s tm e n t b o lt a t rear tip o f
to ol until cu ttin g ed g e o f to o l c o n tacts
set gauge.
iii) T ig h te n to ol cla m p bolt.

2. A sse m b ly o f boring b it
1) Clean fittin g o f boring b it and bit holder.
2) Fit c u tter plate on boring b it and tig h ten fo u r
set screw s.

3. A ctio n b efo re m achining


1) Clean to p fa c e o f cylin der blo ck and c o u n te r­
bore and re m o v e all carb on and scale.
2) Polish to p fa c e o f cylin der block and re m o ve
all burrs and scratches.
★ Be p articularly ca re fu l to polish th e
boring to ol m o u nt.
3) Polish pilot bore and liner O -rin g bore w ith
sandpaper and re m o v e all burrs and
scratches.
★ S an d paper: No. 8 0 — No. 1 0 0

155-4 SERIES 15-029


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

4. In stallin g boring to o l
1) Loosen lock b olt (D and lock n ut ( D , and
ad just w ith m ach ining d ep th ad ju s tm e n t
s c re w ® to dim en sion "a ".
★ M a c h in in g d e p th "a ": 2 8 6 ° mm
—0.5

★ C h e c k th a t th e c o n ta c t fa c e s o f th e a d ­
ju s tm e n t s c re w and bearing (D are in
close c o n ta c t and are n o t dirty.
2) Install boring to ol on radial drilling m achine.

/f\ Insert sto p p e r (9) in th e oblo ng hole to


p re v e n t th e to o l fro m falling.

3) P u t parallel stand (0) on tab le o f radial drill­


ing m ach ine.
4) Raise cylin d er block, se t on radial drilling m a ­
chine and tig h te n clam ps.
★ W ip e th e su rfa c e o f th e cylin der block
m o u n tin g th e oil pan w ith a cloth.
5) P u t a d a p te r plate (3) o f boring to ol in c o n ta c t
w ith sto p p e r (9).
6) Insert boring to o l inside cylin der block. 6 I2 7 F 2 2 2
7) Insert boring to o l until a d a p te r p late (3) can
be set on to p fa c e o f cylin der block.
8) Insert a d a p te r p la te inside pilo t bore, and
tig h te n cla m p b olt ® to hold in position.
★ W ip e ca re fu lly w ith a clo th to m a k e sure
th a t th e re is no d irt b e tw e e n th e a d a p te r
plate and th e cylin der block.

15-030 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT CYLINDER BLOCK SECTION

5. Cutting (primary machining)


1) P erfo rm rough finishing u nd er th e fo llo w in g 1 _ 0
conditions.
★ D ia m e te r o f m ach in ed hole:
1 8 0 .5 ± 0 . 1 m m
★ C u ttin g speed: 1 0 3 rpm
★ Feed: 0 .0 9 m m /re v (m anual fe e d )
★ C u ttin g flu id : D ry
2) R em o ve clam p bolt 0 and pull o u t boring
tool.
★ Be carefu l n o t to d a m a g e th e tip o f th e
to ol bit.
3) S e t m achining d ep th g au g e (Q) in position,
and m easure protrusion fro m to p fa c e o f
cylinder block to c h ec k finishing allow an ce.
★ Finishing allo w an c e: 0 . 5 0 m m
4) R epeat fro m step 4 - 5 ) to finish rem aining
cylinders.

6. C utting (final m achining)


1) S e t bit to final m ach ining d im ension as in
step 1 -1 ).
2) S e t to ol as in steps 4 - 5 ) to 8).
3) T o adjust final m ach ining dim en sion , loosen
lock b olt (6) and lock n ut (5).
4) S e t dial g au ge on to p fa c e o f a d ju s tm e n t
screw (7).
5) Turn b ack a d ju s tm e n t s c re w (7) until finish ­
ing allo w an c e m easured in step 5 -3 ) is
reached.
6) T ig h ten lock n ut (5) and lock b olt (6).
7) P erform lapping u nd er th e fo llo w in g
conditions.
★ D ia m e te r o f m ach in ed hole:
1 81 + ?°®mm
+ 0.02
★ C uttin g speed: 1 4 2 rpm
if Feed: 0 .0 4 — 0 .0 6 m m /re v . (m anual
feed )
8) R em o ve clam p b olt 0 and pull o u t boring
tool.
★ Be carefu l n o t to d a m a g e th e tip o f the
to ol bit.

155-4 SERIES 15-031


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

9) Set machining depth gauge in position, and


measure protrusion from top face of cylinder
block to check that it is within standard
value.
★ Machining depth: 2 8 6 _ ° Q5 mm

10) Machine remaining cylinders in the same


way.

7. P ress fittin g s le e v e
1) Polish machined edge of 0-ring bore with
sandpaper to remove wire edge.
★ Sandpaper: No. 8 0 — No. 1 0 0
2) Push part of sleeve (marked with arrow) in
by hand to insert inside cylinder block.
3) Set outside chamfered edge of sleeve at
bottom and set on O-ring bore.
4) Coat O-ring bore with adhesive.
/C k Adhesive: Locktite No. 5 4
5) Using sleeve push tool as in diagram, press
fit sleeve.
★ To press fit, tap the push tool in slowly
until change of sound indicates that the
tool is in contact with the O-ring bore.
6) Leave for twenty-four hours to cure
adhesive.

8. C h eckin g a fte r c o rre c tin g s le e v e


1) Check press-fitting depth and inside diame­
ter of sleeve.
2) Measure protrusion of liner to check that it is
within standard value.
★ Protrusion of liner
Permitted range: 0 .1 0 — 0 .1 6 mm
3) Carry out water pressure test to check that
there is no leakage from any point.
★ W ater pressure: 10 kg/cm 2 for at least
10 minutes.

15-032 155-4 SERIES


<D
from the library of Barrington Diesel Club
REPAIR AND REPLACEMENT CYLINDER BLOCK SECTION

6. REPAIRING W A T E R LEAKAGE PLUG


★ If there is any leakage of water from the plug, 4) If there is no dowel hole, machine width of
build up surface with Roy. bearing cap to make it level with thrust face
★ If the plug is corroded, or leaking because of of cylinder block. Then drill dowel hole.
deformation, replace the plug. ★ To decide the position of the dowel hole,
coat the mounting face of the cylinder
7. REPLACING M A IN BEARING CAP block bearing cap with red lead. Then
★ If the main bearing cap is damaged or needs to assemble the cap so that the mark of the
be replaced, replace as follows. dowel hole is made on the cap.
★ The main bearing cap is supplied as a semi­
machined part.
See the Parts Book for details of the part number
for the main bearing cap.

1. Machining main bearing cap bore


1) Remove cylinder liner.
2) Install main bearing cap (semi-machined) on
cylinder block and tighten it to the specified
torque.
IE] Mounting bolt of main bearing cap

Unit: kgm

Step Target Range


A. Machining with horizontal boring machine
1st time 31 30-32 i) Install cylinder block jig (1) on table of
horizontal boring machine.
2nd time 61 60-62
ii) Fit standard block (3) in contact with
3rd time 0 Loosen fully standard pivot (2) of jig. Put dial gauge
(4) in contact with block (3) at right
4th time 15.5 15 - 16
angles, then move in direction of arrow
5th time 29 28 - 30 to center jig.
6th time 52 50-54

7th time 74 70 - 78

★ Align notch of cap with notch of cylinder


block.
3) Surface (A) of main bearing cap is semi­
machined, so if it does not fit on cylinder
block, machine surface (A).
★ When machining surface (A), remove
the same amount from botn sides for
each time of cutting, and machine to
within the interference allowance for the
cylinder block.

155-4 SERIES 15-033


from the library of Barrington Diesel Club
CYLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

iii) S e t cylin d er b lo ck w ith to p fa c e fac in g


d o w n . Fit cylin d er liner m o u ntin g hole on
sta n d ard pivot. S e t cylin der b lo ck on
ta b le o f h orizo n tal boring m achine.
iv) P u t dial g au g e (installed on arb o r (5)) in
c o n ta c t w ith inside d ia m e te r of tw o
p laces w h ic h w ill be th e lo n g est pitch o f
th e m ain bearing caps to be reused, and
c e n te r m ain bearing m o u n tin g holes.
T h e n fix in position w ith cylin der block.
★ S u rfa c e roughness: W ith in 3 .3 S

6 127F228

B. M ac h in in g w ith ream in g bar


★ T h e ream in g b ar is a special to o l and is
n o t availab le fo r all engines.
i) Insert ream in g b ar in cylin der block. U se
tw o good cap holes behind b ar as
g uides.
ii) C o a t re a m e r c u tte r and m ain bearing
hole w ith oil. T u rn re a m e r w ith hand
driven to finish.
★ U s e th e re a m e r on all cap holes.

V r "1 615P023

15-034 155-4 SERIES


<3>
from the library of Barrington Diesel Club
REPAIR A ND REPLACEMENT CYLINDER BLOCK SECTION

C. M achin in g w ith boring to o l


★ T h e ream in g b ar is a speical to o l and is
n o t available fo r all engines.

5) C h eck th a t radial ru n ou t (m ain bore m isalig n ­


m ent) of m ain bearing m o u ntin g hole is
w ith in repair lim it.
6) M ea su re inside d ia m e te r o f m ain bearing
m ou ntin g hole and c h e c k th a t it is w ith in th e
repair lim it.

2. M ac h in in g w id th o f m ain b earin g cap


1) Insert ca st iron bushing (6) su p po rtin g arb o r
into m ain bearing cap and pass arb o r (7)
th ro ug h it.
2) Install fac in g to ol (8) on arb o r (7)
C ut m ain bearing cap (9) until arb o r fac in g
bit reaches bearing c o n ta c t fa c e o f cylinder
block side.
3) C u t th e o th e r side o f th e cap in th e sam e
w ay.
★ W id th o f m ain cap T o leran ce:

8 1 +0.035 m m
★ R oughness o f th ru s t bearing m o u ntin g
su rface: W ith in 1 2 .5 S
★ N e v e r c u t cylin der block side.

155-4 SERIES 15-035


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

8 . GRINDING CRANKSHAFT
W h e n co rrectin g w e a r,s lig h t seizure o r d a m a g e ★ W h e n co rrectin g th e cran ks h a ft, pay particular
to th e cra n k s h a ft, grind to o ne o f th e n ext u n d er­ atte n tio n w h e n finishing fille t R, shoulder r and
size dim ensions. area R around hole.
U n d ersize d im en sion s: • Finishing dim ensions o f fille t (corner w eld)
0 .2 5 , 0 .5 0 , 0 . 7 5 , 1 . 0 0 m m
★ If th e c ra n k s h a ft is bent, it is b e tte r to replace
th e c ra n k s h a ft instead o f co rrectin g it.
R : 6 + o '5 '
★ D o n o t try to c o rre c t a b en t c ra k s h a ft w ith a
press. W h e n th e en g in e is run, th e c ra n k s h a ft 6.4mm
w ill g rad u ally return to its b en t shape.
★ T h e jou rn al area has been g iven induction
hardening, so do n o t try to repair by bead
w eld in g o r plating.
★ U n ev en ly w o rn c ra n k s h a fts w ill bend or be
u nb alan ced even if repaired , so alw a y s re­
place unevenly w o rn cran ks h a fts.
★ M e a s u re th e p art fo r grinding to d ecid e th e
6 I2 7 F 2 3 I
undersize dim en sion .
★ If the u nd ersize d im en sion is n o t w ith in th e
repair lim it, rep lace th e cra n k s h a ft. • Finishing d im en sion s o f m ain journal oil hole
★ W h e n repairing th e plating o f th e d am a g e d
Edge of circumference of oil hole with ^ ax 4 g
su rface, repair only th e fo llo w in g surfaces. length over 1.52 and within 1.62
1) R ear seal jou rn al area Range of remainder of part R within 6S
2) C ra n k s h a ft g e a r m o u n t

Intersection 1.6S with


smooth change of shape
6 I2 7 F 2 3 2

★ Facilities and jigs need ed fo r grinding


1) M a g n e tic flo w d e te c to r
2) S h o re hardness te s te r
3) Etching kit
i) 4 % nitric acid solution: 2 5 0 g
ii) 2% h yd ro ch lo ric acid + ac eto n e solu­
tion: 2 5 0 g
iii) A c e to n e : 2 5 0 g
iv) C o tto n w o o l: 1 p a c k e t
v) S tain less steel p in ce tte: 1

15-036 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR A N D REPLACEMENT CYLINDER BLOCK SECTION

4) Crankshaft milling machine 2) Checking hardness of journal surface


i) Milling machine Measure the hardness of the journal surface
ii) V gauge, attachment type for other mill­ with a Shore hardness tester. If it is not
ing machines within the standard value, there has been ex­
iii) Dresser (for oilstone) cessive heat damage, so replace the
iv) Oilstone (reference) crankshaft.
• 1 9 A 5 4M , 1 9 A 4 6 M or 1 9A 54L H ardness o f jo u rn al s u rfac e (Shore
• Material: W A or A hardness)
• Grain size: Medium, No. 4 6 or P e rm itte d range: 6 0 — 7 0 Hs
No.54 R epair lim it: 6 0 Hs
• Grade: Medium, M, L, N or 0
5) Crankshaft grinding machine 3) Checking twisting
6) Roughness gauge ★ Measure the throw to judge if the crank­
7) Ball gauge for measuring fillet R shaft is twisted. The throw shows the
relationship in position between the
1 . Inspection before grinding center of the shaft and the center of the
1) Visual inspection pin journal.
• If any heat cracks can be seen, some part of
the hardened surface is lost, so replace the
crankshaft.
• If there is discoloration up to the un­
machined shoulder near the journal face or
thrust face, it shows that the crankshaft has
been heated to an excessive temperature.
Replace the crankshaft.
• If the wear or damage to the journal means
that it cannot be corrected to an undersize,
replace the crankshaft. (Skill needed)
• Replace any part if there is any damaged i) Install crankshaft on crankshaft grinder.
part which will affect the strength of the R ii) Fit crankshaft with crankshaft pin of No.
part. 1 cylinder immediately St top.
• If only one of the crankshaft journals is iii) Measure throw position of No. 1 cylinder
worn, it will affect the balancing. Replace the with horizontal V gauge. Then move V
crankshaft. gauge and measure throw position of
rear cylinder.
iv) If the difference in throw position of No.
1 cylinder and rear cylinder (horizontal
variation of throw) is not within repair
limit, replace crankshaft.
Throw
Allowance: 85 ± 0 .1 0 mm
Repair limit:
8 4 .7 8 - 8 5 .2 2 mm
Horizontal variation (difference in throw
between No. 1 cylinder and rear cylinder)
Repair limit: 0 .9 4 mm
Variation in throw between cylinders:
Within 0 .2 0
Replace if not within repair limit and dis­
card oil part.

155-4 SERIES 15-037


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

C h e ckin g during and a fte r co rrectio n


1) Checking R portion of fillet Good

e Check that R portion of fillet connects


smoothly with shoulder of journal.
• Check for scratches or seizure around R por­
tion of fillet. No good
• Using ball gauge for measuring fillet R,
check that dimension R is between dimen­
sion of minimum value gauge and dimension
of maximum value gauge. No good
• To check the R dimension of the fillet, use a
ball gauge for measuring the fillet and a
panel light. Measure as follows.
i) Move the minimum radius ball gauge
from the journal face to the fillet area.
No good
Shine a light from behind the ball and
check the contact.
• If the fillet is correct, the ball will roll
and always be in contact with one
point.
No good
• If the ball is in contact with two (R is too small)
places at the same time, part of the
615F031
diameter of the fillet is smaller than
the minimum value, so correct it
again.
ii) Move the maximum radius ball gauge
from the journal face to the fillet area in
the same way as in i). Shine a light from
behind the ball and check the contact.
• If the fillet is correct, the ball will
always be in contact with two
points at R.
6 I2 7 F 2 3 4
• If the ball is in contact with only one
place at any time, part of the diame­
ter of the fillet is larger than the
maximum value, so correct it again.
Radius R can be adjusted by correcting the
grindstone.

615F023

Fillet R Minimum radius: 6.00 mm


Maximum radius: 6.50 mm

15-038 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT CYLINDER BLOCK SECTION

2) Checking for traces of seizure by using etching • If there is any suspicious pattern,
• After correcting the crankshaft, carry out an polish the etched surface, and etch
etching inspection to check that there are no again.
traces of grinding seizure. • If there is any seizure, the same pat­
• If bearing failure has caused any damage, tern will appear again when the
seizure or dents in the journal, carry out an etching is repeated.
etching inspection to check that there are no vii) After the inspection, polish o ff the dis­
traces of seizure. This helps to judge if there coloration caused by etching, then clean
has been any drop in hardness, and to and dry the surface.
decide undersize dimensions. To neutralize the surface, wipe with a
• Inspection using etching is used to find out if weak solution of slaked lime or with any
there are any traces of seizure which cannot similar weak alkali solution.
be found by visual check or hardness check. viii) After drying, coat with anti-corrosion oil.
It is also used to find traces of grinding sei­ Pay particular attention to the inspection
zure caused by heating of the surface during surface and oil hole.
grinding. If the crankshaft is installed immediately
• Grinding seizure and traces of seizure in the in the engine, it can be coated with
journal or fillet area destroy the structure of engine oil.
the metal because heat is applied. This nor­ • If any seizure is found, grind off about 0 .0 2
mally occurs near to the surface, but it may mm and correct to the next undersize.
cause concentration of stress which in turn
will lead to breakage of the crankshaft.
• Procedure for inspection by etching
i) Clean the inspection surface completely.
ii) Wipe the inspection surface with a 4%
nitric acid solution.
Roll a piece of cotton wool into a diame­
ter of 2 to 3 cm. Soak it with the nitric
acid solution, hold with pincettes and
wipe for 1 to 2 minutes.
iii) Wash o ff the nitric acid solution with
water, and dry.
Soak some cotton wool in acetone, wipe
again, and dry.
iv) Soak some cotton wool with dilute hy­
drochloric acid (2% hydrochloric acid
mixed in acetone) and apply for 3 0 sec.
to 1 min. to etch inspection surface.
v) Wash off the dilute hydrochloric acid
with water, wipe with acetone, then dry
with compressed air.
vi) Check the inspection surface.
• If there is no seizure, the whole
etched surface will be a uniform
bright color.
• If there are streaks or dark patches
in a bright gray surface, this shows
the existence of grinding seizure.
• If there are stripes brighter than the
gray surface, this shows the exis­
tence of traces of seizure or exces­
sive grinding seizure.

155-4 SERIES 15-039


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

3) Magnetic flaw detection ii) Measuring aligment of adjacent journals


• Before using a corrected crankshaft, perform Support the rear journal and the journal
a magnetic flaw detection test to confirm next to the journal to be measured. Mea­
that there are no cracks. sure the runout of the journal with a dial
• Check particularly carefully the journal fillets gauge.
which enter the danger zones of the web of
the crankshaft.
Alignment of A, B and next main journal
Danger'zone of crankshaft web (total reading of indicator)

• The stress on the crankshaft is greatest at


this point, so there must not be even the
smallest crack.
4) Measuring curvature (measuring alignment) iii) Measuring alignment at front tip of
• Measure the curvature of the crankshaft crankshaft
after milling and check that it is within the Support the front and rear journals of
standard range. the crankshaft.
• Check the bend (alignment) at the following Measure the runout at a point within 6
four places. mm of the front end of the crankshaft.
Before measuring the curvature of the crank­ iv) Measuring alignment at rear tip of
shaft, check that the cylindricity and out- crankshaft
of-roundness are within the repair limit, Support the front and rear journals of
i) Measuring alignment of overall length of the crankshaft. Measure the runout at a
crankshaft point within 6 mm of the rear end of the
Support the front and rear ends of the crankshaft.
crankshaft. Rotate the shaft and mea­ a) Overall length
sure the radial runout at the center main Allowance Within 0 .0 9 mm
journal with a dial gauge. Repair limit: 0 .1 0 mm
b) Adjacent point
Repair limit: 0 .0 5 mm
c) Tip Repair limit: 0 .05 mm
d) Rear tip Repair limit: 0 .0 3 mm

15-040 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT CYLINDER BLOCK SECTION

3. Machining main journal 4. C u ttin g th ru s t fa c e


★ Machine every main journal to the same under­ ★ It is not always necessary to cut the front and
size dimensions. rear thrust faces to the same undersize.
★ After milling the shaft, mark the undersize dimen­ ★ A fter milling the shaft, mark the undersize dimen­
sion as shown in the diagram to prevent assem­ sion as shown in the diagram to prevent assem­
bly of the wrong size of bearing. bly of the wrong size of thrust bearing.

M: Main journal
R: Crankshaft pin journal

★ After milling, check that the dimensions of the ★ When correcting the thrust face, check that the
journal are within the permitted range. end play of the crankshaft is within the permitted
range. (For details, see GENERAL ASSEMBLY.)
• U nd ersize dim ensions o f th ru s t fa c e

Unit: mm

• Conditions for milling (reference) Rear thrust face


Milling speed: 1 8 0 0 — 2 2 0 0 rpm S.T.D 0.25OS
Feeding speed: 0.2 — 0.4 mm/min. QO+0.035
★ A llo w 0 .0 0 7 to 0 .0 0 8 m m fo r finishing Standard 0
0) 9 2.25+° - 035
o size
w h e n m illin g . <0 S.T.D * 9 2 +° - 05
• U nd ersize dim ensions fo r m ain journal +-
3
-C Repair limit 92.23 92.48
Unit: mm c
o Standard
9 2 .25 +®'035 9 2 .50 +2 '035
Size Standard size Allowance Li. size
0.25OS
S.T.D. 125.00 Repair limit 92.48 92.73

0.25US 124.75

0.50US 1 24.50 -0 .0 5 0
★ The standard dimension for both front and rear
0.75US 124.25 - 0 .0 8 0 faces of crankshafts marked with "B" at the tip
1 .oous 124.00 is the same.
Standard dimension: 92 + ° 05mm

• O ut o f roundness o f m ain journal (TIR) • S quareness o f th ru s t fa c e (TIR)


T ole ra n c e : W ith in 0 .0 1 0 m m R epair lim it: 0 .0 4 m m
Repair lim it: 0 .0 1 5 m m

155-4 SERIES 15-041


from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

5. G rinding c ra n k s h a ft pin jo u rn al 6 . C u ttin g w id th o f m ain journal and cran ksh aft


★ G rind every c ra n k s h a ft pin jou rn al to th e sam e pin jo u rn al
und ersize dim ensions. If th ere are any streaks, scratchers or dents on
A f t e r milling th e s h a ft, m a rk th e c ra n k s h a ft pin th e frictio n su rfa ce on eith e r side o f th e main
u nd ersize dim en sion s in th e sa m e w a y as fo r th e journal or pin journal, re m o ve w ith th e m inim un
m ain journal. o f milling.
Leave a th ickn ess o f a t least 0 .2 5 m m on th e fric ­
tion su rfa c e o f th e m ain journal.

Thickness of friction surface

Pin journal
Main journal

M: Main journal
P: Crankshaft pin journal 615F028 Friction surface
6 I2 7 F 2 3 6
A ft e r milling, ch ec k th a t th e d im en sion s o f th e • W id th o f c ra n k s h a ft pin jo u rn al
jo u rn a l are w ith in th e p e rm itte d range. W h e n c u ttin g one side only
C o n d itio n s fo r m illing (referen ce) S tandard: 74 + ° 075mm
M illing speed: 1 8 0 0 — 2 2 0 0 rpm
R epair lim it: 7 4 .3 2 mm
Feeding speed: 0 .2 — 0 . 4 m m /m in .
T h ic k n e s s o f fric tio n s u rfa c e
A llo w 0 . 0 0 7 to 0 . 0 0 8 m m fo r finish ing w h e n
R epair lim it: 0 .5 0 m m
m illing.
S quareness of th ru s t fa c e (TIR)
U n d e rs ize d im en sion s fo r pin journal
R epair lim it: 0 .0 4 m m
★ A llo w 0 . 0 0 7 to 0 . 0 0 8 m m fo r finishing w h e n
• If th e w id th o f th e pin jou rn al is too large, the
grinding.
co n n e ctin g rod w ill m o ve up and d o w n or side to
U n d e rs ize d im en sion s o f pin jou rn al
side on th e cra n k s h a ft w h e n th e engine is run­
Unit: mm ning. T h is w ill cause uneven w ear. T o avoid this,

Standard size Allowance re m o ve th e m in im um possible am o u n t w h en mill­


Size
ing, and a lw a y s keep strictly to th e repair limit.
S.T.D 102.00
0.25U S 101.75
-0 .0 5 0
0.50US 101.50
-0 .0 8 0
0.75US 101.25

1.oous 101.00

• O u t o f roundness o f pin jo u rn al (TIR)


T o leran ce : W ith in 0 . 0 1 0 m m
R epair lim it: 0 . 0 1 5 m m

15-042 155-4 SERIES


(D
from the library of Barrington Diesel Club
REPAIR A N D REPLACEMENT CYLINDER BLOCK SECTION

7. Correcting w ith grindstone


• Apply dressing to the grindstone after grinding 4) Hold a small coarse grindstone in your hand
each journal. and put in contact with the front face of the
• The start and the R dimension of the journal fillet grindstone. Then grind lightly so that the arc
has a big effect on the strength of the crankshaft, of the edge contacts smoothly with the
so adjust with the following grinding method. front face of the grindstone.
1) Grindstone dresser W hen doing this, slightly change the angle
Angle of tip:7 5 ° ± 1 ° of the grindstone in your hand and put lightly
Radius of tip:0.38 ± 0 .2 5 mm in contact with the grindstone.
Use a tubular type with inset industrial 5) When testing the start or the R dimension of
diamonds. the f illet, first grind a piece of wood as a test.
Check with a ball gauge, and correct to a per­
fect fillet shape.
6) Correct the edge on the other side of the
grindstone in the same way.
7) Make a test grinding of the crankshaft, then
finally check the shape of the fillet.

6 127F2 37

When using the dresser, adjust so that


the tip of the conical part is at the center
of the shank.
2) Adjust the diamond of the device for correct­
ing the grindstone, and modify the edge of
the grindstone to match the tip of the fillet.

615F030

3) First, correct the surface of the grindstone


and make a record of the feed dial gauge
reading.
Next, put the radius of one of the arcs in con­
tact with the surface of the grindstone.
• The final feed of the corrected surface
should be within 0 .0 1 3 mm.

15-043
155-4 SERIES
<3>
from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT

8. P re v e n tio n o f s e iz u re w h e n grinding 9. Finishing su rface


T o p re v e n t seizure w h e n grinding, o b e y th e fo l­ • Finish th e journal su rfa ce sm oothly as this a f ­
lo w in g p rec au tio n s ex ac tly . fe c ts th e fa tig u e stren g th o f th e cran ks h a ft and
1) A lw a y s p u t th e g rin d sto n e a t rig h t an g les to th e w e a r o f th e bearing.
th e cra n k s h a ft. • S ta n d a rd ro u gh n ess o f su rfa ce
U s e th e p lu n ge m e th o d fo r grinding. Jo u rn al fa c e , th ru s t fa c e , fillet: W ith in 1 .6S
If th e g rin d sto n e is p u t in c o n ta c t w ith th e T a p e r a t tip, boss o f pin and m ain journal:
c ra n k s h a ft an d th e n m oved to th e side W ith in 3 .2 S
(b u m p m e th o d ), th e re is a h ig h er risk o f • N o se o f tip, rear fla n g e fac e: W ith in 2 .0 S
seizure. • W h e n using a b e lt-ty p e lapping m achine, pull th e
2) Even w h e n using th e w h o le w id th o f th e em e ry clo th in th e sa m e directio n as th e rotation
g rin d sto n e, as fa r as p ossible do n o t grind o f th e cran ks h a ft.
th e bearing w id th . T h is is to avoid fin e particles flying in th e direc­
Finish th e bearing w id th by polishing. tion o f ro tatio n . T h e s e fin e particles m ay cause
If th e g rin d sto n e c o n ta c ts th e bearing w id th , sc ra tch es if th e y are c a u g h t in th e crankshaft.
th e fe e d in g sp eed should be b e lo w 0 . 0 2 5 • Finish th e area around th e oil holes in to th e
m m /s e c . sa m e s u rfa c e roughness as th e journal area.
3) T h e cooling oil se n t to th e side fa c e g uid e • Finishing allow an ce: 0 . 0 0 7 — 0 . 0 0 8 m m
an d th e m ain je t should fu lly c o n ta c t th e • R ust or corrosion causes w e a r o f the bearing, so
g rinding area. S ta rt th e flo w o f oil b e fo re re m o v e all ru st and corrosion com pletely, and
sta rtin g to grind. c o a t w ith h ig h -q u ality ru st preventive oil.
4) W h e n th e c ra n k s h a ft is m o vin g a t a b o u t 5 0 • Finishing co n dition s (reference)
rp m , th e sta n d ard sp eed a t th e c irc u m fe r­ P ap e r to use: A A No. 1 2 0
e n ce of th e g rin d sto n e should be 2000 S h a ft speed: 1 0 0 rp m
m /m in . G rinding speed: 3 6 m /m in .

10. A c tio n a fte r grinding


• C h ec k again th a t all dim en sion s are as specified.
• C lean all parts, especially th e oil hole, th orou gh ly
and c o a t all th e c ra n k s h a ft w ith high q uality rust
p reven tive oil.
• W h e n storing fo r a long period, support a t th ree
points o r m o re, or use a sling and stand vertically.

15-044 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR A ND REPLACEMENT CYLINDER BLOCK SECTION

9. REPLACING W E A R SLEEVE

Special tools

Part number Part name Q 'ty

A 7 9 5 -1 0 0 -1 2 8 0 Sleeve driver (front) 1

B 7 9 5 -1 0 0 -1 2 9 1 Sleeve driver (rear) 1

★ If the wear sleeve is worn or damaged, replace as ii) Insert chisel into V cut and split sleeve to
follows. remove.

1. Removing sleeve /f \ Be careful not to let the chisel fly off.


1) Cut groove in sleeve with grinder.
★ Be careful not to damage the shaft.
Wear sleeve
2. Press fittin g sleeve
1) Check interference of sleeve and shaft
Front sleeve
Permitted interference:
0.01 5 — 0 .0 7 0 mm
6 I2 7 F 2 4 0 2) Using sleeve drivers A and B, shrink fit
sleeves.
2) Fit chisel in sleeve groove, and tap out sleeve ★ Sleeve shrink fitting temperature:
with hammer. 2 3 0 - 2 5 0 °C
Heating time: 15 min
★ When heating, do not let the tempera­
ture exceed 250°C .
★ Press fit the front sleeve until the end
face of the sleeve contacts the shoulder
of the crankshaft flange.
★ Press fit the rear sleeve to a point 22
mm from the rear face of the crankshaft.

22

Rear sleeve

Rear face of
crankshaft

★ If th e f i t is t o o tig h t, re m o v e a s f o llo w s ,
i) C u t a V in s le e v e (1 ) w it h g rin d e r.

Wear sleeve 6 I2 7 F 2 3 9

6 I2 7 F 2 3 8

155-4 SERIES 15-045


from the library of Barrington Diesel Club
PRESS F ITTIN G OF BUSHING REPAIR A N D REPLACEMENT

P R E S S FITTING OF BU SH IN G
1. REPLACING C A M S H A F T B U S H IN G

Assembly drawing of camshaft bushing


Special tools
Oil hole
Part No. Part name Q 'ty Bushing

A 7 9 5 -2 2 5 -1 3 0 0 Push tool seat 1

A 7 9 2 -1 0 3 -0 4 0 0 Grip 1

B 7 9 5 -1 0 0 -2 7 8 0 Push plate 1

B 7 9 5 -1 0 1 -5 8 2 1 Grip 1

Removing blind plug


Remove blind plug at rear of cylinder block.

Removing front and rear bushings


Assemble push tool (2), collar (4), spacer (5) and
grip (7) of tool set A and drive out bushing (9)
from cylinder block (8) as shown in the figure
below.

Rem oving bushings 6 I I4 F 5 3 3


Assemble push bar (1), push tool (3), collar (4)
and guide (6) of push tool A and drive out bush­ 4 3 6 1
ings from front.
/
Press fittin g center bushings -rp p -

Assemble tool set A and bushing (9) and press


fit bushing until end face at push tool (3) comes 6 I I4 F 5 3 4
into contact with cylinder block (8).
★ Press fit so that the bushing notch is at the
top.
★ Align the oil hole of the bushing.
★ Be careful that the bushing does not block
the oil return hole of the cylinder block.

5. Press fittin g fro nt and rear bushings


Assemble tool set A and bushing (9) and press
fit bushing until end face of spacer (5) comes
into contact with cylinder block (8).
★ Press fit so that the bushing notch is at the 4 9
top.
★ Align the oil hole of the bushing.
★ Be careful that the bushing does not block
the oil return hole of the cylinder block.

Press fittin g blind plug


1) Coat circumference of plug hole with gasket
sealant (LG-1). 6 1 14F536
2) Using push plate B, knock in blind plug.

15-046 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR A ND REPLACEMENT PRESS FITTING OF BUSHING

Check the clearance between the bushing


and shaft. If the clearance is not within the
permitted range, or if the shaft does not
rotate smoothly, or when replacing the bush­
ing with a semi-machined bushing, correct
the inside diameter of the bushing by
reaming.
★ When correcting by reaming, remove all
metal dust from the oil hole and oil
groove.

615P024

2. REPLACING BALANCER S H A FT
BUSHING (S 4 D 1 5 5 -4 )

Special tools Assembly position of balancer shaft bushings


Part number Part name Q 'ty
Na 1 Na 2 Na 3 Na 4 Na 5
A 7 9 5 -2 2 5 -1 4 0 0 Push tool set 1 Z. o
o -Q
(O *-
H- ©
A 7 9 2 -1 0 3 -0 4 0 0 Grip 1
11
a- o
►14
224
449
674

6 I2 7 F 2 4 7
1. Removing front and rear bushings (No. 1, 5
bushings)
Assemble push tool (2), collar (4), spacer (5) and 5 2
grip (7) of tool set A and drive out bushing (9)
from cylinder block (8) from front and rear as II /
shown in the figure below.
★ Spacer (5) is not needed when removing the
n n
rear bushing. II-
6 1 I4 F 5 3 3
2. Removing center bushings (No. 2, 3, 4
bushings)
Assemble push bar (1), push tool (3), collar (4)
and guide (6) of push tool A and drive out bush­ 4 3 6 1
ings from front and rear.
- L
3. Press fitting center bushings (No. 2, 3, 4 -rp p -

bushings)
Assemble tool set A and bushing (9) and press 6 I I4 F 5 3 4
fit bushing until end face at push tool (3) comes
into contact with cylinder block (8).
★ Check that the oil hole is correctly
positioned.
★ Press fit No. 3 bushing first.

155-4 SERIES 15-047


from the library of Barrington Diesel Club
PRESS FITT IN G OF BUSHING REPAIR A N D REPLACEMENT

4. Press fittin g front and rear bushings (No. 1,5


bushings) 4 9 7
Assemble tool set A and bushing (9) and press
fit bushing until end face of spacer (5) (rear bush­
ing) or end face of push tool (2) (front bushing)
comes into contact with cylinder block (8).
★ Check that the oil hole is correctly
positioned.
★ Spacer (5) is not needed when press fitting 5 2
the front bushing. 6 1 I4 F 5 3 6

3. REPLACING OF IDLER GEAR


B U S H IN G

Special tools

Part number Part name Q 'ty

A 7 9 5 -1 0 2 -2 4 0 2 Push tool set 1


A 7 9 0 -1 0 1 -5 2 2 1 Grip 1

• Replace bushing of main idler gear and balancer


idler gear as follows.

1. Removing gear bushing


Pull out bushing with puller.

2. Press fittin g bushing


Press fit idler gear bushing (2) with push tool A
until tool end face comes into contact with face
of gear (1).

61 14F538

15-048 155-4 SERIES

from the library of Barrington Diesel Club


REPAIR AND REPLACEMENT REPLACING S H R IN K -FITTED GEAR

REPLACING S H R IN K -F IT T E D
GEAR

1. REPLACING C R A N K S H A F T GEAR 3. REPLACING BALANCER GEAR


(S 4 D 1 5 5 -4 )
1. Removing gear ★ To replace the balancer gear, follow the proce­
Make a cut on gear tooth bottom with grinder dure for replacing the crankshaft gear.
and crack it with chisel to remove gear. ★ Check that the left and right balancer gears are
★ Be careful not to damage shaft. facing in the correct direction before press fitting.
★ Balancer ger shrink fitting temperature:
Be careful when using grinder and chisel. 2 5 5 - 2 75 °C
Heating time: 4 5 min.
2. Press fitting gear
1) Check gear mounting face, key groove and 4. REPLACING FLYW H EEL RING GEAR
flange surface for damage. If any is found,
correct with oilstone. /f\ Be careful not to drop the flywheel and
2) Drive new key into key groove on shaft. cause injury.
(Rear crankshaft gear is unnecessary in this
item.) 1. Removing ring gear
3) Heat gear at the specified shrinking tempera­ Make a cut on gear tooth bottom with grinder
ture for the given time. and crack it with chisel to remove gear.
★ Crankshaft gear shrink fitting temperature:
2 4 0 - 2 6 0 °C /f\ Be careful when using grinder and chisel.
Heating time: 4 5 mins.
4) Face timing mark outside and press fit gear 2. Press fittin g ring gear
with driving tool until gear side face comes 1) Check ring gear mounting face for damage.
into close contact with shaft flange. If any is found, correct with oilstone.
(Rear crankshaft gear is unnecessary in this 2) Heat gear at the specified shrinking tempera­
item.) ture for the given time.
★ Ring gear shrink fitting temperature:
2 9 5 - 3 05 °C
★ Drive gear quickly while it is hot. (For items Heating time: 4 5 mins.
4) and 5)) 3) Face tapered side of flywheel ring gear to fly­
wheel side and press fit until side face
2. REPLACING C A M GEAR comes into close contact with flywheel.
★ To replace the cam gear, follow the procedure
for replacing the crankshaft gear.
★ Cam gear shrink fitting temperature:
2 4 0 - 2 6 0 °C
Heating time: 4 5 min.

155-4 SERIES 15-049

from the library of Barrington Diesel Club


OTHERS REPAIR A N D REPLACEMENT

OTHERS
1. M O D IF Y IN G F U N C T IO N 2. Press fittin g sleeve
★ Sleeve Part No. 6 1 2 7 -2 9 -3 2 5 1
Machine according to drawing below. 1) Heat sleeve
★ Sleeve shrink fitting temperature:
1 90 - 2 10 °C
Heating time: 10 mins.
2) Face chamfered side of sleeve to gear case
and fit it with driving tool.
★ Fit sleeve quickly while it is h o t

3. Confirm ing after fittin g sleeve


1) Check that sleeve is fitted completely and
that there is no crack.
2) Coat front support grease groove with
grease and install support on gear case.
3) Check that front support moves smoothly.

★ Press fittin g sleeve


6 I2 7 F 2 5 2

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6 I2 7 F 2 5 4

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Detail P
6 1 2 7 F2 5 3

15-050 155-4 SERIES

from the library of Barrington Diesel Club

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