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(2
C5:
7A
J \
KOMATSU ENGINE
155-4 SERIES
Printed in Japan 0 0 -1
02-90(01)05881
(3)
from the library of Barrington Diesel Club
LIST OF REVISED PAGES LIST OF REVISED PAGES
• 14-017 ® 15-011 (D
• 14-018 ® 15-012 (D
14-019 D 15-013 CD
• 14-020 ® 15-014 CD
• 14-021 ® 15-015 CD
14-022 <D 15-016 cD
14-023 CD 15-017 ®
14-024 CD 15-018 D
14-025 (D 15-019 D
• 14-026 ® 15-020 ®
• 14-027 ® 15-021 D
14-028 (D 15-022 D
• 14-029 ® 15-023 ®
14-030 (D 15-024
• 14-031 ® 15-025
• 14-032 ® 15-026 D
14-033 CD 15-027 ®
14-034 15-028 D
14-035 ® 15-029 D
14-036 CD 15-030 D
14-037 (D 15-031 D
14-038 (D 15-032 D
14-039 (D 15-033 . D
14-040 (D 15-034 D
14-042 (D 15-035 D
14-043 15-036 D -
(D
14-044 D 15-037 D
• 14-045 ® 15-038 D
00 2-2
- 155-4 SERIES
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
1 2 T E S T IN G AND A D J U S T IN G
1 4 M A IN T E N A N C E STANDARD
155-4 SERIES 0 0 - 2 -3
( ?)
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
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-)
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 - - - 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 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
6 I2 7 P 0 0 2
0 1 -0 0 4 155-4 SERIES
<D
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
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
1. Fuel filter
2. Fuel injection pipe
3. Air cleaner
4. Oil filter
5. Oil filler
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
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
3. Front support
4. Oil level gauge
5. Fuel injection pump
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
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
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
6 I2 7 P 0 I 5
14. Turbocharger
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
S P E C IF IC A T IO N S
Firing order 1- 2 - 4 - 3
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
Coolant aount (2 ) 84 79
Starting motor 24 V, 11 kW
Turbocharger K TR130
Air compressor -
A fter cooler -
S6D155-4
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
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
KTR130
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 -
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
Turbocharger KTR130
Air compressor -
0 1 -1 0 4 155-4 SERIES
< s>
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
1,839 - -
- 2,894 2,894
78 83 75 83 75
(*58) (47) (47) (47) (47)
160
12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2
KTR130
Firing order 1 — 5 — 3 — 6 —2 —4
o
Overall height (Including exhaust pipe) (mm) 2,914 2,852 2.844
Air compressor -
After cooler -
S6D155-4 S6D155G-4
6 - 155 x 170
19,260
1 — 5 —3 —6 —2 —4
- - 1,660
3,155 3,155 -
150/1,400 150/1,400 -
600 ± 50 600 ± 50 -
185
180 180
(at flywheel horsepower)
83 75 83 75 77
(47) (47) (47) (47) (*57)
180 85
12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2 12V 200Ah x 2
KTR130
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 - -
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)
77 (*57)
Lubricating oil amount 75 Engine Serial No. — 25899 75
m
(Refill capacity) (*55) 75 (*55) (*55)
Engine Serial No. 25900 —
Air compressor - - -
1 - 5 - 3 -- 6 - 2 - 4 1- 2 1- 2 1 -2
2,240 ± 50 2,240 ± 40 - - -
175 175 - - -
24V, 2kW
24V, 11 kW - 24V, 2 kW 24V, 2 kW
(For starting engine)
KTR130 KTR130 - - -
Standard Standard - - —
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
S4D155-4 (D95S-1)
1414
6 I2 7 F 0 0 2
S4D155-4 (D95S-1)
6 I2 7 F 0 0 3
S4D155-4 (D95S-1)
6 I2 7 F 0 0 4
6 I2 7 F 0 0 5
6 I2 7 F 0 0 6
2933
6 127F007
1 2 -12 X 1.75
( D155A)
12 -12 X 1.7
(D150A)
6 127F0 08
SA6D155-4 (D355A-3)
6 127F009
SA6D155-4 (D355A-3)
6 127F0IO
SA6D155-4 (D355A-3)
6 127F01 I
SA6D155-4 (D355A-3)
6 127F0I 2
W E IG H T T A B L E
Unit: kg
KTR130 30 30 30
1 Turbocharger
RH1521 - 50 -
2 After cooler - - 25
Welding type 60 65 65
6 Oil pan
Pressed type - 55 55
13 Oil pump 20 20 20
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 -
ENGINE P E R F O R M A N C E C U R V E
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
S4D155-4 (D95S-1)
Torque (kg.m)
Fuel consumption ratio (g/HP*h)
Torque (kg.m)
Fuel consumption ratio (g/HP*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
Torque (kg.m)
Fuel consumption ratio (g/HP*h)
155-4 SERIES 0 1 -4 0 5
(2)
from the library of Barrington Diesel Club
ENGINE PERFORMANCE CURVE GENERAL
w
o
I-
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)
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)
S6D155G-4 (EG300-2)
Torque (kg.m)
Fuel consumption ratio (g/HP*h)
SA6D155-4A (D355A-3)
Torque (kg.m)
Fuel consumption ratio (g/HP*h)
11 STRUCTURE
AND FUNCTION
GENERAL STRUCTURE
S4D155-4
36 43 6 I2 7 F 0 2 5
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
6 127F027
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
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
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
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
1. Exhaust pipe
2. Muffler
3. Turbocharger
4. Exhaust manifold
5. Rain cap
6 I2 7 F 0 3 5 A
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
w m iF
6 I27F037
)
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
6 I27F038
1. Cover plate
2. Cover
3. Cover plate
4. Body
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
1. Cylinder head
2. Rocker arm housing
3. Rocker arm housing cover
4. Nozzle holder sleeve
5. Cross head guide
6. Valve guide
ROCKER A R M
5 6 10
6 I27F04I
V A L V E S Y S TE M
S4D155-4
10
6 I27F042
V A L V E T IM IN G
section view
(No. 4 cylinder)
6 I27F044
Intake valve
section view
(No. 4 cylinder) 6 I 27F043
Valve clearance
S6D155-4, SA6D155-4
1 2 3 4 5 6
(No. 4 cylinder)
section view
(No. 4 cylinder)
6 I27F047
V A L V E T IM IN G Valve clearance
S6D155-4
0.4 0.6
No. 11 7 4 6 -
260 \
------ / / f ' Exhaust open
ntake close -'C
---------
Lower dead point
C Y L IN D E R BLOCK
S4D155-4
6 127F048
14
Cylinder block
Crankshaft : 5 metals
Camshaft : 5 metals
Balancer shaft : 5 metals
Cylinder liner
Wet type liner
Crevice seal, O-ring x 2
S 6D 155-4, S A 6D 155-4
1 2 3 4 6 7 8
6 I2 7 F 0 5 0
13
Cylinder block
Crankshaft : 7 metals
Camshaft : 7 metals
Cylinder liner
Wet type liner
Crevice seal, O-ring x 2
M A IN R E V O L V IN G
S 4D 155-4
6 I 27 F 05 2 A
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
1 2 3 4 5 6 7
10 11 12 13
6 I27F054
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)
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)
S 6D155-4, S A 6D 155-4
6127F058A
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
P.T.O
S4D155-4
6 I27F060
S A6D 155-4
6 I27F062
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
1. Oil pan
8. Safety valve
9. Regulator valve
10. Piston cooling valve
18. Camshaft
19. Turbocharger
6 I2 7 F 0 6 3 -I
6 127F064B
1. Oil pan
2. Scavenging pump (Excluding generator)
3. Oil pump
4. Main relief valve
6 . By-pass filter
7. Oil cooler
8. Regulator valve
9. Fullflow filter
14. Crankshaft
15. Piston cooling nozzle
19. Camshaft
20. Turbocharger
21. Oil pressure gauge
W. Cooling water
O IL P U M P
Serial No. 2 6 4 7 3 -
6 7 8 6127F065A
1. Retainer
2. Valve case
3. Valve spring, outer
4. Valve spring, inner
5. Main relief valve
6 . Oil pump body
6 I27F066A
6 5 4 3 2 1
6 I27F068
S TA N D IN G TYPE
S 4D 155-4
S6D155-4 (Engine Serial No. 10011 ~ 19999)
6127F069A
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
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)
HANGING TYPE
S6D155-4 {Engine Serial No. 20000 ~ 24804)
SA6D155-4 (Engine Serial No. 20338 ~ 25899)
6127F073A
CARTRIDGE TYPE
S6D155-4 (Engine Serial No. 24805 and up)
SA6D155-4 (Engine Serial No. 25900 and up)
6127F074A
A. Oil inlet
B. Oil outlet
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
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
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
O IL COOLER
S 4D 155-4
CO
Section A —A 6 127F078
S6D155-4, SA6D155-4
B 6 I2 7 F 0 7 9
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
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
S 6D 155-4, S A 6D 155-4
6 I27F083A
F U E L PIPING
S4D155-4
S 6D 155-4
1 2
6 I27F085
SA6D155-4
IT T
6 . Coupling
7. Housing
8 . Shaft
F U E L IN JEC TIO N P U M P
PUMP
6 127F088
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.
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.
GOVERNER
13 12 6 I2 7 F 0 8 9
Governer
Type Bosch RSUV centrifugal all-speed type
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.
Start spring
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.
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
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
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.
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.
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.
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.
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
F U E L IN JE C TIO N P U M P D R IVE
4 5 6
6 I27 F 09 I
FU EL IN JE C T IO N N O ZZLE
1 0 0 1 1 -1 4 2 5 6 175
S6D 155-4
14257- 220
11-411
<3>
155-4 SERIES
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.
F U E L F IL T E R
A. Fuel inlet
B. Fuel outlet
CARTRIDGE TYPE
A. Fuel inlet
B. Fuel outlet
COOLING SYSTEM
COOLING S Y S T E M C H A R T
S4D155-4
6 127F095A
S6D155-4
W ATER PUM P
1. Cover
2. Impeller
3. Floating seal
4. Water seal
7. Bearing housing
8. Pump shaft
9. V-ring
A. From radiator
B. From thermostat
C. To oil cooler
6 I2 7 F 0 9 7 -5
8. Pump shaft
9. V-ring
10. Retainer
6 I2 7 F 0 9 7 -3
6 I2 7 F 0 9 7 -4
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
2. Impeller
3. Floating seal
4. Water seal
8. Pump shaft
9. V-ring
6 I2 7 F 0 9 9 - I
2 3 4 5 8
6 I2 7 F IO O A
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
CORROSION R E S IS TO R
1 A
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
A LTER N A TO R
m r\
Alternator Regulator
F6120A001
A L T E R N A T O R W ITH R EG U LA TO R
6210F116A
M aker: S A W A FU JI
D355C-3 24V, 50A 84.4 12
T yp e: O pened
DYNAMO
1 2
6 I2 7 F I 0 7
1. Dynamo ass'y
2. Pinion gear (number of teeth 22)
S T A R T IN G M O T O R
6 I2 7 F I 0 8
S T A R T IN G M O T O R
F6120A002
W eig h t
Applicable m achine Type S pecification
(kg)
S T A R T IN G ENGINE (2G84)
STRUCTURE
7 8 9
25 24 23 22 21
LUBRICATION SYSTEM
POWER TRAIN
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
WATER PUMP
1. Impeller
2. Water seal
3. Pump shfat
4. Felt
5. Pump case
AIR C O M P R E S S O R
CJOm m
6 I 2 7 F I 10
D155W-1
' (DIESEL KIKi)
D155AR-1
C. Coolant inlet
D. Coolant outlet
t From oil pump (oil)
F. To compressor (oil)
G. To air governor
6 I 2 7 F I I I -3
6. Spring guide
7. Spring seat
8. Piston
9. Exhaust stem
ENGINE S T A R T IN G AIDS
C. Water jacket
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
D. To heater nozzle
10. Battery
11. Shield
12. Igniter
17. Terminal
A. Intake air
B. To injection nozzle
1514 13 6 I 2 7 F I 68
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
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.
• S6D155-4 (Optional)
SA6D155-4 (Engine Serial No. 26691 — 35760: Standard)
6 I IF I3 9 A
6 I 27F094- I
8. Fuse (5A)
★ 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.
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.
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.
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.
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
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
6127-71-1011 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
6127-71-1017 2000- •
6127-71-1018 2000 -
6127-71-1004 1 0 0 1 4 - 10066
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
6127-71-1033 2000 -
6127-71-1052 2000-
6127-71-1082 24805 -
6127-71-1090
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-
6127-71-1150
6127-71-1152
6128-71-1010 1 0 1 1 3 - 10691
6128-71-1011 10692- •
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 -
6127-71-1301 28770 -
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-
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.
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
★ 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).
Load T im e (M inute)
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
Time min 5 15 5 5 20 10
★ 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).
Time min 5 15 5 5 20 10
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
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
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.
0 0 - 7 0 -9 0 8 0 -9 5 3.5 - 4.5 -
253.0 - 267.4 - 20.0 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 8 0 -9 5 3.5 - 4.5 -
0 0 - 70 - 90 80 - 95 3.5 - 4.5 -
0 0 - 70 - 95 8 0 -1 0 0 3.5 - 4.5 -
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
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
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
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
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
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/)
0 0 - 7 0 -9 0 8 0 -1 0 0 3.5 - 4.5 -
0 0 - 7 0 -9 0 8 0 -9 5 3.5 - 4.5 -
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
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
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
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
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
0 0 - 7 0 -9 5 8 0 - 100 - -
0 0 - 7 0 -9 5 80 min. - -
0 0 - 70 - 95 80 - 100 - -
0 0 - 7 0 -9 5 80 min. - -
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.
1. Load test
No. Inspection and measuring item Faultfinding tool Part No. Remarks
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
Intake pressure,
8 Exhaust pressure Engine pressure measuring kit 799-203-2002 0 — 1,500 mmHg
18 Cooling water quality Water quality tester 799-202-7001 pH, nitrite ion concentration
Commercially
23 Electrical circuits Tester Current, voltage, resistance
available
Classifi
Item Condition, etc. Unit Standard Tolerance Standard Tolerance
cation
Intake resistance At rated horsepower mmH20 380 max. 762 380 max. 762
—
Nozzle tester kg/cm2 -
pressure 220 220
Fuel
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.
Protrusion of adjusting
Fan belt tension mm See attached sheet
screw
S6D155-4
380 max. 762 380 max. 762 380 max. 762 380 max. 762
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.
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)
0.5 max. 1.0 max. 0.5 max. 1.0 max. 0.5 max. 1.0 max. 0.5 max. 1.0 max.
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 -
- - - -
D155A-1
Machine Serial No. D155S-1
(Engine Serial No. 14257 —)
Classifi
Item Condition, etc. Unit Standard Tolerance Standard Tolerance
cation
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
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)
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
S6D155-4
D355A-1
D155W-1 D155C-1 D155A-2
(Engine Serial No. 10011 — 14049)
380 max. 762 380 max. 762 380 max. 762 380 max. 762
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
(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)
0.5 max. 1.0 max. 0.5 max. 1.0 max. 0.5 max. 1.0 max. 0.5 max. 1.0 max.
38 - 38 - 38 - 37 -
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 -
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
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.
Protrusion of adjusting
Fan belt tension mm See attached sheet
screw
S6D155G-4 SA6D155-4
D355A-3
EG300-1 EG300-2 D355A-3
(—506C spec)
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
380 max. 635 380 max. 762 380 max. 762 380 max. 762
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
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)
0.5 max. 1.0 max. 0.5 max. 1.0 mx. 0.5 max. 1.0 max. 0.5 max. 1.0 max.
38 - 38 - 38 - 38 -
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 -
D355A-3
Machine Serial No. D355A-5
(High altitude, 4000 m spec.)
Classifi
Item Condition, etc. Unit Standard Tolerance Standard Tolerance
cation
Intake resistance At rated horsepower mmHjO 380 max. 762 380 max. 762
Fuel injection
system
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.
Protrusion of adjusting
Fan belt tension mm See attached sheet
screw
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
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
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
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
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
15
Water to B
manifold
16 17
18
Breather to D
tube
to E
23
to L
19 20
22
Dipstick
pipe
to A
from B
from C
41
47
from H
38
Injection
pump
drive ass'y
from I
from J
from K
from L
S P E C IA L T O O L S
Preparation w ork
• Set engine ass'y(1) on engine stand (T).
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.
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).
Drive shaft: 2 5 kg
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
20. Oilfiller
Remove oil filler (3).
6 I2 7 P 0 4 5
6 I2 7 P 0 5 I 6 I2 7 P 0 5 2
I2 7 P 0 5 3 ,
I2 7 P 0 5 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).
37. Timer
1) Remove nut (1) and take out the shaft key.
51. Piping
Remove oil pum p pipings (2) and (3).
Oil pump: 2 0 kg
012x2
6 I2 7 P 0 9 I
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
5 9. Cylinder liner
★ Before removing the cylinder liner, measure the
liner protrusion. Set liner puller G, then remove
cylinder liner (1).
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
16
22
to L
to M
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
S P E C IA L T O O L S
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 -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 0-101-5221 Grip 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
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
7 9 5 -1 2 5 -1 3 2 0 Feller gauge y 1
Preparation work
• Wash cylinder block (1), then raise it using suspension
tool H and m ount it on engine repair stand A.
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:
Cylinder head
Up to 6127-11-1814 From 6127-11-1815
gasket
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.
6I27PI03
kg.m
1st pass 33 3 0 -3 2
2nd pass 61 6 0 -6 2
Slacken off
3rd pass 0
completely.
5th pass 29 2 8 -3 0
6 th pass 52 5 0 -5 4
7th pass 74 7 0 -7 8
13-110
<D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY
6 I2 7 P I I I
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
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.
kgm
1st pass 21 2 0 -2 2
5th pass 21 2 0 -2 2
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.
6 I27PI 20 6127PI 2 I
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.
Unit: mm
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 -
6 Accessory gear 0 .0 9 -0 .3 1
13-116©
155-4 SERIES
1 ,
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.
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
6 I 2 7 P I 34
Unit: kg.m
1st pass 38 3 6 -4 0
Slacken off
2nd pass 0
completely.
3rd pass 42 4 0 -4 4
6 I 2 7 P I 39
13-120<D
155-4 SERIES
6 I2 7 P 0 5 2 6 I2 7 P I 4 3
6 I2 7 P 0 5 I
6 I2 7 P 0 5 0
4
I 27P049 I
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
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
U nit: kg.m
Nozzle holder
★ Tighten them taking a balance m utually.
Mounting bolt: 3 .2 5 ± 0 .2 5 kg.m.
12
11 ® A®
6 I 2.7F I 34
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
13-126
(D
from the library of Barrington Diesel Club
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY
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.
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).
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 )
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.
A S S E M B LY OF W ATER PU M P
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.
D IS A S S E M B L Y OF TU RB O CHARG ER (K T R 100,130)
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.
6 I2 7 P I 6 4 i
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
6 I 2 7 P I 68
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
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
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).
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
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.
D IS A S S E M B L Y O F TURBOCHARG ER (RH1521)
★ 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
A S S E M B L Y OF TURBOCHARG ER (RH1521)
4 5
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
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
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
★ Magnet
Dismount the magnet after making a match mark on
the flange.
★ Camshaft
Extract the camshaft after removing the thrust plate
mounting bolt from the camshaft gear hole.
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
2G84 Cylinder
Starting head
engine
Piston
connecting
rod
10 17
Connecting ...„ Flywheel to A
rod cap rear cover
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
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.
6 I2 7 FI4 I- I
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.
4 5 6 7
6 I2 7 FI3 5 - I
Special tools
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
2. Feed pump
3. O verflow pipe
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.
8. Bearing
9. Upper cover
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.
• 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.
Special tool
L 10 57 92 -0 02 0 Extractor 1
6 127P16 0 - I I
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.
Snap ring has its one end fitted into the small hole in the
body. Remove snap ring by prising its opposite end.
O O BBC
6 I27FI 35-3
Special tools
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
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
★ 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
»<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
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
14 MAINTENANCE
STANDARD
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
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
T IM IN G G E A R ................................................................................................... 14-024
LU B R IC A T IO N SYSTEM
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
ACCESSORY
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
Unit: mm
Replace
2 Radial play 0 .2 5 -0 .4 3 0.60
parts
-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
RH1521
Unit: mm
Replace
2 Radial play 0 .1 0 -0 .1 5 0.05
parts
Unit: mm
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
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
C Y L IN D E R HEAD
Unit: mm
1st 29 2 5 .5 -3 2 .5
3rd 55 5 3 .5 -5 6 .5
Unit: mm
Repair or
2 Valve head wear Repair lim it: 0.15
replace
■K).020
Valve guide I.D 11 11.17
-0 .0 1 0
Valve
spring 88 66 40±2kg — 36.5 kg Replace
7
+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
1 0 0 1 1 -5 0 1 5 6 0.3 0.3
S4D155-4
50157- 0.4 0.6
S6D155-4
11 7 4 6 - 0.4 0.6
ROCKER HOUSING
1
2 3 4
Unit: mm
-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
T A P P E T , PUSH ROD
6 I 2 7 F I 49
Unit: mm
Tightening torque of
3 6.9±1 .Okg.m Retighten
locknut
C Y L IN D E R BLOCK
S4D155-4
Unit: mm
6; w —^- Tolerance
Serial Standard Clearance
Standard
number clearance limit
Block Liner
o o
CO 00
50041~ - 0 .0 3 4-0.08 -
176 0 .1 0 ~ 0 .1 8
-0 .1 0 40.02
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
Unit: mm
+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
Interference
Engine Serial No. Tolerance Tolerance limit
50041- 185.5 - -0 .1 0 0 -0 .2 4 4
1st 31 3 0 -3 2
2nd 61 6 0 -6 2
5th 29 2 8 -3 0
6th 52 5 0 -5 4
O
00
7th 74
I
S6D155-4, S A 6 D 155-4
Unit: mm
Tolerance
Serial No. Standard Clearance
Standard
clearance limit
Block Liner
+0.08
1 I
+ 0.08
o o
o
I I
11704- 176 0 .0 5 -0 .1 8 -
+0.02
o
S A 6D 155-4
3 0
Main metal thickness 3.5 -0 .0 6
-0 .0 5 0
+0.050
Main metal I.D 125 125.12
0
+0.070 Repair or
Cam shaft bushing I.D 61 61.10 replace
0
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
1st 31 3 0 -3 2
2nd 61 6 0 -6 2
CO
0
5th 29
1
6th 52 5 0 -5 4
7th 74 7 0 -7 8
C Y L IN D E R LIN E R
Detail P
6127F152B
Unit: mm
Standard Tolerance
Cylinder liner O.D
(Counter bore lower part) Replace
178.5
4
Unit: mm
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 -
CRANKSHAFT
S4D155-4
6 I27FI53A
S6D155-4
SA6D155-4
6 I 2 7 F I 54
Unit: mm
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
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
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
-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
BA LA N C ER S H A F T (S4D155 4)
a
Balancer shaft (R .H .)
2
Forward
6I27FI57A
Unit: mm
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
T IM IN G GEAR
„ Unit: mm
Repair
Position Measuring point Standard
limit
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
Replace
12 End play of idle gear (S4D155-4) 0 .0 6 -0 .1 9 0.30 thrust
bearing
4-
Top ring
3. Piston ring gap
2nd ring 0.45 - 0.65 3.5
Oil ring
Unit: mm
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
TOP ring
Piston ring gap Replace
2nd ring 0 .4 5 -0 .6 5 3.5
Oil ring
SA 6D 155-4 4,285 ± 10
C O N N EC TIN G ROD
6 I 2 7 F I 59
Unit: mm
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
Bend or twist
Repair limit of twist : 0.25
1st 21 2 0 -2 2
2nd 41.5 4 0 -4 3
5th 21 2 0 -2 2
6th 28.5 2 7 -3 0
7th 41.5 4 0 -4 3
O IL P U M P
Unit: mm
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
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)
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
Unit: mm
8 4 11
6 I27FI 63-7
9 2 6
6 I27 FI 63-5
10 3 7
Unit: mm
Free length Installed length Installed load Free length Installed load
1 Piston cooling valve spring
Replace
2 Piston cooling valve spring 92.5 64 14.1 kg - -
4 Oil cooler by-pass valve spring 72.9 50.0 12.0 kg 65.6 11.5 kg
W A TE R P U M P
Unit: mm
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
7.75
I
Retighten
3 Valve spring Free length Installed length Preload Free length Preload Replace
38 - - 50 14.2 kg
(4) Crankshaft
Unit: mm
STD 55 54.75
0.25 US 54.50
1.00 US 53.75
Repair or
1.50 US 53.25 replace
STD 54 53.75
0.25 US 53.50
0.75 US 53.00
1.00 US 52.75
(5) Camshaft
Unit: mm
(7) Clutch
Unit: mm
Replace
Clearance between sleeve sleeve or
4 8.0 0 .0 7 - 0.15 0.30
and shifter groove shifter
Replace
Clearance between pinion
2 0 .0 5 -0 .1 0 0.20 pinion or
and shaft spline
shaft
AIR C O M P R E S S O R (Nippon a i r b r a k e )
1 11
Unit: mm
Standard
Check
Standard Repair limit
point
Ring Piston
No. 2 0 .1 3 -0 .3 8 -
Repair or
7 Crankshaft journal roundness Maximum roundness: 0.0075
replace
A IR C O M P R E S S O R
Unit: mm
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
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
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
Unit: kg.m
Nominal bolt
Width across
flats (mm)
dia. (mm)
k j Q j
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.
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 )
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.
• 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 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
6 I2 7 F 2 0 5
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
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
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
Special tools
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
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
615F009
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
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
6 I2 7 F 2 1 0
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.
6 I2 7 F 2 I 2
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.
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
6 127P202
Special tools
6127P203
6 I2 7 P 2 0 4
615F018
Special tools
1. Nut
2. Sleeve
3. Nut
4. Bearing
5. Collet
6. Block
9. CORRECTING VA LVE
Special tool
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 °
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
Special tools
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
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
6 I2 7 P 2 0 8
6 I2 7 P 2 0 9
6 I2 7 P 2 1 0
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
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.
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.
6 I2 7 P 2 I 6
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.
6 I2 7 P 2 2 0
6 I2 7 P 2 2 I
S p e c ia l to o ls
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
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.
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.
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.
Unit: kgm
7th time 74 70 - 78
6 127F228
V r "1 615P023
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.
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
615F023
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.
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
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
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,
1.oous 101.00
6 127F2 37
615F030
15-043
155-4 SERIES
<3>
from the library of Barrington Diesel Club
C YLIN D ER BLOCK SECTION REPAIR A N D REPLACEMENT
9. REPLACING W E A R SLEEVE
Special tools
★ If the wear sleeve is worn or damaged, replace as ii) Insert chisel into V cut and split sleeve to
follows. remove.
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
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
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
615P024
2. REPLACING BALANCER S H A FT
BUSHING (S 4 D 1 5 5 -4 )
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.
Special tools
61 14F538
REPLACING S H R IN K -F IT T E D
GEAR
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
4 6 :-j
18
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6 I2 7 F 2 5 4
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Detail P
6 1 2 7 F2 5 3