6D110 Series

-.
STRUCTURE AND FUNCTION
GENERAL STRUCTURE ................................................................ 1 I-004
INTAKE AND EXHAUST SYSTEM ...................................................... 1 I-008
Turbocharger ..................................................................... II-016

After-cooler ...................................................................... II-018
ENGINE BODY ......................................................................... 1 I-020

Cylinderhead ..................................................................... 11-020
Mainmovingparts ................................................................ 11-022

LUBRICATION SYSTEM ................................................................ 1 I-032
Lubricationsystemchart ........................................................... II-032
Oil pump ......................................................................... 1 I-034
Regulatorvalve.. ................................................................. II-036
Oil filter (Built-in safety valve) ...................................................... 1 I-036
Oil filter (with element clogging caution sensor) ...................................... 1 I-037
By-passoilfilter .................................................................. II-038
Oil cooler ........................................................................ 1 I-040
2
FUEL SYSTEM ........................................................................ 1 I-043
Fz
w Fuelsystemchart ................................................................. II-043
Fuelinjectionpump ............................................................... II-044
Governor ........................................................................ II-052
Feedpump ....................................................................... II-058
Fuel injection nozzle ............................................................... 1 I-060
Fuelfilter ......................................................................... II-062
Fuelcutsolenoid.. ................................................................ II-064
Engine stop motor ............................................................... 11-064-I
COOLING SYSTEM .................................................................... 1 I-065
Cooling system chart .............................................................. 1 I-065
Waterpump ...................................................................... II-066
Thermostat ...................................................................... II-068
ELECTRICAL SYSTEM ................................................................. 11-070
Wiringdiagram ................................................................... II-070
Alternator ........................................................................ II-072
Startingmotor .................................................................... II-074
Electrical intake air heater .......................................................... II-076
Oilpressureswitch ................................................................ II-078
Relayswitch ..................................................................... II-078
ACCESSORY .......................................................................... II-080
Aircompressor .................................................................. 11-OBO
11-003
0
GENERAL STRUCTURE
SAGDllO-1 Engine No. 10001 - 49999
3i 3i 3b 2'9 2'8 i7 i6 i5
1. Fan 11. Cylinder head 21. Thrust bearing
2. Water pump 12. Cylinder block 22. Main bearing cap
3. Cylinder liner 13. Flywheel housing 23. Main bearing
4. Valve seat insert 14. Ring gear 24. Oil pan
5. Valve guide 15. Flywheel 25. Connecting rod cap
6. Valve (exhaust) 16. Tappet 26. Connecting rod bearing
7. Rocker arm shaft 17. Cam bushing 27. Front plate
8. Valve (intake) 18. Camshaft 28. Crankshaft gear
9. Cylinder head cover 19. Rear seal 29. Oil pump drive gear
10. Breather 20. Crankshaft 30. Front seal
11-004
0
STRUCTURE AND FUNCTION GENERAL STRUCTURE
6138F102
31. Crankshaft pulley 41. Turbocharger 51. Oil pump
32. Vibration damper 42. Piston 52. Feed pump
33. idler gear 43. Exhaust manifold 53. Fuel injection pump
34. Front cover 44. Top ring 54. Intake manifold
35. Cam gear 45. Second ring 55. Oil filter
36. Connecting rod 46. Oil ring 56. Electrical intake air heater
37. Piston pin 47. Oil filler 57. Fuel filter
38. Nozzle holder 48. Oil level gauge 58. Fuel injection pipe
39. Oil filler 49. Starting motor 59. After cooler
40. Rocker arm 50. Oil strainer
110 SERIES 1 l-005

0
GENERAL STRUCTURE STRUCTURE AND FUNCTION
SAGD.llO-1 Engine No. 50001 and up
11
12
13
14
15
16
17
16
6138F105
1. Fan 11. Cylinder head 21. Thrust bearing
2. Water pump 12. Cylinder block 22. Main bearing cap
3. Cylinder liner 13. Flywheel housing 23. Main bearing
4. Valve seat insert 14. Ring gear 24. Oil pan
5. Valve guide 15. Flywheel 25. Connecting rod cap
6. Valve (exhaust) 16. Tappet 26. Connecting rod bearing
7. Rocker arm shaft 17. Cam bushing 27. Front plate
8. Valve (intake) 18. Camshaft 28. Crankshaft gear
9. Cylinder head cover 19. Reaseal 29. Oil pump drive gear
10. Breather 20. Crankshaft 30. Front seal
11-006 110 SERIES

0
STRUCTURE AND FUNCTION GENERAL STRUCTURE
6138F106
31. Crankshaft pulley 41. Turbocharger 51. Oil pump
32. Vibration damper 42. Piston 52. Feed pump
33. Idler Qear 43. Exhaust manifold 53. Fuel injection pump
34. Front cover 44. Top ring 54. Intake manifold
35. Cam gear 45. Second ring 55. Oil filter
36. Connecting rod 46. Oil ring 56. Electrical intake air heater
37. Piston pin 47. Oil filler 57. Fuel filter
38. Nozzle holder 48. Oil level gauge 58. Fuel injection pipe
39. Oil filler 49. Starting motor 59. After cooler
40. Rocker arm 50. Oil strainer
110 SERIES 1 l-007

0
INTAKE AND EXHAUST SYSTEM STRUCTURE AND FUNCTION
INTAKE AND EXHAUST SYSTEM

S6DllO-1 (For WA350-1)
INTAKE SYSTEM
I. Air cleaner
2. Turbocharger
3. Intake pipe
4. Electrical intake air heater
5. Intake rqanifold
6. Inner element
7. Outer element
A. Intake
6138F109A
EXHAUST SYSTEM
8. Exhaust manifold
9. Muffler
10. Exhaust pipe
8. Exhaust
6138FllOA
11-008 110 SERIES

0
STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM
SAGDllO-1 (For D66S-1)
INTAKE SYSTEM
1. Precleaner
2. Air cleaner
3. Connector pipe
4. Turbocharger
5. Intake pipe
6. After-cooler
7. Intake manifold
A. Intake
6138F114-2A
EXHAUST SYSTEM
8. Exhaust manifold
9. Muffer
B. Exhaust
v 6138F1143A
110 SERIES 11-009

0
SAGDllO-1 (For W120-2 and W120-3)
INTAKE SYSTEM
1. Precleaner
2. Ejector pipe
3. Muffler
4. Turbocharger
5. Intake pipe
6. After-cooler element
7. After-cooler
8. Intake manifold
9. Electrical intake air heater
10. Air cleaner
11. Connector pipe
12. Outer element
13. Inner element
14. Dust indicator
A. Intake
6138Fll 1A
EXHAUST SYTEM
15. Exhaust manifold
B. Exhaust
6138F112A
110 SERIES
SAGDllO-1 (For WA400-I)
INTAKE SYSTEM
1. Air cleaner
2. Turbocharger
3. Intake pipe
4. After-cooler
5. Intake manifold
A. Intake
6138F1144A
EXHAUST SYSTEM
6. Exhaust manifold
7. Muffer
8. Exhaust pipe
B. Exhaust
6138F114-6A
110 SERIES 11-011

0
SAGDllO-1 (For EG150-3)
INTAKE SYSTEM
1. Air cleaner
2. Precleaner
3. Turbocharger
4. Intake pipe
5. After-cooler
6. Intake manifold
A. Intake
6138Flll-1A
EXHAUST SYSTEM
7. Connector pipe
8. Exhaust manifold
9. Muffler
B. Exhaust
6138F113-1A
11-012 110 SERIES

0
SAGDllO-1 (For EG150S-3)
INTAKE SYSTEM
1. Air cleaner
2. Turbocharger
3. Muffler
4. Bellows
5. Intake pipe
6. After-cooler
7. Intake manifold
A. Intake
6138Flll-2B
EXHAUST SYSTEM
8. Connector
9. Exhaust manifold
8. Exhaust
by 6138F113-2B
110 SERIES 11-013

0
SAGDllO-1 (For EC21OZ-1)
INTAKE SYSTEM
1. Air cleaner
2 2. Turbocharger
3. Intake pipe
4. After-cooler
5. Intake manifold
A. Intake
a. TO air tank (for air compressor)
a 6138F1113A
EXHAUST SYSTEM
6. Connector pipe
7. Exhaust manifold
8. Muffler
8. Exhaust
6138F113-1A
11-014 110 SERIES

0
Air cleaner
- Centrifugal type + filter paper type with automatic

ejector
Dust indicator
* Operating pressure (negative): 635 mmH,O
General description
1. Structure of intake and echaust system

. The intake and exhaust system consists of the pre-
cleaner, air cleaner, exhaust manifold, muffler and
exhaust pipe.
2. Circulation of intake
. The air intake is first filtered through the precleaner
to remove large dust particles after which it is clean-
ed of fine dirt and dust by the air cleaner. The air is
then charged into the engine.
. In case of turbocharger type engine, after filter
through the air cleaner, the air intake is charged
into the cylinders under pressure by the blower
impellers in the turbocharger.
3. Function of dust indicator

. After filtered through the air cleaner, the negative
intake air pressure is transmitted to the dust in-
dicator on the operator’s instrument panel. There-
by, the clogged condition of the air cleaner can be
sensed by the operator in his seat.
Dust indicator is actuated (gives a red warning
mark) when the negative air pressure reaches 635
mmHs0 (water column).
4. Circulation of exhaust
. Gases produced by the combustion in the cylinders
pass through the exhaust manifold, silenced by muf-
fler, and expelled from the exhaust pipe.
. In case of turbocharger type engine, gases passed
through the exhaust manifold are charged into muf-
fler after driving the turbine impellers (the blower
impellers).
110 SERIES 1 l-015

0
TURBOCHARGER
14
,15
1 I F059A
1. Turbine impeller 12. Thrust collar Specifications of turbocharger
2. Piston ring 13. Blower impeller Type: GARRET CO. TO4B
3. Turbine housing 14. Blower housing Overall length: 225 mm
4. Shroud 15. Lock nut Overall width: 210 mm
5. Journal bearing Overall height: 180 mm
6. Retaining ring A. Intake Weight: 6.5 kg
7. Center housing B. Air supply Continuous speed: 125,000 rpm (max.)
8. Seal ring C. Exhaust (inlet port) Max. air supply: 22 kg/min.
9. Thrust bearing D. Exhaust (outlet port) Compression ratio: 3 (max.1
10. Back plate E. Oil (inlet port) ’ Applicable exhaust temp.: Max. 675°C (at inlet)
11. Spring F. Oil (outlet port) Direction of rotation: Clockwise

(as seen from belower side)
11-016 110 SERIES
0
Structure
* The turbocharger for S6DllO-1 and SA6DllO-1 en-

gines is the Type T04B.
* The turbocharger consists mainly of the blower

housing, blower impeller, turbine housing, wheel
shaft and the center housing provided with bearings
and seals and forming the lubrication and support
section.
* As the rotating components of a turbocharger, a

wheel shaft consists of turbine impellers and a shaft
integrated together, and blower impellers are force-
fitted on the shaft portion opposite to the turbine
impellers and fixed positively with lock nuts.
- The blower housing and the center housing and

interconnected with ring type V-clamps, while the
center housing and the turbine housing are mutually
secured with 6 bolts.
Function
- In the turbocharger, the turbine impeller is rotated

by the energy of the flowing gases produced by
combustion in the cylinders, and the blower impeller
on the same shaft in turn charges the intake air into
the cylinders under pressure.
- For lubrication, the engine oil is supplied through

a hole in the top of the center housing. The oil
flows back into the engine oil pan through a hole
in the bottom of the center housing after lubricating
the bearings.
Oil in the turbocharger is prevented from leaking
out by means of the seals on both sides of the center
housing.
110 SERIES 11-017

Co
AFTER-COOLER (SAGDI 1 O-l)
1 2
1. After-cooler cover
2. After-cooler core
3. Intake manifold
11-018 110 SERIES

0
ENGINE BODY STRUCTURE AND FUNCTION
ENGINE BODY
CYLINDER HEAD
1. Cylinder head mounting bolt 11. Nozzle holder sleeve
2. Nozzle holder 12. Fuel injection nozzle
3. Rocker arm shaft 13. Oil filler cap
4. Cylinder head 14. Valve spring guide
5. Cylinder head gasket 15. Valve cotter
6. Head cover 16. Valve spring
7. Valve guide 17. Valve spring seat
8. Exhaust valve 18. Intake valve
9. Valve seat insert 19. Push rod
IO. Nozzle holder packing
1 l-020 110 SERIES

0
ENGINE BODY
Cross section of exhaust val 13

(No. 1 cylinder)
14
15
1 16
1 17
18
1
19
Crosssection of intake valve

(No. 1 cylinder)
6138FOO88
Cylinder head
Direct injection, 2 valve, injection nozzle assembled, one

piece
Valve seat
Valve seat insert press fitted for both intake and exhaust
valves
110 SERIES
1 l-021
0
.
MAIN MOVING PARTS ‘(l/3)
Section A - A
Section B - B (no adapter) Section B - B (with adapter)
1. Bearing cover 10. Cylinder block Cylinder block

2. Front cover 11. Thrust plate (for cam gear) Crankshaft: 7 bearings
3. Rotation pick-up cap 12. Main bearing cap Camshaft: 4 bearings
4. Camshaft gear (52 teeth) 13. Bolt of main bearing cap
5. Idler gear (40 teeth)
6. Idler gearshaft
7. Bushing
8. Thrust plate (for idler gear)
9. Front elate
11-022 110 SERIES

0
STRUCTURE AND FUNCTION ENGINE BODY
9
\
6138FOO82A
Valve timing
Engine No. 50001-
Engine No. 10001 - 49999
Top dead center

Top dead center
Bottom dead center 6136FOlO Bottom dead center 6136F116
110 SERIES 1 l-023

0
ENGINE BODY
MAIN MOVING PARTS (2/3)

Engine No. 10001 - 49999
\ \ \ :,
li 13 14 15 16
14. Oil pump drive gear
1. Piston
2. Top ring 15. Crankshaft gear
Second ring 16. Connecting rod bearing

3.
4. Oil ring 17. Tappet
Snap ring 18. Camshaft

5.
6. Piston pin 19. Crankshaft
Connecting rod 20. Main bearing (upper)

7.
8. Mounting bolt of crankshaft pulley 21. Main bearing (lower)
Spacer 22. Thrust bearing

9.
10. Crankshaft pulley (0.0.144 mm) 23. Rear seal
11. Vibration damper 24. Ring gear
Taper collar 25. ‘Flywheel

12.
Front seal 26. Front P.T.O. pulley (0.D. 200 mm)

13.
110 SERIES
1 l-024
0’
/
23 6136FOO96
Piston Piston ring
Elliptical taper profile, thermal flow type

Engine Top ring Second ring Oil ring
MTCC: Micro Turbulence Combustion Chamber
Both faces: One face: With coil ex-
Front seal keystone keystone pander
barrel face taper face
Single lip with dust seal Hard chrome Hard chrome
S8DllO plating plating
Rear seal SAGDI 10
Double lip
Single lip (generator)
r--i--l
Connecting rod bolt
6138FOO9-1
Screw-in type
Piston cooling: Yes
110 SERIES 1 l-025

0
Engine No. 50001 and up
11'
\
12 13 Ih 1‘5 16
1. Piston 14. Oil pump drive gear
2. Top ring 15. Crankshaft gear
3. Second ring 16. Connecting rod bearing
4. Oil ring 17. Tappet
5. Snap ring 18. Camshaft
6. Piston pin 19. Crankshaft
7. Connecting rod 20. Main bearing (upper)
8. Mounting bolt of crankshaft pulley 21. Main bearing (lower)
9. Spacer 22. Thrust bearing
10. Crankshaft pulley (0-D. 144 mm) 23. Rear seal
11. Vibration damper 24. Ring gear
12. Taper collar 25. Flywheel
13. Front seal 26. Front P.T.O. pulley (0.D. 200 mm)
11-026 110 SERIES

0
1c 2b 21 22 23 24 25
6138FO12
Piston Piston ring

Elliptical taper profile, thermal flow type
Engine Too rinq Second rirw Oil ring
MTCC: Micro Turbulence Combustion Chamber
Both faces: One face: With coil ex-
keystone keystone pander
Front seal barrel face taper face
Hard chrome Hard chrome
Single lip with dust seal S6DllO olatina plating
SAGDllO
Rear seal
Double lip
Single lip (generator) Both faces: One face:
keystone keystone M-shape, steel
barrel face taper face
Connecting rod bolt ring, hard
S6D110 Hard chrome Hard chrome
chrome plating
(WA360-1 plating plating with coil ex-
Screw-in type
SAGDllO pander
lWA400-1
Piston cooling: Yes
6138F009.1A
110 SERIES 11-027

Co
MAIN MOVING PARTS (3/3)

Engine No. 10001 - 49999
1. Flywheel housing X-X’: Center of crankshaft
2. Flywheel mounting bolt Y-Y’: Center of cylinder
3. Cylinder liner
4. Oil pump regulator valve
5. Tappet cover
6. Camshaft bushing
1l-028 110 SERIES
0
ENGINE BODY
Y
I
3
\
6136FOll
Cylinder liner
Dry type
110 SERIES
11-029
0
1. Flywheel housing X-X’: Center of crankshaft
2. Flywheel mounting bolt Y-Y’: Center of cylinder
3. Cylinder liner
4. Oil pump regulator valve
5. Camshaft bushing
1 l-030 110 SERIES

0
ENGINE BODY
6136F116
Cylinder liner
Dry type
1lOSERlES
11-031
0
LUBRICATION SYSTEM STRUCTURE AND FUNCTION
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART
Engine No. 10001 - 49
1. Oil strainer
2. Oil pump
3. Oil cooler
4. Oil filter
5. Regulator valve
6. Oil filter safety valve
7. Oil cooler relief valve
8. Crankshaft
9. Camshaft
IO. Piston
u u u u
/
17 11. Piston cooling
8 12. Rocker arm
13. Intake/exhaust valve
14. Turbocharger
15. Fuel injection pump
16. Timing gear
17. Oil pressure switch

(Option)
18. Oil pressure sensor

(Option)
6138f131
LUBRICATION SYSTEM
1. Structure of Lubricating system

The oil discharged from the pump is cleaned fully
The lubricating system consists mainly of the oil
through the oil filter (full-flow type).
strainer, oil pump, oil pump regulator, oil cooler
Thus, the oil is distributed to various lubrication
oil filter and safety valve to lubricate various engine
points in the engine.
parts.
Circulation of lubricating oil . The oil is cooled, through heat exchanger with the
The lube oil flows from the oil pan to the oil pump engine cooling water at pipes in the oil bracket or
through the oil strainer where relatively large parti- in the oil cooler.
cles of dust, dirt, or, foreign matter is removed
from the oil. The oil pump is driven by the gear in
the crankshaft cluster to such in and charge out the
oil under pressure.
1l-032 110 SERIES

0
STRUCTURE AND FUNCTION LUBRICATION SYSTEM
Engine No. 5000 1 and up
6136F014.5A
1. Oil strainer Il. Piston cooling nozzle
2. Oil pump 12. Rocker arm
3. Oil cooler 13. Intake/exhaust valve
4. Oil filter 14. Turbocharger
5. Regulator valve 15. Fuel injection pump
6. Safety valve 16. Timing gear
7. Oil cooler therm0 valve W. Cooling water
8. Crankshaft
9. Camshaft
10. Piston
110 SERIES 11-033

0
LUBRICATION SYTSTEM STRUCTURE AND FUNCTION
OIL PUMP
Engine No. 10001 - 49999
6
I. Outer rotor 5. inner rotor
2. Pump cover 6. Pump body
3. Pump shaft 7. Drive gear (38 teeth)
4. Bushing
6138FO13
Structure Oil pump

* Oil pump a trochoid type and installed in the engine Type: Trochoid pump
front cover. Speed: Engine speed x 1 .I 58
* The drive gear is attached at the rear end of the

rotor shaft of the oil pump and is in gear with the
drive gear at the front side of the crankshaft.
Function
- The inner rotor (1) of a trochoid pump is rotated - The oil is sucked into the pump when the tooth
together with the rotor shaft (3). The number of clearance between the inner and outer rotors is
teeth in the inner rotor is one less than the outer extended. The oil is discharged when the tooth
rotor (2). Both rotors rotate in the same direction clearance becomes smaller.
with their respective centers set off.
Intake Exhaust
I IF018
11-034 110 SERIES

10/
Regulator valve 6136FO15-1
1. Oil pump body (9 teeth) Oil pump
2. Drive gear Type: Gear pump
3. Pump cover Speed: Engine speed x 1 .I 58

4. Pump drive gear (38 teeth)
5. Drive shaft Regulator valve
6. Driven gear (9 teeth) * Cracking pressure: 6.5 f 0.5 kg/cm2

7. Driven shaft
8. Regulator valve
9. Valve spring
10. Valve retainer
A. From oil strainer
B. From oil pump
C. To engine
D. To oil pan
110 SERIES 11-035

0
REGULATOR VALVE
Engine No. 10001 - 49999 1. Nut
2. Adjustment shim
3. Valve body
1 4. Valve
5. Valve spring
Regulator valve
Cracking pressure: 7.4 f 0.8 kg/cm’
6136FO16
OIL FILTER (Built-in safety valve)

1. Filter bracket
2. Cartridge
3. Safety valve
A-
A. From oil pump
B- 6. To engine
a. Oil pressure tap
Safety valve
Actuating pressure: 2 +_ 0.2 kg/cm2
Oil filter
Filtration area: 0.5 m2
6136FO17C
11-036 110 SERIES
0
OIL FILTER (with element clogging caution sensor)
A
2
1. Caution sensor
B
2. Filter bracket
3. Cartridge
4. Safety valve
3
A. From oil pump
B. To engine
Safety valve
Cracking pressure: 2 f 0.2 kg/cm’
Oil filter
Filtration area: 0.5 m2
6136FO13-1
CLOGGING CAUTION SENSOR
1. Spring
2. Spring
3. Contactor
4. Contactor
Caution sensor
Actuating pressure: 1 .5+$4 kg/cm2
6136FO152
110 SERIES 1 l-037

Co
BY-PASS OIL FILTER

Engine No. 10001 - 49999
1. Filter cover
2. Filter element
3. Filter case
4. Drain plug
5. Center bolt
A. Oil inlet port
B. Oil outlet port
Filtration area: 2,450 cm2
14 6138FO14
1 l-038 110 SERIES

0
,-
OIL COOLER
Engine No. 10001 - 49999
Section A - A
Section B - B
Section C - C
6138FO15
1. Valve case Oil cooler by-pass valve
2. Valve spring
Actuating pressure: 4 + 0.2 kg/cm2
3. By-pass’valve
4. Cooler cover
5. Cooler element
D. From oil pump
a. Water drain port
Structure and function
* The oil cooler consists of element and cover. The

oil flowing through the cooler element with the
cooling fin is cooled properly by the engine cooling
water flowing outside the element.
11-040 110 SERIES

0
Section B - B
Section A - A
6136FO16.3
Section E - E
1. Spring Oil cooler therm0 valve

2. Then-no valve - Opening temperature: 104°C
3. Valve spring * Full opening temperature: 11 O’C
4. Cooler cover * Full opening lift: min. 5 mm
5. Cooler element
G. From oil pump (oil)
H. To engine (oil)
I. From water pump (cooling water)
J. To oil filter (oil)
K. To engine (cooling water)
110 SERIES 11-041

0
STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM CHART
Engine No.50001 -
1. Fuel tank
2. Feed pump
3. Fuel filter

‘2
5. Fuel injection nozzle 6138FOl B-2A
GENERAL DESCRIPTION
Structure of fuel system
The fuel system consists mainly of the fuel tank, 2) Fuel entering the injection pump is pressurized by
feed pump, fuel filter, fuel injection pump, fuel the pump plunger to that required for injection
injection nozzles and governor (built as one unit and injected into each cylinder through the injection
with the fuel injection pump). nozzle in the quantity required, meeting the in-
jection timing for the cylinder.
Circulation of fuel
Fuel is delivered from the fuel tank to the injection

pump through the fuel filter by the feed pump
driven by the fuel injection pump cam. During the
course from the tank to the injection pump, the
fuel is cleaned of rough dirt through the gauge
filter at the inlet to the feed pump. Then, complete
dust removal and water separation from the oil
are accomplished through the filter.
110 SERIES 11-043

0
FUEL SYSTEM STRUCTURE AND FUNCTION
FUEL INJECTION PUMP

Without air compressor
i i ‘11
1. Fuel injection pipe (No. 6) IO. Rotation pick-up shaft a: From fuel tank (fuel)
2. Fuel injection pipe (No. 5) 11. Drive shaft b: To fuel filter (fuel)
3. Fuel injection pipe (No. 4) 12. Automatic timer c: To fuel injection pump (fuel)
4. Fuel injection pipe (No. 3) 13. Injection pump bracket d: To injection nozzle (fuel)
5. Fuel injection pipe (No. 2) 14. Fuel injection pump e: To fuel tank (fuel return)
6. Fuel injection pipe (No. I) 15. Boost compensation pipe f: From cylinder block (oil)
7. Fuel hose 16. Fuel filter 9: To cylinder block (oil)
8. Injection pump gear 17. Oil pipe
9. Ball bearing 18. Oil pipe
11-044 110 SERIES

0
FUEL SYSTEM
El i 111
View Z View Z
613SFO19
Fuel injection pump
Type: Diesel Kiki Bosch PE-AD

with automatic timer
(EC21 OZ-1)
with boost compensator (D66S-I)
Lubrication: Forced lubrication with engine oil
Governor
Type: Diesel Kiki Bosch RSV

(Centrifugal, all-speed type)
Fuel injection timing:
See, 12 TESTING AND ADJUSTING DATA
110 SERIES 1 l-045

0
With air compressor
6138FO16
1. Fuel injection pipe (No. 6) 12. Drive shaft a: From fuel tank (fuel)
2. Fuel injection pipe (No. 5) 13. Rotation pick-up shaft b: To fuel filter (fuel)
3. Fuel injection pipe (No. 4) 14. Automatic timer c: To fuel injection pump (fuel)
4. Fuel injection pipe (No. 3) 15. Injection pump bracket d: To injection nozzle (fuel)
5. Fuel injection pipe (No. 2) 16. Fuel injection pump e: To fuel tank (fuel return)
6. Fuel injection pipe (No. 1) 17. Oil pipe f: From cylinder block (oil)
7. Air hose 18. Boost compensation pipe 9: To air compressor (oil)
8. Fuel hose 19. Relay switch h. To cylinder block (oil)
9. Air compressor 20. Fuel filter bracket
10. Injection pump gear 21. Oil pipe
11. Ball bearing
11-046 110 SERIES

0
Y ‘\M \ i ::
--A I I
+
6138FO17
Fuel injection pump
Type: Diesel Kiki Bosch PE-AD

with automatic timer (W120-2,3)
with boost compensator
(W120-2,3, WA350-1, WA400-1)
Lubrication: Forced lubrication with engine oil
Governor
Type: Diesel Kiki Bosch RSV

(centrifugal, all-speed type)
Injector
Type: Multiple hole
Injection pressure: 250 kg/cm2
Fuel injection timing:

See, 12 TESTING AND ADJUSTING DATA
110 SERIES 11-047

0
FUEL SYSTEM
FUEL INJECTION PUMP
1. Delivery valve holder
2. Delivery valve spring
3. Delivery valve
4. Oil reservoir
5. Plunger barrel
6. Plunger
7. Deflector
8. Control rack
9. Control sleeve
10. Plunger spring
11. Tappet
12. Camshaft
GENERAL DESCRIPTION
. The fuel injection pump is a Bosch type PE-AD.

Its pump housing, governor housing are forced
lubricated with the engine oil.
* The fuel injection pump is driven by the pump

drive gear in the timing gear cluster and the direc-
tion of its rotation is clockwise as viewed from the
driving side.
13. Oil inlet port A. From main gallery
14. Oil outlet port B. To oil pan
15. Drain plug
16. Drain plug I I F025
1 l-048 110 SERIES
0
1. Structure of injection pump 5. Plunger barrel
. 6. Plunger
The Bosch type fuel injection pump contains; plunger
barrels (5). plunger (6), plunger springs (IO), taPPets 9. Control sleeve
(ll), and tappet rollers (18), each in the same quan- 10. Plunger spring
tity as the engine cylinders, and these serve, together 11. Tappet
with the camshaft (12), as the parts giving rise to the
12. Camshaft
fuel injection pressure.
17. Fuel outlet and inlet port
18. Tappet roller

2. Pumping action
1) Each plunger makes a vertical piston movement to

deliver fuel under pressure by the combined action
of the cam on the camshaft and plunger spring.
I I F026
2) If the plunger (6) is lowered so that the inlet and 5. Plunger

discharge ports (17) in the plunger barrel (5) are 17 barrel
opened by the tip of plunger, fuel will begin to flow 6. Plunger
into the barrel and stop flowing in when the plunger 17. Fuel outlet
and inlet
comes into its lowest position.
5 Port
(suction and
discharge
Port)
L.cJ I I F027
3) Then, the plunger (6) will start to rise, and as soon

as the inlet and discharge ports (17) in the plunger
barrel (5) are closed, the fuel pressure in the barrel
will begin to rise.
4) If the plunger rises further so that a helical relief Increase of Completion Withdrawal
pressure Under transfer of transfer (no oil transfer)
(19) in the plunger comes in line with the inlet and
discharge ports, fuel will flow back to the inlet and I I F026
discharge ports through the helix from the plunger
center, causing the fuel pressure to drop rapidly.
5. Plunger barrel
6. Plunger
17. Suction and discharge ports
19. helical relief (Helix)
110 SERIES 1 l-049

0
20
Effective stroke
5
Distance from a position where the rising plunger
(6) closes the suction and discharge ports (17) in
the plunger barrel (5) with its tip to a point where 6
the helical relief (19) in the plunger comes in line
with the inlet and discharge ports is called the ef- 19
fective stroke (20). Quantity of fuel to be injected Effective stroke is short Effective stroke is long
varies in proportion to this effective stroke. I I F029
The helical relief in the plunger is cut diagonally
with reference to the upper surface. Rotating the
5. Plunger barrel 19. Helical relief
plunger causes the effective stroke or the quantity
6. Plunger 20. Effective stroke
of fuel to be injected to vary as desired.
17. Suction and discharge port
Adjustment mechanism for fuel injection capacity
In the lower part of plunger (6) is provided a T-

shaped flange (211, which is fitted into the helix
in the control sleeve (9).
8
On the control sleeve is mounted the control pinion
(22) which is meshed with the control rack (6). 22
The control rack is connected to the governor and

fuel control lever. The movement of the control
rack rotates the plunger, thereby adjusting the
quantity of fuel to be injected.
I I FO30
5. Plunger barrel 9. Control sleeve
6. Plunger 21. Plunger flange

5. Switching of fuel injection
8. Control rack 22. Control pinion
On the top of plunger is installed the delivery valve
holder (I) in which the dlivery valve (3) and spring
1. Delivery valve holder
(2) are set.
2. Delivery valve spring
. Fuel highly pressurized by the plunger openes the 1 3. Delivery valve
delivery valve, overcoming the tension of the delivery
valve spring, and is discharged into the injection pipe.
I IF031
11-050 110 SERIES
0
The piston section (23) is provided at the lower end

of delivery valve (3). If the fuel pressure drops after
fuel discharge by the plunger is completed, the deli-
very valve will be pushed down by the delivery valve
spring (2). causing the piston section in the valve to
close the fuel port at first, which will, in turn, prevent
the reverse flow of fuel. I I F032
Retraction work
The delivery valve will be pushed down further, 2. Delivery valve spring
causing fuel in’the fuel injection pipe to flow back,
3. Delivery valve
and the .valve will be stopped at its tapered seat.
23. Piston
The above valve action is called the RETRACTION 24. Retraction stroke
WORK of injection, and such a working stroke of
the valve is called the retraction stroke (24).
The RETRACTION WORK, prevents dribbling or

assists in producing a satisfactory cut-off of fuel
injection through the nozzle.
,. Special functions of the injection pump
1) Damping valve
* A damping valve serves to slow down the drawing-

back action of discharged fuel for smaller pulsa-
tion of fuel being discharged.
- The necessity of using a damping valve depends on

the amount of fuel required by an engine and the
engine speed.
2) Cancelling spring
A cancelling spring is used at the injection pump con-

trol lever and serves to lessen the lever operating
effort.
110 SERIES 11-051

0
FUEL SYSTEM
GOVERNOR ’
1. Tension lever
2. Start spring
3. Floating lever
4. Guide lever
5. Idling sub-spring
6. Shifter
7. Sleeve
8. Adapter spring
9. Flyweight
10. Full-load stopper
11. Control rack
12. Swivel lever
13. Governor spring
14. Control lever
15. Camshaft
16. Torque spring
17. Lever
I I F033
General description
Functions of governor * In addition to the above, the angleich unit adjusting

the maximum fuel injection quantity at various
The governor is a Bosch RSV mechanical ail-speed
rotational speeds, the torque spring unit to obtain
type and serves to control the engine output power
an injection quantity corresponding to a sharp
by changing the position of the control rack in the
change in load during engine operation, an idling
fuej injection pump (by adjusting the quantity of
sub-spring to maintain an idling speed, a start spring
fuel injected).
to ease the engine starting, etc. are installed in the
A flyweight actuated by the centrifugal force in the governor.
governor serves to move the sleeve depending on
change in the rotational speed and adjust the move-
ment of control rack through the guide lever.
On the other hand, the fuel control lever adjusts
the movement of the control rack through the
tension lever for the governor spring.
110 SERIES
1 l-052
Co
Function of the governor
1. Engine starting
* If the fuel control lever (14) is pushed to START

position, the governor spring (13) connected to the
swivel lever (12) integrated with the control lever
will be pushed until the tension lever (1) is brought
into contact with the full-load stopper (IO) at the
lower end.
- Then, the sleeve (7) will be shifted to the left, and

the control rack (11) will be pulled by the start
spring (2) in the direction of increasing the fuel
quantity, making ease the engine starting.
I I F034
1. Tension lever I 3. Governor spring

2. Start spring 14. Control lever
7. Sleeve A. Start position
10. Full-load stopper B. Full-load position
11. Control rack C. Idling position
12. Swivel lever 0. Stopping position
2. Engine idling
- If the control lever (14) is moved back to IDLING

position after engine start, the governor spring (13)
will become weak in tension, causing the flyweight
to open outward at a low speed. Then, the sleeve
(7) will move to the right, pushing the tension lever
(1) to a point where the idling sub-spring (5) applies
tension. Consequently, the floating lever (3) will
move to the right with the lower end used as the
fulcrum, bringing the control rack (11) into the
idling position.
- When the revolution increases, the flyweight opens

and move the tension lever to the right, then the
idling sub-spring operates to adjust the idling re-
volution. If the revolution decrease excessively, the
start spring (2) works to keep the idling revolution.
I F035
1. Tension lever 7. Sleeve

2. Start spring 9. Flyweight
3. Floating lever 11. Control rack

4. Guide lever 13. Governor spring
5. Idling sub-spring 14. Control lever
C. Idling position
110 SERIES 1 l-053

0
3. Max. speed control
* If the control lever (14) is pushed into FULL-LOAD

position, the governor spring (13) will be extended
all the way, pulling the tension lever (1) unit the
lever comes into contact with the full-load stopper
(IO). The flyweight (9) will be closed and at the
same time, the control rack will be moved in the
direction of increasing the fuel quantity. Thereby,
the maximum speed will be obtained.
- If the engine revolutions exceeds the specified range,

the centrifugal force of the flyweight will be larger
than the governor spring tension, causing the sleeve
(7) to move to the right, which will, in turn, move
the control rack (11) in the direction of decreasing i YO I I F036
the fuel quantity. Thereby, the excessive increase
in the revolutions will be prevented.
1. Tension lever 11. Control rack
7. Sleeve 13. Governor spring
9. Flyweight 14. Control lever
10. Full-load stopper B. Full-load position
4. Angleich unit
0 In the engine, if the revolution increases excessively,

the intake air resistance will increase, deteriorating
the air suction efficiency. In the injection pump,
fuel is injected approximately in proportion to the
revolutions and therefore, the complete combustion
over the whole range of revolution will be difficult.
- The Angleich unit serves to prevent the torque re-

duction due to the trend of LOCK IS FUEL at low
speed, while aiming. at COMPLETE COMBUSTION
at high speeds, thereby improving the above un-
satisfactory conditions.
- Where the revolutions are low withe the tension

lever (1) in contact with the full-load stopper (IO)
and the centrifugal force of flyweight (9) is smaller
than the tension of the adapter spring (81, the
adapter spring will shift the sleeve (7) to the left,
causing the control rack (11) to move in the direc-
I I F037
tion of increasing the fuel quantity. Thereby, the
torque at low speeds will be increased.
1. Tension lever 9. Flyweight
- As the engine speed increases, the centrifugal force 7. Sleeve 10. Full-load stopper
of the flyweight will push the adapter spring through 8. Adapter spring 11. Control rack
the sleeve. When the spring comes into contact with
the tension lever, the function of increasing the fuel
quantity will be terminated.
11-054 110 SERIES

0
5. Engine stop
- The swivel lever (12) has a protrusion. If the control

lever (14) is pushed into STOP position, the swivel
lever protrusion integrated with the control lever
will come into contact with the guide lever (4).
- Then, the guide lever will move the control rack to

the NON-INJECTION position through the floating
lever (3).
I IF038
2. Floating lever 12. Swivel lever
4. Guide lever 14. Control lever
9. Flyweight D. Stop position
6. Function of the torque spring

16
* The torque spring serves to prevent the abrupt
reduction in the engine revolutions or the engine
stoppage due to a sharp increase in load.
- If the engine speed is about to decrease due to a

* sharp increase in load during operation, the fly
weight (9) will close to move the sleeve (7) to the
left, which will cause the control rack (I I) to move
in the direction to decrease the fuel quantity.
- At this time, the torque spring (16) connected to

the tension lever (1) will apply its tension in the
direction of increasing the fuel quantity, slowing
down the control rack. Thereby, the abrupt reduc-
tion in the engine speed or the engine stoppage will
be prevented.
I IF039
7. Sleeve 16. Torque spring
9. Flyweight 17. Lever
1lOSERlES 11-055
0
WITH BOOST COMPENSATOR
1 2 3 4 5 6
1. Governor spring
2. Floating lever
3. Guide lever
4. Tension lever
5. Push rod
6. Boost compensator spring
7. Adjustment screw
8. Diaphragm
9. Boost compensator lever
10. Idling subspring
11. Adapter spring
12. Full-load stopper
13. Camshaft
14. Flyweight
15. Swivel lever
16. Control rack
17. Start spring
A Boost pressure (From air CrOSSOVer)
B. Fuel injection quantity

increasing direction
Function of boost compensator - The governor with boost compensator improve

largely exhaust gas as compare with governor with-
* The boost compensator is actuated by boost pressure
out boost compensator, because fuel injection quan-
of a turbocharger and serves to increase fuel injection
tity is decreased when an engine is accelerated or
quantity at high-speed, high-load engine operation
running at low speed.
conditions, without regard to governor operation.
- In a turbocharged engine, inertia of the turbocharger
rotation accelerates increase of fuel injection quantity
in advance of intake air when the fuel control lever is
pulled to accelerate engine speed, thus making ex-
haust smoky during transitional period of time.
Operation
- Accordingly, any of three kinds of fuel injection sett‘-
ing must be selected: reducing fuel injection quantity . When boost pressure exceeds a set value, the dia-
to obtain clean exhaust with restricted turbocharger phragm (8) is pressed in. The movement of dia-
capacity; keeping the maximum fuel injection setting phragm is transmitted through the push rod (5),
while smoky exhaust being left unvaried; and an boost compensator lever (9) and floating lever (2) to
intermediate fuel injection setting which can partially the control rack (16) to move it in the fuel injection
improve exhaust. quantity increasing direction.
- The boost compensator improves the above problem, . Working booster pressure and movement of dia-
so that the turbocharger can function efficiently phragm depend on tension of the boost compensator
with fine exhaust gas color when accelerating. spring (6) and setting of spring tension can be ad-
justed with the adjustment screw (7).
11-056 110 SERIES

FEED PUMP
1. Nut
2. Oil seal
3. Priming pump
4. Camshaft
5. Piston
A. Suction port
6. Dischargeport
. The fuel pump is driven by the cam on the fuel injec-

tion pump camshaft and delivers fuel under pressure
of approx. 1.5 kg/cm’. When removing the air, you
can feed the fuel by pushing the priming pump by
hands.
Function
4. Camshaft
1. Preparation for fuel delivery
5. Piston
. The piston (5) in the feed pump is pushed in by the
6. Check valve
cam on the camshaft (4) causing the fuel in the lower
section below the piston to open the check valve 7. Check valve
(6) on the discharge side and flow into the upper 8. Piston spring
section of the piston.
A. Suction port
. At this time, the check valve (7) on the suction side 6. Discharge port
is closed under the pressure of fuel pushed in by the
piston, thereby preventing the reverse flow of fuel.
A llF041A
2. Suction and discharge
. If the camshaft (4) is rotated, bringing the cam out
of the piston, the piston (5) will be pushed upward
by the piston spring (8). The resultant fuel pressure
will close the check valve (6) on the discharge side,
while fuel is delivered to the discharge port (8).
. In the section below the piston will be generated the

negative pressure, causing the check valve (7) on the
suction side to open so as to draw in fuel.
A 11 FO42A
11-058 110 SERIES
0
3. Control fuel supply 4. Camshaft
. Fuel in the section above the piston is through direct- 5. Piston

ly to the passage on the discharge side. If the fuel 6. Check valve
pressure on the discharge side increases, it will be-
7. Check valve
come impossible to push the piston (5) upward by
the piston spring (8). Thus, the suction and dis- 8. Piston spring
charge of fuel will be stopped until the fuel pressure
A. Suction port
on the discharge side drops by controlling the fuel
B. Discharge port
quantity to be delivered.
A 11 FO43A
4. Function of the priming pump
. The priming pump discharges fuel in the section
below the piston when the piston (IO) is pushed in
by hand, and sucks in fuel when the piston is drawn
up by spring (9).
. The check valves on the suction and the discharge

sides (6) and (7) are used in common with those B B
in the feed pump body. When delivery fuel, the

6 6
valves on the suction side are closed and those on the
discharge side are opened. When sucking in fuel,
the valves on the suction sides are opened and those
on the discharge side are closed.
n Oil suction
Oil discharge
llFO44A
6. Check valve 10. Piston
7. Check valve A. Suction port
9. Spring B. Discharge port
110 SERIES 11-059

0
FUEL SYSTEM STRUCTURE AND FUNCTION’
FUEL INJECTION NOZZLE

Engine No. 10001 -
6137FOlO.2
1. Nozzle holder cap FUEL INJECTION NOZZLE
2. Adjustment screw * Maker: DIESEL KIKI

- Type: Multi-hole type
3. Nozzle spring
* Injection pressure: 250 kg/cm2
4. Nozzle holder * Adjustment of injection pressure: by adjustment screw
5. Push rod
6. Retaining cap
7. Nozzle body
8. Nozzle
A. From fuel injection pump
B. To cylinder (injection)
C. To fuel tank
1 l-060 110 SERIES
Co
6138Fllg
1. Nozzle holder cap FUEL INJECTION NOZZLE
2. Adjustment screw - Maker: DIESEL KlKl

* Type: Multi-hole type
3. Nozzle spring
- Injection pressure: 250 kg/cm2
4. Nozzle holder * Adjustment of injection pressure: by adjustment screw
5. Push rod
6. Retaining cap
7. Nozzle body
8. Nozzle
A. From fuel injection nozzle
8. To cylinder (injection)
C. To fuel tank
110 SERIES 11-061

0
FUEL FILTER
S6DllO-1
6136F120
1. Air bleed plug FUEL FILTER
2. Bracket - Filtration area: 0.5 m2
3. Cartridge
A. From feed pump
6. To injection pump
1 l-062 110 SERIES
Co
SAGDllO-1
1
6138FOlSA
1. Air bleed plug FUEL FILTER

2. Bracket * Filtration area: 0.5 m2
3. Cartridge
A. From feed pump
B. To injection pump
110 SERIES 1 1-063

0
FUEL SYSTEM
FUEL CUT SOLENOID
Inner wiring 6138F122
1. Shaft
SOLENOID
2. Boot
- Maker: NIKKO DENKI
- Type: Sealed
3. EOdV
- Rated voltage: 24V
4. Cover - Operating current
Maximum: Max. 35A
C,: O.BSX
Continuity: Max. 0.5A
c,: 6Oi-L
* Stroke: 12 f 0.3 mm
- Weight: 2.9 kg
110 SERIES
1 l-064
0
ENGINE STOP MOTOR
I-A i /
Shape of cable tip
-(non-threaded stopper type)-
..r---.‘r
:_;._:.:,
35
Stroke
Shape of cable tip

- (threaded stopper type)
Stroke
Made by AMP Co.,

Econoseal connector,
8P male
2. Not used (filler plug added)
\ / !. Not used (filler plug added)

4.8(AV 0.85LR)
3. P, (AV 0.85LY)
. Not used (filler plug added)
8. E(AV 0.858)
Engine stop motor

1. Motor assembly
- Maker: Jidosha Denki Kogyo Co., Ltd.
2. Cover - Rated voltage: DC24V
3. Cable assembly - Operating force: 15 kg min.
* Stroke: .J5 +1.o,
4. Cable clamp -0.4 mm
5. Coil spring * Weight: 1.2 kg
6. Cable
7. Screw
6. Breather
9. Bracket assembly
10. Cover assembly

STRUCTURAL DRAWING (1)
1. Gear cover assembly
2. Slider assembly
3. Armature shaft
4. Contactor assembly
5. Roller
6. Worm wheel assembly
7. Motor assembly
8. Gear case assembly
’’-“;4-2
STRUCTURAL DRAWING (2)
1. Gear cover assembly
2. Motor assembly
3. Cable clamp
4. Cable assembly
5. Gear case assembly
1 l-064-3
Gc
DESCRIPTION OF OPERATION AND CIRCUITS
1. Stop condition (O” or 360’)

A, , Battery
The above drawing shows the stopped condition assembly is stopped at the auto-stop position on the
when a closed circuit has been formed. The slider PI side.
2. When switch is turned (when starting the motor)
Batterv
+1+-i
When the switch is moved to the P, side (starting bly, thereby starting the motor. The slider assembly
switch ON), an electric current flows from the plus starts to move in the direction of the arrow at the
side contactor plate through.the P, auto-stop ter- same time as the roller starts to move.
minal and switch and into the armature shaft assem-
3. Turning condition (90’ in the drawing)
Electric current continues to pass through the arma- slider assembly also continues to move in the direc-
ture shaft assembly and the motor continues to tion of the arrow.
turn. Because of the rotation of the roller, the
11-064-4 -:,
@ ..
4. When stopped (180°)
Battery
44
A closed circuit is formed when the P, auto-stop and the motor comes to a sudden stop. The slider
terminal rides on the minus-side contactor plate, assembly also stops.
5. When switch is turned (when starting the motor)
A_ Battery
,
B:
! IW
P,
1
\
j$$@
/-
-+
-++I
A0-J
6 P, II
I’ E,
When the switch is moved to the PI side (starting thereby starting the motor. The slider assembly
switch OFF), an electric current flows from the plus starts to move in the direction of the arrow at the
contactor plate through the PI auto-stop terminal same time as the roller starts to move.
and switch and into the armature shaft assembly,
6. Turning condition (270’ in the drawing)
A_ Battery
B,
/El3 PI
\.\ I
Electric current continues to pass through the arma- the direction of the arrow. Then the circuit returns
ture shaft assembly and the motor continues to to stop condition 1.
turn. The slider assembly also continues to move in
1 l-064-5
0
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM CHART
6138F151A
1. Radiator 7. Corrosion resistor
8. Cylinder head A. From oil pump (oil)

2. Thermostat
3. Water pump 9. Cylinder liner
4. Water temperature gauge 10. Piston
5. Water manifold (one unit with cylinder head) 11. Cylinder block
6. After-cooler 12. Oil cooler ’
General description
1. Structure of cooling system 3) The cooling water in thermostat will flow back to
- The cooling system consists of the water pump,

the water pump, when the water temperature is
thermostat, radiator, fan and water piping. It serves below approx. 76°C. If the water temperature is
to cool the cylinder liners, and the areas surround- over approx. 90°C or so, the thermostat will be open-
ing the combustion parts in the cylinder heads. ed fully, causing the water to flow into the radiator
for cooling.
. In addition, oil piping or oil cooler is equipped for
cooling oil by the engine cooling water. 4) While the water temperature ranges from 76’ to ap-
prox. 9O”C, some of the water flows back to the
2. Circulation of cooling water
water pump and the other to the raddiator. The ratio
1) The cooling water is distributed under pressure of water flowing to the pump and the radiator de-
from the water pump driven together with the fan pends on the degree of opening (varying with the
through the fan belt from the crank pulley. temperature) of the thermostat.
2) The cooling water distributed under pressure from

the water pump passes through the oil cooler, cools
various parts in the engine, collects in the cylinder
heads, and from there flows into the thermostat.
110 SERIES 11-065

0
COOLING SYSTEM STRUCTURE AND FUNCTION
WATER PUMP
Engine No. 10001 - 10351
-A
6136FO21C
1. Nut 6. Pump body Fan pulley
2. Fan pulley 7. Impeller
3. Pump shaft 8. Snap ring Fan pulley O.D. Applicable machine
4. Spacer 9. Pump cover 215 mm w 120-2
5. Water seal A. To engine
11-066 110 SERIES

0
STRUCTURE AND FUNCTION COOLING SYSTEM
DOUBLE PULLEY TYPE

1. Nut
2. Fan pulley
3. Pump shaft
4. Spacer
5. Water seal
6. Pumpbody
7. Impeller
8. Snap ring
9. Pump cover
A. To engine
Fan pulley
Fan pulley O.D. 1 Applicable machine
215mm 1 W120-2,3, EC21 02-l
192 mm EG150M3
225 mm WA350-1
235 mm WA400-1
6138FO21.1
TRIPLE PULLEY TYPE

1. Nut
2. Fan pulley
3. Pump shaft
4. Spacer
5. Water seal
6. Pump body
7. Impeller
8. Snap ring
9. Pump cover
A. To engine
Fan pulley
Fan pul- Air conditioner Applicable

ley O.D. pulley O.D. machine
215mm 1 175 mm I D66S-1
215mm I 215 mm / W120-3 (Option)
-A
6136FO21.2
110 SERIES 1 l-067

0
COOLING SYSTEM STRUCTURE AND FUNCTION’
THERMOSTAT
1. Intake manifold
2. Water pipe
3. Thermostat
4. Fan pulley
5. Thermostat housing
6. water pump
7. Water hose
A. From radiator
To radiator
From engine
To aftercooler
E. Water temperature sensor (generator)
Thermostat (construction equipment)
Cracking temperature: 76.5”C

Full open temperature: 90°C
Full open lift: 10 mm
Thermostat (generator)
Cracking temperature: 82’C

6138F154 Full open temperature: 95’C
A
Full open lift: IOmm
Structure and function
The thermostat opens or closes depending on the * If the engine cooling water temperature is too high,
water temperature and serves to keep the cooling oil deterioration, premature deterioration of seals,
water temperature within the optimum range by O-rings, etc. and overheating will be caused.
automatically adjusting the flow rate of the engine
l Function of the thermostat
cooling water into the radiator.
Within the thermostat is a cylinder containing wax;

with a high expansion coefficient, movement of the
For construction For generator
case opens and closes the termostat valve. Aoolication
machine set
The optimum temperature of the engine cooling

Valve cracking tem-
water ranges from 75” to 90°C. If the water tempera- 75-78 80-84
perature (OC)
ture is too low, the engine will not be warmed up, I I
resulting in poor engine performance due to improper
Valve’ full opening
clearances between pistons and liners. Eventually, 90 95
temperature (‘Cl
excessive oil lubrication, oil contamination, and
excessive BLOWBY will be encountered, during
Valve full opening
engine operation. IO 10
lift (mm)
Where a thermostat is used for a generator, its operat-
ing temperature is set at a high degree, because a
continuous operation under light load is relatively
frequent and the engine is difficult to warm up.
11-068 110 SERIES
0
ELECTRICAL SYSTEM STRUCTURE AND FUNCTION
ELECTRICAL SYSTEM
WIRING DIAGRAM
Engine No. 10001 - 10348
Starting switch key positions
6138F024B
Relay switch Electrical intake air heater
I I
-I
Heater signal
l!n,
Starting switch key POsitions

Starting switch connections
PREHEAT o;F PN
\
6138FO24.1
11-070 110 SERIES

0
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
EG150W3
Relay switch Electrical intake air heater
I /I
Engine stop:
switch Emergency relay
Starting
switch
Starting stitch key positions

Starting switch connections
I I I
6138FO24.2
110 SERIES 11-071

0
STRUCTURE AND FUNCTION .:ELECTRICAL SYSTEM
ALTERNATOR
Alternator Regulator
I
internal wiring diagram
6138Flg2
Engine Machine Type Specifications Weight Pulley O.D.
D66.s1 Nikko Denki 24V. 35A
SAGDllO-1
w120-2.3
Nikko Denki!
EC21 OZ-1 24V, 25A 7.3 kg 95
Open type with built-in regulator
EG 150, 15OS-3
110 SERIES 11-073

0
STARTING MOTOR
Engine No. 10001 - 10348
r
SW
B C
Internal wiring diagram 6138F022B
1. Starting motor
2. Starling motor pinion
B. B,C,SW: Terminals
No. of
Engine Machine TYPO Specifications Weight
pinion teeth
I
W120-2, W120-3 Nikko Denki, sealed type 24V. 7.5 kW 24.5 kg 13

SAGDI 1 O-l
EGI 50,15OS-3
11-074 110 SERIES

0
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
Bult-in safety relay
Internal wiring diagram Starting motor
6138F194
1. Starting motor a, b, c: Oil filler
2. Starting motor pinion
3. Safety relay
B,C,E,S,R: Terminals
No. of pinion
Engine Applicable machine Type Specifications Weight
teeth
Nikko Denki
S6Dll O-l WA350-1 Water proof, oil proof type
1 24”,7.5KW / 18 kg 1 13
D66S-1 Nikko Denki 18 kg 13

24V. 7.5 KW
WA400-1 Water proof, oil proof type
I
SAGDllO-1 1 !
W120-2.3 Nikko Denki
EG150(.9-3 / 24V,7.5KW / 24.5 kg ( 13
Sealed type
EC21 02-l
110 SERIES 1 l-075

0
ELECTRICAL SYTSTEM STRUCTURE AND FUNCTION
ELECTRICAL INTAKE AIR HEATER
Engine No. 10001 - 10006
1 2
\ / P
=v CA
Section A -
Section B - B
Section B - B
Section A -
r/7
Wiring diagram
6138F023A
1. Heater coil
2. Housing
Rated current: 164AI22V

Capacity: 3.6 KW [(6OOW x 3) x 21
11-076 110 SERIES

0
STRUCTURE AND FUNCTION ELECTRICAL SYTSTEM
Bi- -IA
Section A - A Section B - B
SectionA-A Section B - B
,,--
1
I__
Section A - A Section B - B
A Wiring diagram
6138F193
1. Heater coil
2. Housing
Rated current: 173Al22V

Capacity: 3.8 KW [(63OW x 2) x 31
110 SERIES
OIL PRESSURE SWITCH
1. Nipple
2. Switch
3. Connector
OIL PRESSURE SWITCH
* Operating point
ON: 1.5fi.z kg/cm2
OFF: l.Ozi:,’ kg/cm2
t-l:,
Return Action
6136F125
RELAY SWITCH
RELAY SWITCH
- Rated voltage: DC24V
* Current: 200A (60 sec.)
To switch
To battery
To load
%k--
Inner wiring
6136F126
11-078 110 SERIES

0
ACCESSORY STRUCTURE AND FUNCTION
ACCESSORY
AIR COMPRESSOR
14 15
1. Crankshaft 11. Unloader valve A. Air inlet
2. Oil seal 12. Unloader valve guide B. Air outlet
3. Ball bearing 13. Unloader valve spring C. Unloader
4. Crankcase 14. Outlet valve spring
5. Cylinder block 15. Outlet valve
6. Connecting rod 16. Outlet valve seat
7. Piston pin 17. Piston
8. Cylinder head 18. .Top ring
9. Inlet valve spring 19. Second ring
10. Inlet valve 20. Oil ring
11-080 110 SERIES
0
STRUCTURE AND FUNCTION ACCESSORY
I 6137FOll-2
Al R COMPRESSOR UNLOADER VALVE
* Maker: DIESEL KIKI - Valve opening pressure: 7.0 - 8.0 kg/cm2

- Type: Single-cylinder, double acting * Valve shutting pressure: 6.2 - 7.3 kg/cm2
- Bore x stroke: 70mmx40mm
- Discharge volume: 38O!Umin. (2,500 rpm)
- Air pressure: 10 kg/cm2
* Weight: 6.5 kg .
110 SERIES 11-081

0
12 TESTING AND ADJUSTING
ENGINE
110 SERIES
Engine Numbers: 10001 and up
12 TESTING AND ADJUSTING
110 SERIES
..
TESTING AND ADJUSTING
INTAKE AND EXHAUST SYSTEM ...................................... . . 12-004

Measuring exhaust gas color ........................................ . . . 12-004
Adjusting valve clearance .......................................... . . . 12-005
ENGINEBODY .................................................... ... 12-006
Measuring compression pressure ..................................... .. 12-006
Measuring blow-by pressure ... 1 .................................... . . . 12-007
LUBRICATIONSYSTEM ............................................. .. 12-008
Measuring oil pressure ............................................ . . 12-008
Measuring oil temperature ......................................... . . 12-008
FUELSYSTEM .................................................... . . 12-009
Testing and adjusting fuel injection timing. .............................. . . 12-009
Adjusting fuel cut solenoid ......................................... . . 12-010-1
COOLINGSYSTEM ................................................. ... 12-011
Testing and adjusting fan belt tension .................................. ... 12-011
PERFORMANCETEST ............................................... ... 12-013
Run-in standard ................................................ . . . 12-013
z
R Performance test criteria .......................................... ... 12-014
CD TESTING AND ADJUSTING DATA ...................................... . 12-017
Fuel injection pump calibration data .................................. ... 12-017
Testing and adjusting tool list ....................................... . . . 12-022
Testing and adjusting data ......................................... . . . 12-023
TROUBLESHOOTING ............................................... . . 12-028
Method of reading troubleshooting table ................................ . . . 12-028
Troubleshooting table ............................................ . . . 12-030
12-003
0
MEASURING EXHAUST GAS COLOR
A When measuring the exhaust gas color,

not to touch the exhaust pipe.
be careful
* Measure the exhaust gas color while engine is warm

(Oil temperature: Min. 6O’C)
1. Insert probe @ in outlet of exhaust pipe (I) and

secure to exhaust pipe with clip.
2. Connect probe hose, connector

switch and air hose to handy smoke checker A.
02 of accelerator
* The pressure of air supply should be under 15 kg/cm2
3. Connect power cable to AClOOV socket

* Check that the power switch is OFF before con-
necting the cable.
4. Loosen cap nut of suction pump and insert filter paper.
5. Turn power siwtch ON.
6. Accelerate engine suddenly. At the same time, depress

accelerator pedal, operate relief valve and catch exhaust
gas color on filter paper.
7. Lay filter paper used to catch exhaust gas color on top

unused filter papers (IO sheet or more) inside filter
paper holder, and read indicated value.
* For the reference values of the exhaust gas color,
see TESTING AND ADJUSTING DATA.
12-004
0
TESTING AND ADJUSTING INTAKE AND EXHAUST SYSTEM
ADJUSTING VALVE CLEARANCE

1. Remove cylinder head cover (1).
2. Rotate the crankshaft in the normal direction. While

watching the movement of the valves, bring the No. 1
cylinder into the compression top dead center and align
“1.6 TOP” mark on crakshaft pulley with pointer (2).
3. When No. 1 cylinder is at compression top dead center,

adjust the valves marked l in the valve arrangement
chart.
When No. 6 cylinder is at ompression top dead center,
adjust the valves marked 0.
* Valve arrangement chart
Cylinder No. 1 2 3 4 5 6
Intake valve a l 0 a 0 0
Exhaust valve l 0 l 0 l o
4. To adjust, insert feeler gauge A between rocker arm

lever (3) and valve stem (4) and turn adjustment screw
(5) until feeler gauge is slide fit. Then tighten locknut
(6) to hold adjustment screw in position.
m Locknut: 3.2 f 0.3 kgm
5. Next rotate the crankshaft in the normal direction and

adjust the valve clearance of the remaining valves marked,
0.
* It is also possible to adjust the valve clearance as follows:

Adjust valve clearance of No. 1 cylinder which is at com-
pression top dead center, then turn the crankshaft 120”
each time and adjust valve clearances following firing
order.
* Firing order: 1-5-3-6-2-4
* After tightening the locknut, check the clearance again.
* For the reference valves of the valve clearance, see TEST-

ING AND ADJUSTING DATA.
PIKFIOI
110 SERIES 12-005

0
ENGINE BODY TESTING AND ADJUSTING
ENGINE BODY
MEASURING COMPRESSION PRESSURE
* If performance tests or troubleshooting shows that the
piston, piston ring or cylinder liner may be worn, measure
the compression pressure.
When measuring the compression pressure, be

f
Q careful not to touch the exhaust manifold or
muffler, or to get caught in rotating parts.
* Measure the compression pressure while the engine is

warm.
(Oil temperature: 40 - 60°C)
1. Adjust the valve clearance properly.

* For detail see 12 ADJUSTING VALVE CLEAR-
ANCE
2. Remove nozzle holder assembly

* For detail see 13 DISASSEMBLY AND ASSEMBLY
+ Take care not to let any dirt or foreign matter get
into cylinder.
3. Install adapter of compression gauge to nozzle ho!der

mounting section.
4. Connect ompression gauge A to the adapter.
5. Set engine tachometer in position.
6. Place fuel control in NO INJECTION position, crank

the engine with starting motor and measure compres-
sion pressure.
* Measure the compression pressure at point where
the compression gauge indicate remains steady.
* When measuring the compression pressure, measure
the engine speed to confirm that it is within specified
range.
* For the reference values of the compression pressure,
see 12 TESTING AND ADJUSTING DATA.
* After measuring the compression pressure, install nozzle

holder assembly.
12-006 110 SERIES

0
TESTING AND ADJUSTING ENGINE BODY
•t
MEASURING BLOW-BY PRESSURE

* Measure blow-by pressure while engine is warm.
(Oil temperature: Min. 85’C)
1. Install adapter of blow-by checker in breather hose (1).
2. Connect adapter to blow-by checker A with tube.
3. Run the engine at high idling, and measure the blow-by

pressure.
* Blow-by pressure varies greatly according to the
condition of the engine.
Therefore, if the blow-by value is considered ab-
normal, check for problem connected with defec-
tive blow-by, such as excessive oil consumption,
defective exhaust gas color, and prematurely dirty
or deteriorated oil.
* For the reference values of blow-by pressure, see 12
TESTING AND ADJUSTING DATA.
110 SERIES 12-007

0
LUBRICATION SYSTEM TESTING AND ADJUSTING
LUBRICATION SYSTEM
MEASURING OIL PRESSURE
When measuring the oil pressure, be careful not to
A
. get caught in rotating parts.
Af
Always remove or install plugs or oil pressure gauges
with engine stopped.
Measure the oil pressure while engine is warm.

(Oil temperature: Min. 80°C)
Remove plug (1).
Install oil pressure gauge A.
Start the engine, and measure the oil pressure.

* For the reference values of oil pressure, see TESTING
AND ADJUSTING DATA.
MEASURING OIL TEMPERATURE
1. Remove dipstick (1).
2. Insert sensor of thermistor temperature gauge in dipstick

guide.
3. Connect sensor to therrnistor temperature gauge A and

measure temperature of oil in oil pan.
* For the reference values of oil temperature, see
12-008 110 SERIES
0
FUEL SYSTEM
TESTING AND ADJUSTING FUEL INJECTION TIMING
‘.
There are two methods for checking adjusting the fuel

injection timing of an injection pump.
The “MATCH MARK ALIGNMENT” method, which
is used when the injeciton pump is installed to the
original engine and the pump is not being repaired.
The “DELIVERY VALVE method”, which is used when
a repaired or replaced injection pump is installed to
the engine.
When using the DELIVERY VALVE method, make
preparations to replace the delivery valve copper
gasket and O-rings with new parts.
Before inspecting and adjusting the fuel injection
timing, bring the No.1 cylinder piston to the top dead
center of the compression stroke. For details, see 12
ADJUSTING VALVE CLEARANCE.
TESTING AND ADJUSTING BY THE MATCH

MARK ALIGNMENT METHOD
1. With No.1 cylinder piston at top position. rotate the

crankshaft 30° to 40° in the reverse direction.
2. Align the injection timing stamp line on crankshaft

pulley (1) with pointer (2) by slowly rotating the
crankshaft in the normal direction.
3. Confirm that stamp line a on the injeciton pump

is aligned with stamp line b on the coupling.
* If the stamp lines are out of alignment, loosen

nut (3), align the stamp lines by shifting the
coupoing, and tighten the nut.
m Nut: 6.2 + 0.2 kgm
TESTING AND ADJUSTING BY THE DELIVERY

VALVE METHOD
1. Disconnect fuel injection tube (5) for the No.1

cylinder.
2. Remove delivery valve holder (7).

3. Remove spring (8) and delivery valve (9) from the
delivery valve holder (7), and reassemble the delivery
valve holder.
4. With No. 1 cylinder piston at TOP position, rotate the

crankshaft 30” to 40’ in the reverse direction.
5. Place the fuel control lever in FULL position, slowly

rotate the crankshaft in the normal direction while
operating the priming pump, and observe the position
when the fuel stops flowing out of the delivery valve
holder.
6. In the position where the outflow of fuel stops, check

the injection timing stamp line on the crankshaft pulley
to see if it is aligned with the pointer.
* If the injection timing stamp line passed through the
pointer: The injection timing is late.
* If the injection timing stamp line did not reach the
pointer: The injection timing is advanced.
If the inspection shows that the injection timing is out

of adjustment, adjust the fuel injection timing in the
following manner.
1) Rotate the crankshaft 30’ to 40” in the reverse

direction, starting from TOP position in No. 1
cylinder.
2) Align the injection timing stamp line on damper (1)

with pointer (2) by slowly rotating the crankshaft
in the normal direction.
3) Loosen nut (3) on the injection pump mounting

flange slot, and rotate the flange on the pump side
little by little by operating the priming pump until
no fuel flows out of the delivery valve holder.
4) Tighten the nut on the injection pump mounting

flange slot.
* Recheck the injection timing to see if it is pro-
perly adjusted.
5) If match marks a and b are not aligned, stamp new

one.
After the checking and adjusting, be sure to reassemble

the spring and the delivery valve.
Always replace the delivery valve copper gasket and
O-rings with new parts.
ADJUSTING FUEL CUT SOLENOID (For WA380-1)
1. Confirm that stop lever (2) of the fuel injection 4. Start and stop the engine 2 - 3 times, and check
pump (1) is at the STOP position. that the solenoid moves smoothly and that the
(Usually, the return sp.ring holds the stop lever at engine stops. (It must stop within IO seconds.)
the STOP position.)
2. Adjust rod so that the solenoid has a maximum

* Problems caused by improper adjustment of
stroke.
solenoid.
Adjust rod so clearance “b” is 0.4 + 0.1 mm be-
tween injection pump stopper lever (2) and stop- l If clearance l Solenoid coil is’burned
per (3). between stopper (when solenoid is half
lever and stopper engaged)
Stroke “a” = 12 mm
is 0 when current l Breakage or scuffing of
3. Pass current through the solenoid, check the is passed. injection pump governor
stroke of the solinoid (12 mm) and the clearance (excessive force brought
between the stopper lever and stopper (0.4 f 0.1 to bear on lever).
mm), then make final adjustments.
l If clearance l Lack of engine output
between stopper caused by drop in fuel
lever and bolt at injection amount.
FULL end is too
large when free
(linkage defective).
12-010-l
69
TESTING AND ADJUSTING COOLING SYSTEM
COOLING SYSTEM
TESTING AND ADJUSTING FAN BELT TENSION
TESTING FAN BELT TENSION
/f--y ‘I I- 1Omm
Approx. 6 kg
Check the amount the fan belt deflects when pushed with
a force of 6 kg at a point midway between the fan pulley
and the alternator pulley.
* For the reference values of the fan belt tension, see
2lKFl02
ADJUSTING FAN BELT TENSION
1. Loosen mounting bolt (1) of alternator and belt tension

adjustment bolt (2).
2. Using a bar or pipe, move alternator and adjust tension

of beIt (3). Tighten adjustment bolt, then tighten
mounting bolt.
110 SERIES 12-011

0
PERFORMANCE TEST
RUN-IN STANDARD
* Load are give for the case of the dynamometer arm length is 716 mm.
This list shows the standard on condition that the fan is removed.
Engine Applicable
Item
model machine
1 2 3 4 5 6
Running time min. 5 10 10 15 15 5
Engine speed rpm 700 - 75C 1,000 1,300 1,600 1,900 2,200
S6Dl IO-1 WA35O-1
Load kg 0 10 19 38 56 75
output HP 0 9.9 24.2 60.1 105 163
Engine speed rpm 700 - 7E.f 1,050 1,350 1,650 1,900 2,100
D66.S1
Load kg 0 21 32 53 68 83
output HP 0 21.3 41.7 84.4 126.1 168.3
Engine speed rpm 700 - 75( 1,250 1,600 2,000 2,300 2,500
WI 20-2
WI 20-3
Load kg 0 22 33 53 69 85
output HP 0 27 53 105 159 212.5
Running time min. 5 10 IO 15 15 5
Engine speed rpm ‘30 - 780 1,000 1,300 1,600 1,900 2,200
SAGDllO-1
WA38O-1
Load kg 0 12 23 46 68 86
output HP 0 11.8 29.6 73 127.2 186.3
Engine speed rpm ‘00 - 750 1,000 1,300 1,600 1,900 2,200
WA400-1
Load ks 0 12 23 46 68 92
output HP 0 11.8 29.6 73 127.2 199.2
Engine speed rpm 750 - 80( 1,000 1,300 1,600 1,900 2,200
WA420-1
Load kg 0 12 23 46 68 97
output HP 0 11.8 29.6 73 ‘I 27.2 210.4
12-013
0
Order
Engine Applicable
Item
mode I machine
1 2 3 4 5 6
-
Engine speed rpm 00-750 1,250 1,600 2,000 2,300 2,500

ECZIOZ-1
Load kg 0 22 33 52 68 83
output HP 0 26.2 51.4 100.9 151.3 201.3
Engine speed rpm ‘00 - 80C 1,000 1,200 1,400 1,700 1,800
EG150-3
EG15O.S3
Load kg 0 22 39 68 84 105
output HP 0 23.3 45.6 92.2 138.7 183.3
Running time min.
Engine speed rpm
Load kg
output HP
SA6Dl 1 O-l
Running time min.
Engine speed rpm
Load kg
output HP
Running time min.
Engine speed rpm
Load kg
output HP
Running time min.
Engine speed rpm
Load kg
output HP
12-013-l
@
PERFORMANCE TEST CRITERIA
Engine Applicable Specified value Engine speed Dynamometer load

Test item
model machine (fully equipped) (rpm) (kg)
Flywheel horsepower 163 HP/2,200 rpm 2,195 - 2,205 74.8 - 79.4
Maximum torque 70 kgm/l,500 rpm 1,400 - 1,600 75.9 - 101.5

S6DllO-1 WA350-1
High idling speed 2,370 - 2.470 rpm 2,370 - 2,470 0
Low idling speed 700 - 750 rpm 700 - 750 0
Flywheel horsepower 160 HPl2.100 rpm 2,095 - 2,105 80.5 - 85.2
Maximum torque 70 kgmIl.450 rpm 1,350 - 1,550 99.8 - 105.4

D66S1
High idling speed 2,250 - 2,350 rpm 2,250 - 2,350 0
Flywheel horsepower 200 HPi2.500 rpm 2,495 - 2,505 82.2 - 87.0
Maximum torque 68 kgm/l,SOO rpm 1,700 - 1,900 96.9 - 102.8

w 120-2
WI 20-3
Maximum torque 78 kgmil.500 rpm 1,400 - 1,600 107.3 - 113.9

SA6Dl IO-1 WA380-1

WA400-1
Maximum torque 82 kgm/l,500 rpm 1,400 - 1,600 112.8-119.6

WA420-1
12-014
0
The values in the table are indicated at standard conditions (atmospheric temperature 25’C. atmospheric pressure
750 mmHg).
The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from
those of the specification.
Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air
compressor (if installed) open.
Dynamometer loads are given for the case of the arm length is 716 mm.
Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
Lubrication oil used: CLASS-CD SAEBO.
Exhaust temperature column t: intake temperature - 25°C.
Fuel Coolant Lubrication oil. Lubrication oil Exhaust temper-

output Torque
consumption temperature temperature pressure ature (“C) (t: In-
(HP) (kgm)
(set/200 cc) (“C) 1°C) PC) take temp. -25’C)
162.6 - 172.2 19.9 - 21 .l 70-80 90-110 3.5 - 5.5 Max. 650 f 3t

- 68.7 - 72.7 24.3 - 25.8 70 - 80 90- 110 3.5 - 5.5 Max. 650 f 3t
0 0 - 70 - 80 90-110 3.5 - 5.5 -

0 0 - 70 - 80 Min. 80 Min. 1.5 -
163.9 - 173.6 20.7 - 22.0 70 - 80 go- 110 3.5 - 5.5 Max. 650 + 3t
- 71.5 - 75.5 23.7 - 25.2 70-80 90-110 3.5 - 5.5 Max. 650 + 3t
0 0 0 70 - 80 go- 110 3.5 - 5.5 -

0 0 70 - 80. Min. 80 Min. 1.5 -
265.5 - 217.5 16.3 - 17.4 70 - 80 go- 110 3.5 - 5.5 Max. 660 + 3t
s - 68.6 - 72.8 21 .O - 22.5 70 - 80 90- 110 3.5 - 5.5 Max. 650 + 3t
8
0 0 70 - 80 90-110 3.5 - 5.5 -
z
0 0 70 - 80 Min. 80 Min. 1.5 -
190.9 - 202.8 70 - 80 SO- 110 3.5 - 5.5 Max. 650 + 3t
- 76.8 - 81.6 70 - 80 80- 110 Max. 660 + 3t
0 0 70 - 80 80- 110 3.5 - 5.5 -
0 0 70 - 80 Min. 80 Min. 1.5 -
195.8 - 207.7 70-80 go- 110 3.5 - 5.5 Max. 660 + 3t
- 78.2 - 83.0 70 - 80 go- 110 3.5 - 5.5 Max. 650 + 3t
0 0 70 - 86 go- 110 3.5 - 5.5 -
0 0 70 - 89 Min. 80 Min. 1.5
204.5 - 216.8 - Min. 16.3 70 - 80 80- 110 3.5 - 5.5 Max. 660 + 3t
- 80.7 - 85.7 70 - 80 80-110 - Max. 700 + 3t
0 0 - 70 - 80 80-110 3.5 - 5.5
0 0 70 - 80 Min. 80 Min. 1.5
12-015
0
Engine Applicable Specified value Engine speed Dynamometer load
Test item
model machine (fully equipped) (rpm) (kg)
I
, Flywheel horsepower 189 HP/2,500 rpm 2,495 - 2,505 80.2 - 85.0

EC2102-1
SAGD 11 o-1
Flywheel (50 Hz) 148 HP/l,500 rpm 1,495 - 1,505 101.3 : 107.4
EGI 50-3 horsepower
(60 Hz) 177 HP/l ,800 rpm 1,795 - 1,805 102.5 - 108.6
EG 1505-3
(50 Hz) Max. 1,560 rpm Max. 1,560 0
High idling
speed
(60 Hz) Max. 1,872 rpm Max. 1,872 0
2
%
a
12-016
0
The values in the table are indicated at standard conditions (atmospheric temperature 25’C, atmospheric pressure
750 mmHg).
The values given for the dynamometer loads, output and torque are with the fan removed, so they differ from
those of the specification.
Values are standardized under the following conditions: Muffler and air cleaner installed; alternator idling; and air
compressor (if installed) open.
Dynamometer loads are given for the case of the arm length is 716 mm.
Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel.
Lubrication oil used: CLASS-CD SAE30.
Exhaust temperature column t: Intake temperature - 25’C.
Fuel Exhaust
Coolant Lubrication Lubrication
Output Torque temperetu re (“Cd
consumption temperature oil temperature oil pressure
(HP) (kgm) (set/200 cc) t=intake temp.
1°C) 1°C) (kg/cm*)
-25’C
194.5 - 206.1 - 16.2 - 17.2 70 - 80 go- I10 3.5 - 5.5 Max. 650 f 3t
- 66.5 - 72.5 21 .o - 22.0 70 - 80 go- 110 3.5 - 5.5 Max. 650 + 3t
0 0 - 70 - 80 90-110 3.5 - 5.5 -
0 0 - 70 - 80 Min. 80 Min. I.5 -
147.3 - 156.3 - 25.5 - 26.5 70 - 80 90-110 3.5 - 5.5 Max. 650 + 3t
179.0 - 189.6 - 19.5 - 20.5 70 - 80 go- 110 3.5 - 5.5 Max. 650 + 3t
0 0 70 - 80 90-110 3.5 - 5.5 -
0 0 0 70 - 80 90-110 3.5 - 5.5 -
12-016-l
0
TESTING AND ADJUSTING DATA
FUEL INJECTION PUMP CALIBRATION DATA
Engine model Engine serial number Applicable machine Pump assembly number Page
D66S-1 6138-72-l 600 12-018
WI 20-2
6138-71-l 300 12-019
W120-3
EG 150-3
6138-71-1400 12-020
EG 15OS-3
6138-72-I 320 12-019-I

SAGDIIO-1 10001 and up WA360-1
6136-72-I 321 12-019-2
WA400-1 6138-72-l 111 12419-3
EG150-3 12-020
6138-71-1400
EG 15OS-3
EC210Z-1 ,6138-7 l-1 510 12-021
12-017
@
Injection Pump
Machine Model Engine Model
Pump Type Manufacturer Pump Assembly Number
D66S-1 SAGDllO-1 PEGAD DIESEL KlKl 6138-72-1600~101601-3100)...0
Injection Timing
Unit Basis Allowance

I
Clockwise viewed
Rotating direction
from drive end
Specification for engine with fan (reference only)
Delivery valve
80 High idling: rpm 2250 to 2350
retraction volume mm3
Low idling: rpm 700 to 800

CCalibration Standard
Manufacturer standard Service standard
>onditions Unit
(with nearly the same actual machine parts) (with calibration test parts)
Nozzle Dart no. (105015-5680) (105780-0000)
Nozzle holder part no. (105031-4480) (105780-2080)

In echon rpe
mm 6x2~730 6x2~600
Id/D x lI#x length)
Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature “C 43 to 47 43 to 47
Nozzle opening pressure kg/cm* 250 175
Transfer oumo oressure ka/cm* 1.6 1.6
ipecifications
Injection volume (cc/l OOOst) Injection volumebz/l OOOst)
for manufacturer standard for service standard
Maximum Maximum
Rack variance
variance
osition i% Basis Allowance Basis Allowance
between between
Pmm) cylinder
cylinder
Calibration Each cyl. Each cyl.
basic point 9.9 1050 85.5 84.5 to 86.5 * 1.71 76.0 75.0 to 77.0 tl.52
’ Rack cositions 8 10.9 725 102.0 * 100.0 to 104.0 k4.08 85.0 * 83.0 to 87.0 -1-3.40
B to Bare the refer-
ence volume when C 7.3 375 12.0 * 10.8 to 13.2 *I.20 13.0 * 11.8 to 14.2 kl.30
adjusting the injec-
tion volume. D * *
’ Marks * are sver-
age volumes. E * *
jovernor performance
Pump speed (rpm)
Numbers in parentheses are pump manufacturer part numbers.
12-018 ,-J
0
Injection Pump
WlZO-2.3 SAGDllO-1 PEGAD DIESEL KIKI 6138-71-1300~101601-3030)...1
Injection Timing
Unit Basis Allowance I

Clockwise viewed
Rotating direction
from drive end
Specification for engine with fan (reference only)
Rated horsepower: HP/rpm 200/2500
Maximum torque: kgm/rpm 69 /I800
High idling: rpm 2700 to 2800

Calibration Standard
Conditions Unit
Nozzle part no. (I 05015-2860) ( )
Nozzle holder part no. (105031-3390) ( 1

In ection Ipe
mm 6x2~600
(d/D x l/ix length)
Oil temperature OC 43 to 47
Nozzle opening pressure kg/cm2 200
Transfer pump pressure kg/cm* 1.6
jpecifications
Injection volume (cc/l OOOst) Injection volumeb/ St)
Maximum Maximum
Rack Pump
variance variance
osition speed Basis Allowance Basis Allowance
between between
Pmm) (rpm) cylinder cylinder
basic point 10.8 1250 93.5 92.5 to 94.5 21.87
’ Rack Dositions B 11.0 900 96.0 * 94.0 to 98.0 +3.84 *

B to iare the refer-
ence volume when C 7.4 350 12.0 * 10.8 to13.2 k-c.20 *
tion volume. D
’ Marks * are aver-
age volumes. E
8
a
Pump speed (rpm)
12-019
0
I
Injection
Pump Type
Pump
Manufacturer I Pump Assembly Number
WA380-1 SAGDI 1 O-l PE-AD DIESEL KIKI 6138-72-I 320 (I 01601-3370). . 0

S/N 54352 and up
Injection Timing
Unit Basis Allowance 1
Rotating direction Clockwise viewed

from drive end
Injection order l-5-3-6-2-4 Specification for engine with fan (reference only)
Injection interval 60’ 59”30’ to 60”30
Plunger pre-stroke mm 4 3.95 to 4.05 y
Delivery valve
mm3 80
retraction volume
Low idling: rpm 730to 780

Calibration Standard I
Conditions Unit Manufacturer standard Service standard

Nozzle part no. 6138-12-3320(105015-5810) (I 05780-0000)

Nozzle holder part no. 6136-12-3110(105031-4480) (105780-2080)
I’ . mm
r”d%t?l%?%angth) 6x2~730 6x2~600
Test oil ASTM 0975 No. 2 diesel fuel or equivalent
Oil temperature “C 40 to 45 40 to 45
Nozzle opening pressure kg/cm2 250 175
Transfer pump pressure kg/cm2 1.6 1.6
Specifications Injection volume (cc/l OOOst) Injection volume (cc/l OOOst)

l [ 1 : Reference data
Rack Pump Maximum Maximum
osition speed Basis variance variance
Allowance Basis Allowance
Pmm) between between
(rpm)
cylinder cylinder
basic point A 10.0 1100 L93.31 82.4 81.4to83.4 ~b1.64
8 approx.
l Rack positions 375 j21.41 * 15.5 *14.3to 16.7 k1.55
7.4
B to E are the refer-
ence volume when C * *
adjustingthe injec-
tion volume. D * *
l Marks t are aver-
age volumes. E * *
Governor performance (375 - 1100 rpm) Boost compensator Automatic timer

performace (600 rpm) performance
14
or more
12.8CO.l
11.1*0.1
10.4
10.0
-T
.k
.-s 7.4
.z
%
Y 5.3
0 Pump speed (rpm)
a: Boost pressure (mmHg)
Line @ : At boost pressure

300 mmHg or more
Line @ : At boost pressure
0 mmHg
Pump speed (rpm) SEBH4548
-- _-- _ _.
12-019-l Numbers in parentheses are pump manufacturer part numbers.
@ -.
Pump Assembly Number Applicable Machine Applicable Engine
6138-72-1321 (101601-3430)
Model Serial No. Model Serial No.
( ): Manufacturer’s part No.
WA380-1 SAGDI IO-I
Injection Timing Engine specification
Clockwise viewed from drive end
Plunger pre-stroke mm 4.0 + 0.05

Pump tester capacity
Delivery valve Motor 7.5 KW
retraction volume mm3/st 80 for Service standard
onditions Service standard Manufacturer standard

iervice standard
Nozzle part no. (105780-0000) 6138-12-3320 (105015-5810)
ndicates data
Ising calibration Nozzle holder part no. (I 05780-2080) 6136-12-3110 (105031-4480)
est parts.
Injection ipe
danufacture 6 x 2 x 600 6x2~730
(O/D x l/g x length) mm
tandard is data
or factory test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Nozzle opening pressure kg/cm2 175 250
Transfer pump pressure kg/cm* 1.6 1.6
ljection volume Service standard (cc/lOOOst) Manufacturer standard (cc/l OOOst

Rack Pump
Rack
position speed Maximum Maximurr
point variance
(mm) (rpm) Basis Allowance rerzE”, Basis Allowance
between
cylinder cylinder
lack positions
8l o Each cyl. g3 3 Each cyl.
I to E are the refer- Basic point 10.0 1100 . *I.62 .
nce volume when 80.0 to 82.0
djusting the injec- B 1,l.l 750 93.6 * 91.6 to95.6 - 113.7 *
ion volume.
larks l are aver- Approx.
C 7.4 375 15.5 * 14.3 to 16.7 +I .55 21.4 t
ge volumes.
D * *
E * *
wernor performance ( 375 - 1100 rpm) Boost compensator performance (600 rpm)
200
Boost pressure (mmHg)
Automatic timer performance
Pump speed (rpm) Line @ : At boost pressure 300 mmHg or more Pump speed (rpm)
Line @ : At boost pressure OmmHg SE8 H4752
12-019-2
'. 0
Pump Assembly Number Applicable Machine Applicable Engine
6138-72-1111 (101601-3440)
Model Serial No. Model Serial No.
( 1: Manufacturer’s part No.
WA400-1 SAGD 11 O-l
/I
injection Timing Engine specification
I Rotating direction Clockwise viewed from drive end

I
1 Rated horsepower HP/rpm 1 197.2/2200 I
1 Injection order l-5-3-6-2-4 Maximum torque kgm/rpm 80/l 500

I I
High idling 2370 to 2470
I
rpm
Injection interval 60’ f 30’
I
II I LOW idling
I
rpm I
I
730 to 780
J
I
Plunger pre-stroke mm 4.0 f. 0.05
Pump tester capacity
Delivery valve Motor 7.5 KW
retraction volume mm3/st 80 for Service standard
Conditions Service standard Manufacturer standard

- Service standard
Nozzle part no. (105780-0000) 6138-12-3320 (105015-5810)
indicates data
using calibration Nozzle holder part no. (105780-2080) 6136-12-31 IO (105031-4480)
test parts.
Injection ipe
* Manufacture (O/D x I/! x length) mm 6 x 2 x 600 6 x 2 x 730
standard is data
for factory test. Test oil ASTM D975 No. 2 diesel fuel or equivalent
Oil temperature “C 43 to 47
Nozzle opening pressure kg/cm’ 175 250
Transfer pump pressure kg/cm2 1.6 1.6
Injection volume Service standard h/l OOOst) Manufacturer standard (cc/l 000 st:
Rack Pump
Rack
position speed Maximum Maximum
point variance
(mm) (rpm) Basis Allowance yergi?, Basis Allowance
between
cylinder cylinder
BRack positions 85 8 Each cyl.
B to E are the refer- Basic point 10.5 1100 . 84.8 to 86.8 *I.716 104.0 Each “1.
ence volume when
adjusting the injec- B APP;“J”. 375 15.5 +14.3 to 16.7 fl.55 21.4 t
tion volume.
* Marks * are aver- C * *
age volumes.
D * *
E * *
Governor performance ( 375 - 1100 rpm) Boost compensator performance (600 rpm)
Boost pressure (mmHg)
Automatic timer performance
700 go0 1100

1100::; Line @ : At boost pressure 300mmHg or more Pump sped crpm)
Pump speed (rpm)
Line @ : At boost pressure OmmHg SEBH4753
12-019-3 __:
@ _-.
IMachine Model Engine Model
Injection
Pump Type
Pump
Manufacturer Pump Assembly Number
EG15O(SI-3 SA6Dll O-l PEGAD DIESEL KIKI 6138-71-1400(101602-3231)... 1
Injection Timing
Unit Basis Allowance
Clockwise viewed
Rotating direction
from drive end
148/l 500 (50Hz)

Injection interval 60” 59”30’ to 60”30 Rated horsepower: HP/rpm
177/l 800 (60Hz)
Plunger pre-stroke mm 4 3.95 to 4.05 Maximum torque: kgm/rpm
Delivery valve Max. 1580 (50Hz)

mm3 80 High idling: rpm
retraction volume Max. 1872 (60Hz)


:onditions Unit
Nozzle part no. (105015-4570) ( )

Nozzle holder part no. (10503 l-4360) ( )
I.
mm 6x2~730
%t%?%ngth)
Nozzle opening pressure kg/cm* 250
Transfer pump pressure kg/cm2 1.6
ipecifications
Injection volume (cc/l OOst) Injection volumeb2/ St)
Maximum Maximum
Rack Pump
variance variance
between between
Pmm) (rpm)
cylinder cylinder
Calibration Each c 1. Each cyl.
basic point 10.2 900 11.8 11. 3 to11.9 20.24
’ Rack positions B 7.7 325 1.2 * 1.08to 1.32 kO.12 *

ence volume when C * *
tion volume. D :* *
* Marks * are aver-
age volumes. E * *
0 to
0 szl3
: Y)mwc
Pump speed (rpm)
12-020
0
Injection Pump
EC21 OZ-1 SA6Dl 10 PEGAD DIESEL KIKI 6138-71-1510(101601-309OL.. 1
Injection Timing
Unit Basis Allowance I

Clockwise viewed
Rotating direction
from drive end
I
Rated horsepower: HP/rpm 19512500
Maximum torque: kgm/rpm 68 I1700
High idling: rpm 2650 to 2850

Conditions Unit
Nozzle part no. (105015-4570) ( ‘)

Nozzle holder part no. (105031-4360) ( 1
I’
mm 6x2~730
%%%r?fength)
Oil temperature “C 43 to 47
Nozzle opening pressure kg/cm2 250
Transfer pump pressure kg/cm2 1.6
Specifications
Injection volume (cc/l OOOstj Injection volume(cc/l OOOst)
Maximum Maximum
Rack Pump
variance variance
between between
Pmm) (rpmj cylinder cylinder
basic point 10.6 1250 85 84 to 86 f1.7
’ Rack positions B 10.8 1200 90 * 88 to 92 +-3.6 * ’

ence volume when C 7.2 350 7.5 * 6.3 to8.7 50.75 *
tion volume. D * *
’ Marks * are aver-
age volumes. E * *
Governor performance
;s ;g
4
--
Pump speed (rpm)
110 SERIES 12-021

0
TESTING AND ADJUSTING DATA TESTING AND ADJUSTING
TESTING AND ADJUSTING TOOL LIST
r-
No. ’ Testing and measuring item
I Fault finding tool Part No.
I
Remarks
1 IBngine speed Multi-tachometer 799-203-8000 Digital reading: 60 - 20,000 rpm

I
2 I 1.100 - 1.300
795-500-I 000
I
3 -5 - -50” c
‘
\
4 o-2o0°c
i
790-500-I 300
5 I o-1,000”c
6 ILubricating oil pressure 0 - 10 kg/cm’
7 IQel pressure
I 0 - 20 kglcm’
IIntake pressure, Engine pressure

8 799-203-2002 0 - 1.500 mmHg
6exhaust pressure measuring kit
9 I3low-by pressure 0-l,000mmH,O
10 IIntake resistance -1,000 - 0 mmH, 0
11 tCompression pressure Compression gauge 795-502-I 203 0 - 70 kglcm’

-
12 IBlow-by pressure Blow-by checker
13 Valve clearance Feeler gauge
-
Dirtiness 0 - 70% with standard
14 Exhaust gas color Handy smoke checker color (Dirtiness % x l/IO = Bosch
-
Provided with 0.1 and 0.2 water
15 1Water and fuel content in oil Engine oil checker 799-201-6000
content standard sample
-
Fuel injection pressure Commercially
16 Nozzle tester 0 - 300 kg/cm’
Fuel injection nozzle spray condition available
-
17 Coolant quality Water quality tester 799-202-7001 PH. nitrite ion concentration
-
Pressure valve function Radiator cap tester
18 799-202-9001 0 - 2 kg/cm’
Leakage in cooling system
-
Anemometer
19 Radiator blockage 799-202-2001 1-40mls
(Air speed gauge)
-
79561 o-1 000
20
795-215-1600
-
Commercially
21 Current, Voltage, Resistance
available
-
12-022 110 SERIES

0
TESTING AND ADJUSTING DATA
I
Engine model S6DllO-1 SAGDI 10-l
WA350- 1 D66S-1
Applicable machine model (50001 and up) (50001 and up)
Standard Perr$s;ble Standard Permissible

Item Condition, etc. Unit
value value value
High idling speed rpm ,370-2,47( !.370-2,47( !,250-2.35C !,250-2,350

Engine speed
Low idling speed rpm 700 - 750 700 - 750 700 - 750 700 - 750
OT rpm Min. 150 - Min. 150 -

Necessary
starting speed -20°C (with starting aid) rpm Min. 100 - Min. 100 -
Intake resistance At all speed mmHz0 Max. 300 635 Max. 380 635
Intake pressure At rated output mmHg Min. 450 Min. 400 - -
Exhaust pressure - - - -
At rated output mmHg
(Turbine inlet press.)
Exhaust temperature
All speed (20°C) OC Max. 650 Max. 650 Max. 650 Max. 650
(Turbine inlet temp.)
Quick acceleration Max. 5.0 6.0 Max. 5.5 6.5

(Low idling-High idling: Bosch
Exhaust gas color
At rated output scale - - - -
At high idling Max. 1.0 2.0 Max. 1.5 2.5
Valve clearance Intake valve mm 0.25 - 0.25 -

(When engine is
hot or cold.) Exhaust valve mm 0.45 - 0.45 -
Oil temperature: Min. 29 23

Compresion pressure kg/cm2 Min. 30 24
40 - 60°C
(SAE30 oil)
(Engine speed) (rpm) 300 - 350) 300 - 350) 300 - 350) 300 - 350)
Blow-by pressure At rated output

(SAE30 oil) (Water temp.: Min. 70°C mmHz0 Max. 150 300 Max. 150 300
At rated SAE30 oil kg/cm2 3.5 - 5.5 3.5 - 5.5 3.5 - 5.5 3.5 - 5.5
Oil pressure output SAElOW oil kg/cm2 - - - -
[Oil temperature:
Mln. 80°C) At low SAE30 oil kg/cm2 Min. 1.5 Min. 1.5 Min. 1.5 1.2
idling SAEl OW oil kg/cm2 - - - -
Oil temperature All speed (oil in oil pan) OC 90 - 110 120 go- 110 120
Oil consumption At continuous rated output

ratio [Ratio of fuel consumption) % Max. 0.5 1 .o Max. 0.5 1.5
Fuel injection
Nozzle tester kg/cm2 250 200 250 200
pressure
Fuel injection timing 8.T.D.C degree 16 161t 1 16 16zt 1
~;ldisrtor pressure Opening pressure

:Differential pressure) kg/cm2 0.5 It 0.1 0.5 f 0.1 0.5 * 0.1 0.5 f 0.1
Fan speed At rated engine speed rpm 375 - 1,4X 1,340
Deflects when pushed

Fan belt tension mm 7.5 5- 10 7.5 5 - 10
with a force of 6 kg
* The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.
Engine model SAGDllO-1
W120-2, W120-3
Applicable machine model
Classi-
Item Condition, etc. Unit
fication
High idling speed rpm

2 Engine speed
: Low idling speed rpm
E
B
5 Necessary ooc rpm
a starting speed -2O’C (with starting aid) rpm
Intake resistance At all speed mmH20

Intake pressure At rated output mmHg
5 Exhaust pressure
mmHg
; (Turbine inlet press.) At rated Output
Exhaust temperature All speed (200C) OC

2 (Turbine Inlet temp.)
_c
Quick acceleration
3
(Low idling-High idling) Bosch
g Exhaust gas color
At rated output scale
% At high idling
-E
Valve clearance Intake valve mm
(When engine is
hot or cold.) Exhaust valve mm
Oil temperature:
2 Compresion pressure kg/cm2
40 - 60°C
2 (SAEBO oil)
(Engine speed) (rpm)
.-z
P
w Blow-by pressure At rated output
(SAEBO oil) (Water temp.: Min. 70°C) mmH20
At rated SAEBO oil kg/cm2

5 Oil pressure output SAElOW oil kg/cm2
5 (Oil temperature:
Min. 80°C) At low SAE30 oil kg/cm2
k
idling SAEIOW oil kg/cm2
.-s
5
5 Oil temperature All speed (oil in oil pan) OC
’ Oil consumption At continuous rated output

%
ratio (Ratio of fuel consumption)
E Fuel injection
Nozzle tester kg/cm2
pressure
z$-
L= t Fuel injection timing B.T.D.C degree
5 Radiator pressure Opening pressure

valve (Differential pressure) kg/cm2
5
2
p Fan speed At rated engine speed rpm
.-
z
Deflects when pushed
s Fan belt tension mm
with a force of 6 kg
+ The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
SAGDI IO-I
WA400- 1
WA380- 1 WA420- 1
I (50001 and up) I
Standard Permissible Standard Permissible Standard Permissible Permissible
value value value value value value value
2,530 k 50
730 +y
Min. 150
Min. 100
Max. 300 762 Max. 380 635 Max. 300 762

- - Min. 500 450 - -
- - - - - -
Max. 650 Max. 700 Max. 650 Max. 650 Max. 700 Max. 700
Max. 6.0 8.0 Max. 6.0 7.0 Max. 6.4 8.4
Max. 3.5 4.5 - - Max. 4.0 5.0

Max. 1.5 2.5 Max. 1.5 2.5 Max. 1.5 2.5
0.25 - 0.25 - 0.25 -

$ 0.45 - 0.45 - 0.45 -
z
;;, Min. 28 22 Min. 28 22 Min. 28 22
(300 - 350) (300 - 350) (300 - 350) (300 - 350) (300 - 350) (300 - 350)
Max. 150 300 Max. 150 300 Max. 150 300
3.5 - 5.5 2.5 3.5 - 5.5 3.5 - 5.5 3.5 - 5.5 2.5
3.0 - 5.0 2.1 - - 3.0 - 5.0 2.1
Min. 1.5 0.7 Min. 1.5 1.2 Min. 1.5 0.7
Min. 1.0 0.7 - - Min. 1.0 0.7
go- 110 120 go- 110 120 go- 110 120
Max. 0.5 1 .o Max. 0.5 1 .o Max. 0.5 1 .o
250 +f’; 206 250 200 250 z’g 206

I I I
16-t 1 16k 1 16 16+ 1 16k 1 161t 1
- - 0.5 + 0.1 0.5 + 0.1 - -
1,342 + 40 1,342 + 40 1,220-1,280 1,185 1,342 + 40 1,342 + 40
7.5 5- 10 7.5 5- 10 7.5 5- 10
12-025
0
Engine model SAGDI 1 O-l
!
EC21 OZ-1 EC21 OZ-1
Applicable machine model
(10001 - 49999) I (50001 and up)
Classi- Standard Permissible

ficatior
Item I Condition, etc. Unit
value ‘%duaerd value
-
rpm 2,700-2,800
rpm 700 - 750
wm Min. 200 - Min. 150 -

wm Min. 130 - Min. 100 -
Intake resistance At all speed mmHz0 Max. 380 635 Max. 380 635
Intake pressure At rated output mmHg Min. 1,000 - - -
Exhaust pressure Max. 900 - - -
mmHg
(Turbine inlet press.) At rated Output
OC Max. 650 Max. 650 Max. 650 Max. 650
( Quick acceleration Max. 5.0 6.0 Max. 5.0 6.0

(Low idling- High idling) Bosch
Exhaust gas color
At rated output scale - - - -
At high idling Max. 1.5 2.5 Max. 1.5 2.5
I
Valve clearance Intake valve mm 0.35 - 0.25 -
(When engine is
hot or cold.) Exhaust valve mm
0.65 - 0.45 - s
%
kg/cm2 Min. 27 21 Min. 29 23 z
(mm) (300 - 350) (300 - 350) (300 - 350) (300 - 350)
mmHz0 Max. 150 300 Max. 150 300
At rated SAE30 oil kg/cm2 3.5 - 5.5 3.5 - 5.5 3.5 - 5.5 3.5 - 5.5
Oil pressure output SAElOW oil kg/cm2 - - -
(Oil temperature:
Min. BOOC) At low SAE30 oil kg/cm2 Min. 1.5 1.2 Min. 1.5 1.2
-
idling SAElOW oil kg/cm2 - - - -
Oil temperature All speed (oil in oil pan) OC go- 110 120 go- 110 120
% Max. 0.5 1.0 Max. 0.5 1 .o
kg/cm2 250 200 250 200
degree 19 19f 1 19 19f 1
Radiator pressure Opening pressure

kg/cm2 0.75 + 0.1 0.75 + 0.1 0.75 It 0.1 0.75 f 0.1
valve (Differential pressure)
1,635-1,715 1,590 1,635-1,715 1,590
7.5 5- 10 7.5 5-10
+ The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
12-026
0
SAGDI 10-I
I
EG150-3, EG150S-3
Engine No.10001 - 49999 50001 and UD I
Standard Permissible Standard Permissible

value value value value
Max.l,560 (50 Hz) Max.l,560 (50 Hz) Max.l,560 (50 Hz) Max.l,560 (50 Hz)
Max.l,872 (60 Hz) Max.l,872 (60 Hz) Max.l,872 (60 Hz) Max.l,872 (60 Hz)
- - - -
Min. 200 - Min. 150 -

Min. 100 - Min. 100 -
Max. 380 635 Max. 380 635

Max. 1,000 - - -
Max. 900 - - -
Max. 650 Max. 650 Max. 650 Max. 650

I
Max. 5.0 6.0 Max. 5.0 6.0
- - - -
Max. 1.5 2.5 Max. 1.5 2.5
0.35 - 0.25 -
$
R
0.65 - 0.45 -
I
Min. 27 21 Min. 29 23
CD
(300 - 350) (300 - 350) (300 - 350) (300 - 350)
Max. 150 300 Max. 150 300
3.5 - 5.5 3.5 - 5.5 3.5 - 5.5 3.5 - 5.5

- - - -
Min. 1.5 1.2 Min. 1.5 1.2
I
- -
I - I - I
go- 110 120 90 - 110 120
I 1 I
Max. 0.5 1 .o Max. 0.5 1.0
250 200 250 200
18 18k 1 18 181!z 1
0.75 f 0.1 0.75 i- 0.1 0.75 + 0.1 0.75 * 0.1 I

I I
1,095-l ,155(50 Hz) 1,070 (50 Hz) 1,095-l ,I 55(50 Hz) 1,070 (50 Hz)
1,315-l ,385(60 Hz) 1,280 (60 Hz) I,31 5-l ,385(60 Hz) 1,280 (60 Hz)
7.5 5- 10 7.5 5 - 10
12-027
0
TROUBLESHOOTING
METHOD OF READING TROUBLESHOOTING TABLE
The following symbols are used in the “Remedy”

column to indicate the method of eliminating the
cause of a fault.
X : Replace; 0: Repair;
A: Adjusting; C: Clean
METHOD OF READING TROUBLESHOOTING

TABLE
The symbol 0 in the table is inserted only for causes

which can be diagnosed. If a cause cannot be diag-
nosed, the corresponding box is left blank.
If the result of problem 1 using the troubleshooting

table shown at right is abnormal, the cause of the
trouble can be assumed to lie between a and d. Be-
cause it is not possible to make a problems regarding
e, it is necessary to perform the next problems (owing
to the possibility of a multiple fault).
If the result of problem 1 is normal, the cause of the
fault does not lie between a and d. In such a case, be-
fore diagnosing the cause as e, however, carry out a
check by means of problems 2 or 5.
If now the result of problem 1 is abnormal and the
result of problem 2 normal, the cause is one of a, b
or d. In addition, if the result of problem 3 is ab-
normal, the cause will be narrowed down to one of b
or d. To determine which of b or d is the actual
cause, perform problem 4.
If the result of problems is abnormal, blacken out the
corresponding 0 in the table and then perform the
Not necessary
next problems on these causes in order to narrow the problems
likely causes.
Example 1:
Problem 1 + Abnormal
From the table of ex-
Problem 2 + Normal
ample 1, the cause of
the fault is b.
Problem 4 + Normal
Example 2:
From the table of ex- Not necessary
Problem 1 + Normal
ample 2, the cause of problems
the fault is e.
* In example 2, it is evident that the cause is e

without carrying out problem 2, however pro-
blem 2 is performed by way of an additional
check.
12-028
0
TESTING AND ADJUSTING TROUBLESHOOTING
Example 3:
Problems 1 + Abnormal From the table of ex-
Problems,2 + Normal ample 3, the cause is
Problems 3 7 Normal I one of a, c and e.
kontinue problems
i From the table of ex-

Problems 4 + Normal
ample 3-1, the cause
Problems 5 + Normal
is c.
Example 4:
From the table of ex-
Problems 1 + Abnormal
ample 4, the cause is
Problems 2 T Normal
one of a, b or d.
Continue problems
Problems 3 i Abnormal From the table of ex-

Problems ,4 + Abnormal ample 4-1, the cause
Problems 5 + Normal I is a or d.
Example 4-1
As can be seen from the above examples, it is not neces-
sary to perform all of the problems. Rem& x c A A x
Also, looking at a particular cause, no matter how many X
l marks there are in the column corresponding to that

cause, it will cease to be an actual cause if there is even
one 0 mark in the same column.
110 SERIES 12-029

Co
TROUBLESHOOTING TESTING AND ADJUSTING
TROUBLESHOOTING TABLE
1. Starting defective or badness.
1) Engine does not turn.
Questions to ask operator before starting trouble-

shooting
1. Did machine stop suddenly during operation? +
Damage or seizure of internal parts.
2. Did machine make abnormal noise during opera-
tion? + Damaged parts.
* Cause h: battery charging rate
-_ _ I 1.26 1 1.24 1 1.23 1 1.22
0°C 1.28 1.27 1.25 1.24
-lODC 1.36 1.28 1.26 1.25
- Specific gravity should be at least figure for

70% charging rate.
- In cold weather, specific gravity must be at
least figure for 75% charging rate.
When setting the starting switch to START;

1) No sound of pinion moving out.
Remove head cover. When checking valve cotter, it is

4
out of place.
0
Remove oil pan. When checking internal parts, they
5
are abnormal. 0
Remove cylinder head. When checking internal
6 parts, foreign matter appears. 0
The following symbols are used to indicated the action

to be taken when a cause of failure is located.
12-030 110 SERIES
0
2) Engine turns but no exhaust gas is emitted.

Check before troubleshooting
1. Is there any fuel in fuel tank?
2. Is fuel feed valve open?
3. Is fuel piping leaking or damaged between fuel
tank and injection pump?
4. Is there any leak from fuel filter?
5. Is there any water, rust or sludge mixed with fuel
drained from fuel tank or fuel filter?
(Injection pump or nozzle are frequent causes of
failure.)
No.
No fuel comes out even if injection pump bleed plug

is loosened and priming pump operated.
When cranking engine with starting motor;

1) Injection pump (coupling) does not rotate.
2) No fuel comes out even if injection pump bleed

2
plug is loosened.
3) No fuel spurts out even if injection pump pipe

sleeve nut is loosened.
When removing injection pump tappet cover,

3 control rack does not move.

X: Replace A: Repair
A: Adjust C: Clean
110 SERIES 12-03 1

0
3) Exhaust gas is emitted but engine does not start.

If there is always great difficulty in starting, lack of
output power is a possible cause, so perform this
troubleshooting.

1. Is dust indicator red? + Air cleaner element clogged.
2. Is SAEBO oil being used at temperatures below O’C?
(Oil viscosity is too high) +At temperature below
O’C, use SAElOW oil.
3. Is ASTM D975 No. 2 diesel fuel being used at tem-
peratures below - IO’C? (Clogging caused by
precipitated parafin) + Use ASTM D975 No. 1 at
temperature below - IO’C.
4. Is fuel control lever bent? Is there any play? Is the
pin out of place?
Engine starts if air cleaner element is removed.
When removing injection pump tappet cover, control

5
rack and plunger do not move. I I j I I lol I I I I
When checking injection nozzle with nozzle tester,
6
it does not inject.
0
7 Compression pressure is too low; blow-by is high. 0
8 Valve clearance is not proper value. 0
9 1 Injection timing is not proper position. I loI I rII-I
Air cleaner does not aspirate air.
10 0
(After maintenance)

x: Replace A: Repair
A: Adjust C: Clean
12-032 110 SERIES
Co
2. Engine stopped during operation.
Questions to ask operator before troubleshooting.

1. Did engine stop slowly? + Fuel supply cut.
2. Did engine stop suddenly? + Internal parts damag-
ed or seized.
3. Did engine make abnormal noise? * Parts damag-
ed.

1. Is there any fuel in fuel tank?
2. Is fuel control lever bent? Is there any play?
Is the pin out of place?
3. Is fuel piping leaking or damaged between fuel
tank and injection pump.
4. Is beed hole of fuel tank cap clogged?
Starting mo!or does not crank engine.

not turn when cranking engine with
out even if injection p
When cranking engine with starting motor;

1) Injection pump (coupling) does not rotate.
plug is loosened.
rack does not move.

A: Adjust C: Clean
12-033
0
3. Engine runs abnormally. 4. Fuel consumption too high.
1) Engine speed is too high. l Before starting the troubleshooting, ask the opera-
tor why he noticed the fuel consumption was too
high.
Governor adjustment defective

Cause T Remedy
External leakage of fuel;

Fuel tank, injection pump, fuel
filter and piping. XA
2) Engine does not stop. (Common cause when fuel con-
sumption increases suddenly.)
Cause Remedy
Follow “6.
Fuel control lever linkage is bent; Excessive fuel injection, poor fuel
Exhaust
a there is too much play; pin is out A consumption ratio (in this case
gas is
of position; something is catching. exhaust gas is black).
black”
Injection pump control rack func- Internal leakage of fuel;

b XA
tion defective Leakage from fuel tube inside
A
cylinder head cover.
Injection pump function defective Change oil
C XAA (In this case, oil level rises and oil
(part other than rack) smells of kerosens.)
d Governor function defective XAA
Defective adjustment of fuel cut

e A
solenoid link
Defective adjustment of fuel cut X

f
solenoid
3) Hunting.
Cause Remedy
Air sucking into system between xA

a
fuel tank and feed pump
b Governor function defective XAA
C Governor adjustment defective A
d
Injection pump control rack func- xA
tion defective
* Set injection pump and governor on test stand

when adjusting.
* Making up fuel pump by injecting more fuel
than standard may damaged engine.
The following symbols are used to indicated the

action to be taken when a cause of failure is
located.
A: Adjust C: Clean
12-034
0
5. Lack of power. 5. Is there any water, rust or siudge mixed with fuel
drained from fuel tank?
* If lack of power is accompanied by black exhaust
(Injection pump or nozzle are frequent causes of
gas, follow problems “6. Black exhaust smoke.”
failure.)
* First troubleshoot whether the cause is in the en-
(Check strainer clogged when no fuel comes out.)
gine or in the chassis as follows.
At torque converter oil

stall speed. (tachometer) temperature approx.
76’C. and at Forward-
N.G. ,Good
1 I highest speed
- Judge mainly checking for track tension, brake

function, acceleration and engine high idling speed
when mounting DIRECT transmission.

1. Is fuel piping damaged or fuel leaking between fuel
tank and injection pump?
2. Is bleed hole of fuel tank cap clogged?
3. IS tube damaged or leaking between injection
pump and nozzle holder?
4. Is incorrect fuel being used?
1
Even with fuel control lever at FULL position, injec-
tion pump lever does not contact to the full-stopper. 0
When operating priming pump:
1) No reaction or slight reaction and quick return. 00
2
2) No reaction or slight reaction with normal return. 0
No fuel comes out even if injection pump bleed plug
3
is loosened and priming pump operated. 0
4 Improper engine-running happens by hunting. 0

When checking with nozzle tester, injection spray is
5 0
defective or injection pressure is low.
No fuel spurts out even if injection pump pipe sleeve

6
nut is loosened. I lolol I I I I
Some cylinders little or no pulse when injection pipe is
When removing injection pump tappet cover and

checking movement of control rack, does not move

A: Adjust C: Clean
1lOSERlES 12-035
0
6. Exhaust gas is black.

Is dust indicator red? *<Air cleaner element clogged.
Is injection pump seal out of, position? + Pump
out of adjustment (excessive injection).
Is air leaking between turbocharger and cylinder
head?
Is standard spec. machine operating at high alti-
tude?
method shows
7 Exhaust gas color improves when muffler is removed. 0

Turbocharger is sluggish when turned by hands.
8
(For engineswith turbocharger) 0
I
9
Exhaust gas color improves when injection pump is
replaced. _____~ ~~ I loi-I I T-I I /
Exhaust gas color improves when auto-timer is
10 replaced. (For engines with auto-timer) 0

A: Adjust C: Clean
12-036 110 SERIES

0
7. Exhaust gas is blue. (Combustion of engine oil)
Check before troubleshooting (For engine with turbocharger)

1. Has engine continued to run for over 20 mins at
low idling? -f Oil coming up into cylinder, oil leak
from seal at turbocharger turbine side.
2. Has engine continued to run for over 20 mins
at high idling? + Oil coming up or down into
cylinder, oil leak from seal at turbocharger blower
side.
3. Is turbocharger oil return pipe damaged? + oil leak
from turbocharger seal.
ipe is coated with oil.

110 SERIES 12-037

0
8. Oil consumption too high.
Before starting the problems, ask the operator why he

noticed the fuel consumption was too high.
* If answer is: “Oil consumption was high and ex-
haust gas was blue”, follow problems “7. Ex-
haust gas is blue”.

l Is engine or engine lower part coated with oil.
(Remove earth and sand and check.)
1 Oil leaking out of engine (check around engine). 0
2 Cooling water is mixed with engine oil. 0
3
Oil in main clutch or TORQFLOW transmission
0
or damper increases.

J 2-038 110 SERIES
Cc
9. Oil level rises. (Mixed water or fuel)

* Is the cooler of engine oil dirt - white? + Mixed
water.
Seal or seal contact face of hydraulic pump drive

4
shaft is worn or damaged. 0
I

1 IO SERIES 12-039
0
10. Oil quickly becomes dirty.
Before starting the troubleshooting, ask the oper-

ator the following questions.
1. Were oil and oil filter changed in accordance with
the “Qperation and Maintenance Manual”?
2. Was improper oil used? I’/ I I I1
No. 1 Problems \ Remedy /X /X4-

X 'p,
7LLoaliohtload.
Exhaust gas is blue when engine is run at high speed
; 1~;;;y~~islack. 1 ~o~Cl~
After running at high idling for approx. 10 mins., oil

can be seen leaking from turbocharger turbine outlet.
5 Turbocharger shaft play is excessive. 0
6 Oil cooler therm0 valve does not open (check directly). 0
t If the above problems does not reveal the cause, a common secondary cause of dirty oil is carbon from incom-
plete combustion mixing with the oil. In this case follow problems in “6. Exhaust gas is black”.

A: Adjust C: Clean
12-040 110 SERIES
0
11. Engine oil pressure gauge indicator fluctuates abnormally.
or valve guide is damage

A: Adjust C: Clean
110 SERIES 12-041

0
12. Lack of oil pressure.
(At engine speed of over 700 rpm, indicator of

engine oil pressure gauge is to left of “Operating
range”.)
Question to be asked before starting trouble-

shooting.
Is IOW oil being used at temperatures above O’C?
e
Water or fuel mixed with fuel.
2 I I I I I I I I I lol
I
Oil in oil pan is lack (no sign of external oil leakage).
Engme or1 pressure IS normal If gauge IS replaced
Oil hose, tube are clogged or damaged.
6
Oil filter is clogged and bypass valve function is
defective. (Check directly) II II0 I/II
Metal particles are caught in oil filter element.
7
K.0.W.A (oil analysis) shows abnormality. 0
Remove oil pan. When checking oil, strainer is
8
clogged or oil pipe is damaged. 0
9
Regulator valveb catching, spring is fatigued, valve
or valve guide is damaged. (Check directly) lol III I/II
10
I Oil pump does not rotate smoothly and oil pump
shaft play is excessive. 0

A: Adjust C: Clean
12-042 110 SERIES

0
13. Oil in cooling system.
14. Water temperature does not rise.
Water temperature gauge indicator is to left of

“Operating range”.
* In cold weather operation, if reversible fan
and radiator shutters are not fitted, the en-
gine may not warm up. (If equipped.)
1 Water temperature rises if gauge is replaced.

0
When thermostat is removed, it is found to stay open;
2 or performance test shown cracking temperature is 0
toolow.

110 SERIES 12-043

0
.-
15. Water temperature rises excessively.
(Water temperature gauge indicator goes to right of

“Operating range”; engine overheats.)
Never remove the radiator cap when the tem-

LI
perature is still high. Boiling water may spurt out
and cause serious burns.
* When the engine overheats, stopping the engine
immediately means water is no longer sent out by
the water pump. As a result the temperature of
the parts being cooled rises sharply and this may
cause cracking or other damage to the engine.
Before starting the troubleshooting, ask the oper-

ator the following questions.
1. Is anti-freeze being used in summer?
2. Is water being supplied according to the “Opera-
tion and Maintenance Manual”.

1. Is machine being operated under excessive
load?
2. Is fan damaged or deformed?
3. Is belt groove of fan pulley or crank pulley
worn?
4. Are radiator shutter and reversible fan
being used properly?
Coolant level is too low.
Cooling water mixed with oil.
3 Fan belt loosens. 0
4 Radiator core is damaged or clogged with mud or dust. 0

Difference in temperature between upper and
5
lower tanks is extreme. 0
6 Radiator is only slightly warm. I I lolol I I I I
7 Valve opens when testing thermostat only. 0
If water temperature gauge is replaced, it returns

8
to normal.
0
Torque converter oil temperature is too high.

9
(with TORQFLOW transmission)
0
t If exhaust smoke is black, follow problems “6. Exhaust gas is black”.

12-044 110 SERIES
Co
16. Too much vibration.
No. Problems
AX
Ill lllllllll/
1 Engine mounting bolts are loose. (Check directly) 0
Vibration damper is not warm to touch after operation,
2
during operation, gear noise is also excessive. 0
3 Air is mixed in fuel system. 0

Engine runs abnormally at low idling. (No air in fuel
4 line; exhaust gas color normal) 0 0
5 Exhaust gas is black. 000
6 Water temperature does not rise or rises slowly. 0
7
I When checking injection nozzle with nozzle tester, in-
jection spray is defective or injection pressure is low.
8
I
Injection pump seal is out of position, injection pump
is Out of adjustment. (Check directly with pliers) I I I I I lo1I I I I l-1
When loosening injection pipe sleeve nuts in order at
9 00
low idling, speed of some cylinders does not change.
10 oil pressure is low at low idling. 0

11 Remove cylinder head when checking it, the tappet 0 0
or intake and exhaust valves are abnormal.

110 SERIES 12-045

0
17. Abnormal noise emitted.
* When noises indicating internal damaged are be-

ing emitted continuing to operate the machine
may make the damage worse.
* As far as possible, classify the abnormal noise to
make location of the cause easier.
Type of noisr
- lnterferenl
* Abnormal combustion
* Gears
* Internal, external
* Engine, power train
2 1 Exhaust gas is black.
3 Combustion noise is abnormal. 00 00 00
4 Seal is broken. (Check injection volume on test stand.) 0

5 Water temperature does not rise. 0
6
Vibration damper is not warm to touch after
during operation, gear noise is also excessive. 1-1 I ! I I I I4 I I 1
When loosening injection pipe sleeve nut and setting
7 0
engine to low idling, engine speed does not change.
8 Valve clearance is too large or too small. 0

9 Compression pressure is lack; blow-by is excessive. 0
When checking injector nozzle with nozzle tester, in-
10
jection spray is defective or injection pressure is low.
Remove oil pan. When checking it, internal engine

11
noise is excessive. I IlolllllllllI
12 Remove gear cover. Gear noise is occured. 0
When removing cylinder head, Internal engine noise
13 0
is excessive.
Other causes of abnormal noise (direct check)

A: Adjust C: Clean
12-046 110 SERIES
0
18. Excessive wear of engine parts.
Before starting the troubleshooting, ask the opera-

tor the following questions.
1. Is the specified oil being used?
2. Is the specified fuel being used?
3. Is the air cleaner element cleaned and replaced
according to the “Operation and Maintenance
Manual”?
4. Is the fuel filter element cleaned and replaced
according to the “Operation and Maintenance
Manual”?
5. Are the engine oil and oil filter element replaced
according to the “Operation and Mainten
Manual”?
6. Has there been repeated rapid acceleration
rapid gear shifting?
7. Is the machine warmed up before operation
and left idling before stopping engine ac
cording to the “Operation and Maintena
Manual”?

A: Adjust C: Clean
12-047
0
19. Engine does not start because of fault in electrical system. (Check starting circuit)
A When checking, take care not to be caught

in fan or other rotating parts if engine starts.

1. Is battery electrolyte level or specific gravity too
low?
2. Check starting circuit for broken or disconnected
wires, loose terminals or short circuits (Visual
check)
Battery - Safety relay - Starting switch
~--2 Battery relay switch - Battery
3. Immediately after repair, mistaken wiring con-
nection is possible cause.
4. When problems l-1) “Engine does not turn”
gives cause i “Electrical system defective”,
use this problems.
No. Problems
Remove the stop lever of injection pump

1 then set the injection pump lever to the RUN
side, engine will start.
If terminals (6) and (C) of starting motor are

connected, pinion moves out.
2 l Sparks are produced by this test.
A. When pinion movement is confirmed,

drsconnect-terminals immediately.
If terminals (6) and (Cl of starting switch are

3 connected, engine will start.
If terminals (b) and (El of battery relay switch are

connected, engine will start.
If plug terminal of safety switch is connected to

terminal (B) or (+) of starting motor, engine will start.
If terminals (6) and (C) of safety relay are connected,

engine will start.
Starting motor does not turn even if No. 1 starting

7 motor terminals (6) and (C) are connected.

A: Adjust C: Clean
12-048
0
20. Battery does not charge. (Check charging circuit)
7 When checking, take care not to be caught in

Q
fan or other rotating parts if engine starts.
Take care also not to cause short circuits.
Before starting the troubleshooting, ask the opera-

tor if the battery is old (in use for 2 or more years).
I Ill
1. Is alternator or dinamo drive belt loose?
2. Check starting circuit for broken or disconnected
wires, loose terminals or short circuits. (Visual
check, continuity check)
Battery cf Starting switch * Ammeter *
Regulator * Alternator
- Battery relay switch - Battery
3. Do lamps or heater exceed specified limit? Are
they left on?
* When engine is stopped and charged
lamp stays on, or ammeter indicator
deflects to one side, lamps are still on,
or there is a short circuit.
4. Following repairs, mistaken wiring connec-
tion is possible cause.
During operation, deflection of ammeter and charging

1
lamp are normal.
Continuity test using tester shows;

1) Little or no continuity when terminals (AC) and (6
of starting switch are connected. (with switch ON)
2 2) When the starting switch is ON, continuity be-

tween them above I) is proper, but when being
OFF, no continuity.
I 3) Little or no continuity between (+j terminal and

(-) terminal of ammeter or charging lamp.
Run engine at medium speed (1,000 - 1,500 rpm) and

measure charging voltage with tester.
1) Tester does not show charging voltage (26-3OV3
between terminal (E) of alternator and terminal 00
(N) of regulator.
2) Tester shows charging voltage, or between terminal

(B) and (E) of alternator, but does not show with 0
above.
I 3) Tester shows charging voltage with 2) only. 0

A: Adjust C: Clean
110 SERIES 12-049

0
13 DISASSEMBLY AND ASSEMBLY
ENGINE
110 SERIES
Engine Numbers: 10001 and up
13 DISASSEMBLY AND ASSEMBLY
110 SERIES
DISASSEMBLY AND ASSEMBLY
Overalldisassembly.. .................................................................. 13-004
Overallassembly...........................~ ............................................ 13-102
Disassembly and assembly of components ............................................... 13-201
* The description of overall engine disassembly and assembly given in this section is based on the
SAGDI 1 O-l engine, assuming the use of an overhaul stand.
Sr The work procedure may differ slightly from that given here depending upon the machine in which
the engine is mounted, engine accessories. and also the particular stand used, however it is funda-
mentally the same.
* Use the correct service tools when performing disassembly and assembly.
110 SERIES 13-003

Co
OVERALL DISASSEMBLY DISASSEMBLY AND ASSEMBLY
OVERALL DISASSEMBLY
Oil filler,
dipstick guide
Engine
SAGDI IO-1
13-004 1lOSERlES
0
DISASSEMBLY AND ASSEMBLY OVERALL DISASSEMBLY
6138F301
110 SERIES 13-005

Special tools required for overall disassembly
Part No. Part Name A B C D E

- Engine stand 1
790-501-2000 Engine overhaul stand 1
790-901-l 006 1 - Adapter plate 111 1 1
795-215-2000 ) Remover 111 /
795-l 00-2800 1 Piston ring tool 1
795-102-2101 1 Spring pusher / 1
Preparatory work
. Clean off all mud and dirt.
. Drain cooling water and engine oil.
b
& Engine oil: Approx. 22 R
. Prepare a stable engine stand A so that the engine will

not overturn, and set the engine securely on the stand.
Engine assembly: Approx. 650 kg

el kg (Differs according to machine)
13-006 110 SERIES

1. Oil filler, dipstick guide
1) Remove oil filler (1).

2) Remove dipstick guide (2).
2. Starting motor
. Remove starting motor (3).
3. Turbocharger, exhaust manifold assembly
1) Remove muffler drain pipe (1).

2) Disconnect turbocharger intake tube (2) at cylinder
block end.
3) Disconnect intermediate hose (3) between turbo-
charger and aftercooler.
4) Remove turbocharger (4) and exhaust manifold
assembly.
4. Setting engine in engine overhaul stand
1) Install adapter plate B’ (supplied with engine overhaul

stand) on engine.
2) Raise engine assembly, align plate B’ with engine

overhaul stand, and install engine.
Engine assembly: Approx. 630 kg
110 SERIES 13-007

Fuel filter
Disconnect fuel filter inlet hose (1) and outlet hose (2)
at fuel injection pump end, then remove fuel filter (3).
Oil filter
Disconnect oil filter inlet tube (4) and outlet tube (5),
then remove oil filter (6).
7. Fuel injection pipe
1) Remove boost compensation pipe (1).

2) Disconnect hose (2) at air compressor end.
3) Remove fuel injection pipe (3).
8. Aftercooler
1) Disconnect wiring between relay switch and ribbon

heater at switch end.
2) Disconnect aftercooler inlet tube (1) at cylinder
block end.
3) Disconnect aftercooler outlet tube (2) at thermostat
end.
4) Using eye bolts @ (8 mm, P =. 1.25), sling aftercooler
(3).
5) Remove mounting bolts, then lift off .aftercooler and
ribbon heater (4).
13-008 110 SERIES

9. Thermostat
. Remove thermostat with case (1).
1) Remove return tube (I) of fuel injection pump.

2) Disconnect feed tube (2) of fuel injection pump.
3) Remove bolts (3) connecting fuel injection pump
air compressor.
4) Remove fuel injection pump (4).
5) Remove fuel injection pump bracket (5).
11. Oil cooler
1) Remove oil cooler inlet tube (1).

2) Remove oil cooler (2).
12. Air compressor
1) Remove oil feed tube (1) of air compressor.

2) Remove air compressor (2).
110 SERIES
13. Fan belt
l Loosen mounting bolt of alternator, move alternator

to inside, and remove fan belt (1).
14. Alternator
1) Remove mounting bolts (I) and (2), then remove

alternator (3).
2) Remove plate (4).
15. Water pump
l Remove water pump (1).
16. Spill pipe
. Remove spill pipe (I).
17. Nozzle holder
l Remove nozzle holders (2).

* Mark each nozzle holder with a number before
removing. Keep the nozzle holders in a safe place and
be careful not to damage them.
13-010 110 SERIES

18. Cylinder head cover
. Remove cylinder head cover (1).
Rocker arm assembly
1) Loosen lock nut of adjustment screw, then loosen

each adjustment screw 2 to 3 turns.
* Loosen the adjustment screws at this point to
avoid excessive pressure being brought to bear on
the push rods when installing the rocker arm
assembly.
2) Remove rocker arm assembly (1).
20. Push rods
. Remove push rods (1).
110 SERIES 13-011

21. Cylinder head
1) Remove mounting bolts of cylinder head.

2) Remove cylinder head (1).
el kg Cylinder head assembly: 57 kg
3) Remove cylinder head gasket.
. Disassemble cylinder head assembly as follows.

i) Using spring pusher B, compress valve spring and
remove valve cotter (I ).
ii) Slowly releaSe spring tension and remOve spri”g
guide (2), valve spring (3) and spring seat (4).
iii) Lift up cylinder head (5) and remove valves (6).
* Valve spring
- Engine No. 10001 - 50000: Equal pitch

50001 and up: Unequal pitch
13-012 110 SERIES

0
22. Oil pan

. Turn over engine to put oil pan at top.
. Remove oil pan (1).
* Be careful not to deform or damage the oil pan
when removing it, as this will cause oil leakage.
23. Suction tube
l Remove suction tube (1).
24. Vibration damper
l Turn over engine to put cylinder head side at top.

1) Remove vibration damper (1).
2) Remove spacer (2).
25. Crankshaft pulley
1) Remove bolt (I), then remove plate (2).

2) Remove crankshaft pulley (3) and taper collar (4).
110 SERIES
26. Gear case cover

0 Remove gear case cover (I).
27. Drive gear for fuel injection pump

l Remove drive gear (1) for fuel injection pump.
28. Oil pump
0 Remove oil pump (2).
Ir When disassembling the oil pump, see to Section

“DISASSEMBLY AND ASSEMBLY”.
Engine No. 10001 - 50000: Trochoid pump

50001 and up: Gear pump
29. Drive gear for oil pump
. Using puller 0, remove drive gear (1) for oil pump.
30. Idler gear, shaft assembly
1) Remove thrust plate (I), then remove idler gear (2).

2) Remove idler shaft (3).
13-014 110 SERIES

0
31. Flywheel
l Screw in guide bolt @ (14 mm, P = 1.5), remove

mounting bolts (l), then remove flywheel (2).
Flywheel: 22 kg
(Differs according to the machine)
32. Flywheel housing
1) Using eye bolts @ (12 mm, P = 1,75), sling flywheel

housing (1).
2) Remove mounting bolts and lift off flywheel housing.
Flywheel housing: 26 kg
110 SERIES 13-015

-.
33. Piston, connecting rod assembly
. Turn over engine so that piston and connecting rod

assembly is at side.
* To avoid damage when removing the piston, remove
the top inside surface of the liner with fine sand-
paper.
1) Rotate crankshaft so that piston to be removed is at
bottom dead center.
2) Remove connecting rod cap (1).
3) Using wooden bar, push piston and connecting rod
from oil pan side. Support piston (2) at cylinder
head side and remove.
* When removing, be careful not to damage the
inside surface of the liner with the corners of the
connecting rod.
4) Remove remaining pistons and connecting rods in the
same way.
* Keep the pistons and connecting rods in a safe place
and be careful not to damage the sliding surface of
the piston or the bearing.
* Disassemble piston and connecting rod assembly as

follows
i) Using pliers (a), remove spring (4).
ii) Hold connecting rod (5) by hand, and tap out piston
pin (6) from opposite side.
iii) Disconnect piston assembly and connecting rod.
iv) Remove snap ring on opposite side.
VI Using piston ring tool C, remove rings in turn, starting

with top ring (5).
* Keep piston, connecting rod, bearing, piston rings and
piston pin in sets according to cylinder number.
13-016 110SERlES
34. Crankshaft
l Turn over engine so that crankshaft side is at top.
1) Remove main bearing caps (1).
* The lower thrust bearing is assembled on both
sides of the No. 7 main bearing cap, so after
removing, mark the position for assembly.
2) Using a nylon sling, remove crankshaft (2).

* When raising the crankshaft, be careful not to let
it hit or damage the cylinder block.
* Keep the crankshaft in a safe place, and be careful
not to damage the sliding surface.
3) Remove upper thrust bearing (3) on crankshaft side.
4) Remove upper bearing (4).
* Mark the positions for assembly of the main bearing

cap, main bearing and thrust bearing with a tag or felt
pen. Keep in sets according to the cap number. Keep
them in a safe place and be careful not to damage
them.
110 SERIES
35. Camshaft
1) Remove thrust plate (1).
2) Remove camshaft (2).
36. Front plate
0 Remove front plate (3).
37. Tappets
0 Remove tappets (1).
38. Cylinder liner
l Turn over engine so that cylinder head side is at top.

l Before removing the cylinder liner, measure the
protrusion of the liner.
* If there is any leakage from the cylinder head
mounting gasket, or any leakage of water into the
oil pan, always measure the liner protrusion
without fail.
l The standard for the liner ID is determined for when
it is assembled in the cylinder block. So to judge
wear of the liner ID, measure it before removing the
liner.
1) Set tool C in position.
2) Rotate tool counterclockwise and remove cylinder
liner (1).
6136F302
13-018 110 SERIES

OVERALL ASSEMBLY DISASSEMBLY AND ASSEMBLY
OVERALL ASSEMBLY
Camshaft
LCylinder
block
Front plate
19
13-102 110 SERIES

0
DISASSEMBLY AND ASSEMBLY OVERALL ASSEMBLY
I -II
24
\
26
II
36
30
III
6138F311
110 SERIES 13-103

Special tools required for overall assembly
Part No. Part Name A BCDEFGH

- Engine stand 1
790-501-2000 Engine overhaul stand 1
790-901-I 106 * Adapter plate 1
795-215-2000 Remover 1
795-l 00-2800 Piston ring tool 1
795-l 02-2101 Spring pusher 1
795-217-2800 1 Pistbn holder I I I I I Ill I
795-215-I 800 1 Seal guide II 1
795-l 16-l 330 Feeler gauge 11
Preparatory work
. Install tool B’ on cylinder block, raise and set on engine

overhaul stand B.
13-104 110 SERIES

DISASSEMBLY AND ASSEMBLY OVERALL -ASSEMBLY
1. Cylinder liner
m
1 or11
* For each cylinder, check that the mark on the cylinder Liner mark
liner and stamped mark (A or B) at the top and top left
side of the cylinder block are correctly positioned.
Mark
Block mark Liner Part No.
Bottom Top
A 6138-21-2210 A 1 Liner mark

Aor 8
B 6138-21-2220 B 11
6136FO25
* Clean the press-fitting surface of the cylinder liner and

cylinder block thoroughly. (Completely remove the rust
preventive oil from the liner)
* Coat the press-fitting surface of the cylinder liner and
cylinder block thinly with engine oil (E030).
1) Bet cylinder liner (1) on cylinder block.
* Bet the cylinder liner (1) with the top mark facing
the front of the engine.
2) Using tool C, press fit liner in block.

* Press fit slowly for the first 10 - 20 mm and make
sure that the liner is not at an angle.
* If the liner is not straight, there is a danger that it
will crack. Use a pulling tool to remove it and
press fit from the beginning again.
* If there is any dust or dirt on the press-fitting
surface of the liner or the bottom surface of the
flange, the liner will be deformed or the protrusion
will not be even. Never try to install the liner by
putting a wooden block on top of the liner and
hammering the liner into the block.
11_ 6138FO26
110 SERIES 13-105

3) Measure protrusion of cylinder liner

l After press-fitting the cylinder liner, measure the
amount that the cylinder liner protrudes.
* Protrusion of cylinder liner: 0.05 to 0.13 mm
4) Measure inside diameter of cylinder liner

l After press-fitting the cylinder liner, measure the
inside diameter of the cylinder liner and check
that it is within the standard value.
2. Tappets
l Turn over engine so that crankshaft side is at top.

l Assemble tappets (1).
* Check that the tappets move up and down
smoothly.
3. Front plate
l Fit gasket and install front plate (1).

* There is a danger that the bolt cannot be aligned
when the front ear case is installed, so coat the
gasket with gasket sealant before installing.
* Be sure to tighten all four mounting bolts.
13-106 110 SERIES

4. Camshaft
1) Assemble camshaft (2).

* Be careful not to damage the cam bushing when
installing.
* Must not knock at the gear with hammer.
2) Install thrust plate (1).
5. Idler gear shaft
l Align position of roll pin, and install idler gear shaft

(1).
6. Crankshaft
1) Align protrusion of upper main bearing (4) with

notch in cylinder block, and install.
* After installing the bearing, coat the sliding surface
with engine oil.
2) Install upper thrust bearing (3) on crankshaft side.

* Install the thrust bearing with the groove on the
outside.
* Check that the protrusioti of the roll pin is 1.5 to
1.9 mm.
* Coat the sliding surface of the thrust bearing with
engine oil.
110 SERIES 13-107

0
3) Using a nylon sling, raise crankshaft (2) and set in

position on cylinder block.
* When assembling, align the A mark on the
crankshaft gear with the A mark on the idler gear.
* When installing the crankshaft, be careful not to
let it hit or damage the cylinder block.
4) Align protrusion of lower main bearing (5) with

notch in main bearing cap and install bearing on cap.
5) Assemble lower thrust bearing (6) on both sides of
No. 7 main cap bearing.
* Install the thrust bearing with the groove on the
outside.
* Check that the protrusion of the roll pin is 1.5 to
1.9 mm.
6) Assemble main bearing cap (I).
* Coat the sliding surface of the bearing with engine
oil before installing.
* Match bearing no. and block no., and install the
main bearing cap with the “F” mark facing the
front of the engine
7) Tighten bolts of main bearing cap as follows.
* Coat the threads of the bolts and the seat face
with engine oil before tightening the bolts.
* Tighten both bolts uniformly in turn.
m Main bearing cap
Unit: kgm
Order Target Range
1st step 7 6-8

2nd step 20 IQ-21
3rd step 0 Loosen completely
4th step 7 6-8
5th step 14 13- 15
6th step 20 19 - 21
* After tightening the bolt, check that the crank-

shaft rotates smoothly. There must be no catching
or other abnormality.
13-108 110 SERIES

8) Measure end play of crankshaft

l After tightening the main bearing cap, measure the
end play of the crankshaft.
* End play of the crankshaft: 0.14 to 0.315 mm
7. Piston, connecting rod assembly
* Assemble piston and connecting rod assembly as follows.

i) Install expander (6) on piston (4).
ii) Using tool D, install oil ring (7).

Install the piston ring with the stamped mark at
the end gap facing up.
When fitting the oil ring, check that the
expander is fitted completely inside the oil ring.
Position the expander and oil ring as shown in
the diagram.
* ,, ,, ,,
6136F304
a: Join of coil
b: Teflon tube
c: End gap
iii) Install compression ring (5).

* If the connecting rod bushing has been removed,
install the bushing with push tool @ (0.D.50
mm).
110 SERIES 13-109

iv) Set “FRONT” mark on piston head and cast part

number on connecting rod facing the same
direction. Insert piston pin (3) and assemble
connecting rod (2) with piston pin.
If the piston pin will not go in easily, warm the
piston in hot water before installing.
Match the numbers on the piston connecting rods
with the cylinders.
Use an electric pen to mark the cylinder numbers
on the connecting rods.
Install snap rings (1) on both sides.
Turn over engine to put cylinder block facing
the side.
Set the crankshaft pin to top dead center in the
cylinder where the piston and connecting rod
assembly is to be installed.
Coat the inside surface of the cylinder, and the
surface of the piston rings and connecting rod
bearing with engine oil.
1) Align end gaps of piston rings as shown in diagram.

2) Insert piston and connecting rod assembly (2) from
cylinder head side as far as piston ring.
* Assemble the piston with the “FRONT” mark
6136FO31
facing the front of the engine.
* Assemble the piston and connecting rod assembly
with the cylinder number facing the cam side.
3) Using piston holder F, compress piston rings and push

piston head with a wooden bar. Then pull big end of
connecting rod and fit on crankshaft pin.
13-110 110 SERIES

4) Align notch in connecting rod cap with protrusion in

lower bearing of connecting rod and install bearing.
5) Match cylinder number stamped on connecting rod
cap cylinder number stamped on connecting rod.
Install connecting rod cap (1) so that stamped
number is on cam side.
* Coat connecting rod cap bearing with engine oil.
6) Assemble connecting rod cap as follows.

* Coat the threads of the bolts and the seat face
with engine oil before tightening the bolts.
* Tighten the bolts uniformly in turn.
m Connecting rod cap:

Unit: kgm
Order Target Range

1ststep 6 5-7
2nd step 11 IO-2
3rd step 0 Loosencompletely
4th step 6 5-7
5th step 11.2 10.6 - 11.7
* After tightening the bolt, check that the crankshaft

rotates smoothly. There must be no catching or
other abnormality.
7) Measure side clearance of connecting rod cap

l After installing the piston and connecting rod ”
assembly, measure the side clearance between the cap ,,‘, ,‘,’
and the side face of the crankshaft.
* Side clearance of cap: 0.16 to 0.33 mm
110 SERIES 13-111

_ . ..
8. Flywheel housing
1) Using push tool @ (O.D. 135 mm), press fit rear seal
on housing.
* Press fit until the face of the seal plate is level with
the face of the flywheel housing boss.
* If there is any wear on the lip contact surface

(over 0.1 mm, enough for fingernails to catch) or Flywheel
housing
if it is worn as mirror surface, move the rear seal
forward about 3 mm when assembling. Rear seal
Lip contact
surface
6138FO27-1
2) Install tool G on end face of crankshaft.

3) Using eye bolts @ (12 mm, P = 1.75), raise flywheel
housing (1). Fit gasket, align dowel pin hole and
install.
4 Coat lip surface of rear seal (50 to 80% of

iip space) with grease (G2-Ll).
* Tighten the flywheel housing and cylinder block

mounting bolts in the order shown in the diagram.
m Flywheel housing mounting bolt:

11 f 1.5kgm
6136F305
13-112 110 SERIES

4) Measure face runout and radial runout of flywheel

housing. After installing the flywheel housing,
measure the face runout and radial runout.
* Repair limit of face runout: 0.35 mm
* Repair limit of radial runout: 0.3 mm
9. Flywheel
1) Screw guide bolt @ (14 mm, P = 1.5) into mounting

face of flywheel.
2) Set flywheel (2) on crankshaft.
3) Tighten flywheel mounting bolts (1) as follows.

* Coat the threads of the bolts, the seat face, and
l
the washers with
bolts.
engine oil before tightening
Tighren the bolts in the order given in the diagram,

the
p_
6
7. 1
T .”
and to the following tightening torques.
4 l .
3
B Flywheel mounting bolt:
Unit: kgm
2 .- 5 6136F306
Order Target Range
1ststep 9 6-12
2nd steD 18 16-20
4) Measure face runout and radial runout of flywheel.

l After installing the flywheel, measure the face
runout and radial runout.
* Repair limit of face runout: 0.2 mm
* Repair limit of radial runout: 0.15 mm
110 SERIES 13-113

10. Oil pump
l Install oil pump (2).
* When assembling the oil pump, see the Section
-.“DISASSEMBLY AND ASSEMBLY”:-
Engine No. 10001 - 50000: Trochoid pump

50001andup : Gear pump
11. Drive gear for fuel injection pump
Knock key (7) into shaft (6). press fit gear (8), then
press fit bearings (9) and (10). Assemble washer (11)
and tighten nut (12).
w Nut: 33 + 2 kgm
Install drive gear (1) for fuel injection pump.
12. Drive gear of oil pump
1) Assemble idler gear (3), align position of roll pin and

install thrust plate (4).
m Mounting bolt: 11 f 1.5 kgm
2) Install drive gear (5) of oil pump.
\9 6
6138F315
* Check that the match marks of all drive gears and

idler gears are correctly aligned.
* Measure the backlash and end play of each gear.

l Align assembling the drive gears and idler gears,
measure the backlash and end play of the follow-
ing gears.
i) Backlash
Position Gears Range (mm)
13-114 110 SERIES

0
* End play of camshaft: 0.15 to 0.35 mm

* End play of idler gear: 0.05 to 0.21 mm
13. Gear case cover

1) Using push tool press fit oil seal (2)
in case.
14. Crankshaft pulley

1) Align key of crankshaft, and assemble crankshaft
pulley (3).
2) Assemble taper collar (4).
3) Fit plate (2) and install bolt (1).
Ir Coat the bolt thread and seat surface with engine
oil.
m Mounting bolt: 38 + 3 kgm
110 SERIES 13-115

15. Vibration damper
l Assemble spacer (2) and install vibration damper (1).

* Install the vibration damper with the concave side
on the inside.
16. Suction tube
. Turn over engine to put crankshaft sie at top.

l Fit O-ring and install suction tube (1).
17. Oil pan
1) Cut gasket so that it is level with cylinder block, front

cover and flywheel housing lower face.
2) Check difference in level with cylinder block.
(Unit: mm)
Measurement point Difference in lower face
Within 0.04
Block and front plate
(recess: within 0.22)
Block and front cover I Within 0.105
Block and flywheel housing 1 Within 0.13
3) Coat three Bond No. 45 on joining surface (stepped

part) of oil pan, front cover, front plate and flywheel
housing.
13-116 110 SERIES

4) Fit gasket and install oil pan (1).

t Arrange the hot-rolled face (polished face) of the
gasket, and set it facing down on the surface of the
oil pan.
+ To make assembly easier, use an adhesive
compound (Three Bond No. 201) and stick the
gasket on the oil pan.
18. Cylinder head
* Assemble cylinder head as follows.
* If the valve guide has been removed, use push tool I to

install valve guide (7).
i) Install valve (6).

* Coat the stem of the valve with engine oil
(EOSO-CD).
6136F308
ii) Assemble spring seat (4), valve spring (3) and

spring guide (2).
* Valve spring
Engine No. 10001 - 50000: Equal pitch

50001 and up : Unequal pitch
Engine No. 50001 and up use an unequal pitch

valve spring, so be sure to install with the tight
coils at the bottom (cylinder head end).
110 SERIES
,ii) Using valve pusher B, compress valve spring and fit

valve cotter (1) on valve stem.
* Remove tool B and tap the valve stem with a
plastic hammer to check that the cotter is com-
pletely fitted.
* The material of the cylinder head differs according
to whether a turbocharger is mounted or not, so
be careful when replacing or modifying.
Ir The shape of the intake port swirl is different for
the construction equipment engine and the marine
engine, so be careful when procuring or repairing.
. Turn over engine to put cylinder head side on top.

* Check that the mounting surfaces of the cylinder
head and cylinder block are clean and that there is no
dirt or foreign matter inside the cylinder.
1) Install cylinder head gasket (2).
2) Raise cylinder head assembly (I), use about four

mounting bolts as guides and set on cylinder block.
3) Coat thread of mounting bolts with antifriction com-
pound or engine oil. Tighten mounting bolts in order
shown in diagram and to following tightening
torques.
& Mounting bolt:

Antifriction compound (LM-P)
m Cylinder head:
Antifriction compound Engine oil

Order -
Target Range Target Range
1St step 9 8 - 10 9 S-10

2ndstep 1 13 1 12-14 1 13 1 12-14
3rd step 18 17.5 - 18.5 20 19.5 - 20.5
* Order for tightening cylinder head bolts
Center
6136FO35
13-118 110 SERIES

19. Push rods
l Assemble push rod (1).

t The push rods on the intake and exhaust sides are the
same part.
* Check that the push rod is properly fitted into the
tappet.
20. Rocker arm assembly
1) Position rocker arm assembly (1).

* Check that the ball of the adjustment screw is pro-
perly fitted into the socket of the push rod.
* If the spring is pushing the rocker arm, loosen the
adjustement screw.
2) Tighten mounting bolt (2).
3) Adjust valve clearance as follows.
Adjust clearance between valve and rocker arm as
follows (cold).
Intake valve: 0.35 mm
Exhaust valve: 0.65 mm
Firing order: 1- 5 - 3 - 6 - 2 - 4
Rotate the crankshaft in the normal direction to
align pointer (4) with the 1.6 TOP mark on
crankshaft pulley (3). When rotating, check the
movement of the valves.
* When No. 1 cylinder is at compression top dead
center, adjust the valves marked 0.
* When No. 6 cylinder is at compression top dead
center, adjust the valves marked 0.
Cylinder No. 1 2 3 4 5 6
Intake valve 0 0 0 0 0 0
Exhaust valve l 0 0 0 0 0
110 SERIES 13-119

2) To adjust, insert feeler gauge H between rocker arm

(5) and valve stem (6) and turn adjustment screw (7)
until clearance is a sliding fit.
3) Tighten lock nut (8) to hold adjustment screw in

position.
w Lock nut: 3.2 f 0.3 kgm
+ After tightening the lock nut, check the clearance

again.
21. Cylinder head cover
. Fit O-ring and install cylinder head cover (I).

* Apply adhesive compound and fit the O-ring of the
head cover without twisting.
w Head cover mounting bolt: 0.9 z 1 kgm
22. Nozzle holder
* Check that there is no dirt or damage inside the holder

sleeve or on the contact surface of the nozzle holder.
* Coat the thread of the nozzle holder mounting bolt with
engine oil.
. Install nozzle holder (2) in cylinder head.

* Tighten the nozzle holder mounting bolts uniformly
to prevent them from being unevenly tightened.
m Mounting bolt: 1.7 f 0.2 kgm
23. Spill pipe
. Fit gasket and install spill pipe (1).
13-120 110 SERIES

24. Water pump
. Fit gasket and install water pump (1).
25. Alternator
1) Temporarily install plate (4).

2) Assemble spacers, then set alternator (3) in position.
* Install the thick spacer at the rear and the thin
spacer at the front.
3) Tighten mounting bolts (2) and (I) to temporarily
install alternator.
26. Fan belt
1) Install fan belt (3).

2) Adjust fan belt tension as follows.
i) Raise alternator to outside and tighten alternator
mounting bolt (2) and plate mounting bolt (1).
ii) After adjusting tension, tighten bolts fully.
iii) After adjusting tension, check amount belt
deflects when pushed by a finger force of 6 kg at a
point midway between fan pulley and alternator
pulley.
* Standard slack: 5to 10mm
6 kg.
6138F317
110 SERIES 13-121

27. Air compressor

1) Fit gasket, align match mark “0” of split-red part and
install air compressor (2).
* Mounting bolt thread: Thread tightener (LT-2)
* Align the gasket with the front plate hole when
installing.
2) Fit gasket and install oil feed tube (1) of air compres-
sor.
28. Oil cooler
1) Fit gasket and install oil cooler (2).

2) Fit O-ring and install oil cooler inlet tube (1).
* For the parts where the tube is tightened with the
cooler mounting bolt, insert a plate between the
cooler and the tube support, then tighten.
1) Knock key into drive shaft of fuel injection pump.

2) Put fuel injection pump (4) and bracket (5) together,
align key groove of pump coupling and fit pump drive
shaft.
3) Secure bracket.
4) Install bolts (3) connecting fuel injection pump and
air compressor.
m Connecting bolt: 5.2 f 0.2 kgm
5) Adjust fuel injection timing as follows.

i) Rotate crankshaft in normal direction and align
pointer (7) with injection timing line on crank-
shaft pulley (6).
* When doing this, if the line on the timer side is
not at the front, rotate one more turn.
13-122 110 SERIES

ii) Align line A on injection pump side with line B on

timer side.
iii) In this position, tighten four pump mounting bolts
(8) uniformly and in turn.
* After repairing or replacing the fuel injection
pump, or if there is no line, adjust the injection
timing by the delivery method.
Align A Align B 6138FO26
30. Thermostat
. Fit gasket and install thermostat with case (1).

* Engine hanger (2) is tightened with the same bolt.
* If the thermostat has been removed from the case,

assemble with the leak hole positioned as in the diagram.
Leak hole h
6136FO33
110 SERIES 13-123

31. Aftercooler
1) Assemble ribbon heater (4) as shown in diagram

below.
* Coat all of surface of area A with adhesive com-
pound (Three Bond No. 1215) and stick in
position.
6138F318
2) Fit gasket and position ribbon heater (4) on cylinder

head as shown in diagram below.
+ Install the ribbon heater so that the terminals are
positioned as shown in the diagram.
Terminal
Ii%
I r
Rear of
engine a 1~
w 6138F319
3) Using eye bolts @ (8 mm, P = 1.25), raise aftercooler

assembly (3). fit gasket and install together with
ribbon heater.
m Mounting bolt: 3.1 f 0.3 kgm
4) Fit gasket and connect aftercooler outlet tube (2).

5) Fig gasket and connect aftercooler inlet tube (1).
6) Connect wire (ground connection) and the wiring
between relay switch and ribbon heater at switch end.
32. Fuel injection pipe
1) Install fuel injection pipe (3).

2) Connect hose (2).
3) Install boost compensation pipe (1).
13-124 110 SERIES

33. Oil filter
. Fit O-ring, and install oil filter (6). oil filter inlet tube
(4) and outlet tube (5).
* The clamp for the engine breather hose is tightened
with the outlet tube mounting bolt.
34. Fuel filter
1) Install fuel filter (3).

2) Connect fuel filter inlet hose (1).
3) Connect fuel filter outlet hose (2).
* The intermediate bracket of the fuel hose is tightened
with the aftercooler mounting bolt.
35. Resetting engine in engine stand
1) Sling engine assembly, remove bolts connecting

adapter plate and overhaul stand to disconnect engine
assembly.
2) Set engine assembly (I) on engine stand A.
3) Remove adapter plate B’.
110 SERIES 13-l 25

.’
36. Turbocharger, exhaust manifold assembly

* When connecting the inlet and outlet pipes, and oil
feed and return tubes to the turbocharger, make sure
that there is no twisting or any other excessive force
on the pipes and tubes.
1) Fit gasket and install turbocharger (4) and exhaust

manifold assembly.
* Assemble the gasket with the mark on the outside.
m Mounting bolt: 6.5 + 1.0 kgm
2) Connect intermediate hose (3) between turbocharger

and aftercooler.
3) Connect tube (2) between turbocharger and cylinder
block.
4) Install muffler drain pipe (1).
1) Check that engine drain plug is tightened.

2) Add engine oil through oil filler.
1 Engine oil pan: Approx. 28 Q

Q
* Check the oil level after mounting the engine on
the machine, and add oil to the specified level.
13-126 110 SERIES

DISASSEMBLY AND ASSEMBLY OF COMPONENTS
Item Page
Turbocharger
Disassembly 13-201-l
Assembly 13-2014
Oil pump
Disassembly 13-202
Assembly 13-203
Water pump
Disassembly 13-204
Assembly 13-206
110 SERIES 13-201

0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF CdMPONENTS
* The subsequent disassembling and reassembling operations

should be performed in a KOMATSU authorized maintenance
shop.
9
Center hous-
7 ing A&
Rotor Wheel shaft
Ass’y AS’Y
15
Retaining
rina
Center
housing Thrust col-
Acc’v lar Ass’y
I .--I I -
1 I
’ 1
Piston
ring
1
13F015A
5. Locknut
1) Secure cartridge holder with a vice. Put rotor ass’y (4) in the
holder and keep it so that the end of wheel shaft is set in socket.
2) Remove lock nut (6). using T wrench C.
t If the lock nut is removed, the wheel shaft ass’y will fall out
of the rotor ass’y. Therefore, when carrying the rotor ass’y,
be sure to support the wheel and center housing sections by
two hands.
6. Impeller
1) Remove rotor ass’y (4) from the cartridge holder and rest it
on blower housing (3).
2) Remove back plate (7) mounting bolts.
3)’ Remove impeller (8) out of place.
7. Back plate
- Remove back plate (7) out of Place.
8. Wheel shaft ass’y
* Remove wheel shaft ass’y (9) from center housing (10).
9. Shroud
- Remove shroud (11) from the center housing.
110 SERIES l-3-201-2

0
DISASSEMBLY AND ASSEMBLY OF COMPONENTS DISASSEMBLY AND ASSEMBLY
10. Piston ring
* Remove piston ring (12) from wheel shaft ass’y by separat-

ing the mating parts wide by fingers.
11. Thrust collar ass’y
- Remove. thrust collar ass’y (13) from center housing (IO).
12. Thrust bearing
- Remove thrust bearing (14) from center housing (10).
13. Seal ring
* Remove seal ring (15) from center housing (10)
14. Piston ring
. Remove piston ring (16) from thrust collar ass’y (13).
15. Retaining ring and bearing
1) Remove outer retaining ring (17) from the blower side of

center housing (IO), using a retaining ring remove D.
2) Remove bearing (18) from the blower side of center housing

(IO).
3) Remove inner retaining ring from the center housing in the
same manner as described in 1) above.
4) Remove retaining ring (17) and bearing (18) from the turbine
side of center housing (10) in the same manner as described
in l), 2) and 3) above.
13-201-3 110 SERIES
0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF COMPONENTS
ASSEMBLY OF TURBOCHARGER
1 4 5 6
Center
A
housing
8 9 10 11 12
7 8
13FOl6A
Tools to be prepared
Japan Gallet P/N Part Name

I-l~l6lClDlEl~ IGTH
801066 Lubriplate 1
801051 Deep socket 1
801090 Cartridge holder 1
801059 1T-wrench I I I III I I I I

801058 Retaining ring remover 1
801050 Piston ring guide 1
801052 I Pig I I I I I I Ill I

801056 1Radial play measuring tool I I I I I I I Ill
601057 Radial play measuring probe 1
801083 End play measuring tool 1
801054 End play measuring probe 1
110 SERIES 13-201-4

0
1. Retaining ring and bearing
1) Insert retaining ring (17) into center housing (lo), using retain-
ing ring remover 0.
* Make sure that the mating ends of ring are in a correct con-
tact with each other with the oil outlet side up.
2) Coat the inner and outer surfaces of bearing with engine oil.
3) Set bearing (18) in the center housing.
4) Insert the outer retaining ring in the same manner as described
in 1).
18
Oil outlet port 13FOl7
2. Piston ring
+ Install piston ring (16) on thrust collar (19).
3. Thrust bearing
1) Coat thrust bearing (14) with engine oil.

2) Install the thrust bearing in groove in thrust collar (19).
+ At this time, oil groove (a) in the thrust collar should face
outside.
4. Thrust collar ass’y
- Install thrust collar ass’y in center housing (10).
5. Seal ring
- Install seal ring (15) in the groove on the circumference of

center housing (10).
13P219,
6. Back plate
11 Coat the ihside hole of back plate with engine oil.

2) Install back plate (7) with threaded hole in plate and drilled
hole in center housing (IO) aligned with each other.
* Provide a space for name plate away from oil hole in the
housing.
13-201-5 110 SERIES
0
3) Hold the center housing and back plate by hands, taking care
not to allow the set parts to get out of place, and turn them
with the back plate down.
4) Tighten the back plate (7) mounting bolts.
Tightening torque of the back plate mounting bolts:

0.95 f 0.1 kgm
7. Piston ring
* Install piston ring (12) on wheel shaft (20). using piston

ring guide E.
8. Wheel shaft ass’y

I) Rest center housing ass’y (21) on blower housing (3) used as
support.
2) Coat a bearing section in wheel shaft ass’y (9) with oil.
3) Contract piston ring in the wheel shaft ass’y, using pig F and
insert wheel into the center housing, rotating the wheel gently.
9. Shroud
* Install shroud (11) in center housing ass’y (21).
IO. Impeller
1) Remove the center housing wheel shaft ass’y from the blower
housing and set it in cartridge holder B.
2) Coat the impeller mounting shaft and the lock nut installing
thread area with lubriplate (to prevent seizure).
3) Install impeller (8).
11. Locknut
1) Tighten lock nut (6).
Lock nut tightening torque: 0.22 f 0.01 kgm
2) Retighten the lock nut further by 90°, using T-wrench C.
110 SERIES 13-201-6

0
-.
’
12 13 14 15 16
Turbine
housing
13F019A
12. Rotor ass’y
1) Install rotor ass’y (4) in turbine housing (I).

* Install the rotor ass’y gently, taking care not to impair parts.
* Install the turbine housing in place as shown in schematic
drawing.
* Locate drilled hole in shroud so as to face an oil inlet side.
2) Coat turbine housing mounting bolt holes with antifriction
compound.
+ Antifriction compounds: NICHIMOLI PG Paste or MOLI-
COAT AST Compount ‘j,
* 1 t 3P.227
3) Tighten the turbine housing mounting bolts.
Tightening torque of turbine housing mounting bolts:

1.7 f 0.1 kgm
4) Bend lock plates.

Oil
as viewed from
turbine side
I3FO20
13. Diffuser
Install diffuser (5) on back plate (7).

Bring protrusion (b) of the diffuser to the right side of
protrusion (c) of the back plate to prevent the diffuser
from turning clockwise.
If the diffuser has three protrusions, bring these protrusions
in holes in the back plate.
I3P228
14. Blower housing
1) Install blower housing in place as shown in schematic drawing

below.
Oil oket
(as viewed from dower side)
I 3FO2 I
2) Tighten the blower housing mounting bolts.
m 1.35 kO.15 kgm
13-201-7 110 SERIES
0
15. V band
- Attach and tighten V band (2), using deep socket A and

torque wrench (d).
V band tightening torque: 0.8 f 0.1 kgm
16. Checks after completion of assembling
I) Make sure that the rotor ass’y rotates smoothly by giving light
push thereto.
2) Check play of rotor in the radial direction (radial play).
i) Attach a measuring instrument G to oil outlet of center
housing (10) and set a dial gauge so that its probe comes
into contact with shaft.
ii) Hold the rotor by hands on both ends and move it in
parallel in the radial direction to measure play.
+ Rotor radial play (allowable range: 0.075 to 0.150 mm
31 Check play of rotor in the axial direction. (End play)

i) Set dial gauge in end play measuring instrument H and
replace the gauge probe with an exclusive one for this
measurement.
ii) Attach the measuring instrument to inlet port in blower
housing (3) and set the dial gauge so that a probe comes
into contact with the shaft end,
iii) Measure end play by moving the rotor in its axial direction.
t Play of rotor in axial direction (End play)
Allowable range: 0.025 to 0.075 mm
110 SERIES 13-201-8

0
DISASSEMBLY AND ASSEMBLY COMPONENTS DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF OIL PUMP

TROCHOID PUMP (Engine No. 10001 - 49999)
DISASSEMBLY
1. Remove cover (1).
2. Remove outer rotor (2).
3. Disconnect gear (3) and inner rotor (4).
4. Remove bushing (5).
5. Remove dowel pin (6).
,,, ,,, ,,
110 SERIES
13-202
0
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY COMPONENTS
ASSEMBLY
1. Install bushing (5).
2. Knock in dowel pin (6).
3. Press fit gear (3) on inner rotor (4).
4. Install outer rotor (2).
5. Align dowel pin and install cover (1).
110 SERIES 13-203

DISASSEMBLY AND ASSEMBLY COMPONENTS DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF WATER PUMP

DISASSEMBLY
1. Remove nut (1).
2. Using puller 0, remove fan pulley (2).
3. Remove snap ring (3). then remove cover (4).
4. Using puller@, remove impeller (5).
13-204 110 SERIES

5. Remove snap ring (6).
6. Remove shaft (7) from impeller side. -Wq&>,

* Remove shaft and bearing as one unit. + “‘,,‘, ,,
,j ,\\
7. Remove water seal (8).
8. Remove bearings (9) and (10) from shaft.
110 SERIES 13-205

y/ ,:...
DISASSEMBLY AND ASSEMBLY COMPOhlENTS DISASSEMBLY AND ASSEMBLY
ASSEMBLY
1. Install bearings (9) and (IO) on shaft.

* The side of the bearing where the ball can be seen
faces the inside.
2. Install shaft assembly (7) in water pump case (11) from

pulley side.
& Space between bearings: Grease (G2-Ll)
3. Secure shaft assembly with snap ring (6).
4. Press fit fan pulley (2).
5. Tighten nut.
13-206 110 SERIES

6. Install water seal (8).
7. Press fit impeller (5).
8. Fit O-ring and install cover (4).
9. Install snap ring (3).
110 SERIES 13-207

14 MAINTENANCE STANDARD
110
Engine
SERIES
Numbers: 10001 and up
14 MAINTENANCE STANDARD
110 SERIES
MAINTENANCE STANDARD
INTAKE AND EXHAUST SYSTEM ...................................................... 14-004

Turbocharger ..................................................................... 14-004
ENGINE BODY ....... .: ............................................................... 14-005
Cylinder head ..................................................................... 14-005
Valve and Valve guide .............................. I .............................. 14-006
Rocker arm, Push rod and Tapet .................................................... 14-008
Cylinderliner ..................................................................... 14-009
Cylinderblock.. .................................................................. 14-010
Crankshaft ....................................................................... 14-012
Camshaft ........................................................................ 14-013
Piston, Piston ring and Piston pin ................................................... 14-014
Connectingrod.. ................................................................. 14-016
Timinggear ...................................................................... 14-017
Flywheel and Flywheel housing ..................................................... 14-018
LUBRICATION SYSTEM ................................................................ 14-019
Oilpump ......................................................................... 14-019
Regulator valve and Safety valve ................................................... 14-02 1
COOLING SYSTEM .................................................................... 14-023
Water pump and Thermostat ....................................................... 14-023
110 SERIES 14-003

0
INTAKE AND EXHAUST SYSTEM MAINTENANCE STANDARD

TURBOCHARGER
5
8 3
14FO366 14FO36-10 14F036-2B
Unit: mm
NOI. Check item Criteria
-
Standard size Repair limit
1 Radial play of rotor

Repair or
0.075 - 0.150 0.18
replace
2 End play of rotor 0.025 - 0.075 0.10
Thickness of thrust
3 4.36 4.35 ’
bearing
I I
I
Measuring portion Standard size Repair limit
Outside diameter of A 17.340 17.25

wheel shaft
4
B 10.155 10.15
Bend of wheel shaft Repair limit: 0.010 (Total indicator reading) Replace

Inside diameter of
5
back plate
I 12.70
I
I
12.73
Measuring portion Standard size Repair limit
6 Inside diameter of C 15.80 15.81

center housing
D 18.03 18.08
Tightening torque
blower housing boltof
7 1.3 + 0.15 kgm
Tightening torquebolt
turbine housing of
8 2.0 + 0.2 kgm
14-004 110 SERIES

0
MAINTENANCE STANDARD ENGINE BODY
ENGINE BODY
CYLINDER HEAD
Center
Front Rear
6136FO35
6136FO34
Unit: mm
No. Check item Criteria Remedy

-
Tolerance Repair limit
Deformation of cyl-
1 Grind or
inder head mounting
surface replace
0 - 0.09 0.12
-
Engine No. Standard
Replace
2 Protrusion of nozzle
10001 - 49999 0.79 - 1.71 nozzle
sleeve
50001andup 1.29 - 2.21
Molybdenum sulphide Engine oil

Tightening torque of Order
cylinder head
mounting bolt
3
(Coat thread with
molybdenum sulphide
or engine oil)
Tightening torque of
Target 1kgm) Range (kgml
Tighten
4 nozzle holder mounting
bolt
1.75 1.5 - 2.0
-
110 SERIES 14-005

0
ENGINE BODY
MAINTENANCE STANDARD
VALVE AND VALVE GUIDE
6136F036
14-006 110 SERIES

0
Unit: mm
Nc Check item Criteria Remedy

I
Engine No. Valve Standard size Tolerance Repair limit

I I I
10001 - Intake valve 1.5 to.24 2.6
Replace
1 Sinking of valve 49999
valve or
Exhaust valve 1.5 kO.28 2.6 valve seat
Intake, ex-
50001 and up 0 to.1 1.1
haust valves I I I
-
Valve Standard size Repair limit
Thickness of Intake valve 2.10 1.7 Replace

2
valve lip valve
Exhaust valve 1.50 1.2

-
Intake valve Exhaust valve Repair or
Angle of replace
3
valve seat valve or
Standard 3o” 45O
valve seat
Engine No. Valve Standard size Tolerance
Intake valve 10 -0.040

-0.060
O.D. of valve 10001 -
stem 49999 -0.065 Replace
Exhaust valve IO
-0.085 valve
50001andup Intake, exhaust 9 -0.030

va Ives -0.045
10001 - Intake, exhaust +0.025

49999 valves 10 -0.005 Replace valve
I.D. of valve guide
4 guide Intake, exhaust +0.030
50001 and up 9
valves +0.010
Engine No. 1 Valves Standard clearance Clearance limit
Intake valve 0.035 - 0.085 0.22

Clearance between 10001-
valve guide and 49999 Replace valve
stem Exhaust valve 0.060 - 0.110 0.24 or
valve guide
Intake, exhaust
5001 and up valves 0.040 - 0.075 0.20
Curvature of Repair limit: 0.02 (total variation of indicator, per 100 mm) Replace
valve stem
Engine No. Standard Tolerance

Height of valve
5 guide when 10001 - 49999 19 *0.2 Repair
knocked in
50001 and up 25.9 r0.25
Engine No. Standard size Repair limit

Free length of
valve spring 10001 - 49999 59.4 58
50001 and up 63.8 62.4

6
Installed length Installed length Standard load Repair limit
of valve Replace valve
spring 50.1 29.0 * 1.3 kg 26.0 kg spring
Out-of straight of
Repair limit 2” (at both ends)
valve spring
110 SERIES 14-007

0
ENGINE BODY MAINTENANCE STANDARD
ROCKER ARM, PUSH ROD AND TAPPET
6136FO38
6136FO37
Unit: mm
-
Standard size Tolerance

Replace
O.D. of rocker arm
rocker arm
shaft -0.010
19 shaft
-0.030
I I I
I I
Engine No. Standard clearance Clearance limit

I.D. of rocker arm Replace
+0.030
shaft hole 10001 - 49999 19 rocker arm
+O.OlO
1 iC.020
50001andup 19
0
Replace
Standard clearance Clearance limit
Clearance between rocker arm
rocker arm shaft and or rocker
rocker arm shaft hole 0.020 - 0.060 0.13 arm shaft
Curvature of rocker
Valve clearance
4
(when cold)
O.D. of tappet
I I
+0.020 Replace
5 I.D. of tappet hole 18
0 cylinder head
Standard clearance Clearance limit Replace

Clearance between tappet or
tappet and tappet hole cylinder
0.015 - 0.055 0.20
head
14-008 110 SERIES

0
CYLINDER LINER
6138F028A
Unit: mm
-
0. Check item Criteria Remedy
1 IProtrusion of cylinder liner Permissible range: 0.05 - 0.13 %%Zkr

cylinder block
Standard size Tolerance Repair limit
Inside diameter of +0.035

cylinder liner 110 110.20
0
2_
Roundness of cylinder liner Repair limit: 0.15

Replace
cylinder
liner
Cylindricity of cylinder liner Repair limit: 0.08

Outside diameter of
cylinder liner 0
(Counter bore) 120
3 -0.08
I
Clearance between cylinder Replace cyl-

block and cylinder liner Standard clearance: 0.10 - 0.28 inder liner or
(Counter bore) cylinder block
Standard
size
Interference between
Replace cyl-
4 cylinder liner and
inder liner or
cylinder block
cylinder block
115
+0.0425 +0.0250
B
+0.0300 +0.0125
1
110 SERIES 14-009

0
CYLINDER BLOCK
5
11
4
3
2 ’
8
\
9 10
6130F039A
14-010 110 SERIES
0
Unit: mm

Repair by
Distortion of cylinder grinding or
1
head mounting surface 0 - 0.080 0.12 replace
Inside diameter of main

+0.020
bearing mounting hole 91
0
I Replace main
2
bearing cap
Straightness of main Repair limit: 0.010
bearing mounting hole
Roundness of main bearing

mounting hole Repair limit: 0.005

Inside diameter of Replace main
3 +0.060
main bearing 85 85.16 bearing
+0.010
I I

Inside diameter of camshaft Repair or
4
bushing mounting hole +0.030 replace
57.5
0

inside diameter of Replace cam-
5 +0.070 shaft bushing
camshaft bushing 54.5 54.78
0
Difference between cylinder

6 block lower face and Repair limit: 0.13
flywheel housing
Difference between cylinder Repair by

7 block lower face and Repair limit: 0.11 reassembling
front cover
Difference between cylinder Plate protrusion: 0.04

8 block lower face and Repair limit
Plate inset: 0.22
front plate
I Order
I Target (kgm)
I Range (kgm)
I
1st step 7 6-8
Tightening torque of main 2nd step 20 19-21

bearing cap mounting bolt
(Coat bolt thread with
3rd step Loosen completely
engine oil)
4th step 7 6-8
5th step 14 13 - 15
6th step 20 19-21
Tightening torque of oil pan

10 2.5 * 1.0 kgm
mounting bolt
I
Tightening torque of crank-
11 38+3kgm
shaft pulley mounting bolt
110 SERIES 14-011

0
CRANKSHAFT
6136FO42
Unit: mm
NC Check item Criteria Remedy
Replace
thrust’
1 End play bearing or
correct
0.140 - 0.315 0.40
oversize
-
O.D. of main journal
Correct
undersize
or replace
2
Out-of round-
ness of main Repair limit: 0.020
journal

Replace
Clearance at
main
main journal
0.060 - 0.130 bearing
I 0.30
S.T.D. 66 65.91
0.25 U.S. 65.75 65.66

O.D. of crank pin journal
0.50 U.S. 65.50 65.41 Correct
-0.050 undersize
0.75 U.S. 65.25 -0.070 65.16 .or replace
1 .oo U.S. 65.00 64.91
3
Out-of-round-
ness of crank Repair limit: 0.020
Din iournal
Standard Clearance limit Replace

Clearance at crank pin I connecting
journal
rod bearing
0.040 - 0.105 I 0.30
-
Correct under-
4 Bend of crankshaft Repair limit: 0.09 (total-variation of indicator)
size or replace
14-012 110 SERIES

0
CAMSHAFT
1 2 Section A-A
3
6136FO43
Unit: mm
No Check item Criteria Remedy

Replace
1 End play thrust
plate
0.15 - 0.35 0.50
O.D. of camshaft journal Replace

-0.080
54.5
-0.110
2
Replace
Clearance at camshaft bushing
journal
0.080 - 0.180 0.28
3 Curvature of camshaft I Repair limit: 0.03 (total variation of indicator)

I
-
Replace
4 Cam height
Intake 45.82 f 0.10 45.32
50001 and up
Exhaust 46.24 * 0.10 45.74
110 SERIES 14-013

0
PISTON, PISTON RING AND PISTON PIN

S6DllO-1
No Check item
Outside diameter of piston Replace piston
Thickness of piston ring
Width of piston ring

groove
Replace piston
Clearance between piston Judge using groove wear gauge
ring and piston ring groove
Replace piston
Piston ring gap
Outside diameter of
piston pin
C!earance between piston

pin and piston
14-014 110 SERIES
0
SAGDI 10-l
Engine No. 10001 - 49999 Engine No. 50001 and up
3-
4-
6136F6451
6136FO29
Unit: mm

1 Outside diameter of piston Replace piston
lg9.280 20.015
-
No. Measuring point Standard size Tolerance
2 Top ring 3 Replace

Thickness of piston ring piston
-0.01
3 Second ring 2.5 ring
-0.03
4 Oil ring 5
Width of piston ring

groove
ll-+-EzA Measure with groove-wear gauge
+0.04
Replace
piston
4 Oil ring 5
+0.02
No. Measuring point Standard clearance Clearance limit
2 Top ring Replace piston

Clearance between piston
Measure with groove-wear gauge or piston
ring and ring groove
ring
3 Second ring
4 Oil ring 0.03 - 0.07 0.15
2 Top ring 0.45 - 0.65 2.0

. Replace piston
Piston ring gap 3 Second ring 0.40 - 0.60 1.5 ring or
cylinder
4 Oil ring 0.30 - 0.50 1.0 . liner

Outside diameter of Replace
piston pin piston pin
40
-Loo5
5 Inside diameter of piston +0.015

40
pin hole I 0

Replace
Clearance between piston
piston or
pin and piston
0 - 0.020 0.05 piston pin
110 SERIES 14-015

0
CONNECTING ROD
‘6
6136FO46
Unit: mm
Check item Criteria Remedy

I.D. of bushing at small
Replace
end of connecting rod
bushing
+0.040
40
+0.025
1
Clearance between bush- Standard clearance Clearance limit 1 Reolace

ing and piston pin at small bushing or
end of connecting rod piston rod
0.025 -0.045 0.10
I
Standard size Tolerance Replace
I.D. of bushing mounting
2 connecting
hole at small end of
connecting rod +0.035 rod
43
+0.010

I.D. of bearing at big end
Replace
3 of connecting rod (crank
bearing
pin journal) +0.035
66 66.15
+0.010
-
+0.025
I.D. of bearing mounting 70 70.04
0
4 hole at big end of I I
connecting rod
- Measure after tightening connecting rod cap to specified torque.
-
Replace
Bend connecting
rod
Curvature and twist of Twist Bend Repair limit: 0.08
5
connecting rod Twist Repair limit: 0.30
Order Target (kgm) Range (kgm)

Tightening torque of I
connecting rod cap
mounting bolts
1st 6 5-7
6 2nd Tighten
Coat bolt threads and 11 10 -12
nut seats with engine
Loosen 0 0
oil)
3rd 6 5-7
4th 11.2 10.6-l 1.7
Weight of connecting rod Replace

7 Repair limit: 2,087 i- 70 (g)
- 1
14-016 110 SERIES

Co
TIMING GEAR
U t: mm
Measurement points Standard Repair limit

I I
A Replace
bushing
? Gear backlash or gear
11 Idler gear and injection pump gear 0.6
C

I
O.D. of idler gear shaft Reolace shaft
-0.025
44
I -0.050
+0.075
I.D. of idler gear bushing 44
+0.010
Replace
1 Standard clearance Clearance limit bushing
Clearance between idler
gear bushing and shaft
0.035 - 0.125 0.20
I
Standard Repair limit Replace
Idler gear end play thrust
plate
0.05 - 0.21 0.4
I
110 SERIES 14-017

0
FLYWHEEL AND FLYWHEEL HOUSING
6138FO31
6 6138FO30
Unit: mm
-
Face runout of
1 Repair limit: 0.35
flywheel housing
Correct and
reassemble
Radial runout of
flywheel housing
Target (kern) Range (kgm)

3 flywheel housing Tighten
mounting bolts 11 9.5 - 12.5
4 Face runout of flywheel Repair limit: 0.20

Correct and
reassemble
Radial runout of
flywheel
Order Target (kgm) Range (kgm)

Tightening torque of I I
flywheel mounting
bolts 9 6-12
6 Coat thread, seat Tighten
18 16-20
and washer with
engine oil. >
14-018 110 SERIES

@
LUBRICATION SYSTEM
OIL PUMP
Engine No. 10001 - 49999
6136FO49
Unit: mm
‘if-r- Criteria Remedy
Axial clearance of
1
rotor Reolace
I.D. of rotor Standard Clearance

O.D. of rotor
Radial clearance of
I
2 room clearance limit
rotor
78 -0.10 +0.055
-0.13 +0.010 0.110 -0.135 0.25
Standard
Clearance between
shaft and bushing
I Shaft
I
Hole
clearance
Clearance
limit
Replace
bushing
22 I 0 +0.060
-0.015 +0.030 0.030 - 0.075 0.10
33 I -0.010
-0.035 +0.025
0 0.010 - 0.060 0.10 Replace
c
pump and block
Standard Interference
Interference between Shaft O.D. Gear I.D.
interference limit
5 oil pump gear and
Replace
shaft
22 0
-0.015 -0.040
-0.060 0.025 - 0.060 0.02

Backlash between oil
6 pump gear and oil Repair or
pump drive gear replace
0.120-0.370 0.60
I
110 SERIES 14-019

Co
LUBRICATION SYSTEM MAINTENANCE STANDARD
6136FO49.1
Unit: mm

I I
Tolerance Standard Clearance
Standard size clearance limit
T;&.k.a;ss Dt%tJyof (End play) (End play)
Axial clearance of
1
pump gear
+0.065
32 0.03 - 0.09 0.10
-:.025 +0.040
Reolace oear
Tolerance
Standard Clearance
Standard size
O.D. of I.D. of clearance limit
Radial clearance of gear body
2
pump gear
51.4 -0.15 +0.06 0.03 - 0.10 0.13
-0.21 0
-
Tolerance
Standard Clearance
Standard size
Interference between clearance limit
Shaft Hole
3 pump drive gear and Replace
drive shaft
+0.105 +0.060 I nterference -
18
+0.090 +0.045 0.030 - 0.060
--
Clearance between drive
4 shaft and cover bushing Replace bushing
+0.105 +0.065 I nterference -
5 pump gear and 18 Replace
+0.090 +0.045 0.025 - 0.060
drive shaft
Clearance between
-0.005 +0.060
6 drive shaft and 18 0.040 - 0.085 - Replace bushing
-0.025 +0.035
body bushing
- I I I I I I
Clearance between
7 driven shaft and body 18 1 $$!g 1 ~~:~“,~ 1 0.020 -0.065 1 - 1 Replace
Clearance between
8 body bushing
driven shaft and 18 1 ;;:,“;; 1 z;:;;,” 1 0.040 -0.080 1 - Replace bushing
-
9 driven shaft and Replace
cover
-
14-020 110 SERIES

0
MAINTENANCE STANDARD LUBRICATION
REGULATOR VALVE SAFETY VALVE

Engine No. 10001 - 49999
4 5
6136FO50 14FO27
Unit: mm
-
-
Standard size -1 Standard clearance
Clearance between
1 Replace
valve and body
-0.020 +0.050
20 0.040 - 0.090
-0.040 +0.020
-
* Free length
Standard size: 66.6
- Installed load
2 Regulator valve spring Replace

Installed length Standard load (kg) Repair limit (kg)
61.2 11.6 11.2

I
Target (kgm) Range (kgm)

3 Tighten
regulator valve plug
13 12 - 14
,
-
I
Target (kern) I Range (kgm)
4 regulator valve
Tighten
I
assembly
IO 8-12
-
Operating pressure of
5 7.4 f 0.8 (kg/cm21 Adjust
regulator valve
Operating pressure of Replace

6 2 * 0.2 (kg/cm’)
relief valve cartridge
110 SERIES 14-02 1

0
LUBRICATION SYSTEM MAINTENANCE STANDARD
REGULATOR VALVE
6136FO501
Unit: mm
Clearance between Replace

1
valve and body
. Free length
Standard size: 49.1
. Installed load
Replace
Regulator valve
2
spring
Installed length Standard load (kg) Repair limit (kg)
34.8 10.8 9.8
Operating pressure Repair or

3 Standard: 6.5 f 0.5 kg/cm’
of regulator valve replace spring
14-022 110 SERIES

Co
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
WATER PUMP AND THERMOSTAT
-
I:
A
4
1
6138F033A 6136FO34
Unit: mm
5
-
NC Check item
T Criteria Remedy
Replace (usual-
Standard size 1 Shaft O.D. ) Impeller I.D. 1Standard interfereno ly replace
Clearance between
1 impeller; shaft
impeller and shaft O.D. reraly
+0.020 -0.020
15.9 0.025 - 0.070 changes)
+0.005 -0.059
Clearance between
2 Standard clearance: 0.2 - 0.6
body and impeller
Abrasion of seal A dimension repair limit: 0 Replace

3
ring in water seal
14FO35
Total variation of indicator; measure by face run-out

4 Curvature of shaft Repair limit: 0.1 mm
at point 40 mm from center of fan pulley
-
Construction Inspect after immersion for 4 - 5 minutes in water at
Min. IO goOc.
equipment
Full open lift of
thermostat Inspect after immersion for 4 - 5 minutes in water at
Generator Min. 10 g5oc.
5
Construction Valve should be fully closed after immersion for 4 - 5 min
Opening and closing equipment in water from fully open (90°C) to fully closed (71’C).
of thermostat
Generator Valve should be fully closed after immersion for 4 - 5 min
in water from fully open (95’C) to fully closed (76OC).
110 SERIES 14-023

0
15 REPAIR AND REPLACEMENT OF PARTS
ENGINE
15 REPAIR AND REPLACEMENT OF
PARTS
Replacing valve seat inserts ...................... 15-002

Replacing nozzle holder sleeve ................ .15-006
Pressure test ............................................... 15-008
Replacing valve guide ................................ 15-009
Grinding valve ............................................ 15-010
Replacing camshaft bushing ..................... 15-01 1
Replacing crankshaft gear.. ........................ 15-013
Replacing camshaft gear ........................... 15-013
Replacing flywheel ring gear.. ................... 15-014
15001
0
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE SEAT INSERTS
REPLACING VALVE SEAT

INSERTS
Special tools
. . Pulling out the valve seat insert

A Before using the grinder, run it for a minute
to test it.
l After replacing the grindstone, run the
grinder for three minutes to test it.
4L Confirm that the grindstone is not damaged,

then install it to the shaft of the grinder with-
out appling excessive force.
Confirm that there is no play between the
grindstone and shaft.
AL When using the grinder, wear safety goggles.
. When using a valve seat puller to remove the

valve seat
1) Install grindstone @ to grinder 0. 6162F504
2) Align the groove of sleeve @ with holder 0,
then insert.
15002
0
3) Adjust the position of the grinder so that the

center of grindstone @ will be at the center of
seat insert (I),then tighten the set screw @
to secure the grinder.
4) Rotate the grindstone and move slowly until
it contacts insert (I).
5) Press the grindstone against the inside of the
insert, move it in a circular pattern, and make
a groove about 1 mm deep.
w
6162F505
6) Push in the three claws (a) on puller head @

of tool A by hand to insert it into the groove
of the insert (I).
7) Tighten screw @ to press the three claws
against the groove on the inside surface of
the insert.
Ir When the claws contact the groove com-
pletely, stop tightening.
8) Place bridge @ over the puller head, then
place plates @! and @I on the bridge.
Tighten nut @I to pull out the insert.
6162F506A
. When welding a bar to the insert to remove the

seat insert.
I) Weld bar (I) of radius approx. $110, that is 0.1
- 0.5 mm shorter than the inside diameter of
insert (2).
* Be careful not to let the welding metal stick
to the cylinder head itself.
a E’
-
2) When the temperature of the weld goes down 1
to around room temperature, insert an old
valve (3) in the reverse direction, and tap the @IT
head of the valve with a small hammer to
knock out the insert.
6127F205
* If the valve is hitted too hard, the weld may
break.
15-003
0
2. Press fitting the valve seat insert

Press
l When not grinding and correcting the press fit-
ting surface for the valve seat insert.
1) Using tool B or C guided by the inside diam-
eter of the valve guide (4), press fit standard
valve seat insert (2).
+ Do not use a hammer to press fit.
* Press-fitting force for valve seat (intake and
exhaust sides): Approx. 1 ton
4
HEE00290
21 Check the depth of insert from the bottom Bottom surface of cylinder head
surface of the cylinder head.

* Depth of the insert (h) (intake and exhaust
sides)
: 2.05kO.15 mm (intake)
: 1.55f0.15 mm (exhaust)
HEE00291
3. Machining valve seat insert mounting hole to

oversize
1) Using tools Dl and D2, grind the hole to one
size larger.
* Machine within a range of 1.0 mm over-
size.
If it is more than 1.0 mm, replace the cylin-
der head.
. Dimention of insert and mounting hole
Insert Unit: mm
1 Valve 1 O.D. (d) 1 Height (hl) “Y 622FO1037
Intake 48.50:::: 8.50_;.,0

S.T.D.
Exhaust 44.00:;:;; 9.00_: _.,”
._
Intake 48.75:;:od: 8.50-i.,,
0.25 OS.
Exhaust 44.25:;:;; 9.00_;.,rJ
Intake 49.00:~:~~ 8.62_&
0.50 O.S. -
Exhaust 44.50 ::::; 9.12_:.,rJ
Intake 49.25::::; 8.75_&
0.75 O.S.
Exhaust 44.75 ::II:
_.-. 9.25-t _.I”
._ HEE00292
Intake 49.50$:$! 8.88-i.,,

1 .oo O.S.
Exhaust 45.00::::; 9.38_:.,0
15-004
0
Mounting hole for valve seat insert Unit: mm

Insert mounting hole
I dl --I
Bottom’surface of
cylinder head
HEE00293
Inside surface roughness: max. 6.3 S Intake valve Exhaust valve

Mounting hole bottom roughness: max. 12.5 S
Concentricity of valve guide hole and insert:
max. 0.05 mm (T.1.R)
2) Press fit the over size valve seat insert.
3) Check the depth of inset-t from the bottom sur-

face of the cylinder head. 2.14 1.67
W!dth of
finishing
i surface >
Finishing insert seat surface HEE00294
1) Using tools Dl, D3 and D4, finish the insert

seat surface to the dimensions shown in the
diagram.
* When inserting the pilot D5 into the valve
guide, select a pilotthat will enter and leave
no clearance.
2) Fit the seat surface using the compound.
Final check
l Coat the seat surface thinly with minimum
(red lead), and insert a new valve into the
valve guide. Put it lightly in contact with the
valve insert surface, and rotate IO”, then check
the contact surface with the valve insert. Con- Pencil marks
firm that the contact is uniform with no breaks. (about 20 places1
. Another way is to mark the new valve with

pencil marks as shown in the diagram, insert
into the valve guide, bring into light contact
with the valve insert surface, and rotate IO”. F6164701
Check that the pencil marks are erased uni-
formly around the whole circumference.
* If a vacuum tester is available, carry out an
airtightness test to check.
15-005
0
REPAIR AND REPLACEMENT OF PARTS REPLACING NOZZLE HOLDER SLEEVE
REPLACING NOZZLE HOLDER

SLEEVE
Sr3ecial tools
I Part No. 1 Part Name I Q’W
A 1 795-600-1191 1 Push bar I 1
B 1 795-100-1540 1 Push tool I 1
C / 795-600-1410 1 Rolling tool I 1
D 795-901-1210 Sleeve holder 1
E 795-600-1420 Sleeve expander 1
F 795-600-l 460 Guide bushing 1
G 795-600-I 430 Sleeve cutter 1
1. Removing the sleeve

2) Using sleeve extraction tap 0, cut tap to about
25 mm depth from top face of sleeve. Add oil
while cutting.
* Extraction tap: M25, P=1.5
3) Insert push bar A from the bottom of the head

and tap with the hammer to remove the
sleeve.
HEE00297
2. Press-fitting the sleeve

Insert sleeve (I) into the cylinder head, then us-
ing push tool B, tap lightly until the sleeve is com-
pletely in close contact with the seat surface.
* Before installing the sleeve, clean the sleeve
and seat.
* Apply adhesive to outside taper part of the
sleeve.
6 Adhesive: LT-2
6162F510A
15006
0
REPAIR AND REPLACEMENT OF PARTS REPLACING NOZZLE HOLDER SLEEVE
3. Roll-fitting the taper section of sleeve

Using rolling tool C, roll-fit the taper section of
the sleeve.
f Set the roll-fitting amount with stopper @ of
the rolling tool.
* Install the rolling tool to a radial drilling ma-
chine or upright drilling machine to roll-fit with
its own weight.
-k Rotating speed: 200 to 300 rpm.
4. Roll-fitting press-fitting portion at top of sleeve HEE00298
1) Using sleeve holder D, tighten the sleeve from

the bottom surface of the cylinder.
w Sleeve holder: 19 Nm (2 kgm}
2) Using sleeve expander E, carry out rolling to

caulk the press-fitting portion.
Sr Rotating speed: 450 rpm
Ir Inside diameter: 23.9fO.l mm
* Amount of insertion of roller (h): 16 mm
k Using stopper 0, fit inside diameter.
3) After rolling, turn in the reverse direction and
remove the sleeve expander.
4) Remove the sleeve holder.
5. Spot-facing the inside seat of the sleeve

1) Using guide bushing F as the guide, spot-face
the seat with sleeve cutter G.
* When grinding the seat surface, insert the
nozzle holder, check that the protrusion is
within the standard value, and cut a little
more each time.
* Rotating speed: 500 to 600 rpm
HEE00299
* Protrusion of nozzle (S.T.D.):
1.29 - 2.21 mm
2) Remove all the metal chips and dust from the

machined surface.
6. Checking the leakage from the seat

Carry out a water pressure or air pressure test to
check that there is no leakage from the sleeve seat
surface or upper press-fitting portion.
* When checking for leakage from the seat sur-
face, install a used nozzle holder.
6162F514A
REPAIR AND REPLACEMENT OF PARTS PRESSURE TEST
PRESSURE TEST
. If the area around the head has been corrected,
test as follows.
Special tools
Part No. Part Name Q’ty

A - Coolant tester kit 1
B 79A-471-1050 Pump ass’y 1
1. Water pressure test

1) Tighten the nozzle holder assembly to the
specified torque.
21 Assemble tool A and tool B, and connect a
hose to flange (1).
3) Apply water pressure 0.35-0.4 MPa (3.5-4.0
kg/cm*) for approx. 10 minutes, and check for
any leakage from around the head.
* It is preferable to warm the whole cylinder
head and carry out the test with hot water
82-93X.
2. Air pressure test

I) Tighten the nozzle holder assembly to the
specified torque.
2) Connect the compressed air hose to flange
6202FO20
(I).
3) Place the cylinder head in a water bath, apply
air pressure 0.3-0.35 MPa (3.0-3.5 kg/cm*} for
approx. 30 seconds, and checkfor any air leak-
age in the water.
Ir If the above test shows that there are cracks
around the nozzle holder and plugs, replace
the cylinder head.
15-008
0
REPAIR AND REPLACEMENT OF PARTS REPLACING VALVE GUIDE
REPLACING VALVE GUIDE

Special tools
Part No. Part Name CYty

A 795-100-1820 Valve guide remover 1
B 795-116-1410 Valve guide driver 1
1. Removing the guide

Remove the valve guide with valve guide remover
A.
2. Press-fitting the valve guide

I) Press-fitting the valve guide until the tip of
valve guide driver B contacts the cylinder
head.
* After press fitting, insert the valve. If the
valve does not enter smoothly, modify with
a reamer (#16+~.“‘8 ).
2) Confirm that the protrusion of the valve guide

8 is within specification.
% * Protrusion of valve guide:
z 25.9f0.25 mm
622FOlO43
15-009
0
REPAIR AND REPLACEMENT OF PARTS GRINDING VALVE
GRINDING VALVE
Special tools

A - Valve refacer 1
(ourchase)
1. Grinding the seat surface

. Grinding the seat surface with valve refacer A.
+ Angle of valve seat (a): Intake valve: 30”
Exhaust valve: 45”
2. Checking after grinding

. Confirm that the thickness of valve head, protru-
sion of the valve, and the contact surface of the
F6164107A
valve seat are within specification.
+ Allowable thickness of valve head (h)

Standard Repair limit
Intake valve: 2.10 mm 1.7 mm
Exhaust valve: 1.50 mm a
1.2 mm
HEE00300
* Sinking distance of valve:

Standard Repair limit
OkO.1 mm 1.1 mm
h
HEE00301
Sinking of valve
When usino a When usins a

master valve master valve
OT”.’ Bottom surface OS”.’ Bottom surface
Intake side Exhaust side
HEE00296
15010
0
REPAIR AND REPLACEMENT OF PARTS REPLACING CAMSHAFT BUSHING
REPLACING CAMSHAFT
BUSHING
Special tc 01s

795-216-1000 Push tool 1
1 795-215-1110 Push bar 1
A
k
I 4
2
3
795-216-1130
795-216-l 140
795-2 16-l 150
Push tool
Collar
Guide
1
1
1
I 5 792-103-0400 ) Grip 1
* Before replacing the camshaft bushing, remove

the blind plug from the rear side of the cylinder
block.
1. Pulling out No. I,7 bushings

. Assemble push bar Al, push tool A2 and collar A3 n2 Al
A3 of push tool A, then tap the push bar and re- 2

8 move bushing (2) from cylinder block (I).
% c
z 1
Y
I 1 6162F518
A3 A2
3
2. Pulling out No. 2,6 bushing
l
Assemble push bar Al, push tool A2, collar A3,
1 c
and guide A4 of push tool A, then tap the push
bar and remove bushing (3) from cylinder block
6162F519
(I).
3. Pulling out No. 3,4,5 bushing

l Assemble push bar Al, push tool A2, collar A3, 4
and guide A4 of push tool A, then tap the push
bar and remove bushing (4) from cylinder block 1
(I).
6162F520
15-011
0
REPAIR AND REPLACEMENT OF PARTS REPLACING CAMSHAFT BUSHING
. After pulling out bushing, removing all burrs and

clean all dirt and dust from the bushing mount-
ing hole.
1. Press fitting No. 3,4,5 bushing

. 4
Assemble bushing (4) to tool A, then press fit the
bushing until the oil hole in cylinder block (I) is
aligned with the oil hole in bushing. 1 +
6202FOl7
2. Press fitting No. 2,6 bushings

. Assemble bushing (3) to tool A, then press fit the 3
bushing until the oil hole in cylinder block (1) is
aligned with the oil hole in bushing.
1 c
8
6162F522 tz
t;
3. Press fitting No. I,7 bushings

. Assemble bushing (2) to tool A, then press fit the
bushing until the oil hole in cylinder block (I) is
aligned with the oil hole in bushing.
6202FO18
. Using inside gauge 0, measure the inside diam-

eter of the bushing.
. Check the clearance between the bushing and the
shaft, and if the clearance is not within the stan-
dard range, or if the shaft does not pass through
smoothly, correct the inside diameter of the bush-
ing with a reamer.
. After correcting the inside diameter of the
bushing with a reamer, clean all chips from
the oil hole and oil groove.
* Inside diameter of camshaft bushing:
4160’~~’ mm 6202FO19
* Clearance at camshaft journal:
0.080-0.180 mm
15012
0
REPLACING CRANKSHAFT GEAR
REPAIR AND REPLACEMENT OF PARTS REPLACING CAMSHAFT GEAR
REPLACING CRANKSHAFT
GEAR
1. Removing the crankshaft gear
. Make a groove on the tooth bottom surface of
the gear with a grinder, then crack the gear with a
chisel.
A Take care in handling the grinder and chisel.
2. Press-fitting the crankshaft gear

1) Check the fitting surfaceof the ring gear. If
any flaw is found, repair it with an oilstone.
2) Heat the ring at the specified temperature for
the specified time for shrinkage fitting.
* Heating temperature for crankshaft gear:
250°C
Heating time: 30 minutes
3) With the timing mark side of crankshaft gear
facing outside, fit it until its side contacts the
crankshaft flange.
REPLACING CAMSHAFT GEAR

1. Removing of camshaft gear Press
Set the camshaft assembly on a press stand, then +

push the camshaft out with press.
I-J
2. Press fitting camshaft gear
1) Heat the gear to the specified shrink-fitting
temperature for the specified period of time.
Ir Heating temperature for camshaft gear:
250°C
2) Set the timing mark on the outside, then use
a driving tool to press fit until the surface of
HE00302
the gear is in tight contact with the camshaft
flange.
15013
0
REPAIR AND REPLACEMENT OF PARTS REPLACING FLYWHEEL RING GEAR
REPLACING FLYWHEEL RING

GEAR
a Take care not to let the flywheel fall.
1. Removing the ring gear

. Make a groove on the tooth bottom surface of
the gear with a grinder, then crack the gear with a
chisel.
A Take care in handling the grinder and chisel.
2. Press-fitting the ring gear

1) Check the fitting surface of the ring gear. If
any flaw is found, repair it with an oilstone.
2) Heat the ring at the specified temperature for
the specified time for shrinkage fitting.
* Heating temperature for ring gear:
315°C
3) With the chamferred side of ring gear facing
the front side of the engine, fit it until its side
contacts the flywheel flange.
15-014
0
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

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

CORRECTIVE ACTION:
PFMRl 081696

6D110 Series

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STRUCTURE AND FUNCTION

GENERAL STRUCTURE ................................................................ 1 I-004

INTAKE AND EXHAUST SYSTEM ...................................................... 1 I-008

Turbocharger ..................................................................... II-016

ENGINE BODY ......................................................................... 1 I-020

Mainmovingparts ................................................................ 11-022

1. Fan 11. Cylinder head 21. Thrust bearing

2. Water pump 12. Cylinder block 22. Main bearing cap

3. Cylinder liner 13. Flywheel housing 23. Main bearing

4. Valve seat insert 14. Ring gear 24. Oil pan

5. Valve guide 15. Flywheel 25. Connecting rod cap

6. Valve (exhaust) 16. Tappet 26. Connecting rod bearing

7. Rocker arm shaft 17. Cam bushing 27. Front plate

8. Valve (intake) 18. Camshaft 28. Crankshaft gear

10. Breather 20. Crankshaft 30. Front seal

31. Crankshaft pulley 41. Turbocharger 51. Oil pump

32. Vibration damper 42. Piston 52. Feed pump

34. Front cover 44. Top ring 54. Intake manifold

35. Cam gear 45. Second ring 55. Oil filter

37. Piston pin 47. Oil filler 57. Fuel filter

40. Rocker arm 50. Oil strainer

110 SERIES 1 l-005

SAGD.llO-1 Engine No. 50001 and up

1. Fan 11. Cylinder head 21. Thrust bearing

2. Water pump 12. Cylinder block 22. Main bearing cap

3. Cylinder liner 13. Flywheel housing 23. Main bearing

4. Valve seat insert 14. Ring gear 24. Oil pan

5. Valve guide 15. Flywheel 25. Connecting rod cap

6. Valve (exhaust) 16. Tappet 26. Connecting rod bearing

7. Rocker arm shaft 17. Cam bushing 27. Front plate

8. Valve (intake) 18. Camshaft 28. Crankshaft gear

10. Breather 20. Crankshaft 30. Front seal

11-006 110 SERIES

31. Crankshaft pulley 41. Turbocharger 51. Oil pump

32. Vibration damper 42. Piston 52. Feed pump

34. Front cover 44. Top ring 54. Intake manifold

35. Cam gear 45. Second ring 55. Oil filter

37. Piston pin 47. Oil filler 57. Fuel filter

39. Oil filler 49. Starting motor 59. After cooler

40. Rocker arm 50. Oil strainer

110 SERIES 1 l-007

INTAKE AND EXHAUST SYSTEM

4. Electrical intake air heater

10. Exhaust pipe

11-008 110 SERIES

SAGDllO-1 (For D66S-1)

110 SERIES 11-009

SAGDllO-1 (For W120-2 and W120-3)

9. Electrical intake air heater

10. Air cleaner

11. Connector pipe

12. Outer element

13. Inner element

14. Dust indicator

15. Exhaust manifold

SAGDllO-1 (For WA400-I)

110 SERIES 11-011