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COMPONENT CODE A6

PARTS & SERVICE REF NO. AT06195


DATE October 28, 2006
NEWS (C) Page 1 of 17

SUBJECT: MODIFICATION PROCEDURE FOR WATER PUMP SEAL ON 6D140


SERIES ENGINES
PURPOSE: To inform field personnel.
APPLICATION: 12M140A-1 Engine Serial Number
12M140A-2 Engine Serial Number
6M132A-1 Engine Serial Number
6M132A-2 Engine Serial Number
6MJ132A-3 Engine Serial Number
6M137A-1 Engine Serial Number
6M137B-1 Engine Serial Number
6M140A-1 Engine Serial Number
6M140A-2 Engine Serial Number
6M140A-3 Engine Serial Number
6M140A-5 Engine Serial Number
6M140B-2 Engine Serial Number
A6D140E-GD-3 Engine Serial Number
A6D140E-KC-3 Engine Serial Number
A6D140E-KC-5 Engine Serial Number
BR1000JG-1 Mobile Crusher Serial Number 1001 to 1003
BR700C-1 Mobile Crusher Serial Number 1001 to 1001
CS360-2 ______ Serial Number 11001 to 11096
CS360SD-2 ______ Serial Number 11501 to 11533
D155A-2 Dozer Serial Number
D155A-5 Dozer Serial Number 56001 to 65551
D155AX-5 Dozer Serial Number
D155AX-6 Dozer Serial Number
D155C-1 Dozer Serial Number
D275A-5 Dozer Serial Number
D275AX-5 Dozer Serial Number
D355C-3 Dozer Serial Number
D475A-3 Dozer Serial Number 10601 to 10768
D475A-5 Dozer Serial Number 2001 to 20123
EG300-5 Engine Serial Number
EG300-L-5 Engine Serial Number
EG300B-5 Engine Serial Number
EG300BS-5 Engine Serial Number
EG350A-L-1 Engine Serial Number

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EG350B-L-1 Engine Serial Number
EG400-2 Engine Serial Number
EG400B-2 Engine Serial Number
EG400B-L-2 Engine Serial Number
EG400BS-2 Engine Serial Number
EM665A-00 Engine Serial Number
GC380F-2 Grader Serial Number 12002 to 12088
GC380F-2 Grader Serial Number 13001 to 13008
GD825A-2 Grader Serial Number
GS360-2 Grader Serial Number 12001 to 12081
GS500-1 Grader Serial Number 1002 to 1003
HD325-6 Dump Truck Serial Number
HD325-7 Dump Truck Serial Number
HD 405-6 Dump Truck Serial Number 1001 to 1186
HD405-7 Dump Truck Serial Number
HM350-1 Dump Truck Serial Number
HM350-2 Dump Truck Serial Number
HM400-1 Dump Truck Serial Number
HM400-2 Dump Truck Serial Number
HV3000-1 Dump Truck Serial Number
HV6000-1 Dump Truck Serial Number 1001 to 1036
J6D140E-G1-2 Engine Serial Number
J6D140E-GD-2 Engine Serial Number
J6D140E-GD-3 Engine Serial Number
J6D140E-GE-2 Engine Serial Number
J6D140E-KC-2 Engine Serial Number
J6D140E-KC-3 Engine Serial Number
J6D140E-W2-2 Engine Serial Number
J6D140HE-R-2 Engine Serial Number
LW500-1 _______ Serial Number 10001 to 11035
PC1600-1 Excavator Serial Number 10001 to 10142
PC1800-6 Excavator Serial Number 10001 to 10017
PC1800-6 Excavator Serial Number
PC600-7 Excavator Serial Number
PC600-8 Excavator Serial Number
PC600LC-7 Excavator Serial Number
PC600LC-8 Excavator Serial Number
PC650-5 Excavator Serial Number
PC650-7 Excavator Serial Number
PC650-8 Excavator Serial Number
PC750-6 Excavator Serial Number
PC750-7 Excavator Serial Number
PC750LC-7 Excavator Serial Number
PC800-6 Excavator Serial Number 31001 to 31110
PC800-7 Excavator Serial Number

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PC800-8 Excavator Serial Number
PC800LC-8 Excavator Serial Number
PC850-8 Excavator Serial Number
S6D140-1 Engine Serial Number
S6D140-G1-1 Engine Serial Number
S6D140-G2-1 Engine Serial Number
S6D140-G3-1 Engine Serial Number
S6D140-GD-1 Engine Serial Number
S6D140-GH-1 Engine Serial Number
S6D140-GJP-1 Engine Serial Number
S6D140-GT-1 Engine Serial Number
S6D140-P-1 Engine Serial Number
S6D140-PGA-1 Engine Serial Number
SA12V140-M-1 Engine Serial Number
SA6D140-A2-1 Engine Serial Number
SA6D140-C2-1 Engine Serial Number
SA6D140-M-1 Engine Serial Number
SA6D140-P-1 Engine Serial Number
SA6D140-W1-1 Engine Serial Number
SA6D140A-1 Engine Serial Number
SA6D140A1-1 Engine Serial Number
SA6D140A-G1-1 Engine Serial Number
SA6D140A-G2-1 Engine Serial Number
SA6D140A-G3-1 Engine Serial Number
SA6D140A-GA-1 Engine Serial Number
SA6D140A-GB-1 Engine Serial Number
SA6D140A-GD-1 Engine Serial Number
SA6D140A-GH-1 Engine Serial Number
SA6D140A-GJ-1 Engine Serial Number
SA6D140A-GT-1 Engine Serial Number
SA6D140A-M-1 Engine Serial Number
SA6D140A-P-1 Engine Serial Number
SA6D140A-W1-1 Engine Serial Number
SA6D140B-1 Engine Serial Number
SA6D140B-A1-1 Engine Serial Number
SA6D140B-G1-1 Engine Serial Number
SA6D140B-G3-1 Engine Serial Number
SA6D140B-GA-1 Engine Serial Number
SA6D140H-GJ-1 Engine Serial Number
SA6D140H-R-1 Engine Serial Number
SAA6D140-G1-1 Engine Serial Number
SAA6D140-G3-1 Engine Serial Number
T6D140E-2W-2 Engine Serial Number
TA6D140-G1-2 Engine Serial Number
WA500-3 Waste Handler Serial Number
WA500-6 Waste Handler Serial Number
WD500-3 Waste Handler Serial Number
WZ4000-1 Waste Handler Serial Number 1001 to 1006

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Page 4 of 17
FAILURE CODE: A601AE
DESCRIPTION:

1. Introduction
Regarding the 6D140 Series engines, reliability against initial water leakage has been improved
through geometrical improvement of the rubber bellows of the water pump seal.
Please modify the engines in accordance with this Service if the water leakage occurs.

2. List of Parts
(1) When performing modification according to this Service News, remove the water pump
assembly and replace the water seal unit alone.
(2) Improve previous water pump assemblies in stock as spare parts according to the attached
modification procedure to make them identical with the unit assigned the new part number and
keep them in stock.
(3) The correlation between water pump part numbers and machine model incorporating them are
indicated in the Major Machine Model Execution Confirmation Table.
The following shows the assembly number of the subject water pump and part numbers of the
water seal and consumable parts.

Part No. Part Name Purpose of Part Q’ty Remarks


6212-61-1205 WATERPUMP 1
Modification
(6212-61-1204) (WATERPUMP) (1)
6211-61-1533 SEAL 1 Spare water seal
Replacement
(6211-61-1532) (SEAL) (1) (common)
Wear parts used
07000-02145 O-RING 1
Replacement when modifying
() () ()
6212-61-1205
Wear parts used
07000-72115 O-RING 1
Replacement when modifying
() () ()
6212-61-1205
Wear parts used
07000-72070 O-RING 1
Replacement when modifying
() () ()
6212-61-1205
Wear parts used
07000-G5065 O-RING 1
Replacement when modifying
() () ()
6212-61-1205
Wear parts used
07000-G3032 O-RING 1
Replacement when modifying
() () ()
6212-61-1205
Wear parts used
6210-61-6371 GASKET 1
Replacement when modifying
() () ()
6212-61-1205

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Part No. Part Name Purpose of Part Q’ty Remarks
Wear parts used
6210-61-6341 GASKET 1
Replacement when modifying
() () ()
6212-61-1205
Wear parts used
6210-61-6551 GASKET 1
Replacement when modifying
() () ()
6212-61-1205
Wear parts used
6212-61-6821 GASKET 1
Replacement when modifying
() () ()
6212-61-1205
6211-62-1403 WATERPUMP 1
Modification
(6211-62-1402) (WATERPUMP) (1)
6211-61-1533 SEAL 1 Spare water seal
Replacement
(6211-61-1532) (SEAL) (1) (common)
Wear parts used
07000-02145 O-RING 1
Replacement when modifying
() () ()
6211-62-1403
Wear parts used
07000-72115 O-RING 1
Replacement when modifying
() () ()
6211-62-1403
Wear parts used
07000-72070 O-RING 1
Replacement when modifying
() () ()
6211-62-1403
Wear parts used
02893-05037 O-RING 2
Replacement when modifying
() () ()
6211-62-1403
Wear parts used
6217-61-6330 GASKET 1
Replacement when modifying
() () ()
6211-62-1403
Wear parts used
6217-61-6340 GASKET 1
Replacement when modifying
() () ()
6211-62-1403
Wear parts used
6212-61-6821 GASKET 1
Replacement when modifying
() () ()
6211-62-1403
6212-61-1305 WATERPUMP 1
Modification
(6212-61-1304) (WATERPUMP) (1)
6211-61-1533 SEAL 1 Spare water seal
Replacement
(6211-61-1532) (SEAL) (1) (common)

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Page 6 of 17
Part No. Part Name Purpose of Part Q’ty Remarks
Wear parts used
07000-02145 O-RING 1
Replacement when modifying
() () ()
6212-61-1305
Wear parts used
07000-72115 O-RING 1
Replacement when modifying
() () ()
6212-61-1305
Wear parts used
07000-72070 O-RING 1
Replacement when modifying
() () ()
6212-61-1305
Wear parts used
07000-G5065 O-RING 1
Replacement when modifying
() () ()
6212-61-1305
Wear parts used
07000-G3032 O-RING 1
Replacement when modifying
() () ()
6212-61-1305
Wear parts used
02893-05037 O-RING 2
Replacement when modifying
() () ()
6212-61-1305
Wear parts used
6210-61-6371 GASKET 1
Replacement when modifying
() () ()
6212-61-1305
Wear parts used
6210-61-6341 GASKET 1
Replacement when modifying
() () ()
6212-61-1305
Wear parts used
6212-61-6821 GASKET 1
Replacement when modifying
() () ()
6212-61-1305
6261-61-1101 WATERPUMP 1
Modification
(6261-61-1100) (WATERPUMP) (1)
6211-61-1533 SEAL 1 Spare water seal
Replacement
(6211-61-1532) (SEAL) (1) (common)
Wear parts used
6261-61-1170 O-RING 1
Replacement when modifying
() () ()
6261-61-1101
Wear parts used
02893-05037 O-RING 2
Replacement when modifying
() () ()
6261-61-1101

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Part No. Part Name Purpose of Part Q’ty Remarks
Wear parts used
07000-72070 O-RING 1
Replacement when modifying
() () ()
6261-61-1101
Wear parts used
07000-72115 O-RING 1
Replacement when modifying
() () ()
6261-61-1101
Wear parts used
6261-61-6330 GASKET 1
Replacement when modifying
() () ()
6261-61-1101
Wear parts used
6261-61-6340 GASKET 1
Replacement when modifying
() () ()
6261-61-1101
Wear parts used
6212-61-6821 GASKET 1
Replacement when modifying
() () ()
6261-61-1101
6261-62-1201 WATERPUMP 1
Modification
(6261-62-1200) (WATERPUMP) (1)
6211-61-1533 SEAL 1 Spare water seal
Replacement
(6211-61-1532) (SEAL) (1) (common)
Wear parts used
6261-61-1170 O-RING 1
Replacement when modifying
() () ()
6261-61-1201
Wear parts used
07000-72070 O-RING 1
Replacement when modifying
() () ()
6261-61-1201
Wear parts used
07000-72115 O-RING 1
Replacement when modifying
() () ()
6261-61-1201
Wear parts used
6261-61-6330 GASKET 1
Replacement when modifying
() () ()
6261-61-1201
Wear parts used
6261-61-6340 GASKET 1
Replacement when modifying
() () ()
6261-61-1201
Wear parts used
6212-61-6821 GASKET 1
Replacement when modifying
() () ()
6261-61-1201

AT06195
Service News AT06195 Page 8 of 17

1. Purpose
With the water pump for the 6D140 series engine, we modified the shape of the rubber
bellows unit that is a component of the water seal assembly to improve reliability of the
water pump performance.
If water leakage occurs from the water pump, perform modification according to this service
news.

2. Details of Improvement
In order to improve reliability against initial water leakage, we modified the shape of the
rubber bellows of the water seal to a shape with deflection on one side and eliminated the
holder on the case side of the spring for seal surface pressure adjustment previously
retained via a spring holder so that the spring rotation is prevented to stabilize the surface
pressure of the seal ring.

1). Details of modification on the water seal

(New) (Current)

Modification of the spring holder


(to prevent rotation of the spring)
Spring holder: 1 Spring holder: 2
Cross-sectional view of
the water seal (The holder on the case
side to be eliminated)
Parts fixed onto
the body of the Seal ring
water seal

The seal located on the Spring


rotation side to be
inserted in the shaft is not
Rubber bellows
modified.
One-sided deflection Deflection on both sides

Modification of the shape of the rubber bellows

Water seal part number 6211-61-1533 6211-61-1532

None Blue paint

Identification painting position

Identification marking for


the water seal

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Service News AT06195 Page 9 of 17

2). About the identification punch mark for the subject water pump assembly
The identification mark is punched on the side of the water inlet flange of the water pump.

New water pump assembly Current water pump assembly


Identification Identification Remarks
New Part No. Old Part No.
marking marking
1 6212-61-1205 E 6212-61-1204 B 140 Construction equipment
2 6211-62-1403 T 6211-62-1402 B 140 Construction equipment
3 6212-61-1305 E 6212-61-1304 B 140 Construction equipment
4 6261-61-1101 D 6261-61-1100 C 140 Construction equipment (Tier3)
5 6261-61-1201 D 6261-61-1200 C 140 Construction equipment (Tier3)
6 6212-65-1404 G 6212-65-1403 E 140 Marine
7 6212-65-1503 G 6212-65-1502 E 140 Marine
8 6212-65-1603 CN 6212-65-1602 E 140 Marine
9 6212-61-1723 G 6212-61-1722 E 140 Power generator
10 6212-61-1704 G 6212-61-1703 E 140 Power generator
11 6218-61-1102 E 6218-61-1102 B 140 For the dual model
12 6215-61-9102 E 6215-61-9101 B 12V140 For the dual model
13 6215-65-1104 G 6215-65-1103 E 12V140 Marine
14 6215-65-1304 G 6215-65-1303 E 12V140 Marine
15 6934-61-1106 F 6934-61-1105 - JR 140
16 6934-62-1101 F 6934-62-1100 - JR 140

3. Water Pump and Water Seal Replacement procedure


Do not replace the water pump assembly. Remove the water pump and replace the water
seal.
1) Discharge engine coolant.
2) Remove the water pump assembly by following the Machine Shop Manual.
3) Replace the water seal by following the Shop Manual on the following pages.
Also take similar steps for the water pump in the dual circuit (6218-61-1102, 6215-61-
9102) as no procedure for that water pump is covered in this Shop Manual.
4) Mount the water pump assembly, and then flush the coolant channel with clean water to
wash off residual foreign matters inside the channel.
5) Last, follow the instructions in the instruction manual to supply coolant.
Control the antifreeze concentration at the specified value.

4. Inspections after the Modification Work


After running the engine, check that no water leakage is found in each section.

Precautions:
Intrusion of air in the coolant or operating the machine with failure occurring on the
pressurizing valve of the radiator results in inadequate cooling around the water seal, which
may cause durability of the water seal to degrade. To avoid such results, check for water
leakage in each section as well as checking the radiator and the pressurizing valve when
performing modification, and repair as needed.
Note that coolant level control should be minded for the radiator after the modification just as
ever.
Use of water soiled with sand, rust or other foreign matters as coolant would affect the
friction surface of the water seal due to abrasion with those foreign matters, also causing
durability of the water seal to degrade. Only use clean water.
Keep in mind that the inside of the coolant system needs to be washed periodically and
according to the instruction manual.
AT06195
Service News AT06195 Page 10 of 17

5. Shop Manual (detailed description of the procedure for


water seal replacement)
The following is an abstract from the Shop Manual.
(Reference: English documentation)
Title of the Shop Manual: COMPONENT OF ENGINE (COMPONENT OF ENGINE)
Manual No.: S650WP000-000 (SEBM026200)
Page: Total disassembly/assembly (13-018 - 13-024)
13-018 - 13-024

Dimensions of each section are shown on page 17.


Total disassembly (6D140 series) Disassembly/assembly

Total disassembly

6D140 series
Disassembly of Water Pump Assembly

Prior to disassembly, wash and clean the assembly


and check the external damage condition and
check to see if any water leakage is occurring.

Water pump assembly

1. Bolt
2. Cover
3. Impeller
4. Floating seal
5. Shaft
6. Sleeve
7. Water seal
8. Oil seal
9. Ball bearing
10. Spacer
11. Gear
12. Spacer
13. Snap ring
14. Ball bearing
15. Oil seal
16. Body

Water pump

AT06195
Service News AT06195 Page 11 of 17

Disassembly/assembly Total disassembly (6D140 series)

1. Cover
Remove mounting bolt (1) and then remove cover (2).
Depending on the machine type (WS23-2),
covers may be fixed in place with snap rings.

2. Impeller
Remove impeller (3) using gear puller <1>.

3. Shaft
Pull out shaft (5) using pushing tool <2>.
Pull out sleeve (6), water seal (7), oil seal (8),
bearing (9), spacer (10), gear (11) and spacer
(12), in that order.

4. Snap ring and bearing


1) Remove snap ring (13).
2) Remove snap ring (14).

Water pump

AT06195
Service News AT06195 Page 12 of 17

Total disassembly (6D140 series) Disassembly/assembly

5. Oil seal
Remove oil seal (15).

Water pump

AT06195
Service News AT06195 Page 13 of 17

Disassembly/assembly Total disassembly (6D140 series)

Total disassembly

Prior to assembly, wash and clean all parts and perform air blow.
When press-fitting a bearing/gear, apply clean engine oil and
press fit.

Water pump assembly

1. Bolt
2. Cover
3. Impeller
4. Floating seal
5. Shaft
6. Sleeve
7. Water seal
8. Oil seal
9. Ball bearing
10. Spacer
11. Gear
12. Spacer
13. Snap ring
14. Ball bearing
15. Oil seal
16. Body

Water pump

AT06195
Service News AT06195 Page 14 of 17

Total disassembly (6D140 series) Disassembly/assembly

1. Oil seal
Use pushing tool <3> to press fit oil seal (15) onto
body (16).
Circumference of the oil seal engagement
section Three Bond No. 2
(nondrying gasket sealant)
Oil seal lip section: Grease (G-L1)
Turn the oil seal lip side to the gear and press
fit it until it is flush with the mounting position.
Ensure that no dust or cut chips has attached
around the lip.
Carefully handle the lip to avoid any damage.

2. Bearing/snap ring
1) Use pushing tool <4> to press fit bearing (14)
onto body (16).

2) Snap ring
Fix the bearing in place using snap ring (13).
Check that the snap ring is completely
stuck in the groove.

4. Shaft
Assemble spacer (10) and gear (11), in that order, into
the body and press fit shaft (5), using pushing tool <5>.
With the thinner end up, press fit the shaft until
its tip is slightly out of the bearing surface
(Take care not to overly press in the shaft as
gear (11) may be blocked upon insertion.)
Place a retaining deck (100 mm in length, 45
mm in external diameter, and 30 mm in
internal diameter) beneath the gear and press
fit it until the flange surface contacts the
bearing surface.

Water pump

AT06195
Service News AT06195 Page 15 of 17

Disassembly/assembly Total disassembly (6D140 series)

Do not press the thin section of the shaft as it


may be bent; press the flange surface.
3) Bearing
Assemble spacer (12) and press fit bearing (9)
using pushing tool <6>.

4) Oil seal
Press fit the oil seal (8) using a pushing tool.

Lip section: Grease (G-L1)


Ensure that no dust or cut chips has
attached around the lip.
Carefully handle the lip to avoid any damage.

5) Sleeve
Press fit sleeve (6) using pushing tool <7>.

6) Water seal
Use pushing tool <8> to press fit water seal
(7) onto the body.
Circumference of the water seal's
external drum: Three Bond No. 1102
(nondrying gasket sealant)
Press fit with the rubber side oriented to the
impeller.
When replacing the water seal, replace
floating seal (4) at the same time.
Thinly apply water soluble lubricant (beauty
soap, for example) around the circumference
Water pump

AT06195
Service News AT06195 Page 16 of 17

Total disassembly (6D140 series) Disassembly/assembly

of the seat assembly rubber.

5. Impeller
Press fit impeller (3) using pushing tool <9>.

6. Cover
Install the gasket and tighten cover (2) with
mounting bolt (1).
Mounting bolt: See a list of reference values
for tightening torques
After completing the assembling procedure, manually
turn the gear and check that it turns smoothly.

Water pump

AT06195
Service News AT06195 Page 17 of 17

140 series Maintenance standards

Unit: mm
Corrective
Item Judgment criteria action
Replacement
Basic Tolerance Standard Typically, the
Interference between dimensions Shaft Hole interference impeller is replaced
the impeller and the shaft (the shaft's external
diameter hardly
varies).
Replacement
Interference between the (Typically the gear is
drive gear and the shaft replaced.)

Interference between the


flange and the shaft
Clearance between the
Standard clearance: 0.6 - 0.9 (including end play)
impeller and the body
Replacement

Water seal Allowable limit for dimension A: 1.5


Wear of the seal ring

Water pump

AT06195